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Instruction

Document No.: C66-A446

Version: 15.0

Page 1 of 51

Instruction Manual
Ful-Vane Compressors, Vacuum Pumps
And Boosters
Single Stage Rotary Sliding Vane
Air And Gas Service
Caution
Read this instruction manual before performing any installation, operation or
maintenance procedure.
All equipment must be operated and maintained in accordance with all applicable
governmental safety and health laws and regulations, generally recognized industrial
standards, and the users plant standards.

Version
15.0

Signed by
Tom Krulick

Release Date
10/05/2004

F.L.Smidth, Inc. 2040 Avenue C Bethlehem, PA 18017-2188


Telephone: 610-264-6011 Fax: +1-610-264-6701 www.flsmidth.com

Parts and Service Call 1-800-795-6825

CONTENTS
Page
INTRODUCTION ...............................................................................................................3
RECEIVING AND STORAGE...........................................................................................4
INSTALLATION
Location ...............................................................................................................................4
Foundation ...........................................................................................................................4
Erection & Alignment..........................................................................................................5
Cooling System....................................................................................................................6
Water Piping ........................................................................................................................7
Air Piping.............................................................................................................................8
Accessories .................................................................................................................... 9-10
OPERATION
Before Start ........................................................................................................................11
Start-Up..............................................................................................................................12
Operation Notes .................................................................................................................12
Stopping .............................................................................................................................13
Lubrication................................................................................................................... 14-15
Maintenance Guide ............................................................................................................16
INSPECTION AND SERVICE
Internal Inspection ....................................................................................................... 17-18
Dismantling........................................................................................................................19
Assembly............................................................................................................................19
Descriptive Views........................................................................................................ 20-22
Cylinder Head Gaskets ......................................................................................................23
Rotor End Clearances .................................................................................................. 23-25
Doweling and Bottom Clearance ................................................................................. 25-28
Renewal Parts.....................................................................................................................29
SPECIAL NOTICE PARTS ...........................................................................................30
PARTS LIST................................................................................................................ 31-34
APPENDIXES
A. Cog Belt Tension Adjustment......................................................................................35
B. Lubrication Feed Rate ..................................................................................................36
C. Re-machining Procedure ........................................................................................ 37-38
D. Rotor Slot Criteria........................................................................................................39
E. Clearance Setting Methods..................................................................................... 40-41
F. Reconditioning Limits ............................................................................................ 42-47
G. Trouble Shooting Chart................................................................................................48
H. F.L.Smidth Exchange Programs ..................................................................................50
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Single Stage Rotary Sliding Vane
F.L.Smidth

Here's Why You're Ahead with F.L.Smidth


Ful-Vane Rotary Compressors

LIGHTER FOUNDATIONS NEEDED


No reciprocating motion to set up vibration. Air flow is free from pulsations. You can install F.L.Smidth rotaries
on much lighter foundations even on balconies.

SIMPLER PIPING, TOO


Intake and discharge openings are on horizontal plane on opposite sides of cylinder-avoiding reversal of air flow,
simplifying piping, making easier access to rotating parts.

DIRECT DRIVE, COG BELT DRIVE, OR GEAR REDUCER . . . FOR VERSATILITY


ECONOMY AND SAFETY
SLIDING FUL-VANE EFFICIENCY
F.L.Smidth rotary compressors, vacuum pumps and boosters are of the multivane type. Each unit consists of a
water-jacketed cast iron casing in which a forged steel rotor revolves. Its axis being eccentric to that of the casting.
Arranged in milled slots on the rotor is a series of composition blades, free to slide by centrifugal force, against the
interior wall of cylinder as the rotor turns, forming numerous crescent-shaped cells that trap the air being
compressed. Since these rotor blades are free riding in their rotor slots, they automatically compensate for blade
wear, maintaining perfect cylinder with contact through centrifugal force.

UNDERCUT BORE
F.L.Smidth's exclusive undercut bore is a key to higher volumetric efficiency of the F.L.Smidth rotary compressor.
After boring the cylinder to size, the boring bar is dropped to the point of rotor eccentricity and a second cut is taken
at bottom only and at same radius as the rotor. After the bore intersections are blended this undercut section of the
cylinder is parallel to the rotor surface for approximately 30 circumference and, with close running clearance, acts
as an effective seal between discharge and suction pressures.

High quality F.L.Smidth circular bore type compressors are also available. These units provide rotary compressor
advantages of higher speeds and capacities in competitive cylinder sizes.
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Single Stage Rotary Sliding Vane
F.L.Smidth

RECEIVING AND STORAGE


Before and after uncrating, look for damage that may have occurred in transit. Check for shortages by comparing
each item received with those listed on the shipping manifest. If damage or shortage is noted, advise carrier within
fifteen (15) days of receipt and request an inspection report. Make proper claim with carrier and order replacement
part/s from F.L.Smidth.
If unit is not used immediately, place equipment in a clean, dry storage area protected from inclement weather. The
compressor interior has been serviced with a special anti-corrosion agent which will allow storage for a reasonable
period of time but, consult F.L.Smidth if storage periods are extended.

INSTALLATION
Location the unit should be installed in a clean, dry, well-ventilated area adjacent to points of use. Ample space
and facilities should be provided for convenience in servicing and inspection

The Air Intake should be located where the atmosphere is:


Clean because dirty, gritty air quickly chokes filters
and if allowed to pass into the compressor, causes rapid
wear.

Cool - because the cooler the intake air, the more air
is compressed per revolution.

Free from Chemical Fumes - which cause


corrosion in compressor mains and tools-exhaust gases
from engines and furnaces come under this heading.

Dry - because wet intake conditions will wash


cylinder lubrication, pit bearings, and cause abnormal
precipitation of moisture in receiver or distribution
CC300 Ful-Paks
system. Keep intakes clear of steam exhausts and
outlets from dryers or cooling towers. An outdoor
intake must be protected from severe weather conditions. If unusually dirty or dusty conditions exist, consult
F.L.Smidth Company for information about special filters or cleaners.

FOUNDATION - concrete foundations, extending to firm bearing and with moderate steel rod reinforcing, are
recommended. However, installations on balconies or steel supports are also satisfactory providing that sufficient
stiffness is designed into the supports to maintain coupling alignment. Ful-Paks must be mounted on a solid
foundation for noise containment.
Simple slab type foundations are normally used to raise the compressor unit to reasonable height above floor for
convenient servicing and/or inspection.
Basic design should be for static loadings only.
The foundation drawing indicates the necessary dimensions for the construction of these foundations and gives
anchor bolt and pipe sleeve locations.

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Single Stage Rotary Sliding Vane
F.L.Smidth

ERECTION AND ALIGNMENT - the unit should be placed on foundation, leveled carefully with wedges
located as close to foundation bolts as possible. The driver, with the coupling half assembled, should be placed on
foundation and aligned with the unit. All anchor bolt nuts must be sufficiently tight to hold unit firmly on wedges or
plate. Check for proper shaft gap (refer to general arrangement drawing) and proceed with coupling alignment.
For a unit with driver on combination base and factory assembled, alignment has already been made but, must be
reestablished at installation. Set entire unit in place on foundation bolts, and using wedges at each bolt, level in both
directions. Keep nuts only finger tight until coupling alignment has been rechecked and reestablished. Do not
spring base.
One method to check coupling alignment is with a dial indicator having magnetic bases or clamps and as follows:
With one coupling pin in place, turn both coupling halves through 360 to check parallel alignment. See Fig. 1.
Readings are taken at four points; top, each side and bottom. The difference between the two side radial readings
indicates the motor must be shifted sideways and the difference
between top and bottom radial readings indicates that the driver
must be raised or lowered by adding or removing the same
thickness of shims under all four feet. The amount of correction
to make in each case is one-half of the difference between the
two indicator readings. Align to within .003" (.076mm) actual or
.006 (.152mm) total indicator reading.
Figure 1

To check angular alignment, mount indicator as shown in fig.


2 with pickup against coupling face. With one coupling pin in
place, turn through one revolution. A reading on the dial will
show amount of misalignment and location. Correct this to
within .003 (.075mm) by shimming under front or rear feet, as
required, of the driver or cylinder.
Figure 2

The straight edge-taper gauge method can be used as an alternative to the foregoing procedure with following
variations:

Figure 3

Use feelers and straight edge and check coupling parallel


alignment at four positions turning the rotor by hand 90 for
each step and align by shimming under all four feet of driver.
See Fig. 3.

Use a taper gauge and check coupling angular alignment.


Align by shimming under front or rear feet, where required, of
driver or cylinder. See Fig. 4.
Figure 4

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Single Stage Rotary Sliding Vane
F.L.Smidth

After alignment is complete, proceed as follows:

Use a cement grout and grout in thoroughly around and well under the base, filling all anchor bolt sleeve
openings.

After grout is set, tighten all anchor bolts firmly. Be sure to recheck coupling alignment and if necessary to
realign, use shim stock between cylinder and base.

Where required, mount the lubricator on its support and locate as shown on general arrangement drawing.

The driver should be checked for rotation, making sure that it agrees with the compressor rotation arrow.
Do not put in the coupling pins for this check.

For V-belt driven units, check the alignment of the sheaves before final grouting. Locate sheaves as
dimensioned on the general arrangement drawing. Install driver and its base with allowance for lateral
motion to install V-belts and provide proper tension during operation. In adjusting tension of V-belts,
follow instructions of the V-belt manufacturer.

Cog belts are not to be tensioned as a V-belt. They should be installed with snug fit, neither too taut nor
loose. See Appendix A: Cog Belt Tension Adjustment Chart.

The balance of the erection should be completed by following the general arrangement and special
drawings supplied.

NOTE! Coupling halves are bored for a medium push fit to shaft and must be securely locked to shafts with set
screws over keys. Coupling halves should be mounted to clean and thoroughly oiled shafts with a soft lead hammer
by lightly tapping into position.

COOLING SYSTEM-the water supply should be clean and ample. Dirty, scale-forming cooling water coats
and clogs water passages, thereby reducing cooling effect.
Ample cooling water to cylinder jackets is necessary, but excessive cooling is not advantageous. The temperature of
cooling water at cylinder outlet should range between 80F (26C) and 110F (43C). Check coolant
temperature/flow thru open sight funnel under full load conditions.
To minimize sweating and condensation inside compressor, it is always recommended that the cooling water be
shut-off as soon as compressor is stopped. To do this automatically, it is suggested that a solenoid-operated water
valve be used in cooling water supply line. Connect valve to open, only when compressor is running.

The minimum cooling water requirements per 100 hp input (75 kw) to produce exit water temperature of 110 F. are as follows:
2.4 gpm (9 lpm) for 50F (10C) Incoming Water
3.7 gpm (14 lpm) for 70 (21C) Incoming water
7.5 gpm (28.5 lmp) for 90 (32C) Incoming Water
At no time should water pressure in the cylinder jackets exceed 70 psig (4.2 bar).

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Single Stage Rotary Sliding Vane
F.L.Smidth

WATER PIPING-The supply line valve should be located conveniently for use of the operator. An open sight
funnel for gauging water flow and temperature is supplied with every unit. Provide connections at the lowest
elevation of the water piping to allow complete drainage of the cooling water from the compressor. See Fig. 5.

Figure 5
Compressors are sometimes furnished with a self-contained water cooling system consisting of an air-cooled
radiator, water pump and complete re-circulating piping system. A fan is used to pass atmospheric air through the
radiator core and to cool the water. Locate the system so there is an unrestricted flow of cool, clean air through the
radiator. In freezing weather, drain or be sure to add suitable anti-freeze solution. Follow instructions given on
special drawings for installation and operation. See Fig. 6 and 6A.

This two stage gas compressor package uses a radiator for


intercooling, aftercooling and for cooling the jacket cooling
water.

This compressor package uses a radiator to


cool the cooling water.

Figure 6

Note: For gas services, it is


recommended that a thermostatic
control valve be installed on the water
exit to avoid condensing liquids that
may be present in the gas stream.

Figure 6A

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Single Stage Rotary Sliding Vane
F.L.Smidth

AIR PIPING-piping can be cast iron, black iron or galvanized steel pipe. With welded piping, be sure to provide a
removable flanged connection at the compressor proper. Provide adequate supports for piping and align carefully to
remove all strains on the compressor.
The intake air filter-silencer (normally supplied with each compressor) should be located to provide a source of cool,
dry, clean air and convenient for easy servicing and frequent inspection. HVAC ducting is not recommended for
inlet piping. Pipeline type filters are recommended for the intake line of vacuum pumps and gas boosters. Intake
air/gas must be free of all dirt, scale, slugs of liquid, etc.
The intake piping should be cleaned thoroughly before final connection and if necessary, acid pickled and wash
cleaned prior to initial operation. Do not install any stop valves in the intake line of compressors. Large vacuum
pumps require a vacuum limiting device between any stop valves and pump inlet. See drawings furnished with unit
for specific instructions.
A flanged non-return valve is furnished each unit, automatically preventing any back flow created by discharge
pressure when unit is not running. Normal mounting is horizontal. A simple drop-leg should be provided after the
non-return valve, to trap all excess lubricant or moisture entrained in the air or gas.
All compressors and boosters should be protected against overpressure in the discharge line with a safety valve. Be
sure no stop valve is placed between compressor and safety valve.
Vacuum pumps are normally supplied with discharge silencers.
See Figures 7 through 9 for typical installation arrangements.

Figure 7

Figure 8

Figure 9
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Single Stage Rotary Sliding Vane
F.L.Smidth

ACCESSORIES
Many accessories are available and necessary for use on a well-designed compressor system. The important ones
are listed as follows:
Protective Controls - the following controls are typical and available for use. However, check drawings furnished
for individual unit.

Discharge temperature switch-in discharge flange of unit and set to operate when the discharge temperature
reaches temperatures equivalent to the internal clearances in unit.

Pressure switch-used by boosters and gas compressors to control either or both the discharge and intake
pressure by actually starting and stopping the motor.

Solenoid flow valve-in the water supply line to open and close with operation of motor.

Cooling water flow switch-in water discharge line to operate on water failure or inadequate flow.

Flow control valve-in water supply line and its temperature bulb in discharge line which controls amount of
water flow.

Solenoid drain valve-installed in water piping low point to drain compressor jackets when motor stops.
Protection during freezing weather.

Lubricator low oil level switch and lubricator belt failure switch are some of the other controls available to
stop the motor or sound an alarm on lubrication failure.

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Single Stage Rotary Sliding Vane
F.L.Smidth

Figure 10

Single Stage Typical Gas Compressor Package

Oil and Moisture Separator-on installations where aftercoolers are not used, a separator such as impingement type,
change of direction of flow type, cyclonic action type, or coarse mesh screen type can be used to remove any
condensation which may occur. Adequate drainage facilities should be provided. It should be located in the
discharge line as far from the compressor as possible.
Aftercooler and Separator-on air compressors, the discharge air contains atomized oil and moisture from the
atmosphere. The amount of moisture is considerable and cooling, during transmission in the discharge piping,
causes unwanted condensation. An aftercooler will cool the compressed air close to the cooling water temperature.
This will reduce the water and oil vapor to a liquid for easy removal in the separator. Adequate drainage facilities
should be provided.
By-Pass Regulator-furnished for special applications to vary the final delivery of the unit and to control either the
discharge of the intake pressure. A pressure-operated valve by-passes excess capacity from the discharge to the inlet
or atmosphere. When by-passing to inlet, the air or gas is cooled to its approximate inlet temperature to prevent
overheating during continuous maximum by-passing. Special instructions and drawings are submitted for these
arrangements.
Air Receiver-the chief function of a receiver is to furnish reserve air capacity and should be sized large enough to
avoid frequent operation of the regulating device. They also act as excellent separators and remove a good
percentage of any condensate in the air stream. Therefore, adequate drainage facilities should be provided.
It is important that receivers be equipped with a safety valve sized to meet the compressor capacity.

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Single Stage Rotary Sliding Vane
F.L.Smidth

Figure 10A Ful-Pak

OPERATION
The following checkpoints are mandatory and are to be made before initial start or after any repairs. They are
general in nature and applicable to single stage compressors, vacuum pumps and boosters:
BEFORE START:

Recheck coupling alignment, direction of rotation. all piping connections, water and air, and adjust as required.

Fill the lubricator with oil. Loosen the tubing nuts at the oil line check valves. Be sure each oil line is purged
of all entrapped air and retighten the nuts. Follow instructions in the lubricator manual.

Fill the oil bath filters with oil to the proper level per the instructions shown on filter. If filter is installed
outdoors, use SAE 10-30 in cold weather and SAE 30-50 in hot weather.

Check dry type filters for any blanks or strapping used for shipment.

Where a bag-type dust collector intake filters is used, on an installation at heavy dust loads such as a cement
plant, be sure to check all features from the special instructions furnished.

In any event, recheck that no shipping protector or blind flange is blocking the intake line or filter.

Important-disconnect piping at intake of unit and install a 16 mesh screen between flanges, folded twice, and
reconnect piping firmly. This dirt catching screen is temporary and should be removed after the intake line is
clean. Rap entire intake line thoroughly, at start up, to dislodge all loose material. Repeat until line is clean!

Check all protective devices or controls making sure they are properly connected electrically and/or
mechanically.

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Single Stage Rotary Sliding Vane
F.L.Smidth

START-UP
PROCEED WITH START-UP AS FOLLOWS:

Open cooling water supply valve fully to check the adequacy of the discharge facilities. Throttle the flow to a
moderate rate. Where the unit has a recirculating cooling system, make sure the system is filled.

Start the driver and bring unit up to full speed.

When starting boosters, be sure intake line valves are fully open. Boosters can usually be started against normal
discharge pressure; however, some boosters are piped with a manually valved by-pass, from discharge to
suction, for pressure equalization during startup and shutdown.

When starting vacuum pumps, the discharge line is open to atmosphere and the intake line valve fully open. For
large vacuum pumps, the inlet valve can be closed to reduce starting power and then slowly opened after the
vacuum pump is at full speed.

Adjust the flow of cooling water so that the final discharge ranges from 80F (26 C) to 110F (38 C).

Check and adjust lubricator feed rates to the drop rate indicated on the lubricator nameplate.

Check all protective devices or controls making sure they are working properly.

Check and adjust shaft packing, where used so that there is small amount of leakage of air and oil. Normal
operating temperature will range from 110F (43C) to 180F (82C). Packing running too tight will overheat
excessively. Where mechanical seals are used, no adjustment is required, and cover temperature will operate at
from 125F (52C) to 210F (99C).

MISCELLANEOUS OPERATING NOTES:

Excessive discharge temperature-for normal operation, the discharge temperature will vary over a definite range
as determined with a thermometer. A sudden or gradual rise above this range is indicative of trouble such as
inadequate cooling, faulty lubrication, dirty intake filter, etc. The unit should be stopped and inspected. Any
continuous operation involving discharge air/gas temperatures exceeding 325/350F (163/177C) range
severely affects lubrication and blade strength promoting excessive wear and breakage.

Dirty cooling water causes cooling inefficiency by clogging the jackets. Unit must be dismantled and jackets
scraped and hosed clean. If clean water is not available, suggest back flushing jackets with high pressure air
through the connections on the bottom of cylinder heads.

Loss of cooling water-stop unit immediately and DO NOT turn on unit until unit is completely cool.

Condensibles can cause severe blade wear on special gas boosters or "wet" vacuum pumps and require careful
throttling of jacket water or preheat of suction to maintain internal temperatures above the dew" point.

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Single Stage Rotary Sliding Vane
F.L.Smidth

STOPPING PROCEDURE:

On standard compressors and vacuum pumps, stop the motor or driver.

Shut off water. Continuous flow of water can cause condensation in bearing chambers. Drain cooling system if
freezing is possible.

Where unit is on standby service, run weekly for three to four minutes or turn rotor over by hand with full
lubrication adjustment.

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Single Stage Rotary Sliding Vane
F.L.Smidth

LUBRICATION
F.L.Smidth Company now has as standard an innovative FUL-LUBE Lubrication System...that greatly reduces risk
of rotary compressor damage due to lubrication failure. An advanced distribution block design with a high-capacity
reservoir in a self-contained package is the key to:

increased compressor protection

decreased maintenance man-hours

FUL-LUBE Lubrication System is standard for single-stage, two-stage and duplex compressor arrangements. See
Figures 11 and 11A.
1. 15 and 30 Gallon Storage Tanks allow
approximately one month of continuous operation
between refills...reducing maintenance man-hours and
risk of water contamination.
2. Direct-Driven Pumping Unit with 110-volt
enclosed 1/3-HP motor eliminates risk of compressor
failure due to belt breakage and lubrication loss. Three
phase motors are available as an option.
3. 20-Micron Filter removes entrained
impurities in the lubricant.
4. Distribution Block meters precise
amount of lubricant to each compressor
lube point while eliminating the need for
constant monitoring and adjustment.
5. Digital No Flowtimer (DNFT)
monitors movement of divider valve
piston for dependable timed shutdown
protection.

Figure 11

Figure 11A

Oil is fed to cylinder walls, bearings and mechanical seal with a forcefeed, positive-pressure, lubricator. Each connection on the unit is
equipped with a check valve to prevent leakage of air or gas to the
lubricator. See Fig. 12.
Adjust lubricator feed rates to the drop rate indicated on the lubricator
nameplate. On units with mechanical seals, be sure to hand pump oil to
the seal face at start- up. Never exceed the 3 to 4 drops/minute rate
recommended for the seal.
Whenever unit is disassembled, add approximately 1/2 pint (.231) of oil
to each bearing cavity through pipe tap on top of each bearing retainer at
reassembly.
Figure 12
During the first internal inspection, determine if the proper oil is being
used. Bearings, cylinder walls, rotor slots and blades should show a polished surface with a light film of oil.
Hard, baked deposits indicate inferior oil, dirt or excessive temperature.
Where excessive moisture is present, use suitably compounded oil having the ability to wet metal surfaces in
preference to water.
Gas compressors and boosters are lubricated similar to air compressors except when special gases are being
handled. Special material and lubrication is required.
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Single Stage Rotary Sliding Vane
F.L.Smidth

The following are the characteristics of an oil which will be suitable for units operating on straight air service in
normal room temperatures of 60F (16C) to 90F (32C).
TYPICAL CHARACTERISTICS FOR A PARAFFINIC OIL WITH ADDITIVES:
9
9
9
9
9
9
9

Normal discharge air temp, range: 250 F (121 C) to 325 F (163 C)


Grade: SAE 40
70 to 90 SSU viscosity @ 210 F (99 C)
Gravity: 25 API minimum
Viscosity index: 87 min.
Flash: 450 F (232 C)
0.5% max. carbon residue of base stock (Conradson).

Must meet performance level of former MIL-L-2104A suppl. #1. For abnormal discharge air temperatures above 325 F (163
C) a 90 to 110 SSU @ 210 F (99 C) viscosity oil is required.

TYPICAL BRAND NAME OILS OF NATIONAL SUPPLY SUGGESTED ARE:


Chevron: Chevron Delo 100 Motor Oil

Mobil: Delvac 1640

SAE 40

Compounded oil for wet vacuums:


Texaco: URSA Oil C 150 or Chevron

Cities Service: Citgo C-340

Shell: Shell Morlina / NA150

Marine Oil 150X

Exxon: XD-3 SAE 40

Texaco: URSA ED40 or URSA Extra

For wet compressor service:

Duty SAE 40

Chevron EP Industrial 220X

See Appendix B for Oil Feed Rates


We do not recommend the use of kerosene, gasoline, or any other volatile cleaning agent in the cylinder during
operation. Their use can cause a temporary lack of proper lubrication. Contact FL Smidth Inc. for synthetic
lubricants.

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Single Stage Rotary Sliding Vane
F.L.Smidth

MULTIPLE LUBRICATOR PUMP SYSTEM OPERATION

Figure 13

To Regulate the Feed:


To increase the feed, place a screw driver in the slot
of the feed regulator and turn to the left until the
desired amount is being supplied. To decrease turn
to the right.
Crank for Hand Operation:
The hand crank on the end of the lubricator is for use
before starting, or for momentarily increasing the oil
supplied while the machine is in operation. The hand
crank operates all of the feeds at one time. Its use
does not affect the feed regulation.
Check 'V'-Belt Drive:
Lubricator belts are of the 'endless' variety and
require removal of a link to adjust tension. Check
belt periodically for wear and proper adjustment.

Keep Lubricator CleanUse only new or filtered lubricant. Periodic cleaning of the lubricator is
recommended since lubricant is subject to fouling from atmospheric
dusts and additives. To do this, remove all pumping units; clean them
and the reservoir by dipping and brushing in a cleaning solvent.

To Remove a Pumping UnitAny single unit may be removed from the reservoir by removing the
two screws, which hold it to the cover. After the screws have been
taken out, pry up the front end of unit with a screwdriver, pull unit
forward as far as possible, at the same time tilting the front end upward,
and the unit will readily lift out.

Ful-Lube System
Read the instruction manual for proper installation, operation and
maintenance of this type system

Force feed oiling to cylinder wall (as shown)


on intake quill on other size machines;
assures proper oil distribution to all surfaces.
Bearing oiling connections on cylinder heads
are always located on discharge side.

MAINTENANCE GUIDE
Set up a schedule along the following lines:
Daily
Fill and/or check lubricator.
Drain airlines of condensate including drain on pilot valve, where furnished.
Monthly
Replace oil in oil-bath filter silencers and note if more frequent servicing is needed.
Check operation of safety valves and controls for proper operation.
Check shaft packing take up as required.
Check lubricator drop rate or count rate.
Yearly
Inspect unit as outlined under Inspection and Service
Clean lubricator, oil lines and check valves.
Where furnished, clean regulator and pilot valve.
Clean filter and element.
Recheck alignment and shaft gap.
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Single Stage Rotary Sliding Vane
F.L.Smidth

INSPECTION & SERVICE


INTERNAL INSPECTION
A new unit should be inspected internally during its first year of operation.
Normally, an internal inspection requires removal of the rear end cylinder
head only. See Fig. 13A. The expansion bearing, hub seal ring, blades,
rotor slots, cylinder bore and cylinder jacketing can then be examined. If
all items appear reasonably clean and unworn, further dismantling is not
required. The head gaskets can be reused if not damaged at dismantling.
Should they require replacement, see section on cylinder head gaskets.
However, if preliminary inspection indicates closer examination is
required, proceed to dismantle unit as outlined in following sections and
check items on front or fixed end.
NOTE! Refer to paragraph concerning inspection under lubrication section
to assure proper lubricant is being used.
Figure 13A
Cylinder bore must provide a smooth and true surface for smooth blade action thru each revolution of rotor. Rotor
slots must provide full, even support to blades from end to end and top to bottom. See illustration on page 18.
Clean all carbon build-up, flush jackets, stone any minor corrugations in bore and clean up head faces for a good
gasket surface. Clean out dirt and carbon in the bottom and sides of rotor slots so the blades can retract in slots
freely. When new blades are fully retracted in slots, the top of blades should be flush with the top of the rotor.
Excessive slot wear or major bore corrugations can be repaired in the field; however, a complete factory
reconditioning is recommended.
Occasionally the dowel pins will become offset, which is difficult to determine visually without their complete
removal. This usually happens after blade breakage. Offset dowels can cause premature bearing failure and
rotor damage through contact with heads or cylinder bottom. To check a dowel pin, insert a # 10 drill in the center
hole. A straight dowel pin allows the drill to pass completely through the dowel.
Some machines are built with solid dowel pins. These should be pulled and replaced.
Complete and modern rebuilding facilities exist at F.L.Smidth's manufacturing plant at Manheim, Pennsylvania.
Your compressor can be rebuilt by experienced craftsmen to new machine standards with a six-month warranty on
materials and workmanship. In addition, cylinder assemblies, rebuilt to factory specifications including new
wearing parts, and carrying a six-month factory warranty on material and workmanship from date of shipment, are
available for immediate shipment on an exchange basis.
If major reconstruction in the field is mandatory, special service can be extended for parts. See the following
appendix for special field instructions.
Appendix C: Procedure for remachining cylinder
Appendix E: Indicator method of setting rotor end clearance

Appendix D: Rotor slot criteria


Appendix F: Instructions for reconditioning of cylinder rotor
and head

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Single Stage Rotary Sliding Vane
F.L.Smidth

Compressor
Size
CC15
C30-40
C50
C60
C70
C80
C100
C110 thru C350
C375
C400
C450
C508
C608

Measure blade wear as shown and


replace blades when wear exceeds limits indicated
above.

Figure 15

Blade Wear
SS / LP

(12.7mm)
(12.7mm)
(6.3mm)
(12.7mm)
(9.5mm)
(12.7mm)
(9.5mm)
(12.7mm)
(12.7mm)
(12.7mm)
(12.7mm)
(12.7mm)
(9.5mm)

HP
N/A

(12.7mm)
(6.3mm)
(12.7mm)
(9.5mm)
(12.7mm)
(9.5mm)
(12.7mm)
N/A
N/A
N/A
N/A
N/A

Blades-the maximum recommended blade wear in width can be roughly checked by measuring the distance
between the top of the rotor and top of worn blade(s) with blade seated in bottom of slots - See Fig. 15.
Blades should be checked also for charring, splitting or chipping on the running edge and for concave wear in
thickness at point of rubbing contact with rotor slot. For any wear other than a 'polish', replace with new blades.
Before installing new blades, thoroughly clean rotor slots using keystock as wide as slot width. Bevel one side to
chisel point and work back and forth in slot removing all carbon. Be sure new blades are lightly oiled and fit freely
in slot. File away any metal tending to bind blade from free movement.
New B3000 blades are slightly longer and thinner than other blades, but are interchangeable. Do not modify. The
B3000 may also have cosmetic blemishes and spots on the surface, which will not affect blade performance. If
blade containers are cracked or damaged, blade dimensions will not change with exposure to air and moisture.
Bearings - Any rough, pitted or irregular markings on the bearing running surfaces will cause noise and vibration
and careful examination of the inner race and rollers will indicate when replacement is required. Use a torch to
apply quick heat to the bearing inner race for removal. Note-race temper will be destroyed and bearing is not
reusable.
Shaft Seal-Packing or Mechanical Seal - replace packing if worn or if rotor shaft shows signs of scoring.
If unit has mechanical seal, examine carefully and if face is worn or chipped and ring torn, replace complete seal.
Check the seal cover to assure a smooth mating surface for the seal face and be sure lubricating oil hole is open.
Hub Seal Rings - replace if any signs of wear or breakage are noted. Replacement rings are split for easy assembly.

18
Single Stage Rotary Sliding Vane
F.L.Smidth

DISMANTLING
Remove Rear End Cylinder Head:
Drain water jackets and disconnect oil tubing to head. Remove cylinder head stud nuts. Use two hexagon set screw
wrenches and turn into cylinder head to force head equidistant off the dowel pins and away from the cylinder end.
Return hexagon screws to original position after head is free to be lifted off the studs. Try to preserve cylinder head
gaskets.
Remove Front End Cylinder Head:
For units without spacer coupling, remove piping, hold down bolts, lubrication tubing and swing entire cylinder
assembly so the coupling can be removed.
Remove fixed bearing retainer. Use a long drift pin and hammer to loosen bearing locknut. Look for rotation
direction arrow on locknut since they are furnished with right or left hand threads*. Remove the locknut, lock
washer, spacer and fixed bearing thrust ring. Then, jack off the head following procedure outlined under rear end
head removal. The bearing shims, used to establish the fixed end clearance, should be carefully removed for reuse
on reassembly. Again, try to preserve the cylinder head gaskets.
*On certain, older machines

ASSEMBLY
Bearings and Seal Ring Retainers to RotorPlace rotor on "v" blocks, clean shaft thoroughly
and oil lightly. The hub seal retainers and inner
race of the bearings are furnished for a shrink fit
and must be heated in an oil bath before
assembling to shaft. Heat the bearing inner races
to 200F (93C) or 225F (107C) for 15 minutes
and ring retainers to 450F (235C). Do not heat
with a torch and do not overheat.

Figure 16 Installing pre-heated bearing inner race


Retainers are usually furnished in a one-piece
construction. The rings are split for replacement since
they can be extended over the assembled bearing race
and retainer and slipped into the ring groove.

Inner Ring

Bearing inner races are not alike. The fixed bearing


inner race, assembled on shaft end nearest driver, has a
shoulder and separate collar to hold rotor axially.
See Fig. 17.

Outer Ring

Figure 17

Collar

Fixed bearing parts with inner race assembled.

19
Single Stage Rotary Sliding Vane
F.L.Smidth

Interior view of cylinder


showing intake and
discharge ports. Note
smooth intersection of main
and undercut bores.

20
Single Stage Rotary Sliding Vane
F.L.Smidth

View showing rotor slots. Note parallel side walls to


provide proper blade support.
21
Single Stage Rotary Sliding Vane
F.L.Smidth

CYLINDER HEAD
STUD BOLT INFORMATION
Compressor
Size
11-12-13
15 to 25
30-40-50
60 to 100
110 to 150
175 to 225
175H to 300H
250-300
350
350H
375-608

Torque
Ft-Lbs / Newton
Meters

Qty. Per Set

Stud Dia.

50 / 68
100 / 135
100 / 135

12
12
12

1/2 (12.7 mm)


5/8 (15.8 mm)
5/8 (15.8 mm)

165 / 224
165 / 224
265 / 304
265 / 304
400 / 542
400 / 542

12
12
12
16
16
20

3/4 (19.1 mm)


3/4 (19.1 mm)
7/8 (22.2 mm)
7/8 (22.2 mm)
1 (25.4 mm)
1 (25.4 mm)

400 / 542

20

1 (25.4 mm)

400 / 542

20

1 (25.4 mm)

400 / 542

24

1 (25.4 mm)

400 / 542

24

1 (25.4 mm)

650 / 881

28

1-1/8 (28.5 mm)

Rotor End Clearances (cold)

When the machine is cold,


free end clearance is greater
than fixed end clearance. The
rotor expands from the fixed
end and clearances will
become equalized when hot.

Rotor End Clearances (hot)

Rotor end clearances must


be held to a minimum to
prevent air leakage and the
resultant decrease in
compressor volumetric
efficiency.

22
Single Stage Rotary Sliding Vane
F.L.Smidth

CYLINDER HEAD GASKETS


In replacing gaskets, first measure by micrometer the total thickness of gasket material formerly employed under each
cylinder head, then replace with new gaskets under same total thickness as before, plus .002" (0.5mm) for each layer
of gasket used. This is to allow for compression of new gasket material, which amounts to about .002" (.05mm) for
each sheet.
For new parts or if machine work has been
done on cylinder, rotor, or heads or if old
gaskets cannot be measured, see section on
rotor end clearances.
Two gaskets should be used at each end of
the cylinder and if greater thickness is
required to secure proper rotor end
clearance, the extra may be made of paper.
In this case put the gasket in contact with the
cylinder proper and the paper next to the
head. This will preserve the life of the
paper.
The center of the gasket has purposely not
been cut out. This is because it is necessary
to match the edge of cylinder wall with the
edge of the gasket as nearly as possible.
Place gasket over the head studs, cutting
Figure 18 Trim cylinder head gaskets to suit cylinder bore
proper openings for dowels, then with the
gasket pressed against the end of the face of the cylinder, run a sharp knife blade around to match the edge of cylinder
wall all the way around. See Fig. 17. Gasket must NOT extend inside the edge of cylinder bore as that will interfere
with the action of the rotor blades.

ROTOR END CLEARANCES- LEAD WIRE/FEELER METHOD


(See Appendix E for alternate indicator method)
Front and Rear Heads (See clearance plates on compressor and illustration on page 22.)
Determine fixed end clearance at front head as follows:
Place three bearing shims and outer race of front bearing into housing of cylinder head. Shims are available in
thicknesses of .003" (.076mm), .005" (.125mm) and 0.10" (.25mm).
Place cylinder head over front end of rotor assembly. Care should be taken
to hold bearing outer race and head central to rotor to prevent damaging
bearing inner race and hub seal retainer surfaces.
Assemble the fixed bearing locating collar, fixed spacer and locknut. Do
not assemble lock washer at this time. Tighten locknut firmly.
Assemble front retainer and fasten tightly to cylinder head. Do not use the
retainer gasket at this time.

Figure 19 Checking fixed-end


clearance between rotor and front
head.

Check for maximum clearance by using three feelers, of equal thickness,


inserted between face of cylinder head and end of rotor at three equally
spaced points. See Fig. 19. Be sure cylinder head is pulled away from
rotor face so that the clearance obtained is maximum. Actual clearance
may vary plus .002" (.05mm), minus .000".
23
Single Stage Rotary Sliding Vane
F.L.Smidth

If clearance obtained is more than required amount, the cylinder head must be removed and extra shims added. If
less, necessary shims must be removed.

Check minimum clearance by pushing cylinder head against rotor and inserting .005" (.125mm) minimum feeler
at three equally spaced points.

If doweling is required, establish bottom clearance as indicated in next section.

If doweling is not required, complete fixed end assembly as follows:


Remove bearing retainer, locknut, bearing locating collar and cylinder head with bearing outer race assembled.
Place two synthetic fiber gaskets next to cylinder face, trim to suit and reassemble head. Be sure hub seal ring is
in place. Assemble lock washer to rotor at this time and bend locking ear into nut groove after tightening locknut
firmly.

Tighten nuts on studs evenly and tightly. Be sure backing-off screws and pins are in place in head. Do not install
front bearing retainer.
Proceed to establish expansion end clearance at rear head as
follows:
Place straight edge across face of cylinder at rear end and with
feelers, measure clearance back to face of rotor as shown on
Fig. 20. Subtract this clearance from the sum of the fixed-end
clearance, expansion-end clearance and .002" (.05mm) for each
gasket estimated to be used. This gives the total gasket
thickness required at expansion end between rear head and
cylinder.

NOTE: Where
rotor extends
beyond end of
cylinder, add
Figure 20 Checking clearance between rotor and
cylinder face at rear end.
this clearance
dimension to the
sum of the fixed end clearance, expansion end clearance and .002"
(.05mm) for each gasket to give the' total gasket thickness.

Install the quantity of gaskets as estimated above with the synthetic


fiber placed next to the cylinder and trim to suit.

Check for proper gasketing by installing a lead wire with a


diameter slightly greater than the sum of the fixed end clearance,
expansion end clearance and .002" (.05mm) for each gasket and
hang from the top of the rotor with two ends extending in an arc
around the expansion end face of the rotor. See Fig, 21.

Checking total rotor end


clearance with lead wire to verify expansion
end clearance at rear head. Wire
measurements must be uniform to .002
(.05mm). If not, invert some asbestos gaskets
used.

Figure 21

With bearing outer race assembled, install rear head on studs and
tighten firmly and evenly. Then, remove head, using backing-off
screws and pins to pull clear of dowel pins. Remove lead wire and
measure. If lead measurement exceeds sum of fixed end clearance, expansion end clearance and .001" (.025mm)
for each gasket for future compression; remove sufficient head gaskets to correct. If less, add sufficient gaskets.
Tolerance on this total clearance is plus .005" (.125mm), minus .002 (.05mm) for machines over 700 cfm
(1189m/hr) capacity and plus .003" (.075mm), minus .001" (.025mm) for smaller units.

If doweling is required, establish bottom clearance as indicated in next section.


24
Single Stage Rotary Sliding Vane
F.L.Smidth

If doweling is not required, complete final assembly as follows:

Install blades from rear end and be sure they are lightly oiled and fit freely in slots.

Install hub seal rings.

Reassemble rear head and tighten nuts on studs evenly and tightly. Be sure backing-off screws and pins are in
place in head.

Push rotor towards rear end and assemble both bearing retainers, installing retainer gaskets or "0" rings as
required. Be sure to tighten retainers evenly and firmly to heads.

Replace the packing gland and packing or mechanical seal as required. If packed, install ring by ring, push each
firmly into stuffing box, and tighten with gland after each ring. Install last ring in same manner and then back off
approximately one-half turn. Install split seal In gland.

Replace the rotor half coupling, which is bored for medium push fit, and lock in place with set screw over key.
Some units are equipped with spacer type couplings for ease in making inspections and repairs.

Set unit back on base, shim and realign, connect all external oil, water and air piping. Be sure to recharge bearing
cavity with oil.

Refer to operation section and proceed with start-up accordingly.

DOWELING AND BOTTOM CLEARANCE(See page 21 and clearance plate on compressor.)

Bolt cylinder feet to firm support. Insert rotor (with bearing inner races
assembled) into cylinder and place on shim stock or feeder located
approximately 1-1/2 (38mm) from each end. Rotor is assumed to have
been indicated and runs true within .001" (.025mm), body to bearing
journals, and .003" (.075mm) for shaft at coupling.

Figure 23 Check bottom clearance using


long feeler gauge through inlet or outlet ports.

Select shims or feelers that


are .001" (.025mm) to
.002" (.05mm) thicker
than bottom clearance
specified on name plate
and equivalent in length to
about half of rotor
diameter.

Figure 22 Wedge rotor against shim stock


laid across bottom of cylinder bore at each end
to establish bottom clearance.

Place fixed end of rotor flush with cylinder face. Insert rotor
'jacks' (between top of rotor and cylinder bore) directly above
feelers and wedge tightly to cylinder bore. (See Fig. 22.) NOTEIf an assembled nut and bolt is used as a rotor 'jack,' be sure to
protect rotor and cylinder surfaces with brass or aluminum sheet
stock. Brass or hardwood wedges can also be used.

Verify bottom clearance at center and both ends of cylinder with


long feeler gauges inserted thru inlet and/or discharge ports. Be
sure feelers are inserted far enough to carry down over cylinder
undercut and underneath rotor body. (See Fig. 23.)
25
Single Stage Rotary Sliding Vane
F.L.Smidth

Tolerances on bottom clearances shown in table below:


Compressor Size Bottom Clearance Tolerance
15 to 100
+ 001 (.025mm), -0
110 to 350
+.002 (.050 MM), -0
375 to 608
+.003 (.076 mm), -0

Install cylinder head gaskets as determined by section on rotor end clearances. Use a minimum of two gaskets at
fixed end-I.E. (1) synthetic fiber & (1) paper with synthetic fiber gasket next to cylinder. Do not trim center to
suit bore at this point.

Assemble the heads to cylinder (with bearing outer races in


place) and centralize on studs. Caution - exercise care as head
passes over hub seal ring to avoid breakage. Temporarily install
plain flat washers on bottom two studs and tighten these nuts.
The bearing rollers should now turn freely in the outer race.
Position bearing so that the bottom two rollers straddle the
vertical centerline.

Figure 24. Lift or jack cylinder head to remove


clearance between bottom two bearing rollers and
inner race.

Jack, or lift with hoist, each head vertically till all


clearance is removed between bottom two rollers and
Figure 25. Equalize clearance between
bearing races. See Fig. 24. Centralize remaining rollers
corresponding
rollers on either side of inner race by
by shifting head radially from side to side, so that
positioning cylinder heads on studs. Use feeler
clearances between corresponding rollers on either side of gauge.
vertical centerline are equal. See Fig. 25. Check roller
clearance with 'feelers' as shown in Fig. 24. Tighten all cylinder head stud nuts firmly.
Cover exposed bearings with cloths and drill (2) (6mm) diameter holes (180) apart 5/8" (15mm) to
(19mm) deep into cylinder using 'lead' holes in cylinder head. Re-drill these holes to 1/64 (.37mm) less than
dowel pin diameter and hand ream to size. Blow out cuttings and remove covers.
Drive a dowel pin into each hole with a solid 'drift' until pin bottoms in cylinder. Pins are inserted beveled end
first.
Remove cylinder heads, rotor jacks and feeler strip so that rotor is free in cylinder. Break edges of newly drilled
dowel holes on cylinder side of heads with a counter-sink. Dowels must be tight in cylinder and protrude
approximately (9.5mm) to (12mm) beyond cylinder ends.
Reassemble heads to cylinder and bearing retainers to heads and make a final check of bottom clearance as
described previously. Be sure cylinder head backing-off pins are in place before assembly.

Complete final assembly as described on page 24.


Special tools, as follows, can be procured from F L Smidth for the (13mm) dowels:
19/64 (8mm) high speed drill, 9" (230mm) flute, 12" (300mm) overall
31/64 (12.3mm) high speed, straight shank extension drill, 9" (230mm) flute, 12' (300mm) overall
.500 (13mm) spiral flute reamer with extended shank, 12 (300mm) overall
Note: English & metric dowel systems are distinctly different sizes.
26
Single Stage Rotary Sliding Vane
F.L.Smidth

DOWELING AND BOTTOM CLEARANCE CIRCULAR BORE CYLINDERS


(See Page 22 and clearance plate on Compressor)
Bolt cylinder feet to firm support. Insert rotor (with bearing inner races assembled) into cylinder and place on shim
stock or feeler located approximately 1-1/2" (38mm) from each end. Rotor is assumed to have been indicated and runs
true within .001" (.025mm), body to bearing journals, and .003" (.075 mm) for shaft at coupling.
Select shims or feelers that are .001" (.025 mm) to .002" (.05mm) thicker than bottom clearance specified on name
plate and equivalent in length to about half of rotor diameter.
Place fixed end of rotor flush with cylinder face. Vertical surfaces have been precision machined on both sides and at
each end of the cylinder. Each surface is equidistant from the centerline of the cylinder bore. To center the rotor, use
depth micrometer to obtain equal measurements from each machined surface to a bearing or shaft diameter and to be
within .002" of each other. (See Fig. 26.)
Insert rotor 'jacks' with loose clamping force (between
top of rotor and cylinder bore) directly above feelers and
wedge tightly to cylinder bore. Install round bars (drill
rod or equal) between sides of rotor and cylinder (See
Fig. 26). Apply light force to these bars to prevent any
horizontal movement of the rotor during the head
doweling procedure. NOTE-If an assembled unit and
bolt is used as a 'jack', be sure to protect rotor and
cylinder surfaces with brass or aluminum sheet stock.
Brass or hardwood wedges can also be used. Recheck
dimensions after 'jacks' have been tightened.
Verify bottom clearance at center and both ends of
cylinder with long feeler gauges inserted thru inlet
and/or discharge ports. Be sure feelers are inserted far
enough to carry down over cylinder and underneath
rotor body. (See Fig. 23.)

Wedge rotor against shim stock laid across bottom


of cylinder bore at each end to establish bottom clearance.
Circular bore cylinders.

Figure 26

Tolerances on bottom clearances are plus .001"


(.025mm) - minus .000 (0.0mm) for rotors to 10"
(255mm) in diameter and plus or minus .001" (.025mm)
for larger rotors.

Install cylinder head gaskets as determined by section on


rotor end clearances. Use a minimum of two regular
gaskets at fixed end. Paper gaskets may only be used
between regular gaskets. Do not trim center to suit bore at this point.
Assemble the heads to cylinder (with bearing outer races in place) and centralize on studs. Caution - exercise care as
head passes over hub seal ring to avoid breakage. Temporarily install plain flat washer on bottom two studs and
tighten these nuts. The bearing rollers should now turn freely in the outer race. Position bearing so that the bottom
two rollers straddle the vertical centerline.

27
Single Stage Rotary Sliding Vane
F.L.Smidth

Jack, or lift with hoist each head vertically till all clearance is removed
between bottom two rollers and bearing races. See Fig. 24. Centralize
remaining rollers by shifting head radially from side to side, so that
clearance between corresponding rollers on either side of vertical
centerline are equal. See Fig. 25. Check roller clearance with 'feelers'
as shown in Fig. 27. Tighten all cylinder head stud nuts firmly.
Cover exposed bearings with cloths and drill (2) (6mm) diameter
holes (180) apart 5/8" (15mm) to (19mm) deep into cylinder using
'lead' holes in cylinder head. Redrill these holes to 1/64" (.37mm) less
than dowel pin diameter and hand ream to size. Blow out cuttings and
remove covers.
Drive a dowel pin into each hole with a solid 'drift' until pin bottoms in
cylinder. Pins are inserted beveled end first.
Remove cylinder heads, rotor jacks, round bars and feeler strip so that
rotor is free in cylinder. Break edges of newly drilled dowel holes on
cylinder side of heads with a counter-sink. Dowels must be tight in
cylinder and protrude approximately .3/8 (9.5mm) to (12mm)
beyond cylinder ends.
Reassemble heads to cylinder and bearing retainers to heads and make a
final check of bottom clearance as described previously. Be sure
cylinder head backing-off pins are in place before assembly.

Fig 27 Equalize clearance between


corresponding rollers on either side of
inner race by positioning cylinder
heads on studs.

Special tools, as follows, can be procured from FL Smidth for the 7/16" (10mm) dowels:

1/4" (6mm) high speed drill, 8 (200mm) flute, 12" (300mm) overall
27/64 (9.6mm) high speed, straight shank extension drill, 8 (200mm) flute, 12 (300mm) overall
7/16 (10mm) spiral flute reamer with extended shank, 12 (300mm) overall
NOTE: English & metric dowel systems are distinctly different sizes.

28
Single Stage Rotary Sliding Vane
F.L.Smidth

RENEWAL PARTS

Blades, bearings, head gaskets, coupling pins, hub seal rings, packing or mechanical seal, shaft seal or "O" ring,
lubricator belt (for multiple lubricator), lube pump motor, pumping unit and rupture disc are parts suggested for
stock to meet an emergency.

Spare blades are supplied in a sealed can to provide protection during storage. Do not open the can until blades
are actually required.

Replacement bearings should be procured from FL Smidth. While they are of a standard design, they are built
with special internal clearances to suit the design of the compressor. In addition, interchange of inner races and
outer races cannot be made.

Coupling pins are supplied in plastic bags with moisture absorbing compound to maintain dimensional stability.
Keep bags tightly sealed.

When placing repair orders, refer to the item and item number shown on parts list, together with the compressor
size and serial number as stamped on nameplate.

FL Smidth sales offices are located in principal cities and as listed on back cover.

Also Available
Two Stage Compressors
For producing pressures to 125 pounds (8.8 bar) gauge, these two-stage
compressors equipped with overhead intercoolers are especially functional
where a space problem exists. They produce from 150 (255) to 4000 cfm
(6797mhr) pressures to 125 Ibs. (8.8 bar) gauge.

Vacuum Pumps
Well suited to most all wet and dry
vacuum work, F.L.Smidth rotary
vacuum pumps are especially
effective at higher vacuums to 29.97
Inches (761mm) of mercury.

29
Single Stage Rotary Sliding Vane
F.L.Smidth

SPECIAL NOTICE PARTS


For your protection in today's changing industrial scene, FL Smidth, maintains a policy of "multiple sources" for
many, important purchased compressor components.
This permits mutual pricing benefits and insurance that the parts are available from our stock when your needs are
urgent.
FL Smidth's years of experience and knowledge of the applications are used to achieve interchangeability both
dimensionally and in service life.
Such parts are never under severe service or heavy load so that sizing is conservative.
This procedure is efficiently handled by a modern computer system since each part can be identified by a single
number - regardless of its manufacturer.
Current stock, at any one time, may thereby reflect the continuous changes in purchasing quantities and deliveries
from any one specific supplier.
This makes it difficult and at certain times, impossible to supply a part of a "specified manufacturer."
Should your storeroom or expeditor encounter this situation, we request your cooperation to update your records and
accept the part supplied with full confidence of FL Smidth's concern and experience to provide reliability.
Some compressor parts in this category are:

Parts List Numbers

Item
Blades
Front bearing
Rear bearing
Bearing locknut
Bearing lockwasher
Shaft packing
Hub seal rings
Cylinder head gaskets
Coupling pins
Pressure gages
Mechanical shaft seals
Safety valves

C66-A446
Single Stage
3
6
7
8
9
14
17
21
42
54
62
---

C67-A114 Two Stage


Low
Pressure
High Pressure
103
1003
106
1006
107
1007
108
1008
109
1009
114
1014
117
1017
121
1021
142
1042
-1054
-1062
---

30
Single Stage Rotary Sliding Vane
F.L.Smidth

31
Single Stage Rotary Sliding Vane
F.L.Smidth

IMPORTANT!

For major factory repairs or reconditioning:


Send Purchase Order to:

Ship Compressor to:

F.L.Smidth
2040 Avenue C
PO Box 2040
Bethlehem, PA 18017

F.L.Smidth
236 South Cherry Street
Manheim, PA 17545
Note: Before shipping please call
F.L.Smidth and request a Return
Material Permit.

Or call toll-free: 1-800-523-9482

32
Single Stage Rotary Sliding Vane
F.L.Smidth

33
Single Stage Rotary Sliding Vane
F.L.Smidth

34
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX A
Cog (Synchronous) Belt Tension Adjustment for Integral Drives
Measure the force required to deflect belt 1/64" for every inch of span length. For example for a 32" span between
sprockets, the deflection would be 32/64 or 1/2" deflection. The belt tension should be then adjusted to equal the
force in the table below based on motor hp and smaller sprocket diameter.
Force perpendicular to belt at mid span between drive and driven sprocket.
Note: Force is based on 1800 rpm motor. For other speeds multiply force by: 1800/Actual RPM
Drive Motor Horsepower at 100 RPM
Smaller
Sprocket
200
250
300
350
400
Diameter
in / mm
Force # / Newtons
8 in
56 #
69 #
83 #
97 #
111 #
203 mm
247 N
309 N
371 N
433 N
494 N
10 in
44 #
56 #
67 #
78 #
89 #
203 mm
198 N
247 N
297 N
346 N
396 N
12 in
37 #
46 #
56 #
65 #
74 #
305 mm
165 N
206 N
247 N
288 N
330 N
14 in
32 #
40 #
48 #
56 #
63 #
356 mm
141 N
177 N
212 N
247 N
283 N

450

125 #
556 N
100 #
445 N
83 #
371 N
71 #
318 N

35
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX B
Compressor Lubrication Feed Rate
Tabulation
Drops per Minute Rate of Feed
Cyl.
Cyl.
Wall
Int.
No.
Drops
Total
Flange
Feeder
Each
Drops

Total
No.
Feeds

Pints
(Liters)
Per Day

12

1.23
(6)

--

12

1.23
(.6)

--

--

12

1.23
(.6)

25

2.57
(1.22)

25

2.57
(1.22)

705

--

30

3.09
(1.5)

175-200

590

--

35

3.60
(1.7)

225

590

--

40

4.11
(1.95)

250-300

590

--

49

5.04
(2.4)

350

590

--

63

6.48
(3.1)

375-400-450

500

11

--

11

77

7.92
(3.7)

508-608

500

11

--

11

99

10.18
(4.8)

Size

(60hz)
Rpm

Each
Head

15

1780

--

--

30-40-50

1180

--

60-70

880

75-80-100

880

110-120

705

135-150

1.

All mechanical shaft seals; three (3) drops per minute each.

2.

Basis of drop rate - approximately .491 grains/drop, 28,000 drops/quart (29,600 drops/liter).

3.

Some compressors with mechanical seals also have oil buffered bearing seals. These compressors have
two (2) additional lube points.

4.

For other compressor speeds, readjust feed rate in direct proportion to speed change.

5.

Lube rates can be reduced depending on compressor applications. Consult F.L.Smidth Compressor
Engineering.

36
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX C
PROCEDURE FOR REMACHINING CYLINDER MAIN BORE, UNDERCUT BORE &
BROACH BORE ON HORIZONTAL BORING MILL

As shown by these drawings, the undercut is a key to the high volumetric efficiency of the F.L.Smidth rotary
compressor. After boring the cylinder to size, the boring bar is dropped to the point of rotor eccentricity and a
second cut is taken at bottom only and at same radius as the rotor. After the bore intersections are blended, this
undercut section of the cylinder is parallel to the rotor surface for approximately 30 and, with close running
clearance, acts as an effective seal between discharge and suction pressures. At assembly, the rotor is placed on
clearance shims in the undercut and the heads are dowelled to the cylinder to maintain the bottom running clearance.
REMACHINE MAIN BORE ONLY - (A)
1. Indicate diagonally from 2 positions from end to end, to establish and position the original main cylinder bore
centerline.
2. Measure the main bore horizontally.
3. The boring bar should be set to cut a diameter equal to this horizontal bore plus the small amount required to
remove major corrugations.
4. The intersection of this new cut with the untouched part of the cylinder must be stoned for a smooth surface.
REMACHINE UNDERCUT BORE ONLY - (B)
11. Repeat operation (1) for main bore remachining.
12. Lower boring bar, from original cylinder bore centerline, an amount equal to the eccentricity for the cylinder.
This amount, stamped on the face of the cylinder inlet flange and referred to as "ECC" or "be", ranges from
.420" (10.7mm) to 1.142" (29mm).
13. Measure the major rotor body diameter.
14. The boring bar should be set to cut-a diameter equal to this rotor body diameter plus the small amount required
to remove major corrugations.
15. The intersection of this new cut with untouched part of the cylinder must be stoned for a smooth surface.
REMACHINE BOTH MAIN BORE AND UNDERCUT BORE - (A) AND (B)
21. Repeat operations 1 to 3 for main bore remachining and operations 12 to 14 for undercut bore remachining.
22. The intersection made by above two cuts must be removed by either stoning or machining followed by stoning.
In order to do this by machining, the boring bar, following remachining of undercut bore, is raised 2/3 of the
eccentricity and the cutting tool is extended to start its cut in the undercut section at a predetermined horizontal
distance from the vertical centerline and as tabulated below:
Size (See nameplate)
Horizontal Distance
30, 40, 50
1-3/16 (30.2mm)
60, 70, 75, 80, 100
1-3/4" (44.5mm)
110, 120, 135, 150
2-3/32" (53.2mm)
175, 200, 225, 250, 300, 350
2-5/8 (66.7mm)
375, 400, 450, 508, 608
2-3/8" (60.3mm)
This third cut, called the "broach bore, will remove the large ridges at the intersection of the main bore and
undercut bore leaving four small ridges and which can readily be removed by stoning.
The circular bore design requires remachine of main bore only. (A) See bore charts on page 45 and 46 for both
undercut and circular bore design.
37
Single Stage Rotary Sliding Vane
F.L.Smidth

GENERAL NOTES:
I.

Finish of cylinder to be equivalent to G. E. Co. "F" roughness specimen (125 average micro inches roughness
by profileometer) or smoother.
II.
For hand stoning of the bore intersections, suggest using an abrasive dressing stone having an approximately
120 grit size. A typical stone is a #C120P-Vuf as manufactured by Carborundum Company, use light oil in
dressing.
III. After boring operation is completed, the cylinder ends must be checked square (90 within .002" (.05mm)
with surface of undercut. If necessary, face one end from the boring mill set-up and machine opposite end
parallel. (See VIII).
IV. After remachining undercut bore, it is always necessary to redowel in order to restore the bottom clearance as
stamp D. on cylinder nameplate. If more than .030" (.75mm) metal has been removed from the undercut, the
cylinder head stud holes may need enlargement by 1/8 (3.2mm) maximum to obtain some latitude in
obtaining the proper bottom clearance.
V.
Minor surface imperfections are of no importance. The creation of a smooth, continuous surface for even
blade peripheral rubbing contact thru each revolution is important.
VI. Should the cylinder bore show cracks or holes, it must be hydrostatically tested to 125# (8.8 bar) ga. for
tightness. Use the cylinder heads with gaskets to close the cylinder ends and pressurize the jacketing.
Examine interior thru bearing cavity in each head.
VII. As a general guide, an average reboring involves the removal of from .020" (.5mm) to .060 (1.5mm) metal
with a corresponding slight increase in displacement and horsepower. On this basis, a cylinder can be
reworked from two to three times.
VIII. FES - F.L.Smidth Ammonia Boosters, designed by prefix "A" on nameplate, have CYL, ends skewed from
square on horizontal centerline.
After operation of note III, adjust cylinder on boring table to check and reface ends, by shortening length of
discharge side with respect to intake side, by the amount given, per end, and measured on the O.D.
A135, A150 - .005" (.125mm)
A2S0, A300 - .010" (.25mm)
A508, A608 - .0I5" (.381mm)
A175, A200 -.005" (.125mm)
A350, -.012" (,30mm)
Tolerance .002" (.O5mm)
Tolerance .003'(.076mm)
Tolerance .003" (.076mm)

38
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX D

ROTOR SLOT CRITERIA


NOTES
A. Slots must be straight & true with parallel
sides. See slot dimension tabulation.
B. Bell mouthing, at finish sanding or filing;
must not exceed, .004" (.10mm) over maximum
width tolerance. (New or reconditioning work)
C. Major - finish area approx. (6.4mm)
deep x full length. Desired finish E(63M.I.)
Max. finish F (125 to 150 M.I.). For short
sections not exceeding 2 (50mm), minor unidirectional saw tear marks, not exceeding 1/32
(.8mm) width x .005 (.125mm) depth, are
approved provided spacing creates good blade
support area. File break corner knife top edges
of slot to an equivalent 1/32" (.8mm) radius.
D. Minor - finish area - length x standout finish F (125 to 150 M.I.) maximum.
E. Since rotor may be rotated in either
direction, finish of "C" and "D" applies to both
walls or slot.
F. Finish designations to G. E. surface finish
gages or by sight and feel to Manheim slot gage
blocks.

G. See other notes on rotor drawings.


H. For repairs to worn slots: Reslotting, for a thicker blade, is required if .040" (1.0mm) feelers (maximum) can be
inserted, alongside of a new blade, for 3/8 (9.5mm) depth or more - extending 1/4 or more of blade length.
Two reslottings - limit.

Standard Slot Blades


Blades T
Min. in (mm)
Max. in. (mm)
.231 (5.86)
.241 (6.12)
.292 (7.42)
.302 (7.67)
.350 (8.89)
.360 (9.14)
.411 (10.43)
.421 (10.69)
.480 (12.19)
.490 (12.44)

Slots A
Min. in (mm)
Max. in. (mm)
.252 (6.4)
.256 (6.5)
.315 (8.0)
.319 (8.1)
.375 (9.5)
.379 (9.6)
.438 (11.1)
.442 (11.2 )
.499 (12.9)
.503 (12.8)

39
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX E
INDICATOR METHOD OF SETTING ROTOR
END CLEARANCE FOR F.L.SMIDTH SLIDING VANE COMPRESSOR
STEP #1:
STEP #2:

STEP #3:

STEP #4:
STEP #5:
STEP #6:
STEP #7:

STEP #8:

STEP #9:

STEP #10:

STEP #11:

STEP #12:

STEP #13

Place rotor in cylinder. Install two 1/64" (.4mm) gaskets on each end of the cylinder per instruction
book.
Assemble fixed end cylinder head, with outer race of fixed bearing, on rotor. Place race with bearing
manufacturer's name at the top and facing outside. Install .010", (.25mm) bearing shims behind outer
race. Do not install locknut or bearing retainer.
Assemble expansion end cylinder head on rotor with exp. bearing. Position outer bearing race with
manufacturer's name at top, facing outside. Do not assemble bearing retainer, but use retainer gasket
behind outer race in head. Lock washer tine in locknut slot after tightening locknut.
Tighten heads firmly using all the stud nuts except one on exp. head.
Mount dial indicator on exp. end cyl. head stud firmly and set to indicate end of rotor shaft or face of
locknut. Alternate firm mountings acceptable.
Force rotor forward against the fixed head using a bar or jack. With rotor in contact with fixed head set
dial indicator to zero making sure the indicator point is in contact.
Using bar or jack, force rotor against the exp. head. With rotor against head, read and record dial
indicator reading as "A". This reading is the total possible float of the rotor between the heads.
Repeat procedure several times for an accurate reading. It should match the total rotor float clearance
given on the clearance plate, plus .001" (.025mm) for each head gasket used. If reading differs from this
sum, readjust gasket thickness at exp. end. (The .001" (.025mm) allowance per gasket, compensates for
compression set or shrinkage during initial heat of operation).
The rotor should now be forced against the fixed head. Install bearing thrust collar, bearing inner race
spacer (on older machine), lockwasher and locknut. Tighten locknut but do not bend washer tine. Set
the dial indicator to zero.
Mount fixed end bearing retainer, with bearing retainer flat gasket or "0" ring seal removed, and bolt
tightly. Do not attempt to draw retainer flange against head because the skirt comes into contact with the
bearing outer race before the flange contacts the head. This step moves the rotor away from the fixed
end head in the amount of the minimum fixed end clearance. Read dial indicator and record. Repeat
procedure several times for accuracy. Adjust bearing shims to obtain correct minimum fixed end
clearance "B"-add shims to decrease, remove shims to increase.
Again set the dial indicator to zero with rotor positioned toward fixed end but with bearing retainer
(from #9 bolted in place). Optionally, leave indicator reading from #9 as is, and measure difference to
new reading for this operation as "C". The rotor should now be forced towards the exp, head using a bar
or jack. This movement represents the axial clearance or play in the fixed end bearing. Read and
record as "C". This dimension should not exceed the maximum play "C" shown on the clearance plate
and tabulation. Repeat procedure.
After clearances are final, remember to install bearing retainer flat gaskets or "0" ring seals and bend
down lockwasher tine in locknut at fixed end. Install exp. end bearing retainer with its gaskets.
Complete assembly per instruction book.
This indicator method creates directly the min. fixed end running clearance "B" as opposed to the old
procedure described in the main section of the instruction book (using feeler stock) which is obtained
indirectly by setting a max. fixed end clearance, and reliance on bearing manufacturers' axial end-play
limits. The lesser figures in these columns correspond approximately to the old clearance plate stamping
of-Max. Fixed End Clearance". The figures listed are the sum of "B" plus "C".
The procedure applies to all machines having a #103-10-12932-01 clearance plate which lists: A" Total.
Rotor Float; B" Minimum Fixed End Clearance; C" Maximum Fixed End Bearing Axial Play; Rotor
Bottom "D". The plate also shows, for correlation to the old feeler-lead wire procedure, the Maximum
Fixed End clearance and Minimum Expansion End clearance used for assembly and stamped on A12932
clearance plates. This Minimum Exp. End clearance is approximately figured as the sum of "B" and "C"
subtracted from A".

40
Single Stage Rotary Sliding Vane
F.L.Smidth

STEP #14:

BASIC
MACHINE
SIZE

TOLER.
ROTOR
TOTAL
FLOAT
A

15, 16
30, 40, 50
60, 70, 80,
100

+.003
(+.076mm)
-.000

110, 120
135, 150
175, 200,
225
250, 300

+.005
(+.127mm)
-.000

350
375, 400,
450

508, 608

+.007
(+.178mm)
-.000

MINIMUM FIXED END


CLEARANCE B
C/V
Toler.
A/F FES
F.L.Smidth
Both
in.(mm)
in.(mm)
in.(mm)
(.076)
.003
(.076)
(.076)
+.001
.003
.003
(+.025)
(.1)
(.1)
-.000:
.004
.004
(.127)
(.1)
.005
.004
(.15)
(.25)
+.002
.006
.010
(.05)
-.000
(.15)
(.25)
.006
.010
(.178)
(.25)
+.003
.007
.010
(.076)
-.000
(.178)
(.30)
.007
.012
(.25)
.010
(.25)

MAX.PLAY
F.BRG.C

In.(mm)
(.203)
.008
(.225)
.009
(.25)
.010
(.25)
.010
(.31)
.012
(.330)
.013
(.381)
.015)
(.381)
.015
(.381)
.015
(.381)

MAX. FIXED END


CLEARANCE RANGE
C/V
A/F FES
F.L.Smidth
In.(mm)
in.(mm)
.008(.203)
.010(.254)
.009(.229)
.009(.229)
.013(.330)
.013(.330)
.011(.279)
.011(.279)
.015(.381)
.015(.381)
.012(.305)
.011(.279)
.016(.406)
.015(.381)
.014(.35)
.018(.457)
.020(.508)
.024(.610)
.015(.381)
.019(.483)
.021(.533)
.025(.635)
.017(.432)
.020(.508)
.025(.635)
.028(.711)
.017(.432)
.022(.559)
.025(.635)
.030(.762)
.017(.432)
.025(.635)
.023(.584)

.010

.015

.031(.788)

NOTE: For FES-A refrigeration machines using synthetic fiber gaskets only, a tolerance of -.005 (.127mm) is
permitted for total rotor float A.

STEP #15: Remove (1) stud nut on exp. end head on


horizontal centerline. (Cylinder head must be in place.)
With 5/16" (8mm) dia. rod upright screwed to clamp,
attach clamp securely to exposed threads of stud. With
indicator screwed to (6.4mm) dia. rod, connect to
upright with sliding swivel clamp. Adjust so that indicator
spindle contacts firmly any vertical surface of the exposed
rotor such as the bearing locknut face or end of rotor shaft.
Suggested: Brown & Sharpe Cat. #599-7740 Universal
Dial Indicator Set.

SHOWING INDICATOR SETUP (on small machine.)

41
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX F
RECONDITIONING LIMITS - GUIDELINES
The units returned will be disassembled, cleaned and given a thorough inspection. Cylinders and/or heads will be
hydrostatically tested where necessary. A complete report will be submitted to Parts and Engineering Departments. In
addition to the normal obvious examination criteria, the following is a list of allowable limits for repair-ability.
CYLINDERS:

See Table 1 for rebore limitations (pages 45 & 46)

Minor repairs of the outer jacket by "Devcon" procedure are permissible. (103-79-1-2003)

Small gouge or pit marks in the bore and minor cracks above the discharge port are permissible.

Cylinders with corroded water connections can be re-tapped to the next size.

Cylinder and/or heads, repaired by welding, brazing, or metalocking, by customer, are acceptable for temporary
repair but not suitable for the exchange program.

Cylinders having corroded water ports on ends, for less than 1/4" (6.35 mm) gasket seal width, are to be scrapped
for the exchange program.

Max. undersize in length 0.030" (.762 mm).

When remachining cylinder bore and/or undercut, remove only enough metal to restore to a smooth surface.

ROTORS:

Repair of shafting is permissible by steel bonding or metallizing under packing, seal or bearing journal areas.

Repair of shaft in coupling area is to be done by welding.

Reslotting criteria per manual (Y) page 38; (B) page 49

LP/SS allowed (2) 1/16 (25.4 mm) reslots over standard.

HP allowed (1) 1/16" (25.4 mm) reslot over standard.

Maximum allowable undersize for body diameter from standard after rework
- C30 to 50
.005" (.127 mm)
- C60 to 350
.010" (.254 mm)

Undersize body diameter over these limits indicates scrapping rotor.

Maximum allowable undersize for body length from standard after rework
- C30 to 120
.010" (.254 mm)
- 30H to 120H .005"(.127 mm)
- C135 to 225
.015" (.381 mm)
- 135H to 350H .010" (.254 mm)
- C250 to 350
.020" (.508 mm)

Undersize body length over these limits can be built up by spraying ends of body with aluminum-bronze material.

Machine rotor body to proper length and reslot or sand slots accordingly.

Increase keyway length for all standard coupling type LP and HP in sizes 110 and larger per Table 2.

Maximum allowable for rework of a bent rotor shaft is .030" in coupling area.
42
Single Stage Rotary Sliding Vane
F.L.Smidth

CYLINDER HEADS:

Maximum allowable refacing .015" (.381 mm) to 100 size and .025" (.635 mm) above (103-78-1-2003)

Bushing hub bore acceptable per manual (Y) P. 37; (B) P.46)

Heads with graphitic corrosion of the water ports and/or lubrication boss exceeding 1/8" (3.2 mm) shall be scrapped.

Old bearing retainers may be reused with longer bolts for new heads.

Minor cracks in the hub bore, which do not reach the internal jacketing diameter nor leak, and not exceeding (3) in
number, are permitted.

Standard displacements, dimensions, and blade size per 103-70-4-2001-1- shall be followed. All unused dowel pin holes
on outside of head are to be plugged using drive lock pins.

When one head is replaced, install new head on fixed end with proper bearing retainer.

When an NRV or coupling half is returned with the assembly, it will be repaired as a separate item and returned to
the customer with separate billing.

Miscellaneous general repair standards apply.

After reboring cylinder, reface ends to be 90 exact true to undercut bore to assure bearing alignment. Cylinder
reboring instructions are given by C66-B244. Hydrostatic test required after reboring as required on note VI p. 33.

When refacing heads, be sure resulting wall thickness to bearing cavity is true within .0005 (.0127 mm) for 360 at
bore I.D.

When refacing, minor indentations or raised hard spots to 0.5 sq in (322 sq.mm) max are permissible to 0.001
(.025mm) to C100; and 0.002 max variation from flat.

Rotor is always indicated for alignment of body to bearing journals and shaft to journals. When reworking, recenter ends to zero run-out on journals and work body or shaft to this base. Always reface rotor body ends with
light cut for 90 trueness to O.D. Body must be true to journals within .001" (.0254 mm). Shaft at coupling: .001
(.0254 mm) for shafts to 2-3/4" (69.85 mm) diameter and .0025 (.0635 mm) above.

Page 38 describes slotting standards. (Manual)


Where reboring undercut lowers rotor by more than .030" (.762 mm), it may be necessary to re-drill cylinder head stud
holes 1/16 (1.38 mm) larger to permit dowelling, for proper bottom clearance.
For general reconditioning other than the exchange program, these limits and guidelines are followed. However,
exceptions and relaxations of limits, for specific cases of practical and economical reasons, are permissible but do not
allow the use of standard parts as being interchangeable.
Rebore limitations, per Table 2, apply except for size change,
Heads can be refaced to a greater extent than given and up to 3/32" (23.8 mm) maximum, however, a special shim,
matching bearing retainer gasket I.D. and O.D. and of thickness equal to amount removed from head face, must be
inserted in cylinder head behind bearing to realign bearing outer race assembly to its inner race on rotor. Aluminum,
steel, or brass materials are OK. (103-78-1-2003)

43
Single Stage Rotary Sliding Vane
F.L.Smidth

Compressor instruction book gives detailed information on overall assembly procedures including gaskets for rotor end
clearances and dowelling procedures for bottom clearance.
Cylinder and head jackets must be cleaned, for all reconditioning, to achieve a minimum of +40F above adiabatic
discharge air temperature, during test, at clearance pressure.
Cleaning procedures must suit type of jacket fouling; i.e. - chemical for hard scale type and mechanical-flushing type for
soft, mud/sludge deposits.

Reference Instruction List


103-72-2-3401
103-75-2-2003
103-75-2-2016
C67 -A458 (7 Pages)
C66-B244
C64-A402
103-70-4-2001 (2 pages)
103-71-3-3701
103-69-1-2008
103-71-1-2016
C66-A446
C67-A114
103-87-1-3405

Cylinder Assembly Part Nos. and Construction


Single Stage Shop Card (Clearances, Porting, etc.)
Two Stage Shop Card (Clearances, Porting, etc.)
Servicing Instructions
Cylinder Rebore Instructions
Rotor Slot Criteria
Basic Engineering Data
Cross Section & Change Old to #69 Construction
Method of determining Fixed End Bearing Alignment Using Dial Indicator
Indicator Method for Setting End Clearances
Single Stage Instruction Book (Y)
Two Stage Instruction Book (B)
Dowelling Instructions

44
Single Stage Rotary Sliding Vane
F.L.Smidth

COMPRESSOR SERVICE
Certain emergency field procedures must be, and are justified, and the customer should realize the remote possibility
of failures-balanced against the urgency of the repair.
Included in these procedures are:

Cold straightening of rotor shafts

Cold straightening of rotor slot segments

Welding of rotor shafts particularly at shaft section changes

Cold welding (Devcon) interior or exterior cylinder cracks

Metalock of cylinder bore cracks

Rotor shaft metalizing on v-belt drives

Coupling fits made with shim stock

Any other emergency repair where the original strength or design is weakened

Welding of internal cylinder cracks

45
Single Stage Rotary Sliding Vane
F.L.Smidth

TABLE 1: CYLINDER RE-BORE LIMITATIONS, SINGLE STAGE (SS) UNDERCUT BORE DESIGN (C)

Size
R.P.M.
30
40
50
60
70
80
100
110
120
135
150
175
200
225
250
300
350
375
400
450
508
608

1180

Cylinder
Drawing
No.: 10386-4-3106

880

86-4-3107

880

85-4-3101

705

85-4-3108

705

86-4-3109

590

86-4-3110

590

86-4-3111

590

86-4-3112

5590

82-5-3101

500

88-4-3105

500

68-5-3101

New Cylinder Bore


7.024 (178.4 mm)
7.182 (182.4 mm)
7.340 (186.4 mm)
10.039 (245 mm)
10.236 (260 mm)
10.040 (255 mm)
10.236 (260 mm)
12.024 (305.4 mm)
12.208 (310.1 mm)
12.038 (305.8 mm)
12.206 (310 mm)
15.064 (382.6 mm)
15.355 (390 mm)
15.189 (385.8 mm)
15.109 (383.8 mm)
15.355 (390 mm)
15.355 (390 mm)
17.790 (451.9 mm)
17.930 (455.4 mm)
18.180 (461.8 mm)
17.950 (455.9 mm)
18.310 (465.1 mm)

New Cylinder
Undercut

Max. Cylinder Rebore

6.287 (159.7
mm)

.075 (1.91 mm)

7.438 (188.9 mm)

8.937 (227 mm)

.079 (2.0 mm)

10.370 (263.3 mm)

8.937 (227 mm)

.079 (2.0 mm)

10.370 (263.3 mm)

10.630 (270 mm)

.118 (3.0 mm)

12.413 (315.3 mm)

13.307 (338 mm)

.118 (3.0 mm)

12.413 (315.3 mm)

13.307 (338 mm)

.118 (3.0 mm)

15.439 (392.2 mm)

13.307 (338 mm)

.118 (3.0 mm)

15.433 (392 mm)

13.307 (338 mm)

.118 (3.0 mm)

15.439 (392.3 mm)

15.530 (394.5
mm)

.120 (3.0 mm)

18.410 (467.6 mm)

15.530 (394.5
mm)

.120 (3.0 mm)

18.410 (467.6 mm)

New Rotor Body


Diameter

46
Single Stage Rotary Sliding Vane
F.L.Smidth

TABLE 2: CYLINDER RE-BORE LIMITATIONS; SINGLE STAGE (SS), CIRCULAR BORE (CC)

Size
15
30
40
50
60
70
80
100
110
120
135
150
175
200
225
250
300

RPM
1780

Cylinder Dwg
No. 10388-4-3104

1180

86-4-3102

880

85-4-3111

880

84-4-3101

705

85-4-3109

705

86-4-3103

590

86-4-3104

590

86-4-3105

590

86-4-3101

New Cylinder Bore


6.315 (160.4 mm)
7.099 (180.3 mm)
7.257 (184.3 mm)
7.415 (188.3 mm)
10.118 (256.99 mm)
10.315 (262 mm)
10.118 (257 mm)
10.315 (262 mm)
12.142 (308.4 mm)
12.324 (313 mm)
12.156 (308.8 mm)
12.324 (313 mm)
15.182 (385.6 mm)
15.473 (393 mm)
15.307 (388.8 mm)
15.227 (386.7 mm)
15.473 (393 mm)

New Rotor
Diameter
5.315 (135 mm)

Max Cylinder Rebore


6.415 (298 mm)

6.287 (159.7 mm)

7.513 (190.8 mm)

8.937 (227 mm)

10.449 (265.4 mm)

8.937 (227 mm)

10.449 (265.4 mm)

10.630 (270 mm)

12.531 (318.3 mm)

10.630 (270 mm)

12.531 (318.3 mm)

13.307 (338 mm)

15.557 (395.1 mm)

13.307 (338 mm)

15.557 (395.1 mm)

13.307 (338 mm)

15.557 (395.1 mm)

47
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX G
TROUBLE SHOOTING CHART
Trouble
Discharge air or gas temperature
excessive

Probable Causes

Remedy

1. Operation of machine at a higher pressure ratio


than rated.
2. Excessive suction temperature
3. Insufficient or high temperature inlet water

1. Operate unit at rating plate pressures.


2. Reduce suction temperature to rating plate
value.
3. Increase water gpm or provide cool water
supply.
4. Clean water jacket and filter or treat water
supply as required.
5. Clean intake filter.
6. Clean valve and replace any parts.
7. Open suction valve.
8. Use correct oil and feed rates
recommended in instruction manual.
9. Dry out or replace rotor blades.
1. Increase gpm or provide cool water
supply.
2. Clean, repair or replace regulating valve.
3. Open or clean valve. Check solenoid and
wiring on automatic type valve.
4. Clean strainer.

4. Scale or residue build-up in water jacket


5.
6.
7.
8.

Jacket outlet water temperature


excessive.

Clogged intake filter


Unloading valve not fully open or clogged
Suction valve not fully open.
Insufficient or wrong lubricating oil

9. Swelled or warped rotor blades


1. Insufficient or high temperature inlet water
2. Fouled or faulty water temperature flow
regulator.
3. Supply valve (manual or automatic type) either
not fully open or clogged.
4. Leaky head gasket

Water drained from main or inspection


ports.
Undue noise, vibration or periodic
knocking

1. Replace gasket.
2. Remove cooler and hydrostatic test for
leaks. Repair or replace leaky cooler.

1. Leaky head gasket


2. Leaky aftercooler

1. Worn bearing
2. Excessive blade wear
3. Erratic cylinder wear
4. Insufficient lubrication
5. Rotor contacting cylinder or heads

Compressor with unloading valve will


not unload properly

Excessive blade wear

6. Misalignment
7. Swelled or warped rotor blades
1. Faulty pressure switch or three-way solenoid
pilot valve
2. Clogged control airline or ports in three-way
solenoid pilot valve
3. Unloading valve dirty or internal parts worn.
1. Insufficient quantity of lubricant to one or more
cylinder feeds.

2. Incorrect lubricant and/or viscosity


3. Dirty inlet air or gas.
4. Excessive operating temperature

1.
2.
3.
4.
5.

Replace bearing.
Replace blades and check lubrication.
Rebore, redowel, and check lubrication.
Increase lube feed rate.
Check temperature and pressure
conditions, check internal clearances.
6. Realign units.
7. Dry out or replace rotor blades.
1. Repair or replace switch or valve.
2. Clean airline and three-way valve.
3. Clean or replace unloading valve parts
1. If Ful-Lube System, refer to Ful-Lube
manual; otherwise
a) Inspect lubricator V-belt for slippage or
breakage, tighten or replace as required.
b) Check lube rate and increase by several
drops per minute.
c) Inspect lubricator sight glasses, replace
if cracked
d) Inspect cylinder lubr check valves; clean
or replace as required.
e) Inspect oil holes in cylinder; clean if
dirty
2. Use correct oil and viscosity as
recommended in instruction manual.
3. Clean and inspect intake filter.
4. See remedies under excessive discharge
gas or water temperatures.

NOTE: If assistance is needed in determining and correcting cause of malfunction, notify local field sales office or the factory.

48
Single Stage Rotary Sliding Vane
F.L.Smidth

REPLACEMENT PARTS
REPLACEMENT PARTS
Replacement parts are ordered by item number and description, quantity and the rating plate serial number of your unit.
If the fitted part you need is not illustrated, describe it completely and include the unit serial number.
Place the order with your nearest F.L.Smidth Sales Office. Offices are listed on the back cover.
Cylinder head gaskets must be of the proper type and. thickness.
Bearings used in these machines are specially ground and fitted. If it becomes necessary to replace bearings, order them
from FL Smidth. Standard bearings will cause trouble.
It is recommended that the following parts be stocked to insure quick repairs and minimum downtime: Rotor blades,
bearings, shims, gaskets, O rings, seal rings and either stuffing box packing or a mechanical seal.

49
Single Stage Rotary Sliding Vane
F.L.Smidth

APPENDIX H
F.L.SMIDTH PROVIDES A COMPLETE
COMPRESSOR REBUILDING PROGRAM
F.L.Smidth Ful-Vane (typical) rotary compressors have long trouble-free performance records in virtually every
type of air and gas handling service. Hundreds of Ful-Vane rotary compressors have run for years, maintaining
constant volume without loss of pressure, and with minimal wear of working parts. In time, like all equipment, your
Ful-Vane compressor may need an overhaul so when that time comes have F.L.Smidth restore your compressor to
like new condition. No one else can do it better, faster or more economically.

Your F.L.Smidth Ful-Vane Compressor will be rebuilt to new machine standards at a fraction of new machine
cost.

Your Ful-Vane Compressor will be rebuilt by experienced craftsmen more efficiently, economically and in less
time.

In emergencies your Ful-Vane Compressor can be rebuilt and back to you in a matter of days.

Ful-Vane rebuilt compressors are covered by our 6-month factory warranty on materials and workmanship.
Complete and modern rebuilding facilities at Pennsylvania FL Smidth Manufacturing Plant

Find out more about our emergency program and why it pays to have us rebuild your F.L.Smidth Ful-Vane
Compressor - Call today.

EXCHANGE PROGRAMS
F.L.Smidth equipment is designed for long
service life; however, eventually replacement of
key operating parts may become necessary.
F.L.Smidth has developed exchange programs,
which apply to standard Fuller-Kinyon pump
screws, Fuller-Kinyon air-cooled seal
assemblies, rotary compressors and F-K
Diverter valves.
In all F.L.Smidth exchange programs, each
component-or complete machine-is
reconstructed to the original factory
specification and standards of quality.
Therefore, the exchange equipment is identical
to new replacement items and is backed by an
F.L.Smidth warranty. In addition, credit is issued for useable returned parts.
Where exchange replacement parts are not available, F.L.Smidth stocks new parts
for most systems. In both cases, F.L.Smidth maintains a large inventory of
components ready for immediate shipment anywhere in the world.
For more information on exchange programs, call or write F.L.Smidth requesting our Machinery Exchange and
Repair Program book.
Note: Currently, compressors used in gas services are not included in the exchange program.

50

C67-Al14-13

Pneumatic Transport
F.L.Smidth Inc.
2040 Avenue C Bethlehem, PA 18017-2188 USA
Tel +1 610 264 6011 Fax +1 610 264 6735
Toll-free: 1 800 523 9482
www.fls-pt.com

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C67-Al14-13