PG-1028-N (HOS) Maintenance

2. Install the assembled operator and valve cover assembly into the valve hole, sliding the
pushrod over the extension bolt (loose fit).

3. Clean the threads (both internal and external) of the valve cover stud nuts or
capscrews, then apply anaerobic adhesive primer and allow it to dry for five minutes.
Apply Loctite® #242 threadlocker (two drops) to each capscrew. Tighten the valve
cover squarely by tightening the capscrews gradually, in several stages, working back
and forth across the stud circle.

Valve cover stud nuts must be correctly tightened to the

design pre-stress to ensure safe and efficient operation of
the compressor. Refer to CHAPTER 5 of this manual for
detailed tightening requirements.

4. Adjust the stroke of the unloader.

H. Adjusting the Stroke

1. Loosen the setscrew adapter locknut.

2. Slowly rotate the operator assembly clockwise until rotation is resisted without the
locknut, washer, and Threadseal™ assembly contacting the valve cover.

3. Slowly rotate the operator assembly counterclockwise 1-1/2 turns if the suction valve lift
is greater than 0.100 inch (2.54 mm), or 1 turn if the suction valve lift is less than or
equal to 0.100 inch (2.54 mm).

4. Tighten the setscrew adapter locknut, pressing the washer and Threadseal™ firmly
against the valve cover. Be sure not to rotate the operator, setscrew adapter
assembly.

5. Connect operating pressure line and cycle unloader several times to ensure that free
movement exists and that the unloader is functioning. Connect vent lines.

4-17.2 Variable Volume Clearance Pockets

The Variable Volume Clearance Pocket (VVCP) is installed in the outer head of the
compressor cylinder. For cylinder bores 13.00 inch and smaller, the outer head is a one-piece
style (See Figure 4-35). For cylinder bores larger that 13.00 inch, the outer head is a two-piece
style (See Figure 4-36). For plug style (See Figure 4-37). The VVCP can be adjusted while the
compressor is running OR when the compressor is shut down and the cylinder depressurized.

4-87
Maintenance PG-1028-N (HOS)

DO NOT plug the vent connection in the VVCP housing. The

vent opening must always be left open to assure safe and
effective operation of the lantern ring seals. When the process
gas is toxic, flammable, narcotic, or in any other way
objectionable in the compressor building, all applicable safety
precautions must be observed. The vent must be piped to a
non-hazardous area, such as a gas disposal (flare) or vapor
recovery system. Vent piping must not be less than 3/8-inch (9.5
mm) O.D. and, if combined with other vent systems, there must
not be any back pressure or vacuum in this piping.

The VVCP is equipped with seals that are installed on each side of a lantern ring. This
seal assembly is held in place by a flat washer and secured by a retaining ring (See Detail A in
Figures 4-35, 4-36 and 4-37). There is also a vent port in the main body housing that is located
over the lantern ring that allows a test gauge or a vent to be connected.

tại vị trí tiếp giáp giữa Locking

Wrench và actuating Wrench,
VVCP Rod sẽ chịu ứng suất thay
đổi cả hướng và độ lớn, độ lớn
cực đại cũng tại vị trí này.

Figure 4-35. Variable Volume Clearance Pocket (One-Piece Head)

4-88
PG-1028-N (HOS) Maintenance

Figure 4-36. Variable Volume Clearance Pocket (Two-Piece Head)

4-89
Maintenance PG-1028-N (HOS)

Figure 4-37. Variable Volume Clearance Pocket (Plug Type)

TP-5138

Figure 4-38. VVCP Position Indicator

4-90
PG-1028-N (HOS) Maintenance

Table 4-5. Maximum Allowable Clearance Volume

Nominal Cylinder Maximum Stroke Maximum Total

Size of VVCP Piston VVCP Volume
3
Inch Inch Inch
4.75 5.00 79.5
5.75 5.00 84.0
6.00 5.00 93.3
6.50 5.00 98.2
7.00 5.00 108.2
7.75 5.00 141.4
8.00 5.00 153.4
9.00 5.00 192.4
9.50 5.00 220.9
10.50 5.00 267.3
11.50 5.00 318.1
12.25 5.00 354.4
13.00 5.00 392.7
14.00 5.00 464.4
15.00 5.00 542.2
16.25 5.00 663.7
17.50 5.00 825.7
19.00 5.00 883.6
20.50 5.00 1037.0
22.00 5.00 1151.7
23.00 5.00 1254.7
24.50 5.00 1610.3
26.00 5.00 797.4
26.50 5.00 797.4

The volume is changed by means of a movable piston. The piston is attached to the
piston rod by a threaded connection between the piston and the rod. Loosening the Locking
Wrench and turning the Actuating Wrench handle in the clockwise direction, which will draw the
piston outward away from the cylinder, increases the clearance volume. Within the limits of the
pocket capacity (See Table 4-5), the exact amount of clearance volume can be added by
turning the Actuating Wrench. Close control over the required cylinder capacity can be
accomplished by setting the piston at some intermediate position between fully closed and fully
open.

A grease fitting in the main body housing allows the piston rod threads to be greased.
Periodic maintenance consists of applying a small amount of grease, compatible with the
process gas, to this grease fitting. It is suggested that the grease fitting be greased before each
adjustment. If adjustment is infrequent, then the grease fitting should be greased at least one a
month.

4-91
Maintenance PG-1028-N (HOS)

To operate the VVCP, first use an NON-SPARKING HAMMER to loosen the Locking
Wrench in the counter-clockwise direction. Move the plunger pin handle to the locked (slotted)
position and continue to turn the Locking Wrench counter-clockwise until the plunger pin
engages the Actuating Wrench. Once the Locking Wrench is loose and engaged with the
Actuating Wrench, the Adjusting Wrench handle can be turned by hand clockwise to open the
pocket, or counter-clockwise to close the pocket. The position of the pocket is conveyed by the
Position Indicator, which can be seen through the sight glass (See Figure 4-38). Once the
pocket is in the desired position, the plunger pin needs to be pulled out of the slot and rotated to
the unlocked position. Then, just the Locking Wrench can be hand tightened in the clockwise
direction. To finish locking, use the non-sparking hammer to fully tighten the Locking Wrench.

A. Removal/Disassembly of the One-Piece Style Outer Head

Observe the safety precautions (Paragraph 4-2 in this Instruction

Manual) before attempting to remove a compressor outer head. It
is particularly important that ALL PRESSURE is released from the
cylinder passages and piping before pulling the VVCP.
CAREFULLY CRACKING OPEN drain valves on inlet and
discharge manifolds is a good method to determine if any pressure
exists in the cylinder bore, cylinder passages and piping. INJURY
TO PERSONNEL CAN OCCUR IF THESE PRECAUTIONS ARE
NOT STRICTLY OBSERVED.

Figure 4-39. VVCP Assembly – (One-Piece Head)

4-92