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McQuay HallScrew HS-3100 Series Compressor Service Manual
McQuay HallScrew HS-3100 Series Compressor Service Manual
McQuay HallScrew HS-3100 Series Compressor Service Manual
Service Manual
HS L/M 3100
HSS 3100
©
J & E Hall International 2007
All rights reserved. No part of this publication may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying, recording or by any information
storage or retrieval system, without permission in writing from the copyright holder.
The copyright in this publication shall be and remain the sole property of J & E Hall International.
Contents
1. About this Publication ................................................................................................5
1.1. Safety Warnings and Symbols ............................................................................................... 5
1.2. Units of Measurement ............................................................................................................ 5
1.3. Terminology ............................................................................................................................ 5
1.4. Ordering Extra Copies............................................................................................................ 5
2. Introduction................................................................................................................6
2.1. Cleaning and Storing Components ........................................................................................ 6
2.2. Preparations for Reassembly................................................................................................. 6
2.3. Special Tools .......................................................................................................................... 7
3. Essential Operations Prior to Dismantling, Recommissioning....................................8
3.1. Pumping Out The Compressor .............................................................................................. 8
3.2. Recommissioning the Compressor ........................................................................................ 9
4. Star and Star Bearing Assembly..............................................................................10
4.1. Star Rotor Assembly – Dismantling ..................................................................................... 12
4.2. Star Rotor - Reassembly ...................................................................................................... 17
4.3. Fitting New Star Rotors ........................................................................................................ 19
5. Discharge End Cover (HS L/M 3100).......................................................................21
5.1. End Cover (HS L/M 3100) – Removal ................................................................................. 21
5.2. End Cover (HS L/M 3100) – Refitting .................................................................................. 21
6. Oil Separator Assembly (HSS 3100) .......................................................................24
6.1. Oil Separator Assembly (HSS 3100) – Removal ................................................................. 24
6.2. Oil Separator Assembly (HSS 3100) – Refitting .................................................................. 24
7. Slide Valve, Main Rotor and Main Bearings.............................................................27
7.1. Main Rotor Assembly – Dismantling .................................................................................... 29
7.2. Main Rotor Assembly – Reassembly ................................................................................... 35
8. Stator/Rotor Assembly, Motor Terminal Plate and Suction Strainer.........................41
8.1. Motor Terminal Plate – Dismantling ..................................................................................... 42
8.2. Motor Terminal Plate – Reassembly .................................................................................... 42
8.3. Suction Strainer – Dismantling............................................................................................. 46
8.4. Suction Strainer – Reassembly............................................................................................ 46
8.5. Stator/Rotor Assembly – Dismantling .................................................................................. 48
8.6. Stator/Rotor Assembly – Reassembly ................................................................................. 52
9. Discharge Non-return Valve (HSS 3100) .................................................................58
9.1. Discharge Non-return Valve (HSS 3100) – Dismantling...................................................... 59
9.2. Discharge Non-return Valve (HSS 3100) – Reassembly..................................................... 59
10. Oil Filter (HSS 3100)................................................................................................62
10.1. Fitting a New Oil Filter Element (HSS 3100) - Dismantling ................................................. 63
10.2. Fitting a New Oil Filter Element (HSS 3100) - Reassembly ................................................ 63
11. LVDT .......................................................................................................................66
11.1. LVDT – Dismantling and Reassembly ................................................................................. 67
12. Discharge Thermistor ..............................................................................................68
12.1. Discharge Thermistor – Removal......................................................................................... 68
12.2. Discharge Thermistor – Refitting.......................................................................................... 68
13. Capacity Control Solenoid Valves............................................................................70
13.1. Capacity Control Solenoid Valve - Dismantling ................................................................... 70
13.2. Capacity Control Solenoid Valve- Reassembly ................................................................... 71
List of Figures
Fig 1 Guide Studs ..................................................................................................................................... 7
Fig 2 Star Rotor and Star Bearing Housing Assembly........................................................................... 10
Fig 3 Removing Star Rotor Bearing Taper Roller Race......................................................................... 12
Fig 4 Fitting New Star Rotor Bearing Inner Race................................................................................... 13
Fig 5 Star Rotor Assembly – Dismantling............................................................................................... 14
Fig 6 Star Rotor Assembly – Dismantling............................................................................................... 15
Fig 7 Star Rotor Assembly – Reassembly.............................................................................................. 16
Fig 8 Star Rotor Components ................................................................................................................. 19
Fig 9 Fitting New Star Rotor ................................................................................................................... 20
Fig 10 Discharge End Cover – Removal and Refitting (HS L/M 3100).................................................. 23
Fig 11 Oil Separator Assembly – Removal and Refitting (HSS 3100)................................................... 26
Fig 12 Slide Valve, Main Rotor and Main Bearings................................................................................ 27
Fig 13 Main Rotor Assembly – Dismantling ........................................................................................... 31
Fig 14 Main Rotor Assembly – Reassembly .......................................................................................... 37
Fig 15 Stator/Rotor Assembly, Motor Terminal Plate and Suction Strainer........................................... 41
Fig 16 Motor Terminal Plate – Dismantling ............................................................................................ 43
Fig 17 Motor Terminal Plate – Reassembly ........................................................................................... 44
Fig 18 Suction Strainer – Removal and Refitting ................................................................................... 47
Fig 19 Stator/Rotor Assembly – Dismantling ......................................................................................... 49
Fig 20 Stator/Rotor Assembly – Reassembly ........................................................................................ 54
Fig 21 Discharge Non-return Valve (HSS 3100) .................................................................................... 58
Fig 22 Discharge Non-return Valve (HSS 3100) - Dismantling and Reassembly ................................. 60
Fig 23 Oil Filter (HSS 3100).................................................................................................................... 62
Fig 24 Fitting a New Oil Filter Element (HSS 3100)............................................................................... 64
Fig 25 LVDT Components ...................................................................................................................... 66
Fig 26 Discharge Thermistor .................................................................................................................. 69
Fig 27 Capacity Control Solenoid Valve Location .................................................................................. 70
Fig 28 Solenoid Valve Armature Tube - Dismantling ............................................................................. 71
Fig 29 Capacity Control Solenoid Valve Components ........................................................................... 72
Fig 30 Armature Tube and Coil Assembly- Reassembly ....................................................................... 73
List of Tables
Table 1 Recommended Tightening Torques for Fastenings – HS 3100 Series Compressors ............. 74
WARNING
This denotes an immediate hazard with a high likelihood
of personal injury or death if instructions, including
recommended precautions, are not followed. There is
also a potential risk of damage to the product, process
or its surroundings.
CAUTION
This draws attention to instructions which must be
complied with to avoid damage to the product, process
or its surroundings.
NOTE: draws attention to important additional
information.
1.2. Units of Measurement
Quantities are expressed in SI units or SI derived units.
1.3. Terminology
Terminology, abbreviations and acronyms are those currently in use
throughout the refrigeration and air conditioning industry.
1.4. Ordering Extra Copies
Obtain extra copies of these instructions from the address below:
J & E Hall International Telephone: +44 (0) 1634-731-400
Engineering & Projects, Fax: +44 (0) 1634-731-401
Invicta House, Email: helpline@jehall.co.uk
Sir Thomas Longley Road, Website: www.jehall.co.uk
Medway City Estate,
Rochester,
Kent ME2 4DP
England
2. Introduction
This manual illustrates and describes servicing HS 3100 series HallScrew
compressors.
Some operations, for example, removing the main rotor assembly, are
exercises not to be undertaken without careful preparation and should
certainly not be carried out without careful consideration of what is
involved. Read through all parts of these instructions before starting
work, note the sequence of operations and identify each part.
Before any work is undertaken, remember that each time the compressor
or any other part of the plant is opened up there is increased opportunity
for air, moisture, dirt or other harmful contaminants to enter the system.
For this reason dismantling the compressor should be limited to those
occasions necessary to ensure efficient operation.
2.1. Cleaning and Storing Components
During the dismantling process the greatest care must be taken to keep
exposed parts free from dirt. As an aid to achieving this, thoroughly clean
down the outside of the compressor, remove all traces of oil and
congealed dirt. If the dirt is particularly thick or oily, use a proprietary
cleaner to dissolve and loosen the dirt. Finally, wipe down the exterior of
the compressor with clean rag, and only then, when it is free from dirt,
should the dismantling process begin.
All traces of the old gasket material must be removed from the joint faces.
Oilways can be cleaned out with pipe cleaners or a thin wire brush. If an
air line is available, oilways should be blown through as an added
precaution. Whenever possible refit nuts, bolts and washers finger-tight
on the original stud, bolt or hole from which they were removed, or keep
them in clearly labelled containers or polythene bags. Shims, where
fitted, should also be retained in their original positions.
As parts are dismantled and cleaned, neatly arrange item on clean paper
in the correct order for reassembly. Similar sub-assemblies, for example,
stars, slides etc., should be kept separate from each other, do not
interchange items. Wipe unpainted metal surfaces with a clean, lint-free
cloth moistened with fresh refrigeration oil; this will prevent corrosion
forming. Finally, wrap or cover items with polythene sheet to protect
them from dust and dirt until they are required for reassembly.
If the compressor has to be left partially dismantled for a prolonged
period of time, it is important to prevent dirt or other foreign matter from
entering by blanking-off opening to the main casing. Covers can be
temporarily refitted but, if this is impractical, sheets of hardboard or thick
cardboard can be employed instead or a large polythene bag used to
completely cover the compressor.
2.2. Preparations for Reassembly
After the compressor has been dismantled and all parts thoroughly
cleaned, each component should be carefully examined for damage or
wear. Before reassembly commences, carefully examine all capscrews
and studs and renew any which have damaged threads.
Only new gaskets, ‘O’ rings, joint rings, seals and lockwashers must be
used during reassembly. Reuse of the old components is a false
economy and can give rise to oil and/or refrigerant leaks; avoid this
possibility by always using new parts. To ensure good sealing and to
make future dismantling easier, gaskets should be smeared with clean
refrigeration oil during reassembly.
WARNING
Pumping out the compressor, isolating the electrical
supply and clearing the compressor of gas are the first
steps in all maintenance exercises which involve
breaking into the refrigeration or oil systems. Personnel
should be thoroughly acquainted with the principles laid
down in this part before further work is undertaken.
3.1. Pumping Out The Compressor
Differences in plant layout, with particular reference to the position of
pipeline stop valves, means that it is impossible to give precise
instructions for every installation. However, the following method of
pumping out the compressor is generally applicable where suction and
discharge stop valves are provided.
(a) It is desirable to reduce the capacity of the compressor as much as
possible when pumping out. Turn the plant capacity control switch
to ‘manual’ then press the ‘unload’ push-button to move the slide
valve(s) to the minimum load position.
(b) If the compressor is fitted with oil cooling by liquid injection, close
the stop valve in the liquid line before the thermostatic injection
valve.
(c) Very slowly partially close the suction stop valve while keeping the
compressor running. The compressor will pump down, trip and
stop on the LP cut-out when suction pressure falls to the trip
setting. Close the discharge stop valve after the compressor has
stopped.
If the plant is not fitted with a suction stop valve, it is usually
necessary to close the stop valve in the main liquid line and pump
out from the evaporator.
The LP cut-out must not be bypassed in order to obtain a lower
suction pressure. This practice may ultimately result in marginal
compressor lubrication conditions if excessive amounts of oil are
pumped over.
(d) Close the stop valve at the oil outlet line from the oil
separator/reservoir (HS L/M 3100 only) and all stop valves in the
lubrication and oil injection lines to the compressor.
(e) Isolate the electrical supply to the control panel(s) and stator/rotor.
WARNING
Precautions must be taken to prevent circuits being
accidentally energised, i.e. withdraw the mains fuses or,
if this is not feasible, place a warning notice over the
mains supply.
(f) Carefully discharge the gas remaining in the compressor and oil
separator into a suitable recovery container.
Refrigerant should never be discharged to atmosphere. The
precise method to adopt depends on the type of refrigerant; further
details can be found in the appropriate publication for the
refrigerant available from J & E Hall International.
Even after pumping out as described, great care must be exercised
when opening up the compressor since pockets of gas will still
remain.
19
17
18
10
16
8
13 12 7
15
SBH LBH 6
11
3
4
14
2
Increase the lip clearance by Adding shims to the LBH
bearing housing.
Adjusting Lip Clearance
Reduce the lip clearance by Subtracting shims from the
LBH bearing housing.
13 7
11 10
12
1
2
15
6
11 7
8
16
1 Star backing
2 Star rotor
14 M8 x 25 capscrew – star
bearing housing
15 Pre-load spring washer
16 Shim(s)
17 Top cover
18 Gasket – top cover to casing
CAUTION
Disengaging the star teeth from the main rotor may
require turning the main rotor by a small amount.
Beware trapping fingers between the star teeth and the
main rotor.
(l) Remove the star rotor assembly through the top cover opening.
(m) If a new star rotor or star bearings are to be fitted, remove the star
rotor inner races using a suitable bearing puller; refer to Fig 3.
Use a pneumatic, hydraulic or mechanical bearing press to fit new
star bearing inner races; refer to Fig 4.
Fitting a new star rotor is described in 4.3. and Fig 9.
(a) Use M12 guide studs (arrowed) to safely remove the (b) Lift away the top cover
top cover.
LBH SBH
(c) Remove the top cover to casing gasket. A new item (d) The star rotor assembly in-situ: g
must be fitted during reassembly.
(e) Use guide studs (arrowed) to remove the SBH. (f) Withdraw the SBH.
(g) The SBH after removal. (h) Use guide studs (arrowed) to remove the LBH.
(i) Withdraw the LBH, plus any shims which may be (j) The LBH after removal.
fitted.
(k) Disengage the star teeth from the main rotor. (l) The star rotor assembly after removal.
Remove the star rotor assembly through the top cover
opening.
(a) Offer up the star assembly to the top cover opening. (b) Manipulate the star assembly through the top cover
opening. Engage the star teeth with the flutes in the
main rotor.
(c) Use the guide studs to locate the shims under the (d) Secure the LBH with four capscrews spaced 90°
LBH. apart.
(e) Fit the SBH in the same way. (f) Check the lip clearance.
CAUTION
Any attempt to continue turning the compressor over
when no lip clearance exists may seriously damage the
star teeth.
Now slacken off the screws to allow the SBH, which is spring-
loaded, to lift off. Carefully retighten the capscrews to keep the
bearing housing in this position, i.e. against the spring but without
taking up any compression.
(f) Measure the lip clearance by inserting feeler gauges between the
surface of the star and the lip which runs across the star. Rotate
the main rotor and repeat the measurement at several points
around the star.
The lip clearance should be set to 0.005 to 0.040 mm (0.000 to
0.002 ins)
• Increase the lip clearance by Adding shims to the LHB
bearing housing.
• Reduce the lip clearance by Subtracting shims from the
LHB bearing housing.
(g) Having determined the lip clearance, remove the bearing housings,
one at a time, and fit new ‘O’ rings ‘8’ and ‘13’.
(h) Lubricate the ‘O’ rings before refitting the bearing housings and
shims.
Note: Align the treaded forcing holes in the bearing
housing flange with the corresponding holes in the
shims or the shims will be damaged the next time
forcing screws are used.
(i) Insert the housing capscrews and tighten finger-tight. Unscrew
and remove the guide studs. Insert the other two screws, then
tighten all the screws evenly, alternately and a little at a time to the
following torque
• Small Bearing Housing (SBH) 30 N m (22 lbf ft).
• Large Bearing Housing (LBH) 59 N m (44 lbf ft).
(j) Recheck the lip clearance.
(k) With the correct clearances, the compressor should be free to turn
by hand and should rotate smoothly and evenly.
(l) Spray refrigeration oil over the star, star bearings, main rotor flutes
etc.
(m) Refit the top cover.
Locate a new top cover gasket onto the casing flange.
Offer up the top cover, locate over the guide studs.
Insert the cover capscrews and tighten finger-tight. Unscrew and
remove the guide studs. Insert the other two screws, then tighten
all the screws evenly, alternately and a little at a time to 104 N m
(77 lbf ft).
(n) Recommission the compressor as described in 3. Essential
Operations Prior to Dismantling, Recommissioning.
3
2
4 5
1 Star backing
2 Star rotor
3 Star locating pin
4 ‘O’ ring 15.54 OD x 2.62 section
– star locating pin
5 M5 x 35 capscrew – star locating
pin
(a) Clean the star rotor backing. (b) Locate the star rotor over the backing.
(c) Fit star locating pin ‘O’ rings. (d) Fit the star locating pins.
(e) Turn the star rotor assembly over. (f) Degrease the star locating pin capscrews, apply
Loctite 275 to the threads.
(g) Tighten the capscrews finger-tight. (h) Torque capscrews to 15 N m (11 ft lbf).
WARNING
The discharge end cover is a heavy component.
Attempting to remove the cover without using guide
studs may result in serious injury to the operator.
Remove the rest of the capscrews. If necessary, use forcing
screws to jack the cover from its joint face.
(e) Refer to diagrams (d) to (f).
Swing the end cover out of the way. Remove the cover gasket.
Take care not to damage the discharge temperature sensor
(arrowed).
5.2. End Cover (HS L/M 3100) – Refitting
Refer to Fig 10.
Before reassembly commences, remove any paint from joint faces.
Inspect parts individually for damage, ensure they are completely clean
before laying them out on a sheet of clean paper in a logical order ready
for reassembly.
A new discharge end cover to casing gasket must be used. Use fresh
refrigerant oil to lubricate the gasket during reassembly.
(a) Refitting the discharge end cover is the reverse of the dismantling
sequence; follow steps (f) to (c) in Fig 10.
WARNING
The discharge end cover is a heavy component.
Attempting to refit the cover without using guide studs
may result in serious injury to the operator.
Oil Drain
Connection
(a) Drain the oil from the compressor. (b) The drain connection maybe fitted with a valve.
(c) Screw guide studs (arrowed) into two capscrew (d) Swing the end cover out of the way.
positions, screw eyebolts into the cover flange.
(e) Protect the discharge thermistor (arrowed). (f) Remove the cover gasket.
Fig 10 Discharge End Cover – Removal and Refitting (HS L/M 3100)
WARNING
The oil separator assembly is a very heavy component.
Attempting to remove the separator without using guide
studs may result in serious injury to the operator.
Using the eyebolt as a handle, withdraw the non-return valve
assembly from the separator housing. Remove the gasket.
(e) Refer to diagram (e).
Screw eyebolts into two threaded holes in the separator housing
flange. Attach suitable lifting apparatus to the eyebolts. Take up
the slack in the lifting apparatus.
Unscrew and remove two capscrews 180° apart. Insert M12 guide
studs into the vacant holes on the separator housing flange.
Remove the rest of the capscrews. If necessary, use forcing
screws to jack the cover from its joint face.
(f) Refer to diagrams (g) and (h).
Swing the oil separator assembly out of the way. Remove the
cover gasket.
6.2. Oil Separator Assembly (HSS 3100) – Refitting
Refer to Fig 11.
Take this opportunity to remove any dirt that may have accumulated
inside the oil separator. Clean out the inside with lint-free rag.
WARNING
The oil separator assembly is a very heavy component.
Attempting to refit the separator without using guide
studs may result in serious injury to the operator.
Insert the cover capscrews and tighten finger-tight. Unscrew and
remove the guide studs. Insert the other two screws, then tighten
all the screws evenly, alternately and a little at a time to 104 N m
(77 lbf ft).
(b) Immediately before refitting the discharge non-return valve
assembly (the reverse of the dismantling sequence; follow steps
(d) and (c) in Fig 11), fill the oil separator with 10 litres of fresh
refrigeration oil of the same type and grade used in the system.
Insert the cover capscrews and tighten finger-tight. Unscrew and
remove the guide studs. Insert the other two screws, then tighten
all the screws evenly, alternately and a little at a time to 104 N m
(77 lbf ft).
(c) Reconnect the discharge line.
(d) If an oil temperature sensor or oil level sensor was fitted, reconnect
wiring at the terminal box.
(e) Recommission the compressor as described in 3. Essential
Operations Prior to Dismantling, Recommissioning.
Oil
Drain
(a) Drain the oil from the compressor. (b) The drain connection maybe fitted with a valve.
(c) Make an alignment mark (arrowed). Screw an M16 (d) Screw guide studs into two capscrew positions.
eyebolt into the top of the non-return valve assembly.
(e) Screw guide studs into two capscrew positions on the (f) Unscrew the remaining capscrews.
oil separator flange.
(g) Swing the oil separator assembly out of the way. (h) Remove the cover gasket.
14
13
16
15
12
8 4 4 5
10
11
2
3
5 Roller bearing
6 Roller bearing – suction end
7 Circlip
8 M45 locknut
9 M45 lock washer
10 Main bearing retaining plate
11 M6 x 16 capscrew - main
bearing retaining plate
12 Bearing housing cover
13 Capacity control cylinder
14 M5 x 25 capscrew - capacity
control cylinder
(a) View with end cover (HS L/M 3100) or oil separator (b) Unscrew the slide stop screw.
assembly (HSS 3100) removed
(c) Remove the slide stop screw. (d) Loosen the capscrews securing the capacity control
cylinder.
(e) Hold the capacity control cover against the spring (f) Remove the capacity control assembly.
force while removing the last two screws.
(g) Capacity control assembly after removal. (h) Remove the gasket.
(i) Remove the unloading spring. (j) Unscrew and remove the bearing housing cover
capscrews.
(k) Remove the bearing housing cover. (l) Shimming behind the bearing housing cover is used to
centralise the main rotor assembly.
(m) The capacity control slide bore. (n) Remove the two orifice plugs (arrowed).
(o) Screw an eyebolt into the end of the main rotor shaft. (p) Screw a length of rod into the other end of the shaft.
Attach a shackle to the eyebolt. Wrap paper round the rod to protect the bearings.
(q) Withdraw the main rotor assembly. (r) Use the handling rod to guide and support the main
rotor assembly.
(s) The suction end main bearing roller race is located by (t) Remove the circlip and withdraw the roller race.
a large internal circlip.
Use a metal rod through the hole for the slide stop to check that
the slide loads smoothly against the spring force.
(k) Refer to diagrams (v) to (x).
Refit a new ‘O’ ring to the slide stop screw. Lubricate the ‘O’ ring
before assembly. Tighten the slide stop screw.
(l) Finish reassembling the compressor.
• Reassemble the star rotor; refer to 4.2.
• Refit the delivery end cover (HS L/M 3100) or oil separator
assembly (HSS 3100); refer to 5.2. or 6.2.
• Refit the motor rotor; refer to 8.6. Stator/Rotor Assembly –
Reassembly steps (d) and (e).
• Reassemble the suction strainer: refer to 8.4.
(m) Recommission the compressor as described in 3. Essential
Operations Prior to Dismantling, Recommissioning.
(a) Fit the suction end main bearing outer roller race. (b) Fit the circlip.
(c) Screw the handling rod into the end of the main rotor (d) Guide the main rotor into the casing bore.
shaft.
(e) Slide the main rotor assembly into place. (f) Fit the orifice.
(i) Fit a new O’ ring. (j) Position any shimming over the main bearing retaining
plate.
(k) Fit the bearing housing cover. (l) Torque the capscrews to 30 N m (22 lbf ft).
(m) Lubricate the cover flange. (n) Locate a new gasket on the cover flange.
(o) Locate the unloading spring inside the capacity control (p) The capacity control slide valve assembly.
slide bore.
(q) Enter the slide into the bore. (r) Push the slide valve home against the spring.
(s) Enter the cover capscrews and tighten to 30 N m (22 (t) Check the slide loads smoothly against the spring
lbf ft). force.
(u) The unloading spring in-situ. (v) Fit a new ‘O’ to the slide stop screw.
(w) Screw into the capacity control cover. (x) Tighten the slide stop screw.
13
2 1 3 11
12
9
10
15
8
15
6
4 14
6
7
1 Motor housing
2 Stator
3 Rotor
4 Rotor shaft spacer
5 Rotor retaining plate
6 M16 x 40 hex head screw – rotor
retaining plate
7 Spring washer
8 Suction end cover
13 M8 x 30 capscrew – motor
terminal plate
14 Suction strainer
15 2 x gaskets
(a) The motor terminal plate with the terminal box (b) Unscrew and remove the capscrews, lift of the
removed. terminal plate.
(c) Use pliers to pull the thermistor wire off the spade (d) Remove the second thermistor wire.
terminal.
(e) Unscrew the stator lead terminal nuts and bolts (6 off). (f) Lift off the terminal plate.
(a) Screw guide studs into the housing flange. (b) Position a new gasket and the terminal plate over the
guide studs.
(c) Insert the bolt through the hole in the terminal post. (d) Place the terminal over the bolt.
(e) Place the plain washer over the bolt. (f) Add the spring washer.
(g) Screw the brass nut onto the terminal bolt. (h) Hold the nut with a spanner, then tighten the bolt to
21 N m (15 lbf ft).
(i) Wind the thermistor wire around a stator lead. (j) Engage the thermistor over the terminal.
(k) Push the terminal plate assembly against the housing (l) Insert the capscrews, tighten to 30 N m (22 lbf ft).
flange.
(a) The suction strainer in-situ. (b) Remove the strainer to suction flange gasket.
(c) Withdraw the strainer. Clean as described in 8.3. (d) Remove the strainer to suction cover gasket.
(a) Draw an alignment mark (arrowed). (b) Remove two capscrews, screw guide studs (arrowed)
into the vacant holes.
(c) Unscrew and remove the capscrews. (d) Remove the suction end cover.
(e) Stator/rotor housing with cover removed. (f) Position a capscrew as shown to lock the rotor.
(g) The rotor retaining plate in-situ. (h) Loosen the rotor retaining plate screw.
(i) Remove the screw, spring washer and retaining plate. (j) Remove the rotor shaft spacer.
(k) Withdraw the rotor. (l) Remove the rotor key from the shaft.
(m) View of the motor housing with the rotor removed. (n) Stator location dowel in-situ.
(o) Remove the dowel. (p) Fit the stator handling tool.
(q) Attach a shackle to the eyebolt. (r) Withdraw the stator from the housing.
Offer up the suction cover ‘8’, locate over the guide studs.
Insert the cover capscrews ‘10’ and tighten finger-tight. Unscrew
and remove the guide studs. Insert the other two screws, then
tighten all the screws evenly, alternately and a little at a time to 104
N m (77 lbf ft).
(g) Reassemble the suction strainer; refer to 8.4.
(h) Recommission the compressor as described in 3. Essential
Operations Prior to Dismantling, Recommissioning.
(a) Keyway in housing for the stator key. (b) Stator key in position.
(c) Lower the stator into its housing. (d) Check the stator leads do not foul the housing.
(e) Fit a new ‘O’ ring to the stator location dowel (f) Screw in the dowel and tighten.
(g) Gather the stator leads together with a cable tie. (h) Cut off any excess tie.
(i) Oil the rotor key. (j) Fit the key into the keyway on the motor shaft.
(k) The motor rotor. (l) Fit the rotor over the shaft and key.
(o) Fit the spacer over the shaft and key. (p) Position a capscrew as shown to lock the rotor.
(q) Screw the rotor retaining plate assembly into the end (r) Tighten the screw to 163 N m (120 lbf ft).
of the shaft.
(s) Lubricate the suction end cover joint face. (t) Position a new gasket over the guide studs.
(u) Fit the suction end cover. (v) Torque the capscrews to 104 N m (77 lbf ft).
9
7
4
5
6
8
10
2 Support
3 ‘O’ ring 78.97 x 3.53 section –
support
4 Valve plate
5 ‘O’ ring 53.34 x 5.33 section –
valve plate
(a) The discharge non-return valve in situ. (b) Lift out the support.
(c) Note the support ‘O’ ring. (d) The support ‘O’ ring must be renewed during
reassembly.
(e) Withdraw the spring. (f) Withdraw the valve spindle/plate assembly.
(g) Hold the valve spindle in a vice fitted with soft jaws. (h) Unscrew and remove the M8 nut with nylon insert.
(i) Lift off the valve plate retainer. (j) Remove the valve plate ‘O’ ring. Fit a new ‘O’ ring
during reassembly.
(k) Remove the valve spindle/plate retainer ‘O’ ring. Fit a (l) Withdraw the valve spindle from the plate.
new ‘O’ ring during reassembly.
Fig 22 (continued) Discharge Non-return Valve (HSS 3100) - Dismantling and Reassembly
5 3 1 2 6 7
WARNING
After the compressor has been pumped down and
isolated, the oil contained inside the filter housing will
remain hot enough to cause burns for some time
afterwards. Always allow sufficient time for the oil to
cool down so that it is cool enough not to be a danger
when drained off (less than 35 °C is recommended).
Proceed as follows, refer to Fig 23 and Fig 24.
(a) Position a suitable container underneath the filter housing to catch
the escaping oil.
(b) Dismantle the oil filter, follow steps (a) to (d) in Fig 24.
10.2. Fitting a New Oil Filter Element (HSS 3100) - Reassembly
Refer to Fig 23 and Fig 24.
Before assembly commences, remove any paint from joint faces. Inspect
parts individually for damage, ensure they are completely clean before
laying them out on a sheet of clean paper in a logical order ready for
reassembly.
Use fresh refrigerant oil to lubricate parts during reassembly. New ‘O’
rings must be used.
(a) Reassemble using a new oil filter element, follow steps (e) to (h) in
Fig 24.
Leave the new oil filter inside its protective wrapping until
immediately before it is fitted.
(b) Recommission the compressor as described in 3. Essential
Operations Prior to Dismantling, Recommissioning.
(a) Unscrew and remove the cover capscrews. (b) Lift away the cover and ‘O’ ring. Fit a new ‘O’ ring
during reassembly.
(c) Withdraw the oil filter and spindle. (d) Discard the dirty filter element. Use clean paper to
remove dirt and sediment from inside the filter
housing.
(e) The new oil filter element inside its protective (f) Fit a new spindle ‘O’ ring (arrowed). Locate the new
wrapping. filter element over the spindle.
(g) Insert the filter/spindle assembly into the housing. (h) Locate the oil filter cover onto the housing flange.
Insert the cover capscrews, tighten to 59 N m
(44 lbf ft).
11. LVDT
The LVDT provides a continuous 4 to 20 mA slide valve position signal
between minimum load (25 %) and maximum load (100 %).
If fitted, the LVDT is screwed into the compressor casing in the position
shown in Fig 25 picture (a).
LVDT
4 3
1 2
Discharge
Thermistor
(b) Discharge thermistor and seal. (c) Locate the seal (arrowed) onto the shoulder.
(b) Screw the thermistor into place. Do not overtighten. (c) Discharge thermistor in-situ.
The location of the ‘load’ and ‘unload’ capacity control solenoid valves is
illustrated in Fig 27.
Unload
Solenoid
Load Valve
Solenoid
Valve
CAUTION
When ordering a new coil, remember to specify the
make (Sporlan or Alco), voltage and frequency.
Prior to this procedure, stop the compressor and isolate the electrical
supply to the control panels and compressor stator/rotor as described in
3. Essential Operations Prior to Dismantling, Recommissioning.
Proceed as follows, refer to Fig 28 and Fig 29.
(a) Remove the coil assembly.
Sporlan Coil
Undo and remove screw ‘3’ which secures the coil data plate ‘2’
and coil assembly ‘1’ to the armature tube ‘6’.
Lift off the coil data plate and coil assembly.
Asco Coil
Remove the clip ‘5’. Lift off the coil assembly ‘4’.
WARNING
If it is necessary to remove the armature tube ‘6’, the
compressor must be pumped out and cleared of gas as
described in 3. Essential Operations Prior to
Dismantling, Recommissioning.
(b) Use a ring spanner to unscrew the armature tube ‘6’ from the
casing.
Remove the armature ‘9’ and spring ‘8’.
(a) Use a ring spanner to unscrew the armature tube from (b) A deep socket is required to remove the orifice. Note
the casing the PTFE gasket (arrowed).
3 4
1 2
10
9
1 Coil assembly
Sporlan
4 Coil assembly
Asco
8 Spring
9 Armature
10 Orifice
(a) If the orifice was removed, use a deep socket to screw (b) Locate the PTFE gasket onto the shoulder inside the
it into place. recess.
(c) Use a ring spanner to screw the armature tube into (d) Locate the coil assembly over the armature tube.
place.
(e) Position the data plate onto the coil. (f) Secure the plate into place.
NM LBF FT
Common
()
Top cover M12 x 45
() 104 77
()
Suction end cover M12 x 45
Main bearing housing
M8 x 25 30 22
cover
Item Diagram Description Part Number Old P/No 3118 3120 3121 3122
Stars
1 1 Hallplas Star Kit (also require items 17 & 22) N02280022 95813-106 1
1 1 Hallplas Star Kit (also require items 17 & 22) N02280023 95813-206 1
1 1 Hallplas Star Kit (also require items 17 & 22) N02280024 95813-306 1
1 1 Hallplas Star Kit (also require items 17 & 22) N02280025 95813-406 1
Bearings
2 1 Star Bearing Kit (also require items 17 & 22) N02050124 95813-203 1 1 1 1
Thermostats
3 1 Discharge Thermostat 100oC N05060031 95814-502 1 1 1 1
Solenoid Valves
4&5 1 Capacity Control Solenoid Valve Kit 115V (Sporlan) (kit includes 2 valves & 2 coils) N30010041 95823-417 1 1 1 1
4&5 1 Capacity Control Solenoid Valve Kit 230V (Sporlan) (kit includes 2 valves & 2 coils) N30010042 95823-418 1 1 1 1
5 1 Capacity Control Solenoid Valve Coil 24V (Sporlan) (usa only) N30020046 95823-419 2 2 2 2
Filters
6 1 Oil Filter (also require item 19 or 22) N02370008 95816-401 1 1 1 1
Item Diagram Description Part Number Old P/No 3118 3120 3121 3122
Heaters 115v
8 1 Oil Heater 115V 250W (not for usa) N19070002 95813-217 1 1 1 1
Heaters 230v
8 1 Oil Heater 230V 250W (not for usa) N19070003 95813-218 1 1 1 1
Heater Pockets
9 1 Oil Heater Pocket N13390001 131506010 1 1 1 1
10 1 Capacity Control Slide Kit 3.0VR (also require items 16 & 22) N02860111 95823-102 1
10 1 Capacity Control Slide Kit 3.0VR (also require items 16 & 22) N02860112 95823-201 1 1 1
10 1 Capacity Control Slide Kit 4.9VR (also require items 16 & 22) N02860113 95823-106 1
10 1 Capacity Control Slide Kit 4.9VR (also require items 16 & 22) N02860114 95823-202 1
10 1 Capacity Control Slide Kit 4.9VR (also require items 16 & 22) N02860115 95823-301 1
10 1 Capacity Control Slide Kit 4.9VR (also require items 16 & 22) N02860116 95823-401 1
Motor Terminals
11 1 Terminal Plate Kit (Europe/Asia) (also require item 18 or 22) N02470010 95812-423 1 1 1 1
11 1 Terminal Plate Kit (USA) (also require item 18 or 22) N02470011 95812-142 1 1 1 1
12 1 Motor Terminal Plastic Cap N13060020 131083020 As Req As Req As Req As Req
HS3100
Issue 4 (H) HS3100 Spare Parts List Quantity for Each Compressor
Page 5
Semi-Hermetic Compressor
Item Diagram Description Part Number Old P/No 3118 3120 3121 3122
Valves
13 1 Discharge Check Valve 3-in-1 (Optional) (also require item 20 or 22) N30150074 95814-210 1 1 1 1
Sight Glasses
14 1 Oil Separator 1/2" Sight Glass N27070002 95816-106 1 1 1 1
Sensors
N/S N/S Oil Level Sensor N05110010 95814-602 1 1 1 1
HS3100
Issue 4 (H) HS3100 Spare Parts List Quantity for Each Compressor
Page 5
Semi-Hermetic Compressor
Item Diagram Description Part Number Old P/No 3118 3120 3121 3122
Stators R134a
15 1 Stator 400V 50Hz 43kW / 460V 60Hz 52kW (also require item 18 or 22) N02330016 95813-501 1 1
15 1 Stator 400V 50Hz 60kW / 460V 60Hz 72kW (also require item 18 or 22) N02330017 95813-502 1 1
15 1 Stator 575V 60Hz 52kW (also require item 18 or 22) N02330019 95813-504 1 1
15 1 Stator 575V 60Hz 72kW (also require item 18 or 22) N02330020 95813-505 1 1
15 1 Stator 380V 60Hz 52kW (also require item 18 or 22) N02330022 95813-507 1 1
15 1 Stator 380V 60Hz 72kW (also require item 18 or 22) N02330023 95813-508 1 1
15 1 Stator 230V 60Hz 52kW (also require item 18 or 22) N02330025 95813-510 1 1
15 1 Stator 230V 60Hz 72kW (also require item 18 or 22) N02330026 95813-511 1 1
15 1 Stator 208V 60Hz 52kW (also require item 18 or 22) N02330028 95813-513 1 1
15 1 Stator 208V 60Hz 72kW (also require item 18 or 22) N02330029 95813-514 1 1
Stators R22/R407c/R410A
15 1 Stator 400V 50Hz 60kW / 460V 60Hz 72kW (also require item 18 or 22) N02330017 95813-502 1 1
15 1 Stator 400V 50 82kW / 460V 60Hz 98kW (also require item 18 or 22) N02330018 95813-503 1 1
15 1 Stator 575V 60Hz 72kW (also require item 18 or 22) N02330020 95813-505 1 1
15 1 Stator 575V 60Hz 98kW (also require item 18 or 22) N02330021 95813-506 1 1
15 1 Stator 380V 60Hz 72kW (also require item 18 or 22) N02330023 95813-508 1 1
15 1 Stator 380V 60Hz 98kW (also require item 18 or 22) N02330024 95813-509 1 1
15 1 Stator 230V 60Hz 72kW (also require item 18 or 22) N02330026 95813-511 1 1
15 1 Stator 230V 60Hz 98kW (also require item 18 or 22) N02330027 95813-512 1 1
15 1 Stator 208V 60Hz 72kW (also require item 18 or 22) N02330029 95813-514 1 1
15 1 Stator 208V 60Hz 98kW (also require item 18 or 22) N02330030 95813-515 1 1
HS3100
Issue 4 (H) HS3100 Spare Parts List Quantity for Each Compressor
Page 5
Semi-Hermetic Compressor
Item Diagram Description Part Number Old P/No 3118 3120 3121 3122
Piston Rings
16 1 Piston Ring (Glyd Ring) & Gasket Set N02630040 95813-108 1 1 1 1
Shims
17 1 Shim Set N02260014 92847-301 1 1 1 1
Gasket Sets
18 1 Motor Replacement Gasket & O-Ring Set N33010065 95822-315 1 1 1 1
20 1 Discharge Check Valve Replacement Gasket & O-Ring Set N33010066 95822-316 1 1 1 1
Oils
N/S N/S J & E Hall Ester Oil TBA TBA 12L 12L 12L 12L
N/S N/S J & E Hall Mineral Oil TBA TBA 12L 12L 12L 12L
HS 3100 Series Service Manual
The copyright in this publication shall be and remain the sole property of J & E Hall International.
Questor House, 191 Hawley Road, Dartford, Kent DA1 1PU England
Telephone: +44 (0) 1322 223 456 Facsimile: +44 (0) 1322 291 458
www.jehall.co.uk