INSTRUCTIONS

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*XX99TA526312* Instruction Sheet Number: T-BOLT COMPRESSION

INSP.doc
*XX99TAXXXXXX* (for RCD use only)

Description: COMPRESSION END INSPECTION

Author: Steve Von Borstel Date: SEPTEMBER 29, 2005
Part Number:

!
WARNING

HAZARDS: ELECTRIC SHOCK / PRESSURE / EXPLOSION

REFRIGERANT AND OIL UNDER PRESSURE

• Bodily injury may result from explosion and/or fire if power is supplied to compressor with terminal box cover removed or
unsecured. Terminal pins may blow-out causing injuries, death or fire.
• Do not touch terminals, or wiring at terminals, or remove terminal cover or any part of compressor until power is
disconnected and pressure is relieved. See safety instructions A, B, and C.

ELECTRIC SHOCK
• Bodily injury or death may result from electrocution if terminal cover is removed while power is supplied to compressor.
• Do not supply power to compressor unless terminal cover is secured in place and all service valves are open.

Safety Instructions:
Service or maintenance must be performed only by trained certified technicians and according to service instructions.

A. Follow recognized safety practices and wear protective goggles.

B. Disconnect and lockout all electrical power. Electrical measurements during operation must be taken outside of the compressor
terminal box.
C. Isolate the compressor from the system. Reclaim all refrigerant in the compressor. Do not disassemble bolts, plugs, fittings, etc.
unless all pressure has been relieved from the compressor. .

This procedure explains how to visually inspect the discharge end of the screw rotors on a
Thunderbolt compressor without removing the compressor from the chiller. If compression end
damage is suspected this check should be performed before the compressor is removed or
replaced. Examples of when this check may be performed are:

1. Presence of abnormal noise or vibration.

2. Compressor is drawing locked rotor amps (will not start)
1 3. Higher than normal economizer pressures when the compressor fully loaded and the
economizer isolation valve is closed. (See Step X).
4. Compressor is started in reverse (miss wired)
5. Compressor experienced very low SSTs or operated in a vacuum.
6. The compressor does not appear to be loading or unloading correctly

Because most compression end failure scenarios involve damage to the discharge end of the
screw rotors, this inspection can be very useful. Although compression end damage is not

T-BOLT COMPRESSION INSP

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considered to be field serviceable, the check can justify a decision to remove a compressor for
major repair/replacement, or support the need for more investigation.

If the compressor is operational, there are some pressure measurements that can be
performed which can also indicate if damage has occurred to the compression end. There are
three pressures that need to recorded:

1. Suction Pressure
2. Discharge Pressure
3. Economizer pressure

The are only three criteria that need to be met when measuring this pressures:

A) Compressor IS fully loaded (slide valve is in the fully loaded position)

B) There is NO economizer flow
C) Minimum pressure differentials (100 psid between expected economizer pressure and
discharge pressure)

If these two criteria have been met, the pressures can be recorded immediately. The actual
SST & SCTs are not critical as long as all three readings are taken simultaneously. Using the
table shown in Appendix II, lookup the suction pressure across the top and discharge
pressure along the left side of the table. Then read the corresponding economizer pressure
from the table.
2

SUCTION PRESSURE (PSIG)

A/C 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
80 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
DISCH PRESS (PSIG)

100 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

SAMPLE 06N TABLE

120 18 20 23 26 28 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
140 20 23 26 28 31 34 36 39 41 44 47 49 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
160 23 26 28 31 34 36 39 42 44 47 49 52 55 57 60 63 65 68 --- --- --- --- --- --- --- --- --- --- ---
180 26 28 31 34 36 39 42 44 47 50 52 55 57 60 63 65 68 71 73 76 79 81 84 86 89 --- --- --- ---
200 28 31 34 36 39 42 44 47 50 52 55 57 60 63 65 68 71 73 76 79 81 84 87 89 92 94 97 100 102
220 30 33 36 39 42 44 47 50 52 55 58 60 63 65 68 71 73 76 79 81 84 87 89 92 95 97 100 102 105
240 31 34 37 40 43 46 49 52 54 57 60 63 66 68 71 73 76 79 81 84 87 89 92 95 97 100 103 105 108
260 32 35 38 41 44 46 49 52 55 58 61 64 67 70 73 76 79 81 84 87 89 92 95 97 100 103 105 108 110
280 33 36 38 41 44 47 50 53 56 59 62 65 68 71 74 77 80 82 85 88 91 94 97 100 103 105 108 111 113
300 33 36 39 42 45 48 51 54 57 60 63 66 69 72 74 77 80 83 86 89 92 95 98 101 104 107 110 113 115

A/C ECONOMIZER PRESSURE MAXIMUMS

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LOCATE
READ DISCHARGE
MAXIMUM PRESSURE
ECONOMIZER PRESSURE LOCATE SUCTION PRESSURE

If the measure economizer pressure is greater than the maximums shown in the table there is
probably excessive leakage in the compression end. The most likely cause for this is damage
to the screw rotors, outlet rotor housing bores, or slide valve. If high economizer pressures are
encountered, a compression end inspection should be performed.

Before starting disassembly make sure you have the proper tools and parts to complete the
job. Refer to Appendix I for a list of required tools. The compressor does not have to be
removed to perform this inspection. The slide valve housing will have to be removed so a new
slide valve case gasket will be required for re-assembly. Part numbers for the different gaskets
are shown below:
RCD KIT NUMBER SLIDE VALVE HOUSING
COMP’R MODEL GASKET
3 06TS 06TT660042 8TS0708
06TT 06TT660043 8TT0732
06TU 06TT660044 8TU0714

The recommended “touch-up” paint for this compressor is Part No. PH23GH022 (gray) and is
available from RCD.
If the compressor is mounted on the unit, make sure the power has been properly locked out
4 and the refrigerant charge has been safely isolated and removed from the compressor.
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If the economizer line is in the way of removing the slide

valve housing it will have to be moved. The filter drier
located in this line may have to be disconnected from its
bracket located on the oil separator.

FILTER DRIER

OIL SEPARATOR
ECONOMIZER LINE

Disconnect the economizer

flange from the compressor by
removing the M12 bolts. This
is either a two bolt flange (TS &
TT) or a four bolt flange which
is used on the TU. The bolts
used may have either a 18mm
or 19mm hex head bolts.

6 TIE LINE UP AND

OUT OF THE WAY

ECONOMIZER PORT
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Remove two of the slide valve housing bolts on

either side. The TS & TT compressors use M12
bolts (18mm hex head) the TU compressor uses
M16 (24mm hex head). Install the appropriate
guide pins. Remove the remaining bolts.

GUIDE PINS
7

Use a tray or container that will fit underneath the slide valve housing and outlet case joint to
capture the residual oil when the housing is removed. Use a hammer and drift to knock the
housing free. There are two dowel pins with an interference fit that locate the housing. The
housing will have to be separated 1/2” (12mm) before it will be free from the dowel pins.

CONTAINER FOR OIL

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Remove M12 bolt (18mm hex head) which secures

the slide valve piston to the rod. Remove the piston
and spring.

Using an 1-1/8” (29mm) deep well socket,

unscrew the slide valve rod from the stud.
Make sure that the slide valve rod (and
slide valve) remain pulled out during this
operation.

10
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It does not matter if the threaded stud

remains in the slide valve or if it is removed
with the slide valve rod.

After the rod has been disengaged from the

slide valve, use the rod to push the slide all
the way in to the fully loaded position. The
slide valve should move smoothly and
should not bind.

11

Once the rod is free of the

slide valve, push the slide
valve all the way in to the
“fully loaded position”.
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Using a flashlight look MALE ROTOR FEMALE ROTOR

in through the hole for (DISCH END FACE) (DISCH END FACE)
the slide valve rod.
You will be to see the
discharge end of the
screw rotors.
If there is evidence of
scoring or galling on
the ends of the screw
rotors, then end plane
contact has occurred.
Even if the
compressor still
rotates, the thrust
bearings are probably
12 damaged.
Compressor life will be
dranmatically shorter
and internal leakages
significantly higher.

SLIDE VALVE
“EARS” IN
OUTLET CASE

SLIDE VALVE

If there is scoring on the end of the screw rotors, endplane contact between the screw rotor(s)
has occurred. When this happens, very high axial loads can be generated usually leading to
permanent damge of the Angular Contact Ball Bearings even if the compressor still rotates.
Typically the bearing life has been severly compromised.

13
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After the inspection has been completed,

start the reassembly process by positioning
the slide valve to the fully unloaded
position. This can be accomplished by
threading the slide valve rod on to the slide
valve, and pulling it all the way back.
Again, it does not matter if the threaded
14 stud remains in the slide valve or if it is
removed with the slide valve rod.

Make sure the exposed threads are clean

and dry. Apply Loc-Tite to the threads.

15

Thread the slide valve rod and stud

assembly into the slide valve.

16
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Torque the slide valve rod to:

120-135 lb-ft
(163-183 Nm)
17

Make sure the threads on the slide valve piston

bolt are clean. Apply LOCTITE to the threads of
the bolt. Make sure the lock washer is present.

18

Install the spring and slide valve piston

onto the slide valve rod. The spring will
have to be compressed slightly in order to
get the bolt started.

19

Torque the slide valve piston bolt to:

90-110 lb-ft
(122-149 Nm)
20
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Ensure that the gap in the slide valve piston seal is

facing up. If any of the seals have been damaged,
they will have to be replaced. The RCD kit are for the
complete piston (w/seal ring and springs installed) and
housing gasket. Note: Special tools are required to
install seals on the piston.

21
COMP’R GUIDE RING SEAL RING &
MODEL RCD KIT & SPRING SPRING
06TS 06TT660012 8TS0835 8TS0836
06TT 06TT660020 8TT0817 8TT0818
06TU 06TT660028 8TU0843 8TU0844

Remove and discard the old

slide valve housing gasket
and install a new one.
Install a suitable hose
clamp over the slide valve
piston seal. Do not tighten
hose too tight. It will hold
the seal in place while the
hosing is being installed.

22
HOSE CLAMP

Two people will be required to lift and slide the housing over the piston and onto the guide
pins.

SLIDE VALVE
23 COMP’R HOUSING
MODEL WEIGHT
06TS 47 LBS
06TT 55 LBS
06TU 101 LBS
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SHOWN W/RING COMPRESSOR
INSTEAD OF HOSE CLAMP

As the casing is being slid over the piston it will

push the hose clamp out of the way and will
eventually pop off. Once the housing is on the
guide pins remove the hose clamp.

23

After the hose clamp has been removed

finish sliding the hosing into position.
Make sure the gasket is on the dowel
pins.

25 GASKET NEEDS
TO REMAIN ON
DOWEL PINS
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Before the bolts are installed make sure there is no loose paint. A wire wheel mounted on a
bench grinder can be used to remove any loose paint

26

Install the bolts into the cover. Use the bolts to draw the casing into
position. Use a typical “cris-cross” pattern to tighten the bolts. Remove the
lifting plate and install the last bolt. Final torque the bolts to:

TS & TT: 122 –149 Nm (90 – 110 lb-ft)

TU: 291 –305 Nm (215 – 225 lb-ft)
27

After the bolts have been torqued, clean the bolt heads
and the around the bolts for painting. Use a clean cloth
to remove any dirt, oil or loose paint chips. Mask any
areas that should not be painted like the name plate.

28
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Using RCD touch-up paint PH 23GH

022 GRAY, carefully paint the bolt
heads and area around the bolts.

29

If the economizer line was removed, reinstall the line and install a new o-ring or gasket if
required. Final torque the bolts to:
30 122 –149 Nm (90 – 110 lb-ft)

End.
31
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APPENDIX I: TOOLS FOR TERMINAL PIN REPLACEMENT

S
T
E
TOOL P
TOOL NUMBER SUPPLIER OPERATION (s) NOTES
• ½” DRIVE F50A SNAP-ON REMOVAL OF: 4
RATCHET • ECONOMIZER FLANGE 5
• ½” DRIVE
SN25 SNAP-ON • SLIDE VALVE HOUSING 7
BREAKER BAR • PISTON BOLT 8
• SLIDE VALVE ROD
HAMMER BP32B SNAP-ON REMOVE SLIDE VALVE HSG 6

18mm SOCKET OR TWM18 SNAP-ON REMOVAL/INSTALLATION 4 19mm SOCKET

24mm FOR 06TU TWM24 OF: 5 MAY BE REQ’D
SLIDE VALVE • ECONOMIZER FLANGE 7 FOR SOME
HOUSING BOLTS • SLIDE VALVE HOUSING ECONOMIZER
• PISTON BOLT FLANGES
GUIDE PINS 9TB0775 RCD REMOVAL & 5 ALTERNATIVE:
(TWO) (M12 ONLY) INSTALLATION SLIDE M12 OR M16 LONG
VALVE HOUSING BOLTS W/O
HEADS
10” (250mm) ADJ. FAD10 SNAP-ON REMOVAL OF PISTON BOLT 7
WRENCH & SLIDE VALVE STUD 9
10
• PULLER CJ700-20 SNAP-ON REMOVE SLIDE VALVE 9
HOUSING STUD
• LOAD SCREW CJ700-21 SNAP-ON
• M12x1.75 COLLET CJM700-8 SNAP-ON
BRONZE PUNCH PPB1002 SNAP-ON REMOVE SLIDE VALVE HSG 6
HOSE CLAMP IDEAL INSTALLATION OF SLIDE 19 TS: 3-4” 
VALVE HOUSING ON TT: 4-5” 
PISTON TU: 5-6” 
1 1/8” DEEP WELL TS361 SNAP-ON REMOVAL & 8 29mm SOCKET
SOCKET INSTALLATION OF SLIDE 14 MAY BE USED
VALVE ROD (SNAP-ON TSM29)
PAINT PH 23GH 022 RCD TOUCH-UP BOLT HEADS 26
WIRE WHEEL REMOVING LOOSE PAINT 23
FROM BOLT HEADS
LOCTITE 554 554 LOCTITE INSTALLATION OF: 11 REFRIGERANT
• SLIDE VALVE STUD 12 SEALANT,
• PISTON BOLT 15 THREAD LOCK
½” DRIVE TORQUE QC3R250 SNAP-ON INSTALLATION OF: 14 50-250 LB-FT
WRENCH • SLIDE VALVE ROD 17 (60-340 Nm)
• PISTON BOLT 24
• SLIDE VALVE HOUSING 27
CONTAINER OR CAPTURE RESIDUAL OIL 6
TRAY DURING REMOVAL OF
SLIDE VALVE HOUSING