Maintenace sheet for Compressor

Unit model Unit serial System Name

Compressor model Comp Serial No. Cuircut No.
Date Last maintened date Comp Total operating time
No. Activity Criterion & Description Result
Befor Opening Compressor
1 Make sure the No Voltage Check it using a electrical tester.Attention to VFD.
2 Terminal Condition Check the loose wiring, burned etc.
3 Closed Valves Attention to misoperation.
4 Recovery Refrigerant Recover down to under 10 kPa pressure inside the compressor. kg
Inspection of Compressor (Before replacement)
5 Gate rotor condition Must be smooth.
6 Lip Clearance Max 0.04 mm mm
7 Backash Max 0.16 mm mm
8 Rotor/Bore Radial Clearance 0.09mm - 0.11mm mm

Oil and Oil fillter

9 Oil Type Beforehand Must be confirmation. Emkarate RL 68H
10 Drained Oil Quantity Under 13L L
11 Replace Oil Fillter
12 Chaged Oil Quantity Under 13L L
Must be check it between 30 min and 1 hour after starting the
13 Oil Level compressor, preferably with the compressor load at 100%.
Adjust the oil quantity if necessary.
Bottom Top
Replace Gate Rotor and Bearings (After replacement)
14 Lip Clearance Max 0.04 mm mm
15 Backash Max 0.16 mm mm
16 Rotor/Bore Radial Clearance 0.09mm - 0.11mm mm
17 Adjust shims If adjusted by shims, should be writing. mm

Restoration and Commissioning

18 Heat Insulating Material Should be fix it if necessary.
19 Evacuate the Compressor Over 20 min and Under -0.1 kPaG.
20 Recharging Refrigerant If necessary. kg
21 Oil Temperature Saturated Temperature at gas pressure <= 5°C ℃
Covers
Must be using Laeck Ditector and Form.
22 Refrigerant Leak Ditection Valves
Especially, examine the parts removed and operated in this time.
Piping
L1 A
23 Compressor Running Amps L2 A
L3 A
Condensation Pressure (High Pressure) kPa
24 Refrigerant Pressure
Evaporation Pressure (Low Pressure) kPa
25 Oil Pressure kPa
Comment

Company Name : Signature :

[Result] A: Good B:Recommend additional maintaince(Operable) C: Repair required(Inoperable) D : Already repared

 Maintenace sheet for Compressor
Unit model Unit serial System Name
Compressor model Comp Serial No. Cuircut No.
Total operating time Last maintened date Date
No. Activity Criterion & Description Result
Befor Opening Compressor
1 Make sure the No Voltage Check it using a electrical tester.Attention to VFD.
2 Terminal Condition Check the loose wiring, burned etc.
3 Closed Valves Attention to misoperation.
4 Recovery Refrigerant Recover down to under 10 kPa pressure inside the compressor. kg
Inspection of Compressor (Before replacement) L side R side
5 Gate rotor condition Must be smooth.
6 Lip Clearance Max 0.04 mm mm mm
7 Backash Max 0.16 mm mm mm
8 Rotor/Bore Radial Clearance 0.09mm - 0.11mm mm mm

Oil and Oil fillter

9 Oil Type Beforehand Must be confirmation. Emkarate RL 68H
10 Drained Oil Quantity Under 16L L
11 Replace Oil Fillter
12 Chaged Oil Quantity Under 16L L
Must be check it between 30 min and 1 hour after starting the
13 Oil Level compressor, preferably with the compressor load at 100%.
Adjust the oil quantity if necessary.
Bottom Top
Replace Gate Rotor and Bearings (After replacement) L side R side
14 Lip Clearance Max 0.04 mm mm mm
15 Backash Max 0.16 mm mm mm
16 Rotor/Bore Radial Clearance 0.09mm - 0.11mm mm mm
17 Adjust shims If adjusted by shims, should be writing. +/- mm +/- mm

Restoration and Commissioning

18 Heat Insulating Material Should be fix it if necessary.
19 Evacuate the Compressor Over 20 min and Under -0.1 kPaG.
20 Recharging Refrigerant If necessary. kg
21 Oil Temperature Saturated Temperature at gas pressure <= 5°C ℃
Covers
Must be using Laeck Ditector and Form.
22 Refrigerant Leak Ditection Valves
Especially, examine the parts removed and operated in this time.
Piping
L1 A
23 Compressor Running Amps L2 A
L3 A
Condensation Pressure (High Pressure) kPa
24 Refrigerant Pressure
Evaporation Pressure (Low Pressure) kPa
25 Oil Pressure kPa
Comment

Company Name : Signature :

[Result] A: Good B:Recommend additional maintaince(Operable) C: Repair required(Inoperable) D : Already repared

 Maintenace sheet for Compressor
Unit model Unit serial System Name
Compressor model Comp Serial No. Cuircut No.
Total operating time Last maintened date Date
No. Activity Criterion & Description Result
Befor Opening Compressor
1 Make sure the No Voltage Check it using a electrical tester.Attention to VFD.
2 Terminal Condition Check the loose wiring, burned etc.
3 Closed Valves Attention to misoperation.
4 Recovery Refrigerant Recover down to under 10 kPa pressure inside the compressor. kg
Inspection of Compressor (Before replacement) L side R side
5 Gate rotor condition Must be smooth.
6 Lip Clearance 0.03mm - 0.05mm mm mm
7 Backash Max 0.13 mm mm mm
8 Rotor/Bore Radial Clearance 0.06mm - 0.8mm mm mm

Oil and Oil fillter

9 Oil Type Beforehand Must be confirmation. Emkarate RL 68H
10 Drained Oil Quantity Under 18L L
11 Replace Oil Fillter
12 Chaged Oil Quantity Under 18L L
Must be check it between 30 min and 1 hour after starting the
13 Oil Level compressor, preferably with the compressor load at 100%.
Adjust the oil quantity if necessary.
Bottom Top
Replace Gate Rotor and Bearings (After replacement) L side R side
14 Lip Clearance 0.03mm - 0.05mm mm mm
15 Backash Max 0.13 mm mm mm
16 Rotor/Bore Radial Clearance 0.06mm - 0.8mm mm mm
17 Adjust shims If adjusted by shims, should be writing. +/- mm +/- mm

Restoration and Commissioning

18 Heat Insulating Material Should be fix it if necessary.
19 Evacuate the Compressor Over 20 min and Under -0.1 kPaG.
20 Recharging Refrigerant If necessary. kg
21 Oil Temperature Saturated Temperature at gas pressure <= 5°C ℃
Covers
Must be using Laeck Ditector and Form.
22 Refrigerant Leak Ditection Valves
Especially, examine the parts removed and operated in this time.
Piping
L1 A
23 Compressor Running Amps L2 A
L3 A
Condensation Pressure (High Pressure) kPa
24 Refrigerant Pressure
Evaporation Pressure (Low Pressure) kPa
25 Oil Pressure kPa
Comment

Company Name : Signature :

[Result] A: Good B:Recommend additional maintaince(Operable) C: Repair required(Inoperable) D : Already repared

 Maintenace sheet for Compressor
Unit model Unit serial System Name
Compressor model Comp Serial No. Cuircut No.
Total operating time Last maintened date Date
No. Activity Criterion & Description Result
Befor Opening Compressor
1 Make sure the No Voltage Check it using a electrical tester.Attention to VFD.
2 Terminal Condition Check the loose wiring, burned etc.
3 Closed Valves Attention to misoperation.
4 Recovery Refrigerant Recover down to under 10 kPa pressure inside the compressor. kg
Inspection of Compressor (Before replacement) L side R side
5 Gate rotor condition Must be smooth.
6 Lip Clearance Max 0.04mm mm mm
7 Backash Max 0.08mm mm mm
8 Rotor/Bore Radial Clearance 0.06mm - 0.8mm mm mm

Oil and Oil fillter

9 Oil Type Beforehand Must be confirmation. Emkarate RL 68H
10 Drained Oil Quantity [F3AS/SL:Under 17L] [F3BS/BL:Under 19L] [F4AS/AL/XL:Under 25L] L
11 Replace Oil Fillter
12 Chaged Oil Quantity [F3AS/SL:Under 17L] [F3BS/BL:Under 19L] [F4AS/AL/XL:Under 25L] L
Must be check it between 30 min and 1 hour after starting
13 Oil Level the compressor, preferably with the compressor load at
100%. Adjust the oil quantity if necessary.
Bottom Middle Top
Replace Gate Rotor and Bearings (After replacement) L side R side
14 Lip Clearance Max 0.04mm mm mm
15 Backash Max 0.08mm mm mm
16 Rotor/Bore Radial Clearance 0.06mm - 0.8mm mm mm
17 Adjust shims If adjusted by shims, should be writing. +/- mm +/- mm

Restoration and Commissioning

18 Heat Insulating Material Should be fix it if necessary.
19 Evacuate the Compressor Over 20 min and Under -0.1 kPaG.
20 Recharging Refrigerant If necessary. kg
21 Oil Temperature Saturated Temperature at gas pressure <= 5°C ℃
Covers
Must be using Laeck Ditector and Form.
22 Refrigerant Leak Ditection Valves
Especially, examine the parts removed and operated in this time.
Piping
L1 A
23 Compressor Running Amps L2 A
L3 A
Condensation Pressure (High Pressure) kPa
24 Refrigerant Pressure
Evaporation Pressure (Low Pressure) kPa
25 Oil Pressure kPa
Comment

Company Name : Signature :

[Result] A: Good B:Recommend additional maintaince(Operable) C: Repair required(Inoperable) D : Already repared

 Refarence
Item No. Item Name Quantity
Picture
3100 1
3200(Old Version)
1 Side(Top) Cover Gasket
4200(Square type) 2
F3AS/L

3200(New Version)
2 Side Cover O-ring 2
F3BS/L,F4AS/L/XL

3 Filler gage 1

4 Dial Gage & Stand 1

5 Bearing pooler ( For inner race) 1

6 Bearing pooler ( For outer race) 1

7 Bearing press 1

8 Oil Jug 1

9 Oil Feeder 1

10 Oil Pan 3

11 Mani Hold Gage and Hose 1

12 Vacuum Pump 1
 12 Vacuum Pump 1

13 Refrigerant Recovery Device 1

14 Extension Power Cable 1

15 Recovery Refrigerant Cylinder As necessry

16 Refrigerant As necessry

17 Digital Charging Scale 1

18 Socket Wrench 1

19 Torque Wrench 1

20 Hexagon Socket M5 1

21 Hexagon Socket M6 1
Mandatory item

22 Hexagon Socket M8 1

23 Hexagon Socket M10 1

24 Hexagon Socket M12 1

24 Hexagon Socket M12 1

25 Conversion Adapter Joint 1

26 Wrench As necessry

27 Adjustable Wrench As necessry

28 Valve Wrench 1

29 Guide stud 2

30 Forcing screws 2

31 Plastic Scraper 1

32 Sharpening stone 1

33 Parts cleaner Spray 1

34 Mallet 1

35 leak Detector 1

36 Gas leak detection spray(Form) 1

 36 Gas leak detection spray(Form) 1

37 Hand mirror 1

38 Towel Waste As necessry

39 White Maker 1

40 Digital Multi Meter w/ Clamp 1

41 Digital Thermometer 1

42 Pen Light 1

43 Electrical Panel Key 1

44 Micrometer 1

45 Nitrogen As necessry

46 Silicone caulking compound As necessry

47 Caulking gun 1
Usefull items

48 Adhesive 1
Usefull ite
48 Adhesive 1

49 Screw Threading Die 1

50 Bolt Tap 1

51 Working table 1

3100 1

52 Gate rotor 3200 2

4200 2
F3,F4 2
3100 2
3200 4
53 Bearing
4200 4
F3,F4 4
3100 2
3200 4
54 Beraring Houging O-ring
4200 4
F3,F4 4
3100 2
3200 4
55 Locating Pin
4200 4
F3,F4 4
3100 2
3200 4
56 Locating Pin O-ring
4200 4
Parts

F3,F4 4

57 Shim As necessry

58 Oil (Emkarate RL 68H) As necessry

59 Oil Filter 1

60 Oil Filter O-ring 1

 60 Oil Filter O-ring 1

61 Loctite 275 1

62 Grove 1
Safety

63 Safety shoe 1
 Remark

Must be Changing if did opened Sied (Top) Cover.

Cannot reuse the used gasket.

Must be Changing if did opened Sied Cover.

Cannot reuse the used O-ring.

Please prepare what can be measured from 0.03 to 0.11mm.

Things like the photos are useful.

Please prepare what can be measured 0.16mm.

Required the stand for measuring.
Must be using correctly calibrated ones.

Those type are useful that has a separator things like the photos.

Nomaly be able to remove bearing outer race by hands.

But recommended preparing it .

Using a hammer may not be able to install the bearing correctly.

Please prepare the press like the photos.

Required measuring oil quantity correctly.

Should be cleaning those before using.

There must be preparing for each oil type.

Please choose those what can place under the compressor.

It is useful to have lots of them.

Must be using correctly calibrated ones.

If will use hose for charging oil, must prepare for each oil type.
And cleaning those before using.

Should be do the maintenance before using.

Should be do the maintenance before using.

Should be do the maintenance before using.

Should be do the maintenance before using.

Also prepare a transformer and generator as needed.

It must be prepared according to the type of refrigerant to be recovered.

Prepared according to the type of refrigerant and as needed quantity.

Must be using correctly calibrated ones.

It is useful to have the small one and big one both.

Must be prepare those what can apply the torques

from 10 to 148 Nm.And must be using correctly calibrated ones.
The adjustable tyepe is useful.

Expensive ones will protect the screws.

Expensive ones will protect the screws.

Expensive ones will protect the screws.

Expensive ones will protect the screws.

Expensive ones will protect the screws.

Expensive ones will protect the screws.

For Socket Wrench.

If necessary.

3100 M12 & M10 & M8

3200 M10
4200 M12
F3,F4 M10

Please prepare 2 each size of the M8,M10,M12.

Don't should use metal type.

Using a sharpening stone be able to make flat the damage of flange.

Cleaning the parts and some tools.

Should use rubber or plastic.

It must be prepared according to the type of refrigerant.

Must be using correctly calibrated ones.

Should use with leak detector.

Should use with leak detector.

Should use those that do not scatter fiber.

For marking.

Must be using correctly calibrated ones.

Must be using correctly calibrated ones.

Must be using correctly calibrated ones.

Be able to measure the shims thickness.

Using the nitrogen be able to drain the oil from compressor

more quickly.

If heat insulating material got a damage, must be fixing it by silicone.

Required the using silicone coulking.

If heat insulating material removed, must be reattach it by adhesive.

Must be make sure that material is not dissolved by adhesive
before do it.
If heat insulating material removed, must be reattach it by adhesive.
Must be make sure that material is not dissolved by adhesive
before do it.

Be able to wipe off the old loctite and rust of bolts.

Be able to wipe off the rust inside bolt holes.

If removed the bearing housing, must be changing the O-rings.

Cannot Reuse the used O-ring.

Please change the locating pin when replace the gate rotor
if necessary.

If replace the gate rotor, must be changing the O-rings.

Cannot reuse the used O-ring.

If lip clearance was incorrect, must be adjusting those by shims.

If changed the shim, should be recording it.

Must be Emkarate RL 68H if screw compressor.

Should check the oil type and basic oil quantity
before maintenance.

Cannot reuse the used oil filter.

If opened the oil filter flange, must be changing the O-ring.

Cannot reuse the used O-ring.
If opened the oil filter flange, must be changing the O-ring.
Cannot reuse the used O-ring.

Must be Loctite 275.

Please chek it what not condensing befor using it.

Should use those that do not scatter fiber.

For exanple by leather etc.