McQuay HallScrew HS-3100 Series Compressor Service Manual

HallScrew HS 3100 Series
Semi-hermetic Single Screw Compressors

HSS 3118, HSS 3120, HSS 3121 and HSS 3122
HS L/M 3118, HS L/M 3120, HS L/M 3121 and HS L/M 3122
Service Manual
HS L/M 3100
HSS 3100
Issue 1 : 08/07 Page 1 of 82

HS 3100 Series Service Manual
©
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.
Page 2 of 82 Issue 1 : 08/07

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
Issue 1 : 08/07 Page 3 of 82

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
Page 4 of 82 Issue 1 : 08/07

1. About this Publication

These instructions have been prepared according to the following
standards:
BS 4884 : Technical Manuals:
Part 1 : 1992 Specification for Presentation of Essential
Information.
Part 2 : 1993 Guide to Content.
Part 3 : 1993 Guide to Presentation.
BS 4899 : User’s Requirements for Technical Manuals:
Part 1 : 1991 Content.
Part 2 : 1992 Presentation.
BS 4899 is based on the principles of BS 4884.
BS 5378 : Part 2 : 1982 Safety Signs.
1.1. Safety Warnings and Symbols
The system of safety warnings and symbols is based on BS 5378 :
Part 2 : 1982 Safety Signs and BS 4884 : Technical Manuals : Part 1 :
1992 Specification for Presentation of Essential Information.
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
Issue 1 : 08/07 Page 5 of 82

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.
Page 6 of 82 Issue 1 : 08/07

To ensure maximum efficiency, not only must components be correctly

assembled but everything must be spotlessly clean, all oilways must be
clear, joint rings must be fitted where indicated and during assembly all
bearings and other working surfaces must be liberally coated with fresh
refrigeration oil of the correct grade.
2.3. Special Tools
Generally speaking, special tools are not required to work on the
compressor. However, for the safe removal of covers and their speedy
and accurate refitting, it is worth making-up a set of purpose-made guide
studs; refer to Fig 1. The sizes required are M8, M10 and M12.
M10 and M16 eyebolts for lifting are also required, their application is
described in the text.
Fig 1 Guide Studs
Issue 1 : 08/07 Page 7 of 82

3. Essential Operations Prior to Dismantling, Recommissioning
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.
Page 8 of 82 Issue 1 : 08/07

3.2. Recommissioning the Compressor

(g) Evacuate the compressor (or compressor and oil separator – HS
L/M 3100 only) to as low a vacuum as possible. In practice this
may only be as low as 5 to 6 mm Hg (5 to 6 Torr) due to refrigerant
gassing-off as the pressure is reduced.
Disconnect and remove the vacuum pump.
Slowly bleed refrigerant from the rest of the system into the
compressor until the pressures have equalised.
(h) Check the compressor for leaks in the conventional manner for the
refrigerant. Make good any leaks.
(i) Check that all stop valves associated with the compressor (and oil
separator – HS L/M 3100 only) are in the normal running mode.
(j) Reinstate the electrical supply to the control panel(s) and
compressor stator/rotor.
(k) Carry out the normal prestart system checks. A general routine to
follow is outlined under Commissioning and Operation in the
HallScrew Operator Manual.
Start the compressor. During the first hour or so of operation,
check:
• that the discharge temperature is normal for the installation;
• if the bearings were dismantled or new ones fitted, check
that there are no unusual ‘hot-spots’ on the compressor in
their vicinity which would indicate that a bearing is
overheating;
• that the compressor is not making any unusual or peculiar
noise.
Issue 1 : 08/07 Page 9 of 82

4. Star and Star Bearing Assembly
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.
Fig 2 Star Rotor and Star Bearing Housing Assembly
Page 10 of 82 Issue 1 : 08/07

13 7
11 10
12
1
2
15
6
11 7
8
16
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 socket head capscrew –
star locating pin
6 Star bearing housing
7 Taper roller bearing

8 ‘O’ ring 142.47 OD x 3.53
LBH
section - housing to casing

9 M10 x 30 capscrew – star
bearing housing
10 Shim(s)
11 Star bearing housing

12 Taper roller bearing
13 ‘O’ ring 72.62 OD x 3.53
section – housing to casing
SBH
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
19 M12 x 45 capscrew – top cover
Fig 2 (continued) Star Rotor and Star Bearing Housing Assembly
Issue 1 : 08/07 Page 11 of 82

4.1. Star Rotor Assembly – Dismantling

Prior to this procedure, pump out the compressor, isolate the electrical
supply to the control panels and compressor stator/rotor, clear the
compressor of gas as described in 3. Essential Operations Prior to
Dismantling, Recommissioning.
Refer to Fig 2 to Fig 6.
(a) Unscrew and remove two hex head top cover screws ‘19’ 180°
apart. Insert M12 guide studs into the vacant holes.
(b) Remove the rest of the screws, then lift off the top cover ‘17’.
(c) Remove the top cover gasket ‘18’. A new item must be fitted
during reassembly.
(d) The star rotor assembly shown in-situ.
The two star bearing housings are of different sizes, designated
Small Bearing Housing (SBH) and Large Bearing Housing (LBH) in
the text.
(e) Unscrew and remove two hex head SBH cover screws ‘14’ 180°
(f) Unscrew and remove the remaining hex head screws ‘14’ from the
SBH.
(g) Remove the SBH.
(h) Unscrew and remove two hex head LBH cover screws ‘9’ 180°
(i) Unscrew and remove the remaining hex head screws ‘14’ from the
LBH.
(j) Remove the LBH, plus any shims which may be fitted.
Fig 3 Removing Star Rotor Bearing Taper Roller Race
Page 12 of 82 Issue 1 : 08/07

Using Hydraulic or Pneumatic Press Using Mechanical Press
Fig 4 Fitting New Star Rotor Bearing Inner Race
(k) Disengage the star rotor from the main rotor.
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.
Issue 1 : 08/07 Page 13 of 82

(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.
SBH = Small Bearing Housing () ()

LBH = Large Bearing Housing () ()
Fig 5 Star Rotor Assembly – Dismantling
Page 14 of 82 Issue 1 : 08/07

(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.

Fig 6 Star Rotor Assembly – Dismantling
Issue 1 : 08/07 Page 15 of 82

(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.

Fig 7 Star Rotor Assembly – Reassembly
Page 16 of 82 Issue 1 : 08/07

4.2. Star Rotor - Reassembly

Refer to Fig 2 to Fig 6.
Before assembly commences, remove any paint and all traces of the old
gaskets 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 assembly.
Use fresh refrigerant oil to lubricate parts during assembly. All new
gaskets and ‘O’ rings must be used.
Unlike other ranges of HallScrew compressor, the HS 3100 does not
need shim adjustment to achieve the correct spring compression for
bearing pre-loading. Once the correct lip clearance has been
established, tightening the bearing housing screws compresses the
spring by the correct amount.
The following procedure assumes that a new star and/or star bearings
have been fitted and it is necessary to reset the lip clearance.
(a) Manipulate the star assembly through the top cover opening and
carefully mesh the star teeth with the main rotor flutes. It is
necessary to tilt the star shaft before the teeth can be fully meshed
with the flutes, however, force MUST NOT be applied since this
might damage the teeth.
Remove the old ‘O’ rings ‘8’ and ‘13’ from the star bearing
housings.
Assemble bearing housing components; refer to Fig 2.
Do not fit new ‘O’ rings at this stage since it may be necessary to
remove the housings several times and this is a lot easier to do
without the ‘O’ rings in position.
(b) Screw M10 guide studs into two holes 180° apart on the Large
Bearing Housing (LBH) flange face.
(c) Locate the LBH ‘11’ over the studs, including any shims that may
have been fitted.
(d) Secure the LBH into position with four capscrews spaced 90°
apart. Tighten the screws finger-tight.
(e) In the same way, use guide studs to fit the Small Bearing Housing
(SBH) . Secure with four capscrews and tighten fully using a
spanner or wrench.
Fully tighten the LBH while checking that the compressor rotates
freely. Stop immediately if the compressor binds or locks as this
means that the star is being forced against the lip as there is
insufficient shim thickness. Extra shimming must be added before
the lip clearance can be measured.
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.
Issue 1 : 08/07 Page 17 of 82

(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.
Page 18 of 82 Issue 1 : 08/07

4.3. Fitting New Star Rotors

Follow steps (a) to (h) in Fig 9. Assembly is made much easier if the star
backing is mounted over the end of a suitable length of thick walled pipe
(see diagrams).
3
2
4 5
1 Star backing
2 Star rotor
3 Star locating pin
– star locating pin
5 M5 x 35 capscrew – star locating
pin
Fig 8 Star Rotor Components
Issue 1 : 08/07 Page 19 of 82

(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).
Fig 9 Fitting New Star Rotor
Page 20 of 82 Issue 1 : 08/07

5. Discharge End Cover (HS L/M 3100)

5.1. End Cover (HS L/M 3100) – Removal
Then proceed as follows, refer to Fig 10.
(a) Refer to diagrams (a) and (b).
Drain the oil from the compressor. Position a suitable container
underneath the drain to catch the escaping oil.
(b) Disconnect the discharge line and oil injection lines at the outlet
flanges. Move the pipes out of the way.
(c) If a discharge temperature sensor is fitted, disconnect sensor
wiring at the terminal box.
(d) Refer to diagram (c).
Screw eyebolts into the threaded holes provided. 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 cover flange.
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.
Issue 1 : 08/07 Page 21 of 82


(77 lbf ft).
(b) Reconnect the discharge and oil injection lines.
(c) If a discharge temperature sensor was fitted, reconnect sensor
(d) Refill the compressor with 4 litres of fresh refrigeration oil of the
same type and grade used in the system.
(e) Recommission the compressor as described in 3. Essential
Page 22 of 82 Issue 1 : 08/07

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)
Issue 1 : 08/07 Page 23 of 82

6. Oil Separator Assembly (HSS 3100)
6.1. Oil Separator Assembly (HSS 3100) – Removal

Drain the oil from the separator. Position a suitable container
underneath the drain to catch the escaping oil.
(b) Disconnect the discharge line at the outlet flange. Move the pipe
out of the way.
(c) If an oil temperature sensor or oil level sensor is fitted, disconnect
(d) Refer to diagrams (c) and (d).
Draw an alignment mark across the non-return valve housing and
oil separator flange as show in the diagram (arrowed).
studs into the vacant holes. Remove the rest of the capscrews.
Screw an M16 eyebolt into one of the threaded holes for the
discharge flange.
WARNING
The oil separator assembly is a very heavy component.
Attempting to remove the separator without using guide
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.
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.
Page 24 of 82 Issue 1 : 08/07


for reassembly.
A new gaskets must be used. Use fresh refrigerant oil to lubricate the
gaskets during reassembly.
(a) Refit the oil separator assembly, this is the reverse of the
dismantling sequence; follow steps (h) to (e) in Fig 11.
WARNING
The oil separator assembly is a very heavy component.
Attempting to refit the separator without using guide
(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.
(77 lbf ft).
(c) Reconnect the discharge line.
(d) If an oil temperature sensor or oil level sensor was fitted, reconnect
(e) Recommission the compressor as described in 3. Essential
Issue 1 : 08/07 Page 25 of 82

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.
Fig 11 Oil Separator Assembly – Removal and Refitting (HSS 3100)
Page 26 of 82 Issue 1 : 08/07

7. Slide Valve, Main Rotor and Main Bearings
14
13
16
15
12
8 4 4 5
10
11
2
3
1 Main rotor shaft

2 Main bearing housing
3 Shim location (main rotor
assembly centralisation)
4 Angular contact ball bearings
(pair)
5 Roller bearing
6 Roller bearing – suction end
7 Circlip
Fig 12 Slide Valve, Main Rotor and Main Bearings
Issue 1 : 08/07 Page 27 of 82

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
15 Slide stop screw

16 ‘O’ ring 16.36 OD x 2.2 section –
slide stop screw to cylinder
Fig 12 (continued) Slide Valve, Main Rotor and Main Bearings
Page 28 of 82 Issue 1 : 08/07

7.1. Main Rotor Assembly – Dismantling

• Dismantle the star rotor assembly; refer to 4.1.
• Remove the end cover (HS L/M 3100) or oil separator
assembly (HSS 3100); refer to 5.1. or 6.1.
• Dismantle and remove the suction strainer; refer to 8.3.
• Dismantle and remove the motor rotor; refer to 8.5.
Stator/Rotor Assembly – Dismantling steps (a) and (b).
Then proceed as follows; refer to Fig 12 and Fig 13.
(a) Refer to diagrams (a) to (c).
Unscrew and remove the slide stop screw ‘15’.
(b) Refer to diagrams (d) and (e).
Loosen the capscrews ‘14’ securing the capacity control cylinder.
Leave two screws in position 180° apart, remove the remaining five
capscrews.
Hold the capacity control cover against the spring force while
removing the last two screws. Ease the cover off its joint face.
(c) Refer to diagrams (f) to (i).
Withdraw the capacity control assembly. Remove the cover
gasket.
Remove the unloading spring.
(d) Refer to diagrams (j) to (m).
Unscrew and remove the capscrews securing the bearing housing
cover ‘12’.
Shimming behind the bearing housing cover is used to centralise
the main rotor assembly. Avoid damaging any shims which may
be found.
(e) Refer to diagram (n).
Remove the two orifice plugs and ‘O’ rings.
(f) Refer to diagrams (o) to (r).
Screw an M16 eyebolt into the threaded hole provided in the end of
the main rotor shaft.
Either attach a shackle to the eyebolt in the end of the main rotor
shaft or insert a length of round bar so as to obtain a purchase.
Screw a length of rod into the other end of the shaft. Wrap paper
round the rod to protect the bearings.
(g) Pull on the bar to withdraw the main rotor assembly. Use the
handling rod to guide and support the main rotor assembly.
Lower the main rotor assembly onto a surface which is not likely to
damage the rotor, for example, a wooden pallet. Chock the
assembly to prevent it rolling and damaging the main rotor flutes.
Unscrew and remove the handling rod.
Issue 1 : 08/07 Page 29 of 82

If it is required to dismantle the assembly further, contact J & E Hall

International.
(h) The suction end main bearing roller race ‘6’ is located by a large
internal circlip ‘7’.
Remove the circlip and withdraw the roller race.
Use a suitable puller to remove the bearing inner ring from the end
of the mainshaft.
Page 30 of 82 Issue 1 : 08/07

(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.
Fig 13 Main Rotor Assembly – Dismantling
Issue 1 : 08/07 Page 31 of 82

(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.
Fig 13 (continued) Main Rotor Assembly – Dismantling
Page 32 of 82 Issue 1 : 08/07

(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.
Issue 1 : 08/07 Page 33 of 82

(s) The suction end main bearing roller race is located by (t) Remove the circlip and withdraw the roller race.
a large internal circlip.
Page 34 of 82 Issue 1 : 08/07

7.2. Main Rotor Assembly – Reassembly

Refer to Fig 12 and Fig 14.
The following procedure refers to refitting the original main rotor
assembly. If a new assembly is to be fitted the shimming behind the rear
main bearing housing must be adjusted to centralise the main rotor to the
star rotors; refer to J & E Hall International.
for reassembly.
Use fresh refrigerant oil to lubricate parts during reassembly. New
Fit the suction end main bearing outer roller race ‘6’ and secure in
place with circlip ‘7’.
(b) Refer to diagrams (c) to (d).
Screw the handing rod into the end of the main rotor shaft. Use
the lifting apparatus to present the assembly square with the face
of the casing. Enter the handling rod through the casing and use it
to guide the main rotor into the casing bore. Slide the assembly
into place. Unscrew the handling rod and remove the lifting
apparatus.
(c) Refer to diagrams (f) to (i).
Using new ‘O’ rings, fit the two orifice plugs.
(d) Refer to diagram (j).
Check the shimming behind the bearing housing cover is in
position over the main bearing retaining plate ‘14’..
(e) Refer to diagrams (k) and (l).
Fit the bearing housing cover.
Apply Loctite 275 to the threads of the capscrews which secure the
bearing housing cover; degrease the threads first if necessary.
Insert the capscrews and tighten finger-tight, then tighten evenly,
alternately and a little at a time to 30 N m (22 lbf ft).
(f) Refer to diagrams (m) and (n).
Lubricate the cover flange before locating a new capacity control
cylinder cover gasket in position.
(g) Refer to diagram (o).
Locate the unloading spring inside the capacity control slide bore.
(h) Refer to diagrams (p) to (r).
Offer up the capacity control assembly, engage the spring into the
recess in the end of the slide. Enter the slide into the bore and
push home against the spring.
(i) Refer to diagram (s).
Push the cylinder against the cover flange. Enter the cover
capscrews and tighten finger tight. Tighten the screws evenly,
alternately and a little at a time to 30 N m (22 lbf ft).
(j) Refer to diagrams (t) and (u).
Issue 1 : 08/07 Page 35 of 82

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
Page 36 of 82 Issue 1 : 08/07

(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.
Fig 14 Main Rotor Assembly – Reassembly
Issue 1 : 08/07 Page 37 of 82

(g) Fit a new O’ ring. (h) Fit the second 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).
Fig 14(continued) Main Rotor Assembly – Reassembly
Page 38 of 82 Issue 1 : 08/07

(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.
Fig 14 (continued) Main Rotor Assembly – Reassembly
Issue 1 : 08/07 Page 39 of 82

(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.
Fig 14 (continued) Main Rotor Assembly – Reassembly
Page 40 of 82 Issue 1 : 08/07

8. Stator/Rotor Assembly, Motor Terminal Plate and Suction Strainer
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
9 Gasket – suction end cover to

motor housing
10 M12 x 45 capscrew – suction
end cover
11 Motor terminal plate
12 Gasket – motor terminal plate to
motor housing
13 M8 x 30 capscrew – motor
terminal plate
14 Suction strainer
15 2 x gaskets
Fig 15 Stator/Rotor Assembly, Motor Terminal Plate and Suction Strainer
Issue 1 : 08/07 Page 41 of 82

8.1. Motor Terminal Plate – Dismantling

Proceed as follows; refer to Fig 16.
(a) Disconnect wiring to the motor terminal box. Remove the terminal
box.
(b) Refer to diagrams (a) and (b).
Dismantle the motor terminal plate.
(c) Refer to diagrams (c) and (d).
Use pliers to pull off the thermistor wires.
(d) Refer to diagrams (e) and (f).
Unscrew the stator lead terminal nuts and bolts. Lift off the
terminal plate.
8.2. Motor Terminal Plate – Reassembly
Refer to Fig 17.
for reassembly.
Use a new terminal plate to motor housing gasket. Lubricate the gasket
during assembly.
Reassembly is made much easier by using guide studs to locate
the terminal plate in a convenient position to attach the stator
leads. If its not possible to orientate the compressor as shown,
position the terminal plate above the housing by using studding
with a nut each side of the plate.
Position a new gasket and the terminal plate over the guide studs.
(b) Refer to diagrams (c) to (h).
Reconnect the stator leads, note the order in which components
are fitted. Tighten each terminal bolt to 21 N m (15 lbf ft). Do Not
overtighten.
(c) Refer to diagrams (i) and (j).
Wind each thermistor wire around a stator lead before
reconnecting to the back of the terminal plate.
(d) Refer to diagrams (k) and (l).
Oil the terminal plate gasket.
Push the terminal plate assembly against the housing flange.
Check the stator leads are not kinked as they enter the housing.
(22 lbf ft).
(e) Refit the terminal box. Reconnect wiring to the terminal box.
(f) Recommission the compressor as described in 3. Essential
Page 42 of 82 Issue 1 : 08/07

(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.
Fig 16 Motor Terminal Plate – Dismantling
Issue 1 : 08/07 Page 43 of 82

(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.
Fig 17 Motor Terminal Plate – Reassembly
Page 44 of 82 Issue 1 : 08/07

(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.
Fig 17 (continued) Motor Terminal Plate – Reassembly
Issue 1 : 08/07 Page 45 of 82

8.3. Suction Strainer – Dismantling

Proceed as follows; refer to Fig 18.
(a) Disconnect the suction line at the outlet flange. Move the pipe out
of the way.
(b) Dismantle the suction strainer, following steps (a) to (d) in Fig 18.
(c) The strainer basket consists of a perforated cylinder, flanged at
one end, lined with a fine mesh screen. Flow is into the basket and
out through the mesh, any dirt obstructing the flow will be found
inside. If there is a hole torn in the mesh, a new basket must be
fitted.
(d) Wash the strainer basket in a proprietary CFC-free cleaning agent.
Do not replace the strainer until it is perfectly dry. Wipe off any
surplus liquid with a piece of clean, lint-free cloth.
8.4. Suction Strainer – Reassembly
Refer to Fig 18.
Before reassembly commences, 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.
New gaskets ('15' in Fig 15) must be used. Use fresh refrigerant oil to
lubricate the gaskets during reassembly.
(a) Reassembling the suction strainer is the reverse of the dismantling
sequence; follow steps (d) to (a) in Fig 18.
(b) Reconnect the suction line at the outlet flange.
(c) Recommission the compressor as described in 3. Essential
Page 46 of 82 Issue 1 : 08/07

(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.
Fig 18 Suction Strainer – Removal and Refitting
Issue 1 : 08/07 Page 47 of 82

8.5. Stator/Rotor Assembly – Dismantling

• Dismantle and remove the motor terminal plate: refer to 8.1.
This step is not necessary if only the rotor is to be removed
prior to dismantling and removing the main rotor assembly.
• Dismantle and remove the suction strainer; refer to 8.3.
Then proceed as follows; refer to Fig 15 and Fig 19.
(a) Refer to diagrams (a) to (e).
Draw an alignment mark across the front cover and casing flange
as show in the diagram (arrowed).
Unscrew and remove two capscrews ‘10’ 180° apart. Insert M16
guide studs into the vacant holes.
Remove the rest of the capscrews.
Remove the suction end cover ‘8’ and cover gasket ‘9’.
(b) Refer to diagrams (f) to (n).
Position a capscrew as shown to lock the rotor.
Unscrew the rotor retaining plate screw ‘6’. Remove the screw,
spring washer ‘7’ and retaining plate ‘5’.
Remove the rotor shaft spacer ‘4’. Withdraw the rotor and rotor
key.
NOTE: no further dismantling is required if the purpose
of this exercise is to dismantle the main rotor assembly.
To remove the stator proceed as follows:
(c) Refer to diagram (m)
The stator leads are grouped together with cable ties. Cut the ties
and pull the leads from the terminal box so that they don’t foul the
stator when it is withdrawn from its housing.
(d) Refer to diagrams (n) and (o).
Unscrew the stator location dowel.
(e) Refer to diagrams (p) to (r).
Fit the stator handling tool so that it grips the inside of the stator.
Present the casing vertically. Attach a shackle to the eyebolt on
the end of the handling tool.
Withdraw the stator. Note the key which locates the stator in the
housing.
Page 48 of 82 Issue 1 : 08/07

(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.
Fig 19 Stator/Rotor Assembly – Dismantling
Issue 1 : 08/07 Page 49 of 82

(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.
Fig 19 (continued) Stator/Rotor Assembly – Dismantling
Page 50 of 82 Issue 1 : 08/07

(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.
Fig 19 (continued) Stator/Rotor Assembly – Dismantling
Issue 1 : 08/07 Page 51 of 82

8.6. Stator/Rotor Assembly – Reassembly

for reassembly.
Use fresh refrigerant oil to lubricate parts during reassembly. New
(a) Refer to diagrams (a) to (d).
Check the stator housing, stator, stator key and keyway are
completely clean. Lightly oil the stator key before fitting it into the
groove in the side of the rotor.
Fit the stator handling tool so that it grips the inside of the stator.
Present the casing vertically. The weight of the stator, the tight
clearances and the difficulty of aligning the stator key means that it
is very difficult to fit the stator with the casing in the horizontal
position.
Attach a shackle to the eyebolt on the end of the handling tool.
Lower the stator into the housing, at the same time align the stator
key with the keyway. Avoid pinching the stator leads between the
stator and the side of the housing.
Check the stator slides fully home. The hole in the stator for the
location dowel must align with the corresponding hole in the
housing.
Remove the stator handling tool.
(b) Refer to diagrams (e) and (f).
Fit a new ‘O’ ring to the stator location dowel. Screw the dowel into
place to lock the rotor into the housing.
(c) Refer to diagrams (g) and (h).
The stator leads are grouped together with cable ties. Feed the
leads into the terminal housing.
Reconnect the leads to the terminal plate; refer to 8.2. Motor
Terminal Plate – Reassembly. Group the leads together and
secure with new cable ties. Cut off any excess.
(d) Refer to diagrams (i) to (r).
Oil the rotor key. Locate the key into the keyway on the motor
shaft.
Fit the rotor ‘3’ and rotor shaft spacer ‘4’ over the motor shaft and
key.
Position a capscrew as shown to lock the rotor.
Assemble the rotor retaining plate ‘5’, spring washer ‘7’ and screw
‘6’. Tighten the screw to 163 N m (120 lbf ft). Remove the
capscrew.
(e) Refer to diagrams (s) to (v).
(f) Lubricate the suction end cover joint face.
Insert 2 x M16 guide studs into holes 180° apart on the suction
cover flange.
Locate a new housing gasket ‘9’ over the guide studs.
Page 52 of 82 Issue 1 : 08/07

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
Issue 1 : 08/07 Page 53 of 82

(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.
Fig 20 Stator/Rotor Assembly – Reassembly
Page 54 of 82 Issue 1 : 08/07

(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.
Fig 20 (continued) Stator/Rotor Assembly – Reassembly
Issue 1 : 08/07 Page 55 of 82

(m) The rotor in-situ. (n) The rotor shaft spacer.
(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.
Page 56 of 82 Issue 1 : 08/07

(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).
Issue 1 : 08/07 Page 57 of 82

9. Discharge Non-return Valve (HSS 3100)
9
7
4
5
6
8
10
1 Oil separator cover
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
6 Valve plate retainer

7 Valve spindle
8 ‘O’ ring 9.25 x 1.78 section –
valve spindle/plate retainer
9 Spring
10 M8 nut with nylon insert
Fig 21 Discharge Non-return Valve (HSS 3100)
Page 58 of 82 Issue 1 : 08/07

9.1. Discharge Non-return Valve (HSS 3100) – Dismantling

Proceed as follows; refer to Fig 21 and Fig 22.
(a) Disconnect the discharge line at the oil separator outlet flange.
Move the pipe out of the way.
(b) The non-return valve can be dismantled in-situ or removed from
the separator first of all as described in 6.1. Oil Separator
Assembly (HSS 3100) – Removal step (d).
(c) Dismantle the non-return valve, following steps (a) to (l) in Fig 22.
9.2. Discharge Non-return Valve (HSS 3100) – Reassembly
for reassembly.
Use fresh refrigerant oil to lubricate parts during reassembly. New ‘O’
rings must be used.
(a) Reassembling the non-return valve is the reverse of the
dismantling sequence; follow steps (l) to (a) in Fig 22.
(b) If the non-return valve was removed from the separator before
dismantling, refit it as described in 6.2. Oil Separator Assembly
(HSS 3100) – Refitting step (b).
(c) Reconnect the discharge line at the oil separator outlet flange.
(d) Recommission the compressor as described in 3. Essential
Issue 1 : 08/07 Page 59 of 82

(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.
Fig 22 Discharge Non-return Valve (HSS 3100) - Dismantling and Reassembly
Page 60 of 82 Issue 1 : 08/07

(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
Issue 1 : 08/07 Page 61 of 82

10. Oil Filter (HSS 3100)
5 3 1 2 6 7
1 Oil separator housing

2 Oil filter
3 Cover
4 ‘O’ ring 88.49 x 3.53 section –

cover to housing
5 M10 x 25 capscrew - cover to
housing
6 Spindle
7 ‘O’ ring 15.54 x 2.62 section –
spindle to housing
Fig 23 Oil Filter (HSS 3100)
The HSS 3100 compressor is provided with an integral oil filter.

However, an integral filter is not applicable to every application,
sometimes it is necessary to use an external oil filter in which case the
integral filter element and spindle are removed before commissioning.
Refer to the HS 3100 Application Manual for further details.
Page 62 of 82 Issue 1 : 08/07

10.1. Fitting a New Oil Filter Element (HSS 3100) - Dismantling

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
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
Issue 1 : 08/07 Page 63 of 82

(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.
Fig 24 Fitting a New Oil Filter Element (HSS 3100)
Page 64 of 82 Issue 1 : 08/07

(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).
Fig 24 (continued) Fitting a New Oil Filter Element (HSS 3100)
Issue 1 : 08/07 Page 65 of 82

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
(a) LVDT location () () ()
4 3
1 2
(b) LVDT assembly () () ()
1 Pressure contaiN ment body

- pressure contaiN ment body to
casing
3 Indicator rod (spring loaded)
4 Din plug
Fig 25 LVDT Components
Page 66 of 82 Issue 1 : 08/07

11.1. LVDT – Dismantling and Reassembly

(a) Disconnect the DIN plug ‘4’.
(b) Unscrew the LVDT using a spanner on the flats provided on the
pressure contaiN ment body.
(c) Reassembly is the reversal of dismantling. Use a new ‘O’ ring ‘2’.
Issue 1 : 08/07 Page 67 of 82

12. Discharge Thermistor
The compressor is fitted with a discharge thermistor adjacent to the

discharge port; refer to Fig 9 diagram (a).
12.1. Discharge Thermistor – Removal
(d) Disconnect the thermistor wiring at the terminal box. This is
essential to avoid twisting the wires as the thermistor is unscrewed.
(e) Unscrew the thermistor from the casing. Note the seal underneath
the thermistor body.
12.2. Discharge Thermistor – Refitting
Refer to Fig 26.
Refitting the thermistor is the reverse of the remove sequence. Do not
overtighten when screwing the thermistor into the casing.
Page 68 of 82 Issue 1 : 08/07

Discharge
Thermistor
(a) Discharge thermistor location. () () ()
(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.
Fig 26 Discharge Thermistor
Issue 1 : 08/07 Page 69 of 82

13. Capacity Control Solenoid Valves
The location of the ‘load’ and ‘unload’ capacity control solenoid valves is
illustrated in Fig 27.
Unload
Solenoid
Load Valve
Solenoid
Valve
Fig 27 Capacity Control Solenoid Valve Location
13.1. Capacity Control Solenoid Valve - Dismantling

The compressor may be fitted with Sporlan or Alco solenoid valves.
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
(b) Use a ring spanner to unscrew the armature tube ‘6’ from the
casing.
Remove the armature ‘9’ and spring ‘8’.
Page 70 of 82 Issue 1 : 08/07

(c) If necessary, use a deep socket to unscrew the orifice ‘10’.

Clean the orifice by blowing though with an air line.
13.2. Capacity Control Solenoid Valve- Reassembly
Refer to Fig 30.
Before assembly commences, 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) Refer to diagrams (a) to (b)
If the orifice ‘1’ was removed, use a deep socket to screw it into
place.
Locate the spring ‘8’ and armature ‘9’ into the armature tube ‘6’.
Check the PTFE gasket ‘7’ is in position inside the recess in the
casing. Screw the armature tube assembly into the casing.
(b) Refit the coil assembly.
Sporlan Coil
Refer to diagrams (d) to (f)
Locate the coil assembly ‘1’ over the armature tube ‘6’. Position
the coil data plate ‘2’ on top of the coil and secure with the screw
‘3’.
Asco Coil
Locate the coil assembly ‘6’ over the armature tube ‘2’. Secure
with the clip ‘5’.
(c) Recommission the compressor as described in 3. Essential
(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).
Fig 28 Solenoid Valve Armature Tube - Dismantling
Issue 1 : 08/07 Page 71 of 82

3 4
1 2
Sporlan Coil Assembly Asco Coil Assembly
10
9
1 Coil assembly
Sporlan
2 Coil data plate

3 Screw – coil data plate and
coil to armature tube
4 Coil assembly
Asco
5 Clip – coil assembly to

armature tube
6 Armature tube
7 PTFE gasket – armature tube to
casing
8 Spring
9 Armature
10 Orifice
Fig 29 Capacity Control Solenoid Valve Components
Page 72 of 82 Issue 1 : 08/07

(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.
Fig 30 Armature Tube and Coil Assembly- Reassembly
Issue 1 : 08/07 Page 73 of 82

Appendix 1 Tightening Torques
COMPONENT FASTENING TORQUE

SIZE (MM)
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
Main bearing retaining

M6 x 16 5 4
plate
Capacity control
M5 x 25
cylinder
Oil filter cover M10 x 25 59 44
Star bearing housing
M10 x 30 59 44
(larger)
Star bearing housing

M8 x 25 30 22
(smaller)
Star locating pin M5 x 35

Motor terminal plate M8 x 30 30 22
Motor terminals M8 x 25
21 15
(stator/rotor side) (brass)
Motor terminals
M10 x 16 59 44
(motor cable side)
Motor terminal box M6 x 10 12 9

Motor terminal box
cover
Rotor retaining plate M16 x 40 163 120
Liquid injection/
M8 x 55 30 22
economiser block
Oil separator M12 x 45

HSS 3100
Oil separator cover M12 x 40
104 77
HS L/M
Discharge end cover M12 x 45
3100
Table 1 Recommended Tightening Torques for Fastenings – HS 3100 Series Compressors
Page 74 of 82 Issue 1 : 08/07

Appendix 2 Spare Parts

Refer to the following pages to identify spare parts. Obtain spares from
the address below:
J & E Hall International Telephone: +44 (0) 1332-253400

Hansard Gate, Fax: +44 (0) 1332-371061
West Meadows, Email: Halltherm@jehall.co.uk
Derby, Website: www.jehall.com
DE21 6JN
England
Always quote the compressor serial number(s) and J & E Hall
International contract number when ordering spares.
Issue 1 : 08/07 Page 75 of 82

HS3100
Issue 4 (H) HS3100 Spare Parts List Quantity for Each Compressor
Page 3
Semi-Hermetic Compressor
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
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 115V (Sporlan) N30020039 131066072 2 2 2 2
5 1 Capacity Control Solenoid Valve Coil 230V (Sporlan) N30020045 131066071 2 2 2 2
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
7 1 Suction Filter (also require item 18 or 22) N12010011 87211-301 1 1 1 1

HS3100
Page 4
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
Capacity Control Slides

10 1 Capacity Control Slide Kit 2.0VR (also require items 16 & 22) N02860110 95823-101 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
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
Page 5
Valves
13 1 Discharge Check Valve 3-in-1 (Optional) (also require item 20 or 22) N30150074 95814-210 1 1 1 1
N/S N/S Suction Shut-Off Valve (optional) N30150072 93256-826 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
Page 5
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 575V 60Hz 52kW (also require item 18 or 22) N02330019 95813-504 1 1
Stators R22/R407c/R410A
15 1 Stator 400V 50 82kW / 460V 60Hz 98kW (also require item 18 or 22) N02330018 95813-503 1 1
HS3100
Page 5
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
19 1 Oil Filter Replacement Gasket & O-Ring Set N33010027 128810988 1 1 1 1
20 1 Discharge Check Valve Replacement Gasket & O-Ring Set N33010066 95822-316 1 1 1 1
21 1 Economiser / Liquid Injection Gasket Set N33010067 95822-317 1 1 1 1
22 1 Full Gasket & O-Ring Set N33010068 128810982 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
©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.
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
Page 82 of 82 Issue 1 : 08/07

McQuay HallScrew HS-3100 Series Compressor Service Manual

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HallScrew HS 3100 Series

Semi-hermetic Single Screw Compressors

Issue 1 : 08/07 Page 1 of 82

Page 2 of 82 Issue 1 : 08/07

Issue 1 : 08/07 Page 3 of 82

Page 4 of 82 Issue 1 : 08/07

1. About this Publication

Issue 1 : 08/07 Page 5 of 82

Page 6 of 82 Issue 1 : 08/07

To ensure maximum efficiency, not only must components be correctly

Fig 1 Guide Studs

Issue 1 : 08/07 Page 7 of 82

3. Essential Operations Prior to Dismantling, Recommissioning

Page 8 of 82 Issue 1 : 08/07

3.2. Recommissioning the Compressor

Issue 1 : 08/07 Page 9 of 82

4. Star and Star Bearing Assembly

Fig 2 Star Rotor and Star Bearing Housing Assembly

Page 10 of 82 Issue 1 : 08/07

3 Star locating pin

7 Taper roller bearing

section - housing to casing

11 Star bearing housing

19 M12 x 45 capscrew – top cover

Fig 2 (continued) Star Rotor and Star Bearing Housing Assembly

Issue 1 : 08/07 Page 11 of 82

4.1. Star Rotor Assembly – Dismantling

Fig 3 Removing Star Rotor Bearing Taper Roller Race

Page 12 of 82 Issue 1 : 08/07

Using Hydraulic or Pneumatic Press Using Mechanical Press

Fig 4 Fitting New Star Rotor Bearing Inner Race

(k) Disengage the star rotor from the main rotor.

Issue 1 : 08/07 Page 13 of 82

SBH = Small Bearing Housing () ()

Fig 5 Star Rotor Assembly – Dismantling

Page 14 of 82 Issue 1 : 08/07

SBH = Small Bearing Housing () ()

Fig 6 Star Rotor Assembly – Dismantling

Issue 1 : 08/07 Page 15 of 82

SBH = Small Bearing Housing () ()

Fig 7 Star Rotor Assembly – Reassembly

Page 16 of 82 Issue 1 : 08/07

4.2. Star Rotor - Reassembly

Issue 1 : 08/07 Page 17 of 82

Page 18 of 82 Issue 1 : 08/07

4.3. Fitting New Star Rotors

Fig 8 Star Rotor Components

Issue 1 : 08/07 Page 19 of 82

Fig 9 Fitting New Star Rotor

Page 20 of 82 Issue 1 : 08/07

5. Discharge End Cover (HS L/M 3100)

Issue 1 : 08/07 Page 21 of 82

Insert the cover capscrews and tighten finger-tight. Unscrew and

Page 22 of 82 Issue 1 : 08/07

Issue 1 : 08/07 Page 23 of 82

6. Oil Separator Assembly (HSS 3100)

6.1. Oil Separator Assembly (HSS 3100) – Removal

Page 24 of 82 Issue 1 : 08/07

Before reassembly commences, remove any paint from joint faces.

Issue 1 : 08/07 Page 25 of 82

Fig 11 Oil Separator Assembly – Removal and Refitting (HSS 3100)

Page 26 of 82 Issue 1 : 08/07

7. Slide Valve, Main Rotor and Main Bearings