ARIEL

Head End Pneumatic

Fixed Volume Clearance
Pocket Unloader
(FVCP)
TECHNICAL MANUAL

ARIEL CORPORATION
35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050
TELEPHONE: 740-397-0311 FAX: 740-397-3856
VISIT OUR WEB SITE: www.arielcorp.com 5/00
 ! CAUTION
TO PREVENT PERSONAL INJURY, ENSURE THAT COM-
PRESSOR CRANKSHAFT CANNOT BE TURNED BY THE
DRIVER OR COMPRESSOR CYLINDER GAS PRESSURE
DURING MAINTENANCE: -- ON ENGINE-DRIVEN COMPRES-
SORS, REMOVE THE CENTER COUPLING OR LOCK THE
FLYWHEEL. -- ON ELECTRIC MOTOR-DRIVEN COMPRES-
SORS, IF IT IS INCONVIENIENT TO DETACH THE DRIVER
FROM THE COMPRESSOR, THE DRIVER SWITCH GEAR
MUST BE LOCKED OUT DURING MAINTENANCE.
BEFORE STARTING ANY MAINTENANCE OR REMOVING
ANY COMPONENTS, RELIEVE ALL PRESSURE FROM THE
COMPRESSOR CYLINDERS. SEE PACKAGER’S INSTRUC-
TIONS FOR COMPLETELY VENTING THE SYSTEM.









! CAUTION
SEVERE PERSONAL INJURY AND PROPERTY DAMAGE
CAN RESULT IF PRESSURE SYSTEM IS NOT
COMPLETELY VENTED BEFORE LOOSENING THE BOLTS
ON FLANGES OR FITTINGS TO PRESSURE CONTAINING
AREAS. CONSULT ARIEL TECHNICAL MANUAL BEFORE
PERFORMING ANY MAINTENANCE.

! CAUTION
HOT GAS TEMPERATURES, ESPECIALLY THE GAS
DISCHARGE AREAS, HOT OIL AND HIGH FRICTION
AREAS CAN BE A SOURCE FOR BURNS. WEAR PROPER
INSULATION WHEN WORKING AROUND THESE AREAS.
SHUT DOWN UNIT AND ALLOW TO COOL BEFORE
DOING MAINTENANCE IN THESE AREAS.

 






Data Plate O-ring

Actuator
Valve Gasket Cylinder

Actuator
Spring
Piston
Drake (if required)
Locknut
Vent to Safe
Atmosphere

Spring

O-rings

Glyd Ring
(with O-ring)

Roll Pin
Valve
Guide
Indicator
Pin - Open

Washer
Control Media
Crossbar Connection

Stat-O-Seal
Washer

Actuator Cap

O-ring

U-Cup
O-rings Seal Ring
Breather
Adapter Vent to Safe
Flange Atmosphere

Adapter Flange
Vent to Safe to Unloader
Pneumatic-Unloader Stem Seal Cylinder Head
Atmosphere Cylinder-Head
Cylinder-Head Gland Fasteners
Fasteners

OPEN POSITION - UNLOADED

 

  
      

  

   



  





1/2”- 20 Spring Vent to Safe

Actuator 12 Point Capscrew Atmosphere
Piston
O-rings
Stem

Roll Pin

Indicator
Pin - Open
(Unloaded)

Washer

Control Media
Connection
Spring
(if required)
Stat-O-Seal
Washer

Breather
Vent to Safe (6) 1/2”- 20
Atmosphere Hex Head Capscrew

Actuator Cap
Actuator
Cylinder
U-Cup O-ring
Seal Ring

 
   
 
  

     


 
 





(4) 7/16”- 14 (6) 3/8”- 16

Socket Head Capscrews Socket Head Capscrews
Lockwire in Pairs

(4) 5/16”- 18
Socket Head Capscrews
Lockwire in Pairs (1) 1/2”- 20
12 Point Capscrew

1/8 inch
NPT

Indicator
Pin - Closed

1/8 inch
NPT

(6) 1/2”- 20
Hex Head Capscrew

1/8 inch
(1) 1/2”- 20
NPT
Drake Locknut

1/2 inch NPT Oil drain at

Shutdown/Blow-down
(Not Shown)

 
   

  



  





  

    


 
 





  

The pneumatic or automatic fixed volume clearance pocket (FVCP) unloader is designed to
add a fixed amount of volumetric clearance to a compressor cylinder. By adding clearance,
the cylinder's throughput and power consumption are reduced, allowing the operator to uti-
lize automated power and capacity control through a range of pressures. When the pocket is
open, all of its internal volume is added to the cylinder's base clearance, reducing power
consumption and throughput. When the pocket is closed, the cylinder is operating at base
clearance, with maximum power consumption and throughput. There is no intermediate step
with a FVCP - it's either open or closed.



The actuator assembly is attached to the unloader flange, and is the outer most portion of
the unloader. It consists of a cylinder, cap, piston, stem, bolt, return spring (in some cases),
indicator, fasteners and seals. An actuating medium (typically compressed air or fuel gas) is
supplied at the outboard end of the actuator, via a control valve. When pressure is applied,
the actuator piston travels toward the crankshaft, forcing the unloader valve to close. When
pressure is released, the compressor cylinder gas pressure (and return spring where appli-
cable) force the piston away from the crankshaft, until the piston stops when it contacts the
cap, opening the unloader valve. An indicator in the actuator cap indicates when the actua-
tor piston is outboard, meaning that the pocket is open.
Actuating gas pressure will be supplied via a control valve, which will allow compressed gas
to enter the actuator and close the pocket, and which will allow this gas to leave the actuator
and open the pocket. The actuator MAWP is 150 psig (10.3 bar), and actuating gas should
be supplied at no more than 125 psig (8.62 bar). The minimum actuating pressure varies
with cylinder design pressure, and will be stamped on a data plate, located on the unloader
assembly, and will also be published in the unloader parts list.

 

The unloader valve is located inside the clearance pocket, and it is attached to the actuator
stem via the crossbar. Gas pressure in the actuator cylinder causes the chamfered end of
the valve to seal against the chamfered seat on the cylinder head. When the actuating gas
pressure is released, the valve moves away from the seat, opening the pocket volume to the
cylinder.

 

Gas pressure in the actuating cylinder is contained by three sets of seals. The cap utilizes
an o-ring face seal, the piston utilizes a u-cup style piston seal, and the mechanical indicator
utilizes a pair of o-ring seals. In addition, there is a Stat-o-seal between the actuator piston
and the bolt that holds the piston to the stem. At the interface of the actuator cylinder to the


  




adapter flange, a fiber gasket contains any leaked process gas or actuating gas that may
escape past primary seals.
Inside the volume pocket, the unloader valve is sealed against the guide by a Glyd Ring.
This is a relatively large diameter o-ring seal in the bottom of a groove, with a step-cut piston
ring above it. An o-ring provides the seal between the adapter flange and the head, and
pairs of o-rings seal between the adapter flange and the seal gland, and between the seal
gland and the actuator stem.

  

The following vent connections must be made by the packager, and all are critical to proper
operation and durability of the unloader, as well as to safety of operation and maintenance
personnel. All vents and drains must be installed in such a manner as to prevent the collec-
tion of liquids that could cause the build up of either gas or liquid. When a heavier than air
gas is involved, vent and drain design must be accommodating.
A 1/8 inch NPT connection on the actuator cap outside diameter allows leakage gas from
the actuator cylinder to be safely conducted to flare or a safe atmosphere. This connection is
important if the actuating medium is fuel gas or some other non-inert gas. If the actuating
medium is air or inert gas, the connection can be plugged or left open.
A 1/8 inch NPT breather connection on the actuator cylinder outside diameter allows leak-
age gas from the actuating cylinder and the volume pocket to be safely conducted to flare or
a safe atmosphere. Additionally, this connection allows for the air trapped behind the actua-
tor piston to escape when the valve closes, so that the actuating piston does not do the work
of compressing this air.
A 1/8 inch NPT connection on the adapter flange outside diameter allows leakage gas from
the actuator stem seal to be safely conducted to flare or a safe atmosphere.
A 1/2 inch NPT connection on the head flange outside diameter allows trapped cylinder
lubricating oil to be drained whenever the unit is shut down and blown down for servicing.
The pocket could conceivably retain oil to a depth reaching the unloader valve diameter,
effectively decreasing the pocket volume by that amount. This oil should be drained at every
opportunity in order to ensure proper compressor performance.
It is critical, for the safe operation of the compressor, to ensure that all vents and drains are
open, functional and, if necessary, tubed off of the skid or out of the building. Depending
upon your climate and insect population it can be necessary to install screens over the vents
and drains to ensure that they do not become blocked. This can be essential if the compres-
sor is shutdown for a long period of time.

  

Routine maintenance will include inspection of the sealing elements and sealing surfaces,
and replacement of these items as required. Before attempting any maintenance on the
unloader, all applicable safety precautions must be observed, including but not limited to:

 
 




shut down the compressor and blow down the piping and cylinders to relieve all pressure;
lock the unit to prevent the crankshaft from rolling.
For any unloader maintenance, the recommended first step is to disconnect all vent and
drain lines and the actuating gas line from the unloader, and to remove the unloader flange
assembly from the head. Remove the adapter flange fasteners and separate the assembly
from the head. Threaded holes are provided in the adapter flange for jackscrews to facilitate
disassembly. Threaded holes are provided in the adapter flange (and cylinder-head) for tool-
box eye bolts to assist lifting. The assembly is heavy and caution must be exercised to pre-
vent injury. Using a crane is recommended. Inspect o-ring and replace as necessary.
Remove the (six) 1/2 inch - 20TPI capscrews that hold the actuator cap and cylinder on the
adapter flange. Remove the cap and inspect the o-ring face seal and sealing surfaces, and
replace as necessary. If actuating gas leakage was detected either around the indicator pin
or from the actuator cap vent line, remove and replace the indicator pin, spring and o-rings.
Disconnect the actuator cylinder breather vent tube. Remove the actuator cylinder by pulling
it away from the flange, over the piston. Inspect the cylinder bore and the piston seal, and
replace as necessary. Inspect the gasket in the groove on the flange, and replace as neces-
sary.
Cut and remove the lockwire from the (four) 5/16 inch - 18TPI socket head capscrews on the
crossbar, and remove the capscrews. Remove the unloader valve by sliding it away from the
crossbar, over the valve seal. Inspect the valve bore and chamfered sealing surface for wear
or damage, and repair or replace if necessary. Take care not to damage the sealing end of
the valve while handling or storing. Inspect the Glyd Ring (with its step cut sealing ring and
o-ring back-up) for wear or damage, and replace if necessary. Also, inspect the chamfered
sealing surface in the head for wear or damage. If damaged, it may be possible to rework
this surface.
Remove the drake locknut from the actuator stem, under the crossbar, and gently pull the
piston and stem assembly away from the adapter flange. Inspect the entire stem and the
locknut for wear or damage, and replace if necessary. If the piston and stem must be disas-
sembled, replace the Stat-o-seal washer. Take care not to damage the stem during handling
or storage.
Cut and remove the lockwire from the (four) 7/16 inch - 14TPI socket head capscrews that
hold the seal gland on the adapter flange. Remove the seal gland and valve guide assembly
from the adapter flange. Inspect the flange bore, seal gland and o-rings for damage, and
replace if necessary.
Remove the (six) 3/8 inch - 16TPI socket head capscrews that hold the seal gland and valve
guide together, and remove the seal gland from the valve guide. Inspect the seal gland bore
and o-rings for wear or damage, and replace as necessary.



Oil all o-rings and all moving parts prior to, during or after assembly. With o-rings installed in
the bore grooves, assemble the seal gland and valve guide as shown in Figure 1: Make sure
the two pieces are oriented so that the crossbar will be horizontal when the unloader is
installed on the cylinder (and that the adapter flange vent connection will re-align with its


  




vent line). This will prevent the valve assembly from rotating, which could allow the crossbar
to rub on the valve guide during operation. Tighten the (six) 3/8 inch x 16TPI socket head
capscrews to 193 lb-in (22 N•m) torque.
With o-rings installed in the seal gland outside grooves, and the adapter flange bore oiled,
install the seal gland and valve guide assembly on the flange. Be sure to align the valve
guide so that the crossbar will be horizontal after the unloader is installed on the cylinder.
Tighten the (four) 7/16 inch - 14TPI capscrews to 26 lb-ft (35 N•m) torque. Lockwire the cap-
screws in pairs. Use new 0.039 to 0.041 inch (1 mm) 302/304 stainless steel lockwire, made
for this purpose. Match pairs of cap screws so that the holes in the heads are between 2 and
6 o’clock to a line running thru the heads, see Figure 6:, Step #1. Insert wire thru first screw
head, bend around the head and twist ends together in a clockwise direction, see Figure 6:,
Step #2. Continue twisting wire ends together to the paired cap screw. Insert the top end of
the wire into the screw head hole and bend the bottom end around the head. Twist ends
together in a counter-clockwise direction, see Figure 6:, Step #3. Cut off excessive length
and turn the twisted ends in along the screw head, leaving no sharp ends to avoid safely
hazards, Figure 6:, step #4.

STEP STEP STEP STEP

#1 #2 #3 #4

   



If the piston and stem were disassembled, reassemble them with a new stat-o-seal. Apply a
lubricant to both sides of the stat-o-seal before assembly. Tighten the 1/2 inch - 20TPI 12-
point capscrew to 46 lb-ft (62 N•m) torque. Use the 7/8 inch (22 mm) wrench flats on the
stem behind the piston. If the piston u-cup seal ring is being replaced, be sure the u-cup
faces the actuator cap.
Install a new actuator cylinder gasket in the groove in the adapter flange if required. Oil the
actuator cylinder bore and place it in position over the gasket. The cylinder vent connection
should be oriented to be nearest to the adapter flange. Place the return spring (if used) in
the groove on the adapter flange. Spread lubricating oil on the actuator stem and insert it
through the seal gland. Twist and wiggle the stem slightly as required to get it started
through the o-rings in the seal gland. Push the piston and stem assembly until you can
engage the crossbar on the threaded end of the stem and install the lower half of the 1/2
inch - 20TPI Drake locknut. There will be some resistance from the return spring, but you

 
 




should be able to overcome the spring (if used) by hand. The starting chamfer at the top of
the actuating cylinder will properly compress the piston seal.
Tighten the bottom half of the Drake locknut to 36 lb-ft (49 N•m) torque, with a 3/4 inch box
wrench on the Drake nut and a torque wrench on the 12-point capscrew. This method
requires a slight amount of torque to overcome the friction of the seal gland o-rings, but this
friction is negligible. Install the top locking half of the Drake locknut and tighten it to 20 lb-ft
(27 N•m) torque.

TOP - LOCKING

BOTTOM HALF

    

Replace the actuator cap o-ring and indicator assembly as required. Install the cap on the
actuator cylinder. Rotate the cylinder and actuator cap as required to properly align the vent
and control media connections with their line connections, relatve to the vent connection in
the adapter flange. Install and tighten the (six) 1/2 inch - 20 TPI hex head capscrews to 46
lb-ft (62 N•m) torque.
Replace the Glyd Ring seal components (located on the valve guide) as necessary. Oil the
valve bore and install over the end of the guide. Pinch the Glyd Ring as necessary to allow
the valve chamfer to ride up onto the Glyd Ring. The ring is being squeezed by the valve, so
there will be some amount of resistance to movement. Continue pushing the valve until it
engages the crossbar, being careful not to damage the sealing surface of the valve.
Install the (four) 5/16 inch - 18TPI socket head capscrews and tighten to 108 lb-in (12 N•m)
torque. Lockwire these capscrews in pairs using new stainless steel lockwire using the tech-
niques as noted previously.
Install the unloader assembly in the head and align with the connection lines. Go slowly to
ensure that the guide enters the unloader valve bore without damaging any components.
Tighten the adapter flange to unloader-head fasteners as indicated in the compressor tech-
nical manual or toolbox chart.
Reconnect actuating gas line, vents and drains.


  





 



1. If shutdown and blown down, drain cylinder oil from the unloader.


  

1. Check vents for blowing. If blowing, replace seals.

 
 





    !" #

Switchboard 740-397-0311 Weekdays 8 am - 5 pm Eastern Time, except holidays

General Fax 740-397-3856
Field Service 740-393-5052 Emergency from 5 pm - 8 am, weekends and holidays
Spare Parts1 740-397-3602 For all calls to Spare Parts Group, day or night
Spare Parts Fax 740-393-5054
The after hours system works as follows:
1. Dial number.
2. Calls are answered by voice mail.
3. Leave message: caller’s name, telephone number, serial number of equipment
in question (frame, cylinder, unloader) and brief description of emergency.
4. The call message is immediately forwarded to a responsible individual, who will
return the call as soon as possible.

1. Users must order all parts thru Authorized Distributors.