440 & 550 service manual
Contents
1. Unicla UWX compressor is fitted with either PAG oil Unidap 7 or POE oil Unidap 6 When adding oil to the system Unicla oil must be used Warranty is void if these guidelines are not followed I Compressor Refrigerant Oil Type Viscosity Viscosity Application Low side Oil Separator Model Unicla 40 C 100 C Saturation UWX440 550 R134a Unidap7 48 01 10 51 Airconditioning 0 Optional UWX440 550 R134a Unidap6 65 5 9 3 Airconditioning gt 0 C Optional The following labels will determine the type of oil in each UWX440 550 compressor Ep SER NOE HFC 134a UNIDAPT P POE type PAG type Unicla Storage guidelines l Evacuate compressor for 3 minutes and fill with nitrogen N at 0 1 0 2 MPa ll Place the compressor in a clean and dry area with low humidity and tag with details Ill Keep compressor away from direct sunlight IV Store the compressor horizontally on a flat even surface V Donotstore the compressor in temperatures above 30 C VI Place the compressor in a well ventilated area to avoid corrosion damage The contents of this manual are subject to change without prior notice 13 Unicla International Limited Unit 1109 11F Manhattan Centre 8 Kwai Cheong Rd Kwai Chung N T Hong Kong Phone 852 2422 0180 Fax 852 2422 0680 Email sales unicla hk Website www unicla hk Unicla Cat No M12042. disclaims all and any liability and responsibility to any person or business as a result of any actions taken on the basis of information in this publication Specifications Top view Rear view Side view Compressor Model UWX440 UWX550 Bottom view e Magnetic clutch Y E mi f Eg NIA 2H 3g il ff 3g e m cm ns a Pa e vw ur F 15 ATT ud gals H AF P 1 el M o e Wk A Type xa B Type Dia A Type Dia B Type Dia 11 Mi L DF AA 178 BB 174 27205 000550 D C 12V 27205 000580 D C 12V AA 210 BB 210 27205 00550 D C 24V 27205 000570 D C 24V 27205 000590 D C 24V 27205 000600 D C 24V Diameter 178mm Diameter 210mm Compressor part numbers No Partnumber Description Qty 3 2151000000 Fromteap J1 4 2150 00050 Rearcap 1 5 21501 000010 Headcover 1 6 2151000080 Frontnose 1 8 22601 000090 Valve plate rear assembly 1 9 22602000260 Valveplatesuction 2 10 9320100000 Gasket front J1 Gasket rear 12__ 92503 000110 Mechanical seal assembly 1 13 2310000000 Gerpump 1 14 53101000080 Thermalswitth Sggus J2 16 1320100040 Pg 17 1320100050 Plug M4 2 18 380101000400 Shuoffvave 19 42200 Copespgo 2 22 93200500000 Gasket 2 23 92404 000040 Snmpring J1 24 42
3. oil Il Removal of seal Refer to page 9 for instructions lil Removal of bolts on rear cap Tools required 8mm hexagonal socket Stand Procedure Remove the M10 securing bolts 6pcs from the rear cap IV Removal of rear cap Procedure Remove the rear cap by gently inserting a screw driver or lever into the recess Lever all around not just at one position Caution do not damage cap or body Ring installer 10 V Removal of valves and working assembly Procedure Remove rear gasket valve plate and suction valve Remove oil pipe first then remove working assembly by pressing the end of the shaft into the front of the body as shown Remove front gasket valve and suction valve VI Removal of front cap Tools required 8mm hexagonal socket Procedure Remove the M10 bolts 6pcs from the front cap Remove the front cap by gently inserting a screwdriver or lever into the recess Lever all around not just at one position Caution do not damage cap or body Assembly of body Installation of the oring for front and rear cap Procedure The o ring must be free from marks and dust Thoroughly lubricate new o ring properly and insert into the groove Ensure the o ring is lying straight in the groove without a twist Il Installation of the front cap Tools required Torque wrench 8mm hexagonal socket Procedure Place the body with front section facing upward Place the front cap on the body be
4. 203 000161 Nipple Oilseparator 1 26 38010100000 i chargevalve 1 27 as1oroooo30 Hehagevae 28 42102000000 Oilpie 1 9 13201 00010 PugMI d 31_ 92501 000500 lom 32 92501000499 Oring 0 00 00 a eue tio a EN 91013 10035 Bolt T x 35 91913 08030 Bolt M8 x 30 37 91913 08020 Bolt M8 x 20 i i mmm hl Exploded view Service tool part numbers No Partnumber Description 4 5 7 8 03301 000350 Installer pulley o 9 0330100370 Clutchwrench S o 03301 000390 Plastic hammer Bolt torque specifications Description Bolt diameter mm Tightening torque Nem Housing cap bolts M10 33 3 35 3 High low service valve 10 8 12 7 Blind plugs 23 5 25 5 Clutch coil bolts 69 88 18 6 20 6 Service tools E Genuine Unicla tools gg Optional generic tools EJ 03301 004230 FJ 03301 003140 EJ 03301 03301 003180 003190 EJ 03301 03301 03301 003230 J 03301 000350 004950 000490 KJ 03301 M 03301 Y 03301 003301 E 03301 03301 000370 010010 012370 000380 000440 000450 03301 W 03301 03301 000400 000410 000390 LE 03301 03301 FT 03301 EY 000430 000420 000650 Removal of magnetic clutch Removal of armature bolt Tools required Stand Clutch wrench Wrench 14mm socket Procedure Place the compre
5. F x f T a 5 NEN z AN T i m uL rg ii iw UWX440 550 Compressor Service Manual att od 440 550 Series Compressor Service Manual Table of contents 1 Specifications UWX440 550 Magnetic clutch 2 2 Component part list Compressor part numbers 3 ll Exploded view 3 Service Service tools part numbers 5 Bolt torque specifications 5 Service tools 6 Removal of magnetic clutch 7 Installation of magnetic clutch 8 Removal of mechanical seal 9 Installation of mechanical seal 9 Installation of mechanical seal continued 10 Disassembly of body 10 Assembly of body 11 Assembly of body continued 12 System oil quantity 13 Oil type and grade 13 Storage guidelines 13 Copyright 2007 All rights reserved No part of this document shall be reproduced in whole or in part without the permission of Unicla International Ltd This includes reproduction or copies in any form or by any means including photocopying printing or electronic media IMPORTANT DISCLAIMER This is a guideline document containing professional information using representative graphs charts and tables Manufacturers specifications must be consulted for specific guidelines and performance data Unicla published data specific to all models is available in promotional literature and from Unicla International Ltd on request or through your Unicla supplier Unicla International Ltd expressly
6. careful not to twist the oring Tighten M10 bolts 6pcs with torque wrench Tightening torque 34 3 1 Nem lil Installation of the front valve plate and body Tools required Working assembly bench Procedure Place the working assembly on locating pins Stack the suction plate the valve plate and gasket on locating pins in sequence as shown Carefully lower the body over the working assembly until it stops next to the working bench guide 11 Assembly of body continued IV Installation of rear valve plate Tools required Stand Procedure Insert vacuum pipe Place the body in an inverted position on the stand and stack the suction plate valve plate and gasket as shown install the gear pump V Inspection tightening and clearance of the rear cap Tools required Torque wrench 8mm hexagonal socket e Thickness guage Procedure Place the rear cap on the body be careful not to twist the oring Tension the M10 bolts 6pcs diagonally alternately and carefully Check the rear cap clearance as specified 0 4 lt Gap lt 1 2mm Tightening torque 34 3 1 Nem VI Installation of mechanical seal Refer to page 9 VII Installation of front nose and key Tools required Torque wrench 6mm hexagonal socket Procedure Install the key in keyway Install front nose with M8 bolts 6 pieces Clutch lead wire groove is located at 1 o clock position as shown on page 8 Tightening torque 24 5 1 N m VIII Test working a
7. dure Push remover lightly Turn right and hook then remove upward slowly V Removal of oring Tools required Hook tool Procedure Remove oring with hook tool VI Inspection of mechanical seal component Caution plate ring must be clean and unmarked Installation of mechanical seal Installation of seal Tools required Installer seal Procedure Install oring Insert seal until stop point then turn right Fix on shaft notch Place the remover on the seal correctly and press the seal with the remover until it stops Caution damage will occur if too much force is used Do not touch surface on seal ring Il Installation of plate ring Tools required Installer ring Procedure Insert ring moving surface side to be downward until in stop position Socket wrench Plate ring remover Seal remover Installation of mechanical seal continued lil Installation of snap ring Tools required Snap ring pliers hole Installer ring Procedure Insert the snap ring into nose section tapered part of the snap ring must be facing downwards Push the snap ring downward with the installer and fit into groove IV Installation of felt seal Tools required Installer ring Procedure Install the felt seal into the nose section Push the felt seal until it touches the snap ring Disassembly of body Caution o ring should not be reused Removal of oil Procedure Remove the drain plug and drain the
8. ssembly rotation Tools required Shaft rotating handle Procedure Install the handle into the front section to check the shaft rotates smoothly IX Filling compressor oil Procedure Fill the following amount of oil into the low pressure port as shown Ensure drain correctly plugged Standard oil type Unidap 7 PAG or Unidap 6 POE Amount of oil 1000 20cc X Plug cap on oil port Tools 8mm hexagonal socket Procedure Tighten high low pressure port cap bolts Tightening torque 34 3 1 Nem 12 System oil quantity The correct amount of oil must be maintained in the compressor and system Long hose runs and dual evaporator systems must have additional oil added to the system Severe oil starvation problems may result from insufficient system oil being allowed To determine oil quantity required Unicla recommends a calculation as a percentage of refrigerant charge as follows 20 for UWX440 550 compressors in standard applications where the suction and discharge lines are less than 6 metres in length 30 for UWX440 550 compressors in applications where suction and discharge lines exceed 6m in length Example Calculate oil charge as 20 of refrigerant charge 5 kg charge 5000 g x 2096 1000 ml cc of oil If fitting a UP UX200 compressor then deduct the compressor initial oil charge to determine amount of oil to be added Therefore 1000 600 400cc oil to be added to system Oil type and grade Each
9. ssor on the stand Hold clutch by inserting the claws of the clutch wrench into the holes on the armature Remove the centre bolt by using the wrench Il Removal of armature Tools required Hub remover Procedure Pull the armature upwards lil Removal of snap ring Tools required Snap ring pliers shaft Procedure Remove the snap ring with the snap ring pliers IV Removal of pulley assembly Tools required Remover pulley Wrench Pulley pad Procedure Remove the pulley assembly with the remover and pad V Removal of coil Tools required Standard screwdriver Procedure Remove 3 M6 bolts with screwdriver VI Inspection of clutch components 1 Armature Contact surface must be clean smooth and unmarked with no abnormal scoring 2 Pulley Contact surface must be clean smooth and unmarked with no abnormal scoring 3 Coil Wiring harness must be in good condition Armature Pulley pad B in place Wrench Hub remover Installation of magnetic clutch Installation of coil Tools required Stand Standard screwdriver Procedure Tighten 3 bolts wire must be visible at 1 oclock position when viewed from the front Tightening torque 7 8 1 Nem Il Installation of pulley Tools required Pulley installer Plastic hammer Procedure Place the pulley on the nose top and install it by tapping on the installer until it stops Do not tap if the pulley is not located correctly lll In
10. stallation of clutch key and snap ring Tools required Snap ring pliers shaft Procedure Install the snap ring into the groove tapered side up Install the key in keyway IV Installation of shims and armature Tools required Guide pin Procedure Install the guide pin into the centre threaded hole of the shaft and select shims 0 1 0 3 and 0 5mm to ensure the clutch clearance V Installation of armature Tools required Clutch wrench Torque wrench 14mm Socket Procedure Place washers and spring washers on M8 bolt Hold clutch by inserting the claws of the clutch wrench into the holes on the armature Tighten the centre bolt by using the wrench Tightening torque 19 6 1 Nem VI Air gap Tools required Thickness guage Procedure Ensure clutch clearance is correct all around 0 3mms gap lt 0 6mm Clutch wrench Removal of mechanical seal Removal of front nose Tools required 6mm hexagonal socket Procedure Remove M8 bolt 6 locations with socket wrench Remove key Tap edge of key with driver or punch Do not damage shaft Il Removal of snap ring Tools required Snap ring pliers hole Procedure Remove the snap ring slowly with pliers as shown Ill Removal of plate ring Tools required Remover plate ring Procedure Hook and remove plate ring with remover as shown turn around lightly and pull it IV Removal of seal Tools required Remover mechanical seal Proce
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