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
REV: 2/01

! CAUTION
TO PREVENT PERSONAL INJURY, ENSURE THAT COMPRESSOR CRANKSHAFT CANNOT BE TURNED BY THE
DRIVER OR COMPRESSOR CYLINDER GAS PRESSURE
DURING MAINTENANCE: -- ON ENGINE-DRIVEN COMPRESSORS, REMOVE THE CENTER COUPLING OR LOCK THE
FLYWHEEL. -- ON ELECTRIC MOTOR-DRIVEN COMPRESSORS, 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 PACKAGERS INSTRUCTIONS FOR COMPLETELY VENTING THE SYSTEM.

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Important Safety Information

! 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.

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Data Plate
O-ring

Actuator
Cylinder

Gasket

Valve

Spring
(if required)

Drake
Locknut

Actuator
Piston

Orange Open Position

(Unloaded)
Mechanical
Indicator

Glyd Ring
(with O-ring

Valve
Guide

Control Media
Connection
Crossbar
Stat-O-Seal
Washer
Actuator Cap
O-ring
O-rings

U-Cup
Seal Ring
Breather
Vent to Safe
Atmosphere

Adapter Flange to
Unloader CylinderHead Fasteners
Pneumatic-Unloader
Cylinder-Head

Stem

Volume Filler
(as required)

Cylinder Head
Fasteners

Vent to Safe
Atmosphere

Adapter
Flange

OPEN POSITION - UNLOADED

FIGURE 1: FIXED VOLUME CLEARANCE POCKET (FVCP) HEAD END PNEUMATIC

UNLOADER - TYPICAL

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Actuator
Piston

1/2- 20
12 Point Capscrew

Stem

(6) 1/2- 20
Hex Head Capscrew

Orange
Open Position
(Unloaded)

Mechanical
Indicator

Control Media
Connection

Spring
(if required)
Stat-O-Seal
Washer

Breather
Vent to Safe
Atmosphere

Actuator Cap
Actuator
Cylinder

U-Cup
Seal Ring

O-ring

FIGURE 2: FVCP ACTUATOR CYLINDER DETAILS (OPEN POSITION - UNLOADED) TYPICAL

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(3) 1/2- 20 Typical

Stud/Drake Locknut
(4) 5/16- 18
Socket Head Capscrews
Lockwire in Pairs

(4) 1/2- 13
12 point Capscrew

(1) 1/2- 20
12 Point Capscrew

(6) 1/2- 20
Hex Head Capscrew

Black - Closed
Position

Mechanical
Indicator

1/8 inch
NPT
(3) 3/8- 16 Socket
Head Capscrew
(1) 1/2- 20
Drake Locknut

1/8 inch
NPT

1/2 inch NPT Oil drain at

Shutdown/Blow-down
(Not Shown)

FIGURE 3: FVCP CLOSED POSITION - TYPICAL

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FIGURE 4: CROSSBAR

FIGURE 5:

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ALVE

GUIDE

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Description and Operation

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 utilize 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.

Actuator
The actuator assembly is attached to the unloader adapterflange, 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 applicable) 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 actuator 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.

Unloader Valve
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.

Sealing Elements
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 an o-ring/chamfer style seal. 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

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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.

Vents and Drains

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 collection 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 breather connection on the actuator cylinder outside diameter allows leakage 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 actuator 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 compressor is shutdown for a long period of time.

Disassembly and Maintenance

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
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from the head. Threaded holes are provided in the adapter flange (and cylinder-head) for
toolbox eye bolts to assist lifting. The assembly is heavy and caution must be exercised to
prevent injury. Using a crane is recommended. Inspect o-rings 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 at the mechanical indicator oring seal, remove indicator and replace o-ring. Reassemble and tighten indicator to 15 lb-ft
(20 Nm) maximum.
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 necessary.
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 disassembled, replace the Stat-o-seal washer. Take care not to damage the stem during handling
or storage.
Remove the (four) 1/2 inch - 13TPI 12-point capscrews that fasten the unloader guide to the
adapter flange. Remove the guide, inspect the o-rings and sealing surfaces, and replace orings as necessary.
Remove the (three) 3/8 inch x 16TPI socket-head capscrews that fasten the stainless steel
o-ring retainer to the adapter flange. Inspect the o-ring and sealing surfaces, and replace 0ring if necessary.

Assembly
Oil all o-rings and all moving parts prior to, during or after assembly.
Insert the o-ring into the counterbore on the outside surface of the adapter flange, and install
the o-ring into the groove in the stem bore, near the opposite face of the adapter flange.
Install the stainless steel o-ring retainer, and fasten with the (three) 3/8 inch x 16TPI socket
head capscrews. Tighten capscrews to 193 lb-in (22 Nm) torque.
Install the o-rings on the gland outside diameter and in the adapter flange face groove, and
install the guide. Be sure to align the crossbar opening so that the crossbar will be horizontal
when the unloader assembly is installed in the head. This will prevent the valve assembly
from rotating, which could allow the crossbar to rub on the valve guide during operation.
Tighten the (four) 1/2 inch - 13TPI 12-point capscrews to 40 lb-ft (54 Nm) torque.
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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 12point capscrew to 46 lb-ft (62 Nm) 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 (when provided) in the cylinder, located around the (four) 1/2 inch 12-point capscrew heads. 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 (when provided), but you should be able to overcome the spring
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 Nm) 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 Nm) torque.
TOP - LOCKING

BOTTOM HALF

FIGURE 6: DRAKE LOCKNUT

Replace the actuator cap o-ring and indicator o-ring as required. Install the cap on the actuator cylinder. Rotate the cylinder and actuator cap as required to properly align the control
media connection with its line connection, relative 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 Nm)
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.

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Install the (four) 5/16 inch - 18TPI socket head capscrews and tighten to 108 lb-in (12 Nm)
torque. Lockwire these capscrews 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 oclock to a line running thru the heads, see Figure 7:,
Step #1. Insert wire thru first screw head, bend around the head and twist ends together in a
clockwise direction, see Figure 7:, 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
7:, 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 7:, step #4.

STEP
#1

STEP
#2

STEP
#3

STEP
#4

FIGURE 7: LOCKWIRING
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 technical manual or toolbox chart.
Reconnect actuating gas line, vents and drains.

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Recommended Maintenance Intervals

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

Monthly (plus Daily)

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

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Ariel Telephone, Fax, E-Mail and Web Numbers

TABLE 7-1: NUMBERS FOR CONTACTING ARIEL
CONTACT

TELEPHONE

FAX

E-MAIL

Ariel Response Center

888-397-7766
(toll free USA & Canada) or
740-397-3602 (International)

740-397-1060

arc@arielcorp.com

740-393-5054

spareparts@arielcorp.com

740-397-6450

---

740-397-3856

info@arielcorp.com

Spare Parts
Order Entry
Ariel World Headquarters

740-397-0311

Technical Field Service

fieldservice@arielcorp.com
Web site: www.arielcorp.com

Ariel Response Center Technicians or Switchboard Operators will answer the telephones during Ariel business hours, Eastern time - USA or after hours by voice mail.
The after hours system works as follows:
1. Follow automated instructions to Field Service EmergencyTechnical Assistance
or Spare Parts Emergency Service.
2. Calls are answered by voice mail.
3. Leave message: callers name, telephone number, serial number of equipment
in question (frame, cylinder, unloader) and brief description of emergency.
4. Your voice mail message is routed to an on-call representative, who will respond
as soon as possible.
Users must order all parts through Authorized Distributors.

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