5437.1

CompAir UK Ltd ADOBE ACROBAT READERPage 1 TO VIEW CONTENTS. FROM TOP MENU BAR SELECT WINDOW. PULL DOWN TO SHOW BOOKMARK AND CLICK. ALTERNATIVELY PUSH (F5) ON KEYBOARD. INDEX WILL NOW BE SHOWN ON THE LEFT. SELECT BY CLICKING ON THE PARTICULAR SECTION REQUIRED. BY CLICKING ON THE + MORE INFORMATION WILL BE SHOWN. TO VIEW A PARTICULAR SECTION FROM SECTION INDEX. CLICK ON SECTION REQUIRED ON INDEX PAGE. Acrobatreader.doc CompAir UK Ltd OPERATOR MANUAL for a HGP37 HIGH PRESSURE Natural Gas Compressor In any correspondence please quote: JOB NUMBER: MACHINE NUMBERS: PUBLICATION NUMBER: ISSUE DATE CUSTOMER ORDER NUMBER: (on nameplate) 98407.1293 SEPTEMBER 2002 CompAir UK Ltd. Ranelagh Road, IPSWICH. ENGLAND IP2 0AQ Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027 www.CompAir.com e-mail: [email protected] CompAir UK Ltd DECLARATION OF CONFORMITY 98/37/EEC BS EN292: BS EN1012-1 97/23/EC CERTIFICATE 'B' CATEGORY 2 ( Known as the ‘Machinery Directive’ ) ( Safety of Machinery ) ( Compressors - Safety Requirements ) ( Known as the ‘Pressure Equipment Directive’ [PED] ) We of COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole responsibility for supply / manufacture, the machinery described below, Machine Type Rotary Compressor Reciprocating Compressor Other Pressure Equipment. Serial No.________________________________ Model No. _________________________ is in conformity with the essential Health and Safety Requirements identified in the above directives. This machine/equipment complies with 97/23/EC the Pressure Equipment Directive. IPSWICH, ENGLAND Signature and name of responsible person DATE __________________ ENGINEERING DIRECTOR Position Notified Body: Lloyds Register European Directive Services UK Hiramford Middlemarch Office Village Coventry. CV4 4FJ (Notified Body Reference: 0038) Conformity assessment procedure: Module H (H1 where appropriate) Language. English. French. German. Spanish. Italian. Dutch. conformityPED-B Italian. incorporationPED-D . IPSWICH. This machine/equipment complies with 97/23/EC the Pressure Equipment Directive. Machine Type Rotary Compressor Reciprocating Compressor Other Pressure Equipment.Safety Requirements ) ( Known as the ‘Pressure Equipment Directive’ [PED] ) DECLARATION OF CONFORMITY FOR BELOW We of COMPAIR UK LIMITED RANELAGH ROAD. French. Dutch. the machinery described below. Serial No. Spanish.CompAir UK Ltd DECLARATION OF INCORPORATION 98/37/EEC BS EN292: BS EN1012-1 97/23/EC CERTIFICATE 'D' CATEGORY 2 ( Known as the ‘Machinery Directive’ ) ( Safety of Machinery ) ( Compressors . German. English. ENGLAND Signature and name of responsible person DATE __________________ ENGINEERING DIRECTOR Position Notified Body: Lloyds Register European Directive Services UK Hiramford Middlemarch Office Village Coventry. STATEMENT This machinery must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the above Directives.________________________________ Model No. ENGLAND IP2 0AQ declare that under our sole responsibility for supply / manufacture. IPSWICH. CV4 4FJ (Notified Body Reference: 0038) Conformity assessment procedure: Module H (H1 where appropriate) Language. _________________________ to which this declaration relates is in conformity with the essential Health and Safety Requirements identified in the above Directives. DRIVE: *HOURS STAGE RUN TEMP.COMPRESSOR LOG SHEET COMPRESSOR TYPE: SPEED: SERIAL NO: DATE TIME PRIME MOVER TYPE: B.PSI) NUMBER #(BAR . OIL GRADE USED: CHECK OIL LEVEL CHECK WATER IN/OUT TEMPERATURE CHECK COOLING FAN BLADES REMARKS SEE OVER FOR MORE SIGNED *FILL IN HOURS RUN AS DETAILED ON SERVICE PLAN FOR PARTICULAR COMPRESSOR TYPE # DELETE AS NECESSARY .† FILL IN APPROPRIATE STAGE TRIP TEMPERATURE READING SERVICE ENGINEER TO SIGN & FILL IN ANY OTHER COMMENTS IN REMARKS COLUMN SERVICE TELEPHONE +44 (0) 1473 556027 .H.PSI) 1 2 3 4 5 REF.doc .PARTS +44 (0) 1473 601282 logsheetm.°C INSTALLED AT DATE INSTALLED: FINAL AIR SERVICE PLAN PRESSURE STAGE PRESSURES #(BAR .P. NO.°C #50/100 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500 FINAL STAGE TEMP. doc .DATE REMARKS DATE REMARKS logsheetm. 18.1019 APP070 7.1491 APP12g 9.1.3.2 6.1042 APP088 6.16.NG Bare Shaft Compressor H5437.1.1360 APP12g 9.001 9.16 98524.1.NG Valve Solenoid inlet SOL01 Valve Purge Gas inlet PGE01 Gauge Pressure Gas Inlet PI01 Valve Non-Return NRV01 Valve Gas recovery ISOL01 Valve Relief recovery vessel PSV01 Switch Pressure Low Inlet PSLL01 Switch Pressure High Inlet PSHH01 Valve Purge Gas inlet PGE02 Valve Relief surge vessel PSV02 SHEET No PART NO ANCILLARY PUBLICATION.NG Belt Adjustments Vee Drive H5437.NG Belt SPC 2800 FRAS Vee Drive H5437.6 98288.NG Switch Low Oil Pressure PSLL101 Gauge Pressure Oil PI101 Valve Relief crankcase PSV03 Gauge Pressure crankcase COOLING WATER PATH H5437.1293.8 98524.2.2 Y55153.1971 APP154 98281.1 98407.12.1.17 E61673 9.18 98080.13 98650.55153C201658.2088-2.doc 04/09/02 Page 1 .NG GAS SYSTEM H5437.1293.4 98407.55153 9.1086 APP070 7.1.1APP167 7.NG COMPRESSOR MODULE 55153 H5437 .2.5.1.1.11 98650.1 98650.1APP167 7.1.5.1.10.3 5437CNG.1.22 98650.1.14 98524.1.2078 APP154 9.1 98650.16.002 APP034C 9.1.2.5 E61674 9.13 5437CNG.3 98650.16 98080.1127 APP086 7.1.22 C85737.1APP167 7.1293 2.NG Pulley Motor H5437.24 98288.9 APP12g 9.003 APP153 9.1128 APP086 7.2082 APP154 9.11.NG Motor Electric .55153 STAGE 40 Y55153.16.Main 380V/3PH/50HZ H5437.2076 APP154 7.1.2088-2.2 6.1347 APP12g 9.4 98650.1.1002 6.1.1.1.NG CRANKCASE & LUBRICATION SYSTEM H5437.NG Bush Taper Lock Motor H5437.5.NG BELT DRIVE COMPONENTS H5437.26 98650.NG Pulley Flywheel Compressor H5437. SECTION No Y55153.1086 APP070 7.2.2 98074.31 98288.6 6&7 5437CNG.55153 98407.1 5437CNG.2.2091 APP169A 9.16.NG Valve Isolating Lubricating Oil Drain ISOL101 Gauge Oil Level LG101 Pump Oil H5437.Page 1 QUICK REFERENCE GUIDE TO OPERATOR MANUAL 98407/1293 PART NUMBERS USING P & I DIAGRAM D70938 PART DESCRIPTION DESIGNATION SCHEDULE No CONTROL PANEL H5437.6 Page No 102 51/85 100 102 100 100 100 100 100 100 17 52 52 52 88 86 88 81 56 100 100 87 101 100 87 87 87 87 86 1293ind55153.1.16.1.NG Bursting disc H5437.NG Guard Belt Drive H5437.2088-2. 2 98650.11 98288.3 98650.8 E61518 7.GAS H5437.6 U334.24 D101760 6.1.1.NG PI20 PSV20 DDV20 H5437.14 E61641 6.2 E61641 6.8 -APP090 6.1021-40 APP167 6.GAS H5437.1.19.1020-10 APP167 6.3 E61642 6.1.Page 2 QUICK REFERENCE GUIDE TO OPERATOR MANUAL 98407/1293 PART NUMBERS USING P & I DIAGRAM D70938 PART DESCRIPTION RELIEF VALVE MANIFOLD COMPRESSOR ASSEMBLY Running gear Assembly 1st Stage Liner valve parts 1st Stage Cylinder Assembly 1st & 2nd Stage Cooler Assembly 1st & 2nd Stage Separator Assembly 1st Stage Gauge Pressure 1st Stage Valve Safety 1st Stage Diaphragm Drain Valve 1st Stage Valve Solenoid DDV Running gear Assembly 2nd Stage Liner valve parts 2nd Stage Cylinder Assembly 1st & 2nd Stage Cooler Assembly 1st & 2nd Stage Separator Assembly 2nd Stage Gauge Pressure 2nd Stage Valve Safety 2nd Stage Diaphragm Drain Valve 2nd Stage Running gear Assembly 3rd Stage Liner valve parts 3rd Stage Cylinder Assembly 3rd & 4th Stage Cooler Coil Assembly 3rd Stage Temperature Trip 3rd Stage Separator Assembly 3rd Stage Gauge Pressure 3rd Stage Valve Safety 3rd Stage Diaphragm Drain Valve 3rd Stage Running Gear Assembly 4th Stage Liner valve parts 4th Stage Cylinder Assembly 3rd & 4th Stage Cooler Coil Assembly 4th Stage Gauge Pressure 4th Stage DESIGNATION SCHEDULE No H5437.3 98288.doc - Page No 101 51 & 85 86 87 54 54 86 88 57 75 102 53 56 54 54 54 88 57 75 49 56 55 55 56 55 88 57 76 54 56 55 56 88 04/09/02 Page 2 .GAS H5437.1020 APP070 7.1.5 U334.1.NG H5437.1022-150 APP167 6.1.9 D101610 6.GAS TE/TI/TS30 H5437.18.004 APP152 9.14.7 D101725 6.GAS H5437.1.J APP041 6.19.1.8 98288.18.4 E61642 6.GAS H5437.NG H5437.1022 APP070 7.1.1023 APP070 6.55153 STAGE 50 9.4 D101731 6.18.2 D101729 6.8 E61519 6.1.NG H5437.1.1.5.18.24 Y55153.18.NG H5437.4 98650.19.5 1293ind55153.10 C202556.5.NG PI10 PSV10 DDV10 SOL10 H5437.1.1.3 98288.GAS H5437.3 D101730 6.14.1 D101750 6.1.NG 6&7 D101719 7.1.10.7 D101726 6.5 D101728 7.1.1.GAS PI40 SHEET No PART NO ANCILLARY PUBLICATION. SECTION No 5437CNG.1.1.GAS H5437.4 U334.L APP041 6.L APP041 6.1.5.GAS H5437.NG H5437.GAS/.8.NG H5437.6 5437.1021 APP070 7.7 D101725 6.9 D101609 6.1.GAS H5437.GAS PI30 PSV30 DDV30 H5437.24 D101751 6.13.GAS H5437.1.14. 15 Flexible Hose Inlet 5437CNG.B APP059 9.5.1 Separator Assembly Final Stage H5437.3 Valve Pressure Compressor Delivery PCV61 U572.1004 APP081 9.1.24 Temperature Trip 4th Stage TE/TI/TS40 C202960.1212 9.55153 98315.3 Switch Pressure Final Delivery PSHH/LL/I61 98524.1214 9. Flexible Hose Return R/V Manifold 5437CNG.1211 9.1190-275 APP167 7. Flexible Hose Return Surge Vessel 5437CNG.17 1.21 FINAL DELIVERY CONNECTION 1000 MM LONG FLEXIBLE HOSE SUITABLE FOR Ø12 MM COMPRESSION FITTING.1071 C203998 7.29 1.30 INLET CONNECTION 600 MM LONG FLEXIBLE HOSE 80 NB FLANGE BS4505 PN16.1/2" BSPT CONNECTION FLEXIBLE HOSE.5.55153 98315.1 -APP090 6. Flexible Hose Final Delivery 5437CNG.18.55153 98315.8.6 Diaphragm Drain Valve 4th Stage DDV30 U334.20.1655 APP158 6.55153 98315.8 Valve Non-Return Compressor Delivery NRV61 98650.1/2" BSPT CONNECTION FLEXIBLE HOSE.6.19.Page 3 QUICK REFERENCE GUIDE TO OPERATOR MANUAL 98407/1293 PART NUMBERS USING P & I DIAGRAM D70938 PART DESCRIPTION DESIGNATION SCHEDULE No SHEET No PART NO ANCILLARY PUBLICATION.8.21. Page No 88 88 89 76 56 57 101 101 101 101 101 102 1293ind55153.1212 9.NG D101619 7.20 Valve Isolating Separator Drain ISOL61 98261.8. SECTION No Valve Safety 4th Stage PSV40 98650.4.doc 04/09/02 Page 3 .J APP041 6. CHANGE .NG PUBLICATION 98407.M/C SERIAL No. DATE JULY 2000 SEPT 2002 PAGE No’s ALL SECTIONS 1 TO 5 1293amendments. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 MOD NOTE No.1.1293 ISSUE No. typing error. NEW Amend 'air' to 'gas' where appropriate.1293 Page 1 AMENDMENTS 5437.doc .CompAir UK Ltd AMENDMENTS 98407. CompAir UK Ltd AMENDMENTS 98407.doc .1293 Page 2 1293amendments. cause equipment failure. CompAir UK Ltd cannot accept responsibility for damage.5 Dry Gases ----------------------------------------------------------------------------11 Typical Gas Purging Instructions --------------------------------------------12 WARNING The use of replacement parts or lubricating oils not supplied.3 Safety Precautions ---------------------------------------------------------------. recommended or approved by CompAir UK Ltd.2 Foreword ----------------------------------------------------------------------------. create unsafe or hazardous conditions or result in damage to the equipment. or the failure to maintain this equipment in accordance with the maintenance instructions.5000 SERIES GAS COMPRESSORS CONTENTS Page Ownership Data -------------------------------------------------------------------.doc 04/09/02 Page 1 .CompAir UK Ltd PUBLICATION GAS SAFETY Page 1 OPERATOR MANUAL . injury or failure caused by these situations. USE ONLY CompAir UK Ltd GENUINE PARTS AND AUTHORISED SERVICE AGENTS gassafety. may invalidate the WARRANTY. Page 2 04/09/02 gassafety. Ipswich 1P2 0AQ. Technical Publications Engineer. Ranelagh Road. England marked for the attention of Mr. Hz: Compressor Lubricant: Motor Bearing Grease: (if applicable) Notes: Capacity M³/hr .CFM CompAir UK Ltd CONTACT DETAILS Contact Name: Sales Telephone: +44 (0) 1473 602222 Address: CompAir UK Ltd Ranelagh Road Ipswich IP2 0AQ ENGLAND Notes: Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Contact Names: Parts Telephone: +44 (0) 1473 602222 Parts Fax: +44 (0) 1473 601282 Contact Names: Service: +44 (0) 1473 556027 For any comments or queries about the contents of this MANUAL please write to CompAir UK Ltd.CompAir UK Ltd PUBLICATION GAS SAFETY Page 2 OWNERSHIP DATA TECHNICAL DATA Model Type: Motor Serial Number: Serial Number Motor RPM: Year: Motor kW: Maximum Pressure: Motor V.doc . Dennis Beeton. Ph. Throughout the Manual all pressures quoted are gauge pressures. Protect the environment by using only approved methods of disposal. please ensure when disposing of condensate. In any communication concerning the compressor it is essential to quote the MODEL. Please note: a. Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network of CompAir Companies and CompAir UK Ltd Distributors. which will ensure the maximum satisfactory service life. Details of warranty for a particular unit may be obtained from the local CompAir Company or authorised Distributor. used filter elements and any discarded parts or waste material of any kind make sure that there is no pollution to any natural watercourse. b. fax: +44 (0) 1473 601704. Conditions of CompAir UK Ltd warranty are stated in our Conditions of Sale. with long life and reliability. backed by the Service and Parts Departments at CompAir UK Ltd.doc 04/09/02 Page 3 . Substitution of parts not manufactured or approved by CompAir UK Ltd can create a potential personnel hazard. for safe and reliable operation use only genuine CompAir UK Ltd Parts To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance with the information given in this manual . SERIAL No. Ensure that the new user is made fully aware of the need to study the Safety Section and any Warnings for safe operation given throughout the text. Customer Service +44 (0) 1473 556027 or Parts fax: +44 (0) 1473 601282. It is important this Manual is retained with the compressor for reference and should remain with the compressor if it is sold or transferred to another user. Whilst recyclable materials are used as far as possible. which will not be covered by warranty. This Manual will help you to obtain the best performance from your compressor. and any CONTRACT Ref. It provides the information required to install. drain system and that no burning waste takes place which could cause pollution of the atmosphere. The use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd can lead to expensive failures. CAUTION Use only CompAir UK Ltd Genuine Parts when carrying out routine maintenance or repair. commission and operate the compressor and carry out regular maintenance schedules.refer to the “Maintenance Section”.CompAir UK Ltd PUBLICATION GAS SAFETY Page 3 FOREWORD CompAir UK Ltd 5000 Series compressors are designed and manufactured to give optimum performance. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or CompAir UK Ltd Distributor for revised or up-dated information. This is a High Pressure Compressor. Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing. The information in this Manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressor. spent oil. Ipswich (UK) tel: +44 (0) 1473 602222. gassafety. doc .CompAir UK Ltd PUBLICATION GAS SAFETY Page 4 Page 4 04/09/02 gassafety. Cautions & Notes ----------------------------7 General Safety Precautions -----------------------------7 Installation Precautions ----------------------------------8 Operational Precautions----------------------------------8 Maintenance and Repair Precautions----------------9 Precautions in the Event of Fire ---------------------.10 gassafety.CompAir UK Ltd PUBLICATION GAS SAFETY Page 5 SAFETY PRECAUTIONS Page Warnings General-------------------------------------------6 1 2 3 4 5 6 7 Regulations ---------------------------------------------------7 Warnings.doc 04/09/02 Page 5 . doc . Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance instructions may make it unsafe. Page 6 04/09/02 gassafety. MAINTENANCE To ensure continued trouble free operation of the compressor it is important that periodic maintenance and servicing are carried out in accordance with the information given in the "Maintenance" section of this Manual. cause substantial bodily injury or result in damage to the equipment. If any replacement or repair is needed use genuine CompAir UK Ltd parts. Such hazardous conditions may lead to accidents that can be life threatening. The use of replacement parts not supplied by CompAir UK Ltd may create hazardous conditions over which CompAir UK Ltd has no control. ∗ WARNING The use of replacement parts or lubricating oils not supplied or approved by CompAir UK Ltd may lead to failures in service which would not be covered by warranty. SPECIAL NOTE: THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.CompAir UK Ltd PUBLICATION GAS SAFETY Page 6 WARNINGS GENERAL • • WARRANTY The Conditions of the CompAir UK Ltd Warranty are set out in the Standard Conditions of Sale. CompAir UK Ltd can bear no responsibility for equipment for which unapproved replacement parts are included. • If using compressed air for cleaning purposes. CAUTIONS & NOTES 3. safety glass. • Failure to observe these precautions given under "Safety Precautions" may be considered dangerous practice or misuse of the compressor • Read and understand all WARNINGS. ensure safety regulations are complied with and appropriate clothing worn. which might represent a potential hazard. • Most accidents which occur during the operation and maintenance of machinery result of failure to observe basic safety rules or precautions. an item of equipment or a method of working which is not specifically recommended by CompAir UK Ltd then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property. and the regulations of the Institution of Electrical Engineers. local Health and Safety Regulations must be complied with.CompAir UK Ltd PUBLICATION GAS SAFETY Page 7 SAFETY PRECAUTIONS 1. 2. Safety helmets must be worn if there is any risk of falling objects. • Safety footwear should be compulsory in all workshops. • CompAir UK Ltd cannot anticipate every possible circumstance. operating or carrying out maintenance on the unit.doc 04/09/02 Page 7 . Amended 91/286/EEC. 3. • When handling. Recognising a situation that is potentially hazardous can often prevent an accident.) • Warnings call for attention to operation procedures involving specific hazards which could cause injury or death and are identified by the following:- gassafety. • When using cleaning solvents. CAUTION AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating procedure. The attention of users is drawn to the Health and Safety at Work Act 1974. protective apron and gloves. RISK OF DANGER RISK OF ELECTRIC SHOCK RISK OF HIGH PRESSURE RISK OF HOT SURFACE RISK OF GAS EXHAUST CONSULT MANUAL GENERAL SAFETY PRECAUTIONS • The following details for this Safety Section relate to the ESSENTIAL SAFETY REQUIREMENTS referred to in Directive 89/392/EEC. WARNINGS. GENERAL SAFETY PRECAUTIONS (Cont. Provide good ventilation and use suitable protection such as a breathing filter mask. REGULATIONS CompAir UK Ltd compressor safety relates to the document BS EN1012-1 Compressors and Vacuum Pumps .Safety requirements and the UK Pressure Systems and Transportable Gas Containers Regulations 1989. personnel must observe safe engineering practices and all relevant local regulations. • Compressed gas and gas piping.g. Use a spreader bar to avoid side loads on hooks. one on the outside of the unit. or equipment containing gas or gas above atmospheric pressure. guards or insulation fitted. attach warning notices stating "THIS UNIT CAN BE STARTED REMOTELY" in prominent locations. lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system. • Before releasing compressed air through a hose make sure the free end is held securely so that it cannot whip and cause injury. Never remove or tamper with safety devices. the other inside the control compartment. • Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement. receiver or storage is free to expand and that no flammable material is within the vicinity. Always use an appropriate shackle or hook. crankcase doors.doc . • When a load is on a hoist stay clear of the danger area beneath and around it. • When mains power is ON. If any such material is close-by take steps to preclude ignition. • Cables. INSTALLATION PRECAUTIONS • Competent personnel under a qualified supervisor must only carry out installation work. properly positioned. take adequate precautions that no one is working or checking the unit before attempting to switch on remotely controlled equipment. Attach a "CHECK THAT ALL PERSONNEL ARE CLEAR OF UNIT BEFORE STARTING" or similar notice. Non return valves cannot be relied upon for isolating parts from a pressure system. Arrange lifting cables so that there are no sharp bends. They must be tested and approved according to local safety regulations. • If the unit is equipped with a Remote Control device. 4. Electrician with appropriates tools and protection against an electrical hazard. • Do not operate compressor with any removable inspection cover removed e. which may be accidentally touched in normal operation. Closed circuit or direct mains cooling is preferred. hooks. Page 8 04/09/02 gassafety. together with cooling water piping and other parts. In order to limit the risk of Legionnaires Disease. shackles and slings are in good condition and are of the correct capacity. • A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated. A safety valve must be installed between any compressor unit and the isolating valve. eyes and shackles and never leave a heavy load unattended. Always isolate power before maintenance or servicing. Such work should always be carried out by a qualified. test or adjustment. • As a further safeguard. • The compressor must only be operated at the supply voltage and frequency for which it is designed. • Never remove or tamper with safety devices. • Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into compressor intake. Never use compressed air to clean loose dirt from clothing. ALWAYS CONSULT A QUALIFIED ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK. Check that all chains. with surface temperature greater than 70°C and may be accidentally touched. Keep lifting acceleration and speed within safe limits.CompAir UK Ltd PUBLICATION GAS SAFETY Page 8 • Never direct compressed air onto your skin or at other people. must be guarded or insulated. CompAir UK LTD advise caution with the use of cooling towers for water cooling the compressor. • Ensure that the discharge pipe from the compressor to the user pipework. Other high temperature pipework should be clearly marked and all pipework should be clearly marked. chains or ropes should never be applied to lifting eyes. should be guarded or insulated. valve covers etc. OPERATIONAL PRECAUTIONS • Competent personnel under a qualified supervisor must only operate the compressor. 5. • A pressure-reliving device must be fitted to every pressure vessel. • Avoid injury by using a hoist to lift heavy loads. • A fused isolator switch must be fitted between the main power supply and the compressor. • Pipework or other parts with a surface temperature above 70°C. guards or insulation materials. • Viton 'O' seals under normal operating conditions are safe. treat all damaged gaskets as asbestos . • 5. Be aware high noise levels can interfere with communication. Close the isolating valve between the compression unit and user's pipework.) • If there is any indication that the compressor is overheating it must be shutdown. • Wash the area with limewater and avoid breathing any fumes.when the Asbestos at work regulations apply. Remove the securing screws and take out valve cover.CompAir UK Ltd PUBLICATION GAS SAFETY Page 9 5. Beware of burns from hot oil and water when working on a unit recently shutdown. Ensure that the cooling water system has been drained. • 4. • 3. Ear defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter. should there be a fire within the compressor or these seals are likely to exceed a temperature of 300°C the material will decompose. gaskets and diaphragms should not present a personnel hazard. Preservation oils again should not present a personnel hazard if handled under normal handling practices. Close the isolating valve in the cooling water inlet pipe. • Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance. Oil free models will have desiccant bags in valve covers and distance pieces. Lock the isolator in the OFF position and remove fuses. • 7. OPERATION PRECAUTIONS (Cont. Attach a label " WORK IN PROGRESS . • 6. • If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC gloves.doc 04/09/02 Page 9 . • Use only lubricating oils and greases approved by CompAir UK LTD to avoid potential hazards especially the risk of explosion or fire and the possibility of decomposition or generation of hazardous gases. If contamination of the skin gassafety. • However. Pre-Maintenance Operation • 1. MAINTENANCE & REPAIR PRECAUTIONS • Competent persons under qualified supervisor must carry out maintenance repair and modifications. Isolate the compressor from the main electrical supply. Attach a label "WORK IN PROGRESS . • Local noise regulations must be observed. • Handling components such as seals. 6. Lever the valve cover until the 'O' seal is disengaged from the port in the cylinder head. ensure a minimum of two threads is left engaged on the valve cover securing screws. Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage. (A high air or gas temperature switch is fitted as standard to guard against operating with excessive temperature). Secure guards following any servicing or repair. • Always clean oil spills from the surrounding floor before and after maintenance work.DO NOT OPEN". Check that all interstage drains are open to ensure any gas trapped between stages has been released. • 2. • Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns. Check that the drain valve on the delivery manifold is clear and gas pressure has been released. • The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models).DO NOT APPLY VOLTAGE". occurs washes with limewater and seeks medical advice. • Stand clear of all valve covers when removing the securing screws. Check that all pressure gauges register zero. • When removing valve covers for valve replacement. • Whilst compressors are asbestos free. ) • Keep the compressor clean at all times. nose and throat. steam cleaning. The adjacent components must be screened with non-flammable material and if oil present. is kept in good order. which decompose under these conditions to form highly corrosive residues. • After completion of any maintenance or repair ensure that no tools. eyes. • Precautions must be taken against using acids. • Do not use any flammable liquid to clean valves. safety precautions must be taken against toxic vapours. If chlorinated hydrocarbon substances are used for cleaning. • The accuracy of pressure gauges and temperature switches should be regularly checked at least 13 month intervals and thoroughly examined at least every 48 months. Some components may contain fluoroelastomer materials. with all accessories and safety devices. cooler passages. They must be renewed or service exchanged when acceptable tolerances are exceeded. • When disposing of condensate. alkalis and chemical detergents for cleaning machined parts. PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL. Do not breathe mists. used filter elements and other parts and waste material of any kind make sure that there is no pollution to any drain or natural water course and that no burning of waste takes place which could cause pollution of the atmosphere.CompAir UK Ltd PUBLICATION GAS SAFETY Page 10 6. intake. the set pressure being a minimum of 1. 7. • Make sure all instructions concerning operation and maintenance are strictly followed and that the complete unit. the system must first be cleansed thoroughly by steam cleaning. which may be released. Ensure water and soap is readily available. • Condensate (oil and water mixture from compression process) must be regarded as trade effluent and is therefore not suitable for discharge into a surface water sewer. • Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks. old oil. pipe bores or any component carrying a flow of air or gas during normal operation.10 times the set pressure. • Never use a light source with an open flame for inspection. • Before dismantling any part of the compressor be sure that all heavy movable parts are secure. These materials cause irritation and are corrosive to the skin.05 times the maximum operating pressure to ensure seat tightness. The maximum pressure for safety valves under fault conditions is 1. This is a high pressure Compressor use only: GENUINE CompAir UK Ltd PARTS Page 10 04/09/02 gassafety. MAINTENANCE & REPAIR (Cont. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage. loose items or rags are left on or inside the compressor.g. Avoid splashes and wear suitable protective clothing and safety glasses. • Protect components and exposed openings by covering with a clean cloth or tape during repair or maintenance work. soakaway or watercourse. filter elements. electrical and regulation components against the entry of moisture e. PRECAUTIONS IN THE EVENT OF FIRE • Use extreme caution when handling components that have been subjected to fire or very high temperature. • Protect the motor.doc . • Protection devices should be tested at each regular service interval and replaced or service exchanged if not functioning correctly. DO NOT USE CARBON TETRACHLORIDE. preventing its breakdown.CompAir UK Ltd PUBLICATION GAS SAFETY Page 11 DRY GASES Lubrication is the introduction and maintenance of a continuous film of oil between two moving surfaces. it has been established that if moisture is present. the help from these skins is not normally available. a HIGH level of anti-wear additives and a LIMITED amount of anti-oxidant additives. film breakdown is prevented. When this breaks down. even in small amounts. The oxygen in the entrained gas gradually forms and maintains oxide skins on the moving surfaces. provides the oxygen for oxide skin formation. caused by the oil distribution and recovery system. However.doc 04/09/02 Page 11 . it is recommended that the machine is run on air for 10 hours using the recommended oil as this will speed up the formation of oxide skins before changing to gas and Anderol 1200. gassafety. wear occurs. When gas is being compressed and there is no oxygen present. The lubricant we recommend for this duty is Anderol 1200. These are provided by an oil which has a HIGH viscosity. When commissioning or re-commissioning the compressor. These improve the adhesive strength of the oil film. results in the lubricant absorbing some gas whilst it is in the crankcase and cylinders. The reason is that gas entrained in the water at source. If the gas is dry (we define this as less than 50 ppm by weight) and if no oxygen is present (less than 10 ppm by volume) it is necessary to use a special lubricant capable of maintaining a high film strength to prevent its breakdown. The properties needed are a stronger than normal adhesion to the metal surfaces and additives which will help oxide film formation. In an gas compressor the agitation. filtration isolation valve ISOL68 and purge valve PGE061. The compressor system should now be filled with gas. Purging with Gas Vent nitrogen from vent system by opening the filtration isolation valve ISOL 62 and venting nitrogen from the recovery vessel ISOL 07 ensuring a small positive pressure is kept in the system. will speed the process. The filtration will be pressurised before the pressure-maintaining valve PCV 61 opens. Close PGE 02 and open DDV valve ISOL 09. Open recovery vessel valve ISOL08 and compressor inlet purge valve PGE02.CompAir UK Ltd PUBLICATION GAS SAFETY Page 12 TYPICAL GAS PURGING INSTRUCTIONS Before allowing any Natural Gas to enter the compressor or ancillary piping the whole system must be purged free of air in accordance with the following procedure. ISOL02. Purge nitrogen through until air is displaced by checking with an oxygen meter at the delivery purge valve. Vent gas from compressor purge valve PGE 02. This can be checked with an oxygen meter at the vent stack. Most of the compressor system should now be filled with nitrogen. Repurging with gas Open compressor purge valve PGE 02 and DDV valve ISOL 09 until gas is present. DDV valve ISOL09. Shut off nitrogen supply when complete. If the downstream equipment needs to be purged with nitrogen then the compressor can be run by feeding nitrogen into the inlet vessel and maintaining the required inlet pressure. the system must always be re-purged. Purge nitrogen through until air is displaced. After any maintenance or repairs have been carried out which involves dismantling and opening up gas containing parts. ALWAYS REPEAT THE PROCEDURE. Page 12 04/09/02 gassafety. PURGING PRIOR TO INITIAL START-UP Purging with Nitrogen Connect nitrogen to the inlet purge valve PGE01. COMPRESSOR MAINTENANCE Releasing gas To isolate compressor close DDV and recovery vessel valves ISOL 09 and ISOL 08. Open recovery vessel drain ISOL 07 until gas is sensed and then vent from delivery purge valve PGE 61. This will allow gas to enter the system. Close inlet valve ISOL01. Open inlet gas isolating valve ISOL 01 and open inlet gas solenoid valve SOL 01 by switching vent valve inlet switch on starter to Hand. Close Open compressor purge valve PGE 02 to expel the gas and then open delivery purge valve PGE 61 to vent remaining gas. Purge nitrogen through until air is displaced. expel gas into the recovery vessel via ISOL63. Close compressor inlet purge valve PGE 02 and open delivery purge valve PGE 61. FINAL COALESCER Releasing gas Close filtration isolation valve ISOL 62 & ISOL61.doc . Feeding the purge gas at a pressure equal to the inlet pressure to the compressor. Close DDV valve ISOL 09 and open recovery vessel valve ISOL 08 and purge gas to PGE 02. If the downstream equipment has been purged with nitrogen then it should be vented to a small positive pressure. If in any doubt as to the efficiency of the purging. The filtration isolation valve ISOL 62 should then be closed. Close recovery vessel valve ISOL 08 and open DDV valve ISOL 09 select manual operation on Control Panel and open Solenoid valve SOL01. 1 TEMPERATURES ------------------------------------------------------------.7 TECHNICAL DATA .2.2.9 1.2.21 CONNECTIONS --------------------------------------------------------------------------.8 1.3 3.2.2 PROTECTION ---------------------------------------------------------------.3 1.1 GAS CONNECTION--------------------------------------------------------.2 3.5.18 2.2.2.8 1.18 SECTION 3 3.11 WEIGHTS-----------------------------------------------------------------------.18 2. & I.2.4 UNIT DESIGNATION ---------------------------------------------------------------------.2 OPERATING SPEEDS ------------------------------------------------------.18 2.12 EXTERNAL DIMENSIONS -------------------------------------------------.5.2 WATER CONNECTION ---------------------------------------------------.6 INTERNAL DIMENSIONS --------------------------------------------------.4.9 1.3 GAS DETECTOR --------------------------------------------.1 2.GENERAL -------------------------------------------------------.3 OPERATING PRESSURES ------------------------------------------------.2.21 LOCATION---------------------------------------------------------------------------------.9 INCLINATION------------------------------------------------------------------.18 2.5.2 2.8 1.4.CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX Page 1 CONTENTS QUICK REFERENCE GUIDE TO PARTS USING P.7 CONNECTIONS --------------------------------------------------------------.7 1. DIAGRAM D70983 CERTIFICATE OF CONFORMITY COMPRESSOR PLANNED MAINTENANCE LOG SHEET WARNINGS & SAFETY SECTION DRY GAS LUBRICANT RESTRICTIONS TYPICAL GAS PURGING INSTRUCTIONS SECTION 1 1.4 LUBRICATION-----------------------------------------------------------------.8 1.2.8 1.1 STAGE RELIEF VALVES ----------------------------------.18 2.2.2.1 GAS INLET TRAIN ---------------------------------------------------------.8 1.11 SECTION 2 2.doc 04/09/02 Page 1 .9 TORQUE WRENCH SETTINGS -----------------------------------------------------.2 BURSTING DISC---------------------------------------------.18 2.5 COOLING -----------------------------------------------------------------------.5 TECHNICAL DESCRIPTION PAGE 13 GENERAL DESCRIPTION --------------------------------------------------------------15 CONSTRUCTIONAL DETAILS ---------------------------------------------------------16 LUBRICATION DETAILS-----------------------------------------------------------------17 CONDENSATE REMOVAL--------------------------------------------------------------17 EXTERNAL COMPONENTS ------------------------------------------------------------18 2.18 2.4 INSTALLATION INFORMATION PAGE 19 UNPACKING AND HANDLING-------------------------------------------------------.10 RELIEF VALVE SETTINGS ------------------------------------------------.5.22 3.3.5.7 1.5.4 2.5.18 2.8 WATER TEST PRESSURES ----------------------------------------------.18 2.3 PRESSURE GAUGES --------------------------------------.5.7 1.22 1293-index.2.5.1 1.2 FINAL FILTRATION -----------------------------------------.2.5 HIGH GAS TEMPERATURE SWITCHES--------------.2.21 MOUNTING--------------------------------------------------------------------------------.2.21 3.3 DELIVERY --------------------------------------------------------------------.5.3 2.3.2.5.10 RUNNING CLEARANCES AND WEARING DIMENSIONS -------------------.3.1 3.21 3.18 2.4 PNEUMATIC WATER VALVE ----------------------------.2 LEADING PARTICULARS PAGE 5 1.9 1.4.1 DISCHARGE NON-RETURN VALVE ------------------.2.3 ELECTRICAL CONNECTION -------------------------------------------. 12 HIGH OIL CONSUMPTION ---------------------------------------------------34 4.8 4.GAS.10.3 5.4 STOPS SUDDENLY ------------------------------------------------------------33 4.10.18 THIRD STAGE TEMPERATURE SWITCH TRIPS----------------------35 4.10.----44 COMPRESSOR PROTECTIONS ----------------------------------------------------.5 WILL NOT START --------------------------------------------------------------33 4.48 SECTION 6 6.8 LOW OIL PRESSURE----------------------------------------------------------34 4.10.10.1.10.20 FINAL STAGE TEMPERATURE SWITCH TRIPS ----------------------35 4.6 MAINTENANCE AND REPAIR PAGE 37 MAINTENANCE---------------------------------------------------------------------------.41 AFTER THE FIRST 100 HOURS OR A MAJOR SERVICE--------------------.5 4.10.1 6.10.10.doc 04/09/02 .10 OPERATING INFORMATION WARNING ---------------------------------------------25 SAFETY PRECAUTIONS -----------------------------------------------------------------26 COMMISSIONING --------------------------------------------------------------------------26 STARTING AFTER COMMISSIONING ------------------------------------------------27 STARTING DAILY---------------------------------------------------------------------------27 ROUTINE ATTENTION WHILE RUNNING -------------------------------------------28 STOPPING PROCEDURE ----------------------------------------------------------------29 PREPARATION FOR SPECIAL ENVIRONMENTS---------------------------------29 STARTING AFTER LONG PERIOD OF IDLENESS--------------------------------29 INHIBITION FOR STORAGE -------------------------------------------------------------29 4.23 MOTOR PROTECTION SWITCH TRIPS----------------------------------36 4.7 4.42 MAINTENANCE PERIODS AND SERVICE HOURS ----------------------------.NG---------------------------------------------------------86 .6 4.3 4.3 LOW COMPRESSOR OUTPUT ---------------------------------------------32 4.96 Page 2 1293-index.9 CUTS OUT ON START-UP ---------------------------------------------------34 4.10.10.1 RELIEF/SAFETY VALVE(S) BLOWING -----------------------------------32 4.16 INLET SAFETY VALVE BLOWING -----------------------------------------35 4.13 PREMATURE WEAR OF PARTS -------------------------------------------34 4.21 FINAL DELIVERY SAFETY VALVE BLOWING -------------------------35 4.1 5.6 OVERHEATING -----------------------------------------------------------------33 4.10.COMMON -------------------------------------------52 .10.43 SERVICING STAGE VALVES ----------------------------------------------------.10.14 HIGH INLET PRESSURE SWITCH TRIPS -------------------------------35 4.1 7.84 SECTION 7 7.1 4.4 4.GAS.10.10.10.9 OPERATING INFORMATION PAGE 23 4.22 DISPENSER PRESSURE SWITCH TRIPS-------------------------------35 4.47 SERVICING COMPRESSOR----------------------------------------------------------.9.10.COMMON---------------------------------------58 .11 UNUSUAL NOISE RUNNING UNLOADED-------------------------------34 4.2 FAILS TO REACH ‘TOP’ PRESSURE -------------------------------------32 4.9.5 5.57 ILLUSTRATIONS R-5437.15 LOW INLET PRESSURE SWITCH TRIPS--------------------------------35 4.10.2 4.17 INTERSTAGE SAFETY VALVES BLOWING ----------------------------35 4.1.CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX Page 2 SECTION 4 4.2 LONG TERM---------------------------------------------------------------------30 FAULT GUIDE--------------------------------------------------------------------------------31 4.24 INSUFFICIENT COOLING ----------------------------------------------------36 SECTION 5 5.90 ILLUSTRATIONS R-5437.7 OVERHEATING RADIATOR STES-----------------------------------------33 4.2 5.10.19 FINAL DELIVERY TEMPERATURE SWITCH TRIPS------------------35 4.10.2 BUILD PARTS LIST & ILLUSTRATIONS PAGE 85 PARTS LISTS R-5437.1 UP T0 6 MONTHS-------------------------------------------------------------29 4.10 UNUSUAL NOISE RUNNING ON LOAD ----------------------------------34 4.2 COMMON PARTS LIST & ILLUSTRATIONS PAGE 51 PARTS LISTS R-5437.NG ----------------------------------------------------91 .4 5.10.10.10. E46319 P.NG.APP012G ELECTRIC MOTOR DETAILS---------------------------------------------------. & I.APP154 NON RETURN VALVE FINAL ----------------------------------------------------.10 9.APP088 THERMOMETER SWITCH 3RD STAGE & FINAL DELIVERY ----------.APP070 WATER PUMP DRIVE DETAILS ------------------------------------------------.S RECOMMENDED SERVICE PLAN (MINERAL OIL)-------------------------.102 ELECTRIC MOTOR .R-5437.4 9.102 EXTRA PUBLICATIONS DRIVE DETAILS --------------------------------------------------------------------.7 9.11 9.APP086 PRESSURE SWITCH LOW OIL -------------------------------------------------.100 INLET TRAIN ----------------------------------------------------------------------------.APP152 ------------------------------------------------.8 9.D70938 SINGLE LINE DIAGRAM ----------------------------------------------------------------------------.R-5437. DIAGRAM --------------------------------------------------------------------------------------.APP059 PRESSURE GAUGES GENERAL ----------------------------------------------.101 CONTROL PANEL --------------------------------------------------------------------.101 CONTROL BOX SUPPORT ---------------------------------------------------------.NG.APP081 PRESSURE SWITCHES INLET CONTROL----------------------------------.APP034C ----------------------------------------------------.102 SOLENOID VALVE INLET .C89092 9.M427 RECOMMENDED SERVICE PLAN (MINERAL OIL)------------------------.doc 04/09/02 Page 3 .1.APP073 PRESSURE SWITCH FINAL DELIVERY--------------------------------------.APP153----------------------------------------------.1 8.5437CNG.APP034C DIAPHRAGM DRAIN VALVE DETAILS----------------------------------------.55153 GENERAL ARRANGEMENT -----------------------------------------------------------------------.APP041 PRESSURE MAINTAINING VALVE DETAILS -------------------------------.12 9.1.101 PRESSURE CONTROL---------------------------------------------------------------.NG.APP167 CHECK VALVE INLET ------------------------------------------------------------.APP169A 1293-index.5 9.2 8.APP152 SOLENOID VALVE INLET CONTROL -----------------------------------------.V MOUNTS .1.13 NATURAL GAS COMPRESSOR PARTS ---------------------------------SEE SECTION 7 VEE DRIVE & ADJUSTMENT PARTS .C89091 WIRING DIAGRAM -----------------------------------------------------------------------------------.APP003 --------------------------------------------------------------.3 SERVICE PLANS PAGE 97 RECOMMENDED SERVICE PLAN (SYNTHETIC OIL) -------------------------R-5437.APP12G ------------------------------.APP158 SAFETY VALVES GENERAL ----------------------------------------------------.APP153 BALL VALVES GENERAL---------------------------------------------------------.MP100 SECTION 9 ANCILIARY EQUIPMENT PAGE 99 BUILD ------------------------------------------------------------------------------------.100 WATER PUMP .1 9.CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX Page 3 SECTION 8 8.100 A.9 9.APP090 SOLENOID VALVE DIAPHRAGM DRAIN VALVE CONTROL-----------.100 SAFETY VALVE MANIFOLD -------------------------------------------------------.3 9.APP073-------------------------------------------------------------.2 9.102 SOLENOID VALVE DDV . doc 04/09/02 .CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX Page 4 Page 4 1293-index. 2.2.2.10 1.10 1.3 TORQUE WRENCH SETTINGS 1.2.2.1 PAGE 10 TORQUE WRENCH SETTING --------------------------------------------------------.2 1.4 1.1 1.GENERAL 1.CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 5 SECTION 1 CONTENTS LEADING PARTICULARS 1.11 PAGE 7 PAGE 7 TEMPERATURES---------------------------------------------------------------------------7 OPERATING SPEEDS---------------------------------------------------------------------7 PRESSURES---------------------------------------------------------------------------------8 LUBRICATION -------------------------------------------------------------------------------8 COOLING -------------------------------------------------------------------------------------8 INTERNAL DIMENSIONS-----------------------------------------------------------------8 CONNECTIONS (STANDARD) ----------------------------------------------------------8 WATER TEST PRESSURES-------------------------------------------------------------9 RELIEF VALVE SETTINGS --------------------------------------------------------------9 WEIGHTS -------------------------------------------------------------------------------------9 EXTERNAL DIMENSIONS----------------------------------------------------------------9 1.5 1.3.7 1.9 1.4 RUNNING CLEARANCES AND WEARING DIMENSIONS PAGE 11 1293-1.8 1.2.6 1.1 1.2.2.2.3 1.2 UNIT DESIGNATION TECHNICAL DATA .2.doc 04/09/02 Page 5 .2. doc 04/09/02 .37 ILLUSTRATED RADIATOR COOLED SET STANDARD SET Page 6 1293-1.CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 6 TYPICAL HGP. ........ 30°C.........................217....1............................................................ Anti-clockwise Number of valves ...... 1 bar g...................................................1 TEMPERATURES .1............... Minimum gas intake temperature.............................................. Running Speed 1800 rpm ......................... Inlet Pressure (Bar g) 3rd Stage Temperature Controller 3rd Stage Temperature Controller Maximum 0 160°C 190°C 0....250 bar g delivery Cooling water inlet temperature .................. Flat plate.Sea or fresh water Direction of rotation........ electric powered .......... Note: It is important for the life and safety of the machine not to exceed the maximum operating temperatures.........................................................................15°C with a 10°C to 12°C rise across machine............................................................12°C....NG 1.......2..........................................64 170°C 200°C Maximum gas inlet pressure (subject to a speed restriction)............1 UNIT DESIGNATION Belt drive compressor................... viewed from drive end.2 OPERATING SPEEDS Minimum speed --------------------------------------------------------------------------------------------750 rev/min Maximum speed -----------------------------------------------------------------------------------------... Single acting................................................. Temperature rise across machine (Normal requirement) ............................NG Examples of 3rd stage temperature controller settings.............CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 7 SECTION 1 LEADING PARTICULARS 1....... R-5437.... (Higher ambients possible contact CompAir UK Ltd Ipswich Engineering for more information......................................................... 1....................... 37°C......................doc 04/09/02 Page 7 .......GENERAL Type..................................................7m³/hr 1293-1....... 90° vee Cooling ...Four Type of valve ............... Maximum cooling water inlet temperature ... Maximum gas intake ambient temperature for radiator sets...................................................2..... 45°C...........3 165°C 195°C 0................................................................... Maximum gas intake ambient temperature ..........10°C .............R-5437....................................2 TECHNICAL DATA ..1800 rev/min 1st stage piston displacement at maximum speed -----------------------------------------------........... 0°C....... low lift 1..................................... four stage........... ... 1. nominal 75 mm Fourth stage delivery ..................4 LUBRICATION * Crankcase oil capacity .....................................................................................75 mm First stage cylinder bore -----------------------------------------------------------------------------------...................................................................7 CONNECTIONS (STANDARD) Gas inlet connection ............................................ 2................................Mobil Rarus 427 Recommended oil: Mineral ..............................................................................................................................................................2............................55 bar intake) ---------------------------------------------------.......................5 COOLING Coolant Sea or fresh water Cooling water flow @ 15°C inlet temp ............... 1½" BSPP Water inlet...... 1.................. Anderol 555 Recommended oil: Mineral ............................................................................2............................45 mm Fourth stage cylinder bore ---------------------------------------------------------------------------------...........1¼" BSPT Page 8 1293-1........................95 mm Third stage cylinder bore -----------------------------------------------------------------------------------..................................refer to Ipswich Works.........................5..............................................350 bar Minimum working pressure (with atmospheric pressure intake) ---------------------------------........ 46 litres Note: Water must not be allowed to freeze in the compressor water jackets.... 45 litres Recommended silicone grease (for assembly) ...2............ If difficulty is experienced a change may be advisable ..................................................2..140 bar Minimum working pressure (with 0..........75 l/h/kW (12 gals/bhp/hr) Coolant capacity (Approx......) ..........75 bar Minimum oil pressure (Worn machine).......6 INTERNAL DIMENSIONS Piston stroke---------------------------------------------------------------------------------------------------.................................................................................... coolers or in a sea water / fresh water heat exchanger.................22 mm Mean piston speed at maximum speed ------------------------------------------------------------------4.........................2...........1 bar 1......................Dow Corning MS33 Recommended oil: Synthetic ..........0............................... ½" BSPP Condensate drain.3 PRESSURES * Maximum working pressure -------------------------------------------------------------------------------..doc 04/09/02 .....................................................................................................Reavellite.....................200 bar Minimum water pressure ................................. 1" BSPT Water outlet......0-2......6 bar Maximum water pressure ....................185 mm Second stage cylinder bore --------------------------------------------------------------------------------.......................................1 bar Oil pressure (New machine) ......................CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 8 1.......................................................................Shell Corena P100 * Oil recommendations are based on normal conditions..............................5 m/s 1........ ........ 1090 Kg Cooling water and lubricating oil.......................................................10 RELIEF VALVE SETTINGS First stage ............................................................................................................................................................CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 9 1.............2......................................................................... 250 Kg Typical Belt Driven Set (Complete set dry)...........12 EXTERNAL DIMENSIONS Typical Belt Driven Set ........................................................ 2.......................................................................................................................................doc 04/09/02 Page 9 . 10 bar g Second stage........................ 40 bar g Third stage .................................................................................................................................................................... 690 bar g Water jacket . 2 bar g First stage delivery ................................... 146 Kg rd Cylinder block 3 & 4th Stage ............................ 155 Kg Crankcase.......8 bar g Crankcase...............................................1090 mm 1293-1..............2................... 81 bar g Third stage ...................................................................Length --------------------------------------------------------------------------.................................................... 90 Kg Crankshaft ...1320 mm Height -----------------------------------------------------------------------------------------------------------............................................................8 WATER TEST PRESSURES First stage suction ....................................................................................................... rotational compressor and flywheel .......................................................................................................................................................... 150 bar g Fourth stage........................................................................................... Supply pressure +10% Surge vessel Relief valve ............ 45 Kg Flywheel.................................................................................1700 mm Width ----------------------------------------------------------------------------------------------------------............................................................................................................... 21 bar g Second stage ........................................ 51 Kg nd Cylinder block 1st & 2 Stage ........................................................................79 kgm² 1......................................................1 bar g 1.................................................................................................................................................................11 WEIGHTS Machine (bare)............................................. 2........................................................... 100 bar g 1........................................................................................................................................................................................................................................ 300 bar g Fourth stage .......................... 0....................................... 1600 Kg Inertia.....................................................2....2............................... CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 10 1.doc 04/09/02 .1/8" ¾” UNF 19MM M12 19MM M12 13MM M8 17MM M10 17MM M10 13MM M8 10MM M6 8MM M5 17MM M10 19MM M12 1.3 1.1/8" ¾” UNC 13MM M8 13MM M8 13MM M8 19MM M12 24MM M16 30MM M20 NEWTON METRE (Nm) 203 236 55 55 55 95 50 121 237 28 118 118 55 27 162 95 95 28 55 39 19 8 4. Page 10 1293-1. * Note: Must be tightened sequentially in 27 Nm ( 20 Lb. Under no circumstances are any deviations from the above figures allowable.4 40 70 175 20 20 20 70 175 175 Big End Bearing Bolts First and Second Stage Cylinder Block to Crankcase First Stage Separator First and Second Stage Cooler Cover – fixed end First and Second Stage Cooler Cover – floating end Second Stage Separator Cover First Stage Valve Cover * Second Stage Valve Cover * Third and Fourth Stage Cylinder Block to Crankcase Third Stage Cooler Cover Third Stage Valve Cover * Fourth Stage Valve Cover * Fourth Stage Cooler Cover Third and Fourth Stage Piston Flywheel bolt to Crankshaft Driving-end Main-end Bearing Housing to Crankcase Outer-end Main-end Bearing Housing to Crankcase Crankcase Door Bursting Disc Cover First Stage Valve Second Stage Valve Third Stage Valve Fourth Stage Valve Coupling Ring to Flywheel Bell-Housing to Crankcase Bell-Housing to Motor Oil Pump Surge Vessel Door Diaphragm Drain Valve to Surge Vessel Door AV-Shock Mount Bracket to Crankcase AV-Shock Mount Bracket to Motor Bracket to AV-Shock Mount.ft) steps.3.ft) 150 175 40 40 40 70 37 90 175 20 87 87 40 20 119 70 70 20 40 29 14 6 3.1 TORQUE WRENCH SETTINGS (All figures ±5%) TORQUE WRENCH SETTINGS FOR NON-LUBRICATED FASTENERS FASTENING SPANNER THREAD SIZE SIZE A/F 24MM M16 24MM M16 17MM M10 17MM M10 17MM M10 19MM M12 19MM M12 30MM M20 24MM M16 13MM M8 24MM M16 24MM M16 17MM M10 13MM M8 1.6 55 95 237 28 28 28 95 237 237 POUND FEET (lb. 03 0.24 0.30 4.025 / 0.89 21.4 1 2.11 95.90 0.85 21.120 0.23 0.10 45.950 0.30 0.55 84.05 / 0.63 1.10 0.30 0.22 79.31 4.013 0.04 / 95.20/0.00 0.4 11.04 0.23 0.24 / 84.80 2.04 79.69 94.10 / 0.200 0.46 0.050 / 0.93 1.08 0.350 / 1.066 / 0.20 / 0.99 4.50 0.3.29 0.060 / 0.43 1.044 0.935 185.9 185.05 Needle roller -0.500 / 1.09 22.83 8.66 10 13.905 / 21.13 2.10/0.09 3.05 / 2.4 Piston ring axial clearance (Measured between groove & top face of ring with ring in normal running position) Piston ring groove width Taper Scraper Taper Scraper Plain Plain Taper Scraper Taper Scraper Plain Plain Taper Scraper Taper Scraper Plain Plain Piston skirt diameter Liner bore diameter Crosshead diametral clearance S/E bearing diametral clearance In connection rod In piston S/E bearing end float Crankshaft journal B/E bearing diameter B/E bearing out of round Main bearing diameter Main bearing out of round B/E bearing diametral clearance Main bearing diametral clearance Crankshaft end float Cooler tube nominal bore sizes 0.91 2.99 3.40 0.01 2.92 / 44.74 94.28 0.150 0.00 95.27 1.32 1.88 44.08 0.01 / 0.1 6.91 / 94.04 / 0.03 / 45.4 10 13.46 0.15 / 0.10 0.CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 11 1.3.0 1.02 / 0.150 0.18 0.64 184.01 / 0.4 1 2 3 4 23 off 8 off 8 off 6 off 1 off 1 off 0.08 0.2 1293-1.135 0.83 / 4.2 0.92 0.09 0.83 44.10 / 0.2.75 ------- Piston vertical clearance (ie.003 / 0.95 / 79.doc 04/09/02 Page 11 .250 / 0.23 / 7.4 1 2.56/2.09 1.77 / 184.06 4.00 45.15 / 0.23 / 0.1 -0.53 184.350 / 1. Distance from top of piston to top of liner) Piston ring gaps (Measured in unworn portion of cylinder / liner) 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 3.4 RUNNING CLEARANCES AND WEARING DIMENSIONS DESCRIPTION STAGE AS FITTED (mm) MAX.37 1.0 83.19 0.00 22.3.91 8.125 0.64 0.20 / 0. PERMITTED (mm) ----1.28 0.02 / 22.05 / 0.05 / 185.4 1 2.3.80 / 4.05 / 0.01 / 7. CompAir UK Ltd PUBLICATION 98407/1293 Section 1 Page 12 Page 12 1293-1.doc 04/09/02 . 5 HIGH GAS TEMPERATURE SWITCHES --------.2.5.4.4 2.3.3 PRESSURE GAUGES---------------------------------.doc 04/09/02 Page 13 .CompAir UK Ltd PUBLICATION 98407/1293 Section 2 Page 13 SECTION 2 CONTENTS TECHNICAL DESCRIPTION 2.1 2.18 1293-2.5.5.2 FINAL FILTRATION ------------------------------------.2.5.3 2.4 PNEUMATIC WATER VALVE (IF FITTED) ------.1 STAGE GAS RELIEF VALVES----------------------.18 2.18 2.2.18 2.2.17 2.5.5.3.2 EXTERNAL COMPONENTS PAGE 18 2.17 2.2 2.18 2.2 BURSTING DISC ---------------------------------------.1 CONDENSATE REMOVAL PAGE 17 DIAPHRAGM DRAIN VALVES ------------------------------------.3 GAS INLET TRAIN----------------------------------------------------.18 DELIVERY --------------------------------------------------------------.5.16 2.2.3 GAS DETECTOR ---------------------------------------.1 2.18 2.5 2.1 GENERAL DESCRIPTION CONSTRUCTIONAL DETAILS PAGE 15 PAGE 16 MATERIAL of CONSTRUCTION----------------------------------.1 LUBRICATION DETAILS PAGE 17 MAIN LUBRICATION SYSTEM -----------------------------------.5.18 2.5.18 2.3.3.18 PROTECTION ---------------------------------------------------------.5.18 2.1 DISCHARGE NON-RETURN VALVE--------------.2.5. CompAir UK Ltd PUBLICATION 98407/1293 Section 2 Page 14 Page 14 1293-2.doc 04/09/02 . All stage coolers are withdrawable to ease maintenance. single acting. connecting rods. The 1 & 2 stage cylinder blocks contains renewable wet cylinder liners and are jacketed for rd th water-cooling.CompAir UK Ltd PUBLICATION 98407/1293 Section 2 Page 15 TECHNICAL DESCRIPTION 2. The fourth or final stage cooler cools the hot gas delivered from the fourth stage cylinder to within 5°C of the cooling water inlet temperature. A low oil pressure switch is provided to protect the running gear against lubrication failure. 2 and 3 stages. All are fitted with split piston rings. Each block is complete with individual cylinder liners. nd st 1 Stage cylinder 2 Stage cylinder Surge vessel safety valve Diaphragm Drain valves The R-5437. The gas end consists of two cylinder blocks . an oil level sight gauge is provided in the crankcase for maintaining oil to the correct level. 2 .combined 3 & 4 stage – combined 1 & 2 stage. 3 and 4 stages and condensate separators for 1 .doc 04/09/02 Page 15 . Pressure gauge panel. The oil pump is directly driven from the crankshaft to provide a forced-feed lubrication system via a suction strainer through a filter element to the running gear. cylinder lubricator and other accessories. inter-stage st nd rd th st nd rd coolers for the 1 . 4 stage. whilst the third and fourth are an integral piston and crosshead assemblies. and the 2nd and 4th stage lines on the opposite crank throw of a counterbalanced crankshaft. valve covers. bearings.1 GENERAL DESCRIPTION TYPICAL ARRANGEMENT 1 Stg Safety Valve 2 stage Safety valve. Water-cooled inter-stage coolers are provided after each stage of compression. with condensate separators after each inter-stage cooler. water cooled machine with the 1st and 3rd stage lines on one crank throw. pistons. The cylinders. An automatic drainage system drains each stage condensate separator at approximately 10 to 20 st nd rd th st nd nd st 1293-2. The water flows over the tubes and the gas through for all stage coolers.1. A single combined suction and discharge (concentric) valve is fitted at the head of each cylinder. oil pump. The 3 and 4 stage cylinder blocks contains renewable dry cylinder liners again jacketed for water-cooling. Water flow is arranged within the cylinder jackets and coolers in series to provide even and effective cooling for either sea or fresh water. valves. The running gear consists of the crankshaft.NG compressor is a reciprocating 90° vee configuration. pistons and valves are splash/spray lubricated. First and second stage pistons are conventional trunk type. 2.1 MATERIALS of CONSTRUCTION Component Crankcase Crankshaft Main-End Bearings Connecting Rods Big-End Bearings Small-end Bearing – 1st stage Small-end Bearings – 2nd. 3rd & 4th stage Flywheel First Stage Piston Second Stage Piston Third Stage Piston Fourth Stage Piston First & Second Stage Cylinder Block Third & Fourth Stage Cylinder Block 1st. The drainage system whilst removing oil/moisture also acts as an unloading device to prevent the compressor starting under load. A non-return valve is located at the final discharge connection to prevent system pressure returning to the cylinders when the compressor is shut down. Pressure gauges to indicate all gas stage pressures and oil pressure are located in a gauge board mounted between each cylinder block.doc 04/09/02 . inlet (or exit from the third stage cooler) and exit from the 4th stage delivery after cooling to stop the compressor on over-temperature in the gas stream. These switches combine both a visual dial display of the temperature and again an indication of the switch setting. Gas relief valves for each stage are fitted to prevent over-pressure in cylinders and coolers. A pneumatic water inlet valve (if fitted) will not allow the cooling water to flow when the compressor stops this helps to prevent over-cooling. and bursting diaphragms are fitted to protect the water jackets from accidental application of gas pressure to the cooling system. This interval and period is dependent upon the ambient temperature and humidity and for high ambient high humidity conditions the interval must be reduced and the period increased.CompAir UK Ltd PUBLICATION 98407/1293 Section 2 Page 16 minute intervals for a period of 5-10 seconds into a discharge surge vessel. 2nd & 3rd Stage Cylinder Liners 4th Stage Cylinder Liner 1st & 2nd Stage Cooler Tubes 3rd & 4th Stage Cooler Tubes Cooler covers & separators Gudgeon Pins Tube plates Piston Rings Material Cast Iron Spheriodal Graphite Iron White-metal lined Gun Metal Spheriodal Graphite Iron Steel backed aluminium-tin with overlay Phosphor Bronze Steel – needle roller Cast Iron Aluminium alloy Cast Iron Cast Iron Cast Iron Speriodal Graphite Iron Speriodal Graphite Iron Grey Cast Iron Nitrided steel Copper Stainless Steel Spheriodal Graphite Iron Steel Cast Iron Cast Iron Page 16 1293-2. High gas temperature switches are fitted to the 3rd stage cylinder discharge.2. in-built in crankcase. by bleeding off automatically all the gas in the compressor through the condensate separators whenever the compressor stops. The compressor gas intake should be fitted with a filter to prevent solid particles entering the compressor cylinders.2 CONSTRUCTION DETAILS 2. 4 CONDENSATE REMOVAL 2.1 DIAPHRAGM DRAIN VALVES Diaphragm Drain Valves or DDV’s are installed after each compression stage to automatically drain oil/moisture collected in each inter-stage separator and to act as unloader valves to remove any gas load on starting. Oil returns to the crankcase and is drawn up to the pump suction through a strainer. Oil thrown off the moving parts ensures adequate lubrication to all stage pistons. 1293-2. gas pressure from the 1 stage acts on the diaphragm to close the valves. With no gas pressure st all valves are open to the blowdown vessel. On starting if the oil pressure has not built up within about 10 seconds the LOP.4. Low Oil Pressure Switch Conn Rods Oil filter Oil filter By-pass Oil Strainer Oil Pump Main Bearing D/E Main Bearing O/E An oil pressure gauge indicates if over-pressure and is relieved through a safety valve within the oil pump. Each valve to operated from first stage pressure via a three-way solenoid valve.CompAir UK Ltd PUBLICATION 98407/1293 Section 2 Page 17 2. A timed signal every 10 .doc 04/09/02 Page 17 . All these valves are similar in design and operation – only the valve orifice and seat vary to suit each stage. will shut down the compressor. big end and small end bearings via a replaceable filter element . A protective Low Oil Pressure Switch or LOP s installed to shut-down the compressor if the pressure falls below 1 bar ( 15 psig).3 LUBRICATION 2.20 minutes actuates the three-way solenoid valve for 5-10 seconds to release the gas pressure and allow the valves to open and drain the collected condensate in each separator to drain. connected to a delay timer in the motor starter control. In operation. to attenuate the noise. THE GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED TO THE USE OF A LUBRICANT NOT RECOMMENDED BY COMPAIR IPSWICH 2. The sudden release of gas and condensate is passed via an integral surge vessel.1 MAIN LUBRICATION SYSTEM A forced feed oil pump pressurises the lubrication system conveying oil from the crankcase to the main. crossheads and cylinders.3. for connection to drain trap to drainage vessel. ready for safe disposal. CompAir UK Ltd PUBLICATION 98407/1293 Section 2 Page 18 2.5 GAS INLET TRAIN 2.5.1 GAS INLET TRAIN Attached to the first stage gas intake flange and to provide maximum sound attenuation with minimum gas resistance together with a replaceable filter to prevent particle ingress. Gas should be drawn from a clean, dry, cool source. COMPRESSOR PROTECTION 2.5.2.1 STAGE GAS RELIEF VALVES. Gas Safety valves are fitted to all four stages. 2.5.2.2 BURSTING DISC Thin plastic membrane and PTFE/metal discs protect the cooling water system against a possible cooler gas leak, ruptured cooler tube etc. It is not intended as a protection against water over-pressure and therefore the burst pressure (17 bar or 250 psig) has no particular relationship to the cooling water system operating pressure. 2.5.2.3 PRESSURE GAUGES Glycerine filled pressure gauges are supplied for each compression stage and for monitoring the main lubrication oil system pressures. 2.5.2.4 PNEUMATIC WATER VALVE ( IF FITTED ) This valve is a normally closed diaphragm operated shut off valve to prevent cooling water flow whenever the compressor is not operating. This function is automatic since the valve is actuated by the first stage gas pressure. 2.5.2.5 HIGH GAS TEMPERATURE SWITCHES rd rd Temperature sensors are fitted into the 3 stage delivery port, exit from 3 stage separator at th inlet to 4 stage inlet and at the final delivery after cooling. Each connected to a temperature switch. 2.5.3 DELIVERY 2.5.3.1 FINAL DISCHARGE NON-RETURN VALVE Fitted at the compressor exit to prevent gas under pressure in the downstream piping or reservoir from flowing back through the machine when the compressor is unloaded and stationary. 2.5.3.2 2.5.3.3 FINAL FILTRATION GAS DETECTOR 2.5.2 Page 18 1293-2.doc 04/09/02 CompAir UK Ltd PUBLICATION 98407/1293 Section 3 Page 19 SECTION 3 CONTENTS INSTALLATION INFORMATION 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 UNPACKING AND HANDLING LOCATION MOUNTING CONNECTIONS PAGE 21 PAGE 21 PAGE 21 PAGE 21 GAS CONNECTIONS ------------------------------------------------------- 21 WATER CONNECTIONS--------------------------------------------------- 22 ELECTRICAL CONNECTIONS ------------------------------------------- 22 TYPICAL RADIATOR COOLED HGP.37 1293-3.doc 04/09/02 Page 19 CompAir UK Ltd PUBLICATION 98407/1293 Section 3 Page 20 TYPICAL HGP.37 LIFTING EYES LOAD SPREADING LIFTING BAR VIEW FROM TOP Page 20 1293-3.doc 04/09/02 3 MOUNTING The compressor unit is mounted on anti-vibration mounts. 3. must be flat and capable of bearing the total weight of the unit without distortion. Sufficient clearance must be allowed to ensure that the set will not touch any obstruction or any flexibly mounted equipment. cool and dry environment within the parameters stated in the ‘Leading Particulars’ section.2 LOCATION It is desirable that the compressor unit is installed in as clean.doc 04/09/02 Page 21 . and loose components packed separately.CompAir UK Ltd PUBLICATION 98407/1293 Section 3 Page 21 SECTION 3 INSTALLATION INFORMATION 3. This pipe must be led away with a minimum of bends. and must have a minimum internal diameter of 38mm (1½”). Short flexible sections must be incorporated. is screwed 1½” BSPT female to accept the discharge pipe. and valves etc. and that any protective lacquer is intact. There must be no obstruction in the line as any restriction during operation may cause the safety valve at the crankcase for the surge vessel to open.02 and 1bar g from a local gas utility and must be as clean and dry as possible. on which the unit is to stand. Unloading / Condensate Drain The unloading / condensate drain connection at the crankcase. These mounts should be inspected for any tear of the rubber to metal plate bond or ageing before use. All openings will have been sealed with plastic plugs or adhesive tape. all connections must also be flexible. Final Delivery The final delivery connection ½ ” BSPP is situated at the end of the non-return valve. and that the set will not touch any obstructions or other flexibly mounted equipment.4. • 3. In selecting the location it is essential to consider accessibility. The surface.1 GAS CONNECTIONS Suction The intake gas pressure can vary. Note: Condensate drainage is dirty and it is advisable to pipe direct to a suitable tundish. Lower the compressor unit onto the mounts and screw on the mount holding down nuts. should be suitable for the pressures and temperatures involved and capable of easy removal to facilitate maintenance. The packing case should be carefully disassembled to avoid damage to gauges.1 UNPACKING AND HANDLING The compressor unit is delivered in a packing case. Allow sufficient space around the installation for safe maintenance work. typically between 0. 3. Reject any mount that is not in good condition. pipework. with an added allowance for maximum movement from the mounting system. for the surge vessel. 1293-3. Rock unit to ensure mounts is free and not distorted.4 CONNECTIONS Note: As the compressor unit is flexibly mounted. Ensure the mount is not impregnated with oil or grease. The unit should be lifted by the eyebolts on the motor and compressor. 3. The flexible connection must be suitable for the set working pressure. A flexible braided earth strap of suitable length to ensure it will not fail under maximum movement of the set must be fitted between the set and the its seating. Too low a rise reduces the average temperature and may improve the cooler efficiency but can cause condensation in the cylinders. The size of the cable shall be suitable for the supply voltage and current involved. High Gas Temperature Switches for Hazardous Area Zone 1 The cable entry is through a conduit entry hole. quantity and temperature of the water used can materially affect maintenance. An hours-run meter fitted to the motor starter is recommended for maintenance scheduling. Contact CompAir UK Ltd Ipswich for more information on humidity if required. The inlet connection is to the pneumatic water control valve (if fitted) inlet only.CompAir UK Ltd PUBLICATION 98407/1293 Section 3 Page 22 3. over-cooling) Pneumatic Water Inlet Valve A compatible CompAir UK Ltd Ipswich automatic pneumatic water inlet valve can be fitted to control water supply and prevent overcooling. installed before the pneumatic water inlet valve (if fitted). clean water.30 minutes to periodically. It is recommended that temperature indication or gauges are fitted to water inlet (1 ¼” BSPT) and outlet (1 ¼” BSPT) pipes to monitor water temperature rise across the compressor to approximately 10-12 °C.4. A suitable overload device should always be fitted. dependent upon ambient temperature and humidity. Note: When the compressor set is on flexible mounting it can become electrically insulated. 3. Note: Continued water circulation when stationary can cause condensation within the cylinders and breakdown of oil lubrication creating premature wear.e.2 WATER CONNECTIONS Cooling Water The quality. and the terminal connections shall be as shown in the terminal box. Adequate flexibility shall be ensured to allow for movement of the set on the anti-vibration mounts. Low Oil Pressure Switch for Hazardous Area Zone 1 See High Gas Temperature Switches above. A lockable throttle valve is recommended at the inlet. Water flow arrangements should be fail-safe to ensure that compressor can not run on full load without water flow. to allow adjustment the water flow to achieve the correct temperature rise then locked for security.4. A timer should be incorporated in the starter to de-energise the solenoid valve for between 5-10 seconds every 10 . Cable should run through a suitable Zone 1 flexible armoured sheath. Page 22 1293-3. A positive circulation of cool but not cold.3 ELECTRICAL CONNECTIONS Electric Motor for Hazardous Area Zone 1 Main leads from the motor controller / starter should be brought through a suitable Zone 1 flexible armoured cable sheath to the terminal box on the side of the motor. (I. Solenoid Valve for Hazardous Area Zone 1 The cable should be run through a suitable Zone 1 flexible armoured cable sheath from the motor controller. Details of the terminal connections are on the switch. Note: It is vital a suitable inhibitor is used especially in HARD WATER areas. If this rise is too high the average water temperature is high and can cause overheating and accelerate formation of scale in the coolers and water passages.doc 04/09/02 . Therefore it is recommended that a suitable water softener unit be fitted to the inlet water line. free from suspended particles is required for satisfactory continuous operation. This valve is operated by the first stage compressor gas pressure to only allow water in when the compressor operates. This will allow the diaphragm drain valves to operate and discharge any accumulated condensate. 7 4.23 4.10.20 4.10.9.10 FAULT GUIDE 4.10.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 23 SECTION 4 CONTENTS OPERATING INFORMATION 4.10.doc 04/09/02 Page 23 .10.6 4.3 4.4 4.10.5 4.4 4.9 4.21 4.10.2 PAGE 26 PAGE 26 PAGE 27 PAGE 27 PAGE 28 PAGE 29 PAGE 29 PAGE 29 PAGE 29 INHIBITION FOR UP TO SIX MONTHS ----------------------------------29 LONG TERM STORAGE -----------------------------------------------------30 4.10.1 4.10.19 4.10.10.10.1 4.10.2 4.10.24 PAGE 31 RELIEF/SAFETY VALVE(S) BLOWING ----------------------------------32 FAILS TO REACH ‘TOP’ PRESSURE ------------------------------------32 LOW COMPRESSOR OUTPUT ---------------------------------------------32 STOPS SUDDENLY -----------------------------------------------------------33 WILL NOT START--------------------------------------------------------------33 OVERHEATING-----------------------------------------------------------------33 OVERHEATING RADIATOR STES ----------------------------------------33 LOW OIL PRESSURE---------------------------------------------------------34 CUTS OUT ON START-UP --------------------------------------------------34 UNUSUAL NOISE RUNNING ON LOAD ---------------------------------34 UNUSUAL NOISE RUNNING UNLOADED ------------------------------34 HIGH OIL CONSUMPTION --------------------------------------------------34 PREMATURE WEAR OF PARTS ------------------------------------------34 HIGH INLET PRESSURE SWITCH TRIPS ------------------------------35 LOW INLET PRESSURE SWITCH TRIPS -------------------------------35 INLET SAFETY VALVE BLOWING ----------------------------------------35 INTERSTAGE SAFETY VALVES BLOWING----------------------------35 THIRD STAGE TEMPERATURE SWITCH TRIPS ---------------------35 FINAL DELIVERY TEMPERATURE SWITCH TRIPS -----------------35 FINAL STAGE TEMPERATURE SWITCH TRIPS----------------------35 FINAL DELIVERY SAFETY VALVE BLOWING-------------------------35 DISPENSER PRESSURE SWITCH TRIPS ------------------------------35 MOTOR PROTECTION SWITCH TRIPS---------------------------------36 INSUFFICIENT COOLING ---------------------------------------------------36 1293-4.9.9 SAFETY PRECAUTIONS COMMISSIONING ON AIR RUNNING ON AIR AFTER COMMISSIONING PURGING THE COMPRESSOR READY FOR GAS ROUTINE ATTENTION WHILE RUNNING STOPPING PROCEDURE PREPARATION FOR SPECIAL ENVIRONMENT STARTING AFTER LONG PERIOD OF IDLENESS INHIBITION FOR STORAGE RUNNING ON AIR 4.17 4.12 4.3 4.13 4.11 4.10.8 4.10.10.8 4.22 4.10.10.7 4.14 4.5 4.10.16 4.10 4.10.18 4.2 4.10.15 4.10.10.1 4.6 4. CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 24 TYPICAL HGP.37 STAGE TEMPERATURE GAUGES SAFETY VALVE MANIFOLD STAGE PRESSURE GAUGES 3RD STAGE CYLINDER 4TH STAGE CYLINDER 2ND STAGE CYLINDER 1ST STAGE CYLINDER SAFETY VALVES Page 24 1293-4.doc 04/09/02 CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 25 SECTION 4 OPERATING INFORMATION WARNING: BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE COMPLIANCE WITH LOCAL HEALTH AND SAFETY REGULATIONS & CONTROL OF SUBSTANCES HAZARDOUS APPROPRIATE TO THIS CLASS OF WORK. TAMPERING WITH SAFETY VALVES IS DANGEROUS AND ALSO INVALIDATES THE GUARANTEE. Oil 1 , 2 , 3 & 4 Pressure gauges 2 stage safety valve nd 2 stage cylinder. nd st nd rd th 1 stage safety valve st 1 stage cylinder. st Unloader valves Surge vessel safety valve 3 stage, Final Delivery Temperature Switches rd 4 stage safety valve rd 3 stage safety valve th 4 stage cylinder. Oil filler th 3 stage cylinder rd 1293-4.doc 04/09/02 Page 25 CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 26 4.1 SAFETY PRECAUTIONS When operating or working on the compressor unit at any time the following safety precautions must be observed. Read all starting and operating instructions before running compressor. Do not bar over or work on compressor without ensuring that all equipment is isolated from the electrical supply, and will remain isolated whilst work is in progress. Always open high pressure gas line valves SLOWLY. Never attempt to stop leakage or tighten joints or loose parts when compressor is running or parts are under pressure. The compressor must NEVER be operated with a malfunction in the oil or cooling water system. Should a fault develop in either of these, the compressor must be stopped immediately and the fault investigated and remedied. 4.2 COMMISSIONING ON AIR Remove all covers, plastic plugs and adhesive tape used to seal compressor openings during shipment. Check all electrical connections. Ensure water is available to the cooling circuit(s). Fill compressor with cool clean sea or fresh water, which must be free of suspended particles. The system is self-venting. Remove two crankcase doors and ensure that the crankcase interior is clean and free from foreign bodies and obstructions. Check that bolts on connecting rods are tight. Check for any water leaks inside crankcase. Fill crankcase with the correct grade of lubricant until oil level is up to the maximum level mark on the sight glass. IMPORTANT: Maintain oil level up to maximum mark. Replace crankcase doors. Remove all valve covers and valves. Check for signs of rust or water. Clean as necessary. Re-oil inside of the cylinders sparingly. Refit valves. Smear 'O' rings on valves and valve covers lightly with grease and replace covers. Tighten holding down nuts progressively in a "cross" sequence. Tighten to correct torque. Check all external nuts, bolts and other fastenings are tight and correctly torqued, that all external connections are made and pipework adequately supported. Oil pump, priming plug. Oil pump. Oil Filter Remove oil pump priming plug, using a pump type oil can, fill system with correct grade oil. Replace plug. Arrange for compressor to discharge temporarily to atmosphere (unloaded) by opening the manual Page 26 1293-4.doc 04/09/02 Replace solenoid valve plug. and listen for any uncharacteristic noises. Rotation must be counter clockwise looking on the driving end. Remove cover in the bell housing or vee belt guard and bar over compressor several times to distribute oil and confirm free movement. stop compressor isolate supplies and rectify. ALWAYS REPEAT THE PROCEDURE. Before allowing any process gas to enter the compressor or ancillary piping. will speed the process. Check the following: Oil Pressure . high temperature/humidity conditions will require the drain times to be more frequent. Where there is such a requirement. 1293-4. check oil pressure is greater than 2 bar ( 30 psig). On completion of test run. it is usually a plant requirement to purge the compressor to remove any air before letting gas into the system. Safety valves are not leaking. Stage Pressures . contact CompAir UK Ltd Ipswich for more details. • DO NOT TRY TO CORRECT LEAKS WHEN ITEMS ARE PRESSURISED. Press "ON" button on motor controller and immediately press "OFF" button.30 minutes dependent upon ambient temperature and humidity. Feeding the purge gas at a pressure equal to the inlet pressure to the compressor. After any maintenance or repairs have been carried out which involves dismantling and opening up the gas containing parts. 4. the installation will normally have purge valves fitted to allow purging gas (Nitrogen) to be discharged to atmosphere from the delivery line beyond CompAir UK Ltd supplied parts. Restart compressor. electrically disconnect solenoid valve by removing cable plug from socket connections. Rewire if rotation is incorrect. increasing pressure by 70 bar at 15 minute intervals up to working pressure. If leaks are found. that air is being delivered from each stage.3 RUNNING COMPRESSOR ON AIR AFTER COMMISSIONING On completion of preliminary checks.2 Check for air leaks by using soapy water. Unloader valves are not leaking.1 PURGING PROCEDURE If in any doubt as to the efficiency of the purging. Ensure electrical supplies are available. oil and water leaks.4.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 27 drain valve at the 4 stage separator drain and disconnect pipe.record at 15 minute intervals. Stop compressor and isolate power supplies after running unloaded for 30 minutes and check that outer surfaces of crankcase and cylinders are cool. If leaks are found. 4. Compressor should now be running "on load" and delivering compressed air. th 4. the system should always be re-purged. This must to be carefully monitored.record at 15 minute intervals.record at 15 minute intervals. Stage Temperatures . Open stop valve in delivery line to gas receiver. Compare pressure and temperature readings with those figures given in Section 1. the whole system must be purged free of air in accordance with the purging procedure which apply to the whole plant.4 PURGING THE COMPRESSOR READY FOR NATURAL GAS When gas is being compressed and its purity is important. the compressor should be run to prove operation. Restart compressor and continue with run. Close manual drain valve at 4th stage separator drain reconnect pipe. Check for air leaks by using soapy water. stop compressor isolate supplies and rectify. Condensate drain valves operate for approximately 5-10 seconds after every 10 . oil and water leaks. checking rotation of compressor is correct.doc 04/09/02 Page 27 . stop compressor. Purging with Gas Vent nitrogen from vent system by opening the filtration isolation valve ISOL 62 and venting nitrogen from the recovery vessel ISOL 07 ensuring a small positive pressure is kept in the system. expel gas into the recovery vessel via ISOL63. If the downstream equipment has been purged with nitrogen then it should be vented to a small positive pressure. The filtration will be pressurised before the pressure-maintaining valve PCV 61 opens. Purge nitrogen through until air is displaced by checking with an oxygen meter at the delivery purge valve. COMPRESSOR MAINTENANCE Releasing gas To isolate compressor close DDV and recovery vessel valves ISOL 09 and ISOL 08. ISOL02. Open recovery vessel drain ISOL 07 until gas is sensed and then vent from delivery purge valve PGE 61. Vent gas from compressor purge valve PGE 02. Open recovery vessel valve ISOL08 and compressor inlet purge valve PGE02. Note for rectification when compressor is stopped any slight gas. PURGING PRIOR TO INITIAL START-UP Purging with Nitrogen Connect nitrogen to the inlet purge valve PGE01. Check motor bearings are not overheating. Repurging with gas Open compressor purge valve PGE 02 and DDV valve ISOL 09 until gas is present. Close inlet valve ISOL01. Close compressor inlet purge valve PGE 02 and open delivery purge valve PGE 61. Most of the compressor system should now be filled with nitrogen. Close DDV valve ISOL 09 and open recovery vessel valve ISOL 08 and purge gas to PGE 02. 4. The filtration isolation valve ISOL 62 should then be closed. Purge nitrogen through until air is displaced. This will allow gas to enter the system. Shut off nitrogen supply when complete. Abnormal readings must be reported and investigated. Open inlet gas isolating valve ISOL 01 and open inlet gas solenoid valve SOL 01 by switching vent valve inlet switch on starter to Hand. Check that no gas relief valve is operating continuously.5 ROUTINE ATTENTION WHILST RUNNING At two hourly intervals.doc 04/09/02 . If the downstream equipment needs to be purged with nitrogen then the compressor can be run by feeding nitrogen into the inlet vessel and maintaining the required inlet pressure. DDV valve ISOL09. Close PGE 02 and open DDV valve ISOL 09. Purge nitrogen through until air is displaced. This can be checked with an oxygen meter at the vent stack. the system must always be re-purged. Close recovery vessel valve ISOL 08 and open DDV valve ISOL 09 select manual operation on Control Panel and open Solenoid valve SOL01. Close Open compressor purge valve PGE 02 to expel the gas and then open delivery purge valve PGE 61 to vent remaining gas. FINAL COALESCER Releasing gas Close filtration isolation valve ISOL 62 & ISOL61. The compressor system should now be filled with gas. check pressure on gas and oil pressure gauges.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 28 After any maintenance or repairs have been carried out which involves dismantling and opening up gas containing parts. oil or water leaks. filtration isolation valve ISOL68 and purge valve PGE061. Ensure drains operate at approximately pre-set time interval. Page 28 1293-4. Run on AIR with the recommended oil. Listen for any unusual noises during first few minutes of run. allowing approximately 1/3 cc. if available. OR: Alternatively. Turn compressor over a few times by hand to ensure unrestricted rotation. fill jacket with PX10 water-displacing fluid and allow standing for 15 minutes before draining off. Ensure cooling system water is available. Check for oil and water leaks and rectify. 1293-4.7 PREPARATION FOR SPECIAL ENVIRONMENT No special preparations are required other than making sure that should the compressor operate in sub-zero temperatures. An excess of water in crankcase should be investigated. 4. Cut down the cooling water supply during this run so that the water outlet temperature is from 38°C to 49°C. isolate from electrical supply and. Open 4th stage. IMPORTANT: Do not pressurise jacket with air during this procedure. manual drain valve. Start compressor. bolts and other fastenings are tight. and attach a warning label to this effect. if air is not available.6 STOPPING PROCEDURE When compressor has been stopped. disconnect the water supply and drain off the water. pipework (or sea water/fresh water heat exchanger when fitted). adequate precautions must be taken to ensure water is not allowed to freeze in the compressor water jackets. Insert PX4 into each cylinder.9. EITHER: Dry out the water jackets with compressed air. Check that no gas safety valve opens continuously. Rectify any gas leaks noted while compressor was running. Remove and clean compressor valves and wipe out any moisture in valve pockets and passages. Replace valves carefully and coat valve covers with PX4. Close 4th stage. Run the compressor for 30 minutes on light load with the final delivery pipe disconnected and with all separators open.doc 04/09/02 Page 29 . Close off stop valve on discharge line to relieve gas reservoir back pressure from compressor non-return valve. Immerse valve units in PX4 fluid and allow surplus to drain off. Insert air hose at water outlet connection and pass air through jackets until water ceases to flow from water inlet connection. After approximately two hours remove drain plug from sump and drain off any water which may have accumulated. 4. Replenish oil where necessary. manual drain valve. 4. turn off the cooling water. Ensure separator drains operate at approximately 10-30 minute at pre-set intervals. Coat all surfaces and gas passages.9 INHIBITION FOR STORAGE RUNNING ON AIR 4. After 30 minutes stop the compressor. Seal all screw openings with threaded plastic or metal caps and flanged openings with PX4 . Check associated and external pipework is intact and adequately supported. Check gas pressure gauges. of fluid to each square inch of cylinder surface area. by means of stop button on control panel.8 STARTING AFTER LONG PERIOD OF IDLENESS Check that all-external nuts. Do not drain oil.1 INHIBITION FOR UP TO SIX MONTHS Disconnect compressor from the GAS system.coating shims clamped between the flanges.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 29 4. OR: Alternatively. displacing fluid and allow standing for 15 minutes before draining off. of fluid to each square inch of cylinder surface area.2 LONG TERM STORAGE Check that the compressor has been run on AIR with the recommended oil. Turn the compressor round by hand to ensure that the running gear is free. (When completed. rotating the compressor lowly by hand. turn off the cooling water. Page 30 1293-4.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 30 4. a six-monthly inspection is to be carried out as follows. Remove and clean compressor valves and wipe out any moisture in valve pockets and passages. (When completed.) Replace the crankcase doors. Drain oil from the sump. preferably while still warm. Seal flanged openings with PX4 . disconnect the water supply and drain off the water. Note: PX4 Inhibition Fluid . Coat all surfaces and gas passages. allowing approximately 1/3 cc. if air is not available. Check that all openings are still sealed. After 30 minutes stop the compressor. Immerse valve units in PX4 fluid and allow surplus to drain off. fill jacket with PX10 water. Inspect the machine for signs of corrosion and carefully remove any rust that has formed.doc 04/09/02 . of the cylinder air passages. Cut down the cooling water supply during this run so that the water outlet temperature is from 38°C to 49°C. valves and crankcase doors. Insert PX4 into each cylinder. Remove the valve covers. pistons should be in mid-stroke position in readiness for inhibition of cylinders etc.Trade Name Crodafluid PQ11. EITHER: Dry out the water jackets with compressed air. IMPORTANT: Do not pressurise jacket with air during this procedure. Insert PX4 into each cylinder. if available. remove the crankcase doors and coat running gear and crankcase with PX4 using spray gun. including bottom surface. Attach instruction label "DO NOT ROTATE THIS MACHINE" For any compressor which is in storage for a long period.) Replace crankcase doors. Coat all surfaces. Run the compressor for 30 minutes on light load with the final delivery pipe disconnected and with all separators open. Coat the valve covers with PX4 and replace the valves and valve covers. and till to normal level with PX4 fluid.9. Insert air hose at water outlet connection and pass air through jackets until water ceases to flow from water inlet connection.coating shims clamped between the flanges and attach a warning label to this effect. Immerse valves in PX4 fluid and allow surplus to drain off. If it is impossible to run the compressor. rotating compressor slowly by hand. Seal all screwed openings with threaded plastic or metal caps and tape afterwards. pistons should be in mid-stroke position in readiness for inhibition of cylinders etc. allowing approximately 1/3 cc of fluid to each square inch of cylinder surface area. Replace valves carefully and coat valve covers with PX4. Coat the running gear and crankcase with PX4 using a spray gun. and flow rate are correct. COMPRESSOR GAS INLET AND OUTLET VALVES CLOSED AND VISIBLE WARNING NOTICES DISPLAYED.doc 04/09/02 Page 31 . 1293-4. Before investigating a potential fault. Following is a list covering the probably causes of operational faults. temperature rise across the machine. first examine those parts disturbed during the service.10 FAULT GUIDE WARNING 1. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 31 4. If fault appears immediately or shortly after a service. BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED ISOLATED ELECTRICALLY AND MECHANICALLY. together with the suggested remedies. Compressor servicing is up to date. Electrical supply is correct. Direction of rotation is correct. NOTE: A safety valve opening indicates excessive pressure and under NO CIRCUMSTANCES must a safety valve be screwed down to accommodate excessive pressure. 2. Sump is correctly filled. ensure however that: Cooling water temperature. If safety valve opens or appears faulty shut down compressor immediately and investigate. first examine those parts disturbed during the service. THIS IS DANGEROUS. If fault appears immediately or shortly after a service. but check for correct assembly malfunction. ! Renew diaphragm and valves in the DDVs. ‘Blowby’ noted from oil breather pipe. top pressure. 4 stage concentric valve springs th and/or plates or replace 4 stage valve complete. rd 3 stage safety valve blowing 2 stage safety valve blowing 1 stage safety valve blowing st nd Recommendation(s) ! Renew final pressure switch or re-adjust top pressure cut-out point.3 LOW COMPRESSOR OUTPUT ? Verify pipework bore is large enough. nd Check. DO NOT ADJUST SAFETY blowing. th ! 4 stage relief valve blowing new Installations - Check. th Page 32 1293-4. Check stage safety valve operation.10. Check stage safety valve operation. Check stage safety valve operation. ! Check that operating gas pipework is not damaged (or blocked at 1st stage separator end). Ensure any Uni-directional flow valve is fitted the right way round. th ! 4 stage relief valve blowing incorrectly set or re-assembled items. valves not closing.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 32 Ref. ! Check solenoid valve is operating correctly and Unloader / drain the DDVs seat properly. ! Renew diaphragm and valves in the DDVs. Intake filter dirty or ! Check intake Filter element – if dirty – renew element. 2 and 1 . ! Check solenoid valve is operating correctly and Does not reach the DDVs seat properly. blocked. ! Check and renew inlet filter element Low output due to ! Check for Piston ring leakage – ‘blow-by’ – th check final (4 ) stage piston rings for wear cylinder/piston rd nd st then progressively 3 .doc 04/09/02 . ring wear. rd Check. Compressor valve ! 1st stage gas valve.2 FAILS TO REACH ‘TOP’ PRESSURE ? ? ? ? ? 4. 2 stage concentric valve springs nd and/or plates or replace 2 stage valve complete.10. has a minimum of bends at the largest possible radius. Electrical fault. ! ! ! ? ? 4.1 Symptom ? RELIEF/SAFETY VALVE(S) BLOWING ? ? ? ? th Fault 4 stage relief valve blowing final pressure switch not cutting out. and condition or for leak from plates/springs in all stage gas valves. 3 stage concentric valve springs rd and/or plates or replace 3 stage valve complete. Check setting of downstream system valves. Check stage safety valve operation.10. 4. ! Check safety valve is not faulty and replace if Safety valve not serviceable. ! Check that operating gas pipework is not damaged (or blocked at 1st stage separator end). VALVES ! Check pressure switch setting. suction valve most likely to need attention. Examine condition of water circuit. reduced cooling efficiency Water pump faulty or drive slipping Insufficient water flow Incorrect siting. Resite unit to give correct cooling air flow.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 33 Ref.10. Renew oil filter. 4. Renew pump. ! ! ! ! ! ! ? ! ! ! ! ! ! ! ! ! ! ? ! ! ! ! ! ? ! ! Recommendation(s) Check switch.doc 04/09/02 Page 33 . Check oil level . adjust drive belt tension.6 OVERHEATING ? Incorrect grade of lubricant. ? 3 stage High gas temperature switch operating. Check condition of valves and gas passageways. 4.10.4 Symptom STOPS SUDDENLY ? Fault Low oil pressure switch operating. 4.replenish sump oil after removing any condensate in sump. clean and refill crankcase with correct grade of lubricant. Clean matrix and flush out tubes.5 WILL NOT START Electrical fault. Renew oil pump Check if Bearings worn – replace as necessary Check switch Check cooling water exit temperature does not exceed 50°C ( 122°F) Check cooling water temperature rise is 10-12°C ( 21°F) Remove 4th stage cooler coil assembly. replace and add inhibitor. low oil pressure switch Check via bell-housing inspection cover compressor free to turn by hand Check fuses within starter Check wiring connections to motor terminal Check continuity in motor windings Drain. Clean exterior of tubes and remove any sludge. Check cooling water exit temperature does not exceed 50°C ( 122°F) Check cooling water temperature rise is 10-12°C ( 21°F) Check safety valves are not faulty and replace if not serviceable. DO NOT ADJUST SAFETY VALVES Remove 3rd stage cooler assemblies.10. Check power to starter Check for previous STOP fault condition – high gas temperature switches. Clean exterior of tubes and remove any sludge. remove any sludge or scale build-up. insufficient cooling air flow Radiator blocked ! ! ! ! ! 1293-4. Check & clean oil strainer.7 OVERHEATING RADIATOR SET ? ? ? ? Insufficient water flow. Contaminated water. Check switch & setting.10. Final High gas temperature switch operating. rd 4. ! ! ! ! 4.10.10.13 PREMATURE WEAR ? ? Faulty pipeline intake filter Incorrect grade of lubricant ! ! Check Top Dead Centre clearance.11 UNUSUAL NOISE (UNLOADED) ? ? ! ! 4. Page 34 1293-4.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 34 Ref.8 Symptom LOW OIL PRESSURE ? ? ? ? ? Fault Oil filter blocked. Worn bearings Bearing end plate gasket distorted partially blocking suction port Loose pipe connections Loose B/E bearing bolts or incorrectly fitted bearings Motor overload set too low Insufficient electrical supply causing low voltage.10. Low inlet pressure switch operating.9 CUTS OUT ON START-UP ? ? ? ? ? ! ! ! ! ! ! ! ! Low oil pressure switch operating. Change to recommended lubricant. See fault 'LOW OIL PRESSURE' or reset timer. Check bearing clearances Examine gasket. Trace and rectify. 4. Check compressor pipework system is firmly secured. check supply. Trace. depressurise if safe to do so. position correctly. Insufficient gas flow. break glaze on cylinder walls if using existing cylinders Check to ensure filter is not damaged Change to recommended lubricant. replace if necessary. Consult qualified electrician.12 HIGH OIL CONSUMPTION ? ? Incorrect grade of lubricant Piston rings/cylinder worn or damaged ! ! 4. Excess gas pressure in supply line.10. ? 4.doc 04/09/02 . Trace and rectify Examine and re-tighten to correct torque. stop compressor. Extend timer period to suit. rumbling or slapping. cylinders and rings. Piston knocking Compressor set-up or pipework system vibration. adjust as necessary.10 UNUSUAL NOISE (ON LOAD) ? ? ? High inlet pressure switch operating. Check for wear and renew as necessary. check pressure reducing valve setting. When renewing piston rings. Full speed should be attained by Star before switching to Delta. renew seal. Check clearances and renew as necessary. Loose components Gas leaks (usually hissing or whistling Worn bearings. Timed delay by-passing switch in starter set incorrectly. Consult qualified electrician.usually heavy knocking. Star/Delta timer ! ! ! Recommendation(s) Fit new oil filter element.10. 4. check clearances and alignment of couplings and tension of vee belts.10. 14 HIGH INLET PRESSURE SWITCH TRIPS 4. Incorrect setting or faulty temperature switch Insufficient cooling. Vehicle filling line failure.10.10. ? ! Check function of dispenser valves. overhaul as necessary.10. Incorrect setting of pressure maintaining valve.17 4.15 LOW INLET PRESSURE SWITCH TRIPS ? ? ? ? ? ? ? ? ? 4.10. Reset to correct value. Leaking suction valve in following stage Insufficient cooling.10. ! ! ! ! Recommendation(s) Check function and setting of valve and switch Remove and check condition of valve.22 FINAL DELIVERY SAFETY VALVE BLOWING DISPENSER PRESSURE SWITCH TRIPS Reset to correct value. 4. Incorrect setting of pressure maintaining valve. Incorrect setting or faulty temperature switch Failure of non-return or pressure maintaining valve Restriction in delivery line. Faulty inlet solenoid valve Inlet gas filter blocked Time delay by-passing switch in starter set incorrectly. 1293-4. Check supply and consult gas company Check function and settings of valves and switch. overhaul or replace as necessary.21 4. Check function of valves. Incorrect setting or faulty high inlet pressure switch. Symptom ? ? Fault Incorrect setting or faulty pressure reducing valve. Leaking fourth stage suction valve.10. overhaul as necessary. Check cooling system. Remove and check condition of valve. clean and check pipeline. Check cooling system. Check function and setting of switch.16 4. Remove and check condition of valve.10. Check function and setting of switch.doc 04/09/02 Page 35 . Check and clean pipeline.20 4. GAS SYSTEM 4.19 FINAL DELIVERY TEMPERATURE SWITCH TRIPS FINAL STAGE SAFETY VALVE BLOWING ? ? ? ? ? ? ! ! ! ! ! ! ! ! ! ! ! ! ! Fit new filter element Adjust as necessary 4.18 INLET SAFETY VALVE BLOWING INTERSTAGE SAFETY VALVE BLOWING THIRD STAGE TEMPERATURE SWITCH TRIPS Check function and setting of switch.10. or pressure switch Leaking 1st stage compressor suction valve Main gas supply failure Incorrect setting or faulty pressure reducing valve or pressure switch.10.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 35 Ref. open manual vent valves and purge system. Water pump failure.10.doc 04/09/02 .10. Bursting disc rupture ! Recommendation(s) Get qualified electrician to check compressor motor circuits. Due to excess pressure .24 INSUFFICIENT COOLING ! ! ! ! ? Gas in cooling system Radiator sets Check condition of water pump and overhaul as necessary. Due to fatigue . Symptom ? ? ? ? Fault Short circuit.renew parts. ELECTRIC MOTOR 4. Page 36 1293-4. topping up with coolant as necessary.23 MOTOR PROTECTION SWITCHES TRIP COOLING SYSTEM 4. Remove header tank filler cap.check condition of coolers and overhaul as necessary.CompAir UK Ltd PUBLICATION 98407/1293 Section 4 Page 36 Ref. Thermal overload thermistor trip. 4.6 5.45 FIRST STAGE VALVE REASSEMBLY -----------------------------------------------.4 5.1.1.5.45 ROUTINE VALVE REPLACEMENT ---------------------------------------------------.7 5.47 SERVICING SCARIFICAL ANODE (CORROSION RODS) ---------------------.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 37 SECTION 5 CONTENTS MAINTENANCE AND REPAIR 5.1 5.47 MAINTENANCE OF NON-RETURN VALVE ----------------------------------------.2 5.4.8 5.45 THIRD STAGE VALVE REASSEMBLY-----------------------------------------------.44 ROUTINE CLEANING VALVE UNITS ------------------------------------------------.44 ROUTINE CLEANING AND INSPECTION .2 5.4.3 MAINTENANCE PAGE 41 GENERAL------------------------------------------------------------------------------------.47 MAINTENANCE OF SOLENOID VALVE---------------------------------------------.6 5.5.5.5.2.41 DAILY -----------------------------------------------------------------------------------------.47 MAINTENANCE OF OIL PRESSURE SWITCH ------------------------------------.5 5.9 COMPRESSOR PROTECTION PAGE 47 ` SERVICING BURSTING DISC ---------------------------------------------------------.7 5.41 WEEKLY--------------------------------------------------------------------------------------.2 5.3 5.4.4.1 5.5.46 5.1 MAINTENANCE PERIODS – SERVICE (HOURS) PAGE 43 COMPRESSOR UNIT----------------------------------------------------------------------.41 5.2 AFTER THE FIRST 100 HOURS & A MAJOR OVERHAUL 5.46 FOURTH STAGE VALVE REASSEMBLY -------------------------------------------.47 SAFETY VALVES --------------------------------------------------------------------------.47 MAINTENANCE OF HIGH GAS TEMPERATURE SWITCH --------------------.5.1 PAGE 42 RUNNING-IN FOR FIRST 100 HOURS-----------------------------------------------.4.4 5.47 OIL FILTER ----------------------------------------------------------------------------------.4 5.3 5.5 5.4.8 5.3 5.5.1 5.3.4.5 5.1.43 5.5.9 SERVICING STAGE VALVES PAGE 44 GENERAL------------------------------------------------------------------------------------.42 5.47 GAS INTAKE FILTER/SILENCER -----------------------------------------------------.4.5.44 ROUTINE VALVE REMOVAL AND SERVICING ----------------------------------.1 5.45 SECOND STAGE VALVE REASSEMBLY -------------------------------------------.doc 04/09/02 Page 37 .47 1293-5.ALL STAGES----------------------. CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 38 Page 38 1293-5.doc 04/09/02 . 3 THIRD & FOURTH STAGE------------------------------------------------.50 5.15 OIL PUMP--------.50 5.50 DIAPHRAGM DRAIN VALVES ----------------------------------------------------------.10 5.11.---------------------------------------------------------------------------.6.6 5.612.4 5.6.6.6.11.50 FLYWHEEL .6 5.BELT DRIVE -----.6. VEE BELTS & MOTOR PULLEY .5 5.6.6.6.49 CYLINDER LINERS 5.3 5.9 5.6.1 FIRST STAGE ----------------------------------------------------------------.DIRECT DRIVE-----------------------------------------------------------.7 5.48 st nd 1 & 2 STAGE COOLER TUBESTACK ---------------------------------------------.13 5.12.50 FLYWHEEL/PULLEY.48 CRANKSHAFT ------------------------------------------------------------------------------.2 SECOND STAGE ------------------------------------------------------------.12 5.6.50 1293-5.6.6.12.1 5.6.11 COMPRESSOR MAINTENANCE PAGE 48 5.doc 04/09/02 Page 39 .2 5.1 FIRST STAGE ----------------------------------------------------------------.48 TH 4 STAGE COOLER COIL --------------------------------------------------------------.49 SMALL-END BEARING -------------------------------------------------------------------.6.6.2 SECOND STAGE ------------------------------------------------------------.6.14 5.6.49 INTER-STAGE PISTON & RINGS 5.6.48 PRESSURE GAUGES---------------------------------------------------------------------.3 THIRD & FOURTH STAGE------------------------------------------------.11.49 5.49 BIG-END BEARING ------------------------------------------------------------------------.6.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 39 5.49 GUDGEON PIN -----------------------------------------------------------------------------.49 MAIN-END BEARING----------------------------------------------------------------------.6.48 RD 3 STAGE COOLER COIL --------------------------------------------------------------.8 5.49 5. doc 04/09/02 .CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 40 Page 40 1293-5. Note: An O&M manual must cater for a wide variety of operating duties. Flush out water passages either with high-pressure water or steam cleaning. seals and joints – fit new! Grease O rings used for all ‘dry’ joints in contact gas.1 5.3 WEEKLY Check bursting disc for signs of cracking. rectify as necessary. Trace cause of contamination. Crankcase oil contamination is often accompanied by increase in sight glass oil level. oil used in a log against hour’s run. rectify. gas or water leaks. and fit new oil filter and refill crankcase with recommended oil. It may be found advantageous or desirable to vary the maintenance periods depending on operating conditions and experience. 5.e. Use a liberal smear of silicone for all O rings st nd used in possible contact with the cooling water. remove carbon deposits by gently tapping and scraping. oil pressure and temperatures. Do not re-use O rings. 5. If emulsification takes place the oil must be changed and the crankcase cleaned.1.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 41 SECTION 5 MAINTENANCE AND REPAIR WARNING BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED ISOLATED ELECTRICALLY AND MECHANICALLY. condensate may be drained from below the oil by means on the drain plug. Examine oil in crankcase and ensure that it is not contaminated with condensate. Check correct operation of all controls. Where practical. Clean thoroughly all oil-ways and carefully blow clean using compressed air. as two separate liquids. The oil level should be replenished accordingly with clean oil.2 DAILY Check oil level in crankcase and top up as necessary. oil level indicator and must be rectified immediately.1 MAINTENANCE GENERAL It is useful to record stage pressure. Depending on the degree of contamination. 1293-5. cooler assemblies.1. COMPRESSOR GAS INLET AND OUTLET VALVES CLOSED AND VISIBLE WARNING NOTICES DISPLAYED. ambient conditions and methods of control. as this builds up a detailed record of machine condition. The following maintenance schedules are only a recommended guide to maintenance periods. 5. Lightly grease or oil all surfaces of ferrous components after cleaning to prevent rusting.1. Check stage pressures. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE SUPPLY AND STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF. due to oil being supported by condensate fluid. I. taking care not to remove metal. Check for oil. If moisture forms without emulsification.doc 04/09/02 Page 41 . the oil may appear emulsified (creamy in colour) especially if the recommended lubricant is not used. This condition is usually visible through the sight glass. 1 and 2 stage ‘wet’ cylinder liners. It can also provide a trend and indication of a possible problem. temperatures. 2.4) Clean suction and delivery valves. Clean oil suction strainer. clean sump & refill with recommended synthetic oil * (see SECTION 1. Replace crankcase doors and refill crankcase to correct levels with recommended synthetic oil.2. METHOD Drain the oil completely from compressor whilst the oil remains warm. All components on these compressors are compatible with the recommended synthetic oil but as problems may exist with downstream ancillary equipment. passageway pipes and separators.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 42 5. replace oil filter.doc 04/09/02 . thoroughly clean and refit all suction and delivery valves. When inspecting valves. Remove crankcase doors and thoroughly clean interior of the crankcase.READ MAINTENANCE WARNING BEFORE COMMENCING Drain sump. Page 42 1293-5. also remove as far as is possible any carbon deposit in valve pockets.2 AFTER THE FIRST 100 HOURS & AFTER MAJOR OVERHAUL 5. the equipment manufacturer should be consulted. Renew oil filter. Remove.1 RUNNING IN FOR FIRST 100 HOURS . 5 1.NG 0.2 and then above service hours and after 18000.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 43 5.READ MAINTENANCE WARNING BEFORE COMMENCING Service Hours ( x 1000) R-5437. 1293-5.5 3 4.5 9* 18 Component Synthetic Oil Gas inlet Filter C C R C R C R R Sump Oil R R R R Sump Oil Filter R R R R R R R Motor Drive Coupling C C C C C Gas passages and valve covers C C C Diaphragm Drain valve & seats O O O Drain valve diaphragm R R R Water passages within Coolers C C C Corrosion Rods I I R Bursting Disc R R R 1st Stage Piston Rings I I 2nd Stage Piston Rings R R 3rd Stage Piston Rings R R R 4th Stage Piston Rings R R R R 1st Stage Piston & Bore IR IR 2nd Stage Piston & Liner IR IR 3rd Stage Piston R R R 4th Stage Piston R R R 1st Stage Cooler Tubes C IR IR 2nd Stage Cooler Tubes C IR IR 3rd Stage Cooler Tubes C IR IR 4th Stage Cooler Tubes C IR IR 1st Stage Small End bearing & gudgeon pin IR IR 2nd Stage Small End bearing & gudgeon pin R R 3rd Stage Small End bearing & gudgeon pin R R 4th Stage Small End bearing & gudgeon pin R R Big-end bearings IR IR Crankshaft C C Main-end bearings & Thrust Washer C C Oil Pump C C Oil Pump Drive C C Crankshaft Oil Seal IR IR Pressure Gauges T T Temperature Gauge/Switch Controllers T T Safety Valves T T Low Oil Pressure Switch T T Non-Return Valve ‘O’ Ring R R R C Check NK New Kit (plates & springs) I Inspect IR Inspect & Replace as necessary O Overhaul R Replace T Test TC Test & Calibrate *After 9000 hour overhaul repeat Section 5.doc 04/09/02 Page 43 . COMPRESSOR UNIT.1.5 6 7.3 MAINTENANCE PERIODS AND SERVICE HOURS AFTER THE FIRST 100 HOURS. g. blunt instrument. Rotate crankshaft by hand until relevant stage piston is at top dead centre. WARNING: Great care should be taken when removing carbon deposits to ensure that the seating faces of the valve components are not damaged.5 3.0 7.4.4 SERVICING COMPRESSOR STAGE VALVES SEE SECTION 6 FOR ILLUSTRATIONS. remove valve assemblies. A gentle rocking action pulling at the same time will free the valve from any carbon build up in the pocket. the order in which these components are removed should be carefully noted so that the valves may be reassembled with the same seating faces in contact. e.1 GENERAL Valve maintenance is a simple procedure but the following guidelines should be observed: Keep a spare oiled and maintained set of valve units in store for quick compressor servicing.5 C NK NK 1. Remove valve covers nuts. If the seats show severe wear or indentations. Valve plates and springs must always be replaced at recommended life periods. 5.2 Service Hours ( x 1000) 4. warped. a piece of wood. Use forcing screws to remove valve covers. regardless of appearance. to achieve maximum reliability.4. when removed. Carefully wipe any loose carbon from valve pocket ensuring that no carbon is left in valve pocket or on top of the piston.5 6. or have wear grooves which exceed 10% of the plate thickness.0 NK NK R R 18. Move valve to a workbench and remove central nut from valve unit. cracked. the complete valve assembly must be renewed. The remaining components should be checked for cracks. with no evidence of uneven contact.0 9. Valves.3 Page 44 1293-5. noting very carefully their relative positions to the body and each other if they are to be re-used. Remove valve plates and springs. Using the special valve lifting tools. may have only a thin carbon layer and be slightly moist with oil. ROUTINE VALVE REMOVAL AND SERVICING Valve removal is as follows for all stages: (Special tools that are available from CompAir UK Ltd Ipswich will assist in valve removal) Clean all grease and dirt from valve covers and surrounding areas. Note: Unless replacement of the springs and plates is intended.doc 04/09/02 .ALL STAGES May be removed scraping with a soft.4. These faces should be clean and bright over their whole area. distortion or other damage liable to impair the valve operation.READ MAINTENANCE WARNING BEFORE COMMENCING 5. with unit on a level surface. Renew any plates which are indented. lift off upper body. VALVES SYNTHETIC OIL st 1 Stage Valve nd 2 Stage Valve rd 3 Stage Valve th 4 Stage Valve C Check I Inspect O Overhaul T Test 5. Carefully separate upper and lower bodies and.0 R R R R C C C NK R R NK New Kit ( plates & springs) IR Inspect & Replace as necessary R Replace TC Test & Calibrate C NK ROUTINE CLEANING AND INSPECTION .CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 44 5. CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 45 5. dismantle. If satisfactory tighten to the correct torque. If all components are located correctly upper and lower bodies will contact. relocate misplaced part and reassemble. Place suction valve seat (1) onto assembly. and the surrounding area is clean before replacing valve assembly.7 1293-5. NEVER reverse plates / springs as this will lead to rapid failure. tighten these nuts sequentially in 27Nm (37 lb. position spring plates (3) to located over pegs (9) with bridging strip resting between pegs and springs facing upwards. Renew "O" rings. Ensure "O" ring (11) is secure in slot in upper valve body. Reassemble valve plates and springs exactly as dismantled. lightly greasing before fitting. There should be at least a 2mm (0. springs facing downwards. ensuring inner (8) and outer pegs (9) engage correctly. Again check valve cover for cleanliness before assembly. Place delivery valve springs (3) onto valve / backing plate having first positioned them as follows: Assemble the delivery plate springs (3) in pairs.4. SECOND STAGE VALVE REASSEMBLY. Screw nut (12) on stud and hand tighten only at this stage.SECTION 6 PAGE 69 Place delivery valve seat (8) face downwards on suitable metal ring or protected open vice jaws with locating peg (7) uppermost and position valve plate (6) to locate over peg (7). Fit spring plates (5) onto valve plate. dismantle. If plates are not free. ensuring concentricity on centre hole.80”) gap between the top of cylinder and bottom of valve cover. This is facilitated by gently pushing a small diameter plastic or nylon rod through the ports in the valve to check plates for freedom.6 5.4. Test for correct operation by ensuring free movement of suction and delivery valve plates. rotating one spring in each pair until the inner and outer circumferences are matched perfectly. If plates are not free.doc 04/09/02 Page 45 . If assembly has been carried out correctly. ROUTINE VALVE REPLACEMENT Recheck that valve / valve pocket. The seating faces of each valve plate and body half should be clean and bright with all round. Screw nut (10) on stud and hand tighten only at this stage. Section 5. Ensure "O" ring (9) is secure in slot in upper valve body. check again for free movement of plates before tightening to the correct torque. Place valve plate (2) on spring plates and then after ensuring concentricity place suction valve seat (1) onto assembly. Place valve plate (2) onto spring plate.2 Always renew valve plates and springs in complete sets. 5. Put lower lift washer (7) onto locating pegs. Sequentially tighten cover fasteners evenly to 75% and then 100% the correct torque. Test for correct operation by ensuring free movement of suction and delivery valve plates. Place valve spring plates (4) onto locating pegs (8) with springs pointing downwards. Hold the two springs together with the concave faces facing each other and then rotate one pair until edges touch all round the circumference and there is a constant gap around the inner edge. top of piston. Ensure valve seats properly as a slight misfit will entail loss of gas. locating them on peg (7). Follow this with valve backing plate (4). except for fourth stage valve cover. Place valve plate (6) onto locating pegs (8).5. even contact and be free from indentations. relocate misplaced part and assemble.4.All stages".ft) steps to the correct torque.5 5.4. upper and lower body faces will contact. This is facilitated by gently pushing a small diameter plastic or nylon rod through the ports in the valve to check plates for freedom. If satisfactory tighten to the correct torque.4 ROUTINE VALVE CLEANING Completely clean all components as detailed in "Cleaning and Inspection . checking again for free movement of plates before tightening to the correct torque. FIRST STAGE VALVE REASSEMBLY .SECTION 6 PAGE 68 Place delivery valve seat (10) face downwards on suitable metal ring. Place middle lift washer (7) over hole. or protected open vice jaws with locating pegs uppermost. Any item with indentations will require renewal. located as above. DO NOT FORCE. Centralise the plates and springs. relocate misplaced part and reassemble. Fit central body (8) over stud and lower until locating hole engages with peg in lower body. together with delivery plate (5). Carefully push two valve body sections (8 & 13) together until in full and firm contact. ensuring that the hole in central body engages with peg in upper body. however. arranged as shown.doc 04/09/02 . If the sections will not locate correctly: separate and re-align to plates and springs.4. Ensure "O" ring (8) is secure in slot in upper valve body. If centre section will not locate correctly with upper body: remove and re-align plates and springs. When correctly located and tighten and fit new O ring (3). THIRD STAGE VALVE REASSEMBLY. Fit plate (11) in the valve recess followed by spring plates (10). positions delivery valve seat (7) face downwards and insert valve plate (6) followed by three spring rings (5) bowed two against one as shown. if plates are not free. With the central (8) and lower body (12) held firmly together. If satisfactory tighten to correct torque. Page 46 1293-5. remove from the vice and fit washer (2) and nut (1) and tighten to correct torque. dismantle.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 46 5.SECTION 6 PAGE 71 Place valve body (13) on a clean flat surface with stud (12) uppermost. hand tighten only at this stage.4 5.4. and suction valve plate (9). Ensuring that all components are correctly located and held firmly together. place lower body (1) and centre stud through assembly. Follow this with valve backing plate (4). This is facilitated by gently pushing a small diameter plastic or nylon rod through the ports in the valve to check plates for freedom. turn upside down and pass stud through hole in upper body (4). Fit plate (7) into recess followed by spring plates (6). Press together and ensure edges of upper and lower body contact then place washer (9) over stud. Place delivery valve springs (3) onto valve / backing plate having first positioned them as follows: Assemble the delivery plate springs (3) in pairs. 5. screws on nut (10).8 SERVICING COMPRESSOR STAGE VALVES CONT. Invert upper body (4) and hole in a soft jawed vice or similar. DO NOT FORCE TOGETHER. arranged as shown. checking for free movement of plates before tightening to the correct torque. Test for correct operation by ensuring free movement of suction and delivery valve plates.9 FOURTH STAGE VALVE REASSEMBLY. rotating one spring in each pair until the inner and outer circumferences are matched perfectly.SECTION 6 PAGE 70 Using suitable metal ring or open protected vice jaws. Follow up with valve plate (2) and when satisfied all components are correctly aligned. Hold the two pairs of springs together with the concave faces facing each other and then rotate one pair until their edges touch all round the circumference and there is a constant gap around the inner edge. 5 5. by unscrewing anti-clockwise. If faulty. SAFETY NOTE: ONLY USE GENUINE REPLACEMENT DISCS 5. renew.5.2 SERVICING SACRIFICIAL ANODE (CORROSION ROD) SEE SECTION 6 PAGE 79 Every 500 hours or monthly drain the water from cylinder blocks and remove the anodes.7 SERVICING NON-RETURN VALVE None. lightly oil sealing ring before fitting. renew.5.5. Tighten hand tight . DO NOT listen or look directly at discharge ports. renew. Check for leaks on restart. 2. If faulty. DO NOT ATTEMPT REPAIR. 5. 5.5. Brush or blow out dust and dirt from suction silencer.4 MAINTENANCE OF OIL PRESSURE SWITCH None. Reassemble in the correct order and tighten screws evenly to the correct torque.doc 04/09/02 Page 47 . 3. spin-on type. 5. Renew faulty valves. If seriously corroded.5. Replace paper element. adjust or repair.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 47 5. A simple method is to fit a balloon (or similar) over the discharge. Gasket Bursting Disk Bursting Disk Cover Plastic Metal Before refitting ensure the radiused edges of the cylinder hole and cover are smooth and have no burrs or corrosion.5.3 SAFETY VALVES do not attempt to dismantle. renew. If faulty. Fit new spin-on filter. 5.5.9 OIL FILTER Remove filter. 1293-5. With machine running at or near maximum pressure ensure valves are not leaking significantly.5. If faulty.1 SERVICING COMPRESSOR PROTECTION SERVICING BURSTING DISCS SEE SECTION 6 PAGE 52 1.5 MAINTENANCE OF HIGH GAS TEMPERATURE SWITCHES None. renew. 5.8 GAS INTAKE FILTER / SILENCER Remove gas filter element from unit.6 MAINTENANCE OF SOLENOID VALVE None. 5.5. 5. Cylinder 4. Replace gas filter element into unit ensuring it sits firmly on the seal. A very slight leakage of gas is quite normal. Support weight of crankshaft using lifting tackle or blocks. Fit new oil seal and thrust washer to driving end bearing housing and install housing. If airflow through tube coil is restricted. Inspect for corrosion and hydrostatically test and replace as necessary Fit new "O" ring seals. 5. smear cooler end covers 'O' rings and cooler body bore with silicone sealant. remove cooler cover from outer-end withdraw using TOOL C203734. or there is any doubt to internal cleanliness. Remove all pipes from the crankshaft interior. Page 48 1293-5. Push the cooler assembly through body. Check freedom of rotation of shaft and correct end float. Loosen screws holding clamp rings. remove large circlip from outer-end withdraw using TOOL C203734.2 FIRST & SECOND STAGE COOLER TUBESTACK SEE SECTION 6 PAGE 63 & 77 Remove cooler end cover and separator from non drive-end.6 CRANKSHAFT Remove crankcase doors and remove all big end caps. silicone and fit 'O' rings to drive end only. Note: Silicone sealant should be applied to "O" ring seals fitted on third and fourth stage cooler coil assemblies and cooler bores before inserting these in respective cooler blocks. Insert crankshaft to bearing housing. remove separator. Ensure all journals of crankshaft are clean and free from burrs and oil all surfaces. Fit new "O" ring seals to cooler end covers. Refit to body.6. Remove three corrosion rods (anodes) from cylinder block. Inspect for corrosion and hydrostatically test and replace as necessary To refit smear cooler end covers and cooler body bore with silicone sealant. fits new thrust washers at outer-end bearing housing and install housing to crankcase.1 Wash and brush down exterior of tubes.5 PRESSURE GAUGES SEE SECTION 6 PAGE 53 Remove gauge panel complete with gauges. renew complete assembly. Inspect for corrosion and hydrostatically test and replace as necessary.6. nd Remove from drive-end 2 stage separator (remove separator cover to gain access to all studs). Send gauges for calibration on dead-weight tester. Prise out and discard oil seal.6.6 MAINTENANCE ~ COMPRESSOR 5.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 48 5. after releasing pressure gauge tail nuts. Remove main-bearing housing screws at driving end and main bearing housing. If airflow through tube coil is restricted.6. or there is any doubt to internal cleanliness. 5. Fit gasket and then finish assembly.1 Remove outer shroud tube. silicone and fit 'O' rings and then push in flush with body. studded end first.1 Remove outer shroud tube. then remove cover and clean excess silicone from face. This is a brazed assembly containing high pressure! th Disconnect 4 stage inlet pipe. This is a brazed assembly containing high pressure! rd Disconnect 3 stage inlet pipe. Fit outer end cover without gasket. baffle plates and clean water passages.4 FOURTH STAGE COOLER COIL SEE SECTION 6 PAGE 64 & 77 DO NOT ATTEMPT to remove cooler coil assembly end fittings. st nd Remove and withdraw combined cooler tubestack for 1 and 2 stage from driving end using tool C203733. tighten bolts.3 THIRD STAGE COOLER COIL SEE SECTION 6 PAGE 63 & 77 DO NOT ATTEMPT to remove cooler coil assembly end fittings. 5.6. If crankshaft journals or thrust faces are scored oval or worn below limits: renew shaft. push through further until non drive end 'O' ring grooves are exposed. Wash and brush down exterior of tubes and clean cylinder block water passages. Wash and brush down exterior of tubes and clean cylinder block water passages. To renew.1 OIL PUMP SEE SECTION 6 PAGE 48 & 49 If the pump is in anyway unsatisfactory – replace. 5. Carefully remove crankshaft through driving end of crankcase. 5.6.doc 04/09/02 . remove gauges. renew complete assembly. Remove main-end bearing housing screws at outer end and remove housing. Undo piston-retaining capscrew. SMALL-END BEARINGS st Note: The 1 stage bearing is a plain bush.1 complete upwards from valve opening. If there is detectable movement of the piston or crosshead at 90° to its normal plane of movement of the conn-rod. This is quite normal and does not indicate a fault in the bearing or the need for shell replacement.6. rd 1293-5. If satisfactory refit big end bearings.1 Measure and replace rings. Carefully lower the complete line through the bore. steel backed shell type. Note the needle rollers may dislodge from their holder when dismantling. Withdraw piston ( cartridge) from crosshead using TOOL C203704. ensuring identity numbers are adjacent and facing upwards. Measure crankshaft journals in two positions at 90° for each big end. Note: The big end bearings fitted to the connecting rods are of the aluminium / tin line overlay. care must be taken when refitting gudgeon pin.6. NOT a rolling contact needle roller bearing. the complete bearing must be replaced. Remove valve and valve covers. Check pins for any ‘flaking’ of the surface. SERVICNG INTERSTAGE PISTON & RINGS st 1 Piston & Ring removal See Section 6 pages 50. Place piston ring compressor into valve pocket and oil well. Oil surface of cylinder liner and piston before re-assembly. It is important to note that due to the bedding process. Refit big-end bearing and conn-rod caps. If any one dimension is below the minimum given in Section 1. Measure and replace rings. Undo big-end bearing cap from conn-rod.6 SERVICING ~ COMPRESSOR CONT. Replace all O rings for valve cover and coat with silicone grease 2 nd 5. Coat bottom face of liner & 'O' rings with silicon sealent.6.7 MAIN-END BEARINGS Use a hydraulic press to remove old bearings from bearing housings. renew if worn or flaking of surface is evident.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 49 5. When rings are engaged.10 5. 66 & 76) Remove valve and valve covers. which occurs during running-in.6. Ensure the gaps for new rings are staggered.MEASURING BEARING CLEARANCES Remove crankcase doors and remove all big end caps. Torque piston capscrew to correct value. Do not rotate piston.doc 04/09/02 Page 49 .11 stage Piston & Ring removal See Section 6 pages 50.8 5.4 it is recommended the compressor be overhauled. and tighten to correct torque setting. that the aluminium / tin overlay will be removed in the areas of highest load exposing the underlying copper based bearing material. GUDGEON PINS Remove circlips and gently drift out all gudgeon pins. Do NOT merely fit new bearing shells. Carefully lower the complete line through the bore. Replace all O rings for valve cover and coat with silicone grease.9 5. Oil cylinder liner bore and piston before re-assembly. 65 & 74 Remove valve and valve covers. remove compressor and refit big-end bearing and conn-rod caps. After initial bedding in to this level the bearing will show no significant further change for several thousand hours.THIS IS CRITICAL. When aluminium / tin lining overlay has been removed from an area greater than 90% of the bearing surface of either top or bottom half bearing shell. remove and discard the gudgeon pin and needle roller bearing.and tighten to correct torque setting. st 1 piston line removes using TOOL C 200223. on an underlying copper based bearing material. Undo big-end bearing cap from conn-rod.6. Withdraw liner and piston line using TOOL C200223. Do not rotate piston. 65 & 75 Ensure water is drained from cylinder block.1 Measure and replace rings. Fit piston into liner. th 3 and 4 Piston & Ring removal See Section 6 pages 51. 5. BIG-END BEARINGS . at the bottom and again near the top. BELTS & MOTOR PULLEY (Belt Drive) Remove vee belt.12 SERVICING INTERSTAGE CYLINDER LINERS Ensure water is drained from cylinder blocks.CompAir UK Ltd PUBLICATION 98407/1293 Section 5 Page 50 Stagger piston ring gaps and liberally oil surface of cylinder liner and piston before re-assembly. FLYWHEEL (Direct Drive) Remove motor complete with bell housing and half coupling Remove compressor half coupling. The valves cannot be effectively refurbished if re-lapping of seats is insufficient to restore valve seating. Withdraw liner using TOOL C203718. the valve seats may now be tapped out of the body halves if they are to be renewed. withdraw complete.6. 3 and 4 stages See Section 6 pages 51.6. For motor pulley. Checks that the relative position of outlets. 59.DO NOT hammer liners in place. 60 74 & 75 Remove valve and valve covers.1 complete upwards from valve opening. separator pipe and pilot gas connections are all-correct.15 Page 50 1293-5. 62 & 76 Remove valve and valve covers. Replace all O rings. Support flywheel and release from the crankshaft taper. Tighten all six screws sequentially. Replace as necessary using least possible force . 5. renew. Withdraw piston (cartridge) from crosshead using TOOL C203704. ease back tab washer and remove keep bolt.040”) width. If the valve seat has been worn to more than approximately 1mm (0.1. Otherwise leave in-situ. where ring wear will be greatest. 61.6 SERVICING ~ COMPRESSOR CONT. Replace all O rings and coat with silicone sealant. De-glaze liner bore by light honing if fitting new rings into existing liners. rd th 5.14 5. A withdrawing tool may be required.6. 5. Support flywheel and release from the crankshaft taper. st nd 1 and 2 stages. Loosen the motor holding down bolts. After removing pipe fittings and locknuts. The cap screws retaining the mushroom plates to the valve can now be removed it the valves are to be renewed. Withdraw liner-using TOOL as shown in diagram C203705. release taperlock bush screws. See Section 6 pages 50.1 Measure liner bore in two positions. Remove flywheel and key. Measure liner bore in two positions. Reassemble units with three screws each end finger tight only. ease back tab washer and remove keep bolt. FLYWHEEL/PULLEY. at the bottom and again near the top. 5. where ring wear will be greatest. Discard diaphragm and joints. keep plate and tab washer.doc 04/09/02 . Replace all O rings and coat with silicone grease. keep plate and tab washer. 72 & 73 Remove the three screws at each end of the units and pull bodies apart from the cover. Undo piston-retaining capscrew. A withdrawing tool may be required. Piston lines remove using TOOL C 200223. Undo big-end bearing cap from conn-rod. Use thread sealant between the valve seats and body halves and the cap screws securing the mushroom plates to the valves. Otherwise leave in-situ.13 DIAPHRAGM DRAIN VALVE UNITS SEE SECTION 6 PAGES 54. securing bolt hole.6. Remove flywheel and key. Using vee drive tensioning bolts slacken and then remove vee belts To remove compressor half coupling. Inspect valves and discard if there is any significant wear. E61640 BEARING HOUSING ASSEMBLY OUTER-END .D101723 OIL PUMP DRIVE ASSEMBLY BEARING HOUSING ASSEMBLY DRIVE-END – D101752 ND RUNNING GEAR PARTS 2 STAGE – D101750 RD RUNNING GEAR PARTS 3 STAGE – D101751 TH RUNNING GEAR PARTS 4 STAGE – D101760 CRANKSHAFT ASSEMBLY – D66397 ST ND CYLINDER PARTS 1 & 2 STAGE – E61641 ST ND COOLER PARTS 1 & 2 STAGE – D101725 ST ND TUBESTACK ASSEMBLY 1 & 2 STAGE – E61533 SEPARATOR COVER D101764 RD TH CYLINDER PARTS 3 & 4 STAGE – E61642 RD COOLER COIL ASSEMBLY 3 STAGE – D101609 RD COOLER PARTS 3 STAGE – D101726 TH COOLER COIL ASSEMBLY 4 STAGE – D101610 TH COOLER PARTS 4 STAGE – D101727 CORROSION ROD SET – C203868 BURSTING DISCS – C201658.2 ND LINER/VALVE PARTS 2 STAGE – D101729 RD LINER/VALVE PARTS 3 STAGE – D101730 TH LINER/VALVE PARTS 4 STAGE – D101731 TEMPERATURE SWITCHES RELIEF VALVES NON-RETURN VALVE PIPE ASSEMBLIES SERVICE TOOLS VALVE UNITS . The assemblies have been chosen based on the experience gained by our own Parts and Service Departments. Ipswich.ALL DIAPHRAGM DRAIN VALVE UNITS . * IF FITTED . are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd.H-5437. LIST 1 3 3 4 5 5 5 6 7 8 8 8 9 10 10 11 11 12 13 14 14 14 18 19 20 21 22 23 24 PAGE PARTS ILLUSTR 52 70 52 70 52 66 53 70 53 67 53 68 54 68 54 69 54 61/62 54 65 55 65 55 55 63/64 55 65 55 65 56 65 56 65 56 82 56 56 62 56 63 56 64 56 57 57 57 57 77/80 71/74 71/74 75/76 75/76 77/78 77/78 79/80 79/80 81 82 83 84 1293-6. and the information given is in no way binding on the manufacturers.1.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 51 SECTION 6 CONTENTS BUILD .ALL ST ND 1 2 STAGE VALVE & LINER REMOVEL RD TH 3 & 4 STAGE VALVE. The letters indicate than an item is available as a component of an assembly. Non-listed or individual items of assemblies where reference number are not indicated. without notice. PISTON & LINER REMOVAL COOLING WATER PATH CORROSION ROD POSITIONS MAINTENANCE OVERHAUL JOINT KITS MAINTENANCE SERVICE PARTS & KITS NOTE: Standard parts are available where indicated by either a number or letters. The right is reserved to modify the contents of this list. AS THE THRUST WASHERS ARE NOW OBSOLETE.GAS COMMON ILLUSTRATIONS & PARTS LIST CRANKCASE ASSEMBLY .LATER COMPRESSORS HAVE A MODIFIED MAIN BEARING BUSH.doc Page 51 . Plug 3/4" BSP Plug 3/4" BSPT Rivet Rokut Nameplate serial Setscrew Setscrew Setscrew Capscrew Nut M8 Nut M16 rd th ‘O’-ring – 3 .outer.13 3.155 98262.4 95000.oil pump to cover Bush Outer end cover Joint .5 PS1454.1154 98660.1 RP513 95000.2 D54109.16 3.9 3.7 1.doc . 3. 1.11 1.17 Description.6 1.1 3.5 1.25 1.16 1.2 D100234 D100354 PS1068.27 1.o.1156 A30051.end bearing cover Joint .1155 98660.1042 Part Number.1132 98281.1002 98381. Main bearing housing O/E parts Bearing housing Joint .2 3.11 3.7 3.8. 1 1 1 1 1 1 3 1 10 1 2 2 2 1 1 1 1 SPARE PART • • • # # # # # # • • # # # # # # SPARE PART • • # # # • Page 52 1293-6.274 95111.3 1.3 3.26 1.2 PS1454.9 1.20 1.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 52 Item No.8 1.8.17 1. Crankcase parts Door Door Breather cover Breather retaining plate Joint – breather cover Joint .4 stg. 1 3 1 1 2 1 4 2 2 12 1 2 2 1 6 40 16 2 2 12 2 2 1 1 1 2 1 1 1 1 1 1 1 Number OFF.256 95000.2# D100809.5 95111.314 95018.256 95000.1 1.19 1.14 1.o.2 98524.4 3.c/case door Joint – filler to c/case Stud M8 x 20 s.28 Number OFF.8 3.366 98074.2 stg.29 1.4 1.255 95000.6 3.1009 98660.69 PS1068.22 1.24 1.15 1.16.1 D100809. Body to c/case st nd ‘O’-ring – 1 .31 Item No.outer end bearing housing Plug Plug 3/4" BSPT Setscrew Setscrew Setscrew Dowel Thrust washer IF FITTED* SEE NOTE Oil filter Seal Oil pump assembly Stud Part Number.1004 98262.9 95602.14 3.10 1.1.15 3.228 95000.10 3.5 3.21 1. E61640 LIST 1 C201802 C203270 C201815 C201816 C201819 C201821 C201829 D54109.6 PS2189. Stud M16 x 45 s.2 1. Body to c/case Breather Element Oil Level Gauge Oil Level Label Seal Seal Seal ¾" BSP Crankcase supplied with parts # Suction oil pipe assembly Oil service pipe assembly Oil feed pipe assembly Low oil pressure switch Description.28 1.18 1.149 95602.13 1.23 1.1013 98660.1 D100973.1153 C85737.28 D66720.1 1.12 1.30 1.257 95502.12 3. D101723 LIST 3 E60010 C200869 C200900 C85736. 7 5.1022 96076. 1 1 1 4 1 2 1 1 1 1 1 SPARE PART # # # # # # # # # # # SPARE PART • ¥ ¥ ¥ ¥ ¥ SPARE PART • ¥ ¥ ¥ • ¥ 1293-6.1129 D101745 C203684 98086.4 4.6 4.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 53 3.8 4.8 5.2.3.22 3.110 C203986 95527.5 5.1001 Part Number. D101750 LIST 5 C201109 C203984 D101743 D101744 95650.3. Running gear 2nd stage Bearings B/E Gudgeon pin Connecting Rod.3.9 4.3.-piston ring.2 5.10 4. 1 1 1 1 1 4 1 1 2 1 1 1 Number OFF.11 Item No.9 5. D101752 LIST 4 C203296 C202992 C203129 D100353 95440. Running gear 3rd stage Bearings B/E Gudgeon pin Connecting Rod.3.3.2.18 3.8.doc Page 53 .21 3.50 95000.312 95405.5 T6495.11 Stud Nut Copper washer Cover Plate 'O' Ring Setscrew M6 X 16lg Description.1 5.1004 98150.19 3.3 4.1022 96076.2. Rings – third stage Circlips – gudgeon pin Small end bearing Crosshead supplied with parts ‡ rd Piston – 3 stage supplied with parts ¥ Retaining bolt – piston Spacer for small bearing Spirol pin Ø4mm x 22 lg D66720.6 5.96 2 3 10 1 1 4 Number OFF.2.227 95018.1 4.5 5.3.3 5.3.1060 98477.20 3. 2 stage Spacer for small end bearing Spirol pin Ø4mm x 22 lg Description.1061 PS1159.96 Part Number.5 4. D101751 LIST 5 C201109 C203984 D101743 PS1159.2.10 5.2.3.3. 5.7 5.2.4 5.6 5. Bearing Housing Assy D/E Bearing housing Bush Bracket Joint – drive end bearing housing Coupling Setscrew M6 x 12 Capscrew M5 Socket female 1/8" BSP Thrust washer IF FITTED* SEE NOTE Pipe clip Banjo Pipe M5 Description. 2 stage nd Ring .1129 98477.23 Item No.10 5.8 5.28 95000.9 5. 2 stage nd Ring – Oil control ring.42 95111.2 4.108 95650.228 Part Number.56 C203648 95602.3. 5.11 Item No.2 5.3 5. 1 1 1 1 1 2 1 1 1 1 1 Number OFF.2.2.7 4.2. 4 4.4 5.1 5.1462 98617. nd Piston – 2 stage supplied with parts ¥ Circlips – gudgeon pin Small end bearing nd Ring – Piston ring.1001 98074.2.1035 98156.1028 C203986 95527. 10.315 E61521 E61519 D101601 C203697 C203698 C203699 Number OFF.96 C203986 Part Number.6 8.2 7.doc .12.160 D66720. LIST 6 C11359-44 C11359-45 C75163.3 5.75 D66720.7 5.o.84 95000.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 54 Item No.6 7. Circlips – gudgeon pin Small end bearing Piston ring th Piston – 4 stage supplied with parts ¥ Retaining bolt – piston Spirol pin Ø4mm x 22 lg Spacer S/E bearing Description.4. 8.6 5.1.3 D66397 PS1130.312 95111. Gasket Nut M10 Description. Running gear 4th stage Bearings B/E Gudgeon pin Connecting Rod. Cylinder parts 1st & 2nd stage Stud M10 x 60 s.7 Description.o. Stud M10 x 97 s.4.10.1143 C203685 98086.1.7 95242.5 5. Cooler parts 1st & 2nd stage Screw M12 x 35 First stage separator cover.10 Item No.6 Part Number.1 6.4. 1 1 1 2 2 6 1 1 1 1 Number OFF.10 7.2 A30200 D66720.3 6.4.4.21 Part Number.4 8. Second stage separator st nd Joint – 1 & 2 stage separator Gasket 2nd stage separator Gasket 1st stage separator Gasket 2nd stage separator Part Number. 1 1 1 1 1 Number OFF.7 7.4 6. 7. Crankshaft Keep plate Tab washer Setscrew 3/4-16 unf x 1 1/2 LG Crankshaft supplied with parts # Key Description.1.62 95111.12 Item No. D101760 LIST 5 C201109 C203984 D101743 95650. E61641 LIST 7 D66720.1 7.1.4. 8 1 1 1 1 1 1 SPARE PART • ¥ ¥ ¥ • ¥ ¥ ¥ SPARE PART # # # # SPARE PART SPARE PART Page 54 1293-6.1022 96076. 6.1 5. 5.4 5.3 7.1028 95527.1. Stud M12 X 40 Stud M20 X 45 Screw M12 x 20 Nut M20 Nut M12 M16 eyebolt st nd 1 and 2 stage cylinder body Stud M10 x 145 s.58 D66720.5 Item No.11 95111.4. 2 4 4 4 4 4 2 1 12 7 1 20 Number OFF.16.5 7.3 8.9 7.4.112 C11359.11 7.1.2 5.1129 98477.4.8 7.1 8.9 5.1.10.4 7. D101725 LIST 8 95000.4.2 8.5 8.o.2 6.8 5. 3 8.110 C200796.2.31 Number OFF. 1 1 Number OFF.9 9.4 10. 1 Number OFF. Cylinder parts 3rd & 4th stage Bursting disc cover Pocket thermometer Gasket Stud M8 X 45 s.2. Tube plate Baffle plate Baffle plate Rod spacer Stud M10 x 165 s.7 9.6 PS1322.8 Description.75 95111. Tubestack assembly 1st & 2nd stage Stud M10 x 60 s.160 D66720. Description.2.1033 E61522 D66720.2.4 8.o.2.10.2 8.10.2.13 9. D101764 D101764 Part Number.74 D66720.10 9. 10.6 8.94 95440.5 8. 1 1 2 3 4 4 4 4 4 3 8 2 1 1 Number OFF.180 95602.6 9.60 E61525 D100598 D100599 C203692 D66720. 'O' ring.2.2 Item No.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 55 Item No.2.1 9. D101609 LIST 10 D101586 D101629 Part Number.o.3 10.3 Item No.2.10.6 98148.o Stud M16 X 50 s. Stud M10 x 45 s. E61642 LIST 9 C200584 C201708 C81788 D100171.9 95242.11 8.61 D66720.9 8.o.3 9.7 10.16.6 10. 7 24 36 1 5 8 1 3 3 3 4 4 31 14 Number OFF. Separator 3rd stage Circlip retaining 'O' ring.8 95000. E61533 LIST 8 D66720.13 8.1110 95602. 2nd stage separator cover. 9.2 98660.8 8.4 9.16.2. Tension pin.2.14 Item No.o Stud M16 X 60 s.1156 A30201 Part Number. Cooler parts 3rd stage 'O' ring.o.1 10.7 8.14 Item No.1031 Part Number.o Plug 1" BSP Dowty seal 1" BSP Setscrew M10 Nut M8 Nut M16 Eyebolts Seal ¾" BSP Body 3rd & 4th Description.12 8. 8. 10.12 9.2.10 8. 'O' ring Cooler tube 1st & 2nd stage Cooler tube starfin Description.10. 2 2 1 1 1 1 SPARE PART SPARE PART SPARE PART SPARE PART SPARE PART 1293-6.5 10. Cooler coil assembly 3rd stage Shroud outer Tube stack Description.285 E61517 95650. 8.11 9. Nut M10 Circlip Tube plate Stud M10 x 145 s. Part Number.8 9.91 95602.1 8.5 9.2.5 98617. D101726 LIST 10 95602.doc Page 55 .2.84 PS1068.2 9.282 95111.5 95111.8. 1 14. Locating lugs Fitting Setscrew M8 Capscrew M10 Description.4. 13. 1 1 8 SPARE PART SPARE PART SPARE PART SPARE PART SPARE PART SPARE PART SPARE PART SPARE PART Page 56 1293-6.1 13.6 14.1 12.doc .2 14.1112 C203686 C203680 98504.1106 C203687 98504.386 Number OFF. 11.1386 C203681 98504.87 95602. D101730 LIST 14 98504.1 14.100 95602.2. 2 1 1 2 2 Number OFF.7 Item No.1105 98504. 14.melinex Description. Cooler parts 4th stage 'O' ring.8 18.4.141 95602.2 14. 11. 'O' ring 'O' ring Liner 'O' ring Valve cover 'O' ring Description. Corrosion rod.3 14. Temperature switch .1090 98504.Final stage Button head screws Part Number.6 Item No. Liner/valve cover parts 4th stage Back up ring.3 14.2 Item No.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 56 Item No. D101729 LIST 14 D100604 D100005 95602. Liner/valve cover parts 3rd stage Back up ring. 4 4 Number OFF.4. 1 1 Number OFF. 'O' ring.4.2.4.5 Item No. Tube outer Description. C203868 LIST 12 C203869 C203870 Part Number.9 Description.2.2. D101731 LIST 14 98504.3. Description.1 95034.3.88 C203809 C203849 95000. 1 1 1 2 2 2 Number OFF.1 11.2. 14.3.1.2.2 C84735.3 11.5 14. 12.140 95602. LIST 13 C201658.2.1385 98504. 2 2 2 1 4 2 Number OFF.6 Item No. Cooler coil assembly 4th stage Tube stack.1387 Part Number. Liner/valve cover parts 2nd stage Valve cover Liner 'O' ring 'O' ring 'O' ring 'O' ring Description.3.4.5 11.3.8 C202960. 18.2 14.98 Part Number.230 Part Number. D101610 LIST 11 D101630 C202949 Part Number.2 `Item No.2.1 Part Number.1.3 14.262 95018.4 14.2. D101727 LIST 11 95602.1384 Part Number.4 14. Corrosion rod set Corrosion rod. Bursting discs Bursting disc Bursting disc . Liner Valve cover 'O' ring 'O' ring Description.2. 1 1 1 1 1 1 2 Number OFF.3rd stage Temperature switch . 1 1 Number OFF.4.4 14.2.1 14.2.7 18.5 14.2 Item No.4 11.2 11. LIST18 C202556.1 11. 14. 5 19.3 19. LIST 20 C82148 PS1322.1 C203706 C203740 C203705 C203739 Number OFF. 2 3 3 1 1 1 Number OFF. 2 1 1 1 1 1 SPARE PART SPARE PART SPARE PART SPARE PART ex ex ex 1293-6. Description.1022-150 98650.1020-10 Part Number. Pipe assemblies Pipe assembly .3 20.2 20. LIST 22 C200066.4 Item No. Non return valves Union Seal Dowty Non return valve Banjo Coupling ½" BSP Description. LIST19 95405.2690 98156.3 ex ex ex Description. LIST 21 C203858 Part Number.4 98650.doc Page 57 . Elbow – male/female Connector Swivel nut adaptor Safety valve 3rd stage Safety valve 2nd stage Safety valve 1st stage Description.4th stage.1655 98156. 1 2 1 1 Number OFF.1st stage Valve lifter . 22.2 22.1 22.1 20.54 98156.1st & 2nd stage valve Valve/piston lifter st nd 1 & 2 stage special tool assembly rd th 3 & 4 stage special tool assembly Special Tool Assembly – all coolers Part Number. 1 Number OFF.1 Item No. Tools Valve lifter .6 Item No.3200 98650.1021-40 98650.2 19. 19.1 19.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 57 Item No. 21.4 19.1455 Part Number.1 C84096. 20. doc .4 nd Safety valve 2 stage LIST 7 & 14 LIST 18 LIST 19.6 17.1 Safety valve Surge vessel LIST 16 17.5 LIST 17 LIST 12 LIST 2 Optional Water Pump (if fitted) OIL LEVEL GAUGE LIST 1 LIST 3 LIST 3 OIL DRAIN PLUG Page 58 1293-6.2 st Safety valve 1 stage LIST 12 LIST 7 & 14 LIST 3 LIST 1 LIST 4 LIST 19.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 58 LIST 19. CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 59 1ST & 4TH STAGE CYLINDERS 1 ST LIST 8 ND & 2 STAGE 4 TH LIST 11 STAGE 4 TH LIST 9 STAGE 1 ST LIST 7 STAGE 1293-6.doc Page 59 CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 60 2ND & 3RD STAGE CYLINDERS LIST 10 RD 3 STAGE 3 RD 1 ST LIST 8 ND & 2 STAGE LIST 7 STAGE LIST 9 STAGE 2 ND Page 60 1293-6.doc CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 61 1ST STAGE CYLINDER PARTS 14.1.1 14.1.5 15.1 7.2 7.6 14.1.4 14.1.2 14.1.3 5.1.1 5.1.3 5.1.6 5.1.8 5.1.7 5.1.4 1293-6.doc Page 61 2.2.7 5.8 Page 62 1293-6.6 5.2.2.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 62 2ND STAGE CYLINDER PARTS 7.2.4 14.4 5.5 14.2.2 14.2.doc .2.6 5.2.5 5.3 14.2 14.3 7.2.2 5.2.1 15.2.5 14. 7 5.3.3.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 63 3RD STAGE CYLINDER PARTS 14.3.3 4.3.5 5.5 9.3.2 5.9 15.3.4 5.8 5.3.4 9.1 4.5 5.doc Page 63 .3.3.3.6 14.2 1293-6.3 14.11 5.3.3. 8 5.4 14.7 14.4.4.4.2 14.4 5.4.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 64 4TH STAGE CYLINDER PARTS 15.2 5.4.4 5.4.3 14.6 14.7 5.4.4.7 5.4.4.4.4.1 Section 7 5.6 14.4.1 14.doc .5 Page 64 1293-6. 5 4 TH LIST 10 D101609 10.6 8.4 10.6 10.7 LIST 8 E61533 8.1.5 8.1.1 11.2.2 3 STAGE COOLER / SEPARATOR ASSEMBLY D101726 8.8 8.1.1.2.1.6 8.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 65 1 / 2 STAGE COOLER / SEPARATOR SECTION D101725 8.doc Page 65 .3 RD 8.3 10.2.2 1293-6.1 8.2.5 8.8 10.1 LIST 11 D101610 11.1.7 STAGE COOLER SECTION D101727 11.2.2.1 ST ND 8.2.1.4 10. 2 1.30 Page 66 1293-6.19 3.16 3.31 1.17 3.4 1.7 3.29 1.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 66 OIL PUMP DRIVE ASSEMBLY 3.9 3.18 3.29 1.12 3.3 3.14 1.3 3.21 1.16 3.12 1.16 3.10 3.18 3.13 1.20 3.5 3.2 3.doc .17 3.15 3.28 1.16 3. 8 5.6 5.2.2.4 5.3 FOR 1 STAGE SEE H5437.2.2 5.5 5.2.7 5.2.2.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 67 LIST 5 .NG BUILDS ST 1293-6.1.1ST & 2ND STAGE RUNNING GEAR 5.1 5.2.doc Page 67 .2. doc .4.3RD & 4TH STAGE RUNNING GEAR 5.4.5 5.3 5.4.4 5.3.3.3.4 5.7 5.3.1 5.1.4.3.3.8 5.6 5.3.2 5.4.7 5.6 5.4.4.1 Page 68 1293-6.9 5.3.2 SEE H5437.5 5.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 68 LIST 5 .4.8 5.3 5.3.NG BUILDS 5. CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 69 LIST 6 .5 5.4.CRANKSHAFT ASSEMBLY 5.3 5.3.3 6.2.4 6.doc Page 69 .3 6.3 5.1 6.1.2 1293-6.5 6. 2 2.6 3.7 1.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 70 LIST 1 CRANKCASE * Thrust Washers fitted to older machines are now obsolete.1 4.1 1.12 1. 4.26 1.4 1.11 1. New compressors have new type main bearing bush fitted with integral thrust washer.13 3. If a replacement part is required a new type main bearing bush may be supplied.15 2.14 1.doc .25 Page 70 1293-6.3 1.4 4.2 4 4.10 1.16 3.8 1.23 1.17 1.6 1.18 1.8 1.1 1.1 3.13 3.5 1.22 1.9 1.10 1. 1518 3 SPRING PLATE 98650.1518 1293-6. SERVICE KIT NUMBER 2 VALVE PLATE 98650. 10 SUCTION VALVE SEAT NOT AVAIL.1518 98650.1518 NOT AVAIL.1519 1 DELIVERY VALVE SEAT NOT AVAIL.1518 5 LIFT WASHER 98650.doc Page 71 .1518 98650.1518 4 SPRING PLATE 98650.1518 6 7 8 9 VALVE PLATE LIFT WASHER PEG PEG 98650.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 71 1ST STAGE VALVE 98650.93 NUT 98650. 11 12 'O' RING 95602. NOT AVAIL. doc .1533 95602.1533 SPRING PLATE 5 98650. PEG 7 NOT AVAIL.1533 98650.1533 BACKING PLATE 4 98650. SUCTION VALVE SEAT 8 98650.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 72 2ND STAGE VALVE 98650.1039 NOT AVAIL. DELIVERY VALVE SEAT 1 SERVICE KIT NUMBER 98650.55 'O' RING NUT 9 10 Page 72 1293-6.1533 SPRING PLATE 3 98650.1533 VALVE PLATE 2 98650.1533 VALVE PLATE 6 NOT AVAIL. 1059 5 SPRING PLATE 98650.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 73 3RD STAGE VALVE 98650.1059 98650.1059 4 BACKING PLATE 98650.1059 7 SUCTION VALVE SEAT NOT AVAIL.1049 1 DELIVERY VALVE SEAT NOT AVAIL.1059 1293-6. 8 9 10 ‘O’ RING 95604.1059 6 VALVE PLATE 98650. SERVICE KIT NUNBER 2 VALVE PLATE 98650.24 WASHER NUT 98650.1059 98650.doc Page 73 .1059 3 SPRING PLATE 98650. 2040 98650.15 98650.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 74 4TH STAGE VALVE 98650.doc . 3.2040 12 STUD NOT AVAIL.2040 4 VALVE BODY NOT AVAIL. 13 VALVE BODY NOT AVAIL PEG Page 74 1293-6.2040 6 SPRING PLATE 98650. NUT WASHER ‘O’ RING 95604.2040 98650.2040 98650. PEG 5 VALVE PLATE 98650.2040 8 SUCT & DELY BODY NOT AVAIL 9 10 11 VALVE PLATE SPRING PLATE BACKING PLATE 98650.2040 98650.2040 7 VALVE PLATE 98650.2037 SERVICE KIT NUMBER 1 2. doc Page 75 .CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 75 1ST & 2ND D.L 4 2 1 6 8 7 1 6 1 9 4 5 5 5 9 4 8 7 6 3 1 ITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION JOINT SEAT SEAT VALVE ASSY VALVE ASSY BODY ASSY LOCKNUT BOLT M6 X 75 DIAPHRAGM PART NO C200722 C200842 C201417 C201980 C201981 C203190.4 95006.V ASSEMBLY U334.D.1002 NO OFF 4 1 1 1 1 1 2 6 2 1293-6.1 PS1290.133 98210. 1002 NO OFF 4 1 1 1 2 6 2 Page 76 1293-6.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 76 3RD & 4TH D.doc .J 3 2 1 4 6 5 1 4 1 7 3 3 3 3 7 3 6 5 4 2 1 ITEM 1 2 3 4 5 6 7 DESCRIPTION JOINT VALVE SEAT VALVE ASSY BODY ASSY LOCKNUT BOLT M6 X 75 DIAPHRAGM PART NO C200722 C201159 C201981 C203190.1 PS1290.D.V ASSEMBLY U334.4 95006.133 98210. 1 C200223 95111.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 77 1ST STAGE ITEM 1 2 3 4 5 6 DESCRIPTION 1 STAGE VALVE LIFTER PISTON LIFTING TOOL M20 NUTS BAR STUD PLATE ST PART NO C200066.11 C203716 C203717 C203718 NO OFF 2 1 2 1 1 1 1 2 4 3 5 6 1293-6.doc Page 77 . 1 C200223 C203716 95111.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 78 2ND STAGE ITEM 1 2 3 4 5 DESCRIPTION ND 2 STAGE VALVE LIFTER PISTON LIFTER BAR M12 NUTS STUDS PART NO C84096.doc .7 C200421 NO OFF 1 1 1 2 2 1 4 2 3 5 Page 78 1293-6. 3 STAGE TH 6.doc Page 79 .9 C203738 C203736 C203737 NO OFF 1 1 1 2 1 1 3 1 2 VALVE REMOVAL 3 2 1 5. 4 STAGE RD PISTON REMOVAL 3 4 2 LINER REMOVAL 1293-6.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 79 3RD & 4TH STAGE VALVE. PISTON & LINER REMOVAL ITEM 1 2 3 4 5 6 DESCRIPTION VALVE / PISTON LIFTER PLATE M16 NUT WITHDRAWING SCREW RD GUIDE BLOCK – 3 STAGE TH GUIDE BLOCK – 4 STAGE PART NO C203706 C203704 95111. CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 80 1ST.1026 NO OFF 1 2 1 2 1 1 2 1 REMOVAL OF 1 4 ST /2 ND STAGE TUBESTACK 3 5 6 REMOVAL OF 3 4 RD STAGE TUBESTACK 3 5 6 REMOVAL OF 4 TH STAGE TUBESTACK Page 80 1293-6. 3RD & 4TH COOLER REMOVAL ITEM 1 2 3 4 5 6 DESCRIPTION WITHDRAWING PLATE SCREW M12 X 80 WITHDRAWING PLATE SCREW M10 X 80 ADAPTOR CIRCLIP PART NO C203733 95000.doc .294 C203735 95650. 2ND.324 C203734 95000. doc Page 81 .CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 81 WATER FLOW PATH DIAGRAM WATER INLET INLET THROTTLE VALVE PNEUMATIC WATER VALVE 4 TH STAGE COOLER 4 WATER DRAIN TH STAGE CYLINDER 3 RD STAGE CYLINDER 3 RD STAGE COOLER WATER DRAIN 1 ST STAGE CYLINDER WATER DRAIN 2 ND STAGE CYLINDER 1 ST &2 ND STAGE COOLER WATER OUTLET 1293-6. CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 82 CORROSION ROD ASSEMBLIES POSITIONS LIST 016 C203868 C203869 C203870 MAINTENANCE Replace ALL every 4500 hours. Page 82 1293-6.doc . 1155 98660. D.2 PS1322.98 95602.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 83 MAINTENANCE KITS Item No.1156 98660.doc Page 83 .1153 98660. Valve to surge vessel – Nylon Joint – Surge Vessel to crankcase st ‘O’ Ring – 1 stage liner st ‘O’ Ring – 1 stage liner st ‘O’ Ring – 1 stage valve cover nd ‘O’ Ring – 2 stage liner nd ‘O’ Ring – 2 stage liner nd ‘O’ Ring – 2 stage valve cover nd ‘O’ Ring – 2 stage valve cover rd ‘O’ Ring – 3 stage valve cover rd Back-up ring 3 stage valve cover rd ‘O’ Ring – 3 stage liner th Back-up ring 4 stage valve cover th ‘O’ Ring – 4 stage valve cover th ‘O’ Ring – 4 stage valve cover th ‘O’ Ring – 4 stage liner th Back-up ring 4 stage liner rd th ‘O’ Ring – 3 & 4 stage body to crankcase st nd ‘O’ Ring – 1 & 2 stage body to crankcase rd ‘O’ Ring – 3 stage cooler to separator rd ‘O’ Ring – 3 stage cooler rd ‘O’ Ring – 3 stage cooler th ‘O’ Ring – 4 stage cooler th ‘O’ Ring – 4 stage cooler to cover Dowty seal ¼” BSP Dowty seal ½” BSP Dowty seal ¾” BSP Seal – 1/4” BSP copper Seal – 3/8” BSP copper Seal – 1/2” BSP copper Seal – 3/4” BSP copper Seal – Pressure gauge copper Part Number. D.151 95602.1106 98504.1406.140 95602. 4 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 2 2 1 2 1 1 2 1 2 1 1 1 1 2 4 4 1 2 2 2 2 3 2 1 3 2 1 6 5 1293-6.1102 Number OFF.91 95602.1 C201488.6 98660.94 95602.1112 98504.87 95602.1090 98504.88 PS1322.1387 95602.1105 98504.100 95602.153 95602. Valve to surge vessel – Nylon Joint – D.31 95602. Overhaul Joint Kit Joint – Crankcase door Joint – Oil filler to crankcase Joint – D/E bearing housing to crankcase Joint – O/E bearing housing to crankcase Joint – O/E bearing cover to housing Joint – Oil pump to cover Joint – Breather cover Joint – Inlet connection nd Joint – 2 stage separator nd Joint – 2 stage separator st Joint – 1 stage separator st nd Joint – 1 & 2 stage separator Joint – D.1386 98504.1154 98660. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Description.2 C201820 95602. C201821 C201829 D100353 D100354 C200869 C200900 C201819 C11359-62 C203697 C203699 C203698 D101601 C201488.1385 98504.155 95602.141 98504.149 95602.4 PS1322. 98504.1384 98504.152 95602. 1 2 3 4 5 6 7 8 9 10 11 12 Item No.1086 98477.doc . 1 1 1 1 4 2 1 1 1 1 1 1 1 2 1 2 2 1 1 1 4 1 1 98650.CompAir UK Ltd PUBLICATION 98407/1293 Section 6 Page 84 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Description. Service Parts & Kits st 1 stage valve (Plates & springs) nd 2 stage valve (Plates & springs) rd 3 stage valve (Plates & springs) th 4 stage valve (Plates & springs) Diaphragm Drain Valves (Diaphragms & joints) Diaphragm Drain Valves (Valve overhaul) U334.1188 98262.1407.141 98504.1029 98262.1254 98262.1106 95602. 98504.2040 98650.1532 98262.1259 C203868 C201556.1090 98504.K Coalescer element 3rd stage No 1 st 1 stage piston rings nd 2 stage piston rings rd 3 stage piston rings th 4 stage piston rings Oil filter Oil Reavellite (synthetic) 20 litres Oil Reavellite (synthetic) 5 litres Oil Mineral (Mobil Rarus 427) 25 litres Oil Mineral (Shell Corena P100) 25 litres Coalescer element 3rd stage No 2 Coalescer element 4th stage No 1 Coalescer element 4th stage No 2 Seal kits for above Corrosion rod set Bursting disc kit Part Number.1009 98384.1085 98477. 2 1 1 2 1 1 1 1 1 1 1 1 Number OFF.153 95602.1258 98262.140 95602. Number OFF.1252 98477.1112 98504.1022 98384.93 95602.100 Page 84 1293-6.1087 98477.24 95604.1533 98650. Valve Maintenance ‘O’ ring Kit st ‘O’ Ring – 1 stage valve cover nd ‘O’ Ring – 2 stage valve cover nd ‘O’ Ring – 2 stage valve cover rd ‘O’ Ring – 3 stage valve cover rd Back-up ring 3 stage valve cover th Back-up ring 4 stage valve cover th ‘O’ Ring – 4 stage valve cover th ‘O’ Ring – 4 stage valve cover st ‘O’ Ring – 1 stage valve nd ‘O’ Ring – 2 stage valve rd ‘O’ Ring – 3 stage valve PTFE th ‘O’ Ring – 4 stage valve PTFE Description.1256 98262.1518 98650.1105 98504.1384 98504. 95602.20 Part Number.1001 98384.55 95604.1535 98650.1531 98650.1002 98384.1059 98650.J Diaphragm Drain Valves (Valve overhaul) U334. The letters indicate than an item is available as a component of an assembly.C204002 DRAIN SYSTEM PARTS .1. Ipswich. PAGE BUILD.C203297 CROSSHEAD .NG PARTS ILLUSTR 1 86 2 86 4 86 5 86 95 5 86 94 7 86 8 86 9 86 14 87 15 87 16 87 91 17 87 18 88 92 19 88 91 20 88 91 21 88/90 91/93 1293-7NG.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 85 SECTION 7 CONTENTS BUILD H5437. The right is reserved to modify the contents of this list.D101719 PLUGS & SEALS ST SEPARATOR 1 STAGE – E61518 PLUG AND SEAL LINER/VALVE COVER PARTS 1ST STAGE . The assemblies have been chosen based on the experience gained by our own Parts and Service Departments. and the information given is in no way binding on the manufacturers. Non-listed or individual items of assemblies where reference number are not indicated. are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd.NG ILLUSTRATIONS & PARTS LIST CRANKCASE OIL FILLER COMPLETE OIL SEAL ASSEMBLY D/E .D101728 STAGE CONCENTRIC VALVE UNITS INLET DAMPER PARTS .E61643 PRESSURE GAUGE PANEL PARTS SAFETY VALVES TH SEPARATOR ASSEMBLY 4 STAGE PIPE ASSEMBLIES NOTE: Standard parts are available where indicated by either a number or letters.D101745 ST RUNNING GEAR 1 STAGE . without notice.doc 04/09/02 Page 85 . Rod Circlips Oil control ring Piston ring Description.1 Item No.1.6 Item No.1.6 5. Part Number.95 98504. BUILD NG 7 PS1068. SPARE PART 8.1049 98477.1 9.7 5. # SPARE PART 9.1 D66376 D66395 95650.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 86 Item No. • ¥ ¥ ¥ ¥ SPARE PART # SPARE PART 5. 1 1 1 1 1 2 1 2 Number OFF.1. 1 Number OFF.3 5.3 7. BUILD NG 9 PS1068.1. SPARE PART 5. C203297 BUILD NG 4 95602.3 D66720.4 Item No.2 1.2 5.1. SPARE PART 4. Crankcase Socket-female Nipple Pressure gauge Swivel nut adaptor Union male Safety valve Description. Oil seal Assembly D/E 'O' ring Oil seal PTFE Oil seal plate Description. BUILD NG 2 U421-E Part Number.13 4.14 Item No.3 PS1322. D101719 BUILD NG 5 C200016 C201109 C85727. Separator 1st stage Setscrew Separator Cooler cover Description.797 98288. 1 2 1 Number OFF.1 Item No.1 8.1.1195 C203295 Part Number.1.30 98477. Crosshead Crosshead Description.10.1 5.2 8.160 Part number E61518 BUILD NG 8 95000. Fittings Plug Seal Dowty Stud M10 X 123 s.4 1. BUILD NG 1 95405.o Stud M10 X 170 s. 1 1 1 1 1 1 Number OFF.doc 04/09/02 . 1 Number OFF. Running gear parts 1 stage Bush – small end Bearing pairs Gudgeon pin Piston Con.3201 98156.10.3 PS1322.2 7. 1 1 SPARE PART 1.315 E61518 D101764 Part Number.1 Part Number.4 5.1 7.5 1. Oil filler Oil filler complete Description.2 Plug Seal Dowty Page 86 1293-7NG.o Description.112 D66720.3 1.2.1 1. 2 2 1 3 Number OFF.1086 98156.3 Item No.3 Number OFF.1059 Part Number. BUILD NG 5 D101745 Part Number.8 Item No.1. Description.1002 95405. 4 1 1 Number OFF. st SPARE PART 2.2136 98650.2088-2.5 5. 7.12 4. C204002 BUILD NG 16 PS1454.3201 98288. Gasket. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 Number OFF.1.2088-2.3 Swivel nut adaptor` Union male Safety valve 1293-7NG. 4 2 1 2 1 1 16 2 1 Number OFF.2.7 17.151 95602.1.2135 98650. 1 1 1 SPARE PART SPARE PART 15.8 Number OFF.4 17.5 Item No. D101728 BUILD NG 14 D100609 D100802 95602.4 16.1 PS1322. SPARE PART 16.3 16.1.2 15.5 16.1 17.2076 98650.3 14.2 C201820 D66720.10 16.9 16. Liner/valve cover parts 1st stage Valve cover Liner 'O' ring 'O' ring 'O' ring Description.1.8 16. 14.o Diaphragm drain valve 3rd & 4th stage Diaphragm drain valve 1st & 2nd stage Setscrew M8 Nut M8 Surge vessel cover Description.3201 98156.L 95000.8.1.2 17. SPARE PART 17.1127 98156.4 Item No.1 16. Valve units Valve unit 1st stage Valve unit 2nd stage Valve unit 3rd stage Valve unit 4th stage Description.3 17.3 15.5 C201804 Part Number. E61643 BUILD NG 17 C201488.2 14.1 15. BUILD NG 17 98156.12 16.153 Part Number.1 17. SPARE PART 17.1 14.2136 98650.1102 98660. Inlet damper parts Plug 3/8" BSP Nipple hex 1" BSP Bush hex 3/8" BSP Pressure gauge Pressure gauge washer Copper washer ¾" BSP Vessel pulsation Pressure Switch LOW Swivel nut adaptor Pressure gauge snubber Pressure Switch HIGH Union male Valve ball Valve safety Seal Dowty Description.1086 98660.7 16.2037 Part Number.1.1.1.256 95111.6 16.14 16.1039 98650.6 17.1.5 17. BUILD NG 15 98650.797 95405. Description.9 Item No.8 17.1 C201488.13 16.2.2 Part Number.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 87 Item No.1049 98650.1.15 Item No.102 U334.1128 98156.2.doc 04/09/02 Page 87 . Part Number. 1 1 1 2 2 Number OFF.1.2 16.2088-2. 1 1 1 1 Number OFF.2 17.1.J U334. Stud M8 X 90 s.1519 98650.11 16.1.1.4 14.152 95602.3 95405.851 98288.1164 98524.1156 A40424 98524. Washer nylon. Drain system parts Washer nylon. 1 21.1207 C204004 95602.1355-275 Part Number.1021 98288. Pipe assembly 4 Stage cooler inlet Seamless st/stl Male connector ‘O’ ring.1023 E46188 E61534 Part Number. SPARE PART 21.22 PS1322. D101619 BUILD NG 20 C73732. 1 1 1 1 1 SPARE PART 18.8 Item No. 1 1 1 1 1 1 1 Number OFF.doc 04/09/02 .1.1. SPARE PART 20.3896 Part Number.2 C203999. 1 Number OFF.6 21.3 C203999.2.4 21.5 21.4 21. Nipple 3/8” BSP .798 95414. Elbow Flow control valve Sleeve Nut Description.2 18.5 Item No.1022 98288.1.3881 98156.2.Pressure gauges 1 st Stage Pressure Gauge Pipe 2nd Stage Pressure Gauge Pipe 3 rd Stage Pressure Gauge Pipe 4 th Stage Pressure Gauge Pipe Oil Pressure Gauge Pipe th th Part Number.1 21. BUILD NG 19 98650.1 18.4 C203999.21. C203999 BUILD NG 21.2 20.3 95405.1 C203999.9 C203669 C203766 D101618 95018. 914 2 2 2 2 Number OFF.1 21.2. C203989 BUILD NG 21 M3201.1019 98288.1 20. Elbow . BUILD NG 18 98288.3881 98156.5 20.163 98156. C204005 BUILD NG.4 20. Pressure gauge panel parts Pressure gauge . SPARE PART 21.3 21.7 Item No. SPARE PART 19.243 Part Number. Pipe assembly breather Pipe .6 18.3 20.1 Item No.5 18. Nipple hex .2 21.1 M3089.2.1.2nd stage Pressure gauge . Sleeve o-lok Nut o-lok Description.2 C203999. 300 1 1 1 2 1 2 2 Number OFF.7 21.2 21.1209 95405.3rd stage Pressure gauge . Pipe assembly . Safety valves Safety valve 4th stage Description. SPARE PART 21.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 88 Item No.3954 C203466 98156.5 Page 88 1293-7NG.5 Number OFF.4 18.oil Pressure gauge .3 18. Description.4 21.3896 Part Number.1.1st stage Pressure gauge .2 21.2.5 Item No.3 21. Separator assembly 4 stage Plug Seal-dowty Swirl fitting th Body 4 stage separator Top fitting Cap screw Description.3 21.4th stage Gauge panel label Gauge panel Description.10 98156. 1 2 1 1 1 2 Number OFF.1020 98288. 3898 98156. Pipe assembly .1005 98156.4.3919 98156.3.9 21.4.3.3895 98156.4056 98156.2 21.3 21.6.3.3 21.4120 98156. 762 1 1 2 2 SPARE PART SPARE PART SPARE PART SPARE PART 1293-7NG.3949 98156.6 M3090.4 21.DDV control Nut Male connector Elbow Sleeve Tee Body cap Swivel connector Seamless st/stl Description.5.4127 98156.3878 Part Number.5 21.8 C73732.1071 M3089.0805 M3090.3963 98156.4120 98156. 21.14 21.6.1st & 2nd stage separator drains Pipe st/st Pipe st/st Socket female Nut Nut Male connector Elbow Male connector Nut Sleeve Elbow Sleeve Sleeve Elbow Tee Body cap Swivel connector Description.3.5.6.4022 98156.3868 Number OFF.6 21.12 Item No.1398 98156.3902 98156.5.2 98156.1 21.3 21.1 21. Pipe assembly .5 Part Number. 21.3 M3090.4045 M3089.doc 04/09/02 Page 89 . 3 1 3 1 1 1 600 1 1 1 4 4 Number OFF.2 21.4 PS1322.3949 98156.4 21.7 21.3.6 21. C203859 BUILD NG 21. Pipe assembly – 4th stage inlet Pipe st/st Elbow Male connector Nut Sleeve 21.7 21.9 21.1 21.3.5.4.4045 Part Number. C203998 BUILD NG 21.3949 98156.2811 98261.10 21.11 21.13 21.7 21.3951 98156.3.2 21.3 21.3.2017 95405. C204000 BUILD NG 21. C203860 BUILD NG 21.3.8 Item No.3.4.0603 Part Number.5 21.3920 98156.12 98156.3898 98156.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 89 Item No. Description.16 21.3107 PS1322.3.4.0603 98156.2 21.4056 98156. 1016 762 1 2 4 1 1 1 2 2 1 4 2 2 2 1 3 Number OFF.8 21. 21.3894 98156.5.4.3.4.4.4 21.1 21.3894 98156.11 21.3. 4 1 1 4 2 1 3 1016 Number OFF.8 21.15 21.3.5.3.3902 98156.17 Item No.5.4.5 21.5.4.3.3894 98156. Pipe Assembly Sep Drain Seal-dowty Union Connector Elbow Equal Female Tee Line Valve Seamless st/stl Adaptor Seal-dowty Plug-reducing Nut Sleeve Description.6.4 21.2017 98156.6 21.5 98156.3963 98156.10 21.6.4.12 21.3.4022 98156.3903 98156.4121 98156.4. 4 Part Number.2 21.8.3888 M3089.8 98156.3. 1 2 2 1 500 Number OFF.2017 98156.7 98156.3 21. 1524 1 2 1 SPARE PART SPARE PART SPARE PART SPARE PART SECTION 7 BUILD NG 2.3927 98156. Pipe assembly 2nd stage delivery Male connector Nut Sleeve 45°Elbow Pipe st/st Description.4 21.9.4 Item No.doc 04/09/02 .2 21.22 Oil level gauge Page 90 1293-7NG.3rd stage suction pipe Male connector Nut Sleeve Pipe st/st Description.3924 98156.3024 Part Number. C203856 BUILD NG 21.2521 Part Number.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 90 Item No. Pipe assembly water transfer Pipe cu Elbow Stud Coupling Nipple rd 21. Description.8. C203951 BUILD NG 21.3886 Part Number.3 21.4 Item No.2 21.2 21.9.7.8.10.1 Oil filler SECTION 6 LIST 3.5 95440.8.1 21.1 21.7.4 Water pump SECTION 6 LIST 1. 21.3 21.10.3 21. C203855 BUILD NG 21.2522 PS1073.3998 98156.10. 2 2 2 30 Number OFF.5 Item No. 812 2 2 2 Number OFF.9 M3090. Pipe assembly .48 98156.9. 21. C204001 BUILD NG 21. 21.3900 98156.4112 M3089.3919 98156.3899 98156.9.1 21.10.8.1 21. Pipe assembly 3 stage Dely Seamless st/stl Coupling Nut Sleeve Description.7.16 Oil Pump & Filter SECTION 9 62759 NG 015 9.10 M3201.1358 Number OFF.7.3890 98156. CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 91 BUILD NG .NG SECTION 7 BUILD NG 19.5 Pipe Assy SECTION 7 BUILD NG 21.4 Safety valve 3rd stage SECTION 7 BUILD NG 20 th 4 stage separator SECTION 7 BUILD NG 2.14 Safety Valve SECTION 7 BUILD NG 16 Inlet damper SECTION 7 BUILD NG 21.1.4 Pressure Gauge SECTION 7 BUILD NG 1.6 Safety valve 1st stage SECTION 7 BUILD NG 21.1 Safety valve 4th stage SECTION 7 LIST 19.5 Safety valve SECTION 7 BUILD NG 21.8 Pipe Assy SECTION 7 BUILD NG 16.1 Oil filler SECTION 7 BUILD NG 8 1st stage separator SECTION 7 LIST 19.doc 04/09/02 Page 91 .3 Pressure Gauge SECTION 7 BUILD NG 1.4 Pipe Assy Water outlet SECTION 7 BUILD NG 16.3 Pipe Assy 1293-7NG.H5437.6 Pipe Assy SECTION 7 LIST 19.6 Safety Valve SECTION 7 BUILD NG 21. 31 Oil Pressure switch SECTION 7 BUILD NG 16 Inlet Damper Page 92 1293-7NG.CompAir UK Ltd PUBLICATION 98407.1.12 Inlet solenoid valve SECTION LIST 1.doc .6 Pipe assy SECTION 9 BUILD NG 9.NG SECTION 7 BUILD NG 18 Gauge panel Water outlet SECTION 7 BUILD NG 21.H5437.1293 NG Section 7 Page 92 BUILD NG . CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 93 BUILD NG .8 PRESSURE SWITCH LOW SECTION 7 BUILD NG 16.doc 04/09/02 Page 93 .13 SOLENOID VALVE SECTION 7 BUILD NG 17.1.3 PRESSURE GAUGE SECTION 7 BUILD NG 16.14 SAFETY VALVE NG 1.6 SAFETY VALVE SECTION 7 BUILD NG 16.H5437.7 Pipe Assy SECTION 7 BUILD NG 21.1.4 PRESSURE GAUGE NG 1.11 PRESSURE SWITCH HIGH SECTION 7 BUILD NG 9.1 Pipe Assy BUILD NG SURGE VESSEL & DIAPHRAGM DRAIN VALVES SECTION 7 BUILD NG 16.6 2ND & 1ST STAGE DIAPHRAGM DRAIN VALVE 1293-7NG.NG SECTION 7 BUILD NG 21.1.9 Pipe Assy SECTION 7 BUILD NG 21.5 4TH & 3RD STAGE DIAPHRAGM DRAIN VALVE SECTION 7 BUILD NG 17. 1.1.1.8 5.2 Page 94 1293-7NG.1.3 5.5 5.7 5.4 5.6 5.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 94 5.1.1.1 5.doc 04/09/02 .1.1. 4TH STAGE RUNNING GEAR DIFFERENCES 5.2.doc 04/09/02 Page 95 .1 1293-7NG.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 95 BUILD NG 5 . doc 04/09/02 .CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7 Page 96 Page 96 1293-7NG. MINERAL OIL 8.1.doc 04/09/02 Page 97 .1 GAS COMPRESSOR .NG MP100 1293-8NG.CompAir UK Ltd PUBLICATION 98407/1293 NG Section 8 Page 97 SECTION 8 CONTENTS BUILD .NG .R-5437.1.1.R-5437.NG .MINERAL OIL R-5437.NG M427 R-5437.NG .R-5437.NG S R-5437.NG RECOMENDED SERVICE PLANS 8.1.1.R-5437.1.2 GAS COMPRESSOR .3 GAS COMPRESSOR .SYNTHETIC OIL 8.1. doc 04/09/02 .CompAir UK Ltd PUBLICATION 98407/1293 NG Section 8 Page 98 Page 98 1293-8NG. 2 98504.1ng/s.1106 ‘O’ Ring 4th stage valve cover lower 1 98504. Check tightness of all fasteners. AT 3000 Change oil & oil filter element. Change oil (total capacity 45 litres) .1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.REAVELLITE ‘S’ 20 Litres.1384 Back-up ring 3rd stage valve cover.1. Check condition of corrosion rods.4 24 MONTHS. Part Ref No Off 2 1 1 RSP5437.1009 Service kit 3rd stage valve 1 98650.1009 12 MONTHS. Clean inline filter strainer. Cleanse crankcase.1105 Back-up ring 4th stage valve cover lower 1 98504. AT 1500 Clean inline filter strainer.2040 ‘O’ Ring 4th stage valve cover upper 1 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.1143 4th stage valve 1 98650.1112 ‘O’ Ring 3rd stage valve 1 95604.DAILY & BEFORE STARTING Check oil level top up if necessary INITIAL SERVICE 100 HOURS. Change oil filter. Part Ref HOURS OR service 4th stage valve.1001 98262. Clean inline filter strainer.RECOMMENDED SERVICE PLAN . Check HOURS OR drive couplings/belt drive. No Off RSP5437.1002 +REAVELLITE ‘S’ 5 Iitres 1 98384.2 ELAPSED TIME.doc Page 1 .1112 4th stage piston rings 6 98477. Routine check of drive & all ancillaries. 6 MONTHS Check for oil & gas leaks. 2 98504.1090 ‘O’ Ring 4th stage valve 1 95604.15 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 4th stage cylinder liner & clean gas passages.1090 ‘O’ Ring 4th stage valve 1 95604. 13/12/02 54371ngs.1106 ‘O’ Ring 4th stage valve cover lower 1 98504. 2 98504.1059 ‘O’ Ring 3rd stage valve cover. Check belt tension/drive couplings & check condition of all ancillaries. Routine check of drive & all ancillaries. Change 4th stage piston rings. + REAVELLITE ‘S’ 5 litres Change oil filter Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Clean inline filter strainer.1ng/s. 2 98384.3 ELAPSED TIME Change oil filter 1 98262. ‘O’ Ring 3rd stage valve cover. No Off RSP5437. Change oil & oil filter element.1002 98384.24 Service kit 4th stage valve 1 98650.5437.1ng/s. Replace 4th Part Ref ELAPSED TIME stage valve. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul.2037 ‘O’ Ring 4th stage valve cover upper 1 98504.15 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 3rd & 4th stage cylinder bores & clean gas passages.1001 Change oil filter 1 98262.1 98384. Change oil (total capacity 45 litres) . 2 98504. Check 3rd stage valve.1009 SERVICE Part Ref 500 HOURS OR No Off RSP5437. Clean 3rd stage valve.REAVELLITE ‘S’ 20 litres.NG-S CompAir UK Ltd Page 1 SYNTHETIC OIL IMPORTANT .1ng/s. Clean inline filter strainer.1384 Back-up ring 3rd stage valve cover. 1.1384 98504.1002 98384.5 98262.2037 98504.1ng/s.1105 98504.1009 98504.24 98650. HOURS Routine check drive & ancillaries No Off OR ELAPSED Change oil filter 1 TIME ‘O’ Ring 3rd stage valve cover. Check sacrificial anode.15 13/12/02 54371ngs. 2 60 MONTHS Back-up ring 3rd stage valve cover.1112 95604.5437. 2 ‘O’ Ring 3rd stage valve 1 Service kit 4th stage valve 1 ‘O’ Ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve 1 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries.1112 95604.1407 98650.1533 98650.7 98262.1105 98504. Replace 4th stage piston & rings.2040 98504. Clean 3rd stage valve HOURS Replace 4th stage valve. Part Ref RSP5437.1009 98504.1ng/s. Service diaphragm drain valves.6 98384. Check 2nd.108 C203686 Part Ref RSP5437. 3rd & 4th stage cylinder bores & clean all gas passages.1090 95604. Check and clean final cooler coil assembly and pipework if fitted AT 6000 Change oil & oil filter. Clean 3rd stage valve. No Off Change oil filter 1 Valve maintenance 'O' ring kit 1 Service kit 2nd stage valve 1 Service kit 3rd stage valve 1 Service kit diaphragm drain valves 4 3rd stage piston rings. Replace 3rd stage piston & liner. 2 48 MONTHS + REAVELLITE ‘S’ 5 Litres 1 Change oil filter 1 ‘O’ Ring 3rd stage valve cover.1001 98262.REAVELLITE ‘S’ 20 litres.RECOMMENDED SERVICE PLAN . 2 ‘O’ Ring 3rd stage valve 1 4th stage valve 1 ‘O’ Ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover upper 1 4th stage piston & piston rings 1 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries.1387 98504.doc Page 2 . No Off TIME Change oil (total capacity 45 litres) .1090 C203685 Part Ref RSP5437. Service 2nd & 3rd stage valves. 3rd & 4th stage cooler assemblies.1ng/s.1009 98504.1384 98504.1059 98650. AT 7500 Change oil filter. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.NG-S CompAir UK Ltd Page 2 AT 4500 HOURS OR ELAPSED TIME 36 MONTHS Check 2nd stage valve. Clean inline filter strainer.1106 98504. 4 3rd stage liner 1 Check belt tension/drive & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 2nd. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.1535 PS1159. Service 4th stage valve. Change oil filter element.1387 98504. Clean OR ELAPSED inline filter strainer. 2 Back-up ring 3rd stage valve cover.24 98650. Cleanse crankcase.1106 98504. hydraulic test all coolers.1406 13/12/02 54371ngs.1021-40 98650.2 98074.1022-150 98650. clean or replace as necessary.95 C85736. Replace all piston rings.1.1ng/s. 3rd & 4th stage S/E bearings 2nd. Check inline filter strainer.1086 98477. 2nd & 3rd stage cylinder bores.2037 98650.1129 C203986 C201109 98504.1087 98477. Change oil (sump capacity 45 litres) REAVELLITE ‘S’ 20 litres. Replace all safety valves. Clean all water jackets.1195 95602.1022 95527.96 95650.K Service kit diaphragm drain valves U334. Part Ref No Off 2 1 1 1 1 1 1 4 1 2 2 1 RSP5437.1004 98650.1020-10 98650. 3rd & 4th stage gudgeon pin 2nd.1009 98650. Renew vee belts or drive couplings.1011 98504.1532 98650.1002 98384. cooler covers & cooler assemblies Hydraulically test all cooler assemblies Check oil pump & drive Check tightness of all fasteners after initial run Check condition of all other ancillaries. bearings etc.1085 98477.1 C203984 95650.1001 98262.30 C200016 98076.doc Page 3 .1143 C203685 C203687 C85727.1535 98650.1049 98650.8 98384.NG-S CompAir UK Ltd Page 3 AT 9000 HOURS MAJOR OVERHAUL Replace 3rd & 4th stage valves. 2nd. 3rd & 4th stage B/E bearings Crankshaft D/E oil seal Crankshaft D/E oil seal 'O' ring Main bearing bush Thrust washer 1st stage safety valve 2nd stage safety valve 3rd stage safety valve 4th stage safety valve (see contract for correct valve) Surge vessel safety valve Overhaul joint kit Re-calibrate/renew or check high temperature switch settings Re-calibrate/renew or check pressure gauges Cleanse 4th stage cooler coil internally/externally Cleanse all separators. re-calibrate all pressure gauges replace if faulty.1039 98650. 3rd stage valve 4th stage valve 1st stage valve 2nd stage valve Service kit diaphragm drain valves Service kit diaphragm drain valves U334. Check condition of 1st. 3rd & 4th stage S/E bearings spacer Check crankshaft journals & oil seal diameter for wear 1st. +REAVELLITE ‘S’ 5 Litres Change oil filter.RECOMMENDED SERVICE PLAN . 3rd & 4th stage gudgeon pin tension pin 1st stage gudgeon pin circlips 1st stage S/E bush 2nd.100 C203868 1 1 1 6 1 1 1 3 3 3 2 1 6 3 4 1 1 2 2 1 1 1 1 1 1 98477. Replace 4th stage piston & liner. Function test all ancillaries.1531 C201556.5437. Replace drive belts/coupling rubbers.1519 98650.J Service kit bursting disc Corrosion rod set Check cylinder bores for wear Inspect all piston ring grooves and piston lands for wear Deglaze all liners/bores when fitting new piston rings. gudgeon pins. 3rd & 4th stage gudgeon pin circlips 2nd. 1st stage piston ring set 2nd stage piston ring set 3rd stage piston ring set 4th stage piston rings 4th stage piston 4th stage liner 1st stage gudgeon pin 2nd. RECOMMENDED SERVICE PLAN .1.5437.doc Page 4 .NG-S CompAir UK Ltd Page 4 13/12/02 54371ngs. No Off Change oil filter 1 ‘O’ Ring 3rd stage valve cover. Clean inline filter strainer.1009 98504.3 98262.1106 98504.1022 98262. Check drive couplings/belt drive.15 AT 3000 HOURS OR ELAPSED TIME 24 MONTHS.2037 98504.1384 98504.1ng/m427.1022 98262. Check 3rd stage valve.1112 98477. Part Ref RSP5437.1387 98504.1384 98504. Change 4th stage piston rings. Check condition of corrosion rods. Routine check of drive & all ancillaries.doc Page 1 .1106 98504. service 4th stage valve.1105 98504. Cleanse crankcase.1 98384.1ng/m427.4 98384. No Off Check belt tension/drive couplings & check condition of all ancillaries.2040 98504.1009 98650. Clean inline filter strainer.DAILY & BEFORE STARTING Check oil level top up if necessary INITIAL SERVICE 100 HOURS. 2 ‘O’ Ring 3rd stage valve 1 Service kit 4th stage valve 1 ‘O’ Ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve 1 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 3rd & 4th stage cylinder bores & clean gas passages.1ng/m427. Change oil & oil filter element.1112 95604. 2 4th stage piston rings 6 4th stage valve 1 ‘O’ Ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve 1 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 4th stage cylinder liner & clean gas passages.1387 98504. 2 Back-up ring 3rd stage valve cover. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul. Routine check of drive & all ancillaries. Clean 3rd stage valve. Check tightness of all fasteners.1090 95604. Clean inline filter strainer.NG-M427 CompAir UK Ltd Page 1 MINERAL OIL MOBIL RARUS 427 IMPORTANT .2 AT 1500 HOURS OR ELAPSED TIME 12 MONTHS.15 54371ngm427.1009 SERVICE 500 HOURS OR ELAPSED TIME.24 98650. Check for oil & gas leaks. Part Ref RSP5437. 6 MONTHS Part Ref RSP5437. Part Ref RSP5437.1ng/m427. No Off Change oil (total capacity 45 litres) Mineral Mobil Rarus 427 2 Change oil filter 1 Service kit 3rd stage valve 1 ‘O’ Ring 3rd stage valve cover. Change oil filter. Change oil & oil filter element.5437. Clean inline filter strainer.1059 98504. Replace 4th stage valve. No Off Change oil (total capacity 45 litres) Mineral Mobil Rarus 427 2 Change oil filter 1 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Clean inline filter strainer.1.1143 98650. 2 Back-up ring 3rd stage valve cover.1090 95604.1105 98504.RECOMMENDED SERVICE PLAN . Service 2nd & 3rd stage valves.1535 3rd stage piston rings. Service diaphragm drain valves. 2 98504.NG-M427 CompAir UK Ltd Page 2 AT 4500 HOURS OR ELAPSED TIME 36 MONTHS Check 2nd stage valve.1384 Back-up ring 3rd stage valve cover.5 Change oil filter 1 98262.2037 ‘O’ Ring 4th stage valve cover upper 1 98504.6 TIME Change oil (total capacity 45 litres) Mineral Mobil Rarus 427 2 98384. 2 98504. Check and clean final cooler coil assembly and pipework if fitted AT 6000 Change oil & oil filter.2040 ‘O’ Ring 4th stage valve cover upper 1 98504.RECOMMENDED SERVICE PLAN .1ng/m427. Clean 3rd stage valve.1106 ‘O’ Ring 4th stage valve cover lower 1 98504. 2 98504.24 4th stage valve 1 98650.1387 Back-up ring 4th stage valve cover upper 1 98504.108 3rd stage liner 1 C203686 Check belt tension/drive & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 2nd.doc Page 2 .1ng/m427. No Off RSP5437.1059 Service kit diaphragm drain valves 4 98650. Check 2nd.1009 ‘O’ Ring 3rd stage valve cover.1533 Service kit 3rd stage valve 1 98650. Cleanse crankcase.1112 ‘O’ Ring 3rd stage valve 1 95604.1090 4th stage piston & piston rings 1 C203685 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries.1ng/m427. Clean 3rd stage valve HOURS Replace 4th stage valve.24 Service kit 4th stage valve 1 98650. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.15 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries. 3rd & 4th stage cooler assemblies. 2 98504.1009 Valve maintenance 'O' ring kit 1 98504. 54371ngm427.1407 Service kit 2nd stage valve 1 98650. Service 4th stage valve. Replace 4th stage piston & rings. 4 PS1159.1387 Back-up ring 4th stage valve cover upper 1 98504. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.1009 TIME ‘O’ Ring 3rd stage valve cover.1106 ‘O’ Ring 4th stage valve cover lower 1 98504.1090 ‘O’ Ring 4th stage valve 1 95604.1112 ‘O’ Ring 3rd stage valve 1 95604. No Off RSP5437. Clean Part Ref OR ELAPSED inline filter strainer.7 OR ELAPSED Change oil filter 1 98262. Replace 3rd stage piston Part Ref & liner.1.1105 Back-up ring 4th stage valve cover lower 1 98504. AT 7500 Change oil filter.1384 60 MONTHS Back-up ring 3rd stage valve cover. Change oil filter element.1105 Back-up ring 4th stage valve cover lower 1 98504. Check sacrificial anode. 3rd & 4th stage cylinder bores & clean all gas passages. Part Ref HOURS Routine check drive & ancillaries No Off RSP5437.5437.1022 48 MONTHS Change oil filter 1 98262. Clean inline filter strainer. 1049 98650.1531 C201556.1086 98477.RECOMMENDED SERVICE PLAN . Check condition of 1st.1535 98650.100 C203868 98477.1ng/m427.2 98074. 3rd & 4th stage S/E bearings 6 2nd.1021-40 98650. re-calibrate all pressure gauges replace if faulty.1011 98504. Part Ref RSP5437.1195 95602. No Off Change oil (total capacity 45 litres) Mineral Mobil Rarus 427 2 Change oil filter. 3rd & 4th stage gudgeon pin tension pin 3 1st stage gudgeon pin circlips 2 1st stage S/E bush 1 2nd. bearings etc.96 95650.1022 98262.J 2 Service kit bursting disc 2 Corrosion rod set 1 Check cylinder bores for wear Inspect all piston ring grooves and piston lands for wear Deglaze all liners/bores when fitting new piston rings.95 C85736.1. Replace drive belts/coupling rubbers. Check inline filter strainer. 1st stage piston ring set 1 2nd stage piston ring set 1 3rd stage piston ring set 1 4th stage piston rings 6 4th stage piston 1 4th stage liner 1 1st stage gudgeon pin 1 2nd.1532 98650. hydraulic test all coolers.1519 98650.NG-M427 CompAir UK Ltd Page 3 AT 9000 HOURS Replace 3rd & 4th stage valves.5437.doc Page 3 .1020-10 98650. clean or replace as necessary.1009 98650.1087 98477.1 C203984 95650.1085 98477. MAJOR gudgeon pins. Replace all piston rings. Replace 4th stage piston & liner.1129 C203986 C201109 98504. 3rd & 4th stage gudgeon pin 3 2nd.1143 C203685 C203687 C85727. 3rd & 4th stage gudgeon pin circlips 3 2nd. Clean all water jackets. 2nd.1406 54371ngm427. Renew vee belts or drive couplings.1022-150 98650. Replace all safety valves.K 1 Service kit diaphragm drain valves U334. 3rd & 4th stage S/E bearings spacer 3 Check crankshaft journals & oil seal diameter for wear 1st.1039 98650. cooler covers & cooler assemblies Hydraulically test all cooler assemblies Check oil pump & drive Check tightness of all fasteners after initial run Check condition of all other ancillaries.2037 98650.1004 98650.8 98384. 1 3rd stage valve 1 4th stage valve 1 1st stage valve 1 2nd stage valve 1 Service kit diaphragm drain valves 4 Service kit diaphragm drain valves U334.1022 95527. 2nd & 3rd OVERHAUL stage cylinder bores. 3rd & 4th stage B/E bearings 4 Crankshaft D/E oil seal 1 Crankshaft D/E oil seal 'O' ring 1 Main bearing bush 2 Thrust washer 2 1st stage safety valve 1 2nd stage safety valve 1 3rd stage safety valve 1 4th stage safety valve (see contract for correct valve) 1 Surge vessel safety valve 1 Overhaul joint kit 1 Re-calibrate/renew or check high temperature switch settings Re-calibrate/renew or check pressure gauges Cleanse 4th stage cooler coil internally/externally Cleanse all separators.30 C200016 98076. Function test all ancillaries. 2 4th stage piston rings 6 4th stage valve 1 ‘O’ Ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve 1 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 4th stage cylinder liner & clean gas passages.RECOMMENDED SERVICE PLAN .1105 98504.5437. Routine check of drive & all ancillaries.1143 98650. Change 4th stage piston rings. Check 3rd stage valve. Check drive couplings/belt drive.15 54371ngmmp100. Clean inline filter strainer.1090 95604.1029 98262.1.1105 98504.1112 95604.24 98650. Clean inline filter strainer. 2 ‘O’ Ring 3rd stage valve 1 Service kit 4th stage valve 1 ‘O’ Ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover lower 1 Back-up ring 4th stage valve cover upper 1 ‘O’ Ring 4th stage valve 1 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 3rd & 4th stage cylinder bores & clean gas passages.2037 98504.1112 98477.1009 98650. 6 MONTHS Part Ref RSP5437.1059 98504.2040 98504.1ng/mp100.DAILY & BEFORE STARTING Check oil level top up if necessary INITIAL SERVICE 100 HOURS.1009 SERVICE 500 HOURS OR ELAPSED TIME. Check tightness of all fasteners. Part Ref RSP5437.1ng/mp100. Part Ref RSP5437.3 98262. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul.1387 98504.1106 98504.1009 98504.doc Page 1 . Part Ref RSP5437. 2 Back-up ring 3rd stage valve cover.15 AT 3000 HOURS OR ELAPSED TIME 24 MONTHS. Check condition of corrosion rods. Cleanse crankcase. Routine check of drive & all ancillaries. service 4th stage valve.1ng/mp100.1 98384.1387 98504. Change oil filter.1090 95604. No Off Check belt tension/drive couplings & check condition of all ancillaries.1029 98262. Change oil & oil filter element. No Off Change oil (total capacity 45 litres) Mineral Shell Corena P100 2 Change oil filter 1 Check belt tension/drive couplings & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Clean inline filter strainer.1384 98504. No Off Change oil filter 1 ‘O’ Ring 3rd stage valve cover.1384 98504. No Off Change oil (total capacity 45 litres) Mineral Shell Corena P100 2 Change oil filter 1 Service kit 3rd stage valve 1 ‘O’ Ring 3rd stage valve cover.2 AT 1500 HOURS OR ELAPSED TIME 12 MONTHS. 2 Back-up ring 3rd stage valve cover.4 98384.1ng/mp100.1106 98504. Clean inline filter strainer. Change oil & oil filter element. Clean 3rd stage valve. Replace 4th stage valve. Clean inline filter strainer.NG-MP100 CompAir UK Ltd Page 1 MINERAL OIL SHELL CORENA P100 IMPORTANT . Check for oil & gas leaks. 2037 ‘O’ Ring 4th stage valve cover upper 1 98504.1009 TIME ‘O’ Ring 3rd stage valve cover. No Off RSP5437. Part Ref HOURS Routine check drive & ancillaries No Off RSP5437.1112 ‘O’ Ring 3rd stage valve 1 95604. 3rd & 4th stage cooler assemblies.1106 ‘O’ Ring 4th stage valve cover lower 1 98504.1090 ‘O’ Ring 4th stage valve 1 95604.6 TIME Change oil (total capacity 45 litres) Mineral Shell Corena P100 2 98384.1106 ‘O’ Ring 4th stage valve cover lower 1 98504.1. 3rd & 4th stage cylinder bores & clean all gas passages. Check and clean final cooler coil assembly and pipework if fitted AT 6000 Change oil & oil filter. Replace 3rd stage piston Part Ref & liner.2040 ‘O’ Ring 4th stage valve cover upper 1 98504.1ng/mp100.1ng/mp100.5437.1105 Back-up ring 4th stage valve cover lower 1 98504.1535 3rd stage piston rings. Check 2nd.1387 Back-up ring 4th stage valve cover upper 1 98504.1112 ‘O’ Ring 3rd stage valve 1 95604. Cleanse crankcase.1059 Service kit diaphragm drain valves 4 98650. Clean 3rd stage valve. Change oil filter element. 54371ngmmp100.1384 Back-up ring 3rd stage valve cover.1ng/mp100. 2 98504. 2 98504.1009 Valve maintenance 'O' ring kit 1 98504.RECOMMENDED SERVICE PLAN . Clean Part Ref OR ELAPSED inline filter strainer.7 OR ELAPSED Change oil filter 1 98262. Check sacrificial anode.1105 Back-up ring 4th stage valve cover lower 1 98504. Replace 4th stage piston & rings. 4 PS1159. Check condition of 3rd & 4th stage cylinder bores & clean gas passages. 2 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.1533 Service kit 3rd stage valve 1 98650. Clean 3rd stage valve HOURS Replace 4th stage valve.15 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries. AT 7500 Change oil filter.1407 Service kit 2nd stage valve 1 98650. Service 4th stage valve. No Off RSP5437. 2 98504.NG-MP100 CompAir UK Ltd Page 2 AT 4500 HOURS OR ELAPSED TIME 36 MONTHS Check 2nd stage valve.1384 60 MONTHS Back-up ring 3rd stage valve cover.5 Change oil filter 1 98262.1029 48 MONTHS Change oil filter 1 98262.24 4th stage valve 1 98650. Service diaphragm drain valves.1009 ‘O’ Ring 3rd stage valve cover. Service 2nd & 3rd stage valves.1090 4th stage piston & piston rings 1 C203685 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries.108 3rd stage liner 1 C203686 Check belt tension/drive & check condition of all ancillaries Check for oil & gas leaks Check tightness of all fasteners Check condition of 2nd. Clean inline filter strainer.24 Service kit 4th stage valve 1 98650. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.doc Page 2 . 5 9.436200000000002 – 5437.NG DDV CONTROL ----------------------------.065 ------------------.NG.1.4 9.NG ------------------------------------------.1.1 9.100 WATER PUMP .020 ------------------.NG INLET -----------------------------------------.2 9.100 ------------------.095 ------------------. & I.6 9.1.100 INLET TRAIN – 5437.101 PRESSURE CONTROL – 5437.5437.NG------------.C89091 WIRING DIAGRAM -------------------------------------------------.NG ---------------------------------------------. DIAGRAM----------------------------------------------------.PAKISTAN PARTS 9.1.102 9.005 -------------. are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd. Ipswich.NG-------------------------------.9 BUILD NG PAGE NATURAL GAS COMPRESSOR . The letters indicate than an item is available as a component of an assembly.NG --------------------------------------.101 CONTROL BOX SUPPORT – 5437.3 9.1.437M10000000000000 -----------------.C89092 ANCILLARY PARTS PUBLICATIONS DRIVE DETAILS ----------------------------------------------------------------------APP012G2 ELECTRIC MOTOR DETAILS------------------------------------------------------APP034C DIAPHRAGM DRAIN VALVE DETAILS ------------------------------------------APP041 PRESSURE MAINTAINING VALVE DETAILS----------------------------------APP059 PRESSURE GAUGES GENERAL--------------------------------------------------APP070 WATER PUMP DRIVE DETAILS ---------------------------------------------------APP073 PRESSURE SWITCH FINAL DELIVERY-----------------------------------------APP081 PRESSURE SWITCH INLET CONTROL -----------------------------------------APP086 PRESSURE SWITCH LOW OIL ----------------------------------------------------APP088 THERMOMETER SWITCH 3RD STAGE & FINAL DELIVERY -------------APP090 SOLENOID VALVE DIAPHRAGM DRAIN VALVE CONTROL -------------APP152 SOLENOID VALVE INLET CONTROL--------------------------------------------APP153 BALL VALVES GENERAL -----------------------------------------------------------APP154 NON RETURN VALVE FINAL -------------------------------------------------------APP158 SAFETY VALVE GENERAL ---------------------------------------------------------APP167 CHECK VALVE INLET ---------------------------------------------------------------APP169A COMPAC HIGH FLOW PRIORITY FLOW PANEL-----------------------------APP224 NOTE: Standard parts are available where indicated by either a number or letters.015 ------------------.100 ANTI VIBRATION MOUNTS .SECTION 7 VEE DRIVE & ADJUSTMENT PARTS. The right is reserved to modify the contents of this list.103 ------------------.11 ELECTRIC MOTOR – 5437. without notice. Non-listed or individual items of assemblies where reference number are not indicated.1.D70938 SINGLE LINE DIAGRAM -----------------------------------------.doc Page 99 .010/012 ---------------.040 ------------------.101 ------------------.8 9.E46316 P.NG ----------------------------------------------------------.NG --------------------------------------------------.101 CRANKCASE OIL DRAIN – 5437. 1293-9.102 9.1.1293 NG Section 9 Page 99 SECTION 9 CONTENTS TYPICAL BUILD GP37.1.100 SAFETY VALVE MANIFOLD – 5437. The assemblies have been chosen based on the experience gained by our own Parts and Service Departments.12 SOLENOID VALVE – 5437.1.1.NG----------------------------------------.NG ---------------------------------------------------.436200000003000.102 9.NG-------------------------. and the information given is in no way binding on the manufacturers.102 9.060 ------------------.1.1.102 TYPICAL DRAWINGS GENERAL ARRANGEMENT ------------------------------------.7 9.13 SOLENOID VALVE – 5437.050 ------------------.10 CONTROL PANEL – 5437.102 ------------------.5437.CompAir UK Ltd PUBLICATION 98407. 10 9.315 95000.7 95148.2.372 95111.2.5.3 9.202 95006.2.2 9.2.945 98504.58 95351.7 9.5.1293 NG Section 9 Page 100 Item No.335 C73514.6 9.9 95148.16 9.W-EF250MN Water Pump Parts Anti Vibration Mounts Parts Anti vibration mount Screw M12 X 60lg Screw M12 X 70lg Nut M12 Washer M12 Support Channel Support Channel Inlet Train Bolt M12 Bolt M16 X 65lg Bolt M16 X 90lg Nut M12 Nut M16 Washer M16 Elbow ½" BSP Nipple ½" BSP Nipple 1.20 9.doc .2.1360 98080.11 9.4.5.5.15 9.1 9.1130.4 9.18 9.105 C73514.176 95000.4 9.16.2.2.½" BSP Flange 3" NB PN16 Inline filter Elbow 3" BSP Pipe 3" NB X 105lg Pipe 3" NB X 335lg Pipe 3" NB X 380lg Pipe 3" NB X 108lg Equal Cross Tee 3" BSP Reducing Bush Part Number. 9.3 9. GP37.2. 1 APP NO.7 9.9 9.4.21 Description.2 9. 012G 2 2 2 1 1 2 1 1 1 4 4 7 8 2 8 012G 1 3 1 1 034C 073 003 4 2 4 6 6 2 1 6 40 8 6 48 48 1 1 1 1 8 1 8 1 2 1 1 1 1 1 1 170 Page 100 1293-9.CompAir UK Ltd PUBLICATION 98407.13 9.235 95111.1 E61674 E61673 D66720.4 9.4.½" BSP Plug Joint Ring 80NB Elbow 1.19 9. Compressor Parts Natural Gas Compressor Vee Drive Adjustment Parts Motor plate Adjusting block Adjusting screws Vee belt guard Flywheel pulley Stud M16 X 36lg Motor bracket Key Screw M10 X 16lg Screw M10 Screw M12 X 35lg Screw M16 X 35lg Screw M20 Nut M16 Washer M20 Vee Drive Parts Motor pulley Vee belt Taperlock bush Electric motor 75 kW/3PH/50 HZ .281 95006.5.5.14 9.12 9.14 9.54 95405.2 9.5.6 9.5.1 9.1 9.799 95405.5 9.16 9.8 9.755 95405.803 95405.5.380 C73514.18 95405.PAKISTAN BUILD NG 005 5437.18 9.5.6 9.1 9.4.1491 98074.1348 BUILD NG 015 BUILD NG 020 98418.4 9.2.5.17 9.5.9 9.5.16 D70896 D70897 BUILD NG 040 95000.5.11.5 9.5.13 9.8 9.20 BUILD NG 012 98080.5.15 9.344 95001.1347 A/98412.1130.314 95006.11 9.1.2.21 95000.9 95148.5.3 9.4.1130.12 9.5.5 9.2.11 C73514.204 95111.2.2.2.2.180 95405.1271 95405.2.1.1015 95006.4.0 9.5.3 9.17 9.NG BUILD NG 010 C89081 C89082 C86470.208 98650.2.1 9.231 95006.7 95111.893 Number OFF.2 9.5 9.1130.5.2.1258 95405.60 E60017 PS1130.4.5.NG.10 9. 1 1 1 2 1 3 3 1 1 1 1 1 1 2 2 4 2 1 1 4 2 1 4 1 3 8 1 3 2 4 1 3 4 4 1 1 1 1 2 2 4 4 2 5 2 5 1 1 1 1 2 APP NO 154 154 169A 059 070 081 1293-9.5.30 9.5 9.1294 98156.6.6.6.8.5.8.1/2" Connector Reducing Bush Coupling Elbow 1.5.doc Page 101 .8. GP37.5 9.CompAir UK Ltd PUBLICATION 98407.13 98156.5.1789 98156.1/2" NB X 90lg Capscrew M12 X 90lg Swivel Elbow Union 1.282 98156.16 9.4 9.6.6.8.22 9.1 9.NG.6.873 95405.6.2343 98524.6.6.1015 98660.8 9.28 9.314 95111.6.6.58 98150.1/2" BSP Equal Cross Tee 1.5.9 9.6.2091 98150.752 C73514.5.5.14 9.1613 M3130.11 9.26 9.1613 98156.1/2" BSP Bush Hex 1.22 9.1212 95405.29 9.6.8.1/2" BSP Bush Hex 1.20 9.6 9.1364 98156.2599 98156.7.5.10 9.7.8 9.12 9.2 9.600 bar Tee Piece Pressure switch Tube Bundy Washer 3/8" BSP Part Number.8.2082 95405. 9.1050 98156.229 95006.19 9.16 9.6.8.5.1779 98156.2078 95405.1/2" BSP Elbow 1.31 9.17 Description.1099 C89058 98315.803 95405.8.1/2" BSP Nipple Hex 1.1 M3089.1 9.1386 98288.5.14 9.9 9.1/2" BSPT Pipe Clamp Ø1.7 9.90 95018.1 9.3 9.8.6.PAKISTAN 98650.21 9.1004 98617.6 9.11 9.7 D70898 BUILD NG 065 C88316.18 9.889 98261.3 9.8.3025 95405.17 9.27 9.6.B 95000.4 95148.23 9.2143 BUILD NG 060 95000.6.1154 Number OFF.1315 98156.260 BUILD NG 050 M3124.2133 98315.15 9.134 95111.8.1023 98156.1205 U572.872 95405.8.870 98156.1211 C73514.1212 98315.6.2 9.2 9.6.1/4" BSP X Ø30 Connector Union Flexible Hose 1.13 9.2521 M3130.1130.10 9.7.1/2" BSP Flexible Hose 80NB Pipe 3" NB X 260lg Safety Valve Manifold Pipe Ø25 Pipe Ø16 Pipe Ø30 Tee 1.875 95405.8 9.7 9.1293 NG Section 9 Page 101 Item No.2140 95405.0820.13 9.6.837 98650.8.15 9.24 9. Isolating valve Reducing Bush Purge valve Reducing Nipple Non-return valve Pipe Clip 'U' Bolt Ø3" Bracket Flexible Hose 1.1/4" BSP Control Box Support Setscrew M12 Nut M12 Support Pressure Control Tee Piece Tube Pressure Maintaining Valve Setscrew M6 X 20lg Bolt M6 X 80lg Nut M6 Washer M6 Adaptor Ø4 Tube Nut Ø4 Reducing Bush Tube Sleeve Ø4 Pressure gauge 0 .3 9.6.25 9.8.1/2" BSP Pipe 1.12 9.4 9.8.7 9.356 95405.8.1/2" BSP Bush Hex 1.6. 9.1017 BUILD NG 102 A/98516.19 9.1161 BUILD NG 103 A/98516.3 9.5 9.1214 BUILD NG 095 C73514.1155 98156.9 9.NG.1156 98650.18 9.1293 NG Section 9 Page 102 Item No.1 9.13.10.9.4174 98315.2 9. Washer 1/2" BSP Adaptor Coupling Flexible Hose 12 mm Ends Crankcase Oil Drain Pipe ¾" BSP X 200lg Plug ¾" BSP Socket ¾" BSP Elbow ¾" BSP Washer Ball Valve Control Panel Parts Cabling Solenoid Valve INLET Solenoid valve 230VAC/IPH/50HZ Solenoid Valve DDV Solenoid valve 230VAC/IPH/50HZ Part Number.4 9.20 9.55 98660.1162 Number OFF. 2 2 1 1 1 1 1 1 1 1 1 1 1 APP NO 154 153 152 Page 102 1293-9.1971 BUILD NG 100 98523.2126 98156.12.6 9.9.8.9.9. 9.9.10 9.8.21 9.1 Description.200 PS1068.8. GP37.0515.CompAir UK Ltd PUBLICATION 98407.1 9.1005 95405.PAKISTAN 98660.5 95405.8.12 9.doc .13 9.1 9. . . . doc . see above. Check belt tension by method described on following page. if the pulley faces are not parallel use appropriate size distance pieces to ensure belt grooves are correctly aligned.CompAir UK Ltd APP012g2 .BELT ALIGNMENT & TENSIONING Page 1 RECOMMENDED VEE BELT ALIGNMENT & TENSIONING BELT DRIVE ALIGNMENT STRAIGHT EDGE DISTANCE PIECES 5 MM STRAIGHT EDGE COMPRESSOR ELECTRIC MOTOR BELT ADJUSTING SCREWS It is very important that the driving and driven pulley grooves are in line and both pulley shafts are parallel. RECOMMENDED TENSIONING FORCES BELT TENSION INDICATOR APPLIED TO MID-SPAN CENTRE DISTANCE SEE CHART STRAIGHT EDGE app012g2. Compare this force to kgf value shown in the table above.doc . BELT TENSION INDICATOR 10 20 30 MM 40 50 60 14 12 10 8 6 4 2 DEFLECTION IN MM DEFLECTION FORCE IN KGF app012g2.2 9. 5. 1.CompAir UK Ltd APP012g2 . If the measured force falls within the values given.5 to 5. Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt deflecting it to the point where the lower marker ring is level with the adjacent belt. Note:. 4. using a suitable straight edge (long enough to span both pulleys). on single belt drives place a straight edge across the two pulleys to act as a datum. Set the lower marker ring at the deflection distance required in mm on the lower scale. Set the upper marker ring against the bottom edge of the top tube. 9.6 6.BELT ALIGNMENT & TENSIONING Page 2 ADJUSTMENT METHOD If the belt tension is incorrect.If a belt tension indicator is not available. a suitably scaled spring balance and rule will suffice. Centre distance (metres) X 16 = Deflection (mm). 8. 3. the drive should be satisfactory. Using a Belt Tension Indicator.2 to 12. 6.1 5.2 Method of Belt Tensioning.1 to 9. 2. Measure small pulley diameter (motor/engine) Calculate the deflection distance in mm on a basis of 16 mm per metre of span. Belt Section Belt Section SPB SPB SPC SPC TABLE Force required to deflect belt 16 mm per metre of span Small Pulley Ø mm 160 to 224 224 to 315 224 to 355 375 to 560 Newton (N) 35 to 50 50 to 65 60 to 90 90 to 120 Kilogram force (kgf) 3. go to 3. Tighten or loosen belt tensioner to achieve the correct value. 7.1 to 6. Read off the force value indicated by the top edge of the upper marker ring. If distance & deflection is known. correct it by using the adjusting screw provided..established the correct deflection and pulley alignment. BELT ALIGNMENT & TENSIONING Page 3 TYPICAL DRIVE ARRANGEMENT SEE SECTION 9 FOR DETAILS 1 3 2 5 4 20 11 12 17 13 19 18 14 10 6 7 16 12 9 22 15 8 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Description Key Pulley Compressor Vee Belt Taper Lock Bush Pulley Motor Stud Washer Anti Vibration Mount Motor Bracket Screw M10 x 16 Screw M12 x 35 Screw M16 x 35 Screw M16 x 45 Screw M8 x 45 Screw M12 x 45 Nut Motor Plate Adjusting screws Adjusting Block Vee Belt guard Screw M16 x 50 Washer PARTS LIST Part Number SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER SEE SECTION 9 FOR PART NUMBER No Off 1 1 1 1 2 2 4 1 1 4 7 4 4 4 2 2 2 2 1 4 4 app012g2.doc .CompAir UK Ltd APP012g2 . CompAir UK Ltd APP012g2 .BELT ALIGNMENT & TENSIONING Page 4 app012g2.doc . 869 C201724 98154.256 95111. WATER PUMP & DRIVE 5437.NG LIST .27 98156.1 D100526 D100527 PS1180. Item No 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 Part No C201503 C201504 C201537 C201538 C201809 C85739. WATER PUMP & DRIVE 5437.3113 95405.1.253 95000.1009 95071.doc 17/10/03 Page 1 .1.1034 E61507 Description Gasket water pump Gasket water pump Sprocket water pump drive Gasket water pump bracket Flange water pump Sprocket water pump drive Cover outer end Bracket water pump housing Clip hose Capscrew Chain water pump drive Setscrew M6 X 12 Setscrew M8 X Setscrew M8 X Nut M8 Hose plastic Pump water Screw cone point Hose adaptor Reducing Bush Extension Shaft Radiator Fan Radiator Aftercooler Coil No Off 2 2 1 1 2 1 1 1 6 4 1 2 6 3 3 4572 1 1 1 1 1 1 1 1 App073ng.5 98315.NG Page 1 RADIATOR.9 PS1923.1102 98446.1016 98154.437100000005000 15 22 1 21 5 3 14 18 10 11 19 2 16 4 9 20 12 8 6 13 SEE LUBRICATION SECTION IN HANDBOOK FOR DETAILS OF OIL PUMP ETC.227 95000.3 PS2062 95000.CompAir UK Ltd APP073ng RADIATOR. 7 95179.1606 98241.doc .125 M1103.3881 D70897 Bracket Radiator Support Strap Radiator Support Fan washer Adaptor Distance Piece Radiator Packer Pipe Bracket Elbow Clip hose Washer Taper Plug ¼" BSP Setscrew M10 X Setscrew M12 X Setscrew M12 X Setscrew M12 X Bolt M8 X 50 Bolt M12 X 45 Bolt M12 X 65 Nut M10 Nut M12 Washer Plain M12 Washer Spring M10 Washer Spring M12 Key 10 X 8 X 50 Washer Copper 1.3 PS1742.1.203 95111.10 98150.NG Page 2 Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus Not Illus C89076 C89076 C201699.315 95000.1205 98156.5 PS1180.281 95000.3113 D70948 98156.1053 98156.4227 M3089.1155 98660.7 95148.314 95000. WATER PUMP & DRIVE 5437.CompAir UK Ltd APP073ng RADIATOR.199 95006.620.6 95111.1156 98315.23 95635.8 95301.2 PS1814.1358 98156.16 95179.5010 98150.318 95006.3 C201722 C201737 C201780 C73514.1/2" Hose Mounting Nipple 1" BSP Elbow 12 mm Cable Tye Washer ½" BSP Washer ¾" BSP Hose 10 I/D Pipe Clamp Pipe Adaptor Baseframe Unoin Elbow Pipe St/St Ø12 Sleeve O-lock Support Channel 1 2 1 2 1 2 1 1193 2 4 10 1 6 4 5 2 4 3 4 3 7 5 3 6 1 1 6 1 2 1 1 2 1066 10 1 1 3 2500 6 1 Page 2 17/10/03 App073ng.3154 PS1073.1038 98156.4 95000.150 95006.1042 98660. CompAir UK Ltd APP073ng RADIATOR, WATER PUMP & DRIVE 5437.1.NG Page 3 TYPICAL RADIATOR WATER COOLING SYSTEM SPECIAL INSTRUCTIONS FOR STARTING COMPRESSOR COOLANT (ANTI-FREEZE) FILLER CAP COOLING WATER PIPE OUTLET RADIATOR DRAIN WATER PUMP COOLING WATER PIPE INLET COOLING WATER PIPE RETURN BEFORE INITIAL STARTING 1. FILLING AND BLEEDING THE WATER SYSTEM. COMPRESSOR SET 5437.1 APPROXIMATE CAPACITY 100 LITRES See before starting procedure in HANDBOOK in conjunction with the following. 1. Ensure all water drain plugs/cocks etc. are closed. 2. Remove radiator filler cap. 3. Fill system with clean coolant. (Antifreeze mixture should be used in low temperature environments) 4. Replace filler cap. 5. Start compressor, run for 2 minutes and stop. 6. Gently release filler cap, remove and top-up. 7. Replace filler cap. 8. Re-start compressor, if any large air bubbles are evident in the pipework stop compressor. 9. Repeat (6), (7) & (8) until air bubbles are evacuated. Note: any small air bubbles will evacuate during normal running through the vent pipe. 2. TOPPING UP. If hot, it is best to leave until cool before attempting to top-up cooling water. 1. 2. 3. 4. Gently release filler cap, Remove and top-up to required level. Replace filler cap. Start compressor, check for air bubbles in water pipes as above. App073ng.doc 17/10/03 Page 3 CompAir UK Ltd APP073ng RADIATOR, WATER PUMP & DRIVE 5437.1.NG Page 4 AIR BLAST RADIATOR GENERAL The radiator is constructed of metals with a very high co-efficient of heat transfer, e.g. copper and aluminium, care should be exercised at all times when handling or cleaning. Working Pressure 0.5 bar Ensure fan/vee belt guards are always fitted before operating compressor. 1. FILLING COOLING SYSTEM 1. Remove radiator filler cap and fill the system with clean water. TOTAL CAPACITY OF SYSTEM IS APPROXIMATELY 22 GALLONS (100 LITRES). Replace filler cap. Start compressor run for a few minutes to pump water through the system. Shut down compressor. Remove radiator filler cap and top up system if necessary. Once the compressor is filled it is only necessary to periodically top up the radiator. 2. 3. 4. 5. 6. 2. COLD WEATHER PRECAUTIONS 1. In freezing conditions ant-freeze (recommended type:- Ethlene glycol (ethanediol) should be added to the cooling system. Use quantities recommended by the anti-freeze manufacturer. 3. MAINTENANCE 1. Very little maintenance is required as the strong airflow and flat fins minimize any fouling tendencies. DO NOT remove grease and dirt with the use of TRICHLORETHYLENE. Check periodically for leaks from pipe connections, which could result from excessive mechanical or hydraulic vibration. Tighten or renew joints as necessary. Drain and flush through and replenish cooling system every 2 years. More often in a high contaminating hard water area. 2. 3. 4. 4. RADIATOR FAN MAINTENANCE 1. 2. 3. Periodically check security of fan hub attachment to shaft. Check security-fixing screws of blades to hub. Ensure blades are clean and there is no build-up of dirt and grime, as this will cause out of balance loading and subsequent vibration on the motor shaft. Page 4 17/10/03 App073ng.doc CompAir UK Ltd APP073ng RADIATOR, WATER PUMP & DRIVE 5437.1.NG Page 5 RADIATOR TYPICAL ARRANGEMENT 25 24 26 23 App073ng.doc 17/10/03 Page 5 Contact Compair UK Ltd Spares Department for more details. Loosen packing nut. Slack belt may give inefficient pump performance. renew as necessary. Fill system with water. 2. 2. clean off all old jointing compound. Remove packing unit and gland. Inspect all parts for. 2. 3. Service Kit Service kits are available for all water pumps. bets and pulley. The pump is self-priming. Over tightening belt will cause a reduction in pump bearing life. Remove cam screw and cam. 6. Remove shaft and impeller assembly from body. Dip new packing in light machine oil. 4. To dismantle. Always ensure the belt tension is correct as. remove belt guard. 2. Reassembly 1. Coat cam screw threads and top of cam with non-setting jointing compound and fit into pump. 4. MAINTENANCE Dismantle 1. b. WATER PUMP & DRIVE 5437. Undo screws and remove end cover. Keep pump exterior and pipework clean so any leaks can be easily detected. discard gasket.CompAir UK Ltd APP073ng RADIATOR. Replace key in shaft.1. packing gland and nut. must never be run DRY for more than 30 seconds.37 bar (20psi) Temperature range 7°C to 82°C 1. a. slide the new impeller on the shaft from the flatted end. 7. Page 6 17/10/03 App073ng. OPERATING INSTRUCTIONS 1. 9. Lubricate impeller bore with good quality water pump grease and shaft with machine oil Fit shaft and impeller assembly in body Fit new gasket to end cover and fit to body with tighten screws. assembly packing. Set locking nut. 3. wear or damage. 3. Maximum pressure 1.NG Page 6 WATER PUMP GENERAL The water pump is of Bronze body with Stainless Steel Shaft and Neoprene Compound Impeller construction. 5. 6. During this operation hand tighten packing nut gradually until pumps stops dripping water. 5. Remove old packing and discard. 8. Pump should be lubricated with water pump grease (Manful 2DH or equivalent). as this will burn the impeller. Remove impeller by sliding off toward the flatted end of shaft.doc . 4. The inlet and outlet ports being 1/2" BSP. Record height dimension (H) of each mount. 6) Temperatures in excess of 70° C will have an adverse effect on the rubber and will shorten the life expectancy. 5) Under normal working conditions the life expectancy will be 5 to 8 years.doc .e. Note: This dimension may only change a small amount during the life of the mount approximately 1mm. 2) After a week or 100 hours running time recheck and record dimension (H) 3) Check this dimension every 3 to 6 months depending on usage i. 4) Any oil or paint contact with the rubber mount will affect the life and performance. H H app003.CompAir UK Ltd APP 003 ANTI VIBRATION MOUNTS Page 1 AVA TYPE PART NUMBERS VARIOUS PREVENTIVE MAINTENANCE 1) After installation and initial running in. so keep to a minimum by regularly cleaning and clearing any contamination from the surrounding area. regular usage every 3 months. CompAir UK Ltd APP 003 ANTI VIBRATION MOUNTS Page 2 app003.doc . CAP NUTS & STUDS GASKET SCREEN SERVICING Ensure the strainer is isolated from the pipeline before commencing work. Place the cap in position on the body studs and push home. If the leakage persists. PUBLICATION APP170 'Y' TYPE STRAINER Page 1 Servicing & Maintenance Instructions ROUTINE MAINTENANCE Check for leaks at the body/cap joint.DOC . Remove the strainer cap and screen. APP170 . Place the screen inside the body making sure it is seated correctly. tighten the nuts on the studs take care not to overtighten. Caps are provided with lever entry grooves to assist with cap removal.CompAir UK Ltd. 1. before fully tightening. Take care not to overtighten the nuts. Follow the instructions below to ensure correct location of screen into strainer body. Tighten down each nut in sequence to ensure equal compression of gasket. Check for damage to the screen and renew if necessary. 3. If leaks are present. 2. RECOMMENDED SPARES Body / cap gaskets. Reassemble the screen and cap using a new gasket. clean out any sediment and other debris. making sure the screen engages the seating in the cap. Keep the screen in this position using a steel rule or similar temporarily hold across the opening in the body. renew the cap gasket having first isolated the strainer from the pipeline. Fit gasket into groove in the cap. DOC .CompAir UK Ltd. PUBLICATION APP170 'Y' TYPE STRAINER Page 2 APP170 . CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 .W-EF SERIES Page 1 ELECTRIC MOTOR W-DF200 & W-EF200 SERIES PARTS LIST Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Flange adaptor (optional) Flange adaptor fixing bolts (optional) Endshield fixing bolts D/E Oil seal O/E bearing cap bolt & Washer Plug Grease nipple D/E Endshield Stator frame assembly Stator core pack D/E Circlip D/E Bearing D/E Bearing cap Rotor assembly O/E bearing cap O/E bearing O/E bearing circlip Ref 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Description Pre-load washer O/E Endshield O/E Endshield fixing bolts O/E Inner bearing cap fixing bolt & washer O/E Oil seal Fan Fan locking screw Fan cover fixing bolt & washer Fan cover Self adhesive nameplate Multi-mounting feet Foot fixing bolt Foot fixing nut Lifting lug Lifting lug fixing bolt & washer Lifting lug nut Terminal box to frame gasket Ref 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Description Terminal box Gland plate gasket Gland plate Gland plate fixing bolt & washer Main terminal Block Auxiliary terminal bracket Clip-in auxiliary terminal block Main terminal retaining plug Main terminal block fixing bolt & washer Terminal cover Gasket Terminal box lid Fixing bolt & washer Terminal lock nuts.doc 23/10/02 Page 1 . Spring washers & plain washer Terminal link Drain plug app034c. 3 1.4 1.6 1.15 1.1112 .15 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT TYPE OF START FLC STARTING CURRENT Page 2 app034c.9 1.5 1.7 1.15 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT TYPE OF START FLC STARTING CURRENT 1.16 1.37 KW SQUIRREL CAGE IP55 TEFV W-DF200L FOOT CLASS 'F' 80°C 40°C 400/3PH 50 2 3000 RPM 2940 RPM STAR/DELTA 136.14 1.17 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT THERMISTORS ANTI-CONDENSATE HEATER GENERAL DESCRIPTION 98412.16 1.4 1.8 1.2 AMPS 210% FLC DIRECT ON LINE 549.90 KW SQUIRREL CAGE IP55 TEFV W-DF280 SN FOOT CLASS 'F' 80°C 40°C 400/3PH 50 4 1500 RPM 1475 RPM STAR/DELTA 157 AMPS 240% FLC ONE FITTED PER PHASE FITTED – RATING 2 X 40 WATTS – 230VAC/1PH/50HZ 98412.2 1.4 AMPS 220% FLC DIRECT ON LINE 434AMPS 700% FLC 1.W-EF SERIES Page 2 1.8 1.1 1.11 1.14 1.6 1.4AMPS 670% FLC 98412.CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 .16 1.6 1.10 1.5 1.doc 23/10/02 .11 1.7 1.13 1.13 1.4 1.7 1.1113 .11 1.1 1.45 KW SQUIRREL CAGE IP55 TEFV W-DF225M FOOT & FLANGE CLASS 'F' 80°C 40°C 400/3PH 50 4 1500 RPM 1470 RPM STAR/DELTA 172.2 1.10 1.13 1.2 1.12 1.14 1.12 1.1116 .15 1.9 1.3 1.15 1.1 1.12 1.9 1.14 1.5 1.10 1.8 1.14 1.3 1. 2 1.1116 .45 KW SQUIRREL CAGE IP55 TEFV W-DF225ML FOOT CLASS 'F' 80°C 40°C 400/3PH 50 2 3000 RPM 2940 RPM STAR/DELTA 220% FLC 1.CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 .6 1.9 1.6 1.3 1.10 1.2 1.8 1.14 1.2 1.55 KW SQUIRREL CAGE IP55 TEFV W-DF250S FOOT CLASS 'F' 80°C 40°C 400/3PH 50 2 3000 RPM 2940 RPM STAR/DELTA 220% 700% FLC 1.1 1.003 + EXTENSION SHAFT 72416-00 TYPE SQUIRREL CAGE PROTECTION IP55 TEFV FRAME SIZE W-DF225MNF-H MOUNTING FOOT & FLANGE INSULATION CLASS 'F' TEMPERATURE RISE 70°C AMBIENT TEMPERATURE 40°C VOLTAGE 3 PHASE 440/3PH FREQUENCY HZ 60 POLES 4 SYNCHRONOUS SPEED 1800 RPM ACTUAL SPEED 1765 RPM TYPE OF START DIRECT ON LINE FLC 79 AMPS STARTING CURRENT 427 AMPS 98412.doc 23/10/02 Page 3 .15 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT app034c.4 1.11 1.1 1.10 1.1 1.11 1.12 1.4 1.6 1.7 1.9 1.3 1.W-EF SERIES Page 3 1.12 1.5 1.5 1.13 1.8 1.11 1.7 1.15 Y807363.7 1.8 1.4 1.5 1.13 1.14 1.12 1.9 1.10 1.14 1.13 1.15 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT 98412.3 1.1116 . 7 1.7 1.3 1.14 1.5 1.14 1.16 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT THERMISTORS Y46064.2 1.5 1.1 1.87764 .13 1.doc 23/10/02 .W-EF SERIES Page 4 1.15 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT 1.9 1.3 1.15 1.002 .8 1.16 TYPE PROTECTION FRAME SIZE MOUNTING INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START FLC STARTING CURRENT THERMISTORS 1.6 1.11 1.4 1.12 1.1 1.6 1.6 TYPE PROTECTION FRAME SIZE MOUNTING B3/B5 INSULATION TEMPERATURE RISE Page 4 app034c.N2.7 1.2 1.2 1.45 KW SQUIRREL CAGE IP55 TEFV W-DF225MN FOOT CLASS 'F' 80°C 40°C 400/3PH 50 4 1500 RPM 1470 RPM STAR/DELTA 80 AMPS 192 AMPS 93994/94340.5 1.9 1.8 1.12 1.4 1.10 1.3 1.6 1.14 1.10 1.11 1.4 1.30 KW SQUIRREL CAGE IP55 TEFV W-DF200L FOOT & FLANGE CLASS 'F' 80°C 1.5 1.CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 .15 1.8 1.003 .12 1.3 1.13 1.11 1.003 .75 KW SQUIRREL CAGE TEFV EEXD T4 IP55 CERTIFIED GROUPS IIA & IIB W-EF250 MN FOOT CLASS 'F' 80°C 40°C 400/3PH 50 4 1500 RPM 1480 RPM STAR/DELTA 133 AMPS 306 AMPS ONE FITTED PER PHASE 5436.10 1.90 KW SQUIRREL CAGE TEFV EEXD T4 IP55 CERTIFIED GROUPS IIA & IIB W-EF280 SN FOOT CLASS 'F' 80°C 40°C 380/3PH 50 4 1500 RPM 1475 RPM STAR/DELTA 165 AMPS 330 AMPS ONE FITTED PER PHASE Y55153.1 1.4 1.13 1.2 1.1 1.9 1. 12 1.002 .8 1.10 1.5 1.11 1.8 1.10 1.30 KW SQUIRREL CAGE IP55 TEFV W-DF200L FOOT & FLANGE CLASS 'F' 80°C 40°C 440/3PH 60 4 1800 RPM 1760 RPM DIRECT ON LINE 1.13 AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START 40°C 380/3PH 50 4 1500 RPM 1460 RPM DIRECT ON LINE 94430.9 1.CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 .doc 23/10/02 Page 5 .3 1.12 1.13 TYPE PROTECTION FRAME SIZE MOUNTING B3/B5 INSULATION TEMPERATURE RISE AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START app034c.9 1.4 1.7 1.2 1.1 1.11 1.6 1.7 1.W-EF SERIES Page 5 1. taking care not to damage the windings on insertion of rotor. Refit any pulley.doc 23/10/02 . as misalignment may lead to ultimate bearing failure and shaft breakage. provided there is little or no grease leakage. use only good quality lithium based grease and avoid overfilling the bearing housing. taking care not to damage the windings on insertion of rotor. Dry. Motors should be reassembled in the reverse order from dismantling. which have been removed. compressed air under comparatively low pressure is best as a high velocity stream can force dirt into the spaces between windings. Before starting.CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 . Page 6 app034c. remembering to ease endshields on bearings and spigots. Clear any dirt and fluff from behind the fan and along the ribs of the frame. Periodic Maintenance : Remove the cover and the fan which is fitted on the shaft extension. Grease removing solvents should only be used very sparingly so as not to damage impregnating varnish or insulation. etc. Routine Cleaning : Remove the fan cover and ensure that all holes are completely open. DO NOT USE FORCE.W-EF SERIES Page 6 ELECTRIC MOTOR MAINTENANCE WARNING : Isolate power supply to motor before commencing any routine cleaning or maintenance work. Ensure that the electrical connections are correct and terminal nuts tight. Bearings are charged with sufficient grease to last at least two years. Slacken and remove bearing cover screws and endshield bolts/studs. The rotor can now be withdrawn carefully from the stator. When replenishing. check that the rotor revolves freely. Having dismantled the motor.. being particularly careful to ensure correct alignment with the driven part. The endshields should then be eased off their spigots. maintenance can now be carried out to remove all dirt. sprocket etc. coupling. Tighten setscrews (10) nuts (15) evenly to the correct torque setting of 27Nm. tighten lock nut (1). 10 2 4 14 13 1 12 11 8 4 9 10 8 7 6 5 4 3 4 16 2 1 15 9 4 1 5 10 2 3 4 7 6 8 APP041.14) to valve body(s) (2) using silicon sealant on joint faces.Vs GENERAL Page 1 DIAPHRAGM DRAIN VALVES ASSEMBLY INSTRUCTIONS 1) 2) 3) 4) Assemble drain valve seat(s) (3 .D.CompAir UK Ltd APP 041 D. Assemble diaphragm (8) and joints (4) to cover (9) and body(s) (2).DOC . Assemble complete assembly tighten setscrews (10) nuts (15) finger tight. 13&14 3.2 C 201159 C 201417 C 200722 C 201981 98210.U334 J to M Item No 1 2&9 2&9 3 3 4 5.4 C 203190.1535 98650.DOC .CompAir UK Ltd APP 041 D.5.1532 Description DIAPHRAGM REPLACEMENT KIT VALVE REPLACEMENT KIT (LP) VALVE REPLACEMENT KIT (HP) J 2 0 2 K 1 0 1 L 2 1 1 M 2 1 1 APP041.12 &13 14 15 16 Part No PS 1290.D.1531 98650.6 & 7 8 10 11.6 &7 Part No 98650.1002 95006.133 C 201980 C 200842 95111.12.G J 2 1 0 2 0 4 2 2 6 0 0 0 0 K 1 0 1 1 0 2 1 1 3 0 0 3 3 L 2 1 0 0 1 4 1 2 6 1 1 0 0 M 2 1 0 0 1 4 1 2 6 1 1 0 0 SPARE PARTS LIST Item No 4&8 11.4 95000.1 C 203190.Vs GENERAL Page 2 PARTS LIST FOR STANDARD SINGLE AND DOUBLE UNITS .229 Description LOCK NUT DOUBLE DRAIN VALVE BODY ASSEMBLY SINGLE DRAIN VALVE BODY ASSEMBLY VALVE SEAT (HP) VALVE SEAT (HP) DIAPHRAGM JOINT VALVE/VALVE PLATE ASSEMBLY (HP) DIAPHRAGM HEX BOLT M6 X 75 LG VALVE/VALVE PLATE ASSEMBLY (LP) VALVE SEAT (LP) NUT M6 SETSCREW M6 X 20 L. C76320/1 C76320/2 C76319 C200302 76317/2 C200303 PS1205/4 PS1205/14 C77555 C76320/3 C23005 C74454/5 DESCRIPTION ADJUSTING SCREW LOCKNUT COVER VALVE BODY VALVE SEAT SEAT RETAINING PLUG “O” RING “O” RING VALVE SPRING COLLAR SPRING VALVE ROD NO OFF 1 1 1 1 1 1 2 2 1 1 1 1 App059. filters and the dryers (if fitted). 1 12 2 11 3 10 9 4 8 INLET 5 7 6 OUTLET ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. to give long filter life. locking in position with locknut (2). Adjustment is by adjusting screw (1) for setting to the desired pressure.CompAir UK Ltd APP 059 PRESSURE MAINTAINING VALVE U572B Page 1 PRESSURE MAINTAINING VALVE U572/B This valve is fitted to maintain a back pressure through the separators. good oil separation and low oil consumption.doc . This ensures that these items of equipment reach their optimum working pressure as soon as possible. doc .CompAir UK Ltd APP 059 PRESSURE MAINTAINING VALVE U572B Page 2 App059. a pointer not returning to zero may indicate serious damage to the gauge. This should be considered when handling and storing the removed pressure gauge. or also the minimum working pressure in cases of vacuum. The remainder of the pressure medium contained in the element may be hazardous or toxic. The pressure system must be totally relieved if the gauge can not be isolated otherwise. as this may generate sudden pressure surges that may damage the gauge. Unless the gauge temperature is considerably higher or lower than 20°C. app070. No attempt should be made to remove a pressurised gauge.doc . The pointer must fall within the thickened portion of the zero mark. INSTALLATION & COMMISSIONING The tightening and loosening of torque applied to the connection should be by means of the spanner flats provided on the stem and should not be by means of grasping the case as this may damage the gauge. Always open isolating devices always gently and never abruptly. Fluctuating pressure always reduces the maximum working pressure of the gauge. is indicated on the dial by corresponding marks w. On-site testing of the pressure gauge is feasible by means of special isolating devices enabling connection of a test gauge together with a suitable pressure source. Correct zeroing may be inspected by closing the isolating valve and relieving the gauge from pressure.CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL Page 1 PRESSURE GAUGES GENERAL The pressure gauge should be installed such as to avoid exposure to heat and vibration and to enable easy observation of the dial indication. No pressure higher than indicated by the working pressure symbol w must be applied to the gauge during hydrostatic pressure testing of the system. so to facilitate calibration or replacement the system must be de pressurised before any work is carried out. The maximum working pressure for which the gauge is suitable. IMPORTANT It is common practise to install the pressure gauge without an isolating device. The pressure gauge is liquid filled to provide better damping from pulsation’s. PRESSURE GAUGES IN SERVICE. Otherwise the gauge must be isolated or removed during this operation. doc .CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL Page 2 app070. CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.P.doc . Turn screw (A) again to set the lower pressure 150 bar on the GREEN pointer. NOTE: ALWAYS USE A CALIBRATED PRESSURE GAUGE WHEN SETTING PRESSURE SWITCHES. app081. When a pre-set pressure is reached the snap action contact changes state. delivery line. line.P. the pressure switch stops the compressor when the upper pressure limit is attained and triggers off the start when the lower limit is reached. It is usual to connect 1 and 2 to the compressor electrical control circuit terminals marked pressure switch'. INSTALLATION Pressure switches may be mounted in any convenient position close to the H. Where possible the pressure switch operating line should be taken from the receiver to avoid pressure oscillations. Mount the switch by the lugs provided on the casing. Turn screw (A) to raise the GREEN pointer to its highest point.1004 Page 1 PRESSURE SWITCH 98524/1004 OPERATION Located as close as possible to the H. Turn screw (B) so that the higher setting (175 bar) coincides with the RED pointer. AS THE MARKINGS ON SWITCHES ARE FOR INDICATION ONLY. B A Red Pointer 3 1 Green Pointer 4 2 SETTING Example of pressure setting to 150 bar minimum and 175 bar maximum. provided it is not subject to vibration and that the connecting pipe to the receiver does not exceed five metres. The switch transforms a change of pressure into an electrical 'On' or 'Off' signal. 1004 Page 2 app081.doc .CompAir UK Ltd APP 081 PRESSURE SWITCH 98524. 98524/1135 Setting Range 0.66. app086. 1096.CompAir UK Ltd APP 086 HIGH AIR PRESSURE SWITCH 98524.28 bar g rising Reset Differential 0. Set pressures: 98524/1049 Setting Range 2 . 98524/1137 Setting Range 3 .07 bar 98524/1103 Setting range 2 .15 psig rising 98524/1094 Setting Range 0. the compressor restarts.11 psig rising 98524/1096 Setting Range 1.1025/49/94/95/96/1103/4/7/28/35/36/37 Page 1 HIGH AIR/GAS PRESSURE SWITCHES PART NO: 98524/1025. When a pre-set pressure is reached the snap action contact stops the compressor.AUTO START/STOP Located as close as possible to the delivery air/gas line. TYPICAL SETTINGS . When a pre-set high pressure is reached the snap action contact stops the compressor. TYPICAL SETTINGS . 1094. 1103.4 bar g rising Reset Differential 0.6 bar 98524/1128 Setting Range 2. inlet air/gas line. the pressure switch stops the compressor when the upper pre-set pressure setting is attained and triggers off the start when the lower differential pressure limit is reached.14 . 1095.4 psig rising 98524/1095 Setting Range 0. 1049. The switch transforms a change of pressure into an electrical "On" or "Off" signal. 1128.07 bar 98524/1136 Setting Range 3 .5 mbar . 1104.42 bar g rising Set Pressure HIGH 31 bar g rising Set Pressure LOW 28 bar g falling.4 bar g rising Reset Differential 0.2 bar overload.2 .6 bar 98524/1107 Setting range 0. 1102. 98524/1104 Setting Range 2 .35 . ADJUSTING NUT CONDUIT THREAD INSTALLATION Mount the switch by the bracket provided.5 bar g rising. OPERATION .2 . The switch transforms a change of pressure into an electrical "On" or "Off" signal.70 bar g rising. after dropping to the lower setting.Set to actual operating pressures or check contract for details.MANUAL START/AUTO STOP Located as close as possible to the delivery. 1135.Set to actual operating pressures or check contract for details.66.4 bar g rising Reset Differential 0.doc .5 bar g rising Set Pressure HIGH 42 bar g rising Set Pressure LOW 39 bar g falling. Set pressures: 98524/1025 Setting Range 30"hg vac .4 . 1107. 98524/1137 Setting Range 3 . the pressure switch stops the compressor when the air/gas pressure rises or falls above or below the pre-set pressure setting. It is usual to connect 1 (C) and 2 (NC) to the compressor electrical control circuit terminals marked "Pressure Switch".2 . 1136 & 1137 OPERATION .70 bar g rising Set Pressure HIGH 40 bar g rising Set Pressure LOW 36 bar g falling.28 psig rising 98524/1102 Setting Range 0.125 mbar To withstand 2. CompAir UK Ltd APP 086 HIGH AIR PRESSURE SWITCH 98524. Turn adjusting nut clockwise to lower set point. a. Note:.1025/49/94/95/96/1103/4/7/28/35/36/37 Page 2 Remove cover to set pressure setting. Please confirm with Engineering at CompAir UK Ltd Ipswich if switches are to be adjusted. app086. c. To adjust differential use knotched wheel below the microswitch. b. Turn adjusting nut anti clockwise to raise set point.Switches are pre-set and do not usually need adjusting.doc . using a pressure gauge. 1 bar Standard SETTING 1 bar (15 psi) falling 0. 98524/1042 98524/1122 98524/1042 98524/1042 98524/1122 98524/1140 COMPRESSOR TYPE WATERCOOLED AIRCOOLED AIRCOOLED GAZPACKS AIRCOOLED 5450/5470 AIRCOOLED GAZPACKS AIRCOOLED GAS INLET PRESSURE Standard Standard over 0.1042/1122/1140 Page 1 LOW OIL PRESSURE SWITCH PART NO: 98524.CompAir UK Ltd APP 088 LOW OIL PRESSURE SWITCH 98524.1122 & 98524. PART NO.5 bar (7. the pressure switch stops the compressor when the oil pressure drops to pre-set pressure setting. app088.5 bar (7.1042. When a pre-set pressure is reached the snap action contact stops the compressor. in the oil filter body on aircooled. 98524. INSTALLATION It is usual to connect 1 (C) and 4 (N/O) to the compressor electrical control circuit terminals marked "Oil Pressure Switch".doc .1140 OPERATION Located in the crankcase on watercooled & large aircooled compressors.5 psi) falling 1 bar (15 psi) falling The switch transforms a change of pressure into an electrical "On" or "Off" signal.1 bar Standard up to 0.5 psi) falling 1 bar (15 psi) falling 1 bar (15 psi) falling 0. CompAir UK Ltd APP 088 LOW OIL PRESSURE SWITCH 98524.doc .1042/1122/1140 Page 2 app088. 2 C202749.1 &.doc . ALWAYS LOCATE AND CORRECT POSSIBLE FAULT BEFORE ANY ATTEMPT IS MADE TO ALTER SETTING.1 C202960.5470 DELY A TO SET.5415 5215 & 5217 5236. ESTABLISH NORMAL RUNNING TEMPERATURE.4 C202960.5417.2 C202960. C202749. see Note Below.1 5212 5336.1 C202556.5436N.3 C202960. IF THE SWITCH NEEDS TO BE RE-ADJUSTED DUE TO A HIGHER AMBIENT TEMPERATURE OR ANY REASONS PLEASE CONTACT COMPAIR UK LTD.5436N 5280. app090.2.CompAir UK Ltd APP 090 THERMOMETER SWITCH C202556/749/960/964 Page 1 THERMOMETER SWITCH C202556.5436SN & 5437 5280 5280 5409 WATERCOOLED M/C’S DELIVERY 5211 WATER OUTLET 5207.4 C202556. THE FOLLOWING INFORMATION IS FOR SETTING INFORMATION ONLY.5 C202556.1 C202749.8 C202749.7 C202556.2 C202556.5417N 5436(CU TUBES) 5436.5282. C202960 & C202964 THESE THEMOMETER SWITCHES ARE SET TO THE FIGURES QUOTED BELOW.2. SET POINTER BY TURNING CENTRAL KNOB ADJUSTER ‘A’ TO 10°C ABOVE THIS TEMPERATURE NOTE: DO NOT RESET TEMPERATURE CONTROLLER SETTING IF IT TRIPS.5283.3 C202960.3 C202556.5436H. IPSWICH FOR MORE INFORMATION.5209. IF THE TEMPERATURE SWITCH HAS TO BE REPLACED OR RE-ADJUSTED.5315 5415E5317.5 C202964.1 C202964. DELY 5450. CONTACT CompAir UK Ltd IPSWICH ENGINEERING DEPARTMENT FOR MORE INFORMATION BEFORE RESETTING TEMPERATURE SWITCHES AS THIS COULD BE DETRIMENTAL TO THE SAFE OPERATING OF THE COMPRESSOR. CONTROLLER PART No C202556.5213 5417N.6 C202556.5281.2 TRIP POINTER STOP SETTING °C 125 140 150 155 170 180 205 220 200 210 175 75 60 55 80 50 75 60 USED ON COMPRESSOR MODEL 5236. doc .CompAir UK Ltd APP 090 THERMOMETER SWITCH C202556/749/960/964 Page 2 app090. NBF BA320 A182 – 1.6 Ø NBF BD320 A182 – 1.8 Ø 1 2 3 4 5 6 8 7 9 11 12 10 13 MAINTENANCE WARNING: The following procedures should only be undertaken by a qualified BASEEFA approved electrician. app152.8 Ø NBF BD320 A180 – 0.6 Ø NBF BA320 A180 – 0. with flameproof construction cast iron housing & cover. Turn off electrical power supply and line pressure to valve before making any repairs.doc .8 Ø NBF TB320 A180 – 0. Note: It is not necessary to remove valve from pipeline to effect repair.6 Ø NBF BE320 A182 – 1. as any illegal attempts to repair may render the BASEEFA certificate void.CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES Page 1 FLAMEPROOF SOLENOID VALVE Connections 1/4” NPT Connections 1/4” BSPP Connections 1/4” BSPT Connections 1/4” NPT Connections 1/4” NPT Connections 1/4” BSPP Connections 1/4” BSPT GENERAL Three way normally closed valve.8 Ø NBF BE320 A180 – 0. When re-assembling. Replace worn or damaged parts with a complete spare parts kit for the best results. remove body gasket (11) (lower). d. core spring (7). j. I. g.CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES Page 2 CLEANING A periodic cleaning of all solenoid valves is desirable. Replace worn or damaged parts with a complete Spare Parts Kit for best results. Replace if necessary. Remove lock screw 2mm A/F hexagon wrench. Remove core assembly (6). The time between cleaning will vary depending on the medium and service conditions. IMPROPER OPERATION a. VALVE DISASSEMBLY & RE-ASSEMBLY a. e. c. Keep medium flowing through valve as free from dirt and foreign matter as possible. Withdraw complete solenoid valve enclosure from solenoid base. non combustible fluid.doc . broken lead wires terminals or spliced connections. WARNING: To prevent the possibility of severe personal. c. Thoroughly clean all parts. Faulty Control Circuit: Check electrical system by energising solenoid. c. In general if the voltage to the coil is correct sluggish valve operation. Note: Any repair to this unit should be undertaken by the manufacturer or his agent. core guide (8) and body gasket (upper) (9). njury or property damage. Re-assemble in reverse order of dismantling. high grade Silicon Grease. All parts are now accessible for cleaning or replacement. Burned Out Coil: Check for open-circuited coil. Excessive Leakage: Disassemble valve and clean all parts. Pressure to valve must be within the range specified on the nameplate. gaskets & disc spring. h. d. f. Whilst in service operate valve at least once a month to ensure proper opening and closing. check valve for proper operation before returning to service. as it may invalidate the BASEEFA certificate. b. paying careful attention to cleanliness. Also perform internal seat and external leakage tests with non-hazardous. Depressurise valve and turn off electrical power supply. After maintenance. app152. Clean valve strainer or filter when cleaning solenoid valve. b. sub-assembly and end cap on assembly to 19. operate the valve a few times to be sure of proper operation. A metallic click signifies the solenoid is operating. core guide. Check for loose or blown fuses. a metallic click signifies the solenoid is operating. Lift out terminal block and insulator (2) Remove retaining cap (3) and clip (4). Unscrew cover (1) use suitable flat bar. COIL REPLACEMENT (Refer to Drawing) Turn off electrical power supply and disconnect coil lead wires. open-circuited or grounded coil. lubricate body gaskets with DOW CORNING 111 compound lubricant or equivalent. e. Unscrew end cap (10). Incorrect Pressure: Check valve pressure. Remove terminal block screws. Replace parts that are worn or damaged. Excessive leakage or noise will indicate that cleaning is required. k.8 Newton metres. Change whole assembly if faulty. Torque both solenoid base. SPARE PARTS KIT Comprises Retaining Clip & cap. b. disc spring (12) and disc holder sub-assembly (13). Voltage must be at least 85% of nameplate rating. core assembly. Unscrew solenoid base sub-assembly (5). Absence of the click indicates loss of power supply. Low Voltage: Check voltage across coil leads. Periodic inspection (depending upon medium and service conditions) of internal valve parts for damage or excessive wear is recommended. PREVENTIVE MAINTENANCE a. 004 Description 3/2 Solenoid valve Orifice Ø0.1141 Description 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve Orifice Ø1.1078 98516.6 Orifice Ø1.6 Orifice Ø1.6 Orifice Part Number .8 Orifice Ø0.6 Orifice Ø1.1038 Description 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve NBF BD320 A182 Coil Voltage 230V/1PH/50HZ 220V/1PH/50HZ 110V/1PH/50HZ 220V/1PH/60HZ 110V/1PH/60HZ 110 VDC NBF BA320 A182 Coil Voltage 230V/1PH/50HZ 220V/1PH/50HZ 110V/1PH/50HZ 220V/1PH/60HZ 110V/1PH/60HZ 24 VDC NBF BE320 A182 Coil Voltage 220V/1PH/50HZ 240V/1PH/50HZ 120V/1PH/50HZ 240V/1PH/60HZ 24 VDC 110V/1PH/50HZ 115V/1PH/50HZ N/C Thread Connection ¼” BSPP ¼” BSPP ¼” BSPP ¼” BSPP ¼” BSPP ¼” BSPP N/C Thread Connection ¼" NPT ¼" NPT ¼" NPT ¼" NPT ¼" NPT ¼" NPT N/C Thread Connection ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT Orifice Ø1.8 Orifice Ø0.6 Orifice Ø1.6 Orifice Ø1.1100 Description 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve Orifice Ø0.6 Orifice Ø1.1131 98516.1080 98516.1036 98516.6 Orifice Ø1.CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES Page 3 PARTS LIST Part Number 98516.1035 98516.6 Orifice Part Number 98516.1074 98516.1073 98516.1135 Description 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve 3/2 Solenoid valve Orifice Ø1.6 Orifice Ø1.1077 98516.6 Orifice Part Number 98516.8 Orifice Part Number 98516.8 Orifice Ø0.1079 98516.1037 98516.1034 98516.1033 98516.1133 98516.8 Orifice app152.8 Orifice Ø0.6 Orifice Ø1.6 Orifice Ø1. Description 3/2 Solenoid valve NBF BB320 A180 Coil Voltage 110V/1PH/50HZ NBF TB320 A180 Coil Voltage 230V/1PH/50HZ NBF BB320 A190 Coil Voltage 220V/1PH/50HZ 240V/1PH/50HZ 120V/1PH/50HZ 240V/1PH/60HZ 24 VDC 110V/1PH/50HZ N/C Thread Connection ¼" NPT N/C Thread Connection ¼" NPT N/O Thread Connection ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT ¼" BSPT Orifice Ø0.1132 98516.8 Orifice Ø0.6 Orifice Ø1.1081 98516.6 Orifice Ø1.6 Orifice Ø1.1082 98516.8 Orifice Part Number .1134 98516.55153.6 Orifice Ø1.1075 98516.1130 98516.1076 98516.doc .6 Orifice Ø1.1099 98516.6 Orifice Ø1. doc .CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES Page 4 app152. with flameproof construction cast iron housing & cover.doc .CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE Page 1 FLAMEPROOF SOLENOID VALVE GENERAL Two way normally closed valve. 1 2 3 4 5 8 7 9 6 10 app153. Turn off electrical power supply and line pressure to valve before making any repairs. b. In general if the voltage to the coil is correct sluggish valve operation. Low Voltage: Check voltage across coil leads. Excessive leakage or noise will indicate that cleaning is required. Replace worn or damaged parts with a complete spare parts kit for the best results. broken lead wires. Burned Out Coil: Check for open-circuited coil. Faulty Control Circuit: Check electrical system by energising solenoid. Change whole assembly if faulty. Pressure to valve must be within the range specified on the nameplate. PARTS LIST Part Number Description Coil Voltage Thread Connection 2" BSPP 1. Incorrect Pressure: Check valve pressure. Absence of the click indicates loss of power supply.1143 2 Way Solenoid valve NBE 215 B080 230V/1PH/50HZ NBE 215 B070 2 Way Solenoid valve 220V/1PH/50HZ Ø53 Orifice Ø42 Orifice app153. Note: Any repair to this unit should be undertaken by the manufacturer or his agent. Note: It is not necessary to remove valve from pipeline to effect repair.CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE Page 2 MAINTENANCE WARNING: The following procedures should only be undertaken by a qualified BASEEFA approved electrician.1129 98516. Voltage must be at least 85% of nameplate rating. as it may invalidate the BASEEFA certificate. IMPROPER OPERATION a.1/2" BSPP Orifice 98516. d. Excessive Leakage: Disassemble valve and clean all parts. as any illegal attempts to repair may render the BASEEFA certificate void. Check for loose or blown fuses. Keep medium flowing through valve as free from dirt and foreign matter as possible. Whilst in service operate valve at least once a month to ensure proper opening and closing.doc . Clean valve strainer or filter when cleaning solenoid valve. terminals or spliced connections. COIL REPLACEMENT (Refer to Drawing) Turn off electrical power supply and disconnect coil lead wires. Replace parts that are worn or damaged. c. b. e. open-circuited or grounded coil. CLEANING A periodic cleaning of all solenoid valves is desirable. Replace if necessary. a metallic click signifies the solenoid is operating. Thoroughly clean all parts. The time between cleaning will vary depending on the medium and service conditions. c. Periodic inspection (depending upon medium and service conditions) of internal valve parts for damage or excessive wear is recommended. PREVENTIVE MAINTENANCE a. Lift out terminal block and insulator (2) Remove retaining cap (3) and clip (4). All parts are now accessible for cleaning or replacement. lubricate the following parts with RemGrit TFL50 dry lubricant: Diaphragm assembly on both sides. Replace solenoid assembly. Unscrew solenoid base sub-assembly (5) using special wrench. n.8 Newton metres. Replace. check valve for proper operation before returning to service. high grade Silicon Liquid. l. Caution: Do not distort hanger spring between core assembly and diaphragm assembly when lubricating pilot disc. Also perform internal seat and external leakage tests with non-hazardous. Unscrew cover (1) use suitable flat bar. Torque solenoid base sub-assembly to 19. WARNING: To prevent the possibility of severe personal injury or property damage. Remove bonnet screws (6). lubricate bonnet and body gaskets with DOW CORNING 200 fluid liquid or equivalent. Torque screws in a criss-cross manner to 11. Replace body gasket (10) and core/diaphragm sub-assembly with closing spring attached. Withdraw complete solenoid valve enclosure from solenoid base. Important: If the valve has been disassembled for inspection and cleaning only and a rebuild kit is not being used. valve bonnet and bonnet screws (6). pilot disc at base of core assembly. A metallic click signifies the solenoid is working. e. Locate bleed hole in core/diaphragm sub-assembly approximately 30° form the valve inlet. bonnet gasket (8) core diaphragm (9) subassembly and body gasket (10). main disc at base of core/diaphragm sub-assembly.CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE Page 3 VALVE DISASSEMBLY & RE-ASSEMBLY Depressurise valve and turn off electrical power supply. Remove terminal block screws. operate the valve a few times to be sure of proper operation. d. non combustible fluid. Remove lock screw 2mm A/F hexagon wrench. After maintenance. j. Replace worn or damaged parts with a complete Spare Parts Kit for best results. SPARE PARTS KIT Always quote number stamped on nameplate when ordering spare parts. g.doc . valve body where diaphragm assembly contacts the valve body and body gaskets. internal surface of valve bonnet where diaphragm assembly contacts bonnet when valve is energised (open position). Apply a light coat of RemGrit TFL50 Dry lubricant to the following: Valve seat. i. app153.3 Newton metres. m. b. When re-assembling. Replace bonnet gasket (8) and solenoid base assembly the install bonnet gasket (see earlier instructions on lubricants) housing and solenoid base sub-assembly. c. k. f. h. a. valve bonnet (7). CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE Page 4 app153.doc . 5 58 63 73. Note valves with 'O' ring seals do not need maintenance.20°C to +170°C ID Number 118001C 118002C 118003C 118004C 118005C 118006C 118007C 118008C 118009C 118010C 118011C A 46. 40 bar at 90°C . any leaks or faulty operation replace complete valve.1/2” BSPP 2” BSPP 2.5 46.5 58 63 73.Stainless Steel female / female TECHNICAL SPECIFICATION Working Pressure Temperature Range TYPE CompAir Part No 98650/2076 98650/2077 98650/2078 98650/2079 98650/2080 98650/2081 98650/2082 98650/2083 98650/2084 98650/2085 98650/2086 40 bar at 90°C .1/2” BSPT 2” BSPT 2.5 59 69 82 93 104 126 146 170 200 B 80 80 90 110 110 140 140 160 180 225 270 C 39 39 52. maintenance consists of periodically tightening the stem nut 1/4 turn to compensate for wear on the stem and seal.20°C to +170°C ID Number 118001 118002 118003 118004 118005 118006 118007 118008 118009 118010 118011 A 46.1/2” BSPT 3” BSPT 4” BSPT Bore Ø mm 8 10 15 20 25 32 40 50 GENERAL PARALLEL THREADS CP90 .5 59 69 82 93 104 126 146 170 200 B 80 80 90 110 110 140 140 160 180 225 270 C 39 39 52.CompAir UK Ltd PUBLICATION APP154 BALL VALVES 98650.1968/78/2076/86 Page 1 BALL VALVE GENERAL TAPER THREADS CP90T .Stainless Steel female / female TECHNICAL SPECIFICATION Working Pressure Temperature Range TYPE CompAir Part No 98650/1968 98650/1969 98650/1970 98650/1971 98650/1972 98650/1973 98650/1974 98650/1975 98650/1976 98650/1977 98650/1978 MAINTENANCE The only maintenance necessary is to check for smooth operation and for gas leaks.6 95 127 155 170 D 8 108 15 20 25 32 40 50 65 80 100 Thread Ø 1/4” BSPT 3/8” BSPT 1/2” BSPT 3/4” BSPT 1” BSPT 1.6 79.doc .1/4” BSPT 1.1/4” BSPP 1. For valves fitted with adjustable gland seal.1/2” BSPP 3” BSPP 4” BSPP Bore Ø mm 8 10 15 20 25 32 40 50 app154.6 95 127 155 170 D 8 108 15 20 25 32 40 50 65 80 100 Thread Ø 1/4” BSPP 3/8” BSPP 1/2” BSPP 3/4” BSPP 1” BSPP 1.6 79.5 46. doc .2076/86 Page 2 B C D A App154.CompAir UK Ltd PUBLICATION APP154 BALL VALVES 98650. 6000 psi Body material (Chrome plated brass) CZ121 6 4 5 1 3 7 2 Item No. 1 2 3 4 5 6 7 8 Connections 1/4” BSP (G1/4) CompAir Part Number 98650/1422 TECHNICAL SPECIFICATION Description Body Spindle ‘O’ ring collar Guide Washer Spring Locknut ‘O’ Ring .1422/1655 Page 1 NON-RETURN VALVE Connections 1/2” BSP (G1/2) CompAir Part Number 98650/1655 TECHNICAL SPECIFICATION Maximum Working Pressure .doc .6000 psi Body material (Stainless Steel) 1 6 4 5 3 7 8 2 Item No.CompAir UK Ltd PUBLICATION APP158 NON RETURN VALVE 98650.PS1205/9 Retainer Clip No Off 1 1 1 1 1 1 1 1 Maximum Working Pressure . 1 2 3 4 5 6 7 Description Body Spindle ‘O’ ring collar Guide Washer Spring Locknut ‘O’ Ring No Off 1 1 1 1 1 1 1 app158. 1422/1655 Page 2 App158.doc .CompAir UK Ltd PUBLICATION APP158 NON RETURN VALVE 98650. APP167 . Any condition that could lead to blockage of discharge piping or discharge ports on safety valves must be avoided. Where valves are supplied without easing gear. to ensure that foreign matter does not pass through the valve. material and type etc.F. valve so that no unacceptable mechanical load or vibration is transmitted to the valve. This should be carried out by operating the easing gear when the valve is under a pressure of not less than 75'% of the set pressure. of storage. Discharge pipes should be as short as possible and of such a size that the pressure developed therein not reduce the relieving capacity. Process or other conditions which might adversely affect the performance of the safety valve. Installation must be undertaken by qualified technicians and to good engineering practice. Testing should not create a hazard. Safety valves should be mounted as close as possible to the protected system. particular attention being given to foreign matter located in discharge outlets. To prevent unnecessary lifting of the safety valve it is recommended that there is a margin of at least 10% between the maximum operating pressure and the set pressure of the safety valve.CompAir UK Ltd. user's attention is drawn to our joint responsibility to ensure that the Health and Safety at Work Act is not contravened by incorrect installation. VALVE OUTLET: No isolating devices shall be fitted to the outlet pipe. Where appropriate. INSTALLATION VALVE INLET: Under no circumstances should it be possible to isolate the safety valve from the protected system. Particular care should be taken with the use of scaling compounds and P. It is important that the valve to be installed is correct in every aspect. at least equal to that of the safety valve inlet. GENERAL: Inlet and outlet piping should be capable of supporting the safety. as they also prevent the ingress of foreign matter. discharge pipes should be provided to a non-hazardous location. the test should be in accordance with the full functional test described overleaf. or more. STORAGE OF VALVE BEFORE INSTALLATION Valves should be stored preferably between-5°C and +25°C and a relative humidity of less that 75%. a drain should be provided which leads to a safe discharge location. Ensure arrows indicating the direction of the flow are pointing in the correct direction. prior to testing or installation. it must be subjected to functional test before commissioning. Atmospheric discharge or discharge pipes should terminate at a location which will not cause a hazard to personnel. Thread protectors should not be removed until immediately.T.e. which could harm the valve. size. Where safety valves are discharged into a manifold.E. APP167 SAFETY VALVE I&O INSTRUCTIONS Page 1 Installation and Operating Instructions SAFETY VALVES INTRODUCTION Due consideration should be taken of climatic. If a safety valve is installed after six months. i. the manifold must be capable of accommodating simultaneous discharge of all valves connected to the manifold. The inlet line to the safety valve should have an effective area of flow. which could possibly obstruct or restrict free and full discharge through the valve. and be sufficiently strong to withstand 'the effects of the reaction forces when the valve is discharging. The maximum pressure drop through the inlet line to the safety valve should not exceed 3% of the set pressure when the valve is discharging at its rated capacity. Atmospheric discharge valves should not be painted or coated with any substance. The cross-sectional area of the discharge pipe should not be less than the area of the safety valve outlet. Where there is a possibility of a liquid head forming in a discharge pipe. FUNCTIONAL TESTING Once installed in service. Valves should be tested at least once every six months to ensure free movement of parts. Very moist or dry conditions should be avoided. Due regard must be paid to the safety personnel. for the application. Commissioning or servicing. All pipework or pressure vessels to which the safety valve is connected should be thoroughly cleaned before fitting the safety valve. In addition. set pressure. The connecting pipe should be straight and as short as possible. CompAir Limited should be consulted if the safety valve is to be mounted in any position other than vertically. particular attention being given to hazardous fluids or particles. Suitable protection should be provided to prevent environmental build up or ingress of foreign matter. tape to ensure that they do not enter the valve.DOC . wire locked.1021 is the base unit number.1022-90T -90 being to the setting in bar g .wire locked.wire locked.1020 is the base unit number.6 -7. 98650.1164-28 -28 being to the setting in bar g .1021-9.1020-3. examples:98650. -96.wire locked and tagged.wire locked.1022 is the base unit number.1163-7.8T -3.2073 is the base unit number.1164 is the base unit number. 98650. 98650.wire locked and tagged.25 being to the setting in bar g .DOC . APP167 SAFETY VALVE I&O INSTRUCTIONS Page 2 CONFIGURATION The valves have a base number for different type valve arrangement from this information the valve set pressure can be obtained.2073-16.1163 is the base unit number. 98650. APP167 . Note the valves cannot be interchanged as the range of setting is limited.2 98650.6 being to the setting in bar g .25 -16.6 being to the setting in bar g .wire locked. 98650. 98650.2 being to the setting in bar g . 98650.6 -9.8 being to the setting in bar g .CompAir UK Ltd. 98650. 98650. 98650.2073-96. 98650. INTRODUCTION For mounting between BS4504 NP16 flanges.8 Page 1 SWING CHECK VALVE. PUBLICATION APP169a SWING CHECK VALVE 98650.2091 98316-080-746-P-16B/PN16 Ø50 BS4504 NP16 APP169a . Part Number: S5.2091 Y408546.SBE Ø46 NP16 98650.8 S5.SBE Description Part number Orifice Flange Description Part number Orifice Flange Y408546.065.DOC .065.CompAir UK Ltd. PUBLICATION APP169a SWING CHECK VALVE 98650.DOC .8 Page2 APP169a .2091 Y408546.CompAir UK Ltd. This ensures that these items of equipment reach their optimum working pressure as soon as possible. good oil separation and low oil consumption. locking in position with locknut (2). filters and the dryers (if fitted). to give long filter life. 1 12 2 11 3 10 9 4 8 INLET 5 7 6 OUTLET ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO.CompAir UK Ltd APP 059 PRESSURE MAINTAINING VALVE U572B Page 1 PRESSURE MAINTAINING VALVE U572/B This valve is fitted to maintain a back pressure through the separators. C76320/1 C76320/2 C76319 C200302 76317/2 C200303 PS1205/4 PS1205/14 C77555 C76320/3 C23005 C74454/5 DESCRIPTION ADJUSTING SCREW LOCKNUT COVER VALVE BODY VALVE SEAT SEAT RETAINING PLUG “O” RING “O” RING VALVE SPRING COLLAR SPRING VALVE ROD NO OFF 1 1 1 1 1 1 2 2 1 1 1 1 App059. Adjustment is by adjusting screw (1) for setting to the desired pressure.doc . doc .CompAir UK Ltd APP 059 PRESSURE MAINTAINING VALVE U572B Page 2 App059. The use of replacement parts not supplied by or recommended by CompAir UK Ltd may create unsafe and hazardous conditions or result in damage to the equipment over which CompAir UK Ltd has no control. Longer valve life. Reduces oil consumption. GENUINE PARTS CompAir UK Ltd Use Reavellite compressor lubricant. may lead to failure in service which would not be covered by the warranty. Ipswich. Such hazardous conditions may lead to accidents that can be life threatening.com e-mail: Ipswich@CompAir. Longer time between oil changes. CompAir UK Ltd can bear no responsibility for equipment in which unapproved replacement parts are included.WARNING The use of replacement parts or lubricating oils not supplied. Reduces carbon build up. Can be used in new or old compressors. Any unauthorised modifications or failures to maintain this equipment is accordance with the manufacturers maintenance instructions may make it unsafe. CompAir UK Ltd Sales. recommended or approved by CompAir UK Ltd. Service and Parts Ranelagh Road Ipswich IP2 0AE England +44 (0) 1473 602222 +44 (0) 1473 556027 +44 (0) 1473 601704 +44 (0) 1473 601282 Telephone: Customer Service: Fax: Parts Fax: www. Advantages: • • • • • • Longer life. cause substantial bodily injury or result in damage to the equipment.com .CompAir.