Sie sind auf Seite 1von 190

CompAir UK Ltd ADOBE ACROBAT READER

Page 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: Ipswich@CompAir.com

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

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 - Safety Requirements ) ( Known as the Pressure Equipment Directive [PED] )

DECLARATION OF CONFORMITY FOR BELOW

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. _________________________

to which this declaration relates 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.

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.

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.

incorporationPED-D

COMPRESSOR LOG SHEET


COMPRESSOR TYPE: SPEED: SERIAL NO: DATE TIME PRIME MOVER TYPE: B.H.P. DRIVE: *HOURS STAGE RUN TEMP.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.C INSTALLED AT DATE INSTALLED: FINAL AIR SERVICE PLAN PRESSURE STAGE PRESSURES #(BAR - PSI) NUMBER #(BAR - PSI) 1 2 3 4 5

REF. NO.
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 - PARTS +44 (0) 1473 601282
logsheetm.doc

DATE

REMARKS

DATE

REMARKS

logsheetm.doc

Page 1

QUICK REFERENCE GUIDE TO OPERATOR MANUAL 98407/1293 PART NUMBERS USING P & I DIAGRAM D70938
PART DESCRIPTION DESIGNATION SCHEDULE No CONTROL PANEL H5437.1.NG COMPRESSOR MODULE 55153 H5437 .1.NG Bare Shaft Compressor H5437.1.NG BELT DRIVE COMPONENTS H5437.1.NG Motor Electric - Main 380V/3PH/50HZ H5437.1.NG Belt Adjustments Vee Drive H5437.1.NG Bush Taper Lock Motor H5437.1.NG Pulley Motor H5437.1.NG Belt SPC 2800 FRAS Vee Drive H5437.1.NG Pulley Flywheel Compressor H5437.1.NG Guard Belt Drive H5437.1.NG CRANKCASE & LUBRICATION SYSTEM H5437.1.NG Valve Isolating Lubricating Oil Drain ISOL101 Gauge Oil Level LG101 Pump Oil H5437.1.NG Switch Low Oil Pressure PSLL101 Gauge Pressure Oil PI101 Valve Relief crankcase PSV03 Gauge Pressure crankcase COOLING WATER PATH H5437.1.NG Bursting disc H5437.1.NG GAS SYSTEM H5437.1.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. SECTION No Y55153.001 9.10.1 5437CNG.55153 98407.1293.6 6&7 5437CNG.55153 9.2 Y55153.002 APP034C 9.11.1 98407.1293.9 APP12g 9.2 98074.1347 APP12g 9.2.18 98080.1360 APP12g 9.2.16 98080.1491 APP12g 9.2.17 E61673 9.2.5 E61674 9.2.4 98407.1293 2.3 98650.1971 APP154 98281.1002 6.1.22 C85737.2 6.3.16 98524.1042 APP088 6.1.31 98288.1019 APP070 7.18.1 98650.2088-2.1APP167 7.1.6 98288.1086 APP070 7.1.3 5437CNG.55153C201658.2 6.13 5437CNG.55153 STAGE 40 Y55153.003 APP153 9.12.1 98650.2078 APP154 9.5.24 98288.1086 APP070 7.16.4 98650.2091 APP169A 9.5.26 98650.2082 APP154 9.5.22 98650.2088-2.1APP167 7.16.14 98524.1128 APP086 7.16.8 98524.1127 APP086 7.16.11 98650.2076 APP154 7.16.13 98650.2088-2.1APP167 7.1.6 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.doc

04/09/02

Page 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 H5437.1.NG H5437.1.NG H5437.1.NG H5437.1.NG H5437.1.GAS H5437.1.GAS H5437.1.NG PI10 PSV10 DDV10 SOL10 H5437.1.GAS H5437.1.NG H5437.1.GAS H5437.1.GAS H5437.1.NG PI20 PSV20 DDV20 H5437.1.GAS H5437.1.GAS H5437.1.GAS H5437.1.GAS TE/TI/TS30 H5437.1.GAS PI30 PSV30 DDV30 H5437.1.NG H5437.1.GAS H5437.1.GAS H5437.1.GAS PI40 SHEET No PART NO ANCILLARY PUBLICATION. SECTION No 5437CNG.55153 STAGE 50 9.6 5437.1.GAS/.1.NG 6&7 D101719 7.5 D101728 7.14 E61641 6.7 D101725 6.8 E61518 7.8 98288.1020 APP070 7.18.2 98650.1020-10 APP167 6.19.6 U334.L APP041 6.24 Y55153.004 APP152 9.13.1 D101750 6.5.2 D101729 6.14.2 E61641 6.7 D101725 6.8 E61519 6.8.1.3 98288.1021 APP070 7.18.3 98650.1021-40 APP167 6.19.5 U334.L APP041 6.24 D101751 6.5.3 D101730 6.14.3 E61642 6.9 D101609 6.10 C202556.8 -APP090 6.18.7 D101726 6.10.3 98288.1022 APP070 7.18.4 98650.1022-150 APP167 6.19.4 U334.J APP041 6.24 D101760 6.5.4 D101731 6.14.4 E61642 6.9 D101610 6.11 98288.1023 APP070 6.18.5
1293ind55153.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

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. SECTION No Valve Safety 4th Stage PSV40 98650.1190-275 APP167 7.19.1 Separator Assembly Final Stage H5437.1.NG D101619 7.20 Valve Isolating Separator Drain ISOL61 98261.1071 C203998 7.21.4.6 Diaphragm Drain Valve 4th Stage DDV30 U334.J APP041 6.24 Temperature Trip 4th Stage TE/TI/TS40 C202960.1 -APP090 6.18.8 Valve Non-Return Compressor Delivery NRV61 98650.1655 APP158 6.20.3 Valve Pressure Compressor Delivery PCV61 U572.B APP059 9.8.3 Switch Pressure Final Delivery PSHH/LL/I61 98524.1004 APP081 9.8.15 Flexible Hose Inlet 5437CNG.55153 98315.1211 9.5.30 INLET CONNECTION 600 MM LONG FLEXIBLE HOSE 80 NB FLANGE BS4505 PN16. Flexible Hose Return R/V Manifold 5437CNG.55153 98315.1212 9.6.17 1.1/2" BSPT CONNECTION FLEXIBLE HOSE. Flexible Hose Return Surge Vessel 5437CNG.55153 98315.1212 9.5.29 1.1/2" BSPT CONNECTION FLEXIBLE HOSE. Flexible Hose Final Delivery 5437CNG.55153 98315.1214 9.8.21 FINAL DELIVERY CONNECTION 1000 MM LONG FLEXIBLE HOSE SUITABLE FOR 12 MM COMPRESSION FITTING. Page No 88 88 89 76 56 57 101 101 101 101 101 102

1293ind55153.doc

04/09/02

Page 3

CompAir UK Ltd AMENDMENTS 98407.1293


Page 1

AMENDMENTS 5437.1.NG PUBLICATION 98407.1293


ISSUE No. 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. CHANGE - M/C SERIAL No. NEW Amend 'air' to 'gas' where appropriate, typing error. DATE JULY 2000 SEPT 2002 PAGE Nos ALL SECTIONS 1 TO 5

1293amendments.doc

CompAir UK Ltd AMENDMENTS 98407.1293


Page 2

1293amendments.doc

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 1

OPERATOR MANUAL - 5000 SERIES GAS COMPRESSORS


CONTENTS
Page Ownership Data -------------------------------------------------------------------- 2 Foreword ----------------------------------------------------------------------------- 3 Safety Precautions ---------------------------------------------------------------- 5 Dry Gases ----------------------------------------------------------------------------11 Typical Gas Purging Instructions --------------------------------------------12

WARNING
The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd, or the failure to maintain this equipment in accordance with the maintenance instructions, may invalidate the WARRANTY, cause equipment failure, create unsafe or hazardous conditions or result in damage to the equipment. CompAir UK Ltd cannot accept responsibility for damage, injury or failure caused by these situations.

USE ONLY

CompAir UK Ltd GENUINE PARTS AND AUTHORISED SERVICE AGENTS

gassafety.doc

04/09/02

Page 1

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. Ph. Hz:

Compressor Lubricant:

Motor Bearing Grease: (if applicable) Notes:

Capacity M/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, Ranelagh Road, Ipswich 1P2 0AQ. England marked for the attention of Mr. Dennis Beeton, Technical Publications Engineer.

Page 2

04/09/02

gassafety.doc

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 3

FOREWORD
CompAir UK Ltd 5000 Series compressors are designed and manufactured to give optimum performance, with long life and reliability. This Manual will help you to obtain the best performance from your compressor. It provides the information required to install, commission and operate the compressor and carry out regular maintenance schedules, which will ensure the maximum satisfactory service life. Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing. Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network of CompAir Companies and CompAir UK Ltd Distributors, backed by the Service and Parts Departments at CompAir UK Ltd, Ipswich (UK) tel: +44 (0) 1473 602222. fax: +44 (0) 1473 601704. Customer Service +44 (0) 1473 556027 or Parts fax: +44 (0) 1473 601282. 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. 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. In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No. and any CONTRACT Ref. 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. 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. Protect the environment by using only approved methods of disposal. Please note: a. b. Throughout the Manual all pressures quoted are gauge pressures. Whilst recyclable materials are used as far as possible, please ensure when disposing of condensate, spent oil, used filter elements and any discarded parts or waste material of any kind make sure that there is no pollution to any natural watercourse, drain system and that no burning waste takes place which could cause pollution of the atmosphere.

CAUTION
Use only CompAir UK Ltd Genuine Parts when carrying out routine maintenance or repair. The use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd can lead to expensive failures, which will not be covered by warranty. Substitution of parts not manufactured or approved by CompAir UK Ltd can create a potential personnel hazard. This is a High Pressure Compressor, 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 - refer to the Maintenance Section.

Conditions of CompAir UK Ltd warranty are stated in our Conditions of Sale. Details of warranty for a particular unit may be obtained from the local CompAir Company or authorised Distributor.

gassafety.doc

04/09/02

Page 3

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 4

Page 4

04/09/02

gassafety.doc

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 5

SAFETY PRECAUTIONS
Page Warnings General-------------------------------------------6 1 2 3 4 5 6 7 Regulations ---------------------------------------------------7 Warnings, 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.doc

04/09/02

Page 5

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. 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. If any replacement or repair is needed use genuine CompAir UK Ltd parts.

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.

Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance instructions may make it unsafe. The use of replacement parts not supplied by CompAir UK Ltd may create hazardous conditions over which CompAir UK Ltd has no control.

Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury or result in damage to the equipment. CompAir UK Ltd can bear no responsibility for equipment for which unapproved replacement parts are included.

SPECIAL NOTE:
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.

Page 6

04/09/02

gassafety.doc

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 7

SAFETY PRECAUTIONS
1. 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. Most accidents which occur during the operation and maintenance of machinery result of failure to observe basic safety rules or precautions. Recognising a situation that is potentially hazardous can often prevent an accident. When handling, operating or carrying out maintenance on the unit, personnel must observe safe engineering practices and all relevant local regulations. The attention of users is drawn to the Health and Safety at Work Act 1974, and the regulations of the Institution of Electrical Engineers. CompAir UK Ltd cannot anticipate every possible circumstance, which might represent a potential hazard. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating procedure, 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. Failure to observe these precautions given under "Safety Precautions" may be considered dangerous practice or misuse of the compressor Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing. 2. WARNINGS, CAUTIONS & NOTES 3.

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, Amended 91/286/EEC.

When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and gloves. Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any risk of falling objects. If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing worn. 3. GENERAL SAFETY PRECAUTIONS (Cont.)

Warnings call for attention to operation procedures involving specific hazards which could cause injury or death and are identified by the following:-

gassafety.doc

04/09/02

Page 7

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 8

Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing. Before releasing compressed air through a hose make sure the free end is held securely so that it cannot whip and cause injury. Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to local safety regulations. Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended. When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits. 4. INSTALLATION PRECAUTIONS Competent personnel under a qualified supervisor must only carry out installation work. A fused isolator switch must be fitted between the main power supply and the compressor. Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into compressor intake. Ensure that the discharge pipe from the compressor to the user pipework, receiver or storage is free to expand and that no flammable material is within the vicinity. If any such material is close-by take steps to preclude ignition. A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated. Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must be installed between any compressor unit and the isolating valve. A pressure-reliving device must be fitted to every pressure vessel, or equipment containing gas or gas above atmospheric pressure. Never remove or tamper with safety devices, guards or insulation fitted. In order to limit the risk of Legionnaires Disease, CompAir UK LTD advise caution with the use of cooling towers for water cooling the compressor. Closed circuit or direct mains cooling is preferred.

Pipework or other parts with a surface temperature above 70C, which may be accidentally touched in normal operation, must be guarded or insulated. Other high temperature pipework should be clearly marked and all pipework should be clearly marked. 5. OPERATIONAL PRECAUTIONS Competent personnel under a qualified supervisor must only operate the compressor. Do not operate compressor with any removable inspection cover removed e.g. crankcase doors, valve covers etc. Never remove or tamper with safety devices, guards or insulation materials. The compressor must only be operated at the supply voltage and frequency for which it is designed. Always isolate power before maintenance or servicing. When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system. ALWAYS CONSULT A QUALIFIED ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK. Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement, test or adjustment. Such work should always be carried out by a qualified. Electrician with appropriates tools and protection against an electrical hazard. If the unit is equipped with a Remote Control device, attach warning notices stating "THIS UNIT CAN BE STARTED REMOTELY" in prominent locations, one on the outside of the unit, the other inside the control compartment. As a further safeguard, 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. Compressed gas and gas piping, together with cooling water piping and other parts, with surface temperature greater than 70C and may be accidentally touched, should be guarded or insulated.

Page 8

04/09/02

gassafety.doc

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 9

5. OPERATION PRECAUTIONS (Cont.) If there is any indication that the compressor is overheating it must be shutdown. (A high air or gas temperature switch is fitted as standard to guard against operating with excessive temperature). Beware of burns from hot oil and water when working on a unit recently shutdown. Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance. Secure guards following any servicing or repair. Local noise regulations must be observed. Ear defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with communication. 6. MAINTENANCE & REPAIR PRECAUTIONS Competent persons under qualified supervisor must carry out maintenance repair and modifications. The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models). Oil free models will have desiccant bags in valve covers and distance pieces. Handling components such as seals, gaskets and diaphragms should not present a personnel hazard. Preservation oils again should not present a personnel hazard if handled under normal handling practices. Whilst compressors are asbestos free, treat all damaged gaskets as asbestos - when the Asbestos at work regulations apply. Viton 'O' seals under normal operating conditions are safe. However, should there be a fire within the compressor or these seals are likely to exceed a temperature of 300C the material will decompose. Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns. If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC gloves.

occurs washes with limewater and seeks medical advice. Pre-Maintenance Operation 1. Isolate the compressor from the main electrical supply. Lock the isolator in the OFF position and remove fuses. 2. Attach a label " WORK IN PROGRESS - DO NOT APPLY VOLTAGE". 3. Close the isolating valve between the compression unit and user's pipework. Close the isolating valve in the cooling water inlet pipe. Attach a label "WORK IN PROGRESS - DO NOT OPEN". 4. Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage. Check that all pressure gauges register zero. 5. Ensure that the cooling water system has been drained. 6. Check that the drain valve on the delivery manifold is clear and gas pressure has been released. 7. Check that all interstage drains are open to ensure any gas trapped between stages has been released. Stand clear of all valve covers when removing the securing screws. When removing valve covers for valve replacement, ensure a minimum of two threads is left engaged on the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port in the cylinder head. Remove the securing screws and take out valve cover. 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. Always clean oil spills from the surrounding floor before and after maintenance work.

Wash the area with limewater and avoid breathing any fumes. If contamination of the skin

gassafety.doc

04/09/02

Page 9

CompAir UK Ltd PUBLICATION GAS SAFETY


Page 10

6.

MAINTENANCE & REPAIR (Cont.)

Keep the compressor clean at all times. Protect components and exposed openings by covering with a clean cloth or tape during repair or maintenance work. Protect the motor, intake, electrical and regulation components against the entry of moisture e.g. steam cleaning. Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks. The adjacent components must be screened with non-flammable material and if oil present, the system must first be cleansed thoroughly by steam cleaning. 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, soakaway or watercourse. PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL. 7. PRECAUTIONS IN THE EVENT OF FIRE Use extreme caution when handling components that have been subjected to fire or very high temperature. Some components may contain fluoroelastomer materials, which decompose under these conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage.

Make sure all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good order. 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. They must be renewed or service exchanged when acceptable tolerances are exceeded. Protection devices should be tested at each regular service interval and replaced or service exchanged if not functioning correctly. The maximum pressure for safety valves under fault conditions is 1.10 times the set pressure, the set pressure being a minimum of 1.05 times the maximum operating pressure to ensure seat tightness. 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. After completion of any maintenance or repair ensure that no tools, loose items or rags are left on or inside the compressor. Do not use any flammable liquid to clean valves, filter elements, cooler passages, pipe bores or any component carrying a flow of air or gas during normal operation. If chlorinated hydrocarbon substances are used for cleaning, safety precautions must be taken against toxic vapours, which may be released. DO NOT USE CARBON TETRACHLORIDE. Precautions must be taken against using acids, alkalis and chemical detergents for cleaning machined parts. These materials cause irritation and are corrosive to the skin, eyes, nose and throat. Avoid splashes and wear suitable protective clothing and safety glasses. Do not breathe mists. Ensure water and soap is readily available. When disposing of condensate, old oil, 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.

This is a high pressure Compressor use only:


GENUINE CompAir UK Ltd PARTS

Page 10

04/09/02

gassafety.doc

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. When this breaks down, wear occurs. In an gas compressor the agitation, caused by the oil distribution and recovery system, results in the lubricant absorbing some gas whilst it is in the crankcase and cylinders. The oxygen in the entrained gas gradually forms and maintains oxide skins on the moving surfaces. These improve the adhesive strength of the oil film, preventing its breakdown. When gas is being compressed and there is no oxygen present, even in small amounts, the help from these skins is not normally available. However, it has been established that if moisture is present, film breakdown is prevented. The reason is that gas entrained in the water at source, provides the oxygen for oxide skin formation. 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. These are provided by an oil which has a HIGH viscosity, a HIGH level of anti-wear additives and a LIMITED amount of anti-oxidant additives. The lubricant we recommend for this duty is Anderol 1200. When commissioning or re-commissioning the compressor, 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.doc

04/09/02 Page 11

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. If in any doubt as to the efficiency of the purging, ALWAYS REPEAT THE PROCEDURE. Feeding the purge gas at a pressure equal to the inlet pressure to the compressor, will speed the process. After any maintenance or repairs have been carried out which involves dismantling and opening up gas containing parts, the system must always be re-purged. PURGING PRIOR TO INITIAL START-UP Purging with Nitrogen Connect nitrogen to the inlet purge valve PGE01. Close inlet valve ISOL01, ISOL02, DDV valve ISOL09, filtration isolation valve ISOL68 and purge valve PGE061. Open recovery vessel valve ISOL08 and compressor inlet purge valve PGE02. Purge nitrogen through until air is displaced. This can be checked with an oxygen meter at the vent stack. Close recovery vessel valve ISOL 08 and open DDV valve ISOL 09 select manual operation on Control Panel and open Solenoid valve SOL01. Purge nitrogen through until air is displaced. Close compressor inlet purge valve PGE 02 and open delivery purge valve PGE 61. Purge nitrogen through until air is displaced by checking with an oxygen meter at the delivery purge valve. Most of the compressor system should now be filled with nitrogen. 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 filtration will be pressurised before the pressure-maintaining valve PCV 61 opens. Shut off nitrogen supply when complete. 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. The filtration isolation valve ISOL 62 should then be closed. If the downstream equipment has been purged with nitrogen then it should be vented to a small positive pressure. 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. This will allow gas to enter the system. Open recovery vessel drain ISOL 07 until gas is sensed and then vent from delivery purge valve PGE 61. The compressor system should now be filled with gas.

COMPRESSOR MAINTENANCE
Releasing gas To isolate compressor close DDV and recovery vessel valves ISOL 09 and ISOL 08. Vent gas from compressor purge valve PGE 02. Repurging with gas Open compressor purge valve PGE 02 and DDV valve ISOL 09 until gas is present. Close DDV valve ISOL 09 and open recovery vessel valve ISOL 08 and purge gas to PGE 02. Close PGE 02 and open DDV valve ISOL 09. FINAL COALESCER Releasing gas Close filtration isolation valve ISOL 62 & ISOL61, expel gas into the recovery vessel via ISOL63. Close Open compressor purge valve PGE 02 to expel the gas and then open delivery purge valve PGE 61 to vent remaining gas.

Page 12

04/09/02

gassafety.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX


Page 1

CONTENTS
QUICK REFERENCE GUIDE TO PARTS USING P. & I. DIAGRAM D70983 CERTIFICATE OF CONFORMITY COMPRESSOR PLANNED MAINTENANCE LOG SHEET WARNINGS & SAFETY SECTION DRY GAS LUBRICANT RESTRICTIONS TYPICAL GAS PURGING INSTRUCTIONS
SECTION 1
1.1 1.2

LEADING PARTICULARS

PAGE 5

1.3 1.4

UNIT DESIGNATION ---------------------------------------------------------------------- 7 TECHNICAL DATA - GENERAL -------------------------------------------------------- 7 1.2.1 TEMPERATURES ------------------------------------------------------------- 7 1.2.2 OPERATING SPEEDS ------------------------------------------------------- 7 1.2.3 OPERATING PRESSURES ------------------------------------------------- 8 1.2.4 LUBRICATION------------------------------------------------------------------ 8 1.2.5 COOLING ------------------------------------------------------------------------ 8 1.2.6 INTERNAL DIMENSIONS --------------------------------------------------- 8 1.2.7 CONNECTIONS --------------------------------------------------------------- 8 1.2.8 WATER TEST PRESSURES ----------------------------------------------- 8 1.2.9 INCLINATION------------------------------------------------------------------- 9 1.2.10 RELIEF VALVE SETTINGS ------------------------------------------------- 9 1.2.11 WEIGHTS------------------------------------------------------------------------ 9 1.2.12 EXTERNAL DIMENSIONS -------------------------------------------------- 9 TORQUE WRENCH SETTINGS ------------------------------------------------------ 10 RUNNING CLEARANCES AND WEARING DIMENSIONS -------------------- 11

SECTION 2
2.1 2.2 2.3 2.4 2.5

TECHNICAL DESCRIPTION

PAGE 13

GENERAL DESCRIPTION --------------------------------------------------------------15 CONSTRUCTIONAL DETAILS ---------------------------------------------------------16 LUBRICATION DETAILS-----------------------------------------------------------------17 CONDENSATE REMOVAL--------------------------------------------------------------17 EXTERNAL COMPONENTS ------------------------------------------------------------18 2.5.1 GAS INLET TRAIN ---------------------------------------------------------- 18 2.5.2 PROTECTION ---------------------------------------------------------------- 18 2.5.2.1 STAGE RELIEF VALVES ----------------------------------- 18 2.5.2.2 BURSTING DISC---------------------------------------------- 18 2.5.2.3 PRESSURE GAUGES --------------------------------------- 18 2.5.2.4 PNEUMATIC WATER VALVE ----------------------------- 18 2.5.2.5 HIGH GAS TEMPERATURE SWITCHES--------------- 18 2.5.3 DELIVERY --------------------------------------------------------------------- 18 2.5.3.1 DISCHARGE NON-RETURN VALVE ------------------- 18 2.5.3.2 FINAL FILTRATION ------------------------------------------ 18 2.5.3.3 GAS DETECTOR --------------------------------------------- 18

SECTION 3
3.1 3.2 3.3 3.4

INSTALLATION INFORMATION

PAGE 19

UNPACKING AND HANDLING-------------------------------------------------------- 21 LOCATION---------------------------------------------------------------------------------- 21 MOUNTING--------------------------------------------------------------------------------- 21 CONNECTIONS --------------------------------------------------------------------------- 21 3.4.1 GAS CONNECTION--------------------------------------------------------- 21 3.4.2 WATER CONNECTION ---------------------------------------------------- 22 3.4.3 ELECTRICAL CONNECTION -------------------------------------------- 22

1293-index.doc

04/09/02

Page 1

CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX


Page 2

SECTION 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

OPERATING INFORMATION

PAGE 23

4.10

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 4.9.1 UP T0 6 MONTHS-------------------------------------------------------------29 4.9.2 LONG TERM---------------------------------------------------------------------30 FAULT GUIDE--------------------------------------------------------------------------------31 4.10.1 RELIEF/SAFETY VALVE(S) BLOWING -----------------------------------32 4.10.2 FAILS TO REACH TOP PRESSURE -------------------------------------32 4.10.3 LOW COMPRESSOR OUTPUT ---------------------------------------------32 4.10.4 STOPS SUDDENLY ------------------------------------------------------------33 4.10.5 WILL NOT START --------------------------------------------------------------33 4.10.6 OVERHEATING -----------------------------------------------------------------33 4.10.7 OVERHEATING RADIATOR STES-----------------------------------------33 4.10.8 LOW OIL PRESSURE----------------------------------------------------------34 4.10.9 CUTS OUT ON START-UP ---------------------------------------------------34 4.10.10 UNUSUAL NOISE RUNNING ON LOAD ----------------------------------34 4.10.11 UNUSUAL NOISE RUNNING UNLOADED-------------------------------34 4.10.12 HIGH OIL CONSUMPTION ---------------------------------------------------34 4.10.13 PREMATURE WEAR OF PARTS -------------------------------------------34 4.10.14 HIGH INLET PRESSURE SWITCH TRIPS -------------------------------35 4.10.15 LOW INLET PRESSURE SWITCH TRIPS--------------------------------35 4.10.16 INLET SAFETY VALVE BLOWING -----------------------------------------35 4.10.17 INTERSTAGE SAFETY VALVES BLOWING ----------------------------35 4.10.18 THIRD STAGE TEMPERATURE SWITCH TRIPS----------------------35 4.10.19 FINAL DELIVERY TEMPERATURE SWITCH TRIPS------------------35 4.10.20 FINAL STAGE TEMPERATURE SWITCH TRIPS ----------------------35 4.10.21 FINAL DELIVERY SAFETY VALVE BLOWING -------------------------35 4.10.22 DISPENSER PRESSURE SWITCH TRIPS-------------------------------35 4.10.23 MOTOR PROTECTION SWITCH TRIPS----------------------------------36 4.10.24 INSUFFICIENT COOLING ----------------------------------------------------36

SECTION 5
5.1 5.2 5.3 5.4 5.5 5.6

MAINTENANCE AND REPAIR

PAGE 37

MAINTENANCE---------------------------------------------------------------------------- 41 AFTER THE FIRST 100 HOURS OR A MAJOR SERVICE--------------------- 42 MAINTENANCE PERIODS AND SERVICE HOURS ----------------------------- 43 SERVICING STAGE VALVES ----------------------------------------------------- ----44 COMPRESSOR PROTECTIONS ----------------------------------------------------- 47 SERVICING COMPRESSOR----------------------------------------------------------- 48

SECTION 6
6.1 6.2

COMMON PARTS LIST & ILLUSTRATIONS

PAGE 51

PARTS LISTS R-5437.GAS.COMMON -------------------------------------------52 - 57 ILLUSTRATIONS R-5437.GAS.COMMON---------------------------------------58 - 84

SECTION 7
7.1 7.2

BUILD PARTS LIST & ILLUSTRATIONS

PAGE 85

PARTS LISTS R-5437.1.NG---------------------------------------------------------86 - 90 ILLUSTRATIONS R-5437.1.NG ----------------------------------------------------91 - 96

Page 2

1293-index.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX


Page 3

SECTION 8
8.1 8.2 8.3

SERVICE PLANS

PAGE 97

RECOMMENDED SERVICE PLAN (SYNTHETIC OIL) -------------------------R-5437.1.NG.S RECOMMENDED SERVICE PLAN (MINERAL OIL)-------------------------- R-5437.1.NG.M427 RECOMMENDED SERVICE PLAN (MINERAL OIL)------------------------- R-5437.1.NG.MP100

SECTION 9

ANCILIARY EQUIPMENT

PAGE 99

BUILD ------------------------------------------------------------------------------------- 5437CNG.55153 GENERAL ARRANGEMENT ------------------------------------------------------------------------ E46319 P. & I. DIAGRAM --------------------------------------------------------------------------------------- D70938 SINGLE LINE DIAGRAM ----------------------------------------------------------------------------- C89091 WIRING DIAGRAM ------------------------------------------------------------------------------------ C89092 9.1 9.2 9.3 9.4 9.5 9.7 9.8 9.9 9.10 9.11 9.12 9.13 NATURAL GAS COMPRESSOR PARTS ---------------------------------SEE SECTION 7 VEE DRIVE & ADJUSTMENT PARTS - APP12G ------------------------------- 100 WATER PUMP - APP073-------------------------------------------------------------- 100 A.V MOUNTS - APP003 --------------------------------------------------------------- 100 INLET TRAIN ----------------------------------------------------------------------------- 100 SAFETY VALVE MANIFOLD -------------------------------------------------------- 101 CONTROL BOX SUPPORT ---------------------------------------------------------- 101 PRESSURE CONTROL---------------------------------------------------------------- 101 CONTROL PANEL --------------------------------------------------------------------- 102 ELECTRIC MOTOR - APP034C ----------------------------------------------------- 102 SOLENOID VALVE INLET - APP153----------------------------------------------- 102 SOLENOID VALVE DDV - APP152 ------------------------------------------------- 102

EXTRA PUBLICATIONS DRIVE DETAILS --------------------------------------------------------------------- APP012G 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 SWITCHES 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 VALVES GENERAL ----------------------------------------------------- APP167 CHECK VALVE INLET ------------------------------------------------------------- APP169A

1293-index.doc

04/09/02

Page 3

CompAir UK Ltd PUBLICATION 98407/1293 Section INDEX


Page 4

Page 4

1293-index.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 5

SECTION 1 CONTENTS LEADING PARTICULARS


1.1 1.2 UNIT DESIGNATION TECHNICAL DATA - GENERAL
1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11

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

1.3

TORQUE WRENCH SETTINGS


1.3.1

PAGE 10

TORQUE WRENCH SETTING --------------------------------------------------------- 10

1.4

RUNNING CLEARANCES AND WEARING DIMENSIONS

PAGE 11

1293-1.doc 04/09/02

Page 5

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 6

TYPICAL HGP.37 ILLUSTRATED RADIATOR COOLED SET

STANDARD SET

Page 6

1293-1.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 7

SECTION 1 LEADING PARTICULARS


1.1 UNIT DESIGNATION
Belt drive compressor, electric powered .......................................................................... R-5437.1.NG

1.2

TECHNICAL DATA - GENERAL


Type................................................................................................... Single acting, four stage, 90 vee Cooling ......................................................................................................................Sea or fresh water Direction of rotation, viewed from drive end.................................................................... Anti-clockwise Number of valves ............................................................................................................................Four Type of valve ............................................................................................................... Flat plate, low lift

1.2.1

TEMPERATURES - R-5437.1.NG
Examples of 3rd stage temperature controller settings. Running Speed 1800 rpm - 250 bar g delivery Cooling water inlet temperature - 15C with a 10C to 12C rise across machine. Inlet Pressure (Bar g) 3rd Stage Temperature Controller 3rd Stage Temperature Controller Maximum 0 160C 190C 0.3 165C 195C 0.64 170C 200C

Maximum gas inlet pressure (subject to a speed restriction).................................................... 1 bar g. Minimum gas intake temperature................................................................................................... 0C. Maximum gas intake ambient temperature .................................................................................. 45C. Maximum gas intake ambient temperature for radiator sets........................................................ 30C. (Higher ambients possible contact CompAir UK Ltd Ipswich Engineering for more information. Maximum cooling water inlet temperature ................................................................................... 37C. Temperature rise across machine (Normal requirement) .................................................10C - 12C. Note: It is important for the life and safety of the machine not to exceed the maximum operating temperatures.

1.2.2

OPERATING SPEEDS
Minimum speed --------------------------------------------------------------------------------------------750 rev/min Maximum speed ------------------------------------------------------------------------------------------ 1800 rev/min 1st stage piston displacement at maximum speed ------------------------------------------------ 217.7m/hr

1293-1.doc 04/09/02

Page 7

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 8

1.2.3

PRESSURES *
Maximum working pressure -------------------------------------------------------------------------------- 350 bar Minimum working pressure (with atmospheric pressure intake) ---------------------------------- 140 bar Minimum working pressure (with 0.55 bar intake) ---------------------------------------------------- 200 bar Minimum water pressure ........................................................................................................0.6 bar Maximum water pressure .......................................................................................................5.1 bar Oil pressure (New machine) .......................................................................................... 2.0-2.75 bar Minimum oil pressure (Worn machine)......................................................................................1 bar

1.2.4

LUBRICATION *
Crankcase oil capacity ................................................................................. 45 litres Recommended silicone grease (for assembly) ...................................................Dow Corning MS33 Recommended oil: Synthetic ..........................................Reavellite, Anderol 555 Recommended oil: Mineral ........................................................Mobil Rarus 427 Recommended oil: Mineral ....................................................Shell Corena P100

* Oil recommendations are based on normal conditions. If difficulty is experienced a change may be advisable - refer to Ipswich Works.

1.2.5

COOLING
Coolant Sea or fresh water Cooling water flow @ 15C inlet temp .......................................................75 l/h/kW (12 gals/bhp/hr) Coolant capacity (Approx.) .................................................................................................... 46 litres Note: Water must not be allowed to freeze in the compressor water jackets, coolers or in a sea water / fresh water heat exchanger.

1.2.6

INTERNAL DIMENSIONS
Piston stroke---------------------------------------------------------------------------------------------------- 75 mm First stage cylinder bore ------------------------------------------------------------------------------------ 185 mm Second stage cylinder bore --------------------------------------------------------------------------------- 95 mm Third stage cylinder bore ------------------------------------------------------------------------------------ 45 mm Fourth stage cylinder bore ---------------------------------------------------------------------------------- 22 mm Mean piston speed at maximum speed ------------------------------------------------------------------4.5 m/s

1.2.7

CONNECTIONS (STANDARD)
Gas inlet connection ................................................................................................. nominal 75 mm Fourth stage delivery ........................................................................................................... " BSPP Condensate drain............................................................................................................... 1" BSPP Water inlet............................................................................................................................. 1" BSPT Water outlet.........................................................................................................................1" BSPT

Page 8

1293-1.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 9

1.2.8

WATER TEST PRESSURES


First stage suction ..................................................................................................................... 2 bar g First stage delivery .................................................................................................................. 21 bar g Second stage .......................................................................................................................... 81 bar g Third stage ............................................................................................................................ 300 bar g Fourth stage .......................................................................................................................... 690 bar g Water jacket .......................................................................................................................... 100 bar g

1.2.10

RELIEF VALVE SETTINGS


First stage ............................................................................................................................... 10 bar g Second stage.......................................................................................................................... 40 bar g Third stage ............................................................................................................................ 150 bar g Fourth stage..................................................................................................... Supply pressure +10% Surge vessel Relief valve ...................................................................................................... 2.8 bar g Crankcase.............................................................................................................................. 2.1 bar g

1.2.11

WEIGHTS
Machine (bare)........................................................................................................................ 1090 Kg Cooling water and lubricating oil................................................................................................. 90 Kg Crankshaft .................................................................................................................................. 45 Kg Flywheel...................................................................................................................................... 51 Kg nd Cylinder block 1st & 2 Stage .................................................................................................. 146 Kg rd Cylinder block 3 & 4th Stage .................................................................................................. 155 Kg Crankcase................................................................................................................................. 250 Kg Typical Belt Driven Set (Complete set dry)............................................................................. 1600 Kg Inertia, rotational compressor and flywheel ......................................................................... 0.79 kgm

1.2.12

EXTERNAL DIMENSIONS
Typical Belt Driven Set - Length --------------------------------------------------------------------------- 1700 mm Width ----------------------------------------------------------------------------------------------------------- 1320 mm Height ------------------------------------------------------------------------------------------------------------ 1090 mm

1293-1.doc 04/09/02

Page 9

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 10

1.3
1.3.1

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 1.1/8" UNF 19MM M12 19MM M12 13MM M8 17MM M10 17MM M10 13MM M8 10MM M6 8MM M5 17MM M10 19MM M12 1.1/8" 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 4.6 55 95 237 28 28 28 95 237 237 POUND FEET (lb.ft) 150 175 40 40 40 70 37 90 175 20 87 87 40 20 119 70 70 20 40 29 14 6 3.4 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.

Under no circumstances are any deviations from the above figures allowable. * Note: Must be tightened sequentially in 27 Nm ( 20 Lb.ft) steps.

Page 10

1293-1.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 11

1.4 RUNNING CLEARANCES AND WEARING DIMENSIONS


DESCRIPTION STAGE AS FITTED (mm) MAX. PERMITTED (mm) ----1.63 1.43 1.37 1.27 1.32 1.50 0.29 0.30 0.28 0.30 0.28 0.30 4.91 8.09 3.31 4.91 2.13 2.64 184.69 94.83 44.85 21.9 185.11 95.10 45.09 22.08 0.19 0.1 -0.03 0.09 1.0 1.0 83.92 0.04 79.90 0.04 0.24 0.2 0.75 -------

Piston vertical clearance (ie. 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 1 2,3,4 1 2,3,4 1 2,3,4

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

0.500 / 1.200 0.250 / 0.950 0.350 / 1.150 0.350 / 1.150 0.20 / 0.46 0.20 / 0.46 0.10 / 0.23 0.10 / 0.23 0.05 / 0.18 0.20/0.40 0.04 / 0.09 0.05 / 0.10 0.02 / 0.08 0.05 / 0.10 0.01 / 0.08 0.10/0.06 4.80 / 4.83 8.01 / 7.99 3.23 / 7.99 4.83 / 4.80 2.05 / 2.01 2.56/2.53 184.77 / 184.74 94.91 / 94.88 44.92 / 44.89 21.905 / 21.935 185.05 / 185.00 95.04 / 95.00 45.03 / 45.00 22.02 / 22.00 0.060 / 0.125 0.01 / 0.05 Needle roller -0.003 / 0.013 0.025 / 0.044 0.15 / 0.64 0.15 / 0.55 84.24 / 84.22 79.95 / 79.93

1,2,3,4

1 2 3 4

23 off 8 off 8 off 6 off 1 off 1 off

0.066 / 0.120 0.050 / 0.135 0.23 / 0.66 10 13.4 10 13.4 11.1 6.2

1293-1.doc 04/09/02

Page 11

CompAir UK Ltd PUBLICATION 98407/1293 Section 1


Page 12

Page 12

1293-1.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 2


Page 13

SECTION 2 CONTENTS TECHNICAL DESCRIPTION


2.1 2.2
2.2.1

GENERAL DESCRIPTION CONSTRUCTIONAL DETAILS

PAGE 15 PAGE 16

MATERIAL of CONSTRUCTION----------------------------------- 16

2.3
2.3.1

LUBRICATION DETAILS

PAGE 17

MAIN LUBRICATION SYSTEM ------------------------------------ 17

2.4
2.4.1

CONDENSATE REMOVAL

PAGE 17

DIAPHRAGM DRAIN VALVES ------------------------------------- 17

2.5
2.5.1 2.5.2

EXTERNAL COMPONENTS

PAGE 18

2.5.3

GAS INLET TRAIN----------------------------------------------------- 18 PROTECTION ---------------------------------------------------------- 18 2.5.2.1 STAGE GAS RELIEF VALVES----------------------- 18 2.5.2.2 BURSTING DISC ---------------------------------------- 18 2.5.2.3 PRESSURE GAUGES---------------------------------- 18 2.5.2.4 PNEUMATIC WATER VALVE (IF FITTED) ------- 18 2.5.2.5 HIGH GAS TEMPERATURE SWITCHES --------- 18 DELIVERY --------------------------------------------------------------- 18 2.5.3.1 DISCHARGE NON-RETURN VALVE--------------- 18 2.5.3.2 FINAL FILTRATION ------------------------------------- 18 2.5.3.3 GAS DETECTOR ---------------------------------------- 18

1293-2.doc 04/09/02

Page 13

CompAir UK Ltd PUBLICATION 98407/1293 Section 2


Page 14

Page 14

1293-2.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 2


Page 15

TECHNICAL DESCRIPTION
2.1 GENERAL DESCRIPTION TYPICAL ARRANGEMENT
1 Stg Safety Valve 2 stage Safety valve. Pressure gauge panel.
nd st

1 Stage cylinder 2 Stage cylinder Surge vessel safety valve Diaphragm Drain valves The R-5437.1.NG compressor is a reciprocating 90 vee configuration, 4 stage, single acting, water cooled machine with the 1st and 3rd stage lines on one crank throw, and the 2nd and 4th stage lines on the opposite crank throw of a counterbalanced crankshaft. The running gear consists of the crankshaft, bearings, connecting rods, oil pump, cylinder lubricator and other accessories. The gas end consists of two cylinder blocks - combined 3 & 4 stage combined 1 & 2 stage. Each block is complete with individual cylinder liners, pistons, valves, valve covers, inter-stage st nd rd th st nd rd coolers for the 1 , 2 , 3 and 4 stages and condensate separators for 1 , 2 and 3 stages. The 1 & 2 stage cylinder blocks contains renewable wet cylinder liners and are jacketed for rd th water-cooling. 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. First and second stage pistons are conventional trunk type, whilst the third and fourth are an integral piston and crosshead assemblies. All are fitted with split piston rings. A single combined suction and discharge (concentric) valve is fitted at the head of each cylinder. Water-cooled inter-stage coolers are provided after each stage of compression, with condensate separators after each inter-stage cooler. The water flows over the tubes and the gas through for all stage coolers. All stage coolers are withdrawable to ease maintenance. The fourth or final stage cooler cools the hot gas delivered from the fourth stage cylinder to within 5C of the cooling water inlet temperature. 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. The cylinders, pistons and valves are splash/spray lubricated. A low oil pressure switch is provided to protect the running gear against lubrication failure, an oil level sight gauge is provided in the crankcase for maintaining oil to the correct level. An automatic drainage system drains each stage condensate separator at approximately 10 to 20
st nd rd th st nd nd

st

1293-2.doc 04/09/02

Page 15

CompAir UK Ltd PUBLICATION 98407/1293 Section 2


Page 16

minute intervals for a period of 5-10 seconds into a discharge surge vessel, in-built in crankcase. 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. The drainage system whilst removing oil/moisture also acts as an unloading device to prevent the compressor starting under load, by bleeding off automatically all the gas in the compressor through the condensate separators whenever the compressor stops. Pressure gauges to indicate all gas stage pressures and oil pressure are located in a gauge board mounted between each cylinder block. Gas relief valves for each stage are fitted to prevent over-pressure in cylinders and coolers, and bursting diaphragms are fitted to protect the water jackets from accidental application of gas pressure to the cooling system. 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. High gas temperature switches are fitted to the 3rd stage cylinder discharge, 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. The compressor gas intake should be fitted with a filter to prevent solid particles entering the compressor cylinders. 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.

2.2

CONSTRUCTION DETAILS

2.2.1 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, 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.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 2


Page 17

2.3

LUBRICATION
2.3.1 MAIN LUBRICATION SYSTEM A forced feed oil pump pressurises the lubrication system conveying oil from the crankcase to the main, big end and small end bearings via a replaceable filter element . Oil thrown off the moving parts ensures adequate lubrication to all stage pistons, crossheads and cylinders. Oil returns to the crankcase and is drawn up to the pump suction through a strainer.

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. A protective Low Oil Pressure Switch or LOP s installed to shut-down the compressor if the pressure falls below 1 bar ( 15 psig). On starting if the oil pressure has not built up within about 10 seconds the LOP, connected to a delay timer in the motor starter control, will shut down the compressor. THE GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED TO THE USE OF A LUBRICANT NOT RECOMMENDED BY COMPAIR IPSWICH

2.4

CONDENSATE REMOVAL

2.4.1 DIAPHRAGM DRAIN VALVES Diaphragm Drain Valves or DDVs 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. All these valves are similar in design and operation only the valve orifice and seat vary to suit each stage. Each valve to operated from first stage pressure via a three-way solenoid valve. With no gas pressure st all valves are open to the blowdown vessel. In operation, gas pressure from the 1 stage acts on the diaphragm to close the valves. A timed signal every 10 - 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. The sudden release of gas and condensate is passed via an integral surge vessel, to attenuate the noise, for connection to drain trap to drainage vessel, ready for safe disposal.

1293-2.doc 04/09/02

Page 17

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

CompAir UK Ltd PUBLICATION 98407/1293 Section 3


Page 21

SECTION 3

INSTALLATION INFORMATION
3.1 UNPACKING AND HANDLING
The compressor unit is delivered in a packing case. All openings will have been sealed with plastic plugs or adhesive tape. The packing case should be carefully disassembled to avoid damage to gauges, pipework, and valves etc. and loose components packed separately. The unit should be lifted by the eyebolts on the motor and compressor.

3.2 LOCATION
It is desirable that the compressor unit is installed in as clean, cool and dry environment within the parameters stated in the Leading Particulars section. The surface, on which the unit is to stand, must be flat and capable of bearing the total weight of the unit without distortion. In selecting the location it is essential to consider accessibility. Allow sufficient space around the installation for safe maintenance work. Sufficient clearance must be allowed to ensure that the set will not touch any obstruction or any flexibly mounted equipment, with an added allowance for maximum movement from the mounting system.

3.3 MOUNTING
The compressor unit is mounted on anti-vibration mounts. These mounts should be inspected for any tear of the rubber to metal plate bond or ageing before use. Ensure the mount is not impregnated with oil or grease, and that any protective lacquer is intact. Reject any mount that is not in good condition. Lower the compressor unit onto the mounts and screw on the mount holding down nuts. Rock unit to ensure mounts is free and not distorted, and that the set will not touch any obstructions or other flexibly mounted equipment.

3.4 CONNECTIONS
Note: As the compressor unit is flexibly mounted, all connections must also be flexible. Short flexible sections must be incorporated, should be suitable for the pressures and temperatures involved and capable of easy removal to facilitate maintenance. 3.4.1 GAS CONNECTIONS Suction The intake gas pressure can vary, typically between 0.02 and 1bar g from a local gas utility and must be as clean and dry as possible. Final Delivery The final delivery connection BSPP is situated at the end of the non-return valve. The flexible connection must be suitable for the set working pressure. Unloading / Condensate Drain The unloading / condensate drain connection at the crankcase, for the surge vessel, is screwed 1 BSPT female to accept the discharge pipe. This pipe must be led away with a minimum of bends, and must have a minimum internal diameter of 38mm (1). 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. Note: Condensate drainage is dirty and it is advisable to pipe direct to a suitable tundish.

1293-3.doc 04/09/02

Page 21

CompAir UK Ltd PUBLICATION 98407/1293 Section 3


Page 22

3.4.2

WATER CONNECTIONS

Cooling Water The quality, quantity and temperature of the water used can materially affect maintenance. A positive circulation of cool but not cold, clean water, free from suspended particles is required for satisfactory continuous operation. Note: It is vital a suitable inhibitor is used especially in HARD WATER areas. Therefore it is recommended that a suitable water softener unit be fitted to the inlet water line. It is recommended that temperature indication or gauges are fitted to water inlet (1 BSPT) and outlet (1 BSPT) pipes to monitor water temperature rise across the compressor to approximately 10-12 C. 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. Too low a rise reduces the average temperature and may improve the cooler efficiency but can cause condensation in the cylinders. A lockable throttle valve is recommended at the inlet, installed before the pneumatic water inlet valve (if fitted), to allow adjustment the water flow to achieve the correct temperature rise then locked for security, The inlet connection is to the pneumatic water control valve (if fitted) inlet only. This valve is operated by the first stage compressor gas pressure to only allow water in when the compressor operates. Note: Continued water circulation when stationary can cause condensation within the cylinders and breakdown of oil lubrication creating premature wear. (I.e. 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. Water flow arrangements should be fail-safe to ensure that compressor can not run on full load without water flow. 3.4.3 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. The size of the cable shall be suitable for the supply voltage and current involved, and the terminal connections shall be as shown in the terminal box. A suitable overload device should always be fitted. An hours-run meter fitted to the motor starter is recommended for maintenance scheduling. A timer should be incorporated in the starter to de-energise the solenoid valve for between 5-10 seconds every 10 - 30 minutes to periodically, dependent upon ambient temperature and humidity. Contact CompAir UK Ltd Ipswich for more information on humidity if required. This will allow the diaphragm drain valves to operate and discharge any accumulated condensate. Adequate flexibility shall be ensured to allow for movement of the set on the anti-vibration mounts. 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. High Gas Temperature Switches for Hazardous Area Zone 1 The cable entry is through a conduit entry hole. Details of the terminal connections are on the switch. Cable should run through a suitable Zone 1 flexible armoured sheath. Low Oil Pressure Switch for Hazardous Area Zone 1 See High Gas Temperature Switches above. Note: When the compressor set is on flexible mounting it can become electrically insulated. 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.

Page 22

1293-3.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 23

SECTION 4 CONTENTS OPERATING INFORMATION


4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 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
4.9.1 4.9.2

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

FAULT GUIDE
4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 4.10.7 4.10.8 4.10.9 4.10.10 4.10.11 4.10.12 4.10.13 4.10.14 4.10.15 4.10.16 4.10.17 4.10.18 4.10.19 4.10.20 4.10.21 4.10.22 4.10.23 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.doc 04/09/02

Page 23

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

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 27

drain valve at the 4 stage separator drain and disconnect pipe, electrically disconnect solenoid valve by removing cable plug from socket connections. Remove cover in the bell housing or vee belt guard and bar over compressor several times to distribute oil and confirm free movement.

th

4.3 RUNNING COMPRESSOR ON AIR AFTER COMMISSIONING


On completion of preliminary checks, the compressor should be run to prove operation. Ensure electrical supplies are available. Press "ON" button on motor controller and immediately press "OFF" button, checking rotation of compressor is correct. Rewire if rotation is incorrect. Rotation must be counter clockwise looking on the driving end. Restart compressor, check oil pressure is greater than 2 bar ( 30 psig), that air is being delivered from each stage, and listen for any uncharacteristic noises. Check for air leaks by using soapy water, oil and water leaks. If leaks are found, stop compressor isolate supplies and rectify. DO NOT TRY TO CORRECT LEAKS WHEN ITEMS ARE PRESSURISED. Stop compressor and isolate power supplies after running unloaded for 30 minutes and check that outer surfaces of crankcase and cylinders are cool. Replace solenoid valve plug. Close manual drain valve at 4th stage separator drain reconnect pipe. Open stop valve in delivery line to gas receiver. Restart compressor and continue with run, increasing pressure by 70 bar at 15 minute intervals up to working pressure. Compressor should now be running "on load" and delivering compressed air. Check the following: Oil Pressure - record at 15 minute intervals. Stage Pressures - record at 15 minute intervals. Stage Temperatures - record at 15 minute intervals. Safety valves are not leaking. Unloader valves are not leaking. Condensate drain valves operate for approximately 5-10 seconds after every 10 - 30 minutes dependent upon ambient temperature and humidity. This must to be carefully monitored, high temperature/humidity conditions will require the drain times to be more frequent, contact CompAir UK Ltd Ipswich for more details. Compare pressure and temperature readings with those figures given in Section 1.2 Check for air leaks by using soapy water, oil and water leaks. If leaks are found, stop compressor isolate supplies and rectify. On completion of test run, stop compressor.

4.4 PURGING THE COMPRESSOR READY FOR NATURAL GAS


When gas is being compressed and its purity is important, it is usually a plant requirement to purge the compressor to remove any air before letting gas into the system. Where there is such a requirement, 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. After any maintenance or repairs have been carried out which involves dismantling and opening up the gas containing parts, the system should always be re-purged. Before allowing any process gas to enter the compressor or ancillary piping, the whole system must be purged free of air in accordance with the purging procedure which apply to the whole plant. 4.4.1 PURGING PROCEDURE If in any doubt as to the efficiency of the purging, ALWAYS REPEAT THE PROCEDURE. Feeding the purge gas at a pressure equal to the inlet pressure to the compressor, will speed the process.

1293-4.doc 04/09/02

Page 27

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, the system must always be re-purged. PURGING PRIOR TO INITIAL START-UP Purging with Nitrogen Connect nitrogen to the inlet purge valve PGE01. Close inlet valve ISOL01, ISOL02, DDV valve ISOL09, filtration isolation valve ISOL68 and purge valve PGE061. Open recovery vessel valve ISOL08 and compressor inlet purge valve PGE02. Purge nitrogen through until air is displaced. This can be checked with an oxygen meter at the vent stack. Close recovery vessel valve ISOL 08 and open DDV valve ISOL 09 select manual operation on Control Panel and open Solenoid valve SOL01. Purge nitrogen through until air is displaced. Close compressor inlet purge valve PGE 02 and open delivery purge valve PGE 61. Purge nitrogen through until air is displaced by checking with an oxygen meter at the delivery purge valve. Most of the compressor system should now be filled with nitrogen. 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 filtration will be pressurised before the pressure-maintaining valve PCV 61 opens. Shut off nitrogen supply when complete. 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. The filtration isolation valve ISOL 62 should then be closed. If the downstream equipment has been purged with nitrogen then it should be vented to a small positive pressure. 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. This will allow gas to enter the system. Open recovery vessel drain ISOL 07 until gas is sensed and then vent from delivery purge valve PGE 61. The compressor system should now be filled with gas.

COMPRESSOR MAINTENANCE
Releasing gas To isolate compressor close DDV and recovery vessel valves ISOL 09 and ISOL 08. Vent gas from compressor purge valve PGE 02. Repurging with gas Open compressor purge valve PGE 02 and DDV valve ISOL 09 until gas is present. Close DDV valve ISOL 09 and open recovery vessel valve ISOL 08 and purge gas to PGE 02. Close PGE 02 and open DDV valve ISOL 09.

FINAL COALESCER
Releasing gas Close filtration isolation valve ISOL 62 & ISOL61, expel gas into the recovery vessel via ISOL63. Close Open compressor purge valve PGE 02 to expel the gas and then open delivery purge valve PGE 61 to vent remaining gas.

4.5 ROUTINE ATTENTION WHILST RUNNING


At two hourly intervals, check pressure on gas and oil pressure gauges. Abnormal readings must be reported and investigated. Check motor bearings are not overheating. Ensure drains operate at approximately pre-set time interval. Check that no gas relief valve is operating continuously. Note for rectification when compressor is stopped any slight gas, oil or water leaks.

Page 28

1293-4.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 29

4.6 STOPPING PROCEDURE


When compressor has been stopped, by means of stop button on control panel, isolate from electrical supply and; Check for oil and water leaks and rectify. Rectify any gas leaks noted while compressor was running. After approximately two hours remove drain plug from sump and drain off any water which may have accumulated. Do not drain oil. An excess of water in crankcase should be investigated. Replenish oil where necessary. Close off stop valve on discharge line to relieve gas reservoir back pressure from compressor non-return valve.

4.7 PREPARATION FOR SPECIAL ENVIRONMENT


No special preparations are required other than making sure that should the compressor operate in sub-zero temperatures, adequate precautions must be taken to ensure water is not allowed to freeze in the compressor water jackets, pipework (or sea water/fresh water heat exchanger when fitted).

4.8 STARTING AFTER LONG PERIOD OF IDLENESS


Check that all-external nuts, bolts and other fastenings are tight. Check associated and external pipework is intact and adequately supported. Turn compressor over a few times by hand to ensure unrestricted rotation. Ensure cooling system water is available. Open 4th stage, manual drain valve. Start compressor. Listen for any unusual noises during first few minutes of run. Close 4th stage, manual drain valve. Check gas pressure gauges. Check that no gas safety valve opens continuously. Ensure separator drains operate at approximately 10-30 minute at pre-set intervals.

4.9 INHIBITION FOR STORAGE RUNNING ON AIR


4.9.1 INHIBITION FOR UP TO SIX MONTHS Disconnect compressor from the GAS system. Run on AIR with the recommended oil. Run the compressor for 30 minutes on light load with the final delivery pipe disconnected and with all separators open. Cut down the cooling water supply during this run so that the water outlet temperature is from 38C to 49C. After 30 minutes stop the compressor, turn off the cooling water, disconnect the water supply and drain off the water. EITHER: Dry out the water jackets with compressed air, if available. Insert air hose at water outlet connection and pass air through jackets until water ceases to flow from water inlet connection. IMPORTANT: Do not pressurise jacket with air during this procedure. OR: Alternatively, if air is not available, fill jacket with PX10 water-displacing fluid and allow standing for 15 minutes before draining off. Remove and clean compressor valves and wipe out any moisture in valve pockets and passages. Immerse valve units in PX4 fluid and allow surplus to drain off. Insert PX4 into each cylinder, allowing approximately 1/3 cc. of fluid to each square inch of cylinder surface area. Coat all surfaces and gas passages. Replace valves carefully and coat valve covers with PX4. Seal all screw openings with threaded plastic or metal caps and flanged openings with PX4 - coating shims clamped between the flanges, and attach a warning label to this effect.

1293-4.doc 04/09/02

Page 29

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 30

4.9.2 LONG TERM STORAGE Check that the compressor has been run on AIR with the recommended oil. Drain oil from the sump, preferably while still warm, and till to normal level with PX4 fluid. Run the compressor for 30 minutes on light load with the final delivery pipe disconnected and with all separators open. Cut down the cooling water supply during this run so that the water outlet temperature is from 38C to 49C. After 30 minutes stop the compressor, turn off the cooling water, disconnect the water supply and drain off the water. EITHER: Dry out the water jackets with compressed air, if available. Insert air hose at water outlet connection and pass air through jackets until water ceases to flow from water inlet connection. IMPORTANT: Do not pressurise jacket with air during this procedure. OR: Alternatively, if air is not available, fill jacket with PX10 water, displacing fluid and allow standing for 15 minutes before draining off. If it is impossible to run the compressor, remove the crankcase doors and coat running gear and crankcase with PX4 using spray gun, rotating compressor slowly by hand. (When completed, pistons should be in mid-stroke position in readiness for inhibition of cylinders etc.) Replace crankcase doors. Remove and clean compressor valves and wipe out any moisture in valve pockets and passages. Immerse valves in PX4 fluid and allow surplus to drain off. Insert PX4 into each cylinder, allowing approximately 1/3 cc. of fluid to each square inch of cylinder surface area. Coat all surfaces and gas passages. Replace valves carefully and coat valve covers with PX4. Seal all screwed openings with threaded plastic or metal caps and tape afterwards. Seal flanged openings with PX4 - coating shims clamped between the flanges and attach a warning label to this effect. Attach instruction label "DO NOT ROTATE THIS MACHINE" For any compressor which is in storage for a long period, a six-monthly inspection is to be carried out as follows; Remove the valve covers, valves and crankcase doors. Inspect the machine for signs of corrosion and carefully remove any rust that has formed. Turn the compressor round by hand to ensure that the running gear is free. Coat the running gear and crankcase with PX4 using a spray gun, rotating the compressor lowly by hand. (When completed, pistons should be in mid-stroke position in readiness for inhibition of cylinders etc.) Replace the crankcase doors. Immerse valve units in PX4 fluid and allow surplus to drain off. Insert PX4 into each cylinder, allowing approximately 1/3 cc of fluid to each square inch of cylinder surface area. Coat all surfaces, including bottom surface, of the cylinder air passages. Coat the valve covers with PX4 and replace the valves and valve covers. Check that all openings are still sealed.

Note: PX4 Inhibition Fluid - Trade Name Crodafluid PQ11.

Page 30

1293-4.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 31

4.10 FAULT GUIDE WARNING


1. BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED ISOLATED ELECTRICALLY AND MECHANICALLY, COMPRESSOR GAS INLET AND OUTLET VALVES CLOSED AND VISIBLE WARNING NOTICES DISPLAYED. 2. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF. NOTE: A safety valve opening indicates excessive pressure and under NO CIRCUMSTANCES must a safety valve be screwed down to accommodate excessive pressure. THIS IS DANGEROUS. If safety valve opens or appears faulty shut down compressor immediately and investigate. If fault appears immediately or shortly after a service, first examine those parts disturbed during the service. Following is a list covering the probably causes of operational faults, together with the suggested remedies. Before investigating a potential fault, ensure however that: Cooling water temperature, temperature rise across the machine, and flow rate are correct. Direction of rotation is correct. Sump is correctly filled. Compressor servicing is up to date. Electrical supply is correct. If fault appears immediately or shortly after a service, first examine those parts disturbed during the service.

1293-4.doc 04/09/02

Page 31

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 32

Ref.
4.10.1

Symptom
? RELIEF/SAFETY VALVE(S) BLOWING ? ? ? ?
th

Fault
4 stage relief valve blowing final pressure switch not cutting out. 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.

! ! !

? 4.10.2 FAILS TO REACH TOP PRESSURE ?

? ? ? 4.10.3 LOW COMPRESSOR OUTPUT

Verify pipework bore is large enough, has a minimum of bends at the largest possible radius. Ensure any Uni-directional flow valve is fitted the right way round. Intake filter dirty or ! Check intake Filter element if dirty renew element. blocked. ! Check solenoid valve is operating correctly and Unloader / drain the DDVs seat properly. valves not closing. ! Check that operating gas pipework is not damaged (or blocked at 1st stage separator end). ! Renew diaphragm and valves in the DDVs. Compressor valve ! 1st stage gas valve, suction valve most likely to need attention, but check for correct assembly malfunction. and condition or for leak from plates/springs in all stage gas valves. ! Check safety valve is not faulty and replace if Safety valve not serviceable. DO NOT ADJUST SAFETY blowing. VALVES ! Check pressure switch setting. Electrical fault. ! Check solenoid valve is operating correctly and Does not reach the DDVs seat properly. top pressure. ! Check that operating gas pipework is not damaged (or blocked at 1st stage separator end). ! Renew diaphragm and valves in the DDVs. ! 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 , 2 and 1 . ring wear. Blowby noted from oil breather pipe.

th ! 4 stage relief valve blowing incorrectly set or re-assembled items. th ! 4 stage relief valve blowing new Installations -

Check, 4 stage concentric valve springs th and/or plates or replace 4 stage valve complete. Check stage safety valve operation. rd Check, 3 stage concentric valve springs rd and/or plates or replace 3 stage valve complete. Check stage safety valve operation. nd Check, 2 stage concentric valve springs nd and/or plates or replace 2 stage valve complete. Check stage safety valve operation. Check setting of downstream system valves. Check stage safety valve operation.

th

Page 32

1293-4.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 33

Ref.
4.10.4

Symptom
STOPS SUDDENLY ?

Fault
Low oil pressure switch operating. ! ! ! ! ! ! ? ! ! ! ! ! ! ! ! ! ! ? ! ! ! ! ! ? ! !

Recommendation(s)
Check switch. Check oil level - replenish sump oil after removing any condensate in sump. Check & clean oil strainer. Renew oil filter. Renew oil pump Check if Bearings worn replace as necessary Check switch Check cooling water exit temperature does not exceed 50C ( 122F) Check cooling water temperature rise is 10-12C ( 21F) Remove 4th stage cooler coil assembly. Clean exterior of tubes and remove any sludge. Check switch & setting. Check cooling water exit temperature does not exceed 50C ( 122F) Check cooling water temperature rise is 10-12C ( 21F) Check safety valves are not faulty and replace if not serviceable. DO NOT ADJUST SAFETY VALVES Remove 3rd stage cooler assemblies. Clean exterior of tubes and remove any sludge. Check power to starter Check for previous STOP fault condition high gas temperature switches, 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 and refill crankcase with correct grade of lubricant. Check condition of valves and gas passageways. Examine condition of water circuit, remove any sludge or scale build-up. Renew pump, adjust drive belt tension. Contaminated water, replace and add inhibitor. Resite unit to give correct cooling air flow. Clean matrix and flush out tubes.

Final High gas temperature switch operating.

3 stage High gas temperature switch operating.

rd

4.10.5

WILL NOT START

Electrical fault.

4.10.6

OVERHEATING ?

Incorrect grade of lubricant.

4.10.7

OVERHEATING RADIATOR SET

? ? ? ?

Insufficient water flow, reduced cooling efficiency Water pump faulty or drive slipping Insufficient water flow Incorrect siting, insufficient cooling air flow Radiator blocked

! ! ! ! !

1293-4.doc 04/09/02

Page 33

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 34

Ref.
4.10.8

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. Star/Delta timer ! ! !

Recommendation(s)
Fit new oil filter element. Check bearing clearances Examine gasket, replace if necessary, position correctly. Trace and rectify Examine and re-tighten to correct torque. Consult qualified electrician. Consult qualified electrician.

! ! ! !

4.10.9

CUTS OUT ON START-UP

? ? ? ? ?

! ! ! ! ! ! ! !

Low oil pressure switch operating. Low inlet pressure switch operating.

? 4.10.10 UNUSUAL NOISE (ON LOAD) ? ? ?

High inlet pressure switch operating. Loose components Gas leaks (usually hissing or whistling Worn bearings, cylinders and rings- usually heavy knocking, rumbling or slapping. Piston knocking Compressor set-up or pipework system vibration.

Full speed should be attained by Star before switching to Delta. Extend timer period to suit. See fault 'LOW OIL PRESSURE' or reset timer. Insufficient gas flow, check supply. Timed delay by-passing switch in starter set incorrectly, adjust as necessary. Excess gas pressure in supply line, check pressure reducing valve setting. Trace and rectify. Trace, stop compressor, depressurise if safe to do so, renew seal. Check clearances and renew as necessary.

4.10.11

UNUSUAL NOISE (UNLOADED)

? ?

! !

4.10.12

HIGH OIL CONSUMPTION

? ?

Incorrect grade of lubricant Piston rings/cylinder worn or damaged

! !

4.10.13

PREMATURE WEAR

? ?

Faulty pipeline intake filter Incorrect grade of lubricant

! !

Check Top Dead Centre clearance. Check compressor pipework system is firmly secured, check clearances and alignment of couplings and tension of vee belts. Change to recommended lubricant. Check for wear and renew as necessary. When renewing piston rings, break glaze on cylinder walls if using existing cylinders Check to ensure filter is not damaged Change to recommended lubricant.

Page 34

1293-4.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 35

Ref.

Symptom
? ?

Fault
Incorrect setting or faulty pressure reducing valve. or pressure switch Leaking 1st stage compressor suction valve Main gas supply failure Incorrect setting or faulty pressure reducing valve or pressure switch. Faulty inlet solenoid valve Inlet gas filter blocked Time delay by-passing switch in starter set incorrectly. Incorrect setting or faulty high inlet pressure switch. Leaking suction valve in following stage Insufficient cooling. Leaking fourth stage suction valve. Incorrect setting or faulty temperature switch Insufficient cooling. Incorrect setting or faulty temperature switch Failure of non-return or pressure maintaining valve Restriction in delivery line. Incorrect setting of pressure maintaining valve. Incorrect setting of pressure maintaining valve. Vehicle filling line failure. ! ! ! !

Recommendation(s)
Check function and setting of valve and switch Remove and check condition of valve, overhaul or replace as necessary. Check supply and consult gas company Check function and settings of valves and switch.

GAS SYSTEM 4.10.14 HIGH INLET PRESSURE SWITCH TRIPS

4.10.15

LOW INLET PRESSURE SWITCH TRIPS

? ?

? ? ? ? ? ? ? 4.10.19 FINAL DELIVERY TEMPERATURE SWITCH TRIPS FINAL STAGE SAFETY VALVE BLOWING ? ? ? ? ? ?

! ! ! ! ! ! ! ! ! ! ! ! !

Fit new filter element Adjust as necessary

4.10.16

4.10.17

4.10.18

INLET SAFETY VALVE BLOWING INTERSTAGE SAFETY VALVE BLOWING THIRD STAGE TEMPERATURE SWITCH TRIPS

Check function and setting of switch.

Remove and check condition of valve, overhaul as necessary. Check cooling system. Remove and check condition of valve, overhaul as necessary. Check function and setting of switch. Check cooling system. Check function and setting of switch. Check function of valves. Check and clean pipeline. Reset to correct value.

4.10.20

4.10.21

4.10.22

FINAL DELIVERY SAFETY VALVE BLOWING DISPENSER PRESSURE SWITCH TRIPS

Reset to correct value.

Check function of dispenser valves, clean and check pipeline.

1293-4.doc 04/09/02

Page 35

CompAir UK Ltd PUBLICATION 98407/1293 Section 4


Page 36

Ref.

Symptom
? ? ? ?

Fault
Short circuit. Thermal overload thermistor trip. Water pump failure. Bursting disc rupture !

Recommendation(s)
Get qualified electrician to check compressor motor circuits.

ELECTRIC MOTOR 4.10.23 MOTOR PROTECTION SWITCHES TRIP COOLING SYSTEM 4.10.24 INSUFFICIENT COOLING

! ! ! !

Gas in cooling system Radiator sets

Check condition of water pump and overhaul as necessary. Due to fatigue - renew parts. Due to excess pressure - check condition of coolers and overhaul as necessary. Remove header tank filler cap, open manual vent valves and purge system, topping up with coolant as necessary.

Page 36

1293-4.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 37

SECTION 5 CONTENTS MAINTENANCE AND REPAIR


5.1
5.1.1 5.1.2 5.1.3

MAINTENANCE

PAGE 41

GENERAL------------------------------------------------------------------------------------- 41 DAILY ------------------------------------------------------------------------------------------ 41 WEEKLY--------------------------------------------------------------------------------------- 41

5.2

AFTER THE FIRST 100 HOURS & A MAJOR OVERHAUL


5.2.1

PAGE 42

RUNNING-IN FOR FIRST 100 HOURS------------------------------------------------ 42

5.3
5.3.1

MAINTENANCE PERIODS SERVICE (HOURS)

PAGE 43

COMPRESSOR UNIT----------------------------------------------------------------------- 43

5.4
5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9

SERVICING STAGE VALVES

PAGE 44

GENERAL------------------------------------------------------------------------------------- 44 ROUTINE CLEANING AND INSPECTION - ALL STAGES----------------------- 44 ROUTINE VALVE REMOVAL AND SERVICING ----------------------------------- 44 ROUTINE CLEANING VALVE UNITS ------------------------------------------------- 45 ROUTINE VALVE REPLACEMENT ---------------------------------------------------- 45 FIRST STAGE VALVE REASSEMBLY ------------------------------------------------ 45 SECOND STAGE VALVE REASSEMBLY -------------------------------------------- 45 THIRD STAGE VALVE REASSEMBLY------------------------------------------------ 46 FOURTH STAGE VALVE REASSEMBLY -------------------------------------------- 46

5.5
5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8 5.5.9

COMPRESSOR PROTECTION

PAGE 47

SERVICING BURSTING DISC ---------------------------------------------------------- 47 SERVICING SCARIFICAL ANODE (CORROSION RODS) ---------------------- 47 SAFETY VALVES --------------------------------------------------------------------------- 47 MAINTENANCE OF OIL PRESSURE SWITCH ------------------------------------- 47 MAINTENANCE OF HIGH GAS TEMPERATURE SWITCH --------------------- 47 MAINTENANCE OF SOLENOID VALVE---------------------------------------------- 47 MAINTENANCE OF NON-RETURN VALVE ----------------------------------------- 47 GAS INTAKE FILTER/SILENCER ------------------------------------------------------ 47 OIL FILTER ----------------------------------------------------------------------------------- 47

1293-5.doc 04/09/02

Page 37

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 38

Page 38

1293-5.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 39

5.6
5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 5.6.8 5.6.9 5.6.10 5.6.11

COMPRESSOR MAINTENANCE

PAGE 48

5.6.12

5.6.13 5.6.14 5.6.15

OIL PUMP--------- ---------------------------------------------------------------------------- 48 st nd 1 & 2 STAGE COOLER TUBESTACK ---------------------------------------------- 48 RD 3 STAGE COOLER COIL --------------------------------------------------------------- 48 TH 4 STAGE COOLER COIL --------------------------------------------------------------- 48 PRESSURE GAUGES---------------------------------------------------------------------- 48 CRANKSHAFT ------------------------------------------------------------------------------- 49 MAIN-END BEARING----------------------------------------------------------------------- 49 BIG-END BEARING ------------------------------------------------------------------------- 49 SMALL-END BEARING -------------------------------------------------------------------- 49 GUDGEON PIN ------------------------------------------------------------------------------ 49 INTER-STAGE PISTON & RINGS 5.6.11.1 FIRST STAGE ----------------------------------------------------------------- 49 5.6.11.2 SECOND STAGE ------------------------------------------------------------- 49 5.6.11.3 THIRD & FOURTH STAGE------------------------------------------------- 49 CYLINDER LINERS 5.612.1 FIRST STAGE ----------------------------------------------------------------- 50 5.6.12.2 SECOND STAGE ------------------------------------------------------------- 50 5.6.12.3 THIRD & FOURTH STAGE------------------------------------------------- 50 DIAPHRAGM DRAIN VALVES ----------------------------------------------------------- 50 FLYWHEEL - DIRECT DRIVE------------------------------------------------------------ 50 FLYWHEEL/PULLEY, VEE BELTS & MOTOR PULLEY - BELT DRIVE ------ 50

1293-5.doc 04/09/02

Page 39

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 40

Page 40

1293-5.doc 04/09/02

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, COMPRESSOR GAS INLET AND OUTLET VALVES CLOSED AND VISIBLE WARNING NOTICES DISPLAYED. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE SUPPLY AND STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF.
Note: An O&M manual must cater for a wide variety of operating duties, ambient conditions and methods of control. The following maintenance schedules are only a recommended guide to maintenance periods. It may be found advantageous or desirable to vary the maintenance periods depending on operating conditions and experience.

5.1
5.1.1

MAINTENANCE
GENERAL It is useful to record stage pressure, temperatures, oil used in a log against hours run, as this builds up a detailed record of machine condition. It can also provide a trend and indication of a possible problem. Do not re-use O rings, seals and joints fit new! Grease O rings used for all dry joints in contact gas. Use a liberal smear of silicone for all O rings st nd used in possible contact with the cooling water. I.e. cooler assemblies, 1 and 2 stage wet cylinder liners. Flush out water passages either with high-pressure water or steam cleaning. Clean thoroughly all oil-ways and carefully blow clean using compressed air. Lightly grease or oil all surfaces of ferrous components after cleaning to prevent rusting. Where practical, remove carbon deposits by gently tapping and scraping, taking care not to remove metal.

5.1.2

DAILY Check oil level in crankcase and top up as necessary. Check stage pressures, oil pressure and temperatures.

5.1.3

WEEKLY Check bursting disc for signs of cracking. Check for oil, gas or water leaks; rectify as necessary. Examine oil in crankcase and ensure that it is not contaminated with condensate. Depending on the degree of contamination, the oil may appear emulsified (creamy in colour) especially if the recommended lubricant is not used. If emulsification takes place the oil must be changed and the crankcase cleaned. This condition is usually visible through the sight glass, oil level indicator and must be rectified immediately. Trace cause of contamination, rectify, and fit new oil filter and refill crankcase with recommended oil. If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the oil by means on the drain plug. The oil level should be replenished accordingly with clean oil. Crankcase oil contamination is often accompanied by increase in sight glass oil level, due to oil being supported by condensate fluid. Check correct operation of all controls.

1293-5.doc 04/09/02

Page 41

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 42

5.2

AFTER THE FIRST 100 HOURS & AFTER MAJOR OVERHAUL

5.2.1 RUNNING IN FOR FIRST 100 HOURS - READ MAINTENANCE WARNING BEFORE COMMENCING Drain sump, replace oil filter, clean sump & refill with recommended synthetic oil * (see SECTION 1.2.4) Clean suction and delivery valves. All components on these compressors are compatible with the recommended synthetic oil but as problems may exist with downstream ancillary equipment, the equipment manufacturer should be consulted. METHOD Drain the oil completely from compressor whilst the oil remains warm. Remove crankcase doors and thoroughly clean interior of the crankcase. Clean oil suction strainer. Renew oil filter. Remove, thoroughly clean and refit all suction and delivery valves. When inspecting valves, also remove as far as is possible any carbon deposit in valve pockets, passageway pipes and separators. Replace crankcase doors and refill crankcase to correct levels with recommended synthetic oil.

Page 42

1293-5.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 43

5.3 MAINTENANCE PERIODS AND SERVICE HOURS AFTER THE FIRST 100 HOURS.
COMPRESSOR UNIT- READ MAINTENANCE WARNING BEFORE COMMENCING Service Hours ( x 1000) R-5437.1.NG 0.5 1.5 3 4.5 6 7.5 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 5.2 and then above service hours and after 18000.

1293-5.doc 04/09/02

Page 43

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 44

5.4

SERVICING COMPRESSOR STAGE VALVES

SEE SECTION 6 FOR ILLUSTRATIONS- READ MAINTENANCE WARNING BEFORE COMMENCING 5.4.1 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. Valves, when removed, may have only a thin carbon layer and be slightly moist with oil. Note: Unless replacement of the springs and plates is intended, 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. 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 5.4.2 Service Hours ( x 1000) 4.5 6.0 7.5 C NK NK

1.5

3.0

9.0 NK NK R R

18.0 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 - ALL STAGES May be removed scraping with a soft, blunt instrument, e.g. a piece of wood. WARNING: Great care should be taken when removing carbon deposits to ensure that the seating faces of the valve components are not damaged. These faces should be clean and bright over their whole area, with no evidence of uneven contact. Renew any plates which are indented, cracked, warped, or have wear grooves which exceed 10% of the plate thickness. Valve plates and springs must always be replaced at recommended life periods, regardless of appearance, to achieve maximum reliability. If the seats show severe wear or indentations, the complete valve assembly must be renewed. The remaining components should be checked for cracks, distortion or other damage liable to impair the valve operation. 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. Rotate crankshaft by hand until relevant stage piston is at top dead centre. Remove valve covers nuts. Use forcing screws to remove valve covers. Using the special valve lifting tools, remove valve assemblies. A gentle rocking action pulling at the same time will free the valve from any carbon build up in the pocket. Carefully wipe any loose carbon from valve pocket ensuring that no carbon is left in valve pocket or on top of the piston. Move valve to a workbench and remove central nut from valve unit. Carefully separate upper and lower bodies and, with unit on a level surface, lift off upper body. Remove valve plates and springs, noting very carefully their relative positions to the body and each other if they are to be re-used.

5.4.3

Page 44

1293-5.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 45

5.4.4

ROUTINE VALVE CLEANING Completely clean all components as detailed in "Cleaning and Inspection - All stages", Section 5.5.2 Always renew valve plates and springs in complete sets. The seating faces of each valve plate and body half should be clean and bright with all round, even contact and be free from indentations. Any item with indentations will require renewal. Reassemble valve plates and springs exactly as dismantled. NEVER reverse plates / springs as this will lead to rapid failure. ROUTINE VALVE REPLACEMENT Recheck that valve / valve pocket, top of piston, and the surrounding area is clean before replacing valve assembly. Ensure valve seats properly as a slight misfit will entail loss of gas. Again check valve cover for cleanliness before assembly. Renew "O" rings, lightly greasing before fitting. There should be at least a 2mm (0.80) gap between the top of cylinder and bottom of valve cover. Sequentially tighten cover fasteners evenly to 75% and then 100% the correct torque, except for fourth stage valve cover; tighten these nuts sequentially in 27Nm (37 lb.ft) steps to the correct torque. FIRST STAGE VALVE REASSEMBLY - SECTION 6 PAGE 68 Place delivery valve seat (10) face downwards on suitable metal ring, or protected open vice jaws with locating pegs uppermost, position spring plates (3) to located over pegs (9) with bridging strip resting between pegs and springs facing upwards. Place valve plate (2) onto spring plate, located as above, ensuring concentricity on centre hole. Place middle lift washer (7) over hole. Place valve plate (6) onto locating pegs (8). Put lower lift washer (7) onto locating pegs. Place valve spring plates (4) onto locating pegs (8) with springs pointing downwards. Place suction valve seat (1) onto assembly, ensuring inner (8) and outer pegs (9) engage correctly. If assembly has been carried out correctly, upper and lower body faces will contact. Screw nut (12) on stud and hand tighten only at this stage. Test for correct operation by ensuring free movement of suction and delivery valve plates. 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. If plates are not free, dismantle, relocate misplaced part and assemble, check again for free movement of plates before tightening to the correct torque. Ensure "O" ring (11) is secure in slot in upper valve body. SECOND STAGE VALVE REASSEMBLY- 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, locating them on peg (7), springs facing downwards. Follow this with valve backing plate (4). Place delivery valve springs (3) onto valve / backing plate having first positioned them as follows: Assemble the delivery plate springs (3) in pairs, rotating one spring in each pair until the inner and outer circumferences are matched perfectly. 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. Place valve plate (2) on spring plates and then after ensuring concentricity place suction valve seat (1) onto assembly. If all components are located correctly upper and lower bodies will contact. Screw nut (10) on stud and hand tighten only at this stage. Test for correct operation by ensuring free movement of suction and delivery valve plates. 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. If plates are not free, dismantle; relocate misplaced part and reassemble, checking again for free movement of plates before tightening to the correct torque. Ensure "O" ring (9) is secure in slot in upper valve body.

5.4.5

5.4.6

5.4.7

1293-5.doc 04/09/02

Page 45

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 46

5.4
5.4.8

SERVICING COMPRESSOR STAGE VALVES CONT.


THIRD STAGE VALVE REASSEMBLY- SECTION 6 PAGE 70 Using suitable metal ring or open protected vice jaws, positions delivery valve seat (7) face downwards and insert valve plate (6) followed by three spring rings (5) bowed two against one as shown. Follow this with valve backing plate (4). Place delivery valve springs (3) onto valve / backing plate having first positioned them as follows: Assemble the delivery plate springs (3) in pairs, rotating one spring in each pair until the inner and outer circumferences are matched perfectly. 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. Follow up with valve plate (2) and when satisfied all components are correctly aligned, place lower body (1) and centre stud through assembly. Press together and ensure edges of upper and lower body contact then place washer (9) over stud, screws on nut (10), hand tighten only at this stage. Test for correct operation by ensuring free movement of suction and delivery valve plates. 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 correct torque, however, if plates are not free, dismantle, relocate misplaced part and reassemble, checking for free movement of plates before tightening to the correct torque. Ensure "O" ring (8) is secure in slot in upper valve body.

5.4.9 FOURTH STAGE VALVE REASSEMBLY- SECTION 6 PAGE 71 Place valve body (13) on a clean flat surface with stud (12) uppermost. Fit plate (11) in the valve recess followed by spring plates (10), arranged as shown, and suction valve plate (9). Fit central body (8) over stud and lower until locating hole engages with peg in lower body. Carefully push two valve body sections (8 & 13) together until in full and firm contact. If the sections will not locate correctly: separate and re-align to plates and springs. DO NOT FORCE TOGETHER. Invert upper body (4) and hole in a soft jawed vice or similar. Fit plate (7) into recess followed by spring plates (6), arranged as shown, together with delivery plate (5). Centralise the plates and springs. With the central (8) and lower body (12) held firmly together; turn upside down and pass stud through hole in upper body (4), ensuring that the hole in central body engages with peg in upper body. If centre section will not locate correctly with upper body: remove and re-align plates and springs. DO NOT FORCE. Ensuring that all components are correctly located and held firmly together, remove from the vice and fit washer (2) and nut (1) and tighten to correct torque. When correctly located and tighten and fit new O ring (3).

Page 46

1293-5.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 47

5.5
5.5.1

SERVICING COMPRESSOR PROTECTION


SERVICING BURSTING DISCS SEE SECTION 6 PAGE 52 1. 2. 3. Cylinder 4. 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. Reassemble in the correct order and tighten screws evenly to the correct torque. SAFETY NOTE: ONLY USE GENUINE REPLACEMENT DISCS 5.5.2 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. If seriously corroded, renew. 5.5.3 SAFETY VALVES do not attempt to dismantle, adjust or repair. With machine running at or near maximum pressure ensure valves are not leaking significantly. A very slight leakage of gas is quite normal. DO NOT listen or look directly at discharge ports. A simple method is to fit a balloon (or similar) over the discharge. Renew faulty valves, DO NOT ATTEMPT REPAIR. 5.5.4 MAINTENANCE OF OIL PRESSURE SWITCH None. If faulty, renew. 5.5.5 MAINTENANCE OF HIGH GAS TEMPERATURE SWITCHES None. If faulty, renew. 5.5.6 MAINTENANCE OF SOLENOID VALVE None. If faulty, renew. 5.5.7 SERVICING NON-RETURN VALVE None. If faulty, renew. 5.5.8 GAS INTAKE FILTER / SILENCER Remove gas filter element from unit. Replace paper element. Brush or blow out dust and dirt from suction silencer. Replace gas filter element into unit ensuring it sits firmly on the seal. 5.5.9 OIL FILTER Remove filter, spin-on type, by unscrewing anti-clockwise. Fit new spin-on filter, lightly oil sealing ring before fitting. Tighten hand tight . Check for leaks on restart.

1293-5.doc 04/09/02

Page 47

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 48

5.6 MAINTENANCE ~ COMPRESSOR


5.6.1 OIL PUMP SEE SECTION 6 PAGE 48 & 49 If the pump is in anyway unsatisfactory replace. 5.6.2 FIRST & SECOND STAGE COOLER TUBESTACK SEE SECTION 6 PAGE 63 & 77 Remove cooler end cover and separator from non drive-end. nd Remove from drive-end 2 stage separator (remove separator cover to gain access to all studs). Remove three corrosion rods (anodes) from cylinder block. st nd Remove and withdraw combined cooler tubestack for 1 and 2 stage from driving end using tool C203733.1 Wash and brush down exterior of tubes, baffle plates and clean water passages. Inspect for corrosion and hydrostatically test and replace as necessary To refit smear cooler end covers and cooler body bore with silicone sealant. Push the cooler assembly through body, studded end first. silicone and fit 'O' rings to drive end only, push through further until non drive end 'O' ring grooves are exposed, silicone and fit 'O' rings and then push in flush with body. Fit outer end cover without gasket, tighten bolts, then remove cover and clean excess silicone from face. Fit gasket and then finish assembly. 5.6.3 THIRD STAGE COOLER COIL SEE SECTION 6 PAGE 63 & 77

DO NOT ATTEMPT to remove cooler coil assembly end fittings. This is a brazed assembly containing high pressure! rd Disconnect 3 stage inlet pipe, remove separator, remove large circlip from outer-end withdraw using TOOL C203734.1 Remove outer shroud tube. Wash and brush down exterior of tubes and clean cylinder block water passages. If airflow through tube coil is restricted, or there is any doubt to internal cleanliness, renew complete assembly. Inspect for corrosion and hydrostatically test and replace as necessary Fit new "O" ring seals, smear cooler end covers 'O' rings and cooler body bore with silicone sealant. Refit to body. 5.6.4 FOURTH STAGE COOLER COIL SEE SECTION 6 PAGE 64 & 77 DO NOT ATTEMPT to remove cooler coil assembly end fittings. This is a brazed assembly containing high pressure! th Disconnect 4 stage inlet pipe, remove cooler cover from outer-end withdraw using TOOL C203734.1 Remove outer shroud tube. Wash and brush down exterior of tubes and clean cylinder block water passages. If airflow through tube coil is restricted, or there is any doubt to internal cleanliness, renew complete assembly. Fit new "O" ring seals to cooler end covers. Inspect for corrosion and hydrostatically test and replace as necessary. 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. 5.6.5 PRESSURE GAUGES SEE SECTION 6 PAGE 53 Remove gauge panel complete with gauges, after releasing pressure gauge tail nuts. Loosen screws holding clamp rings, remove gauges. Send gauges for calibration on dead-weight tester. 5.6.6 CRANKSHAFT Remove crankcase doors and remove all big end caps. Remove all pipes from the crankshaft interior. Remove main-bearing housing screws at driving end and main bearing housing. Prise out and discard oil seal. Support weight of crankshaft using lifting tackle or blocks. Carefully remove crankshaft through driving end of crankcase. Remove main-end bearing housing screws at outer end and remove housing. If crankshaft journals or thrust faces are scored oval or worn below limits: renew shaft. To renew, fits new thrust washers at outer-end bearing housing and install housing to crankcase. Ensure all journals of crankshaft are clean and free from burrs and oil all surfaces. Insert crankshaft to bearing housing. Fit new oil seal and thrust washer to driving end bearing housing and install housing. Check freedom of rotation of shaft and correct end float.

Page 48

1293-5.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 5


Page 49

5.6 SERVICING ~ COMPRESSOR CONT.


5.6.7 MAIN-END BEARINGS Use a hydraulic press to remove old bearings from bearing housings. BIG-END BEARINGS - MEASURING BEARING CLEARANCES Remove crankcase doors and remove all big end caps. Measure crankshaft journals in two positions at 90 for each big end. If any one dimension is below the minimum given in Section 1.4 it is recommended the compressor be overhauled. Do NOT merely fit new bearing shells. If satisfactory refit big end bearings, ensuring identity numbers are adjacent and facing upwards. Note: The big end bearings fitted to the connecting rods are of the aluminium / tin line overlay, steel backed shell type, on an underlying copper based bearing material. It is important to note that due to the bedding process, which occurs during running-in, that the aluminium / tin overlay will be removed in the areas of highest load exposing the underlying copper based bearing material. This is quite normal and does not indicate a fault in the bearing or the need for shell replacement. After initial bedding in to this level the bearing will show no significant further change for several thousand hours. 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, the complete bearing must be replaced. SMALL-END BEARINGS st Note: The 1 stage bearing is a plain bush, NOT a rolling contact needle roller bearing. If there is detectable movement of the piston or crosshead at 90 to its normal plane of movement of the conn-rod, remove and discard the gudgeon pin and needle roller bearing. Note the needle rollers may dislodge from their holder when dismantling, care must be taken when refitting gudgeon pin. GUDGEON PINS Remove circlips and gently drift out all gudgeon pins. Check pins for any flaking of the surface; renew if worn or flaking of surface is evident. SERVICNG INTERSTAGE PISTON & RINGS st 1 Piston & Ring removal See Section 6 pages 50, 65 & 74 Remove valve and valve covers. Undo big-end bearing cap from conn-rod. st 1 piston line removes using TOOL C 200223.1 complete upwards from valve opening. Measure and replace rings. Ensure the gaps for new rings are staggered. Oil surface of cylinder liner and piston before re-assembly. Place piston ring compressor into valve pocket and oil well. Carefully lower the complete line through the bore. Do not rotate piston. When rings are engaged, remove compressor and refit big-end bearing and conn-rod caps.and tighten to correct torque setting. Replace all O rings for valve cover and coat with silicone grease 2
nd

5.6.8

5.6.9

5.6.10

5.6.11

stage Piston & Ring removal See Section 6 pages 50, 65 & 75 Ensure water is drained from cylinder block. Remove valve and valve covers. Undo big-end bearing cap from conn-rod. Withdraw liner and piston line using TOOL C200223.1 Measure and replace rings. Oil cylinder liner bore and piston before re-assembly. Coat bottom face of liner & 'O' rings with silicon sealent. Fit piston into liner. Carefully lower the complete line through the bore. Do not rotate piston. Refit big-end bearing and conn-rod caps, and tighten to correct torque setting. Replace all O rings for valve cover and coat with silicone grease.
th

3 and 4 Piston & Ring removal See Section 6 pages 51, 66 & 76) Remove valve and valve covers. Undo piston-retaining capscrew. Withdraw piston ( cartridge) from crosshead using TOOL C203704.1 Measure and replace rings. Torque piston capscrew to correct value.THIS IS CRITICAL.

rd

1293-5.doc 04/09/02

Page 49

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. Replace all O rings and coat with silicone grease.

5.6 SERVICING ~ COMPRESSOR CONT.


5.6.12 SERVICING INTERSTAGE CYLINDER LINERS Ensure water is drained from cylinder blocks. st nd 1 and 2 stages. See Section 6 pages 50, 59, 60 74 & 75 Remove valve and valve covers. Undo big-end bearing cap from conn-rod. Piston lines remove using TOOL C 200223.1 complete upwards from valve opening. Withdraw liner using TOOL C203718.1 Measure liner bore in two positions, at the bottom and again near the top, where ring wear will be greatest. De-glaze liner bore by light honing if fitting new rings into existing liners. Replace all O rings and coat with silicone sealant. 3 and 4 stages See Section 6 pages 51, 61, 62 & 76 Remove valve and valve covers. Undo piston-retaining capscrew. Withdraw piston (cartridge) from crosshead using TOOL C203704.1. Withdraw liner-using TOOL as shown in diagram C203705. Measure liner bore in two positions, at the bottom and again near the top, where ring wear will be greatest. Replace as necessary using least possible force - DO NOT hammer liners in place. Replace all O rings. 5.6.13 DIAPHRAGM DRAIN VALVE UNITS SEE SECTION 6 PAGES 54, 72 & 73 Remove the three screws at each end of the units and pull bodies apart from the cover. Discard diaphragm and joints. Inspect valves and discard if there is any significant wear. The valves cannot be effectively refurbished if re-lapping of seats is insufficient to restore valve seating. If the valve seat has been worn to more than approximately 1mm (0.040) width, renew. After removing pipe fittings and locknuts, the valve seats may now be tapped out of the body halves if they are to be renewed. Otherwise leave in-situ. The cap screws retaining the mushroom plates to the valve can now be removed it the valves are to be renewed. Otherwise leave in-situ. Use thread sealant between the valve seats and body halves and the cap screws securing the mushroom plates to the valves. Reassemble units with three screws each end finger tight only. Checks that the relative position of outlets, securing bolt hole, separator pipe and pilot gas connections are all-correct. Tighten all six screws sequentially. FLYWHEEL (Direct Drive) Remove motor complete with bell housing and half coupling Remove compressor half coupling, ease back tab washer and remove keep bolt, keep plate and tab washer. Support flywheel and release from the crankshaft taper. A withdrawing tool may be required. Remove flywheel and key. FLYWHEEL/PULLEY, BELTS & MOTOR PULLEY (Belt Drive) Remove vee belt. Loosen the motor holding down bolts. Using vee drive tensioning bolts slacken and then remove vee belts To remove compressor half coupling, ease back tab washer and remove keep bolt, keep plate and tab washer. Support flywheel and release from the crankshaft taper. A withdrawing tool may be required. Remove flywheel and key. For motor pulley, release taperlock bush screws, withdraw complete.
rd th

5.6.14

5.6.15

Page 50

1293-5.doc 04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 51

SECTION 6 CONTENTS
BUILD - H-5437.1.GAS COMMON

ILLUSTRATIONS & PARTS LIST


CRANKCASE ASSEMBLY - 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 - ALL DIAPHRAGM DRAIN VALVE UNITS - ALL ST ND 1 2 STAGE VALVE & LINER REMOVEL RD TH 3 & 4 STAGE VALVE, 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 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, are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd. Ipswich. The assemblies have been chosen based on the experience gained by our own Parts and Service Departments. The right is reserved to modify the contents of this list, without notice, and the information given is in no way binding on the manufacturers.
* IF FITTED - LATER COMPRESSORS HAVE A MODIFIED MAIN BEARING BUSH, AS THE THRUST WASHERS ARE NOW OBSOLETE.

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.doc Page 51

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 52

Item No. 1.1 1.1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 Item No. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17

Description. Crankcase parts Door Door Breather cover Breather retaining plate Joint breather cover Joint - c/case door Joint filler to c/case Stud M8 x 20 s.o. Stud M16 x 45 s.o. 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 ,4 stg. Body to c/case st nd O-ring 1 ,2 stg. Body to c/case Breather Element Oil Level Gauge Oil Level Label Seal Seal Seal " BSP Crankcase supplied with parts # Suction oil pipe assembly Oil service pipe assembly Oil feed pipe assembly Low oil pressure switch Description. Main bearing housing O/E parts Bearing housing Joint - outer- end bearing cover Joint - oil pump to cover Bush Outer end cover Joint - 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. E61640 LIST 1 C201802 C203270 C201815 C201816 C201819 C201821 C201829 D54109.8.28 D66720.16.69 PS1068.5 PS1454.6 PS2189.1 RP513 95000.228 95000.256 95000.314 95018.274 95111.5 95111.9 95602.149 95602.155 98262.1132 98281.1002 98381.1013 98660.1154 98660.1155 98660.1156 A30051.2# D100809.1 D100973.1 D100809.2 98524.1042 Part Number. D101723 LIST 3 E60010 C200869 C200900 C85736.2 D100234 D100354 PS1068.2 PS1454.4 95000.255 95000.256 95000.257 95502.366 98074.1004 98262.1009 98660.1153 C85737.2 D54109.8.28

Number OFF. 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. 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.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 53

3.18 3.19 3.20 3.21 3.22 3.23 Item No. 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 Item No. 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10 5.2.11 Item No. 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8 5.3.9 5.3.10 5.3.11

Stud Nut Copper washer Cover Plate 'O' Ring Setscrew M6 X 16lg Description. 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. Running gear 2nd stage Bearings B/E Gudgeon pin Connecting Rod. nd Piston 2 stage supplied with parts Circlips gudgeon pin Small end bearing nd Ring Piston ring, 2 stage nd Ring Oil control ring, 2 stage nd Ring - -piston ring, 2 stage Spacer for small end bearing Spirol pin 4mm x 22 lg Description. Running gear 3rd stage Bearings B/E Gudgeon pin Connecting Rod. 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 4mm x 22 lg

D66720.8.42 95111.5 T6495.56 C203648 95602.50 95000.228 Part Number. D101752 LIST 4 C203296 C202992 C203129 D100353 95440.28 95000.227 95018.312 95405.1001 98074.1004 98150.1035 98156.1462 98617.1001 Part Number. D101750 LIST 5 C201109 C203984 D101743 D101744 95650.1022 96076.1129 98477.1060 98477.1061 PS1159.110 C203986 95527.96 Part Number. D101751 LIST 5 C201109 C203984 D101743 PS1159.108 95650.1022 96076.1129 D101745 C203684 98086.1028 C203986 95527.96

2 3 10 1 1 4 Number OFF. 1 1 1 1 1 4 1 1 2 1 1 1 Number OFF. 1 1 1 1 1 2 1 1 1 1 1 Number OFF. 1 1 1 4 1 2 1 1 1 1 1

SPARE PART

# # # # # # # # # # # SPARE PART

SPARE PART

1293-6.doc Page 53

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 54

Item No. 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 Item No. 6.1 6.2 6.3 6.4 6.5 Item No. 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 Item No. 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7

Description. Running gear 4th stage Bearings B/E Gudgeon pin Connecting Rod. Circlips gudgeon pin Small end bearing Piston ring th Piston 4 stage supplied with parts Retaining bolt piston Spirol pin 4mm x 22 lg Spacer S/E bearing Description. Crankshaft Keep plate Tab washer Setscrew 3/4-16 unf x 1 1/2 LG Crankshaft supplied with parts # Key Description. Cylinder parts 1st & 2nd stage Stud M10 x 60 s.o. 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.o. Stud M10 x 97 s.o. Gasket Nut M10 Description. Cooler parts 1st & 2nd stage Screw M12 x 35 First stage separator cover. Second stage separator st nd Joint 1 & 2 stage separator Gasket 2nd stage separator Gasket 1st stage separator Gasket 2nd stage separator

Part Number. D101760 LIST 5 C201109 C203984 D101743 95650.1022 96076.1129 98477.1143 C203685 98086.1028 95527.96 C203986 Part Number. LIST 6 C11359-44 C11359-45 C75163.3 D66397 PS1130.21 Part Number. E61641 LIST 7 D66720.10.75 D66720.12.58 D66720.16.84 95000.312 95111.11 95111.7 95242.2 A30200 D66720.10.160 D66720.10.112 C11359.62 95111.6 Part Number. D101725 LIST 8 95000.315 E61521 E61519 D101601 C203697 C203698 C203699

Number OFF. 1 1 1 2 2 6 1 1 1 1 Number OFF. 1 1 1 1 1 Number OFF. 2 4 4 4 4 4 2 1 12 7 1 20 Number OFF. 8 1 1 1 1 1 1

SPARE PART SPARE PART # # # # SPARE PART

SPARE PART

Page 54

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 55

Item No. 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13 8.2.14 Item No. 8.3 Item No. 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 Item No. 10.1 10.2 Item No. 10.3 10.4 10.5 10.6 10.7 10.8

Description. Tubestack assembly 1st & 2nd stage Stud M10 x 60 s.o. Nut M10 Circlip Tube plate Stud M10 x 145 s.o. Stud M10 x 45 s.o. Tube plate Baffle plate Baffle plate Rod spacer Stud M10 x 165 s.o. 'O' ring Cooler tube 1st & 2nd stage Cooler tube starfin Description. 2nd stage separator cover. Description. Cylinder parts 3rd & 4th stage Bursting disc cover Pocket thermometer Gasket Stud M8 X 45 s.o Stud M16 X 50 s.o Stud M16 X 60 s.o Plug 1" BSP Dowty seal 1" BSP Setscrew M10 Nut M8 Nut M16 Eyebolts Seal " BSP Body 3rd & 4th Description. Cooler coil assembly 3rd stage Shroud outer Tube stack Description. Cooler parts 3rd stage 'O' ring. 'O' ring. Tension pin. Separator 3rd stage Circlip retaining 'O' ring.

Part Number. E61533 LIST 8 D66720.10.75 95111.6 98148.1033 E61522 D66720.10.160 D66720.10.60 E61525 D100598 D100599 C203692 D66720.10.180 95602.110 C200796.5 98617.1031 Part Number. D101764 D101764 Part Number. E61642 LIST 9 C200584 C201708 C81788 D100171.8.61 D66720.16.74 D66720.16.84 PS1068.6 PS1322.8 95000.282 95111.5 95111.9 95242.2 98660.1156 A30201 Part Number. D101609 LIST 10 D101586 D101629 Part Number. D101726 LIST 10 95602.91 95602.94 95440.285 E61517 95650.1110 95602.31

Number OFF. 7 24 36 1 5 8 1 3 3 3 4 4 31 14 Number OFF. 1 Number OFF. 1 1 2 3 4 4 4 4 4 3 8 2 1 1 Number OFF. 1 1 Number OFF. 2 2 1 1 1 1

SPARE PART

SPARE PART

SPARE PART

SPARE PART

SPARE PART

1293-6.doc Page 55

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 56

Item No. 11.1.1 11.1.2 Item No. 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 Item No. 12.1 12.2 `Item No. 13.1 13.2 Item No. 14.2.1 14.2.2 14.2.3 14.2.4 14.2.5 14.2.6 Item No. 14.3.1 14.3.2 14.3.3 14.3.4 14.3.5 Item No. 14.4.1 14.4.2 14.4.3 14.4.4 14.4.5 14.4.6 14.4.7 Item No. 18.7 18.8 18.9

Description. Cooler coil assembly 4th stage Tube stack. Tube outer Description. Cooler parts 4th stage 'O' ring. 'O' ring. Locating lugs Fitting Setscrew M8 Capscrew M10 Description. Corrosion rod set Corrosion rod. Corrosion rod. Description. Bursting discs Bursting disc Bursting disc - melinex Description. Liner/valve cover parts 2nd stage Valve cover Liner 'O' ring 'O' ring 'O' ring 'O' ring Description. Liner/valve cover parts 3rd stage Back up ring. Liner Valve cover 'O' ring 'O' ring Description. Liner/valve cover parts 4th stage Back up ring. 'O' ring 'O' ring Liner 'O' ring Valve cover 'O' ring Description. Temperature switch - 3rd stage Temperature switch - Final stage Button head screws

Part Number. D101610 LIST 11 D101630 C202949 Part Number. D101727 LIST 11 95602.87 95602.88 C203809 C203849 95000.262 95018.230 Part Number. C203868 LIST 12 C203869 C203870 Part Number. LIST 13 C201658.2 C84735.1 Part Number. D101729 LIST 14 D100604 D100005 95602.100 95602.140 95602.141 95602.98 Part Number. D101730 LIST 14 98504.1112 C203686 C203680 98504.1385 98504.1384 Part Number. D101731 LIST 14 98504.1090 98504.1105 98504.1106 C203687 98504.1386 C203681 98504.1387 Part Number. LIST18 C202556.8 C202960.1 95034.386

Number OFF. 1 1 Number OFF. 2 2 2 1 4 2 Number OFF. 4 4 Number OFF. 1 1 Number OFF. 1 1 1 2 2 2 Number OFF. 2 1 1 2 2 Number OFF. 1 1 1 1 1 1 2 Number OFF. 1 1 8

SPARE PART

SPARE PART

SPARE PART

SPARE PART

SPARE PART

SPARE PART

SPARE PART

SPARE PART

Page 56

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 57

Item No. 19.1 19.2 19.3 19.4 19.5 19.6 Item No. 20.1 20.2 20.3 20.4 Item No. 21.1 Item No. 22.1 22.2 22.3 ex ex ex

Description. Elbow male/female Connector Swivel nut adaptor Safety valve 3rd stage Safety valve 2nd stage Safety valve 1st stage Description. Non return valves Union Seal Dowty Non return valve Banjo Coupling " BSP Description. Pipe assemblies Pipe assembly - 4th stage. Description. Tools Valve lifter - 1st stage Valve lifter - 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. LIST19 95405.54 98156.2690 98156.3200 98650.1022-150 98650.1021-40 98650.1020-10 Part Number. LIST 20 C82148 PS1322.4 98650.1655 98156.1455 Part Number. LIST 21 C203858 Part Number. LIST 22 C200066.1 C84096.1 C203706 C203740 C203705 C203739

Number OFF. 2 3 3 1 1 1 Number OFF. 1 2 1 1 Number OFF. 1 Number OFF. 2 1 1 1 1 1

SPARE PART

SPARE PART

SPARE PART

SPARE PART

ex ex ex

1293-6.doc Page 57

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 58

LIST 19.4 nd Safety valve 2 stage LIST 7 & 14

LIST 18 LIST 19.2 st Safety valve 1 stage

LIST 12

LIST 7 & 14

LIST 3 LIST 1 LIST 4 LIST 19.1 Safety valve Surge vessel LIST 16 17.6 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.doc

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

TH

LIST 9 STAGE

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

ST

LIST 8 ND & 2 STAGE LIST 7 STAGE

LIST 9 STAGE

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

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 62

2ND STAGE CYLINDER PARTS

7.3 7.5 14.2.5

14.2.1 15.2 14.2.4 14.2.3 14.2.2

14.2.6 5.2.2 5.2.5 5.2.4 5.2.6 5.2.7 5.2.8

Page 62

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 63

3RD STAGE CYLINDER PARTS


14.3.3

4.3.1 4.3.5

5.3.4

9.5 9.11 5.3.9

15.3 14.3.4 5.3.8 5.3.7 5.3.2 5.3.5 5.3.6 14.3.2

1293-6.doc Page 63

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 64

4TH STAGE CYLINDER PARTS


15.4 14.4.3 14.4.2 14.4.6

14.4.7 14.4.1 14.4.7 5.4.6 14.4.4

5.4.8 5.4.7 5.4.2 5.4.4 5.1 Section 7 5.4.5

Page 64

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 65

1 / 2 STAGE COOLER / SEPARATOR SECTION D101725 8.2.5 8.2.1 8.1.1

ST

ND

8.1.8 8.1.6 8.2.5 8.2.6 8.1.3


RD

8.1.7

LIST 8 E61533 8.1.2 3 STAGE COOLER / SEPARATOR ASSEMBLY D101726

8.1.4 10.6 10.8

10.3

10.4

10.5 4
TH

LIST 10 D101609

10.7

STAGE COOLER SECTION D101727

11.2.1

LIST 11 D101610

11.2.1

11.2.2

1293-6.doc Page 65

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 66

OIL PUMP DRIVE ASSEMBLY

3.9 3.12 3.17 3.19 3.18 3.15 3.7 3.10 3.17 3.18

3.5 3.20

3.2

3.16 3.16 3.16

3.3 3.16 3.14 1.2 1.3

3.12 1.31 1.29

1.29

1.21 1.13 1.4

1.28

1.30

Page 66

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 67

LIST 5 - 1ST & 2ND STAGE RUNNING GEAR


5.2.4 5.2.7 5.2.8 5.2.2

5.2.5

5.2.6

5.2.1 5.2.3

FOR 1 STAGE SEE H5437.1.NG BUILDS

ST

1293-6.doc Page 67

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 68

LIST 5 - 3RD & 4TH STAGE RUNNING GEAR


5.3.9

5.3.4 5.4.8 5.3.8 5.4.6 5.3.7

5.4.7

5.3.5

5.3.2 SEE H5437.1.NG BUILDS 5.4.5 5.3.6

5.4.3 5.3.3

5.4.2 5.4.4

5.4.1 5.3.1

Page 68

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 69

LIST 6 - CRANKSHAFT ASSEMBLY

5.1.5 5.2.3 5.3.3 5.4.3

6.5

6.3 6.1

6.4

6.2

1293-6.doc Page 69

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 70

LIST 1 CRANKCASE
* Thrust Washers fitted to older machines are now obsolete. If a replacement part is required a new type main bearing bush may be supplied. New compressors have new type main bearing bush fitted with integral thrust washer.

4.4

4.1

4.2

4.3

1.13 3.13 3.8 1.16 3.1 3.6 3.4 1.11 1.12 1.8 1.18

1.10 1.15

2.2 2.1

1.17

1.6 1.9 1.10 1.26 1.22 1.23

1.5 1.7

1.1

1.14

1.25

Page 70

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 71

1ST STAGE VALVE 98650.1519

DELIVERY VALVE SEAT

NOT AVAIL.

SERVICE KIT NUMBER 2 VALVE PLATE 98650.1518

SPRING PLATE

98650.1518

SPRING PLATE

98650.1518

LIFT WASHER

98650.1518

6 7 8 9

VALVE PLATE LIFT WASHER PEG PEG

98650.1518 98650.1518 NOT AVAIL. NOT AVAIL.

10

SUCTION VALVE SEAT

NOT AVAIL.

11 12

'O' RING 95602.93 NUT

98650.1518 98650.1518

1293-6.doc Page 71

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 72

2ND STAGE VALVE 98650.1039

NOT AVAIL. DELIVERY VALVE SEAT 1

SERVICE KIT NUMBER 98650.1533 VALVE PLATE 2

98650.1533

SPRING PLATE

98650.1533

BACKING PLATE

98650.1533

SPRING PLATE

98650.1533

VALVE PLATE

NOT AVAIL. PEG

NOT AVAIL. SUCTION VALVE SEAT 8 98650.1533 98650.1533 95602.55 'O' RING NUT 9 10

Page 72

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 73

3RD STAGE VALVE 98650.1049

DELIVERY VALVE SEAT

NOT AVAIL.

SERVICE KIT NUNBER 2 VALVE PLATE 98650.1059

SPRING PLATE

98650.1059

BACKING PLATE

98650.1059

SPRING PLATE

98650.1059

VALVE PLATE

98650.1059

SUCTION VALVE SEAT

NOT AVAIL.

8 9 10

O RING 95604.24 WASHER NUT

98650.1059 98650.1059 98650.1059

1293-6.doc Page 73

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 74

4TH STAGE VALVE 98650.2037


SERVICE KIT NUMBER 1 2. 3. NUT WASHER O RING 95604.15 98650.2040 98650.2040 98650.2040

VALVE BODY

NOT AVAIL. PEG

VALVE PLATE

98650.2040

SPRING PLATE

98650.2040

VALVE PLATE

98650.2040

SUCT & DELY BODY

NOT AVAIL

9 10 11

VALVE PLATE SPRING PLATE BACKING PLATE

98650.2040 98650.2040 98650.2040

12

STUD

NOT AVAIL.

13

VALVE BODY

NOT AVAIL PEG

Page 74

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 75

1ST & 2ND D.D.V ASSEMBLY U334.L


4 2 1 6 8 7 1 6 1 9 4

5 5

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 C203190.1 PS1290.4 95006.133 98210.1002

NO OFF 4 1 1 1 1 1 2 6 2

1293-6.doc Page 75

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 76

3RD & 4TH D.D.V ASSEMBLY U334.J


3 2 1 4 6 5 1 4 1 7 3

3 3

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 PS1290.4 95006.133 98210.1002

NO OFF 4 1 1 1 2 6 2

Page 76

1293-6.doc

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 C200066.1 C200223 95111.11 C203716 C203717 C203718

NO OFF 2 1 2 1 1 1

1293-6.doc Page 77

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 C84096.1 C200223 C203716 95111.7 C200421 NO OFF 1 1 1 2 2

2 3

Page 78

1293-6.doc

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 95111.9 C203738 C203736 C203737 NO OFF 1 1 1 2 1 1

2 VALVE REMOVAL

2 1 5. 3 STAGE TH 6. 4 STAGE
RD

PISTON REMOVAL

LINER REMOVAL

1293-6.doc Page 79

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 80

1ST, 2ND, 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 95000.324 C203734 95000.294 C203735 95650.1026 NO OFF 1 2 1 2 1 1

REMOVAL OF 1 4

ST

/2

ND

STAGE TUBESTACK

6 REMOVAL OF 3 4
RD

STAGE TUBESTACK

6 REMOVAL OF 4
TH

STAGE TUBESTACK

Page 80

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 81

WATER FLOW PATH DIAGRAM


WATER INLET

INLET THROTTLE VALVE

PNEUMATIC WATER VALVE

TH

STAGE COOLER

4 WATER DRAIN

TH

STAGE CYLINDER

RD

STAGE CYLINDER

RD

STAGE COOLER

WATER DRAIN

ST

STAGE CYLINDER

WATER DRAIN

ND

STAGE CYLINDER

ST

&2

ND

STAGE COOLER

WATER OUTLET

1293-6.doc Page 81

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

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 83

MAINTENANCE KITS 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 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Description. 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. D. Valve to surge vessel Nylon Joint D. D. 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 BSP Dowty seal BSP Dowty seal 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. 98504.1406. C201821 C201829 D100353 D100354 C200869 C200900 C201819 C11359-62 C203697 C203699 C203698 D101601 C201488.1 C201488.2 C201820 95602.151 95602.152 95602.153 95602.98 95602.100 95602.140 95602.141 98504.1384 98504.1112 98504.1385 98504.1090 98504.1105 98504.1106 98504.1386 98504.1387 95602.149 95602.155 95602.31 95602.91 95602.94 95602.87 95602.88 PS1322.2 PS1322.4 PS1322.6 98660.1153 98660.1154 98660.1155 98660.1156 98660.1102 Number OFF. 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.doc Page 83

CompAir UK Ltd PUBLICATION 98407/1293 Section 6


Page 84

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 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. 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. 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.J Diaphragm Drain Valves (Valve overhaul) U334.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. 98504.1407. 95602.153 95602.140 95602.141 98504.1384 98504.1112 98504.1090 98504.1105 98504.1106 95602.93 95602.55 95604.24 95604.20 Part Number.

Number OFF. 2 1 1 2 1 1 1 1 1 1 1 1 Number OFF. 1 1 1 1 4 2 1 1 1 1 1 1 1 2 1 2 2 1 1 1 4 1 1

98650.1518 98650.1533 98650.1059 98650.2040 98650.1535 98650.1531 98650.1532 98262.1252 98477.1085 98477.1086 98477.1087 98477.1188 98262.1009 98384.1002 98384.1001 98384.1022 98384.1029 98262.1254 98262.1256 98262.1258 98262.1259 C203868 C201556.100

Page 84

1293-6.doc

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 85

SECTION 7 CONTENTS
BUILD H5437.1.NG

ILLUSTRATIONS & PARTS LIST


CRANKCASE OIL FILLER COMPLETE OIL SEAL ASSEMBLY D/E - C203297 CROSSHEAD - D101745 ST RUNNING GEAR 1 STAGE - D101719 PLUGS & SEALS ST SEPARATOR 1 STAGE E61518 PLUG AND SEAL LINER/VALVE COVER PARTS 1ST STAGE - D101728 STAGE CONCENTRIC VALVE UNITS INLET DAMPER PARTS - C204002 DRAIN SYSTEM 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. 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, are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd. Ipswich. The assemblies have been chosen based on the experience gained by our own Parts and Service Departments. The right is reserved to modify the contents of this list, without notice, and the information given is in no way binding on the manufacturers. PAGE BUILD- 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.doc

04/09/02

Page 85

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 86

Item No. Crankcase Socket-female Nipple Pressure gauge Swivel nut adaptor Union male Safety valve

Description.

Part Number. BUILD NG 1 95405.1002 95405.797 98288.1086 98156.3201 98156.2136 98650.2088-2.1 Part Number. BUILD NG 2 U421-E Part Number. C203297 BUILD NG 4 95602.95 98504.1195 C203295 Part Number. D101719 BUILD NG 5 C200016 C201109 C85727.1 D66376 D66395 95650.30 98477.1049 98477.1059 Part Number. BUILD NG 5 D101745 Part Number. BUILD NG 7 PS1068.3 PS1322.3 D66720.10.112 D66720.10.160 Part number E61518 BUILD NG 8 95000.315 E61518 D101764 Part Number. BUILD NG 9 PS1068.3 PS1322.3

Number OFF. 1 1 1 1 1 1 Number OFF. 1 Number OFF. 1 2 1 Number OFF. 1 1 1 1 1 2 1 2 Number OFF. 1 Number OFF. 2 2 1 3 Number OFF. 4 1 1 Number OFF. 1 1

SPARE PART

1.1 1.2 1.3 1.4 1.5 1.6 Item No.

Description. Oil filler Oil filler complete Description. Oil seal Assembly D/E 'O' ring Oil seal PTFE Oil seal plate Description. Running gear parts 1 stage Bush small end Bearing pairs Gudgeon pin Piston Con. Rod Circlips Oil control ring Piston ring Description. Crosshead Crosshead Description. Fittings Plug Seal Dowty Stud M10 X 123 s.o Stud M10 X 170 s.o Description. Separator 1st stage Setscrew Separator Cooler cover Description.
st

SPARE PART

2.1 Item No.

SPARE PART

4.12 4.13 4.14 Item No.

SPARE PART

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 Item No.

SPARE PART # SPARE PART

5.2.1 Item No.

7.1 7.2 7.3 7.4 Item No.

SPARE PART

8.1 8.2 8.3 Item No.

# SPARE PART

9.1 9.2

Plug Seal Dowty

Page 86

1293-7NG.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 87

Item No.

Description. Liner/valve cover parts 1st stage Valve cover Liner 'O' ring 'O' ring 'O' ring Description. Valve units Valve unit 1st stage Valve unit 2nd stage Valve unit 3rd stage Valve unit 4th stage Description. Inlet damper parts Plug 3/8" BSP Nipple hex 1" BSP Bush hex 3/8" BSP Pressure gauge Pressure gauge washer Copper washer " BSP Vessel pulsation Pressure Switch LOW Swivel nut adaptor Pressure gauge snubber Pressure Switch HIGH Union male Valve ball Valve safety Seal Dowty Description. Drain system parts Washer nylon. Washer nylon. Gasket. Stud M8 X 90 s.o Diaphragm drain valve 3rd & 4th stage Diaphragm drain valve 1st & 2nd stage Setscrew M8 Nut M8 Surge vessel cover Description.

14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 Item No.

Part Number. D101728 BUILD NG 14 D100609 D100802 95602.151 95602.152 95602.153 Part Number. BUILD NG 15 98650.1519 98650.1039 98650.1049 98650.2037 Part Number. C204002 BUILD NG 16 PS1454.3 95405.797 95405.851 98288.1086 98660.1102 98660.1156 A40424 98524.1128 98156.3201 98288.1164 98524.1127 98156.2135 98650.2076 98650.2088-2.1 PS1322.2 Part Number. E61643 BUILD NG 17 C201488.1 C201488.2 C201820 D66720.8.102 U334.J U334.L 95000.256 95111.5 C201804 Part Number. BUILD NG 17 98156.3201 98156.2136 98650.2088-2.8

Number OFF. 1 1 1 2 2 Number OFF. 1 1 1 1 Number OFF. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 Number OFF. 4 2 1 2 1 1 16 2 1 Number OFF. 1 1 1

SPARE PART

SPARE PART

15.1 15.2 15.3 15.4 Item No.

SPARE PART

16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 16.11 16.12 16.13 16.14 16.15 Item No.

SPARE PART

17.1.1 17.1.2 17.1.3 17.1.4 17.1.5 17.1.6 17.1.7 17.1.8 17.1.9 Item No.

SPARE PART

17.2.1 17.2.2 17.2.3

Swivel nut adaptor` Union male Safety valve

1293-7NG.doc

04/09/02

Page 87

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 88

Item No.

Description. Pressure gauge panel parts Pressure gauge - oil Pressure gauge - 1st stage Pressure gauge - 2nd stage Pressure gauge - 3rd stage Pressure gauge - 4th stage Gauge panel label Gauge panel Description. Safety valves Safety valve 4th stage Description. Separator assembly 4 stage Plug Seal-dowty Swirl fitting th Body 4 stage separator Top fitting Cap screw Description. Pipe assembly breather Pipe . Elbow . Nipple hex . Nipple 3/8 BSP . Elbow Flow control valve Sleeve Nut Description. Pipe assembly 4 Stage cooler inlet Seamless st/stl Male connector O ring, Sleeve o-lok Nut o-lok Description. Pipe assembly - 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. BUILD NG 18 98288.1019 98288.1020 98288.1021 98288.1022 98288.1023 E46188 E61534 Part Number. BUILD NG 19 98650.1355-275 Part Number. D101619 BUILD NG 20 C73732.22 PS1322.9 C203669 C203766 D101618 95018.243 Part Number. C203989 BUILD NG 21 M3201.1209 95405.3 95405.798 95414.163 98156.3954 C203466 98156.3881 98156.3896 Part Number. C204005 BUILD NG.21.1 M3089.1207 C204004 95602.10 98156.3881 98156.3896 Part Number. C203999 BUILD NG 21.2 C203999.1 C203999.2 C203999.3 C203999.4 C203999.5

Number OFF. 1 1 1 1 1 1 1 Number OFF. 1 Number OFF. 1 2 1 1 1 2 Number OFF. 300 1 1 1 2 1 2 2 Number OFF. 914 2 2 2 2 Number OFF. 1 1 1 1 1

SPARE PART

18.1 18.2 18.3 18.4 18.5 18.6 18.7 Item No.

SPARE PART

19.1 Item No.

SPARE PART

20.1 20.2 20.3 20.4 20.5 20.5 Item No.

SPARE PART

21.1 21.2 21.3 21.4 21.5 21.6 21.7 21.8 Item No.

SPARE PART

21.1.1 21.1.2 21.1.3 21.1.4 21.1.5 Item No.

SPARE PART

21.2.1 21.2.2 21.2.3 21.2.4 21.2.5

Page 88

1293-7NG.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 89

Item No.

Description. Pipe assembly - 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. 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. Pipe assembly - DDV control Nut Male connector Elbow Sleeve Tee Body cap Swivel connector Seamless st/stl Description. Pipe assembly 4th stage inlet Pipe st/st Elbow Male connector Nut Sleeve

21.3.1 21.3.2 21.3.3 21.3.4 21.3.5 21.3.6 21.3.7 21.3.8 21.3.9 21.3.10 21.3.11 21.3.12 21.3.13 21.3.14 21.3.15 21.3.16 21.3.17 Item No.

21.4.1 21.4.2 21.4.3 21.4.4 21.4.5 21.4.6 21.4.7 21.4.8 21.4.9 21.4.10 21.4.11 21.4.12 Item No.

21.5.1 21.5.2 21.5.3 21.5.4 21.5.5 21.5.6 21.5.7 21.5.8 Item No.

21.6.1 21.6.2 21.6.3 21.6.4 21.6.5

Part Number. C203859 BUILD NG 21.3 M3090.0805 M3090.2017 95405.1005 98156.3895 98156.3894 98156.3902 98156.3963 98156.3919 98156.3898 98156.4127 98156.3949 98156.4120 98156.4121 98156.3951 98156.4022 98156.4056 98156.4045 Part Number. C203998 BUILD NG 21.4 PS1322.2 98156.1398 98156.3903 98156.3949 98156.2811 98261.1071 M3089.0603 98156.3107 PS1322.8 C73732.12 98156.3894 98156.3878 Part Number. C203860 BUILD NG 21.5 98156.3894 98156.3902 98156.3949 98156.4120 98156.4022 98156.4056 98156.4045 M3089.0603 Part Number. C204000 BUILD NG 21.6 M3090.2017 98156.3963 98156.3920 98156.3898 98156.3868

Number OFF. 1016 762 1 2 4 1 1 1 2 2 1 4 2 2 2 1 3 Number OFF. 3 1 3 1 1 1 600 1 1 1 4 4 Number OFF. 4 1 1 4 2 1 3 1016 Number OFF. 762 1 1 2 2

SPARE PART

SPARE PART

SPARE PART

SPARE PART

1293-7NG.doc

04/09/02

Page 89

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 90

Item No.

Description. Pipe assembly - 3rd stage suction pipe Male connector Nut Sleeve Pipe st/st Description. Pipe assembly 2nd stage delivery Male connector Nut Sleeve 45Elbow Pipe st/st Description. Pipe assembly 3 stage Dely Seamless st/stl Coupling Nut Sleeve Description. Pipe assembly water transfer Pipe cu Elbow Stud Coupling Nipple
rd

21.7.1 21.7.2 21.7.3 21.7.4 Item No.

21.8.1 21.8.2 21.8.3 21.8.4 21.8.5 Item No.

21.9.1 21.9.2 21.9.3 21.9.4 Item No.

21.10.1 21.10.2 21.10.3 21.10.4

Part Number. C203856 BUILD NG 21.7 98156.3924 98156.3899 98156.3888 M3089.2521 Part Number. C203855 BUILD NG 21.8 98156.3927 98156.3900 98156.3890 98156.4112 M3089.3024 Part Number. C204001 BUILD NG 21.9 M3090.2017 98156.3919 98156.3998 98156.3886 Part Number. C203951 BUILD NG 21.10 M3201.2522 PS1073.5 95440.48 98156.1358

Number OFF. 2 2 2 30 Number OFF. 1 2 2 1 500 Number OFF. 812 2 2 2 Number OFF. 1524 1 2 1

SPARE PART

SPARE PART

SPARE PART

SPARE PART

SECTION 7 BUILD NG 2.1 Oil filler

SECTION 6 LIST 3.16 Oil Pump & Filter SECTION 9 62759 NG 015 9.3.4 Water pump SECTION 6 LIST 1.22 Oil level gauge

Page 90

1293-7NG.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 91

BUILD NG - H5437.1.NG

SECTION 7 BUILD NG 19.1 Safety valve 4th stage

SECTION 7 LIST 19.6 Safety valve 1st stage

SECTION 7 BUILD NG 21.6 Pipe Assy SECTION 7 LIST 19.4 Safety valve 3rd stage SECTION 7 BUILD NG 20 th 4 stage separator SECTION 7 BUILD NG 2.1 Oil filler

SECTION 7 BUILD NG 8 1st stage separator

SECTION 7 LIST 19.5 Safety valve SECTION 7 BUILD NG 21.8 Pipe Assy SECTION 7 BUILD NG 16.4 Pressure Gauge SECTION 7 BUILD NG 1.3 Pressure Gauge SECTION 7 BUILD NG 1.6 Safety Valve SECTION 7 BUILD NG 21.4 Pipe Assy

Water outlet

SECTION 7 BUILD NG 16.14 Safety Valve SECTION 7 BUILD NG 16 Inlet damper

SECTION 7 BUILD NG 21.5 Pipe Assy

SECTION 7 BUILD NG 21.3 Pipe Assy

1293-7NG.doc

04/09/02

Page 91

CompAir UK Ltd PUBLICATION 98407.1293 NG Section 7


Page 92

BUILD NG - H5437.1.NG
SECTION 7 BUILD NG 18 Gauge panel

Water outlet

SECTION 7 BUILD NG 21.6 Pipe assy

SECTION 9 BUILD NG 9.12 Inlet solenoid valve

SECTION LIST 1.31 Oil Pressure switch

SECTION 7 BUILD NG 16 Inlet Damper

Page 92

1293-7NG.doc

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 93

BUILD NG - H5437.1.NG

SECTION 7 BUILD NG 21.7 Pipe Assy

SECTION 7 BUILD NG 21.9 Pipe Assy

SECTION 7 BUILD NG 21.1 Pipe Assy

BUILD NG SURGE VESSEL & DIAPHRAGM DRAIN VALVES

SECTION 7 BUILD NG 16.8 PRESSURE SWITCH LOW SECTION 7 BUILD NG 16.4 PRESSURE GAUGE NG 1.3 PRESSURE GAUGE SECTION 7 BUILD NG 16.14 SAFETY VALVE NG 1.6 SAFETY VALVE

SECTION 7 BUILD NG 16.11 PRESSURE SWITCH HIGH

SECTION 7 BUILD NG 9.13 SOLENOID VALVE

SECTION 7 BUILD NG 17.1.5 4TH & 3RD STAGE DIAPHRAGM DRAIN VALVE

SECTION 7 BUILD NG 17.1.6 2ND & 1ST STAGE DIAPHRAGM DRAIN VALVE

1293-7NG.doc

04/09/02

Page 93

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 94

5.1.8 5.1.4 5.1.7

5.1.3

5.1.6

5.1.5 5.1.1

5.1.2

Page 94

1293-7NG.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 95

BUILD NG 5 - 4TH STAGE RUNNING GEAR DIFFERENCES

5.2.1

1293-7NG.doc

04/09/02

Page 95

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 7


Page 96

Page 96

1293-7NG.doc

04/09/02

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 8


Page 97

SECTION 8 CONTENTS
BUILD - R-5437.1.NG

RECOMENDED SERVICE PLANS

8.1 GAS COMPRESSOR - R-5437.1.NG - SYNTHETIC OIL 8.2 GAS COMPRESSOR - R-5437.1.NG - MINERAL OIL 8.3 GAS COMPRESSOR - R-5437.1.NG - MINERAL OIL

R-5437.1.NG S R-5437.1.NG M427 R-5437.1.NG MP100

1293-8NG.doc

04/09/02

Page 97

CompAir UK Ltd PUBLICATION 98407/1293 NG Section 8


Page 98

Page 98

1293-8NG.doc

04/09/02

RECOMMENDED SERVICE PLAN - 5437.1.NG-S

CompAir UK Ltd
Page 1

SYNTHETIC OIL IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary
INITIAL SERVICE 100 HOURS. Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul. Change oil (total capacity 45 litres) - REAVELLITE S 20 litres. + 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. Routine check of drive & all ancillaries. Part Ref No Off 2 1 1
RSP5437.1ng/s.1

98384.1002 98384.1001 98262.1009

SERVICE Part Ref 500 HOURS OR No Off RSP5437.1ng/s.2 ELAPSED TIME. Check belt tension/drive couplings & check condition of all ancillaries. 6 MONTHS Check for oil & gas leaks. Check tightness of all fasteners. Clean inline filter strainer. AT 1500 Clean inline filter strainer. Change oil filter. Clean 3rd stage valve, Part Ref HOURS OR service 4th stage valve. Routine check of drive & all ancillaries. No Off RSP5437.1ng/s.3 ELAPSED TIME Change oil filter 1 98262.1009 12 MONTHS. O Ring 3rd stage valve cover. 2 98504.1384 Back-up ring 3rd stage valve cover. 2 98504.1112 O Ring 3rd stage valve 1 95604.24 Service kit 4th stage valve 1 98650.2040 O Ring 4th stage valve cover upper 1 98504.1106 O Ring 4th stage valve cover lower 1 98504.1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 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 3rd & 4th stage cylinder bores & clean gas passages. Clean inline filter strainer. AT 3000 Change oil & oil filter element. Clean inline filter strainer. Check HOURS OR drive couplings/belt drive. Check 3rd stage valve. Replace 4th Part Ref ELAPSED TIME stage valve. Change 4th stage piston rings. No Off RSP5437.1ng/s.4 24 MONTHS. Change oil (total capacity 45 litres) - REAVELLITE S 20 Litres. 2 98384.1002 +REAVELLITE S 5 Iitres 1 98384.1001 Change oil filter 1 98262.1009 Service kit 3rd stage valve 1 98650.1059 O Ring 3rd stage valve cover. 2 98504.1384 Back-up ring 3rd stage valve cover. 2 98504.1112 4th stage piston rings 6 98477.1143 4th stage valve 1 98650.2037 O Ring 4th stage valve cover upper 1 98504.1106 O Ring 4th stage valve cover lower 1 98504.1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 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. Check condition of corrosion rods.

13/12/02

54371ngs.doc Page 1

RECOMMENDED SERVICE PLAN - 5437.1.NG-S

CompAir UK Ltd
Page 2

AT 4500 HOURS OR ELAPSED TIME 36 MONTHS

Check 2nd stage valve. Service 2nd & 3rd stage valves. Clean inline filter strainer. Change oil filter element. Check sacrificial anode. Service diaphragm drain valves. Replace 3rd stage piston & liner. Check 2nd, 3rd & 4th stage cooler assemblies. 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. 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, 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. Cleanse crankcase. Clean 3rd stage valve HOURS Replace 4th stage valve. Replace 4th stage piston & rings. Clean OR ELAPSED inline filter strainer. No Off TIME Change oil (total capacity 45 litres) - REAVELLITE S 20 litres. 2 48 MONTHS + REAVELLITE S 5 Litres 1 Change oil filter 1 O Ring 3rd stage valve cover. 2 Back-up ring 3rd stage valve cover. 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. Check condition of 3rd & 4th stage cylinder bores & clean gas passages. AT 7500 Change oil filter. Clean 3rd stage valve. Service 4th stage valve. HOURS Routine check drive & ancillaries No Off OR ELAPSED Change oil filter 1 TIME O Ring 3rd stage valve cover. 2 60 MONTHS Back-up ring 3rd stage valve cover. 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. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.

Part Ref
RSP5437.1ng/s.5

98262.1009 98504.1407 98650.1533 98650.1059 98650.1535 PS1159.108 C203686

Part Ref
RSP5437.1ng/s.6

98384.1002 98384.1001 98262.1009 98504.1384 98504.1112 95604.24 98650.2037 98504.1106 98504.1105 98504.1387 98504.1090 C203685

Part Ref
RSP5437.1ng/s.7

98262.1009 98504.1384 98504.1112 95604.24 98650.2040 98504.1106 98504.1105 98504.1387 98504.1090 95604.15

13/12/02

54371ngs.doc Page 2

RECOMMENDED SERVICE PLAN - 5437.1.NG-S

CompAir UK Ltd
Page 3

AT 9000 HOURS MAJOR OVERHAUL

Replace 3rd & 4th stage valves. Replace all piston rings, gudgeon pins, bearings etc. Check condition of 1st, 2nd & 3rd stage cylinder bores. Replace 4th stage piston & liner. Clean all water jackets, hydraulic test all coolers. re-calibrate all pressure gauges replace if faulty. Replace all safety valves. Replace drive belts/coupling rubbers. Function test all ancillaries. Check inline filter strainer, clean or replace as necessary. Change oil (sump capacity 45 litres) REAVELLITE S 20 litres. +REAVELLITE S 5 Litres Change oil filter. 3rd stage valve 4th stage valve 1st stage valve 2nd stage valve Service kit diaphragm drain valves Service kit diaphragm drain valves U334.K Service kit diaphragm drain valves U334.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. 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, 3rd & 4th stage gudgeon pin 2nd, 3rd & 4th stage gudgeon pin circlips 2nd, 3rd & 4th stage gudgeon pin tension pin 1st stage gudgeon pin circlips 1st stage S/E bush 2nd, 3rd & 4th stage S/E bearings 2nd, 3rd & 4th stage S/E bearings spacer Check crankshaft journals & oil seal diameter for wear 1st, 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, 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. Renew vee belts or drive couplings.

Part Ref No Off 2 1 1 1 1 1 1 4 1 2 2 1


RSP5437.1ng/s.8

98384.1002 98384.1001 98262.1009 98650.1049 98650.2037 98650.1519 98650.1039 98650.1535 98650.1532 98650.1531 C201556.100 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

98477.1085 98477.1086 98477.1087 98477.1143 C203685 C203687 C85727.1 C203984 95650.1022 95527.96 95650.30 C200016 98076.1129 C203986 C201109 98504.1195 95602.95 C85736.2 98074.1004 98650.1020-10 98650.1021-40 98650.1022-150 98650.1011 98504.1406

13/12/02

54371ngs.doc Page 3

RECOMMENDED SERVICE PLAN - 5437.1.NG-S

CompAir UK Ltd
Page 4

13/12/02

54371ngs.doc Page 4

RECOMMENDED SERVICE PLAN - 5437.1.NG-M427

CompAir UK Ltd
Page 1

MINERAL OIL MOBIL RARUS 427 IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary
INITIAL SERVICE 100 HOURS. Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul. 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. Routine check of drive & all ancillaries. No Off Check belt tension/drive couplings & check condition of all ancillaries. Check for oil & gas leaks. Check tightness of all fasteners. Clean inline filter strainer. Clean inline filter strainer. Change oil filter. Clean 3rd stage valve, service 4th stage valve. Routine check of drive & all ancillaries. No Off Change oil filter 1 O Ring 3rd stage valve cover. 2 Back-up ring 3rd stage valve cover. 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. Clean inline filter strainer. Change oil & oil filter element. Clean inline filter strainer. Check drive couplings/belt drive. Check 3rd stage valve. Replace 4th stage valve. Change 4th stage piston rings. 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. 2 Back-up ring 3rd stage valve cover. 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. Check condition of corrosion rods. Part Ref
RSP5437.1ng/m427.1

98384.1022 98262.1009

SERVICE 500 HOURS OR ELAPSED TIME. 6 MONTHS

Part Ref
RSP5437.1ng/m427.2

AT 1500 HOURS OR ELAPSED TIME 12 MONTHS.

Part Ref
RSP5437.1ng/m427.3

98262.1009 98504.1384 98504.1112 95604.24 98650.2040 98504.1106 98504.1105 98504.1387 98504.1090 95604.15

AT 3000 HOURS OR ELAPSED TIME 24 MONTHS.

Part Ref
RSP5437.1ng/m427.4

98384.1022 98262.1009 98650.1059 98504.1384 98504.1112 98477.1143 98650.2037 98504.1106 98504.1105 98504.1387 98504.1090 95604.15

54371ngm427.doc

Page 1

RECOMMENDED SERVICE PLAN - 5437.1.NG-M427

CompAir UK Ltd
Page 2

AT 4500 HOURS OR ELAPSED TIME 36 MONTHS

Check 2nd stage valve. Service 2nd & 3rd stage valves. Clean inline filter strainer. Change oil filter element. Check sacrificial anode. Service diaphragm drain valves. Replace 3rd stage piston Part Ref & liner. Check 2nd, 3rd & 4th stage cooler assemblies. No Off RSP5437.1ng/m427.5 Change oil filter 1 98262.1009 Valve maintenance 'O' ring kit 1 98504.1407 Service kit 2nd stage valve 1 98650.1533 Service kit 3rd stage valve 1 98650.1059 Service kit diaphragm drain valves 4 98650.1535 3rd stage piston rings. 4 PS1159.108 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, 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. Cleanse crankcase. Clean 3rd stage valve HOURS Replace 4th stage valve. Replace 4th stage piston & rings. Clean Part Ref OR ELAPSED inline filter strainer. No Off RSP5437.1ng/m427.6 TIME Change oil (total capacity 45 litres) Mineral Mobil Rarus 427 2 98384.1022 48 MONTHS Change oil filter 1 98262.1009 O Ring 3rd stage valve cover. 2 98504.1384 Back-up ring 3rd stage valve cover. 2 98504.1112 O Ring 3rd stage valve 1 95604.24 4th stage valve 1 98650.2037 O Ring 4th stage valve cover upper 1 98504.1106 O Ring 4th stage valve cover lower 1 98504.1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.1090 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. Check condition of 3rd & 4th stage cylinder bores & clean gas passages. AT 7500 Change oil filter. Clean 3rd stage valve. Service 4th stage valve. Part Ref HOURS Routine check drive & ancillaries No Off RSP5437.1ng/m427.7 OR ELAPSED Change oil filter 1 98262.1009 TIME O Ring 3rd stage valve cover. 2 98504.1384 60 MONTHS Back-up ring 3rd stage valve cover. 2 98504.1112 O Ring 3rd stage valve 1 95604.24 Service kit 4th stage valve 1 98650.2040 O Ring 4th stage valve cover upper 1 98504.1106 O Ring 4th stage valve cover lower 1 98504.1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.1090 O Ring 4th stage valve 1 95604.15 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.

54371ngm427.doc

Page 2

RECOMMENDED SERVICE PLAN - 5437.1.NG-M427

CompAir UK Ltd
Page 3

AT 9000 HOURS Replace 3rd & 4th stage valves. Replace all piston rings, MAJOR gudgeon pins, bearings etc. Check condition of 1st, 2nd & 3rd OVERHAUL stage cylinder bores. Replace 4th stage piston & liner. Clean all water jackets, hydraulic test all coolers. re-calibrate all pressure gauges replace if faulty. Replace all safety valves. Replace drive belts/coupling rubbers. Function test all ancillaries. Check inline filter strainer, clean or replace as necessary. No Off Change oil (total capacity 45 litres) Mineral Mobil Rarus 427 2 Change oil filter. 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.K 1 Service kit diaphragm drain valves U334.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. 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, 3rd & 4th stage gudgeon pin 3 2nd, 3rd & 4th stage gudgeon pin circlips 3 2nd, 3rd & 4th stage gudgeon pin tension pin 3 1st stage gudgeon pin circlips 2 1st stage S/E bush 1 2nd, 3rd & 4th stage S/E bearings 6 2nd, 3rd & 4th stage S/E bearings spacer 3 Check crankshaft journals & oil seal diameter for wear 1st, 2nd, 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, 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. Renew vee belts or drive couplings.

Part Ref
RSP5437.1ng/m427.8

98384.1022 98262.1009 98650.1049 98650.2037 98650.1519 98650.1039 98650.1535 98650.1532 98650.1531 C201556.100 C203868

98477.1085 98477.1086 98477.1087 98477.1143 C203685 C203687 C85727.1 C203984 95650.1022 95527.96 95650.30 C200016 98076.1129 C203986 C201109 98504.1195 95602.95 C85736.2 98074.1004 98650.1020-10 98650.1021-40 98650.1022-150 98650.1011 98504.1406

54371ngm427.doc

Page 3

RECOMMENDED SERVICE PLAN - 5437.1.NG-MP100

CompAir UK Ltd
Page 1

MINERAL OIL SHELL CORENA P100 IMPORTANT - DAILY & BEFORE STARTING Check oil level top up if necessary
INITIAL SERVICE 100 HOURS. Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (9000) hours or any intermediate overhaul. 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. Routine check of drive & all ancillaries. No Off Check belt tension/drive couplings & check condition of all ancillaries. Check for oil & gas leaks. Check tightness of all fasteners. Clean inline filter strainer. Clean inline filter strainer. Change oil filter. Clean 3rd stage valve, service 4th stage valve. Routine check of drive & all ancillaries. No Off Change oil filter 1 O Ring 3rd stage valve cover. 2 Back-up ring 3rd stage valve cover. 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. Clean inline filter strainer. Change oil & oil filter element. Clean inline filter strainer. Check drive couplings/belt drive. Check 3rd stage valve. Replace 4th stage valve. Change 4th stage piston rings. 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 Back-up ring 3rd stage valve cover. 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. Check condition of corrosion rods. Part Ref
RSP5437.1ng/mp100.1

98384.1029 98262.1009

SERVICE 500 HOURS OR ELAPSED TIME. 6 MONTHS

Part Ref
RSP5437.1ng/mp100.2

AT 1500 HOURS OR ELAPSED TIME 12 MONTHS.

Part Ref
RSP5437.1ng/mp100.3

98262.1009 98504.1384 98504.1112 95604.24 98650.2040 98504.1106 98504.1105 98504.1387 98504.1090 95604.15

AT 3000 HOURS OR ELAPSED TIME 24 MONTHS.

Part Ref
RSP5437.1ng/mp100.4

98384.1029 98262.1009 98650.1059 98504.1384 98504.1112 98477.1143 98650.2037 98504.1106 98504.1105 98504.1387 98504.1090 95604.15

54371ngmmp100.doc

Page 1

RECOMMENDED SERVICE PLAN - 5437.1.NG-MP100

CompAir UK Ltd
Page 2

AT 4500 HOURS OR ELAPSED TIME 36 MONTHS

Check 2nd stage valve. Service 2nd & 3rd stage valves. Clean inline filter strainer. Change oil filter element. Check sacrificial anode. Service diaphragm drain valves. Replace 3rd stage piston Part Ref & liner. Check 2nd, 3rd & 4th stage cooler assemblies. No Off RSP5437.1ng/mp100.5 Change oil filter 1 98262.1009 Valve maintenance 'O' ring kit 1 98504.1407 Service kit 2nd stage valve 1 98650.1533 Service kit 3rd stage valve 1 98650.1059 Service kit diaphragm drain valves 4 98650.1535 3rd stage piston rings. 4 PS1159.108 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, 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. Cleanse crankcase. Clean 3rd stage valve HOURS Replace 4th stage valve. Replace 4th stage piston & rings. Clean Part Ref OR ELAPSED inline filter strainer. No Off RSP5437.1ng/mp100.6 TIME Change oil (total capacity 45 litres) Mineral Shell Corena P100 2 98384.1029 48 MONTHS Change oil filter 1 98262.1009 O Ring 3rd stage valve cover. 2 98504.1384 Back-up ring 3rd stage valve cover. 2 98504.1112 O Ring 3rd stage valve 1 95604.24 4th stage valve 1 98650.2037 O Ring 4th stage valve cover upper 1 98504.1106 O Ring 4th stage valve cover lower 1 98504.1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.1090 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. Check condition of 3rd & 4th stage cylinder bores & clean gas passages. AT 7500 Change oil filter. Clean 3rd stage valve. Service 4th stage valve. Part Ref HOURS Routine check drive & ancillaries No Off RSP5437.1ng/mp100.7 OR ELAPSED Change oil filter 1 98262.1009 TIME O Ring 3rd stage valve cover. 2 98504.1384 60 MONTHS Back-up ring 3rd stage valve cover. 2 98504.1112 O Ring 3rd stage valve 1 95604.24 Service kit 4th stage valve 1 98650.2040 O Ring 4th stage valve cover upper 1 98504.1106 O Ring 4th stage valve cover lower 1 98504.1105 Back-up ring 4th stage valve cover lower 1 98504.1387 Back-up ring 4th stage valve cover upper 1 98504.1090 O Ring 4th stage valve 1 95604.15 Check for oil & gas leaks Check tightness of all fasteners Check belt tension/drive couplings & check condition of all ancillaries. Check condition of 3rd & 4th stage cylinder bores & clean gas passages.

54371ngmmp100.doc

Page 2

CompAir UK Ltd PUBLICATION 98407.1293 NG Section 9


Page 99

SECTION 9 CONTENTS TYPICAL BUILD GP37.PAKISTAN PARTS


9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 BUILD NG PAGE NATURAL GAS COMPRESSOR - 437M10000000000000 ------------------ 005 -------------- SECTION 7 VEE DRIVE & ADJUSTMENT PARTS- 5437.1.NG-------------------------- 010/012 ---------------- 100 WATER PUMP - 436200000003000- 5437.1.NG-------------------------------- 015 ------------------- 100 ANTI VIBRATION MOUNTS - 436200000000002 5437.1.NG------------- 020 ------------------- 100 INLET TRAIN 5437.1.NG ----------------------------------------------------------- 040 ------------------- 100 SAFETY VALVE MANIFOLD 5437.1.NG --------------------------------------- 050 ------------------- 101 CONTROL BOX SUPPORT 5437.1.NG----------------------------------------- 060 ------------------- 101 PRESSURE CONTROL 5437.1.NG ---------------------------------------------- 065 ------------------- 101 CRANKCASE OIL DRAIN 5437.1.NG ------------------------------------------- 095 ------------------- 102

9.10 CONTROL PANEL 5437.1.NG ---------------------------------------------------- 100 ------------------- 102 9.11 ELECTRIC MOTOR 5437.1.NG --------------------------------------------------- 101 ------------------- 102 9.12 SOLENOID VALVE 5437.1.NG INLET ------------------------------------------ 102 ------------------- 102 9.13 SOLENOID VALVE 5437.1.NG DDV CONTROL ----------------------------- 103 ------------------- 102

TYPICAL DRAWINGS

GENERAL ARRANGEMENT ------------------------------------- E46316 P. & I. DIAGRAM----------------------------------------------------- D70938 SINGLE LINE DIAGRAM ------------------------------------------ C89091 WIRING DIAGRAM -------------------------------------------------- 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. 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, are not standard replacement parts and can only be obtained at the discretion of CompAir UK Ltd. Ipswich. The assemblies have been chosen based on the experience gained by our own Parts and Service Departments. The right is reserved to modify the contents of this list, without notice, and the information given is in no way binding on the manufacturers.

1293-9.NG.doc

Page 99

CompAir UK Ltd PUBLICATION 98407.1293 NG Section 9


Page 100

Item No. 9.1.1 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.2.9 9.2.10 9.2.11 9.2.12 9.2.13 9.2.14 9.2.15 9.2.16 9.2.17 9.2.18 9.11.1 9.3 9.4 9.4.0 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.5.5 9.5.6 9.5.7 9.5.8 9.5.9 9.5.10 9.5.11 9.5.12 9.5.13 9.5.14 9.5.15 9.5.16 9.5.17 9.5.18 9.5.19 9.5.20 9.5.21

Description. 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 - 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 " BSP Nipple " BSP Nipple 1." BSP Plug Joint Ring 80NB Elbow 1." 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. GP37.PAKISTAN BUILD NG 005 5437.1.NG BUILD NG 010 C89081 C89082 C86470.1 E61674 E61673 D66720.16.60 E60017 PS1130.21 95000.281 95006.176 95000.315 95000.344 95001.372 95111.9 95148.20 BUILD NG 012 98080.1360 98080.1491 98074.1347 A/98412.1348 BUILD NG 015 BUILD NG 020 98418.1015 95006.202 95006.204 95111.7 95148.16 D70896 D70897 BUILD NG 040 95000.314 95006.231 95006.235 95111.7 95111.9 95148.18 95405.54 95405.799 95405.803 95405.945 98504.1258 95405.58 95351.208 98650.1271 95405.11 C73514.1130.105 C73514.1130.335 C73514.1130.380 C73514.1130.180 95405.755 95405.893

Number OFF. 1

APP NO.

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.NG.doc

CompAir UK Ltd PUBLICATION 98407.1293 NG Section 9


Page 101

Item No. 9.5.22 9.5.23 9.5.24 9.5.25 9.5.26 9.5.27 9.5.28 9.5.29 9.5.30 9.5.31 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.6.7 9.6.8 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14 9.6.15 9.6.16 9.6.17 9.6.18 9.6.19 9.6.20 9.6.21 9.6.22 9.7 9.7.1 9.7.2 9.7.3 9.8 9.8.1 9.8.2 9.8.3 9.8.4 9.8.5 9.8.7 9.8.8 9.8.9 9.8.10 9.8.11 9.8.12 9.8.13 9.8.14 9.8.15 9.8.16 9.8.17

Description. Isolating valve Reducing Bush Purge valve Reducing Nipple Non-return valve Pipe Clip 'U' Bolt 3" Bracket Flexible Hose 1.1/2" BSP Flexible Hose 80NB Pipe 3" NB X 260lg Safety Valve Manifold Pipe 25 Pipe 16 Pipe 30 Tee 1.1/2" BSP Nipple Hex 1.1/2" BSP Bush Hex 1.1/2" BSP Bush Hex 1.1/2" BSP Bush Hex 1.1/2" BSP Elbow 1.1/2" BSPT Pipe Clamp 1.1/2" Connector Reducing Bush Coupling Elbow 1.1/4" BSP X 30 Connector Union Flexible Hose 1.1/2" BSP Equal Cross Tee 1.1/2" BSP Pipe 1.1/2" NB X 90lg Capscrew M12 X 90lg Swivel Elbow Union 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 4 Tube Nut 4 Reducing Bush Tube Sleeve 4 Pressure gauge 0 - 600 bar Tee Piece Pressure switch Tube Bundy Washer 3/8" BSP

Part Number. GP37.PAKISTAN 98650.2082 95405.889 98261.2078 95405.837 98650.2091 98150.1099 C89058 98315.1212 98315.1211 C73514.1130.260 BUILD NG 050 M3124.2521 M3130.1613 M3130.3025 95405.356 95405.803 95405.872 95405.873 95405.875 95405.58 98150.1050 98156.2140 95405.870 98156.1779 98156.2599 98156.1789 98156.2133 98315.1212 95405.752 C73514.0820.90 95018.282 98156.1613 98156.2143 BUILD NG 060 95000.314 95111.7 D70898 BUILD NG 065 C88316.1 M3089.1205 U572.B 95000.229 95006.134 95111.4 95148.13 98156.1294 98156.1315 98156.1364 98156.1386 98288.1023 98156.2343 98524.1004 98617.1015 98660.1154

Number OFF. 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.NG.doc

Page 101

CompAir UK Ltd PUBLICATION 98407.1293 NG Section 9


Page 102

Item No. 9.8.18 9.8.19 9.8.20 9.8.21 9.9 9.9.1 9.9.2 9.9.3 9.9.4 9.9.5 9.9.6 9.10 9.10.1 9.12 9.12.1 9.13 9.13.1

Description. Washer 1/2" BSP Adaptor Coupling Flexible Hose 12 mm Ends Crankcase Oil Drain Pipe " BSP X 200lg Plug " BSP Socket " BSP Elbow " 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. GP37.PAKISTAN 98660.1155 98156.2126 98156.4174 98315.1214 BUILD NG 095 C73514.0515.200 PS1068.5 95405.1005 95405.55 98660.1156 98650.1971 BUILD NG 100 98523.1017 BUILD NG 102 A/98516.1161 BUILD NG 103 A/98516.1162

Number OFF. 2 2 1 1 1 1 1 1 1 1 1 1 1

APP NO

154

153 152

Page 102

1293-9.NG.doc

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, see above, if the pulley faces are not parallel use appropriate size distance pieces to ensure belt grooves are correctly aligned. Check belt tension by method described on following page.

RECOMMENDED TENSIONING FORCES

BELT TENSION INDICATOR APPLIED TO MID-SPAN CENTRE DISTANCE SEE CHART

STRAIGHT EDGE

app012g2.doc

CompAir UK Ltd APP012g2 - BELT ALIGNMENT & TENSIONING


Page 2

ADJUSTMENT METHOD
If the belt tension is incorrect, correct it by using the adjusting screw provided, using a suitable straight edge (long enough to span both pulleys),.established the correct deflection and pulley alignment.

Belt Section Belt Section SPB SPB SPC SPC

TABLE Force required to deflect belt 16 mm per metre of span Small Pulley 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) 3.5 to 5.1 5.1 to 6.6 6.1 to 9.2 9.2 to 12.2

Method of Belt Tensioning. Using a Belt Tension Indicator. 1. 2. Measure small pulley diameter (motor/engine) Calculate the deflection distance in mm on a basis of 16 mm per metre of span. Centre distance (metres) X 16 = Deflection (mm). If distance & deflection is known, go to 3. 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. 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, on single belt drives place a straight edge across the two pulleys to act as a datum. Read off the force value indicated by the top edge of the upper marker ring. Compare this force to kgf value shown in the table above. Tighten or loosen belt tensioner to achieve the correct value. If the measured force falls within the values given, the drive should be satisfactory.

3. 4. 5.

6. 7. 8. 9.

Note:- If a belt tension indicator is not available, a suitably scaled spring balance and rule will suffice. BELT TENSION INDICATOR

10

20

30 MM

40

50

60

14

12

10

DEFLECTION IN MM

DEFLECTION FORCE IN KGF

app012g2.doc

CompAir UK Ltd APP012g2 - 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 - BELT ALIGNMENT & TENSIONING


Page 4

app012g2.doc

CompAir UK Ltd APP073ng RADIATOR, WATER PUMP & DRIVE 5437.1.NG


Page 1

RADIATOR, WATER PUMP & DRIVE 5437.1.NG LIST - 437100000005000


15 22 1 21 5 3 14 18 10 11 19 2 16 4 9 20

12

13

SEE LUBRICATION SECTION IN HANDBOOK FOR DETAILS OF OIL PUMP ETC. 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 C85739.1 D100526 D100527 PS1180.9 PS1923.3 PS2062 95000.227 95000.253 95000.256 95111.5 98315.1102 98446.1009 95071.27 98156.3113 95405.869 C201724 98154.1016 98154.1034 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.doc

17/10/03

Page 1

CompAir UK Ltd APP073ng RADIATOR, WATER PUMP & DRIVE 5437.1.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 C201699.3 C201722 C201737 C201780 C73514.620.125 M1103.3154 PS1073.5 PS1180.3 PS1742.2 PS1814.4 95000.281 95000.314 95000.315 95000.318 95006.150 95006.199 95006.203 95111.6 95111.7 95148.16 95179.7 95179.8 95301.23 95635.10 98150.1038 98156.1358 98156.1606 98241.1042 98660.1155 98660.1156 98315.5010 98150.1053 98156.3113 D70948 98156.4227 M3089.1205 98156.3881 D70897

Bracket Radiator Support Strap Radiator Support Fan washer Adaptor Distance Piece Radiator Packer Pipe Bracket Elbow Clip hose Washer Taper Plug " 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 1.1/2" Hose Mounting Nipple 1" BSP Elbow 12 mm Cable Tye Washer " BSP Washer " BSP Hose 10 I/D Pipe Clamp Pipe Adaptor Baseframe Unoin Elbow Pipe St/St 12 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.doc

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

CompAir UK Ltd APP073ng RADIATOR, WATER PUMP & DRIVE 5437.1.NG


Page 6

WATER PUMP
GENERAL The water pump is of Bronze body with Stainless Steel Shaft and Neoprene Compound Impeller construction. The inlet and outlet ports being 1/2" BSP. Maximum pressure 1.37 bar (20psi) Temperature range 7C to 82C 1. OPERATING INSTRUCTIONS 1. 2. a. b. 3. 4. 2. The pump is self-priming, must never be run DRY for more than 30 seconds, as this will burn the impeller. Always ensure the belt tension is correct as. Over tightening belt will cause a reduction in pump bearing life. Slack belt may give inefficient pump performance. Pump should be lubricated with water pump grease (Manful 2DH or equivalent). Keep pump exterior and pipework clean so any leaks can be easily detected.

MAINTENANCE Dismantle 1. 2. 3. 4. 5. 6. 7. 8. 9. To dismantle, remove belt guard, bets and pulley. Undo screws and remove end cover, discard gasket. Loosen packing nut. Remove shaft and impeller assembly from body. Remove impeller by sliding off toward the flatted end of shaft. Remove cam screw and cam, clean off all old jointing compound. Remove packing unit and gland. Remove old packing and discard. Inspect all parts for, wear or damage, renew as necessary. Reassembly 1. 2. 3. 4. 5. 6. Dip new packing in light machine oil, assembly packing, packing gland and nut. Coat cam screw threads and top of cam with non-setting jointing compound and fit into pump. Replace key in shaft, slide the new impeller on the shaft from the flatted end. 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. Fill system with water. During this operation hand tighten packing nut gradually until pumps stops dripping water. Set locking nut. Service Kit Service kits are available for all water pumps, Contact Compair UK Ltd Spares Department for more details.

Page 6

17/10/03

App073ng.doc

CompAir UK Ltd APP 003 ANTI VIBRATION MOUNTS


Page 1

AVA TYPE
PART NUMBERS VARIOUS PREVENTIVE MAINTENANCE 1) After installation and initial running in. Record height dimension (H) of each mount. 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.e. regular usage every 3 months. Note: This dimension may only change a small amount during the life of the mount approximately 1mm. 4) Any oil or paint contact with the rubber mount will affect the life and performance, so keep to a minimum by regularly cleaning and clearing any contamination from the surrounding area. 5) Under normal working conditions the life expectancy will be 5 to 8 years. 6) Temperatures in excess of 70 C will have an adverse effect on the rubber and will shorten the life expectancy.

app003.doc

CompAir UK Ltd APP 003 ANTI VIBRATION MOUNTS


Page 2

app003.doc

CompAir UK Ltd. PUBLICATION APP170 'Y' TYPE STRAINER


Page 1

Servicing & Maintenance Instructions


ROUTINE MAINTENANCE
Check for leaks at the body/cap joint. If leaks are present, tighten the nuts on the studs take care not to overtighten. If the leakage persists, renew the cap gasket having first isolated the strainer from the pipeline. Caps are provided with lever entry grooves to assist with cap removal.

CAP

NUTS & STUDS

GASKET

SCREEN

SERVICING
Ensure the strainer is isolated from the pipeline before commencing work. Remove the strainer cap and screen, clean out any sediment and other debris. Check for damage to the screen and renew if necessary. Reassemble the screen and cap using a new gasket. Follow the instructions below to ensure correct location of screen into strainer body. 1. 2. 3. Fit gasket into groove in the cap. Place the screen inside the body making sure it is seated correctly. Keep the screen in this position using a steel rule or similar temporarily hold across the opening in the body. Place the cap in position on the body studs and push home, making sure the screen engages the seating in the cap. Tighten down each nut in sequence to ensure equal compression of gasket, before fully tightening. Take care not to overtighten the nuts.

RECOMMENDED SPARES
Body / cap gaskets.

APP170 .DOC

CompAir UK Ltd. PUBLICATION APP170 'Y' TYPE STRAINER


Page 2

APP170 .DOC

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. Spring washers & plain washer Terminal link Drain plug

app034c.doc 23/10/02

Page 1

CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 - W-EF SERIES


Page 2

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 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 98412.1112 - 90 KW SQUIRREL CAGE IP55 TEFV W-DF280 SN FOOT CLASS 'F' 80C 40C 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 98412.1113 - 45 KW SQUIRREL CAGE IP55 TEFV W-DF225M FOOT & FLANGE CLASS 'F' 80C 40C 400/3PH 50 4 1500 RPM 1470 RPM STAR/DELTA 172.2 AMPS 210% FLC DIRECT ON LINE 549.4AMPS 670% FLC 98412.1116 - 37 KW SQUIRREL CAGE IP55 TEFV W-DF200L FOOT CLASS 'F' 80C 40C 400/3PH 50 2 3000 RPM 2940 RPM STAR/DELTA 136.4 AMPS 220% FLC DIRECT ON LINE 434AMPS 700% FLC

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.14 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

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.14 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

Page 2

app034c.doc

23/10/02

CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 - W-EF SERIES


Page 3

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 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

98412.1116 - 45 KW SQUIRREL CAGE IP55 TEFV W-DF225ML FOOT CLASS 'F' 80C 40C 400/3PH 50 2 3000 RPM 2940 RPM STAR/DELTA 220% FLC

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15

Y807363.003 + EXTENSION SHAFT 72416-00 TYPE SQUIRREL CAGE PROTECTION IP55 TEFV FRAME SIZE W-DF225MNF-H MOUNTING FOOT & FLANGE INSULATION CLASS 'F' TEMPERATURE RISE 70C AMBIENT TEMPERATURE 40C 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 98412.1116 - 55 KW SQUIRREL CAGE IP55 TEFV W-DF250S FOOT CLASS 'F' 80C 40C 400/3PH 50 2 3000 RPM 2940 RPM STAR/DELTA 220% 700% FLC

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 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

app034c.doc 23/10/02

Page 3

CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 - W-EF SERIES


Page 4

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 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

Y46064.003 - 90 KW SQUIRREL CAGE TEFV EEXD T4 IP55 CERTIFIED GROUPS IIA & IIB W-EF280 SN FOOT CLASS 'F' 80C 40C 380/3PH 50 4 1500 RPM 1475 RPM STAR/DELTA 165 AMPS 330 AMPS ONE FITTED PER PHASE Y55153.002 - 75 KW SQUIRREL CAGE TEFV EEXD T4 IP55 CERTIFIED GROUPS IIA & IIB W-EF250 MN FOOT CLASS 'F' 80C 40C 400/3PH 50 4 1500 RPM 1480 RPM STAR/DELTA 133 AMPS 306 AMPS ONE FITTED PER PHASE 5436.N2.87764 - 45 KW SQUIRREL CAGE IP55 TEFV W-DF225MN FOOT CLASS 'F' 80C 40C 400/3PH 50 4 1500 RPM 1470 RPM STAR/DELTA 80 AMPS 192 AMPS 93994/94340.003 - 30 KW SQUIRREL CAGE IP55 TEFV W-DF200L FOOT & FLANGE CLASS 'F' 80C

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 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

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 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

1.1 1.2 1.3 1.4 1.5 1.6

TYPE PROTECTION FRAME SIZE MOUNTING B3/B5 INSULATION TEMPERATURE RISE

Page 4

app034c.doc

23/10/02

CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 - W-EF SERIES


Page 5

1.7 1.8 1.9 1.10 1.11 1.12 1.13

AMBIENT TEMPERATURE VOLTAGE 3 PHASE FREQUENCY HZ POLES SYNCHRONOUS SPEED ACTUAL SPEED TYPE OF START

40C 380/3PH 50 4 1500 RPM 1460 RPM DIRECT ON LINE 94430.002 - 30 KW SQUIRREL CAGE IP55 TEFV W-DF200L FOOT & FLANGE CLASS 'F' 80C 40C 440/3PH 60 4 1800 RPM 1760 RPM DIRECT ON LINE

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 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.doc 23/10/02

Page 5

CompAir UK Ltd PUBLICATION APP034C ELECTRIC MOTOR W-DF200 - W-EF SERIES


Page 6

ELECTRIC MOTOR MAINTENANCE


WARNING : Isolate power supply to motor before commencing any routine cleaning or maintenance work. Routine Cleaning : Remove the fan cover and ensure that all holes are completely open. 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. Slacken and remove bearing cover screws and endshield bolts/studs. The endshields should then be eased off their spigots. The rotor can now be withdrawn carefully from the stator. Having dismantled the motor, maintenance can now be carried out to remove all dirt. Dry, compressed air under comparatively low pressure is best as a high velocity stream can force dirt into the spaces between windings, etc. Grease removing solvents should only be used very sparingly so as not to damage impregnating varnish or insulation. Bearings are charged with sufficient grease to last at least two years, provided there is little or no grease leakage. When replenishing, use only good quality lithium based grease and avoid overfilling the bearing housing. Motors should be reassembled in the reverse order from dismantling, taking care not to damage the windings on insertion of rotor, taking care not to damage the windings on insertion of rotor, remembering to ease endshields on bearings and spigots. DO NOT USE FORCE. Before starting, check that the rotor revolves freely. Ensure that the electrical connections are correct and terminal nuts tight. Refit any pulley, coupling, sprocket etc. which have been removed, being particularly careful to ensure correct alignment with the driven part, as misalignment may lead to ultimate bearing failure and shaft breakage.

Page 6

app034c.doc

23/10/02

CompAir UK Ltd APP 041 D.D.Vs GENERAL


Page 1

DIAPHRAGM DRAIN VALVES ASSEMBLY INSTRUCTIONS


1) 2) 3) 4) Assemble drain valve seat(s) (3 - 14) to valve body(s) (2) using silicon sealant on joint faces, tighten lock nut (1). Assemble diaphragm (8) and joints (4) to cover (9) and body(s) (2). Assemble complete assembly tighten setscrews (10) nuts (15) finger tight. Tighten setscrews (10) nuts (15) evenly to the correct torque setting of 27Nm.

10

2 4 14 13

12 11 8 4 9

10 8 7 6 5 4 3

16

2 1

15

9 4 1 5 10 2 3 4 7 6 8

APP041.DOC

CompAir UK Ltd APP 041 D.D.Vs GENERAL


Page 2

PARTS LIST FOR STANDARD SINGLE AND DOUBLE UNITS - U334 J to M

Item No 1 2&9 2&9 3 3 4 5,6 & 7 8 10 11,12 &13 14 15 16

Part No PS 1290.4 C 203190.1 C 203190.2 C 201159 C 201417 C 200722 C 201981 98210.1002 95006.133 C 201980 C 200842 95111.4 95000.229

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.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 11,12,13&14 3,5,6 &7 Part No 98650.1535 98650.1531 98650.1532 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.DOC

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, filters and the dryers (if fitted). This ensures that these items of equipment reach their optimum working pressure as soon as possible, to give long filter life, good oil separation and low oil consumption. Adjustment is by adjusting screw (1) for setting to the desired pressure, locking in position with locknut (2).

12

11

10 9

8 INLET 5 7 6

OUTLET

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. 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.doc

CompAir UK Ltd APP 059 PRESSURE MAINTAINING VALVE U572B


Page 2

App059.doc

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. IMPORTANT It is common practise to install the pressure gauge without an isolating device, so to facilitate calibration or replacement the system must be de pressurised before any work is carried out. The pressure gauge is liquid filled to provide better damping from pulsations. 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. No pressure higher than indicated by the working pressure symbol w must be applied to the gauge during hydrostatic pressure testing of the system. Otherwise the gauge must be isolated or removed during this operation. No attempt should be made to remove a pressurised gauge. The pressure system must be totally relieved if the gauge can not be isolated otherwise. The remainder of the pressure medium contained in the element may be hazardous or toxic. This should be considered when handling and storing the removed pressure gauge.

PRESSURE GAUGES IN SERVICE. Always open isolating devices always gently and never abruptly, as this may generate sudden pressure surges that may damage the gauge. The maximum working pressure for which the gauge is suitable, or also the minimum working pressure in cases of vacuum, is indicated on the dial by corresponding marks w. Fluctuating pressure always reduces the maximum working pressure of the gauge. Correct zeroing may be inspected by closing the isolating valve and relieving the gauge from pressure. The pointer must fall within the thickened portion of the zero mark. Unless the gauge temperature is considerably higher or lower than 20C, a pointer not returning to zero may indicate serious damage to the gauge. 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.

app070.doc

CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL


Page 2

app070.doc

CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.1004


Page 1

PRESSURE SWITCH
98524/1004 OPERATION
Located as close as possible to the H.P. delivery line, the pressure switch stops the compressor when the upper pressure limit is attained and triggers off the start when the lower limit is reached. The switch transforms a change of pressure into an electrical 'On' or 'Off' signal. When a pre-set pressure is reached the snap action contact changes state.

INSTALLATION
Pressure switches may be mounted in any convenient position close to the H.P. line, provided it is not subject to vibration and that the connecting pipe to the receiver does not exceed five metres. Mount the switch by the lugs provided on the casing. Where possible the pressure switch operating line should be taken from the receiver to avoid pressure oscillations. It is usual to connect 1 and 2 to the compressor electrical control circuit terminals marked pressure switch'.

B A

Red Pointer 3 1 Green Pointer

SETTING
Example of pressure setting to 150 bar minimum and 175 bar maximum. Turn screw (A) to raise the GREEN pointer to its highest point. Turn screw (B) so that the higher setting (175 bar) coincides with the RED pointer. 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, AS THE MARKINGS ON SWITCHES ARE FOR INDICATION ONLY.

app081.doc

CompAir UK Ltd APP 081 PRESSURE SWITCH 98524.1004


Page 2

app081.doc

CompAir UK Ltd APP 086 HIGH AIR PRESSURE SWITCH 98524.1025/49/94/95/96/1103/4/7/28/35/36/37


Page 1

HIGH AIR/GAS PRESSURE SWITCHES PART NO: 98524/1025, 1049, 1094, 1095, 1096, 1102, 1103, 1104, 1107, 1128, 1135, 1136 & 1137
OPERATION - MANUAL START/AUTO STOP Located as close as possible to the delivery, inlet air/gas line, the pressure switch stops the compressor when the air/gas pressure rises or falls above or below the pre-set pressure setting. TYPICAL SETTINGS - Set to actual operating pressures or check contract for details. Set pressures: 98524/1025 Setting Range 30"hg vac - 15 psig rising 98524/1094 Setting Range 0.14 - 4 psig rising 98524/1095 Setting Range 0.35 - 11 psig rising 98524/1096 Setting Range 1.4 - 28 psig rising 98524/1102 Setting Range 0.2 - 4 bar g rising Reset Differential 0.07 bar 98524/1103 Setting range 2 - 28 bar g rising Reset Differential 0.6 bar 98524/1107 Setting range 0.2 - 4 bar g rising Reset Differential 0.6 bar 98524/1128 Setting Range 2.5 mbar - 125 mbar To withstand 2.2 bar overload. 98524/1135 Setting Range 0.2 - 4 bar g rising Reset Differential 0.07 bar 98524/1136 Setting Range 3 - 70 bar g rising. 98524/1137 Setting Range 3 - 66.5 bar g rising. The switch transforms a change of pressure into an electrical "On" or "Off" signal. When a pre-set pressure is reached the snap action contact stops the compressor. OPERATION - AUTO START/STOP Located as close as possible to the delivery 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. TYPICAL SETTINGS - Set to actual operating pressures or check contract for details. Set pressures: 98524/1049 Setting Range 2 - 42 bar g rising Set Pressure HIGH 31 bar g rising Set Pressure LOW 28 bar g falling. 98524/1104 Setting Range 2 - 70 bar g rising Set Pressure HIGH 40 bar g rising Set Pressure LOW 36 bar g falling. 98524/1137 Setting Range 3 - 66.5 bar g rising Set Pressure HIGH 42 bar g rising Set Pressure LOW 39 bar g falling. The switch transforms a change of pressure into an electrical "On" or "Off" signal. When a pre-set high pressure is reached the snap action contact stops the compressor, after dropping to the lower setting, the compressor restarts. ADJUSTING NUT CONDUIT THREAD

INSTALLATION Mount the switch by the bracket provided. It is usual to connect 1 (C) and 2 (NC) to the compressor electrical control circuit terminals marked "Pressure Switch".

app086.doc

CompAir UK Ltd APP 086 HIGH AIR PRESSURE SWITCH 98524.1025/49/94/95/96/1103/4/7/28/35/36/37


Page 2

Remove cover to set pressure setting, using a pressure gauge. Note:- Switches are pre-set and do not usually need adjusting. Please confirm with Engineering at CompAir UK Ltd Ipswich if switches are to be adjusted. a. Turn adjusting nut clockwise to lower set point. b. Turn adjusting nut anti clockwise to raise set point. c. To adjust differential use knotched wheel below the microswitch.

app086.doc

CompAir UK Ltd APP 088 LOW OIL PRESSURE SWITCH 98524.1042/1122/1140


Page 1

LOW OIL PRESSURE SWITCH PART NO: 98524.1042, 98524.1122 & 98524.1140
OPERATION Located in the crankcase on watercooled & large aircooled compressors, in the oil filter body on aircooled, the pressure switch stops the compressor when the oil pressure drops to pre-set pressure setting. PART NO. 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 0.1 bar Standard up to 0.1 bar Standard SETTING 1 bar (15 psi) falling 0.5 bar (7.5 psi) falling 1 bar (15 psi) falling 1 bar (15 psi) falling 0.5 bar (7.5 psi) falling 1 bar (15 psi) falling

The switch transforms a change of pressure into an electrical "On" or "Off" signal. When a pre-set pressure is reached the snap action contact stops the compressor. INSTALLATION It is usual to connect 1 (C) and 4 (N/O) to the compressor electrical control circuit terminals marked "Oil Pressure Switch".

app088.doc

CompAir UK Ltd APP 088 LOW OIL PRESSURE SWITCH 98524.1042/1122/1140


Page 2

app088.doc

CompAir UK Ltd APP 090 THERMOMETER SWITCH C202556/749/960/964


Page 1

THERMOMETER SWITCH
C202556, C202749, C202960 & C202964
THESE THEMOMETER SWITCHES ARE SET TO THE FIGURES QUOTED BELOW, THE FOLLOWING INFORMATION IS FOR SETTING INFORMATION ONLY, IF THE TEMPERATURE SWITCH HAS TO BE REPLACED OR RE-ADJUSTED. IF THE SWITCH NEEDS TO BE RE-ADJUSTED DUE TO A HIGHER AMBIENT TEMPERATURE OR ANY REASONS PLEASE CONTACT COMPAIR UK LTD. IPSWICH FOR MORE INFORMATION. CONTROLLER PART No C202556.1 C202556.2 C202556.3 C202556.4 C202556.5 C202556.6 C202556.7 C202556.8 C202749.1 C202749.2 C202749.3 C202960.1 C202960.2 C202960.3 C202960.4 C202960.5 C202964.1 C202964.2 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 5236.1 5212 5336,5415 5215 & 5217 5236.2,5315 5415E5317,5417.5417N 5436(CU TUBES) 5436.1 &.2,5436H,5436N,5436SN & 5437 5280 5280 5409 WATERCOOLED M/CS DELIVERY 5211 WATER OUTLET 5207,5209,5213 5417N,5436N 5280,5281,5282,5283, DELY 5450,5470 DELY

TO SET. see Note Below. ESTABLISH NORMAL RUNNING TEMPERATURE. SET POINTER BY TURNING CENTRAL KNOB ADJUSTER A TO 10C ABOVE THIS TEMPERATURE NOTE: DO NOT RESET TEMPERATURE CONTROLLER SETTING IF IT TRIPS, ALWAYS LOCATE AND CORRECT POSSIBLE FAULT BEFORE ANY ATTEMPT IS MADE TO ALTER SETTING. 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.

app090.doc

CompAir UK Ltd APP 090 THERMOMETER SWITCH C202556/749/960/964


Page 2

app090.doc

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, with flameproof construction cast iron housing & cover. NBF BA320 A182 1.6 NBF BD320 A182 1.6 NBF BE320 A182 1.6 NBF BA320 A180 0.8 NBF TB320 A180 0.8 NBF BD320 A180 0.8 NBF BE320 A180 0.8

3 4 5

8 7 9

11 12 10

13

MAINTENANCE WARNING: The following procedures should only be undertaken by a qualified BASEEFA approved electrician, as any illegal attempts to repair may render the BASEEFA certificate void. Turn off electrical power supply and line pressure to valve before making any repairs. Note: It is not necessary to remove valve from pipeline to effect repair.

app152.doc

CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES


Page 2

CLEANING A periodic cleaning of all solenoid valves is desirable. The time between cleaning will vary depending on the medium and service conditions. In general if the voltage to the coil is correct sluggish valve operation. Excessive leakage or noise will indicate that cleaning is required. Clean valve strainer or filter when cleaning solenoid valve. PREVENTIVE MAINTENANCE a. b. c. 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. Periodic inspection (depending upon medium and service conditions) of internal valve parts for damage or excessive wear is recommended. Thoroughly clean all parts. Replace parts that are worn or damaged.

IMPROPER OPERATION a. Faulty Control Circuit: Check electrical system by energising solenoid, a metallic click signifies the solenoid is operating. Absence of the click indicates loss of power supply. Check for loose or blown fuses, open-circuited or grounded coil, broken lead wires terminals or spliced connections. Burned Out Coil: Check for open-circuited coil. Replace if necessary. Low Voltage: Check voltage across coil leads. Voltage must be at least 85% of nameplate rating. Incorrect Pressure: Check valve pressure. Pressure to valve must be within the range specified on the nameplate. Excessive Leakage: Disassemble valve and clean all parts. Replace worn or damaged parts with a complete spare parts kit for the best results.

b. c. d. e. Note:

Any repair to this unit should be undertaken by the manufacturer or his agent, as it may invalidate the BASEEFA certificate.

COIL REPLACEMENT (Refer to Drawing) Turn off electrical power supply and disconnect coil lead wires. Change whole assembly if faulty. VALVE DISASSEMBLY & RE-ASSEMBLY a. b. c. d. e. f. g. h. I. j. k. Depressurise valve and turn off electrical power supply. Remove lock screw 2mm A/F hexagon wrench. Unscrew cover (1) use suitable flat bar. Remove terminal block screws. Lift out terminal block and insulator (2) Remove retaining cap (3) and clip (4). Withdraw complete solenoid valve enclosure from solenoid base. Unscrew solenoid base sub-assembly (5). Remove core assembly (6), core spring (7), core guide (8) and body gasket (upper) (9). Unscrew end cap (10), remove body gasket (11) (lower), disc spring (12) and disc holder sub-assembly (13). All parts are now accessible for cleaning or replacement. Replace worn or damaged parts with a complete Spare Parts Kit for best results. When re-assembling, lubricate body gaskets with DOW CORNING 111 compound lubricant or equivalent; high grade Silicon Grease. Re-assemble in reverse order of dismantling, paying careful attention to cleanliness. Torque both solenoid base, sub-assembly and end cap on assembly to 19.8 Newton metres.

WARNING: To prevent the possibility of severe personal, njury or property damage, check valve for proper operation before returning to service. Also perform internal seat and external leakage tests with non-hazardous, non combustible fluid. After maintenance, operate the valve a few times to be sure of proper operation. A metallic click signifies the solenoid is operating. SPARE PARTS KIT Comprises Retaining Clip & cap, core guide, core assembly, gaskets & disc spring.

app152.doc

CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES


Page 3

PARTS LIST
Part Number 98516.1033 98516.1034 98516.1035 98516.1036 98516.1037 98516.1038 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 BSPP BSPP BSPP BSPP BSPP BSPP N/C Thread Connection " NPT " NPT " NPT " NPT " NPT " NPT N/C Thread Connection " BSPT " BSPT " BSPT " BSPT " BSPT " BSPT " BSPT Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice

Part Number 98516.1130 98516.1131 98516.1132 98516.1133 98516.1134 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 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice

Part Number 98516.1073 98516.1074 98516.1075 98516.1076 98516.1077 98516.1099 98516.1141

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 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice 1.6 Orifice

Part Number .

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 " NPT N/C Thread Connection " NPT N/O Thread Connection " BSPT " BSPT " BSPT " BSPT " BSPT " BSPT

Orifice 0.8 Orifice

Part Number .55153.004

Description 3/2 Solenoid valve

Orifice 0.8 Orifice

Part Number 98516.1078 98516.1079 98516.1080 98516.1081 98516.1082 98516.1100

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 0.8 Orifice 0.8 Orifice 0.8 Orifice 0.8 Orifice 0.8 Orifice 0.8 Orifice

app152.doc

CompAir UK Ltd PUBLICATION APP152 FLAMEPROOF SOLENOID VALVES


Page 4

app152.doc

CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE


Page 1

FLAMEPROOF SOLENOID VALVE

GENERAL Two way normally closed valve, with flameproof construction cast iron housing & cover.

1 2 3 4

8 7 9 6 10

app153.doc

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, as any illegal attempts to repair may render the BASEEFA certificate void. Turn off electrical power supply and line pressure to valve before making any repairs. Note: It is not necessary to remove valve from pipeline to effect repair.

CLEANING A periodic cleaning of all solenoid valves is desirable. The time between cleaning will vary depending on the medium and service conditions. In general if the voltage to the coil is correct sluggish valve operation. Excessive leakage or noise will indicate that cleaning is required. Clean valve strainer or filter when cleaning solenoid valve. PREVENTIVE MAINTENANCE a. b. c. 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. Periodic inspection (depending upon medium and service conditions) of internal valve parts for damage or excessive wear is recommended. Thoroughly clean all parts. Replace parts that are worn or damaged.

IMPROPER OPERATION a. Faulty Control Circuit: Check electrical system by energising solenoid, a metallic click signifies the solenoid is operating. Absence of the click indicates loss of power supply. Check for loose or blown fuses, open-circuited or grounded coil, broken lead wires, terminals or spliced connections. Burned Out Coil: Check for open-circuited coil. Replace if necessary. Low Voltage: Check voltage across coil leads. Voltage must be at least 85% of nameplate rating. Incorrect Pressure: Check valve pressure. Pressure to valve must be within the range specified on the nameplate. Excessive Leakage: Disassemble valve and clean all parts. Replace worn or damaged parts with a complete spare parts kit for the best results.

b. c. d. e.

Note:

Any repair to this unit should be undertaken by the manufacturer or his agent, as it may invalidate the BASEEFA certificate.

COIL REPLACEMENT (Refer to Drawing) Turn off electrical power supply and disconnect coil lead wires. Change whole assembly if faulty.

PARTS LIST
Part Number Description Coil Voltage Thread Connection 2" BSPP 1.1/2" BSPP Orifice

98516.1129 98516.1143

2 Way Solenoid valve

NBE 215 B080 230V/1PH/50HZ NBE 215 B070 2 Way Solenoid valve 220V/1PH/50HZ

53 Orifice 42 Orifice

app153.doc

CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE


Page 3

VALVE DISASSEMBLY & RE-ASSEMBLY Depressurise valve and turn off electrical power supply. Remove lock screw 2mm A/F hexagon wrench. Unscrew cover (1) use suitable flat bar. Remove terminal block screws. Lift out terminal block and insulator (2) Remove retaining cap (3) and clip (4). Withdraw complete solenoid valve enclosure from solenoid base. Unscrew solenoid base sub-assembly (5) using special wrench. Remove bonnet screws (6), valve bonnet (7), bonnet gasket (8) core diaphragm (9) subassembly and body gasket (10). h. All parts are now accessible for cleaning or replacement. Replace worn or damaged parts with a complete Spare Parts Kit for best results. i. When re-assembling, lubricate bonnet and body gaskets with DOW CORNING 200 fluid liquid or equivalent; high grade Silicon Liquid. Apply a light coat of RemGrit TFL50 Dry lubricant to the following: Valve seat, 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). Important: If the valve has been disassembled for inspection and cleaning only and a rebuild kit is not being used, lubricate the following parts with RemGrit TFL50 dry lubricant: Diaphragm assembly on both sides, main disc at base of core/diaphragm sub-assembly, pilot disc at base of core assembly. Caution: Do not distort hanger spring between core assembly and diaphragm assembly when lubricating pilot disc. j. Replace body gasket (10) and core/diaphragm sub-assembly with closing spring attached. Locate bleed hole in core/diaphragm sub-assembly approximately 30 form the valve inlet. k. Replace, valve bonnet and bonnet screws (6). Torque screws in a criss-cross manner to 11.3 Newton metres. l. Replace bonnet gasket (8) and solenoid base assembly the install bonnet gasket (see earlier instructions on lubricants) housing and solenoid base sub-assembly. Torque solenoid base sub-assembly to 19.8 Newton metres. m. Replace solenoid assembly. WARNING: To prevent the possibility of severe personal injury or property damage, check valve for proper operation before returning to service. Also perform internal seat and external leakage tests with non-hazardous, non combustible fluid. n. After maintenance, operate the valve a few times to be sure of proper operation. A metallic click signifies the solenoid is working. a. b. c. d. e. f. g.

SPARE PARTS KIT Always quote number stamped on nameplate when ordering spare parts.

app153.doc

CompAir UK Ltd PUBLICATION APP153 FLAMEPROOF SOLENOID VALVE


Page 4

app153.doc

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 98650/2076 98650/2077 98650/2078 98650/2079 98650/2080 98650/2081 98650/2082 98650/2083 98650/2084 98650/2085 98650/2086 40 bar at 90C - 20C to +170C

ID Number 118001 118002 118003 118004 118005 118006 118007 118008 118009 118010 118011

A 46.5 46.5 59 69 82 93 104 126 146 170 200

B 80 80 90 110 110 140 140 160 180 225 270

C 39 39 52.5 58 63 73.6 79.6 95 127 155 170

D 8 108 15 20 25 32 40 50 65 80 100

Thread 1/4 BSPT 3/8 BSPT 1/2 BSPT 3/4 BSPT 1 BSPT 1.1/4 BSPT 1.1/2 BSPT 2 BSPT 2.1/2 BSPT 3 BSPT 4 BSPT

Bore mm 8 10 15 20 25 32 40 50

GENERAL PARALLEL THREADS CP90 - 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, any leaks or faulty operation replace complete valve. For valves fitted with adjustable gland seal, maintenance consists of periodically tightening the stem nut 1/4 turn to compensate for wear on the stem and seal. Note valves with 'O' ring seals do not need maintenance. 40 bar at 90C - 20C to +170C

ID Number 118001C 118002C 118003C 118004C 118005C 118006C 118007C 118008C 118009C 118010C 118011C

A 46.5 46.5 59 69 82 93 104 126 146 170 200

B 80 80 90 110 110 140 140 160 180 225 270

C 39 39 52.5 58 63 73.6 79.6 95 127 155 170

D 8 108 15 20 25 32 40 50 65 80 100

Thread 1/4 BSPP 3/8 BSPP 1/2 BSPP 3/4 BSPP 1 BSPP 1.1/4 BSPP 1.1/2 BSPP 2 BSPP 2.1/2 BSPP 3 BSPP 4 BSPP

Bore mm 8 10 15 20 25 32 40 50

app154.doc

CompAir UK Ltd PUBLICATION APP154 BALL VALVES 98650.2076/86


Page 2

App154.doc

CompAir UK Ltd PUBLICATION APP158 NON RETURN VALVE 98650.1422/1655


Page 1

NON-RETURN VALVE
Connections 1/2 BSP (G1/2) CompAir Part Number 98650/1655 TECHNICAL SPECIFICATION Maximum Working Pressure - 6000 psi Body material (Stainless Steel) 1 6 4 5 3 7 8 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 - PS1205/9 Retainer Clip

No Off 1 1 1 1 1 1 1 1

Maximum Working Pressure - 6000 psi Body material (Chrome plated brass) CZ121 6 4 5

1 3 7 2

Item No. 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.doc

CompAir UK Ltd PUBLICATION APP158 NON RETURN VALVE 98650.1422/1655


Page 2

App158.doc

CompAir UK Ltd. APP167 SAFETY VALVE I&O INSTRUCTIONS


Page 1

Installation and Operating Instructions


SAFETY VALVES
INTRODUCTION
Due consideration should be taken of climatic. 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. In addition, 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. Commissioning or servicing. It is important that the valve to be installed is correct in every aspect, i.e. set pressure, size, material and type etc. for the application.

STORAGE OF VALVE BEFORE INSTALLATION


Valves should be stored preferably between-5C and +25C and a relative humidity of less that 75%. Very moist or dry conditions should be avoided. If a safety valve is installed after six months, or more, of storage, it must be subjected to functional test before commissioning. Thread protectors should not be removed until immediately, prior to testing or installation, as they also prevent the ingress of foreign matter, which could harm the valve.

INSTALLATION
VALVE INLET: Under no circumstances should it be possible to isolate the safety valve from the protected system. Safety valves should be mounted as close as possible to the protected system. The connecting pipe should be straight and as short as possible. The inlet line to the safety valve should have an effective area of flow, at least equal to that of the safety valve inlet. CompAir Limited should be consulted if the safety valve is to be mounted in any position other than vertically. 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. VALVE OUTLET: No isolating devices shall be fitted to the outlet pipe. Discharge pipes should be as short as possible and of such a size that the pressure developed therein not reduce the relieving capacity. Ensure arrows indicating the direction of the flow are pointing in the correct direction. The cross-sectional area of the discharge pipe should not be less than the area of the safety valve outlet. Where safety valves are discharged into a manifold, the manifold must be capable of accommodating simultaneous discharge of all valves connected to the manifold. Atmospheric discharge or discharge pipes should terminate at a location which will not cause a hazard to personnel, particular attention being given to hazardous fluids or particles. GENERAL: Inlet and outlet piping should be capable of supporting the safety, valve so that no unacceptable mechanical load or vibration is transmitted to the valve, and be sufficiently strong to withstand 'the effects of the reaction forces when the valve is discharging. All pipework or pressure vessels to which the safety valve is connected should be thoroughly cleaned before fitting the safety valve, to ensure that foreign matter does not pass through the valve. Particular care should be taken with the use of scaling compounds and P.T.F.E. tape to ensure that they do not enter the valve. Atmospheric discharge valves should not be painted or coated with any substance, which could possibly obstruct or restrict free and full discharge through the valve. Suitable protection should be provided to prevent environmental build up or ingress of foreign matter. Any condition that could lead to blockage of discharge piping or discharge ports on safety valves must be avoided. Where appropriate, discharge pipes should be provided to a non-hazardous location. Where there is a possibility of a liquid head forming in a discharge pipe, a drain should be provided which leads to a safe discharge location. 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. FUNCTIONAL TESTING Once installed in service. Valves should be tested at least once every six months to ensure free movement of parts. 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. Where valves are supplied without easing gear, the test should be in accordance with the full functional test described overleaf. Due regard must be paid to the safety personnel. Testing should not create a hazard, particular attention being given to foreign matter located in discharge outlets.

APP167 .DOC

CompAir UK Ltd. 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, examples:98650.2073 is the base unit number. 98650.2073-16.2 98650.2073-96.25 -16.2 being to the setting in bar g - wire locked. -96.25 being to the setting in bar g - wire locked.

98650.1164 is the base unit number. 98650.1164-28 -28 being to the setting in bar g - wire locked.

98650.1163 is the base unit number. 98650.1163-7.6 -7.6 being to the setting in bar g - wire locked.

98650.1020 is the base unit number. 98650.1020-3.8T -3.8 being to the setting in bar g - wire locked and tagged.

98650.1021 is the base unit number. 98650.1021-9.6 -9.6 being to the setting in bar g - wire locked.

98650.1022 is the base unit number. 98650.1022-90T -90 being to the setting in bar g - wire locked and tagged.

Note the valves cannot be interchanged as the range of setting is limited.

APP167 .DOC

CompAir UK Ltd. PUBLICATION APP169a SWING CHECK VALVE 98650.2091 Y408546.8


Page 1

SWING CHECK VALVE.


INTRODUCTION
For mounting between BS4504 NP16 flanges. Part Number: S5.065.SBE

Description Part number Orifice Flange Description Part number Orifice Flange

Y408546.8 S5.065.SBE 46 NP16 98650.2091 98316-080-746-P-16B/PN16 50 BS4504 NP16

APP169a .DOC

CompAir UK Ltd. PUBLICATION APP169a SWING CHECK VALVE 98650.2091 Y408546.8


Page2

APP169a .DOC

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, filters and the dryers (if fitted). This ensures that these items of equipment reach their optimum working pressure as soon as possible, to give long filter life, good oil separation and low oil consumption. Adjustment is by adjusting screw (1) for setting to the desired pressure, locking in position with locknut (2).

12

11

10 9

8 INLET 5 7 6

OUTLET

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. 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.doc

CompAir UK Ltd APP 059 PRESSURE MAINTAINING VALVE U572B


Page 2

App059.doc

WARNING
The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd. Ipswich, may lead to failure in service which would not be covered by the warranty. Any unauthorised modifications or failures to maintain this equipment is accordance with the manufacturers maintenance instructions may make it unsafe. 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. Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury or result in damage to the equipment. CompAir UK Ltd can bear no responsibility for equipment in which unapproved replacement parts are included.

GENUINE PARTS CompAir UK Ltd


Use Reavellite compressor lubricant. Advantages:
Longer life. Longer time between oil changes. Longer valve life. Can be used in new or old compressors. Reduces carbon build up. Reduces oil consumption.

CompAir UK Ltd
Sales, 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.CompAir.com e-mail: Ipswich@CompAir.com