Instruction book

AN

Compressors
BLOCAIR
Type BL20 - 30 - 55 - 75 - 100 - 150
BK20 - 30 - 55 - 75 - 100
No. 2920 1421 00

GUARANTEE
The BLOCAIR compressor is guaranteed for 12 months from date of commissioning
or a maximum of 18 months from date of manufacture (which ever occurs first)
The guarantee will only be applicable subject to strict observation of the installation conditions
and the maintenance operations specified in these operating instructions.

NOTE
This instruction book meets the requirements for instructions specified by the machinery directive 98/37/EC
and is valid for CE as well as non-CE labelled machines.

Copyright 2000, Worthington-Creyssensac - ZI - BP, 4 rue Emile Zola, F-60114 MERU

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations,
part numbers and drawings.

2000-09

Instruction book

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the
beginning. The maintenance schedule comprises measures for keeping the machine in good condition.
Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according
to the instructions. Record all operating data, maintenance performed, etc. in an operator's logbook. Follow all relevant safety
precautions, including those mentioned on the cover of this book.
Repairs must be carried out by trained personnel from Worthington-Creyssensac who can be contacted for any further information.
In all correspondence mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data".
The company reserves the right to make changes without prior notice.

Contents
Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Compressor variants . . . . . . . . . . . . . . . . . 3
1.2 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.1 BK20 up to -55, BL20(A) up to -75(A),
BL100(A) 50Hz . . . . . . . . . . . . . . . . . . . . . 3
1.2.2 BK75/100, BL100(A) 60Hz, BL150(A)
and BL20(B) up to -150(B) . . . . . . . . . . . . 3
1.3 Regulating system . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.1 BK/BL20 up to -75 with DOL starter . . . . 3
1.3.2 BK/BL55 up to -100 and BL150 with
Y/D starter . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Installation and handling . . . . . . . . . . . . . . . . . . . . . . 9
2.1 BK/BL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Settings of overload relay - fuses - cable size . . 10
2.3.1 Compressors with DOL starter . . . . . . . . 10
2.3.2 Compressors with Y/D starter . . . . . . . . . 10
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . .
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Taking out of operation at end of compressor
service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
12
12
12

5 Servicing and adjustment procedures . . . . . . . . . .

5.1 Unloader or check valve . . . . . . . . . . . . . . . . . . .
5.2 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Adjustment for MDR4 . . . . . . . . . . . . . . .
5.4.2 Adjustment for MDR6 . . . . . . . . . . . . . . .
5.4.3 Adjustment for MDR3 . . . . . . . . . . . . . . .
5.5 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Relief valve on BL/BK two-stage . . . . . . . . . . . .

Page
15
15
15
16
17
17
18
19
19
19

6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Reference conditions . . . . . . . . . . . . . . . . . . . . .
7.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Compressor data for BL 10 bar . . . . . . . . . . . . .
7.3.1 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Compressor data for BK 10 bar . . . . . . . . . . . . .
7.4.1 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Compressor data for BL 15 bar . . . . . . . . . . . . .
7.5.1 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.2 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 Conversion list of SI units into US/British units

21
21
21
21
21
21
22
22
22
22
22
23
23

12
8 Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Preventive maintenance schedule of the
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Lubrication of BL compressors . . . . . . . . . . . . .
4.3 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2

13
9 Installation proposals . . . . . . . . . . . . . . . . . . . . . . . . 27
13
13
14

10 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . 29

2920 1421 00

Instruction book

1 LEADING PARTICULARS
1.1 General description
Blocair compressors are air-cooled, single-acting piston
compressors. BL are lubricated compressors; BK are oil-less
compressors which deliver oil-free air. As 10 bar versions
(version A), BK20 up to -55, BL20 up to -75 and BL100-50Hz
are single-stage compressors. BK75, BK100, BL100-60Hz,
BL150 are two-stage compressors. As 15 bar versions (version
B), BL20 up to -150 are two-stage compressors.
BK20 up to -75, BL20 up to -75 and BL100-50Hz are twocylinder compressors, BK100, BL100-60Hz, BL150 are threecylinder compressors.
Note: Take care that three-cylinder compressors rotate in the
direction as indicated by the arrow on the fan housing.
Blocair BL compressors are built for effective working
pressures up to 10 bar (version A) or up to 15 bar (version B).
Blocair BK compressors are built for effective working
pressures up to 10 bar.
For BL compressors:
- BL(A) stands for BL 10 bar
- BL(B) stands for BL 15 bar
- BL stands for BL 10 bar and 15 bar
1.1.1 Compressor variants
The Compressor Block (Fig. 1.1) includes:
- Crankcase (4) and cylinders
- Air inlet filter (AF) and inlet silencer (3)
- Fan (FN)
- Air cooler piping (2) and (5)
- Check valve (7, for BK55, BK75, BL55 and BL75 DOL
starter)
- Check valve/unloader (7, for BK55 up to -100, BL55 up to
-150 Y/D starter)
- Relief valve (8, for BK and BL two-stage)
The motor-compressor set comprises (Figs. 1.2/1.3):
- the Compressor Block as described above
- the flanged-on electric motor (M)
The Complete Unit comprises (Figs. 1.4, 1.5, 1.6 and 1.7):
- BL/BK20 and -30: the motor-compressor set mounted on a
horizontal (Fig. 1.4) or vertical (Fig. 1.5) air receiver (AR)
with check valve (CV), air pressure switch/start switch
(MDR), air outlet valve (AV), pressure gauge (Gp), safety
valve (SV) and condensate drain valve (Dm).
- BL/BK55 up to -100, BL150: the motor-compressor set
mounted on an air receiver (AR) with air outlet valve (AV),
pressure gauge (Gp), safety valve (SV) and condensate drain
valve (Dm), and also:
- for DOL starters an air pressure switch/start switch
(MDR)
2920 1421 00

for Y/D starters air pressure switch (MDR), solenoid

valve (Y1), electric cabinet (6) including the motor
starter

The frame version (Fig. 1.8) comprises:

- the motor-compressor set mounted on a frame
- for Y/D starters: a pressure gauge, a safety valve, electric
cabinet including the motor starter, air pressure switch and
start switch
- for DOL starters: a check valve, an air pressure switch/start
switch (MDR), a pressure gauge, a safety valve

1.2 Air flow

1.2.1 BK20 up to -55, BL20(A) up to -75(A), BL100(A)50Hz (Fig. 1.9)
Air drawn through air filter (AF) into cylinders (3) and inlet
silencer (1) is compressed, then discharged through cooler
piping (4) and (6) and check valve (CV) into air receiver (AR).
1.2.2 BK75/100, BL100(A)-60Hz, BL150(A) and
BL20(B) up to -150(B) (Fig. 1.10)
Air drawn through air filter (AF) and inlet silencer (1) into LP
(low-pressure) cylinder(s) (7) is compressed, then discharged
to HP (high-pressure) cylinder (8) via intercooler (10).
The air is further compressed and discharged through cooler
piping (6) and check valve (CV) into air receiver (AR).

1.3 Regulating system

1.3.1 BK/BL20 up to -75 with DOL starter (Fig. 1.9)
The regulating system includes:
- Check valve (CV)
- Air pressure switch (MDR) with pressure release valve (2)
and on/off buttons (5).
Operation
Air pressure switch (MDR) opens and closes its contacts at
pre-set pressures. During loaded operation, the contacts are
closed: the motor is running.
When the pressure in the air receiver reaches the pre-set
maximum pressure, the contacts as well as pressure release valve
(2) are opened. The motor stops, the air at the delivery side of
the compressor is vented to the atmosphere and check valve
(CV) closes to prevent venting of the receiver.
When the pressure in the air receiver decreases to the pre-set
minimum pressure, the contacts of the air pressure switch close
and pressure release valve (2) closes. The motor restarts and
compressed air is supplied to the receiver again.

Instruction book

AF 1
6

8
4

FN

7
50988F

10

AF

FN

Fig. 1.1 Example of Compressor Block

50985F

DP

SG

Fig. 1.2 Example of motor-compressor set

10

AF
3

9
8

2
M

FN

7
50984F

AF
DP
FN
M
SG
1
2
3
4
5
6
7
8
9
10

Air filter
Oil drain plug
Fan
Motor
Oil level sight-glass
Cover
Intercooler
Air inlet silencer
Crankcase
Cooling pipe
Cylinder
Unloader
Relief valve
HP cylinder
LP cylinder

Figs. 1.1 up to 1.3

Fig. 1.3 Example of motor-compressor set
4

General views, Compressor

Block motor-compressor set
2920 1421 00

Instruction book

AF SV

AF 1
8

MDR
AV

M
MDR

Gp

CV

AR

SV
Gp

Dm

50983F

9
AR
AV

Fig. 1.4 Complete Unit, horizontal receiver

Dm
50987F

Fig. 1.5 Complete Unit, vertical receiver

1 AF

3
2

Y1

P1
MDR
6
Gp

AV

50986F

AR

Dm

Fig. 1.6 Complete Unit (3-cylinder)

2920 1421 00

Instruction book

Fig. 1.7 Complete Unit (3-cylinder)

AF
AR
AV
CV
Dm
FN
Gp
M

MDR
P1
SV
Y1
1
2
3
4

Air filter
Air receiver
Air outlet valve
Check valve
Condensate drain valve
Fan
Air pressure gauge
Motor

Air pressure switch

Hourmeter, running hours
Safety valve
Loading solenoid valve
Cover
Blow-off silencer
Air inlet silencer
LP cylinder

5
6
7
8
9

HP cylinder
Electric cabinet
Check valve/Unloader
Relief valve
Pictograph, switch off
voltage and depressurize
before maintenance or
repair

Figs. 1.4 up to 1.7 General views, Complete Unit

AF

2
FC
M

SV

MDR

Gp
4
50994F

1
2
3
4

Cover
Air inlet silencer
Unloader
Pictograph, switch
off voltage and
depressurize before
maintenance or repair

AF
FC
Gp
M
MDR
SV

Air filter
Filler cap
Air pressure gauge
Motor
Air pressure switch
Safety valve

Fig. 1.8 Frame version

6

2920 1421 00

Instruction book

Fig. 1.9 Air flow of single-stage compressors and regulating system of BK/BL20 up to -75 with DOL starter

Fig. 1.10 Air flow of two-stage compressors and regulating system of BL55 up to -150 and BK55 up to -100 with Y/D starter

AF
AR
AV
CV
Dm
DP
FC
FN
Gp
M

Air filter
Air receiver
Air outlet valve
Check valve
Condensate drain valve
Oil drain plug
Oil filler cap
Fan
Air pressure gauge
Motor

MDR
SG
SV
UA
UV
Y1
1
2
3
4

Air pressure switch

Oil level sight-glass
Safety valve
Unloader
Unloading valve
Loading solenoid valve
Air inlet silencer
Pressure release valve
Cylinder
Cooler

5
6
7
8
9
10
11
12
13

On/off switch or
buttons
Cooling pipe
LP cylinder
HP cylinder
Blow-off silencer
Intercooler
Electric cabinet
Plunger
Spring

Figs. 1.9 and 1.10 Air flow and regulating systems

2920 1421 00

Instruction book

1.3.2

BK/BL55 up to -100 and BL150 with Y/D starter

(Fig. 1.10)

The regulating system includes:

- Electric cabinet (11) with on/off switch (5)
- Air pressure switch (MDR)
- Solenoid valve (Y1)
- Unloader (UA) with integrated check valve (CV)
Operation
Air pressure switch (MDR) opens and closes its contacts at
pre-set pressures. During loaded operation, the contacts are
closed: the motor is running and solenoid valve (Y1) is
energized preventing the compressed air from flowing to
unloader (UA).
When the pressure in the air receiver reaches the pre-set
maximum pressure, the contacts of pressure switch (MDR)
open. The motor stops and solenoid valve (Y1) is de-energized.
Compressed air from the receiver will flow via the solenoid
valve to plunger (12) which causes unloading valve (UV) to
open. The air at the delivery side of the compressor is blown
through silencer (9) to the atmosphere and check valve (CV)
closes to prevent venting of the receiver.
When the pressure in the air receiver decreases to the pre-set
minimum pressure, the contacts of the pressure switch close.
The motor restarts and, after switching over from star to delta,
solenoid valve (Y1) is energized. Control air from the unloader
plunger chamber is vented to the atmosphere. Unloading valve
(UV) closes and compressed air is supplied to the receiver again.

2920 1421 00

Instruction book

2 INSTALLATION AND HANDLING

2.1 BK/BL

The electrical installation must be carried out by an electrician

and correspond to the local codes.

Install the compressor horizontally, in a cool but frost-free and

well-ventilated room. Place the compressor as level as possible.
The maximum angular deviation for BL is 22.5 degrees in any
direction. The air should be clean. Also consult section 9.
A condensate drain valve must be installed downstream of the
compressor in the lowest part of the air net. If any further
information is required, consult Worthington-Creyssensac.

2.2 Electrical connections

The electrical diagrams are shown in section 8.

S1

F1 K1

K3

K2

The indications on the motor data plate must correspond to the

mains supply voltage and frequency. The installation must
include an isolating switch in the power line near to the unit
and be protected against short-circuits by fuses in each phase.
See section 2.3.
The mains supply and earthing lines must be of suitable size.
See section 2.3.
For DOL starters, connect the power supply cables as shown
on Figs. 8.1/8.2. For Y/D starters, connect the power supply
cables to strip (X1-Fig. 2.1) as shown on Fig. 8.3/8.4. Check
the setting of the overload relay. See section 2.3.

P1

F1
K1
K2
K3
P1
S1
X1

X1

2920 1421 00

Fuse
Line contactor with integrated Y/D timer
Star contactor
Delta contactor
Hourmeter, running hours
On/off switch
Terminal block

50959F
Fig. 2.1

Electric cabinet with star-delta starter,

typical example
9

Instruction book

2.3 Settings of overload relay - fuses - cable size

2.3.1 Compressors with DOL starter
50 Hz
Type

Voltage
(V)

Overload relay
(A)

Fuses
(A)

BL/BK20
BL/BK20
BL/BK20
BL20(A)

230 (1-phase)
230
400
500

10.7
6.7
4.1
3.5

16
10
10
10

BL/BK30
BL/BK30

230
400

9.3
5.6

16
10

BL/BK55
BL/BK55

230
400

15.7
9.3

25
16

BL/BK75
BL/BK75

230
400

20.3
12.0

25
25

Type

Voltage
(V)

Overload relay
(A)

Fuses
(A)

BL20
BL20
BL20(A)
BL/BK20

230 (1-phase)
230/460
380
440/460

11.7
4.5
4.7
4.1

16
10
10
10

BL30
BL30
BL/BK30

230 (1-phase)
230/460
440/460

17.9
7.6
5.7

25
10
10

BL/BK55
BL/BK55
BL/BK55

230 (1-phase)
230/460
440/460

29.0
11.6
9.6

40
16
16

BL/BK75
BL/BK75

230
440/460

13.2
12.3

25
25

60 Hz

2.3.2 Compressors with Y/D starter

50Hz
Type

Voltage
(V)

Overload relay
(A)

Fuses
(A)

BL55(A)
BL55(B)
BL55
BL55

230
230
400
500

9.1
9.1
5.6
4.5

25
25
16
16

BL/BK75
BL/BK75
BL/BK75
BL75

230
400
500
575

12.2
7.2
5.5
5.1

40
25
16
16

10

2920 1421 00

Instruction book

Type

Voltage
(V)

Overload relay
(A)

Fuses
(A)

BL/BK100
BL/BK100
BL/BK100(A)
BL/BK100

230
400
440
500

14.5
8.5
7.8
6.9

40
25
25
25

BL150
BL150

230
400

22.5
13.1

63
40

Type

Voltage
(V)

Overload relay
(A)

Fuses
(A)

BL55
BL55
BL55
BL55(B)

230
380
440/460
575

11.8
6.9
5.5
4.7

25
25
16
16

BL/BK75
BL/BK75
BL/BK75(A)
BL/BK75

230
380
400
440/460

14.4
8.5
7.2
7.2

40
25
25
25

BK100, BL100(B)
BL/BK100
BL100(B)
BL100(B)
BL100(B)

230
380
440
440/460
575

18.2
10.6
9.0
8.6
7.2

63
25
25
25
25

BL150(A)
BL150

380
440

10.6
13.1

40
40

60Hz

Cable size
Type

Starter

Cable size
(mm)

BL/BK20/30
BL/BK55/75
BL/BK55
BL/BK75
BL/BK100
BL150

DOL
DOL
Y/D
Y/D
Y/D
Y/D

2.5
4
2.5
4
6
6

2920 1421 00

11

Instruction book

2.4 Pictographs

1
2
3
4
5
6
7
8
9

Temperature
Pressure
On
Off
Warning: voltage
Switch off voltage and depressurize before maintenance
or repair
Read Instruction book before starting
Consult Instruction book for correct direction of rotation
Do not adjust switch if it is depressurized

Fig. 2.2 Pictographs (typical examples)

3 OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all relevant safety precautions,
including those mentioned in this book.

4-Fig. 5.10) to ON or press the ON button on switch (MDRFigs. 1.4/1.5)

4. Open air outlet valve (AV-Figs. 1.4/1.6).
5. Regularly drain condensate (Dm-Figs. 1.4/1.6).

3.1 Initial start-up

3.3 Stopping

Note: It is strongly recommended to install an intercooler drain

kit, to remove excess condensate, on BL version B (15 bar)
compressors with a load factor less than 20% per hour. Consult
Worthington-Creyssensac.

1. Depending on the starter type, move switch (S1-Fig. 2.1 or

4-Fig. 5.10) to OFF or press the OFF button on switch
(MDR-Figs. 1.4/1.5)
2. Close air outlet valve (AV-Figs. 1.4/1.6).
3. Switch off the voltage.

1. For versions mounted on a receiver, remove the transport

brackets from underneath the compressor.
2. Check the electrical installation, which must be in
accordance with the instructions given in section 2.2.
3. BL are filled with ALTAIR 3000 PAO (polyalphaolefine)
compressor oil. Check that the oil level is still near the top
of the red circle of sight-glass (SG-Fig. 1.2). Top up, if
necessary.
4. Switch on the voltage. Start the motor.
5. On three-cylinder compressors, check for correct direction
of rotation as indicated by the arrow on the fan housing. If
the rotation direction is wrong, switch off the voltage and
reverse two of the input line connections.
6. Check the operation of the air pressure switch (MDR). See
section 5.4.

3.2 Starting
1. On BL, check the oil level, which must be near the top of
the red circle of sight-glass (SG-Fig. 1.2). The minimum
level is the lower part of the red circle.
2. Switch on the voltage.
3. Depending on the starter type, move switch (S1-Fig. 2.1 or
12

If a compressor with pressure switch with pressure release valve

stops during operation through a power failure, the pressure
from the air receiver must be released by pressing the OFF
button on the air pressure switch to prevent the compressor
from restarting against back-pressure when the power becomes
live again.

3.4 Taking out of operation at end of

compressor service life
At the end of the service life of the compressor, proceed as
follows:
1. Stop the compressor and close the air outlet valve(s).
2. Switch off the voltage and disconnect the compressor from
the mains.
3. Depressurize the compressor.
4. Shut off and depressurize the part of the air net which is
connected to the outlet valve. Disconnect the compressor
from the air net.
5. On BL, drain the oil.

2920 1421 00

Instruction book

4 MAINTENANCE
4.1 Preventive maintenance schedule of the compressor 1)
The schedule contains a summary of the maintenance instructions. Read the respective section before taking maintenance
measures.
When servicing, replace all disengaged packings, e.g. gaskets, O-rings, washers.
The "longer interval" checks must also include the "shorter interval" checks.

Period 2)

Running
hours 2)

Consult
section

See notes
below table

Operation

Weekly
"

-----------

3.2
--

1
--

On BL, check oil level

Drain condensate from air receiver or pulsation damper

6-monthly -----"
------

5.5/5.6
4.3/5.3

2
3

Test safety valve, and if provided also relief valve

Inspect air filter

Yearly
"
"
"
"

500
600
800
2000
2000

4.3/5.3
4.3/5.3
4.3/5.3
4.3
--

3/4
3/4
3/4
-5

On BK100, BL75(60Hz), BL150, replace air filter

On BL55 up to -75(50Hz) and BK55/75, replace air filter
On BL/BK20 and -30, replace air filter
Change blow-off silencer, if provided
On BL, if mineral oil used, change oil

2-yearly

3000

4.2/4.3

--

On BL, if Worthington-Creyssensac ALTAIR 3000 oil is used,

change oil

-----

3000 to
4000

4.3/5.1

--

Replace check valve or unloader

4000
5000

4.3/5.2
4.3/5.2

---

On BL/BK20 up to -55, replace valve discs

On BL75 up to -150 and BK75/100, replace valve discs

---------

Notes
1. Maintain the level in the red circle of the sight-glass.
2. Wear gloves and safety glasses.
3. For normal operation in clean surroundings. More frequently when operating in dusty environment.
4. In a dusty environment, a heavy duty filter is essential (available as an option).
5. Consult Worthington - Creyssensac.

4.2 Lubrication of BL compressors

It is strongly recommended to use the Worthington-Creyssensac approved ALTAIR 3000 (polyalphaolefine) compressor oil to
keep the compressor in excellent operating condition. See section 4.3.
2920 1421 00

13

Instruction book

4.3 Service kits

Service kits are available offering the benefits of genuine
Worthington-Creyssensac parts while keeping the maintenance
budget low. The kits comprise all parts needed for servicing.
Consult the Parts list for the contents of all kits.
Service kit for air filter (AF)
BK/BL20 up to -75 and BL100-50Hz
BL100-60 Hz, BK100, BL150

Ordering number
1503 0189 00
1503 0190 00

Service kit for ALTAIR 3000 oil (5 l)

All BL

Ordering number
6215 7111 00

Service kit for unloader (UA)

BK/BL55 up to -150 (Y/D)

Ordering number
6219 0140 00

Service kit for blow-off silencer

BK/BL55 up to -150 (Y/D)

Ordering number
1503 2420 00

Service kit for check valve (CV)

BK/BL55 up to -75 (DOL)

Ordering number
6219 0141 00

Service kit for valve discs

BL20(A) up to -55(A) and BK20/30
BL75(A), BL100(A) 50 Hz and BK55
BL20(B) up to -55(B)
BL75(B), BL100(B) 50 Hz and BK75
BL100-60 Hz, BL150 and BK100

Ordering number
6219 0072 00
6219 0073 00
6219 0074 00
6219 0075 00
6219 0076 00

Footnotes chapter 4
1) Use only authorized parts. Any damage or malfunction caused
by the use of unauthorized parts is not covered by Warranty or
Product Liability.
2) Whichever interval comes first. The local Sales Company may
overrule the maintenance schedule, especially the service
intervals, depending upon the environmental and working
conditions of the compressor.

14

2920 1421 00

Instruction book

5 SERVICING AND ADJUSTMENT

PROCEDURES
Warning

Release the pressure from the compressor before

starting repair or maintenance works. Switch off
the voltage and isolate the compressor from the
mains.

5.1 Unloader or check valve

Dirt, condensate, coke formation and oxidation influence the
proper operation of the valve. Depending on the working
conditions (ambient temperature, working pressure, load cycle,
oil type), it is recommended to replace the unloader or check
valve as indicated in section 4.2. Replacement instructions are
included in the maintenance kits.

Replacement of valve discs (Figs. 5.1 and 5.2)

BL20/75(A)
BL100(A) 50 Hz
BK20/55
BL100(A) 60 Hz
LP Cylinder
BL150(A)
LP Cylinder
BL20/150(B)
LP Cylinder
BK75/100
LP Cylinder

BL100(A) 60 Hz
HP Cylinder
BL150(A)
HP Cylinder
BL20/150(B)
HP Cylinder
BK75/100
HP Cylinder

Operation sequence

Remove the fan

guard, unscrew the
cap and remove the
cover (1-Fig. 1.1), air
filter and cover of the
air inlet silencer.

5.2 Valves
A faulty valve must be replaced immediately. A faulty valve
can be discovered as stated in section 6, points 1 and 4. It is
highly recommended to replace the valve discs, O-rings and
joints in case the cylinder heads are disassembled.

Fig. 5.1

Fig. 5.2

1
2
3
4

Low-pressure cylinder of BL20 up to -150 and

BK20 up to -100

Bolt
Joint
O-ring
Spring

5
6
7

Outlet valve guard

Outlet valve disc
Valve seat

Disconnect cylinder
head cover (12) from
the inlet and outlet
pipe flanges.
Remove cover (12).

High-pressure cylinder of BL20 up to -75(B),

BL100(B)-50Hz and BK75

8 Inlet valve disc

9 Guide pin
10 Joint

11
12
13
14

Cylinder
Cylinder cover
Cylinder head
Joint

Figs. 5.1 and 5.2 Cylinder heads

2920 1421 00

15

Instruction book

BL20/75(A)
BL100(A) 50 Hz
BK20/55
BL100(A) 60 Hz
LP Cylinder
BL150(A)
LP Cylinder
BL20/150(B)
LP Cylinder
BK75/100
LP Cylinder

BL100(A) 60 Hz
HP Cylinder
BL150(A)
HP Cylinder
BL20/150(B)
HP Cylinder
BK75/100
HP Cylinder

Operation sequence

BL20/75(A)
BL100(A) 50 Hz
BK20/55
BL100(A) 60 Hz
LP Cylinder
BL150(A)
LP Cylinder
BL20/150(B)
LP Cylinder
BK75/100
LP Cylinder

BL100(A) 60 Hz
HP Cylinder
BL150(A)
HP Cylinder
BL20/150(B)
HP Cylinder
BK75/100
HP Cylinder

Operation sequence

Disconnect head (13)

from the inlet and
outlet pipe flanges.
Remove cylinder
head cover (12).
Remove head (13).

Install a new outlet

valve disc (6), guard
(5) and spring (4).

Remove spring (4),

outlet valve guard (5)
and outlet valve disc
(6).

Lift off valve seat (7)

and remove inlet
valve disc (8). Do
not remove guide
pins (9).

Remove and discard

all O-rings and
rubber joints.

If necessary, remove
the carbon deposits
from the inlet valve
guard at the cylinder
top. Take care that
no dirt drops into the
cylinder.

Clean and inspect all

parts.

Fit a new joint (10).

Do not stretch the
cord while inserting
it in its groove; the
ends should meet.

Put a new inlet valve

disc (8) into place
and install valve seat
(7).

Fit a new O-ring (3)

and joint (2).

16

Install cylinder head

cover (12). Use new
flange gaskets, if necessary. Fit the
flange and cylinder
head bolts and tighten them alternately.

Reinstall head (13).

Fit a new joint (14).
Install cylinder head
cover (12). Fit the
flange and cylinder
head bolts and tighten them alternately.

Reinstall the fan

guard, cover of the
air inlet silencer, air
filter, cover (1-Fig.
1.1) and cap.

Torque values
M6:
10 Nm +/- 2
M8:
23 Nm +/- 2
M10:
46 Nm +/- 5

5.3 Air filter

1. Stop the compressor.
2. On BL/BK20 up to -75 and BL100-50 Hz: unscrew the
cap on top of cover (1-Fig. 1.1). Lift off the cover and
filter element. Take care that no dirt drops inside the suction
silencer.
On BL100-60 Hz, BK100, BL150: unscrew cap (1-Fig.
1.7) and take out the air filter. Take care that no dirt drops
inside the suction silencer.
3. Using a damp cloth, clean the filter chamber and cover.
Discard damaged elements.
4. Install the new element, cover and cap.

2920 1421 00

Instruction book

5.4 Air pressure switch

Caution
- Switch off the voltage before removing the cover of the
switch; reinstall it after an adjustment has been made and
before the voltage is switched on again.
-

1
2

Adjustment may only be carried out when the air pressure

switch is pressurized.

5.4.1 Adjustment for MDR4 (Fig. 5.4)

The switch allows the operator to select the stopping pressure
and the pressure difference between stopping and starting
pressures. The stopping and starting pressures are the opening
and closing pressures of the switch.
50982F
The stopping pressure is controlled by adjusting screw (1).
Turn the screw clockwise to raise the stopping pressure, anticlockwise to lower it.
The pressure difference between starting and stopping is
adjusted by means of adjusting screw (2). The adjustment range
is given in Figs. 5.5 and 5.6. Turn the screw anti-clockwise to
reduce the pressure difference, clockwise to increase it.

1
2
3

Adjusting screw, stopping pressure

Adjusting screw, pressure difference

Fig. 5.4 Adjusting screws, MDR4

50960F

Air pressure switch

Loading solenoid valve
Safety valve

Fig. 5.3 Air pressure switch MDR4

2920 1421 00

1
2

Fig. 5.5 Pressure difference diagram, switch MDR4/11

Example:
Stopping pressure: 7 bar(e)
Starting pressure: adjustable between 3 and 5.7 bar(e)
17

Instruction book

5.4.2 Adjustment for MDR6 (Fig. 5.7)

The maximum (stopping) pressure is controlled by adjusting
knob (1).
Turn the knob clockwise to raise the maximum or stopping
pressure, anti-clockwise to lower it.
The pressure difference is adjusted by means of the same knob.
Push down the knob and turn it clockwise to reduce the
difference between the stopping and starting pressures, i.e. to
increase the starting pressure. Turn the knob anti-clockwise to
increase the pressure difference. The adjustment range is shown
on the diagrams (Figs. 5.8 and 5.9).

Fig. 5.6 Pressure difference diagram, switch MDR4/25

1
Fig. 5.8 Pressure difference diagram, switch MDR6/11

50974F

3
1
2
3
4
5
6

Adjusting knob for stopping and starting pressures

Spring housing, air pressure switch
Pressure release valve
Setting dial, overload relay
Motor overload relay
Switching mechanism

Fig. 5.7 MDR6

18

Fig. 5.9 Pressure difference diagram, switch MDR6/16

2920 1421 00

Instruction book

5.4.3 Adjustment for MDR3 (Fig. 5.10)

The switch allows the operator to select the stopping pressure

and the pressure difference between stopping and starting
pressures. The stopping and starting pressures are the opening
and closing pressures of the switch.
The stopping pressure is controlled by adjusting screw (2).
Turn the screw clockwise to raise the stopping pressure, anticlockwise to lower it.
The pressure difference between starting and stopping is
adjusted by means of adjusting screw (3). The adjustment range
is given in Figs. 5.11 and 5.12. Turn the screw anti-clockwise
to reduce the pressure difference, clockwise to increase it.

5.5 Safety valve (3-Fig. 5.3) 1)

Replace the valve if it does not open at the correct pressure.
No adjustments are allowed.

51052F
1 Dial, overload relay
2 Adjusting screw, stopping
pressure

3 Adjusting screw, pressure

difference
4 On/off switch

Fig. 5.10 Air pressure switch MDR3

1. Close the air outlet valve, depressurize and disconnect the

hose or pipe from the valve.
2. Start the compressor and run it until it stops automatically.
3. Switch off the voltage.
Remove the cover from the air pressure switch and, with
the air receiver now under pressure, turn the adjusting knob
or screw one turn clockwise to increase the stopping pressure
(see also section 5.4). Reinstall the cover.
4. Switch on the voltage, slightly open the outlet valve and
start the compressor.
5. Gradually close the outlet valve while checking the air
pressure gauge. If the safety valve has not opened at the
pressure specified in section 7, it must be replaced by a
new one. If the compressor unloads before the specified
opening pressure is reached, repeat the procedure as
mentioned from step 3.
6. Readjust the pressure switch as described in section 5.4.
7. Reconnect the hose or pipe to the closed air outlet valve.
Fig. 5.11 Pressure difference diagram, switch MDR3/11

5.6 Relief valve (8-Fig. 1.1) on BL/BK twostage

The relief valve protects the LP side of the compressor. No
adjustments are allowed.
Remove the relief valve and fit a 3/8 inch B.S.P. plug instead.
Remove the safety valve from the air receiver and replace it by
the relief valve. The latter can then be tested at increasing air
receiver pressure after the compressor has been started with
open air outlet valve. If the valve has not opened at the pressure
specified in section 7, it must be replaced by a new one.
Reinstall the valves in their respective places after testing.

Footnote chapter 5
1) Not on Compressor Block/motor-compressor set.

2920 1421 00

Fig. 5.12 Pressure difference diagram, switch MDR3/25

19

Instruction book

6 PROBLEM SOLVING
1 Insufficient air pressure
a Air leak
a Check and correct as necessary
b Air filter choked
b Replace filter
c Air pressure switch incorrectly set
c Adjust switch
d Air consumption exceeds maximum output of
compressor
d Check equipment connected
e Damaged valve
e Inspect valves and replace parts where necessary
f Unloader 1) malfunctioning
f Inspect and replace parts where necessary
g Solenoid valve 1) out of order
g Remove and check. Replace if necessary
2 Unit does not speed up
a Voltage drop at motor terminals
a Consult power supplier. Use correct size of cable
b Unloader malfunctioning
b See 1f
c Solenoid valve out of order
c See 1g
d Blow-off silencer 1) choked
d Replace
3 Air receiver pressure rises above maximum and causes
safety valve to blow
a Air pressure switch or regulating valve 1) incorrectly
set or out of order
a Check. Replace switch or valve, if necessary
b Solenoid valve defective
b See 1g
c Unloader malfunctioning
c See 1f
d Blow-off silencer choked
d See 2d

7 High oil consumption on BL compressors

a Oil level too high
a Do not overfill crankcase. Keep level in red circle of
sight-glass
b Piston ring(s) worn or broken
b Have condition of piston rings checked
8 Unit does not start
a Electrical failure
a Have electrical system checked. Check fuses and line
terminals for tightness
b Overload relay cut out
b Reset overload relay. If the relay cuts out again after
starting, see point 9
c Air pressure above pre-set starting pressure
c Compressor will start when air pressure is lower than
pre-set starting pressure of air pressure switch
9 Overload relay cuts out
a Overload relay incorrectly set
a Check and adjust. Reset relay
b Solenoid valve out of order
b See 1g
c Unloader plunger jammed
c See 1f
d Blow-off silencer choked
d See 2d
e Ambient temperature too high
e Improve ventilation of room
f Motor stops and starts too frequently
f See 6
g Overcurrent due to motor or compressor failure
g Consult Worthington - Creyssensac

4 Relief valve blows 1)

a Defective inlet valve in HP cylinder head
a Inspect and replace part(s) as necessary
b Relief valve not airtight
b Replace valve
5 Receiver does not hold pressure
a Check valve leaks
a Check for broken valve and springs
b Air leaks
b Check and correct as necessary
6 Too frequent starting/too short operating periods
a Air pressure switch or regulating valve 1) incorrectly
set
a Increase pressure difference
b Check valve leaks
b See 5a

20

Footnotes chapter 6
1) If provided.

2920 1421 00

Instruction book

7 PRINCIPAL DATA
7.1 Reference conditions
Inlet pressure (absolute) . . . . . . . . . . . . . . . . . . . . . . . . . bar
Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . %
Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . C

1
0
20

Working pressure:
- BL version A (10 bar) . . . . . . . . . . . . . . . . . . . . . . . . . bar(e)
- BK 10 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e)
- BL version B (15 bar) . . . . . . . . . . . . . . . . . . . . . . . . . bar(e)

7
7
12

7.2 Limitations
Minimum inlet temperature . . . . . . . . . . . . . . . . . . . . . . C
Maximum inlet temperature . . . . . . . . . . . . . . . . . . . . . . C
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . bar(e)

0
40
See below

7.3 Compressor data for BL 10 bar

7.3.1 50 Hz
Compressor type

Maximum working pressure . . . . . . . . . .

Temperature at outlet valve, approx. . . .
Power input at max. working pressure . .
Motor shaft speed . . . . . . . . . . . . . . . . . .
Free air delivery 3) . . . . . . . . . . . . . . . . .
Oil capacity . . . . . . . . . . . . . . . . . . . . . . .
Opening pressure of safety valve . . . . . .
Maximum sound pressure level 1) . . . . .

bar(e)
C
kW
r/min
l/s
l
bar(e)
dB(A)

BL20(A)

BL30(A)

BL55(A)

BL75(A)

BL100(A) BL150(A)

10
40
1.82
1500
3.4
0.8
11
78

10
44
2.54
1500
4.4
0.8
11
79

10
66
4.57
1500
8.4
0.8
11
79

10
59
6.11
1500
11.7
1.4
11
80

10
80
8.28
1500
15.7
1.4
11
81

BL20(A)

BL30(A)

BL55(A)

BL75(A)

BL100(A) BL150(A)

10
49
2.36
1800
3.9
0.8
11
80

10
54
3.38
1800
5.1
0.8
11
81

10
80
6.36
1800
9.7
0.8
11
81

10
74
7.57
1800
13.6
1.4
11
82

10
59
9.97
1800
17.4
1.7
11
83

10
65
10.69
1500
18.6
1.7
11
84

7.3.2 60 Hz
Compressor type

Maximum working pressure . . . . . . . . . .

Temperature at outlet valve, approx. . . .
Power input at max. working pressure . .
Motor shaft speed . . . . . . . . . . . . . . . . . .
Free air delivery 3) . . . . . . . . . . . . . . . . .
Oil capacity . . . . . . . . . . . . . . . . . . . . . . .
Opening pressure of safety valve . . . . . .
Maximum sound pressure level 1) . . . . .

2920 1421 00

bar(e)
C
kW
r/min
l/s
l
bar(e)
dB(A)

10
67
12.83
1800
21.9
1.7
11
84

21

Instruction book

7.4 Compressor data for BK 10 bar

7.4.1 50 Hz
Compressor type

Maximum working pressure . . . . . . . . . . . . . . . . . . . .

Temperature at outlet valve, approx. . . . . . . . . . . . . .
Power input at max. working pressure . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free air delivery 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening pressure of safety valve . . . . . . . . . . . . . . . .
Maximum sound pressure level 1) . . . . . . . . . . . . . . .

BK20

BK30

BK55

BK75

BK100

10
40
2.05
1500
3.1
11
82

10
44
2.71
1500
4.0
11
83

10
45
5.11
1500
7.6
11
83

10
50
5.89
1500
9.2
11
84

10
51
8.65
1500
14.4
11
86

BK20

BK30

BK55

BK75

BK100

bar(e)
C
kW
r/min
l/s
bar(e)
dB(A)

10
49
2.36
1800
3.6
11
84

10
54
3.10
1800
4.6
11
85

10
54
5.89
1800
8.8
11
85

10
60
6.70
1800
10.7
11
86

10
58
10.66
1800
17.1
11
88

BL20(B)

BL30(B)

BL55(B)

BL75(B)

BL100(B) BL150(B)

15
49
2.29
1500
3.1
0.8
16
6.5
78

15
57
2.87
1500
4.0
0.8
16
6.5
79

15
68
4.95
1500
6.7
0.8
16
6.5
79

15
56
6.64
1500
9.2
1.4
16
6.5
80

15
75
8.67
1500
11.7
1.4
16
6.5
81

bar(e)
C
kW
r/min
l/s
bar(e)
dB(A)

7.4.2 60 Hz
Compressor type

Maximum working pressure . . . . . . . . . . . . . . . . . . . .

Temperature at outlet valve, approx. . . . . . . . . . . . . .
Power input at max. working pressure . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free air delivery 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening pressure of safety valve . . . . . . . . . . . . . . . .
Maximum sound pressure level 1) . . . . . . . . . . . . . . .

7.5 Compressor data for BL 15 bar

7.5.1 50 Hz
Compressor type

Maximum working pressure . . . . . . . . . .

Temperature at outlet valve, approx. . . .
Power input at max. working pressure . .
Motor shaft speed . . . . . . . . . . . . . . . . . .
Free air delivery 3) . . . . . . . . . . . . . . . . .
Oil capacity . . . . . . . . . . . . . . . . . . . . . . .
Opening pressure of safety valve . . . . . .
Opening pressure of relief valve . . . . . .
Maximum sound pressure level 1) . . . . .

22

bar(e)
C
kW
r/min
l/s
l
bar(e)
bar(e)
dB(A)

15
72
12.10
1500
18.1
1.7
16
6.5
84

2920 1421 00

Instruction book

7.5.2

60 Hz

Compressor type

Maximum working pressure . . . . . . . . . .

Temperature at outlet valve, approx. . . .
Power input at max. working pressure . .
Motor shaft speed . . . . . . . . . . . . . . . . . .
Free air delivery 3) . . . . . . . . . . . . . . . . .
Oil capacity . . . . . . . . . . . . . . . . . . . . . . .
Opening pressure of safety valve . . . . . .
Opening pressure of relief valve . . . . . .
Maximum sound pressure level 1): . . . .

bar(e)
C
kW
r/min
l/s
l
bar(e)
bar(e)
dB(A)

BL20(B)

BL30(B)

BL55(B)

BL75(B)

BL100(B) BL150(B)

15
57
2.49
1800
3.6
0.8
16
6.5
80

15
66
3.44
1800
4.7
0.8
16
6.5
81

15
81
6.16
1800
7.9
0.8
16
6.5
81

15
65
8.27
1800
10.9
1.4
16
6.5
82

15
40
9.28
1800
14.2
1.7
16
6.5
83

15
76
14.55
1800
21.4
1.7
16
6.5
84

7.6 Conversion list of SI units into British/American units

1 bar = 14.504 psi
1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)

1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 m = 3.281 ft
1 mm = 0.039 in

1 m/min = 35.315 cfm

1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x degrees celsius = (32 + 1.8 x) degrees
fahrenheit 2)

Footnotes chapter 7
1) According to CAGI PNEUROP PN8NTC2.2.
2) A temperature difference of 1 degree celsius = a temperature difference of 1.8 degrees fahrenheit.
3) At reference conditions

2920 1421 00

23

Instruction book

8 ELECTRICAL DIAGRAMS

Fig. 8.1 Electrical diagram of single-phase BL/BK with direct-on-line starter

Fig. 8.2 Electrical diagram of 3-phase BL/BK20 up to -75 with direct-on-line starter
24

2920 1421 00

Instruction book

Fig. 8.3 Electrical diagram of 3-phase BL55 up to -150 and BK55 up to -100 with star-delta starter

F1/3
F4
K1
K2
K3
M

Fuses
Overload relay
Line contactor
Star contactor
Delta contactor
Compressor motor

MDR
P1
S1
T1
Y1
X1

Air pressure switch

Hourmeter, running hours
On/off switch
Transformer
Loading solenoid valve
Terminal strip

Figs. 8.1 up to 8.4 Electrical diagrams

2920 1421 00

25

Instruction book

Fig. 8.4 Electrical diagram of 3-phase BL/BK55 up to -150 and BK55 up to -100 with transformer and star-delta starter

26

2920 1421 00

Instruction book

9 INSTALLATION PROPOSALS

Fig. 9.1 Installation proposal for compressors on horizontal air receiver (120 l)

Fig. 9.2 Installation proposal for compressors on horizontal air receiver (250/475 l)
2920 1421 00

27

Instruction book

Fig. 9.3 Installation proposal for compressors on vertical air receiver (250 l)

28

2920 1421 00

Instruction book

10 DIMENSION DRAWINGS

Fig. 10.1 Dimension drawing, BL20/55 compressors on horizontal air receiver (120 l)

2920 1421 00

29

Instruction book

Fig. 10.2 Dimension drawing, BL15/40 compressors on vertical air receiver (250 l)

30

2920 1421 00

Instruction book

Fig. 10.3 Dimension drawing, BL55 compressors on horizontal air receiver (250/475 l)

2920 1421 00

31

Instruction book

Fig. 10.4 Dimension drawing, BK55/75 and BL75/100 compressors on horizontal air receiver (250/475 l)

32

2920 1421 00

Instruction book

Fig. 10.5 Dimension drawing, BK20/30 and BL20/55 compressors on frame

2920 1421 00

33

Instruction book

Fig. 10.6 Dimension drawing, BK55/75 and BL75/100 compressors on frame

34

2920 1421 00

Instruction book

Fig. 10.7 Dimension drawing, BK100 and BL100/150 compressors on horizontal air receiver (250/475 l)

2920 1421 00

35

Instruction book

Export Department

U.K. Operation

France

Great Britain

Phone : 33 (0) 3 44 52 67 31
Fax : 33 (0) 3 44 52 67 35

Zone industrielle BP
4 rue mile Zola
F-60114 Mru Cedex

Phone : (01474) 322 999

Fax : (01474) 325 052

C5 Springhead Industrial Estate

Northfleet Gravesend
Kent DA 11 8HD

Worthington - Creyssensac
http://www.airwco.com

36

2920 1421 00