LeROI Gas Gompressors

By Rotary Gompression Technologies, lnc.

ISO 90{rl-t]t:oCI

Rotary Screrr- Compressor

Models:
HGlO
HGFlO
HG12
HGFU
HGS17
HGSF17
HG17
HG24
LG3O
LGI*30

LeROI.
RCT-INST0O1 Rev 6 -8108
ECN 4U31ó

t
ROTARY COMPRESSION TECHNOLOGIES, INC.
THANKS YOU FOR PURCHASING LEROI GAS
COMPRESSORS, MODULES AI{D PARTS
Safety lnformation and Warnings

Protecting Your Compressor Before Service

I dentifying Your Compressor

U nderstanding Your Compressor

The Compressor System

Oil Flow and Orifice Sizing 7-10

Variable ViAdjustment 11-13

Versatrol (Capacity Control) 14-15

Oil and Related ltems 16

lnstallation 17-18

lnstallation - Component Location 19

Operation and Preventive Maintenance

Service Procedures - Components 21-29

Rebuild Kits 30

Website 31

Contact List 32

Service Diagnosis 34

Warranty 35
 Safetv Information and §Tarnings
LeROI gas compressors are designed with safety in mind. Howeveq there is no substitute

for safe operating procedutes. Throughout this manual üere will be additional "Notes",

"Caud.ons" and'qWarnings" intended to ptotect the operator and the equipment. These

additions are not all inclusive. Extueme care must be exetcised when operating or servic-

ing this eqüpment.

A Careful Operator is the Best Insurance against an

The operator and or serviceperson should:

o Be knowledgeable of one's equip¡oent.

a Develop safe work habits.

a Never operate a unit without guards and shields in p1ace.

a Never operate a unit that is not proper\ electrica\ grounded.

a Never serl-ice a unit with the pressure in the receiver-oil reservoir unless

following specifi c operation manual instrucdons.

Never serr-ice a unit without disconnecting and locking out the electrical

power supply unless follow-tng specific operadon manual instructions.

Take a1l riecessary precautions, when ad)usring controls, etc., to prevent elec-

trical shock.

Take all necessary precautions when rvorking \r1th flammable gases to pre-

vent fire or explosion.

 Protecting, úr Compressor
a
Béfoie, ServiCe

THIS COMPRESSOR IS SHIPPED WITHOUT OIL. ALTHOUGH

RE,SIDLIAL OIL FRONT TFTE F.\CTORY TEST IS SUFFICIE,NT TO PREVE,NT

RUST DURING SHIPPI\G. IT DOES NOT PROVIDE, ADEQUATE,

PROTE,CTION F'OR STOL\GE

IF THE CON{PRE.SSOR §rILL NOT E,NTER S;i.-,,-]I-E \\-ITHIN ONE, \'EEK OF BE,ING
RECEI\'ED, COMPRESSOR OIL MUST BE ADDED II]ROUGH THE, GAS INLE,T SO THAT

iTS LE.VEL IS AT LE,AST AS HIGH AS THE BOTTC)],{ OF THE INLE.T CAVITY ALLO§r A FE§r

\II\UTE,S FOR THE, OIL TO FILL INTE,RNT.\T CLE.\R-\\CES THEN ADD TO BRING LE,VE,L
B.\CK UP. REINSTALL THE INLET COVER PL{TE AND BOLT IT DOWN SECURELY.

THE, DRIVE SHAFT MUST BE ROTATED ,: TT RN MONTHLY TO INSURE, THAT ALL

N{OVING PARTS HAVE AN OIL COATING.

2
 Identifving Your Compres sor
LeROI gas compressots have a nameplate that ptovides valuable informadon

on your compressor. This information is needed for ordering parts and con-

version kits, as lvell as for accessing \ñ'arrant\- information and understanding

the design of the compressor. Belorv is a Nlodel Designauon chart to help vou

identify your compressor.

LeROI-RCT Model Designations - September 1, 2006

FDrbaresha&comprEssDrs,thefrstletterdesig¡alesLowPrEssureorHighPressureDesign Thisis¡hEsamewheflf6llowirganlü
The next etler designales gas This never changes
When the c0mpressor is drilen ofilhe fema e ro10r inslead ofthe mále rolor (the slandard), an F @ill aplear n this spol
ATwi iFper in lhrs spotfortwo staqe compressErs
AnSorarLwl appearf

the rated HP ofthe module

3
 {Jnder§tanding Your Compre s_s or
\bur compressor is either a LG ,Lc,r Pressure) or HG (Hrgh Pressure) single stage,

positive displacement, oil-flooded scre-¡- compressor. There are two basic general

configurations; geared (trrgure 1) ani Dc)n-geared (Frgure 2).

b-igtre / - geared comprexor L-iyre 2 - Tl,pical non-geared comprexor

Orl-flooding provides cooling, lubrication and sealins r üe compressor. The oil must be cooled using either
§-ater or at in a heat exchanger that is properly sized ¡,:,: .ll :,perating conditions.

Geared uruts (Figure 1) come standard with integral ge::::: :l Lncrease or decrease the speed intetnall¡
allorving for direct connecdon with standard drivers. Ti:. ;::-.-c rnput) shaft is an integral ertension of the
male rotor. Compressors with gears use an independe:r: r::.': .hail, commonly referred to as a jackshaft,
mounted on roller andf or special deep groove ball be.:----. re gear mounted on the iackshaft drives the
gear mounted on the male rotot and the male totor mr.::=. ;":::: and drives the female rotor.

Fgu¡e 3 shows the direction of the rotor rotation

andúe gs/onflow through the compressor. Note
úet üis florr¡ is between the rotots and the inside
diarr¡e,re¡ (bore of the cylinder).

The uncompressed gas entets the compressor at the

fulet flange, passes into the front bearing retaifier,
and eates the cylinder bore at the ftont (inlet) end.
(F'Igsre 3). As the gas passes a predetermined inlet
cm-off point in the cylinder, compression takes place
due to decreasing totor to cylindet volume as the
Figure 3 - Oil/Gas Flow-Typical rtrtt>rs tum. Gas at the desired pressure is discharged
at ¡l¡e rear (discharge) end. Oil is injected into the
rmpressor at specific locadons for cooling.

4
 tt

The I-eROI gas compressor is one pafi of the compressor s'.':t.n. The compressor combined üth the drirrcr

forms üe heart of üe svstem. FIou-eveq the oüer rital elemenr: .rre essential to eflsule üe heart of \.our sr.stem

continues to operate.

Suction Scrubber (uitb flnatiau {necessary)

This is required to prer''ent the carry over of üqüds into üe compressor. Filt¡auon i: otten nece::.rfl, especiallv in vacuum installatioos, to

prevent debns (e.g. hon sulfides) from getting into the compressor.

Gas/AlSeparator

1'he gas/oil separator is a kev component of üe compressor system. The separator should be designed to handle the ma-timum capaotv at

the lorvest discharge pressure and the hrghest discharge temperature. It is impon;rnt d-r¿t dre r e ssel '¡rd coalescing filter a¡e sized propedv

to insure optimum gas and oil separation. The separator also acts as üe oil resel1-o1r .or1 sump.. siü the oil collecting in üe bottom.

Oil Coobr

The oil cooler is an air cooled or u,ater cooled heat exchanger that is sized to srut üe slze c¿p¿otr , of the compressor berng cooled. 'fhe

cooler should be desgned to handle üe worst operating condition, which is usuallr- i,¡¿sed on dre los-est suction pressure and the highest

discharge pressure. Horveveg üe oil flow plal s a critical role in determining the heat ¡elecdon of the oil cooler.

Minimum Prcsstre Vahte

The minimum pressure vah'e is recommended to maintain a minimum pres.ure in rhe q.r. o11 seperrltor. It is especiallrv importaflt to use

üis der,-ice when the possibiütv exists that the system pressure ma)¡ not be sui6o.nr tn mlrnT.r11 f ressure in üe seperator to achie\.e

adequate gas /oil seperation.

TbermalBy-Pass Valae

The injection temperarure of üe oil used to cool, seal, and lubricate the compressor i. conrolled br the thermal bv-pass r,alve.

As the name implies, this valve allorvs part or ali of the oil flow 16 f1:pass the oil c,¡,ri¡r deoendmg ofl the temperarure of the oil

leaving the compressor. This 'r,ah,'e can be controlled thermostatjcallr' or t'ith more soplusticated temperanrre cofltrol valve where

more precise control of oil temperarure is required.

5
 Oil Fiher

It i: -\-'ri:r].'1: rjn: ']r:'r'nr that the comp:-:: : - ::: .-.: possible. The oi1 filter should be generoush, sizer-1
oil injected into the

to i-1"::i'' ::- l - '''. -'.rcl -sl1r¡u1d have a filter element that -¡. -.^ : r..:-:--:
- do\yfl to 10 micron. If the co'-rpressor is in an
applicaú,:,n \\-hcr- c, :t-rjt . ,Lls operadon rs tm¡ortant or rrh.:. -:. : j :t - i¡tr_ in a short period -_: of time, it is recommendecl
tl'rat a ciual fi1ter arranq.nen¡ be used.

In¡tntmentatioru and Contro k

The compressorhas operaringlimitations thatmustbemom: ::- :: -:--- : ---.-rccs arereclurrecl ro thepfotectthe compressor
ilon: ¡rperlencing a catastrophic failure. These include, bur ar. :- :: . - lr-qh
-:--- remperature and pressure, as rvell as üquid
ici el ss-itches in the sucuon scrubbe r u,.here there is a poten:.- : : --. .jnts
:.r_-
- oi [quid in the gas stream.
, :::a SEP ELEII4ENT
PRES, GAUGE
TEI.IP SWITCH

SHUT OFF VALVES

SEPARATOR DRA]N
LINE PRESSURE RELIEF
VALVE

CHECK VALVE
SEPARATOR --] ..
TUBE
ELEMENT)
COMPRESSOR iNLET
3l:lT'.1'^."- : --={EL

LOW OIL
PRESS SWITCH
ALTERNATE PRESSURE
RELIEF VALVE
WITH EXTENDED
OIL FILTER VENT FIPE
GAUGE

GAS AND OIL

OIL COOLER OIL FILTER

GAUGE otL
SHUT OFF
THERMAL B' VALVE \
VALVE

SHUT OFF VALVE

GAS DiS'FTi::

FROM ¡NLET
FI LTER, SCRUBBER,
MOISTER
SEPARATOR,,-EIC

CHECK VAL\/=
i

AIR COOLED
TO RECEIVER-i
OIL COOLER OIL RESERVO R
STARTING UNLOADER
(BYPASS VALVE)
Figure 4 - Typical Basi.c piping Diagram

6
 As mentioned prer,'iousl1. in this manual, rotar\- scre\\- compressors require oil lubricauon

of the bearings, cylinder and rotors. Beanng lubrrcation i-s necessar\. for long ltfe. C1ünder

and rotor lubrication does three things:

7. Reduces friction betr,veen the rotors

2. Prol-ides a seal betw-een the c),linder and rotors to reduce gas shppage.

3. Cools the gas.

In certain appücations the pressure diffetential (discharge-sucrion) is such that an oil pump is not required.

Holever, if the appJication has a lor¡,'er pressure diffetenual than an oil pump urllbe required. It is impor-

tant for the application to be ter.ieu,ed especiaily if the unit s.iL1 be mored trom one site to another resulting

in diffetent conditions.

Figare 5 - Tltpical Oil Flow Figare 6 - Oi¡1n Installation

LeROI gas compressors have an oil injection manifold that distributes oil supplied by the pump or pressure

differential. The orifice creates a restriction. A smaller orifice results in a greater restriction, which forces

more oil to the bearing and less oil to the rotors. The goal is to create a proper balance in the compressor

for reliabie operation.

7
 Pumps are installed at the factorr- bas.i :n packager instructions or specified operating

conütions. Everv LeROI ColnpreSSr,: -s :¿sred at the factory to ensure reiiable operation.

-\fter testing, the standard orifice or ::: , ince specified bv the customer is installed in the
urrit.

MISSIONING OF THE COMPRESSOR PACIT.{GE.

There are several size options for each compressor. I:: .r:- ¡r-ent that an orifrce is needed and one is not

readilr' alzilabie one can easily be created. Simplv drLLir: ..- :r, .¡ rn a soLid plug wiil pror.ide the orifice. It is

also important to note that you ma,v need to create ¿rr ¡,:i-,c. ;r ihe eyeflt \rour desired size is in betureen

manufacturer available sizes.

ture
Refet to Figure 7 for temperature and pressure methods :ni ic,cations.

Gas discharge temperature range: 175-210 "F

(Iemperature must be high enough to reduce condensation in separator tank.)

High temperature shut down: 230.F

(Switch must be located between compressor discharge flange and separator tank inlet.)

WARNING! NEVER EXCEED 230"F DISCHARGE

8
 For Most Situations:

Temperature rise - From oil injection to gas discharge: 30 - 40" F

For beaay gas strentns, a 30-40 "F ternperature dffirence lnay not be possible

Temperature rise - From oil iniection to üscharge bearing oil drain: 15 "F

'ARNING! NEVER EXCEED 2O"F BEARING RISE

Oil pressure difference - gas inlet versus oil injection: 60-100 psi

(X/hen gas discharge pressures are 50 psig or less, it may nor be possible

to achieve 60 psig oil pressure. That is acceptable if all other specihcations are met.)

Oil üscosity at injection temperature: 13-40 cSt

(Refer to oil suppJier dam for viscosit\. at acfual injection temperature.)

9
-4

Temperature/Viscosiry / P rcs sure

For Most Situations:

Temperature rise - From oil iniection b gB discharge: 30 - 40' F

For beauy gas srTeams, a 30-40 oF tenptüc ffemue rna! not be possible
Temperature rise - From oil injection o disch¡qe bearing oil drain: 15 "F

,ARNING! NEYER EXCEED zO"F BEARING RISE

Oil pressure difference - gas inler versus oil iniection: 6U-100 psi

(üíhen gas discharge pressures are 50 psig or less, it irr.,- .- - re possible

to achier.e (r0 psie oi1 pressure. That is acceptable ii r- r.: specifications afe met.)

Oil viscosity at iniection temperature: 13-40 cSt

(Refer to oil suppher data for l-rscosiw at actualinjcc-_ :: :.-::;rature.)

9
 Equ:e:::e::: & \f e¿s¡-rrement Location :- - -,:: i-:,rSurements atpoints t\, B, and C should
-
-: - I i:--_ rrs of pipe or tube (not fittings) as
-, .: - :¡:: , ---'.: :::-t- -:-lcnt instlumentation is .-:
i-c-ss.trr, rttti t1-_ 1, r-:t- or-etall package per_
- : - :tt:trcssof aSpossible.
i-1-rrrrAnce. the i - -; ._: ...re specillcally for the
p-i:p{rs. oi er-al,--._:_- -.r. pump and orifice siz.,
. :, -- : ::.: D and E should be as close to the
T:.b,¡ I Insúum.:,. -t lrleasurement Locations
- - . -- : ,., : ssrb1e. There is npicalll. an unused
, " - ': :: -.don manifold for E. Point D is
11:=ÍÉai Loc¿tion -, : - r-, . --.,,,qe inletpiping. If pressures are not
:::.::.: lR
_::l-l:t-::tft
: : i--l_,tl
---::a:a-:::
(A) prpe - :' : r : : r:-ic locations, the1. s[6.r1¿ at least be
-- :
pip.
r -:. i:a-r.r¿t @)
- ::_)re ssor side of anr maior restrictions
:::ll-::--:f (C) rubc (goes 'i ,-- 'aa
- - -
: : ::- :::: beating oil dou-n on some
l: : ::::_:'.:lmfc models)
rfessufe gage of
.: ::. . i- -:a isufe (D) inlet pipe Larger pump or orflce is
tansduccr 1

Pressure gage or required, Use performance

@,) injection
program to resrze
manifiild

Smaller pump or orifce is

required. Use performance
program to resize

Reduce oil injection temp

by changing cooler or
thermostat
Figure 7 -Tbmperature / Pressure Measurement Locations

Nthough probes insered directly in the gas

or oil stream will give more accurate results,
an infrared (IR) temperature gun is rec-
ommended for this procedure. Since a Note: When gas disch
pressure is below 60 PSI it
probe cannor be readily used ori the discharge
may not be possible to
bearing drain, the IR gun szill allow a better achieve 60 PSI oil pressure,
even with the smallest orifice.
comparison.
This is acceptable if the
bearing oil drain temp is
within spec.
For be st results uüen using an IR gun, slo\Á¡h
mor-rng the IR gun over the item to obtain
the LLrghest temperature. Be careful not to
pick up temperatures from background
objects.

ro
Vadable Vi is used to minimize the pou¡er required by the compressor. It does not change f1ou. direct-
l,r,', but can allou, an increase in flou¡ through more eff,cient use of porr,'er. Vi is the yo/ame compression ratio of

a compressor: V1 / Y2. The intetnal Vi of the compressor is determined b,v the size of the discharge port.
A small port causes gas to be released later in the comptession cr-c1e resulttng in a higher internal Vi, a
"vhile
larger port allows the gas to be released eadier in the cvcle resulting in a lower internal Vi. The ideal Vi for
an application can be calculated if the inlet and discharge pressures and k (C./C,) of the €las are known.

The comoressor makes rhe mosr efñcient use of Dower rvhen rhe inrernal Vi equals the ideal Vi. For ex-
ample, if the internal Vi is high but the ideal Vi is low, the gas is compressed to a pressure greater than the
extetnal pressure prior to being released. On the other hand, if the internal Vi is low but the ideal Vi is high,
gas momentarilv flows backw-ard into the compressor and is re-compressed. Both of these scenarios result
in wasted energ\r

The standard discharge housings of the HG17, HG24, LG30, and LGL30 compressors have a 4.4Yrport,
but are fitted with four valves that can be opened to increase the total size of the discharge port, so that the
following internal Vi's can be achieved.

Vi -- 4.4 (HIGH) Al1r,'alves closed

Vi = 3.0 (N{EDIUL,D Two innet valves opened (two outer valves closed)
Vi = 1.9 GO\X) All valves opened

lnstructions
THE COMPRESSOR CAN BE VERY HOT!
PROTECT YOUR SKIN WHEN ADJUSTING A RUNNING OR HOT COM.
PRESSOR.

DO NOT TIGHTEN VAL\rES.

Valves are not intended to be closed or opened by tightening. Doing so may
damage the valve a¡d/ot compressor rotors. The valve should only be turned until
it "touches" the end of its stroke and then backed off about 1/16 af a turn.

The first item to be performed is to determine the ideal Vi of the application.

There are thtee ways to do this:

(1) Trial and etror - adjust the valves while monitoring horsepouret dtaw.
(2) Use the LeROI Screw Comptessor Petfotmance Program by alternatively selecting High, Medium,
and Low Vi on the Compressor tab, and see which results in the lowest horsepower.
(3) Calculate the ideal Vi mathematically (ot fuolr, a spreadsheet calculator available ftom wwvrleroigas.com):
vi - (Pr/P,),/n

lt
 rfulet
and discharge flanges. Be sure to account
tlrcssure ald increase the discharge pressure at
- .. : :--:r-:s t,r danges. As a quick refere r.-: - - qÉzl natural gas with k 1.26, the
= pressure
:,: r .-.,, J :ie spond to available intefna- -.::

\-r P] ,' P1
:
:
-
.:
Since the:¡ :.:¡ :rree available internal \-i :: _. -- :- _. - :.)\-er a range of ideal appJication Vi,s:

Greater üan 2.5, but not greater : -t --- I,I Inner valves open, Outer
than 3.,i ----, ¡-,-r.ed)
Less than or equal to 2.5 I LO\f lAll valves onened)
Aftet Determining the appropriate Vi ratio perform rhe following steps to adjust the internal
Vi ratio:

Figure 8:
::rre ssor discharge end showing four
- ,. j \-i r-a1r.es htted r¡'ith special locknut-
- - :: ..--
trotectofs.

, . ::¡ssof models mav also have an oil

- -u : :],-lLutted above the tu¡o tal\.es on
: ai'

I
ñgret
Xmre locknuts with wrench before mak-
ir1g adiustn-rents.

It k not necessary to remove the outer

lochuts if only the inner valves are being
¡fiusre¿

Thc model represented in the figure has a

fmp and is part of a package.

t2
 Figure l0: For MEDIUNf Vi, turn the in-
ner r-alr-es couriterciockrvise until ther. are
tulh- crut.

DO NOT FORCE THE VALVES.

Once ther- "touch" the end of their stroke
re\-erse tl-rem br- 1/16 of a turn. This a/so
trpp/les »,her ilo.ring talues.

Figure 1l: For LOW Vi, jn addition to

turrung the r-alves for I,ÍEDIUX{, tr-rrn the
outer r-alr-e,s counterclocks.ise untrl tl-rel' are
fi-rLh our.
,.:,,iirr

DO NOT FORCE THE VAI\'ES.

Once tl-rer- "touch" the end of their srroke
reverse them bv 1/16 of a turn. Tl.,i.¡ ¡l¡rt
applies a,lten cla.ring m ites.

Figure 12r Rernstall and tighten locknuts jr-r-st

snuglr's-hde hoiding vair.es so the\- do not
turn. The rzive positions in this figure are
los- \-i. \ote that all of the valves are our.
PERIODICALLY LUBRICATE THE
VAL\IE STEM THREADS §TITH
GREASE TO PREVENT RUST AND
ALLOW FOR FUTURE ADJUST-
MENT.

Figure 13: The val.",es in this figure are in

a NTEDIUNI \ri position (inner r.alves out,
outer r-alves in). It is not possible to hold
the outer valve while tightening the locknut
- just ughten the locknut lightly to prevent
jamming the valve.

t3
VersaÉol czpaorty control is used to regulate com[rrsrr flow and reduce power requirements.
Versat¡ol consists of a set of pressure actuated vafve ¡ts".Íilt¡i€s mounted on the side of the compressor.
When opened, these valves allow gas to leave the coqrasslm cvcle and returrl to the .o-p..rro, inlet prior
to compression and delivery, thus reducing flow and hoil¡qlorrer A valve is closed by applying actuating
prcssure and opened by releasing actuating pressure. Ttfo.-n be used to ramp up the compressor during
start up. Start üe compressor with all the ports open ' - dme them.

The by-pass valve assemblies are sometimes referred to r unloaders or pockets.

Versatrol is available on the HG12 and larger models Due to úe smali cylinder size, the Hc1,2has two
valves andanextetnalby-pass Fg"t. 14). AXlatgermoddshevefourvalveswithaninternalby-pass (Fig-
ures 15 and 16).

Figure 1+ - j-- Depending on actual operating

-
shos::lr' :,: . conditions, \¡ersatroi can reduce
tu,o\¡r..,:. t:. ilos, b\, approxrmatelr. 509/o and
ets. Scc, ,::-- ,-::- - porrrer b,v 25%. Versatrol can be
cal pocl--. -, :- :-:. operated in steps or stepless.
opposr:: .- -.
J'tE Contro/- each r.alve is fulh-
opened of closed. For each l-alr-e
opened in sequence, caprcin
and po\\rer r-r.ill be reduced br.
approximateh. 139ó and 60/o
t' Figure 15 -I{G77
respectir.eh,..
showing four
Vetsatrol pockers.
HG24 arrange-
ment is the same Step/ess Contro/- each valve is
(Pockets 2 aad posttioned anl-lrrhere between
4 are undet the fulh,6p.t .¿ and fully ciosed, thus
siu,.... ,ti., - .qdrI comptessor) thtotüng the b1-pass and allolr-
ing in{initeiv variable florv con-
{NSglillllllllllililliliillliitrliiiliil:llrrr'

trol. Stepiess control is achieved

Figure 16 through the use of electronic
-LG30 shou'ng conttols, rvhich monitors flou'and
four Versatrol po\ver, and adjusts valve posiuon.
pockets. (Pockets LeROI-RCT does not supplv con-
on HG17 and trol svstems, but thev are commer-
HG 24 are on ciallv ar.ailable,
the other side r

t4
 Versatrol Capacity Control
Actuation:
The Vetsatrol valves can be operated wtth prusuriqed au, gas or lubricating fluid depenüng on whether it is
step or stepless control. The actuation pressure should be üe same or nearlv the same as the compfessor
discharge pressure. The valves should be opened in the 1-2-34 sequerrce and closed in the 4-3-2-1 sequence,
except the HG12. The HG12 can be opened or closed in a-rr.¡'sequence.

Oil may be used fot either step or stepless control. Oil taken from úe gas/ oil separator or zfter the oil
pump should have adequate pressure to allow Versatrol actuation- Oil should alurays be filtered prior to
entering the control system.

Ait or gas can be used for step control systems only. Air and gas are compressible and will not allow accu-
rate or quick conttol tesponses. Air can be used for stepless control srstems s"ithout a problem.

As mentioned pteviously, the valve is unloaded or opened by rcducing the contol pressure. 'W-hen the
conttol pressure is teduced the highet pressure inside of the compressor opens the valve. Therefore, it is
important for the actuation pressure during the unloading stage to be lower than the cylinder pressure. To
erisure this occurs, the Versattol valve assembly should be vented to the c,vlinder inlet if acttztedby gas or
oil. If the m is used in the controi system then it will have to be veated to the atmosphere.

NE\rER UNDER AI{Y NE\'ER UNDER ANY

@ CIRCUMSTANCES VENT GAS OR

OIL TO THE ATMOSPHERE
CICUMSTANCES \IENT AIR
INTO A GAS COMPRESSOR

An oversight that occasionally occurs is the testing of a compressor on air with a

vacuum inlet. If the Versatrol valve is vented to atmospheric pressure, the valve fre-

@
Plumbing:
quently does not open because the pressure in the cvlinder is less than atmospheric
pfessufe.

Steel or stainless steel tubing and fittings should be used. Copper tubing i-s not recommended. Copper and
gas can react and reduce the reliabiliq, of your svstem.

Tubing runs should not be any longer than necessarv in order to ar-oid reduced response dmes betu,een
controls and the Versattol valves. Tubing should be 3 / 8" . Tubrng size increases in importance in cold envi-
ronments or when rubing runs exceed 4 feet.

Control Valve Selection:

Since actuating pressure is applied and released through the same port in the \rersatrol assemblli it is nec-
essary to use a valve that can be turned betrveen the pressure source and a r.ent (o-hnder for oil and gas,
atmosphere for air). Generalll', a three or a four-way valve is required. Three-rval- r.alves are a good choice
for manually operated Versatrol. Fout-way valves are best for automatic, stepless control slstems.

I5
 -l

t
Th¡- -'.-:'--''' r ::-:ll ls r-ital fot reiiable operation of - .-
'- -. - i--:rie ssors. Follou.ing these guideJines about oil
E ani :.-,. .-t - ..--: -: -lsure r-eats of teliable sefl,ice.
E

Starr-L p: l:r:rostart-upthecompressorsh _ - :- _-:--.

E

Oil Filter: t,.-.cck aiter first 100 hours. Chanf. : . ^ ,- : rntinuouslr¡ operated or e\¡ery 1000 hours
:r:.nr-i,se. Filtermustbechangeci . - r -I -i--¡,
'\' ¡1.re minimum a differential pre S, *:: -: - - :.. --i trrr the oil filter. A drfferenual gauge with
:-:t ¡arm is adr.ised.

Viscosity: The packagetf oser is responsible r, : .: : _-. ::-,..: ls compatible with

the gas, and can main-
trir rrinimum'iscosit\'' at the oper,..-. - - -- r!. Ti-re recommencled r.rscositl, 1. 15 centistokes
reEardess of the opetating condiu :-.- - -: r--r.:ttrr-r r-rscosifi,,is 13
centistokes regatdless of the
operating conditions.

oil rrscosiq-greaterthan15cends:-:::-.- ::-:,rmance,especiall¡,rhorsepowcr.

Analysis: Oil should be analvzed on a regula: : .,,. ,:-. '^-c ¡e checked once a rveek for the first month,
r¡-tth :t least t\¡/o of those samples b. :,. -1-., "r.cl. if rhe first month of samples is okal. then the
anal'' srs can be reduced to once a rr- .-'.. -:- --:-.1scs in water content
ancl metals should be r.r,atched
close'-'. -\i1 reputable oil suppJiers anr :r'-.
-- :-.lrers rvill analr-ze oil samples at no charge.
Recirculation: It is :nportant that the oil recircular¡. : : :: - -. ' , rimes per minute, especially with hear-ier
hr-d¡crcarbon and §'ater saturated gas;. , - : -r::s the oil temperature
high.i, thereb¡ reducrng
¡h¡ :r-.'ssibilin'of hldrocarbons coni.:,-.,-
---- ,,:rectrng the r.iscositr,'olit e oil, or har.ing u.atet
coaiense and cause lubrication prob.:, ,

Strainer: \\-hen thete is an oil PumP, it is rec, . .-: ,: - . : .. \--strainet be installed betrveen the separator
and the suction to the pump

It rs recommended that a Y-strainer '¡. .:., : , -.':tstream

- of where the oi-1 leaves the discharge
bearing retainer, andwhere it is injc-c:.: . -.: -.,:-:. This will reduce the possrbiüq, of a cata-
strophic failure if a bearing fails on :::. , ---:.. .1---

Coalescing: The coalescing element in the gas c,r' ,.:-: - : , : ¡e monitored with
- a differential pressure
gauge' This element should be chan:.: ,: .hould be checked at least once
-, i- - a r.ear. It is
imporrant rhar the {ilrer elemenr h.r-.i. -: __ --:--. -. ..rr-1 ro remo\e ril f.;;,h.;r;;*;*.
Gas Filtration: Gas filtration is recommended. Pafr:¡*- :-: .- - - : .-: :--:-:1m can contaminate the oil anci cause
premature failure.

Temperature: Oil temperature in and out of the re.: ' r::-:.: :: :-:-: .hould be checked regularil,.
If clifferential
is greater than 30oF, there may nor b; , ..: _.=::
--:--:_.a,ln for that are. This could also be an indi_
cation of worn bearings.

t6
 In§tallation
The compressor and pdme mover must be mounted on a rigid ftame so that the drive, piping, etc. are not
subject to strain andf or misalignment. Mounting holes are provided to securely zttzch the compressor.

The mounting surface must be a smooth, level surface tl'm;twill support tle weight of the compressot and
handle the associated vibration. Shims must be installed between the frame and the mounting surface to
elirninate strain on the frame.

Adequate airflow for cooling must be provided. Uncontrolled recirculation (from unit to other source) of
hot air must be prevented. Refer to figure 1,7 fot a tlpiczl insallation.

I*OTE: i
§uiuely s¡Fpdrt CI piFiñg
t{ FltrGñt fütfn eq* ¡arÉprq¡sur, F¡n rr¡d
:asl*r ¡r¡d e$rcr r¡mpro*l*nü* F¡*t ldetsr
áLL FIFIN€. I¡ALI¡E§, FI LTE*&"ETE- F*+i++rl
Tü ÉE SSTAIFJEtr tüEÁLI-Y. úi{ Etrertú'ir
)
C-oqpling
aI 6u¡rd
tl I
€ngins I
of --
t1 Mot¿¡ l-
)
t, ¡
:

Sraooth
Lertl §Efl¡6 :, Higid Frarne

Urr Shimr ill.ndror ¡*n¡ruiy herr. Arttrit fompr+i:or rn{

¡r mquircd. if ruquirud. F¡ims fulot*r ts ffifilc .80l.lFE
(Mininrum 4 in. tigidly and *errrruly.
EÉñcruta flaer cr ¡l¡bl

Figure 17 - Typical Instalktion

,1

t7
 Dnr-e:
Ser-e¡,..-::-) : j:.:ble andunir¡ersat jointt\pes afe
::- . couplings malrbeused. Horve\-r:.
--::--
recon:rr-:rr:: 1;'.':r¡::usingadirectflexiblecouplinE: ',-:: rplingmanufacturer's
instrucuc,n.. -.\. .. ¡-:¡ra1 ru1e, for this trpe of coupLi:,.. : .- .--r-¡nt should be as near "in line" as
possible. In an', c,...-. r-ruplingmisalignmentmayn.-J-:.-::- - ,l'¡arallel andf or 2o angular
misalignment. Refer to figure 18.

FlllÍhlt
Hub Msmhf,r THE DRIVE
COUPLING
(COUPLING, SHAFT,
1 Cdrit*fliffi
BELTS) MUST BE
I COVERED BY A
Lrd: s,r.g": Drjvrr/Oriven
' .I I : --1, 9" ¿f lpÉifr+.d hy SUITABT F' GUARD
cc-J -! -j--"E-ryr. OR SHIELD. ALL
Hub ro b+ parChl
2 drqrctr io botJr wr-:iel GUARDS A}ID
rnd hqri¿o¡ul p{*r+s,
(Or * ¡p¡¿ ¡¡¿¡ Íy crupling SHIELDS MUST BE
m¡nuftcturt¡..
IN PI-ACE \THEN
OPERATING THE
Figare / I UNIT

Depending ofl the size oi the com-

pressor, it ma\. be possible to belt drive
the compressor.

However, there is a limrt to the po§/er

that each compressor cxn sustaifl.
Refer belo¡¡':

HG10;30 HP
HGF10; 50 HP
Figure 19
HG12;50 HP
HGtrI2;50 HP
HGSF17; 50 HP

If the shaft horsepou/er exceeds these

i
numbers then the compressor must
\ har.e the pulley mounted on a"jack"
1 ot idler shaft. If the idler pulley has
a raúo other than 1:1 you will need
to ensure vou have not exceeded the
speed rating on the compressor

Figure ))

t8
 Installation
The components (Figure 17) of a gas compressor svstem ..r :-,: r - ::r , unicd on the frame to make sen-ic-
ing the unit as conr,,enient as possible. Oil piping and hoses sr- --: :; . -:i:ed and fastened to prevent ac-
cidental damage. All mol'ing parts (coupüng, belts, fans, etc :::'--.. ::-.- - :-,-.:rds or -shields installed.
Compressor Inlet:
Comptessor Discharge:
Separator out:
Comp Instrumentation:
Location
The inlet piping must be cle:rn ...:lj :, -: -. -:rr suirable filters, (scrubber, mois-
ture sepafator, etc.) to pre\-cn: i :,-.:, :r-,.-::-r i:om entering the compressor.
All piping and other componcir- :lr-..- rL ,ii--luateh' supported. Prorisions
must aiso be made to install orher c,',r-n),-.,íriiriS such as gages, r-ah-es, tem-
pefatufe measufing and pressurÜ Ct-,n¡rr,,1 ier-ices.
The discharge line between the compre ssor end rl-re oil recel\-er :::-isr be as
large as permitted bi. the size oi the compre ssor discharge op.rlr:rg. The dis-
charge ltne must neuerbe reducecl in size. T1-re dlscharge Line shc,u-c L¡e as short
as possible with the minimum number of bends and fittinss.
A high discharge temperature shut dos-n ss-itch, wired into rl-r. :r-:rlc mo\-er
controls, must be instailed in the discharge hne. This trip ss-rtc:r si'Lould have
a maximum tip setting of 230oF.
Pror,,isions must also be made to install other components sucl-r ¡s gauges,
vah,es, temperature measuring and pressure control devices.
The piping from the separator out (minimum pressure check valve) must be
as large as permitted b,v the outlet port of the minimum pressure valr-e. The
length must be as short as possible u,,ith the minimum number of bends and
fittings.
The piping must be adequatel,v supported and fastened securehr
Provisions must be made to mount and connect othet colnponents in this
line such as aftercooler, valves, pressure and temperature serising der-ices, etc.
Ptessure gauges should be provided to monitor the pressure drop (restric-
tion) across the oil filter element, separator element, and oil cooler.
A single gauge for each is recommended, with a manifold and shut off ¿
valves, to ted both upstream and downstream (inlet and oudet) pressures.
This limits the possibility of gauge error affecting pressure reaüngs.
t9
Satisfacton-pi::r1,¡¡l2nceofastatiofiaf\.scfewCo1i--]r::, :r:---:::rqoodpfeventisemaintenancepfo-
gram. The r,-, :,..,-.rg iltormation is provided m o .-, -: - -- - : ::,-)qram.

Start Up:

1.. Serr-ic¡ .;equrpment (hlters, moistur. i., -. - :- : :r.)\-er, etc.) foilou,ingthe equipment
manu :., r r-:rcr's instrucdons.
2. Drarn ci,¡ndensate (water) from the o' :.,-:- - r : - -!:ii1-1 valve securelyrvhen oil appears.
J. Check tite compressor oi1 reservoir j:'.,- , - -. :r-:e ssary to the correct ievel. Do not
overhll,
4. N{ake ceir¿rn adequate ventilation an¡ : i:.-*ired, is provided.
5. Start the uirir b-r. actuating the electrc- - - -- - .. :i-Lc engine follov'ing the eql'}lpment
manutac r¿rer's instructions.
6. Obsen-e the unit for leaks, unusual nc)-:." ' - r: -, I _ : .t _irtutdown the unit and corfect as fe-
quired.)
7. Obserr-e all rnstrumentation for prope : r:: r- :

Shut Down:

1. Stop the prtme mover following manl-._--_:,- - :--r'.J.jollS.

Preventive Maintenance:

1. Ensure the oi1 is properlv maintained ::: :- - -- - i.--ered Items" section of this manual.
2. tnspect the entire unit for leaks. - , , .: -
Yi-s¡1211¡ - : :, :rs often as feasrble. Correct as required.
-:
3. Sen-ice all equipment (filters, moisrure :-r,:-' r ,'- -rri-ingthe manufacturer's instructions.
4.
5. Checkthecompressotoilreservoitlc',-- , -- -::- :cofoilasrequired.Donotoverfill.
6. \\ith the unit running, obserr-e the oü rr:: : - : - -.: . -:.i compare readings (iilter in-filter out)
A üfference in ptessute readings of 1-: Ii- : :: .- J-lrcs that the filter element must be
renewed.
7. Withtheunitrunningobserl'ethesrsrr:::-i: ---.:,,::icomparereadings.Apressuredrop
across the separator element of 15 PSl : .-. :. - -- :: .rte separator element is restricted. If
-
thetestrictioniscausedbydirtororl¡:: :-:: ---:: :-:r-\\-theseparatoreiement.

OiI satutation can cause excessire resrririm across a separator element. Always
check the separator drain tube and lirr frr restrlction, the check valve (installation
and condition) and clean or renew rüF dE in line 6lter before condemning a separa-
tor element.
8. Remove sutface dirt and dust from :::. _ .:,_. __ ,-: .uoler.

20
 BEFORE REMOVING AI§Y COMPONENTS SHUT THE UNIT DOWN,
CLOSE ALL INLET AND DISCHARGE SITUTOFF VAL\rES, RELIEVE ALL
PRESSURE BY "PUMPING OUT". MAKE CERIAIN THE PRESSURE SYS.
TEM REMAINS VENTED TO ATMOSPHERE. DISABLE, LOCKOUT AND
TAG THE PRIME MOVER.
Comptessor Service:
The compressor for these units is setviced onl,v as a comp-;,; ...¡nb1r'using a ne\\,'or factorl'rebuilt com-
pressor. parts available tbr fie1d service include the input sir,.--. : ,:n- oil seal and the seal retainer gasket or
o-ring seal.

The compressor input shaft rotary seal may be teplaced as follorrs, Refer to trigxe 21.:

I. Make cetain the unit cannot be statted and system ha-. all pressure temoved.
III. Remove any coupling guards andf or shieids.
m. Clean the front of the compressor thoroughly to preYent dirt trom entedng
the compressor.
fV. Disconnect the drive coupling.

the compressor or prime movef must be unfastened from the frame, save and
If
mark all mounting shims if any, for reuse,

NOTE: Always vedfy Seal Kit P/N by referring to appmptiate compressot assembly / parts draw-
ing.

The seal kit includes:

(1) Rotary shaft seal assembly (1) 100 grit silicoo carbide emery cloth
(1) Technical / Service Bulletin TSB0B02 (1) Tube P80 Rubber I-¡rbricaat Emulson

The following procedure is to be used for installing ail.rctaryface trpe shaft seals:

Follow the maintenaace maoual procedure for the specific unit being : e\Pose the rotatv seal retainer.

Disconnect the lubrication line (tube) ftom the seal retainer or bearing reainet (depends on unit model).

NOTE
THE FTTTING INSTALLED IN THE SEAL OR BEARING REIAINER OR THE OlL PASSAGE IN THE
RETAINE& WHICH DELTVERS OIL TO THE SEAL, MAYBE RESTRTCTED OR ORTF'ICED.

INSPECT THIS FTTIING AND OIL PASSAGE AND THE ATTACHING LTNE, CruBE) TO MAKE CE'RTAIN
THE ORIFICE IS CLEAN AND THAT THE TUBE HAS BEEN CORRE,CTLY INSTALLED G'TO EXCESSIVE
FTTTINGCRUSH).

2t
 SONIE FITTI\GS (lR OIL PASSAGES NL{Y HAYE _-. .-- : - - 1 r,.,_, .JzuFICE. IF ONE IS PRESENT,IN_
SLTRE OzuF](,E ]S RE]\STALLE,D.

3§rt ie?rry

-/a@
:_,e }lri

/€ ll

I
E

E
Figure I Figure 2 Figure 3
r Remor-etheseairetalnci:'.nr,lsea1 assembirrasdesctibe.:. -: - --.- .-.::r:,nual
:
for the urut berng s.¡r-iced. Discard the o1d seal par . . --- :,

clean the seal retainer anri seal car.it).'in the bearing rci-. - :: : --.- Frqure 2)

To protect the exposecl sh,.,rt beadngs from dirt, dampe:: ; : :.: : .. ...i1c1 clean compressot oil ancl insert the rag
into the bearing rcrxincr . n.

Inspect the shati suri:'.cc i,rr nicks and burts. If found. r- :-. ' - -- . r ' r -, Éne file or stone. Remor.e any sharp edges
from tapers or chrmñrs r-,n the shaft. (trigure 3)

I f oú ¡ir ir sir¡c.rn
Éi'
&

f,igure d Figure 5 Ffgure S

22
On the shaft atea, where the seal is to be located, polish the sheft nsirtse rnrrnher 100
grit silicon carbide emery cloth
e /N 204-2385). \il/rap a strip of emery cloth atound the shaft. Gresp úe cmtry doth and use a rotary motion to pol-
ish the shaft. (Figure 4)

Catefully remove the oil dampened ragfromthe bearing caütywiü avipfumotion-

Dampen a lint free rag with a non-hydrocarbon solvent (suggest acetorle, nail polish remover, or equivalent) and care-
firlly remove any temaining dirt from the shaft. Make cetain the shaft is oil and dirt free. (Figure 5)

\TARNING
SOL\ENTS SUCH AS ACETONE MAY BE TOXIC §7HEN L\ilt\LED. -\I§.\15 USE IN A §7EII-VENTI-
LATED AREA.

Catefully remove üe new seal from the wrapping, check for any damage, aod wipe clean.

CAUTION
CHECK THAT THE SEAL FACE IS LOCATED IN THE RET,{.hER §TTH THE I-APPED FACE OUT-
§rARDS, AND TAKE CARE THAT THE FACE DOE,S NOT DROP OLT OF THE RETAINE,RWHEN
HANDLING AND FITTING THE SEAL. HANDLE THE SEAT ASSE}IBLY WITH GREAT CARE. DO NOT
TOUCH THE SEAL INISERT OR CARBON RING POLISHED FACES.

Lubdcate the steel face insert seal ring (o-ring) and seal retairier counter bore with P- 80 Rubber Lubricaot Emulsion
e /N 204-2386). (Frgure 6)

Protect the poJished side of the seal inset using the paste board seal protector furnished with the seal assembly and
push the inset into the seal retainer until it bottoms in the counter bore.

Frgure f Frgurc I Figura S - TYPfraI

CAUTION
DO NOT TOUCH THE, POLISHE,D FACE, OF THE SEAL INSE,RT \\,1TH FINGERS, RAGS, E,TC.
Appl.v a film of P-80 on the gas end shaft and on the inside diameter of the flexible section of the seal assembl¡,,.

23
CAUTION
TO ]I-\KE CERT-\IN THAT THE FLEXIBLE :r' - l: a THE SEAL ADHERES TO THE SHAFT
IN THE CORRECT LOCATION, IT IS NECE:-i ...-' - ),\IPI_ETE THE ASSENIBLY ONCE
ST.\RTFD
Lubricatethe cart¡onringsectionof theseaiassemb-"'- -:-- -' :--:¡essoroil.

CAUTIO\
DO \OT L SE OTHE,RT\?ES OF OIL OR GRE'.::

Nlake certain all parts and supplies (gasket, sealer. i.: 1:. - - - . --:.,re begrnning f,nal assembhr

\X'ithout touching the polished area of the carbc,: ::: : . :.: : ::-.: .cal assemblv (spring, etc.) on the shaft.
(Figure 8)

Apply sealer (or install gasket on the seal retainer I ::- s .-: : ! - r- : : - -:t :it. r¡srruction manual for the urut betng serr.,iced.

Immediately install the seal retainer and attaching c::.:.:::-, i ,:.: r;:.il-oq retainer mating surface. Tighten all cap-
scre\r/s securelu figure 9)

After installation is completed allow the seal to sit t-ir - -: ::)r3ung üe shaft for approximately 30 minutes.

Complete reassembh' of drive coupling, guard, etc. tbl '.-.--:r...

-rst¡ucrions providecl in the manual for the unit being
serviced.

24
 b) bFilfig. 3ll,etl
7l Q¡:l
Ii| Üheck Valve Fiston
g) Seat
101 ÉápsÉ.rew

l- WIth a suitsbl* *renth rÉinüve f.he'ralv* cap

from the val+e b*d1'.

ii Oii §€¿; F¿cu i;,srri i) Spring

2) Carbon ñinP 5) Sprlns GuiCe {when usÉd)
l) Shalt Seal Assem: ¡

Figure 21-Compressor Inpur Shafi Seal tigut 22- Minirnurn Pressure Chech Valae (Small)

parts are available, how-

The minimum pressure valve may be purchased as an assemblyif required. Setvice
evef, to rcpauf overhaul this valve. This valve may be serviced as follov¿s:
1,. Make certain the unit canrrot be started and üat all the pressure has been temoved ftom the
s\-stem.
2. Remove the service piping from dl' :l-:-::um pressure l'alve'
3. Remove üe vall'e ftom the receir-er-'- '' :.se rr-oir cap'
4. securelyclampüelah-einaverticaip:,:-:,,rn capendup)inasuitablefixture@enchvise)'
5. \\,ith a suitable wrench remove the r-:--,-c cap from the valve bodl-.

The spring beneath the caP is

under pressufe; exercise extfeme
care when temoving the caP

25
6. R¡:r- : t: :)rir-rg ftom the bodr-.
5;.-' ¡ i:r:::r- shim(s) (u,ashers) (if anr,) for r¡--..
7. I:l..: ,: .--r¡-'.ble tool (u.ood stick) into the n: :- -- r-alr-e and push the piston and the r.alr.e
¡ss-i:ti--, -tir\l-erd and out of the bodr..
8. Remor-. :r:. che ck valr,'e piston from inside .r- : . : - : - : : ,l. Take care not to lose the srnall spring.
9. Remor-e t|.- ,.r-ring from the large piston ALi , . _ : - -- -:iltg.
10. Thorougirir- clean a1l the remaining parts. \-'. - .. .- : : - .. :¡rts for damage or wear. Replace as
required.
11. Instali a ne\\- o-ring on the large piston.
12. Reassemble r1're small check vahre piston. r,-' - - - ,-, :--c large piston.
13. Lubricate tl-re o-ringonthepistonwith a s:-:,- :. . -:: ---tr1c,anr. (Example: Dov.Corning5510.
74. Reinstall the check lzlve and piston assem-:- .:-- . . ..,-.'e bodr-. Take care flot to damage the o-dns
dudng instaiLatlon.
15. Install the large spring in the vall.e bodr- on : - : r -- jr, Reinstall spring shim§).
16. Ltghtlv coat the caP threads u.ith "Loctite'' l-. ..:,- ., ,. :r¡ cap (compress spring) bv threading
the cap into rhe ralr-e bodv Torque the cap
17. Reinstall the mtnimum pressure valve on thc' :---:,- :r- t:Sir\-oir cor.er. Use a good grade of pipe
thread sealer on all pipe threads. Tighten sec--:r--. l) :-- - .\-er tighten.
18. Reconnect the service piping to the r-alr.e u.r:r: r.-:, r.,:¡.ld sealer on the pipe threads. Tighten
service piping securel1,. Do not oyer tighten,

Figure 23- Minirnum Pressure/Chech Vahe (Larg)

lJ Valve Body 5] Fiston Seat {oFIingi

2) Check Vatre/Pistc,n 6) Large §pring
Assembly I Shim (\{hen Usect
3) Large Piston 8] CaF
4) Small Spr¡ng

26
 §ervice Procedure-Components (Contínued)
Changing Minimum Pressure Valve Spring

This section contains the instructions to replace a high-pre.s..:. irlnLmum pfessufe r,alve with a
los¡-pressure spdng.

i
l
I

I
¡

Figure 24 - MPV Parts. Figure 25 - Seated Piston Depth.

ApproximatelyT /8 inch ftom the top of the body.
May be installed before or after spacers shou¡n in
€gures 26 ar-.d 27 .

=ffi

Figure 26- Instalhtion of First Spacer. Figtre 2- - Insrall.ttiatt

of rrnmining:p,i;;,:
NIarked "1". Insrall "Do§-n" side down ' t
InS:: - ,,: "l :r. -:ma to ;lSu¡. ¡l-i¡- . -. :
(chamfered to keep sharp edges from I.D. Smor-r,::t--,., 772 .p:cers are u.sed fc,: ]. l-i-
of piston) Pfes sur-.

27
 Service Procedure-Componenrs (Continued)
/

Changing Minimum pressure valve - Continued

Figure 28 - Ten Sltacers Installed it: I, F igarc2 9-Ins allatio n oJSp ringpanNo. 24- g I 0.
Eirher encl mav be installed dou,-n.

Figure 30 - Installation of Couer.

Keep cor.er faid1.ls\.sl dudng instaliation,
ttghtening bolt on either side a little at a rime so
cover does not tilt. Bolts should be tightened
securelr-, but do not need to be torqued accuratelv
(50 - 80 ft-lb is adequate).

28
An oil separator may be removed as follows:
1,. Make certain the unit caffiot be stated and that all pressure has been removed from the system.
2. Disconnect the piping from the minimum pressure v.atve-
3. Disconnect the separator dtainline and remove the drain tube from tüe separator. Mark the position
of the receiver-reservoir cover to aid in correct assembh.
4. Remove the separator cover to teceiver-resetvoir zttzchsngcapscrews (mrts) and remove the cover.
5. Remove the separator element by lifting it out of the reservoir.
6. Clean the cover and reservoit cover mounting flange. I\feke certain all traces of gasket lrrraterra) arc
temoved.

If the gaskets do not have grounding staples.

install tu-o large copper clad staples in each
gasket.

7. Inspect the new element gaskets to make certain the electrical grounding staples are installed.
8. Reinstall the separator element in the receiver-reserr-oir.
9. Reinstall the reservoit cover, correctlv positioned, u-ith :.¡.::.,rcil1:- cilpscre\r,s (nuts) and ughten secureh,-.
10. Reinstall the separator drain tube and {rtting.

The drain tube must extend into the separ¿ruÍ c1--

ment far enough to touch the bottom of the elernen:.
If the tube is not long enough to touch bottom.
obtain/make a new tube.

1.1.. Reconnect the separator &ain line.

MAKE CERTAIN THE DRAIN LINE FILTER

AND CHECKVALVE ARE CORRECTLYIN-
STALLED

12. Reconnect the service piping to the minimum pressure ..-a1r-e , L-se -.- ..'...':'' :-:- ülead sealer on al1
pipe threads. Tighten securell,. Do not over tighten.

29
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 §feb§itE
LeROI-RCT has a rvebsite that contains useful tips, features, sizing information, and technical dara.
We encourage using and exploring the rvebsite to learn rvhat tools are au-atlable to you. Visit us ar
s-wrv.leroisas. com

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ffie*r - 'ffi - §l ,-§ i-,¡uil**+ "j'iiFu*,it", S ;E-.'i j§l - J ffi @":$

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!s.a¡r páEwlhilt*i LeflOl Gas Compressors by Rolarl ComÉressisn Technolsgies,
,:$.yfipre.,'lf=: In8, Srdney, OH. USA is sne sft¡e world's ieading máilufacturers 0f
:,.
compressed gas syslpms. Our range 0f¡lr0ducls a*d ssmces
rnclude the most eftci8fit rangÉ ol üompress0rs ú n tha rflarh?l
today.

Pnrrs ürÉi$ij*fi**htii,tl.$lf, {rd üi:i

UBfiqlls pr-Édlrnlli*r i*rlinɧ b{nF,f]l$ fiue i+ intagral gaar¡ng, Foliry
l0ntlE' beariftq lifB, Váriabre M i I nleqral P0dinq, hpaúfduty
túnstu[ton andyr]s;U.rty-qas eqd 0r müdule oF,$ons. From a tdf**fi$|Éá.rse ü¡¡ c+r-rtBfii§$fi
range Bf:0 lo 350 PSIG, LÉR0l qas prDdücts can meeithB PcrtorMM .

dBmands olihe gas ¡ndJstry

3t
 act List
Beloq- is : : :t::crs in case you need any assisi':-:. - : :::: :'lr pror''ide
: ". you with the latest
informan-1--.-: ": -. :Iso ar-ailable on thewebsite: ; ' :r .--l: - i:l

USA
Com pressor Sales I Pricing I Applications ,r Specifications I

Phone: 281-693-1950
F ax: 281-693-1952
Cell: 7 1 3-586-9005
Email: sales@,letoigas.com O I maro.;o:-:' : : . -r -::L : : -

Com!'ieisor Orders' SñipBing f Parts Orders A ShippinÚ I'Wqnti

Tina Edwards
Phone: 937-498-2550
F ax: 937 -492-3424

Email: tina.edwards@ leroigas : : -

N ote: Atl warranty claimS now sUbfld uia the web. Visit www.leroigas.com.

Eñ§ineering I Technicál §ttpport / Website

§*n.K*gn =
Phone: 937-498-2558
F ax: 937 -492-3424
Em ail: ron.keen@leroigas.com

Accou*'ting
Arn andá Y*'llrrg
Phone: 937-498-2638
Fax: 937 -492-3424
Em ail: amanda.young@ leroig as : : -

32
 CANADA
:::::::::=

.:: =-
:a::::::a l tl::l:::::::::::a::=.:'". ,r .. :r'l=

Phone: 403-808-8377
F ax: 403-945-1910
Em ail: sales@ leroigas.ca

33
 Serfice

MALFU NCTI ON PROBABLE GAUSE REMEDY

High Discharge 1. lnsufficient or incorrect oil, '1
. Fill, or drain and re-fill oil reservoir to correct
Temperature ievel with correct o¡1.
2. Operating above rated press,-: :' :: 2. Operate at correct pressures.
excessive ratio.
3. Excessive inlet temperature. 3. Lower inlet temperature.
4. :-:-
Restricted oil cooler (inside c. :. Clean (inside and outside) or replace with
side). new cooler.
5. Damaged or inoperative ther-: : _.
- 5. Service thermal by-pass valve.
pass valve.
6. Restricted cooling oil flow. 6 a Service oil filter'
b. Check oil lines and hoses for restrictions.
Service as required.

1. lmproperly set inlet valve :- ::-:- 1. Set or adjust control correctly.

Low lnlet Pressure control.
2. Restricted inlet (dirty or clc-c;:: 2. Service inlet filters or screens.
filters, screens, etc).
3. Damaged or faulty inlet press --: J. Service inlet pressure regulator.
reoulator.

High lnlet Pressure 1 . lmproperly set inlet valve or ::-:- 1. Set or adjust control correctly.
control

High Discharge Pressure 1. Operating at higher than ratec tres- 1. Adjust to operate at rated pressure.
sure. 2. Service discharge check valve.
2. Damaged or worn discharge :t'::<
valve. 3. lnstall correct minimum pressure valve.
3. lncorrect minimum pressure . ,: ' 4. Service minimum pressure valve.
installed.
4. Damaged or worn minimum ::=:s --= 5. Conect cause of excessive restriction.
valve.
5. Excessive restriction in sepa::::- :-
outlet piping.

Excessive Oil Consumption 1. lncorrect o¡l installed in reser,c -

1. Drain unit and install correct oil.
2. Reservoirover-filled.
3. External oil leaks. 2. Drain to conect level.
4. Operating with discharge pressur-3 tcrc 3. Check for and correct all leaks.
low. 4. Operate at rated pressure.
5. Drain tube missing, broken or noi
touch¡ng bottom of separator element. 5. Replace dra¡n tube with correct length tube.
6. Worn, damaged, or restricted
separator element. 6. Service separator element.
7. Clogged or restricted separator arain
line drain tube or filter. 7. a. Service drain line filter.
b. Check condlt¡on and installation of drain
line check valve. Clean or install correctly.
Replace if wom. Service drain line as
required.

34
 ROTARY COMPRESSION TECHNOLOG¡ES, INC
d.b.a. LEROI GAS COMPRESSORS
WARRANW FOR ROTARY SCREW GAS ENDS
USED ¡N NON.CONSUMER APPLICATIONS
O.E.M. & GAS

Manufactured
LeROI-RCT warrants its rotary screw compressor products and parts to be in compliance with their respective specifi-
cations and free from defects in materials and workmanship during a wananty period ending the earlier of (i) 12 months
after the product start up date, or (ii) 18 months after the original date of shipment of the product by LeROI-RCT.

Remanufactured
LeROI-RCT warrants its remanufactured rotary screw compressor products and parts to be in compliance with their
respective specifications and free from defects in materials and workmanship during a warranty period ending the
earlier of (i) 90 days after the product start up date, or (ii) 9 months after the original date of shipment of the product
by LeROI-RCT.

LeROI-RCT's only obligation under this warranty will be, at its election, to repair or replace any part determined to be
non-conforming or defective during the applicable warranty period, including ground freight (Domestic USA only for
overseas warranty) for the gas end. Labor to change out the gas end is not covered. THIS WARRANTY DOES NOT
COVER CORROSION.

THE OWNER/USER ASSUMES ALL OTHER RISKS, IF ANY SUCH AS THE RISK OF ANY DIRECT, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGES ARISING OUT OF THE USE OF, OR INABILIW TO USE,
THE COMPRESSOR ORANY PART.

THIS WARRANTY IS MADE IN LIEU OF THE WARRANTIES OF MERCHANTABILITY FITNESS FOR PARTICULAR
PURPOSE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND MAY NOT BE VARIED OR EXTENDED
EXCEPT lN WRITING BYAN AUTHORIZED OFFICIAL OF LeROI-RCT.

Rotary Comptession Technologies

2llEast Russell Road
Sidney, Ohio 45373
Phone: 937-498-2555
Fax:937'492-3424
www. s ales @leroigas. com
www.letoigas.com
Effective 9 /2/05- Revised 8-10-07

35
THIS PAGE INTENTIOI§ALLY BLANK

3ó
 It Pays to use Genuine LeROI Parts
Provided by Rotary Compression Technologies, Inc

Rotaty Compression Technologies

ZLlEast Russell Road
Sidney, Ohio 45365
Phone: 937-498-2555
Fax:937-492-3424
sales@leroigas.com
www.leroisas.com

37