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OPERATOR MANUAL - Std - Alpha Seismic Compressors

1. c eh de me e ii Que hamuta an as 1090 mm Typical Belt Driven Set Length 1700 mm ial tete t uta ted coi CLER ta aeta 1320 mm LEADING PARTICULARS PAGE 22 4 3 WRENCH SETTINGS Torque wrench settings for non lubricated fasteners All figures 5 Under no circumstances are any deviations from these figures allowable Note These items must be tightened sequentially in 27 Nm 20 Lb ft steps FASTENING SPANNER THREAD NEWTON POUND SIZE SIZE METRE FEET BULUM ft 150 First Stage ValveCover 19MM 12 50 37 Second Stage ValveCover 30MM M20 121 90 Third Stage Valve Cove meer Fourth Stage ValveCover 24MM Mi6 118 87 Fourth Stage CoolerCover 17MM mio 55 40 4 UNF Third Stage COMM Me 8 Y UNC LEADING PARTICULARS PAGE 23 4 4 RUNNING CLEARANCES AND WEARING DIMENSIONS DESCRIPTION STAGE AS FITTED mm MAX PERMITTED mm Piston vertical clearance 0 500 1 200 0 250 0 950 0 350 1 150 0 350 1 150 Taper 0 20 0 46 Scraper 0 20 0 46 Taper 0 10 0 23 Scraper 0 10 0 23 Plain 0 05 0 18 Plain 0 20 0 40 Taper Scraper Taper Scraper Plain Plain Taper Scraper Taper Scraper Plain Plain ie Distance from top of piston to top of liner Piston ring gaps Measured in unworn portion of cyl
2. Denver COMPAIR REAVELL QUALITY MANAGEMENT OPERATOR HANDBOOK Fora 5437 1 1A Water cooled Air Compressor In any correspondence please quote COMPAIR JOB NUMBER 1323436 CUSTOMER GARDNER DENVER INC CUSTOMER ORDER NUMBER 1509468 MACHINE NUMBER H21060001 amp H21060002 H21069001 amp H21069002 PUBLICATION NUMBER 98407 1849 ISSUE DATE FEBRUARY 2011 Gardner Denver Ltd Reavell House 53 56 White House Road IPSWICH ENGLAND 1 1 5 Telephone 44 0 1473 242000 Fax 44 0 1473 745451 Parts Fax 44 0 1473 743468 Service 44 0 1527 838632 www compair com e mail sales ipswich compair com TABLE OF CONTENTS Page 1 OPERATOR HANDBOOK 5437 1 1A CONTRACT NUMBER 1323436 TABLE OF CONTENTS NOTE a N 7 8 THE REQUIREMENTS OF THE CONTRACT MAY RESULT IN PART NUMBERS IN THE INCLUDED STANDARD HANDBOOK BEING INCORRECT ANY ALTERED PART NUMBERS ARE INCLUDED IN THE CONTRACT SPECIFIC PARTS SECTION SAFE 2 CEOREWORD iie ede die pared a 33 aint de redeat aar er DEREN aa MURIS 4 SAFETY PROCEDURES viie aea ere denen free teo nep decet eee thi nenn 1 4 1 einig 1 4 2 WARNINGS CAUTIONS 8 5 1 4 3 GENERAL SAFETY PRECAUTIONS 2 2 144 INSTALLATION PRECAUTIONS cece eene nenne nennen nnns 145 OPERATIONA
3. 76 10 7 4TH STAGE CYLINDER PARTS ae 77 168 bis 78 10 8 1 1 T 2ND STAGE don d ne een 78 78 109 S TAGE C ee 78 109 OIL PUMP DRIVE ASSEMBLY ccsccseccsccsesscsssecersesscecescersesececeveessnsucecsceevarsesaceveesavsesacetsecavansecenes 79 10 10 157 amp 2P STAGE RUNNING GEAR I n etti lea ecd 80 10 11 3FD amp 4 H STAGE RUNNING GEAR d cane tend onte baut c eau etu factu 81 10 12 CRANKSHAFT ASSEMBLY a ea 82 1 83 10 14 A35 STAGE VALVE 5 Rol 84 TABLE 5 10 18 STAGE AE 85 104346 STAGEVALVE ee 86 1047 4 STAGE A ee ee 87 10 18 AST amp 2ND D D V ASSEMBLY a a To 88 10 19 3RD S 4TH D D V ASSEMBLY 89 dd Sa 91 11 1 1 STAGE RUNNING a Satta a ee 91 11 2 2ND STAGE RUNNING GEAR nina ae Er 92 118 SP 4 STAGE RUNNING GEAR Eee 93 93 113 2 0 93 193 2 ag am BEIN 93 11 4 Z COOLER Bea sale e 94 ee ee nen 94 ee tere 94 94 A z S Tuala Tua Dum u sa Dau a au 95 13 EQUIPMENT DATA SHES Secunda nde eae eier 101 13 1 ANTI VIBRATION MOUNT dl Sees
4. 3 CHANGE TO MAN BEARING BUSKTERUST WASHER Jausznot je NEW SERVICE PLAN INSERTED SECTION 11 REPAGINATION APRIL 2008 1574 2 STAGE SAFETY VALVE PRESSURES CORRECTED 2009 CORROSION ROD QUANTITIES AND POSITIONS CLARIFIED ANCILIARY PARTS ADDED AT SECTION 13 18 LEADING PARTICULARS PAGE 19 4 LEADING PARTICULARS 4 1 UNIT DESIGNATION Direct coupled or drive compressor electric powered R 5437 1 1A 4 2 TECHNICAL DATA 4 2 1 GENERAL Single acting four stage 90 vee Sea or fresh water 0 Direction of rotation viewed from drive Anti clockwise Nurmber of valves cie e e dr ee Four valve noe ap de uda Flat plate low lift TEMPERATURES 4 22 Air Inlet and ambient temperatures nenn 20 C 1 013 bar Gooling water let reete dro ict t 15 10 12 C rise Temperatures are maximum mid stream for 310 bar duty Compressor Speed 1180 rpm 1500 rpm 1800 rpm Maximum air inlet u u uu 0 03 bar g Minimum ambient air inlet 0 C Maximum air intake ambient 45 C Maximum
5. 54 Inspect test 3rd stage cooler 2 2 ring 1 Tension pin 1 Circlip retaining 1 55 Inspect test 4th stage cooler ring 2 2 SERVICE PLAN PAGE 99 Service Kit Number o GN sf Y xxx 290999 Service Plan 5437AIR 12 Months From Installation Last Service Or Run Hours Suction filter silencer Silencer Joint 1 Inspect test safety valves in accordance with regional requirements 1 stage 1 XX 2nd stage 1 XX 3rd stage 1 XX 4th stage 1 XX Surge vessel 1 XX Test pressure gauges 1st stage 1 XX 2nd stage 1 XX 3rd stage 1 XX 4th stage 1 XX Oil 1 XX Test temperature switches 3rd stage 1 XX Final stage 1 XX Test low oil pressure switch L O P 1 XX Test non return valve non return valve 1 XX Seal 1 SERVICE PLAN PAGE 100 EQUIPMENT DATA SHEETS PAGE 101 13 EQUIPMENT DATA SHEETS The following details are for those items that are most commonly supplied with the compressor Not all of these items are fitted to the standard compressor build and some contracts will have extra equipment that is not included within this section 13 1 ANTI VIBRATION MOUNT 13 1 1 MARINE 1 NOVIBRA TYPE WITH STOPS PART NUMBERS 98418 1018 1019 1029 amp 1030 NOVIB
6. Y Remove 4th stage cooler coil assembly Clean interior of cooler body and exterior of coil assembly Y Check switch amp setting 39 stage High air Check cooling water exit temperature does not temperature exceed 50 C switch operating Check cooling water temperature rise is 10 12 Y Remove stage cooler assemblies Clean interior of cooler body and exterior of cooler assemblies Electrical fault Y Check power to starter Y Check for previous STOP fault condition high air temperature switches low oil pressure switch Y Check via bell housing inspection cover compressor free to turn by hand Y Check fuses within starter Y Check wiring connections to motor terminal Y Check continuity in motor windings Incorrect grade of v Drain clean and refill crankcase with correct OVERHEATING grade of lubricant Check condition of valves and gas passageways Insufficient water Y Examine condition of water circuit remove any cooling efficiency 7 10 7 OVERHEATING bu pump Y Renew pump adjust drive belt tension RADIATOR SET aulty onduive slipping flow 2 Incorrect siting Resite unit to give correct cooling air flow insufficient cooling air flow Radiator blocked Y Clean matrix and flush out tubes 7 10 5 WILL NOT START OPERATING INFORMATION PAGE 41 Symptom EN Recommendation s Bearing end plate gasket Y Examine gasket replace if distorted partially blocking necessary
7. BE ADJUSTED BUT REFERENCE MUST BE MADE TO THE MANUAL SECTION APP 059 FOR INSTRUCTIONS MAX WORKING PRESSURE 430 BAR 6250 PSI 150mm MAX XX 3 4 sawa cam i COMPAIR UK LIMITED REAVELL HOUSE 53 56 WHITE HOUSE ROAD A CompAir I BR 29 09 2008 IPSWICH SUFFOLK SPB U K TEL 44 0 1473 242 000 www sec PATTERN NO NONE yer 5 sorroveo T J Chick 29 09 2008 0572 MAINTENANCE REFERENCE DRAWING mec 8 ISSUE DATE 20 09 2008 s Me gt As ISSUE DATE 108 No LAST MOD No DV SK210 159 EQUIPMENT DATA SHEETS PAGE 111 MAINTENANCE Replacing valve and Ensure all pressure has been released from pressure maintaining valve and system Remove any pipework from valve Dismount valve from system and hold securely in workshop vice Measure and record dimension between underside of adjusting screw 11 and valve body 1 It will be less than 150 mm Slacken locknut 12 and remove together with adjusting screw 11 Withdraw valve rod 9 spring 10 and spring collar 8 through cover 2 Unscrew and remove seat retaining plug 7 Using a suitable small soft drift through the top adjustment end ofthe valve body tap out valve 3 and seat 5 taking care not to damage valve bore Discard old valve seat and o rings Thoroughly clean all parts to be re used Fit new valve seat 5 into valve body 1 Fit ligh
8. Ah US SS ILLUSTRATIONS PAGE 78 10 8 COOLER SEPARATORS 10 8 1 17 2ND STAGE 7 1 7 12 7 9 7 12 8 2 6 pa VN 8 3 E pli Y F T 2 m 5 5 AT x ZN SA eas PSSS 8 2 3 8 2 8 8 1 7 im 8 2 9 8 2 10 8 2 1 8 2 2 7 10 7 12 8 1 3 A 533 2 A pP ten lt a ZZ uz N 2 90 SM 10 7 V TEE m Ne SASS NESS um RS 11 2 2 ILLUSTRATIONS PAGE 79 10 9 OIL PUMP DRIVE ASSEMBLY 1 30 ILLUSTRATIONS ILLUSTRATIONS PAGE 81 ILLUSTRATIONS PAGE 82 ILLUSTRATIONS PAGE 83 10 13 CRANKCASE 3 1 Re TX t x AAA 4 24 oS 24 gt eate s 0 ILLUSTRATIONS PAGE 84 10 14 1 STAGE VALVE 19 STAGE VALVE PL gt ZN AU Ws 22 9 4 1 DELIVERY VALVE SEAT Senn lt DELIVERY VALVE PLATE DELIVERY SPRING PLATE SUCTION SPRING PLATE LIFT WASHER SUCTION VALVE PLATE LIFT WASHER PEG PEG SUCTION VALVE SEAT ILLUSTRATIONS
9. QR ds 43 IDA Toten latte ah allan 43 43 8 2 AFTER THE FIRST 100 HOURS 8 AFTER MAJOR 44 8 24 REMOVE CRANKCASE DOORS AND THOROUGHLY CLEAN INTERIOR OF THE A O 44 83 SERVICING COMPRESSOR STAGE VALVES 44 8 31 ROUTINE CLEANING AND INSPECTION ALL 44 8 3 2 ROUTINE VALVE REMOVAL AND SERVICING eee 44 8 3 3 ROUTINE VALVE REPLACEMENT atri cade Dee 45 8 34 FIRST STAGE VALVE REASSEMBLY 47 8 85 SECOND STAGE VALVE REASSEMBLY 49 8 36 THIRD STAGE VALVE REASSEMBLY 51 8 3 7 FOURTH STAGE VALVE REASSEMBLY retener tetti 53 84 SERVICING COMPRESSOR PROTECTION 54 8 4 1 BUBSTINGDISC el E LEE 54 8 4 2 CORROSION ROD 55 ase ones e elas acidos 54 Z 4 8 4 4 LOW OIL PRESSURE SWITCH 54 8 4 5 HIGH AIR TEMPERATURE SWITCHES Ne 54 8 4 6 MAINTENANCE OF SOLENOID VALVE eerte tette 54 8 4 7 NON RETURN VALVE ee tt Roa tete oy 54 8 48 AIR INTAKE FILTER SILENCER o tetto 54 poo SOULE IE Me 54 85 SERVICING ta oec 55 dosi 55 8 5 2 FIRST 8 SECOND STAGE COOLER TUBESTACK 55
10. STAGE e 9885569 m S S S 5558586 LAIA 2 a O CD E E lt lt m m 2210 2 Zx Zx lt EIE gt gt m gt gt O tc lt E 5 lt 60 gt W o 6 Hours Service Number HSK1201 HSK1228 HSK1236 HSK1244 HSK1252 HSK1244 HSK1236 HSK1228 HSK1260 HSK1279 12 Months From Installation Last Service Or 12 SERVICE PLAN Service Plan 5437 SERVICE PLAN PAGE 95 XXXXXXXXX Replace inlet filter Filter element X Xx 1 4 Clean sump 2 Inspect replace Belt Tension or Drive coupling Me lan Corrosion rods kit 1 XX XX XX Remove crankcase doors Door joints CompAir Mineral x as di space Dil lubricant 20 Litres X XX X X 6 7 4 Replace po LE Reavellite S lubricant 5 1 Litres XXXXXXXXXX Replace Oil filter Oil filter 1 Replace water pump XXXXXXX impellor ONLY Impellor kit 1 XXXXXXXXX X 9 ui Cover O ring 1 ring 1 Back up ring 1 Back up ring 1 x 10 9 Service 4th stage valve Valve kit 1 XX 11
11. 9 6 1 STAGE VALVE COOLER COVER amp LINER 9 16 1 STAGE VALVE 9 3 1 1 STAGE RUNNING GEAR O 2 PL 9 15 4 47 STAGE VALVE COVER amp LINER I 9 16 4 STAGE VALVE 9 3 4 47 STAGE RUNNING GEAR ILLUSTRATIONS PAGE 73 10 3 2ND amp 3RD STAGE CYLINDERS 9 9 9 6 312 STAGE 2MD STAGE COOLER COOLER 9 15 3 er 3 STAGE VALVE COVER amp LINER T 2 STAGE VALVE COVER amp LINER iof A lt lt iw i iN AS E 5 UN lt lt yu 9 1 312 STAGE VALVE 9 16 2 STAGE VALVE 9 3 3 3 STAGE 932 RUNNING GEAR 2ND STAGE RUNNING GEAR ILLUSTRATIONS PAGE 74 10 4 1ST STAGE CYLINDER PARTS 14 1 1 14 1 5 Ol TAN PAN SA N 7 y di ILLUSTRATIONS PAGE 10 5 2ND STAGE CYLINDER PARTS 14 2 3 14 2 2 Z Z N 4 14 26 S a p 5 O 52 ERO 5 2 4 N S 5 2 6 ILLUSTRATIONS PAGE 76 10 6 3RD STAGE CYLINDER PARTS Y Y lt ILLUSTRATIONS PAGE 77 10 7 4TH STAGE CYLINDER PARTS d p 7 27 e 3 i E SR 5 Hi Y N 2 x 15 x
12. Do open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement test or adjustment Such work should always be carried out by a qualified electrician with appropriates tools and protection against an electrical hazard e lf the unit is equipped with a Remote Control device attach warning notices stating THIS UNIT CAN BE STARTED REMOTELY in prominent locations one on the outside of the unit the other inside the control compartment As afurther safeguard take adequate precautions that no one is working or checking the unit before attempting to switch on remotely controlled equipment Attach a CHECK THAT ALL PERSONNEL ARE CLEAR OF UNIT BEFORE STARTING or similar notice e Compressed air and gas piping together with cooling water piping and other parts with surface temperature greater than 70 and may be accidentally touched should be guarded or insulated e fthere is any indication that the compressor is overheating it must be shutdown A high air or gas temperature switch is fitted as standard to guard against operating with excessive temperature Beware of burns from hot oil and water when working on a unit recently shutdown Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance Secure guards following any servicing or repair Local noise regulations must be observed
13. USE ONLY CompAir Reavell GENUINE PARTS AND AUTHORISED SERVICE AGENTS 8 1 1 OWNERSHIP DATA TECHNICAL DATA is recommended that details taken from compressor and motor nameplates are recorded below 7 Gardner Denver Ltd 55 56 White House Road COMPAIR Ipswich REAVELL Suffolk IP1 5PB United Kingdom W ww reavel Serial Weight kgs Maximum Pressure Notified Body Ref Motor Shaft Power Number Compressor Shaft Speed CompAir Reavell CONTACT DETAILS Contact Name Sales Telephone 44 0 1473 242000 Address Gardner Denver Reavell House 53 56 White House Road Ipswich 1 1 5PB ENGLAND Telephone 44 0 1473 242000 Fax 44 0 1473 745451 Contact Names Parts Telephone 44 0 1473 242000 Parts Fax 44 0 1473 743468 Contact Names Service 44 0 1527 838632 For any comments or queries about the contents of this manual please write to CompAir Reavell at the above address marked for the attention of Mr Owen Dale Technical Author 9 1 2 FOREWORD SPECIAL STANDARD BUILD of all CompAir Reavell products are not intended for use in either Explosive Potentially Explosive Atmospheres as defined in Directive 95 9 EC An Explosive atmosphere is a mixture with air under atmospher
14. Maximum Working Pressure 6000 psi Body material Stainless Steel 6 8 O Ring PS1205 9 Retainer Clip Connections 1 4 G1 4 Number 98261 1422 TECHNICAL SPECIFICATION Maximum Working Pressure 6000 psi Body material Chrome plated brass CZ121 1 EQUIPMENT SHEETS PAGE 118 NON RETURN VALVE APP161 Connections table below CompAir Number 98650 1562 1569 TECHNICAL SPECIFICATION Maximum Working Pressure see table below Material see table below 1 2 BSP RHD1 R1 2 1TL 0 5BAR71 1 4 BSP RHD1 R1 4 1TL 0 5BAR71 1 4 BSP RHD1 R1 4 1TL 0 5BAR71 VaveSeat YES 41 2 Outer NO 400 1 4 11 4 Si YES 1 40 11 5 VaveGude YES 40 1 6 Retaining Washer YES 400 1 O EQUIPMENT DATA SHEETS PAGE 119 13 9 WATER FLOW VALVE APP704 APP704 WATER VALVE COMPAIR PART NUMBERS PORT SIZE BODY MATERIAL 98650 2584 1 1 BSP BRONZE 98650 2584 2 1 BSP STAINLESS STEEL 98650 2585 1 34 BSP BRONZE 98650 2585 2 34 BSP STAINLESS STEEL 98650 2612 1 12 BSP BRONZE DESCRIPTION A 2 port pneumatically actuated on off valve for use on water air oil and gasses A pneumatic signal acts on the actuator piston to open or close the valve with a spring return action The valve plugs have a PTFE soft seal to p
15. manual drain valve Check air pressure gauges Check that no air safety valve opens continuously Ensure separator drains operate at approximately 10 30 minute at pre set intervals 7 9 INHIBITION FOR STORAGE 7 9 1 INHIBITION FOR UP TO SIX MONTHS Check that the compressor has been run with the recommended oil Run the compressor for 30 minutes on light load with the final delivery pipe disconnected and with all separators open Cut down the cooling water supply during this run so that the water outlet temperature is from 38 C to 49 After 30 minutes stop the compressor turn off the cooling water disconnect the water supply and drain off the water EITHER Dry out the water jackets with compressed air if available Insert air hose at water outlet connection and pass air through jackets until water ceases to flow from water inlet connection IMPORTANT Do not pressurise jacket with air during this procedure OR Alternatively if air is not available fill jacket with PX10 water displacing fluid and allow standing for 15 minutes before draining off Remove and clean compressor valves and wipe out any moisture in valve pockets and passages Immerse valve units in PQ11 fluid and allow surplus to drain off Insert PQ11 into each cylinder allowing approximately 1 3 cc of fluid to each square inch of cylinder surface area Coat all surfaces and gas passages Replace valves carefully and coat valve covers with PQ11 Seal
16. 2073 96 25 96 25 being to the setting in bar g wire locked 98650 1164 is the base unit number 98650 1164 28 28 being to the setting in bar g wire locked 98650 1163 is the base unit number 98650 1163 7 6 7 6 being to the setting in bar g wire locked 98650 1020 is the base unit number 98650 1020 3 8T 3 8 being to the setting in bar g wire locked and tagged 98650 1021 is the base unit number 98650 1021 9 6 9 6 being to the setting in bar g wire locked 98650 1022 is the base unit number 98650 1022 90 90 being to the setting in wire locked and tagged Note the valves cannot be interchanged as the range of setting is limited EQUIPMENT SHEETS PAGE 110 13 6 PRESSURE MAINTAINING VALVE APP059 PRESSURE MAINTAINING VALVE U572 B U572 G amp U572 H U572 B This valve is fitted to maintain back pressure through separators filters and dryers if fitted This ensures that equipment reaches optimum working pressure as soon as possible to give long filter life good oil separation and low oil consumption Setting Procedure This valve is factory set or set during commissioning to the correct back pressure for the contract duty and should not require adjustment However if necessary it can be adjusted by a competent person who understands the valve function Adjustment is made by rotating adjusting screw 11 Rotation is clockwise for increasing back pressure and counter clockwise for red
17. 8 CYLINDER BODY 3 8 4 STAGE Description Part Number Number OFF 96 StudM16X60so 667201684 4 98 Dowysed 1 814228 4 92 SetscrewM10 195000282 4 911 6 951108 8 Seal BSP Body 8 4th 9 9 COOLER 3 STAGE Item No Description Part Number Number OFF 10 1 Shroud outer D101586 10 2 Tube stack D101629 9 10 SEPARATOR 3 STAGE Item No Description Part Number Number OFF 10 3 2 10 4 10 5 10 6 10 7 10 8 ring 9 11 COOLER 41 STAGE 0101610 OFF 11 1 1 1 11 1 2 11 2 1 11 2 2 11 2 3 11 2 4 11 2 5 11 2 6 PARTS LISTS PAGE 66 9 12 SEPARATOR 417 STAGE Description Part Number C203868 20 1 20 2 20 3 20 4 20 5 20 6 fitting 9 13 CORROSION ROD 9 13 1 CORROSION ROD STANDARD Item No Description Part Number Number C203868 OFF 12 1 Corrosion rod 150 mm C203869 2 9 13 2 CORROSION ROD OPTIONAL Item No Description Number ee 7 OFF 12 2 2 12 3 Corrosion rod 100 mm 4 9 14 BURSTING DISC on OFF 13 1 Bursting disc C201658 2 1 13 2 Bursting disc melinex C84735 1 1 9 15 LINER VALVE COVER 9 15 1 1 STAGE N 71 EI Number OFF 14 1 1 D100609 14 12 D100802 14 1 3 95602 151 14 14 95602 152 14 15 O ring 95602 153 9 15 2 2 STAGE Number OFF 14 2 1 D100604 14 2 2 D100005 14 2
18. 853 THIRD STAGE COOLER COM sl 55 8 5 4 FOURTH STAGE COOLER COIL tone 55 855 PRESSURE CAUCES 5 856 0 aren 56 8 5 7 MAIN BEARINGS a t ace oda 56 8 5 7 1 BIG END BHAR NGO encarta te an 56 858 SMALL END BEARINGS ias 56 8 5 9 GUDGEON PING acum tva e oec 56 8 5 10 RUNNING GEAR xia cec o up 57 em O o E m A aina aa kayana akapa Yon as P aos 57 B5402 STAGE 57 85104 S Rd STAGE uuu 58 8 5 11 DIAPHRAGM DRAIN VALVE cerent tette tette treten teint 58 I efti a ha tief o 59 8 5 13 PULLEY BELTS 8 MOTOR PULLEY ceret tete te aaa 59 61 Ga ota Lb cda 61 92 MAIN BEARING HOUSING ee aan 62 o odore A RM 62 UI MENSIS Dr CL 62 93 RUNNING GEAR ert 62 IL I STAGE an san 62 63 OF 4 938 ae iat 63 o e W HE LASIN C u ala Qa ay ukukuna aaa a ACO Qa Qasa 63 94 CRANKSHAFT ae ang 63 9 5 1 amp 2 STAGE Nana ea 64 G6 COOLER T STAGE e boa ee Lt mated ene a 64
19. 9 Replace 4th stage valve Valve assy 1 X X X Inspect 4th stage liner 3000 9000 amp 15000 Hrs Replace 4th stage liner X X 12 9 4 6000 12000 amp 18000 Hrs Liner assy 1 XX XX x xX 13 9 4th stage piston ring Piston assy 1 14 4 Replace 4th stage X head Bearing S E 4 small end gudgeon pin 1 Circlips 2 SERVICE PLAN PAGE 96 Service Kit Number T CO CO sf CN T Oooo iw 582 Service Plan 5437AIR 12 Months From Installation Last Service Or Run Hours 15 9 replace 4th big end Bearing Shells Pair 1 earings Big end bolts 2 16 Cover ring 2 Cover 2 XXX XXX 17 6 Inspect 8 Clean 3rd stage O ring valve to valve 4 valve cover 19 16 Service 3rd stage Valve kit 1 20 16 Replace 3rd stage Valve 1 X XX 21 4 Piston assy 1 x 22 16 4 Replace 3rd stage liner Liner asy 1 XXX X X X Inspect stage liner 23 1644 Replace 3rd stage Xhead Bearing S E 1 small end Gudgeon pins 1 Circlips 2 24 4 en 3rd big end Bearing Shells Pair 1 earings Big end bolts 2 5 Remove 2nd stage valve Cover O ring 1 Cover ring 1 26 25 Servi
20. 932 2 0 a bua 64 98 BODY 32 8 4 T STAGES cnt rettet uma h qay 65 95 COBLER ES de de el una o Sa 65 9 10 SEPARATOR S60 STAGE 65 OAT COOLER S4 tale esc trout ut fnt 65 912 SEPARATOR 4 STAGE 66 ttn deos 6 9 13 1 CORROSION ROD STANDARD a u a beetle o itte edad o 66 9 13 2 CORROSION 66 BURSTING DIS unn da A c 66 9 15 66 e res ade e ale es ee alle aya 66 O 6 A a buz y a aus hinam 67 o usu ahua u uapa Danau E PR ME 67 uya apamuna 0 67 517 SUCTION PIETER ma Cero dope nera un en 67 18 67 919 INSTRUMENTATION sumar ario acia 68 920 SAREE IY ud touc ert elles E AI 68 Sahne 68 9 22 _PIPE ASSEMBLIES ode ena nae 68 ncs A 68 10 ABEUSTBATONS se 69 IS Sn 69 10 2 AST RATA STAGE CYLINDERS 72 10 3 2ND amp 3RD STAGE CYLINDERS cols 73 10 4 ASTSTAGE CYLINDER PAR Sarral tler ae 74 10 5 2ND STAGE CYLINDER PARTS LH Aare 75 10 6 3RD STAGE CYLINDER PARTS an een
21. DATE REMARKS DATE 98407 1825 iss 1 15 4 TEST SHEET TEST CERTIFICATE New Block Test Serial Number H21060001 From Gardner Denver Ltd To GARDNER DENVER INC High Pressure Division Reavell House 53 56 White House Road Ipswich Suffolk England IP1 5PB Tel 44 0 1473 242000 Fax 44 0 1473 745451 www compair com Contract Number 1323436 Customer Reference L C Number 1509468 Description of Equipment 5437 1323436 5437 COMPRESSOR BLOCK Vee Type Four Stage Two Crank Single Acting Reciprocating Water Cooled Gas Design Type AIR Test Medium Air Test Date 07 February 2011 Target Speed Adjusted Customer Unit Of Pressure PSIG lt Customer RPM 1800 1745 EE Raised Customer Free Air Delivery M Hr 157 161 34 166 43 Rise Inlet Pressure De gt Outlet Pressure 5003 8 150038 Final Delivery Safety VaveSet 5584 MotorNo Test Performed By Dated Test Supervisor Dated British Standard BS ISO 1217 2001 Capacity Test The results contained in this report are valid only for the conditions under which the test was conducted and the specific item tested COMPAIR REAVELL 98407 1825 iss 1 16 TEST CERTIFICATE New Block Test Serial Number H21060002
22. FOURTH STAGE COOLER DO NOT ATTEMPT to remove cooler coil assembly end fittings This is a brazed assembly containing high pressure Disconnect 4 stage inlet pipe remove cooler cover from outer end and withdraw Remove outer shroud tube Wash and brush down exterior of tubes and clean cylinder block water passages If airflow through tube coil is restricted or there is any doubt to internal cleanliness renew complete assembly Inspect for corrosion and hydrostatically test and replace as necessary Fit new ring seals smear cooler end covers O rings and cooler body bore with silicone sealant Refit to body 8 5 5 PRESSURE GAUGES Remove gauge panel complete with gauges after releasing pressure gauge tail nuts Loosen screws holding clamp rings remove gauges Send gauges for calibration on dead weight tester MAINTENANCE AND REPAIR PAGE 56 8 5 6 CRANKSHAFT Remove crankcase doors and remove all big end caps Raise running gear clear of crankshaft or remove completely Remove all pipes from the crankshaft interior Remove main bearing housing screws at driving end and main bearing housing Prise out and discard oil seal Support weight of crankshaft using lifting tackle or blocks Carefully remove crankshaft through driving end of crankcase Remove main end bearing housing screws at outer end and remove housing Inspect running surfaces of crankshaft and main bearings If any of the surfaces are scored o
23. ILLUSTRATIONS PAGE 90 TOOLS PAGE 91 11 TOOLS 11 1 157 STAGE RUNNING GEAR 4 N N N 6 ITEM DESCRIPTION PART NO NO OFF 1 157 STAGE VALVE LIFTER 200066 1 2 2 LIFTING TOOL C200223 1 3 M20 NUTS 95111 11 2 4 BAR C203716 1 5 STUD C203717 1 6 PLATE C203718 1 TOOLS PAGE 92 11 2 2ND STAGE RUNNING GEAR ITEM DESCRIPTION PART NO NO OFF 1 2 STAGE VALVE LIFTER C84096 1 1 2 PISTON LIFTER C200223 1 3 BAR C203716 1 4 M12 NUTS 95111 7 2 5 STUDS C200421 2 TOOLS PAGE 93 11 3 389 8 47 STAGE RUNNING GEAR 11 3 1 VALVE 11 3 2 LZ 11 3 3 LINER 5 3 STAGE 6 STAGE a ST 222222222222 7277 ITEM DESCRIPTION PART NO OFF 1 VALVE PISTON LIFTER C203706 1 2 PLATE C203704 1 3 M16 NUT 95111 9 1 4 WITHDRAWING SCREW C203738 2 5 GUIDE BLOCK 3 STAGE C203736 1 6 GUIDE BLOCK 4 STAGE C203737 1 AAAS RA 11 4 COOLERS 11 4 1 1 8 2 STAGE 11 4 2 380 STAGE TOOLS PAGE 94 A Z 11 4 3 4
24. INSERT END OF KEY INTO CENTRAL ADJUSTER KNOB B AND TURN TO ADJUST SET POINTER TO REQUIRED MINIMUM TEMPERATURE ABOVE 10 C REPLACE ADJUSTING KEY AND SECURE WITH NUT CONTROLLER TEMPERATURE TRIP POINTER USED ON PART No RANGE STOP SETTING C COMPRESSOR MODEL 98288 1215 40 80 10 C FALLING 5000 SERIES WATER COOLED COMPRESSORS SWITCH DIAL EQUIPMENT DATA SHEETS PAGE 125 13 13 STARTER CONTROL PANEL APP091 INSTALLATION amp MAINTENANCE INSTRUCTIONS FOR MOTOR CONTROLS AND CUSTOM BUILT EQUIPMENT IMPORTANT SAFETY All control panels starters for operating on low voltage contains devices which are dangerous and can cause serious or fatal injury Some control panels starters may contain live terminals which are supplied from a separate external source It is essential that all supplies are isolated before working on the control panel starter Because of this danger it is recommended that any personnel working on the equipment are within sight of other personnel at all times Persons responsible for installation should have a working knowledge of the IEE Wiring Regulations Health amp Safety At Work Act 1974 and the Electricity At Work Regulations 1989 No special tools are required to service the control panel starter EQUIPMENT SHEETS PAGE 126 GUIDANCE ON INSTALLATION BEFORE INSTALLATION Remove packing materials and check inside and outsid
25. Road Ipswich Suffolk England IP1 5PB Tel 44 0 1473 242000 Fax 44 0 1473 745451 www compalr com Contract Number 1323436 Customer Reference L C Number 1509468 Description of Equipment 5437 1323436 5437 COMPRESSOR BLOCK Vee Type Four Stage Two Crank Single Acting Reciprocating Water Cooled Gas Design Type AIR Test Medium Air Test Date 10 February 2011 Target Speed Customer Unit Of Pressure PSIG Customer RPM 1800 L CL mua Customer Free Air Delivery M Hr 166 60 sine Inlet ES Inlet Pressure EN 5003 8 85 Final Delivery SafetyValveSet 5584 Motor Used 63 3KW Volts 40 RPM Motor 1 Amps 60Hz Manufacturer Kw Phase Type NN Test Performed By Dated Test Supervisor Dated British Standard BS ISO 1217 2001 Capacity Test The results contained in this report are valid only for the conditions under which the test was conducted and the specific item tested COMPAIR REAVELL 98407 1825 iss 1 TEST SHEET TEST CERTIFICATE New Set Test Serial Number H21069002 From Gardner Denver Ltd To GARDNER DENVER INC High Pressure Division Reavell House 53 56 White House Road Ipswich Suffolk England IP1 5PB Tel 44 0 1473 242000 Fax 44 0 1473 745451 www compair com Contract Number 1323436 Customer Reference L C Number 1509468 Descrip
26. Road IPSWICH ENGLAND IP1 5PB Telephone 44 0 1473 242000 Fax 44 0 1473 745451 Parts Fax 44 0 1473 743468 Service 44 0 1527 838632 www compair com e mail sales ipswich compair com TABLE 1 SERVICE MANUAL FOR A 5437 1 1A WATER COOLED AIR COMPRESSOR ie e 7 aa lid 8 A 9 10 1 4 SAFETY PROCEDURES quce cte 10 13433 GENERAL haa otra tal aan 11 ate eter a 11 1 4 3 12 1 4 4 INSTALLATION PRECAUTIONS 12 1 4 5 OPERATIONAL PRECAUTIONS corte leida 12 1 4 6 MAINTENANCE 8 REPAIR PRECAUTIONS 13 1 47 PRECAUTIONS IN THE EVENT OF FIRE 14 2 COMPRESSOR LOG SHEET ttt ttt ttt ttt ttt ttt ttt ttt ttt ttt ttt Dette dtd 15 8 O AMENDMENTS dede tette Mera nee esas 17 4 LEADING PARTICULARS dada Donee Satu Este Eres 19 44 UNIT DESIGNATIONS a ed ci a teat e e dm 19 AD TECHNICA a O gaya AD n 19 0 aeg 19 422 TEMPERATURES ta khaka cat co 19 4 2 3 OPERATING SPEEDS usina ade dal al cid 19 en 20 425 PRESSURE ar nee een 20 95 20 BOT 20 428 INTERNAL sehr 20 0 0 20 4 2 10
27. Service 44 0 1527 838632 Fax 44 0 1473 745451 Parts Fax 44 0 1473 743468 www CompAir com e mail sales ipswich CompAir com EQUIPMENT DATA SHEETS Page 27 8 CONTRACT SPECIFIC PARTS 8 1 DIFFERING FROM STANDARD COMPRESSOR REF No PART No DESCRIPTION QUANTITY 3 5 D100526 BEARING HOUSING COVER OUTER END 1 8 2 EXTRA TO STANDARD COMPRESSOR PART NUMBER DESCRIPTION QUANTITY E60248 1 FLYWHEEL COMPRESSOR 1 D72878 ADAPTOR PLATE FLYWHEEL 1 98446 1009 WATER PUMP 1 C201809 FLANGE WATER PUMP INLET 8 OUTLET 2 C201503 JOINT WATER PUMP FLANGE 2 PS1923 3 CAPSCREW WATER PUMP FLANGE 4 C201504 JOINT WATER PUMP TO BRACKET 1 D100527 BRACKET WATER PUMP 1 C201538 JOINT WATER PUMP BRACKET TO COVER 1 C201537 SPROCKET 17 TOOTH WATER PUMP DRIVE 1 C85739 1 GEAR WHEEL 18 TOOTH WATER PUMP DRIVE 1 PS2062 ROLLER CHAIN WATER PUMP DRIVE 1 98418 1018 ANTI VIBRATION MOUNT 4 PS2197 4 SOLENOID VALVE DDV S 1 1 98650 1355 385 SAFETY VALVE COMPRESSOR DELIVERY 98407 1825 iss 1 EQUIPMENT DATA SHEETS Page 28 98407 1825 iss 1 A WARNING A The use of replacement parts or lubricating oils not supplied recommended or approved by CompAir Reavell may lead to failure in service which would not be covered by the warranty Any unauthorised modifications or failures to maintain this equipment
28. Speriodal Graphite Iron Third amp Fourth Stage Cylinder Block Speriodal Graphite Iron 1st 2nd 8 Stage Cylinder Liners Grey Cast Iron 4th Stage Cylinder Liner Nitrided steel 1st amp 2nd Stage Cooler Tubes Copper 3rd 8 4th Stage Cooler Tubes Stainless Steel Cooler covers amp separators Spheriodal Graphite Iron Gudgeon Pins Steel Tube plates Cast Iron Piston Rings Cast Iron TECHNICAL DESCRIPTION PAGE 27 5 3 LUBRICATION A forced feed oil pump pressurises the lubrication system conveying oil from the crankcase to the main big end and small end bearings via a replaceable filter element Oil thrown off the moving parts ensures adequate lubrication to all stage pistons crossheads and cylinders Oil returns to the crankcase and is drawn up to the pump suction through a strainer Low Oil Pressure Oil filter Switch Oil filter By pass Oil Pump Main Bearing O E An oil pressure gauge indicates if over pressure and is relieved through a safety valve within the oil pump A protective Low Oil Pressure Switch or LOP is installed to shut down the compressor if the pressure falls below 1 bar 15 psig On starting if the oil pressure has not built up within about 10 seconds the LOP connected to a delay timer in the motor starter control will shut down the compressor THE GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED TO THE USE OF LU
29. TO 12 FEMALE ADAPTOR ANTI VIBRATION MOUNTS lt 25 98241 1173 TERMINAL BOX 120 122 91 1 26 70025 ADAPTOR 172 BSP TO 1 2 1 MATERIAL REAVELL CODE brawn H Ayala COMPAIR UK LIMITED H A DO NOT SCALE IF IN DOUBT ASK pan 2 Men or add GENERAL ARRG T 5437 O B A M THIS DRAWING IS THE COPYRIGHT 7 THIRD ANGLE MANUFACTURING TOLERANCES TO BE AS FOLLOWS UNLESS OTHERWISE STATED SCALE 1 8 APPROVED R Blake 11 01 2011 IPSWICH GARNER DENVER INC PROPERTY OF COMPAIR UK LIMITED je PROJECTION MACHINED 3 ANGULAR 05 A1 PLOT PHASE DRAWING ISSUE AND MUST NOT BE COMMUNICATED 1 S 0 COPIED WITHOUT THEIR WRITTEN Sac TEGERE m FABRICATED 15 GAST BS66IS CT pooner 5437 ISSUE DATE 11 01 2011 UNITED KINGDOM SHT 1 PERMISSION LOCATION DIMENSIONS IN MILLIMETRES SURFACE TEXTURE VALUE IN MICROMETRES TEL 44 0 1473 242 000 IS A4 1 6 1 4 A AS ISSUE DATE sortune Inventor 11 MACHINE WHERE REMOVE SHARP EDGES 1323436 LAST OF 1 SHTs al DRAWINGS Page 23 6 2 P amp l DIAGRAM E47724 98407 1825 iss 1 DRAWINGS Page 24 98407 1825 iss 1 SUCTION FILTER SILENCER COOLING WATER OUTLET CONNECTION 1 1 4 NPT F 1ST STG 1ST STG 2ND STG 2ND 576 3RD STG 3RD STC 4TH STG 4TH STG COOLER SEPARATOR COOLER SEPARATOR COOLER SEPARATOR COOLER SEPARATOR 1 2 COO
30. WATER TEST PRESSURES nennen 21 4211 SAFETY VALVE SETTINGS Seal air 21 21 4213 EXTERNAL DIMENSIONS ae tee adea Pa pco ba n it 21 43 TORQUE WRENCHISETTINGS strato on cta ba Gus od uas 22 44 RUNNING CLEARANCES AND WEARING DIMENSIONS ttes 23 5 TECHNICAL DESCRIPTION LES na nen te ee 25 Bair GENERAL d re 25 52 MATERIALS OF CONSTRUCTION nun 26 3 0 i 27 5 4 CONDENSATE REMOVAL eerte aN 27 5 5 28 551 SUCTION SILENCER AIR FILTER et eines 28 5 5 2 STAGE AIR RELIEF VALVES 28 bb BURSTING deities ar pier eee Het cedet ege pee 28 OF 2 PRESSURE UE e e dl e 28 555 PNEUMATIC WATER VALVE ad 28 556 HIGH AIR TEMPERATURE SWITCHES 0 28 5 57 FINAL DISCHARGE NON RETURN VALVE trarne 28 6 INSTALLATION INFORMATION en ee 29 6 1 UNPACKING AND HANDLINGE anne ei 29 TOC ATION RR n rr 29 65 5 oce ae es en ee el 29 64 CONNECTIONS ee en 29 29 642 PINAL DELIVERY na un an el en nee een aa 29 29 B4 een er ee 30 6 4 5 PNEUMATIC WATER INLET VALVE 30 546 MOTORS mrt 30 64 7 JSOLENOID VALVE es 30 6 4 8 HIGH AIR TEMPERATURE SWITCHES 30 6 4 9 LOW OIL PRESSURE 30 6 5 WATER FLOW P
31. WHEN SWITCH IS SET AT MAXIMUM VALUE EQUIPMENT SHEETS PAGE 124 CONTROLLER TRIP POINTER USED ON PART No STOP SETTING COMPRESSOR MODEL 202556 1 125 5236 1 202556 2 140 5212 202556 3 150 5336 5415 202556 4 155 5215 amp 5217 202556 5 170 5236 2 5315 202556 6 180 5415E5317 5417 5417N C202556 7 205 5436 CU TUBES 202556 8 220 5436 1 2 5436 5436 54365 8 5437 202749 1 200 5280 202749 2 210 5280 202749 3 175 5409 202960 1 75 WATERCOOLED 5 DELIVERY C202960 2 60 5211 C202960 3 55 WATER OUTLET C202960 4 80 5207 5209 5213 C202960 5 50 5417N 5436N C202964 1 75 5280 5281 5282 5283 DELY C202964 2 60 5450 5470 DELY CONTROLLER TEMPERATURE RANGE USED ON PART No C COMPRESSOR MODEL 98288 1089 50 250 WATERCOOLED 5000 SERIES 98288 1121 0 120 WATERCOOLED 5000 SERIES CONTROLLER WHERE FITTED USED ON PART No COMPRESSOR MODEL 98288 1093 151 5th STG DELIVERY 5450 amp 5470 98288 1094 FINAL DELIVERY 5450 amp 5470 TO SET 98288 1215 THE PURPOSE OF THIS SWITCH IS TO PREVENT THE COMPRESSOR FROM STARTING IN LOWER THAN RECOMMENDED AMBIENT TEMPERATURES IT IS FITTED AT THE COMPRESSOR GAS INLET PORT THE MINIMUM TEMPERATURE OF 10 C HAS BEEN SET AT THE FACTORY BUT THIS CAN BE RAISED ON SITE IF REQUIRED BY FOLLOWING THE PROCEDURE BELOW RELEASE ADJUSTING KEY A FROM BACK OF INSTRUMENT BY REMOVING SECURING NUT
32. and all the wiring is effectively supported 12 INSTRUMENTS Ensure all instruments are reading zero when no power is supplied Adjust if necessary Check that all instrument cases and glasses are intact Replace if necessary Ensure instrument mountings are effectively tight and that instrument connections particularly ammeters are tight and not suffering from any corrosion Remove corrosion and protect with electrical varnish or replace instrument if necessary CHECKING INTERVALS It is also advisable to carry out the mechanical checks detailed previously at regular intervals throughout the life of the equipment How often these checks are carried out depends on the particular circumstances of the site and operation involved For starters operating once or twice a day in a relatively clean environment a check every 12 months is probably all that is necessary However for a site which is very dusty and where a starter may operate several hundred times a day it may be necessary to carry out the checks every 2 to 3 months to ensure that no problems develop to an extent that could cause failures SPARES Most parts of the equipment are not regarded as serviceable items and therefore in general complete components are required In order to ensure that the correct parts are supplied please quote the details given on the starter legend plate WARRANTY All goods are guaranteed for one year from date of purchase This does not effect the statu
33. and have burrs or corrosion Reassemble in the correct order and tighten screws evenly to the correct torque SAFETY NOTE ONLY USE GENUINE REPLACEMENT DISCS 8 4 2 CORROSION ROD Drain the water from cylinder blocks and remove the assemblies If seriously corroded renew 8 4 3 SAFETY VALVES With machine running at or near maximum pressure ensure valves are not leaking significantly A very slight leakage of air is quite normal DO NOT listen or look directly at discharge ports A simple method is to fit a balloon or similar over the discharge Renew faulty valves DO NOT ATTEMPT REPAIR 8 4 4 LOW OIL PRESSURE SWITCH None If faulty renew 8 4 5 HIGH AIR TEMPERATURE SWITCHES None If faulty renew 8 4 6 MAINTENANCE OF SOLENOID VALVE None If faulty renew 8 47 NON RETURN VALVE None If faulty renew 8 4 8 AIR INTAKE FILTER SILENCER Remove air filter element from unit Replace paper element Brush or blow out dust and dirt from suction silencer Replace air filter element into unit ensuring it sits firmly on the seal 8 49 OIL FILTER Remove filter spin on type by unscrewing anti clockwise Fit new spin on filter lightly oil sealing ring before fitting Tighten hand tight Check for leaks on restart MAINTENANCE AND REPAIR PAGE 55 8 5 SERVICING COMPRESSOR 851 OIL PUMP If the pump is in anyway unsatisfactory replace 8 52 FIRST 8 SECOND STAGE COOLER TUBESTACK Remove cooler end cover
34. and separator from non drive end Remove from drive end 274 stage separator remove separator cover to gain access to all studs Remove and withdraw combined cooler tubestack for 1 and 274 stage from driving end Wash and brush down exterior of tubes baffle plates and clean water passages Inspect for corrosion and hydrostatically test and replace as necessary To refit smear cooler end covers and cooler body bore with silicone sealant Push the cooler assembly through body studded end first until O ring groove is exposed Silicone and fit O rings pull back cooler and silicone and fit O rings to other end and then push in flush with O E Fit outer end cover without gasket tighten bolts then remove cover and clean excess silicone from face Fit gasket and then finish assembly 8 5 3 THIRD STAGE COOLER COIL DO NOT ATTEMPT to remove cooler coil assembly end fittings This is a brazed assembly containing high pressure Disconnect 3 stage inlet pipe remove separator remove large circlip from outer end and withdraw Remove outer shroud tube Wash and brush down exterior of tubes and clean cylinder block water passages If airflow through tube coil is restricted or there is any doubt to internal cleanliness renew complete assembly Inspect for corrosion and hydrostatically test and replace as necessary Fit new O ring seals smear cooler end covers O rings and cooler body bore with silicone sealant Refit to body 8 5 4
35. energise the solenoid valve for between 5 10 seconds every 10 30 minutes to periodically dependent upon ambient temperature and humidity Contact CompAir UK Ltd for more information on humidity if required This will allow the diaphragm drain valves to operate and discharge any accumulated condensate Adequate flexibility shall be ensured to allow for movement of the set on the anti vibration mounts 6 4 7 SOLENOID VALVE The cable should be run through a suitable flexible armoured cable sheath from the motor controller 6 4 8 HIGH AIR TEMPERATURE SWITCHES The cable entry is through a conduit entry hole Details of the terminal connections are on the switch Cable should run through a suitable flexible armoured sheath 6 4 9 LOW OIL PRESSURE SWITCH See High Air Temperature Switches above Note When the compressor set is on flexible mounting it can become electrically insulated A flexible braided earth strap of suitable length to ensure it will not fail under maximum movement of the set must be fitted between the set and the its seating INSTALLATION INFORMATION PAGE 31 6 5 WATER FLOW PATH DIAGRAM WATER INLET INLET THROTTLE VALVE PNEUMATIC WATER VALVE 4 STAGE COOLER 4 STAGE CYLINDER WATER DRAIN 3 STAGE CYLINDER 3 STAGE COOLER WATER DRAIN 1 STAGE CYLINDER PN N ND WATER DRAIN _ 2ND STAGE CYLINDER 1 8 2 STAGE COOLER WATER OUTLET INSTALLATION INFORMATION PAGE
36. seat and o rings Thoroughly clean all parts to be re used Fit lightly greased new o rings 7 to new valve 6 and carefully fit into valve seat 8 Fit lightly greased new o rings 10 amp 11 to new valve seat 8 and fit into valve body 1 Refit valve rod 5 spring 9 and spring collar 3 through valve body 1 Refit adjusting screw 2 and locknut 4 Screw down adjusting screw 2 to tension spring 9 Adjust to measured set dimension recorded at start of this procedure Remove complete assembly from vice Refit completed valve to its original position Refit any pipework Start compressor and check for leaks Check back pressure is correct After maintenance of the valve it maybe necessary to make small adjustments to the preset factory or commissioning dimension to attain correct back pressure Refer to setting procedure previously described EQUIPMENT SHEETS PAGE 114 U572 H This valve is fitted to maintain back pressure through separators filters and dryers if fitted This ensures equipment reaches optimum working pressure as soon as possible to give long filter life good oil separation and low oil consumption Setting This valve is factory set or set during commissioning to the correct back pressure for the contract duty and should not require adjustment However if necessary it can be adjusted by a competent person who understands the valve function Adjustment is made by rotating adju
37. stages 5 5 3 BURSTING DISC Thin plastic membrane and PTFE metal discs protect the cooling water system against a possible cooler gas leak ruptured cooler tube etc It is not intended as a protection against water over pressure and therefore the burst pressure 17 bar or 250 psig has no particular relationship to the cooling water system operating pressure 5 5 4 PRESSURE GAUGES Pressure gauges are supplied for inlet crankcase oil and each compression stage 5 5 5 PNEUMATIC WATER VALVE This valve is a normally closed diaphragm operated shut off valve to prevent cooling water flow whenever the compressor is not operating This function is automatic since the valve is actuated by the first stage gas pressure 5 5 6 HIGH AIR TEMPERATURE SWITCHES Combined temperature indicator switches are fitted into the 3 stage delivery and at the final delivery after cooling 5 57 FINAL DISCHARGE NON RETURN VALVE Fitted at the compressor exit to prevent gas under pressure in the downstream piping or reservoir from flowing back through the machine when the compressor is unloaded and stationary INSTALLATION INFORMATION PAGE 29 6 INSTALLATION INFORMATION 6 1 UNPACKING AND HANDLING The compressor unit is delivered in a packing case All openings will have been sealed with plastic plugs or adhesive tape The packing case should be carefully disassembled to avoid damage to gauges pipework and valves etc and loose components pac
38. that periodic servicing is carried out in accordance with the information given in this manual refer to the Maintenance Section Conditions of CompAir Reavell warranty are stated in our Conditions of Sale Details of warranty for a particular unit may be obtained from the local CompAir Company or authorised Distributor 1 4 SAFETY PROCEDURES WARRANTY The Conditions of the CompAir Reavell Warranty are set out in the Standard Conditions of Sale MAINTENANCE To ensure continued trouble free operation of the compressor it is important that periodic maintenance and servicing are carried out in accordance with the information given in the Maintenance section of this Manual If any replacement or repair is needed use genuine CompAir Reavell parts WARNING The use of replacement parts or lubricating oils not supplied or approved by CompAir Reavell may lead to failures in service which would not be covered by warranty Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance instructions may make it unsafe The use of replacement parts not supplied by CompAir Reavell may create hazardous conditions over which CompAir Reavell has no control Such hazardous conditions may lead to accidents that can be life threatening cause substantial bodily injury or result in damage to the equipment CompAir Reavell can bear no responsibility for equipment for which unapproved replacement parts are i
39. to the H P line provided it is not subject to vibration and that the connecting pipe to the receiver does not exceed five metres Mount the switch by the lugs provided on the casing Where possible the pressure switch operating line should be taken from the receiver to avoid pressure oscillations It is usual to connect 1 and 2 to the compressor electrical control circuit terminals marked pressure Switch Red Pointer A Green Pointer 3 O 1 4 O 2 SETTING Example of pressure setting to 200 bar minimum and 225 bar maximum Turn screw A to raise the GREEN pointer to its highest point Turn screw B so that the higher setting 225 bar coincides with the RED pointer Turn screw A again to set the lower pressure 200 bar on the GREEN pointer NOTE ALWAYS USE A CALIBRATED PRESSURE GAUGE WHEN SETTING PRESSURE SWITCHES AS THE MARKINGS ON SWITCHES ARE FOR INDICATION EQUIPMENT SHEETS PAGE 122 13 11 PRESSURE GAUGE APP070 PRESSURE GAUGES GENERAL The pressure gauge should be installed such as to avoid exposure to heat and vibration and to enable easy observation of the dial indication IMPORTANT It is common practise to install the pressure gauge without an isolating device so to facilitate calibration or replacement the system must be de pressurised before any work is carried out The pressure gauge is liquid filled to provide better damping from pulsation s INSTALLAT
40. work Make sure all instructions concerning operation and maintenance are strictly followed and that the complete unit with all accessories and safety devices is kept in good order The accuracy of pressure gauges and temperature switches should be regularly checked at least 13 month intervals and thoroughly examined at least every 48 months They must be renewed or service exchanged when acceptable tolerances are exceeded Protection devices should be tested at each regular service interval and replaced or service exchanged if not functioning correctly The maximum pressure for safety valves under fault conditions is 1 10 times the set pressure the set pressure being a minimum of 1 05 times the maximum operating pressure to ensure seat tightness Never use a light source with an open flame for inspection Before dismantling any part of the compressor be sure that all heavy movable parts are secure After completion of any maintenance or repair ensure that no tools loose items or rags are left on or inside the compressor Do not use any flammable liquid to clean valves filter elements cooler passages pipe bores or any component carrying a flow of air or gas during normal operation If chlorinated hydrocarbon substances are used for cleaning safety precautions must be taken against toxic vapours which may be released DO NOT USE CARBON TETRACHLORIDE Precautions must be taken against using acids alkalis and chemical detergents for cleani
41. 101 13 1 1 MARINE APP001 e 101 13 1 2 STANDARD APP003 a ne 102 13 2 MOTOR SAP POG une en nee 103 133 VEEBEITDRIVE SAPPOH seele ame 104 13 4 DIRECT COUPLED DRIVE 107 135 _ SAFETY 1 67 a a dod ten baud 108 136 PRESSURE MAINTAINING VALVE APPOB9 110 13 7 SOLENOID VALVE APP138 116 13 8 VALVE 158 8 APP161 117 13 9 WATER FLOW VALVE APP704 ai 119 1340 PRESSI BESWITCH Er 120 13 10 1 LOW OIL PRESSURE APPQSB un ns ea 120 13 10 2 COMPRESSOR CONTROL na nennen 121 13 11 PRESSURE GAUGE 122 13 12 TEMPERATURE CONTROLLER APP090C tete 123 13 13 STARTER CONTROL PANEL 091 125 OF 6 7 1 SAFETY 5000 SERIES COMPRESSORS A WARNING A The use of replacement parts or lubricating oils not supplied recommended or approved by Reavell Ipswich or the failure to maintain this equipment in accordance with the maintenance instructions may invalidate the WARRANTY cause equipment failure create unsafe or hazardous conditions or result in damage to the equipment CompAir Reavell Ipswich cannot accept responsibility for damage injury or failure caused by these situations
42. 3 95602 100 14 2 4 95602 140 14 2 5 95602 141 14 2 6 ring 95602 98 PARTS LISTS PAGE 67 9 15 3 380 STAGE Number 14 3 1 98504 1112 14 3 2 C203686 14 3 3 203680 14 3 4 98504 1385 14 8 5 O ring 98504 1384 9 15 4 41 STAGE 14 4 1 98504 1090 14 4 2 98504 1105 14 4 3 98504 1106 14 4 4 C203687 14 4 5 98504 1386 14 4 6 C203681 14 4 7 98504 1387 9 16 VALVE 5 ees 15 1 98650 1519 15 2 98650 1039 15 3 98650 1049 15 4 98650 2037 9 17 SUCTION FILTER ree ees 16 1 Suction filter 98262 1010 1 16 1 Element suction filter 98262 1063 1 9 18 DRAIN SYSTEM Er 17 1 Washer nylon C201488 1 17 2 Washer nylon 201488 2 17 3 201820 Number Nm 17 4 066720 8 102 17 5 U334 J 17 6 U334 L 95000 256 17 8 95111 5 17 9 201804 PS2129 1 N O PARTS LISTS PAGE 68 9 19 INSTRUMENTATION Item No Number OFF 18 1 1 18 2 18 3 18 4 18 5 Pressure gauge 4th stage 98288 1005 18 6 Temperature switch 3rd stage C202556 8 18 7 Temperature switch Final stage C202960 1 9 20 SAFETY VALVES Item No Number OFF 19 1 1 19 2 1 19 3 1 19 4 1 19 5 1 9 21 RETURN VALVE Item No Number OFF 20 1 1 20 2 2 20 3 1 9 22 PIPE ASSEMBLIES 9 23 5 Item No Numbe
43. 32 OPERATING INFORMATION PAGE 33 7 OPERATING INFORMATION WARNING BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE COMPLIANCE WITH LOCAL HEALTH AND SAFETY REGULATIONS amp CONTROL OF SUBSTANCES HAZARDOUS APPROPRIATE TO THIS CLASS OF WORK TAMPERING WITH SAFETY VALVES IS DANGEROUS AND ALSO INVALIDATES THE GUARANTEE 2 stage safety valve 2 stage cylinder Oil 17 2 9 39 8 4 Pressure gauges 15 stage safety valve 1 stage cylinder Surge vessel safety valve pd LI 3 Ug 3 stage cylinder 4 stage safety valve 3 stage safety valve 4 stage cvlinder Oil filler OPERATING INFORMATION PAGE 34 7 1 SAFETY PRECAUTIONS When operating or working on the compressor unit at any time the following safety precautions must be observed Read all starting and operating instructions before running compressor Keep and rest of body clear of relief valves when compressor is being started or is running Do not bar over or work on compressor without ensuring that all equipment is isolated from the electrical supply and will remain isolated whilst work is in progress Always open high pressure air line valves SLOWLY Never attempt to stop leakage or tighten joints or loose parts when compressor is running or parts are under pressure The compressor must NEVER be operated with a malfunction in the oil or cooling water s
44. 49 7 4 1 4 2 4 3 9 3 RUNNING GEAR 9 3 1 1 STAGE Item No Description Part Number Number OFF 5 1 1 1 5 1 2 5 1 3 5 1 4 5 1 5 5 1 6 5 1 7 5 1 8 PARTS LISTS PAGE 63 9 3 2 2 STAGE ltem No Description Part Number Number OFF Bearings B E 1 5 2 2 Gudgeon pin 5 2 3 Connecting Rod 5 2 4 Piston 27 stage supplied with parts Y 5 2 5 Circlips gudgeon pin 5 2 6 Small end bearing 5 2 7 Rings Piston ring 2 stage 5 2 8 Rings Oil control ring 2 stage 9 3 3 3 STAGE Description Part Number Number OFF No Bearings B E 1 Gudgeon pin Connecting Rod Rings third stage Circlips gudgeon pin Small end bearing Crosshead supplied with parts 5 3 8 Piston 3 stage supplied with parts Y 5 3 9 Retaining bolt piston 9 3 4 41 STAGE Item Description 5 2 1 m 5 5 3 1 5 3 2 5 3 3 5 3 4 5 3 5 5 3 6 5 3 7 Number 2 5 4 5 4 2 5 4 3 5 4 4 5 4 5 5 4 6 1 5 4 7 5 4 8 09 85727 2 066395 95650 25 96072 74 98477 1143 0101589 203685 98086 1028 Bearings Gudgeon Connecting Rod Circlips gudgeon pin Small end bearing Piston ring Crosshead Piston 4 stage supplied with parts Y Retaining bolt piston 9 4 CRANKSHAFT Description Number Item No Keep plate Tab washer Setscrew 3 4 16 unf x 1 LG Crankshaft supplied with parts Key 1 6 2 6 3
45. 6 5 bd PARTS LISTS PAGE 64 9 5 CYLINDER BODY 17 2ND STAGE Item No Description Part Number 7 1 Stud M10 x 60 8 0 Stud M12 X 40 Stud M20 X 45 Screw M12 x 20 N 7 4 7 5 7 6 7 7 Nut M20 Nut M12 M16 eyebolt 1 and 2 stage cylinder body 7 9 Stud M10 x 145 8 0 7 10 Stud M10 x 97 0 7 11 Gasket 7 12 Nut M10 2 9 6 COOLER 1271 2 STAGE Description Part Number Number OFF Stud M10 x 60 s o 7 Nut M10 Circlip Tube plate 1 Stud M10 x 145 s o 5 Stud M10 x 45 s o 12 7 1 0 NIN N 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 8 2 7 8 2 8 8 2 9 8 2 10 8 2 11 8 2 12 8 2 13 8 2 14 plate Baffle plate Baffle plate Rod spacer Stud M10 x 165 s o ring Cooler tube 1st amp 2nd stage Cooler tube starfin 9 7 SEPARATOR 1 8 2ND STAGE Description Part Number Number OFF 8 2 Separator 1 stage 1 8 1 2 Cover 1 stage separator 8 1 3 Separator 2 stage 8 3 1 Cover 2 stage separator 8 1 4 Joint 1 8 2 stage separator 8 1 5 Joint 2 stage separator 8 1 6 Joint 1 stage separator 8 1 7 Joint 2 stage separator 20 821 m 822 823 824 wami 825 5c 1 826 827 828 829 82 10 82 11 8212 8213 82 14 A ltem No PARTS LISTS PAGE 65 9
46. 9 O RING VITON BS REF No 0251 16 BRACKET DO NOT REMOVE THE BRACKET 11 1 8 O RING VITON BS REF No 0221 16 IN SERVICE AND REFIT AFTER MAINTENANCE MAX WORKING PRESSURE 430 BAR 6250 PSI SETTING THIS VALVE IS FACTORY SET HOWEVER IT CAN BE ADJUSTED BUT REFERENCE MUST BE MADE TO THE MANUAL SECTION APP 059 FOR INSTRUCTIONS x L 150mm MAX 8 10 11 CY 4 6 3 9 4 Z x 2 5 2 COMPAIR UK LIMITED REAVELL HOUSE 53 56 WHITE HOUSE ROAD di com pari 20 12 2005 IPSWICH SUFFOLK IP1 PB U K TEL 44 0 1473 242 000 ww REVISED GENERAL MANUFACTURING TOLS s EAE aremoveo T J Chick 30 09 2008 U572 G PMV REFERENCE DRAWING PRODUC ISSUE DATE 30 09 2008 PHASE DRAWING No ISLE LAST MOD No Dv 510 158 A1 EQUIPMENT DATA SHEETS PAGE 113 MAINTENANCE Removing valve and Ensure all pressure has been released from pressure maintaining valve and system Remove any pipework from valve Dismount valve from system and hold securely in workshop vice Measure and record dimension between underside of adjusting screw 2 and valve body 1 It will be less than 150 mm Slacken locknut 4 and remove together with adjusting screw 2 Withdraw valve rod 5 spring 9 and spring collar 3 through valve body 1 Unscrew and remove seat 8 together with valve 6 Discard old valve
47. A 80 to 140 10 to 15 1 0 to 1 5 B 125 to 200 20 to 30 2 0 to 3 1 200 10 400 40 to 60 4 1 1 D 355 to 600 70 to 105 7 1 to 10 7 Method of Belt Tensioning Using a Belt Tension Indicator 1 Calculate the deflection distance in mm on a basis of 16 mm per metre of span Centre distance m X 16 Deflection mm If distance amp deflection is known go to 2 2 Set the lower marker ring at the deflection distance required in mm on the lower scale 3 Set the upper marker ring against the bottom edge of the top tube 4 Place the belt tension indicator on top of the the centre of span And apply a force at right angles to the belt deflecting it to the point where the lower marker ring is level with the adjacent belt on single belt drives place a straight edge across the two pulleys to act as a datum 5 Read off the force value indicated by the top edge of the upper marker ring 6 Compare this force to kgf value shown in the table above 7 Tighten or loosen tensioning screws to achieve correct value 8 If measured force falls within the values given the drive should be satisfactory Note If a belt tension indicator is not available a suitably scaled spring balance and rule will suffice BELT TENSION INDICATOR 10 20 30 40 50 0 14 12 10 6 L L E L DEFLECTION DEFLECTION FORCE IN mm IN kgf EQUIPMENT DATA SHEETS PAGE 107 13 4 DIREC
48. ATH DAA e rsen tun een 31 7 OPERATING INFORMATION ties 33 0 ae ae 34 7 2 COMMISSIONING CHECKS Ne 34 73 STARTING AFTER COMMISSIONING CHECKS Ne 35 A U San 35 75 ROUTINE ATTENTION WHILE 35 76 STOPPING PROCEDURE ar 36 77 PREPARATION FOR SPECIAL ENVIRONMENT Ne 36 78 STARTING AFTER LONG PERIOD OF IDLENESS 36 7 9 INHIBITION FOR STORAGE urat enndem ee 36 794 INHIBITION FOR UP TO SDCMONTES een 36 7 9 2 LONG TERM STORAGE uda oec tet 37 7210 aec m 38 7 10 1 SAFETY VALVE S BLOWING eek 39 7 10 2 FAILS TO REACH PRESSURE ricas dais 39 7 10 3 LOW COMPRESSOR OUTPUT una een 39 73104 STOPS SUDDENLY ada at 40 7 10 5 WILL NOT START ae ee en ms era 40 7106 OVERHEATING Mul En 40 7 10 7 OVERHEATING RADIATOR SET 40 7 109 LOW OIEPRESSUBE ate 41 710 9 CUTS OUT 41 7 10 10 UNUSUAL NOISE ON LOAD inen 41 7 10 11 UNUSUAL NOISE UNLOADED come Basen are en 41 7 10 12 HIGH OIL CONSUMPTION se ee ee re 41 7 10 19 000 41 B MAINTENANCE AND REPAIR 2 25 een lin 43 8 1 MAINTENANCE ae len teta fases d Outre 43 TABLE PAGE 3
49. BLOWING OPERATING INFORMATION PAGE 39 Recommendation s Renew final pressure switch or re adjust top pressure cut out point 4 stage relief valve blowing final pressure switch not cutting out 3 stage safety valve blowing 27 stage safety valve blowing 1 stage safety valve blowing 4 stage relief valve blowing incorrectly set or re assembled items 4 stage relief valve blowing new Installations Intake air filter dirty or blocked 2 Unloader drain valves not closing 7 10 2 FAILS TO REACH PRESSURE Compressor valve malfunction Safety valve blowing Check 4 stage valve springs and plates replace 4 stage valve complete Check safety valve operating pressure Check 3 stage valve springs and plates or replace 3 stage valve complete Check safety valve operating pressure Check 27 stage valve springs and plates or replace 274 stage valve complete Check safety valve operating pressure Check setting of downstream system valves Check stage safety valve operation Verify pipework bore is large enough has a minimum of bends at the largest possible radius Ensure any Uni directional flow valve is fitted the right way round v Check air intake filter detector if dirty renew Y Check solenoid valve is operating correctly and the DDVs seat properly Y Check that operating air pipework is not damaged or blocked at 1st stage separator end
50. BRICANT NOT RECOMMENDED BY COMPAIR 5 4 CONDENSATE REMOVAL Diaphragm Drain Valves or DDV s are installed after each compression stage to automatically drain oil moisture collected in each inter stage separator and to act as unloader valves to remove any air load on starting All these valves are similar in design and operation only the valve orifice and seat vary to suit each stage Each DDV is operated by pilot air pressure from 1 stage via a three way solenoid valve With no pilot air pressure DDV outlets are open to atmosphere In operation pilot air pressure acts on the DDV diaphragms to close the valves A timed signal every 10 20 minutes actuates the three way solenoid valve for 5 10 seconds to release the air pressure and allow the valves to open and drain the collected condensate in each separator The sudden release of air and condensate exits the compressor via an integral surge vessel for connection to a suitable containment treatment system TECHNICAL DESCRIPTION 28 5 5 EXTERNAL COMPONENTS 5 5 1 SUCTION SILENCER AIR FILTER Should be attached by customer to air intake pipework to provide maximum sound attenuation with minimum air resistance together with a replaceable filter prevent particle ingress Air should be drawn from a clean dry cool source 5 5 2 STAGE AIR RELIEF VALVES Safety valves are fitted to compressor inlet crankcase surge vessel and all compression
51. ENT Required Deflection Force at Centre of Span Compressor Speed Ranges Newtons Above follows current BS3790 practice RECOMMENDED TENSIONING FORCE oe Centre Distance Belt tension indicator applied to mid span n IR Straight edge If belt tension is incorrect release the compressor holding down screws enough to allow the adjustment screws to be free to slide the compressor on its adjustment slots without being too loose Using a suitable straight edge long enough to span both pulleys use method as described on page 3 to tension the belt Note When using the adjusting screws it is important to maintain both the correct belt tension and pulley alignment Having established the correct deflection and pulley alignment tighten compressor holding down screws check deflection is correct If not repeat tne whole sequence again ADJUSTMENT METHOD EQUIPMENT SHEETS PAGE 106 TABLE Belt Force required to deflect 16 mm metre of span Section Small Pulley Newton Kilogram force 6 N kgf SPZ 67 to 95 10 to 15 1 0 to 1 5 100 to 140 15 to 20 1 5 to 2 0 SPA 100 to 132 20 to 27 1 5 to 2 7 140 to 250 27 to 35 2 7 to 5 160 to 224 35 to 50 3 5 to 5 1 236 to 315 50 to 65 5 1 to 6 6 SPC 224 to 355 60 to 90 6 1 to 9 2 375 to 560 90 to 120 9 2 to 12 2 8V 335 amp above 150 to 200 15 3 to 20 4 Z 56 to 100 5 to 7 5 0 5 to 0 8
52. Ear defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter Be aware high noise levels can interfere with communication 1 4 6 8 REPAIR PRECAUTIONS Competent persons under qualified supervisor must carry out maintenance repair and modifications e The compressor will have a preserving oil applied to interior surfaces Oil lubricated models Oil free models will have desiccant bags in valve covers and distance pieces e Handling components such as seals gaskets and diaphragms should not present a personnel hazard Preservation oils again should not present a personnel hazard if handled under normal handling practices e Whilst compressors are asbestos free treat all damaged gaskets as asbestos when the Asbestos at work regulations apply e Viton O seals under normal operating conditions are safe However should there be a fire within the compressor or these seals are likely to exceed a temperature of 300 the material will decompose Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns f Viton seals appear charred or gummy do not touch with unprotected hands use neoprene or PVC gloves e Wash the area with limewater and avoid breathing any fumes If contamination of the skin occurs washes with limewater and seeks medical advice Pre Maintenance Operation e Isolate the com
53. From Gardner Denver Ltd To GARDNER DENVER INC High Pressure Division Reavell House 53 56 White House Road Ipswich Suffolk England IP1 5PB Tel 44 0 1473 242000 Fax 44 0 1473 745451 www compair com Contract Number 1323436 Customer Reference L C Number 1509468 Description of Equipment 5437 1323436 5437 COMPRESSOR BLOCK Vee Type Four Stage Two Crank Single Acting Reciprocating Water Cooled Gas Design Type AIR Test Medium Air Test Date 08 February 2011 Target Speed c Customer Unit Of Pressure PSIG Customer RPM 1800 Ama 1730 L L mus O Customer Free Air Delivery M Hr 169 80 Inlet NER AONO S Inlet Pressure Outlet Pressure 5003 8 88 Final Delivery Safety Valve St 0 5584 Test Motor Used 63 3KW Vols 40 RPM Motor No 1 60 2 Manufacturer 3PHASE Performed By Dated Test Supervisor Dated British Standard 25 ISO 1217 2001 Capacity Test The results contained in this report are valid only for the conditions under which the test was conducted and the specific item tested COMPAIR REAVELL 98407 1825 iss 1 TEST SHEET Page 17 TEST CERTIFICATE New Block Test Serial Number H21069001 From Gardner Denver Ltd GARDNER DENVER INC High Pressure Division Reavell House 53 56 White House
54. H ESSENTIAL WORK 13 Do starter to touch electrical components while is applied unless it is necessary for measurement test or adjustment Such work should always be carried out by a qualified electrician with appropriates tools and protection against an electrical hazard e Ifthe unit is equipped with a Remote Control device attach warning notices stating THIS UNIT CAN BE STARTED REMOTELY in prominent locations on the outside of the unit the other inside the control compartment Asa further safeguard take adequate precautions no one is working or checking the unit before attempting to switch on remotely controlled equipment Attach a THAT ALL PERSONNEL ARE CLEAR OF UNIT BEFORE STARTING or similar notice e Compressed air and gas piping together with cooling water piping and other parts with surface temperature greater than 70 C and may be accidentally touched should be guarded or insulated e If there is any indication that the compressor is overheating it must be shutdown A high air or gas temperature switch is fitted as standard to guard against operating with excessive temperature Beware of burns from hot oil and water when working on a unit recently shutdown e Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance Secure guards following a
55. ION amp COMMISSIONING The tightening and loosening of torque applied to the connection should be by means of the spanner flats provided on the stem and should not be by means of grasping the case as this may damage the gauge No pressure higher than indicated by the working pressure symbol W must be applied to the gauge during hydrostatic pressure testing of the system Otherwise the gauge must be isolated or removed during this operation No attempt should be made to remove a pressurised gauge The pressure system must be totally relieved if the gauge can not be isolated otherwise The remainder of the pressure medium contained in the element may be hazardous or toxic This should be considered when handling and storing the removed pressure gauge PRESSURE GAUGES IN SERVICE Always open isolating devices always gently and never abruptly as this may generate sudden pressure surges that may damage the gauge The maximum working pressure for which the gauge is suitable or also the minimum working pressure in cases of vacuum is indicated on the dial by corresponding marks Y Fluctuating pressure always reduces the maximum working pressure of the gauge Correct zeroing may be inspected by closing the isolating valve and relieving the gauge from pressure The pointer must fall within the thickened portion of the zero mark Unless the gauge temperature is considerably higher or lower than 20 C a pointer not returning to zero may indicate ser
56. J 1206 e DRAWING REFERENCE P amp I DIAGRAM E47724 1 APPROXIMATE WEIGHTS BARE COMPRESSOR 1100 Kg gt FLYWHEEL 48 5 TOTAL 1148 gt lt gt 2 ITEM PART NUMBER DESCRIPTION QTY N lt 0 pa 1 PS2197 4 SOLENOID VALVE 12 BAR 100V 60HZ 1 2 98650 1011 SAFETY VALVE 2 1 BAR 3 0334 DDV ASSEMBLY 2 4 U334 L DIAPHRAGM DRAIN VALVE 1 5 98262 1010 FILTER SILENCER MAIN BODY 1 a 2 6 98262 1063 ELEMENT PAPER 5 7 98288 1001 GAUGE 0 6 1 4 BSPP 1 8 98288 1002 GAUGE PRESS 0 6 BAR CU ALLOY 1 9 98288 1003 GAUGE PRESS 0 40 BAR CU ALLOY 174 10 98288 1004 GAUGE 55 0 160 BAR CU 1 CONNECTION DETAILS 11 98288 1005 GAUGE 0 600 BAR 1 4 BSPP 1 12 202556 8 INDICATING TEMP CONTROLLER 220 E o 2 2 8 CONNECT TO Y FEMALE ADAPTOR 2 m 15 98650 1020 3 8 SAFETY VALVE 3 8 BAR 1 2 BSPT M 3 4 BSPP F 1 lt WATER INLET 16 98650 1022 117 SAFETY VALVE 117 BAR 1 2 BSPP M 1 2 BSPP F 1 CONNECT WATER PUMP Hose rn BL E ADAPTOR TO SUIT 32mm NOM BORE FLEXIBLE HOSE 12 D 19 88134 ADAPTOR 1 1 4 NPT F 1 1 4 BSPP M 1 20 98262 1009 OIL FILTER EFL89 1 ac m CONNECT 1 FEMALE ADAPTOR gt 7 5 DIE ur A DRIVE FITTING ASSEMBLY gt a CONDENSATE DRAIN FROM SURGE VESSEL L la on op z CONNECT
57. L PRECAUTIONS near 146 MAINTENANCE 8 REPAIR PRECAUTIONS 147 PRECAUTIONS IN THE EVENT OF AMENDNMENTS ua na a aa eb rn COMPRESSOR LOG SHEET TESTSHEE diia DESCRIPTION OF OPERATION DRAWINGS 6 1 GENERAL ARRANGEMENT 41614 6 2 PSIUDIAGRAM B46 COMPRESSOR CONTRACT SPECIFIC 2 8 1 DIFFERING FROM STANDARD 82 EXTRA TO STANDARD COMPRESSOR 98407 1825 iss 1 TABLE OF CONTENTS Page 2 98407 1825 iss 1 3 1 SAFETY 5000 SERIES COMPRESSORS A WARNING A The use of replacement parts or lubricating oils not supplied recommended or approved by CompAir Reavell Ipswich or the failure to maintain this equipment in accordance with the maintenance instructions may invalidate the WARRANTY cause equipment failure create unsafe or hazardous conditions or result in damage to the equipment CompAir Reavell Ipswich cannot accept responsibility for damage injury or failure caused by these situations USE ONLY CompAir Reavell GENUINE PARTS AND AUTHORISED SERVICE AGENTS 98407 1825 iss 1 4 1 1
58. LING WATER INLET CONNECTION HOSE ADAPTOR TO TO SUIT 32mm NOM BORE FLEXIBLE HOSE CONDENSATE CONNECTION 1 1 2 FEMALE CRANKCASE REFERENCE DRAWINGS LUBRICATION GENERAL ARRANGEMENT A41614 SYSTEM e x 2 2 lt 4 lt kr O 2 e 2 lt 02 lt 02 gt 5 oc 5 gt 5 O MATERIAL prawn H Ayala 11 01 2011 Gardner Denver Ltd DO NOT SCALE IF IN DOUBT ASK u cox 11 DIAGRAM 5457 0 COMTAR ME OE AE ron Re REAVELL AND MUST NOT COMMUNICATED FABRICATED 5 CAST BS6615 CT9 UNITED KINGDOM ISSUE OR COPIED WITHOUT THEIR WRITTEN sus Released propuct 5437 ISSUE DATE 11 01 2011 TEL CEI O era 242000 PERMISSION LOCATION E47724 A dug DIMENSIONS IN MILLIMETRES SURFACE TEXTURE VALUE IN MICROMETRES AS ISSUE DATE MACHINE WERE MARKED REMOVE SHARP EDGES JoB no 1323436 LAST MOD No NONE www reavell com WorkCentre Release 1 2 COMPRESSOR HANDBOOK Page 25 7 COMPRESSOR HANDBOOK 98407 1825 iss 1 COMPRESSOR HANDBOOK Page 26 98407 1825 iss 1 Denver COMPAIR REAVELL Fora H5437 1 IA HIGH PRESSURE Compressor In any correspondence please quote COMPAIR JOB NUMBER CUSTOMER CUSTOMER ORDER NUMBER MACHINE NUMBER PUBLICATION NUMBER 98407 1273 iss6 ISSUE DATE JULY 2010 Gardner Denver Ltd Reavell House 53 56 White House
59. OWNERSHIP DATA TECHNICAL DATA It is recommended that details taken from the compressor and motor nameplates are recorded below 7 Denver Ltd 56 White House Road COMPAIR REAVELL Suffo United Kingdom www reovell com Sales Order Machine Serial Weight kgs Maximum Pressure Motor Shaft Power Number Compressor Shaft Speed S CompAir Reavell CONTACT DETAILS Contact Name Sales Telephone 44 0 1473 242000 Address Gardner Denver Reavell House 53 56 White House Road Ipswich IP1 5PB ENGLAND Telephone 44 0 1473 242000 Fax 44 0 1473 745451 Contact Names Parts Telephone 44 0 1473 242000 Parts Fax 44 0 1473 743468 Contact Names Service 44 0 1527 838632 For any comments or queries about the contents of this manual please write to CompAir Reavell at the above address marked for the attention of Mr Owen Dale Technical Author 98407 1825 iss 1 5 1 2 FOREWORD SPECIAL ATTENTION The STANDARD BUILD of all CompAir Reavell products are not intended for use in either Explosive or Potentially Explosive Atmospheres as defined in Directive 95 9 EC An Explosive atmosphere is a mixture with air under atmospheric conditions of flammable gases vapours hazes or dusts in which after ignition has occurred combination propagates to the en
60. PAGE 85 10 15 2ND STAGE VALVE 2ND STAGE VALVE DELIVERY VALVE SEAT DELIVERY VALVE PLATE DELIVERY SPRING PLATE DELIVERY BACKING PLATE SUCTION SPRING PLATE SUCTION VALVE PLATE SUCTION VALVE SEAT RING NUT ILLUSTRATIONS PAGE 86 10 16 389 STAGE VALVE 389 STAGE VALVE DELIVERY VALVE SEAT DELIVERY VALVE PLATE DELIVERY SPRING PLATE DELIVERY BACKING PLATE SUCTION SPRING PLATE SUCTION VALVE PLATE SUCTION VALVE SEAT 8 O RING 9 WASHER 10 NUT ILLUSTRATIONS PAGE 87 10 17 47 STAGE VALVE 4 STAGE VALVE NUT WASHER O RING VALVE BODY PEG VALVE PLATE SPRING PLATE VALVE PLATE SUCT amp DELY BODY VALVE PLATE SPRING PLATE BACKING PLATE VALVE BODY PEG ILLUSTRATIONS E 88 PAG 10 18 15 8 2ND D D V ASSEMBLY ITEM DESCRIPTION PART NO NO OFF 1 JOINT C200722 4 2 SEAT C200842 1 3 SEAT C201417 1 4 VALVE ASSY C201980 1 5 VALVE ASSY C201981 1 6 BODY ASSY C203190 1 1 7 LOCKNUT PS1290 4 2 8 BOLT M6 5 95006 133 6 9 DIAPHRAGM 98210 1002 2 ILLUSTRATIONS PAGE 89 10 19 8 4TH D D V ASSEMBLY ITEM DESCRIPTION PART NO NO OFF 1 JOINT C200722 4 2 VALVE SEAT C201159 1 3 VALVE ASSY C201981 1 4 BODY ASSY C203190 1 1 5 LOCKNUT PS1290 4 2 6 BOLT M6 X 75 95006 133 6 7 DIAPHRAGM 98210 1002 2
61. RA TYPE RAEM WITHOUT STOPS PART NUMBERS 98418 1022 1023 amp 1024 PREVENTIVE MAINTENANCE 1 After installation and initial running in Record height dimension H of each mount 2 After a week or 100 hours running time recheck and record dimension 3 Check this dimension every 3 to 6 months depending on usage i e regular usage every 3 months Note This dimension may only change a small amount during the life of the mount approximately 1mm 4 Any oil contact with the rubber mount will affect the life and performance so keep to a minimum by regularly cleaning and clearing any contamination from the surrounding area 5 Under normal working conditions the life expectancy will be 5 to 8 years 6 Temperatures in excess of 70 C will have an adverse effect on the rubber which will shorten the life expectancy a P 4 EQUIPMENT SHEETS PAGE 102 13 1 2 STANDARD APP003 AVA TYPE PART NUMBERS VARIOUS PREVENTIVE MAINTENANCE 1 2 3 After installation and initial running in Record height dimension of each mount After a week or 100 hours running time recheck and record dimension H Check this dimension every 3 to 6 months depending on usage i e regular usage every 3 months Note This dimension may only change a small amount during the life of the mount approximately 1mm Any oil or paint contact with the rubber mount will affect the life and performance so keep to
62. RICATION Oil recommendations are based normal conditions If difficulty is experienced a change may be advisable refer to CompAir Reavell actina rore Od 45 litres Recommended silicone grease for assembly Dow Corning 3 Recommended Synthetic Reavellite Anderol 555 Recommended oil Running in only Mineral Shell Corena P100 427 COOLING Note Water must not be allowed to freeze in the compressor water jackets coolers or in a sea water fresh water heat exchanger Sat unas a Aha Sea or fresh water Cooling water flow 15 C inlet 75 I h kW 12 gals bhp hr Coolant capacity n 46 litres 4 28 INTERNAL DIMENSIONS PISTON 0 75 First stage cylinder Dore cn cita 185 Second stage cylinder seine 95 Third stage cylinder 0 45 Fourth stage cylinder bore x AR 22mm Mean piston speed at maximum SPeed bb 4 5 m s 4 2 9 CONNECTIONS Air inlet connection nominal 75 mm Suction Filter Silencer Fourth stage 1 BSPP Condensate drain este e dde a den e E RR ae 1 BSPP W te
63. Remove oil pump priming plug using pump type oilcan prime system with correct grade oil Replace plug Arrange for compressor to discharge temporarily to atmosphere unloaded by opening the manual drain valve at the 4 stage coalescer filter drain and electrically disconnect solenoid valve by removing cable plug from solenoid coil Remove cover in the bell housing or vee belt guard and rotate compressor by hand several times to distribute oil and confirm free movement OPERATING INFORMATION PAGE 35 7 3 STARTING AFTER COMMISSIONING CHECKS On completion of preliminary checks the compressor should be run to prove operation Ensure electrical supplies are available Press ON button on motor controller and immediately press OFF button checking rotation of compressor is correct Rewire if rotation is incorrect Rotation must be counter clockwise looking on the driving end Restart compressor check oil pressure is greater than 2 bar 30 psig that air is being delivered from each stage and listen for any uncharacteristic noises Check for air oil and water leaks If leaks are found stop compressor isolate supplies and rectify NOTE DO NOT TRY TO CORRECT LEAKS WHEN ITEMS ARE PRESSURISED Stop compressor and isolate power supplies after running unloaded for 30 minutes and check that outer surfaces of crankcase and cylinders are cool Replace solenoid valve plug Close manual drain valve at 4th stage coalescer filter drai
64. T COUPLED DRIVE APP011B DIRECT DRIVE Ensure compressor and drive motor is correctly aligned as the flexible couplings are for vibration duties only and not as non alignment couplings Note direct coupled sets with bell type housing see below are self aligning TYPICAL DRIVE COMPONENTS 10 e AS FITTED GAP 2 0 2 5mm DIRECT DRIVE CHECKING FOR FREE PLAY AND WEAR After the first 500 hours and every 2000 hours more frequently on arduous duties such as more than 6 starts per hour on auto stop start operation check the following Ensuring compressor is isolated from mains supply remove inspection cover 1 from bell housing 3 to expose drive components 5 6 amp 7 then by gripping the motor half coupling 5 firmly check for free movement by rotating backwards and forwards The amount of free movement should be minimal 0 5 to 1 0 mm excessive movement i e 3 to 4 or more should be investigated and the rubber couplings 6 replaced complete set as necessary EQUIPMENT SHEETS PAGE 108 13 5 SAFETY VALVE APP167 INSTALLATION AND OPERATING INSTRUCTIONS SAFETY VALVES INTRODUCTION Due consideration should be taken of climatic Process or other conditions which might adversely affect the performance of the safety valve Installation must be undertaken by qualified technicians and to good engineering practice In addition user s attention is drawn to our joint responsibility to ensure
65. Y Renew diaphragm and valves in the DDVs 15 stage air valve suction valve most likely to need attention but check for correct assembly and condition or for leak from plates springs in all stage air valves Check safety valve is not faulty and replace if not serviceable DO NOT ADJUST SAFETY VALVES Electrical fault Y Check pressure switch setting Does not reach pressure 7 10 3 LOW COMPRESSOR OUTPUT Low output due to cylinder piston ring wear Blow by noted from crankcase breather pipe Y Check solenoid valve is operating correctly and the DDVs seat properly v Check that operating air pipework is not damaged or blocked at 1st stage separator end Y Renew diaphragm and valves in the DDVs Y Check and renew inlet filter element Check for Piston ring leakage blow by check final 4 stage piston rings for wear then progressively 39 2 and 1 OPERATING INFORMATION PAGE 40 Symptom poe Recommendation s 740 4 STOPS Low oil pressure Y Check switch switch operating gt Check oil level replenish sump after removing SUDDENLY any condensate in sump Check amp clean oil strainer Y Renew oil filter Y Renew oil pump Y Check for bearing wear replace as necessary v Check switch amp setting Final High air Y Check cooling water exit temperature does not temperature exceed 50 switch operating Check cooling water temperature rise is 10 12
66. a minimum by regularly cleaning and clearing any contamination from the surrounding area Under normal working conditions the life expectancy will be 5 to 8 years Temperatures in excess of 70 C will have an adverse effect on the rubber and will shorten the life expectancy 2 6 EQUIPMENT DATA SHEETS PAGE 103 13 2 MOTOR APP034 ELECTRIC MOTOR MAINTENANCE WARNING Isolate power supply to motor before commencing any routine cleaning or maintenance work Routine Cleaning Remove the fan cover and ensure that all holes are completely open Clear any dirt and fluff from behind the fan and along the ribs of the frame Periodic Maintenance Remove the cover and the fan which is fitted on the shaft extension Slacken and remove bearing cover screws and endshield bolts studs The endshields should then be eased off their spigots The rotor can now be withdrawn carefully from the stator Having dismantled the motor maintenance can now be carried out to remove all dirt Dry compressed air under comparatively low pressure is best as a high velocity stream can force dirt into the spaces between windings etc Grease removing solvents should only be used very sparingly so as not to damage impregnating varnish or insulation Bearings are charged with sufficient grease to last at least two years provided there is little or no grease leakage When replenishing use only good quality lithium based grease and avoid overfilling the be
67. ailure to observe these precautions given under Safety Precautions may be considered dangerous practice or misuse of the compressor Read and understand all WARNINGS CAUTION AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing 1 4 WARNINGS CAUTIONS 8 NOTES The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in Machinery Directive 89 392 EEC Amended 91 286 Warnings call for attention to operating procedures involving specific hazards which could cause injury or death and are identified by the following RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST AN A RISK OF ELECTRIC SHOCK RISK OF HOT SURFACE CONSULT MANUAL 12 1 4 3 GENERAL SAFETY PRECAUTIONS e When using cleaning solvents local Health and Safety Regulations must be complied with Provide good ventilation and use suitable protection such as a breathing filter mask safety glass protective apron and gloves e Safety footwear should be compulsory in all workshops Safety helmets must be worn if there is any risk of falling objects e If using compressed air for cleaning purposes ensure safety regulations are complied with and appropriate clothing worn e Never direct compressed air onto your skin or at other people Never use compressed air to clean loose dirt from clothing e Before releasing compressed air through a hose make
68. air intake ambient temperature for radiator 5 5 30 C Higher ambients possible contact Compair UK Ltd Engineering for more information Maximum cooling water inlet temperature 37 C Temperature rise across machine Normal requirement 10 12 C Note It is important for the life and safety of the machine not to exceed the maximum operating temperatures 4 23 OPERATING SPEEDS Minimum t ce a a eee ote da 750 rev min Maximuim speed n er co ede reo ced Ein 1800 rev min 1st stage piston displacement at maximum speed 217 7m3 hr LEADING PARTICULARS PAGE 20 4 2 4 CAPACITY R 5437 1 1A Capacity at constant pressure Speed 160 bar 250 bar 350bar rpm m3 hr m3 hr m3 hr 750 69 7 605 9 64 9 1000 89 2 88 7 87 0 1250 111 6 110 7 109 8 1460 132 7 131 7 130 5 1500 136 7 135 6 134 5 1760 156 2 154 8 153 9 1800 159 2 157 8 156 9 4 2 5 PRESSURE Maximum Working pressure P cei 350 bar Minimum working DSS 140 bar MINIMUM Water preSSUre 0 6 Maximum water pressure 5 1 Oil pressure New 2 0 2 75 bar Minimum oil pressure Worn MACHINE Q 1 bar 4 26 LUB
69. all screw openings with threaded plastic or metal caps and flanged openings with PQ11 coating shims clamped between the flanges and attach a warning label to this effect OPERATING INFORMATION PAGE 37 7 9 2 LONG TERM STORAGE Check that the compressor has been run with the recommended oil Drain oil from the sump preferably while still warm and till to normal level with PQ11 fluid Run the compressor for 30 minutes on light load with the final delivery pipe disconnected and with all separators open Cut down the cooling water supply during this run so that the water outlet temperature is from 38 C to 49 C After 30 minutes stop the compressor turn off the cooling water disconnect the water supply and drain off the water EITHER Dry out the water jackets with compressed air if available Insert air hose at water outlet connection and pass air through jackets until water ceases to flow from water inlet connection IMPORTANT Do not pressurise jacket with air during this procedure OR Alternatively if air is not available fill jacket with PX10 water displacing fluid and allow standing for 15 minutes before draining off If it is impossible to run the compressor remove the crankcase doors and coat running gear and crankcase with PQ11 using spray gun rotating compressor slowly by hand When completed pistons should be in mid stroke position in readiness for inhibition of cylinders etc Replace crankcase doors R
70. and reliable operation use only genuine CompAir Reavell Parts To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance with the information given in this manual refer to the Maintenance Section Conditions of CompAir Reavell warranty are stated in our Conditions of Sale Details of warranty for a particular unit may be obtained from the local CompAir Company or authorised Distributor 1 4 SAFETY PROCEDURES WARRANTY The Conditions of the CompAir Reavell Warranty are set out in the Standard Conditions of Sale MAINTENANCE To ensure continued trouble free operation of the compressor it is important that periodic maintenance and servicing are carried out in accordance with the information given in the Maintenance section of this Manual If any replacement or repair is needed use genuine CompAir Reavell parts WARNING The use of replacement parts or lubricating oils not supplied or approved by CompAir Reavell may lead to failures in service which would not be covered by warranty Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance instructions may make it unsafe The use of replacement parts not supplied by CompAir Reavell may create hazardous conditions over which CompAir Reavell has no control Such hazardous conditions may lead to accidents that can be life threatening cause substantial bodily injury or result i
71. any CONTRACT Ref It is important this Manual is retained with the compressor for reference and should remain with the compressor if it is sold or transferred to another user Ensure that the new user is made fully aware of the need to study the Safety Section and any Warnings for safe operation given throughout the text Protect the environment by using only approved method of disposal of condensates lubricating oil etc Please note a Throughout the Manual all pressures quoted are gauge pressures b Whilst recyclable materials are used as far as possible please ensure when disposing of condensate spent oil used filter elements and any discarded parts or waste material of any kind make sure that there is no pollution to any natural water course drain system and that no burning waste takes place which could cause pollution of the atmosphere 98407 1825 iss 1 6 1 3 CAUTION Use only CompAir Reavell Genuine Parts when carrying out routine maintenance or repair The use of replacement parts or lubricating oils not supplied or recommended by CompAir Reavell can lead to expensive failures which will not be covered by warranty Substitution of parts not manufactured or approved by CompAir Reavell can create a potential personnel hazard This is a High Pressure Compressor for safe and reliable operation use only genuine CompAir Reavell Parts To ensure continued trouble free operation it is important
72. aring housing Motors should be reassembled in the reverse order from dismantling taking care not to damage the windings on insertion of rotor taking care not to damage the windings on insertion of rotor remembering to ease endshields on bearings and spigots DO NOT USE FORCE Before starting check that the rotor revolves freely Ensure that the electrical connections are correct and terminal nuts tight Refit any pulley coupling sprocket etc which have been removed being particularly careful to ensure correct alignment with the driven part as misalignment may lead to ultimate bearing failure and shaft breakage EQUIPMENT SHEETS PAGE 104 13 3 VEE BELT DRIVE 011 DRIVE RECOMMENDATIONS V BELT TRANSMISSION Details of drive arrangements and non isolation pad mountings are available from Reavell Works Ipswich An overload device must always be fitted to motors Manufacturers terminal box wiring instructions must be observed An hours run meter fitted to the motor starter is recommended for efficient maintenance scheduling Belt Drive is very important that the driving and driven pulley grooves are in line and both pulley shafts parallel V belt tensioning procedures follow normal BS 3790 1981 practice TYPICAL DRIVE ARRANGEMENT Use straight edge Use distance pieces Use straight edge for alignment as necessary Tension amp alignment adjusting screws may be on prime mover Belt Drive Tension
73. cause the compressor to stop and will prevent restart until the reset button is pressed e If current overload has operated the manual reset button located on the unit will have to be pressed e Fault light on control panel will illuminate to indicate fault status During normal running the cyclic timer will cause the diaphragm drain valves to periodically unload the separators and discharge collected condensate to a suitable collection vessel 98407 1825 iss 1 DESCRIPTION 20 98407 1825 15 1 6 DRAWINGS DRAWINGS Page 21 6 1 GENERAL ARRANGEMENT 41614 98407 1825 iss 1 DRAWINGS Page 22 98407 1825 iss 1 1 101 TI 40 PSLL101 110 TSHH 40 PI 20 PI 30 247 9 2 TSHH 30 WATER OUTLET 7 CONNECTION INAL DELIVERY CONNECTION 16 PSV 30 5 PSV 10 C g 8 OIL FILLING POINT S ITEM 24 DETAILS IN A SEPARATE DRAWING e Sl amp CONDENSATE DRAIN CONNECTION 8 WATER INLET L 250 250 A DDV RJ DDV 40 DDV 20 Q wo L 484 537 ion T Le N M L 1021 1
74. ce 2nd stage valve Valve kit 1 27 25 Replace 2nd stage valve Valve assy 1 Inspect 2 stage piston 28 29 25 Replace 2nd stage piston Piston ring kit 4 4 rings Inspect 2nd stage liner 29 Remove 2nd stage liner O ring 2 O ring 1 X X 0 Deglaze 2nd stage liner Hours Service Number HSK1201 HSK1228 HSK1236 HSK1244 HSK1252 HSK1244 HSK1236 HSK1228 HSK1260 HSK1279 12 Months From Installation Last Service Or SERVICE PLAN Service Plan 5437 PAGE 97 X X 31 Replace 2nd stage smallend Bearing S E 1 Gudgeon pins 1 Circlips 2 32 4 E replace 2nd big end Bearing Shells Pair 1 earings Big end bolts 2 X X X 33 Remove 1st stage valve Cover O ring 2 cover X 34 433 Inspect amp clean 1st stage O ring valve to valve 1 valve cover X X 35 33 Replace 1st stage valve Valve assy 1 XX Inspect 1st stage piston 36 37 33 151 stage piston Piston Ring Kit 4 4 rings XX Inspect 1st stage liner X X 37 Deglaze 1st stage liner X X 38 33 4 Replace 1st stage small end Bush 1 Gudgeon pin 1 Circlip 2 39 4 nn replace big end Bearing Shells Pair 1 earings Big end bolts 2 Inspect crankshaft IF 40 Servic
75. d hold securely in workshop vice Measure and record dimension between underside of adjusting screw 2 and valve body 1 It will be less than 150 mm Slacken locknut 4 and remove together with adjusting screw 2 Withdraw valve rod 5 spring 9 and spring collar 3 through valve body 1 Unscrew and remove seat 8 together with valve 6 retaining washer 12 and circlip 13 Remove circlip 13 from seat 8 and withdraw valve 6 and retaining washer 12 Discard old valve seat and o rings Thoroughly clean all parts to be re used Fit lightly greased new o rings 7 to new valve 6 and carefully fit into valve seat 8 Fit retaining washer 12 over valve and locate in seat 8 securing with circlip 13 Fit lightly greased new o rings 10 amp 11 to new valve seat 8 and fit into valve body 1 Refit valve rod 5 spring collar 3 and spring 9 through valve body 1 Refit adjusting screw 2 and locknut 4 Screw down adjusting screw 2 to tension spring 9 Adjust to measured set dimension recorded at start of this procedure Remove complete from vice Refit completed valve to its original position Refit any pipework Start compressor and check for leaks Check that operating pressure is correct After maintenance of the valve it maybe necessary to make small adjustments to the preset factory or commissioning dimension to attain correct operating pressure Refer to setting procedur
76. e Pre Maintenance Operation e Isolate the compressor from the main electrical supply Lock the isolator in the OFF position and remove fuses Attach label WORK IN PROGRESS DO NOT APPLY VOLTAGE e Close the isolating valve between the compression unit and user s pipework Close the isolating valve in the cooling water inlet pipe Attach a label WORK IN PROGRESS DO NOT OPEN e Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage Check that all pressure gauges register zero e Ensure that the cooling water system has been drained e Check that the drain valve on the delivery manifold is clear and gas pressure has been released e Check that all interstage drains are open to ensure any gas trapped between stages has been released 14 Stand clear of all covers when removing the securing screws When removing valve covers for valve replacement ensure a minimum of two threads is left engaged on the valve cover securing screws Lever the valve cover until the O seal is disengaged from the port in the cylinder head Remove the securing screws and take out valve cover Use only lubricating oils and greases approved by CompAir Reavell to avoid potential hazards especially the risk of explosion or fire and the possibility of decomposition or generation of hazardous gases Always clean oil spills from the surrounding floor before and after maintenance
77. e or malfunction replace the complete unit unless a simple repair is obvious 8 TIMERS Examine timers for correct range and check with suitable test equipment that the contacts are correct in the off position Timers in general are not serviceable units and should be replaced completely if suspected of faulty operation EQUIPMENT SHEETS PAGE 130 9 THERMISTOR PROTECTION UNITS Thermistor protection units should be checked with care certain parts of the circuit are vulnerable to higher voltages In the off state ie no supply voltage the relay should be checked for normally open closed contacts in accordance with the circuit diagram A test voltage of approx 500v can be applied between all terminals and earth but on no account should this check be made between the thermistor terminals terminals 1 and 2 All other checks have to be made with the supply voltage applied See Page 3 Section 4 Thermistor units are not serviceable units and should be replaced if faulty 10 INDICATOR LAMPS Check all connections to indicator lamps and ensure that they are tight Ensure that the correct type of bulb is fitted and that the lenses are not cracked In either case replace the bulb lens or complete indicator lamp 11 WIRING Should any of the insulation on the panel wiring appear damaged or should any wire fail on the insulation test then the wire involved should be replaced immediately Check that all cable supports are in position
78. e outlet pipe Discharge pipes should be as short as possible and of such a size that the pressure developed therein not reduce the relieving capacity Ensure arrows indicating the direction of the flow are pointing in the correct direction The cross sectional area of the discharge pipe should not be less than the area of the safety valve outlet Where safety valves are discharged into a manifold the manifold must be capable of accommodating simultaneous discharge of all valves connected to the manifold Atmospheric discharge or discharge pipes should terminate at a location which will not cause a hazard to personnel particular attention being given to hazardous fluids or particles GENERAL Inlet and outlet piping should be capable of supporting the safety valve so that no unacceptable mechanical load or vibration is transmitted to the valve and be sufficiently strong to withstand the effects of the reaction forces when the valve is discharging All pipework or pressure vessels to which the safety valve is connected should be thoroughly cleaned before fitting the safety valve to ensure that foreign matter does not pass through the valve Particular care should be taken with the use of scaling compounds and P T F E tape to ensure that they do not enter the valve Atmospheric discharge valves should not be painted or coated with any substance which could possibly obstruct or restrict free and full discharge through the valve Suitable protection shou
79. e previously described EQUIPMENT SHEETS PAGE 116 13 7 SOLENOID VALVE APP138 3 WAY SOLENOID VALVE PS2197 OPERATION 3 way normally closed energise to open continuous duty On starting the solenoid valve opens energised this operates the diaphragms which in turn closes the valves within the D D Vs Diaphragm Drain Valves thus allowing pressure to build up in the system to the desired pressure On shutdown the solenoid valve closes de energised this takes the pressure of diaphragms thus allowing the drains to blow any condensate collected within the stage separators INSTALLATION Technical Details Current consumption Voltage Inrush PS2197 1 a pe ais PS21976 8 DC po M0 watts PS21978 EVA Nisva PS21979 PS29711 125 108808 985165121 440 60 Electrical connection Amps pin to DIN 46242 Connector To DIN 43650 Protection IP65 Cable thread size PG9 Coil Class H 180 C insulation Coil duty Continuous Voltage tolerance from normal 10 to 10 Port Size G 1 8 Orifice Size Q1 6mm Maximum working pressure 12 bar g Working fluid Air water gas fuel oil amp non corrosive liquids Ambient temperature range 15 C to 50 EQUIPMENT DATA SHEETS PAGE 117 13 8 NON RETURN VALVE APP158 amp APP161 NON RETURN VALVES Connections 1 2 G1 2 CompAir Part Number 98650 1655 TECHNICAL SPECIFICATION
80. e remaining components should be checked for cracks distortion or other damage liable to impair the valve operation 8 3 2 ROUTINE VALVE REMOVAL AND SERVICING Valve removal is as follows for all stages Clean all grease and dirt from valve covers and surrounding areas Rotate crankshaft by hand until relevant stage piston is at top dead centre Remove valve covers nuts Use forcing screws to remove valve covers Using the special valve lifting tools remove valve assemblies A gentle rocking action pulling at the same time will free the valve from any carbon build up in the pocket Carefully wipe any loose carbon from valve pocket ensuring that no carbon is left in valve pocket or on top of the piston Move valve to a workbench and remove central nut from valve unit Carefully separate upper and lower bodies and with unit on a level surface lift off upper body Remove valve plates and springs noting very carefully their relative positions to the body and each other if they are to be re used MAINTENANCE AND REPAIR PAGE 45 8 3 3 ROUTINE VALVE REPLACEMENT Recheck that valve valve pocket top of piston and the surrounding area is clean before replacing valve assembly Ensure valve seats properly as a slight misfit will entail loss of gas Check valve cover for cleanliness before assembly Renew O rings lightly greasing before fitting There should be at least a 2mm gap between the top of cylinder and bottom of valve c
81. e the control panel starter for any obvious defects damage Check that the control panel starter is correct in all respects for the application particularly in respect of Voltage Frequency Number of phases Current rating The starter is suitable for the operating environment EDS Check all moving parts of contactors relays etc for ease of operation to ensure that they have been damaged in transit NOTE Where control panel starters have been in transit for long periods which may have subjected the equipment to vibration it is advisable to check all terminals and fixings for tightness before installation LOCATION AND MOUNTING 1 Vibration free location 2 Protect from moisture and water ingress fit anti condensation heaters 3 Ensure enclosure is dust free 4 DO NOT allow swarf to enter enclosure WIRING 1 All external connections to be in accordance with IEE Regulations 2 Fit separate earth conductor connecting through to the motor 3 DO NOT earth via conduit fittings EQUIPMENT DATA SHEETS PAGE 127 OPERATIONAL CHECKS 1 Connect incoming supply cables as shown in circuit diagram 2 Conduct operational checks before connecting the motor 3 Check the operation of control circuit It is also advisable to remove as many mains fuses is practical The number of mains fuses which may be removed is dependent on how the control circuit is supplied see circuit diagram In this condition the operati
82. e water valve U231 H Service kit 1 Replace main bearing amp oil X X 41 seal D E Bearing bush 1 Joint 1 Brg Hsg Oil seal 1 Remove end cover oil pump 42 plate O E Joint end cover 1 43 42 Replace main bearing O E Bearing bush 1 bearing hsg 1 Hours SERVICE PLAN PAGE 98 Service Kit Number HSK1201 HSK1228 HSK1236 HSK1244 HSK1252 HSK1244 HSK1236 HSK1228 HSK1260 HSK1279 12 Months From Installation Last Service Or Service Plan 5437 44 42 Replace oil pump 1 42 IF Replace water pump drive 45 ohn pump chain 1 46 a Service water pump seal 8 impellor kit 1 Joint water pump 4 bracket Joint water pump 1 Joint water pump 2 IN OUT Replace bursting discs X X X 47 Bearer Set 1 Bursting discs kit 1 X 48 drain valve Service kit diaphragm Screw seal Joint drain to surge vessel Replace diaphragm drain X 49 48 valves amp seats 4thStage 4th valves amp seats 1 50 Inspect replace diaphragm 1st 2nd valves amp seats 1 drain valves amp seats U334L 51 3rd 4th valves amp seats 2 U334J 52 Inspect test separators Joint 1st amp 2ndstage 1 Joint 1st stage 1 Joint 2nd stage 1 Joint 2nd stage 1 3 Inspect test 1st 2nd stage O ring 4 cooler
83. ed or up dated information In any communication concerning the compressor it is essential to quote the MODEL SERIAL No and any CONTRACT Ref It is important this Manual is retained with the compressor for reference and should remain with the compressor if it is sold or transferred to another user Ensure that the new user is made fully aware of the need to study the Safety Section and any Warnings for safe operation given throughout the text Protect the environment by using only approved method of disposal of condensates lubricating oil etc Please note Throughout the Manual all pressures quoted are gauge pressures b Whilst recyclable materials are used as far as possible please ensure when disposing of condensate spent oil used filter elements and any discarded parts or waste material of any kind make sure that there is no pollution to any natural water course drain system and that no burning waste takes place which could cause pollution of the atmosphere 10 1 3 CAUTION Use only CompAirReavell Parts when carrying out routine maintenance repair The use of replacement parts or lubricating oils not supplied or recommended by CompAir Reavell can lead to expensive failures which will not be covered by warranty Substitution of parts not manufactured or approved by CompAir Reavell can create a potential personnel hazard This is a High Pressure Compressor for safe
84. emove and clean compressor valves and wipe out any moisture in valve pockets and passages Immerse valves in PQ11 fluid and allow surplus to drain off Insert PQ11 into each cylinder allowing approximately 1 3 cc of fluid to each square inch of cylinder surface area Coat all surfaces and gas passages Replace valves carefully and coat valve covers with PQ11 Seal all screwed openings with threaded plastic or metal caps and tape afterwards Seal flanged openings with PQ11 coating shims clamped between the flanges and attach a warning label to this effect Attach instruction label DO NOT ROTATE THIS MACHINE For any compressor which is in storage for a long period a six monthly inspection is to be carried out as follows Remove the valve covers valves and crankcase doors Inspect the machine for signs of corrosion and carefully remove any rust that has formed Turn the compressor round by hand to ensure that the running gear is free Coat the running gear and crankcase with PQ11 using a spray gun rotating the compressor lowly by hand When completed pistons should be in mid stroke position in readiness for inhibition of cylinders etc Replace the crankcase doors Immerse valve units in PQ11 fluid and allow surplus to drain off Insert PQ11 into each cylinder allowing approximately 1 3 cc of fluid to each square inch of cylinder surface area Coat all surfaces including bottom surface of the cylinder air passages Coat the valve cov
85. ers with PQ11 and replace the valves and valve covers Check that all openings are still sealed Note PQ11 Inhibition Fluid Trade Name Crodafluid PQ11 OPERATING INFORMATION PAGE 38 7 10 FAULT GUIDE WARNING BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED ADDITIONALLY ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF NOTE A safety valve opening indicates excessive pressure and under NO CIRCUMSTANCES must a safety valve be screwed down to accommodate excessive pressure THIS IS DANGEROUS If safety valve opens or appears faulty shut down compressor immediately and investigate If fault appears immediately or shortly after a service first examine those parts disturbed during the service Following is a list covering the probably causes of operational faults together with the suggested remedies Before investigating a potential fault ensure however that Cooling water temperature temperature rise across the machine and flow rate are correct Direction of rotation is correct Sump is correctly filled Compressor servicing is up to date Electrical supply is correct If fault appears immediately or shortly after a service first examine those parts disturbed during the service 7 10 1 SAFETY VALVE S
86. essor was not part of the contract of supply the control panel operation referred to in the following philosophy is typical only To be read in conjunction with General Arrangement Drawing 41614 8 P amp I Diagram 47724 Following on site connection of electrical supply cables between compressor control panel marshalling box and motor terminal box e When control panel isolator is turned to its on position the power on light and fault light will illuminate e Press the reset button to reset trip circuit and extinguish fault light Set MANUAL OFF AUTO switch to MANUAL or AUTO as appropriate e MANUAL operation will prevent re starting of compressor once full pressure has been reached AUTO operation will allow the compressor to cycle on and off in response to delivery pressure switch e Press the start button e Immediately the low oil pressure override timer will energise power will be supplied to the star delta timer and the main and star motor contactors will be energised causing the motor to start in star mode e When the star delta timer operates the star contactor is de energised and the delta contactor is energised causing the motor to run in delta mode e Additionally timers for delay to load and diaphragm drain valve operation will be activated together with motor running light and hours run meter As soon as air flows into the compressor it exits via the delivery drain valve e Whilst the comp
87. f air pressure to the cooling system A pneumatic water inlet valve if fitted will not allow the cooling water to flow when the compressor stops This helps to prevent over cooling High air temperature switches are fitted to the 3rd stage cylinder discharge and exit from the 4th stage delivery after cooling to stop the compressor on over temperature in the air stream These switches combine both a visual dial display of the temperature and again an indication of the switch setting The compressor air intake is fitted with a filter to prevent solid particles entering the compressor cylinders A suction silencer is incorporated within the filter casing A non return valve is located at the final discharge connection to prevent system pressure returning to the cylinders when the compressor is shut down 5 2 MATERIALS OF CONSTRUCTION Component Material Crankcase Cast Crankshaft Spheriodal Graphite Iron Main End Bearings White metal lined Gun Metal Connecting Rods Spheriodal Graphite Big End Bearings Steel backed aluminium tin with overlay Small end Bearing 1st stage Phosphor Bronze Small end Bearings 2nd 3rd amp 4th stage Steel needle roller Flywheel Cast Iron First Stage Piston Aluminium alloy Second Stage Piston Cast Iron Third Stage Piston Cast Iron Fourth Stage Piston Cast Iron First amp Second Stage Cylinder Block
88. f satisfactory tighten to the correct torque If plates are not free dismantle relocate misplaced part and assemble check again for free movement of plates before tightening to the correct torque Ensure ring 11 is secure in slot in upper valve body MAINTENANCE AND REPAIR PAGE 48 2ND STAGE VALVE DELIVERY VALVE SEAT DELIVERY VALVE PLATE DELIVERY SPRING PLATE DELIVERY BACKING PLATE SUCTION SPRING PLATE SUCTION VALVE PLATE SUCTION VALVE SEAT O RING NUT MAINTENANCE AND REPAIR PAGE 49 8 3 5 SECOND STAGE VALVE REASSEMBLY Place suction valve seat 8 face downwards on suitable metal ring or protected open vice jaws with locating peg 7 uppermost Position suction valve plate 6 to locate over peg 7 Fit suction spring plates 5 onto valve plate locating them on peg 7 springs facing downwards Fit delivery valve backing plate 4 into outer recess of valve body Place delivery valve springs 3 onto backing plate having first positioned them as follows Assemble the delivery plate springs 3 in pairs rotating one spring in each pair until the inner and outer circumferences are matched perfectly Hold the two springs together with their concave faces facing each other and then rotate one pair until edges touch all round the outer circumference and there is a constant gap around the inner edge Place delivery valve plate 2 on spring plates and ensure concentricity Place delivery valve seat 1 ont
89. face with stud 12 uppermost Fit suction valve backing plate 11 in the valve recess followed by spring plates 10 arranged as shown and suction valve plate 9 Fit central body 8 over stud and lower until locating hole engages with peg in lower body Carefully push two valve body sections 8 amp 13 together until in full and firm contact If the sections will not locate correctly separate and re align to plates and springs DO NOT FORCE TOGETHER Invert upper body 4 and hold in a soft jawed vice or similar Fit delivery valve backing plate 5 into recess followed by spring plates 6 arranged as shown and delivery valve plate 7 With the central 8 and lower body 12 held firmly together turn upside down and pass stud through hole in upper body 4 ensuring that the hole in central body engages with peg in upper body If centre section will not locate correctly with upper body remove and re align plates and springs DO NOT FORCE Ensuring that all components are correctly located and held firmly together remove from the vice and fit washer 2 and nut 1 and tighten to correct torque When correctly located and tighten and fit new O ring 3 MAINTENANCE AND REPAIR PAGE 54 8 4 SERVICING COMPRESSOR PROTECTION 8 41 BURSTING DISC 1 Gasket Bursting Disk Plastic 2 Bursting Disk Metal 3 Cover Before refitting ensure the radiused edges of the cylinder hole and cover are smooth
90. g to determine the cause for failure Checks of the main and auxiliary contacts should be made with suitable checking equipment to ensure that main and auxiliary contacts are opening closing properly NOTE This may not be practical on some auxiliary contacts because of interwiring If in doubt disconnect one side of the contact involved Mechanically interlocked contactors should be checked for freedom of operation to ensure that the interlock is not interfering with normal operation of the contactor Whilst holding one contactor in the closed position the other contactor should be checked to ensure that it cannot be pushed into the closed position If this test fails dismantle and examine the interlock and contactor mountings 5 OVERLOAD UNITS Check that the current range and the position of the setting lever are suitable for the motor involved Adjust if necessary If the overload unit is fitted with a test arrangement check that the unit trips when tested and resets either automatically or via the reset button In the event of suspected faulty operation check by replacing the overload unit 6 RELAYS Relays should be checked in a similar manner to contactors 7 PUSH BUTTONS SWITCHES Examine push buttons and switches for any external signs of damage and check with suitable test equipment that circuits are operating in accordance with circuit diagram ie that contacts are closed open when required In the event of any damag
91. ge and ensure door hinges are also free from damage and do not restrict door opening 10 Check cable entry plates and glands to ensure that incoming and outgoing cables are securely fastened to the enclosure 11 Check all earth connections are tight and free from corrosion Particular attention should be paid to the earth links between the enclosure and the doors where they are fitted 12 Electrical checking of the wiring should be carried out by means of high voltage test equipment to check the insulation resistance to earth and between phases It should be noted that electronic equipment may require disconnecting in order to carry out this test 13 Check all earth connections for continuity particularly on enclosure doors which are fitted with electrical equipment N o CON DETAILED CHECK OF COMPONENTS AND ACTION REQUIRED 1 BUSBARS Check all busbar connections for tightness and ensure that all busbar mountings are secure Check all busbar mountings for damage and replace any that are cracked or broken Check that all busbar surfaces are clean and free from corrosion If any dirt or corrosion is present clean or replace as appropriate and determine reason for problem 2 FUSES Check that all fuses are intact and of the correct size for the application Ensure that connections to the fuseholder are tight and that the fuse is securely fastened to the fuse carriers Examine fuse connections for signs of overheating ie di
92. he cooling water inlet temperature The oil pump is directly driven from the crankshaft to provide a forced feed lubrication system via a suction strainer through a filter element to the running gear The cylinders pistons and valves are splash spray lubricated A low oil pressure switch is provided to protect the running gear against lubrication failure an oil level sight gauge is provided in the crankcase for maintaining oil to the correct level TECHNICAL DESCRIPTION 26 An automatic drainage system drains each stage condensate separator and all coalescing filters at approximately 10 to 20 minute intervals for a period of 5 10 seconds into a discharge surge vessel in built in crankcase This interval and period is dependent upon the ambient temperature and humidity and for high ambient high humidity conditions the interval must be reduced and the period increased The drainage system whilst removing oil moisture also acts as an unloading device to prevent the compressor starting under load by bleeding off automatically all the air in the compressor through the condensate separators whenever the compressor stops Pressure gauges to indicate all air stage pressures and oil pressure are located in a gauge board mounted between each cylinder block Air relief valves for each stage are fitted to prevent over pressure in cylinders and coolers and bursting diaphragms are fitted to protect the water jackets from accidental application o
93. he valve function Adjustment is made by rotating adjusting screw 2 Rotation is clockwise for increasing back pressure and counter clockwise for reducing back pressure Locknut 4 secures the adjusting screw in position Under all circumstances the maximum dimension between underside of adjusting screw 2 and valve body 1 as shown on following drawing must not exceed 150 mm If the desired pressure cannot be attained then consult CompAir Note Later models have a bracket fitted as shown to limit the maximum allowable adjusting screw travel DO NOT REMOVE THE BRACKET IN SERVICE REFIT AFTER MAINTENANCE This bracket is available and can be retrofitted COMPUTER GENERATED DRAWING DO NOT ALTER MANUALLY S THIRD ANGLE DO NOT SCALE des 10 20 30 40 50 60 70 80 90 100 125 150 7 HI PROJECTION IF DOUBT ASK eer 1 1 1 1 1 1 1 1 Parts List ITEM QTY PART NUMBER DESCRIPTION SUPPLIMENTARY TITLE BRACKET C204512 1 1 C204326 VALVE BODY 2 1 1 ADJUSTING SCREW 3 16204328 SPRING COLLAR 4 C763202 LOCKNUT 5 1 C 4454 1 VALVE ROD NOTE U572 G ISSUE B PMVs INCLUDE 6 1 C77555 VALVE BRACKET C204512 TO ACT AS A STOP TO 7 2 PS1205 14 O RING NITRILE BS 1806 No 010 LIMIT THE EXTENT TO WHICH THE ADJUSTING 8 1 C204327 VALVE SEAT SCREW MAY BE UNSCREWED U572 G ISSUE A 9 5 SPRING PMVs MAY BE RETRO FITTED WITH THIS 10 1 95602 1
94. ic conditions of flammable gases vapours hazes or dusts in which after ignition has occurred combination propagates to the entire unburned mixture and may cause a hazard A Potential Explosive atmosphere is an atmosphere which could become explosive due to local conditions CompAir Reavell H5000 Series compressors are designed and manufactured to give optimum performance with long life and reliability This Manual will help you to obtain the best performance from your compressor It provides the information required to install commission and operate the compressor and carry out regular maintenance schedules which will ensure the maximum satisfactory service life Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing Servicing facilities and the supply of genuine replacement parts are provided through a world wide network of CompAir companies and authouised distributors backed by the Service tel 44 0 1527 838632 and Parts department tel 44 0 1473 242000 Fax 44 0 1473 743468 and Sales 44 0 1473 242000 Fax 44 0 1473 743482 The information in this Manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressor Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or authorised distributor for revis
95. inder liner Piston ring axial clearance Measured between groove amp top face of ring with ring in normal running position Piston ring groove width 184 77 184 74 94 91 94 88 44 92 44 89 21 905 21 935 185 05 185 00 95 04 95 00 45 03 45 00 22 02 22 00 Piston skirt diameter Liner bore diameter 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 S E bearing diametral clearance In connection rod Needle roller In piston 0 003 0 013 0 025 0 044 S E bearing end float 1 Crankshaft journal B E bearing diameter 84 24 84 22 B E bearing out of round Main bearing diameter 79 95 79 93 Main bearing out of round B E bearing diametral clearance 1 2 3 4 0 066 0 120 Main bearing diametral clearance Bee 0 050 0 135 Crankshaft end float 0 23 0 66 gt Coolertube nominal sizes 1 10 5 3 4 CD gt LEADING PARTICULARS PAGE 24 TECHNICAL DESCRIPTION PAGE 25 5 TECHNICAL DESCRIPTION 5 1 GENERAL DESCRIPTION TYPICAL ARRANGEMENT 1 Stg Safety Valve 274 stage Safety valve Pressure gauge panel 1 Stage cylinder 274 Stage cylinder Surge vessel safety valve Diaphragm Drain valves The R 5437 1 IA compressor is a reciprocating 90 vee configuration 4 stage single acting water cooled machine with the 1st and 3rd stage lines on one crank throw and the 2nd and 4th stage lines on the opposite crank throw
96. ing Recommended Practice for Installation Tension in Belt Drives It is necessary to be able to measure the belt tensions with sufficient accuracy to avoid belt slip or overloaded bearings or to meet particularly arduous conditions Measure the length of the span in millimetres At the centre of the span apply a force with a spring scale ina direction perpendicular to the span until the belt is deflected from the normal by an amount equal to 0 015 mm for every millimetre of span length For example the deflection for a span of 1 metre would be 1000 mm x 0 015 mm or 15 mm In all cases it is essential that the pulley centres be fixed and that the larger pulley be then rotated at least four times before making the measurement On a multiple belt drive it is essential that a matched set of belts be used and the above procedure be carried out on each belt A measured forced below the lower value in the table indicates under tensioning whilst a measured force above the higher value indicates over tensioning However when starting up a drive with new belts the drive should be tensioned to the higher value since the tension falls rapidly in the early stages of running in All belts should be watched carefully during the running in period after initial start up Retensioning and checking for wear should be carried out every 2000 hours using the above procedure for alignment and tensioning EQUIPMENT DATA SHEETS PAGE 105 BELT DEFLECTION MEASUREM
97. injury e Avoid injury by using a hoist to lift heavy loads Check that all chains hooks shackles and slings are in good condition and are of the correct capacity They must be tested and approved according to local safety regulations e Cables chains or ropes should never be applied to lifting eyes Always use an appropriate shackle or hook properly positioned Arrange lifting cables so that there are no sharp bends Use a spreader bar to avoid side loads on hooks eyes and shackles and never leave a heavy load unattended When a load is on a hoist stay clear of the danger area beneath and around it Keep lifting acceleration and speed within safe limits 1 4 4 INSTALLATION PRECAUTIONS e Competent personnel under a qualified supervisor must only carry out installation work e A fused isolator switch must be fitted between the main power supply and the compressor e Precautions must be taken to ensure that no injury is caused to passers by through loose clothing being sucked into compressor intake e Ensure that the discharge pipe from the compressor to the user pipework receiver or storage is free to expand and that no flammable material is within the vicinity If any such material is close by take steps to preclude ignition e manual shut off valve should be fitted in the discharge line to allow the compressor to be isolated Non return valves cannot be relied upon for isolating parts from a pressure system A safety valve must be i
98. ious damage to the gauge On site testing of the pressure gauge is feasible by means of special isolating devices enabling connection of a test gauge together with a suitable pressure source EQUIPMENT DATA SHEETS PAGE 123 13 12 TEMPERATURE CONTROLLER APP090C THERMOMETER SWITCHES 202556 202749 202960 amp 202964 98288 1093 98288 1094 8 98288 1215 THESE THERMOMETER SWITCHES ARE SET TO THE FIGURES QUOTED THE FOLLOWING INFORMATION IS FOR SETTING INFORMATION ONLY IF THE TEMPERATURE SWITCH HAS TO BE REPLACED OR RE ADJUSTED IF THE SWITCH NEEDS TO BE RE ADJUSTED DUE TO A HIGHER AMBIENT TEMPERATURE OR ANY REASONS PLEASE CONTACT COMPAIR UK LTD IPSWICH FOR MORE INFORMATION TO SET TRIP INDICATOR POINTER RUN COMPRESSOR ESTABLISH NORMAL RUNNING TEMPERATURE OF BLACK POINTER WHEN READING IS STABLE REMOVE ADJUSTING KEY B FROM REAR OF SWITCH AND INSERT INTO FRONT OF CENTRAL KNOB ADJUSTER C ROTATE KEY ADJUST RED POINTER 0 TO 10 C ABOVE RUNNING TEMPERATURE POINTER A ADJUSTMENT OF TRIP POINTER MUST BE WITHIN RANGE THAT HAS BEEN PRE SET AT COMPAIR BEFORE DESPATCH BUT MAY BE ADJUSTED WITHIN THIS RANGE DEPENDING ON AMBIENT CONDITIONS NOTE DO NOT RESET TEMPERATURE CONTROLLER SETTING IF IT TRIPS ALWAYS LOCATE AND CORRECT POSSIBLE FAULT BEFORE ANY ATTEMPT IS MADE TO ALTER SETTING CONTACT CompAir UK Ltd IPSWICH ENGINEERING DEPARTMENT FOR MORE INFORMATION IF THE COMPRESSOR TRIPS
99. is accordance with the manufacturers maintenance instructions may make it unsafe The use of replacement parts not supplied by or recommended by CompAir Reavell may create unsafe and hazardous conditions or result in damage to the equipment over which CompAir Reavell has no control Such hazardous conditions may lead to accidents that can be life threatening cause substantial bodily injury or result in damage to the equipment CompAir Reavell can bear no responsibility for equipment in whin hil replacement parts are included GENUINE PARTS A CompAir Reavell Use Synteck compressor lubricant Advantages Longer time between oil changes Longer valve life Can be used in new or old compressors Reduces carbon build up Reduces oil consumption CompAir Reavell Gardner Denver Reavell House 53 56 White House Road Ipswich IP1 5PB England Telephone 44 0 1473 242000 Customer Service 44 0 1527 838632 Fax 44 0 1473 745451 Parts Fax 44 0 1473 743468 www CompAir com e mail sales ipswich CompAir com
100. ked separately The unit should be lifted by the eyebolts the motor and compressor 6 2 LOCATION It is desirable that the compressor unit is installed in as clean cool and dry environment within the parameters stated in the Leading Particulars section The surface on which the unit is to stand must be flat and capable of bearing the total weight of the unit without distortion In selecting the location it is essential to consider accessibility Allow sufficient space around the installation for safe maintenance work Sufficient clearance must be allowed to ensure that the set will not touch any obstruction or any flexibly mounted equipment with an added allowance for maximum movement from the mounting system 6 3 MOUNTING The compressor unit is mounted on anti vibration mounts These mounts should be inspected for any tear of the rubber to metal plate bond or ageing before use Ensure the mount is not impregnated with oil or grease and that any protective lacquer is intact Reject any mount that is not in good condition Lower the compressor unit onto the mounts and screw on the mount holding down nuts Rock unit to ensure mounts is free and not distorted and that the set will not touch any obstructions or other flexibly mounted equipment 6 4 CONNECTIONS 6 4 1 Note As the compressor unit is flexibly mounted all connections must also be flexible Short flexible sections must be incorp
101. ld be provided to prevent environmental build up or ingress of foreign matter Any condition that could lead to blockage of discharge piping or discharge ports on safety valves must be avoided Where appropriate discharge pipes should be provided to a non hazardous location Where there is a possibility of a liquid head forming in a discharge pipe a drain should be provided which leads to a safe discharge location To prevent unnecessary lifting of the safety valve it is recommended that there is a margin of at least 1096 between the maximum operating pressure and the set pressure of the safety valve EQUIPMENT DATA SHEETS PAGE 109 FUNCTIONAL TESTING Once installed in service Valves should be tested at least once every Six months to ensure free movement of parts This should be carried out by operating the easing gear when the valve is under a pressure of less than 75 of the set pressure Where valves are supplied without easing gear the test should be in accordance with the full functional test described overleaf Due regard must be paid to the safety personnel Testing should not create a hazard particular attention being given to foreign matter located in discharge outlets CONFIGURATION The valves have a base number for different type valve arrangement from this information the valve set pressure can be obtained examples 98650 2073 is the base unit number 98650 2073 16 2 16 2 being to the setting in bar 0 wire locked 98650
102. ls cause irritation and are corrosive to the skin eyes nose and throat Avoid splashes and wear suitable protective clothing and safety glasses Do not breathe mists Ensure water and soap is readily available When disposing of condensate old oil used filter elements and other parts and waste material of any kind make sure that there is no pollution to any drain or natural water course and that no burning of waste takes place which could cause pollution of the atmosphere Keep the compressor clean at all times Protect components and exposed openings by covering with a clean cloth or tape during repair or maintenance work Protect the motor intake electrical and regulation components against the entry of moisture e g steam cleaning Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks The adjacent components must be screened with non flammable material and if oil present the system must first be cleansed thoroughly by steam cleaning Condensate oil and water mixture from compression process must be regarded as trade effluent and is therefore not suitable for discharge into a surface water sewer or watercourse PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL 1 47 PRECAUTIONS IN THE EVENT OF FIRE Use extreme caution when handling components that have been subjected to fire or very high temperature Some components may contain fluoroelastomer materials
103. ly supported Ensure that all earth connections are secure and free from mechanical stress WORKING ON LIVE EQUIPMENT During servicing when it is necessary to work on the equipment with the supply connected eg checking voltages are currents It is essential to observe the following precautions before working on the starters with the supply connected 1 Ensure that it is absolutely necessary to work on the equipment whilst in the a live condition 2 Ensure that you are fully aware of the layout of the starter and where to expect live connections 3 Ensure that you are within sight of other people who could come to your aid if necessary 4 Ensure that any tools or equipment used are suitable for working on live equipment EQUIPMENT SHEETS PAGE 128 GENERAL GUIDANCE ON ROUTINE INSPECTION DISCONNECT ALL EXTERNAL SUPPLIES Open panel starter and make visual inspections for Overheating arcing Ingress of dirt moisture Check all screws and fixings to ensure that they are tight Check all wiring connections to ensure that they are tight Check all moving parts for ease of operation Examine all wiring particularly in the vicinity of metal parts of the equipment to ensure that none of the insulation is Check mechanical interlocks of contactors isolators etc to ensure that they are functioning correctly Check push buttons and switches for normal mechanical operation Check door seals are free from dama
104. n Open stop valve in delivery line to air receiver Restart compressor and continue with run increasing pressure by 40 bar at 15 minute intervals up to working pressure Compressor should now be running on load and delivering compressed air Check the following Pressure record at 15 minute intervals Stage Pressures record at 15 minute intervals Stage Temperatures record at 15 minute intervals Safety valves are not leaking Unloader valves are not leaking Condensate drain valves operate for approximately 5 10 seconds after every 10 30 minutes dependent upon ambient temperature and humidity This must to be carefully monitored high temperature humidity conditions will require the drain times to be more frequent contact CompAir UK Ltd for more details Compare pressure and temperature readings with those figures given in Leading Particulars After approximately two hours of test run stop compressor remove drain plug from sump and drain off any water which may have accumulated Do not drain oil An excess of water in crankcase should be investigated Replenish oil where necessary 7 4 STARTING DAILY Ensure that electrical supply is available Ensure cooling water is available Check crankcase oil level Top up if necessary Start compressor and run as required 7 5 ROUTINE ATTENTION WHILE RUNNING At two hourly intervals check pressure on air and oil pressure gauges Abnormal readings mus
105. n damage to the equipment CompAir Reavell can bear no responsibility for equipment for which unapproved replacement parts are included SPECIAL NOTE THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED 11 1 41 GENERAL CompAir Reavell compressor safety relates to the document BS EN1012 1 Compressors and Vacuum Pumps Safety requirements and the UK Pressure Systems Health amp Safety Regulations 9 1 No 128 Most accidents which occur during the operation and maintenance of machinery result of failure to observe basic safety rules or precautions Recognising a situation that is potentially hazardous can often prevent an accident When handling operating or carrying out maintenance on the unit personnel must observe safe engineering practices and all relevant local regulations The attention of users is drawn to the Health and Safety at Work Act 1974 and the regulations of the Institution of Electrical Engineers CompAir Reavell cannot anticipate every possible circumstance which might represent a potential hazard The WARNINGS in this manual are therefore not all inclusive If the user employs an operating procedure an item of equipment or a method of working which is not specifically recommended by CompAir Reavell then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property F
106. ncluded SPECIAL NOTE THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED 98407 1825 iss 1 7 1 41 GENERAL CompAir Reavell compressor safety relates to the document BS EN1012 1 Compressors and Vacuum Pumps Safety requirements and the UK Pressure Systems Health amp Safety Regulations S l No 128 Most accidents which occur during the operation and maintenance of machinery result of failure to observe basic safety rules or precautions Recognising a situation that is potentially hazardous can often prevent an accident e When handling operating or carrying out maintenance on the unit personnel must observe safe engineering practices and all relevant local regulations The attention of users is drawn to the Health and Safety at Work Act 1974 and the regulations of the Institution of Electrical Engineers CompAir Reavell cannot anticipate every possible circumstance which might represent a potential hazard The WARNINGS in this manual are therefore not all inclusive If the user employs an operating procedure an item of equipment or a method of working which is not specifically recommended by CompAir Heavell then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property Failure to observe these precautions given under Safety Precautions may be considered dangerou
107. ndard 0 5 bar 7 5 psi falling 98524 1042 AIRCOOLED GAZPACKS over 0 1 bar 1 bar 15 psi falling 98524 1042 AIRCOOLED 5450 5470 Standard 1 bar 15 psi falling 98524 1122 AIRCOOLED GAZPACKS up to 0 1 bar 0 5 bar 7 5 psi falling 98524 1140 AIRCOOLED GAS Standard 1 bar 15 psi falling 98524 1169 AIRCOOLED IZAR up to 0 1 bar 0 5 bar 7 5 psi falling 98524 1170 WATERCOOLED GAS 24 VDC Gold Contacts 1 bar 15 psi falling The switch transforms a change of pressure into an electrical On or Off signal When a pre set pressure is reached the snap action contact stops the compressor INSTALLATION Either of two makes of low oil pressure switch may be fitted as shown below Terminal connections are shown for clarity Connect Common 1 and Connect Common 3 and Normally Open 4 terminals Normally Open 2 terminals to compressor control panel to compressor control panel EQUIPMENT DATA SHEETS PAGE 121 13 10 2 COMPRESSOR CONTROL APP081 PRESSURE SWITCH 98524 1004 amp 1139 OPERATION Located as close as possible to the H P delivery line the pressure switch stops compressor when the upper pressure limit is attained and triggers off the start when the lower limit is reached The switch transforms a change of pressure into an electrical or signal When a pre set pressure is reached the snap action contact changes state INSTALLATION Pressure switches may be mounted in any convenient position close
108. ndensate Depending on the degree of contamination the oil may appear emulsified creamy in colour especially if the recommended lubricant is not used If emulsification takes place the oil must be changed and the crankcase cleaned This condition is usually visible through the sight glass oil level indicator and must be rectified immediately Trace cause of contamination rectify and fit new oil filter and refill crankcase with recommended oil If moisture forms without emulsification as two separate liquids condensate may be drained from below the oil by means on the drain plug The oil level should be replenished accordingly with clean oil Crankcase oil contamination is often accompanied by increase in sight glass oil level due to oil being supported by condensate fluid Check correct operation of all controls MAINTENANCE AND REPAIR PAGE 44 82 AFTER THE FIRST 100 HOURS amp AFTER MAJOR OVERHAUL Drain sump replace oil filter clean sump 8 refill with recommended synthetic oil Clean suction and delivery valves All components on these compressors are compatible with the recommended synthetic oil but as problems may exist with downstream ancillary equipment the equipment manufacturer should be consulted METHOD Drain the oil completely from compressor whilst the oil remains warm 8 2 1 REMOVE CRANKCASE DOORS AND THOROUGHLY CLEAN INTERIOR OF THE CRANKCASE Clean suction strainer Renew oil filter Remove
109. ng machined parts These materials cause irritation and are corrosive to the skin eyes nose and throat Avoid splashes and wear suitable protective clothing and safety glasses Do not breathe mists Ensure water and soap is readily available When disposing of condensate old oil used filter elements and other parts and waste material of any kind make sure that there is no pollution to any drain or natural water course and that no burning of waste takes place which could cause pollution of the atmosphere Keep the compressor clean at all times Protect components and exposed openings by covering with a clean cloth or tape during repair or maintenance work Protect the motor intake electrical and regulation components against the entry of moisture e g steam cleaning Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks The adjacent components must be screened with non flammable material and if oil present the system must first be cleansed thoroughly by steam cleaning Condensate oil and water mixture from compression process must be regarded as trade effluent and is therefore not suitable for discharge into a surface water sewer soakaway or watercourse PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL 1 47 PRECAUTIONS IN THE EVENT OF FIRE Use extreme caution when handling components that have been subjected to fire or very high temperature Some components may contain fl
110. ns concerning operation and maintenance are strictly followed and that the complete unit with all accessories and safety devices is kept in good order The accuracy of pressure gauges and temperature switches should be regularly checked at least 13 month intervals and thoroughly examined at least every 48 months They must be renewed or service exchanged when acceptable tolerances are exceeded Protection devices should be tested at each regular service interval and replaced or service exchanged if not functioning correctly The maximum pressure for safety valves under fault conditions is 1 10 times the set pressure the set pressure being a minimum of 1 05 times the maximum operating pressure to ensure seat tightness Never use a light source with an open flame for inspection Before dismantling any part of the compressor be sure that all heavy movable parts are secure After completion of any maintenance or repair ensure that no tools loose items or rags are left on or inside the compressor Do not use any flammable liquid to clean valves filter elements cooler passages pipe bores or any component carrying a flow of air or gas during normal operation If chlorinated hydrocarbon substances are used for cleaning safety precautions must be taken against toxic vapours which may be released DO NOT USE CARBON TETRACHLORIDE Precautions must be taken against using acids alkalis and chemical detergents for cleaning machined parts These materia
111. nstalled between any compressor unit and the isolating valve e Apressure reliving device must be fitted to every pressure vessel or equipment containing air or gas above atmospheric pressure Never remove or tamper with safety devices guards or insulation fitted In order to limit the risk of Legionnaires Disease CompAir Reavell advise caution with the use of cooling towers for water cooling the compressor Closed circuit or direct mains cooling is preferred e Pipework or other parts with a surface temperature above 70 C which may be accidentally touched in normal operation must be guarded or insulated Other high temperature pipework should be clearly marked and all pipework should be clearly marked 1 4 5 OPERATIONAL PRECAUTIONS e Competent personnel under a qualified supervisor must only operate the compressor Do not operate compressor with any removable inspection cover removed e g crankcase doors valve covers etc e Never remove or tamper with safety devices guards or insulation materials e The compressor must only be operated at the supply voltage and frequency for which it is designed Always isolate power before maintenance or servicing e When mains power is ON lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system ALWAYS CONSULT A QUALIFIED ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK 98407 1825 iss 1 9
112. nt further change for several thousand hours When aluminium tin lining overlay has been removed from an area greater than 90 the bearing surface of either top or bottom half bearing shell the complete bearing must be replaced 8 5 8 SMALL END BEARINGS Note The 1 stage bearing is a plain bush NOT a rolling contact needle roller bearing If there is detectable movement of the piston or crosshead at 90 degrees to its normal plane of movement of the conn rod remove and discard the gudgeon pin and needle roller bearing 8 5 9 GUDGEON PINS Remove circlips and gently drift out all gudgeon pins Check pins for any flaking of the surface renew if worn or flaking of surface is evident MAINTENANCE AND REPAIR PAGE 57 8 5 10 RUNNING GEAR 8 5 10 1 8 5 10 2 17 STAGE Note If removing cylinder liner ensure that cooler body has been drained of water Remove valve cover and valve Remove crankcase door on opposite side of crankcase Remove big end bearing cap from conn rod Remove piston and conn rod assembly upwards through valve port using service tools Remove cylinder liner upwards through valve port using service tools Measure cylinder liner piston and piston rings and replace or re use as necessary De glaze cylinder liner bore by light honing if re using Thoroughly clean all seating faces in cylinder Replace all cylinder liner O rings and coat with silicone sealant Refit cylinder liner to bod
113. ny servicing or repair e Local noise regulations must be observed Ear defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter Be aware high noise levels can interfere with communication 1 4 6 MAINTENANCE 8 REPAIR PRECAUTIONS e Competent persons under qualified supervisor must carry out maintenance repair and modifications e The compressor will have a preserving oil applied to interior surfaces Oil lubricated models Oil free models will have desiccant bags in valve covers and distance pieces e Handling components such as seals gaskets and diaphragms should not present a personnel hazard Preservation oils again should not present a personnel hazard if handled under normal handling practices e Whilst compressors are asbestos free treat all damaged gaskets as asbestos when the Asbestos at work regulations apply e Viton O seals under normal operating conditions are safe e However should there be a fire within the compressor or these seals are likely to exceed a temperature of 300 C the material will decompose e Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns f Viton seals appear charred or gummy do not touch with unprotected hands use neoprene or PVC gloves e Wash the area with limewater and avoid breathing any fumes If contamination of the skin occurs washes with limewater and seeks medical advic
114. o assembly If all components are located correctly upper and lower bodies will contact Screw nut 10 on stud and hand tighten only at this stage Test for correct operation by ensuring free movement of suction and delivery valve plates This is facilitated by gently pushing a small diameter plastic or nylon rod through the ports in the valve to check plates for freedom If satisfactory tighten to the correct torque If plates are not free dismantle relocate misplaced part and reassemble checking again for free movement of plates before tightening to the correct torque Ensure ring 9 is secure in slot in upper valve body MAINTENANCE AND REPAIR PAGE 50 3 STAGE VALVE DELIVERY VALVE SEAT DELIVERY VALVE PLATE DELIVERY SPRING PLATE DELIVERY BACKING PLATE SUCTION SPRING PLATE SUCTION VALVE PLATE SUCTION VALVE SEAT 8 O RING 9 WASHER 10 NUT MAINTENANCE AND REPAIR PAGE 51 8 3 6 THIRD STAGE VALVE REASSEMBLY Position suction valve seat 7 face downwards on suitable metal ring or open protected vice jaws Fit delivery valve backing plate 4 into outer recess of valve body Fit delivery valve spring plates 3 onto backing plate having first positioned them as follows Assemble the delivery plate springs 3 in pairs rotating one spring in each pair until the inner and outer circumferences are matched perfectly Hold the two springs together with their concave faces facing each other and then rotate one
115. of a counterbalanced crankshaft The running gear consists of the crankshaft bearings connecting rods oil pump cylinder lubricator and other accessories The air end consists of two cylinder blocks combined 3 8 4 stage combined 1 8 2 stage Each block is complete with individual cylinder liners pistons valves valve covers inter stage coolers for the 1s 2 d 39 and 4 stages and condensate separators for 1 2 and 3 stages The 1 amp 2 stage cylinder blocks contains renewable wet cylinder liners and are jacketed for water cooling The 39 and 4 stage cylinder blocks contains renewable dry cylinder liners again jacketed for water cooling Water flow is arranged within the cylinder jackets and coolers in series to provide even and effective cooling for either sea or fresh water First and second stage pistons are conventional trunk type whilst the third and fourth are an integral piston and crosshead assemblies All are fitted with split piston rings A single combined suction and discharge concentric valve is fitted at the head of each cylinder Water cooled inter stage coolers are provided after each stage of compression with condensate separators after each inter stage cooler The water flows over the tubes and the air through for all stage coolers All stage coolers are withdrawable to ease maintenance The fourth or final stage cooler cools the hot air delivered from the fourth stage cylinder to within 5 of t
116. on of the control circuit can be carried out by means of the push buttons control circuit switches and remote switches ie pressure switches level switches etc If a remote switch is not available or functioning its operation may be simulated by a switch or push button wired across the terminals In this mode correct sequencing can be checked indicator lamps checked and operation of contactors and relays can be checked for noisy operation without the corresponding equipment being used thus avoiding the possibility of machine noise interfering with the checks 4 Check thermistor protection units by disconnecting the thermistors and connecting a push button switch across the thermistor unit terminals With this switch closed the starter circuit should be operated normally With the switch open the starter should stop This test can be used to differentiate between a faulty Thermistor Protection unit and faulty thermistors See page 6 Section 9 5 Ensure that any overload devices are set to the appropriate full load current as marked on the motor 6 Check that all timers are set to give the correct time delay 7 Soft Starts if fitted require setting for appropriate voltage ramp time and current limit potentiometer if fitted 8 Inverters if fitted require setting FINAL CONNECTION Ensure that any cables are kept clear of any parts that are liable to excessive temperature rise and that any lengthy cable runs are adequate
117. or isolating parts from a pressure system A safety valve must be installed between any compressor unit and the isolating valve e Apressure reliving device must be fitted to every pressure vessel or equipment containing air or gas above atmospheric pressure Never remove or tamper with safety devices guards or insulation fitted In order to limit the risk of Legionnaires Disease CompAir Reavell advise caution with the use of cooling towers for water cooling the compressor Closed circuit or direct mains cooling is preferred Pipework or other parts with a surface temperature above 70 C which may be accidentally touched in normal operation must be guarded or insulated Other high temperature pipework should be clearly marked and all pipework should be clearly marked 1 4 5 OPERATIONAL PRECAUTIONS e Competent personnel under a qualified supervisor must only operate the compressor Do not operate compressor with any removable inspection cover removed e g crankcase doors valve covers etc Never remove or tamper with safety devices guards or insulation materials e The compressor must only be operated at the supply voltage and frequency for which it is designed Always isolate power before maintenance or servicing e When mains power is ON lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system ALWAYS CONSULT A QUALIFIED ELECTRICIAN BEFORE ANY SUC
118. orated should be suitable for the pressures and temperatures involved and capable of easy removal to facilitate maintenance SUCTION The intake air pressure can vary between 0 5 barg and 1 0 barg and must be as clean and dry as possible 6 4 2 FINAL DELIVERY The final delivery connection is situated at the end of the non return valve The flexible connection must be suitable for the set working pressure 6 4 3 UNLOADING CONDENSATE DRAIN The unloading condensate drain connection at the crankcase for the surge vessel is screwed to accept the discharge pipe This pipe must be led away with a minimum of bends and must have a minimum internal diameter of 38mm 172 There must be no obstruction in the line as any restriction during operation may cause the safety valve at the crankcase for the surge vessel to open Note Condensate should be piped away to a suitable containment vessel before disposal in accordance with local Health amp Safety regulations INSTALLATION INFORMATION PAGE 30 6 4 4 COOLING WATER The quality quantity and temperature of the water used can materially affect maintenance positive circulation of cool but not cold clean water free from suspended particles is required for satisfactory continuous operation Note It is vital a suitable inhibitor is used especially in HARD WATER areas Therefore it is recommended that a suitable water softener unit be fitted to the inlet water line It i
119. ort using the service tools taking care not to rotate the piston Refit big end bearing and conn rod cap and tighten to correct torque setting Replace all valve cover O rings and coat with silicone grease Refit valve and valve cover and tighten to correct torque setting MAINTENANCE AND REPAIR PAGE 58 8 5 10 3 3 amp 4 STAGE Remove cover and valve Undo piston retaining capscrew Withdraw piston from crosshead using service tools Remove crankcase door on opposite side of crankcase Remove big end bearing cap from conn rod Withdraw conn rod and crosshead assembly downwards through crankcase door opening passing over crankshaft Remove cylinder liner upwards through valve port using service tools Measure cylinder liner piston and piston rings and replace or re use as necessary De glaze cylinder liner bore by light honing if re using Thoroughly clean all seating faces in cylinder body Refit piston rings to piston ensuring that the gaps are staggered around piston Oil all wearing surfaces before re assembly Replace all cylinder liner O rings and coat with silicone grease Refit cylinder liner into cylinder body Refit conn rod and crosshead assembly upwards through crankcase door opening passing over crankshaft and locate with crosshead guide and crankshaft journal Refit big end bearing and conn rod cap and tighten to correct torque setting Refit piston to crosshead using service tools Refit pi
120. ousing and half coupling Remove compressor half coupling ease back tab washer and remove keep bolt keep plate and tab washer Support flywheel and release from the crankshaft taper withdrawing tool may be required Remove flywheel and key 8 5 13 PULLEY BELTS amp MOTOR PULLEY Remove drive belt guard Loosen the motor holding down bolts Using vee drive tensioning screws slacken and then remove vee belts To remove compressor pulley ease back tab washer and remove keep bolt keep plate and tab washer Support pulley and release from the crankshaft taper a withdrawing tool may be required Remove pulley and key To remove motor pulley release taperlock bush screws withdraw complete MAINTENANCE AND REPAIR PAGE 60 PARTS LISTS PAGE 61 9 PARTSLISTS 9 1 CRANKCASE Description Number Number OFF 12 Breathercover COTA 41 Joint breather cover 0201819 1 Setscrew 1 1 195000228 6 2 NutM8 2 _ lss 1 Seal BSP Suction oil pipe assembly D100809 1 PARTS LISTS PAGE 62 9 2 MAIN BEARING HOUSING 9 2 1 OUTER END Item No Description Part Number Number OFF 3 1 3 3 3 3 3 3 3 10 3 10 3 11 3 12 3 14 3 16 3 17 3 18 O Ring 3 19 9 2 2 DRIVING END Item No Description Part Number Number OFF 1 2 3 4 5 6 7 8 3 10 311 3 12 314 316 3 17 348 3
121. over Tighten cover retaining nuts sequentially to the correct torque MAINTENANCE AND REPAIR PAGE 46 19 STAGE VALVE gt IF se ESS SU DELIVERY VALVE SEAT DELIVERY VALVE PLATE DELIVERY SPRING PLATE SUCTION SPRING PLATE LIFT WASHER SUCTION VALVE PLATE LIFT WASHER PEG PEG MAINTENANCE AND REPAIR PAGE 47 8 3 4 FIRST STAGE VALVE REASSEMBLY Place suction valve seat 10 face downwards on suitable metal ring or protected open vice jaws with locating pegs uppermost Position spring plates 3 to locate over pegs 9 with bridging strip resting between pegs and springs facing upwards Place valve plate 2 onto spring plate located as above ensuring concentricity with centre hole Place middle lift washer 7 over hole locating pegs 8 Place valve plate 6 onto locating pegs 8 Place lower lift washer 7 onto locating pegs 8 Place valve spring plates 4 onto locating pegs 8 with springs pointing downwards Place delivery valve seat 1 onto assembly ensuring inner 8 and outer pegs 9 engage correctly If assembly has been carried out correctly upper and lower body faces will contact Screw nut 12 on stud and hand tighten only at this stage Test for correct operation by ensuring free movement of suction and delivery valve plates This is facilitated by gently pushing a small diameter plastic or nylon rod through the ports in the valve to check plates for freedom I
122. pair until edges touch all round the outer circumference and there is a constant gap around the inner edge Place delivery valve plate 2 on spring plates and ensure concentricity Place suction valve plate 6 onto valve body ensuring concentricity with centre hole Assemble the suction plate springs 5 and place on suction valve plate with springs facing downwards Place delivery valve seat 1 onto assembly If all components are located correctly upper and lower bodies will contact Press together and ensure edges of upper and lower body contact then fit washer 9 and nut 10 hand tighten only at this stage Test for correct operation by ensuring free movement of suction and delivery valve plates This is facilitated by gently pushing a small diameter plastic or nylon rod through the ports in the valve to check plates for freedom If satisfactory tighten to correct torque however if plates are not free dismantle relocate misplaced part and reassemble checking for free movement of plates before tightening to the correct torque Ensure ring 8 is secure in slot in upper valve body MAINTENANCE AND REPAIR PAGE 52 4 4 STAGE VALVE NUT WASHER O RING VALVE BODY PEG VALVE PLATE SPRING PLATE VALVE PLATE SUCT amp DELY BODY VALVE PLATE SPRING PLATE BACKING PLATE VALVE BODY PEG MAINTENANCE AND REPAIR PAGE 53 8 37 FOURTH STAGE VALVE REASSEMBLY Place lower valve body 13 on a clean flat sur
123. position correctly suction port Loose pipe connections Y Trace and rectify 7 Loose B E bearing bolts Examine and re tighten to correct incorrectly fitted bearings torque 7 10 9 CUTSOUTON Motor overload too low Consult qualified electrician START UP 2 Insufficient electrical Consult qualified electrician supply causing low voltage 2 Star Delta timer Y Full speed should be attained by Star before switching to Delta Extend timer period to suit 5 Low oil pressure switch See fault LOW OIL PRESSURE or operating reset timer 7 10 10 UNUSUAL NOISE Trace and rectify or whistling if safe to do so renew seal Worn bearings cylinders Check clearances and renew as and rings usually heavy necessary knocking rumbling or slapping VICI UNUSUAL NOISE UNLOADED Compressor set up or Check compressor pipework system pipework system vibration is firmly secured check clearances and alignment of couplings and tension of vee belts or damaged necessary OPERATING INFORMATION PAGE 42 MAINTENANCE AND REPAIR PAGE 43 8 MAINTENANCE AND REPAIR MAINTENANCE AND REPAIR WARNING BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED AND ISOLATED FROM ELECTRICAL AIR AND WATER CIRCUITS ALL INTERNAL PRESSURES MUST BE RELEASED FROM THE COMPRESSOR AND VISIBLE WARNING NOTICES DISPLAYED Note An O amp M manual must cater for a wide variety of opera
124. pressor from the main electrical supply Lock the isolator in the OFF position and remove fuses Attach a label WORK IN PROGRESS DO NOT APPLY VOLTAGE e Close the isolating valve between the compression unit and user s pipework Close the isolating valve in the cooling water inlet pipe Attach a label WORK IN PROGRESS DO NOT OPEN Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage Check that all pressure gauges register zero e Ensure that the cooling water system has been drained e Check that the drain valve on the delivery manifold is clear and gas pressure has been released Check that all interstage drains are open to ensure any gas trapped between stages has been released 98407 1825 iss 1 10 Stand clear of all valve covers when removing the securing screws When removing valve covers for valve replacement ensure a minimum of two threads is left engaged on the valve cover securing screws Lever the valve cover until the O seal is disengaged from the port in the cylinder head Remove the securing screws and take out valve cover Use only lubricating oils and greases approved by CompAir Reavell to avoid potential hazards especially the risk of explosion or fire and the possibility of decomposition or generation of hazardous gases Always clean oil spills from the surrounding floor before and after maintenance work Make sure all instructio
125. r OFF 22 1 2 22 2 84096 1 22 3 21 1 21 2 ILLUSTRATIONS PAGE 69 10 ILLUSTRATIONS 10 1 EXTERNAL VIEWS 9 19 9 21 9 20 INSTRUMENTATION NON RETURN 2MD STAGE VALVE OUTLET SAFETY VALVE 9 13 2 CORROSION OPTIONAL 9154 157 STAGE LINER 8 VALVE COVER 9 5 ST ND 9 15 2 SEM 2 STAGE LINER 8 CYLINDER VALVE COVER d 9 13 1 SUCTION FILTER STANDARD 9 2 2 9 2 1 OUTER END DRIVING END BEARING HOUSING gt BEARING HOUSING 9 1 CRANKCASE 9 20 SURGE VESSEL SAFETY VALVE 9 20 9 10 3 STAGE NP 9 18 97 STAGE 157 STAGE SAFETY VALVE 9 20 18 STAGE VALVE 9 13 1 CORROSION STANDARD 9 12 OUTER END 4 STAGE BEARING HOUSING SEPARATOR ILLUSTRATIONS 9 22 2 STAGE SUCTION PIPE 4 PIPE 9 22 DELIVERY PIPE Uu a STAGE IT 9 13 2 CORROSION ROD OPTIONAL 9 22 SUCTION PIPE Fr 9 22 1 1 DELIVERY PIR Ir m ILLUSTRATIONS PAGE DDV CONTROL PIPE 9 22 3 STAGE SEPARATOR DRAIN PIPE 9 22 47 STAGE SEPARATOR DRAIN PIPE 9 22 157 STAGE SEPARATOR DRAIN PIPE 9 18 9 18 3 amp 4 STAGE 1 amp 2 STAGE DDV DDV ILLUSTRATIONS PAGE 72 10 2 1ST amp 4TH STAGE CYLINDERS
126. ressor is reaching full running speed the oil pressure rises causing the low oil pressure switch contacts to close and maintain electrical circuit when override timer operates e The delay to load timer then operates in conjunction with the diaphragm drain valve timer energising the diaphragm drain valve solenoid to close the valve and bringing the compressor onto load e Air pressure will increase in the compressor as indicated on the delivery pressure gauge e Pressure will continue to rise until the setting of the control pressure switch is reached and its contacts open In MANUAL mode electrical supply will then be cut to motor contactors hours run meter solenoid valves and their timers together with low oil and low inlet override timers and enable relay The compressor will stop and unload all pressure and will not restart until the start button is pressed irrespective of control pressure switch state In AUTO mode electrical supply is cut a similar way to MANUAL mode except for the enable relay which remains energised allowing automatic restart depending on state of control pressure switch The compressor will continue to operate in this way until one of the following occurs 1 Stop button is pressed 2 Oil pressure drops to low oil pressure switch setting 3 Motor power rises to current overload setting 4 Delivery air temperature rises to temperature switch setting e of the above circumstances will
127. rinlet ei a e d e RR a 1 BSPT Water outlet est ep beet eir awa A tilt sec d ee ne 1 BSPT LEADING PARTICULARS PAGE 21 4 2 10 WATER TEST PRESSURES First stage ars iba rc 2 bar g FirSE Stage dellVety cil th si eed tek xd d ek eee 21 bar g Second stage ie iet a eet let eret pele duet amaba tite epee 81 Third 300 g dei eee 690 bar g Walter Huren einen ln 25 4 2 11 VALVE SETTINGS 100 3 8 7 24 bar g e oii mE RE 117 Fo rthistage isn NL Supply pressure 5 Viu na ra Era Wal alae Ballade 2 1barg 4 2 12 WEIGHTS Machine DU Rn nine eee 1090 Kg Cooling water and lt 90 Granksh ft ip e alte mtn 45 mile EET 51 Kg Cylinder block 151 amp 2 146 Kg Cylinder block 3 9 amp 4th Stage eese en 000 155 Kg 090 000 rindas 250 Typical Direct Coupled Set Complete set dry 1500 Kg Typical Belt Driven Set Complete set gry nenne 1600 Kg Inertia rotational compressor and flywheel 0 79 kgm 4 2 13 EXTERNAL DIMENSIONS Typical Direct Coupled Set Length nen 1990 mm asla reda ua ys tp uwa A odes ama 1200
128. rovide a tight shut off A valve position indicator is included on standard and flow regulator models The valves are normally closed and flow is from port 1 to port 2 BRONZE BODY NO PART MATERIAL NC Normally Closed 1 BODY BRONZE 2 BONNET BRASS 3 PLUG STAINLESS STEEL 8 4 PLUG SEAL PTFE 5 VALVE STEM STAINLESS STEEL 6 STEM SEALS CHEVRONS 10 7 STEM O RING 8 ACTUATOR HOUSING GLASS FILLED POLYMIDE 9 9 PISTON GLASS FILLED POLYMIDE 10 PISTON LIP SEAL 11 12 O RING 2 STAINLESS STEEL BODY 5 NO PART MATERIAL 1 BODY STAINLESS STEEL a 2 BONNET STAINLESS STEEL 4 3 PLUG STAINLESS STEEL 4 VALVE PLUG SEAL TFM 1600 5 VALVE STEM STAINLESS STEEL 6 STEM SEAL PTFE FKM CHEVRON 7 STEM O RING FKM 8 ACTUATOR HOUSING 30 GLASS FILLED POLYMIDE 9 PISTON 50 GLASS FILLED POLYMIDE 10 PISTON LIP SEAL NBR 11 GASKET PTFE 12 O RING FKM EQUIPMENT SHEETS PAGE 120 13 10 PRESSURE SWITCH 13 10 1 LOW OIL PRESSURE APP088 LOW OIL PRESSURE SWITCH PART NO 98524 1042 98524 1122 98524 1140 amp 98524 1170 OPERATION Located in the crankcase on water cooled 8 large air cooled compressors in oil filter body on air cooled the pressure switch stops the compressor when the oil pressure drops to pre set pressure setting Part No Compressor Type Inlet Pressure Setting 98524 1042 WATERCOOLED Standard 1 bar 15 psi falling 98524 1122 AIRCOOLED Sta
129. s practice or misuse of the compressor Read and understand all WARNINGS CAUTION AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing 1 4 2 WARNINGS CAUTIONS amp NOTES The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in Machinery Directive 89 392 EEC Amended 91 286 EEC Warnings call for attention to operating procedures involving specific hazards which could cause injury or death and are identified by the following A A RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST A A RISK OF ELECTRIC SHOCK RISK OF HOT SURFACE CONSULT MANUAL 98407 1825 iss 1 8 1 4 3 GENERAL SAFETY PRECAUTIONS e When using cleaning solvents local Health and Safety Regulations must be complied with Provide good ventilation and use suitable protection such as a breathing filter mask safety glass protective apron and gloves e Safety footwear should be compulsory in all workshops Safety helmets must be worn if there is any risk of falling objects e If using compressed air for cleaning purposes ensure safety regulations are complied with and appropriate clothing worn e Never direct compressed air onto your skin or at other people Never use compressed air to clean loose dirt from clothing e Before releasing compressed air through a hose make sure the free end is held securely so that it cannot whip and cause
130. s recommended that temperature indication or gauges are fitted to water inlet and outlet pipes to monitor water temperature rise across the compressor If the rise is too high overheating can cause and accelerate formation of scale in the coolers and water passages Too low a rise may improve the cooler efficiency but can cause condensation in the cylinders A lockable throttle valve is recommended at the inlet to allow adjustment the water flow to achieve the correct temperature Water supply should be prevented when compressor is not running Note Continued water circulation when stationary can cause condensation within the cylinders and breakdown of oil lubrication creating premature wear 6 45 PNEUMATIC WATER INLET VALVE A pneumatic water inlet valve can be supplied to control water supply and prevent overcooling It is controlled by 1 stage air pressure to ensure that compressor can not run on full load without water flow 6 4 6 MOTOR Main leads from the motor controller starter should be brought through a suitable flexible armoured cable sheath to the terminal box on the side of the motor The size of the cable shall be suitable for the supply voltage and current involved and the terminal connections shall be as shown in the terminal box A suitable overload device should always be fitted An hours run meter fitted to the motor starter is recommended for maintenance scheduling A timer should be incorporated in the starter to de
131. scoloration of surrounding metal parts and if present replace complete fuseholder assembly DO NOT Replace cartridge fuses with wire Replace fuses with fuses of a different type or size Attempt to rewire a cartridge fuse EQUIPMENT DATA SHEETS PAGE 129 3 ISOLATORS Check connections for tightness and examine the immediate vicinity of the main contacts for excessive arcing Check the main terminal areas for signs of overheating If either of the above is present dismantle isolator and check state of operating mechanism for wear and examine contacts for excessive damage If appropriate replace contacts or isolator assembly complete Where fitted ensure that door interlocks are effective in preventing door being opened with isolator in position and ensure that isolator operation via the handle is satisfactory 4 CONTACTORS Check that the moving contact carriage is free to operate and that it returns freely to the fully open position If the contactor does not return to the fully open position then it is probable that there is some internal damage to the contactor If so the contactor should be dismantled and repaired or replaced An attempt should be made to determine the cause for the failure Check areas around main contacts for signs of excessive arcing and areas around main terminals for signs of overheating If either is present dismantle contactor and examine for damage Repair or replace as necessary again attemptin
132. sting screw 2 Rotation is clockwise for increasing back pressure and counter clockwise for reducing back pressure Locknut 4 secures the adjusting screw in position If the desired pressure cannot be attained consult CompAir The valve is fitted with a retaining ring 12 and circlip 13 which prevent the internal parts of the valve from being ejected under pressure if the adjusting screw 2 is unscrewed from the valve body 1 COMPUTER GENERATED DRAWING DO NOT ALTER MANUALLY THIRD 45 DO NOT SCALE 10 20 32 4 50 90 125 150 PROJECTION IF IN DOUBT ASK QTY PARTNUMBER DESCRIPTION SUPPLIMENTARY TITLE 1 1 2204326 BODY 2 1176204 ADJUSTING SCREW 3 1 jc20328 SPRING COLAR 4 1176202 0 5 12 1 6204445 RETAIMIMG WASHER Er gt 2 BS NS Tti ISSUE 09 12 2006 LAST amei 66 MOTE RINGS TO GREASED USING FOOD GRADE GREASE WITH A NSF USDA CLASSIFICATION OF H 1 AND WITH A TYPICAL TEMP RANGE OF 20 TO 100 C E G ROCOL FOODLUSE UNIVERSAL MAX WORKING PRESSURE 6250 PSIG 431 BAR EQUIPMENT DATA SHEETS PAGE 115 MAINTENANCE Replacing valve and Ensure all pressure has been released from pressure maintaining valve and system Remove any pipework from valve Dismount valve from system an
133. ston securing capscrew and tighten to correct torque setting Replace all valve cover O rings and coat with silicone grease Refit valve and valve cover and tighten to correct torque setting 8 5 11 DIAPHRAGM DRAIN VALVE Remove all external pipework from valve unit Remove securing nut from central stud and remove valve unit from crankcase Remove the screws at each end of the valve unit and pull bodies apart from the central cover Discard diaphragm and joints Remove and inspect valves lapping with fine grinding paste if necessary to obtain a leak free seal If the valve seat has been worn to more than approximately 1mm width or lapping cannot obtain a satisfactory seal valve and seat must be renewed The pipe fittings and locknuts attached to the valve seats can be removed if the body halves are to be renewed otherwise leave in place The cap screws retaining the mushroom plates to the valve can be removed it the valves are to be renewed Otherwise leave in place Use thread sealant between the valve seats and body halves and the cap screws securing the mushroom plates to the valves on re assembly Reassemble units using new diaphragms and joints tightening the retaining screws finger tight initially whilst checking the relative position of outlets securing bolt hole separator pipe and pilot air connection Tighten all six screws sequentially MAINTENANCE AND REPAIR PAGE 59 8 5 12 FLYWHEEL Remove motor complete with bell h
134. sure the free end is held securely so that it cannot whip and cause injury e Avoid injury by using a hoist to lift heavy loads Check that all chains hooks shackles and slings are in good condition and are of the correct capacity They must be tested and approved according to local safety regulations e Cables chains or ropes should never be applied to lifting eyes Always use an appropriate shackle or hook properly positioned Arrange lifting cables so that there are no sharp bends Use a spreader bar to avoid side loads on hooks eyes and shackles and never leave a heavy load unattended e When a load is on hoist stay clear of the danger area beneath and around it Keep lifting acceleration and speed within safe limits 1 4 4 INSTALLATION PRECAUTIONS e Competent personnel under a qualified supervisor must only carry out installation work e A fused isolator switch must be fitted between the main power supply and the compressor e Precautions must be taken to ensure that no injury is caused to passers by through loose clothing being sucked into compressor intake e Ensure that the discharge pipe from the compressor to the user pipework receiver or storage is free to expand and that no flammable material is within the vicinity If any such material is close by take steps to preclude ignition e manual shut off valve should be fitted in the discharge line to allow the compressor to be isolated Non return valves cannot be relied upon f
135. t be reported and investigated Check motor bearings are not overheating Ensure drains operate at approximately pre set time interval Check that no air relief valve is operating continuously Note for rectification when compressor is stopped any slight air oil or water leaks OPERATING INFORMATION PAGE 36 7 6 STOPPING PROCEDURE When compressor has been stopped by means of stop button on control panel isolate from electrical supply and Check for oil and water leaks and rectify Rectify any leaks noted while compressor was running Close off stop valve on discharge line to relieve air reservoir back pressure from compressor non return valve 77 PREPARATION FOR SPECIAL ENVIRONMENT No special preparations are required other than making sure that should the compressor operate in sub zero temperatures adequate precautions must be taken to ensure water is not allowed to freeze in the compressor water jackets pipework or sea water fresh water heat exchanger when fitted 7 8 STARTING AFTER LONG PERIOD OF IDLENESS Check that all external nuts bolts and other fastenings are tight Check associated and external pipework is intact and adequately supported Turn compressor over a few times by hand to ensure unrestricted rotation Ensure cooling system water is available Open 4th stage manual drain valve Start compressor Listen for any unusual noises during first few minutes of run Close 4th stage
136. that the Health and Safety at Work Act is not contravened by incorrect installation Commissioning or servicing It is important that the valve to be installed is correct in every aspect i e set pressure size material and type for the application STORAGE OF VALVE BEFORE INSTALLATION Valves should be stored preferably between 5 C and 25 C and a relative humidity of less that 75 Very moist or dry conditions should be avoided If a safety valve is installed after six months or more of storage it must be subjected to functional test before commissioning Thread protectors should not be removed until immediately prior to testing or installation as they also prevent the ingress of foreign matter which could harm the valve INSTALLATION VALVE INLET Under no circumstances should it be possible to isolate the safety valve from the protected system Safety valves should be mounted as close as possible to the protected system The connecting pipe should be straight and as short as possible The inlet line to the safety valve should have an effective area of flow at least equal to that of the safety valve inlet CompAir Limited should be consulted if the safety valve is to be mounted in any position other than vertically The maximum pressure drop through the inlet line to the safety valve should not exceed 3 of the set pressure when the valve is discharging at its rated capacity VALVE OUTLET No isolating devices shall be fitted to th
137. thoroughly clean and refit all suction and delivery valves When inspecting valves also remove as far as is possible any carbon deposit in valve pockets passageway pipes and separators Replace crankcase doors and refill crankcase to correct levels with recommended synthetic oil 8 3 SERVICING COMPRESSOR STAGE VALVES 831 ROUTINE CLEANING AND INSPECTION ALL STAGES Valve maintenance is a simple procedure but the following guidelines should be observed Keep a spare oiled and maintained set of valve units in store for quick compressor servicing e Carbon may be removed scraping with a soft blunt instrument e g a piece of wood e WARNING Great care should be taken when removing carbon deposits to ensure that the seating faces of the valve components are not damaged e Note Unless replacement of the springs and plates is intended the order in which these components are removed should be carefully noted so that the valves may be reassembled with the same seating faces in contact e These faces should be clean and bright over their whole area with no evidence of uneven contact Renew any plates that are indented cracked warped or have wear grooves which exceed 10 of the plate thickness e Valve plates and springs must always be replaced at recommended life periods regardless of appearance to achieve maximum reliability e the valve seats show severe wear or indentations the complete valve assembly must be renewed Th
138. ting duties ambient conditions and methods of control The following maintenance schedules are only a recommended guide to maintenance periods It may be found advantageous or desirable to vary the maintenance periods depending on operating conditions and experience 8 1 MAINTENANCE 8 1 1 GENERAL It is useful to record stage pressure temperatures oil used a log against hour s run as this builds up a detailed record of machine condition It can also provide a trend and indication of a possible problem Do not re use O rings seals and joints fit new Grease O rings used for all dry joints in contact air Use a liberal smear of silicone for all O rings used in possible contact with the cooling water l e cooler assemblies 1 and p stage Wet cylinder liners Flush out water passages either with high pressure water or steam cleaning Clean thoroughly all oil ways and carefully blow clean using compressed air Lightly grease or oil all surfaces of ferrous components after cleaning to prevent rusting Where practical remove carbon deposits by gently tapping and scraping taking care not to remove metal 8 1 2 DAILY Check oil level in crankcase and top up as necessary Check stage pressures oil pressure and temperatures 8 1 3 WEEKLY Check bursting disc for signs of cracking Check for oil air or water leaks rectify as necessary Examine oil in crankcase and ensure that it is not contaminated with co
139. tion of Equipment 5437 1323436 5437 COMPRESSOR BLOCK Vee Type Four Stage Two Crank Single Acting Reciprocating Water Cooled Gas Design Type AIR Test Medium Air Test Date 14 February 2011 Target Speed ee _ Customer Unit Of Pressure PSIG Customer RPM 1800 78 Customer Free Air Delivery M Hr 164 57 Tam NM D EN Inlet Pressure EN Outlet Pressure 5000 0 Final Delivery Safety Valve Seta 55 Test Motor Used 63 3KW Volts RPM Motor cyces Manufacturer Test Performed By Dated Test Supervisor Dated British Standard BS ISO 1217 2001 Capacity Test The results contained in this report are valid only for the conditions under which the test was conducted and the specific item tested COMPAIR REAVELL 98407 1825 iss 1 DESCRIPTION OF OPERATION Page 19 5 DESCRIPTION OF OPERATION WARNING BEFORE OPERATING THIS EQUIPMENT USERS SHOULD ENSURE COMPETENCY AND BE MADE AWARE OF AND ENSURE COMPLIANCE WITH THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK ATTENTION OF U K USERS IS DRAWN TO THE HEALTH AND SAFETY AT WORK ACT 1974 amp CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988 TAMPERING WITH SAFETY VALVES IS DANGEROUS AND ALSO INVALIDATES THE GUARANTEE NOTE Because the control panel for this compr
140. tire unburned mixture and may cause a hazard A Potential Explosive atmosphere is an atmosphere which could become explosive due to local conditions CompAir Reavell H5000 Series compressors are designed and manufactured to give optimum performance with long life and reliability This Manual will help you to obtain the best performance from your compressor It provides the information required to install commission and operate the compressor and carry out regular maintenance schedules which will ensure the maximum satisfactory service life Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing Servicing facilities and the supply of genuine replacement parts are provided through a world wide network of CompAir companies and authouised distributors backed by the Service tel 44 0 1527 838632 and Parts department tel 44 0 1473 242000 Fax 44 0 1473 743468 and Sales 44 0 1473 242000 Fax 44 0 1473 743482 The information in this Manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressor Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or authorised distributor for revised or up dated information In any communication concerning the compressor it is essential to quote the MODEL SERIAL No and
141. tly greased new o ring 6 to seat retaining plug 7 and fit to valve body to retain valve seat 5 Fit lightly greased new o rings 4 to new valve 3 and carefully fit into valve body 1 through the valve cover 2 Never fit valve from valve seat end of body as this will cut or damage the O rings Refit valve rod 9 spring 10 and spring collar 8 through cover 2 Refit adjusting screw 11 and locknut 12 Screw down adjusting screw 11 to tension spring 10 Adjust to measured set dimension recorded at start of this procedure Remove complete assembly from vice Refit completed valve to its original position Refit any pipework Start compressor and check for leaks Check back pressure is correct After maintenance of the valve it maybe necessary to make small adjustments to the preset factory or commissioning dimension to attain correct back pressure Refer to setting procedure previously described EQUIPMENT SHEETS PAGE 112 U572 G This valve is fitted to maintain back pressure through separators filters and dryers if fitted This ensures equipment reaches optimum working pressure as soon as possible to give long filter life good oil separation and low oil consumption Setting This valve is factory set or set during commissioning to the correct back pressure for the contract duty and should not require adjustment However if necessary it can be adjusted by a competent person who understands t
142. tory rights of the user All information contained in this publication is as far as possible correct at the time of going to print However due to our policy of continued improvement we reserve the right to alter specifications without prior notice A WARNING A The use of replacement parts or lubricating oils not supplied recommended or approved by CompAir Reavell may lead to failure in service which would not be covered by the warranty Any unauthorised modifications or failures to maintain this equipment is accordance with the manufacturers maintenance instructions may make it unsafe The use of replacement parts not supplied by or recommended by CompAir Reavell may create unsafe and hazardous conditions or result in damage to the equipment over which CompAir Reavell has no control Such hazardous conditions may lead to accidents that can be life threatening cause substantial bodily injury or result in damage to the equipment CompAir Reavell can bear no responsibility for equipment in whin hil replacement parts are included GENUINE PARTS A CompAir Reavell Use Synteck compressor lubricant Advantages Longer time between oil changes Longer valve life Can be used in new or old compressors Reduces carbon build up Reduces oil consumption CompAir Reavell Gardner Denver Reavell House 53 56 White House Road Ipswich IP1 5PB England Telephone 44 0 1473 242000 Customer
143. ucing back pressure Locknut 12 secures the adjusting screw in position Under all circumstances the maximum dimension between underside of adjusting screw 11 and valve body 1 as shown on following drawing must not exceed 150 mm If the desired pressure cannot be attained then consult CompAir Note Later models have a bracket fitted as shown in the following drawing limiting the maximum allowable dimension to 150mm DO NOT REMOVE THE BRACKET IN SERVICE REFIT AFTER MAINTENANCE This bracket is available and can be retrofitted COMPUTER GENERATED DRAWING DO NOT ALTER MANUALLY CN El THIRD ANGLE DO NOT SCALE ped 10 20 30 40 50 60 70 80 90 100 125 150 Y PROJECTION IF IN DOUBT ASK 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 NOTE U572 B PMVs DO MOT INCLUDE ITEM PART NUMBER DESCRIPTION QTY BRACKET C204512 THIS BRACKET MAY 1 1 200302 VALVE BODY 1 BE RETRO FITTED AND ACTS AS A STOP 2 76319 COVER PMV 1 TO LIMIT THE EXTENT TO WHICH THE 3 77555 VALVE 1 ADJUSTING SCREW MAY BE UNSCREWED 4 PS1205 14 O RING NITRILE 2 IF RETRO FITTED DO NOT REMOVE S C763172 VALVE SEAT 1 THE BRACKET IN SERVICE AND 6 4 O RING NITRILE 2 REFIT AFTER MAINTENANCE 7 200303 SEAT RETAINING PLUG 1 1 76320 3 SPRING COLLAR 1 9 74454 1 VALVE 1 2 10 23005 SPRING 1 11 1 ADJUSTING SCREW 1 12 76320 2 LOCKNUT 1 SETTING THIS VALVE IS FACTORY SET HOWEVER IT
144. uoroelastomer materials which decompose under these conditions to form highly corrosive residues Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage 15 COMPRESSOR LOG 2 COMPRESSOR LOG SHEET 0081 00051 0091 00011 0060 00001 0096 0006 0058 0008 0092 0004 0099 0009 0059 0005 0057 0007 0098 0008 0055 0005 0091 0001 009 2 L 001 06 ISd 4va 2 2 335 dINAL dINAL 39IAH3S 53 55 5 39V1S SHH S3GV18 193HO9 G3 TIVLSNI 3LVG ON 1V143S LNO NI YSLVM Y93HO 43MOd 03345 13441 MOSHO 3av85 LV GATIVLSNI 334 LAAHS 901 COMPRESSOR LOG SHEET PAGE 16 REMARKS DATE REMARKS DATE 17 3 AMENDMENTS ISSUE No BESCHIPHON DATE PAGENos 2 ADDRUNNNGINMINERALOIRECOMMENDATION io
145. val or worn below limits those parts should be renewed Refit outer end bearing housing and install housing to crankcase Ensure all journals of crankshaft are clean and free from burrs and oil all surfaces Insert crankshaft to bearing housing Fit new oil seal to driving end bearing housing and install housing Check freedom of rotation of shaft and correct end float 8 5 7 MAIN BEARINGS 8 5 7 1 Use a hydraulic press to remove old bearings from bearing housings BIG END BEARINGS Remove crankcase doors and remove all big end caps Measure crankshaft journals in two positions at 90 for each big end If any one dimension is below the minimum given in Running Clearances and Wearing Dimensions table it is recommended the compressor be overhauled DO NOT merely fit new bearing shells If satisfactory refit big end bearings ensuring identity numbers are adjacent and facing upwards Note The big end bearings fitted to the connecting rods are of the aluminium tin line overlay steel backed shell type on an underlying copper based bearing material It is important to note that due to the bedding process which occurs during running in that the aluminium tin overlay will be removed in the areas of highest load exposing the underlying copper based bearing material This is quite normal and does not indicate a fault in the bearing or the need for shell replacement After initial bedding in to this level the bearing will show no significa
146. which decompose under these conditions to form highly corrosive residues Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage 98407 1825 iss 1 AMENDMENTS Page 11 2 AMENDMENTS ISSUE No REASON DATE PAGE NEW FEB2011 ALL O1 98407 1825 iss 1 AMENDMENTS Page 12 98407 1825 iss 1 13 COMPRESSOR LOG 3 COMPRESSOR LOG 00571 00051 0091 00011 00801 00001 0046 0006 0058 0008 0092 0002 0099 0009 0099 0009 0097 0007 0056 0006 0052 0005 0091 0001 009 2 L 001 05 ISd dV8 2 2 33S 9 31 9 34 GANDIS 39IAH3S 53 55 5 5 SHH SINIL 1 S3GV18 X93HO9 1 LVA JAYA 1143 LnO NI d3LVA 43MOd 03345 13441 MOSHO 1 1 3av85 LV GATIVLSNI YSAOW 055200 334 LAAHS 901 98407 1825 iss 1 COMPRESSOR LOG Page 14 REMARKS
147. y Refit piston rings to piston ensuring that the gaps are staggered around piston Oil all wearing surfaces before re assembly Place piston ring compressor into valve pocket and oil surface Carefully lower the complete piston and conn rod assembly through the piston ring compressor into the cylinder liner using service tools taking care not to rotate the piston When rings are engaged in cylinder liner remove piston ring compressor refit big end bearing and conn rod cap and tighten to correct torque setting Replace all valve cover O rings and coat with silicone grease Refit valve and valve cover and tighten to correct torque setting 2 STAGE Note If removing cylinder liner ensure that cooler body has been drained of water Remove valve cover and valve Remove crankcase door on opposite side of crankcase Remove big end bearing cap from conn rod Withdraw liner piston and conn rod assembly upwards through valve port using the service tools Measure cylinder liner piston and piston rings and replace or re use as necessary De glaze cylinder liner bore by light honing if re using Thoroughly clean all seating faces in cylinder body Refit piston rings to piston ensuring that the gaps are staggered around piston Oil all wearing surfaces before re assembly Replace all cylinder liner O rings and coat with silicone sealant Fit piston assembly into cylinder liner Carefully lower the complete assembly through the valve p
148. ystem Should a fault develop in either of these the compressor must be stopped immediately and the fault investigated and remedied 7 2 COMMISSIONING CHECKS Remove all covers plastic plugs and adhesive tape used to seal compressor openings during shipment Check all electrical connections Ensure water is available to the cooling circuit s Fill compressor water jackets with cool clean sea or fresh water which must be free of suspended particles Remove two crankcase doors and ensure that the crankcase interior is clean and free from foreign bodies and obstructions Check that bolts on connecting rods are tight Check for any water leaks inside crankcase Fill crankcase to the maximum level mark on the sight glass with the correct grade of lubricant Replace crankcase doors Remove oil filter and fill with correct grade of lubricant Smear oil on filter sealing washer and refit filter Tighten by hand only Remove all valve covers and valves Check for signs of rust or water Clean as necessary Re oil inside of the cylinders sparingly Refit valves Smear O rings on valves and valve covers lightly with grease and replace covers Tighten holding down nuts progressively to correct torque in a cross sequence Check all external nuts bolts and other fastenings are tight and correctly torqued that all external connections are made and pipework adequately supported Oil pump priming plug Oil pump Oil Filter

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