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Comp Air UK Ltd abcdef OPERATOR MANUAL for H5336.2, & H5436.2 Water-cooled High Pressure Reciprocating Air
Comp Air UK Ltd
abcdef
OPERATOR MANUAL
for
H5336.2, & H5436.2
Water-cooled High Pressure
Reciprocating Air Compressors.
In any correspondence please quote: JOB NUMBER:
MACHINE NUMBERS:
PUBLICATION NUMBER:
ISSUE DATE:
(on nameplate)
98407/1176 iss2
OCTOBER 2000
CUSTOMER ORDER NUMBER:
CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ
Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027
www.CompAir.com
e-mail: Ipswich@CompAir.com
CompAir UK Ltd DECLARATION OF CONFORMITY 98/37/EEC (Machinery Directive) (Safety of Machinery) (Compressors and Vacuum Pumps

CompAir UK Ltd

CompAir UK Ltd DECLARATION OF CONFORMITY 98/37/EEC (Machinery Directive) (Safety of Machinery) (Compressors and Vacuum Pumps

DECLARATION OF CONFORMITY

98/37/EEC

(Machinery Directive) (Safety of Machinery) (Compressors and Vacuum Pumps – Safety Requirements)

BS EN292: 1991 BS EN1012-1: 1997

We

COMPAIR UK LIMITED

of

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

declare that under our sole responsibility for supply / manufacture, the machinery described below,

Machine Type

Rotary Compressor

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

Reciprocating Compressor

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

Model

is

in

directives.

Serial No .________________________________

_________________________

conformity with the

essential Health and Safety Requirements identified in the above

essential Health and Safety Requirements identified in the above Signature and name of responsible person

Signature and name of responsible person

IPSWICH, ENGLAND

DATE

__________________

PRODUCT MANAGER

Position

CompAir UK Ltd DECLARATION OF CONFORMITY 98/37/EEC (Machinery Directive) (Safety of Machinery) (Compressors and Vacuum Pumps

DECLARATION DE CONFORMITE - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

Nous,

de

COMPAIR UK LIMITED

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

déclarons que sous notre seule responsabilité quant à sa fourniture / fabrication, le matérial décrit ci- dessous,

Type de machine Compresseur rotif

Compresseur alternatif à pistons

No de modèle _________________________

No de série __________________________________

est conforme aux exigences essentielles d’hygiène et sécurité établies aux Directives ci-dessus.

IPSWICH, ENGLAND

est conforme aux exigences essentielles d’hygiène et sécurité établies aux Directives ci-dessus. IPSWICH, ENGLAND

Signature et nom de la personne responsable

DATE

____________________

_______________________

Position

 
Deutsch Español Nederlands !!!!
 
Deutsch Español Nederlands !!!!
     

Deutsch

Español

Nederlands

 

!!!!

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

Wir

COMPAIR UK LIMITED

mit Sitz in

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2

erklären unsere volle Haftung für Lieferung / Erzeugung der folgenden gelisteten Maschinen,

Maschinenart

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2

Modellnr. __________________________________

Kolbenkompressor

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2

Seriennr .__________________________________________

gemäß den Gesundheits-und Sicherheitsanforderungen der oben genannten Richtlinien.

IPSWICH, ENGLAND

DATUM

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2

Unterschrift und Name der verantworlichen Person

Position

DECLARACIÓN DE CONFORMIDAD - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

con domicilio en

COMPAIR UK LIMITED

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

declara, bajo su exclusiva responsabilidad por el suministro o fabricación, que la maquinaria descrita a continuación

Tipo de máquina

Compresor rotativo

Nº de modelo ______________________________

DECLARACIÓN DE CONFORMIDAD - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND

Compresor alternativo

Nº de serie ________________________________________

cumple las principales normas de seguridad e higiene estipuladas en las directivas mencionadas anteriormente.

IPSWICH, ENGLAND

cumple las principales normas de seguridad e higiene estipuladas en las directivas mencionadas anteriormente . IPSWICH,

Nombre y firma de la persona responsable

FECHA ______________________

_______________________

Cargo

KONFORMIT ÄTSBESCHEINIGUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2
VERKLARING VAN CONFORMITEIT - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wij COMPAIR UK LIMITED Van RANELAGH ROAD,
VERKLARING VAN CONFORMITEIT - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997
Wij
COMPAIR UK LIMITED
Van
RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
verklaren onder onze volle aansprakelijkheid voor de levering / vervaardiging dat de hierna beschreven machinerie,
Soort machine
Zuigercompressor
Type nr ___________________________________
Serie nr ___________________________________________
voldoet aan de essentiële Vereisten voor Gezondheid en Veilgheid als geïdentificeerd in de hiervoor vermelde directieven.
IPSWICH, ENGLAND
Handtekening en naam van de verantwoordelijk persoon
DATUM
_____________________
_______________________
Functie
CompAir UK Ltd DECLARATION OF INCORPORATION 98/37/EEC BS EN292: 1991 BS EN1012-1: 1997 (Machinery Directive) (Safety

CompAir UK Ltd

CompAir UK Ltd DECLARATION OF INCORPORATION 98/37/EEC BS EN292: 1991 BS EN1012-1: 1997 (Machinery Directive) (Safety

DECLARATION OF INCORPORATION

98/37/EEC

BS EN292: 1991 BS EN1012-1: 1997

(Machinery Directive) (Safety of Machinery) (Compressors an vacuum pumps – Safety Requirements)

We

COMPAIR UK LIMITED

of

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

declare that under our sole responsibility for supply / manufacture, the machinery described below,

Machine Type

Rotary Compressor

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

Reciprocating Compressor

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

Model

No.

_________________________

Serial

No.

_______________________________

to which this declaration relates is in conformity with the essential Health and Safety Requirements identified in the above Directives.

STATEMENT

This machinery must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the above Directives.

IPSWICH, ENGLAND

We COMPAIR UK LIMITED of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ declare that under our sole

Signature and name of responsible person

DATE __________________

PRODUCTS MANAGER

______________

Position

DECLARATION DE INCORPORATION –98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Nous, COMPAIR UK LIMITED de RANELAGH ROAD, IPSWICH,
DECLARATION DE INCORPORATION –98/37/EEC, BS EN292:1991, BS EN1012-1:1997
Nous,
COMPAIR UK LIMITED
de
RANELAGH ROAD, IPSWICH, ANGLETERRE IP2 0AQ
déclarons que sous notre seule responsabilité quant à sa fourniture / fabrication, le matériel décrit ci-dessous,
Type de machine
Compresseur rotatif
Compresseur à pistons
No de modèle
______________________
No de série ______________________________
concerné par la présente déclaration, est conforme aux exigences essentielles d’hygiène et
sécurité identifiées dans les Directives susmentionnées.
Cet équipement ne doit être mis en service que lorsque l’équipement dans lequel il doit être
intégré a été certifié conforme aux dispositions des Directives susmentionnées.
IPSWICH, ANGLETERRE
Signature et nom du responsable
DATE
__________________
__________________________________
Poste
Deutsch
Español
!!!!

EINBEZIEHUNGSERKLÄRUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

Wir

COMPAIR UK LIMITED

aus

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

EINBEZIEHUNGSERKLÄRUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wir COMPAIR UK LIMITED aus RANELAGH ROAD, IPSWICH, ENGLAND

erklären daß unter unserer alleinigen Verantwortung für Lieferung/Herstellung die unten aufgeführte Maschine.

Maschinentyp:

Kreiskolbenverdichter

Modell-Nr. _________________________________

  • Hubkolbenverdichter

Serien-Nr.

EINBEZIEHUNGSERKLÄRUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wir COMPAIR UK LIMITED aus RANELAGH ROAD, IPSWICH, ENGLAND

_________________________________________

auf die sich diese Erklärung bezieht, den grundlegenden Arbeitsschutzbedingungen in oben genannten Direktiven entspricht.

ERKLÄRUNG

Diese Maschine darf nicht in Betrieb genommen werden, solenge die Konformität der Maschinen, in die sie einbezogen werden soll, mit den Auflagen der oben genannten Directiven nicht erklärt worden ist.

EINBEZIEHUNGSERKLÄRUNG - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 Wir COMPAIR UK LIMITED aus RANELAGH ROAD, IPSWICH, ENGLAND

IPSWICH, ENGLAND

Unterschrift und Name der Verantworlichen Person

DATUM _______________________

Position

COMPAIR UK LIMITED

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ con domicilio en declara, bajo su exclusiva

con domicilio en

declara, bajo su exclusiva responsabilidad por el suministro o fabricación, que la maquinaria descrita a continuación

Tipo de máquina

Compresor rotativo

COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ con domicilio en declara, bajo su exclusiva

Compresor alternativo

COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ con domicilio en declara, bajo su exclusiva

Nº de modelo ______________________________

Nº de serie ________________________________________

a la que se refiere esta declaración, cumple las principales normas de seguridad e higiene estipuladas en las directivas mencionadas anteriormente.

DECLARACIÓN

Esta máquina no podrá ponerse en marcha hasta que haya quedado demostrado que la máquina a la que va incorporada cumple las disposiciones estipuladas en las directivas mencionadas anteriormente.

IPSWICH, ENGLAND

Nombre y firma de la persona responsable

FECHA _______________________

_______________________

cargo

Nederlands !!!!
Nederlands
!!!!

VERKLARING VAN SAMENVOEGING - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997

Wij

te

COMPAIR UK LIMITED

RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

VERKLARING VAN SAMENVOEGING - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 te COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH,

verklaren dat, onder onze volledige verantwoordelijkheid ten aanzien val levering/fabricage van de hieronder beschreven machine.

Type machine

Roterende compressor

VERKLARING VAN SAMENVOEGING - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 te COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH,

Zuigcompressor

VERKLARING VAN SAMENVOEGING - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 te COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH,

Model nr __________________________________

Serie nr ___________________________________________

waarop deze verklaring betrekking heeft in overeenstemming is met de essentiële gezondheids-en veiligheidsvoorschriften, zoals beschreven in de bovengenoemde.

VERKLARING

Deze machine mag pas in werking worden geseld als verklaatd is dat de machine waarmee het wordt samengevoegd in overeenstemming is met de bepalingen van de bovengenoemde richtlijnen.

IPSWICH, ENGLAND

VERKLARING VAN SAMENVOEGING - 98/37/EEC, BS EN292:1991, BS EN1012-1:1997 te COMPAIR UK LIMITED RANELAGH ROAD, IPSWICH,

Handtekening en naam van de verantwoordelijke persoon

DATUM ______________________

______________________

functie

COMPRESSOR LOG SHEET REF. NO. COMPRESSOR PRIME MOVER INSTALLED AT OIL GRADE USED: TYPE: TYPE: SPEED:
COMPRESSOR LOG SHEET
REF. NO.
COMPRESSOR
PRIME MOVER
INSTALLED AT
OIL GRADE USED:
TYPE:
TYPE:
SPEED:
B.H.P.
SERIAL NO:
DRIVE:
DATE INSTALLED:
CHECK OIL LEVEL
CHECK WATER IN/OUT TEMPERATURE
CHECK COOLING FAN BLADES
FINAL
FINAL AIR
PRESSURE
#(BAR - PSI)
SERVICE
DATE
TIME
*HOURS
STAGE
STAGE
RUN
TEMP.°C
TEMP.°C
STAGE PRESSURES
#(BAR - PSI)
PLAN
NUMBER
REMARKS SEE
OVER FOR MORE
SIGNED
#50/100
1234 5
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
10500
11000
11500
12000
12500

*FILL IN HOURS RUN AS DETAILED ON SERVICE PLAN FOR PARTICULAR COMPRESSOR TYPE # DELETE AS NECESSARY - † FILL IN APPROPRIATE STAGE TRIP TEMPERATURE READING SERVICE ENGINEER TO SIGN & FILL IN ANY OTHER COMMENTS IN REMARKS COLUMN SERVICE TELEPHONE +44 (0) 1473 556027 - PARTS +44 (0) 1473 601282

COMPRESSOR LOG SHEET REF. NO. COMPRESSOR PRIME MOVER INSTALLED AT OIL GRADE USED: TYPE: TYPE: SPEED:

logsheetm.doc

DATE REMARKS DATE REMARKS
DATE
REMARKS
DATE
REMARKS

logsheetm.doc

CompAir UK Ltd SAFETY SECTION

Page 1

OPERATOR MANUAL - 5000 SERIES AIR COMPRESSORS

CONTENTS

Page

Ownership Data

2

Foreword

3

Safety Procedures

5

WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir

WARNING

WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir

The

use

of

replacement

parts

or

lubricating

oils

not supplied,

recommended or approved by CompAir UK Ltd 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 UK Ltd Ipswich cannot accept responsibility for damage, injury or failure caused by these situations.

USE ONLY

WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir

CompAir UK Ltd Ipswich GENUINE PARTS AND AUTHORISED SERVICE AGENTS

CompAir UK Ltd SAFETY SECTION

Page 2

OWNERSHIP DATA

TECHNICAL DATA

It is recommended that details taken from the compressor and motor nameplates are recorded below.

Model Type:

Motor Serial Number:

Serial Number

Motor RPM:

Year:

Motor kW:

Maximum Pressure:

Motor V. Ph. Hz:

Compressor Lubricant:

Motor Bearing Grease:

(if applicable)

Capacity M³/hr - CFM

Notes:

CompAir UK Ltd Ipswich CONTACT DETAILS

Contact Name:

Sales Telephone: +44 (0) 1473 602222

Address:

Notes:

CompAir UK Ltd Ranelagh Road Ipswich IP2 0AQ ENGLAND

Telephone: +44 (0) 1473 602222

Fax: +44 (0) 1473 601704

Contact Names:

Parts Telephone: +44 (0) 1473 602222 Parts Fax: +44 (0) 1473 601282

Contact Names:

Service: +44 (0) 1473 556027

For any comments or queries about the contents of this MANUAL please write to CompAir UK Ltd. Ranelagh Road, Ipswich 1P2 0AQ. England marked for the attention of Mr. Dennis Beeton, Technical Publications Engineer.

CompAir UK Ltd SAFETY SECTION

FOREWORD

Page 3

CompAir UK Ltd Ipswich H5000 Series compressors are designed and manufactured to give optimum performance, with long life and reliability.

SPECIAL ATTENTION The STANDARD BUILD of all CompAir UK Ltd (Ipswich Operations) 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 entire unburned mixture and may cause a hazard.

A Potential Explosive atmosphere is an atmosphere, which could become explosive due to local conditions.

This Manual will help you to obtain the best performance from your compressor. It provides the information required to install, commission and operate the compressor and carry out regular maintenance schedules, which will ensure the maximum satisfactory service life.

Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing. Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network of CompAir Companies and CompAir UK Ltd Distributors, backed by the Service and Parts Departments at CompAir UK Ltd, Ipswich (UK) tel: +44 (0) 1473 602222. fax: +44 (0) 1473 601704. Customer Service +44 (0) 1473 556027 or Parts fax: +44 (0) 1473 601282.

The information in this Manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressor. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or CompAir UK Ltd Distributor for revised or up-dated information.

In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No. and any CONTRACT Ref.

It is important this Manual is retained with the compressor for reference and should remain with the compressor if it is sold or transferred to another user. Ensure that the new user is made fully aware of the need to study the Safety Section and any Warnings for safe operation given throughout the text.

Protect the environment by using only approved 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.

CompAir UK Ltd SAFETY SECTION

Page 4

CAUTION

Use only CompAir UK Ltd Ipswich Genuine Parts when carrying out routine maintenance or repair. The use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd Ipswich can lead to expensive failures, which will not be covered by warranty.

Substitution of parts not manufactured or approved by CompAir UK Ltd Ipswich can create a potential personnel hazard.

This is a High Pressure Compressor, for safe and reliable operation use only genuine CompAir UK Ltd Ipswich Parts

To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance with the information given in this manual - refer to the “Maintenance Section”.

Conditions of CompAir UK Ltd Ipswich 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.

CompAir UK Ltd SAFETY SECTION

Page 5

SAFETY PROCEDURES

Page

..............................................................................

General

........................................

7

Warnings, Cautions and Notes

7

General Safety Precautions

.............................................

7

Installation Precautions

8

................................................... Operational Precautions

8

.............................

9

.....................................

10

CompAir UK Ltd SAFETY SECTION

Page 6

 

SAFETY

WARRANTY

The Conditions of the CompAir UK Ltd Ipswich Warranty are set out in the Standard Conditions of

Sale.

MAINTENANCE

To ensure continued trouble free operation of the compressor it is important that periodic maintenance and servicing are carried out in accordance with the information given in the "Maintenance" section of

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

WARNING The use of replacement parts or lubricating oils not supplied or approved by CompAir UK Ltd Ipswich may lead to failures in service which would not be covered by warranty.

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

Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury or result in damage to the equipment. CompAir UK Ltd Ipswich 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.

CompAir UK Ltd SAFETY SECTION

Page 7

SAFETY

1.

GENERAL

CompAir UK Ltd Ipswich compressor safety relates to the document BS EN1012-1 Compressors and Vacuum Pumps - Safety requirements and the UK Pressure Systems Health & Safety Regulations S.I. 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 UK Ltd cannot anticipate every possible circumstance, which might represent a potential hazard. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by CompAir UK Ltd then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property.

Failure to observe these precautions given under "Safety Precautions" may be considered dangerous practice or misuse of the compressor

Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing.

2.

WARNINGS, CAUTIONS & NOTES

The following details for this Safety Section relate to the ESSENTIAL SAFETY REQUIREMENTS referred to in Directive 89/392/EEC, Amended 91/286/EEC.

1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to the document BS EN1012-1 Compressors and

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

SAFETY SECTION Page 7 SAFETY 1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to

RISK OF DANGER

SAFETY SECTION Page 7 SAFETY 1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to

RISK OF ELECTRIC SHOCK

SAFETY SECTION Page 7 SAFETY 1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to

RISK OF HIGH PRESSURE

SAFETY SECTION Page 7 SAFETY 1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to

RISK OF HOT SURFACE

SAFETY SECTION Page 7 SAFETY 1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to

RISK OF GAS EXHAUST

SAFETY SECTION Page 7 SAFETY 1. GENERAL CompAir UK Ltd Ipswich compressor safety relates to

CONSULT MANUAL

  • 3. GENERAL SAFETY PRECAUTIONS

When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and gloves.

Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any risk of falling objects.

If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing worn.

Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing.

CompAir UK Ltd SAFETY SECTION

Page 8

3.

GENERAL SAFETY PRECAUTIONS (Cont.)

Before releasing compressed air through a hose make sure the free end is held securely so that it cannot whip and cause injury.

Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to local safety regulations.

Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended.

When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits.

4.

INSTALLATION PRECAUTIONS

Competent personnel under a qualified supervisor must only carry out installation work.

A fused isolator switch must be fitted between the main power supply and the compressor.

Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into compressor intake.

Ensure that the discharge pipe from the compressor to the user pipework, receiver or storage is free to expand and that no flammable material is within the vicinity. If any such material is close-by take steps to preclude ignition.

A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated. Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must be installed between any compressor unit and the isolating valve.

A pressure-reliving device must be fitted to every pressure vessel, or equipment containing 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 UK LTD advise caution with the use of cooling towers for water cooling the compressor. Closed circuit or direct mains cooling is preferred.

Pipework or other parts with a surface temperature above 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.

  • 5. OPERATIONAL PRECAUTIONS

Competent personnel under a qualified supervisor must only operate the compressor.

Do not operate compressor with any removable inspection cover removed e.g. crankcase doors, valve covers etc.

Never remove or tamper with safety devices, guards or insulation materials.

The compressor must only be operated at the supply voltage and frequency for which it is designed. Always isolate power before maintenance or servicing.

When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system. ALWAYS CONSULT A QUALIFIED ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK.

Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement, test or adjustment. Such work should always be carried out by a qualified. Electrician with appropriates tools and protection against an electrical hazard.

If the unit is equipped with a Remote Control device, attach warning notices stating "THIS UNIT CAN BE STARTED REMOTELY" in prominent locations, one on the outside of the unit, the other inside the control compartment.

As a further safeguard, take adequate precautions that no one is working or checking the unit before attempting to switch on remotely controlled equipment. Attach a "CHECK THAT ALL PERSONNEL ARE CLEAR OF UNIT BEFORE STARTING" or similar notice.

Compressed 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.

5.

OPERATION PRECAUTIONS (Cont.)

If there is any indication that the compressor is overheating it must be shutdown. (A high air or gas temperature switch is fitted as standard to guard against operating with excessive temperature). Beware of burns from hot oil and water when working on a unit recently shutdown.

Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance. Secure guards following any servicing or repair.

Local noise regulations must be observed. Ear defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with communication.

6.

MAINTENANCE & REPAIR PRECAUTIONS

Competent persons under qualified supervisor must carry out maintenance repair and modifications.

The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models). Oil free models will have desiccant bags in valve covers and distance pieces.

Handling components such as seals, gaskets and diaphragms should not present a personnel hazard. Preservation oils again should not present a personnel hazard if handled under normal handling practices.

Whilst compressors are asbestos free, treat all damaged gaskets as asbestos - when the Asbestos at work regulations apply.

Viton 'O' seals under normal operating conditions are safe.

However, should there be a fire within the compressor or these seals are likely to exceed a temperature of 300°C the material will decompose.

Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns.

If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC gloves.

CompAir UK Ltd SAFETY SECTION

Page 9

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

1. Isolate the compressor from the main electrical supply. Lock the isolator in the OFF position and remove fuses.

2. Attach a label " WORK IN PROGRESS - DO NOT APPLY VOLTAGE".

3. Close the isolating valve between the compression unit and user's pipework. Close the isolating valve in the cooling water inlet pipe. Attach a label "WORK IN PROGRESS - DO NOT OPEN".

4. Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage. Check that all pressure gauges register zero.

5. Ensure that the cooling water system has been drained.

6. Check that the drain valve on the delivery manifold is clear and gas pressure has been released.

7. Check that all interstage drains are open to ensure any gas trapped between stages has been released.

Stand clear of all valve covers when removing the securing screws.

When removing valve covers for valve replacement, ensure a minimum of two threads is left engaged on the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port in the cylinder head. Remove the securing screws and take out valve cover.

Use only lubricating oils and greases

approved by CompAir UK LTD to avoid

potential hazards especially the risk of explosion or fire and the possibility of decomposition or generation of hazardous gases.

Always clean oil spills from the surrounding floor before and after maintenance work.

CompAir UK Ltd SAFETY SECTION

Page 10

  • 6. MAINTENANCE & REPAIR (Cont.)

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.

Keep the compressor clean at all times.

Protect components and exposed openings by covering with a clean cloth or tape during repair or maintenance work.

Protect the motor, intake, electrical and regulation components against the entry of moisture e.g. steam cleaning.

Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks. The adjacent components must be screened with non-flammable material and if oil present, the system must first be cleansed thoroughly by steam cleaning.

Condensate (oil and water mixture from compression process) must be regarded as trade effluent and is therefore not suitable for discharge into a surface water sewer, soakaway or watercourse.

PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL.

  • 7. PRECAUTIONS IN THE EVENT OF FIRE

Use extreme caution when handling components that have been subjected to fire or very high temperature. Some components may contain fluoroelastomer materials, which decompose under these conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage.

This is a high pressure Compressor use only:

GENUINE CompAir UK Ltd Ipswich PARTS

Precautions must be taken against using acids, alkalis and chemical detergents for cleaning machined parts. These materials cause irritation and are corrosive to the skin, eyes, nose and throat. Avoid splashes and wear suitable protective clothing and safety glasses. Do not breathe mists. Ensure water and soap is readily available.

When disposing of condensate, old oil, used filter elements and other parts and waste material of any kind make sure that there is no pollution to any drain or natural water course and that no burning of waste takes place which could cause pollution of the atmosphere.

CompAir UK Ltd PUBLICATION 98407.1176 Page 1

HISTORY RECORD H5336.2, 5436.2 COMPRESSORS

ISSUE

MOD Note

M/C SERIAL No CHANGE. - REASON

DATE

PAGE No

No

No

1

NEW

NEW

FEB 1999

ALL

2

NONE

NONE - ADD H5436.N2.B2 DETAILS TO MANUAL & PARTS LIST

OCT 2000

VARIOUS

3

NONE

DELETED H5436.2. N2.B2 NOW 98407.1307

NOV 2001

VARIOUS

4

       

5

       

6

       

7

       

8

       

CompAir UK Ltd PUBLICATION 98407.1176 Page 2

Page 2 1176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 3

CONTENTS

PAGE

CERTIFICATE OF CONFORMITY/INCORPORATION.

ex

COMPRESSOR LOG SHEET.

ex

SAFETY GENERAL

ex

AMENDMENTS

1

INDEX

3

SECTION 1

LEADING PARTICULARS

1.1

UNIT DESIGNATION------------------------------------------------------------------------5

1.2

TECHNICAL DATA - GENERAL ---------------------------------------------------------5

1.3

PRESSURE AND TEMPERATURE ACCEPTANCE LEVELS--------------------6

1.4

RUNNING CLEARANCES -----------------------------------------------------------------7

1.5

CRITICAL TORQUE WRENCH SETTINGS-------------------------------------------8

1.6

NON-CRITICAL TORQUE WRENCH SETTINGS -----------------------------------8

SECTION 2

GENERAL DESCRIPTION

2.1

GENERAL DETAILS ------------------------------------------------------------------------9

2.2

SYNTHETIC OILS --------------------------------------------------------------------------10

2.3

COMPATIBILITY OF MATERIALS WITH SYNTHETIC TYPE OILS -----------11

SECTION 3

INSTALLATION

3.1

HANDLING OF UNIT-----------------------------------------------------------------------13

3.2

LOCATION------------------------------------------------------------------------------------13

3.3

MOUNTING-----------------------------------------------------------------------------------14

3.4

CONNECTIONS, PIPEWORK AND FITTINGS--------------------------------------14

3.5

DRIVE RECOMMENDATIONS ----------------------------------------------------------14

3.6

COOLING -------------------------------------------------------------------------------------15

3.7

ELECTRICAL CONNECTIONS----------------------------------------------------------15

3.8

CONTROL FOR AUTO STOP/START-------------------------------------------------16

3.9

RECOMMENDED ANCILLARIES SUMMARY---------------------------------------16

SECTION 4

COMMISSIONING OR RECOMMISSIONING

4.1

BEFORE STARTING-----------------------------------------------------------------------17

4.2

START-UP PROCEDURE ----------------------------------------------------------------18

4.3

AFTER THE FIRST 15 HOURS RUNNING TIME-----------------------------------18

4.4

AFTER THE FIRST 100 HOURS RUNNING TIME---------------------------------18

4.5

CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT----------19

SECTION 5

OPERATION & ROUTINE MAINTENANCE

5.1

OPERATION AND DAILY MAINTENANCE ------------------------------------------21

5.2

MAINTENANCE PERIODS ---------------------------------------------------------------22

5.3

VALVE MAINTENANCE PERIODS-----------------------------------------------------23

5.4

MAINTENANCE DETAILS ----------------------------------------------------------------23

CompAir UK Ltd PUBLICATION 98407.1176 Page 4

SECTION 6

VALVE SERVICING

6.1

GENERAL ------------------------------------------------------------------------------------ 27

6.2

CLEANING AND INSPECTION ALL STAGES -------------------------------------- 27

6.3

VALVE REMOVAL AND DISMANTLING --------------------------------------------- 27

SECTION 7

FAULT GUIDE

7.1

EXCESSIVE PRESSURE ---------------------------------------------------------------- 31

7.2

INSUFFICIENT PRESSURE OR VOLUME ------------------------------------------ 31

7.3

OVERHEATING----------------------------------------------------------------------------- 32

7.4

EXCESSIVE NOISE ----------------------------------------------------------------------- 32

7.5

EXCESSIVE WEAR------------------------------------------------------------------------ 32

7.6

EXTENDED RUNNING ------------------------------------------------------------------- 32

7.7

FAILURE TO START ---------------------------------------------------------------------- 32

SECTION 8

RECOMMENDED SERVICE PLANS--------------------------------33

RSP5436M - H5436.2 - Mineral Oil --------------------------------------------------- ex 1 RSP5436S - H5436.2 - Synthetic Oil ------------------------------------------------- ex 2 RSP5336M - H5336.2 - Mineral Oil --------------------------------------------------- ex 3 RSP5336S - H5336.2 - Synthetic Oil ------------------------------------------------- ex 4

SECTION 9

ILLUSTRATED LIST OF PARTS-------------------------------------35

98407/1176PL

SECTION 10 ANCILLARY EQUIPMENT ---------------------------------------------37

COMPRESSOR CROSS REFERENCE CHART

NEW DESIGNATION

OLD DESIGNATION

H5336.2

C5336 MK2

H5346.2

C5436 MK2

Page 4 1176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 5

SECTION 1

LEADING PARTICULARS

  • 1.1 UNIT DESIGNATION Flange mounted, motor driven machine -----------------------------------------------H5336.2, & H5436.2 V-belt driven machine, electric or internal combustion engine powered--------------------------------------------------------------H5336.2, & H5436.2

  • 1.2 TECHNICAL DATA - GENERAL Type ----------------------------------------------------------------Single acting, three stage H5336, 90° vee Type ---------------------------------------------------------- Single acting, three stage H5436, 90° Booster Type -----------------------------------------------------------------Single acting, four stage, H5436, 90° vee Cooling------------------------------------------------------------------------------------------------------------Water Direction or rotation, viewed from drive end -------------------------------------------------- Anti-clockwise Number of valves------------------------------------------- One combined suction and delivery per stage Type of valve --------------------------------------------------------------------------------------Flat plate, low lift Mounting----------------------------------------------------------------------Three point, anti-vibration mounts Lifting points ----------------------------------------------------------------------------------------------------- Three TEMPERATURES: Minimum ambient temperature --------------------------------------------------------------------------------0°C Maximum compressor air intake temperature------------------------------------------------------------ 45°C Maximum ambient for radiator sets (Contact CompAir UK Ltd for lubricant/duty restrictions) ------------------------------------------ 30\40°C Maximum water inlet temperature--------------------------------------------------------------------------- 37°C Temperature rise across machine -------------------------------------------------------------------10°C\12°C SPEEDS: Maximum speed---------------------------------------------------------------------------------------1500 rev/min Minimum speed----------------------------------------------------------------------------------------- 725 rev/min PRESSURES:

H5336.2

H5436.2

Minimum working pressure ------------------------------------------- ---------------- 40 bar -----------140 bar Maximum working pressure ------------------------------------------ ---------------- 85 bar -----------350 bar

Maximum water pressure --------------------------------------------- ----------------- 5 bar ------------- 5 bar Oil pressure------------------------------------------------------------------------------------- all 2.0-2.75 bar # Contact CompAir UK Ltd for more details.

LUBRICATION:

Crankcase oil capacity---------------------------------------------------------------------------------- all 45 litres

Recommended grease (for assembly) -------------------------------------------------- all Shell Alvania R3

Recommended oil (Synthetic). --------------------------------------------------------------- Reavellite

Recommended oil------------------------- Mineral .See duty restrictions --------------- Mobil Rarus 427

¤ Oil recommendations are based on normal conditions. If difficulty is experienced a change may be advisable - refer to CompAir UK Ltd.

COOLING:

Water----------------------------------------------------------------------------Mains or water pump circulation Cooling water flow @ 15°C ------------------------------------------------------------------------------ 75 l/h/kw

CompAir UK Ltd PUBLICATION 98407.1176 Page 6

INTERNAL DIMENSIONS:

H5336.2

H5436.2

Piston stroke -------------------------------------------------------------- --------------------75 mm -----------75 mm First stage cylinder bore ----------------------------------------------- -------------------185 mm --------- 185 mm Second stage cylinder bore (1st stage on SP1)------------------ --------------------95 mm ----------- 95mm Third stage cylinder bore (2nd stage on SP1) -------------------- -------------------- 45mm------------ 45mm Fourth stage cylinder bore (3rd stage on SP1)------------------- ----------------------N/A ------------- 22mm

CONNECTIONS:

First stage suction ----------------------------------------------------------------------Special flange adaptor Rp3 Final delivery H5436.2---------------------------------------------------------------------------------------------- Rp½ Final delivery H5336.2---------------------------------------------------------------------------------------------- Rp¾ Water inlet ------------------------------------------------------------------------------------------------------------- Rp1 Water outlet ----------------------------------------------------------------------------------------------------------- Rp1

WATER TEST PRESSURES:

First stage cooler ------------------------------------------------------------------------------------------------10.3 bar Second Stage cooler---------------------------------------------------------------------------------------------- 55 bar Third stage cooler ------------------------------------------------------------------------------------------------285 bar Fourth stage cooler-----------------------------------------------------------------------------------------------690 bar Water Jacket------------------------------------------------------------------------------------------------------10.3 bar

UNIT WEIGHT (APPROX.):

Bare machine----------------------------------------------------------------------------------------------------1070 kgs Crankcase--------------------------------------------------------------------------------------------------------- 230 kgs Cooler body ------------------------------------------------------------------------------------------------------- 180 kgs

  • 1.3 PRESSURE AND TEMPERATURE ACCEPTANCE LEVELS

Pressures:

 
   

Stages (bar)

 

M/c Type

Oil

First

Second

Third

4th Delivery

H5336.2:

- 2.7

  • 2.0 - 2.9

  • 2.5 - 13.9

12.8

  • 27.5 N/A

 
 

- 2.7

  • 2.0 - 3.0

  • 2.6 - 15.2

13.5

  • 41.3 N/A

 
 

- 2.7

  • 2.0 - 3.1

  • 2.7 - 15.9

14.2

 
  • 55 N/A

 

- 2.7

  • 2.0 - 3.2

  • 2.75 - 16.5

14.8

 
  • 69 N/A

 

- 2.7

  • 2.0 - 3.2

  • 2.75 - 17.4

15.7

 
  • 85 N/A

H5436.2:

- 2.7

  • 2.0 - 3.1

  • 2.7 - 17.9

16.3

  • 66.1 - 74.1

137.8

 

- 2.7

  • 2.0 - 3.1

  • 2.7 - 18.2

16.5

  • 73.0 - 81.3

206.8

 

- 2.7

  • 2.0 - 3.1

  • 2.7 - 18.4

16.7

  • 79.9 - 88.9

257.7

 

- 2.7

  • 2.0 - 3.1

  • 2.7 - 18.7

17.0

  • 86.8 - 96.5

344.7

Temperatures:

 

Maximum stage-------------------------------------------------------------------------------------------------------------- 215° C Final Delivery (Max) ----------------------------------------------------------------------------------------------------------70°C

These temperatures must not be exceeded except under certain reduced operating conditions, details of which can be obtained from CompAir Distributors or from CompAir UK Ltd Customer Service Department. NOTE: THE MAXIMUM OPERATING TEMPERATURES ARE IMPORTANT TO THE LIFE AND SAFETY OF THE MACHINE.

Page 6 1176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 7

  • 1.4 RUNNING CLEARANCES (MILLIMETRES)

Part Description

 

Stage

As Fitted

Max.

 

(mm)

Permissible

(mm)

Piston (Plunger) Vertical Clearance

 

1

0./0.9

0.9

2

0.4/0.9

0.9

3

0.45/1.0

1.0

4

0.35/1.46

1.46

Piston Ring Gaps

1

Taper

0.2/0.45

1.63

Scraper

0.2/0.45

1.43

(Measured in unworn portion of cylinder/liner)

2

Taper

0.1/0.23

1.47

Scraper

0.1/0.23

1.27

3

Plain

0.05/0.18

1.32

H5436.2 Peek 450

4

Plain

0.2/0.4

1.32

Piston Ring Axial Width Clearance

1

Taper

0.04/0.09

0.29

(Measured between groove & top face of ring with

Scraper

0.05/0.10

0.30

ring in normal running position).

2

Taper

0.02/0.08

0.28

Scraper

0.05/0.10

0.30

3

Plain

0.03/0.09

0.29

H5436.2 Peek 450

4

Plain

0.03/0.07

0.20

Piston Ring Groove Width

1

Taper

4.80/4.83

4.91

Scraper

8.01/7.99

8.09

2

Taper

3.23/3.20

3.31

Scraper

4.83/4.80

4.91

3

Plain

2.05/2.01

2.13

H5436.2

4

Plain

2.05/2.01

2.13

Piston/Plunger Diameter Above Top Ring

 

1

184.77/184.74

184.69

1

184.54/184.49

184.44

2

94.91/94.88

94.83

3

44.93/44.90

44.85

H5436.2

4

21.955/21.945

21.9

Cylinder/Liner Diameter

 

1

185.05/185.00

185.11

2

95.04/95.00

95.10

3

45.03/45.00

45.09

4

22.01/22.00

22.07

Crosshead Diametrical Clearance

 

3

0.06/0.13

0.19

4

0.06/0.13

0.19

Small End Bearing Diametrical Clearance In Conn Rod

 

1

0.01/0.05

0.1

2,3,4

Needle Roller

In Piston

1

-0.003/0.013

0.03

2,3,4

0.025/0.044

0.09

   

1,2,3,4

0.066/0.12

0.24

Big End Bearing Diametrical Clearance Small End Bearing End Float

 

1

0.15/0.64

1.0

2,3,4

0.15/0.55

1.0

   

0.05/0.14

0.2

Main Bearing Diametrical Clearance Crankshaft End Float

 

0.66/0.23

0.75

Coupling Face Distance for Direct Coupled Sets

 

2.0/6.0

6

CompAir UK Ltd PUBLICATION 98407.1176 Page 8

  • 1.5 CRITICAL TORQUE WRENCH SETTINGS

Part Description

 

Size

No Off

Newton metre (Nm)

Lbs/Ft

Big end bearing bolts

 

M16

8

203

150

1st & 2nd stage cooler covers

 

M10

17

54

40

3rd stage cooler covers

 

M16

10

236

174

1st stage valve cover

 

M12

6

41

30

2nd stage valve cover

 

M12

6

41

30

3rd stage valve cover

 

M20

4

95

70

4th stage valve cover*

 

M20

4

108

80

4th stage valve cover (5436H only)*

M20

4

122

90

1st stage cylinder to crankcase

 

M12

4

95

70

2nd stage cylinder to crankcase

M12

4

95

70

3rd & 4th stage crosshead to crankcase

M12

6

95

70

3rd & 4th stage cylinders to crosshead guide

M12

8

95

70

   

¾"UNF

1

162

120

Flywheel bolt 3rd stage piston to crosshead

 

M8

1

27

20

NOTE:

1.

Under no circumstances are any deviations from the above figures allowed unless authorised in writing by CompAir UK Ltd.

 
  • 2. All figures are subjected to a tolerance of ±5%.

 
  • 3. Figures are for NON-LUBRICATED fastenings. * To be tightened sequentially in 27 Nm steps.

  • 1.6 NON-CRITICAL TORQUE WRENCH SETTINGS

 

Part Description

 

Size

No Off

Newton Metre (Nm)

Lbs/Ft

D/E main bearing housing to crankcase

M12

8

95

70

 

M12

10

95

70

O/E main bearing housing to crankcase O/E cover

M8

10

27

20

Crankcase door

 

M10

24

54

40

Cooler body to cylinders

 

M12

6

95

70

   

M10

4

54

40

Bursting disc cover Cooler door

 

M10

26

27

20

1st stage valve

 

M10

1

21

16

2nd stage valve

 

M8

1

11

8

3rd stage valve

 

M6

1

6

5

4th stage valve

 

M5

1

3

2

   

M12

10

95

70

Motor bell housing Motor bracket to crankcase

 

M16

5

162

120

   

M8

3

27

20

Oil pump Cylinder lubricator

 

3/8"

4

35

26

NOTE:

1.

Under no circumstances are any deviations from the above figures allowed unless authorised in writing by CompAir UK Ltd.

  • 2. All figures are subjected to a tolerance of +5% -15%.

  • 3. Figures are for NON-LUBRICATED fastenings.

Page 8 1176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 9

SECTION 2

GENERAL DESCRIPTION

2.1 GENERAL

Pressure gauges Lifting eyes rd 3 stage safety valve 4 th stage cylinder 1 st stage
Pressure gauges
Lifting eyes
rd
3
stage safety valve
4 th stage cylinder
1 st stage safety valve
Stage temperature gauges
Final stage non-return valve
3 rd stage cylinder
th
4
stage safety valve
Suction/inlet filter silencer
1 st stage cylinder
Coolant drains
Oil filler
Oil pump
Final separator drain valve
4 th stage cylinder lubricator
Oil level gauge
Oil drain plug

H5436.2 ILLUSTRATED

These compressors have four stages H5436.2, single acting, 90°-vee configuration, which provides complete primary balance.

Air enters the machine through a filter/silencer and is compressed by the first stage piston, after which it passes through cooler tubes to the second stage for further compression. Cooled again, the process is repeated through the third stage (final stage on H5336.2 after further cooling, the air is delivered at the designed pressure to the system), After which it is cooled again before entering the final stage for compression. After further cooling, the air is delivered at the designed pressure to the system.

Cooling is by water through the jackets and passages either from the mains or by a radiator cooled, self-contained system. Seawater cooling is used for marine applications.

Drive is by either flange mounted motor or v-belt transmission from a suitable power source, such as electric motor or internal combustion engine.

Cylinders are bolted to the crankcase in a 90°-vee formation and the second, third and fourth stage cylinders are fitted with liners.

Main bearing bushes, big end bearing halves and small end bearings are all replaceable.

First and second stage pistons are conventional, whilst the third has an integral piston and crosshead assembly. The fourth stage has a floating solid plunger fitted to a crosshead. All are fitted with piston rings. On the H5336.2 is different a dummy piston being fitted in place of the fourth stage.

Multi-stage coolers are fitted after each compression stage and maintained through access doors. First, second and third stage coolers are fixed, whilst the fourth stage has a withdrawable tubestack (not on H5336.2 this is blanked off).

All stage valves are of the flat plate, low lift, multi-ported type and combine both suction and delivery functions. Ease of access, only one valve cover per cylinder and good flow characteristics are a feature of this reliable valve design.

CompAir UK Ltd PUBLICATION 98407.1176 Page 10

System Description - Lubrication

A forced lubrication system is utilised, conveying oil to the big end and main bearings via a filter and crankshaft passages. The connecting rods are drilled to supply small end bearing/bushes. Oil is forced through the bearing clearance and thrown off the rotating crankshaft to ensure an adequate supply to cylinders, pistons and crossheads. Return flow oil is drawn through a strainer and excess pressure regulated by a spring-loaded relief valve. Oil pressure is gauge indicated. The H5436.2 4th stage cylinder being fed from the crankcase oil pump via a non-return valve.

The crankcase is filled through the filler on the crankcase and the oil level is indicated in a sight glass on the crankcase end.

Lubricating oil to the recommended specification must be used at all times to ensure safe and efficient operation with minimum wear and protection against moist air corrosion. Recommendations are the result of extended research at CompAir UK Ltd and all responsibility for the use of oil other than that recommended is placed on the purchaser and his oil supplier.

THE NORMAL GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED, BY CompAir UK Ltd, TO THE USE OF A LUBRICANT NOT RECOMMENDED.

OIL FLOW DIAGRAM H5436.2 ILLUSTRATED

4TH STAGE OIL 25 MICRON CYLINDER PUMP FILTER 5436 ONLY OIL RELIEF O/E MAIN D/E MAIN
4TH STAGE
OIL
25 MICRON
CYLINDER
PUMP
FILTER
5436 ONLY
OIL
RELIEF
O/E MAIN
D/E MAIN
BYPASS
VALVE
BEARING
BEARING
VALVE
ONLY OPENS IF
FILTER BLOCKS
CRANK
SHAFT
OIL
STRAINER
FILLER
SUMP
CompAir UK Ltd PUBLICATION 98407.1176 Page 10 System Description - Lubrication A forced lubrication system is
CompAir UK Ltd PUBLICATION 98407.1176 Page 10 System Description - Lubrication A forced lubrication system is
  • BEARING

BIG END

  • SMALL END

BEARING

  • GAUGE

PRESSURE

LOW OIL

PRESSURE

Page 101176.doc

System Description - Controls

CompAir UK Ltd PUBLICATION 98407.1176 Page 11

For starting purposes, automatic or manual unloaders/drains are fitted to all stages. Automatic unloaders provide initial venting when starting and close as the compressor attains operational speed, opening again for condensate draining when the machine is shut down.

A timer may be incorporated in the unloading circuit to effect timed drainage (compatible with environmental and operating conditions). High humidity requires more frequent draining.

Pressure safety valves are fitted at each stage.

Oil and air pressure gauges for each stage are mounted on a common panel.

Low oil pressure and high temperature switches are standard equipment.

A bursting disc is fitted to prevent excessive pressure build up in the water passages. Excessive pressure will rupture specified pressure disc to relieve internal pressure.

  • 2.2 SYNTHETIC OILS

These are oils which are arrived at by chemical synthesis from petroleum feed stocks, although in some cases would be from vegetable and mineral oils, rather than by straight run distillation of crude.

Advantages

  • 1. Carbon deposits are significantly reduced compared with mineral type oils, thus extending, by 1½ to 3 times, the maintenance periods normally expected for high pressure valves.

  • 2. Oil change periods can be increased by 2 to 3 times normally expected.

  • 3. Wear rates are reduced.

  • 4. These oils being produced to close tolerances have properties, and hence obtain performance, which are consistent from batch to batch.

  • 5. Oil carry-over reduced by up to 35%.

Disadvantages

  • 1. There are some materials, e.g. certain rubbers, paints, plastics and metals that are not compatible with synthetic oils (see: Compatibility of Materials Chart). Components on the 500 series compressors are compatible with synthetic lubricants but a problem may exist with auxiliary equipment, so consult their manufacturer to determine compatibility. The following synthetic type oils are approved:- REAVELLITE ANDEROL 555

These oils are approved for use in the 5000 series compressors, having been evaluated for performance and compatibility with materials used in their construction.

The above oils have been found to give better and more consistent valve life on high pressure valves (i.e. third and fourth stages).

REAVELLITE is non-toxic and suitable for use in breathing air compressors.

CompAir UK Ltd PUBLICATION 98407.1176 Page 12

  • 2.3 COMPATIBILITY OF MATERIALS WITH SYNTHETIC TYPE OILS

 

Acceptable

Marginal

Not Recommended

A.

SEAL MATERIALS

   

Fluorocarbon (Teflon, FEP) Fluorosilicone Rubber Silicone Rubber ¤ Nitrile Rubber (Buna-N-NBR) Polysulfide (Thiokol)

Nitrile Rubber (Buna-N- NBR) Polyurethane Ethylene-Propylene Terpolymer Epichlorohydrin

Polychloroprene (Neoprene) Natural Rubber Styrene-Butadiene Rubber (SBR, Buna-S) Butyl Rubber Chlorosulfonated Polyethylene Polyacrylate Rubber × Nitrile Rubber (Buna-N-NBR)

  • B. PAINT

   

Epoxy Baked Phenolic Two Component Urethane Moisture cured Urethane

Alkyds (baked finish preferred) Phenolic Single Component Urethane Industrial Latex

Acrylic Latex (household type) Vinyl (PVC) Varnish Lacquer

  • C. PLASTICS

   

Nylon Fluorocarbon (Teflon) Polyacetal Polysulfone

Urethane Polyethylene Polypropylene Polycarbonate Acrylate & Methacrylate

Polystyrene Polyvinyl Chloride ABS (acrylonitrile/butadiene/styrene

  • D. METALS

   

Steel and alloys Aluminium and alloys Copper and Alloys Tin Nickel Inconel, Monel

Cadmium

Zinc

¤ High nitrile content (<36% acrylonitrile) × Low nitrile content (>30% acrylonitrile) medium nitrile content (30-36% acrylonitrile) Minimising exposure to copper will extend the life of any oil

Page 121176.doc

  • 3.1 HANDLING OF UNIT

CompAir UK Ltd PUBLICATION 98407.1176 Page 13

SECTION 3

INSTALLATION

When using the compressor and motor eyebolts as the slinging attachment, it is essential that a spreader be used. The lift should always be made vertical; as inclined loading drastically reduced the eyebolt strength. Suitable shackles should be used for this operation.

3.1 HANDLING OF UNIT CompAir UK Ltd PUBLICATION 98407.1176 Page 13 SECTION 3 INSTALLATION When using
  • 3.2 LOCATION Compressor should be installed in a cool, level, well-ventilated position, clear of fumes, heat or high humidity, to ensure efficient performance and also to prevent temperature problems. Should circumstances necessitate installation in an unsuitable atmosphere, clean cool air must be piped to the compressor via a suction filter to eliminate ingress of abrasive or foreign matter. Suction ducting, when fitted, must be structurally rigid to withstand pulsating suction effects. It is imperative that the radiator fan works in a cool, clean, direct airflow and that there is a reasonable air gap around the radiator or it is fixed into a wall. As a large percentage of the compressor cooling water heat is dissipated via the radiator to the inducted air stream, it is essential that expired cooling air has an unobstructed passage and exit and does not, under any circumstances, re-circulate in the immediate compressor environment. If more than one compressor set is installed, each must have its own direct air flow and in small buildings and enclosures the radiator(s) should be sealed to an outside wall by means of a duct of a sufficient area for the ventilation required. Allow sufficient space around the installation to enable safe maintenance working conditions. Protection from severe weather conditions is desirable. Maximum allowable ambient cooling air temperature for radiator cooled sets is dependant on many variables e.g. pressure speed and type of oil. Contact UK Ltd to ascertain allowable temperature for operating conditions.

3.1 HANDLING OF UNIT CompAir UK Ltd PUBLICATION 98407.1176 Page 13 SECTION 3 INSTALLATION When using

RECOMMENDED INSTALLATION COOLING AIR ENTERS, PASSES OVER MACHINE AND AS HEATED AIR, IT IS EXHAUSTED FROM THE MACHINE ENVIRONMENT.

3.1 HANDLING OF UNIT CompAir UK Ltd PUBLICATION 98407.1176 Page 13 SECTION 3 INSTALLATION When using

INCORRECT INSTALLATION COOLING AIR ENTERS, PASSES OVER MACHINE AND THEN AS HEATED AIR, RE-CIRCULATES IN MACHINE ENVIRONMENT.

CompAir UK Ltd PUBLICATION 98407.1176 Page 14

3.3

MOUNTING

Under normal circumstances a special foundation is unnecessary but verification must be obtained that the support floor is structurally adequate as well as flat and level. If installed adjacent to vibrating machinery it may be necessary to bolt down the isolation pads but when tightening, ensure the isolation pads are not distorted.

If bedplate mounted, ensure floor is level and even surfaced, to prevent distortion.

  • 3.4 CONNECTIONS, PIPEWORK AND FITTINGS

Full consideration must be given to system and pipework layout. Check piping and connections are suitable for pressures and capacities and as the compressor is flexibly mounted, (must allow 75mm all round movement) adjacent pipework and electrical cables must be flexible.

Pipework adjoining the compressor should consist of short flexible sections to facilitate maintenance removal of pipework and absorb any vibration.

It is essential that all pipework is made and installed so that it is not constrained or distorted when connected to the compressor. Wherever possible use 90° bends with 8" (0.2m) radius, not elbows. This will help to provide the discharge pipework with the necessary flexibility to allow for thermal expansion.

Before completing pipework assembly, ensure all port protection plugs and blanks are removed and suction pipe sections are clear of jointing compound, scale, swarf, dirt or other foreign substance. The system must be suitably braced to prevent vibration and coupling strain on the compressor. Flexible suction piping should be suitable to withstand suction collapse.

If suction delivery is from an air main prevent transfer of liquid from the main to the compressor pipe by connecting the latter to the top of the main pipe.

Separators and drain traps of adequate capacity should be fitted in an easily accessible low section of the pipework system to prevent condensate or oil carry over build up. These must be drained regularly.

The delivery line should incorporate non-return valves, especially for large capacity systems or where two or more compressors are linked to common main.

Unloading and control gear piping must be as short as possible.

CompAir UK Ltd compressors incorporate safety valves at all stages as standard equipment. However, they must also be fitted to the receiver and pipework system to protect it from excess pressure build up.

  • 3.5 DRIVE RECOMMENDATIONS (DIRECT OR V-BELT TRANSMISSION) Details of drive arrangements and non isolation pad mountings are available from CompAir UK Ltd, 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: It 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. See Section 5.4.5 page 22 for more details on belt tensioning and alignment.

Page 141176.doc

Direct Drive:

CompAir UK Ltd PUBLICATION 98407.1176 Page 15

Ensure compressor and drive motor is correctly aligned as the flexible couplings are for vibration duties only and not as non-alignment couplings. See Section 5.4.4 page 22 for more details.

  • 3.6 COOLING Satisfactory compressor operation depends on correct cooling, which requires positive circulation of cool, clean water, free from suspended particles. Seawater may be used for marine applications. It is recommended that a filter be fitted in the inlet water line (mains). Maximum permitted water pressure within the compressor is 5 bar equivalent to 52 metres of water head. Cooling water flow rate is determined by temperature rise across the machine adjusted on site to 10°C to 12°C. Maximum recommended water inlet temperature is 37°C. It is recommended that temperature gauges be fitted to water inlet and outlet pipes to monitor water temperatures (mains). Water flow rate at 15°C inlet temperature will be 75 l/h/kW approximately (mains). Prevent overcooling by shutting off flow water when compressor is not running (mains). Thermostatic water temperature control, a regulating valve, or orifice in the water inlet pipe will govern the flow. The latter should only be installed where there is a constant water pressure (mains). A CompAir UK Ltd automatic water valve can be fitted to govern water supply when stopping or starting the compressor (mains). Water flow arrangements should be fail-safe to ensure that compressor can only run on full load for short periods without water flow (mains). During freezing weather conditions, cooling water should be drained from the system if the compressor is not being used (mains) or anti-freeze added to radiator sets in manufacturers specified quantities (radiator).

  • 3.7 ELECTRICAL CONNECTIONS Ensure compressor is installed to comply with local electricity authority stipulations and that necessary electrical work is carried out by a competent electrical engineer. Check electrical requirements for machine with manufacturer before commencing installation wiring.

CompAir UK Ltd PUBLICATION 98407.1176 Page 16

  • 3.8 CONTROL CIRCUIT FOR AUTO STOP/START

CompAir UK Ltd PUBLICATION 98407.1176 Page 16 3.8 CONTROL CIRCUIT FOR AUTO STOP/START KEY R. RELAY.

KEY

R.

RELAY.

T ..

TIMER.

SV.

SOLENOID VALVE

HTS.

HIGH TEMPERATURE CUT OUT

SWITCH. LOPS. LOW OIL PRESSURE CUT OUT SWITCH.

MPS.

MAIN PRESSURE SWITCH

OPERATION

START ON LOW PRESSURE SIGNAL FROM MPS. ON REACHING HIGH PRESSURE COMPRESSOR STOPS, UNLOADS & DRAINS. IF IT RUNS FOR 30 MINUTES WITHOUT STOPPING, DRAINS OPEN FOR 5/6 SECONDS.

10 SEC. DELAY ON. INSTANT OFF.

MAIN COIL.

INSTANT ON. DE-ENERGISES 5 SEC. EVERY 30 MIN. RE-ZEROS ON

RE-ENERGISING. HOURS RUN METER.

FOR WATER PUMP MOTOR IF FITTED.

FOR DELIVERY UNLOADERS/DRAINS

SUCTION UNLOADERS (H5236 ONLY)

  • 3.9 RECOMMENDED ANCILLARIES SUMMARY

    • 1. Flexible pipe fitted on final delivery.

    • 2. Overload trips.

    • 3. Water inlet and outlet thermometers.

    • 4. Water flow control.

    • 5. Separators and drain traps.

    • 6. Non-return valves.

Page 161176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 17

SECTION 4

COMMISSIONING OR RECOMMISSIONING

WARNING:

BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE COMPLIANCE WITH THE HEALTH & SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. ATTENTION OF U.K. USERS IS DRAWN TO THE HEALTH & SAFETY AT WORK ACT, 1974 & CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988.

TAMPERING WITH SAFETY VALVES IS DANGEROUS AND ALSO INVALIDATES THE GUARANTEE

  • 4.1 BEFORE STARTING

Low oil pressure switch Remove protective blank Remove priming plug Oil filler Oil pump High air/gas
Low oil pressure switch
Remove protective blank
Remove priming
plug
Oil filler
Oil pump
High air/gas
temperature
Oil level gauge
switches
Drain Plug

Before starting up ensure one is familiar with safety devices and type of control.

NOTE: Low oil pressure and high air temperature switches are pre-set and should not be adjusted. H5336.2, & H5436.2: 3rd stage (2nd stage on H5336.2)air temperature protection switch is pre- set and should not be adjusted.

CompAir UK Ltd PUBLICATION 98407.1176 Page 18

On H5336.2 & H5436.2 ensure suction filter is in good condition. Make sure that protective blank fitted to the first stage suction is removed. Check that silencer bore and any suction pipework is clean before reassembling.

Check that the inside of the crankcase is clean and filled with the correct grade of oil until oil level sight glass is at maximum level. It is important to maintain oil level between upper and lower limits.

Important: Do not overfill.

H5336.2, & H5436.2 must be run-in on mineral oil only. See later section for operation on synthetic oil.

Remove the plug from the outer end cover, immediately above the main lubrication pump and prime the pump suction port with the recommended oil. Replace the plug. Turn over the machine at least one revolution by hand, to ensure freedom of movement.

Replace all items, which have been removed.

NOTE:

It is not necessary to remove any inhibitor oil which may have been applied before despatch, unless there are specific instructions attached to the machine stating otherwise.

  • 4.2 START-UP PROCEDURE

If automatic drainage/unloading is provided - set to hand control unload the compressor by operating the drains. If no hand switch is fitted, disconnect solenoid valve electric supply to achieve this.

Check radiator is topped up on radiator sets or water is flowing in mains water installations.

Operate starter. Check immediately that rotation is counterclockwise looking on driving end.

Check oil pressure is above 2 bar. Compressor must not be run for more than 30 seconds with no oil pressure.

Check there are no uncharacteristic noises.

Run for 30 minutes unloaded.

Stop and isolate the compressor and release all pressures.

Check that outer surface of the compressor is cool.

Remove crankcase doors and check that bearings and running gear are not over-heating. Replace doors, ensuring joints are corrected seated.

Reconnect solenoid valve electric supply. Start the compressor and bring slowly onto load. Build up to full pressure within 30 minutes.

If appropriate, set the machine for automatic operation.

Check and adjust the control equipment settings, if applicable. For example, final air delivery pressure switch.

Continue to check that machine is functioning correctly and not over-heating. If thermostats are fitted check temperatures are within normal limits.

Observe stage pressures and temperatures are normal.

Check for air, water or oil leaks.

Page 181176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 19

WARNING: Do not try to correct leaks when items are pressurised.

Ensure that automatic controls (if applicable) are operating correctly. If machine is manually controlled open all condensate drains at 30-minute intervals.

Adjust cooling water flow to give 11°C rise across machine.

Run at full load for one and a half hours and record compressor rpm, oil pressure and stage pressures at 30-minute intervals.

  • 4.3 AFTER THE FIRST 15 HOURS RUNNING TIME Check alignment and belt tensioning (if applicable) is correct.

  • 4.4 AFTER THE FIRST 100 HOURS RUNNING TIME

H5336.2, & H5436.2 At 100 hours:-

1

Check motor drive belt tension (if fitted)

2

Check water pump drive belt tension (if fitted)

Drain sump, replace oil filter & refill sump with Mineral oil If it is desired to use synthetic lubricant, follow directions as in later section.

3

FOR FURTHER MAINTENANCE PERIODS REFER TO LATER SECTION.

  • 4.5 CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT H5336.2, & H5436.2 Basically all compressor components in contact with the lubricant should be as clean as it is practical before changing over. This is necessitated by the excellent solvency of synthetic oils that tend to loosen and remove existing deposits.

    • 1. Drain the old mineral lubricant completely whilst the oil is warm from crankcase sump.

    • 2. Remove from crankcase sump all deposits and/or sludge,

    • 3. Renew oil filter.

    • 4. Inspect suction and delivery valves. If they are covered by carbon and/or heavy lacquer deposits, Remove and thoroughly clean.

    • 5. Replace all items removed, renew any damaged seals or gaskets.

    • 6. Fill crankcase sump with Reavellite synthetic oil until oil level sight glasses are filled to upper level.

    • 7. Run compressor following starting procedures.

CompAir UK Ltd PUBLICATION 98407.1176 Page 20

Page 201176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 21

SECTION 5

OPERATION AND ROUTINE MAINTENANCE

  • 5.1 OPERATING AND DAILY MAINTENANCE

The commissioning procedure should be used:-

  • (A) For the first commissioning run;

  • (B) Following overhaul;

  • (C) After standing idle for a long period.

The exterior of the compressor, especially pipe connections and joints, should be kept clean at all times. If oil film and condensate are wiped away regularly, any leaks that occur will be more easily seen.

It is good practice to monitor and record stage pressures. This information gives a good indication of machine operation and can give advanced warning of a malfunction. The readings vary with ambient conditions but pressure readings are usually within plus or minus 4%.

A useful visual indication can be obtained if the gauge glass is marked.

Starting Up:

Before starting up ensure one is familiar with the safety devices and types of control.

Check oil level in crankcase and top up, if necessary, using recommended oil until oil level sight glass is on maximum.

Check v-belts are in good condition and correctly tensioned. (See later section).

Ensure there is adequate water in the cooling system (radiator sets) or supply from mains.

Check stop valves fitted in main and control pipework are set correctly.

Check main isolator is on.

Ensure fault circuits are re-set.

For automatic starting control the machine should already be unloaded ready for starting.

Operate main control/motor starter.

For automatically controlled machines the machine should function according to the type of control.

Running on Load:

Check gauges are indicating normal pressures.

Temperature rise of water flowing through the machine should be 10°C to 12°C. This should be checked once the machine has settled.

Check that machine is running correctly; for example no excessive vibration or noise.

Stopping:

Machine will stop automatically when pressure falls to set point on final pressure switch.

Manual or emergency stops may be made by use of stop button on starter panel.

Standing Idle:

Condensate drains will be left automatically open.

CompAir UK Ltd PUBLICATION 98407.1176 Page 22

For ambient temperatures below 0°C protect machine by draining off cooling water system, unless protected by anti-freeze.

After one week standing idle, turn the machine over by hand before starting to ensure it turns freely.

If the compressor is to stand idle for more than four weeks or shorter period if ambient conditions are unfavourable, it is advised to consult CompAir UK Ltd for correct inhibition procedure.

5.2 MAINTENANCE PERIODS SEE SECTION 8 FOR RECOMMENDED SERVICE PLANS

The optimum period between servicing will depend upon the operating conditions. Regular servicing is essential if the design performance of the compressor is to be maintained.

Periodically:

In addition to operational checks, check all nuts, screws and fittings for tightness and inspect for air, oil or

water leaks, which should be rectified immediately,

Examine oil in crankcase and ensure that it is not contaminated with condensate. Depending on the degree of contamination, the oil may appear emulsified (creamy in colour) especially if the recommended lubricant is not used. If emulsification takes place the oil must be changed and the crankcase cleaned. This condition is usually visible through the oil level indicator and must be rectified immediately.

Trace cause of contamination, rectify, fit new oil filter and refill crankcase sump with recommended oil.

If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the oil by means of the drain plug. The oil level should be replenished accordingly with clean oil. Crankcase oil contamination is often accompanied by increase in sight glass level, due to oil being supported by condensate fluid.

Initial Running & After Major Overhaul:

H5336.2, & H5436.2 Mineral Oil

Run in on mineral oil.

At 100 hours: -

1

Check motor drive belt tension (if fitted)

2

Check water pump drive belt tension (if fitted)

3

Drain sump, replace oil filter & refill sump with mineral oil

H5336.2, & H5436.2 Synthetic Oil

Run in on mineral oil.

At 100 hours: -

1

Check motor drive belt tension (if fitted)

2

Check water pump drive belt tension (if fitted)

3

Drain sump, replace oil filter, clean & refill sump with synthetic oil

4

Clean suction and delivery valves

N.B. This compressor must not be run on mineral oil.

Daily

1

Check oil level in sump

2

Check oil level in mechanical lubricator (if fitted)

3

Check stage pressure gauge readings

Weekly

  • 1 Check oil flow rate in lubricator flow indicators (if fitted)

  • 2 Check bursting disc for signs of cracking

A complete overhaul is recommended every 3 years if 8000 (Mineral) or 9000 (Synthetic) running hours are not reached. After a minor service run compressor briefly to confirm satisfactory operation. After a major service recommission the compressor as per commissioning procedure.

Page 221176.doc

  • 5.3 VALVE MAINTENANCE PERIODS

Compressor Valve Inspection:

CompAir UK Ltd PUBLICATION 98407.1176 Page 23

The periods quoted in the table for valve inspection are based on our experience and average usage.

When operating these compressors under adverse running conditions, such as high ambient temperatures and pressures, more frequent inspection may be necessary for the final stage.

For compressors being used on light duties, i.e. low pressure, low speed and non-arduous ambient conditions, assessing valve condition on initial running periods and extending them to suit may often increase the period between valve inspections.

  • 5.4 MAINTENANCE DETAILS

WARNING:

Before maintenance or dismantling, isolate all electrical supply from machine and ancillary equipment. Isolate compressor from storage pipework and release pressure from all compressor stages, pipework or storage vessels.

THE ATTENTION OF U.K. USERS IS DRAWN TO THE HEALTH & SAFETY AT WORK ACT, 1974 AND CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 1988.

  • 5.4.1 Pressure Gauges: Relate pressure readings against a gauge of known accuracy and if faulty, renew.

  • 5.4.2 Bursting Disc: Should a rupture occur, stop compressor immediately and turn off cooling water supply. Rectify cause of excess pressure before fitting a new bursting disc.

Fluctuating water pressure can cause such failure and if pulsing water supply is unavoidable, renew bursting disc more frequently than scheduled.

USE ONLY GENUINE COMPAIR BURSTING DISC AS REPLACEMENT

  • 5.4.3 Corrosion Rod:

If severe electrolytic action is encountered inspect rod more frequently than specified in maintenance cycle.

  • 5.4.4 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 that direct-coupled sets with bell type housing (see below) are self-aligning.

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 & 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 mm or more should be investigated and the rubber coupling (6) replaced (complete set) as necessary.

CompAir UK Ltd PUBLICATION 98407.1176 Page 24

8

1 2 10 3 9 4 5 6 7
1
2
10
3
9
4
5
6
7
  • 5.4.5 Belt Drive Tensioning:

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 in a 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 should be carried out by the above procedure, when necessary.

BELT DRIVE ALIGNMENT

STRAIGHT EDGE STRAIGHT EDGE DISTANCE PIECES ELECTRIC MOTOR ELECTRIC MOTOR COMPRESSOR
STRAIGHT EDGE
STRAIGHT EDGE
DISTANCE PIECES
ELECTRIC
MOTOR
ELECTRIC
MOTOR
COMPRESSOR

It is very important that the driving and driven pulley grooves are in line and both pulley shafts are parallel, see above, if the pulley faces are not parallel use appropriate size distance pieces to ensure belt grooves are correctly aligned. Check belt tension by method described later.

Page 241176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 25

CENTRE DISTANCE BELT TENSION INDICATOR APPLIED TO MID-SPAN STRAIGHT EDGE
CENTRE DISTANCE
BELT TENSION INDICATOR
APPLIED TO MID-SPAN
STRAIGHT EDGE

RECOMMENDED TENSIONING FORCES ADJUSTMENT METHOD

If the belt tension is incorrect, correct it by using the adjusting screws provided, using a suitable straight edge (long enough to span both pulleys) or by use of the second belt. Release motor holding down screws enough to allow the adjustment screws to be free to slide the motor on its adjustment slots without it being loose. Use method as described on page 2. 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 the motor holding their correct torque setting.

down screws to

BELT DEFLECTION MEASUREMENT

Required Deflection Force "P" at Centre of Span for Compressor Speed Ranges (Newtons)

Above follows current BS3790 practice.

     

Speed (rpm) 725 - 1230

1300 - 1500

 

Small Pulley

160 - 265

  • 35.0 - 50.0 N

29.5

- 34.0 N

Diameter (mm)

265 and above

  • 52.5 - 64.0 N

52.0

- 57.0 N

 

SELECTION TABLE

 
 

Belt

 

Force required to deflect belt 15 mm per metre of span

Section

 

Small Pulley

Newton

Kilogram force

 

Ø mm

 

(N)

 

(kgf)

 

SPB

 
  • 160 to 224

35

to 50

  • 3.5 to 5.1

   
  • 236 to 315

50

to 65

  • 5.1 to 6.6

Method of Belt Tensioning. Using a Belt Tension Indicator.

  • 1. Calculate the deflection distance in mm on a basis of 15 mm per metre of span. Centre distance (m) X 15 = Deflection (mm). If distance & 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 belt at the centre of span. And apply a force at right angles to the belt deflecting it to the point where the lower marker ring is level with the adjacent belt, On single belt drives place a straight edge across the two pulleys to act as a datum.

CompAir UK Ltd PUBLICATION 98407.1176 Page 26

  • 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 belt tensioner to achieve the correct value.

  • 8. If the 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

DEFLECTION DEFLECTION FORCE IN MM IN kgf
DEFLECTION
DEFLECTION FORCE
IN MM
IN kgf

Page 261176.doc

  • 6.1 GENERAL

CompAir UK Ltd PUBLICATION 98407.1176 Page 27

SECTION 6

VALVE SERVICING

Keep a spare oiled and maintained set of valves in store for quick compressor servicing.

Valves should have only a thin carbon layer and be slightly moist with oil.

Valve removal is a simple procedure but the following guidelines should be observed.

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.

  • 6.2 CLEANING AND INSPECTION - ALL STAGES

The valve components should be degreased using a suitable solvent and stiff brush. Carbon

deposits may be removed scraping with a soft, blunt instrument, e.g. a piece of wood.

WARNING: - Great care should be taken when removing carbon deposits to ensure that the seating faces; of the above components are not damaged.

These faces should be clean and bright over their whole area, with no evidence of uneven contact. Renew any plates which are indented, cracked, warped, or have wear grooves which exceed 1\10th of the plate thickness.

If the seats show severe wear or indentations the complete valve assembly must be renewed. The remaining components should be checked for cracks, distortion or other damage liable to impair valves operation.

  • 6.3 VALVE REMOVAL AND DISMANTLING

Valve removal is as follows for all stages:

(Special tools, which are available from CompAir UK Ltd, will assist in valve removal).

Remove valve covers nuts.

Using forcing screws, to remove valve covers.

Using the special valve lifting tools, remove valve assemblies.

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.

Cleaning Valve Units:

Completely clean all documents.

Always renew valve plates and springs in complete sets.

The seating faces of each valve plate and body half should be clean and bright with all round, even contact and be free from indentations. Any item with indentations will require renewal.

Reassemble valve plates and springs exactly as dismantled. NEVER reverse plates/springs as this will lead to rapid failure.

CompAir UK Ltd PUBLICATION 98407.1176 Page 28

First Stage Valve Reassembly (Diagram 'M' Page 24 IN PARTS LIST)

  • 1. Place upper body (M12) face downward on suitable metal ring, or protected open vice jaws with locating pegs uppermost.

  • 2. Place spring plates (M3) to locate over pegs (M9) with bridging strip resting between pegs and springs facing upwards.

  • 3. Place valve plate (M2) onto spring plate, located as above, ensuring concentricity on centre hole.

  • 4. Place middle life washer (M7) over centre hole.

  • 5. Place valve plate (M6) onto locating pegs (M8).

  • 6. Put lower lift washer (M5) onto locating pegs.

  • 7. Place valve spring plates (M4) onto locating pegs with springs pointing downwards.

  • 8. Place lower body (M1) onto assembly, ensuring inner and outer pegs engage correctly. If assembly has been carried out correctly upper and lower body faces will contact.

  • 9. Place nut (M11) on stud and tighten to recommended torque.

    • 10. Test for correct operation by ensuring free movement of suction and delivery valve plates.

    • 11. Ensure `O` ring is secure in slot in upper valve body.

Second Stage Valve Reassembly (Diagram 'N' Page 2 IN PARTS LIST)

  • 1. Place upper body (N9) face downward on suitable metal ring or protected open vice jaws with locating peg uppermost.

  • 2. Place valve plate (N5) to locate over peg.

  • 3. Place three spring plates onto valve plate, locating them on peg, springs facing downwards.

  • 4. Follow this with valve backing plate (N2). Place delivery valve springs (N3) onto valve/backing plate having first positioned them as follows:-

Assemble the delivery plate springs (N3) in pairs, rotating one spring in each pair until the inner and outer circumferences are matched perfectly. Hold the two pairs of springs together with the concave faces facing each other and then rotate one pair until their edges touch all round the circumference and there is a constant gap around the inner edge.

  • 5. Place the second valve backing plate (N2) on spring plates and then after ensuring concentricity place lower body (N1) onto assembly. If all components are located correctly upper and lower bodies will contact.

  • 6. Screw on nut (N9) and tighten to recommended torque.

  • 7. Test for correct operation by ensuring free movement of suction and delivery valve plates.

  • 8. Ensure ‘O’ ring is secure in slot in upper valve body.

Page 281176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 29

Third Stage Valve Reassembly (Diagram 'P' Page 29 IN PARTS LIST)

  • 1. Using suitable metal ring or open protected vice jaws, place upper valve body, (P6) face downwards.

  • 2. Insert valve plate (P5) followed by three spring rings (P4) bowed two against one as shown.

  • 3. Follow with valve backing plate (P2) and then four spring plates (P3) bowed in pairs.

  • 4. Follow up with the second valve backing plate (P2) and when satisfied all components are correctly aligned, place lower body (P1) and centre stud through assembly.

  • 5. Press together and ensure edges of upper and lower body contact then place washer (P8) over stud, screw on nut (P9) and tighten to recommended torque.

  • 6. Test for correct operation by ensuring free movement of suction and delivery valve plates.

  • 7. Ensure `O` ring is secure in slot in upper valve body.

Fourth Stage Valve Reassembly (Diagram 'Q' Page 31 IN PARTS LIST)

  • 1. Place upper body (Q6) face downward on suitable metal ring or protected vice jaws.

  • 2. Insert bowed spring plates (Q3) in pairs into valve body recess.

  • 3. Place valve plate (Q2) on top of spring plates (Q3) and then locate plate (Q5) over hole in

centre of upper valve body (Q6).

  • 4. Insert spring (Q4) centrally over stud in lower valve body (Q1), ensuring that smaller diameter end of spring is inserted into valve body.

  • 5. Using steel rule or similar thin flat object, depress bowed springs into upper valve body (Q6), and holding spring (Q4) onto lower valve body (Q1), assemble so that stud passes through hole in upper valve body (Q6).

  • 6. Ensure both valve bodies contact, screw nut (Q8) onto stud and tighten to recommended torque.

  • 7. See that `O` ring is secure in slot in face of upper valve body.

Valve Reassembly into Compressor:

Ensure valve pocket is clean before replacing valve assembly.

When fitting new valve it should be lapped into its pocket using fine Carborundum paste and finishing with metal polish. Ensure complete cleanliness before fitting.

Ensure valve beds properly as a slight misfit will entail the loss of a large amount of air.

Check valve cover for cleanliness before reassembly.

Renew `O` rings lightly greasing before fitting.

There should be at least a 2-mm gap between the top of cylinder and bottom of valve cover.

CompAir UK Ltd PUBLICATION 98407.1176 Page 30

Page 301176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 31

SECTION 7

FAULT GUIDE

These suggestions are a guide to the more common aspects of fault location. It is assumed that:-

  • 1. Cooling water inlet temperature is correct.

  • 2. Temperature rise across machine is within limits.

  • 3. Cooling water flow rate is correct.

  • 4. Driving unit is efficient and power supply adequate.

  • 5. Correct uncontaminated lubricant.

  • 6. Lubrication system is fully operational.

NOTE:- 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.

Fault

Probable Cause

Recommendation(s)

  • 7.1 Excessive Pressure

Faulty suction or delivery

Service valve(s) as necessary.

valve(s)

NOTE: A faulty suction valve gives excess pressure in previous

stage.

Pressure gauge

Check gauge against instrument of

inaccurate.

known accuracy.

Pipeline restriction

Existing Installation:

Check functioning and setting of all control valves. Clean pipeline filters and service elements.

New Installation:

Ensure all protective plugs are removed from ports and control valves are set correctly. Ascertain pipework is of adequate dimensions with minimum of bends. Check joint gaskets for correct positioning and size.

Final delivery pressure control

Automatic Control:

fault, i.e. air governor (relay) or pressure switch.

Inspect control equipment for malfunction, rectify as necessary.

  • 7.2 Insufficient Pressure or

   

Volume.

Blocked suction filter.

Remove and service.

First stage suction valve fault.

Remove, examine and rectify.

Air leakage from machine\system.

Locate and rectify. Check drain valves.

Wear.

If general wear is suspected, strip machine, examine components and renew as necessary.

Loss of drive.

Check coupling, v-belt drive and tension.

CompAir UK Ltd PUBLICATION 98407.1176 Page 32

Fault

Probable Cause

Recommendation(s)

  • 7.3 Overheating

Above maximum recommended operation.

Reduce operation level.

Reduced cooling efficiency.

Examine cooler(s) for partial

  • 7.4 Excessive Noise

Machine set up or pipework system vibration.

blockage. Examine machine seating, ascertain pipework system is firmly secured, check clearances and alignment of couplings and tension of v-belts.

  • 7.5 Excessive Wear

Excessive speed and\or pressure.

Operation within limits.

Dirty air and\or suction pipeline.

Examine filters and renew elements. Clean out suction pipeline.

Excessive moisture content in air cylinder.

Check drainage system and crankcase oil for contamination.

  • 7.6 Extended Running

Insufficient speed or machine capacity too low.

Up-rate machines if possible or install parallel unit or larger

  • 7.7 Failure to Start

Seizure

replacement. Check v-belts. Failure to turn freely when unloaded indicates a serious fault. Examine and ensure there are no broken or damaged components, before attempting to re-start.

Electrical or control fault.

Trace and rectify.

Page 321176.doc

CompAir UK Ltd PUBLICATION 98407.1176 Page 33

SECTION 8

RECOMMENDED SERVICE PLANS

RSP5436M - H5436.2 - MINERAL OIL -----------------------------EX1

RSP5436S - H5436.2 - SYNTHETIC OIL --------------------------EX2

RSP5336M - H5336.2 - MINERAL OIL -----------------------------EX3

RSP5336S - H5336.2 - SYNTHETIC OIL --------------------------EX4

CompAir UK Ltd PUBLICATION 98407.1176 Page 34

Page 341176.doc

RECOMMENDED SERVICE PLAN - 5336 Mk2-M

CompAir UK Ltd

Page 1

MINERAL OIL - SUBJECT TO OPERATING RESTRICTIONS IMPORTANT - DAILY & BEFORE STARTING

Check oil level top up if necessary

INITIAL SERVICE 100 HOURS OR

Change oil & oil filter element. Cleanse crankcase. Repeat after MAJOR OVERHAUL (8000) hours or any intermediate

 

Part Ref

ELAPSED TIME

overhaul.

No Off

RSP5336/2/m.1

6 MONTHS

Change oil (total capacity 45 litres) - Mineral oil 25 litres.

2

98384/1022

Change oil filter

1

98262/1009

Check belt tension/drive couplings & condition of all ancillaries

Check for oil & air leaks

Check tightness of all fasteners

AT 1000 HOURS OR

Change suction filter element. Clean 3rd stage valves.

 

Part Ref

ELAPSED TIME

<