P6a Blown Fibre Compressor Rev-2 - B

Transcript

1.0 INTRODUCTION P6A Petrol-Engine-Driven Blown Fibre Compressor The P6A Blown Fibre Compressor is designed to deliver clean, dry air for installation of optical fibre using the blown fibre technique. The set is mounted within a tubular steel frame which is equipped with two wheels and handles for one man on site operation. Model P6A Blown Fibre Compressor is a portable, petrol enginedriven rotary vane compressor unit. Producing 120 l/min of pulsefree treated compressed air at a working pressure of 10 bar, it provides the ideal source for field installation of fibre optic cable. The unit incorporates a 12V DC air-cooled after-cooler reducing the compressed air temperature to within 5°C of ambient. A 3stage filtration system, complete with a pressure-maintaining valve, provides technically oil-free air, which reduces the moisture levels to prevent problems in the blowing operation. The unit is supplied with a 3-way control valve with purge position, 10m of 3/8” air hose with safety-type Instantair coupling and is complete with 24V DC outlet socket to supply the blowing head (other voltages available on request). The P6A compressor is fitted with a temperature mixing valve system to allow the temperature of the air entering the filters to be manually raised to increase the pressure dewpoint of the compressed air to prevent over drying in cold conditions. P6A -1- AUGUST 2003 2.0 GENERAL INFORMATION 2.1 P6A On Site P6A -2- AUGUST 2003 2.2 P6A Components Fuel tank 3.6 litres Pressure maintaining valve (9 bar) Dual filter (see section 5.3) Pre-filter (hidden by the after-cooler) Temperature gauge and temperature mixing valve hidden by the after-cooler) After-cooler Recoil starter handle Hose storage Engine switch 24V DC outlet socket Engine oil filler 0.6 litres 3-way outlet valve P6A -3- Condensate bottle AUGUST 2003 Air outlet and ON/OFF valve 2.3 General Data Engine The engine is a preset, mechanically-governed, single cylinder, fourstroke with air cooling and electronic ignition. The carburettor is fitted with a manual choke and a dry air cleaner. Starting is controlled by an on/off switch and is effected by a manual recoil starter mounted externally on the crankshaft. The engine is equipped with an oil alert system which, when activated by either high temperature compressor oil or low engine oil pressure, will automatically stop the engine. Type Horse power Oil capacity Oil grades Fuel grade Fuel consumption Fuel capacity Starting Honda GX160 K1 LX4 5.2 HP 4.0 kW @ 4000 rpm 0.60 litre (0.53 Imperial quart) SAE 10W-30 (recommended for general use) Petrol – automotive unleaded 313g/kWh (230g/HP hr) 3.6 litres (0.79 Imperial gallon) Recoil Compressor The compressor is an oil-flooded, rotary vane unit driven through a two-piece coupling by a petrol engine. Air enters the compressor via an air filter located at the end of the compressor unit and is cooled by a fan which draws air over the cooler. The compressor is automatically controlled. Type Operating speed Oil capacity Oil grades 0°C - 40°C -15°C - +45°C Free air delivered Maximum operating pressure Hydrovane VO1 1440 rpm 1 litre (1.76 pints) Hydrovane Fluid Force 2000) see Hydrovane Fluid Force HPO) page 9 4.0 cfm (1.88 litres/sec) 150 psi (10 bar) Dimensions Length Width Height Weight P6A 905 mm 435 mm 650 mm 68 kg -4- AUGUST 2003 3.0 SAFETY PRECAUTIONS GENERAL WARNING Run the engine in a well-ventilated area. The machine should be as level as possible in both planes whilst in operation. Operate the unit at least 1 metre away from buildings and flammable objects. Do not smoke or allow flames in the refuelling area. Avoid inhaling the exhaust fumes. Do not run the unit except when it is positioned down-wind from the work site. If any fuel is spilt make sure the area is dry before starting the engine. Many parts, especially the exhaust muffler and spark arrestor, if fitted, become very hot during operation and remain hot for a while after stopping the engine. To avoid burns or fire hazards, always let the unit cool before transporting, storing or servicing. Do not attempt any work on the compressor until the engine has been stopped and the system completely depressurised. Wait until the pressure gauge reads zero. Do not insert any object through the fan guard rings. Serious damage to the compressor and personal injury could result. If changing the oil when the compressor is still warm, take necessary precautions to avoid contact of hot oil with the skin. Dispose of used oil with due regard to the environment. Be aware of the location of the nearest fire extinguishers and their method of operation. Great care should be taken not to spill fuel, especially near a hot exhaust. P6A -5- AUGUST 2003 4.0 OPERATING INSTRUCTIONS 4.1 PREOPERATION CHECKS Engine – GX160 The engine and lubricator oil levels must be checked daily and topped up if necessary. Ensure the unit is on a level surface with the engine stopped and the unit fully depressurised. Remove the oil filler cap and wipe the dipstick clean. Insert dipstick into the oil filler neck – do not screw in. If the level is low, fill to the top of the oil filler neck with the recommended oil – Grade SAE 10W-30. Engine oil level alert An engine oil alert system, which automatically stops the engine, is activated if the engine oil level is allowed to fall below acceptable levels or if the compressor oil overheats. Fuel Before attempting to start the engine make sure the fuel tank is full. Use automotive petrol (unleaded or low-leaded is preferred to minimise combustion chamber deposits). NEVER use oil/petrol mix or dirty fuel. P6A -6- AUGUST 2003 4.1 continued Compressor – VO1 Check the oil level weekly when the compressor is cold, stopped and depressurised, i.e. gauge reads zero. For oil grades see General Data – page 4. Top up by slowly unscrewing the filler plug (A). If there is any escape of oil or air, DO NOT CONTINUE REMOVING THE PLUG UNTIL ALL PRESSURE IS RELEASED. Remove filler plug (A) and bonded seal (B). Top up with approved oil to the top of the plug hole. Replace seal to filler plug, then refit and tighten plug. Machine and its associated equipment Check for obvious damage to machine frame, carrying handles, hoses, isolating cocks and associated equipment to be used with the machine. THE MACHINE AND ITS ASSOCIATED EQUIPMENT MUST NOT BE USED IF DAMAGE MAKES THEM UNSAFE. P6A -7- AUGUST 2003 4.2 STARTING INSTRUCTIONS – RECOIL Turn fuel valve to ON position Turn ignition switch to the ON position Close the carburettor choke by moving the lever in the direction indicated. Note: A warm engine requires less choke level than a cold engine. Turn the outlet valve to the venting position. Take hold of the handle of the recoil start rope, pull lightly until resistance is felt, return the handle to the initial position, pull the handle briskly with both hands. Do not let the rope back into its housing quickly but keep some tension on it and let it rewind slowly. Repeat the above until the engine starts. Decrease the choke level when the engine starts and is running evenly. Turn the outlet valve to the open position, once maximum pressure has been reached let the engine warm up for a few minutes. P6A -8- AUGUST 2003 4.3 STOPPING INSTRUCTIONS Disconnect all air hoses. Turn 3-way valve to the OFF position. Turn the ignition switch to the OFF position. Turn the fuel valve to the OFF position. VENT/START OFF/STOP ON 4.4 TEMPERATURE MIXING VALVE ADJUSTMENT The P6A compressor is fitted with a temperature mixing system to allow the temperature of the air entering the filters to be manually raised to increase the pressure dewpoint of the compressed air to prevent over drying in cold conditions. To adjust, start the compressor and turn the 3-way outlet valve to the venting position. Progressively open the temperature mixing valve and monitor the compressed air temperature on the temperature gauge. (Note: when the compressor is started from cold the temperature will take approximately 15 minutes to stabilise.) When the desired temperature (dewpoint) is reached, close the 3-way outlet valve and use the compressor as normal. Temperature gauge IND066 Temperature mixing valve VAL0152 P6A -9- AUGUST 2003 5.0 MAINTENANCE 5.1 SERVICE SCHEDULE – COMPRESSOR (HYDROVANE V01) OPERATION Check oil level Check cable connection over-temperature switch Clean air filter Clean oil cooler Change air filter Change oil Every day on First month or 20 hrs PERIOD Every 3 months or 50 hrs Every 6 months or 100 hrs Every year or 250 hrs Every year or 2000 hrs • • • (1) • • (1) • (2) Note: 1 Service more frequently when used in dusty conditions. Note: 2 Interval reduced to 500 hours if not using HYDROVANE 2000 oil. ALWAYS OBSERVE SAFETY PRECAUTIONS WORKING ON THE COMPRESSOR BEFORE Approved Oils - Compressor Hydrovane Fluid Force 2000 oil for 2000-hour oil change (ambient temperature range 0°C to +40°C). Note: For applications where compressor is stored or used outside in winter then we recommend using HPO synthetic compressor oil. (Available from Factair.) FOR 500-HOUR OIL CHANGE AMBIENT TEMPERATURE RANGE °C MAKE Max 40 Min -6 Max 30 Min -12 Max 20 BP Vanellus M40 M30 M20 Shell Rimula X40 X30 - Mobil Delvac 1240 1230 1220 Mobil Rarus 327 - - CRI 40 CRB 40 CRI 30 CRB 30 CRI 20 CRB 20 40 30 20 Essolube HDX 40 HDX 30 HDX 20 Gulflube Motor Oil XHD 40 XHD 30 XHD 20 Texaco Ursa Oil Extra Duty SAE 40 SAE 30 SAE 20 68X 55X 55X Castrol Agricastrol Chevron EP Industrial Oil P6A Min 0 - 10 - AUGUST 2003 5.1 continued Servicing the Air Intake Filter Every 50 hours a) b) c) d) e) On PUTS models, first remove the outlet valve and pipework. Unscrew and remove two screws (A) from filter cover (B). Remove cover (B) on PUTS models, or slide it over the air delivery pipe, if fitted, on PUAS and PURS models. Remove the filter support (C) and filter (D). Wash the filter (D) with soap and water, and allow to dry before replacing. DO NOT USE ANY OTHER METHOD OF CLEANING. f) g) h) i) j) P6A Renew the filter (D) if it cannot be cleaned satisfactorily. Clean inside of cover (B) and filter support (C). Refit filter (D) and support (C) ensuring they are correctly located and secured in the filter clip (E). Refit cover (B) and secure with the two screws (A). Refit outlet valve and pipework on PUTS models. - 11 - AUGUST 2003 5.1 continued Every 2000 hours a) b) c) Carry out operations (a – d) as described above. Discard old filter and fit new one. Carry out operations (g – j) as described above. Changing the Oil P6A a) The oil change is best carried out as soon as possible after stopping the compressor, as warm oil will drain more easily. Wear suitable protective clothing to avoid possibility of oil burns. (See SAFETY PRECAUTIONS). b) Ensure that the compressor is depressurised. The pressure gauge should read zero. - 12 - AUGUST 2003 5.1 5.2 continued c) Slowly unscrew the filler plug (A). If there is any escape of oil or air, DO NOT CONTINUE REMOVING THE PLUG UNTIL ALL PRESSURE IS RELEASED. d) Remove the filler plug (A) and discard its bonded seal (B). e) Position a suitable container under the compressor drain plug (C). (Compressor oil capacity is 1.2 litres, 1.9 pints.) g) Drain oil into container. h) Fit a new bonded seal (d) to the drain plug (C). Refit and tighten the drain plug (C). i) Fill the compressor with APPROVED OIL to the top of the filler plug hole. j) Fit a new bonded seal (B) to the filler plug. Refit and tighten the filler plug. k) Run compressor for 10 seconds, then recheck the oil level. Top up the oil as necessary. SERVICE SCHEDULE – ENGINE (HONDA GX160) Operation Engine oil Air cleaner Sediment cup Spark plug Period Each Use Check Check Every 3 months or 50 hrs Every 6 months or 100 hrs Change Every year or 250 hrs Every year or 300 hrs Clean Clean Clean Adjust Fuel tank and filter Spark arrestor (optional) Valve clearance check/adjust P6A First Month or 20 hrs Change Clean Clean Adjust - 13 - AUGUST 2003 5.2 continued Approved Oils – Engine Use a high detergent, premium quality motor oil. SAE 10W –30 or SAE 10W –40 are recommended for general all temperature use. In temperature range of –15°C to +40°C use 15W– 40 or 15W-50 In temperature range of -10°C to +40°C use 20W-40 or 20W-50 Oil Change Drain the oil while the engine is still warm to assure rapid and complete draining. 1 Remove the oil filler cap and drain plug to drain the oil. 2 Install the drain plug and tighten it securely. 3 Refill with the recommended oil and check the oil level. 4 Install the oil filler cap. Engine oil capacity: 0.60 litre (0.53 Imp qt) Air Cleaner Service A dirty air cleaner will restrict air flow to the carburettor. To prevent carburettor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty conditions. WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result. Caution: Never run the engine without the air cleaner. Rapid engine wear will result. P6A - 14 - AUGUST 2003 5.2 continued Dual element type 1 Remove the wing nut and the air cleaner cover. Remove the elements and separate them. Carefully check both elements for holes or tears and replace if damaged. 2 Foam element: Wash the element in a solution of household detergent and warm water, then rinse thoroughly, or wash in non-flammable or high flash point solvent. Allow the element to dry thoroughly. Soak the element in clean engine oil and squeeze out the excess oil. The engine will smoke during initial startup if too much oil is left in the foam. 3 Paper element: Tap the element lightly several times on a hard surface to remove excess dirt, or blow compressed air through the filter from the inside out. Never try to brush the dirt off; brushing will force dirt into the fibres. Replace the paper element if it is excessively dirty. Spark Plug Service CAUTION: Never use a spark plug of the incorrect heat range. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. P6A 1 Remove the spark plug cap and use the proper size spark plug wrench to remove the spark plug. 2 Visually inspect the spark plug. Discard the spark plug if there is apparent wear, or if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused. - 15 - AUGUST 2003 5.2 continued 3 Measure the plug gap with a feeler gauge. necessary by bending the side electrode. Correct as The gap should be: 0.70 - 0.80mm (0.028 - 0.031") P6A 4 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading. 5 After the spark plug is seated, tighten with a spark plug wrench to compress the washer. - 16 - AUGUST 2003 5.3 P6A HIGH EFFICIENCY FILTRATION The pre-filter element which removes particulate, can be partially cleaned by washing in warm soapy water; it should be replaced annually, sooner if heavily contaminated. The dual function filter body incorporates an oil removal element (bottom) and an oil vapour activated carbon upper element. These elements are not washable and should be replaced if the unit is unable to produce 15 bar. If the top element becomes saturated with oil within a short period, the main element and/or ‘O’ ring may be faulty and should be replaced. Both the activated carbon and coalescing elements should be replaced every 6 months. The quality of air and condition of the elements may indicate an adjustment of maintenance interval, at which time the inside of the filter bowls should be washed in warm soapy water and cleaned. Before undertaking any servicing of the filter system, stop the compressor and wait until the compressor-mounted pressure gauge reads zero. Pressure Maintaining Valve VAL0131 Dual filter FIL0081 Pre-filter FIL0086 Temperature Gauge IND066 Temperature Mixing Valve VAL 0152 For filtration service procedures and service kits see spares page P6A - 17 - AUGUST 2003 5.4 TROUBLESHOOTING Problem Solution Engine will not start 1 Is ignition switch turned to ON? Set switch to ON. 2 Is there enough fuel? Top up fuel tank. 3 Is there a spark at the spark plug? Remove the plug and install the plug in the cap, ground the side electrode, pull the recoil starter, check if spark jumps gap, clean or replace as necessary. 4 If unit has stopped previously on compressor over temperature or low engine oil Allow engine to cool before attempting to restart and see (6) below. Engine stops when running 5 Has it run out of petrol? P6A Fill up fuel tank. 6 Did it shutdown through over temperature of the compressor or because engine oil was low? Check compressor for overtemperature which could be low oil or debris blocking the oil cooler matrix. Over temperature switch will automatically reset when temperature has reduced. Check and top up engine oil if necessary. 7 Engine shutdown on low oil The Honda GX160 petrol engine is fitted with an oil alert system which is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the oil alert system will automatically stop the engine, (the engine switch will remain in the ‘ON’ position). 8 Compressor shutdown on over temperature The compressor is fitted with a sensor and a switch mounted below the compressor which is activated by high temperature compressor oil causing the engine to stop. - 18 - AUGUST 2003 5.4 continued Compressor – Hydrovane 501C10 INTRODUCTION The charts on the following pages detail the symptoms and remedial action required for faults which may occur on the Hydrovane compressor. HIGH PRESSURE Pressure rises until safety valve lifts HIGH TEMPERATURE Oil temperature higher than 100°C LOW AIR OUTPUT Lack of air at point of usage OIL DISCHARGE Oil discharged into air system IMPORTANT • All remedial action must be performed by suitable qualified persons and safe working practices must be employed • All seals and gaskets disturbed during this work must be renewed • Contact your distributor if you are unable to rectify a fault HIGH PRESSURE INDICATIONS • Pressure rises and safety valve blows • Air/oil vapour discharged from intake on stopping compressor • Rapid pressure loss on stopping compressor • High temperature and power absorption CHECK • First ensure that the safety valve lifts at the correct pressure HIGH TEMPERATURE INDICATIONS • Compressor cuts out. • Compressor seizing • Low air output • High power absorption CHECK • Check compressor oil temperature ENVIRONMENTAL CHECK 1 Insufficient ventilation 2 Excessively dusty conditions 3 Air intake near heat source COMPRESSOR CHECK 1 Low oil level 2 Wrong type/grade of oil 3 Blocked oil cooler LOW AIR OUTPUT INDICATIONS • Malfunction in tools/equipment • Rapid pressure loss in air system • Pressure gauge reading low CHECK • Check compressor air output • Check for excessive air demand • Check pressure gauge for accuracy IF PRESSURE GAUGE READING NORMAL : 1 Restriction in airline e.g. valves closed 2 Pipework too small IF PRESSURE GAUGE READING LESS THAN NORMAL: 1 Air intake filter blockage P6A - 19 - OIL DISCHARGE INDICATIONS • Heavy oil consumption • Low air output • Possible high power absorption CHECK • Verify that oil discharge exceeds specification GENERAL CHECK 1 Wrong type/grade of oil 2 Excessive air demand 3 Compressor not sited level AUGUST 2003 6.0 TRANSPORTING/STORAGE WARNING When transporting the engine, turn the fuel valve OFF and keep the engine level to prevent fuel spillage. Fuel vapour or spilled fuel may ignite. Before storing the unit for an extended period; 1 Be sure the storage area is free of excessive humidity and dust. 2 Drain the fuel. WARNING Petrol is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area. a) Remove and empty the sediment cup. b) Replace the sediment cup and tighten securely. c) Drain the carburettor by loosening the drain screw. Drain the petrol into a suitable container. 3 Change the engine oil. 4 Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug. P6A 5 Pull the starter rope slowly until resistance is felt. Continue pulling until the notch on the starter pulley aligns with the hole on the recoil starter (see illustration below). At this point, the intake and exhaust valves are closed, and this will help to protect the engine from internal corrosion. 6 Cover the engine to keep out dust. - 20 - AUGUST 2003 7.0 SPARES 7.1 STANDARD COMPONENTS Part Nos BOT0001 COM0044 COO0003 DRA0008 ELE0200 ELE0216 ELE0243 ELE0244 ELE0529 ENG0036 FAB0206 FAB0208 FAB0209 FIL0081 FIL0086 HOS0018 IND0066 SIL 0019 VAL0131 VAL0152 VAL0181 WHE0012 Description Plastic bottle 0.5L Compressor Oil Cooler 115mm Auto-drain Heat sink Rectifier Fuse holder Capacitor DC converter Petrol engine Sub-frame Main frame Handle Filter Filter Rubber hose 3/8” Temperature gauge -30 +50 Silencer Ported relief valve Flow control valve ½” Three-way valve ¼” Wheel red plain bore 7.2 SERVICE SPARES High efficiency filtration P6A Description Pre-filter assembly Part No FIL0086 Auto-drain Dual function filter assembly FIL0081 Dual function filter assembly FIL0081 Dual function filter assembly FIL0081 Auto-drain Pressure regulator REG0025 - 21 - Element/Service Kit Particulate removal – FIL0185 element 40 µm Change annually (washable) Service kit – DRA0006 Top element - oil vapour removal – FIL0019 (activated carbon). Change every 6 months or sooner. Bottom element – oil removal – FIL0184 (coalescing). Change every 6 months or sooner. Service kit – KIT0026 Gaskets only Service kit – DRA0006 Service kit – KIT0027 AUGUST 2003