Transcript
Yacht ProTM 135 Automatic Compressor Operator’s Manual
YP135DF BROWNIE’S THIRD LUNG 940 NW First Street Fort Lauderdale, FL 33311 Ph 954-462-5570 Fx 954-462-6115 www.tankfill.com / info@tankfill.com
Thank You for purchasing a Brownie’s Yacht ProTM Series Compressor System. This manual explains the use and maintenance of your unit. All information here is based on the latest product data available at the time of publication. Brownie’s Third Lung reserves the right to make unannounced changes at any time without incurring any obligations whatsoever. This Operator’s Manual is to be considered a part of the overall compressor package and should remain with the compressor in the event of sale to another party.
This information is believed to be accurate by Brownie’s Third Lung as of it’s date of publication, but Brownie’s offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein. Brownie’s shall not be liable for inaccuracies in, or consequences resulting from, your use of this information. All information supplied is in connection with sales of Brownie’s products, and is thus subject to Brownie’s standard terms and conditions of sale. Brownie’s reserves the right to change this information and has no obligation to update these materials. This information is Copyright © 2007 by Brownie’s Third Lung, and Brownie’s reserves to itself all rights to this publication. Brownie’s customers have no right to reproduce, rewrite, modify, license or permit anyone else’s use of this information, without the express written permission of Brownie’s Third Lung. Edition 1.0 04/2007
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Table of Contents CHAPTER 1: INTRODUCTION 1.1 How to Use this Manual 1.2 Manual Safety Notices 1.3 General Safety Precautions 1.4 Description of Unit 1.5 Standard Features 1.6 Compressor Quality Analysis Record 1.7 Product Data 1.8 Installation
5 5 5 6 7 7 8 9 10
CHAPTER: 2 OPERATIONS 2.1 Pre Start-up Checks 2.1.1 Check oil level 2.1.2 Check Visual Carbon Monoxide / Moisture Indicator 2.1.3 Check Air Intake 2.1.4 Pre-startup Maintenance/Inspection Notations 2.1.5 Tank Inspection 2.2 Tankfill Procedures 2.3 Lubrication Specifications
11 11 11 11 11 11 11 12 14
CHAPTER 3: MAINTENANCE AND PARTS 3.1 Recommended Maintenance 3.2 Compressor Block 3.3 Intake Filter 3.4 Oil Level Check 3.5 Oil Types 3.6 Oil Change Procedure 3.6.1 Oil Filter Replacement Procedure 3.6.2 Changing Oil Type 3.7 Check Drive Belt/Replace Belt 3.8 Intermediate Separators 3.9 Cooling System 3.9.1 Maintenance 3.9.2 Compressor Valves and Heads 3.9.3 Functional Description 3.10 Torque Valves and Sequencing 3.11 Valves 3.11.1 Valve Functioning 3.11.2 Initial Operational Check 3.11.3 Valve Change General Instructions 3.11.4 Changing 1st Stage Valves 3.11.4.1 Removal 3.11.4.2 Reassembly 3.11.5 Changing the 2nd Stage Valves 3.11.6 Changing the 3rd Stage Valves 3.11.6.1 Removal 3.11.6.2 Reassembly 3.11.7 Changing the 4th Stage Valves 3.11.7.1 Removal 3.11.7.2 Reassembly
15 15 16 17 17 17 18 18 18 19 20 22 22 22 22 23 24 24 24 24 24 24 25 26 27 27 28 29 29 30
* Any applicable addendums will be inserted just before the last page before the Warranty Information. 3
3.12 Exploded View Diagrams 3.12.1 Crankcase Assembly 3.12.2 1st/2nd Stage Piston and Cylinder 3.12.3 3rd Stage Piston and Cylinder 3.12.4 4th Stage Piston and Cylinder 3.12.5 1st Stage Valve Head and Valve 3.12.6 2nd Stage Valves and Valve Head 3.12.7 3rd Stage Valves and Valve Head 3.12.8 4th Stage Valve and Valve Head 3.12.9 Intermediate Separator 3.12.10 3rd Stage Intermediate Separator 3.12.11 Intake Filter 3.12.12 Cooling System 3.12.13 Lubrication System 3.13 Sightglass CO/Moisture Element Replacement Procedure 3.14 Compressor Components 3.14.1 Compressor Details 3.14.2 Mechanical Separator 3.14.2.1 Chamber 3.14.2.2 Cartridge Construction 3.14.2.3 Cartridge Handling 3.15 Electrical Panel
32 34 35 36 37 38 39 40 41 42 43 44 46 48 50 51 52 52 52 52 53
CHAPTER 4: TROUBLESHOOTING
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CHAPTER 5: OPERATION LOG 5.1 Yacht ProTM System Operation Log 5.2 Notes
56 56 62
CHAPTER 6: WARRANTY
63
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WARNING This Instruction Manual and Replacement Parts List contains safety information and instructions for the YachtProTM 135 Compressor. You must read, understand and follow all safety precautions and instructions. Not doing so may result in damage to the system and/or personal injury or death.
CHAPTER 1: INTRODUCTION 1.1 HOW TO USE THIS MANUAL This manual contains the operating and maintenance instructions for the Brownie’s Third Lung product(s) listed on the front cover. In order to familiarize yourself with the compressor features, please read this manual thoroughly before using the equipment. All instructions in this manual should be observed and carried out as written to prevent damage or premature wear to the product or the equipment served by it. If your unit is equipped with nonstandard accessories and/or options, supplemental information is normally included in other documentation; i.e. OEM Manuals or additional Brownie’s Third Lung Manuals. While every effort is made to ensure the accuracy of the information contained in this manual, Brownie’s Third Lung will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof.
1.2 MANUAL SAFETY NOTICES Important instructions concerning the endangerment of personnel, technical safety or operator safety will be specially emphasized in this manual by placing the information in the following types of safety notices.
DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This is limited to the most extreme situations.
WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.
CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
NOTE NOTE advise of technical requirements that require particular attention by the operator or the maintenance technician for proper maintenance and utilization of the equipment.
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1.3 GENERAL SAFETY PRECAUTIONS • Read the operating manual before installing or operating this compressor unit. Follow appropriate handling, operation and maintenance procedures from the very beginning. The maintenance schedule contains measures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed regularly to achieve safe operation, maximum efficiency and long service life. • We recommend that all maintenance work be recorded in a service book, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient maintenance. • This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel. • Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering then installation and operation of this compressor and accessories before operating the unit. • Do not operate this unit in excess of it’s rated capacity, speed, pressure, temperature, or otherwise than in accordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set forth in this manual will subject the unit to limits which it may not be designed to withstand. • Keep safety guards in place. • Do not modify the compressor or its systems. • Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, bracelets, hand rags, etc. are potential hazards. • Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes of escape and post such routes. • Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats, safety shoes and fire extinguisher. • Visually inspect the unit before starting. Remove and /or replace any loose or broken components, tools, valves, missing equipment, etc. Do not operate the compressor if the compressor is damaged. • Do not tamper with, modify, or bypass safety and shutdown equipment. • Do not tighten or adjust fitting or connections under pressure. • The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to insure system compatibility of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death. • The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous. • Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced fan can fly apart and create an extremely dangerous condition. • Allow the compressor to cool before servicing. Whenever the compressor is shut down and overheating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase. • Premature opening of the crankcase of an overheated unit can result in an explosion. • Incorrect placement of the inlet and pressure valves in a compressor cylinder head can cause an extremely dangerous condition. Refer to the appropriate section of this manual before installing or replacing valves. • Before doing any work involving maintenance or adjustment, be sure the electrical supply has been disconnected, and the complete compressor system has been vented of all internal pressure. Failure to follow these warnings may result in an accident causing personal injury and/or property damage. 6
• Before working on the electrical system, be sure to disconnect the electrical supply from the system at the circuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the electrical supply. • Installer must provide an earth ground and maintain proper clearance for all electrical components. • All electrical installation must be in accordance with recognized national, state, and local electrical codes. • Do not use gasoline, diesel fuel or other flammable products as a cleaning solution. • Do not operate the compressor near flammable substances or objects • A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser/user assumes all liability resulting therefrom without any responsibility being assumed by Brownie’s Tankfill. • The purchaser is urged to include the above provision in any agreement for resale of this compressor. • The use of repair parts other than those listed in this manual or purchased from Brownie’s Tankfill, Inc. may create unsafe conditions over which Brownie’s has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Brownie’s Tankfill can bear no responsibility for equipment in which non-approved repair parts are installed.
1.4 DESCRIPTION OF THE UNIT Your Yacht ProTM Series is a fully automatic compressor, equipped with Automatic Condensate Drain (ACD). The YP series has been designed specifically with the traveling yacht owner in mind. The compressor system is designed for “HANDS FREE” operation.
1.5 STANDARD FEATURES The complete Yacht ProTM Series package includes: • One 316L Stainless Steel Base • One High Pressure Compressor with a 10 HP Motor • One Digital Frequency Drive (see manufacturer’s owner’s manual) • One Automatic Condensate Drains • Two Condensate Collection Jugs • Securus® Filtration System (see manufacturer’s owner’s manual) • One Dual Pressure Switch • One Sightglass Element (moisture and CO monitor) • Tool Kit • One gallon, Synthetic Compressor Oil (Part Number CF-2000) • One Operator’s Manual • One Four-way Manifold with 10-foot connection hose including stainless steel quick disconnect end • One padded Custom Manifold Bag Optional Equipment: • Stainless Steel Quick Disconnect Set • Custom Hose Lengths • Remote Fill Plumbing Kit • Cordura Nylon Cover • Remote On/Off Switch (with installation only) Use of Compressor: The Yacht ProTM Series is intended for the compression of air and other gas mixtures. Make sure the air entering the compressor is clean atmospheric air.
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1.6 COMPRESSOR QUALITY ANALYSIS RECORD
Date: Serial # Motor Wiring
Model #
Order# PH
V
Belt Size
Tension
Connections Tight
Nuts & Bolts Tight
No Leaks
Control Wiring Correct
Final Pressure Setting
Tank Fill Time
Drain System Operation
Interval
Oil Level
Oil Removed
Hour Meter Reading
Test Run Time
HZ
(80 ft³ 500-3000 PSI)
STANDARD EQUIPMENT Securus® Filtration
Frequency Drive
Manual
Lubricant
4TKMAN
Sightglass Elements
Block # OPTIONAL EQUIPMENT & MISC Remote Fill Panel FC374-04RL (Additional for 4TKMAN Main)
FT
Technician
Installer
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1.7 PRODUCT DATA
Category COMPRESSOR DATA Air Delivery Rate: * Operating Pressure (max): ** Pressure setting, final: Dimensions: Weight: Use: Intake Pressure: Compressor RPM: Drive Belt Type: Number of Stages: Number of Cylinders: Cylinder Bore 1st Stage: Cylinder Bore 2nd Stage: Cylinder Bore 3rd Stage: Cylinder Bore 4th Stage: Piston Stroke: Intermediate Pressure 1st Stage: Intermediate Pressure 2nd Stage: Compressor Block Oil Cap.: Recommended Oil Types: Max. ambient temperature: Recommended Operating Temp: Max. permissible inclination: Duty Cycle at max pressure: Vibration Mounts: Capacity Range: BTU’s: MOTOR DATA Motor: Frame: Shaft Diameter: Duty Cycle: Motor RPM: Voltage: F.L.A.: BTU’s: Rotation reconn. Mounting rigid Ball Bearing
Specifications 10.8 scfm2 FAD/ 142 LPM 6000 PSI 3200 PSI pressure safety valve (STD) 27.5”H x 36”L x 21”D (699mm x 914mm x 533mm) 350 lbs. Approx (158.8 kg) Compression of atmospheric air Atmospheric Pressure 3600 AP73 4 3 4.2 in (105 mm) 4.15/3.46 in (105/88 mm) 1.10 in (28 mm) 0.47 in (12 mm) 1.57 in (40 mm) 49.3-60.9 psig (3.4-4.2 bar) 203-261 psig (14-18 bar) 3 qts / 2.8 liters CF-2000 Synthetic Compressor Lubricant +32º to +100º F (+0º to +37.8º C) 70º F (21.1ºC) 15º in all directions Continuous Vulcanized neoprene over steel 190-380 lbs. (86-172kg) each 27,880 10hp TEFC / 3-ph / 60 hz 215T 1-3/8” (34.9mm) Continuous 1760 208-230 or 380-460 24 / 12.6 25,483
* Unit has a max pressure rating of 6000 psi (3200 psi by default) ** May be set higher or lower based on Pressure Switch settings
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1.8 INSTALLATION
WARNING Improper installation may result in damage to the unit, personal injury or death. All persons operating the Yacht ProTM Series system must read this manual completely and fully understand the procedures for system operation and the responsibilities of the operator to insure the safety of divers supplied with air from the system. We recommend professional installation by our experienced installation technicians. The Yacht ProTM Series must not be operated in an enclosure that does not meet the installation/operation guidelines for the unit. Contact our Technical Department for advice. The Yacht Pro™ series tank fill compressor must be installed in accordance with the following recommendations: 1. Ambient temperature during operation must not exceed 100 deg F (38 deg C) maximum. The unit will produce heat when operating, therefore adequate ventilation must be provided to stay well within the maximum limit listed above. We recommend operating unit well below the maximum limit. Forced Ventilation must be used where poor air circulation is present. Contact our Technical Department with questions regarding proper ventilation. 2. Proper clearances must be allowed for the following: •
6” minimum from the fan cover to any bulkhead. This provides adequate air supply for the cooling fan.
•
8” minimum above the filter tower. This allows easy filter removal/replacement and easy access to remove the oil dipstick for checking/changing oil.
•
Allow working access to the electrical box for service/repair.
•
The oil drain tube must have clearance for oil changes.
•
The condensate drain reservoir must be accessible for removal.
•
Hour meter, on/off switch, and visual monitor must be accessible for safe operation.
•
Belt Guard must be accessible for service of drive belt.
3. The unit must be installed on a flat, level surface. No more than 10 deg inclination must occur during operation. 4. The Yacht ProTM Series units are provided as a complete assembly ready for installation. Some installations may require remote mounting of package components. This must be approved by our Technical Department. 5. Clean, fresh air must be provided to the air intake of the compressor as close to the operating ambient temperature of the unit as possible. Remote air intake plumbing may be required. A non-collapsible plastic hose with 3/4” ID is the simplest method. The 3/4” ID may be run for a length of 10’. Longer runs may be used by following this guideline: For every 10’ of run the preceding 10’ diameter must be doubled. All 90 deg fittings should be considered as 1 foot of length.
NOTE The intake must be protected from water entry, as this will cause severe damage to the unit. 6. The unit must be protected from any type of water exposure. Such exposure will seriously effect the longevity of the unit and may result in personal injury or death. 7. Electrical Requirements: Yacht ProTM series compressors come standard with 220 VAC 60 HZ single phase electric motors. They are equipped with 120 VAC 60HZ controls and components. All units require correct electrical supply components be provided in accordance with local, state and federal codes for land installation and marine codes for on-board installation. An electrician should be consulted for supply power recommendations. Standard units require that a neutral wire be provided with the standard power supply, for correct operation. An optional remote transformer can be used to provide control voltage if neutral is not available. Some voltage and cycle combinations will require an optional transformer for correct operation.Yacht ProTM Series are available for other electrical requirements. Please contact our Technical Department for specifications. 10
CHAPTER 2: OPERATIONS WARNING Divers lives depend upon proper operation of the system. Brownie’s Third Lung highly recommends that all system operators take a System Training Course.
2.1 PRE START-UP CHECKS Consult the system log to see if the following maintenance needs to be done: • • •
Purification Cartridge inspection/replacement (see supplemental manuals). Sightglass Element replacement (6 month installed life) (see page 48) Oil Check/Change (see pages 17-18)
2.1.1 Check oil level The oil level must be between the upper and lower marks on the dipstick (see page 17). If the oil is low, add oil through the dipstick tube. Use only Brownie’s recommended oil. Do not mix oils or use non-recommended oils which may adversely affect the life of the unit or even destroy the unit.
WARNING Failure to monitor or replace the purification cartridge WILL contaminate all air lines, fill assemblies, divers air tanks, regulators, and may cause severe injury or even diver death. The system operator is responsible for the lives and safety of the divers using air produced by the system. 2.1.2 Check Visual Carbon Monoxide / Moisture Indicator The visual indicator has two elements. An outer blue ring for indicating the presence of moisture, and a central tan to orange disc, indicating the presence of carbon monoxide. Any change in color, (the central disc (CO) turns dark brown or has black spots, and/or the outer ring (moisture) turns pink or beige, indicates that the air leaving the purification system is contaminated and not breathable. The visual monitor is the last monitor of the air leaving the purification system, and must be checked during operation for any changes. DANGEROUS
Good Conditions: Inner Ring - Yellow
DO NOT USE AIR GOOD
CHANGE CARTRIDGE SATURATED
Outer Ring - Blue GOOD
WARNING Any color change in the elements of the visual indicator means that contaminated air has passed downstream. All air lines, fill assemblies, and equipment must be cleaned or replaced. An Air Quality Test must be done to insure thoroughness of all cleaning. Breathing contaminated air may result in personal injury or death. 2.1.3 Check Air Intake Remove and inspect the Air Intake Filter. If the system is equipped with a remote air intake, be sure it is properly located, and clear of any water or obstructions. 2.1.4 Pre-startup Maintenance/Inspection Notations Add all pre-startup maintenance/inspection notations to the system log with date, hours, and operator name. 2.1.5 Inspect ALL tanks to be filled: • Make sure the tanks are in good condition with no deep scratches, gouges, or pitting. • The tanks must be within current hydrostatic test and Visual Inspection dates. • Do not fill empty tanks without first visually inspecting them for water intrusion. • Make sure that the valves are in good condition and not in need of service. Do not fill tanks with damaged valves. • Do not fill tanks that have been exposed to extreme heat, i.e.: tanks that have been in or near fires. 11
A
2.2 TANKFILL PROCEDURES Tank Fill Whip Assemblies: Shown are the tankfill whip ends for DIN and Yoke systems. A. Yoke connector D B. DIN connector C. bleeder valve D. fill valve
D B
C
WARNING Tanks must be secured (protected from falling or being knocked over) during filling. 1. Hook up fill manifold to compressor air outlet or remote fill panel. 2. Open tank valve slightly to blow any moisture or particles clear of connection surfaces.
Figure 1
3. Standard Yoke - Hook fill yokes to the tank valves and tighten yoke hand wheel “finger tight” (Figure 1). a. Close bleed screws (Figure 2) b. Open tank valves counter-clockwise (Figure 3) c. Open Fill Valves (Figure 4) Counter-clockwise rotation of this valve will open the line to the tanks. The tanks will now equalize any differences in their pressures. Din Yoke - Screw the male din yokes into the valves until the “o-ring” is snugly in place against the base of the female din valves. a. Close bleed screws (Figure 2) b. Open tank valves counter-clockwise (Figure 3) c. Open Fill Valves (Figure 4) Counter-clockwise rotation of this valve will open the line to the tanks. The tanks will now equalize any differences in their pressures. 4. Start the Compressor The compressor will now operate automatically, draining the condensate and shutting off when the tanks are full. The operator need only check the operation from time to time during the filling process to verify the following:
Figure 2
Figure 3
• Condensate is accumulating in the reservoir. • No color change has occurred in the visual indicator. • Pressure is building on the fill gauge.
Figure 4
12
C
WARNING Do not try to remove the quick disconnect while the system is pressurized. Doing so may result in property damage or personal injury.
Fill times are based on filling a single standard 80 cu. ft aluminum cylinder from 500 psi to 3000 psi and are approximately 5 minutes per tank. Cylinder volume, starting tank pressure, and tank pressure ratings will vary the fill times. Note that the indicator light is still on after the compressor automatically stops. This indicates that the compressor is in an AUTOMATIC START MODE and will restart if the stop pressure drops approximately 500 psi. If you intend to fill more tanks you may leave the on/off switch in the “on” position while changing the tanks out. Simply opening the tank and fill yoke valves will restart the compressor.
Figure 5
5. Remove full tanks by first closing the fill yokes and tank valves (Figure 5). Depressurize the yokes by opening the bleed screws (Figure 6). Remove the fill yokes from the tanks (Figure 7). 6. When you are done filling for the day, turn the on/off switch to the off position. Empty the condensate reservoir. 7. Bleed the pressure from the fill manifold by opening one of the fill yoke valves slowly until all pressure is vented and the gauge reads zero. 8. Remove the manifold from the hose using the quick disconnect fitting and store the manifold in its bag.
Figure 6
9. Allow the compressor to cool prior to installing the optional Cordura fabric cover. 10. Update the system log, noting running hours of compressor and any maintenance performed.
Figure 7
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2.3 LUBRICATION SPECIFICATIONS
Use
Lubricant
O-rings, rubber and plastic parts, filter housing threads
White Petroleum DAB9 # N19091 or WEICON WP 300 White part # N19752
Sealing Rings
Universal grease
Paper Gaskets
Apply silicone compound on both sides (WACKER silicone compound part # N 18247) before assembly
Bolts, nuts, studs, valve parts, CU gaskets and pipe connectors (threads, cap nuts, compression rings)
Compounds with Copper or MoS² additives (WEICON ANTI-SEIZE AS 040 P part # N 19753)
High Temperature connections (valve heads / cylinders)
Temperature resistant compound (WACKER silicone compound, part # N 18247
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CHAPTER 3: MAINTENANCE AND PARTS 3.1 RECOMMENDED MAINTENANCE
WARNING We recommend that any maintenance other than preventative be performed by an authorized service center or technician. Contact Brownie’s for service center information. INTERVAL
TYPE OF MAINTENANCE
DATE
After 25 hrs initially, and every 50 - 100 hrs thereafter
Oil Change (every 50 hours when using regular oil, and every 100 hours if using synthetics) or six months
After 25 hrs initially, and every 150 hours thereafter
Check function and tightness of filling valve Clean and change intake filter Check tightness of o-rings Check drive belt and condition Check cooler brackets Check zero on gauge when depressurized
After 1st year or 300 hours of operation
Air and tightness check Replace filter chamber o-rings Drive belt inspection (replace after 300 hrs) Cleaning of air intake filter and filter unit.
After 2nd year or 600 hours of operation
Check air tightness and performance Drive belt inspection (replace after 600 hrs) Replace filter chamber o-rings Cleaning of air intake filter and filter unit.
After 3rd year or 900 hours of operation
Check air tightness and performance Drive belt inspection (replace after 900 hrs) Replace filter chamber o-rings Cleaning of air intake filter and filter unit.
After 4th year or 1200 hours of operation
Check air tightness and performance Drive belt inspection (replace after 1200 hrs) Replace filter chamber o-rings Replacement of air vent hos Replace cylinder head o-rings. Clean air intake filter & unit.
After 5th year or 1500 hours of operation
Check air tightness and performance Drive belt inspection (replace after 1500 hrs) Replace filter chamber O-rings Cleaning of air intake filter and filter unit.
After 6th year or 1800 hours, of operation
Check air tightness and performance Drive belt inspection (replace after 1800 hrs) Replace filter chamber o-rings Cleaning of air intake filter and filter unit.
After 7th year or 2100 hours of operation
Check air tightness and performance Drive belt inspection (replace after 2100 hrs) Replace filter chamber o-rings Cleaning of air intake filter and filter unit.
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SERVICE CENTER
3.2 COMPRESSOR BLOCK The compressor block is used to compress air up to 6000 psi. This compressor is a four stage, three cylinder air cooled, oil lubricated reciprocating compressor. The cylinders are arranged in a “W” configuration, the 1st/2nd stage vertical stepped cylinder is in the center, 3rd stage on the right and 4th stage on the left looking from the intake filter side. These compressor blocks are particularly suitable for continuous operation because of their rugged design and corrosion resistant intermediate filter and cooler assemblies.
Compressor Block, Front View 11
1 2 3 4 5 6
12 13 14
15
7
16 8
1. 2. 3. 4. 5. 6. 7.
17
9
18
10
19
Intake Filter 1st Stage Safety Valve 2nd Stage Intake Manifold Oil Filler Neck 4th Stage Cylinder 3rd Stage Safety Valve 3rd Stage Separator
8. 3rd Stage Intercooler 9. Oil Drain Plug 10. Condensate Drain Connector 11. 1st Stage Valve Head 12. 2nd Stage Pressure Manifold 13. 3rd Stage Cylinder 14. 2nd Stage Safety Valve
16
15. Oil Filter Housing 16. 2nd Stage Separator 17. 2nd Stage Intercooler 18. Compressed Air Outlet 19. 4th Stage Aftercooler
Intake Filter
3.3 INTAKE FILTER A dry, micronic filter is used to filter the intake air, see image to the right. The filter cartridge must be changed at regular intervals. See the Maintenance Schedule for the recommended interval. 1. Unscrew and remove Knurled Nut (1) 2. Remove Washer (2) and Filter Housing (3). 3. Discard Filter Element (4) and replace with new Filter Element Bauer. 4. Reassemble in reverse order.
3.4 OIL LEVEL CHECK
4
Check the oil level at the sight glass on the side of the compressor block everyday before operating the compressor. Note that the oil level must be between the minimum and maximum notch. Add oil if necessary and recheck level. Oil should not exceed the maximum level, as this could result in carbon build up on the valves
3.5 OIL TYPES
3
2 1
1. Knurled Nut 2. Washer
3. Filter Housing 4. Filter Element
Using the correct oil is of utmost importance for proper care and maintenance of the compressor, along with keeping the life and function of your compressor at its best. Only use oils that: • are low in deposits • have no carbonizing effect, especially in the valves • have good anti-corrosive properties • provide emulsification of the condensate in the crankcase • are physiologically and toxicologically suitable
maximum minimum
Due to the thermal load on the compressor, only high quality oil should be used. For operating under severe conditions such as continuous running and/or higher ambient temperatures, we recommend Part No. CF-2000 (Synthetic Compressor Lubricant, Food Grade). CF-2000 has been specially formulated for use in high pressure compressors and will provide optimal performance through a wide range of conditions. Compressor systems are delivered with one gallon of synthetic oil, Part No. CF-2000.
Figure 1
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3.6 OIL CHANGE PROCEDURE Care should be taken in draining oil into a proper container for disposal per local guidelines and laws. 1. Turn on the compressor and run it until warm 2. Remove the red cap on the oil filler neck (Figure 2) 3. Remove the ball valve cap at the base of the compressor block (Figure 3) 4. Attach appropriate drain valve and hose (Figure 4) 5. Open ball valve by rotating handle (Figure 4) 6. After oil is completely drained, close the ball valve (Figure 4) 7. Slowly pour new oil* through the oil filler neck (Figure 2) until the level reaches the maximum mark on the sight glass
Figure 2
NOTE Replace the oil filter every oil change. Failure to do so will cause the filter to clog and bypass valve to open resulting in unfiltered oil being circulated and possible damage to the compressor. 3.6.1 OIL FILTER REPLACEMENT PROCEDURE 1. Remove the two bolts (Figure 5-1) using a 13mm wrench 2. Remove the oil cover(Figure 5-2) 3. Remove the oil filter from the rubber gasket at the cover (Figure 6) 4. Mount a new filter element (P/N N25326) 5. Replace and fasten oil cover 6. Slowly pour new oil* through the oil filler neck (Figure 2) until the level reaches the maximum mark on the sight glass 7. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation 3.6.2 CHANGING OIL TYPE 1. Changing from synthetic type oil to petroleum type oil requires no special procedures 2. Changing from petroleum type oil to synthetic type oil requires the following steps to avoid severe damage to the compressor unit: a. Drain petroleum based oil completely while it is warm b. Replace or clean all deposits from valves, coolers, separators, purifiers, tubes and hoses c. Fill with 12 fluid ounces (360 mL) of synthetic oil d. After 100 operating hours check oil for degree of contamination and change oil again if necessary e. On subsequent oil changes refill only with synthetic oil
Figure 3
Figure 4
1
2 Figure 5
* Brownie’s supplies CF-2000 food-grade synthetic compressor lubricant with all compressors.
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Figure 6
3.7 CHECK DRIVE BELT/REPLACE BELT The drive belt should be checked at least every 125 hours, assessing the belt for wear or damage. Should the belt need to be replaced: 1. Remove the belt guard from the compressor unit. Lift the motor to release the tension on the belt (Figure 2). 2. Remove the old belt and replace. 3. Release the motor. The weight of the motor will adjust the tension of the belt (Figure 1). Replace the belt guard.
Figure 1 Motor at Normal Position
Figure 2 Motor Lifted to Relieve Tension on Belt
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3.8 INTERMEDIATE SEPARATORS Intermediate separators are mounted on the compressor between the 2nd and 3rd stage and between the 3rd and 4th stages. These separators are designed to remove oil and water which accumulates due to the cooling of the medium after the compression process. Separation is achieved by means of centrifugal action.
2nd Stage Intermediate Separator 8
3
1
2 4
5
6
7 1. Safety Valve 2. Separator Head 3. O-ring
4. Screw-in Insert 5. Knurled Nut 6. Separator Body
20
7. Gasket 8. Fitting
3rd Stage Intermediate Separator
4
8
1 5
2
3
6
7
1. Vortex Plate 2. Hollow Screw 3. Center Insert
4. O-ring 5. Knurled Nut 6. Gasket
7. Fitting 8. Safety Valve
1.1.5.1 Maintenance The Intermediate Separator requires no maintenance.
^ WARNING
^
The rapid depressurizing and repressurizing of the intermediate separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one depressurization- repressurization. The Bauer recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and maintaining the quality of the delivered air.
21
3.9 COOLING SYSTEM The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this purpose, the compressor is equipped with a fanwheel connected to the counter-weight at the crankshaft end opposite to the V-belt pulley. It draws the cooling air through the fanwheel cover from the surroundings. Refer to the Product Data page for ambient temperature information. 3.9.1 Maintenance When dirty, clean the finned tubes, valve heads and cylinders by blowing off the dirt and dust with low pressure compressed air (80 -125 psi) 3.9.2 Compressor Valves and Heads The valve heads of the individual stages form the top part of the cylinders. 3.9.3 Functional Description The intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylinders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve. The intake and pressure valve of the 1st stage are in a combined plate valve under the valve head.
Valve Operation
Intake
Pressure
Figure 1
22
3.10 TORQUE VALUES AND SEQUENCING 3.10.1 Torque Values Unless otherwise noted in text, the following torque values apply. All valve head screws require torque wrench tightening. The indicated values are for bolts in greased condition. Replace self-retaining nuts on reassembly. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more than finger tight plus up to an additional 1/2 turn.
Screw or Bolt
Thread
Max Torque
Hex and socket head
1/4” (M6)
7 ft.lbs (10 Nm)
Hex and socket head
5/16” (M8)
18 ft.lbs (25 Nm)
Hex and socket head
3/8” (M10)
32 ft.lbs (45 Nm)
Hex and socket head
1/2” (M12)
53 ft.lbs (75 Nm)
Hex and socket head
9/16” (M14)
85 ft.lbs (120 Nm)
Hex and socket head
5/8” (M16)
141 ft.lbs (200 Nm)
Pipe Connections (swivel nuts)
Finger tight + ½ turn
3.10.2 Torque Sequencing: Tighten valve head and cylinder bolts/nuts equally in the sequence shown here. Be sure to tighten all parts in cold condition only.
1 3
2
1
6
3
4
5
4 2
3.10.3 Conversion Formulas °F = 9/5°C + 32 °C = 5/9 x (°F-32) PSI = BAR x 14.5 BAR =PSI x 0.0689 23
3.11 VALVES 3.11.1 Valve Functioning The valve heads of the individual stages form the top part of the cylinders. The intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the flow of the gas. On the suction stroke, the intake valves open and the gas flows into the cylinders, and on the compression the intake valve closes, and gas flows out the pressure valve. 3.11.2 Initial Operational Check After roughly half an hour’s operation, valves should be checked. Note that the inlet line to the valve heads should be warm, and outlet piping should be hot. Valves are then shown to be operating properly. If the intake pipe to the valve head of the second stage heats up excessively, and the first stage safety valve blows off, either the intake or pressure valve of the second stage is malfunctioning. It is necessary then to remove the valve head and to check and clean these valves or to replace them. 3.11.3 Valve Change General Instructions • Always replace valves as a complete set. • Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in diesel oil or petroleum, and clean with a soft brush. • Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the valves. • Valve head screws must be tightened with a torque wrench (See tightening instructions page 23) • Check the valve space in the valve heads for dirt, and clean if necessary. • Use gaskets and o-rings in reassembly only if they are in satisfactory condition, otherwise replace them. • Observe the correct sequence when reassembling. • When maintenance work has been completed, turn the compressor manually using the flywheel to verify correct assembly. • 30 minutes after restarting the compressor unit, stop the unit, let it cool to ambient temperature, and retighten the valve studs and cap nuts to specifications (page 23). Otherwise valves could work loose due to setting of the gaskets. • Replace valves every 2000 hours to avoid fatigue failure. 3.11.4 Changing 1st Stage Valves 3.11.4.1 Removal Intake and pressure valves for the 1st stage are combined in one plate valve under the valve head, as seen in the diagram.
1st Stage Valve Operation
1. Remove all tubing connections and lines from the Valve Head (2). 2. Remove Hex Head Bolts (4) and Washers (3) 3. Remove the Plate Valve (1). 4. Clean Plate Valve, preferably in a ultrasonic cleaner, and check for damage. 5. Replace worn or damaged parts. 6. Check the underside of the Valve Head for flatness using a precision straightedge. If necessary use an emery cloth to smooth out the surface.
TOP VIEW Intake Side
Pressure Side 24
Intake and pressure valves for the 1st stage are combined in one plate valve under the valve head, as seen in the diagram. 1. Remove all tubing connections and lines from the Valve Head (2). 2. Remove Hex Head Bolts (4) and Washers (3) 3. Remove the Plate Valve (1). 4. Clean Plate Valve, preferably in a ultrasonic cleaner, and check for damage. 5. Replace worn or damaged parts. 6. Check the underside of the Valve Head for flatness using a precision straightedge. If necessary use an emery cloth to smooth out the surface. 3.11.4.2 Reassembly 1. Replace the Plate Valve ensuring that the side marked TOP is really at the top and the stamped “S” is on the intake side. 2. Place the Valve Head (2) on the cylinder and secure it with the Washers (3) and Hex Head Bolts (4). Tighten these bolts. 3. Reconnect all tubing connections and lines to the Valve Head (2).
1st Stage Valve Head and Valves
4
4
3
3
5
2
1
1. Plate Valve 2. Valve Head 3. Washer
4. Hex Head Bolts 5. O-ring
25
3.11.5 Changing the 2nd Stage Valves 1. Remove the lines from the intake and pressure manifolds (1). 2. Remove the Allen Screws (5). 3. Remove gaskets (2) and replace with new ones. 4. Clean intake valve (3) and pressure valve(4) and check for wear or damage. 5. Reassemble in reverse order of above.
2nd Stage Valves
1 2 3 2 2 4 2 1
5
1. Manifold 2. Gasket 3. Intake Valve
4. Pressure Valve 5. Allen Screw
26
3.11.6 Changing the 3rd Stage Valves 3.11.6.1 Removal 1. Remove the intake and pressure lines from the valve head (7). 2. Remove the allen screws (8) holding the valve head onto the cylinder. 3. Replace two of the screws with two 8mm diameter metal pins of any length. 4. Use these pins as a holding fixture by securing them in a vise with the valve head on top. 5. Using the special tool provided with the unit, remove the intake valve (6) (See Figure 1-16). 6. Turn the valve head over and replace it on the metal pins. 7. Remove the cap nut (1) 8. Unscrew the stud (2) approximately five turns. 9. Remove the pressure plug (3) and take out the valve parts. 10. Clean the intake and pressure valves and check for wear and damage 11. Clean the valve head. check that the intake and pressure valve bores are in perfect condition. 12. Using a precision straightedge, check that the underside of the valve head is flat. If necessary use an emery cloth to smooth out the surface.
3rd Stage Valve Head and Valves 1
8
2
3 7 4
6 5
1. 2. 3. 4.
5. 6. 7. 8.
Cap Nut Stud Pressure Plug O-ring
27
Pressure Valve Intake Valve Valve Head Allen Screw
Using the Special Tool PN004555
Securing the Intake Valve
NOTE NOTE: Valve seats and plate valves must not show any signs of wear or damage. Replace damaged or worn parts. 3.11.6.2 Reassembly. 1. Replace the intake valve (6) using the special tool to tighten it.
CAUTION CAUTION: The intake valve plate and valve spring must not be jammed. 2. Check the intake valve functions correctly by blowing compressed air through the valve in the direction of flow. 3. Secure the intake valve by peening the valve head aluminum over the screw-in thread of the intake valve in two places opposite one another. Use a small drift pin, approximately 5mm in diameter. 4. Insert the O-ring (4) and the pressure valve parts(5). 5. Check the pressure valve function and stroke by lifting the valve parts. 6. Ensure the stud (2) is unscrewed, then screw in the pressure plug (3) and tighten. 7. Screw the stud (2) in firmly, fit a new gasket and secure it with the cap nut (1). 8. Replace the valve head (7) on the cylinder and secure it with the screws (8). 9. Reconnect the intake and pressure lines.
28
3.11.7 Changing the 4th Stage Valves 3.11.7.1 Removal 1. Remove the intake and pressure lines from the valve head (2). 2. Remove the cap nut (8) and loosen stud (6) three or four turns. 3. Remove the bolts (9) holding the valve head onto the cylinder and take off valve head cover (5). 4. Remove the pressure valve by putting two screwdrivers into the removal groove of the pressure valve body. It may be necessary to loosen the valve body first by turning it with a 13 mm wrench used on the flat surfaces. 5. Insert two 8mm diameter metal pins, any length, in the holes in the valve head and secure them in a vise with the valve head on top of the vise. The intake valve should be facing up. 6. Using the special tool provided with the unit (See figures on opposite page), remove the intake valve (1).
4th Stage Valve Head and Valves 9 10
8 7 6
5 1
4 3
2
1. 2. 3. 4. 5.
6. Stud 7. Gasket 8. Cap Nut 9. Gasket 10. Bolt
Intake Valve Valve Head O-ring Pressure Valve Valve Head Cover
29
3.11.8.2 Reassembly 1. Replace the intake valve (1) using the special tool to tighten it. 2. Check the intake valve functions correctly by blowing compressed air through the valve in the direction of flow. 3. Secure the intake valve as follows: Peen the valve head aluminum over the screw in thread of the intake valve in two places opposite one another. Use a small drift pin, approximately 5mm in diameter. 4. Reinstall the pressure valve (4) by putting O-ring (3) into valve head (2). Check it for abrasions. 5. Insert pressure valve through O-ring and into valve bore. 6. Put on valve head cover (5). 7. Reassemble valve head cover and valve head to cylinder. Torque bolts (9) to the proper value. 8. Screw in stud (6). Put on gasket (7). Screw on cap nut. (8).
Removing the 4th Stage Pressure Valve
30
This page is inserted to provide proper page sequencing
6
8
9
5
1
2
7
10 4
3
31
3.12 EXPLODED VIEW DIAGRAMS 3.12.1 Crankcase Assembly Crankcase Assembly
6
11
2
12 13
15
3
28
4
16
1 14
17 8
27
9
10 26
16
19
25 5
4 7
30
29
22
19
# KIT
Qty Part No.
Description
1 2 3 4 5 6 7 8 9 10 11
1 1 1 1 2 1 1 1 1 1 1 1
Crankcase assembly Crankcase Crankshaft, complete Roller Bearing Circlip Bearing Cap Roller Bearing O-ring Cover Shaft Seal O-ring Plug
… … … … … … … … … … …
18
076743 076740 083467 N2638 N2635 66209 N15406 N15265 66684 N170 N3745 61054
23 24
22
Notes
32
20 21
Crankcase Assembly cont. # KIT
Qty Part No.
Description
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 1 1 2 8 2 2 2 1 1 2 4 4 4 4 6 3 1 1
O-ring Oil Filling Pipe O-ring Allen Screw Washer Gasket Plug Oil Sight Gauge Gasket Plug Support Spring Washer Hex Nut Washer Hex Head Screw Hex Head Screw Countersunk Screw Coupling Ball Valve
… … … … … a.. … … … … … … … … … … … … …
N15412 73830 N4776 SCR-0020 WAS-0021 N4163 PLU-0040 N25475 N1316 N4570 78038 WAS-0030 NUT-0076 WAS-0031 N350 SCR-0113 N16126 N2375 N25638
Notes
33
3.12.2 1st/2nd Piston and Cylinder 1st/2nd StageStage Piston and Cylinder
11 10 1 2
9
3 4
5 8
6
5
7
# KIT
Qty Part No.
Description
� 1 2 � 3 4 5 6 7 8 9 10 11
1 1 1 1 1 1 2 1 1 1 4 4 4
1st/2nd Stage Cylinder Assembly Stepped Cylinder O-ring Piston Assembly Guide Ring Piston Ring Set, 1st Stage Circlip Stepped Piston Piston Ring Set, 2nd Stage Piston Pin Stud Washer Self Locking Hex Nut
… ..c … … … … … … … … ..c
84240 80729 N4654 84238 N28554 N25842 N484 84212 N25396 N1216 N215 WAS-0021 NUT-0119
Notes
34
Item 3 - 8
3.12.3 3rd Stage Piston and Cylinder
3rd Stage Piston and Cylinder
1
2
3
11 10
4 5 7
6
9
8 7
# KIT
Qty Part No.
Description
� 1 2 3 4 � 5 6 7 8 9 10 11
1 1 1 1 1 1 1 1 2 † 4 4 4
3rd Stage Cylinder Assembly Cylinder O-ring Guide Cylinder O-ring Piston Assembly Piston Ring Set Piston Circlip Available only with 78334 Stud Washer Self Locking Hex Nut
… ..c … ..c … … … … … … ..c
78335 67940 N7063 83404 N2640 78334 N19833 67942 N484 Piston Pin N2790 WAS-0021 N370
Notes
35
Items 5 - 8
4th Stage Piston and Cylinder 3.12.4 4th Stage Piston and Cylinder 1 2 3
4 5
16 15
6
7 8
14
9
13
12
7
11 10
# KIT 1 2 3 4 5 6
a.. … … ..c … ..c
7 8 9 10
… … … …
11 12 13 14 15 16
… … … a.. ..c …
Qty Part No.
Description
1 1 1 1 1 1 1 1 2 1 1 4 1 † † † 1 4 4
4th Stage Cylinder Assembly O-ring Cylinder Screw O-ring Guide Cylinder O-ring Guide Piston Assembly Circlip Guide Piston Piston Pin Stud Piston and Sleeve Assembly Available only with 078045 Available only with 078045 Available only with 078045 O-ring Washer Self Locking Hex Nut
083457 N4868 082480 N27318 N7063 083404 N2640 072165 N484 N858 N1429 N2790 078045 Piston Sleeve Piston Pin Piston Ring Set N23755 NUT-0119 WAS-0021
Notes
36
Items 7 - 9
Items 11 - 14
1st Stage ValveValve HeadHead and Valve 3.12.5 1st Stage and Valve
5
4
3
3
6
2
1
# KIT
Qty Part No.
Description
1 2 3 4 5 6
1 1 1 7 6 1 1
1st Stage Valve Head Assembly Reed Valve Valve Head Washer Hex Head Screw Hex Head Screw O-ring
… … … … … …
083652 N26531 080677 N102 N26568 N26646 N17959
Notes
37
3.12.6 2nd Stage Valves and Valve 2nd Stage Valves and Valve HeadHead
1 2 3 2 2 4 2 1
5
# KIT
Qty Part No.
Description
� 1 2 3 4 5
1 2 4 1 1 8
Valve Head, 2nd Stage Manifold Gasket Intake Valve Pressure Valve Allen Screw
… a.. .b. .b. …
073435 78562 56668 N4067 N4068 SCR-0133
Notes
38
3.12.7 3rd Stage Valves and Valve 3rd Stage Valves and Valve HeadHead
15 14 13 16 12
11
4
1
10 9
2
8 7 5
3
6 2
# KIT
Qty Part No.
Description
� 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 1 2 1 1 1 † † 1 † 1 1 1 1 1
3rd Stage Valve Head Assembly Valve Head Gasket Intake Valve Pressure Valve Assembly Pressure Valve Insert Available only with 012835 Available only with 012835 Spring Available only with 012835 O-ring Spring Washer Coupling Stud Gasket
… a.. .b. … .b. … … … … … … … .b. a..
069792 14123 240 012836 014582 012835 Valve Seat Valve Plate 1026 Valve Insert N3521 14332 14124 71064 N380
Notes
39
Items 2, 5, & 10 - 15 Items 2 & 6 - 9
3.12.8 4th Stage Valves and Valve 4th Stage Valves and Valve HeadHead
9 10
8 7 6
5 1
4 3
2
# KIT
Qty Part No.
Description
� 1 2 3 4 5 6 7 8 9 10
1 1 1 1 1 1 1 1 1 6 6
4th Stage Valve Head Assembly Intake Valve Valve Head O-ring Pressure Valve Valve Head Cover Stud Gasket Cap Nut Hex Head Cap Screw Gasket
.b. … … .b. … .b. a.. … … …
082096 81409 65191 N2789 014121 14118 71065 N3625 N3623 N1282 N58
Notes
40
Includes Item 3
3.12.9 Intermediate Separator Intermediate Separator
#
KIT
� 1 2 3 4 5 6 7 8
… a.. … … … … … …
Qty Part No.
Description
Notes
1 † 1 1 1 † 1 1 1
Intermediate Separator Separator Head O-ring Screw-in Insert Knurled Nut Separator Housing Gasket Straight Connector Safety Valve
Items 1 - 7 Available only with 080690
080690 080691 N3556 076613 13937 14150 N1316 N20215 078706
41
Available only with 080690
3rd Stage Intermediate Separator 3.12.10 3rd Stage Intermediate Separator
4
8
5
1 2 3
6 7
# KIT
Qty Part No.
Description
Notes
� 1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1 1
Intermediate Separator Assembly Plate Hollow Screw Inset Assembly O-ring Knurled Ring Gasket Fitting Safety Valve
Items 1 - 7
… … … … … … … …
081799 81148 81643 76613 N3556 13937 N1316 N20215 81810
42
3.12.11 Intake Intake FilterFilter
7 6
5
4
3
2 1
# KIT
Qty Part No.
Description
� 1 2 3 4 5 6 7
1 1 1 1 1 1 1 1
Intake Filter Assembly Knurled Nut Washer Filter Housing, Front Filter Element Filter Housing, Back Hex Head Bolt Clamp
… … … a.. … … …
79577 N4870 N3313 79574 N25950 79575 N19502 N3374
Notes
43
3.12.12 Cooling System Cooling System
7
11 47
89
10
44 43
1
2
4 5 6 7 18
12 13 14
17
22 20
30 32
22
27
27
33
7 6 5
39
27
26 27 45
28 27
27
49 37 36 38
46 7 6 54
27
Qty Part No.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 1 1 1 4 4 4 4 1 4 3 3 1 3 3 1 1
Cooling System Assembly 1st - 2nd Stage Intercooler Fitting Connecting Tube Gasket O-ring Banjo Fitting Banjo Bolt Male Connector Gasket Washer Hexagon Nut Self Locking Fan Guard Double Strap Bracket Stud Aftercooler Connector
31
27
33
35 34
Notes
44
26 27
31
48
32 33
# KIT … … … … … … … … … … … … … … … …
31 32
42 9
35 34
25
78293 078295 N20202 78854 N25451 N25452 N25449 N25450 N20231 N00293 WAS-0021 NUT-0119 078200 011887 078199 078301 N20208
4140
15 26
24
30
27 28
16 27 26 29 4 28 27
19
21
31
4
42
9
27
3
23
65
32
30
Cooling System, IK12.14 II (con’t.) # KIT
Qty Part No.
Description
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
1 1 4 12 4 8 2 5 1 5 14 3 1 4 4 4 4 4 4 2 1 1 1 1 2 2 1 1 1 1 1 1 1
Gasket Connector, Male Hexagon Screw Hexagon Nut Self Locking Washer Washer Tube Clamp Stud 3rd - 4th Stage Intercooler Fitting Gasket Plug Connecting Tube Plug Nut Male Connector Clamp Hexagon Screw Washer Gasket, Copper Stud Male Connector Connecting Tube Male Connector Gasket Plug Plug Connector Connecting Tube 2nd - 3rd Stage Intercooler Safety Valve Safety Valve Safety Valve
… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … …
056983 071148 N19501 NUT-0118 N03313 WAS-0024 062773 N03494 078195 N20059 N01316 N00052 078197 N04530 NUT-0119 CON-0041 077894 SCR-0020 N02460 004479 N20197 N20014 078303 N20188 N00842 PLU-0036 N00204 N20201 078300 078297 81801 78706 81810
Notes
45
3.12.13 Lubrication System Lubrication System
1
11 12
2 3 4 5 10
19
14
15
9 6 13 14
18 17
14
15
8 14
7
15
# KIT
Qty Part No.
Description
� � 1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1 2 2
Lubrication System Assembly Lubricating System Oil Filter Cover O-ring O-ring Rubber Gasket Filter Element Oil Pump Cover Allen Screw Gasket
… … … … … … … …
83417 081075 77885 N4058 N25327 77774 N25326 77878 N25328 N2889
Notes
46
Items 1 - 15
16
# KIT
Qty Part No.
Description
9 10 11 12 13 14 15 16 17 18 19
1 2 2 2 1 4 3 4 1 1 1
Gear Pump O-ring Hex Head Screw Gasket Regulating Valve Gasket Plug Allen Screw Connecting Tube Assembly Male Connector Gasket
… … … … … … … … … … …
N24585 N3489 N19506 N58 81050 N1316 N52 N123 076757 N2037 78421
Notes
47
3.13 SIGHTGLASS CO/MOISTURE ELEMENT REPLACEMENT PROCEDURE Replacement Element Part #M7414 (Assy #VM211-EL)
WARNING Make sure all pressure is relieved prior to changing element. DANGEROUS
Good Conditions: Inner Ring - Yellow Outer Ring - Blue
DO NOT USE AIR GOOD
CHANGE CARTRIDGE SATURATED
GOOD
1. Unscrew window cap in counter-clockwise direction. (NOTE: The orientation of the sightglass assembly may vary.)
2. Here the cap is shown having been removed, and the retaining spring exposed. Old elements are removed from the window at this time. Inspect o-ring for wear, and replace if worn. Lube threads with food grade silicone grease if needed.
3. The moisture indicator ring is placed into the window first. Minimal handling is best, and care should be taken with the packaging contents and their disposal.
4. This view shows the ring properly installed in the window. 48
5. The CO monitoring disc is shown ready to install into the window. It is placed in and then centered in the moisture indicator ring.
6. The spring is placed into the window, centered on the CO disc and the whole unit is then ready to be reassembled.
7. The cap is replaced and it is screwed back into place, finger tight. Make sure the CO disc remains in place.
8. With change and reassembly completed, both indicators are easily viewed in the window and the cap is tightened down.
49
Automatic Condensate Drain System (third timer)
TEFC Motor
Hyme Joint
Belt Guard
50
Air Intake Filter Housing
Heavy Duty Stainless Steel Frame with Vibration Isolators Automatic Condensate Drain System with three programmable timers (third timer can be seen in adjacent image)
Oil Fill Tube
3.14 COMPRESSOR COMPONENTS
3.14.1 Compressor Details Auto Drain System
LED Pressure Switch
Intermediate Separator Automatic Drain Solenoid Timer (3 total)
Mechanical Separator Intermediate Separator (Manual Drain Valve (normally closed)
Intermediate Separator Automatic Drain Solenoid Valve
(manufacturers manual can be found at the back of this manual)
Hyme Joint
Condensate Drain Bottle
51
3.14.2 MECHANICAL SEPARATOR
Oil and Water Separator Oil and Water
The air leaving the final stage is cooled in the aftercooler to approximately 18 - 27°F (10 -15°C) above ambient temperature and then enters the oil and water separator. The oil and water Separator separator works by means of a sintered metal filter which separates liquid oil and water particles from the compressed air. 3.14.2.1 Chamber Each chamber is made up of an anodized aluminum housing and a filtering cartridge. There are two general types of filtering cartridges, drying or purifying. The cartridge type is determined by the ingredients packed in the cartridge. The chamber is named after the type of cartridge it contains, i.e. dryer chamber or purification chamber.
r Separator Labels
3.14.2.2 Cartridge Construction The cartridge casing, top and bottom are aluminum and are packed with one or more of the following. 1. A catalyst to convert carbon monoxide to carbon dioxide. 2. Activated carbon which absorbs oil vapors effecting taste and odor. 3. Molecular sieve to absorb oil and water.
Oil and Water Separator Labels
3.14.2.3 Cartridge Handling 1. Never open the protective packaging a cartridge comes in prior to its actual use. The highly sensitive filter materials will absorb moisture from the atmosphere becoming saturated and useless. 2. Used cartridges must be disposed of in accordance with local regulations.
Oil and Water Separator Cartridge Protective Cap
52
3.15 ELECTRICAL PANEL
Electrical Panel Label MODEL: SERIAL: BLOCK: MFG DATE:
NORFOLK, VA 23502 USA 757-855-6006
PANEL:
ASY-0819
60/75° C COPPER WIRE ONLY Terminal Wire Range Torque
600 VAC Max. 3 Ph 60Hz
1 Ph 60Hz
120V 230V 208V 230V 460V 380V N/A N/A
10HP 42A
N/A N/A
N/A N/A
2/2004
UL File No. E109698
MAXIMUM RATING (AC3)
600 VAC Max.
43857
N/A N/A
N/A N/A
Line
awg 10-3
45 in-lb
Load
awg 10-0
100 in-lb
Ground
awg 14-2
35 in-lb
This electrical panel will power up to a single 20 HP NEMA Design B motor at 208 VAC or up to a single 50 HP NEMA Design B motor at 460 VAC. The panel is provided with a 120 VAC, 200 VA, singlephase transformer for powering 120-volt loads. 120 VAC single-phase panel loads are as follows: AC Power Available Light Warning & Alarm lights ACD coils (up to 4) Motor Starter coil (max) CO Monitor Solenoid valve CO Monitor power Securus® Electronic Moisture Monitor System PLC Controller
Transformer and Fuses
53
Negligible Negligible 35 W each maximum, with 3 max energized 26.0 VA (sealed, max) 8W 0.9 W 20.4 VA 22.0 VA
CHAPTER 4: TROUBLESHOOTING WARNING Compressor repairs are to be performed by an authorized dealer/service center only. Any repairs made by the user are to be made at the user’s own risk and will void Brownie’s Third Lung warranty unless the user has been authorized to make a repair and has been given appropriate repair instructions. Repairs must never be carried out without sufficient knowledge and understanding of compressor technology. If you have any questions or are unsure of a problem’s cause, contact our Service Department for advice prior to disassembly of the unit or component parts.
PROBLEM
CAUSE
ACTION
Unit does not start
a) Power off b) Loose electrical connections c) Bad internal fuse d) Overload in motor activated
a) Check breaker b) Check electrical connections & retighten c) Check electrical legs for proper voltage and replace fuse if necessary d) Press reset button
Not automatically draining (ACD does not operate properly)
a) Line valve closed b) Loose electrical terminal at solenoid c) Bad solenoid d) Bad drain timer
a) Make sure line valve is fully open b) Make sure connections are tight at solenoid c) Remove and replace solenoid d) Replace drain timer
Compressor does not reach final pressure
a) Leak in tubing or Automatic Condensate Drain b) Final pressure safety valve blows too soon (defective) c) Service unloader valve
a) Tighten all threaded attachments and connectors. b) Replace safety valve c) Unloader valve needs service
Pressure Relief valves of 1st and 2nd Stages engage
a) Intermediate pressures too high b) Pressure relief valve leaking c) Check valve bad on ACD
a) Check intake valve of next stage: Clean it (replace if necessary) b) Replace pressure relief valve
Air delivery rate decreases
a) piston rings worn out b) 1st stage valve leaking c) Intake filter soiled d) Pipe coupling leaking e) Excessive wear of 3rd stage f) Drive belt slipping
a) Replace piston rings b) Replace intake valve c) Clean or replace filter d) Retighten couplings e) Replace piston and sleeve of 3rd stage piston f) Tighten or replace drive belt
NOTE Troubleshooting of electrical problems may require the use of a multimeter with AC capability.
54
PROBLEM
CAUSE
ACTION
Intermediate pressure safety valve blows
a) Intermediate pressure too high due to defective inlet or pressure valve of the next stage b) Safety valve leaking
a) Check / replace inlet or pressure valve b) Replace safety valve
Any taste in air
a) Filter cartridge saturated b) Unqualified lubricant being
a) Replace cartridge b) Replace oil with an approved brand used c) Air Test (contact our Service Dept for kit)
Compressor overheats
a) Insufficient cooling air b) Ambient temp. too high c) Direction of rotation wrong d) Inlet/pressure valves on one
a) Inlet and pressure valve of one stage incorrect leaking: direction of rotation b) Check location, ventilation for max +100º F (+38º C) c) Check / correct rotation d) Check valves, clean or replace stage leak
Unit cannot be switched off Unit runs rough and/or vibrates
a) Turn breaker off b) Call Brownie’s for technical advice a) Drive belt worn out b) Drive belt loose
a) Replace drive belt b) Tighten drive belt
If you encounter a problem that cannot be solved with this troubleshooting guide, please contact an authorized Brownie’s Third Lung Service Center. In the case of problems with the electrical system, consult a qualified electrician for repairs. When you call for service or technical advice, please have the following information: a) unit serial number and/or model number b) hours of operation
55
CHAPTER 5: LOGS 5.1 YACHT PROTM SYSTEM OPERATION LOG We recommend that all maintenance work be recorded, showing the date and details of the work carried out. DATE
HOURS
TECHNICIAN/ AMBIENT AIR CHECK MAINTENANCE PERFORMED/ SERVICE CENTER TEMP COMMENTS c aUpon Completion c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
KEEP THIS LOG MAINTAINED!!! Brownie’s recommends making copies of these blank pages for future use. Completed pages should be copied and kept in a safe place.
NOTE All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the Brownie’s service department. Use records of ambient temperature to determine actual filter life. 56
5.1 YACHT PROTM SYSTEM OPERATION LOG We recommend that all maintenance work be recorded, showing the date and details of the work carried out. DATE
HOURS
TECHNICIAN/ AMBIENT AIR CHECK MAINTENANCE PERFORMED/ SERVICE CENTER TEMP COMMENTS c aUpon Completion c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
KEEP THIS LOG MAINTAINED!!! Brownie’s recommends making copies of these blank pages for future use. Completed pages should be copied and kept in a safe place.
NOTE All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the Brownie’s service department. Use records of ambient temperature to determine actual filter life. 57
5.1 YACHT PROTM SYSTEM OPERATION LOG We recommend that all maintenance work be recorded, showing the date and details of the work carried out. DATE
HOURS
TECHNICIAN/ AMBIENT AIR CHECK MAINTENANCE PERFORMED/ SERVICE CENTER TEMP COMMENTS c aUpon Completion c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
KEEP THIS LOG MAINTAINED!!! Brownie’s recommends making copies of these blank pages for future use. Completed pages should be copied and kept in a safe place.
NOTE All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the Brownie’s service department. Use records of ambient temperature to determine actual filter life. 58
5.1 YACHT PROTM SYSTEM OPERATION LOG We recommend that all maintenance work be recorded, showing the date and details of the work carried out. DATE
HOURS
TECHNICIAN/ AMBIENT AIR CHECK MAINTENANCE PERFORMED/ SERVICE CENTER TEMP COMMENTS c aUpon Completion c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
KEEP THIS LOG MAINTAINED!!! Brownie’s recommends making copies of these blank pages for future use. Completed pages should be copied and kept in a safe place.
NOTE All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the Brownie’s service department. Use records of ambient temperature to determine actual filter life. 59
5.1 YACHT PROTM SYSTEM OPERATION LOG We recommend that all maintenance work be recorded, showing the date and details of the work carried out. DATE
HOURS
TECHNICIAN/ AMBIENT AIR CHECK MAINTENANCE PERFORMED/ SERVICE CENTER TEMP COMMENTS c aUpon Completion c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
KEEP THIS LOG MAINTAINED!!! Brownie’s recommends making copies of these blank pages for future use. Completed pages should be copied and kept in a safe place.
NOTE All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the Brownie’s service department. Use records of ambient temperature to determine actual filter life. 60
5.1 YACHT PROTM SYSTEM OPERATION LOG We recommend that all maintenance work be recorded, showing the date and details of the work carried out. DATE
HOURS
TECHNICIAN/ AMBIENT AIR CHECK MAINTENANCE PERFORMED/ SERVICE CENTER TEMP COMMENTS c aUpon Completion c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
c c c c
Oil Level Purification CO Sightglass Air Intake
KEEP THIS LOG MAINTAINED!!! Brownie’s recommends making copies of these blank pages for future use. Completed pages should be copied and kept in a safe place.
NOTE All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the Brownie’s service department. Use records of ambient temperature to determine actual filter life. 61
5.2 NOTES
62
CHAPTER 6: WARRANTY BROWNIE’S THIRD LUNG warrants that this tank fill compressor system conforms to applicable drawings and specifications approved in writing by BROWNIE’S THIRD LUNG, and that the compressor and BROWNIE’S THIRD LUNG manufactured components are free of defects in both material and workmanship for a period of eighteen months from the date of shipment from BROWNIE’S THIRD LUNG, or 12 months from date of start-up, whichever occurs first. WARRANTY REGISTRATION CARD must be on file at BROWNIE’S THIRD LUNG within 30 days of start-up. If, within such periods, BROWNIE’S THIRD LUNG receives from the Buyer written notice of any alleged defect or non-conformance in the compressor system, and if in the judgement of BROWNIE’S THIRD LUNG the system does not conform or is found to be defective in the material or workmanship, BROWNIE’S will, at its option, either: a. Upon return of the component F.O.B. to BROWNIE’S THIRD LUNG in Ft Lauderdale, Florida, USA, the part will be repaired or replaced, or credit issued (defective material must be shipped within 30 days of receipt of authorized return instructions), with return freight charges to be incurred by the Buyer, or b. Furnish a service representative to correct the defective workmanship. Deterioration or wear occasioned by chemical and/or abrasive action, excessive heat or abuse shall not constitute defects. The sole responsibility of BROWNIE’S THIRD LUNG and Buyers exclusive remedy hereunder is limited to such repair, replacement, and repayment of the purchase price. Component parts or assemblies not manufactured by BROWNIE’S THIRD LUNG are warranted only to the extent that they are warranted by the original manufacturer. BROWNIE’S THIRD LUNG shall have no responsibility for any cost or expense incurred by Buyer due to the inability of BROWNIE’S THIRD LUNG to repair under said warranty when such inability is beyond the control of BROWNIE’S THIRD LUNG, or caused solely by the Buyer. THERE ARE NO OTHER WARRANTIES, EXPRESSED, STATUTORY, OR IMPLIED, INCLUDING THOSE OF MERCHANTABILITY AND/OR FITNESS FOR PURPOSE; NOR ANY AFFIRMATION OF FACT OR REPRESENTATION WHICH EXTENDS BEYOND THE DESCRIPTION ON THE FACE HEREOF. This warranty shall be void and BROWNIE’S THIRD LUNG shall have no responsibility to repair, replace, or repay the purchase price of defective or damaged parts or components resulting directly or indirectly from the use of repair or replacement parts including filters or oil, not manufactured or approved by BROWNIE’S THIRD LUNG or from Buyer’s failure to store, install, maintain, and operate the compressor according to recommendations contained in the OWNER’S MANUAL included with your compressor and standard engineering practices.
BROWNIE’S THIRD LUNG 940 NW First Street Fort Lauderdale, FL 33311 (800) 327-0412 (954) 462-5570 FAX (954) 462-6115 www.tankfill.com / info@tankfill.com
63
BROWNIE’S THIRD LUNG 940 NW First St, Fort Lauderdale, FL 33311 Ph (954) 462-5570 Fx (954) 462-6115 www.tankfill.com info@tankfill.com
