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Summary of Contents for Brownie’s Yacht Pro 135
- Page 1 Yacht Pro 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...
- Page 2 Thank You for purchasing a Brownie’s Yacht Pro 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.
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Page 3: Table Of Contents
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 CHAPTER: 2 OPERATIONS 2.1 Pre Start-up Checks 2.1.1 Check oil level 2.1.2 Check Visual Carbon Monoxide / Moisture Indicator... - Page 4 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...
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Page 5: Chapter 1: Introduction
WARNING This Instruction Manual and Replacement Parts List contains safety information and instructions for the YachtPro 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... -
Page 6: General Safety Precautions
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 mea- sures 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. -
Page 7: Description Of Unit
• Before working on the electrical system, be sure to disconnect the electrical supply from the system at the cir- cuit 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. •... -
Page 8: Compressor Quality Analysis Record
1.6 COMPRESSOR QUALITY ANALYSIS RECORD Date: Serial # Model # Order# Motor Wiring Belt Size Tension Connections Tight Nuts & Bolts Tight No Leaks Control Wiring Correct Final Pressure Setting Tank Fill Time (80 ft³ 500-3000 PSI) Drain System Operation Interval Oil Level Oil Removed... -
Page 9: Product Data
1.7 PRODUCT DATA Category Specifications COMPRESSOR DATA Air Delivery Rate: 10.8 scfm FAD/ 142 LPM * Operating Pressure (max): 6000 PSI ** Pressure setting, final: 3200 PSI pressure safety valve (STD) Dimensions: 27.5”H x 36”L x 21”D (699mm x 914mm x 533mm) Weight: 350 lbs. -
Page 10: Installation
1.8 INSTALLATION WARNING Improper installation may result in damage to the unit, personal injury or death. All persons operating the Yacht Pro 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. -
Page 11: Chapter: 2 Operations
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: •... -
Page 12: Tankfill Procedures
2.2 TANKFILL PROCEDURES Tank Fill Whip Assemblies: Shown are the tankfill whip ends for DIN and Yoke systems. A. Yoke connector B. DIN connector C. bleeder valve D. fill valve WARNING Tanks must be secured (protected from falling or being knocked over) during filling. - Page 13 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.
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Page 14: Lubrication Specifications
2.3 LUBRICATION SPECIFICATIONS Lubricant O-rings, rubber and plastic parts, White Petroleum DAB9 # N19091 or WEICON WP 300 filter housing threads 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 Compounds with Copper or MoS²... -
Page 15: Chapter 3: Maintenance And Parts
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 SERVICE CENTER After 25 hrs initially, Oil Change (every 50 hours when using regular and every 50 - 100 hrs oil, and every 100 hours if using synthetics) or six... -
Page 16: Compressor Block
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. -
Page 17: Intake Filter
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. -
Page 18: Oil Change Procedure
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. -
Page 19: Check Drive Belt/Replace Belt
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. -
Page 20: Intermediate Separators
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 1. - Page 21 3rd Stage Intermediate Separator 1. Vortex Plate 4. O-ring 7. Fitting 2. Hollow Screw 5. Knurled Nut 8. Safety Valve 3. Center Insert 6. Gasket 1.1.5.1 Maintenance The Intermediate Separator requires no maintenance. ^ WARNING The rapid depressurizing and repressurizing of the intermediate separator during condensate draining sub- jects it to metallurgical stresses.
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Page 22: Cooling System
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. -
Page 23: Torque Valves And Sequencing
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. -
Page 24: Valves
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. -
Page 25: Reassembly
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. -
Page 26: Changing The 2Nd Stage Valves
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. -
Page 27: Changing The 3Rd Stage Valves
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. -
Page 28: Reassembly
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. -
Page 29: Changing The 4Th Stage Valves
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. -
Page 30: Reassembly
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. - Page 31 This page is inserted to provide proper page sequencing...
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Page 32: Crankcase Assembly
3.12 EXPLODED VIEW DIAGRAMS 3.12.1 Crankcase Assembly Crankcase Assembly # KIT Qty Part No. Description Notes 076743 Crankcase assembly … 076740 Crankcase … 083467 Crankshaft, complete … N2638 Roller Bearing … N2635 Circlip … 66209 Bearing Cap … N15406 Roller Bearing …... - Page 33 Crankcase Assembly cont. # KIT Qty Part No. Description Notes 12 … N15412 O-ring 13 … 73830 Oil Filling Pipe 14 … N4776 O-ring 15 … SCR-0020 Allen Screw 16 … WAS-0021 Washer 17 a.. N4163 Gasket 18 … PLU-0040 Plug 19 …...
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Page 34: 1St/2Nd Stage Piston And Cylinder
1st/2nd Stage Piston and Cylinder 3.12.2 1st/2nd Stage Piston and Cylinder # KIT Qty Part No. Description Notes � 84240 1st/2nd Stage Cylinder Assembly … 80729 Stepped Cylinder N4654 O-ring � 84238 Piston Assembly Item 3 - 8 … N28554 Guide Ring …... -
Page 35: 3Rd Stage Piston And Cylinder
3.12.3 3rd Stage Piston and Cylinder 3rd Stage Piston and Cylinder # KIT Qty Part No. Description Notes � 78335 3rd Stage Cylinder Assembly … 67940 Cylinder N7063 O-ring … 83404 Guide Cylinder N2640 O-ring � 78334 Piston Assembly Items 5 - 8 …... -
Page 36: 4Th Stage Piston And Cylinder
4th Stage Piston and Cylinder 3.12.4 4th Stage Piston and Cylinder # KIT Qty Part No. Description Notes 083457 4th Stage Cylinder Assembly N4868 O-ring … 082480 Cylinder … N27318 Screw N7063 O-ring … 083404 Guide Cylinder N2640 O-ring 072165 Guide Piston Assembly Items 7 - 9 …... -
Page 37: 1St Stage Valve Head And Valve
1st Stage Valve Head and Valve 3.12.5 1st Stage Valve Head and Valve # KIT Qty Part No. Description Notes 083652 1st Stage Valve Head Assembly … N26531 Reed Valve … 080677 Valve Head … N102 Washer … N26568 Hex Head Screw …... -
Page 38: 2Nd Stage Valves And Valve Head
3.12.6 2nd Stage Valves and Valve Head 2nd Stage Valves and Valve Head # KIT Qty Part No. Description Notes � 073435 Valve Head, 2nd Stage … 78562 Manifold 56668 Gasket N4067 Intake Valve N4068 Pressure Valve … SCR-0133 Allen Screw... -
Page 39: 3Rd Stage Valves And Valve Head
3rd Stage Valves and Valve Head 3.12.7 3rd Stage Valves and Valve Head # KIT Qty Part No. Description Notes � 069792 3rd Stage Valve Head Assembly … 14123 Valve Head Gasket 012836 Intake Valve … 014582 Pressure Valve Assembly Items 2, 5, &... -
Page 40: 4Th Stage Valve And Valve Head
3.12.8 4th Stage Valves and Valve Head 4th Stage Valves and Valve Head # KIT Qty Part No. Description Notes � 082096 4th Stage Valve Head Assembly 81409 Intake Valve … 65191 Valve Head … N2789 O-ring 014121 Pressure Valve Includes Item 3 …... -
Page 41: Intermediate Separator
3.12.9 Intermediate Separator Intermediate Separator # KIT Qty Part No. Description Notes � 080690 Intermediate Separator Items 1 - 7 … † 080691 Separator Head Available only with 080690 N3556 O-ring … 076613 Screw-in Insert … 13937 Knurled Nut … †... -
Page 42: 3Rd Stage Intermediate Separator
3rd Stage Intermediate Separator 3.12.10 3rd Stage Intermediate Separator # KIT Qty Part No. Description Notes � 081799 Intermediate Separator Assembly Items 1 - 7 … 81148 Plate … 81643 Hollow Screw … 76613 Inset Assembly … N3556 O-ring … 13937 Knurled Ring …... -
Page 43: Intake Filter
Intake Filter 3.12.11 Intake Filter # KIT Qty Part No. Description Notes � 79577 Intake Filter Assembly … N4870 Knurled Nut … N3313 Washer … 79574 Filter Housing, Front N25950 Filter Element … 79575 Filter Housing, Back … N19502 Hex Head Bolt …... -
Page 44: Cooling System
3.12.12 Cooling System Cooling System 41 40 12 13 14 # KIT Qty Part No. Description Notes 78293 Cooling System Assembly … 078295 1st - 2nd Stage Intercooler … N20202 Fitting … 78854 Connecting Tube … N25451 Gasket … N25452 O-ring …... - Page 45 Cooling System, IK12.14 II (con’t.) # KIT Qty Part No. Description Notes 17 … 056983 Gasket 18 … 071148 Connector, Male 19 … N19501 Hexagon Screw 20 … NUT-0118 Hexagon Nut Self Locking 21 … N03313 Washer 22 … WAS-0024 Washer 23 …...
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Page 46: Lubrication System
3.12.13 Lubrication System Lubrication System # KIT Qty Part No. Description Notes � 83417 Lubrication System Assembly � 081075 Lubricating System Items 1 - 15 … 77885 Oil Filter Cover … N4058 O-ring … N25327 O-ring … 77774 Rubber Gasket …... - Page 47 # KIT Qty Part No. Description Notes … N24585 Gear Pump 10 … N3489 O-ring 11 … N19506 Hex Head Screw 12 … Gasket 13 … 81050 Regulating Valve 14 … N1316 Gasket 15 … Plug 16 … N123 Allen Screw 17 …...
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Page 48: Sightglass Co/Moisture Element Replacement Procedure
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 DO NOT USE AIR GOOD Outer Ring - Blue CHANGE CARTRIDGE SATURATED GOOD 1. - Page 49 5. The CO monitoring disc is shown ready to 6. The spring is placed into the window, centered on the install into the window. It is placed in and CO disc and the whole unit is then ready to be reas- then centered in the moisture indicator ring.
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Page 50: Compressor Components
3.14 COMPRESSOR COMPONENTS... -
Page 51: Compressor Details
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 (manufacturers manual can be Automatic Drain found at the back of this manual) Solenoid Valve Hyme Joint Condensate Drain Bottle... -
Page 52: Mechanical Separator
3.14.2 MECHANICAL SEPARATOR Oil and Water Separator 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 Oil and Water Separator separator works by means of a sintered metal filter which sepa- rates liquid oil and water particles from the compressed air. -
Page 53: Electrical Panel
3.15 ELECTRICAL PANEL Electrical Panel Label MODEL: SERIAL: 43857 BLOCK: NORFOLK, VA 23502 USA MFG DATE: 2/2004 757-855-6006 PANEL: ASY-0819 UL File No. 109698 MAXIMUM RATING (AC3) 60/75° C COPPER WIRE ONLY 600 VAC Max. 600 VAC Max. Terminal Wire Range Torque 3 Ph 60Hz 1 Ph 60Hz... -
Page 54: Chapter 4: Troubleshooting
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. - Page 55 PROBLEM CAUSE ACTION Intermediate pressure safety a) Intermediate pressure too high a) Check / replace inlet or pressure valve blows due to defective inlet or pressure valve valve of the next stage b) Replace safety valve b) Safety valve leaking Any taste in air a) Filter cartridge saturated a) Replace cartridge...
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Page 56: Chapter 5: Operation Log
CHAPTER 5: LOGS 5.1 YACHT PRO 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 Upon Completion c Oil Level c Purification c CO Sightglass... - Page 57 5.1 YACHT PRO 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 Upon Completion c Oil Level c Purification c CO Sightglass c Air Intake...
- Page 58 5.1 YACHT PRO 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 Upon Completion c Oil Level c Purification c CO Sightglass c Air Intake...
- Page 59 5.1 YACHT PRO 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 Upon Completion c Oil Level c Purification c CO Sightglass c Air Intake...
- Page 60 5.1 YACHT PRO 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 Upon Completion c Oil Level c Purification c CO Sightglass c Air Intake...
- Page 61 5.1 YACHT PRO 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 Upon Completion c Oil Level c Purification c CO Sightglass c Air Intake...
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Page 62: Notes
5.2 NOTES... -
Page 63: Chapter 6: Warranty
CHAPTER 6: WARRANTY BROWNIE’S THIRD LUNG warrants that this tank fill compressor system conforms to applicable draw- ings 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 work- manship 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. - Page 64 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...
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