Table of Contents
Advertisement
Quick Links
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
WARNING
THIS PRODUCT MUST ONLY BE INSTALLED IN
SYSTEMS WHICH HAVE BEEN DESIGNED BY THOSE
QUALIFIED TO ENGINEER SUCH SYSTEMS. THE
SYSTEM MUST BE IN ACCORDANCE WITH ALL
APPLICABLE REGULATIONS AND SAFETY CODES
AND WARN OF ANY HAZARDS UNIQUE TO THE
PARTICULAR SYSTEM.
WARNING DANGER
DO NOT ATTEMPT TO OPEN THE COMPRESSOR
UNTIL YOU HAVE BLED OFF ALL PRESSURE. THE
COMPRESSOR VALVES MAY HOLD PRESSURE
INDEFINITELY IN THE DISCHARGE PIPING
CAUTION:
IF SYSTEM IS TO BE HYDROSTATICALLY TESTED,
COMPRESSOR MUST BE ISOLATED. WATER
ENTERING THE UNIT CAN CAUSE CORROSION AND
NOTE NAMEPLATE DATA HERE
MODEL: HD
ID#:
SERIAL NUMBER:
Before proceeding:
1. Note the nameplate data in the space provided above.
2. Obtain the appropriate parts lists for the model in question.
3. These compressors are used on a wide variety of gasses.
Before doing any work on the compressor, be certain of the identification of the
gas and the precautions to be followed when around that gas.
COMPRESSORS
DISCONTINUED
HD161A
HD361A
HD601A
DAMAGE.
MODELS
HD162A
HD163A
HD362A
HD363A
HD602A
HD603A
TABLE OF CONTENTS
GENERAL INFORMATION.............................2
OPTIONAL COMPONENTS ...........................6
Temperature and Pressure Switches
INSTALLATION ..............................................7
OPERATION ...................................................8
MAINTENANCE ..............................................9
Bolt Torque Table
Crankcase Lubrication / Oil Capacity
Rotation Direction
EXTENDED STORAGE PROCEDURES......23
TROUBLESHOOTING ..................................24
CB9A-020 2009/10
www.blackmer.com
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for BLACKMER HD161A
Summary of Contents for BLACKMER HD161A
-
Page 1: Table Of Contents
COMPRESSORS CB9A-020 2009/10 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS DISCONTINUED MODELS HD161A HD162A HD163A HD361A HD362A HD363A HD601A HD602A HD603A WARNING TABLE OF CONTENTS THIS PRODUCT MUST ONLY BE INSTALLED IN GENERAL INFORMATION......2 SYSTEMS WHICH HAVE BEEN DESIGNED BY THOSE Compressor Data QUALIFIED TO ENGINEER SUCH SYSTEMS. -
Page 2: General Information
Type: Single-stage, vertical, air-cooled reciprocating with single acting cylinders. NOTE: Reduce maximum speeds by 9% for continuous duty operation. NAMEPLATE DATA A nameplate is attached to the side of all Blackmer compressors showing the Model No., I.D. No., and Serial No. These numbers... - Page 3 GENERAL INFORMATION HD SINGLE-STAGE COMPRESSORS ID NUMBER KEY VALVES Code Fields TNT-12 steel 1 & 2 TNT-12 steel w/ Unloaders Ductile Iron / PEEK DI/PEEK w/ Unloaders TNT-12 DI/PEEK TNT-12 DI/PEEK w/ Unloaders Stainless Steel SS w/ Unloaders O-RINGS Field 3 Buna-N Neoprene PTFE...
-
Page 4: Maximizing Compressor Life
Compressors may be fitted with suction valve unloaders to provide loadless start or capacity control functions. Blackmer unloaders are basically a piston and a plunger atop the suction valve. When pressure is applied to the top of the unloader piston, it and the plunger move downward, pushing the suction valve off its seat and unloading the compressor. -
Page 5: Seal Arrangements
GENERAL INFORMATION TYPICAL SEAL AREA CONSTRUCTION SEAL ARRANGEMENTS - ALL DOUBLE SEAL COMPRESSORS Type Inlet Atmospheric Pressure or above Vacuum to 25 psia Pressure Service General Gas Toxic, Flammable or otherwise Hazardous Gases General Gas Special Transfer Transfer Upper Plugged Purge with Inert gas below suction Pressurize Connect to:... -
Page 6: Optional Components
The relief valve should be installed in the discharge line between the compressor head and the first block valve. The type of relief valve should be appropriate to the application. Blackmer offers three relief valves for gas compatibility: brass for LP-Gas service; aluminum for anhydrous ammonia; A.S.M.E. steel for both services, and other applications. -
Page 7: Installation
OPTIONAL COMPONENTS LOW OIL PRESSURE SWITCHES Loss of crankcase oil pressure is a rare occurrence, but can result in costly damage. A low oil pressure switch set at about 15 psig (1 bar-g) may be installed to stop the compressor in the event of a lubrication failure. A 10 second delay timer should be used to lock the low oil pressure switch out during compressor startup. -
Page 8: Operation
Check the electrical connections for proper wiring, grounding, etc. Blackmer compressors are shipped from the factory without oil in the crankcase. Fill with a high quality oil of the proper viscosity (see "Lubrication"). -
Page 9: Maintenance
MAINTENANCE MAINTENANCE AND TROUBLESHOOTING MUST BE DONE BY AN INDIVIDUAL EXPERIENCED WITH COMPRESSOR MAINTENANCE AND THE TYPE OF SYSTEM INVOLVED. CAUTION: Before work is started on the compressor make sure all pressure is bled off on both the suction and discharge. NOTE: When servicing the compressor, refer to the appropriate Parts Lists for detailed exploded views of the compressor parts. -
Page 10: Tool List
Crankshaft Bearings Torque Wrench, 0 to 45 ft-lb range Various Hoist (useful) Cylinder and Crosshead Guide BOLT TORQUES Proper bolt torques to use when reassembling the compressor. BOLT TORQUE FOR BLACKMER COMPRESSORS FT-LBS (Nm) Size Con. Bearing Bearing Crank Cross... - Page 11 MAINTENANCE CRANKCASE LUBRICATION Non-detergent motor oils are recommended. However, detergent oils can be used providing the gas being handled does not react with the detergent in the oil. If using a detergent oil, be sure there is not a compatibility problem.
-
Page 12: Compressor Disassembly
For valve disassembly instructions refer to "Valve Replacement." Removal of the piston requires a 3" adjustable spanner wrench with 1/4" pins (such as Blackmer PN 790316) Rotate the flywheel by hand to bring a piston to top dead center of the cylinder. -
Page 13: Compressor Assembly
MAINTENANCE Lift the crosshead assembly and connecting rod off the top of the crankcase. NOTE: The connecting rod parts are not interchangeable and must be reassembled with the same upper and lower halves. To avoid confusion, it is advisable to work on one connecting rod at a time, or to mark the individual halves with corresponding numbers. - Page 14 Before installing the packing boxes into the crosshead guide, inspect the piston rods for scoring or roughness. Remove any burrs or sharp edges. Lubricate the piston rods and packing box O-rings with light oil. Do not damage the packing when starting it over the rod. Use of a Blackmer packing installation tool is recommended.
- Page 15 MAINTENANCE 10. PISTONS a. If necessary, replace the piston rings and piston ring expanders (see "Piston Ring Replacement"). b. Rotate the flywheel by hand to bring one piston rod to top dead center of the cylinder assembly. c. Set one (1) thrust washer and one (1) shim down against the shoulder of the piston rod. d.
-
Page 16: Valve Replacement
MAINTENANCE VALVE REPLACEMENT When replacing the valves, it is important to install the suction and discharge valves in the correct location in the cylinder head. NOTE: The valves may be removed without removing the cylinder head from the cylinder. Be sure to remove and replace the valve gaskets. - Page 17 1. Remove the valve cap (or unloader assembly) and O-ring from each valve. 2. Remove the valve hold down screw with a spanner wrench (such as Blackmer PN 790535). 3. Valve Removal and Disassembly Models HD161, HD162 & HD163 a.
-
Page 18: Unloader Seal Replacement
MAINTENANCE To reinstall valves: a. Install a new valve gasket into the cylinder head (remove any old gaskets). b. Install the valve assembly in the cylinder head. Make sure the valve's orientation and location are correct. c. Center the valve cage on the valve assembly. d. -
Page 19: Seal (Packing) Replacement
MAINTENANCE SEAL (PACKING) REPLACEMENT Follow the "Compressor Disassembly" section to remove the packing boxes. Remove the upper and lower retainer ring from the packing box being serviced. Disassemble the packing box and discard the old packing sets and packing springs. NOTE: Before reassembling the packing boxes, refer back to "Seal Arrangements". - Page 20 MAINTENANCE Packing boxes may contain either one or two sets of packing, depending on the compressor being serviced. To reassemble a packing box: Clean the packing box in a suitable solvent. Inspect the bore for wear, roughness, or corrosion. Install the first retainer ring (start with the inner ring on two seal packing boxes). See "Seal Arrangements"...
-
Page 21: Bearing Replacement
MAINTENANCE BEARING REPLACEMENT NOTE: When replacing the bearings, the entire bearing assembly, including the bearing cup and the bearing cone, must be replaced. Follow steps "Compressor Disassembly." Remove the Oil Pump per the section on "Oil Pump Replacement". Remove the flywheel. Remove the bearing carrier and gasket from the outboard end of the crankcase. -
Page 22: Oil Pump Replacement
MAINTENANCE OIL PUMP REPLACEMENT Remove the oil pump cover bolts and the oil pump cover. Remove the cover O-ring, oil pump ring and shaft assembly. Clean, inspect and replace parts as necessary. Place the oil pump shaft assembly (complete with oil pump rotor, key, retainer ring and new shaft O-ring) into the bearing housing. -
Page 23: Extended Storage Procedures
EXTENDED STORAGE PROCEDURES If a compressor is not to be put into service for some time, or if a compressor is to be taken out of service for an extended period, the following procedures should be taken. Fill the crankcase with rust inhibiting oil. (New compressors are shipped from the factory without oil.) Squirt oil on the piston rods and crossheads through the nameplate opening. -
Page 24: Troubleshooting
TROUBLESHOOTING PROBLEM STEP PROBABLE CAUSE WHAT TO CHECK IF PROBLEM STILL EXISTS GO TO STEP ... Low Transfer Worn or Broken Piston Rings Check condition of rings by restricting Rate discharge line. If pressure increases slowly, rings are probably faulty. Compressor Valve Faulty Remove and inspect for broken or worn springs, discs, or bodies.
Need help?
Do you have a question about the HD161A and is the answer not in the manual?
Questions and answers