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Brownie’s YachtPro YP55DF Operator's Manual

Automatic compressor
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YachtPro™ Automatic
Compressor Operator's Manual
YP55DF
YP75DF

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Summary of Contents for Brownie’s YachtPro YP55DF

  • Page 1 YachtPro™ Automatic Compressor Operator’s Manual YP55DF YP75DF...

  • Page 3: Preface

    PREFACE Thank You for purchasing a Brownie’s Yacht Pro Series Compressor System. This manual ex- plains 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 unan- nounced changes at any time without incurring any obligations whatsoever.

  • Page 4: Table Of Contents

    Table of Contents Preface Table of Contents Quality Analysis Product Data Description of Unit Standard Features Installation Pre Start-Up Checks Tankfill Procedures Purification System Lubrication Specifications Maintenance Schedule Torque Valves and Sequencing Valves Drive Belt V-belt Tension Adjustment Cooling System Oil Level Check Oil Types Intake Filter...

  • Page 5: Quality Analysis

    COMPRESSOR QUALITY ANALYSIS RECORD 07/20/2010 Date: Serial # Model # Order# 16906 YP55DF-M 98840 Motor Wiring AP69 Belt Size Tension Connections Tight Nuts & Bolts Tight No Leaks Control Wiring Correct 3200 PSI 13 min. Final Pressure Setting Tank Fill Time (80 ft³...

  • Page 6: Product Data

    Product Data Category Specifications Air Delivery Rate: YP55DF 5.0 scfm FAD/ 142 LPM YP75DF 7.0 scfm FAD/ 198 LPM * Operating Pressure (max): 5000 PSI ** Pressure setting, final 3200 PSI pressure safety valve (STD) Dimensions: 33“ L x 20.5“ W x 22“ H Weight: YP55DF 220 lbs.

  • Page 7: Description Of Unit

    DESCRIPTION OF THE UNIT: Your Yacht Pro 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. STANDARD FEATURES The complete Yacht Pro Series package includes: •...

  • Page 8: Installation

    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 under- stand the procedures for system operation and the responsibilities of the operator to insure the safety of divers supplied with air from the system.

  • Page 9: Pre Start-Up Checks

    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. PRE START-UP CHECKS Consult the system log to see if the following maintenance needs to be done: •...

  • Page 10: Tankfill Procedures

    TANKFILL PROCEDURES (See Demonstration p 24-26) 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. Slightly open tank valve just long enough to blow any moisture or particles clear of connection surfaces. 3.

  • Page 11: Purification System

    PURIFICATION SYSTEM Explanation: The YP55DF and YP75DF compress air in three stages. Air leaving the outlet (discharge) of each stage is at an elevated temperature. The air passes through cooling tubes and the temperature is reduced prior to entering the inlet of the next stage.
  • Page 12 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. MAINTENANCE TYPE OF MAINTENANCE DATE SERVICE INTERVAL CENTER After 25 hrs initially, and Oil Change (every 50 hours when using regular oil, every 50 - 100 hours and every 100 hours if using synthetics) or thereafter...

  • Page 13: Torque Valves And Sequencing

    TORQUE VALUES AND SEQUENCING 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. Screw or Bolt Thread Max Torque Hex and Allen Head...

  • Page 14: Valves

    VALVES 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.
  • Page 15 CHANGING THE 2ND STAGE VALVES • Remove the intake and pressure lines from the valve head (7). • Remove the screws (8) holding the valve head onto the cylinder. • 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.

  • Page 16: Drive Belt

    CHECKING THE DRIVE BELT/REPLACING 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 17: Oil Level Check

    OIL LEVEL CHECK Check the oil level at the sight glass on the side of the com- pressor block everyday before operating the compressor. Note that the oil level must be between the minimum and maximum notches. 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.

  • Page 18: Sightglass Element Change Demonstration

    SIGHTGLASS CO MOISTURE ELEMENT CHANGE DEMONSTRATION Replacement Element Part #M7414 (Assy #VM211-EL) WARNING: Make sure all pressure is relieved prior to changing element. 1. Unscrew window cap in counter-clockwise 2. Here the cap is shown having been re- direction. (NOTE: The orientation of the sight- moved, and the retaining spring exposed.
  • Page 19 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.

  • Page 20: Black Filter Cartridge Replacement Demonstration

    BLACK FILTER CARTRIDGE REPLACEMENT DEMONSTRATION REPLACEMENT CARTRIDGE PART #X53240 WARNING: Prior to changing the filter, purge all pressure using the bleeder valve. 1. Remove Cap 2. Remove Old Filter Counter-clockwise rotation of the cap using a wrench as shown will loosen the cap for removal. While removing the old filter, check the Lifeband ™...
  • Page 21 6. Replace Cap 5. Prepare to replace cap Clockwise rotation of the cap using a wrench as Inspect o-rings for damage and replace if necessary. shown will tighten the cap for replacement. Use a food grade silicone grease to lube threads and ring if needed.

  • Page 22: Gold Filter Cartridge Replacement Demonstration

    GOLD FILTER TOWER CARTRIDGE REPLACEMENT DEMONSTRATION 2. Remove Cap 1. Vent Pressure Insert rod tool into holes in cap and Prior to changing the filter, purge all pressure us- turn counter-clockwise. ing the bleeder valve. It may be necessary to vent excess pressure by turning the small cap on the gold tower clockwise.
  • Page 23 6. Lubricate O-ring Inspect o-rings for damage and replace if necessary. Use a food grade silicone grease to lube threads and ring if needed. 5. Install Cartridge Insert new cartridge making sure to push down as far as possible. Figure 2 Gold Filter Cartridge 7.

  • Page 24: Tankfill Demonstration

    TANKFILL DEMONSTRATION 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 NOTE: Remember to check the system log before compressor use and to update the system log after you are done.
  • Page 25 2. Close Bleeder Valves Clockwise rotation of the valve closes the bleeder valve. 3. Open Tank Valves Counter-clockwise rotation of this valve will open the tanks for filling. 4. Open Fill Valves Counter-clockwise rotation of this valve will open the line to the tanks.
  • Page 26 NOTE: If you are filling more tanks, the compressor may be left “ON”. 6. Close Fill Lines Clockwise rotation of the knob closes off the fill lines. 7. Close Tanks Clockwise rotation of the knob closes the tank valves. 8. Open Bleeder Valves Counter-clockwise rotation of this valve will allow pressure to vent.

  • Page 27: Oil Change Demonstration

    OIL CHANGE DEMONSTRATION Figure 1 Oil Sight Glass Figure 2 Oil Filler Cap 1. Run the compressor until it is warm. Remove the cap for the oil filler neck (as pictured below in Figure 2). Re- move the oil plug at the end of the black hose. 2.

  • Page 28: Compressor View

    Figure 3 Compressor View...
  • Page 29 Figure 4 Auto Drain System Intermediate Separator Gold Filter Tower Manual Drain Valve (normally closed) Gold Filter Tower Automatic Drain Solenoid Timer Intermediate Separator Gold Filter Tower Automatic Manual Drain Valve (normally Drain Solenoid Valve closed) Outlet to Condensate Drain Intermediate Separator Automatic Drain Solenoid Valve Intermediate Separator...

  • Page 30: Compressor Detail Images

    LED Pressure Switch Air Outlet to Black Filter Tower Oil Drain...
  • Page 31 REMOTE BLACK FILTER TOWER Co/Moisture Indicator Sightglass Outlet to Fill Manifold Back Pressure Regulator Bleeder Valve Inlet to Condensate Bottle Hyme Joint...

  • Page 32: Parts Drawing 1

    Parts Drawing 1...

  • Page 34: Parts Drawing 2

    Parts Drawing 2...

  • Page 36: Parts Drawing 3

    Parts Drawing 3...
  • Page 38 Figure 5 Black Filter Tower...

  • Page 39: Troubleshooting

    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. Re- pairs must never be carried out without sufficient knowledge and understanding of compressor technol- ogy.
  • Page 40 PROBLEM CAUSE ACTION Intermediate pressure safety a) Intermediate pressure too a) Check / replace inlet or pressure valve valve blows high due to defective inlet or pressure valve of the next stage b) Safety valve leaking b) Replace safety valve Any taste in air a) Filter cartridge saturated a) Replace cartridge...

  • Page 41: Systems Operations Log

    User manual EDS 8000 US Page 3 EDS 8000 (Menu navigation according to VDMA) User manual EDS 8000 US Page 3 Electronic Pressure Switch User Manual Safety Information (Translation of original instructions) EDS 8000 Before commissioning, check the instrument and any accessories supplied Safety Information read the operating instructions Before commissioning,...
  • Page 42 Controls of the EDS 8000 2 keys ( and E) for adjusting the switch points, switch- back points and additional functions 4-digit digital display LED backlight to indicate switch points (red = active / green = inactive) Use the keys to select the next menu point, or alternatively to adjust the values. To scroll through the menu To select the menu point To increase the value...
  • Page 43 Reading the digital display Representation on Description ASCII representation 7-segment display Switch point, output 1 Switch-back point, output 1 Switch point, output 2 Switch-back point, output 2 Pressure window upper value, output 1 Pressure window lower value, output 1 Pressure window upper value, output 2 Pressure window lower value, output 2 Extended functions Reset...
  • Page 44 User manual EDS 8000 US Page 6 NOTE: If the actual pressure exceeds the instrument's nominal pressure it can no longer be displayed. The nominal pressure flashes in the display. As a result, when the menu point Max Value (Hi) is selected, the value of the highest measured pressure which has been stored flashes until the instrument is reset (rES).
  • Page 45 User manual EDS 8000 US Page 7 Output function Switching Outputs The EDS 8000 has 2 switching outputs. The following settings can be made under the basic settings: 6.1.1 Switch point setting (SP) One switch point and one switch-back point can be set for each switching output. The particular output will switch when the set switch point is reached and switch back when the pressure drops below the switch-back point.
  • Page 46 User manual EDS 8000 US Page 8 Example for switch output 1 (normally closed and normally open function): FH1 plus 0,4%FS Rückschaltwert Rückschaltwert Reverse switch point Sicherheitszone Sicherheitszone Safety zone Schaltwert Schaltwert Switch point Schaltwert Schaltwert Switch point Sicherheitszone Sicherheitszone Safety zone Rückschaltwert Rückschaltwert...
  • Page 47 User manual EDS 8000 US Page 9 Menu navigation The EDS 8000 can be adapted to suit the particular application as required by changing multiple settings. These settings are combined in a single menu. NOTE: If no key is pressed for approx. 60 seconds, the menu closes automatically, and any changes that may have been made will not be saved.
  • Page 48 Extended functions Status 09.09.2009 HYDAC ELECTRONIC GMBH Part No. 669820...
  • Page 49 Error message If an error is detected, a corresponding error message appears that must be acknowledged by pressing any key. Possible error messages: E.10 A data error was detected in the saved settings. This could be due to strong electromagnetic interference or a component fault. Action: Press and confirm "RES"...
  • Page 50 10 Technical specifications Input data Measuring ranges 500; 1000; 3000; 6000; 9000 psi 25; 40; 100; 250; 400; 600 bar Overload pressures 1160; 2900; 7250; 11600; 14500 psi 80; 80; 200; 500; 800; 1000 bar Burst pressure 2900; 7250; 14500; 29000; 29000 psi 200;...
  • Page 54 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 55 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 56 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 57 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 58 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 59 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 60 Yacht Pro Systems Operation Log NOTE: Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed & Comments c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification...
  • Page 61 NOTES:...
  • Page 62 Warranty Information 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 63 TankFill.com...

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