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Honeywell WP241 Series Service Data

Dual air compressors.
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Subject
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M A I N T E N A N C E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DrainingTank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Cartridge (at PRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Wiring Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Adjustment (See Fig. 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Noisy Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Not Locatable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 1 -Motor Won't Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 2-Circuit Breaker Trips (Fuse Opens), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-Won't Pump Air-Runs, but Tank Shows No Pressure Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 4 -Won't Pump Air-Builds Up Slowly, or Not Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Removal and Replacement . . . . . . . . . .
Oil Pump Replacement. . . . . . . . . . . . . . . . .
Belt Replacement . . . . . . . . . . . . . . . . . . . .
Motor Replacement. . . . . . . . . . . . . . . . . . .
Rev. 4-80
AIR COMPRESSORS

TABLE OF CONTENTS

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WP241 DUAL
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Table of Contents

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   Summary of Contents for Honeywell WP241 Series

  • Page 1: Table Of Contents

    WP241 DUAL AIR COMPRESSORS TABLE OF CONTENTS Page Subject GENERAL ..............SPECIFICATIONS .
  • Page 2: General

    GENERAL This sheet contains maintenance and repair informa- tion for the WP241 series air compressors. The WP241 Dual Air Compressor has two electric motor-driven pumps mounted on a common storage tank, allowing automatic alternating operation with standby capability. IONS PRESSURE RANGE: Cut-in pressure-70 lb/in 2 (483 MAXIMUM AMBIENT TEMPERATURE: 104 F (57 C).
  • Page 3: Maintenance Schedule

    M A I N T E N A N C E S C H E D U L E L U B R I C A T I O N WEEKLY Quincy units use splash lubrication on the 1/3 to 3/4 hp (0.25 to 0.56 kW) units and pressurized lubrication on 1 hp to 7-l/2 hp (0.75 to 5.6 kW) units, Stop both 1.
  • Page 4: Drainingtank

    NOTE. The frequency of draining depends on climatic conditions. In humid climates, daily draining may be necessary. Consider adding the Honeywell AK3485 automatic drain kit. Visually check the air intake filter on l/3- to 2-hp (0.25 to 1.49 kW) compressors for build-up of foreign material on a routine basis.
  • Page 5: Pressures

    PRESSURES During weekly checks, verify that the tank pressure is prv pressure is at the proper setting. W I R I N G OPTiONS Dual Compressors usually have automatic alternation BELOW CUT-IN PRESSURE between pumps after each pump cycle, and with auto- matic backup.
  • Page 6: Operational Check

    6 0 H Z -1 PRESSURE S W I T C H A L T E R N A T O R f - - - - - - - _ - i - --L--L-. PRESSURE S T A R T E R S W I T C H SET PS-2 AND PS-3 TO OPERATE , ABOUT...
  • Page 7: Troubleshooting

    TROUBLESHOOTING If oil pressure is low, check oil pump(s) and pressure This section aids isolation of most common problems and pinpoints causes. Notify Honeywell Applications gage(s) by unscrewing the pressure gage(s) slowly until Engineering (Arlington Heights) of any other problems...
  • Page 8: Excessive Oil Consumption

    Excessive oil on the after cooler pipe or compressor per- values in Table 3. Differences greater than 10 head usually indicates air leakage. Locate air leaks with cent indicate worn parts (see WON’T PUMP AIR While soap solution while the compressor is operating. paragraph).
  • Page 9: Chart 1 -motor Won't Start

    valve. (Larger units do not have a check valve.) Dis- assemble the check valve and inspect. If cleaning does Before using listening rod near spinning flywheel, not stop the noise, replace check valve. belts, etc, determine if it is long enough to avoid moving parts.
  • Page 10: Chart 2-circuit Breaker Trips (fuse Opens)

    C H A R T 2 - C I R C U I T B R E A K E R T R I P S ( F U S E O P E N S ) START DISCONNECT POWER, REINSTALL BELTS, PLUG INTAKE (BY HAND),...
  • Page 11: Chart 3-won't Pump Air-runs, But Tank Shows No Pressure Build-up

    CHART 3-WON’T PUMP AIR START ISOLATE BUILDING Al R SUPPLY TURN UNIT ON REPLACE BETWEEN PUMP AND OUTLET VALVE* DISASSEMBLE AND INSPECT VALVES REPAIR AS NEEDED, SEE “PARTS LIST” *CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, ETC.
  • Page 12: Chart 4 -won't Pump Air-builds Up Slowly, Or Not Complete

    UP SLOWLY, OR NOT COMPLETE I S O L A T E BUILDING SUPPLY SHUT OFF UNIT, R E P A I R 1 DISCONNECT COPPER LINE REMOVE COVER BOLTS & COVER (TAP WITH BLUNT UP IIM INSTRUMENT TO LOOSEN) 1 (0.25 0 .
  • Page 13: Chart S-won't Pump Air-pump Slows, Stalls, Or Trips Circuit Breaker (fuse Opens)

    Shim out excessive rocking. Use adjustable levelers for is considered excessive in noise or vibration. In such cases, uneven floors. a remote air intake, adjustable pads, and air-line vibration isolators may be required. Isolators are stocked by Belt guards often produce a vibrating noise even under Honeywell.
  • Page 14: Repair

    REPAIR P U M P R E M O V A L A N D R E P L A C E M E N T Remove pump hold-down bolts, and pump. Remove fly- If major repair is needed, order a Parts List for the wheel if not done previously.
  • Page 15: Belt Replacement

    B E L T R E P L A C E M E N T (Refer to Fig. 2) DISCHARGE /VALVE Disconnect electric power and loosen motor clamping ASS’Y bolts. Slide motor towards pump. If the compressor has a totally enclosed belt guard, remove it. Remove and replace belt(s).
  • Page 16: Pressure Regulating Valve (prv) Station

    UNLOADER ASSEMBLY - H E A D Fig. 12. Hydraulic Unloader Assembly-l-IHP (0.75 kW) Units and Larger. Fig. 10. Air Unloading of Intake Valves--3/4 HP (0.56 P R E S S U R E R E G U L A T I N G V A L V E (PRV) STATION The unloader pilot is located on the crankcase and is...
  • Page 17 ASSEMBLY Replacement element kit for PI?901 -PI?902 PRV is 14003121-001. See Form 75-2558 for other prv parts. Fig. 13. Honeywell Intake Filter, Part No. J&3895-4. See Fig. 15 and Table 5. Table 5. 7-l /2 HP Filter-PRV Parts List. Nomenclature...
  • Page 18 F R O N T V I E W 6 2 8 6 Fig. 15. Typical PALL-TRINITY-MICRO (PTM) Filter-PRV Assembly-for 7-l/2 HP (5.60 kW) Units. O T H E R C O M P R E S S O R P A R T S Table 6.
  • Page 19 For best results, all devices in your system should be serviced at one time. Time and trouble can be saved by arranging with Honeywell for a maintenance agreement which will guarantee expert, economical care, and insure maximum life and efficiency from your system.
  • Page 20 OKLAHOMA T a m p a , F L Oklahoma Clfy MAINE NEW MEXICO JTAH Portland Albuquerque Salt Lake CltY tii CANADA -Honeywell Limited - Honeywell Limit&, 740 Ellesmere Road - Scarborough, Ont QUEBEC ALBERTA MANITOBA NEWFOUNDLAND ONTARIO Hamilton Calgary...

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