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BLACKMER NGH COMPRESSORS
Installation, Operation, and Maintenance Instructions
TABLE OF CONTENTS
SAFETY DATA .......................................................... 2
Compressor Data ................................................. 3
General Data ........................................................ 4
Nameplate Data ................................................... 5
Maximizing Compressor Life ................................ 6
Location and Piping .............................................. 7
Mounting the Compressor Unit ............................ 7
Compressor Flywheel ........................................... 8
V-Belt Drive ........................................................... 8
Seal Arrangement ................................................. 9
Relief Valves ......................................................... 9
4-Way Valves ........................................................ 9
Pressure Gauges .................................................. 9
Inter-Stage Piping ................................................. 9
Liquid Traps ........................................................ 10
Temperature and Pressure Switches ................ 10
Models: NGH100
Pre-Startup Check List .......................................... 12
Start Up Procedure ............................................... 12
Bolt Torque Table.................................................. 13
Service Schedule .................................................. 14
Tool List ................................................................. 14
Crankcase Lubrication .......................................... 15
Setting the Oil Pressure ........................................ 15
COMPRESSOR DISASSEMBLY .............................. 16
COMPRESSOR ASSEMBLY .................................... 20
VALVE REPLACEMENT ........................................... 23
SEAL (PACKING) REPLACEMENT ......................... 24
BEARING REPLACEMENT ...................................... 25
OIL PUMP REPLACEMENT ..................................... 26
EXTENDED STORAGE ............................................. 26
TROUBLESHOOTING ............................................... 27
960494
INSTRUCTIONS CB6a-210
Section
602
Effective
Oct 2019
Replaces
Mar 2019
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Summary of Contents for BLACKMER NGH1013
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Page 1: Table Of Contents
960494 BLACKMER NGH COMPRESSORS INSTRUCTIONS CB6a-210 Section Installation, Operation, and Maintenance Instructions Effective Oct 2019 Replaces Mar 2019 Models: NGH100 TABLE OF CONTENTS SAFETY DATA ............2 OPERATION GENERAL INFORMATION Pre-Startup Check List .......... 12 Compressor Data ..........3 Start Up Procedure ..........12 General Data ............ -
Page 2: Safety Data
COMPRESSOR DATA SAFETY DATA NOTICE Blackmer compressors MUST only be installed in This is a SAFETY ALERT SYMBOL. systems which have been designed by qualified When you see this symbol on the product, or in the engineering personnel. The system MUST conform to... - Page 3 PERFORMANCE DATA Triple Seal NGH1013 NGH1023 6.00 Inch Cylinder MAWP - psia (Bar) 500 (34.4) 3.25 Inch Cylinder MAWP – psia (Bar) 1500 (103.4) Displacement CFM (m...
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Page 4: General Information
1. Note the nameplate data in the space provided above. 2. Obtain the appropriate parts lists for the model in question. Manuals and Parts Lists for Blackmer products may be obtained from Blackmer's website (www.blackmer.com) or be contacting Blackmer's Customer Service. -
Page 5: Nameplate Data
GENERAL INFORMATION 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 should be available when information or parts are needed for a particular unit. The basic size and type of compressor is indicated by “Model No.”... -
Page 6: Maximizing Compressor Life
GENERAL INFORMATION MAXIMIZING COMPRESSOR LIFE Foreign Material Solid particles in the gas stream will: Life of critical compressor components such as piston Rapidly wear the piston rings and score the rings, valves and packing will vary considerably with each application, installation, and operating procedures. cylinder wall. -
Page 7: Installation
INSTALLATION NOTICE: Blackmer compressors must only be installed in systems designed qualified engineering Discharge piping surface temperatures personnel. System design must conform with all may be hot during operation (over applicable regulations and codes and provide 158°F, 70°C). Temperatures should be warning of all system hazards. -
Page 8: Compressor Flywheel
V-BELT DRIVES compressor running up to 1800 RPM. Refer to Direct Drive section if a v-belt and flywheel system is not being Most Blackmer compressors are driven via V-belts which implemented. must be properly designed, aligned, and tensioned. 1. Lay a straight edge along the face of the motor sheave and compressor flywheel. -
Page 9: Seal Arrangement
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,... -
Page 10: Liquid Traps
INSTALLATION low oil pressure switch out during compressor startup. PRESSURE SWITCHES Excessive gas recirculation using suction Pressure switches may be installed in the suction or valve unloaders can be a source of discharge stream protective devices, ignition in explosive atmospheres compressor control, or for other uses varying with each causing severe personal injury or death Hazardous... - Page 11 INSTALLATION Figure 4 – Recommended Optional Oil Cooler Assembly CB6A-210 page 11/32...
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Page 12: Operation
Failure to disconnect and lockout inlet and discharge of the compressor. electrical power or engine drive before 5. Blackmer compressors are shipped from the factory attempting maintenance can cause without oil in the crankcase. Fill with a high quality severe personal injury or death... -
Page 13: Maintenance
Hazardous gases Extreme Heat can cause personal can cause property injury or property damage, personal damage injury or death NOTICE Blackmer compressor service S atmospheres can cause maintenance shall performed serious personal injury or qualified technicians only. Service and death. -
Page 14: Service Schedule
Piston Lock Nut 6.0” Cylinder Blackmer Piston Nut Socket Tool (Part # 798026) Piston Lock Nut 3.25” Cylinder Blackmer Packing Installation/Removal Tool (Part # 797049) Rod-Packing protection during installation. 1/2” Drive 6” Extension Piston Lock Nut 3/8”, 1/2”, 5/8”, 12 Point Drive Sockets Main Bolting, Bearing Carrier, Packing Bolts 100 ft*lb 3/8”... - Page 15 MAINTENANCE CB6A-210 page 15/32...
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Page 16: Crankcase Lubrication
MAINTENANCE Refill the crankcase via the vent pipe or the crankcase cover. A sight glass is located on the lower portion of the crankcase below the oil filter. This should register at the halfway mark. DO NOT OVERFILL THE CRANKCASE! The oil pump on these models will operate in either direction of crankshaft rotation. -
Page 17: Compressor Disassembly
COMPRESSOR DISASSEMBLY Failure to disconnect and lockout electrical power or engine drive before PISTON REMOVAL attempting maintenance can cause severe personal injury or death 5. Rotate the crankshaft by hand to bring a piston to the Hazardous machinery can top dead center position. cause serious personal injury. - Page 18 COMPRESSOR DISASSEMBLY Figure 7 – Upper Compressor Assembly CB6A-210 page 18/32...
- Page 19 COMPRESSOR DISASSEMBLY Figure 8 – Lower Compressor Assembly CB6A-210 page 19/32...
- Page 20 COMPRESSOR DISASSEMBLY CYLINDER / ADAPTOR REMOVAL c. The seal will be damaged during removal due to the snap ring groove and must be 14. To remove the Adaptor (Figure 7) replaced if removed. a. Remove the Adaptor to Distance Piece bolts 19.
- Page 21 COMPRESSOR ASSEMBLY Compressor assembly is generally the opposite of d. With the connecting rod cap removed, carefully compressor disassembly. Before reassembling, clean set and slide the crosshead assembly into the each part thoroughly. Check all machined surfaces for crosshead guide making sure the connecting burrs or roughness, and file lightly if necessary.
- Page 22 COMPRESSOR ASSEMBLY bolts and torque properly per the Torque Table. the stroke. With feeler gauges, use one of the valve ports to 6. ADAPTOR ASSEMBLY access and measure the clearance between the a. These instructions are for Adaptors with new Adaptor head surface and the Piston face.
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Page 23: Compressor Assembly
COMPRESSOR ASSEMBLY Figure 9 - Variable Volume Clearance Pocket (VVCP) Assembly 9. VARIABLE VALVE CLEARANCE POCKET 10. ADJUSTING-VARIABLE-VALVE (VVCP) HEAD ASSEMBLY - OPTIONAL CLEARANCE POCKET (VVCP) - OPTIONAL a. Install Head O-Ring to the VVCP Head and install a. BEFORE ADJUSTING VVCP, ASSURE... -
Page 24: Valve Replacement
VALVE REPLACEMENT Fig. 10 – Valve Installation – Discharge Shown Suction and discharge valves MUST be installed in the correct cylinder head locations. See Figure 10. Failure to install compressor valves 1. VALVE REMOVAL properly can lead to component failure, Remove the Valve Cover bolts. -
Page 25: Seal (Packing) Replacement
SEAL (PACKING) REPLACEMENT Verify carefully Suction and Discharge Valve location prior to installation. It is easiest to install the Valve Gasket, Valve, and Cage at the same time as an assembly. Make sure the assembly is properly seated completely in the valve pocket. Install the Valve Cover O-ring onto the Valve Cover, apply o-ring lubricant to the O-ring to ease installation. -
Page 26: Bearing Replacement
BEARING REPLACEMENT NOTICE: c. Note the proper orientation and carefully press When replacing the bearings, the entire bearing the outboard bearing cup into the bearing carrier assembly, including the bearing cup and the bearing assembly. cone, must be replaced and the crankshaft endplay d. -
Page 27: Oil Pump Replacement
OIL PUMP REPLACEMENT 4. Place the spring and the drive cone in the end of the crankshaft. 5. Note the slot in the end of the crankshaft and the drive tab on the back of the oil pump assembly. Install the oil pump assembly into the bearing carrier with the tab and slot aligned. -
Page 28: Troubleshooting
TROUBLESHOOTING IF PROBLEM PROBLEM STEP PROBABLE CAUSE WHAT TO CHECK STILL EXISTS GO TO STEP ... 4-Way Valve Leaking Lubricate with a stick lubricant compatible (when equipped) with material being transferred. Check condition of rings by restricting Worn or Broken Piston Rings discharge line. - Page 29 DECLARATIONS CB6A-210 page 29/32...
- Page 30 DECLARATIONS Insert ATEX cert CB6A-210 page 30/32...
- Page 31 NOTES: CB6A-210 page 31/32...
- Page 32 Accessories Dispensing, Transfer, In-line Gear Reducers, Bypass Valves, Strainers Visit www.blackmer.com for complete information on all Blackmer products 1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A. Telephone: (616) 241-1611 • Fax: (616) 241-3752 E-mail: blackmer@blackmer.com • Internet Address: www .blackmer.com...
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