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BLACKMER HD COMPRESSORS
Installation, Operation, and Maintenance Instructions
TABLE OF CONTENTS
Safety Data ................................................................ 2
Compressor Data ................................................. 3
Nameplate Data .................................................... 4
Location and Piping .............................................. 6
Mounting the Compressor Unit ............................ 6
Stationary Compressors ....................................... 6
Truck Mounted Compressors ............................... 6
Compressor Flywheel ........................................... 7
V-Belt Drive ........................................................... 7
PTO Drive ............................................................. 7
Maximizing Compressor Life ................................ 8
Relief Valves ......................................................... 8
Liquid Traps .......................................................... 8
4-Way Valves ........................................................ 9
Temperature and Pressure Switches .................. 9
Pressure Gauges .................................................. 9
Suction Valve Unloaders ...................................... 9
Seal (Packing) Arrangements ............................ 10
MODEL: HD082C
Page 1 of 28
960515
INSTRUCTIONS CB9A-005
Pre Startup Check List .......................................... 11
Start Up Procedure ............................................... 12
Service Schedule .................................................. 13
Tool List ................................................................. 14
Bolt Torque Table .................................................. 14
Crankcase Lubrication .......................................... 15
Setting the Oil Pressure ........................................ 15
Compressor Disassembly ....................................... 16
Compressor Assembly ............................................ 17
Valve Replacement ................................................... 19
Unloader Seal Replacement .................................... 20
Piston Ring Replacement ........................................ 20
Seal (Packing) Replacement ................................... 21
Bearing Replacement ............................................... 22
Oil Pump Replacement ............................................ 23
Extended Storage ..................................................... 23
Troubleshooting ....................................................... 24
Section
901
Effective
Sep 2021
Replaces
Oct 2019
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Summary of Contents for BLACKMER HD082C
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Page 1: Table Of Contents
960515 BLACKMER HD COMPRESSORS INSTRUCTIONS CB9A-005 Section Installation, Operation, and Maintenance Instructions Effective Sep 2021 Replaces Oct 2019 MODEL: HD082C TABLE OF CONTENTS Operation Safety Data ..............2 Pre Startup Check List .......... 11 General Information Start Up Procedure ..........12 Compressor Data .......... -
Page 2: Safety Data
SAFETY 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: General Information
GENERAL INFORMATION Compressor Data The models listed are single-stage, vertical, air-cooled reciprocating style compressors with single acting cylinders. Double-Seal Models HD082C Minimum / Maximum RPM * 350 / 825 Reduce maximum speeds by 9% for continuous duty operation. -
Page 4: Nameplate Data
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 by contacting Blackmer's Customer Service. - Page 5 GENERAL INFORMATION An 11 character "I.D. No." identifies the construction of the compressor. Table 2 - ID NUMBER KEY HD SINGLE-STAGE COMPRESSORS 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...
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Page 6: Installation
Contact the flexible Truck Mounted Compressors connector/hose manufacturer required Blackmer compressors may be mounted to the frame maintenance/care and design assistance in their rails of a truck/transport and driven by either a V-belt or use. PTO drive. 4. Piping must be adequately supported to ensure that The compressor should be solidly mounted and care no piping loads are placed upon the compressor. -
Page 7: Compressor Flywheel
INSTALLATION COMPRESSOR FLYWHEEL V-BELT DRIVES Most Blackmer compressors are driven via V-belts which Blackmer compressors are fitted with flywheels which must be properly aligned and tensioned. MUST be used regardless of the type of drive system employed. Failure to disconnect and lockout... -
Page 8: Maximizing Compressor Life
Extreme temperatures caused by See the 'Troubleshooting' section. abnormally high discharge pressure or Blackmer offers various relief valves for gas and valve problems can be a source of ignition in explosive atmospheres application compatibility. -
Page 9: 4-Way Valves
Compressors may be fitted with suction valve unloaders to provide loadless start or capacity control functions. 3. For additional protection, a larger ASME code Blackmer unloaders are basically a piston and a plunger stamped vessel is available. This liquid trap is atop the suction valve. -
Page 10: Seal (Packing) Arrangements
INSTALLATION SEAL (PACKING) ARRANGEMENTS Also note any tubing connections in the seal area. 1/4" Single, Double and Triple Seal models are available to NPT ports are provided between each pair of seals to provide a wide range of leakage control/containment allow proper venting or pressurization of the seal areas options. -
Page 11: Operation
4. Ensure that pressure gauges are installed on both inlet and discharge of the compressor. 5. Blackmer compressors are shipped from the factory without oil in the crankcase. Fill with a high quality non-detergent oil of the proper viscosity via the compressor nameplate opening. -
Page 12: Startup Procedure
OPERATION STARTUP PROCEDURE NOTICE: Consult the 'Troubleshooting' section of this manual if difficulties during startup are experienced. 1. Start the compressor. Oil pressure should register 25 psig (172 kPa) within 10 seconds. If proper oil pressure is not present, stop the compressor and correct the problem. -
Page 13: Maintenance
NOTICE: Blackmer compressor service and maintenance shall be performed by qualified technicians only. Service and maintenance shall conform to all applicable local and national regulations and safety standards. SERVICE SCHEDULE Daily Weekly Monthly... -
Page 14: Tool List
Rubber Mallet Arbor Press Wrist Pin Removal Bearing Puller Crankshaft Bearings Torque Wrench Various Hoist (useful) Cylinder and Crosshead Guide Table 6 - TOOL LIST BOLT TORQUES FOR BLACKMER COMPRESSORS LBS-FT (Nm) Packing Valve Crank- Con. Bearing Cross Piston Valve Hold... -
Page 15: Crankcase Lubrication
MAINTENANCE Fig. 8 - Compressor Lubrication System Models Quarts Liters HD082C CRANKCASE LUBRICATION Table 8 - Oil Capacity Change the crankcase oil every 1,000 hours or 180 days, whichever is shorter. Under severe dusty, sandy or wet operating conditions, the oil should be changed every Mineral Based Oil - API Grade SN, SM, SL, SJ 500 hours or every 90 days. -
Page 16: Compressor Disassembly
3. Removal of the piston requires a 3" adjustable crosshead and connecting rod using a suitable pin spanner wrench with 1/4" pins, such as Blackmer PN driver or an arbor press. Removal of the pin releases 790316. -
Page 17: Compressor Assembly
Do not damage the packing when a. To attach the connecting rod to the crosshead starting it over the rod. Use of a Blackmer assembly, first coat the wrist pin, the wrist pin packing installation tool is recommended. (see bore in the crosshead assembly, and the wrist ‘Tool List’... - Page 18 Rotate the flywheel by hand to bring one piston to the top. b. Measure the distance from the top of the piston to the top of the cylinder. HD082C .015" to .030" (.381 to .762 mm) Table 10 - Piston Clearance c.
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Page 19: Valve Replacement
5. After replacing the valves, rotate the flywheel by MODELS HD082C - see Fig. 10. hand to check for interference between the pistons 1. Remove the valve cap and O-ring from the valve and the valves. -
Page 20: Unloader Seal Replacement
VALVE REPLACEMENT with its break in the same position as the top expander. UNLOADER SEAL REPLACEMENT b. Place piston rings in all three grooves of the 1. Remove the unloader cap and O-ring. piston. Make sure the breaks in the piston rings are directly opposite the breaks in the 2. -
Page 21: Seal (Packing) Replacement
SEAL (PACKING) REPLACEMENT Follow steps 1 through 6 of the "Compressor a. See "Seal Arrangements" (Fig. 6 & 7) for the Disassembly" section of this manual. proper location and orientation of the packing components. Install the first retainer ring (start 1. -
Page 22: Bearing Replacement
BEARING REPLACEMENT NOTICE: When replacing the bearings, the entire c. Note the proper orientation and carefully press bearing assembly, including the bearing cup and the the outboard bearing cup into the bearing carrier bearing cone, must be replaced and the crankshaft assembly. -
Page 23: 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 24: 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 with (when equipped) material being transferred. Check condition of rings by restricting Worn or Broken Piston Rings discharge line. - Page 25 This Page Intentionally left blank CB9A-005 page 25/28...
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- Page 28 1809 Century Avenue, Grand Rapids, Michigan 49503 U.S.A. (616) 241-1611 Fax: (616) 241-3752 www.blackmer.com CB9A-005 page 28/28...
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