Page 1 98407.1924 ISSUE DATE:- NOVEMBER 2011 Gardner Denver Ltd. Reavell House 53-56 White House Road IPSWICH ENGLAND IP1 5PB Telephone: +44 (0) 1473 242000 Fax: +44 (0) 1473 745451 Parts Fax: +44 (0) 1473 743468 Service +44 (0) 1527 838632 www.compair.com...
Page 3: Table Of Contents
TABLE OF CONTENTS Page 1 OPERATOR HANDBOOK – 5236.2.IA CONTRACT NUMBER 1514462 TABLE OF CONTENTS NOTE: THE REQUIREMENTS OF THE CONTRACT MAY RESULT IN PART NUMBERS IN THE INCLUDED STANDARD HANDBOOK BEING INCORRECT. ANY ALTERED PART NUMBERS ARE INCLUDED IN THE CONTRACT SPECIFIC PARTS SECTION.
Page 4 TABLE OF CONTENTS Page 2 DEMAND CONTROL.......................... 22 5.4.1 STARTING AND STOPPING ...................... 22 5.4.2 DELIVERY AIR PRESSURE CONTROL ..................22 5.4.2.1 ANALOG TRANSMITTER BASED SIGNAL TYPE ............22 5.4.2.2 DIGITAL INPUT, SWITCH BASED TYPE ................22 ALARM HANDLING ..........................22 5.5.1 GENERAL DESCRIPTION ......................
Page 5: Control Access Requirements From
TABLE OF CONTENTS Page 3 CONTRACT SPECIFIC PARTS ........................ 47 DIFFERING FROM STANDARD COMPRESSOR ................47 EXTRA TO STANDARD COMPRESSOR ..................47 EQUIPMENT DATA SHEETS ........................49 MOTOR – APP034..........................49 SOLENOID VALVE ~ SUCTION UNLOADER – APP139 ..............50 PRESSURE TRANSMITTER –...
Page 6 TABLE OF CONTENTS Page 4 98407.1924 iss1...
Page 7: Safety
SAFETY Page 5 1 SAFETY 5000 SERIES COMPRESSORS WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir Reavell Ipswich, or the failure to maintain this equipment in accordance with the maintenance instructions, may invalidate the WARRANTY, cause equipment failure, create unsafe or hazardous conditions or result in damage to the equipment.
Page 8: Ownership Data
It is recommended that details taken from the compressor and motor nameplates are recorded below. CompAir Reavell CONTACT DETAILS Contact Name: Sales Telephone: +44 (0) 1473 242000 Address: Notes: Gardner Denver Reavell House 53-56 White House Road Ipswich IP1 5PB ENGLAND Telephone: +44 (0) 1473 242000...
Page 9: Foreword
SAFETY Page 7 1.2 FOREWORD SPECIAL ATTENTION The STANDARD BUILD of all CompAir Reavell products are not intended for use in either Explosive or Potentially Explosive Atmospheres as defined in Directive 94/9/EC. An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours, hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture and may cause a hazard.
Page 10: Caution
SAFETY Page 8 1.3 CAUTION Use only CompAir Reavell Genuine Parts when carrying out routine maintenance or repair. The use of replacement parts or lubricating oils not supplied or recommended by CompAir Reavell can lead to expensive failures, which will not be covered by warranty. Substitution of parts not manufactured or approved by CompAir Reavell can create a potential personnel hazard.
Page 11: General
SAFETY Page 9 1.4.1 GENERAL CompAir Reavell compressor safety relates to the document BS EN1012-1 Compressors and Vacuum Pumps - Safety requirements and the UK Pressure Systems Health & Safety Regulations S.I. No. 128. • Most accidents which occur during the operation and maintenance of machinery result of failure to observe basic safety rules or precautions.
Page 12: General Safety Precautions
SAFETY Page 10 1.4.3 GENERAL SAFETY PRECAUTIONS • When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and gloves. •...
Page 13: Maintenance & Repair Precautions
SAFETY Page 11 • Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement, test or adjustment. Such work should always be carried out by a qualified electrician with appropriates tools and protection against an electrical hazard. •...
Page 14: Precautions In The Event Of Fire
SAFETY Page 12 • Stand clear of all valve covers when removing the securing screws. • When removing valve covers for valve replacement, ensure a minimum of two threads is left engaged on the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port in the cylinder head.
Page 15: Amendments
AMENDMENTS Page 13 2 AMENDMENTS ISSUE No REASON DATE PAGE NOV 2011 98407.1924 iss1...
Page 16 AMENDMENTS Page 14 98407.1924 iss1...
Page 17: Compressor Log Sheet
COMPRESSOR LOG SHEET Page 15 3 COMPRESSOR LOG SHEET 98407.1924 iss1...
Page 18 COMPRESSOR LOG SHEET Page 16 98407.1924 iss1...
Page 19: Test Sheet
TEST SHEET Page 17 4 TEST SHEET 98407.1924 iss1...
Page 20 TEST SHEET Page 18 98407.1924 iss1...
Page 21: Control Philosophy
DESCRIPTION OF OPERATION Page 19 5 CONTROL PHILOSOPHY W A R N I N G :- BEFORE OPERATING THIS EQUIPMENT USERS SHOULD ENSURE COMPETENCY AND BE MADE AWARE OF AND ENSURE COMPLIANCE WITH THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. ATTENTION OF U.K.
Page 22: Loading
DESCRIPTION OF OPERATION Page 20 5.1.4 LOADING The loading delay timer now runs. This is typically set to 10 seconds. When the loading delay timer times out the suction unloader solenoid valve is energised, allowing the system to load-up. When the loading delay timer times out the delivery unloader solenoid valve is also energised, allowing the system to load-up.
Page 23: Trip : Shutdown With Normal Stop
DESCRIPTION OF OPERATION Page 21 If the system was set for Local (Manual) operation and the instruction to stop was initiated by the Delivery Air Pressure demand signal, the machine will also indicate “Standby” status. It will re-start again as soon as the Delivery Air Pressure drops below the start setting. If set for Local (Manual) operation and the Stop push button was pressed, the machine will go to “Off Line”...
Page 24: Demand Control
DESCRIPTION OF OPERATION Page 22 Remote operation includes systems which have hard wired control action links for these functions as well as those which rely on a communications link. For a remote system, the Start / Stop signals are combined into a single Run Required signal. This is Logic 1, closed contacts, ON, for compressor run required and Logic 0, open contacts, OFF for compressor stop.
Page 25: Warning Alarms
DESCRIPTION OF OPERATION Page 23 Each alarm has it’s own adjustable de-bounce delay timer which can be used to reduce nuisance triggering. This delay is applied for each and every triggering event for the alarm. It is in addition to any specific requirement for a start-up delay, such as that mentioned above for the Lube Oil pressure to establish.
Page 26: Upstream Equipment
DESCRIPTION OF OPERATION Page 24 Low Lube Oil Level – Normal Shutdown. This alarm is active at all times. High Cooling Water Temperature – Normal Shutdown. This alarm is active at all times. High 1st Stage Temperature – Normal Shutdown. This alarm is active at all times. High 2nd Stage Temperature –...
Page 27: Local Push Buttons, Selector Switches And Indicators
DESCRIPTION OF OPERATION Page 25 Status Screen. This screen gives a simple graphical overview of the compressor status. Key analog process values are displayed, together with indications of the machine status and warning and trip alarms. Start, Stop and Reset control functions are available from this screen as well as the ability to select Local / Remote operation modes.
Page 28: System Setup
DESCRIPTION OF OPERATION Page 26 The following standard actions are provided : Start Stop Reset Full details of the remote control write access data block, it’s layout and signal data types, ranges, etc are given in the Communications Data Exchange Map document. 5.10 SYSTEM SETUP 5.10.1 GENERAL The Control System uses adjustable Parameter settings to allow the system response to be tuned to...
Page 29: Level Settings
DESCRIPTION OF OPERATION Page 27 5.10.6 LEVEL SETTINGS Lube Oil Low Warning Alarm Level Lube Oil Low Trip Alarm Level 5.10.7 VIBRATION SETTINGS Vibration High Warning Alarm Vibration High Trip Alarm 5.11 HMI SCREEN DESCRIPTION The following description shows a screen dump from each of the HMI display screens used to control the compressor.
Page 30 DESCRIPTION OF OPERATION Page 28 All screens on the system have the following common elements, with the exception of the two Alarm display screens. The top line of the display shows a screen number and title used for identification of the display. To the right of the top line is the current system time and date.
Page 31: Main Machine Controls (Status) Screen
DESCRIPTION OF OPERATION Page 29 5.11.1 MAIN MACHINE CONTROLS (STATUS) SCREEN. This screen displays the machine’s running status and allows access to most control functions Common features are as described under the Welcome Display’s entry. In the centre of the display on the top line, the current operational mode of the machine is displayed. This shows either “LOCAL”...
Page 32: Alarm Display Screen
DESCRIPTION OF OPERATION Page 30 5.11.2 ALARM DISPLAY SCREEN. This screen displays the full list of active alarm messages underneath the screen title and job reference. Only currently active alarms are displayed. 98407.1924 iss1...
Page 33: Alarm History Screen
DESCRIPTION OF OPERATION Page 31 5.11.3 ALARM HISTORY SCREEN. This screen displays the full historical list of alarms. All alarms which have triggered on the system are displayed, subject to the maximum number which the HMI can hold (512). When the list is full, new alarms are added and an equivalent number of old alarms are discarded from the list.
Page 34: Process Setting Screen
DESCRIPTION OF OPERATION Page 32 5.11.4 PROCESS SETTING SCREEN. This screen displays the machine’s parameter settings for time delays and process value trip and control points. To alter a value, touch the required setting value and a pop-up banner will appear allowing a new entry to be made.
Page 35: Alarm Delay Timer Setting Screen
DESCRIPTION OF OPERATION Page 33 5.11.5 ALARM DELAY TIMER SETTING SCREEN. This screen allows alarm delay timer settings to be viewed and altered if required. To alter a value, touch the required setting value and a pop-up banner will appear allowing a new entry to be made.
Page 36: System Access Screen
DESCRIPTION OF OPERATION Page 34 5.11.6 SYSTEM ACCESS SCREEN. This screen allows access to the HMI’s system settings, including time and date alteration. The screen is password protected, and care should be taken not to adjust settings unless fully conversant with the consequences and effects of any change. If the “Eng”...
Page 37: Analog Input Setup Screen
DESCRIPTION OF OPERATION Page 35 5.11.7 ANALOG INPUT SETUP SCREEN. This screen allows adjustment of the raw signal values from the analog input card as well as the associated Engineering Units minimum and maximum values. To adjust a value, touch the current setting and a numeric input entry pop-up will appear allowing the setting to be changed.
Page 38 DESCRIPTION OF OPERATION Page 36 98407.1924 iss1...
Page 39: Set Point Schedule
SET POINT SCHEDULE SHEET 01 OF 03 COMPAIR UK Ltd., SALES ORDER NUMBER 1514462 ISSUE A : MRP : 05/10/11 CLIENT : GARDNER DENVER INC - USA REFERENCE DRAWINGS:- P & I DIAGRAM - D73024 SINGLE LINE DIAGRAM – D73025 GENERAL ARRGT.
Page 40 SET POINT SCHEDULE Page 38 98407.1924 iss1...
Page 41: Drawings
DRAWINGS Page 39 7 DRAWINGS 7.1 GENERAL ARRANGEMENT – A41676 98407.1924 iss1...
Page 42 DRAWINGS Page 40 98407.1924 iss1...
Page 43 THIS DRAWING IS THE COPYRIGHT MANUFACTURING TOLERANCES TO BE AS FOLLOWS UNLESS OTHERWISE STATED SCALE Neil Crane 11/10/11 THIRD ANGLE APPROVED IPSWICH PROPERTY OF GARDNER DENVER Ltd. MACHINED ANGULAR 0.5 ~ (A0 PLOT) SUFFOLK 95112.9 NUT M16 HEX NORMAL ZINC PLATED 98288.1014...
Page 45: P&I Diagram - D73024
DRAWINGS Page 41 7.2 P&I DIAGRAM – D73024 98407.1924 iss1...
Page 46 DRAWINGS Page 42 98407.1924 iss1...
Page 49 DRAWINGS Page 43 7.3 SINGLE LINE DIAGRAM – D73025 98407.1924 iss1...
Page 50 DRAWINGS Page 44 98407.1924 iss1...
Page 53: Wiring Diagram - Y98520.1613-12393
DRAWINGS Page 45 7.4 WIRING DIAGRAM – Y98520.1613-12393 98407.1924 iss1...
Page 54 DRAWINGS Page 46 98407.1924 iss1...
Page 63: Contract Specific Parts
CONTRACT SPECIFIC PARTS Page 47 8 CONTRACT SPECIFIC PARTS 8.1 DIFFERING FROM STANDARD COMPRESSOR REF No. PART No. DESCRIPTION QUANTITY C203270 CRANKCASE DOOR PS2197.4 SOLENOID VALVE – DDV 98650.1754 SOLENOID VALVE – SUCTION UNLOADER 8.2 EXTRA TO STANDARD COMPRESSOR PART NUMBER DESCRIPTION QUANTITY E45829.1...
Page 64 CONTRACT SPECIFIC PARTS Page 48 98407.1924 iss1...
Page 65: Equipment Data Sheets
EQUIPMENT DATA SHEETS Page 49 9 EQUIPMENT DATA SHEETS NOTE: THE FOLLOWING DATA SHEETS ARE FOR EQUIPMENT THAT EITHER DIFFERS FROM, OR IS IN ADDITION TO, THAT WHICH IS INCLUDED IN THE STANDARD COMPRESSOR HANDBOOK 9.1 MOTOR – APP034 ELECTRIC MOTOR MAINTENANCE WARNING : Isolate power supply to motor before commencing any routine cleaning or maintenance work.
Page 66: Solenoid Valve ~ Suction Unloader - App139
EQUIPMENT DATA SHEETS Page 50 9.2 SOLENOID VALVE ~ SUCTION UNLOADER – APP139 3 WAY SOLENOID VALVE OPERATION 3 way normally open energise to close, continuous duty. On starting the solenoid valve closes (energised) this stops the air from the receiver to the hand/automatic 1st stage valve unloaders which in turn allows the compressor to come on to load, at the same time another solenoid valve (PS2197) opens to close the diaphragm Drain Valves...
Page 67: Pressure Transmitter - App703
EQUIPMENT DATA SHEETS Page 51 9.3 PRESSURE TRANSMITTER – APP703 APP703 COMPAIR PART NUMBERS - Y98615.1045-6, 1071, 1101, 1003-7, 1110 98407.1924 iss1...
Page 68 EQUIPMENT DATA SHEETS Page 52 98407.1924 iss1...
Page 69: Pressure Maintaining Valve - App057
EQUIPMENT DATA SHEETS Page 53 98407.1924 iss1...
Page 70 EQUIPMENT DATA SHEETS Page 54 98407.1924 iss1...
Page 71 EQUIPMENT DATA SHEETS Page 55 98407.1924 iss1...
Page 72 EQUIPMENT DATA SHEETS Page 56 98407.1924 iss1...
Page 73 EQUIPMENT DATA SHEETS Page 57 98407.1924 iss1...
Page 74 EQUIPMENT DATA SHEETS Page 58 98407.1924 iss1...
Page 75 EQUIPMENT DATA SHEETS Page 59 98407.1924 iss1...
Page 76 EQUIPMENT DATA SHEETS Page 60 98407.1924 iss1...
Page 77 EQUIPMENT DATA SHEETS Page 61 98407.1924 iss1...
Page 78 EQUIPMENT DATA SHEETS Page 62 98407.1924 iss1...
Page 79 EQUIPMENT DATA SHEETS Page 63 98407.1924 iss1...
Page 80 EQUIPMENT DATA SHEETS Page 64 98407.1924 iss1...
Page 81 EQUIPMENT DATA SHEETS Page 65 98407.1924 iss1...
Page 82 EQUIPMENT DATA SHEETS Page 66 98407.1924 iss1...
Page 83 EQUIPMENT DATA SHEETS Page 67 9.4 PRESSURE MAINTAINING VALVE – APP057 PRESSURE MAINTAINING VALVE (BACK PRESSURE REGULATING VALVE) 98650.1759 Maximum Pressure 40 bar Temperature Range - 10 to 100°C Flow Rate 300m³/hr Connections 1" BSPP This valve is fitted to maintain a back pressure through the separators, filters and the dryers (if fitted).
Page 84: Water Flow Control Valve - App704
EQUIPMENT DATA SHEETS Page 68 9.5 WATER FLOW CONTROL VALVE – APP704 APP704 PNEUMATIC WATER VALVE COMPAIR PART NUMBERS: PORT SIZE BODY MATERIAL 98650.2584.1 1” BSP BRONZE 98650.2584.2 1” BSP STAINLESS STEEL 98650.2585.1 ¾” BSP BRONZE 98650.2585.2 ¾” BSP STAINLESS STEEL 98650.2612 1 ½”...
Page 85: Temperature Transmitter - App645
EQUIPMENT DATA SHEETS Page 69 9.6 TEMPERATURE TRANSMITTER – APP645 APP645 COMPAIR PART NUMBER Y/98615.1043 & 1044 FLEXTOP TEMPERATURE TRANSMITTER FlexTop 2201 Temperature Transmitter • 4...20 mA transmitter for Pt100 sensors 2-, 3- or 4-wire sensors • Accuracy better than 0.25°C Sensor offset correction •...
Page 86 EQUIPMENT DATA SHEETS Page 70 Technical Data Input Environmental conditions Accuracy Operating temperature -40...85°C Span 250°C: < 0.25°C {2} Storage temperature -55...90°C Span > 250°C: 0.1% of span Humidity < 98% RH, cond. (IEC 68-2- Sample time < 0.7 sec. Vibrations GL, test 2 (IEC 68-2-6) Pt100 Standard...
Page 87 EQUIPMENT DATA SHEETS Page 71 Non-Ex Application Electrical Installation Dimensional Drawing 98407.1924 iss1...
Page 88 EQUIPMENT DATA SHEETS Page 72 Ex Application Configuration 98407.1924 iss1...
Page 89: Thermocouple - App597
EQUIPMENT DATA SHEETS Page 73 9.7 THERMOCOUPLE – APP597 APP597 RTD TEMPERATURE PROBE PT 100 CLASS B, 3 WIRE SHEATHED SENSOR. BRAZED TO 5MM CONVOLUTE TUBE SEALED COLD END POT GLAND PART ØA – mm B – mm C – bspt D –...
Page 90: Starter / Control Panel - App091
EQUIPMENT DATA SHEETS Page 74 9.8 STARTER / CONTROL PANEL – APP091 INSTALLATION & MAINTENANCE INSTRUCTIONS A.C MOTOR CONTROLS AND CUSTOM BUILT EQUIPMENT IMPORTANT/SAFETY All control panels/starters for operating on low voltage contains devices which are dangerous and can cause serious or fatal injury. Some control panels/starters may contain live terminals which are supplied from a separate external source.
Page 91 EQUIPMENT DATA SHEETS Page 75 GUIDANCE ON INSTALLATION BEFORE INSTALLATION Remove all packing materials and check inside and outside the control panel/starter for any obvious defects or damage. Check that the control panel/starter is correct in all respects for the application, particularly in respect 1) Voltage.
Page 92 EQUIPMENT DATA SHEETS Page 76 OPERATIONAL CHECKS 1) Connect incoming supply cables as shown in circuit diagram. 2) Conduct operational checks before connecting the motor. 3) Check the operation of control circuit. It is also advisable to remove as many mains fuses as is practical. The number of mains fuses which may be removed is dependent on how the control circuit is supplied (see circuit diagram).
Page 93 EQUIPMENT DATA SHEETS Page 77 GENERAL GUIDANCE ON ROUTINE INSPECTION DISCONNECT ALL EXTERNAL SUPPLIES Open panel/starter and make visual inspections for: Overheating/arcing. Ingress of dirt/moisture. Check all screws and fixings to ensure that they are tight. Check all wiring connections to ensure that they are tight. Check all moving parts for ease of operation.
Page 94 EQUIPMENT DATA SHEETS Page 78 3. ISOLATORS Check all connections for tightness and examine the immediate vicinity of the main contacts for excessive arcing. Check the main terminal areas for signs of overheating. If either of the above is present, dismantle isolator and check state of operating mechanism for wear and examine contacts for excessive damage.
Page 95 EQUIPMENT DATA SHEETS Page 79 9. THERMISTOR PROTECTION UNITS Thermistor protection units should be checked with care, certain parts of the circuit are vulnerable to higher voltages. In the off state (ie. no supply voltage) the relay should be checked for normally open/closed contacts in accordance with the circuit diagram.
Page 96 EQUIPMENT DATA SHEETS Page 80 98407.1924 iss1...
Page 97: Compressor Handbook
COMPRESSOR HANDBOOK Page 81 10 COMPRESSOR HANDBOOK 98407.1924 iss1...
Page 98 COMPRESSOR HANDBOOK Page 82 98407.1924 iss1...
Page 99 CompAir UK Ltd OPERATOR HANDBOOK for a CompAir UK Ltd H5236 MK2 Water-cooled Air Compressor In any correspondence please quote; COMPAIR JOB NUMBER:- CUSTOMER:- CUSTOMER ORDER NUMBER:- MACHINE NUMBER:- 5236.MK2 PUBLICATION NUMBER:- 98407/1039 issue 7 ISSUE DATE:- FEBRUARY 2009 CompAir UK Ltd. Reavell House 53-56 White House Road IPSWICH ENGLAND IP1 5PB Telephone: +44 (0) 1473 242000 Fax: +44 (0) 1473 745451 Parts Fax: +44 (0) 1473 743468 Service +44 (01473 242097 www.compair.com...
Page 101 CompAir UK Ltd PUBLICATION 98407.1039 Page 1 SAFETY ............................... 5 OWNERSHIP DATA ..........................6 FOREWORD ............................7 CAUTION .............................. 8 SAFETY PROCEDURES ........................8 1.4.1 GENERAL ............................9 1.4.2 WARNINGS, CAUTIONS & NOTES ....................9 1.4.3 GENERAL SAFETY PRECAUTIONS ..................10 1.4.4 INSTALLATION PRECAUTIONS ....................
Page 102 CompAir UK Ltd PUBLICATION 98407.1039 Page 2 INSTALLATION ............................27 HANDLING OF UNIT .......................... 27 LOCATION ............................27 MOUNTING ............................28 CONNECTIONS, PIPEWORK AND FITTINGS .................. 28 DRIVE RECOMMENDATIONS ......................28 COOLING ............................29 ELECTRICAL CONNECTIONS ......................30 RECOMMENDED ANCILLARIES SUMMARY ...................
Page 103 CompAir UK Ltd PUBLICATION 98407.1039 Page 3 FAULT GUIDE ............................47 11.1 LOW FIRST STAGE PRESSURE ....................47 11.2 1ST STAGE SAFETY VALVE BLOWING AND/OR HIGH FIRST STAGE PRESSURE ....47 11.3 2ND STAGE SAFETY VALVE BLOWING ..................47 11.4 COMPRESSOR RUNS LONGER TO ACHIEVE SYSTEM PRESSURE ........
Page 104 CompAir UK Ltd PUBLICATION 98407.1039 Page 4 1039.doc...
Page 105: Safety
CompAir UK Ltd PUBLICATION 98407.1039 Page 5 1 SAFETY 5000 SERIES COMPRESSORS WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd Ipswich, or the failure to maintain this equipment in accordance with the maintenance instructions, may invalidate the WARRANTY, cause equipment failure, create unsafe or hazardous conditions or result in damage to the equipment.
Page 106: Ownership Data
CompAir UK Ltd PUBLICATION 98407.1039 Page 6 OWNERSHIP DATA TECHNICAL DATA It is recommended that details taken from the compressor and motor nameplates are recorded below. CompAir UK Ltd Ipswich CONTACT DETAILS Contact Name: Sales Telephone: +44 (0) 1473 242000 Address: Notes: CompAir UK Ltd...
Page 107: Foreword
CompAir UK Ltd PUBLICATION 98407.1039 Page 7 FOREWORD SPECIAL ATTENTION The STANDARD BUILD of all CompAir UK Ltd (Ipswich Operations) products are not intended for use in either Explosive or Potentially Explosive Atmospheres as defined in Directive 95/9/EC. An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours, hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture and may cause a hazard.
Page 108: Caution
CompAir UK Ltd PUBLICATION 98407.1039 Page 8 CAUTION Use only CompAir UK Ltd Ipswich Genuine Parts when carrying out routine maintenance or repair. The use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd Ipswich can lead to expensive failures, which will not be covered by warranty.
Page 109: General
CompAir UK Ltd PUBLICATION 98407.1039 Page 9 1.4.1 GENERAL CompAir UK Ltd Ipswich compressor safety relates to the document BS EN1012-1 Compressors and Vacuum Pumps - Safety requirements and the UK Pressure Systems Health & Safety Regulations S.I. No. 128. •...
Page 110: General Safety Precautions
CompAir UK Ltd PUBLICATION 98407.1039 Page 10 1.4.3 GENERAL SAFETY PRECAUTIONS • When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and gloves.
Page 111: Maintenance & Repair Precautions
CompAir UK Ltd PUBLICATION 98407.1039 Page 11 • Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement, test or adjustment. Such work should always be carried out by a qualified. Electrician with appropriates tools and protection against an electrical hazard.
Page 112: Precautions In The Event Of Fire
CompAir UK Ltd PUBLICATION 98407.1039 Page 12 • Stand clear of all valve covers when removing the securing screws. • When removing valve covers for valve replacement, ensure a minimum of two threads is left engaged on the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port in the cylinder head.
Page 113: Amendments
CompAir UK Ltd PUBLICATION 98407.1039 Page 13 2 AMENDMENTS H-5236.2.IA HANDBOOK ISSUE No. MOD NOTE No. M/C SERIAL No. DATE PAGE No’s NOV 1997 MAY 1999 R005122 Change to Main Bearing Bush/thrust washer AUGUST 2001 Add Studs & Nuts to Service Plans Major Overhaul JULY 2002 Add check condition of crankcase to cylinder studs &...
Page 114 CompAir UK Ltd PUBLICATION 98407.1039 Page 14 1039.doc...
Page 115: Logsheet
CompAir UK Ltd PUBLICATION 98407.1039 Page 15 3 LOGSHEET 1039.doc...
Page 116 CompAir UK Ltd PUBLICATION 98407.1039 Page 16 1039.doc...
Page 117: General Description And Operation
CompAir UK Ltd PUBLICATION 98407.1039 Page 17 4 GENERAL DESCRIPTION AND OPERATION Hand Unloaders. Suction Unloader System Gauge Panel Suction Filter Diaphragm Drain Valves Condensate Drainage CONFIGURATION The 5236 Mk2 is a four cylinder, single acting, two stage, 90° vee configuration, water cooled machine.
Page 118: Synthetic Oils
CompAir UK Ltd PUBLICATION 98407.1039 Page 18 SYNTHETIC OILS These are oils which are arrived at by chemical synthesis from petroleum feed stocks, although in some cases they would be from vegetable and mineral oils rather than by straight run distillation of crude. Advantages Carbon deposits are reduced compared with mineral type oils.
Page 119: Lubrication Schematic Flow Diagram
CompAir UK Ltd PUBLICATION 98407.1039 Page 19 LUBRICATION SCHEMATIC FLOW DIAGRAM Cylinders are lubricated by the oil mist created by oil thrown from the big end bearings 25 MICRON PUMP FILTER BY-PASS VALVE RELIEF only opens VALVE when blocked LOW OIL MAIN MAIN PRESSURE...
Page 120: Cooling
CompAir UK Ltd PUBLICATION 98407.1039 Page 20 COOLING Cooling is by water flowing through the jackets and passages, either from the mains or a closed circuit system using a radiator or cooling tower. A bursting disc is fitted to prevent excessive pressure build up in the water spaces if a leak should occur from the coolers.
Page 121: Condensate Drainage System
CompAir UK Ltd PUBLICATION 98407.1039 Page 21 4.10 CONDENSATE DRAINAGE SYSTEM FROM STAGE DELIVERY FROM SEPARATOR DRAIN CONNECTIONS 3 WAY STAGE STAGE SOLENOID VENT VALVE DIAPHRAGM TYPE UNLOADER VALVES DRAIN UNLOADER SURGE VESSEL SAFETY DRAIN VALVE This system comprises a pilot unloader valve, (PUV), and two diaphragm drain valves, (DDV's). The PUV comprises a three way air valve operated by a solenoid in one direction and a combination of air and spring pressure in the opposite direction and is automatically actuated by a signal from the motor starter or a electronic timer.
Page 122: Suction Unloading - Compair Standard
CompAir UK Ltd PUBLICATION 98407.1039 Page 22 4.11 SUCTION UNLOADING – COMPAIR STANDARD The unloading of the suction valves during compressor start-up is necessary to reduce starting torque and prevent motor overload. This system comprises a PUV and two first stage suction unloaders. The PUV comprises a three-way air valve operated by a solenoid in one direction and a combination of air and spring pressure in the opposite direction this is automatically actuated by a signal from the starter/control panel.
Page 123: Leading Particulars
CompAir UK Ltd PUBLICATION 98407.1039 Page 23 5 LEADING PARTICULARS UNIT DESIGNATION Model........................... 5236 Mk.2 TECHNICAL DATA – GENERAL Type..................Four cylinder, 2 stage, vee configuration Cooling ............................Water Direction of rotation, viewed from drive end..............Anti-clockwise Number of valves ............. One combined suction and delivery per cylinder Type of valve ......................Flat plate, low lift Mounting..................Three point, anti-vibration mounts TEMPERATURES...
Page 124: Connections
CompAir UK Ltd PUBLICATION 98407.1039 Page 24 CONNECTIONS Suction connection ......................... Rp3 Final stage delivery connection...................... Rp1 Water inlet and outlet connections ....................Rp1 5.10 RUNNING CLEARANCES (MILLIMETRES) Description Stage As Fitted (mm) Max Permissible (mm) Piston vertical clearance 0.5/1.2 0.25/1.35 1.35 Piston ring gaps 0.2/0.45...
Page 125: Torque Wrench Settings
CompAir UK Ltd PUBLICATION 98407.1039 Page 25 5.11 TORQUE WRENCH SETTINGS 5.11.1 CLASS A – CRITICAL (All figures ± 5%) NEWTON ASSEMBLY OPERATION SIZE METRE Big End Bearing Bolts First, Second Stage Cylinders to Crankcase First Stage Cooler Cover – Floating End First Stage Cooler Cover –...
Page 126 CompAir UK Ltd PUBLICATION 98407.1039 Page 26 1039.doc...
Page 127: Installation
CompAir UK Ltd PUBLICATION 98407.1039 Page 27 6 INSTALLATION HANDLING OF UNIT When using the compressor and motor eyebolts as the slinging attachment, it is essential that a spreader is used. The lift should always be made vertical, as inclined loadings drastically reduce the eyebolts' strength.
Page 128: Mounting
CompAir UK Ltd PUBLICATION 98407.1039 Page 28 Allow sufficient space around the installation to enable safe maintenance working conditions. Protection from severe weather conditions is desirable. Maximum allowable ambient cooling air temperature for radiator cooled sets is dependant on many variables eg, pressure, speed and type of oil.
Page 129: Cooling
CompAir UK Ltd PUBLICATION 98407.1039 Page 29 COOLING Satisfactory compressor operation depends on correct cooling, which requires positive circulation of cool, clean water, free from suspended particles. Check water is flowing in mains installations or, if closed circuit, that radiator is full. It is recommended that a filter be fitted in the inlet water line (mains).
Page 130: Electrical Connections
CompAir UK Ltd PUBLICATION 98407.1039 Page 30 ELECTRICAL CONNECTIONS Ensure compressor is installed to comply with local electricity authority stipulations and that necessary electrical work is carried out by a competent electrical engineer. Check electrical requirements for machine with manufacturer before commencing installation wiring. Read "Hazardous Area Operation"...
Page 131: Commissioning Or Recommissioning
CompAir UK Ltd PUBLICATION 98407.1039 Page 31 7 COMMISSIONING OR RECOMMISSIONING W A R N I N G :- BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE COMPLIANCE WITH THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK.
Page 132: Start-Up Procedure
CompAir UK Ltd PUBLICATION 98407.1039 Page 32 START-UP PROCEDURE NOTE: It is not necessary to remove any inhibition lubricant which may have been applied before despatch, unless there are specific instructions attached to the compressor stating otherwise. Screw down fully the first stage suction unloaders. Check radiator is topped up on radiator sets or water is flowing in correct volume in mains water installations.
Page 133: Operation And Routine Maintenance
CompAir UK Ltd PUBLICATION 98407.1039 Page 33 8 OPERATION AND ROUTINE MAINTENANCE OPERATION AND GENERAL MAINTENANCE The commissioning procedure (Section 4) should be used:– For the first commissioning run; Following overhaul; After standing idle for an extended period. External cleanliness of the compressor pipework and jointing is imperative in order that any leakages may be readily detected.
Page 134: Stopping
CompAir UK Ltd PUBLICATION 98407.1039 Page 34 STOPPING Stop compressor by depressing stop button on motor control panel. Turn off cooling water flow if no automatic water valve or water pump is fitted. The machine will automatically unload via unloader system. STANDING IDLE The unloaders will automatically be left open.
Page 135: Maintenance Schedule
CompAir UK Ltd PUBLICATION 98407.1039 Page 35 9 MAINTENANCE SCHEDULE W A R N I N G : 1. BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED AND ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED. 2.
Page 136: Changing Over From Mineral To Synthetic Lubricant
CompAir UK Ltd PUBLICATION 98407.1039 Page 36 CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT Compressor components in contact with the lubricant should be as clean as is practical before changing over. This is necessitated by the excellent solvency of synthetic oils which tend to loosen and remove existing deposits.
Page 137: Service Plan
CompAir UK Ltd PUBLICATION 98407.1039 Page 37 SERVICE PLAN Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided Change air intake element Suction filter element (air compressor only) Inspect Belt Tension Inspect Drive Coupling Inspect corrosion rods Replace corrosion rods Corrosion rod assy...
Page 138 CompAir UK Ltd PUBLICATION 98407.1039 Page 38 Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided Remove 1st stage valve Cover O ring covers Service 1st stage valves Valve kit Replace 1st stage valves Valve assy Inspect 1st stage pistons Deglaze 1st stage liners...
Page 139 CompAir UK Ltd PUBLICATION 98407.1039 Page 39 Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided FITT Joint-water pump bracket Joint-water pump Joint-water pump IN/OUT Replace bursting discs ( Bursting discs kit Radiator Set @9000hrs.) Replace drain valve Service kit...
Page 140 CompAir UK Ltd PUBLICATION 98407.1039 Page 40 Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided switch Test non return valve non return valve Seal 1039.doc...
Page 141: Dismantling And Reassembly Of Valves
CompAir UK Ltd PUBLICATION 98407.1039 Page 41 10 DISMANTLING AND REASSEMBLY OF VALVES GENERAL 10.1 Keep a spare oiled and maintained set of valves in store for quick compressor servicing. Valves should have a thin carbon layer and be slightly moist with oil. Valve removal is a simple procedure but the following guidelines should be observed.
Page 142: First Stage Valves - With Suction Unloaders
CompAir UK Ltd PUBLICATION 98407.1039 Page 42 10.3 FIRST STAGE VALVES – WITH SUCTION UNLOADERS 10.3.1 REMOVAL Remove the first stage suction unloader pipework and the nuts securing each of the two valve covers and withdraw the covers from the locating studs using forcing screws in the tapped holes provided in each cover.
Page 143 CompAir UK Ltd PUBLICATION 98407.1039 Page 43 Automatic unloader 1st STAGE CONCENTRIC VALVE Note: Valve is shown inverted for ease of assembly 1039.doc...
Page 144: First Stage Valves - Without Suction Unloaders
CompAir UK Ltd PUBLICATION 98407.1039 Page 44 10.4 FIRST STAGE VALVES – WITHOUT SUCTION UNLOADERS 10.4.1 REMOVAL Remove the nuts securing each of the two valve covers from the locating studs using forcing screws in the tapped holes provided in each cover. Screw valve lifters to each valve and lift from the cylinders.
Page 145: Second Stage Valves
CompAir UK Ltd PUBLICATION 98407.1039 Page 45 10.5 SECOND STAGE VALVES 10.5.1 REMOVAL As 7.3 A. i) except for removal of suction unloader pipework. 10.5.2 DISMANTLING Remove and discard 'O' ring (7). Unscrew and remove nut (8) whilst holding the valve in a soft jawed vice with just sufficient force to prevent it from turning.
Page 146 CompAir UK Ltd PUBLICATION 98407.1039 Page 46 2nd STAGE CONCENTRIC VALVE Note: Valve is shown inverted for ease assembly 1039.doc...
Page 147: Fault Guide
CompAir UK Ltd PUBLICATION 98407.1039 Page 47 11 FAULT GUIDE W A R N I N G :- BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED AND ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF.
Page 148: Compressor Runs Longer To Achieve System Pressure
CompAir UK Ltd PUBLICATION 98407.1039 Page 48 Fault Probable Cause Recommendation(s) Check LOW FIRST STAGE 11.4 COMPRESSOR PRESSURE symptoms. RUNS LONGER TO Piston ring wear. Check components, renew rings and ACHIEVE SYSTEM liners on 1st and 2nd stages as necessary. Check blowby on crankcase PRESSURE breather pipe.
Page 149: Illustrated Parts List
CompAir UK Ltd PUBLICATION 98407.1039 Page 49 12 ILLUSTRATED PARTS LIST CONTENTS PAGE CRANKCASE................A RUNNING GEAR ................. B 1st STAGE CYLINDERS ............. C 2nd STAGE CYLINDERS ............D 1st STAGE COOLER..............E 2nd STAGE COOLER..............F LUBRICATION................G UNLOADERS................H EXTERNAL COMPONENTS ............
Page 150: Crankcase
CompAir UK Ltd PUBLICATION 98407.1039 Page 50 * Thrust Washers fitted to older machines are now obsolete. If a replacement part is required a new type main bearing bush may be supplied. New compressors have new type main bearing bush fitted with integral thrust washer.
Page 151 CompAir UK Ltd PUBLICATION 98407.1039 Page 51 CRANKCASE PARTS ASSEMBLIES ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No CRANKCASE ASSEMBLY A1, 2, 3, 4, 5, 6, 27, 28 & 32 A30051.50 BEARING HOUSING ASSEMBLY A13, 14, 15, 16*, & 17 E60010.50 BEARING HOUSING ASSEMBLY A18, 19*, 20, 21, 22, &...
Page 152: Running Gear
CompAir UK Ltd PUBLICATION 98407.1039 Page 52 14 12 15 RUNNING GEAR 1039.doc...
Page 153 CompAir UK Ltd PUBLICATION 98407.1039 Page 53 RUNNING GEAR PARTS ASSEMBLIES ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No CONN-ROD ASSEMBLY B1, 2, 3 & 4 U.270.A PISTON ASSEMBLY B6, 7, 8, 9 & 10 D66376.50 PISTON RING SET B9 &...
Page 154: 1St Stage Cylinders
CompAir UK Ltd PUBLICATION 98407.1039 Page 54 10 9 8 7 6 5 4 3 2 1 1st STAGE CYLINDERS 1039.doc...
Page 155 CompAir UK Ltd PUBLICATION 98407.1039 Page 55 1st STAGE CYLINDERS PARTS ASSEMBLIES ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No CYLINDER & COOLER BODY ASSY C1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 21, & 22 A30053.50 VALVE COVER ASSEMBLY C19 &...
Page 156: 2Nd Stage Cylinders
CompAir UK Ltd PUBLICATION 98407.1039 Page 56 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 2nd STAGE CYLINDERS 1039.doc...
Page 157 CompAir UK Ltd PUBLICATION 98407.1039 Page 57 2nd STAGE CYLINDERS PARTS ASSEMBLIES ASSY No PER PARTS ASSEMBLY No DESCRIPTION MACHIN COMPRISING OF ITEMS CYLINDER & COOLER BODY ASSY D1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11& 12 A30052.50 VALVE COVER ASSEMBLY D26, 27 &...
Page 158: 1St Stage Cooler
CompAir UK Ltd PUBLICATION 98407.1039 Page 58 13 12 11 10 9 8 7 6 5 1st STAGE COOLER 1039.doc...
Page 159 CompAir UK Ltd PUBLICATION 98407.1039 Page 59 1st STAGE COOLER PARTS ASSEMBLIES ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No TUBESTACK ASSEMBLY E5, 6, 7, 8, 9, 10, 11, 12 & 13. D100619.100 COOLER COVER/SEPARATOR ASSY E3 & E4 E60659.50 INDIVIDUAL PARTS ITEM...
Page 160: 2Nd Stage Cooler
CompAir UK Ltd PUBLICATION 98407.1039 Page 60 10 11 12 13 14 15 16 17 18 19 20 21 6 5 4 3 2 1 9 8 7 2nd STAGE COOLER 1039.doc...
Page 161 CompAir UK Ltd PUBLICATION 98407.1039 Page 61 2nd STAGE COOLER PARTS ASSEMBLY ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No TUBESTACK ASSEMBLY F10, 11, 12, 13, 14, 15, 16, 17, & 18. NON RETURN VALVE ASSEMBLY F22, 23, 24 & 25 INDIVIDUAL PARTS ITEM ASSEMBLY...
Page 162: Lubrication
CompAir UK Ltd PUBLICATION 98407.1039 Page 62 4 5 6 To 1 stage suction LUBRICATION 1039.doc...
Page 163 CompAir UK Ltd PUBLICATION 98407.1039 Page 63 LUBRICATION PARTS ASSEMBLIES ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No OIL PUMP DRIVE ASSEMBLY G7, 8 & 9 C85737.3 INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No PLUG PS1068.2 SEAL 98660.1153...
Page 164: Unloaders
CompAir UK Ltd PUBLICATION 98407.1039 Page 64 To 1 stage seperator 12 13 14 15 To 1 stage seperator UNLOADERS 1039.doc...
Page 165 CompAir UK Ltd PUBLICATION 98407.1039 Page 65 UNLOADERS INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No SETSCREW 95000.256 RELIEF VALVE 98650.1011 SEAL 98660.1157 95111.5 STUD D66720.8.102 DIAPHRAGM DRAIN VALVE U334-L PLUG 98156.2560 NIPPLE 95414.165 SEAL 98504.1143 SEAL 98660.1156 ELBOW 95405.97 DRAIN PIPE ASSEMBLY - 1st Stage D100973.3...
Page 166: External Components
CompAir UK Ltd PUBLICATION 98407.1039 Page 66 EXTERNAL COMPONENTS 1039.doc...
Page 167 CompAir UK Ltd PUBLICATION 98407.1039 Page 67 EXTERNAL COMPONENTS INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No SETSCREW 95000.312 JOINT PS1813.20 SUCTION FILTER SILENCER 98262.1010 SUCTION FILTER SILENCER ELEMENT 98262.1063 PRESSURE GAUGE - 2ND STAGE 98288.1027 PRESSURE GAUGE - 1ST STAGE 98288.1026 THERMOMETER FINAL DELIVERY 98288.1085...
Page 168: Typical Drive Arrangements
CompAir UK Ltd PUBLICATION 98407.1039 Page 68 To motor Direct Drive Belt Drive TYPICAL DRIVE ARRANGEMENTS 1039.doc...
Page 169 CompAir UK Ltd PUBLICATION 98407.1039 Page 69 TYPICAL DRIVE ARRANGEMENTS INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No BELT DRIVE C200716 MOTOR PLATES C86469 C86470.1 ADJUSTING BLOCKS ADJUSTING SCREWS D66720.16.20 E60017 STUD M16 X 36 MOTOR BRACKET E.60249 E60253 PULLEY PS1130.21 BELT GUARD...
Page 170: 1St Stage Concentric Valve
CompAir UK Ltd PUBLICATION 98407.1039 Page 70 Note: Valve is shown inverted for ease of assembly 1ST STAGE CONCENTRIC VALVE 1039.doc...
Page 171 CompAir UK Ltd PUBLICATION 98407.1039 Page 71 1ST STAGE CONCENTRIC VALVE (AUTOMATIC UNLOADER VERSION) INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No CONCENTRIC VALVE COMPLETE 98650.1520 L1/1 LOWER BODY (including stud) L1/2 VALVE PLATE L1/3 VALVE SPRING L1/4 VALVE SPRING L1/5 LIFT WASHER - Lower (0.8mm) L1/6...
Page 172: 2Nd Stage Concentric Valve
CompAir UK Ltd PUBLICATION 98407.1039 Page 72 Note: Valve is shown inverted for ease of assembly 2ND STAGE CONCENTRIC VALVE 1039.doc...
Page 173 CompAir UK Ltd PUBLICATION 98407.1039 Page 73 2ND STAGE CONCENTRIC VALVE INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No CONCENTRIC VALVE COMPLETE 98650.1039 LOWER BODY (including stud) VALVE/BACKING PLATE SPRING PLATE SPRING PLATE VALVE PLATE 'O' RING 95602.55 RA,RC,RD UPPER BODY 1039.doc...
Page 174: Diaphragm Drain Valve
CompAir UK Ltd PUBLICATION 98407.1039 Page 74 DIAPHRAGM DRAIN VALVE 1039.doc...
Page 175 CompAir UK Ltd PUBLICATION 98407.1039 Page 75 DIAPHRAGM DRAIN VALVE PARTS ASSEMBLIES ASSY No PER PARTS DESCRIPTION COMPRISING OF ITEMS MACHINE ASSEMBLY No MAINTENANCE KIT - 1st and 2nd N3, 5, 6, 7, 11 & 12 98650.1531 stage Diaphragm Valve SERVICE KIT - 1st and 2nd stage N4 &...
Page 176: Control System
CompAir UK Ltd PUBLICATION 98407.1039 Page 76 To 2 Stage Cylinder Condensate Drain Connection SUCTION UNLOADER STAGE STAGE PRESS PRESS PRESS GAUGE GAUGE GAUGE To 2 Stage Cylinder Condensate Drain Connection To 1 Stage To 2 Stage Separator Separator Pressure Pressure Connection Connection...
Page 177 CompAir UK Ltd PUBLICATION 98407.1039 Page 77 CONTROL SYSTEM INDIVIDUAL PARTS ITEM ASSEMBLY DESCRIPTION No OFF PART No BRACKET C202283 SETSCREW 95000.227 CAPSCREW 95018.132 PILOT UNLOADING VALVE PS2197 95410/264 PLUG C73732/7 WASHER 98660/1153 LOW OIL PRESSURE SWITCH 98524/1042 CAPSCREW 95018.100 P10# SUCTION UNLOADING VALVE 98650.1658...
Page 178 CompAir UK Ltd PUBLICATION 98407.1039 Page 78 1039.doc...
Page 179: Ancillary Equipment
CompAir UK Ltd PUBLICATION 98407.1039 Page 79 13 ANCILLARY EQUIPMENT 13.1 VEE BELT ADJUSTMENT & TENSIONING – APP011 DRIVE RECOMMENDATIONS (V-BELT TRANSMISSION) Details of drive arrangements and non isolation pad mountings are available from Reavell Works, Ipswich. An overload device must always be fitted to motors. Manufacturers terminal box wiring instructions must be observed.
Page 180 CompAir UK Ltd PUBLICATION 98407.1039 Page 80 BELT DEFLECTION MEASUREMENT Required Deflection Force "P" at Centre of Span For Compressor Speed Ranges (Newtons) Above follows current BS3790 practice. RECOMMENDED TENSIONING FORCE Centre Distance Belt tension indicator applied to mid-span Straight edge ADJUSTMENT METHOD If belt tension is incorrect, release the compressor holding down screws enough to allow the adjustment screws to be free to slide the compressor on its adjustment slots without being too loose.
Page 181 CompAir UK Ltd PUBLICATION 98407.1039 Page 81 TABLE Belt Force required to deflect belt 16 mm per metre of span Section Small Pulley Newton Kilogram force Ø mm (kgf) 67 to 95 10 to 15 1.0 to 1.5 100 to 140 15 to 20 1.5 to 2.0 100 to 132...
Page 182: Direct Drive - App011B
CompAir UK Ltd PUBLICATION 98407.1039 Page 82 13.2 DIRECT DRIVE – APP011B DIRECT DRIVE: Ensure compressor and drive motor is correctly aligned as the flexible couplings are for vibration duties only and not as non-alignment couplings. Note direct coupled sets with bell type housing (see below) are self aligning.
Page 183: Radiator Filling Water Cooling System - App077
CompAir UK Ltd PUBLICATION 98407.1039 Page 83 13.3 RADIATOR FILLING WATER COOLING SYSTEM – APP077 TYPICAL RADIATOR WATER COOLING SYSTEM SPECIAL INSTRUCTIONS FOR STARTING COMPRESSOR COOLANT (ANTI-FREEZE) FILLER CAP COOLING WATER PIPE OUTLET RADIATOR DRAIN WATER PUMP COOLING WATER PIPE INLET COOLING WATER PIPE RETURN BEFORE INITIAL STARTING FILLING AND BLEEDING THE WATER SYSTEM.
Page 184: Water Pump Assembly & Drive - App073
CompAir UK Ltd PUBLICATION 98407.1039 Page 84 13.4 WATER PUMP ASSEMBLY & DRIVE – APP073 WATER PUMP DRIVE 5236, 5336, 5436 MK2, 5436.3 & 5437.1 Item No Part No Description No Off C201503 Gasket water pump C201504 Gasket water pump C201537 Sprocket water pump drive C201538...
Page 185: Pressure Maintaining Valve - App057
CompAir UK Ltd PUBLICATION 98407.1039 Page 85 13.5 PRESSURE MAINTAINING VALVE – APP057 PRESSURE MAINTAINING VALVE (BACK PRESSURE REGULATING VALVE) 98650.1759 Maximum Pressure 40 bar Temperature Range - 10 to 100°C Flow Rate 300m³/hr Connections 1" BSPP This valve is fitted to maintain a back pressure through the separators, filters and the dryers (if fitted). This ensures that these items of equipment reach their optimum working pressure as soon as possible, to give long filter life, good oil separation and low oil consumption.
Page 186: Solenoid Valves - App138
CompAir UK Ltd PUBLICATION 98407.1039 Page 86 13.6 SOLENOID VALVES – APP138 3 WAY SOLENOID VALVE PS2197 OPERATION 3 way normally closed energise to open, continuous duty. On starting the solenoid valve opens (energised) this operates the diaphragms which in turn closes the valves within the D.D.Vs.
Page 187: Safety Valve - App167
CompAir UK Ltd PUBLICATION 98407.1039 Page 87 13.7 SAFETY VALVE – APP167 Installation and Operating Instructions SAFETY VALVES INTRODUCTION Due consideration should be taken of climatic. Process or other conditions which might adversely affect the performance of the safety valve. Installation must be undertaken by qualified technicians and to good engineering practice.
Page 188 CompAir UK Ltd PUBLICATION 98407.1039 Page 88 FUNCTIONAL TESTING Once installed in service. Valves should be tested at least once every six months to ensure free movement of parts. This should be carried out by operating the easing gear when the valve is under a pressure of not less than 75'% of the set pressure.
Page 189: Temperature Controller - App090C
CompAir UK Ltd PUBLICATION 98407.1039 Page 89 13.8 TEMPERATURE CONTROLLER – APP090C THERMOMETER SWITCHES C202556, C202749, C202960 & C202964 98288.1093, 98288.1094 & 98288.1215 THESE THERMOMETER SWITCHES ARE SET TO THE FIGURES QUOTED BELOW, THE FOLLOWING INFORMATION IS FOR SETTING INFORMATION ONLY, IF THE TEMPERATURE SWITCH HAS TO BE REPLACED OR RE-ADJUSTED.
Page 190 CompAir UK Ltd PUBLICATION 98407.1039 Page 90 CONTROLLER TRIP POINTER USED ON PART No STOP SETTING °C COMPRESSOR MODEL C202556.1 5236.1 C202556.2 5212 C202556.3 5336,5415 C202556.4 5215 & 5217 C202556.5 5236.2,5315 C202556.6 5415E5317,5417.5417N C202556.7 5436(CU TUBES) C202556.8 5436.1 &.2,5436H,5436N,5436SN & 5437 C202749.1 5280 C202749.2...
Page 191: Pressure Gauge - App070
CompAir UK Ltd PUBLICATION 98407.1039 Page 91 13.9 PRESSURE GAUGE – APP070 PRESSURE GAUGES GENERAL The pressure gauge should be installed such as to avoid exposure to heat and vibration and to enable easy observation of the dial indication. IMPORTANT It is common practise to install the pressure gauge without an isolating device, so to facilitate calibration or replacement the system must be de pressurised before any work is carried out.
Page 192: Pressure Switch - App086 & 088
CompAir UK Ltd PUBLICATION 98407.1039 Page 92 13.10 PRESSURE SWITCH – APP086 & 088 HIGH AIR/GAS PRESSURE SWITCHES PART NO: 98524/1025, 1049, 1094, 1095, 1096, 1102, 1103, 1104, 1107, 1128, 1135, 1136, 1137, 1210 & 1212 OPERATION - MANUAL START/AUTO STOP Located as close as possible to the delivery, inlet air/gas line, the pressure switch stops the compressor when the air/gas pressure rises or falls above or below the pre-set pressure setting.
Page 193 CompAir UK Ltd PUBLICATION 98407.1039 Page 93 ADJUSTING NUT CONDUIT THREAD INSTALLATION Mount the switch by the bracket provided. It is usual to connect 1 (C) and 2 (NC) to the compressor electrical control circuit terminals marked "Pressure Switch". Remove cover to set pressure setting, using a pressure gauge. Note:- Switches are pre-set and do not usually need adjusting.
Page 194 CompAir UK Ltd PUBLICATION 98407.1039 Page 94 LOW OIL PRESSURE SWITCH PART NO: 98524.1042, 98524.1122, 98524.1140 & 98524.1170 OPERATION Located in the crankcase on water-cooled & large air-cooled compressors, in the oil filter body on air-cooled, the pressure switch stops the compressor when the oil pressure drops to pre-set pressure setting. PART NO.
Page 195: Anti-Vibration Mounts - App003
CompAir UK Ltd PUBLICATION 98407.1039 Page 95 13.11 ANTI-VIBRATION MOUNTS – APP003 AVA TYPE PART NUMBERS VARIOUS PREVENTIVE MAINTENANCE After installation and initial running in. Record height dimension (H) of each mount. After a week or 100 hours running time recheck and record dimension (H) Check this dimension every 3 to 6 months depending on usage i.e.
Page 196: Demister - App043
CompAir UK Ltd PUBLICATION 98407.1039 Page 96 13.12 DEMISTER – APP043 OIL/MOISTURE DEMISTER VESSELS TYPICAL ARRANGEMENT GENERAL DESCRIPTION These Demister Vessels are designed to separate condensate from the compressor drainage blowdown system, discharging clean air through coalescer filters to the atmosphere. The discharge air contains less than 0.5-mg/M³-oil mist with a noise level hardly above the compressor noise.
Page 197 CompAir UK Ltd PUBLICATION 98407.1039 Page 97 DEMISTER VESSELS PARTS Item No. Description E61201 E61187 E61198 E61106 Used on 5215/5217 5315/5317 5280/5336 5436N/5437N 5236 5415/5417/5420 5436/5437 5417N/5420N Demister Tank E61200 E61188 E61197 E61105 Dowty Seal PS1322.8 PS1322.8 PS1322.8 PS1322.8 Cable PS1481 PS1481 PS1481...
Page 198: Water Inlet Control Valve - App071 & 704
CompAir UK Ltd PUBLICATION 98407.1039 Page 98 13.13 WATER INLET CONTROL VALVE – APP071 & 704 WATER VALVE NORMALLY CLOSED U231.F & U231.H OPERATION Located on the water inlet to the compressor the valve stops water flowing through the compressor on shut down.
Page 199 CompAir UK Ltd PUBLICATION 98407.1039 Page 99 MAINTENANCE AND SPARES KITS Part Number Description Makers Part Number Used on Stem & Disc Kit 97701319 98405.1004 Stuffing Box & Nut Kit 97701320 98650.1291 Diaphragm Kit 97700017 Stem & Disc Kit 97701321 98650.1292 98504.1005 Stuffing Box &...
Page 200 CompAir UK Ltd PUBLICATION 98407.1039 Page 100 WATER VALVE NORMALLY OPEN 98650.1298 IF FITTED OPERATION Located on the water inlet to the compressor this valve is often used as a by pass valve when compressors are operating in tandem and using the same water supply i.e. a normally closed and normally open valve fitted.
Page 201 CompAir UK Ltd PUBLICATION 98407.1039 Page 101 APP704 PNEUMATIC WATER VALVE COMPAIR PART NUMBERS: PORT SIZE BODY MATERIAL 98650.2584.1 1” BSP BRONZE 98650.2584.2 1” BSP STAINLESS STEEL 98650.2585.1 ¾” BSP BRONZE 98650.2585.2 ¾” BSP STAINLESS STEEL DESCRIPTION A 2-port pneumatically actuated on/off valve for use on water, air, oil and gasses.
Page 202 CompAir UK Ltd PUBLICATION 98407.1039 Page 102 1039.doc...
Page 204 WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd. Ipswich, may lead to failure in service which would not be covered by the warranty. Any unauthorised modifications or failures to maintain this equipment is accordance with the manufacturers maintenance instructions may make it unsafe.

Gardner Denver Compair Reavell 5236.2.IA Operator's Handbook Manual

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