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BLACKMER HD COMPRESSORS
Installation, Operation, and Maintenance Instructions
NON-LUBE, RECIPROCATING GAS COMPRESSORS
Water Cooled: HDL602C, HDL603C, HDL642C, HDL643C
Table of Contents
Safety Data ................................................................ 2
Compressor Data ................................................. 3
Nameplate Data .................................................... 3
Location and Piping .............................................. 5
Mounting the Compressor Unit ............................ 5
Stationary Compressors ....................................... 5
Compressor Flywheel ........................................... 6
V-Belt Drives ......................................................... 6
PTO Drives ........................................................... 6
Suction Valve Unloaders ...................................... 7
Interstage Piping / Cooling ................................... 7
Water Cooled Compressors ................................. 7
Maximizing Compressor Life ................................ 7
Seal (Packing) Arrangements .............................. 8
Relief Valves ......................................................... 9
Liquid Traps ........................................................ 10
4-Way Valves ...................................................... 10
Temperature and Pressure Switches ................ 10
Pressure Gauges ................................................ 10
Single-Stage Models
Air-Cooled: HD602C, HD603C
Two-Stage Models
Air-Cooled: HD612C, HD613C
Water Cooled: HDL612C, HDL613C
960485
INSTRUCTIONS CB9A-081
Pre-Start up Check List ......................................... 11
Start Up Procedure ............................................... 11
Service Schedule .................................................. 12
Tool List ................................................................. 13
Bolt Torque Table .................................................. 13
Crankcase Lubrication .......................................... 14
Setting the Oil Pressure ........................................ 14
Compressor Disassembly ....................................... 15
Compressor Assembly ............................................ 16
Valve Replacement ................................................... 18
Unloader Seal Replacement .................................... 19
Piston Ring Replacement ........................................ 19
Seal (Packing) Replacement ................................... 20
Bearing Replacement ............................................... 22
Oil Pump Replacement ............................................ 23
Extended Storage ..................................................... 23
Troubleshooting ....................................................... 24
Section
901
Effective
Feb 2019
Replaces
Mar 2017
r130716
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Summary of Contents for BLACKMER HD602C
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Page 1: Table Of Contents
Installation, Operation, and Maintenance Instructions Effective Feb 2019 Replaces Mar 2017 r130716 NON-LUBE, RECIPROCATING GAS COMPRESSORS Single-Stage Models Air-Cooled: HD602C, HD603C Water Cooled: HDL602C, HDL603C, HDL642C, HDL643C Two-Stage Models Air-Cooled: HD612C, HD613C Water Cooled: HDL612C, HDL613C Table of Contents Safety Data ..............2 Operation General Information Pre-Start up Check List ......... -
Page 2: 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
The basic size and type of the compressor is indicated by "Model No." A suffix letter is used to indicate the version. For detailed ATEX Declaration information, refer to FORM 576 found in the Certification section of Blackmer’s website. CB9A-081... - Page 4 GENERAL INFORMATION An 11 character "I.D. No." identifies the construction of the compressor. Table 3 - ID NUMBER KEY HD 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 5: Installation
INSTALLATION NOTICE: Blackmer compressors must only be installed in systems designed by qualified engineering personnel. Discharge piping surface temperatures System design must conform with all applicable may be hot during operation (over 158°f, regulations and codes and provide warning of all 70°c). -
Page 6: Compressor Flywheel
Failure to disconnect and lockout electrical power or engine drive before V-BELT DRIVES attempting maintenance can cause Most Blackmer compressors are driven via V-belts which severe personal injury or death Hazardous must be properly aligned and tensioned. machinery can cause serious personal injury. -
Page 7: Suction Valve Unloaders
Compressors may be fitted with suction valve unloaders to Life of critical compressor components such as piston rings, provide loadless start or capacity control functions. valves and packing will vary considerably with each Blackmer unloaders are basically a piston and a plunger application, installation, operating procedures. -
Page 8: Seal (Packing) Arrangements
INSTALLATION SEAL (PACKING) ARRANGEMENTS Also note any tubing connections in the seal area. 1/4" NPT ports are provided between each pair of seals to allow Double and Triple Seal models are available to provide a proper venting or pressurization of the seal areas (double wide range of leakage control/containment options. -
Page 9: Relief Valves
See the 'Troubleshooting' section. Since all systems differ in design, care must be taken to ensure the relief valve is installed to safely vent away from Blackmer offers various relief valves for gas and application sources of ignition and personnel. This can be compatibility. -
Page 10: Liquid Traps
If used, a 2nd stage inlet system design. liquid trap would be located after the intercooler. Blackmer offers a variety of liquid traps. The most common variations include: Optional liquid trap level switches, A non-code vessel fitted with a stainless steel float... -
Page 11: Operation
Ensure that pressure gauges are installed on both inlet and discharge of the compressor. Failure to disconnect and lockout Blackmer compressors are shipped from the factory electrical power or engine drive before without oil in the crankcase. Fill with a high quality... -
Page 12: 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... -
Page 13: Tool List
Crankshaft Bearings Torque Wrench Various Hoist (useful) Cylinder and Crosshead Guide BOLT TORQUES Proper bolt torques to use when reassembling the compressor. Table 8 - BOLT TORQUES FOR BLACKMER COMPRESSORS FT-LBS (Nm) Crankcase Packing Box Con. Rod Bearing Bearing Oil Pump... -
Page 14: Crankcase Lubrication
MAINTENANCE Sizes Quarts Liters All 600, 640, 610 Series 6.62 Table 9 - Oil Capacity Mineral Based Oil - API Grade SN, SM, SL, SJ Ambient Product Grade Temperature 80°F (27°C) and above 32 to 80°F Mobil® (0 to 27°C) Rarus 427 0 to 32°F equivalent... -
Page 15: Compressor Disassembly
COMPRESSOR DISASSEMBLY Removal of the packing boxes is dependent on the Model Number of the Compressor. For disassembly of the packing boxes, refer to "Seal (Packing) Failure to disconnect and lockout Replacement". electrical power or engine drive before attempting maintenance can cause Double-Seal Models severe personal injury or death Using an adjustable spanner wrench, remove the... -
Page 16: Crankcase Assembly
The packing installation assembly, first coat the wrist pin, the wrist pin bore tool (Blackmer Part No. 795038) MUST be used to in the crosshead assembly, and the wrist pin avoid damaging the packing when starting it over bearing in the connecting rod with grease. - Page 17 COMPRESSOR ASSEMBLY CYLINDER ASSEMBLY 12. Rotate the compressor by hand to verify that it turns Install new O-rings in the bottom of the cylinder. A freely. Make sure the pistons are not hitting against the small amount of grease may be used to hold the O- bottom of the cylinder head assembly.
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Page 18: Valve Replacement
VALVE REPLACEMENT When replacing the valves, it is important to install the suction and discharge valves in the correct location in the cylinder head. NOTE: The valves may be removed without removing the cylinder head from the cylinder. Be sure to remove and replace the valve gaskets. -
Page 19: Unloader Seal Replacement
VALVE REPLACEMENT Remove the valve cap (or unloader assembly) and Install the hold down screw and tighten according O-ring from each valve. to the Bolt Torque Table. Install the valve cap (or unloader assembly) and Remove the valve hold down screw with valve hold- O-ring. -
Page 20: Seal (Packing) Replacement
SEAL (PACKING) REPLACEMENT Follow the steps in "Compressor Disassembly" to remove the packing boxes. Seal (Packing) disassembly Remove the upper retainer ring from the packing box being serviced. Disassemble the packing box and discard the old packing sets and packing springs. Seal (Packing) assembly NOTE: Before reassembling the packing boxes, refer back to "Seal Arrangements". - Page 21 SEAL (PACKING) REPLACEMENT S3R Seal Cup Disassembly Remove the seal cup from the packing box by removing the eight socket head capscrews. Remove the retainer ring, spring, packing and washers. Remove remaining socket head capscrews to remove the seal cup cover. Remove the S3R seal from the seal cup.
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Page 22: Bearing Replacement
BEARING REPLACEMENT NOTICE Note the proper orientation and carefully press the When replacing the bearings, the entire bearing outboard bearing cup into the bearing carrier assembly, including the bearing cup and the bearing assembly. and the crankshaft endplay cone, must be replaced Press a bearing cone onto each end of the must be readjusted. -
Page 23: Oil Pump Replacement
OIL PUMP REPLACEMENT Place the spring and the drive cone in the end of the crankshaft. 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 discharge Worn or Broken Piston Rings line. - Page 25 Notes CB9A-081 page 25/28...
- Page 26 CB9A-081 page 26/28...
- Page 27 This page intentionally left blank CB9A-081 page 27/28...
- Page 28 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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