Hycomp Ambient Installation & Operation Manual

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COMPRESSOR

INSTALLATION

OPERATION

MANUAL

for

Ambient Air Compressors

Air Boosters

Gas Compressors

OIL FREE AIR & GAS COMPRESSORS

WI-400-010 APP 1, Rev. 5

Rev 2/13

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Troubleshooting

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Summary of Contents for Hycomp Ambient

Page 1: Compressor Installation
COMPRESSOR INSTALLATION & OPERATION MANUAL Ambient Air Compressors Air Boosters Gas Compressors OIL FREE AIR & GAS COMPRESSORS WI-400-010 APP 1, Rev. 5 Rev 2/13...
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Page 3: Table Of Contents
CONTENTS Warranty ....................................4 General Information ................................5 Compressor Nameplates ..............................5 Safety ....................................6 Introduction to Oil Free Ambient Air Compressors ......................7 Introduction to Air Boosters and Gas Compressors ......................8 Section 1 - Compressor Installation...........................9 Using This Manual ..............................9 Receipt of Compressor...............................9 Location ..................................9 Foundation .................................9...
Page 4: Warranty
WARRANTY - GENERAL Hycomp warrants that its compressors will be free from defects in material and workmanship for a period of twelve (12) months from the date of purchase. Hycomp compressors which fail within the 12 month period due to defects in material or workmanship, will be repaired or replaced at Hycomp’s discretion provided the Purchaser meets all of the applicable requirements of the warranty...
Page 5: General Information
2AN13C, AN10C, AN6C, This manual is intended to assist qualiﬁ ed technical 2AN3C personnel in the installation, operation and maintenance of Hycomp compressors, and should be kept with the D Block: AN44, WN44, 2AN26, 2AN35, compressor at all times. AN20D, 2AN35, 2WN35,...
Page 6: Safety
This parameters should only be made with the approval includes, but may not be limited to, gas containment of Hycomp. Contact the factory should a change be policy, protection required for personnel working necessary.
Page 7: Introduction To Oil Free Ambient Air Compressors
Hycomp oil free compressors are designed for heavy, All Hycomp air compressors are tested at the factory industrial duty service. Slower compressor speeds to ensure they meet contractual requirements. When prevent heat buildup, increase valve efﬁ ciency, and properly installed, the air compressor should be ready increase overall life expectancy of wearing parts.
Page 8: Introduction To Air Boosters And Gas Compressors
“boost” it to an even higher pressure. Because these compressors do not All Hycomp boosters & compressors are tested at the draw from atmosphere they require special attention factory to ensure they meet contractual requirements.
Page 9: Section 1 - Compressor Installation
Air Boosters - these are compressors that compress accordingly. Noise from a typical Hycomp compressor air that is taken from a source other than the ambient will often exceeds 80 dBA @ 3ft. air. Generally the inlet air source is at an elevated...
Page 10: Inlet Piping And Inlet Filtration
See Figure 3 for additional details. Ambient Air Compressors – In most cases, the standard air ﬁ lter furnished from the factory is Epoxy based grouting is required to firmly seat sufﬁ ciently large to meet normal operating conditions and attach the compressor skid to the concrete when periodically serviced.
Page 11: Discharge Piping
5-15 15-20 placed at the discharge receiver and upstream of the 20-50 8-12 aftercooler. Never place a line valve in the discharge piping between the compressor discharge and the Table 1: Receiver Sizing for Ambient Air safety valve. Compressors...
Page 12: Receivers - Ambient Air Compressors
Keep RECEIVERS the cylinder and head clean and free from dust and Ambient Air Compressors - In general, larger debris to help maximize heat dissipation. Air cooled receivers give better service from a compressor. intercoolers and aftercoolers are generally located in Ideally, the receiver should be large enough so that close proximity to the ﬂ...
Page 13: Compressor Control Panel
COMPRESSOR CONTROL PANEL Hycomp recommends the use of the following valves Your Hycomp compressor may be provided with a and devices to regulate cooling water: factory installed compressor control panel (see Figure Optional accessories specific to the control Solenoid Shutoff Valve –...
Page 14: Unloader Controls
(See Figure 7). Unloader Tower – Provided on all pressure lubricated Hycomp model ambient air compressors and provided Figure 7: Unloader Device Locations on some air booster and gas compressors. If the...
Page 15 1/4” tube of appropriate pressure rating, to supply unloading gas/air to the unloader towers. Constant Speed Unloader (Pilot Valve) – Provided upon request for any Hycomp model air compressor. Hydraulic Unloader Valve – Provided on all pressure Not used on air boosters or gas compressors. Located...
Page 16 Check valve if a hydraulic unloader is also so that if electrical power is lost or the solenoid fails, used. If included as part of a Hycomp controls package, the valve will unload the compressor. There are the unloader valve (Port #2) is already plumbed.
Page 17: Safety Devices
SAFETY DEVICES The following devices may be included with your Hycomp compressor system (see Figure 14). However, if they are not included, it is required that they be installed and properly adjusted, prior to operation of the compressor. Lack of these safety devices will void the compressor warranty.
Page 18: Plumbing Of Air Booster And Gas Compressor Packings
Pressure Hycomp gas compressors utilize piston rod gas safety valves are preset by the manufacturer and the packings to maintain a pressure on the backside of...
Page 19 The gas vent/purge ports are 1/8” NPT. Hycomp Three main styles of rod-packing arrangements suggests the use of minimum 1/4” tubing to vent or are used on Hycomp oil-free air boosters and gas purge the ports. Use proper tubing practices for vent/ compressors: the ‘B’...
Page 20 B22 process gases. arrangement.
Page 21 B31 Series: No. of Packings per Rod: Pressure side: Vents: Plugged Maximum Inlet Pressure: 165 psig Minimum Inlet Pressure: 1 psig B22 Series: No. of Packings per Rod: Pressure side: Bottom Vents: Plugged Maximum Inlet Pressure: ≤ atmospheric Minimum Inlet Pressure: 8 psia B32 Series: No.
Page 22 Two pairs of tangent-tangent above local ambient pressure. If the purge gas cannot packings per rod provide the ﬁ rst isolation of the meet these pressure requirements, or if it is necessary process gas.
Page 23 G211 Series: No. of Packings: 2 Upper 1 Lower Pressure side: Vent Pressure: ≥ Atmospheric < Suction Maximum Inlet Pressure: 99 psig Minimum Inlet Pressure: 10 psig 1/8” NPT Vent ports must be plumbed to safe vent location, purged, or padded. G221 Series: No.
Page 24 G212 Series: No. of Packings: 2 Upper 1 Lower Pressure side: Bottom Vent Pressure: ≥ Atmospheric > Suction Maximum Inlet Pressure: 10 psig Minimum Inlet Pressure: 0 psig 1/8” NPT Vent ports must be plumbed to safe vent location, purged, or padded. G222 Series: No.
Page 25: Section 2 - Compressor Startup
(6 bag / 4000 psi mix) weighing at least twice the weight of  Ambient Air Compressors must have an inlet ﬁ lter the bare compressor. Fill a permanent mounted installed. baseplate/skid with epoxy grout.
Page 26: Using This Manual
Air Boosters - these are compressors that compress Hycomp compressors ship with HYSYN SAE 30/ISO air that is taken from a source other than the ambient 68 synthetic compressor oil in the crankcase, unless air. Generally the inlet air source is at an elevated otherwise requested.
Page 27: Oil Pressure Regulation
Suitable oils for use in Hycomp compressors valve located in the bearing carrier on the end of include: the compressor opposite the flywheel. Pressure is controlled by an adjusting screw and lock nut . Adjustment must be made while the compressor is...
Page 28: V' Belt Tension Settings
The motor drive shaft must be parallel sheave. A parallel misalignment will be observed as an to the compressor crankshaft. Hycomp recommends offset between the center line of a belt on the ﬂ ywheel banded belts rather than multiple individual belts.
Page 29 edge not in contact with the motor sheave. Observe alignment of the face of the motor sheave with the line At the center of the span (t), apply force using the of the straight edge. Adjustment of the motor and/or tension tester perpendicular to the span.
Page 30: Adjustment Of Manual Unloader Controls
No other adjustment of UNLOADER CONTROLS the hydraulic unloader is possible. Hydraulic Unloading - All pressure lubricated Hycomp model air compressors come with hydraulic unloading, Constant Speed Unloading (Dual Control if Used in also known as load-less start. The hydraulic unloader...
Page 31 unload pressure, counterclockwise for decreased Plumbing of the constant speed unloader valve is unload pressure. When adjusted properly, tighten covered in Section 1, Compressor Installation. down locknut. Three air pressure ranges are available for constant The differential pressure is set by use of the screw speed unloading.
Page 32: Adjustment Of Automatic Unloader Controls
ADDITIONAL CONTROLS ADJUSTMENT Discharge Pressure Switch - This switch commonly Hycomp tests and adjusts all compressors at the factory has two adjustments: one for the discharge pressure to perform to the requirements of the sales contract. setpoint and the other for deadband (the range of falling discharge pressure before the compressor loads Bare compressors are factory tested for operability.
Page 33 Control Power Transformer Enclosure (Fused) Control Relays Motor Starter (with overload protection Timer Relays allow adjustment of: Oil Pressure Fault Delay Unload Time-out Unloaded Startup Time Figure 21a: Unloader Control Timer Relay Adjustment Discharge Pressure Switch with Suction Pressure Switch adjustable deadband.
Page 34: Additional Controls Adjustment
(see Figure 21a). tensions. Changes in oil viscosity or ambient temperature may require minor timer adjustment. Manually rotate compressor sheave through several full rotations to be sure there is no Discharge Temperature Switch - This switch is factory mechanical interference felt.
Page 35 Controls Adjustment Notes (make notes here) Device Setting Date...
Page 36: Pre-Startup Checklist
Ambient Air Compressors are compressors whose inlet Steps 1-14 must be performed prior to connecting source is the ambient air surrounding the compressor. the unit to a power source. All air compressors are broken in and tested at the factory prior to shipment.
Page 37: Initial Startup And Operation (Air Boosters And Gas Compressors)
Air Boosters - these are compressors that compress should be monitored at least once every 6-8 hours. air that is taken from a source other than the ambient After two days of operation, check the belt tension, oil air. Generally the inlet air source is at an elevated level and inspect for leaks.
Page 38: Daily Startup Checklist
be completely isolated from the supply gas. If the air or nitrogen break-in gas will adversely affect the downstream system, it too must be isolated. Since all industrial gases are dangerous to human life, it must be ensured that there are no leaks in the system that would compromise the safety of personnel or property.
Page 39: Section 3 - Maintenance And Troubleshooting
Air Boosters - these are compressors that compress your compressor, a routine preventive maintenance air that is taken from a source other than the ambient schedule should be developed and followed. Table air. Generally the inlet air source is at an elevated...
Page 40 (no acidic components, ﬁ ltered to 0.1 micron) and 75°F ambient temperatures, running 8 hours per day. Time frames may need to be shortened in harsher environments.
Page 41 MENDATIONS** REPLACE RINGS, VALVES, PACKINGS (not on Ambient Air Compressors), OIL SCRAPERS * OIL AND FILTER SHOULD BE CHANGED EVERY 2,000 HOURS OR 6 MONTHS, WHICHEVER OCCURS FIRST. UNITS WITHOUT AN OIL FILTER SHOULD BE CHANGED EVERY 1,000 HOURS OR 6 MONTHS, WHICHEVER OCCURS FIRST.
Page 42: Troubleshooting
WARNING: The compressor MUST be locked out If it is not possible to diagnose the cause of the from all energy sources prior to inspection, and problem, contact Hycomp or a Hycomp authorized all pressure MUST be relieved from unit to prevent dealer for assistance.
Page 43 TOUBLESHOOTING CHART (cont’d) LOW OR NO OIL PRESSURE SUGGESTED REMEDY PROBABLE CAUSE LOW OIL LEVEL FILL CRANKCASE TO FULL MARK. CLOGGED OIL STRAINER REMOVE AND CLEAN OIL STRAINER. DEFECTIVE OIL PRESSURE ‘B’, ‘C’, ‘D’, ‘E’ AND ‘V’ BLOCKS: REMOVE REGULATING VALVE REGULATING VALVE ADJUSTING SCREW, SPRING AND BALL.
Page 44 TOUBLESHOOTING CHART (cont’d) KNOCKING OR THUMPING SOUNDS SUGGESTED REMEDY PROBABLE CAUSE LOW OIL LEVEL CHECK FOR PROPER OIL LEVEL. IF LOW, CHECK FOR DAMAGE TO BEARINGS. NO OIL PRESSURE CHECK ALL POSSIBLE REMEDIES LISTED UNDER “LOW OIL PRESSURE” IN THIS SECTION. LOOSE FLYWHEEL OR MOTOR PULLEY CHECK FOR TIGHTNESS OF FLYWHEEL AND PULLEY CLAMPING BOLTS.
Page 45: Section 4 - Compressor Servicing
Air Boosters - these are compressors that compress and gas compressors. It is not meant to replace proper air that is taken from a source other than the ambient training and common sense. air. Generally the inlet air source is at an elevated pressure, but vacuum applications can also be accomplished.
Page 46: Torque Settings
TORQUE VALUES TOOL LIST FOR SERVICING Each compressor parts manual lists the torque values A list of tools needed for service Hycomp compressors required for each bolt within the compressor. Torque is included in Appendix 1. This is a fairly comprehensive values are DRY.
Page 47: Clearances And Tolerances
CLEARANCES AND TOLERANCES - GENERAL For all compressors, measured in inches Crankshaft end play 0.002 loose to 0.003 interference Oil pump end clearance (ring & rotor) 0.001 to 0.003 Piston rod diameter 0.8735 to 0.8755 Cylinder bore diameter (under 1.50”) 0.0015 maximum over nominal Cylinder bore diameter (1.50”...
Page 48 CLEARANCES AND TOLERANCES - CRANKCASE AND CROSSHEAD For individual compressors, measured in inches Cross Head Cross Head Wrist Pin Rod Bearing Piston Piston Crank Pin Bushing Wrist Pin Block / Model Clearance Clearance Diameter Diameter Clearance Diameter ‘A’ & ‘B’ Blocks, including 0.0015 to 0.003 to 2.9960 to...
Page 49: Compressor Disassembly
This is only a general outline of how to disassemble a Hycomp compressor. Certain speciﬁ cs may apply to PLENUM CHAMBER your compressor that are not listed here. Contact an...
Page 50: Oil Pump Replacement
realigned during assembly. The connecting rod parts d. Remove the O-ring from the oil pump shaft are not interchangeable and must be reassembled with and slide the shaft/gear assembly through the the same mating parts. Work on only one connecting bearing carrier bushing.
Page 51: Bearing Replacement
if necessary. 3. Remove the oil pump and/or bearing carrier per the “Oil Pump Replacement” section. e. Replace thrust plate onto oil pump housing. Be careful to align valve spring vertically over 4. Remove the bearing cup from the bearing carrier the center of the valve discs.
Page 52: Compressor Assembly
This is only a general outline of how to assemble a assembly over the crankshaft journal. Replace the Hycomp compressor. Certain speciﬁ cs may apply to proper connecting rod cap, aligning the dots or numbers your compressor that are not listed here. Contact an...
Page 53 F Blocks: Do not tighten oil packing box bolts. f. Recheck piston to head clearance. PLENUM CHAMBER & GAS PACKING CASE Air and gas boosters require the plenum chamber F Blocks: installed on top of the crosshead guide. a. Remove bolts holding oil packing box to crosshead cylinder.
Page 54: Valve Replacement
valves: After 1-2 hours of normal operating temperatures, a. Remove the valve hold-down screw nut (P/N stop the compressor, lock it out from electrical sources, FQ003 or FQ004). Remove the valve hold-down and retighten the valve hold down screws and cylinder screw with an Allen wrench head bolts to proper tightness.
Page 55 Install the unloader tower and gasket on suction MODELS 2WN150L, 2WN150H valve covers. Torque to ﬁ nal tightness. Remove unloader piping from unloader towers and unloader controls.. Rotate the ﬂ ywheel by hand to insure there is no interference between the valves and pistons. Also Suction valves: listen for air moving across the valves.
Page 56: Appendix 1 Tool List
APPENDIX 1 TOOL LIST Hycomp compressor assemblies utilize “English Customary Measurements” for sizing tools and specifying torque values, tolerances, and clearances. Common tools and sizes suitable for Hycomp compressor service include: Open end box wrench set 3/8” to 1-1/4” 12 point 1/2” drive socket set & ratchet 1/2” to 1-1/4”...
Page 57: Appendix 2 - Compressor Storage
APPENDIX 2 COMPRESSOR STORAGE If a compressor is not to be put into service or is to be taken out of service for an extended length of time, the following procedures should be taken to prevent corrosion and deterioration. 1. Fill the crankcase with rust inhibiting oil. Squirt oil on the piston rods and crosshead pistons.
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This manual is also suitable for:

Ambient air compressors Air boosters Gas compressors