Download SUPBRPRESSURE - Newport Scientific, Inc.

SUPBRPRESSURE
MOTOR DRIVEN
DIAPHRAGM-TYPE COMPRESSORS
46-134tr-2
46-13416-2
46-134r8
46-1342r-2
46-13427-2
46-13429
46-13435
46-13484
46-13487
SINGLE ENDEI)
SINGLE EhIDED
DOUBLE ENDED
DOUBLE EI\DED
TWO STAGE
TWO STAGE
TWO STAGE
SINGLE ENDEI)
DOUBLE ENDED
lOK PSI
3OKPSI
3OKPSI
lOK PSI
lOK & 3OKPSI
6K & lOK PSI
6K & 3OKPSI
6K PSI
6K PSI
This Manual is for:
CompressorPart No.
SalesOrder No.
SerialNo.
Date Manufactured
SystemPart No.
:
:
:
:
:
NEWPORTSCIENTIFIC,INC
8246-ESANDY COURT
JESSUP,l,tD20794
PHONE: 301-498-6700FAX: 301-490-2313
WEBSITE:WWW.NEWPORT-SCIENTIFIC.COM
[email protected]
E-MAIL: NEWPORTS
ADM II.I\MANUAL\N,IOTORCOMPR
CONTENTS
I. INSPECTION
il. INTRODUCTION
III. PRINCPLESOF OPERATION
ry. PERFORMANCECHARACTERISTICS& SPECIFICATIONS
V. INSTALLATION
a. ElectricalRequirements
b. SpaceRequirements
c. Gas/LiquidServiceConversion
d. InstallationProcedure
VI. OPERATION
a. PrimingProcedure
b. Veriff CheckValve Operation
VII. TROUBLESHOOTING
vm.
WARNINGS, PERCAUTIONS,& LIMITATIONS
IX. MAINTENANCE
a. PeriodicMaintenance,
b. Adjustrnentof PressureLimiting Device
c. CrankStrokeAdjushlent
d. CorrectiveMaintenance
X. RECOMMENDED SPAREPARTS
K. ASSEMBLY DRAWINGS & CAPACITY CURVES_ SEELIST
I.INSPECTION
If damageis discoveredupon ulpacking the equipment,an immediate requestshould be
forwarded to the delivering carrier to perform an inspection and proparea concealed-damagereport.
Concurrently, the nature and extent of damageshould be reported to Newport Scientific, Inc., giving
catalog and serial numbers, so that action may be initiated to replace damagedparts, or instructions
issuedfor the return of the apparafus.
II. INTRODUCTION
Diaphragm-TpeGasCompressors
handlefluids of all typeswith absolute
The Superpressure
purity. The fluid beingcompressed
comesinto contactonly with clean,dry, corrosion-resistant
metallicsurfaces.The compressors
a^resuitedfor all typesof laboratoryapplicationsaswell asfor
pilot plant andindustrialapplicationsrequiringlow gasflows. The compressors
operateat a 14to i
ma:rimumcompressionratio and aredesignedto circulateor boost gasfrom a low pressureto
pressures
of 6,000,10,000,or 30,000psi. Thesecompressors
may be usedfor testingandcalibration
of critical devicessuchasmissilesystemcomponentso
etc.,wherehydrostaticpressuretestingand
cali.bration
would be difficult or impossible.
may be easilycleaned.Fluidsotherthanordinaryoil, suchasoxygenThesecompressors
compatiblefluorinatedproducts,may be usedfor diaphragmpulsingif requiredfor specific
applications.Compressors
canbe constructed
of materialsotherthanthosenormallysuppliedfor
particularcorrosion-resistant
applicationson specialorder. The compressors
when specifically
cleanedandservices,arealsousedfor oxygenservice.
areadaptableto eithergasor intermittentliquid service.Changeover
Thesecompressors
from
oneto the otheris accomplished
by interchanglnga setof intakeandexhaustcheckvalves. Singleor
doubleball checkvalvesareavailablefrom NewportScientific,Inc. which enablethe compressors
to
be usedfor intermittentliquid service.
III.
PRINCIPLES
OF OPERATION
Theplungerof the compression
headis reciprocated
asin a pump. Oil from the
storagebulb is compressed
by the plunger,which in turn pulsesthe diaphragrn.The fluid to be
compressedis takenin and dischargedon the oppositesideof the diaphragmthroughthe check
valvesin theheadplateon the down andup strokeof the diaphragm.Oil is drawninto the chamber
beneaththe diaphragmby the suctioncreatedon theplungerbackstroke.Excessoil in the chamber
canflow back to the storagebulb during the fonvardplungerstrokethroughthe pressurelimiting
device. This built-in hydraulicdeviceis manuallyadjustableandensuresthat the dischargepressure
of the compressor
cannotexceeda presetlimit. Theplungerstrokeis presetso that undernormal
operatingconditions,oil will not flow throughthe pressurelimiting deviceunlessthe maximum
dischargepressureis exceeded.
PERFORMANCE CHARACTERISTICS AND SPECIFICATIONS
IV.
CHARACTERISTICS:
-
Contamination-freegas compression.
Parts in contact with gas are made of the following materials:
Upperheadplates,l7-4PH SS;Valves,302,304,316,17-4PHSS andNylon 101;
Diaphragms,302SS.Compressoris suitable for suction at constantor continually varying suction pressuresup to
the maximum permissible dischargepressure.
Compressionratios of up to 14-to-l are obtainablefor each stage.
Diaphragm life in excessof 500 hours of operation normally attained.
Absence of stuffing box permits leak-free operation.
Elastomerpacking provides a leak-free oil seal,long life and never needstightening.
Interchangeable check valves permit either continuous gas or intermittent liquid service.
Check valves can be easily removed for cleaning and replacement.
Floating hydraulic plunger ensuresminimum wear on packing.
SPECIFICATIONS: All compressorintake and dischargecheck valve openings (female) are for Yo
inch O.D. Superpressuretubing.
MOTOR-DRTVENDIAPHRAGM COMPRESSOR SPECIFICATIONS
DOUBLE-END
SINGLE-END
CATALOGNUMBER
46-13484
MAX. WORKING
(PSI)
PRESSURE
MIN. WORKING
PRESSURE
GSI)
PLUNCERDTA.(TN.)
6,000
STROKE,
NOMINAL fiN.)
STROKES/ MINUTE
VOLUMEAT
ATMOS.PRESSURE
fiU. IN./STROKE)
WEIGHT(LB.)
NET/SHIPPING
OVERALLDIM.
LXWXHON,)
MOUNTING DATA
MOTOR
CHARACTERISTICS
PORTS,WORKINGFLIjID
INLET: OUTLET
46-t34lt-2
TWO STAGE
46-13427-2
46-r3429
10,000
30,000
10,000 30,000
150
150
50
3/8
7/8
3t4
7/8
t-U16
58
.10
58
.72
58
.52
46-t3416-2
46-13487
10,000
30,000
6,000
150
150
150
3/4
7 t8
9/16
t-U16
58
.3 6
58
.26
46-13421-2
9/16
50
46-13435
50
9/16,3/8 314.9 1163/4.3t8
r-t/16
s8
.36
t-yt6
t-t/t6
58
.62
58
.46
24s/295 238/289 254/305 285/335 270/320 286/327 2861327 286/327
20x22 X 19
2 9X 2 2 X 1 9
4 HOLES.9/ 6 DIA. ON 13XI4-I/4 CENTERS
1 }IP, I8OORPM,23O/460
VOLT, 3 PHASE,6OHZ,EXPLOSIONPROOF,W58
RPM SPEEDREDUCER
%O.D.TUBING;%O.D.TUBING
V.
INSTALLATION
Installationrequirements,installationprocedures,andcheckoutproceduresare containedin this
section.
ELECTRICAL REQUIREMENTS
require20S-220or 440Y,3-phase,60Hz power.
Motors for the motor-drivencompressors
with local andnationalelectricalcode
This powermustbe connectedby an electricianin accordance
regulations.Observethe directionsprovidedon the instructionplateattachedto the motor.
SPACEREQUIRJMENTS
requirethe following minimumarea:L 35 x W 2l xH 2l inches.
Thesecompressors
cAS/LrQUrD SERVICE COTYVERSTON
canbe adaptedfor intermittentliquid service.To convertfrom gasto
Thesecompressors
intermittentliquid serviceor vice-vers4replacethe setof intakeandexhaustcheckvalveson the
with the setspecifiedin Tablefor theparticularserviceapplication.On the 6,000and
compressors
10,000psi gashead,for intermittentservicewith normalliquids,double-ballcheckvalvesmustbe
low or high-viscosityliquids andliquids
used. Difficult liquids arewater,volatilehydrocarbons,
containingsediments.On 30,000psi gasheads,for intermittentliquid service,double-ballcheck
valvesmustbe usedfor all liquids'
pREcAUTIoN
**Liquid servicecheckvalvesCAI\INOTbe usedon Two-StageCompressors.**
ORDERING DATA A}tD SPECIFICATIONS FOR CIIECK VALVES
COMPRESSOR QTY
CATALOG
NUMBER
46-t34tt-2
lEa
46-13484
2Ea
46-1342t-2
46-t3429
46-13487
46-134t6-2
lEa
46-t3427-2
46-13435
lEa
STANDARD GAS
CHECKVALVES
INLET/DISCHARGE
44-LLt02
44-ttt07
44-rtt02
44-ltt07
44-13100
44-t3t20
44-tlt02
44-ttt07
44-13100
44-13120
LIQUID SERVICE
LIQUID SERVICE
DOUBLE BALL
SINGLEBALL
INLET/DISCHARGE INLET/DISCHARGE
44-14210
44-t4tO0
44-t4215
44-t4tt5
44-14210
44-14t00
44-142t5
44-r4tts
44-13140
44-13160
*Also usedwhereultra-purecleaningis required.
Eachcheckvalve listedin Tablehasa% inch O.D. femaletubing opening.Special-lnlet
Adapter45-16705for liquid servicecanbe usedwith the 44-13140,44-14100,
and 44-l42t0Intake
CheckValveswhen aYqinchNPTconnectionis desired.This adapterconvertsthe% inch O.D.
femaleconnectionto VcinchNPT. female.
OXYGEN SERVICE COI\WERSION
All compressorscan be modified for Oxygen Service. This involves Oxygen-cleaningall
parts in contact with the gas, installing a set of Oxygen-service check valves, and replacing the
packing. Contact Newport Scientific for details.
INSTALLATION
PROCEDURE
to installyour compressor:
Performthe following procedures
1.
Removecork sealfrom reservoir.
Removeplasticplugsfrom the intakeandexhaustcheckvalves.
2.
throughmountingholes.
Securecompressor
a
J.
Fill oil reservoirwith OildyneHydraulicFluid 15-40oil, exceptfor oxygenservice
oil reservoirwith fluorocarbonoil or
compressors.Fill oxygenservicecompressor's
halocarbonoil.
4.
asfollows: Wheninstallingor removingtubing,keepall
Connectinlet tubingto compressor
tubinglinesandfittings clean. Flushtubingwith solventusinga syringeandblow dry with
cleanair or gas.(Includingnew tubing.)
PRECAUTION
the diaphragmandcheckvalvesmay be damaged.
If dirt enterscompressor,
A.
B.
Install a 5 microndry-type filter 49-14405in the inlet tubingline.
Connectinlet tubingline from filter asfollows:
-For the singleendor two-stagecompressor,
connect45-11020tubingto checkvalvemarked
IN on the head.
-For the double-endcompressor,
connectto the inlet manifold.
Connectoutlettubingfrom Dischargecheckvalveto a pressurerelief valveor rupture-disc
assemblyin accordance
with standardASME practice.
PRECAUTION
A relief valve or rupture-discmust be installedto prevent
conditionoccurs.
damageto equipmentif an overpressure
Connectoutlet tubing from relief valve or rupturedisc to systemequipment.
with local and
connectpowerline to motor in accordance
For motor-drivencompressors,
anddirectionsprovided
nationalelectricalcoderegulations.Observethe powerrequirements
on the instructionplateattachedto themotor. A switchor circuit breakershouldbe connected
in the power line to enableturning the compressoron andoff, asrequired.
WARNING
IMPROPER WIRING CONNECTIONS COULD PRESENT A SHOCK HAZARD.
7.
If necessary,
adjustthe crankstrokelength. The cranklengthwaspresetby NEWPORT
only if:
SCIENTIFIC,INC. andwill requirereadjustment
-the shoeclampingboltswork looseor areintentionallyloosened.
-theheadassemblyis changed.
To adjustthe crank strokelength,perform the "Crank StrokeAdjustmentProcedure"in
SectionIX.
8.
by performingthe procedurein SectionVI.
Checkoutthe operationof the compressor
PRECAUTION
Do not run the compressorwith no suction pressure,or very low suction pressure,this
the diaphragmandwill resultin the compressor
will causea build up of oil underneath
ceasingto pumpgas. If this doesoccur,turn on the gassuction,loosenthe lock nut on the
pressurelimiting device(be surenot to losethe original setting),backoff the setscrew,and
to allow the excessoil to re-circulate.The limiter shouldthenbe returned
run the compressor
to its original setting.
VI.
OPERATION
how to
in this sectiondescribehow to operatethe compressor,
The operatingprocedures
performthe priming procedureif the compressor
fails to build-uppressure,andhow to verify proper
checkvalveoperation.
PRECAUTION
If dirt entersthe compressor,
the diaphragmandcheckvalvesmay be damaged.It is
absolutelyessentialthat the incoming gasis filtered. We suggesta 5 or 10 micron inline Filter suchas Cat.# 49-14405.
shouldbe
Also any linesto be placedbetweentheFilter andthe compressor
thoroughlycleaned.Flushwith solventusinga syringe,andblow dry with cleanair or
gas. (Evena newpieceof high pressuretubingmay containsufficientparticulate
matterto foul the checkvalves).
To operatethe motor-drivencompressor,
tum on electricpowerto the compressor.Observe
fails
the gasdischargepressureto ensurethatthe compressor
is operatingproperly. If the compressor
to build-uppressure,shutoffpower andperformthe'?riming Procedure"in the nextparagraph.
PRIMING PROCEDI'RE
performthe following:
To primethe compressor,
l.
Closeoff the gasdischargeline.
2.
inlet. (Theterm suctionpressuremeansthepositive
Apply suctionpressureto the compressor
pressureappliedto the compressor
inlet, e.g.a minimumsuctionpressureof 700psi is
for 10,000psi dischargeon 46-134ll-2).
recommended
a
J.
Add oil to the reservoirif required.
4.
Loosenthe stopnut on the top ofpressurelimiting device,beingcarefulnot to losethe
setting. Reversethe setscrewbackuntil it no longerappliestensionto the spring. The stop
nut will turn with the set screw,therebymaintainingthe original Factorysetting.
5.
Run the compressor.While it is running,loosenthe largeglandnut at thebaseof thepressure
limiting deviceby l-ll2 turns,andpull backon thebody of the limiter to releasethe orifice
piece. This removesall forcefrom the seatandallowsfreshoil to be pulled in from the
reservoir.
just for a coupleof strokesof the compressor
andthen
The largeglandnut shouldbe loosened
retightened.Someoil will be spilledout duringthe aboveoperation.
6.
Retum the setscrewto its' original settingandretightenthe stopnut.
PROCEDURB FOR VERIF"TING PROPER CHECK VALYE OPERATION
Inlet & Outlet,if not alreadypresent.
1. Installpressuregaugeson Compressor
Inlet.
2. Apply suctionpressureof 1,000psi to Compressor
3. OperateCompressor.
4. If either gaugefluctuateswildly thenremovecheckvalvesandcleanor replace.
VII. TROUBLESHOOTING
malfunction.Referto
Thetablebelowprovidesguidelinesin localizinga compressor
"CorrectiveMaintenance"procedureto replacea component.
Malfunction Indication
ProbableCause
Action
COMPRESSOROPERATESAI\[D
BUILDS-UP PRESST]REBUT
OUTPUT VOLT]ME IS
IMPROPER
l.Externalleakageat checkvalveor
diaphragm.
l.Check for leakageusing bubble test.
Tighten or replace component as
req'd.
2.Pressurelimiting devicesettingis
too low. Oil level in reservoirchanges 2.Perform "Adjustnent of Pressure
Limiting Device" procedure in Section
more than a little on eachstroke.
IX Maintenance. Pressure limiting
device should never heat.
3.Intakeor exhaustcheckvalve
malfunctioning.
COMPRESSOROPERATESBUT
PRESSIJREDOES NOT BIMDTJPTO MAXIMT]M
BUBBLES IN OIL RESERVOIR
v[I.
l.Inlet Pressure
too low.
3.Perform the "Procedure for
Veri$ing Proper Check Valve
ODeration" in Section VI. Operation.
l.Check that compressionratio is
l4:l maximum.
2.Pressure
leakage.
2.Isolate compressorfrom rest of
system and check for pressure leaks.
3.Faultycheckvalve.
3.Perform'?rocedure for Verifying
Proper Check Valve Operation" in
Section VI, Operation.
4.Compressoris not primed.
4.Perform "Priming Procedure" in
Section VI, Operation.
5.Defective hydraulic check valve or
pressure-limiting device.
l.Leaking packing.
5.Replace.
2.RupturedDiaphragm(s)
2.Replacediaphragm(s) according to
"Corrective Maintenance" in Section
IX. Maintenance.
l.Replace packing according to
"Corrective Maintenance" in Section
IX, Maintenance.
WARNINGS, PRECAUTTONS,AND LIMITATIONS
andlimitationscontainedin this
This sectionsummarizes
all warnings,precautions,
list hazardswhich, if not observed,could leadto personnelinju.y.
Thewamingsparagraphs
precautionsparagraphlists actionswhich could result in damageto the equipment.
WARNINGS
shouldbe continuousto the
Thepowerline groundcircuit for themotor-drivencompressor
mainpowerpanel. The panelshouldbe groundeddirectlyto a waterpipe or otherelectricalearth
ground. Impropergroundingcould result in a shockhazard.
Whenperformingmaintenanceon a motor-drivencompressor,disconnectpower from
andattacha warninglabelDO NOT TURN ON SWITCH, MAINTENANCE BEING
compressor
PERFORMED to the powerswitchto ensureagainstinadvertentstart-upof the compressor.
PRECAUTIONS
Liquid servicecheckvalvesCANNOT be usedon Two-StageCompressors.
A relief valveor rupture-discmustbe installedin the outlettubing line to preventdamageto
conditionoccurs.
equipmentif an overpressure
is maintainedfreeof solid particulatecontaminates.If
Ensurethat the fluid beingcompressed
dirt entersthe compressor,the diaphragmandcheckvalvesmay be damaged.
LIMITATIONS
The pressure-limitingdeviceshouldbe setto an upperlimit pressureof approximately110
percentof the maximumoperatingpressure.
(46-13427)sholld be setat
Thepressurelimiter on the first stageof a two-stagecompressor
5000psi andthe inter-stagepressureshouldnot exceed4500psi for optimumdiaphragmlife, andfor
(46-L3429and 46-t3435)setat 6,600psi not to exceed6,000psi.
conipressors
IX. MAINTENAIICE
PERIODIC MAINTENAI\CE
A.
Lubrication
This systemis designedto automaticallylubethe drive mechanism.It will providethe right amount
of greaseto meetlubricationrequirementsfor the SlottedLever.
to determinegreaselevel.
This unit shouldbe checkedevery3-5 hoursof run time on the compressor
To refill Lube Site: Removefastenersandguardfrom compressor.Simply refill by attachingthe
greasegun that is suppliedwith the unit to the greasefitting. Fill until the sealring risesto the
bottomedgeof the "CAUTION" label. DO NOT OVERFILL. This shouldbe donebeforethe seal
ring is downto the top of the base.
Also, when serviceis beingdoneon the Lube Site,thepivot pins on the drive unit shouldbe oiled
with any 10W30W or lOW 40W oil.
Theseinstructions will allow the Lube Site to give you many years of trouble-free automatic
lubrication.
Filter Replacement
B.
If a 49-14405dry-type filter is installed in the inlet tubing line, periodically replacethe filter
discs(49-14490,set offour).
ADJUSTMENT OF PRESSURE LIMITING
DEVICE
NOTE: The PressureLimiting Device was presetby Newport Scientific and should never needreadjustment. This device was set to releaseoil back to the storagebulb when the dischargepressure
reachesll0% of the maximum pressurerating of the compressor. This setting was obtainedby
turning the setscrewat the top of the pressurelimiter until the desiredreleasepressurewas obtained.
The setscrewwas then held stationarywhile the outer stop nut was tightened down to the limiter body
to lock in the setting. As long as the stop nut is not turned relative to the setscrew,the setscrewcan
be tumed out and in for priming and still maintain the original factory setting.
If the stop nut has been turned relative to the setscrew,the following procedurecan be followed to
reproducethe original setting.
1.
Install pressuregaugesin the inlet & outlet lines of the compressorif not alreadypresent.
2.
Make sure system is primed and check valves are operating properly as per Section VI,
Operation.
'
operation.
Stopcompressor
Loosenouterstopnut on top of pressurelimiter andtum setscrewbackuntil all
removedfrom the spring.
Apply suctionpressureof at least1000psi.
Adjust setscrewslowly inwardto obtainthe following maximumdischargepressure.
-for 6,000psi compressors,
setto 6,600psi
-for 10,000psi compressors,
setto 11,000psi
-for 30,000psi compressor,
setto 33,000psi
setto 5,000psi on first stage.
NOTE: For a two stagecompressor,
NOTE: Outletpressuregaugeneedlewill fluctuateslightly with eachpistonsffoke,usingthe
highest reading on each stroke when setting the pressure.
Hold setscrew stationary and tighten outer stop nut to lock in pressure setting.
that thepressurelimiter be setat a pressurelower thanthe original
NOTE: It is not recommended
factory setting. If it is desiredto maintainthe systemat a lower pressure,to preventoverpressurization
of components,
the following configurationis recommended.
CRANK STROKE ADJUSTMENT PROCEDURE
On Motor-Driven Compressors,the piston stroke length is presetby Newport Scientific and
must be re-adjustedif:
.
- The slide block clamping bolts work loose or are intentionally loosened.
- The head assembly or packing are changed.
NOTE: The pressurelimiter adjustrnentneed not be changedunlessthe original factory setting was
lost accordingto the last section on Adjustrnent of the PressureLimiting Device. If the pressure
limiter and the crank stroke both need adjustment,they must be performed simultaneouslyaccording
to No. 11 of this section.
For maximum compressoreffrciency, the volume of oil displaced is critical. This volume is
proportional to the length of the piston sffoke, and the adjustmentprocedureis the samefor all
compressorsand all piston sizes.-Refer to Section [V, Specifications.
1.
operation.Disconnectpowerandattacha waming label("DO NOT TURN
Stopcompressor
ON SWITCH, MAIN'TENAIICE BEING PERFORMED")to the power switch to assure
againstinadvertentstart-upof the compressor.
2.
Removeguard.
J.
Cracktubing glandnut on dischargecheckvalve(s)to releasesystempressure.Retighten
glandnut(s).
4.
Bring crankto the verticalposition. Rotatethemotor armatureby insertinga metalrod
throughthe cooling slotsin the rearof the motor andcarefully turning the fan bladesuntil
crankis in the verticalposition.
5.
Loosenthe two (2) slideblock clampingbolts on the crank.
6.
While crankis in verticalposition,adjustthe dimensionto a distancebetweenthebottomof
the slot in the crankandthe endof the slideblock to approximately7116inch. Tightenthetwo
(2) slideblock clampingbolts to 50-60ft-lbs torque.
7.
Placea pieceof maskingtapeon the slottedleverbesidethe slideblock andmark theposition
of the slideblock with a pencil.
8.
Apply suctionpressureof at least1000psi.
t2
9.
on a pressuregauge.
with the dischargedead-ended
Operatethe compressor
10.
Make surecompressor
is primedandthat checkvalvesareoperatingproperly.
I l.
The slideblock adjustment"A" of 7116inch wasdeliberatelysetin the high rangeto cause
over stroking of the compressor.Over strokingis presentwhen the oil level in the oil
reservoirrisesandfalls beforell0% of the maximumpressureis reached.While compressor
is over stroking,pressureshouldbuild up to ll0%oof themanimumoperatingpressure.
Ma:rimumOperatingPressure
6,000psi
10,000psi
30,000psi
NOTE:
llOYo
6,600psi
psi
11,000
33,000psi
Thepressurelimiter on the first stageof a two-stagecompressorshouldbe setat 5,000
psi andthe interstagepressureshouldnot exceed4500psi for optimumdiaphragm
life.
If the pressureobtainedis lower or higherthanthat shownabove,thenadjustthepressure
limiter accordingto theAdjustmentof Pressure
Limiting Deviceearlierin this section.
12.
With pressurelimiter setat properpressure,adjustthe crankdimension"A" to obtain
optimumshoke. Optimumstrokeis obtainedwhenoil leveljust beginsto rise andfall as
7l0ohof maximumpressureis reached.
13.
Stopcompressor
operation.
14.
Bring crank to vertical position and loosen bolts according to steps3, 4, and 5.
15.
Adjust slide block downward in incrementsof Il32 inch from the last setting and tighten bolts
to 50-60 ft-lb. Mark new position of slide block.
16.
Operatethe compressor.
t7 .
Check for over stoking accordingto step 11. If compressoris still over stroking, repeatsteps
13 through 17 until optimum stroke is achieved.
NOTE:
18.
Compressoris under stroking when pressurefails to build up to ll0%o of the maximum
pressure.
Replace guard.
CORRECTIYE MAINTENAI\ICE
The following paragraphs
describehow to replacethe checkvalves,the diaphragm,the
packingandthe pressure-limiting
device.
WARNING
DISCONNECTPOWERFROM
ON MOTOR.DRTVENCOMPRESSORS,
coMpRESSOR AND ATTACH A WARNTNGLABEL ("DO NOT TURN
oN swrTCH, MAINTENANCE BEING PERFORMED")TO THE POWER
SWITCH TO ENSUREAGAINST INADVERTENT START-UP OF LINIT.
CheckValve Replacement
1.
operation.
Stopcompressor
2.
Releasepressurefrom tubing lines.
J.
Discorurecttubingconnectedto checkvalve.
4.
Removecheckvalve.
).
Examinecheckvalvefor foreignparticles,wearor damage.Replacewith new checkvalve,if
required.
6.
Installcheckvalveon compressor.Ensurethatthe lensrings areproperlyseated.Improper
seatingof the lensringsmay resultin a leakingcheckvalve.
Diaphragm Replacement
1.
operation.
Stopcompressor
2.
Releasepressurefrom systemandtubing lines to compressor.
J.
Closeoff intake anddischargelines.
4.
Crackconnectionto checkvalvesto allow trappedpressurizedfluid to escape,then
disconnectall gaslines.
5.
Supportheadandremovethe four (4) capsscrewswhich secureit to the frame.
6.
to
Pull headstraightback,beingcarefulnot to scratchthepistonwhich will remainconnected
the drive assembly.
7.
Securehydraulicsectionin a clampingdevice.
8.
Removeheadbolts andpull the headplate. Inspectthe headfor damage.Cleanheadand
coverwith a protectivecloth.
9.
Removethe checkvalves,inspect,cleanandcoverwith a protectivecloth.
t4
10.
Remove diaphragm. The 6,000 psi and 10,000psi compressorheadshave one (1) diaphragm
per head. The 30,000 psi compressorheadshave two (2) diaphragmsper head.
11.
Thoroughly clean and install new diaphragm(s).
12.
Reinstall head,headbolts, and check valves. Lubricate head's washer and bolt threadswith
bearing greasewhen compressoris used for normal fluids. When used for oxygen service,
use fluorocarbon grease. Reinstall all tubing removed (use check valves as guide for proper
tubing installation).
13.. Hand-tighten all the head bolts, using a torque wrench. Sequentially tighten OPPOSING head
bolts in 10 ft-lb increments to a final torque of:
-150 ft-lbs for 6,000psi and 10,000 psi compressorheads
-350 ft-lbs for 30,000 psi compressorheads
14.
Attach all gas connections.
15.
Performthe "Priming Procedure"in SectionVI, Operation.
PackingReplacement
1.
Perform Steps 1 through 9 of Diaphragm Replacement(above).
2.
Remove packing and clean packing cavity.
a
J.
Replace worn packing components according to the spareparts list.
4.
Perform steps 13 through 16 of diaphragm replacement.
Pressure-Limiting Device Replacement
1.
operation.
Stopcompressor
2.
Releasepressurefrom systemandtubinglinesto compressor.
a
J.
Crackconnectionat bottom of pressure-limitingdeviceto allow trappedpressurizedfluid to
escape.
4.
Hold body of pressure-limitingdevicewith one (1) wrenchwhile unscrewingglandnut with
anotherwrench,Figure5-1.
5.
2 or 4 by wrenchingat the flats or the seat.
Unscreworifice 62006001001,
6.
or parts,asrequired.
or 62006001202)
Replacethe pressurelimiting device(62006001201
7.
andreinstallon compressor.
Reassemble
l5
X. RECOMMENDED SPARE PARTS
DESCRIPTION CAT. NO
OR
PART NO.
CHECK VALVE,
44-r4rt0
46t34tt-2
464613416-2 t3421-2
46t3427-2
4613429
4613435
4613484
46t3487
I
I
2
2
2
2
I
2
I{YDRAULIC
CHECKVALVE,
44-llt02
t
2
2
I
2
INTAKE
CHECK VALVE,
44-ttlo7
I
I
I
2
I
2
2
DISCHARGE
CHECKVALVE,
44-13100
I
INTAKE
CHECKVALVE,
44-13120
I
I
I
DISCHARGE
I
2
DIAPHRAGM
62018000500
2
2
3
I
DIAPHRAGM
84001001
r00
I
2
I
P1004002900
I
I
2
2
2
I
2
OILER
2
I
I
I
SOFTGOOD
85001000900
2
PACKINGKIT
I
I
SOFTGOOD
85001000500
I
PACKING KIT
I
I
I
2
SOFTGOOD
85001001100
PACKING KIT
I
PACKING
64042002500
I
I
2
RETAINER
I
PACKING
65013002700
I
RETAINER
I
I
I
2
PACKING
84001000800
RETAINER
I
I
I
2
PACKING
64042002200
FOLLOWER
I
I
65013002800
PACKING
FOLLOWER
I
I
2
I
84001000700
PACKING
FOLLOWER
Y""DIA PISTONASSEMBLY FROM POLY-PACKTO LEATHERPACKING SEEDRAWING # 85OO1OO13OO
XI.
ASSEMBLY DRAWINGS & CAPACITY CURVES
COMPRESSOR# 46-134II-2 MOTOR DRIVEN SINGLE ENDED lOK PSI
46-T34lI-2
64042002702
64042002802
84001000400
44-ttt02
44-rlt07
44-t4710
6200600t200
Curve10K Motor
Compressor
AssemblySheet
Head& Drive AssemblySingleActing
HeadAssembly(Left Side)10,000PSI
Drive PistonAssembly
IntakeCheckValve 10,000PSI
DischargeCheckValve 10,000PSI
Inlet CheckValve SingleBall
AssemblyRelief Valve-LiquidService
CapacrtyCurve
COMPRESSOR# 46-13418MOTOR DRIVEN DOUBLE ENDED 3OKPSI
46-t34r8
73064000302
65013000502
6s013000602
84002000400
44-13r00
44-13720
44-l4tt0
62006001200
Curve30K Motor
Compressor
AssemblySheet
Head& Drive AssemblyDoubleActing
HeadAssemblyLeft Side30,000PSI
HeadAssemblyRightSide30,000PSI
Drive PistonAssembly
IntakeCheckValve 30,000PSI
DischargeCheckValve 30,000PSI
Inlet CheckValve SingleBall
AssemblyReliefValve - Liquid Service
CapacityCurve
COMPRESSOR# 46-1342I-2MOTOR DRIVEN DOUBLE ENDED 1OKPSI
46-1342r-2
64042002902
64042002602
64042002802
84002000400
44-rtt02
44-ttt07
44-14110
62006001200
Curve10K Motor
Compressor
AssemblySheet
Head& Drive AssemblyDoubleActing
HeadAssembly10,000PSI
HeadAssembly10,000PSI
Drive PistonAssembly
IntakeCheckValve 10,000PSI
DischargeCheckValve 10,000PSI
Inlet CheckValve SingleBall
AssemblyRelief Valve-LiquidService
CapacrtyCurve
t7
COMPRESSOR# 46-13427-2MOTOR DRTVENTWO STAGE 10 & 3OKPSI
46-13427-2
73064000202
AssemblySheet
Compressor
Head& Drive PistonAssembly
44-lll02
PSI
Valve10,000
Check
Intake
44-trr07
DischargeCheckValve 10,000PSI
Intake Check Valve 30,000 PSI
Discharge Check Valve 30,000 PSI
Head Assembly 10,000PSI
Head Assembly 30,000PSI Left Side
Inlet Check Valve Single Ball
Assembly Relief Valve - Liquid Service
Capacity Curve
44-t3LOO
44-73120
64042002602
65013000502
44-14110
62006001200
Curve1030Motor
COMPRESSOR# 46.13429MOTOR DRIVEN TWO STAGE 6 & TOKPSI
46-13429
84002000300
64042002802
84001001500M
84002000400
44-ttl02
44-rtl07
44-t4lr0
62006001200
Curve610Motor
AssemblySheetI
Compressor
Head& Drive PistonAssemblY
HeadAssembly10,000PSI
HeadAssembly6,000PSI
Drive PistonAssembly
IntakeCheckValve 10,000PSI
CheckValve 10,000PSI
Discharge
Inlet CheckValve SingleBall
AssemblyReliefValve-LiquidService
CapacityCurve
COMPRESSOR# 46-13435MOTOR DRIVEN TWO STAGE 6 & 3OKPSI
46-13435
84002000600
84001001500
65013000502
84002000400
44-rtl02
44-ttl07
44-13100
44-13120
62006001200
Curve630 Motor
AssemblySheet
Compressor
Head& Drive PistonAssembly
HeadAssembly6,000PSI
HeadAssembly30,000PSI
Drive PistonAssembly
IntakeCheckValve 10,000PSI
Discharge
CheckValve 10,000PSI
Inlet CheckValve30,000PSI
CheckValve30,000PSI
Discharge
AssemblyRelief Valve-LiquidService
CapacityCurve
l8
l9