All-Star Products RP-40 Series Installation and user guide

ALL-STARROCKINGPISTONCOMPRESSORANDVACUUMPUMPOPERATINGSERVICEMAINTENANCEMANUALISO9001RoHSCompliant
CE
Registered by one or more of these standards agency

Readthroughcarefullyandunderstandtheseinstructionsbeforeuse.InformationContactyoursupplierorAll-StarProductsTel901-755-9613www.all-star-usa.comSafetyRulesReadtheSafetyRulesbelowbeforeworkingonthepump.HavethepumpmodelandserialnumberswhenorderingpartsorwhencontactingAll-Staroryoursupplier.!!!DANGERCAUTIONIndicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.Indicatesapotentiallyhazardoussituation,which,ifnotavoided,couldresultindeathorseriousinjury.WARNINGIndicatesapotentiallyhazardoussituation,which,ifnotavoided,mayresultinminorormoderateinjury.NOTE:ThisServiceManualisintendedforuseONLYbyaservicecenterwithproperlytrainedandexperiencedrepairpersonnel.Theinstructionsandwarningscontainedhereinpresumeexistingfamiliaritywiththedesignandfunctionofthistypeofproductandtheircomponents.Theinformationcontainedinthismanualissubjecttochangewithoutpriornotice.Themanufacturershouldbecontactedpriorperformanceanymaintenancetodetermineifanychangeshavebeenmadetotheinformationcontainedherein,priortoperforminganyserviceormaintenancework.1

COMPRESSORCONNECTIONDischargeConnectionInlet(Suction)&FilterCapacitorConnectionDiagramNote:Theintake(suction)andthedischargepipingshouldnotbesmallerthantheconnectionsintheunit.Thepipingcanbealargerdiameter.Iftheunitisusedinanetworkarrangementwithotherpumpsorcompressors,thediameterofthepipingshouldnotbelessthanthetotalsurfaceareaofthetotalnumberofpumpsconnectedinthenetwork.2VACUUMPUMPCONNECTIONInlet FilterCapacitorDischargeConnection

!WARNINGCOMMISSIONING1.0RISKOFBURNS-DONOTTOUCHThesurfacetemperatureofthemachinecanreach80DegC(175DegF)whenoperatingatfullloadconditions.Waituntiltheunitcoolsdownpriortoperformingservicework.Theunitmustbeinstalledinawell-ventilated,dust-freeroom.Themaximumambientif40DegC(104DegF).Intakeanddischargeairshouldbepipedtolimitambientairtemperatureasnotedabove.Therockingpistonpumpisdesignedforcontinuousduty.Thecoolingfinsontheunitshouldremainopentoallowfree-aircirculationandtheunitmustbelocateatleast150mm(6inches)awayfromanysurface.Donotallowhotairtocirculateonorabouttheunit.Iftheunitisplacedintostorageforaperiodoftimegreaterthanone(1)year,itshouldbestoredinadustfreeareasubjecttoamaximumtemperatureof40DegC(104DegF),andwhereitwillnotbesubjecttovibration.Ifstoredforlongerthanone(1)year,thebearingsshouldbereplacedpriortostart-up.STORAGE2.0MechanicalConnectionsIftheunitistobeconnectedtoanetwork,aflexiblehoseshouldbeinstalledtoeliminatemini-vibrationsfromreverberatinginthesystempiping.Theconnectionsontheunitareeither.25”or.375.NPTthreads.Forvacuumapplications,pipingconnectionstotheexhaustorificecanbemadetodirecttheheateddischargeairtoanexhaustoutlet.Thispipingshouldnotbesmallerthantheconnectionontheunit.Ifasmallerdischargepipesizeisused,thiscanresultinreducingthepumpspeedandcouldoverloadthemotor.Ifmultipleunitsareinstalledonanetworksystem,theexhaustpipemustequalorbegreaterthanthecoss-sectionofthetotaldiameterofalloftheunitsinthesystem.Adrainvalveatthelowestpointoftheexhaustlinemustbeinstalledtopreventanycondensationfromdrainingbackintotheunit(s).Theunitshouldbemountedonanadequatemountingbaseusingtherubberfootpadstoisolateanyvibrationbeingtransmittedtothemountingsurface.Mountingofunit!DANGERThispumpandcompressoristobeusedforpumpingnon-aggressivegasses(air)containingnomorethat22%oxygen.Thisunitisnotapprovedfornorshouldbeusedforexplosiveortoxicgasses.3

!DANGERThemotormustalwaysbedisconnectedfromthepowersupplypriortoperforminganymaintenanceontheunit.Theelectricaldisconnectshouldhavealock-outfeaturetopreventanaccidentalstart-upwhiletheunitisbeingserviced.ELECTRICALCONNECTIONThepowersupplymustbethesamevoltageandfrequencyaslistedonthenameplate.Themotorisasinglephase,capacitortypeandithasonecableconnection.Connecttheincomingpowertwoconductorstothemotorterminalsandconnecttheearth(ground)wiretotheearthterminal.Themotormustbeprotectedbyamotorstarterwithathermaloverload.Acircuitbreakerofadequatecapacity,basedonthemotornameplateamperagemustbeused.Athermalprotectoriswoundintothemotorwindingthatcanbeuseforadditionaltemperatureprotectionofthemotor.3MAINTENANCECleaningAnnualMaintenanceTheexternalsurfaceofthepumpshouldbecleanedofanydebristoallowforeffectivecoolingoftheunit.Thesilencershouldbedismantledandcleanedorreplacedifnecessary.Thefiltercartridgeshouldbereplaced.Thepointsmentionedinthissectionarebaseduponthepumpbeingappliedinwhatcanbeconsideredanormalorstandardinstallation.Iftheunitisinstalledoroperatedinanyexcessiveconditioneg,dirtyenviron-ment,hightemperatureandsoforth,theneedstobemaintainedfrequently.TheAll-Starrockingpistonpumphasadesignedservicelifeofapproximately10,000hours.Oncethepumpreachesthispoint,orapproximatelytwo(2)years,thecylinderheadandcasingsealneedstobereplaced.Thisperiodismerelyasuggestionandisdependentuponthedutycycleandenvironmentalconditions.Inperformingthismaintenance,itisrecommendedtoperformthefollowing:a)Replacetheconnectingrodsorpistoncupsandsleevesb)Replacetheflappervalvesc)ReplacetheheadO-ringheadgasketd)ReplacethevalveplateO-ringsRequiredtoolsforblowermaintenancea)Torquewrench(requiredforheadscrews,connectingrod,flappervalvescrewsandpipeplugsb)Allenheadwrenchwithattachmentsfortorquewrenchc)Cross-headattachmentfortorquewrenchd)Screwdriverd)Soft,cleancloth10,000HourorTwoYearMaintenance4

ServicingtheHead,ValvePlateAssemblyandConnectingRodandBearingAssembly-Figure1Note:Theheadwouldonlyneedtobereplacedifitisvisiblydamaged.PartsRequired:-Headifdamaged-Headgasket-ValveplateO-ring-Completevalveplateassemblyorindividualflappervalves-Flappervalvescrew(s)ifreplacingindividualvalve(s)RemovingtheHead1.Disconnectthepowertothemotor3.Disconnectallairlinesandremovetheunitfromanyenclosure3.Removeallscrews(1)thatfasterthehead(2)tothepumphousing4.Carefullyseparatetheheadfrompumpbody.5.Carefullyseparatethevalveplateassemblies(4)fromtheheads6.RemovetheheadgasketO-ringsandreplace7.TurnthevalveplatesoverandreplacethevalveplategasketO-ringsFIGURE15

RemovingFlapperValvesNote:Itisrecommendedthatyoureplaceoneflappervalveatatime.Thiswillhelptosimplifytherepairprocessandcorrectlyorienttheflappervalvesinthevalveplate.1.Ifyouarereplacingaflappervalveonthetopsideofhevalveplate(thesidefacingthehead),removetheflappervalvescrew(1).Liftoffthevalvekeeperstrip(2),liftoffthestrengthenvalve(3)andliftofftheexistingflappervalve(4).2.Removeanydebrisfromthevalveplatewithwater-freealcohol(soaporotherdetergentshouldnotbeusedduetothepotentialforcorrosionfromthesoap3.Pleasethevalveplateonthecompressorhousingandorientitasillustrated.MakesuretheO-ringheadgasketistowardsthecylinder.Notetheorientationofthevalveports.4.Orientanewflappervalve(4)overPort1.Observethelocationoftheendoftheflappervalve(continuedonnextpage.)1234Port2Port1FIGURE26

5.Placeavalverestraint(3)overtheflappervalve6.Placeavalvekeeperstrip(4)overthevalverestraint,observingthattherestraint’sradiumisfacingthevalveplateandorientedasshowninFigure3.7.Lineupthescrewholesinallofthevalvecomponentsandfixthescrewonthevalveplate.8.Makesuretheflappervalveiscenteredovertheportofthevalveplateandthatalloftheothercomponentslineupwiththeflappervalve.9.Tightentheflappervalvescrewto11.5”lbsusingatorquewrenchwithascrewattachment.RemovingFlapperValves(continued)FIGURE3543CAUTION:Donotovertightentheflappervalvescreworitwillshearoffinthevalveplate.7

ReplacingAFlapperValveOnTheBottomSideOfTheValvePlate1.Toreplaceaflappervalveonthebottomsideofthevalveplate(sidefacingthepumphousing),removetheflappervalvescrew(1),liftoffthevalvekeeperstrip(2).2.Cleananydebriswithasoft,dampcloth.TurnthepumphousingheadupsidedownandplacethevalveplateonthepumpheadandorientitshowninFigure4.3.Orientaflappervalve(3)overPort2.Observethelocationofthelocationofthenotchesattheendoftheflappervalve.4.Placeavalvekeeperstrip(4)overtheflappervalve,observingthattheradiusofthevalveplate,andorientedasshowninFigure4.5.Lineupthescrewholesinallofthevalvecomponentsandfixthemupontheflappervalvescrewbyscrews.6.MakesuretheflappervalveiscenteredoverthePortandthatthevalvekeeperstriplinesupwiththeflappervalve.7.Tightentheflappervalvescrewto12.4”lbswithatorquewrench.FIGURE4Port1Port232148

ServicingConnectingRodandEccentricAssembliesNote:RefertothePreventativeMaintenanceandTroubleshootingguideinthismanualtodeterminewhetheracompeteconnectingrodassembly,orit’scomponentpartsoraneccentricneedstobeserviced.ComponentsRequired1.Connectingrodassembly,pistoncupsandsleeves.2.ValveplategasketO-rings3.HeadgasketO-rings,ifdefectiveRemovingTheConnectingRodandEccentricAssemblyNote:Onlyremoveoneconnectingrodassemblyatatime.1.Carefullyremovethecoolingfanbypullingitstraightoffthepumpshaft.Donotpullthemotorfanblades.FIGURE5CoolingFans9

FIGURE6RemovingTheConnectingRodAndEccentricAssemblies(cont’d)2.Turnthemotorshafttoaligntheeccentricsetscrew,theconnectingrodscrewseparatelyandwiththeholeofthehousing.SeeFigure6forlocationofaccesshole.EccentricscrewaccessholeEccentric10

RemovingTheConnectingRodAndEccentricAssemblies(cont’d)3.Slidetheeccentricbearingassemblystraightofftheshaft.FIGURE711

RemovingTheConnectingRodAndEccentricAssemblies(cont’d)4.Slideandrotatetheconnectingrod,removeitfromthehousing.Removetheconnectingrodandpistonfromthehousing.FIGURE812

RemovingTheConnectingRodAndEccentricAssemblies(cont’d)4.Slideandrotatetheconnectingrod,removeitfromthehousing.Removetheconnectingrodandpistonfromthehousing.FIGURE8Note:Donotdamagethepistoncup(4)whenremovingtheconnectingrodassemblyfromthepumphousing.Ifthecupisdamaged,itmustbereplaced.13

RebuildingConnectingRodAssembliesIfyouarerebuildingtheconnectingrodassemblyusingcomponentparts,followtheprocedurebelow.Whenreplacingthepistoncup(4),besuretoreplacethesleeve(1)atthesametime.Pleasetheconnectingrodinafixturebeforeattemptingtoremovetheretainerscrew.Ifnecessary,heatwillhelptoremovethepistoncup.1.Removetheretainerscrew(2)fromthecupretainer2.Removetheretainer(3)fromtheconnectingrod3.Removethecup(4)anddiscard4.Placethenewpistoncup(4)ontheconnectingrod.5.Placethenewpistoncupretainer(3)onthecupconnectionmakingsurethebossoftheretainerisseatedinthepilotofthepistonrod.6.Inserttheretainerscrew(2)intotheconnectingrod(5)andtightenthescrewwithatorquewrenchto26”lbs.FIGURE91234514

AssemblyOfTheConnectingRodToThePump1.Putcylindersleeveintothetroughofhousingkeeperandmakeconnectingrodvertical.Note:Connectingrodscrewtofacethehousing.FIGURE1015

AssemblyOfTheConnectingRodToThePump(cont’d)2.Replacetheeccentricontotheshaftandinsertbearingintoconnectingrodbearinghousing.Rotateeccentrictolineupsetscrewwithaccessholeinbottomofhousing.Rotatemainshaftandletshaftflatandeccentricscreenholelineupvertically.Tightenscrewtowithatorquewrenchto35“lbs.3.Rotateshaftwithconnectingrodmovingupanddown.Theconnectingrodshouldmovefreelywithoutanyobstacleorrestriction.UseAllenheadwrenchtotightenrodscrews.FIGURE11Setscrewaccesshole16

AssemblingThePump1.Aftertheconnectingrodassemblyandtheeccentricarecorrectlyassembled,assemblyofthevalveplatesandO-ringshouldbeassemblednext.Topreventdamagetothepump,neverapplyanysealantorlubricanttotheO-rings.CAUTION:FIGURE12O-ringgroveBottomofvalveplate17

AssemblingThePump(cont’d)2.InsertthevalveplategasketO-ringintotheO-ringgroovelocatedonthebottomofthevalveplate.3.PositionthepumphousingasshowninFigure13.Notetheorientationofthepowerleads.FIGURE13NOTE:Insuretheconnectingrodsleevesareseatedagainstthepumphousing.18

AssemblingThePump(cont’d)4.Notetheorientationofthevalveplateassemblies.PlacethemonthepumphousingasshowninFigure14FIGURE14TabPumpHousingValvePlate19