Brownie’s Yp25df User manual

YP25DF & YP25SF

YP35DF & YP35SF

Yacht Pro Automatic Compressor

Operator’s Manual

Brownie’s Southport Divers

1530 Cordova Road

Fort Lauderdale, FL 33316

Ph 954.524.2112 Fx 954.524.7598

info@yachtdiver.com

Brownie's Yacht Toys

2301 South Federal Hwy

Fort Lauderdale, FL 33316

Ph 954.463.9446 Fx 954.524.6722

Toll Free 800.949.0822

Brownie's Palm Beach Divers

3619 Broadway

Riviera Beach, FL 33404

Ph 561.844.3483 Fx 561.845.1500

info@yachtdiver.com

PREFACE

Thank You for purchasing a Brownie’s Yacht Pro Series Compressor System. This manual

explains the use and maintenance of your unit. All information here is based on the latest product

data available at the time of publication. Brownie’s Third Lung reserves the right to make

unannounced changes at any time without incurring any obligations whatsoever.

This Operator’s Manual is to be considered a part of the overall compressor package and

should remain with the compressor in the event of sale to another party.

In order to familiarize yourself with the compressor features, please read this manual thoroughly

before using the equipment. Physical layout is pictured on page 28.

For service, please contact:

IMPORTANT NOTICE:

Read this manual before you operate your Yacht Pro Series Compressor, as it contains

pertinent information for the safe operation of the system. Failure to follow the

instructions in this manual may result in damage to the compressor and/or personal

injury or death.

WARNING: Installation and operation of the system without the guidelines set

forth in this manual may result in damage to the system and/or personal injury

or death.

WARNING: Never tamper with or modify factory settings. This will void the

warranty and could result in personal injury or death.

Brownie’s Southport Divers

1530 Cordova Road

Fort Lauderdale, FL 33316

Ph 954.524.2112 Fx 954.524.7598

www.yachtdiver.com

info@yachtdiver.com

Brownie's Yacht Toys

2301 South Federal Hwy

Fort Lauderdale, FL 33316

Ph 954.463.9446 Fx 954.524.6722

Toll Free 800.949.0822

www.yachtdiver.com

[email protected]

Brownie's Palm Beach Divers

3619 Broadway

Riviera Beach, FL 33404

Ph 561.844.3483 Fx 561.845.1500

www.yachtdiver.com

info@yachtdiver.com

writing from the publisher. Edition 4.0 02/2004

Table of Contents

Preface 3

Table of Contents 4

Quality Analysis 5

Product Data 6

Description of Unit 7

Standard Features 7

Installation 8

Pre Start-Up Checks 9

Tankfill Procedures 10

Purification System 11

Lubrication Specifications 11

Maintenance Schedule 12

Torque Valves and Sequencing 13

Valves 14

Drive Belt 16

V-belt Tension Adjustment 16

Cooling System 16

Oil Level Check 17

Oil Types 17

Intake Filter 17

Sightglass Element Change Demonstration 18

Black Filter Cartridge Replacement Demonstration 20

Gold Filter Cartridge Replacement Demonstration 22

Tankfill Demonstration 24

Oil Change Demonstration 27

Troubleshooting 36

Systems Operations Log 38

Warranty Information 45

Physical Layout Features:

Figure 1 Black Filter Cartridges 21

Figure 2 Gold Filter Cartridges 23

Figure 3 Front and Rear Compressor View 28

Figure 4 Auto Drain System & Comp. Features 29

Figure 5 Black Filter Tower Exploded View 35

Parts Drawings:

Parts Drawing 1 Crankcase 30

Parts Drawing 2 Valve Heads 32

Parts Drawing 3 Intake/Intermediate Seperator 34

Date:

Serial # Model # Order#

Motor Wiring V PH HZ

Belt Size Tension

Connections Tight Nuts & Bolts Tight

No Leaks

Control Wiring Correct Final Pressure Setting

Drain System Operation Interval

Oil Level Tank Fill Time

(80 ft³ 500-3000 PSI)

Hour Meter Reading Test Run Time

STANDARD EQUIPMENT PROVIDED

Filter Sightglass Elements

Manual Lubricant

OPTIONAL EQUIPMENT ORDERED

4TKMAN HIP-RFPK

FC374-04RL (Additional for 4TKMAN Main) FT

Transformer Oil Removed

Technician Installer

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COMPRESSOR QUALITY ANALYSIS RECORD

Product Data

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Category Specifications

Air Delivery Rate (a)(b):

YP25DF 3.0 scfm, 2.5 FAD

YP35DF 3.5 scfm, 3.0 FAD

* Operating Pressure (Std): 3200 PSI

** Pressure setting, final 3400 PSI pressure safety valve (STD)

Dimensions: 36”L x 17”W x 18”H (91 x 44 x 46 cm)

Weight: Approx 110 lbs (50kg)

Use: Compression of atmospheric air.

Intake Pressure: Atmospheric Pressure

Compressor RPM:

YP25DF 1800

YP35DF 2300

Drive Belt Type: 3VX355

Number of Stages 3

Number of Cylinders 3

Cylinder Bore 1st Stage 60 mm

Cylinder Bore 2nd Stage 28 mm

Cylinder Bore 3rd Stage 12 mm

Piston Stroke 24 mm

Intermediate Pressure 1st Stage

YP25DF 80 psi / 5.5 bar

YP35DF 95 psi / 6.5 bar

Intermediate Pressure 2nd Stage

YP25DF 800 psi / 55 bar

YP35DF 942 psi / 65 bar

Compressor Block Oil Cap. 12 fl. oz. / 360 cm³

Recommended Oil Types: CF-2000 Synthetic Compressor Lubricant

Max. ambient temperature +43º to +100º F

+5º to +38º C

Max. permissible inclination 10º

of compressor (b):

* Unit has a max pressure rating of 5000 psi (3800 psi recommended)

** May be set higher or lower based on Pressure Switch settings

*** Electric motors also available; 3 phase, 50 or 60 HZ; and Single Phase 50 HZ

(a) free air delivered at tank filling from 0 to 3000 psi

(b) Value only valid if oil in level unit position is at highest mark on dipstick.

DESCRIPTION OF THE UNIT:

Your Yacht Pro Series is a fully automatic compressor, equipped with Automatic Condensate Drain (ACD). The YP

series has been designed speciﬁcally with the traveling yacht owner in mind. The compressor system is designed

for “HANDS FREE” operation.

STANDARD FEATURES

The complete Yacht Pro Series package includes:

• Dual Programmable Stainless Condensate Drain System Switch

• Digital Frequency Drive Control System

• One High Pressure Compressor with a 2HP (YP25DF) or 3HP (YP35DF) Motor

• Stainless Programmable Digital Pressure Switch with LED Display

• One Condensate Collection Jug

• One Puriﬁcation Cartridge (X22679 for Gold Tower)

• One Puriﬁcation Cartridge (X53240 for Black Tower)

• One Operator’s Manual

• One Sightglass Element (moisture and CO monitor)

• Tool Kit

• One liter, Synthetic Compressor Oil

The following are included with the YP25DF & YP35DF

• One Four-way Manifold with 10 foot connection hose including stainless steel quick disconnect end

• One ½ inch padded Custom Cordura Manifold Bag

NOTICE:

Please read this Owner’s Manual before you operate your Yacht Pro Series Compressor

Optional Equipment:

• One Starboard Mounting and Spill Containment Tray

• Stainless Steel Quick Disconnect Set

• Custom Hose Lengths

• Remote Fill Plumbing Kit

• Cordura Nylon Cover

• Remote On/Off Switch (with installation)

WARNINGS:

• Do not operate the compressor if the compressor is damaged.

• Do not operate the compressor near ﬂammable substances or objects

• Make sure the air entering the compressor is clean atmospheric air.

• Do not operate unit in Ambient Temperatures exceeding 100ºF (38ºC)

USE OF COMPRESSOR:

The Yacht Pro Series is intended for the compression of air.

WARNING:

DO NOT ADD OXYGEN TO THE COMPRESSOR: THERE IS A DANGER OF EXPLOSION.

INSTALLATION

WARNING:

Improper installation may result in damage to the unit, personal injury or death.

All persons operating the Yacht Pro Series system must read this manual completely and fully understand the

procedures for system operation and the responsibilities of the operator to insure the safety of divers supplied with

air from the system. We recommend professional installation by our experienced installation technicians. The Yacht

Pro Series must not be operated in an enclosure that does not meet the installation/operation guidelines for the unit.

Contact our Technical Department for advice.

The Yacht Pro series tank fill compressor must be installed in accordance with the following recommendations:

1. Ambient temperature during operation must not exceed 100 deg F (38 deg C) maximum. The unit will produce heat

when operating, therefore adequate ventilation must be provided to stay well within the maximum limit listed above.

We recommend operating unit well below the maximum limit. Forced Ventilation must be used where poor air

circulation is present. Contact our Technical Department with questions regarding proper ventilation.

2. Proper clearances must be allowed for the following:

a. 6" minimum from the fan cover to any bulkhead. This provides adequate air supply for the cooling fan.

b. 8" minimum above the filter tower. This allows easy filter removal/replacement and easy access to remove

the oil dipstick for checking/changing oil.

c. Allow working access to the electrical box for service/repair.

d. The Oil drain tube must have clearance for oil changes.

e. The condensate drain reservoir must be accessible for removal.

f. Hour meter, on/off switch, and visual monitor must be accessible for safe operation.

g. Belt Guard must be accessible for service of drive belt.

3. The unit must be installed on a flat, level surface. No more than 10 deg inclination must occur during operation.

4. The Yacht Pro Series units are provided as a complete assembly ready for installation. NOTE: Some

installations may require remote mounting of package components. This must be approved by our Technical

Department.

NOTE: Any alterations of the original system without approval by our technical department will void the

manufacturer’s warranties.

5. Clean, fresh air must be provided to the air intake of the compressor as close to the operating ambient

temperature of the unit as possible. Remote air intake plumbing may be required. A non-collapsible plastic hose with

3/4" ID is the simplest method. The 3/4" ID may be run for a length of 10'. Longer runs may be used by following this

guideline: For every 10' of run the preceding 10' diameter must be doubled. All 90 deg fittings should be considered

as 1 foot of length.

NOTE: The intake must be protected from water entry, as this will cause severe damage to the unit.

6. The unit must be protected from any type of water exposure. Such exposure will seriously effect the longevity of

the unit and may result in personal injury or death.

7. Electrical Requirements:

Yacht Pro series compressors come standard with 220 VAC 60HZ single phase electric motors. They are equipped with

120 VAC 60HZ controls and components. All units require correct electrical supply components be provided in

accordance with local, state and federal codes for land installation and marine codes for on-board installation. An

electrician should be consulted for supply power recommendations. Standard units require that a neutral wire be provided

with the standard power supply, for correct operation. An optional remote transformer can be used to provide control

voltage if neutral is not available. Some voltage and cycle combinations will require an optional transformer for correct

operation.Yacht Pro Series are available for other electrical requirements. Please contact our Technical Department for

specifications.

WARNING: Divers lives depend upon proper operation of the system.

Brownie’s Third Lung highly recommends that all system operators take a

System Training Course.

PRE START-UP CHECKS

Consult the system log to see if the following maintenance needs to be done:

• Puriﬁcation Cartridge inspection/replacement (see pages 11, 20, 22)

• Sightglass Element replacement (see page 18) (6 month installed life)

• Oil Check/Change (see pages 17, 27)

1. Check oil level

The oil level must be between the upper and lower marks on the dipstick (see picture page 17). If the oil is low,

add oil through the dipstick tube. Use only Brownie’s recommended oil (see page 11 for recommended oils). Do

not mix oils or use non-recommended oils which may adversely affect the life of the unit or even destroy the unit.

2. Check Puriﬁcation Cartridges

Inspect both cartridges by following the procedure on page 11. Replace either cartridge if present cartridge has

been used up or the cartridge has been in place for 6 months. (This is the maximum installed life of the puriﬁca-

tion cartridges. If the cartridges are close to expiration, Brownie’s recommends replacing the cartridge with a new

one.) Replacement Cartridge for the Black Tower is X53240. Replacement cartridge for the Gold Tower is X22679.

WARNING: Failure to monitor or replace the puriﬁcation cartridge WILL contaminate all air

lines, ﬁll assemblies, divers air tanks, regulators, and may cause severe injury or even diver

death. The system operator is responsible for the lives and safety of the divers using air pro-

duced by the system.

3. Check Visual Carbon Monoxide / Moisture Indicator

The visual indicator has two elements. An outer blue ring for indicating the presence of moisture, and a central tan

to orange disc, indicating the presence of carbon monoxide. Any change in color, (the central disc (CO) turns dark

brown or has black spots, and/or the outer ring (moisture) turns pink or beige, indicates that the air leaving the

puriﬁcation system is contaminated and not breathable. The visual monitor is the last monitor of the air leaving the

puriﬁcation system, and must be checked during operation for any changes.

WARNING: Any color change in the elements of the visual indicator means that con-

taminated air has passed downstream. All air lines, ﬁll assemblies, and equipment must

be cleaned or replaced. An Air Test must be done to insure thoroughness of all cleaning.

Breathing contaminated air may result in personal injury or death.

4. Check Air Intake

Remove and inspect the Air Intake Filter. If the system is equipped with a remote air intake, be sure it is properly

located, and clear of any water or obstructions.

5. Add all pre-startup maintenance/inspection notations to the system log with date, hours, and operator name.

6. Inspect ALL tanks to be ﬁlled:

• Make sure the tanks are in good condition with no deep scratches, gouges, or pitting.

• The tanks must be within current hydrostatic test and Visual Inspection dates.

• Do not ﬁll empty tanks without ﬁrst visually inspecting them for water intrusion.

• Make sure that the valves are in good condition and not in need of service. Do not ﬁll tanks with damaged

valves.

• Do not ﬁll tanks that have been exposed to extreme heat, i.e.: tanks that have been in or near ﬁres.

• Do not ﬁll tanks designated for air with other gas mixtures, ie: Nitrox, Trimix, etc.

TANKFILL PROCEDURES

(See Demonstration p 24-26)

WARNING: Tanks must be secured (protected from falling or being knocked over) during filling.

1. Hook up fill manifold to compressor air outlet or remote fill panel.

2. Slightly open tank valve just long enough to blow any moisture or particles clear of connection surfaces.

3. Standard Yoke - Hook fill yokes to the tank valves and tighten yoke hand wheel “finger tight”. Close bleed screws

and open tank valves. Open the fill yoke valves. The tanks will now equalize.

Din Yoke - Screw the male din yokes into the valves until the “o-ring” is snugly in place against the base of the

female din valves. Close bleed screws and open tank valves. Open the fill yoke valves. The tanks will now equalize.

4. Start the Compressor

Note the indicator light is now on. If the compressor is equipped with a dual pressure switch, be sure the control

switch is in the correct pressure position (high or low) for the tanks being filled. The compressor will now operate

automatically, draining the condensate and shutting off when the tanks are full. The operator need only check the

operation from time to time during the filling process to verify the following:

• Condensate is accumulating in the reservoir.

• No color change has occurred in the visual indicator.

• Pressure is building on the fill gauge.

Fill times are based on filling a single standard 80 cu ft aluminum cylinder from 500 psi to 3000 psi and are

approximately as follows: YP25DF - 28 minutes per tank and YP35DF - 22 minutes per tank. Cylinder volume,

starting tank pressure, and tank pressure ratings will vary the fill times.

WARNING: Brownie’s recommends a two hour (approximately 4 tanks) duty cycle, with a one

hour period between cycles.

Note that the indicator light is still on after the compressor automatically stops. This indicates that the compressor

is in an AUTOMATIC START MODE and will restart if the stop pressure drops approximately 500 psi.

If you intend to fill more tanks you may leave the on/off switch in the “on” position while changing the tanks out.

Simply opening the tank and fill yoke valves will restart the compressor.

5. Remove full tanks by first closing the fill yokes and tank valves. Depressurize the yokes by opening the bleed

screws. Remove the fill yokes from the tanks.

6. When you are done filling for the day, turn the on/off switch to the off position. Empty the condensate reservoir.

7. Bleed the pressure from the fill manifold by opening one of the fill yoke valves slowly until all pressure is vented

and the gauge reads zero.

8. Remove the manifold from the hose using the quick disconnect and store the manifold in its bag.

WARNING: Do not try to remove the quick disconnect while the system is pressurized. Doing so

may result in property damage or personal injury.

9. Allow the compressor to cool prior to installing the optional Cordura fabric cover.

10. Update the system log, noting running hours of compressor and any maintenance performed.

PURIFICATION SYSTEM

Explanation:

The YP25DF and the YP35DF compress air in three stages. Air leaving the outlet (discharge) of each stage is at an

elevated temperature. The air passes through cooling tubes and the temperature is reduced prior to entering the inlet

of the next stage. As this air cools, moisture is released and accumulates in the condensate traps (separators). This

process of moisture removal is based on dew point. Dew point is the total moisture saturation point of air at a

specific temperature. The higher the temperature, the greater the amount of suspended moisture. When air leaves

the last or final separator and enters the purification cartridge it is at approximately 15 deg F above the ambient

temperature. This temperature is referred to as inlet temperature. Higher inlet temperatures reduce the life of the

purification cartridge.

As an example, an ambient temperature of 90 deg F will yield an inlet temperature of 105 deg F. The life of the

purification cartridge at this temperature will be significantly less than a cartridge processing air at an 80 deg F

ambient temperature, which yields a 95 deg F inlet temperature.

The Yacht Pro purification system will process 15,000 cu ft of CGA Grade “E” Air at an inlet temperature of 80 deg F.

At this inlet temperature the purification system cartridges should last approximately 80 hours in the YP25DF, and

approximately 70 hours in the YP35DF.

The Yacht Pro Purification system uses three chemicals to process the air. The first chemical is molecular sieve

13x, and is the desiccant or moisture/oil remover. The second chemical is a catalyst called hopacolite, that converts

carbon monoxide to carbon dioxide. The third chemical is activated carbon which removes taste and odor. The

X53240 cartridge uses a Lifeband ™ to indicate usage and replacement (see page 21). The cartridge Lifeband ™

should be inspected prior to each use to determine whether the cartridge needs to be replaced. The hours the

cartridge is used and replaced needs to be recorded in the system log.

The Yacht Pro purification cartridges have a shelf life of two years in the original sealed package and a maximum

installed life of six months.

Spare cartridges should be kept in a cool, dry location. The boxes must not be crushed and the packaging must not

be punctured.

WARNING: Do not use cartridges that have expired, have punctured packaging or that are

damaged in any way!

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Lubrication Specifications

Use Lubricant

O-rings, rubber and plastic parts, White Petroleum DAB9 # N19091 or WEICON WP 300

filter housing threads White part # N19752

Sealing Rings Universal grease

Paper Gaskets Apply silicone compound on both sides (WACKER

silicone compound part # N 18247) before assembly

Bolts, nuts, studs, valve parts, CU gaskets and pipe Compounds with Copper or MoS² additives (WEICON

connectors (threads, cap nuts, compression rings) ANTI-SEIZE AS 040 P part # N 19753)

High Temperature connections Temperature resistant compound (WACKER

(valve heads / cylinders) silicone compound, part # N 18247

MAINTENANCE TYPE OF MAINTENANCE DATE SERVICE

INTERVAL CENTER

After 25 hrs initially, and Oil Change (every 50 hours when using regular oil,

every 50 - 100 hours and every 100 hours if using synthetics) or

thereafter six months

After 25 hrs initially, Check function and tightness of filling valve

and every 150 hours Clean and change intake filter

thereafter Check tightness of o-rings

Check drive belt and condition

Check cooler brackets

Check zero on gauge when depressurized

After 1st year or 300 Air and tightness check

hours of operation Replace filter chamber o-rings

Drive belt inspection (replace after 300 hrs)

Cleaning of air intake filter and filter unit.

After 2nd year or 600 Check air tightness and performance

hours of operation Drive belt inspection (replace after 600 hrs)

Replace filter chamber o-rings

Cleaning of air intake filter and filter unit.

After 3rd year or 900 Check air tightness and performance

hours of operation Drive belt inspection (replace after 900 hrs)

Replace filter chamber o-rings

Cleaning of air intake filter and filter unit.

WARNING: We recommend that any maintenance other than preventative be performed by an

authorized service center or technician. Contact Brownie’s for service center information.

After 4th year or 1200 Check air tightness and performance

hours of operation Drive belt inspection (replace after 1200 hrs)

Replace filter chamber o-rings

Replacement of air vent hose

Replace cylinder head o-rings.

Clean air intake filter & unit.

After 5th year or 1500 Check air tightness and performance

hours of operation Drive belt inspection (replace after 1500 hrs)

Replace filter chamber O-rings

Cleaning of air intake filter and filter unit.

After 6th year or 1800 Check air tightness and performance

hours of operation Drive belt inspection (replace after 1800 hrs)

Replace filter chamber o-rings

Cleaning of air intake filter and filter unit.

After 7th year or 2100 Check air tightness and performance

hours of operation Drive belt inspection (replace after 2100 hrs)

Replace filter chamber o-rings

Cleaning of air intake filter and filter unit.

Recommended Maintenance

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TORQUE VALUES AND SEQUENCING

Torque Values: Unless otherwise noted in text, the following torque values apply. All valve head screws require

torque wrench tightening.

The indicated values are for bolts in greased condition. Replace self-retaining nuts on reassembly.

Screw or Bolt Thread Max Torque

Hex and Allen Head M 6 7 ft.lbs (10 Nm)

Hex and Allen Head M 8 18 ft.lbs (25 Nm)

Hex and Allen Head M10 32 ft.lbs (45 Nm)

Hex and Allen Head M12 53 ft.lbs (75 Nm)

Hex and Allen Head M14 85 ft.lbs (120 Nm)

Hex and Allen Head M16 141 ft.lbs (200 Nm)

Pipe Connections (swivel nuts) Finger tight + ½ turn

Torque Sequencing:

Tighten valve head and cylinder bolts/nuts equally in the sequence shown here. Be sure to tighten

all parts in cold condition only.

CHANGING THE 1ST STAGE VALVES

Intake and pressure valves for the 1st stage are combined in one plate

valve under the valve head, as seen in the diagram.

• Loosen two cap nuts from tube connectors and remove after-cooler.

• Remove four allen screws (5) from valve head (1). Take off valve-head.

• Remove gasket (2) and plate valve (3).

• When re-installing the valve, check that the mark “TOP” is facing

upwards. Also pay attention to the orientation of the valve: check that

the two eye-shaped inlet openings are facing the intake filter side.

The crossbar of the gasket (2) seals these openings with respect to

the outlet openings of the pressure valve.

1.Valve Head 2.Gasket 3.Plate Valve 4.O-ring 5.Valve Head Screw

VALVES

Valve Functioning

The valve heads of the individual stages form the top part of the

cylinders. The intake and pressure valves are fitted inside the

valve heads. Note that the valves are operated by the flow of

the gas. On the suction stroke, the intake valves open and the

gas flows into the cylinders, and on the compression the

intake valve closes, and gas flows out the pressure valve.

Initial Operational Check

After roughly half an hour’s operation, valves should be checked.

Note that the inlet line to the valve heads should be warm, and

outlet piping should be hot. Valves are then shown to be operating

properly.

If the intake pipe to the valve head of the second stage heats up

excessively, and the first stage safety valve blows off, either the

intake or pressure valve of the second stage is malfunctioning. It is necessary then to remove the valve head and to

check and clean these valves or to replace them.

Valve Change General Instructions

• Always replace valves as a complete set.

• Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in diesel oil or

petroleum, and clean with a soft brush.

• Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the

valves.

• Valve head screws must be tightened with a torque wrench (See tightening instructions page 13)

• Check the valve space in the valve heads for dirt, and clean if necessary.

• Use gaskets and o-rings in reassembly only if they are in satisfactory condition, otherwise replace them.

• Observe the correct sequence when reassembling.

• When maintenance work has been completed, turn the compressor manually using the flywheel to verify

correct assembly.

• 30 minutes after restarting the compressor unit, stop the unit, let it cool to ambient temperature, and

retighten the valve studs and cap nuts to specifications (page 13). Otherwise valves could work loose due to

setting of the gaskets.

• Replace valves every 2000 hours to avoid fatigue failure.

CHANGING THE 2ND STAGE VALVES

Both the pressure and intake valves can be serviced from the outside.

• Remove two captive nuts (1) and springwashers (2).

• Remove plate (3).

• Remove valves (4) and (7) using two screwdrivers as shown in the

diagram below.

• Assemble in reverse sequence.

Position springwashers (2) with curved side facing up.

Fasten nuts so that plate (3) is parallel to the valve head.

Torque as specified.

1.Nut 2.Springwasher 3.Plate 4.Pressure Valve 5.O-ring

6.Valve Head 7.Intake Valve 8.Valve Head Screw

Removal of 2nd and 3rd stage valves:

• Place two screwdrivers into the groove of pressure valve body. If

necessary turn valve loose using a 13mm wrench on the flat surfaces.

• Lift out pressure valve together with o-ring.

CHANGING THE 3RD STAGE VALVES

• On this valve head, the valves are arranged on the upper and lower side

due to the small diameter of the cylinder.

• For removal and installation of the intake valve (4) use the special tool

(part # 004555) which is part of the tool set provided with the unit.

•Pressure valve (3) is merely inserted into valve head (5). It is sealed by

the o-ring (2), and fixed to the valve head by bolt (1).

CHANGE INTAKE AND PRESSURE VALVES OF THE 3RD STAGE AS A SET ONLY

Removal of the 3rd stage pressure valve (3).

• Unscrew screw (1) a couple turns.

• Remove allen screws (7), take off valve head cover (6).

• Using screwdrivers as shown above, lifting out the pressure valve (3) together with the O-ring (2).

Reinstall pressure valve (3) in reverse sequence:

• Put o-ring (2) into valve head (5). Check o-ring for abrasion, and replace if worn.

• Insert pressure valve (3). Install valve head cover (6).

• Fasten valve head with allen screws (7) and washers (8).

• Screw in and torque stud (1) as specified.

V-BELT TENSION ADJUSTMENT

• Slightly loosen motor mounting nuts.

• Adjust motor until the v-belt tension is correct.

• Tighten motor mounting nuts.

• Run motor for approximately 5 minutes. Stop motor, check belt tension, and readjust if necessary.

• Check that after tension adjustment and tightening the motor mounting nuts, both pulleys are in a straight

line to avoid excessive wear of the v-belt. Hold a straight edge against the compressor and motor pulleys as

shown. Edge must touch the pulleys at four points, or you must re-adjust motor.

COOLING SYSTEM

• The cylinders of the compressor block, the intermediate coolers, and the after-cooler are all air cooled.

• For this purpose, the compressor is equipped with a fanwheel connected to the counter-weight at the

crankshaft end opposite to the V-belt pulley. It draws the cooling air through the fanwheel cover from the

surroundings.

• Refer to page 6 for specific ambient temperature data.

CHECKING THE DRIVE BELT

The best tension for belt drive is the lowest possible, while not

slipping when under full load. This is best quantified by belt

depression with thumb pressure between the two pulleys, with

the belt deflecting ¼ “ (10mm) .

• Re-adjust v-belt after 25 hours of operation.

• Check the tension and adjust every 125 hours, assessing

the belt for wear or damage.

INTAKE FILTER

The intake filter is a dry micronic filter used to filter the intake air.

Filter Maintenance:

Filter cartridge must be changed at regular intervals

according to maintenance schedule on page 12.

• Remove knurled nut (1) and take off plastic cap

(2). Remove filter cartridge (3) and clean with a

brush or by blowing air from the inside to out.

• Turn the cartridge 90º when replacing. Replace the

dirty cartridge once it has been turned three times

and been used through the full system.

• Clean filter housing inside with a damp cloth. Take

care to prevent dust from entering the intake pipe.

• Replace o-ring (4) if damaged.

OIL LEVEL CHECK

Check oil level daily prior to operating compressor. Use the

dipstick and a lint free cloth to check the oil, by wiping off oil

several times. Note that the oil level must be between the

minimum and maximum dipstick notches.

Add oil if necessary and recheck level. Oil should not exceed

the maximum level, as this could result in valves sooting up.

OIL TYPES

Using the correct oil is of utmost importance for proper care and

maintenance of the compressor, along with keeping the life and function of your compressor at its best.

Only use oils that:

• are low in deposits

• have no carbonizing effect, especially in the valves

• have good anti-corrosive properties

• provide emulsification of the condensate in the crankcase

• are physiologically and toxicologically suitable

Due to the thermal load on the compressor, only high quality oil should be used. You are recommended to restrict

oils to those which have been approved by the manufacturer and are in our list of oils (see page 11).

Synthetic Lube Oils

For operating under severe conditions such as continuous running and/or higher ambient temperatures, we

recommend Part No. CF-2000 (Synthetic Compressor Lubricant, Food Grade). CF-2000 has been specially

formulated for use in high pressure compressors and will provide optimal performance through a wide range of

conditions.

NOTE: The compressor systems are delivered with one liter of natural oil, Part No. BTLHPN-25.

3. The moisture indicator ring is placed into the

window first. Minimal handling is best, and care

should be taken with the packaging contents

and their disposal. 4. This view shows the ring properly installed in

the window.

Inspect o-ring for wear, and

replace if worn.

Lube threads with food grade

silicone grease if needed.

1. Unscrew window cap in counter-clockwise

direction. (NOTE: The orientation of the

sightglass assembly may vary.)

2. Here the cap is shown having been removed,

and the retaining spring exposed. Old

elements are removed from the window at

this time.

WARNING: Make sure all pressure is relieved prior to changing element.

SIGHTGLASS CO MOISTURE ELEMENT CHANGE DEMONSTRATION

Replacement Element Part # M7414 (Assy # VM211-EL)

5. The CO monitoring disc is shown ready to

install into the window. It is placed in and then

centered in the moisture indicator ring.

6. The spring is placed into the window, centered on the CO

disc and the whole unit is then ready to be reassembled.

7. The cap is replaced and it is screwed back

into place, finger tight. Make sure the CO

disc remains in place.

8. With change and reassembly completed, both

indicators are easily viewed in the window and the

cap is tightened down.

3. Prepare Filter

• Uncover top plug by removing

tape.

• Remove top plug with pliers

using rocking motion.

• Remove bottom plug.

Discarded Items:

4. Place New Filter

Place the new filter into the chamber seating it

on the bottom.

BLACK FILTER CARTRIDGE REPLACEMENT DEMONSTRATION

REPLACEMENT CARTRIDGE PART #X53240

WARNING:

Prior to changing the filter, purge all pressure using the bleeder valve.

1. Remove Cap

Counter-clockwise rotation of the cap using a wrench

as shown will loosen the cap for removal.

2. Remove Old Filter

While removing the old filter, check the Lifeband ™

indicator to determine filter usage or replacement.

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