Dover Blackmer TYPHON 1000 User manual

COLD FRONT OUTLET
INTERCOOLER TYPHON
INSTRUCTIONS 1401-F00 e
Section 1401
Effective December 2005
Replaces December 2004
OEM PRODUCT existing only in front version.
INSTALLATION
OPERATION
MAINTENANCE
SAFETY
STORAGE
Your distributor :
BLACKMER
ZI PLAINE DES ISLES
F- 89000 AUXERRE
Tel. : [phone]
Fax : [phone]
e-mail : [email protected]

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SAFETY, STORAGE, INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
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1. GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 TYPHON characteristics . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 TYPHON operating ranges . . . . . . . . . . . . . . . . . . . . . .5
1.4 Outline drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 Check relief / Safety valve . . . . . . . . . . . . . . . . . . . . . .7
2.4 Drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.5 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.6 Instrumentation connections . . . . . . . . . . . . . . . . . . . . .9
2.7 Chair modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3. PACKAGE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .10
3.1 Lubricant recommendations . . . . . . . . . . . . . . . . . . . .10
3.2 Before start up - Filling of lubricant . . . . . . . . . . . . . .10
3.3 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.4 Compressor start up procedure . . . . . . . . . . . . . . . . .10
3.5 Shutting down procedure . . . . . . . . . . . . . . . . . . . . . .11
4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . .11
4.2 Compressor oil draining procedure . . . . . . . . . . . . . . .11
4.3 Air filter replacement procedure . . . . . . . . . . . . . . . . .12
4.4 Belt and pulley drive inspection procedure . . . . . . . .12
4.5 How to change pulley shaft position . . . . . . . . . . . . . .13
4.6 Safety valve / Check valve inspection . . . . . . . . . . . .14
4.7 Mounting procedure for the transmission pulley axis .14
4.8 Fan and thermocontact connectors replacement . . . .16
5. SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.1 Chair and transmission . . . . . . . . . . . . . . . . . . . . . . . .17
5.2 TYPHON INTERCOOLER package . . . . . . . . . . . . . .18
5.3 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6. STORAGE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . .20
7. AFTER SALES RETURN FORM . . . . . . . . . . . . . . . . . . .21
SUMMARY Page
NOTE :
The item numbers that follow the names of the parts correspond to
the reference numbers present on the outline drawings.
REMARKS :
Blackmer truck screw-type compressors package MUST be instal-
led in systems designed by qualified personnel. The installation
MUST be in compliance with local standards, national regulations
and rules of safety.
This manual is designed to permit installation and commissioning
of Blackmer truck screw-type compressors package and MUST
accompany the compressor.
Maintenance of Blackmer screw-type compressors and package
must ONLY be carried out by qualified technicians. This mainte-
nance must meet local and national standards as well as all safe-
ty regulations.
Read this manual, including all instructions and warnings, in full
BEFORE any use of Blackmer compressors.
Do not remove the warning and use label stickers that are found
on the compressors.
This is a SAFETY ALERT SYMBOL
When you see this symbol on the product, or in the manual, look
for one of the following signal words and be alert to the potential for
personal injury, death or major property damage.
Warns of hazards that WILL cause serious personal injury,
death or major property damage
Warns of hazards that CAN cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause personal injury or property
damage.
NOTICE
Indicates special instructions which are very important and
must be followed.
SAFETY INFORMATIONS
WARNING
CAUTION
DANGER

SAFETY
CHECKLIST
1. Before operating the compressor, ensure the vessel to
which the compressor is connected is certified to with-
stand the pressure and /or vacuum produced.
2. Verify adequately sized relief valves (if necessary, CE
approved) have been fitted to protect the vessel.
3. Gas/air mixtures which are potentially volatile/explosive
must not be introduced or allowed to be introduced into
the compressor.
4. All pressure vessel and piping connected to the compres-
sor must be isolated and in a safe operating condition.
5. Operators should wear ear protection when operating
truck mounted compressors.
6. There are components within the compressor of sufficient
weight to cause injury if mishandled. Use proper lifting
devices as necessary.
7. Where necessary, this equipment should be grounded to
control static electricity.
8. The temperature of the air leaving the compressor is ele-
vated above ambient due to air compression. Check that
the elevated temperatures do not adversely affect the
product and any material used in design of the system.
Attach clearly marked warning signs to warn of potential-
ly hot surfaces on the compressor, piping and accessories
which will burn if touched.
9. Mounting of the compressor must be correctly engineered
and the compressor must be properly secured. Refer to
the Compressor Mounting section of this manual. In par-
ticular, the installation shall be done in such a way that no
rotary part may be touched by the operator in normal
operation.
NOTICE :
BLACKMER COMPRESSORS ARE NOT DESIGNED FOR HANDLING
LIQUID, POWDER OR CONDENSATE.
TO DO SO WILL VOID THE WARRANTY.
CONTENTS OF THE COMPRESSOR,
TANK, PIPING, AND FILTERS COULD BE
HAZARDOUS TO HEALTH. TAKE ALL
NECESSARY PRECAUTIONS WHEN PER-
FORMING COMPRESSOR SERVICE OR
MAINTENANCE.
WARNING
Hazardous or toxic
fluids can cause
serious injury.
COMPRESSOR, PIPING AND ACCESSO-
RIES WILL BECOME HOT DURING OPERA-
TION AND CAN CAUSE SERIOUS PERSO-
NAL INJURY.
CAUTION
Extreme heat can
cause injury or
property damage.
FAILURE TO INSTALL ADEQUATELY SIZED
PRESSURE RELIEF VALVE(S) CAN CAUSE
PROPERTY DAMAGE, PERSONAL INJURY
OR DEATH.
CAUTION
Hazardous pressure
can cause
personal injury
or property damage.
COMPRESSING GASES INTO A VESSEL
CONTAINING FLAMMABLE OR EXPLOSI-
VE GASES, OR COMPRESSING FLAMMA-
BLE OR EXPLOSIVE GASES, CAN CAUSE
PROPERTY DAMAGE, PERSONAL INJURY
OR DEATH.
WARNING
Hazardous fluids
can cause fire,
serious personal
injury or property
damage.
IT IS IMPERATIVE TO APPLY THE TRUCK
PARKING BRAKE AND TO BLOCK THE
WHEELS BEFORE ANY INTERVENTION
DUE TO RISKS OF SERIOUS BODILY INJU-
RIES OR PROPERTY DAMAGE.
WARNING
Hazardous machinery can
cause severe
personal injury or
property damage
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1.1 Principle of operation
The male screw and the female screw mesh and rotate
in opposite directions inside the casing fitted with inlet
and discharge ports.
Rotation generates a volume increase on the inner face
between threads and grooves, which corresponds to
inlet, and a volume reduction on the upper face, which
corresponds to compression.
On the discharge port side, a set of gears synchronizes
the male screw and the female screw. Thus, the screws
are not in contact. The discharged air does not enter in
contact with any friction part and remains clean and free
from particles.
On the drive shaft side, the female screw is driven by a
set of step-up gears.
An oil pump delivers pressurized oil which circulates,
lubricating gears and ball bearings.
Sealing is provided between lubricated parts and the
compression stage by means of labyrinth seals. These
seals do not enter in contact with the shaft and are not
subject to wear.
Thanks to its technology, TYPHON compressor is relia-
ble and has a long service life.
TYPHON compressor needs very limited maintenance,
which reduces vehicle downtime.
TYPHON version 2C drive speed (2000 rpm) was defi-
ned so as to drive it directly through universal joints from
a P.T.O shaft.
Our compressors are delivered without oil. The use of
a compressor with an oil level that is not located bet-
ween the two limits indicated by the gauge can lead
to important property damage and serious injuries.
TYPHON 1000 INTERCOOLER package includes the follo-
wing accessories :
• Inlet filter
• Silencer
• Check and relief valve
• Chair and pulley driving system
• Electrically propeller cooling fan
• Heat exchanger
• Filter clogging gauge
TYPHON 1000 COVER package includes the following
accessories :
• Inlet filter
• Silencer
• Check and relief valve
• Chair and pulley driving system
• Filter clogging gauge
This package is similar to the INTERCOOLER package with-
out the air cooling function.
Cooler
Outlet
port
Inlet filter
Oil gauge
Chair
Pulley Compressor
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1.2 TYPHON 1000 Intercooler characteristics
These operating characteristics for TYPHON compres-
sor package are given in the indicative operation condi-
tions : ambient temperature and air inlet temperature
20°C, atmospheric pressure : 1013 mbar.
1.3 TYPHON operating ranges
These operating ranges give the conditions that must be
respected on mounting and packaging of the TYPHON
pulley driven packages, in order to be able to benefit
from the guarantees for these pieces of equipment.
1.3.1 Conditions at suction
The compressor inlet suction air must be filtered in order
to eliminate particles bigger than 5 µm.
The maximum pressure drop at suction must be lower
than 75 mbar.
On the TYPHON 1000 IC packages, a pressure gauges
gives the measurement of the line loss on the inlet part.
The filter element must be changed or cleaned when the
gauge reaches the red area (75 mbar pressure drop).
The filter element used on TYPHON 1000 IC is not was-
hable and needs to be replaced.
The maximum acceptable temperature at suction is
given in the tables below, as a function of equipment
operating conditions :
1.3.2 Recommended drive conditions
Operating torques on the package driving shaft :
Maximum acceptable torque at start up on the compres-
sor shaft :
The transmission lines (universal joint, pulley belt, etc.)
must be sized so as to be able to accept the loads
above.
In any case where the compressors are to be driven by
diesel motor, the system must be able to disengage the
compressor at equipment start up and stop.
It is imperative that the drive shafts be dynamically ba-
lanced.
The non balancing of the drive shafts can lead to mecha-
nical ruptures that are susceptible of causing important
property damage and/or serious injuries.
Align the PTO shaft axis with the package pulley axis or
refer to the truck PTO documentation.
Not following assembly instruction can lead to mechani-
cal ruptures that may create major property damage
and/or serious injuries.
1.3.3 Maximum discharge pressure
The maximum acceptable pressure at discharge is indi-
cated in the tables below, as a function of drive speed
and pulley ratio :
The pressures given in the tables above correspond to the
Typhon 1000 Pressure
(bar)
PTO drive speed
(rpm)
2,0 1200 - 1600
1 : 1 ratio 2,3 1600 - 2000
2,0 1075 - 1434
1 : 1,12 ratio 2,3 1434 - 1792
2,0 960 - 1280
1 : 1,25 ratio 2,3 1280 - 1600
2,0 853 - 1138
1 : 1,40 ratio 2,3 1138 - 1422
CAUTION
Maximum starting torque
Typhon 1000
Pulley ratio 1 : 1 469
Pulley ratio 1 : 1,12 532
Pulley ratio 1 : 1,25 599
Pulley ratio 1 : 1,40 673
PTO drive
speed
Typhon
1000
Screw compressor
speed Maxi (rpm) 2,3 bar pressure
Pulley ratio 1 : 1 2000 345
Pulley ratio 1 : 1,12 1792 385
Pulley ratio 1 : 1,25 1600 431
Pulley ratio 1 : 1,40 1423 485
TYPHON
PTO
Speed in
rpm
Relative pressure
at discharge in bar
Max T°
in °C
2000 242
1200 238
2000 2.3 40
1600 2.3 35
TYPHON
1000
PTO
Drive
speed
Pressure
(bar)
Discharge
Flow rate
(M3/h)
Power at
coupling
(KW)
Weight
(kg)
Oil
volume
in liter
1200 2,0 470 35
1600 2,3 700 53
Ratio
1:1,00 2000 2,3 950 70
1075 2,0 470 35
1434 2,3 700 53
Ratio
1:1,12 1792 2,3 950 70
960 2,0 470 35
1280 2,3 700 53
Ratio
1:1,25 1600 2,3 950 70
854 2,0 470 35
1139 2,3 700 53
Ratio
1:1,40 1423 2,3 950 70
350 5
Typhon 1000 2 bar pressure
2,3 bar pressure
Screw compressor
speed
Mini
(rpm)
Maxi
(rpm)
Mini
(rpm)
Maxi
(rpm)
Pulley ratio 1 : 1 1200 2000 1600 2000
Pulley ratio 1 : 1,12 1075 1792 1434 1792
Pulley ratio 1 : 1,25 960 1600 1280 1600
Pulley ratio 1 : 1,40 854 1423 1139 1423
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valve opening start pressure. In a period of 60 seconds, it
is acceptable to have a pressure of 0.2 bar higher when
the valve passes the complete flow rate.
The value above apply to all package configurations
having the same pulley ration and compressor.
1.3.4 Acceptable oil pressure range
The oil pressure is measured at the tap point located on the
synchromesh gear box (item G on the outline dra-wings) :
In normal operation, the compressor, the silencer, the
outlet piping and their surrounding parts (covers…) may
reach high temperatures (up to 200°C). Make sure that
you do not put sensitive components close to a heat
source, and affix plates warning users that the compres-
sor is hot, to avoid any burn hazards.
Having the compressor run above its maximal temperatu-
re may lead to serious body injuries or property damages.
1.4 Outlines drawings
The overall dimensions of the different packages are
given on the table below :
TYPHON 1000 IC
The above dimensions are given with the shaft axis
mounted in the closest position to the chair.3 hole loca-
tions exist on the chair :
1st hole
3rd hole
2nd hole
Pulley
ratio X Y D
1:1 185 524 231
1:1,12 172 503 257
1:1,25 173 503 287
RIGTH
DRIVEN
PTO 1:1,4 170 506,5 322
1:1 134 519 231
1:1,12 188,5 499 257
1:1,25 119 498 287
LEFT
DRIVEN
PTO 1:1,4 116 502,5 322
Pulley
ratio
Pulley
dia.
Pulley
dia.
Belt
lenght
Tension
setting with
66N
1:1 224 224 1400 6,4
1:1,12 224 250 1500 6
1:1,25 224 280 1550 6
1:1,4 224 315 1600 6
D
X +10
Y+10
Length
Width
Height
TYPHON
1000 IC
Width 870
Length to truck frame
775
Overall length 1034
Height 650
Pressure (bar) TYPHON Packages
Mini 0.2
Maxi 2.3
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During the assembly, watch that no foreign body penetrates
into the packages outlet. The piping of expulsion must be per-
fectly clean. Any foreign body risks to damage seriously the
compressor.
The installation should comply with the CE regulations on
machinery directives. In particular, the pulley and belt should
not be accessible once the compressor package is mounted
on the truck.
The presence of foreign bodies in the compressor inlet
channel is susceptible of leading to serious property
damages or serious injuries and would void the warranty.
2.1 Mounting location
The package must be installed in a location where it is
easily accessible.
In particular, make sure that the oil filling plug and the fil-
ter are accessible.
Choose a location where the compressor is relatively
protected from gravel projections and road spray as well
as exhaust fumes and engine heat.
The best location for the compressor is the side of the
truck.
In normal operation, the compressor, the silencer, the
outlet piping and their surrounding parts (covers, …)
may reach high temperatures (up to 200°C). Make sure
that you do not put sensitive components close to a heat
source, and affix plates warning users that the compres-
sor is hot, to avoid any burn hazards.
The package should respect the minimum distance to
the road specified on the truck manual to reduce road
dirt damages. In case no such information is available,
use 200 mm.
The belts and pulley transmission should maintain a
mimimum 30 mm clearance away from any stationary or
mobile part mounted or used on the truck. In particular,
the pulley and shaft should be properly cleared from the
truck main drive shaft.
Failure to do so may result in bodily injury or property
damage.
2.2 Inlet filter
The installation shall be such that the air sucked by the
filter is within 5°C of the ambient air temperature.
To prevent any excessive clogging of the filter, the air
sucked inside the filter shall be free of any exhaust fume
residue or road dust.
In front of the filter, an area of a minimum of 200 mm
should be left free to allow enough space to change the
cartridge.
2.3 Check relief / Safety valve
The compressor packages are protected by a check
relief/safety valve.
The check valve prevents any air from returning in the
compressor when it is no longer in operation.
The setting of the safety valve has been done before
delivery of the compressor. This setting is sealed. Any
tampering with the safety valve sealing will void the war-
ranty. Should you require to change the setting value,
contact one of Blackmer authorized service center.
The use of a TYPHON compressor at a pressure
higher than that specified can lead to serious pro-
perty damage and/or serious injuries.
The maximum setting of the relief valve is 2,3 bar on
Typhon packages.
This setting should take into account the normal working
speed, as described in § 1.3.
2.4 Drive systems
WARNING :
To comply with European machinery directives, the rota-
tive drive part of the compressor packages installation
(pulley, belt, PTO) must not be accessible to the truck
driver in normal conditions. If necessary, install the
necessary protection to prevent any risk of property
dama-ge or body injury. The installation of those protec-
tions is the installer responsibility. Blackmer shall not be
liable from damage or injuries resulting in the lack or
poor quality of installation of such protective device on
the truck.
CAUTION
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The chair location used to mount the axis is given on the
table below :
The distance between each hole is 40 mm, so using a
hole farther from the chair will increase distance X by 40
mm on the encumbrance drawing.
Pulley ratio
Typhon Package
Mistral package
1:1 2nd hole 1st hole
1:1,12 1st hole 2nd hole
1:1,25 1st hole 2nd hole
1:1,4 1st hole 1st hole

2.4.1. Speed range
The use of TYPHON compressor package outside of
their operating speed range can lead to property dama-
ge or serious injuries.
The operating speed of the Blackmer compressor pac-
kage is a function of the pulley ratio choosen for those
package. See § 1.2 for details.
IMPORTANT :
Any system providing for a compressor being driven by
a thermal motor must include a system making it possi-
ble to disengage the compressor at startup and stop of
the motor.
In all cases, the drive must make it possible :
- To maintain the compressor rotation speed during load
variations (pressure variations).
- Not to subject the compressor to sudden or insufficient
starts.
Follow the below steps to select the proper engine
speed to operate the package in the right condition :
• Identify the flow and pressure conditions wanted
from the package
• Identify the package rotational speed needed to
meet the above flow requirements, using 1,2
• Take into account the PTO gear factors to compute
the engine set speed :
• If your PTO gear box has a split, make the calcula-
tion with both gear ratio, and select the split giving
the optimal engine speed (lowest fuel consumption)
• Write down the split value and engine speed on the
truck wind shield, so that the driver has easy access
to the proper driving conditions
2.4.2 PTO shaft drive
It is mandatory to comply with the following instructions :
• The shaft must be dynamically balanced.
• Its length and its inclination must be as small as pos-
sible, see table
• The package shaft must be horizontal, with a parallel
tolerance with the P.T.O shaft of 5°.
• The drive shaft slides perfectly well during rotation.
• The jaws of the universal joints are parallel.
• Coupling flanges show no eccentricity nor warping of
the bearing surface.
• The angle formed by the universal joint and the drive
shaft must not exceed 15°.
• Belts shall be sufficiently tensioned to avoid any
slack or slide.
2.4.3 Belt / Pulley arrangements
• In order to select the right package configuration the
PTO rotational direction needs to be known.
The package must be mounted on the right side of the
truck.
To identify PTO direction and compare it with the sketch
below, look at the truck from the rear :
• If the PTO goes from right to top to left, the PTO is left
driven
• If the PTO goes from left to top to right, the PTO is right
driven
This feature will prevent power consumption on the pac-
kage when the system is not operating.
Rear
right driven PTO
Front
left driven PTO
Left package Right package
A Universal joint angle
0.017 1°
0.035 2° VERY
0.052 3° GOOD
0.070 4°
0.087 5°
0.105 6°
0.125 7°
0.141 8° GOOD
0.158 9°
0.176 10°
0.194 11°
0.213 12° Limit
0.231 13° values
0.249 14°
0.268 15°
H² + W²
A=
L
Vitesse moteur =vit
Ratio entrai
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2.4.4. Location and Piping
An improperly designed piping system or unit installation
WILL significantly reduce package performance and life.
Blackmer recommends the following piping system
layout and unit installation.
1. Piping MUST be properly supported to prevent any
piping loads from being placed on the pump.
2. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection.
3. Minimize the number of intake line fittings (valves,
elbows, etc.) and piping turns or bends.
4. Discharge piping MUST be free of all leaks.
2.5 Electrical wiring
The TYPHON 1000 INTERCOOLER package needs
electrical power to propel the fan pulsing the cooling air
through the radiator.
To prevent unwanted operations of the fan, a temperatu-
re switch set to 78°C on the climb and 68°C on the fall
controls the supply of power to the fan. This system will
prevent power consumption on the package when the
system is not operating.
The systems are equipped with a button, which controls
the fan speed. When the button is on the cool position,
the fan works at max speed, and the discharge tempe-
rature of the compressor is at its minimum. When the
button is on the hot position, the fan is only supplied with
12 V, and the discharge temperature of the compressor
will remain above 150°C. You may want to use those
temperatures to dry the trailer after a cleaning cycle.
DO NOT FORGET TO CONNNECT THE 12 V
CONNEXION, as this will lead the package to work
without cooling and will create temperature inside the
package the fan is not abble to handle.
This thermal switch needs the package to stabilize in
temperature before operating. This may take several
minutes, depending on the ambiant temperature. Typical
start up time for ambiant temperature of 20°C is 150 s at
2 bar package discharge pressure.
2.5.1 Electrical wiring diagram
2.5.2 Connection procedure
The supply line used to power the intercooler package
must be protected by a 16 Amps fuse on both the 12 V
and 24 V supply lines to prevent property damage and
body injuries.
The 3 wires to connect the main power supply to the bat-
tery are stripped 10 cm at the end of an 8 m long cable.
Color code for the wires :
• Blue . . . . . . . . . . . . . . . . .24 V connection
• Brown . . . . . . . . . . . . . . . .12 V connection
• Yellow / green . . . . . . . . . .Grounding connection
The electric cable connecting the Typhon intercooler to
the power supply should be properly supported to pre-
vent wear of the insulation coating.
The electrical wiring should be made in order to avoid
shorts to ground and microcuts.
DO NOT FORGET TO CONNNECT THE 12 V
CONNEXION, as this will lead the package to work
without cooling and will create temperature inside the
package the fan is not abble to handle.
2.6 Instrumentation connections
On gauges are available on the Intercooler and Cover
packages to check the clogging of the inlet filter,
This gauge has a resettable red clogging alarm. Any
operation with the clogging alarm on will lead to prema-
ture failure of the compressor and potential bodily injury
or property damage.
2.7 Chair modification
If the top of the chair is too high for a given application,
it is allowed to cut the extra high, provided that the chair
is closed on top by a steel plate equivalent to the one
delivered with the package, welded according to
ISO 5817 category C.
THE POWER SOURCE SHOULD BE SWIT-
CHED OFF PRIOR TO ANY ELECTRIC
WORK ON THE INSTALLATION TO PRE-
VENT ELECTROCUTIONS, PROPERTIES
DAMAGES AND INJURIES.
WARNING
Hazardous voltage.
Can shock, burn or
cause death.
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3.1 Lubricant recommendations
The oil grade will be selected according to the ambient
temperature under which the compressor will be operated.
Between . . . . . . -10°C & 30°C SAE 15 W 40
Below . . . . . . . . -10°C . . . . . .SAE 10 W 40
Above . . . . . . . 30°C . . . . . . .SAE 15 W 50
An oil change must be performed after 10 h of working.
Denial of this item will void the warranty.
With the above recommanded oil, oil change is reques-
ted every 300 working hours or 6 month.
Blackmer recommends the use of BSC oil for the opera-
tion of its screw compressors. Using BSC allow an
increase of the time between oil change to 1 year or 500
working hours.
Blackmer offers an extra year of warranty if only BSC oil
is used inside its compressors.
3.2 Before start-up - Filling of Lubricant
Our package are delivered without oil. The use of a com-
pressor with an oil level that is not located between the
two limits indicated by the gauge can lead to important
property damage and serious injuries.
The filling of the oil tank must be made so that the level
is comprised between the minimum and maximum mark
of the gage. For information, the tank size is approxima-
tely 5 liters for TYPHON. Please note that the oil level is
checked after fully tigh-tening the gauge on the filling
tube.
3.3 Start-up procedure
The compressor must be started with the discharge valves
open.
When it is started for the first time, check the compres-
sor rotation direction (clockwise direction for an observer
facing the compressor shaft). Also check rotation speed
(refer to § 1.2. and 1.3).
The compressor shall be started without any counter-
pressure at discharge.
At commissioning, check that the combinations of rota-
tion speed and discharge pressure of the compressors
are in conformity with those indicated in §1.2.
During operation, the temperature of the surface of a
compressor and nearby parts can be in the region of
200°C. The compressor and the parts located nearby are
thus susceptible of provoking serious burns and property
damage. Be careful to not approach elements that are
sensitive to heat and affix plates informing users that the
compressor is hot, in order to prevent any risks of burns.
A transparent self-adhesive label sticker on which
instructions of use are indicated is provided with the
compressor. It should be stamped on the windshield and
filled with the proper information for the driver to know
how to operate properly the package.
3.4 COMPRESSOR START UP PROCEDURE -
Vehicle Mounted
STEP 1
BEFORE starting compressor, open all air valves neces-
sary to vent the tank and compressor to atmosphere.
Verify there is no possibility of operating at pressure
before compressor reaches correct speed.
STEP 2
Start the engine and run will standard speed.
Depress clutch and engage the PTO.
Release the clutch SLOWLY.
Set engine speed to give the correct compressor speed.
PTO
EMBRAYEE
LENTEMENT
ON
SLOWLY
"OUVERT"
OPEN
Niveau
Maxi
Maxi
Mini
Compressor
With BSC oil
First oil
change
(h)
Oil change
Warranty
period
(year)
TYPHON 20R / 30R 10 500 h 3
MISTRAL 20R / 30R 10 500 h / 1 year 3
Compressor
Without BSC oil
First oil
change
(h)
Oil change
Warranty
period
(year)
TYPHON 20R / 30R 10 300 h / 6 months 2
MISTRAL 20R / 30R 10 300 h / 6 months 2
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STEP 3
Close all valves and proceed to pressurize the tank and
discharge the cargo.
3.5 SHUTTING DOWN PROCEDURE - Vehicle
Mounted
STEP 1
Depress the clutch and disengage the PTO.
STEP 2
Reduce engine speed to idle.
ALWAYS DISENGAGE THE DRIVE BEFORE SLOWING ENGINE
DOWN.
STEP 3
Release the clutch.
NOTICE :
DO NOT attempt to restart the compressor in the follow-
ing instances :
a. If there is still pressure or vacuum in the system. In
this instance, open the vent valve first, than restart the
compressor. Once the pump is up to speed, close the
vent valve slowly.
b. If the compressor input speed is too slow.
CAUTION
PTO
OFF
NOTICE :
THE COMPRESSOR MUST OPERATE AT FIXED SPEED WITHIN
THECOMPRESSOR MODEL SPEEDLIMITS. SPEED MUST
REMAINCONSTANT THROUGHOUT THE OFF LOADING OPE-
RATION.
« FERME »
CLOSE
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MMAAIINNTTEENNAANNCCEE
4.1 Maintenance schedules
After each water cleaning of the truck or compressor
Always run the compressor for 15 minutes to remove
any water that inadvertently gets into the piping.
DO NOT fog or introduce anti-corrosive liquids into the
compressor to prevent corrosion. Use of liquids in the
compressor will cause failure.
After the first 50 hours of operation
Change compressor oil.
After 300 hours and at least every year
Change compressor oil.
Weekly
1. The compressor should be run once a week for at
least 15 minutes to prevent moisture from collecting
inside. This will reduce the risk of corrosion damage to
the compressor and other equipment in the piping.
2. Inspect and clean air filter. Clean the compressor
external surfaces and cooling fins. Inspect DAILY if
operating in dirty or severe environment. Check the
condition of the inlet filter hose for splits and tears.
Replace or repair as necessary.
3. Inspect compressor, system piping and components.
Clean or repair as necessary.
4. Check power transmission line (pulley, shaft, torque
limitor...).
Per manufacturer’s recommendations
Lubricate the universal seal.
Monthly
1. Check the relief valve(s) for wear and proper settings.
Replace or adjust as necessary.
2. Check that the check valve works properly, replace as
necessary.
4.2 Compressor oil draining procedure
Compressor maintenance is limited to a periodic oil
change.
For oils recommended, see § 3.1.
Unscrew and remove the oil filter with its seal. Drip-drain
all the oil contained in the casing.
Carefully clean the oil filter with solvent. Blow out all
impurities with a compressed air blast.
After checking that no particles remain in the filter, reins-
tall it making sure that the seal is in good condition.
Fill the compressor. See § 3.2.

4.3 Air filter replacement procedure
Periodically check the air filter indicator. When it turns
red, or the gage is in the red, replace the filter cartridge.
Procedure to replace filter on TYPHON INTERCOOLER
packages :
• Unscrew the filter on TYPHON INTERCOOLER
packages :
• Open the filter box
• Remove and discard the old cartridge
• Before installing a new cartridge, clean the internal
part of the filter housing with a clean damp cloth.
WARNING :
The presence of foreign bodies in the compressor
inlet channel may cause bodily injuries or serious
property damage.
• Put the new cartridge in place as shown on above
picture
• Close the filter box
• The cartridge used for those compressors is wash-
able, and may be reused, provided it is not torn.
• To open and close the two filter box, move the two
closing screw by 90°.
The presence of foreign bodies in the compressor
inlet channel is susceptible of leading to serious
property damage or serious injuries.
4.4 Belt & Pulley drive inspection procedure
Periodically check that belt tension is sufficient. Re-ten-
sion belts as required, as shown bellow.
Belt Drive installation :
1) Pulleys
I Check the grooves for any chips, bruising or scoring.
II Clean-up the shaft if necessary, and smear some
copper slip on it.
III Assemble each pulley and tapered bush onto the
shafts - ensuring the correct pulley size goes onto
the correct shaft. Push them as far onto the shaft
as the guards will allow, then tighten the grub
screws lightly.
Belts :
Check for swelling or softening caused by contamination
by oil or cutting fluids.
2) Fitting Belts
I Set the motor and compressor to the correct cen-
tre distance, as shown in § 1.4.
II Before fitting belts, move the motor towards the
chair by "30" mm.
III Fit belts onto pulleys.
Move motor away from compressor to set the proper
tension on the belts.
3) Alignment
Using a good quality straight edge, ensure that both pul-
leys are correctly orientated to each other. Both shafts
and pulleys should be parallel to each other as well as in
good alignment.
Do not prise belts
onto the pulleys !
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4) Setting The Belt Tension
Step 1
1) Lock the motor in position.
2) Measure the actual centre distance B
3) Calculate M (mm)
Step 2
1) Set the belt tensioner to "M" on the "mm" scale.
2) Using the tensioner, measure the force, "F" to
deflect belt "M" (mm).
Step 3
Recommended values for F.
If necessary, slacken off the motor and adjust to the
correct tension indicated in the table.
If new belts are to be installed, adjust the tension to
the maximum allowed, this will allow for initial belt
stretch.
To increase the tension, turn the screw clockwise. To
release the tension, turn the screw counterclockwise.
Re-check the belt tension after 30 mins running. If
the compressor is supplied on a base-frame with
belts and pulleys ready-fitted, the alignment and
tension still needs to be re-checked once the
base frame has been installed and again after 30
mins. running time.
5) Maintenance
Consult the belt and pulley suppliers for any other
maintenance information.
4.5 How to change pulley shaft position
For a specific use, one intallor may want to use a different
position for the pulley axis to optimize drive line position.
In this case, please check :
• That you maintain the proper clearance with any
truck or equipement stationary or mobile part.
• That you have available the proper length of belt.
Use XPB belts only.
To change the pulley shaft position :
• Lock the engine in place
• Remove the tension on the belts
• Move the pulley 30 mm closer to the chair
• Remove the belt
• Disengage the screw from the tension axis
• Remove pulley by unlocking the veco block
• Remove the securing rings at both ends of the pulley
shaft
• Remove the shaft from the Aluminum bushing
• Engage the shaft on the first hole of the wanted position
• Align the Aluminum bushing with the proper hole
• Fully engage the shaft on the holes and Aluminum
bushing
• Place the securing rings back into position
Package configuration F (N)
All Typhon packages 65 ±10%
All Typhon packages
M (mm)
6,5
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• Place the pulley back in position following guidelines
explained in § 4.3.
• Engage the tension setting screw on the tension axis
hole
• Engage belts and set tension as describe in § 4.3
4.6 Safety valve - Check valve inspection
Check adjustment of the safety valve :
Remove the check valve and make sure that the valve
operates freely.
The procedure to check the setting value is the following :
• If the package is not equipped with a discharge pres-
sure gauge, install a pressure sensor on point shown
on the sketch below.
• To prevent any damage to the tank during the relief
valve setting pressure check, disconnect the pack-
age outlet from the tank inlet.
• Connect the package outlet to a line including a clo-
sing valve.
• Open fully the closing valve.
• Start the truck engine and engage the compressor.
• Gradually close the valve to the point where the relief
valve opens, do not allow overpressure to the com-
pressor.
• Read the pressure value. This value is the crack
pressure.
• Fully close the valve, do not allow overpressure to
the compressor.
• Read the pressure value. This value is the full flow
pressure.
• Open the closing valve fully, disengage compressor
and stop engine.
The full flow setting pressure should be compliant with the
values given in § 1.3.3 maximum discharge pressure.
4.7 Mounting procedure for the transmission
pulley axis
Remove all scratch and burr from the aluminum bushing
Remove all scratch and burr from the aluminum bushing
from the keyway.
Press the roller bearing onto the shaft, on the pulley side.
Fill in the roller bearing with grease.
Remove the side protection of the ball bearing, and fill in
it with grease.
Pressure port
for relief valve
setting check
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Assemble the ball bearing on the aluminum bushing, on
the side opposite to the pulley.
Install the securing ring maintaining the ball bearing.
Put a 25 cl in the bushing. The quantity is important, as
it provides the life sealed properties of the assembled
bushing.
Press the shaft into the bushing, paying attention to the
position of the roller bearing external plate position when
it enters the bushing.
Install the securing ring maintaining the roller bearing.
Fill in in excess the lipseals with grease. Grease bet-
ween the two lips of the lipseals. Use a soft hammer to
install them on each side of the bushing.
Screw the greasing filling port onto the bushing.
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4.8 Fan and thermocontact connectors
replacement
If needed, to give ease, remove the cooler cover.
For the thermocontact connector replacement :
• Unplug the connector from the thermocontact.
• Remove the old connector and contacts.
• Connect the 2 new contacts with appropriated tool.
• Insert cable into the black protection before thermocon-
tact connector.
• Heat the black protection, starting from connector side.
• Spray some oily liquid on both connections sides
(thermocontact and thermocontact connector).
For the fan connector replacement :
• Unplug the connector from the fan side.
• Remove the old connector and contacts.
• Connect the 2 new contacts with appropriated tool.
• Insert contacts the white connector.
• Insert cable into the black protection.
• Spray some oily liquid on both connections sides (Fan
and relay side).
• Heat the black protection, starting from middle.
Thermocontact
connector
Thermocontact
Fan connector
Fan
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5.1 Chair and transmission (exploded view without belts and pulley)
Exploded view
reference Order number Description Quantity
1Included in order number 312547 Key 1
2Included in order number 312547 Key 1
3219588 (rear)
219589 (front) Steel Chair 1
4219570 Aluminum bushing 1
5219592 Seal 2
6219572 Support shaft 1
7219574 Tension shaft 1
8219575 Rotation shaft 1
9219745 Screw 1
10 215422 Bolt 1
11 219586 (rear)
219585 (front) Pulley shaft 1
12 207698 Securing ring 2
13 219591 Joint roller bearing 1
14 200559 Ball bearing 1
15 219594 Securing ring 8
16 204660 Grease filling port 1
17 215580 Screw 4
18 209591 Spacer 4
19 Included in order number 312547
20 Included in order number 312547
21 Included in order number 312547
22 Included in order number 312547
23 220821 Sliding bushing 4
312547 Coupling kit 1
* The chair and transmission are identical for TYPHON and
MISTRAL package, independently of the pulley ratio.
NOTE - To order spare parts specify :
•The PART NUMBER and SERIAL NUMBER of the package (stamped on an identification plate)
•The reference to the current INSTRUCTIONS N° 1401-F00 with its revision number
•REFERENCE and QUANTITY wanted for each part.

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Repère Référence Désignation
Quantité
Remarques
2Inclus dans la référence 312523 Clogging indicator connection tube
3312536 (avant) Boîte à filtre 1
4312529 (avant) Couvercle 1
5312523 Kit instrumentation 1
6313050 Ensemble sortie 1
7312532 (avant) Silencieux 1Inclut combiné
clapet/soupape
8312538 Echangeur 1
9312312 (avant) Chaise 1
10 217037 Rondelle 4
11 205058 Ecrou borgne 4
12 219824 (avant) Support échangeur 1
13 312542 Kit jauge à huile 1
14 204903 Plaque 1
5.2 TYPHON INTERCOOLER package
Exploded view of INTERCOOLER package.
PART
LIST FOR INTERCOOLER PACKAGE, INCLUDED IN THE ABOVE EXPLODED VIEW
NOTE - To order spare parts specify :
•The PART NUMBER and SERIAL NUMBER of the package (stamped on an identification plate)
•The reference to the current INSTRUCTIONS N° 1401-F00 with its revision number
•REFERENCE and QUANTITY wanted for each part.

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Référence Désignation Quantité Remarques
312112 Kit filtre à huile 1 Pièce détachée compresseur
216404 Cartouche filtrante 2
312569 Kit fixation : filtre 1
312568 Kit fixation : silencieux 1
312570 Kit fixation : échangeur 1
219842 Thermocontact 1
312567 Matériel électrique interne 1
312534 Clapet anti-retour 2.3 bar 1
312637 Clapet anti-retour 2.0 bar 1
312535 Soupape 1
312523 Ensemble instrumentation 1
Référence Rapport 1:1 Rapport 1:1,12 Rapport 1:1,25 Rapport 1:1,4
Kit poulie & courroie 312287 312316 312553 312317
PART
LIST FOR INTERCOOLER PACKAGE, NOT INCLUDED IN THE PREVIOUS EXPLODED VIEW
NOTE - To order spare parts specify :
•The PART NUMBER and SERIAL NUMBER of the package (stamped on an identification plate)
•The reference to the current INSTRUCTIONS N° 1401-F00 with its revision number
•REFERENCE and QUANTITY wanted for each part.

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5.3 Warranty claims
The following part are considered as wear part :
• Belt
• Pulley
• Chair bearings
• Inlet filter cartridge
• Compressor oil
No failure connected with wear part damage will be
accepted under warranty conditions.
The following situations will void warranty for all compo-
nents of the package :
• Tampering with the setting of the relief valve.
• Presence of foreign material inside the compressor
body.
• Traces of damage representative of abnormal use
of the package.
• Use of non genuine parts.
• Construction of the package not validated by our
design office.
A return sheet shall be filled by the installer or distributor
and send to Blackmer in order to claim for a warranty.
The equipment must be systematically stored in an area shelte-
red from bad weather.
The equipment must bear its original protective components until
it is installed in its final application.
If installation is interrupted, put back in place the original protec-
tive components or equivalent components.
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