Gardner Denver Compair Reavell 5236.2.IA Service manual

Gardner Denver Ltd. Reavell House
53-56 White House Road IPSWICH ENGLAND IP1 5PB
Telephone: [phone] Fax: [phone] Parts Fax: [phone] Service [phone]
www.reavell.com e-mail:- reav[email protected]
Gardner Denver Ltd
OPERATOR HANDBOOK
For a
5236.2.IA
Water-cooled Air Compressor
In any correspondence please quote;
REAVELL JOB NUMBER:-
CUSTOMER:-
CUSTOMER ORDER NUMBER:-
MACHINE NUMBER:-
PUBLICATION NUMBER:- 98407.1039 iss8
ISSUE DATE:- MARCH 2012

TABLE OF CONTENTS
Page 1
OPERATOR HANDBOOK FOR A
2365.2.IA COMPRESSOR
TABLE OF CONTENTS
1SAFETY .......................................................................................................................................................5
1.1OWNERSHIP DATA .............................................................................................................................6
1.2FOREWORD.........................................................................................................................................7
1.3CAUTION..............................................................................................................................................8
1.4SAFETY PROCEDURES......................................................................................................................8
1.4.1GENERAL......................................................................................................................................9
1.4.2WARNINGS, CAUTIONS & NOTES..............................................................................................9
1.4.3GENERAL SAFETY PRECAUTIONS..........................................................................................10
1.4.4INSTALLATION PRECAUTIONS................................................................................................10
1.4.5OPERATIONAL PRECAUTIONS................................................................................................10
1.4.6MAINTENANCE & REPAIR PRECAUTIONS..............................................................................11
1.4.7PRECAUTIONS IN THE EVENT OF FIRE..................................................................................12
2AMENDMENTS..........................................................................................................................................13
3LOGSHEET................................................................................................................................................15
4GENERAL DESCRIPTION AND OPERATION.........................................................................................17
4.1CONFIGURATION..............................................................................................................................17
4.2LUBRICATION....................................................................................................................................17
4.3SYNTHETIC OILS...............................................................................................................................18
4.4LUBRICATION SCHEMATIC FLOW DIAGRAM................................................................................19
4.5COOLING............................................................................................................................................20
4.6DRIVE .................................................................................................................................................20
4.7RUNNING GEAR................................................................................................................................20
4.8VALVES ..............................................................................................................................................20
4.9INSTRUMENTATION..........................................................................................................................20
4.10CONDENSATE DRAINAGE SYSTEM............................................................................................21
4.11SUCTION UNLOADING..................................................................................................................22
4.12AUTOMATIC STOP/START CONTROL.........................................................................................22
5LEADING PARTICULARS ........................................................................................................................23
5.1UNIT DESIGNATION..........................................................................................................................23
5.2TECHNICAL DATA – GENERAL........................................................................................................23
5.3TEMPERATURES...............................................................................................................................23
5.4SPEEDS..............................................................................................................................................23
5.5PRESSURES......................................................................................................................................23
5.6INTERNAL DIMENSIONS...................................................................................................................23
5.7LUBRICATION....................................................................................................................................23
5.8COOLING............................................................................................................................................23
5.9CONNECTIONS..................................................................................................................................24
5.10RUNNING CLEARANCES ..............................................................................................................24
5.11TORQUE WRENCH SETTINGS.....................................................................................................25
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Page 2
5.11.1CLASS A – CRITICAL .................................................................................................................25
5.11.2CLASS B – NON-CRITICAL........................................................................................................25
6INSTALLATION.........................................................................................................................................27
6.1HANDLING OF UNIT..........................................................................................................................27
6.2LOCATION..........................................................................................................................................27
6.3MOUNTING.........................................................................................................................................28
6.4CONNECTIONS, PIPEWORK AND FITTINGS..................................................................................28
6.5DRIVE RECOMMENDATIONS...........................................................................................................28
6.6COOLING............................................................................................................................................29
6.7ELECTRICAL CONNECTIONS..........................................................................................................30
6.8RECOMMENDED ANCILLARIES SUMMARY...................................................................................30
7COMMISSIONING OR RECOMMISSIONING........................................................................................... 31
7.1BEFORE STARTING..........................................................................................................................31
7.2START-UP PROCEDURE..................................................................................................................32
8OPERATION AND ROUTINE MAINTENANCE........................................................................................33
8.1OPERATION AND GENERAL MAINTENANCE.................................................................................33
8.2STARTING UP....................................................................................................................................33
8.3RUNNING ON LOAD..........................................................................................................................33
8.4STOPPING..........................................................................................................................................34
8.5STANDING IDLE.................................................................................................................................34
9MAINTENANCE SCHEDULE.................................................................................................................... 35
9.1GENERAL...........................................................................................................................................35
9.2DAILY..................................................................................................................................................35
9.3WEEKLY .............................................................................................................................................35
9.4AFTER THE FIRST 100 HOURS RUNNING TIME ON MINERAL OIL..............................................35
9.5CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT................................................36
9.6SERVICE PLAN..................................................................................................................................37
10DISMANTLING AND REASSEMBLY OF VALVES ..............................................................................41
10.1GENERAL........................................................................................................................................41
10.2CLEANING AND INSPECTION – ALL STAGES............................................................................41
10.3FIRST STAGE VALVES – WITH SUCTION UNLOADERS............................................................42
10.3.1REMOVAL ...................................................................................................................................42
10.3.2DISMANTLING ............................................................................................................................42
10.3.3REASSEMBLY.............................................................................................................................42
10.3.4REFITTING..................................................................................................................................42
10.4FIRST STAGE VALVES – WITHOUT SUCTION UNLOADERS....................................................44
10.4.1REMOVAL ...................................................................................................................................44
10.4.2DISMANTLING ............................................................................................................................44
10.4.3REASSEMBLY.............................................................................................................................44
10.4.4REFITTING..................................................................................................................................44
10.5SECOND STAGE VALVES.............................................................................................................45
10.5.1REMOVAL ...................................................................................................................................45
10.5.2DISMANTLING ............................................................................................................................45
10.5.3REASSEMBLY.............................................................................................................................45
10.5.4REFITTING..................................................................................................................................45
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Page 3
11FAULT GUIDE........................................................................................................................................47
11.1LOW FIRST STAGE PRESSURE...................................................................................................47
11.21ST STAGE SAFETY VALVE BLOWING AND/OR HIGH FIRST STAGE PRESSURE................47
11.32ND STAGE SAFETY VALVE BLOWING ......................................................................................47
11.4COMPRESSOR RUNS LONGER TO ACHIEVE SYSTEM PRESSURE.......................................48
11.5OVERHEATING ..............................................................................................................................48
11.6OVERHEATING – R ADIATOR SETS............................................................................................48
11.7LOW OIL PRESSURE.....................................................................................................................48
11.8CUTS OUT ON START UP.............................................................................................................48
11.9UNUSUAL NOISE (ON LOAD) .......................................................................................................48
11.10UNUSUAL NOISE (UNLOADED)....................................................................................................48
11.11HIGH OIL CONSUMPTION.............................................................................................................48
11.12PREMATURE WEAR......................................................................................................................48
12ILLUSTRATED PARTS LIST.................................................................................................................49
12.1CRANKCASE..................................................................................................................................51
12.2RUNNING GEAR.............................................................................................................................53
12.31ST STAGE CYLINDERS...............................................................................................................55
12.42ND STAGE CYLINDERS...............................................................................................................57
12.51ST STAGE COOLER.....................................................................................................................59
12.62ND STAGE COOLER....................................................................................................................61
12.7LUBRICATION ................................................................................................................................63
12.8UNLOADERS..................................................................................................................................65
12.9EXTERNAL COMPONENTS...........................................................................................................67
12.10TYPICAL DRIVE ARRANGEMENTS..............................................................................................69
12.111ST STAGE CONCENTRIC VALVE...............................................................................................71
12.122ND STAGE CONCENTRIC VALVE .............................................................................................73
12.13DIAPHRAGM DRAIN VALVE..........................................................................................................75
12.14CONTROL SYSTEM.......................................................................................................................77
13ANCILLARY EQUIPMENT.....................................................................................................................79
13.1VEE BELT ADJUSTMENT & TENSIONING – APP011..................................................................79
13.2DIRECT DRIVE – APP011B............................................................................................................82
13.3RADIATOR FILLING WATER COOLING SYSTEM – APP077 ......................................................83
13.4WATER PUMP ASSEMBLY & DRIVE – APP073...........................................................................84
13.5PRESSURE MAINTAINING VALVE – APP057..............................................................................85
13.6SOLENOID VALVES – APP138......................................................................................................86
13.7SAFETY VALVE – APP167.............................................................................................................87
13.8TEMPERATURE CONTROLLER – APP090C................................................................................89
13.9PRESSURE GAUGE – APP070 .....................................................................................................91
13.10PRESSURE SWITCH – APP086 & 088..........................................................................................92
13.11ANTI-VIBRATION MOUNTS – APP003..........................................................................................95
13.12DEMISTER – APP043.....................................................................................................................96
13.13WATER INLET CONTROL VALVE – APP071 & 704.....................................................................98
14STANDARD WIRING TERMINAL NUMBERS....................................................................................103
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98407.1039 iss8

SAFETY
Page 5
1 SAFETY
5000 SERIES COMPRESSORS
WARNING
The use of replacement parts or lubricating oils not supplied,
recommended or approved by CompAir UK Ltd Ipswich, or the failure to
maintain this equipment in accordance with the maintenance instructions,
may invalidate the WARRANTY, cause equipment failure, create unsafe or
hazardous conditions or result in damage to the equipment.
CompAir UK Ltd Ipswich cannot accept responsibility for damage, injury
or failure caused by these situations.
USE ONLY
CompAir UK Ltd Ipswich
GENUINE PARTS
AND
AUTHORISED SERVICE AGENTS
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SAFETY
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1.1 OWNERSHIP DATA
TECHNICAL DATA
It is recommended that details taken from the compressor and motor nameplates are recorded below.
CompAir UK Ltd Ipswich CONTACT DETAILS
Contact Name:
Sales Telephone: [phone]
Address:
CompAir UK Ltd
Reavell House
53-56 White House Road
Ipswich IP1 5PB
ENGLAND
Notes:
Telephone: [phone]
Fax: [phone]
Contact Names:
Parts Telephone: [phone]
Parts Fax: [phone]
Contact Names: Service: [phone]
For any comments or queries about the contents of this manual, please write to CompAir UK Ltd. at
the above address, marked for the attention of Mr. Owen Dale, Technical Author.
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SAFETY
Page 7
1.2 FOREWORD
SPECIAL ATTENTION
The STANDARD BUILD of all CompAir UK Ltd (Ipswich Operations) products are not intended for use in
either Explosive or Potentially Explosive Atmospheres as defined in Directive 95/9/EC.
An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours,
hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture
and may cause a hazard.
A Potential Explosive atmosphere is an atmosphere, which could become explosive due to local
conditions.
CompAir UK Ltd Ipswich H5000 Series compressors are designed and manufactured to give optimum
performance, with long life and reliability.
This Manual will help you to obtain the best performance from your compressor. It provides the information
required to install, commission and operate the compressor and carry out regular maintenance schedules,
which will ensure the maximum satisfactory service life.
Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing.
Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network
of CompAir companies and CompAir UK Ltd. distributors, backed by the Service tel[phone]
and Parts department tel [phone]) Fax [phone] and Sales (+44 (0) 1473
242000 Fax [phone] at CompAir UK Ltd., Ipswich (UK)
The information in this Manual was correct at the time of printing but modifications to parts and procedures
may be made without notice which could affect the servicing requirements of the compressor. Before any
servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or
CompAir UK Ltd Distributor for revised or up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No.
and any CONTRACT Ref.
It is important this Manual is retained with the compressor for reference and should remain with the
compressor if it is sold or transferred to another user. Ensure that the new user is made fully aware of the
need to study the Safety Section and any Warnings for safe operation given throughout the text.
Protect the environment by using only approved method of disposal of condensates lubricating oil etc.
Please note: a. Throughout the Manual all pressures quoted are gauge pressures.
b. Whilst recyclable materials are used as far as possible, please ensure when
disposing of condensate, spent oil, used filter elements and any discarded parts or
waste material of any kind make sure that there is no pollution to any natural water-
course, drain system and that no burning waste takes place which could cause
pollution of the atmosphere.
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SAFETY
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1.3 CAUTION
Use only CompAir UK Ltd Ipswich Genuine Parts when carrying out routine maintenance or repair. The
use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd Ipswich can
lead to expensive failures, which will not be covered by warranty.
Substitution of parts not manufactured or approved by CompAir UK Ltd Ipswich can create a potential
personnel hazard.
This is a High Pressure Compressor, for safe and reliable operation use only
genuine CompAir UK Ltd Ipswich Parts
To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance
with the information given in this manual - refer to the “Maintenance Section”.
Conditions of CompAir UK Ltd Ipswich warranty are stated in our Conditions of Sale. Details of warranty for
a particular unit may be obtained from the local CompAir Company or authorised Distributor.
1.4 SAFETY PROCEDURES
•WARRANTY
The Conditions of the CompAir UK Ltd Ipswich Warranty are set out in the Standard Conditions of
Sale.
•MAINTENANCE
To ensure continued trouble free operation of the compressor it is important that periodic maintenance
and servicing are carried out in accordance with the information given in the "Maintenance" section of
this Manual. If any replacement or repair is needed use genuine CompAir UK Ltd Ipswich parts.
∗WARNING
The use of replacement parts or lubricating oils not supplied or approved by
CompAir UK Ltd Ipswich may lead to failures in service which would not be
covered by warranty.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance
instructions may make it unsafe. The use of replacement parts not supplied by CompAir UK Ltd
Ipswich may create hazardous conditions over which CompAir UK Ltd Ipswich has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury
or result in damage to the equipment. CompAir UK Ltd Ipswich can bear no responsibility for
equipment for which unapproved replacement parts are included.
SPECIAL NOTE:
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH
ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.
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1.4.1 GENERAL
CompAir UK Ltd Ipswich compressor safety relates to the document BS EN1012-1 Compressors and
Vacuum Pumps - Safety requirements and the UK Pressure Systems Health & Safety Regulations S.I. No.
128.
•Most accidents which occur during the operation and maintenance of machinery result of failure to
observe basic safety rules or precautions. Recognising a situation that is potentially hazardous can often
prevent an accident.
•When handling, operating or carrying out maintenance on the unit, personnel must observe safe
engineering practices and all relevant local regulations. The attention of users is drawn to the Health and
Safety at Work Act 1974, and the regulations of the Institution of Electrical Engineers.
•CompAir UK Ltd cannot anticipate every possible circumstance, which might represent a potential
hazard. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating
procedure, an item of equipment or a method of working which is not specifically recommended by
CompAir UK Ltd then they must ensure that the unit will not be damaged or made unsafe and that there
is no risk to persons or property.
•Failure to observe these precautions given under "Safety Precautions" may be considered dangerous
practice or misuse of the compressor
•Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the unit before
operating or carrying out maintenance or servicing.
1.4.2 WARNINGS, CAUTIONS & NOTES
The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in
Machinery Directive 89/392/EEC, Amended 91/286/EEC.
∗Warnings call for attention to operating procedures involving specific hazards which could cause injury
or death and are identified by the following
RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST
RISK OF ELECTRIC SHOCK RISK OF HOT SURFACE CONSULT MANUAL
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SAFETY
Page 10
1.4.3 GENERAL SAFETY PRECAUTIONS
•When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good
ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and
gloves.
•Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any risk
of falling objects.
•If using compressed air for cleaning purposes, ensure safety regulations are complied with and
appropriate clothing worn.
•Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose
dirt from clothing.
•Before releasing compressed air through a hose make sure the free end is held securely so that it cannot
whip and cause injury.
•Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in
good condition and are of the correct capacity. They must be tested and approved according to local
safety regulations.
•Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or
hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to
avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended.
•When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration
and speed within safe limits.
1.4.4 INSTALLATION PRECAUTIONS
•Competent personnel under a qualified supervisor must only carry out installation work.
•A fused isolator switch must be fitted between the main power supply and the compressor.
•Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being
sucked into compressor intake.
•Ensure that the discharge pipe from the compressor to the user pipework, receiver or storage is free to
expand and that no flammable material is within the vicinity. If any such material is close-by take steps to
preclude ignition.
•A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated. Non
return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must be
installed between any compressor unit and the isolating valve.
•A pressure-reliving device must be fitted to every pressure vessel, or equipment containing air or gas
above atmospheric pressure. Never remove or tamper with safety devices, guards or insulation fitted. In
order to limit the risk of Legionnaires Disease, CompAir UK LTD advise caution with the use of cooling
towers for water cooling the compressor. Closed circuit or direct mains cooling is preferred.
•Pipework or other parts with a surface temperature above 70°C, which may be accidentally touched in
normal operation, must be guarded or insulated. Other high temperature pipework should be clearly
marked and all pipework should be clearly marked.
1.4.5 OPERATIONAL PRECAUTIONS
•Competent personnel under a qualified supervisor must only operate the compressor.
•Do not operate compressor with any removable inspection cover removed e.g. crankcase doors, valve
covers etc.
•Never remove or tamper with safety devices, guards or insulation materials.
•The compressor must only be operated at the supply voltage and frequency for which it is designed.
Always isolate power before maintenance or servicing.
•When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is
need when essential work is carried out on the electrical system. ALWAYS CONSULT A QUALIFIED
ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK.
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SAFETY
Page 11
•Do not open starter compartment to touch electrical components while voltage is applied unless it is
necessary for measurement, test or adjustment. Such work should always be carried out by a qualified.
Electrician with appropriates tools and protection against an electrical hazard.
•If the unit is equipped with a Remote Control device, attach warning notices stating "THIS UNIT CAN BE
STARTED REMOTELY" in prominent locations, one on the outside of the unit, the other inside the
control compartment.
•As a further safeguard, take adequate precautions that no one is working or checking the unit before
attempting to switch on remotely controlled equipment. Attach a "CHECK THAT ALL PERSONNEL ARE
CLEAR OF UNIT BEFORE STARTING" or similar notice.
•Compressed air and gas piping, together with cooling water piping and other parts, with surface
temperature greater than 70°C and may be accidentally touched, should be guarded or insulated.
•If there is any indication that the compressor is overheating it must be shutdown. (A high air or gas
temperature switch is fitted as standard to guard against operating with excessive temperature). Beware
of burns from hot oil and water when working on a unit recently shutdown.
•Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have
been removed for essential maintenance. Secure guards following any servicing or repair.
•Local noise regulations must be observed. Ear defenders are suggested by Noise at Work Regulations
1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with
communication.
1.4.6 MAINTENANCE & REPAIR PRECAUTIONS
•Competent persons under qualified supervisor must carry out maintenance repair and modifications.
•The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models). Oil free
models will have desiccant bags in valve covers and distance pieces.
•Handling components such as seals, gaskets and diaphragms should not present a personnel hazard.
Preservation oils again should not present a personnel hazard if handled under normal handling
practices.
•Whilst compressors are asbestos free, treat all damaged gaskets as asbestos - when the Asbestos at
work regulations apply.
•Viton 'O' seals under normal operating conditions are safe.
•However, should there be a fire within the compressor or these seals are likely to exceed a temperature
of 300°C the material will decompose.
•Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed
causes severe burns.
•If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC
gloves.
•Wash the area with limewater and avoid breathing any fumes. If contamination of the skin occurs washes
with limewater and seeks medical advice.
Pre-Maintenance Operation
•Isolate the compressor from the main electrical supply. Lock the isolator in the OFF position and remove
fuses.
•Attach a label " WORK IN PROGRESS - DO NOT APPLY VOLTAGE".
•Close the isolating valve between the compression unit and user's pipework. Close the isolating valve in
the cooling water inlet pipe. Attach a label "WORK IN PROGRESS - DO NOT OPEN".
•Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage.
Check that all pressure gauges register zero.
•Ensure that the cooling water system has been drained.
•Check that the drain valve on the delivery manifold is clear and gas pressure has been released.
•Check that all interstage drains are open to ensure any gas trapped between stages has been released.
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SAFETY
Page 12
98407.1039 iss8
•Stand clear of all valve covers when removing the securing screws.
•When removing valve covers for valve replacement, ensure a minimum of two threads is left engaged on
the valve cover securing screws. Lever the valve cover until the 'O' seal is disengaged from the port in
the cylinder head. Remove the securing screws and take out valve cover.
•Use only lubricating oils and greases approved by CompAir UK LTD to avoid potential hazards
especially the risk of explosion or fire and the possibility of decomposition or generation of
hazardous gases.
•Always clean oil spills from the surrounding floor before and after maintenance work.
•Make sure all instructions concerning operation and maintenance are strictly followed and that the
complete unit, with all accessories and safety devices, is kept in good order.
•The accuracy of pressure gauges and temperature switches should be regularly checked at least 13
month intervals and thoroughly examined at least every 48 months. They must be renewed or service
exchanged when acceptable tolerances are exceeded.
•Protection devices should be tested at each regular service interval and replaced or service exchanged if
not functioning correctly. The maximum pressure for safety valves under fault conditions is 1.10 times the
set pressure, the set pressure being a minimum of 1.05 times the maximum operating pressure to ensure
seat tightness.
•Never use a light source with an open flame for inspection.
•Before dismantling any part of the compressor be sure that all heavy movable parts are secure.
•After completion of any maintenance or repair ensure that no tools, loose items or rags are left on or
inside the compressor.
•Do not use any flammable liquid to clean valves, filter elements, cooler passages, pipe bores or any
component carrying a flow of air or gas during normal operation. If chlorinated hydrocarbon substances
are used for cleaning, safety precautions must be taken against toxic vapours, which may be released.
DO NOT USE CARBON TETRACHLORIDE.
•Precautions must be taken against using acids, alkalis and chemical detergents for cleaning machined
parts. These materials cause irritation and are corrosive to the skin, eyes, nose and throat. Avoid
splashes and wear suitable protective clothing and safety glasses. Do not breathe mists. Ensure water
and soap is readily available.
•When disposing of condensate, old oil, used filter elements and other parts and waste material of any
kind make sure that there is no pollution to any drain or natural water course and that no burning of
waste takes place which could cause pollution of the atmosphere.
•Keep the compressor clean at all times.
•Protect components and exposed openings by covering with a clean cloth or tape during repair or
maintenance work.
•Protect the motor, intake, electrical and regulation components against the entry of moisture e.g. steam
cleaning.
•Precautions must be taken when carrying out welding or any repair operation which generates flames or
sparks. The adjacent components must be screened with non-flammable material and if oil present, the
system must first be cleansed thoroughly by steam cleaning.
•Condensate (oil and water mixture from compression process) must be regarded as trade effluent and is
therefore not suitable for discharge into a surface water sewer, soakaway or watercourse.
PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL.
1.4.7 PRECAUTIONS IN THE EVENT OF FIRE
•Use extreme caution when handling components that have been subjected to fire or very high
temperature. Some components may contain fluoroelastomer materials, which decompose under these
conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns
resulting in permanent skin and tissue damage.

AMENDMENTS
Page 13
2 AMENDMENTS
ISSUE No. MOD NOTE No. M/C SERIAL No. DATE SECTION
1 NEW - NOV 1997 ALL
2 2 - MAY 1999 9E
3 R005122 Change to Main Bearing Bush/thrust washer AUGUST 2001 9A
4 Add Studs & Nuts to Service Plans Major Overhaul JULY 2002 10
5 Add check condition of crankcase to cylinder studs & 2nd
stage piston rings to 6000 hours service plan. NOV 2002 10
6 Replace RSP’s with new HSK Service Plan Oct 2008 9.6
7 Minimum pressure for suction unloaders added,
Alternative water valve added Feb 2009 4.11 13.13
8 Standard Wiring Terminal Numbers added March 2012 14
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
98407.1039 iss8

AMENDMENTS
Page 14
98407.1039 iss8

LOGSHEET
Page 15
3 LOGSHEET
REF NO: OIL GRADE USED: CHECK OIL LEVEL CHECK WATER IN/OUT TEMPS. CHECK COOLING FANSIGNED
REMARKS.
SEE OVER
FOR MORE
SERVICE
PLAN
NUMBER
COMPRESSOR LOG SHEET
INSTALLED AT: DATE INSTALLED:
DELY
PRESS.
BAR/PS
STAGE PRESSURES
BAR / PSI
5
4
3
PRIME MOVER
TYPE: POWER: DRIVE:
2
1
DELY
TEMP
°
C
STAGE
TEMP
°
C
COMPRESS0R
TYPE: SPEED: SERIAL NO
HRS
RUN
50/100 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500
TIME
DATE
98407.1039 iss8

LOGSHEET
Page 16
98407.1039 iss8
REMARKS
DATE
REMARKS
DATE

GENERAL DESCRIPTION AND OPERATION
Page 17
4 GENERAL DESCRIPTION AND OPERATION
Hand Unloaders.
Suction Unloader
S
y
stem
Gauge Panel
Suction Filter
Diaphragm Drain Valves
Condensate Draina
g
e
4.1 CONFIGURATION
The 5236 Mk2 is a four cylinder, single acting, two stage, 90° vee configuration, water cooled
machine. It has complete primary balance when fitted with aluminium first stage pistons, giving excellent
balance characteristics.
4.2 LUBRICATION
The forced feed system is shown on following page.
The specified lubricant must be used at all times to ensure safe and efficient operation with minimum wear
and maximum protection against moist air corrosion.
Recommendations are the result of extensive research at Ipswich Works and all responsibility for the use of
an oil other than that recommended is placed on the purchaser and his oil company.
THE NORMAL GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE
ATTRIBUTED, BY IPSWICH WORKS, TO THE USE OF A LUBRICANT NOT
RECOMMENDED.
98407.1039 iss8

GENERAL DESCRIPTION AND OPERATION
Page 18
4.3 SYNTHETIC OILS
These are oils which are arrived at by chemical synthesis from petroleum feed stocks, although in some
cases they would be from vegetable and mineral oils rather than by straight run distillation of crude.
Advantages
1. Carbon deposits are reduced compared with mineral type oils. However, the lack – or very
low level – of oxygen in the gas being compressed, means carbon deposits are much less
than in an air compressor, so this advantage of synthetic oil is less noticeable.
2. It may be possible to extend oil change periods in some cases.
3. Wear rates are reduced.
4. These oils, being produced to close tolerances, have properties and performance which are
consistent from batch to batch.
5. Oil consumption and carry-over can be reduced by up to 35%.
Disadvantages
1. There are some materials, e.g. certain rubbers, paints, plastics and metals which are not
compatible with synthetic oils (see: Compatibility of Materials Chart). Components on the
5000 series compressors are compatible with synthetic lubricants but a problem may exist
with auxiliary equipment, so consult their manufacturer to determine compatibility.
98407.1039 iss8