MAXIMATOR VP30 Setup guide

VP30/VP500
MAINTENANCE INFORMATION
MAINTENANCE
INFORMATION
VP30/VP500 Compressor
Introduction
Description of compressor parts
Maintenance
Checking the oil level
Storage of Compressor
Changing the oil
Microfilter element change
Valve Inspection
Unloader system inspection
Cooler inspection
Starting compressor after Maintenance
General maintenance notes
Troubleshooting
Low output flow or pressure
Blowing safety Valves
Leakage from HP receivers
Low oil pressure
Knocking
Rumbling
Diagrams
Fig 1 - Compressor, complete
Fig 2 – Crankcase
Fig 3 – Crankcase
Fig 4 – Piston and connecting rod
July 21 1 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 5 – 1st Stage Cylinder
Fig 6 – 2nd Stage Cylinder
Fig 7 – 3rd Stage Cylinder
Fig 8 – Fan and guard
Fig 9 – Coolers
Fig 10 – Unloader Manifold
Fig 11 – Unloaders
Fig 12 – Oil Lubrication
Fig 13 – Crankcase Breather
Fig 14 – Motor
Fig 15 - Microfilter
July 21 2 of 42

VP30/VP500
MAINTENANCE INFORMATION
Introduction
This section provides detailed information about the high pressure compressor, including:
•General information
•Description of components
•Servicing
•Parts lists
•Drawings
The VP30 (also referred to as VP500) compressor is a Three Stage reciprocating Air cooled
compressor with a maximum
working pressure of 350 Bar (5000 psi). Lubrication is by Integral crankshaft driven oil pump to
crankshaft and big end bearings and by splash/oil mist to the cylinder bores and small end
bearings.
Intercoolers are fitted at each stage of compression, with condensate separators and safety
valves. The compressor is driven by an induction motor and belt driven at 1230 RPM.
The main compressor components are identified in the photographs below.
July 21 3 of 42

VP30/VP500
MAINTENANCE INFORMATION
Description of compressor parts
Compressor Stages
The Compressor takes gas from the suction vessel at approximately 6 BarG and compresses it in
three stages up to a maximum of 350 Bar (5000 psi). Three stages of compression are used
together with the intercoolers, to reduce the temperatures at each stage of compression.
The cylinder bores reduce in size from the first to the third stage, as the pressure in-creases.
All cylinders have cooling fins to dissipate the compression heat in the blast from the fan. Each
stage of compression has a suction valve and a delivery valve located in the cylinder head to
prevent the gas from flowing back into the previous stage.
Coolers
After each stage of compression, the gas is passed through the coiled cooling coils at the front of
the compressor to remove the heat of compression. In front of the cooling coils is a large air blast
fan which blows cooling air first over the cooling coils and then over the finned cylinders and
cylinder heads. The cooling coils are copper.
Crankcase Breather
Because the compressor is a gas compressor, the crankcase is connected to the first stage inlet, to
prevent wastage of any gas which blows past the piston rings.
Motor
The motor is a three-phase induction motor. It is linked via a belt drive coupling to the end of the
compressor crankshaft.
Oil Filler
The oil filler cap is where the lubricating oil is added to the
compressor. See later this section for filling and changing
instructions.
Microfilter
After the final cooler and condensate separator is a small
Microfilter, which removes any remaining oil droplets from the
compressed gas. The drain of the filter is piped to the unloader
system so that it vents automatically whenever the compressor
stops running. It is not necessary to drain this filter periodically.
Because of the limited volume of the filter, CINPRES’s control
systems Include an ‘Autovent’ facility to stop the compressor for
a short period (normally 1 minute) after a set running time
(normally 30 minutes). This ensures that the filter bowl does not
become full and prevents oil from being passed over into the
high pressure gas line.
July 21 4 of 42

VP30/VP500
MAINTENANCE INFORMATION
Unloaders
Every time the compressor stops, gas pressure is retained in the cylinders and coolers of each
stage. This gas pressure must be vented to allow the compressor to be started ‘off-load’. The
unloader system is an automatic system for venting this pressure. The system is operated by oil
pressure from the lubrication system, which prevents the gas from each stage from venting to the
unloader vent. Therefore, when the compressor stops and the oil pressure subsides, the unloader
valves will open and the gas will be vented. The Microfilter is also connected to the unloader
system, and its contents, including any condensed oil, will be vented every time the compressor is
stopped.
Stage Pressure gauges Stage Pressure gauges
After each cooler there is a pressure gauge, which shows the gas pressure for each stage when
the compressor is running. The gauges should all reduce to zero after the unloader has vented the
gas from each stage when the compressor stops.
Safety valves Safety valves
After the cooler at each stage is also fitted a safety valve, which prevents each stage from
becoming over pressurised. If a safety valve begins to ‘blow’ (or vent gas to atmosphere), it is
normally a sign that the compressor needs to be serviced.
Outlet
At the compressor outlet, there is a non return valve (check valve). This stops gas from the HP gas
receivers and pipes from venting back through the compressor’s unloader system to atmosphere
when the compressor stops.
July 21 5 of 42

VP30/VP500
MAINTENANCE INFORMATION
Oil sight glass
The oil sight glass is used to check the oil level in the compressor sump. It is essential that the oil
level is checked regularly and kept between the minimum and maximum marks. Failure to maintain
the correct oil level will result in failure of the compressor:
● If the oil level is too low, it will result in failure of the compressor due to insufficient
lubrication and overheating.
● If the oil level is too high, it is likely that the crankshaft oil seals will fail.
Oil pressure gauge and switch
A pressure gauge indicates the compressor’s oil pressure. The oil pressure should normally
remain between 2 - 4 Bar when the compressor is running.
The oil pressure switch provides a signal to the control system. The compressor will be stopped
immediately in an alarm state if the compressor oil pressure is lost when the compressor is
running.
Oil drain plug
The oil drain plug is used to drain the lubricating oil from the compressor sump. Note that the oil
should be drained from the compressor when it is warm. On some systems, where accessibility is
limited, a valve and a pipe may be found instead of the drain plug.
July 21 6 of 42

VP30/VP500
MAINTENANCE INFORMATION
Maintenance
It is essential that regular maintenance is carried out. During
operation of the compressor, carbon deposits will build up on the
compressor valves. If the maintenance is not carried out in
accordance with the instructions in this manual, these deposits can
cause loss of performance and damage to pistons and cylinders.
Checking the oil level
Check the oil level when the compressor is STOPPED. The oil
level must be between the minimum and maximum marks on the
oil sight glass. If required, top up the oil level using the
recommended lubricating oil. Remove the oil filler cap to top up.
After topping up, wipe off any spillage to prevent burning of oil lying
on hot surfaces.
Recommended Lubricating oil:
Use only the following synthetic lubricating oils:
ANDEROL 500
ANDEROL 555
MOBIL RARUS 827
NEVER mix two different oils from the list. If you wish to change to
a different lubricant, the oil must be drained first.
Storage of Compressor
If the compressor is stored without running for an extended period
(i.e. greater than 2 months), the cylinders, cylinder heads and
valves must be checked for cleanliness and condition before
re-starting. All parts must be lubricated on assembly. See ‘Valve
inspection’ below for more information.
Changing the oil
Run the compressor until warm (about 10 minutes). Stop the
compressor and isolate the power. Place a container underneath
the drain plug (or drain pipe) to collect the drained oil. Note: the oil
sump capacity is 3.5 litres. Unscrew and remove the drain plug (or
open the drain valve, if fitted). Allow the oil to drain into the
container. Whilst the oil is drained, if required, remove and clean
the oil sight glass and replace. Clean the drain plug with
petroleum (gasoline), replace and tighten. Remove the oil filler
plug and refill with the recommended lubricant, checking for
correct oil level using the oil sight glass. Replace the oil filler plug.
July 21 7 of 42

VP30/VP500
MAINTENANCE INFORMATION
Microfilter element change
The Microfilter has a replaceable element (Part number 163140). The “O” ring 169531 and the disc
101184 should be replaced together with the element. To change the element, the compressor
must be stopped:
Unscrew the locking grub screw 2 turns.
Remove the drain pipe.
Using a large spanner, unscrew the filter bowl from the body.
Unscrew and remove the filter element by hand.
Clean the inside of the bowl and body with a cloth.
Check the condition of the internal ‘O’ ring. If in doubt, re-place the ‘O’
ring.
Screw on the new filter element by hand.
Replace the filter bowl and tighten until the bowl only UNTIL it stops
turning. The bowl seals on its ‘O’ ring, not on the thread or the face.
DO NOT OVERTIGHTEN.
Replace the drain pipe. If necessary, loosen the Banjo fitting to align
the pipe, ensuring that the arrows on the 1 way valve point upwards.
Tighten the locking grub screw.
July 21 8 of 42

VP30/VP500
MAINTENANCE INFORMATION
Valve Inspection
Make sure that the compressor is stopped and the power is isolated before carrying out this
work.
Valve Cleaning
Note: do not dismantle valve assemblies for cleaning purposes. Parts within the assembly
can be easily damaged.
Carefully clean the valve plate assemblies using soft scrappers (e.g. Copper, wood, plastic), and
petroleum (gasoline) to remove carbon deposits and dirt. Ensure that any traces of gasket material
are removed and that the mating surfaces are clean and smooth.
1st Stage Valves
Disconnect the inlet hose from the cylinder head 5/14
Unscrew the tubing nut adaptor and detach cooler tube from the cylinder
head.
Unscrew and remove capscrews 5/16 and washers 5/15 evenly.
Remove the cylinder head 5/14 from the cylinder 5/6, removing the valve
plate 5/10
Carefully clean the valve plate assembly 5/10 using soft scrapers (e.g.
copper, wood, plastic) and petroleum (gasoline) to remove carbon deposits
and dirt. Ensure that any traces of gasket material are removed and that the
mating surfaces are clean and smooth.
Clean the inside of the cylinder head 5/14. Ensure that any traces of gasket
material are removed and that the mating surfaces are clean and smooth.
Clean the mating surface and cylinder bore of the cylinder 5/6. Ensure that no dust or dirt particles
remain in the cylinder 5/6. Use compressed air to blow out if necessary.
If the valve plate assembly 5/10 is excessively worn it must be re-placed.
Reassemble in reverse order, fitting new gaskets. When reassembling, lubricate every component
(except gaskets) with clean lubricating oil.
On reassembly, tighten the cylinder head screws to the correct torque loading.
2nd Stage Valves
Unscrew the tubing nut adaptors and detach cooler tubes from the cylinder head.
Unscrew and remove capscrews 6/15 and washers 6/14 evenly.
Remove the cylinder head 6/13 from the cylinder 6/7, carefully removing the 2nd stage valve plate
assembly 6/11 which is located between the cylinder head and cylinder.
Carefully clean the valve plate assembly 6/11 using soft scrapers (e.g. copper, wood, plastic) and
petroleum (gasoline) to remove carbon deposits and dirt. Ensure that any traces of gasket material
are removed and that the mating surfaces are clean and smooth.
Clean the inside of the cylinder head 6/13. Ensure that any traces of gasket material are removed
and that the mating surfaces are clean and smooth.
Clean the mating surface and cylinder bore of the cylinder 6/7. Ensure that no dust or dirt particles
remain in the cylinder. Use compressed air to blow out if necessary.
July 21 9 of 42

VP30/VP500
MAINTENANCE INFORMATION
If the valve plate assembly 6/11 is excessively worn it must be replaced.
Reassemble in reverse order, fitting new gaskets. When reassembling, lubricate every component
(except gaskets) with clean lubricating oil.
On reassembly, tighten the cylinder head screws to the correct torque loading.
3rd Stage Valves
Unscrew the tubing nut adaptors and detach cooler tubes from the cylinder head.
Unscrew and remove vavle retainer 7/15 and locking nut 7/14, together with seal 7/13.
Unscrew and remove caphead screws 7/12 and lift off cylinder head valves 7/11.
Remove valve 7/10 together with seals 7/9 and 7/8.
Carefully clean valves using soft scrapers, (eg. copper, wood, plastic) and petroleum (gasoline) to
remove carbon deposits and dirt.
Clean the cylinder face of 7/7 and clean cylinder head 7/11 thoroughly, removing all traces of
carbon buildup. Ensure that all mating surfaces are clean and smooth.
Clean the mating surface and cylinder bore of the cylinder 7/7and remove the rest of 7/7 above.
Ensure that no dust or dirt particles remain in the cylinder. Use compressed air to blow out if
necessary. If the valve 7/10 is excessively worn it must be replaced.
Seals 7/8, 7/9, 7/13 should always be replaced, to avoid premature leakage. When installing these
seals ensure that they are correctly located around the valves.
Reassemble in reverse order. When reassembling lubricate every component, (except gaskets but
including O-rings) with clean lubricating oil.
To reassemble, locate valve 7/10 into the cylinder head 7/11 with seals 7/8 and 7/9. Mate the
assembly with the cylinder 7/7. Replace the capscrews 7/12, turning 1/16th turn at a time in a
diagonal pattern. Tighten to the correct torque loading.
Replace locking nut 7/14 with seal 7/13 and tighten against the valve.
Replace lock-ring 7/15 and tighten.
Re-attach the cooler tubes.
Type of screw
MMax
M6 screw, quality 8.8
10 Nm
M6 screw, quality 10.9
14 Nm
M8 screw, quality 8.8
24 Nm
M8 screw, quality 10.9
32 Nm
M10 screw, quality 8.8
50 Nm
M10 screw, quality 10.9
70 Nm
M12 screw, quality 8.8
88 Nm
M12 screw, quality 10.9
120 Nm
M12 screw, quality 12.9
130 Nm
Central pressure screw conc. valve
200 Nm
Maximum tightening torques for cylinder head screws and connecting rod screws
July 21 10 of 42

VP30/VP500
MAINTENANCE INFORMATION
Identifying screw head type, e.g. 8.8 and 10.9
See marking on the screw head to determination the correct maximum torque setting.
Unloader system inspection
General Disassembly
Before the unloader blocks can be re-moved from the
compressor, the pipes to them must be removed.
Remove the oil pipes from the bottom of the 1st and 2nd
stage unloaders. Take care to catch any spilt oil.
Remove the gas pipes from the bottom of then 3rd stage
unloader.
Remove the gas pipe from the top of the 3rd stage unloader.
Unloader valve disassembly
NOTE: When disassembling unloader valves, to avoid
confusion and incorrect operation, remove and replace only
one unloader at a time.
Remove the 3 M6 screws which hold the unloader valve onto
the separator block. Remove the valve from the compressor.
Unscrew and remove the four cover retaining screws and
remove the cover from the bottom of the valve. Withdraw the
piston and seals from inside the valve, noting the arrangement of parts.
Clean the piston and the inside of the unloader valve using a cloth and petroleum (gasoline).
Check the piston seals for wear or damage. Replace any worn or damaged seals.
Check the piston and unloader valve for scoring. If the scoring cannot be removed by rubbing with
800 grade emery paper, replace the parts.
Lubricate the piston seals with acid-free grease (e.g. silicone grease).
Reassemble the parts in reverse order. Always renew the cover gasket and the ‘O’ ring seal
between the unloader valve and the separator block.
Cooler inspection
Clean the cooling tubes with a cloth to remove accumulated dirt and dust. Use an airline to blow
dirt away, to maintain maximum cooling efficiency.
Check all coolers for signs of corrosion or fatigue. Replace any coolers which are cracked or
damaged.
July 21 11 of 42

VP30/VP500
MAINTENANCE INFORMATION
Starting compressor after Maintenance
Turn the compressor by hand for a few revolutions. Check that the motion is smooth and free.
Re-check all screws and connections for tightness.
Run the compressor for 10 - 15 minutes until warm.
Re-check all screws and connections for tightness.
General maintenance notes
Delivery valves will wear out before suction valves, due to the higher temperatures.
When replacing piston rings, ALWAYS replace as a complete set for each stage (i.e. do not mix old
and new rings in the same cylinder)
Always lubricate components (not paper gaskets) on assembly with clean lubricating oil.
Make sure that cylinders and cylinder head components are extremely clean on assembly. Any
particles of dirt left inside can score the cylinder bores and reduce the performance of the
compressor valves.
Troubleshooting
Low output flow or pressure
Leakage
If gas is leaking from the compressor cylinders or coolers, the output flowrate will fall, resulting in
low pressure. Carry out leakage test.
1st stage cylinder head
If the 1st stage cylinder head gasket is leaking, or the valve plate gasket is damaged, the flowrate
will fall. Check that the gaskets 5/9 and 5/11 are correctly fitted, and in good condition.
Unloader system
If the unloader valves do not seat correctly, gas from the compressor will vent through the unloader
vent when the compressor is running. With the compressor running, check that
no gas is venting through the unloader vent. If there is gas venting when the
compressor is running, carry out the unloader inspection and replace any worn
components.
Worn piston rings
Worn piston rings will reduce the output capacity of the compressor. Replace the
piston rings.
Piston rings marked ‘TOP’ or with a coloured dot, must be installed with the
‘TOP’/ dot marks facing the top of the piston.
Illustration is used to show orientation marks on piston rings only.
IMPORTANT:
Piston ring gaps must be rotated through 90 or 120 degrees from each other.
July 21 12 of 42

VP30/VP500
MAINTENANCE INFORMATION
Blowing safety Valves
Possible reasons for safety valves blowing are given below. In addition to these reasons, it may be
possible that the safety valves themselves can be faulty. Safety valve adjustments may change
due to vibration, or the valve may be worn.
In general, the normal operating pressures of the three stages of the compressor will be as follows:
1st stage: up to 21 Bar
2nd stage: up to 97 Bar
3rd stage: up to 350 Bar
If a safety valve is blowing below the pressures given above for each stage, then it is likely that the
valve requires adjustment or replacement. Note: It is extremely dangerous to adjust safety
valves pressures without the correct equipment. Replacement is recommended.
Crankcase breather safety valve blowing
1st stage cylinder head gasket damaged. Check and replace.
1st stage suction valve faulty. Check and clean/replace.
1st Stage safety valve blowing
2nd stage cylinder head gasket damaged. Check and replace.
2nd stage suction valve faulty. Check and clean/replace.
2nd Stage safety valve blowing
3rd stage concentric valve and/or seals worn or damaged. Check and clean/replace.
3rd Stage safety valve blowing
Outlet Check Valve or outlet pipes blocked. Check and Clean/Replace
Leakage from HP receivers
If the pressure in the HP receivers or pipework reduces, even when no gas is being consumed, it is
possible that the compressor outlet check valve is faulty and that gas is leaking back through it and
to the unloader vent, when the compressor is not running. Check and replace check valve.
Low oil pressure
Low oil level - Check and refill oil pump suction strainer fitted to drain plug 2/15 is clogged. Drain
the compressor oil and clean the strainer. Use compressed air to blow away any dirt, from the
inside of the strainer.
Knocking
Hard metallic knocking noises normally indicate worn crankpin journals or big end bearings. If the
crankpin journals are excessively worn, the crankshaft 3/1 must be replaced. If the wear is minor,
the connecting rods 4/1 (3 pcs) may be replaced.
July 21 13 of 42

VP30/VP500
MAINTENANCE INFORMATION
Rumbling
A deep rumbling sound can indicate that the main bearings 3/17 and 3/8 are worn. Check the
crankshaft wear by pulling the shaft from side to side. No movement should be detectable.
Diagrams
FIGURE
REF
DETAILS
MANUAL PAGE
1
INDEX OF PICTURES
17
2
CRANK CASE
18
3
CRANKSHAFT
20
4
PISTON AND CONNECTING ROD
22
5
CYLINDER, COMPL. 1ST. STAGE
24
6
CYLINDER, COMPL. 2ND. STAGE
26
7
CYLINDER, COMPL. 3RD. STAGE
28
8
FAN WHEEL AND GEAR WHEEL GUARD FOR AXIAL FAN
30
9
COOLING
32
10
UNLOADER MANIFOLD
34
11
UNLOADERS
37
12
OIL LUBRICATION
39
13
CRANK CASE BREATHER
41
14
MOTOR
43
15
MICROFILTER
45
Fig 1 - Compressor,
complete
July 21 14 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 2 – Crankcase
July 21 15 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 2 – Crankcase, parts list
POS.
PART NUMBER
DESCRIPTION
QUANTITY
1
161901
CRANK CASE
1
2
139491
STUD M12 X 30
12
3
094471
SPRING WASHER D12
12
4
080764
NUT M12
12
5
162027
RETAINING RING 85 X 3
1
6
162235
EXTENSION 1" X 100
1
7
181379
O-RING 30 X 2,5
1
8
179742
FITTING RI 1 X 1/4
2
9
151882
FILLER PLUG
1
10
125407
SPRING WASHER D5
6
11
002224
SCREW M5 X 25
6
12
074047
O-RING 180 X 3
1
13
161876
GASKET RING 17,4 X 24 X 1,5
1
14
148784
VALVE SPINDLE CPL.
1
15
125814
FILTER
1
16
125997
EXTENSION 1/2" X 50
1
17
030880
GASKET RING 20,7 X 28 X 1,5
1
18
001180
LOCKING SCREW R1/2
1
19
076333
SCREW M12 X 45
4
20
161874
GASKET RING 34,3 X 42 X 2
1
21
165851
BEARING COVER SV 225/350
1
22
181539
SCREW M6 X 30
6
23
094447
SPRING WASHER D6
4
24
181539
SCREW M6 X 30
4
25
073466
O-RING 71 X 2
1
26
138703
PUMP COVER
1
27
153818
RETAINING RING 47X1,75
1
28
001104
LOCKING SCREW 1/2"
1
29
001074
LOCKING SCREW R 1/8"
1
30
080764
NUT M12
4
31
094471
SPRING WASHER D12
4
32
088668
LOCKING SCREW 1/4"
1
33
160363
O-RING 24 X 2,5
1
34
150010
VALVE HOUSING
1
35
108758
O-RING 14 X 2
1
36
030880
GASKET RING 20,7 X 28 X 1,5
1
37
096172
LOCKING SCREW M20 X 1,5
1
38
162024
OIL LEVEL GLASS SP100
1
July 21 16 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 3 – Crankcase
July 21 17 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 3 – Crankcase – parts list
Pos.
Part Number
Description
Quantity
1
196913
crankshaft
1
2
139459
feather key 6 x 6 x 22
1
3
139467
feather key 5 x 5 x 5
1
4
197973
feather key 12 x 8 x 45
1
5
157732
cylinder roller bearing
1
6
162036
shaft sealing ring A 55 x 80 x 10
1
7
007390
reataining ring 55 x 2
1
8
500473
bearing
1
9
001511
screw M8 x 30
1
10
094455
spring washer D8
1
11
089893
washer
1
12
153818
spring washer 47 x 1,75
1
13
039942
axial bearing washer
1
14
139475
radial shaft seal DG 22 x 35 x 7S
1
15
16
139416
oil pump
1
17
139394
cylinder roller bearing
1
July 21 18 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 4 – Piston and connecting rod
July 21 19 of 42

VP30/VP500
MAINTENANCE INFORMATION
Fig 4 – Piston and connecting rod – parts list
Pos.
Part Number
Description
Quantity
1
162021
CONNECTING ROD CPL.
3
2
519239
PISTON CPL. 50/70
1
3
148962
PISTON RING M50X45,8X2,5
6
4
197829
PISTON CPL. 27/70
1
5
198276
PISTON RING M 27X24,6X2
6
6
519676
PISTON CPL. 16/70
1
7
198274
PISTON RING M 16X14,5X2
8
July 21 20 of 42