FOREWORD

Congratulations on your purchase of the Chicago Pneumatic Compressor Package! You are now a part of
the evergrowing family of Satisfied CP Customers.
This manual containing Operating & Servicing Instructions is an integral part of your Compressor Package
and should be kept with it at all times so as to be available to the operator or service engineer.
Before stertlng the Compressor Package read this manual carefully so as to understand the contents clearly.
For additional information, please contact the nearest CPIL office or the dealer from whom the machine was
purchased.

TO OBTAIN THE BEST RESULTS

1.

Read this Instruction Manual carefully.

2.

Install the Compressor Package as instructed. Costly installation errors and possible damage to the
compressor can be avoided if the instructions are followed carefully.

3.

Use only recommended brands of lubricating oil.

4.

Keep the compressor valves and cylinders free from carbon.

5.

Keep the plant clean.

6.

Do not run the compressor without suction air filter.

7.

Do not put paraffin or other inflammable spirits into the compressor or air receiver.

IMPORTANT
The company reserves the right to alter the design or construction and to supply the same when so altered
w!thout reference to illustrations or description given in this instruction manual.
Since CP is dedicated to a process of ongoing improvements in its products, the illustrations and
specifications are subject to change without notice.

Contents
SR.
NO.
1

DESCRIPTION

PAGE NO.

Introduction

Construction

Systems
a. Air System.
b. Lubrication Systems
c. Water Cooling System
d. Capacity Control System

3
3
5
6
6

Salient Features

Installation

Compressor Operation
a. Initial Commissioning
b. Routine Starting & Stopping
c. Recently Overhauled Unit

9
10
11

Maintenance

11

Electricals

17

Safety Devices

18

10

Maintenance Schedule

20

11

Faults And Remedies

22

12

Trouble Shooting Chart .

24

APPENDICES
I LUBRICATING OIL
II RUNNING CLEARANCES AND WEAR LIMITS
III TORQUES

25
26
27

INTRODUCTION

compressed air. Wide water jacket doors provided on

cylinders ensure easy access for cleaning of cylinder
jackets. Designed for streamlined air passage and
maximum number of valves, cylinders provide smooth
flow of air thereby minimizing the pressure drop.

The Compressor Package is a complete unit ready to

install, easy to commission, easy to operate, easy to
maintain and an extremely reliable package unit
engineered for excellence.

7. PISTONS: Low inertia. light-weight, pistons in two

halves of special Aluminium alloy are double acting
and provided with suitable compression rings to
ensure perfect sealing during compression. In nonlube compressors, in addition to piston rings. piston
are also provided with Teflon rider ring to take the
load of the piston during unloaded condition.

The package comprises of state-of-the-art horizontal

balanced opposed reciprocating water cooled air
compressor, water cooled heat exchangers, drive
motor, v belt or direct drive arrangement, starter cum
control panel, safety devices, interconnecting piping,
cabling, etc. and ordered accessories duly mounted
on a rigid steel deck. These packages are provided
with Anti Vibration Mountings (AVM), to reduce the
vibrations from being transmitted to the floor, hence
eliminating elaborate civil foundation.

8. PISTON ROD AND PACKING: Alloy steel piston rods

fitted with wear. resistant packing rings of antifriction
type. to prevent any possibility of compressed air
leakage.

The following paragraphs explain the various features

incorporated with the package unit.

9. VALVES : Reduced lift with large flow area,

stainless steel, ported plate type valves, both for
suction and discharge, arranged symmetrically,
provide longer life. A protection grill fitted on suction
valves prevent any valve part falling into the cylinders
in case of any accident. Ease of accessibility of these
valves and non-reversibility of suction and discharge
valves makes it simpler and foolproof for regular
maintenance.

CONSTRUCTION
1. FRAME: Totally enclosed, rigid, pressure tight
made of high grade, close grained C.I., precision
machined and stress relieved for permanent
alignment. Two bearings fitted on the drive end side
gives better support to the crankshaft aided with one
bearing fitted on the purpp end. Main bearing housing
bores are accurately bored to avoid misalignment or
eccentricity.

10. HEAT EXCHANGERS: Horizontal or vertical. shell

and tube type, with removable tube bundle. with water
through shell and air through tubes, heat exchangers
are fitted on the cylinders at a height which is easily.
accessible. Designed for optimum heat exchange, the
heat exchangers cools the air received from the
previous stage discharge effectively before its entry to
the next stage cylinder and so on for successive
stages. Provided with a pulsation bottle on inlet side
(in select models) and an efficient moisture
separator on discharge, the heat exchangers are of
counter flow type and complete with a safety valve and
auto drain valve with bypass arrangement.

2. CRANKSHAFT: High grade S.G. Iron crankshaft and

journals duly ground and polished ensure a long life
of bearings.
3.CONNECTING RODS: Forged alloy steel connecting
rods duly normalised, are designed to provide
minimum, thrust on the cross head bearing surfaces.
Big
end
bearing
bores
finish
machined
accommodate prefinished replaceable bearing
halves of copper lead alloy, designed for k)nger
operation. Small end bearing bushings .are of special
bronze metal.

11. OIL PUMP: Gear type oil pump directly driven by

the crankshaft and fitted on the bearing housing. it
feeds oil to the main bearings.. connecting rod
bearings and to one cross slide in HX model (side
opposite to crankshaft rotatfon) and to both the cross
slides through choke in HN model. The oil pressure
is regulated by a pressure regulating screw provided
on the oil pump body. To increase the pressure,
regulating screw has to be screwed in and viceversa.

4. MAIN BEARINGS AND BIG END BEARINGS: Thin

walled, pre-finished to the size, small width and
sufficiently large diameter perfect rigidity to running
gear. Both the bearings are of copper-lead alloy.
designed for longer life of operation.
5. CROSS HEAD: Made of high grade S.G. Iron. its low
inertia along with low friction cross-slides ensures
perfect running of cross head. Its hollow design on
either sides ensures true running of piston rod
thereby resulting in improved life of packings and
maximum life of piston rod. The doors fitted on cross
slide provide easy and wide access to the crosshead
pins which are held in position by two circlips on
either sides.

SYSTEMS
AIR SYSTEM
This is the heart of the unit and the same is
responsible for delivering quality compressed air at
the outlet. It starts from the suction filter of the
compressr and ends at the final service valve of the
package. Keeping the air passages as clean as
possible will reward you in terms of quality air and

6. CYLINDERS: Graded C.t. cylinders designed with

adequate water jackets ensure optimum heat
dissipation of the surfaces in contact with

Choke

Connecting rod

Cross slide with

cross head

Oil filter

Oil pressure gauge

Strainer

FRAME LUBRICATION

Notes : 1 no. Choke at cross side is provided on model - HX

2 nos. Choke one on each side provided on model - HN

Belt wheel

Oil pump

reduced power consumption.

incorrect direction, the oil pump will not pump oil.

resulting in seizure and damage. To avoid this a Low
Oil Pressure Switch (LOPS) is fitted on the panel. The
common connection for the LOPS & Oil Pressure
Gauge is tapped from the farthest point of the frame.
i.e. f: urn the last bearing when viewed from the drive
end side.

CP provides a filter of superior grade at the section of

the compressor to avoid any ingress of solid
particles. The compressor cylinder, during suction
stroke, aspires atmospheric air through the filter and
compresses it to the delivery pressure. In case of
multi-stage compressors the delivery pressure is
achieved by compressing the air in stages. Between
successive stages a highly efficient heat exchanger is
provided to remove the heat of compression. Air,
before passing to the next stage is cooled to near
about atmospheric temperature in the heat
exchanger. This helps in reducing the final air
discharge temperature as well as the power
consumption of the compressor.

The oil pressure regulating valve is housed in the oil

pump body. The oil pressure adjusting screw should
be turned clockwise to increase the oil pressure and
vice versa.
The oil pump and oil pressure regulating valve can
be approached by removing front cover. In case the
compressor has undergone recent overhaul or
prolonged storage then it is essential to rotate belt
wheel several turns to ensure that the bearings are
flooded with oil.

LUBRICATION SYSTEM
FRAME LUBRICATION

OIL GRADE

Full forced feed lubrication is used throughout. A

positive displacement rotary type pump is directly
driven by the crankshaft through a oil pump drive
shaft. Oil from the sump is drawn by the oil pump
through a fine perforated sheet strainer. The oil pump
discharge is taken to oil.filter (cartridge paper type)
and the filtered oil is led through copper tubes to
each main bearing (drive end and non drive end). refer
fig. The oil from the main journals of the crankshaft
flows to crank pins through the rifle drilled holes and
also from crank pins to small end bushing through
rifle drilled holes in connecting rods.

The life of a machine depends almost entirely upon

the effectiveness of lubrication and therefore the
selection of proper lubricants shoulQ be given
considerable thought. Use a high quality industrial
oil, as experience has shown that it is poor economy
to use a cheap oil.
Normally a good quality non detergent mineral oil
containing rust and oxidation inhibitors, anti foam and
good water separating properties should be used.
Sludge and other impurities in the oil will cause the
oil strainer to clog, resulting in lubrication starvation
to bearings.

Facing belt wheel, haying clockwise direction of

rotation. the left hand cross slide (1 st stage) is
pressure lubricate9. A 10 mm copper tube connection
is taken through a tee connection in main oil line and
connected to a choke (Oia. 1 mm hole) which is fitted
on the top face side of the cross slide, The oil through
the choke flows to the centre of cross slide to top of
the cross head.

OIL LEVEL
The red dot on the oil level gauge (visual screw) fitted
on the frame indicates the desired oil level in the
frame,

WARNING !

The 2nd stage cross head is splash lubricated in

case HX models. Since the direction of rotation is
clock wise when viewed facing the belt wheel, the
splashed oil from the 2nd stage connecting rod
bearing falls on top of the cross slide. The top of the
cross slide is specially built with all around small
dam inwhich the splashed oil accumulates and
through the drilled hole, faJls on top of cross head for
lubrication.

1. Never mix different brands of oil. While using other

brand of oil, the existing all must be completely
drained and inside of the f,rame thoroughly cleaned
and dried out.
2. Maintain correct all level in frame. Low level will
cause foaming due to mixture of air and all thus
damaging the bearings. Higher 011 level will capse
excessive high all temperature due to continuous
paddling of the oil, resulting In an early reduction of
lubricating all properties. The normal working temp.
of all is around 70C.

The 2nd stage cross head is lubricated through

choke in case of HN models.

OIL PUMP AND PRESSURE

3.With a new machine the oil should be examined

and drained after the flist 50 hours of operation since
the lubricating 011 will wash out the dirt and dust that
may have collected during shipment and installation.
If the inspection of the oil found in the bottom of the
frame, shows it to be contaminated, it should be
removed immediately and disposed. It is impractical

A gear type positive displacement oil pump is

employed. It is therefore absolutely essential that the
correct direction of rotation of the belt wheel is
maintained as per arrow marked on non drive end
bearing housing. In case the compressor is run in

to state definitely how often the frame oil should be

changed because operating conditions vary
considerably. We recommend oil to be changed every
6 months or 3000 working hours, whichever is earlier.

PRECAUTION SHOULD BE TAKEN TO KEEP THE

PISTON FROM BEING MOVED IN THE CYLINDER.
THE AIR BACK PRESSURE FROM THE RECEIVER
OR MAINS SHOULD BE ENTIRELY RELEASED
FROM THE CYLINDER. IF A VALVE HAS BEEN
REPLACED IN THE. DISCHARGE LINE, IT SHOULD
BE CLOSED AND AIR VENTED BETWEEN VALVE AND
CYLINDER.

4. A close watch must be kept on oil pressure. Any

Indications of low oil pressure must be investigated
and oil filters replacedJmmedlately. We recommend
oil filter to be replaced every 1500 hours I 3 months
whichever Is earlier.

6. The lubricator should be cleaned periodically, to

ensure that clean oil is supplied to cylinders

CYLINDER LUBRICATION
(Lube model only).:

WATER COOLING SYSTEM

(CYLINDERS AND HEAT EXCHANGERS)

The cylinders are lubricated by multiple mechanical

force feed lubricator delivering a controlled quantity of
oil under pressure to each cylinder. Normally a good
quality, properly inhibited pur.e mineral oil as
explained in frame lubrication and appendix I s.hould
be used. A common oil for frame and forced feed
lubricator is recommended.

1. A good clean water shquld be provided for cooling.

If the cooling water has a high percentage of lime
sulphur. silt. mud or other impurities. these will be
deposited in the cylinder jackets. head. intercoolers
andaftercoo~er tubes and shells. The scale deposits
unless removed. will obstruct the flow of water. lower
the rate of heat transfer and may result in damage to
the machine. Cleaning holes are provided in the
sides of the cylinders for cleaning the jackets and
cylinder heads. Periodically the cylinder jackets.
cylinder heads. inter-cooler and after cooler tubes
and inside of the shell should be inspecte,d and
cleaned.

1. A new machine may require the lubricator pumps

to be pumping their full capacity in order to prevent
over heating or flushing out of entrained dirt in the air
system, Upon reducing the quantity of oil fed to the
cylinder bores, the cylinder bore and piston rod must
be inspected for the presence of an oil film within 2
hours after oil reduction is made. If oil supply is cut
too much, scoring, rapid wear and overheating will
occur. During the first month, adjust the oil feed 50%
higher than the, feed required for normal operation.

2. The cooling water pipe connections for the

compressor package cooler should be arranged as
shown on the General Arrangement drawing..
3. A generous amount of cooling water should be
provided to each cylinder, inter-cooler and aftercooler.
The inlet water pressure is recommended to be
maintained between Min 1.5 kg/cm2 and max. 3.5kg/
cm2 The inlet water temperature must not exceed 32
C and this should be very strictly taken care off. The
water temperature differential between inlet and outlet
should not exceed 7 to SoC and should preferably ?e
lower.
.

2. A test for the proper amount of cylinder oil is to

remove one of the valves occasionally and visually
note the appearance of the cylinder wall. Wipe
cylinder wall with cigarette paper to see if an oil film
is present. The surfa,ce of ttie cylinder walls should
have a slight film of oil covering them - they should
not be dry. If the surface is dry, the cylinder is not
receiving sufficient lubrication.
3, If the surface appears to be saturated with oil, the
cylinder lubrication is excessive and will result in
heavy carbon deposits which affect the efficient
operation of the compressor. The excessive
lubrication is not a supplementary safety but may
accelerate the causes of serious fire or explosion In
pipe lines due to the presence of carbon dust and
other Impurities in oil and air. The malfunctioning of
valves is often caused by excessive cylinder
lubrication.

4. please refer compressor I package G.A. Org. for

quantity of cooling water required.

OPEN TANK
Where the water cooling tower is not available and
the location requir~s aDen tank system. then the.
tank should have min.1 hour water circulating
capacity.
It is preferred to have low depth so that more water
surface area is available to cool the water by natural
air in addition to adequate water sprinkl.ers.

4. Clean frequently all the valve pockets in cylinders,

discharge lines. heat exchangers and receivers in
which such accumulation can take place.

CAPACITY CONTROL

5. The oil level in the cylinder lubricator should be

ch,ecked at frequent intervals and an ample supply
maintained therein at all times.

The compressor package is provided with either 2 or

3 step Electro Pneumatic Capacity Control System
comprising of 3 way solenoid valve operated by
pressure switch, actuating at delivery I pressure
(receiver pressure). This also ai(:ls the I compressor

WARNING!
BEFORE REACHING INTO A CYLINDER, EVERY
6

EASY INSTALLATION:

to operate at no load till the motor attains I normal

speed and lube oil pressure builds up to the required
value, at the time of inltal starting.

Since the compressor in supplied as a package i.e.

all piping and wiring upto battery limit being done at
factory, the installation of the unit can be done in very
quick time. The package can be installed anywhere
on the levelled shop floor and can be made ready just
by connecting three phase electrical supply, water
supply and air discharge piping.

OPERATION:
Load Percentage: A single pressure switch and
solenoid valve will work either at 0% or 100% (2 step).
This is usually applied to single acting compressors.
In double acting compressors, two nos. of pressure!
switches and solenoid valves are used thus
achieving! 0%,50% and 100% (3 step) load
conditions.

EASY ACCESSIBILITY:
Besides being compact, the compressor is also
designed in such a way that it provides easy
accessibility to all the parts and facilitates the
supervision and maintenance of the same.

In 3 step capacity control, the outer end of LP and

inner end of HP get unloaded by one pair of pressure
switch and solenoid valve thus the compressor runs
on 50% load. The inner end of LP and outer end of
Hpget unloaded by the other pair of pressure switch
and solenoid valve thus the compressor runs on 0%
load.

PORTABILITY:
The package has provision for lifting the entire unit,
enabling you to shift the package from one shop floor
to another, as per site requirements, without any
headache.

The principle of operation of 2 step capacity control

Is explained in the following paragraph:

HIGH THERMAL EFFICIENCY:

Double acting type with the reciprocation of the piston
fully utilized for compression in either movement of
the piston, the compressor efficiency Is enhanced
added to the fact of accurately machined parts,
symmetrically arranged valves watercooled cylinders
with adequate water jackets for optimum heat
dissipation and and efficient intercoolers. This also
reduces the power consumption considerably.

The delivery (receiver) pressure being low during

starting the compressor, the pressure switches
energises the solenoid valves thus stopping air
supply to suction valves and the compressor comes
on full load I.e. known as 100% load. As the delivery
(receiver) pressure increases than the set pressure
of the pressure switch, the contacts of the switch
opens and de-energises the solenoid valve. Air is
supplied to the suction valves thus opening the
same. The compressor thus gets fully unloaded i.e.
0% load.

MAXIMUM RELIABILITY:
The valves used in the compressor absorb the
shocks of the movement of valve plates, thereby
providing a noise less operation. The damper plate
used in the valve assembly dampens the Impact of
the valve plates and lead to prolonged life of plates.
The accurate selection of materials, Its heat
treatmenf and the accurate machining of the.
components gives further reliability to the operation of
the compressor. The forced feed lubrication u~ed for
the running gear parts give excellent wear resisting
characteristics. All essential sections are designed
adequately to make the structure rigid and undergo
the strictest of quality acceptance tests. On
completion, each package is tested thoroughly for
parameters of capacity, pressure, power, vibration,
etc. before the despatch of the unit. Further, safety
devices provided for the oil pressure and other lines,
gauges for oil pressure and air pressures in each
stage mounted on the panel simplifies the
supervision in operational Conditions.

SALIENT FEATURES
NO FOUNDATION:
This package Is ready ,to use with no concrete
foundation required. A simple Industrial levelled floor
Is a must for installing the package. Due to the above
feature the cost of foundation and man power is totally
saved and site engineering hassles are eliminated.

REDUCED VIBRATION:
The symmetrical reciprocating action, balanced
compression ratios in each stage and equal weights
of the moving parts keep the inertia forces of the
reciprocating and rotating masses in perfect
equilibrium. As no unbalanced inertia force exists in
the primary or seconQary inertia forces, the inertia
couples are negligible. Further, the anti-vibration
mountings (AVM) provided between the sub-deck and
main deck dampen out the vibrations of the package
considerably.

INSTAllATION
The,following instructions are provided to aid in the
proper installation of the machine and to assist the
operator in its operation and servicing. Costly
installation errors and possible damage to the
compressor can be avoided if these instructions are
followed carefully.

LESS FLOOR SPACE:

Since the entire package is mounted on the skid and
the heat exchangers and ordered accessories are
arranged in such a fashion, it effectively reduces the
floor space. The short stroke of the compressor also
makes the unit more compact.
7

LOCATION

installed outside the building so as to prevent rain

water entering into it.

Install the compressor in clean, dry well-lit and 6)

ventilated place (preferably having cross-ventilation al
provision) with sufficient space reserved for the pi
cleaning, inspection and repairing of the unit. The cc
general arrangement drawing shows the space in
required for the removal of pistons, heat exchanger
b4 tube bundles. Provide sufficient space for their
removal when locating the machine.

6) It is advisable not to use unusually long pipe lines

as It will increase the resistance to flow and Increase
pressure drop thereby resulting In loss of
compressor capacity. In case of bends being used n
the pipe line, it is advised to use large radius bends
which will give minimum resistance to air flow.
7) Ti:1e sucion pipe line must be very clean from
inslde and should not have any foreign particles
sticking Inside the wall and also be free from rust, as
such particles can cause damage to the compressor
cylinder, If supked. Intake pipes should oe painted
with a rust-preventive from inside.

The electric equipment will operate better and at

higher efficiency if the package is located in a cool, dry
place.
Before deciding upon a definite location and making
CI a final layout the following chapters are to be
referred.

B) As a reciprocating compressor inhales air at

pulsating rate, it causes variations in the intake
pressure. At certain critical lengths of the intake pipe
resonance may occur which can cause disturbing
noise levels and sufficient stresses to break the
Intake pipe. They can also cause damage to
compressor suction valves In certain cases.
Resonance occurs when the suction frequency of the
compressor coincides with the natural frequency of
the intake pipe. Therefore it is imperative to correctly
design the intake pipe, especially its length and
diameter and elimin~te resonance.

Air intake Piping

Air Discharge Piping
Air Receiver

AIR INTAKE TO PACKAGE

CP Package Compressors are supplied with a
suction silencer cum filter mounted on the LP cylinder
inlet flange.
As it is imperative that the air sucked in by the
package compressor should be clean, dry and cool,
in case of dusty environments nearby of package a
compressor location, it is advisable to fit an Air intake
pipe to be taken towards clean atmosphere and then
mount the filter. However a flexible hose Ipipe is to be
installed between the package compressor suction
flange and air intake pipe.

9) The Intake pipe should be properly supported so

that. it does not transmit any undue load to the
Package. Compressor.
10) Intake pipes subjected to pulsating air must not
be rigidly attached to walls and ceilings since
vibrations may be transmitted to the building.

Guidelines for Air Intake piping :

11) It is advisable to have independent air intake pipe

lines for each cylinder. A common intake pipe should
be avoided as far as possible.

1) The intake air for a Package Compressor must 1

be clean and free from solid and gaseous impurities,
abrasive dust particles and corrosive gases being
particularly harmful.

12) For Package Compressor installations in areas

of excessive contamination such as in quarries or
cement Industries, some sort of pre-filtering device
should be added, otherwise the Package
Compressor air filter will clog up too quickly.

2) For the best working of the Package Compressor

and for maximum efficiency, it is advisable that the
Package Compressor sucks air as cold as possible.
A temperature decrease of 3C. increases the volume
delivered by the compressor by 1 %. all other
parameters remaining the same. Intake pipe should
not be located in the vicinity of any delivery pipe line.
which is normally hot.

AIR DISCHARGE PIPING OF COMPRESSOR:

The discharge pipe should be connected as direct as
possible to the bottom of the receiver. It should be the
same size as shown in the general arrangement
drawing and should have as few turns as possible.

3) The Air Intake system should be sized so as to I

give a low pressure dr9P. A pressure drop of 100 mm
of water column in the air intake system causes a
compressor capacity loss of 1 % because of the
lower suction air pressure.

The flow of air discharge from a reciprocating

compressor is a pulsating flow. In certain cases, the
discharge pipe system may resonate causing severe
pipe oscillations and compressor valve damage. It is
therefore advisable to design the discharge pipe
system to prevent resonance and excessive
pulsation. It is also advisable to support the
discharge pipe system but the same should be free
from thermal expansion in order to avoid stresses.

4) The velocity of air through the suction pipe line

should be about 400 m/min.
5) A suction filter incorporated in the suction prevents
sucking of foreign particles. dirt and dust. It is advised
to build a roof on top of the suction filter in case itis

If the discharge line is long, it is good. practice to

increase the pipe one size higher for every 100 feet
length from the compressor.

The rate of corrosion varies with climatic conditions.

Variance in climatic conditions makes it impossible to
state the length of time any Package Compressor
can be stored without rust and corrosion damage.
The following procedure covers the basic method of
preparing the Package Compressor for temporary/
long storage.

It is essential that pipes should be sized to prevent

excessive pressure drop to avoid power loss.
The following table shows power losses in air mains.
Pipe nominal
bore (mm)

Pressure drop (bar)

per 100m.

40

108

9.5

50

0.65

3.4

65

0.22

1.2

80

0.04

0.2

100

0.02

Procedure:

Equivalent
power
losses (kw)

0.1

1. Clean frame sump and cross slides and lubricator

in case of lube models.
2.FIII frame with H.P. RUSTOP.286 oil and rotate
compressor belt wheel several revolutions to ensure
that the oil is circulated to all moving parts, cross
slides and cross heads.
3. For lube models clean cylinders and spray liberal
qty. of HP RUSTOP-286 and rotate compressor
several revolutions to ensure that the oil reaches all
valve parts.

It is very important to make all piping as direct and

short as possible. Wherever bends are necessary,
use 16ng radius elbows to reduce air friction.

4. For non lube models do not spray HP RUSTOP286

in cylinders. Place silica gel bags in valve ports and
refit valve holders.

NEVER PLACE A SHUT-OFF VALVE IN THE

DISCHARGE LINE BETWEEN THE COMPRESSOR c
AND THE RECEIVER UNLESS A SAFETY VALVE IS
INSERTED BETWEEN THE COMPRESSOR AND THE
SHUT - OFF VALVE.

5. Drain water from cooling water system, cylinder

jackets and heat exchangers and thoroughly flush
with clean water and radiator cleaner. The system
then has to be refilled with a 10: 1 mixture of water .
and radiator cleaner. Drain this mixture after 5 days.
If ambient is very low, water freezing may occur, drain
the mixture immediately. .

If two or more compressors and connected to the t

same system, it is advisable to place a shut-off valve
in each discharge line in order that the compressor
valves and cylinders can be inspected and repaired
without releasing air from the entire system.

6. Drain RUSTOP-286 oil from the frame and

lubricator (in case of lube models only).

NOTE: INSTALL DRAIN VALVES IN ALL LOW SPOTS

IN THE DISCHARGE PIPING, SO THAT. LINES CAN
BE DRAINED PERIODICALLY TO PREVENT ANY
ACCUMULATION OF WATER OR I SLUDGE IN THE
PIPING.

7. Slacken the V belts completely.

8. Apply liberal quantity of preserving grease on
piston rod (in case of lube models only).

RECEIVER

9. Plug and seal all openings thoroughly to prevent

entry of moist air and dirt.

The receiver should be placed in a cool position as

near as possible to the Package Compressor. The
discharge pipe from the Package Compressor
should enter the receiver at the lower flange. The
pipes leading to the electro~pneumatic capacity
controller should be of a material which will eliminate
the possibility of corrosion and rust or scale
formation. The supply line from the receiver to the
various points of distribution should be connected to
the upper flange of the receiver.

10. Store the package compressor in a dry place

under shed.

PACKAGE COMPRESSOR OPERATION

INITIAL COMMISIONING
1. Remove polythene covers, tapes, wrappings from
openings which have been blanked and sealed.
2. Clean off all accumulated dirt from exterior of
Package.

PACKAGE COMPRESSOR STORAGE

Any Package Compressor not in service, whether
installed or waiting to be installed, the unpainted
machined surfaces are subjected to rust and
corrosion. Often a Package Compressor is not
prepared for long time storage. However every
Package Compressor going out of the factory is
always processed with rust preventive oil for
shipment purpose (maximum period of four weeks).

3. Check and clean thoroughly the inside of the

frame. (The entire interior should be washed down
with VARSOL or any other cleaning agent, and then
wiped dry with lint free rags).

NOTE :
1. ENSURE THAT THE AVM PROTECTION SPACERS
PAINTED IN RED ARE REMOVED BEFORE
COMMISSIONING.

2. REMOVE SILICA GEL BAGS FROM VALVE

POCKETS AND CROSS SLIDE COMPARTMENTS
ONLY IN CASE OF NON LUBE COMPRESSOR
PACKAGES.

tested temperature gauge (capillary type) should be

placed on the motor to record the optimum
temperature the winding has achieved and to control
the temperature to below 85 0C. It is necessary to
cover with asbestos clothing to prevent heat
radimtipn.

3. NEVER USE COTTON WASTE ON ANY ( INTERNAL

PARTS AS COTTON WASTE MAY CAUSE STRAINER
AND OIL FILTER CLOGGING.

The insulation resistance m,ust be measured every

hour till the insulation value stabilises at certain point
; then the heating process is to be discontinued.
When the motor cools down to the ambient temp.
favourable insulation resistance will be obtained.

4. CHECK FRAME FOR WATER CONTENTS. IN CASE

WATER/SLUDGE IS FOUND IT MUST BE . DRAINED
OUT IMMEDIATELY FROM FRAME, THOROUGHLY
AND FillED WITH NEW OIL.

Before a motor is started after a long idle period

(more than 8 months), the Iearing cover should be
removed an9 the grease in the bearing cover should
be pressed with thumbs betweE!n the race of the
bearing. If any deterioration of grease is apparent, the
old grease should be removed and new grease
pressed irto the bearing al1d housing.

5. DO NOT WIPE CARBON AND TEFLON I POWDER

FROM CYLINDERS IN CASE OF NON LUBE
COMPRESSOR PACKAGES.
4. Fill compressor frame with correct grade of
lubricating oil upto the centre of visual screw.
5. Rotate the compressor beltwheel manually, in the
direction of rotatipn for about 20-30 revolutions to
ensure bearing lubrication and free rotation.

11. Start the cQmpressor in unload condition.

12. Check the direction of rotation.

6. Turn on the cooling water and remove air lock from

the water system.

DIRECTION OF ROTATION
THE DIRECTION OF ROTATIO IS ANTI-CLOCK WISE
WHEN VIEWED FROM NON DRIVING END. AN
ARROW MARK INDICATING THE SAME IS GIVEN ON
BEARING HOUSING. .

7. Drain condensed water from heat exchangers.

8. Check V belt tightness.,
9. Check all Electrical connections fOr tightness.
10. Check the insulation resistance with a megger. Its
value should not be less than 1 mega ohm per rated
kilovolt of the machine plus 1 mega ohm subject to a
minimum Qf 2 mega ohms, when cold. If this is not
the case, presence of moisture or dust in the
windings is iridicated. and the machine needs to be
dried out.

RUNNING IN OPPOSITE DIRECTION WILL CAUSE

SERIQU DAMAGE.

Method of Drying Out Motor:

16. Check voltage available at terminals and current

drawn by the motor.

13. Check lube oil pressure.

14. Put the compressor on load and check interstage
pressute(s) and various temperatures.
15. Check for leakages (Air, Water and Oil).

1. A convenient method of doing this is to block the

motor so that it cannot rotate and apply a very low C
voltage of about 10% of the normal voltage to the
starter terminals.

17. Check for unusual noises.

18. Check tripping of all safety devices.

2. The motor can be placed in an oven, if available,

but the temp. shall not be allowed to exceed 85C.
Alternatively, hot air can be blown into the motor but
the air should be clean and dry at a temperature not
more than 85C.

19. Switch off the power supply to the motor through

the on-off sw,tch on the starter cum control panel. The
compressor automatically unloads before stopping.

3. By placing 6-12 carbon filament lamps (according

to the frame size of the motor) closer around the
frame of the motor, properly hung to the fixtures.

1. Turn on cooling water 8.fld remoVe air lock from

water system.

ROUTINE STARTING

2. Check position of safety shut down switches.

4. By applying DC current (not more than 80% of the

motor rated current) continuously to the starter of the
motor, the large motors can be .dried out. An added
advantage of DC current is the easy control of DC
current through rheostat.

3. Drain condensed water from heat exchangers.

4. Check the tightness of V belts.
5. Open stop valve (if fitted) between aftercooler and
air receiver.

While the motor is in drying out process, the small

vents, if provided. on both the sides of the motor
should be kept open for the escape of moisture. A

6. Drain condensed water from control air filter fitted

before unloading solenoid valve on the starter cum

10

control panel.

explosion.

7. Start the compressor by following the instructions

displayed on the MMI (Man Machine Interface) of the
PLC (Programmable Logic Control) unit fitted on the
starter cum control panel.

3. Inspection & Reconditioning:

a) Valve Plates: When a valve plate or damper plate
shows signs of wear, it is imperative to.replace these
parts, even if no breakage has occurred. We allow a
maximum wear of about 10% of the total thickness of
the valve plate. Valve plates when worn should be
replaced, not ground or inverted.

8. Check lube oil pressure.

9. Load the compressor.
10. Check interstage pressures.
11. Check interstage
compressor discharge)

temperatures

b) Springs & Spring Plates: If the springs and spring

plates show, any sign of wear, these must be
replaced immediately.

(especially

c) Seats: For highest efficiency of the valve it is

important that the seat .face is flatand free from any
traces of wear, thus preventing valve leakage. If any
damage of the seat face appears, it is necessary to
remachine and lap the seating areas. Locating pins,
if fitted, have to be removed first before carrying out
above operations. Generally remachining is done by
concentric grinding and lapping. If the seat face
shows only slight defects, lapping along may prove
satisfactory.. Also remachining on a centre lathe with
very low feed may be considered, particular attention
being paid .to the seat face being machined plane,
burrs are best removed with emery paper.

12. Check for leaks in air. water and oil lines.

13. Check voltage and current drawn by the motor.
14. Drain all low points in compressor suction and
discharge lines.
15. Drain condensed water from air receiver
pulsation bottles and moisture separators.
16. Check for loose bolts and nuts and tighten.
17. Check for unusual noises.

ROUTINE STOPPING
1. Switch off the power supply to the motor through
the on-off switch on the starter cum control panel. The
compressor automatically unloads before stopping.

Do not remachine valve seats excessively otherwise

there is a danger of breakage.
Remachining has to be extended over the entire seat,
face, including the centre part where 11ft washers or
guide pins are located, in order to avoid any change
of the valve lift.

2. Shut off cooling water.

FOR RECENTLY OVERHAULED UNIT

1. Be certain that all the bolts are tightened securely.
2. Check all locking devices (split pins. circlips, etc.)

The height of the locating pins/dowel pins will alter

after the valve seat has been machined / ground. It is
therefore essential that the height of locating pins/
dowel pins is maintained either by grinding these or
deepening the holes.

3. Follow steps 3-19 mentioned under INITIAL

COMMISSIONING.

MAINTENANCE

When valve seat surface is remachined, a new valve

plate must be used to ensure proper seating.

A) VALVE MAINTENANCE:
1. Valve Dismantling: It is advisable to use a simple
fixture to facilitate dismantling and assembling valves
and also to avoid damage to the valve and inside
locating pins. The holding pins on the fixture do riot
permit the valve to rotate when the self locking nut is
unscrewed.

4. Reassembly & Installation:

a) After the valve has been reassembled, tighten valve
nut to proper torque, using the.fixture. Check valve
plate for free movement.
b) Test valve for leakage and ensure that after testing
it is made dry before installing on compressor.

NEVER SHOULD A VA LV.E BE DIRECTLY

TIGHTENED IN A VICE ON THE SHOULDER. DO
NOT HAMMER ON TH~ WRENCH WHEN
LOOSENING OR TIGHTENING THE NUT.

c) For suction valves equipped with unloaders, the

clearance between valve plate and unloader lifter as
well as the clearance between unloading piston and
lifter is to be checked.

2. Valve Cleaning: Examine all parts thoroughly when

the valve Is dismantled. When cleaning a valve, a
thorough soaking in trichlorethlyene followed by
brushing with soft brush or a light scraping will
remove any carbon formation. Be careful not to
scratch the valve plates or seats and before installing
a valve on the compressor, be .absolutely sure that it
is completely dry, else the presence may cause an

d) When reinstalling valves, do not interchange

suction and discharge valves. Also, do not install
discharge valves upside down failing which adanger
of explosion and damage can occur.
e) Valve cover nuts, holding the valve and valve cover
in place, have to be tightened to specific torques,or

11

else there is a danger of either valve or valve seat

falling into the cylinder causing severe damage.

the piston Butts. against a shoulder on the rod.

Install nut and tighten with specified torque. Align the
cut of the nut to milled slot on piston rod and with a
blunt punch lock piston nut to piston rod.

AFTER ALL THE VALVES ARE INSTALLED. ROTATE

COMPRESSOR
MANUALLY
ATLEAST
ONE
COMPLETE REVOLUTION TO BE CERTAIN THAT
THERE IS NO INTERFERENCE WITH MOVING
PARTS.

2. Be certain packing rings and springs are installed

correctly. The stamped face of teflon packing ringscan
either face to cylinder side or krankcase side refer
following fig.

During dismantling and reassembly, special care

must be taken. The sequence of reassembly is
indicated in the Spare Parts List.

Whenever replacing a valve plate, the valve seat be

slightly ground on plain surface with fine grinding
paste to remove the roughness and scratches. Clean
all parts and reassemble the valve and check for free
movement of valve plate. Also check valve for leakage.

B) COMPRESSOR CYLINDERS:
The following general instructions for disassembly
and reassembly of compressor cylinder applies to all
stages.

The stamping is done for matching three pieces.

Stampings on two pieces should come near to each
other.

(FOR REFERENCE. SEE THE SECTIONAL CYLINDER

DRAWINGS SHOWN IN THE SPARE PARTS LIST)
To disassemble the cylinder the following procedure
must be followed:

The circular cuts on the periphery of oil wiper rings

halves should be towards the crankcase. The flat
surface having rac;lial slots should face towards
cylinder. .

a) Drain water from the cylinder and remove water, oil

and process piping as required.

The brass ring fitted in sealing ring should come

towards crankcase side.

b) Be certain air pressure has been bled off all

cylinders.

3. Be certain that the piston is properly placed in the

cylinder. The total bumping clearance of frame end
and outer end be divided as mentioned in the
clearance chart.

c) Remove all sucti9n and discharge valves.

d) Remove bolts or- nuts from outer head.

4. Be certain piston rings and their grooves are clean.

for C.i. pilston rings in lube models, it is desirable
before assembling the rings on the pistons to try each
ring in the cylinder for fit and make sure that piston
ring end gap is maintained as specified. File the
ends of the rings, if necessary, to obtain this
clearance.

e) Remove outer head.

f) Remove packings from inner head.
g) Loosen crosshead nut and piston rod out of the
crosshead and remove nut from rod.
h) Push piston from cylinder with block between
crosshead and piston rod. After section of piston
emerges from cylinder attach rope around piston and
attach either to crane hook or toa bar held by one/ two
persons as applicable. Remove the piston assembly.

When assembling the rings on the piston make sure

that the rings are free in the grooves and do not bind
at any point. This can be checked by rotating the rings
the grooves completely with respect to the piston.
New rings will be required if side clearance or ring
gap clearance is equal to, or greater than clearances.
Refer Clearance Chart given in Appendix.

i) Remove bolts and nuts from frame end head or

from cross slide as applicable. If complete cylinder
heads and cylinder is removed ensure that the inter
cooler is removed first.

5.The cylinder needs replacement if worn excessively.

Check for maximum diametrical I clearance between
cylinder and piston. Refer Clearance Chart given in
Appendix.

j) Piston can be pressed out and removed from

piston rod after removal of piston nut.
Reassembly of the compressor cylinder can be
accomplished by reversing the procedure of
disassembly, and in addition the following items
must be carefully assembled and checked.

6. Be certain that the cross head nut is tightened as

per specified torque.

D) LUBE OIL COOLER (If fitted) :

This is a shell and tube type oil cooler. The cooling
medium is water which is forced through the tubes.
while the oil is forced through the shell side of the oil

C) PISTON:
1. It is necessary to press the piston on the rod until

12

13

Pump end

Oil Drain

Plug

Drive end

Oil Pressure Gauge

Connection

To Crosshead thru chok

Plug

MODEL HX BEARING FITMENT & LUBRICATION

Oil inlet to Main Bearing

frame (drive end side). Install locator (1) from

beltwheel end. Locate 99ide (2) in the centre of
locator (1). Insert sub-cooled bearing in proper
position. Matching of oil-holes is ensured by inserting
a rod through oil-hole. After fixing first bearing install
spacer (3). The distance between two main bearings
is decided by thickness of spacer. Assemble second
sub-cooled bearing in a similar way.

cooler
The tube or water side of the cooler can be inspected
I by removing the end bonnets/headers. Dirt and
foreign matter can be removed either by chemica
cleaning or a rotary brush. The shell side should be
cleaned in trichloroethylene bath and flushed with
clean air.

E) LUBE OIL SYSTEM:

ii. Assembly of 1 main bearing in pump-end-cover

(driven side) is also similar. The same locator (1) and
Gufde (2) are to be used.

a) Suction :- This strainer is located on the lube oil

suction pipe in the compressor sump. It is very
important that this strainer be cleaned as a build-up
of foreign matter around the strainer will cause a drop
in oil pressure. The strainer should be cleaned each
time the oil is changed in the compressor or more
often if the lube oil pressure begins to drop. The
strainer is cleaned by unscrewing it from the lube oil
suction line. and then washing it in a solvent.
Reassemble by reversing the above operations.

NOTE: In HX models, oil gorges (two numbers per

bearing) come at sides when bearings are in
assembled condition.
b. Assembly of New Main Bearings In HN Model
i. Fitment of 2 main bearings in flywheel end cover
First note positions of oil-holes in bearings and
housing. Install locator (1) from belt-wheel end.
locate guide (2) in the centre of locator (1) Assemble
sub-cooled bearing in proper position. Matching of oilholes is ensured by inserting a rod through oil. hole.
After fixing first bearing install spacer (3) The distance
between two bearings is decided by thickness of
spacer. Assemble second sub-cooled bearing in a
similar way.

b). Oil filter cartridge type :- It is throw-away type oil

filter. This shotlld be replaced each time the oil is
changed in the compressor or more ofte.n if the lube
oil pressure begins to drop.

DO NOT ATTEMPT TO CLEAN AND REFIT

To remove this filter. hold the complete body
inbetween hands and unscrew anticlock-wise. New
filter be fitted by reversing the above operation. If
necessary a suitable strap wrench may be used.

ii. Assembly of 1 main bearing in pump-end-cover

(driven side) is also similar. The same locator (1) and
guide (2) are to be used.

c) Lube oil Rellefvalve :- The lube oil relief valve is

located on the oil pump assembly. The valve has
been set at the factory and should not require
adjustment.

NOTE: In HN Models, oil gorges (two number per

bearing) come on top when bearings are in
assembled condition.

F) MAIN BEARINGS:

G) REASSEMBLY OF CRANKSHAFT:

The main bearings are full precision and should not

require attention for many months. Failure of oil
pressure or a slight knock some times indicates
main bearing failure.

Ensure that the crankshaft Rifle Drilled holes and

the main pins are absolutely clean and free from
scratches/rough surface.

Two numbers bush type bearings on drive end side

and one number on non drive end side are
interference fit. These bearings can be removed by a
suitable extractor.

Two number thrust washers are fitted, one on each

side of the crank web outer end. The hollow sides of
the thrust washers are to face the crank web as the
lubricating oil is allowed to pass through these.

ASSEMBLY OF NEW MAIN BEARINGS:

H) CONNECTING ROD BEARINGS:

These are prefinished and non-scrapable type of

bearings, little burrs or sharp corners may be
cleaned before fitting. Ensure that the parent bores
are absolutely clean.

The connecting rod bearings are also full precision

and must not be hand fitted or scraped However
sharp corners/burrs be cleaned. Side thrust between
the crank web and connecting rod is limited by the
thrust faces on the connecting rod.

These bearings are fitted in housings by subcoolingin liquid nitrogen. The centre-line is to be
drawn along the oil-hole of the bearing by red sketch
pen to facilitate matching of holes in bearing housing.
This line is extended upto the face of the Qearlng.

Lubrication to the bearings (crank side) is from the

drilled crankshaft and grooved bearings shells.
Piston pin is lubricated by oil passing through rifle
drilled hole of connecting rod.
Half of the crank pin bearing will come off with the.
cap. By lightly tapping, the other half of the bearing can
be removed. For assembly purpose the caps and
rods are numbered.

a. Assembly of New Main Bearings In HX Model

i.Fitment of 2 main bearings in frame (drive end side)
First, note positions of oil-holes in bearings and

14

15

Oil gorges

Oil inlet to
bearing
Oil drain

Oil Pressure Gauge

Connection

Splash oil
enters

Oil seal

Oil gorges

This thin walled Bearing are shrunk fit by cooling in Liquid Nitrogen.
When fitting in Bearing Housing, ensurelubricating oil holes are properly
aligned. The worn out Bearing may be extracted by suitable extractor.

MODEL HN BEARING FITMENT & LUBRICATION

Oil inlet to bearing

Pump end

Bottom
Brg. Hsg.

Drive end

The cross head pin bushing can be pressed from the

eye of the connecting rod. It is recommended that
cross head pin bushings be sub-cooled and. pressed
into place.

normally be cleaned by using steam high pressure

air or if necessary the tube bundle can be immersed
in a vat and boiled in a detergent solution. The type
of cleaning solution will depend upon the type of dirt
or scale to be removed.

Con. rod big end diametrical clearance is taken by

measuring crank pin and con. rod bearing bore.
Crass head pin/piston pin clearance are normally
taken with inside and outside micrometers. Refer
clearance chart .

The following chemicals may be used to remove

heavy carbon deposits.

1. TRICHLOROETHYLENE:
Fill with trichloroethylene through all the openings,
until completely full, blank off all openings to avoid
evaporation loss and keep it for 12 to 16 hours. Blow
with air and clean and refill with clean trichlorethylene
and repeat operation till thoroughly clean.

I) CROSS HEAD:
It is important that the cross heads fit the cross head
guides within the allowable tolerance or excessive
damage may be done. to the cross head or piston rod
and packings. If there is not enough clearance
between the cross head and cross head guide, deep
scorings and wear with seizure will occur. In case of
excessive clearance a knock will be heard while the
unit is in operation and the piston rod may start to rub
against the side of the packing case, which will
damage the rod and in turn damage the packing.

2. CASTROl ATLAS GREESKllLA NO.2 :

Marketed by MIs Castrol. This is in powder form and
is to be mixed up with water in the ratio of 1 kg. of
greeskilla No.2 and 10 Itrs. of water. Heat the solution
to 75 - 90C and circulate through the cooler. After
having cleaned this internally, flush with water and air.

3. CAUSTIC SODA:

When checking the clearance a feeler gauge long

enough to cover the full bearing surface cross-wise

Mix with water and boil.

After having cleaned the cooler internally, flush with
fresh water and air.

should be used. The clearance should be checked

over the full length of the cross head with the cross
head in both extrem end positions.

Cleaning of Oil Cooler and other similar heat

exchangers.

J) CROSS HEAD PIN:

A worn or improperly fitted cross head pin will usually
be indicated by knocking sound coming form the
cross head guide. If allowed to knock, the worn pin
could cause damage to the connecting rod cross
head pin bushing.

Remove the oil cooler form the compressor, set in upright position, ensure that the oil is completely
removed from the cooler, fill up the cooler with 25%
solution of PRODUCT -BWF in water through oil inlet
hole. Ensure that outlet hole is securely closedl
plugged. Also ensure that the oil cooler Is completely
filled with the solution:

K) HEAT EXCHANGERS:
After the unit has worked for three months the water
side of the coolers should be checked for erosion,
corrosion, dirt, scale etc. If any of these are noticed,
a competent water treating engineer should be
consulted for recommendations. After the water has
been properly Treated, yearly inspection of the
water side of the cooler should be sufficient.

Let the solution remain in the oil cooler for atleast 2

hours .If the condition of the oil cooler demands the
solution should be allowed to remain in the cooler
for 8-12 hours. After standing, turn the oil
coolerupside down and drain out the dirty fluid
completely. Rinse the cooler with fresh water 5-6
times and ensure that chemicals are completely
removed washed out. This can be ensured by
checking the pH of fresh water coming out of outlet
with litmus (pH) paper. Fresh water drained out from
oil cooler should show Neutral pH.

At the same time the water side of the coolers is

checked the air side should also be checked for
carbon deposit. Normally the air side of the cooler will
not require cleaning more than once a year, providing
the suction air filter is kept clean.

In case the tubes of air/oil coolers are clogged with

solid carbon particles, itis essential that the solution
of PRODUCT -BWF is circulated with the help of
suitable pump for a period of 2 hours to 8 hours.till
such time the clogging is removed and cooler is
completely cleaned. After the chemical cleaning,
cooler should be rinsed with fresh water through
water jets or pump cleaning/rinsing should be
continued till clear and neutral water starts flowing
from the outlet.

EXCESSIVE HEAT (CAUSED BY VALVE FAilURE) Will

CAUSE CARBON TO FORM AND BE CARRIED INTO
THE COOLERS. IT IS THEREFORE IMPORTANT
THAT THE COMPRESSOR VALVES BE KEPT IN
GOOD CONDITION.
To clean a cooler (water through tubes) remove the
fixed water head, pull tube bundle and remove the
floating head. The inside of the cooler tubes can
normally be cleaned with conventional type of tube
cleaning brushes. The outside of the tube bundle can

16

WARNING!

all times, clean every week.

PRODUCT -BWF IS AN ALKALINE PRODUCT AND AS

SUCH IT IS ADVISABLE TO USE RUBBER HAND
GLOVES AND GOGGLES TO AVOID CONTACT WITH
SKIN OR EYE,S.

After every 2000 hours, the piston must be pulled out

and rotated by one third of a turn i.e. 1200 C. Such
action distributes the load evenly and hence uniform
wear thereby prolonging the life of Teflon parts.

In case of contact with skin or eyes, the affected part.

should be washed with plenty of water and mild boric
solution or boric powder should be applied, if need be
doctors help be solicited.

To maintain piston bumping clearances, either rotate

the piston on piston rod or add a gasket on the outer
air head.
When two or more compressors feed the same
system and one of the compressor is kept idle as
standby, it is recommended that the standby
compressor be run for aUeast an hour every 3rd or
4th day to avoid condensation and corrosion
formation

NOTE: PRODUCT -BWF can also used to remove

carbon and oil/grease for other parts like valves,
bearings, etc. The ideal way to clean such parts is to
immerse these parts in 25% solution of PRODUCT.
I BWF in water and the solution be heated at 60C to
65C for a period of 2 - 2 Yz hours. After this, the parts
should be washed with the help of water jets so that
oil/carbon can be completely washed Qut form. the
parts. After cleaning it is advisable to apply oil/ grease
or kerosene to the parts to avoid corrosion.

ELECTRICALS
This chapter contains general information about the
electricals viz. motor, switch gear, safety devices,
control devices, etc. supplied along with the
compressor package.

Depending upon, the condition of oil and carbon

coating PRODUCT -BWF can be used between 5% to
25% level. At lower concentration, the contact time
should be longer.

SQuirrel cage motors of various ratings and suitable

motor starting melhods are employed according to
the capacity of the compressor.

THIS CHEMICAL SHOULD NOT BE USED

STAR DELTA STARTER:

ON ALUMINIUM OR ITS ALLOYS.

These starters are used where starting current

limitations do not permit the use of DOL starter.

Upon reassembly, be certain all gaskets and 0 ring

surfaces are clean, renew all gaskets and 0 rings,
install heads and evenly tighten all nuts and bolts on
heads.

In Star-Delta starting, the motor ;s started in Star

connedion, the connection being changed over to
Delta when the motor has reached nearly 80% of the
rated speed, and the starting current dropped to the
lowest. By connecting the motor in Star during the
starting period, the impressed phase voltage is
reduced to 58% of the voltage in Delta connection
The corresponding current in Star is thus only onethird that in Delta. By starting in Star the current is
reduced to only about 2-2.5 times the rated current.

The water through the shell type coolers can be

cleaned in similar manner to the water through the
tube type except the disassembly and reassembly
differs.

PRECAUTIONS FOR COMPRESSORS FITTED WITH

NON-LUBRICATED CYLINDERS:

The motor is started in Star and once it has picked

up speed, its connections arli changed over to Delta
by means of a timer. This timing varies from 6-12
sees. or more according to the load factor.

Particular care must be taken for compressors fitted

with non-lubricated cylinders. Corrosion on
nonstainless steel elements requires thorough
investigation. The lack of an oil film on the non
lubricated cylinder walls subject the same to severe
c,:mosion caused by condensation. Therefore, the
cylinder walls must be protected against corrosion
and the causes for condensation be eliminated.

OVERLOAD PROTECTION RELAY:

The prevention of damage a motor due to excessive
current is an important function of motor starter.
Excessive current may be due to either of the
following; mechanical overload on the motor; electrical
system, unbalanced supply voltage, single phasing,
defective starter, defect in the motor itself. In either
case it is essential that the supply should! be
disconnected before any damage is done to the
motor. An overload device thus usually operates by
releasing the latching-in device by activating the
operating coil circuit.

Before stopping the compressor the following steps

are to be carried out :
1. Do not keep the compressor idle for long, it should
be run for atleast half an hour every 3rd or 4th day.
2. Unloading piston in suction valve cover must be
cleaned aUeast once in a month and slight grease or
silicone be applied to avoid sticking.

Thermal Overload Relay:

This consists of strips of bi-metal, since the action is

3. The suction air filter element must be kept clean at

17

due to their heating up. a time element ia always

present. The action of a bi-metal strip overload
release depends on the movement resulting from the
different rates of expansion of the two metals forming
t the combined strip when heated. The bi-metal strip
i may be directly heated by the current or indirectly
heated by a coil of resistance wire which carries the
current. Thermal trips are usually of the hand reset
type, the reset feature is combined with the relay.

crankcase to the oil pressure gauge, through a tee

connection.
The bellows of the pressure switch is connected to
the oil line. The main spring can be set to balance
different pressures on the bellows. When the
pressure increases, the bellows is affected so that
the main spindle is moved upwords until the spring
pressure balances the bellows pressure. The
spindle has a guiding knob and a differential
adjusting nut which jointly transmit the spindle
moverments to the switch.

Setting of the relay:

For closer protection of the motor, particularly against
single phasing condition, the bi-metal overload relay
is connected in the phase circuit. The relay has been
factory set at 0.6 times the actual line current drawn
by the motor, as measured by an ammeter, In case
the setting has been disturbed, please follow the
following steps:

Low oil pressure switch has to function when the oil

pressure falls below the minimum pressure required
by the compressor. Therefore, the differential has to
be set at zero, and the main scale is set to the
required pressure (minimum oil pressure required by
the compressor) by rotating the knob on the switch.
Connect an ohm meter across normal open contacts
of the switch to observe the switch operation. Start the
compressor and watch the pressure at which the
contact closes. Then, stop the compressor to see at
what pressure the contact opens. By adjusting the
knob further, fine adjustment can be done. to the
exact pressure required. So confirm the setting by
starting and stopping the compressor or by adjusting
the oil pressure regulator. Then set the regulator in
its original position.

1. Sart the motor with the overload relay setting at 0.6

times the rated motor current for Star-Delta starter.
2. After the motor reaches peak load condition,
reduce the relay setting gradually till the relay trips.
3. Set the relay slightly higher than the tripped value.
4. To check that this setting is correct, allow the relay
to cool, and then restart the motor and make sure that
it does not trip during starting. If it does, increase the
relay setting slightly and check again.

Since the switch remains open during starting, a

normally closed contact of a timer is connected
across the normally open contact of the switch. The
timer is set for 30 sees. As the compressor starts,
the timet starts its timing cycle, the compressor oil
pressure also starts building up . In 30 sees. the
timer contact will open. Since the oil pressure is
already developed, LOPS contact closes and the
compressor runs in the healthy condition.

5. To check the tripping, increase the unloading

pressure setting by 1 kg/cm2 (say 8 kg/cm 2, for a
compressor set to unload atf 7 kg/cm 2) when the
current increases above the normal peak load
current, the relay should trip. If it does not trip, slightly
reduce the setting.

SAFETY DEVICES:
The following safety devices are used to protect the
compressor from damages likely to occur if any of the
systems fails due to any reascm.

In case the oil pressure does not build up due to any

I reason, these contacts will remain open and will trip
the compressor motor in 30 sees. time.

1. Low oil pressure switch.

2. LOW COOLING WATER PRESSURE

SWITCH (LCWPS) :

2. Low cooling water pressure switch.

Operating of this switch is same as that of Low. Oil

Pressure Switch discussed ea~ier. This switch is
connected in the water outlet line.

3. High discharge air temperature controller.

The electrical contacts of the above switches are
connected either to a common annunciator or PLC.
The connections are in series with the no-volt coil or
under voltage release or hold-on contact of the starter
so as to enable the starter to operate in healthy
condition. When any failure occurs in any of the
systems during operation, the switches trip the
starter by de-energizing th no-volt coil or the under
voltage release to stop the compressor.

Open the water line. throttie the inlet value to

maximum flow available, .keeping the water outlet
valve fuliy open. I Now set the main scale of the
pressure switch till normally open contact doses,
then stop the water supply to the compressor, now
the closed contact of presure switch should open.

1. LOW OIL PRESSURE SWITCH (LOPS) :

3. HIGH DISCHARGE AIR TEMP.

CONTROLLER:

The function of this switch is to monitor the oil

pressure in the compressor. This switch is connected
in the oil pres~ure sensing line coming from the

This is a digital type controller with RTDs (Resistance

Temperature Detectors) as sensors. The RTQs are
connected to the controller by flexible RTD cable

18

WARNING !

neatly laid throug cable trays. The temperature

controller is factory set at 170C.

IF STUDS ARE REMOVED FOR ANY REASON,

REFITMENT SHOULD BE DONE USING THREAD
SEALANT
COMPOUND
lOCTITE
542
OR
EQUIVALENT.

SOLENOID VALVES:
The compressor package uses normally. open (NO)
type. 3-way solenoid valve having 3 ports (i) Inlet (ii)
Outlet and (iii) Exhaust.
(i) Inlet Port - Impluse air supply from the discharge
point or receiver through control filter is connected to
this port of the solenoid valve.
(ii) Outlet Port - This is connected to suction valves of
the compressor.
(iii) Exhaust Port - This port is for the escape of
trapped air ir the line. it is always kept open to the
atmosphere.
The NO type of solenoid valve allows air supply to
flow from the inlet port to outlet port. in the deenergised condition. When energised, it stops the air
supply. These are used for capacity control of the
compressor package. hence are connected to the
suction valves.

Maintenance Of Solenoid Valves:

a. For perfect functioning of the solenoid valves,
always use an air filter in the air line connected to the
solenoid valve.
b. Always see if the nut tightening the solenoid coil is
intact. If loose, tighten.

Fault Finding Of Solenoid Valves:

a. Coli Chattering: This may happen due to two
reasons
i. Because of under voltage.
ii. Because of dirt entering the plunger housing of the
solenoid.
Take remedial action accordingly.
b. leaking Valve: This may happen because of the
following reasons
i. The valve is being tested with the outlet port kept
open to atmosphere. In this case, the problem can be
solved by connecting the outlet port to the suction
valves.
ii. Inlet pressure is so low that the pilot mechanism
catinot be actuated. This can be remedied by keeping
the min. pressure above 15 PSI.
iii. Air leaking through the solenoid plunger housing
when the coil is not energised. This can be remedied
by replacing the plunger or plunger plug.
iv. Air leaking through the exhaust port. This may
occur either due to entry of dirt in the valve or due to
worn out sealing components. In the former case,
clean the valve and in the latter, replace the worn out
sealing components.

19

MAINTENANCE AND INSPECTION

SCHEDULE OF STANDARD MAINTENNCE INSPECTION FOR CP COMPRESSOR PACKAGE
SUB ASSY.

PART NAME

ACTION RECOMMENDED

Air suction &

dischare valve

Valve assembly

Rebuild, replace /
Recondition worn out parts.
Replace
Check for wear and lubricate

Valve seat gasket

unloading pistion
Pistion Oring
Valve holder O
ring

Check for wear and replace

Replace

Cylinder bore

Check for wear & ovality

Cylinder jackets
Cylinder heads

Clean & remove scale

Clean & remove scale

Piston

Check bumping clearance

Lube models
Non lube models

C.I. rings
Teflon rings

Check
Check
Check
Check

Piston rods &

Packing rings

Piston rod

Check for scoring

Piston rod nut

Teflon paking
rngs
Oil wiper rings

Check fro tightness

Check for leakage
and replace
Check for leackage
and replace

Cross head
Cross head guide
Cross head pin
and bushing
Main & con. rod
& bearings
Crankshaft
Connecting rod
nut, bolts & split
pins

Check for wear and scoring

Check for wear and scoring
Check for wear and scoring

Frame sump level

Gear pump

Cartidge oil filter

Oil strainer
Oil Pipe conection
Oil cooler
Oil transfer pipe

Check level
Check wear of gears and
bearings
Replace oil and Clean Frame
From within
Replace
Clean
Check for loosening
Clean scale
Replace O rings

Lubricator and
cylinder
lubrication
(lube models
only)

Lubricator oil tank

Oil lines cyl. lyb.
N.R.V. at cylinder

Check and refill

Check for loosening & leakage
Check for carbon & clean

Lubricator tank level

Check level and make up.

Heat exchangers

Tube bundle assly.

Clean scale & carbon check

tubes for chaffing.
Clean from inside
Replace
Check & clean stainer, check
for operation
Check for operation

Cylinder &
clinder heads

Piston & piston

rings

Running Gear

Lubrication
running gear

Frame sump oil

Shell
O Rings & gaskets
Drain trap
Safety valve

for wear & ovality

piston nut for loosening.
end gap
wear & rotate 1200C.

Check for wear

Check for wear
Check for tightness & locking
Replace bolts & nuts

20

AFTER PERIOD OF EVERY (Hrs.)

50 500 1500 3000 4500 6000 10000/AS
& WHEN
REQD.

SUB ASSY.

PART NAME

ACTION RECOMMENDED

Suction filter

Filter element

AFTER PERIOD OF EVERY (Hrs.)

50 500 1500 3000 4500 6000 10000/AS
& WHEN
REQD.

Clean
Replace

Subject to local
enveironment, if
bad advance)
Bolts & nuts

Cylinder & Cross

Slide nuts

Check for loosening and

tighten

Motor alignment
and belt tension

Belt Tension
Motor alignment

Check & adjust

Check & ajust

Instruments

Pressure gauges
Temp. indicator/
controller.
Oil, water, pressure
Switches.

Inspect
Inspect & tighten electrical
connections
Check for operation

Air discharge
piping

Air discharge bottle

Air discharge pipe
Air receiver
Safety Valve
Drain Cock

Clean carborn
Clean carbon
Clean
Check operation
Drain moisture several times a
day

AVMs

Replace

Air Piping

Metalic hose

Replace

Remarks :
: Indicate the time period for the first check after commissioning.
: Indicate the period for check up, adjustment, repair, replacement and refitting.
: This is the enhances time period for all above action if they are found to be satisfactory after check up & operaton at
abovemarked ( and
) periods.
Switching over to this period may only be done after experiencing it at least twice that the above marked period do not
show any remarkable need for check up.

21

FAULTS AND REMEDIES:

The following chart has been prepared indicating troubles, probable causes and remedies as a guide to
assist in locating troubles:

Compressor dose not start:

Set recommended lubrication oil pressure
Set recommended cooling water flow
Check electrical systems or compressor for overload
Release the push button

1. Lube. oil pressure low

2. Cooling water pressure low
3. Motor overloaded
4. Emergency stop push button pressed

Noise in cylinder:

Broken piston rings

Check piston nut for tightness.

Check bumping clearance and also tighten cross
head nut. if required.
Check; replace as necessary. and hone score marks
in cylinder bore.

6.

Check. replace. reassemble.

Check. replace. reassemble.
Check oil flow to the cylinder

4.
5.

Valve assembly not seated properly

Leaking valve.
Piston rings lubrication
(Only in lube models)
Loose piston on rod.
Piston hitting head.

1.
2
3.

Excess carbon .on compressor valves:

1.

Excessive amount of lubricating oil being

placed on piston (Only in lube models)
2. To long operation without cleaning
3. Poor quality of lubricating oil
4. Piston rings stuck in grooves or worn out.
3. Air filter system is dirty.

Reduce oil flow

Establish definite periods of cleaning.
Use recommended oil.
Clean or replace as required.
Clean, repair or replace.

Safety valve popping:

Compressor valve failure

3.

Check for leakage.

Check for air pressure at which safety valve blows.
Set safety valve to correct pressure.
Check interstage pressure: if not normal. check
compressor valves for leakage and check for broken
piston rings.

Safety valve faulty

Wrong setting.

1.
2.

No oil pressure recorded at gauge when starting:

Fill to proper level.
Repair or replace
Check and clean if necessary
Replace.
Replace
Check & refit or replace if necessary

Compressor crankcase knocks:

1.
2.
3.

Loose crosshead pin. crankpin bearings.

main brgs.
Crosshead
Lack of lubrication

4.

Loose con-rod bolts

Check and repair or replace if necessary

Check and replace as necessary
Check oil pressures and for chokedline to part
causing the knock.
Check for tightness

22

No oil in Frame.
Broken oil line.
Clogged oil line
Broken or defective oil pressure gauge
Broken oil pump shaft
Main bearing rotated

1,
2.
3.
4.
5.
6.

Low Air Pressure

Low pressure suction or discharge

Repair or replace valves.

Valve leaking.
Repair or replace.
Tighten

2.
3.

Leaking intercooler section

Leaking pipe between cylinders and
heat exchanger
4. Worn cylinders or rings in low pressure
cylinders
5. Drain cocks open
6. Suction air filter clogged

Repair or replace
Close
Clean or replace.

1.

Heat exchanger does not cool effectively:

Clean outside of tube bundle
Set the water flow rate correctly as per
recommendations.

23

Use recommended grade of oil

Replace
Tighten or replace
Clean thoroughly
Repair or replace
Repair or replace
Repair or replace
Replace cartridge oil filter

1. Incorrect grade of oil

2. Loose bearings due to wear
3. A leaking or broken oil pipe
4. Clogged inlet strainer at pump
5. Defective gauge
6. Defective oil pump
7. Defective relief valve
8. Oil filter clogged

Lubrication 011 pressure drops:

Dirty tubes.
Insufficient water supply

1.
2.

Failure to deliver air

Insufficient capacity
Insufficient pressure
Compr. running gear over heats
Comp. cylinder over heats
Compressor knocks
Compressor vibrates
Excessive intercooler pressure
Intercooler pressure low
Receiver pressure high
Discharge air temperature high
Cooling water disch. temp. high
Motor fails to start
Motor over heats
Valves over heat

TROUBLE SHOOTING CHART FOR RECIPROCATING COMPRESSORPACKAGE

(Check list for compressor inspection & observation

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Restricted suction line
Dirty air filter
Worn or broken valves L.P.
Defective unloading system L.P.
Defective Unloading sysem H.P.
Excessive system leakage
Speed incorrect
Worn piston rings L.P.
Worn piston rings H.P.
System demand excessed compressor capacity
Inadequate cooling water quantity.
Excessive dischare pressure
Inadequate cylinder lubrication
Inadequate runninggear lubrication
Incorrece electrical characteristics
Motor too small
Excessive belt tension
Voltage low
Loose flywheel pulley
Excessive bearing clearance
Loose piston rod nut
Loose Motor rotor or shaft
Excessive crosshead clearance
Insufficient head clearance
Loose piston
Running unloaded too long
Abnormal interstage pressure
Dirty intercooler
Dirty cylinder jackets
Motor overload relay tripped
Worn out AVMs

24

APPENDIX I
LUBRICATING OIL
1. RECOMMENDEDBRANDS OF OIL
Manufacturer

Ambient Temp.
+ 0 to + 15 Deg. C

Ambient Temp.
+ 15 to + 48 Deg. C

Indian Oil Corporatin

For Crankcase
For Cylinders

Servo Press 150

Servo Press C 150

Servo Press 220

Servo Press C220

Hindustan Petroleum

Enklo 150

Enklo 220

Bharat Petroleum

Bharat Hydrol 150

Bharat Hydrol 220

Cstrol

Castorl Hyspin AWS 150

Castrol Hyspin AWS 220

2. OIL SUMP CAPACITY

Model

Oil Sump Capacity

HX

15 Litres

HN

35 Liters

3. OIL PRESSURE
Model

Oil Pressure kg/cm2g

HX
Hn

1.5 in steady condition

4. CYLINDER LUBRICATION
All models

For the first month

Subsequent

LP & HP

5-6 drops/min.

3-4 drops/min

NOTE : FOR PROPER DISPOSAL OF USED OIL PLEASE ADHERE TO LOCAL

ENVIRONMENTAL REGULATIONS

25

APPENDIX II
RUNNING CLEARANCES, WEAR LIMITS FOR HX MODELS
SR.

COMPONENT
CLEARANCE
mm

RUNNING
LIMITS
mm

WEAR

Diametrical clearance main bearings

0.05 / 0.10

0.25

Diametrical clearance con. rod big end bearing

0.06 / 0.11

0.25

Diametrical clearance small end bush and

crosshead pin

0.04 / 0.09

0.20

Diametrical clearance crosshead and guide

0.15 / 0.25

0.50

5.

Crankshaft end float / axial clearance

0.25 / 0.50

0.82

Connecting rod big end side clearance

0.22 / 0.36

0.50

Piston bumping clearance - outer end.

Both cyls.
Piston bumping clearance - frame end.
Bumping clearance shall be 2:1 ratio
i.e. outer end 2 and frame end 1

2:1 Ratio

C.I. Piston ring end gap (Lube. models)

Min : 0.3/100 mm of cyl.

Mix : 1 / 100 mm of cyl.

Teflon piston ring end gap (Non lube. models)

Min : 2.4/100 mm of cyl.

Mix : 8 / 100 mm of cyl.

10

Diametrical clearance between piston

and cylinder (Lube. Models)
a. C.I. Piston

Min : 0.1/100 mm of cyl.

Mix : 0.4/100 mm of cyl.
Min:0.15/100 mm of cyl.
Mix : 0.4/100 mm of cyl.

b. Aluminum piston
11

Diametrical clearance between piston and cylinder

(Non-lube models)
Aluminum Piston
Teflon rider ring will protrude out from rider
ring groove
Min. 0.5 mm (Max. wear limit)

3 to 4

12

Main journal dia. X length

69.970 / 69.951 x 153

13

Crankpin dia. X length

69.994 / 69.993 X 46

RUNNING CLEARANCES,WEAR LIMITS FOR HN MODELS

SR.

COMPONENT
CLEARANCE
mm

RUNNING
LIMITS
mm

WEAR

Diametrical clearance main bearings

0.14 / 0.22

0.3

Diametrical clearance com. rod big end bearing

0.08 / 0.15

0.3

Diametrical clearance small end bush and

crosshead pin

0.06 / 0.12

0.3

Diametrical clearance crosshead and guide

0.18 / 0.26

0.6

Crankshaft end float / axial clearance

0.40 / 0.70

0.9

Connecting rod big end side clearance

0.33 / 0.42

0.6

Piston bumping clearance - outer end.

Both cyls.
Piston bumping clearance - frame end.

2:1 ratio

Main journal dia. X length

Crankpin dia. X length

110.00 / 109.978 X 191.5

110.00 / 109.978 X 55.0

26

APPENDIX III
TORQUES
1.

GENERAL TORQUES
BOLT DIA.
mm

kg-m

TORQUE
ft-lbs

10

1.5

11

12

2.7

19.77

14

4.3

31.5

16

6.8

49.8

18

9.3

68

20

13

95.2

22

18

131.8

24

22

161

27

33

241.5

30

45

329.5

2 . SPECIFIC TORQUES FOR COMPRESSOR COMPONENTS

CMPONENT

TORQUE kg-m
HX

Connecting rod bold

Valve helilock nut (This nut can be used

3 to 4 times and there after must be replaced)

4
5

HN
9

22

2/2.45

Piston rod nut

67.2

110

Crosshead nut

62

67.5

3. SPECFIC TORQUES FOR VALVE HOLDER NUTS

THREAD SIZE
mm

TORQUE kg-m
MIN.

MAX

MIN

TORQUE ft-lbs
MAX.

1.00

1.2

7.25

8.68

10

2.00

2.45

14.5

17.72

12

3.60

4.40

26.03

31.82

14

5.70

6.90

41.25

50.00

16

9.00

11.00

65.10

79.56

18

12.50

15.00

90.04

108.50

20

17.80

29.50

128.75

155.51

22

24.50

29.50

177.21

213.37

24

30.50

37.00

220.60

266.62

27

33.00

40.00

238.69

289.32

30

45.00

54.00

325.48

390.58

27

OWNERSHIP DATA
Unit type: ...........................................................................
Motor type: .......................................................................
Delivery date: ...................................................................
Service Plan: ....................................................................

Owners machine No.: ...............................................................

Unit Serial No.: ......................................................................
Motor serial No.: ....................................................................
First start-up date:
Capacity: ...............................................................................

Local CP Representatives
Name: .........................................................................................................................................................................................................
Address: ......................................................................................................................................................................................................
Telephone: ............................................................................ Contact persons:
Service: .............................................................
Telex: ....................................................................................
Parts .................................................................

SAFETY PRECAUTIONS
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
In addition to normal safety rules which should be observed with stationery air compressors and equipment, the following safety directions and precautions
are of special importance.
When operating this unit, the operator must employ safe working practices and observe all related local work safety requirements and ordinances.
The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.
Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent personnel.
Normal ratings (pressures, temperatures, time settings etc.) shall be durably marked.
Any modifications on the compressor shall only be performed in agreement with CP and under supervision of authorized, competent personnel.
6.
If any statement in this book, especially with regard to safety, does not comply with
local legislation, the stricter of the two shall apply.
These precautions are general and cover several machine types and equipment;
hence some statements may not apply to the unit(s) described in this book.

Arrange the air intake so that loose clothing of people cannot be sucked in.

7.

Ensure that the discharge pipe from the compressor to the after cooler or air
net is free to expand under heat and that it is not in contact with or close to
flammable material.

8.

No external force may be exerted on the air outlet valve; the connected pipe
must be free of strain.

9.

If remote control is installed, the unit shall bear an obvious sign reading:

Installation
Apart from general engineering practice in conformity with the local safety regulations,
the following directives are specially stressed:
1.

DANGER: This machine is remotely controlled and may start

without warning.

A compressor shall be lifted only with adequate equipment in conformity with

local safety rules.

As a further safeguard, persons switching or remotely controlled

units shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.

Loose or pivoting parts shall be securely fastened before lifting. It is strictly

forbidden do dwell or stay in the risk zone under a lifted load. Lifting acceleration
and retardation shall be kept within safe limits.
Wear a safety helmet when working in the area of overhead or lifting equipment.
2.

3.

Any blanking flanges, plugs, caps and desiccant bags shall be removed
before connecting up the pipes. Distribution pipes and connections shall be of
correct size and suitable for the working pressure.
Place the unit where the ambient air is as cool and clean as possible. If
necessary, install a suction duct. Never obstruct the air inlet. Care shall be
taken to minimize the entry of moisture with the inlet air.

4.

The aspirated air shall be free from flammable fumes or vapours, e.g. paint
solvents, that can lead to internal fire or explosion.

5.

Air-cooled units shall be installed in such a way that an adequate flow of

cooling air is available and that the exhausted air does not recirculate to the
inlet.

10. On units with automatic start-stop system, a sign stating This

machine may start without warning shall be attached near the
instrument panel.
11.

In multiple compressor systems manual valves shall be installed to

isolate each compressor. Non-return valves (check valves) shall not
be relied upon for isolating pressure systems.

12. Never remove or tamper with the safety devices, guards or insulations
fitted on the unit. Every pressure vessel or auxiliary installed outside
the unit to contain air above atmospheric. pressure shall be protected
by a pressure-relieving device or devices as required.

SAFETY PRECAUTIONS (CONTINUED)

13.

Pipework or other parts with a temperature in excess of 80 degress celsius

and which may be accidentally touched by personnel in normal operation shall
be guarded or insulated. Other high-temperature pipework shall be clearly
marked.

14.

If the ground is not level or can be subject to variable inclination, consult

Chicago Pneumatic.

15.

to the srarting equipment.

4.

Before removing any pressurized component, effectively isolate the unit from
all sources of pressure and relieve the entire system of pressure.

5.

Never use flammable solvents or carbon tetrachloride for cleaning parts.

Take safety precautions against toxic vapours of cleaning liquids.

6.

Scrupulously observe cleanlines during maintenance and repair. Keep

dirt away by covering the parts and exposed openings with a clean cloth,
paper or tape.

7.

Never weld or perform any operation involving heat near the oil system.
Oil tanks must be completely purged. e.g. by steam-cleaning, before
carrying out such operations.

The electrical connections shall correspond to the local codes. The

units shall be grounded and protected against short circuits by fuses.

Operation
1.

Air hoses shall be of correct size and suitable for the working pressure.
Never use frayed, damaged or deteriorated hoses. Use only the correct
type and size of hose and fittings and connections. When blowing through
a hose or air line, ensure that the open end is held securely. A free end
will whip and may cause injury. Make sure that a hose is fully
depressurized before disconnecting it.

Never weld on, or in any way modify, pressure vessels.

Whenever there is an indication or any suspicion that an internal part of
a machine is overheated, the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling time has elapsed; this
to avoid the risk of spontaneous ignition of the oil vapour when air is
admitted.

Never play with compressed air. Do not apply it to your skin or direct an
air stream at people. Never use it to clean dirt from your clothes. When
using it to clean equipment, do so with extreme caution and use eye
protection.
2.

The compressor is not considered as capable of producing air of

breathing quality. For breathing air quality, the compressed air must be
adequately purified according to local legislation and standards.

Never use a light source with open flame for inspecting the interior of
machine, pressure vessel, etc.
8.

Make sure that no tools, loose parts or rags ae left in or on the unit.

9.

Before cleaning the unit for use after maintenance or overhaul, check
that operating pressures, temperaturea and time settings are correct
and tha the control and shut-down devices function correctly. If removed,
check that the coupling guard of the compressor drive shaft has been
reinstalled.

3.

Never operate the unit when there is a possibility of taking in flammable

or toxic fumes.

4.

Never operate the unit at pressures below or in excess of its limit ratings
as indicated on the Principal Data sheet.

10.

Keep all bodywork doors shut during operation. The doors may be opened
for short period ony e.g. to carry out checks. Wear ear protectors when
opening a door.

Every time the separator element is renewed, examine the discharge

pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.

11.

People staying in environments or rooms where the sound pressure

level reaches or exceeds 90 dB (A) shall wear ear protectors.

Protect the motor, air filter, electrical and regulating components, etc. to
prevent moisture from entering them e.g. when steam-cleaning.

12.

Make sure that all sound-damping material, e.g. on the bodywork and in
the air inlet and outlet systems of the compressor, is in good condtions.
If damaged, repalce it by genuine CP material to prevent the sound
pressure level from increasing.

5.

6.
7.

Periodically check that:

a.
b.

13.

Never use caustic solvents which can damage materials of the air net,
e.g. polycarbonate bowls.

There are no leaks

14.

The following safety precautions are stressed when handling refregerant:

d.

All fasteners are tight

e.

All electrical leads are secure and in good order.

f.

Safety valves and other pressure - relief devices are not obstructed
by dirt or paint.

g.

9.

All hoses and / or pipes inside the unit are in good condition, secure
and not rubbing.

c.

8.

All guards are in place and securely fastened

Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves,
hoses, etc. are in good repair, free of water or abuse.

If warm cooling air from compressors is used in air heating systems e.g.
to warm up a workroom, take precautions against air pollution and
possible contamination of the breating air.
Do not remove any of, or tamper with, the sound - damping material.

Maintenance
Maintenance and repair work shall only be carried out under supervisior of
someone qualified for the job.
1.

Use only the correct tools for maintenance and repair work.

2.

Use only genuine spare parts.

3.

All maintenance work, other than routine attention, shall only be

undertaken when the unit is stopped, the main power supply is switched
off and the machine has cooled down. Take positive precaution to ensure
that the unit cannot be started inadvertently. In addition, a warning sign
bearing a legend such as work in progress; do not start shall be attached

a
b

Always wear special gloves. In case of regrigerant contact with

the skin, rinse the shin with water. If liquid refrigerant contacts the
skin through clothing, never tear off or remove the latter; flush
abundantlty with fresh water over seek medical until all regrigerant
is flushed away; then seek medical first aid.

c
15.

Never inhale refrigerant vapours. Check that the working area is

adequately ventilated; if rquired, use breathing protection.

Always wear safety glasses.

protect hands to avoid injury from hot machine parts, e.g. during draining
of oil.

Note :

With stationery machine units driven by an internal

combustion engine, allowance has to be made for extra
safety precautions, e.g. spark arrestors, fuelling care, etc.
Consult Chicago Pneumatic.

All responsibility for any damage or injury resulting from neglecting

these precautions, or by non-obsrvance of ordinary caution and due
care required in handling, operating, maintenance or repair, even if not
expressly mentioned in this book, will be discalimed by
Chicago Pneumatic.