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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.
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.
4.
5.
6.
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
22
12
24
APPENDICES
I LUBRICATING OIL
II RUNNING CLEARANCES AND WEAR LIMITS
III TORQUES
25
26
27
INTRODUCTION
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.
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
Choke
Connecting rod
Oil filter
Strainer
FRAME LUBRICATION
Belt wheel
Oil pump
LUBRICATION SYSTEM
FRAME LUBRICATION
OIL GRADE
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 !
CYLINDER LUBRICATION
(Lube model only).:
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.
CAPACITY CONTROL
WARNING!
BEFORE REACHING INTO A CYLINDER, EVERY
6
EASY INSTALLATION:
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.
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.
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.
LOCATION
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
RECEIVER
NOTE :
1. ENSURE THAT THE AVM PROTECTION SPACERS
PAINTED IN RED ARE REMOVED BEFORE
COMMISSIONING.
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. .
ROUTINE STARTING
10
control panel.
explosion.
temperatures
(especially
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.
MAINTENANCE
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.
11
B) COMPRESSOR CYLINDERS:
The following general instructions for disassembly
and reassembly of compressor cylinder applies to all
stages.
C) PISTON:
1. It is necessary to press the piston on the rod until
12
13
Pump end
Oil Drain
Plug
Drive end
Plug
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.
F) MAIN BEARINGS:
G) REASSEMBLY OF CRANKSHAFT:
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.
14
15
Oil gorges
Oil inlet to
bearing
Oil drain
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.
Pump end
Bottom
Brg. Hsg.
Drive end
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.
3. CAUSTIC SODA:
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.
16
WARNING!
ELECTRICALS
This chapter contains general information about the
electricals viz. motor, switch gear, safety devices,
control devices, etc. supplied along with the
compressor package.
17
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.
18
WARNING !
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.
19
PART NAME
ACTION RECOMMENDED
Valve assembly
Rebuild, replace /
Recondition worn out parts.
Replace
Check for wear and lubricate
Cylinder bore
Cylinder jackets
Cylinder heads
Piston
Lube models
Non lube models
C.I. rings
Teflon rings
Check
Check
Check
Check
Piston rod
Cross head
Cross head guide
Cross head pin
and bushing
Main & con. rod
& bearings
Crankshaft
Connecting rod
nut, bolts & split
pins
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)
Heat exchangers
Cylinder &
clinder heads
Running Gear
Lubrication
running gear
Shell
O Rings & gaskets
Drain trap
Safety valve
20
SUB ASSY.
PART NAME
ACTION RECOMMENDED
Suction filter
Filter element
Clean
Replace
Subject to local
enveironment, if
bad advance)
Bolts & nuts
Motor alignment
and belt tension
Belt Tension
Motor alignment
Instruments
Pressure gauges
Temp. indicator/
controller.
Oil, water, pressure
Switches.
Inspect
Inspect & tighten electrical
connections
Check for operation
Air discharge
piping
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
Noise in cylinder:
6.
4.
5.
1.
2
3.
3.
1.
2.
4.
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.
2.
3.
Repair or replace
Close
Clean or replace.
1.
23
Dirty tubes.
Insufficient water supply
1.
2.
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
Hindustan Petroleum
Enklo 150
Enklo 220
Bharat Petroleum
Cstrol
HX
15 Litres
HN
35 Liters
3. OIL PRESSURE
Model
HX
Hn
4. CYLINDER LUBRICATION
All models
Subsequent
LP & HP
5-6 drops/min.
3-4 drops/min
25
APPENDIX II
RUNNING CLEARANCES, WEAR LIMITS FOR HX MODELS
SR.
COMPONENT
CLEARANCE
mm
RUNNING
LIMITS
mm
WEAR
0.05 / 0.10
0.25
0.06 / 0.11
0.25
0.04 / 0.09
0.20
0.15 / 0.25
0.50
5.
0.25 / 0.50
0.82
0.22 / 0.36
0.50
2:1 Ratio
10
b. Aluminum piston
11
3 to 4
12
13
69.994 / 69.993 X 46
COMPONENT
CLEARANCE
mm
RUNNING
LIMITS
mm
WEAR
0.14 / 0.22
0.3
0.08 / 0.15
0.3
0.06 / 0.12
0.3
0.18 / 0.26
0.6
0.40 / 0.70
0.9
0.33 / 0.42
0.6
2:1 ratio
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
TORQUE kg-m
HX
4
5
HN
9
22
2/2.45
67.2
110
Crosshead nut
62
67.5
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: ....................................................................
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.
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.
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.
14.
15.
Before removing any pressurized component, effectively isolate the unit from
all sources of pressure and relieve the entire system of pressure.
5.
6.
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.
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 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.
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.
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.
11.
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.
13.
Never use caustic solvents which can damage materials of the air net,
e.g. polycarbonate bowls.
14.
d.
e.
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.
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.
3.
a
b
c
15.
protect hands to avoid injury from hot machine parts, e.g. during draining
of oil.
Note :