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LeROI.
RCT-INST0O1 Rev 6 -8108
ECN 4U31ó
t
ROTARY COMPRESSION TECHNOLOGIES, INC.
THANKS YOU FOR PURCHASING LEROI GAS
COMPRESSORS, MODULES AI{D PARTS
Safety lnformation and Warnings
lnstallation 17-18
Rebuild Kits 30
Website 31
Contact List 32
Service Diagnosis 34
Warranty 35
Safetv Information and §Tarnings
LeROI gas compressors are designed with safety in mind. Howeveq there is no substitute
for safe operating procedutes. Throughout this manual üere will be additional "Notes",
"Caud.ons" and'qWarnings" intended to ptotect the operator and the equipment. These
additions are not all inclusive. Extueme care must be exetcised when operating or servic-
a Never serl-ice a unit with the pressure in the receiver-oil reservoir unless
Never serr-ice a unit without disconnecting and locking out the electrical
Take a1l riecessary precautions, when ad)usring controls, etc., to prevent elec-
trical shock.
Take all necessary precautions when rvorking \r1th flammable gases to pre-
IF THE CON{PRE.SSOR §rILL NOT E,NTER S;i.-,,-]I-E \\-ITHIN ONE, \'EEK OF BE,ING
RECEI\'ED, COMPRESSOR OIL MUST BE ADDED II]ROUGH THE, GAS INLE,T SO THAT
iTS LE.VEL IS AT LE,AST AS HIGH AS THE BOTTC)],{ OF THE INLE.T CAVITY ALLO§r A FE§r
\II\UTE,S FOR THE, OIL TO FILL INTE,RNT.\T CLE.\R-\\CES THEN ADD TO BRING LE,VE,L
B.\CK UP. REINSTALL THE INLET COVER PL{TE AND BOLT IT DOWN SECURELY.
2
Identifving Your Compres sor
LeROI gas compressots have a nameplate that ptovides valuable informadon
on your compressor. This information is needed for ordering parts and con-
the design of the compressor. Belorv is a Nlodel Designauon chart to help vou
FDrbaresha&comprEssDrs,thefrstletterdesig¡alesLowPrEssureorHighPressureDesign Thisis¡hEsamewheflf6llowirganlü
The next etler designales gas This never changes
When the c0mpressor is drilen ofilhe fema e ro10r inslead ofthe mále rolor (the slandard), an F @ill aplear n this spol
ATwi iFper in lhrs spotfortwo staqe compressErs
AnSorarLwl appearf
3
{Jnder§tanding Your Compre s_s or
\bur compressor is either a LG ,Lc,r Pressure) or HG (Hrgh Pressure) single stage,
positive displacement, oil-flooded scre-¡- compressor. There are two basic general
Orl-flooding provides cooling, lubrication and sealins r üe compressor. The oil must be cooled using either
§-ater or at in a heat exchanger that is properly sized ¡,:,: .ll :,perating conditions.
Geared uruts (Figure 1) come standard with integral ge::::: :l Lncrease or decrease the speed intetnall¡
allorving for direct connecdon with standard drivers. Ti:. ;::-.-c rnput) shaft is an integral ertension of the
male rotor. Compressors with gears use an independe:r: r::.': .hail, commonly referred to as a jackshaft,
mounted on roller andf or special deep groove ball be.:----. re gear mounted on the iackshaft drives the
gear mounted on the male rotot and the male totor mr.::=. ;":::: and drives the female rotor.
4
tt
The I-eROI gas compressor is one pafi of the compressor s'.':t.n. The compressor combined üth the drirrcr
forms üe heart of üe svstem. FIou-eveq the oüer rital elemenr: .rre essential to eflsule üe heart of \.our sr.stem
continues to operate.
This is required to prer''ent the carry over of üqüds into üe compressor. Filt¡auon i: otten nece::.rfl, especiallv in vacuum installatioos, to
prevent debns (e.g. hon sulfides) from getting into the compressor.
Gas/AlSeparator
1'he gas/oil separator is a kev component of üe compressor system. The separator should be designed to handle the ma-timum capaotv at
the lorvest discharge pressure and the hrghest discharge temperature. It is impon;rnt d-r¿t dre r e ssel '¡rd coalescing filter a¡e sized propedv
to insure optimum gas and oil separation. The separator also acts as üe oil resel1-o1r .or1 sump.. siü the oil collecting in üe bottom.
Oil Coobr
The oil cooler is an air cooled or u,ater cooled heat exchanger that is sized to srut üe slze c¿p¿otr , of the compressor berng cooled. 'fhe
cooler should be desgned to handle üe worst operating condition, which is usuallr- i,¡¿sed on dre los-est suction pressure and the highest
discharge pressure. Horveveg üe oil flow plal s a critical role in determining the heat ¡elecdon of the oil cooler.
The minimum pressure vah'e is recommended to maintain a minimum pres.ure in rhe q.r. o11 seperrltor. It is especiallrv importaflt to use
üis der,-ice when the possibiütv exists that the system pressure ma)¡ not be sui6o.nr tn mlrnT.r11 f ressure in üe seperator to achie\.e
TbermalBy-Pass Valae
The injection temperarure of üe oil used to cool, seal, and lubricate the compressor i. conrolled br the thermal bv-pass r,alve.
As the name implies, this valve allorvs part or ali of the oil flow 16 f1:pass the oil c,¡,ri¡r deoendmg ofl the temperarure of the oil
leaving the compressor. This 'r,ah,'e can be controlled thermostatjcallr' or t'ith more soplusticated temperanrre cofltrol valve where
5
Oil Fiher
It i: -\-'ri:r].'1: rjn: ']r:'r'nr that the comp:-:: : - ::: .-.: possible. The oi1 filter should be generoush, sizer-1
oil injected into the
to i-1"::i'' ::- l - '''. -'.rcl -sl1r¡u1d have a filter element that -¡. -.^ : r..:-:--:
- do\yfl to 10 micron. If the co'-rpressor is in an
applicaú,:,n \\-hcr- c, :t-rjt . ,Lls operadon rs tm¡ortant or rrh.:. -:. : j :t - i¡tr_ in a short period -_: of time, it is recommendecl
tl'rat a ciual fi1ter arranq.nen¡ be used.
The compressorhas operaringlimitations thatmustbemom: ::- :: -:--- : ---.-rccs arereclurrecl ro thepfotectthe compressor
ilon: ¡rperlencing a catastrophic failure. These include, bur ar. :- :: . - lr-qh
-:--- remperature and pressure, as rvell as üquid
ici el ss-itches in the sucuon scrubbe r u,.here there is a poten:.- : : --. .jnts
:.r_-
- oi [quid in the gas stream.
, :::a SEP ELEII4ENT
PRES, GAUGE
TEI.IP SWITCH
SEPARATOR DRA]N
LINE PRESSURE RELIEF
VALVE
CHECK VALVE
SEPARATOR --] ..
TUBE
ELEMENT)
COMPRESSOR iNLET
3l:lT'.1'^."- : --={EL
LOW OIL
PRESS SWITCH
ALTERNATE PRESSURE
RELIEF VALVE
WITH EXTENDED
OIL FILTER VENT FIPE
GAUGE
GAS DiS'FTi::
FROM ¡NLET
FI LTER, SCRUBBER,
MOISTER
SEPARATOR,,-EIC
CHECK VAL\/=
i
AIR COOLED
TO RECEIVER-i
OIL COOLER OIL RESERVO R
STARTING UNLOADER
(BYPASS VALVE)
Figure 4 - Typical Basi.c piping Diagram
6
As mentioned prer,'iousl1. in this manual, rotar\- scre\\- compressors require oil lubricauon
of the bearings, cylinder and rotors. Beanng lubrrcation i-s necessar\. for long ltfe. C1ünder
2. Prol-ides a seal betw-een the c),linder and rotors to reduce gas shppage.
In certain appücations the pressure diffetential (discharge-sucrion) is such that an oil pump is not required.
Holever, if the appJication has a lor¡,'er pressure diffetenual than an oil pump urllbe required. It is impor-
tant for the application to be ter.ieu,ed especiaily if the unit s.iL1 be mored trom one site to another resulting
in diffetent conditions.
LeROI gas compressors have an oil injection manifold that distributes oil supplied by the pump or pressure
differential. The orifice creates a restriction. A smaller orifice results in a greater restriction, which forces
more oil to the bearing and less oil to the rotors. The goal is to create a proper balance in the compressor
7
Pumps are installed at the factorr- bas.i :n packager instructions or specified operating
conütions. Everv LeROI ColnpreSSr,: -s :¿sred at the factory to ensure reiiable operation.
-\fter testing, the standard orifice or ::: , ince specified bv the customer is installed in the
urrit.
readilr' alzilabie one can easily be created. Simplv drLLir: ..- :r, .¡ rn a soLid plug wiil pror.ide the orifice. It is
also important to note that you ma,v need to create ¿rr ¡,:i-,c. ;r ihe eyeflt \rour desired size is in betureen
ture
Refet to Figure 7 for temperature and pressure methods :ni ic,cations.
8
For Most Situations:
For beaay gas strentns, a 30-40 "F ternperature dffirence lnay not be possible
Temperature rise - From oil iniection to üscharge bearing oil drain: 15 "F
Oil pressure difference - gas inlet versus oil injection: 60-100 psi
(X/hen gas discharge pressures are 50 psig or less, it may nor be possible
to achieve 60 psig oil pressure. That is acceptable if all other specihcations are met.)
9
-4
Oil pressure difference - gas inler versus oil iniection: 6U-100 psi
to achier.e (r0 psie oi1 pressure. That is acceptable ii r- r.: specifications afe met.)
9
Equ:e:::e::: & \f e¿s¡-rrement Location :- - -,:: i-:,rSurements atpoints t\, B, and C should
-
-: - I i:--_ rrs of pipe or tube (not fittings) as
-, .: - :¡:: , ---'.: :::-t- -:-lcnt instlumentation is .-:
i-c-ss.trr, rttti t1-_ 1, r-:t- or-etall package per_
- : - :tt:trcssof aSpossible.
i-1-rrrrAnce. the i - -; ._: ...re specillcally for the
p-i:p{rs. oi er-al,--._:_- -.r. pump and orifice siz.,
. :, -- : ::.: D and E should be as close to the
T:.b,¡ I Insúum.:,. -t lrleasurement Locations
- - . -- : ,., : ssrb1e. There is npicalll. an unused
, " - ': :: -.don manifold for E. Point D is
11:=ÍÉai Loc¿tion -, : - r-, . --.,,,qe inletpiping. If pressures are not
:::.::.: lR
_::l-l:t-::tft
: : i--l_,tl
---::a:a-:::
(A) prpe - :' : r : : r:-ic locations, the1. s[6.r1¿ at least be
-- :
pip.
r -:. i:a-r.r¿t @)
- ::_)re ssor side of anr maior restrictions
:::ll-::--:f (C) rubc (goes 'i ,-- 'aa
- - -
: : ::- :::: beating oil dou-n on some
l: : ::::_:'.:lmfc models)
rfessufe gage of
.: ::. . i- -:a isufe (D) inlet pipe Larger pump or orflce is
tansduccr 1
ro
Vadable Vi is used to minimize the pou¡er required by the compressor. It does not change f1ou. direct-
l,r,', but can allou, an increase in flou¡ through more eff,cient use of porr,'er. Vi is the yo/ame compression ratio of
a compressor: V1 / Y2. The intetnal Vi of the compressor is determined b,v the size of the discharge port.
A small port causes gas to be released later in the comptession cr-c1e resulttng in a higher internal Vi, a
"vhile
larger port allows the gas to be released eadier in the cvcle resulting in a lower internal Vi. The ideal Vi for
an application can be calculated if the inlet and discharge pressures and k (C./C,) of the €las are known.
The comoressor makes rhe mosr efñcient use of Dower rvhen rhe inrernal Vi equals the ideal Vi. For ex-
ample, if the internal Vi is high but the ideal Vi is low, the gas is compressed to a pressure greater than the
extetnal pressure prior to being released. On the other hand, if the internal Vi is low but the ideal Vi is high,
gas momentarilv flows backw-ard into the compressor and is re-compressed. Both of these scenarios result
in wasted energ\r
The standard discharge housings of the HG17, HG24, LG30, and LGL30 compressors have a 4.4Yrport,
but are fitted with four valves that can be opened to increase the total size of the discharge port, so that the
following internal Vi's can be achieved.
lnstructions
THE COMPRESSOR CAN BE VERY HOT!
PROTECT YOUR SKIN WHEN ADJUSTING A RUNNING OR HOT COM.
PRESSOR.
lt
rfulet
and discharge flanges. Be sure to account
tlrcssure ald increase the discharge pressure at
- .. : :--:r-:s t,r danges. As a quick refere r.-: - - qÉzl natural gas with k 1.26, the
= pressure
:,: r .-.,, J :ie spond to available intefna- -.::
\-r P] ,' P1
:
:
-
.:
Since the:¡ :.:¡ :rree available internal \-i :: _. -- :- _. - :.)\-er a range of ideal appJication Vi,s:
Greater üan 2.5, but not greater : -t --- I,I Inner valves open, Outer
than 3.,i ----, ¡-,-r.ed)
Less than or equal to 2.5 I LO\f lAll valves onened)
Aftet Determining the appropriate Vi ratio perform rhe following steps to adjust the internal
Vi ratio:
Figure 8:
::rre ssor discharge end showing four
- ,. j \-i r-a1r.es htted r¡'ith special locknut-
- - :: ..--
trotectofs.
I
ñgret
Xmre locknuts with wrench before mak-
ir1g adiustn-rents.
t2
Figure l0: For MEDIUNf Vi, turn the in-
ner r-alr-es couriterciockrvise until ther. are
tulh- crut.
t3
VersaÉol czpaorty control is used to regulate com[rrsrr flow and reduce power requirements.
Versat¡ol consists of a set of pressure actuated vafve ¡ts".Íilt¡i€s mounted on the side of the compressor.
When opened, these valves allow gas to leave the coqrasslm cvcle and returrl to the .o-p..rro, inlet prior
to compression and delivery, thus reducing flow and hoil¡qlorrer A valve is closed by applying actuating
prcssure and opened by releasing actuating pressure. Ttfo.-n be used to ramp up the compressor during
start up. Start üe compressor with all the ports open ' - dme them.
Versatrol is available on the HG12 and larger models Due to úe smali cylinder size, the Hc1,2has two
valves andanextetnalby-pass Fg"t. 14). AXlatgermoddshevefourvalveswithaninternalby-pass (Fig-
ures 15 and 16).
t4
Versatrol Capacity Control
Actuation:
The Vetsatrol valves can be operated wtth prusuriqed au, gas or lubricating fluid depenüng on whether it is
step or stepless control. The actuation pressure should be üe same or nearlv the same as the compfessor
discharge pressure. The valves should be opened in the 1-2-34 sequerrce and closed in the 4-3-2-1 sequence,
except the HG12. The HG12 can be opened or closed in a-rr.¡'sequence.
Oil may be used fot either step or stepless control. Oil taken from úe gas/ oil separator or zfter the oil
pump should have adequate pressure to allow Versatrol actuation- Oil should alurays be filtered prior to
entering the control system.
Ait or gas can be used for step control systems only. Air and gas are compressible and will not allow accu-
rate or quick conttol tesponses. Air can be used for stepless control srstems s"ithout a problem.
As mentioned pteviously, the valve is unloaded or opened by rcducing the contol pressure. 'W-hen the
conttol pressure is teduced the highet pressure inside of the compressor opens the valve. Therefore, it is
important for the actuation pressure during the unloading stage to be lower than the cylinder pressure. To
erisure this occurs, the Versattol valve assembly should be vented to the c,vlinder inlet if acttztedby gas or
oil. If the m is used in the controi system then it will have to be veated to the atmosphere.
@
Plumbing:
quently does not open because the pressure in the cvlinder is less than atmospheric
pfessufe.
Steel or stainless steel tubing and fittings should be used. Copper tubing i-s not recommended. Copper and
gas can react and reduce the reliabiliq, of your svstem.
Tubing runs should not be any longer than necessarv in order to ar-oid reduced response dmes betu,een
controls and the Versattol valves. Tubing should be 3 / 8" . Tubrng size increases in importance in cold envi-
ronments or when rubing runs exceed 4 feet.
I5
-l
t
Th¡- -'.-:'--''' r ::-:ll ls r-ital fot reiiable operation of - .-
'- -. - i--:rie ssors. Follou.ing these guideJines about oil
E ani :.-,. .-t - ..--: -: -lsure r-eats of teliable sefl,ice.
E
Oil Filter: t,.-.cck aiter first 100 hours. Chanf. : . ^ ,- : rntinuouslr¡ operated or e\¡ery 1000 hours
:r:.nr-i,se. Filtermustbechangeci . - r -I -i--¡,
'\' ¡1.re minimum a differential pre S, *:: -: - - :.. --i trrr the oil filter. A drfferenual gauge with
:-:t ¡arm is adr.ised.
Analysis: Oil should be analvzed on a regula: : .,,. ,:-. '^-c ¡e checked once a rveek for the first month,
r¡-tth :t least t\¡/o of those samples b. :,. -1-., "r.cl. if rhe first month of samples is okal. then the
anal'' srs can be reduced to once a rr- .-'.. -:- --:-.1scs in water content
ancl metals should be r.r,atched
close'-'. -\i1 reputable oil suppJiers anr :r'-.
-- :-.lrers rvill analr-ze oil samples at no charge.
Recirculation: It is :nportant that the oil recircular¡. : : :: - -. ' , rimes per minute, especially with hear-ier
hr-d¡crcarbon and §'ater saturated gas;. , - : -r::s the oil temperature
high.i, thereb¡ reducrng
¡h¡ :r-.'ssibilin'of hldrocarbons coni.:,-.,-
---- ,,:rectrng the r.iscositr,'olit e oil, or har.ing u.atet
coaiense and cause lubrication prob.:, ,
Strainer: \\-hen thete is an oil PumP, it is rec, . .-: ,: - . : .. \--strainet be installed betrveen the separator
and the suction to the pump
Coalescing: The coalescing element in the gas c,r' ,.:-: - : , : ¡e monitored with
- a differential pressure
gauge' This element should be chan:.: ,: .hould be checked at least once
-, i- - a r.ear. It is
imporrant rhar the {ilrer elemenr h.r-.i. -: __ --:--. -. ..rr-1 ro remo\e ril f.;;,h.;r;;*;*.
Gas Filtration: Gas filtration is recommended. Pafr:¡*- :-: .- - - : .-: :--:-:1m can contaminate the oil anci cause
premature failure.
Temperature: Oil temperature in and out of the re.: ' r::-:.: :: :-:-: .hould be checked regularil,.
If clifferential
is greater than 30oF, there may nor b; , ..: _.=::
--:--:_.a,ln for that are. This could also be an indi_
cation of worn bearings.
t6
In§tallation
The compressor and pdme mover must be mounted on a rigid ftame so that the drive, piping, etc. are not
subject to strain andf or misalignment. Mounting holes are provided to securely zttzch the compressor.
The mounting surface must be a smooth, level surface tl'm;twill support tle weight of the compressot and
handle the associated vibration. Shims must be installed between the frame and the mounting surface to
elirninate strain on the frame.
Adequate airflow for cooling must be provided. Uncontrolled recirculation (from unit to other source) of
hot air must be prevented. Refer to figure 1,7 fot a tlpiczl insallation.
I*OTE: i
§uiuely s¡Fpdrt CI piFiñg
t{ FltrGñt fütfn eq* ¡arÉprq¡sur, F¡n rr¡d
:asl*r ¡r¡d e$rcr r¡mpro*l*nü* F¡*t ldetsr
áLL FIFIN€. I¡ALI¡E§, FI LTE*&"ETE- F*+i++rl
Tü ÉE SSTAIFJEtr tüEÁLI-Y. úi{ Etrertú'ir
)
C-oqpling
aI 6u¡rd
tl I
€ngins I
of --
t1 Mot¿¡ l-
)
t, ¡
:
Sraooth
Lertl §Efl¡6 :, Higid Frarne
,1
t7
Dnr-e:
Ser-e¡,..-::-) : j:.:ble andunir¡ersat jointt\pes afe
::- . couplings malrbeused. Horve\-r:.
--::--
recon:rr-:rr:: 1;'.':r¡::usingadirectflexiblecouplinE: ',-:: rplingmanufacturer's
instrucuc,n.. -.\. .. ¡-:¡ra1 ru1e, for this trpe of coupLi:,.. : .- .--r-¡nt should be as near "in line" as
possible. In an', c,...-. r-ruplingmisalignmentmayn.-J-:.-::- - ,l'¡arallel andf or 2o angular
misalignment. Refer to figure 18.
FlllÍhlt
Hub Msmhf,r THE DRIVE
COUPLING
(COUPLING, SHAFT,
1 Cdrit*fliffi
BELTS) MUST BE
I COVERED BY A
Lrd: s,r.g": Drjvrr/Oriven
' .I I : --1, 9" ¿f lpÉifr+.d hy SUITABT F' GUARD
cc-J -! -j--"E-ryr. OR SHIELD. ALL
Hub ro b+ parChl
2 drqrctr io botJr wr-:iel GUARDS A}ID
rnd hqri¿o¡ul p{*r+s,
(Or * ¡p¡¿ ¡¡¿¡ Íy crupling SHIELDS MUST BE
m¡nuftcturt¡..
IN PI-ACE \THEN
OPERATING THE
Figare / I UNIT
HG10;30 HP
HGF10; 50 HP
Figure 19
HG12;50 HP
HGtrI2;50 HP
HGSF17; 50 HP
Figure ))
t8
Installation Location
The components (Figure 17) of a gas compressor svstem ..r :-,: r - ::r , unicd on the frame to make sen-ic-
ing the unit as conr,,enient as possible. Oil piping and hoses sr- --: :; . -:i:ed and fastened to prevent ac-
cidental damage. All mol'ing parts (coupüng, belts, fans, etc :::'--.. ::-.- - :-,-.:rds or -shields installed.
Compressor Inlet: The inlet piping must be cle:rn ...:lj :, -: -. -:rr suirable filters, (scrubber, mois-
ture sepafator, etc.) to pre\-cn: i :,-.:, :r-,.-::-r i:om entering the compressor.
All piping and other componcir- :lr-..- rL ,ii--luateh' supported. Prorisions
must aiso be made to install orher c,',r-n),-.,íriiriS such as gages, r-ah-es, tem-
pefatufe measufing and pressurÜ Ct-,n¡rr,,1 ier-ices.
Comptessor Discharge: The discharge line between the compre ssor end rl-re oil recel\-er :::-isr be as
large as permitted bi. the size oi the compre ssor discharge op.rlr:rg. The dis-
charge ltne must neuerbe reducecl in size. T1-re dlscharge Line shc,u-c L¡e as short
as possible with the minimum number of bends and fittinss.
A high discharge temperature shut dos-n ss-itch, wired into rl-r. :r-:rlc mo\-er
controls, must be instailed in the discharge hne. This trip ss-rtc:r si'Lould have
a maximum tip setting of 230oF.
Separator out: The piping from the separator out (minimum pressure check valve) must be
as large as permitted b,v the outlet port of the minimum pressure valr-e. The
length must be as short as possible u,,ith the minimum number of bends and
fittings.
A single gauge for each is recommended, with a manifold and shut off ¿
valves, to ted both upstream and downstream (inlet and oudet) pressures.
This limits the possibility of gauge error affecting pressure reaüngs.
t9
Satisfacton-pi::r1,¡¡l2nceofastatiofiaf\.scfewCo1i--]r::, :r:---:::rqoodpfeventisemaintenancepfo-
gram. The r,-, :,..,-.rg iltormation is provided m o .-, -: - -- - : ::,-)qram.
Start Up:
1.. Serr-ic¡ .;equrpment (hlters, moistur. i., -. - :- : :r.)\-er, etc.) foilou,ingthe equipment
manu :., r r-:rcr's instrucdons.
2. Drarn ci,¡ndensate (water) from the o' :.,-:- - r : - -!:ii1-1 valve securelyrvhen oil appears.
J. Check tite compressor oi1 reservoir j:'.,- , - -. :r-:e ssary to the correct ievel. Do not
overhll,
4. N{ake ceir¿rn adequate ventilation an¡ : i:.-*ired, is provided.
5. Start the uirir b-r. actuating the electrc- - - -- - .. :i-Lc engine follov'ing the eql'}lpment
manutac r¿rer's instructions.
6. Obsen-e the unit for leaks, unusual nc)-:." ' - r: -, I _ : .t _irtutdown the unit and corfect as fe-
quired.)
7. Obserr-e all rnstrumentation for prope : r:: r- :
Shut Down:
Preventive Maintenance:
1. Ensure the oi1 is properlv maintained ::: :- - -- - i.--ered Items" section of this manual.
2. tnspect the entire unit for leaks. - , , .: -
Yi-s¡1211¡ - : :, :rs often as feasrble. Correct as required.
-:
3. Sen-ice all equipment (filters, moisrure :-r,:-' r ,'- -rri-ingthe manufacturer's instructions.
4.
5. Checkthecompressotoilreservoitlc',-- , -- -::- :cofoilasrequired.Donotoverfill.
6. \\ith the unit running, obserr-e the oü rr:: : - : - -.: . -:.i compare readings (iilter in-filter out)
A üfference in ptessute readings of 1-: Ii- : :: .- J-lrcs that the filter element must be
renewed.
7. Withtheunitrunningobserl'ethesrsrr:::-i: ---.:,,::icomparereadings.Apressuredrop
across the separator element of 15 PSl : .-. :. - -- :: .rte separator element is restricted. If
-
thetestrictioniscausedbydirtororl¡:: :-:: ---:: :-:r-\\-theseparatoreiement.
OiI satutation can cause excessire resrririm across a separator element. Always
check the separator drain tube and lirr frr restrlction, the check valve (installation
and condition) and clean or renew rüF dE in line 6lter before condemning a separa-
tor element.
8. Remove sutface dirt and dust from :::. _ .:,_. __ ,-: .uoler.
20
BEFORE REMOVING AI§Y COMPONENTS SHUT THE UNIT DOWN,
CLOSE ALL INLET AND DISCHARGE SITUTOFF VAL\rES, RELIEVE ALL
PRESSURE BY "PUMPING OUT". MAKE CERIAIN THE PRESSURE SYS.
TEM REMAINS VENTED TO ATMOSPHERE. DISABLE, LOCKOUT AND
TAG THE PRIME MOVER.
Comptessor Service:
The compressor for these units is setviced onl,v as a comp-;,; ...¡nb1r'using a ne\\,'or factorl'rebuilt com-
pressor. parts available tbr fie1d service include the input sir,.--. : ,:n- oil seal and the seal retainer gasket or
o-ring seal.
The compressor input shaft rotary seal may be teplaced as follorrs, Refer to trigxe 21.:
I. Make cetain the unit cannot be statted and system ha-. all pressure temoved.
III. Remove any coupling guards andf or shieids.
m. Clean the front of the compressor thoroughly to preYent dirt trom entedng
the compressor.
fV. Disconnect the drive coupling.
the compressor or prime movef must be unfastened from the frame, save and
If
mark all mounting shims if any, for reuse,
NOTE: Always vedfy Seal Kit P/N by referring to appmptiate compressot assembly / parts draw-
ing.
The following procedure is to be used for installing ail.rctaryface trpe shaft seals:
Follow the maintenaace maoual procedure for the specific unit being : e\Pose the rotatv seal retainer.
Disconnect the lubrication line (tube) ftom the seal retainer or bearing reainet (depends on unit model).
NOTE
THE FTTTING INSTALLED IN THE SEAL OR BEARING REIAINER OR THE OlL PASSAGE IN THE
RETAINE& WHICH DELTVERS OIL TO THE SEAL, MAYBE RESTRTCTED OR ORTF'ICED.
INSPECT THIS FTTIING AND OIL PASSAGE AND THE ATTACHING LTNE, CruBE) TO MAKE CE'RTAIN
THE ORIFICE IS CLEAN AND THAT THE TUBE HAS BEEN CORRE,CTLY INSTALLED G'TO EXCESSIVE
FTTTINGCRUSH).
2t
SONIE FITTI\GS (lR OIL PASSAGES NL{Y HAYE _-. .-- : - - 1 r,.,_, .JzuFICE. IF ONE IS PRESENT,IN_
SLTRE OzuF](,E ]S RE]\STALLE,D.
3§rt ie?rry
-/a@
:_,e }lri
/€ ll
I
E
E
Figure I Figure 2 Figure 3
r Remor-etheseairetalnci:'.nr,lsea1 assembirrasdesctibe.:. -: - --.- .-.::r:,nual
:
for the urut berng s.¡r-iced. Discard the o1d seal par . . --- :,
clean the seal retainer anri seal car.it).'in the bearing rci-. - :: : --.- Frqure 2)
To protect the exposecl sh,.,rt beadngs from dirt, dampe:: ; : :.: : .. ...i1c1 clean compressot oil ancl insert the rag
into the bearing rcrxincr . n.
Inspect the shati suri:'.cc i,rr nicks and burts. If found. r- :-. ' - -- . r ' r -, Éne file or stone. Remor.e any sharp edges
from tapers or chrmñrs r-,n the shaft. (trigure 3)
I f oú ¡ir ir sir¡c.rn
Éi'
&
22
On the shaft atea, where the seal is to be located, polish the sheft nsirtse rnrrnher 100
grit silicon carbide emery cloth
e /N 204-2385). \il/rap a strip of emery cloth atound the shaft. Gresp úe cmtry doth and use a rotary motion to pol-
ish the shaft. (Figure 4)
Dampen a lint free rag with a non-hydrocarbon solvent (suggest acetorle, nail polish remover, or equivalent) and care-
firlly remove any temaining dirt from the shaft. Make cetain the shaft is oil and dirt free. (Figure 5)
\TARNING
SOL\ENTS SUCH AS ACETONE MAY BE TOXIC §7HEN L\ilt\LED. -\I§.\15 USE IN A §7EII-VENTI-
LATED AREA.
Catefully remove üe new seal from the wrapping, check for any damage, aod wipe clean.
CAUTION
CHECK THAT THE SEAL FACE IS LOCATED IN THE RET,{.hER §TTH THE I-APPED FACE OUT-
§rARDS, AND TAKE CARE THAT THE FACE DOE,S NOT DROP OLT OF THE RETAINE,RWHEN
HANDLING AND FITTING THE SEAL. HANDLE THE SEAT ASSE}IBLY WITH GREAT CARE. DO NOT
TOUCH THE SEAL INISERT OR CARBON RING POLISHED FACES.
Lubdcate the steel face insert seal ring (o-ring) and seal retairier counter bore with P- 80 Rubber Lubricaot Emulsion
e /N 204-2386). (Frgure 6)
Protect the poJished side of the seal inset using the paste board seal protector furnished with the seal assembly and
push the inset into the seal retainer until it bottoms in the counter bore.
CAUTION
DO NOT TOUCH THE, POLISHE,D FACE, OF THE SEAL INSE,RT \\,1TH FINGERS, RAGS, E,TC.
Appl.v a film of P-80 on the gas end shaft and on the inside diameter of the flexible section of the seal assembl¡,,.
23
CAUTION
TO ]I-\KE CERT-\IN THAT THE FLEXIBLE :r' - l: a THE SEAL ADHERES TO THE SHAFT
IN THE CORRECT LOCATION, IT IS NECE:-i ...-' - ),\IPI_ETE THE ASSENIBLY ONCE
ST.\RTFD
Lubricatethe cart¡onringsectionof theseaiassemb-"'- -:-- -' :--:¡essoroil.
CAUTIO\
DO \OT L SE OTHE,RT\?ES OF OIL OR GRE'.::
Nlake certain all parts and supplies (gasket, sealer. i.: 1:. - - - . --:.,re begrnning f,nal assembhr
\X'ithout touching the polished area of the carbc,: ::: : . :.: : ::-.: .cal assemblv (spring, etc.) on the shaft.
(Figure 8)
Apply sealer (or install gasket on the seal retainer I ::- s .-: : ! - r- : : - -:t :it. r¡srruction manual for the urut betng serr.,iced.
Immediately install the seal retainer and attaching c::.:.:::-, i ,:.: r;:.il-oq retainer mating surface. Tighten all cap-
scre\r/s securelu figure 9)
After installation is completed allow the seal to sit t-ir - -: ::)r3ung üe shaft for approximately 30 minutes.
24
b) bFilfig. 3ll,etl
7l Q¡:l
Ii| Üheck Valve Fiston
g) Seat
101 ÉápsÉ.rew
Figure 21-Compressor Inpur Shafi Seal tigut 22- Minirnurn Pressure Chech Valae (Small)
25
6. R¡:r- : t: :)rir-rg ftom the bodr-.
5;.-' ¡ i:r:::r- shim(s) (u,ashers) (if anr,) for r¡--..
7. I:l..: ,: .--r¡-'.ble tool (u.ood stick) into the n: :- -- r-alr-e and push the piston and the r.alr.e
¡ss-i:ti--, -tir\l-erd and out of the bodr..
8. Remor-. :r:. che ck valr,'e piston from inside .r- : . : - : - : : ,l. Take care not to lose the srnall spring.
9. Remor-e t|.- ,.r-ring from the large piston ALi , . _ : - -- -:iltg.
10. Thorougirir- clean a1l the remaining parts. \-'. - .. .- : : - .. :¡rts for damage or wear. Replace as
required.
11. Instali a ne\\- o-ring on the large piston.
12. Reassemble r1're small check vahre piston. r,-' - - - ,-, :--c large piston.
13. Lubricate tl-re o-ringonthepistonwith a s:-:,- :. . -:: ---tr1c,anr. (Example: Dov.Corning5510.
74. Reinstall the check lzlve and piston assem-:- .:-- . . ..,-.'e bodr-. Take care flot to damage the o-dns
dudng instaiLatlon.
15. Install the large spring in the vall.e bodr- on : - : r -- jr, Reinstall spring shim§).
16. Ltghtlv coat the caP threads u.ith "Loctite'' l-. ..:,- ., ,. :r¡ cap (compress spring) bv threading
the cap into rhe ralr-e bodv Torque the cap
17. Reinstall the mtnimum pressure valve on thc' :---:,- :r- t:Sir\-oir cor.er. Use a good grade of pipe
thread sealer on all pipe threads. Tighten sec--:r--. l) :-- - .\-er tighten.
18. Reconnect the service piping to the r-alr.e u.r:r: r.-:, r.,:¡.ld sealer on the pipe threads. Tighten
service piping securel1,. Do not oyer tighten,
26
§ervice Procedure-Components (Contínued)
Changing Minimum Pressure Valve Spring
This section contains the instructions to replace a high-pre.s..:. irlnLmum pfessufe r,alve with a
los¡-pressure spdng.
i
l
I
I
¡
=ffi
27
Service Procedure-Componenrs (Continued)
/
Figure 28 - Ten Sltacers Installed it: I, F igarc2 9-Ins allatio n oJSp ringpanNo. 24- g I 0.
Eirher encl mav be installed dou,-n.
28
An oil separator may be removed as follows:
1,. Make certain the unit caffiot be stated and that all pressure has been removed from the system.
2. Disconnect the piping from the minimum pressure v.atve-
3. Disconnect the separator dtainline and remove the drain tube from tüe separator. Mark the position
of the receiver-reservoir cover to aid in correct assembh.
4. Remove the separator cover to teceiver-resetvoir zttzchsngcapscrews (mrts) and remove the cover.
5. Remove the separator element by lifting it out of the reservoir.
6. Clean the cover and reservoit cover mounting flange. I\feke certain all traces of gasket lrrraterra) arc
temoved.
7. Inspect the new element gaskets to make certain the electrical grounding staples are installed.
8. Reinstall the separator element in the receiver-reserr-oir.
9. Reinstall the reservoit cover, correctlv positioned, u-ith :.¡.::.,rcil1:- cilpscre\r,s (nuts) and ughten secureh,-.
10. Reinstall the separator drain tube and {rtting.
12. Reconnect the service piping to the minimum pressure ..-a1r-e , L-se -.- ..'...':'' :-:- ülead sealer on al1
pipe threads. Tighten securell,. Do not over tighten.
29
Ren*.uild Kits
Please refer to ou¡ s ebsite, wl.wv.le ae.com, producr '': :::.:' ,n pages for the latest rebuild kits listmgs.
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§feb§itE
LeROI-RCT has a rvebsite that contains useful tips, features, sizing information, and technical dara.
We encourage using and exploring the rvebsite to learn rvhat tools are au-atlable to you. Visit us ar
s-wrv.leroisas. com
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feiasin Cd$l¡k
keüú.P§ú.d: :=:
ül.ectic.,¡ Pr(qú'*ii*
r\dim Iüe := ¡:
:*:x.
3t
act List
Beloq- is : : :t::crs in case you need any assisi':-:. - : :::: :'lr pror''ide
: ". you with the latest
informan-1--.-: ": -. :Iso ar-ailable on thewebsite: ; ' :r .--l: - i:l
USA
Com pressor Sales I Pricing I Applications ,r Specifications I
Phone: 281-693-1950
F ax: 281-693-1952
Cell: 7 1 3-586-9005
Email: sales@,letoigas.com O I maro.;o:-:' : : . -r -::L : : -
Accou*'ting
Arn andá Y*'llrrg
Phone: 937-498-2638
Fax: 937 -492-3424
Em ail: amanda.young@ leroig as : : -
32
CANADA
:::::::::=
.:: =-
:a::::::a l tl::l:::::::::::a::=.:'". ,r .. :r'l=
Phone: 403-808-8377
F ax: 403-945-1910
Em ail: sales@ leroigas.ca
33
Serfice
High lnlet Pressure 1 . lmproperly set inlet valve or ::-:- 1. Set or adjust control correctly.
control
High Discharge Pressure 1. Operating at higher than ratec tres- 1. Adjust to operate at rated pressure.
sure. 2. Service discharge check valve.
2. Damaged or worn discharge :t'::<
valve. 3. lnstall correct minimum pressure valve.
3. lncorrect minimum pressure . ,: ' 4. Service minimum pressure valve.
installed.
4. Damaged or worn minimum ::=:s --= 5. Conect cause of excessive restriction.
valve.
5. Excessive restriction in sepa::::- :-
outlet piping.
34
ROTARY COMPRESSION TECHNOLOG¡ES, INC
d.b.a. LEROI GAS COMPRESSORS
WARRANW FOR ROTARY SCREW GAS ENDS
USED ¡N NON.CONSUMER APPLICATIONS
O.E.M. & GAS
Manufactured
LeROI-RCT warrants its rotary screw compressor products and parts to be in compliance with their respective specifi-
cations and free from defects in materials and workmanship during a wananty period ending the earlier of (i) 12 months
after the product start up date, or (ii) 18 months after the original date of shipment of the product by LeROI-RCT.
Remanufactured
LeROI-RCT warrants its remanufactured rotary screw compressor products and parts to be in compliance with their
respective specifications and free from defects in materials and workmanship during a warranty period ending the
earlier of (i) 90 days after the product start up date, or (ii) 9 months after the original date of shipment of the product
by LeROI-RCT.
LeROI-RCT's only obligation under this warranty will be, at its election, to repair or replace any part determined to be
non-conforming or defective during the applicable warranty period, including ground freight (Domestic USA only for
overseas warranty) for the gas end. Labor to change out the gas end is not covered. THIS WARRANTY DOES NOT
COVER CORROSION.
THE OWNER/USER ASSUMES ALL OTHER RISKS, IF ANY SUCH AS THE RISK OF ANY DIRECT, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGES ARISING OUT OF THE USE OF, OR INABILIW TO USE,
THE COMPRESSOR ORANY PART.
THIS WARRANTY IS MADE IN LIEU OF THE WARRANTIES OF MERCHANTABILITY FITNESS FOR PARTICULAR
PURPOSE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND MAY NOT BE VARIED OR EXTENDED
EXCEPT lN WRITING BYAN AUTHORIZED OFFICIAL OF LeROI-RCT.
35
THIS PAGE INTENTIOI§ALLY BLANK
3ó
It Pays to use Genuine LeROI Parts
Provided by Rotary Compression Technologies, Inc
37