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WARRANTY - GENERAL

Hycomp warrants that its compressors will be free from defects in material and workmanship for a period of  twelve 
(12) months from the date of purchase.

Hycomp compressors which fail within the 12 month period due to defects in material or workmanship, will be repaired 
or replaced at Hycomp’s discretion provided the Purchaser meets all of the applicable requirements of the warranty 
and none of the limitations apply.

Any parts subject to wear or abuse are not covered by this limited warranty.  These may include, but are not limited 
to, mechanical seals, bearings, piston rings, valves, packings, and other parts showing signs of abuse.

This limited warranty is void if any product or accessory has been serviced or altered by anyone not authorized by 
Hycomp.  

Additional warranty limitations apply.  Please see complete warranty policy for details.

See complete warranty policy for details

(available from the factory)

NOTICE TO HYCOMP CUSTOMERS

Hycomp recommends you order service and replacement parts according to the model number and serial number 
found on the nameplate of your compressor.  Do not order parts from the general descriptions in this manual.  
Ordering directly from Hycomp or a registered vendor will minimize the possibility of receiving incorrect parts for 
your compressor.

Summary of Contents for Air Boosters

Page 1: ...OIL FREE AIR GAS COMPRESSORS COMPRESSOR INSTALLATION OPERATION MANUAL for Ambient Air Compressors Air Boosters Gas Compressors Rev 2 13 WI 400 010 APP 1 Rev 5 ...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...6 Inspection After Extended Storage 26 Compressor Speed 26 Crankcase Lubrication 26 Oil Pressure Regulation 27 Oil Pump Direction of Rotation 27 V Belt Tension Settings 28 Adjustment of Manual Unloader Controls 30 Adjustment of Automatic Unloader Controls 32 Additional Controls Adjustment 34 Pre Startup Check List 36 Initial Startup and Operation Ambient Air Compressors 36 Initial Startup and Oper...

Page 4: ...ed to mechanical seals bearings piston rings valves packings and other parts showing signs of abuse This limited warranty is void if any product or accessory has been serviced or altered by anyone not authorized by Hycomp Additional warranty limitations apply Please see complete warranty policy for details See complete warranty policy for details available from the factory NOTICE TO HYCOMP CUSTOME...

Page 5: ...ring parts for the compressor or requesting assistance with troubleshooting maintenance installation or operation Before contacting Hycomp note who you purchased the compressor from who installed it installation date the purchase date and model number This will help Hycomp identify your compressor and any special parts and materials that may have been used Fill in the information from the new comp...

Page 6: ...acking intake pressures may range up to 300 psig while discharge pressures may vary up to 1000 psig Pressures above 1000 psig are possible with customized units Most Hycomp compressors are sized for specific applications therefore it is essential to contact the factory before changing running conditions of the compressor ALL INDUSTRIAL GASES WILL PROVE FATAL TO PERSONNEL EXPOSED Some gases are imm...

Page 7: ... the side thrust developed by the connecting rod onto the oil lubricated crosshead piston cylinder By removing this side thrust from the compression piston the piston rings provide an extended life expectancy in comparison to permanently sealed ball bearing oil less designs Hycomp air compressor cylinders and cylinder heads are single piece iron castings This significantly decreases warpage proble...

Page 8: ...utilizes self adjusting segmented packings to seal against the piston rod and safely contain the gas This gas can then be vented to a safe location or a variety of purging venting or padding options may be used to control the gas leakage With this system Hycomp compressors can pressurize flammable and toxic gases Hycomp compressors boosters are specialized and engineered specifically for each appl...

Page 9: ...irety LOCATION Locate the compressor in a dry well ventilated and well lit area that accommodates inspection and maintenance COMPRESSOR INSTALLATION SECTION 1 access Provide an unobstructed machine boundary of at least 18 with adequate air flow and service space around the compressor Rotating machinery should always display appropriate restrictive warnings and cautions to minimize risk of injury t...

Page 10: ...leeve all foundation bolts to prevent adhesion and allow bolt stretch Steel baseplates should be sanded and cleaned to provide adequate adhesion surface Steel fabricated foundations must be adequately engineered to support the weight and vibration of the compressor INLET PIPING INLET FILTRATION Compressor life can be substantially increased by providing clean dry cool gas to the compressor inlet A...

Page 11: ...ore compressor startup Unless otherwise indicated air boosters and gas compressors do NOT come with an inlet gas filter Damage to the machine will occur if contamination is drawn into the booster compressor and will void the warranty Hycomp air boosters and gas compressors require an inlet receiver to be installed just upstream of the booster compressor See RECEIVERS Air Boosters Gas Compressors f...

Page 12: ...d be avoided For continuously operating compressors a fan directed to move air across the cylinder and head can be used to lower operating temperatures decrease maintenance and increase compressor life Keep the cylinder and head clean and free from dust and debris to help maximize heat dissipation Air cooled intercoolers and aftercoolers are generally located in close proximity to the flywheel whi...

Page 13: ...quired to actuate the valve The sensing bulb should be placed in the discharge water stream while the main valve body should be placed in front of the compressor Visual Flow Indicator Flow indicators display to the operator when there is water flow through the compressor On large scale water tower systems backpressures within the system can prevent water flow through the compressor causing overhea...

Page 14: ...p compressors are often supplied with an unloading device of some type This unloading device allows the compressor to load and unload based upon discharge and suction pressures as well as allowing the compressor to start and stop unloaded Even if the unit does not include a control system from the factory many Hycomp compressors have unloader devices installed A piping and instrument diagram P ID ...

Page 15: ...ulic unloader valve vents the unloader pressure to atmosphere This provides protection to the compressor in the event of a potentially damaging oil pressure drop It also insures the compressor will not begin compression until oil pressure has risen to an acceptable level THIS VALVE IS ONLY TO BE USED WHEN THE UNLOADER GAS IS AIR OR A NON CONTAMINATING GAS THAT CAN BE SAFELY RELEASED TO THE LOCAL E...

Page 16: ...is different than that listed above it will be noted on the Piping and Instrumentation Diagram If the unloader gas is air or a non contaminating gas the solenoid can vent Port 1 the gas to atmosphere If the unloading gas is a contaminating gas that cannot be vented to atmosphere then the solenoid must vent this gas to the booster compressor suction line or a safe location If this valve is part of ...

Page 17: ...h Use a minimum of 3 8 tubing of appropriate pressure rating to connect to the pressure source All other ports will be connected The valve is set to close unload the compressor when there is no power or unloader pressure present When the valve is energized and has a pneumatic pressure source the valve will open thereby loading the compressor The actuated valve is specially sized for the pulsing fl...

Page 18: ...ngs should not be changed by anyone other than the manufacturer or an authorized service facility Any line leading to or from a compressor that can be blocked by a valve or other device whether during normal operation or during a failed operation MUST be equipped with a safety relief device The safety valve must be of a material compatible with the gas being compressed and must be able to handle a...

Page 19: ...ases and the H series Gas Packing Case Vent Purge Connection Port must be plumbed at installation for G H series boosters used with gases that require the highest degree of containment To operate effectively the packing cases must be properly plumbed see Figure 15 If your booster compressor is of the B configuration you do not need to add any additional plumbing If your booster compressor is of th...

Page 20: ... or nonhazardous non contaminating gases as follows see Figure 16 B21 Two pairs of tangent tangent segmented packings per rod set for suction pressures above ambient and below 100 psig B31 Three pairs of tangent tangent segmented packings per rod for inlet pressures of 100 psig to 165 psig B22 Two pairs of tangent tangent segmented packings per rod set for suction pressures at or below ambient B32...

Page 21: ...o of Packings per Rod 2 Pressure side Bottom Vents Plugged Maximum Inlet Pressure atmospheric Minimum Inlet Pressure 8 psia B32 Series No of Packings per Rod 3 Pressure side Bottom Vents Plugged Maximum Inlet Pressure atmospheric Minimum Inlet Pressure 8 psia Figure 16 Gas Packing Arrangements for B Series Air Boosters and Gas Compressors Cont d ...

Page 22: ...pensive and difficult to solve without completely reinstalling the compressor and may void the warranty Call the factory for assistance Remember There is no safe gas other than air G SERIES BOOSTERS The G series booster compressor is designed to compress standard industrial gases and allows for venting or purging of the packings This gives a much greater degree of leakage control In the G series t...

Page 23: ...ure 10 psig Note Tighter gas control G321 Series No of Packings 3 Upper 2 Lower Pressure side Top Vent Pressure Atmospheric Suction Maximum Inlet Pressure 165 psig Minimum Inlet Pressure 10 psig Note Tightest gas control 1 8 NPT Vent ports must be plumbed to safe vent location purged or padded 1 8 NPT Vent ports must be plumbed to safe vent location purged or padded 1 8 NPT Vent ports must be plum...

Page 24: ...re 0 psig Note Tighter gas control G322 Series No of Packings 3 Upper 2 Lower Pressure side Bottom Vent Pressure Atmospheric Suction Maximum Inlet Pressure 10 psig Minimum Inlet Pressure 0 psig Note Tightest gas control 1 8 NPT Vent ports must be plumbed to safe vent location purged or padded 1 8 NPT Vent ports must be plumbed to safe vent location purged or padded 1 8 NPT Vent ports must be plumb...

Page 25: ... tanks are secured and bolted down Air Booster and Gas compressors must have a properly sized filter installed at the suction receiver inlet to protect the booster from system contamination Filter should be 1 micron or better sized for minimal pressure drop Ambient Air Compressors must have an inlet filter installed Ensure properly sized pressure safety valves are protecting the inlet and discharg...

Page 26: ... have been operated at speeds in excess of 800 RPM reduced volumetric efficiencies and shortened valve and piston ring life result Hycomp recommends keeping compressor speed below the maximum recommended for optimum service life and warranty compliance CRANKCASE LUBRICATION Hycomp compressors ship with HYSYN SAE 30 ISO 68 synthetic compressor oil in the crankcase unless otherwise requested All Hyc...

Page 27: ...sure to 45 50 PSIG with compressor at normal operating temperature Each valve disc changes the oil pressure by approximately 2 5 PSIG OIL PUMP DIRECTION OF ROTATION The oil pumps on B C D E G H and V blocks are reversible F blocks are not reversible To reverse the operating direction of the oil pump perform the following steps 1 Remove the hydraulic unloader constant speed unloader control piping ...

Page 28: ...ushing and sheave on the motor shaft 3 Place the belt s on the motor sheave and compressor flywheel and temporarily tighten belt by adjusting the motor base mount Note Banded V belts may need to be installed at the same time as the motor sheave for ease of assembly 4 Place a straight edge across the face of the compressor flywheel spanning the motor sheave An angular misalignment will be observed ...

Page 29: ...ablish a reference line Deflect the belt until the bottom edge of the lower o ring is at the correct deflection distance Find the deflection force on the upper scale of the tension tester The sliding rubber O ring will move up the scale as the tester is compressed See figure 19e Figure 19c V Belt Deflection Measurement Figure 19e Tension Gauge Example Compare the deflection force with the range of...

Page 30: ...essure lubricated Hycomp model ambient air compressors can be set up for constant speed unloading When used in conjunction with a hyrdraulic unloader valve this allows protection from low oil pressure damage as well as allowing the compressor to run continuously with varying air demands If the compressor starts stops more than six 6 times per hour this is the preferred control Air pressure from th...

Page 31: ... 5 18 150 5 20 RV008 160 5 15 170 5 20 175 5 23 200 5 25 250 10 30 Table 6 Constant Speed Unloader Valve Differential Pressure Setting unload pressure counterclockwise for decreased unload pressure When adjusted properly tighten down locknut The differential pressure is set by use of the screw marked differential adjustment Increase the differential pressure by turning clockwise decrease by turnin...

Page 32: ... receiver tank directly to the switch Contact the factory if adjustments of more than 5 are required Unload Timeout Timer UTO This timer relay is set at the factory so the compressor motor will shut down after a pre set amount of time when running in an unloaded state Generally this length of time is 10 20 minutes Adjustment may be made to fine tune the compressor system for maximum operational ef...

Page 33: ...d Time out Unloaded Startup Time Enclosure Control Relays Discharge Pressure Switch with adjustable deadband Adjust as needed for actual site requirements Suction Pressure Switch with fixed deadband Adjust for actual site conditions Figure 21b Unloader Control Pressuer Switch Adjustments Figure 21a Unloader Control Timer Relay Adjustment ...

Page 34: ...crease valve opening in relation to the coolant temperature normally 115 F to 150 F range 25 F minimum above maximum gas inlet temperature Coolant pressure must not exceed 100 PSIG The valve has an integral bypass orifice to permit accurate opening response to increasing fluid temperatures Warning Hycomp compressors are uniquely engineered for service specific application Consult the factory befor...

Page 35: ...35 Controls Adjustment Notes make notes here Device Setting Date ...

Page 36: ...ctory prior to shipment In most cases it is not necessary to perform any special start up procedures on a new compressor Occasionally the unit may need an extended amount of break in time to seat the piston rings and create proper wear patterns Units that have been in storage for an extended length of time may require special attention Refer to sections in this manual on Inspection After Extended ...

Page 37: ...ise to working pressure within 10 15 seconds If there is a question about oil pressure stop the compressor and investigate Refer to the Section titled Maintenance and Troubleshooting for assistance if operation is not normal Check the pressure gauges or system pressure gauges for proper readings If inadequate or excessive pressure conditions occur shutdown the compressor Design conditions must be ...

Page 38: ... a bubble test or an electronic sniffer that determines the amount of the gas in the surrounding air Any leaks that are found must be fixed at once before standard operation of the compressor is resumed DAILY STARTUP CHECKLIST 1 Check the oil level in the crankcase 2 Drain liquid from the air receiver and moisture traps if equipped 3 Turn on cooling water if not regulated by the system 4 Start com...

Page 39: ...g that the compressor is being serviced 3 Lock open a pressure relief valve within the pressurized system to allow the system to completely depressurize SECTION 3 MAINTENANCE AND TROUBLESHOOTING 4 Shut off the cooling water supply where applicable 5 Open all drain valves within the area to be serviced 6 Wait for the unit to cool before servicing Temperatures above 120 F can cause burns to the skin...

Page 40: ...o fit requirements differing from the listed conditions Reasonable judgement in the frequency of maintenance and the stocking of spares must be exercised by the customer Facilities that cannot afford to be shutdown without excessive costs or hardships must provide a more rigorous schedule and larger quantity of spares than facilities that can do without the compressor for a short period of time Th...

Page 41: ...HECK THE COMPRESSOR X CHECK OIL PRESSURE X CHECK DISCHARGE PRESSURE X DRAIN THE CONDENSATE FROM PIPING SYSTEM DRAIN LEGS AND AIR RECEIVER X CHECK FOR OIL IN DISTANCE PIECE X CHECK THE CRANKCASE OIL LEVEL X CHECK FOR LEAKS IN THE PIPING SYSTEM X MANUALLY OPERATE ALL SAFETY VALVES X CLEAN CYLINDER INTERCOOLER AND AFTERCOOLER COOLING SURFACES X CHECK V BELT TENSION X REPLACE INTAKE FILTER ELEMENT X C...

Page 42: ...OMPRESSOR RUNNING CHECK FOR LOW OIL PRESSURE IF AIR ESCAPES BUT OIL PRESSURE IS NORMAL REMOVE THE HYDRAULIC UNLOADER AND PILOT VALVE AND CHECK THEIR VALVE SEATS IT IS NORMAL FOR AIR TO LEAK FROM THE DISCONNECTED TUBE WHEN THE COMPRESSOR IS STOPPED IF A HYDRAULIC UNLOADER IS USED TOUBLESHOOTING CHART INSUFFICIENT AIR PRESSURE OR VOLUME TROUBLESHOOTING WARNING The compressor MUST be locked out from ...

Page 43: ...KWISE WHEN VIEWED FROM THE OIL PUMP END IF NOT CHECK WITH A COMPETENT ELECTRICIAN TO SEE IF THE MOTOR ROTATION CAN BE CHANGED BY RECONNECTING THE MOTOR LEADS TOUBLESHOOTING CHART cont d LOW OR NO OIL PRESSURE DIRTY COOLING SURFACES INADEQUATE VENTILATION LEAKING SECOND STAGE VALVES CAUSING HIGH FIRST STAGE AIR PRESSURES RESTRICTION IN AIR LINES CLEAN THE COOLING SURFACES OF THE CYLINDER HEAD CYLIN...

Page 44: ...NGS PROCEED WITH REMOVING CRANKSHAFT END PLAY PER SERVICE SECTION CHECK DIAMETER OF GUIDE PISTON IF WITHIN SPECIFICATION GUIDE CYLINDER MAY BE WORN REPLACE GUIDE RING BY REMOVING CYLINDER HEAD AND PISTON CHECK COMPRESSION CYLINDER AND PISTON FOR DAMAGE REMOVE VALVES AND INSPECT VALVE AND CYLINDER HEAD FOR DAMAGE USING A NEW VALVE SEAT GASKET TIGHTEN VALVE COVER THEN VALVE CLAMP SCREW REMOVE COMPRE...

Page 45: ...ir Compressors these are compressors whose inlet source is the ambient air surrounding the compressor Air Boosters these are compressors that compress air that is taken from a source other than the ambient air Generally the inlet air source is at an elevated pressure but vacuum applications can also be accomplished The inlet air is usually taken from customer s existing plant air system Gas Compre...

Page 46: ...tension value to be greatly higher and may lead to bolt failure Table 8 is supplied as a guideline only for use where a torque setting is not given The table is not meant to replace researching the proper torque value for the application TOOL LIST FOR SERVICING Alist of tools needed for service Hycomp compressors is included inAppendix 1 This is a fairly comprehensive list but site conditions may ...

Page 47: ...linder wall surface finish 12 18 RMS HM HN style piston rings are available in a wide variety of materials and designs Contact the factory if you are unsure if your rings need to be replaced MODEL MINIMUM CLEARANCE A B Block General 0 045 C Block General 0 050 D Block General 0 055 E Block General 0 060 F Block General 0 070 AN3A AN4A AN6 WN4A 0 045 AN12 2AN8 0 045 AN6C AN10C AN26 0 050 2AN3C 2AN1...

Page 48: ...7500 to 1 7505 0 0003 to 0 0006 0 8745 to 0 8755 D Block including AN12D AN17D AN44 2AN10D 2AN15D 2AN26 2AN35 2AN40 WN44 2WN35 2WN40 0 0020 to 0 0035 0 003 to 0 004 2 9960 to 2 9930 2 2475 to 2 2485 0 0003 to 0 0006 0 8745 to 0 8755 E Block including AN14E AN20E AN27E AN72E 2AN61 2AN76 WN14E WN20E WN72 WN90 2WN13E 2WN17E 2WN22E 2WN61 2WN76 0 0020 to 0 0035 0 0035 to 0 0050 3 9929 to 3 9950 2 2475 ...

Page 49: ...ny shims or thrust washers with the piston Repeat this process for the second piston You may remove the piston rings from the piston at this point F Block Use the special rod clamping tool P N SA003 to hold the piston rod while removing the upper piston rod nut Remove piston from the piston rod Repeat for the second piston There are NO shims You may remove the piston rings from the piston at this ...

Page 50: ...gear assembly through the bearing carrier bushing Install new shaft gear assembly in bearing carrier and replace O ring Replace outer rotor in oil pump cover Place a few drops of oil or grease in the oil pump cover to lubricate at start up e With the oil pump drive shaft assembly in the bearing carrier set the oil pump shaft so that the slot in the shaft aligns with the drive pin in the crankshaft...

Page 51: ...he crankshaft through the oil pump end of the crankcase The bearing cones can be removed from the crankshaft with a bearing puller 6 Remove the bearing cover plate from the flywheel end of the crankcase The bearing cup is pressed into the crankcase and must be removed with a bearing puller Remove all shims from the bearing cover plate and crankcase 7 Grease the outer edges of the new bearing cups ...

Page 52: ... connecting rod and into other end of the crosshead piston Put the second snap ring in place Allow the assembly to cool Repeat with second assembly 3 After connecting rod and crosshead assembly have cooled place the split bearing halves into the connecting rod halves aligning the bearing tang with the grooves in the connecting rod Liberally coat the bearing faces with grease 4 Set the top of the c...

Page 53: ...lace 4 drops of Loctite Item 266 near end of thread of each of the two bolts Being careful not to contaminate Loctite screw both bolts into rods and tighten to specified torque Use piston rod tool P N SA003 to keep piston rod from spinning and loosening lower bolt f Recheck piston to head clearance F Blocks a Remove bolts holding oil packing box to crosshead cylinder Slide oil packing box up the p...

Page 54: ...valve models unloader fingers springs platform Install valve clamp 3 Discharge valves and non unloaded suction valves a Remove the valve hold down screw nut P N FQ003 or FQ004 Remove the valve hold down screw with an Allen wrench b Remove the valve cover and discard valve cover gasket c Remove the clamp and or spacer valve assembly and valve gasket d Disassemble the valve and inspect the valve sea...

Page 55: ... plate should move down when pushed from above with a probe 3 Discharge valves a Remove the valve cover and discard valve cover O ring Remove the valve assembly b Disassemble the valve and inspect the valve seat plate and spring Repair or replace as necessary Valve seats can be lapped to clean up minor damage Valve plates should be replaced if damaged Turning over a damaged valve plate will lead t...

Page 56: ...r 8 Precision caliper 0001 accuracy o Precision depth gauge dial indicator 001 accuracy o V belt gauge o Gasket scraper tool o 6 Rule o Flashlight o Brass drift o Propane torch o Multimeter w temperature probe desirable o Ammeter o Abrasive pad ScotchBrite or similar o Oil free silicone o ring lubricant o Teflon pipe thread tape and Loctite 545 thread sealant o High temperature silicone gasket sea...

Page 57: ...r Place several bags of desiccant into crosshead area NOTICE Tag the unit with a warning that the compressor is partially disassembled Copy the tag printed on this page 4 Store the unit under plastic off the ground The box pallet the unit came in is excellent storage container Store the unit indoors 5 When the compressor is to be put into service change the crankcase oil remove any desiccant and r...

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Page 60: ...WI 400 010 APP 1 Rev 5 Rev 2 13 ...

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