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VP30/VP500

MAINTENANCE INFORMATION

MAINTENANCE

INFORMATION

VP30/VP500 Compressor

Introduction
Description of compressor parts
Maintenance

Checking the oil level
Storage of Compressor
Changing the oil
Microfilter element change
Valve Inspection
Unloader system inspection
Cooler inspection
Starting compressor after Maintenance
General maintenance notes

Troubleshooting

Low output flow or pressure
Blowing safety Valves
Leakage from HP receivers
Low oil pressure
Knocking
Rumbling

Fig 1 - Compressor, complete
Fig 2 – Crankcase
Fig 3 – Crankcase
Fig 4 – Piston and connecting rod

July 21

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Summary of Contents for VP30

Page 1: ...oil Microfilter element change Valve Inspection Unloader system inspection Cooler inspection Starting compressor after Maintenance General maintenance notes Troubleshooting Low output flow or pressure Blowing safety Valves Leakage from HP receivers Low oil pressure Knocking Rumbling Diagrams Fig 1 Compressor complete Fig 2 Crankcase Fig 3 Crankcase Fig 4 Piston and connecting rod July 21 1 of 42 ...

Page 2: ... 1st Stage Cylinder Fig 6 2nd Stage Cylinder Fig 7 3rd Stage Cylinder Fig 8 Fan and guard Fig 9 Coolers Fig 10 Unloader Manifold Fig 11 Unloaders Fig 12 Oil Lubrication Fig 13 Crankcase Breather Fig 14 Motor Fig 15 Microfilter July 21 2 of 42 ...

Page 3: ... Air cooled compressor with a maximum working pressure of 350 Bar 5000 psi Lubrication is by Integral crankshaft driven oil pump to crankshaft and big end bearings and by splash oil mist to the cylinder bores and small end bearings Intercoolers are fitted at each stage of compression with condensate separators and safety valves The compressor is driven by an induction motor and belt driven at 1230...

Page 4: ... cylinders and cylinder heads The cooling coils are copper Crankcase Breather Because the compressor is a gas compressor the crankcase is connected to the first stage inlet to prevent wastage of any gas which blows past the piston rings Motor The motor is a three phase induction motor It is linked via a belt drive coupling to the end of the compressor crankshaft Oil Filler The oil filler cap is wh...

Page 5: ...ndensed oil will be vented every time the compressor is stopped Stage Pressure gauges Stage Pressure gauges After each cooler there is a pressure gauge which shows the gas pressure for each stage when the compressor is running The gauges should all reduce to zero after the unloader has vented the gas from each stage when the compressor stops Safety valves Safety valves After the cooler at each sta...

Page 6: ...ankshaft oil seals will fail Oil pressure gauge and switch A pressure gauge indicates the compressor s oil pressure The oil pressure should normally remain between 2 4 Bar when the compressor is running The oil pressure switch provides a signal to the control system The compressor will be stopped immediately in an alarm state if the compressor oil pressure is lost when the compressor is running Oi...

Page 7: ...from the list If you wish to change to a different lubricant the oil must be drained first Storage of Compressor If the compressor is stored without running for an extended period i e greater than 2 months the cylinders cylinder heads and valves must be checked for cleanliness and condition before re starting All parts must be lubricated on assembly See Valve inspection below for more information ...

Page 8: ... from the body Unscrew and remove the filter element by hand Clean the inside of the bowl and body with a cloth Check the condition of the internal O ring If in doubt re place the O ring Screw on the new filter element by hand Replace the filter bowl and tighten until the bowl only UNTIL it stops turning The bowl seals on its O ring not on the thread or the face DO NOT OVERTIGHTEN Replace the drai...

Page 9: ...aces are clean and smooth Clean the mating surface and cylinder bore of the cylinder 5 6 Ensure that no dust or dirt particles remain in the cylinder 5 6 Use compressed air to blow out if necessary If the valve plate assembly 5 10 is excessively worn it must be re placed Reassemble in reverse order fitting new gaskets When reassembling lubricate every component except gaskets with clean lubricatin...

Page 10: ... dust or dirt particles remain in the cylinder Use compressed air to blow out if necessary If the valve 7 10 is excessively worn it must be replaced Seals 7 8 7 9 7 13 should always be replaced to avoid premature leakage When installing these seals ensure that they are correctly located around the valves Reassemble in reverse order When reassembling lubricate every component except gaskets but inc...

Page 11: ...the compressor Unscrew and remove the four cover retaining screws and remove the cover from the bottom of the valve Withdraw the piston and seals from inside the valve noting the arrangement of parts Clean the piston and the inside of the unloader valve using a cloth and petroleum gasoline Check the piston seals for wear or damage Replace any worn or damaged seals Check the piston and unloader val...

Page 12: ... is leaking from the compressor cylinders or coolers the output flowrate will fall resulting in low pressure Carry out leakage test 1st stage cylinder head If the 1st stage cylinder head gasket is leaking or the valve plate gasket is damaged the flowrate will fall Check that the gaskets 5 9 and 5 11 are correctly fitted and in good condition Unloader system If the unloader valves do not seat corre...

Page 13: ...cylinder head gasket damaged Check and replace 2nd stage suction valve faulty Check and clean replace 2nd Stage safety valve blowing 3rd stage concentric valve and or seals worn or damaged Check and clean replace 3rd Stage safety valve blowing Outlet Check Valve or outlet pipes blocked Check and Clean Replace Leakage from HP receivers If the pressure in the HP receivers or pipework reduces even wh...

Page 14: ... FIGURE REF DETAILS MANUAL PAGE 1 INDEX OF PICTURES 17 2 CRANK CASE 18 3 CRANKSHAFT 20 4 PISTON AND CONNECTING ROD 22 5 CYLINDER COMPL 1ST STAGE 24 6 CYLINDER COMPL 2ND STAGE 26 7 CYLINDER COMPL 3RD STAGE 28 8 FAN WHEEL AND GEAR WHEEL GUARD FOR AXIAL FAN 30 9 COOLING 32 10 UNLOADER MANIFOLD 34 11 UNLOADERS 37 12 OIL LUBRICATION 39 13 CRANK CASE BREATHER 41 14 MOTOR 43 15 MICROFILTER 45 Fig 1 Compr...

Page 15: ...VP30 VP500 MAINTENANCE INFORMATION Fig 2 Crankcase July 21 15 of 42 ...

Page 16: ...125997 EXTENSION 1 2 X 50 1 17 030880 GASKET RING 20 7 X 28 X 1 5 1 18 001180 LOCKING SCREW R1 2 1 19 076333 SCREW M12 X 45 4 20 161874 GASKET RING 34 3 X 42 X 2 1 21 165851 BEARING COVER SV 225 350 1 22 181539 SCREW M6 X 30 6 23 094447 SPRING WASHER D6 4 24 181539 SCREW M6 X 30 4 25 073466 O RING 71 X 2 1 26 138703 PUMP COVER 1 27 153818 RETAINING RING 47X1 75 1 28 001104 LOCKING SCREW 1 2 1 29 0...

Page 17: ...VP30 VP500 MAINTENANCE INFORMATION Fig 3 Crankcase July 21 17 of 42 ...

Page 18: ...12 x 8 x 45 1 5 157732 cylinder roller bearing 1 6 162036 shaft sealing ring A 55 x 80 x 10 1 7 007390 reataining ring 55 x 2 1 8 500473 bearing 1 9 001511 screw M8 x 30 1 10 094455 spring washer D8 1 11 089893 washer 1 12 153818 spring washer 47 x 1 75 1 13 039942 axial bearing washer 1 14 139475 radial shaft seal DG 22 x 35 x 7S 1 15 16 139416 oil pump 1 17 139394 cylinder roller bearing 1 July ...

Page 19: ...VP30 VP500 MAINTENANCE INFORMATION Fig 4 Piston and connecting rod July 21 19 of 42 ...

Page 20: ...st Pos Part Number Description Quantity 1 162021 CONNECTING ROD CPL 3 2 519239 PISTON CPL 50 70 1 3 148962 PISTON RING M50X45 8X2 5 6 4 197829 PISTON CPL 27 70 1 5 198276 PISTON RING M 27X24 6X2 6 6 519676 PISTON CPL 16 70 1 7 198274 PISTON RING M 16X14 5X2 8 July 21 20 of 42 ...

Page 21: ...VP30 VP500 MAINTENANCE INFORMATION Fig 5 1st Stage Cylinder July 21 21 of 42 ...

Page 22: ...er D12 4 4 080764 nut M12 4 5 004286 stud M10 x 25 4 6 181429 cylinder d50 1 7 094463 spring washer D10 4 8 080772 nut M10 4 9 112925 cylinder gasket 1 10 113239 lamella valve 1 11 112950 cylinder head gasket 1 12 001147 locking screw 1 8 1 13 175110 gasket ring 10 x 13 5 x 2 0 Cu 1 14 181568 cylinder head 1 15 094447 spring washer D6 6 16 001414 screw M6 x 45 6 July 21 22 of 42 ...

Page 23: ...VP30 VP500 MAINTENANCE INFORMATION Fig 6 2nd Stage Cylinder July 21 23 of 42 ...

Page 24: ...094471 SPRING WASHER D12 4 4 080764 NUT M12 4 5 004286 STUD M10 X 25 4 6 073440 O RING 70 X 2 1 7 164542 CYLINDER D27 1 8 094463 SPRING WASHER D10 4 9 080772 NUT M10 4 10 161559 CYLINDER GASKET D38 1 11 162033 LAMELLA VALVE LV 111 1 12 161560 CYLINDER HEAD GASKET 1 13 161920 CYLINDER HEAD 1 14 094455 SPRING WASHER D8 4 15 514339 SCREW M8 X 75 4 July 21 24 of 42 ...

Page 25: ...VP30 VP500 MAINTENANCE INFORMATION Fig 7 3rd Stage Cylinder July 21 25 of 42 ...

Page 26: ...ER 1 3 004294 STUD M10X30 6 4 073440 O RING 70 X 2 1 5 094463 SPRING WASHER D10 6 6 080772 NUT M10 6 7 197040 CYLINDER D16 1 8 028070 GASKET RING 58X65X0 6 CU 1 9 028193 GASKET RING 28 2X34X0 5 CU 1 10 172951 VALVE 1 11 175119 CYLINDER HEAD 1 12 163547 SCREW M12X90 4 13 175588 GASKET RING 1 14 175118 NUT M42X2 1 15 175117 PRESSURE SCREW 1 July 21 26 of 42 ...

Page 27: ...VP30 VP500 MAINTENANCE INFORMATION Fig 8 Fan and guard July 21 27 of 42 ...

Page 28: ...n and Guard parts list Pos Part Number Description Quantity 1 156710 cover 1 2 138800 washer D6 4 3 3 002275 screw M 6x12 3 4 001368 screw M6 x 25 9 5 094447 spring washer D6 9 6 163602 fan blade type E 189 9 7 197490 boss fan 1 July 21 28 of 42 ...

Page 29: ...VP30 VP500 MAINTENANCE INFORMATION Fig 9 Coolers July 21 29 of 42 ...

Page 30: ...25003 pipe 12 0 x 1 5 3 163292 pipe 8 0 x 1 5 4 162176 fitting EVW 15 LR 2 5 069028 fitting EVT 8 PSR 1 6 096130 fitting EVT 12 L 1 7 082988 fitting GE 12 LR 1 2 1 8 068390 fitting Ri 1 2 x 1 4 1 9 148733 fitting SWVE 12 LR 3 8 1 10 161015 fitting G 15 PL 1 11 103829 fitting G 8 S 1 12 069256 fitting G 12 L 1 July 21 30 of 42 ...

Page 31: ...VP30 VP500 MAINTENANCE INFORMATION Fig 10 Unloader Manifold July 21 31 of 42 ...

Page 32: ... 1 13 14 093270 FITTING SWVE 6 LR 4 15 096423 DISCHARGE VALVE CPL 2 16 094447 SPRING WASHER D6 9 17 002372 SCREW M6 X 50 9 18 163294 NOZZLE D1 M5 2 19 039063 GAUGE 63D 0 63 BAR 1 20 039047 GAUGE 63D 0 160 BAR 1 21 198331 GAUGE 63D 0 600 BAR 1 22 001597 SCREW M8 X 55 4 23 026760 GASKET RING R 1 4 CU 3 24 106860 REDUCING FITTING 1 8 X 1 4 3 25 175110 GASKET RING 10 X 13 5 X 2 0 CU 3 26 068390 FITTIN...

Page 33: ...TING SWVE 6SR 1 40 103128 NON RETURN VALVE RHD 6S 1 41 191069 NOZZLE D0 8 M8 1 42 501658 MICRO FILTER CPL 1 43 170426 FITTING GE 8PSR 3 8 1 44 030872 GASKET RING 21 5X28 7X2 5 1 45 187101 SAFTY VALVE 375BAR 1 46 186683 SAFTY VALVE 125BAR 1 47 158796 SAFTY VALVE 30BAR 1 48 069027 FITTING EVW 8 SR 1 49 197838 FITTING GE 6 L R1 4 1 50 094455 SPRING WASHER D8 6 51 002488 SCREW M8X25 2 52 005550 NUT M8...

Page 34: ...VP30 VP500 MAINTENANCE INFORMATION Fig 11 Unloaders July 21 34 of 42 ...

Page 35: ... cover 1 11 072737 o ring 10 x 3 6 12 96768 nozzle D2 M5 2 13 030848 gasket ring UA 16 x 10 x 1 5 3 14 064254 discharge valve seat 3 15 027871 Gasket ring A 21x26 Cu 3 16 125121 locking screw R1 2 3 17 186671 screw M5x4 1 18 027782 Gasket ring A 10x13 5 Cu 3 19 125130 locking screw 1 8 3 20 094447 spring washer D6 9 21 002372 screw M6 x 50 9 22 163295 nozzle D1 5 2 23 163294 nozzle D1 M5 2 24 0932...

Page 36: ...VP30 VP500 MAINTENANCE INFORMATION Fig 12 Oil Lubrication July 21 36 of 42 ...

Page 37: ...cription Quantity 1 162057 connecting piece 1 2 197840 fitting Ge 6 Zlr 3 3 162025 fitting RHV 6 LR 3 4 125407 spring washer D5 4 5 000230 screw M5 x 60 4 6 33693 ball valve 1 7 161875 gasket ring 14 7 x 22 x 1 5 1 8 162059 oil pressure switch 1 9 197839 fitting Ge 6 Zlr 1 July 21 37 of 42 ...

Page 38: ...VP30 VP500 MAINTENANCE INFORMATION Fig 13 Crankcase Breather July 21 38 of 42 ...

Page 39: ...ing GE 12 LR 1 2 1 4 068101 tube socket 1 2 x 1 2 1 5 189711 non return valve 1 6 163287 fitting GE 12 LR 1 2 1 7 155772 tube socket R1 4 x 12 2 8 160530 non return valve 1 4 3 9 159846 fitting MAV EV 12 LR 1 10 189715 fitting Ge 12 L R 1 4 1 11 159846 fitting MAV EV 12 LR 1 12 069078 fitting EVW 12 L 1 13 068713 fitting EVL 12 L 1 14 160531 safty valve 1 July 21 39 of 42 ...

Page 40: ...VP30 VP500 MAINTENANCE INFORMATION Fig 14 Motor July 21 40 of 42 ...

Page 41: ...lley D 132 1 6 080772 nut M10 4 7 196925 motor base 1 8 196926 motor base 1 9 006319 splint 4 x 32 2 10 162448 washer D13 4 11 197453 shaft pivoting motor base 1 12 196924 holder pivoting motor base 1 13 157155 distance tube 1 14 002690 screw M10 x 50 1 15 198336 grid down 1 16 138800 washer 6 4 8 17 002259 screw M6 x 8 8 18 198335 grid top 1 19 197454 v belt 2 20 197844 v belt pulley D 315 1 July...

Page 42: ...VP30 VP500 MAINTENANCE INFORMATION Fig 15 Microfilter 1 169531 2 101184 3 163140 July 21 42 of 42 ...

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