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Page

BLACKMER HD COMPRESSORS

960515
INSTRUCTIONS CB9A-005

Installation, Operation, and Maintenance Instructions

Section

Effective

Replaces

901
Sep 2021
Oct 2019

MODEL: HD082C

TABLE OF CONTENTS

Safety Data

................................................................ 2

General Information

Compressor Data ................................................. 3

Nameplate Data .................................................... 4

Installation

Location and Piping .............................................. 6

Mounting the Compressor Unit ............................ 6

Stationary Compressors ....................................... 6

Truck Mounted Compressors ............................... 6

Compressor Flywheel ........................................... 7

V-Belt Drive ........................................................... 7

PTO Drive ............................................................. 7

Maximizing Compressor Life ................................ 8

Relief Valves ......................................................... 8

Liquid Traps .......................................................... 8

4-Way Valves ........................................................ 9

Temperature and Pressure Switches .................. 9

Pressure Gauges .................................................. 9

Suction Valve Unloaders ...................................... 9
Seal (Packing) Arrangements ............................ 10

Operation

Pre Startup Check List .......................................... 11

Start Up Procedure ............................................... 12

Maintenance

Service Schedule .................................................. 13

Tool List ................................................................. 14

Bolt Torque Table .................................................. 14

Crankcase Lubrication .......................................... 15

Setting the Oil Pressure ........................................ 15

Compressor Disassembly

....................................... 16

Compressor Assembly

............................................ 17

Valve Replacement

................................................... 19

Unloader Seal Replacement

.................................... 20

Piston Ring Replacement

........................................ 20

Seal (Packing) Replacement

................................... 21

Bearing Replacement

............................................... 22

Oil Pump Replacement

............................................ 23

Extended Storage

..................................................... 23

Troubleshooting

....................................................... 24

Содержание HD082C

Страница 1: ...ive 7 PTO Drive 7 Maximizing Compressor Life 8 Relief Valves 8 Liquid Traps 8 4 Way Valves 9 Temperature and Pressure Switches 9 Pressure Gauges 9 Suction Valve Unloaders 9 Seal Packing Arrangements 10 Operation Pre Startup Check List 11 Start Up Procedure 12 Maintenance Service Schedule 13 Tool List 14 Bolt Torque Table 14 Crankcase Lubrication 15 Setting the Oil Pressure 15 Compressor Disassembl...

Страница 2: ... compressors MUST only be installed in systems which have been designed by qualified engineering personnel The system MUST conform to all applicable local and national regulations and safety standards These instructions are intended to assist in the installation and operation of Blackmer compressors and MUST be kept with the compressor Blackmer compressor service and maintenance shall be performed...

Страница 3: ...and out prior to performing service or maintenance Disconnecting fluid or pressure containment components during compressor operation can cause serious personal injury death or major property damage Hazardous or toxic fluids can cause serious injury Hazardous pressure can cause serious personal injury or property damage Explosive gas can cause property damage personal injury or death Extreme heat ...

Страница 4: ... com or by contacting Blackmer s Customer Service NAMEPLATE DATA A nameplate is attached to the side of all Blackmer compressors showing the Model No I D No and Serial No These numbers should be available when information or parts are needed for a particular unit The basic size and type of the compressor is indicated by Model No A suffix letter is used on most models to indicate the version For de...

Страница 5: ...E A SEAL PACKING ORIENTATION Field 6 All Lips up 1 Top Lips Down Bottom Up Tube to Stage 1 outlet 2 Top Lips Up Bottom Down 3 Up Down Up 5 Down Down Up 6 Down Up Down 7 Up Up Down Vented 8 Down Up Down Vented 9 SEAL MATERIAL Field 7 PTFE T CYLINDER HEAD Field 8 Ductile Iron A TNT 12 DI Cylinder B TNT 12 DI Cyl Head C PISTON RODS Field 9 Chrome Plated Steel 1 CrO2 Coated Steel 3 Black Surface Steel...

Страница 6: ...ct the flexible connector hose manufacturer for required maintenance care and design assistance in their use 4 Piping must be adequately supported to ensure that no piping loads are placed upon the compressor 5 Both suction and discharge piping should slope down from the compressor The compressor should not be placed at a low point in the piping system Discharge piping surface temperatures may be ...

Страница 7: ...n explosive atmospheres causing severe personal injury or death Hazardous gases can cause property damage personal injury or death V BELT DRIVES Most Blackmer compressors are driven via V belts which must be properly aligned and tensioned Failure to disconnect and lockout electrical power or engine drive before attempting maintenance can cause severe personal injury or death Hazardous machinery ca...

Страница 8: ...RELIEF VALVES A relief valve of a type material and pressure rating suitable to the installation MUST be installed The relief valve shall be installed in the discharge line between the compressor head and the first block valve Compressor operating against closed valve can cause system component failure personal injury or property damage Hazardous pressure can cause serious personal injury or prope...

Страница 9: ... A 10 second delay timer should be used to lock the low oil pressure switch out during compressor startup PRESSURE SWITCHES Pressure switches may be installed in the suction or discharge gas stream as protective devices for compressor control or for other uses varying with each application and system design PRESSURE GAUGES Install pressure gauges in the discharge and inlet lines to verify actual s...

Страница 10: ...ns Fig 5 SEAL ORIENTATION SINGLE SEAL COMPRESSORS Fig 6 Typical Seal Area Construction Fig 7 Seal orientation double seal models Table 4 SEAL ARRANGEMENTS ALL DOUBLE SEAL COMPRESSORS Type 1 2 3 Inlet Pressure Atmospheric Pressure or above Vacuum to 25 psia Service General Gas Transfer Toxic Flammable or otherwise Hazardous Gases General Gas Transfer Special Upper Distance Piece Connections Plugged...

Страница 11: ... can cause personal injury or property damage 3 If V belt driven check the alignment of the motor and the compressor sheaves The faces of the sheaves must be parallel 4 Ensure that pressure gauges are installed on both inlet and discharge of the compressor 5 Blackmer compressors are shipped from the factory without oil in the crankcase Fill with a high quality non detergent oil of the proper visco...

Страница 12: ...erty damage personal injury or death The oil pump on these models will operate in either direction of crankshaft rotation 2 Verify that the suction and discharge pressures are within the expected ranges Operating limits listed in the Compressor Data section must not be exceeded 3 Check for leakage from the piping and equipment and repair as necessary 4 If the seals packing have just been replaced ...

Страница 13: ...ious injury Hazardous pressure can cause serious personal injury or property damage Explosive gas can cause property damage personal injury or death Extreme heat can cause personal injury or property damage Hazardous gases can cause property damage personal injury or death Extreme Heat can cause personal injury or property damage NOTICE Blackmer compressor service and maintenance shall be performe...

Страница 14: ...6 1 4 3 8 Valves Sockets 7 16 1 2 9 16 5 8 3 4 7 8 Various Internal Snap Ring Pliers Seal Replacement Feeler gauges or Depth Micrometer Piston Clearance Screwdriver Flat Blade Nameplate screws Packing Installation Pliers Rubber Mallet Arbor Press Wrist Pin Removal Bearing Puller Crankshaft Bearings Torque Wrench Various Hoist useful Cylinder and Crosshead Guide Table 6 TOOL LIST BOLT TORQUES FOR B...

Страница 15: ...ing requirements Before changing the oil bring the compressor up to normal operating temperature Remove the crankcase drain plug and drain the oil into an adequately sized container Remove the oil pickup screen and clean in a suitable solvent When reinstalling the pickup screen inspect the metal gasket and the O ring for damage replacing as necessary If equipped replace the external oil filter See...

Страница 16: ...crews 5 Lift the cylinder and cylinder O rings from the crosshead guide or distance piece 6 Packing Box Removal a Using an adjustable spanner wrench remove the packing box hold down rings Replace the nylon locking inserts in the hold down rings during reassembly b Remove the packing box and packing box O ring from the piston rod c For disassembly of the packing box refer to the Seal Packing Replac...

Страница 17: ...ton rod and crosshead and slowly lower it against the crankcase Make certain that the crosshead assembly is started straight in the bore of the crosshead guide to prevent binding when lowering the crosshead guide into position d Install the crosshead guide capscrews DO NOT tighten 3 Fill the crankcase with oil Refer to the Crankcase Lubrication section Squirt oil into the crankshaft roller bearing...

Страница 18: ... 11 PISTON CLEARANCE a Rotate the flywheel by hand to bring one piston to the top b Measure the distance from the top of the piston to the top of the cylinder HD082C 015 to 030 381 to 762 mm Table 10 Piston Clearance c If necessary remove the piston and add or subtract shims accordingly d Install new nylon locking inserts in the piston retainer nuts e Thread the piston nut onto the piston rod and ...

Страница 19: ...h as Blackmer PN 790535 3 Valve Removal and Disassembly 080 Series Models a Remove the valve cage and unloader plunger actuator and spring b Remove the valve assembly and the valve gasket c Inspect the valve for wear or breakage d Valve Repair i Unscrew the valve halves and remove the spring and plate ii Inspect and replace worn components iii Reassemble valves as shown below and tighten the valve...

Страница 20: ...ollow steps 1 through 3 of Compressor Disassembly 2 Remove the piston rings and the piston ring expanders from the pistons 3 To replace the piston rings a Place an expander in the top groove of the piston Place an expander in the second groove with the break in this expander 180 degrees from the break of the top expander Place the third expander in the bottom groove with its break in the same posi...

Страница 21: ...ng through the top of the packing box flat side down into the cavity between the upper and lower packing NOTE The oil deflector ring will be positioned between the two sets of packing Install the second set of packing per step b 4 Packing Break in The lower packing MUST be manually lubricated with oil several times during the first 60 minutes of compressor operation to prevent overheating of the p...

Страница 22: ... bearing cone onto each end of the crankshaft with the tapered end outward The bearing race should rest against the shoulder on the crankshaft e Lubricate the bearings with grease 8 Install the crankshaft through the outboard end of the crankcase 9 With the oil pump assembly removed install the bearing carrier and new gasket The bolt hole positions ensure proper orientation Tighten the bolts evenl...

Страница 23: ...mage to the compressor may occur Complete compressor disassembly and replacement of rod packing bearings and other parts may be required 1 Keep a written record storage procedures performed preferably on the unit itself 2 Fill the crankcase with rust inhibiting oil New compressors leave the factory without oil Squirt oil on the piston rods and crossheads through the nameplate opening Loosen the V ...

Страница 24: ...ion plates and repair as necessary 4 No Oil Pressure 9 Oil Pump Relief Valve Not Properly Set Set oil pump relief valve 10 10 Oil Pump Not Working Check the Oil Pump drive tab or stop pin for damage 11 11 Low Oil Level Check and fill as necessary 12 12 Dirty Oil Inlet Strainer Clean Oil Inlet Strainer Gas Leaking from Crankcase Breather 13 Faulty Worn Packing Replace Packing 14 14 Piston Rod Score...

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Страница 28: ...CB9A 005 page 28 28 1809 Century Avenue Grand Rapids Michigan 49503 U S A 616 241 1611 Fax 616 241 3752 www blackmer com ...

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