MAXIMATOR VP30 Einrichtungshandbuch

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
Diagrams
Fig 1 - Compressor, complete
Fig 2 – Crankcase
Fig 3 – Crankcase
Fig 4 – Piston and connecting rod
July 21 1 of 42

VP30/VP500

MAINTENANCE INFORMATION

Fig 5 – 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

VP30/VP500

MAINTENANCE INFORMATION

Introduction

This section provides detailed information about the high pressure compressor, including:

•General information

•Description of components

•Servicing

•Parts lists

•Drawings

The VP30 (also referred to as VP500) compressor is a Three Stage reciprocating 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 RPM.

The main compressor components are identified in the photographs below.

July 21 3 of 42

VP30/VP500

MAINTENANCE INFORMATION

Description of compressor parts

Compressor Stages

The Compressor takes gas from the suction vessel at approximately 6 BarG and compresses it in

three stages up to a maximum of 350 Bar (5000 psi). Three stages of compression are used

together with the intercoolers, to reduce the temperatures at each stage of compression.

The cylinder bores reduce in size from the first to the third stage, as the pressure in-creases.

All cylinders have cooling fins to dissipate the compression heat in the blast from the fan. Each

stage of compression has a suction valve and a delivery valve located in the cylinder head to

prevent the gas from flowing back into the previous stage.

Coolers

After each stage of compression, the gas is passed through the coiled cooling coils at the front of

the compressor to remove the heat of compression. In front of the cooling coils is a large air blast

fan which blows cooling air first over the cooling coils and then over the finned 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 where the lubricating oil is added to the

compressor. See later this section for filling and changing

instructions.

Microfilter

After the final cooler and condensate separator is a small

Microfilter, which removes any remaining oil droplets from the

compressed gas. The drain of the filter is piped to the unloader

system so that it vents automatically whenever the compressor

stops running. It is not necessary to drain this filter periodically.

Because of the limited volume of the filter, CINPRES’s control

systems Include an ‘Autovent’ facility to stop the compressor for

a short period (normally 1 minute) after a set running time

(normally 30 minutes). This ensures that the filter bowl does not

become full and prevents oil from being passed over into the

high pressure gas line.

July 21 4 of 42

VP30/VP500

MAINTENANCE INFORMATION

Unloaders

Every time the compressor stops, gas pressure is retained in the cylinders and coolers of each

stage. This gas pressure must be vented to allow the compressor to be started ‘off-load’. The

unloader system is an automatic system for venting this pressure. The system is operated by oil

pressure from the lubrication system, which prevents the gas from each stage from venting to the

unloader vent. Therefore, when the compressor stops and the oil pressure subsides, the unloader

valves will open and the gas will be vented. The Microfilter is also connected to the unloader

system, and its contents, including any condensed 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 stage is also fitted a safety valve, which prevents each stage from

becoming over pressurised. If a safety valve begins to ‘blow’ (or vent gas to atmosphere), it is

normally a sign that the compressor needs to be serviced.

Outlet

At the compressor outlet, there is a non return valve (check valve). This stops gas from the HP gas

receivers and pipes from venting back through the compressor’s unloader system to atmosphere

when the compressor stops.

July 21 5 of 42

VP30/VP500

MAINTENANCE INFORMATION

Oil sight glass

The oil sight glass is used to check the oil level in the compressor sump. It is essential that the oil

level is checked regularly and kept between the minimum and maximum marks. Failure to maintain

the correct oil level will result in failure of the compressor:

● If the oil level is too low, it will result in failure of the compressor due to insufficient

lubrication and overheating.

● If the oil level is too high, it is likely that the crankshaft 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.

Oil drain plug

The oil drain plug is used to drain the lubricating oil from the compressor sump. Note that the oil

should be drained from the compressor when it is warm. On some systems, where accessibility is

limited, a valve and a pipe may be found instead of the drain plug.

July 21 6 of 42

VP30/VP500

MAINTENANCE INFORMATION

Maintenance

It is essential that regular maintenance is carried out. During

operation of the compressor, carbon deposits will build up on the

compressor valves. If the maintenance is not carried out in

accordance with the instructions in this manual, these deposits can

cause loss of performance and damage to pistons and cylinders.

Checking the oil level

Check the oil level when the compressor is STOPPED. The oil

level must be between the minimum and maximum marks on the

oil sight glass. If required, top up the oil level using the

recommended lubricating oil. Remove the oil filler cap to top up.

After topping up, wipe off any spillage to prevent burning of oil lying

on hot surfaces.

Recommended Lubricating oil:

Use only the following synthetic lubricating oils:

ANDEROL 500

ANDEROL 555

MOBIL RARUS 827

NEVER mix two different oils 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.

Changing the oil

Run the compressor until warm (about 10 minutes). Stop the

compressor and isolate the power. Place a container underneath

the drain plug (or drain pipe) to collect the drained oil. Note: the oil

sump capacity is 3.5 litres. Unscrew and remove the drain plug (or

open the drain valve, if fitted). Allow the oil to drain into the

container. Whilst the oil is drained, if required, remove and clean

the oil sight glass and replace. Clean the drain plug with

petroleum (gasoline), replace and tighten. Remove the oil filler

plug and refill with the recommended lubricant, checking for

correct oil level using the oil sight glass. Replace the oil filler plug.

July 21 7 of 42

VP30/VP500

MAINTENANCE INFORMATION

Microfilter element change

The Microfilter has a replaceable element (Part number 163140). The “O” ring 169531 and the disc

101184 should be replaced together with the element. To change the element, the compressor

must be stopped:

Unscrew the locking grub screw 2 turns.

Remove the drain pipe.

Using a large spanner, unscrew the filter bowl 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 drain pipe. If necessary, loosen the Banjo fitting to align

the pipe, ensuring that the arrows on the 1 way valve point upwards.

Tighten the locking grub screw.

July 21 8 of 42

VP30/VP500

MAINTENANCE INFORMATION

Valve Inspection

Make sure that the compressor is stopped and the power is isolated before carrying out this

work.

Valve Cleaning

Note: do not dismantle valve assemblies for cleaning purposes. Parts within the assembly

can be easily damaged.

Carefully clean the valve plate assemblies using soft scrappers (e.g. Copper, wood, plastic), and

petroleum (gasoline) to remove carbon deposits and dirt. Ensure that any traces of gasket material

are removed and that the mating surfaces are clean and smooth.

1st Stage Valves

Disconnect the inlet hose from the cylinder head 5/14

Unscrew the tubing nut adaptor and detach cooler tube from the cylinder

head.

Unscrew and remove capscrews 5/16 and washers 5/15 evenly.

Remove the cylinder head 5/14 from the cylinder 5/6, removing the valve

plate 5/10

Carefully clean the valve plate assembly 5/10 using soft scrapers (e.g.

copper, wood, plastic) and petroleum (gasoline) to remove carbon deposits

and dirt. Ensure that any traces of gasket material are removed and that the

mating surfaces are clean and smooth.

Clean the inside of the cylinder head 5/14. Ensure that any traces of gasket

material are removed and that the mating surfaces 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 lubricating oil.

On reassembly, tighten the cylinder head screws to the correct torque loading.

2nd Stage Valves

Unscrew the tubing nut adaptors and detach cooler tubes from the cylinder head.

Unscrew and remove capscrews 6/15 and washers 6/14 evenly.

Remove the cylinder head 6/13 from the cylinder 6/7, carefully removing the 2nd stage valve plate

assembly 6/11 which is located between the cylinder head and cylinder.

Carefully clean the valve plate assembly 6/11 using soft scrapers (e.g. copper, wood, plastic) and

petroleum (gasoline) to remove carbon deposits and dirt. Ensure that any traces of gasket material

are removed and that the mating surfaces are clean and smooth.

Clean the inside of the cylinder head 6/13. Ensure that any traces of gasket material are removed

and that the mating surfaces are clean and smooth.

Clean the mating surface and cylinder bore of the cylinder 6/7. Ensure that no dust or dirt particles

remain in the cylinder. Use compressed air to blow out if necessary.

July 21 9 of 42

VP30/VP500

MAINTENANCE INFORMATION

If the valve plate assembly 6/11 is excessively worn it must be replaced.

Reassemble in reverse order, fitting new gaskets. When reassembling, lubricate every component

(except gaskets) with clean lubricating oil.

On reassembly, tighten the cylinder head screws to the correct torque loading.

3rd Stage Valves

Unscrew the tubing nut adaptors and detach cooler tubes from the cylinder head.

Unscrew and remove vavle retainer 7/15 and locking nut 7/14, together with seal 7/13.

Unscrew and remove caphead screws 7/12 and lift off cylinder head valves 7/11.

Remove valve 7/10 together with seals 7/9 and 7/8.

Carefully clean valves using soft scrapers, (eg. copper, wood, plastic) and petroleum (gasoline) to

remove carbon deposits and dirt.

Clean the cylinder face of 7/7 and clean cylinder head 7/11 thoroughly, removing all traces of

carbon buildup. Ensure that all mating surfaces are clean and smooth.

Clean the mating surface and cylinder bore of the cylinder 7/7and remove the rest of 7/7 above.

Ensure that no 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

including O-rings) with clean lubricating oil.

To reassemble, locate valve 7/10 into the cylinder head 7/11 with seals 7/8 and 7/9. Mate the

assembly with the cylinder 7/7. Replace the capscrews 7/12, turning 1/16th turn at a time in a

diagonal pattern. Tighten to the correct torque loading.

Replace locking nut 7/14 with seal 7/13 and tighten against the valve.

Replace lock-ring 7/15 and tighten.

Re-attach the cooler tubes.

Type of screw

MMax

M6 screw, quality 8.8

10 Nm

M6 screw, quality 10.9

14 Nm

M8 screw, quality 8.8

24 Nm

M8 screw, quality 10.9

32 Nm

M10 screw, quality 8.8

50 Nm

M10 screw, quality 10.9

70 Nm

M12 screw, quality 8.8

88 Nm

M12 screw, quality 10.9

120 Nm

M12 screw, quality 12.9

130 Nm

Central pressure screw conc. valve

200 Nm

Maximum tightening torques for cylinder head screws and connecting rod screws

July 21 10 of 42

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