jordair/bauer ik12 - Jordair Compressors Inc.

Transcription

“JBP” SERIES FILTER SYSTEMS
OPERATIONS MANUAL
101-7950 Huston Rd.
Delta, BC V4G 1C2 Canada
Website: www.jordair.ca
JORDAIR – “RELIABILITY & SAFETY” - BAUER
Doc. Jordair COMPRESSOR-MANUAL-2013
Phone: 1-604-940-8101
Fax: 1-604-940-8131
Email: [email protected]
WARNING!
High pressure air has Tremendous Kinetic Energy;
Shut off valves on air storage cylinders, fill station and any other air control panels.
Depressurize system slowly before starting any service work.
This reduces risk of Explosive Venting.
General instructions for filter maintenance
–
Dry inside of filter housing with a clean cloth before installing new cartridge and check for corrosion.
–
Lubricate threads and o-rings as well as threads on filter chamber.
–
Observe number of operating hours to ensure compliance with service intervals.
–
Change cartridge before returning to service any compressor that has out of service for more than six months.
–
Leave cartridge in the filter chamber as long as the unit is out of service, in order to absorb moisture in the filter system.
–
Keep all condensate drain-valves and shut-off valves closed. Maintain a minimum pressure of approximately 50 to 80 barg
(700 to 1000 psig) within the system to prevent moisture entering the filter system.
Maintenance intervals
•
Replace cartridges every six months or according to Securus indicator.
•
All o-rings and back-up rings are to be changed with filters; lower filter cap o-ring and back-up ring changed annually.
•
Service check valve annually; replace kit.
•
Service auto drain annually; replace kit.
•
PMV serviced annually replace kit.
•
See respective section for complete procedures.
All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, or stored in a database or
retrieval system, without the prior written permission of Jordair Compressors Ltd.
101-7950 Huston Rd.
Doc. FILTER-SYSTEMS-MANUAL-2013
1
Phone: 1-604-940-8101
Fax: 1-604-940-8131
DESCRIPTION
PART NO.
DESCRIPTION
PART NO.
AD-101
QTY.
1
Autodrain, Single Bank
J-BD-1-5
PMV-101
1
Pressure Maintaining Valve
J-PMV-6000
CH-101
1
Check Valve
J-5CV-P-4
PRV-101
1
Pressure Relief Valve
3305-A01-KC3750
EB-101
1
Electrical Box / System
see Fig. 2
SEC-101
1
Securus Monitor
N15096
FIL-101
1
Filter Chamber, Drying
JBF-6300-32
SEP-101
1
Oil / Water Separator
JS-6300-4.5-18-1008
FIL-102
1
Filter Chamber, Drying
JBF-6300-32
SV-101
1
Solenoid Valve
7131KBN2BR00N0C111P3
FIL-103
1
Filter Chamber, Purifying
JBF-6300-32S
VA-101
1
Drain Valve
11430
PI-101
1
Pressure Gauge
J-0-6000
VA-102
1
Drain Valve
11430
101-7950 Huston Rd.
QTY.
2
Phone: 1-604-940-8101
Fax: 1-604-940-8131
101-7950 Huston Rd.
3
Phone: 1-604-940-8101
Fax: 1-604-940-8131
330S-A01-KC3750 Relief valve
Relief valve needs to be tested, set and certified to the
operating pressure and to be replaced as a complete unit if
found defective.
330S-A01-KC3750 RELIEF VALVE
ITEM
QTY
MATERIAL
DESCRIPTION
1
1
SS SA479-304
Nozzle
2
1
Teflon®
O-ring
3
1
SB211 Alloy 2024 T3511
Body Aluminum
4
1
SS A313-302
Bottom Spring
5
1
SS A582-303
Bottom Disc
6
1
Aluminum B211 Alloy 2024 T351
Bottom Spring Step
7
1
Kynar®
Insert
8
1
Teflon®
Seal
9
1
SS A582-303
Top Disc
10
1
Steel A231 Aluminum Coated
Top Spring
11
1
SB-211 Alloy 6061-T6
Cap Aluminum
12
1
Aluminum B211 Alloy 2024 T351
Top Spring Step
13
1
SS A582-303
Compression Screw
14
1
SS A582-303
Jam Nut
101-7950 Huston Rd.
4
Phone: 1-604-940-8101
Fax: 1-604-940-8131
SERVICE OF THE SEPARATOR NON-RETURN VALVE
•
The separator non-return valve is located on the outlet of
the oil and water separator.
Ensure that the separator is vented of all pressure and the
filter towers are also depressurized.
Remove the valve from the system and remove the tube
connecting fittings so that the internal poppet can be
removed.
Clean and check the valve for any seat damage.
The poppet assembly is to be replaced annually, the
complete valve is to be replaced if there is any leakage or
seat body wear or damage noticed during inspection.
Thoroughly clean the body of all old lubricant or oil
emulsions.
Lubricate all contact surfaces in the body and install the
poppet with the new seals.
Install the valve in the system while ensuring the valve is
oriented in the correct direction of the airflow.
•
•
•
•
•
•
•
SEPARATOR NON-RETURN VALVE
101-7950 Huston Rd.
ITEM
QTY
1
1
J-03-P017
PART NO.
Body
2
1
J-2-009
O-ring
3
1
J-03-P016
Sleeve
4
1
J-03-P013
Spindle
5
1
J-5CV-P-4-S
Spring
6
1
J-03-P014
Seat
J-CVP-5K
Kit includes items 2,3,4,5,6
5
DESCRIPTION
Phone: 1-604-940-8101
Fax: 1-604-940-8131
SERVICE OF THE OIL AND WATER SEPARATOR
•
•
•
•
•
•
•
•
•
•
•
•
Disconnect the inlet and outlet pressure lines so that
the separator top cap can be removed for service of the
filter element.
Carefully remove the top cap from the barrel by turning
counter-clockwise with the filter wrench (Jordair part #
J-FW-FD).
Inspect the interior of the barrel chamber, Oring/backup ring groove and the internal/external
threads of each mating component to ensure that they
are free from any damage and debris.
Loosen top retainer (Item 2; Fig 6).
Remove the bottom retainer (Item 5; Fig 6).
Remove the element (Item 4; Fig 6).
Replace the O-ring (Item 5; Fig 5) and the backup ring
(Item 4; Fig 5) in each cap. Carefully insert the rings
into the O-ring/backup ring groove ensuring that the Oring directly experiences the pressure and the concave
side of the backup ring experiences the pressure
imposed by the O-ring.
Carefully insert the new element (Item 4; Fig 6) over the
retainer stem (Item 3; Fig 6).
Ensure that the element has been fully seated into the
groove in the top retainer (Item 2; Fig 6).
Cautiously tighten the bottom retainer onto the
retainer stem, tightening the element. Ensure that the
element is snug by loosening, then tightening the top
retainer onto the element. Ensure, also, that the
retainer stem has remained securely tightened within
the separator cap.
Lubricate the O-rings/back-up rings, cap and chamber
threads with a silicone based O-ring and thread
lubricant.
– Jordair part number SIL-2 or SIL-4.
Carefully lower the top cap into the chamber, vertically
centered, and fully engage the top cap. The O-ringsealing surface prevents leakage once the barrel and
cap are fully engaged so that the mating surfaces are in
contact. Do not tighten beyond initial contact of these
surfaces.
101-7950 Huston Rd.
JS6300-4.5-18 SPEARATOR CHAMBER
ITEM
QTY
1
1
JS-TOP CAP-6300
PART NO.
Cap, Top
2
1
JS-BOTTOM CAP-6300
Cap, Bottom
3
4
SHOP-POPAD42ABS
Pop Rivet
4
2
J-8-333
Back-up Ring
5
2
J-2-333
O-ring
6
1
JS-BARREL-6300
Barrel
7
1
FC-1008
Assembly, Separator Element (Fig.3)
8
1
NAMEPLATE-8
Nameplate
6
DESCRIPTION
Phone: 1-604-940-8101
Fax: 1-604-940-8131
SERVICE OF THE OIL AND WATER SEPARATOR
•
•
•
•
•
•
•
•
•
•
•
Disconnect the inlet and outlet pressure lines so that the
separator top cap can be removed for service of the filter
element.
counter-clockwise with the filter wrench (Jordair part # JFW-FD).
Inspect the interior of the barrel chamber, O-ring/backup
ring groove and the internal/external threads of each
mating component to ensure that they are free from any
damage and debris.
Loosen top retainer (Item 2; Fig 6).
Remove the bottom retainer (Item 5; Fig 6).
Remove the element (Item 4; Fig 6).
Replace the O-ring (Item 5; Fig 5) and the backup ring
(Item 4; Fig 5) in each cap. Carefully insert the rings into
the O-ring/ backup ring groove ensuring that the O-ring
directly experiences the pressure and the concave side of
the backup ring experiences the pressure imposed by the
O-ring.
Carefully insert the new element (Item 4; Fig 6) over the
retainer stem (Item 3; Fig 6).
Ensure that the element has been fully seated into the
groove in the top retainer (Item 2; Fig 6).
Cautiously tighten the bottom retainer onto the retainer
stem, tightening the element. Ensure that the element is
snug by loosening, then tightening the top retainer onto
the element. Ensure, also, that the retainer stem has
remained securely tightened within the separator cap.
threads with a silicone based O-ring and thread lubricant.
101-7950 Huston Rd.
JS6000-4.5-18 SPEARATOR CHAMBER
ITEM
QTY
1
1
JS-TOP CAP-6300
PART NO.
Cap, Top
2
1
NAMEPLATE-8
Nameplate
3
4
SHOP-POPAD42ABS
Pop Rivet
4
2
J-8-326
Back-up Ring
5
2
J-2-326
6
1
FC-708-SE
7
1
JS-BARREL-6300
O-ring
Assembly, Separator Element
(Fig.3)
Barrel
7
DESCRIPTION
Phone: 1-604-940-8101
Fax: 1-604-940-8131
FC-708-SE SEPARATOR ASSEMBLY
PART NO.
FC-1008-SE SEPARATOR ASSEMBLY
ITEM
QTY.
ITEM
QTY.
1
1
HN18.8F012
Nut
1
1
HN18.8F012
Nut
2
1
FC-74-T
Retainer, Top
2
1
FC-104-T
Retainer, Top
3
1
FC-73
Stem
3
1
FC-103
Stem
4
1
FC-708-SE
Separator Cartridge
4
1
FC-1008-SE
Separator Cartridge
5
1
FC-74-B
Retainer, Bottom
5
1
FC-104-B
Retainer, Bottom
101-7950 Huston Rd.
DESCRIPTION
PART NO.
8
DESCRIPTION
Phone: 1-604-940-8101
Fax: 1-604-940-8131
SERVICE OF THE SEPARATOR AUTODRAIN
•
The separator automatic drain block is connected to the base of the
separator by a 1/4" drain line.
The drain is designed to fail open which prevents a large quantity of
liquid accumulating in the event of a failure of the drain solenoid
valve.
The timer located in the control box will drain accumulating liquids
every 15 minutes and is inter-locked to open the valve when the
compressors shut down venting all air from the separator.
The drain valve is to be serviced each year and checked for wear,
have all seats, seals and O-rings replaced and lubricated.
Remove the valve top four cap screws, which allows the top and base
to be disconnected from the body.
Remove the piston and the base seat.
Check the piston for wear or damage on the sealing surface.
Replace the lower seat and O-rings from the kit and lubricate.
Replace the piston cup seal and O-rings.
Thoroughly clean the body of all old lubricant or oil emulsions.
Lubricate all contact surfaces in the body and install the piston with
the new seal.
Replace the lower and upper caps and tighten the four cap screws in
an opposite sequence and then the drain is ready to be placed back
in service.
•
•
•
•
•
•
•
•
•
•
•
SEPARATOR AUTODRAIN
ITEM
QTY
PART NO.
1
4
SHC18.8C14.4
Cap Screw
2
1
J-ADTM-1
Manifold Top
3
1
J-2-029
O-ring, Manifold, Top
4
1
J-BD-CUPSEAL
Cupseal
5
1
J-ADP-HP
Piston, High Pressure, J-BD-X-5
6
1
J-2-111
O-ring, Piston, High Pressure, -X-5
7
1
J-CADB-K
Body
8
1
J-2-018
O-ring, Manifold, Side
9
1
J-2-017
O-ring, Seat, Top
10
1
J-BD-HP
Seat, High Pressure
11
1
J-2-010
O-ring, Seat, Bottom
12
1
J-BADB
Base, High Pressure
13
1
J-ADMB
Mounting Bracket
14
1
J-ADSM-1
Manifold, Side
15
2
SHC18.8C14.112
Cap Screw
J-ADK-HP
Repair Kit: Incl. #2, 4, 6, 8, 9, 10, 11
101-7950 Huston Rd.
DESCRIPTION
9
Phone: 1-604-940-8101
Fax: 1-604-940-8131
VENT BLOCK
•
•
•
The vent block gauge provides the air pressure in the
filter system.
Use the vent valve (item 2) to drain all pressure prior
to replacing filter cartridges.
The vent valve seat (part no. 13283) is to be replaced
during each annual service of the system.
J-PSVB-6000 VENT BLOCK
ITEM
QTY
PART NO.
1
1
J-0-6000
6000 psig, 2 1/2", Oil-filled Pressure Gauge
2
1
11430
Valve
13283
Repair Kit
101-7950 Huston Rd.
DESCRIPTION
10
Phone: 1-604-940-8101
Fax: 1-604-940-8131
Use Jordair cartridge #FTP-3408-JB.
Bauer cartridge #58825 can also be
substituted.
ITEM
QTY
1
2
3
4
5
6
6
7
8
9
10
11
12
2
1
1
2
2
1
1
1
1
1
1
1
4
Use Bauer Securus
cartridge #60037 only.
JBF-6300-16 FILTER CHAMBER
PART NO.
DESCRIPTION
SHC18.8C38.12
JBF-COVERPLATE
JBF-TOPCAP
J-8-339
J-2-339
058825
FTP-1807-JB
J-2-112
J-2-110
JBF-BARREL-33
JBF-BOTTOMCAP
NAMPLATES-10
SHOP-POPAD42ABS
Cap Screw
Cover Plate
Assembly, Cap, Top
Back-up Ring, Cap
O-ring, Cap
Filter Cartridge
Filter Cartridge
O-ring, Filter Element
Barrel
Cap, Bottom
Nameplate
Pop Rivet
Bauer Securus
ITEM
ITEM
QTY
1
2
3
4
5
2
1
1
2
2
6
1
6
1
7
8
9
10
11
12
1
1
1
1
1
4
ITEM
QTY
1
2
3
4
5
2
1
1
2
2
6
1
6
1
7
8
9
10
11
12
1
1
1
1
1
4
PART NO.
DESCRIPTION
SHC18.8C38.12
JBF-COVERPLATE
JBF-TOPCAP
J-8-339
J-2-339
FTP-2807-JB or
67224 or 61687
FTP-2804-JB or
062504
J-2-112
J-2-110
JBF-BARREL-33
JBF-BOTTOMCAP
NAMPLATES-10
SHOP-POPAD42ABS
1
2
3
4
5
6
7
8
9
10
11
12
Cap Screw
Cover Plate
Assembly, Cap, Top
Back-up Ring, Cap
O-ring, Cap
Filter Cartridge
Filter Cartridge
Barrel
Cap, Bottom
Nameplate
Pop Rivet
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
PART NO.
DESCRIPTION
SHC18.8C38.12
JBF-COVERPLATE
JBF-TOPCAP
J-8-339
J-2-339
FTP-3804-JB or
058825
FTP-3807-JB or
060037 or 058827
J-2-112
J-2-110
JBF-BARREL-33
JBF-BOTTOMCAP
NAMPLATES-10
SHOP-POPAD42ABS
101-7950 Huston Rd.
Cap Screw
Cover Plate
Assembly, Cap, Top
Back-up Ring, Cap
O-ring, Cap
Filter Cartridge
Filter Cartridge
JBF-6300-22-S SECURUS FILTER CHAMBER
QTY
PART NO.
DESCRIPTION
2
1
1
2
2
1
1
1
1
1
1
4
SHC18.8C38.12
JBF-COVERPLATE-S
JBF-TOPCAP
J-8-339
J-2-339
060037
J-2-112
J-2-110
JBF-BARREL-33
JBF-BOTTOMCAP
NAMPLATES-10
SHOP-POPAD42ABS
Cap Screw
Cover Plate
Assembly, Cap, Top
Back-up Ring, Cap
O-ring, Cap
Filter Cartridge
Barrel
Cap, Bottom
Nameplate
Pop Rivet
JBF-6300-32-S SECURUS FILTER CHAMBER
QTY
PART NO.
DESCRIPTION
2
1
1
2
2
1
1
1
1
1
1
4
SHC18.8C38.12
JBF-COVERPLATE-S
JBF-TOPCAP
J-8-339
J-2-339
060037
J-2-112
J-2-110
JBF-BARREL-33
JBF-BOTTOMCAP
NAMPLATES-10
SHOP-POPAD42ABS
Cap Screw
Cover Plate
Assembly, Cap, Top
Back-up Ring, Cap
O-ring, Cap
Filter Cartridge
Barrel
Cap, Bottom
Nameplate
Pop Rivet
Barrel
Cap, Bottom
Nameplate
Pop Rivet
11
Phone: 1-604-940-8101
Fax: 1-604-940-8131
SERVICE OF THE FILTER CHAMBERS
•
•
•
•
•
•
•
•
•
•
JBF-TOP CAP-S SECURUS CAP
ITEM
QTY
1
1
59850-410
PART NO.
RF Connector
2
1
JBF-CAP TOP-S
Cap, Top, Securus, JBF-6300 Filter
3
1
59851-410
Plug
4
1
59852-410
Drawback Screw
5
1
JBF-PIN
Pin, JBF-6300-32S Filter
6
1
60062-640
Spring, Pin
7
1
59854-410
Stud
8
1
59855-410
Nut
9
1
2181-640
Spring, Cap, Top
101-7950 Huston Rd.
DESCRIPTION
•
•
In order to service the lower cap O-ring and back up ring
the filter chamber lower base support must be removed.
Disconnect the inlet and outlet pressure lines so that the
lower cap can be removed for service of the O-rings and
back up rings.
counter-clockwise with the filter wrench (Jordair part # JFW-FD).
Inspect the interior of the barrel chamber, O-ring/backup
ring groove and the internal/external threads of each
mating component to ensure that they are free from any
damage and debris.
Cautiously remove the drying/filtering element by pulling
up on the extraction handle of the cartridge.
Replace the O-ring (Item 5; Fig 9, Fig 10) and the backup
ring (Item 4; Fig 9, Fig 10) in each cap. Carefully insert the
rings into the O-ring/backup ring groove ensuring that the
O-ring directly experiences the pressure and the concave
side of the backup ring experiences the pressure imposed
by the O-ring.
Carefully insert the new drying or filtering cartridge until it
is fully contained in the lower cap.
threads with a silicone based O-ring and thread lubricant.
– Jordair part number SIL-2 or SIL-4.
Carefully lower the top cap into the chamber, vertically
centered, and fully engage the top cap into the barrel.
The barrel is to be installed so that the threads are fully
engaged and the top cap meets the lower face. It is not
recommended to tighten the barrel and cap beyond the
point of meeting of the surfaces. Over-tightening the cap
could potentially seize the cap and barrel making it very
difficult or impossible to open in the future.
Acquire new and correct O-ring and backup ring sizes and
quantities, and carefully insert the rings into the Oring/backup ring groove ensuring that downstream of the
pressurized side, the O-ring directly experiences the
pressure and the concave side of the backup ring
experiences the pressure imposed by the O-ring.
Vertically center the mating components and cautiously
fully engage them. The O-ring-sealing surface prevents
leakage once the barrel and cap are fully engaged so that
the mating surfaces are in contact. Do not tighten beyond
initial contact of these surfaces.
12
Phone: 1-604-940-8101
Fax: 1-604-940-8131
SERVICE OF THE PRESSURE MAINTAINING VALVE
•
•
•
•
•
•
•
•
•
•
•
•
The purifying system pressure maintaining and non-return
valve is located on the outlet of the final purification
chamber.
The purifying system pressure maintaining and non-return
valve is located on the outlet of the final purification
chamber.
Remove the valve from the system and remove the tube
connecting fittings so that the seat retainer (item 5; fig 12)
and seat poppet (item 7; fig 12) can be removed for
replacement and service.
Clean and check the valve for any seat damage or sign of
wear or marks in the body of the valve.
The seat poppet located on the end of the seat retainer is to
be replaced annually, the complete valve is to be replaced if
there is any leakage or body wear or damage noticed during
inspection.
Thoroughly clean the body and all parts of all old lubricant.
Lubricate all contact surfaces in the body and install the seat
assembly and the stainless steel control seat (item 10; fig 12)
with the new seals (item 6, item 9; fig 12).
Install the seat retainer in the body.
Insert the spring over the retainer stem and screw down the
spring retainer until it bottoms on the face of the body
section.
Install the stainless control seat and replace the retaining
fitting to install back on the base of the final filter chamber.
Install the valve in the system while ensuring the valve is
oriented in the correct direction of the airflow.
Adjust the valve to the correct backpressure by turning the
spring tension screw assembly until the correct holding
pressure is reached for the filter system.
J-PMV-6000 PRESSURE MAINTAINING VALVE
PRESSURE SETTING CHART FOR THE PMV VALVE
The chart provides the Pressure Maintaining Valve (PMV) setting
point for the various operating pressures of the filter systems. The
set pressure of the valve is designed to optimize the adsorption
capacity of the drying media and provide the highest quality
breathing air.
ITEM
QTY
1
1
J-PAN-1
PART NO.
Spring, Tensioner
DESCRIPTION
2
1
J-BARREL-1
Spring, Retainer
3
1
FWUSSZ0516
Washer
4
1
J-PMV-S
Spring
5
1
J-PISTON-1
Seat, Retainer
6
1
J-2-008
O-ring, Retainer Seat
7
1
J-GASKET-1
Seat Poppet
8
1
J-BODY-1
Body
PMV SET PRESSURE
FILTER FINAL PRESSURE
9
1
J-0-010
O-ring, Control Seat
1200 PSIG
2000 PSIG
10
1
J-VALVE-1
Control Seat
J-PMV-K
Kit Includes Items 6, 7, 9
1800 PSIG
3000 PSIG
2400 PSIG
5000 PSIG
2800 PSIG
6000 PSIG
101-7950 Huston Rd.
13
Phone: 1-604-940-8101
Fax: 1-604-940-8131

jordair/bauer ik12 - Jordair Compressors Inc.

Transcription

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