BLACKMER HD COMPRESSORS
Installation, Operation, and Maintenance Instructions
MODELS HD942B , HDL942B and HDS942B
960483
INSTRUCTIONS CB9A-031
Section
Effective
Replaces
901
Jun 2011
Mar 2011
TABLE OF CONTENTS
SAFETY DATA .......................................................... 1
GENERAL INFORMATION
Compressor Data ................................................. 2
Nameplate Data ................................................... 3
INSTALLATION
Location and Piping .............................................. 5
Mounting the Compressor Unit ............................ 5
Compressor Flywheel .......................................... 6
V-Belt Drive........................................................... 6
Seal Arrangements............................................... 6
Suction Valve Unloaders ...................................... 7
Maximizing Compressor Life................................ 7
Typical Compressor, Drawing.............................. 8
Relief Valves ......................................................... 8
4-Way Valves ....................................................... 8
Liquid Traps .......................................................... 8
Temperature and Pressure Switches .................. 8
Pressure Gauges ................................................. 8
OPERATION
Pre-Start up Check List .......................................... 9
Start Up Procedure ................................................. 9
MAINTENANCE
Bolt Torque Table ................................................. 10
Service Schedule / Tool List ................................. 11
Crankcase Lubrication / Oil Pressure Setting ...... 12
COMPRESSOR DISASSEMBLY.............................. 13
COMPRESSOR ASSEMBLY .................................... 14
UNLOADER SEAL REPLACEMENT ....................... 17
VALVE REPLACEMENT........................................... 17
SEAL (PACKING) REPLACEMENT ........................ 19
BEARING REPLACEMENT ...................................... 21
OIL PUMP REPLACEMENT ..................................... 22
EXTENDED STORAGE ............................................. 22
TROUBLESHOOTING............................................... 23
SAFETY DATA
NOTICE
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the product, or in the
manual, look for one of the following signal words and
be alert to the potential for personal injury or property
damage.
Warns of hazards that WILL cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury, or
property damage.
NOTICE
Indicates special instructions which are very important
and must be followed.
NOTICE
The HDS942 is designed for use in Sour Gas
Applications. Persons maintaining, repairing, or
working near the compressor or surrounding area
must have adequate safety training and
protection.
Blackmer 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 by qualified technicians ONLY. Service
and maintenance shall conform to all applicable local
and national regulations and safety standards.
Thoroughly review this manual, all instructions and
hazard warnings, BEFORE performing any work on
the compressor.
Maintain ALL system and compressor operation and
hazard warning decals.
For handling liquefied gas, NFPA Pamphlet 58 should
be consulted.
H2S atmospheres can cause serious
personal injury or death.
H2S atmospheres
can cause
serious personal
injury or death.
SAFETY DATA
Flammable gas can
cause death, serious
personal injury or
property damage
Flammable gas and/or liquid can form
explosive mixtures with air causing
property damage, serious personal injury
or death
Hazardous pressure
can cause serious
personal injury or
property damage
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Failure to relieve system pressure
prior to performing compressor
service or maintenance can cause
serious personal injury or property
damage.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Hazardous voltage.
Can shock, burn or
cause death.
Hazardous
machinery can
cause serious
personal injury.
If handling hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance
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.
Disconnecting fluid or pressure
containment components during
compressor operation can cause
serious personal injury, death or
major property damage
Extreme heat can cause personal
injury or property damage
Extreme Heat can
cause personal injury
or property damage
Hazardous gases
can cause property
damage, personal
injury or death
GENERAL INFORMATION
TABLE 1 - COMPRESSOR DATA
Air-Cooled
HD942B
Maximum Allowable Working Pressure
Water-Cooled
HDL942B
H2S Service
HDS942
350 psia (24.1 Bar)
52.5 CFM (89.1 m3/hr)
125.1 CFM (213 m3/hr)
Displacement @ 350 rpm (Minimum Speed)
Displacement @ 835 rpm (Maximum Speed) *
Maximum Motor Size
50 HP (37 kw)
Maximum Discharge Temperature
350F (176C)
Rotation Direction
Bi-Directional
Bore x Stroke, Two Double-Acting Cylinders
4.625" X 4" (117 mm X 102 mm)
Maximum H2S (Hydrogen Sulfide) Concentration
---
---
Type: Single-stage, vertical, air-cooled or water-cooled, non-lubricated, reciprocating compressor.
* NOTE: Reduce maximum speeds by 9% for continuous duty operation.
CB9A-031
page 2/24
8%
GENERAL INFORMATION
Figure 1 – Air-Cooled HD942B Compressor
MODEL: HD
ID#:
SERIAL NO:
Before proceeding:
1. Note the nameplate data in the space provided above.
2. Obtain the appropriate parts lists for the model in question.
Manuals and Parts Lists for Blackmer products may be obtained from
Blackmer's website (www.blackmer.com) or be 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.
Figure 2 - Compressor Nameplate
CB9A-031
page 3/24
GENERAL INFORMATION
An 11 character "I.D. No." identifies the construction of the compressor.
P
B
B
F
M
1
T
A
TABLE 2 - COMPRESSOR ID NUMBER KEY
VALVES
Ductile Iron / PEEK
DI/PEEK w/ Unloaders
TNT-12 DI/PEEK
TNT-12 DI/PEEK w/ Unloaders
Stainless Steel
SS w/ Unloaders
O-RINGS
Buna-N
Neoprene
PTFE
FKM
Ethylene-Propylene
Code
PB
PC
PE
PF
SB
SC
Field 3
B
N
T
V
E
Field 4
GASKETS
Aluminum
Iron
Copper
PISTON RINGS
Glass & Moly Filled
Poly Filled PTFE
SEAL (PACKING) ORIENTATION
5-ring Segmented
SEAL MATERIAL
PTFE
CYLINDER & HEAD
Ductile Iron
TNT-12 DI Cylinder
TNT-12 DI Cyl. & Head
PISTON RODS
CrO2 Coated Steel
Black Surface Steel
CRANKSHAFT & OIL FILTER
Spin-on Oil Filter
OTHER
Fields
A
F
C
Field 5
M
A
Field 6
B
Field 7
T
Field 8
A
B
C
Field 9
3
4
Field 10
C
A
Field 11
Notes: A 'Z' in any field indicates a non-standard option.
CB9A-031
page 4/24
4
C
A
INSTALLATION
NOTICE:
MOUNTING THE COMPRESSOR UNIT
Blackmer compressors must only be installed in
systems designed by qualified engineering personnel.
System design must conform with all applicable
regulations and codes and provide warning of all
system hazards.
NOTICE:
This compressor shall be installed in accordance with
the requirements of NFPA 58 and all applicable local,
state and national regulations.
A solid foundation reduces noise and vibration, and will
improve compressor performance.
On permanent
installations, it is recommended the compressor be
secured by anchor bolts as shown. This arrangement
allows for slight shifting of position to accommodate
alignment with the mounting holes in the base plate.
Install, ground and wire to local and
National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Hazardous voltage.
Can shock, burn or
cause death.
Disconnect and lockout electrical power
before installation or service
Electrical supply MUST match motor nameplate
specifications.
Motors equipped with thermal protection automatically
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
LOCATION AND PIPING
Compressor life and performance can be significantly
reduced when installed in an improperly designed system.
Before starting layout and installation of the piping system,
consider the following:
1. All piping must be leak free to a pressure of 1.5 times
the maximum system pressure.
NOTICE: If the system is to be hydro-statically
tested, the compressor MUST be isolated. Liquid
entering the compressor will cause damage and
void the warranty.
2. A strainer should be installed in the inlet line to protect
the compressor from foreign matter. A #30 mesh
screen or finer is recommended. Strainers must be
cleaned every 180 days, or more frequently if the
system requires.
3. Expansion joints, placed within 36" (0.9 m) of the
compressor, will compensate for expansion and
contraction of the pipes.
Contact 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.
Extreme Heat can
cause personal injury
or property damage
Figure 3 - Anchor Bolt
Set the anchor bolts in concrete for new foundations.
When compressors are to be located on existing concrete
floors, holes should be drilled into the concrete to hold the
anchor bolts.
To keep vibration at a minimum, in addition to a solid
concrete foundation, it is important that the concrete be
located on a stable soil foundation. The base must have
complete contact along its entire length with the
foundation. Visible separations will result in vibrations
which are magnified in the upper part of the unit.
Check compressor mounting bolts and baseplate anchor
bolts regularly.
See CB220 “Compressor Bases,
Foundations” for additional information.
Discharge piping surface temperatures
may be hot during operation (over
158°F, 70°). Temperatures should be
monitored and adequate warnings
posted.
CB9A-031
page 5/24
Skids
and
INSTALLATION
COMPRESSOR DRIVE SYSTEMS
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Hazardous
machinery can
cause serious
personal injury.
6.
Ensure that the radial and axial runout values at the
rim do not exceed the following values:
Radial O.D. Runout: 0.016 in. (0.4046 mm)
Axial Rim Runout: 0.021 in. (0.5334 mm)
7.
Ensure that the compressor flywheel guard is properly
installed before operation. The guard must not contact
moving parts.
V-BELT DRIVES
Most Blackmer compressors are driven via V-belts which
must be properly aligned and tensioned.
1.
Hazardous gases
can cause property
damage, personal
injury or death
Flywheel guard contact with moving
parts may be a source of ignition in
explosive atmospheres causing severe
personal injury or death
Operation without guards in place can
cause serious personal injury, major
property damage or death.
Hazardous
machinery can
cause serious
personal injury.
Lay a straight edge along the face of the motor sheave
and compressor flywheel.
2. Adjust either as needed to provide alignment.
3. Tighten the V-belts such that they are taut, but not
overly tight. Moderate thumb pressure should deflect
each belt about 1/4 – 3/8 in. (6 – 10 mm). Consult
your V-belt supplier for specific values.
4. Check the belt tension after 24 - 48 hours run-in.
Recheck the tension periodically, and tighten the
belts as required.
Caution should be used to avoid overtightening belts,
which can shorten bearing and belt life. Belts should be
inspected periodically for signs of excessive wear and
replaced if necessary.
FLYWHEEL
Blackmer compressors are fitted with flywheels which
MUST be used regardless of the type of drive system
employed.
Flywheels must be properly installed and aligned:
1. Ensure that the mating surface between the hub and
flywheel are clean and dry – do not use a lubricant.
2. Install the hub and key on clean compressor shaft,
flange end first.
3. Tighten the hub setscrew just enough to prevent it
from sliding on the shaft – do not overtighten.
4. Place the flywheel on the hub and loosely thread the
capscrews with lockwashers into the assembly. Do
not use lubricant on the capscrews.
5. Tighten all capscrews evenly and progressively in
rotation to the torque value in Table 4. There must be
a gap between the hub flange and the flywheel with
installation is complete. Do not over-torque. Do not
attempt to close gap between hub flange and
flywheel.
Hub
Size
SF
E (std)
F
Capscrew
Size
3/8 – 16
1/2 - 13
9/16 – 12
Torque
ft-lbs. (Nm)
30 (40.7)
60 (81)
75 (101)
SEAL ARRANGEMENTS
The seal arrangement type is noted by the 6th digit of the
compressor's ID Number on the nameplate. Refer to the
section 'SEAL REPLACEMENT' for seal arrangement
drawings.
Improper seal installation could release
explosive gas to the atmosphere
creating an explosion hazard, possibly
causing severe personal injury or death.
Hazardous gases
can cause property
damage, personal
injury or death
Seal Type B
The crosshead guide casting includes four 1/4" NPT
openings into the distance piece area. This is the area
separating the upper and lower sets of packing. The
upper openings should only be used after consulting the
factory.
The lower distance piece openings may used to drain any
oil/condensate that might accumulate in the distance
piece. If used, a normally closed valve must be fitted in
the drain line. Opening the valve will result in some
product leakage. Only one opening need be used.
Table 4 – Flywheel Hub Torque Values
CB9A-031
page 6/24
INSTALLATION
SUCTION VALVE UNLOADERS (Optional)
MAXIMIZING COMPRESSOR LIFE
Compressors may be fitted with suction valve unloaders to
provide loadless start or capacity control functions.
Blackmer unloaders are basically a piston and a plunger
atop the suction valve. When pressure is applied to the
top of the unloader piston, it and the plunger move
downward, pushing the suction valve off its seat and
unloading the compressor. When the pressure signal is
removed, the unloader spring pushes the piston and
plunger back up and the suction valve will resume normal
operation.
1. In order for the unloaders to function, the unloader
pressure must be at least 30 psi (2.1 Bar) above
suction pressure.
2. Do not operate unloaders for longer than 10 minutes
as gas recirculation through the suction valves will
cause overheating.
Life of critical compressor components such as piston
rings, valves and packing will vary considerably with each
application, installation, and operating procedures.
Premature failure of wear parts can often be attributed to
one of the following causes:
Excessive gas recirculation using
suction valve unloaders can be a source
of ignition in explosive atmospheres
causing severe personal injury or death
1.
Excessive Temperatures
Primary causes are:
 Operating at pressures other than those originally
specified.
 Handling a different gas than originally specified.
 Clogged strainer or filter elements.
 Line sizes too small, or other flow restrictions.
 Excessive ambient temperature or suction gas
temperature.
 Valve problems. (See Foreign Material.)
 Badly worn piston rings. (See Foreign Material.)
Lower operating temperatures will increase valve and
piston ring life significantly.
Hazardous gases
can cause property
damage, personal
injury or death
3.
Do not place a restrictive device such as a back check
valve in the suction line near the compressor. If such
a device must be installed, the volume in the piping
between the device and the compressor must be at
least 10 times the cylinder swept volume.
WATER-COOLED COMPRESSORS
NOTICE:
Do not operate water-cooled units without water flow!
Cooling water should be clean and at not more than 100
psig (6.90 Bar-g). A flow of 1 gpm (4 lpm) is normally
adequate. In general, cooler water temperatures are
preferable. However, care must be taken as condensation
may occur inside the compressor if the water is too cold.
Such condensation can cause corrosion or even destroy
the compressor.
Hazardous gases
can cause property
damage, personal
injury or death
Extreme temperatures caused by
abnormally high discharge pressure or
valve problems can be a source of
ignition in explosive atmospheres
causing severe personal injury or death.
2. Foreign Material
Solid particles in the gas stream will:
 Rapidly wear the piston rings and score the cylinder
wall.
 Destroy the rod packing causing excessive leakage
and score the piston rods.
 Lodge in the valves causing loss of capacity and
broken valve plates and springs.
Liquid in the gas stream will:
 Cause broken valve plates and springs.
 Destroy the compressor if present in sufficient
quantity.
On new installations, it is suggested that the valves
and piston rings be inspected after the first few
hundred hours of operation. This will give an early
indication of any abnormal problems and allow for
corrective action to be taken before a costly failure
results.
Although piston ring life will vary from
application to application, wear will be fairly consistent
on subsequent sets of rings.
Figure 4 - HDL942 Water Connections
CB9A-031
page 7/24
INSTALLATION
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.
Hazardous pressure
can cause serious
personal injury or
property damage
Compressor operating against closed
valve can cause system component
failure, personal injury or property
damage.
Since all systems differ in design, care must be taken to
ensure the relief valve is installed to safely vent away from
sources of ignition and personnel.
This can be
accomplished by either orientation or a pipe-away, consult
the Relief Valve manufacture for assistance.
Should the Relief Valve actuate, the cause MUST be
determined and corrected before continuing operations.
See the 'Troubleshooting' section.
Operation of the relief valve can release
explosive gas to the atmosphere
creating an explosion hazard, possibly
causing personal injury or death
Hazardous gases
can cause property
damage, personal
injury or death
Figure 5 – Typical HD942 Compressor Package
4-WAY VALVES
Many liquefied gas compressors are used for both liquid
transfer and vapor recovery operations. An optional 4-way
valve is used to reverse the direction of flow through the
system when changing from liquid transfer to vapor
recovery. Both lubricated and nonlubricated models are
available. Lubricated models should be lubricated every 6
months.
TEMPERATURE SWITCHES
Blackmer offers various relief valves for gas and
application compatibility.
PRESSURE GAUGES
Install pressure gauges in the discharge and inlet lines to
verify actual suction and discharge pressures.
LIQUID TRAPS
Compressors handling gasses that contain condensates or
other liquids MUST be protected from entry of the liquid.
Liquid can also enter the compressor from the discharge
piping, particularly if the piping slopes down toward the
compressor.
To prevent liquid from entering the
compressor and causing major damage, it is necessary to
carefully consider the system design and have strict
procedures for operation.
NOTICE: Liquid in the compressor cylinder can cause
destruction of the compressor.
Suction liquid traps collect liquid entrained in the suction
gas stream, preventing it from entering the compressor.
The most common liquid trap is an ASME code vessel
(approx. 12" diameter X 50" tall) fitted with an internal
stainless steel mist pad, a relief valve, a manual drain
valve, and one or two electric float switches. Level gauges
and automatic drain systems are also available.
If the liquid level rises too high in the trap, a float switch is
tripped, sending a signal to stop the compressor or sound
an alarm. The trap must then be drained before the
compressor can be restarted. The cause of the high liquid
level must be found and the problem corrected.
CB9A-031
Excessive discharge temperature is a leading cause of
premature component failure and is often an early warning
sign of impending problems.
Optional temperature switches should be installed with a
thermowell as close to the compressor discharge as
possible. The switch should be set to actuate at a
temperature just above the maximum operating
temperature of the compressor.
ATEX compliant compressors must have a temperature
switch installed.
LOW OIL PRESSURE SWITCHES
Loss of crankcase oil pressure is a rare occurrence, but
can result in costly damage. An optional low oil pressure
switch set at about 15 psig (1 bar-g) may be installed to
shut down the compressor in the event of a lubrication
failure. 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.
Hazardous gases
can cause property
damage, personal
injury or death
page 8/24
Optional liquid trap level switches,
temperature switches, pressure
switches or other electrical devices
must be properly specified for
applications using explosive gases.
OPERATION
PRE-STARTUP CHECK LIST
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Hazardous
machinery can
cause serious
personal injury.
1.
After the compressor is installed in the system, a
complete leak test MUST be performed on both the
compressor and the piping.
Hazardous gases
can cause property
damage, personal
injury or death
2.
4.
5.
6.
7.
8.
Hazardous gases
can cause property
damage, personal
injury or death
STARTUP PROCEDURE
NOTICE:
Consult the 'Troubleshooting' section of this manual if
difficulties during startup are experienced.
1.
Re-check the system piping and the piping supports to
ensure that no piping loads are being placed on the
compressor.
Extreme Heat can
cause personal injury
or property damage
3.
Failure to properly leak test the
compressor installation may result in
leakage of explosive gas to the
atmosphere creating an explosion
hazard, possibly causing severe
personal injury or death.
Flywheel guard contact with moving
parts may be a source of ignition in
explosive atmospheres causing severe
personal injury or death
Discharge piping surface temperatures
may be hot during operation (over
158°F, 70°C). Temperatures should be
monitored and adequate warnings
posted.
If V-belt driven, check the alignment of the motor and
the compressor sheaves. The faces of the sheaves
must be parallel.
Ensure that pressure gauges are installed on both inlet
and discharge of the compressor.
Blackmer compressors are shipped from the factory
without oil in the crankcase. Fill with a high quality
non-detergent oil of the proper viscosity via the
compressor nameplate opening. See "Crankcase
Lubrication" in this manual.
Check the electrical connections for proper wiring,
grounding, etc.
With the power disconnected, remove the compressor
nameplate. Squirt oil onto each crosshead while
rotating the compressor by hand to verify smooth
operation.
Ensure that all guarding is properly installed.
Start the compressor. Oil pressure should register 25
psig (1.7 bar-g) within 10 seconds.
If proper oil pressure is not present, stop the
compressor and correct the problem.
Operating the compressor with low oil pressure will
cause severe damage to the unit. Adjust if necessary.
See "Setting the Oil Pressure" in this manual.
Hazardous gases
can cause property
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, or if the
compressor has been out of service for over 6 months,
the lower seal MUST be manually lubricated during
the first 60 minutes of operation. See "Seal (Packing)
Replacement" section. New compressors have had
the packing broken in at the factory.
5.
On newly rebuilt units, the valve hold down screws,
valve cover plate bolts and cylinder head bolts MUST
have their torque checked after 60 minutes running
time. Also re-tighten all hold down bolts, flywheel
bolts, etc. after 60 minutes running time. See the "Bolt
Torque." table.
Operation without guards in place can
cause serious personal injury, major
property damage or death.
Hazardous
machinery can
cause serious
personal injury.
CB9A-031
Operation of the compressor with low or
no oil may result in extreme
temperature in the crankcase. This
could be an ignition source in the
presence of explosive gas and could
lead to severe personal injury or death.
page 9/24
MAINTENANCE
Flammable gas can
cause death, serious
personal injury or
property damage
Flammable gas and/or liquid can form
explosive mixtures with air causing
property damage, serious personal injury
or death
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Hazardous
machinery can
cause serious
personal injury.
If handling hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance
Hazardous or toxic
fluids can cause
serious injury.
Hazardous pressure
can cause serious
personal injury or
property damage
Hazardous voltage.
Can shock, burn or
cause death.
Hazardous pressure
can cause serious
personal injury or
property damage
Explosive gas can cause property
damage, personal injury, or death.
Failure to relieve system pressure
prior to performing compressor
service or maintenance can cause
serious personal injury or property
damage.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Disconnecting fluid or pressure
containment components during
compressor operation can cause
serious personal injury, death or
major property damage
Extreme heat can cause personal
injury or property damage
Extreme Heat can
cause personal injury
or property damage
Hazardous gases
can cause property
damage, personal
injury or death
NOTICE:
H2S atmospheres can cause serious
personal injury or death.
H2S atmospheres
can cause
serious personal
injury or death.
Blackmer compressor service and maintenance shall
be performed by qualified technicians only. Service
and maintenance shall conform to all applicable local
and national regulations and safety standards.
Table 5 - BOLT TORQUE VALUES LBS-FT (Nm)
Connecting
Rod Bolt
Bearing
Carrier
Bearing
Cover Plate
Crankcase
Inspection
Cover
Oil Pump
Cover
Crosshead
Guide
Cylinder
Head
45 (61.0)
30 (40.7)
40 (54.2)
7 (9.5)
12 (16.3)
40 (54.2)
40 (54.2)
40 (54.2)
Piston
Nut
60 (81)
Valve
Unloader
Assembly Nut /
Retainer Bolt
Unloader Post
10 (13.6)
10 (13.6)
Valve Cover
Plate
Valve Hold
Down Screw
Packing Box
Hold Down
Ring
Upper
Packing Box
Screw
Flywheel Hub
Bolt
35 (47.5)
120 (163)
75 (102)
50 (68)
see Table 4
CB9A-031
page 10/24
MAINTENANCE
Table 6 – SERVICE SCHEDULE
Daily
Weekly
Monthly
6 Months
Yearly
Overall Visual Check
X
Check Crankcase Oil Pressure
X
Check Suction & Discharge Pressure
X
Drain Distance Piece
X
Drain Liquid From Accumulation Points
X
Clean Compressor Cooling Fins
X
Check Crankcase Oil Level *
X*
Check Mounting and Anchor Bolts
X
Check V-Belt Tension
X
Change Oil and External Oil Filter *
X*
Check Inlet Filter/Strainer Element
X
Inspect Valves
X
Lubricate 4-way Valve
X
Lubricate Motor Bearings per Manufacturer's Suggestions
X
Inspect Motor Starter Contact Points
X
* Change oil every 1,000 hours of operation, or every 6 months whichever occurs first. If the oil becomes dirty or
diluted, change oil and external filter as often as needed to maintain clean oil.
Table 7 - TOOL LIST
Description
Used For:
Blackmer Wrench 790535
Valve Hold-down screw
Blackmer Packing Installation Tool 790540
Rod-packing protection during installation.
3" Adjustable Spanner with 1/4" pins (Blackmer PN 790316)
Lower Packing Box Hold-down Ring
15/16" socket with 4" extension
Piston Nut
3/4" End Wrench
Cylinder and Crosshead Guide
1-1/16" Wrench or Socket
Valve Caps
Allen Wrenches: 3/16", 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
CB9A-031
page 11/24
MAINTENANCE
Figure 6 - Compressor Lubrication System
CRANKCASE LUBRICATION
Change the crankcase oil every 1,000 hours or 180 days,
whichever is shorter. Under severe dusty or sandy
operating conditions, the oil should be changed every 500
hours or every 90 days
Non-detergent motor oils are recommended. However,
detergent oils can be used providing the gas being
handled does not react with the detergent in the oil. If
using a detergent oil, be sure there is not a compatibility
problem. The following gasses are known to react with
detergents in oil:
Ammonia Monoethylamine
Monomethylamine Dimethylamine Trimethylamine
The oil used, detergent or non-detergent, should be
of high quality such as API grade SF, SG, SH or
similar.
API grade SA, SB, SC or similar oils should never be
used. Recycled oils should never be used.
Consult factory for special lubricating requirements.
Models
Quarts
Liters
HD942B / HDL942B / HDS942B
7
6.62
Table 8 - Oil Capacity
Air Temperature
SAE
5W
Below 0F (-18C)
10W
0 to 32F (-18 to 0C)
20W
32 to 80F (0 to 27C)
30W
80F (27C) and above
Table 9 - Oil Viscosity
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
Figure 6.
Refill the crankcase via the dipstick or nameplate opening.
Do not overfill the crankcase!
The oil pump on these models will operate in either
direction of crankshaft rotation.
SETTING THE OIL PRESSURE (see Figure 6)
1.
2.
3.
4.
The oil pressure should be about 25 psig (1.73 Bar).
Loosen the locknut.
Increase the pressure setting by turning the adjusting
screw inward, CLOCKWISE.
Decrease the pressure setting by turning the adjusting
screw outward, COUNTER-CLOCKWISE.
Retighten the locknut.
ISO Grade
15
22
46
100
CB9A-031
page 12/24
COMPRESSOR DISASSEMBLY
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Hazardous
machinery can
cause serious
personal injury.
Hazardous pressure
can cause serious
personal injury or
property damage
Hazardous gases
can cause property
damage, personal
injury or death
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
Venting pressure from the compressor
piping could release explosive gas to
the atmosphere creating an explosion
hazard, possibly causing severe
personal injury or death.
NOTICE:
Before starting work on the compressor, make sure all
pressure is bled off on both the suction and discharge.
1.
2.
3.
4.
5.
Remove the head bolts from the head.
Remove the head and cylinder head O-rings from the
cylinder.
Remove the valves per the "Valve Replacement"
section.
PISTON REMOVAL
a. Rotate the crankshaft by hand to bring a piston to
the top dead center position.
b. Remove the piston nut.
c. Remove the piston cap using the two 1/4"
threaded puller holes. (If two 1/4" bolts are not
readily available, the oil pump cover bolts may be
used.)
d. Remove the upper shims, the piston and the lower
shims. Keep the upper and lower shim sets
together to simplify reassembly.
e. Repeat these steps for the other piston.
Remove the cylinder capscrews and lift cylinder from
the crosshead guide. Do not allow the upper packing
boxes to be lifted off with the cylinder as the packing
will be damaged.
CB9A-031
Figure 7 - Cylinder and Piston
6.
7.
PACKING BOX REMOVAL
a. Remove nameplate from the crosshead guide.
b. Lift the upper packing box assembly and O-rings
off the rod.
c. Remove oil deflector ring from the piston rod.
d. Remove the lower packing box hold-down ring
using a 3" adjustable spanner with ¼" pins
(Blackmer PN 790316).
e. Place a wooden block (or the end of a mallet
handle) through the nameplate opening on top of
the crosshead. Rotate the crankshaft by hand
until the crosshead pushes the wooden block
against the lower packing box, unseating it. Do
not place fingers inside the nameplate
opening!
f. Lift the lower packing box assembly and O-ring off
the piston rod.
g. Repeat the above steps for the packing boxes on
the other rod.
h. For disassembly of the packing boxes, refer to
"Seal (Packing) Replacement."
Remove the crosshead guide capscrews, and lift off
the crosshead guide and gasket.
page 13/24
COMPRESSOR DISASSEMBLY
Figure 8 - Packing Boxes, Crosshead
and Connecting Rod Detail
8.
REMOVING THE CONNECTING ROD ASSEMBLIES
(with the crossheads attached). The piston rod is
permanently attached to the crosshead to form a
single assembly. Do not attempt disassembly.
a. Drain the oil from the crankcase.
b. Remove the inspection plate from the crankcase.
c. Remove the locknuts from the two connecting rod
bolts. This will release the connecting rod cap
(the lower half of the connecting rod) and the two
halves of the bearing insert. The connecting rod
and the connecting rod cap are marked with a dot
on one side so that they can be matched properly
when reassembling.
d. Lift the crosshead assembly and connecting rod
off the crankshaft.
NOTICE: The connecting rod parts are not
interchangeable and must be reassembled with
the same upper and lower halves. To avoid
confusion, work on one connecting rod at a time,
or mark the individual halves with corresponding
numbers.
CB9A-031
9.
Remove the opposite connecting rod and crosshead
assembly.
10. Rest the crosshead assembly on a bench. Carefully
drive the wrist pin and wrist pin plugs out of the
crosshead and connecting rod using a suitable pin
driver or an arbor press. Removal of the pin releases
the crosshead assembly from the connecting rod.
11. If necessary, the wrist pin bearings can be replaced
after the crossheads are removed. The small end of
the connecting rod is fitted with two roller bearings
separated by a spacer. When properly installed, the
roller bearings should protrude 0.075" (1.9 mm) on
each side of the conrod.
12. To replace the crankshaft bearings, the crankcase
must be disassembled, and the crankshaft removed.
Refer to "Bearing Replacement" for disassembly
instructions.
page 14/24
COMPRESSOR ASSEMBLY
Compressor assembly is generally the opposite of
compressor disassembly. Before reassembling, clean
each part thoroughly. Check all machined surfaces for
burrs or roughness, and file lightly if necessary. Replace
any O-rings or gaskets that are removed or disturbed
during service.
1.
CRANKCASE ASSEMBLY
After replacing the crankshaft, bearing carrier, and
bearing cover plate, the connecting rod and crosshead
can be assembled in the crankcase. See the "Bearing
Replacement" section.
a. To attach the connecting rod to the crosshead
assembly, first coat the wrist pin, the wrist pin bore
in the crosshead assembly, and the wrist pin
bearing in the connecting rod with grease.
b. Start the wrist pin in the bore of the crosshead
assembly until the pin begins to project through to
the inside of the crosshead assembly. (Use an
3.
Fill the crankcase with oil. Refer to the "Crankcase
Lubrication" section. Squirt oil into the crankshaft,
roller bearings, crankshaft journals, and crosshead
assemblies to ensure proper lubrication at start up.
4.
Attach the inspection plate and the inspection plate
gasket to the crankcase.
5.
PACKING BOX ASSEMBLIES
Refer to the section 'SEAL REPLACEMENT' for
packing box assembly. Before installing the packing
boxes into the crosshead guide, inspect the piston
rods for scoring or roughness. Remove any burrs or
sharp edges. Lubricate the piston rods, packing and
packing box O-rings with light oil. The packing
installation tool (Blackmer Part No. 795040) MUST
be used to avoid damaging the packing when
starting it over the rod.
a. Place the packing installation tool over the end of
the piston rod.
b. Install the O-ring on the lower packing box then
slide it onto the piston rod and down into the
crosshead guide.
c. Install the packing box retainer ring, with new
nylon locking inserts, and tighten.
d. Place the two O-rings on the upper packing box,
then slide the box over the piston rod until the
upper packing box assembly rests on top of the
crosshead guide.
arbor press if available.)
c.
d.
e.
f.
g.
h.
i.
2.
Slide the connecting rod up inside of the
crosshead assembly and align the bearing with
the wrist pin.
Install the wrist pin through the connecting rod
until it is centered in the crosshead assembly.
The wrist pin should be snug in the crosshead
assembly. The connecting rod should rotate
freely on the wrist pin, but should not be loose.
Dip the wrist pin plugs in grease and press them
against the ends of the wrist pin.
Place the bearing halves into each half of the
connecting rod, aligning the bearing tangs with the
slots in the connecting rod. Coat the bearing with
grease.
Set the top of the connecting rod over the
crankshaft journal. Replace the connecting rod
cap with the dots on the connecting rod and cap
on the same side.
Start the nuts on the connecting rod bolts and
torque per Table 5 - "Bolt Torque."
Follow this same procedure for the opposite
connecting rod.
CROSSHEAD GUIDE
a. Place the crosshead guide gasket on top of the
crankcase.
b. Lubricate the inside bore of the crosshead guide
with light oil.
c. Set the crosshead guide over the piston rods and
the crossheads, and slowly lower it against the
crankcase. Make certain that the crosshead
assemblies are started straight in the crosshead
guide bores to prevent binding when lowering the
crosshead guide into position.
d. Install the crosshead guide capscrews. DO NOT
tighten.
CB9A-031
Figure 9 - Upper Packing Box Alignment
e.
6.
Note the orientation of the valve cutouts on the
packing box. The cutouts must align with the
valve pockets in the cylinder. Rotate the packing
box as needed for the proper alignment.
f. Remove the packing installation tool from the
piston rod.
g. Repeat steps a - g for the other piston rod and
packing boxes.
Packing must be broken in. Finish compressor
assembly then refer to "Packing Lubrication."
page 15/24
COMPRESSOR ASSEMBLY
7.
8.
CYLINDER ASSEMBLY
a. The cylinder should be installed with the valves
removed.
b. Set the cylinder on the crosshead guide over the
piston rods and packing boxes.
c. Ensure that the valve cutouts on the upper
packing boxes are aligned with the cylinder valve
pockets.
d. Place the pistons (without shims or rings) on the
rods. Rotate the compressor by hand and verify
that the pistons are centered in the cylinder bores.
The pistons must not touch the cylinder walls.
Adjust the cylinder as necessary.
e. Install the cylinder capscrews and tighten evenly
per Table 5 - "Bolt Torque."
f. Remove the pistons.
e.
f.
g.
h.
i.
j.
k.
Place the upper shim washer(s) over the rod onto
the piston.
Install the piston cap (without the O-ring).
Tighten the piston nut on securely.
Install the head (without the O-ring), and tighten
the head bolts securely.
Ensure that the piston is at top dead center.
Measure the clearance between the piston and
head through one of the upper valve pockets.
Rotate the crankshaft until the piston is at bottom
dead center. Measure the clearance between the
piston and packing box through a lower valve
pockets.
Compare the piston clearance values to those in
Table 10 - "Piston Clearance."
Rotate the flywheel by hand to ensure the compressor
turns freely.
Upper Piston
Clearance
0.035" - 0.050"
(0.89 to 1.27 mm)
Lower Piston
Clearance
0.003" - 0.005"
(0.08 to 0.13 mm)
Table 10 - Piston Clearance
l.
Remove the piston. Repeat steps b - k with
revised shimming until both clearances values are
satisfactory.
m. Once the proper shims are determined, remove
the piston again.
n. Install an expander and piston ring in each groove
in the piston. The gap in each expander should
be 180° from the gap in the piston ring. In
addition, each piston ring's gap should be 180°
from that of adjacent ring(s).
o. Squeeze the piston rings inward with light
pressure and work the piston into the cylinder
over the rod.
p. Place the upper shim washer(s) over the rod onto
the piston.
q. Install the piston cap and O-ring.
r. Tighten the piston nut per Table 5 - "Bolt Torque."
s. Install the head with its O-ring, and evenly tighten
the head bolts per Table 7 - "Bolt Torque."
t. Repeat same procedure for the second piston.
u. Verify the proper upper and lower piston
clearance before proceeding.
10. Install the valves per "Valve Replacement" Section.
11. Rotate the compressor by hand to verify that it turns
freely.
Figure 10 - Cylinder and Piston
9.
PISTON INSTALLATION
a. To set the piston clearance, remove the valves
from one side of the cylinder.
b. Rotate the flywheel by hand to bring one piston
rod to top dead center.
c. Set the bottom shim washer(s) onto the piston
rod.
d. Place the piston (without rings and expanders) on
the piston rod.
CB9A-031
12. Refer to the "Pre-Startup Check List", and "Startup
Procedure."
13. After the compressor has run for a sufficient time to
reach operating temperature, allow to cool and
retighten the valve hold down screws.
page 16/24
UNLOADER SEAL REPLACEMENT (not used on HDS942)
1.
2.
3.
Remove the unloader cap and O-ring.
Remove the unloader body from the cylinder head (a
strap wrench is helpful).
Push the unloader piston out the top of the unloader
body.
4.
5.
6.
Inspect and replace the seals as needed - note the
seal orientation!
Inspect the unloader body bore - it must be clean and
smooth.
Reassemble in the reverse order.
VALVE REPLACEMENT
Fig. 11 –
Valve Installation
Fig. 12 –
Valve Installation with
Suction Valve Unloaders
(not used on HDS942)
CB9A-031
page 17/24
VALVE REPLACEMENT
Suction and discharge valves MUST be installed in the
correct cylinder head locations. See Figures 11 & 12.
b.
Failure to install compressor valves
properly can lead to component failure,
personal injury or property damage.
Hazardous pressure
can cause serious
personal injury or
property damage
Hazardous gases
can cause property
damage, personal
injury or death
Hazardous gases
can cause property
damage, personal
injury or death
1.
2.
3.
4.
5.
Failure to install compressor valves
properly can result in leakage of
explosive gas creating an explosion
hazard, possibly causing severe
personal injury or death.
6.
7.
Failure to install compressor valves
properly can result in extreme
discharge temperatures. This could be
an ignition source in the presence of
explosive gas possibly causing severe
personal injury or death.
Remove the valve cap and O-ring from each valve.
Remove the valve hold down screw with a spanner
wrench (Blackmer PN 790535).
VALVE REMOVAL
a. Remove the valve cover plate capscrews then lift
off the cover plate and O-ring.
b. Remove the cage, (and unloader plunger) valve
assembly and valve gasket.
c. Inspect the valve for wear or breakage.
VALVE REPAIR
a. Remove hex nut or unloader post from valve (after
removing the retainer bolt, actuator assembly,
and unloader spring).
b. Separate the valve halves and remove springs
and plate.
c. Inspect and replace worn components.
d. Reassemble valves as shown in the drawings and
tighten the valve assembly nut or unloader post
per Table 5 - "Bolt Torque".
e. If unloaders are present, reassemble the unloader
spring and actuator assembly, then tighten the
retainer bolt per Table 5 – “Bolt Toque”.
VALVE INSTALLATION
The pistons should be installed and the proper piston
clearance set before the valves are installed.
a. Remove the old gasket and install a new valve
gasket into the cylinder head.
CB9A-031
Install the valve assembly in the cylinder head.
Make sure the valve's orientation and location are
correct.
c. Hold the valve in place with a socket and
extension for steps d - f.
d. Center the valve cage on the valve assembly.
e. Remove the valve hold down screw from the
cover plate, then install the valve cover plate with
a new O-ring. Tighten the cover plate capscrews
according to Table 5 - "Bolt Torque."
f. Install the hold down screw and tighten according
to Table 5 - "Bolt Torque."
g. If suction valve unloaders are used: Install the
unloader plunger through the hold down screw.
h. Install the valve cap and O-ring.
After replacing the valves, rotate the flywheel by hand
to check for interference between the pistons and the
valves.
After 60 minutes of running time, remove the valve cap
and retorque the hold down screw. Replace the valve
cap and O-ring.
Figure 13 – Ductile Iron / PEEK Valve Detail
Figure 14 – Stainless Steel Valve Detail
page 18/24
SEAL (PACKING) REPLACEMENT
Two seals separated by a distance piece seal the gas in
the cylinder and prevent contamination by the crankcase
oil. The upper seal consists of pairs of segmented packing
rings. The the lower seal utilizes a number of PTFE Vrings and an S3R segmented oil seal.
Before starting work on the compressor, note the seal
orientation indicated by the 6th digit of the Compressor ID
# shown on the compressor's nameplate. Also note any
tubing connections in the seal area. See section 'SEAL
ARRANGEMENTS”.
1. Follow steps 1 - 6 of "Compressor Disassembly."
2. UPPER PACKING BOX
a. Remove the bolts from the bottom of the packing
box then remove the packing gland.
b. Remove the packing cups with packing ring pairs
and O-rings. If the packing cups are difficult to
remove, place a screwdriver blade in the groove
in each packing cup and tap lightly with a rubber
mallet. Do not deform the packing cups or scratch
their sealing surfaces.
c. Remove the packing cup gasket.
d. Clean and inspect all parts, replacing as needed.
e. Refer to the appropriate drawing for the proper
orientation of the packing cups and rings. Note:
the bottom ring set differs from the upper pairs.
f. Install the gasket packing cups, packing ring sets
and O-rings per the appropriate drawing.
g. Install the packing spacer and gland, then secure
by tightening the bolts evenly.
Figure 15 Packing Ring Detail
Figure 17 –
Type 'B' Packing Detail
CB9A-031
page 19/24
SEAL (PACKING) REPLACEMENT
Figure 20b - S3R Oil Seal Installation
3.
Figure 20 - Lower Packing Assembly
4.
5.
LOWER PACKING BOX
Disassembly
a. Remove the seal cup from the packing box by
removing the eight socket head capscrews.
b. Remove the retainer ring, spring, packing and
washers.
c. Remove the remaining two socket head
capscrews to remove the seal cup cover.
d. Remove the S3R seal from the seal cup.
Assembly
e. Clean the seal cup in a suitable solvent. Inspect
the bore for wear, roughness, or corrosion.
f. Refer to the sketch of the lower packing box for
the proper location and orientation of the packing
components. Lightly oil the packing rings, then
install the packing rings, washers and spring.
Install the retainer ring while using the handle end
of a screwdriver to compress the packing spring.
g. Install the S3R seal in the seal cup as shown in
figure 20a. Place the S3R seal on the packing
installation tool in the order shown in figure 20b,
with the upper segment toward the tapered end
of the installation tool. Insert the installation tool,
with the S3R seal, into the seal cup, with the
tapered end toward the packing rings. Place
seal cup cover on seal cup and secure with two
capscrews
h. Install the O-ring on the seal cup. Secure the
seal cup to the packing box with eight
capscrews.
Proceed according to steps 5 through 13 of
"Compressor Assembly."
Proceed to “LOWER PACKING BREAK-IN” on the
next page.
Figure 20a – Seal Cup Assembly
CB9A-031
page 20/24
SEAL (PACKING) REPLACEMENT
6.
LOWER PACKING BREAK-IN
For maximum packing life, perform the following
packing break-in procedure.
a. If possible, perform the packing break-in at a
lower speed – 400-500 rpm.
b. Run the compressor for 5 minutes then stop the
compressor for 5 minutes to allow adequate
cooling of the piston rods.
c. Repeat Step b six times.
Do not insert objects or fingers in
inspection cavity. Can cause severe
personal injury
Hazardous
machinery can
cause serious
personal injury.
Improper seal installation could release
explosive gas to the atmosphere
creating an explosion hazard, possibly
causing severe personal injury or death.
Hazardous gases
can cause property
damage, personal
injury or death
BEARING REPLACEMENT
NOTICE: When replacing the bearings, the entire
bearing assembly, including the bearing cup and the
bearing cone, must be replaced and the crankshaft
endplay must be readjusted.
1.
2.
3.
4.
5.
6.
Follow the "Compressor Disassembly" section steps.
Remove the Oil Pump per "Oil Pump Replacement."
Remove the flywheel.
Remove the bearing carrier and gasket from the
outboard end of the crankcase. The outboard bearing
cup will come off with the bearing carrier and will need
to be removed with a bearing removal tool.
Remove the key from the crankshaft and slide the
crankshaft through the outboard end of the crankcase.
The bearing cones can then be removed with a
bearing puller.
Remove the bearing cover plate from the inboard end
of the crankcase. The inboard bearing cup is pressed
into the crankcase and can be removed with the use of
a bearing removal tool.
c.
Note the proper orientation and carefully press the
outboard bearing cup into the bearing carrier.
d. Press a 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
evenly per Table 5 - Bolt Torque."
10. If the bearings have not been replaced, reinstall the
inboard bearing cover plate using the existing shim
set. If the bearings have been replaced, use a thicker
set of shims.
11. Rotate the crankshaft by hand to verify free movement
of the shaft.
a. If the crankshaft has an excessive amount of end
play, too many shims have been used. Lateral
crankshaft movement (end play) between the
bearings should be:
End Play at Room Temperature
0.0015 to 0.0030" (0.038 to 0.076 mm)
7.
Figure 21 - Bearing Locations
To install the bearings:
a. Grease the outer edges of the bearing cups.
b. Note the proper orientation in Figure 21 and
carefully press the inboard bearing cup into the
crankcase until it is flush with the outer surface of
the crankcase.
CB9A-031
If necessary, remove shims until the end play is
within tolerance.
b. If the crankshaft binds, or will not turn, not enough
shims have been used pushing the bearing cup
too tight against the bearing cone. Remove the
crankshaft from the crankcase and drive the
inboard bearing cup out toward the inboard side of
the crankcase. Reinstall the crankshaft and the
bearing cover plate using additional shims as
required.
12. Install the oil pump per the "Oil Pump Replacement"
section of this manual.
13. Reassemble the compressor according to the
"Compressor Assembly" section.
page 21/24
OIL PUMP REPLACEMENT
4.
5.
6.
7.
Figure 22 – Oil Pump
1.
2.
3.
Remove the oil pump cover bolts and oil pump cover.
Remove the oil pump assembly, drive cone and
spring.
Clean and inspect parts for wear or damage, replace
as necessary.
8.
Place the spring and the drive cone in the end of the
crankshaft.
Note the slot in the end of the crankshaft and the drive
tab on the back of the oil pump assembly. Install the
oil pump assembly into the bearing carrier with the tab
and slot aligned.
Note the groove around outer edge of the oil pump
assembly and the stop pin in the oil pump cover.
Position the oil pump cover and new gasket with the
pin in the oil pump groove, rotating the oil pump as
needed.
The bolt hole positions ensure proper
orientation of the oil pump cover.
BY HAND, tighten the oil pump cover bolts while the
pump cover is held flush with the bearing carrier.
NOTICE: If by hand tightening, the oil pump cover
cannot be drawn flush with the bearing carrier, the
drive tab or the stop pin are improperly aligned.
Do not wrench tighten or the oil pump will be
damaged.
Once the oil pump cover is secured by hand, the bolts
may be evenly tightened per Table 5 - "Bolt Torque."
EXTENDED STORAGE PROCEDURES
If a compressor is not to be put into service for some time,
or if a compressor is to be taken out of service for an
extended period, care must be taken to protect the
compressor. The following steps must be taken for both
bare compressors and those already piped into a system.
If proper storage procedures are not followed, damage
to the compressor may occur. Complete compressor
disassembly and replacement of rod packing, bearings
and other parts may be required.
1.
2.
3.
Keep a written record storage procedures performed –
preferably on the unit itself.
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-belts to relieve the
load on the bearings. Rotate the compressor by hand
a few times to distribute the oil.
Plug all openings and purge the compressor with an
inert gas such as nitrogen or dry air at about 50 psig
(3.5 bar-g). This may be done at the factory if
requested. Leave the compressor pressurized to
prevent air or moisture from entering the unit.
Check the unit monthly and add additional purge gas
as needed.
NOTICE: Tag the unit with a warning that it is
pressurized.
CB9A-031
4.
5.
6.
7.
If a purge gas is not available, fog oil into the
compressor suction while rotating the unit. Then plug
all openings to keep out moisture, insects, etc.
Turn the flywheel by hand a few revolutions once
a month to distribute the oil.
Store the unit under a plastic wrap on its wooden
shipping base up off the ground. If the unit was boxed
for export shipment, leave it in its box. An indoor or
covered storage area is preferable.
Placing the Compressor back in service.
When the compressor is to be put in service, vent the
remaining purge gas and change the crankcase oil.
Follow the "Pre-Startup Checklist" and "Startup
Procedure" sections in this manual.
Hazardous pressure can
cause property damage,
serious personal injury
or death.

Compressor is pressurized with inert gas.
CAREFULLY bleed off gas BEFORE
attempting any service.
Figure 23 – Pressurized Compressor Tag
page 22/24
TROUBLESHOOTING
PROBLEM
STEP PROBABLE CAUSE
WHAT TO CHECK
IF PROBLEM
STILL EXISTS
GO TO STEP ...
1
4-Way Valve Leaking
(when equipped)
Lubricate with a stick lubricant compatible with
material being transferred.
2
2
Worn or Broken Piston Rings
Check condition of rings by restricting discharge
line. If pressure increases slowly, rings are
probably faulty.
3
3
Plugged Strainer
Clean screen as necessary.
4
4
Compressor Valve Faulty
Remove and inspect for broken or worn springs,
discs, or bodies. See "Valve Replacement".
5
5
Compressor Drive Slipping
Tighten belts, check for sheared keys, loose keys
or loose flywheel.
6
6
Piping Improperly Designed or
Installed
Use proper pipe sizes.
7
No
Flow
7
Excess Flow Valves Slugged
Stop the compressor to let the excess flow open.
Installation of a valved bypass line between the
suction and discharge lines may be necessary.
Knocks or
Other
Noises
8
Loose Valves
Tighten valve hold-down screws.
9
9
Worn Internal Parts
Inspect through inspection plates and repair as
necessary.
4
10
Oil Pump Relief Valve Not Properly
Set oil pump relief valve.
Set.
11
Oil Pump Not Working
Check the Oil Pump drive tab or stop pin for
damage.
12
12
Low Oil Level
Check and fill as necessary
13
Low
Transfer
Rate
No Oil
Pressure
Gas
Leaking
from
Crankcase
Breather
Relief
Valve
Actuates
Shake
or Vibration
3& 4
11
13
Dirty Oil Inlet Strainer
Clean Inlet Strainer
14
Faulty/Worn Packing
Replace Packing.
15
15
Piston Rod Scored
Replace crosshead assemblies and packing.
16
16
Improper Seal Arrangement
See "Seal (Packing) Replacement."
---
17
Valve Closed Downstream of the
Compressor
Open Valve
18
18
Line Blockage Downstream of the
Compressor
Locate Blockage and Correct
---
19
Loose/Broken Mounting or Anchor
Bolts
See “Mounting the Compressor Unit“
20
20
Improper Mounting
Ensure base is supported full length. See
"Mounting the Compressor."
21
21
Improperly Aligned V-belt Sheaves See "V-Belt Drives"
22
22
Improperly Installed Flywheel
See "Compressor Flywheel"
23
23
Nonfunctioning Valves
Replace or repair valves.
---
CB9A-031
page 23/24
ATEX Declarations
Compressors
Page Number
Form 576
Effective
February
2012
Replaces
Section
June 2010
Forms
Blackmer, A Dover Company,
1809 Century Avenue S.W., Grand Rapids, Michigan 49503-1530, United States of America
DECLARATION OF
CONFORMITY
As defined by the ATEX directive 94/9/EC
Herewith we declare that all Blackmer LB and HD
compressor product lines to which this declaration relates
are in conformity with the provisions of the ATEX
Directive 94/9/EC as of 01 July 2003. This equipment is a
reciprocating compressor for liquefied gas transfer or gas
compression applications. This device is not intended to act
as a safety accessory.
Applied Harmonized Standards:
EN1127-1, EN13463-1
DECLARATION OF CONFORMITY
As defined by the Machinery Directive 2006/42/EC
Herewith we declare that all Blackmer LB and HD
compressor product lines to which this declaration relates
are in conformity with the provisions of the Machinery
Directive, 2006/42/EC Annex IIA as of 17 May 2006. The
above equipment is a reciprocating compressor designed for
liquefied gas transfer or gas compression applications. This
device is not intended to act as a safety accessory.
This component must not be operated until the machine into
which it is incorporated has been declared in conformity
with the provision of the directive.
Applied Harmonized Standards:
EN1012-1, EN292
Date:
29 February 2012
Thomas Madden.
Vice President and General Manager
Date:
29 February 2012
Thomas Madden.
Vice President and General Manager
ATEX/ Machinery Directive Notifications:
Maximum Surface Temperature: An ATEX compliant temperature switch must be installed if the compressor is
used in an ATEX zone. It is the end users responsibility to ensure the compressor does not exceed the
temperature limits for the relevant ATEX zone. Closed inlet or outlet valves can result in excess compressor
surface temperature conditions.
Intended Use: Blackmer compressors are intended for use in liquefied gas transfer or gas compression
applications. The compressor must be operated in systems, with gasses and at conditions for which it is
specifically designed and sized.
Possible Misuse Warning: The compressor must only be installed in systems designed for its intended use.
Mechanical Ignition Sources: Guards, intended to protect from personal injury from rotating components, must
be fabricated from ATEX compliant materials to prevent a potential ignition source. The compressor and its drive
system must be properly grounded to prevent electrostatic discharge. The compressor has internal parts that rub
together. These parts require proper viscosity lubricant to lubricate the rubbing surfaces. Compressor must be
properly maintained and lubricated, see IOM (Installation, Operation, & Maintenance Instructions) for service
information.
Sound Measurements: Sound Levels for gas compression equipment vary greatly, depending on operating
conditions, piping system design, foundation design, etc. You can expect the following sound levels when
operating a Blackmer compressor at its’ maximum rated speed and discharge pressure. Sound levels are
measured at 1 meter from the compressor and 1.6 meters from the foundation per European Machinery Directive
2006/42/EC. Maximum Noise Level: 85 dba
Equipment Marking: All compressor models are classified Group II category 2, Gas Group IIB and have a
temperature limit of 176 C. Compressors are marked “Ex II 2 G IIB 176 C MAX ”
Compressor Models Covered: LB, HD
Technical file is archived with LCIE notified body number 0081, file no. LCIE 60052731-553645.
Telephone: (616) 241-1611 / Fax: (616) 241-3752 / E-Mail: blackmer@blackmer.com
www.blackmer.com
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