TABLE OF CONTENTS INTRODUCTION--------------------------page PERIODIC ~lAINTEh'ANCE---------------------- 1 1 Periodic Maintenance Schedule------2. Check of Drier Operation-----------3. Lubrication------------------------4. Safety Relief Valves---------------5, Electric Motor Servicing-----------6. pressure Switch--------------------7. Cleaning the Compressor------------a. Filters and Muffler --------------9. Compressor Belt Tension------------10. Compressor Pump-up Time------------REPAIR-----------------------------------Belt---------------------1. Replacing 2. Removing Pulley--------------------Valves--------------------3. Changing 4‘ Operation Check--------------------5. Trouble-Shooting Chart-------------PARTS LIST-------------------------------1. 1 1. 1 2 2 2 2 2 3 3 3 3 3 3 3 3 5 This sheet contains maintenance and repair information and a parts list for WP220 A-F Compressor-driers. Standard tools may be used throughout. For information on PP901 PRV's and PP902 PRV station with sub-micron filter, see Form 75-25.58. TABLE I - COMPRESSOR DATA - Compressor WD73flA PERIODIC De Vilbiss Pump No. No. of 1 Flywheel/ Motor |No. of Cylinders 1 Size 1 H.P. |Belts 17n 1 I I l/A I1 n-r 3 2 839 8 7 8 MAINTENANCE 1. PERIODIC MAINTENANCE SCHEDULE. Provide definite maintenance schedules for all compressors. Frequent inspections and proper cleaning and lubrication will lengthen the life of a compressor. Time intervals indicated for maintenance procedures are suggestions only. Operating conditions may dictate more or less frequent inspections. (See PERIODIC MAINTENANCE SCHEDULE Chart at the top of Page 2.) 2. CHECK OF DKIER OPERATION Check the tank by opening the drain cock. A dry receiver tank indicates normal compressor-drier operation. REV. 7-68 D.E.L. ln” Parts List in De Vilbiss Form# If increasing amounts of oil are present in the tank, check the compressor pump for wear. Check the air lines leading from the compressor if cocks are provided. 3. LUBRICATION Keep constant level oiler supplied with the oil recommended in Table II. On WP220A thru F, the oil level is indicated by a sight glass or a dipstick. (Screw dipstick all the way in for a correct reading.) Use only nondetergent oil with rust and oxidation inhibitors. (Continued) F o r m Number File 77-5000 75-5568 Commercial Div. PERIODIC MONTHLY 1. Check 2. Check ulator 3. Check 4. Check MAINTENANCE SCHEDULE 1 drier operation. compressor tank, pressure regand air lines (para, 2). oil level (para. 3). safety relie TABLE PI RECOMMENDED OIL --~Ambient Temperature Viscosity Recommended _____---7Below 3 2 º F SAE-10 -.32º to 100º II F SAE-20 Above 100º F SAE-30 -_I-_____ I_ Change first oil filling after one week of break-in operation. Thereafter, change oil every 3 months, If operating conditions are exceptionally dirty, change oil more often. EVERY THREE MONTHS 1. Inspect electric motor (para. 5). 2. Check pressure switch setting (para. 6). 3. Change crankcase oil (para. 3). 4. Clean compressor (para. 7). 5. Check belt tension (para. 9). 6. Check pump-up time (para. 10). WP220 TABLE III COMPRESSOR PUMP OIL CAPACITIES ANNUALLY 1. Wash muffler. 2. Change paper air intake filter element. EVERY TWO YEARS 1. Change desiccant tank. 73± up way out 4. SAFETY RELIEF VALVES Safety relief valves are factory-set to approximately 15 psi higher than the rated pressure of the compressor. Check each safety relief valve by pulling on the ring to unseat it, MALFUNCTIONING VALVES SHOULD BE REPLACED OR REPAIRED IMMEDIATELY. Safety relief valves are located near the pressure switch on the tank. 3 psi. Adjustment is made during pumpby screwing the adjustment screw all the in and backing off the screw until cutis observed at 75 psi. 7. CLEANING THE COMPRESSOR Clean the fins on cylinders, heads, intercoolers, aftercoolers and other parts of the compressor with Trichloroethane, Inhibited l,l,l. (obtain from any office supply store,) 5. ELECTRIC MOTOR INSPECTION a. Inspection--The motor should bring its normal load up to speed within a few seconds, If not, check connections between the motor and the power supply. Be sure the power supply is correct as specified on the namealate. b. Cleaning--If the motor has been exposed to dirt, grit or moisture, clean and dry thoroughly. Remove dirt and oil from motor and stator windings. c. Lubrication--Use only a light-grade electric motor oil. Lubricate bearings every year. When oiling, be sure that the oil wells are completely filled. CAUTION: DISCONNECT POWER SUPPLY BEFORE OILING THE MOTOR. CAUTION: SPECIAL CARE SHOULD BE EXERCISED IN THE USE OF SOLVENTS, AVOID PROLONGED INHALATION AND/OR CONTACT WITH THE SKIN. CARELESS HANDLING CAN RESULT IN PERMANENT DAMAGE TO THE RESPIRATORY SYSTEM OR SKIN TISSUE. 8. CLEANING AIR FILTERS AND MUFFLER. (See Fig. 2) Wash the muffler in a non-explosive solvent, dry and reinstall, The intake filter should be changed annually, In an emergency, the paper filter may be washed in a mild detergent solution, 6. PRESSURE SWITCH Remove exhaust muffler if switch action is not easily determined, The pressure switch should divert air out the exhaust pipe at Figure 1 - Intake air filter (left) and exhaust muffler. Page 2 10. COMPRESSOR PUMP-UP TIME Release pressure until motor starts and note the time the pump takes to build up to cuto f f p r e s s u r e . Check Table IV for correct times, If compressor requires substantially more time than indicated in the chart see the Trouble-Shooting Chart for corrective measures. NOTE: For this check, there must be no air usage or leakage. Shut-off valve must be closed. 9. COMPRESSOR BELT TENSION (See Fig. 3) Hand pressure should depress the belt about l/2 inch, The belt should be tight enough to prevent slipping but no tighter. Adjust tension by loosening the motor hold-down bolts, moving the motor until tension is correct , then retighten the bolts, Ensure that belt and pulleys are aligned. FOR MORE EXTENSIVE REPAIRS THAN LISTED HERE, CONSULT THE NEAREST HONEYWELL BRANCH OFFICE, 1. REPLACING BELT Loosen the electric motor hold-down bolts and slide the motor toward the compressor pump . Remove the old belt and install the new. Slide the motor away from the pump until proper belt tension is reached and tighten the hold-down bolts, Insure that belt and pulleys are properly aligned, New belts may stretch, so recheck tension after one week of service and readjust if necessary. [See Para. 9 under Periodic Maintenance for proper belt tension.) 2. REMOVING PULLEY Remove belt (See Para. 1). Loosen pulley set-screw and remove pulley from shaft. TABLE IV. PUMP-UP TIMES (NO LOAD) 3. CHANGING VALVES WP220A, B, C, D, E, and F (See Fig. 4) Intake Valve--Unscrew valve cap, lift out valve spacer and valve assembly. Replace in reverse order, Exhaust Valve--Unscrew valve cap, remove gasket and unscrew valve plug. Lift out valve spacer and valve assembly. Replace in reverse order, NOTE: The compressor-drier uses a high quality valve assembly. It is identified by the use of a washer-type spring instead of a conical spring for valve disc return. 4. OPERATION CHECK Operate compressor and check pump-up time as outlined in para. 10 on Page 3. EXHAUST Y GASKET VALVE P L U G VALVE SEAT S EXHAUST VALVE P A C E R - - ASSEMBLY 5. TROUBLE SHOOTING A. Noisy compressor CHART (For all compressor checks, disconnect Loose flywheel flywheel Assembly loose !1 Valve in compressor head ,I V a l v e A s s e m b l y l o o s e compressor from system) on compressor shaft Remove cap screw and tighten retainer screw Remove valve assembly, tighten or replace if necessary F a r m N o . 75-5568 5. TROUBLE-SHOOTING CHART (Continued) emove compressor y is evident, piston comes can be rotated movement of pis- B. Excessive oil consumption (Normal consumption is below 1 oz. per 100 H.P. hours . ) Crankcase filled over- Incorrect type, grade or viscosity of oil Check oiler for leaks, bottle for cracks. Drain and fill with proper oil (See Pg, 2) Change filter (See Pg. 2) Dust talcum on suspected ssor for leaks. Repair remote air Plugged or inoperative crankcase breather assembly or crankcase vent Clean or replace breather assembly or crankcase vent. Worn rings or scored Remove head and inspect cylinder for scoring. cylinder If scored, replace pump. Wipe top of piston clean. Run compressor with head removed for 10 minutes, If oil builds up on top of piston, rings are worn. Replace or rebuild pump, C. Compressor takes too long to build up pressure. Too small or restricted air intake piping 1 Slipping belt Leaks in system / Dirty valves Warped valve disc Valve loose I Clean piping or replace with proper size |Tighten belt Check system |Clean or replace Hold valve to light to check for warped disc. Replace if warped, | Tighten or replace if necessary. Intake air filter clogged or dirty Change filter. Pressure switch improperly set Reset Compressor sized See Honeywell form 77-9364 under- Worn rings Leaking check valve I See last item under B, above. Turn off compressor during regeneration cycle and check for leak thru muffler. If there is air leakage, clean or replace check valve. Page 4 5, TROUBLE-SHOOTING D. Compressor does not operate CHART (Continued] Remove belt and see if motor will run, If motor will not run: Faulty wiring Inspect and repair Motor burned out Replace motor. Inspect compressor overload protection, wiring, etc. to determine cause of motor burn-out, If motor will run with belt removed: Compressor starting Turn off power and turn flywheel to detect air pressure in cylinder. Inspect check against head pressure. [not unloaded) valve and relief valve. Compressor seized Turn off power and turn flywheel to detect binding, If binding is evident, cylinder walls are scored or bearings are frozen. Replace pump. Improper wiring or overload protection Inspect and repair Improper power supply Use voltage within on nameplate Check side play of motor shaft. If loose, replace motor. Worn motor bearings E. Drier not functioning, Not in operation long enough to dry air in system Depending on system size, it takes from a day to more than a week of operation to desiccate air in system. Regeneration cycle too low a % of total operating time. Plugged muffler. Desiccant tank ineffective. To provide for fast, economical replacement of parts, all parts and assemblies have been given a special procurement procedure. A1ways use exact replacement parts when making repairs . Parts which are standard hardware items (screws) washers, etc .) available from various suppliers: These parts, designated by a single dagger (t), should be obtained locally. A complete description has been provided to facilitate exact replacement. 10% of voltage shown Change pressure switch and exhaust valve. (After making sure compressor pumps up properly per section C) . If a measurable pressure drop exists across muffler, replace or clean it. Replace desiccant tank. Parts shown in Fig. 6, 7, and 8 are manufactured specifically by Honeywell or processed for specific requirements: These parts have only the Honeywell part number and name shown. Replacements must be ordered from Honeywell (see ordering information on Page 10). Parts shown in Fig. 5 and 9 are manufactured by DeVilbiss for Honeywell requirements, These parts must be ordered from DeVilbiss on Page 10). (see ordering information Page 5 75-5568 NOTE:The filter cartridge in the air intake filter (WPZ20A thru F) is disposable and should be changed once a year under average operating conditions. If the intake is in an unusually dusty or fume-laden location, it should more _-often. _------.- be changed C O M P L E T E Fl L T E R 4 3 6 3 3 - 5 1 6 F O R COMPLETE FILTER ASSEMBLY 4 3 6 3 2 - 5 1 4 F O R WP22OA 4 3 6 3 3 - 0 0 7 F O R WP220B EMENT 835-064 ,SKET 257-118 COMPLETE FILTER ASSEMBLY 43634-010 F O R WP220E 4 3 6 3 4 - 5 0 7 F O R WP22OF Fig + 5--Air Intake Filters. Page 6 ASSEMBLY WP22OC & D 3 0 4 4 4 9 3 0 5 4 5 1 ELBOW 305458 I I (MODELS WP220A & B) (MODELS WP220C & D) NUT 305262A CONNECTOR 305051 305151 TEE LS 305453 WP220C 305454 WP720E 1/2"x10 & D) 1/2" x 13 (MODELS (MODEL & F) WP220A & B ) 316473A (MODELS WP220C & D) I I 305469 NIPPLE 305084 305483 EET ow 084 TEE I 30544.8 (l/2”) 305450 (3/8") E L B O W , 45º 305026 ELBOW 3 0 5 4 7 0 NIPPLE 316150 (3/8") 316151 (l/2") EXHAUST MUFFLER (2”) Fig. 6 (Part 1 of Z)--Drier Part s . Page 7 316480A C H E C K 305088 BUSHING / 305472 316189A FILTER-DRIER NIPPLE I 0 5 0 7 8 NIPPLE 305473 147 TE NIPPLE I I i Fig. 6 (Part 2 of 3160 91 3158 0 9 (WP220E & F B O D Y (3/8”) O N L Y 1/2") )--Drier Parts. 315823A DIAPHRAGM ASSEMBLY 313342 CAP 305023 NUT ELL † 316039 SPRING ig. 7--Exhaust Valve (315809A for Q531A 1045 Page 8 3 2 0 0 8 1 S C R E W (6) #6-32NC, H E X HD. S E L F - T H R E A D I N G , 1 / 2 " LONG. * only; 316091A for A11 Others). / A---- / 3 2 0 0 0 1 S E T SCREW /- O- R I N I 305023 NUT r 311709 /-- rc- G LUBRICATE WITH 31404 LUBRICANT 315850 CAP 315851 315852 871 ING SUPPORT BUTTON WASHER DIAPHRAGM I , 315824 SPRING 310354 315871 SPRING SUPPORT a/ 315800J 310779 O-RING O-RING HONEYWELL RDER ig. 8--Pneumatic Pressure SW itch PART FROM NUMBERS HONEYWELL) (315820A). BREATHE!? ASSY COMPRESSOR VALVES BELT GUARD COMPRESSOR PUMP Fig. 9--Compressor Page 9 Parts, 75-5568 Parts List for Fig, 9 COMPRESSOR PUMP, 0a air filter, WP220A WP220B WP220C & D WP220E WP220F BELT GUARD Partially Enclosed WP220A WP220B WP220C & D WP220E & F Fully Enclosed WP220A WP220B WP220C & D WP220E & F less flywheel and intake M-120-4512 M-2202-4502-1 M-220-4502 M-%30-4568 M-230-4502 UBH-420 UBJ-420 UBK-420 UBNT-420-l UBH-470 UBJ-470 UBK-470 UBNT-470 0 BELT 0 Single Drive WP220A WP220B WP220C WP220D Double Drive WP220A WP220B, C & D WP220E Triple Drive WP220F WP220A WP220B WP220C WP220D Double Belt WP 2 2 OA WP220B WP220C WP220D WP220E Triple Belt WP220F M-PU-1184 M-PU-1163 M-PU-1185 M-PU-1186 M-PU-1189 M-PU-1190 M-PU-1198 M-PU-1192 M-PU-2218 M-PU-2603 - C.-l' OIL BREATHER ASSEMBLY WP220C, D & F @ FLYWHEEL 0Single Bel t WP220A & B WP220C & D Double Belt WP220A, B, C & D WP220E Triple Belt WP220F 0Single E PULLEY Belt M-120-458 M-1202-457 G OIL GAGE OR FILLER 0 WP2206 & D WP220E & F 130-469 PLUG 220-112 342-112 M-%20-463 M-130-458 M-230-457 BT-36 BT-84 BT-69 BT-68 BT-140 BT-142 BT-60 BT-62 ORDERING INFORMATION: (In United States) --Repair Parts or Assemblies. -~ Repair parts or assemblies only (except on DeVilbiss compressor components) should be ordered from Honeywell Inc., 1885 Douglas Drive, Minneapolis, Minnesota 55422, Compressor parts may be ordered from DeVilbiss CO.) 300 Phillips Ave., Toledo, Ohio. Fig. 10- Please order by Part No., Description, and Quantity. Also give complete Order Specification number of-the Compressor-Drier: The number is stamped on the plate next to the compressor pump (See Fig. 10). Example: On the label shown in Fig.. 10, the O.S. Number is WP220 E 1010, In some cases it may be necessary to return the entire device to our reconditionfactory for complete repair and ing. Nameplate -- Inquiries on Orders. Direct all inquiries on orders to Honeywell, Inc., 1885 Douglas Drive, Minneapolis, Minnesota 55422, (In Canada, direct all orders and inquiries to Honeywell Controls Limited, Vanderhoof Avenue, Leaside, Toronto 17, Ontario). --Return of Complete Device. For prices or further information on Iioneywell parts, contact your nearest Honeywell Branch Office, Such information on DeVilbiss parts should be obtained from the DeVilbiss co. When a complete device is returned for reit should be mailed with a repair 1pairs, order to Honeywell Inc., 8330 North Austin Avenue, Morton Grove, Illinois 60053. Page 10 Mechanical devices must be serviced periodically if they are expected to give continued satisfactory performance, and controls are not an exception. Now accurate and how troublefree your control system will be in the years to come depends largely on the maintenance given it, For best results, all devices in your system should be serviced at one time. Time and trouble can be saved by arranging with Honeywell for a maintenance agreement which will guarantee expert, economical cam, and insure maximum life and efficiency from your system.
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