"JP" SERIES FILTER SYSTEMS OPERATIONS MANUAL - Jordair ...

“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.



Doc. FILTER-SYSTEMS-MANUAL-2013

1


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


QTY.



2





3


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




4


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


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


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.


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


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 # 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. Lubricate the O-rings/back-up rings, cap and chamber threads with a silicone based O-ring and thread lubricant.


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


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


DESCRIPTION

PART NO.



8

DESCRIPTION


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


DESCRIPTION



9


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


DESCRIPTION



10


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 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

JBF-6300-22 FILTER CHAMBER 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 O-ring, Filter Element O-ring, Filter Element Barrel Cap, Bottom Nameplate Pop Rivet

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

JBF-6300-32 FILTER CHAMBER 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


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 O-ring, Filter Element O-ring, Filter Element 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 O-ring, Filter Element O-ring, Filter Element Barrel Cap, Bottom Nameplate Pop Rivet

O-ring, Filter Element O-ring, Filter Element Barrel Cap, Bottom Nameplate Pop Rivet



11


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


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. Carefully remove the top cap from the barrel by turning 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. 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 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


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




13
