Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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Section 3 - Maintenance For Models: JGH:E:K:T 1. For new divider valves, verify working piston section fastener torque is 75 lb-in. Loosen the section fasteners, then step-torque them first to 40 lb-in, and then to 75 lb-in. Used divider valves can be tested “as is”, with approximate section fastener torque verified after testing. 6. Place the distribution block in an open container with all base outlets open. Connect purge gun filled with room temperature (65°F) 10 wt. (ISO 32) mineral oil to the divider block inlet. Pump the purge gun to purge air from the divider block assembly. Verify that oil flows freely from all outlets (see Fig. 3-8 “Divider Block All Outlets Open”). Testing with 10 wt. mineral oil at 65°F simulates divider block operation at 120°F with 40 wt. (ISO 150) mineral oil. If 10 wt. mineral oil is unavailable, use 40 wt. (ISO 150); however, the pressure test will be less sensitive in detecting a bypassing divider valve. 7. The divider block assembly should cycle at less than 300 psi while purging at a steady rate. Cycle pressures above 300 psi indicate inhibited piston movement, possibly caused by the piston rubbing the bore, oil contamination, part geometry, or bore distortion due to over-tightening the section fastners. 8. For divider valves stamped with a “T” (for “twin”), use a 1/8 inch pipe or tubing plug to plug only one base outlet when testing that side of the piston, and leave all other outlets open. Plug and test each base outlet of divider valves stamped with a “T” one side at a time. See Fig. 3-8 “Testing ‘T’ Divider Valve”. Individual testing of each outlet ensures both sides of the piston build adequate pressure. For all divider valves stamped with an “S” on the front (for “single”), leave the one side plugged and plug the other outlet as well to test both sides of the piston for by-passing simultaneously. See Fig. 3-8 “Testing ‘S’ Divider Valve”. 9. Pump the purge gun until the pressure gauge indicates 3000 psi. Hold this pressure for 5 seconds, then increase it to 3500 psi. Stop pumping at 3500 psi. 10. Start timer and monitor the pressure drop from 3500 psi for 30 seconds. Check discharge outlet(s) plug(s) to confirm no external leaks. If the valve bypasses rapidly, repeat the test to ensure the bypass wasn’t due to trapped air. New valves should not exceed a 400 psi pressure drop in 30 seconds. Used valves should not exceed 1000 psi pressure drop in 30 seconds. If pressure drops exceed these limits, the divider valve fails the test. 11. Repeat Steps 4 thru 6 for the remaining outlets on the divider block assembly. NOTE: Test distribution blocks at higher pressures if the application dictates higher system operating pressure. If a divider valve fails, replace it. Discard worn divider valves. If the tested valve passes the test, relieve the pressure, move the plug to the next outlet, and repeat the test for all divider valves. When all divider valves either pass this pressure test or are replaced, reassemble the distribution block, purge it with the proper force feed lubricant, and put it into service. This distribution block pressure test procedure is not infallible. <strong>Ariel</strong> recommends periodic tests for proper cylinder bore lubrication rates and/or aftermarket devices that measure flow. Balance Valves Install balance valves on low-pressure lube lines to artificially increase lube line pressure and reduce differential pressure between lube points downstream of a divider block. Important considerations: • Set and maintain balance valves downstream of a divider block within 500 psi (3400kPa) of each other or less. The closer the balance valve set pressures, the more reliable the system. • Avoid situations in which the balance valve set pressure is the greatest contributor of pressure to the divider block immediately upstream. • With a balanced divider block, the upstream divider block pressure gauge should exhibit no erratic needle movement as the divider block cycles. PAGE 3-18 3/11
For Models: JGH:E:K:T Section 3 - Maintenance To maintain the force feed lube system, record the maximum injection pressure indicated at each divider block gauge, balance valve set pressures, and divider block cycle time at least once a day for each zone in the system. See Appendix E. Do not adjust balance valves prior to operating the unit. Verify the tightness of all fittings and fix any known leaks. To remove any trapped air or gas in the force feed lube system, use a high-pressure hand purge pump and the same oil recommended for the cylinder application to purge it. DO NOT USE ANY OTHER FLUIDS FOR PURGING! Call the <strong>Ariel</strong> Reponse Center for details about purchasing a hand purge pump. To prepare for balance valve adjustment: 1. Start the compressor and bring the cylinders up to normal operating pressure. 2. Allow operating pressures to stabilize. 3. See the cylinder lube sheets for balance valve locations and proper spring type for each device. Adjustment of Balance Valves Fed by a Divider Block 1. Select one divider block that feeds one or more balance valves nearest the compressor cylinder/ packing. 1 2. For each balance valve downstream of the selected divider block, loosen the balance valve lock nut and rotate the adjustment cap counterclockwise until the cap is loose. Some residual 2 pressure may remain on the balance valve gauge. 3. Monitor the selected divider block gauge for one minute and record the minimum and maximum pressures in Appendix E. 4. Calculate the balance valve set pressure by multiplying the maximum recorded pressure by 0.85 5. Set balance valve(s) downstream of the selected divider block to the pressure calculated in step 4 1. Balance Valve 2. Balance Valve Pressure Gauge 3. Adjustment Cap 4. Lock Nut 5. Divider Block Pressure Gauge 6. Divider Block FIGURE 3-9 Balance Valves Fed by Divider Block by rotating the adjustment cap clockwise to increase pressure. Set pressure within ±50 psi of the calculated value. 6. Monitor the divider block gauge for one minute and record the minimum and maximum pressures in Appendix E. The difference between the minimum and maximum should not exceed 1200 psig. If it does, repeat steps 2 through 6. 7. Tighten the balance valve lock nut. DO NOT lockwire the adjustment cap. 8. Repeat steps 2 through 7 for any remaining divider block that feeds one or more balance valves nearest the compressor cylinder/packing. 9. After setting all balance valves in the force feed system, operate the system for 4 to 6 hours, then repeat step 6 for each divider block. 3/11 PAGE 3-19 3 4 5 6
Page 1: Maintenance and Repair Manual For J
Page 4 and 5: For Models: JGE:H:K:T Oil Strainer.
Page 6 and 7: For Models: JGE:H:K:T SECTION 5 - S
Page 8 and 9: For Models: JGH:E:K:T FIGURE 4-23
Page 10 and 11: For Models: JGH:E:K:T General Safet
Page 12 and 13: For Models: JGH:E:K:T Ariel Contact
Page 14 and 15: Section 1 - Tools For Models: JGH:E
Page 16 and 17: Section 1 - Tools For Models: JGH:E
Page 18 and 19: Section 2 - Instrumentation For Mod
Page 32 and 33: Section 3 - Maintenance For Models:
Page 58 and 59: Section 4 Part Replacement For Mode
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Section 4 Part Replacement For Mode
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Section 4 Part Replacement For Mode
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Section 5 - Start Up For Models: JG
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Section 6 - Troubleshooting For Mod
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Section 6 - Troubleshooting For Mod
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Appendix A Ariel Fasteners and Torq
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Appendix B - Clearances For Models:
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Appendix C - Frame Specifications F
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Appendix C - Frame Specifications F
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Appendix D Compressor Clearance, Oi
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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