OPERATION AND SERVICE MANUAL Cylinder Filling Unit Cardox Model Number 1-042-0050 CHEMETRON Fire Systems 22222! comm Designers and Manufacturers of Cardox and Fire Boss Fire Protection SystemsSECTION 1 INTRODUCTION 11 General... 5 12. Description of the Cylinder Filling, Unit S I OPERATION AND SERVICE 2-1 Installation of the Cylinder Filling Unit . 22 Location 23° Unpacking... 24 Setting Up the Equipment F Prior to Operation 25 Operating Instructions. 246 Cylinder Preparation 27 General 5 29 Cylinder Connections 2:10 Operating Procedure - 2-15 Filling A Single High Pressure Cylinder 2.18 Filing High Pressure Cylinders Alternately : A 2.28 Service Instructions 2.26 Lubrication 228 Periodic Inspection 2.29 Trouble Shooting IIL REPAIR INSTRUCTIONS 31 General Leak Testing 33 V-Belts TABLE OF CONTENTS PAGE SECTION 34 Adjustment 3 Alignment 36 Valves 1 37 General 39 Compressor ‘sembly 3 3440 General 3411 Valves: 3 3.12 Disassembiy 3 3443 Inspection . 3 3-14 Reassembly .-- 3.15 Piston Packing Gland. “3 3416 General . 3 3 3 3 3 3:17 Disassembly -- 3-18 Inspection 319 Reassembly .. 3-22 General 3.23 Disassembly 324 Inspection 3.25 Reasembly - IV PARTS LIST 41 General wld 42 Electrical Parts n 43 Connection Piping H 44 Spare Parts... LIST OF ILLUSTRATIONS NUMBER 21 Components and Controls . 22 Typical Hookup and Flow Schematic. 23. Cylinder Filling Unit Details (Sheet I of 2) 23. Cylinder Filling Unit Details (Sheet 2 of 2) . PAGE NUMBER 2 2-4 Compressor Assembly, Exploded View 34 1/4 Inch and 1/2 Inch Barstock Valve ‘Aseembly (Bleedoff and Cylinder Filling) 12 Inch Angle Valve Assrbly (Retum Valve) 32 33. Pressure Regulating Valve 41 Safety Disc Assembly 3.20 Test After Reassembly 321 Crakeate Beane 4 s : : aed 3.26 Test After Complete Reassembly 3 of the Equipment ...... 9 9SECTION! INTRODUCTION 11, GENERAL. This manual contains the operating and maintenance instructions for the Cardox Cylinder Filling Unit, Cardox Stock Number 1-042-0050.A complete illustrated parts list is given at the back of the manual ‘The cylinder filling unit is used in the transfer of liquid carbon dioxide from a Cardox Low Pressure Storage Unit to carbon dioxide cylinders 1-2. DESCRIPTION OF THE CYLINDER FILLING UNIT. Basically 2 transfer pump fitted with operating controls, the unit is designed to receive liquid carbon dioxide at an induction pressure of about 300 pounds per square inch (psi), and deliver it into portable cylinders at a regulated pressure ranging from about 600 psi to 1000 psi, as needed. The cylinder filling unit includes the ‘equipment listed below. COMPRESSOR — Single stage single cylinder transfer pump with automatic valves, This unit is intended for handling only liquid carbon dioxide. DRIVE MOTOR A five horsepower electric motor is, furnished, The standard motor is a 220/440 volt S0/60 cycle three-phase item; however, any motor meeting spe- cial requirements may be used. The data plate on the motor will identify special characteristics, if any are specified. MOTOR SWITCH — This is a commercial ON-OFF push- button switch which includes the motor thermal overload devices PRESSURE REGULATOR - This is a ball type relief valve, arranged to both regulate filing pressure, and return excess carbon dioxide to the storage tank. In filling a number of cylinders, each requiring the same filling pressure, the operator sets the pressure once, then turns the valve ON and OFF by a full throw of the handle for ‘each cylinder. In OFF position pumped liquid is returned to the storage tank, so the unit need not be shut down between filings of cylinders. PRESSURE GAGE ~ This gage indicates delivery pressure to a filling cylinder. BLEEDOFF VALVES — These hand operated valves are used to relieve pressure in certain lines when those lines, are to be disconnected. RELIEF VALVES AND SAFETY DISC— Two relief valves and a safety disc are installed in the system to protect those parts of the system in which liquid might be trapped by closed valves. The items listed above are supplied as part of the Cylinder Filling Unit. The follow- ing items, not part of the unit, are needed for installation and use of the unit. TWO FLEXIBLE CHARGING HOSES — To connect the unit to the cylinders being filled. PLATFORM SCALE — To indicate when FULL weight of cylinder is reached. SUPPLY AND RETURN PIPING ~ To connect the cylin- der filling unit to the user's storage unit. ‘TABLE OF LEADING PARTICULARS Length... eeeeeeceee cece 39 in Width ee 2141/2 in, Height - 33-1/2 in Weight... eee ea s50 lb Power Source 220/440 volts, 50/60 cycle, 3 phase, of as specified by customer's order Inlet Pressure . ee 300 psi Discharge Pressure (adjustable) . {600-1000 psi Capacity, pounds per minute about 353 4. Return Line Supply Line Motor Switch Cylinders Flexible Charging Lines Gylinder Filling Valves Seale Cylinder Valve Figure 2-1. Components and Controls 201-1 9. Pressure Regulating Valve 10. Vapor Return Valve IL. Pressure Gage 12. Bleedoff ValveSECTION II OPERATION AND SERVICE 2.1. INSTALLATION OF THE CYLINDER FILLING UNIT. 22. LOCATION. Select a site with a reasonably level floor, as near as practical to the carbon dioxide storage tunit, The site must provide enough room for the operator to work when connecting cylinders, and must have electric power available for the motor. 23. UNPACKING. At the selected site, remove the shipping crate and protective wrappings. Fasten the unit to the floor with lag bolts through the four feet. 24, SETTING UP THE EQUIPMENT PRIOR TO OPERATION. After the equipment is located and secured to the floor, connect the piping (1/2 inch pipe return line (1, figure 2-1) and 1 inch pipe liquid supply line (2)) between the storage unit and the equipment, Use pipe unions at the connection to the equipment. Connect a power supply, corresponding {othe electrical characteristics of the motor used, to the terminals on the motor switch (3). Unless the purchaser has requested otherwise, the motor will be a 220/440 volt, 50/60 cycle, three-phase unit, connected at the factory for 220 volt operation, with 220 volt overload elements installed in the switch. Additionally, a set of 440 volt overload clements is packed with the equipment. If the equipment is to be operated on 440 volts, reconnect the motor leads according to the diagram on the motor, and install the 440 volt overload elements in the motor switch. Note that these are motor protecting devices. Their use does not obviate the need for supply line fuses or circuit breakers, 15 amperes for a 440 volt line, or 30 amperes for a 220 volt line 2:5. OPERATING INSTRUCTIONS. 2-6. CYLINDER PREPARATION. High pressure cylinders should be properly prepared prior to filling them with carbon dioxide. This preparation will vary with, factors beyond the scope of this manual, and is to be determined by the policy and needs of the user. 2-7. GENERAL, The charging lines and valving used between the cylinder filling unit and the cylinders being filled may vary. Figure 2-2 illustrates the recommended valving on the charging lines. ach charging line must contain a shutoff valve and a bleedoff valve, 2-8. With two charging lines available, continuous eylin- der filling is possible; as a filled cylinder is being replaced at one charging line, filling of a second cylinder can ‘continue at the other charging line 29. CYLINDER CONNECTIONS. Connect the cylin- ders to be filled as shown in figure 2-1, and place them fon the scale, one at a time. Compare the weight indicated on the scale with the “empty” and “full” weights stamped on the cylinder to determine the amount of CO2 remaining in it. The difference between the actual weight and “full” weight will indicate the amount of CO2 required to fill the cylinder. NOTE Do not start the motor until the following steps have been completed to insure pressure on the piston head, and to avoid popping off the relief valves or safety disc 2-10, OPERATING PROCEDURE. Open the storage tank liquid valve (18, figure 2-2). This will pressurize the ‘compressor (17) through the discharge valve port, the pressure regulating valve (9), the eylinder filling valves (6) and bleedoff valve (12). 2-11. With the handle of the pressure regulating valve (9, figure 2-1) raised, open the return valve (10) to the storage unit, and open the storage tank vapor valve (8, figure 2-2). All carbon dioxide pumped now will return to, the storage tank until the regulator valve handle is lowered and a pressure adjustment is made. The entire cylinder filling unit is now at storage tank pressure. 212. Open bleedoff valve (12) to vent vapor, until carbon dioxide snow is discharged, then close the valve. Press the motor START button (3, figure 2-1), operating the compressor until a coat of frost has formed on the return line (1) and on the compressor cylinder head. 2-13. Throw the regulator handle to the horizontal posi- tion, and with an Allen wrench inserted in the recess head screw at the top of the regulator, adjust the charging pressure (indicated on the pressure gage, (11)). Cold cylinders will fill readily at 600 to 800 pounds pressures however, warm cylinders require higher pressures, ranging from 800 {0 1000 pounds pressure. 214. Should a vapor lock form (indicated by a defrosting of the piping on the discharge side of the compressor), fully open the pressure regulating valve (9) by raising the handle. Allow carbon dioxide to bypass back into the 31, Return Line 7. Scale 13. Charging Line Bleedoff Valves 2. Supply Line 8. Storage Tank Vapor Valve 14. Charging Line Shutoff Valves 3. Cylinder Valve 9. Pressure Regulating Valve 15. Pressure Relief Valves 4. Cylinders 10. Return Valve 16. Safety Dise 5. Flexible Charging Lines 11. Pressure Gage 17. Compressor 6. Cylinder Filling Valves 12, Bleedoff Valve 18, Storage Tank Liquid Valve Figure 2-2. Typical Hookup and Flow Schematic storage unit until a coating of frost reappears on the piping and then proceed to readjust the pressure regulat- ing valve to proper charging pressure as indicated in paragraph 2-13. At certain temperatures and pressures there will be a pressure regulating valve noise. It will not, however, afeet the operation of the equipment, 2.15. FILLING A SINGLE HIGH PRESSURE CYLIN- DER. Open the appropriate cylinder filing valve (6, figure 2-2), charging line shutoff valve (14) and cylinder valve (3). NOTE [As the empty cylinder starts filling, the charging pressure indicated on the pressure gage will de- ‘crease and gradually regain the charging pressure as filling proceeds. 216. Allow the carbon dioxide to fill the high pressure cylinder until the “full” weight stamped on the cylinder js reached, as indicated on the scale (7). Do not overfill the high pressure cylinders. If @ cylinder is overfiled, bleed off the excess carbon ‘dioxide so that the safety dise on the cylinder will not rupture. 2.17. When the cylinder is full, shut down the equipment as follows: 1, Close the cylinder valve (3). b. Close the eylinder filling valve (6).c. Bleed the carbon dioxide trapped in the flexible charging line (5) by opening the charging line bleedoft valve (73) and then disconnect the eylinder WARNING Liquid carbon dioxide trapped in the flexible charging line between the two valves might reach extreme pressures if the line is not bled down at ‘once, Never discharge or bleed off carbon diox- ie through the flexible charging lines unless they are gonnected to cylinders or firmly secured. A exible charging line will whip around it not my scetted and may cause personal injury 4. Fully open the pressure regulating valve (raise the lever handle} and then stop the electric motor by pressing the STOP button on the motor switch. ©. Close the storage tank liquid valve (18). f When the return tine (1) hus defrosted, close the storage tank vapor valve (8). 2. Bleed the cathon dioxide from the cylinder filing unit assembly and interconnecting piping from the liquid storage tank by opening tie bleedoft valve (12). Close all DleedotY valves now to exclude moisture from the system, hh. The seturn valve (10) may. if desired, be closed at this time. This operation is not necessary i the liquid storage tank is used only as a carbon dioxide supply’ for the cylinder filing unit assembly 2.18, PILLING HIGH PRESSURE CYLINDERS ALTER: NATELY. If cylinders of the same size are being tilled alternately with continuous charging taking place, one cylinder ling valve (G) connection is open for filling while the other cylinder filling valve connection is closed ‘while attaching or removing the second cylinder. Keep the setting of the pressure regulating valve constant until all cylinders have been filled, to reduce packing wear. Do not allow the equipment to idle at charging pressure for long periods of time. This will cause pressure buildup within the storage tank and excessive wear to the cylinder filling unit 219, See figure 2-2 for reference to cylinders A. B, and € discussed in the following paragraphs. The following procedure should be adhered to when filling cylinders alternately. With cylinders A and B attached to the flexible charging lines and the operating instructions in paragraphs 2-10 through 2-14 performed, open the cylin- Ger filling valve (6), charging line shutoff valve (14) and cylinder valve (3) to eylinder A. NOTE As the empty cylinder starts filling, the charging pressure gige (11) will decrease and gradually regain the charging pressure as filing, proceeds. 220. Allow the carbon dioxide to fill eylinder A until the “full” weight is indicated on the seale (7). Do not overfill the cylinders. If a cylinder is overflled, the excess carbon dioxide must be bled off so that the safety disc on the cylinder will not rupture, 221. When cylinder A is full, perform the following steps 4, Close the cylinder valve (3) on eylinder A. b. Open the cylinder valve (6), charging tine shutoff valve (14) and cylinder valve (3) to cylinder B. This will permit charging of empty cylinder B wlule filled cylinder ‘A is being removed and empty cylinder C is being connected fo the charging line €. Close charging line shutoff valve (14) to eylinder A. and crack bleedsft valve (13), 4. Remove filled cylinder A and replace with empty cylinder C, connecting it 1 the exible charging tine Close bleedoff valve (13). fe, When cylinder B js filled, repeat steps a, through d for cylinder B and additional emply cylinders, 2.22. After all cylinders have been filled and the last cylinder removed from the Mesible charging line, close both cylinder filling valves (6). 2.23, Perform procedural steps 217d through 2-17g to completely shut down the equipment after all filing has been completed for the day. 2.24. Figure 2-3 illustrates the appearance and location of the components referenced inthe preceding operational text to figure 22, 2.28. SERVICE INSTRUCTIONS. 2.26. LUBRICATION. The equipment requires no lubri- cation other than maintaining the oil level in the compres sor crankcase. When the equipment is in frequent opera- tion, check the oil level at least twice a week and change the vil at least every three months, To check the oil level. remove the oil level plug (53, figure 2-4). The oil is at the proper level when it is even with the bottom of the vil level hole, If the oil level is Jow, fill to the proper level with good SAE 30 motor oil. High detergent oil is not needed, but may be used.13. 14, 18. 16, 1. 18, Cylinder Filling Unit Details. (Sheet 1 of 2) Pressure Regulating ValveCardox C02 Compressor V Belt Set Sheave Suction Piping Assembly 3. Bent Pipe Reducer Bushing 1/2 Inch Valve 1/4 Inch Valve Pressure Gage Manifold Start-Stop Switch ble Connector (90) 31 33 34 35. Bi 36, Figure 2-3. Cylinder Filling Unit Details (Sheet 2 of 2) Motor Adjustment Serewcap Gasket Seat Valve Spring Cage Seat Valve . Spring Cage Gasket Adapter Gasket Gland Head 16. Bolt 17. Washer 18. Spacer 19. Wiper 20. Bearing 23A. Spacer 24. Cylinder 21. Adapter 23B. Packingset_ 25. Bolt 22, Packing 23C. Packing ting 26. Washer 23. Adapter 23D. Wave spring 27. Nameplate 28. Screw 29. Gasket 30. Plunger 31. Sheave and Bushing 32. Bushing 33. Key 34, Sideplate 35. Bolt 36. Washer 40. Cone 41. Locknut 42. Lockwasher 43. Bearing, 44, Ring 45. Counterbalance 46. Setserew 47. Key 48, Eccentric 49. Pin 50. Crankshaft SI. Plug 52. Nipple 53. Plug 54. Vent 55. Elbow Crankease Replaces Index Numbers 18 thro 23 for eylinder filing unit assembly Models 1-042 (0050 Serial Numbers 199 tnd up and Compressor Models F5-21561-G2 Serial Numbers 2607 and up. 1569-4 Figure 2-4, Compressor Assembly, Exploded View227. To drain the crankcase oil, remove oil drain plug G1). Replace plug when the erankease has been thorough ly drained. Remove filler vent (54) and oil evel plug (53). Fill the crankcase with proper oil through the filler vent hole until oil begins to run out through the oil level plug hole. Replace the filler vent and oil level plugs. Crankcase capacity is approximately one and one-half pints, 2.28. PERIODIC INSPECTION. No definite periodic in- spection or preventive maintenance schedule is established for the cylinder filling unit assembly other than periodic Iubrication. Any trouble that may arise will be observed while the equipment is in operation. 2.29. TROUBLE SHOOTING. Table 2-1 is tabulated for ease in locating possible troubles, their probable cause and remedy. The remedy column references applicable para- graphs when detailed maintenance procedures are Fequited, TABLE 2:1. TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Low Capacity Cylinder filing valves not Open valves fully open Pressure regulating valve Adjust valve until pressure pressure setting too low. ‘age indicates proper charging presse. Pressure regulating valve Won valve ball or seat. cannot be adjusted to maintain See paragraph 3-6. charging pressure. Vebelts broken or sipping Readjust belt tension ot replace if necessary. See paragraphs 34 and 3-5 Excessive leakage through ‘Tighten packing gland. If compressor packing around leakage persists, replace plunger packing or packing set. See paragraphs 3-16 through 3-20. Compressor valve gaskets Tighten caps (1, figure 2-4) (2,11 oF 13, figure 24) or adapter (12) as required leaking or replace gaskets it damaged Compressor plunger rubbing Loosen bolts securing head cylinder wal and retighten evenly. Re place plunger or head if damaged Compressor valves not ean valves and valve seats operating properly Replace if worn oF damaged See paragraphs 312 through aid Safety clit valves Replace valve teaking Compresor Excesive moisture in ear Remove and diy vale, Add @ Valve bon dioxide supply dchydrator in the liquid Freezeup supply line if trouble continues, Piston Too Piston packing gand too Loosen packing gland; replace Hot cht. packing or packing sti Worn See puugraphs 3-16 through 320. Compressor it level tow: Add ol. Knocking Looe crankcase bearings. Replace bearings. See para ‘graphs 3-22 through 3-25. Locse pulley (Aywheel) TightenWMS 7. O+ing 16. Spacer wow on 2014 Figure 3-3. Pressure Regulating ValveSECTION III REPAIR INSTRUCTIONS 31. GENERAL LEAK TESTING. After maint hhas been performed on any pressurized components re moved from the system, test the connections with soap- suds when the equipment is again operated to check for Feakage. Leakage is usually detected by a hissing noise and the appearance of a white fog similar to snow. Small leaks are neither audiblé or visible 3-2. To detect small leaks, make a mixture of soap and ‘water. The suds produced should be of a fluffy texture rather than a efeamy mixture. Apply the soapsuds to the connections, being certain the suds cover all parts of the connection under test at the same time, Gradual enlarge ment of the bubbles indicates a carbon dioxide leak. ‘Allow approximately one minute for each test. If no bubbles form in that time, it can be assumed the joint is, rot leaking. 33. V-BELTS, 34, ADJUSTMENT. Loosen the motor mounts and Adjust the V-belt tension so that no slipping occurs, by moving the electric motor on its base with the motor adjustment serew (36, figure 2-3) as required. The belts should be just tight enough to prevent slipping. Deflection fof cach belt when exerting firm thumb pressure should rot exceed one and oneshalf inches. 35. ALIGNMENT. Check alignment of the electric mo- tor pulley and compressor pulley with a straight edge against the pulley faces. Adjust the pulleys as required by Toosening the bushing setscrews and moving the pulleys in for out. The V-belts should run parallel to the straight edge and the pulleys should be in alignment. Belts showing signs of wear or deterioration should be replaced as a matched set 36. VALVES. 37. GENERAL. Valve maintenance is generally limited to lightening the stem packing nuts or replacement of stem packing to stop leakage of carbon dioxide around the valve stem, If leakage around the stem cannot be stopped by either of the previously described procedures, replace the valve as an assembly. Before servicing valves, be certain all carbon dioxide has been bled from the cylinder filing unit assembly. 3-8, If leakage through the valves cannot be controlled by completely closing the valve, proceed as indicated below: a. 1/4 Inch and 1/2 Inch Barstock Valves (Bleedoff and. Cylinder Filling Valves, see figure 3-1). If leakage cannot be controlled by completely closing the valve, replace the complete valve. b. 1/2 Inch Angle Valve (Return Valve, see figure 3-2) IF leakage cannot be controlled by completely closing the valve, disassemble the valve by following the key index numbers and replace the neoprene disc (8). If leakage persists, replace the complete valve. c. Pressure Regulating Valve (see figure 3.3), If regula: tion of charging pressure cannot be maintained, disissem- ble the valve in the order of the index numbers, and check the ball (3), spring (4) and seat (2) for wear or ‘damage. Replace any parts found to be defective. 4. Safety Relief Valves and Safety Dise. No maintenance is to be performed on the safety relief valves (9, igure 23) or safety disc (15), The two safety relief valves are preset to relieve pressure in excess of 450 pounds per square inch trapped in the supply line, retum ine and the piping between the compressor and cylinder filling valves. ‘They should seal completely when the pressure drops below 450 pounds per square inch. If leakage of carbon dioxide through the valves is observed when the pressure is below 450 pounds per square inch, depressurize the complete cylinder filling unit and replace the defective valve us.a complete assembly. ‘The safety dise is a pressure relieving device set to rupture at 1500 pounds per square inch. This device protects the compressor when the pressure regulating valve is completely closed while the compressor is running. If the disc ruptures, depressurize the complete cylinder filling unit and replace the dis. 3.9, COMPRESSOR ASSEMBLY. (See figure 24.) 3410. GENERAL, Loss of capacity (excessive time re quired to fill @ cylinder) is usually due to faulty operation for obstructions in the valves (I through 10). A fifty pound cylinder should take approximately one and one: half minutes to fill under average operating conditions. If no excessive leakage is observed past the piston packing gland (14), the valves should be removed and inspected. 3411. VALVES. 3.12, DISASSEMBLY. Remove the valves as an assem bly. If it is determined the valves are damaged, they must be replaced as assemblies, 3.13. INSPECTION. Inspect the valves to determine that they seat properly and that the faces are not worn or pitted. Remove all obstructions that may prevent the valves from seating properly. uNOTE Inspect the valves for moisture. Valves must be thoroughly dry before they are reassembled. 3:14, REASSEMBLY. Replace the entire valve assembly, if damaged, using new valve cap gaskets (2 and 11). Be sure that the gaskets are in straight so that they do not leak or obstruct the valve opening. 3-15. PISTON PACKING GLAND. 3.416. GENERAL. Heavy spurts of carbon dioxide snow around the piston will indicate excessive leakage past the packing. Tighten the packing gland (14) to stop excessive leakage. If the leakage persists, proceed as indicated in following paragraphs. 3417, DISASSEMBLY. Disassemble the packing from the piston head by removing the packing gland (14) and then the head as an assembly (1 through 25 excluding 14). Follow the order of key index mumbers assigned to the exploded view illustration when removing the packing from the head. 3-18, INSPECTION. Inspect spacer (18), wiper (19), bear jing (20), adapter (21), packing (22) snd adapter (23) for wear or damage, For cylinder filling unit assembly Models, 1-042-0050-Serial Numbers 199 and up and Compressor Models FS-21561-G2 Serial Numbers 2607 and up, in- spect spacer (23A), packing set (23B), packing ring (23C) and wave spring (23D) for wear or damage. Packing set (23B) should be replaced whenever excessive leakage is noted, Inspect plunger (30) for scratches, gouges or exces- sive scoring. Replace all damaged parts. 3.19, REASSEMBLY. Reassemble the items removed from the piston in the reverse order of disassembly. The packings must be inserted one at a time. The sequence ‘must not change. Reassemble the head as an assembly and tighten down the bolts (16) evenly to prevent cocking of the head. Tighten the packing gland (14) by hand. When breaking in new packing, pressurize and operate the equipment to determine that the plunger (30) is not misaligned and is not leaking. If the packing is too tight ‘or the head is cocked when reassembled, overheating and wear will result. 2 3.20. TEST AFTER REASSEMBLY. Frost should always ‘be maintained around the cylinder head packing during operation. If leakage is observed with a new packing, generally the packing gland (14) is too tight and should be loosened. The packing gland is properly adjusted when only a slight amount of vapor or no visible vapor is discharged around the packing. On cylinder filling unit assembly Models 1-042-0050 Serial Numbers 199 and up and Compressor Models FS-21561-G2 Serial Numbers 2607 and up, the packing set is preloaded by use of the wave spring (23D) and requires no packing adjustment. Slight carbon dioxide leakage past the packing cools the piston for more efficient operation, 3.21. CRANKCASE BEARINGS. 3-22. GENERAL. Parts inthe compressor crankcase should not be removed unless excessive vibration and knocking cannot be eliminated by adding oil to the crankcase or tightening the pulley 3:23, DISASSEMBLY. If excessive vibration and knock- jing cannot be eliminated by performing the previously described operations, disassemble the pulley and all other parts from the crankcase (56) to the degree necesary to Inspect cups (39), cones (40) and bearing (43) by follow ing the sequence of key index numbers assigned to the exploded view illustration. Use a bearing puller or arbor press to remove cones (40) from crankshaft (50). 3.24. INSPECTION. Inspect all parts visually for exces- ‘ive wear or damage. Inspect the cups (39) and cones (40) for galling, pitting, scoring, fractures or abraded surfaces. Bearing (43) will generally be the cause of vibration or Knocking if damaged. Discoloration of rollers or rings indicates insufficient lubricant supply. Replace all dam- aged parts. 3.25. REASSEMBLY. Reassemble in the reverse order of disassembly. During reassembly, use a new oil seal (37), gasket (88) and lockwasher (42). 3.26. TEST AFTER COMPLETE REASSEMBLY OF THE EQUIPMENT. After the complete equipment has been reassembled, all connections in the piping that have been broken should be tested as instructed in paragraphs 31 and 3-2 for carbon dioxide leakage. An operational iest will determine if the equipment is up to the proper standard.SECTION IV PARTS LIST 4-1. GENERAL. All parts listed in this section, except those listed as NS (not stocked) in the Part Number ‘column can be ordered from Cardox Division of Cheme- tron, Ine. by giving the part number. Parts bearing the indication NS arc not sold separately. If any of these parts is needed, order the mext higher assembly with Which it is associated. Replacements for these items in rating values not listed can be ordered by the part description and electrical rating. 43. CONNECTION PIPING. Connection piping is not listed, since this item depends on the individual installa- tion. 44. SPARE PARTS. Cardox recommends that cach 4-2, ELECTRICAL PARTS. Since original motors, user of a cylinder filing unit Keep at least a small stock switches and overload heaters are specified by the uscr of certain spare parts on hand, These parts are identified according to his power source characteristies, omly the by (S) in the Units Per Assembly column of the parts most frequently ordered ratings are listed for these parts. listing. UNITS FIGURE & DESCRIPTION PER INDEXNO.| PARTNO. 1234567 ASSY. 23. 1-042.0050_| CYLINDER FILLING UNIT ASSEMBLY 1 4 3071-0029. | . SIDE, Housing 2 3.071.027 | | COVER ASSEMBLY 1 6029-0061 HANDLE 1 6.005.064 SCREW, Machine 3 6-007-0093 NUT 3 6-008.0073, WASHER 4 4 5.039.243 | - UNION, Female, 2000 psi 1/2 in 2 3 5.040.028 | | NIPPLE, Pipe, heavy weight, 1/2 2 dia x 1-1/2 in. Ig 6 sox6o724 |. NAME PLATE \ 6007-0197 |. NUT 2 7.005.008. | | BOLT, U 2 007.0030 | | NUT 4 008.0028 | | WASHER 4 8 | 3071-0032 : : 1 2 1061-0753 | | VALVE, Safety reli, 450 psi = 2 “10 | 1061-0168 | | VALVE'ASSEMBLY, Globe, angle type, - 1 1/2 in. size, bronze -l_ | 3071-0013 |. DISCHARGE PIPING ASSEMBLY 1 212, | 5039-0135 |. ELBOW, Steet, 3000 psi. 1/2 in 3 “13 BOLT. U t a4 NIPPLE, Pipe, heavy weight, 1/2. 1 dia xin le is | 2.063.002 | . DISC ASSEMBLY, safety 1 “16 | 1061-0713 | ° VALVE ASSEMBLY, Relir, pressure 1 regulating -17 | $-040.0028 | NIPPLE, Pipe. heavy weight, 1/2 dia, 1 x EI -18 | 5.039.090 | . CROSS, Screwed, 3000 psi 1/2 in. 1 19 | 1-071-0023._| © COMPRESSOR ASSEMBLY, Carbon dioxide 1 6005-0489 | * SCREW, Hexagon socket head, I-13, 4 x2 in. Ig cadmium plated steel 6008-0078. |. WASHER 4UNITS FIGURE & DESCRIPTION PER INDEXNO. | PARTNO. [1234567 Assy, 5.004.0016 |. BELT, V, matehed set 1s) 5.004.0117 | | SHEAVE, 2 groove, 3.35 in. outside V diameter o-008.0134 |. KEY. Square, 1/4 square x 2 in ig, steel 3.071.012 | . SUCTION PIPING ASSEMBLY 1 6007-0030. |. NUT 4 008.0024 |. WASHER 4 23 | s.049.0552 | - PIPE, Bent 1 24 — | 5.039.003 | - BUSHING, Hexagon reducer, 1/4 x 1/2 2 in, forged steel. 6000 psi as 1.961-0017. |. VALVE ASSEMBLY. Barstock 1/2 in, 2 26 | 1061-0015 |. VALVE ASSEMBLY, Barstock, 1/4 in. ' 27 | 7-024-0008 |. GAGE, Pressure, 4-1/2 in.,0-2000 psi ' 28 3042-0050 | | MANIFOLD ASSEMBLY, Welded. t 29 | $.017.0230 | | SWITCH ASSEMBLY, Manual starting It size 1, 220/440 volt alternating | ceurrent, 3 pliase, 60 cycle | 6-006-0192, SCREW | 3 6007-0003 || NUT 3 6008-0073 | | WASHER 3 7-016.0008 | | HEATER ELEMENT. 20 volt alternating 3 current 70160012 |. HEATER ELEMENT, 440 volt alternating 2 eurent -30 | $.012.0038 |. CONNECTOR. Flexible cable, 1/2 in 1 31 5.012.037 |, CONNECTOR, Flexible cable, 1/2 in, 1 232 | $021-0014 | | CABLE, Flexible metal, 1/2 in. size 1 x 12in. Ig 33 | 5.014.0028 |. MOTOR ASSEMBLY, Electric 1847 frame, 5 horsepower. 220/440 volt, 3 phase, 60 eyele 6007-0054 |. NUT 4 6-008.0020 | WASHER 4 34 | 50360724 | | NAMEPLATE 1 6006-0307 |. SCREW 4 35 | 3071-0030 |. BASE ASSEMBLY, Welded 1 336 | 5.071-0246 | | SCREW, Motor adjustment t 6008-0153 | | WASHER 1 1.071-0023_ | COMPRESSOR ASSEMBLY. Carbon dioxide 5.071-0028 | . CAP. Valve : 2 4071-0004 | | GASKET, Valve 21s) 3.071.0034 |. VALVE ASSEMBLY, Suction us) 3 NS SEAT 1 4 NS VALVE 1 $s NS SPRING 1 6 NS. CAGE L 3071-0034 |. VALVE ASSEMBLY, Discharge 4s) NS SEAT. Discharge valve t‘UNITS FiguRE & DESCRIPTION TER INDEX NO. | PART NO. assy. 248 NS VALVE. Discharge 1 5 NS | 2 SPRING, Dichage save! | -10 NS. CAGE, Discharge valve 1 are $.023-0176 | - GASKET, lead ....... 4S) 12 5071-0158 | . ADAPTER, Plug, cyl th 1 13 5023-0246 GASKET, Plug, cylinder head (S) ory $-071-0111 GLAND, Packing .. . - 1 AS 5071-0107 HEAD, Cylinder 1 ‘ts | Soososig j | Bout.” 4 U7 | S8888519 | > Wastek’ i 18 | Sortorso |< SeackRe 221" i 19 | SSAG1E3 | + Wate cinder cad us) 220 | Soproiea |! BEARING. Gaphned 2200000000002 mennp i St | SOnkOIS6 |< ADAPTER, Bottom.” DUEEEEEE | 22 $-023-0304 PACKING, Leather, 60° chrometan been eae neenee AS) Wee. 25)lo outside diameter x 1-5/8 inside diameter x 1/8 in. ee height 1-1/4 in. cet of wees and keeper a | sonore, | anita Nm 1 fortooid | > PACKING KIT ASSEMBLY 20020.02! i axa | Sort ous SPACER, Fucking == : i 238 | 50230199 PACKING SET, Chemioa (5) 23¢ | 3071-0047 RING, Packing 1 “Bb | Souporso SPRING Wane rr) cH? | Sororty | eylinner } 25, 6005-0449 BOLT. Hexagon head, 3/8-16 x 1-3/4 6 i ig tude pleted ster | | coosooa |. wast : | 6 | | Sohoonss |: NAMeptaTE : | dooosor | Sa 4 Sos80587 | GASKET: Cilindse i Sutiorss |. PLUNGER ; I Fon900s | SHEAVE-AND BUSHING, Vee! 9p, i | gs | roca 000 BUSHING. anceluee Te 1 Fas | cams key, Sune Ser sie boat \ | on ' oonsnsw) | BOL é | Sosoes |) Wasik 1g | Shao. ' | 2 GASRET, Brine dediac 1 | CON Neat ie | CONE: Hoe! pun | fe rots , oi 2 soyraibs | LocRwasnie'e I | 43 |SonrSt0s |. BRARING Ro 1 } Sa |S0h G09 |S RING: Retamng 3 | |Soriois7 | CRANKSHAFT ASSEMBLY i | as [Sort oes COUNTERBALANCE | te |bose83 SETSCREW : ' 47 | Soos995 REY, Siar, 4x 1x Vin I iste 48 ecctitieic 1 % Tapered pin, No. 6 x i itn gy steel 50 CRANKSHAFE 1UNITS FIGURE & DESCRIPTION PER INDEXNO. | PARTNO. |123.45 67 ASSY. 5.039.0322 | . PLUG, Pipe, 1/4 in., 150 ps, 1 malleable ion s.030.0567 | NIPPLE, Pipe, 1/4 dia x 7 in. Ig, 1 salvanized iron $3 | so300148 | . PLUG, Pipe, square head, 1/8 in, 1 galvanized iron 34 | 30920068 | | VENT, Plug 1 385 | So39.0468 | © ELBOW. Stet, 1/2 in. 150 psi, i galvanized iron so | so71ois6 | . CRANKCASE 1 3H 1.061.015 | VALVE ASSEMBLY, Batstock, 1/4 in 1 NS HANDLE, Cross 1 2 NS NUT, Cross handle 1 3 NS NUT, Gland 1 4 [NS FOLLOWER, Giand Hl 5 NS PACKING 1 a | NS STEM I 4 NS BONNET 1 8 NS BODY 1 32. 1-061-0168 | VALVE ASSEMBLY, Globe. angle ype, 1/2 in. size, bronze 1 NS HANDWHEEL U 2 NUT, Handwheel 1 3 NUT, Packing 1 4 GLAND, Packing I 3 PACKING 1 4 BONNET 1 a NUT, Ring 1 3 Disc 1 9 LOCKNUT, Dise 1 “10 HOLDER, Disc 1 au STEM 1 2 SEAT 1 a3 BODY 1 33 1061-0713 | VALVE ASSEMBLY, Relief pressuse regulating a | sosi0664 |. BODY ' 2 5061-0665 | ° SEAT, Vale 1 3 50610611 |. BALL’ 1 4 5047-0129 | > SPRING t 3 5.023.004 | | O-RING ! “ 3061-0127 | | RETAINER, Spring 1 a 5023-0463 | | O-RING 1UNITS FIGURE & DESCRIPTION PER INDEXNO. | PARTNO. 1.23.45 67 Assy. 338 3061-0130 |. SLEEVE....... 1 2 3.061-0129 | | RING, Coupling 1 10 | 6005-0521 | | SETSCREW, Socket 1 cit | 3061-0134 | | ARM, LEVER 1 112 | $029.0001 |. KNOB, BALL. 1 113 | 605.0753 | - SETSCREW, Socket .. 1 sa | 3061-0133 |. CaM... I cis | 3061-0131 | . ADJUSTING BODY . 1 -16 | 3061-0128 | . SPACER..... 1 17 | 3061-0132 | - PISTON, Adjusting 1 <18 | 3061-0126 |. CAP : 1 an 2.063-0002 | DISC ASSEMBLY, Safety 1 5071-0031 | . NUT, Disc 1 2 7063-0002 | - DISC, Safety 5 us) 3 7023-0040 | | WASHER, Fiber : 18) 4 5.039-0469 | | CONNECTOR, Double male 20.02... 1 10260237 | CYLINDER FILLING HOSE ASSEMBLY (hose, stop valve, bleed valve, cylinder connector) (see figure 2-1) 1.061-0015 |. VALVE (2 used) for above (see figure 34) 1.260169 | . HOSE ASSEMBLY, 1/4 in. x6 ft Ig FIBER GASKET 5.939-0441 | | SWIVEL CONNECTOR NUT 5.039.045 | | SWIVEL CONNECTOR NIPPLE 1-026.0142 | CYLINDER FILLING HOSE ASSEMBLY, Same as part No, 14026-0237 except less valves listed, for purpose of this list. This partis listed on the assumption the ‘user will install valves listed with 1-026.0237 at assembly to unit. 5.072.001 PLATFORM SCALE, 300 pound capacity x 1/4 pound (see figure 2-1), full capacity beam, platform size 11 in. x 11 in., overall dimensions 13-1/4 in. high, 14-1/2 in, wide, 17-3/4 in. ig Figure 4-1. Safety Disc Assembly 7