Section 1. Compressor VH21H3N PDF

INSTALLATION, OPERATION & MAINTENANCE
MANUAL
PET COMPRESSOR
TYPE VH21H3N
VH21H3N
PET Compressor
Introduction
Important
This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of the
Gardner Denver Belliss & Morcom ‘PET’ range of compressors.
It is ESSENTIAL that this document is read and understood by everyone who will work with this
equipment, as failure to do so may result in death, injury or damage to the compressor or its
associated equipment.
Disclaimer
While every care was taken in the preparation of these instructions, it cannot be guaranteed that
every aspect has been covered. Gardner Denver Belliss & Morcom cannot, therefore, accept
liability for direct or consequential damage that may arise resulting from non-conformity with this
Manual, from repairs carried out improperly, from using other than original spare parts, and from
non-observance of good operating and maintenance engineering practices. Should there be any
doubt whatsoever, or should any further information or explanation be required, Gardner Denver
Belliss & Morcom must be contacted.
This information is given in good faith, no warranty or representation is given concerning such
information, which must not be taken as establishing any contractual or other commitment binding
upon Gardner Denver Belliss & Morcom .
Gardner Denver Belliss & Morcom reserve the right to make changes to any information
contained within this manual without prior notice.
Warranty Statement
The compressor(s) and ancillary equipment supplied by Gardner Denver Belliss & Morcom are
covered under Warranty for the period agreed in the Supply Contract.
The equipment provided is well designed to afford many years of trouble free service. However,
should the need arise to implement a warranty claim then this can be done using Warranty Claim
Form obtainable from Gardner Denver Belliss & Morcom Service Department. A copy of this form
is provided in Appendices located at the end of this manual.
It should be noted that consumable parts that require replacement during normal compressor
operations are not normally covered under Warranty. Similarly, the Warranty does not cover running
adjustments.
Gardner Denver Belliss & Morcom are well known in the market place for the design,
manufacture and supply of high-quality air compressor equipment. This Instruction Manual is
produced for the ‘PET' range of compressors. These compressors are constructed from the highest
quality materials and are designed and built according to the latest manufacturing techniques. The
compressor design will give good service providing that it is operated and maintained in accordance
with the information contained within this Manual.
The information and notes presented in the 'Ancillary Devices’ Instruction Manuals will provide
operational and maintenance information for the control and instrumentation system, motor/drive
unit and where appropriate, any other device associated with the compressor package.
Targeted Personnel
This document is designed to provide competent operatives, who are fully conversant with
compressor operating and maintenance techniques, with an understanding of the compressor
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elements and their operation and subsequent maintenance. It should be noted that the term
'competent' implies that the operative is a compressor engineer suitably trained in the installation,
operation and maintenance of the Gardner Denver Belliss & Morcom product.
This Instruction manual is not intended to supersede or take the place of the Gardner Denver
Belliss & Morcom product-training course. For further information regarding training courses or to
book a place, please contact Gardner Denver Belliss & Morcom Service Department. The
address, telephone/facsimile number is provided at the start of this documentation.
How to Use this Instruction Manual

The Instruction Manual is designed to enable speedy location of relevant information. To this end
the document is divided into six chapters, each of which covers an individual topic. Cross-
references between topics and illustrations are identified within the text using bold characters i.e.
(Refer to Chap 2 Section 4.1) or see Fig 3.
At appropriate locations within this document you will see 'Information Boxes'. It is VERY
IMPORTANT that the information contained within these boxes is adhered to, as failure to do so
may result in death, injury or damage to the compressor or its associated equipment. The following
outlines the philosophy applied to each of the three levels of boxed notation.
WARNING !
THIS PICTOGRAM WITH THE REMARK "WARNING!" IDENTIFIES
A POTENTIAL DANGEROUS HAZARD. NON-COMPLIANCE WILL
PUT THE OPERATOR OR A THIRD PARTY AT RISK OF DEATH
OR INJURY.
CAUTION!
THIS PICTOGRAM WITH THE REMARK “CAUTION!” IDENTIFIES
THE POSSIBILITY THAT IF NON-COMPLIANT THE
COMPRESSOR AND/OR ITS ASSOCIATED EQUIPMENT CAN BE
DAMAGED.
THIS PICTOGRAM MARKS IMPORTANT NOTES, WHICH

IDENTIFIES SUPPLEMENTARY INFORMATION FOR THE
COMPETENT AND ECONOMIC USE/OPERATION OF THIS
COMPRESSOR PACKAGE.
Documentation Storage
Always store this Instruction Manual near the compressor so that it is available for reference at all
times. If the instruction manual is lost, Gardner Denver Belliss & Morcom can supply a new copy
for a small fee. When requesting new or additional copies, of this document, please include your
compressor details with your order.
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Point of Contact
For sales, service or spare parts enquiries, please contact :
Address : Gardner Denver Ltd

Belliss & Morcom
Chequers Bridge,
Gloucester,
GL1 4LL,
England
Telephone : +44 (0)1452 338338
Fax : +44 (0)1452 338317
E-mail : petsales@gardnerdenver.co.uk
Website : www.gardnerdenver.com
Comments and Suggestions

We would welcome comments and suggestions for improvements to this Instruction Manual. If you
would like to comment, please make a copy of the page or pages concerned and add your
comments. Then send your response to Gardner Denver Belliss & Morcom. Please do not forget
to include your name and the name of your company, your company address and your telephone
and facsimile numbers.
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Table of contents
Chapter 1 - Technical Data and Description
1.1 Data and Compressor Description . . . . . . . . . 1-2
1.2 Technical Data . . . . . . . . . . . . . . . 1-3
1.3 Technical Description of the Compressor . . . . . . . 1-9
Chapter 2 - Safety Information

2.1 Safety Policy . . . . . . . . . . . . . . . . 2-2
Chapter 3 - Installation and Commissioning

3.1 Safety Precautions . . . . . . . . . . . . . . 3-2
3.2 Installation Requirements . . . . . . . . . . . . 3-2
3.3 Handling and Unpacking . . . . . . . . . . . . 3-9
3.4 Installation Procedure . . . . . . . . . . . . . 3-11
3.5 Preparation for Commissioning . . . . . . . . . . 3-12
3.6 Commissioning the Compressor . . . . . . . . . . 3-14
Chapter 4 - Operating Instructions

4.1 Controls and Indicators . . . . . . . . . . . . 4-2
4.2 Preparation for Starting . . . . . . . . . . . . 4-3
4.3 Starting the Compressor . . . . . . . . . . . . 4-4
4.4 Running . . . . . . . . . . . . . . . . . 4-4
4.5 Stopping the Compressor . . . . . . . . . . . . 4-4
4.6 Fault Indications . . . . . . . . . . . . . . 4-5
Chapter 5 - Compressor Maintenance

5.1 Preventive Maintenance . . . . . . . . . . . . 5-2
5.2 Approved Lubricants . . . . . . . . . . . . . 5-6
5.3 Maintenance Instructions . . . . . . . . . . . . 5-7
JOB No: 1 - Crankcase Oil Change . . . . . . . . . . . . . . 5-8
JOB No: 2 - Fit Piston Rod Clamps . . . . . . . . . . . . . . 5-10
JOB No: 3 - Cylinder Top Covers - Remove and Re-fit . . . . . . . . 5-11
JOB No: 4 - Piston rings - Remove and Re-fit . . . . . . . . . . . 5-15
JOB No: 5 - Piston/Cylinder End (Bumping) Clearances . . . . . . . 5-17
JOB No: 6 - Packing Assembly - Remove and Re-fit . . . . . . . . 5-20
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JOB No: 7 - PACKING ASSEMBLY - OVERHAUL . . . . . . . . . 5-23

JOB No: 8 - Piston Rod Oil-Shedder - Remove and Re-fit . . . . . . 5-25
JOB No: 9 - Oil Scraper Gland - Remove and Re-fit . . . . . . . . 5-27
JOB No: 10 - Suction and Delivery Valves - Remove and Re-fit . . . . 5-29
JOB No: 11 - Suction and Delivery Valves - Overhaul . . . . . . . . 5-32
JOB No: 12 - Suction Valve Unloader Actuators - Remove and Refit . . . 5-34
JOB No: 13 - Piston Rods - Remove and Re-fit . . . . . . . . . . 5-36
JOB No: 14 - Oil Filter - Remove and Re-fit . . . . . . . . . . . . 5-38
JOB No: 15 - Oil Pressure Relief Valve - Adjustment . . . . . . . . 5-39
JOB No: 16 - Lubricating Oil Pump and Drive - Inspect and Overhaul . . 5-40
JOB No: 17 - Intercooler - Inspection and Overhaul . . . . . . . . 5-41
5.4 Lists of Tools . . . . . . . . . . . . . . . . 5-42
5.5 Waste Products . . . . . . . . . . . . . . 5-43
Chapter 6 - Spare Parts

6.1 Spare Parts . . . . . . . . . . . . . . . . 6-2
6.2 Ordering Spares and Spares Stock . . . . . . . . 6-2
6.3 Spares List . . . . . . . . . . . . . . . . 6-2
6.4 Drawings . . . . . . . . . . . . . . . . . 6-4
APPENDIX A
Warranty Claim Form
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Chapter 1 - Technical Data and Description
Issue 0 1-1 Technical Data and Description

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1.1 Data and Compressor Description

The information contained in this section is intended for the use of the engineer responsible
for the operation and maintenance of the plant. It is essential that any necessary adjustments,
servicing or overhaul work should be carried out by competent persons who are familiar with
the installation, operation and maintenance of this product and who have the appropriate
authorisation.
When communicating with Gardner Denver Belliss & Morcom on matters relating to the
compressor always quote the compressor type and serial number (e.g.VH21H3N Serial No.
C00xxxx).
1 - Standards and Legislation

The compressor is manufactured in accordance with the European Economic Community
Directive: BS EN 1012-1: 1997, and is tested in accordance with British Standard: BS 1571
Part 2.

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1.2 Technical Data
a) Operating Data
Table 1-1: Operating Data
Compressor
Model VH21H3N
Number of Stages 3
Inlet Pressure Atmospheric
Cylinder Type Double Acting - Non Lubricated

Direction of Rotation Clockwise looking on the flywheel
Metric Imperial
Flow 1314 m3/hr 733 ft3/min
Stage Pressures
Stage 1 3.0 - 3.5 bar.g 43 - 51 lb/in2
Stage 2 14.5 - 15.4 bar.g 210 - 223 lb/in2
Delivery 45.0 bar.g 650 lb/in2
Safety Valve Settings

Stage 1 4.5 bar.g 65.3 lb/in2
Stage 2 16.5 bar.g 239 lb/in2
Stage 3 49.5 bar.g 718 lb/in2
Oil Pressure * 3.0 - 4.8 bar.g 43.5 - 69.6 lb/in2

Oil Pump Pressure 3.5 bar.g 51 lb/in2
Sump Capacity 9.8 UKgal
45 litres
11.8 USgal
Compressor Speed 735 rpm 735 rpm
Vibration 2.5 mm/s 2 0.01 ft/s 2
Sound Pressure Level 90 db(A) 90 db(A)
Sound Power Level 110 db(A) 110 db(A)
Weight (Without Motor) 5.5 tonne 6.0 sh ton
Weight (With Motor) tonne sh ton
Max Maintenance Lift 500 kg 1100 lb
Instrument Air
Normal Pressure 7 bar.g 101.5 lb/in2
Maximum Pressure 10 bar.g 145.04 lb/in2

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Table 1-1: Operating Data (Continued)
Cooling
Design Ambient 0 - 40 o
C 32 - 104 o
F
Cooling Water Flow ** 36.7 UKgal/min
267 l/min
USgal/min
Cooling Water Pressure 4-7 bar.g 58 - 102 lb/in2
Water Pressure Drop bar.g lb/in2
Water Temperature Rise 8 o
C 14 o
F
Compressor Body
24 kW 81800 Btu/h
Radiated Heat
Motor
Motor Rated Power 250 kW 335 hp
Absorbed Power at Full
243 kW 325 hp
Load
Absorbed Power at Half
kW hp
Load
Absorbed Power at No
kW hp
Load
Full Load Current A A
Starting Current (Start/
A A
Delta Start)
*Oil pressure will fluctuate with ambient conditions, compressor loading and with the type and
viscosity of the oil being used. Also; oil pressure peaks during start-up before settling back as
the oil reaches operating temperature.
** Cooling Water Flow rates are design estimates and may have to be adjusted to suit ambient
site conditions.
This machine is fitted with over-temperature monitoring safety switches for final air from both
the third stage cylinder and the aftercooler. Details of the settings for these devices are given
in Table 1-4:Protection device settings on page 7
b) Compressor Data
Figures are quoted for new parts. The upper and lower limits arise due to accumulated effect
of manufacturing tolerances. All butt gaps are measured with the piston ring in the cylinder.

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c) Mechanical Data
Table 1-2: Piston and Cylinder Data
Piston Data Metric Imperial
Piston Stroke 165.10 mm 6.5 in
Stage 1 Cylinder Line

408.06 16.065
Cylinder Bore mm in
408.00 16.063
Diametrical Clearance -
4.74 - 4.58 mm 0.187 - 0.180 in
Piston Body in Cyl. Bore
Piston Ring
Radial Thickness 19.99 - 20.09 mm 0.787 - 0.791 in

Axial Clearance in
0.36 - 0.19 mm 0.014 - 0.007 in
Groove
Gap at ring Butt joint 10.31 - 9.80 mm 0.406 - 0.386 in
Bearer Ring
Diametrical Clearance in
N/A mm N/A in
Cylinder bore
Axial Clearance in
0.50 - 0.32 mm 0.020 - 0.013 in
Groove
Standout from piston
2.13 - 1.98 mm 0.084 - 0.078 in
body
Gap at joint 12.09 - 12.04 mm 0.476 - 0.474 in
Bumping Clearance
Piston Top to Top Cover 2.89 - 3.31 mm 0.114 - 0.130 in

Piston Bottom to Cyl. 1.92 - 2.20 mm 0.076 - 0.087 in

282.05 11.104
Cylinder Bore mm in
282.00 11.102
Diametrical Clearance - 0.191

4.85 - 4.70 mm in
Piston Body in Cyl. Bore 0.185
Piston Ring

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Table 1-2: Piston and Cylinder Data (Continued)
Axial Clearance in
0.45 - 0.28 mm 0.018 - 0.011 in
Groove
Gap at ring Butt joint 9.00 - 10.00 mm 0.354 - 0.394 in
Bearer Ring
2.95 - 3.30 mm 0.116 - 0.130 in
Cylinder bore
Axial Clearance in
0.45 - 0.65 mm 0.018 - 0.026 in
Groove
0.71 - 0.90 mm 0.028 - 0.035 in
body
Gap at joint N/A mm N/A in
Bumping Clearance
Piston Top to Top Cover N/A mm N/A in

Piston Bottom to Cyl. 1.20 -1.76 mm 0.047 - 0.069 in

142.04
Cylinder Bore mm 5.592 - 5.591 in
142.00
Diametrical Clearance -
4.05 - 4.19 mm 0.159 - 0.165 in
Piston Body in Cyl. Bore
Piston Ring
Axial Clearance in
0.21 - 0.37 mm 0.008 - 0.015 in
Groove
Gap at ring Butt joint
4.00 - 4.07 mm 0.157 - 0.160 in
(Each Gap)
Bearer Ring
0.54 - 0.82 mm 0.021 - 0.032 in
Cylinder bore
Axial Clearance in
1.00 - 0.78 mm 0.039 - 0.031 in
Groove
1.63 - 1.80 mm 0.064 - 0.071 in
body
Gap at joint N/A mm N/A in

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Table 1-2: Piston and Cylinder Data (Continued)
Bumping Clearance
Piston Top to Top Cover 1.80 - 2.64 mm 0.071 - 0.104 in

Piston Bottom to Cyl. N/A mm N/A in
d) Crankcase Components Clearances

The clearances for new components given are between the limits indicated - the upper and
lower limits arise due to accumulated effect of manufacturing tolerances. The corresponding
maximum figure is the point where renewal of the component is required. No maximum figure
is given against parts which, are not expected to wear to any significant extent in service.
Table 1-3: Crankase Component Clearances
Metric Imperial
Crankshaft Bearings
0.06 - 0.11 mm 0.002 - 0.004 in
(radial clearance)
Connecting Rod Bottom

End Bearing
New 0.10 - 0.15 mm 0.004 - 0.006 in
Maximum 0.20 mm 0.008 in
Connecting Rod Top End

Bearing
New 0.07 - 0.10 mm 0.003 - 0.004 in
Crosshead to Main Guide

Slide
New 0.22 - 0.30 mm 0.009 - 0.012 in
Table 1-4: Protection device settings

High air temperature (AST) 177 ºC (350ºF) (rising)
High air temperature (Separator) 65 ºC (149ºF) (rising)*
Low lubricating oil pressure 1.8 BarG (26.1 psi) (falling)
Low cooling water flow 65% of normal flow (falling)
* Switch is factory set to 65 ºC. for temperate (UK type) climates. The switch may be adjusted
up to a maximum of 75 ºC. to suit tropical climates during or after installation. However,
adjustments MUST only be performed by a competent, authorised person.

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Table 1-5: Pressure switch settings for Load Control System (40 bar.g delivery)
*40.0 BarG. (unload trip)
Pressure Switch 1 (PS1)
*38.0 BarG. (reload trip)
*39.0 BarG. (unload trip)
Pressure Switch 2 (PS2)
*37.0 BarG. (reload trip)
Differential Pressure (between unload and reload trips): = *1.0 BarG (minimum)
The settings quoted above are typical and may be adjusted to suit site requirements during or
after installation. However, the switch setting must not exceed the specified design operating
pressure.
Adjustments MUST only be performed by competent, authorised persons.
e) Tightening Torques (Dry Threads)
CAUTION!
OVER-TIGHTENING OF THE FASTENERS CAN LEAD TO
DAMAGE TO THE FASTENERS AND/OR THE COMPONENTS.
Table 1-6: Component tightening Torques

Thread
Component Torque Nm
Size
Crankcase Components:
Bearing End Cover M20 128 - 140
Flywheel End Cover M16 98 - 108
Oil Pump to End Cover M8 15 - 20
Crankcase Access Covers M10 25 - 30
Scraper Support Plate M10 45 - 55
Scraper Gland Fasteners M12 45 - 55
Crosshead Guide Fasteners M20 128 - 140
Flywheel Retaining M42 375 - 400
Distance Piece Components:
Distance Piece to Crankcase M20 200 - 220
Cylinder to Distance Piece M24 200 - 220
Distance Piece Access Cover M6 10 - 15
1st Stage Cylinder Components:
Cylinder/Top Cover M20 190 - 210
Valve Covers M12 29 - 32
1st Stage Valve Nuts M16 90 - 110
Inlet Flange M20 190 - 210
Outlet Flange M16 98 - 108
Packing Gland Fasteners M20 128 - 140

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Table 1-6: Component tightening Torques (Continued)

2nd Stage Cylinder Components:
Cylinder to Cylinder M24 200 - 220
Valve Nuts M16 90 - 100
Inlet/Outlet Flange M24 200 - 210
Packing Gland Fasteners M20 128 - 140
3rd Stage Cylinder Components:
CylinderTop Cap to Piston M8 16 - 18
3rd Stage to 2nd Stage piston assembly bolts M16 134 - 140
Valve Nuts M16 90 - 100
Inlet / Outlet Flange M20 190 - 210
Motion Work Components:
Crosshead Nut to Crosshead 1 5/8” BSF 555 - 610
Piston Nut to Piston 1 3/8” BSF 510 - 560
Crankshaft Lock-nut M160 1750
1.3 Technical Description of the Compressor
a) Purpose of the Equipment

The compressor provides a constant supply of compressed air, at a regulated pressure and of
a known volume. The compressed air can then be used as part of an industrial process.
b) Compressor Identification
All Gardner Denver Belliss & Morcom compressors have a rating plate located on the
crankcase. The information stamped onto this plate identifies the compressor type, capacity
and serial number. The compressor designation indicates the following:
V - Denotes cylinder configuration
H - Denotes multi-stage compression
21 - Denotes nominal capacity
H3 - Denotes high pressure three stage
N - Denotes oil free cylinder operation

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Illustration 1-1 : External View of VH21H3N Compressor
Aftercooler
3rd Stage Cylinder
Inlet Filter
and Silencer
2nd Stage
Cylinder
1st Stage
Cylinder
Separator
Main Guide Access

Cover
Distance Piece
Lubricating Oil Pump Intercooler
Access Cover
and Filter
c) Compressor Operation
The compressor operates by drawing air from atmosphere via an efficient air filter and silencer
system into the first stage cylinder where it is compressed to approximately 3 Bar G. The heat,
generated by compressing air, is dissipated by passing through the water-cooled intercooler.
The cooled air then flows through the 2nd stage suction separator, which removes any free
moisture, condensed during cooling.
Air then passes to the 2nd stage cylinder where the air is further compressed to approximately
15 Bar G. The heat generated by compressing the air is dissipated in the second stage
intercoler. Air then flows through the 3rd stage suction separator, which removes any moisture
condensed during second stage cooling.
The air then passes to the 3rd stage cylinder where the air is further compressed to its final
delivery pressure of 45 Bar G (max). The heat from compression is dissipated in the water-
cooled aftercooler positioned after the 3rd stage cylinder. The final delivery separator removes
any moisture condensed during cooling. The compressed air is then discharged into the
delivery pipework.
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d) Crankcase and Lower Motion Work
1 - Crankcase
The crankcase is a heavily-ribbed iron casting with integral mounting feet and cylinder
mounting flanges. Also integral within the crankcase are housings for the two crankshaft drive-
end bearings. There are machined faces for the flange mounted motor, bearing end cover,
crankcase and main guide doors. The bolt-on bearing end cover incorporates the housing for
the third crankshaft bearing.
The crankcase forms the lubricating oil sump, and is complete with tapped holes for the oil
level window nut, the oil pump suction feed pipe, the crankcase drain plug and the oil cooler.
Oil retention in the crankcase is made possible by a lip seal fitted at the drive-end of the
crankshaft and by scraper rings fitted around the piston rods. Immediately beneath the drive-
end crankshaft seal housing is an integral oil return passage.
2 - Crankshaft
The single throw, cast high-tensile iron, crankshaft has integral design counter-balanced
weights. The standard throw is 82.55 mm, giving a piston stroke of 165.10 mm. The
crankshaft is supported by three self-aligning, double-race spherical roller bearings, two at the
driving end and one at the oil-pump end. Endwise location is by clamping the outer drive-end
main bearing (in the oil seal holding cover) against a machined shoulder in the crankcase. The
driving end has a tapered shaft, which is keyed to accommodate the rotor of a direct mounted
motor. The oil pump end of the crankshaft has internal oil passages to the crankpin.
3 - Oil Pump
The gear type oil pump is mounted on the crankshaft bearing end cover and is driven via a
coupling off the non-drive end of the crankshaft. Oil is drawn by the pump from the crankcase
sump through a wire mesh strainer and external pipe. The oil is delivered through a full-flow
fine-mesh cartridge filter to the oil ways in the crankshaft. Any excess oil output is by-passed
back to the sump by a spring-loaded pressure relief valve mounted on the crankcase main
bearing housing.
All the bearing surfaces in the crankcase are lubricated by the oil passing through the bore of
the crankshaft and connecting rods. The main roller bearings are splash lubricated by the oil
from the crosshead, and also by the general oil mist in the crankcase.
4 - Connecting Rods
The connecting rods have detachable bottom end caps to enble removal of the rods and rods
have split-shell bottom end bearings and bush type top end bearings. The bottom end bearing
shells are steel backed copper-lead, lead-tin plated. The pressed-in top end bushes are lead
bronze.
An oil passage connects the top and bottom bearings allowing oil under pressure (from the oil
pump via passages in the crankshaft) to lubricate both. Oil is sprayed, from an annular groove
around the top end bush and through two small holes, onto both slides of the crosshead
guide.

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5 - Crossheads
The crossheads run in the main guides which are bolted to the cylinder mounting flange of the
crankcase. The crossheads are attached to the top of the connecting rods by gudgeon pins
(which are retained themselves by circlips). The top face of the crosshead is drilled and
tapped for reception of the piston rod. The piston rod is retained by a securing pin which
passes through the side of the crosshead into the slot in the end of the piston rod. The piston
rod is then clamped by a nut, which is tightened down against the top of the crosshead. The
securing pin is prevented from coming loose by a retaining plate.
e) Cylinders, Pistons and Piston Rod Packings
1 - Cylinders
The double-jacketed cylinders are cast complete with mounting base, valve chambers and a
housing for the piston rod packing assembly. They have machined faces for the top cover,
lower mating flange, valve covers, distance rings and valves and the air and water inlets and
outlets. The inner jacket of the cylinder is for the cooling water, the outer jacket is divided into
air valve chambers.
The first and second stage cylinders are cast with integral valve chambers, cooling water
passages and air chambers. The third stage cylinder and top cover is a combined casting. The
cylinders all have machined faces for the cylinder joint, valve covers, distance rings and
valves.
The cylinders are non-lubricated, the piston rings being made of low friction material, and are
spaced off the crankcase by distance pieces. This is to help prevent oil from the crankcase
sump getting into the cylinders. Cooling is provided by passing water first through the
compressor intercoolers, and then, via a series of flexible pipes, around the cylinder water
jackets and cylinder top covers..
2 - Pistons and Rings

The pistons are of a two-piece hollow construction, with machined piston-ring grooves. The
centre body is drilled and recessed to take the piston rod. The pistons are made from
aluminium and the piston rings are made from composite PTFE material. Both sets of rings
are jointed to assist with replacement during servicing..
3 - Piston Rods and Packings

The piston rods are threaded at both ends. The piston rod bottom end has a cruciform slot to
accommodate a securing pin (to prevent rotation of the rod in the crosshead) and is held in the
crosshead by a locknut. The top end of the rod is shouldered and waisted inside the piston. A
self-locking nut secures the piston to the rod.
The piston/cylinder end clearances at the top and bottom are governed by the distance the
piston rod is screwed into the crosshead.
The oil-free cylinder compressor has separate packing gland assemblies. The packing
comprises multiple pairs of PTFE rings, each pair of rings being housed in a container and
held against the piston rod by a garter spring. The containers are assembled to a base by long
studs and nuts, and the assembly held in its housing in the base of the cylinder by studs and

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nuts. A soft iron ring is recessed into the top surface of the upper container to prevent air
leakage around the packing.
The separate scraper assembly is housed in the crosshead-guide loose plate and comprises
a number of segmented rings in a split casing, each ring is held in contact with the piston rod
by a garter spring.
An oil shedder is also fitted to the piston rod between the packing and the scraper assemblies
to prevent any oil-creep along the rod.
f) Valves
Suction and delivery valves are similar in construction but differ in detail. Care must always be
taken when servicing the compressor to ensure that the correct valve is fitted into the correct
valve chamber.
All suction valves are controlled by plate depressors (or unloaders), their location being
identified by the presence of actuators on the valve covers. The actuators have small bore
instrument air pipes connected to them.
The valve assemblies are held in their seats by valve cages. The cages have 'O' rings
recessed into their upper circumference to prevent leakage of air. The first and second valve
covers have an additional 'O' ring seal between them and their cages. The valve covers are
the 'raised face' type.
To unload a working compressor. the suction valves are rendered inoperative by the valve
plates being pressed off their seats. This is accomplished by plate depressors (unloaders)
being operated by load control actuators.
A plate depressor is basically an inverted cup-shaped body with fingers protruding from its
rim, assembled with a spring-loaded central guide surmounted by a cylindrical cap. The
fingers operate through slots in the suction valve seat directly onto the valve plate.
In action the plate is depressed, against its spring, by the pneumatically operated actuator.
Compressed air fed to the load control actuator, by the load control solenoid valve, acts on a
multi-layer diaphragm, which is sandwiched between the two halves of the actuator body. The
diaphragm is in contact with the head of the spring loaded plunger immediately under the disk.
The plunger, guided in the lower half of the actuator body, has its stem end in contact with the
cap of the plate depressors. When the control air is exhausted by the solenoid valve, springs
return the plunger away from the valve plate.
g) Coolers, Separators and Drains

The standard intercooler stack is made up of multiple copper tubes soldered into a brass fixed
end plate and a brass expansion end plate. The tubes have internal copper coil secondary
surfaces. The fixed end plate is sandwiched between the cooler body inlet flange and the
cylinder air delivery adaptor; the expansion end plate is free to move axially in rubber 'O' ring
seals at the outlet end.
The stack is contained either in a cast iron body or mild steel fabricated body with cast iron
adaptors at either end. The body has water inlet and outlet connections and internal brass
baffle plates to guide the cooling water over the tubes.
If an aftercooler is fitted it is of similar construction. Separators are fitted after each cooler and
have drains fitted.

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h) Motor and Couplings

The compressor can be supplied with a direct drive, overhung flange mounted motor, or a foot
mounted motor with a direct in-line drive through a flexible coupling, or indirect drive through a
vee belt pulley wheel.
When a flange mounted motor is used, the rotor is keyed directly onto the crankshaft and the
stator casing is bolted to the crankcase. For a flexible coupling drive, a flywheel is keyed on to
the crankshaft, and for a vee belt drive the heavy crankshaft mounted pulley provides the
flywheel effect.
The standard motor is a brush-less cage rotor type, with a power output suited to the delivery
requirements of the compressor.
The motor's rotor is keyed directly onto the crankshaft and the stator casing is bolted to the
crankcase.
i) Control Panel and Controls

The compressor can be supplied with or without a starter system. The standard starter system
is housed in a two-compartment dust and damp proof wall or floor mounted sheet steel
cubicle. The control panel is an integral part of the front of the cubicle and the controls and
gauges are divided between the upper and lower compartments. (For full details of the
controls their operation and functions refer to the supplementary information provided with
your compressor).

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Chapter 2 - Safety Information
Issue 0 2-1 Safety Information

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2.1 Safety Policy

The compressor and its associated equipment are to be operated in accordance with current
Statutory Health & Safety Policies (and any such regulations applicable in the country of
installation). It is the responsibility of the operative to familiarise him/her self with these
policies/regulations.
Any work practices that may pose a potential health and safety hazard or any faulty/suspect
equipment associated with the safe operation or maintenance of the compressor package
must be brought to the immediate attention of the supervisor or supervising authority.
Always wear appropriate personal protective equipment (PPE) when operating or maintaining
this equipment. PPE should include, but not limited to:-
Ear Defenders
Safety Glasses.
Industrial Boots.
Safety Headwear
Appropriate Hand Protection (gloves and/or barrier cream).
Any other safety item identified under Risk or COSHH Assessments.
Loose fitting or frayed/ripped clothing MUST NOT be worn while operating or maintaining this
equipment.
a) Commonplace Hazards
If a hazard is identified that is not identified within the Operating Authority 'Standing Safety
Instructions' a separate Risk Assessment must be made. Similarly If a hazard in the form of a
hazardous substance (Substance identified under COSHH regulations in the UK) is identified,
steps must be taken to assess the risk of injury to staff.
The compressor and its associated equipment are to be operated in accordance with current
statutory Health & Safety at Work policies. It is the responsibility of the operative to familiarise
him/herself with these policies. Any work practices that may pose a potential health and safety
hazard or any faulty/suspect equipment associated with the safe operation and maintenance
of the compressor must be brought to the attention of the supervisor or supervising authority.
b) Proper Use
The compressor is built to stringent manufacturing guidelines to guarantee safe operation.

However, using compressed air can be linked to dangerous occurrences if compressed air is
not properly handled. Proper use also includes the following:
Follow the guideline laid down within this instruction manual, observing all pertinent
regulations and notes for the compressor.
Maintaining the equipment at the mandatory inspection and maintenance intervals.
Correct repair of the compressor equipment.
Operation of the compressor in accordance with the original design parameters.

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Operation is carried out in accordance with the relevant environmental and operating
regulations.
c) Organisational Measures
It is the customer’s responsibility to ensure that the operating manual is adequately

supplemented with internal regulations regarding supervision and notification duties, work
organisation, and personnel qualification etc.
No modifications may be carried out on the compressor or its peripheral devices without the
written consent of Gardner Denver Belliss & Morcom. Unauthorised Modification of the
equipment will invalidate the WARRANTY.
When renewing compressor components use only original spare parts and accessories
supplied by Gardner Denver Belliss & Morcom.
d) General Safety Precautions for Compressors
Electrical System - Before performing work on the electrical system the compressor and the
peripheral devices must be isolated from the mains and secured against accidental switch-on.
Work on the electrical system must only be carried out by qualified staff who are aware of the
risk involved with the task. All electrical work must be carried out in accordance with local laws
relating to electrical working.
Pressure Relief Valves - These MUST be Full Compressor Capacity relief valves
connected directly to the flow pipework to relieve any excess pressure that may build-up
between the cylinder discharge flange and in line equipment (e.g., stop valve, non-return
valve, cooler, etc).
There must be no restriction of any kind between the relief valve position and the preceding
cylinder. Relief valves must be directly mounted with no isolating valves interposed between
the relief valve and the pressure sensing point. The exhaust from the relief valves must only
discharge into designated safe areas. The setting of relief valves must be checked regularly
as required by statutory codes and regulations.
Pressure vessels must be fitted with a full capacity pressure relief valve. Vessels must not be
operated above their stated operation rating and must be checked regularly as required by
codes and regulations.
WARNING !
THIS COMPRESSOR MUST NOT BE OPERATED UNLESS RELIEF
VALVES ARE IN A FULLY OPERATIONAL CONDITION AND ARE
CORRECTLY SET TO THE CORRECT RELIEF PRESSURE.
Protection Equipment - All protection, control switches and circuits must be regularly
checked for correct operation.
Switches can be tested by checking in calibration rigs, or by carefully controlled simulation of
fault conditions at the actual machine. Circuits can be checked by mechanically operating the
switches.

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Frost Protection - Where, due to its location, the compressor could be exposed to frost, then
adequate precautions must be taken to prevent freezing of the water system.
Guards - All guards and covers must be in position and secure before start-up.
Operating Records - It is IMPORTANT that a regular log sheet be kept for the compressor
recording operating pressures, temperatures and oil pressure (a copy of a Log Sheet is
provided within the Appendices located at the end of this manual). Variances from normal
running performance should be brought to the immediate attention of the Supervisor
responsible for consideration and action.
Lifting Equipment - Before using any lifting equipment, it is IMPORTANT that the crane,
gantry, hoist or chain block and any slings employed must be certified capable of lifting the
weight of the compressor (or motor/compressor assembly). Any such lifting equipment MUST
have a current CITB Test Certificate (or an equivalent certificate applicable to the country of
installation).
e) Installation, Commissioning and Operation
In all matters of safety regarding the Installation, Commissioning and Operation of the
compressor or package, the reader's attention is directed to the full implementation of the
requirements of the Health & Safety at Work Act (and any such regulation applicable in the
country of installation). Gardner Denver Belliss & Morcom may be consulted should any
doubt exist regarding matters of safety related to their product.
f) Maintenance
In addition to the General Safety Precautions, the following safety precautions MUST be
observed when maintaining your machine.
a. Before commencing any maintenance work on the compressor or its driving unit or any
ancillary, the driving unit must be rendered incapable of being started whilst
maintenance and adjustment work is in progress.
In the case of an electric motor for example, the machine must be isolated from the main
electricity supply, the isolator locked off and/or the fuses withdrawn. This is particularly
important with auto start/stop machines where the machine could be started
automatically.
b. Affix "NOT TO BE USED" boards to the compressor and control cabinet.
c. Isolate the compressor from the discharge main and the instrument air. Where a
compressor is isolated from the delivery of other machines by a non-return valve, the
non-return valve must not be used as the only source of isolation. The compressor must
also be positively isolated from the delivery by closure of an isolating valve.
d. Before opening up the machine, all pressurised compartments MUST be depressurised
down to atmospheric pressure in a safe and controlled manner.
e. Isolate the compressor from the cooling water supply and drain all relevant water
containing compartments.
f. If the compressor motion work or rotational parts are to be worked on then piston rod
clamps MUST be fitted to prevent accidental movement. Also chocking the crankshaft
should be considered where necessary.
g. ALL lifting equipment MUST be correctly rated for the loads being applied and MUST be
certified as being in good working condition. Always ensure that when lifting equipment
is used, only specified lifting or slinging points are used.

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h. Always refer to the applicable procedure when undertaking maintenance and overhaul
procedures.
i. Bolts and nuts must not be under or over tightened, see appropriate torque values
(Refer to c ”Tightening Torques (Dry Threads)” on page 1-8)
j. Ensure that ALL tools and spare parts are accounted for after reassembly, since any
items left on or within the compressor may cause serious damage upon restarting.
k. DO NOT place the electrical isolating switch to the 'ON' position until all work has been
completed by all personel working on the equipment. The site supervisor must inspect
and approve the work carried out before re-connecting the equipment to the electrical
supply.
l. Before starting the compressor, bar over the machine by hand where possible to ensure
free rotation and that no metallic 'knocking' noise is evident. If any ‘solid’ resistance to
rotation is found, investigate the cause.

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Chapter 3 - Installation and Commissioning
Issue 0 3-1 Chapter 3 - Installation and

11/12/07 Commissioning
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3.1 Safety Precautions

Before carrying out any work related to this Section, it is a requirement that you read and work
in accordance with, the Safety Precautions given in Chapter 2 of this manual. For your own
protection, be sure to read and obey the WARNING and CAUTION notices you find in this
Section and any associated literature.
WARNING!
IF THE COMPRESSOR IS TO BE SUPPORTED ON ANTI-
VIBRATION MOUNTINGS, AIR, WATER AND ELECTRICAL
SERVICES ARE TO BE MADE WITH NON-RIGID (FLEXIBLE)
CONNECTIONS.
DUE TO POSSIBLE ELECTRICAL INSULATION EFFECTS OF
PIPE GASKET MATERIAL AND ANTI-VIBRATION MOUNTINGS,
THE MACHINE MUST BE PROVIDED WITH A PERMANENT
EARTH CONTINUITY CONNECTION OF A NON-RIGID
(FLEXIBLE) TYPE, WHICH SHOULD COMPLY WITH LOCAL
REGULATIONS AND SAFETY REQUIREMENTS.
3.2 Installation Requirements

The installation of the compressor, and its associated pipework, should be the subject of
careful consideration before undertaking the actual task. This section of the manual provides
the necessary information for the installation engineer to locate and to install the compressor
to the best advantage.
a) Location
The compressor should be located in a clean, well-lit, well-ventilated area with ample space all
around it to facilitate inspection and maintenance. Sufficient room must be allowed for the
removal of pistons and cylinders, crankshaft and motor, and as the compressor and many of
its components are heavy, there must be headroom sufficient to permit the operation of a
crane or hoist, which must be certified capable of lifting safely the weight.
Statutory regulations and local by-laws governing the operation of heavy machinery must be
complied with, this may have some influence on the choice of location.
b) Ventilation
Approximately 10% of the energy consumed by a compressor is lost as heat. This is the heat
generated by the motor, the mechanical losses of the compressor and straight-forward heat
radiation from the air manifolds.
For example, a 365kW water-cooled compressor would require some 486 m3/min of ambient
air circulation to limit the compressor room temperature rise to 6ºC. Natural convection is
normally adequate with the outlet vents at a high level to prevent the temperature building
down from the roof.

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c) Foundations
For vibration isolator mounted compressors, all that is required is a floor of sufficient strength
to carry the weight of the compressor, motor and ancillaries. For solidly mounted compressors
the foundation dimensions must be determined for each installation, consideration being given
to the nature of the subsoil and local surroundings.
WARNING!
THE FLOOR MUST BE LEVEL AND FLAT.
Foundation depth must be such that the subsoil reached is, in the opinion of an expert,
capable of taking the load of the working compressor and preventing the transmission of
vibration. Unless the foundation rests on bed-rock or hard-pan, a sub-footing should be made
of such a size and design as to provide a solid bottom. In extreme cases of poor subsoil, piling
may be required, and in such circumstances a competent foundation engineer should be
consulted.
If the compressor is to be mounted on a metal floor, it can be either bolted direct to the floor, or
beam or skid mounted. The beams or skids may be bolted or welded to the floor, with due
consideration being given to structural vibrations and floor strength.
A foundation plan (for good subsoil conditions) is furnished in advance of the shipment of the
compressor, and the foundation used must not be less than given in the plan.
When installing a solidly mounted compressor, it must be ensured that the crankcase feet are
ALL flat down and fully supported BEFORE tightening the "Holding Down" fasteners. A
detailed foundation drawing is available (on request) from Gardner Denver Belliss & Morcom
d) Pipework Installation
These paragraphs give recommendations with regard to delivery pipework and will help the
plant engineer plan the best possible installation.
Pipes must not be fixed inflexibly such that heavy thrust can act back onto the compressor
otherwise serious damage could result, examine carefully the anchoring point locations and
pipework support arrangements.
WARNING!
ALL INLET AND OUTLET CONNECTIONS TO COMPRESSORS
MOUNTED ON VIBRATION ISOLATORS MUST USE SUITABLE
FLEXIBLE PIPES. ALL FLEXIBLE PIPES MUST BE INSTALLED
IN ACCORDANCE WITH THE MANUFACTURER'S
INSTRUCTIONS.
1 - Inlet System
An efficient air intake filtration system is essential to ensure that debris is removed from the air
flow to the compressor thereby prolonging the life of the machine.

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Standard Gardner Denver Belliss & Morcom practice is to fit a machine mounted, combined
filter/silencer, however, in hot or dirty locations, or in the presence of difficult combinations
(e.g. fumes, alumina or cement dust), filtration may be improved by mounted the intake
remotely and ducting the air to the compressor. Special filter/silencer arrangements are
available for this type of installation.
Only dry type filters must be used with oil-free compressors.
Noise regulations should be taken into account when deciding silencer requirements and
locations.
2 - Delivery System
The flexible delivery pipe connects the aftercooler to the receiver (where fitted). It must be of
the correct specification for the pressure and temperature and nature of the medium being
compressed, and not smaller than the size specified below.
The pipe must be well supported to avoid strain on the compressor cylinders, and it's
configuration be such that any expansion effect, due to the air/gas temperature rise for
whatever reason, can adequately be dissipated within the natural elasticity of the pipework
leading from the compressor and cannot act back on the cylinder.
At the junction with the receiver, or pipe main, a shut-off valve should be fitted to isolate the
compressor as required. On automatic and multi-machine installations, non-return valves
should also be fitted to isolate standby units from system pressure.
A safety valve must be fitted, close to the compressor, in the delivery pipe. The valve must be
fitted before any shut-off valve, non-return valve or aftercooler to prevent damage in the event
of the compressor being run with the shut-off valve closed. The valve should be a spring-
loaded type and of sufficient size to pass safely the maximum compressor output.
A small blow-down valve should be fitted between the compressor and shut-off valve to
relieve residual pressure when required for maintenance purposes.
3 - Air Receiver
An air receiver of suficient capacity is required for use with this equipment. The receiver
should have a capacity equal to a one minute supply of compressed air (neglecting
temperature rise).
The air receivers should, ideally, be located in the coldest place possible, to ensure that as
much condensate as possible is precipitated from the air in the receiver. This means that the
receiver must be drained frequently, either by fitting an adequate drain or an automatic drain
trap.
To facilitate servicing of the drain trap whilst the receiver is in commission, a by-pass should
also be incorporated.
4 - Distribution Piping (air systems)

Water collectors of an automatic discharge type should be fitted at suitable points in the pipe
system. They should be fitted with three-way cocks (either in connection with the traps or
separately) so that pipes may be blown through to disperse condensation.
Delivery pipework must be arranged to prevent condensation running back from the
aftercooler or receiver into the compressor cylinders.

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The pipe system for air distribution should be carefully considered if optimum results are to be
obtained. Moisture-laden air can cause rusting in low-lying parts of the pipe system so, ideally,
all distribution pipework should be internally galvanized and angled slightly towards the drain
points.
An effective way of eliminating possible water damage is to install a refrigerative air dryer or,
for dryer air, an adsorption dryer.
5 - Load Control Piping

Connect (with similar size piping) the load control system on the compressor to the control air
take-off points on the compressor panel, the connections on the compressor will indicate the
size.
Connect (with similar size piping) the compressor panel control air inlet point to the
compressed air/instrument air main - any isolating valve fitted here must be of the lockable-
open type.
6 - Drain Valves & Drain Valve Piping

It is important that the drain pipes from the water separator drain traps are run individually to
open ends (e.g., over OPEN containers). They must NOT be piped together as there would
then be a risk of "blow-back" along adjacent pipes in the event of a trap malfunctioning.
Drain valves are fitted to the separators of each compression stage. These valves exhaust the
collected moisture at high pressure and must be piped away to a safe area using solid
pipework.
MOST IMPORTANT - if the exhausts of any vent valves are piped away, it is essential that
these have direct outlets to atmosphere, they must NOT be connected into any other pipe. It is
also recommended that a silencer is fitted to the exhaust in order to reduce noise levels.
e) Cooling Water
An adequate source of clean, cool water for the compressor cylinders, intercoolers and
aftercooler should be provided.
Cooling water must be as free as possible from scale forming salts, with (if the water is not
clean) an efficient filter(s) placed in the intake pipeline. A Duplex type arrangement is
recommended as this will allow one filter to be cleaned whilst the other is in service.
The temperature of the cooling water supply to the compressor (NOT aftercooler) should not
be less than the ambient temperature. The methods of achieving this depend on the cooling
system employed:
The temperature of the cooling water supply should be in the range 20ºC to 35ºC
In situations where the ambient temperature is in excess of 35ºC., advice should be sought
from Gardner Denver Belliss & Morcom.
The pressure in the cooling water pipeline at the compressor must be sufficient to promote the
flow required by the size and duty of the machine. This should take into consideration all the
friction losses in the overall pipework and valves and across the heat exchanger units (as may
be installed) as well as across the compressor.

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Except for compressors made to special customer requirements, water pressure in the jackets
should not exceed 7 Bar g.
It is recommended that thermometer pockets are fitted to the water inlet and outlet pipes to the
compressor and, the aftercooler. Temperature differentials between these points will give a
good indication of sufficient water flow, 10 to 12ºC being usual.
CAUTION!
FAILURE OF WATER FLOW IS A CAUSE OF MAJOR DAMAGE
AND MUST BE AVOIDED. ENSURE THAT COOLING WATER
PIPES TO AND FROM THE COMPRESSOR ARE CONSTRUCTED
TO AVOID THE FORMATION OF AIR LOCK
For compressors operating in cold environments, drain points are present on the cylinders to
empty the water jackets of the machine (when out of service) to prevent damage in the case of
frost. Open air vent cocks at the tops of the cylinders at the time of water drainage. Certain
water pipe connections should afterwards be disconnected to completely drain the system.
CAUTION!
EXPOSURE TO FROST CONDITIONS WILL DAMAGE YOUR
MACHINE UNLESS THE PROPER FROST PRECAUTIONS ARE
TAKEN. IF ADVICE IS REQUIRED, PLEASE CONTACT
GARDNER DENVER BELLISS & MORCOM.
f) Electric Cabling
The electric cabling to the motor must be run such that small amounts of movement at the
motor terminals can be safely absorbed within inherent flexibility of the type of cabling used.
Check that the motor nameplate details agree with those of the electricity supply on which the
motor is to be used.
Connect motor in accordance with the instruction supplied. Use cables of adequate size to
carry the full load current and also large enough to carry the starting current without excessive
voltage drop.
Ensure that the motor frame is properly earthed.
g) Electrical Suppy
Voltage - Steady state voltage with 90% to 110% of nominal value.

Frequency - Variations should be no lower than 99% or higher than 101% of the nominal
frequency for continual operation. Exceptionally limits can be extended to 98% to 102% for
short periods.
Harmonics - Harmonic distortion not to exceed 10% of the total r.m.s. voltage between live
conductors for the sum of the second through to the fifth harmonic. An additional 2% of the

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total r.m.s. voltage between live conductors for the sum of the sixth through to the thirtieth
harmonic is permissible.
Voltage imbalance - Neither the voltage of the negative sequence component nor the voltage
of the zero sequence component shall exceed 2% of the positive sequence component.
Voltage interruption - Supply interrupted or at zero voltage for not more than 3 µs at any
random time in the supply cycle. There shall be more than 1 s between successive
interruptions.
Voltage dips - Voltage dips shall not exceed 20% of the peak voltage of the supply for more
than one cycle. There shall be more than 1 s between successive dips.
h) Motor Starters
1 - Motor Protection Equipment

The following has been prepared to describe the minimum protection requirements for
shaftless motors used on the compressor.
Protection of the motor should consist of as a minimum the following : -
1. Thermal motor overload by monitoring motor current
2. Motor overheating using PTC thermistor probes
3. Phase imbalance
4. Phase failure
The Group Schnieder (Telemecanique) thermal overload motor protection relay provides the
above levels of protection.
2 - Basic Starter Equipment Requirements

Equipment supplied within a starter control panel should as a minimum consist of the following
:
1. Mains Isolator
2. Star Delta Starter complete with thermal overload motor protection relay (above)
3. PTC thermistor protection relay
4. Soft start unit (optional)
5. Soft start by pass contactor ( for by pass after run up time)
6. Thermal overload motor protection relay (as above)
7. Motor short circuit protection (either fuses or mccb) should be provided by the customer,
unless otherwise specified.
The equivalent manufacturer of equipment in the USA may be used, however for consistency,
using the same manufacturer both in the UK and USA should be considered.
3 - General
All equipment shall be selected for use on AC 3 phase circuits up to 600 Volts.
Control circuits may generally be either 110 Volts AC or 24 Volts DC.

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All motor starting equipment should be rated for AC3 motor starting duties and be selected in
accordance with the motor rating information provided. All equipment should conform to the
latest ISO standards.
All thermal overload motor protection relays must be set at the phase current. (rated current of
the motor divided by 1.732).
i) Drive Motor
The motor used to drive the compressor must comply with the following specification :
1 - Application
Motors should be designed, manufactured and tested in accordance with the following
standards:-BS
EN 60034 - Rotating electrical machines
BS 4999 - General requirements for rotating electrical machines
BS EN 50347 - General purpose three phase induction motors
The design of the motor should take into account the irregular turning effort required for this
application, it should also take into account the requirement for it to overhang the rotor
mounted on the compressor shaft eliminating the need for bearings. The design should take
into account both the need to ensure a constant air gap and to achieve optimal power factors
at various load conditions. The motor design should also take into account the rotor inertia
needed to meet the requirements of this type of load. The motor should be capable of
continuous operation (S1 duty) and be able to be started with electronic "soft start" equipment
or a start/delta starter.
The motor may be subjected to a maximum of three (3) starts in a one (1) hour period. The
compressor can be loaded and unloaded several times a minute via a two (2) or three (3) step
control.
2 - Rating
The motor shall be rated as follows:-
Power rating and speed as shown in ‘Technical Data’, Chapter 1
Drip protected (IP21S) to IEC 60034-6, suitable for 400C ambient, a maximum altitude of 1000
metres above sea level and limited to class F temperature rise. Maximum voltage variation
permissible shall be within 90% and 110% of nominal value. Whilst the motor will be rated for
operation at supply voltage, its insulation standard should be for 1000 volts which includes
consideration in respect of the winding inter-turn insulation. The dielectric strength of the
insulation should be rated for a voltage waveform with a rise time of not less than 3 kV/µ sec.
Direction of rotation - Motor to drive the compressor clockwise looking from the motor end.
Insulation class H.

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3.3 Handling and Unpacking
a) Stability
Due consideration must be given to maintaining the compressor's stability during all lifting
procedures. The compressor is only in a stable condition when standing on a suitable, level
floor surface with all four crankcase feet firmly down. It MUST be noted that the Centre of
Gravity (C of G) for each machine will change depending on whether the compressor is 'bare-
shaft' or fitted with a 'drive unit'.
WARNING!
THE CRANE, GANTRY, HOIST OR CHAIN BLOCK OR ANY
SLINGS EMPLOYED MUST BE CERTIFIED CAPABLE OF
LIFTING THE WEIGHT OF THE COMPRESSOR (OR MOTOR/
COMPRESSOR ASSEMBLY).
Compressor Slinging Diagram (Typical)

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b) Slinging Instructions
On all compressors two cradle slings are positioned, one under each of the two outer cylinder
crankcase flanges. A third sling is used to balance the compressor.
1. In the case of a compressor fitted with a flange mounted motor, a cradle sling is passed
under the motor, taking care to keep it clear of the fan housing.
2. In the case of a bare shaft compressor, a sling is passed round the intercooler pipework.
3. If the compressor is fitted with a flywheel, a balancing sling is passed around the shaft.
WARNING!
UNDER NO CIRCUMSTANCES USE THE MOTOR LIFTING HOLE
FOR BALANCING THE WEIGHT (THIS LIFTING POINT IS FOR
THE MOTOR ONLY WHEN DETACHED OR DETACHING FROM
THE COMPRESSOR).
Care MUST be taken to ensure that no small bore pipes or other components are trapped by
slings.
c) Lifting Instructions
Because the type of lifting equipment for each installation will be different the following
instructions have been written with the intent of being a general guide rather than specific
instructions.
For compressor maintenance purposes a one tonne block is usually suitable to give good
control of the lifting of components.
1. Whatever your equipment or conditions, good safety procedures must be practiced, i.e.:
i. Establish the actual weight of the load.
ii. Check whether the lift will be a straight lift, or will an angle rig be needed. These
factors will affect the lifting capacity required.
iii. The slings must be free of kinks, knots, broken strands or loose connections etc,
and meet the regulation requirements.
iv. Check the clearance available to make sure the lift can be carried out safely.
v. To prevent damage to the machine's finish or the edges of the machine from
cutting into the slings, use proper blocking and padding.
2. When involved in the lifting of heavy loads, we suggest you protect yourself by wearing
approved protective gear such as: safety helmets, steel toe cap safety shoes, gloves,
eye protection, etc.
3. Prepare the installation area before moving the machine.
4. Refer to the machine installation drawings and note the location of the machine support
points. Review all machine installation requirements carefully before positioning the
machine.
d) Unpacking
No special unpacking instructions can be given here as the compressors may be transported
fully boxed, crated, or on open bases, depending on destination and mode of transportation.
Issue 0 3 - 10 Chapter 3 - Installation and

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Boxed compressors have directions for lifting and opening on or with the boxes. Some of the
cylinder valves will have been replaced with silica-gel bags. The displaced valves and the
accessories are packed in a separate container, which should be located and safeguarded
until after the installation of the compressor.
3.4 Installation Procedure
a) Safety Precautions
The following additional safety precautions should be observed before installing the
compressor onto its foundation.
Personnel must be a safe distance from the compressor during positioning, guide ropes may
be used to assist, but not 'hands-on'. The compressor must be lowered slowly, in small stages
with no sudden jerks whilst observing for any indications of potential problems. Once in
position the compressor must be properly secured with suitable foundation bolts or anti-
vibration mounts (AVM's).
If the floor is to be drilled for foundation bolts, the compressor must be moved away whilst
work proceeds.
Each time the compressor is moved check for stability and correct sling placement.
DO NOT apply load tension to the slings if the compressor is held to the floor.
b) Mounting Arrangements - Anti-Vibration Mounts
A flat and level floor of sufficient strength to support the combined weight of the motor,
compressor and ancillaries should be prepared in advance of the compressor delivery. The
procedure should then be as follows:
1. Ensure that the underfaces of the compressor feet are clean.
2. Bolt the anti-vibration mountings on to the compressor feet.
3. Move the compressor into position and mark on the floor the position of the holding
down bolt holes in the anti-vibration mounting plate.
4. Remove the compressor and attached mounts and drill the floor for appropriate size
holes for the Raw-bolt shells.
5. Insert shells, reposition compressor and bolt onto floor by means of the mounting
holding down bolts.
OR:
The anti-vibration mountings may be held down by bolts or anchors of a similar diameter
to the holes in the mounting plate. Use of these will eliminate the need to move the
compressor to drill the floor holes. The appropriate instructions supplied with the bolts
should be followed precisely.
6. Finally, check the bolts holding the compressor onto the anti-vibration mountings and
use these bolts to finish levelling the compressor (See Levelling and Alignment).

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c) Levelling and Alignment - Flange Mounted Motors
Compressors with flange mounted motors are completely assembled and lined-up before
shipping, it is therefore only necessary to set the machine on the foundations and level it in
both directions as follows:
1. Adjust the pressure within the pneumatic AVM's around the machine until the desired
level is achieved. Do not inflate AVM's unless the static weight of the compressor is
placed on them.
2. Ensure that the final levelled height of each mount is within the makers limits and that
each mount is levelled until it carries its correct proportion of the overall machine weight.
3. If any mount is compressed solid, levelling must be carried out on the free mounts to
redistribute the load.
4. Using a spirit level on any horizontal surface, check that the compressor is level in both
planes (i.e. parallel to and at right angles to the crankshaft).
5. If NOT, then adjust again until satisfied.
3.5 Preparation for Commissioning
a) Cleaning the Compressor
The compressor must be thoroughly cleaned before preparing for commissioning.

Care should be taken when making connections to see that no grit or impurities of any kind
are allowed to enter while the compressor is being piped up and prepared for work.
b) Preparing the Compressor
After works testing, the compressor is prepared for shipment. Before use therefore, the
compressor will require to be prepared for use as follows:
1. Remove the 'mouldable' wrapping from around the piston rods and clean the rod
surfaces.
2. Remove control piping from cylinder valve covers marked with adhesive labels and
remove the covers.
3. Extract the silica gel bags from the valve chambers; ensuring that where more than one
bag is present, ALL bags are removed.
4. Using a plastic or soft metal scraper, remove rust resistant paint from the seating in the
valve chambers.
5. Remove the valve assemblies from their wrappings.
6. Fit components in their correct order, ensuring that suction and delivery valves are fitted
in the correct valve chambers. Where plate lifters are fitted to suction valves, care must
be taken to ensure correct assembly.
7. Tighten the valve covers and refit the control air pipes
8. Remove and store the adhesive labels and warning plates with the silica gel bags.
9. Check that all gauges and small-bore pipework are undamaged, and are properly
connected.
10. Ensure that all external nuts and bolts on the compressor and its ancillary equipment
are tight, including all holding down bolts and bolts of all pipework flanges and supports.

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11. Remove the crankcase access covers (and wooden blocks where fitted), and crosshead
access aperture covers, and check to ensure that the interior of the crankcase is clean
and free of foreign matter.
12. Ensure free movement of compressor motion by turning the crankshaft round a number
of times in the correct direction of rotation.
13. Fill the oil sump (in the bottom of the crankcase) with the recommended grade of
lubricant to level indicated by the window nut on the front of the crankcase. Initially fill to
near the top of the window, the level will fall towards the bottom of the window when the
compressor is started, rising to about half-way when the oil has reached its sustained
running temperature.
14. Wearing suitable (oil resistant) protective gloves, liberally coat clean oil onto all the main
guide slides - turning the crank to different positions to achieve full face coverage (keep
hands out of the crankcase when the shaft is being turned).
15. As the compressor may have been in transit/storage for some time, prime the suction
side of the lubricating oil pump by disconnecting the suction pipe top fitting. Then using
the recommended grade of lubricant pump oil 'in' to 'wet' the gears and fill partially the
suction side of the pump body. This promotes a quick pick up of oil pressure on start up
of the compressor.
16. Refit the crankcase and crosshead access covers.
17. Ensure that the compressor pressure instrument isolating cocks are open.
18. Ensure that the pipes of the rubber filling plugs are removed to vent the gauge cases
and allow correct gauge indication.
19. Ensure that the pressure signal pipelines of the load control system are open (i.e., make
certain that any isolating valves are fixed open).
20. Fill slowly and carefully (to avoid trapping air) in the cooling water spaces of the
compressor - do not rush this operation. Open the air vent cocks, at the tops of the
cylinder covers to rid the system of trapped air. The operation is carried out in
association with any other water-cooled ancillary items in the overall cooling water
system of the installation.
c) Preparing the Motor
Check the driving motor insulation resistance (IR) using a 500 volt megohmeter taking note
that the insulation resistance in mega-ohms, measured between any terminal and the frame
with the machine cool, is infinity.
If the windings have become damp and the insulation resistance is low, then the windings
must be thoroughly dried out and re-tested for satisfactory condition before commissioning.
CAUTION!
BEFORE USING THE INSULATION TESTER DISCONNECT THE
SUPPLY LEADS AT THE MOTOR TERMINALS SO THAT ONLY
THE MOTOR WINDINGS ARE TESTED. THIS WILL AVOID THE
POSSIBILITY OF THE TEST INSTRUMENT POTENTIAL
DESTROYING ANY ELECTRONIC EQUIPMENT THAT MAY BE IN
ANCILLARY CIRCUITS.

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d) Motor Rotation Check
The compressor is designed to rotate in a clockwise direction when viewed from the drive end.
CAUTION!
RUNNING THE COMPRESSOR WITH INCORRECT ROTATION
WILL RESULT IN SERIOUS DAMAGE.
After checking it is safe to do so, switch on the electricity supply to the compressor control
panel. Prepare the compressor for an 'unloaded' start and perform a ‘flick test’ (Start then
quickly stop the compressor motor). Check motor is rotating in the correct direction (indicated
on motor end). In the event of wrong direction of rotation, isolate the machine immediately. A
qualified electrician must rectify the problem before rechecking.
e) Vent Control System
The compressor is fitted with an auto-vent valve which will vent air from the final delivery pipe
in the following instances:
• When the compressor is isolated from the electrical supply
• When the emergency stop is pressed
• When stop is selected on the standard control panel.
The vent valves are closed via a 6-8 bar control air supply.
In normal operation, when the pressure control system is active, the auto vent valves remain
closed. When a standard Gardner Denver control panel is supplied with the compressor,
control of the pneumatic signal to the valves will be provided from the control panel. In
instances where other manufacturer’s control panels are used appropriate control circuitry,
solenoids and fittings will be required to control the vent valves.
3.6 Commissioning the Compressor

Before commissioning the compressor, read and fully understand Part 3 "Operation" and any
associated literature regarding the control panel and any other ancillary equipment.
a) Trial Run
When commissioning, the trial run must include certain vital checks, and these should be
carried out as follows:
1. Ensure that the factory delivery mains and air using equipment are safe to pressurise -
and all delivery isolating valves in the system are open.
2. Ensure that the load control sensing pipework is open to the compressed air main.
3. Ensure that the isolating cocks of all pressure gauges are open.
4. Ensure that the by-pass valves situated at the drain traps are closed.

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5. Start compressor in the unloaded condition and allow to run up to full speed, observe oil
pressure is quickly established (this will be high with a cold machine) and observe
compressor running generally.
6. After a 3 minute run, stop and electrically isolate the compressor. Remove the
crankcase main doors and check the temperatures of the motion work bearings and
guides. This should be done using a thermometer fitted with a suitable surface probe.
WARNING!
TAKE CARE DURING EXAMINATION, AS SOME OF THE
PARTS WILL HAVE BECOME HEATED.
All should be cool except the bottom end bearings, which can be a little warmer than
other bearings - also one side (the 'working face' side) of main guides may be slightly
warmer than the opposite side.
7. Refit the crankcase main doors and reconnect the compressor.
8. Run the compressor for a further 10 minutes and repeat checks as in step 6.
9. When satisfied that all is in order, restart the compressor. When the compressor has
settled on speed place the load control to the load condition whereupon the compressor
will commence compressing.
10. Observe compressor operation and the build up of pressure.
The load control must be set for no higher pressure than that for which the compressor is
supplied. (See Section 1.1.1 Technical Data).
During the first commissioning run on load, make careful observation of the general operation
of the compressor.
Observe the compressor gauges, until the desired unloading set-point (as set on the load
control pressure switches) is reached, at this point the compressor will unload automatically
as described in Load Control System.
Check that the loading/unloading sequence is in accordance with requirements - adjust the
control as necessary.
b) Completion of Commissioning
1. Run the compressor until it attains operational temperature and check that the oil
pressure settles at a satisfactory level, approx. 3.5 Bar or above; this will depend upon
ambient temperature, oil viscosity at running temperature, and on-load/off-load running
pattern.
2. After a settled period of running (approx. 24 hours) check the tightness of all external
bolts and nuts - particularly cylinder and valve cover fasteners, also compressor and
compressor driver fixings.
3. During this run adjust the cooling water flow control valve to achieve the required
temperature rise. When on sustained full load, the optimum temperature rise is about
10o to 12o C.

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Chapter 4 - Operating Instructions
Issue 0 4-1 Operating Instructions

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These instructions are designed to providing experienced operatives, who are fully conversant
with compressor operating techniques, with operational information for the Gardner Denver
Belliss & Morcom 'PET' range compressors.
NOTE: THE FOLLOWING OPERATING INFORMATION ASSUMES

THAT THE COMPRESSOR IS FITTED WITH A STANDARD
GARDNER DENVER BELLISS & MORCOM CONTROL SYSTEM.
HOWEVER, IF THE CONTROL EQUIPMENT IS OF DIFFERENT
MANUFACTURE, THE COMPRESSOR MUST BE OPERATED IN
ACCORDANCE WITH THE SUPPLEMENTARY OPERATING
INFORMATION SUPPLIED WITH THE CONTROL SYSTEM.
The compressor is designed and built for continuous running and will provide long term
reliable operation if regular periodic checks and servicing are carried out in accordance with
the information provided within Chapter 5 of this Instruction Manual.
CAUTION!
PROLONGED UNLOADED RUNNING OF THE MACHINE
SHOULD BE AVOIDED NOT ONLY BECAUSE OF POWER
WASTAGE, BUT UNNECESSARY COMPONENT WEAR CAN
RESULT.
It is the customer's responsibility to:

1. Maintain the inlet filter system and air blast cooler in a clean condition as dictated by site
conditions.
2. Ensure that the specified, clean lubricant is added to ensure the correct crankcase oil
level is maintained
3. Report promptly to Gardner Denver Belliss & Morcom Service Department any
operating abnormalities faults defects or malfunctions of the compressor and/or
associated ancillary equipment. Such reports must be forwarded in writing by facsimile
transmission. Oral reporting shall be deemed to be acceptable if confirmed in writing
within 48 hours.
4.1 Controls and Indicators
a) Starter System
Where the starter system has been supplied by Gardner Denver Belliss & Morcom details are
provided in the supplementary material at the rear of this manual. Where the control system is
provided by others, details will be supplied by the manufacturer.

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b) Load Control System Functions
All of the suction valves in the compressor have actuators, which cause the valve plate to be
held off its seat whenever a pneumatic signal is applied. When the plate is held open no
compression can take place. If all suction valves are held open then the compressor is 'OFF
LOAD'. On removal of the pneumatic signal the plate returns to its seat and compression can
then recommence. The unloader is pushed back by the valve plate springs and the unloader
return spring. If only the upper set of suction valves are held open then the compressor is on
'HALF LOAD'.
Three-Step Load Control means that the compressor is either on:-
1. FULL LOAD (compression taking place) - all suction valves being in service
or
2. HALF LOAD (compression taking place in bottom half of cylinder only) - lower set of
suction valves only in service.
or
3. OFF LOAD (no compression taking place) - all suction valves being held open.
4.2 Preparation for Starting
NOTE: THE FOLLOWING OPERATING INFORMATION ASSUMES

THAT THE COMPRESSOR IS FITTED WITH A STANDARD
GARDNER DENVER BELLISS & MORCOM CONTROL SYSTEM.
HOWEVER, IF THE CONTROL EQUIPMENT IS OF DIFFERENT
MANUFACTURE, THE COMPRESSOR MUST BE OPERATED IN
ACCORDANCE WITH THE SUPPLEMENTARY OPERATING
INFORMATION SUPPLIED WITH THE CONTROL SYSTEM.
a) Before Operating the Machine (Pre-Start Checks)
1. Establish that it is safe to discharge high-pressure air into the delivery lines.
2. Ensure that all machine guards are correctly fitted to the machine and auxiliary
equipment. It is IMPORTANT that any loose, missing or damaged guards are correctly
fitted before attempting to operating the compressor.
3. Check that access ways around the machine are clear and free from tripping or slipping
hazards. Remove any obstacles and neutralise any fluid spillage such as oils or
greases, using an absorbent material. Allow spillage to be absorbed for a short time
before thoroughly cleaning the spillage area.
4. Ensure that all of the fault warning, annunciators are extinguished and that the
compressor is safe to start.
5. Check oil level in sump. Correct level is halfway up window nut in front face of
crankcase.
6. If the machine has been standing idle for some time it may be necessary to prime the oil
pump.
7. Ensure that the cooling water supply valve is open promoting water circulation through
the compressor jackets, intercoolers, aftercooler and oil cooler.
8. Ensure that the air pressure sensing pipeline from the air main to the pressure switches
and solenoid valves in the control panel is locked open.

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9. Ensure that the main air-isolating valve is OPEN.
4.3 Starting the Compressor
a) Under Normal Conditions
Refer to the control panel manual for details of starting and operation.
b) After An Emergency Stop
Rectify fault condition and restart.
4.4 Running
a) Running Checks
1. Allow the compressor to run up to full speed and then close the small drain cocks.
2. Check the oil pressure. This will fall initially as the oil temperature rises, but should
steady at between 3.0 to 4.0 BarG even in a hot environment.
3. Check the cooling water is flowing at the visible outlet or flow indicator. On multi-
compressor installations balance the flows in the parallel systems of the compressors
(including intercooler) to give equal water temperature rise across both - ideally 11ºC.
4. Check all automatic drain traps for unusual discharge.
5. Check all temperatures and pressures periodically.
6. Check for undue noise, vibration or heat. If present, report immediately.
7. It is good practice to carry out these checks regularly and log the results.
b) Automatic Operation
Before Automatic Operation is selected, the compressor must be prepared for starting as
described in “Before Operating the Machine (Pre-Start Checks)” on page 4-3.
For details of operation, refer to the control panel manufacturers literature.
c) Faults/Hazards
Should a fault develop, this will be detected by the appropriate sensing switch
4.5 Stopping the Compressor
a) Normal Stopping
Refer to the control panel manufacturers literature for details of the stopping procedure.

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b) Emergency Stopping
Pressing the 'EMERGENCY STOP' mushroom button stops the machine instantly in whatever
mode of operation it is operating.
CAUTION!
THIS IS NOT RECOMMENDED FOR ROUTINE STOPPING AND
SHOULD ONLY BE USED IN THE CASE OF AN EMERGENCY
WHERE NORMAL STOPPING IS NOT POSSIBLE.
4.6 Fault Indications

The following is a list of indications of possible faults which could arise in service; periodic
surveillance of pressures and temperatures, etc, will establish the normally experienced levels
applicable to the site and load conditions.
Variation from these due to a fault arising may be slow to occur - the early effect of a fault (with
the robust reciprocating type machine) being, usually very gradual. It is IMPORTANT
therefore, to retain a simple daily record sheet of pressures and temperatures. Comparison
with previous readings will then warn if there is an untoward trend arising - when reference to
the following fault indication's list will indicate the probable cause and remedial action to take.
A copy of a typical log sheet is provided in the Appendices located at the end of this manual.
The running performance of the compressor can also indicate when it is necessary to renew a
particular part: Generally, wear or malfunction of valves or piston rings will be indicated by
variations (other than those due to suction or delivery conditions) in the interstage or final
delivery pressure and temperature.
Progressive crankcase bearing wear will slowly give rise to a gradual lowering of the lube oil
pressure; if low oil pressure does occur and cannot be traced to any other cause listed, then
connecting rod bottom end bearings should be inspected.
a) Fault Finding
Minor variations in pressure and temperature readings may occur, due to possible small
changes in the suction or delivery conditions. These factors should be considered when
checking and assessing instrument readings.
Table 4-1: Fault Finding
Fault Possible Cause Remedial Action
1. Leaking or broken suction valve Replace valve plate -examine seat for
Low first stage delivery plate in first stage. damage.
pressure (normal or low
first stage air delivery 2. One or more 1st stage suction
Remove, clean and refit depressor(s) -
temperature). valve depressor(s) sticking in "off-
examine valve for damage.
load" position.

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1. Fouling of inlet filter. Renew filter elements.
Low first stage delivery 2. Leaking or broken delivery valve Replace valve plate - examine seat for
pressure (high first stage plate in first stage. damage.
air delivery temperature).
3. Worn, broken or malfunctioning
Renew rings - clean grooves.
piston rings in first stage.
1. Leaking or broken suction valve Replace valve plate - examine seat for
High first stage delivery
plate in second stage. damage.
pressure (normal or high
first stage delivery 2. Second stage suction valve Examine, clean, and refit valve plate
temperature). depressor sticking in "off-load" depressor, also examine valve for
position. damage.

piston rings in third or second stage Renew rings - clean grooves.
cylinders.
High first stage air 1. Cooling water flow through first

Examine and clean intercooler tubes
delivery temperature after stage intercooler restricted or
ceased by blockage. (both on air and water sides).
cooler.
1. Leaking or broken delivery valve Replace valve plate -examine seat for
plate in second stage. damage.

First stage delivery Renew rings - clean grooves.
piston rings in third stage.
pressure relief valve
blowing. 3. First stage intercooler tubes Examine and clean air side of intercooler
blocked on air side. tubes.
4. Relief valve defective. Repair or fit new valve.
1. Leaking or broken suction valve Replace valve plate – examine seat for
Low second stage plate in second stage. damage.
delivery pressure (normal
or low second stage 2. Second stage suction valve
delivery temperature). Remove, clean and refit depressor, also
depressor sticking in "off-load"
examine valve for damage.
position.
1. Leaking or broken delivery plate in Replace valve plate – examine seat for
Low second stage
second stage. damage.
delivery pressure (high
second valve stage 2. Worn, broken or malfunctioning
delivery temperature). Renew rings - clean grooves.
piston rings in second stage.
High second stage 1. Leaking or broken suction valve

Replace valve plate – examine seat for
delivery air pressure and plate in third stage.
damage.
temperature.
High second stage air 1. Cooling water flow through second

stage intercooler restricted or Examine and clean intercooler cooler
delivery temperature after
tubes (both on air and by water sides).
intercooler. ceased blockage.

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1. Leaking or broken suction valve or Replace valve plate – examine seat for
delivery valve plate in third stage. damage.
2. Third stage suction valve depressor Remove, clean and refit depressor, also
Second stage delivery
sticking in "off-load" position. examine valve for damage.
pressure relief valve
blowing. 3. Second stage intercooler tubes Examine and clean air side of intercooler
blocked on air side. tubes.
4. Relief valve defective. Repair or replace valve.
1. Demand of end using equipment If none of the previous faults are present,
has overtaken capacity of i.e. compressor running normally, no
compressor. remedial action possible.
When demand reduces, the pressure will
Low third stage delivery rise to normal level (as set by the load
pressure. controller).
2. Low setting of load controller. Adjust to required pressure.
3. Malfunction of load controller. Repair/replace pressure controller.
1. Leaking or broken delivery valve Replace valve plate – examine seat for
plate in third stage. damage.
2. Leaking or broken suction valve Replace valve plate – examine seat for
plate in third stage. damage.
High third stage delivery
temperature. 3. Third stage suction valve depressor Remove, clean and refit depressor, also
sticking in "off-load" position examine valve for damage.
4. Worn, broken or malfunctioning Renew rings and clean piston ring

piston rings in third stage. grooves.
1. Isolating valve between

compressor and delivery main Open valve.
closed or partially closed.
High third stage delivery 2. Incorrect setting or malfunction of Adjust to required pressure or repair/
pressure (relief valve
load controller. replace pressure controller.
blowing).
3. Restriction or blockage of control
signal to compressor unloader Remove restriction.
system.
4. Aftercooler tubes blocked or Examine and clean air side of aftercooler

restricted on air side. tubes.
5. Seized closed, or partially closed

non-return valve in delivery main (if Repair valve.
fitted).
6. Relief valve defective. Repair or fit new valve.

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1. Cooling water flow through

aftercooler is restricted or ceased Check and adjust hand valve openings.
High final air temperature by maladjustment of hand valves.
from aftercooler. 2. Aftercooler tubes partially blocked
Examine and clean air and water sides of
on airside, or waterside of tubes is
tubes.
fouled.
1. Crankcase oil level is low. Check oil level, add oil as required.
2. Air leakage into suction side of Check oil level. Check connecting unions
pumping system. on suction pipe to pump.
3. Partially blocked oil pump suction

Remove, clean and refit.
strainer in crankcase.
Low lubricating oil
pressure. 4. Oil relief valve set too low or valve
Remove, check and reset.
sticking open.
5. Failure or wear of big end or small Renew bearing(s). Check crankshaft for
end bearings. damage.
6. Partially blocked oil pump delivery

Replace element.
filter element.
1. Compressor rotation incorrect (first Change compressor rotation and

trial run, or after a rebuild). recheck.
2. Crankcase oil level very low. Check oil level, add oil as required.
3. Serious air leakage into oil pump

Loss of oil pressure.
section pipe or complete Check suction pipe and unions to pump.
disconnection.
4. Complete blockage of oil pump Check and clean oil sump. Remove,
suction strainer. clean and refit strainer. Change oil as
necessary.
5. Oil pump drive failure. Examine drive coupling, ascertain cause

of failure and rectify.
6. Oil pump seizure. Replace pump. Check drive coupling.
No condensate from 1. Drain trap blocked. Dismantle, clean and refit.

drain trap of interstage
2. Separator drain pipe to trap
moisture separator or Dismantle, clean and refit.
blocked.
aftercooler moisture
separator. 3. Dry atmospheric conditions. Applies to 1st stage only.
1. This suggests that there is an

Large quantity of internal leakage from the cooling
condensate emitted from water spaces into the air spaces of Trace the fault and rectify as necessary.
drain trap. the compressor (low pressure
stage).

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NOTE: WATER EMITTED FROM THE TRAPS IS USUALLY IN THE

FORM OF A TRICKLE (INTERMITTENT OR STEADY) -
DEPENDING ON THE HUMIDITY OF THE AIR TAKEN IN BY THE
COMPRESSOR - OR NIL IN THE CASE OF VERY DRY
ATMOSPHERIC CONDITIONS.

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Chapter 5 - Compressor Maintenance
Issue 0 5-1 Compressor Maintenance

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5.1 Preventive Maintenance

This schedule of maintenance, in general terms, is a preventive maintenance guide and
running service necessary for our range of reciprocating compressors. However, it does not
cover for any eventualities, which could occur from neglect or incorrect operation by the
customer or adverse environmental conditions.
Before carrying out any preventive maintenance work related to this equipment it is a
requirement that you read and work in accordance with the Safety Precautions given in
Chapter 2 - Safety Information of this Instruction Manual. Also, for your own protection, be
sure to read and obey WARNING and CAUTION notices and observe any special notes you
find in this Chapter and any associated literature.
When working on the compressors rotational parts you MUST fit piston rod clamps to prevent
possible uncontrolled movement of the crankshaft and motion work. Refer to Maintenance
Procedure JOB No: 2 - Fit Piston Rod Clamps (page 5-10).
On plants with two or more compressors the opportunity should be taken during the early
weeks of running, following commissioning, to vary the service hours of the compressors so
that no two machines reach their maintenance interval at the same time. A gap of about 200
hours between machine running times is recommended.
When 'running-in' a new compressor the crankcase oil MUST be renewed after the first 500
hours of operation and thereafter change in accordance with the intervals laid down in the
following maintenance schedule.
a) Maintenance Schedule
The following schedule, lists recommended maintenance tasks which are designed to both
prevent unplanned machine breakdowns and to help the maintenance teams to plan
maintenance activities. Where a maintenance activity requires greater explanation than that
given in the schedule a reference to the relevant associated maintenance instruction is given.
All materials used for scheduled maintenance and repair MUST COMPLY with Gardner
Denver Belliss & Morcom standards and the standards laid down by associated equipment
manufacturers. Only approved spares may be used.
When a system component associated with a mechanical or electrical device is changed or
renewed, the system must undergo a functional test before the equipment is returned to
service.
Gardner Denver Belliss & Morcom are not responsible for premature failures of parts which
are caused by neglect, inappropriate servicing, use of none Gardner Denver Belliss & Morcom
parts, or any other similar conditions over which we have no control.

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b) Each Day or Shift
A shutdown of the compressor is not normally required for a Shift inspection.

Tasks Supplementary Information
Check all temperature and pressure gauge
Report immediately any abnormality.
readings are normal.
Moisture shoud be regularly draining from the base of
Check operation of moisture trap drains.
the drain trap.
Check for undue noise, oil leakage, vibration
Report immediately any abnormality.
or heat.
Ensure that load control equipment is Check that the compressor loads and unloads in
operating correctly. response to demand by the air supply system.
The 'Test' push-button is normally located on the
Test protection circuits annunciator lamps. compressor control panel. If a lamp fails, renew the
All lamps MUST illuminate bulb. If the new bulb does not illuminate report failure to
the Supervisor.
Use the breather aperture in the top of the crankcase to
Check the crankcase oil level. Oil level
top-up the oil. Refer to the table of lubricants for oil
should be halfway up the window nut.
type.
Where vee belts are fitted check tension Refer to drive belt manufacturers instructions for details
and adjust if necessary. of tensioning
Any aspect of the Shift inspection requiring further attention MUST be reported for action as
required.
c) Monthly Inspection
A shutdown of the compressor is not normally required for a monthly inspection.

Carry out a running examination to ensure
Record all temperatures, pressures and hours run on
satisfactory operation of all compressor and
compressor log sheet.
ancillary equipment.
Check air inlet filter element cleanliness -
renew if necessary.
Check the cleanliness and ensure correct
Clean drains and renew worn or damaged parts, as
operation of drain traps on compressor and
required.
ancillary equipment where applicable.
Check all external bolts and nuts on the
Re-tighten or renew any missing nuts and bolts. Tighten
compressor including the holding down
nuts to appropriate torque.
nuts for tightness.
Check air pressure supplied to compressor
Pressure should be 7 bar minimum at unloader.
unloaders and note pressure drop.
Any aspect of the Monthly inspection requiring further attention MUST be reported for action
as required.

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VH21H3N
PET Compressor
d) Six Monthly Service
The compressor is required to be shutdown for two days to perform this service schedule.
Record all temperatures, pressures and hours run on
Carry out a running examination to ensure
compressor log sheet. A copy of this form is provided in
satisfactory operation of all compressor and ancillary
Appendices located at the end of this manual. Check
equipment.
cooling water flow rate (If flow recorder is fitted).
Check the cleanliness and ensure correct operation
Strip and clean drains and renew worn or damaged
of drain traps on compressor and ancillary
parts, as required.
equipment where applicable.
Check all external bolts and nuts on the compressor Re-tighten or renew any missing nuts and bolts. Tighten
including the holding down nuts for tightness. nuts to appropriate torque.
Visually examine (through the valve pockets) the
general surface condition of cylinder bores for Replace worn or damaged parts, as required
evidence of ring wear or scoring.
Check valve unloaders, actuators & interconnecting Clean and service as necessary. Replace worn or
small bore pipework for defects. damaged parts as required.
Examine piston rods along gland travel to ensure no Clean and service as necessary. Renew worn or
scoring is present. damaged parts as required.
Check that inlet filter is clean Clean and service as necessary.
Check that inter and aftercooler moisture drains are
operational and that the diffusers on the blowdown Clean and service as necessary
valves are clear and clean..
Check one suction and one delivery valve from each Clean and service as necessary. Renew worn or
stage for cleanliness or fouling. damaged parts as required.
Renew third stage piston rod packing, piston rings
Renew worn or damaged parts as required.
and rider rings.
Record condition. Renew worn or damaged parts as
Check integrity of all flexible air and water pipes.
required.
CRANKCASE INSPECTION
Examine crossheads and main guide slipper paths, Clean and service as necessary. Renew worn or
condition and clearances. damaged parts as required.
Check connecting rod bottom end bolts are pinned. Rectify as required.
Check that lubrication oil suction strainer is clean
Clean and service as necessary. Tighten unions and
and all pipework to main pump is in good order and
renew worn or damaged parts as required.
that unions are tight.
Check that crankcase oil is clean and no foreign If dirty renew crankcase oil and delivery filter element. If
particles are present. Ensure that oil delivery filter is necessary investigate source of any foreign particles.
clean and that oil pressure is satisfactory. Refer to table of lubricants for oil type and quantity.
Check for any oil leaks. Wherever possible fix the The crankcase oil and the delivery filter are renewed as
leak. a matter of course during the Annual Service.
Any aspect of the Six Monthly service requiring further attention MUST be reported for action
as required. On completion of the service, re-commission the compressor and recording all
operating pressures and temperatures. Ensure that the working area is left in a clean and tidy
condition.

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VH21H3N
PET Compressor
e) Annual Service - (or as stipulated by local regulations)

The compressor is required to be shutdown for five days to perform this service schedule. All
Six Monthly tasks are to be undertaken as part of this schedule.

Where possible use factory re-conditioned valve units.
Remove all air valves and replace with factory
Where this is not possible. all valves re-conditioned on
refurbished units.
site must be leak tested before re-fitting.
Renew crankcase oil and delivery filter element. Refer to table of lubricants for oil type and quantity.
Inspect connecting rod bottom end shells, crankpin,
Clean and service as necessary. Renew worn or
top end bearing and gudgeon pin. Check motion work
damaged parts as required.
clearances.
Withdraw pistons and piston rods and examine wear.
Renew piston rings, piston rod packings, and piston rod
Gauge cylinder bores and piston rods for wear and
scrapers.
record readings.
Check condition of water jacket spacers for fouling
Report condition.
from lime deposits.
Check cleanliness of motor ventilation fan and that air
flow paths are clean. Carry out an insulation Clean and service as necessary. Renew worn or
resistance check on motor windings and record damaged parts as required.
readings.
Use a calibrated test rig to test the protection devices.
Check all system protection devices and circuits for
Alternatively the devices can be tested by simulation of
correct operation.
fault conditions at the machine.
Any aspect of the Annual service requiring further attention MUST be reported for action as
required. On completion of the service close compressor using new gaskets and 'O' rings. Re-
commission the compressor and recording all operating pressures and temperatures. Ensure
that the working area is left in a clean and tidy condition.

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VH21H3N
PET Compressor
5.2 Approved Lubricants
Lubricant Supplementary Information

Crankcase Oil For cooling water INLET temperatures 0 to 40oC:
Use SAE 30 oil (ISO VG 100)
Approved Brands:-
BP Vanellus C3 Mono 30
Mobil Delvac 1330
Shell Rimula X30
For cooling water INLET temperatures 40oC to 50oC:
Use SAE 40 oil (ISO VG 150)
Approved Brands:-
BP Vanellus C3 Mono 40
Mobil Delvac 1340
Shell Rimula X40
Alternatively:- The oil used MUST be a good quality mineral oil meeting the requirements of
SAE 30 (ISO VG 100) or SAE 40 (IS0 VG 150) dependent upon the cooling water inlet
temperature, as shown in the table above.
The oil used must contain rust and oxidation inhibitors and anti-foam additives.

25/2/08
VH21H3N
PET Compressor
5.3 Maintenance Instructions

The following procedures are intended for the use of the technician responsible for the
maintenance of the compressor. It is essential that any necessary adjustments, servicing or
overhaul work should only be carried out by competent persons who are familiar with the
compressor installation and who have the appropriate authority (Permit to Work). To avoid
possible warranty invalidation the following instructions should be read before attempting to
maintain the machine.
WARNING !
WHEN WORKING ON COMPRESSOR ROTATIONAL PARTS YOU
MUST FIT PISTON ROD CLAMPS TO PREVENT POSSIBLE
UNCONTROLLED MOVEMENT OF THE CRANKSHAFT AND
MOTION WORK. THIS COULD RESULT IN INJURY OR LOSS OF
LIFE.
REFER TO JOB NO. 002

11/12/07
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PET Compressor
JOB No: 1 - Crankcase Oil Change
List of Special Tools

27mm (1-1/16”) Spanner (no more than 10 mm thick) 1
List of Consumables
Crankcase Oil (see page 5-6 for reccommended oils) A/R
Industrial cleaning fluid (White Spirit) & lint free cloth A/R
WARNING!
TO AVOID SCALDING FROM HOT OIL, ALLOW THE
COMPRESSOR TO COOL BEFORE BEGINNING WORK.
1. Isolate mains power and display appropriate warning signs.

2. Remove the crankcase doors, taking care not to damage the oil seals.
3. Wipe any excess oil off the doors using an industrial cleaning fluid and a lint free cloth.
Place the door in a clean location to avoid oil contamination when refitting.
4. Empty the oil sump using suitable pumping equipment and clean out the crankcase
sump (use lint-free cloths, to avoid fouling of the oil strainer).
5. Once all oil has been removed from the sump, remove the oil strainer. Use a thin
spanner, on the strainer body hexagon to unscrew the strainer whilst holding the
external hexagon fitting to prevent turning. This fitting is not screwed into the crankcase
- it passes through a clear hole. Re-fit the oil strainer, ensuring that all sealing washers
are fitted in the correct locations.

11/12/07 Crankcase Oil Change
VH21H3N
PET Compressor
Illustration 5-1 : Crankcase Oil Strainer Arrangement
Socket
Copper Washer
Strainer
Copper Washer
6. Check that all tools and cleaning cloths have been removed from the crankcase sump.
7. Refill the crankcase sump with the required quantity of clean, new oil.
8. Refit the crankcase doors after checking, and if necessary replacing, the door seals.
9. Test run the compressor and check for oil leaks around the strainer seal and crankcase
doors. If all is satisfactory, return the machine to service.
Illustration 5-2 : Lubrication System
Lub. Oil Pressure

Relief Valve
Oil Pump
Lub. Oil to Cooler
Return Pipe
Oil Level Oil Suction

Sight Glass Hose
Cooling Water Oil Filter

Outlet
Lub. Oil to Cooler

Delivery pipe Oil Cooler Cooling Water
Inlet

11/12/07 Crankcase Oil Change
VH21H3N
PET Compressor
JOB No: 2 - Fit Piston Rod Clamps
LIST OF SPECIAL TOOLS

Piston Rod Clamps 1 set
LIST OF CONSUMABLES
1. Before starting this operation, carry out the following safety steps :
i. Isolate mains power and display appropriate warning signs.
ii. Ensure that all pressure is vented from the compressor.
iii. Carefully open the vent valves on the third stage cylinder to check de-pressurising
has been completed successfully.
iv. Ensure that the compressor is isolated from the delivery system and that the
compressor is positively isolated from the delivery non-return valve.
v. Vent air pressure from the unloader system.
vi. Post signs instructing personnel that the machine MUST NOT be used.
2. Remove the distance piece access covers from the line of motion works NOT being
worked on. Wipe any excess oil off the covers using an industrial cleaning fluid and a lint
free cloth. Place the cover in a clean location to avoid oil contamination.
3. Mark the position of the oil shedder on the piston rod and remove shedder.
4. Loosely assemble the piston rod clamps onto the piston rod.
5. Manually 'bar-over' the compressor to the desired position and hold steady.
6. Whilst one person holds the crankshaft bar in position, the other must tighten the one
piston rod clamp firmly against the packing gland box and the other firmly against the
scraper gland box.
7. Only when both clamps are tight in place can the crankshaft bar be carefully released
and safe work or inspection take place.
WARNING!
WHEN MAINTENANCE WORK HAS BEEN COMPLETED THE
PISTON ROD CLAMP MUST BE REMOVED.
8. When returning the compressor to service, check that all above steps have been
reversed, all clamps and fittings have been removed and that the compressor is safe to
run.
Issue 0 5 - 10 Compressor Maintenance

11/12/07 Fit Piston Rod Clamps
VH21H3N
PET Compressor
JOB No: 3 - Cylinder Top Covers - Remove and Re-fit

Lifting Eye-Bolt 1 set
Slings, Lifting Equipment A/R
LIST OF CONSUMABLES
a) Removal top cover - First Stage Cylinder
2. Isolate and drain the cooling water from the compressor cylinders.
3. Remove cooling water pipes from the top cover and fit blanking plugs to prevent dirt
ingress.
4. Disconnect and remove all unloader pipes from the top cover unloaders.
5. Loosen and remove the top cover securing nuts from the cylinder fixing studs. (sixteen)
6. Remove four of the valve cage nuts and attach suitable eye nuts. The lifting eye
locations should be arranged so that when the cylinder head is lifted, with slings, from
these points, the natural hanging angle will be 45 Deg.
7. Attach a suitable sling to the eye-bolts, and using lifting equipment, take up the slack in
the sling.
8. Slowly lift and guide the top cover from the cylinder studs. Adjust the position of the
slings so that the head cover will not swing when lifted clear of the cylinder studs.
9. Clean the top cover using an industrial cleaning fluid and a lint free cloth.
10. Lower the top cover onto a suitable, clean work-surface taking care not to damage the
machined face.
11. Ensure that the piston and cylinder is clean and dry. Ensure that all liquid and loose
material is removed from the top of the cylinder and piston.
b) Re-fitting Top Cover - First Stage Cylinder
If any maintenance has been carried out on the motion work which may affect the piston to
cylinder (bumping) clearances, check the clearances are correct before refitting the top cover.
Refer to Job No. 004.

11/12/07 Cylinder Top Covers - Remove and
Re-fit
VH21H3N
PET Compressor
1. Ensure that the cylinder top cover and cylinder top mating faces are clean.
2. Check the condition of the cylinder top cover gasket. Renew if necessary.
3. Fit a new gasket over the cylinder studs and onto the cylinder mating face.
4. Attach a suitable sling to the eye-nuts fitted for cylinder head removal (See section a.
above), and using suitable overhead lifting equipment, raise and position the top cover
over the cylinder.
5. Slowly lower and guide the top cover onto the cylinder, ensuring the correct positioning
of the cooling water and gas pockets.
6. When in position, remove the sling and lightly secure the top cover to the cylinder with
the fixing nuts.
7. Tighten the cylinder cover nuts (centre nuts first), tighten the nuts down evenly and
progressively. Nuts to be torque tightened to the appropriate torque figure. Refer to
Chapter 1 Section 1.1.3.
8. Remove the eye-bolts from the top cover and re-fit valve cage fasteners.
9. Refit all pipes.
10. Secure the supply lines to the cylinder top cover with their fasteners.
11. Re-establish water and electrical supplies to the compressor.
12. Bleed off any trapped air in the cooling system using the plugs in the cylinder water
jacket.
13. Test run the compressor on clean, dry air or nitrogen and check for correct operation
and freedom from leaks around any of the disturbed gaskets.
c) Removal - Integral 3rd Stage Cylinder / 2nd Stage Top Cover
2. Isolate and drain the cooling water from the compressor cylinders.
3. Remove cooling water pipes from the top cover/cylinder and fit blanking plugs to prevent
dirt ingress.
4. Disconnect and remove all unloader pipes that connect to the top cover unloaders.
5. Remove cooling water pipes from the top cover and fit blanking plugs to prevent dirt
ingress.
6. Check that there are no supply pipes or hoses fastened to the top cover.
7. Disconnect and remove as necessary the 3rd stage aftercooler and the 2nd stage
intercooler using suitable lifting equipment.

Re-fit
VH21H3N
PET Compressor
8. Loosen and remove the cylinder securing screws from the base of the 3rd stage
cylinder.
9. Remove the top-most delivery valve cover fastener (M20) and fix a suitable eye bolt in
its place. Attach a sling to the 3rd Stage Cylinder and, using suitable lifting equipment,
take up the slack in the sling.
CAUTION!
Take care when removing this cylinder/top cover casting that the 3rd stage piston
rings are not damaged as they are exposed.
10. Slowly lift and guide the 3rd stage cylinder casting from the 2nd stage cylinder and 3rd
stage piston.
11. As the cylinder reaches the end of the piston, ensure that the cylinder is supported so
that it will not swing wildly as it emerges from the end of the piston.
12. Lower the 3rd stage cylinder casting onto a clean work surface taking care not to
damage the machined face.
13. Collect the 3rd stage piston rings as they are exposed and place them on to a clean
work-surface.
d) To Refit- Integral 3rd Stage Cylinder / 2nd Stage Top Cover
If any maintenance has been carried out on the motion work which may affect the piston to
cylinder (bumping) clearances, check the clearances are correct before refitting the top cover.
Refer to Job No. 005.
1. Ensure that the combined 3rd stage cylinder/cylinder top cover and 2nd stage cylinder
top mating faces are clean.
2. Check the condition of the cylinder-to-cylinder gasket. Renew if necessary.
3. Fit the gasket to the cylinder mating face.
4. Check dimensions of used piston pressure rings. Fit new or used (as appropriate) piston
rings to the 3rd stage piston.
5. Check the wear limits of the 3rd stage bearer ring. Replace if necessary.
6. Attach a suitable sling to the eye-bolts in the 3rd stage cylinder and using suitable lifting
equipment, raise and position over the 2nd stage cylinder.
7. Slowly lower and guide the 3rd stage cylinder onto the 2nd stage cylinder, ensuring the
3rd stage piston rings are not damaged as the 3rd stage cylinder is lowered into position.
Also ensure that the cooling water and gas pockets are correctly positioned.
8. When in position, remove the sling and lightly secure the 3rd stage cylinder to the 2nd
stage cylinder with the fixing screws.
9. Tighten the cylinder screws down evenly and progressively. Screws to be torque
tightened to the appropriate torque figure. Refer to Chapter 1 Section 1.1.3.
10. Remove the eye-bolts from the top of the 3rd stage cylinder and refit the cooling water
pipe
11. Re-make all unloader pipework.

Re-fit
VH21H3N
PET Compressor
12. Re-fit the 2nd stage intercooler and final stage aftercooler.
13. Re-establish water and electrical supplies to the compressor. Bleed off any trapped air
in the cooling system using the plugs in the cylinder water jacket.
14. Test run the compressor and check for correct operation and freedom from leaks around
any of the disturbed gaskets.

Re-fit
VH21H3N
PET Compressor
JOB No: 4 - Piston rings - Remove and Re-fit

Piston-rod Bullet 1 set
LIST OF CONSUMABLES
a) To Remove
Piston removal procedure is detailed as part of Job No.013 Piston Rod - Remove/Refit.
b) Examination
Piston Pressure Rings - For piston pressure ring dimensions refer to Chapter 1 Technical
Data. The pressure rings MUST be replaced with new ones when the radial thickness at any
point has worn to 65% or less of the original thickness.
Piston Bearer Rings - For piston bearer ring dimensions refer to Chapter 1 Technical Data.
The bearer rings MUST be replaced by new ones, when the standout at any point has worn to
0.5mm or less.
c) Piston Rings Renew
1. Remove and discard the old piston and bearer rings. Carefully clean piston ring
grooves.
2. Insert the new piston ring squarely into the cylinder bore and check that the bearing ring
standout and clearance is correct. Refer to Chapter 1 Technical Data.

11/12/07 Piston rings - Remove and Re-fit
VH21H3N
PET Compressor
Illustration 5-3 : Typical Piston Ring Configuration
3. Fit the new piston rings by carefully springing them over the piston body.
4. Ensure that the rings are correctly seated in the piston groove and that all ring gaps are
staggered.
5. If the cylinder bore is cored or very lightly polished with no signs of honing marks it may
be necessary to re-hone the bore. (In some cases a flexi-hone can be used).

11/12/07 Piston rings - Remove and Re-fit
VH21H3N
PET Compressor
JOB No: 5 - Piston/Cylinder End (Bumping) Clearances
LIST OF CONSUMABLES
Sealing Gasket (between 0.8mm - 1.0mm thick) A/R
There are two ways of measuring the piston Top-Dead-Centre (TDC) clearance: Method 1 is
used when the cylinder top covers are removed and Method 2 is by removing the valves and
checking the clearance through the valve pockets. The Bottom-Dead-Centre (BDC) clearance
is checked using Method 2.
The third stage cylinder line can only be checked using Method 2.
Illustration 5-4 : Piston features

11/12/07 Piston/Cylinder End (Bumping)
Clearances
VH21H3N
PET Compressor
a) Method 1
1. Remove the cylinder top cover refer to Job No.003.

2. Place a sealing gasket of between 0.8mm - 1.0mm on to the cylinder mating face.
3. Place the machined straight-edge across the top of the gasket on the cylinder.
4. Bar over the compressor to place the piston exactly at TDC.
5. Measure the clearance between the straight edge and the piston crown. Ensure that the
straight edge is held firmly against the gasket when measuring clearance. record the
with a feeler (thickness) gauge. The required clearances are detailed (See “Crankase
Component Clearances” on page 1-7.) If the clearances are out side of the tolerance
band the clearance MUST be adjusted (see later in this procedure).
b) Method 2
1. Remove either a suction or delivery valve from a top cylinder pocket (if measuring TDC
clearance) or a bottom cylinder pocket (if measuring BDC clearance).
2. With the piston exactly at TDC or BDC, insert a feeler gauge through the valve pocket
and measure the clearance. Record the end ("bumping") clearances with the piston at
the top (Top-Dead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. The
clearances are detailed in . If the clearances are outside of the tolerance band the
clearance MUST be adjusted (see later in this procedure).
CAUTION
FEELER GAUGES MUST NOT BE INSERTED INTO THE VALVE
POCKET WHILST TURNING THE MACHINE OVER BECAUSE IF
TRAPPED, THE MACHINE COMPONENTS COULD BE STRAINED
OR DAMAGED.
c) Piston/Cylinder End Clearances - Adjustment
The end ("bumping") clearance is adjusted by screwing the piston rod into, or out of, the
crosshead. To adjust the piston to cylinder end clearances proceed as follows:
1. Remove the crosshead access cover and gasket from the crankcase.
2. Bar over the crankshaft to reveal the crosshead locknut and the piston rod securing pin.
3. Bend back the locking plate tab retaining the securing pin and remove the pin. Ensure
that the securing pin is removed before slackening the crosshead nut. Otherwise, if the
piston rod turns in the crosshead while the securing pin is in position, the pin will distort
making it extremely difficult to remove
4. Slacken the crosshead locknut.
5. The piston rod has a slotted end at the crosshead (through which the securing pin fits) it
can only be turned in 90o steps, one step represents a linear movement of 0.8mm, (the
screwed end of the rod having 8 threads per inch, equivalent to 1 thread every
3.175mm).
6. To adjust the top end clearance, screw the piston rod into or out of the crosshead.
Ensure that the top and bottom clearances are as close to equal as is possible. If equal

Clearances
VH21H3N
PET Compressor
clearances are not obtainable then always, on final setting, make the TOP clearance the
larger of the two (by an amount equal to no more than one quarter turn only of the piston
rod in the crosshead i.e., by no more than 0.8mm).
7. Fully tighten the crosshead locknut.
8. Recheck that the piston rod slots are correctly aligned for clearance of the piston rod
securing pin.
9. Fit a new locking plate to the securing pin before fitting and fully tighten the pin.
10. Bend over the locking plate tab to prevent the securing pin from rotating.
11. Inspect the crosshead access cover gasket. Renew if necessary.
12. Refit the access cover.

Clearances
VH21H3N
PET Compressor
JOB No: 6 - Packing Assembly - Remove and Re-fit
LIST OF CONSUMABLES
Due to their construction, these packing glands can only be satisfactorily examined and
repaired when they are removed from the compressor and disassembled on a suitable
workbench.
a) To Remove Packing Assemblies
1. Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and
motion works. Refer to Job No:2 (Page 5-10)
2. Mark the position of the oil shedder on the rod surface and remove shedder with its two
clamping screws.
3. Remove the nuts from the small diameter gland assembly tie studs.
4. Remove the securing nuts from the gland cover and lower the cover down the piston rod
until it is resting on the oil scraper gland assembly.
5. Slide each container assembly down the piston rod until it is clear of the gland.
6. Slide the container a little way back up the piston rod to expose the packing rings and in
turn, unhook the garter springs and remove the packing ring segments.
7. Reassemble and carefully store each ring of segments and garter spring, immediately
on removal. Repeat this step until all of the packing rings have been removed.
8. Observe that each ring is marked with matching numbers and letters for use in
reassembly. Also the lowermost ring has a peg which locates into a hole in the
uppermost ring to form a container pair. The rings can be re-used depending upon
condition after inspection.

11/12/07 Packing Assembly - Remove and
Re-fit
VH21H3N
PET Compressor
b) To Refit Packing Assemblies
CAUTION!
THE RINGS AND GLANDS REFITTED COMPLETELY WITHOUT
OIL (THE COMPRESSOR BEING AN OIL-FREE CYLINDER
MACHINE) - ON NO ACCOUNT INTRODUCE OIL OR GREASE
INTO THE GLAND. IF REFITTING "USED" RINGS FIRST ENSURE
THAT THERE IS NO DIRT OR GRIT EMBEDDED
If the piston rod is out of the compressor, the gland can be assembled on the work-bench,
then fitted into place as a finished unit. If the rod is in place, the rings and their springs are
assembled around the rod by working through the distance piece apertures.
1. Check the piston rod surface for wearing or any sign of scoring. If evidence of wearing
or scoring is heavy the piston rod should be replaced.
2. Assemble each ring onto the piston rod with its garter spring.
Illustration 5-5 : Ring Assemblies
‘B’ Ring ‘T’ Ring
3. Fit the rings as pairs into their respective containers (ensure peg is pointing upwards).
4. Slide each container assembly up the piston rod in turn, finally clamping the completed
gland assembly with the tie rod nuts.Refit and tighten the packing nuts and secure the
gland assembly to the cylinder bottom.
5. Refit the oil shedder to the piston rod in the position marked during removal and secure
with its clamping screws.
6. Remove piston rod clamps.
7. Inspect the crosshead access cover gasket. Renew if necessary.
8. Refit the access cover.

Re-fit
VH21H3N
PET Compressor
Illustration 5-6 : Stage Gland Packing

Packing Gland in position
Packing Gland tie nuts
Securing Nuts
1st Stage Packing Assembly
2nd Stage Packing Assembly
GARTER
SPRING
‘T’ Ring ‘B’ Ring

Re-fit
VH21H3N
PET Compressor
JOB No: 7 - PACKING ASSEMBLY - OVERHAUL

Wear Check Tool 1
Thread Guard Cap 1
LIST OF CONSUMABLES
Due to their construction, these packing glands can only be satisfactorily examined and
repaired when they are removed from the compressor and disassembled on a suitable
workbench. To remove the packing gland completely from the compressor, the piston rod
must first be removed.
a) To Disassemble
1. Remove the nuts from the small diameter gland tie studs and separate and disassemble
the containers. As each container ring is lifted off the assembly, take meticulous care of
the precision ground and lapped faces between the containers and the plates.
2. Observe carefully that the ring containers and the plates between them are staggered
sequentially, with number 1 being the top container ring.
3. Observe that the tie studs are unequally spaced to ensure the correct orientation of the
internal water passageways is maintained.
4. Observe and carefully record the construction and sequence of assembly for the rings,
noting that each ring of segments is marked with matching numbers and letters. In
addition note that there is a peg and hole location in the segmented ring pairs in the
containers with the peg pointing upwards.
5. As each container is lifted off the assembly, remove and store the packing rings and
carefully retain the various 'O' rings as they become free (it is recommended that 'O'
rings are renewed, if not guard the displaced rings against loss and damage). There is
an 'O' ring on each tie stud
6. Observe the condition of the soft metal sealing ring in the top face of the uppermost
gland ring ensure that it is not damaged during handling and storage.
7. Unscrew the small diameter tie studs from the uppermost container ring.
b) To Inspect
1. The packing rings are checked for wear by re-assembling, with garter spring, squarely
around the piston rod, or on the Wear Check Tool and examining the butt clearances.
2. When parts are new the butts are each approx. 3mm wide; discard the ring when the
butts reduce to 0.5mm.
3. Examine the soft metal sealing ring on the top-most container of the gland ring to ensure
this is in good condition.

11/12/07 PACKING ASSEMBLY -
OVERHAUL
VH21H3N
PET Compressor
4. Examine the 'O' rings to ascertain their condition - renew if required. (3rd stage only).
c) To Reassemble
Scrupulous cleanliness of all parts is required on assembly, particularly of the lapped faces
between the containers and plates.
1. Identify and layout the gland components in sequential order in preparation for
reassembly.
2. Place piston rod/piston assembly onto a clean work-bench resting on the piston crown
with the piston rod pointing upwards so that the rod can be used as an assembly tool.
3. Thoroughly clean the rod surface and fit the thread guard cap to the rod end.
4. Thread the packing gland cover plate over the piston rod to rest on the piston.
5. Locate the lowest ring pair of the packing assembly onto the flange cover recess, first
the ring with the peg pointing upwards, then the ring with the hole located over the peg.
6. Locate the tie studs (temporarily removed from the top container) in the holes in the
cover to align subsequent containers.
7. Fit the 'O' rings into the grooves around around each tie stud. Great care must be taken
not to knock or disturb these during later stages of assembly.
8. Progressively build up the gland assembly in the correct numbered sequence of the
plates and containers refitting packing rings and O rings in their correct positions as
noted during dismantling.
9. When the top container ring is reached, very carefully withdraw the tie studs taking great
care not to shake the assembly.
10. Firmly screw the tie studs back into their original positions in the top gland ring.
11. Carefully thread the tie rods back through the gland assembly until the top gland ring
rests squarely onto the top container.
12. Whilst clamping the assembly firmly to prevent, separation, displacement of 'O' rings or
misalignment, lift the assembly sufficiently to fit the nuts to the tie studs.
13. Progressively tighten the nuts evenly to clamp the assembly.
14. Refit the gland assembly as described in JOB No: 6 - Packing Assembly - Remove and
Re-fit (page 5-20).

11/12/07 PACKING ASSEMBLY -
OVERHAUL
VH21H3N
PET Compressor
JOB No: 8 - Piston Rod Oil-Shedder - Remove and Re-fit
LIST OF CONSUMABLES
The piston rod oil shedder is clamped in halves to the piston rod by socket head screws. The
shedder is fitted so as to run clear of the packing gland and the scraper gland covers. If the
shedder becomes damaged renew as follows:
The oil shedder should only be fitted onto the piston rod when both the oil scraper gland and
packing gland are fully fitted in place.
Illustration 5-7 : Piston-rod Oil Shedder in situ.
Oil Shedder
a) To Remove
motion works. Refer to JOB No: 2 - Fit Piston Rod Clamps (page 5-10)
2. Mark the position of the oil shedder on the rod surface and remove shedder with its two
clamping screws.

11/12/07 Piston Rod Oil-Shedder - Remove
and Re-fit
VH21H3N
PET Compressor
b) To Refit
1. Place the piston in BDC position and assemble the shedder onto the piston rod with the
hollowed side placed downwards.
2. Position the shedder 2.5mm above the top face of the scraper gland and lightly but
firmly tighten the two screws.
3. Turn over the compressor to ensure that the oil shedder does not foul either the upper
packing gland or the lower scraper gland.
4. When adjustment is satisfactory, fully tighten the shedder clamping screws.
5. Refit the access cover to the cylinder distance piece.
6. Two small diameter washers of the required thickness placed either side on top of the
scraper gland are helpful in setting the shedder position - remove the washers
immediately afterwards.

11/12/07 Piston Rod Oil-Shedder - Remove
and Re-fit
VH21H3N
PET Compressor
JOB No: 9 - Oil Scraper Gland - Remove and Re-fit

Wear Check Tool 1
LIST OF CONSUMABLES
The support housings of the scraper glands fit directly on to the top of the guide for the
crossheads
Illustration 5-8 : Oil Shedder and Scraper Assembly
a) To Remove
motion works. Refer to JOB No: 2 - Fit Piston Rod Clamps (page 5-10).

11/12/07 Oil Scraper Gland - Remove and
Re-fit
VH21H3N
PET Compressor
2. Lift the plate and slide the upper pair of scrapers up the rod.
3. Unhook the garter springs and remove the scraper ring segments.
4. Re-assemble and carefully store each ring of segments immediately upon removal.
5. The segments are marked relative to each other, the lower ring pair having a peg and
locating hole arrangement for correct re-assembly. The rings can be re-used depending
upon condition.
6. Lift the container and slide the lower pair of scrapers up the rod.
7. Re-assemble and carefully store each ring of segments immediately upon removal.
b) Oil Scraper Gland - Inspection
1. The oil scraper rings are checked for wear by re-assembly, with garter spring, squarely
around the piston rod, or on the wear check tool and examining the butt clearances in
the case of ring W1 and W2.
2. When parts are new the butts of W1 and W2 are each 0.8mm (0.032") wide.
3. Discard the rings and their sealing rings when the butts reduce to 0.12mm (0.005") each
or a total of 0.36mm (0.015") or less, and replace with a new pair.
4. The segments of the sealing ring have angle cut contact faces - there are no butt
clearances.
c) To Refit
1. Ensure that the correct relationship is maintained between the rings.

2. There are oil drain slots cast in the bottom of the housing. Should the housing need to
be removed it must be refitted with these slots (in the case of the inclined cylinders)
positioned lower-must. "TOP" is staggered on the housing.
3. Remove piston rod clamps.
4. Bar over the compressor a couple of turns to check for correct operation.
5. Refit the access covers to the cylinder distance piece.

11/12/07 Oil Scraper Gland - Remove and
Re-fit
VH21H3N
PET Compressor
JOB No: 10 - Suction and Delivery Valves - Remove and Re-fit
LIST OF CONSUMABLES
Grinding Paste A/R
Each valve is installed in an individual pocket. They are fitted with metal-to-metal contact (i.e.
no gasket material) to the seat face in the cylinders.
i. Isolate mains power. Lock all isolators in the ‘Off’ position and / or remove all
fuses. Display appropriate warning signs.
ii. Ensure that all pressurised compartments are vented down to atmospheric
pressure and that all pressure gauges read zero. Pressure venting must be
carried out as slowly as possible in order to prevent freezing of the valve or
possible personnel injury.
iii. Ensure that the final delivery pipework vent valve has had its plug removed and is
fully opened. Ensure that all pressure is dissipated and that the valve is left in an
open unplugged condition until all work is completed.
iv. Carefully open the vent valves on the third stage cylinder to check de-pressurising
v. Ensure that the compressor is isolated from the delivery system and that the
vi. Vent air pressure from the unloader system.
vii. Post signs instructing personnel that the machine MUST NOT be used.
a) To Remove
1. Carry out and complete all safety steps described above before starting this procedure
2. On each of the third stage valve covers, one standard fastener is replaced by a stud,
locknut, castle nut and split pin. This is fitted in order to remind service personnel that all
pressure must be vented before attempting any valve cage removal. Ensure that all
pressure is fully vented to atmosphere and that pressure gauges all read zero
before removing the split pin, castle nut and locknut from the valve cover stud.
3. Remove the securing bolts from the valve cover.
4. Remove the valve cover/cage complete with 'O' ring.
5. Remove the valve from its pocket (using a valve extraction tool where necessary).

11/12/07 Suction and Delivery Valves -
Remove and Re-fit
VH21H3N
PET Compressor
b) To Refit
CAUTION!
SERIOUS DAMAGE COULD RESULT FROM SUCTION VALVES
AND THEIR ASSOCIATED COMPONENTS, BEING FITTED IN
DELIVERY VALVE POCKETS OR VICE-VERSA. THEREFORE,
ENSURE VALVES ARE CORRECTLY IDENTIFIED WITH THEIR
POCKETS.
1. Ensure that there are no bruises or burrs on the valve seat or pocket seat. A light
grinding-in operation may be needed, it is important to ensure that no grinding paste
enters the cylinder and that all is clean after completion.
2. The diametric clearance between the valve seat and the seating in the cylinder is small,
therefore the valve has to be fitted very carefully to ensure that it fits squarely on to its
seat. It is essential that the valve is squarely fitted on its seat and metal to metal contact
established.
3. Check that 'O' rings are in good condition and that their associate grooves are clean
before final assembly of valve cover/cage. Renew if necessary.
4. Refit the valve cage and the valve cover.
5. Refit the cover securing bolts and tighten evenly and squarely to the correct torque
6. On third stage cylinder ensure that the locknut, castle-nut and split pin are correctly re-
fitted
CAUTION!
IT IS IMPORTANT AFTER FITTING VALVES (OR AFTER WORK
OF ANY KIND WHICH HAS BEEN DONE INSIDE THE
CYLINDERS) TO ENSURE THAT ALL IS CLEAR IN THE
CYLINDERS BY BARRING OVER THE CRANKSHAFT A FEW
REVOLUTIONS.
7. Once all work is complete, close all vent valves and re-fit any plugs that were removed
during the pressure venting procedure.

Remove and Re-fit
VH21H3N
PET Compressor
Illustration 5-9 : 1st and 2nd Stage Valves
‘O’-ring
Valve
Unloader
Actuator
Valve Cage
Valve Cover
Suction Valve
Delivery Valve
Illustration 5-10 : Stage 3 Valves
‘O’-ring
Valve
Unloader
Actuator
Valve Cage

Remove and Re-fit
VH21H3N
PET Compressor
JOB No: 11 - Suction and Delivery Valves - Overhaul

Valve Holding Tool 1
LIST OF CONSUMABLES
Gardner Denver Belliss & Morcom are able to offer a valve exchange service, whereby re-
furbished valves are supplied in exchange for valves returned by customers. The refurbished
valves supplied by Gardner Denver Belliss & Morcom are factory reconditioned and all parts
are guaranteed . Use of this service may be more cost effective than stripping and cleaning
valves on customers own site. Please contact Gardner Denver Belliss & Morcom service
department for details.
a) To Remove
1. Remove the suction delivery valve in accordance with JOB No: 10 -“Suction and
Delivery Valves - Remove and Re-fit” on page 5-29
b) To Inspect
CAUTION!
THE CORRECT HOLDING TOOL MUST BE USED WHEN
DISMANTLING AND ASSEMBLING VALVES. THE VALVES
THEMSELVES MUST NEVER BE GRIPPED IN A VICE.
1. Inspect the 'O' ring for each valve cover/cage. Renew if necessary.
2. Disassemble the valves.
3. There are locating pegs in all valve seats; these ensure correct relationship between
various components, except the valve coil springs.
4. Thoroughly clean all parts and examine for signs of fatigue or wear.
5. Check for distortion or damage to the sealing faces of valve seats, examine also the
guards.
6. Check for distortion, wear, cracks or breakage of valve plates.
7. Compare the height of displaced springs, with new spares, to determine any
deterioration in spring loading.
8. Replace any part, which is found to be defective.

Overhaul
VH21H3N
PET Compressor
c) To Overhaul
CAUTION!
CARE MUST BE TAKEN WHEN REASSEMBLING OVERHAULED
VALVE COMPONENTS. THE COMPONENTS MUST BE
ASSEMBLED CORRECTLY. AN INCORRECTLY ASSEMBLED
VALVE WILL QUICKLY DETERIORATE IN SERVICE AND
CONSEQUENTLY MAY DAMAGE OTHER PARTS OR AFFECT
THE COMPRESSOR PERFORMANCE. PARTICULAR CARE
MUST BE TAKEN WHEN ASSEMBLING VALVES TO ENSURE
THAT THE SPRINGS REMAIN CORRECTLY IN THEIR
LOCATIONS.
1. The valves have locating pins, which ensure that the various components are correctly
related radially. The pins are of differing diameters which ensures that the valve seat,
valve plate, valve damper plates, and valve guard are correctly fitted, one to the other.
2. If new locating pins are fitted to an old seat it is essential that they are of the correct
sizes and positioned exactly as on original valve seats, with correct standout height
above the valve seat top surface.
3. Lift Washers - when not of identical thickness - should be fitted with the thinner one next
to the valve seat (this thinner one is referred to as the lower lift washer).
4. Conical type springs are fitted with the large diameter end located in the holes in the
valve guard.
5. Torque the centre bolt nut to the correct value (see Chapter 1 - Technical Data and
Description ).

Overhaul
VH21H3N
PET Compressor
JOB No: 12 - Suction Valve Unloader Actuators - Remove and Refit
LIST OF CONSUMABLES
a) To Remove
1. Disconnect the control air pipe from the actuator. Place a cap on open ends.
2. Remove the fittings from the actuators and store carefully.
3. Slacken locknut and screw actuator out of top cover. Place the actuator onto a clean
work surface.
b) To Inspect
1. Check that the small vent hole in the side of the lower half case is clear (if this becomes
blocked then the diaphragm cannot deflect properly due to pressure build-up).
2. Under normal circumstances actuators give long and trouble free service. If there is
deterioration of any part, it is recommended that the complete actuator is replaced.
c) To Refit
1. Ensure that the suction valve is fitted correctly and that its securing cover is fully
tightened down squarely.
2. It is essential that the correct gap is present between the actuator and the valve,
otherwise the suction valve may not open or close fully.
3. Carefully screw the actuator (with its locknut screwed back) until the spindle just
contacts the valve unloader.
4. The unloader is spring loaded so take care to just contact it and NOT depress it.
5. Screw back the actuator about 1.5mm and pinch tighten the locknut.
6. Insert a hard wood dowel/rod through the control air connection hole in the top of the
actuator casing until it just touches the top of the diaphragm.
7. With the dowel/rod in position, mark it accurately in line with the actuator cover plate top.

11/12/07 Suction Valve Unloader Actuators -
Remove and Refit
VH21H3N
PET Compressor
8. Using the dowel/rod depress the actuator (against the action of the spindle return
spring) until it just contacts the unloader, but do not depress it.
9. While holding the dowel/rod in position, mark it accurately again in line with the actuator
cover plate top. Then release the dowel/rod (it will rise under the action of the actuator
spindle return spring).
10. Remove the dowel/rod and measure the distance between the marks. If it is NOT
between 1.4mm and 1.6mm then adjust the actuator position, by screwing it in or, out of
the cover plate, as required.
11. When the gap is set correctly, tighten the locknut to the correct torque.
12. When all the actuators on the compressor are correctly set, fit the end fittings to the
actuators; reconnect the control air pipework to the actuators and to the associated vent
vale and test the compressor for correct operation.

11/12/07 Suction Valve Unloader Actuators -
Remove and Refit
VH21H3N
PET Compressor
JOB No: 13 - Piston Rods - Remove and Re-fit
LIST OF CONSUMABLES
a) To Remove
1. Remove the cylinder top cover as described in Chapter 5 - Cylinder Top Covers -
Remove and Re-fit.
2. Remove the crosshead access cover and gasket from the crankcase.
3. Bar over the crankshaft to reveal the crosshead locknut and the piston rod securing pin.
4. Bend back the locking plate tab retaining the securing pin and remove the pin. Ensure
that the securing pin is removed before slackening the crosshead nut. Otherwise, if the
piston rod turns in the crosshead while the securing pin is in position, the pin will distort
making it extremely difficult to remove.
5. Mark on the crosshead two fine centre-punch dots (about 70 to 75mm apart). One on
the piston rods taper portion and the other on the crosshead. Then, set a pair of dividers
to the length between the dots and record this figure.
6. On 2nd/3rd Stage cylinder line. - Loosen and remove bolts holding the 3rd stage piston
assembly to the 2nd stage piston assembly. Lift the 3rd stage piston from the
compressor.
7. Slacken the crosshead locknut.
8. Unscrew the piston rod from the crosshead - the loosened locknut should be held by a
spanner to be unscrewed off the rod end simultaneously, and removed as the rod is
withdrawn.
9. Fit a lifting eye to the M12 tapping in the end of the piston rod. (In some cases, this
tapping may be plugged)
10. Using suitable lifting equipment, carefully withdraw the piston and rod assembly from
the cylinder.
11. If the packing gland is to be reused, great care must be taken as the threaded portion of
the rod is lifted through the packing gland. If possible fit the piston rod thread protector.
See illustration below.

11/12/07 Piston Rods - Remove and Re-fit
VH21H3N
PET Compressor
b) To Refit
Prior to refitting the piston rod, examine the rod. If it is found to be worn (evenly or tapered) or
scored then renew as necessary.
Illustration 5-11 : Fitting the Piston-rod thread guard (Bullet)
Nose
Collar
1. Fit the piston rod, using a piston rod thread guard cap, to pass through the packing
gland and scraper gland until it just enters the guide top.
2. As the piston rod thread guard emerges from the scraper box, remove the cap and fit
the crosshead locknut.
3. When refitting the rod, ensure that the centre-punch dots coincide at the correct
distance apart and check the alignment of the cruciform slot at the bottom of the rod to
the securing pin hole in the crosshead, before tightening the locknut on the crosshead.
4. 2nd/3rd stage Piston rod assembly : Re -fit the 3rd stage piston.
5. Ensure that the securing pin can pass through the piston rod foot (slot in line) and
tighten the locknut to the crosshead.
6. Check the piston bumping clearances as described in JOB No: 5 - Piston/Cylinder End
(Bumping) Clearances (page 5-17).
7. Turn the compressor over a number of times by hand to ensure satisfactory operation.

11/12/07 Piston Rods - Remove and Re-fit
VH21H3N
PET Compressor
JOB No: 14 - Oil Filter - Remove and Re-fit
LIST OF CONSUMABLES
a) To Remove
1. To open the filter body undo the bottom bolt (using a clean bucket to catch spilled oil),
the filter body and element draw off vertically downwards.
2. Discard the old element and clean out the body.
3. When replacing the assembly (with a new filter pack) care should be taken that the seal
ring gasket at the top and the washer at the bottom are in their correct positions. A new
seal ring gasket is supplied as part of the filter element spare.
4. There is a spring fitted internally onto the bolt - this is installed to hold the filter element
up against the top cover and so form the seal; it also provides the automatic safety filter
bypass (for use should the element become heavily fouled).
5. Before assembly of the filter body to its cover, fill the body with clean compressor
lubricating oil.

11/12/07 Oil Filter - Remove and Re-fit
VH21H3N
PET Compressor
JOB No: 15 - Oil Pressure Relief Valve - Adjustment
LIST OF CONSUMABLES
a) To Adjust
1. Remove the valve cap.

2. Slacken the locknut on the adjusting screw and adjust to obtain the required oil pressure
(screw IN to raise the pressure, screw OUT to decrease the pressure).
3. Tighten the locknut and refit the cap.
4. Normally adjustment is not necessary after initial setting by the manufacturer. If a fault
should occur and adjustment has no noticeable effect, the trouble could be a particle of
foreign matter trapped under the valve. Dismantling, cleaning and re-assembly is then
required (first noting the valve adjusting screw setting).

11/12/07 Oil Pressure Relief Valve -
Adjustment
VH21H3N
PET Compressor
JOB No: 16 - Lubricating Oil Pump and Drive - Inspect and Overhaul
LIST OF CONSUMABLES
a) To Overhaul
1. Disconnect all pipes connected to the oil pump.

2. Remove the cap screws securing the oil pump to bearing housing and carefully
withdraw the pump, together with the filter body attached, its drive coupling can then be
inspected.
3. Wear on the coupling is expected to be negligible but if excessive wear is present
investigate the cause, remove, and fit a new drive coupling.
4. When refitting the oil pump renew the gasket if the old one has deteriorated.
5. Prime the suction side of the pump with oil.
6. Refit the pipework to the oil pump.

11/12/07 Lubricating Oil Pump and Drive -
Inspect and Overhaul
VH21H3N
PET Compressor
JOB No: 17 - Intercooler - Inspection and Overhaul
LIST OF CONSUMABLES
a) To Inspect
1. The cooler MUST be removed completely in order for a complete examination to be

performed. Internal and external inspection, to check for fouling or damage, is annual.
This period will, however, vary depending on site conditions (being extended with good
clean water circulating).
b) To Overhaul
1. It is not expected that the inside (i.e., tube internals) will foul. Any untoward
accumulation of soft deposits at the tube entrance may be removed by blowing
backwards with compressed air, the cooler being off the compressor for this purpose.
2. If hard carbonaceous deposits have accumulated, specialist attention may be required.
3. Should the cooling water side become fouled then use a proprietary procedure as
recommended by local water treatment specialists - this to be compatible with the
materials of construction (see Chapter 1 - Technical Data and Description).
4. When refitting (after cleaning) all joints must be in good condition.

11/12/07 Intercooler - Inspection and
Overhaul
VH21H3N
PET Compressor
5.4 Lists of Tools
a) Commercially Available Tools List
The following is the recommended list of tools required to perform maintenance tasks on this
compressor:
Tool Supplementary Information

Standard tool box tools including:-
A range of open-jaw, ring, and socket
type spanners Various job locations
A set of hexagonal section Allen keys
(Metric)
Torque wrench Tightening range 0 to 1500 Nm
For removal and refitting crosshead gudgeon pin retaining
Circlip pliers
circlips.
M16 x 2.0 male thread for cylinder top cover lifting
Eyebolts
M12 x 1.75 (for piston rod lifting).
Fitters tools Feeler (thickness) gauges, standard sizes
Long-nosed pliers Thin ended, for removal of circlip from suction valve unloader
b) Specialist Service Tools List
Specialist service tools (which can be manufactured locally) or purchased direct from
Gardner Denver Belliss & Morcom, can be used to aid compressor maintenance work.
Tool Drg No Supplementary Information
Valve extractor DD594 (2nd & 3rd Stage)
Valve extractor DD622 (1st Stage)
Valve holding clamp DD816 -
Valve supporting details - Use of clamp DD816
Piston rod gland wear checking tool DD600
Tool for assembling piston rod packing gland DD938
Piston rod clamp DD579
Piston rod thread guard cap DD615

Overhaul
VH21H3N
PET Compressor
5.5 Waste Products

There are very few waste products associated with air compressors: old lubricating oil and oil
filter elements and condensate. On closed loop systems, coolant may also be considered.
a) Oil - After Oil Changes
When handling and disposing of sump oil after an oil change several important points need to
be followed:
1. Avoid contact with the skin and wash off any contamination immediately.
2. Dispose of old oil and filter elements in accordance with local regulations.
For further details contact your local oil company representative, or local government
department dealing with factory wastes. .
b) Coolant
Coolant from closed loop systems ie. water with anti-freeze added, should be disposed of in a
safe manner. For further advice contact the local Water Authority.

Overhaul
VH21H3N
PET Compressor
Chapter 6 - Spare Parts
Issue 0 6-1 Spare Parts

24/4/06
VH21H3N
PET Compressor
6.1 Spare Parts

This document provides information regarding the recommended spare parts policy for this
equipment. Information regarding recommended consumables and special tool requirements
are provided at the end of Chapter 5.
Items not identified as a spare can be found within the drawings and parts list for the
compressor. These items, under normal operating conditions, will last for the designed lifetime
of the equipment.
Fasteners used on this equipment, such as screws, nuts, washers, bolts and clips etc; have
not been included within the Spare Lists. For details regarding the fastener refer to the
Illustrated Parts List for this equipment.
WARNING!
ALWAYS USE THE SPECIFIED FASTENER. ON NO ACCOUNT
SHOULD A LOWER SPECIFICATION FASTENER BE USED.
6.2 Ordering Spares and Spares Stock

IMPORTANT - When ordering spare parts please quote the following details:
• Compressor Serial Number
• Compressor Type
• Description of Part required.
• Part Number (if available)
• Quantity required
We recommend that users of our compressors should hold in stock a complete set of spares.
The spares stock should be maintained at the original level, replacements being ordered in
good time to ensure availability when required. Parts must be kept in good order with
appropriate preservation precautions to meet the climatic conditions.
The quantities given within the lists are the recommended minimum holding.
For spare parts associated with the control console, drive system etc; reference should be
made to the spares information and recommendations provided with these items.
6.3 Spares List
Item Description Qty Part No.

1 Crankcase door gasket 2 PSB008-005
2 Main guide door gasket 2 PSB009-002
3 1st Stage top cover gasket 1 PSB008-001

24/4/06
VH21H3N
PET Compressor
Item Description Qty Part No.

4 1st Stage Air inlet/Outlet Gasket 2 PSB008-002
5 1st Stage Actuator 4 PSB028-045

6 1st Stage Valve Cage ‘O’ ring - Top 12 MB133-49
7 1st Stage Valve Cage ‘O’ ring - Side 12 MB133-48
8 1st Stage piston rings (2 rings) 1 set 2-28-764-03
9 1st Stage rider ring 1 2-28-764-04
10 Piston Nut PSB002-004
11 1st Stage piston rod PKG WRG parts 1 set
12 2nd Stage top cover/ 3rd Stage Cylinder gasket 1 2-01-842-02
13 2nd Stage Inlet Gasket 1 2-01-842-03

14 2nd Stage Outlet Gasket 1 2-01-842-04
15 2nd Stage valve cage 'O' ring 4 MB133-48
16 2nd Stage valve cover 'O' ring 4 MB133-49
17 3rd Stage Suction valve cage 'O' ring 2 MB133-48
18 2nd Stage Piston Rod Nut 1 PSB002-004

19 3rd Stage Inlet/Outlet Gasket 2 2-01-843-02
20 2nd Stage Piston Ring 3 2-28-833-04
21 2nd Stage Bearer Ring 1 2-28-833-05
22 3rd Stage Piston Ring 6 2-28-833-06
23 3rd Stage Bearer Ring 1 2-28-833-07
24 2nd Stage Unloader Actuator 2 PSB028-017
25 3rd Stage Unloader Actuator 1 PSB028-045
26 2nd Stage piston rod PKG WRG parts 1 set
27 Piston rod scraper wearing parts 3 sets

28 Bottom end bearings 2 pairs PSB014-002
29 Cross head nut 2 PSB002-009
30 Oil suction strainer 1 PSB025-001
31 Oil delivery filter - C/W 'O' ring 1 CC1004009
32 Air inlet filter element 1

24/4/06
VH21H3N
PET Compressor
6.4 Drawings
The following drawings contain all items used in the construction of the compressor.
Table 6-1: Drawings

Drawing Ref Description
General Arrangement
2-150-009 Lower Parts Assembly
2-150-011 1st Stage Cylinder Assembly

2-150-012 2nd/3rd Stage Cylinder Assembly
2-46-1253 Pressure Gauge and Unloader pipework

2-71-801 2nd Stage Intercooler
2-71-766 1st Stage Pipework
2-72-690 Aftercooler Assembly
2-45-2520 Cooling Water Pipework

24/4/06
1 2 3 4 5 6 7 8
ITEM QTY PART NUMBER DESCRIPTION

1 1 2-71-801-01 DELIVERY PIPE
2 1 2-71-801-02 VH21H3N 2ND STAGE HEAT EXCHANGER
3 1 2-71-801-03 SEPARATOR
A 4 1 2-71-801-04 INLET PIPE A
5 3 2-71-801-05 RING GASKET
6 36 MB021-11 M20x2.5 HEXAGON NUT
7 33 MB011-22 M20x2.5x100 LONG BOLT
8 1 PSB013-074 DIRECT SPRING LOADED SAFETY VALVE
9 2 2-136-001 TEMPERATURE GAUGE
10 3 MB011-24 M20x2.5x110 LONG BOLT
11 1 2-71-801-06 SUPPORT BRACKET
B B
4 5
C C
11
8
7 6
6 10
9
9
D D
3 5
5 1
7 6 2 6 7
SEE DRAIN TRAP
ASSEMBLY DRG
E E
TIGHTENING TORQUES
DRY THREADS
DELIVERY PIPE TO COOLER M16 98-108 Nm
INLET PIPE TO COOLER M16 98-108 Nm
ECN NO. DATE WEIGHT: CHEQUERS BRIDGE

UNLESS OTHERWISE STATED ISS. ECN NO. DATE DRN. ISS. DRN. 270 Kg GLOUCESTER GL1 4LL
F DIMENSIONS IN MM A 1ST ISS 8-4-00 JMW MATERIAL: ENGLAND F
MACHINE WHERE SHOWN TEL: ++44(0)1452 338338
REMOVE SHARP EDGES
B 20767 8-7-00 DK
FAX: ++44(0)1452 338307
FORM; GDB&M_A2-REV.1
CHAMFER TH'DS AT 90-120~ INC C 20819 14-8-00 DK ASSEMBLY Website: www.belliss.com SHEET 1 OF 1
TO DEPTH OF TH'D CONTRACT/QUOTE NO.
D 1035120 20-3-07 MAS TITLE:
APP'D BY:
APP'D BY:
MACHINING TOLERANCE `0.25

CASTING TOLERANCE `2% FINISH TO B&M ST'D ES005
ANGLE TOLERANCE `0.5~ SECTION: 2ND STAGE INTERCOOLER ASSY DRG. NO.
2-71-801
IF IN DOUBT ASK COLOUR:
10 20 30 40 50 60 70 80 90 100
5
A2 1 2 3
SCALE = MM WHEN PRINTED AT A2 SIZE 420 x 297 MM
4 6 7 8
1 2 3 4 5 6 7 8

A A
2 1 2-71-766-02 VH21H3N 1ST STAGE HEAT EXCHANGER
3 1 2-71-766-03 INLET PIPE
4 16 MB013-13 M24x80 LONG BOLT
5 16 MB021-13 M24x3 HEXAGON NUT
6 2 2-01-842-03 INLET GASKET
8 1 PSB013-073 DIRECT SPRING LOADED SAFETY VALVE
9 2 2-136-001 TEMPERATURE GAUGE
B B
C C
4 5 2 6
3
D D
WATER OUTLET
9
WATER INLET
6
E 5 4 9 E
TO DRAIN TRAP ASSEMBLY
TIGHTENING TORQUES
DRY THREADS
ECN NO. DATE WEIGHT: CHEQUERS BRIDGE

UNLESS OTHERWISE STATED ISS. ECN NO. DATE DRN. ISS. DRN. 220 Kg GLOUCESTER GL1 4LL
F DIMENSIONS IN MM A 1ST ISS 27-8-98 DTP MATERIAL: ENGLAND F
REMOVE SHARP EDGES
B 20343 3-9-99 ME
FAX: ++44(0)1452 338307
CHAMFER TH'DS AT 90-120~ INC C 20672 26-4-00 ME ASSEMBLY Website: www.belliss.com SHEET 1 OF 1
D 21218 26-6-01 DTP TITLE:
APP'D BY:
APP'D BY:

CASTING TOLERANCE `2% E 1035120 20-3-07 MAS FINISH TO B&M ST'D ES005
ANGLE TOLERANCE `0.5~ SECTION: 1ST STAGE INTERSTAGE PIPEWORK DRG. NO.
2-71-766
IF IN DOUBT ASK COLOUR:
10 20 30 40 50 60 70 80 90 100
5
A2 1 2 3
4 6 7 8
1 2 3 4 5 6 7 8
2 1 2-72-688-02 VH21H3N AFTERCOOLER
3 1 2-72-690-02 AFTERCOOLER PIPE
4 26 MCB16-110Z M16x2x110 LONG BOLT
A TIGHTENING TORQUES 5 34 MB021-09 M16x2 HEXAGON NUT A
DRY THREADS 6 1 PSB013-075 RELIEF VALVE
7 1 MB120-01 LOW PRESSURE COCK
8 1 MB118-08 1/2" BSP BRASS PLUG
9 1 MB118-04 1/4" BSP BRASS PLUG
10 1 2-72-690-03 BRACKET
11 2 MB021-13 M24x3 HEXAGON NUT
12 2 MB013-24 M24x130 LONG SETSCREW
13 2 2-72-688-06 INTERCOOLER GASKET
14 2 MB084-24 M16x120 LONG STUD
B 15 1 PSB012-015 TEMPERATURE SWITCH 1/2"BSP SET 65 DEG C
B
1 16 2 2-136-001 TEMPERATURE GAUGE 0-200 DEG C
8 17 4 MCB16/120Z M16x2x120 LONG BOLT
5 4 18 1 MB041-11 COPPER WASHER 21 I/D X 40 O/D X 3 THK
19 1 CC1032499 3rd STAGE VENT ASSEMBLY (1/2" CONNECTION)
7 6
C C
5 4
16
13
10
D D
5
16 12 11
13
14
15 18 5 17 5
19
3
E E
9
TO DRAIN WEIGHT: CHEQUERS BRIDGE

TRAP ASSEMBLY UNLESS OTHERWISE STATED ISS. ECN NO. DATE DRN. ISS. ECN NO. DATE DRN. 164 Kg GLOUCESTER GL1 4LL
F DIMENSIONS IN MM A 1ST ISS 27-8-98 DTP H 21218 26-6-01 DTP MATERIAL: ENGLAND F
REMOVE SHARP EDGES
B 20013 29-1-99 DTP J 21878 2-4-03 ME
FAX: ++44(0)1452 338307
CHAMFER TH'DS AT 90-120~ INC C 20180 29-3-99 DTP K 1025895 27-5-05 MAS ASSEMBLY Website: www.belliss.com SHEET 1 OF 1
D 20343 3-9-99 ME L 1035385 29-3-07 MAS TITLE:
APP'D BY:
APP'D BY:

CASTING TOLERANCE `2% E 20446 11-11-99 MTP M 1037557 07-9-07 A.W. FINISH TO B&M ST'D ES005
ANGLE TOLERANCE `0.5~ F 20672 15-5-00 ME SECTION:
AFTERCOOLER ASSEMBLY DRG. NO.
IF IN DOUBT ASK G 21026 6-2-01 ME COLOUR: VH21H3N 2-72-690
10 20 30 40 50 60 70 80 90 100
5 7
A2 1 2 3
4 6 8

Section 1. Compressor VH21H3N PDF

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Section 1. Compressor VH21H3N PDF

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INSTALLATION, OPERATION & MAINTENANCE

How to Use this Instruction Manual

THIS PICTOGRAM MARKS IMPORTANT NOTES, WHICH

Address : Gardner Denver Ltd

Comments and Suggestions

Chapter 2 - Safety Information

Chapter 3 - Installation and Commissioning

Chapter 4 - Operating Instructions

Chapter 5 - Compressor Maintenance

JOB No: 7 - PACKING ASSEMBLY - OVERHAUL . . . . . . . . . 5-23

Chapter 6 - Spare Parts

Chapter 1 - Technical Data and Description

Issue 0 1-1 Technical Data and Description

1.1 Data and Compressor Description

1 - Standards and Legislation

Issue 0 1-2 Technical Data and Description

1.2 Technical Data

Table 1-1: Operating Data

Inlet Pressure Atmospheric

Cylinder Type Double Acting - Non Lubricated

Safety Valve Settings

Oil Pressure * 3.0 - 4.8 bar.g 43.5 - 69.6 lb/in2

Issue 0 1-3 Technical Data and Description

Table 1-1: Operating Data (Continued)

Issue 0 1-4 Technical Data and Description

Piston Data Metric Imperial

Piston Stroke 165.10 mm 6.5 in

Stage 1 Cylinder Line

Radial Thickness 19.99 - 20.09 mm 0.787 - 0.791 in

Piston Top to Top Cover 2.89 - 3.31 mm 0.114 - 0.130 in

Stage 2 Cylinder Line

Diametrical Clearance - 0.191

Radial Thickness 11.67 - 11.77 mm 0.459 - 0.463 in

Issue 0 1-5 Technical Data and Description

Table 1-2: Piston and Cylinder Data (Continued)

Piston Top to Top Cover N/A mm N/A in

Stage 3 Cylinder Line

Issue 0 1-6 Technical Data and Description

Table 1-2: Piston and Cylinder Data (Continued)

Piston Top to Top Cover 1.80 - 2.64 mm 0.071 - 0.104 in

d) Crankcase Components Clearances

Connecting Rod Bottom

Connecting Rod Top End

Crosshead to Main Guide

Table 1-4: Protection device settings

Issue 0 1-7 Technical Data and Description

e) Tightening Torques (Dry Threads)

Table 1-6: Component tightening Torques

Issue 0 1-8 Technical Data and Description

Table 1-6: Component tightening Torques (Continued)

1.3 Technical Description of the Compressor

a) Purpose of the Equipment

Issue 0 1-9 Technical Data and Description

Illustration 1-1 : External View of VH21H3N Compressor

3rd Stage Cylinder

Main Guide Access

Issue 0 1 - 10 Technical Data and Description

d) Crankcase and Lower Motion Work

Issue 0 1 - 11 Technical Data and Description

e) Cylinders, Pistons and Piston Rod Packings

2 - Pistons and Rings

3 - Piston Rods and Packings

Issue 0 1 - 12 Technical Data and Description