WP241 DUALAIR COMPRESSORS

Subject TABLE OF CONTENTS Page

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

M A I N T E N A N C E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 3Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3DrainingTank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Filter Cartridge (at PRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Belts (SeeFig.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Wiring Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Operational Check. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Wrong Oil Pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Oil Pressure Adjustment (See Fig. 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7

Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Noisy Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Noisy Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Noise Not Locatable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chart 1 -Motor Won’t Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Chart 2-Circuit Breaker Trips (Fuse Opens), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Chart 3-Won’t Pump Air-Runs, but Tank Shows No Pressure Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chart 4 -Won’t Pump Air-Builds Up Slowly, or Not Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chart S-Won’t Pump Air-Pump Slows, Stalls, or Trips Circuit Breaker (Fuse Opens) . . . . . . . . . . . . . . . . . . . 13

Excessive Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pump Removal and Replacement . . . . . . . . . .Oil Pump Replacement. . . . . . . . . . . . . . . . .Belt Replacement . . . . . . . . . . . . . . . . . . . .Motor Replacement. . . . . . . . . . . . . . . . . . .Intake and Exhaust Valves, Unloader . . . . . . .Pressure Regulating Valve (PRV) Station . . . . .

. . . . . .

....... . . . . . . . . . . . . . . . . . . . . . . . . 14

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Rev. 4-80

GENERAL

This sheet contains maintenance and repair informa-tion for the WP241 series air compressors. The WP241Dual Air Compressor has two electric motor-driven pumpsmounted on a common storage tank, allowing automaticalternating operation with standby capability.

SPECIFB IONS

PRESSURE RANGE: Cut-in pressure-70 lb/in2 (483kPa), Cut-out pressure -90 lb/in2 (621 kPa).

MAXIMUM AMBIENT TEMPERATURE: 104 F (57 C).

TANK CAPACITY: 30, 80, or 200 gallons (114,303, or757 R).

Table 1. WP241 Dual Air Compressor Specifications.-~

Compressor WP241 Y WP241B WP241C WP241D WP241E WP241F WP241G WP241H W P 2 4 1 J

No. of Cylinders 11 1 1 2 2 2 2 2 2

RPM Compressor 500 410 460 480 460 400 570 550 61 0~-

Displacement ft3/min (l/min) 1 1.6 (45) 2.9 0 (82) 4.7 (13.3) 5.4 (153) 5.9 (269) 13.3 (377) 16.0 (453) 24.3 (688) 40.0 (1l33)

Delivery ft3/min. (l/min)at 70 to 90 lb/in2 1.1 (31) 1.9 (54) 3.3 (93) 3.8 (108) 5.9 (167) 8.6 (144 12.6 (357) 19.3 (547) 30.0 (849)

(483 to 621 kPa) One unit only

T a n k Size Gal (l) 30 (114) 80 (303) 80 (303) 80 (303) 80 (303) 80 (303) 80 (303) 700 (757) 200 (757)

Intake Size NPT-Compressor 1/4 3/4 3/4 1/2 3/4 1-1/4 1 1-1/2 2

Outlet Size-NPT-Compressor 1/4 3/4 3/4 1/2 3/4 1-1/4 3/4 1-1/4 1 - 1 / 4___-

Flywheel O.D. (in.) 10 14 14 12 14 16 16 19.5 19.5 -

Motor Pulley Pitch Dia. (in.) 2.8 3.2 3.6 3.2 3.6 3.6 5.1 6.0 6.6

Safety Valve-Receiver-NPT 1 1/4 1/4 1/4 1/4 1/4 1/2 1/2 1/2 1/2

Crankcase Oil Capacity 4 oz (118 ml) 28 oz. (828 ml) 28 oz (828 ml) 22 oz (651 ml) 48 oz (1.4l) 2 qt (1.4l) 2 qt (1.9l) 6 qt (5.7l) 6 qt (5.7l)

Lubrication System Splash Pressure Pump

WP241Y

1/3 (0.25)

115/60/1

-48

WP241B

1/2 (0 .37)

208/60/3/60/3

-56

WP241C

3/4 (0.56)

230/60/3

-56

WP241D

1 (0.75)

460/60/3

-143T

WP241E WP241F WP241G WP241H WP241 J

1 - 1 / 4 ( 1 . 1 2 ) 2 (1.49) 3 (2.24) 5 (3.73) 7-1/2 (5.60)

208/60/3 230/60/3 460/60/3 460/60/3 460/60/3

-145T -145T -182P -184T t -213T

APPLICATION

The WP241 Dual Air Compressors are used wherecontinual operation is a necessity. The motors are inter- maintenance, or be unable to maintain minimum storageconnected to operate on alternate cycles with standby tank pressure, the other motor provides backup by start-capability. Should one motor fail, be shut down for ing automatically.

OPERATION

Air is drawn through the intake filter of the operatingmotor-pump unit(s), compressed, and stored in the tank.As the control system consumes air, the tank pressuredrops. When tank pressure drops to 70 lb/in2 (480 kPa),

the motor energizes operating the compressor pump,which restores tank pressure to 90 lb/in2 (620 kPa). Whentank pressure increases to 90 lb/in2 (620 kPa), a pressureswitch stops the motor.

75-7268 2

MAINTENANCE SCHEDULE

WEEKLY

1. Check oil level and pressure on 1 hp (0.75 kW) andlarger compressors. See LUBRICATION paragraph.

2. Drain water from tank or check automatic drainoperation. See DRAINING TANK paragraph.

3. Check tank and pressure relief valve (prv) pressure.See PRESSURES paragraph.

4. Observe operation to confirm that pumps build up tocut-off pressure and shut off. See OPERATIONALCHECK paragraph.

EVERY THREE MONTHS

1. Change oil. See LUBRICATION paragraph.

2. Check intake filters. See AIR INTAKE FILTER para-graph.

3. Drain water from tank and filter bowls. See DRAIN-ING TANK paragraph.

4. Check tension and condition of belts. See BELTSparagraph.

5. Check sequential operation. See OPERATIONALCHECK paragraph.

6. Check safety relief valves. See SAFETY RELIEFVALVES paragraph.

7. Check filter cartridge on 7-l/2 hp (5.6 kW) only. SeeFILTER CARTRIDGE paragraph.

EVERY YEAR

1. *Change intake filters. See AIR INTAKE FILTERparagraph.

2. *Change prv filter on 7-l/2 hp (5.6 kW) only. SeeFILTER CARTRIDGE paragraph,

3. Service motors. See LUBRICATION paragraph.

*Dirty operating environment may require changing theseitems more often. The three-month checks will uncoverany need for more frequent replacement.

LUBRICATION

Quincy units use splash lubrication on the 1/3 to 3/4hp (0.25 to 0.56 kW) units and pressurized lubricationon 1 hp to 7-l/2 hp (0.75 to 5.6 kW) units, Stop bothpumps, remove and wipe off dipsticks; reinsert dipsticks;remove again and read. If necessary, add oil through dip-stick port. Use oil in accordance with Table 1 . A highquality, nondetergent automotive oil is satisfactory(Table 2).

On 1-hp (0.75 kW) units and larger, in addition tochecking oil level, check the oil pressure gage. Gage read-ing should be in the 10 to 20 lb/in2 (70 to 140 kPa)range. Recommended operating pressure is 15 lb/in2(100 kPa).

To change oil, stop both units.

WARNING

Personal injury could result from starting a unitnot containing oil.

Remove the drain plug and dipstick and allow oil todrain completely. Ordinarily, a crankcase need not beflushed. If flushing seems necessary, use a nonflammablesolvent (available at most auto parts stores). Replaceplug and refill according to Table 2. DO NOT OVER-FILL! Overfilling causes excessive oil consumption andcontamination of the compressed air.

Lubricate the motor annually in accordance withinstruction on nameplate.

Table 2. Compressor Oil Requirements.

3 75-7268

To drain tank, open drain cock, located in the middleof the tank at one end. Allow a few seconds to purge thetank of water. Weekly draining is usually the minimumrequirement.

NOTE. The frequency of draining depends on climaticconditions. In humid climates, daily drainingmay be necessary.

Consider adding the Honeywell AK3485 automaticdrain kit.

Visually check the air intake filter on l/3- to 2-hp(0.25 to 1.49 kW) compressors for build-up of foreignmaterial on a routine basis. A dirty filter causes excessiveoil consumption, replace it.

The 3-hp (2.24 kW) and larger units use the QuincyAir Maze filter silencer, which is checked for dirt byremoving it from the unit and holding a strong lightagainst the intake openings. Light should be visible whenobserving from the inside of the filter. ash the filterin nonflammable solvent or in warm, soapy water.

Check filter element condition by comparing tankpressure to line pressure downstream from filter. If onedoesn’t exist, a gage tap may have to be installed in theline to read the pressure. The pressure difference shouldnot exceed 15 lb/in2 (100 kPa) at any time. Filter ele-ment should be replaced if the difference in pressure isapproaching this limit. Subtract the line pressure readingfrom the tank pressure. The difference should not exceed15 lb/in2 (100 kPa).

Allowing system pressure to drop to zero duringreplacement of element or gage tap installationwill cause all actuators in the system to assume

stem drawings fo r

To change a filter in the 7-l/2 hp (5.6 kto Fig. 1. Shut off air to filter at point (A) and bleeddown housing by manually operating drain trap (B).Remove wing nut and clamp ring (C) from housing andremove housing and automatic drain. Remove knurlednut at bottom of filter and replace filter. Reassemble,taking care that O-ring seal on bottom side of cover hasnot been disturbed. Turn on air slowly, checking forleaks.

6275

-1/2 HP (5.60 kW)Fig. 1 . Changing Filter Cartridge on 7Units .

Safety relief valves are factory set to approximately15 lb/in2 (100 kPa) higher than the rated pressure of thecompressor. Check each safety relief valve by pulling onthe ring to unseat it. Replace o r repair malfunctioning

valves immediately. Safety relief’ valves are located nextto the pressure switch or on the tank.

.

Hand pressure should depress the belt about 1/2 inch(13 mm). Tighten the belt just enough to prevent slippage.Adjust tension by loosening the motor hold-down bolts,moving the motor until tension is correct, then retightenthe bolts. Insure that belt and pulleys are aligned. Replaceworn or frayed belts.

HAND PRESSURP U M P 1/2” (13mm) APPROXIMATEF L Y W H E E L

Fig. 2. Checking Belt Tension.

4 7.5-7268

II5VAC 6 0 H Z

PRESSURES

During weekly checks, verify that the tank pressure isin the 70 to 90 lb/in2 (480 to 620 kPa) range and eachprv pressure is at the proper setting.

W I R I N G OPTiONS

Dual Compressors usually have automatic alternationbetween pumps after each pump cycle, and with auto-matic backup. See wiring options shown in Fig. 3,4 and

* S E T P S - 2 5-10 lb/in*(35-70 kPdBELOWCUT-IN PRESSURE

6278- 1

Fig. 4. Automatic Alternation with Automatic Backup.For Single-Phase Internally Protected MotorsOdy .

F U S E S . F U S E D DISCONNECT, OR CIRCUIT BREAKERI+ I F SPiClFlED

----a - - - - -

- - - 0 - - - - -

__----

r-PRESSURE SWITCHES 7

: ji

II

I

i - - -r-- M 2 1

I *I Qs /

3

C O M P# I

L-4 I TI ’--I*

I L 2

I L - - - - & ’L-------i C O M P

MOTOR*2

STARTER6277-l

Fig. 3. Automatic Alternation with Automatic Backup. Three-Phase Motor with Low Voltage Control.

75-7268 5

j+.- 115VAC 6 0 H Z -1

r----7

PRESSURESWITCH

I

ALTERNATOR I COMP+rl

1 S W I T C H I f - - - - - - - _ - i - --L--L-.

PRESSURESWITCH

S T A R T E R

COMP*2

*SET PS-2 AND PS-3 TO OPERATE IN SEQUENCE, ABOUT 5-10 LB/IN2 (35-70 kPa)BELOW CUT-IN PRESSURE POINT OF PSl.

6279-l

Fig. 5. Automatic Alternation with Backup and 11 SV Isolated Control of Three-Phase Motors.

OPERATIONAL CHECK

It is sufficient to confirm that both compressor pumpshave an off cycle and are not running continuously.Switch over the manual alternation system or bleed airfrom tank on automatic alternation system to confirmstartup and off cycle of both pumps.

Measure the cut-in pressure, pump-up time, cut-outpressure, and off time under normal operating conditions.Pump-up time should be below 50 percent operation(less on time than off time) and operate between 70 to90 lb/in2 (480 to 620 kPa) pressure. Check operation ofeach pump using manual switch over if necessary.

Record these figures for reference (a card attached tothe unit is handy). Decreasing off periods (with no changein pressure range) indicate an increase in air consumptionwith an increasing pump-up time. This could be due to

75-7268 6

added devices or leaks. Increasing pump-up time with nochange in pressure range or off time indicates wear in thecompressor pump and may warrant closer observation asit is usually followed by an increase in oil consumption.

Check backup operation by operating the safety reliefvalve (see SAFETY RELIEF VALVE paragraph). The

second pump should cut in after the tank pressure hasdropped 5 to 10 lb/in2 (35 to 70 kPa) below cut-inpressure for the first unit.

If wear is suspected, check the dead-ended pump-uptime (pumping up tank with the system off) against thevalue given in Table 3. If this time differs from the tableby more than 10 percent, troubleshoot according toinstructions given under WON’T PUMP AIR paragraph,and take proper action.

TROUBLESHOOTING

This section aids isolation of most common problemsand pinpoints causes. Notify Honeywell ApplicationsEngineering (Arlington Heights) of any other problemsfrequently encountered.

WRONG OIL PRESSUREIHP (0.75 kw) AND UP

Oil pressure in the 10 to 20 lb/in2 (70 to 140 kPa)range is normal. The recommended operating pressure is15 lb/in2 (100 kPa). There should be no pressure duringthe off cycle.

OIL PRESSURE ADJUSTMENT(See Fig. 6)

Check oil level before adjusting pressure The oilpressure is regulated by a spring-loaded ball mounted inthe bearing carrier on the same side as the dipstick,Loosen the adjustment lock nut before making anyadjustment. Turn the pressure adjusting screw slowlyclockwise (pressure increases) until the oil gage registersapproximately 15 lb/in2 (100 kPa). After adjustment,tighten adjustment screw lock nut.

DIPSTICK 01 L PRESSURE ROTATION OF FLYWHEEL

xE -)~~~~i%JR:fii’%TS

/ IDRAIN PLUG OIL INTAKE FILTER (I TO 3 HP ONLY)

M A Y B E R E M O V E D F O R C L E A N I N GAND INSPECTION OF CRANKCASEA C C U M U L A T I O N

6280

Fig. 6. Crankcase End View of l-HP (0.75 kW) Model.

If oil pressure is low, check oil pump(s) and pressuregage(s) by unscrewing the pressure gage(s) slowly untiloil seeps out around the threads during compressor(s)operation. This indicates that oil pressure is reaching thesystem and the pressure gage(s). The pumps require oilpressure to operate intake valve unloaders and for lubri-cation. Lack of pumping ability indicates possible loss ofoil pressure. If oil appears at the threads of the gage andthe oil pressure gage indicates no pressure, replace the oilpressure gage. No oil appearing at the threads of the oilgage indicates possible oil pump failure (see OIL PUMPREPLACEMENT paragraph in the REPAIR section),

NOTE: A clogged oil intake filter will cause restrictedoil flow in the loop system and no air pressurein the system. Clean or replace filter as neces-sary.

In cases of low (not zero) pressure, the cause may beexcessive wear in the pumping unit or a gage not in calibra-tion. Check the pump-up time against Table 3 and listenfor unusual knocks indicating worn bearings. If pump uptime is normal and no unusual noises are detected, recali-brate or replace the gage.

Table 3. Pump Up Time in Min:Sec.

WP241H 8:45 2:lS

WP241J 5:45 1:30

OIL LEAKS

Oil leaks usually occur around screws and gaskets.These are normally corrected by tightening screws orreplacing gaskets.

If unable to locate the source of the leak, clean theunit as much as possible and sprinkle the suspected areawith talcum powder (avoid getting powder into intake).After several hours, check powder to locate leak.

75-7268

Excessive oil on the after cooler pipe or compressorhead usually indicates air leakage. Locate air leaks withsoap solution while the compressor is operating. Whilethe compressor is in the off cycle, check the unloadersunder pressure.

XCESSSV NSUAA

Excessive oil consumption is a difficult problem.Before repair, take the following steps:

a. Confirm the Complaint-Oil at the tank drain doesnot necessarily indicate high oil consumption.Table 4 shows acceptable oil consumption in termsof fill amount and time between refills.

Oil capacity in crankcase between high and low

Days running time between high and low dipsticklevels, based on three oz oil per 100,00C1 ft3 air used(31 ml oil per Ml air used) and 50 percent maxi-mum duty cycle. Does not allow for spillage orleakage.

b. Make certain proper grade of nondetergent oil isbeing used (see Table 2) and compressors are notbeing overfilled. Overfilling always causes high oilconsumption. Oil level should never be above thehigh mark on the dipstick.

c. Check for leaks.

d. Check intake filter/piping and crankcase breathervalve(s) for cleanliness and obstruction.

e. Check for excessive oil pressure or high percentoperation (see LUBRICATION and PRESSUREparagraphs in MAINTENANCE section). If, afterperforming the above, a unit is still considered anoil consumer with no apparent external cause, then:

f. Check pump-up and cycle pressures against thevalues in Table 3. Differences greater than 10 per-cent indicate worn parts (see WON’T PUMP AIRparagraph).

g. Remove valves and examine piston top for oil. Oilwetting is acceptable, but an accumulation of oilindicates a defective pump.

The most common reason for a noisy pump is a looseflywheel or motor pulley. Check for these first, thencheck:

Oil pressure-If low, check pump as described inWRONG OIL PRESSURE paragraph. Lack of oilpressure may have caused bearing damage.

Valve assemblies -Make certain they are tight.

Wrist pin OY connecting rod bearings-Stop pumpand remove belts. Using the flywheel, rotate pumpback and forth about two inches (5 1 mm). If knockis heard, a bad wrist pin or connecting rod bushingprobably exists. Inspect the rod bushings byremoving side plate and rod caps or remove headand observe piston while rocking flywheel. Pistonshould follow movement without play (except attop and bottom dead center where piston appearsto hesitate). Inspect cylinder and head for carbonbuild-up.

Bad main bearings-Check for end play by attempt-ing to move flywheel in different directions. Listenand feel for any play. End play on the crankshaftis usually eliminated by removing one of the shimsbeneath the bearing housing adjustment plate. Aslight drag, when turned by hand, is proper,

Check for a loose motor pulley. A low-pitch growl isan indication of low voltage.

If noise is slight, lubricate motor in accordance withinstructions on nameplate. Noise should disappear somotor runs properly. Watch for dry bearings, as theseshorten motor life. To check bearings, stop motor,remove belt and check for side play in motor shaft. Turnmotor by hand. Any side play or noise is an indicationof bad bearings. If bearings are bad, replace motor. Endplay (movement or motor shaft in and out) is commonin this type of motor and is not an indication of wear.

Use a large screwdriver or similar implement. Placethe point end against suspected areas and the other againstthe ear. Listen for abnormalities.

75-7268 8

r‘--p WARNING ~1 valve. (Larger units do not have a check valve.) Dis-Before using listening rod near spinning flywheel, assemble the check valve and inspect. If cleaning does

belts, etc, determine if it is long enough to avoid not stop the noise, replace check valve.

moving parts. I Another noise which is not easily traceable is aIn the l/2 and l/3 hp (0.37 and 0.25 kW) a noise vibrating guard. Check the belt guard by applying hand

which cannot be traced to the pump is usually the check pressure to outside surfaces at different points.

CHART l-MOTOR WON’T START

CHECK CIRCUITBREAKER OR FUSE

CHECK PRESSURESWITCH,

TRACE WIRINGTO FIND FAULT

DISCONNECT POWER,COOL MOTOR

RECONNECT POWER

NO*

+ R E P L A C EMOTOR

c A

REPLACE CAPACITOR,STARTING SWITCH,

OR MOTOR I

*ON l-HP (0.75 kW) OR SMALLER MOTORS, THERMAL OVERLOAD PROTECTORS MAY SHUTMOTOR OFF AFTER A SHORT PERIOD OF TIME. I1033

9 75-7268

C H A R T 2 - C I R C U I T B R E A K E R T R I P S ( F U S E O P E N S )

START0

1 YES

S E ETROUBLESHOOTING

CHART 5

Y E S

, -\S E E

TROUBLESHOOTING 4N O

PROPERLYCHART 1

4 .

DISCONNECT POWER,REINSTALL BELTS,

PLUG INTAKE (BY HAND),RECONNECT POWER

S E ETROUBLESHOOTING

t C H A R T 5 A

Y E S

*GROWL IS LOW VOLTAGE CLUE.I I034

75-7268 1 0

CHART 3-WON’T PUMP AIR

- RUNS, BUT TANK SHOWS NO PRESSURE BUILD-UP

START9ISOLATE BUILDING

Al R SUPPLY

N O

TURN UNIT ON REPLACE

+ LOOK FOR AIR LEAKBETWEEN PUMP AND

OUTLET VALVE*

j YES YES4DISASSEMBLEAND INSPECT

VALVESc

,REPAIR AS NEEDED,

SEE “PARTS LIST”

*CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, ETC.11035

11 7.5-7268

CHART4-BUILDS UP SLOWLY, OR NOT COMPLETE

,ISOLATE

BUILDING AIRSUPPLY

. *

1 UP IIM

1/3 & l/2 H P(0 .25 / 0.37 kW)

REMOVE DlSCtHARGETUBE, HAND BLOCK

n I- CI _I.

R E P A I R 1

3/4 HP (0.56 kW) & UP

1

LOOK FOR AIRLEAK BETWEEN

PUMP ANDOUTLET VALVE*

*CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, E TC.

ZIPPER LINEI\ I HM~ VALVES

I

SHUT OFF UNIT,

DISCONNECT COPPER LINEL REMOVE COVER BOLTS &

COVER (TAP WITH BLUNTINSTRUMENT TO LOOSEN) 1

SLOWLY DEPRESS PISTONTO FEEL RESISTANCE OF

L RETURN SPRING ANDPISTON CONTACTING VALVE

REMOVE PISTONCUP AND CLEANLUNDERNEATH

N O

NORMALOPERATION*

N OIN INTAKE

VALVES, INSPECTPISTON TOP AND

REPAI R AS NEEDED,

SEE “PARTS LIST”

11036

75-7268 1 2

CHART 5-WON’T PUMP AIR

- PUMP SLOWS, STALLS, OR TRIPS CIRCUIT BREAKER (FUSE OPENS)

CHECK FOR PLUGGEDDISCHARGE TUBE

DISCONNECT TUBE ATCOMPRESSOR PUMP

MOTOR DEt=ECTIVE,REPLACE

CLEAN ORREPLACE

AND TESTv 1 CHECK VALVE ]

N O

REPLACE OR REPAIRPUMP, SEE “PUMP

REMOVAL & REPLACEMENT” II J

I1037

EXCESSIVE VIBRATION normal operating conditions. Readjust to eliminate orreduce vibration noise.

This problem is usually due to omission of vibrationpads or an uneven weight distribution on the pads. Shutunit off and apply weight to different corners of the unit.Shim out excessive rocking. Use adjustable levelers foruneven floors.

Belt guards often produce a vibrating noise even under

Sometimes, even normal operation of the compressoris considered excessive in noise or vibration. In such cases,a remote air intake, adjustable pads, and air-line vibrationisolators may be required. Isolators are stocked byHoneywell.

13 75-7268

REPAIR

PUMP REMOVALAND REPLACEMENT

If major repair is needed, order a Parts List for thespecific pump. See ORDERING INFORMATION para-graph in PARTS LIST section.

Remove pump hold-down bolts, and pump. Remove fly-wheel if not done previously.

Shut off power to both units. Drain oil from faulty When installing new pump, be sure flywheel is in line

unit, and bleed down tank. Remove belt guard, loosen with motor pulley before removing wedge and tighten-

motor mounts and remove belt(s). ing hub bolts.

Remove discharge tube at pump end. If tube wrapsaround crankshaft, remove both ends and any hold-downstraps.

If accessible, remove flywheel at this time. The l/2-hp(0.27 kW) unit is held on with a keyed shaft and setscrewand a puller will probably be necessary. All others use asplit hub and key. Remove flywheel by removing hubbolts and nuts and driving a wedge into split.

NOTE: When removing discharge tube connector fromold pump, loosely install the male coupling onthe discharge tube in the connection to preventcollapse during removal.

OIL PUMP REPLACEMENT

Remove pump intake filter and the unloader air supplyline of 3/4 hp (0.56 kW) and up.

If flywheel has not been removed, its weight maytopple pump when the hold-down bolts are

The oil pump is factory machined as an assembly, andpartial replacement is not possible. In the event the pump(or crank bearing which is part of the pump) is faulty,replace whole assembly. The assembly is held by fourbolts (see Fig. 7). Order the replacement oil gage sep-arately if needed. After installation, adjust oil pressureon replacement pump (see WRONG OIL PRESSUREparagraph in TROUBLESHOOTING section).

OIL PUMP

X 1 0 8 2 - l

75-7268

Fig. 7. Crankcase Group.

14

BELT REPLACEMENT(Refer to Fig. 2)

Disconnect electric power and loosen motor clampingbolts. Slide motor towards pump. If the compressor hasa totally enclosed belt guard, remove it. Remove andreplace belt(s). Hold motor against belts when retighten-ing so the belt(s) have no more than l/2 in. (13 mm)total play. Make certain motor is square to belts. Reinstallguard and turn on power.

NOTE: Sometimes new belts stretch excessively afterbeing installed. Recheck belt tension after oneweek as stated in BELTS paragraph of MAIN-TENANCE section.

MOTOR REPLACEMENT

Before replacing motor, see NOISY MOTOR andWON’T START paragraphs in TROUBLESHOOTINGsection. If motor is defective, disconnect power andreplace. Use motor of identical type, hp, voltage, speed,and frame when reinstalling motor. Reset belt tension,see BELTS paragraph in MAINTENANCE section.

CAUTION

Many motors are dual voltage and/or reversible.Check motor’s internal wiring against diagram onmotor or inside of wiring cover plate for properconnections for voltage being used and/or rotation.The compressor will pump air if rotated backwardsbut will not cool properly.

INTAKE AND EXHAUST VALVES,

UNLOADER

Intake valves, exhaust valves and unloader mechanismscan be disassembled for inspection, cleaning, or repairfor all compressor sizes except the l/2 hp (0.37 kW).The l/2-hp (0.37 kW) unit has a head sealed assembly.In the event the valves are deemed defective, replaceentire head assembly.

For the l/3-hp (0.25 kW) unit, remove the two valvelocking nuts in the head. Remove valve parts for inspec-tion See Fig. 8 for reassembly order.

iDISCHARGE/VALVEASS’Y‘I

Fig. 8. Unloader for l/3-HP (0.25 kW) Unit.

The 3/4-hp (0.56 kW) and larger units have automaticunloaders on the intake valve(s). Some preliminarychecks on unloaders are described in CIRCUIT BREAKERTRIPS (FUSE OPENS) paragraph in TROUBLESHOOT-ING section. The unloader for the l-hp (0.75 kW) unitis shown in Fig. 9. All other units (3/4 hp, 0.56 kW;l-l /2 hp, 1.1 kW; and up) use the unloader shown inFig. 10.

UNLOADER ASS’Y

INTAKE VALVE ASS’Y

6282

Fig. 9. Air Unloading of Intake Valves--l HP (0.75 kW).

15 75-7268

zii3xUNLOADERASSEMBLY

- H E A D

6283

Fig. 10. Air Unloading of Intake Valves--3/4 HP (0.56kW), l-1/2 HP (1.1 kW) and Up.

The unloader pilot is located on the crankcase and isconnected to the unloader by a copper line. The l/2-and 3/4-hp (0.37 and 0.56 kW) units use a pilot that ismechanically activated (see Fig. 11). All other units areoperated by oil pressure (see Fig. 12). Disassemble andclean units if suspect. See PARTS LIST section forrepair kit numbers.

Fig. 11. Three-Way Valve Assembly-l/2- and 3/4-HP(0.37 and 0.56 kW) Units.

Fig. 12. Hydraulic Unloader Assembly-l-IHP (0.75 kW)Units and Larger.

PRESSURE REGULATING VALVE(PRV) STATION

The l/3- to 2-hp (0.25 to 1.5 kW) units use a Honey-well PP901 or PP902 PRV. For detailed maintenanceand repair information, see Form No. 75-2558.

The prv station used on the 3-11~ (2.2 kW) units is acombination of a Pall-Trinity-Micro Corp. filter, and aNorgren regulator and relief valve (see Fig. 15 andTable 3).

To perform maintenance and repair work on the prvstation, shut off air supply from tank. Bleed down thesystem by manually operating the drain (push red buttonon drain valve).

CAUTION

All valves and dampers return to the normal posi-tion when system is bled. Study job drawings forcritical problems before bleeding down system.

The regulator and relief valve can now be replaced orrepaired with the appropriate repair kit (see PARTSLJST section).

After repairing or replacing, slowly turn air back on,checking for leaks.

75-7268 16

PARTS LIST

INTAKE F ILTERS

See Fig. 13 and 14.

R2373

Fig. 14. Quincy Air Maze Intake Filters.

FILTER-PRV ASSEMBLY

Replacement element kit for PI?901 -PI?902 PRV is14003121-001. See Form 75-2558 for other prv parts.

Fig. 13. Honeywell Intake Filter, Part No. J&3895-4. See Fig. 15 and Table 5.

Table 5. 7-l /2 HP Filter-PRV Parts List.

Nomenclature 7-l/2 HP-WP241

Refer all inquiries toQuincy Compressor

Refer all inquiries toQuincy Compressor

17 75-7268

F R O N T V I E W

6 2 8 6

Fig. 15. Typical PALL-TRINITY-MICRO (PTM) Filter-PRV Assembly-for 7-l/2 HP (5.60 kW) Units.

OTHER COMPRESSOR PARTS

Table 6. WP241 Duplex Air Compressor Parts List .*

Qumcy Model No.

Model Compressor Only

Motor Horsepower (kW)Motor Frame No

Motor Voitagc/Frcq/Phase

R P M - Compressor

V-Belt-Quantity, Type,L,ength (In )

Air Intake Fdter

Unloader Dcvlce i-

Unloader Valve’

rkk Valve4

WP241Y WP24lB WP241C WP241D WP241E WP241F WP241G WP241H WP241J

FFHX2 FFlIlOh FFIIl08 FFII210 EFIJ216 FFH230 FFII325 FFH340 FF11370

X2 Plain 106 Loadless 108 Loadiess 2 IO Loadlegs 2 16 Loadless 230 Loadless 325 Loadless 340 Loadless 370 Loadless

l/3 (0 ‘5) l/2 (0 37) 3/4 (0 56) 1 (0 75) l-l/2(1 1) 2(1 5) 3 (2 2) 5 (3 7) 7-l/7 (S 6)-48 -56 -56 -14x -145T -145T -182T 184T .71:-y - -

1 I S/60/ 1 ‘08/60/3 ‘30/60/3 460/60/3 208/60/3 230/60/3 460/60/3 460/60/3 460/60/3

500 410 460 480 460 400 570 550 610

I -A-44 I -B-5 1 1 -B-5 1 I -B-45 I -B-54 2-B-60 2-B-60 3-B-8 1 3-B-X 1

Iloneywell Part No AK38954 7069% 70704 7071*

None 3444 3444 7970x 7970x 7970x 7970x 7970x 7970x

5993 7483X 7483X 8125 7483X 7483X 7483X 718iY 7483X

8405 8405 N o n e N o n e None N o n e None h o n e VCXlC

75-7268 18

ORDERING INFORMATION

(In United States)

When ordering parts, it is important to supply infor-mation shown on the nameplate.

QUINCY PARTS

Order from local Quincy representative or:

Colt IndustriesQuincy Compressor DivisionQuincy, IL 62301

NOTE: Supply complete Quincy compressor serialnumber as stamped on the nameplate of eachcompressor when ordering parts or discussingservicing or problems on a specific compressor.See Fig. 16. A list of Quincy service depots isincluded with the instructions packed with eachcompressor.

~~

Colt hdustries Quincy Compressor Division QUWKY, ~IIIIKHS us A

D A T E C O D E 1j

6 2 8 7

Fig. 16. Compressor Nameplate.

PTM (Pall-Trinity-Micro) PARTS

Local distributor or:

Pall-Trinity-Micro CorporationCortland, NY 13045

Supply exact part number.

NORGREN PARTS

Local distributor or:

C .A. Norgren CompanyLittletown, CO 80 120

Supply exact part number.

HONEYWELL PARTS

Local Honeywell Serviceline Center.

Supply part number and compressor model number,

Mechanical devices must be serviced periodically if they are expected to give continued satisfactory performance,

and controls are not an exception. How accurate and how troublefree your control system will be in the years to

come depends largely on the maintenance given it. For best results, all devices in your system should be serviced

at one time.

Time and trouble can be saved by arranging with Honeywell for a maintenance agreement which will guarantee

expert, economical care, and insure maximum life and efficiency from your system.

19 75-7268

SALES AND SERVHCE -ALABAMA GEORGIA

alrmingham, AL Aflanfa G A(2051323 2 4 3 1 (404) 32, 2 4 9 5

MARY LAND NEW YORKBaltimore MU Albsny N Y(301 I 8 2 8 0 9 0 0 x 2 4 7 (518) 4 5 6 7 0 0 0

PENNSYLVANIAHdrrlsburg P A(717) 5 6 4 8 0 0 0

VIRGINIAtvlcl.sari (Wastungton u c I “ A(703) 8213705

Richmond “ A

(804) 2 8 5 8111 or

1 8 0 0 5 2 2 3807 (Toll Free)

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MASSACHUSETTS8”SfO” (Newton) MA(617) 9 6 9 0 2 5 0

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(215) 6 6 6 8 3 0 2

Long Idand N Y Pittsburgh P A( 2 1 2 1 3 9 2 4 3 0 0 (412) 9 2 8 4 2 3 6

PlaInvIew N Y

(516) 9 3 1 ,500wllces B a r r e P A17171654 2 4 7 ,

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Ustroit (FarmIngron Hails) M I1313) 4 7 8 1 6 0 0

G r a n d Rap,& M,

( 6 1 6 1 2 4 7 4811

sag,naw M l

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(312) 5 6 8 4 2 0 0Syracuse NY1 3 1 5 1 4 5 1 4 0 0 0

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(501) 3 7 2 0 1 6 6

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1803) 7 7 9 3 2 4 0

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(312) 6 9 7 7 8 8 0MINNESOTA

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lWlrl% CA(714) 5 5 7 6 4 3 ,

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Lanrlng I L(3121474 9300

Peoria ii

(309) 6 9 2 0 6 1 0 X 2 2 0

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(2191 4 9 2 9 6 5 4

D”iUfh M N

(218) 727 040,

Charlotte NC(704) 3 6 4 4 7 7 0

Grsenvills S C

1803) 288 7 8 2 5WEST VIRGINIA

C h a r l e s t o n W V

(513) 9 4 8 4 1 8 5

MlSSlSSlPPlG r e e n s b o r o N C

(919) 2 9 2 1556SOUTH DAKOTA

SIOUX Fail* S D(6051 3 3 6 0 9 8 6

Clarksl?urg WV(304) 6 2 3 6 5 5 ,

Jackson M S(601) 982 2090 NORTH DAKOTAor1601) 8 3 3 7 2 4 , F a r g o NO

1701) 2 3 5 4 2 2 , TENNESSEEMemphis T N(901) 3 4 5 6 2 2 2

WISCONSINApl3ie*on W I(414) 7 3 3 4 4 9 1

Mad,*“” WI

(608) 2 2 2 1400

Miiwa”kee WI

(414) 771 6 3 0 0

S a n mego C A

(714) 2 9 2 5 3 1 I

ind,a”apolls I N

(317) 2 4 3 0831

X 281 o r 2 4 8

MISSOURIKansas CliY h”o(8161 3 5 8 4 2 0 0

OHIOAkron O H1216) 7 3 3 2 2 4 4

Ssn Franc~sco C A

(415) 9 5 7 2 6 7 4

N a s h v i l l e T N

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1 8 0 0 341 2 3 1 4 (Toil Free1St Lo”!* M O(314) 5 7 6 2 5 6 6

Canton OH(216) 4 5 4 6 9 6 0IOWA

Esttendorf IA3 7 0 5 Utscs Ridge R d

D a v e n p o r t I A(319) 3 5 9 3 4 4 1

Des MO,“% IA

(515) 2 8 8 3 6 0 1

KANSASWlfchlta KA(316) 5 2 2 3 4 3 1

KENTUCKYLo”ls”,iis K Y1 5 0 2 1 4 5 9 5 9 7 0

LOUISIANAaaron Rouge Lh(504) 9 2 4 8 6 2 6

COLORADODenver (Engelwoodj CO1303) 7 7 9 6 2 9 5 or1 800 332 7031 [Toll Free)

CONNECTICUTHartford CT

12031 7 6 2 3 1 0 0

DISTRICT OF COLUMBIAWs.h,ngto” D C (McLean V A

(703) 8 2 7 3 7 0 5

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(904) 3 9 6 6 9 7 1

MONTANAMlsrouia M T(406) 7 2 8 7 4 4 2

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Cleveland O H

(216) 361 7 3 7 3

TEXASALIst,” TX(512) 4 7 8 1788

WYOMINGCarper W Y(307) 2 6 5 9 3 7 4 or

1 8 0 0 4 4 3 8 4 4 6 (?Oll Freei

NEBRASKAO m a h a N8

( 4 0 2 1 3 3 1 3 2 0 0Colurnb”s O H1 6 1 4 1 4 8 6 5 9 7 1 X El P a s o T X

I91 5) 5 3 3 9 9 2 4NEW HAMPSHIRE Dayton OH

Bedford N H (5131 2 3 7 4 0 3 5(603) 6 2 5 6 5 0 2

F t Worfh TX

(214) 2 6 3 2 3 1 1Toiedo O H

NEW JERSEY (419) 473 972, x

Mt Laurs, N J1 6 0 9 1 2 3 4 2 2 2 4 YO”“gsfOL+” OH

1216) 7 4 7 0 0 7 2

Ho”ston T X

(713) 7 8 0 6603 or

1 8 0 0 3 9 2 2 3 2 8 (Toil F r e e )

L u b b o c k T X

(806) 7 6 2 5 2 0 2

M i a m i F L

(305) 5 9 2 8 1 4 0Parslp~any N J

(201) 2 6 3 2 2 2 5OREGON

Porrisnd O R(503) 2 3 5 8 4 1 1

N e w Orlsanr L A

(504) 8 3 3 7 2 4 1Orisndo F L

(3051 894 3131Wsrrfield, N J

(201) 2 3 3 9 2 0 0OKLAHOMA

Oklahoma Clfy OK

S a n Anton,* T X

1512) 3 4 1 4 6 9 1Schrevaport L A

(318) 2 2 2 5 3 2 5

MAINEPortland ME(207) 775 3 5 0 1

T a m p a , F L

(813) 8 7 0 3 7 3 3 (405)8482811NEW MEXICO

Albuquerque NM Tulsa OKJTAH

Salt Lake CltY tiiwest Palm Beach F L

(305) 6 8 3 1 9 9 0 (505) 3 4 5 1 6 5 6 ($18) 4 3 7 5 9 3 4 801)487 0 6 8 1

CANADA -Honeywell Limited - Honeywell Limit&, 740 Ellesmere Road - Scarborough, Ont

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By using this Honeywell literature, you agree that Honeywell will have no liability for any damages arising out of your use or modification to, the literature. You will defend and indemnify Honeywell, its affiliates and subsidiaries, from and against any liability, cost, or damages, including attorneys’ fees, arising out of, or resulting from, any modification to the literature by you.