JBP SERIES FILTER SYSTEMS

Transcription

1 JBP SERIES FILTER SYSTEMS OPERATIONS MANUAL Doc. Jordair FILTRATION-MANUAL

2 WARNING! High pressure air has Tremendous Kinetic Energy; Shut off valves on air storage cylinders, fill station and any other air control panels. Depressurize system slowly before starting any service work. This reduces risk of Explosive Venting. General instructions for filter maintenance Dry inside of filter housing with a clean cloth before installing new cartridge and check for corrosion. Lubricate threads and o-rings as well as threads on filter chamber. Observe number of operating hours to ensure compliance with service intervals. Change cartridge before returning to service any compressor that has out of service for more than six months. Leave cartridge in the filter chamber as long as the unit is out of service, in order to absorb moisture in the filter system. Keep all condensate drain-valves and shut-off valves closed. Maintain a minimum pressure of approximately 50 to 80 barg (700 to 1000 psig) within the system to prevent moisture entering the filter system. Maintenance intervals Replace cartridges every six months or according to Securus indicator. All o-rings and back-up rings are to be changed with filters; lower filter cap o-ring and back-up ring changed annually. Service check valve annually; replace kit. Service auto drain annually; replace kit. PMV serviced annually replace kit. See respective section for complete procedures. All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, or stored in a database or retrieval system, without the prior written permission of Jordair Compressors Ltd. 1

3 QTY. DESCRIPTION PART NO. AD Autodrain, Single Bank J-BD-1-5 CH Check Valve J-5CV-P-4 EB Electrical Box / System see Fig. 2 FIL Filter Chamber, Drying JBF FIL Filter Chamber, Drying JBF FIL Filter Chamber, Purifying JBF S PI Pressure Gauge J QTY. DESCRIPTION PART NO. PMV Pressure Maintaining Valve J-PMV-6000 PRV Pressure Relief Valve 3305-A01-KC3750 SEC Securus Monitor N15096 SEP Oil / Water Separator JS SV Solenoid Valve 7131KBN2BR00N0C111P3 VA Drain Valve VA Drain Valve

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5 J-PRV Relief valve Relief valve needs to be tested, set and certified to the operating pressure and to be replaced as a complete unit if found defective. J-PRV RELIEF VALVE ITEM QTY MATERIAL DESCRIPTION 1 1 SS SA Nozzle 2 1 Teflon O-ring 3 1 SB211 Alloy 2024 T3511 Body Aluminum 4 1 SS A Bottom Spring 5 1 SS A Bottom Disc 6 1 Aluminum B211 Alloy 2024 T351 Bottom Spring Step 7 1 Kynar Insert 8 1 Teflon Seal 9 1 SS A Top Disc 10 1 Steel A231 Aluminum Coated Top Spring 11 1 SB-211 Alloy 6061-T6 Cap Aluminum 12 1 Aluminum B211 Alloy 2024 T351 Top Spring Step 13 1 SS A Compression Screw 14 1 SS A Jam Nut 4

6 SERVICE OF THE SEPARATOR NON-RETURN VALVE The separator non-return valve is located on the outlet of the oil and water separator. Ensure that the separator is vented of all pressure and the filter towers are also depressurized. Remove the valve from the system and remove the tube connecting fittings so that the internal poppet can be removed. Clean and check the valve for any seat damage. The poppet assembly is to be replaced annually, the complete valve is to be replaced if there is any leakage or seat body wear or damage noticed during inspection. Thoroughly clean the body of all old lubricant or oil emulsions. Lubricate all contact surfaces in the body and install the poppet with the new seals. Install the valve in the system while ensuring the valve is oriented in the correct direction of the airflow. SEPARATOR NON-RETURN VALVE 1 1 J-03-P017 Body 2 1 J O-ring 3 1 J-03-P016 Sleeve 4 1 J-03-P013 Spindle 5 1 J-5CV-P-4-S Spring 6 1 J-03-P014 Seat J-CVP-5K Kit includes items 2,3,4,5,6 5

7 SERVICE OF THE OIL AND WATER SEPARATOR Disconnect the inlet and outlet pressure lines so that the separator top cap can be removed for service of the filter element. Carefully remove the top cap from the barrel by turning counter-clockwise with the filter wrench (Jordair part # J-FW-FD). Inspect the interior of the barrel chamber, O- ring/backup ring groove and the internal/external threads of each mating component to ensure that they are free from any damage and debris. Loosen top retainer (Item 2; Fig 6). Remove the bottom retainer (Item 5; Fig 6). Remove the element (Item 4; Fig 6). Replace the O-ring (Item 5; Fig 5) and the backup ring (Item 4; Fig 5) in each cap. Carefully insert the rings into the O-ring/backup ring groove ensuring that the O- ring directly experiences the pressure and the concave side of the backup ring experiences the pressure imposed by the O-ring. Carefully insert the new element (Item 4; Fig 6) over the retainer stem (Item 3; Fig 6). Ensure that the element has been fully seated into the groove in the top retainer (Item 2; Fig 6). Cautiously tighten the bottom retainer onto the retainer stem, tightening the element. Ensure that the element is snug by loosening, then tightening the top retainer onto the element. Ensure, also, that the retainer stem has remained securely tightened within the separator cap. Lubricate the O-rings/back-up rings, cap and chamber threads with a silicone based O-ring and thread lubricant. Jordair part number SIL-2 or SIL-4. Carefully lower the top cap into the chamber, vertically centered, and fully engage the top cap. The O-ringsealing surface prevents leakage once the barrel and cap are fully engaged so that the mating surfaces are in contact. Do not tighten beyond initial contact of these surfaces. JS SPEARATOR CHAMBER 1 1 JS-TOP CAP-6300 Cap, Top 2 1 JS-BOTTOM CAP-6300 Cap, Bottom 3 4 SHOP-POPAD42ABS Pop Rivet 4 2 J Back-up Ring 5 2 J O-ring 6 1 JS-BARREL-6300 Barrel 7 1 FC-1008 Assembly, Separator Element (Fig.3) 8 1 NAMEPLATE-8 Nameplate 6

8 SERVICE OF THE OIL AND WATER SEPARATOR Disconnect the inlet and outlet pressure lines so that the separator top cap can be removed for service of the filter element. Carefully remove the top cap from the barrel by turning counter-clockwise with the filter wrench (Jordair part # J- FW-FD). Inspect the interior of the barrel chamber, O-ring/backup ring groove and the internal/external threads of each mating component to ensure that they are free from any damage and debris. Loosen top retainer (Item 2; Fig 6). Remove the bottom retainer (Item 5; Fig 6). Remove the element (Item 4; Fig 6). Replace the O-ring (Item 5; Fig 5) and the backup ring (Item 4; Fig 5) in each cap. Carefully insert the rings into the O-ring/ backup ring groove ensuring that the O-ring directly experiences the pressure and the concave side of the backup ring experiences the pressure imposed by the O-ring. Carefully insert the new element (Item 4; Fig 6) over the retainer stem (Item 3; Fig 6). Ensure that the element has been fully seated into the groove in the top retainer (Item 2; Fig 6). Cautiously tighten the bottom retainer onto the retainer stem, tightening the element. Ensure that the element is snug by loosening, then tightening the top retainer onto the element. Ensure, also, that the retainer stem has remained securely tightened within the separator cap. Lubricate the O-rings/back-up rings, cap and chamber threads with a silicone based O-ring and thread lubricant. JS SPEARATOR CHAMBER 1 1 JS-TOP CAP-6300 Cap, Top 2 1 NAMEPLATE-8 Nameplate 3 4 SHOP-POPAD42ABS Pop Rivet 4 2 J Back-up Ring 5 2 J O-ring 6 1 FC-708-SE Assembly, Separator Element (Fig.3) 7 1 JS-BARREL-6300 Barrel 7

9 FC-708-SE SEPARATOR ASSEMBLY ITEM QTY. PART NO. DESCRIPTION 1 1 HN18.8F012 Nut 2 1 FC-74-T Retainer, Top 3 1 FC-73 Stem 4 1 FC-708-SE Separator Cartridge 5 1 FC-74-B Retainer, Bottom FC-1008-SE SEPARATOR ASSEMBLY ITEM QTY. PART NO. DESCRIPTION 1 1 HN18.8F012 Nut 2 1 FC-104-T Retainer, Top 3 1 FC-103 Stem 4 1 FC-1008-SE Separator Cartridge 5 1 FC-104-B Retainer, Bottom 8

10 SERVICE OF THE SEPARATOR AUTODRAIN The separator automatic drain block is connected to the base of the separator by a 1/4" drain line. The drain is designed to fail open which prevents a large quantity of liquid accumulating in the event of a failure of the drain solenoid valve. The timer located in the control box will drain accumulating liquids every 15 minutes and is inter-locked to open the valve when the compressors shut down venting all air from the separator. The drain valve is to be serviced each year and checked for wear, have all seats, seals and O-rings replaced and lubricated. Remove the valve top four cap screws, which allows the top and base to be disconnected from the body. Remove the piston and the base seat. Check the piston for wear or damage on the sealing surface. Replace the lower seat and O-rings from the kit and lubricate. Replace the piston cup seal and O-rings. Thoroughly clean the body of all old lubricant or oil emulsions. Lubricate all contact surfaces in the body and install the piston with the new seal. Replace the lower and upper caps and tighten the four cap screws in an opposite sequence and then the drain is ready to be placed back in service. SEPARATOR AUTODRAIN 1 4 SHC18.8C14.4 Cap Screw 2 1 J-ADTM-1 Manifold Top 3 1 J O-ring, Manifold, Top 4 1 J-BD-CUPSEAL Cupseal 5 1 J-ADP-HP Piston, High Pressure, J-BD-X J O-ring, Piston, High Pressure, -X J-CADB-K Body 8 1 J O-ring, Manifold, Side 9 1 J O-ring, Seat, Top 10 1 J-BD-HP Seat, High Pressure 11 1 J O-ring, Seat, Bottom 12 1 J-BADB Base, High Pressure 13 1 J-ADMB Mounting Bracket 14 1 J-ADSM-1 Manifold, Side 15 2 SHC18.8C Cap Screw J-ADK-HP Repair Kit: Incl. #2, 4, 6, 8, 9, 10, 11 9

11 VENT BLOCK The vent block gauge provides the air pressure in the filter system. Use the vent valve (item 2) to drain all pressure prior to replacing filter cartridges. The vent valve seat (part no ) is to be replaced during each annual service of the system. J-PSVB-6000 VENT BLOCK 1 1 J psig, 2 1/2", Oil-filled Pressure Gauge Valve Repair Kit 10

12 Use Jordair cartridge #FTP-3408-JB. Bauer cartridge #58825 can also be substituted. Use Bauer Securus cartridge #60037 only. JBF FILTER CHAMBER 1 2 SHC18.8C38.12 Cap Screw 2 1 JBF-COVERPLATE Cover Plate 3 1 JBF-TOPCAP Assembly, Cap, Top 4 2 J Back-up Ring, Cap 5 2 J O-ring, Cap Filter Cartridge 6 1 FTP-1807-JB Filter Cartridge 7 1 J O-ring, Filter Element 8 1 J O-ring, Filter Element 9 1 JBF-BARREL-33 Barrel 10 1 JBF-BOTTOMCAP Cap, Bottom 11 1 NAMPLATES-10 Nameplate 12 4 SHOP-POPAD42ABS Pop Rivet JBF FILTER CHAMBER 1 2 SHC18.8C38.12 Cap Screw 2 1 JBF-COVERPLATE Cover Plate 3 1 JBF-TOPCAP Assembly, Cap, Top 4 2 J Back-up Ring, Cap 5 2 J O-ring, Cap 6 1 FTP-2807-JB or or Filter Cartridge 6 1 FTP-2804-JB or Filter Cartridge 7 1 J O-ring, Filter Element 8 1 J O-ring, Filter Element 9 1 JBF-BARREL-33 Barrel 10 1 JBF-BOTTOMCAP Cap, Bottom 11 1 NAMPLATES-10 Nameplate 12 4 SHOP-POPAD42ABS Pop Rivet JBF FILTER CHAMBER 1 2 SHC18.8C38.12 Cap Screw 2 1 JBF-COVERPLATE Cover Plate 3 1 JBF-TOPCAP Assembly, Cap, Top 4 2 J Back-up Ring, Cap 5 2 J O-ring, Cap 6 1 FTP-3804-JB or Filter Cartridge 6 1 FTP-3807-JB or or Filter Cartridge 7 1 J O-ring, Filter Element 8 1 J O-ring, Filter Element 9 1 JBF-BARREL-33 Barrel 10 1 JBF-BOTTOMCAP Cap, Bottom 11 1 NAMPLATES-10 Nameplate 12 4 SHOP-POPAD42ABS Pop Rivet Bauer Securus JBF S SECURUS FILTER CHAMBER 1 2 SHC18.8C38.12 Cap Screw 2 1 JBF-COVERPLATE-S Cover Plate 3 1 JBF-TOPCAP Assembly, Cap, Top 4 2 J Back-up Ring, Cap 5 2 J O-ring, Cap Filter Cartridge 7 1 J O-ring, Filter Element 8 1 J O-ring, Filter Element 9 1 JBF-BARREL-33 Barrel 10 1 JBF-BOTTOMCAP Cap, Bottom 11 1 NAMPLATES-10 Nameplate 12 4 SHOP-POPAD42ABS Pop Rivet JBF S SECURUS FILTER CHAMBER 1 2 SHC18.8C38.12 Cap Screw 2 1 JBF-COVERPLATE-S Cover Plate 3 1 JBF-TOPCAP Assembly, Cap, Top 4 2 J Back-up Ring, Cap 5 2 J O-ring, Cap Filter Cartridge 7 1 J O-ring, Filter Element 8 1 J O-ring, Filter Element 9 1 JBF-BARREL-33 Barrel 10 1 JBF-BOTTOMCAP Cap, Bottom 11 1 NAMPLATES-10 Nameplate 12 4 SHOP-POPAD42ABS Pop Rivet 11

13 SERVICE OF THE FILTER CHAMBERS JBF-TOP CAP-S SECURUS CAP RF Connector 2 1 JBF-CAP TOP-S Cap, Top, Securus, JBF-6300 Filter Plug Drawback Screw 5 1 JBF-PIN Pin, JBF S Filter Spring, Pin Stud Nut Spring, Cap, Top In order to service the lower cap O-ring and back up ring the filter chamber lower base support must be removed. Disconnect the inlet and outlet pressure lines so that the lower cap can be removed for service of the O-rings and back up rings. Carefully remove the top cap from the barrel by turning counter-clockwise with the filter wrench (Jordair part # J- FW-FD). Inspect the interior of the barrel chamber, O-ring/backup ring groove and the internal/external threads of each mating component to ensure that they are free from any damage and debris. Cautiously remove the drying/filtering element by pulling up on the extraction handle of the cartridge. Replace the O-ring (Item 5; Fig 9, Fig 10) and the backup ring (Item 4; Fig 9, Fig 10) in each cap. Carefully insert the rings into the O-ring/backup ring groove ensuring that the O-ring directly experiences the pressure and the concave side of the backup ring experiences the pressure imposed by the O-ring. Carefully insert the new drying or filtering cartridge until it is fully contained in the lower cap. Lubricate the O-rings/back-up rings, cap and chamber threads with a silicone based O-ring and thread lubricant. Jordair part number SIL-2 or SIL-4. Carefully lower the top cap into the chamber, vertically centered, and fully engage the top cap into the barrel. The barrel is to be installed so that the threads are fully engaged and the top cap meets the lower face. It is not recommended to tighten the barrel and cap beyond the point of meeting of the surfaces. Over-tightening the cap could potentially seize the cap and barrel making it very difficult or impossible to open in the future. Acquire new and correct O-ring and backup ring sizes and quantities, and carefully insert the rings into the O- ring/backup ring groove ensuring that downstream of the pressurized side, the O-ring directly experiences the pressure and the concave side of the backup ring experiences the pressure imposed by the O-ring. Vertically center the mating components and cautiously fully engage them. The O-ring-sealing surface prevents leakage once the barrel and cap are fully engaged so that the mating surfaces are in contact. Do not tighten beyond initial contact of these surfaces. 12

14 SERVICE OF THE PRESSURE MAINTAINING VALVE The purifying system pressure maintaining and non-return valve is located on the outlet of the final purification chamber. The purifying system pressure maintaining and non-return valve is located on the outlet of the final purification chamber. Remove the valve from the system and remove the tube connecting fittings so that the seat retainer (item 5; fig 12) and seat poppet (item 7; fig 12) can be removed for replacement and service. Clean and check the valve for any seat damage or sign of wear or marks in the body of the valve. The seat poppet located on the end of the seat retainer is to be replaced annually, the complete valve is to be replaced if there is any leakage or body wear or damage noticed during inspection. Thoroughly clean the body and all parts of all old lubricant. Lubricate all contact surfaces in the body and install the seat assembly and the stainless steel control seat (item 10; fig 12) with the new seals (item 6, item 9; fig 12). Install the seat retainer in the body. Insert the spring over the retainer stem and screw down the spring retainer until it bottoms on the face of the body section. Install the stainless control seat and replace the retaining fitting to install back on the base of the final filter chamber. Install the valve in the system while ensuring the valve is oriented in the correct direction of the airflow. Adjust the valve to the correct backpressure by turning the spring tension screw assembly until the correct holding pressure is reached for the filter system. PRESSURE SETTING CHART FOR THE PMV VALVE The chart provides the Pressure Maintaining Valve (PMV) setting point for the various operating pressures of the filter systems. The set pressure of the valve is designed to optimize the adsorption capacity of the drying media and provide the highest quality breathing air. PMV SET PRESSURE FILTER FINAL PRESSURE 1200 PSIG 2000 PSIG 1800 PSIG 3000 PSIG 2400 PSIG 5000 PSIG J-PMV-6000 PRESSURE MAINTAINING VALVE 1 1 J-PAN-1 Spring, Tensioner 2 1 J-BARREL-1 Spring, Retainer 3 1 FWUSSZ0516 Washer 4 1 J-PMV-S Spring 5 1 J-PISTON-1 Seat, Retainer 6 1 J O-ring, Retainer Seat 7 1 J-GASKET-1 Seat Poppet 8 1 J-BODY-1 Body 9 1 J O-ring, Control Seat 10 1 J-VALVE-1 Control Seat J-PMV-K Kit Includes Items 6, 7, PSIG 6000 PSIG 13