IMPORTANT INSTRUCTIONS GASMASTER “=, COMPRESSORS CORKEN.WARNING. Install, use and maintain this equipment according to CORKEN, INC. instructions and all applicable federal, state, local laws and codes, and NFPA Pamphlet 58 for LP-Gas or ANSI K61.1 1989 for Anhydrous Ammonia. Periodic inspection and maintenance is essential. CORKEN ONE YEAR LIMITED WARRANTY CORKEN, INC. warrants that its products will be free from defects in material and workmanship for ‘a period of 12 months following date of purchase from CORKEN. CORKEN products which fail within the warranty period due to defects in material or workmanship will be repaired or replaced, at CORKEN's option, when returned, freight prepaid, to CORKEN, INC., 3805 N.W. 36th Street, Oklahoma City, Oklahoma 73112. Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, and packing, and other parts showing signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories not manufactured by CORKEN but furnished with CORKEN products are not covered by this limited warranty and the purchaser must look to the original manufacturer's + warranty, if any. This limited warranty is void if the CORKEN product has been altered or repaired without the consent of CORKEN. All implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, are expressly negated to the extent permitted by law and shall in no event extend beyond the expressed warranty period. CORKEN DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR IMPLIED WARRANTY ON CORKEN PRODUCTS. Transfer of toxic, dangerous, flammable or explosive substances using CORKEN PRODUCTS is at the user's risk. Such substances should be handled by experienced, trained personnel in compliance with governmental and industrial safety standards. WRITING THE FACTORY For your convenience, the valve size and serial code are given on the valve nameplate. This serial code tells the month and year your valve was buill. Space is provided below for you to keep a written record of this information, Always include the valve size and serial code when ordering parts. Valve Model Valve Size Serial Code Date Purchased Date Installed Purchased From Installed ByCORKEN GASMASTER VERTICAL DOUBLE-ACTING COMPRESSOR Installation - Operation - Maintenance INSTRUCTIONS: CONTENTS Mechanical Specifications (Table 1) installation of Your Compressor Location Piping Driver Installation Initia! Operation of Your Compressor Lubrication Ol Pressure Adjustment Compressor Speed and Rotation \VBelt Adjustment Startup After Extended Shutdown Force Feed Cylinder Lubrication Variable Clearance Heads Startup Checklist Repair Service on Your Compressor Routine Maintenance Piston Ring Life Lubricated Cylinder Compressors Valve Repair and Inspection Piston Ring Replacement Packing Replacement and Inspection ‘Compressor Trouble Shooting General ‘Two-Stage Compressor Trouble Shooting Extended Shutdown Procedures External Lubricator Log Sheet COOVHDAAAASBBOANNNM+22s4CORKEN GASMASTER VERTICAL DOUBLE-ACTING GAS COMPRESSOR Your new GORKEN compressor is a vertical double-acting reciprocating _ compressors. CORKEN vertical compressors are available in a number of variations to fit your individual needs, ‘They are manufactured as single-stage or two- stage units; mechanical specifications are given in Table 1. Table 1. Mechanical Specifications ‘SPECIFICATIONS: 331 7a SNGLE-STAGE TWO-STAGE, et Bove Gay Wig | 80s) 325 Gy ‘She in. ran) 4oqon | 4qo) 4409) ead End Clarance & in) 95 wos 35. ‘ead End Clearance % (max) 85 mB a3 (rani End Clearance aa 109 104 Pon Aven (2) Head End ss9(00) | 23sqe 83.635) Gah End sae) | wou 74450) Diphcemen Orn (ry Head End @200 RPA” 6821128) | $90(0% 173 293) Cask nd @o00 RPM — 61.2 (1080) | 5695.4) 148 51) “ial G425 APH sera evesy | 11531953) 32.4 644) ‘Haxioun Gyinde Won Presse PSIG (BAR) aooer.6) | 380.24) oat) InfetOutet Pont Size 2 Weid Maximum Discharge Temperature 960° (177°C) Approximate Weigh wih Flybe! 600, (265 kg) \Masimum Rated Power “45 HP (98 KW) Maximum Allowable Red Load 70008, (8178 kg) Opinder Maton Ductile ken ASTM ASS ‘Compressor Sheave: 5 Groove 5V21.2 NOTE: 8V cross-section belts are modem cross- section V-belts which can transmit much more horsepower than conventional V-belts in the same drive space. For these compressors, four SV belts ‘can transmit wel in excess of the crankcase rating. Low compressor speeds generally result in a smaller motor sheave, which may require 5VX belts. INSTALLATION OF ‘YOUR COMPRESSOR Location Proper installation of your compressor is essential for peak performance and reliable service. installa- tion should be in a clean, ample space. A mini- mum of 18 inches clearance between the unit and the nearest wall is advised to make it accessible from all sides and to provide unrestricted air flow for adequate cooling of the motor and compressor. ‘The unit should be firmly bolted to a solid, level base. It is recommended that the base be con- crete or concrete-filed for adequate damping of vibration. Piping ‘The compressor piping should be designed for the rate of flow anticipated and for the minimum pressure drop; in no case should the piping be smaller than the compressor nozzle to which it connects. If the length of the line must exceed 100 feet, the next larger size pipe should be used. Never install a shutoff valve in the discharge piping unless a safety relief valve is placed in the line between the shutoff valve and the compressor. Care must be taken that the compressor head not support the piping. Adequate supports and sufficient piping flexibility must be provided to absorb mechanical vibration and gas pulsation. Install a strainer at the compressor inlet. Remem- ber to consider future expansion in your pipe sizing and layout. A reciprocating compressor is designed to handle ges (vapor), not liquid! A liquid trap (scrubber) Tust be installed in the suction piping (and discharge line if condensate can drain back to the compressor} when handling any but the driest of gases. An interstage scrubber must be used on two-stage compressors. Driver Installation The wiring of an electric motor is extremely impor- tant, and must be done by a competent electrician, Improper motor wiring will cause you to experi- ence expensive motor difficulties fram low voltage, If you suspect that you have a low voltage prob- lem, call your power company. ‘A humid climate can cause problems, particularly in explosion-proot_ motor applications. The normal breathing of the motor, and alternating between being warm when running and being cool when stopped, often will cause moist alr to be drawn into the motor housing. This moist air will condense and may eventually add enough free water to the inside of the motor to cause it to fail. To prevent this, make a practice of running the motor at least once a week on a bright, dry day for an hour or so without the V-belts. In this period of time the motor will heat up and vapor- ize the condensed moisture, driving it from the motor. No motor manufacturer will guarantee his explosion-proof or totally enclosed (TEFC) motor against damage from moisture.INITIAL OPERATION OF YOUR COMPRESSOR Initial operation of your compressor is the most critical time it will ever face. READ THIS SECTION CAREFULLY - IT WILL SAVE YOU MONEY AND INCREASE THE SAFETY OF YOUR OPERATION! Lubrication The crankcase of your compressor was drained before shipment. Before starting the machine be sure to fill the crankcase to, but not above, the full mark of the oil leval bayonet. On new or newly rebuilt units add oil through the inspection plate opening (Fig. 1). This will assure initial lubrica- tion of crossheads and guide on startup. Failure to do so may cause serious damage to the machine. The type of oit should be a heavy-duty motor oil with rust and oxidation inhibitors of a viscosity shown in Table 2. TABLE 2. Oil Selection Chart ‘Accoplable Grankease Oil Products* Mot Corkon Comprostore ‘Constant Weight Nondetergant - RAO Inhisted ‘OTT Produet 180 | Wi [SAE] _ Ambient Temperatures ‘TeRESSTIO joo [8] ao es | 5 [305 a5_[ 9s] 20 [er [ior Tes "RARUS daT Recproceing | 100 Compressor Ol = a2 ‘2 ‘Genoeo. Dectel REO OF Too_[ os [30 [ee [or [eo ‘a6 [ 9 [20 32 [160 Tio+ [a———— Repel REO OF Too aT —35, eee? | z0+ ra 32[108 [70+ z an ‘Sun Vis 800 Saree Or [160 [700 [50 68 [ 100 [20+ ae_[v00_|_20 Machine O's REO 70 [7 Jao (This was a Gulf On oe | or [20~ Preset tameny acy Fae Fos | at 22 [100 [70+ The Tsting shown fs only a partial listing of boston products ‘Other oi manufacturers products are eceeptable they mest the ‘Specieation equivalency to trove leted above. ** Chankcase heaters are recommended in eoid ambient tempera ‘ures below 82°F whare crankcase ol ae consistently a on ermperatres for ong patiods of ino, Heaters manta oi {ermperaistes et 70° and alow te use of Paver iscostes anc ‘alr adstonel weer protecton Oil Pressure Adjustment (See Figure 1) When the compressor is first started, observe the crankcase oil pressure gauge. If the gauge falls to indicate pressure within 30 seconds, stop the machine. Remove the pressure gauge and loosen the oll pump cover slightly. Restart the compressor and run it until oil comes out of the pressure gauge opening. Tighten the cover and install the gauge. The oil pressure should be at least 20 psi for normal service. It the discharge pressure is above 200 psi then oil pressure must be main- tainad at a minimum of 25 psi. The oil pressure is regulated by a spring-loaded relief valve mounted on the bearing housing opposite the sheave. Turn the adjusting screw clockwise to increase the oil pressure and counterclockwise to lower it. Be sure to loosen the adjusting screw locknut before trying to tum the screw and tighten it after making any adjustment. ‘NOTE: FILL CRANKCASE. WITH O1L THROUGH INSPECTION PLATE ‘OPENING. FIGURE 1. Oil Pressure Adjustment Compressor Speed and Rotation Direction The lubricator systems of the CORKEN Gasmaster compressor are designed to operate a minimum of 400 RPM. If lower speeds are necessary, consult the factory. The maximum speed of the D791 and D891 is 900 RPM. The crankshaft may be rotated in either direction. V-Belt Adjustment Improper belt tension and sheave alignment can cause vibration, excessive belt wear and prema- ture bearing failures. Before operating your com- pressor, check alignment of the V-grooves of the ‘compressor and drive sheaves; visual inspection often will indicate if the belts are properiy aligned, but use of a square is the best method.Before working on the drive assembly be sure that the electric power is off. Aways make sure the driver and compressor are close enough together to avoid forcing when mounting the belts. Tighten the belts so that they are taut, but not extremely tight. Consult your V-belt supplier for specific tension recommendations. Belts that are too tight may cause premature bearing failure. Startup After Extended Shutdown If your compressor has been out of service for a long period of time, you should verify that the cylinder bore and valve areas are free of rust and other debris (see the maintenance section of this manual for valve and/or cylinder head removal instructions). In addition, the crankcase cover should be removed to ensure that no water has condensed in it. Squirt oi! on the %heads and rotate the crank by hand to ensure that all bearing surfaces are coated with oil, then replace the crankcase cover. New compressors are shipped with a special oll designed to cling to metal surfaces. However, these special procedures are still worthwhile as it may have been some time since the unit was actually shipped from the factory. Force Feed Cylinder Lubrication (Lubed Models Only) The standard lubricator is bolted directly to the crankcase and is driven by a chain inside the crankcase at approximately 80% of crankshaft speed. Refer to the external lubricator section for A, Priming instructions. B. Adjusting pump flow rate. ©. Operating and maintenance instructions. The lube pump should be set at maximum capac- ity for the first hour of operation. Then, reduce the flow to the break-in rate for a week. At thal time the pump flow can be reduced to normal operating levels, These rates should be noted on the log sheet (CP-217). NOTE: The lubricator must be supplied with oil from an external supply, not from the compres- sor crankcase. Variable Clearance Heads NOTE: Used on 791, first stage only. ‘The variable clearance head assembly is supplied to allow compressor adjustment for changing operating conditions. Variable clearance heads allow for capacity and BHP requirements of the cylinder to be varied. Normally, the packager will have already provided at least a preliminary adjustment of the VGH. If not, you may wish to adjust the heads for maximum clearance before startup. Then, the heads can be adjusted inward, increasing the capacity and BHP of the cylinder to the desired levels. ‘To Adjust the Variable Clearance Heads: ‘A. Remove the V.C.H. adjusting bolt cap. 8. Turn the adjusting bolt to adjust the cylinder head end clearance. Turning the bolt inward reduces cylinder head end clearance. Turning the bolt out increases cylinder head end clearance. For percent clearance change per turn of the adjusting bolt, please refer to Table 1, ‘Compressor Mechanical Specifications. C. Replace the V.C.H. adjusting bolt cap.Startup Checklist Please verify all of the items on this list before ‘starting your compressor! Failure to do so may result in a costly (or dangerous) mistake. Before Starting the Compressor: 1. Become familiar with the function of all piping associated with the compressor. Know each line's use! 2. Verify that actual operating conditions will match the anticipated conditions. 3, Ensure that line pressures are within cylinder pressure ratings. 4, Clean out all piping. 5. Check that packing vents are open and tubed to proper locations. 6.All_ mounting shims, cylinder and piping ‘supports should be checked to ensure that no undue twisting forces exist on the compressor. 7. Netify that strainer elements are in place and clean. 8. Verify that cylinder bore and valve areas are clean. 9. Check V-belt tension and alignment. Check drive alignment on direct drive units. 10, Rotate unit by hand. 11. Check all fluid levels (crankcase, lubricator, radiator, oil, reservoirs, etc.). 12, Drain all liquid traps, separators, etc. 18. Verity proper electrical supply to motor and panel. 44. Check that all gauges are at zero level read- ing. 15. Test piping system for leaks. 16. Purge unit of air before pressurizing with gas. 17. Carefully check for any loose connections or bolts. 18, Remove all stray objects (rags, tools, etc.) from vicinity of unit. 19. Verity that all valves are open or closed as, required. 20. Double check all of the above. Alter Starting Compressor 1. Verify and note proper oil pressure. Shut down and correct any problem immediately. 2, Observe noise and vibration levels. Correct immediately if excessive. 3. Verify proper compressor speed. 4, Examine entire system for gas, oil or water levels. 8. Note rotation direction, 6. Check startup voltage drop, running amper- age and voltage at mator junction box. 7. Verify proper lube rate (lubed units only). 8. Test each shutdown device and record set points, 9, Test all dump valves, relief valves and unload- ers. 10. Check and record all temperatures, pressures and volumes after 30 minutes and 1 hour. 11. After 1 hour running time, tighten all bolts.REPAIR SERVICE ON YOUR COMPRESSOR Routine Maintenance {f routine maintenance is performed as outlined in Table 3, repair service on your CORKEN gas compressor is generally limited to replacing valves or piston rings. Log Sheet (CP-217) Use the log sheet in this manual on a regular basis. This will enable you to detect changes in operating conditions and give you the opportunity to correct problems while they are stil small (and inexpensive). It you need more copies, call the factory and ask for CR217. TABLE 3. Routine Maintenance Chart TEM TO CHECK (CRANKCASE OIL PRESSURE (COMPRESSOR DISCHARGE PRESSURE OVERALL VISUAL CHECK ‘CRANKCASE OIL LEVEL* LUBRICATOR OIL LEVEL, DRAIN MOISTURE FROM ACCUMULATION POINTS (CLEAN COOUNG SURFACES ON COMPRESSOR ‘CHECK BELTS FOR CORRECT TENSION INSPECT VALVE ASSEMBLES PISTON RiNGS** LLUBRICATE MOTOR BEARINGS IN ACCORDANCE. ‘WITH MANUFACTURER'S RECOMMENDATIONS. INSPECT MOTOR STARTER CONTACT POINTS. * Change crankcase ol and fier at Yeast every 6 month ct more often it needed °* Piston ring ite varies greatly depending on eppliction, gas, ancl operting pressures. Consut factory for ‘eddional fecommendabons foc your spectic appcalone, Piston Ring Life {t is unrealistic to expect the same piston ting life from a dry cylinder compressor as from a lubri- cated cylinder machine because the PTFE rings have greater wear, particularly under high tem- perature conditions. CORKEN uses one of the best PTFE ring formula- tions available, and the normal life expectancy of these rings is 2200 hours continuous service within recommended compression ratios, although longer fife is common. Obviously, this can vary ‘considerably with piston speed (RPM), ambient temperature, intermittent service conditions, ‘compression ratio and the nature of the gas being handled. The secret to long ring life is low temperature operation. The lower the ambient temperature, the better the intercooling; the lower the compression ratio, then the better the ring wear. Lubricated Cylinder Compressors 1f your compressor is equipped with cylinder lubrication you can expect considerably longer life with your piston rings than the dry cylinder units described above.DESCRIPTION Fe covansan-[5a ‘SUCTION VAIVE ASSEMBLY (6) SUCTION VALVE ASSEMBLY (814) DISCHARGE VALVE ASSEMBLY (1 DISCHARGE VALVE ASSEMBLY (31) VALVE CAP O-RING HOLDDOWN SCREW VALVE COVER PLATE O-RING 10, | Valve cage 11, | VALVE GASKET 42, | BouT 13, | VALVE COVER PLATE 14, | o-nine 18, | VALVE cage 10. | VALVE GASKET. ~ “DS “2 —, e. 3 SUCTION [DISCHARGE © SUCTION _| DISCHARGE We 1 16 AST STAGE 2ND STAGE INSTALL THE VALVES: AFTER THE CYLINOER IS IN PLACE. NOTE THIS DRAWING SHOWS 701 COMPONENTS. ‘THE #91 IS VERY SIMILAR, FIGURE 2. Valve Removal Valve Repair and Inspection (See Figure 2) Before starting to work be sure the compressor Is vented and depressurized and power is discon- nected. 1. Remove the valve cap. 2. Remove the holddown screw; a special CORKEN wrench is provided. (Ifthe holddown sorew comes out with the cap, separate them.) 3. Remove the bolts and valve cover plate. 4, Remove the valve cage. 5. The valve assembly can now be cleaning and inspection. Visual inspection will indicate if a spring or valve disc is broken or dirty. When replacing the valve, be sure the gaskets are properly sealed. Gaskets and o- rings are not normally reusable. 6. Remove valve assembly cage. 7. Replace cover plate and tighten bolt to 37ft-Ib. CAUTION: Be sure the holddown screw has been removed before tightening cover plate. 8 Replace holddown screw tightly enough to indent gasket. 9, Replace valve cap.TOP PisToN CLEARANCE: TAKEN AT TDC FROM TOP OF ‘CYLINDER TO PISTON CAP ‘SHIM WASHER, THICK OR THIN, . | SHIMWASHER, THICK OR THIN Lock nur. ‘THRUST WASHEA PISTON |. | PISTON RINGS ‘SHIM WASHER, THICK OR THIN [SCREW [EXPANDER RING [DRAIN VALVE NIPPLE NOTE: THIS DRAWING SHOWS 701 COMPONENTS. ‘THE 891 1S VERY SIMILAR (ALL TORQUE AND CLEARANCE VALUES ARE THE SAME), FIGURE 3. Piston Ring Replacement Piston Ring Replacement Before starting to work, be sure the compressor is vented and depressurized and power is discon nected. 1. Remove the cylinder caps and heads (see Figure 3). 2. Remove the piston cap screws and lift off the piston head and shim washers. 3, Remove the piston nut and lift out the piston, 4, Replace piston rings and expanders as needed. . Install piston, making sure that all shim and thrust washers are in their proper place. . Torque piston nut and verity proper bottom piston clearance (see Figure 3). . Install piston cap and shim washer, then verity Proper top piston clearance. }. Replace cylinder head o-tings if needed and install cylinder head and cap (see Figure 3 for proper torque valves). . Rotate unit by hand to ensure proper assembly.18 Note: GROGYE INTHE BOTTOM SF TRE BARREL ; DESCRIPTION PAGING BARREL (CARTRIDGE, OILSUNGER ANG SNAP RING . | CAUSH GASKET , | PACKING CUP’ , | SEGMENTED PACKING (RADIALTANGENT PAIR 4 | SEGMENTED PACKING (TANGENETANGENT) PAI ‘8, | BACKUP RING. 10. | wasnen . | SARING MALE PACKING AING PACKING FING . | FEMALE PACKING RING ‘O-ING se. |onins 17, | ScREW 16, | paca ser. NOTE: THIS DRAWING SHOWS 701 ‘COMPONENTS, THE 891 1S VERY SIMILAR, IMPORTANT: IDENTIFY AND LINE UP THE PACKING RINGS BEFORE INSTALLING. BE SURE THEY FACE ‘THE WAY SHOWN HERE AND THAT THE PIN AND HOLE ARE ALIGNED WHEN ASSEMBLED, Auatomyeriboue connie enon sos a PACKING DIRECTION eso ssi) -penamense Rae saa er 1” au ait 2 ar) ac 0B cuamtr)P own Hue woe sce ox scr na on Fon san (RSSUR SOE mass ance cur oor To CRANKCASE i cease FIGURE 4, Packing Assembly ammurrmy gut Packing Replacement and Inspection Before starting to work, be sure the compressor is vented and depressurized and power is discon- nected. 1. Remove the cylinder cap, heads, pistons and cylinder (see Figure 3). 2. To remove the packing barrels, pry upward under each one and lift entire barrel/cartridge assembly up from piston rod (see Figure 4), 3. Remove the four socket head screws which hold the packing cartridge to the barrel. 4, Replace packing as required. The segmented 2 packing and cups are in the barrel. The V-ring Packing is in the cartridge. Note the arrange- ment of the particular packing set for the mode! machine you have (see Figure 4). Replace the cartridges to the barrels. install cartridge barrel assemblies, noting the align- ment of the barrels as they sit on the crosshead guide. The valve scallops on the barrels must align properly with the valves of the cylinder. Replace oylinder, pistons, heads and cap. See Figure 3 for proper torque and clearance values, Rotate unit by hand to ensure proper assembly.General In most cases problems with your CORKEN gas compressor can be solved quite simply, Table 4 lists some of the more frequent problems that COMPRESSOR TROUBLE SHOOTING ‘occur with reciprocating compressors along with a jist whi of possible causes. If you are having a problem lich is not listed or if you cannot find the source of the problem, consult the factory. TABLE 4. Compressor Trouble Shooting Guide PROBLEM POSSIBLE CAUSES LOW CAPACITY 4.2.34 OVERHEATING 1:2,3,5,6,11 KNOCKS, RATTLES AND NOISE 1,7,9,10, 11, 16 ABNORMAL PISTON RING WEAR 113,56, 11,14 PRODUCT LEAKING THROUGH CRANKCASE BREATHER 8.15 PRODUCT LEAKAGE 45,14 COIL LEAKAGE AROUND COMPRESSOR BASE 15,16 NO OIL PRESSURE 17,18 EXCESSIVE VIBRATION 4,7,9,10, 14, 12,13, 14, 28 MOTOR OVERHEATING OR STARTER TRIPPING OUT 19, 20, 21, 22, 23, 24, 25 ‘REF. POSSIBLE CAUSES. WHAT TO DO +. | VALVES BROKEN, STUCK OR LEAKING INSPECT AND CLEAN OR REPAIR 2, | Piston ING woRN INSPECT AND REPLACE AS NECESSARY 3. INLET STRAINER CLOGGED CLEAN OR REPLACE SCREEN AS NECESSARY 4 | LEAKSINPIPING INSPECT AND REPAIR 5, | INLETOR AMBIENT TEMPERATURE TOO HIGH ‘CONSULT FACTORY 6. | COMPRESSION RATIO TOO HIGH (CHECK APPLICATION AND CONSULT FACTORY 7. | LOOSE SHEAVE OA BELT TIGHTEN 8 | WORN PISTON ROD PACKING REPLACE 9. | WORN WAIST PIN OR WAIST PIN BUSHING REPLACE 10. | WORN CONNECTING ROD BEARING REPLACE 11. | UNBALANCED LoaD INSPECT VALVES OR CONSULT FACTORY 12. | INADEQUATE COMPRESSOR BASE STRENGTHEN, REPLACE OR GOUT 13, | IMPROPER FOUNDATION OR MOUNTING TIGHTEN MOUNTING OR REBUILD FOUNDATION 14. | LOOSE VALVE, PISTON OA PACKING TIGHTEN OR REPLACE AS NECESSARY 15. LEAKING GAS BLOWING OIL FROM CRANKCASE REPLACE PACKING 16. BAD OIL SEAL REPLACE 17. | NOOILINGRANKCASE ‘ADD OIL ACCORDINGLY ta, | OLPuMP MALFUNCTION SEE OIL PRESSURE ADJUSTMENT” 19, | LowvorTace CHECK LINE VOLTAGE WITH MOTOR NAMEPLATE ‘CONSULT POWER COMPANY 20. MOTOR WIRED WRONG CHECK WIRING DIAGRAM 21. | WIRE SIZE TOO SMALL FOR LENGTH OF AUN, [REPLACE WITH CORRECT SIZE 22, | WRONG POWER CHARACTERISTICS VOLTAGE, PHASE AND FREQUENCY MUST GOINCIDE WITH MOTOR NAMEPLATE ‘GONSULT POWER COMPANY 23, | WRONG SIZE HEATERS IN STARTER CHECK AND REPLACE ACCORDING TO (MANUFACTURER'S INSTAUCTIONS 24, | COMPRESSOR OVERLOADING REDUCE SPEED 25. MOTOR SHORTED OUT SEE "DRIVER INSTALLATION" 28. | BAD MOTOR BEARING LUBRICATE ACCORDING TO MANUFACTURERS INSTRUCTIONS‘Two-Stage Compressor Trouble Shooting ‘Two-stage compressors can have problems that ever occur with single-stage machines. Interstage pressure is an important indicator of the condition of a two-stage compressor, Mf interstage pressure is too high: 1. Second stage valves may be broken or HW interstage pressure is too low: 1. First stage valves may be broken or leaking. 2. First stage piston rings may be worn. lf suction and/or discharge pressures change, the leaking. interstage pressure will also change. 2. Second stage pisten rings may be warn, EXTENDED SHUTDOWN PROCEDURES Properly preparing a unit for extended shutdown will minimize future startup problems. 1. Drain the crankease oll and refill with rust Inhibiting oil. 2. Operate for a few minutes while fogging oll into ‘the compressor suction, 3, Relieve V-belt tension. 4, Plug all openings to prevent entry of insects and moisture. (The cylinders may also be protected by the use of a vapor phase inhibi- tor, silica gal, or dry nitregen gas. If the silica gel is used, hang a tag on the unit indicating that it must be removed before a startup) 5. Stora in a dry area, off the ground if possible. 6. Rotate the flywheel every two weeks if possible. 10EXTERNAL LUBRICATORS USED ‘ON CORKEN COMPRESSORS MADISON-KIPP MODEL DSL LUBRICATOR DATA: ROTATION: Either Direction MAX. OPERATING PRESSURE: 3000 PSIG INLET AND OUTLET SIZE: 1/8" NPT DELIVERY PER PLUNGER STROKE: Adjustable 0-3.4 drops 0 - 0.008 cubic inches MAX, DELIVERY/MIN: ‘Compressor RPM X .0151 X Delivery Per Stroke (Vertical Units 791-891) (Basic drop size equals 0.0024 cubic inches) NOTE: The lubricator supplied on your CORKEN compressor must be supplied with oil from an external supply tank, NOT from the compressor crankcase, or lubricator reservolt. EXTERNAL LUBRICATOR scone owe 0 ‘DURING PRIMING ooMocR xi mayouroise a 3 set ‘aan = nsepar anual PANN PuUNGER ‘sour aus FoR Fuow anus FESERVOIR OW LEVEL ex mr The Madison-Kipp DSL fubricator is manufactured and designed so that each pumping unit can be individually adjusted for the exact amount of Jubricating oil to be fed to a given position. The operation and adjustment methods are described on a metal instruction plate attached to the side of the lubricator reservoir. " To Start: 1. Check that all tubing is free of any kinks. Any replacement tubing should be clean and the ends free of burrs, Fill reservoir with oil. If oilis visible in sight dome, go to Step 7. Remove the sight dome. Fill he pump chamber with oil. Replace the sight dome (linger tight only). Connect tubing between top of sight dome until air bubbles are purged and ol is clear. Remove the discharge tubing from the filter Prime by manually pumping plunger in front of sight dome until air bubbles are purged and oil is clear. Reconnect the discharge tubing to the filter. Operate the compressor manually to check stroke, alignment and operation. Additional precautions taken at this time will eliminate the possibility of maffunction and prevent damage to your lubricator and equipment. Neae ew oe 10, WW. 12. To Adjust Flow: 1. Loosen lock nut on flow adjusting nut, 2. To increase flow, turn adjusting nut counter- clockwise; to decrease, turn clockwise. 3, Tighten lock nut, To Maintain At Peak Performance: 1. Use only clean oil. 2. Keep lubricator reservoir full of oil. 3. See that all connections are tight. 4 |. See that oll leads are supported where ‘excessive vibration occurs. Check lubricator drive system to ensure that all components are in alignment and good condition, Make sure all mounting bolts are tight.cea CORKEN COMPRESSOR LOG SHEET (Electric Driven Units) Compressor Model # Serial # Cylinder Seriai #'s RPM Motor BHP. . Frame . RPM FL, Amps « Manut Packager Package #. Installation Date Startup Date Customer Location Field Contact Tel # Make and Grade of Oil Pressure Switch Settings Stage 1 Stage 2 Suction Pressure Discharge Pressure Cylinder Lube Pump Rate Date Time Outside Temp, Hour Meter Readings: Stage 1 Stage 2 Suction Pressure ee Discharge Pressure Suction Temperature Discharge Temperature Check List: Oil Levet 6. Lube Pump Oil Level Change Oi ——— ¢yI. Lube Pump Supply Level Flywheel Bolts Cyl, Lube Pump Feed Rate Mounting Botts Beit Tension Motor Amperage —— Gauges (Zero Position) Strainers Packing Vents Valve Positions = brain Separators Dump Valves —__ Unloaders Additional Notes: Checked By: 12CORKEN PG Bex 12398, Oklahoma Gi OK FOI? ‘3005 N.VF. 36th St, Oklahoma City, OK 73112 Phone (408) 946:5376 + Fax (408) 948-7343 web site Nttp://www.cerkan.com email [email protected] PRINTED IN USA ‘SEPTEMBER, 1997