Brownie’s Yacht Pro 135 User manual

YP135DF

Yacht ProTM 135 Automatic Compressor

Operator’s Manual

BROWNIE’S THIRD LUNG

940 NW First Street

Fort Lauderdale, FL 33311

Ph 954-462-5570

Fx 954-462-6115

www.tankﬁll.com / info@tankﬁll.com

2

This information is believed to be accurate by Brownie’s Third Lung as of it’s date of publication, but Brownie’s

offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein.

Brownie’s shall not be liable for inaccuracies in, or consequences resulting from, your use of this information. All

information supplied is in connection with sales of Brownie’s products, and is thus subject to Brownie’s standard

terms and conditions of sale. Brownie’s reserves the right to change this information and has no obligation to

to itself all rights to this publication. Brownie’s customers have no right to reproduce, rewrite, modify, license or

permit anyone else’s use of this information, without the express written permission of Brownie’s Third Lung.

Edition 1.0 04/2007

Thank You for purchasing a Brownie’s Yacht ProTM Series Compressor System. This manual explains

the use and maintenance of your unit. All information here is based on the latest product data available

at the time of publication. Brownie’s Third Lung reserves the right to make unannounced changes at

any time without incurring any obligations whatsoever.

This Operator’s Manual is to be considered a part of the overall compressor package and should

remain with the compressor in the event of sale to another party.

3

Table of Contents

CHAPTER 1: INTRODUCTION 5

1.1 How to Use this Manual 5

1.2 Manual Safety Notices 5

1.3 General Safety Precautions 6

1.4 Description of Unit 7

1.5 Standard Features 7

1.6 Compressor Quality Analysis Record 8

1.7 Product Data 9

1.8 Installation 10

CHAPTER: 2 OPERATIONS 11

2.1 Pre Start-up Checks 11

2.1.1 Check oil level 11

2.1.2 Check Visual Carbon Monoxide / Moisture Indicator 11

2.1.3 Check Air Intake 11

2.1.4 Pre-startup Maintenance/Inspection Notations 11

2.1.5 Tank Inspection 11

2.2 Tankﬁll Procedures 12

2.3 Lubrication Speciﬁcations 14

CHAPTER 3: MAINTENANCE AND PARTS 15

3.1 Recommended Maintenance 15

3.2 Compressor Block 16

3.3 Intake Filter 17

3.4 Oil Level Check 17

3.5 Oil Types 17

3.6 Oil Change Procedure 18

3.6.1 Oil Filter Replacement Procedure 18

3.6.2 Changing Oil Type 18

3.7 Check Drive Belt/Replace Belt 19

3.8 Intermediate Separators 20

3.9 Cooling System 22

3.9.1 Maintenance 22

3.9.2 Compressor Valves and Heads 22

3.9.3 Functional Description 22

3.10 Torque Valves and Sequencing 23

3.11 Valves 24

3.11.1 Valve Functioning 24

3.11.2 Initial Operational Check 24

3.11.3 Valve Change General Instructions 24

3.11.4 Changing 1st Stage Valves 24

3.11.4.1 Removal 24

3.11.4.2 Reassembly 25

3.11.5 Changing the 2nd Stage Valves 26

3.11.6 Changing the 3rd Stage Valves 27

3.11.6.1 Removal 27

3.11.6.2 Reassembly 28

3.11.7 Changing the 4th Stage Valves 29

3.11.7.1 Removal 29

3.11.7.2 Reassembly 30

* Any applicable addendums will be inserted just before the last page before the Warranty Information.

4

3.12 Exploded View Diagrams

3.12.1 Crankcase Assembly 32

3.12.2 1st/2nd Stage Piston and Cylinder 34

3.12.3 3rd Stage Piston and Cylinder 35

3.12.4 4th Stage Piston and Cylinder 36

3.12.5 1st Stage Valve Head and Valve 37

3.12.6 2nd Stage Valves and Valve Head 38

3.12.7 3rd Stage Valves and Valve Head 39

3.12.8 4th Stage Valve and Valve Head 40

3.12.9 Intermediate Separator 41

3.12.10 3rd Stage Intermediate Separator 42

3.12.11 Intake Filter 43

3.12.12 Cooling System 44

3.12.13 Lubrication System 46

3.13 Sightglass CO/Moisture Element Replacement Procedure 48

3.14 Compressor Components 50

3.14.1 Compressor Details 51

3.14.2 Mechanical Separator 52

3.14.2.1 Chamber 52

3.14.2.2 Cartridge Construction 52

3.14.2.3 Cartridge Handling 52

3.15 Electrical Panel 53

CHAPTER 4: TROUBLESHOOTING 54

CHAPTER 5: OPERATION LOG 56

5.1 Yacht ProTM System Operation Log 56

5.2 Notes 62

CHAPTER 6: WARRANTY 63

5

DANGER

CAUTION

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury. This is limited to the most extreme situations.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury. It may also be used to alert against unsafe practices.

NOTE

NOTE advise of technical requirements that require particular attention by the operator or the maintenance

technician for proper maintenance and utilization of the equipment.

WARNING

This Instruction Manual and Replacement Parts List contains safety information and instructions for the

YachtProTM 135 Compressor. You must read, understand and follow all safety precautions and instructions. Not

doing so may result in damage to the system and/or personal injury or death.

CHAPTER 1: INTRODUCTION

1.1 HOW TO USE THIS MANUAL

This manual contains the operating and maintenance instructions for the Brownie’s Third Lung product(s) listed on

the front cover. In order to familiarize yourself with the compressor features, please read this manual thoroughly

before using the equipment.

All instructions in this manual should be observed and carried out as written to prevent damage or premature

wear to the product or the equipment served by it.

If your unit is equipped with nonstandard accessories and/or options, supplemental information is normally

included in other documentation; i.e. OEM Manuals or additional Brownie’s Third Lung Manuals.

While every effort is made to ensure the accuracy of the information contained in this manual, Brownie’s Third

Lung will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof.

1.2 MANUAL SAFETY NOTICES

Important instructions concerning the endangerment of personnel, technical safety or operator safety will be

specially emphasized in this manual by placing the information in the following types of safety notices.

6

1.3 GENERAL SAFETY PRECAUTIONS

Read the operating manual before installing or operating this compressor unit. Follow appropriate handling,

operation and maintenance procedures from the very beginning. The maintenance schedule contains mea-

sures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed

regularly to achieve safe operation, maximum efﬁciency and long service life.

We recommend that all maintenance work be recorded in a service book, showing the date and details of the

work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is neces-

sary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried

out and that the damage has not been caused by insufﬁcient maintenance.

This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and

qualiﬁed personnel.

Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering then installation

and operation of this compressor and accessories before operating the unit.

Do not operate this unit in excess of it’s rated capacity, speed, pressure, temperature, or otherwise than in ac-

cordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set

forth in this manual will subject the unit to limits which it may not be designed to withstand.

Keep safety guards in place.

Do not modify the compressor or its systems.

Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, bracelets, hand

rags, etc. are potential hazards.

Provide adequate ﬁre protection. Make sure ﬁre extinguishers are accessible. Select alternate routes of es-

cape and post such routes.

Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats,

safety shoes and ﬁre extinguisher.

Visually inspect the unit before starting. Remove and /or replace any loose or broken components, tools,

valves, missing equipment, etc. Do not operate the compressor if the compressor is damaged.

Do not tamper with, modify, or bypass safety and shutdown equipment.

Do not tighten or adjust ﬁtting or connections under pressure.

The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to insure

system compatibility of ﬂex joints and ﬂexible hose can result in mechanical failure, property damage, and

serious injury or death.

The use of plastic or nonmetallic bowls on line ﬁlters without metal guards can be dangerous.

Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced fan

can ﬂy apart and create an extremely dangerous condition.

Allow the compressor to cool before servicing. Whenever the compressor is shut down and overheating is

suspected, a minimum period of 15 minutes must elapse before opening the crankcase.

Premature opening of the crankcase of an overheated unit can result in an explosion.

Incorrect placement of the inlet and pressure valves in a compressor cylinder head can cause an extremely

dangerous condition. Refer to the appropriate section of this manual before installing or replacing valves.

Before doing any work involving maintenance or adjustment, be sure the electrical supply has been discon-

nected, and the complete compressor system has been vented of all internal pressure. Failure to follow these

warnings may result in an accident causing personal injury and/or property damage.

•

7

1.4 DESCRIPTION OF THE UNIT

Your Yacht ProTM Series is a fully automatic compressor, equipped with Automatic Condensate Drain (ACD). The

YP series has been designed speciﬁcally with the traveling yacht owner in mind. The compressor system is de-

signed for “HANDS FREE” operation.

1.5 STANDARD FEATURES

The complete Yacht ProTM Series package includes:

• One 316L Stainless Steel Base

• One High Pressure Compressor with a 10 HP Motor

One Digital Frequency Drive (see manufacturer’s owner’s manual)

• One Automatic Condensate Drains

• Two Condensate Collection Jugs

• Securus® Filtration System (see manufacturer’s owner’s manual)

One Dual Pressure Switch

• One Sightglass Element (moisture and CO monitor)

• Tool Kit

• One gallon, Synthetic Compressor Oil (Part Number CF-2000)

One Operator’s Manual

• One Four-way Manifold with 10-foot connection hose including stainless steel quick disconnect end

• One padded Custom Manifold Bag

Optional Equipment:

• Stainless Steel Quick Disconnect Set

• Custom Hose Lengths

• Remote Fill Plumbing Kit

• Cordura Nylon Cover

• Remote On/Off Switch (with installation only)

Use of Compressor:

The Yacht ProTM Series is intended for the compression of air and other gas mixtures. Make sure the air entering

the compressor is clean atmospheric air.

•

Before working on the electrical system, be sure to disconnect the electrical supply from the system at the cir-

cuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the electrical supply.

Installer must provide an earth ground and maintain proper clearance for all electrical components.

All electrical installation must be in accordance with recognized national, state, and local electrical codes.

Do not use gasoline, diesel fuel or other ﬂammable products as a cleaning solution.

Do not operate the compressor near ﬂammable substances or objects

A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser

and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser/user

assumes all liability resulting therefrom without any responsibility being assumed by Brownie’s Tankﬁll.

The purchaser is urged to include the above provision in any agreement for resale of this compressor.

The use of repair parts other than those listed in this manual or purchased from Brownie’s Tankﬁll, Inc. may

create unsafe conditions over which Brownie’s has no control. Such unsafe conditions can lead to acci-

dents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment.

Therefore, Brownie’s Tankﬁll can bear no responsibility for equipment in which non-approved repair parts are

installed.

•

8

Date:

Serial # Model # Order#

Motor Wiring V PH HZ

Belt Size Tension

Connections Tight Nuts & Bolts Tight

No Leaks Control Wiring Correct

Final Pressure Setting Tank Fill Time

Drain System Operation Interval

Oil Level Oil Removed

Hour Meter Reading Test Run Time

STANDARD EQUIPMENT

Securus® Filtration Frequency Drive

Manual Lubricant

4TKMAN Sightglass Elements

Block #

OPTIONAL EQUIPMENT & MISC

Remote Fill Panel

FC374-04RL (Additional for 4TKMAN Main) FT

Technician Installer

1.6 COMPRESSOR QUALITY ANALYSIS RECORD

(80 ft³ 500-3000 PSI)

9

1.7 PRODUCT DATA

Category Speciﬁcations

COMPRESSOR DATA

Air Delivery Rate: 10.8 scfm2 FAD/ 142 LPM

* Operating Pressure (max): 6000 PSI

** Pressure setting, ﬁnal: 3200 PSI pressure safety valve (STD)

Dimensions: 27.5”H x 36”L x 21”D (699mm x 914mm x 533mm)

Weight: 350 lbs. Approx (158.8 kg)

Use: Compression of atmospheric air

Intake Pressure: Atmospheric Pressure

Compressor RPM: 3600

Drive Belt Type: AP73

Number of Stages: 4

Number of Cylinders: 3

Cylinder Bore 1st Stage: 4.2 in (105 mm)

Cylinder Bore 2nd Stage: 4.15/3.46 in (105/88 mm)

Cylinder Bore 3rd Stage: 1.10 in (28 mm)

Cylinder Bore 4th Stage: 0.47 in (12 mm)

Piston Stroke: 1.57 in (40 mm)

Intermediate Pressure 1st Stage: 49.3-60.9 psig (3.4-4.2 bar)

Intermediate Pressure 2nd Stage: 203-261 psig (14-18 bar)

Compressor Block Oil Cap.: 3 qts / 2.8 liters

Recommended Oil Types: CF-2000 Synthetic Compressor Lubricant

Max. ambient temperature: +32º to +100º F (+0º to +37.8º C)

Recommended Operating Temp: 70º F (21.1ºC)

Max. permissible inclination: 15º in all directions

Duty Cycle at max pressure: Continuous

Vibration Mounts: Vulcanized neoprene over steel

Capacity Range: 190-380 lbs. (86-172kg) each

BTU’s: 27,880

MOTOR DATA

Motor: 10hp TEFC / 3-ph / 60 hz

Frame: 215T

Shaft Diameter: 1-3/8” (34.9mm)

Duty Cycle: Continuous

Motor RPM: 1760

Voltage: 208-230 or 380-460

F.L.A.: 24 / 12.6

BTU’s: 25,483

Rotation reconn.

Mounting rigid

Ball Bearing

* Unit has a max pressure rating of 6000 psi (3200 psi by default)

** May be set higher or lower based on Pressure Switch settings

10

1.8 INSTALLATION

All persons operating the Yacht ProTM Series system must read this manual completely and fully understand the

procedures for system operation and the responsibilities of the operator to insure the safety of divers supplied

with air from the system. We recommend professional installation by our experienced installation technicians. The

Yacht ProTM Series must not be operated in an enclosure that does not meet the installation/operation guidelines

for the unit. Contact our Technical Department for advice.

The Yacht Pro™ series tank ﬁll compressor must be installed in accordance with the following recommendations:

1. Ambient temperature during operation must not exceed 100 deg F (38 deg C) maximum. The unit will produce

heat when operating, therefore adequate ventilation must be provided to stay well within the maximum limit

listed above.

We recommend operating unit well below the maximum limit. Forced Ventilation must be used where poor air

circulation is present. Contact our Technical Department with questions regarding proper ventilation.

2. Proper clearances must be allowed for the following:

6” minimum from the fan cover to any bulkhead. This provides adequate air supply for the cooling fan.

8” minimum above the ﬁlter tower. This allows easy ﬁlter removal/replacement and easy access to remove

the oil dipstick for checking/changing oil.

Allow working access to the electrical box for service/repair.

The oil drain tube must have clearance for oil changes.

The condensate drain reservoir must be accessible for removal.

Hour meter, on/off switch, and visual monitor must be accessible for safe operation.

Belt Guard must be accessible for service of drive belt.

3. The unit must be installed on a ﬂat, level surface. No more than 10 deg inclination must occur during operation.

4. The Yacht ProTM Series units are provided as a complete assembly ready for installation. Some installations

may require remote mounting of package components. This must be approved by our Technical Department.

5. Clean, fresh air must be provided to the air intake of the compressor as close to the operating ambient

temperature of the unit as possible. Remote air intake plumbing may be required. A non-collapsible plastic

hose with 3/4” ID is the simplest method. The 3/4” ID may be run for a length of 10’. Longer runs may be used

by following this guideline: For every 10’ of run the preceding 10’ diameter must be doubled. All 90 deg ﬁttings

should be considered as 1 foot of length.

6. The unit must be protected from any type of water exposure. Such exposure will seriously effect the longevity

of the unit and may result in personal injury or death.

7. Electrical Requirements:

Yacht ProTM series compressors come standard with 220 VAC 60 HZ single phase electric motors. They are

equipped with 120 VAC 60HZ controls and components. All units require correct electrical supply components

be provided in accordance with local, state and federal codes for land installation and marine codes for on-board

installation. An electrician should be consulted for supply power recommendations. Standard units require that

a neutral wire be provided with the standard power supply, for correct operation. An optional remote transformer

can be used to provide control voltage if neutral is not available. Some voltage and cycle combinations will require

an optional transformer for correct operation.Yacht ProTM Series are available for other electrical requirements.

Please contact our Technical Department for speciﬁcations.

•

WARNING

Improper installation may result in damage to the unit, personal injury or death.

NOTE

The intake must be protected from water entry, as this will cause severe damage to the unit.

11

2.1 PRE START-UP CHECKS

Consult the system log to see if the following maintenance needs to be done:

Puriﬁcation Cartridge inspection/replacement (see supplemental manuals).

Sightglass Element replacement (6 month installed life) (see page 48)

Oil Check/Change (see pages 17-18)

2.1.1 Check oil level

The oil level must be between the upper and lower marks on the dipstick (see page 17). If the oil is low, add oil

through the dipstick tube. Use only Brownie’s recommended oil. Do not mix oils or use non-recommended oils

which may adversely affect the life of the unit or even destroy the unit.

•

2.1.2 Check Visual Carbon Monoxide / Moisture Indicator

The visual indicator has two elements. An outer blue ring for indicating the presence of moisture, and a central tan

to orange disc, indicating the presence of carbon monoxide. Any change in color, (the central disc (CO) turns dark

brown or has black spots, and/or the outer ring (moisture) turns pink or beige, indicates that the air leaving the

puriﬁcation system is contaminated and not breathable. The visual monitor is the last monitor of the air leaving the

puriﬁcation system, and must be checked during operation for any changes.

Good Conditions: Inner Ring - Yellow

Outer Ring - Blue

DANGEROUS

DO NOT USE AIR

CHANGE CARTRIDGE

SATURATED

GOOD

WARNING

Divers lives depend upon proper operation of the system. Brownie’s Third Lung highly recommends that all

system operators take a System Training Course.

WARNING

Any color change in the elements of the visual indicator means that contaminated air has passed downstream.

All air lines, ﬁll assemblies, and equipment must be cleaned or replaced. An Air Quality Test must be done to

insure thoroughness of all cleaning. Breathing contaminated air may result in personal injury or death.

WARNING

Failure to monitor or replace the puriﬁcation cartridge WILL contaminate all air lines, ﬁll assemblies, divers air

tanks, regulators, and may cause severe injury or even diver death. The system operator is responsible for the

lives and safety of the divers using air produced by the system.

CHAPTER 2: OPERATIONS

2.1.3 Check Air Intake

Remove and inspect the Air Intake Filter. If the system is equipped with a remote air intake, be sure it is properly

located, and clear of any water or obstructions.

2.1.4 Pre-startup Maintenance/Inspection Notations

Add all pre-startup maintenance/inspection notations to the system log with date, hours, and operator name.

2.1.5 Inspect ALL tanks to be ﬁlled:

• Make sure the tanks are in good condition with no deep scratches, gouges, or pitting.

• The tanks must be within current hydrostatic test and Visual Inspection dates.

• Do not ﬁll empty tanks without ﬁrst visually inspecting them for water intrusion.

• Make sure that the valves are in good condition and not in need of service. Do not ﬁll tanks with damaged

valves.

• Do not ﬁll tanks that have been exposed to extreme heat, i.e.: tanks that have been in or near ﬁres.

12

2.2 TANKFILL PROCEDURES

WARNING

Tanks must be secured (protected from falling or being

knocked over) during ﬁlling.

Tank Fill Whip Assemblies:

Shown are the tankﬁll whip ends for DIN and Yoke systems.

A. Yoke connector

B. DIN connector

C. bleeder valve

D. ﬁll valve

B

C

D

A

DC

1. Hook up ﬁll manifold to compressor air outlet or remote ﬁll

panel.

2. Open tank valve slightly to blow any moisture or particles clear

of connection surfaces.

3. Standard Yoke - Hook ﬁll yokes to the tank valves and tighten

yoke hand wheel “ﬁnger tight” (Figure 1).

a. Close bleed screws (Figure 2)

b. Open tank valves counter-clockwise (Figure 3)

c. Open Fill Valves (Figure 4)

Counter-clockwise rotation of this valve will open the line

to the tanks. The tanks will now equalize any differences in

their pressures.

Din Yoke - Screw the male din yokes into the valves until the

“o-ring” is snugly in place against the base of the female din

valves.

a. Close bleed screws (Figure 2)

b. Open tank valves counter-clockwise (Figure 3)

c. Open Fill Valves (Figure 4)

Counter-clockwise rotation of this valve will open the line

to the tanks. The tanks will now equalize any differences in

their pressures.

4. Start the Compressor

The compressor will now operate automatically, draining

the condensate and shutting off when the tanks are full. The

operator need only check the operation from time to time during

the ﬁlling process to verify the following:

• Condensate is accumulating in the reservoir.

• No color change has occurred in the visual indicator.

• Pressure is building on the ﬁll gauge.

Figure 1

Figure 2

Figure 3

Figure 4

13

WARNING

Do not try to remove the quick disconnect while the system is pressurized. Doing so may result in property

damage or personal injury.

Fill times are based on ﬁlling a single standard 80 cu. ft aluminum

cylinder from 500 psi to 3000 psi and are approximately 5 minutes

per tank. Cylinder volume, starting tank pressure, and tank pressure

ratings will vary the ﬁll times.

Note that the indicator light is still on after the compressor automati-

cally stops. This indicates that the compressor is in an AUTOMATIC

START MODE and will restart if the stop pressure drops approxi-

mately 500 psi.

If you intend to ﬁll more tanks you may leave the on/off switch in the

“on” position while changing the tanks out. Simply opening the tank

and ﬁll yoke valves will restart the compressor.

5. Remove full tanks by ﬁrst closing the ﬁll yokes and tank valves

(Figure 5). Depressurize the yokes by opening the bleed screws

(Figure 6). Remove the ﬁll yokes from the tanks (Figure 7).

6. When you are done ﬁlling for the day, turn the on/off switch to the

off position. Empty the condensate reservoir.

7. Bleed the pressure from the ﬁll manifold by opening one of the

ﬁll yoke valves slowly until all pressure is vented and the gauge

reads zero.

8. Remove the manifold from the hose using the quick disconnect

ﬁtting and store the manifold in its bag.

9. Allow the compressor to cool prior to installing the optional Cor-

dura fabric cover.

10. Update the system log, noting running hours of compressor and

any maintenance performed.

Figure 5

Figure 6

Figure 7

14

2.3 LUBRICATION SPECIFICATIONS

Use Lubricant

O-rings, rubber and plastic parts, White Petroleum DAB9 # N19091 or WEICON WP 300

ﬁlter housing threads White part # N19752

Sealing Rings Universal grease

Paper Gaskets Apply silicone compound on both sides (WACKER

silicone compound part # N 18247) before assembly

Bolts, nuts, studs, valve parts, CU gaskets and pipe Compounds with Copper or MoS² additives (WEICON

connectors (threads, cap nuts, compression rings) ANTI-SEIZE AS 040 P part # N 19753)

High Temperature connections Temperature resistant compound (WACKER

(valve heads / cylinders) silicone compound, part # N 18247

15

CHAPTER 3: MAINTENANCE AND PARTS

3.1 RECOMMENDED MAINTENANCE

WARNING

We recommend that any maintenance other than preventative be performed by an authorized service center

or technician. Contact Brownie’s for service center information.

INTERVAL TYPE OF MAINTENANCE DATE SERVICE CENTER

After 25 hrs initially,

and every 50 - 100 hrs

thereafter

Oil Change (every 50 hours when using regular

oil, and every 100 hours if using synthetics) or six

months

After 25 hrs initially,

and every 150 hours

thereafter

Check function and tightness of ﬁlling valve

Clean and change intake ﬁlter

Check tightness of o-rings

Check drive belt and condition

Check cooler brackets

Check zero on gauge when depressurized

After 1st year or 300

hours of operation

Air and tightness check

Replace ﬁlter chamber o-rings

Drive belt inspection (replace after 300 hrs)

Cleaning of air intake ﬁlter and ﬁlter unit.

After 2nd year or 600

hours of operation

Check air tightness and performance

Drive belt inspection (replace after 600 hrs)

Replace ﬁlter chamber o-rings

Cleaning of air intake ﬁlter and ﬁlter unit.

After 3rd year or 900

hours of operation

Check air tightness and performance

Drive belt inspection (replace after 900 hrs)

Replace ﬁlter chamber o-rings

Cleaning of air intake ﬁlter and ﬁlter unit.

After 4th year or 1200

hours of operation

Check air tightness and performance

Drive belt inspection (replace after 1200 hrs)

Replace ﬁlter chamber o-rings

Replacement of air vent hos

Replace cylinder head o-rings.

Clean air intake ﬁlter & unit.

After 5th year or 1500

hours of operation

Check air tightness and performance

Drive belt inspection (replace after 1500 hrs)

Replace ﬁlter chamber O-rings

Cleaning of air intake ﬁlter and ﬁlter unit.

After 6th year or 1800

hours, of operation

Check air tightness and performance

Drive belt inspection (replace after 1800 hrs)

Replace ﬁlter chamber o-rings

Cleaning of air intake ﬁlter and ﬁlter unit.

After 7th year or 2100

hours of operation

Check air tightness and performance

Drive belt inspection (replace after 2100 hrs)

Replace ﬁlter chamber o-rings

Cleaning of air intake ﬁlter and ﬁlter unit.

16

3.2 COMPRESSOR BLOCK

The compressor block is used to compress air up to 6000 psi. This compressor is a four stage, three cylinder air

cooled, oil lubricated reciprocating compressor. The cylinders are arranged in a “W” conﬁguration, the 1st/2nd

stage vertical stepped cylinder is in the center, 3rd stage on the right and 4th stage on the left looking from the

intake ﬁlter side. These compressor blocks are particularly suitable for continuous operation because of their rug-

ged design and corrosion resistant intermediate ﬁlter and cooler assemblies.

Compressor Block, Front View

1. Intake Filter

2. 1st Stage Safety Valve

3. 2nd Stage Intake Manifold

4. Oil Filler Neck

5. 4th Stage Cylinder

6. 3rd Stage Safety Valve

7. 3rd Stage Separator

8. 3rd Stage Intercooler

9. Oil Drain Plug

10. Condensate Drain Connector

11. 1st Stage Valve Head

12. 2nd Stage Pressure Manifold

13. 3rd Stage Cylinder

14. 2nd Stage Safety Valve

15. Oil Filter Housing

16. 2nd Stage Separator

17. 2nd Stage Intercooler

18. Compressed Air Outlet

19. 4th Stage Aftercooler

1

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

11

17

3.4 OIL LEVEL CHECK

Check the oil level at the sight glass on the side of

the compressor block everyday before operating the

compressor. Note that the oil level must be between the

minimum and maximum notch.

Add oil if necessary and recheck level. Oil should not

exceed the maximum level, as this could result in carbon

build up on the valves

3.5 OIL TYPES

Using the correct oil is of utmost importance for proper

care and maintenance of the compressor, along with

keeping the life and function of your compressor at its

best.

Only use oils that:

• are low in deposits

• have no carbonizing effect, especially in the

valves

• have good anti-corrosive properties

• provide emulsiﬁcation of the condensate in the

crankcase

• are physiologically and toxicologically suitable

Due to the thermal load on the compressor, only high

quality oil should be used.

For operating under severe conditions such

as continuous running and/or higher ambient

temperatures, we recommend Part No. CF-2000

(Synthetic Compressor Lubricant, Food Grade).

CF-2000 has been specially formulated for use in

high pressure compressors and will provide optimal

performance through a wide range of conditions.

Compressor systems are delivered with one gallon of

synthetic oil, Part No. CF-2000.

3.3 INTAKE FILTER

A dry, micronic ﬁlter is used to ﬁlter the intake air,

see image to the right. The ﬁlter cartridge must be

changed at regular intervals. See the Maintenance

Schedule for the recommended interval.

1. Unscrew and remove Knurled Nut (1)

2. Remove Washer (2) and Filter Housing (3).

3. Discard Filter Element (4) and replace with new

Filter Element Bauer.

4. Reassemble in reverse order.

Intake Filter

1. Knurled Nut

2. Washer

3. Filter Housing

4. Filter Element

1

2

3

4

maximum

minimum

Figure 1

18

3.6.1 OIL FILTER REPLACEMENT PROCEDURE

1. Remove the two bolts (Figure 5-1) using a 13mm wrench

2. Remove the oil cover(Figure 5-2)

3. Remove the oil ﬁlter from the rubber gasket at the cover (Figure 6)

4. Mount a new ﬁlter element (P/N N25326)

5. Replace and fasten oil cover

6. Slowly pour new oil* through the oil ﬁller neck (Figure 2) until the

level reaches the maximum mark on the sight glass

7. Wait a few minutes and adjust the oil level if necessary before putting

the unit into operation

3.6.2 CHANGING OIL TYPE

1. Changing from synthetic type oil to petroleum type oil requires no

special procedures

2. Changing from petroleum type oil to synthetic type oil requires the

following steps to avoid severe damage to the compressor unit:

a. Drain petroleum based oil completely while it is warm

b. Replace or clean all deposits from valves, coolers, separators,

puriﬁers, tubes and hoses

c. Fill with 12 ﬂuid ounces (360 mL) of synthetic oil

d. After 100 operating hours check oil for degree of contamination

and change oil again if necessary

e. On subsequent oil changes reﬁll only with synthetic oil

* Brownie’s supplies CF-2000 food-grade synthetic compressor lubricant

with all compressors.

3.6 OIL CHANGE PROCEDURE

Care should be taken in draining oil into a proper container for disposal

per local guidelines and laws.

1. Turn on the compressor and run it until warm

2. Remove the red cap on the oil ﬁller neck (Figure 2)

3. Remove the ball valve cap at the base of the compressor block

(Figure 3)

4. Attach appropriate drain valve and hose (Figure 4)

5. Open ball valve by rotating handle (Figure 4)

6. After oil is completely drained, close the ball valve (Figure 4)

7. Slowly pour new oil* through the oil ﬁller neck (Figure 2) until the level

reaches the maximum mark on the sight glass

Figure 2

1

2

Figure 3

Figure 4

Figure 5

Figure 6

NOTE

Replace the oil ﬁlter every oil change. Failure to do so will

cause the ﬁlter to clog and bypass valve to open resulting

in unﬁltered oil being circulated and possible damage to the

compressor.

19

3.7 CHECK DRIVE BELT/REPLACE BELT

The drive belt should be checked at least every 125 hours, assessing the belt for wear or damage. Should the belt

need to be replaced:

1. Remove the belt guard from the compressor unit. Lift the motor to release the tension on the belt (Figure 2).

2. Remove the old belt and replace.

3. Release the motor. The weight of the motor will adjust the tension of the belt (Figure 1). Replace the belt guard.

Figure 1 Motor at Normal Position

Figure 2 Motor Lifted to Relieve Tension on Belt

20

3.8 INTERMEDIATE SEPARATORS

Intermediate separators are mounted on the compressor between the 2nd and 3rd stage and between the 3rd

and 4th stages. These separators are designed to remove oil and water which accumulates due to the cooling of

the medium after the compression process. Separation is achieved by means of centrifugal action.

2nd Stage Intermediate Separator

1. Safety Valve

2. Separator Head

3. O-ring

4. Screw-in Insert

5. Knurled Nut

6. Separator Body

7. Gasket

8. Fitting

8

1

2

3

4

5

6

7

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Brownie’s Yacht Pro 135 User manual

Brownie’s Yacht Pro 135 User manual

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