21 BL-BK Instruction Manual (2920142100)

7/26/2019 21 BL-BK Instruction Manual (2920142100)

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No. 2920 1421 00

Copyright 2000, Worthington-Creyssensac - ZI - BP, 4 rue Emile Zola, F-60114 MERU

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations,

part numbers and drawings.

2000-09

The BLOCAIR compressor is guaranteed for 12 months from date of commissioning

or a maximum of 18 months from date of manufacture (which ever occurs first)

The guarantee will only be applicable subject to strict observation of the installation conditions

and the maintenance operations specified in these operating instructions.

NOTE

This instruction book meets the requirements for instructions specified by the machinery directive 98/37/EC

and is valid for CE as well as non-CE labelled machines.


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2920 1421 002

Instruction book

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life.

Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the

beginning. The maintenance schedule comprises measures for keeping the machine in good condition.

Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according

to the instructions. Record all operating data, maintenance performed, etc. in an operator's logbook. Follow all relevant safetyprecautions, including those mentioned on the cover of this book.

Repairs must be carried out by trained personnel from Worthington-Creyssensac who can be contacted for any further information.

In all correspondence mention the type and the serial number, shown on the data plate.

For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data".

The company reserves the right to make changes without prior notice.

Page

1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1.1 Compressor variants . . . . . . . . . . . . . . . . . 3

1.2 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2.1 BK20 up to -55, BL20(A) up to -75(A),BL100(A) 50Hz . . . . . . . . . . . . . . . . . . . . . 3

1.2.2 BK75/100, BL100(A) 60Hz, BL150(A)

and BL20(B) up to -150(B). . . . . . . . . . . . 3

1.3 Regulating system . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.1 BK/BL20 up to -75 with DOL starter . . . . 3

1.3.2 BK/BL55 up to -100 and BL150 with

Y/D starter . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Installationand handling . . . . . . . . . . . . . . . . . . . . . . 9

2.1 BK/BL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Settings of overload relay - fuses - cable size . . 10

2.3.1 Compressors with DOL starter . . . . . . . . 10

2.3.2 Compressors with Y/D starter . . . . . . . . . 10

2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . 12

3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.4 Taking out of operation at end of compressor

service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Preventive maintenance schedule of thecompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Lubrication of BL compressors . . . . . . . . . . . . . 13

4.3 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Page

5 Servicing and adjustment procedures . . . . . . . . . . 15

5.1 Unloader or check valve . . . . . . . . . . . . . . . . . . . 15

5.2 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.4 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . 175.4.1 Adjustment for MDR4. . . . . . . . . . . . . . . 17

5.4.2 Adjustment for MDR6. . . . . . . . . . . . . . . 18

5.4.3 Adjustment for MDR3. . . . . . . . . . . . . . . 19

5.5 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.6 Relief valve on BL/BK two-stage. . . . . . . . . . . . 19

6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.1 Reference conditions . . . . . . . . . . . . . . . . . . . . . 21

7.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.3 Compressor data for BL 10 bar . . . . . . . . . . . . . 21

7.3.1 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217.3.2 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.4 Compressor data for BK 10 bar . . . . . . . . . . . . . 22

7.4.1 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.4.2 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.5 Compressor data for BL 15 bar . . . . . . . . . . . . . 22

7.5.1 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.5.2 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.6 Conversion list of SI units into US/British units 23

8 Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9 Installation proposals . . . . . . . . . . . . . . . . . . . . . . . . 27

10 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . 29


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Instruction book

Blocair compressors are air-cooled, single-acting piston

compressors. BL are lubricated compressors; BK are oil-less

compressors which deliver oil-free air. As 10 bar versions

(version A), BK20 up to -55, BL20 up to -75 and BL100-50Hz

are single-stage compressors. BK75, BK100, BL100-60Hz,

BL150 are two-stage compressors. As 15 bar versions (version

B), BL20 up to -150 are two-stage compressors.

BK20 up to -75, BL20 up to -75 and BL100-50Hz are two-

cylinder compressors, BK100, BL100-60Hz, BL150 are three-

cylinder compressors.

Note: Take care that three-cylinder compressors rotate in the

direction as indicated by the arrow on the fan housing.

Blocair BL compressors are built for effective working

pressures up to 10 bar (version A) or up to 15 bar (version B).

Blocair BK compressors are built for effective working

pressures up to 10 bar.

For BL compressors:

- BL(A) stands for BL 10 bar

- BL(B) stands for BL 15 bar

- BL stands for BL 10 bar and 15 bar

TheCompressor Block(Fig. 1.1) includes:

- Crankcase (4) and cylinders

- Air inlet filter (AF) and inlet silencer (3)

- Fan (FN)

- Air cooler piping (2) and (5)

- Check valve (7, for BK55, BK75, BL55 and BL75 DOL

starter)

- Check valve/unloader (7, for BK55 up to -100, BL55 up to

-150 Y/D starter)

- Relief valve (8, for BK and BL two-stage)

Themotor-compressor setcomprises (Figs. 1.2/1.3):

- the Compressor Block as described above

- the flanged-on electric motor (M)

TheComplete Unitcomprises (Figs. 1.4, 1.5, 1.6 and 1.7):

- BL/BK20 and -30:the motor-compressor set mounted on a

horizontal (Fig. 1.4) or vertical (Fig. 1.5) air receiver (AR)

with check valve (CV), air pressure switch/start switch

(MDR), air outlet valve (AV), pressure gauge (Gp), safety

valve (SV) and condensate drain valve (Dm).

- BL/BK55 up to -100, BL150: the motor-compressor set

mounted on an air receiver (AR) with air outlet valve (AV),

pressure gauge (Gp), safety valve (SV) and condensate drainvalve (Dm), and also:

- for DOL starters an air pressure switch/start switch

(MDR)

- for Y/D starters air pressure switch (MDR), solenoid

valve (Y1), electric cabinet (6) including the motor

starter

The frame version(Fig. 1.8) comprises:

- the motor-compressor set mounted on a frame

- for Y/D starters: a pressure gauge, a safety valve, electriccabinet including the motor starter, air pressure switch and

start switch

- for DOL starters: a check valve, an air pressure switch/start

switch (MDR), a pressure gauge, a safety valve

Air drawn through air filter (AF) into cylinders (3) and inletsilencer (1) is compressed, then discharged through cooler

piping (4) and (6) and check valve (CV) into air receiver (AR).

Air drawn through air filter (AF) and inlet silencer (1) into LP

(low-pressure) cylinder(s) (7) is compressed, then discharged

to HP (high-pressure) cylinder (8) via intercooler (10).

The air is further compressed and discharged through cooler

piping (6) and check valve (CV) into air receiver (AR).

The regulating system includes:

- Check valve (CV)

- Air pressure switch (MDR) with pressure release valve (2)

and on/off buttons (5).

OperationAir pressure switch (MDR) opens and closes its contacts at

pre-set pressures. During loaded operation, the contacts are

closed: the motor is running.

When the pressure in the air receiver reaches the pre-set

maximum pressure, the contacts as well as pressure release valve

(2) are opened. The motor stops, the air at the delivery side of

the compressor is vented to the atmosphere and check valve

(CV) closes to prevent venting of the receiver.

When the pressure in the air receiver decreases to the pre-set

minimum pressure, the contacts of the air pressure switch closeand pressure release valve (2) closes. The motor restarts and

compressed air is supplied to the receiver again.


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Instruction book

Fig. 1.1 Example of Compressor Block

Fig. 1.2 Example of motor-compressor set

Fig. 1.3 Example of motor-compressor set

AF Air filter

DP Oil drain plug

FN Fan

M Motor

SG Oil level sight-glass

1 Cover

2 Intercooler

3 Air inlet silencer

4 Crankcase

5 Cooling pipe

6 Cylinder

7 Unloader

8 Relief valve

9 HP cylinder

10 LP cylinder

Figs. 1.1 up to 1.3 General views, Compressor

Block motor-compressor set

3 AF 1

5

2

FN

6

8

4

7

50988F

M

10 1 AF 3

FN

DP SG 4

50985F

3

AF1

5

2

FN

9

8

7

50984F

10

M

4


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Instruction book

Fig. 1.4 Complete Unit, horizontal receiver

Fig. 1.6 Complete Unit (3-cylinder)

Fig. 1.5 Complete Unit, vertical receiver

4 3 1 AF SV

MDRAV

Gp

9

Dm

M

CV

AR

50983F

Dm

9

AVAR

Gp

MDRM

8

1AF3

50987F

SV

7

1 AF 3

2 M Y1 P1MDR

6Gp

AV

ARDm

50986F


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Instruction book

Fig. 1.7 Complete Unit (3-cylinder)

AF Air filter

AR Air receiver

AV Air outlet valve

CV Check valveDm Condensate drain valve

FN Fan

Gp Air pressure gauge

M Motor

MDR Air pressure switch

P1 Hourmeter, running hours

SV Safety valve

Y1 Loading solenoid valve1 Cover

2 Blow-off silencer


4 LP cylinder

5 HP cylinder

6 Electric cabinet

7 Check valve/Unloader

8 Relief valve9 Pictograph, switch off

voltage and depressurize

before maintenance or

repair

Figs. 1.4 up to 1.7 General views, Complete Unit

1 Cover


3 Unloader

4 Pictograph, switch

off voltage and

depressurize beforemaintenance or repair

AF Air filter

FC Filler cap

Gp Air pressure gauge

M Motor


SV Safety valve

Fig. 1.8 Frame version

3

SV

AF 1 2

MDR

Gp

4

FCM

50994F


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Instruction book

Fig. 1.10 Air flow of two-stage compressors and regulating system of BL55 up to -150 and BK55 up to -100 with Y/D starter

AF Air filter

AR Air receiver

AV Air outlet valve

CV Check valve

Dm Condensate drain valve

DP Oil drain plug

FC Oil filler cap

FN Fan

Gp Air pressure gaugeM Motor


SG Oil level sight-glass

SV Safety valve

UA Unloader

UV Unloading valve

Y1 Loading solenoid valve


2 Pressure release valve

3 Cylinder4 Cooler

5 On/off switch or

buttons

6 Cooling pipe

7 LP cylinder

8 HP cylinder

9 Blow-off silencer

10 Intercooler

11 Electric cabinet

12 Plunger13 Spring

Figs. 1.9 and 1.10 Air flow and regulating systems

Fig. 1.9 Air flow of single-stage compressors and regulating system of BK/BL20 up to -75 with DOL starter


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Instruction book

The regulating system includes:

- Electric cabinet (11) with on/off switch (5)

- Air pressure switch (MDR)

- Solenoid valve (Y1)- Unloader (UA) with integrated check valve (CV)

Operation

Air pressure switch (MDR) opens and closes its contacts at

pre-set pressures. During loaded operation, the contacts are

closed: the motor is running and solenoid valve (Y1) is

energized preventing the compressed air from flowing to

unloader (UA).

When the pressure in the air receiver reaches the pre-set

maximum pressure, the contacts of pressure switch (MDR)

open. The motor stops and solenoid valve (Y1) is de-energized.

Compressed air from the receiver will flow via the solenoid

valve to plunger (12) which causes unloading valve (UV) to

open. The air at the delivery side of the compressor is blown

through silencer (9) to the atmosphere and check valve (CV)

closes to prevent venting of the receiver.

When the pressure in the air receiver decreases to the pre-set

minimum pressure, the contacts of the pressure switch close.

The motor restarts and, after switching over from star to delta,

solenoid valve (Y1) is energized. Control air from the unloader

plunger chamber is vented to the atmosphere. Unloading valve

(UV) closes and compressed air is supplied to the receiver again.


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Instruction book

Install the compressor horizontally, in a cool but frost-free and

well-ventilated room. Place the compressor as level as possible.

The maximum angular deviation for BLis 22.5 degrees in any

direction. The air should be clean. Also consult section 9.

A condensate drain valve must be installed downstream of the

compressor in the lowest part of the air net. If any further

information is required, consult Worthington-Creyssensac.

The electrical diagrams are shown in section 8.

The electrical installation must be carried out by an electrician

and correspond to the local codes.

The indications on the motor data plate must correspond to the

mains supply voltage and frequency. The installation must

include an isolating switch in the power line near to the unit

and be protected against short-circuits by fuses in each phase.

See section 2.3.

The mains supply and earthing lines must be of suitable size.

See section 2.3.

For DOL starters, connect the power supply cables as shown

on Figs. 8.1/8.2. For Y/D starters, connect the power supply

cables to strip (X1-Fig. 2.1) as shown on Fig. 8.3/8.4. Check

the setting of the overload relay. See section 2.3.

F1 Fuse

K1 Line contactor with integrated Y/D timer

K2 Star contactor

K3 Delta contactor


S1 On/off switch

X1 Terminal block

Fig. 2.1 Electric cabinet with star-delta starter,

typical example

S1 F1 K1 K3 K2 P1

X150959F


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Instruction book

50 Hz

Type Voltage Overload relay Fuses(V) (A) (A)

BL/BK20 230 (1-phase) 10.7 16

BL/BK20 230 6.7 10

BL/BK20 400 4.1 10

BL20(A) 500 3.5 10

BL/BK30 230 9.3 16

BL/BK30 400 5.6 10

BL/BK55 230 15.7 25

BL/BK55 400 9.3 16

BL/BK75 230 20.3 25

BL/BK75 400 12.0 25

60 Hz

Type Voltage Overload relay Fuses

(V) (A) (A)

BL20 230 (1-phase) 11.7 16

BL20 230/460 4.5 10

BL20(A) 380 4.7 10

BL/BK20 440/460 4.1 10

BL30 230 (1-phase) 17.9 25

BL30 230/460 7.6 10

BL/BK30 440/460 5.7 10

BL/BK55 230 (1-phase) 29.0 40

BL/BK55 230/460 11.6 16

BL/BK55 440/460 9.6 16

BL/BK75 230 13.2 25

BL/BK75 440/460 12.3 25

50Hz


(V) (A) (A)

BL55(A) 230 9.1 25

BL55(B) 230 9.1 25

BL55 400 5.6 16

BL55 500 4.5 16

BL/BK75 230 12.2 40BL/BK75 400 7.2 25

BL/BK75 500 5.5 16

BL75 575 5.1 16


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Instruction book


(V) (A) (A)

BL/BK100 230 14.5 40

BL/BK100 400 8.5 25

BL/BK100(A) 440 7.8 25BL/BK100 500 6.9 25

BL150 230 22.5 63

BL150 400 13.1 40

60Hz


(V) (A) (A)

BL55 230 11.8 25

BL55 380 6.9 25

BL55 440/460 5.5 16

BL55(B) 575 4.7 16

BL/BK75 230 14.4 40

BL/BK75 380 8.5 25

BL/BK75(A) 400 7.2 25

BL/BK75 440/460 7.2 25

BK100, BL100(B) 230 18.2 63

BL/BK100 380 10.6 25BL100(B) 440 9.0 25

BL100(B) 440/460 8.6 25

BL100(B) 575 7.2 25

BL150(A) 380 10.6 40

BL150 440 13.1 40

Cable size

Type Starter Cable size

(mm)

BL/BK20/30 DOL 2.5

BL/BK55/75 DOL 4

BL/BK55 Y/D 2.5

BL/BK75 Y/D 4

BL/BK100 Y/D 6

BL150 Y/D 6


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Instruction book

1 Temperature2 Pressure

3 On

4 Off

5 Warning: voltage

6 Switch off voltage and depressurize before maintenance

or repair7 Read Instruction book before starting

8 Consult Instruction book for correct direction of rotation

9 Do not adjust switch if it is depressurized

Fig. 2.2 Pictographs (typical examples)

4-Fig. 5.10) to ON or press the ON button on switch (MDR-

Figs. 1.4/1.5)

4. Open air outlet valve (AV-Figs. 1.4/1.6).

5. Regularly drain condensate (Dm-Figs. 1.4/1.6).

1. Depending on the starter type, move switch (S1-Fig. 2.1 or4-Fig. 5.10) to OFF or press the OFF button on switch

(MDR-Figs. 1.4/1.5)

2. Close air outlet valve (AV-Figs. 1.4/1.6).

3. Switch off the voltage.

If a compressor with pressure switch with pressure release valve

stops during operation through a power failure, the pressure

from the air receiver must be released by pressing the OFF

button on the air pressure switch to prevent the compressor

from restarting against back-pressure when the power becomes

live again.

At the end of the service life of the compressor, proceed as

follows:

1. Stop the compressor and close the air outlet valve(s).

2. Switch off the voltage and disconnect the compressor from

the mains.

3. Depressurize the compressor.

4. Shut off and depressurize the part of the air net which is

connected to the outlet valve. Disconnect the compressor

from the air net.

5. On BL, drain the oil.

Safety precautions

The operator must apply all relevant safety precautions,

including those mentioned in this book.

Note: It is strongly recommended to install an intercooler drainkit, to remove excess condensate, on BL version B (15 bar)

compressors with a load factor less than 20% per hour. Consult

Worthington-Creyssensac.

1. For versions mounted on a receiver, remove the transport

brackets from underneath the compressor.

2. Check the electrical installation, which must be in

accordance with the instructions given in section 2.2.

3. BLare filled with ALTAIR 3000 PAO (polyalphaolefine)

compressor oil. Check that the oil level is still near the top

of the red circle of sight-glass (SG-Fig. 1.2). Top up, if

necessary.

4. Switch on the voltage. Start the motor.

5. On three-cylinder compressors, check for correct direction

of rotation as indicated by the arrow on the fan housing. If

the rotation direction is wrong, switch off the voltage and

reverse two of the input line connections.

6. Check the operation of the air pressure switch (MDR). See

section 5.4.

1. On BL, check the oil level, which must be near the top of

the red circle of sight-glass (SG-Fig. 1.2). The minimum

level is the lower part of the red circle.

2. Switch on the voltage.

3. Depending on the starter type, move switch (S1-Fig. 2.1 or


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Instruction book

The schedule contains a summary of the maintenance instructions. Read the respective section before taking maintenance

measures.

When servicing, replace all disengaged packings, e.g. gaskets, O-rings, washers.

The "longer interval" checks must also include the "shorter interval" checks.

Period 2) Running Consult See notes Operation

hours 2) section below table

Weekly ------ 3.2 1 On BL,check oil level

" ------ -- -- Drain condensate from air receiver or pulsation damper

6-monthly ------ 5.5/5.6 2 Test safety valve, and if provided also relief valve

" ------ 4.3/5.3 3 Inspect air filter

Yearly 500 4.3/5.3 3/4 On BK100, BL75(60Hz), BL150,replace air filter

" 600 4.3/5.3 3/4 On BL55 up to -75(50Hz) and BK55/75,replace air filter

" 800 4.3/5.3 3/4 On BL/BK20 and -30, replace air filter

" 2000 4.3 -- Change blow-off silencer, if provided" 2000 -- 5 On BL,if mineral oil used, change oil

2-yearly 3000 4.2/4.3 -- On BL, if Worthington-Creyssensac ALTAIR 3000 oil is used,

change oil

----- 3000 to

4000 4.3/5.1 -- Replace check valve or unloader

----- 4000 4.3/5.2 -- On BL/BK20 up to -55,replace valve discs

----- 5000 4.3/5.2 -- On BL75 up to -150 and BK75/100,replace valve discs

Notes

1. Maintain the level in the red circle of the sight-glass.

2. Wear gloves and safety glasses.

3. For normal operation in clean surroundings. More frequently when operating in dusty environment.

4. In a dusty environment, a heavy duty filter is essential (available as an option).

5. Consult Worthington - Creyssensac.

It is strongly recommended to use the Worthington-Creyssensac approved ALTAIR 3000 (polyalphaolefine) compressor oil to

keep the compressor in excellent operating condition. See section 4.3.


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2920 1421 0014

Instruction book

Service kits are available offering the benefits of genuine

Worthington-Creyssensac parts while keeping the maintenance

budget low. The kits comprise all parts needed for servicing.

Consult the Parts list for the contents of all kits.

Service kit for air filter (AF) Ordering number

BK/BL20 up to -75 and BL100-50Hz 1503 0189 00

BL100-60 Hz, BK100, BL150 1503 0190 00

Service kit for ALTAIR 3000 oil (5 l) Ordering number

All BL 6215 7111 00

Service kit for unloader (UA) Ordering number

BK/BL55 up to -150 (Y/D) 6219 0140 00

Service kit for blow-off silencer Ordering number

BK/BL55 up to -150 (Y/D) 1503 2420 00

Service kit for check valve (CV) Ordering number

BK/BL55 up to -75 (DOL) 6219 0141 00

Service kit for valve discs Ordering number

BL20(A) up to -55(A) and BK20/30 6219 0072 00

BL75(A), BL100(A) 50 Hz and BK55 6219 0073 00

BL20(B) up to -55(B) 6219 0074 00

BL75(B), BL100(B) 50 Hz and BK75 6219 0075 00

BL100-60 Hz, BL150 and BK100 6219 0076 00

Footnotes chapter 4

1) Use only authorized parts. Any damage or malfunction caused

by the use of unauthorized parts is not covered by Warranty or

Product Liability.

2) Whichever interval comes first. The local Sales Company may

overrule the maintenance schedule, especially the service

intervals, depending upon the environmental and working

conditions of the compressor.


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2920 1421 00 15

Instruction book

Warning Release the pressure from the compressor before

starting repair or maintenance works. Switch off

the voltage and isolate the compressor from themains.

Dirt, condensate, coke formation and oxidation influence the

proper operation of the valve. Depending on the working

conditions (ambient temperature, working pressure, load cycle,

oil type), it is recommended to replace the unloader or check

valve as indicated in section 4.2. Replacement instructions are

included in the maintenance kits.

A faulty valve must be replaced immediately.A faulty valve

can be discovered as stated in section 6, points 1 and 4. It is

highly recommended to replace the valve discs, O-rings and

joints in case the cylinder heads are disassembled.

Replacement of valve discs(Figs. 5.1 and 5.2)

BL20/75(A) BL100(A) 60 Hz Operation sequence

BL100(A) 50 Hz HP Cylinder

BK20/55 BL150(A)


LP Cylinder BL20/150(B)

BL150(A) HP Cylinder

LP Cylinder BK75/100

BL20/150(B) HP Cylinder

LP Cylinder

BK75/100

LP Cylinder

Remove the fan

guard, unscrew the

cap and remove the

cover (1-Fig. 1.1), airfilter and cover of the

air inlet silencer.

Disconnect cylinder

head cover (12) from

the inlet and outlet

pipe flanges.

Remove cover (12).

Fig. 5.1 Low-pressure cylinder of BL20 up to -150 and

BK20 up to -100

Fig. 5.2 High-pressure cylinder of BL20 up to -75(B),

BL100(B)-50Hz and BK75

1 Bolt

2 Joint3 O-ring

4 Spring

5 Outlet valve guard

6 Outlet valve disc7 Valve seat

8 Inlet valve disc

9 Guide pin10 Joint

11 Cylinder

12 Cylinder cover13 Cylinder head

14 Joint

Figs. 5.1 and 5.2 Cylinder heads


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Instruction book



BK20/55 BL150(A)






LP Cylinder

BK75/100

LP Cylinder

Disconnect head (13)

from the inlet and

outlet pipe flanges.

Remove cylinder

head cover (12).

Remove head (13).

Remove spring (4),

outlet valve guard (5)

and outlet valve disc

(6).

Lift off valve seat (7)

and remove inlet

valve disc (8). Do

not remove guide

pins (9).

Remove and discard

all O-rings and

rubber joints.

If necessary, remove

the carbon deposits

from the inlet valve

guard at the cylinder

top. Take care that

no dirt drops into the

cylinder.

Clean and inspect allparts.

Fit a new joint (10).

Do not stretch the

cord while inserting

it in its groove; the

ends should meet.

Put a new inlet valve

disc (8) into place

and install valve seat

(7).

Fit a new O-ring (3)

and joint (2).



BK20/55 BL150(A)






LP Cylinder

BK75/100

LP Cylinder

Install a new outlet

valve disc (6), guard

(5) and spring (4).

Install cylinder head

cover (12). Use newflange gaskets, if ne-

cessary. Fit the

flange and cylinder

head bolts and tight-

en them alternately.

Reinstall head (13).

Fit a new joint (14).

Install cylinder head

cover (12). Fit the

flange and cylinder

head bolts and tight-

en them alternately.

Reinstall the fan

guard, cover of the

air inlet silencer, air

filter, cover (1-Fig.

1.1) and cap.

Torque values

M6: 10 Nm +/- 2

M8: 23 Nm +/- 2

M10: 46 Nm +/- 5

1. Stop the compressor.

2. On BL/BK20 up to -75 and BL100-50 Hz: unscrew the

cap on top of cover (1-Fig. 1.1). Lift off the cover and

filter element. Take care that no dirt drops inside the suction

silencer.

On BL100-60 Hz, BK100, BL150:unscrew cap (1-Fig.

1.7) and take out the air filter. Take care that no dirt drops

inside the suction silencer.3. Using a damp cloth, clean the filter chamber and cover.

Discard damaged elements.

4. Install the new element, cover and cap.


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Caution

- Switch off the voltage before removing the cover of the

switch; reinstall it after an adjustment has been made and

before the voltage is switched on again.

- Adjustment may only be carried out when the air pressure

switch is pressurized.

The switch allows the operator to select the stopping pressure

and the pressure difference between stopping and starting

pressures. The stopping and starting pressures are the opening

and closing pressures of the switch.

The stopping pressureis controlled by adjusting screw (1).Turn the screw clockwise to raise the stopping pressure, anti-

clockwise to lower it.

The pressure difference between starting and stopping is

adjusted by means of adjusting screw (2). The adjustment range

is given in Figs. 5.5 and 5.6. Turn the screw anti-clockwise to

reduce the pressure difference, clockwise to increase it.

1 Air pressure switch

2 Loading solenoid valve3 Safety valve

Fig. 5.3 Air pressure switch MDR4

1 Adjusting screw, stopping pressure

2 Adjusting screw, pressure difference

Fig. 5.4 Adjusting screws, MDR4

Fig. 5.5 Pressure difference diagram, switch MDR4/11

Example:

Stopping pressure: 7 bar(e)

Starting pressure: adjustable between 3 and 5.7 bar(e)

1

50982F

2

1 2

350960F


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Instruction book

The maximum (stopping) pressureis controlled by adjusting

knob (1).

Turn the knob clockwise to raise the maximum or stopping

pressure, anti-clockwise to lower it.

The pressure differenceis adjusted by means of the same knob.

Push down the knob and turn it clockwise to reduce the

difference between the stopping and starting pressures, i.e. to

increase the starting pressure. Turn the knob anti-clockwise to

increase the pressure difference. The adjustment range is shown

on the diagrams (Figs. 5.8 and 5.9).


1 Adjusting knob for stopping and starting pressures

2 Spring housing, air pressure switch

3 Pressure release valve

4 Setting dial, overload relay

5 Motor overload relay6 Switching mechanism

Fig. 5.7 MDR6



6

5

4

350974F

2

1


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Instruction book

The switch allows the operator to select the stopping pressure

and the pressure difference between stopping and starting

pressures. The stopping and starting pressures are the opening

and closing pressures of the switch.

The stopping pressureis controlled by adjusting screw (2).

Turn the screw clockwise to raise the stopping pressure, anti-

clockwise to lower it.

The pressure difference between starting and stoppingis

adjusted by means of adjusting screw (3). The adjustment range

is given in Figs. 5.11 and 5.12. Turn the screw anti-clockwise

to reduce the pressure difference, clockwise to increase it.

Replace the valve if it does not open at the correct pressure.

No adjustments are allowed.

1. Close the air outlet valve, depressurize and disconnect the

hose or pipe from the valve.

2. Start the compressor and run it until it stops automatically.

3. Switch off the voltage.

Remove the cover from the air pressure switch and, with

the air receiver now under pressure, turn the adjusting knob

or screw one turn clockwise to increase the stopping pressure

(see also section 5.4). Reinstall the cover.

4. Switch on the voltage, slightly open the outlet valve and

start the compressor.

5. Gradually close the outlet valve while checking the airpressure gauge. If the safety valve has not opened at the

pressure specified in section 7, it must be replaced by a

new one. If the compressor unloads before the specified

opening pressure is reached, repeat the procedure as

mentioned from step 3.

6. Readjust the pressure switch as described in section 5.4.

7. Reconnect the hose or pipe to the closed air outlet valve.

The relief valve protects the LP side of the compressor. No

adjustments are allowed.

Remove the relief valve and fit a 3/8 inch B.S.P. plug instead.

Remove the safety valve from the air receiver and replace it by

the relief valve. The latter can then be tested at increasing air

receiver pressure after the compressor has been started with

open air outlet valve. If the valve has not opened at the pressure

specified in section 7, it must be replaced by a new one.

Reinstall the valves in their respective places after testing.

Footnote chapter 5

1) Not on Compressor Block/motor-compressor set.

1 Dial, overload relay

2 Adjusting screw, stopping

pressure



3 Adjusting screw, pressure

difference

4 On/off switch

Fig. 5.10 Air pressure switch MDR3

4 1 2 3

51052F


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1 Insufficient air pressure

a Air leak

a Check and correct as necessary

b Air filter choked

b Replace filter

c Air pressure switch incorrectly set

c Adjust switch

d Air consumption exceeds maximum output of

compressor

d Check equipment connected

e Damaged valve

e Inspect valves and replace parts where necessary

f Unloader 1)malfunctioning

f Inspect and replace parts where necessary

g Solenoid valve 1)out of order

g Remove and check. Replace if necessary

2 Unit does not speed up

a Voltage drop at motor terminals

a Consult power supplier. Use correct size of cable

b Unloader malfunctioning

b See 1f

c Solenoid valve out of order

c See 1g

d Blow-off silencer 1)choked

d Replace

3 Air receiver pressure rises above maximum and causes

safety valve to blowa Air pressure switch or regulating valve 1) incorrectly

set or out of order

a Check. Replace switch or valve, if necessary

b Solenoid valve defective

b See 1g

c Unloader malfunctioning

c See 1f

d Blow-off silencer choked

d See 2d

4 Relief valve blows1)

a Defective inlet valve in HP cylinder head

a Inspect and replace part(s) as necessaryb Relief valve not airtight

b Replace valve

5 Receiver does not hold pressure

a Check valve leaks

a Check for broken valve and springs

b Air leaks

b Check and correct as necessary

6 Too frequent starting/too short operating periods

a Air pressure switch or regulating valve 1) incorrectly

seta Increase pressure difference

b Check valve leaks

b See 5a

7 High oil consumption on BL compressors

a Oil level too high

a Do not overfill crankcase. Keep level in red circle of

sight-glass

b Piston ring(s) worn or broken

b Have condition of piston rings checked

8 Unit does not start

a Electrical failure

a Have electrical system checked. Check fuses and line

terminals for tightness

b Overload relay cut out

b Reset overload relay. If the relay cuts out again after

starting, see point 9

c Air pressure above pre-set starting pressure

c Compressor will start when air pressure is lower than

pre-set starting pressure of air pressure switch

9 Overload relay cuts out

a Overload relay incorrectly set

a Check and adjust. Reset relay

b Solenoid valve out of order

b See 1g

c Unloader plunger jammed

c See 1f

d Blow-off silencer choked

d See 2d

e Ambient temperature too high

e Improve ventilation of room

f Motor stops and starts too frequently

f See 6

g Overcurrent due to motor or compressor failureg Consult Worthington - Creyssensac

Footnotes chapter 6

1) If provided.


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Inlet pressure (absolute) . . . . . . . . . . . . . . . . . . . . . . . . . bar 1

Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . % 0

Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . C 20

Working pressure:

- BL version A (10 bar) . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7

- BK 10 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7

- BL version B (15 bar) . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 12

Minimum inlet temperature . . . . . . . . . . . . . . . . . . . . . . C 0

Maximum inlet temperature . . . . . . . . . . . . . . . . . . . . . . C 40

Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . bar(e) See below

Compressor type BL20(A) BL30(A) BL55(A) BL75(A) BL100(A) BL150(A)

Maximum working pressure . . . . . . . . . . bar(e) 10 10 10 10 10 10

Temperature at outlet valve, approx. . . . C 40 44 66 59 80 65

Power input at max. working pressure . . kW 1.82 2.54 4.57 6.11 8.28 10.69

Motor shaft speed . . . . . . . . . . . . . . . . . . r/min 1500 1500 1500 1500 1500 1500

Free air delivery 3) . . . . . . . . . . . . . . . . . l/s 3.4 4.4 8.4 11.7 15.7 18.6

Oil capacity . . . . . . . . . . . . . . . . . . . . . . . l 0.8 0.8 0.8 1.4 1.4 1.7

Opening pressure of safety valve . . . . . . bar(e) 11 11 11 11 11 11

Maximum sound pressure level 1) . . . . . dB(A) 78 79 79 80 81 84

Compressor type BL20(A) BL30(A) BL55(A) BL75(A) BL100(A) BL150(A)






Oil capacity . . . . . . . . . . . . . . . . . . . . . . . l 0.8 0.8 0.8 1.4 1.7 1.7




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Compressor type BK20 BK30 BK55 BK75 BK100

Maximum working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 10 10 10 10 10

Temperature at outlet valve, approx. . . . . . . . . . . . . . C 40 44 45 50 51

Power input at max. working pressure . . . . . . . . . . . . kW 2.05 2.71 5.11 5.89 8.65

Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1500 1500 1500 1500 1500

Free air delivery 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 3.1 4.0 7.6 9.2 14.4

Opening pressure of safety valve . . . . . . . . . . . . . . . . bar(e) 11 11 11 11 11

Maximum sound pressure level 1) . . . . . . . . . . . . . . . dB(A) 82 83 83 84 86

Compressor type BK20 BK30 BK55 BK75 BK100

Maximum working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 10 10 10 10 10

Temperature at outlet valve, approx. . . . . . . . . . . . . . C 49 54 54 60 58

Power input at max. working pressure . . . . . . . . . . . . kW 2.36 3.10 5.89 6.70 10.66

Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1800 1800 1800 1800 1800

Free air delivery 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 3.6 4.6 8.8 10.7 17.1

Opening pressure of safety valve . . . . . . . . . . . . . . . . bar(e) 11 11 11 11 11

Maximum sound pressure level 1) . . . . . . . . . . . . . . . dB(A) 84 85 85 86 88

Compressor type BL20(B) BL30(B) BL55(B) BL75(B) BL100(B) BL150(B)

Maximum working pressure . . . . . . . . . . bar(e) 15 15 15 15 15 15Temperature at outlet valve, approx. . . . C 49 57 68 56 75 72




Oil capacity . . . . . . . . . . . . . . . . . . . . . . . l 0.8 0.8 0.8 1.4 1.4 1.7


Opening pressure of relief valve . . . . . . bar(e) 6.5 6.5 6.5 6.5 6.5 6.5



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Instruction book

Compressor type BL20(B) BL30(B) BL55(B) BL75(B) BL100(B) BL150(B)






Oil capacity . . . . . . . . . . . . . . . . . . . . . . . l 0.8 0.8 0.8 1.4 1.7 1.7


Opening pressure of relief valve . . . . . . bar(e) 6.5 6.5 6.5 6.5 6.5 6.5

Maximum sound pressure level 1): . . . . dB(A) 80 81 81 82 83 84

1 bar = 14.504 psi

1 g = 0.035 oz

1 kg = 2.205 lb

1 km/h = 0.621 mile/h

1 kW = 1.341 hp (UK and US)

1 l = 0.264 US gal

1 l = 0.220 Imp gal (UK)

1 l = 0.035 cu.ft

1 m = 3.281 ft

1 mm = 0.039 in

1 m/min = 35.315 cfm

1 mbar = 0.401 in wc

1 N = 0.225 lbf

1 Nm = 0.738 lbf.ft

x degrees celsius = (32 + 1.8 x) degrees

fahrenheit 2)

Footnotes chapter 7

1) According to CAGI PNEUROP PN8NTC2.2.

2) A temperature difference of 1 degree celsius = a temperature difference of 1.8 degrees fahrenheit.

3) At reference conditions


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Instruction book

Fig. 8.1 Electrical diagram of single-phase BL/BK with direct-on-line starter

Fig. 8.2 Electrical diagram of 3-phase BL/BK20 up to -75 with direct-on-line starter


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Instruction book

Fig. 8.3 Electrical diagram of 3-phase BL55 up to -150 and BK55 up to -100 with star-delta starter

F1/3 Fuses

F4 Overload relay

K1 Line contactor

K2 Star contactor

K3 Delta contactor

M Compressor motor



S1 On/off switch

T1 Transformer

Y1 Loading solenoid valve

X1 Terminal strip

Figs. 8.1 up to 8.4 Electrical diagrams


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Instruction book

Fig. 8.4 Electrical diagram of 3-phase BL/BK55 up to -150 and BK55 up to -100 with transformer and star-delta starter


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Instruction book

Fig. 9.1 Installation proposal for compressors on horizontal air receiver (120 l)

Fig. 9.2 Installation proposal for compressors on horizontal air receiver (250/475 l)


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Instruction book

Fig. 9.3 Installation proposal for compressors on vertical air receiver (250 l)


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Instruction book

Fig. 10.1 Dimension drawing, BL20/55 compressors on horizontal air receiver (120 l)


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Instruction book

Fig. 10.2 Dimension drawing, BL15/40 compressors on vertical air receiver (250 l)


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Instruction book

Fig. 10.3 Dimension drawing, BL55 compressors on horizontal air receiver (250/475 l)


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Fig. 10.5 Dimension drawing, BK20/30 and BL20/55 compressors on frame


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Instruction book

Fig. 10.6 Dimension drawing, BK55/75 and BL75/100 compressors on frame


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Documents

21 BL-BK Instruction Manual (2920142100)