Brownie’s YachtPro YP55DF, Operator'S Manual

Page 1: ...YachtPro Automatic Compressor Operator s Manual YP55DF YP75DF ...

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Page 3: ...ize yourself with the compressor features please read this manual thorough ly before using the equipment Physical layout is pictured on page 28 For service please contact IMPORTANT NOTICE Read this manual before you operate your Yacht Pro Series Compressor as it con tains pertinent information for the safe operation of the system Failure to follow the instructions in this manual may result in dama...

Page 4: ...Level Check 17 Oil Types 17 Intake Filter 17 Sightglass Element Change Demonstration 18 Black Filter Cartridge Replacement Demonstration 20 Gold Filter Cartridge Replacement Demonstration 22 Tankfill Demonstration 24 Oil Change Demonstration 27 Troubleshooting 39 Systems Operations Log 41 Warranty Information 49 Any applicable addendums will be inserted just before the last page before the Warranty...

Page 5: ...ill Time Drain System Operation Interval Oil Level Oil Removed Hour Meter Reading Test Run Time STANDARD EQUIPMENT Gold Filter Frequency Drive Manual Lubricant OPTIONAL EQUIPMENT MISC 4TKMAN Remote Fill Panel FC374 04RL Additional for 4TKMAN Main FT Black Filter Block Sightglass Elements Technician Installer COMPRESSOR QUALITY ANALYSIS RECORD 80 ft 500 3000 PSI ...

Page 6: ... AP70 Number of Stages 3 Number of Cylinders 3 Cylinder Bore 1st Stage YP55 2 76 in 70 mm YP75 3 52 in 88 mm Cylinder Bore 2nd Stage 1 42 in 36 mm Cylinder Bore 3rd Stage 0 55 in 14 mm Piston Stroke 1 57 in 40 mm Intermediate Pressure 1st Stage 94 psi 6 5 bar Intermediate Pressure 2nd Stage 682 psi 47 bar Compressor Block Oil Cap 3 qts 2 8 liters Recommended Oil Types CF 2000 Synthetic Compressor ...

Page 7: ...available with the YP55DF and YP75DF One Four way Manifold with 10 foot connection hose including stainless steel quick disconnect end One inch padded Custom Cordura Manifold Bag NOTICE Please read this Owner s Manual before you operate your Yacht Pro Series Compressor Optional Equipment Dual Pressure Switch installed at time of purchase Stainless Steel Quick Disconnect Set Custom Hose Lengths Rem...

Page 8: ... a flat level surface No more than 10 deg inclination must occur during operation 4 The Yacht Pro Series units are provided as a complete assembly ready for installation NOTE Some installa tions may require remote mounting of package components This must be approved by our Technical Department NOTE Any alterations of the original system without approval by our technical department will void the man...

Page 9: ...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 syste...

Page 10: ...Fill times are based on filling a single standard 80 cu ft aluminum cylinder from 500 psi to 3000 psi and are ap proximately as follows YP55DF 13 minutes per tank YP75DF 9 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 automatically stops This indicates that the compressor is in...

Page 11: ... Yacht Pro Purification system uses three chemicals to process the air The first chemical is molecular sieve 13x and is the desiccant or moisture oil remover The second chemical is a catalyst called hopacolite that converts carbon monoxide to carbon dioxide The third chemical is activated carbon which removes taste and odor The X53240 cartridge uses a Lifeband to indicate usage and replacement see p...

Page 12: ...t inspection replace after 900 hrs Replace filter chamber o rings Cleaning of air intake filter and filter unit 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 After 4th year or 1200 Check air tightness and performance hours of operation Drive belt inspection replace after 120...

Page 13: ... Bolt Thread Max Torque Hex and Allen Head M 6 7 ft lbs 10 Nm Hex and Allen Head M 8 18 ft lbs 25 Nm Hex and Allen Head M10 32 ft lbs 45 Nm Hex and Allen Head M12 53 ft lbs 75 Nm Hex and Allen Head M14 85 ft lbs 120 Nm Hex and Allen Head M16 141 ft lbs 200 Nm Pipe Connections swivel nuts Finger tight turn Torque Sequencing Tighten valve head and cylinder bolts nuts equally in the sequence shown he...

Page 14: ... up excessively and the first stage safety valve blows off either the intake or pressure valve of the second stage is malfunctioning It is necessary then to remove the valve head and to check and clean these valves or to replace them Valve Change General Instructions Always replace valves as a complete set Carefully clean dirty valves Never use a sharp tool for this purpose Soak the valves in diese...

Page 15: ... the holes in the valve head and secure them in a vise with the valve head on top Using the special tool provided with the unit remove the intake valve 6 Turn the valve head over and replace it on the metal pins Remove the cap nut 1 Unscrew the stud 2 approximately five turns Remove the pressure plug 3 and take out the valve parts Clean the intake and pressure valves and check for wear Remove the i...

Page 16: ...age 6 for specific ambient temperature data CHECKING THE DRIVE BELT REPLACING 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 ...

Page 17: ... oils to those which have been approved by the manufacturer and are in our list of oils see page 11 Synthetic Lube Oils For operating under severe conditions such as continuous running and or higher ambient temperatures we rec ommend Part No CF 2000 Synthetic Compressor Lubricant Food Grade CF 2000 has been specially formulat ed for use in high pressure compressors and will provide optimal perform...

Page 18: ...n Lube threads with food grade silicone grease if needed 1 Unscrew window cap in counter clockwise direction NOTE The orientation of the sight glass assembly may vary 2 Here the cap is shown having been re moved and the retaining spring exposed Old elements are removed from the window at this time WARNING Make sure all pressure is relieved prior to changing element SIGHTGLASS CO MOISTURE ELEMENT C...

Page 19: ... The spring is placed into the window centered on the CO disc and the whole unit is then ready to be reas sembled 7 The cap is replaced and it is screwed back into place finger tight Make sure the CO disc remains in place 8 With change and reassembly completed both indi cators are easily viewed in the window and the cap is tightened down ...

Page 20: ...it on the bottom BLACK FILTER CARTRIDGE REPLACEMENT DEMONSTRATION REPLACEMENT CARTRIDGE PART X53240 WARNING Prior to changing the filter purge all pressure using the bleeder valve 1 Remove Cap Counter clockwise rotation of the cap using a wrench as shown will loosen the cap for removal 2 Remove Old Filter While removing the old filter check the Lifeband indi cator to determine filter usage or replace...

Page 21: ...gs for damage and replace if necessary Use a food grade silicone grease to lube threads and ring if needed 6 Replace Cap Clockwise rotation of the cap using a wrench as shown will tighten the cap for replacement Figure 1 Black Filter Cartridge ...

Page 22: ...ecessary to vent excess pressure by turning the small cap on the gold tower clockwise After venting pressure close cap by turning counter clockwise 2 Remove Cap Insert rod tool into holes in cap and turn counter clockwise 3 Remove Old Filter Remove old filter by pulling up on wire 4 Prepare Filter Pull plastic cap off of bottom plug of cartridge and discard ...

Page 23: ... 6 Lubricate O ring Inspect o rings for damage and replace if necessary Use a food grade silicone grease to lube threads and ring if needed 7 Replace Cap Insert rod tool into holes and turn clockwise to tighten cap Replacement cartridge part number is X22679 Figure 2 Gold Filter Cartridge ...

Page 24: ...C bleeder valve D fill valve B C D 1 Tank Attachment Open tank valve slightly to blow any moisture clear from fill opening Connect tanks to fill whips using appropriate fittings DIN Yoke or conversion adapters Tighten only finger tight NOTE Remember to check the system log before compressor use and to update the system log after you are done A D C ...

Page 25: ...his valve will open the tanks for filling 4 Open Fill Valves Counter clockwise rotation of this valve will open the line to the tanks The tanks will now equalize any dif ferences in their pressures 5 Start The Compressor The indicator light will come on If you have a dual pressure switch be sure the control is in the correct position ...

Page 26: ...f the knob closes off the fill lines 7 Close Tanks Clockwise rotation of the knob closes the tank valves 8 Open Bleeder Valves Counter clockwise rotation of this valve will allow pressure to vent 9 Remove Tanks Disconnect tanks from the fill line New tanks may be attached at this time and the process repeated ...

Page 27: ...Mount a new filter element P N N25326 and replace and fasten oil filter cover 4 Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the sight glass Wait a few minutes and adjust the oil level if necessary before putting the unit into operation Figure 1 Oil Sight Glass Figure 3 Removing the Oil Filter Cover Figure 4 Replacing Oil Filter Changing the Oil Type To ...

Page 28: ...Outlet to Remote Filter Tower Belt Guard Oil Fill Tube Solid State Pressure Switch with LED Display TEFC Motor Air Intake Filter Housing Hyme Joint Automatic Condensate Drain System with dual programmable timers for maximum efficiency Heavy Duty Stainless Steel Frame with Vibration Isolators ...

Page 29: ...rain Valve normally closed Gold Filter Tower Manual Drain Valve normally closed Intermediate Separator Automatic Drain Solenoid Timer Intermediate Separator Automatic Drain Solenoid Valve Gold Filter Tower Automatic Drain Solenoid Timer Gold Filter Tower Automatic Drain Solenoid Valve Outlet to Condensate Drain ...

Page 30: ...30 Oil Drain LED Pressure Switch Air Outlet to Black Filter Tower ...

Page 31: ...31 Outlet to Fill Manifold Co Moisture Indicator Sightglass Bleeder Valve Hyme Joint Inlet to Condensate Bottle Back Pressure Regulator REMOTE BLACK FILTER TOWER ...

Page 32: ...32 Parts Drawing 1 Parts Drawing 1 ...

Page 33: ...33 Parts Drawing 1 ...

Page 34: ...34 Parts Drawing 2 Parts Drawing 2 ...

Page 35: ...35 Parts Drawing 2 ...

Page 36: ...36 Parts Drawing 3 Parts Drawing 3 ...

Page 37: ...ket 65985 10 Hose N17442 11 Telescopic Intake Tube 062080 12 Intermediate Separator A 069934 13 Filter Head Assy 069933 14 Drain Tap Assy 065500 15 Gasket 4479 16 Hollow Bolt 61364 17 Filter Insert N15705 18 Coupling Nut 61975 19 O ring N3556 20 Filter Housing 61361 21 Threaded Collar 13937 22 Gasket 240 23 Male Elbow N1065 24 Male Run T N16334 25 Hose N17073 26 Safety Valve 2nd Stg 012886 27 Gask...

Page 38: ...38 Figure 5 Black Filter Tower Figure 5 Black Filter Tower ...

Page 39: ...erate b Loose electrical terminal b Make sure connections are tight at properly at solenoid solenoid c Bad solenoid c Remove and replace solenoid d Bad drain timer d Replace drain timer Compressor does not reach a Leak in tubing or Automatic a Tighten all threaded attachments and final pressure Condensate Drain connectors b Final pressure safety valve b Replace safety valve blows too soon defective...

Page 40: ... high b Check location ventilation for max 100º F 38º C c Direction of rotation wrong c Check correct rotation d Inlet pressure valves on one d Check valves clean or replace stage leak Unit cannot be switched off a Turn breaker off b Call Brownie s for technical advice Unit runs rough a Drive belt worn out a Replace drive belt and or vibrates b Drive belt loose b Tighten drive belt If you encounte...

Page 41: ...n Before commissioning check the instrument and any accessories supplied read the operating instructions ensure that the instrument is suitable for your application If the instrument is not handled correctly or if the operating instructions and specifications are not adhered to damage to property or personal injury can result 2 Functions of the EDS 8000 Depending on which model you have the instru...

Page 42: ...x To select the menu point x To confirm value 5 Digital display Once the power supply has been switched on the device briefly flashes EdS and then begins to show the actual pressure To check the unit of measurement being used for the pressure indication press the right hand key Depending on the setting bar psi or MPa will be shown The backlight changes colour according to the settings of the switc...

Page 43: ...fl2 FL2 Extended functions ef EF Reset res RES Switch delay time output 1 ds1 dS1 Switch delay time output 2 ds2 dS2 Switch back delay time output 1 dr1 dR1 Switch back delay time output 2 dr2 dR2 Output 1 ov1 Ou1 Output 2 ov2 Ou2 Normally open when hysteresis function is active kno HNO Normally open when window function is active fno FNO Normally closed when hysteresis function is active knc HNC ...

Page 44: ... s nominal pressure it can no longer be displayed The nominal pressure flashes in the display As a result when the menu point Max Value Hi is selected the value of the highest measured pressure which has been stored flashes until the instrument is reset rES x If the actual pressure is less than 0 6 of the nominal range 0 bar is displayed ...

Page 45: ... active NOTE x It is only possible to set the switch point SP if it is higher than the respective switch back point RP In the case of low SPs we recommend setting the RP first 6 1 2 Window function setting Fno Fnc The window function allows you to monitor a range An upper and a lower switch value can be entered for each switch output These values determine the range The relevant output will then s...

Page 46: ...limit of SP FH Min difference between RP and SP or FL and FH Increment in psi in bar in psi in bar in psi in bar in psi in bar in psi in bar 0 500 0 25 5 0 25 500 25 5 0 25 1 0 05 0 1000 0 40 10 0 40 1000 40 10 0 40 2 0 10 0 3000 0 100 30 1 00 3000 100 30 1 00 5 0 20 0 6000 0 250 60 2 50 6000 250 60 2 50 10 0 50 0 9000 0 400 90 4 00 9000 400 90 4 00 20 1 00 0 600 6 00 600 6 00 1 00 All ranges give...

Page 47: ... combined in a single menu NOTE x If no key is pressed for approx 60 seconds the menu closes automatically and any changes that may have been made will not be saved x If both keys are pressed at the same time the menu closes automatically and any changes made are saved x When an adjusted parameter is confirmed the set value is displayed for a second before returning to the relevant menu point 7 1 ...

Page 48: ...Status 09 09 2009 HYDAC ELECTRONIC GMBH Part No 669820 7 2 Extended functions ...

Page 49: ...the beginning E 12 An error was detected in the saved calibration data This could be due to strong electromagnetic interference or a component fault Action Disconnect then reconnect the supply voltage to the instrument If the error persists the instrument must be returned to the factory for recalibration or repair E 21 A communication error was detected within the instrument This could be due to s...

Page 50: ... Switch outputs Type 2 PNP transistor outputs Switching current max 250 mA per switching output Switching cycles 100 million Reaction time 10 ms Ambient Conditions Compensated temperature range 13 185 F 25 85 C Operating temperature range 13 212 F 25 100 C Storage temperature range 40 185 F 40 85 C Fluid temperature range 13 257 F 25 125 C Nominal temperature range of display read out 5 185 F 15 7...

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Page 54: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 55: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 56: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 57: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 58: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 59: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 60: ...c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake c Oil Level c Purification c CO Sightglass c Air Intake Yacht Pro Systems Operation Log NOTE Check Maintenance Log for Service Intervals with each operation DATE HOURS Operator Checks Maintenance Performed Comments KEEP THIS LOG MAINTAINED Brownie s recommends m...

Page 61: ...48 NOTES ...

Page 62: ...ion or wear occa sioned by chemical and or abrasive action excessive heat or abuse shall not constitute defects The sole responsibility of BROWNIE S THIRD LUNG and Buyers exclusive remedy hereunder is limited to such repair replacement and repayment of the purchase price Component parts or assemblies not manufactured by BROWNIE S THIRD LUNG are warranted only to the extent that they are warranted ...

Page 63: ...TankFill com ...