CO2 compressor

Essential Reading

Haffmans BV is not responsible for any damage caused by the owner’s failure to follow the instructions given in this
manual. Haffmans BV is not responsible for print or translation errors in this edition of the manual. The specifications
and design of this product are subject of change without notice. All rights reserved. No part of this publication may be
reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior
written permission of Haffmans BV.

Art. no. : CO2 compressor

Release date : 03 August 2012
Version : 2010.0
 HAFFMANS CO2 compressor

TABLE OF CONTENTS

1 TECHNICAL SPECIFICATIONS......................................................................................... 6
2 INTRODUCTION ................................................................................................................ 8
2.1 GENERAL INFORMATION ................................................................................................. 8
2.2 INTENDED USE ............................................................................................................... 8
2.3 GUARANTEE CONDITIONS ............................................................................................... 8
2.4 CUSTOMER SERVICE ...................................................................................................... 8
3 SAFETY.............................................................................................................................. 9
4 GENERAL PRODUCT INFORMATION ............................................................................ 10
4.1 GENERAL DESCRIPTION ................................................................................................ 10
4.2 COOLING SYSTEM CONFIGURATIONS ............................................................................. 11
5 TRANSPORT AND INSTALLATION ................................................................................ 13
5.1 TRANSPORT INSTRUCTIONS .......................................................................................... 13
5.2 UNPACKING ................................................................................................................. 13
5.3 ASSEMBLY AND INSTALLATION ...................................................................................... 14
5.4 CALIBRATION AND COMPENSATION ................................................................................ 16
5.4.1 Calibration ........................................................................................................... 16
5.4.2 Compensation ..................................................................................................... 16
5.5 INITIAL START-UP ......................................................................................................... 16
6 OPERATION..................................................................................................................... 17
6.1 LUBRICATION ............................................................................................................... 19
6.2 LUBRICATION CHART .................................................................................................... 19
7 MAINTENANCE AND CLEANING ................................................................................... 20
7.1 MAINTENANCE ............................................................................................................. 20
7.1.1 Before maintenance ............................................................................................ 20
7.1.2 After maintenance ............................................................................................... 20
7.2 MAINTENANCE ............................................................................................................. 21
7.3 CLEANING ................................................................................................................... 21
7.4 CHECKS ...................................................................................................................... 22
7.5 OIL CHANGES .............................................................................................................. 23
7.6 GENERAL NOTES FOR MAINTENANCE OF DRY CYLINDERS ................................................ 23
7.7 OIL-PRESSURE ............................................................................................................ 24
7.8 V-BELT MAINTENANCE .................................................................................................. 24
7.8.1 Installation ........................................................................................................... 24
7.8.2 Belt tensioning..................................................................................................... 25
7.8.3 Pulley misalignment tolerances ........................................................................... 26
7.8.4 Drive inspection................................................................................................... 26
7.8.5 Belt tensioning recommendations ....................................................................... 27
8 TROUBLE SHOOTING AND REPAIR .............................................................................. 28
8.1 TROUBLE SHOOTING .................................................................................................... 28
8.1.1 CO2 compressor unit ........................................................................................... 28
8.1.2 First stage cooler................................................................................................. 34
8.1.3 First stage water separator .................................................................................. 34
8.1.4 Second stage cooler ........................................................................................... 35
8.1.5 Closed loop cooling system ................................................................................. 36
8.1.6 Second stage cooler ........................................................................................... 36

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8.2 REPAIR ....................................................................................................................... 36

9 STORAGE AND DEACTIVATION .................................................................................... 37
9.1 STORAGE .................................................................................................................... 37
9.2 DEACTIVATION ............................................................................................................. 37
10 ENVIRONMENT ............................................................................................................... 38
10.1 ENVIRONMENTAL REQUIREMENTS .............................................................................. 38
10.2 AFTER DEACTIVATION ............................................................................................... 38

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1 TECHNICAL SPECIFICATIONS

General
Compressor 1 Compressor 2 Compressor 3
Manufacturer : Mehrer Mehrer
Type : TZW-60 TZW-60
Serial Number :
Year of : 2013 2013
Manufacture
Capacity : 250 250 kg/h

Compressor 1 Compressor 2 Compressor 3

Motor Motor Motor
Manufacturer : Svend Hoyer S/A Svend Hoyer
S/A
Type : HMC2 200L-4 HMC2 200L-4
Serial Number : - -
Year of : 2013 2013
Manufacture
Power : 30 30 kW
Voltage : 400/690 V
Frequency : 50 Hz

Process design
Compressor 1
Medium : CO2 gas
Humidity : 100 %
1st Stage 2nd Stage
Suction Pressure : 850 4 mbar(a)
Final Pressure : 4 18 mbar(a)
Gas temperature : 20 26.8 °C
suction side
Gas temperature : 141 172 °C
delivery side
Ambient : 20 °C
temperature
Set pressure : 6 20 bar(g)
safety valve
Cooling medium : 2 bar(g)
pressure 4 bar(g)
* Process temperatures may vary depending on cooling medium(s) or ambient temperatures.

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Mechanical design
(per compressor)
Compressor 1 Compressor 2 Compressor 3
Speed of compressor : 630 630 min-1
Cylinder action :
Stroke : 140 140 mm
Cylinder dia 1st stage : 220x110 220x110 mm
Cylinder dia 2nd stage : 220x110 220x110 mm
Cylinder liner 1st : - - mm
stage
Cylinder liner 2nd : - - mm
stage
Power required :
at crankshaft : 23 23 kW
at e-motor : 30 30 kW

Utility consumption
(per compressor)
Cooling medium(s) for Compressor(s)
Cooling Glycol Ice-water Air
Water
Cooling Media : -4 ºC
Temperature
Intercooler : 1 m3/h
After cooler : 1 m3/h
Head cooling : 0.4
Total consumption : 2.4 m3/h

Oil system
Oil charge : 7 Liter
Oil system delivery : l/min
(at 1000 rpm)
Set operating oil : 0.75 bar(g)
pressure
Max. operation oil : 1 bar(g)
pressure
Min. operating oil : 0.5 bar(g)
pressure

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2 INTRODUCTION
2.1 General information
This manual is a guidebook for the compressor unit.

Some of the options written down in this manual may not be included in your delivered system.
The pictures used in this manual are examples and can differ from the system you received.

Refer to the manual of the manufacturer.

2.2 Intended use

The compressor unit is intended to compress CO2 gas with a purity of 90-100% at the conditions
specified in chapter 1. The CO2 is considered free of foam, sugar and liquids. The use of the
compressor unit for other gases and conditions is not allowed.

2.3 Guarantee conditions

See: General Terms & Conditions.

2.4 Customer service

Haffmans BV provides comprehensive service opportunities for maintaining CO2 plants. In most
cases this maintenance is planned but in exceptional cases an experienced Haffmans service
engineer can be on-site at your plant within a few days if required. For details on Haffmans BV
extensive service contracts, contact Haffmans BV

Utmost care is taken in designing, fabricating, commissioning and checking the CO2-plant with
the aim of reliability of systems and convenience for operators.
If you nevertheless encounter troubles operating the CO2 plant please contact Haffmans BV at
NLVENService@[Link].

If spare parts are required please contact Haffmans BV at spareparts@[Link]

When contacting Haffmans BV always mention the project number and if available the tag
number of the specific item. These can be found on chapter ‘03-Drawings P&ID’

Haffmans BV
Marinus Dammeweg 30
5928 PW Venlo, The Netherlands

P.O. box 3150

NL-5902 RD, The Netherlands

T : (+31) 77-3232300
F : (+31) 77-3232323
E : info@[Link]
I : [Link]

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3 SAFETY
Read the general safety issues regarding working with CO2 in the main manual.
Safety issues especially for this part of the installation will be shown in the gray framework.
Read them carefully and act as required.

Warning
Large concentrations of CO2 can cause asphyxia and even death.

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4 GENERAL PRODUCT INFORMATION

4.1 General description

Fig. 4.1: P&ID-CO2 compressor water cooled

The CO2 compressor compresses the low-pressure CO2 gas to approximately 18 bar(g). This
pressure is needed in the CO2 condenser downstream to condense the CO2 gas at
-30 to -40˚C. The compression is done in two stages and depending on plant capacity, one or
more CO2 compressor(s) may be installed.
After each compression a cooler is installed to remove the heat of compression. During this
cooling some water in the CO2 gas will condense. After the first compression and cooling with
the ‘intercooler’ this water must be removed to avoid damage to the next compression stage.
After the second compression the heat will be removed by the ‘after-cooler’ and as much as
water as possible will be removed to relieve the drier located down stream. The removal of
water will be done with the water separators. The collected water is drained to a gully by a level
controlled solenoid valve.

Warning Due to compression the gas and the piping involved can be very
hot and can cause burns.

Besides the cooling of the CO2 gas additional cooling of the cylinder heads is required. Some
models are executed with air cooled heads, but most models are executed with water or glycol
cooled cylinder heads. This cooling is integrated in the cooling system of the unit. There are
several configurations possible which will be described in the paragraph 4.2.
All possible cooling system of the cylinder head are fitted with a safety valve to avoid damage of
the cylinder head by too high pressure. The de-aerator is installed to remove the air in the
cooling circuit.
An inlet valve with compensator divides the compressor unit from the up stream system and
suppresses vibrations to the inlet piping. A switch mounted on the inlet valve detects the open
position.
Safety valves are installed to avoid pressures exceeding the designed pressures.
Pressure gauges are installed to read the pressure and thermometers are installed to check the
temperature.

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An unloaded start up to avoid overload of the motor is controlled by an electro-pneumatic valve

which makes a short cut between discharge and suction piping.
To avoid damage in the cylinders by liquid the cylinder heads are equipped with liquid
separators which remove the liquid automatically.

4.2 Cooling system configurations

Configuration 1:
Cylinder heads glycol / ice water cooled, serial cooling with glycol / ice water.
Glycol / ice water from the main brewery supply is fed in too the compression skid where a
booster pump pumps the glycol / ice water over the after-cooler and then the intercooler. A
thermostatic mixing valve maintains a constant off-skid discharge CO2 temperature by
regulating the intake of cold glycol / ice water from the brewery main supply. A dedicated head
cooling pump with temperature regulation valve and flow switch is installed to ensure correct
cylinder head cooling.

Configuration 2:
Cylinder heads water cooled, inter cooling with cooling water, after cooling with
glycol / ice water.
Glycol / ice water from the main brewery supply is used for the cooling circuit and a pump is
used to circulate the glycol / ice water over the after-cooler. A thermostatic mixing valve
maintains a constant off skid CO2 temperature by regulating the intake of cold glycol / ice water
from the brewery main supply. Cooling water from the main brewery supply (or Haffmans
supplied cooling tower) is passed over the compressor intercooler and cylinder heads. A
dedicated head cooling pump with temperature regulation valve and flow switch is installed to
ensure correct cylinder head cooling.

Configuration 3:
Cylinder heads water cooled, inter / after cooling parallel with water.
Cooling water from the main brewery supply (or Haffmans supplied cooling tower) is passed
over the intercooler and after-cooler in parallel arrangement. A dedicated head cooling pump
with temperature regulation valve and flow switch is installed to ensure correct cylinder head
cooling.

Configuration 4:
Cylinder heads air cooled, serial cooling with glycol / ice water.
Glycol from the main brewery supply is used for the cooling circuit and a pump is used to
circulate the glycol over the after-cooler and then the intercooler. A thermostatic mixing valve
maintains a constant temperature of discharge CO2 by regulating the intake of cold ‘glycol’ from
the brewery main supply. Ambient air is blown over the cylinder heads by a cooling fan. Note
that in some installations the pump is not installed.

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Configuration 5:
Cylinder heads air cooled, Inter cooling with cooling water, after cooling with
glycol / ice water.
Glycol / ice water from the main brewery supply is used for the cooling circuit and a pump is
used to circulate the glycol / ice water over the after-cooler. A thermostatic mixing valve
maintains a constant off skid CO2 temperature by regulating the intake of cold glycol / ice water
from the brewery main supply. Cooling water from the main brewery supply (or Haffmans
supplied cooling tower) is passed over the compressor intercooler. Ambient air is blown over the
cylinder heads by a cooling fan

Configuration 6:
Cylinder heads air cooled, inter / after cooling parallel with water
Cooling water from the main brewery supply (or Haffmans supplied cooling tower) is passed
over the intercooler and after-cooler in parallel arrangement. Ambient air is blown over the
cylinder heads by a cooling fan

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5 TRANSPORT AND INSTALLATION

5.1 Transport instructions
Transport the unit with a forklift, the weight of the total unit is described on the packing.

Fig 5.1 : Transport of a unit with a forklift.

5.2 Unpacking
Before dispatch all parts have been checked. Check on arrival if the delivery has arrived
complete according to the packing lists and if the goods are undamaged.
If the delivery is incomplete or damaged, please contact Haffmans BV immediately.
Take pictures of the damaged goods.

Always include in the correspondence (if available): the serial number, project number, invoice
number and pictures of the part in question.

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5.3 Assembly and Installation

Follow the following guidelines for assembly and erection of the compressor unit:
1. Check if the fundation is constructed in accordance with engineering drawings and
calculations. (Since they are not part of the delivery of Haffmans BV they will be not
available in the manual).

Warning The fundation must be calculated considering the weight and

dynamic forces of the CO2 compressor and must always comply
to local regulations. The calculation and construction of the
foundation is the customer’s responsibility.
A fundation which is not engineered for the forces mentioned
above can cause structural damage to the CO2 compressor and
can cause serious injuries and even death.

2. Check if the concrete steep is level, dry and stable enough to mount the CO2
compressor.
3. Mount the unit on the steep and drill the holes in the concrete.
4. Install the bolts using the chemical anchor capsules.
5. Tighten the bolts according engineering drawing foundation. (Since they are not part of
the delivery of Haffmans BV they will be not available in the manual)

Note! It is advised to install the unit in a room free of dust and

moisture with a normal room temperature. In cold climates,
where heating in the compressor room cannot be installed,
ensure that an anti freeze alarm is installed.

6. Connect all piping according drawings to be found in chapter ’06-Drawings Turn-Key’.

Note! When welding the piping to the valves make sure that no heat can
deform the internals of the valves. This might damage the seats
with leaky valves as a result.

Warning The safety valves must be vented to a safe location.

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7. Check the oil level in the crankcase.

8. Check the tension of the drive belt.

Note! Operate the CO2 compressor with closed side cover plates and
with the drive guard in place. Under no circumstances remove the
side cover plates or drive guard when the machine is not in a
secured state.

9. Connect all electrical connections, the CO2 compressor must be grounded and all
electrical bolts must be checked.
10. Mount the insulation where necessary.
11. Perform a pressure test with CO2 gas (never with water)
12. Purge the unit to remove the air for the system.
13. The CO2 compressor is now ready for operation.

Note! When starting the motor for the first time, check if the
direction of rotation is correct.

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5.4 Calibration and compensation

5.4.1 Calibration
All set points and calibrations which can be preset at Haffmans BV are set and checked in
advance. The settings can be found in chapter '10-Process data and set point list'.
5.4.2 Compensation
There are no compensation issues.

5.5 Initial start-up

1. The CO2 compressor is an oil-free compressor (dry cylinder compressors) but has an oil-
lubricated drive mechanism. Normally the drive mechanism is filled with lubrication oil up
to the level marked on the oil sight glass. Check this before the machine is put into
operation for the first time.
2. The voltage, type of current and number of cycles of the drive motor must be compatible
with those of the supply network.
3. Switch on the operation panel.
4. Open the valves of the inlet and outlet and check on the operation panel if the open
position of the inlet valve has been detected by the switch.
5. Check for leakages and repair if necessary.
6. Open the valves of the cooling system
7. De-aerate the system by removing the de-aerator and opening the valve underneath.
Close the valve when all air has escaped and coolant comes out of it.
8. If systems upstream and downstream are ready to operate the compressor can be
started.

Note! When starting the motor for the first time, check if the
direction of rotation is correct.

9. Check the temperatures of cooling systems

10. Check pressures.

Note! Operate the CO2 compressor with closed side cover plates and
with the drive guard in place. Under no circumstances remove the
side cover plates or drive guard when the machine is not in a
secured state.

11. Fill in the log book.

12. The compressor is ready.

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HAFFMANS CO2 compressor

Valve nests
drained, gas
leakage from side
covers checked,
(Note: Some installations may not have all the indicators as shown below. In such a case the table is to be filled out as completely as possible.)

condensate drains
checked.
Comments
Cooling media
temp 2nd stage
head [°C]
Cooling Medium
on-skid temp.
[°C]
2nd stage
discharge temp ex
cooler [°C]
2nd stage
discharge CO2 gas
temp [°C]
2nd stage suction
CO2 gas temp [°C]
1st stage discharge
CO2 gas temp [°C]
2nd stage
discharge press.
[bar.g]
2nd stage suction
press. [bar.g]
Oil Temp
[°C]
Oil Press.
[bar]
Oil Addition
[litres]
CO2 Compressor, Daily log
OPERATION

Oil Level
Hours of

CO2 Compressor
Operation
Date

01 /
02 /
03 /
04 /
05 /
06 /
07 /
08 /
09 /
10 /
11 /
12 /
13 /
14 /
15 /
16 /
6
 CO2 Compressor
HAFFMANS CO2 compressor

Valve nests
drained, gas
leakage from side
covers checked,
condensate drains
checked.
Comments
Cooling media
temp 2nd stage
head [°C]
Cooling Medium
on-skid temp.
[°C]
2nd stage
discharge temp ex
cooler [°C]
2nd stage
discharge CO2 gas
temp [°C]
2nd stage suction
CO2 gas temp [°C]
1st stage discharge
CO2 gas temp [°C]
2nd stage
discharge press.
[bar.g]
2nd stage suction
press. [bar.g]
Oil Temp
[°C]
Oil Press.
[bar]
Oil Addition
[litres]
Oil Level
Hours of
Operation

Page 18 of 39
Date

17 /
18 /
19 /
20 /
21 /
22 /
23 /
24 /
25 /
26 /
27 /
28 /
29 /
30 /
31 /
 HAFFMANS CO2 compressor

6.1 Lubrication

Refer to the manual of the manufacturer.

6.2 Lubrication chart

In the technical documentation of the manufacturer you find various brands of lubricating oils
(Haffmans does not claim to give the whole range of brands available). The kind of oil is subject
to the ambient temperature at the place of operation.
The brands mentioned have proved to be especially suitable for the delivered compressors and
our warranty obligation is only effective for one of those brands or of a proven equal quality.

Note! A compressor operating in a engine room, in general, will operate

in a high ambient surroundings. Ensure that the oil chosen
reflects the immediate ambient surroundings not simply the local
climate!

Note! If there are large fluctuations in temperature, the use of multi-

grade oil is recommended.

Note! The CO2 compressor starts and stops automatically therefore a

sign must be displayed near the compressor stating “DANGER –
The CO2 compressor starts and stops automatically and without
warning.”

Control of oil level is made according to special instructions.

Special attention should be given to ensure a proper lubrication of the compressor. Proper oil
management ensures efficiency and longer life of compressor without troubles.

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7 MAINTENANCE AND CLEANING

7.1 Maintenance

Note! Oil-free compressors (dry-cylinder compressors), which are not in

constant use and which at times are in idle for days or weeks,
must be allowed to run for a few minutes once a week.

7.1.1 Before maintenance

Make sure maintenance is done safely, therefore the CO2 compressor must be switched off.
This can be done by using the guidelines below:
1. Shut down the compressor in the operation panel
2. Close the valves of the cooling system.
3. Close the inlet and outlet valve of the CO2 compressor and secure the valves using a
lock.
4. Check if by closing the valves if the CO2 the compressor is pressure less.
5. Remove the motor fuses and lock the main switch of the CO2 compressor panel to avoid
a start-up of the CO2 compressor.

Note! Check the position of the crankshaft and secure it against

unintentional rotation.

Warning Maintenance should be carried out by a qualified service person

Warning Under no circumstances shall maintenance be carried out on a

machine in operation.

7.1.2 After maintenance

To prepare the CO2 compressor for operation after maintenance use the guidelines below:
1. Check if all parts are mounted and if it is safe to start up again.
2. Remove the lock on the main switch of the CO2 compressor panel.
3. Replace the fuses of the motor.
4. Purge the system with CO2 to evacuate the air from the system.
5. Open the inlet and outlet valve of the CO2 compressor and remove the lock.
6. Open the valves of the cooling system and de-aerate it.
7. Start the CO2 compressor in the operation panel.
8. Check the temperatures of outlet cooling system (max. 50°)

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7.2 Maintenance
The compressors have an oil-lubricated crank gear, which is separated from the dry-running
compression compartment by oil seal glands. Because of the crank gear lubrication only, there
is no need for compressor oil such as used for compressors with oil-lubricated pressure
chambers. The intervals at which the oil should be changed are given in the manual of the
manufacturer.

Before the first operation, a suitable lubricant according to the lubricant schedule must be filled
at the oil-filling point. The viscosity of the oil depends on the ambient temperature of the
operation side.

In the manual of the manufacturer there is a comprehensive service schedule that should be
followed in order to keep the CO2-compressor in good condition. For warranty and purposes
and diagnosis of potential problems BOTH the daily compressor logbook and maintenance
logbook must be kept up to date.

Dry cylinder compressors must run at least 5 minutes per day if they have been set out of
operation for a certain period.

7.3 Cleaning
There are no cleaning issues.

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7.4 Checks
Refer to the manual of the manufacturer.

Method:
1. Check oil level; refer to the manual of the manufacturer.
2. Check oil pressure of compressors with forced feed lubrication. Refer to the manual of
the manufacturer
3. Check the proper function of the condensate drains from the inter and after cooler
separator vessels,
4. Check the compressor operating temperatures and pressures – Note these down in the
daily log,
5. Gas leakage from gas packing glands (done at side access covers.) Temporarily block
off all but one of the breather holes in the side access covers. Hold a piece of paper over
the remaining breather hole. Under normal operation a very slight ‘puffing’ of air in and
out of the breather hole should be observed. This is normal and is caused by piston
action within the distance piece. A significant continual gas flow suggests incorrectly
operating gas-packing glands.

Every 500 working hours

For air-cooled compressors, clean the cylinder as well as the pipe lines exposed to the cooling
flow as contamination of those parts may badly affect the heat exchange and results in
inefficient compressor cooling.
Every 1000 working hours
For water cooled compressors, open the strainer mounted in the cooling water inlet of the pipe
line and clean it.

Note! Checks means: checking the function and state and, if necessary,
replacing or mending respectively.

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7.5 Oil changes

Method
1. To eliminate contaminants from the lubricant, which are inevitable during the first
operation period, drain off the oil after the first 72 running hours and refill again.
2. The following oil change will be due after 4000 running hours or once a year which ever
comes sooner.
3. A further oil change is necessary after 8000 hours. Ensure that the oil has been
thoroughly removed. DO NOT use fraying cloth or cleaning wool.

At each oil change the oil filter MUST be cleaned. It is also normal during the initial start up and
commissioning period for an additional filter cleaning to be done after 10 and 200 hours.
Cleaning is done with crude petroleum, naphtha or P3. After cleaned thoroughly blow the filter
screen with compressed air.

See also the manufacturer manual.

7.6 General notes for maintenance of dry cylinders

Maintenance duties carried out by the operator are normally confined to changing the valves
and piston rings and sometimes the oil and gas seal gland internals. Any further servicing
should be done by the supplier or by his after-sales-service representative.

For dismantling and re-assembling heavy parts, a suitable lifting jack should be made available.

Always keep a set of spare joints in stock, as flat joints and O-rings can easily be damaged
during dismantling or show grooves after a certain time of operation.

To fix and seal threads and sleeve sockets, make sure that a liquid plastic such as Loctite,
Casco, Omni FIT or a similar type of material is available.

Vital screw connections must always be fastened by a dynamometric key. This is especially
important for the piston rod fixing.

Before re-assembling the glands onto the compressor, make sure that the working cylinder and
the piston rod are free from furrows. Unevenness of piston liners can be removed by honing,
however this is not possible with the piston rod itself which can only be exchanged in that case.

Therefore take special care when doing this work so that the cylinders and piston rods will by no
means be damaged. Also avoid any damage of the sealing lips of the oil wipers, and the
packing rings and piston rings.

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7.7 Oil-pressure
The oil-pressure is indicated on the oil-pressure gauge and should be according the manual of
the manufacturer.

However, cold oil at the starting up of the compressor may cause the oil-pressure be higher as
maximum for a short period of time.

7.8 V-belt maintenance

7.8.1 Installation
V-belts must be fitted to the drive without using any force to clear the pulley outside diameters.
No crow bars, screwdrivers or any other levers should be used, neither should the belts be
wound onto the pulleys.

Excess force is almost guaranteed to damage the belt components especially the tension cord
or the cover fabric. Damaged belts are likely to have a short life, even as little as a few minutes.

It is of major importance to make provisions for a correct V-belt tension in order to ensure a
perfect power transmission and this guarantees normal lifetime of the V-belts.

The highest rate of dilatation on V-belts is normally during the running-in period. Therefore it is
advisable to check and re-tighten them already on the first inspection of the compressor.

Proper care at installation saves time and money.

When the installation adjustment is small it may be necessary to fit the belts to the pulleys with
the small pulley off its shaft. The small pulley can then be replaced on the shaft without over-
stressing the belts.

The table overleaf for the correct tension of new belts is given in the Maintenance Schedule,
chapter 7.8.5.

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7.8.2 Belt tensioning

Belt tensioning values should follow the recommendations given in chapter 7.8.5. Use the motor
positioning bolts to tighten or slacken the V belts. (See below). Ensure that the drive is still in
alignment when the motor has been adjusted to tighten the belts and continue to check the belt
tension as adjustment is taken up. When the required tension is reached rotate the pulleys two
or three times to settle the belts in the grooves and check the tension again. Repeat until the
correct tension is reached. Where a set of belts is fitted apply a tension gauge to one of the
center belts. Run the drive for up to 5 hours after new belts are fitted and re-check and tension
as required. Follow the drive belt check guide for operating hours as described in the manual of
the manufacturer.

Fig. 7.1: Bolts for tension adjustment V-bell

Note! If V-belts are tightened insufficiently, slip, knock off and wear
increases.

Note! If V-belts are tightened too tight, this may cause bearing damage on
both motor and compressor.

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7.8.3 Pulley misalignment tolerances

After tensioning the belts pulley misalignment should not exceed the following tolerances:

Pulley Diameter Dd1, Dd2 Maximum values x1, x2

112 mm 0,5 mm
224 mm 1,0 mm
450 mm 2,0 mm
630 mm 3,0 mm
900 mm 4,0 mm
1.100 mm 5,0 mm
1.400 mm 6,0 mm
1.600 mm 7,0 mm

The measurements x1 and x2 from the outside of the diameters of each pulley Dd1 and Dd2
should be checked using a straight edge laid across the pulley faces. The maximum values of x
shown in the table should not be exceeded. These values depend on the pulley diameter. For
intermediate pulleys diameters these tolerances should be interpolated.
For example: if you have a pulley with diameter of 700 mm. You need to calculate the following;
(4-3)/(900-630)*(700-630) + 3 = 3,259

Fig. 7.2: Pulley misalignment tolerances

7.8.4 Drive inspection

In line with the checking on the belt tension in the Maintenance Schedule, chapter 7.4, the
pulley groove wear should also be checked. For this a pulley groove gauge is required.
A good rule of thumb is; ‘the point should be well clear of the bottom of the pulley groove and no
daylight clearly visible on either side of the gauge. Pulley grooves tend to wear round, so when
the straight edged trapezoid shape of the gauge is in the groove, the rounded wear will show on
either side.

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7.8.5 Belt tensioning recommendations

The following table is to be used when applying the correct tension to the CO2 compressor V-
belts

Profile Check power each V- Diameter of smallest Depth of impression

belt F (N) pulley dk (mm) each 100 mm axe
distance E (mm)
SPZ (9,7) 25 71 ≤ 90 2.86
> 90 ≤ 125 2.66
> 125 2.47
SPA (12,7) 50 100 ≤ 140 3.57
> 140 ≤ 200 3.31
> 200 3.18
SPB (16,3) 75 112 ≤ 160 2.00
> 160 ≤ 224 1.55
> 224 ≤ 355 1.20
> 355 1.10
SPC (22) 125 > 180 ≤ 250 3.31
> 250 ≤ 355 2.86

Note! The indexes named values are only for the run in V-belts.

To correct the above values this for new V-belts, the values have to be multiplied by a factor of
0,77.

When there a no real good technical tools available, it is possible to check the V-belts easily as
in the next example:

e
Ea = xE
100

Where:
e = Axe distance (mm)
dk = diameter of the smallest pulley
F = check power of one V-belt (N) see above table
E = depth of impression of 100 mm axe distance (mm) see above table
Ea = depth of impression of driving belt (mm)

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8 TROUBLE SHOOTING AND REPAIR

8.1 Trouble shooting
8.1.1 CO2 compressor unit
Trouble Reason Solution
CO2 compressor is not The level sensor or switches - Check the function or
starting/ or not starting are not working properly. replace the
correct sensor/switches.
The approach switch is faulty. - Replace the switch.
The approach switch is set - Set the correct distance.
incorrectly.
The cable break for the - Reset the alarm/check the
approach switch is active. switch.
The plastic coating on the - Replace the cable/remove
cable is damaged. the plastic.
The Gaswasher is not giving - Check water flow over the
a signal to start the Gaswasher.
compressor.
The Gaswasher is not giving - Check the high level sensor
a signal to start the in the Gaswasher. (if
compressor. mounted)
Feedback of CIP still active. - Check feedback of CIP.
The cooling plant is not giving - Check if there are problems
a signal to start the with the cooling.
compressor.
CO2 tank is full. - Check the filling of the CO2
tank and the settings in
the display.
Fuse break is active. - Check the fuse break and
the current during start up
and running.
No signal to start the - Check the contact of the
compressor because the relays.
relays are sticking.
A spool is burned. - Check the spools of the
motor.
3 Phases power supply is not - Check the fuses and the 3
correct. phase power supply.
Unloaded start valve stays - Check the function of the
open or not complete closed. unloaded start and
valves.
The V-belts are slipping. - Check the tension and
surface of the V-belts.
Frequency converter wrong - Check the settings of the
settings. frequency converter.
Gas seals are worn. - Check on leakages.
(change the gas seals)
Piston rings are worn. - Change the piston rings.

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Trouble Reason Solution

CO2 compressor is not Mechanical resistance in the - Check the rotating parts of
starting/ or not starting compressor is too high. the compressor.
correct Valves are faulty or broke. - Check the valves and the
cylinders.
Electrical problems. - Check all electrical
connections.
CO2 compressor or Cooling - Check and wait till delay
compressor is in Start/Start time is finished
or Stop/Start Delay
CO2 compressor makes a The valves are faulty. - Replace/repair the valves.
ticking noise. The valves have been fitted - Check the assembly of the
incorrectly. valves.
The valves are loose. - Check the assembly of the
valves.
The valves are polluted. - Clean the valves.
There is pollution in the - Vacuum out the
compression chamber. compression chamber/
check for damage.
Parts of the valves have been - Disassemble the valves and
fitted incorrectly. check the correct
assembly of the parts.
The valves are stuck due to - Clean the valves with
caramel deposit. steam/condensation.
The compressor becomes - Check and/or reduce the
too cold. (small amount of cooling.
condensation)
Piston shaft bolt is loosen on - Check and tighten bolt
piston and piston hits cylinder
cover
CO2 compressor oil is white. Water leaks over the gas - The compressor has had a
stop bushes and the free gas small amount of water
chamber. shock and the
compressor has rotated.
(no inspection by the
brewery)
The oil cooler leaks. - Check the oil cooler coil.
CO2 compressor water in the Water leaks over the gas - The compressor has had a
compressor’s free chamber. stop bushes and the free gas small amount of water
chamber. shock.
CO2 compressor oil in free Oil leaks over the oil scrapers - Change the oil scrapers.
chamber. into the free gas chamber.
(Note: A little oil is normal
and acceptable specially with
NEAC V)

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Trouble Reason Solution

CO2 compressor sucks in air The gas stoppers are leaking - The ∆P measuring device is
via the free chamber. and the filters before the CO2 indicating high differential
compressor are blocked pressure over filter
Overdue maintenance of
sugar filters before CO2
compressor
CO2 compressor CO2 blows The gas stoppers are leaking. - Overdue maintenance.
out of the free chamber. - There is damage to the gas
stoppers due to water
shock.
- The piston rod is
damaged/replace piston
rod
CO2 compressor 1st stage The suction valves of the 2nd - Replace the valves and/or
high pressure phase are faulty. the valve plates.
High excess pressure in the - This can only occur in a
compressor’s inlet. system without a gas
balloon.
CO2 compressor stops The return valve after the - Clean the return valve.
operating at a high pressure after-cooler gets stuck.
in the 2nd phase. Insufficient cooling capacity. - Check the CO2 plant’s
cooling unit.
The filters in the AK/Dryer are - Check the ∆P measurement
blocked with AK. in the tanks. Replace the
mesh/filter (therefore, also
the filling)
The condensation filter is - Replace the filter element in
blocked. the separator.
The pressostaat is set - Check the setting.
incorrectly.
The pressostaat is faulty. - Replace the pressostaat.
The dust filter after the - Replace the dust filter.
ACF/Dryer is blocked.
The purity of the CO2 is bad. - Blow off bad CO2 and check
the purity.
Purge valve is not working - Check the function.
properly. (Calibration, set points
etc)

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Trouble Reason Solution

CO2 compressor oil pressure The oil pressure pressostaat - Replace the pressostaat.
too low is faulty.
The oil pressure is set - Check the setting.
incorrectly.
The oil filter is blocked. - Clean the oil filter.
Insufficient oil. - Top up the oil. (find the
cause)
The pressure control unit is - Clean the oil pressure
polluted. control unit (ball + spring).
The oil pump does not supply - Revise the oil pump.
enough oil. (change over the fans)
There is water in the oil. - Change the oil. Make sure
everything is clean. (this
will have to be repeated
after the compressor has
been operating for a
couple of hours)
non return valve in the - Clean the non return valve
suction pipe is faulty (some times there are 2
non return valves in the
suction pipe of the oil
pump)
External oil pump is not - Check the function of the oil
working. pump and the electrical
connections.
At a frequency controlled CO2 - Check the min frequency to
compressor the frequency set have a good oil pressure
is too low to have enough oil supply.
pressure supply.
CO2 compressor oil The surrounding temperature - Make sure there is more
temperature too high. is too high. cooling in the room. Or
install a separate oil
cooler
The oil thermostat is faulty. - Replace the thermostat.
The oil thermostat is set - Set it correctly.
incorrectly.
The oil cooler spiral is - Free/check the flow.
blocked.

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Trouble Reason Solution

CO2 compressor water in the Leak on the compressor’s - Replace the cylinder head
1st phase of the compressor. cylinder head gasket. gasket.
The gas washer packet is - Clean the gas washer.
polluted (too high ∆P).
The gas washer’s drip tray - Clean the drip tray.
overflows.
The water inlet temperature - Set the temperature
in the cylinder head is too correctly.
low.
There are no pulse absorbers - Have one made or make a
on the inlet. drain.
The demister in the top of the - Replace/repair the
gas washer is faulty. (old type demister..
of gas washer)
There is no condensation - Make a condensation drain.
drain on the inlet pipe. (return
to the gas washer)
The condensation drain pipe - Clean the gas washer
sucks in water. packet (see gas washer).
Condensation forms in the - The surrounding
suction pipe. temperature is too low.
Valve before Gaswasher is - Open valve between gas
closed accidentally washer and balloon.
The drain filter is blocked. - Clean the filter.
The condensation drain valve - Replace the valve.
is faulty.
Insufficient air on the - Set the air pressure
condensation drain valve. correctly. (approx. 6 bar)
No drain on the inlet of the - Fit a drain. (with float pot, if
2nd phase compressor. possible)
CO2 temperature after - Set the temperature
intercooler is too low. (T = correctly (allow the
normal 25°C till 35°C) compressor to run longer
for the correct setting)
The cylinder head cooling - Set the temperature
water temperature is too low. correctly (>40 / <60° C).
A cylinder head gasket leaks. - Replace the cylinder head
gasket (check via the
valves).

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Trouble Reason Solution

CO2 compressor capacity too The suction valves in the 1st - Replace/check the valves.
small section are faulty.
Suction valve capacity control - Check the air
valve lifter in the 1st phase supply/mechanism.
does not work correctly.
The suction valve in the 2nd - Check the valve.
phase is faulty.
Suction valve capacity control - Check the air
valve lifter in the 2nd phase supply/mechanism.
does not work correctly.
The delivery valves of the 1st - Check the valves.
or 2nd phase are faulty.
The piston springs do not - Maintenance. (check via the
seal correctly. valves)
The gas stoppers leak. - Replace. (can be checked
whilst in operation)
The cylinder wall are no - Measure. (if the correct
longer 100% round. tools are available)
CO2 compressor wrong General. - Check CO2-compressor
capacity / flow is shown. capacity.
CO2 compressor vibrations Foundation bolts are not - Check the vibrations of the
around the compressor and tighten sufficiently. CO2 compressor on
piping Compressor base is not filled several places with a
with concrete. vibration pen SKF
CMVP40 (English
inch/sec) or CMVP50
(metric mm/sec) and
communicate this to
Haffmans. Tighten the
foundation bolts of the
compressor/ Fill
compressor base with
concrete.
Not enough supports placed - Place more supports on
or placed at the wrong spot sensitive area's

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8.1.2 First stage cooler

Trouble Reason Solution
CO2 compressor temperature The suction valve in the 2nd - Replace the suction valve in
1st phase too high. phase is faulty. the 2nd phase.
The delivery valve in the 1st - Replace the delivery valve
phase is faulty. in the 1st phase.
The thermostat is faulty. - Replace the thermostat.
The thermostat is set - Check the setting.
incorrectly.
Circulating pump is not - Check mechanical and
working properly electrical the circulating
pump

8.1.3 First stage water separator

Trouble Reason Solution
CO2 compressor water in the The level sensor in the - Replace the sensor.
2nd phase of the compressor condensation drain of the 1st
phase is faulty.
The level sensor in the - Set the sensor correctly.
condensation drain of the 1st
phase is set incorrectly.
The 1st phase condensation - Disassemble and clean the
drain is blocked. condensation separator.
The intercooler leaks. - Pressurize the intercooler.

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8.1.4 Second stage cooler

Trouble Reason Solution
CO2 compressor temperature Too little cooling over the - Check the flow over the
2nd phase too high. intercooler. intercooler.
The thermostat is faulty. - Replace the thermostat.
The thermostat is set - Check the thermostat
incorrectly. setting.
Circulating pump is not - Check mechanical and
working properly electrical the circulating
pump
1st stage cooler is dirty - Clean the first stage cooler
internally
The thermostat is faulty. - Replace the thermostat.
The thermostat is set - Set the thermostat correctly.
incorrectly (look for correct temp on
the P&ID)
Too little cooling over the - Increase the flow.
after-cooler.
The filter for the after– - Clean/replace the filter.
cooler's cooling medium is
blocked.
The after-cooler is polluted. - Clean the after-cooler
(depends on the type of
pollution).
The water control valve is - Replace the control valve.
faulty.
The surrounding temperature - The by-pass timer is set to a
is too high. too short time.
Circulating pump is not - Check mechanical and
working properly electrical the circulating
pump
2nd stage cooler is dirty - Clean the second stage
internally cooler

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8.1.5 Closed loop cooling system

Trouble Reason Solution
CO2 compressor leak in the Aggressive Glycol. - Check the composition of
inter and/or after cooler. the glycol.
Chlorine in the cooling water. - Check the composition of
the cooling water.

8.1.6 Second stage cooler

Trouble Reason Solution
CO2 compressor cylinder Flow too low over the cylinder - Increase the cooling
head temperature too high head. medium flow over the
cylinder head.
Air or steam accumulated in - De-aerate the cylinder head
the cylinder head - Check the correct working
of the automatic de-
aeration valves.
CO2 compressor temperature Too little cooling over the - Increase the cooling
1st phase too high. cylinder head. medium flow over the
cylinder head.
CO2 compressor temperature Too little cooling over the - Increase the cooling
2nd phase too high. cylinder head. medium flow over the
cylinder head.

8.2 Repair
Refer to the manual of the manufacturer.

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9 STORAGE AND DEACTIVATION

9.1 Storage
All parts must be stored in a dry environment with temperatures above 0°C.
Check that equipment can not be filled with water.

Note! If there is a danger of frost. The cooling water/glycol and the rest
of the water/glycol cooled system (Intercooler and after-cooler).
should be drained.

9.2 Deactivation
There are no deactivation issues.

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10 ENVIRONMENT
10.1 Environmental requirements
There are no environmental requirements issues.

10.2 After deactivation

After deactivation the following material will be released:
• Iron
• Stainless steel
• Electronic components
• Oil

Separate these materials and dispose them environmentally friendly and according local
regulations.

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