Service Manual XA030 - Version02

3
Congratulations on your X-range compressor!

Innovations:
Patented X-drive Patented cooling Registered design
The extraordinary X-range compressor is a new generation of true 1800 rpm compressors, and covers all capacities for the marine
market. The Sperre X-range compressor is based on more than 70 years of experience.
This excellent compressor gives you several benefits:
 Safety first – a fully enclosed structure  Easy plug-in for sensors

 Green and clean – no oil mist to the environment  25% fewer wear parts – 50% more reliable
 A new level of control  Best cooling efficiency in the market
 Easy to learn – one common platform  Low vibration level – high grade of isolation
 Less installation time – no special alignment  Improved standard scope of supply
Sperre has developed a unique chain of value, that‟s what it takes to produce reliable compressors that function smoothly for the
life of the ship.
Sperre congratulates you on your choice of compressor!
Mareno K. Nakken
Technical Director
www.sperre.com Service Manual XA030 Version 02 3

Contents
1 Introduction ............................................................................................ 5
1.1 Purpose ........................................................................................................................ 5
1.2 Annotations .................................................................................................................. 5
1.3 Abbreviations ................................................................................................................ 5
1.4 Tags on the compressor ............................................................................................... 6
1.5 Warranty....................................................................................................................... 6
2 Personal safety....................................................................................... 7
3 Service and ordering.............................................................................. 8

3.1 Service schedule .......................................................................................................... 8
3.2 Service Warnings: ......................................................................................................... 9
3.3 Service Alarms: .......................................................................................................... 10
3.4 Service procedures overview ...................................................................................... 12
3.5 Kit overview ................................................................................................................ 13
3.6 Recommended kits and special tools .......................................................................... 15
3.7 Ordering parts and kits................................................................................................ 31
4 Service procedures .............................................................................. 32

4.1 Cover.......................................................................................................................... 32
4.2 Lubricating oil ............................................................................................................. 33
4.3 Air filter ....................................................................................................................... 34
4.4 Safety valves LP and HP ............................................................................................ 35
4.5 Air cooler LP ............................................................................................................... 36
4.6 Air cooler HP .............................................................................................................. 37
4.7 Valve LP ..................................................................................................................... 38
4.8 Valve HP, suction side ................................................................................................ 39
4.9 Valve HP, delivery side ............................................................................................... 40
4.10 Piston and rings LP ..................................................................................................... 41
4.11 Cylinder ...................................................................................................................... 42
4.12 Piston, rings HP and gudgeon bearing ........................................................................ 43
4.13 Bearing fan side.......................................................................................................... 44
4.14 Bearing crank ............................................................................................................. 45
4.15 Electric motor and vibration isolators ........................................................................... 46
4.16 Coupling and sealing flange ........................................................................................ 47
4.17 Crank disk and bearing motor side .............................................................................. 48
4.18 Cyclone separator and non return valve ...................................................................... 49
4.19 Drain/unload valve HP ................................................................................................ 51
4.20 Electrical components ................................................................................................. 52
5 X-range data ......................................................................................... 54

5.1 Torque tables.............................................................................................................. 54

1 Introduction
1.1 Purpose
Sperre has produced this manual to provide information for all users of the compressor
equipment. This includes information about the compressor‟s construction and Note
operation, as well as basic information regarding inspection and maintenance.
Please note that all pictures and
It is important that operators familiarize themselves with the contents of this instruction drawings in this manual are for
manual, to ensure that use and maintenance work are carried out in the correct and illustration only.
safe manner from the outset.
The maintenance intervals and individual technical data are average values based on
experience, and may vary depending on the compressor‟s operational parameters.
The supplier accepts no responsibility for damage resulting from careless operation or
inadequate maintenance. Keep the compressor in good mechanical condition, and
remember that preventive maintenance of the equipment reduces the danger of damage
and unnecessary operational interruptions.
Sperre reserves the right to modify details without prior warning.
1.2 Annotations
All safety directions must be respected in order to avoid damage to personnel, the environment and equipment. In this manual the
annotations are used, as illustrated below:
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal or
Warning severe personnel injuries or substantial product or property damage, if the required
precautions are not taken.
Draws attention to specific information of technical significance that might not be

Note obvious, or highlights important remarks in the procedures to follow.
1.3 Abbreviations
Abbreviation Description
Barg Unit of pressure (Barg = Bar gauge)
CFD Computerized Fluid Dynamics
CR Class Recommendation
CW Cooling Water
dBA Decibel
DOL Direct On Load
HP High Pressure
LP Low Pressure
IMO International Maritime Organization
ISC Internal System Control
MR Makers Recommendation
PMS Planned Maintenance System
RPM Revolutions Per Minute
XA X-range compressor Air-cooled
XW X-range compressor Water-cooled

1.4 Tags on the compressor
Danger Danger Caution

The compressor is remotely controlled Hazardous voltage Burn hazard
May start without warning Risk of electric shock Risk of hot surface
Before using or servicing the compressor The cover must always be on when To connect the signal cable, carefully
Read and understand the user manual running turn the plug to find the right insert point,
Without the cover the compressor will be then push carefully until a click appear
damaged after running even for a short To disconnect, pull the ring on the plug
period
The oil has been drained from the Compressor oil type. Level sight glass
compressor For oil reference, visit www.sperre.com Correct oil level should be in centre of
Do not start the compressor before the level sight glass
correct oil quantity has been added
Drain oil Delivery air outlet Unloading and drain high pressure
The lifting eye bolt is certified for lifting Rotation direction is counter clock wise,
the single compressor with el-motor only when looking at compressor front.
Compressor rating plate
1.5 Warranty
The X-range compressor has a limited warranty that is valid only with use of original spare parts purchased through our Sperre office in
Norway, Singapore, the Netherlands or China.
Please note that the warranty will be void if the equipment is misused or not handled in accordance with prescribed operating and
service standards.

2 Personal safety
Please make yourself familiar with the content in this user manual before operating the compressor.
It is the responsibility of the user to ensure that appropriate controls and precautions are identified and applied in relation to the
work envisaged by this document in accordance with relevant statutory, legal and industry requirements to protect the health and
safety of the persons undertaking the work.
All operation and service of the compressor is to be carried out by personnel who are familiar with the contents of this manual.
The compressor is a high pressure machine that must only be used to compress air. Unauthorized remodelling or modification of
the compressor may result in a safety hazard, and is not permitted.
The compressor must never be operated without cover: the high temperature machine with rotating parts pose a great risk for the
crew.
Before any form of work is commenced on the compressor, the electrical power must be turned off at the starter panel and at the
main switchboard, and the switch on the main switchboard must be marked with a notice indicating that repair work is in progress.
The manual valve between the compressor and the air receiver must be closed, and the pressure must be released in all
pressurized parts of the compressor.
The safety valves for LP air, HP air, cooling water and any other safety equipments must be inspected regularly. Damaged
components should be replaced with new, original parts. Please note that all safety valves are security sealed and any adjustment
of these valves is not recommended. The compressor must never be used if the safety equipment is defective.

3 Service and ordering
3.1 Service schedule
The following schedule is a guideline for normal service procedures. However, the
compressors operating conditions vary widely from installation to installation, based on Warning
climatic differences. It is very important to adapt the maintenance schedule to the
running conditions of the individual compressor.
Before any work is performed the
The X-control will automatically inform the operator when to run scheduled services electrical power must be turned off.
according to the manufacturers recommended service cycle and intervals. Please refer to chapter 2 for safety
There are three main service routine types; each requires the use of the appropriate instructions.
service kit.
Indicated service interval in hours or years depending on which comes first.
Note
A Sperre takes no responsibility for
damage caused by use of non-original
parts.
B C B D B C B E
Note
Service procedure A is change of running in oil, and should always be performed 250
*Use access code 0100 to enter the
hours after first time start up.
menus. When in menus access menu
Service procedures should be performed at 1500-hour intervals. Service procedures B, “P04 SERVICE RESET” and then
C, D and E are to be performed in the order illustrated above. “RESET” to enter reset code.
After service E at 12000 hours proceed to service B and repeat the service procedures Use the following six digit reset codes
as shown. for service completion:
A = 000000
When a service is complete the service technician is required to enter the „six digit ID
code* for that service type. The controller will automatically increment to the next service B = Sperre kit order number or 000000
type using the recommended service interval for the type. C = Sperre kit order number or 000000
Please make sure that a complete gasket kit always is available. D = Sperre kit order number or 000000
E = Sperre kit order number or 000000
Service Months Cycle:

When a service cycle counter begins (service cycle counter is 10), the date is noted and
a future date calculated and recorded in memory for each „date critical‟ service type (B,
C, D, C and E). If the actual calendar date (in accordance to the controller real time
clock) indicates that a service is due within 2 months, but the service cycle counter has
not reached the „service warning‟ hours yet the service cycle counter is automatically
increased to a count of SW hours prior to the service. This action will generate a „service
warning‟ for the service type. If the actual calendar date indicates that a service is now
due, but the service cycle counter has not reached the „service due alarm‟ hours yet the
service cycle counter is automatically increased to the service due hours. This action will
generate a „service due alarm‟ for the service type.
Service Hours Until Next service Due (User Menu P00 – Item HS):
The „Hours Until Next Service Due‟ User menu indication will be calculated from:
„next service hours due value‟ minus „current service cycle hours count‟
For example: if the service cycle hours counter is at 7250 hours the next service due will
be at 8000 hours; the „Service Hours Until Next Service Due‟ will show (8000 – 7250) =
750 Hours.

3.2 Service Warnings:
When a service warning appears on the display (SW)
A service warning will occur 200 running hours or 3 months prior to a service, providing a pre-warning enabling service arrangements,
and/or service kit parts, to be organized prior to the service becoming due. The yellow service LED- indicator will appear as slow-flash.
The Service Warning indication will alternate with the normal running display. The „Service Warning‟ code is also displayed in the „User
menu‟ active error list.
Service warning (pre-alarm):

When a service warning occurs the controller will display the “Service Warning”
indicating the service type [3], code [2] and contact details [1] for service arrangements.
5 secs WARNING 2
BAR
SW4824
SPERRE
Tel: +47 70 16 11 00
1 INDUSTRI@SPERRE.COM
o WWW.SPERRE .COM
C
DEL TEMPERATURE 3 SERVICE 'B'
5 secs
Reset the service warning by pressing the reset button on the controller. The Note
service warnings will not occur again. This facility is intended to provide pre-warning
enabling service arrangements.
The text line on the display will
Order the Sperre service kit. Please refer to “Service procedures overview” in the indicate the type of service.
compressor service manual for the service kit ordering number. Service A will only appear once,
A Sperre service kit contains all necessary spare parts with the relevant step by step throughout the life time of the
service procedures. compressor, and will only be indicated
with a service alarm.
When a „service warning‟ is generated no further service warnings for the service type will be generated. A service warning will only be
generated once prior to a service becoming due and a service alarm being generated. If a „Service Warning‟ has not been manually
reset and is still active when a „Service Alarm‟ is generated, the „Service Warning‟ is automatically reset.
Service ‘A’:
Service type „A‟ does not have a „Warning‟ indication. The controller will show an „Alarm‟ when the service cycle counter reaches 250
hours.
Service type „A‟ is a unique service type. When a service type „A‟ has been carried out once no future service type „A‟ alarms will be
generated. When the service cycle counter automatically resets to 0(zero), when it reaches 96000 hours, a service type „A‟ will not be
generated again; the next service due will be a service type „B‟. A Service type „A‟ normally occurs only once in the operational life of
the compressor.
Service Alarm Overlap:
If a „Service Alarm‟ indication is still active when a „Service Alarm‟ for the next service type due is generated, the service alarm will be
automatically reset and no data will be recorded for the service type.

Service warning codes
Service warning code Text displayed Failure Corrective action

SW4824 “SERVICE B” Pre-alarm, service B due soon Press the “reset” button. Order service kit.
Please refer to “Service procedure overview” in
the Service manual
SW4834 “SERVICE C” Pre-alarm, service C due soon Press the “reset” button. Order service kit.
the Service manual
SW4844 “SERVICE D” Pre-alarm, service D due soon Press the “reset” button. Order service kit.
the Service manual
SW4854 “SERVICE E” Pre-alarm, service E due soon Press the “reset” button. Order service kit.
the Service manual
3.3 Service Alarms:

When a service alarm appears on the display (SA)
A „Service Alarm‟ indication will occur when the „service interval‟ run hours counter reaches 0(zero) hours, or the service interval „time‟
expires (whichever occurs sooner). The yellow service LED-indicator will appear as fast-flash. The Service Alarm indication will
alternate with the normal running display. The „Service Alarm‟ code is also displayed in the „User menu‟ active error list.
Service alarm (service due now):

When a service alarm occurs the controller will display the “Service Alarm” indicating the
service type [3], code [2] and contact details [1] for service arrangements.
5 secs ALARM 2
BAR
! SA5824
SPERRE
Tel: +47 70 16 11 00
1 INDUSTRI@SPERRE .COM
o
C WWW.SPERRE .COM
DEL TEMPERATURE 3 SERVICE 'B'
5 secs
The service type displayed must be performed with the relevant Sperre service kit.
The Service alarm indication can be reset before the service is complete and the “service
interval reset procedure” has been carried out. In this case, the “Service indicator”
(yellow LED) will change to be illuminated continuously. 24 hours after the alarm has
been reset, the indicator will start flashing again and the screen will toggle again. This
goes on until the proper reset procedure has been carried out.

Service alarm codes
Service alarm code Text displayed Failure Corrective action

SA5814 “SERVICE A” Service hours countdown time expired Service A must be performed, refer to
“Service procedure overview” in the
Service manual
SA5824 “SERVICE B” Service hours countdown time expired Service B must be performed, refer to
Service manual
SA5834 “SERVICE C” Service hours countdown time expired Service C must be performed, refer to
Service manual
SA5844 “SERVICE D” Service hours countdown time expired Service D must be performed, refer to
Service manual
SA5854 “SERVICE E” Service hours countdown time expired Service E must be performed, refer to
Service manual
Service Alarm Reset
item# description units step min max default display
SR Service Reset --- --- {-----} RESET {-----} RESET
ST Edit previous service ID --- --- --- --- --- B
Service alarm reset procedure: Note

Using the menu navigation routine, select the „Service Reset‟ item (SR) of menu P04.
A Service level „Access Code‟ is
If the item shows {-----}, there is no service alarm reset procedure necessary or even required to access this menu. The
available. When a valid service alarm is active, the item will show “RESET” and allow to service alarm reset item will be locked
push the enter button. until a „Service Alarm‟ is active.
The controller will than start the reset procedure, which applies to all service types:
The display will request the „six digit ID code‟ for the service type:
Service Type
Indication of current and next service
Six digit ID code entry
The first code character will flash; press UP or DOWN to adjust to the required number then press ENTER. The second code
character will flash; press UP or DOWN to adjust to the required number then press ENTER. Repeat this procedure for all six code
characters.
When the service item ID code has been entered, the service alarm is reset and the
controller will automatically increment to the next service type in the service cycle and Note
initiate the appropriate service interval.
ID code is identical to order number on
service order.
If a „service ID code‟ is unavailable,
press ENTER six times repeatedly to
enter six zero‟s as the ID code.

3.4 Service procedures overview
Service procedure A B C B D B C B E Chap.
Running hours 250 1500 3000 4500 6000 7500 9000 10500 12000
Running years - 1,5 3 4,5 6 7,5 9 10 12
Oil change X X X X X X X X X 4.2
Air filter replacement X X X X X X X X 4.3

Valve LP replacement X X X X 4.7
Valve HP SV/DV replacement X X X X 4.8
Gudgeon bearing + pin 4.11
X X
replacement 4.12
Non return valve replacement X X 4.18
Drain unload/valve HP + coil
X X 4.19
replacement
Bearing crank replacement X X 4.14
Bearing fan side replacement X X 4.13
Piston ring LP replacement X 4.11
Piston ring HP replacement X 4.12
Bearing motor side
X 4.17
replacement
Valve LP check* X* X* X* X* 4.7

Valve HP SV/DV check* X* X* X* X* 4.8
Gudgeon bearing + pin 4.11
X** X**
check** 4.12
Bearing crank check** X** X** 4.14
Air cooler LP check*** X*** X*** X*** X*** 4.5
Flexible tubes check**** X**** X****
Safety valve LP check***** X***** 4.4
Safety valve HP check***** X***** X***** 4.4
* Please check the valve LP and HP condition, and if there is carbon deposit, the valve(s) must be replaced. Sperre
recommend for this compressor valve check every 1.500 hours.
** Please check the gudgeon bearing and the crank bearing condition, and if worn or damaged complete bearing(s)
must be replaced. Sperre recommend for this compressor bearing check every 3.000 hours.
***Please check the cooler condition, and if the cooler have particles in the airflow area inlet, the cooler must be
replaced. Sperre recommends for this compressor cooler check every 3.000 hours.
**** Please check all flexible tubes for wear and aging every 6.000 hours. Refer to standard BS 5244 for details
regarding testing and checking.
***** Please check safety valves and change if necessary (see chapter 4.4).
Compressor serial number must be provided when ordering!
PMS input
The technical data above is the basis for the onboard planned maintenance system. Contact Sperre for the digital version for direct
implementation.

3.5 Kit overview
The letters on the illustration below refer to service and maintenance kits for the compressor, listed in the table on next page, and
described in chapter 3.4.

Ordering number Chapter
Letter Kit Name
Service Kit Maintenance kit Recommended kit Service Procedures
- Service Kit B XA030-045 50034 3.4

- Service Kit C XA030 50063 3.4
- Service Kit D XA030 50103 3.4
- Service Kit E XA030 50133 3.4
MR Kit XA030 XA030-MR 3.4
CR Kit XA030 XA030-CR 3.4
MK Compressor gasket XA030 50903 3.4
a MK Cylinder head LP XA030-045 50334 3.4 4.7
b MK Cylinder head HP SV XA030-045 50364 3.4 4.8
c MK Cylinder head HP DV XA030-045 50404 3.4 4.9
d MK Valve LP XA030-045 50434 3.4 4.7
e MK Valve HP SV XA030 50463 3.4 4.8
f MK Valve HP DV XA030 50503 3.4 4.9
g MK Cylinder XA030 50533 3.4 4.11
h MK Piston rings LP XA030 50633 3.4 4.10
i MK Piston rings HP XA030 50663 3.4 4.12
j MK Piston LP XA030 50703 3.4 4.10
k MK Piston HP XA030 50733 3.4 4.12
l MK Connecting rod XA030 50763 3.4 4.14
m MK Crank Shaft XA030 50803 3.4 4.17
Sperre Tool Box XA030-45 50964 3.4
EK DOL XA030 59211 3.4
EK SOFT XA030 59316 3.4
EK CENTRAL XA008-XW500 66720 3.4
EK CONTROL XA0008-045 59830 3.4
* Safety valve HP / LP 4.4

* Air cooler LP 4.5
* Air cooler HP 4.6
* Compressor serial number must be provided when ordering!

3.6 Recommended kits and special tools
Service-kit overview
Kit name Ordering number Description

Service kit A XA030 - No parts required

Service kit B XA030-045 50034 Required parts for service B included
parts for check
Letter Component Qty. Letter Component Qty.
a Air Filter 1 c Gaskets valve HP DV 1+1

b Gaskets valve LP 1+1+1 d Gaskets valve HP SV 1+1

Service kit C XA030 50063 Required parts for service C included
parts for check
Letter Component Qty. Letter Component Qty. Letter Component Qty.
a Air Filter 1 d Valve HP DV 1 g Gaskets valve HP 1+1

SV
b Valve LP 1 e Gaskets valve LP 1+1+1 h Gaskets valve HP 1+1
DV
c Valve HP SV 1 f Fasteners valve LP 1+1

Service kit D XA030 50103 Required parts for service D included
parts for check

a Air Filter 1 g Drain/unload valve 1 m Gaskets valve HP SV 1+1

HP kit
b Valve LP 1 h Bearing Crank 1 n Gaskets valve HP DV 1+1
c Valve HP SV 1 i Bearing fan side 1+1+1 o Gaskets cylinder 1+1
d Valve HP DV 1 j Gaskets Valve LP 1+1+1 p Gaskets bearing fan 1+1
side
e Bearing gudgeon 1 k Fasteners valve LP 1+1
f Valve HP non return 1 l O-ring piston 1

Service kit E XA030 50133 Required parts for service E included
parts for check

a Air filter 1 h Bearing crank 1 o Fasteners valve LP 1+1

b Valve LP 1 i Bearing fan side 1+1+1 p Gaskets valve HP SV 1+1
c Valve HP SV 1 j Piston rings LP 3 q Gaskets valve HP DV 1+1
d Valve HP DV 1 k Piston rings HP 4 r Gaskets cylinder 1+1
e Bearing gudgeon 1 l Bearing motor side 1+1+1 s Gaskets bearing fan 1+1
side
f Valve HP non return 1 m Gaskets valve LP 1+1+1 t Gaskets bearing 1+1
motor side
g Drain/unload valve 1 n O-ring piston 1

HP kit

MR-kit overview

MR Kit XA030 XA030-MR Air suction filter
CR-kit overview

CR Kit XA030 XA0030-CR Class recommended spare parts
Letter Component Qty.
a Sealing ring LP 1
b Gasket valve LP 1
c Valve LP 1
d Fasteners valve LP 1+1
e O-ring valve LP 1
f Piston rings LP 3
g O-ring Piston 1
h+i Gasket valve HP 1+1
DV
j Valve HP DV 1
k O-rings cylinder 1+1
l Piston rings HP 4
m+n Gasket valve HP 1+1
SV
o Valve HP SV 1

Maintenance kit overview

MK Compressor gasket XA030 50903 All gaskets

MK Cylinder head LP XA030-045 50334 Cylinder head LP with gaskets
a Cylinder head LP 1
b Gaskets valve LP 1+1+1
c Fasteners valve LP 1+1
d Fittings cylinder head 1+1

LP
e Fasteners cylinder 6+6
head LP

MK Cylinder head HP SV XA030-045 50364 Cylinder head HP SV with gaskets
a Cylinder head HP 1
SV
b Gaskets valve HP SV 1+1
c Gasket transmitter LP 1
d Fittings cylinder head 1+1

HP SV
head HP SV

MK Cylinder head HP DV XA030-045 50404 Cylinder head HP DV with gaskets
a Cylinder head HP 1
DV
b Gaskets valve HP DV 1+1
c Gasket safety valve 1

HP
d Fittings cylinder head 1
HP DV
head HP DV

MK Valve LP XA030-045 50434 Valve LP with gaskets
a Valve LP 1
b Gaskets valve LP 1+1+1
c Fasteners valve LP 1+1

MK Valve HP SV XA030 50463 Valve HP SV with gaskets
a Valve HP SV 1
b Gaskets valve HP SV 1+1

MK Valve HP DV XA030 50503 Valve HP DV with gaskets
a Valve HP DV 1
b Gaskets valve HP DV 1+1

MK Cylinder XA030 50533 Cylinder with gaskets
a Cylinder 1
b Gaskets cylinder 1+1
c Gaskets valve LP 1+1
d O-ring piston 1
e+g Gaskets valve HP SV 1+1
f+g Gaskets valve HP DV 1+1
h Fasteners cylinder 4+4

MK Piston ring LP XA030 50633 Piston ring LP with gaskets
a Piston rings LP 3
b Gaskets valve LP 1+1
c O-ring piston 1

MK Piston ring HP XA030 50663 Piston ring HP with gaskets
a Piston rings HP 4
b Gaskets valve LP 1+1
c O-ring piston 1
d Gaskets cylinder 1+1

MK Piston LP XA030 50703 Piston LP with gaskets
a Piston LP 1
b Piston rings LP 3
c Gaskets valve LP 1+1
d O-ring piston 1
e Fasteners piston LP 1+1+1

MK Piston HP XA030 50733 Piston HP with gaskets
a Piston HP 1
b Piston rings HP 4
c Bearing gudgeon 1
d Gudgeon pin 1
e Retaining rings HP 2
f Gaskets cylinder 1+1
g Gaskets valve LP 1+1

MK Connecting rod XA030 50763 Connecting rod with bearings
a Connecting rod 1
b Bearing crank 1
c Bearing gudgeon 1+1+2
d Gaskets valve LP 1+1
e O-ring piston 1
f Gaskets cylinder 1+1
g Gaskets bearing fan 1+1

side
h Splash pin with 1+2
screws

MK Crankshaft XA030 50803 Crank disk with gaskets
a Crankshaft 1
b Bearing crank 1
c Bearing fan side 1+1+1
d Bearing motor side 1+1+1
e Gaskets valve LP 1+1
f O-ring piston 1
g Gaskets cylinder 1+1
h Gaskets bearing fan 1+1

side
i Gaskets bearing 1+1
motor side

Sperre toolbox XA030-045 50964
a Dismantling screw 1
coupling

Electrical kit overview

EK DOL XA030 59211
a Thermal overload 1
relay
b Extended rotary 1+1
handle
c Main switch unit 1
d Main contactor 1

EK SOFT XA030 59316
a MCB 1
b Extended rotary 1+1
handle
c Main switch unit 1
d Soft Starter 1

EK CENTRAL XA008-XW500 66720
a Main contactor 1

EK CONTROL XA008-045 59830
a Plug-in connection 1
b Plug-in cable 1
c Transmitter LP 1
pressure
d Transmitter HP 1
pressure
e Transmitter HP 1
temperature
f Transmitter oil level 1
g Drain unload/valve 1
HP
h Pressure transmitter 1
reciever

3.7 Ordering parts and kits
Information regarding the compressor type and serial number is stamped on the compressor rating plate [a], which is fixed on the
outside of the back cover, as illustrated below.
Letter Description Letter Description
b Type f Compressor capacity

c Serial Number g Speed
d Production year h Compressor power
requirement
e Pressure
The following information must be given when ordering spares:

1. Compressor serial number [c].
2. Quantity, part number and description of the spare parts.
Your X-range compressor is installed with customer-specific components / parts, some parts therefore require specific ordering
numbers. Please contact Sperre for your customer-specific ordering number when needed.
Contact information
Norway The Netherlands Note

Sperre Industri AS Sperre Rotterdam BV
The listed addresses are the only
Ellingsøy, Norway Ridderkerk, The Netherlands places you can purchase original parts
Tel: + 47 70 16 11 00 Tel: + 31 180 463 299 for your X-range compressor.
Fax: + 47 70 16 11 10 Fax: + 31 180 463 264 Sperre takes no responsibility for
industri@sperre.com rotterdam@sperre.com damage caused by use of non-original
parts.
Singapore China Agent Network

Sperre Asia PTE Ltd Sperre China www.sperre.com/agents
Singapore Shanghai, P. R. China
Tel: + 65 6763 6300 Tel: + 86 216 5070436
Fax: + 65 6763 1811 Fax: + 86 216 5070402
asia@sperre.com china@sperre.com

4 Service procedures
4.1 Cover
Dismantle and assemble
Dismantle Note
1. Unscrew the three screws in front [a].
The back cover and base should
2. Remove the front cover [b]. normally not be removed.
3. Unscrew the lifting eye bolt [c].
4. Remove top cover [d] by pulling
forward and lifting up. Note
Assemble
The lifting eye bolt is certified and
1. Assemble top cover [d] by pushing the approved for lifting a single
cover carefully in to place. compressor.
2. Assemble the front cover [b].
3. Mount the three screws [a].
4. Mount the lifting eye bolt [c].
Spare parts
Ordering number
a Cover Front with grid 470x3
b Cover Top 474x3
c Cover Back 471x3
d Cover Seal 473x3
e Cover Base 472x3
f Fasteners (cover front/ 56008
back)
g Fasteners (cover seal) 56111
h Fasteners (cover base) 56134
i Lifting eye bolt 43107
Compressor serial number must be
provided when ordering!

4.2 Lubricating oil
Service
Drain, inspect and clean: Note

1. Place a tray below the draining plug.
Always use fully synthetic, ISO 100
2. Unscrew the four screws and remove grade piston compressor oil.
the crankcase cover [c]. Visit www.sperre.com for
3. Remove the draining plug [a] and drain recommended lubricating oil brands.
the compressor empty.
4. Mount the draining plug [a].
Note
5. Assemble the crankcase cover with
the four screws. Oil level switch LS15 LED indicator [e]
Refilling oil: Green light: Oil and temperature level
normal.
1. Fill necessary amount of oil through
the oil filling hole [b]. Blinking yellow light fast: Temperature
high
2. Check oil level on X-control and level Blinking yellow light slow: Oil level too
sight glass [d]. low.
3. Mount the filling plug [b] No light: Short circuit or malfunction
Filling of new oil:
1. Fill approx. 7 L of new oil through the
oil filling hole [b] or through the crank
case cover opening [c].
2. Check oil level on X-control and level
sight glass [d].
3. Mount the filling plug [b] or the crank
case cover [c].
Spare parts
Ordering number
a Transmitter oil level 56521
b Level sight glass 32601
c Tube oil drain 51204
d Gasket crankcase cover 35515
e Crankcase cover 32010
f Fasteners 56534
g Plug 57771

4.3 Air filter
Service
Inspect and replace

1. Unscrew the two screws [a].
2. Replace the air filter unit [b].
3. Mount the two screws [a].
Spare parts
Ordering number
a Air filter 36163
b Fasteners (air filter) 57864
c Gasket filter holder 35598
d Filter holder 24333
e Fasteners (filter holder) 57834

4.4 Safety valves LP and HP
Service
Inspect and replace Note

1. Replace the safety valves [a] and [b].
Perform a visual inspection of safety
valves and clean for dirt. If clogged
inlet change valve(s).
Perform a function test on safety valve

HP. The valve should blow at
maximum working pressure + 10%.
Change if not functioning correctly.
Spare parts
Ordering number
a Safety valve HP 51xxx
b Safety valve LP 51xxx

4.5 Air cooler LP
Dismantle
1. Unscrew the hoses [a] and [b].
2. Unscrew the cylinder adapter [c].
3. Unscrew the cooler fixing screw [d] and
remove the cooler LP.
Assemble
1. Mount the cooler LP with the cooler
fixing screws [d].
2. Mount the cylinder adapter [c].
3. Mount the hoses [a] and [b].
Service
Inspect and replace

1. Unscrew the adapters [a].
2. Replace the cooler LP [b].
3. Mount the adapters [a].
Spare parts
Ordering number
a Cooler LP 37201
b Flexible tube LP 45104
(transmitter)
c Flexible tube LP (air) 45190
d Cooler bracket LP 32301
e Fasteners (cooler LP) 56334
f Fasteners (cooler bracket 56271
LP)
g Adapter (transmitter) 56934
h Adapter (cooler LP inlet) 56708

4.6 Air cooler HP
Service

1. Unscrew the adapters [a].
Always change the clamps and fittings
2. Unscrew the two screws holding the when replacing the cooler tube.
clamp [b].
3. Replace the cooler tube HP [c].
4. Mount the new clamp with two screws
[b].
5. Mount the adapters [a].
Spare parts
Ordering number
a Cooler tube HP 51904
b Clamp with fasteners 51934

4.7 Valve LP
Dismantle Note
1. Unscrew the cooler adapter [a].
Do not loosen the nut in the middle.
2. Unscrew the six nuts [b], do not remove
the centre nut.
3. Remove the cylinder head [c].
Assemble
Warning
1. Assemble the cylinder head [c].
2. Replace gasket (see service step1) Always mount the six M10 nuts first
3. Mount the six nuts [b]. with torque 50 Nm and then mount the
one nut M10 with torque 50 Nm
4. Mount the centre nut [c] holding the
valve.
5. Mount the adapter [a].
Service

1. Replace the O-ring [a] and the gasket
The flat gaskets, seal ring and O-ring
[b].
must always be replaced. Clean the
2. Unscrew the centre nut [c]. adjacent surfaces before the new flat
gaskets are fitted.
3. Clean the adjacent surfaces and
replace the flat gasket [d].
4. Inspect the valve [e] and replace if
necessary. Replace the stud bolt [f].
Apply Sperre thread-locking fluid on
threads.
5. Assemble.
Spare parts
Ordering number
a Valve LP with gaskets 52003
b Gaskets valve LP 52033
c Fasteners (valve LP) 52104
d Cylinder head LP 20407
e Fasteners (cylinder head 52064
LP)
f Swivel male 57106

4.8 Valve HP, suction side
Dismantle
1. Unscrew the hose [a].
2. Unscrew the transmitter plug [b].
3. Unscrew the four nuts [c].
4. Remove the cylinder head HP [d].
Assemble
1. Assemble the cylinder head HP [d].
2. Mount the four nuts [c].
3. Mount the transmitter plug [b].
4. Mount the hose [a].
Service

1. Inspect the valve [a], and replace if
The flat gaskets should always be
necessary.
replaced. Clean the adjacent surfaces
2. Clean the adjacent surfaces [b]. before the new gaskets are fitted.
3. Place the new gaskets [c], as
illustrated.
4. Assemble.
Spare parts
Ordering number
a Valve HP SV with 52204
gaskets
b Gaskets valve HP SV 52234
c Transmitter LP pressure 56421
d Cylinder head HP 20507
e Fasteners 52264
f Adapter (transmitter) 56934
g Adapter (inlet) 56904
h Plug 44304
i Adjust.elbow 44012

4.9 Valve HP, delivery side
Dismantle
1. Unscrew the cooler tube [a].
2. Unscrew the four nuts [b].
3. Remove the cylinder head HP [c].
Assemble
1. Mount the cylinder head HP [c].
2. Mount the four nuts [b].
3. Mount the cooler tube [a].
Service

1. Inspect the valve [a] and change if
The flat gaskets should always be
necessary.
replaced. Clean the adjacent surfaces
2. Clean adjacent surfaces [b]. before the new gaskets are fitted.
3. Place the new gaskets [c], as
illustrated.
4. Assemble.
Spare parts
Ordering number
a Valve HP DV with gaskets 52403
b Gaskets valve HP DV 52434
c Cylinder head HP 20507
d Fasteners 52264
e Adjust.elbow 44012
f Plug 52534

4.10 Piston and rings LP
Dismantle
Warning
1. Dismount screw, tension washer and
washer [a].
Make sure the washers are assembled
2. Use a M14 eyebolt in the piston LP to correctly and in the right order and that
pull the piston LP up. the tension washer is turned the
3. Remove the LP piston [b]. correct way, as illustrated.
Make sure that a new O-ring is fitted
Assemble between the LP and HP piston.
1. Fit the piston LP [b] with a new O-ring Be careful not to damage the piston.
(see service step 1).
2. Insert the new tension washer [e] and
washer [f]. Fasten the new screw [c]. Note
Before starting this procedure perform
the dismantling procedure described in
4.7 “Valve LP”.
Service

1. Replace the O-ring [a] between the
Piston ring wear limits:
piston LP and piston HP.
Piston ring diameter 105
2. Replace the three piston rings [b]. Maximum allowed end gap: contact
Sperre
3. Inspect for wear inside the cylinder and
outside the piston [c]. Piston groove wear limits:
Maximum allowed vertical clearance:
contact Sperre
Spare parts
Ordering number
a Piston LP with O-ring 52703
b Piston rings LP 52733
c O-ring 35125
d Fasteners 52764

4.11 Cylinder
Dismantle
Warning
1. Unscrew the hose and the transmitter
plug [a].
Be careful not to damage the piston.
2. Unscrew the cooler tube [b].
3. Unscrew the four nuts [c].
4. Lift up the cylinder [d].
Note
Assemble
1. Mount the cylinder [d]. Before starting this procedure, perform
the dismantling procedure described in
2. Mount the four nuts [c]. 4.10 “Piston and rings LP”.
3. Mount the cooler tube [b].
4. Mount the hose and transmitter plug
[a].
Service

1. Inspect for wear inside the cylinder [a]
The cylinder should be honed (45
replace if necessary.
degrees stripes) each time piston rings
2. Replace the two O-rings [b]. are replaced. If there are critical
vertical stripes inside the cylinder after
honing, the cylinder must be replaced.
Spare parts
Ordering number
a Gaskets, cylinder with 52663
gaskets valve LP and
valve HP
b Cylinder 20307
c Front cover rod 32151
d Lifting rod 32141
e Fasteners 57368

4.12 Piston, rings HP and gudgeon bearing
Dismantle Note
1. Remove the two retaining rings [a].
Before starting this procedure, perform
2. Remove the gudgeon pin* [b]. the dismantling procedure described in
4.11 “Cylinder”.
3. Remove the piston [c].
Assemble
1. Assemble the piston [c]. Note
2. Mount the gudgeon pin* [b]. * Heat the piston with a heat gun when
3. Mount the two retaining rings [a]. dismantling and assembling the
gudgeon pin.
Service
Gudgeon bearing: Note

1. Replace the gudgeon bearing [a].
Piston ring wear limits:
2. Inspect the crank bearing by moving Piston ring diameter 85
the connecting rod [b] up and down. Maximum allowed end gap: contact
To replace the crank bearing refer to Sperre
chapter 4.14 Piston groove wear limits:
Piston and piston rings: Maximum allowed vertical clearance:
contact Sperre
1. Inspect the four piston rings [c],
2. Inspect for wear on the outside of the
piston [d] replace if necessary.
Spare parts
Ordering number
a Piston HP with retaining 52903
rings
b Piston rings HP 52933
c Bearing needle HP 52963

4.13 Bearing fan side
Dismantle Note
1. Unscrew the fan centre screw [a].
* After dismantling do not forget to
2. Use a M16 screw to loosen the fan remove the M16 screw and two M10
from the shaft and remove fan [b]. screws.
3. Unscrew the six nuts [c].
4. Use two M10 screws [d] to loosen the
front plate from the crankcase*.
5. Remove the front plate [e].
Assemble
1. Inspect the gasket (see service step 1)
and replace if necessary.
2. Remove the two M10 screws.
3. Mount the front plate with six nuts [c].
4. Remove the M16 bolt and mount fan
[b].
5. Mount the fan centre screw [a], use
hand to prevent fan from rotating.
Service

1. Remove the gasket [a], clean adjacent
* Heat the inner bearing ring with a
surfaces and mount the new gasket.
heat gun when dismantling and
2. Inspect the sealing ring [b], and assembling on the shaft.
3. Remove the retaining rings [c] and the
bearing [d]*.
4. Mount the new bearing.
5. Mount the new retaining rings.
Spare parts
Ordering number
a Bearing fan side with 53004
retaining rings
b Gaskets bearing fan 53034
side
c Front plate 20123
d Fasteners (front plate) 57664
e Fan with fasteners 32403
f Fasteners (fan) 57534

4.14 Bearing crank
Dismantle Note
1. Unscrew the two screws [a].
2. Remove the counter weight [b]. the dismantling procedure described in
4.13 “Bearing fan side”.
3. Carefully remove the connecting rod
[c]*.
Assemble
Note
1. Carefully mount the connecting rod [c].
* Be careful when handling the
2. Mount the counter weight [b]. connecting rod. Pull the bottom first
3. Mount the screws [a]. when removing, and insert the top first
when assembling.
Service

1. Replace bearing crank disk [a]*.
* Heat the bearing with a heat gun
2. Inspect the splash pin [b], replace if when dismantling and assembling on
necessary. the shaft.
3. To replace the gudgeon bearing refer
to chapter 4.12
Spare parts
Ordering number
a Bearing needle 33161
b Connecting rod 53134
c Counter weight 20223
d Fasteners 53164

4.15 Electric motor and vibration isolators
Dismantle Note
1. Unscrew the air outlet hose [a], drain
To loosen the plug-in connection pull
hose [b] and plug-in cable [c].
out the plug-in cable and detach the
2. Unscrew the 3 screws [d] and remove plug-in connection cable by loosening
the back cover. the inside nut.
3. Unscrew the coupling screw [e].
4. Unscrew the 4 nuts [f] to loosen the
motor from the motor flange.
5. Unscrew the nut holding the motor
support [g] to isolator [h].
6. Remove the motor.
Assemble
1. Mount the motor with motor support [g]
to the isolator [h].
2. Mount the 4 nuts[f] to the motor flange.
3. Mount the coupling screw [e].
4. Assemble the back cover with the 3
screws.
5. Mount the air outlet hose [a], drain
hose [b], and plug-in cable [c].
Service

1. Inspect and change the front isolator
* Please refer to www.sperre.com for
[a] and back isolator [b] if necessary.
instruction regarding the Electric motor
2. Electric motor service*. service.
Spare parts
Ordering number
a X-isolator (compressor) 461xx
b X-isolator (Electric motor) 461xx
c Support motor 208xx
d Fasteners (support motor) 53xxx
e Fasteners (EL-motor) 53xxx
f Electric motor 6xxxx
g Flange Electric motor 320xx

4.16 Coupling and sealing flange
Dismantle Note
1. Unscrew the centre screw [a].
2. Use the Sperre M16 dismantling the dismantling procedure described in
screw* to loosen the coupling from 4.15 “El. motor and vibration isolators”.
crank disk.
3. Remove the coupling [b].
4. Unscrew the three screws [c]. Note
5. Use two M10 screws** [d] to loosen * Sperre M16 dismantling screw in
the sealing flange. Sperre tool box
6. Remove the sealing flange [e]. ** After dismantling do not forget to
remove the two M10 screws
Assemble
1. Mount the sealing flange [e] with the
new gaskets (see service).
2. Mount the three screws [c].
3. Mount the coupling [b].
4. Mount the centre screw [a].
Service
Inspect and replace

1. Replace the sealing ring and gasket
[a].
2. Inspect the coupling and change if
necessary.
Spare parts
Ordering number
a Gaskets sealing flange 53704
b Sealing flange 20143
c Coupling with fasteners 53xxx
d Fasteners (coupling) 53xxx
e Fasteners (sealing 57434
flange)

4.17 Crank disk and bearing motor side
Dismantle Note
1. Remove the inner retaining ring [a].
2. Remove the bearing plate [b]. the dismantling procedure described in
4.16 “Coupling and sealing flange”.
3. Remove the crank disk [c].
4. Remove the inner bearing ring [d] from
the crank disk *.
Note
5. Remove the outer retaining ring [e]
and the outer bearing ring [f] from the * Heat the bearing with a heat gun
crankcase. when dismantling and assembling on
the shaft.
Assemble
1. Mount the outer retaining ring [e] and
push in the outer bearing ring [f] in the
crankcase.
2. Mount the inner bearing ring [d] on the
crank disk [c] and mount the crank
disk in the crankcase *.
3. Mount the bearing plate [b].
4. Mount the inner retaining ring [a].
Service
Inspect and replace

1. Replace the bearing on the motor side
[a].
Spare parts
Ordering number
a Bearing motor side with 54104
retaining rings
b Crank shaft 20203
c Crankcase 20103

4.18 Cyclone separator and non return valve
Dismantle
1. Unscrew the air outlet hose [a].
2. Unscrew the transmitter plug [b].
3. Unscrew the three screws [c].
4. Unscrew the nut [d].
5. Remove the outlet cover HP [e].
Assemble
1. Mount the outlet cover HP [e].
2. Mount the nut [d].
3. Mount the three screws [c].
4. Mount the transmitter plug [b] and the
air outlet hose [a].
Service
Inspect and replace

1. Replace the copper ring and inspect
the non return valve [a]. Change the
non return valve if necessary.
2. Inspect the cyclone tube [b] for
corrosion: change if necessary.

Spare parts
Ordering number
a Valve HP non return 54204
b Transmitter HP 56481
temperature
c Transmitter HP pressure 56451
d Cyclone tube 32123
e Outlet connector HP 20657
f Separator housing 20607
g Fasteners (outlet 57404
connector)
h Fasteners (separator 57464
housing)
i Adapter (outlet cover) 56904
j Plug (outlet cover) 44304
k Swivel male (separator 57064
housing outlet)
l Adjust.elbow 44012
m Plug (separator housing) 57771

4.19 Drain/unload valve HP
Service
Inspect and replace

1. Remove the coil plug [a].
2. Remove the coil [b].
3. Unscrew the four screws and remove
the cover [c].
4. Replace the diaphragm, spring and
the two O-rings [d].
5. Mount the cover [c] with the 4 screws.
6. Mount the coil [b].
7. Mount the coil plug [a].
Spare parts
Ordering number
a Coil 64xxx
b Rep.kit drain/unload valve 64211
c Drain/unload valve HP 57906
with gaskets
d Fittings 57166

4.20 Electrical components
Information is given for compressors with working pressure 30 barg, main voltage between 380 - 420VAC / 50Hz and 440 -
480VAC / 60Hz, control voltage 220-240 VAC and ambient temperature 40 °C. For other configurations please provide compressor
serial number when ordering!
Spare parts for starters with DOL start
Ordering number
b Plug-in cable 5M 64405
c Emergency stop 67040
d Thermal overload relay 66313
e Extended rotary handle 66170
f Main switch unit 66110
g Main contactor 66220
h X-control unit 67020
i Emergency run switch 67050
j Current transformer 67162
k Control power 67112
transformer
Spare parts for starters with soft start
Ordering number
d Soft starter 66513
e Extended rotary handle 66170
f Main switch unit 66110
g Motor circuit breaker 66418
h X-control unit 67020
i Emergency run switch 67050
j Current transformer 67162
k Control power 67112
transformer

Spare parts for starters with central start
Ordering number
d X-control unit 67020
e Emergency run switch 67050
f Control power 67110
transformer
g Aux relay 66720

5 X-range data
5.1 Torque tables
XA030
Component Chapter Quantity Thread diameter Spanner with Torque (Nm)
Enclosure Front / Back 4.1 3/3 M8x15 Unbrako 6 24

Enclosure Base / Seal 4.1 5/3 M8x15 Unbrako 6 24
Crank case cover 4.2 4 M8x20 Unbrako 6 24
Air filter 4.3 2 M6x20 Unbrako 5 10
Air filter holder 4.3 2 M8x25 Unbrako 6 24
Cooler bracket LP 4.5 2 M8x12 Unbrako 6 24
Cooler bracket LP 4.5 1 M8x25 Unbrako 6 24
Cooler tube HP 4.6 2 Ermeto 36 Tighten
Cooler tube clamp 4.6 2 M10x55 Unbrako 8 48
Cylinder head LP 4.7 6 M10 17 mm 48
Valve LP 4.7 1 M10 17 mm 48
Cylinder head HP SV / DV 4.8/4.9 4 M10 17 mm 48
Piston LP 4.10 1 M12 19 mm 24
Cylinder 4.11 4 M16 24 mm 200
Fan 4.13 1 M12x65 Unbrako 10 80
Fan centre disk 4.13 3 M6x16 Unbrako 5 10
Front Plate 4.13 6 M10 17 mm 48
Counter weight 4.14 2 M8x30 Unbrako 6 24
Coupling (side screw) 4.15/4.16 1 M12x60 Unbrako 8 80
El-motor 4.15 4 M12 19 mm 80
Sealing flange 4.16 3 M8x16 Unbrako 6 24
Coupling (centre screw) 4.16 1 M12x55 Unbrako 10 80
Outlet connector HP 4.18 3 M10x20 Unbrako 8 48

Service Manual XA030 - Version02

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3

Congratulations on your X-range compressor!

Patented X-drive Patented cooling Registered design

This excellent compressor gives you several benefits:

 Safety first – a fully enclosed structure  Easy plug-in for sensors

www.sperre.com Service Manual XA030 Version 02 3

3 Service and ordering.............................................................................. 8

4 Service procedures .............................................................................. 32

5 X-range data ......................................................................................... 54

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Draws attention to specific information of technical significance that might not be

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Danger Danger Caution

Compressor rating plate

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Service Months Cycle:

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Service warning (pre-alarm):

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Service warning code Text displayed Failure Corrective action

3.3 Service Alarms:

Service alarm (service due now):

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Service alarm code Text displayed Failure Corrective action

Service Alarm Reset

item# description units step min max default display

SR Service Reset --- --- {-----} RESET {-----} RESET

ST Edit previous service ID --- --- --- --- --- B

Service alarm reset procedure: Note

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Running years - 1,5 3 4,5 6 7,5 9 10 12

Oil change X X X X X X X X X 4.2

Air filter replacement X X X X X X X X 4.3

Valve LP check* X* X* X* X* 4.7

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- Service Kit B XA030-045 50034 3.4

* Safety valve HP / LP 4.4

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Kit name Ordering number Description

Kit name Ordering number Description

Letter Component Qty. Letter Component Qty.

a Air Filter 1 c Gaskets valve HP DV 1+1

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Letter Component Qty. Letter Component Qty. Letter Component Qty.

a Air Filter 1 d Valve HP DV 1 g Gaskets valve HP 1+1

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a Air Filter 1 g Drain/unload valve 1 m Gaskets valve HP SV 1+1

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a Air filter 1 h Bearing crank 1 o Fasteners valve LP 1+1

g Drain/unload valve 1 n O-ring piston 1

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Kit name Ordering number Description

Kit name Ordering number Description

Letter Component Qty.