Atlas Copco
Instruction Manual for Air Compressor
BV-80, BV-100, BV-150
Instruction book
Atlas Copco
BV-80, BV-100, BV-150
Instruction book
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book meets the requirements for instructions specified by the
machinery directive 98/37/EC and is valid for CE as well as non-CE labeled
machines.
2011 - 09
No. 0780 0720 00
www.atlascopco.com
Instruction book
Contents
1
Safety precautions ........................................................................................................ 4
1.1
SAFETY ICONS............................................................................................................................................................................... 4
1.2
SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................................................ 4
1.3
SAFETY PRECAUTIONS DURING OPERATION ............................................................................................................................ 6
1.4
SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ................................................................................................... 7
2
Design .......................................................................................................................... 10
2.1
FLOW DIAGRAM ........................................................................................................................................................................... 10
2.2
OVERVIEW ................................................................................................................................................................................... 13
3
Technical data ............................................................................................................. 15
4
Installation ................................................................................................................... 16
4.1
TRANSPORT ................................................................................................................................................................................. 16
4.2
STORAGE BEFORE INSTALLATION ............................................................................................................................................ 16
4.3
INSTALLATION .............................................................................................................................................................................. 17
4.4
CONNECTING THE COMPRESSOR ............................................................................................................................................ 17
4.5
FILLING IN OIL .............................................................................................................................................................................. 19
5
Operation ..................................................................................................................... 20
5.1
BEFORE INITIAL START-UP ........................................................................................................................................................ 20
5.2
INITIAL START-UP ........................................................................................................................................................................ 20
5.3
ROUTINE OPERATION ................................................................................................................................................................. 21
6
Lubricating oil.............................................................................................................. 22
2
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Instruction book
7
Maintenance................................................................................................................. 23
7.1
SAFETY......................................................................................................................................................................................... 23
7.2
ROUTINE MAINTENANCE PERIOD ............................................................................................................................................. 23
7.3
LUBRICATION OIL ........................................................................................................................................................................ 25
7.4
CHECK TIGHTENING OF BOLTS AND NUTS .............................................................................................................................. 26
7.5
CHECK OF AIR FILTER ................................................................................................................................................................ 26
7.6
CHECK OF AIR VALVES............................................................................................................................................................... 27
7.7
CHECK OF PISTION AND CYLINDERS........................................................................................................................................ 29
7.8
CHECK OF PISTON RING ............................................................................................................................................................ 31
7.9
CHECK OF CONNECTING ROD ................................................................................................................................................... 32
7.10
CHANGE OF PISTON PIN AND PISTON PIN BEARING .............................................................................................................. 33
7.11
CHECK OF THE CRANK PIN AND CRANK PIN METALS............................................................................................................. 33
7.12
CHECK OF OIL FILTER ................................................................................................................................................................ 33
7.13
CHECK OF OIL PUMP .................................................................................................................................................................. 34
7.14
CHECK OF ZINC PROTECTION ................................................................................................................................................... 35
7.15
MAINTENANCE OF LONG PERIOD STOPPING .......................................................................................................................... 35
8
Trouble shooting ......................................................................................................... 36
8.1
COMPRESSOR COULD NOT START ........................................................................................................................................... 36
8.2
COMPRESSOR WAS SWITCHED OFF ........................................................................................................................................ 36
8.3
SAFETY VALVE BLOWS OFF....................................................................................................................................................... 37
8.4
PRESSURE GAUGE INDICATES ABNORMAL PRESSURE ......................................................................................................... 37
8.5
SOLENOID VALVE IS NOT WORKED PROPERLY ...................................................................................................................... 38
8.6
LEAKAGE ...................................................................................................................................................................................... 38
8.7
ABNORMAL CONDITION .......................................................................................................... 39
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1. Safety precautions
1.1 Safety icons
Explanation
Danger for life
Warning
Important note
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated, will
be disclaimed by the manufacturer.
1.2 Safety precautions during installation
General precautions
1) The operator must employ safe working practices and observe all related local work safety
requirements and regulations.
2) If any of the following statements does not comply with local legislation, the stricter of the two
shall apply.
3) Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
4) The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to local legislation
and standards.
5) Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the voltage and depressurize the
compressor. In addition, the power isolating switch must be opened and locked.
6) Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
Precautions during installation
1) The machine must only be lifted using suitable equipment in accordance with local safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly
forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits. Wear a safety helmet when working in the area of
overhead or lifting equipment.
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2) Place the machine where the ambient air is as cool and clean as possible. If necessary, install
a suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry of
moisture at the inlet air.
3) Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the
pipes.
4) Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
5) The aspirated air must be free of flammable fumes, vapors and particles, paint solvents, that
can lead to internal fire or explosion.
6) Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7) Ensure that the discharge pipe from the compressor to the after-cooler or air net is free to
expand under heat and that it is not in contact with or close to flammable materials.
8) No external force may be exerted on the air outlet valve; the connected pipe must be free.
9) If remote control is installed, the machine must bear a clear sign stating: DANGER: This
machine is remotely controlled and may start without warning. The operator has to make sure
that the machine is stopped and that the isolating switch is open and locked before any
maintenance or repair. As a further safeguard, persons switching on remotely controlled
machines shall take adequate precautions to ensure that there is no one checking or working
on the machine. To this end, a suitable notice shall be affixed to the start equipment.
10) Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted air does not re-circulate to the compressor air inlet or cooling
air inlet.
11) The electrical connections must correspond to the local codes. The machines must be earthed
and protected against short circuits by fuses in all phases. A lockable power isolating switch
must be installed near the compressor.
12) On machines with automatic start-stop system or if the automatic restart function after voltage
failure is activated, a sign stating "This machine may start without warning" must be affixed
near the instrument panel.
13) In multiple compressor systems, manual valves must be installed to isolate each compressor.
Non-return valves (check valves) must not be relied upon for isolating pressure systems.
14) Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure-relieving device or devices as required.
15) Pipe-work or other parts with a temperature in excess of 80°C (176°F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
temperature must be clearly marked.
16) For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet
pressure.
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17) If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation
and Safety precautions during maintenance. These precautions apply to
machinery processing or consuming air or inert gas. Processing of any other
gas requires additional safety precautions typical to the application which are
not included herein. Some precautions are general and cover several machine
types and equipment; hence some statements may not apply to your machine.
1.3 Safety precautions during operation
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated, will
be disclaimed by the manufacturer.
General precautions
1) The operator must employ safe working practices and observe all related local work safety
requirements and regulations.
2) If any of the following statements does not comply with local legislation, the stricter of the two
shall apply.
3) Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
4) The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to local legislation
and standards.
5) Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the voltage and depressurize the
compressor. In addition, the power isolating switch must be opened and locked.
6) Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
Precautions during operation
1) Use only the correct type and size of hose end fittings and connections. When blowing through
a hose or air line, ensure that the open end is held securely. A free end will whip and may
cause injury. Make sure that a hose is fully depressurized before disconnecting it.
2) Persons switching on remotely controlled machines shall take adequate precautions to ensure
that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the remote start equipment.
3) Never operate the machine when there is a possibility of taking in flammable or toxic fumes,
vapors or particles.
4) Never operate the machine below or in excess of its limit ratings.
5) People staying in environments or rooms where the sound pressure level reaches or exceeds
90dB(A) shall wear ear protectors.
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6) Periodically check that:
.
.
.
.
.
.
All guards are in place and securely fastened
All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
There are no leaks, all fasteners are tight
All electrical leads are secure and in good order
Safety valves and other pressure-relief devices are not obstructed by dirt or paint
Air outlet valve and air net, pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
7) If warm cooling air from compressors is used in air heating systems, to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
8) Do not remove any of, or tamper with, the sound-damping material.
9) Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure-relieving device or devices as required.
Also consult following safety precautions: Safety precautions during installation
and Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert
gas. Processing of any other gas requires additional safety precautions typical
to the application which are not included herein.
Some precautions are general and cover several machine types and
equipment; hence some statements may not apply to your machine.
1.4 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated, will
be disclaimed by the manufacturer.
General precautions
1) The operator must employ safe working practices and observe all related local work safety
requirements and regulations.
2) If any of the following statements does not comply with local legislation, the stricter of the two
shall apply.
3) Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
4) The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to local legislation
and standards.
5) Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the voltage and depressurize the
compressor. In addition, the power isolating switch must be opened and locked.
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Instruction book
6) Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
Precautions during maintenance or repair
7) Always wear safety glasses.
8) Use only the correct tools for maintenance and repair work.
9) Use only genuine spare parts.
10) All maintenance work shall only be undertaken when the machine has cooled down.
11) A warning sign bearing a legend such as "work in progress; do not start" shall be attached to
the starting equipment.
12) Persons switching on remotely controlled machines shall take adequate precautions to ensure
that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the remote start equipment.
13) Close the compressor air outlet valve before connecting or disconnecting a pipe.
14) Before removing any pressurized component, effectively isolate the machine from all sources
of pressure and relieve the entire system of pressure.
15) Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
16) Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering
the parts and exposed openings with a clean cloth, paper or tape.
17) Never weld or perform any operation involving heat near the oil system. Oil tanks must be
completely purged, by steam-cleaning, before carrying out such operations. Never weld on, or
in any way modify, pressure vessels.
18) Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor
when air is admitted.
19) Never use a light source with open flame for inspecting the interior of a machine, pressure
vessel, etc.
20) Make sure that no tools, loose parts or rags are left in or on the machine.
21) All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
22) Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct. Check that all control and shut-down
devices are fitted and that they function correctly. If removed, check that the coupling guard of
the compressor drive shaft has been reinstalled.
23) Every time the separator element is renewed, examine the discharge pipe and the inside of the
oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
24) Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, when steam-cleaning.
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25) Make sure that all sound-damping material, on the bodywork and in the air inlet and outlet
systems of the compressor, is in good condition. If damaged, replace it by genuine material
from the manufacturer to prevent the sound pressure level from increasing.
26) Never use caustic solvents which can damage materials of the air net, polycarbonate bowls.
27) The following safety precautions are stressed when handling refrigerant:
28) Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
29) Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
30) Protect hands to avoid injury from hot machine parts, during draining of oil.
Also consult following safety precautions: Safety precautions during installation
and Safety precautions during operation.
These precautions apply to machinery processing or consuming air or inert
gas.
Processing of any other gas requires safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and
equipment; hence some statements may not apply to your machine.
0780 0720 00
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Instruction book
2.
Design
2.1 Flow diagram
Fig. 1 Piping and Instrument Diagram
I / II
23A
63Q
C1
C2
DC
DS1
DS2
FA
FO
M
MV
NV
OP
Cylinder
Temperature switch, air
Pressure S/W, L.O. low level
alarm
Cooler, 1st stage
Cooler, 2nd stage
Drain chamber
Drain separator, 1st stage
Drain separator, 2nd stage
Air filter and silencer
Oil filter
Motor
Manual valve
Non-return valve
Lubrication oil pump
P1
P2
PO
RV1
RV2
RVW
RVO
SV1
SV2
SVW
TH1
TH2
THW
Pressure gauge, 1st stage
Pressure gauge, 2nd stage
Pressure gauge, L.O.
Safety valve, 1st stage
Safety valve, 2nd stage
Safety valve, cooling water
L.O. relief valve
Solenoid valve, 1st stage
Solenoid valve, 2nd stage
Solenoid valve, cooling water
Thermometer, 1st stage
Thermometer, 2nd stage
Thermometer, cooling water
Table. 1 Designation of Symbol
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Overview
Fig. 2 Air Compressor Overview
0780 0720 00
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Instruction book
No.
Description
Remark
st
1
Cylinder
1 stage
2
Cylinder
2nd stage
3
Air filter and silencer
4
Electric motor
5
Drain separator
6
Vibration damper
7
Air vent valve
8
Safety valve
1st stage
9
Safety valve
2nd stage
10
Safety valve
Cooling water
11
Pressure gauge
1st stage
12
Pressure gauge
2nd stage
13
Pressure gauge
Lubrication oil
14
Level gauge
Lubrication oil
15
Solenoid valve
1st stage
16
Solenoid valve
2nd stage
17
Solenoid valve
Cooling water, Normal close
18
Pressure switch
Lubrication oil low pressure alarm
19
Temperature switch
Air high temperature alarm
20
Thermometer
1st stage
21
Thermometer
2nd stage
22
Thermometer
Cooling water
23
Junction box
24
Sight glass
25
Drain chamber
Table. 2 Part name of air compressor
12
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Instruction book
2.2 Overview
Fig. 3 Sectional view of air compressor
0780 0720 00
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Instruction book
No.
Description
Remark
1
Crank case
2
Crank shaft
3
Balance weight
4
Lubrication oil pump
5
Oil filter
6
Flexible coupling
7
Cylinder head
1st stage
8
Concentric valve
1st stage
9
Cylinder
1st stage
10
Piston
1st stage
11
Connecting rod
1st stage
12
Cylinder head
2nd stage
13
Concentric valve
2nd stage
14
Cylinder
2nd stage
15
Piston
2nd stage
16
Connecting rod
2nd stage
17
Lubrication oil relief valve
Table. 3 Part list of sectional view
14
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Instruction book
3. Technical data
Compressor model
BV-80
BV-100
Number of cylinders
2
Number of compression stages
2
Cylinder diameter 1st stage (mm)
150
Cylinder diameter 2nd stage (mm)
70
Piston stroke (mm)
64
84
Maximum speed (rpm)
BV-150
100
1800
Ambient temperature
+5℃ up to +55℃
Operating pressure
30 bar
Set pressures of 1st safety valve
8 bar
Set pressures of 2nd safety valve
32 bar
Lubrication system
forced lubrication
Oil filling quantity
6.2 liter
Oil quantity between oil level gauge markings
2.0 liter
Max. primary pressure at cooling water inlet
Set pressure of C.W safety valve
2.5 bar with cooling water pump (5 bar without
C.W.P)
> 6 bar
Temperature of cooling water at the outlet
optimal 30℃ ~ 45℃, max. 50℃
Compressor
model
Speed
(rpm)
1170
Capacity, FAD
(㎥/hr)
58
Required power
(kW)
12.0
Heat Dissipation
(kcal/h)
8800
C.W req.
(liter/min)
17
BV-80
1470
72
15.1
11050
21
1770
85
18.2
13310
25
1170
80
16.0
11720
22
1470
100
20.1
14730
28
1770
120
24.3
17730
33
1170
100
19.1
13960
26
1470
120
24.0
17530
33
150
28.9
21110
Table. 4 Technical data of air compressor
39
BV-100
BV-150
1770
0780 0720 00
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Instruction book
4.
Installation
4.1 Transport
Shipping
1) The machine is packed suitable for shipping
2) Immediately on receipt of the compressor it should be checked for completeness and damage.
3) The transport company must be immediately notified of any damage to the packing or the
machine.
Transportation
The compressor must be transported by forklift truck or hoisted by crane.
Ensure that no persons stay within the danger area of the suspended load
and the forklift truck/crane.
Sling the unpacked compressor at the lifting eyes.
Lift, move, and set down carefully.
4.2 Storage before installation
If the compressor has to be stored before installation, do not unpack and store at the following
conditions:
.
.
.
.
.
Temperature : +5 to +55℃
Relative humidity 30~95%
Dry, under a roof and protected against dew
Protected against soiling
Protected against vibrations and shocks
The standard factory conservation is sufficient for a maximum storage period of
12 months.
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4.3 Installation
When in doubt if the intended place of installation and room are suitable,
contact us in time before the installation. There you will also get help with the
design of a ventilating system, if required at the place of installation.
For installation observe the installation instructions and the following
conditions.
Installation conditions
1) The place of installation must be dry and dust free.
2) The place of installation must be vented in such way that the heat generated during operation is
dissipated.
3) Room temperature while the compressor is running is 5~55℃
4) Alternatives suction area and rear side of compressor, the ventilation capacity required to limit the
compressor room temperature can be calculated
The air temperature at the installation place of the compressor must not exceed
55℃when the compressor is running.
Room conditions and the heat, generated by the compressor and other
machines installed in the room, must be taken into consideration.
5) At a room temperature of below 5℃ the room needs to be heated or the compressor must be
equipped with a heating system.
6) Choose the location so that the compressor is accessible and has sufficient clearance to walls
and other machinery.
4.4 Connecting the compressor
The compressor should only be connected by qualified technicians.
Any work on the electrical installation must be carried out by qualified
electricians.
Pipe lines
1) The compressed air outlet, cooling water inlet/outlet and the drain outlets of the compressor must
be connected to the stationary pipelines by hose lines.
Compressed air escapes from the drain outlets when the compressor starts
and when the condensate is drained. Do not operate compressor without the
hose lines connected.
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Instruction book
2) Hose should be installed in a natural position and comply fully with the figures for admissible
bending radius. Axial torsion must be avoided. Early failure of the hose will result from even the
slightest torsion stress. (When tightening unions, grip the hose firmly against the direction of
twist.). Avoid any sharp kinking. (Strain on the hose can be relieved by fitting an anti-kinking
sleeve bending the joint.)
WRONG
POSSIBLE
VERY
GOOD
WRONG
GOOD
WRONG
GOOD
Fig. 4 Flexible hose installation
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Instruction book
3) Drainage
Condensate that is formed contains oil. It may only be disposed of in
compliance with applicable legal regulations.
We can supply condensate collecting pots for separating condensate, as well
as condensate treatment units for separating the oil from the condensate.
We recommend connecting the compressor's drainage separately.
When the drain lines of several compressors are to be connected to a
common pipe, observe the following :
- Choose a sufficient nominal diameter for the common drain line.
- Connect drain lines of the individual compressors at a sharp angle to the
common drain line, so no pressure can build up in the drain line of a stopped
compressor.
4.5 Filling in oil
The compressor is supplied without lubrication oil.
Oil must be filled into the compressor's crankcase before initial operation!
Use lubricating oil which is recommended by L.O. chart. Observe filling amount
1) Unscrew air vent valve.
2) Fill oil to air vent pipe and check level through oil level gauge.
3) Replace the air vent valve.
Fill only to the upper marking on the level gauge.
Otherwise the oil level consumption of the compressor will increase.
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Instruction book
5. Operation
5.1 Before initial start-up
Safety
The operator must apply all relevant safety precautions, including those mentioned in
this book.
Turn compressor immediately “OFF” when persons or objects are endangered.
Start compressor only when the danger is over
Turn compressor “OFF” immediately in the case of faults, abnormal ratings or
irregularities. Refer to “Trouble Shooting” to remove cause.
Only authorized persons are permitted to commission and operate the compressor
Turn on and start the compressor only it has been checked for proper working
condition
Risk of burns by hot surfaces of the compressor when it is running.
Wear gloves.
Risk of hearing damage due to the sound pressure level when the compressor is
running! Wear hearing protection near the compressor
Check point
1) Does electrical connection correspond to the data on nameplate?
2) Are all connections between compressor and the surrounding compressed air unit correctly
3)
4)
5)
6)
7)
installed? Pay special attention to the compressed air outlet.
Are drain lines properly connected?
Are cooling water lines opened?
Is oil filled in the crankcase?
Have all tools and foreign objects been removed from the compressor?
Is the entire unit clean?
5.2 Initial start-up
Safety
The operator must apply all relevant Safety precautions.
Direction of rotation
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Instruction book
Let the compressor run just for a few seconds to check the direction of rotation
1) Turn the power supply on.
2) Set the operating mode selector to “Manual” to start the compressor in Manual mode.
3) Immediately check the compressor's direction of rotation. It must rotate in the direction indicated
by the arrow on the housing.
4) Turn the compressor off.
5) Turn the power supply off.
6) If the direction of rotation is incorrect, have polarity of the electric motor changed by a qualified
electrician.
Test run
No oil pressure if the direction of rotation of the compressor is wrong.
Risk of subsequent damage.
1) Turn the power supply on.
2) Set the operating mode selector to “Manual” to start the compressor in manual mode.
3) If correctly set the drain valves will close after approx. 10 seconds and the compressor
4)
5)
6)
7)
8)
accelerates against pressure.
Check pressure gauges of the stages as well as the oil pressure gauge and compare with
nominal values.
Check the functioning of the automatic intermediate draining.
Check the cooling water flow-rate.
Turn the compressor off then turn the power supply off.
If necessary, remedy the causes for deviations from nominal values and faults.
5.3 Routine operation
Cleaning
1) Keep compressor site clean.
2) Keep indicators and control elements clean.
Checks
1) Inspect connections, pipe lines and electric cables for damage.
2) Check the oil level once a week before starting, top up if necessary.
Operation
1) Turn power supply on.
2) Set operating mode selector to “Auto” to operate the compressor in automatic mode.
Observation
1) Pay attention to abnormal operating sounds.
2) Pay attention to leakages (compressed air, oil, condensate, cooling water).
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Instruction book
3) The oil pressure should be between 1.1 bar and 3.5 bar. In case of deviations see Chapter 8
“Trouble shooting”.
6. Lubricating oil
Use oil of superior quality and suitable for compressor. Compressor oil should be of
such that its lubricating efficiency are not decreased under high temperature.
Following table shows commercially available oil brands.
The lubrication oil list does not apply to temperature ranges of outside of 5~55℃
Description
Company
Mineral Oils
Synthetic Oils
Castrol
Aircol PD 68, 100
Aircol SN 68, 100
TOTAL Lubmarine
DACNIS P100
BARELF CH 68, 100
Shell
Shell Corena Oil P68, 100
Shell Corena Oil AP 68, 100
Mobil
Mobil Rarus 426, 427
Mobil Rarus 826, 827
FAMM (Chevron
Texaco)
Compressor Oil EP VDL100
Cetus DE100
Table. 5 Lubricating oil list
* Initial charged lubricating oil for test : MOBIL RARUS 427 *
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Instruction book
7. Maintenance
The following table and paragraphs outline the maintenance actions required to obtain the
maximum service life from the compressor. The operator is encouraged to keep a written log that
records operating hours.
The maintenance schedules are based on total hours operating. If the operator is unsure on total
hours interval or if the equipment has stood idle for a long period of time, a complete maintenance
check should be made prior to starting.
7.1 Safety
Only authorized persons are permitted to commission and make adjustments to the
compressor
Cut off power source without fail so that compressor may not commence rotation.
The main switch is energized, even when it is turned off!
Risk of burns by hot surfaces of the compressor when it is running.
Wear gloves.
Discharge the compressed air in the air line, and ensure that there is no pressure in
the compressor.
Remove piping or electric apparatus (i.e. pressure switch or the like) if case may
demand
7.2 Routine maintenance periods
The compressor will give long and satisfactory service provided it is regularly maintained in
accordance with the following recommendations.
In order to comply with warranty conditions, the compressor must be correctly operated and
maintained as described in this.
Preventative maintenance can be effectively planned from the compressor log sheets.
The following is a guide line proposal for a normal maintenance schedule table.
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Instruction book
Check and adjustment
Divisi
on
Items
Contents of check
Valve plate
Air
Spring
Valve
Valve
assembly
Inside of
Cylin
cylinder
der
liner
Piston
outside
Piston
Piston ring
Piston pin
bearing
Crank pin
Shaft
metals
Crank case
Oil
Syste
Oil filter
m
Other
s
100 200 300 400 500 600 700 800 Remark
0
0
0
0
0
0
0
0
Check wear amount or
□
replace
Check for extent of
□
fatigue
□
□
□
□
□
□
□
□
□
□
□
Check or replace
□
□
Check extent of wear
Check outside diameter,
Extent of wear of ring
groove
Check extent of wear or
replace
Check extent wear or
replace
Check extent wear or
replace
Replace oil
□
□
□
□
□
□
□
Clean
□
□
□
□
□
□
□
□
Check for leak
□
□
□
□
□
□
□
□
Air filter
Check or replace
□
□
□
□
□
□
□
□
Pressure
gauge
Check and correct
More than every year
Safety valve Check for function
Check for loosening
Anchor bolt Check for break and
fatigue
Gasket, OReplace
ring
Zinc
Replace
protection
Periodic overhaul
Interval
may be
lightene
d
dependi
ng on
conditio
n
□
Piping
Overhaul
24
Operating time (hr)
Check
oil
quantity
daily
Once every year
□
□
At each disassembling
□
□
□
□
□
□
□
□
□
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Instruction book
Table. 6 Maintenance and inspection chart
7.3 Lubrication Oil
Check and change of oil
Check oil level by means of oil level gauge on crankcase and if necessary, refill oil until the middle
of the L.O. level gauge.
Oil change is to be carried out 100 hours after start-up operation, all follow-on oil changes have to
be carried out every 1000 operation hours or six months.
Lubricating oil should be used the recommended oil (see Chapter 6).
Fig. 5 Lubrication oil level gauge
Oil change
1) Unscrew air vent valve in the upper crankcase.
2) Open Lubrication oil drain valve to discharge oil.
3) Close the valve after discharge oil entirely.
4) Refill the oil into the crankcase until the mark of oil level (Maximum) gauge through air vent pipe.
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Instruction book
Fig. 6 Lubrication oil inlet/outlet
7.4 Check Tightening of Bolts and Nuts
Check tightening of bolt and nut is to be carried out 2 hours after start-up operation, then operator
has to be carried out every 1000 operation hours or six months.
Size
Torque(Nm)
M6
M8
M10
M12
M16
M20
6
10.5
21
36
88
170
Table. 7 Tightening torque for bolts and nuts
7.5 Check of Air Filter
Air filter must be serviced weekly or daily, depending on dust conditions, at least check with air filter
1000 hours after start-up operation about damage or filter pollution.
The air filter should be cleaned by blowing compressed air from the inside to the outside.
1) Open clip and take the air filter cap (1) off.
2) Remove the used air filter element (2).
3) Put new air filter element (2) in.
4) Put cap back on and close the clips.
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Fig. 7 Replacement of air filter element
7.6 Check of Air Valves
Disassembly and assembly must be carried out very carefully. The valves have to be
checked for carbonizations and damages. Strongly carbonized and damaged valves
have to be exchanged. Clean valves and their recesses in cylinder or valve covers
carefully. Observe position of plates and springs during assembling. Replace
packing and O-ring.
Required tools
1) Spanner : 17 mm, 19 mm, 22 mm
2) Wrench : 6 mm
3) Box wrench : 17 mm
4) Torque wrench
Put the valve out from the cylinder
1) Disassembly
.
Unscrew the nut of bite type connector (1) by 19 mm spanner to remove copper tube.
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Instruction book
.
.
.
Unscrew two set screws (5) simultaneously by wrench.
Unscrew the nuts (2) on cylinder head by 17 mm spanner or box wrench.
Remove the cylinder head and pull out the air valve (7).
2) Assembly
.
.
.
.
.
.
Place valve on plane surface.
Place new gasket ring (3)
Place cylinder head on the cylinder.
Mount cylinder head to its position. Pay attention to correct position of the valve cover.
Tighten nuts (2) by torque wrench.
Required tightening torque for cylinder head is 45 Nm
Fig. 8 Disassemble air valve
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Check of the valves
1) Disassemble valve.
2) Clean all valve parts. For this purpose soak them in an oil dissolving fluid.
3) Check over carbonizations and damages by visual inspection.
4) If damage is found, these parts are to be exchanged.
5) Carefully reassemble valve (see illustration), tighten nut.
6) Required tightening torque for concentric valve is 50 Nm
7) Use a pin with round tip to check the valve plate’s smoothness of action against the spring
pressure.
1st stage
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Instruction book
Fig. 9 Concentric valve
7.7
Check of Pistons and Cylinders
Required tools
1) Spanner : 17 mm, 19 mm, 27 mm, 32 mm, 46 mm
2) Box wrench : 24 mm
3) Chain block
4) Torque wrench
Disassemble 1st stage cylinder
1) Remove cooling water flexible hose (6) by 32 mm spanner
2) Place water bucket under cylinder to drain
3) Unscrew cooling water plug (1) by 27 mm spanner
4) Drain water in the cylinders as much as possible
5) Remove the cylinder head and valve as described in section 7.6 “Check of Air Valves”
6) Remove cylinder (5) after unscrew cylinder fixed nuts (4) by 19 mm spanner
7) Remove crank case cover (5) after unscrew fixed nuts (4) by 17 mm spanner or box wrench
Fig. 10 Disassemble 1st stage cylinders
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Use hoist machine or chain block to move cylinder assembly part.
Cylinder assembly is too heavy to move by man power.
Disassemble 2nd stage cylinder
1) Place water bucket under cylinder to drain
2) Unscrew cooling water plug (8) by 27 mm spanner
3) Drain water in the cylinders as much as possible
1) Remove the coils of the every solenoid valves (1, 2) and temperature switch (3)
2) Unscrew the cap nut (4) due to separate the ‘Oil and water separator’ (6) with 46 mm spanner
3) Remove the cylinder head and valve as described in section 7.6 “Check of Air Valves”
4) Remove cylinder (11) after unscrew cylinder fixed nuts (10) by 19 mm spanner
Fig. 11 Disassemble 2nd stage cylinders
Check the piston and cylinder
1) Check piston and cylinder for wearing and damage. If such excessive wear or damages are found, these
parts have to be exchanged
2) Measure the bore of piston and cylinder liner. If the measuring value is exceeded wear limit for
cylinder diameter, piston and cylinder liner have to be exchanged
3) Wear limits of cylinders are described in following table
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Instruction book
Description
1st stage
2nd stage
Wear limit (mm)
150.15
70.1
Table. 8 Wear limits of cylinders
7.8 Check of Piston Ring
Required tools
1) Piston ring plier
2) Slip gauge
Check of piston ring
1) Remove the cylinder and piston as described in section 7.7 “Check of Piston and Cylinder”.
2) Remove the piston rings from the piston
3) Insert the piston rings in the corresponding cylinder approximately 10 mm from the top edge.
4) Measure the clearance with a slip gauge. If the measuring values are exceeded compare
measuring values with wearing limit, the piston rings have to be exchanged
5) Wear limit of piston rings are described in following table
Location
1st stage
2nd stage
Wear limit (mm)
1.5
0.7
Table. 9 Wear limits of piston rings
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Instruction book
Fig. 12 Measuring piston ring clearance
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Instruction book
7.9
Check of Connecting Rod
Disassemble connecting rod
1) Remove connecting rod bolts (5) by 17 mm box wrench
2) Remove the piston (1) with connecting rod (2) carefully
Fig. 13 Disassemble connecting rod
Reassemble connecting rods
1) Put connecting rod back with sufficient oil and screw on the bottom part with hand
2) It should be possible to screw in the connecting rod bolts completely with hand. Only then the
correct seat on the crankshaft can be guaranteed. After tightening, the connecting rod should
rotate easily on the crank shaft
3) Required tightening torque for connecting rod is 40 Nm
Numbers are punched on the upper and lower parts of connecting rod. These must
be match in any case. See illustration.
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Instruction book
Fig. 14 Punched number on connecting rod
7.10 Change of Piston Pin and Piston Pin Bearing
Required tools
1) Snap ring pliers
Disassemble piston pin
1) Remove snap rings from piston assembly by snap ring plier
2) Pull out piston pin and pin bearing
3) Check piston pin and pin bearing. If damage is found, these
parts have to be exchanged
Fig. 15 Disassemble piston
7.11 Check of the Crank Pin and Crank Pin Metals
1) Remove the cylinder and connecting rod as described in section 7.7 “Check of Piston and
Cylinder”
2) Check crank pin and crank pin metals for wear and damage. If excessive wear or damage
occurred, crank pin metal must be exchanged
7.12 Check of Oil Filter
Required tools
1) Spanner : 17 mm, 24 mm
Disassemble oil pump
1) Remove fixed nuts (1) by 17mm spanner
2) Remove crankcase cover (2)
3) Remove oil filter (3) by 24 mm spanner
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Instruction book
4) Check and clean the oil filter
5) If damage is found, it must be changed
Fig. 16 Disassemble oil filter
7.13 Check of Oil Pump
Required tools
1) Spanner : 13 mm, 17 mm
2) Wrench : 8 mm
Disassemble oil pump
1) Remove fixed nuts(1,2) by 13 mm, 17mm spanner
2) Remove lubrication oil pump cover (3)
3) Remove liner (5) with oil pump (6) and balls (7)
4) Check and clean the oil pump
5) If excessive wear or damage occurred, oil pump must be
changed
Reassemble of oil pump
1) Replace new O-ring (4) of main bearing cover (8)
2) Place oil pump (6, 7) with liner (5)
3) Replace new O-ring (4) of liner
4) Place oil pump cover (3)
5) Tighten fixing nut (1, 2). Refer to section 7.4.
Fig. 17 Disassemble oil pump
Adjusting lubrication oil pressure
l pump
1) Unscrew Threaded plug (9)
2) Screw set screw by 8 mm wrench to increase oil pressure.
3) Unscrew set screw by 8 mm wrench to decrease oil pressure.
4) After adjusting of oil pressure, tightening threaded plug (9) to cover
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Instruction book
7.14 Check of Zinc Protection ( In Case of Sea Water Cooling )
The zinc protections for the cylinders are located on each cylinder. Refer to Chapter 2, section 2.2
“Overview”
Fig. 18 Replacement of zinc protection
1) Unscrew the zinc protection cover and remove loose parts.
2) Check the zinc protection. Minimum diameter is 10 mm. Replace the zinc protection if the
consumption is too high.
3) Fit the zinc protection back with a new copper packing.
7.15 Maintenance of Long Period Stopping
When compressor is to be operated after it has been isolated from service for long period follow the
necessary steps as mentioned under paragraph of test run.
In case where the compressor is cut off from service for prolonged time it must be attended with
necessary care, otherwise, the compressor may be affected by dust deposit, change of oil quality,
and corrosion by impure gases born in the air. Should compressor is run without knowing this,
unexpected trouble may results.
Operator is requested therefore to take necessary care in cases of suspension of operation,
continued suspension and immediately before starting operation.
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Instruction book
8. Trouble shooting guide
The technical descriptions given in this manual should enable an experienced technician to trace
any fault to a suspect area and further investigations should pinpoint the fault. Table lists fault
symptoms which may arise after long and arduous operations, their possible causes and
recommended remedies. See Chapter 7 for dismantling and reassembling instructions.
Daily operation should be thoroughly attended and whenever anomaly is encountered, compressor
should be immediately stopped to check the faults. Attentive check and care in daily operation
makes it possible to evade serious troubles.
As fault finding chart in plain language is given below, cause of trouble must be firmly griped when it
occurs, then the faulty part should be repaired without resorting to overall disassembling in a flurry.
8.1 Compressor Could Not Start
1) Power failure. Check fuses. If required, replace them.
2) Emergency stop push button is pushed. Locked off the push button.
3) Circuit breaker is turned off. Check the breaker and turn it on.
8.2 Compressor Was Switched Off
“Lubrication Oil Low Pressure” lamp is on
1) Oil level in the crankcase is too low. Check the oil level. If required add lubrication oil. Refer to
Chapter 6 and Chapter 7.
2) Oil pump is out of order. Check the oil pump. If there is foreign object in the pump, remove it and
check the oil filter. If required replace the oil pump.
“Motor Overload” lamp is on
1) Motor is overheated. Determine the cause of the problem and maintenance it.
2) Piston seizure. Check cylinder liner and piston. If required, replace them.
“Air High Temperature” lamp is on
1) Cooling water deficiency. If it has a cooling water pump, increase flow rate of cooling water.
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Instruction book
2) Cooling water inlet temperature is too high. Check cooling water inlet temperature.
3) Poor heat transfer in the cooler as a result of boiler scale formation. Clean cooling water cavities
with boiler scale cleaning compound.
4) Carbon deposit on concentric valve. Check and clean the carbon deposit.
8.3 Safety Valve Blows Off
1st stage safety valve blows off
1) 2nd stage concentric valve is not working properly. Check 2nd stage concentric valve. If required,
replace it.
2) Gasket ring or O-ring of 2nd stage concentric valve is located abnormally. Check the gasket ring
or O-ring and replace it if required.
3) Safety valve is out of order. If the safety valve is blowing off under setting pressure (see Chapter
3 “Technical Data”). Replace it
2nd stage safety valve blows off
1) Air receiver line valve is closed. Check the valve and open it.
2) Pressure switch set too high. Reduce set pressure.
3) Safety valve is out of order. If the safety valve is blowing off under setting pressure (see Chapter
3 “Technical Data”). Replace it
Cooling water line safety valve blows off
Cooling tube is damaged. Check and replace the cylinder body.
8.4 Pressure Gauge Indicates Abnormal Pressure
1st stage pressure gauge indicates too low pressure.
1) 1st stage concentric valve leak. Check 1st stage concentric valve and replace if required. Replace
gasket ring.
2) Air filter is very dirty. Clean the air filter element (see section 7.5). Replace it if required.
3) 1st stage drain solenoid leak. Check 1st stage drain solenoid valve. Clean or replace if required.
2nd stage pressure gauge indicates too low pressure.
0780 0720 00
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Instruction book
1) No power at drain solenoid valve. Clean or replace if required.
2) Drain solenoid valve is out of order. Replace it if required.
1st stage pressure gauge indicates abnormally high pressure.
1st stage concentric valve leak. Check the valve for damage and replace if required. Replace gasket
ring.
2nd stage pressure gauge indicates abnormally high pressure.
2nd stage concentric valve leak. Check the valve for damage and replace if required. Replace
gasket ring.
8.5 solenoid Valve Is Not Worked Properly
Drain solenoid valve does not close
1) No supply power to drain solenoid valve. Check fuses. If required, replace it.
2) Solenoid valve is out of order. Check the solenoid valve and replace it if required.
3) Foreign object penetrate to drain solenoid valve. Disassemble the solenoid valve carefully, then
clean it.
Intermediate drainage is not functioning
Twin timer not set or not set correctly. Set timer drainage for 10 seconds and 15 minutes closing
interval
Cooling water solenoid valve does not open
1) No supply power. Check fuses. Replace it, if required.
2) Solenoid valve is out of order. Check the solenoid valve and replace it if required.
3) Foreign object penetrate to cooling water solenoid valve. Disassemble the solenoid valve
carefully then clean it.
8.6 Leakage
Air escaping from compressed air line
1) Gaskets of connection leak. Replace relevant gasket.
2) Compression ring connections leak. Turn off the compressor. Wait until all parts are relieved of
pressure. Then tight unions.
Oil leak from crank case
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0780 0720 00
Instruction book
Gasket or oil seal is damaged. Tighten screws. If there is heavy leakage, check to see which gasket
is damaged, then replace it. Minor traces of oil on the crank case or oil drops below the compressor
are harmless.
Water is leaking at the cylinder
1) Gasket is damaged. Check the gaskets and replace if required.
2) Screw has become loose. Retighten the screw.
8.7 Abnormal Condition
Compressor makes loud noises.
1) Connecting rod bearing fault. Check connecting rod bearing. Replace it if required. Check oil
supply.
2) Connecting rod bolt has become loose. Retighten to specified torque. (see Chapter 7)
3) Crankshaft bearing fault. Check crankshaft bearing. Replace if required.
4) Worn cylinder and larger clearance between the cylinder and the piston. Check the wear of the
cylinder liner. Replace if required. (see Chapter 7)
Water in oil
1) Compressor is overcooled due to over flow rate of cooling water. Reduce cooling water flow rate.
2) Compressor is overcooled due to improper room ventilation. Change the room ventilation in such
a way that it does not blow directly at the compressor.
3) Compressor is overcooled due to very shot running time. Increase compressor running time.
4) Insufficient drainage. Check drain lines and drain interval.
0780 0720 00
41
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