Air Compressor V150 [PDF]

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Technical Documentation

Deck Machinery - Compressors - Steering gears

Technical Documentation for HATLAPA Compressors

V150

W55

L9

HSC22

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V-Line Water cooled Compressor Electro-mechanical Model V105, V150, V200, V250, V375

PCH 1540

Uetersener Maschinenfabrik GmbH & C0. KG Tornescher Weg 5-7 . D-25436 Uetersen Phone: +49-4122-7 11-0 . Telex: 218510 htlu d Mobile: +49-172-9 81 32 92 . Cable Hatlapa Uetersen Fax.: +49-4122-7 11-104 Sales -7 11-330 Service Internet http://www.hatlapa.de E-mail: [email protected]

Discovery Court Business Centre 551-553 Wallisdown Road, Poole, Dorset BH12 5AG, England Phone: +44 (0)1202 853180 Fax Spare Parts Enquiries: +44 (0)1202 853190 Fax General Sales: +44 (0)1202 853191

Page 2

WARNING 1.

The following manual must be read before proceeding with installation, operation and maintenance of this equipment.

2.

Health & Safety Act Compliance. Before working on this equipment personnel should be made aware of, and ensure compliance with, the Health and Safety Regulations appropriate to this class of work.

3.

The handling points are indicated on the unit and must be used. The hooks of slings must be fitted to lifting eyebolts using shackles.

4.

Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings, it must be stopped and isolated electrically and mechanically and the outlet valves closed. Some units on automatic standby duty, or isolators are remote from the unit and extra care is then necessary to ensure that isolation is complete.

Hamworthy reserves the right to make changes to the design of the machine without prior notice. NOTE: Where the compressor has been supplied with an electronic controller, the operating and maintenance information detailed in supplement 1540A should be read in addition to this instruction manual.

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Page 4

CONTENTS SECTION 1 - INSTALLATION ........................................................................................................................ 1-1 1.1 LOCATION ....................................................................................................................................... 1-1 1.2 MOUNTING ...................................................................................................................................... 1-1 1.3 COMMISSIONING............................................................................................................................ 1-1 1.3.1 Commissioning Procedure ........................................................................................................ 1-1 SECTION 2 - OPERATING PROCEDURE .................................................................................................... 2-1 2.1 DESCRIPTION ................................................................................................................................. 2-1 2.2 CONTROL AND OPERATING PHILOSOPHY................................................................................. 2-1 2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)..................................................... 2-1 2.4 MANUAL MODE RUNNING ............................................................................................................. 2-2 2.5 GENERAL......................................................................................................................................... 2-2 SECTION 3 - MAINTENANCE........................................................................................................................ 3-1 3.1 GENERAL......................................................................................................................................... 3-1 3.2 MAINTENANCE INSTRUCTIONS ................................................................................................... 3-2 3.2.1 Lubrication Oil Checking ........................................................................................................... 3-2 3.2.2 Lubrication Oil: Changing .......................................................................................................... 3-3 3.2.3 Air Suction Filter/Silencer Removal and Replacement ............................................................. 3-3 3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement ............................................... 3-3 3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement .............................................. 3-7 3.2.6 First Stage Cylinder and Piston Removal ............................................................................... 3-10 3.2.7 First Stage Cylinder and Piston Reassembly.......................................................................... 3-11 3.2.8 Final Stage Cylinder and Piston Removal............................................................................... 3-12 3.2.9 Final Stage Cylinder and Piston Reassembly......................................................................... 3-13 3.2.10 Cooler Tubenest and Header Removal................................................................................... 3-14 3.2.11 Tubenest Clean/Examine/Replace.......................................................................................... 3-14 3.2.12 Cooler Tubenest and Header Assembly to Compressor ........................................................ 3-15 3.2.13 Cooler box end cover .............................................................................................................. 3-16 3.2.14 Connecting Rod Big End Bearing Removal ............................................................................ 3-16 3.2.15 Bearing Removal and Reassembly to Connecting Rods ........................................................ 3-16 3.2.16 Connecting Rod Assembly Fitment to Compressor ................................................................ 3-17 3.2.17 V150, V200, and V250 Drive Motor and Coupling Removal from Compressor...................... 3-18 3.2.18 V150, V200, and V250 Drive Motor and Coupling Assembly to Compressor ........................ 3-18 3.2.19 V375 Drive Motor and Coupling Removal from, and Assembly to, Compressor .................... 3-20 3.2.20 Flywheel and Drive End Oil Seals Removal from Compressor .............................................. 3-20 3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor ............................................... 3-21 3.2.22 Crankshaft and Main Bearing Removal from Compressor ..................................................... 3-22 3.2.23 Crankshaft and Main Bearings Reassembly to Compressor .................................................. 3-23 3.2.24 Oil Level Switch Remove/Clean/Replace................................................................................ 3-23 3.2.25 Air and Water Safety Valves ................................................................................................... 3-24 3.2.26 Separator Bowl Removal, Spider Examination and Removal................................................. 3-24 3.2.27 Spider Fitting and Separator Bowl Reassembly...................................................................... 3-24 3.3 WATER CIRCULATING PUMP (if supplied) .................................................................................. 3-25 3.3.1 General Overhaul .................................................................................................................... 3-25 3.3.2 Service Information ................................................................................................................. 3-25 3.3.3 Dismantling.............................................................................................................................. 3-25 3.3.4 Reassembly............................................................................................................................. 3-25 3.4 ELECTRICAL MAINTENANCE ...................................................................................................... 3-26 3.5 FAULT FINDING CHART ............................................................................................................... 3-27 3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE ........................................................ 3-28 SECTION 4 - TECHNICAL DATA................................................................................................................... 4-1 4.1 GENERAL......................................................................................................................................... 4-1 4.2 PERFORMANCE.............................................................................................................................. 4-1 4.3 OTHER DATA .................................................................................................................................. 4-1 4.4 CRANKCASE LUBRICANTS ........................................................................................................... 4-3 4.4.1 Approved Oils............................................................................................................................ 4-3 4.4.2 Oil Company Equivalents .......................................................................................................... 4-3 4.4.3 Additional Maintenance for Machines Lubricated with Synthetic Oils....................................... 4-3 SECTION 5 - DRAWINGS .............................................................................................................................. 5-1 Page 5

FIGURES Figure 3.1 First Stage Concentric Valve V150............................................................................................... 3-5 Figure 3.2 First Stage Concentric Valve V200/250/375................................................................................. 3-6 Figure 3.3 Final Stage Concentric Valve V150/200/250/375......................................................................... 3-8 Figure 3.4 Cooler Header V150 ................................................................................................................... 3-15 Figure 3.5 Cooler Header V200/250/375 ..................................................................................................... 3-15 Figure 3.6 Connecting Rod : V150............................................................................................................... 3-17 Figure 3.7 Connecting Rod : V200/250/375................................................................................................. 3-17 Figure 3.8 Coupling...................................................................................................................................... 3-19 Figure 3.9 Gap Between Coupling and Flywheel......................................................................................... 3-19 Figure 3.10 Location of Angle Steel on Crankcase Rails ............................................................................ 3-21 Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges .................................... 5-1 Figure 5.2 Cooler ........................................................................................................................................... 5-3 Figure 5.3 Crankshaft and Flywheel .............................................................................................................. 5-4 Figure 5.4 First Stage Cylinder and Piston .................................................................................................... 5-5 Figure 5.5 Final Stage Cylinder and Piston ................................................................................................... 5-6 Figure 5.6 Separator ...................................................................................................................................... 5-7 Figure 5.7 Gauges ......................................................................................................................................... 5-8 Figure 5.8 Cover Assembly for Electronic Controller Model .......................................................................... 5-9 Figure 5.9 V375 Drive Coupling Element and Coupling Hub (Drawing 641600, Issue 1) ........................... 5-10 Figure 5.10 V375 Flywheel (Drawing 3416300401, Issue 1).......................................................................5-11

TABLES Table 3.1 Table 3.2 Table 3.3 Table 3.4 Table 3.5 Table 3.6 Table 3.7 Table 3.8 Table 4.1 Table 4.2 Table 4.3 Table 4.4 Table 5.1 Table 5.2

Page 6

Fastener Torque Settings .............................................................................................................. 3-1 Maintenance Schedule .................................................................................................................. 3-2 First Stage Concentric Valves - Items List..................................................................................... 3-7 Final Stage Concentric Valves - Items List .................................................................................... 3-9 Fixtures to Assist Flywheel Removal ........................................................................................... 3-20 Switch Settings............................................................................................................................. 3-26 Fault Finding Chart....................................................................................................................... 3-27 Tools Required for Compressor Maintenance ............................................................................. 3-28 Capacity and Power at 30 Bar ....................................................................................................... 4-1 Operating Parameters.................................................................................................................... 4-1 Recommended Maximum Wear Clearances .................................................................................4-2 Oil Company Equivalents............................................................................................................... 4-3 List of Parts for Figure 5.1.............................................................................................................. 5-2 List Of Parts – V-Line Compressors ............................................................................................ 5-12

Spare Parts and Service Spare Parts can be ordered direct from the following address: Hamworthy KSE Ltd. Telephone: +44 (0)1202 662600 Fleets Corner Facsimile: +44 (0)1202 665444 Poole, Dorset Email: [email protected] BH17 0JT, England or from any Hamworthy office or agency throughout the world. When ordering spare parts, the following information is required to ensure that correct parts are supplied: Obtained from machine nameplate Type and serial number of machine: Obtained from details in this publication Item Number and full description of part required: Technical Service and Advice: Technical service and advice can be obtained during normal working hours from the above address, on the following contact numbers Telephone: Facsimile: Email:

+44 (0)1202 662663 +44 (0)1202 662622 [email protected]

or via any of our overseas companies or offices Outside normal working hours a 24 hour emergency facility is available. Initial telephone contact number is England +44 (0)1202 662663. Overseas Hamworthy Offices Canada

Hamworthy Canada Ltd., 113 Cushman Road, Unit 8, St. Catherines, Ontario. L2M 6S9 Tel. +1 905 688 4922 Fax. +1 905 688 9028

Norway

Hamworthy KSE A/S, Joseph Kellers vei 20 Tranby PO Box 83, N-3401 Lier, Norway Tel. + 47 32 85 92 00 Fax. + 47 32 85 21 93

China

Hamworthy KSE Shanghai Representative Office, Room 7-D Yi Dian Plaza, No. 746 Zhao Jia Bang Road, Shanghai 200030 Tel. + 86 21 64455665 Fax. + 86 21 64459875

Singapore

Hamworthy KSE PTE Ltd, 15 Benoi Crescent Singapore 629978 Tel. + 65 261 6066 Fax. + 65 261 6011

Dubai

C/O Aqua Tech, DY 160/1 Al Jadaf, PO Box 62073 Dubai, UAE Tel. + 971 4324 0335 Fax. + 971 4324 0336

South Africa

Hamworthy Engineering Africa (Pty) Ltd P.O. Box 50435, Randburg 2125, Johannesburg. Tel. + 27 11 7923886 Fax. + 27 11 7923889

Holland

Hamworthy KSE BV, Bristolstraat 1, 3047 A.B., Rotterdam, Netherlands Tel. + 31 10 462 4777 Fax. +31 10 415 9046

U.S.A. Georgia

Hamworthy KSE Inc., 1129 Hospital Drive, Suite 3C, Stockbridge, Georgia 30281. Tel. +1 770 507 8900 Fax. +1 770 507 8989

India

Hamworthy KSE Pvt Ltd C-155 Mittal Court, Nariman Point, Mumbai 400 021 India Tel. + 91 22 2872394 Fax. + 91 22 2872394

New Jersey

187 Route 34 Matawan, NJ 07747 New Jersey Tel: + 732 583 5115 Fax: + 732 583 5116

Korea

Hamworthy KSE Korea Ltd. 14th Floor Hyundai Building #1193-5 Choryang 3 dong, Dong-gu, Pusan, Korea (601-013) Tel: + 8251 465 8461 Fax: + 8251 463 7498

New Orleans

1418 Edwards Avenue Suite B New Orleans Louisiana 70123 Tel: +1 504 734 5525 Fax: +1 504 734 5716

Page 7

Hamworthy Agents Worldwide Abu Dhabi

Ali & Sons Co. Ali & Sons Co. Building Tourist Club, PO Box 915 Abu Dhabi, U.A.E. Tel. + 971 2 723900 Fax. + 971 2 723901

Egypt

International Marine Center PO Box 95 (21321) Imbrahimieh Alexandria, Egypt Tel. + 203 483 6959 Fax. + 203 483 7969

Sultanate of Oman

Trans-Oceanic Trading Est. PO Box 4892 Postal Code 112, Ruwi Sultanate of Oman Tel. + 968 798503 Fax. + 968 702981

Argentina

Neptune S.A. Calle Mendoza 3185 - 5° - B 1428 - Buenos Aires Argentina Tel. + 54 1 322 6041 Fax. + 54 1 322 5790

France

Etablissements Tiano 2 Bis Rue de la Baume Paris 75008, France Tel. + 33 1 4561 9932 Fax. + 33 1 4225 6962

Pakistan

United Traders Haroon Chambers Altaf Hussain Road, Karachi 74000, Pakistan Tel. + 92 21 241 4916 Fax. + 92 21 241 6862

Australia

Caba (Aust.) Pty. Ltd. 41 Barry Avenue Mortdale, N.S.W. 2223 Australia Tel. + 61 29 534 2100 Fax. + 61 29 533 5332

Germany

Wilhelm Rump KG Buchheisterstrasse 6 20457 Hamburg, Germany Tel. + 49 40 317842-0 Fax. + 49 40 3194841

Poland

Romac Ltd. 80/463 Gdansk, Ciolkowskigo 7A/25 Poland Tel. + 48 58 347203 Fax. + 48 58 3463694

Greece

Alpha Marine Engineering Ltd. Qatar 38 Salaminos GR 16674 GLYFADA, Athens Greece Tel: + 301 89 43 220 Fax. + 301 96 80 210

Al Ahed Trading & Contracting Company PO Box 3266, Doha, Qatar Tel. + 974 414022 Fax. + 974 414021

Aries Industrial Y Naval S.A. Parque de las Naciones Edificio Germania Guzman el Bueno 133 Madrid 28003, Spain Tel. + 34 91 533 9200 Fax. + 34 91 534 7402

Bangladesh Marinetec Ltd. 30 Agrabad Commercial Area, PO Box 2018 Bandar, Chittagong Bangladesh Tel. + 880 31 502834 Telex: 66466

Brazil

Tridente Brazil Rua Visconde de Inhuama, 134 – GR 1513 Centro - Rio de Janeiro – RJ 20091-100, Brazil Tel. + 55 21 233 1489 Fax. + 55 21 233 7187

Italy Genoa

S.I.R.N. s.r.l. 22/1 Via Casaregis, 16129 Genoa Tel. + 39 0 10 586771 Fax. + 39 0 10 542678

Spain

Bulgaria

Dawcul Ltd. Cherni Vrah Bul, BL NO 4VH A, 1421 Sofia, Bulgaria Tel. + 359 2 963 0156 Fax. + 359 2 962 5217

Trieste

22/1 Via Del Lazzaretto Vecchio, 9.34123, Trieste Tel. + 39 0 40 304247 Fax. + 39 0 40 308196

Venezuela Oficini Maritima PI. C.A.

Chile

Lanz Y Cia Ltda Israel Calle Dr. Barros Borgono 233. Casilla 16389 Santiago, Chile Tel. + 56 2 235 2707 Fax. + 56 2 235 7329/1070

B. Sofer & Co. Ltd. PO Box 221, Avichail 42910 Israel Tel. + 972 9882 2319 Fax. + 972 9862 5211

Columbia

Consul Naval Ltda Kuwait Edificio Colseguros Oficina 501 Calle Cochera del Gobernador Cartagena, Columbia S.A. Tel. + 575 664 6413 Fax. + 575 664 1640

The Trading & Industrial Equipment Co. (WLL) (TIECO), PO Box 2159, 13022, Safat, Kuwait Tel. 00965 4810385 Fax. + 965 4810387

Denmark

Berendsen PMC A/S, Telefonvej 6, DK 2860 Soborg, Denmark Tel. + 45 70 21 21 21 ext 421 Fax. + 45 39 54 85 11

Malta

Thos. C. Smith & Co. Ltd. 12 St Christopher Street Valetta, Malta Tel. + 356 625071 Fax. + 356 247182

Ecuador

Sertemar Ltd. El Oro 1303 Y Guaranda, PO Box 5899 Guayaquil, Ecuador S.A. Tel. + 593 4 345105/340325 Telex. 043741 AM BU SL

New Zealand

Caba (New Zealand) Ltd 37 Clyde Street Whangarei, New Zealand Tel. + 64 94 383661 Fax. + 64 94 30854

Edif Torre La Previsora Piso 7, Sabana Grande Aptdo 60710, Caracas 1060A Venezuela Tel. + 58 2 7817897 Fax. + 58 2 781 9457

V11

Page 8

SECTION 1 - INSTALLATION

SECTION 1 - INSTALLATION 1.1

LOCATION

The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as cool and dry as possible and there is adequate circulation to the drive motor integral cooling fan and all the compressor external surfaces. The compressor must be positioned with the axis of the crankshaft and motor fore and aft in the vessel to ensure adequate lubrication during the vessels normal roll, pitch, list and trim modes. 1.2

MOUNTING

The compressor should be mounted on support plates/pads and supported by a ribbed structure suitable for the type and weight of the compressor. The pads/plates must be clean and flat to within 0.5 mm (1 mm with anti-vibration mounts). Shims should be used if necessary. Refer to general arrangement drawing supplied with the compressor documentation package for mounting feet or anti-vibration mounts dimensions and positions and weight of the compressor. 1.3

COMMISSIONING

WARNING 1. DO NOT MAKE ANY ADJUSTMENTS TO THE COMPRESSOR, ITS CONNECTIONS OR FITTINGS WHILST THE COMPRESSOR IS RUNNING OR ON STANDBY DUTY. 2. DO NOT RUN THE COMPRESSOR UNLESS ALL PROTECTIVE GUARDS FITTED TO IT AND ITS PRIME MOVER ARE IN PLACE. 1.3.1

Commissioning Procedure

1.

Ensure compressor is isolated from its electrical supply.

2.

Check lubricating oil level in crankcase sump.

3.

Before initial start up, or after any servicing has been carried out, or when the compressor has not been run for 5 weeks or more, carry out the following procedures. Remove the plugs from the side wall of the first stage cylinder and final stage cylinder head. Pour 20 millilitres of lubricating oil through the exposed holes. Replace plugs in cylinders. CAUTION:

After adding oil to the valves, the compressor must be barred over at least 3 complete revolutions to ensure lubrication of the cylinder bores during initial start up and minimise the risk of the piston causing a hydraulic lock when the compressor is started.

Open air bleed valve (Item C10 in Figure 5.2, Cooler) to remove air trapped in water box cooler passages. 4.

Remove guard covering barring over access aperture in crankcase.

5.

Using a bar (not supplied) in one of the holes in the flywheel turn over the compressor through at least three complete revolutions. WARNING: TAKE PRECAUTIONS TO PREVENT INJURY TO PERSONNEL WHILST OBSERVING THE DIRECTION OF ROTATION OF THE FLYWHEEL THROUGH THE UNGUARDED BARRING OVER ACCESS APERTURE. Page 1-1

SECTION 1 - INSTALLATION

6.

Connect the electrical supply and carry out a momentary start and stop.

7.

Check that rotation of compressor is clockwise looking on the drive end of the compressor (indicated by cast arrow). If direction of rotation is incorrect, take appropriate steps to correct.

8.

Isolate starter, refit guard (170) covering barring over access aperture.

9.

Press start button. The compressor is brought on line to charge the air system. Check the following details within the first minute of the run.

10.

a.

Check that the cooling water system is operating and the outlet from the compressor is registering a flow.

b.

Check that final stage air pressure is increasing over ambient pressure values.

Allow compressor to continue to run under the control of the system pressure switch and closely monitor the temperature differential between cooling water inlet and outlet temperatures, adjusting valves etc as appropriate to adjust the water flow rate to achieve a temperature differential of approximately 15°C. (Note: This temperature differential equates to the nominal flow rate as specified in Technical Data). The compressor must run continuously for approximately 30 minutes to reach normal operating temperature. It may be necessary to bleed off air from the system to prevent the compressor stopping prematurely.

11.

Check the operation of the system pressure switch.

12.

After satisfactory operation of the pressure control system, the compressor is now commissioned for use. The compressor may be either left running (on line) to charge the air system or stopped.

Page 1-2

SECTION 2 - OPERATING PROCEDURE

SECTION 2 - OPERATING PROCEDURE 2.1

DESCRIPTION

The standard V-Line compressor is supplied with gauges, a dual set point high air temperature switch, a dual set point low lubricating oil switch and two solenoid operated drain valves. The high air temperature switch (double pole) is fitted to protect the compressor by shutting it down if the temperature rises above the normal maximum operating temperature. As an option, the second pole of the switch may be connected to give a panel indicated warning of approaching shutdown temperature. The low lubricating oil switch (double pole) will also shut down the compressor if it detects the oil level is below the minimum requirement. An adjustable time delay is included to overcome false tripping due to the roll and pitch of the vessel. The second pole may be connected to give a panel warning of approaching shutdown oil level. The compressor starting method can be either star/delta or direct-on-line. The compressor may be supplied with a water circulating pump if required. 2.2

CONTROL AND OPERATING PHILOSOPHY

The compressor is fitted with protection devices which immediately stop and unload the compressor, when it is connected to a suitable starter, (supplied by Hamworthy or the customer) if any of the following events occur: - minimum oil level - high final delivery temperature - high compressor motor current - high water pump motor current - emergency stop button operation

shutdown and optional pre-alarm shutdown and optional pre-alarm shutdown only shutdown only (of water circulating pump supplied) shutdown only

The control panel is capable of the following functions: - selection of automatic mode - local or remote start/stop sequence - selection of manual mode - local start/stop only If more than one compressor is charging the system a selector switch should be fitted enabling the sequence in which the compressors should work i.e. lead and follow. 2.3

NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL)

1.

Energise the starter panel by operating the main isolator. Set mode switch S1 to AUTO. Set local/remote switch S2 as required. Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied) Press RESET push button.

2.

On pressing the START button, the compressor runs off-load for a short time (approximately 15 - 20 seconds) after which the drain/unloading solenoid valves are energised to close to charge the system. (Note that the compressor will only go on load if the system is not fully charged.)

3.

The compressor is now controlled by the air system pressure switch. At 5 minute intervals (adjustable) the drain solenoid valves are de-energised for 2 seconds (adjustable) to drain the separator bowls.

4.

On air system charged signal, the solenoid valves are de-energised to open to drain and unload the compressor until a signal is received:- on recharge signal the solenoid valves are energised to close causing the compressor to charge the system Page 2-1

SECTION 2 - OPERATING PROCEDURE

- if the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the compressor stops leaving the solenoid valves open. On recharge signal the compressor starts as for pressing the START button (and lamp goes out). 5.

On pressing the STOP button (or switching S1 to OFF or MAN) the solenoid valves are de-energised to open to drain the separator bowls, the compressor continues to run-on unloaded for 5 minutes (adjustable) before stopping. Pressing the START button during this cycle brings the compressor back on line to recharge the system.

6.

If the START button is pressed while the air system is fully charged, the compressor starts as described in 2. The compressor is then controlled by the air system pressure switch as in 3 and 4 above.

2.4

MANUAL MODE RUNNING

Energise the starter panel by operating the main isolator. Set mode switch S1 to MAN. Set local/remote switch S2 to LOCAL. Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied). Press RESET push button. The compressor will start and run in this mode overriding the low oil level and high air temperature shutdown devices. The emergency stop button and motor thermal overloads will still stop and unload the machine. Compressor and air system protection during manual mode running are given by first and final stage air and water jacket safety valves and any other safety device fitted to the installed system. Starting, running and run down cycles are as for normal (automatic) running as described with the exception of the following: - oil level switch overridden. - high air temperature switch overridden. - remote start/stop function disabled. 2.5

GENERAL

Individual volt-free change-over contacts and control panel mounted indicator lamps are provided as listed below: - compressor running - water pump running (if fitted) - low oil level shutdown - low oil level warning (if fitted) - high air temperature shutdown - high air temperature warning (if fitted) - compressor motor overload - water pump motor overload (if fitted) Terminals are provided for a remote emergency stop push-button (if required). Warning (pre-alarm) oil level and high air temperature indicator lamps and volt free contacts, are an optional extra and are not fitted as standard.

Page 2-2

SECTION 3 - MAINTENANCE

SECTION 3 - MAINTENANCE WARNING 1.

BEFORE PROCEEDING WITH MAINTENANCE OR OVERHAUL, THE COMPRESSOR MUST BE STOPPED AND ISOLATED MECHANICALLY AND ELECTRICALLY, AND VISIBLE WARNING NOTICES DISPLAYED.

2.

WHEN WORKING ON WATER AND/OR AIR PASSAGES THE COMPRESSOR MUST BE VENTED OF ALL PRESSURISED AIR AND DRAINED OF COOLING WATER.

3.

VITON O-RINGS AND SEALS ARE FITTED TO THIS COMPRESSOR. WHEN VITON IS SUBJECTED TO EXCESSIVE TEMPERATURES (ABOVE 400°C) IT DECOMPOSES AND CAN CAUSE SERIOUS INJURY. WHEN MAINTAINING THE EQUIPMENT PROTECTIVE GLOVES SHOULD BE WORN.

3.1

GENERAL

Routine maintenance of the compressor should be carried out at the intervals listed in the Maintenance Schedule under normal conditions. However, the optimum period between servicing will depend upon the operating conditions. Before re-assembly, clean all parts with a suitable cleaning fluid and examine for wear, corrosion, cracks, distortion, or any other damage. Renew as necessary. Refer to the wear tolerances given in Section 4 Technical Data. When re-assembling compressor components, renew all joints, gaskets, and O-rings seals. Great care must be taken to ensure that they are not damaged. Item numbers in the text refer to items on the Sectional Arrangement Drawings which are at the end of this manual. When using Loctite products for nut and screw retention note the following. The shelf life of Loctite is one year at a storage temperature of 6° - 22°C. All components to be fixed with Loctite should be thoroughly degreased using a Loctite activator. If cured Loctite is present in a tapped hole or external thread, discard the bolt or nut, or clean with a die and tap internal threads. All fasteners must be torqued to their specified level (see table). After any servicing has been carried out, refer to Section 1.3.1, Commissioning Procedure, before restarting. Table 3.1 Fastener Torque Settings M6

M8

M10

M12

M16

6 Nm

16 Nm

32 Nm

53 Nm

132 Nm

Page 3-1

SECTION 3 - MAINTENANCE

!

Time required for operation.

Every 5 years or 5000 hours.

Every 2 years or 2000 hours

Every 6 months or 500 hours.

Daily or every 10 hours

At 50 hours

Daily or every 10 hours

Table 3.2 Maintenance Schedule Commissioning Normal Operating Services Period

!

1.

Check oil level on dipstick.

2.

Drain and refill lubricating oil.

3.

Replace air inlet filter.

!

4.

Clean and inspect delivery line non-return valve.

!

30 mins

5.

Clean first stage valve and replace seals. Renew final stage valve and O-rings.

!

4 hours

6.

Renew first stage valve and O-rings.

!

2 hours

7.

Check settings of all pressure safety valves, replace as necessary.

!

1 hour

8.

Remove inter/after coolers and clean.

!

4 hours

9.

Dismantle and measure moving parts for wear.

!

6 hours

!

6 hours

!

!

st

10. Check condition of spider in 1 nd and 2 stage separators

! 11. Replace bearings 1 hour A complete overhaul, including bearing replacement, is recommended every 5 years or 5,000 running hours. After a major service, follow the commissioning procedure detailed in section 1. 3.2 3.2.1

MAINTENANCE INSTRUCTIONS Lubrication Oil Checking

Refer to Technical Data section for oil capacities and recommended lubricants. 1.

Remove filler/dipstick and check oil level.

2.

Fill/top up crankcase oil level if necessary with lubricating oil to full level on dipstick.

Periodically examine oil in crankcase and ensure that it is not contaminated with condensate. If the oil is emulsified (creamy in colour) it must be changed and the crankcase cleaned. To minimise the risk of emulsification use a recommended oil, ensure that the compressor is not overcooled by fitting of a water shut off valve, and maintaining a 15°C cooling water temperature rise across the machine. If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the oil. The oil level should then be restored with fresh oil. Crankcase oil contamination is often accompanied by an increase in sump oil level, due to oil being supported by condensate fluid. Page 3-2

SECTION 3 - MAINTENANCE

3.2.2

Lubrication Oil: Changing

1.

Remove the drain plug after the compressor has been running, whilst the oil is still warm and drain oil from the compressor. Dispose of used oil in accordance with local regulations.

2.

Clean the magnetic portion of plug before replacing into crankcase.

3.

Remove and clean oil level switch, see section 3.2.23.

4.

Refill with fresh oil.

3.2.3

Air Suction Filter/Silencer Removal and Replacement

1.

Before removing the air filter silencer assembly, clean the outside of the filter body.

2.

Remove wing nut (F8) on top of filter.

3.

Remove top cover (F6). On V150 wing nut (F4) on top element (F2).

4.

Remove filter body (F1) complete with inlet resonator (F10), hose clip (F11), ‘O’ ring (F9), and element (F2).

5.

Unless filter/silencer assembly is to be re-assembled immediately, cover valve cage aperture.

6.

Renew element if necessary.

7.

Reassemble filter.

3.2.4

First Stage Concentric Valve Removal/Servicing/Replacement

1.

Remove air suction filter silencer assembly from valve cage as detailed in Section 3.2.3.

2.

Remove studding (165) and the four nuts (56) and washers (57) from the top of the valve cage (45).

3.

Release crankcase breather hose (32) from the hose connector (46). (Not applicable on V375).

4.

Remove valve cage complete with concentric valve (50) using M12 or M16 screws (not supplied) in the two tapped jacking holes. (On V375 use the eyebolt fitted).

5.

Cover open bores on cylinder and breather hose.

6.

Remove stud connector (54) and washer (55) from concentric valve (A1) central stud.

7.

Remove dome nuts (A2) and joint washers (53) from concentric valve outer side.

8.

Separate concentric valve from valve cage.

Dismantling NOTE: A valve assembly must not be held directly between vice jaws. Never hammer a spanner when loosening or tightening the valve nuts. 1.

Unscrew and remove nut (10).

NOTE: When dismantling valve, note the method and order of renewal of each valve component. Refer to the illustration of the valve assembly to ensure that the components are rebuilt in their correct order. 2.

Clean all components thoroughly. Remove grease and carbon deposits with a soft brush using a hot water and soda solution. Care must be taken during the cleaning operation as any surface scratch may cause leakage and ultimately a breakage. Page 3-3

SECTION 3 - MAINTENANCE

3.

Inspect each component. If any items appear defective, worn or damaged the whole valve must be renewed.

Re-assembly 1.

Assemble the valve components on the lower delivery valve seat (2) and studs.

CAUTION: Ensure that the components are correctly positioned on their locating pins. 2.

Fit the upper suction valve seat (1) in position and fit nut (10).

3.

Check that the valve functions correctly and that plate movement exists. Extreme care must be taken to ensure that the valve is not scraped or damaged in this operation.

Valve Replacement 1.

Renew ‘O’ rings (48) fitted to valve cage (45) and ‘O’ rings (51 and 52) fitted to concentric valve.

2.

Assemble concentric valve to valve cage and loosely fit dome nuts (A2), joint washers (53), stud connector (54) and washer (55) to concentric valve studs.

3.

Fit valve cage and valve to cylinder (39) and re-connect crankcase breather hose (32) to the hose connector.

NOTE: V375 only. Refit the valve with the fitting eye uppermost ensuring that the dowel pin aligns with the mating hole in the cylinder. 4.

Tighten stud connector (54) and dome nuts (50B).

5.

Fit washers (56) and nuts (55) to studs (42) and tighten nuts.

6.

Fit studding (165) to stud connector and tighten.

7.

Reassemble suction filter silencer assembly to valve cage as described in 3.2.3.

Page 3-4

SECTION 3 - MAINTENANCE

Valve Servicing

11 10

12

12 1

7

4

13 3

9

6 5 13

8 15

15

14

15 2

16

Figure 3.1 First Stage Concentric Valve V150 Page 3-5

SECTION 3 - MAINTENANCE

Figure 3.2 First Stage Concentric Valve V200/250/375

Page 3-6

SECTION 3 - MAINTENANCE

Table 3.1 First Stage Concentric Valves - Items List Quantity Item

3.2.5

Description

V150

V200/250

V375

1

Suction valve seat

1

1

1

2

Delivery valve seat

1

1

1

3

Suction valve plate

1

1

1

4

Delivery valve plate

1

1

1

5

Cushion plate

1

1

N/a

6

Suction spring plate

1

3

2

7

Delivery spring plate

3

4

4

8

Centre stud

1

1

1

9

Stud

4

4

8

10

Self locking nut

1

1

1

11

Dome nut

1

1

N/a

12

Dome nut

4

4

8

13

Lift washer

2

2

2

14

Locating pin

1

1

1

15

Locating pin

3

3

3

16

Back peg

1

1

1

17

‘O’ – ring (between 1 and 7, not shown on Figure 3.2)

N/a

N/a

N/a

Final Stage Concentric Valve Removal/Servicing/Replacement

Removal 1.

Remove the four nuts (79) and washers (80) from the top of the valve cage.

2.

Remove valve cage (70) complete with concentric valve (B1) using screws (not supplied) in the two tapped jacking holes.

3.

Cover bores on cylinder.

4.

Remove dome nuts (B2) and joint washers (78) from concentric valve studs.

5.

Separate concentric valve from valve cage.

Page 3-7

SECTION 3 - MAINTENANCE

Figure 3.1 Final Stage Concentric Valve V150/200/250/375

Page 3-8

SECTION 3 - MAINTENANCE

Table 3.1 Final Stage Concentric Valves - Items List Quantity Item

Description

V150/V200/250

V375

1

Suction valve seat

1

1

2

Delivery valve seat

1

1

3

Suction valve plate

1

1

4

Delivery valve plate

1

1

6

Suction spring plate

2

2

7

Delivery spring plate

2

3

9

Centre stud (shorter on V200/250)

1

1

10

Stud

3

6

11

Dome nut

4

7

12

Locating pin

1

1

13

Screw

3

n/a

14

Back peg

1

1

15

Lift washer (below 8, not shown on Figure 3.1)

N/a

1

Dismantling 1.

Unscrew the three socket head cap screws (13) (Not applicable on V375). Unscrew the centre nut (V200/250 only). Note: When dismantling valve, note the method and order of renewal of each valve component. Refer to the illustration of the valve assembly to ensure that the components are rebuilt in the correct order.

2.

Clean all components thoroughly, remove grease and carbon deposits with a soft brush using a hot water and soda solution. Care must be taken during the cleaning operation as any surface scratch may cause leakage and ultimately a breakage.

3.

Inspect each component. If any items appear defective, worn or damaged, the whole valve must be replaced with a new assembly.

Re-assembly 1.

Assemble the valve components on the lower delivery valve seat (2) and studs and ensure that the components are correctly positioned on their locating pins.

2.

Fit the upper suction valve seat (1) in position. Fit the three socket head cap screws. (Not V375)

3.

Check that the valve functions correctly and that plate movement exists. Extreme care must be taken to ensure that the valve is not scraped or damaged in this operation.

Valve Replacement 1.

Renew ‘O’ rings (71 and 72) fitted to valve cage (70) and ‘O’ rings (76 and 77) fitted to concentric valve (B1).

2.

Assemble concentric valve (B1) to valve cage (70) and tighten dome nuts (B2) and joint washers (78) to the valve studs.

3.

Fit valve cage and concentric valve assembly to cylinder (66).

4.

Fit 4 off nuts (79) and bright washers (80) to studs (67) and tighten nuts. Page 3-9

SECTION 3 - MAINTENANCE

3.2.6

First Stage Cylinder and Piston Removal

CAUTION: When removing 1st stage cylinders, it can be difficult to prevent the piston from dropping out of the bore and falling onto the edge of the cylinder aperture. To ensure that this does not occur, strategically place an appropriate cushioning material immediately the cylinder becomes clear of the crankcase so that if the piston does fall no damage can result. 1.

Drain compressor of all cooling water.

2.

Remove water outlet connection from cylinder.

3.

Remove first stage concentric valve and cage assembly from cylinder as detailed in 3.2.4.

4.

Remove guard (170) from crankcase.

5.

Using a bar turn over the compressor until the first stage piston (35) is at the top of its stroke in the cylinder.

NOTE: If final stage cylinder has been removed take precautions to protect exposed components in the crankcase. 6.

Remove the bolts (101) and washers (102) securing the cooler header (93) to the cylinder.

7.

Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting tackle.

8.

Using lifting tackle and by striking the cylinder gently with a soft headed mallet break the seals between the cylinder and crankcase, cylinder and cooler header.

9.

Lift and guide the cylinder off the piston assembly take care to prevent damage to the piston assembly as it becomes free from the cylinder.

WARNING: WITH CYLINDER REMOVED PROTECT PERSONNEL FROM INJURY FROM THE EXPOSED STUDS (56) AT ALL TIMES UNTIL THE CYLINDER IS RE-ASSEMBLED. 10.

Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of compressor.

11.

Slacken the locknuts (42) which secure the cap head screws, from the underside of the piston. Remove the 2 cap head screws (41) from the underside of the piston (35) which lock the gudgeon pin (40) in position.

12.

Supporting the piston push gudgeon pin out of piston and connecting rod (15) taking care when the pin frees to prevent damage of rod striking piston internals and crankcase. Remove piston and pin.

13.

Cover the crankcase aperture.

14.

Examine removed components replacing worn/damaged parts as necessary. For wear allowances see section 4 - Technical Data.

NOTE: If required connecting rod small end needle roller bearing (17) may be removed and refitted without dismantling compressor any further. Section 3.2.15 refers.

Page 3-10

SECTION 3 - MAINTENANCE

3.2.7 1.

First Stage Cylinder and Piston Reassembly Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal the cylinder to the crankcase and retain the cap head screws in the piston. a.

The minimum amount of Loctite flange sealant number 573 required is 50 millilitres

b.

The minimum amount of Loctite nutlock 243 required is 10 millilitres

2.

Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease free. (Ensure sealant does not enter crankcase - remove if necessary.)

3.

Remove all traces of gasketing on joint faces of cylinder to cooler header and ensure faces are grease free. Do not smooth joint faces. Do not use emery cloth or a metal scraper to abrade or clean them. It is recommended that a chemical such as Loctite ‘Chisel’ is used in conjunction with hand brushing with a wire brush.

4.

Remove Loctite from threads in piston using a tap. If the cap head screws are to be re-used, clear threads using a die.

5.

If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.175/0.300mm (V150), 0.20/0.33 (V200/250) or 0.26/0.39mm (V375). Ensure rings are fitted as follows to the piston. a.

Barrel faced ring top groove.

b.

Taper faced ring second groove (this ring can be readily identified against the barrel faced ring by the internal chamfer on the taper faced ring.)

c.

Both rings must be fitted with the face marked “Top” facing towards the piston crown.

d.

S.O.C. ring bottom groove.

6.

Align adjacent ring gaps on piston at 180° to each other.

7.

Clean piston threads and cap head screw with Loctite Activator. With locknut fitted, coat cap head screw with Loctite 243 and screw into piston until the cup end is 4 mm below the gudgeon pin bore.

8.

Assemble piston and ring assembly into cylinder bore exercising caution in fitting the rings around the cast scallop on the cylinder.

9.

Using suitable lifting tackle and exercising caution so that the piston does not drop out of the cylinder, align cylinder assembly on to studs.

10.

Lower cylinder gradually with piston gudgeon pin hole visible until the hole and small end bearing are aligned. Lightly oil the gudgeon pin and fit through the piston into the connecting rod small end bearing, aligning piston and pin markings to front of compressor.

11.

Position gudgeon pin ends equally distant in from the piston side faces and align the machined mark on the gudgeon pin end face in line with the piston axis pointing away from the cylinder.

12.

Torque cap screw and lock nut as appropriate. Refer to torque table Section 3, General Notes.

13.

Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.

14.

Lower cylinder into contact with crankcase

15.

Fit new gasket (100) between cylinder and cooler header. Do not grease gasket or faces.

16.

Fit bolts (101) and bright washers (102) through cooler header into cylinder and tighten finger tight.

17.

Fit concentric valve and cage assembly to cylinder as detailed in section 3.2.4.

18.

Torque bolts (101) to the appropriate level. Refer to torque table, Section 3 General Notes. Page 3-11

SECTION 3 - MAINTENANCE

19.

Reconnect water outlet pipework/hose to cylinder.

20.

Refit guard (170) to crankcase.

3.2.8

Final Stage Cylinder and Piston Removal

1.

Drain compressor of all cooling water. Remove water inlet connection from cylinder.

2.

Remove concentric valve (B1) and valve cage (70) assembly from cylinder (66) as detailed in section 3.2.5.

3.

Remove guard (170) from crankcase.

4.

Using a bar turn over the compressor until the second stage piston (60) is at the top of its stroke in the cylinder.

NOTE: If the first stage cylinder has been removed, take precautions to protect exposed first stage components in the crankcase. 5.

Remove the 2 screws (117) and washers (118) securing the separator assembly to the cylinder. Remove the separator from the cooler box by removing the bolts (112) and stud (113) securing the separator header (E1) to the cooler box (C1).

6.

Remove the bolts (106) securing the cooler header (93) to the cylinder.

7.

Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting tackle.

8.

Using lifting tackle and by striking the cylinder gently with a soft headed mallet, break the seals between the cylinder and crankcase, cylinder and separator, cylinder and cooler header.

9.

Lift and guide the cylinder off the piston assembly taking adequate precautions to prevent damage to the piston assembly as it becomes free from the cylinder.

WARNING: WITH CYLINDER REMOVED PROTECT PERSONNEL FROM INJURY FROM EXPOSED STUDS AT ALL TIMES UNTIL CYLINDER IS REASSEMBLED TO CRANKCASE. 10.

Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of compressor.

11.

Remove the two socket set screws (65) from the underside of the piston (60) which lock the gudgeon pin (64) in position.

12.

Supporting piston push gudgeon pin out of piston and connecting rod (19) taking care when pin frees connecting rod to prevent damage of rod striking piston internals and crankcase. Remove piston and gudgeon pin.

13.

Cover the crankcase aperture, connecting rod small end bearing, and passage ways on separator and cooler header.

14.

Examine removed components replacing worn/damaged parts as appropriate. For wear allowances see Section 4 - Technical Data.

NOTE: If required connecting rod small end needle roller bearing (21) may be removed and refitted without dismantling compressor any further. Section 3.2.15 refers to the procedure.

Page 3-12

SECTION 3 - MAINTENANCE

3.2.9 1.

Final Stage Cylinder and Piston Reassembly Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal the cylinder to the crankcase and retain the hexagon socket set screws in the piston. Minimum amount Loctite flange sealant 573 required is 50 millilitres. Minimum amount Loctite nutlock 243 required is 10 millilitres.

2.

Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease free.

3.

Remove all traces of gasketing on joint faces of cylinder to cooler header, cylinder to separator and separator to cooler box, and ensure surfaces are grease free. Do not smooth joint faces.

4.

Remove Loctite from threads in piston using a tap. If grub screws are to be re-used clean the threads using a die.

5.

If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.075/0.200mm (V150), 0.10/0.23 (V200/250) or 0.11/0.24 mm (V375). Ensure rings are fitted as follows to the piston. a.

Barrel faced ring top groove.

b.

Taper faced ring second groove (this ring can be easily identified against the barrel faced ring by the internal chamfer on the taper faced ring.)

c.

Both rings are to be fitted with the face marked “Top” facing towards the piston crown.

d.

S.O.C. ring bottom groove.

6.

Fit piston and gudgeon pin to connecting rod small end orienting piston and pin markings to front of compressor.

7.

Position gudgeon pin ends equally distant in from the piston side and align machined mark on gudgeon pin end face in line with piston axis pointing towards the crankcase.

8.

Clean threads and screws with Loctite Activator.

9.

Coat thread of one socket set screw (65) with Loctite nutlock 243 and fit to piston by gently pushing pin in from either end ensure screw engages in the counterbore in the pin.

NOTE: Loctite nutlock 243 may not cure on components under oily conditions - see General Notes, Section 3. 10.

Coat thread of second socket set screw (65) with nutlock and fit to piston.

11.

Align adjacent piston ring gaps on piston at 180° to each other.

12.

Using suitable lifting tackle align cylinder over studs (67) and onto piston, compressing rings to guide into cylinder.

13.

Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.

14.

Lower cylinder into contact with crankcase.

15.

Fit new gasket (105) between cylinder and cooler header (93), gasket (116) between cylinder and separator header (E1) and gasket (111) between separator and cooler box. Do not grease gasket or joint faces.

16.

Fit bolts (106) and bright washers (107) through cooler header (93) into cylinder and tighten finger tight. Page 3-13

SECTION 3 - MAINTENANCE

17.

Fit screws (117) and washers (118) through separator header into cylinder, tighten finger tight.

18.

Adjust gap between final stage cylinder and cooler header using feeler gauges, to give the best parallel flange seal. This can be achieved by rotating the cylinder to give an equal gap each end.

19.

Fit concentric valve and cage assembly to cylinder as detailed in section 3.2.5. Torque bolts (106 and 117).

20.

Reconnect water inlet connection to cylinder.

21.

Refit guard and tighten fasteners.

3.2.10 Cooler Tubenest and Header Removal 1.

Drain compressor of all cooling water.

2.

Remove gauge pipes.

3.

Remove the bolts (101) and washers (102) securing the cooler header (93) to the first stage cylinder (39).

4.

Remove the bolts (106) and washers (107) securing the cooler header to the second stage cylinder. Fit 2 x M12 eyebolts (V200/250/V375 only) (not supplied) in the top of the cooler header and suspend the header using a sling.

5.

Remove the remaining bolts (94) securing the cooler header.

6.

Remove cooler header (93) from tubenest (91) and cylinders by gently tapping with a soft headed mallet if necessary to separate the gaskets between the cooler header and tubenest, header and first stage cylinder, header and second stage cylinder.

7.

Remove tubenest (91) from cooler box by gently tapping tubeplate with a soft headed mallet to separate the gasket between the tubenest and cooler box.

3.2.11 Tubenest Clean/Examine/Replace 1.

Remove tubenest assembly.

2.

Clean the outside of the cooler tubes to remove all traces of scale or other foreign bodies taking care not to damage the cooler tube surface.

3.

Chemically clean the tube internals by ‘ARDROX’ or similar chemical cleaner.

4.

Examine tubes for signs of damage/reduction in tube wall thickness. If there is any doubt in the condition of the tubenest Hamworthy recommend replacement of the tubenest assembly. Faulty cooler tubes that are part of a ‘U’ tube nest formation cannot be removed individually, the complete tubenest assembly must be replaced.

Page 3-14

SECTION 3 - MAINTENANCE

3.2.12 Cooler Tubenest and Header Assembly to Compressor NOTE: The following procedure assumes that the first and final stage cylinder assemblies have been assembled to the crankcase. 1.

To assist alignment of gaskets, tubenest and header insert 2 lengths of studding (not supplied) into the top 2 outermost tapped holes in the cooler box front face.

2.

Ensure all the joint faces are clean and grease free. Do not smooth joint faces.

3.

Fit tubenest to cooler box gasket (90) over studs. Do not grease gasket.

4.

Fit tubenest (91) over studs.

5.

Fit cooler header to tubenest gasket (92) over studs. Do not grease gasket.

6.

Fit cooler header (93) over studs.

7.

Insert gasket (100) between header and first stage cylinder, loosely fit the bolts (101) and washers (102) through the header. Do not grease gasket.

8.

Insert gasket (105) between header and final stage cylinder, loosely fit the 3 bolts (106) and washers (107) through the header. Do not grease gasket.

9.

Loosely fit all but 2 of the bolts (94) and washers (95) through the cooler header and tubenest to the cooler box.

10.

Remove the lengths of studding used for guidance and insert the remaining 2 bolts and washers.

11.

Tighten the bolts (101 and 106) cooler header to cylinders. The bolts should be tightened to a torque of 170 Nm. This overrides the value in Table 3.1.

12.

Tighten the bolts (94) in the cooler header progressively in alphabetical order as shown until they are torqued correctly. The bolts should be tightened to a torque of 170 Nm. This overrides the value in Table 3.1.

13.

Re-connect the gauge pipes.

Figure 3.1 Cooler Header V150

Figure 3.2 Cooler Header V200/250/375 Page 3-15

SECTION 3 - MAINTENANCE

3.2.13 Cooler box end cover Removal 1.

Remove cooler drain plug (C6).

2.

Remove the bolts (C4) and washers (C5) and release cooler box end cover (C2).

3.

Clean and remove all traces of gasket (C3) from joint faces on end cover and cooler box. Ensure joint faces are grease/oil free. Do not smooth joint faces.

Re-assembly 4.

Assemble gasket (C3) between cover and cooler box. Note: Do not grease gasket or joint faces.

5.

Secure cover to cooler box with bolts (C4) and plain washers (C5). Fit cooler drain plug (C6) to cover.

3.2.14 Connecting Rod Big End Bearing Removal 1.

Drain compressor of cooling water.

2.

Drain oil and dispose of in accordance with local regulations.

3.

Remove the first and final stage cylinders and pistons as detailed in Section 3.2.6. and 3.2.8

4.

Remove the screws (157) and washers (158) securing the crankcase inspection cover.

5.

Using a soft headed mallet gently tap the side faces of the crankcase inspection cover to break its seal with the crankcase. Remove the cover.

6.

Remove screw (23), tab washer (24) and retaining washer (22).

7.

Using a puller over the second stage connecting rod (19) big end withdraw rod off crankshaft complete with cylindrical roller (big end) bearing (20).

8.

Remove spacer (18) from crankshaft.

9.

Using a puller as in 8 withdraw first stage connecting rod (15) complete with cylindrical roller (big end) bearing (16).

3.2.15 Bearing Removal and Reassembly to Connecting Rods NOTES: When the connecting rods have been removed both the big and small end bearings should be renewed. Gudgeon pins must always be replaced at the same time as the small end bearings. If the existing big end bearings are to be refitted, the inner race, rolls and bearing cage must be replaced in the original position. 1.

Press out the big and small end bearings from the connecting rod.

2.

Clean big and small end bores of connecting rod, ensure all trace of old retaining compound and any oil or moisture is removed from the big end bore, degrease if necessary.

3.

Remove big end bearing from its protective wrapping, clean/degrease outer diameter to remove all trace of oil or grease.

4.

The big end bearing is a transition fit to the connecting rod. Determine if the resultant fit is interference or clearance and fit accordingly as follows:

Page 3-16

SECTION 3 - MAINTENANCE

5.

Interference fit. a.

Coat outer diameter of big end bearing with Loctite 603 high strength retainer ensuring no retainer enters the bearing internals during this operation.

b.

Cold press the big end bearing into the connecting rod. Bearing must be fitted to the connecting rod in accordance with the following sketch ensuring that the NON CIRCLIP SIDE of the bearing is flush with the face shown.

Figure 3.1 Connecting Rod : V150

Machined dimple ref.

Figure 3.2 Connecting Rod : V200/250/375 Clearance fit: Fit as for an interference fit but support the bearing in position to ensure that the NON CIRCLIP SIDE of the bearing is flush with the face shown above until the Loctite 603 has cured sufficiently to retain the bearing in position. 6.

Lubricate small end bore of connecting rod and cold press small end bearing into the connecting rod ensuring that lubricating holes in bearing and con rod eye are aligned.

NOTE: On a V200/250/375 compressor only, the bearing is supplied as a matched pair and must be assembled as such. 3.2.16 Connecting Rod Assembly Fitment to Compressor NOTE: When the connecting rod has been fitted, it must be free to slide through the bearing range of side clearance, from shoulder to circlip. If this is not easily achieved the connecting rod must be removed, the bearing pressed out and the bore cleaned thoroughly prior to re-assembly. 1.

Remove pin (3). Screw a length of M16 x 2 x 185 mm long studding (not supplied) into the tapped hole in the crankshaft pintle.

2.

Arrange the first stage connecting rod (15) with the cast dipper rod pointing downwards and the small end through the crankcase aperture for the first stage cylinder. Align the big end bearing onto the crankshaft pintle. Using the retaining washer (22) and an M16 nut (not supplied) wind the nut onto the studding to push the big end bearing onto the pintle until the washer is flush with pintle end. Remove washer and nut.

3.

Align spacer (18) with big end bearing on pintle and push bearing and spacer onto pintle with washer and nut as described above.

4.

Repeat the procedure for the final stage connecting rod (19) until the assembly is pushed solidly against the shoulder on the crankshaft. Remove studding, nut and retaining washer. Page 3-17

SECTION 3 - MAINTENANCE

5.

Assemble retaining washer (22), new tab washer (24) and screw (23) to pintle. Tighten screw.

6.

Assemble first stage cylinder components to compressor as detailed in 3.2.7.

7.

Assemble second stage cylinder components to compressor as detailed in 3.2.9.

8.

Fit drain plug (160) to crankcase.

9.

Clean joint faces of crankcase inspection cover and crankcase. Apply loctite flange sealant 574 to cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and washers (158) refitting the 2 cable clips between washer and cover.

10.

Recommission compressor as detailed in section 1.

3.2.17 V150, V200, and V250 Drive Motor and Coupling Removal from Compressor For V375, see Section 3.2.19. 1.

Isolate compressor.

2.

On compressors fitted with water circulating pumps only, drain the cooling water.

3.

Place a suitable support under the crankcase close to its connection to the drive motor.

4.

For compressors mounted on anti vibration mounts, remove the fasteners securing the mount under the drive motor to the ship's deck, and for those compressors fitted with anti vibration mounts and a water circulation pump disconnect the water inlet connection to the pump and separate the male union nut on the connector (205) on the pump.

5.

For compressors not mounted on anti-vibration mounts remove the fasteners securing the drive motor to the ship’s deck.

6.

Remove the bolts (191) and washers (192) securing the drive motor to the crankcase.

7.

Using suitable lifting tackle, lift and slide the drive motor complete with drive coupling element (G1), coupling hub (G3), hexagon socket cap screws (G4) out of the crankcase.

8.

If required, remove drive coupling element (G1) from coupling hub (G3) by removing the hexagon cap screws (G4).

9.

If required, remove drive pins (G2) from flywheel.

3.2.18 V150, V200, and V250 Drive Motor and Coupling Assembly to Compressor For V375, see Section 3.2.19. Important notes for fitting Coupling In addition to the operational sequence 1 to 9 listed below the coupling must be assembled in accordance with the following notes: a.

The screws connecting the rubber element to the hubs must be tightened to the torque stated. Tightening torques which are too low will cause damage to the coupling. Ensure that on tightening the screws the aluminium bushes in the rubber part are not twisted. A small amount of grease should be applied under the head of the screw before fitting. Prevent twisting of the rubber part during tightening of the screws. This is particularly important with the radial screws. If the coupling is supplied in a pre-assembled state, do not dismantle it, but fit it in this condition.

Page 3-18

SECTION 3 - MAINTENANCE

b.

1.

2.

3.

Fit the hubs onto the motor shaft and lock using the grub screw. The radial bolt holes should be nearest the motor shaft face. Fit the axial bolts onto the flywheel. Position the element with the side having the rubber free face of the axial aluminium inserts towards the flywheel and, using the radial screws, mount it on the cylindrical hub. During this process, the rubber element is pulled together radially and receives its pre-load. Then push the coupled elements together, carefully sliding the coupling with light axial pressure onto the socket bolts. The rubber element is subjected to a little more radial compression by the socket bolts, and the pre-load is thus increased. The axial bores in the rubber element should be smeared lightly with grease beforehand to allow the socket bolts to slide easily in the inserts.

Figure 3.1 Coupling If removed, reassemble drive coupling pins (G2) to flywheel. Tighten coupling pins to a torque of 220 Nm. If removed, assemble drive coupling hub (G3) to drive motor shaft. To determine the coupling position on the motor shaft, measure the distance from the motor fixing flange to the flywheel. Position the coupling on the motor shaft to give a 1 - 2 mm gap between the coupling extremes (not the hub) and the flywheel, dimension (A).

Figure 3.2 Gap Between Coupling and Flywheel If removed assemble drive element (G1) onto hub (G3) with hexagon socket cap screws (G4). Tighten screws to a torque of 220 Nm (M16) or 500 Nm (M20).

4.

Lightly grease the coupling pins. Using suitable lifting tackle, lift and slide the drive motor whilst aligning the drive element with the coupling pins, slide the drive element onto the coupling pins and the motor flange location diameter on the crankcase.

5.

Fit bolts (191) and spring washers (192) through drive motors flange onto crankcase.

6.

Fit holding down bolts to drive motor or anti vibration mount.

Page 3-19

SECTION 3 - MAINTENANCE

7.

On compressors on anti vibration mounts and fitted with water circulating pumps, reconnect union nut and male connector (205) on the circulating pump and water inlet pipework.

8.

Remove support placed under crankcase.

9.

Recommission compressor as detailed in section 1.

3.2.19 V375 Drive Motor and Coupling Removal from, and Assembly to, Compressor See Figure 5.3, Figure 5.9, Figure 5.10. 3.2.19.1 V375 Drive Motor and Coupling Removal from Compressor Follow Steps 1 to 6 in Section 3.2.17. Then: 7.

Using suitable lifting tackle, lift and slide the drive motor complete with coupling hub (G3) out of the crankcase.

8.

If required, remove drive coupling element (G1) from flywheel (8) by removing the M10 screws.

3.2.19.2 V375 Drive Motor and Coupling Assembly to Compressor 1.

If removed, assemble drive coupling element (G1) onto flywheel (8) with M10 screws.

2.

Using suitable lifting tackle, lift and slide the drive motor whilst aligning the coupling hub with the drive coupling element, slide the coupling hub to engage into the drive coupling element and the motor flange location diameter onto the crankcase.

Then follow Steps 5 to 9 in Section 3.2.18. 3.2.20 Flywheel and Drive End Oil Seals Removal from Compressor 1.

Remove drive motor and coupling as detailed in section 3.2.17. Note drive pins (190B) need not be removed from the flywheel.

2.

Slacken the 7 clamp screws on drive bush (9).

3.

Lay two lengths of 3mm mild steel or similar angle (not supplied) of maximum leg length 30mm on the 2 rails in the crankcase under the flywheel. Alternatively, a fixture can be supplied by Hamworthy. See sketch. Table 3.1 Fixtures to Assist Flywheel Removal

Page 3-20

Machine

Fixture

V150

J31974

V200/250

J32032

V375

J32244

SECTION 3 - MAINTENANCE

4.

Figure 3.1 Location of Angle Steel on Crankcase Rails Remove 2 of the clamp screws and use in the tapped holes provided in the drive bush to jack the bush out of the flywheel. Remove drive bush and ease the flywheel onto the two pieces of angle (operation 3 refers.)

5.

Using suitable lifting tackle remove flywheel from crankcase. (Note tapped hole in periphery of flywheel is M12).

6.

Remove the screw (157) and washer (158) securing the crankcase inspection cover (155).

7.

Using a soft headed mallet gently tap the side faces of the crankcase inspection cover (155) to break its seal with the crankcase. Remove cover.

8.

Wedge a piece of clean bar (not supplied), through the front of the compressor between the crankshaft balance weight and one of the cast webs behind the balance weight to prevent the crankshaft from rotating.

9.

Remove grub screw (11). Using a c-spanner or similar tool (not supplied) unscrew the bearing adjustment sleeve.

10.

Lever lip seal (6) out of crankcase with an appropriate tool (not supplied) exercising caution not to damage the housing bore in the crankcase.

11.

Remove ‘O’ ring (7) from crankshaft.

3.2.21 Flywheel and Drive End Oil Seal Reassembly to Compressor 1.

Fit new radial shaft seal (5) to crankcase.

2.

Fit new ‘O’ ring (7) onto crankshaft adjacent to bearing taking care in passing over the thread on the crankshaft.

3.

Wedge a piece of clean bar (not supplied) through the front of the compressor between the balance weight and one of the cast webs to prevent the crankshaft from turning and carry out the following operation.

4.

Screw the bearing adjustment sleeve onto the crankshaft and engage with the drive end bearing. Use a c-spanner or similar implement (not supplied).

5.

Rotate assembly of crankshaft through two complete turns and check, by trying to rock the assembly, that the taper roller main bearings are seated correctly (i.e. little or no up and down movement of any part of the assembly).

6.

Attach a dial test indicator to the end face of the crankcase resting on the end of the crankshaft. Page 3-21

SECTION 3 - MAINTENANCE

7.

Push or pull the crankshaft balance weight and note the end float.

8.

An end float of between 0.05/0.10mm is required in the main bearings which is to be obtained as follows: a.

If the end float is greater than 0.10mm, using a c-spanner as in operation 4, screw the bearing adjustment sleeve further onto the crankshaft until the required end float is achieved. Rotate the assembly before each reading through two complete revolutions to centralise the bearings.

b.

If the end float is less than 0.05mm or the bearings are preloaded (no end float): Using a c-spanner as in operation 4 unscrew the bearing adjustment sleeve 90°. Lightly tap the drive end of the crankshaft to loosen the drive end main bearing inner race. If this technique does not loosen the bearing, the M16 tapped hole in crankshaft big end bearing pintle may be used to apply tension to crankshaft to loosen the bearing in conjunction with tapping the drive end. Carry out adjustment technique as in (a) until required end float is achieved. Replace grub screw (11).

9.

Position the pieces of angle along the rails in the crankcase (refer to section 3.2.19 operation 3). Using suitable lifting tackle locate flywheel onto the pieces of angle and ease the flywheel onto the crankshaft.

10.

Loosen the drive element clamping screws a couple of turns. Lightly oil the clamping element.

11.

Slide the clamping element onto the crankshaft and locate in the flywheel. Remove the screws from the release threads and screw into the clamping holes.

12.

Tighten the clamping screws diagonally by hand while aligning the hub. With a torque wrench tighten the clamping screws diagonally across with half the tightening torque (see below). Continue tightening but with the full torque. (35 Nm V150/200/250 or 71 Nm V375)

13.

Tighten the clamping screws one after the other, repeat several times. The tightening process is only completed when none of the screws can be tightened any further.

14.

Remove the pieces of angle or fixture placed over the rails in the crankcase.

15.

Check the flywheel alignment with a dial test indicator does not exceed 0.125mm. If this alignment is not achieved release the clamping screws, adjust the flywheel and re-tighten screws as above. Recheck flywheel alignment.

16.

Reassemble drive motor and coupling to compressor as detailed in section 3.2.18.

17.

Clean joint faces of crankcase inspection cover (155) and mating face on crankcase. Apply Loctite multi gasket 574 to cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and washers (158) refitting the 2 cable clips (156) between washer and cover.

18.

Recommission compressor as detailed in section 1.

3.2.22 Crankshaft and Main Bearing Removal from Compressor NOTE: If the main bearings are removed it is recommended that they are renewed. 1.

Remove first and second stage cylinders, connecting rods, drive motor and coupling, flywheel and oil seals as detailed in sections 3.2.6. 3.2.8, 3.2.14, 3.2.17 or 3.2.19, and 3.2.20 respectively.

2.

Screw a length of M16 x 2 studding (not supplied) into the tapped hole in the crankshaft. Place a bar or similar (not supplied) across open front of compressor and using an M16 nut (not supplied) exert a force onto the end of the crankshaft.

Page 3-22

SECTION 3 - MAINTENANCE

3.

Gently tap the drive end of the crankshaft with a soft headed mallet and tighten the nut as in operation 2, drive the crankshaft out of the inner race of the drive end taper roller main bearing.

4.

Taking care to prevent the drive end inner cage dropping off the crankshaft withdraw the crankshaft complete with non-drive end taper roller bearing inner race.

5.

Using a suitable puller (not supplied) or by levering on the inner race lip (not on the rollers) extract the non drive end taper roller bearing inner race from the crankshaft.

6.

Using a mild steel drift (not supplied) drift out the drive end and non drive end taper roller bearing outer races from the crankcase taking care not to damage the housing bore for the lip seal in the crankcase drive end.

3.2.23 Crankshaft and Main Bearings Reassembly to Compressor 1.

Before reassembly ensure crankcase internals and crankshaft are clean.

2.

Lightly oil the drive end main bearing location bore in the crankcase.

3.

Using a mild steel drift (not supplied), drift the outer bearing cup of the drive end main bearing (5) into position in the crankcase.

4.

Lightly oil the non drive end main bearing location bore in the crankcase.

5.

Fit non drive end main bearing (4) outer race in position as described in operation 3.

6.

Preheat non drive end main bearing inner race assembly to 140°C.

7.

Lightly oil crankshaft non drive end bearing journal location.

8.

Fit the heated inner race assembly on to the crankshaft journal and allow to cool before gently tapping home against shoulder with a mild steel sleeve drift (not supplied).

9.

Preheat drive end main bearing inner race assembly to 140°C.

10.

Insert crankshaft into crankcase, wedge crankshaft into position ensuring that the non drive end main bearing inner race assembly is mated correctly to the outer race.

11.

Lightly oil the crankshaft drive end main bearing journal.

12.

Fit the heated inner race assembly onto the crankshaft and into the bearing outer race.

13.

Refit oil seal and flywheel as detailed in section 3.2.20.

3.2.24 Oil Level Switch Remove/Clean/Replace 1.

Drain compressor of lubricating oil as detailed in section 3.2.2.

2.

Remove the DIN connector.

3.

Remove screw (142) and washer (143) securing dual oil level switch (140) to crankcase.

4.

Lever switch out of crankcase.

5.

Remove screws (2) and slide sleeve off body.

6.

Clean switch by removing all metallic particles.

7.

Reassemble switch, fit new O-rings (141), replace DIN connector and re-fill compressor with oil, refer to section 3.2.2. Page 3-23

SECTION 3 - MAINTENANCE

3.2.25 Air and Water Safety Valves These valves are all pre-set at the factory to suit the maximum working pressure duty of the compressor. The air safety valves are statically set at a pressure which equates to the 10% statutory over pressure requirement, making allowance for the dynamic pressure pulses found with the compressor. The safety valves must NOT be tampered with and it is recommended that a replacement valve should always be fitted if there is any doubt as to the valve's condition. Each valve is screwed into position. Water Jacket Safety Valve (145) Located on the cooler box behind the first stage cylinder. Associated joint washer (146). When replacing the water jacket safety valve ensure the outlet port is pointing downwards by using up to 3 joint washers. First Stage Air Pressure Safety Valve (147) Located on the front face of the first stage cylinder on the V200/250/375 and the rear face of the cylinder on the V150. Associated joint washer (148). Final Stage Air Pressure Safety Valve (149) Located on the inlet to the final stage separator. Associated joint washer (150). 3.2.26 Separator Bowl Removal, Spider Examination and Removal 1.

Disconnect the ‘Din’ plug from the solenoid coils (129).

2.

Disconnect the drain pipes from the bottom of the separators (if fitted).

3.

Remove the bolts (E6) and washers (E7) holding the separator bowl (E2) to the separator header (E1). Separate bowl from the header by gently tapping the bowl with a soft headed mallet. Note:It is advisable to leave 2 opposite corner bolts (E6) screwed into the bowl when splitting this assembly as this will take the weight of the bowl when it is free.

4.

Remove separator bowl.

5.

Clean and remove all traces of gasket from the joint faces of the header and bowl. Ensure faces are grease/oil free. Do not smooth faces, use Loctite ‘Chisel’ or similar.

6.

Inspect 1 and 2

7.

If the spiders are not solidly held in position, remove them by knocking them out with a bar placed through the bottom hole of the bowl.

8.

If the spiders are fixed solidly, re-assemble separator components as in 3.2.27.

st

nd

Stage separator spiders for looseness (E3 and E4).

3.2.27 Spider Fitting and Separator Bowl Reassembly 1.

Tap the spider tabs into the location grooves in the bow. Knock the spider from the bottom to straighten the tabs and ensure the spider is firmly positioned in the bowl.

2.

Position gasket (E5) over bowl (E2). do not grease gasket. Ensure faces are grease/oil free.

3.

Fit bowl (E2) to separator header (E1) using 6 bolts (E6) and washers (E7).

4.

Tighten the corner bolts and then the central ones progressively until they are torqued correctly.

5.

Fit separator drain pipes (if fitted).

Page 3-24

SECTION 3 - MAINTENANCE

6.

Fit solenoid coil ‘Din’ plugs (129).

3.3

WATER CIRCULATING PUMP (if supplied)

NOTE: The pump rotation is anti-clockwise looking on motor fan. 3.3.1

General Overhaul

After 3 - 4 years service the pump should be overhauled, to include changing the mechanical seal and motor bearings and cleaning. Check for wear and change worn pump parts. Always use new gaskets on reassembly. 3.3.2

Service Information

WARNING: BEFORE DOING ANY MAINTENANCE OR REPAIRS MAKE SURE THAT THE ELECTRICAL SUPPLY TO THE MOTOR IS ISOLATED AND CANNOT BE ACCIDENTALLY RECONNECTED. PREFERABLY PADLOCK THE ISOLATOR OR REMOVE THE FUSES. IF IN DOUBT CONSULT A QUALIFIED ELECTRICIAN. 3.3.3

Dismantling

Pump Head Close isolating valves, loosen the screws fastening the pump cover to the casing and lift the pump head assembly out of the pump casing. Impeller Remove impeller circlip and remove impeller and tolerance ring. Mechanical Seal Remove rotating part of seal. Unscrew motor flange bolts and remove the cover. Remove seat from cover. 3.3.4

Reassembly

Mechanical Seal Important: Mechanical seals are precision products and should be treated with care. Do not touch the faces with fingers - use a paper tissue. Clean seal recess in pump cover. Use a soap solution (do not use oil) on the rubber seal and press into the pump cover. Make sure that the shaft is clean and smooth and free from sharp edges. Fasten the pump cover to the motor flange. Mount the seal face ring on the bellows unit, taking care that the grooves in the face ring are in line with dimples in the retainer sleeve. Slide the assembly into place. Impeller Fit the tolerance ring onto the shaft. Push the impeller onto the shaft and fit the retaining circlip. The impeller will have pushed the rotating seal partly against the stationary part. Check that the impeller can be turned by hand. Casing Remove any significant volume of water from the casing. Use a new ‘O’ ring and refit the motor head assembly, tightening the screws evenly. Turn the shaft by hand to make sure that nothing is catching.

Page 3-25

SECTION 3 - MAINTENANCE

3.4

ELECTRICAL MAINTENANCE

It is recommended that switch settings are periodically checked. settings:

Refer to the separate data sheet for

Table 3.1 Switch Settings SWITCH

SETTINGS

Oil level switch

Activates when oil level falls below fill mark.

High air temperature switch

60°C alarm 80°C shutdown

Page 3-26

SECTION 3 - MAINTENANCE

3.5

FAULT FINDING CHART Table 3.1 Fault Finding Chart FAULT

POSSIBLE CAUSE

REMEDIAL ACTION

Final stage air safety valve blowing. Whilst in automatic (default) mode

Air system charged signal and final stage air pressure shutdown settings greater than safety valve set pressure

Reset signal pressure settings lower than safety valve set pressure (Note: maximum working pressure of compressor is 33 bar g)

Whilst running in manual mode

Stop valve closed in final air delivery pipework

Open all stop valves in pipework

Non-return valve installed incorrectly.

Correct installation.

Air system pressure safety devices set higher than safety valve setting.

Correct safety device pressure settings as appropriate.

First stage air safety valve blowing.

The first stage air safety valve is unlikely to operate when the compressor is running automatically as the compressor will be shut down by the high first stage air pressure transducer first. See below.

High first stage pressure (First stage air safety valve blowing)

Intercooler blocked

Remove cooler header and tubenest. Clean cooler tubes and first stage air passageways in header, cooler and first stage separator.

Suction side of final stage valve leaking Remove valve, clean/inspect/renew. Delivery side of final stage valve leaking

Remove valve, clean/inspect/renew.

Delivery side of final stage valve leaking to suction side

Remove valve cage, renew O-rings and check joint washers under dome nuts.

Internal knocking noise from Worn big or small end bearings compressor. Worn main bearings.

Strip down compressor, check crankshaft end float. Renew worn parts.

Damaged concentric valve.

Remove valves, clean inspect and renew if necessary.

Piston slap.

Remove cylinders, check clearances, renew worn parts (cylinder, piston rings.)

Worn drive element.

Renew drive coupling element.

Compressor will not achieve Concentric valves damaged or dirty. operating pressure or is operating at a reduced capacity.

Concentric valves require frequent cleaning.

Strip down compressor for inspection, renew worn parts.

Remove valves, clean inspect and renew if necessary. (note reduced capacity normally indicates first stage fault)

Solenoid drain/unload valve faulty.

Check solenoid valve function, renew parts as necessary.

Worn or damaged piston rings/ piston.

Remove cylinders, check rings are free in piston groove, renew worn, distorted or damaged rings, piston as appropriate.

Excessive cylinder component wear

Remove cylinders, renew cylinder, piston, rings as necessary

Suction filter/silencer blocked.

Renew element.

Non-recommended grade of lubricating oil used.

Drain lubricating oil, replace with recommended grade.

Concentric valves overheating.

Ensure concentric valves, cylinder components (cylinder, piston, rings) and cooling water system is maintained in good working order.

Excessive moisture in final Solenoid drain/unload valve faulty. air delivery pipe work and/or final stage cylinder/ intercooler. Unload drain cycle incorrect for operating conditions.

Check solenoid valves function, renew components as necessary.

Reprogram solenoid drain/unload valves “dwell” and “spit” times to suit operating conditions.

Oil seeping out from Drive end lip or O-ring seal adjustment underside of crankcase near sleeve to crankshaft leaking. drive motor.

Remove flywheel adjustment sleeve and drive lip seal and O-ring. Renew seal and O-ring. Refer to Section 3.2.15.

Water jacket safety valve blowing.

Excessive cooling water inlet pressure.

Reduce inlet pressure to 7 bar g maximum that compressor is suitable for.

Intercooler/aftercooler tube failure.

Remove cooler header and tubenest. Renew/refurbish tubenest.

Worn cylinder components.

Remove cylinders, check cylinder, piston, rings. Renew components as appropriate.

Excessive oil consumption.

Page 3-27

SECTION 3 - MAINTENANCE

3.6

TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE

C spanner 2" - 6"

Table 3.1 Tools Required for Compressor Maintenance TOOL V150 V200/250 ✓ ✓

V375 ✓

✓

✓

✓

D.T.I. and magnetic base

✓

✓

✓

3

13mm a/f x /8" square drive flank adaptor

✓

✓

✓

19 mm a/f x ½" square drive crowsfoot

✓

24 mm a/f x ½" square drive crowsfoot

n/a ✓

8" screwdriver

n/a ✓

n/a ✓ ✓

✓

Water pump pliers

✓

✓

✓

2 ½ lb steel lump hammer

✓

✓

✓

12" adjustable spanner

✓

✓

✓

Feeler gauges (0.02 - 1.0mm)

✓

✓

✓

24mm a/f combi spanner

✓

✓

19mm a/f combi spanner

n/a ✓

✓

13mm a/f combi spanner

✓

✓

n/a ✓

24mm a/f ½" square drive socket

✓

✓

19mm a/f ½" square drive socket

n/a ✓

✓

13mm a/f ¼" drive socket

✓

✓

n/a ✓

3mm a/f hexagon key

✓

✓

✓

4mm a/f hexagon key

✓

✓

✓

6mm a/f hexagon key

✓

✓

8mm a/f hexagon key 3mm a/f hexagon key x ¼" square drive

n/a ✓

n/a ✓

n/a ✓

4mm a/f hexagon key x ¼" square drive

✓

✓

✓

6mm a/f hexagon key x /8" square drive

✓

✓

8mm a/f hexagon key x ½" square drive

n/a ✓

n/a ✓

n/a ✓

3

/8" square drive torque wrench (8 - 54 Nm)

✓

✓

½" square drive torque wrench (30 - 150 Nm)

✓

✓

14mm a/f hexagon key x ½" square drive

✓

✓

17mm a/f hexagon key x ½" square drive

n/a

n/a

n/a ✓

¾" square drive torque wrench (up to 500 Nm)

n/a

n/a

✓

¾" square female x ½" square drive adaptor

n/a

n/a

✓

Fly press

3

¼" square drive torque wrench (4 - 20 Nm)

Page 3-28

✓

✓ n/a ✓

SECTION 4 - TECHNICAL DATA

SECTION 4 - TECHNICAL DATA 4.1

GENERAL

Compressor Type 4.2

V150/V200/V250/V375

PERFORMANCE

Maximum working pressure 4.3

33 bar.

OTHER DATA

Nominal Speed R.P.M.

Table 4.1 Capacity and Power at 30 Bar V150 V200 V250 V375 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800

Output 3 M /hour

80

100

120

150

110

132

166

200

137

165

207

250

208

250

310

375

Absorbed Power kW

17

20

25

30

22

26

33

39

28

33

41

49

40

48

60

72

Outputs quoted are bottle charging rates. Noise - 89 dB (A) at 1 Metre Table 4.2 Operating Parameters V150 V200/250 V375 Maximum air inlet temperature 50°C Maximum air outlet temperature 20°C over cooling water inlet Maximum water inlet pressure 7 bar g Maximum water inlet temperature 45°C Minimum water inlet temperature 5°C Cooling water outlet temperature 10°C above water inlet temperature Nominal cooling water flow rate 20/25 litres/minute 60/70 litres/minute 115/120 litres/minute Lubrication system Splash Sump capacity min. 3.5 litres min. 7 litres min. 9 litres max. 4.5 litres max. 8 litres max. 12 litres

Page 4-1

SECTION 4 - TECHNICAL DATA

Feature

Table 4.3 Recommended Maximum Wear Clearances Feature Measured Renew when

Note: All dimensions are in millimetres.

V150

V200/250

V375

First stage cylinder (Nominal bore V150 Ø180 / V200/250 Ø200 / V375 Ø260) Piston

A

Skirt Ø measured 15mm up from base

≤ 179.600

≤ 199.600

≤ 259.6

Cylinder bore

B

Maximum diameter at any point

≥ 180.250

≥ 200.250

≥ 260.25

Piston to cylinder bore

C

Clearance between measured values A & B

> 0.520

> 0.520

> 0.52

Piston ring width

< 3.335

< 3.335

< 4.835

E

Piston ring groove width

> 3.730

> 3.730

> 5.225

F

Clearance between measured values D and E

> 0.200

> 0.200

> 0.200

G

Piston ring gap when fitted to bore

> 1.07

> 1.150

> 1.450

Piston ring width

< 4.850

< 4.850

< 7.85

I

Piston ring groove width

> 5.194

> 5.194

> 8.184

J

Clearance between measured values H and I

> 0.250

> 0.250

> 0.250

K

Piston ring gap when fitted to bore

> 1.07

> 1.150

> 1.450

Gudgeon pin Ø

< 24.892

< 31.892

< 34.892

D Top and second piston rings, piston ring grooves.

Conformable slotted oil H control ring, piston ring groove

Gudgeon pin and small L end bearing

Final stage cylinder (Nominal bore V150 Ø75 / V200/250 Ø85 / V375 Ø110) Piston

M

Skirt Ø measured 15mm up from base

≤ 74.830

≤ 84.830

≤ 109.730

Cylinder bore

N

Maximum Ø at any point

≥ 75.164

≥ 85.164

≥ 110.164

Piston to cylinder bore

O

Clearance between measured values M & N

> 0.210

> 0.210

> 0.210

Piston ring width

< 2.350

< 2.350

< 2.850

Q

Piston ring groove width

> 2.660

> 2.660

> 3.160

R

Clearance between measured values P & Q

> 0.200

> 0.200

> 0.200

S

Piston ring gap fitted to bore

> 0.710

> 0.800

> 0.890

Piston ring width

< 4.850

< 4.850

< 4.850

U

Piston ring groove width

> 5.194

> 5.194

> 5.194

V

Clearance between measured values T & U

> 0.250

> 0.250

> 0.250

W

Piston ring gap fitted to bore

> 0.710

> 0.800

> 0.890

Gudgeon pin Ø

< 24.892

< 31.892

< 34.892

Top and second P piston rings. piston ring grooves

Conformable slotted oil T control ring, piston ring groove

Gudgeon pin and small X end bearing

Page 4-2

SECTION 4 - TECHNICAL DATA

4.4 4.4.1

CRANKCASE LUBRICANTS Approved Oils

Shell Corena Oils P100 Castrol Aircol SN100 Extensive tests have been carried out on the V-Line compressor using Shell Corena P100 (mineral) and Castrol Aircol SN100 (synthetic) lubricants. These oils have been found to give good results over extended service and Hamworthy recommend their use to ensure satisfactory operation of the compressor. 4.4.2

Oil Company Equivalents

The following lubricants have not been tested by Hamworthy with the V-Line compressor, but are offered as equivalents by the oil companies. Table 4.1 Oil Company Equivalents Mineral Oils Supplier

Oil Type

BP

Energol RC 100

Castrol

Aircol PD 100

Esso

Exxcolub 100

Mobil

Rarus 427

Texaco

R & O 100

Synthetic Oils Supplier

Oil Type

BP

Enersyn RX 100

Esso

Synesstic 100

Mobil

Rarus 827

Texaco

Cetus, DE100

The V-Line compressor is designed to achieve the best possible results using mineral oils. A recommended lubricating oil should be used at all times to ensure safe and efficient operation with minimum wear. The suggested maintenance intervals are based on the results of extensive tests using Shell P100 mineral oil. Specific measures have been taken to ensure extended service before components need cleaning to remove carbon. Hamworthy recommend the use of mineral oil as the most economic lubricant. If synthetic oils are to be used the following maintenance revisions are necessary. 4.4.3

Additional Maintenance for Machines Lubricated with Synthetic Oils

Initial run and oil change periods to be as detailed in Maintenance section. After initial 500 running hours using mineral oil lubricant: 1.

Drain the old mineral lubricant completely whilst the oil is warm.

2.

Thoroughly clean the crankcase sump.

3.

Inspect and thoroughly clean compressor valves (as detailed in Maintenance section).

4.

Replace all items removed, renew any damaged seals or gaskets.

5.

Refill with synthetic oils, and run as normal. Page 4-3

SECTION 4 - TECHNICAL DATA

Page 4-4

SECTION 5 - DRAWINGS

SECTION 5 - DRAWINGS

1

9

8

4

2 10

3

5

11 13 12 7

6

Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges

Page 5-1

SECTION 5 - DRAWINGS

Table 5.1 List of Parts for Figure 5.1 Ref Description 1

Gauge panel

2

Suction filter silencer

3

First stage safety valve

4

Final stage safety valve

5

Dual level oil switch

6

Oil drain plug

7

Oil filler/dipstick

8

Final air delivery

9

Motor terminal box

10

Lifting lugs

11

Inter and final stage separator

12

First stage solenoid drain valve Final stage solenoid drain valve

13

Notes on Figures (C)

Parts fitted to controller model only

(E.M.) Parts fitted to electro-mechanical model only Where parts are specific to a particular model, applicable model numbers are shown next to the item number. Figure 5.3 Crankshaft and Flywheel: For V375, the Drive Coupling Sub-assembly (190) is detailed in Figure 5.9, and the flywheel (8) is shown in Figure 5.10 Figure 5.7 Gauges: For V150, copper pipe links adaptors (282), via ball valves (298), to gauges. For other models, copper pipe runs from adaptors beneath the cooler header (93), via ball valves (298), to gauges.

Page 5-2

SECTION 5 - DRAWINGS

Figure 5.2 Cooler

Page 5-3

(V150 ONLY)

SECTION 5 - DRAWINGS

Figure 5.3 Crankshaft and Flywheel See Notes on page 5-2

Page 5-4

SECTION 5 - DRAWINGS

F8 (V150) 168 (V200/V250/V375) F7 (V150) 169 (V200/V250/V375) F6 (V150) F5 (V150) 165 F4 (V150) F3 (V150) F2 (V150) 167 (V200/V250/V375)

F10

(V150)

F2

(V200/V250/V375)

F11

(V150)

F3

(V200/V250/V375)

F1 166 F9

(V150)

A2 56 57 43

46

54

53

55

32

45 48

145

(V150)

146

(V150)

52 54 50

132 300

(E.M.)

51

133 298

(E.M.)

100 39 145 (V200/V250/375) 146 (V200/250/375) 38 37 36 35 42 41 40 17 15 16

Figure 5.4 First Stage Cylinder and Piston

Page 5-5

SECTION 5 - DRAWINGS

79 80 73 70 71 72 77 B2

75

78

81 76 67

105 66 152 151

60 65

63 62 61

19 21 64 20

Figure 5.5 Final Stage Cylinder and Piston

Page 5-6

SECTION 5 - DRAWINGS

(E.M.)

(C)

(E.M.)

(C)

(C)

(C)

Figure 5.6 Separator

Page 5-7

SECTION 5 - DRAWINGS

Figure 5.7 Gauges See Notes on page 5-2

Page 5-8

SECTION 5 - DRAWINGS

Figure 5.8 Cover Assembly for Electronic Controller Model

Page 5-9

SECTION 5 - DRAWINGS

Figure 5.9 V375 Drive Coupling Element and Coupling Hub (Drawing 641600, Issue 1)

Page 5-10

SECTION 5 - DRAWINGS

Figure 5.10 V375 Flywheel (Drawing 3416300401, Issue 1)

Page 5-11

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors NOTE: Where two numbers are shown in the quantity column the first quantity is for the V150 compressor, the second refers to the V200/250/375 compressor. Where the quantity for the V375 is different it is shown in brackets. Items shown in italics apply only to the electronic controller model, and are listed at the end. Ref 1 2 3 4 5 6 7 8 9 10 11 15 16 17 18 19 20 21 22 23 24 30 32 35 36 37 38 39 40 41 42 43 45 46 48 50 51 52 53 54 55 Page 5-12

Description Crankcase Crankshaft Pin spring tension Bearing taper roller (main non drive end) Bearing taper roller (main drive end) Oil seal ‘O’ ring (adjusting sleeve to bearing & crankshaft) Flywheel Bush cone clamping elements Bearing adjusting sleeve Socket set screw Connecting rod (1st stage) Bearing - big end cylindrical roller Bearing - small end needle roller Spacer - connecting rod/crankshaft Connecting rod. (2nd stage) Bearing - big end cylindrical roller. Bearing - small end needle roller. Clamping washer - c/shaft-conn. Rod Set screw Tab washer

Quantity 1 1 1 1

Hose connector (not V375) Hose (crankcase breather) (not V375) Piston (first stage) Piston ring SOC Piston ring taper faced Piston ring barrel faced Cylinder (first stage) Gudgeon pin (first stage) Hexagon socket set screw Locknut Stud (first stage cylinder assembly to crankcase) Valve cage (first stage) Hose connector (not V375) ‘O’ ring (first stage valve cage to cylinder) Concentric valve (first stage) assembly A ‘O’ ring (first stage concentric valve outer groove to cylinder) ‘O’ ring (first stage concentric valve top face to valve cage) Joint washer Stud connector (not V375) Bright washer (not V375)

1 30 cm 1 1 1 1 1 1 2 1 4

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 4 (8) 1 1

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors (Cont’d) Ref Description Quantity 56 Nut 4 57 Bright washer 4 59 Socket set screw (V375 only) 2 60 Piston (second stage) 1 61 Piston ring S.O.C 1 62 Piston ring taper faced 1 63 Piston ring barrel faced 1 64 Gudgeon pin (second stage) 1 65 Socket set screw 2 66 Cylinder (second stage) 1 67 Stud (second stage cylinder 4 Assembly to crankcase) 70 Valve cage (second stage) 1 71 ‘O’ ring (second stage valve 1 Cage top groove to cylinder) 72 ‘O’ ring (second stage valve cage 1 Bottom groove to cylinder) 73 Plug 1 75 Concentric valve (second stage) 1 Assembly B 1 76 ‘O’ ring (second stage concentric 1 Valve outer groove to cylinder) 1 77 ‘O’ ring (second stage concentric 1 Valve top face to valve cage) 1 78 Joint washer 4 79 Nut 4 80 Bright washer 4 81 Anti-extrusion ring (V375 only) 1 85 Cooler box assembly C 1 86 Eyebolt 1 87 Set screw/bolt 4/3 88 Spring washer 4/3 90 Gasket (tubenest to cooler box) 1 91 Tubenest assembly 1 92 Gasket (tubenest to cooler header) 1 93 Cooler header 1 94 Bolt/adjusting screw 13 95 Bright washer 13 100 101 102 105 106 107 110 111 112 113 114 115 116

Gasket (cooler header to first Stage cylinder) Bolt Bright washer Gasket (cooler header to Second stage cylinder) Bolt Bright washer Separator assembly E Gasket (separator /header -cooler box Bolt Bolt/stud Bright washer Nut (not V200/250) Gasket (separator assembly to Second stage cylinder)

1 3/4 3/4 1 3 3 1 1 3 1 4 1 1

Page 5-13

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors (Cont’d) Ref Description Quantity 117 Set screw 2 118 Bright/spring washer 2 120 Joint washer 3 121 Adaptor 1 122 Joint washer 1 123 125 126 127 128 140 141 142 143 145 146 147 148 149 150 151 152 153 154 155 156 157 158 160 161 165 166 167 F2 168 169 170 171 172

Page 5-14

Solenoid valve body First stage drain/unload Washer (V375 only) Nipple Nipple Solenoid valve Final stage drain/unload Oil level switch - crankcase ‘O’ ring (oil switch ) Set screw Bright washer Safety valve (air 1st stage cylinder) Copper washer Safety valve (water jacket safety) Copper washer Safety valve (Air final stage cylinder) Copper washer Plug Joint washer Plug Joint washer Inspection cover Cable clip Set screw Bright washer Magnetic drain plug with seal Oil filler/dipstick Studding Suction filter/silencer assembly F Filter element (V200/250/375 only) Filter element (V150 only) Wing nut (V200/250/375 only) Bright washer (V200/250/375 only) Guard – crankcase Screw Spring washer

1 3 1 1 1 1 2 1 1 1 3 1 3 1 3/1 2 2 2 2 1 2/3 4/6 4/6 1 1 1 1 1 1 1 1 1 1 1

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors (Cont’d) Ref Description Quantity 181 Badge (not shown) 1 190 Drive coupling sub-assembly G 1 191 Bolt/set screw 4/8 192 Spring washer 4/8 194 Motor packing piece (V200/250 only) 2 195 Mounting plate drive motor 1 196 Mounting plate drive motor 1 (Water circulating pump models only) 197 Bolt 2 198 Nut 2 199 Spring washer 2 200 Water circulating pump 1 201 Bolt 4 202 Spring washer 4 203 Bolt (not shown) 2 204 Spring washer (not shown) 2 209 Straight male union Connector 1 210 Joint washer 1 212 Packing piece (V150 only) 2 213 Anti-vibration mount 2 214 Bolt 2 215 Spring washer 2 216 Anti-vibration mount 1 217 Screw 1 218 Spring washer 1 222 Flexible hose (water inlet) To final stage cylinder/ Circulating pump * 1 224 Joint washer (hose to 1 cylinder/circulating pump) 225 Flexible hose (water outlet from first stage cylinder) * 1 227 Joint washer (hose to cylinder) 1 228 Flexible hose (final air delivery) * 1 229 Joint washer (hose to separator) 1 230 Nameplate (not shown) 1 231 Hammer drive screw (not shown) 4 247 Electrical terminal box 1 266 Bolt 1 273 Plug 1 274 Joint washer 1

Page 5-15

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors (Cont’d) Description Quantity Ref COMPRESSOR WITH GAUGES 280 Pressure gauge (direct mount) 0 – 10 bar 1 281 Pressure gauge (direct mount) 0 – 60 bar 1 282 Adaptor 2 283 Joint washer 2 284 Pressure gauge (panel mount) 1 0 –10 bar 285 Pressure gauge (panel mount) 1 0 – 60 bar 286 Gauge panel 1 287 Set screw 2 288 Bright washer 2 289 Legend plate 1 290 Legend plate 1 291 Drive screw 4 292 Copper pipe assembly 50/60 cm 293 Copper pipe assembly 50/60 cm 294 Male stud coupling 2 295 Female stud coupling 2 296 Leather washer 2 298 Joint washer 4(1) 300

Plug

COMPRESSOR WITH MANUAL DRAINS 301 3 way equal tee 302 Adaptor

Page 5-16

2

1 1

304 305 306 307 311 312 315 317

Hex adaptor Ball valve Ball valve Joint washer 3 way equal tee Adaptor Ball valve Joint washer

1 1 1 1 1 1 1 1

320 321

Temperature switch Joint washer

1 1

CONCENTRIC VALVE (1ST STAGE) ITEM 50 Concentric valve body assembly A1 Dome nut A2

1 4(8)

CONCENTRIC VALVE (2ND STAGE) ITEM 75 Concentric valve body assembly B1 Dome nut B2

1 4(6)

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors (Cont’d) Description Ref COOLER BOX SUB-ASSEMBLY ITEM 85 Cooler box C1 Cover cooler box end C2 Gasket (cover cooler box C3 end to cooler box) Bolt C4 Plain washer C5 Plug C6 Joint washer C7 Plug C8 Joint washer C9 Bleed Valve C10 Joint washer C11 SEPARATOR SUB-ASSEMBLY ITEM 110 Separator header E1 Separator bowls and spiders E2 Separator spider (first stage) E3 Separator spider (second stage) E4 Gasket (separator header E5 to separator bowls) Bolt E6 Plain washer E7 DRIVE COUPLING SUB-ASSEMBLY ITEM 190 Drive coupling element (V200) G1 Drive coupling element (V250) G1 Drive pin (not V375) G2 Drive coupling hub G3 Hexagon socket cap screw (not V375) G4 SEALANTS/RETAINERS Loctite 603 high strength J1 Retainer 10ml size Loctite 243 thread locker 10 ml size J2 Loctite 573 flange sealant 50 ml size J3 Loctite 574 multi gasket 50 ml size J4

Quantity 1 1 1 11/9 11/9 1 1 1 1 1 1

1 1 1 1 1 6 6

1 1 4 1 4

1 1 1 1

Page 5-17

SECTION 5 - DRAWINGS

Table 5.2 List Of Parts – V-Line Compressors (Cont’d) ELECTRONIC CONTROLLER MODEL 130 Temperature sensor 0 - 100°C Final air delivery (cooler box) 131 Joint washer 132 Temperature sensor 0 - 60°C Water out (first stage cylinder) 133 Joint washer 135 Pressure transmitter (First stage air) 137 Pressure transmitter (Second/final stage air) 175 Cover/electrical sub assembly 176 Cover base 178 Set screw/bolt 179 Bright washer 182 Cover assembly 187 Plastic screw 188 Plastic washer 236 Joint washer 241 Joint washer 245 Set screw 246 Spring washer 248 Brass stud 249 Brass washer 250 Hex nut 251 Brass washer 252 Lockwasher 253 Brass washer 254 Nut 255 Nut 258 P clip 259 Screw 262 P clip (V200/250/375 only) 263 Screw (V200/250/375 only)

Page 5-18

1 1 1 1 1 1 1 1 4 4 1 4 4 1 1 4/1 4/1 1 1 1 1 1 1 1 1 1 1 2 1

Instruction manual

Piston compressor W55

Type

Instruction manual

W55

Piston Compressors

INTRODUCTION: This Instructions Manual contains a brief technical description and important instructions on commissioning, maintenance and servicing of the compressor. We recommend to read this manual carefully in order to be able, in case of trouble, to detect the cause quickly and care for remedy and, in case of repairs, to make provisions for proper mounting acc. to the instructions. This manual assumes a general technical knowledge of piston compressors and does not claim to be complete. If repairs become necessary, only original HATLAPA spare parts must be used in order to maintain the operational reliability and efficiency of the machine. For identification and supply of spare parts, an order must contain the following information: 1. Serial No. and type designation (see name plate). 2. Ident No. from the spare parts list. 3. Method of the required dispatch, as well as consignee and address for the invoice. 4. Name of the vessel (ex-name), Yard No., and Shipyard. In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5-7 · D-25436 Uetersen / Germany D-2549 Uetersen / Germany Phone: Telex: Cable: Fax: E-mail: Internet:

(+49) 4122 / 711- 0 218510 htlu d HATLAPA Uetersen (+49) 4122 / 711 - 330 [email protected] http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/co-operators as per attached list. We wish to point out that repairs and/or modifications to the compressor which are carried out without our approval during the guarantee period, will release us from our guarantee obligations. The manufacturer cannot be rendered liable for damage to the compressor which can be shown to have been caused by the use of unsuitable lubricants or failure to comply with the operating instructions. Reprint of the text or illustrations, or even extracts therefrom is prohibited. Subject to alterations at all times due to technical development.

TABLE OF CONTENTS:

2

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

Page: Introduction....................................................................................................................2 1 Description ..................................................................................................................4 1.1 Design .......................................................................................................................4 1.2 Specifications ............................................................................................................4 1.3 Working method ........................................................................................................5 1.4 Cooling ......................................................................................................................5 1.5 Lubrication of Working Parts .....................................................................................5 1.6 Cylinder lubrication ....................................................................................................6 1.7 Condensate Separation .............................................................................................6 1.8 Starting without Back-Pressure .................................................................................6 2 Setting-up and installation.........................................................................................7 3 Commissioning...........................................................................................................8 3.1 Safety References .....................................................................................................8 3.2 Before Starting...........................................................................................................9 3.3 After Starting..............................................................................................................9 3.4 During Operation .......................................................................................................9 3.5 After Stopping..........................................................................................................10 4 Servicing and Maintenance .....................................................................................11 4.1 General Servicing Instructions.................................................................................11 4.2 Servicing Schedule ..................................................................................................12 4.3 Overhaul of Valves ..................................................................................................14 4.4 Overhaul of Pistions and Cylinders..........................................................................14 4.5 Overhaul of crankshaft and connecting rod .............................................................17 4.6 Protection against Corrosion during prolonged Shut-Down .....................................18 5 Trouble Shooting ......................................................................................................19 6 Spare Parts................................................................................................................20 7 Instructions for Correctly Ordering Spare Parts....................................................21

Rev.: 15.04.1999

3

Type

Instruction manual

W55

Piston Compressors

1 Description 1.1 Design The compressor W55 is a single-cylinder, two-stage, water-cooled differential compressor with upright cylinder. Direction of rotation of the crankshaft – looking towards the flywheel – is clockwise in standard design (see arrow indicating direction of rotation). The equalization of mass of the crank mechanism guarantees low vibrations during operation and enables a resilient mounting without any problems.

1.2 Specifications Typ

W55

Cylinder Bore 1st Stage [mm]

114

Cylinder Bore 2nd Stage [mm]

98

Piston Stroke [mm]

78

Crankshaft-Axial Clearance [mm]

0,20,3

Quantity of Lub. Oil min. [l]

0,75

Quantity of Lub. Oil max. [l]

1,25

Weight without E-Motor [approx. kg] 100

4

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

1.3 Working method The compressor compresses the ambient air sucked in through the air-intake filter with silencer in two stages to the selected final pressure. Concentric ring plate valves with large flow cross-sections control automatically the gas exchange in the compression chambers. After every stage the heated compressed air flows through a large-dimensioned cooler. To monitor the correct functioning of the compressor pressure gauges are installed after each compression stage. Safety valves, installed, prevent the pressure from rising above the admissible limit.

1.4 Cooling The heat created in the compressor by air compression and mechanical friction, is dissipated to the cooling water. Check immediately after starting whether sufficient cooling water is delivered to the compressor. This is done at the cooling water inspection glass or at the discharge funnel. Under regular operating conditions and with the prescribed cooling water supply as well as with clean cooling chambers, the temperature rise between cooling water inlet and outlet is 10 to 15° C. The temperature of the cooling water must not exceed 50° C at its outlet. A thermometer and a temperature control switch should be provided for controlling the temperature of the discharged cooling water at the outlet pipe.

1.5 Lubrication of Working Parts Only compressor oils according to the enclosed oil specification chart may be used. The lubrication of all working parts is carried out automatically by a lubricating pin fitted to the lower part of the connecting rod. This dips into an oil bath and splashes the oil upwards..

Rev.: 15.04.1999

5

Type

Instruction manual

W55

Piston Compressors

1.6 Cylinder lubrication The first stage of the cylinder is lubricated by oil mist. The oil mist passes through a connecting pipe between crankcase and suction chamber, and is sucked through the combined suction and pressure valve into the cylinder. Faultless oil mist lubrication is guaranteed with a closed crankcase only.

1.7 Condensate Separation Together with the moist ambient air which is sucked in, water enters the compressor in form of vapour. By compression and subsequent cooling of the compressed air, this water vapour condenses. The water separated from the compressed air blends with the oil which is entrained in very small quantities from the lubricated working surfaces of the cylinders. This water-oil mixture is extracted from the compressed-air stream after the 1st and 2nd stage in special condensate collector chambers. At regular intervals – after every 15 min. for about 10 sec. - as well as on starting and stopping of the compressor, the collector chambers must be drained by opening the manual valves or optionally by automatic devices. Such condensate separation reduces wear and tear due to corrosion in the compressor components, and in the connected pipelines and prevents the compressor from damage due to water shocks. Disposal of the condensate has to be carried out according to the locally valid prescriptions.

1.8 Starting without Back-Pressure During starting-up, the driving motor must be unloaded by opening the drain valves. In automatically controlled compressors, unloading is effected by time-lagged closing of these valves.

6

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

2 Setting-up and installation The compressor is driven by a directly-coupled electric motor through a flexible coupling, the shaft centres of motor and compressor must lie in exactly the same axis. Under no circumstances may the shaft centres be offset. The common baseplate for motor and compressor is torsion-free and must be properly aligned to the ships foundation and fully supported at all points. If the foregoing instructions are disregarded and if there are differences caused by modifications to the ship´s foundation or the common baseplate or due to other causes, this may result in inadmissible strain on the shafts due to incorrect alignment. In case of resilient mounting there must be sufficient room for movement. All pipelines must then be connected to the consumer system by flexible hoses, strictly adhering to the installation instructions. All drain pipelines are to be laid with constant descent and must discharge into an open funnel after the shortest possible distance. Each compression stage needs a separate drain pipeline in order to guarantee perfect drainage of the individual stages; stop valves are to be installed as closely as possible to the compressor. Further instructions on the installation of valves, pipelines, and control equipment are to be taken from the enclosed piping diagrams with their respective descriptions.

Rev.: 15.04.1999

7

Type

Instruction manual

W55

Piston Compressors

3 Commissioning 3.1 Safety References The compressor has been produced according to the State-of-art and is operationally reliable. The compressors are a source of danger if inexpertly or improperly used.

8

•

Only authorised and trained persons are allowed to operate and repair the machine or to do maintenance work. Make sure that these persons have read and understood the complete operating instructions and safety instructions.

•

The compressor may only be used for compressing air.

•

The compressor may not be operated without safety or protecting devices.

•

Only sealed safety valves may be used, readjustment is not allowed. They have to be replaced immediately when defective.

•

Before starting any maintenance work it is necessary to stop the compressor system and to prevent it from re-starting. The system has to be voltage–free, all parts containing compressed air have to be depressurized.

•

The compressor system may only be operated in perfect working condition. It must be free of foreign parts.

•

Rebuilding or any other changes to the compressor system that may influence the safety are strictly prohibited.

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

At initial commissioning, after a several months` interruption in operation, or after extensive repair work the operator must observe the following points (see also 4.6 Protection against corrosion during prolonged Shut-Down). 3.2 Before Starting •

The compressor must be filled to the upper oil level mark with prescribed compressor oil (see list of recommended oils).

•

Check that the crankshaft is moving easily by turning over the flywheel by hand; but make sure that the compressor set cannot be started unintentionally.

•

Open the shut-off valve in the pipeline leading to the compressed-air receiver.

•

Open drain valves.

•

Open the shut-off valves in the cooling water pipes.

3.3 After Starting •

Check the direction of rotation of the shaft (see also arrow).

•

Check the cooling water flow.

•

Close the drain valves and check for leakage.

3.4 During Operation •

Once the final pressure is attained, check the safety valves for proper functioning: Slightly turn the knurled nut until the valve blows off. After closure, check for leakage.

•

After fitting of new working parts (repair), run in the compressor for about one hour at low final pressure (5 to 10 bar).

Rev.: 15.04.1999

9

Type

Instruction manual

W55

Piston Compressors

3.5 After Stopping

10

•

Open the drain valves at the condensate separators.

•

Check that the automatic drain valves open properly.

•

Check the non-return valve in the pipe to the compressed-air receiver for leakage.

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

4 Servicing and Maintenance For trouble-free operation, it is necessary to check regularly and carefully the safety devices and the wear and tear parts of the compressor as well as the functioning of fitted valves and instruments. Regularly check the stock of spare parts and seals which must be protected against corrosion, and stock up to the specified quantity again after any servicing and overhaul work. The following maintenance and overhaul instructions must be adhered to. However, they do not claim to be complete. Observance of the servicing intervals as mentioned below guarantees great reliability and long service life of the compressor. In this connection, reference is made to the requirements of the rules of the classification societies and seafarer unions. 4.1 General Servicing Instructions a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil, however, not exceeding the top oil level mark. Too much oil results in foaming due to immersion of rotating parts, with the compressor at extremely inclined position. Intense misting of the oil and uncontrolled cylinder lubrication would result in increased oil consumption and coking of the working valves. b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot from running - and fill in fresh compressor oil . c) Regularly and carefully check the the air pressure of all stages. Varying operating pressure values indicate anomalies in the valves, as well as leaks in the piping system. d) At regular intervals dismantle and strip down the combined suction and pressure valves and clean all parts. Packing rings between valve and cylinder head must be replaced in sets only. For details, see „4.3 Overhaul of Valves„. e) Check the safety valves on the compressor by slightly turning the knurled nut at short intervals.

Rev.: 15.04.1999

11

Type

Instruction manual

W55

Piston Compressors

4.2 Servicing Schedule After first commissioning, after a general overhaul, and after repairs to the crank mechanism or cylinder, the following maintenance work should be done: After 100 working hours 1.) Change the oil. 2.) Check the safety valves. 3.) Check the bolts and nuts on crankcase, cylinders, and pipelines for tightness (See list of tightening torques). 4.) Check the drainage system.

After that the following intervals are to be kept: After every 500 working hours: 1.) Check the safety valves 2.) Check and clean the cooling water chambers and pipes 3.) Check and – if necessary – replace the zinc protection 4.) Check the drainage system

After every 1000 working hours (however, at least once a year): 1.) Change the oil. 2.) Clean the air-intake filter

12

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

After every 1000 working hours: 1.) Clean the combined suction and pressure valves and check for wear. 2.) Check parts which come into direct contact with hot compressed air, such as valves, cylinder heads and compressed-air pipelines for carbon residues and, if necessary, clean them with solvents.

The admissible servicing intervals of the valves are determined above all by the operating conditions and by the properties of the lubricant used. We recommend to reduce the servicing intervals in case of severe operating conditions.

Rev.: 15.04.1999

13

Type

Instruction manual

W55

Piston Compressors

4.3 Overhaul of Valves The suction and pressure valves of the compressor require conscientious care and maintenance. Their springs and plates are the most intensely stressed parts of the compressor. For cleaning, the concentric valves have to be dismantled by removal of the fitting bolt. Soaking of the components in paraffin facilitates removal of coked deposits. Care should be taken that the ground sealing surfaces, and valve plates are neither scratched nor damaged. Springs and valve plates should be checked for damage and wear and replaced, if necessary. For reassembly, adhere strictly to the assembly diagram (parts list). Parts of different valves must not be mixed. Tighten the fitting bolt with the prescribed torque. After reassembling check the soft running of the valve plates against the spring pressure using a rounded pin. Valves or valve parts must be clamped in a vice with smooth jaws only. When fitting the valves, use new packing rings in sets and see that they are properly positioned.

4.4 Overhaul of Pistions and Cylinders All components must first be marked so as to maintain pairings (assignment of pistons and cylinders) and the positioning of the parts for reassembly. To measure clearance and wear, first of all, all parts must be cleaned and checked for damage. The measurement of the cylinder diameter is carried out using a precision internal gauge applied in the operational way of the piston rings. To check the joint clearance, the piston rings should be inserted at a right angle into the upper cylinder aperture and positioned at a location where the cylinder liner shows no signs of wear. The joint clearance is measured using a feeler gauge. Parts, which have reached or exceeded their service life (see List of Wear Limits), should be replaced. When re-installing the cylinder liner, the overflow bore holes in the area of the 2nd stage valve must match.

14

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

When fitting the cylinder liner the bearing surfaces in the cylinder block must be cleaned and applied with sealing grease so that the liner slides into the cylinder without dislodging the O-rings. Only grease may be used which is non-aggressive to the O-rings. Do not grease the cylinder liner, otherwise the grease will be pushed up when fitting the liner, preventing correct contact at the cylinder recess. When fitting the piston observe Fig. Piston Assembly. Clean the piston again after having removed the piston rings by means of piston ring pliers. Oil must be applied to piston and piston rings before the piston is fitted back into the cylinder. The piston must be installed with mounted connecting rod. When fitting the piston proceed as follows: Before fitting make sure that the joints of the rings are staggered and that they are on alternate sides, outside the overflow bore holes for the valves 2nd stage. Take care that the piston rings, particularly those of the 2nd stage, are placed centrically in the piston. Regular radial projection is absolutely necessary, when assembling see detail at "A" of Fig. "Piston Assembly" . Insert the well-oiled piston with its rings and connecting rod from the top of the cylinder liner. Once the piston rings 1st stage have been introduced, the piston has to be pushed downwards until the first ring of the 2nd stage touches the chamfer C. By applying slight pressure to the piston head, the piston can now be twisted about 15° to the left and right and worked easily ring by ring into the cylinder runway of the 2nd stage. Do not introduce the piston with force in order to avoid jams or breaking of piston rings. If the piston jams, it must to be removed again and the piston rings centered again exactly. After fitting of piston and connecting rod turn the compressor by hand to see that nothing jams.

Rev.: 15.04.1999

15

16

Type

Instruction manual

W55

Piston Compressors

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

4.5 Overhaul of crankshaft and connecting rod

Connecting rods and bearing covers are identified by punched figures. The location of the covers must not be changed. Mark the individual parts to maintain correct positions during reassembly. After disassembly, clean all parts, check all bearings and bearing pins for wear and damage. Check the clearance of the connecting rod by means of a precision gauge (see List of Wear Limits).

Refitting of the crankshaft Thoroughly oil the bearings and bearing pins as well as the associated components before assembly. Insert the crankshaft in the crankcase first without shaft seals and then screw on the housing cover with its gasket. Check wether the axial clearance of the crankshaft is within the admissible clearance . Fit the shaft seal and tighten the housing cover screws to the prescribed torque.

Refitting of the connecting rods Oil the crank pin and bolt threads. Place the upper part of the connecting rod with bearing shell on the crank pin and see that the shell is correctly positioned in the connecting rod. Put the lower part of the connecting rod with bearing shell from the opposite side, pass through the fitting bolts and screw them into the upper part of the connecting rod. After pretensioning both bolts to approx. 30 Nm using the torque wrench tighten to the prescribed torque.

Rev.: 15.04.1999

17

Type

Instruction manual

W55

Piston Compressors

4.6 Protection against Corrosion during prolonged Shut-Down Compressors must be stored in a dry room. In case of long storage a protection of all inner components should be carried out according to the manual at least every 8 months. Before first commissioning, the compressors must be checked by a trained engineer for damage which may result from long storage. A report of inspection must be sent to HATLAPA. Noticed damage during this check are not covered by our guarantee. The date of commissioning or supply of the vessel to owner must be advised to us. Compressors which will be put out of operation for several months must be protected against corrosion.

Internal protection: • Open drain valves of 1st and 2nd stage under pressure. • Run the compressor without pressure while the drain valves are open. • Close the drain valves. • Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the air-intake socket within approx. 2 minutes. • Shut down the compressor and open the drain valves.

External protection: • After cleaning, apply rust-preventive paint to all parts. • Components made of light alloy, copper or brass need no treatment.

18

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

5 Trouble Shooting The following details are intended to provide a brief guide to determining the cause of abnormal operation. We do not claim that this information is complete. It only deals with the faults most frequently encountered, as known from experience.

a) Intermediate pressure too low after 1st stage: Leaking suction/pressure valve 1st stage Leaking drain valve 1st stage b) Intermediate pressure too high after 1st stage (safety valve blowing off): Leaking suction valve 2nd stage c) Compressed-air delivery too low: Still open or leaking drain valves. Combined suction/pressure valve damaged or leaking. Leaking cooler or compressed-air delivery line. Clogged cooler or compressed-air delivery line (at the same time, pressure at the compressor considerably higher than in the compressed-air receiver). d) Safety valve blowing off although pressure is normal: Defective safety valve. e) Safety valve of final stage blowing off, final pressure too high : Closed valve on compressed-air receiver / non-return valve does not open. Blockage of cooler or of compressed-air delivery line . Defective pressure control switch (of the automatic system).

Rev.: 15.04.1999

19

Type

Instruction manual

W55

Piston Compressors

6 Spare Parts We recommend to keep some spare parts in stock in order to allow quick remedy of minor failures due to the natural wear and tear.

1 set of valve plates and valve springs for each stage 1 set of piston rings incl. oil scraper ring for each stage 1 set of sealing rings and gaskets for each stage

If the compressor is intended for continuous operation, in addition stock: 1 combined suction and pressure valve for each stage 1 set of crankshaft bearings and connecting-rod bearings 1 piston with wrist pin and piston rings for each stage

20

Rev.: 15.04.1999

Instruction manual

Type

Piston Compressors

W55

7 Instructions for Correctly Ordering Spare Parts When ordering spare parts, the following details must be given: 1.) Serial No. and type designation (see name plate). 2.) Ident. No. from the spare parts list. 3.) Method of the required dispatch, as well as consignee and address for the invoice. 4.) Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5-7 · D-25436 Uetersen / Germany D-2549 Uetersen / Germany Phone: Telex: Cable: Fax: E-mail: Internet:

(+49) 4122 / 711- 0 218510 htlu d HATLAPA Uetersen (+49) 4122 / 711 - 330 [email protected] http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/cooperators as per attached list.

Rev.: 15.04.1999

21

ENGLISH

0280.1400

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ELECTRIC MOTORS

ENGLISH READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR

RECEIVING CHECK Check if any damage has occured during transportation. üCheck nameplate data. üRemove shaft locking device (if any) before operating the motor. üTurn the shaft with the hand to make sure it is turning freely.

HANDLING AND TRANSPORTATION 1 - General

In case the motors are stored for more than two years, the bearings must be replaced or the lubrication grease must be totally removed after cleaning. Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any). We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas. If motor is fitted with space heaters, these should be switched on. Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYEBOLTS Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices then a double chain must be used to lift it. Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged. DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE. THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN WHEN THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE.

STORAGE If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases, corrosive smokes, under constant temperature and in normal position free from other objects. Motor storage temperature must remain between 5ºC to 60ºC, with relative humidity not exceeding 50%.

Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding. The resistance measured at 25ºC must be: Ri ≥ (20 x U) / (1000 + 2P) [MΩ] (measured with a MEGGER at 500 V d.c.) where U = voltage (V); P = power (kW). If the insulation resistance is less than 2 megaohms, the winding must be dried according to the following: Warm it up inside an oven at a minimum temperature of 80ºC increasing 5ºC every hour until 105ºC, remaining under this temperature for at least one hour. Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be reimpregnated.

INSTALLATION 1 - Safety All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be well informed and updated concerning safety standards and principles that govern the work and carefully follow them. We strongly recommend that these jobs are carried out by qualified personnel.

MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE. Motors must be protected against accidental starts. When performing any maintenance service, disconnect the motor from the power supply. Make sure all accessories have been switched off and disconnected. In order to prevent from penetrating dust and/or water into the terminal box, cable glands or threaded pipe in the lead holes must be installed. Do not change the regulation of the protecting devices to avoid damaging. 2 - Operating Conditions Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 0ºC and 40ºC. Any variation is stated on the nameplate. COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE. Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate. KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER. 3 - Foundation Motors provided with feet must be installed on solid foundations to avoid excessive vibrations. The purchaser is fully responsible for the foundation. Metal parts must be painted to avoid corrosion. The foundation must be uniform and sufficiently tough to support any schock. It must be

designed in such a way to stop any vibration originated from resonance. 4 - Drain Holes Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order. 5 - Balancing WEG MOTORS ARE DYNAMICALLY BALANCED WITH HALF KEY, AT NO LOAD AND UNCOUPLED. Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before installation. Use always appropriate tools for installation and removal. 6 - Alignment ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE. Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings. When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings. Suitable assembly of half-coupling: Check that clearance Y is less than 0.05 mm and that the difference X1 to X2 is less than 0.05 mm, as well.

Note: Dimension X1 and X2 must be 3mm minimum Figure and alignment tolerances 7 - Belt Drive When using pulley or belt coupling, the following must be observed: Belts must be tighten just enough to avoid slippage when running, according to the

specifications stated on the belt supplier recommendation. WARNING: Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture. 8 - Connection WARNING: Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating. WARNING: The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even when the motor has reached standstill. A WRONG CONNECTION CAN BURN THE MOTOR. Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ±10%; the acceptable frequency variation is ±5% and the total acceptable variation is ± 10%. 9 - Starting Methods The motor is rather started through direct starting. In case this is not possible, use compatible methods to the motor load and voltage. The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1, L2, L3. To change the rotation direction, interchange two of the connecting leads. THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION. AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED.

Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate. BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE CURRENT STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS. When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, termal protector, etc, connect their terminals to the corresponding devices on the control panel. 10 - Start-Up THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR. a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the connections and the mounting before starting it again. b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done. c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate.

MAINTENANCE WARNING: SAFETY CHECK LIST 1 - General Inspection üCheck the motor periodically. üKeep the motor clean and assure free air flow. üCheck the seals or V Ring and replace them, if required. üCheck the connections as well as supporting screws. üCheck the bearings and observe: Any excessive noise, vibration, bearing temperature and grease condition. üWhen a change, under normal conditions, is detected, check the motor and replace the required parts.

The frequency of the inspections depends on the motor type and on the application conditions.

LUBRICATION FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION. 1 - Machines without Grease Nipples Motors up to frame 200 are normally fitted without grease nipples. In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects: üDisassemble carefully the motors. üTake all the grease out. üWash the bearing with querosene or diesel. üRegrease the bearing immediately.

2 - Machines Fitted with Grease Nipples It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc) that offer some risk to the physical integrity of the operator, proceed as follows: üClean the area near the grease nipple. üPut approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off the motor and insert the rest of the grease. üThe injection of all the grease with the motor in standstill can make the grease penetrate into the motor, through the inner seal of the bearing housing. FOR LUBRICATION USE ONLY MANUAL GREASE GUN.

RELUBRICATION INTERVALS TABLE 1 - BALL BEARINGS - Series 62/63 II pole

Relubrication intervals (running hours – horizontal position) IV pole

VI pole

Bearing 6209 6211 6212

60Hz 18400 14200 12100

50Hz 20000 16500 14400

60Hz 20000 20000 20000

50Hz 20000 20000 20000

60Hz 20000 20000 20000

Bearing 6309 6311 6312 6314 6316 6319 6322

60Hz 15700 11500 9800 3600 -

50Hz 18100 13700 11900 4500 -

60Hz 20000 20000 20000 9700 8500 7000 5100

50Hz 20000 20000 20000 11600 10400 9000 7200

60Hz 20000 20000 20000 14200 12800 11000 9200

Serie 62

VIII pole

50Hz 60Hz 20000 20000 20000 20000 20000 20000 Serie 63 50Hz 60Hz 20000 20000 20000 20000 20000 20000 16400 17300 14900 15900 13000 14000 10800 11800

X pole

XII pole

Grease

50Hz 20000 20000 20000

60Hz 20000 20000 20000

50Hz 20000 20000 20000

60Hz 20000 20000 20000

50Hz 20000 20000 20000

(g) 9 11 13

50Hz 20000 20000 20000 19700 18700 17400 15100

60Hz 20000 20000 20000 19700 18700 17400 15100

50Hz 20000 20000 20000 20000 20000 18600 15500

60Hz 20000 20000 20000 20000 20000 18600 15500

50Hz 20000 20000 20000 20000 20000 20000 19300

(g) 13 18 21 27 34 45 60

TABLE 2 - ROLLER BEARINGS - Series NU 3 Relubrication intervals (running hours – horizontal position) II pole Bearing NU 309 NU 311 NU 312 NU 314 NU 316 NU 319 NU 322 NU 324

60Hz 9800 6400 5100 1600 -

50Hz 13300 9200 7600 2500 -

IV pole 60Hz 20000 19100 17200 7100 6000 4700 3300 2400

50Hz 20000 20000 20000 8900 7600 6000 4400 3500

VI pole 60Hz 20000 20000 20000 11000 9500 7600 5900 5000

50Hz 20000 20000 20000 13100 11600 9800 7800 6600

VIII pole 60Hz 20000 20000 20000 15100 13800 12200 10700 10000

50Hz 20000 20000 20000 16900 15500 13700 11500 10200

X pole 60Hz 20000 20000 20000 16900 15500 13700 11500 10200

50Hz 20000 20000 20000 19300 17800 15700 13400 12100

XII pole 60Hz 20000 20000 20000 19300 17800 15700 13400 12100

50Hz 20000 20000 20000 20000 20000 20000 17300 15000

Grease (g) 13 18 21 27 34 45 60 72

Note: üThe ZZ bearings from 6201 to 6307 do not require relubrication as its life time is about 20,000 hours. üTables 1 and 2 are intended for the lubrication period under bearing temperature of 70°C (for bearings up to 6312 and NU 312) and temperature of 85°C (for bearings 6314 and NU 314 and larger). üFor each 15°C of temperature rise, the relubrication period is reduced by half. üThe relubrication periods given above are for those cases applying Polyrex® EM grease. ü When motors are used on the vertical position, their relubrication interval is reduced by half if compared to horizontal position motors. WE RECOMENDED TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD. WARNING: EXCESS OF GREACE CAN CAUSE BEARNING OVERHEATING RESULTING IN COMPLETE DAMARGE. Compatibility of Polyrex® EM grease with other types of grease: Containing polyurea thickener and mineral oil, the Polyrex® EM grease is compatible with other types of grease that contain: üLithium base or complex of lithium or polyurea and highly refined mineral oil. üInhibitor additive against corrosion, rust and anti-oxidant additive. Notes: üAlthough Polyrex® EM is compatible with types of grease given above, we do not recommended to mix it with any other greases. ü If you intend to use a type of grease different than those recommended above , first contact WEG. üOn applications (with high or low temperatures, speed variation, etc), the type of grease and relubrification interval are given on an additional nameplate attached to the motor. THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE MANUFACTURER OR WEG

DISASSEMBLY AND ASSEMBLY Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated methods.

The stator grips must be applied over the side face of the inner ring to be disassembled or over an adjacent part. It is essential that bearings assembly be done under cleanning conditions to ensure good operation and to avoid damages. New bearings shall only be taken out from their cases when assembling them. Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals. For bearing assembly warm their inner parts withsuitable equipment - inductive pocess - or use suitable tools.

SPARE PARTS When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate. Please also inform the motor serial number stated on the nameplate.

MOTORS FOR HAZARDOUS LOCATIONS Besides the recommendations given previously, these ones must be also followed: THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY, WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS. Motors for hazardous locations are manufactured according to specific standards for such environments and they are certified by worldwide certifying entities. 1 - Installation The complete installation must follow procedures given by the local legislation in effect. THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT. 2 - Maintenance Maintenance must be carried out by repair shops authorized by WEG. Repair shops and people without Weg’s authorization who will perform any service on hazardous location motors will be fully responsible for such service as well as for any consequential damage.

ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION. When performing maintenance, installation or relubrication, follow these instructions: üCheck if all components are free of edges, knocks or dirt. üMake sure all parts are in perfect conditions. üLubricate the surfaces of the endshield fittings with protective oil to make the assembly easier. üUse only rubber hammer to fit the parts. üCheck for correct bolts tightening. üUse clearance calibrator for correct T-box fitting (smaller than 0.05mm). DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE FACTORY.

MOTORS DRIVEN BY VFD Applications using VFD´s without filter can affect motor performance as follows:

üLower efficiency. üHigher vibration. üHigher noise level. üHigher rated current. ü Higher temperature rise. üReduced motor insulation. üReduced bearing life. 1- Standard Motors üVoltages lower than 440V do not require filter. üVoltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters. üVoltages equal or higher than 575V require filter for any size of power supply cables. IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY, MOTOR WARRANTY WILL BE VOID. 2- Inverter Duty Motors: üCheck power supply voltage of the forced cooling set. üFilters are not required.

WARRANTY TERMS Weg warrants its products against defects in workmanship and materials for twelve (12) months from the invoice date issued by the factory, authorized distributor or agent limited to eighteen (18) months from manufacturing date independent of installation date as long as the following items are fulfilled accordingly: -

-

-

Proper transportation, handling and storage; Correct installation based on the specified ambient conditions and free of corrosive gases; Operation under motor capacity limits; Observation of the periodical maintenance services; Repair and/or replacement effected only by personnel duly authorized in writing by Weg; The failed product be available to the supplier and/or repair shop for a required period to detect the cause of the failure and corresponding repair; Immediate notice by the purchaser about failures accured and that these are accepted by Weg as manufacturing defects.

This warranty does not include disassembly services at the purchaser facilities, transportation costs with product, tickets, accomodation and meals for technical personnel when requested by the customer. The warranty service will be only carried out at Weg Authorized Repair Shops or at Weg’s facilities. Components whose useful life, under normal use, is shorter than the warranty period are not covered by these warranty terms. The repair and/or replacement of parts or components, when effected by Weg and/or any Weg Authorized Repair Shop, will not give warranty extension. This constitutes Weg’s only warranty in connection with this sale and the company will have no obligation or liability whatsoever to people, third parties, other equipment or installations, including without limitation, any claims for consequential damages or labor costs.

WEG EXPORTADORA S.A. AV. PREF. WALDEMAR GRUBBA, 3000 89256-900 JARAGUÁ DO SUL, SC - BRAZIL PHONE (55) (47) 372-4002 FAX (55) (47) 372-4060 http://www.weg.com.br FOR FURTHER INFORMATION PLEASE CONTACT YOUR NEAREST WEG SALES OFFICE

Instruction manual

Piston compressor L9 - L14

Type

Instruction manual

L9 - L14

Piston Compressors

INTRODUCTION: This Instructions Manual contains a brief technical description and important instructions on commissioning, maintenance and servicing of the compressor. We recommend to read this manual carefully in order to be able, in case of trouble, to detect the cause quickly and care for remedy and, in case of repairs, to make provisions for proper mounting acc. to the instructions. This manual assumes a general technical knowledge of piston compressors and does not claim to be complete. If repairs become necessary, only original HATLAPA spare parts must be used in order to maintain the operational reliability and efficiency of the machine. For identification and supply of spare parts, an order must contain the following information: 1. Serial No. and type designation (see name plate). 2. Ident No. from the spare parts list. 3. Method of the required dispatch, as well as consignee and address for the invoice. 4. Name of the vessel (ex-name), Yard No., and Shipyard. In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5-7 · D-25436 Uetersen / Germany D-2549 Uetersen / Germany Phone: Telex: Cable: Fax: E-mail: Internet:

(+49) 4122 / 711- 0 218510 htlu d HATLAPA Uetersen (+49) 4122 / 711 - 330 [email protected] http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/co-operators as per attached list. We wish to point out that repairs and/or modifications to the compressor which are carried out without our approval during the guarantee period, will release us from our guarantee obligations. The manufacturer cannot be rendered liable for damage to the compressor which can be shown to have been caused by the use of unsuitable lubricants or failure to comply with the operating instructions. Reprint of the text or illustrations, or even extracts therefrom is prohibited. Subject

2

to

alterations

at

all

times

due

to

technical

development.

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

TABLE OF CONTENTS: Page: 1 Description ..................................................................................................................4 1.1 Design .......................................................................................................................4 1.2 Specifications ............................................................................................................5 1.3 Working method ........................................................................................................5 1.4 Cooling ......................................................................................................................5 1.5 Lubrication of Working Parts .....................................................................................6 1.6 Condensate Separation .............................................................................................6 1.7 Starting without Back-Pressure .................................................................................6 2 Setting-up and Installation.........................................................................................7 3 Commissioning...........................................................................................................8 3.1 Safety References .....................................................................................................8 3.2 Before Starting...........................................................................................................9 3.3 After Starting..............................................................................................................9 3.4 During Operation .......................................................................................................9 3.5 After Stopping............................................................................................................9 4 Servicing and Maintenance .....................................................................................10 4.1 General Servicing Instructions.................................................................................10 4.2 Servicing Schedule ..................................................................................................11 4.3 Overhaul of Valves ..................................................................................................13 4.4 Overhaul of Pistons and Cylinders ..........................................................................13 4.5 Overhaul of Crankshaft and Connecting Rods ........................................................14 4.6 Protection against Corrosion during prolonged Shut-Down .....................................15 5 Trouble Shooting ......................................................................................................16 6 Spare Parts................................................................................................................17 7 Instructions for Correctly Ordering Spare Parts....................................................18

Rev.: 15.09.1999

3

Type

Instruction manual

L9 - L14

Piston Compressors

1 Description 1.1 Design This two-stage compressor has 2 cylinders with trunk piston and a single-throw crankshaft. The 1st and 2nd stage cylinders are of 90°V-arrangement. All bearings of crankshaft and connecting rods are anti-friction bearings. These bearings as well as the working surface of the cylinders are splash lubricated by means of an oil splash pin

The use of trunk pistons at all stages guarantees low wear and safe lubrication with high service life expectancy for pistons and cylinders. The equalization of mass of the crank mechanism and the special arrangement of the two cylinders together with the use of trunk pistons guarantee low vibrations during operation. They allow 3-point resilient mounting without any problems.

4

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

1.2 Specifications Type

L9

L14

Number of Cylinders

2

2

85,5

85,5

40

40

Piston Stroke [mm]

42

42

Crankshaft-Axial Clearance [mm]

0,20,3

0,20,3

Quantity of Lub. Oil min. [l]

1,1

1,1

Quantity of Lub. Oil max. [l]

1,5

1,5

Weight without E-Motor [appox. kg]

83

83

st

Cylinder Bore 1 Stage [mm] Cylinder Bore 2

nd

Stage [mm]

1.3 Working method The compressor compresses the ambient air sucked in through the air-intake filter with silencer in two stages to the selected final pressure. Lamellar valves automatically control the gas exchange in the compression chambers. After every stage the heated compressed air flows through a large-dimensioned cooler. To monitor the correct functioning of the compressor a pressure gauge is installed after each compression stage. Safety valves, installed after every compression stage, prevent the pressure from rising above the admissible limit. 1.4 Cooling The heat generated in the machine by air compression and mechanical friction is led off to the atmosphere. A radial-flow fan fixed directly on the shaft and a streamlined hood guide the cooling air at high speed over the ribbed cylinders, valves and cylinder heads and over the ribbed cooler of the first and second stages installed on the circumference.

Rev.: 15.09.1999

5

Type

Instruction manual

L9 - L14

Piston Compressors

1.5 Lubrication of Working Parts Only compressor oils according to the enclosed oil specification chart may be used. The crankshaft and connecting rod bearings are splash lubricated by means of a pin fixed to the connecting rod of the 1st stage. 1.6 Condensate Separation Together with the moist ambient air which is sucked in, water enters the compressor in form of vapour. By compression and subsequent cooling of the compressed air, this water vapour condenses. The water separated from the compressed air blends with the oil which is entrained in very small quantities from the lubricated working surfaces of the cylinders. This water-oil mixture is extracted from the compressed-air stream in special condensate collector chambers. At regular intervals – after every 15 min. for about 10 sec. - as well as on starting and stopping of the compressor, the collector chambers must be drained by opening the manual valves or optionally by automatic devices. Such condensate separation reduces wear and tear due to corrosion in the compressor components, and in the connected pipelines and prevents the compressor from damage due to water shocks. Disposal of the condensate has to be carried out according to the locally valid prescriptions. 1.7 Starting without Back-Pressure During starting-up, the driving motor must be unloaded by opening the drain valves. In automatically controlled compressors, unloading is effected by time-lagged closing of these valves.

6

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

2 Setting-up and Installation The compressor is driven by a directly-coupled electric motor through a flexible coupling. Motor and compressor are fastened to the common base frame distortionfree before being put into operation. In case of resilient mounting there must be sufficient room for movement. All pipelines must then be connected to the consumer system by flexible hoses, strictly adhering to the installation instructions. All drain pipelines are to be laid with constant descent and must discharge after the shortest possible distance into an open funnel . Each compression stage needs a separate drain pipeline in order to guarantee perfect drainage of the individual stages; stop valves are to be installed as closely as possible to the compressor. For sufficient supply of cooling air, the minimum distance to the cooler must be observed (see final drawing). The air inlets may not be influenced by the warm exhaust of other machinery. Further instructions on the installation of valves, pipelines, and control equipment are to be taken from the enclosed piping diagrams with their respective descriptions.

Rev.: 15.09.1999

7

Type

Instruction manual

L9 - L14

Piston Compressors

3 Commissioning 3.1 Safety References The compressor has been produced according to the State-of-art and is operationally reliable. The compressors are a source of danger if inexpertly or improperly used.

8

•

Only authorised and trained persons are allowed to operate and repair the machine or to do maintenance work. Make sure that these persons have read and understood the complete operating instructions and safety instructions.

•

The compressor may only be used for compressing air.

•

The compressor may not be operated without safety or protecting devices.

•

Only sealed safety valves may be used, readjustment is not allowed. They have to be replaced immediately when defective.

•

Before starting any maintenance work it is necessary to stop the compressor system and to prevent it from re-starting. The system has to be voltage–free, all parts containing compressed air have to be depressurized.

•

The compressor system may only be operated in perfect working condition. It must be free of foreign parts.

•

Rebuilding or any other changes to the compressor system that may influence the safety are strictly prohibited.

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

At initial commissioning, after a several months` interruption in operation, or after extensive repair work the operator must observe the following points (see also 4.6 Protection against corrosion during prolonged Shut-Down).

3.2 Before Starting •

The compressor must be filled to the upper oil level mark with prescribed compressor oil (see list of recommended oils).

•

Check that the crankshaft is moving easily by turning over the flywheel by hand; but make sure that the compressor set cannot be started unintentionally.

•

Open the shut-off valve in the pipeline leading to the compressed-air receiver.

•

Open drain valves.

3.3 After Starting •

Check the direction of rotation of the shaft (see also arrow).

•

Close the drain valves and check for leakage.

3.4 During Operation •

Once the final pressure is attained, check the safety valves for proper functioning: Slightly turn the knurled nut until the valve blows off. After closure, check for leakage.

•

After fitting of new working parts (repair), run in the compressor for about one hour at low final pressure (5 to 10 bar).

3.5 After Stopping •

Open the drain valves at the condensate separators.

•

Check that the automatic drain valves open properly.

•

Check the non-return valve in the pipe to the compressed-air receiver for leakage.

Rev.: 15.09.1999

9

Type

Instruction manual

L9 - L14

Piston Compressors

4 Servicing and Maintenance For trouble-free operation, it is necessary to check regularly and carefully the safety devices and the wear and tear parts of the compressor as well as the functioning of fitted valves and instruments. Regularly check the stock of spare parts and seals which must be protected against corrosion, and stock up to the specified quantity again after any servicing and overhaul work. The following maintenance and overhaul instructions must be adhered to. However, they do not claim to be complete. Observance of the servicing intervals as mentioned below guarantees great reliability and long service life of the compressor. In this connection, reference is made to the requirements of the rules of the classification societies and seafarer unions. 4.1 General Servicing Instructions a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil, however, not exceeding the top oil level mark. Too much oil results in foaming due to immersion of rotating parts, with the compressor at extremely inclined position. Intense misting of the oil and uncontrolled cylinder lubrication would result in increased oil consumption and coking of the working valves. b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot from running - and fill in fresh compressor oil. c) Regularly and carefully check the air pressure of all stages. Varying operating pressure values indicate anomalies in the valves, as well as leaks in the piping system. d) At regular intervals dismantle and strip down combined suction and pressure lamellar valves and clean all parts. For details, see 4.3 „Overhaul of Valves„. e) Check the safety valves on the compressor by slightly turning the knurled nut at short intervals.

10

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

4.2 Servicing Schedule After first commissioning, after a general overhaul, and after repairs to the crank mechanism or cylinder, the following maintenance work should be done: After 100 working hours 1.) Change the oil. 2.) Check the safety valves. 3.) Check the bolts and nuts on crankcase, cylinders, and pipelines for tightness (See list of tightening torques). 4.) Check the drainage system.

After that the following intervals are to be kept: After every 500 working hours: 1.) Check the safety valves 2.) Check the drainage system 3.) Clean the air-intake filter

After every 1000 working hours (however, at least once a year): 1.) Change the oil. 2.) Clean the ribbed coolers, the ribbed cylinders and the radial-flow fan

Rev.: 15.09.1999

11

Type

Instruction manual

L9 - L14

Piston Compressors

After every 1000 working hours: 1.) Clean the combined suction and pressure lamellar valves and clean all parts 2.) Check parts which come into direct contact with hot compressed air, such as valves, cylinder heads and compressed-air pipelines for carbon residues and, if necessary, clean them with solvents.

The admissible servicing intervals of the valves are determined above all by the operating conditions and by the properties of the lubricant used. We recommend to reduce the servicing intervals in case of severe operating conditions.

12

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

4.3 Overhaul of Valves The combined suction and pressure lamellar valves need no special maintenance. During general servicing as per the servicing schedule, the valves should be inspected only and checked as to whether there are breaks on the lamellar. Cleaning must be done very carefully in order to prevent dirt particles from getting between the sealing surfaces of the lamellar. Defective valves cannot be repaired, but must be replaced completely. When installing the valves, only complete sets of packing rings may be used and correctly positioned. Cylinder head nuts and bolts for pipes should first be tightened by hand. Then nuts should be initially tightened cross-wise using a torque wrench at approx. 10 Nm (1 kpm) and then tightened securely in the same sequence to the necessary torque. 4.4 Overhaul of Pistons and Cylinders Pistons and cylinders can be removed for cleaning and checking of wear without dismantling the connecting rod and crankshaft. All components must first be marked so as to maintain pairings (assignment of pistons and cylinders) and the positioning of the parts for reassembly. To dismantle the pistons after pulling out the cylinders, firstly remove each of the retainer rings of the wrist pins using a pair of circlip pliers, and then push the wrist pin out of the piston with a set bolt or other suitable device. Heating the piston to between approx. 60°C and 80°C facilitates insertion of the wrist pin. Piston rings should be removed and inserted only using piston-ring pliers. Observe that the piston rings are correctly positioned (see parts list) and stagger the joints when fitting. On inclined cylinders, the oil scraper ring joint should point upwards when fitting. To measure clearance and wear, first of all, all parts must be cleaned and checked for damage. The measurement of the cylinder diameter is carried out using a precision internal gauge applied in the operational way of the piston rings. The nominal diameter of the piston is stamped on top of the piston head. The actual diameter should be checked at the bottom end of the piston stem, at right angles to the wrist pin axis. For fitting clearances and wear limits refer to the attached list.

Rev.: 15.09.1999

13

Type

Instruction manual

L9 - L14

Piston Compressors

To check the joint clearance, the piston rings should be inserted at a right angle into the upper cylinder aperture and positioned at a location where the cylinder liner shows no signs of wear. The joint clearance is measured using a feeler gauge. Before fitting the pistons and cylinders, the seat face on the crankcase and underside of the cylinder must be carefully cleaned. Use new cylinder foot gaskets. Apply oil to pistons and cylinders. Compress piston rings with a tensioning band and slip the cylinders over the pistons by hand. Take care that the cylinder head bolts do not touch the cooling ribs of the cylinders. Parts, which have reached or exceeded their service life (see List of Wear Limits), must be replaced. 4.5 Overhaul of Crankshaft and Connecting Rods The crankshaft and the connecting rod are supported by anti-frictions. Axial and radial clearance of the crankshaft can be checked at the shaft when fitted. There must be no radial clearance. Axial clearance of 0.2 to 0.3 mm is admissible. Any perceptible radial clearance and excessive axial clearance indicates beginning of damage to the bearings and the bearings should be replaced.To this purpose the mechanism of the compressor has to be dismantled: The crankcase cover and the flywheel housing can be forced out by means of pressure screws. After the inner bearing ring on the fan wheel side has been drawn off and the circlip (together with its thrust washer) of the connecting rod bearing on the crank pin has been loosened, the crankshaft can be drawn out of the needle bearings of the connecting rod bearings to the flywheel side. New inner bearing rings are to be pushed on to the shaft without violence after it has been warmed up to approx. 80° C. Proceed in the reverse manner for re-assembly. When refitting the flywheel casing and the gearcase cover use one new gasket each. Should the axial clearance not be sufficient, further gaskets can be fitted to obtain the required clearance as stated before.

14

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

4.6 Protection against Corrosion during prolonged Shut-Down Compressors must be stored in a dry room. In case of long storage a protection of all inner components should be carried out according to the manual at least every 8 months. Before first commissioning, the compressors must be checked by a trained engineer for damage which may result from long storage. A report of inspection must be sent to HATLAPA. Noticed damage during this check are not covered by our guarantee. The date of commissioning or supply of the vessel to owner must be advised to us. Compressors which will be put out of operation for several months must be protected against corrosion.

Internal protection: st

• Open drain valves of 1 and 2

nd

stage under pressure.

• Run the compressor without pressure while the drain valves are open. • Close the drain valves. • Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the air-intake socket within approx. 2 minutes. • Shut down the compressor and open the drain valves.

External protection: • After cleaning, apply rust-preventive paint to all parts. • Components made of light alloy, copper or brass need no treatment.

Rev.: 15.09.1999

15

Type

Instruction manual

L9 - L14

Piston Compressors

5 Trouble Shooting The following details are intended to provide a brief guide to determining the cause of abnormal operation. We do not claim that this information is complete. It only deals with the faults most frequently encountered, as known from experience.

a) Intermediate pressure too low and / or Compressed-air delivery too low: Leaking lamellar valve(s) Leaking piston rings Leaking cooler Leaking drain valve b) Intermediate pressure too high and / or Compressed-air delivery too low: Leaking lamellar valve(s) Clogged cooler c) Safety valve blowing off although pressure is normal: Defective safety valve. st

d) Safety valve 1 stage blowing off, intermediate pressure is too high: sea b) e) Safety valve of final stage blowing off, final pressure too high : Closed valve on compressed-air receiver / non-return valve does not open. Blockage of cooler or of compressed-air delivery line . Defective pressure control switch (of the automatic system).

16

Rev.: 15.09.1999

Instruction manual

Type

Piston Compressors

L9 - L14

6 Spare Parts We recommend to keep some spare parts in stock in order to allow quick remedy of minor failures due to the natural wear and tear.

1 lamellar valve for each stage 1 set of piston rings incl. oil scraper ring for each stage 1 set of sealing rings and gaskets for each stage

If the compressor is intended for continuous operation, in addition stock: 1 set of crankshaft bearings and connecting-rod bearings 1 piston with wrist pin and piston rings for each stage

Rev.: 15.09.1999

17

Type

Instruction manual

L9 - L14

Piston Compressors

7 Instructions for Correctly Ordering Spare Parts When ordering spare parts, the following details must be given: 1.) Serial No. and type designation (see name plate). 2.) Ident. No. from the spare parts list. 3.) Method of the required dispatch, as well as consignee and address for the invoice. 4.) Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5-7 · D-25436 Uetersen / Germany D-2549 Uetersen / Germany Phone: Telex: Cable: Fax: E-mail: Internet:

(+49) 4122 / 711- 0 218510 htlu d HATLAPA Uetersen (+49) 4122 / 711 - 330 [email protected] http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/cooperators as per attached list.

18

Rev.: 15.09.1999

Ersatzteil-Verzeichnis List of spare parts Liste des pièces de rechange

Kolbenkompressor Piston compressor Compresseur à piston L 9 - L 14 zum Ersatzteilverzeichnis to the list of spare parts vers la liste des pièces de rechanges

Ersatzteilverzeichnis List of spare parts Liste des pièces de rechange

Benennung / designation / désignation

Kompressor L9 / L14 Compressor L9 / L14 Compresseur L9 / L14

Tafel / table / planche

Schnittzeichnung / sectional drawing / plan de coupe Kurbelgehäuse / crank case / carter.............................................................. 1-199-010 Kurbelwelle / crankshaft / arbre manivelle.................................................... 2-501-010 Fußschienen / supports / supports................................................................ 3-199-010 Zylinder und Zylinderköpfe / cylinders and cylinder heads / cylindres et culasses ...................................................................................... 1-199-020 Ventile / valves / soupapes ............................................................................. 2-199-020 Kolben / pistons / pistons............................................................................... 3-199-020 Pleuelstangen / connecting rods / bielles ..................................................... 4-199-020 Kühlsystem / cooling system / système de refroidissement....................... 1-199-030 Armaturen / fittings / robinetterie................................................................... 1-199-040 Schwungrad und Kupplung / flywheel and coupling / volant et accouplement................................................................................... 1-199-014 Ansaugsystem / suction system / système d’aspiration ............................. 1-199-032 Starre Lagerung / rigid mounting / suspension rigide ................................. 1-199-043 Elastische Lagerung / resilient mounting / suspension élastique.............. 1-199-044 Automatische Entwässerung / automatic drainage / vidange automatique....................................................................................... 1-303-053

Stand: 26.03.2003

Kurbelgehäuse Crank case Carter

L9 / L14 Tafel / Table / Planche 1-199-010

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

10.10.10

Kurbelgehäuse

1

Crank case Carter 2

10.10.20

Ölstandsauge

1

Oil level inspection glass Verre de niveau d’huile 3

10.10.30

Verschlußschraube

1

Screw plug Vis de fermeture 4

10.10.40

Dichtring

1

Packing ring Rondelle de joint 5

10.10.50

Schwungradgehäuse

1

Flywheel housing Carter-volant 6

10.10.60

Wellendichtring

1

Radial packing ring Bague d’étanchéité 7

10.10.70

Sechskantschraube

4

Hexagon head bolt Vis à tête hexagonale 8

10.10.80

Sicherungsring

4

Securing ring Segment de sécurité 9

10.10.90

Dichtung

2

Gasket Joint 10

10.10.100

Gehäusedeckel

1

Housing cover Couvercle du carter 11

10.10.110

Sechskantschraube Hexagon head bolt Vis à tete hexagonale

4

Kurbelgehäuse Crank case Carter

L9 / L14 Tafel / Table / Planche 1-199-010

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

12

10.10.120

Sicherungsring

4

Securing ring Segment de sécurité 13

10.10.130

Wellendichtring

1

Radial packing ring Bague d’étanchéité 14

10.10.140

Oeleinfüllstutzen

1

Filler tube for oil Tuyau de remplissage d’huile 15

10.10.150

Gegenmutter

1

Counter nut Contre-écrou 16

10.10.160

Tragösenverschlußschraube

1

Eye bolt/ screw plug Boulon à oeillet/ vis de fermeture 17

10.10.170

Dichtring

1

Packing ring Rondelle de joint 18

10.10.180

Dichtring Packing ring Rondelle de joint

1

Kurbelwelle Crankshaft Arbre manivelle

L9 / L14 Tafel / Table / Planche 2-501-010

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

10.20.10.10

Kurbelwelle

1

Crank shaft Arbre manivelle 2

10.20.10.20

Paßfeder

1

Fitting key Clavette d’ajustage 3

10.20.10.30

Paßfeder

1

Fitting key Clavette d’ajustage 4

10.20.20

Zylinderrollenlager

1

Cylinder roller bearing Palier à rouleaux cylindriques 5

10.20.30

Zylinderrollenlager

1

Cylinder roller bearing Palier à rouleaux cylindriques 6

10.20.40

Paßscheibe Fitting disk Disque d‘ajustage

1

Fußschienen Supports Supports

L9 / L14 Tafel / Table / Planche 3-199-010

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

10.30.10

Fußschiene

1

Support Support 2

10.30.20

Sechskantschraube

2

Hexagon head bolt Vis à téte hexagonale 3

10.30.30

Sicherungsring

2

Securing ring Segmant de sécurité 4

10.30.40

Fußschiene

1

Support Support 5

10.30.50

Sechskantschraube

2

Hexagon head bolt Vis à téte hexagonale 6

10.30.60

Distanzstück Distance piece Pièce d‘écartement

1

Zylinder und Zylinderköpfe Cylinders and cylinder heads Cylindres et culasses

L9 / L14 Tafel / Table / Planche 1-199-020

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

20.10.10

Zylinder 1.Stufe

1

st

Cylinder 1 stage Cylindre 1er étage 2

20.10.20

Dichtung

2

Gasket Joint 3

20.10.30

Zylinderkopf 1. Stufe

1

st

Cylinder head 1 stage Culasse 1er étage 4

20.10.40

Zylinder 2. Stufe

1

nd

Cylinder 2 stage Cylindre 2 ème étage 5

20.10.60

Zylinderkopf 2. Stufe

1

nd

Cylinder head 2 stage Culasse 2 ème étage 6

20.10.70

Stiftschraube

8

Stud bolt Goujon prisonnier 7

20.10.80

Scheibe

8

Disk Disque 8

20.10.90

Sechskantmutter

8

Hexagon nut Écrou hexagonal 9

20.10.100

Stiftschraube

4

Stud bolt Goujon prisonnier 10

20.10.110

Distanzring (nur bei L9) Distance ring (for L9 only) Bague d‘écartement (seulement pour L9)

1

L9 / L14

Ventile Valves Soupapes

Tafel / Table / Planche 2-199-020

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

20.20.10

Lamellenventil 1. Stufe

1

st

Reed-type valve 1 stage Soupape à lamelles 1er étage 2

20.20.20

Dichtung

1

Gasket Garniture 3

20.20.30

Dichtring

1

Packing ring Rondelle de joint 4

20.20.40

Lamellenventil 2. Stufe

1

nd

Reed-type valve 2 stage Soupape à lamelles 2ème étage 5

20.20.50

Dichtung

1

Gasket Garniture 6

20.20.60

Dichtring Packing ring Rondelle de joint

1

Kolben Pistons Pistons

L9 / L14 Tafel / Table / Planche 3-199-020

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

20.30.10

Kolben 1. Stufe kompl.

1

st

Piston 1 stage, complete Piston 1er étage, complet 2

20.30.10.20

Kolbenbolzen

1

Wrist pin Axe du piston 3

20.30.10.30

Sicherungsring

2

Securing ring Segment de sécurité 4

20.30.10.40

Minutenring

1

Taper-faced compression ring Segment compresseur à face conique 5

20.30.10.50

Nasenreing

1

Stepped scraper ring Segment à talon 6

20.30.10.60

Schlauchfederring

1

Oil scraper ring Racleur d’huile 7

20.30.20

Kolben 2. Stufe, kompl.

1

nd

Piston 2 stage, complete Piston 2ème étage, complet 8

20.30.20.20

Kolbenbolzen

1

Wrist pin Axe du piston 9

20.30.20.30

Sicherungsring

1

Securing ring Segment de sécurité 10

20.30.20.40

Nasenring

2

Stepped scraper ring Segment à talon 11

20.30.20.50

Minutenring Taper-faced compression ring Segment compressuer à face conique

1

Pleuelstangen Connecting rods Bielles

L9 / L14 Tafel / Table / Planche 4-199-020

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

20.40.10

Pleuelstange 1. Stufe, kompl.

1

st

Connecting rod 1 stage, complete Bielle 1er étage, complet 2

20.40.10.10.20

Nadelhülse

1

Needle bearing Palier à aiguilles 3

20.40.10.10.30

Nadellager

1

Needle bearing Palier à aiguilles 4

20.40.20

Pleuelstange 2. Stufe, kompl.

1

nd

Connecting rod 2 stage, complete Bielle 2ème étage, complet 5

20.40.20.10.20

Nadelhülse

1

Needle bearing Palier à aiguilles 6

20.40.20.10.30

Nadellager

1

Needle bearing Palier à aiguilles 7

20.40.30

Distanzring

1

Distance ring Bague d’écartement 8

20.40.40

Sicherungsring Securing ring Segment de sécurité

1

Kühlsystem Cooling system Système de refroidissement

L9 / L14 Tafel / Table / Planche 1-199-030

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

30.10.10

Kühler 1. Stufe

1

st

Cooler 1 stage Refroidisseur 1er étage 2

30.10.20

Kühler 2.Stufe

1

nd

Cooler 2 stage Refroidisseur 2ème étage 3

30.10.30

Gerade Einschraubverschraubung

4

Straight male stud coupling Union simple mâle 4

30.10.40

Aramturenträger

1

Fitting support Support de robineterie 5

30.10.50

Dichtung

1

Gasket Garniture 6

30.10.60

Sechskantschraube

2

Hexagon head bolt Vis à tête hexagonale 7

30.10.70

Sicherungsring

2

Securing ring Segment de sécurité 8

30.10.80

Verschlußschraube

2

Screw plug Vis de fermeture 9

30.10.90

Dichtring

2

Packing ring Rondelle de joint 10

30.10.100

Luftauslaß

1

Compressed-air outlet Sortie sur l‘ air comprimé 11

30.10.110

Zylinderschraube Cylinder head bolt Vis à tête cylindrique

2

Kühlsystem Cooling system Système de refroidissement

L9 / L14 Tafel / Table / Planche 1-199-030

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

12

30.10.120

Verschlußschraube

2

Screw plug Vis de fermeture 13

30.10.130

Dichtring

2

Packing ring Rondelle de joint 14

30.10.140

Befestigungsschelle

1

Double clamp Agrafe double de serrage 15

30.10.150

Senkschraube

1

Countersunk head screw Vis à tête fraisée 16

30.10.160

Sicherheitsmutter

1

Locking nut Écrou de blocage 17

30.10.170

Sechskantmutter

1

Hexagon nut Écrou hexagonal 18

30.10.180

Radial-Lüfterrad

1

Radial fan wheel Roue de ventilateur radiale 19

30.10.190

Scheibe

1

Disc Disque 20

30.10.200

Sechskantschraube

1

Hexagon head bolt Vis à tête hexagonale 21

30.10.210

Frontplatte

1

Front cover Couvercle avant 22

30.10.220

Lüfterhaube Air blast housing Carter du ventilateur

1

Kühlsystem Cooling system Système de refroidissement

L9 / L14 Tafel / Table / Planche 1-199-030

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

23

30.10.230

Nietmutter

4

Rivet nut Écrou à river 24

30.10.240

Sechskantschraube

3

Hexagon head bolt Vis à tête hexagonale 25

30.10.250

Sechskantschraube

5

Hexagon head bolt Vis à tête hexagonale 26

30.10.260

Scheibe

5

Disc Disque 27

30.10.270

Scheibe

3

Disc Disque 28

30.10.280

Gerade Einschraubverschraubung Straight male stud coupling Union simple mâle

1

L9 / L14

Armaturen Fittings Robinetterie

Tafel / Table / Planche 1-199-040

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

40.10.10

Manometer 1. Stufe

1

st

Pressure gauge 1 stage Manomètre 1er étage 2

40.10.20

Manometer 2. Stufe

1

nd

Pressure gauge 2 stage Manomètre 2ème étage 3

40.10.30

Anschlußstück

2

Fitting Raccord 4

40.10.40

Wika-Dichtring

2

Wika sealing ring Rondelle de joint wika 5

40.10.50

Dichtring

2

Packing ring Rondelle de joint 6

40.10.60

Sicherheitsventil 1. Stufe

1

st

Safety valve 1 stage Soupape de sûreté 1er étage 7

40.10.70

Sicherheitsventil 2. Stufe

1

nd

Safety valve 2 stage soupape de sûreté 1er étage 8

40.10.80

Dichtring

2

Packing ring Rondelle de joint 9

40.10.100

Handventil

1

Manual drain valve Soupape de vidange 10

40.10.110

Gerader Einschraubstutzen

1

Straight male stud coupling Union simple mâle 11

40.10.120

Einstellbare Winkelverschraubung Adjustable elbow coupling Equerre orientable

1

Schwungrad und Kupplung Flywheel and coupling Volant et accouplement

L9 / L14 Tafel / Table / Planche 1-199-014

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

14.10.10

Kupplungshälfte

1

Coupling half Demi-accouplement 2

14.10.20

Elast. Zahnkranz

1

Flexible gear rim Couronne dentée élastique 3

14.10.30

Kupplungshälfte

1

Coupling half Demi-accouplement 4

14.10.40

Gewindestift

1

Threaded pin Cheville filetée 5

14.20

Scheibe

1

Disc Disque 6

14.30

Sechskantschraube

1

Hexagon head bolt Vis à tête hexagonale 7

14.40

Sicherungsring Securing ring Segment de sécurité

1

Ansaugsystem Suction system Système d’aspiration

L9 / L14 Tafel / Table / Planche 1-199-032

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

32.10

Dämpferfilter

1

Air-intake filter with silencer Filtre d‘ aspiration 2

32.20

Schlauch

1

Hose Tuyauterie 3

32.30

Schlauchschelle Hose clip

2

Starre Lagerung Rigid mounting Suspension rigide

L9 / L14 Tafel / Table / Planche 1-199-043

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

43.10

Fußschiene

2

Support Support 2

43.20

Sechskantschraube

4

Hexagon head bolt Vis à tête hexagonale 3

43.30

Distanzstück

1

Distance piece Pièce d‘ échartement 4

43.40

Sechskantschraube Hexagon head bolt Vis à tête hexagonale

2

Elastische Lagerung Resilient mounting Suspension élastique

L9 / L14 Tafel / Table / Planche 1-199-044

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

44.10

Platte

1

Plate Plaque 2

44.20

Schwingmetallpuffer

2

Rubber to metal bonded foot Pied en caoutchouc-métal 3

44.30

Sechskantschraube

8

Hexagon head bolt Vis à tête hexagonale 4

44.40

Schwingmetallpuffer

1

Rubber to metal bonded foot Pied en caoutchouc-métal 5

44.50

Platte

1

Plate Plaque 6

44.60

Sechskantmutter Hexagon nut Ecrou hexagonal

1

L9 / L14

Automatische Entwässerung Automatic drainage Vidange automatique

Tafel / Table / Planche 1-303-053

Teil-Nr. / Part-No.

Ident-Nr. / Ident-No.

Benennung / Designation

Menge / Qty.

No. de pièces

No. d´identific

Désignation

Qté.

1

53.10.1

2/2-Wege-Magnetventil 1. Stufe

1

st

2/2-way solenoid valve 1 stage Soupape électro-magnetique a 2/2 orifices 1er étage 53.10.2

2/2-Wege-Magnetventil 2. Stufe 2/2-way solenoid valve 2nd stage Soupape électro-magnetique a 2/2 orifices 2ème étage

1

ENGLISH

0280.1400

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ELECTRIC MOTORS

ENGLISH READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR

RECEIVING CHECK Check if any damage has occured during transportation. üCheck nameplate data. üRemove shaft locking device (if any) before operating the motor. üTurn the shaft with the hand to make sure it is turning freely.

HANDLING AND TRANSPORTATION 1 - General

In case the motors are stored for more than two years, the bearings must be replaced or the lubrication grease must be totally removed after cleaning. Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any). We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas. If motor is fitted with space heaters, these should be switched on. Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYEBOLTS Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices then a double chain must be used to lift it. Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged. DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE. THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN WHEN THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE.

STORAGE If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases, corrosive smokes, under constant temperature and in normal position free from other objects. Motor storage temperature must remain between 5ºC to 60ºC, with relative humidity not exceeding 50%.

Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding. The resistance measured at 25ºC must be: Ri ≥ (20 x U) / (1000 + 2P) [MΩ] (measured with a MEGGER at 500 V d.c.) where U = voltage (V); P = power (kW). If the insulation resistance is less than 2 megaohms, the winding must be dried according to the following: Warm it up inside an oven at a minimum temperature of 80ºC increasing 5ºC every hour until 105ºC, remaining under this temperature for at least one hour. Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be reimpregnated.

INSTALLATION 1 - Safety All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be well informed and updated concerning safety standards and principles that govern the work and carefully follow them. We strongly recommend that these jobs are carried out by qualified personnel.

MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE. Motors must be protected against accidental starts. When performing any maintenance service, disconnect the motor from the power supply. Make sure all accessories have been switched off and disconnected. In order to prevent from penetrating dust and/or water into the terminal box, cable glands or threaded pipe in the lead holes must be installed. Do not change the regulation of the protecting devices to avoid damaging. 2 - Operating Conditions Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 0ºC and 40ºC. Any variation is stated on the nameplate. COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE. Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate. KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER. 3 - Foundation Motors provided with feet must be installed on solid foundations to avoid excessive vibrations. The purchaser is fully responsible for the foundation. Metal parts must be painted to avoid corrosion. The foundation must be uniform and sufficiently tough to support any schock. It must be

designed in such a way to stop any vibration originated from resonance. 4 - Drain Holes Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order. 5 - Balancing WEG MOTORS ARE DYNAMICALLY BALANCED WITH HALF KEY, AT NO LOAD AND UNCOUPLED. Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before installation. Use always appropriate tools for installation and removal. 6 - Alignment ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE. Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings. When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings. Suitable assembly of half-coupling: Check that clearance Y is less than 0.05 mm and that the difference X1 to X2 is less than 0.05 mm, as well.

Note: Dimension X1 and X2 must be 3mm minimum Figure and alignment tolerances 7 - Belt Drive When using pulley or belt coupling, the following must be observed: Belts must be tighten just enough to avoid slippage when running, according to the

specifications stated on the belt supplier recommendation. WARNING: Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture. 8 - Connection WARNING: Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating. WARNING: The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even when the motor has reached standstill. A WRONG CONNECTION CAN BURN THE MOTOR. Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ±10%; the acceptable frequency variation is ±5% and the total acceptable variation is ± 10%. 9 - Starting Methods The motor is rather started through direct starting. In case this is not possible, use compatible methods to the motor load and voltage. The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1, L2, L3. To change the rotation direction, interchange two of the connecting leads. THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION. AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED.

Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate. BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE CURRENT STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS. When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, termal protector, etc, connect their terminals to the corresponding devices on the control panel. 10 - Start-Up THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR. a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the connections and the mounting before starting it again. b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done. c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate.

MAINTENANCE WARNING: SAFETY CHECK LIST 1 - General Inspection üCheck the motor periodically. üKeep the motor clean and assure free air flow. üCheck the seals or V Ring and replace them, if required. üCheck the connections as well as supporting screws. üCheck the bearings and observe: Any excessive noise, vibration, bearing temperature and grease condition. üWhen a change, under normal conditions, is detected, check the motor and replace the required parts.

The frequency of the inspections depends on the motor type and on the application conditions.

LUBRICATION FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION. 1 - Machines without Grease Nipples Motors up to frame 200 are normally fitted without grease nipples. In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects: üDisassemble carefully the motors. üTake all the grease out. üWash the bearing with querosene or diesel. üRegrease the bearing immediately.

2 - Machines Fitted with Grease Nipples It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc) that offer some risk to the physical integrity of the operator, proceed as follows: üClean the area near the grease nipple. üPut approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off the motor and insert the rest of the grease. üThe injection of all the grease with the motor in standstill can make the grease penetrate into the motor, through the inner seal of the bearing housing. FOR LUBRICATION USE ONLY MANUAL GREASE GUN.

RELUBRICATION INTERVALS TABLE 1 - BALL BEARINGS - Series 62/63 II pole

Relubrication intervals (running hours – horizontal position) IV pole

VI pole

Bearing 6209 6211 6212

60Hz 18400 14200 12100

50Hz 20000 16500 14400

60Hz 20000 20000 20000

50Hz 20000 20000 20000

60Hz 20000 20000 20000

Bearing 6309 6311 6312 6314 6316 6319 6322

60Hz 15700 11500 9800 3600 -

50Hz 18100 13700 11900 4500 -

60Hz 20000 20000 20000 9700 8500 7000 5100

50Hz 20000 20000 20000 11600 10400 9000 7200

60Hz 20000 20000 20000 14200 12800 11000 9200

Serie 62

VIII pole

50Hz 60Hz 20000 20000 20000 20000 20000 20000 Serie 63 50Hz 60Hz 20000 20000 20000 20000 20000 20000 16400 17300 14900 15900 13000 14000 10800 11800

X pole

XII pole

Grease

50Hz 20000 20000 20000

60Hz 20000 20000 20000

50Hz 20000 20000 20000

60Hz 20000 20000 20000

50Hz 20000 20000 20000

(g) 9 11 13

50Hz 20000 20000 20000 19700 18700 17400 15100

60Hz 20000 20000 20000 19700 18700 17400 15100

50Hz 20000 20000 20000 20000 20000 18600 15500

60Hz 20000 20000 20000 20000 20000 18600 15500

50Hz 20000 20000 20000 20000 20000 20000 19300

(g) 13 18 21 27 34 45 60

TABLE 2 - ROLLER BEARINGS - Series NU 3 Relubrication intervals (running hours – horizontal position) II pole Bearing NU 309 NU 311 NU 312 NU 314 NU 316 NU 319 NU 322 NU 324

60Hz 9800 6400 5100 1600 -

50Hz 13300 9200 7600 2500 -

IV pole 60Hz 20000 19100 17200 7100 6000 4700 3300 2400

50Hz 20000 20000 20000 8900 7600 6000 4400 3500

VI pole 60Hz 20000 20000 20000 11000 9500 7600 5900 5000

50Hz 20000 20000 20000 13100 11600 9800 7800 6600

VIII pole 60Hz 20000 20000 20000 15100 13800 12200 10700 10000

50Hz 20000 20000 20000 16900 15500 13700 11500 10200

X pole 60Hz 20000 20000 20000 16900 15500 13700 11500 10200

50Hz 20000 20000 20000 19300 17800 15700 13400 12100

XII pole 60Hz 20000 20000 20000 19300 17800 15700 13400 12100

50Hz 20000 20000 20000 20000 20000 20000 17300 15000

Grease (g) 13 18 21 27 34 45 60 72

Note: üThe ZZ bearings from 6201 to 6307 do not require relubrication as its life time is about 20,000 hours. üTables 1 and 2 are intended for the lubrication period under bearing temperature of 70°C (for bearings up to 6312 and NU 312) and temperature of 85°C (for bearings 6314 and NU 314 and larger). üFor each 15°C of temperature rise, the relubrication period is reduced by half. üThe relubrication periods given above are for those cases applying Polyrex® EM grease. ü When motors are used on the vertical position, their relubrication interval is reduced by half if compared to horizontal position motors. WE RECOMENDED TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD. WARNING: EXCESS OF GREACE CAN CAUSE BEARNING OVERHEATING RESULTING IN COMPLETE DAMARGE. Compatibility of Polyrex® EM grease with other types of grease: Containing polyurea thickener and mineral oil, the Polyrex® EM grease is compatible with other types of grease that contain: üLithium base or complex of lithium or polyurea and highly refined mineral oil. üInhibitor additive against corrosion, rust and anti-oxidant additive. Notes: üAlthough Polyrex® EM is compatible with types of grease given above, we do not recommended to mix it with any other greases. ü If you intend to use a type of grease different than those recommended above , first contact WEG. üOn applications (with high or low temperatures, speed variation, etc), the type of grease and relubrification interval are given on an additional nameplate attached to the motor. THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE MANUFACTURER OR WEG

DISASSEMBLY AND ASSEMBLY Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated methods.

The stator grips must be applied over the side face of the inner ring to be disassembled or over an adjacent part. It is essential that bearings assembly be done under cleanning conditions to ensure good operation and to avoid damages. New bearings shall only be taken out from their cases when assembling them. Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals. For bearing assembly warm their inner parts withsuitable equipment - inductive pocess - or use suitable tools.

SPARE PARTS When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate. Please also inform the motor serial number stated on the nameplate.

MOTORS FOR HAZARDOUS LOCATIONS Besides the recommendations given previously, these ones must be also followed: THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY, WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS. Motors for hazardous locations are manufactured according to specific standards for such environments and they are certified by worldwide certifying entities. 1 - Installation The complete installation must follow procedures given by the local legislation in effect. THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT. 2 - Maintenance Maintenance must be carried out by repair shops authorized by WEG. Repair shops and people without Weg’s authorization who will perform any service on hazardous location motors will be fully responsible for such service as well as for any consequential damage.

ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION. When performing maintenance, installation or relubrication, follow these instructions: üCheck if all components are free of edges, knocks or dirt. üMake sure all parts are in perfect conditions. üLubricate the surfaces of the endshield fittings with protective oil to make the assembly easier. üUse only rubber hammer to fit the parts. üCheck for correct bolts tightening. üUse clearance calibrator for correct T-box fitting (smaller than 0.05mm). DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE FACTORY.

MOTORS DRIVEN BY VFD Applications using VFD´s without filter can affect motor performance as follows:

üLower efficiency. üHigher vibration. üHigher noise level. üHigher rated current. ü Higher temperature rise. üReduced motor insulation. üReduced bearing life. 1- Standard Motors üVoltages lower than 440V do not require filter. üVoltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters. üVoltages equal or higher than 575V require filter for any size of power supply cables. IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY, MOTOR WARRANTY WILL BE VOID. 2- Inverter Duty Motors: üCheck power supply voltage of the forced cooling set. üFilters are not required.

WARRANTY TERMS Weg warrants its products against defects in workmanship and materials for twelve (12) months from the invoice date issued by the factory, authorized distributor or agent limited to eighteen (18) months from manufacturing date independent of installation date as long as the following items are fulfilled accordingly: -

-

-

Proper transportation, handling and storage; Correct installation based on the specified ambient conditions and free of corrosive gases; Operation under motor capacity limits; Observation of the periodical maintenance services; Repair and/or replacement effected only by personnel duly authorized in writing by Weg; The failed product be available to the supplier and/or repair shop for a required period to detect the cause of the failure and corresponding repair; Immediate notice by the purchaser about failures accured and that these are accepted by Weg as manufacturing defects.

This warranty does not include disassembly services at the purchaser facilities, transportation costs with product, tickets, accomodation and meals for technical personnel when requested by the customer. The warranty service will be only carried out at Weg Authorized Repair Shops or at Weg’s facilities. Components whose useful life, under normal use, is shorter than the warranty period are not covered by these warranty terms. The repair and/or replacement of parts or components, when effected by Weg and/or any Weg Authorized Repair Shop, will not give warranty extension. This constitutes Weg’s only warranty in connection with this sale and the company will have no obligation or liability whatsoever to people, third parties, other equipment or installations, including without limitation, any claims for consequential damages or labor costs.

WEG EXPORTADORA S.A. AV. PREF. WALDEMAR GRUBBA, 3000 89256-900 JARAGUÁ DO SUL, SC - BRAZIL PHONE (55) (47) 372-4002 FAX (55) (47) 372-4060 http://www.weg.com.br FOR FURTHER INFORMATION PLEASE CONTACT YOUR NEAREST WEG SALES OFFICE

Bedienungsanleitung Operating Manual

Schraubenkompressor Screw Compressors HSC 4 - 75

Operating instructions HATLAPA Screw Compressors

Type Serial number

Date

Operating instructions Component overview

7 12

23

Fig. 1: 1 2 3 4 5 6 7 8 9 10 11

24 13

4

28

10

25

5

27 26

6

2

8

19

20

9

3

21

22 1

16 17 11 18 15 14

Component overview

Compressor Compressed air / oil reservoir Oil high-precision separator cartridge Electric motor Fan PROCON control Proportional controller (optional) Name plate Drain line Pressure detector Safety valve

12 Switch box 13 Oil thermostat 14 Temperature sensor

15 16 17 18 19 20 21 22 23 24 25

Oil and condensation water drain valve Pressure reservoir name plate Oil gauge Oil filler neck V-belt tensioning roller Suction stop valve Control valve Relief valve Suction filter Oil filter Compressed-air outlet with cut-off valve (optional) 26 Compressed-air aftercooler 27 Oil cooler 28 Super sound proofing hood

104482 HSC • 03/03

Operating instructions PROCON control

8

9

10

11

12

00 .

20

Fig. 2: 1 2 3 4 5 6 7 8 9 10 11 12 13 14

104482 HSC • 03/03

5

14

bar

°C

4

13

6

7

1

2

3

Operating elements

Power switch Circuit-breaking key Emergency stop In the menu: Edit mode: In the menu: Edit mode: In the menu: Edit mode: In the menu: Edit mode: Permanent yellow: Permanent yellow: Permanent yellow: Permanent green: Green flashing: Blinking yellow: Blinking yellow: Red flashing:

One line up Increase value One line down Selection of the menu Call up information Cancel value input Selection of the menu Apply value Base load sequencer operating mode Remote operation Automatic restart Motor is running Standby, motor can start automatically at any time Maintenance Warning Type of malfunction

1

Operating instructions Table of contents PROCON control Table of contents

Technical annex

Component overview PROCON control 1 1.1 1.2 1.3

Fundamental safety instructions....... 2 Designated use ........................................ 2 Fundamental measures.......................... 2 Description of symbols and notes ........ 2

2 2.1 2.2

Transport and storage ......................... 2 Transport .................................................. 2 Storage...................................................... 2

3 3.1 3.2 3.3 3.4

Mounting ................................................ 3 Mounting conditions............................... 3 Compressed-air port ............................... 4 Electrical connection .............................. 4 Checking the rotating direction ............ 5

4 4.1 4.2 4.3 4.4 4.5 4.6 4.7

Operation................................................ 7 Safety instructions .................................. 7 Switching the unit on ............................. 7 Start-up after an extended idle time..... 7 Weekly check ........................................... 7 Switching the unit off ............................. 7 Remote control ........................................ 8 Original HATLAPA accessories ............ 8

5 5.1 5.2 5.3

PROCON control .................................. 9 Operating elements ................................ 9 Display features....................................... 9 Input of parameters................................. 9

6 6.1 6.2 6.3 6.4 6.5 6.6

Inspection and servicing ................... 13 Safety instructions ................................ 13 Checking and topping up the oil level 13 Changing the oil .................................... 14 Changing oil filter.................................. 14 Draining the condensation water ....... 15 Cleaning the oil cooler and the compressed-air aftercooler.................. 15 Checking safety valve ........................... 15 Changing oil high-precision separator cartridge.................................................. 15 Checking and changing the suction filter cartridge ........................................ 15 Clean proportional controller nozzle. . 16 Cleaning drain restrictor ...................... 16 Checking and adjusting the V-belt ..... 16 Notes on systems equipped with water cooling system....................................... 17 Tighten the screw connections. .......... 17 Checking electric terminals................. 17 Relubricating / replacing motor mounting ................................................ 17

6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16

104482 HSC • 03/03

7

Maintenance schedule....................... 18

8 8.1 8.2 8.3

Trouble shooting ................................ 20 Malfunction, compressor generally.... 20 Malfunction, PROCON control............ 24 Warnings, PROCON control ................ 25

1

Operating instructions Fundamental safety instructions 1

Fundamental safety instructions

1.1

Designated use

2

Transport and storage

2.1

Transport

The compressor system is intended exclusively for the generation of compressed air. Any other use shall be considered an undesignated use.

• •

1.2 • • • • • • • •

• •

1.3

Fundamental measures Never point compressed air at persons. Observe these operating instructions. Keep these operating instructions available at the location of use at all times. Please observe the regular maintenance intervals (refer to chapter 7 “Maintenance schedule”). Use original HATLAPA parts and approved operating material only. Do not use compressed air for breathing without corresponding treatment. Do not modify the system. Use mounting parts and devices downstream from the compressor which have been designed for the maximum operating overpressure of the compressor. In your capacity as proprietor, please ensure that all safety regulations are observed by the operating staff. Do not use the compressor as a climbing aid.

Description of symbols and notes

• • • • •

2.2

Danger Mortal danger caused by incorrect transport. Do not hold the compressor at its cladding elements as you lift it. Only use suitable lifting gear with the corresponding weight-bearing capacity (for data on weight, please refer to chapter “Technical annex”). Fasten and secure the system with belts at the corresponding points. Secure swivelling and loose parts. Transport the compressor by means of crane hooks, fork-lift truck and elevating truck only. Never remain under suspended loads. Depressurise the compressor prior to any transport.

Storage

Store the compressor in a dry location protected against weather influence. Ambient temperature: -10°C to +50°C. Please order the HATLAPA conservation instructions in case of storage of over six months. For information on recommissioning after an extended idle time, please refer to chapter 4.3.

Danger Mortal danger and risk of injury. Caution Damage to property. Information and tips.

2

104482 HSC • 03/03

Operating instructions Mounting 3

Mounting

3.1

Mounting conditions

!

Cooling and exhaust air

Check the compressor for damage during transport.

•

Ambient conditions

•

Danger Mortal danger and explosion hazard when caustic, inflammable or poisonous gases are drawn in. Do not operate the compressor in explosive surroundings or in the vicinity of open flames and flying sparks.

•

Danger Mortal danger and explosion hazard during suction. Ensure that the compressor takes in only clean air which is free from noxious constituents. Noxious substances are liable to accumulate in the lubricating oil of the compressor. They may cause explosions in the system and heavy damages. Do not allow objects or pieces of clothing of persons going past to be sucked in by the intake air flow.

1

Caution Wrong mounting will cause damage to the compressor. Ensure sufficient ventilation of the compressor room. Do not operate the compressor in the open. Systems with a capacity exceeding 40 kW must be installed in such a way that no combustible objects or materials are in the immediate proximity. Systems with a capacity exceeding 100 kW should be installed in a separate room.

2

The space between the compressor and the wall has to be at least 60 cm (cf. Fig. 3: Location). The compressor has to be easily accessible from all sides. The ambient temperature has to be between 3°C and 40°C.

C

• • •

•

A

D

E

Fig. 4: > 60 cm

+3°C - +40 °C

Fig. 3:

104482 HSC • 03/03

B

1 2 A B C D E

A

A

Room ventilation

Intake air Exhaust air Air inlet Air outlet Ventilation duct Exhaust fan Elastic connecting piece

Location

3

Operating instructions Mounting The overall length of all air intake and exhaust ducts must not exceed 4m; one baffle is permissible. In case of conduits exceeding this length or in case of several baffles, a booster fan must be installed. In this case, please contact your technical adviser.

•

For further information on the required ventilation cross sections, please refer to the Technical Annex. •

Ground !

Place the compressor on a horizontal and plane surface.

The ground has to have a suitable loadbearing capacity. HATLAPA offers special solutions for inclined surfaces. In order to reduce vibrations, HATLAPA recommends rubber-metal connections.

3.2

Compressed-air port

The connection to the compressed-air ductwork system may be carried out only by trained experts or by staff members of HATLAPA Company.

•

Danger Danger of injury by pressure in the pipes. Vent the pipes to which the compressor is connected. Use a flexible hose to connect the compressor to the supply network. Thus, stress cracks and sound bridges are prevented.

•

•

Compressed-air lines, filters, aftercoolers and vessels must at their lowest spots be equipped with an outlet for the condensation water accumulated. These outlets must allow to observe the draining condensation water. Condensation water may contain oil! In draining the condensation water, all applicable regulations on the disposal of waste water must be complied with. Remove all securing devices before you start to install the conduits. Use only suitable connecting lines and couplings which are designed for the intended working pressure. Do not use any defect component. Supply lines must not be subjected to stress or tension.

Observe the technical data for the connection of compressed air (cf. chapter “Technical annex”).

3.3

Electrical connection

The connection to the electrical power system may be carried out only by adequately trained expert.

•

Danger Mortal danger caused by electric voltage but also by rotating wheels, Vbelts, and fan blades. Test runs are permissible only if all parts of the casing are closed (exception: check of the rotating direction).

Compressor systems have to be fitted with a power switch or a plug connection to interrupt the power supply. Compressor systems with a motor capacity of more than 3 kW or 16 Amps have to be fitted with a lockable power switch and upstream fuses. In this respect, please refer to the circuit diagram in the chapter titled “Technical annex” or in the switch cabinet as well as to the following connection conditions. Check and retighten where appropriate all electric terminals before first commissioning.

4

104482 HSC • 03/03

Operating instructions Mounting 3.4

Checking the rotating direction

•

! ! !

!

104482 HSC • 03/03

Caution Fire hazard and damage to compressor in case of wrong polarisation of the motor (5 revolutions maximum in the wrong direction of rotation!). Carry out the check of the rotating direction as described below:

Open side cladding of the compressor. Please refer to chapter 4.2 titled “Switching the unit on”. Press the power switch, and immediately after this the emergency stop (see fig. 2: Operating elements). The correct rotating direction of the fan has been marked by an arrow on the fan cover. Change the poles of the electric connection of the motor in case of a wrong rotating direction.

5

Operating instructions Mounting Electrical connection conditions The connection to the electrical power system may be carried out only by adequately trained expert. Caution Overvoltages and undervoltages must not exceed the 10% mark.

This unit is intended for operation on a power supply network with a maximum system impedance Zmax at the interconnection point (house service line), which is listed in the table below in dependence of the performance. The user shall have to ensure that the unit is operated only on a power supply network which meets these requirements. If and when necessary, the local power supply company can provide information on the system impedance.

Motor performance

400V-50Hz 3 ph Protection Motor rated cur- – stardelta rent starting

Protection – direct starting A

Motor performance

230V-50Hz 1 ph Protection Motor rated cur- – stardelta rent starting

kW

A

kW

A

1.1 1.5 2.2

2.6 3.5/4.1 5.0/6.0

6 10 16

1.1 1.5 2.2

2.6 3.5/4.1 5.0/6.0

6 10 16

3.0

6.6/8.1

16

3.0

6.6/8.1

16

4.0

8.5

16

20

4.0

8.5

16

5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0

11.5 15.5 22.5 30.0 36.0 43.0 58.0 68 81 99 134

20 25 35 50 50 63 80 80 100 125 160

5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0

11.5 15.5 22.5 30.0 36.0 43.0 58.0 68 81 99 134

20 25 35 50 50 63 80 80 100 125 160

A

A

Protection – direct starting A

20

Tab. 1: Characteristic value for the electrical connection The supply line cross sections provided are recommended values for a maximum 50m line length at 30°C. For fuse protection, use “slow-to-blow” or “gL” fuses. • 220/240 V systems require a three-core 1P/N/PE cable. • 380/400 V systems require a four-core 3P/PE cable for direct start. • 380/400 V systems require for star-delta starting a five-core supply line 3P/N/PE.

6

104482 HSC • 03/03

Operating instructions Operation 4

Operation

4.2

4.1

Safety instructions

!

•

Danger Mortal danger caused by sudden startup of the system. Systems which are in the standby operating mode are liable to start automatically at any time.

! ! ! !

• • • • • •

• •

• • • • • • • • • • •

104482 HSC • 03/03

All parts installed behind the check valve (e. g. aftercooler, pressure switch) are not released automatically from pressure. Not all transmission lines are de-energised when the system is switched off! Before commissioning, ensure that no person can be injured by the starting compressor. Never point compressed air at persons. Do not use compressed air for breathing without corresponding treatment. Use mounting parts and devices downstream from the compressor which have been designed for the maximum operating pressure of the compressor. Do not reach into the rotating wheels when the compressor is operational. Touch the compressor system at the on and off switch only during and shortly after operation. Hot surface can cause severe injuries. Switch the compressor off immediately in case of faults. Keep combustible materials away from the compressor system. Operate the compressor only with suction filter and if all parts of the casing are closed. Operate the compressor only at the permissible operating pressure of the pressure reservoir. Tighten the screw connections of the pressure pipes. Wear tight-fitting work cloths when handling the compressor. Wear goggles and ear muffs when working with compressed air. Wear a hair net to protect long hair and remove any lose jewellery. Check the cables for damage in regular intervals. Keep domestic animals and children away from the compressor system. Switch the compressor off when not needed.

!

Switching the unit on Check oil level through oil gauge and top up the oil if and when necessary (refer to chapter 6.2 “Checking and topping up the oil level”). Switch on the power switch. Press power switch (see fig. 2: operating elements). Signal lamp indicates readiness for operation. Compressor starts and after approx. 10sec. starts load operation. Open ball valve.

In case of faults, please refer to chapter 8 titled “Trouble shooting” for more help.

4.3

Start-up after an extended idle time.

During an extended idle time, the complete oil content flows into the compressed air / oil reservoir. If this has happened, the screw compressor is not any more lubricated. ! ! !

Dismount intake regulator. Fill approx. 1 litre compressor oil into the air intake fitting. Mount intake regulator. Do not mix different types of oil. In choosing the oil you want to use, refer to the corresponding HATLAPA specifications (refer to chapter 6.2 “Checking and topping up the oil level“).

4.4 •

4.5 ! !

Weekly check Check oil level of the compressor (refer to chapter 6.2 “Checking and topping up the oil level“).

Switching the unit off Press circuit-breaking key “0” (see fig. 2: operating elements). Switch off power switch.

7

Operating instructions Operation 4.6

Remote control

All systems which are equipped with remote control must bear a clearly visible label reading as follows: “Warning! This system is remotely controlled and is liable to start at any time." In addition, persons operating remotely controlled systems must ensure that the system is not started during maintenance or repair work. For this, a corresponding information sign must be affixed to the remote control unit. ! ! ! !

4.7

Open ball valve. Press power switch (see fig. 2: operating elements). Signal lamp indicates readiness for operation. System is now ready to be operated via remote control.

Original HATLAPA accessories

HATLAPA offers you the following accessories: For more information, please refer to the HATLAPA price list or directly to HATLAPA.

Compressed-air filter To clean the compressed air for special applications.

Refrigeration or adsorption dryer To prevent faults of the compressed air ductwork system, compressed-air tools, instruments and controls caused by humid air.

Top sound insulation To reduce noise emissions.

Base load sequencer Intelligent higher-order control system to control several compressors depending on the actual compressed air consumption.

Speed regulator Adapts speed and thus also energy consumption of the screw compressor to the actual compressed air consumption.

Water-cooling system For application conditions under which the standard fan cooling is not sufficient.

Heat exchanger Free of charge energy derived from heat produced by the compressor during operation which is then available to other consumers.

For more information on these and other pneumatic accessories, please refer to HATLAPA. Our address is on the last page of these operating instructions.

Automatic condensation water drain To spare you the daily draining of condensation water.

Oil and water separator Is fitted downstream of the condensation water drain. The separated water can be removed directly into the sewer system.

Rubber-metal connection To reduce vibrations.

8

104482 HSC • 03/03

Operating instructions PROCON control 5

PROCON control

5.1

Operating elements

See fig. 2 PROCON control

5.2

•

•

Display features

Basic display

•

During normal operation, the display indicates both network pressure and final compression temperature as three-digit figures. In the event of pressure or temperature measurement failure, the corresponding field shows “- - -”. The load operation of the system is indicated through a dot following the network pressure value. In the event of malfunction reports or warnings occurring, these will alternate with the analogue quantities in the pressure display every three seconds. Malfunction reports in the display start with an “E” followed by a two-digit malfunction code (refer to chapter 8.2 “Malfunction, PROCON control” and chapter 8.3 “Warnings, PROCON control”) whereas warnings start with an “A”. In addition, in case of malfunction a malfunction LED will light up; in case of a warning a warning LED will light up.

•

•

•

•

Line 3: Load operation hours. Load operation hours are indicated as five-digit figures. “L.“ will appear on the left side of the display (e. g. “ L.12 345“ for 12345h). Line 4: Air filter operating life. In the display “F1” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 5: Oil filter operating life. In the display “F2” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 6: Oil separator operating life. In the display “F3” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 7: Oil operating life. In the display “OIL” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 8: V-belt operating life. In the display “BE.” alternates with the corresponding operating life value. This line will appear only in case the V-belt is activated in the option menu. In addition, the maintenance LED flashes. Line 9: Software version, e. g. “PRO 1.00“ for Version 1.00.

Information menu !

!

!

•

•

104482 HSC • 03/03

To call up the first line of the information menu, keep key 6 (→) pressed for one second. The keys 4 and 5 (↑/↓) allow you to navigate within the menu structure. Press key 6 (→) to exit the menu; alternatively, the menu is also exited if no key has been pressed for 3 minutes. Line 1: System pressure indicator. The system pressure is displayed in place of the network pressure. “P2” will appear on the left side of the display. This line will appear only in case the system pressure input is activated in the option menu. In case an incorrect system pressure value has been obtained, the display will show “- - -”. Line 2: Hours of operation. Hours of operation are indicated as five-digit figures. “R.“ will appear on the left side of the display (e. g. “R.23 456“ for 23456h).

5.3

Input of parameters

Selection menu !

!

!

!

In order to enter parameters, keep key 7 (↵) pressed for three seconds. “COD.000” will appear in the display. Enter the code for the desired menu using the keys 4 and 5 (↑/↓). Confirm by pressing key 7 (↵), and the first parameter of the selected menu is displayed. In case an invalid code has been entered, or key 6 (→) has been pressed, the routine returns to the initial display.

Selection of parameters within a menu !

The keys 4 and 5 (↑/↓) allow you to navigate within the menu structure in the display modus.

9

Operating instructions PROCON control !

Press key 6 (→) to exit the menu; alternatively, the menu is also exited if no key has been pressed for 5 minutes.

Editing parameters within a menu !

!

!

!

Press key 7 (↵) to modify parameters. You are then in the edit mode. This is indicated by the corresponding parameter value flashing. The keys 4 and 5 (↑/↓) allow you now to modify the value. Press key 6 (→) to return to the display mode, and retain the previous value. Press key 7 (↵) to save the current value and to enter the next value that can be modified. In the event values have been modified within one menu, storage of the new values is signalled through a horizontal bar (for one second).

Pressure control menu (Code 010) Name

Message

Minimum A1. ##.# network pressure

Maximum network pressure

A2. ##.#

Setting range

Factory setting

Between 5.0 bar and maximum network pressure Between minimum network pressure and system pressure

8.5 bar

10.0 bar

Oil filter operating life Oil separator operating life Oil operating life V-belt operating life Shutdown maintenance

C2.# ###

0-9999h

500*

C3.# ###

0-9999h

2000

C4.# ###

0-9999h

500*

C5.# ###

0-9999h

C6.

0=No 1=Yes

0 (inactive) No

#

Tab. 3: Maintenance menu *

only first maintenance interval; the remaining intervals are 2000h

The maintenance intervals can be specified between 0-9999h while the input „0“ means that this interval should not be edited. In this place only the target values of the maintenance intervals are indicated; please infer the actual count from the information provided in the initial display (refer to initial display in chapter 5.2 “Display features”). After a maintenance interval has been modified, the corresponding count is reset while the new set value is being applied. Thus the respective interval can start again, for instance after maintenance work has been completed. Use the “C6” parameter to decide whether the compressor should be shut down after the maintenance interval has been exceeded by more than 100h. After the compressor has been shut down this way, the operator can acknowledge this error message and start the compressor for another 100h.

Tab. 2: Pressure control menu

Maintenance menu (Code 020) Name

Message

Air filter C1.# ### operating life

10

Setting range

Factory setting

0-9999h

2000

104482 HSC • 03/03

Operating instructions PROCON control Operating parameter menu (Code 030) Name

Message

Setting range

Factory setting

Base load sequencer operating mode Continuous operation Remote operation Re-starts automatically after power failure Power failure time Re-start delay

B1.

#

0=No 1=Yes

No

B2.

#

0=No 1=Yes

No

0=No 1=Yes 0=No 1=Yes

No

B5. ##

0-60s

1s

B6. ##

0-60s

0s

B3.

#

B4.

#

Tab. 4: Operating parameter menu

104482 HSC • 03/03

No

The pressure control is effected via an external contact during programmed operation of the base load sequencer. In case the remote control is activated the start-up is effected via an external contact. The control system reacts only to the positive signal edge for start-up of the device. If there is no input signal this means that the compressor is switched off. In this case you cannot use the keyboard to switch on or off the device. The “continuous operation” parameter allows to operate the compressor in the no-load operation mode and thus to prevent it from being switched off. You can specify two periods if the automatic restart after voltage breakdown has been activated. The power failure time specifies the maximum allowable period of voltage breakdown after which it is permitted to restart the device. If this value is set to “0”, the device can be restarted at any time. The re-start delay allows to prevent the compressor from restarting immediately after voltage recovery. This may be necessary to prevent several compressors connected to the mains network from starting simultaneously.

11

Operating instructions PROCON control Menu structure, customer menu Pressure control

Information °C 3s

bar

p2

00 .

. r23

456

°C 3s

System pressure (Option)

Hours of operation

. L12

345

F1.

999

F2.

999

F3.

999

oil

999

Maintenance intervals Operating parameter

bar

cod

010

a1.

90 .

A2.

100 .

Cut-in pressure M

Shut-off pressure

Load operation hours

3s

°C

bar

COD

020

. c11

500

Air filter operating life

c2.

500

Oil filter operating life

. c31

500

3s

°C

bar

Cod

030

b1 .

0

b2.

0

b3.

0

b4.

0

b5.

1

b6.

0

Base load sequencer operation Continuous operation

Oil separator operating life Remote operation

Air filter operating life

C4.

500

C5.

0

C6.

0

Oil operating life

Oil filter operating life

V-belt operating life

Oil separator operating life

Disable maintenance

Oil operating life

Automatic restart

Power failure time

Re-start delay

Edit:

be

999

V-belt operating life

Edit mode Increase values

pro

. 100

Software version

Fig. 1:

12

Decrease values Apply value

Cancel: Return to the basic mode without retaining all previous values

Menu structure, customer menu

104482 HSC • 03/03

Operating instructions Inspection and servicing 6

Inspection and servicing

6.1

Safety instructions

6.2

The inspection and servicing may be carried out by experts or trained persons only. • • • • • •

Switch the compressor off for all servicing work, and protect the unit against unintentional operation. Prior to any servicing work set the power switch to off or remove the mains plug. Use original HATLAPA parts and approved operating material only. After having completed the servicing work tighten all screws again. Depressurise the compressor prior to any servicing work. Touch the compressor system at the on and off switch only during and shortly after operation. Permit the compressor to cool down prior to any servicing work. Hot surfaces can cause severe injuries.

Before commencement of work, the following steps must always be carried out. ! ! ! !

! !

!

!

104482 HSC • 03/03

Close cut-off valve at compressed air outlet 25 (see fig. 1: component overview). Shut down the system. Switch off power switch. Open slowly the screw plug of the compressed air aftercooler 26 to release air pressure. Wait until no more air exits the postcooler, and tighten the screw plug. Wait until the remaining system is released from pressure and has cooled down. Unscrew oil filler neck 18 by approx. 1 turn to check whether pressure has been released completely. Wait until no more air exits the oil filler neck 18, and tighten again oil plug.

Checking and topping up the oil level

• •

Danger Scalding hazard by draining hot oil. Slowly open the oil filler neck. Avoid skin contact with hot oil

2

1

Fig. 5: 1 2

Oil level indication

min. mark max. mark

Checking the oil level ! !

!

! ! !

Switch the compressor off and depressurise. Drain off the condensation water before you check the oil level (refer to chapter 6.5 “Draining the condensation water”). Unscrew oil filler neck 18 (see fig. 1: Component overview) by approx. 1 turn to check whether pressure has been released completely. Check oil level through oil gauge 17 (see fig. 1: component overview). The oil level has to be within the min. / max. level. Check whether the oil has a milky discoloration or contains water drops (for measures, please refer to chapter 8 titled “Trouble shooting / Milky colour of the oil, water drops in the oil”).

13

Operating instructions Inspection and servicing Topping up oil

6.3

Do not mix different types of oil. Exclusively use types of oil specified by HATLAPA. ! ! ! !

!

Switch the compressor off and depressurise. Carry out the above steps as described in the “Checking oil level” section. Remove oil filler neck 18. Slowly fill in the oil until the oil level as indicated by the oil gauge 17 is within the min. / max. range. Screw on the oil filler neck.

• •

!

Types of oil

The degree of viscosity of the oil chosen should be based on the ambient temperature according to ISO 3448. Ambient temperature 0 up to +25°C Permanently higher than 25°C Viscosity class Viscosity at 40 °C Point of ignition Pour point

ISO VG 46

ISO VG 68

At least 5°C below lowest ambient temperature.

Tab. 5: Types of oil We assume no warranty unless the lubricants used in our screw compressors show these essential characteristics.

14

!

! ! !

!

Switch the compressor off and depressurise. Place a suitable collecting vessel under the oil and condensation water drain valve 15. Open oil and condensation water drain valve 15 while it is at operating temperature. Drain the oil into the vessel. Close oil and condensation water drain valve 15. Open oil filler neck 18 and fill in the new oil slowly (refer to chapter 6.2 “Types of oil”) until the oil level as indicated by the oil gauge 17 is within the min. / max. range. Screw on the oil filler neck.

6.4

Changing oil filter

• •

41 up to 51 61 up to 75 mm²/s mm²/s > 200°C

Danger Scalding hazard by draining hot oil. Slowly open the oil filler neck. Avoid skin contact with hot oil Used oil has to be disposed of according to the local environmental regulations.

!

On account of the high stress the lubricating oil is exposed to in screw compressors with oil injection cooling, we recommend to use HATLAPA special purpose oils with AFS (anti foam system) additives showing an extremely good aging and water-repellent behaviour; these oils do not foam, and they are anticorrosive.

Changing the oil

Danger Scalding hazard by draining hot oil. Carefully and slowly remove the oil filter. Avoid skin contact with hot oil Use only new oil filters; you cannot clean a used oil filter. If you replace the oil filter while the oil circuit is filled, up to 2l oil can escape the system. Dispose of the oil filter according to the applicable local environmental regulations.

104482 HSC • 03/03

Operating instructions Inspection and servicing ! ! ! ! !

6.5

Place a suitable collecting vessel under the oil filter 24. Turn the oil filter left using chain pliers to screw it off. Clean the oil filter holder. Screw down the new oil filter until the gasket is firmly in place. Replace oil that has escaped by new oil (refer to chapter 6.2 “Checking and topping up the oil level“).

Drain the condensation water every week.

!

! !

6.6 !

6.7

Place a suitable collecting vessel under the oil and condensation water drain valve 15. Open oil and condensation water drain valve 15 while it is at operating temperature. Drain the condensation water into the vessel until pure oil escapes. Close oil and condensation water drain valve 15.

Cleaning the oil cooler and the compressed-air aftercooler. Blow compressed air through the cooling fins of the oil cooler 27 and of the compressed-air aftercooler 26 (see fig. 1: Component overview) from the inside of the machine until dust and deposits have disappeared.

Changing oil high-precision separator cartridge Use only a new oil high-precision separator cartridge; you cannot clean a used high precision separator cartridge. A small amount of oil can escape as you change the oil high-precision separator cartridge. Dispose of the oil high-precision separator cartridge according to the applicable local environmental regulations.

Draining the condensation water The condensation water contains oil and has to be disposed of according to the local environmental regulations.

!

6.8

!

! !

!

6.9 ! !

!

Turn the oil high-precision separator cartridge 3 (see fig. 1: Component overview) left using chain pliers to screw it off. Clean the oil high-precision separator cartridge holder. Oil slightly the O-ring and the gasket of the new oil high-precision separator cartridge. Screw down the new oil high-precision separator cartridge until the gasket is firmly in place.

Checking and changing the suction filter cartridge Remove the cover of the suction filter 23 (see fig. 1: Component overview). In case of severe soiling, immediately replace the suction filter (cf. list of HATLAPA spare parts in the chapter titled “Technical annex”). Refit the cover of the suction filter.

Checking safety valve The safety valve 11 (see fig. 1: Component overview) is secured with a seal which must not be removed.

!

104482 HSC • 03/03

Lift slightly the valve cap to check the function.

15

Operating instructions Inspection and servicing 6.10 Clean proportional controller nozzle. Applies only to systems equipped with proportional control.

6.12 Checking and adjusting the Vbelt HSC up to 7.5 kW

5 1

F

2

Fig. 6:

Proportional controller

1 2

Nozzle Hose connection

!

Remove plastic hose connection of the proportional controller 7 (see. fig. 1: Component overview). Unscrew the nozzle behind. Clean nozzle, controller and hose. Screw in the nozzle. Fix the hose connection again.

! ! ! !

Fig. 7: Checking V-belt tension HSC up to 7.5 kW ! !

! ! ! !

Remove the drain line 9 from the drain restrictor. Unscrew the restrictor from the casing of the compressor 1. Clean the hole of the restrictor. Mount and connect the restrictor again.

3

1

Fig. 8: HSC V-belt tensioning device up to 7.5 kW 1 2 3 4

Motor flange screws Adjusting screw Lock nut Nut

!

Slightly loosen motor flange screws 1. Loosen lock nut 3 at adjusting screw 2. Adjust V-belt tension through adjusting screw 2 and tighten lock nut 3 again. Tighten motor flange screws 1.

! ! !

16

Apply a perpendicular force between 25 N and 35 N in point 1 using a dynamometer. In doing so, the belt must give approx. 5mm. 2

6.11 Cleaning drain restrictor The drain restrictor is where the drain line 9 enters the casing of the compressor 1 (see fig. 1: Component overview).

1

104482 HSC • 03/03

Operating instructions Inspection and servicing HSC up to 7.5 kW

6.14 Tighten the screw connections. After first commissioning, check and – if required – retighten all screws.

3 ! !

4 2

Tighten all screw connections in regular intervals. In doing so, observe the torque (cf. Tab.: 6: Torques).

Screw

Maximum torque

M8 M 10 M 12

25 Nm 50 Nm 85 Nm

1

Fig. 9: HSC V-belt tensioning device over 7.5 kW 1 2 3 4

Bottom adjusting nut Top adjusting nut Lock ring Square pin

The V-belt tension must be corrected if the lock ring 3 touches the square pin 4. ! !

!

Loosen the bottom adjusting nut 1. Unscrew the top adjusting nut 2 until the distance between the lock ring 3 and the square pin 4 is 10-12mm. Tighten the bottom adjusting nut 1.

Tab. 6: Torques

6.15 Checking electric terminals !

6.16 Relubricating / replacing motor mounting !

6.13 Notes on systems equipped with water cooling system

Check and – if required – tighten all electric terminals regularly.

Relubricate or replace the motor mounting as specified by the manufacturer (refer to the name plate of the motor).

In water-cooled screw compressors, the oil / air cooler is replaced by a plate heat exchanger, and the air-to-air cooler is replaced by a tube bundle heat exchanger. You can use fresh water as cooling water. It is recommended to install a sand and a dirt filter before the cooling water preliminary flow.

104482 HSC • 03/03

17

Operating instructions Maintenance schedule 7

Maintenance schedule

500 h1

2 000h1

4 000 h1

6 000h1

8 000 h1

10 000 h1

!

!

!

!

!

!

–

Drain the condensation water (cf. chapter 6.5).

!

!

!

!

!

!

–

Check the oil level (cf. chapter 6.2).

!

!

!

!

!

!

–

!

!

!

!

!

!

–

"

!

!

!

!

!

–

!

!

!

!

!

–

!

–

Application

Interval

Every week

After first commissioning

Before first commissioning

The intervals mentioned are experimental values. They can differ considerably depending on the application conditions.

Check the rotating direction (cf. chapter 3.4).

Check the V-belt (cf. chapter 6.12).

!

!

Clean the proportional controller nozzle (cf. chapter 6.12). Change oil (cf. chapter 6.3), mineral (factoryfilled). Change oil (cf. chapter 6.3), synthetic.

!

Replace oil filter (cf. chapter 6.4).

!

!

!

!

!

–

Check safety valves (cf. chapter 6.7).

!

!

!

!

!

–

!

!

!

!

–

"

!

!

!

!

–

"

!

Clean the drain restrictor (cf. chapter 6.11). Clean the oil-aftercooler (cf. chapter 6.6). Check the suction filter cartridge² (cf. chapter 6.9). Change the suction filter cartridge² (cf. chapter 6.9). Change the oil highprecision separator cartridge (cf. chapter 6.8). Tighten the screw connections (cf. chapter 6.14).

18

!

!

–

!

"

!

!

–

"

!

!

–

!

–

104482 HSC • 03/03

Operating instructions Maintenance schedule Check the electric terminals (cf. chapter 6.15) Relubricate/replace motor mounting (cf. chapter 6.16)

!

–

! !

–

Measures carried out on (date):

Measures carried out by (name):

Key: ! Measure to be carried out: " Measure to take whenever required. – Check at the manufacturer's works. 1 The required maintenance and inspection measures must be carried out on a yearly basis if the hours of operation provided are not reached within a year’s period. 2 Check daily in dusty conditions and replace, if and when necessary.

104482 HSC • 03/03

19

Operating instructions Trouble shooting 8

Trouble shooting

8.1

Malfunction, compressor generally Danger Trouble shooting may be carried out only by trained experts or by staff members of HATLAPA Company. In all actions, please observe the fundamental safety instructions (cf. chapter 1), the safety instructions for operation (cf. chapter 4), and the safety instructions for maintenance (cf. chapter 6).

The compressor does not start up. Potential reasons

Actions

No connection to network. Fuse has blown.

• •

Network pressure is over cut-in pressure. Defect in the pressure detector or cable break. The motor has broken down. Temperature detector of the motor gives a signal.

• • • • • • •

Check the connection to the mains. Check the electric cable, switching units and the motor. Use time-lag fuses only. Replace the fuse. Reduce the pressure in the network. Check cable, or replace pressure detector. Check the electric system and the cables. Replace the motor. Refer to table “Temperature detector of the motor gives a signal”.

Temperature detector of the motor gives a signal. Potential reasons

Actions

Fault at the electric connection.

•

Ambient temperature is too high. Damage on the compressor Motor gets too hot due to high switching frequency. Pressure detector has been set wrongly. The clamping connections have come lose.

20

•

Check the electric connection for undervoltage and phase failure. Check the conductor cross section. Improve the room ventilation. Select a cooler location. Check bearing of the compressor and gear set. Check the pressure switching points.

• •

Check the pressure switching points. Retighten the clamping connections.

• • • •

104482 HSC • 03/03

Operating instructions Trouble shooting The switching frequency of the motor is too high. Potential reasons

Actions

The compressed-air reservoir is too small. Pressure detector has been set wrongly. Too much condensation water in the compressed-air reservoir / compressed-air ductwork system.

• • • •

Use a larger compressed-air reservoir. Check the pressure switching points. Drain the condensation water (refer to chapter 6.5). As a preventive measure, fit an automatic condensation water drain system (HATLAPA accessories).

Low delivery – the setpoint pressure is not made. Potential reasons

Actions

The suction filter is soiled.

• • • • • • •

Pipes and fittings are leaking. Pressure detector has been set wrongly. The air demand is higher than the delivery volume of the compressor.

Clean the suction filter. Change the filter cartridge. Tighten the screws and fittings. Replace the seals. Check the pressure switching points. Check the air demand. Expand the compressed air supply.

The compressor turns too hot. Potential reasons

Actions

Ambient temperature is too high.

• • •

The cooling air volume is not available or too low.

•

104482 HSC • 03/03

The ultimate pressure is too high. Oil level too low.

• •

Oil cooler is dirty. Oil thermostat / thermostat is defective (only in case of water cooling)

• •

Improve the room ventilation. Select a cooler location. The space between fan and wall is to small (cf. chapter 3.1 “Mounting conditions”). Check cooler for dirt, and clean if necessary. Check the pressure switching points. Top up oil (refer to chapter 6.2 'Checking and topping up the oil level'). Clean the oil cooler. Replace oil thermostat / thermostat.

21

Operating instructions Trouble shooting Milky colour of oil, water drops in the oil. Potential reasons

Actions

Water accumulation in the oil vessel (operating temperature is not reached because of too short operation time)

• • • • •

Water accumulation in the oil vessel (caused by humid conditions).

• •

Change the oil immediately. Retrofit a standby heating (HATLAPA accessory item). Select warmer location. Check design of the compressor. Contact manufacturer as to oil specifications. Change the oil immediately. Select dry location.

The oil consumption is too high. Potential reasons

Actions

The wrong oil has been used.

•

• The compressor is too hot. Oil escapes through oil high-precision separa- • tor cartridge. •

Check the type of oil (cf. chapter 6.2 “Types of oil”), and replace, if and when necessary. See Table “Compressor turns too hot”. Check suction – compressor stage. Check oil grade.

Air escapes when the compressor is at rest Potential reasons

Actions

Pressure control valve is defective.

•

Replace pressure control valve.

The compressor is not relieved when switched off. Potential reasons

Actions

Pressure detector or relief valve is defective.

•

Check pressure detector and relief valve at intake regulator and replace if necessary.

The system shuts suddenly down

22

Potential reasons

Actions

Oil level too low.

•

Oil filter is clogged.

•

Refill oil (refer to chapter 6.2 'Checking and topping up the oil level'). Replace oil filter cartridge.

104482 HSC • 03/03

Operating instructions Trouble shooting System fails to shift to no-load operation or fails to shut down. Potential reasons

Actions

Pressure control valve is defective.

•

Replace pressure control valve.

Safety valve blows off Potential reasons

Actions

Pressure detector is set at a too high rate. Pressure sensor is defect. Safety valve is defective. Suction stop valve does not close completely. Solenoid valve is defective. Oil high-precision separator cartridge is used up. Proportional controller nozzle is clogged (only with proportional control).

• • • • • • •

Correct settings of pressure sensor. Replace pressure sensor. Replace safety valve. Check springs of the suction stop valve. Replace solenoid valve. Replace oil high-precision separator cartridge. Clean proportional controller nozzle.

System is operating but is producing no pressure Potential reasons

Actions

Membrane in the adjust cylinder of the reduc- • ing damper is defective (depending on the type of compressor) • The relief valve is defective. • Pressure control valve is leaky.

Replace membrane and check control pressure in the pressure control valve. Replace relief valve. Replace pressure control valve.

Abnormal noises Potential reasons

Actions

“Whistling” sound caused by compressed air escaping the supply network, fittings etc.

• • • • •

The safety valve is “crackling”.

Fan is knocking. Grinding noises

• • •

104482 HSC • 03/03

Remedy leaking points. Replace the seals. Tighten the screw connections. Check pressure settings. Check and replace if necessary safety valve. Check whether the fan does not scrape. Damage in the mounting, compressor needs repair. Damage in the mounting, motor needs repair (HATLAPA service).

23

Operating instructions Trouble shooting 8.2

Malfunction, PROCON control Any malfunction will cause the compressor to shut down. This will last until the cause of the malfunction is eliminated and the corresponding message is acknowledged: • •

24

Press key 6 (→) to enter the basic mode. Keep then both keys 4 and 5 (↑/↓) pressed for at least 2 seconds.

Message

Type of malfunction

Cause

E01

Final temperature

E02

Emergency stop

E03

Temperature of the motor.

E04 E05

Direction of rotation Start temperature

E06 E07

Development of system pressure Excess pressure

E08 E09

Temperature sensor Network pressure sensor

E10

System pressure sensor

E11

Shutdown maintenance

ErE

EEPROM parameter

ErA

EEPROM adjustment

The value set under “Final temperature error” has been reached or exceeded. Emergency stop key 4 has been pressed; or cable break. The temperature of the motor winding is too high; or cable break. Wrong direction of rotation; or cable break. The final temperature is not higher than the value set under “Start temperature”. The system pressure has not been developed within the set period. V-belt may have broken. The maximum allowable system pressure has been exceeded. Defect in the temperature sensor or cable break. Defect in the network pressure detector or cable break. When parameter “System pressure sensor” = 1 and system pressure sensor is defective; or cable break. At least one maintenance interval has been exceeded by more than 100h and parameter active. At least one parameter is outside the valid setting range or EEPROM is defective. Adjusted values of the analogue sensors are incorrect.

104482 HSC • 03/03

Operating instructions Trouble shooting 8.3

Warnings, PROCON control In case of a warning, the compressor is not shut down automatically. The message is acknowledged in the same fashion as with malfunction.

Message

Type of malfunction

Cause

A01

Final temperature

A021

Air filter differential pressure Oil filter differential pressure Separator differential pressure Air filter service life Oil service life Oil filter service life Separator service life V-belt service life

The value set under “Final temperature error” (-5°C) has been reached or exceeded. If Error final temperature is active the warning is reset automatically. Air filter is clogged; or cable break.

A03 A041 A11 A12 A13 A14 A15 1

104482 HSC • 03/03

Oil filter is clogged; or cable break. Defect in the oil separator; or cable break. Maintenance interval for the air filter has elapsed. Maintenance interval for the oil has elapsed. Maintenance interval for the oil filter has elapsed. Maintenance interval for the separator has elapsed. Maintenance interval for the V-belt has elapsed.

Optional

25

03/03 # We reserve the right for technical changes. 104482 HSC •

HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen Telefon: ++49 4122 711- 0 Telefax: ++49 4122 711 - 104 eMail [email protected] Internet www.hatlapa.de

Ersatzteil-Verzeichnis List of spare parts Liste des pièces de rechange

Schraubenkompressor Screw compressor HSC 18,5 - 22

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

19.12.00

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 18,5/22

Name

Küster

Zeichn.Nr.

6990001

Compressor-motor cpl.

Name

Pos.

pcs

101 101 102 103 103 104 105 106 107 108 109 111 113 113 115 116 116 117 117 118 119 120 121 130 131 132 134 135

1 1 4 4 4 4 4 4 1 2 2 2 1 1 8 1 1 1 1 3 4 4 4 1 1 4 1 1

Description E-Motor 18,5kW E-Motor 22kW vibration damper Pin 18,5kW Hexagon bolt 22kW Wheel disc Under leg washer Nut Motor plate Hexagon bolt Spring ring Nut Fan belt disc 18,5kW Fan belt disc 22kW Settling disk 18,5kW Fan hub 18,5kW Fan hub 22kW Fan complete 18,5kW Fan complete 22kW set screw Fan blade Hexagon bolt Spring disc screw compressor block Clamping lever Cylinder screw Pin Compression spring

Order No.

Pos.

pcs

764040 764073 757102 66151039 700250 701407 703412 703103 6990107 700240 7035070 703106 717606 717605 6632115 6985116 6990116 104747 104748 701253 104749 700204 703605 765034 69271311 700839 6927134 6637480

137 139 140 141 145 145 145 145 145 145 151 155 155.9 156 157 160 161 162 163 164 165 166 167 168 169 170 172 173

1 1 1 1 3 3 3 3 3 3 1 1 1 2 1 3 1 1 2 1 1 1 1 1 1 1 4 1

Description

Order-No.

Pin Fan belt disc 7,5bar 18,5/22kW Fan belt disc 10bar 18,5/22kW Fan belt disc 13bar 18,5/22kW Fan belt 7,5bar 18,5kW Fan belt 10bar 18,5kW Fan belt 13bar 18,5kW Fan belt 7,5bar 22kW Fan belt 10bar 22kW Fan belt 13bar 22kW Clamping Clamping roll Clamping roll complete Ball bearing Lock ring Nut Disc Wheel disc Under leg washer Lock nut Lock ring Lock ring Lock ring Cylinder screw Disc Flange Cylinder screw O-Ring 90x3

69271371 717647 717648 717649 707598 707598 707593 707593 707528 707519 6927151 69141551 69141559 705063 704107 703104 705383 701409 703413 703312 704011 704018 704004 700822 703423 6990170 701017 707680

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

19.12.00

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 18,5/22

Name

Küster

Zeichn.Nr.

6990001

Compressor-motor cpl.

Name

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Gez. Gepr.

Datum Datum

Name

10/97

Küster

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 18,5/22

Zeichn.Nr.

6990002 Frame and noise cover

Name

Pos.

pcs.

10 201 211 212 210 213 214 215 216 217

1 1 4 4 1 4 4 1 1 1

Description Shield Frame complete rubber base Cylinder screw Frame Cylinder screw Spring ring Sidpanel front Sidepanel right Sidepanel left

Order-No.

Pos.

pcs.

15030014 6990201 708805 700820 6990210 700822 703604 6990215 6990216 6990217

218 219 220 221 222 223 224 224 228 230

1 1 1 1 6 6 1 1 4 1

Description

Order-No.

ventilation flap cover plate key to the control cubicle protective grid Cylinder screw Nut Wall ring 18,5kW Wall ring 22kW Cylinder screw Cable connection

6990218 6990219 770051 715814 700822 703102 104912 6985224 701004 760365

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Gez. Gepr.

Datum Datum

Name

10/97

Küster

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 18,5/22

Zeichn.Nr.

6990002 Frame and noise cover

Name

434

431

437

427 467

305 304 303

308 306

302

300 309 307 Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

1:10

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Abmaß

Oberflächenbehandlung

Die Maße werden besonders geprüft Ersatz für

Änderung

Datum Datum

Gez. Gepr.

17.12.97

Benennung HSC 18,5/22

Name

Küster

Zeichn.Nr.

6990003

Electric-control Procon

Name

Pos.

pcs.

3 300 302 303 304 305 306 307

1 1 1 1 1 1 1 1

Description

Order-No.

Pos.

pcs.

775089 6980300 775105 775045 7750451 7750453 7750452 6970307

309 310 311 427 431 434 437 467

1 6 6 1 1 1 1 1

Assembly control PROCON kpl. Control cubicle Emergency stop PROCON control Covering cap Cable form Front foil for Procon control Adhesive label

Description

Order-No.

Sealing rubber profile Cylinder screw Under leg washer Temperature sensor Coupling Screw connection Pressure detector Reducer plug

708825 702012 703412 775050 775073 752003 775048 6913467

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

1:10

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Abmaß

Oberflächenbehandlung

Die Maße werden besonders geprüft Ersatz für

Änderung

Datum Datum

Gez. Gepr.

17.12.97

Benennung HSC 18,5/22

Name

Küster

Zeichn.Nr.

6990003

Electric-control Procon

Name

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

10.12.97

Name

Küster

Zeichn.Nr.

Name

6990004

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

Armatures-tubing, Separation system, Cooling system HSC 18,5/22

Pos.

pcs.

401 402 408 409 410 410 422 425 434 435 436 438 440 445 446 447 456 459 461 463 464

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1

Description Screw Screw Screw connection Pressure control valve Separator 18,5kW Separator 22kW Flange 22kW Seal 22kW Screw connection Hose Hose otp. Oil gauge Screw connection Screw connection Reducer plug Double nipple Pneumatic pipe Screw connection Cylinder screw Seal Pressure joint Flexmaster

Order-No.

Pos.

pcs.

705517 705525 102655 711802 6990410 69274103 103052 6931538 752003 755237 101424 752121 752149 87629 706344 6990447 752054 700855 6619461 6990463 706615

470 486 497 498 499 500 526 527 535 543 545 547 548 549 550 551 552 601 602 603 604

1 1 1 1 1 1 1 1 4 1 1 1 1 1 4 4 4 1 3 3 3

Description

Order-No.

Oil temperature controller compl. Screw connection Pipe Pneumatic pipe Pneumatic pipe Pressure vessel Oil filler plug Seal ring Cover vessel Cone cock Angle Screw Screw connection Pneumatic hose Hexagon bolt Disc Spring disc Combi-Cooler Hexagon bolt Nut Under leg washer

6634470 752003 6980497 6990498 6990499 6990500 6913550 703705 6990535 751601 705833 705526 706610 755009 700206 703423 703604 790554 720200 703101 703410

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

10.12.97

Name

Küster

Zeichn.Nr.

Name

6990004

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

Armatures-tubing, Separation system, Cooling system HSC 18,5/22

539

455 454 421 424

405

427

406

426 443

411

442

423 453

457 430 429

452 427 426

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Die Maße werden besonders geprüft Ersatz für

Datum Datum

Gez. Gepr.

Benennung

Abmaß

Oberflächenbehandlung

Änderung

HSC 18,5

18.11.97

Name

Küster

Zeichn.Nr.

6990410

Separator cpl.

Name

Pos.

pcs.

410 405 406 411 421 423 424 426 427 429

1 4 4 1 1 1 1 2 2 1

Description

Order-No.

Pos.

pcs.

6990410 700924 701407 6922411 704013 6922423 707754 705500 703700 705522

430 442 443 452 453 454 455 457 463 539

1 1 1 1 2 1 1 1 1 1

Separator Cylinder screw Wheel disc Valve housing Lock ring Seal O-Ring 22x2,5 Screw Seal ring Screw

Description

Order-No.

Seal ring Lock valve Seal ring Screw connection Seal ring Double nipple Pipe Non-return valve Screw connection Air/oil separator box

703701 751123 703702 752069 703810 6922454 6922455 751206 707372 758159

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Die Maße werden besonders geprüft Ersatz für

Datum Datum

Gez. Gepr.

Benennung

Abmaß

Oberflächenbehandlung

Änderung

HSC 18,5

18.11.97

Name

Küster

Zeichn.Nr.

6990410

Separator cpl.

Name

539

455 454 405

421 424

406

463

411

449

443

423

442 Werkstoff / Halbzeug / DIN

427

Modell Nr. / Werkzeug Nr.

426

a

Ermeto EVGE 28 für Druckluftabgang entfällt

Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Gez. Gepr.

Datum

Name

15.10.01

Küster

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 22-55

Zeichn.Nr.

Separator cpl.

10/01

Hall

Datum

Name

69274103

Pos.

pcs.

410 405 406 411 421 423 424 426

1 4 4 1 1 1 1 1

Description Separator compl. Screw Wheel disc Valve housing Lock ring Seal O-Ring 30x2,5 Screw connection

Order-No.

Pos.

pcs.

69274103 700605 701409 6927411 704018 6931538 707678 705500

427 442 443 449 454 455 463 539

1 1 1 1 1 1 1 1

Description

Order-No.

Seal ring Emergency valve Seal ring Non-return valve Double nipple Pipe Screwing connection Air/oil separator box

703700 751123 703702 751206 6927454 6927455 707322 758164

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Gez. Gepr.

Datum Datum

Name

15.10.01

Küster

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 22-55

Zeichn.Nr.

Separator cpl.

69274103

Name

493

485

482

472

488

473 481 480

483 483

490

477

495

494

476 484

479

478

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

22.10.01

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 18,5/22/30/37

Name

Zeichn.Nr.

6634470 Oil-thermostat cpl. Küster

Name

Pos.

pcs.

470 472 473 476 477 478 478 478 478 479 480

1 1 1 1 1 1 1 1 1 4 1

Description Oil temperature controller compl. O-Ring 28x3 Set for oil temerature controller Valve housing Double nipple Oilfilter 7,5/10bar 18,5/22kW Oilfilter 13bar 18,5/22kW Oilfilter 7,5/10bar 30/37kW Oilfilter 13bar 30/37kW Cylinder screw Compression spring

Order-No.

Pos.

pcs.

6634470 707703 757817 6613476 6633477 758101 758102 708500 758104 701020 6613480

481 482 483 484 485 488 490 493 494 495

1 3 2 4 3 1 1 1 1 1

Description

Order-No.

Piston Cylinder screw O-Ring 16x2,5 Spring washer Spring disc Screw connection Screw connection Cap Screw Seal ring

6613481 701006 707753 703512 703605 752057 752054 6613493 705500 703700

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

22.10.01

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

HSC 18,5/22/30/37

Name

Zeichn.Nr.

6634470 Oil-thermostat cpl. Küster

Name

741 734 732

724 733 730 737 738

735

729

709

745

738

728 727 726 725

731

721

731

720

719

707 708

739

710

725

717

722 755 730

714

730

703

702

716

711

756

713

712

704

705

706

701 718

750 Werkstoff / Halbzeug / DIN

752 Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

6.8.01

Name

Küster

Zeichn.Nr.

Name

6633700

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

Suction regulator without proportional control HSC 18,5/22/30/37

Pos.

pcs.

700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 716 717 718 719 720 721 722 724 725

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 1 2

Description Suction controller Suction body Cylinder Holder O-Ring 55x2,5 Compression spring Seal Seal Piston Restrictor Compression spring Lock ring Valve cone Valve ring O-Ring Steel cone Lock ring Feet seal Cylinder screw Spring disc Hexagon bolt Under leg washer Plug-in nipple Double nipple

Order-No.

Pos.

pcs.

6633700 6633701 6633702 6633703 707670 6633705 707878 708440 66337081 6913709 3173120 704112 6633712 6633713 707608 707304 704109 6996718 701016 703605 700222 703413 2707099 706340

726 7261 727 728 729 730 731 732 733 734 735 737 738 739 741 745 750 752 753 755 756

1 1 1 1 4 3 2 1 1 1 1 1 2 1 1 4 1 1 1 4 1

790

1

Description

Order-No.

Cap Relief valve compl Membrane Relief valve Cylinder screw Screwing connection Angle connection Plastic pipe Plastic pipe Plastic pipe Plastic pipe Sleeve Seal ring Solenoid valve Tee coupling Spring disc Suction filter Filter cartridge Filter cap Wheel disc Screw Maintenance set incl. 704,705,706,707,710,718,727

66137254 66337261 66137252 66137251 701004 707322 707372 757000 757000 757000 757000 6633737 703700 7054071 707321 703606 708989 708501 758027 701409 701601 66337901

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

6.8.01

Name

Küster

Zeichn.Nr.

Name

6633700

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

Suction regulator without proportional control HSC 18,5/22/30/37

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

25.3.03

Name

Küster

Zeichn.Nr.

Name

66337001

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

Suction regulator with proportional control HSC 18,5/22/30/37

Pos.

pcs.

700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 716 717 718 719 720 721 722 724 725 726

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 4 2 1

Description Suction controller compl. Suction body Cylinder Holder O-Ring 55x2,5 Compression spring Seal Seal Piston Restrictor Spring-pressure Nr. 39 Lock ring Valve cone Valve ring O-Ring 10x2,5 Steel cone Lock ring Feet seal Cylinder screw Spring disc Hexagon bolt Under leg washer Plug-in nipple Double nipple Cap

Order-No.

Pos.

pcs.

66337001 6633701 6633702 6633703 707670 6633705 707878 708440 66337081 6913709 3173120 704112 6633712 6633713 707608 707304 704109 6996718 701016 703605 700069 703414 2707099 706340 66137254

7261 727 728 729 730 731 732 733 734 735 736 737 738 739 741 744 745 750 752 755 756 757

1 1 1 4 4 4 1 1 1 1 1 1 2 1 1 1 4 1 1 4 1 1

790

1

Description

Order-No.

Relief valve Membrane Relief valve Cylinder screw Screwing connection Angle connection Plastic pipe Plastic pipe Plastic pipe Plastic pipe Propotion controller Sleeve Seal ring Solenoid vavle Adapter Plastic pipe Spring disc Suction filter with cartridge Filter cartridge Wheel disc Screw connection Seal ring Maintenance set incl. 704,705,706,707,710,718,727

66337261 66137252 66137251 701004 707322 707320 100874 100874 100874 100874 6633736 6633737 703700 7054071 6913741 100874 703606 708989 708501 701408 705500 703700 66337901

Werkstoff / Halbzeug / DIN

Modell Nr. / Werkzeug Nr. Buchstabe

Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad

A B C

l in mm bis 30

±1 ±1 ±1

Winkelmaße

Nennbereich l über 30 bis 120

über 120 bis 315

über 315 bis 1000

±1 ±2 ±3

±1 ±2 ±4

±2 ±3 ±6

a in ° und ' für Schenkellänge

über 1000 bis 2000

über 2000 bis 4000

bis 315

über 315 bis 1000

±3 ±4 ±8

±4 ±6 ±11

±20' ±45' ±1°

±15' ±30' ±45'

über 1000

±10' ±20' ±30'

Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.

Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob

Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3

±0,05 ±0,1 ±0,2

±0,05 ±0,1 ±0,3 ±0,5

über 6 bis 30

±0,1 ±0,2 ±0,5 ±1

über 30 bis 120

±0,15 ±0,3 ±0,8 ±1,5

über 120 bis 400

über 400 bis 1000

über 1000 bis 2000

über 2000 bis 4000

±0,2 ±0,5 ±1,2 ±2,5

±0,3 ±0,8 ±2 ±4

±0,5 ±1,2 ±3 ±6

±2 ±4 ±8

Paßmaß

Datum Datum

Gez. Gepr.

25.3.03

Name

Küster

Zeichn.Nr.

Name

66337001

Benennung

Abmaß

Oberflächenbehandlung

Änderung

Die Maße werden besonders geprüft Ersatz für

Suction regulator with proportional control HSC 18,5/22/30/37

Service

Anleitung zur richtigen Bestellung von Ersatzteilen Für die Bestellung sind folgende Angaben unbedingt erforderlich: 1) Schiffsname (Ex-Name), Neubau-Nr. und Bauwerft 2) Fabriknummer und Typenbezeichnung (siehe Typenschild) 3) Ersatzteilnummer entsprechend Ersatzteilliste 4) Gewünschte Versandart, Versandadresse und Rechnungsanschrift

Instructions for correctly ordering spare parts When ordering spare parts, the following details must be given: 1) Name of vessel (former name), Hull No. and building shipyard 2) Serial number and type of the machine (see name plate) 3) Part number from the Spare Parts List 4) Desired method of dispatch, invoice and consignee’s address

Instruction pour établir les commandes de pièces de rechange Les indications suivantes seront indispensables pour la commande: 1° Nom du navire (ex-nom), No. du navire et chantier de construction 2° Numéro d’usine et type (voir plaque d’identité) 3° Numéro de pièce suivant liste des pièces de rechange 4° Mode de transport désiré, adresses du destinataire et de la facture

Instrucciones para pedir correctamente piezas de repuesto. Cuando se piden piezas de repuesto, deben ser dados los – siguiéntes datos: 1) Número de serie y tipo (ver placa) . 2) Número de la pieza según la Lista de Piezas de Repuesto. 3) Forma de despacho así como consignación y dirección para la facturación. 4) Nombre del buque (nombre antígúo) ‚ número de construción y Astilliero.

Service

Um Ersatzteile schnellstens zu erhalten, wenden Sie sich bitte direkt an

oder an unsere Vertretungen (x), Kundendienststellen (o) oder Lizenznehmer ( +) laut anliegender Liste. In order to receive spare parts with the least possible delay, please get in touch with us directly

or with our representatives (x),service stations (o) or licensees/co-operators (+) as indicated in the enclosed list. Pour assurer une fourniture rapide, veuillez vous adresser á

ou á nos agences (x) , stations-service (o) ,licenciés/partenaires de cooperation (+)

Uetersener Maschinenfabrik GmbH & C0. Tornescher Weg 5-7 . D-25436 Uetersen Phone: +49-4122-7 11-0 Mobile: +49-172-9 81 32 92 Fax.: +49-4122-7 11-104 Sales -7 11-330 Service Internet http://http://www.hatlapa.de/ E-mail: [email protected]

Service-Stations Spare Parts Agencies

Our manufacturing programme: Deck Machinery . Compressors . Steering Gears

HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 . D-25436 Uetersen GERMANY Phone: +49-4122-7 11-0 . Mobile: +49-172-9 81 32 92 . Fax.: +49-4122-7 11-104 Sales -7 11-330 Service Internet:http://www.hatlapa.de E-mail: [email protected]

SUBSIDIARY OFFICE FOR HAMWORTHY TYPE COMPRESSORS HATLAPA Hamworthy Marine Compressors Ltd Discovery Court Business Centre 551-553 Wallisdown Road POOLE, Dorset BH12 5AG UNITED KINGDOM Phone: +44-1202-85 31 80 Fax.: +44-1202-85 31 91 Sales +44-1202-85 31 90 Spares Vertretungen (x), Kundendienststellen (o) und Lizenznehmer (+) Representatives (x), service stations (o) and licensees/co-operators (+) agences (x), stations-service (o) et licenciés/partenaires de cooperation(+)

o Australia

Moorabbin, Vic. 3189 CJA Marine Technology Pty Ltd Unit 3, 136 Cochranes Road

Tel:+61-3-95 32 13 97/95 32 1386 Fax:+61-3-95 32 14 13 E-mail: [email protected]

x Belgium

B-2710 Hoboken Marine & Industrie BVBA Emile de Harvenstraat 50-52

Tel.: +32-3-827 40 91/95 Fax: +32-3-827 40 95 Telex: 33672 mardus b E-mail: [email protected]

o Belgium/ Luxembourg

Antwerp 2030 Service Hydro n.v. Boterhamvaartweg 2

Tel.: +32 3 546 40 80 Fax: +32-3 546 40 81 E-mail: [email protected]

x Brazil

Rio de Janeiro - RJ PML Petersen Matex Ltda Av. Rio Branco 25/18°

Tel.: +55-21-2211 50 50/-50 28 Fax: +55-21-2518 22 20/-30 19 E-mail: [email protected]

Stand 03.06.2004

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Service-Stations Spare Parts Agencies

o Brazil

Santos SP 11013-030 Metalock Brasil Ltda Rua Visconde do Rio Branco 20/26

Tel.: +55-13-3222 46 86 Fax: +55-13-3222 40 88 E-mail: [email protected]

x Bulgaria

9000 Varna Ecatdan ApS 3 “Angel Georgiev” Str.

Tel.: +359-52-23 21 74 Fax: +359-52-23 21 74

x Canada o

St. Catherines, Ontario L2M 6S9 Marine & Offshore Inc 113 Cushman Road, Unit 60

Tel.: +1-905-688-4922 Fax.: +1-905-688-9028 E-mail: [email protected]

o Chile

Concepcion Eurotecnica Ltda Los Carrera No. 1056

Tel.: +56-41-25 32 75 Fax: +56-41-25 32 76 E-mail: [email protected]

x P.R. of China +

Nanjing 210039 CSSC Lüzhou Machine Works Nanjing Zhong Hua Men Wai

Tel.: +86-25-86 70 21 27 Telex: 34106 Fssnk Fax: +86-25-86 71 15 43 E-mail: [email protected]

x P.R. of China

Shanghai 200023 Hatlapa Asia Pacific Pte Ltd No. 600 Lu Ban Road Room 1702, Jiangnan Shipyard Building

Tel.: +86-21-53 01 49 51/52 Mobile: +86-137 01 74 73 14 Fax: +86-21-53 01 49 57 E-mail: [email protected]

x Croatia o

21000 Split Nava International d.o.o. Planciceva 4

Tel.: +385-21 385 267 Fax.: +385-21-385 267 E-mail : [email protected]

x Cyprus

3032 Limassol M.I.E. Services Ltd. 124 Gladstonos Str. The Hawk Building

Tel.: +357-25-34 53 19 Fax: +357-25-34 56 39 E-Mail: [email protected]

x Denmark

DK-2605 BrØndby Northrop Grumman Sperry Marine B.V. Industrivej 16-18

Tel.: +45-77 33 66 33 Fax: +45-77 33 66 11 E-mail: [email protected]

x Egypt/UAR

Alexandria Alexandria Maritime Consultative Office 10 Ahmed Yehya Pasha St. Gleem P.O. Box 1424

Tel.: +20-3-58 58 570 Fax: +20-3-5 82 85 87 Telex: 54539 AMCO E-mail: [email protected]

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Service-Stations Spare Parts Agencies

x Finland

FIN-00811 Helsinki Oy Tapiro Ab Pikkupurontie 11

Tel.: +358-9-75 59 81 Cable: Tapiro Fax: +358-9-75 59 87 00 E-mail: [email protected]

x France

F-92100 Boulogne Wenex S.A. 6, Rue de l’Est

Tel.: +33-1-41 10 23 30 Telex: 633106 wenex Fax: +33-1-41 10 23 45 E-mail: [email protected]

o Germany

D-47119 Duisburg-Ruhrort Fr. Jung König-Friedrich-Wilhelm-Str. 20

Tel/Fax.: 0203-8 28 98

o Great Britain for London and all U.K. ports

Staines/Middlesex TW18 4AX Saville Marine Centurion House London Road

Tel.: +44-1784-41 04 15 Fax: +44-1784-41 03 15 E-Mail: [email protected]

x Greece o

185 37 Piraeus M.I.E. Co. Ltd. Kanari 1

Tel.: +30-210-41 85 301 Fax: +30-210-45 39 234 Telex: 241256 E-mail: [email protected]

o Greece

18863 Perama – Piraeus Inje Cov Ltd. 463, Dimokratias Ave

Tel.: +30-210-43 23 600/1-2 Fax: +30-210-43 12 770 Telex: 213306 Ingv gr E-mail: [email protected]

x India o

Bombay - 400 021 Nicol & Andrew Engineering (Pvt.) Ltd. Suite 7, 2nd Floor “Arcadia” Nariman Point

Tel.:+91-22-22823704/22842200 Fax: +91-22-2285 06 24 Telex: 1183677 kash in E-mail: [email protected]

x Indonesia o

Jakarta 12160 PT API, P.T. Assindo Perniagaan Internasional Victoria Centre 3rd Fl. Jl. Sultan Hasanuddin No. 47-51

Tel.: +62-21-7 25 55 41 Fax: +62-21-7 25 55 46 E-mail: [email protected]

+ Indonesia

Bandung 42028 PT. Pindad (Persero) Jl. Jend. Gatot Subroto

Tel.: +62-22-7 20 73/7 20 76 Telex: 28572 Pindad Fax: +62-22-46 12 22

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Service-Stations Spare Parts Agencies

x Iran o

Tehran 19139 Iran Imexen Co. No. 38 Koye Sh. Yazdanian, Gholhak

Tel.: +98-21-260 13 02/200 00 08 Fax: +98-21-20 04 849 Telex: 226041 imex E-mail: [email protected]

x Italy o

I-29015 Castel San Giovanni (Piacenza) Realizzazioni Tecniche Navalmeccaniche Srl (R.T.N. Srl) Via Mozza 15

Tel.: +39-0523-84 30 46 Cable: Ratenav Fax: +39-0523-84 30 40 E-mail: [email protected]

x Korea o

Nam Gu, Pusan 608-743 Dong Sung Co. Room 1725, “21” Century City Building 55-1, Daeyeon 3-dong

Tel.: +82-51-6 10 12 33 Telex: 53115, Ext. No. 53 Fax: +82-51-6 10 12 32 E-mail:[email protected]

x Lebanon

3032 Limassol, Cyprus Sheerlines Services Ltd 124 Gladstonos Street The Hawk Building

Tel.: 00357-25-34 66 26 Fax.: 00357-25-34 08 56 E-mail: [email protected]

x Mexico o

01010 Mexico,D.F. Nautica S.A. de C.V. Condor No 31 Col. Alpes

Tel.:+52-55-5651 97 40/56 80 21 04 Fax: +52-55-56 51 28 25 E-mail: [email protected]

x Middle East

3032 Limassol, Cyprus

Tel.: +357-25-36 60 77 Fax.: +357-25-36 60 88 E-mail: [email protected]

Saudi Arabia, Oman M.I.E. Services (Middle East) Ltd U.A.E., Qatar, Yemen Gladstonos 124 th Bahrain, Kuwait, The Hawk Bldg., 4 Floor

Jordan x Netherlands o

3084 CC Rotterdam Hamworthy KSE B.V. Aploniastraat 33

Tel.: +31-10-46 24 777 Fax.: +31-10-41 59 046 E-mail: [email protected]

x Norway o

6019 Aalesund Tøssebro AS Vestre Olsvikvej 25

Tel.: +47-70 17 29 80 Fax: +47-70 17 29 90 E-mail: [email protected]

x Poland o

70-672 Stettin Sanger Metal Sp-ka z.o.o.. ul. Mostnika 10

Tel.:+48-91-462 3383/462 30 25 Mobile: +48-0602-337 999/338 030 Fax: +48-91-462 33 45 E-mail: [email protected]

o Poland 80-958 Danzig for deck machinery Hydroster Ship Machinery Works Ltd steering gears Ul. Szafarnia 10

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Tel.:+48-58-301 56 51 Fax.:+48-58-301 17 23 E-mail: [email protected]

Service-Stations Spare Parts Agencies

x Portugal

1101 Lisbon Codex Gellweiler Soc. de Equip. Maritimos e Industriais Lda Travessa do Alecrim, 3-2°

Tel.: +351-21-3 42 00 21 Fax: +351-21-3 42 00 26 E-mail: [email protected]

x Romania

6200 Galati Xerex S.R.L. 1, Closca St., Bl.PS11, Suite 4

Tel./Fax: +40-236-46 20 56 E-Mail: [email protected]

X Singapore o

Singapore 609916 Hatlapa Asia Pacific Pte Ltd German Centre, Unit 02-25 25 International Business Park, Jurong

Tel.:+65-65 62 80 86/65 62 80 88 Mobile: +65-96 33 93 81 Fax: +65-65 62 80 99 E-Mail: [email protected]

x South Africa o

Kraaifontein ZA 7569 DMG Engineering (Pty) Ltd. 4 Karee Street

Tel.: +27-21-86 32 466 Fax: +27-21-86 33 629

x Spain o for compressors

Madrid-28006 Comercial Tecnica Diesel S.A. (Cotedisa) Principe de Vergara 86

Tel.: +34-91-6 76 65 99 Telex: 27262 ctd e Cable: Cotedisa Fax: +34-91-6 77 17 71 E-mail : [email protected]

x Spain Madrid-28033 for deck machinery Javier López-Alonso Morán steering gears Avda. San Luis 166 - 8° E

Tel/Fax: +34-91-3 83 15 77 E-mail: [email protected]

x Sweden o

SE-400 40 Gothenburg A.B. Pegol Djurgardsgatan 9 P.O. Box 4093

Tel.: +46-31-42 63 00 Cable: Pegol Fax: +46-31-12 77 39 E-mail: [email protected]

x Syria

Cyprus Sheerlines Services Ltd 124 Gladstonos Street The Hawk Building

Tel.: 00357-25-34 08 56 Fax.: 00357-25-34 66 26 E-mail: [email protected]

x Taiwan/R.O.C.

Taipei MPC Hanteh International Ltd. 15F, 87 Sung Chiang Road

Tel.: +886-2-25 06 36 88 Fax: +886-2-25 06 39 99

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Service-Stations Spare Parts Agencies

x Turkey

34903 PENDIK/Istanbul Senak Marine Ind. & Trade Co Güzelyali Mah Sahilyolu Cad 61/2

Tel.:+90-216-392 69 92 Fax:+90-216-392 65 05 E-mail: [email protected]

o United Arab Emirates

Sharjah TurboMot Marine Eng. Co. P.O. Box 3178

Tel.: +971 6-56 90 770 Fax: +971-6-56 90 802

x U.S.A. o

Clermont, Florida 34711 Diesel Impex Corp. 11227 Marseilles Blvd

Tel.: +1-352-243 94 55 Fax: +1-352-243 00 38 E-mail: [email protected]

o U.S.A.

Orange, Ca. 92665 CS Controls Inc. 1820 N. Lincoln St.

Tel.: +1-714-9 74 56 84 Fax.¨+1-714-9 74-56 85 E-mail: [email protected]

Houma, La. 70363 CS Controls Inc. 101 Dickson Rd.

Tel.: +1-985-8 76 60 40 Fax.: +1-985-8 76 07 51 E.mail: [email protected]

o U.S.A.

Ft. Lauderdale, Florida 33315 Motor Services Hugo Stamp Inc 3190 SW 4th Ave

Tel.: +1-954-7 63 36 60 Fax: +1-954-7 63 28 72 E-mail: [email protected]

x Venezuela

Caracas TENAVAL Av. Fco. De Miranda Edif. Bco del Orinoco 2°, Piso Ofic 2-B

Tel.: +58-212-285 23 44/7822/7631 Fax: +58-212-285 77 76 E-mail: [email protected]

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