Screw Air Compressor User Manual [PDF]

Zitiervorschau

OZEN COMPRESSOR SCREW COMPRESSOR USER MANUAL

CAUTION Before operating and maintaining the compressor, please read this user manual carefully.

Revision No: 16VK02

I

Thank you for choosing OZEN Screw Air Compressor

In this manual you will find information about safety instructions, handling and installation the compressor, compressor systems and components, system protection equipments, operating procedure and maintenance is described. The Instructions in this manual are valid for all OZEN Screw Air Compressors. All maintenance and repair should be performed with spare parts and consumable materials which have been approved by OZEN Compressor. In case of any problem, firstly please take a look to Troubleshooting section. If problem can't be solved, please contact with authorized OZEN Compressors service agent by mentioning compressor model and serial number as well as working hours.

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS -------------------------------------------------------------------------------------- II 1.

SAFETY ----------------------------------------------------------------------------------------------------- 1 1.1. Moving Parts ---------------------------------------------------------------------------------------------------- 1 1.2. Burn and Sharp Risk ----------------------------------------------------------------------------------------- 1 1.3. Flammable and Harmful Materials ---------------------------------------------------------------------- 1 1.4. Fire and Explosion Risk-------------------------------------------------------------------------------------- 1 1.5. Electric Shock Risk -------------------------------------------------------------------------------------------- 2 1.6. Pressure Line Connections ---------------------------------------------------------------------------------- 2

2.

HANDLING AND INSTALLATION THE COMPRESSOR ---------------------------------- 3 2.1. Lifting and Handling The Compressor ----------------------------------------------------------------- 3 2.2. Locating the Compressor ------------------------------------------------------------------------------------ 3 2.3. Assembly of Air Connection -------------------------------------------------------------------------------- 5 2.4. Assembly of Electric Connection -------------------------------------------------------------------------- 5

3.

COMPRESSOR SYSTEMS AND COMPONENTS ---------------------------------------------- 7 3.1. Operation System ---------------------------------------------------------------------------------------------- 7 3.2. Lubrication System -------------------------------------------------------------------------------------------- 8 3.3. Cooling System-------------------------------------------------------------------------------------------------- 9 3.4. Control System------------------------------------------------------------------------------------------------ 10 3.5. Electric Motor ------------------------------------------------------------------------------------------------- 11 3.5.1. Service instructions for electric motors ----------------------------------------------------------------------- 11

3.6. Rotation Mechanism ---------------------------------------------------------------------------------------- 12 3.6.1. Belt-Pulley Mechanism ------------------------------------------------------------------------------------------- 12 3.6.2. Direct Drive Rotation Mechanism ----------------------------------------------------------------------------- 13

4.

SYSTEM PROTECTION EQUIPMENTS ------------------------------------------------------- 14

5.

OPERATING PROCEDURE ------------------------------------------------------------------------ 15 5.1. First Start-Up ------------------------------------------------------------------------------------------------- 15 5.2. Daily Operating ----------------------------------------------------------------------------------------------- 15 5.3. Operating After Long Time No Running ------------------------------------------------------------- 15 5.4. Operating At Low Temperature ------------------------------------------------------------------------ 15

6.

MAINTENANCE---------------------------------------------------------------------------------------- 16

II

TABLE OF CONTENTS

6.1. General ---------------------------------------------------------------------------------------------------------- 16 6.2. Daily Maintenance ------------------------------------------------------------------------------------------- 16 6.3. Weekly Maintenance ---------------------------------------------------------------------------------------- 16 6.4. Maintenance Period ----------------------------------------------------------------------------------------- 17 6.5. Lubrication and Oil Maintenance ---------------------------------------------------------------------- 17 6.5.1. Oil Level Control --------------------------------------------------------------------------------------------------- 17 6.5.2. Oil Change and Oil Additive ------------------------------------------------------------------------------------ 17 6.5.3. Oil Flow Indicator Cleaning ------------------------------------------------------------------------------------- 20

6.6. Oil Filter Change --------------------------------------------------------------------------------------------- 20 6.7. Separator Filter Change ----------------------------------------------------------------------------------- 20 6.8. Air Filter Maintenance ------------------------------------------------------------------------------------- 21 6.9. Cooler Maintenance ----------------------------------------------------------------------------------------- 21 6.10. Belt-Pulley Maintenance --------------------------------------------------------------------------------- 21 6.11. Air Receiver Maintenance ------------------------------------------------------------------------------- 21 6.12. Maintenance Record--------------------------------------------------------------------------------------- 22

7.

TROUBLESHOOTING-------------------------------------------------------------------------------- 23

III

SAFETY

1. SAFETY  If there is any unsafe case before start, machine should not be operated. In this case, in order to prevent any accident, the energy has to be cut off from the circuit breaker and the authorized person should immediately be informed.

1.1.Moving Parts  During the machine operating, doors have to be in closed position.  When the compressor is running, there hasn’t to be anybody around it except authorized stuff, due to possible splashes and explosions.  Moving parts of compressor such as belt-pulley and fan cooler mustn’t check up with hands.  Hands, arms, clothes, etc. should be kept away from the moving parts of the compressor.

1.2.Burn and Sharp Risk  Please do not touch possibly hot parts on the compressor.  Since compressor oil is hot, any possible oil leakage should not be tried to stop with hand. In this kind of situation the compressor should be stopped with ‘Emergency Stop’ button and the electricity must be cut off.  During the operating, don’t put your hands into compressor no matter what and don’t use rod, bar, etc. for any control.  Don't stand in front of any air outlet point of the compressor.  A safety dress such as glove and head-dress must be worn during any operation in the compressor. A First Aid case must be kept around of the compressor.  A doctor must be called for any injury even if it is a minor injury.

1.3.Flammable and Harmful Materials  Pressured air should not be discharged directly to humans and into rooms that accommodate human being.  Compressor should be operated with sufficient ventilation.  Compressor must be kept away from dusty, hot, and humid ambient.  Compressor should be far enough as it cannot suck from an ambient that consist of chemical and corrosive matters as well as flammable and explosive gases.  Industrial oil is used in compressor. Used oil should not be contact to eyes and skin. If there is a contact, contact place should be washed with plenty of water and soap.

1.4.Fire and Explosion Risk  Explosive matters should not be placed around the compressor.  If there is a fire risk, stop the compressor and cut off the electricity.  Don’t allow the accumulation of the oil in the compressor. If an oil accumulation occurs, please clean it with a non-flammable cleaner.  The electrical and pressure connections should be protected carefully. There should not be any damaged or open ended cable in the compressor.  Welding operation shouldn't be performed on any compressor components.  Lubricated fabrics, papers and wood shavings should not be gathered around the compressor.  Fires should not be approached to compressor and smoking should not be allowed around the compressor.  Full fire extinguisher has always to be placed near the compressor.  The compressor should not be operated in danger condition for it.

1

SAFETY

1.5.Electric Shock Risk     

Electrical connections should be done by an expert electrician. Proper ground connection should be provided. Any part of the body should be kept away from electricity current. While electrical repairing, please pay attention to keep your feet dry and work on a wooden pallet. Electrical repairing and maintenance should be done by right hand as much as possible. Thus, in the case of an electric shock, the risk of passing current through your heart will decrease.  The door of the electrical board of the compressor should be kept closed. When it is needed to open, power must be shut down.  All the electrical connections should be checked before the first start up.

1.6.Pressure Line Connections  All of the equipments on the compressor must be suitable to capacity and working pressure.  Please be sure that there is not any leakage on pressure line and there is not anything which would be harmful for pressure line.  Please consider, while the pressure is still existing in the compressor, in case of try to take off the oil bung or disassemble any equipment, hot oil could erupt and can be harmful.  Don’t make any joke with air hose.  Pressure switch settings shouldn't be changed without consulting to our authorized service. WARNING !!! PRESSURED AIR SHOULDN’T BE USED FOR PERSONNEL CLEANING AND SHOULDN'T BE INHALED.

2

HANDLING AND INSTALLATION THE COMPRESSOR

2. HANDLING AND INSTALLATION THE COMPRESSOR 2.1.Lifting and Handling The Compressor  There is enough space under the compressor for forklift forks entering. Compressor must be carried with forklift by aid of this space. (Figure 1)  Please be sure that compressor settled safely on forklift before lifting.  Raising so high the compressor during handling by forklift is not needed.  Auxiliary tools must be used during handling by crane in order to prevent any damage. (Figure 2)  Handling must be done carefully.

Şekil 1Forklift ileby Taşıma Figure 1 Handling Forklift

Figure 2 Handling by Crane

2.2.Locating the Compressor  Compressor should be installed according to the instructions in these manual as well as per national and international standards.  The floor which the compressor will be placed should be capable of carrying the weight of compressor and should be flat and dry.  The floor which the compressor will be placed shouldn't be slippery. Hence, the floor must be kept away from oil and water to avoid slipping risk.  It is enough to prepare a concrete platform that dimensions are as 20cm larger than main chassis dimensions and its height is 15-20cm. The platform must be regulated balance. The compressor must be located on the platform by using hard rubber wedge.  Compressor room should be easily accessible and sufficiently illuminated.  For more effective operation and easier maintenance & repair, the compressor should have a clearance of at least 1.5m from ceiling (Figure 3-B) and 1m from the wall (Figure 3-A).  Fire and corrosion causing conditions should be prevented around the compressor.  Establishing a separate line for condense discharge of filter, dryer and air tank prevents that the floor of the compressor operating place unnecessarily gets wet.  For general purpose, putting an air outlet and electric box in compressor room is necessary.  The compressor must be located as the side of free air inlet can absorb cool air easily.  Compressor must be kept away from dusty, hot, and humidity ambient.

3

HANDLING AND INSTALLATION THE COMPRESSOR

 Compressor should be operated with enough air circulation. If there will not be sufficient air flow in compressor room, room ventilation should be constructed or hot air comes from compressor should be completely removed from compressor room. When doing this, the outgoing hot air of compressor should not return. For this reason the hot air outlet and air inlet should not be on the same side. (Figure 3)

Figure 3 Room Locating 1  When assembling an air duct to compressor's hot air outlet, the most important point is dimensions of air duct shouldn't be smaller than dimension of compressor's hot air outlet. Furthermore, air duct shouldn't be as long and wiggly as it causes extreme resistance.  In case of the compressor operating in the room without a duct and the hot air discharging off room via a fan, simply use a fan with similar capacity of the fan on the compressor. Place this fan to the closest point of the compressor hot air outlet. (Figure 4)

Figure 4 Room Locating 2

4

HANDLING AND INSTALLATION THE COMPRESSOR

 Please make sure that the compressor cooling system does not subject to direct sun light or regional strong winds.  Please make sure the compressor room doesn't subject to hazardous gas, vapor, heat or corrosive dust emitted by central heating boiler or generator type of equipment.  The compressor should be operated between 0°C and 40°C. In case the temperature is out of this interval, please do not start the compressor unless the temperature is adjusted.  If you cannot assure conditions indicated above, please contact OZEN Compressor.  The air receiver of the stationary compressors have to be in a safety area due to explosion risk.  Portable compressors must be far away minimum 10m from the staff.  If the compressor settled to a high location, there must be a barrier etc. around it to avoid falling down of the machine due to vibration. WARNING !!! IF COMPRESSOR WON'T BE USED FOR A LONG TIME, IT SHOULD BE STORED IN A DRY AND WARM PLACE, AND ITS OIL SHOULD BE EVACUATED.

2.3.Assembly of Air Connection  Outlet pipes sizes are between ½'' – 4'' according to compressor type.  It is recommended to connect an expansion joint to compressor air outlet for cutting vibration.  Please be sure that hoses and fittings on the pressure line must be unharmed and proper to the operating pressure.  If you have further needs about the pressure line, please contact with our authorized service.

2.4.Assembly of Electric Connection  Electric connections should be done by an authorized staff.  A separate circuit breaker should be used for the electric supply to compressor  Suitable cable has to be chosen for proper operating. Engine power, voltage, distances between working area and transformer centre and network fluctuation should be considered at the time of choosing. For selecting suitable cable size please refer to Table 1.

5

HANDLING AND INSTALLATION THE COMPRESSOR

6

Table 1 Cable Dimension and Fuse Choice as per model

Type

Compressor Motor Current Power Kw

0-25 m Cable Length

25-150 m Cable Length

Fuse Type

Fuse Current

OSC-3

5A

2.2

4x1,5

4x1,5

Auto Fuse 6 kA , C 3 Phase

10A

OSC-4

6A

3

4x1,5

4x2,5

Auto Fuse 6 kA , C 3 Phase

10A

OSC-5

8A

4

4x1,5

4x2,5

Auto Fuse 6 kA , C 3 Phase

16A

OSC-7

11A

5.5

4x1,5

4x2,5

Auto Fuse 6 kA , C 3 Phase

16A

OSC-10

14A

7.5

4x2,5

4x4

Auto Fuse 6 kA , C 3 Phase

A25

OSC-15

21A

11

4x2,5

4x4

Auto Fuse 6 kA , C 3 Phase

32A

OSC-20

24A

15

4x4

4x6

Auto Fuse 6 kA , C 3 Phase

50A

OSC-25

34A

18.5

4x4

4x6

Auto Fuse 6 kA , C 3 Phase

50A

OSC-30

41A

22

4x6

4x10

Compact circuit breaker

50-63A

OSC-40

58A

30

4x10

4x16

Compact circuit breaker

63-80A

OSC-50

68A

37

4x16

3x25/16

Compact circuit breaker

63-80A

OSC-60

83A

45

4x16

3x25/16

Compact circuit breaker

80-100A

OSC-75

101A

55

3x25/16

3x35/25

Compact circuit breaker

100-125A

OSC-100

130A

75

3x35/25

3x50/25

Compact circuit breaker

125-160A

OSC-125

155A

90

3x50/25

3x70/35

Compact circuit breaker

160-200A

OSC-150

205A

110

3x70/35

3x95/50

Compact circuit breaker

200-250A

OSC-180

220A

132

3x95/50

3x120/70

Compact circuit breaker

200-250A

OSC-220

270A

160

3X120/70

3x150/70

Compact circuit breaker

250-315A

OSC-270

320A

200

3X150/70

3X185/95

Compact circuit breaker

315-400A

OSC-340

420A

250

3X185/95

3x240/120

Compact circuit breaker

400-500A

 The cable that will be implemented for compressor must have earthing, and the compressor has to be connected to ground line.  Your compressor is equipped with phase protection relay which prevent reverse rotating of motor during first start up. If you receive phase protection error, then change two phases location for having correct phase.

COMPRESSOR SYSTEMS AND COMPONENTS

3. COMPRESSOR SYSTEMS AND COMPONENTS  OZEN Screw Air Compressors consist operation system, lubrication system, cooling system, control system, electric engine and actuation mechanism.

3.1.Operation System  Operation System is the system where air is compressed.  The air which sucks from atmosphere by suction valve is cleaned in air filter. Then it reaches to the air end through suction valve.  The air that comes to air end is compressed via rotors which are located in air end and rotated by electric motor.  Finally, compressed air moves from air end to separator tank.  Air Filter is placed as assembled on suction valve. (Figure 5)  Air filter filters and cleans the intake air.  The maintenance of air filter will explain in "Maintenance" section.    

Suction Valve is located on the air end. Suction valve provides suction of air from atmosphere to air end Suction valve is a valve system with pneumatic and electric control. Once internal pressure reaches proper level, the suction valve totally opens and compression process starts.

 Air End is one of the most important components at compressor.  The air end is located on separator tank in some compressor models, in other compressor models directly located on compressor body.  Air compression process is carried out here.

Figure 5 Air Valve, Suction Valve and Air End  Lubrication of air end that is executed by Lubrication System is a vital issue. WARNING!!! IN CASE ANY OPERATION IS DONE TO AIR END WITHOUT OUR COMPANY CONFIRMATION, COMPRESSOR WILL BE OUT OF WARRANTY.

7

COMPRESSOR SYSTEMS AND COMPONENTS

 Minimum Pressure Valve prevents reverse air flow from air receiver to separator tank during process mentioned above. (Figure 6)  Minimum pressure valve can be imagined as one way check valve.  Furthermore, minimum pressure valve ensures necessary pressure for oil circulation in the system.

3.2.Lubrication System  Lubrication System provides oil cleaning and lubrication of entire system especially air end while compressor is running.  Lubrication of system occurs thanks to internal pressure that minimum pressure valve ensures in separator tank.  The oil first goes to thermostatic valve from separator tank.  If oil temperature is lower than 55°C, then the oil goes to oil filter the thermostatic valve first way send oil to air end  If oil temperature is higher than 55°C, then the oil goes to radiator by thermostatic valve second way. After the oil cools down here, it moves to oil filter, and then reach to air end.  After compression stage at air end the compressed air moves to separator filter which located in separator tank. The separator filter separates air and oil particles from each other. Finally, the separated oil goes either after cooling or directly to air end.  Separator Tank is a component where the oil and compressed air are separated by separator filter. (Figure 6)  Once the air compressed by air end comes to separator tank, the internal pressure starts to be formed here.  In OZEN compressor, there are two kind of separator tank as vertical and horizontal, which depends on compressor model.  Hydraulic test for each separator tanks are implemented more than 1.5 times of working pressure.

Figure 6: Separator Tank and its components  Separator Filter separates oil particles and air from each other.  There are two kind of separator filter as Spin-on and Dipping Separator Filters. (Figure 7-8)  Spin-on type is used for horizontal tanks, and dipping type is used with vertical tanks.

8

COMPRESSOR SYSTEMS AND COMPONENTS

Figure 7 Dipping Type Separator Filter

Figure 8 Spin-on Type Separator Filter

 Thermostatic Valve measures temperature of oil that comes from separator tank.  In light of measurement, the oil send to radiator to cool down or directly sent to oil filter.  Oil Filter ensures cleaning of oil that comes from separator tank.  It has a great importance for system to operate properly.

Figure 9 Oil Filter

3.3.Cooling System  Cooling System cools down oil in the system also compressed air that will be discharge  If oil temperature more than 55°C the oil goes to cooler from thermostatic valve, and after cools down at cooler oil return to system.  The compressed air which separated from oil particles in separator filter passes to cooler, cools down there, it is served to the air receiver.  Radiator is a component where the oil and compressed air cool down through cooling fan.

9

COMPRESSOR SYSTEMS AND COMPONENTS

 Radiator is designed with aluminum material for more effective cooling.  There are two separated division in radiator. The oil cooling occurs at the larger division, and compressed air cooling occurs at the smaller division.    

Cooling Fan cools radiator which hot oil and hot compressed air pass in Cooling fan is located in front of or back side of radiator. There are two types of cooling fan s which are Axial and Radial types Cooling fan has its own electric motor and a propeller.

Figure 10 Radiator and Axial Cooling Fan

Figure 11 Radiator and Radial Cooling Fan

3.4.Control System  Control System controls all systems, and acts proactive by detecting possible problems before they occur.  Control system consists of pressure sensor, temperature sensor, electric box, inverter and control panel components.  Pressure Sensor exists 2 different spots in compressor.  One of them that measures internal pressure in separator tank is located on separator tank, and the other that measures external pressure of receiver tank is located on radiator.  The relation between internal and external pressure is always controlled. If the difference between them is higher than limit value, pressure sensor sends a warning to control panel. WARNING!!! CHANGING PRESSURE VALUES IN COMPRESSOR MODELS WITHOUT INVERTER CAUSES OVERSTRESS FOR ELECTRIC ENGINE. IN CASE A PROBLEM CAUSED BY THIS ISSUE, COMPRESSOR WILL BE OUT OF WARRANTY.  Temperature Sensor is placed under the air end, and measure temperature value of oil comes from air end. If this value is greater than limit value, sensor sends a warning to control panel.

 Electrical box contains electric equipments which are required for compressor running.

10

COMPRESSOR SYSTEMS AND COMPONENTS

 Box covers main circuit breaker, Y-Δ system, auxiliary contactors, electric terminal, transformer control buttons, warning lamps and inverter (up to compressor type).  Inverter exists in electrical box and adjust electric motor's rotation according to air usage.  Compressor always runs in load-unload mode due to variant air demand.  Although the compressor running in unload mode doesn't produce compressed air, it causes waste of energy by consuming about 30-35% of electric motor power.  In case of using inverter, since compressed air is produced based on instant air demand, transition between load and unload modes less occurs. Hence 25-30% energy saving is obtained.  Furthermore, if compressor tends to run with frequently start-stop, inverter ensures less number of start-stop of electric motor by reducing rotation number of electric motor.  Control Panel is used in two different types as Analog and Digital panels depend on customer demand.  Analog Panel contains start-stop button, manometer, thermometer, mode switch, emergency button, hour meter and warning lamps on it.  Manometer shows operating pressure of compressor.  Thermometer indicates oil temperature at air end output. If temperature exceeds limit value, then compressor stops running.  Mode switch contains two cases as 1 and 2 modes. While Mod1 is used in case of compressor is running less often, Mod2 is used in case of compressor is used with full capacity.  Hour meter indicates total duration that compressor has been running.  There are power on, excessive oil temperature, thermic failure and load/unload warning lamps on analog panels.  Digital Panel is a PLC based control panel.  There are emergency button, screen and control buttons on digital panel. The information can be reached is variant depends on digital panel model.  This information basically can be found on electronic screen; oil temperature at air end outlet, external pressure, internal pressure, pressure difference between these two pressures, working hour, working hour on load, maintenance time, air filter-oil filter-separator filter changing time, oil changing time and warnings' detail.  OZEN Compressor Maestro digital control panels have lots of various applications and features. For detailed information please check Maestro Control Panel user manual.

3.5.Electric Motor    

Electric Motor is connected with air end in compressor system. As soon as motor runs, rotors in air end start to rotate. By this way compression of air occurs. Related to compressor models, the large capacity diversity of electric motors are used. The main differentiation points that ensure diversity of motor are as follow; motor power, operating voltage, motor rpm, phase, protection type and insulation class.

3.5.1. Service instructions for electric motors 1. The electric motor has left our ex-works as assembled on air compressor, completed electric connection and dynamically balanced, which is ready for operation. In order to prevent any damage to electric motor during a handling for any maintenance, please handle the motor carefully.

11

COMPRESSOR SYSTEMS AND COMPONENTS

2. When the motor has not been used for a prolonged period of time, the following instructions must be performed before start up:  

Inspect the bearings' oil situation and if necessary please lubricate them. At 500V, if the insulation resistance is less than 2 Mohms and winding temperature is at 25 °C, then heat the winding using hot air with a maximum temperature of 80 °C.

3. The rotor of the motor is dynamically balanced with a fully feather key inserted in the shaft end. Driven equipments such as pulley and coupling must be insert to shaft with suitable tools. Please do not try to insert any part to shaft by heating the shaft. 4. You can prolong the service life of your motors by aligning their connection parts carefully. This can be applied to motors with both flexible and non-flexible couplings. Even slight misalignments may very rapidly result in damage to the bearings. Please be sure that the four feet are evenly loaded. 5. Please use grease oil type that indicated at motor rating plate for lubricating front and back bearings. The grease must be pumped to the inlet ports which are locating at top side of front and back bearings. The lubrication must be done every 3.000 working hours. In severe operating conditions such as high humidity, high air pollution and over 40°C temperature, the lubrication should be carried out every 1.000 working hours. It is recommended to inspect and clean the bearings by an expert every 18.000 working hours as indicated in maintenance period. If the motors are exposed to a high degree of humidity and comparatively heavy air contamination, the bearings should be cleaned at shorter intervals. For cleaning, commercial kerosene should be used. Please attention that same kind of grease should be used for refilling or lubricating. 6. Please check information on the motor rating plate. The voltage marked on the rating plate must correspond with the main voltages. 7. In all of our compressors, electric motors have WYE-DELTA starter (except some special requests). Hence, the terminal board is normally equipped with 6 terminals. 8. When electric motor is running at rated voltage and rated output, the motor temperature rises. If this temperature exceeds limit value, then PTC stops the motor.

3.6.Rotation Mechanism  Two distinct mechanism as belt-pulley and direct drive are used in connection of electric motor and air end. 3.6.1. Belt-Pulley Mechanism  At Belt-Pulley rotation Mechanism, pulleys that fitted to motor and air end shafts turn by belt with suitable length and width. (Figure 12)  Thus, the movement of the motor is transmitted to air end through belt and pulleys.  Belt and pulley dimensions vary depends on motor power and pressure value of compressed air.

12

COMPRESSOR SYSTEMS AND COMPONENTS

Figure 12: Belt-Pulley Rotation Mechanism 3.6.2. Direct Drive Rotation Mechanism  At Direct Drive Rotation Mechanism, motor shaft and air end shaft are connected directly each other via coupling. (Figure 13)  Because of connection directly each other, rotation number of electric motor and air end are equal.  In case of any changing related with rotation number, inverter should be used.  In case of block of air end that don't rotate, the coupling disconnects electric motor and air end connection by deactivates itself.  For this reason coupling has a huge importance for system.

Figure 13: Direct Drive Mechanism

13

SYSTEM PROTECTION EQUIPMENTS

4. SYSTEM PROTECTION EQUIPMENTS  In order to protect compressor from dangerous situation, several equipments are used at compressor system. These can be listed as phase protection, safety valve, pressostat, thermistor and preheating.  Phase Protection prevents electric motor badly influenced from wrong phase connection thanks to phase protection relay.  Phase protection relay never be deactivated.  Safety Valve is located on separator tank or separator block depending on compressor model. (Figure 6)  If internal pressure in separator tank exceeds limit value due to any fault while compressor is running, safety valve intervenes and evacuates air to reduce internal pressure.  In case of air discharging by safety valve, authorized service must be informed.  Pressostat intervenes and stops compressor if internal pressure exceeds limit value due to any fault.  Pressostat is the first stage and safety valve is the second stage protection for internal pressure.  PTC Thermistor measures internal temperature of electric motor.  If internal temperature of motor exceeds limit value, then PTC thermistor allows the motor to stop. Therefore motor is protected from possible burn risk.  PTC thermistor shouldn't be dislodged, and if it fails, then it should be replaced with new one.  Preheating is a heating process of compressor that occurs when the temperature of compressor operating ambient is under 0°C.  If compressor doesn't have preheating system, then air end block, separator tank and oil filter need to be heated with infrared type heater before compressor runs.  Compressor shouldn't be heated with fire and such burning elements. WARNING !!! OPERATING COMPRESSOR WITHOUT PREHEATING PROCESS IN AMBIENT TEMPERATURE OF 0°C OR BELOW CAN DAMAGE AIR END BLOCK.

14

OPERATING PROCEDURE

5. OPERATING PROCEDURE 5.1.First Start-Up  First start-up should be executed by either our technical service or end user according to our technical service's instructions. Therefore, please inform our technical service after preliminary is done by following these steps below.  Please be careful to prevent damage during handling the compressor.  After completion of Locating the Compressor, please implement accurately Assembly of Air Connection.  Please control the input voltage of compressor and electric connections in the compressor according to Assembly of Electric Connection.  Please perform oil level control before run the compressor. If necessary, fill the separator tank up with oil up to suitable oil level.  Please make sure there is no foreign object such as fabric and nylon on compressor before run it.  Please operate the compressor for a while and then observe these issues; uptrend of pressure value, switching to unload mode when pressure value reaches upper limit, switching again to load mode when pressure limit reaches lower limit and whether temperature is in suitable intervals during operation of compressor.  Although tests of all systems and components are fulfill after production, following these steps above is crucial in order to prevent possible damage that can occur during handling and locating.

5.2.Daily Operating    

Please make sure to implement Daily Maintenance Process at daily operating of compressor. Please make sure there is no warning on control panel and no leakage at internal components. Please control pressure and temperature values on control panel. Possible problems and time wasting can be prevent by completing these controls.

5.3.Operating After Long Time No Running  If compressor didn't operate for a long time (2 weeks or more) after running a period of time, then please disassemble air filter and add a small amount of oil (0.5-1 liter) from suction valve before first operating after that no running period. Then, rotate the air end in direction of arrow by hand. Thus, the risk of operating of air end without oil can be prevented.

5.4.Operating At Low Temperature  Compressors should be operated at ambient temperature between 0°C and 40°C. That's why, in case ambient temperature is below 0°C, please heat the compressor room before operate it. After preheating process, compressor can be started. On the other hand, if ambient temperature is above 40°C, then please cool down the compressor room with cooler fan or air conditioner. After that process, compressor can be started.

15

MAINTENANCE

6. MAINTENANCE 6.1. General WARNING !!! PERFORMING OF COMPRESSOR MAINTENANCE BY UNAUTHORIZED OR UNEDUCATED PERSON(S) CAUSES ACCIDENTS AND INJURIES AS WELL AS COMPRESSOR WILL BE OUT OF WARRANTY.       

  



Maintenance of compressor should be performed as indicated in this user manual. Genuine parts should be used in maintenance. Accurate and suitable tools should be used in maintenance. Compressor should be disconnected from power unit before its maintenance. Compressor must be isolated from pressure line and its internal pressure must reduce to zero through closing air relief valve. Cleaning shouldn't be done with flammable materials during maintenance. Soft fabric should be preferred instead of oakum during cleaning. Please make sure there is no loose bolt, nut or fitting left in compressor after maintenance. Furthermore, tools that be used for maintenance as screwdriver shouldn't be forgotten in the compressor. Assembly should be carried out accurately in such a way that it doesn't allow any friction and open ended electric cable after maintenance. Please read this section carefully before compressor maintenance that should be done by authorized people. Thus operating life of compressor will be extended. When you read this section, it will be easily understood that compressor maintenance consists of short and periodic controls, and service indicators on control panel makes maintenance easier for you via warning you at service hours. In case of any problem that you cannot deal with, please contact our technical service.

6.2. Daily Maintenance  Oil level in separator tank should be checked before compressor operates.  If oil level is below the marked point on oil level indicator, it is necessary to fill oil up until this marked point.  If oil decrease issue frequently happens, then there should be a problem causes oil loss. You can check Trouble shooting section for reason and solution of this issue.  After running compressor as usual, please make sure there isn't any warning or alarm on control panel.  After a while compressor runs, please visually check entire internal parts, and be sure that compressor operates properly.  Do not remove any components of compressor while it is running, and do not pull the plug without stopping it.  When you perform any operation, first stop compressor and then discharge all compressed air in system.

6.3.Weekly Maintenance     

Air filter of compressor should be cleaned with compressed air. Honeycomb radiator should be cleaned with compressed air. Oil level of separator tank should be checked. The water accumulated in the air receiver should be discharged. It is necessary to visually check whether there is an oil leakage at hose connections in compressor.

16

MAINTENANCE

6.4.Maintenance Period  As seen at maintenance periods given separately for mineral and synthetic oil in Figure3 and Figure4, there are maintenance times at certain working hours depending on oil type for different components.  Maintenance periods should be followed for more healthy operation of compressor.

6.5.Lubrication and Oil Maintenance  All produced compressors deliver to customers as tested and oil filled up to sufficient level. 6.5.1. Oil Level Control  Oil level control is carried out from oil level indicator on separator tank.  Oil level should be at middle point of oil level indicator on separator tank. WARNING !!! FOR CHECKING OIL LEVEL CONTROL STOPPED AND WAIT FOR A WHILE.         

COMPRESSOR SHOULD BE

6.5.2. Oil Change and Oil Additive Before oil change of compressor it is necessary that compressor is stopped and compressed air in separator tank is discharged. Evacuation of oil in the system is carried out by removing oil drain valve. After evacuation of oil in the system, oil drain valve fits again and oil additive process begins. Oil additive process is fulfill through oil refill plug on separator tank. Oil brand that will be added should be OZEN AIR FORCE 3000 Screw Air Compressor. After refill up to marked point on middle point of oil level indicator, oil refill plug should be assembled again. If low oil level is observed during regular oil level control, oil additive should be done as indicated above. Oil change and oil filter change always should be done simultaneously. Oil and oil filter change should be carried out every 3000 working hours while using mineral oil and every 8000 working hours while using synthetic oil.

WARNING !!! MIXING DIFFERENT TYPE OF OIL AND WATER SHOULDN'T BE USED FOR COMPRESSOR. OTHERWISE, COMPRESSOR WILL BE OUT OF WARRANTY.  Viscosity of using oil varies depending on operating temperature of compressor. (Figure 2)  You can contact our technical service and get advice about oil brand during oil additive or change process. Table 2 Oil Properties

Operating Temperature of Compressor

Oil Type

60-85°C

ISO VG 46-68

85-95°C

ISO VG 68

95-100°C

ISO VG 100

17

MAINTENANCE

18

Table 3 Maintenance Period In Use Of Mineral Oil

Maintenance Period In Use Of Mineral Oil Air Filter Change Oil Filter Change Oil Change Cooler Cleaning Belt Tension Control Electric Connections Control Air/Oil Leakage Control Separator Filter Change Oil Bung O-Rings Change Dryer Filter Change Solenoid Valve Diaphragm Changing Thermostatic Valve Maintenance Kit Change Suction Valve Maintenance Kit Change Belt/Coupling Change Air End and Electric Motor Bearings Control (If Necessary Overhaul) Air End and Electric Motor Bearings Overhaul Minimum Pressure Valve Maintenance Kit Change Hoses Change

Working Hours 3,000 6,000 9,000 12,000 15,000 18,000 21,000 24,000 27,000 30,000

√ √ √ √ √ √ √

√ √ √ √ √ √ √ √ √

√ √ √ √ √ √ √

√ √ √ √ √ √ √ √ √

√ √ √ √ √ √ √

√ √ √

√ √ √ √ √ √ √ √ √ √ √ √

√

√ √ √ √ √ √ √

√ √ √ √ √ √ √ √ √

√ √ √ √ √ √ √

√ √ √ √ √ √ √ √ √

√ √ √ √

√ √ √ √ √

MAINTENANCE

19

Table 4 Maintenance Period In Use Of Mineral Oil

Maintenance Period In Use Of Synthetic Oil Air Filter Change

Working Hours 3,000 6,000 8,000 9,000 12,000 15,000 16,000 18,000 21,000 24,000 27,000 30,000 32,000

√

√

Oil Change

Belt Tension Control Electric Connections Control Air/Oil Leakage Control Separator Filter Change

√

√ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √

√

Suction Valve Maintenance Kit Change Belt/Coupling Change Air End and Electric Motor Bearings Control (If Necessary Overhaul) Air End and Electric Motor Bearings Overhaul Minimum Pressure Valve Maintenance Kit Change Hoses Change

√ √ √ √ √

√ √

√

√ √ √ √

√ √ √ √ √ √ √ √ √

√ √ √

Solenoid Valve Diaphragm Changing Thermostatic Valve Maintenance Kit Change

√ √ √

Oil Bung O-Rings Change Dryer Filter Change

√

√ √

Oil Filter Change

Cooler Cleaning

√

√

√

√ √ √

√ √ √ √

√ √ √ √ √

√ √ √

√

√ √ √ √ √ √

MAINTENANCE

6.5.3. Oil Flow Indicator Cleaning  The oil separated from compressed air in separator filter returns to air end block. This oil flow between separator filter and air end can be monitored via oil flow indicator.  There is a hole with 1mm diameter in aluminum body of oil flow indicator. This hole can congest in time, and oil flow can stop.  In case of oil flow blockage, the risk of compressed air contains oil particle increases. Hence, oil flow indicator cleaning is significant.  The fitting that oil flow indicator connected is removed after compressor stops and waiting for a while. Then, occluded hole is opened by aid of a needle.  After opening hole transparent plastic part places should check on its place, o-ring seals should control, and if necessary seals should be replaced with new ones.  After these arrangements, fitting and pipe connection need re assembled, and oil flow indicator cleaning terminates.

6.6. Oil Filter Change  Oil filter change and oil change always should be done simultaneously.  For this changing, firstly stop the compressor and evacuate the compressed air in the system. Then discharge oil in the system by opening oil drain valve.  Please close oil drain valve after all oil discharges. After that, please remove old oil filter by help of special filter belt key. (Figure 14)  Then you can assembly new oil filter after filling half filter with oil and lubricate slightly its gasket. Finally you can fill separator tank up to suitable level with oil.  If you change oil filter except maintenance schedule, you don't need to change system oil. Please remove old filter, and then assembly new oil filter after fill half of oil filter up with oil and lubricate slightly its gasket.  New oil filter can be assembly by hand.

6.7. Separator Filter Change  For spin-on separator filter change, first stop compressor and wait until whole air is completely discharged from system.  Then please remove old filter with special filter belt key. Finally, assemble new filter by hand.(Figure 14)  For dipping separator filter change, first stop compressor and wait until whole air is completely discharged from system.  Then, dismantle screws of flange and connection hose, which placed on separator tank. During this process please make sure that chrome plated oil drain hose which reaches from top of separator tank to bottom of it doesn't damage.  After that, remove old separator filter, assemble new filter, and reassemble flange by following steps above.  Please make sure that tightened screw on the flange touches to upside of separator filter.  Please check o-ring seals on top and under of separator filter while assembling new filter. If necessary, please renew o-ring seals. WARNING !!! NEVER TRY TO CLEAN SEPARATOR FILTER. IF YOU HAVE PROBLEM WITH IT, REPLACE WITH A NEW ONE.

20

MAINTENANCE

Figure 14 Oil and Spin-on Separator Filter Change

6.8. Air Filter Maintenance  In order to more effective operating of compressor, air filter should be cleaned with compressed air for a two to three weeks time.  For air filter cleaning, first stop compressor and wait for a while.  After that, remove filter and clean filter by dry air up to 5 bar. If filter is so dirty as cannot be cleaned replace it with new one.

6.9. Cooler Maintenance  Cooler can get dirty and congest in time. In that case air temperature rises since cooling process cannot be performed properly. Hence, cooler must be cleaned once a week with compressed air.  If cleaning with compressed air becomes inadequate, then please inform our technical service.

6.10. Belt-Pulley Maintenance  It is necessary to control periodically belt-pulley system during compressor utilization.  If there is a strange noise comes from machinery group, or a bounce at rotation of belt when compressor is running, or black rubber dust around compressor, then there possibly is a problem with belt. In that case, please contact our technical service.  Furthermore, these should be periodically control; whether belt touches accurately on pulleys, and there is any crack or tear at belt.  For accurate pulley choice in need of spare part, please contact us.

6.11. Air Receiver Maintenance  The floor which the air receiver will be placed should be capable of carrying the weight of air receiver and should be flat.  Welding places on air receiver should be regularly checked, and if any damage comes up, our technical service should be informed.  Please make sure there is no harm at air receiver during its maintenance.  After production, air receivers are tested with hydraulic pressure that is one and a half times more of air receivers' maximum working pressure. Then, test certificate which has validation for a year timeis arranged end of this test.  According to the Occupational Health and Safety Regulation, air receiver should be tested end of one year by government agencies. In case it isn't tested by government agencies, test should be carried out by end user at least once a year.  Any maintenance shouldn't be performed when air receiver is under pressure.

21

MAINTENANCE

22

 Serial number, year of manufacture and maximum allowable operating pressure of air receiver is indicated on rating plate on air receiver. Pressure that is more than maximum operating pressure shouldn't be stored in air receiver.  Lifetime of air receivers is 10 years. Air receivers shouldn't be used more than 10 years. WARNING !!! IN CASE ANY PROBLEM WITH AIR RECEIVER, PLEASE INFORM US. OTHERWISE AIR RECEIVER WILL BE OUT OF WARRANTY.

6.12. Maintenance Record Model No : Seri No : DATE

WORKING HOUR

MAINTENANCE EXPLANATION

MAINTENANCE PERFORMED BY

MAINTENANCE CONTROLED BY

TROUBLESHOOTING

23

7. TROUBLESHOOTING FAULT

POSSIBLE CAUSE Lack of electricity Main and control fuse tripped Loose or break cable

Compressor Motor or fan thermic tripped Not Working Stoppage of compressor due to any malfunction

REMEDY Check phase cables and tighten the loose ones. Check fuses and replace with new one if necessary. Check internal cables. Replace break ones and tighten loose ones if exists. Put motor or fan thermic into use again. Resolve the problem shown on control panel.

It is possible not to run due to unfinished internal Not running of compressor very soon after pressure discharging. After a while it will be ready it has stopped to run.

Inaccurate time setting of Y- system Low input voltage or current fluctuation Low ambient temperature and oil freezing Taking Too Long to Start Compressor High oil viscosity Running Broken-down suction valve

Broken-down motor

Leakage at air line Broken-down suction valve Clogged air filter Inadequate of compressor capacity for Not Reaching your usage to Required Pressure Broken-down air end block Value Broken-down safety valve Inaccurate motor thermic setting Inaccurate pressure switch setting

Check time setting of Y- system, and adjust it if necessary. Check your electric infrastructure at your facility and fix troubles. Implement preheating process to separator tank and air end block. Use proper oil type, and change oil if necessary. Suction valve should be in close position during first start. If it is in open position, then there is a problem with suction valve. Please contact us. Stop the compressor and check by hand whether motor shaft rotates easily or not. If it doesn't, then contact our technical service. Check air hoses and connection points. Suction valve can't possibly perform full capacity since it can't completely open. Control suction valve, and contact our technical service if necessary. Air filter can't possibly perform since it is clogged. Clean or replace air filter. You need to increase compressor capacity. Air end block can't compress air if it is out of order. In this case contact our technical service. There can be an air leakage on safety valve. In order to replace with a new one, please contact us. In case motor thermic is out of adjustment, compressor stops before required pressure value. Contact our technical service for new adjustment. Contact us in order to rearrange pressure switch setting.

TROUBLESHOOTING

Exceeding Required Pressure Value

Out of adjustment of pressure settings

Regulate pressure settings on control panel.

Broken-down pressure sensor

Pressure sensor should be replaced with new one. Please contact our technical service.

Broken-down suction valve Inaccurate time setting of Y- system Compressor Not Producing Broken-down minimum pressure valve Compressed Air Broken-down solenoid valve

Broken-down air end block Stoppage Of Compressor Inaccurate thermic settings Due To Motor High pressure settings value Thermic Tripped Low input voltage Problems at electric motor Extremely hot operating ambient

Leakage at oil connection line Severe Oil Diminution Broken-down separator filter

Stoppage Of Compressor Due To Cooler Fan Thermic Tripped

24

Inaccurate thermic settings Problems at hot air outlet Problems at cooler fan motor Extremely hot operating ambient

Suction valve can be stuck in closed position. Contact our technical service. Check time setting of Y- system, and adjust it if necessary. Since minimum pressure valve is broken, internal pressure doesn't exist, and suction valve doesn't open. Contact our technical service. After internal pressure reaches required value, control panel sends signal to suction valve through solenoid valve, and then suction valve opens. If solenoid valve is broken, then suction valve doesn't open. In this case please contact technical service. Because of broken air end block, electric motor can be forced. Stop the compressor and check by hand whether air end shaft rotates easily or not. If it doesn't, then contact our technical service. Control motor thermic settings on control panel. Adjust settings if necessary. Control pressure value on control panel. Adjust if necessary. Control input voltage values of compressor. Please make sure there is no problem about motor. Please ensure that operating ambient of compressor is between 0°C and 40°C. There can be a leakage at oil hoses or connectors. Tighten loosen parts or replace related parts if necessary. In this case air with oil particles goes to air receiver, and oil quantity in compressor decreases. Replace separator filter with new one. Check cooler fan thermic settings on control panel. Adjust if necessary. Please make sure there isn't any obstacle at hot air outlet. Clean honeycomb radiator if necessary. Please make sure there isn't any problem at cooler fan motor. Please ensure that operating ambient of compressor is between 0°C and 40°C.

TROUBLESHOOTING

Very short time of Y-system Rapid Large number of start-stop Breakdown Of Contactor Low input voltage Contacts Using improper parts

Temperature Sensor Or Contact Thermometer Warning Due To Extremely Hot Ambient

System remain oil-free Clogged oil filter Broken-down thermostat Clogged cooler In accurate locating of compressor room

In accurate locating of compressor room Extremely hot operating ambient Stoppage Of Compressor Due To Severe Temperature

Inaccurate temperature settings System remain oil-free Clogged oil filter Clogged air filter Clogged cooler Open covers

Temperature Increasing After Clogged oil line or oil filter Switching To Unload Mode

Broken-down safety valve Intervention Of Safety Valve

Oil Particles In Compressed Air

Inaccurate safety valve settings Inaccurate operating pressure settings Not stoppage automatically

Broken-down separator filter Clogged oil flow indicator High oil level

25

Adjust time setting of Y-system to 4-6 seconds. Contact our technical service. Check your electric infrastructure at your facility and fix troubles. Contact us for choosing contactor type and model.

Please control oil level, and add oil if necessary. Oil filter should be replaced. Thermostat should be replaced. Please contact us. Cooler should be cleaned. Compressor should be located according to locating instructions in this manual. Compressor should be located according to locating instructions in this manual. Please ensure that operating ambient of compressor is between 0°C and 40°C. Please check temperature settings on control panel. Please control oil level, and add oil if necessary. Oil filter should be replaced. Air filter can't possibly perform since it is clogged. Clean or replace air filter. Cooler should be cleaned. Covers should be in closed position during operating.

Oil line and oil filter should be checked, and parts should be replaced if necessary.

There can be an air leakage on safety valve. In order to replace with a new one, please contact us. Adjust safety valve settings. Check and adjust pressure settings on control panel. Please see " Exceeding Required Pressure Value" In this case air with oil particles goes to air receiver, and oil quantity in compressor decreases. Replace separator filter with new one. Oil flow indicator should be cleaned. Control oil level, and discharge if necessary.

TROUBLESHOOTING

Not using recommended oil type High ambient humidity Rapid Feature Losing Of Oil High ambient temperature Matters (gas, dust e.g.) that changes oil property exists in ambient

26

You can contact us learn recommended oil type. Ambient humidity should be decreased. Ambient temperature should be temperature. Ambient should be cleaned from these matters.

Inaccurate waiting in unload mode settings Not Automatically Stopping In Switching again to load mode in a short Unload Mode period of time

Rearrange waiting in unload settings. When pressure value reaches to lower bound before completion of waiting in unload mode, compressor again switches to load mode.

Discharging Broken-down solenoid valve Constantly Some Amount Cut of feeder line that comes to solenoid valve Of Air

Replace solenoid valve with a new one. Please check the line, and fix necessary parts.

Despite Broken-down suction valve Compressor Stoppage, Not Decreasing Of Internal Broken-down minimum pressure valve Pressure

Because of broken-down suction valve, air discharging can't be executed after compressor stops. Please contact our technical service. Because of broken-down minimum pressure valve, the pressure air in air receiver can come back to separator tank. Hence, minimum pressure valve should be replaced. Please contact us.

Shown Up Of Phase Wrong connection of phase cables Protection Warning

Two of phase cables should be switch among them.

Due to motor Due to pulley Compressor Operating Too Due to air end Loud Due to connections

Problems In Belt-Pulley System

Bending of belt or wear of belt edges due to misaligned pulleys Bending of belt due to wrong belt and pulley choice Bending of belt due to abrasion of pulley thread Bending of belt due to severe vibration

There can be a problem in motor. Please contact us. It arises from misaligned pulleys. Please contact us. There can be a problem based on rotors. Please contact us. Internal connections can be loose. Please tighten necessary parts.

Pulleys should be aligned. Please use proper belt and pulley. Pulley should be replaced. Tensioning system and vibration dampers should be checked.

TROUBLESHOOTING

Bending of belt due to foreign materials in pulley thread Wear of belt edges due to high initial torque value Wear of belt edges due to wrong pulley thread angle Belt in sticky form due to contact with chemicals such as oil Expansion of belt due to using it out of its function Expansion of belt due to wrong pulley thread Rupture of belt due to smaller dimension of belt than its normal size Crack or tear at the bottom of belt due to smaller dimension of belt than its normal size Crack or tear at the bottom of belt due to severe warm and cool Changing belt tension adjustment due to inaccurate belt size

27

Foreign materials should be removed. Check and rearrange initial torque value. Pulley should be replaced. Belt system should be cleaned. Belt should be replaced. Belt and pulley should be replaced. Please use correct belt. Please make sure by checking pulley size that you use proper pulley. Please ensure that operating ambient of compressor is between 0°C and 40°C. Please replace with proper belt by checking belt size.

MEHMET ÖZEN MAKINE SAN. TIC. LTD. ŞTI. KONYA ORGANIZE SANAYİ BOLGESİ BUYUK KAYACIK MAH.KUDDUSI CAD. 20. SOK NO:4 42300 KONYA/TURKEY PHONE: +90 332 345 42 45 FAX: +90 332 345 42 48 web: www.ozenkompresor.com e-mail: [email protected]