VEK SCREW COMPRESSOR

Transcription

1 VEK SCREW COMPRESSOR MAINTENANCE AND SPARE PARTS GUIDE Address and communication informations: Ali Bey Köyü,Karasinan Asfaltı Telefon No: (Pbx) Mevkii,Silivri,İstanbul, Turkey Fax : info@komsan.com.tr 09 FRM 020 Rev /04/2008

2 VEK VİDALI KOMPRESÖR KATALOG FİHRİSTİ SAYFA NO IMPORTANT SECURITY RULES IN OPARATING, MAINTANANCE AND REPAIR OF THE COMPRESSORS CARRYING THE COMPRESSOR IMPORTANT THINGS TO BE CHECKED AT THE FIRST START UP PLACING OF THE COMPRESSOR SAMPLE INSTALLATION INLET AND OUTLET AIR FLOW OF THE COMPRESSOR ROOM SAMPLE ELECTRIC INSTALLATION SCHEME PLC COMPRESSOR DIMENSION PLACING OF THE AIR DRYER PLACING OF THE AIR RECEIVER PERIODICAL MAINTENANCE PROGRAM PERIODIC MAINTENANCE INTERVALS PROBABLE BREAKDOWNS AND REMOVING METHODS THE MAINTENANCE THAT MUST BE DONE BY THE USER FİRST OPERATING INSTRUCTIONS SPARE PART LIST MAIN ASSEMBLY DRAW MAIN ASSEMBLY LIST HYDROLIC GROUP DRAW HYDROLIC GROUP LIST MOTOR GROUP DRAW MOTOR GROUP LIST AIREND GROUP DRAW AIREND GROUP LIST OIL RECEIVER DRAW OIL RECEIVER LIST AIR INLET VALVE DRAW AIR INLET VALVE LIST MINUMUM PRESSURE VALVE DRAW MINUMUM PRESSURE VALVE LIST THERMOSTATIC VALVE DRAW THERMOSTATIC VALVE LIST BONNET GROUP DRAW BONNET GROUP LIST PNEUMATIC GROUP DRAW PNEUMATIC GROUP LIST THE SCREW COMPRESSOR S HYDRO-PNEUMATİC CYCLE AND WORKİNG PRİNCİPLE ELECTRICAL GROUP DRAW ELECTRICAL GROUP LIST INSTRUMENT PANEL GROUP DRAW INSTRUMENT PANEL GROUP LIST SERVICE INFORMATIONS COMPRESSOR MAINTENANCE OBSERVATION TABLE /68

3 VEK SCREW COMPRESSOR OPERATION MAINTENANCE AND SPARE PARTS GUIDE MOTOR POWER VEK Hp WORKING PRESSURE Bar Adress And Communication Informations : Ali Bey Köyü Karasinan Asfaltı Phone No : (Pbx) Mevkii TEM Otoyolu Gişeler Yanı İstanbul, Turkey Fax : info@komsan.com.tr 3/68

4 FIRST SAFETY IMPORTANT SECURITY RULES IN OPERATING, MAINTENANCE AND REPAIR OF THE COMPRESSORS 1-) Use KOMSAN air receivers, equipments and KOMSAN original spare parts produced in compliance with the norms of TSE ) In case compressor is worked parallel with another compressor or is connected an air system with the same pressure, do not use check valve in the compressor air outlet. 3-) The materials of the pressurized air, pipe and hoses must be in compliance with the pressure. 4-) Do not use scratched, spoilt, decayed and broken hoses. Store the hoses away from the heat source and direct sun rays.burst of a hose may harm a human. 5-) Fix the suitable connectors to the lip of the hose. 6-) If pressurized air is used to clean the tools and parts, it must be done carefully. Be careful with the dust while it is cleaned from the machine. Use googles during cleaning. 7-) While air is used from the hose and installation directly, there must not be any foreign substance in hose. Hold the hose tip tightly and securely. Otherwise, hose tip may be dangerous because it can hit in the directions of the right and left like a whip. Open the air outlet valve carefully, check if air gets out of the hose freely. Clogged hose could become an air rifle. 8-) Do not hold pressed air onto your skin. Do not hold tip of the hose onto another person. Do not clean dusts on you with pressurized air. 9-) A pressure air system or tool must be operated in accordance with its designed pressure. 10-) Drain compressor pressure completely before dismantling hose and air line. 11-) Tips of the electrical cables must not be open 12-) Electrical connection must be done by authorized electrician. 13-) Pressure tests of the air receivers must be done each year. 14-) Manufacturer company will not be responsible for the damage and life loss caused by the misuse. 4/68

5 CARRYING THE COMPRESSOR : Compressor must be carried in vertical position. All motions and collisions which may cause damage must be avoided. Compressors must not be pushed or pulled through its canopy or doors. Compressors must not be hung in any other way than it is shown in figure 2. CARRYING BY MEANS OF FORKLIFT OR HYDRAULIC CARRIER: When carrying the compressor with a forklift or hydraulic carrier the carrying the support forks of the forklift must be inserted below the compressor as seen in picture 1. CARRYING HANGED BY MEANS OF A HOIST: When carrying the compressor by means of a hoist, insert iron rods to the gaps of the compressor bottom pallet as seen in picture 2. Care must be given that the upper rod must not touch the compressor, nor the ropes rubbing on the side of the compressor. TAKE OUT THE WOODEN FOUNDATION AFTER CARRYING THE COMPRESSOR PICTURE-1 PICTURE-2 INSTALLATION: 1-) Install the compressor in a room as it is indicated in picture-4. 2-) Keep the compressor away from the sunlight or other devices which may increase ambient temperature such as generator sets heating systems etc. 3-) Enough ventilation is absolutely necessary for a compressor. A sample ventilation diagram is presented in picture-7. Inlet air of the compressor room must be clean and without any contamination of porous gases or chemicals. If necessary, an appropriate filtration must be installed at the air entrances of compressor room. 4-) Compressor must be installed on the smooth ground, its feet must be put correctly to the ground. Compressor must not be installed to the ground. Compressor must be seated on the concrete base. (Max. declination of the floor, where the compressor is to be assembled, must not be more than ±2 degrees) 5-) If compressor is to be used with dryers, filters or receiver, please check picture-6 for how to connect these instruments to your compressor. CONNECTING TO MAINS: 1-) Compressor must be separately grounded according to your country s requirements. (See picture-6) Neutral connection is not ground. Compressor may burn because of the static charge if not grounded. 2-) Do not allow main supply cables to lay on the floor freely. D o secure them so that they may not cause any dangerous accidents. 3-) Check all connections are done tight and secure on the mains supply. 4-) Suitable circuit breaker and delayed fuse must be placed on the mains supply (see table-2). 5-) There must be no temporary connection on the mains supply cables. 6-) Compressor operating voltage must be 380±19 volt, unless it is designed for other voltages, during the full load operation. 7-) TTR type cable must be used with appropriate dimensioning (see table-2). 8-) Keep the compressor away from the moisture if it is not going to be used for a long time. 5/68

6 IMPORTANT THINGS TO BE CHECKED AT THE FIRST START UP 1-) Check the earth, neutral and phases (R-S-T) if they are fit into system appropriately when compressor starts. 2-) Check the ambient temperature. 3-) Check the oil level. Ask your dealer s authorized personnel for the first start up. This will prevent your compressor from any possible damages. If you start up compressor on your own, ask your dealer the warranty conditions. For some cases your start up may infringe guarantee claims. IMPORTANT THINGS DURING OPERATION 1-) Covers must be kept close. 2-) Water and oil must not be poured onto compressor and foreign objects must not be put onto compressor. 3-) Do not touch the inside of the compressor or do not try to make any reparations by yourself. STOPPING To stop the compressor completely, push the STOP button. Compressor will stop in a certain time. Push the EMERGENCY STOP button when emergency situation may occur. CONTROL PANEL easy! ELECTRONIC CONTROL SYSTEM ELEKTRONIK KONTROL SISTEMI AIREND OUTLET TEMP. VIDA CIKIS SICAKLIGI MAIN SCREEN SWITCH ANA EKRAN BUTONU START SWITCH CALISTIRMA BUTONU STOP SWITCH DURDURMA BUTONU LOAD - UNLOAD SWITCH YUK - BOS BUTONU EMERGENCY STOP ACIL DURDURMA SCREW COMPRESSOR VIDALI KOMPRESOR VEK20/50 PICTURE-3 6/68

7 PLACING OF THE COPMPRESSOR: ~1000 mm ~1000 mm COOLING AIR INLET (CLEAN AIR) ~1000 mm ~1000 mm WARM AIR OUTLET PICTURE-4 - DIMENSIONS ARE IN MM. - ~: AVARAGE NOT: You should leave 1000 mm space in the both sides of the compressor for service.! It is advised to use a water cooled To Work ower 35ºC am bient preaure mm COMPRESSOR PICTURE-5 7/68

8 SAMPLE INSTALLATION 8/68 REF NO PERT NAME ! CHOOSE THE CORRECTLY SIZED PIPING SO THET THE TOTAL PRESSURE LOSS IN THE SYSTEM WILL NOT EXCEED 1/10 BAR WATER OIL PICTURE-6

9 INLET AND OUTLET AIR FLOW OF THE COMPRESSOR ROOM HOT AIR OUTLET ABSORBER CLEAN AIR INLET SU Max 15 mm WATER CONCRETE FOUNDATION PICTURE 5 PICTURE-7 AIR FLOW ENTERING TO THE COMPRESSOR ROOM COMPRESSOR TYPE INTAKE AIR FLOW (m³ /s) VEK 20 1,65 VEK 30 1,65 VEK 40 2,70 VEK 50 2,70 TABLE-1 - P must not be more than 15 mm. If P is more than 15 mm, a new ventilation system must be designed. - This ventilation system must be designed in such a way that it can drain warm air from the system. - Cool air inlet must be higher than 1,5 fold from the section area of the warm air outlet. - Paddlebox weight must not be overlaped the compressor. - Bellows must be placed between paddlebox and compressor to prevent warm air leakage. - Paddlebox must not be installed to the compressor, in this purpose a hole must not be made on the compressor. 9/68

10 SAMPLE ELECTRIC INSTALLATION SCHEME CIRCUIT BREAKER FUSE TTR CABLE GROUNDING COMPRESSOR R PICTURE-8 AIR DRYER YOU MUST DO THE GROUNDING NEUTRAL LINE IS NOT GROUNDING FUSE AND CABLE TYPES WHICH ARE USED IN THE ELECTRIC INSTALLATION COMPRESSOR TYPE FUSE CABLE (TTR) VEK A 4 x 10 VEK A 4 x 16 VEK A 4 x 16 VEK A 4 x 16 TABLE-2 USE AN UPPER CABLE SECTION IF THE DISTANCE IS OVER 50 M NOT: FUSE SELECTION IS IN COMPLIANCE WITH DIN /68

11 PIC: A (new type) PIC: B (old type) In picture A, you can see EASY 819 used in your new type of compressors and in picture B, you can see EASY 412 used in our older type of compressors. PLC (control relay) exists in the panel control. PLC has several properties such as LCD screen, 24 volt, direct current and real time hourmeter. As seen in the panel control, several functions are carried out with the buttons (see picture c) Operate your compressor by pushing the < button. In this case, your compressor starts to produce air. In order for your compressor to stop, push the > button. In this PIC: C case, your compressor firstly starts to work unload and after a very short time (30 seconds) stops. In order for your compressor to work manually load and unload, push the button. When your compressor works on load, if you press button, your compressor works unload. In another situation, when your compressor works unload, if you press button, your compressor works normally. In case you press the button, all the information on the screen changes. If you press button when compressor works on load; model properties, serial numbers, durations on total load and total unload come up. If you press button again previous information is seen on the screen. Also, some failures regarding working system of your compressor are seen on the PLC screen. For example, excessive temperature and high pressure on the compressor. Do not use OK, ESC, DEL and ALT button because they are on the purpose of service and programming. OK,ESC,DEL AND ALT BUTTONS ARE IN THE PURPOSE OF SERVICE AND PROGRAMMING AND THESE BUTTONS MUST NOT BE USED. 11/68

12 COMPRESSOR DIMENSION COMPRESSOR TYPE A B C VEK VEK VEK VEK ALL DIMENSIONS ARE IN MM. TABLE-3 PICTURE-9 12/68

13 PLACING OF THE AIR DRYER ~500 mm ~1000 mm ~1000 mm ~500 mm COOLING AIR INLET (CLEAN AIR) WARM AIR OUTLET PICTURE 7 - DIMENSIONS ARE IN mm. - ~: AVARAGE NOT: YOU SHOULD LEAVE 1000 mm SPACE IN THE BOTH SIDES OF THE AIR DRAYER FOR SERVICE mm ~1500 mm! COMPRESSOR YOU MUST SELECT THE SUITABLE AIR DRYER ORDER TO WORK OVER 35 C AMBIENT TEMPERATURE AIR DRYER 13/68

14 PLACING HAVA DEPOSUNUN OF THE YERLEŞTİRİLMESİ: AIR RECEIVER ~1000 mm WATER SU DRAINAGE TAHLIYESİ PICTURE INSTALLATION SAYILI İŞ KANUNUNA OF THE GÖRE RECEIVER BASINÇLI MUST KAPLAR BE DONE MEVZUATI ACCORDING İÇ TÜZÜĞÜNE TO UYGUN LOCAL MEKANA PROTECTION GÜVENLİK LAWS ÖNLEMİ FOR ALACAK PRESSURIZED ŞEKİLDE YERLEŞTİRİLMELİDİR. VESSEL!! - - DRAIN DEPO İÇİNDE THE ACCUMULATED BİRİKEN SU HER GÜN WATER BOŞALTILMALIDIR IN THE RECEIVER VEYA DEPO EVERYDAY İÇİNE BİRİKEN OR USE THE SUYU AUTOMATIC ALMAK İÇİN OTOMATİK DRAIN FOR TAHLİYE THIS KULLANILMALIDIR. PURPOSE 14/68

15 PERIODICAL MAINTENANCE PROGRAM CONTROLS AND MAINTENANCE THAT MUST BE DONE DAILY 1-) Compressor chamber a-) Temperature b-) Cleanliness 2-) Air pressure circuit a-) Air leakage control 3-) Oil pressure circuit a-) Oil leakage control b-) Oil level control 4-) Electrical pneumatic circuit a-) Heat control 5-) Airend a-) Airend voice control 6-) Electrical motor a-) Motor voice control CONTROLS AND MAINTENANCES THAT MUST BE DONE DAILY 1-) Cleanliness of air filter ( from inside to outside with pressurized air) 2-) Inside cleanliness of compressor (*) 3-) Compressor cooler cleanliness (*) 4-) Control of working hourmeter (**) 5-) Control of current values 6-) Voltage control 7-) Control of belt tension * Do not use water, thinner etc., abrasive or conductive cleanliness material. ** As soon as you realize that it is not working, inform to the Komsan Authorized Service. 15/68

16 PERIODIC MAINTENANCE INTERVALS Institutions working 8 hours a day 6 Months or 1000 Hours Maintenance A 1 Year or 2000 Hours Maintenance A 2 Years or 4000 Hours Maintenance B 3 Years or 6000 Hours Maintenance A 4 Years or 8000 Hours Maintenance A 5 Years or Hours Maintenance C 6 Years or Hours Maintenance A 7 Years or Hours Maintenance A 8 Years or Hours Maintenance B 9 Years or Hours Maintenance A 10 Years or Hours Maintenance D Institutions working 16 hours a day 3 Months or 1000 Hours Maintenance A 6 Months or 2000 Hours Maintenance A 12 Months or 4000 Hours Maintenance B 18 Months or 6000 Hours Maintenance A 24 Months or 8000 Hours Maintenance A 30 Months or Hours Maintenance C 36 Months or Hours Maintenance A 42 Months or Hours Maintenance A 48 Months or Hours Maintenance B 54 Months or Hours Maintenance A 60 Months or Hours Maintenance D TABLE-4 Institutions working 24 hours a day 2 Months or 1000 Hours Maintenance A 4 Months or 2000 Hours Maintenance A 8 Months or 4000 Hours Maintenance B 6 Months or 6000 Hours Maintenance A 1 Year or 8000 Hours Maintenance A 20 Months or Hours Maintenance C 24 Months or Hours Maintenance A 28 Months or Hours Maintenance A 32 Months or Hours Maintenance B 36 Months or Hours Maintenance A 40 Months or Hours Maintenance D - Maintenance A and B are done by KOMSAN S Technical Service at the place that the compressor is situated. - Maintenance C is done by KOMSAN in KOMSAN COMPRESSOR MANUFACTORING FACTORY or at the place that the compressor is situated. - Maintenance D is done by KOMSAN in KOMSAN COMPRESSOR MANUFACTORING FACTORY - You should make your compressor to have maintenance on time for the most efficiently working without any problems - The user of the compressor must inform KOMSAN COMPRESSOR MANUFACTURING FACTORY or KOMSAN TECHNICAL SERVICE about the related time intervals shown above ; that the compressor is being used - The time table that is given above is valid for normal conditions. The time table can differ according to the working conditions and the working area - The earlier occured working time intervals for montly or hourly working time will be taken in to consideration for the maintanance duration time. 16/68

17 BREAKDOWN PROBABLE REASONS WAYS TO REPAIR Overload relay is out of order Change Electric engine or screw bearings are out of order Call service Regulate and push the reset Overload relay or fuse Star-delta transition time is short button burns Off loading time is very short Regulate Contactors are out of order or sticked Change Fuses are burned Change Working pressure interval is wrong Regulate Pressure switch is out of order Change Solenoid valve coil is burned Change Call service Electrical system is breakdown Change contactor Compressor can not be Change contactor loaded Change the cracked Control air control hoses or crushed ones Air control hose connections could have been dirty ( After maintenance, sealing components could block Clean the connections ) Solenoid valve is dirtied Clean Air filter is blocked Change air filter Separator is blocked Change separator Air efficiency is not enough Air intake setting valve is breakdown Call service Excessive air consumption exists. The cross-section of pipes of Air connection is narrow. Control installation leakage and air consumption of pneumatic tools Compressor heats excessively. (Outlet air +100 C, warning lamp lights.) Oil hoses are blocked There is foam on oil Expiry date of oil has long been passed Cooler is blocked or dirty Cooling air is not enough Termostatic valve does not work Ambient temperature is very high (max 35 C) or ventilation is not enough. Change Wrong oil usage Change Clean cooler Change the inlet and outlet air Call service Be careful about not being leakage in the suction and pumping chimney-hoods. Make chimney-hood and ventilation installation to make ambient temperature decrease. Excessive oil consumption Pressure is increasing excessively. Lamp and relay are out of order Fan blower blades are not strong Oil turning pipe is blocked Separator is blocked or out of order Wrong oil usage or oil expiry date has long been passed. Pressure switch is breakdown The setting of pressure switch has not been done Air intake setting valve is breakdown TABLE-5 Control Change Open and clean Change Change the oil with oil filter and use the suitable oil Change Set Call service If a cabinet filter mounted on the compressor you should change it free of charge. 17/68

18 THE MAINTENANCE THAT MUST BE DONE BY THE USER 1- To check the electrical connections; to check the connections whether they are loose or not, while the switch is closed. 2- Air circuit problems; the control of the air leaks and the pneumatic circuit elements. 3- To protect your compressor against the outer effects; you should keep your compressor away from dirty surroundings and if it is necessary you should build a separate compressor room. 4- To check the thermic, fuse and voltage. 5- To clean the cooler; the cooler must be cleaned with compressed air from its inner side to its outer side. 6- To clean the oil return line; to clean the filter in the oil return check valve. 7- To check the belt tightness; once a week you should check the belt tightness. 8- To arrange the pressure level 9- To clean the air filter; the air filter should be disassembled and cleaned with compressed air from its inner side to its outer side. 10-To check the operating hour meter; whether the operating hour meter is working or not while the compressor is working; if the hour meter is not working you must call immediately the KOMSAN technical service. If the technical service is called, because of the reasons above and things stated in the breakdown finding page, a service expense is paid to KOMSAN.If a brekdown occurs because of not doing the cleaning and maintenance stated above, while your compressor is working your compressor will be out of guarantee. The first start of the compressor process and all the maıntenance will be done in the guarantee period; the maintenance except the things stated above and in the breakdown finding page must be done by KOMSAN technical service. In an opposite occasion the compressor will be out of guarantee. The adress that the compressor is situated : CUSTOMER/Cachet PHONE NUM : DATE : SIGNATURE : 18/68

19 ATTENTION TO THE SERVICE AFTER SALE FIRST OPERATING INSTRUCTIONS DATE :.../.../ TYPE OF THE COMPRESSOR :... SERI NO :... KOMSAN A.Ş. FAX : +90 (212) THE PROCESSES THAT MUST BE DONE BEFORE CALLING THE KOMSAN TECHNICAL SERVICE FOR THE FIRST START OF THE COMPRESSOR YES NO 1-1 Are the compressor and equipments installed as shown in the guide book? 1-2 Is the air installation correctly completed according to the type of the compressor? 1-3 Is the electrical installition completed as shown in the guide book? 1-4 Is the electrical volt value,cable type,quality.fuse,thermic switch;suitable to the motor power and the empty space occupied between the compressor and the power resource? (Please look at the maintenance guide) Is the volt entrance suitable to compressor and the compressedair equipments working with electric? 1-5 Is there a ventilation system established? The processes stated above are done by us. We request the first start and the begin of guarantee applications of the compressor to be done by KOMSAN compressor manufactorıng factory. The adress that the compressor is situated : CUSTOMER/ Cachet PHONE NUMBER : DATE : SIGNATURE : NOTE: If our service technician that will come to your institution, sees some uncompleted processes, then our service will not do the first start. After the needed processes are completed the service will come to your institution again and will do the first start by getting the service expences from you. If you want to get detailed information about the things above, you can call; or comminicate with us by fax from and reach us servis@komsan.com.tr. 19/68

20 YEDEK PARÇA LİSTESİ SPARE PART LIST 20/68

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22 VEK ANA MONTAJ VEK MAIN ASSEMBLY Sıra No/Ref. No Parça No/Series No Sayfa No/Page No Adı Name Kaporta Grubu Bonnet Group Gösterge Grubu Instrument Panel Group Pnömatik Grubu Pneumatic Group Elektrik Grubu Electrical Group Hidrolik Grubu Hydrolic Group Vida Grubu Air End Group Motor Grubu Motor Group 22/68

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24 HİDROLİK GRUBU HYDROLIC GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Soğutucu Cooler Nipel Nipple Boru Hose Boru Hose Termostatik Valf Thermostatic Valve Nipel Nipple Filtre Kapağı Filter Cover Boru Hose Filtre Filter Rakor Nipple Nipel Nipple Vida Ünitesi Airend Vek Boru Tak. Hose Team Vek Boru Tak. Hose Team Yağ Deposu Montajı Oil Receiver Assembly Rakor Nipple Seperatör Separator Seperatör kapağı Separator Cover Nipel Nipple Min. Basınç Valfi (Vek 20-30) Min. Presure Valve Min. Basınç Valfi (Vek 40-50) Min. Presure Valve 24/68

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26 MOTOR GRUBU MOTOR GROUP Sıra No/Ref. No Parça No/Series No Adet/Quant. Parça Adı Part Name Vida Ünitesi Air End Kama Wedge Kama (Vek 20) Wedge (Vek 20) Kama (Vek 30) Wedge (Vek 30) Kama (Vek 40) Wedge (Vek 40) Kama (Vek 50) Wedge (Vek 50) Somun Nut Pul Washer Civata Bolt Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar 1500 dev/dak) Pulley (Vek bar 1500 rpm) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar 1500 dev/dak) Pulley (Vek bar 1500 rpm) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar Tapper Lock Bushing(Vek bar dev/dak) 1500rpm) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) 26/68

27 MOTOR GRUBU MOTOR GROUP Sıra No/Ref. No Parça No/Series No Adet/Quant. Parça Adı Part Name Kas.Göb. (Vek bar Tapper Lock Bushing (Vek dev/dak) bar 1500 rpm) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) TSet Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Civata Bolt Pervane Göbeği Fan Hub Pervane Bağlantı Parçası Blade Assembly Tool Kanat Blade Motor (Vek 20) Motor (Vek 20) Motor (Vek 30) Motor (Vek 30) Motor (Vek 40) Motor (Vek 40) Motor (Vek 50) Motor (Vek 50) Civata Bolt Pul Washer Gönye Direği Montajı Gönye Direği Montajı Somun Nut Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar 1500 dev/dak) 27/68 Pulley (Vek bar 1500 rpm)

28 MOTOR GRUBU MOTOR GROUP Sıra No/Ref. No Parça No/Series No Adet/Quant. Parça Adı Part Name Kasnak (Vek bar) Pulley (Vek bar) Kasnak (Vek bar 1500dev/dak) Pulley (Vek bar 1500rpm) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb.(Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar 1500dev/dak) 28/68 Tapper Lock Bushing(Vek bar rpm) Kas.Göb. (Vek bar) Tapper Lock Bushing(Vek bar) Kas.Göb. (Vek bar - Tapper Lock Bushing(Vek bar dev/dak) 1500 rpm) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) TSet Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur.(Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Setskur. (Vek bar) Set Screw(Vek bar) Kayış (Vek 20-7,5 bar) Belt (Vek 20-7,5 bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar)

29 Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar 1500 dev/dak) Belt (Vek bar 1500 rpm) Kayış (Vek bar) Belt (Vek bar) Kayış (Vek bar 1500 dev/dak) Belt (Vek bar 1500 rpm) 29/68

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31 VİDA GRUBU AIREND GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Somun Nut Filtre Kabı Cover Filtre Fitler Nipel Nipple Civata Bolt Somun Nut Pul Washer Civata Bolt Civata Bolt Emiş Valfi Montajı Intake Valve Assembly O-Ring O-Ring Kama Wedge Nipel Nipple Süzgeç Strainer Çekvalf Check Valve Dirsek Elbow Cıvata Bolt Termometer Orifice Civata Bolt Vida Ünitesi Air End Rakor Nipple 31/68

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33 YAĞ DEPOSU OIL RECEIVER Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Rakor Nipple Nipel Nipple Kör Tapa Plug Yağ deposu Montajı Oil Receiver Assembly Emniyet Subabı Safety Valve Dirsek Elbow Conta Gasket Hortum Hose Dirsek Elbow Boru Hose Ayak Flange 33/68

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35 HAVA EMİŞ VALFİ AIR INLET VALVE Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Gövde Frame O-Ring O-Ring Yay Spring Somun Nut Halka Ring Piston Piston Keçe Seal Mil Pin O-Ring O-Ring Yatak İnnerr Part O-Ring O-Ring Burç Bushing Segman Piston Ring Yay Spring Burç Bushing Klape Clamp Conta Gasket Segman Piston Ring O-Ring O-Ring Kovan Cover Kovan Cover O-Ring O-ring 35/68

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37 MİNİMUM BASINÇ VALFİ MINUMUM PRESSURE VALVE Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Setskur Set Screw Somun Nut Pul Washer İç Gövde Cylinder Oring O-ring Stoper Stopper Yay Spring Kapak Cover O-ring O-ring Yay Spring Piston Piston O-ring O-ring Setskur Set Screw Gövde Body 37/68

38 38/68

39 MİNİMUM BASINÇ VALFİ MINUMUM PRESSURE VALVE Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Cıvata Bolt Somun Nut İç Gövde Cylinder O-ring O-ring Stoper Stopper Yay Spring Yay Spring Kapak Cover Keçe Seal Piston Kapağı Piston Cover Cıvata Bolt Yay Spring Piston Piston O-ring O-ring Gövde Body Setskur Fill Plug 39/68

40 40/68

41 TERMOSTATİK VALF THERMOSTATIC VALVE Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Segman Circlip Kapak Cover O-ring O-ring Müşür Gage Piston Piston Yay Spring Gövde Body 41/68

42 42/68

43 KAPORTA GRUBU BONNET GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Yan Kapak Side Plate Elektrik Panosu Electrical Panel Sheet Tavan Sacı Cover Plate Dav. Borusu (Vek 20) Chimney Hood (Vek 20) Dav. Borusu (Vek 30) Chimney Hood (Vek 30) Dav. Borusu (Vek 40-50) Chimney Hood (Vek 40-50) Davlumbaz Borusu Göv. Scarfed Sheet Cover Arka Kapama Sacı Back Cover Plate Izgara Protecting Plate Gövde Body Filtre Filter Pano Kapağı Panel Sheet Panel Kapak Kilidi Cover Key Kilit Anahtarı Lock Key Ön Kapak Front Plate Menteşe Hinge Sol Direk Left Column Sağ Direk Right Column Ara Bağlantı Parçası Beam Kapak Plate Civata Bolt Civata Bolt Pul Washer Taban Sacı Bottom Plate Lastik Takoz Rubber Block Somun Nut Bağlantı Ayağı Rubber Block Holder 43/68

44 13 17 B /68

45 PNÖMATİK GRUBU PNEUMATIC GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Vida Ünitesi Air End Emiş Valfi IntakeValve Çek Valf Check Valve Ters Dönüş Müşürü Anti Rotation Swich Basınç Sensörü Pressure Sensor Selenoid Valf 2NA Solenoid Valve 2NA Selenoid Valf 2NK Solenoid Valve 2NA Selenoid Valf 3NK Solenoid Valve 3NA Yağ Deposu Oil Receiver Seperatör Separator Min Basınç Valfi (Vek 20-30) Min Basınc Valfi (Vek 40-50) Minumum Presure Valve Minumum Presure Valve Orifis (Vek ) Orifice (Vek ) Orifis (Vek 50) Orifice (Vek 50) Emniyet Subabı Safety Valve Termostatik Valf Thermostatic Valve Filtre Filter Soğutucu Cooler Lt Komsan Yağı Komsan Oil 45/68

46 The Screw Compressor s Hydro-Pneumatic Cycle and Working Principle Compressor working onload: The compressor starts with star contactor and then delta contactor and required energy is provided in order for compressor to start. Airend (1) is driven by electrical motor. With the rotation of the rotors in the airend, a vacuum environment is created. This vacuum environment enable the compressed air goes through the rotors meshing each other to the outlet port. The compressed air which is mixed with oil, inside the airend, leaves the airend with the impact of the high pressure and is sprayed to the separator tank s (oil receiver s) (10) upper section. Inside the separator the oil in the air is accumulated at the bottom of the oil receiver. Under the high pressure conditions, the oil leaves the oil receiver and enters in the thermostatic valve. At this part of the cycle according to the oil s temprature the oil directly passes from the thermostatic valve(15) to the airend, through the oil filter or goes to the cooler (17) just after passing the thermostatic valve. After the oil is cooled in the cooler, it enters in the oil filter (16) and returns back to the rotors that are working together, to decrease the increasing heat produced by the rotors and to prevent the compressed air escaping backwards. In the separator tank(oil receiver) firstly the oil is partly separated. In the second step the oil passes to the separator(11) in which the air is completely separated from oil. After the separation of the oil from air, the air passes through the minimum pressure valve(12) and enters in the cooler in which air is cooled and be ready to be served. On the other hand the oil inside the separator tank is pushed to the airend by passing through check valve (3) and orifice (13) with the impact of the high pressure. Compressor working unloading: As soon as the pressure level of the compressor reaches to the desired level, solenoid valve (7) goes into closed position from open position after pressure switch (6) starts to work. Then, air intake valve closes. As for pressurized air in separator tank, a little portion of pressurized air in separator tank goes to the airend by passing through solenoid valve (7), remaining part of the pressurized air gets out of the system by passing through intake valve. If any air demand emerges when the compressor works unload, pressure switch enable solenoid valve to open position. Therefore, compressor again starts to produce compressed air. Compressor s stop: In case no need of compressed air in the system while the compressor working unload, electrical motor stops after the time controlled by PLC. Compressor resumes to work: When the compressor s pressure decreases to designated level, pressure switch starts to work. After a while, the compressor start to work again to produce compressed air after getting current to its electrical motor from the system. 46/68

47 POWER CIRCUIT INPUTS ~ V 0 0,5/4, P 1 Selenoid Valve Transfer air into Airend Selenoid Valve Discharge Selenoid Valve No Load Delta contactor Star contactor Line Contaactor 47/68

48 ELEKTRİK GRUBU ELECTRICAL GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Acil Stop Butonu Emergency Stop Button Besleme Kartı Supply Card PLC PLC Hat Kontaktörü (Vek 20) Line Contactor (Vek 20) Hat Kontaktörü (Vek 30) Line Contactor (Vek 30) Hat Kontaktörü (Vek 40) Line Contactor (Vek 40) Hat Kontaktörü (Vek 50) Line Contactor (Vek 50) Yıldız Kontaktör (Vek 20) Star Contactor (Vek 20) Yıldız Kontaktör (Vek 30) Star Contactor (Vek 30) Yıldız Kontaktör (Vek 40) Star Contactor (Vek 40) Yıldız Kontaktör (Vek 50) Star Contactor (Vek 50) Üçgen Kontaktör (Vek 20) Delta Contactor (Vek 20) Üçgen Kontaktör (Vek 30) Delta Contactor (Vek 30) Üçgen Kontaktör (Vek 40) Delta Contactor (Vek 40) Üçgen Kontaktör (Vek 50) Delta Contactor (Vek 50) Selenoid Valf Solenoid Valve Termik Röle (Vek 20) Thermic Relay (Vek 20) Termik Röle (Vek 30) Thermic Relay (Vek 30) Termik Röle (Vek 40) Thermic Relay (Vek 40) Termik Röle (Vek 50) Thermic Relay (Vek 50) Trafo Transformer Kontaktör Yardımcı Bloğu Contactor Auxiliary Block alter Circuit Breaker Sigorta Fuse 48/68

49 2 1 easy! ELECTRONIC CONTROL SYSTEM ELEKTRONIK KONTROL SISTEMI AIREND OUTLET TEMP. VIDA CIKIS SICAKLIGI 49/68 MAIN SCREEN SWITCH ANA EKRAN BUTONU START SWITCH CALISTIRMA BUTONU STOP SWITCH DURDURMA BUTONU LOAD - UNLOAD SWITCH YUK - BOS BUTONU EMERGENCY STOP ACIL DURDURMA SCREW COMPRESSOR VIDALI KOMPRESOR 6 5 VEK20/50 3 4

50 GÖSTERGE GRUBU INSTRUMENT PANEL GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name PLC PLC Termometre Thermometer Etiket Label Etiket Label Acil Stop Butonu Emergency Stop Button Etiket Label 50/68

51 SERVİS BİLGİLERİ SERVICE INFORMATIONS 51/68

52 09 FRM 017 Rev KOMPRESÖR BAKIM TAKİP KARTI KOMPRESÖR TİPİ : SERİ NO : BAŞLANGIÇ TARİHLER BİTİŞ YAPILAN PERİYODİK BAKIM VEYA GİDERİLEN ARIZANIN TANIMI RAPOR NO BAKIMI YAPAN ARIZAYI GİDEREN 52/68

53 53/68