VEK VEK VİDALI KOMPRESÖR YEDEK PARÇA SPARE PARTS GUIDE. MOTOR GÜCÜ ÇALIŞMA BASINCI VEK Hp Bar

Transcription

1 VEK VİDALI KOMPRESÖR VEK KULLANIM SCREW COMPRESSOR BAKIM VE YEDEK PARÇA MAINTENANCE KATALOĞU AND SPARE PARTS GUIDE MOTOR GÜCÜ ÇALIŞMA BASINCI VEK Hp Bar Address and communication informations: Ali Bey Köyü,Kara Sinan Asfaltı, Mevkii Telefon No : (Pbx) Silivri,İstanbul, Adres ve İrtibat Turkey Bilgileri : Fax : e - mail : İkitelli Caddesi, Halkalı, Telefon No : (Pbx) İstanbul, Turkey 09 FRM 019 Fax Rev: /

2 VEK SCREW COMPRESSOR MANUAL INDEX 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 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-PNEUMATIC CYCLE AND WORKING PRINCIPLE ELECTRICAL GROUP DRAW ELECTRICAL GROUP LIST INSTRUMENT PANEL GROUP DRAW INSTRUMENT PANEL GROUP LIST SERVICE INFORMATIONS COMPRESSOR MAINTENANCE OBSERVATION TABLE / 64

3 VEK SCREW COMPRESSOR OPERATION MAINTENANCE AND SPARE PARTS GUIDE MOTOR POWER VEK Hp WORKING PRESSURE Bar Adress And Comminication Informations : Ali Bey Köyü Karasinan Asfaltı Phone No : (Pbx) Mevkii TEM Otoyolu Gişeler Yanı Silivri, İstanbul, Turkey Fax : info@komsan.com.tr 3 / 64

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 / 64

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. Do 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 / 64

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 PICTURE-3 6 / 64

7 PLACING OF THE COMPRESSOR: ~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 mm! IT IS ADVISED TO USE A WATER COOLED COMPRESSOR TO WORK OVER 35 C AM BIENT PREATURE. PICTURE-5 7 / 64

8 8 / 64 SIRA NO PARCA ADI COMPRESSOR PIPE INSTALLATION AIR RECEIVER MX FILTER AIR DRYER MY FILTER WATER-OIL SEPARATOR TIME CONTROLLED DRAJNAGE SYSTEM BALL VALVE WATER SEPARATOR SAMPLE INSTALLATION ! 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) VEK5,5 1,35 VEK7,5 1,35 VEK10 1,35 VEK15 1,35 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 / 64

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 5,5 G3 x 16 A 4 x 2,5 VEK 7,5 G3 x 16 A 4 x 2,5 VEK 10 G3 x 26 A 4 x 2,5 VEK A 4 x 2,5 TABLE-2 USE AN UPPER CABLE SECTION IF THE DISTANCE IS OVER 50 M NOT: FUSE SELECTION IS IN COMPLIANCE WITH DIN / 64

11 COMPRESSOR DIMENSION COMPRESSOR TYPE A B C VEK VEK VEK VEK ALL DIMENSIONS ARE IN MM. TABLE-3 C A B PICTURE-9 11 / 64

12 PLACING OF THE AIR DRYER ~500 mm ~1000 mm ~1000 mm ~500 mm COOLING AIR INLET (CLEAN AIR) WARM AIR OUTLET PICTURE 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 PICTURE / 64

13 PLACING OF THE AIR RECEIVER HAVA DEPOSUNUN YERLEŞTİRİLMESİ: ~1000 mm WATER SU DRAINAGE TAHLIYESİ PICTURE-12 - INSTALLATION SAYILI İŞ KANUNUNA OF THE RECEIVER GÖRE BASINÇLI MUST KAPLAR BE DONE MEVZUATI ACCORDING İÇ TÜZÜĞÜNE TO LOCAL UYGUN PROTECTION MEKANA 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 13 / 64

14 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. 14 / 64

15 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 15 / 64

16 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. 16 / 64

17 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 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 : 17 / 64

18 ATTENTION TO THE SERVICE AFTER SALE FİRST OPERATING INSTRUCTIONS DATE :.../.../ TYPE OF THE COMPRESSOR :... SERİ 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 installition 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 manufactoring 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. 18 / 64

19 YEDEK PARÇA LİSTESİ SPARE PART LIST 19 / 64

20 20 / 64

21 VEK 10/15 ANA MONTAJ VEK 10/15 MAIN ASSEMBLY Sıra No/Ref. No Parça No/Series No Sayfa No/Page No Adı Name Kaporta Grubu Bonnet Group Motor Grubu Motor Group Vida Grubu Air End Group Hidrolik Grubu Hydrolic Group Gösterge Grubu Instrument Panel Group Pnömatik Grubu Pneumatic Group Elektrik Grubu Electrical Group 21 / 64

22 / 64

23 HİDROLİK GRUBU HYDROLIC GROUP S.No/Ref.No Parça No/Series No Adet/Quantity Parça Adı Part Name Nipel Nipple Boru Hose Rakor Nipple Termostatik Valf Thermostatic Valve Dirsek Elbow Boru Hose Nipel Nipple Rakor Nipple Boru Hose Yağ Deposu Montajı Oil Receiver Assembly Rakor Nipple Seperatör Separator Seperatör kapağı Separator Cover Rakor Nipple Dirsek Elbow Rakor Nipple Nipel Nipple Redüksiyon Reduction Filtre Kapağı Filter Cover Redüksiyon Reduction Dirsek Elbow Boru Hose Filtre Filter Vida Ünitesi Air End Min. Basınç Valfi Min. Presure Valve Boru Hose Dirsek Elbow Soğutucu Cooler Redüksiyon Reduction 23 / 64

24 24 / 64

25 MOTOR GRUBU MOTOR GROUP S.No/Ref.No Parça No/Series No Adet/Quantity Parça Adı Part Name Civata Bolt Pervane Göbeği Fan Hub Vek 10Kanat Vek 10 Blade Vek 15 Kanat Vek 15 Blade Pervane Bağlantı Parçası Blade Assembly Tool Motor (15KW) Motor (15KW) Motor (7.5KW) Motor (7.5KW) Kama Wedge Civata Bolt Pul Washer Somun Nut Kasnak (Vek bar) Pulley ( Vek 10-7,5 bar ) Kasnak (Vek bar) Pulley ( Vek bar) Kasnak (Vek bar) Pulley ( Vek 15-7,5 bar ) Kasnak (Vek15-10 bar) Pulley ( Vek bar ) Kasnak (Vek15-13 bar) Pulley ( Vek bar ) Kasnak Göbeği Tapper Lock Bushing Setskur Set Screw Kayış (Vek bar) Belt ( Vek 10-7,5 bar ) Kayış (Vek bar) Belt ( Vek bar ) Kayış (Vek bar) Belt ( Vek 15-7,5 bar ) Kayış (Vek bar) Belt ( Vek bar ) Kayış (Vek bar) Belt ( Vek bar ) Kasnak Göbeği (Vek 10-7,5 bar) Tapper Lock Bushing Kasnak Göbeği (Vek Tapper Lock Bushing ( Vek 10 - bar) 10 bar ) Kasnak Göbeği (Vek 15- Tapper Lock Bushing ( Vek bar) 7,5 bar ) Kasnak Göbeği (Vek Tapper Lock Bushing ( Vek 15 - bar) 10 bar ) Kasnak Göbeği (Vek Tapper Lock Bushing ( Vek 15 - bar) 13 bar ) Kasnak (Vek bar) Pulley ( Vek 10-7,5 bar ) Kasnak (Vek bar) Pulley ( Vek bar ) Kasnak (Vek bar) Pulley ( Vek 15-7,5 bar ) Kasnak (Vek bar) Pulley ( Vek bar ) Kasnak (Vek bar) Pulley ( Vek bar ) Gönye Direği Montajı Motor Connection Foot Vida Ünitesi Air End Pul Washer 25 / 64

26 26 / 64

27 VİDA GRUBU AIREND GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Somun Nut Pul Washer Filtre Kapak Filter Cover Filtre Filter Cıvata Bolt Emiş Valfi Montajı Intake Valve Assembly Dirsek Elbow Susturucu Silencer Dirsek Elbow Çekvalf Check valve Süzgeç Strainer Nipel Nipple Dirsek Elbow Civata Bolt Civata Bolt Termometre Termometer Nipel Nippel Vida grubu Air end Civata Bolt Kama Wedge Civata Bolt Conta Gasket Dirsek Elbow Manşon Nippel Filtre Kapak Fitler Cover T-Quick Rekor 8 Quick Rekor T Çekvalf Check Valve 27 / 64

28 28 / 64

29 YAĞ DEPOSU OIL RECEIVER Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Rakor Nipple Yağ Deposu Montajı Oil Receiver Assembly Dirsek Elbow Hortum Hose Kör Tapa Plug Emniyet Subabı Safety Valve Somun Nut Pul Washer Cıvata Bolt 29 / 64

30 30 / 64

31 HAVA EMİŞ VALFİ AIR INLET VALVE Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Setskur Set Screw Segman Circlip Kapak Cover Yay Spring Cıvata Bolt Piston Piston Keçe Seal Mil Piston Shaft Gövde Frame O-Ring O-Ring Burç Bush Yay Spring Burç Bush Cıvata Bolt Segman Circlip Conta Gasket Klape Piston O-Ring O-Ring Kapak Cover Segman Circlip O-Ring O-Ring 31 / 64

32 32 / 64

33 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 33 / 64

34 34 / 64

35 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 35 / 64

36 36 / 64

37 KAPORTA GRUBU BONNET GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Tavan Sacı Cover Plate Taban Sacı Bottom Plate Ön Direkler Front column Bağlantı Ayağı Rubber Block Holder Ön Kapak Front Plate Yan Kapak Side Plate Davlumbaz Borusu Chimney Hood Davlumbaz Borusu Gövdesi Scarfed Sheet Cover Davlumbaz Gövdesi Chimney Housing Arka Kapama Sacı Back Cover Plate Pano Kapağı Panel Sheet Panel Filtre Filter Izgara Protecting Plate Köşebent Brace Plate Elektrik Panosu Electrical Panel Sheet Fitil Wick Somun Nut Civata Bolt Civata Bolt Lastik Takoz Rubber Block Kapak Kilidi Cover Key Kilit Anahtarı Lock Key Somun Nut 37 / 64

38 38 / 64

39 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 R1/4 NA Selonoid Valf Selonoid Valf R1/4 NA Selenoid Valf Solenoid Valve Yağ Deposu Oil Receiver Manometre Manometer Seperatör Separator Minimum Basınç Valfi Minumum Presure Valve Emniyet Subabı Safety Valve Basınç alteri Pressure Switch Orifis Orifice Termostatik Valf Thermostatic Valve Filtre Filter Soğutucu Cooler L Komsan yağ Komsan Oil 39 / 64

40 The Screw Compressor s Hydro-Pneumatic Cycle and Working Principle Compressor working while underloading: With the start of the working of the compressor the star before 4-6 seconds and if delta contactor take place before 3 seconds in the cycle and the energy needed by the compressor is provided. With the provided energy the solenoid valve(5) are switched from open position to closed position. The rotors in the airend(1) which are rotated by the electrical motor produces a vacuum that causes the atmospheric air to be taken in through the air filter and the air intake valve(2) to the helixally entwined male and female rotors in which the air is compressed to the airend s exit 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) (6) 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(13) to the airend, through the oil filter or goes to the cooler just after passing the thermostatic valve. After the oil is cooled in the cooler it enters in the oil filter and returns back to the rotors that are working together, to take the incresing heat produced by the rotors and to prevent the squeezed air escaping backwards. In the separator tank(oil receiver) firstly the oil is separated partly.in the second step the oil is passed to the separator(8) in which the air is completely separated from oil. After the separation of the oil from air, the air passes through the minumum pressure valve(9) 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 with the impact of the high pressure. Compressor while idling working: When the produced air s pressure value reaches to a certain wanted value then the pressure switch(11) takes place in the cycle in order to switch the solenoid valve(4) from close position to open position and causes the intake valve not to absorb air from outside. Some of the air existing in the separator tank moves through the selonoid valve(5) and enters in the air end to make the rotors rotation more silent.. The other part of the air is pushed out to the atmosphere through the solenoid valve (5) and the intake valve in order. During the idling working when an air need occurs, with the decrease in the pressure the pressure switch switches the solenoid valve to closed position. As a result of this the compressor starts to produce compressed air again. 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 time relay. The start of the compressor after it s stop: When the compressors pressure value that can be observed by the manometer(7), becomes less than a certain value, the pressure switch takes place it the cycle to make the electrical motor to be energized with the electrical current in order to make the compressor work again and produce compressed air. 40 / 64

41 UNEMPLOYED WORKİNG TİME RELAY TM C2 (L 2) L1 L2 L3 A A W C3 V U L1 L3 A A M X Y Z C1 SYSTEM CONTROL FUSE F A A V AC 2L 50 HZ L3 L2 FSR PE L1 TR TRANSFORMER SYSTEM CONTROL PHASES V AC 24 V AC 50 HZ H1 Mantar Button FSR (PHASE CONTROL RELAY) 16 VCS (SCREW OUT HEATİNG) C4 A H FAULT LAMP START RELAY SELONOİD SELONOİD STAR-DELTA TİME RELAY STAR CONTACTOR DELTA CONTACTOR MAİN CONTACTOR HOUR METER TM (TERMİC RELAY) Start C4 Butonu D Pressure Gage A1 A1 C3 Delta C3 D2 A2 D1 21 C3 22 C1 15 D1 C1 16 A1 A1 C1 C3 A2 A B A1 C2 C A1 A2 A2 41 / 64

42 ELEKTRİK GRUBU ELECTRICAL GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Çalışma Saati Hour Meter Üçgen Kontaktör Delta Contactor Yıldız Kontaktör Star Contactor Ana Kontaktörü Line Contactor Zaman Rölesi Time Relay Basınç alteri Pressure Gage Selenoid Valf Solenoid Valve İkaz Lambası Fault Lamp Termik Röle Thermic Relay Acil Stop Butonu Emergency Stop Button Termometre Thermometer Start Butonu Start Button Basınç alteri Pressure Gauge Başlama Rölesi Start Relay Trafo Transformer Faz Kontrol Röle Phase Control Relay Sigorta Fuse 42 / 64

43 43 / 64 ARIZA FAILURE Hours TESİSAT BASINCI COMP. OUTLET PRESSURE VİDA ÇIKI SICAKLIĞI AIR END OUTLET TEMP. ACİL STOP START STOP ÇALI MA SAATİ HOUR METER START VİDALI KOMPRESÖR SCREW COMPRESSOR

44 GÖSTERGE GRUBU INSTRUMENT PANEL GROUP Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name Manometre Manometer Termometre Thermometer İkaz Lambası Indicator Lamp Start Butonu Starting Button Acil Stop Butonu Emergency Stop Button Çalışma Saati Operating Hour Meter Etiket Label 44 / 64

45 SERVİS BİLGİLERİ SERVICE INFORMATIONS 45 / 64

46 09 FRM 017 Rev KOMPRESÖR BAKIM TAKİP KARTI KOMPRESÖR TİPİ : SERİ NO : BAŞLANGIÇ TARİHLER BİTİŞ YAPILAN PERİYODİK BAKIM VEYA GİDERİLE ARIZANIN TANIMI RAPOR NO BAKIMI YAPAN ARIZAYI GİDEREN 46 / 64

47 47 / 64