February 18, 2017 | Author: cengiz kutukcu | Category: N/A
Technical Documentation
Original 2011-06-21
Deck Machinery - Compressors - Steering gears
Technical Documentation for HATLAPA Compressors V 105
L20
HSC 11
Start
Start
Start
Technical Documentation Piston Compressor
Technical Documentation for Piston Compressor Type V105
of
Original 2011-06-21
Uetersener Maschinenfabrik GmbH & Co. KG 25436 UETERSEN GERMANY Phone: +49-4122-711 0.. Telefax: +49-4122-711 330 Internet http://www.hatlapa.de E-Mail:
[email protected]
Ref.-No.:
10.2722 / 1
Serial-No.:
10.2722 - 1 - 1 10.2722 - 1 - 2
This technical documentation belong NOT in the office, but in the hands of the operator
Technical Documentation Piston Compressor
Original 2011-06-21
Table of Contents 1
Important Information on this Documentation and Safety
2
Final Drawings / Specification
3
Operating Instructions
4
E-Diagrams
5
E - Motor
6
Lubricating Instructions
7
Service
We recommend reading these instructions through carefully and becoming quite familiar with the design and operation of the piston compressor before putting it into operation, this will avoid damage through imporper handling.
Original 2011-06-21
Important Information on this Documentation and Safety
Important Information on this Documentation and Safety
1
Information on Manuals ........................................................................................................................... 3
2
Copyright ................................................................................................................................................. 3
3
Guarantee................................................................................................................................................ 3
4
Designations ............................................................................................................................................ 4
5
Signs Used .............................................................................................................................................. 5
6
Intended Use ........................................................................................................................................... 5
7
Ban on Arbitrary Modifications................................................................................................................. 5
8
General Safety Instructions ..................................................................................................................... 6
9
Safety Equipment .................................................................................................................................... 6
10 Instruments for Operating Surveillance ................................................................................................... 6 11 Safety Instructions for Assembly ............................................................................................................. 7 12 Additional Safety Instructions for Electrical Installation........................................................................... 7 13 Safety Instructions for Operation and Service......................................................................................... 8
Original 2011-06-21
14 Safety Instructions for Maintenance and Repairs ................................................................................... 9 15 Noise Protection .................................................................................................................................... 10 16 Waste Disposal...................................................................................................................................... 10
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Techen, Kerstin
Important Information on this Documentation and Safety
1 Information on Manuals This manual includes all information necessary for guaranteeing the safety as well as for the operation and maintenance of the equipment. It is directed at instructed and trained personnel who are responsible for the operation and maintenance of the equipment. Only knowledge of this manual can ensure faultless and correct functioning of the equipment, so its contents must be known to the responsible persons. The manual should be kept so that the operating and maintenance personnel have access to it at all times.
2 Copyright The copyright for this technical documentation remains with HATLAPA. This documentation is intended for the operator and their personnel only.
Original 2011-06-21
All rights reserved.
3 Guarantee Guarantee and liability claims for damage to persons and/or objects are excluded, if caused by one or several of the following circumstances:
Techen, Kerstin
−
inappropriate use of the equipment,
−
neglect of the provisions of this documentation,
−
improper assembly, operation or maintenance,
−
operation of the equipment with ineffective protective devices,
−
arbitrary functional or constructive alteration of the equipment,
−
removal of parts or installation of spare parts or additional components, respectively, which have not been supplied or approved by HATLAPA,
−
repairs which have not been authorised by HATLAPA,
−
impact of foreign bodies in case of catastrophes or Force Majeure.
26.11.2009
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Important Information on this Documentation and Safety
4 Designations
Original 2011-06-21
Persons are defined as follows:
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−
The operator is the (natural or legal) person on whose behalf the equipment is used, e.g. the ship’s owner.
−
Operating personnel are personnel trained for the respective work, and who are authorised to operate the equipment and to remedy disturbances. The operating personnel must be trained for the tasks they are entrusted with, and meet the requirements necessary to handle the equipment.
−
Assembling personnel are personnel trained for the respective work, and who are authorised to assemble the equipment. They are able to carry out the tasks assigned to them and to recognise possible dangers because of their completed specialised training.
−
Maintenance personnel are personnel trained for the respective work, and who are authorised to maintain, adjust and modify the equipment. They are able to carry out the tasks assigned to then and to recognise possible dangers because of their completed specialist training.
−
An electrician has electro-technical skills gained by respective education, masters the legal regulations, and is assigned by the operator to carry out work on their electrical equipment and appliances.
26.11.2009
Techen, Kerstin
Important Information on this Documentation and Safety
5 Signs Used Sign for Danger Danger! This sign indicates specific behavioral patterns the non-observance of which is highly dangerous, or which may lead to permanent bodily injury. Sign for Caution Caution! This sign indicates specific behavioral patterns the non-observance of which may lead to injury to persons, severe damage, or severe malfunction of the equipment, or to damage to the environment.
Sign for 'Pay Attention' Pay Attention!
Original 2011-06-21
This sign indicates specific behavioral patterns the non-observance of which may lead to damage or malfunction of the equipment.
Sign for Information Information! This sign indicates tips and useful information which facilitate the operation of the equipment or the understanding of the documentation.
6 Intended Use The compressor is exclusively designed for air compression. Any other use is deemed as not being in compliance with the intended use and requires express written approval from HATLAPA. The intended use also includes compliance with all the regulations contained in this technical documentation, the generally acknowledged rules of technology as well as all the relevant laws, standards and regulations.
7 Ban on Arbitrary Modifications Arbitrary modifications and changes to the machine/system are not permitted, as they may put persons in danger and result in damage to the machine/system. If you are planning modifications or changes, contact HATLAPA and request written authorisation.
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26.11.2009
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Important Information on this Documentation and Safety
8 General Safety Instructions Besides the specific safety-related technical notes contained in these instructions and the sub supplier's documentation, you must also observe the generally applicable safety and accident regulations, such as the: –
Recognised technical regulations for safe and professional work
–
Regional and internal regulations
–
Regulations from the responsible classification authority
–
Rules and regulations for the prevention of accidents from the professional organisation, in particular concerning compressors
–
Safety signs and indicator plates on the machine/system
–
Environmental protection regulations
Original 2011-06-21
Incorrect handling or failure to comply with regulations concerning use can result in the risk of physical injury and death and/or damage to property. Observe the limits specified in the technical data. Find out about the fire detection and fire prevention options, and ensure that these are fully functional and sufficient.
9 Safety Equipment Danger! Faulty safety equipment may put lives and equipment at risk. All safety equipment must always be in a flawless and fully operational condition. You must not make the safety equipment inoperative in any way. If a piece of safety equipment is defective, the machine/system must not be operated. Only remove safety equipment if the machine/system has been isolated and secured. Perform regular checks on the safety equipment, in accordance with the regulations in this documentation and the sub suppliers' documentation.
10 Instruments for Operating Surveillance Caution! If instruments for operating surveillance are out of order, monitoring of the operating conditions of the machine/system may lead to incorrect analyses. This may put lives and/or equipment at risk. Never decommission any instruments for operating surveillance. If instruments for operating surveillance are defective, they must be changed as soon as possible. Take utmost care when operating the machine/system until the instruments are exchanged.
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Important Information on this Documentation and Safety
11 Safety Instructions for Assembly Danger! During assembly and installation, the functioning of the safety equipment is not guaranteed. Therefore, the safety of the assembling personnel is to a great extent dependent on the proper execution of work. Only trained and briefed personnel are permitted to carry out assembling and installation work. The personnel must have a specialised knowledge of compressed air and electrical engineering. Only use suitable and fully functioning tools. During torching or welding work, ensure that risks of fire or explosion are avoided.
12 Additional Safety Instructions for Electrical Installation All work on the electrical systems is only allowed to be performed by qualified electronics specialists. Danger!
Original 2011-06-21
Deadly voltage! Before starting to work on electrical equipment, the machine/system must be deenergized. Ensure that −
the mains supply is deactivated. Check that the disconnected parts are deenergized before commencing work.
−
the electricity supply cannot be reconnected unintentionally or without authorization while work is being performed on the electrical installation.
−
the electricity for parts which must remain connected for the maintenance and repair work only remains connected for as long as is absolutely necessary for the work in question.
Danger! The main switch remains energized even if it is deactivated. Work carried out on electrical systems must be done so in accordance with the valid safety regulations, as well as all other relevant state or local regulations. Under no circumstances repair or tide over defective fuses. Fuses must only be replaced by the same type of fuses. When working on electrical systems, only use permitted and suitable tools. Only use voltage-free tools. When taking measurements with the voltage supply of >65 V activated,
Techen, Kerstin
−
you must under no circumstances touch the electrical connection points,
−
the inspection equipment must be in good condition and safe to operate,
−
you must not wear any jewelry on fingers or wrists,
−
you must stand on insulated ground.
26.11.2009
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Important Information on this Documentation and Safety
13 Safety Instructions for Operation and Service Danger! The machine/system must only be operated by trained and briefed operating personnel. New personnel may only use the machine/system under the constant supervision of trained and briefed operating personnel. Give regular briefings on accident regulations and the requirements stated in this documentation. Danger! Drawing in into moving parts! Body parts or clothing may get caught at the flywheel. Prior to start-up, check that the flywheel cover is fitted! Caution! Burn hazard! The compressor housing and the pressure pipes become hot during operation. Wear protective gloves!
Original 2011-06-21
Caution! Drawing in into moving parts! Long hair or loose clothing may get caught at the air intake filter. When the compressor is in operation, maintain a safe distance to the compressor housing! Caution! In automatic operation mode, the compressor starts automatically without warning.
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26.11.2009
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Important Information on this Documentation and Safety
14 Safety Instructions for Maintenance and Repairs Danger! The machine/system must only be maintained and repaired by trained and briefed maintenance personnel. The personnel must have a specialised knowledge of hydraulic and electrical engineering. Optionally, the compressed air pressure gauges can be equipped with gauge valves. In this case, the compressor may be under pressure although the compressed air pressure gauges show a pressure of 0 bar. Before starting any repair work, shutdown the machine/system and secure it against unintentional restarting. If the work can only be carried out while the machine/system is running, make the necessary safety arrangements. A second person must monitor the work, and be ready to intervene if needed. When carrying out maintenance and repair work, do not decommission more than one piece of safety equipment at a time. Only use suitable and fully functioning tools.
Original 2011-06-21
Caution! Burn hazard! The compressor housing and the pressure pipes become hot during operation. Before beginning maintenance work, allow the compressor to cool down for approx. 2 hours! Caution! Besides the information contained in this documentation, you must also observe the regulations of the classification authorities and professional organisations in order to determine the inspection and maintenance intervals. After disassembly, always exchange self-locking nuts and gaskets. They are not designed for repeat use. If leaks occur at couplings which are sealed with resilient joint gaskets, the leaks cannot be eliminated by retightening the coupling because the resilient joint gaskets are damaged or hardened. Exchange the resilient joint gaskets. Pay particular attention to cleanliness. Cover any openings to prevent the ingress of dirt. Ensure that tools, loose parts or cleaning cloths are not left in or on the compressor. Dispose of old oils and grease in an environmentally friendly manner in accordance with national regulations.
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26.11.2009
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Important Information on this Documentation and Safety
15 Noise Protection Refer to the technical data for information about the noise level. Caution! Make sure to wear ear protection in the vicinity of the compressor when it is in operation.
16 Waste Disposal The following substances which are caused by the operation of the machine/system must be disposed of in an environmentally friendly manner, in accordance with the applicable laws: used oils and grease as well as cloths with such substances on them;
−
cleaning agents, and cloths with cleaning agents on them.
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−
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26.11.2009
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Final Drawings
Original 2011-06-21
for COSCO GUANGDONG SHIPYARD HULL No: N352 - N353 HATLAPA Order No.: 10.2722 - 23 / 1 2x MAIN AIR COMMPRESSORS V105
2011-06-21
1/1
SECTION 1 V105
MAIN STARTING AIR/ BOTTLE CHARGING
EQUIPMENT SPECIFICATION SHEET
SECTION 2 CONTRACT SPECIFIC DRAWINGS
Original 2011-06-21
DRAWING No.
TITLE
D10082 GENERAL ARRANGEMENT – V105 30 BAR MOTOR DATA SHEET D10183 AIR PRESSURE SWITCH D10408 AIR HOSE ASSEMBLY D10409 WATER HOSE ASSEMBLY D10102 DRAIN HOSE ASSEMBLY 450241 PIPING AND INSTRUMENTATION 344181 CONNECTION DIAGRAM 333182 STARTER CONTROLLER 333392 SEQUENCE SELECTOR SWITCH INSTRUMENT LIST
STANDARD COMPRESSOR DRAWINGS DRAWING No.
TITLE
T0401132 T0401133 178483 T0401121 T0401126 178492
CONTROL AND OPERATING PHILOSOPHY INSTALLATION RECOMMENDATIONS FLEXIBLE HOSE INSTALLATION GUIDELINES COOLING WATER DATA HEAT DISSIPATION DATA CRANKCASE LUBRICANTS
SECTION 3 DRAWING No.
TITLE
94301002 ILLUSTRATED SPARES D10262 MOTOR BEARINGS D10201 AIR FILTER
Original 2011-06-21
SECTION 1
T E C H N I C A L S P E C I F I C A T I O N/2 Our Ref. 10.2722/1K MAIN AIR COMPRESSORS 2 x ELECTRO-COMPRESSOR SET T y p e V 105 Type: Description: Capacity: Pressure: Speed: Shaft power: Unloading Control Voltage: Lubrication: Cooling type: Inspection:
V 105 Two stage, twin cylinder in a 90o V format. 105 m3/hr FAD 30 bar G 1800 min-1 22 kW Automatic via 1st and 2nd Stage Solenoid Valves. 220 V Splash Fresh water up to 7 bar maximum pressure. NK survey on mechanical portion only
Original 2011-06-21
Standard Compressor Fittings: • • • • • • • • • • • • • • •
Low Oil Level switch with Alarm and Shutdown feature. High Air Temperature switch with Alarm and Shutdown feature. 1st & 2nd Stage Air Safety Valves. Water Jacket Safety Valve. 1st & 2nd Stage Centrifugal Condensate Separator. 1st & 2nd Stage Solenoid Drain / Unloading valves. Compressor electrical junction box pre-wired by HATLAPA with Cable glands. Suction Filter & Silencer 1st & 2nd Stage Pressure Gauges Graduated in Bar / MPa Integral interstage/ aftercooler with cast passageways for air and water. Fully guarded flywheel with aperture for barring over compressor. Flexible coupling. Combined oil filler / dipstick. `Asbestos-Free` gaskets. Anti Vibration Mounts
Loose Supply Items: •
• • • • •
Air pressure control switch for auto Stop / Start of compressor with 3 way test cock and 40 mm test flange, control air connection fitted with tube coupling to suit 8 mm outer ∅ tube. Final air delivery flexible hose & integral Final air delivery Non-Return Valve. Cooling water inlet flexible hose. Cooling water outlet flexible hose. First stage solenoid drain valve flexible hose. Second stage solenoid drain valve flexible hose.
Prime Mover: • • • • • • • • • • •
Manufacturer – make of our choice 24 kW – Motor Power 1800 RPM 440 V/ 3 ph/ 60 Hz Power Supply IP 55 Enclosure Horizontal Foot & Flange Mounting - B35 & IEC 72 Mechanical dimensions DIRECT ON LINE Starting Method Manufactured to NK Latest requirements Standard terminal box Anti condensation heater Cable gland
Original 2011-06-21
Starter / Controller: 1 contactor cabinet with motor protection, consisting of steel casing, containing: main contactor for the electric motor transformer overcurrent relay for the electric motor main switch PLC (programmable logic control) textdisplay for indication of operating modes, disturbances and service intervals with push buttons for operating the compressor potential free contacts for indicating "compressor on" and "collective alarm" twin control with separate sequence selection switch selector switch for “auto” / “manual” and “local” / “remote” control with interface for ECR and cable gland
FINAL PAINTING of compressor, electric motor and contactor cabinet: MUNSELL 7.5 BG 7/2
TESTING: by NK of compressor 1 set of spare parts for compressor acc. to the rules of NK 1 set of spare parts for electric motor consisting of 1 set anti-friction bearings 1 set of spare parts for contactor cabinet consisting of 1 contactor 1 additional set of air filter inlets for each compressor for SY’s purpose
Original 2011-06-21
SECTION 2
HATLAPA
Original 2011-06-21
Nr.: 180L4
HATLAPA
Date: 08-DEC-2010
DATA SHEET
Original 2011-06-21
Three-phase Induction Motor - Squirrel Cage Customer Motor line
: : Multivoltage
Frame Rated Output Frequency Poles Full load speed Slip Voltage Full load current Locked rotor amps Locked rotor current (Il/In) No load current Full load torque Locked rotor torque Breakdown torque Design Insulation class Temperature rise Locked rotor time Service factor Duty cycle Ambient temperature Altitude Degree of protection Aprox. weight Moment of inertia Noise level
: : : : : : : : : : : : : : : : : : : : : : : : : :
Bearings Regreasing int. Grease amount
D.E. 6311-C3 20000 h 18 g
180L 25,0 kW 60 Hz 4 poles 1765 rpm 1,94 % 440 V 41,3 A 310 A 7,50 15,0 A 135 Nm 260 % 250 % N F 80 K 14 s 1,00 S1 45 €C 1000 m.a.s.l IP55 183 kg 0,1973 kgm• 64 dB(A) N.D.E. 6211-Z- C3 20000 h 11 g
Load 100% 75% 50%
cos ‚ 0,86 0,82 0,73
Efficiency(%) 92,3 92,4 91,5
output for compressor: 24kW with I=appr. 40A / with element type heating 220V, appr. 50W, terminal HE+HE2
*The values shown are subject to change without prior notice.
Performed:
Checked:
Version 4.06
Original 2011-06-21
Original 2011-06-21
Original 2011-06-21
Original 2011-06-21
HATLAPA
Original 2011-06-21
0
2
1
3
4
5
6
Schaltschrank Startluft-Kompressor 1 (22-30kW) STARTER / CONTROLLER MAIN AIR COMPRESSOR 1 (22-30kW)
8
7
9
(344182-44070) NO
NO
NC
26 27
20 21
22 25
-1X1
ø16-28
W
H1 H2
ø16-28
5
ø6-13
5
7
8
5
9
10
5
ø6-13
X1
5
11 12
1
17
1
17
1
18
13 14 15
ø16-28
ø16-28
6
KompressorUmschaltbox
cable glan 08.12.10 A sizes Zust. Änderung Datum
bre Name
Bearb. Gepr. Norm
02.11.10 Bre cpu
343260
NO
-1Y1 -1F13
Ers.f
NO
(Klemmenkasten Kompressor 1) (TERMINAL BOX COMPRESSOR 1)
13
14 15
13-21
ø6-13
ø6-13
24V DC
COM
F3W
COM
Entwässerungsventil letzte Stufe DRAIN VALVE FINAL STAGE
NC
T
1 18
220-230V AC
NC T
WARNING
L
220-230V AC
1
Werft-Lieferung SUPPLIED BY SHIPYARD
-1Y2
-1F3
Anschlußplan Kompressoren V105 CONNECTION DIAGRAM COMPRESSORS V105 Urspr.
1 17
Entwässerungsventil 1. Stufe DRAIN VALVE FIRST STAGE
Luft-TemperaturWächter AIR TEMPERATURE SWITCH
Ölstands-Wächter OIL LEVEL SWITCH
-1F4 CONTACTS SHOWN WITHOUT OIL
Datum
1 17
10
F3S
Heizung HEATING appr. 50W
L
9
SHUTDOWN
StartluftKompressor 1 MAIN AIR COMPRESSOR 1 V105 24 kW
2
5
24V DC
P
3
8
F13.1
M
3
7
SHUTDOWN
HE1 HE2
5
F13.2
W
24V DC
-1M1
V
Druckluftwächter für Führungskompressor AIR PRESSURE SWITCH F.LEADING COMPRESSOR
U
5 11 12
2
24V DC
1
WARNING
440V 60Hz 440V 60Hz
X1
5 9 10
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
5 7 8
COMPRESSOR SELECTION BOX
MAN 0 AUTO
(333392)
Einspeisung SHIP SUPPLY
Original 2011-06-21
6
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
potentialfreier Kontakt für Fernbedienung aktiv FLOATING CONTACT FOR REMOTE CONTROL ACTIVE
L1 L2 L3
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344181-44070 Blatt 1 von 2 Bl.
0
2
1
3
4
5
6
Schaltschrank Startluft-Kompressor 2 (22-30kW) STARTER / CONTROLLER MAIN AIR COMPRESSOR 2 (22-30kW)
8
7
9
(344182-44070) NO
NO
NC
26 27
20 21
22 25
-2X1
ø16-28
W
H1 H2
ø16-28
5
ø6-13
5
7
8
5
9
10
5
ø6-13
X1
7
11 12
1
17
1
17
1
18
13 14 15
ø16-28
ø16-28
8
KompressorUmschaltbox
Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
02.11.10 Bre cpu
343260
NO
-2Y1 -2F13
Ers.f
NO
(Klemmenkasten Kompressor 2) (TERMINAL BOX COMPRESSOR 2)
14 15
-2Y2
Ers.d
ø6-13
ø6-13
Werft-Lieferung SUPPLIED BY SHIPYARD
-2F3
HATLAPA
13
13-21
24V DC
COM
F3W
COM
Entwässerungsventil letzte Stufe DRAIN VALVE FINAL STAGE
NC
T
1 18
220-230V AC
NC T
WARNING
L
220-230V AC
1
Anschlußplan Kompressoren V105 CONNECTION DIAGRAM COMPRESSORS V105 Urspr.
1 17
Entwässerungsventil 1. Stufe DRAIN VALVE FIRST STAGE
Luft-TemperaturWächter AIR TEMPERATURE SWITCH
Ölstands-Wächter OIL LEVEL SWITCH
-2F4 CONTACTS SHOWN WITHOUT OIL
Datum
1 17
10
F3S
Heizung HEATING appr. 50W
L
9
SHUTDOWN
StartluftKompressor 2 MAIN AIR COMPRESSOR 2 V105 24 kW
2
24V DC
P
3
5
F13.1
M
3
8
SHUTDOWN
HE1 HE2
7
F13.2
W
24V DC
-2M1
V
5
24V DC
U
5 11 12
4
Druckluftwächter für Folgekompressor AIR PRESSURE SWITCH F.FOLLOWING COMPRESSOR
3
WARNING
440V 60Hz 440V 60Hz
X1
5 9 10
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
5 7 8
COMPRESSOR SELECTION BOX
MAN 0 AUTO
(333392)
Einspeisung SHIP SUPPLY
Original 2011-06-21
6
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
potentialfreier Kontakt für Fernbedienung aktiv FLOATING CONTACT FOR REMOTE CONTROL ACTIVE
L1 L2 L3
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344181-44070 Blatt 2 von 2 Bl.
0
2
1
3
4
5
600
6
8
7
9
210
Schaltschrank Kompressor STARTER/CONTROLLER COMPRESSOR
Amperemeter (mit Markierungsanzeiger) AMMETER
P2
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
Q1
Hauptschalter (mit Türverriegelung) ISOLATING SWITCH
Q2
Hauptschalter Motor-Heizung MAIN SWITCH MOTOR HEATING
H2
Meldelampe "Motor-Heizung ein" INDICATING LIGHT "MOTOR HEATING ON"
H2 P2
Q2
S2
TD 200
L
R
600
HATLAPA
(BU)
S2
Wahlschalter "Vorort / Fern" SELECTOR SWITCH "LOCAL / REMOTE"
Q1
Gewicht: ca. 50kg WEIGHT: APPR. 50kg 8
Schutzart: IP54 PROTECTION CLASS: IP54
20
Original 2011-06-21
P1
P1
mit Türfeststeller
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 1 von 8 Bl.
0
2
1
3 P2
4
5
Original 2011-06-21
RESET
HATLAPA
SHIFT
black on red
STOP
8
9
TD 200
MAN
schwarz auf rot
7
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
SIEMENS
STOP
6
AUTO
schwarz auf hell-blau black on light blue
AUTO
ESC
schwarz auf grün
schwarz auf weiß
black on green
black on white
MAN
ENTER
RESET
HATLAPA dark blue on white dunkel-blau auf weiß
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 2 von 8 Bl.
Kurzbeschreibung für Kompressorsteuerung mit TD200
short description f.compressor control with TD200: ON / OFF:
The standard text on the text display is:
ready for operation / off Betriebsbereit / aus
Now you can start the compressor in manual or in automatic operation. When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4. Normallay the manual operation is only used for maintenance purposes. After a blackout the cmpressor will not start again in this manual mode.
Original 2011-06-21
When You press the "AUTO" push button the compressor is switched to automatic mode. The compressor starts and stops automatically depending on the air pressure. Normally this should be the standard operation mode. When the pressure switch F4 is closed the compressor starts. When the pressure switch F4 is opened the compressor stops. After a blackout the compressor will start again in automatic mode.
ALARMS:
Jetzt kann man den Kompressor in der Hand- oder in der Automatik-Betriebsart starten. compressor on / man Kompressor ein / Hand
ready for operation / off Betriebsbereit / aus
When You press the "STOP" push button the compressor stops again.
When you want to change the operation mode from manual to automatic or from automatic to manual you must press the "STOP" push button before. When there is any fault, the compressor stops and the belonging disturbance alarm is shown in the display. Not all possible disburbance texts are used for this compressor.
Now the fault must be eliminated. Then press the "RESET" push button and there should be the standard text on the display again. Now You can start the compressor again with the "AUTO" or "MAN" push button.
compressor on / auto Kompressor ein / Auto ready for operation / auto Betriebsbereit / Auto
make maintenance ! Wartung fällig ! motor overload Motor Überlast oil level warning Öl-Level Voralarm low oil level Öl-Level Alarm air temperature warning Lufttemperatur Voralarm high air temperature Lufttemperatur-Alarm
Mit der Taste "MAN" wird der Kompressor in der Hand-Betriebsart gestartet. D.h. ohne Funktion des Druckluftschalters F4. Normalerweise wird diese Fuktion nur für Wartungszwecke benutzt. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Hand" nicht wieder selbsttätig starten. Mit dem Taster "STOP" kann der Kompressor wieder gestoppt werden. Mit dem Taster "AUTO" kann der Kompressor in die Betriebsart "Automatik" geschaltet werden. Der Kompressor startet und stopt dann selbstätig in Abhängigkeit des Druckluftschalters F4. Wenn der Druckluftschalter geschlossen ist, dann startet der Kompressor. Wenn der Druckluftschalter geöffnet ist, dann stopt der Kompressor. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Automatik" selbstständig wieder anlaufen.
ALARME
Wenn eine Störung vorliegt, dann stopt der Kompressor und es wird der zugehörige Alarm im Textdisplay angezeigt. Nicht alle hier dargestellten Alarm-Texte werden für diesen Kompressor benutzt. Jetzt must der entsprechende Fehler behoben werden und dann der "RESET"-Taster betätigt werden. Darauf sollte dann der Standart-Text wieder auf dem Display erscheinen. Jetzt kann der Kompressor wieder mit den Tasten "MAN" oder "AUTO" gestartet werden.
ready for operation / off Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS: When there are one or two arrows in the right side of the display, you can go to other display texts by pressing the belonging arrow push buttons The other texts can show more disturbance alarms, if there is more than one fault. Or you can watch the working hours. Or you can watch some special settings of the software. Normally all settings are done by HATLAPA for a normal purpose of the compressor. If you want to change any setting, you must press the "ENTER" push button one time. Now you can change the value with the arrow push buttons. After this you must quit the new value by pressing "ENTER" again.
workings hours xxxxx h Betriebsstunden drainage time 2sec Entwässerungsdauer drainage interval 5min Entwässerungsinterval star delta time 4sec Stern-Dreieck-Zeit delayed start 0sec verzögerter Anlauf cooling water delay 2min Kühlwassernachlauf continuous time 5min Durchlaufzeit
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
EIN / AUS
Dies ist der Standart-Text auf dem Display.
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
Wenn ganz rechts im Display ein oder zwei Pfeile dargestellt werden, dann kann mit d.entsprechenden Pfeil-Tasten zu anderen möglichen Texten gesprungen werden. Die weiteren Texte können weitere Alarme anzeigen, wenn mehr als eine Störung ansteht. Oder es werden die Betriebsstunden angezeigt. Oder es können einige variable Einstellungen der Software angezeigt werden. Normalerweise sind alle Einstellungen für einen normalen Kompressorbetrieb bereits durch HATLAPA festgelegt. Wenn Einstellungen geändert werden sollen, muß einmalig die "ENTER"-Taset betätigt werden. Dann kann man mit den Pfeil-Tasten den entsprechenden Wert verändern. Daraufhin muß der geänderte Wert nocheinmal mit der "ENTER"-Taste quittiert werden.
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 3 von 8 Bl.
0
2
1
3
4
5
6
8
7 -F2
9
2A
4
L
2
4
6
11
1
3
5
12
1
3
5
2
4
6
0P ±5%
-K1 /8.0
-F3
-T1 440V
-Q1
4
6
220V 250VA 0S
2A
2
-Q4
0,63-1A 2 GV2 RT05
l
Heizungs-Spannung HEATING VOLTAGE
/7.9
1 1
3
5
-Q2
97 95
2
-F1 37-50A
4
3 Hauptschalter Heizung MAIN SWITCH 4 HEATING
98 96
6
Original 2011-06-21
2
/5.0
4
75/1
1N1
Trafo-Einspeisung TRANSFORMER SUPPLY
1
k
-T2
5
3
-P1 75A + A -
K
3
/5.0
Steuerspannung CONTROL VOLTAGE 3
1
2
1
1L1
51
61
/8.0 52
62
-K1 X1
-H2
Heizung ein HEATING ON
220V X2
SHIP SUPPLY 440V
440V Zuleitung
U
V
W
U
V
W
H1 H2 PE
PE
60Hz
L1 L2 L3 PE
60Hz
-X1
-M1
9 10 HE1 HE2
M
3
Heizung HEATING 25-100W
Kompressor COMPRESSOR 22-30 kW Datum 02.11.10 Bearb. Gepr.
Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 4 von 8 Bl.
0 /4.9
/4.9
2
1
3
4
5
6
7
8
9
1L1
1N1
1N1
1L+
+24V DC
/8.0
/6.0
Original 2011-06-21
Softwareversion Hamw_7
16t 17t 18t
S7-CPU 224 Relay-Outputs 14 x Inputs
10 x Outputs Relay
2b 3b 4b 5b 6b 7b 8b 9b
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
/6.0 /6.4 /6.4 /6.5 /6.6 /6.7 /6.8 /6.2
MOTOR PROTECTION RE OIL LEVEL SW.WARNIN OIL LEVEL SW.SHUTDO AIR TEMPERAT.SHUTDO AIR TEMPERAT.WARNIN SPARE Reserve SPARE Reserve AIR PRESSURE SWITCH
2t 3t 4t 5t 8t 9t 10t 13t
11b 12b 13b 14b 15b 16b
E1.0 E1.1 E1.2 E1.3 E1.4 E1.5
/7.1 /7.3 /7.5
REMOTE CONTROL ON REMOTE CONTROL MANU REMOTE CONTROL AUTO
14t A1.0 15t A1.1
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5 A0.6 A0.7
/8.0 /8.5 /8.7 /8.6 /8.2 /8.3 /8.9
PE N L1
17b 18b
-A1
M Exp. L+
1L Out 2L 3L 1M In 2M
1t 7t 12t 1b 10b
0V DC
Supply
MOTOR MAIN CONTACTO DRAIN VALVES Entwäs DISTURBANCE RELAY COOLING WATER VALVE SPARE STAR CONTACTOR DELTA CONACTOR REMOTE CONTROL ACTI
-P2 TD 200
HATLAPA Anzeige- und Bedieneinheit monitoring and operation panel
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 5 von 8 Bl.
0 /5.9
2
1
3
4
5
6
8
7
1L+
9 1L+
-A1
-A1
3b
-A1
5b
E0.1
/5.2
/7.0
7b
E0.3
/5.2
E0.5
/5.2
95 OIL LEVEL SW.WARNING Ölstands-W. Voralarm
-F1
AIR TEMPERAT.SHUTDOWN Lufttemp.-Wächter Alarm
SPARE
Reserve
/4.2 96 Digital Input
-A1
AIR PRESSURE SWITCH Luftdruck-Wächter Digital Input
PE
Optional über KompressorUmschaltbox 2
OPTIONAL VIA COMPRESSOR SEQUENCE Luftdruck-Wächter SELECTION BOX für Auto Start/Stop AIR PRESSURE SWITCH FOR AUTO START/STOP
7
8
3
2
1
24V DC
1
P
5
L
ÖlStandsWächter OIL LEVEL SWITCH
L
Zust. Änderung
Datum
Name
Norm
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
SPARE
10
NC T
PE
/5.2 Reserve
Digital Input
5
11
12
PE
NC
T COM
COM
-F3
Datum 02.11.10 Bre cpu
9
LuftTemp.Wächter AIR TEMP. SWITCH
-F13 Bearb. Gepr.
E0.6
Digital Input
5
PE
/5.2
AIR TEMPERAT.WARNING Lufttemperatur Voralarm
24V DC
6
F13.1
5
E0.4
Digital Input
SHUTDOWN
-X1
/5.2
OIL LEVEL SW.SHUTDOWN Ölstands-Wächert Alarm
F13.2
Digital Input
-F4
E0.2
F3W
MOTOR PROTECTION RELAY Motorschutzrelais
/5.2
8b
WARNING
E0.7
-A1
6b
F3S
/5.2
Digital Input
-A1
4b
WARNING
E0.0
Original 2011-06-21
-A1
9b
SHUTDOWN
-A1 2b
Digital Input
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 6 von 8 Bl.
0 /6.9
2
1
3
4
5
6
8
7
9
1L+
13
potentialfreie Kontakte FLOATING CONTACTS
-S2 Vorort-Fern LOCAL-REMOTE
14
11
-Q1 /4.1 12 13 -A1
-A1
11b E1.0
/5.2
E1.1
REMOTE CONTROL ON Fernbedienung ein
Original 2011-06-21
13b /5.2
REMOTE CONTROL MANUAL Fernbedienung Hand ein
Digital Input
E1.2
-K5
-K1
-K4
14 /8.0
14 /8.4
13
/5.2
REMOTE CONTROL AUTO ON Fernbedienung Auto ein
Digital Input
-X1
13
14 /8.6
-A1
12b
13
Digital Input
14 15 PE
26 27 PE Fernbedienung aktiv REMOTE CONTROL ACTIVE
(NO)
22 25 PE STÖRUNG DISTURBANCE
(NC)
MAN 0 AUTO
(NO)
20 21 PE Kompressor ein COMPRESSOR ON
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 7 von 8 Bl.
0
2
1
3
4
5
-A1
6
-A1
Digital Output MOTOR MAIN CONTACTOR NETZSCHÜTZ
2t
3t
DISTURBANCE RELAY Störungs-Kontakt
/5.2
A0.3
/5.2
A0.2
5t
REMOTE CONTROL ACTIVE Fernbedienung aktiv /5.2
A0.7 13t
A1
A1
-K4
50A A2 INCL. VAR.
Original 2011-06-21
Digital Output
4t
-K1
/5.9
-A1
Digital Output
COOLING WATER VALVE Kühlwasserabsperrventi
/5.2
A0.1
9
-A1
Digital Output
DRAIN VALVES Entwässerungs-Ventile
/5.2
A0.0
-A1
Digital Output
8
7
A1
-K5
INCL. A2 VAR.
INCL. A2 VAR.
1N1
1 3 5 13 21 51 /4.8 61 /4.9 /4.2 /4.2 /4.2 /7.8
2 4 6 14 22 52 62
/7.9 13
14
Störungskontakt DISTURBANCE RELAY
/7.7 13
14
Fernbedienung aktiv REMOTE CONTROL ACTIVE
Kompressor ein COMPRESSOR ON
-X1
17 1
-Y1
PE
17 1
-Y2
Entwässerungsventile DRAIN VALVES
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
18 1
PE
PE
-Y5 Kühlwasser-Absperrventil (optional) COOLING WATER SHUT OFF VALVE (OPTIONAL)
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 8 von 8 Bl.
0
2
1
3
4
5
6
8
7
9
Kompressor-Umschaltbox COMPRESSOR SEQUENCE SELECTION BOX Box de selection de guidage
200
VIEW FROM BEHIND: 200
120
Kompressor-Umschaltbox COMPRESSOR SEQUENCE SELECTION BOX Kompressor 1 = Führungskompressor COMPRESSOR 1 = LEADING COMPRESSOR
Schutzart: IP54 PROTECTION CLASS: IP54 200
2
200
1
Gewicht: ca. 3kg WEIGHT: APPR. 3kg
Kompressor 2 = Führungskompressor COMPRESSOR 2 = LEADING COMPRESSOR
ø8,7 20
Original 2011-06-21
3S1
20
3S1
Führungswahlschalter SEQUENCE SELECTOR SWITCH Commutateur de guidage
Stellung 1: Kompressor 1 = Führungskompressor Kompressor 2 = Folgekompressor
Stellung 2: Kompressor 2 = Führungskompressor Kompressor 1 = Folgekompressor
POSITION 1: COMPRESSOR 1 = LEADING COMPRESSOR COMPRESSOR 2 = FOLLOWING COMPRESSOR
POSITION 2: COMPRESSOR 2 = LEADING COMPRESSOR COMPRESSOR 1 = FOLLOWING COMPRESSOR
Position 1: Compresseur 1 = Compresseur de guidage Compresseur 2 = Compresseur de suivant
Position 2: Compresseur 2 = Compresseur de guidage Compresseur 1 = Compresseur de suivant
Datum french A texts 23.01.09 Zust. Änderung Datum
bre Name
20.02.08 Umschaltbox für Doppelkompressorsteuerung Bearb. Bre Gepr. cpu SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL Norm
Urspr.
330141
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
333392-44070 Blatt 1 von 2 Bl.
3
4
5
2
2
2
1
1
0
6
10
6
8
7
9
14
-3S1
Original 2011-06-21
Führungswahlschalter SEQUENCE SELECTOR SWITCH
-3X1
-1F4
1
2
5
PE
1
6
3
5
7
9
11 13 15
PE
7
8
3
PE
-2F4
P
Druckluftschalter für Führungskompressor AIR PRESSURE SWITCH FOR LEADING COMPRESSOR
4
PE
P
Druckluftschalter für Folgekompressor AIR PRESSURE SWITCH FOR FOLLOWING COMPRESSOR
A
B
C Druckluftwächter-Signal zum Schaltschrank Kompressor 1 AIR PRESSURE SIGNAL TO CONTACTOR CABINET COMPRESSOR 1
Druckluftwächter-Signal zum Schaltschrank Kompressor 2 AIR PRESSURE SIGNAL TO CONTACTOR CABINET COMPRESSOR 2
Datum
20.02.08 Umschaltbox für Doppelkompressorsteuerung Bearb. Bre Gepr. cpu SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL Zust. Änderung
Datum
Name
Norm
Urspr.
330141
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
D
333392-44070 Blatt 2 von 2 Bl.
COPYRIGHT RESERVED
CONTROL AND OPERATING PHILOSOPHY V LINE COMPRESSOR FRESH WATER COOLED ELECTRO-MECHANICAL VERSION
T0401132 Sheet 1 of 4
1.
General Description
1.1
The V Line is a 2 stage, 2 cylinder reciprocating type air compressor direct coupled to an electric motor, all mounted on Anti-Vibration mounts. The equipment is designed to be operated via a remote mounted starter/control panel (supplied by either Hatlapa or the Customer). The compressor rotating and reciprocating elements are splash lubricated via ‘dippers’, integrally cast onto the con-rods, hitting the oil surface - the oil contained in the compressor crankcase.
Original 2011-06-21
The compressor is arranged with a water cooling system, which is be suitable for fresh water only. This system cools both the air interstage and after coolers. An integrally mounted electric motor driven water circulating pump can be supplied by Hatlapa. 1.2
Pressure gauges are provided for monitoring the air interstage and final stage pressures, P1 and P2.
1.3
The compressor has a number of safety features as follows:Safety valves are fitted to each air stage of the compressor, SV1 and SV2 A safety valve is fitted to the water jacket housing the coolers, SV5
1.4
The compressor is fitted with the following protection devices:Minimum oil level, F13 High final delivery temperature, F3 High compressor motor current High water pump motor current
shutdown (1) and optional alarm (2) shutdown (S) and optional alarm (W) shutdown only shutdown only (of water pump supplied)
Note – 1) Both the low oil level switch, F13, and the high air temperature switch, F3, are closed under normal running conditions and open on fault. 2) The low oil level switch, F13, is connected to a timer delay to prevent spurious operation due to ship’s motion, ie, pitch and roll. 1.5.1 The starter/ control panel should be capable of the following functions:Selection of manual mode Selection of automatic mode ECN No. Issue No. 1 2 Date: 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401132-ISS2.doc
local start/stop only local or remote start/stop sequence Drawn WAH Checked Approved SK
COPYRIGHT RESERVED
CONTROL AND OPERATING PHILOSOPHY V LINE COMPRESSOR FRESH WATER COOLED ELECTRO-MECHANICAL VERSION
T0401132 Sheet 2 of 4
Selection sequence of operation - if more than one compressor is charging the system a selector switch should be fitted enabling the sequence in which the compressors should work i.e. lead and follow. Emergency stop operation 2.
-
shutdown only - local or remote
Operation Note - If this is the first commissioning or a re-commission after a significant period out of service then refer to the commissioning procedure for guidance.
2.1
Normal Running Procedure (Automatic Control)
Original 2011-06-21
Note – The manual drain valves (HV1) should be closed 2.1.1 Energise the starter panel via the main isolator Set mode switch S1 to AUTO Set local/remote switch S2 as required Set drain switch S3 to AUTO (S3 not fitted if only hand drains supplied) Press RESET push button. 2.1.2 On pressing the START button, the following events occur:The compressor starts and runs off load The water circulating pump (WP) starts and runs (when fitted) The water shut off valve (Y5) is energised to open (when fitted) The compressor will run off load for 15 – 20 seconds after which solenoid valves Y1 and Y2 are energised to close to charge the air system. (Note - the solenoid valves will only close if the air system is not fully charged) Note – If a visual flow indicator (F1) is fitted to the compressor cooling water outlet this should be checked to ensure that water is circulating through the compressor. In the event that there is no flow the compressor should be stopped and the cause investigated. 2.1.3 The compressor is now controlled by the air system pressure switch. At 5 minute intervals (adjustable dependant on ambient conditions) solenoid valves Y1 and Y2 are de-energised to open for 2 seconds (adjustable) to drain moisture collected in the interstage and final stage separator bowls.
2.1.4 On air system charged signal, from the air system pressure switch, solenoid valves Y1 and Y2 are de-energised to open to drain and unload the compressor and await a signal as follows:ECN No. Issue No. 1 2 Date: 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401132-ISS2.doc
Drawn WAH Checked Approved SK
COPYRIGHT RESERVED
CONTROL AND OPERATING PHILOSOPHY V LINE COMPRESSOR FRESH WATER COOLED ELECTRO-MECHANICAL VERSION
T0401132 Sheet 3 of 4
On recharge signal the solenoid valves Y1 and Y2 close, energise, causing the compressor to charge the system. If the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the compressor stops leaving the solenoid valves Y1 and Y2 open. On recharge signal the compressor starts as for pressing the START button.
Original 2011-06-21
2.1.5 On pressing the STOP button solenoid valves Y1 and Y2 are de-energised to open to drain the separator bowls, the compressor continues to run on for 5 minutes (adjustable) before stopping. Simultaneously with the compressor stopping the water circulating pump (if fitted) stops and the water shut off valve Y5 (if fitted) is de-energised to close. Pressing the START button during this cycle brings the compressor back on line to charge the air system. 2.1.6 If the START button is pressed while the air system is fully charged, the compressor starts as described in Paragraph 2.1.2. The compressor is then controlled by the air system pressure switch as described in Paragraphs 2.1.3 and 2.1.4. 2.2
Sequence Selector Switch
2.2.1 If more than one compressor is charging the receiver, the Sequence Selector Switch changes which compressor is the lead and which is the follow machine. 2.3
Manual Mode Running
2.3.1 Energise the starter panel via the main isolator Set the mode switch S1 to MAN Set local/remote switch S2 to LOCAL Set drain switch S3 to AUTO (S3 not fitted if only hand drain valves fitted) Press RESET push button. The compressor will start and run in this mode overriding the low oil level switch, F13, and high air temperature switch, F3. The emergency stop button and motor thermal overloads will still stop and unload the compressor. Starting, running and stopping cycles are as for Normal (Automatic) Running as described with the exception of the following:Oil level switch overridden High air temperature switch overridden Remote start/stop function disabled 2.4
Emergency Stop
ECN No. Issue No. 1 2 Date: 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401132-ISS2.doc
Drawn WAH Checked Approved SK
COPYRIGHT RESERVED
CONTROL AND OPERATING PHILOSOPHY V LINE COMPRESSOR FRESH WATER COOLED ELECTRO-MECHANICAL VERSION
T0401132 Sheet 4 of 4
Upon pressing the emergency stop button, either local or remote (if fitted), the compressor stops immediately, solenoid valves Y1 and Y2 open, water circulating pump (if fitted) stops and the water shut off valve, Y5, (if fitted) closes. General
3.1
It is recommended that individual volt-free change-over contacts and control panel indicator lamps are provided as follows:Compressor running Water pump running (if fitted) Low oil level shutdown Low oil level warning (if fitted) High air temperature shutdown High air temperature warning (if fitted) Compressor motor overload Water pump motor overload (if fitted)
Original 2011-06-21
3
ECN No. Issue No. 1 2 Date: 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401132-ISS2.doc
Drawn WAH Checked Approved SK
T0401133 V-LINE COMPRESSOR INSTALLATION RECOMMENDATIONS FRESH WATER COOLING
Page 1 of 3
COPYRIGHT RESERVED
1.
LOCATION The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as cool and dry as possible and there is adequate circulation to the drive motor integral cooling fan and all the compressor external surfaces. It is preferable that the compressor be positioned with the axis of the crankshaft and motor fore and aft in the vessel.
2.
MOUNTING The compressor should be mounted on support plates/pads and supported by a ribbed structure suitable for the type and weight of the compressor. The pads/plates must be clean and flat to within 1mm. Shims should be used if necessary. All V-Line compressors are supplied with AV mounts and flexible hoses. Refer to General Arrangement Drawing supplied with the compressor documentation package for anti-vibration mounts dimensions, positions and weight of the compressor. Refer to 178483 for flexible hose installation guidelines.
Original 2011-06-21
3.
COOLING WATER SYSTEM General Comments The Compressor is suitable for fresh water cooling only. The supply of water should be free of solids or any other foreign matter. The compressor coolers have been designed incorporating a fouling factor equivalent to 10%. There must be positive water circulation through the compressor. For optimum compressor performance the operating temperature of the compressor needs to be regulated by the combination of cooling water inlet temperature and flow rate. Note! A compressor running too cold will tend to generate condensation internally within the crankcase, leading to contamination of the lubricating oil with water. A compressor running too hot will have a high final air delivery temperature with an increased risk of mechanical failure. 3.1
Cooling Water Temperature For recommendations see T0401121
3.2
Cooling Water Quantity
3.2.1
When installing the V-Line compressor into the ship's cooling water system, consideration must be given to the cooling water flow requirement for the compressor to operate efficiently. For the cooling water flow recommendations see T0401121. When a water circulating pump is supplied, see T0401131 (V105/150), T0401143 (V200/250), T0401144 (V375) for Pump Performance data. A means of measuring the pressure drop across the system should be provided. A visual flow indicator is fitted as standard.
3.2.2
The system must be designed to ensure a positive back pressure exists on the cooler outlet to prevent the first stage cylinder being starved of cooling water. For the pressure drop across the compressor see T0401121. The nominal cooling water flow rate through the compressor will normally give an acceptable heat transfer rate across the compressor resulting in a cooling water outlet temperature rise of 15°C over water inlet temperature and a final air delivery temperature of 15°C over the cooling water inlet temperature. It may be found necessary to vary the cooling water flow rate in order to achieve these temperature rises.
ECN No. N0054647 Issue No. 1 2 3 Date: 16.3.00 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401133-iss3.DOC
Drawn Checked Approved
RAV RAV AES
T0401133 V-LINE COMPRESSOR INSTALLATION RECOMMENDATIONS FRESH WATER COOLING
Page 2 of 3
COPYRIGHT RESERVED
3.2.3
A water shut off valve should be fitted, to the water inlet to the compressor, see T0401115 figs 1 & 4 (supplied on request), when the temperature of the cooling water is significantly below the temperature of the air surrounding the compressor. In these circumstances it is necessary to avoid overcooling and the resultant generation of condensation. Where cooling water is at a higher temperature particularly with fresh water systems, it is less important to stop the water flow.
3.2.4
The fitting of a 3 way thermostatic valve on the outlet of the compressor is recommended where overcooling problems may be envisaged or experienced. Overcooling occurs mainly when:a) The cooling water inlet temperature is very low. b) The cooling water inlet temperature is low and compressor is running unloaded. c) Cooling water continues to flow through the compressor after the machine has stopped running The effects of overcooling are excessive condensation in the compressor causing corrosion and emulsification of the lubricating oil.
Original 2011-06-21
See T0401115 fig 6 (supplied on request) for a typical fresh water installation fitted with a heat exchanger.
4.
5.
3.3
Cooling System Pressure See T0401121 for limitations.
3.4
Water Pipe Sizing and Layout In order to avoid excessive friction loss through piping, it should be kept as short as possible. See T0401121 for recommended pipe sizes. It should be noted that the compressor connections should not be used to establish the pipe size to be used. Should the pipe work be very long, the next larger size pipe than that recommended in T0401121 should be used. Refer to T0401115 for typical installations/layouts (supplied on request).
3.5
Venting of Air from the Compressor Cooling Water System The compressor is fitted with an air bleed valve on top of the cooler box and it is recommended (in the compressor Manual) that this is bled on a daily basis to ensure air is not trapped in the cooler box water chamber thus preventing hot spots in the machine.
MAIN AIR LINE 4.1
Vertical run-up direct from the compressor must be kept to a minimum and the horizontal run, incorporating the non return valve, should descend away from the compressor to prevent any moisture in the pipeline from running back to the compressor and non return valve.
4.2
See drawing A22002 for a typical 2 compressor installation (supplied on request).
DRAINAGE SYSTEM 5.1
Drain Sizing Refer to recommendations made in T0401124 for typical installations (supplied on request).
ECN No. N0054647 Issue No. 1 2 3 Date: 16.3.00 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401133-iss3.DOC
Drawn Checked Approved
RAV RAV AES
T0401133 V-LINE COMPRESSOR INSTALLATION RECOMMENDATIONS FRESH WATER COOLING
Page 3 of 3
COPYRIGHT RESERVED
6.
SUMMARY OF STANDARDS AND DATA SHEETS REFERENCED IN THIS PROCEDURE. -
Flexible Hose Installation Guidelines Cooling Data Pump performance Data V105/150 Pump performance Data V200/250 Pump performance Data V375 Typical Cooling Installation Diagrams (supplied on request) Typical Air System – 2 Compressors (supplied on request) Drain Sizing Recommendations (supplied on request)
Original 2011-06-21
178483 T0401121 T0401131 T0401143 T0401144 T0401115 A22002 T0401124
ECN No. N0054647 Issue No. 1 2 3 Date: 16.3.00 08.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401133-iss3.DOC
Drawn Checked Approved
RAV RAV AES
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES Flexible hoses are used for connecting a flexible mounted compressor assembly to a rigid piping system. When a hose is installed, it must allow the compressor to move in all three directions. See typical applications below, which show a single bend, to achieve this. The diagrams apply to both air and water. Note: The following diagrams show flexible hoses with threaded end connections, however flanged end connections may be supplied. These guidelines apply to the flexible part of the hose, regardless of the type of end fitting supplied.
No pressure
Original 2011-06-21
High pressure
To allow the flexible part of the hose to move when pressurised, ensure no supporting clamps are located on the bends.
incorrect
correct
On installation, ensure that the flexible part of the hose is not twisted, this could result in hose damage and, when pressurised, it could untwist, loosening the connections.
16.01.2006 122/Pitrowski
1/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Use angle adaptors to eliminate tight bend radii and sharp twists occurring in the hose.
incorrect
correct
If the installation bend radius is less than the minimum allowed, use angle adaptors to eliminate tight bend radii.
16.01.2006 122/Pitrowski
2/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is installed with a smooth bend, avoiding any tight corners, which could cause the flexible part of the hose to collapse.
incorrect
correct
In a collinear application, do not install the hose in a straight line or with kinks, use angle adaptors.
16.01.2006 122/Pitrowski
3/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is kept away from hot surfaces by using suitable clamps. High ambient temperatures can reduce the life of the flexible part of the hose.
16.01.2006 122/Pitrowski
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Safety Instructions for Hoses
1 General Hose pipes are safety relevant parts which may endanger persons and the environment in case of failure.
1.1 Installation and maintenance During installation the hoses must in no way be damaged, bent, twisted or exerted to pressure. They must not be painted or have contact with sharp objects! For cleaning hose pipes and hoses neither aggressive cleaning agents nor pressure cleaners may be used. They can damage the hose surface resp. hose line! Hose pipes must be inspected visually by the assembly/service personnel before commissioning and once a year. Inspection is carried out under the following aspects: Original 2011-06-21
• • • • • • •
Damage to the outer layer Decay of the outer layer Deformation of the hose or hose pipe (alteration of the geometry, layer separation, forming of blisters) Damage or deformation of the hose fitting Corrosion of the fitting (impairs function and strength) Installation (chafing at sharp edges or smooth surfaces) Exceeding the admissible storage resp. operational duration (stated below)
1.2 Storage and durability According to DIN 7716 proper storage is to be understood as follows: • • • • • •
max storage time 2 years dry, cool, dust-free no direct sunlight or UV light protection against ozone protect against heat store lying and without tension
According to EN 982 resp., DIN 20066 following must be observed: 1. Once installed, the hoses have a durability of 6 years and must be replaced after this period. 2. If the max. storage time of 2 years is exceeded, then the hose may no longer be used. If the hose is installed within this period, the durability of 6 years is reduced by the period of storage accordingly. It lies within the responsibility of the user that all hoses mentioned in this manual are checked at regular intervals, and to guarantee correct and safe function once the guarantee period has elapsed, thus preventing damage to persons and the environment.
date 18.04.2005 Created by Tanz
page 1 of 1
T.0401121
V-LINE PERFORMANCE WATER COOLED/AIR COOLED
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COPYRIGHT RESERVED
1. COMPRESSOR Model
Flow l/min
V105 V150 V200 V250 V375
20/25 20/25 60/70 60/70 110/120
Pressure Drop Across Compressor (P2 – P1)* 0.5m 0.5m 2.5m 2.5m 4.4m
Max. Water Jacket Pressure
Inlet & Outlet Connections
Recommended Min. Pipe Bore
7 bar g 7 bar g 7 bar g 7 bar g 7 bar g
G¾ G¾ G1 G1 G1¼
19mm 19mm 25mm 25mm 32mm
Original 2011-06-21
* See T0401115 for positions Water jacket Safety Valve setting = 7.7barg Minimum cooling water inlet temperature = 5oC Maximum cooling water inlet temperature = 45oC For heat dissipation to cooling water see T0401126 2. WATER CIRCULATING PUMP (Option) See Data Sheets T0401125 T0401131 T0401143 T0401144
(Sea Water – All Models) (Fresh Water – V105/150) (Fresh Water – V200/250) (Fresh Water – V375)
2. THERMOSTATIC BY-PASS VALVE (Option) 2.1 Valve actuating temperature = 35°C 2.2 Pressure drop across valve – see table below Pressure Drop Across Valve Model V105 V150 V200 V250 V375
0.68m 0.68m 2.38m 2.38m 5.78m
Valve Connections G¾" G¾" G1" G1" G1¼"
3. WATER SHUT OFF VALVE - Solenoid Operated (Option) 4.1 Pressure drop across valve – see table below Pressure Drop Across Valve Model V105 V150 V200 V250 V375
ECN No. N0054732 Issue No. 1 2 3 Date: 16.03.00 31.05.02 16.01.06 W:\Compressors\ENGINEERING\T Stds\T0401121.DOC
0.1m 0.1m 0.8m 0.8m 0.5m
Valve Connections G¾" G¾" G1" G1" G1¼"
Drawn Checked Approved
RAV RAV AES
V-LINE COMPRESSOR
T0401126
HEAT DISSIPATION
Page 1 of 2
COPYRIGHT RESERVED
pc
WATER COOLED
V105
Original 2011-06-21
V150
V200
V250
V375
Pressure Bar g 33 25 20 15 10 7 33 25 20 15 10 7 33 25 20 15 10 7 33 25 20 15 10 7 33 25 20 15 10 7
BOTTLE CHARGING DUTY Heat Dissipation 1000 rpm 1200 rpm 1500 rpm kW J/s kW J/s kW J/s
1800 rpm kW J/s
9.6
9600
11
11000
14.9
14900
16.5
16500
8.2
8200
9.9
9900
12.7
12700
15.4
15400
7.1
7100
8.8
8800
11
11000
13.8
13800
14
14000
16
16000
21.6
21600
24
24000
12
12000
14.4
14400
18.4
18400
22.4
22400
10.4
10400
12.8
12800
16
16000
20
20000
17.6
17600
21.2
21200
25.6
25600
30.4
30400
16
16000
19.2
19200
24
24000
28.8
28800
14.4
14400
17.6
17600
21.6
21600
24
24000
22.4
22400
26.4
26400
33.6
33600
41.2
41200
20.8
20800
24
24000
30.4
30400
36
36000
19.2
19200
21.6
21600
26.4
26400
31.2
31200
30.4
30400
39.2
39200
46.4
46400
58.4
58400
ECN No. N0054729 Issue No. 1 2 Date: 22.3.00 31.5.02 W:\Compressors\ENGINEERING\T Stds\T0401126.DOC
NOT AVAILABLE NOT AVAILABLE
Drawn Checked Approved
RAV RAV AES
V-LINE COMPRESSOR
T0401126
HEAT DISSIPATION
Page 2 of 2
COPYRIGHT RESERVED
pc
WATER COOLED
V105 V150 V200 V250
Pressure Bar g 30 21 30 21 30 21 30 21
1000 rpm kW J/s 9.6 9600 8.2 8200 14000 14 12 12000 17.6 17600 16 16000 22.4 22400 20.8 20800
FAD (NOZZLE) DUTY Heat Dissipation 1200 rpm 1500 rpm kW J/s kW J/s 11 11000 14.9 14900 9.9 9900 12.7 12700 16 16000 21.6 21600 14.4 18400 14400 18.4 25600 21.2 21200 25.6 24000 19200 24 19.2 33.6 33600 26.4 26400 24000 30.4 30400 24
1800 rpm kW J/s 16.5 16500 15.4 15400 24 24000 22.4 22400 30400 30.4 28800 28.8 41.2 41200 36 36000
NOT AVAILABLE
Original 2011-06-21
V375
AIR COOLED
VA40
Pressure Bar g 33 25 20 15 10 7
BOTTLE CHARGING DUTY Heat Dissipation 1000 rpm 1200 rpm 1500 rpm J/s kW J/s kW kW J/s
1800 rpm J/s kW
4.2
4200
5
5000
6.5
6500
7.3
7300
3.9
3900
4.7
4700
6
6000
6.8
6800
3.2
3200
4
4000
4.9
4900
5.9
5900
ECN No. N0054729 Issue No. 1 2 Date: 22.3.00 31.5.02 W:\Compressors\ENGINEERING\T Stds\T0401126.DOC
Drawn Checked Approved
RAV RAV AES
Lubricating Instructions for V-Line Piston Compressors
178492 Rev. 01.06
1. General Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of the compressor. Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is advisable to contact him when making your choice. Ask only the lubricant manufacturer for his recommendation! He is the expert.
2. Lubrication Oil Quality
Original 2011-06-21
Above all, compressor oils must have good lubrication properties for which their viscosity is highly important. HATLAPA recommends lubrication oils within the following range: viscosity at 100 °C: min. 9 cSt max. 15 cSt viscosity at 40 °C: min. 90 cSt max. 120 cSt The lubrication oils should have low tendency to ageing and coking in order to prevent oil carbon deposits on valves and pipelines. HATLAPA recommends to use oils of class VDL according to DIN 51 506.
3. Guarantee If lubrication oils are used which do not meet the requirements, damage to the compressor may occur. This damage is not covered by HATLAPA's guarantee obligations.
4. Lubricant Examples The following oils are examples which comply with the above specification: Mineral Oils Synthetic Oils BP ENERGOL RC100 ENERSYN RX100 CASTROL AIRCOL PD 100 AIRCOL SN 100 CHEVRON TEXACO (FAMM) COMPRESSOR OIL EP VDL100 CETUS DE 100 ELF TOTAL FINA (Lubmarine) DACNIS P100 BARELF CH 100 ESSO (ExxonMobil Marine) EXXCOLUB 100 SYNESSTIC 100 MOBIL (ExxonMobil Marine) RARUS 427 RARUS 827 SHELL CORENA P 100 CORENA AP 100 However, the oil properties are subject to change without notice by the oil manufacturer. Also, the oil characteristics may vary depending on the regional market. Therefore this list does not release the operator of the compressor from verifying that the selected oil complies with the above specification.
Original 2011-06-21
SECTION 3
Original 2011-06-21
Original 2011-06-21
Instruction Manual V-Line Water Cooled Compressor V105, V150, V200, V250, V375 Original 2011-06-21
PCH 1540
ISSUE 8 1105
Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 25436 Uetersen / Germany
Telephone: +49-4122-711 0.. Facsimile: +49-4122-711 330 Internet http://www.hatlapa.de E-Mail:
[email protected]
Marine Equipment Ltd. Discovery Court Business Centre 551-553 Wallisdown Road, Poole, Dorset BH12 5AG, Great Britain Telephone: +44 (0) 1202 853 180 Facsimile: +44 (0) 1202 853 190 Internet http://www.hatlapa.de E-Mail:
[email protected]
Original 2011-06-21
CAUTION 1.
The following manual must be read before proceeding with installation, operation and maintenance of this equipment.
2.
Health & Safety Act Compliance. Before working on this equipment personnel should be made aware of, and ensure compliance with, the Health and Safety Regulations appropriate to this class of work.
3.
The handling points are indicated on the unit and must be used. The hooks of slings must be fitted to lifting eyebolts using shackles.
4.
Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings, it must be stopped and isolated electrically and mechanically and the outlet valves closed. Some units on automatic standby duty, or isolators are remote from the unit and extra care is then necessary to ensure that isolation is complete.
Original 2011-06-21
HATLAPA MARINE EQUIPMENT reserves the right to make changes to the design of the machine without prior notice.
Original 2011-06-21
CONTENTS 1
2
Original 2011-06-21
3
4
5
1.1 1.2 1.3 2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.2.13 3.2.14 3.2.15 3.2.16 3.2.17 3.2.18 3.2.19 3.2.20 3.2.21 3.2.22 3.2.23 3.2.24 3.2.25 3.2.26 3.3 3.3.1 3.4 3.5 3.6 4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3
INSTALLATION ......................................................................................................................... 1-1 LOCATION ................................................................................................................................. 1-1 MOUNTING ................................................................................................................................ 1-1 COMMISSIONING ..................................................................................................................... 1-1 OPERATING PROCEDURE ...................................................................................................... 2-1 DESCRIPTION........................................................................................................................... 2-1 CONTROL AND OPERATING PHILOSOPHY .......................................................................... 2-1 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL) .............................................. 2-2 MANUAL MODE RUNNING ...................................................................................................... 2-4 GENERAL .................................................................................................................................. 2-5 MAINTENANCE......................................................................................................................... 3-1 GENERAL .................................................................................................................................. 3-1 MAINTENANCE INSTRUCTIONS ............................................................................................. 3-3 Lubrication Oil Checking ............................................................................................................ 3-3 Lubrication Oil Changing ............................................................................................................ 3-3 Air Suction Filter/Silencer Removal and Replacement .............................................................. 3-3 First Stage Concentric Valve Removal/Servicing/Replacement ................................................ 3-4 Final Stage Concentric Valve Removal/Servicing/Replacement ............................................... 3-9 First Stage Cylinder and Piston Removal ................................................................................ 3-13 First Stage Cylinder and Piston Reassembly........................................................................... 3-15 Final Stage Cylinder and Piston Removal ............................................................................... 3-16 Final Stage Cylinder and Piston Reassembly .......................................................................... 3-17 Cooler Tubenest and Header Removal ................................................................................... 3-18 Tubenest Clean/Examine/Replace .......................................................................................... 3-18 Cooler box end cover ............................................................................................................... 3-21 Connecting Rod Removal ........................................................................................................ 3-21 Bearing Removal and Reassembly to Connecting Rods ......................................................... 3-21 Connecting Rod Reassembly to Compressor .......................................................................... 3-27 V105, V150, V200, and V250 Drive Motor and Coupling ........................................................ 3-28 V375 Drive Motor and Coupling ............................................................................................... 3-30 Flywheel and Drive End Oil Seals Removal from Compressor ............................................... 3-31 Flywheel and Drive End Oil Seal Reassembly to Compressor ................................................ 3-32 Crankshaft and Main Bearing Removal from Compressor ...................................................... 3-34 Crankshaft and Main Bearings Reassembly to Compressor ................................................... 3-35 Oil Level Switch Remove/Clean/Replace ................................................................................ 3-35 Air and Water Safety Valves .................................................................................................... 3-36 Separator and Diffuser Plate: Removal and Examination ....................................................... 3-36 Separator and Diffuser Plate: Reassembly .............................................................................. 3-37 WATER CIRCULATING PUMP (if supplied)............................................................................ 3-38 General Overhaul ..................................................................................................................... 3-39 ELECTRICAL MAINTENANCE ................................................................................................ 3-39 FAULT FINDING CHART......................................................................................................... 3-39 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE .................................................. 3-41 TECHNICAL DATA ................................................................................................................... 4-1 GENERAL .................................................................................................................................. 4-1 PERFORMANCE ....................................................................................................................... 4-1 OTHER DATA ............................................................................................................................ 4-1 CRANKCASE LUBRICANTS ..................................................................................................... 4-3 Approved Oils ............................................................................................................................. 4-3 Oil Company Equivalents ........................................................................................................... 4-3 Additional Maintenance for Machines Lubricated with Synthetic Oils ....................................... 4-3 DRAWINGS ............................................................................................................................... 5-1
Original 2011-06-21
FIGURES Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 3.8 Figure 3.9 Figure 3.10 Figure 3.11 Figure 3.12 Figure 3.13 Figure 3.14 Figure 3.15 Figure 5.1 Figure 5.2 Figure 5.3 Figure 5.4 Figure 5.5 Figure 5.6 Figure 5.7
First Stage Concentric Valve V105/150 First Stage Concentric Valve V200/250 First Stage Concentric Valve V375 Final Stage Concentric Valve V105/150 Final Stage Concentric Valve V200/250 Final Stage Concentric Valve V375 Cooler Header V105/V150 Fitting and Orientation of Big End Bearings/Con Rods V200/V250 Fitting and Orientation of Big End Bearings/Con Rods V375 Big End Bearings Fitting & Con Rod Orientation in the Crankcase Coupling Gap between Coupling and Flywheel Coupling Location of Angle Steel on Crankcase Rails Water Circulating Pump Typical Arrangement of V-Line Water Cooled Compressor with Gauges Cooler Crankshaft and Flywheel First Stage Cylinder and Piston Final Stage Cylinder and Piston Separator Gauges
3-5 3-6 3-7 3-10 3-11 3-12 3-20 3-24 3-25 3-26 3-28 3-29 3-30 3-31 3-38 5-1 5-3 5-4 5-5 5-6 5-7 5-8
TABLES Table 3.1 Table 3.2 Table 3.3 Table 3.4 Table 3.5 Table 3.6 Table 3.7 Table 4.1 Table 4.2 Table 4.3 Table 5.1 Table 5.2
Fastener Torque Settings (unlubricated) Maintenance Schedule Fixtures to Assist Flywheel Removal Items List - Water Circulating Pump Switch Settings Fault Finding Chart Tools Required for Compressor Maintenance Capacity and Power at 30 Bar Operating Parameters Recommended Maximum Wear Clearances List of Parts for Figure 5.1 List Of Parts – V-Line Compressors
3-1 3-2 3-31 3-38 3-39 3-39 3-41 4-1 4-1 4-2 5-1 5-9
Spare Parts and Service
Spare Parts can be ordered direct from the following address: HATLAPA Marine Equipment Ltd. Discovery Court Business Centre 551 553 Wallisdown Road BH12 5AG England
Telephone: Facsimile: e-mail
+44 (0) 1202 853180 +44 (0) 1202 853190
[email protected]
When ordering spare parts, the following information is required to ensure that correct parts are supplied: Type and serial number of machine: Obtained from machine nameplate Item Number and full description of part required: Obtained from details in this publication
Original 2011-06-21
Technical Service and Advice: Technical service and advice can be obtained during normal working hours from the above address, on the following contact numbers Telephone: Facsimile: Email:
+44 (0) 1202 853175 +44 (0) 1202 853190
[email protected]
Signs used DANGER This sign indicates behaviour which if not observed is highly dangerous, or which may lead to permanent bodily injury. Observe the warning exactly and pass this to other operators of the equipment also.
CAUTION This sign indicates behaviour which if not observed may lead to injury to persons, severe damage, or severe mal-function of the equipment, or to damage to the environment.
PAY ATTENTION This sign indicates behaviour which if not observed may lead to damage or mal-function of the equipment.
INFORMATION This sign indicates tips and useful information which makes the operation of the equipment or the understanding of the documentation easier.
Original 2011-06-21
CHAPTER 1 INSTALLATION
1
INSTALLATION
1.1
LOCATION
The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as cool and dry as possible and there is adequate circulation to the drive motor integral cooling fan and all the compressor external surfaces. The compressor must be positioned with the axis of the crankshaft and motor fore and aft in the vessel to ensure adequate lubrication during the vessels normal roll, pitch, list and trim modes. 1.2
MOUNTING
The compressor should be mounted on support plates/pads and supported by a ribbed structure suitable for the type and weight of the compressor. The pads/plates must be clean and flat to within 0.5 mm (1 mm with anti-vibration mounts). Shims should be used if necessary. Refer to general arrangement drawing supplied with the compressor documentation package for mounting feet or anti-vibration mounts dimensions and positions and weight of the compressor. 1.3
COMMISSIONING
Original 2011-06-21
DANGER Do not make any adjustments to the compressor, its connections or fittings whilst the compressor is running or on standby duty. Do not run the compressor unless all protective guards fitted to it and its prime mover are in place.
1.
Ensure compressor is isolated from its electrical supply.
2.
Check lubricating oil level in crankcase sump.
3.
Before initial start up, or after any servicing has been carried out, or when the compressor has not been run for 5 weeks or more, carry out the following procedures. a.
Remove the suction filter of the first stage (see chapter 3.2.3 Air Suction Filter/Silencer Removal and Replacement) and the plug from the second stage cylinder head.
b.
Pour 20 millilitres of lubricating oil on the valves of first and second stage.
c.
Replace suction filter and plug. PAY ATTENTION After adding oil to the valves, the compressor must be barred over at least 3 complete revolutions to ensure lubrication of the cylinder bores during initial start up and minimise the risk of the piston causing a hydraulic lock when the compressor is started.
d. 4.
Open air bleed valve (C10 in Figure 5.2) to remove air trapped in water box cooler passages.
Remove guard covering barring over access aperture in crankcase. CAUTION Take precautions to prevent injury to personnel whilst observing the direction of rotation of the flywheel through the unguarded barring over access aperture.
Page 1-1
CHAPTER 1 INSTALLATION 5.
Using a bar (not supplied) in one of the holes in the flywheel turn over the compressor through at least three complete revolutions.
6.
Connect the electrical supply and carry out a momentary start and stop.
7.
Check that rotation of compressor is clockwise looking on the drive end of the compressor (indicated by cast arrow). If direction of rotation is incorrect, take appropriate steps to correct.
8.
Connect compressor control, refit guard (170) covering barring over access aperture.
9.
Start compressor in MAN mode (HATLAPA compressor control: Press MAN button). Check the following details within the first minute of the run.
10.
a.
Check that the cooling water system is operating and the outlet from the compressor is registering a flow.
b.
Check that final stage air pressure is increasing over ambient pressure values.
Start compressor in AUT mode (HATLAPA compressor control: Press AUTO button). Allow compressor to continue to run under the control of the system pressure switch and closely monitor the temperature differential between cooling water inlet and outlet temperatures, adjusting valves etc as appropriate to adjust the water flow rate to achieve a temperature differential of approximately 15°C.
Original 2011-06-21
This temperature differential equates to the nominal flow rate as specified in Technical Data
The compressor must run continuously for approximately 30 minutes to reach normal operating temperature. It may be necessary to bleed off air from the system to prevent the compressor stopping prematurely. 11.
Check the operation of the system pressure switch.
12.
After satisfactory operation of the pressure control system, the compressor is now commissioned for use. The compressor may be either left running (AUT mode) to charge the air system or stopped (HATLAPA compressor control: Press STOP button).
Page 1-2
CHAPTER 2 OPERATING PROCEDURE
2
OPERATING PROCEDURE
2.1
DESCRIPTION
The standard V-Line compressor is supplied with gauges, a dual set point high air temperature switch, a dual set point low lubricating oil switch and two solenoid operated drain valves. The high air temperature switch (double pole) is fitted to protect the compressor by shutting it down if the temperature rises above the normal maximum operating temperature. As an option, the second pole of the switch may be connected to give a panel indicated warning of approaching shutdown temperature. The low lubricating oil switch (double pole) will also shut down the compressor if it detects the oil level is below the minimum requirement. An adjustable time delay is included to overcome false tripping due to the roll and pitch of the vessel. The second pole may be connected to give a panel warning of approaching shutdown oil level. The compressor starting method can be either star/delta or direct-on-line. The compressor may be supplied with a water circulating pump if required.
Original 2011-06-21
2.2
CONTROL AND OPERATING PHILOSOPHY
The compressor is fitted with protection devices which immediately stop and unload the compressor, when it is connected to a suitable compressor control, (supplied by HATLAPA or the customer) if any of the following events occur:
minimum oil level
shutdown and optional pre-alarm
high final delivery temperature
shutdown and optional pre-alarm
high compressor motor current
shutdown only
high water pump motor current
shutdown only (if water circulating pump supplied)
emergency stop button operation
shutdown only (optionally)
The compressor control should be capable of the following functions:
selection of AUTO mode
start/stop sequence local or remote (optionally)
selection of MAN mode
local start/stop only
If more than one compressor is charging the system a selector switch should be fitted enabling the sequence in which the compressors should work i.e. lead and follow. The following functions are optionally:
Emergency stop
shutdown only local or remote (optionally)
selection LOCAL / REMOTE mode
in AUT mode start/stop sequence local or remote
Page 2-1
Original 2011-06-21
CHAPTER 2 OPERATING PROCEDURE
2.3
NORMAL RUNNING (AUTOMATIC CONTROL)
2.3.1
Normal Running with HATLAPA Compressor Control
1.
If manual drain valves are installed in parallel to the solenoid valves, close the manual drain valves.
2.
Energise the starter panel by operating the main isolator. Set LOCAL/REMOTE switch as required.
3.
On pressing the AUTO button, the following events occur:
4.
The compressor starts and runs off load (open solenoid drain valves). The water shut off valve Y5 (optional) is energised to open (when fitted). The compressor will run off load for 20 seconds after which solenoid valves are energised to close to charge the air system.(Note that the compressor will only go on load if the system is not fully charged.) Check the visual flow indicator (FI, optionally) at the compressor cooling water outlet to ensure that water is circulating through the compressor. In the event that there is no flow stop the compressor and investigate the cause.
5.
The compressor is now controlled by the air system pressure switch. At 5 minute intervals (adjustable) the drain solenoid valves are de-energised for 2 seconds (adjustable) to drain the separator bowls. The drainage interval and duration should be adjusted to suit climatic conditions, e.g. high humidity – short intervals and longer duration.
6.
On air system charged signal, the solenoid valves are de-energised to open to drain and unload the compressor until a signal is received:
7.
on recharge signal the solenoid valves are energised to close causing the compressor to charge the system
if the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the compressor stops leaving the solenoid valves open. On recharge signal the compressor starts.
On pressing the STOP button the solenoid drain valves are de-energised to open to drain the separators, the compressor stops off load. With a 2 minutes delay water shut off valve Y5 (optional) is de-energised to close.
Page 2-2
CHAPTER 2 OPERATING PROCEDURE
Original 2011-06-21
2.3.2
Normal Running with Compressor Control by Customer (based on HATLAPA Proposal for Wiring Diagrams)
1.
Energise the starter panel by operating the main isolator. Set mode switch S1 to AUTO. Set local/remote switch S2 as required. Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied). Press RESET push button.
2.
On pressing the START button, the compressor runs off-load for a short time (approximately 15…20 seconds) after which the drain/unloading solenoid valves are energised to close to charge the system. (Note that the compressor will only go on load if the system is not fully charged.)
3.
The compressor is now controlled by the air system pressure switch. At 5 minute intervals (adjustable) the drain solenoid valves are de-energised for 2 seconds (adjustable) to drain the separator bowls. The drainage interval and duration should be adjusted to suit climatic conditions, e.g. high humidity – short intervals and longer duration.
4.
On air system charged signal, the solenoid valves are de-energised to open to drain and unload the compressor until a signal is received:
on recharge signal the solenoid valves are energised to close causing the compressor to charge the system
if the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the compressor stops leaving the solenoid valves open. On recharge signal the compressor starts as for pressing the START button (and lamp goes out).
5.
On pressing the STOP button (or switching S1 to OFF or MAN) the solenoid valves are de-energised to open to drain the separator bowls, the compressor continues to run-on unloaded for 5 minutes (adjustable) before stopping. Pressing the START button during this cycle brings the compressor back on line to recharge the system.
6.
If the START button is pressed while the air system is fully charged, the compressor starts as described in 2. The compressor is then controlled by the air system pressure switch as in 4. and 5. above.
Page 2-3
CHAPTER 2 OPERATING PROCEDURE
2.4
MANUAL MODE RUNNING
2.4.1
Manual Running with HATLAPA Compressor Control
1.
Energise the starter panel by operating the main isolator. Set LOCAL/REMOTE switch to LOCAL..
2.
Press the MAN button. The compressor will start and run in this mode only if the high air temperature switch and oil level switch are not indicating alarm. The emergency stop button and motor overloads will still stop and unload the compressor. Under Manual mode the air system pressure switch will not stop the compressor!
Original 2011-06-21
2.4.2
Manual Running with Compressor Control by Customer (based on HATLAPA Proposal for Wiring Diagrams)
1.
Energise the starter panel by operating the main isolator. Set mode switch S1 to MAN. Set local/remote switch S2 as required. Set drain switch S3 to AUTO (S3 not fitted if hand drain valves supplied). Press RESET push button.
2.
On pressing the START button, the compressor will start and run in this mode overriding the low oil level and high air temperature shutdown devices. The emergency stop button and motor thermal overloads will still stop and unload the machine.
Compressor and air system protection during manual mode running are given by first and final stage air and water jacket safety valves and any other safety device fitted to the installed system. Starting, running and run down cycles are as for normal (automatic) running as described with the exception of the following:
oil level switch overridden.
high air temperature switch overridden.
remote start/stop function disabled.
Page 2-4
CHAPTER 2 OPERATING PROCEDURE
2.5
GENERAL
Individual volt-free change-over contacts and control panel mounted indicator lamps are provided as listed below:
compressor running
water pump running (if fitted)
low oil level shutdown
low oil level warning (if fitted)
high air temperature shutdown
high air temperature warning (if fitted)
compressor motor overload
water pump motor overload (if fitted)
Original 2011-06-21
Terminals are provided for a remote emergency stop push-button (if required). Warning (pre-alarm) oil level and high air temperature indicator lamps and volt free contacts, are an optional extra and are not fitted as standard.
Page 2-5
Original 2011-06-21
CHAPTER 3 MAINTENANCE
3
MAINTENANCE DANGER Before proceeding with maintenance or overhaul, the compressor must be stopped and isolated mechanically and electrically, and visible warning notices displayed. When working on water and/or air passages the compressor must be vented of all pressurised air and drained of cooling water. Viton o-rings and seals are fitted to this compressor. When viton is subjected to excessive temperatures (above 400 °C) it decomposes and can cause serious injury. When maintaining the equipment protective gloves should be worn.
3.1
GENERAL
Original 2011-06-21
Routine maintenance of the compressor should be carried out at the intervals listed in the Maintenance Schedule under normal conditions. However, the optimum period between servicing will depend upon the operating conditions. Before re-assembly, clean all parts with a suitable cleaning fluid and examine for wear, corrosion, cracks, distortion, or any other damage. Renew as necessary. Refer to the wear tolerances given in Chapter 4 TECHNICAL DATA. When re-assembling compressor components, renew all joints, gaskets, and O-rings seals. Great care must be taken to ensure that they are not damaged. Item numbers in the text refer to items on the Sectional Arrangement Drawings which are at the end of this manual. When using Loctite products for nut and screw retention note the following. The shelf life of Loctite is one year at a storage temperature of 6…22°C. All components to be fixed with Loctite should be thoroughly degreased using a Loctite activator. If cured Loctite is present in a tapped hole or external thread, discard the bolt or nut, or clean with a die and tap internal threads. All fasteners must be torqued to their specified level (see Table 3.1). After any servicing has been carried out, refer to Chapter 1.3COMMISSIONING before restarting.
Table 3.1
Standard
Fastener Torque Settings (unlubricated)
M6
M8
M10
M12
6 Nm
16 Nm
32 Nm
70 Nm
170 Nm
70 Nm
170 Nm
Cooler - Header (94) Gudgeon Pin/Piston fasteners (41, 65) Flywheel Cone Clamping screws (9) Coupling Pins (G4)
6 Nm
20 Nm
35 Nm
35 Nm
71 Nm
M14
140 Nm
M16
220 Nm
M20
500 Nm
Page 3-1
CHAPTER 3 MAINTENANCE
Maintenance Schedule
Original 2011-06-21
Time required for operation.
Every 5 years or 5000 hours.
Every 2 years or 2000 hours
Normal Operating Services
Daily or every 10 hours
At 50 hours
Daily or every 10 hours
Commissioning Period
Every 6 months or 500 hours.
Table 3.2
1.
Check oil level on dipstick.
2.
Drain and refill lubricating oil.
3.
Replace air inlet filter.
4.
Clean and inspect delivery line nonreturn valve.
30 mins
5.
Clean first & second stage valves. Renew any parts or complete valve as necessary. Renew seals/ O-rings.
4 hours
6.
Renew first & second stage valves. Renew seals/O-rings.
2 hours
7.
Check settings of all pressure safety valves, replace as necessary.
1 hour
8.
Remove inter/after coolers and clean.
4 hours
9.
Dismantle and measure moving parts for wear.
6 hours
10. Check condition of diffuser in 1st and 2nd stage separators
2 hours
11. Replace bearings
12 hours
A complete overhaul, including bearing replacement, is recommended every 5 years or 5,000 running hours. After a major service, follow the commissioning procedure detailed in chapter 1 INSTALLATION.
Page 3-2
CHAPTER 3 MAINTENANCE
3.2
MAINTENANCE INSTRUCTIONS
3.2.1
Lubrication Oil Checking
Refer to chapter 4 TECHNICAL DATA for oil capacities and recommended lubricants. 7.
Remove filler/dipstick (161) and check oil level.
8.
Fill/top up crankcase oil level if necessary with lubricating oil to full level on dipstick.
Periodically examine oil in crankcase and ensure that it is not contaminated with condensate. If the oil is emulsified (creamy in colour) it must be changed and the crankcase cleaned. To minimise the risk of emulsification use a recommended oil, ensure that the compressor is not overcooled by fitting a water shut off valve, and maintaining a 15 °C cooling water temperature rise across the machine. If moisture forms without emulsification, as two separate liquids, condensate may be drained from below the oil. The oil level should then be restored with fresh oil. Crankcase oil contamination is often accompanied by an increase in sump oil level, due to oil being supported by condensate fluid.
Original 2011-06-21
3.2.2
Lubrication Oil Changing
1.
Remove the drain plug (160) after the compressor has been running, whilst the oil is still warm and drain oil from the compressor. Dispose of used oil in accordance with local regulations.
2.
Clean the magnetic portion of plug before replacing into crankcase.
3.
Remove and clean oil level switch, see chapter 3.2.23 Oil Level Switch Remove/Clean/Replace. Reassemble oil level switch.
4.
Refill with fresh oil.
3.2.3
Air Suction Filter/Silencer Removal and Replacement
1.
Before removing the air filter silencer assembly, clean the outside of the filter body.
2.
Remove wing nut (F8 – V105/150) (168 – V200/250/375) on top of filter assembly.
3.
Remove top cover. On V105/V150 only, remove wing nut (F4).
4.
Remove filter body complete, with inlet resonator, hose clip, ‘O’ ring, and element.
5.
Unless filter/silencer assembly is to be re-assembled immediately, cover valve cage aperture.
6.
Renew element if necessary.
7.
Reassemble filter (Hand tighten only).
Page 3-3
CHAPTER 3 MAINTENANCE
3.2.4
First Stage Concentric Valve Removal/Servicing/Replacement
Removal Remove air suction filter silencer assembly from valve cage as detailed in chapter 3.2.3 Air Suction Filter/Silencer Removal and Replacement.
2.
Remove studding (165) and the four nuts (56) and washers (57) from the top of the valve cage (45).
3.
Release crankcase breather hose (32) from the hose connector (46) (not applicable on V375).
4.
Remove valve cage (45) complete with concentric valve (50) using M12 or M16 screws (not supplied) in the two tapped jacking holes. (On V375 use the eyebolt fitted).
5.
Cover open bores on cylinder and breather hose.
6.
Remove stud connector (54) and washer (55) from concentric valve (A1) central stud.
7.
Remove dome nuts (A2) and joint washers (53) from concentric valve outer side.
8.
Separate concentric valve (50) from valve cage (45).
Original 2011-06-21
1.
Page 3-4
Original 2011-06-21
CHAPTER 3 MAINTENANCE
Figure 3.1
First Stage Concentric Valve V105/150
Page 3-5
Original 2011-06-21
CHAPTER 3 MAINTENANCE
* *
*
Figure 3.2 Page 3-6
First Stage Concentric Valve V200/250
Original 2011-06-21
CHAPTER 3 MAINTENANCE
* *
*
Figure 3.3
First Stage Concentric Valve V375 Page 3-7
CHAPTER 3 MAINTENANCE
Dismantling (See Figure 3.1, Figure 3.2, Figure 3.3) PAY ATTENTION A valve assembly must not be held directly between vice jaws. Never hammer a spanner when loosening or tightening the valve nuts.
1.
Unscrew and remove nut (9 – V105/150) (10 – V200/250/375). When dismantling valve, note the method and order of renewal of each valve component. Refer to the illustration of the valve assembly to ensure that the components are rebuilt in their correct order.
2.
Clean all components thoroughly. Remove grease and carbon deposits with a soft brush using a hot water and soda solution. Care must be taken during the cleaning operation as any surface scratch may cause leakage and ultimately a breakage.
3.
Inspect each component. If any items appear defective, worn or damaged, replace with new parts.
Original 2011-06-21
Re-assembly (See Figure 3.1, Figure 3.2, Figure 3.3) 1.
Assemble the valve components on the lower delivery valve seat (2) and studs. PAY ATTENTION Ensure that the components are correctly positioned on their locating pins.
2.
Fit the upper suction valve seat (1) in position and fit nut (9 – V105/150) (10 – V200/250/375).
3.
Check that the valve functions correctly and that plate movement exists. Extreme care must be taken to ensure that the valve is not scraped or damaged in this operation.
Page 3-8
CHAPTER 3 MAINTENANCE Valve Replacement 1.
Renew ‘O’ rings (48) fitted to valve cage (45) and ‘O’ rings (51, 52) fitted to concentric valve (50).
2.
Assemble concentric valve to valve cage and loosely fit dome nuts (A2), joint washers (53), stud connector (54) and washer (55) to concentric valve studs.
3.
Fit valve cage and valve to cylinder (39) and re-connect crankcase breather hose (32) to the hose connector (46). V375 only. Refit the valve with the fitting eye uppermost ensuring that the dowel pin aligns with the mating hole in the cylinder.
4.
Tighten stud connector (54) and dome nuts (A2).
5.
Fit washers (56) and nuts (55) to studs (42) and tighten nuts. Refer to Table 3.1 for tightening torques.
6.
Fit studding (165) to stud connector and tighten.
7.
Reassemble suction filter silencer assembly to valve cage as described in chapter 3.2.3.
3.2.5
Final Stage Concentric Valve Removal/Servicing/Replacement
Original 2011-06-21
Removal 1.
Remove the four nuts (79) and washers (80) from the top of the valve cage.
2.
Remove valve cage (70) complete with concentric valve (75) using screws (not supplied) in the two tapped jacking holes.
3.
Cover bores on cylinder.
4.
Remove dome nuts (B2) and joint washers (78) from concentric valve studs.
5.
Separate concentric valve (75) from valve cage (70).
Page 3-9
Original 2011-06-21
CHAPTER 3 MAINTENANCE
Figure 3.4 Page 3-10
Final Stage Concentric Valve V105/150
Original 2011-06-21
CHAPTER 3 MAINTENANCE
*
*
Figure 3.5
Final Stage Concentric Valve V200/250
Page 3-11
Original 2011-06-21
CHAPTER 3 MAINTENANCE
*
*
Figure 3.6
Page 3-12
Final Stage Concentric Valve V375
CHAPTER 3 MAINTENANCE Dismantling (See Figure 3.4, Figure 3.5, Figure 3.6) 1.
Unscrew the three socket head cap screws (8 – V105/150) (13 – V200/250) (not applicable on V375). Unscrew the centre nut (9 - V105/150) (10 - V200/250/V375). When dismantling valve, note the method and order of renewal of each valve component. Refer to the illustration of the valve assembly to ensure that the components are rebuilt in their correct order.
2.
Clean all components thoroughly, remove grease and carbon deposits with a soft brush using a hot water and soda solution. Care must be taken during the cleaning operation as any surface scratch may cause leakage and ultimately a breakage.
3.
Inspect each component. If any items appear defective, worn or damaged, replace with new parts.
Original 2011-06-21
Re-assembly (See Figure 3.4, Figure 3.5, Figure 3.6) 1.
Assemble the valve components on the lower delivery valve seat (2) and studs and ensure that the components are correctly positioned on their locating pins.
2.
Fit the upper suction valve seat (1) in position. Fit the three socket head cap screws (8 – V105/150) (13 – V200/250) (not V375).
3.
Check that the valve functions correctly and that plate movement exists. Extreme care must be taken to ensure that the valve is not scraped or damaged in this operation.
Valve Replacement 1.
Renew ‘O’ rings (71, 72) fitted to valve cage (70) and ‘O’ rings (76, 77) fitted to concentric valve (75).
2.
Assemble concentric valve (75) to valve cage (70) and tighten dome nuts (B2) and joint washers (78) to the valve studs.
3.
Fit valve cage and concentric valve assembly to cylinder (66).
4.
Fit 4 off nuts (79) and bright washers (80) to studs (67) and tighten nuts. Refer to Table 3.1 for torque.
3.2.6
First Stage Cylinder and Piston Removal PAY ATTENTION When removing 1st stage cylinders, it can be difficult to prevent the piston from dropping out of the cylinder bore and falling onto the edge of the crankcase. To ensure that this does not occur, strategically place an appropriate cushioning material immediately the cylinder becomes clear of the crankcase so that if the piston does fall no damage can result.
1.
Drain compressor of all cooling water.
2.
Remove water outlet connection from cylinder.
3.
Remove first stage concentric valve and cage assembly from cylinder as detailed in chapter 3.2.4.
4.
Remove guard (170) from crankcase. If final stage cylinder has been removed take precautions to protect exposed components in the crankcase.
5.
Using a bar turn over the compressor until the first stage piston (35) is at the top of its stroke in the cylinder.
6.
Remove the bolts (94, 101, 106) and washers (95, 102, 107) securing the cooler header (93) to the cylinder. Page 3-13
CHAPTER 3 MAINTENANCE 7.
Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting tackle.
8.
Using lifting tackle and by striking the cylinder gently with a soft headed mallet break the seals between the cylinder and crankcase, cylinder and cooler header.
9.
Lift and guide the cylinder off the piston assembly take care to prevent damage to the piston assembly as it becomes free from the cylinder. CAUTION With cylinder removed protect personnel from injury from the exposed studs (43) at all times until the cylinder is re-assembled.
10.
Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of compressor.
11.
Slacken the locknuts (42) which secure the cap head screws, from the underside of the piston. Remove the 2 cap head screws (41) from the underside of the piston (35) which lock the gudgeon pin (40) in position.
Original 2011-06-21
PAY ATTENTION Take care when the pin is free to prevent damage of rod striking piston internals and crankcase.
12.
Push gudgeon pin out of piston and connecting rod (15). Remove piston and pin.
13.
Cover the crankcase aperture.
14.
Examine removed components replacing worn/damaged parts as necessary. For wear allowances see chapter 4 TECHNICAL DATA. If required connecting rod small end needle roller bearing (17) may be removed and refitted without dismantling compressor any further. Chapter 3.2.15 refers.
Page 3-14
CHAPTER 3 MAINTENANCE
3.2.7 1.
First Stage Cylinder and Piston Reassembly Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal the cylinder to the crankcase.
Original 2011-06-21
The minimum amount of Loctite flange sealant number 573 required is 50 millilitres. 2.
Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease free.
3.
Remove all traces of gasketing on joint faces of cylinder to cooler header and ensure faces are grease free. Do not smooth joint faces. Do not use emery cloth or a metal scraper to abrade or clean them. It is recommended that a chemical such as Loctite ‘Chisel’ is used in conjunction with hand brushing with a wire brush.
4.
If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.175/0.300 mm (V105/150), 0.20/0.33 mm (V200/250) or 0.26/0.39 mm (V375). Ensure rings are fitted as follows to the piston. a.
Barrel faced ring (38) top groove.
b.
Taper faced ring (37) second groove (this ring can be readily identified against the barrel faced ring by the internal chamfer on the taper faced ring.)
c.
Both rings must be fitted with the face marked “Top” facing towards the piston crown.
d.
S.O.C. ring (36) bottom groove.
5.
Align adjacent piston ring gaps on piston at 180° to each other.
6.
Ensure threaded holes in piston are clean. Fit lock nuts (42) to cap head screws (41) and ensure that it is fully onto the screw (within 1…2 mm of the screw head). Screw cap head screws and lock nuts into the threaded holes in the piston such that the end of screw is approximately 1 mm from gudgeon pin bore. PAY ATTENTION Care must be taken when passing the ring pack across the cut-out in the cylinder location spigot. Ring gaps must not be in this area.
7.
Fit piston into cylinder bore far enough to enclose the ring pack but to leave the gudgeon pin bore accessible. PAY ATTENTION Exercise caution so that the piston does not drop out of the cylinder.
8.
Using suitable lifting tackle connected to the cylinder lifting eye align cylinder assembly on to studs.
9.
Lower cylinder/piston assembly gradually above the con rod and align the gudgeon pin bore of the piston with the small end of the con rod. Lightly oil the small end roller bearing. Without oiling, fit gudgeon pin (40) to piston, ensuring marks at piston and gudgeon pin are towards front of compressor, with marks aligned to each other.
10.
Ensure that locknuts (42) are loose and have not been clamped by cap head screws (41). Tighten cap head screws (41) - see Table 3.1 for Torques. Fasten locknut.
11.
Lightly oil piston skirt and cylinder bore. Introduce oil into the small end roller bearing. Page 3-15
CHAPTER 3 MAINTENANCE 12.
Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.
13.
Lower cylinder into contact with crankcase
14.
Fit new gasket (100) between cylinder and cooler header. Do not grease gasket or faces.
15.
Fit bolts (101) and bright washers (102) through cooler header into cylinder and tighten finger tight.
16.
Fit concentric valve and cage assembly to cylinder as detailed in chapter 3.2.4.
17.
Torque bolts (101) to the appropriate level. Refer to Table 3.1 for torque.
18.
Reconnect water outlet pipework/hose to cylinder.
19.
Refit guard (170) to crankcase.
Original 2011-06-21
3.2.8
Final Stage Cylinder and Piston Removal
1.
Drain compressor of all cooling water.
2.
Remove water inlet connection from cylinder.
3.
Remove concentric valve and valve cage assembly from cylinder as detailed in chapter 3.2.5.
4.
Remove guard (170) from crankcase. If first stage cylinder has been removed, take precautions to protect exposed components in the crankcase.
5.
Using a bar turn over the compressor until the second stage piston (60) is at the top of its stroke in the cylinder.
6.
Remove the 2 screws (117) and washers (118) securing the separator header to the cylinder. Remove the separator from the cooler box by removing the bolts (112) and stud (113) securing the separator header (E1) to the cooler box (C1).
7.
Remove the bolts (106) and washers (107) securing the cooler header (93) to the cylinder.
8.
Fit an eyebolt (not supplied) into the tapping in the top of the cylinder and connect to suitable lifting tackle.
9.
Using lifting tackle and by striking the cylinder gently with a soft headed mallet, break the seals between the cylinder and crankcase, cylinder and separator, cylinder and cooler header.
10.
Lift and guide the cylinder off the piston assembly taking adequate precautions to prevent damage to the piston assembly as it becomes free from the cylinder. CAUTION With cylinder removed protect personnel from injury from the exposed studs (67) at all times until the cylinder is re-assembled to crankcase.
11.
Identify with non-destructive marker, orientation of piston side and gudgeon pin end towards front of compressor.
12.
Only V200/V250/375: Remove the two socket set screws (59) saving the socket set screws (65) from the underside of the piston (60). Remove the two socket set screws (65) from the underside of the piston (60) which lock the gudgeon pin (64) in position.
Page 3-16
CHAPTER 3 MAINTENANCE PAY ATTENTION Take care when the pin is free to prevent damage of rod striking piston internals and crankcase.
13.
Push gudgeon pin out of piston and connecting rod (19). Remove piston and gudgeon pin.
14.
Cover the crankcase aperture.
15.
Examine removed components replacing worn/damaged parts as appropriate. For wear allowances see chapter 4 TECHNICAL DATA. If required connecting rod small end needle roller bearing (21) may be removed and refitted without dismantling compressor any further. Chapter 3.2.15 refers.
3.2.9
Original 2011-06-21
1.
Final Stage Cylinder and Piston Reassembly Before commencing reassembly ensure that sufficient Loctite sealant and retainer is available to seal the cylinder to the crankcase and retain the hexagon socket set screws in the piston. a.
Minimum amount Loctite flange sealant 573 required is 50 millilitres.
b.
Minimum amount Loctite nutlock 243 required is 10 millilitres.
2.
Remove all traces of sealant on joint faces of cylinder to crankcase and ensure surfaces are grease free.
3.
Remove all traces of gasketing on joint faces of cylinder to cooler header, cylinder to separator and separator to cooler box, and ensure surfaces are grease free. Do not smooth joint faces. Do not use emery cloth or a metal scraper to abrade or clean them. It is recommended that a chemical such as Loctite ‘Chisel’ is used in conjunction with hand brushing with a wire brush.
4.
Remove Loctite from threads in piston using a tap. If grub screws are to be re-used clean the threads using a die.
5.
If new piston rings are being fitted gap rings to cylinder to a closed gap of 0.075/0.200 mm (V105/150), 0.10/0.23 mm (V200/250) or 0.11/0.24 mm (V375). Ensure rings are fitted as follows to the piston.
6.
a.
Barrel faced ring (63) top groove.
b.
Taper faced ring (62) second groove (this ring can be easily identified against the barrel faced ring by the internal chamfer on the taper faced ring.)
c.
Both rings are to be fitted with the face marked “Top” facing towards the piston crown.
d.
S.O.C. ring (61) bottom groove.
For V105/150 Thoroughly clean tapped holes in piston and grub screws (65) with Loctite Activator 7471. Coat grub screws with Loctite 243 liberally. Screw grub screws into the threaded holes in the piston. Screw through until tip of grub screw is approximately 1 mm from gudgeon pin bore. Introduce oil into 2nd stage small end bearing. Align the gudgeon pin bore of piston with the small end of the con rod. Without oiling, fit gudgeon pin (64) to piston, ensuring marks at piston and gudgeon pin are towards front of compressor, with marks aligned to each other. Tighten grub screws (65), see Table 3.1 for tightening torque. For V200/V250/V375 Thoroughly clean tapped holes in piston and grub screws (65) with Loctite Activator 7471. Screw grub screws into the threaded holes in the piston. Screw through until tip of grub screw is approximately 1 mm from gudgeon pin bore. Page 3-17
CHAPTER 3 MAINTENANCE Introduce oil into 2nd stage small end bearing. Align the gudgeon pin bore of piston with the small end of the con rod. Without oiling, fit gudgeon pin (64) to piston, ensuring marks at piston and gudgeon pin are towards front of compressor, with marks aligned to each other. Tighten grub screws (65), see Table 3.1 for tightening torque.
Original 2011-06-21
Coat grub screws (59) with Loctite 243 liberally. Screw grub screws into the threaded holes in the piston for locking grub screws (65), see Table 3.1 for tightening torque. 7.
Align adjacent piston ring gaps on piston at 180° to each other.
8.
Using suitable lifting tackle align cylinder over studs (67) and onto piston. Compressing piston rings to guide the cylinder over piston.
9.
Coat underside of cylinder (joint face to crankcase) with Loctite flange sealant 573.
10.
Lower cylinder into contact with crankcase.
11.
Fit new gasket (105) between cylinder and cooler header (93). Do not grease gasket or joint face. Fit bolts (106) and bright washers (107) through cooler header into cylinder and tighten finger tight.
12.
Fit new gasket gasket (111) between separator header (E1) and cooler box. Do not grease gasket or joint face. Fit bolts (112) and stud bolts (113) along with bright washers (114) through separator header into cooler box, tighten finger tight.
13.
Fit new gasket (116) between cylinder and separator header (E1). Do not grease gasket or joint face. Fit screws (117) and washers (118) through separator header into cylinder, tighten finger tight.
14.
Adjust gap between final stage cylinder and cooler header using feeler gauges, to give the best parallel flange seal. This can be achieved by rotating the cylinder to give an equal gap each end.
15.
Fit concentric valve and cage assembly to cylinder as detailed in chapter 3.2.5.
16.
Torque bolts (106, 112, 113, 117) to the appropriate level. Refer to Table 3.1 for torque.
17.
Reconnect water inlet connection to cylinder.
18.
Refit guard (170) to crankcase.
3.2.10
Cooler Tubenest and Header Removal
1.
Drain compressor of all cooling water.
2.
Remove gauge pipes.
3.
Remove the bolts (101) and washers (102) securing the cooler header (93) to the first stage cylinder (39).
4.
Remove the bolts (106) and washers (107) securing the cooler header to the second stage cylinder. Fit 2 x M12 eyebolts (V200/250/V375 only, not supplied) in the top of the cooler header and connect to suitable lifting tackle.
5.
Remove the remaining bolts (94) securing the cooler header.
6.
Remove cooler header (93) from tubenest (91) and cylinders by gently tapping with a soft headed mallet if necessary to separate the gaskets between the cooler header and tubenest, header and first stage cylinder, header and second stage cylinder.
7.
Remove tubenest (91) from cooler box by gently tapping tubeplate with a soft headed mallet to separate the gasket (90) between the tubenest and cooler box.
3.2.11 1.
Tubenest Clean/Examine/Replace Remove tubenest assembly.
Page 3-18
CHAPTER 3 MAINTENANCE PAY ATTENTION Take care not to damage the cooler tube surface. 2.
Clean the outside of the cooler tubes to remove any scale or sediment.
3.
Clean the internal faces of the cooler box to remove any scale or sediment.
4.
Chemically clean the tube internals using ‘ARDROX’ or similar chemical cleaner to solve any scale.
5.
Examine tubes for signs of damage und reduction in tube wall thickness. If there is any doubt in the condition of the tubenest HATLAPA recommend replacement of the tubenest assembly.
Original 2011-06-21
Faulty cooler tubes that are part of a ‘U’ tube nest formation cannot be removed individually, the complete tubenest assembly must be replaced.
Page 3-19
CHAPTER 3 MAINTENANCE 3.2.12 Cooler Tubenest and Header Assembly to Compressor
Original 2011-06-21
The following procedure assumes that the first and final stage cylinder assemblies have been assembled to the crankcase.
1.
To assist alignment of gaskets, tubenest and header insert 2 threaded bolts (not supplied) into the top 2 outermost tapped holes in the cooler box front face.
2.
Ensure all the joint faces are clean and grease free. Do not smooth joint faces.
3.
Fit cooler box gasket (90) over threaded bolts. Do not grease gasket.
4.
Fit tubenest (91) over bolts.
5.
Fit tubenest gasket (92) over bolts. Do not grease gasket.
6.
Fit cooler header (93) over bolts.
7.
Insert gasket (100) between header and first stage cylinder, loosely fit the bolts (101) and washers (102) through the header. Do not grease gasket.
8.
Insert gasket (105) between header and final stage cylinder, loosely fit the 3 bolts (106) and washers (107) through the header. Do not grease gasket.
9.
Loosely fit all but 2 of the bolts (94) and washers (95) through the cooler header and tubenest to the cooler box.
10.
Remove the lengths of studding used for guidance and insert the remaining 2 bolts and washers.
11.
Tighten the bolts (101, 106) cooler header to cylinders. See Table 3.1 for tightening torques.
Figure 3.7
Cooler Header
12.
Tighten the bolts (94) in the cooler header progressively in numerical order as shown until they are torqued correctly. Refer to Figure 3.7 for order and Table 3.1 for tightening torques.
13.
Re-connect the gauge pipes.
Page 3-20
CHAPTER 3 MAINTENANCE
3.2.13
Cooler box end cover
Removal 14.
Remove cooler drain plug (C6).
15.
Remove the bolts (C4) and washers (C5) and release cooler box end cover (C2).
16.
Clean and remove all traces of gasket (C3) from joint faces on end cover and cooler box. Ensure joint faces are grease/oil free. Do not smooth joint faces.
Re-assembly 1.
Assemble gasket (C3) between cover and cooler box. Note: Do not grease gasket or joint faces.
2.
Secure cover to cooler box with bolts (C4) and plain washers (C5). See Table 3.1 for tightening torques.
3.
Fit cooler drain plug (C6) to cover.
Original 2011-06-21
3.2.14
Connecting Rod Removal
1.
Drain compressor of cooling water.
2.
Drain oil and dispose of in accordance with local regulations.
3.
Remove the first and final stage cylinders and pistons as detailed in chapter 3.2.6. and 3.2.8.
4.
Remove the screws (157) and washers (158) securing the crankcase inspection cover (155).
5.
Using a soft headed mallet gently tap the side faces of the crankcase inspection cover to break its seal with the crankcase. Remove the cover.
6.
Remove screw (23), tab washer (24) and retaining washer (22).
7.
Using a puller over the second stage connecting rod (19) big end withdraw rod off crankshaft complete with cylindrical roller (big end) bearing (20).
8.
Remove spacer (18) from crankshaft.
9.
Using a puller over the first stage connecting rod (15) big end withdraw rod off crankshaft complete with cylindrical roller (big end) bearing (16).
3.2.15
Bearing Removal and Reassembly to Connecting Rods When the connecting rods have been removed both the big and small end bearings should be renewed. Gudgeon pins must always be replaced at the same time as the small end bearings. If the existing big end bearings are undamaged and are to be refitted, the inner race, rolls and bearing cage must be refitted in the original position.
On a V200/250/375 compressor only, the bearing is supplied as a matched pair and must be assembled as such.
1.
Press out the big and small end bearings from the connecting rod.
2.
Clean big and small end bores of connecting rod, ensure all traces of old retaining compound and any oil or moisture is removed from the big end bore.
Page 3-21
CHAPTER 3 MAINTENANCE 3.
V105 and V150 Degrease con rod big end bores (15, 19) and outer race of big end roller bearings (16, 20). Clean with Loctite Cleaner 7200. PAY ATTENTION Ensure no Loctite enters the bearing. Spread Loctite 603 over the outer race of the big end bearing (16, 20). Press bearings into con rods. See Figure 3.8 for the correct orientation of the circlip side of the big end bearing to the dipper. PAY ATTENTION Ensure that the lubrication hole in the small end roller bearing is in line with the lubrication hole in the con rod. Press small end roller bearings (17, 21) into lightly oiled small end bores of con rods. V200 and V250
Original 2011-06-21
Degrease con rod big end bores (15, 19) and outer race of big end roller bearings (16, 20). Clean with Loctite Cleaner 7200. Heat the con rod to 80 °C. PAY ATTENTION Ensure no Loctite enters the bearing. Spread Loctite 603 over the outer race of the big end bearing (16, 20). Position the con rod on a flat surface, ensuring the big end bearings will be fitted according to the orientation shown on Figure 3.8. Spray the Big End bore with Loctite Activator 7471. CAUTION The con rod is hot. Wear protective gloves!
Push the bearing in to the bore by hand to ensure that the bearing has located correctly. PAY ATTENTION Ensure that the lubrication hole in the small end roller bearing is in line with the lubrication hole in the con rod. When the con rod has sufficiently cooled, to clamp the big end bearing, push the small end bearings (17 and 21; note: The small end bearing consists of two bearings matched) into the con rod. When the mounted con rod is cool, use (compressor) lubricating oil to protect both the big and small end bearings. Place assembly in a suitable sealed bag for storage. Do not fit the assembly to the compressor/crankshaft for a further 24 hours.
Page 3-22
CHAPTER 3 MAINTENANCE V375 Use Con Rod 3413100301 (15) for the first stage assembly and 3413100302 (19) for the second stage. Degrease con rod big end bores (15, 19) and outer race of big end roller bearings (16, 20). Clean with Loctite Cleaner 7200. Heat the con rod to 80°C. PAY ATTENTION Ensure no Loctite enters the bearing. Spread Loctite 603 over the outer race of the big end bearing (16, 20). For the First Stage Con Rod: Position the Con Rod on a flat surface with the shoulder face downward. Spray the Big End bore with Loctite Activator 7471. Position the Big End Bearing in the con rod with the circlip facing up (The circlip should be on the opposite side to the con rod shoulder.) CAUTION
Original 2011-06-21
The con rod is hot. Wear protective gloves!
Push the bearing in to the bore by hand to ensure that the bearing has located correctly. For the Second Stage Con Rod: Position the Con Rod on a flat surface with the shoulder face downward. Spray the Big End bore with Loctite Activator 7471. Position the Big End Bearing in the con rod with the circlip facing down (The circlip should be on the same side to the con rod shoulder.) CAUTION The con rod is hot. Wear protective gloves!
Push the bearing in to the bore by hand to ensure that the bearing has located correctly. PAY ATTENTION Ensure that the lubrication hole in the small end roller bearing is in line with the lubrication hole in the con rod. When the con rod has sufficiently cooled, to clamp the big end bearing, push the small end bearings (17 and 21; note: The small end bearing consists of two bearings matched) into the con rod. When the mounted con rod is cool, use (compressor) lubricating oil to protect both the big and small end bearings. Place assembly in a suitable sealed bag for storage. Do not fit the assembly to the compressor/crankshaft for a further 24 hours.
Page 3-23
Original 2011-06-21
CHAPTER 3 MAINTENANCE
Figure 3.8
Page 3-24
V105/V150 Fitting and Orientation of Big End Bearings/Con Rods
Original 2011-06-21
CHAPTER 3 MAINTENANCE
Figure 3.9
V200/V250 Fitting and Orientation of Big End Bearings/Con Rods
Page 3-25
Original 2011-06-21
CHAPTER 3 MAINTENANCE
Figure 3.10
Page 3-26
V375 Big End Bearings Fitting & Con Rod Orientation in the Crankcase
CHAPTER 3 MAINTENANCE 3.2.16
Connecting Rod Reassembly to Compressor
Original 2011-06-21
When the connecting rod has been fitted, it must be free to slide through the bearing range of side clearance, from shoulder to circlip. If this is not easily achieved the connecting rod must be removed, the bearing pressed out and the bore cleaned thoroughly prior to re-assembly.
1.
Remove pin (3). Screw a length of M16x2x185 mm long studding (not supplied) into the tapped hole in the crankshaft pintle.
2.
Arrange the first stage connecting rod (15) with the cast dipper rod pointing downwards and the small end through the crankcase aperture for the first stage cylinder. Align the big end bearing onto the crankshaft pintle.
3.
Using the retaining washer (22) and an M16 nut (not supplied) wind the nut onto the studding to push the big end bearing onto the pintle until the washer is flush with pintle end. Remove washer and nut.
4.
Align spacer (18) with big end bearing on pintle and push bearing and spacer onto pintle with washer and nut as described above.
5.
Repeat the procedure for the final stage connecting rod (19) until the assembly is pushed solidly against the shoulder on the crankshaft. Remove studding, nut and retaining washer.
6.
Strike NEW dowel pin (3) into end of crankshaft. Position disc clamp (22) and NEW tab washer (24) and torque the bolt (23). See Table 3.1 for tightening torques. Fold tab washer to secure bolt.
7.
Assemble first stage cylinder components to compressor as detailed in chapter 3.2.7.
8.
Assemble second stage cylinder components to compressor as detailed in chapter 3.2.9.
9.
Fit drain plug (160) to crankcase.
10.
Clean joint faces of crankcase inspection cover (155) and crankcase. Apply Loctite flange sealant 574 to cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and washers (158) refitting the 2 cable clips (156) between washer and cover.
11.
Recommission compressor as detailed in chapter 1.3.
Page 3-27
CHAPTER 3 MAINTENANCE
3.2.17
V105, V150, V200, and V250 Drive Motor and Coupling For V375, see Chapter 3.2.18.
Original 2011-06-21
Removal from Compressor 1.
Isolate compressor.
2.
On compressors fitted with water circulating pumps only, drain the cooling water.
3.
Place a suitable support under the crankcase close to its connection to the drive motor.
4.
For compressors mounted on anti vibration mounts, remove the fasteners securing the mount under the drive motor to the ship's deck.
5.
For compressors fitted with a water circulation pump disconnect the water inlet connection to the pump and separate the male union nut on the connector on the pump.
6.
For compressors not mounted on anti-vibration mounts remove the fasteners securing the drive motor to the ship’s deck.
7.
Remove the bolts (191) and washers (192) securing the drive motor to the crankcase.
8.
Using suitable lifting tackle, lift and slide the drive motor complete with drive coupling element (G1), coupling hub (G3), hexagon socket cap screws (G4) out of the crankcase.
9.
If required, remove drive coupling element (G1) from coupling hub (G3) by removing the hexagon cap screws (G4).
10.
If required, remove drive pins (G2) from flywheel.
Assembly to Compressor Important notes for fitting Coupling If the coupling is supplied in a pre-assembled state, do not dismantle it, but fit it in this condition.
Figure 3.11
Coupling
1.
If removed, reassemble drive coupling pins (G2) to flywheel. Tighten coupling pins. Refer to Table 3.1 for torque.
2.
If removed, assemble drive coupling hub (G3) to drive motor shaft. The grub screw hole should be in motor direction. Lock the drive coupling hub using the grub screw.
3.
If removed, assemble drive element (G1) onto coupling hub (G3). Position the element with the side having the rubber free face of the axial aluminium inserts towards the flywheel.
Page 3-28
CHAPTER 3 MAINTENANCE PAY ATTENTION Ensure that on tightening the screws the aluminium bushes in the rubber part of the coupling element are not twisted. A small amount of grease should be applied under the head of the screw before fitting. Mount the coupling element on the coupling hub using the hexagon socket screws (G4). During this process, the drive element is pulled together radially and receives its pre-load. PAY ATTENTION The hexagon socket screws connecting the coupling element to the coupling hubs must be tightened to the torque stated. Tightening torques which are too low will cause damage to the coupling Tighten hexagon socket screws (G4) to torque settings – see Table 3.1. 4.
Lightly grease the coupling pins (G2). Using suitable lifting tackle to lift and slide the drive motor. Aligning the drive element with the coupling pins, carefully slide the drive element with light axial pressure onto the coupling pins and the motor flange location diameter onto the crankcase.
Original 2011-06-21
The rubber element is subjected to a little more radial compression by the socket bolts, and the preload is thus increased.
Figure 3.12
Gap between Coupling and Flywheel
To determine the coupling position on the motor shaft, measure the gap between coupling and flywheel. Gap between the coupling element (G1) and the flywheel shall be 1…2 mm, dimension "A". Adjust coupling hub on the motor shaft if necessary. 5.
Fit bolts (191) and spring washers (192) through drive motors flange onto crankcase.
6.
Fit holding down bolts securing drive motor or anti vibration mount to the ship's deck.
7.
On compressors fitted with water circulating pumps, reconnect union nut and male connector on the circulating pump and water inlet pipework.
8.
Remove support placed under crankcase.
9.
Recommission compressor as detailed in chapter 1.3. Page 3-29
CHAPTER 3 MAINTENANCE 3.2.18
V375 Drive Motor and Coupling
Figure 3.13
Coupling
Original 2011-06-21
Removal from Compressor 1.
Isolate compressor.
2.
On compressors fitted with water circulating pumps only, drain the cooling water.
3.
Place a suitable support under the crankcase close to its connection to the drive motor.
4.
For compressors mounted on anti vibration mounts, remove the fasteners securing the mount under the drive motor to the ship's deck.
5.
For compressors fitted with a water circulation pump disconnect the water inlet connection to the pump and separate the male union nut on the connector on the pump.
6.
For compressors not mounted on anti-vibration mounts remove the fasteners securing the drive motor to the ship’s deck.
7.
Remove the bolts (191) and washers (192) securing the drive motor to the crankcase.
8.
Using suitable lifting tackle, lift and slide the drive motor complete with coupling hub (G3) out of the crankcase.
9.
If required, remove drive coupling element (G1) from flywheel (8) by removing the M10 screws.
Assembly to Compressor 1.
If removed, assemble drive coupling element (G1) onto flywheel (8) with M10 screws.
2.
Using suitable lifting tackle to lift and slide the drive motor. Aligning the coupling hub with the drive coupling element, slide the coupling hub to engage into the drive coupling element and the motor flange location diameter onto the crankcase.
3.
Fit bolts (191) and spring washers (192) through drive motors flange onto crankcase.
4.
Fit holding down bolts securing drive motor or anti vibration mount to the ship's deck.
5.
On compressors fitted with water circulating pumps, reconnect union nut and male connector on the circulating pump and water inlet pipework.
6.
Remove support placed under crankcase.
7.
Recommission compressor as detailed in chapter 1.3.
Page 3-30
CHAPTER 3 MAINTENANCE
3.2.19
Flywheel and Drive End Oil Seals Removal from Compressor Note coupling pins (G2 – V105/150/200/250) and coupling drive element (G1 – V375) need not be removed from the flywheel.
1.
Remove drive motor and coupling as detailed in chapter 3.2.17 & 3.2.18.
2.
Slacken the 8 clamp screws on drive bush (9).
3.
Lay two lengths of 3mm mild steel or similar angle (not supplied) of maximum leg length 30mm on the 2 rails in the crankcase under the flywheel. Alternatively, a fixture can be supplied by HATLAPA. See Table 3.3 and Figure 3.14. Fixtures to Assist Flywheel Removal Machine
Fixture
V150
J31974
V200/250
J32032
V375
J32244
Original 2011-06-21
Table 3.3
Figure 3.14 4.
Location of Angle Steel on Crankcase Rails
Remove 2 clamp screws near each tapped hole in the drive bush. Screw 2 clamp screws into the tapped holes to jack the bush out of the flywheel. Remove drive bush and ease the flywheel onto the two pieces of angle (see Figure 3.14). Note tapped hole in periphery of flywheel is M12.
5.
Using suitable lifting tackle remove flywheel from crankcase.
6.
Remove the screw (157) and washer (158) securing the crankcase inspection cover (155).
7.
Using a soft headed mallet gently tap the side faces of the crankcase inspection cover (155) to break its seal with the crankcase. Remove cover.
8.
Wedge a piece of clean bar (not supplied), through the front of the compressor between the crankshaft balance weight and one of the cast webs behind the balance weight to prevent the crankshaft from rotating.
Page 3-31
CHAPTER 3 MAINTENANCE 9.
Remove grub screw (11). Using a c-spanner or similar tool (not supplied) unscrew the bearing adjustment sleeve (10). PAY ATTENTION Take care not to damage the housing bore in the crankcase.
10.
Lever lip seal (6) out of crankcase with an appropriate tool (not supplied).
11.
Remove ‘O’ ring (7) from crankshaft.
3.2.20 1.
Flywheel and Drive End Oil Seal Reassembly to Compressor Fit new radial oil seal (6) to crankcase. PAY ATTENTION
Original 2011-06-21
Take care in passing the 'O'-ring over the thread on the crankshaft. 2.
Fit new ‘O’ ring (7) onto crankshaft adjacent to bearing.
3.
Wedge a piece of clean bar (not supplied) through the front of the compressor between the balance weight and one of the cast webs to prevent the crankshaft from turning and carry out the following operation.
4.
Screw the bearing adjustment sleeve (10) onto the crankshaft and engage with the drive end bearing (5). Use a c-spanner or similar implement (not supplied).
5.
Rotate assembly of crankshaft through two complete turns and check, by trying to rock the assembly, that the taper roller main bearings are seated correctly (i.e. little or no up and down movement of any part of the assembly).
6.
Attach a dial test indicator to the end face of the crankcase resting on the end of the crankshaft.
7.
Push or pull the crankshaft balance weight and note the end float. An end float of between 0.05/0.10mm is required in the main bearings which is to be obtained as follows: a.
If the end float is greater than 0.10 mm, using a c-spanner as in operation 4, screw the bearing adjustment sleeve further onto the crankshaft until the required end float is achieved. Rotate the assembly of crankshaft before each reading through two complete revolutions to centralise the bearings.
b.
If the end float is less than 0.05 mm or the bearings are preloaded (no end float): Using a c-spanner as in operation 4 unscrew the bearing adjustment sleeve 90 °. Lightly tap the drive end of the crankshaft to loosen the drive end main bearing inner race. If this technique does not loosen the bearing, the M16 tapped hole in crankshaft big end bearing pintle may be used to apply tension to crankshaft to loosen the bearing in conjunction with tapping the drive end, see chapter 3.2.21. Carry out adjustment technique as in (a) until required end float is achieved. Replace grub screw (11).
8.
Position the pieces of angle along the rails in the crankcase (refer to chapter 3.2.19 operation 3). Using suitable lifting tackle locate flywheel (8) onto the pieces of angle and ease the flywheel onto the crankshaft.
9.
Loosen the drive element clamping screws a couple of turns. Lightly oil the clamping element.
10.
Slide the clamping element onto the crankshaft and locate in the flywheel. Remove the screws from the release threads and screw into the clamping holes.
Page 3-32
CHAPTER 3 MAINTENANCE Tighten the clamping screws diagonally by hand while aligning the hub. With a torque wrench tighten the clamping screws diagonally across with half the tightening torque, refer to Table 3.1 for tightening torque. Tighten the clamping screws one after the other. Repeat several times. Continue tightening but with the full torque, also diagonally across and repeating several times. The tightening process is only completed when none of the screws can be tightened any further.
12.
Remove the pieces of angle or fixture placed over the rails in the crankcase.
13.
Check the flywheel alignment with a dial test indicator does not exceed 0.125 mm. If this alignment is not achieved release the clamping screws, adjust the flywheel and re-tighten screws as above. Recheck flywheel alignment.
14.
Reassemble drive motor and coupling to compressor as detailed in chapter3.2.17 / 3.2.18.
15.
Clean joint faces of crankcase inspection cover (155) and crankcase. Apply Loctite flange sealant 574 to cover joint face. Fit cover to crankcase and secure with the 4 screws (157) and washers (158) refitting the 2 cable clips (156) between washer and cover.
16.
Recommission compressor as detailed in chapter 1.3.
Original 2011-06-21
11.
Page 3-33
CHAPTER 3 MAINTENANCE
3.2.21
Crankshaft and Main Bearing Removal from Compressor If the main bearings are removed it is recommended that they are renewed.
1.
Remove the following parts: a.
First stage cylinder, see chapter 3.2.6
b.
Second stage cylinder, see chapter 3.2.8
c.
Connecting rods, see chapter 3.2.14
d.
Drive motor and coupling, see chapter 3.2.17 (V105/V150/V200/V250) and 3.2.18 (V375)
e.
Flywheel and oil seals, see chapter 3.2.19
2.
Screw a length of M16x2 studding (not supplied) into the tapped hole in the crankshaft pintle. Place a bar or similar (not supplied) across open front of compressor, using an M16 nut (not supplied), exert a force onto the end of the crankshaft.
3.
Gently tap the drive end of the crankshaft with a soft headed mallet and tighten the nut as in operation 2, drive the crankshaft out of the inner race of the drive end taper roller main bearing.
Original 2011-06-21
Take care to prevent the drive end inner cage dropping off the crankshaft.
4.
Withdraw the crankshaft complete with non-drive end taper roller bearing inner race.
5.
Using a suitable puller (not supplied) or by levering on the inner race lip (not on the rollers) extract the non drive end taper roller bearing inner race from the crankshaft. Take care not to damage the housing bore for the lip seal in the crankcase drive end.
6.
Using a mild steel drift (not supplied) drift out the drive end and non drive end taper roller bearing outer races from the crankcase.
Page 3-34
CHAPTER 3 MAINTENANCE
Original 2011-06-21
3.2.22
Crankshaft and Main Bearings Reassembly to Compressor
1.
Before reassembly ensure crankcase internals and crankshaft are clean.
2.
Lightly oil the drive end main bearing location bore in the crankcase.
3.
Using a mild steel drift (not supplied), drift the outer bearing cup of the drive end main bearing (5) into position in the crankcase.
4.
Lightly oil the non drive end main bearing location bore in the crankcase.
5.
Using a mild steel drift (not supplied), drift the outer bearing cup of the non drive end main bearing (4) into position in the crankcase.
6.
Preheat non drive end main bearing inner race assembly to 120°C maximum.
7.
Lightly oil crankshaft non drive end bearing journal location.
8.
Fit the heated inner race assembly on to the crankshaft journal (crankshaft in vertical position) and allow to cool before gently tapping home against shoulder with a mild steel sleeve drift (not supplied).
9.
Preheat drive end main bearing inner race assembly to 120°C maximum.
10.
Insert crankshaft into crankcase, wedge crankshaft into position ensuring that the non drive end main bearing inner race assembly is mated correctly to the outer race.
11.
Lightly oil the crankshaft drive end main bearing journal.
12.
Fit the heated inner race assembly onto the crankshaft and into the bearing outer race.
13.
Refit oil seal and flywheel as detailed in chapter 3.2.20.
3.2.23
Oil Level Switch Remove/Clean/Replace
1.
Drain compressor of lubricating oil as detailed in chapter 3.2.2.
2.
Remove the DIN connector.
3.
Remove screw (142) and washer (143) securing dual oil level switch (140) to crankcase.
4.
Lever switch out of crankcase.
5.
Remove the 2 retaining screws and slide sleeve off body.
6.
Clean switch by removing all metallic particles.
7.
Reassemble switch, fit new O-rings (141), replace DIN connector and re-fill compressor with oil, refer to chapter 3.2.2.
Page 3-35
CHAPTER 3 MAINTENANCE
3.2.24
Air and Water Safety Valves
These valves are all pre-set at the factory to suit the maximum working pressure duty of the compressor. The air safety valves are statically set at a pressure, which equates to the 10% statutory over pressure requirement, making allowance for the dynamic pressure pulses found within the compressor. The safety valves must NOT be tampered with. It is recommended that a replacement valve is fitted should there be any doubt as to the valve's condition. Each valve is screwed into position. Water Jacket Safety Valve (147):
Located on the cooler box behind the first stage cylinder.
Associated joint washer (148).
When replacing the water jacket safety valve ensure the outlet port is pointing downwards by using up to 3 joint washers.
Original 2011-06-21
First Stage Air Pressure Safety Valve (145):
Located on the front face of the first stage cylinder on the V200/250/375 and the rear face of the cylinder on the V105/150.
Associated joint washer (146).
Final Stage Air Pressure Safety Valve (149):
Located on the inlet to the final stage separator.
Associated joint washer (150).
3.2.25
Separator and Diffuser Plate: Removal and Examination
1.
Disconnect the ‘DIN’ plug from the solenoid coils (129).
2.
Disconnect the drain pipes from the bottom of the separators (if fitted). It is advisable to leave 2 opposite corner bolts (E6) screwed into the bowl when splitting this assembly as this will take the weight of the bowl when it is free.
3.
Remove the bolts (E6) and washers (E7) holding the separator bowl (E2) to the separator header (E1). Separate bowl from the header by gently tapping the bowl with a soft headed mallet.
4.
Remove last bolts (E6) and washers (E7) and remove separator bowl.
5.
Clean and remove all traces of gasket from the joint faces of the header and bowl. Ensure faces are grease/oil free. Do not smooth joint faces. Do not use emery cloth or a metal scraper to abrade or clean them. It is recommended that a chemical such as Loctite ‘Chisel’ is used in conjunction with hand brushing with a wire brush. Do not remove machining surface finish markings
6.
Inspect 1st and 2nd Stage diffuser plates for looseness (E3, E4). If the diffuser plates are not solidly held in position, tighten screws (E13, E15).
Page 3-36
CHAPTER 3 MAINTENANCE
3.2.26
Separator and Diffuser Plate: Reassembly Fit drain connectors (E8, E9) to the base of the separator bowl using joint washers (E10, E11).
2.
Fit diffuser plates (E3, E4) using screws (E13, E15) and washers (E12, E14) see Figure 5.6 for position.
3.
Position gasket (E5) over bowl (E2). Do not grease gasket. Ensure faces are grease/oil free.
4.
Fit bowl (E2) to separator header (E1) using 6 bolts (E6) and washers (E7).
5.
Tighten the corner bolts and then the central ones progressively until they are torqued correctly. Refer to Table 3.1 for torque.
6.
Fit separator drain pipes (if fitted).
7.
Fit the ‘DIN’ connectors to the solenoid valve coils (129).
Original 2011-06-21
1.
Page 3-37
CHAPTER 3 MAINTENANCE
WATER CIRCULATING PUMP (if supplied)
Original 2011-06-21
3.3
Figure 3.15
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Description
Qty
Pump Body Impeller Initial Stage Not Applicable Final Diffuser Seal Holding Disc Motor/Pump Support Shaft+Rotor+Bearing+Shaft Motor Case & Wound Stator Not Applicable Fan Fan Cover ‘O’ Ring ‘O’ Ring ‘O’ Ring Mechanical Seal
1 2 1
Table 3.4
Page 3-38
Water Circulating Pump
1 1 1 1 1 1 1 2 1 5 1
Item No. 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Description
Qty
Bearings – Pump & Fan Side Not Applicable Plug-in element Not Applicable Terminal Box Cover Terminal Box Not Applicable Cable Gland Fill/Drain Plug ‘O’Ring Seal Shoulder Washer Impeller Fixing Washer Not Applicable Not Applicable Not Applicable
2
Items List - Water Circulating Pump
1 1 1 1 2 2 1 1
CHAPTER 3 MAINTENANCE
3.3.1
General Overhaul
After 3…4 years service the pump should be overhauled, to include changing the mechanical seal and motor bearings and cleaning. Check for wear and change worn pump parts. Always use new seals on re-assembly. 3.4
ELECTRICAL MAINTENANCE
It is recommended that switch settings are periodically checked. Refer to the separate data sheet for settings: Table 3.5
Switch Settings
SWITCH
3.5
SETTINGS
Oil level switch
Activates when oil level falls below fill mark.
High air temperature switch
Alarm
60°C ± 10%
Shutdown
80°C ± 10%
FAULT FINDING CHART
Original 2011-06-21
Table 3.6 FAULT
Fault Finding Chart
POSSIBLE CAUSE
REMEDIAL ACTION
Final stage air safety valve blowing. Whilst in automatic (default) mode
Air system charged signal and final stage air pressure shutdown settings greater than safety valve set pressure
Reset signal pressure settings lower than safety valve set pressure (Note: maximum working pressure of compressor is 33 bar g)
Whilst running in manual mode
Stop valve closed in final air delivery pipework
Open all stop valves in pipework
Non-return valve installed incorrectly.
Correct installation.
Air system pressure safety devices set higher than safety valve setting.
Correct safety device pressure settings as appropriate.
Intercooler blocked
Remove cooler header and tubenest. Clean cooler tubes and first stage air passageways in header, cooler and first stage separator.
High first stage pressure (First stage air safety valve blowing)
Suction side of final stage valve leaking Remove valve, clean/inspect/renew. Delivery side of final stage valve leaking
Remove valve, clean/inspect/renew.
Delivery side of final stage valve leaking to suction side
Remove valve cage, renew O-rings and check joint washers under dome nuts.
Page 3-39
CHAPTER 3 MAINTENANCE FAULT
POSSIBLE CAUSE
Internal knocking noise from Worn big or small end bearings compressor. Worn main bearings.
Strip down compressor, check crankshaft end float. Renew worn parts.
Damaged concentric valve.
Remove valves, clean inspect and renew if necessary.
Piston slap.
Remove cylinders, check clearances, renew worn parts (cylinder, piston rings.)
Worn drive element. Compressor will not achieve Concentric valves damaged or dirty. operating pressure or is operating at a reduced capacity.
Original 2011-06-21
Concentric valves require frequent cleaning.
REMEDIAL ACTION Strip down compressor for inspection, renew worn parts.
Renew drive coupling element. Remove valves, clean inspect and renew if necessary. (note reduced capacity normally indicates first stage fault)
Solenoid drain/unload valve faulty.
Check solenoid valve function, renew parts as necessary.
Worn or damaged piston rings/ piston.
Remove cylinders, check rings are free in piston groove, renew worn, distorted or damaged rings, piston as appropriate.
Excessive cylinder component wear
Remove cylinders, renew cylinder, piston, rings as necessary
Suction filter/silencer blocked.
Renew element.
Non-recommended grade of lubricating oil used.
Drain lubricating oil, replace with recommended grade.
Concentric valves overheating.
Ensure concentric valves, cylinder components (cylinder, piston, rings) and cooling water system is maintained in good working order.
Excessive moisture in final Solenoid drain/unload valve faulty. air delivery pipe work and/or final stage cylinder/ intercooler. Unload drain cycle incorrect for operating conditions.
Check solenoid valves function, renew components as necessary.
Reprogram solenoid drain/unload valves “dwell” and “spit” times to suit operating conditions.
Oil seeping out from Drive end lip or O-ring seal adjustment underside of crankcase near sleeve to crankshaft leaking. drive motor.
Remove flywheel adjustment sleeve and drive lip seal and O-ring. Renew seal and O-ring. Refer to Chapter 3.2.19 and 3.2.20
Water jacket safety valve blowing.
Excessive cooling water inlet pressure.
Reduce inlet pressure to 7 bar g maximum that compressor is suitable for.
Intercooler/aftercooler tube failure.
Remove cooler header and tubenest. Renew/refurbish tubenest.
Worn cylinder components.
Remove cylinders, check cylinder, piston, rings. Renew components as appropriate.
Excessive oil consumption.
Page 3-40
CHAPTER 3 MAINTENANCE
3.6
TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE Table 3.7
Tools Required for Compressor Maintenance
TOOL
Original 2011-06-21
V150
V200/250
V375
C spanner 2" - 6"
Fly press
D.T.I. and magnetic base
3
13 mm a/f x /8" square drive flank adaptor
19 mm a/f x ½" square drive crowsfoot
n/a
n/a
24 mm a/f x ½" square drive crowsfoot
n/a
8" screwdriver
Water pump pliers
2 ½ lb steel lump hammer
12" adjustable spanner
Feeler gauges (0.02 - 1.0mm)
24mm a/f combi spanner
n/a
19mm a/f combi spanner
n/a
13mm a/f combi spanner
24mm a/f ½" square drive socket
n/a
19mm a/f ½" square drive socket
n/a
13mm a/f ¼" drive socket
3mm a/f hexagon key
4mm a/f hexagon key
6mm a/f hexagon key
n/a
8mm a/f hexagon key
n/a
n/a
3mm a/f hexagon key x ¼" square drive
4mm a/f hexagon key x ¼" square drive
6mm a/f hexagon key x /8" square drive
n/a
8mm a/f hexagon key x ½" square drive
n/a
n/a
¼" square drive torque wrench (4 - 20 Nm)
3
/8" square drive torque wrench (8 - 54 Nm)
n/a
½" square drive torque wrench (30 - 150 Nm)
14mm a/f hexagon key x ½" square drive
n/a
17mm a/f hexagon key x ½" square drive
n/a
n/a
¾" square drive torque wrench (up to 500 Nm)
n/a
n/a
¾" square female x ½" square drive adaptor
n/a
n/a
3
Page 3-41
Original 2011-06-21
CHAPTER 4 TECHNICAL DATA
4
TECHNICAL DATA
4.1
GENERAL
Compressor Type 4.2
PERFORMANCE
Maximum working pressure 4.3
V105/V150/V200/V250/V375
33 bar.
OTHER DATA Table 4.1
Capacity and Power at 30 Bar
Nominal Speed RPM 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800 1000 1200 1500 1800
Original 2011-06-21
V105
V150
V200
V250
V375
Output m³/hour 55 70 85 105 80 100 120 150 110 132 166 200 137 165 207 250 208 250 310 375
Absorbed Power kW 13 15.5 20 22 17 20 25 30 22 26 33 39 28 33 41 49 40 48 60 72
Outputs quoted are bottle charging rates. Noise - 89 dB (A) at 1 Metre
Table 4.2 Maximum air inlet temperature Maximum air outlet temperature Maximum water inlet pressure Maximum water inlet temperature Minimum water inlet temperature Cooling water outlet temperature Nominal cooling water flow rate Lubrication system Sump capacity
Operating Parameters V105/150
V200/250 V375 50 °C 20 °C over cooling water inlet 7 bar g 45 °C 5 °C 10 °C above water inlet temperature 20/25 litres/minute 60/70 litres/minute 115/120 litres/minute Splash min. 3.5 litres min. 7 litres min. 9 litres max. 4.5 litres max. 8 litres max. 12 litres Page 4-1
CHAPTER 4 TECHNICAL DATA
Table 4.3 Feature
Recommended Maximum Wear Clearances Feature Measured
Note: All dimensions are in millimetres.
Renew when V105/V150
V200/250
V375
First stage cylinder (Nominal bore V105/150 Ø 180 / V200/250 Ø 200 / V375 Ø 260) Piston
A
Skirt Ø measured 15 mm up from base
179.600
199.600
259.6
Cylinder bore
B
Maximum diameter at any point
180.250
200.250
260.25
Piston to cylinder bore
C
Clearance between measured values A & B
> 0.520
> 0.520
> 0.52
Piston ring width
< 3.335
< 3.335
< 4.835
E
Piston ring groove width
> 3.730
> 3.730
> 5.225
F
Clearance between measured values D and E
> 0.200
> 0.200
> 0.200
G
Piston ring gap when fitted to bore
> 1.07
> 1.150
> 1.450
Piston ring width
< 4.850
< 4.850
< 7.85
I
Piston ring groove width
> 5.194
> 5.194
> 8.184
J
Clearance between measured values H and I
> 0.250
> 0.250
> 0.250
K
Piston ring gap when fitted to bore
> 1.07
> 1.150
> 1.450
Gudgeon pin Ø
< 24.892
< 31.892
< 34.892
Original 2011-06-21
Top and second D piston rings, piston ring grooves.
Conformable slotted oil H control ring, piston ring groove
Gudgeon pin and small L end bearing
Final stage cylinder (Nominal bore V105/150 Ø 75 / V200/250 Ø 85 / V375 Ø 110) Piston
M
Skirt Ø measured 15mm up from base
74.830
84.830
109.730
Cylinder bore
N
Maximum Ø at any point
75.164
85.164
110.164
O
Clearance between measured values M & N
> 0.210
> 0.210
> 0.210
Piston ring width
< 2.350
< 2.350
< 2.850
Q
Piston ring groove width
> 2.660
> 2.660
> 3.160
R
Clearance between measured values P & Q
> 0.200
> 0.200
> 0.200
S
Piston ring gap fitted to bore
> 0.710
> 0.800
> 0.890
Piston ring width
< 4.850
< 4.850
< 4.850
U
Piston ring groove width
> 5.194
> 5.194
> 5.194
V
Clearance between measured values T & U
> 0.250
> 0.250
> 0.250
W
Piston ring gap fitted to bore
> 0.710
> 0.800
> 0.890
Gudgeon pin Ø
< 24.892
< 31.892
< 34.892
Piston to cylinder bore
Top and second P piston rings. piston ring grooves
Conformable slotted oil T control ring, piston ring groove
Gudgeon pin and small X end bearing Page 4-2
CHAPTER 4 TECHNICAL DATA 4.4
CRANKCASE LUBRICANTS
4.4.1
Approved Oils
Shell Corena Oils P100 Castrol Aircol SN100 Extensive tests have been carried out on the V-Line compressor using Shell Corena P100 (mineral) and Castrol Aircol SN100 (synthetic) lubricants. These oils have been found to give good results over extended service and HATLAPA recommend their use to ensure satisfactory operation of the compressor. 4.4.2
Oil Company Equivalents For information regarding oil company equivalents see separate sheet:
Original 2011-06-21
Lubricating Instructions for V-line Piston Compressors.
The V-Line compressor is designed to achieve the best possible results using mineral oils. A recommended lubricating oil should be used at all times to ensure safe and efficient operation with minimum wear. The suggested maintenance intervals are based on the results of extensive tests using Shell P100 mineral oil. Specific measures have been taken to ensure extended service before components need cleaning to remove carbon. HATLAPA recommend the use of mineral oil as the most economic lubricant. If synthetic oils are to be used the following maintenance revisions are necessary. 4.4.3
Additional Maintenance for Machines Lubricated with Synthetic Oils
Initial run and oil change periods to be as detailed in Maintenance chapter. After initial 500 running hours using mineral oil lubricant: 1.
Drain the old mineral lubricant completely whilst the oil is warm.
2.
Thoroughly clean the crankcase sump.
3.
Inspect and thoroughly clean compressor valves (as detailed in chapter 3 MAINTENANCE).
4.
Replace all items removed, renew any damaged seals or gaskets.
5.
Refill with synthetic oils, and run as normal.
Page 4-3
Original 2011-06-21
CHAPTER 5 DRAWINGS
5
DRAWINGS 1
9
8
4
2 10
3 5
Original 2011-06-21
11 13 12 7 6
Figure 5.1
Typical Arrangement of V-Line Water Cooled Compressor with Gauges Table 5.1
List of Parts for Figure 5.1
Ref
Description
1
Gauge panel
2
Suction filter silencer
3
First stage safety valve
4
Final stage safety valve
5
Dual level oil switch
6
Oil drain plug
7
Oil filler/dipstick
8
Final air delivery
9
Motor terminal box
10
Lifting lugs
11
Inter and final stage separator
12
First stage solenoid drain valve Final stage solenoid drain valve
13
Page 5-1
CHAPTER 5 DRAWINGS
Notes on Figures Where parts are specific to a particular model, applicable model numbers are shown next to the item number. Figure 5.3
Crankshaft and Flywheel:
For V375, the Drive Coupling Sub-assembly (190) is detailed in Figure 3.13 Figure 5.7
Gauges:
Original 2011-06-21
For V150, steel pipe links adaptors (282), via ball valves (299), to gauges. For other models, steel pipe runs from adaptors beneath the cooler header (93), via ball valves (299), to gauges.
Page 5-2
Original 2011-06-21
CHAPTER 5 DRAWINGS
Figure 5.2
Cooler Page 5-3
Original 2011-06-21
CHAPTER 5 DRAWINGS
Figure 5.3
Crankshaft and Flywheel See Notes on page 5-2
Page 5-4
Original 2011-06-21
CHAPTER 5 DRAWINGS
Figure 5.4
First Stage Cylinder and Piston
Page 5-5
Original 2011-06-21
CHAPTER 5 DRAWINGS
Figure 5.5 Page 5-6
Final Stage Cylinder and Piston
Original 2011-06-21
CHAPTER 5 DRAWINGS
Figure 5.6
Separator Page 5-7
Original 2011-06-21
CHAPTER 5 DRAWINGS
Figure 5.7
Gauges
See Notes on page 5-2
Page 5-8
CHAPTER 5 DRAWINGS
Table 5.2
List Of Parts – V-Line Compressors
Original 2011-06-21
Where two numbers are shown in the quantity column the first quantity is for the V105/150 compressor, the second refers to the V200/250/375 compressor. Where the quantity for the V375 is different it is shown in brackets. Items marked with an asterisk (*) are not shown. Ref 1 2 3 4 5 6 7 8 9 10 11 15 16 17 18 19 20 21 22 23 24
Description Crankcase Crankshaft Pin spring tension Bearing taper roller (main non drive end) Bearing taper roller (main drive end) Oil seal ‘O’ ring (bearing adjusting sleeve) Flywheel Bush cone clamping elements Bearing adjusting sleeve Socket set screw Connecting rod (1st stage) Bearing - big end cylindrical roller Bearing - small end needle roller Spacer - connecting rod/crankshaft Connecting rod (2nd stage) Bearing - big end cylindrical roller Bearing - small end needle roller Clamping washer - c/shaft-conn. Rod Set screw Tab washer
30 32 35 36 37 38 39 40 41 42 43 45 46 48 50 51
Hose connector (not V375) Hose (crankcase breather) (not V375) Piston (first stage) Piston ring SOC (first stage) Piston ring taper faced (first stage) Piston ring barrel faced (first stage) Cylinder (first stage) Gudgeon pin (first stage) Hexagon socket set screw Locknut Stud (first stage cylinder assembly to crankcase) Valve cage (first stage) Hose connector (not V375) ‘O’ ring (first stage valve cage to cylinder) Concentric valve (first stage) assembly A ‘O’ ring (first stage concentric valve outer groove to cylinder) ‘O’ ring (first stage concentric valve top face to valve cage) Joint washer
52 53
Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 30 cm 1 1 1 1 1 1 2 1 4 1 1 1 1 1 1 4 (8)
Page 5-9
CHAPTER 5 DRAWINGS Table 5.2 Ref 54 55 56 57 59* 60 61 62 63 64 65 66 67 70 71 72
Original 2011-06-21
73 75 76 77 78 79 80 81 85 86 87 88 90 91 92 93 94 95 100 100A 100B 100C 101 102 105 105A 105B 105C 106 107 Page 5-10
List Of Parts – V-Line Compressors (Cont’d) Description Stud connector (not V375) Bright washer (not V375) Nut Bright washer Socket set screw (V200, V250, V375 only) Piston (second stage) Piston ring S.O.C (second stage) Piston ring taper faced (second stage) Piston ring barrel faced (second stage) Gudgeon pin (second stage) Socket set screw Cylinder (second stage) Stud (second stage cylinder Assembly to crankcase) Valve cage (second stage) ‘O’ ring (second stage valve Cage top groove to cylinder) ‘O’ ring (second stage valve cage Bottom groove to cylinder) Plug Concentric valve (second stage) Assembly B ‘O’ ring (second stage concentric Valve outer groove to cylinder) ‘O’ ring (second stage concentric Valve top face to valve cage) Joint washer Nut Bright washer Anti-extrusion ring (V375 only) Cooler box assembly C Eyebolt Set screw/bolt Spring washer Gasket (tubenest to cooler box) Tubenest assembly Gasket (tubenest to cooler header) Cooler header Bolt/adjusting screw Bright washer Gasket (cooler header to first stage cylinder) (V105/150/200/250 only) Metal Gasket V375 only) Gasket Seal (V375 only) PTFE Sealing Ring (V375 only) Bolt Bright washer Gasket (cooler header to second stage cylinder) (V105/150/200/250 only) Metal Gasket V375 only) Gasket Seal (V375 only) PTFE Sealing Ring (V375 only) Bolt Bright washer
Quantity 1 1 4 4 2 1 1 1 1 1 2 1 4 1 1 1 1 1 1 1 1 1 1 4 4 4 1 1 1 4/3 4/3 1 1 1 1 13 13 1 1 1 1 3/4 3/4 1 1 1 1 3 3
Original 2011-06-21
CHAPTER 5 DRAWINGS Table 5.2
List Of Parts – V-Line Compressors (Cont’d)
Ref 110 111 112 113 114 115 116 117 118 120 121 122 123 125 126 127 128 129 140 141 142 143 145 146 147 148 149 150 151 152 153* 154* 155 156 157 158 160 161 165 166 167 F2 168 169 170 171 172
Description Separator assembly E Gasket (separator /header - cooler box) Bolt Bolt/stud Bright washer Nut (not V200/250) Gasket (separator assembly to Second stage cylinder) Set screw Bright/spring washer Joint washer Adaptor Joint washer Solenoid valve body First stage drain/unload Washer Nipple Washer Solenoid valve Final stage drain/unload Coil – solenoid valve Oil level switch - crankcase ‘O’ ring (oil switch ) Set screw Bright washer Safety valve (air 1st stage cylinder) Copper washer Safety valve (water jacket safety) Copper washer Safety valve (Air final stage cylinder) Copper washer Plug Joint washer Plug Joint washer Inspection cover Cable clip Set screw Bright washer Magnetic drain plug with seal Oil filler/dipstick Studding Suction filter/silencer assembly F Filter element (V200/250/375 only) Filter element (V150 only) Wing nut (V200/250/375 only) Bright washer (V200/250/375 only) Guard – crankcase Screw Spring washer
Quantity 1 1 3 1 4 1 1 2 2 3 1 1 1 3 1 1 1 2 1 2 1 1 1 3 1 3 1 3/1 2 2 2 2 1 2/3 4/6 4/6 1 1 1 1 1 1 1 1 1 1 1
Page 5-11
CHAPTER 5 DRAWINGS Table 5.2 Ref 190 191* 192* 194* 195* 196*
Original 2011-06-21
197* 198* 199* 200* 201* 202* 203* 204* 209*
Page 5-12
List Of Parts – V-Line Compressors (Cont’d) Description Drive coupling sub-assembly G Bolt/set screw Spring washer Motor packing piece (V200/250 only) Mounting plate drive motor Mounting plate drive motor (Water circulating pump models only) Bolt Nut Spring washer Water circulating pump Bolt Spring washer Bolt Spring washer Straight male unionConnector
210 212 213 214 215 216* 217* 218* 222*
Joint washer Packing piece (V150 only) Anti-vibration mount Bolt Spring washer Anti-vibration mount Screw Spring washer Flexible hose (water inlet)To final stage cylinder/Circulating pump
224* 225*
Joint washer (hose tocylinder/circulating pump) Flexible hose (water outletfrom first stage cylinder
227* 228* 229 230* 231* 245 246 247 248 249 250 251 252 253 254 255 273 274
Joint washer (hose to cylinder) Flexible hose (final air delivery) Joint washer (hose to separator) Nameplate Hammer drive screw Washer Bolt Electrical terminal box Stud (Earth) Washer Nut Washer Lock washer Washer Nut Nut Plug Joint washer
Quantity 1 4/8 4/8 2 1 1 2 2 2 1 4 4 2 2 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1
CHAPTER 5 DRAWINGS
Original 2011-06-21
Table 5.2 Ref 280* 281* 282 283 284 285 286 287 288 289* 290 291 292 293 294 295 296 298 299 300
List Of Parts – V-Line Compressors (Cont’d) Description Pressure gauge (direct mount) 0 – 10 bar Pressure gauge (direct mount) 0 – 60 bar Adaptor Joint washer Pressure gauge (panel mount) 0 –10 bar Pressure gauge (panel mount) 0 – 60 bar Gauge panel Set screw Bright washer Legend plate Legend plate Drive screw Steel pipe assembly Steel pipe assembly Male stud coupling Female stud coupling Joint washer Joint washer Ball Valve Plug
COMPRESSOR WITH MANUAL DRAINS 301 3 way equal tee 302 Adaptor
Quantity 1 1 2 2 1 1 1 2 2 1 1 4 50/60 cm 50/60 cm 2 2 2 4(1) 2 2 1 1
304 305 307 311 312 314 315 317
Hex adaptor Ball valve Joint washer 3 way equal tee Adaptor Hex Adaptor Ball valve Joint washer
1 1 1 1 1 1 1 1
320 321
Temperature switch Joint washer
1 1
CONCENTRIC VALVE (1ST STAGE) ITEM 50 Concentric valve body assembly A1 Dome nut A2
1 4(8)
CONCENTRIC VALVE (2ND STAGE) ITEM 75 Concentric valve body assembly B1 Dome nut B2
1 4(6)
Page 5-13
CHAPTER 5 DRAWINGS Table 5.2
List Of Parts – V-Line Compressors (Cont’d)
Description Ref COOLER BOX SUB-ASSEMBLY ITEM 85 Cooler box C1 Cover cooler box end C2 Gasket (cover cooler boxend to cooler box) C3 Bolt C4 Plain washer C5 Plug C6* Joint washer C7* Plug C8* Joint washer C9* Bleed Valve C10 Joint washer C11
Original 2011-06-21
SEPARATOR SUB-ASSEMBLY ITEM 110 Separator header E1 Separator bowls E2 Diffuser Plate (first stage) E3 Diffuser Plate (second stage) E4 Gasket (separator header E5 to separator bowls) Bolt E6 Plain washer E7 Drain Connection (first stage) E8 Drain Connection (second stage) E9 Joint washer E10 Joint washer E11 Plain washer (brass) E12 Screw E13 Plain washer (stainless steel) E14 not V105/150 Screw E15
Page 5-14
Quantity 1 1 1 11/9 11/9 1 1 1 1 1 1 1 1 1 1 1 6 6 1 1 1 1 2 1 2 1
SUCTION FILTER/SILENCER SUB-ASSEMBLY ITEM 166 V105/150 ONLY Housing F1 Element F2 Seal F3 Wingnut F4 Seal F5 Top Cover F6 Seal F7 Wingnut F8 ‘O’ Ring F9 Inlet Resonator F10 Clamp F11
1 1 1 1 1 1 1 1 1 1 1
SUCTION FILTER/SILENCER SUB-ASSEMBLY ITEM 166 V200/250/V375 ONLY Housing F1 Inlet Resonator F2 Clamp F3
1 1 1
CHAPTER 5 DRAWINGS Table 5.2
List Of Parts – V-Line Compressors (Cont’d)
DRIVE COUPLING SUB-ASSEMBLY ITEM 190 Drive coupling element G1 Drive pin (not V375) G2 Drive coupling hub G3 Hexagon socket cap screw (not V375) G4
1 1 1 1
Original 2011-06-21
SEALANTS/RETAINERS Loctite 603 high strength J1 Retainer 10ml size Loctite 243 thread locker 10 ml size J2 Loctite 573 flange sealant 50 ml size J3 Loctite 574 multi gasket 50 ml size J4
1 4 1 4
Page 5-15
ELECTRICAL DRAWINGS FOR COMPRESSORS Shipyard
Original 2011-06-21
Cosco Guangdong Shipyard Co., Ltd.
Newbuilding
N352 N353
Date
22.12.2010
Our ref.
10.2722 10.2723
ITEM
DESCRIPTION
DRAWING No.
1
Spare part list
2
Connection diagram compressors V105
344181-44070 1-2
3
Starter / controller compressor 22-30kW
344182-44070 1-8
4
Sequence selection box for double compr. control
333392-44070 1-2
5
Connection diagram compressor L20
344183-44070 1
6
Starter / controller compressor 5,5-7,5kW
344184-44070 1-8
1/1 Uetersener Maschinenfabrik GmbH & Co. KG Tornescher W eg 5-7 25436 Uetersen / Germany
Tel.: + 49-(0) 4122 / 711-0 Fax: + 49-(0) 4122 / 711-104
[email protected] www.hatlapa.de
Geschäftsführer / Managing Directors: Dr.-Ing. Alexander Nürnberg Jörg Tollmien
Amtsgericht Elmshorn: HRA 0499 Verwaltungsgesellschaft: HRB 1560 UST.ID-Nr. DE 134527127
ELECTRICAL SPARE PARTS FOR COMPRESSORS
Original 2011-06-21
Shipyard
Newbuilding
Date
02.11.2010
Our ref.
Cosco Guangdong Shipyard Co., Ltd.
N352 N353
10.2722 10.2723
ITEM: QUANTITY:
DESCRIPTION:
IDENT No.:
1
1
MAIN CONTACTOR LC1-D50
121496
2
1
MAIN CONTACTOR LC1-D18
334706
1/1 Uetersener Maschinenfabrik GmbH & Co. KG Tornescher W eg 5-7 25436 Uetersen / Germany
Tel.: + 49-(0) 4122 / 711-0 Fax: + 49-(0) 4122 / 711-104
[email protected] www.hatlapa.de
Geschäftsführer / Managing Directors: Dr.-Ing. Alexander Nürnberg Jörg Tollmien
Amtsgericht Elmshorn: HRA 0499 Verwaltungsgesellschaft: HRB 1560 UST.ID-Nr. DE 134527127
0
2
1
3
4
5
6
Schaltschrank Startluft-Kompressor 1 (22-30kW) STARTER / CONTROLLER MAIN AIR COMPRESSOR 1 (22-30kW)
8
7
9
(344182-44070) NO
NO
NC
26 27
20 21
22 25
-1X1
ø16-28
W
H1 H2
ø16-28
5
ø6-13
5
7
8
5
9
10
5
ø6-13
X1
5
11 12
1
17
1
17
1
18
13 14 15
ø16-28
ø16-28
6
KompressorUmschaltbox
cable glan 08.12.10 A sizes Zust. Änderung Datum
bre Name
Bearb. Gepr. Norm
02.11.10 Bre cpu
343260
NO
-1Y1 -1F13
Ers.f
NO
(Klemmenkasten Kompressor 1) (TERMINAL BOX COMPRESSOR 1)
13
14 15
13-21
ø6-13
ø6-13
24V DC
COM
F3W
COM
Entwässerungsventil letzte Stufe DRAIN VALVE FINAL STAGE
NC
T
1 18
220-230V AC
NC T
WARNING
L
220-230V AC
1
Werft-Lieferung SUPPLIED BY SHIPYARD
-1Y2
-1F3
Anschlußplan Kompressoren V105 CONNECTION DIAGRAM COMPRESSORS V105 Urspr.
1 17
Entwässerungsventil 1. Stufe DRAIN VALVE FIRST STAGE
Luft-TemperaturWächter AIR TEMPERATURE SWITCH
Ölstands-Wächter OIL LEVEL SWITCH
-1F4 CONTACTS SHOWN WITHOUT OIL
Datum
1 17
10
F3S
Heizung HEATING appr. 50W
L
9
SHUTDOWN
StartluftKompressor 1 MAIN AIR COMPRESSOR 1 V105 24 kW
2
5
24V DC
P
3
8
F13.1
M
3
7
SHUTDOWN
HE1 HE2
5
F13.2
W
24V DC
-1M1
V
Druckluftwächter für Führungskompressor AIR PRESSURE SWITCH F.LEADING COMPRESSOR
U
5 11 12
2
24V DC
1
WARNING
440V 60Hz 440V 60Hz
X1
5 9 10
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
5 7 8
COMPRESSOR SELECTION BOX
MAN 0 AUTO
(333392)
Einspeisung SHIP SUPPLY
Original 2011-06-21
6
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
potentialfreier Kontakt für Fernbedienung aktiv FLOATING CONTACT FOR REMOTE CONTROL ACTIVE
L1 L2 L3
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344181-44070 Blatt 1 von 2 Bl.
0
2
1
3
4
5
6
Schaltschrank Startluft-Kompressor 2 (22-30kW) STARTER / CONTROLLER MAIN AIR COMPRESSOR 2 (22-30kW)
8
7
9
(344182-44070) NO
NO
NC
26 27
20 21
22 25
-2X1
ø16-28
W
H1 H2
ø16-28
5
ø6-13
5
7
8
5
9
10
5
ø6-13
X1
7
11 12
1
17
1
17
1
18
13 14 15
ø16-28
ø16-28
8
KompressorUmschaltbox
Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
02.11.10 Bre cpu
343260
NO
-2Y1 -2F13
Ers.f
NO
(Klemmenkasten Kompressor 2) (TERMINAL BOX COMPRESSOR 2)
14 15
-2Y2
Ers.d
ø6-13
ø6-13
Werft-Lieferung SUPPLIED BY SHIPYARD
-2F3
HATLAPA
13
13-21
24V DC
COM
F3W
COM
Entwässerungsventil letzte Stufe DRAIN VALVE FINAL STAGE
NC
T
1 18
220-230V AC
NC T
WARNING
L
220-230V AC
1
Anschlußplan Kompressoren V105 CONNECTION DIAGRAM COMPRESSORS V105 Urspr.
1 17
Entwässerungsventil 1. Stufe DRAIN VALVE FIRST STAGE
Luft-TemperaturWächter AIR TEMPERATURE SWITCH
Ölstands-Wächter OIL LEVEL SWITCH
-2F4 CONTACTS SHOWN WITHOUT OIL
Datum
1 17
10
F3S
Heizung HEATING appr. 50W
L
9
SHUTDOWN
StartluftKompressor 2 MAIN AIR COMPRESSOR 2 V105 24 kW
2
24V DC
P
3
5
F13.1
M
3
8
SHUTDOWN
HE1 HE2
7
F13.2
W
24V DC
-2M1
V
5
24V DC
U
5 11 12
4
Druckluftwächter für Folgekompressor AIR PRESSURE SWITCH F.FOLLOWING COMPRESSOR
3
WARNING
440V 60Hz 440V 60Hz
X1
5 9 10
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
5 7 8
COMPRESSOR SELECTION BOX
MAN 0 AUTO
(333392)
Einspeisung SHIP SUPPLY
Original 2011-06-21
6
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
potentialfreier Kontakt für Fernbedienung aktiv FLOATING CONTACT FOR REMOTE CONTROL ACTIVE
L1 L2 L3
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344181-44070 Blatt 2 von 2 Bl.
0
2
1
3
4
5
600
6
8
7
9
210
Schaltschrank Kompressor STARTER/CONTROLLER COMPRESSOR
Amperemeter (mit Markierungsanzeiger) AMMETER
P2
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
Q1
Hauptschalter (mit Türverriegelung) ISOLATING SWITCH
Q2
Hauptschalter Motor-Heizung MAIN SWITCH MOTOR HEATING
H2
Meldelampe "Motor-Heizung ein" INDICATING LIGHT "MOTOR HEATING ON"
H2 P2
Q2
S2
TD 200
L
R
600
HATLAPA
(BU)
S2
Wahlschalter "Vorort / Fern" SELECTOR SWITCH "LOCAL / REMOTE"
Q1
Gewicht: ca. 50kg WEIGHT: APPR. 50kg 8
Schutzart: IP54 PROTECTION CLASS: IP54
20
Original 2011-06-21
P1
P1
mit Türfeststeller
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 1 von 8 Bl.
0
2
1
3 P2
4
5
Original 2011-06-21
RESET
HATLAPA
SHIFT
black on red
STOP
8
9
TD 200
MAN
schwarz auf rot
7
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
SIEMENS
STOP
6
AUTO
schwarz auf hell-blau black on light blue
AUTO
ESC
schwarz auf grün
schwarz auf weiß
black on green
black on white
MAN
ENTER
RESET
HATLAPA dark blue on white dunkel-blau auf weiß
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 2 von 8 Bl.
Kurzbeschreibung für Kompressorsteuerung mit TD200
short description f.compressor control with TD200: ON / OFF:
The standard text on the text display is:
ready for operation / off Betriebsbereit / aus
Now you can start the compressor in manual or in automatic operation. When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4. Normallay the manual operation is only used for maintenance purposes. After a blackout the cmpressor will not start again in this manual mode.
Original 2011-06-21
When You press the "AUTO" push button the compressor is switched to automatic mode. The compressor starts and stops automatically depending on the air pressure. Normally this should be the standard operation mode. When the pressure switch F4 is closed the compressor starts. When the pressure switch F4 is opened the compressor stops. After a blackout the compressor will start again in automatic mode.
ALARMS:
Jetzt kann man den Kompressor in der Hand- oder in der Automatik-Betriebsart starten. compressor on / man Kompressor ein / Hand
ready for operation / off Betriebsbereit / aus
When You press the "STOP" push button the compressor stops again.
When you want to change the operation mode from manual to automatic or from automatic to manual you must press the "STOP" push button before. When there is any fault, the compressor stops and the belonging disturbance alarm is shown in the display. Not all possible disburbance texts are used for this compressor.
Now the fault must be eliminated. Then press the "RESET" push button and there should be the standard text on the display again. Now You can start the compressor again with the "AUTO" or "MAN" push button.
compressor on / auto Kompressor ein / Auto ready for operation / auto Betriebsbereit / Auto
make maintenance ! Wartung fällig ! motor overload Motor Überlast oil level warning Öl-Level Voralarm low oil level Öl-Level Alarm air temperature warning Lufttemperatur Voralarm high air temperature Lufttemperatur-Alarm
Mit der Taste "MAN" wird der Kompressor in der Hand-Betriebsart gestartet. D.h. ohne Funktion des Druckluftschalters F4. Normalerweise wird diese Fuktion nur für Wartungszwecke benutzt. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Hand" nicht wieder selbsttätig starten. Mit dem Taster "STOP" kann der Kompressor wieder gestoppt werden. Mit dem Taster "AUTO" kann der Kompressor in die Betriebsart "Automatik" geschaltet werden. Der Kompressor startet und stopt dann selbstätig in Abhängigkeit des Druckluftschalters F4. Wenn der Druckluftschalter geschlossen ist, dann startet der Kompressor. Wenn der Druckluftschalter geöffnet ist, dann stopt der Kompressor. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Automatik" selbstständig wieder anlaufen.
ALARME
Wenn eine Störung vorliegt, dann stopt der Kompressor und es wird der zugehörige Alarm im Textdisplay angezeigt. Nicht alle hier dargestellten Alarm-Texte werden für diesen Kompressor benutzt. Jetzt must der entsprechende Fehler behoben werden und dann der "RESET"-Taster betätigt werden. Darauf sollte dann der Standart-Text wieder auf dem Display erscheinen. Jetzt kann der Kompressor wieder mit den Tasten "MAN" oder "AUTO" gestartet werden.
ready for operation / off Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS: When there are one or two arrows in the right side of the display, you can go to other display texts by pressing the belonging arrow push buttons The other texts can show more disturbance alarms, if there is more than one fault. Or you can watch the working hours. Or you can watch some special settings of the software. Normally all settings are done by HATLAPA for a normal purpose of the compressor. If you want to change any setting, you must press the "ENTER" push button one time. Now you can change the value with the arrow push buttons. After this you must quit the new value by pressing "ENTER" again.
workings hours xxxxx h Betriebsstunden drainage time 2sec Entwässerungsdauer drainage interval 5min Entwässerungsinterval star delta time 4sec Stern-Dreieck-Zeit delayed start 0sec verzögerter Anlauf cooling water delay 2min Kühlwassernachlauf continuous time 5min Durchlaufzeit
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
EIN / AUS
Dies ist der Standart-Text auf dem Display.
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
Wenn ganz rechts im Display ein oder zwei Pfeile dargestellt werden, dann kann mit d.entsprechenden Pfeil-Tasten zu anderen möglichen Texten gesprungen werden. Die weiteren Texte können weitere Alarme anzeigen, wenn mehr als eine Störung ansteht. Oder es werden die Betriebsstunden angezeigt. Oder es können einige variable Einstellungen der Software angezeigt werden. Normalerweise sind alle Einstellungen für einen normalen Kompressorbetrieb bereits durch HATLAPA festgelegt. Wenn Einstellungen geändert werden sollen, muß einmalig die "ENTER"-Taset betätigt werden. Dann kann man mit den Pfeil-Tasten den entsprechenden Wert verändern. Daraufhin muß der geänderte Wert nocheinmal mit der "ENTER"-Taste quittiert werden.
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 3 von 8 Bl.
0
2
1
3
4
5
6
8
7 -F2
9
2A
4
L
2
4
6
11
1
3
5
12
1
3
5
2
4
6
0P ±5%
-K1 /8.0
-F3
-T1 440V
-Q1
4
6
220V 250VA 0S
2A
2
-Q4
0,63-1A 2 GV2 RT05
l
Heizungs-Spannung HEATING VOLTAGE
/7.9
1 1
3
5
-Q2
97 95
2
-F1 37-50A
4
3 Hauptschalter Heizung MAIN SWITCH 4 HEATING
98 96
6
Original 2011-06-21
2
/5.0
4
75/1
1N1
Trafo-Einspeisung TRANSFORMER SUPPLY
1
k
-T2
5
3
-P1 75A + A -
K
3
/5.0
Steuerspannung CONTROL VOLTAGE 3
1
2
1
1L1
51
61
/8.0 52
62
-K1 X1
-H2
Heizung ein HEATING ON
220V X2
SHIP SUPPLY 440V
440V Zuleitung
U
V
W
U
V
W
H1 H2 PE
PE
60Hz
L1 L2 L3 PE
60Hz
-X1
-M1
9 10 HE1 HE2
M
3
Heizung HEATING 25-100W
Kompressor COMPRESSOR 22-30 kW Datum 02.11.10 Bearb. Gepr.
Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 4 von 8 Bl.
0 /4.9
/4.9
2
1
3
4
5
6
7
8
9
1L1
1N1
1N1
1L+
+24V DC
/8.0
/6.0
Original 2011-06-21
Softwareversion Hamw_7
16t 17t 18t
S7-CPU 224 Relay-Outputs 14 x Inputs
10 x Outputs Relay
2b 3b 4b 5b 6b 7b 8b 9b
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
/6.0 /6.4 /6.4 /6.5 /6.6 /6.7 /6.8 /6.2
MOTOR PROTECTION RE OIL LEVEL SW.WARNIN OIL LEVEL SW.SHUTDO AIR TEMPERAT.SHUTDO AIR TEMPERAT.WARNIN SPARE Reserve SPARE Reserve AIR PRESSURE SWITCH
2t 3t 4t 5t 8t 9t 10t 13t
11b 12b 13b 14b 15b 16b
E1.0 E1.1 E1.2 E1.3 E1.4 E1.5
/7.1 /7.3 /7.5
REMOTE CONTROL ON REMOTE CONTROL MANU REMOTE CONTROL AUTO
14t A1.0 15t A1.1
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5 A0.6 A0.7
/8.0 /8.5 /8.7 /8.6 /8.2 /8.3 /8.9
PE N L1
17b 18b
-A1
M Exp. L+
1L Out 2L 3L 1M In 2M
1t 7t 12t 1b 10b
0V DC
Supply
MOTOR MAIN CONTACTO DRAIN VALVES Entwäs DISTURBANCE RELAY COOLING WATER VALVE SPARE STAR CONTACTOR DELTA CONACTOR REMOTE CONTROL ACTI
-P2 TD 200
HATLAPA Anzeige- und Bedieneinheit monitoring and operation panel
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 5 von 8 Bl.
0 /5.9
2
1
3
4
5
6
8
7
1L+
9 1L+
-A1
-A1
3b
-A1
5b
E0.1
/5.2
/7.0
7b
E0.3
/5.2
E0.5
/5.2
95 OIL LEVEL SW.WARNING Ölstands-W. Voralarm
-F1
AIR TEMPERAT.SHUTDOWN Lufttemp.-Wächter Alarm
SPARE
Reserve
/4.2 96 Digital Input
-A1
AIR PRESSURE SWITCH Luftdruck-Wächter Digital Input
PE
Optional über KompressorUmschaltbox 2
OPTIONAL VIA COMPRESSOR SEQUENCE Luftdruck-Wächter SELECTION BOX für Auto Start/Stop AIR PRESSURE SWITCH FOR AUTO START/STOP
7
8
3
2
1
24V DC
1
P
5
L
ÖlStandsWächter OIL LEVEL SWITCH
L
Zust. Änderung
Datum
Name
Norm
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
SPARE
10
NC T
PE
/5.2 Reserve
Digital Input
5
11
12
PE
NC
T COM
COM
-F3
Datum 02.11.10 Bre cpu
9
LuftTemp.Wächter AIR TEMP. SWITCH
-F13 Bearb. Gepr.
E0.6
Digital Input
5
PE
/5.2
AIR TEMPERAT.WARNING Lufttemperatur Voralarm
24V DC
6
F13.1
5
E0.4
Digital Input
SHUTDOWN
-X1
/5.2
OIL LEVEL SW.SHUTDOWN Ölstands-Wächert Alarm
F13.2
Digital Input
-F4
E0.2
F3W
MOTOR PROTECTION RELAY Motorschutzrelais
/5.2
8b
WARNING
E0.7
-A1
6b
F3S
/5.2
Digital Input
-A1
4b
WARNING
E0.0
Original 2011-06-21
-A1
9b
SHUTDOWN
-A1 2b
Digital Input
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 6 von 8 Bl.
0 /6.9
2
1
3
4
5
6
8
7
9
1L+
13
potentialfreie Kontakte FLOATING CONTACTS
-S2 Vorort-Fern LOCAL-REMOTE
14
11
-Q1 /4.1 12 13 -A1
-A1
11b E1.0
/5.2
E1.1
REMOTE CONTROL ON Fernbedienung ein
Original 2011-06-21
13b /5.2
REMOTE CONTROL MANUAL Fernbedienung Hand ein
Digital Input
E1.2
-K5
-K1
-K4
14 /8.0
14 /8.4
13
/5.2
REMOTE CONTROL AUTO ON Fernbedienung Auto ein
Digital Input
-X1
13
14 /8.6
-A1
12b
13
Digital Input
14 15 PE
26 27 PE Fernbedienung aktiv REMOTE CONTROL ACTIVE
(NO)
22 25 PE STÖRUNG DISTURBANCE
(NC)
MAN 0 AUTO
(NO)
20 21 PE Kompressor ein COMPRESSOR ON
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 7 von 8 Bl.
0
2
1
3
4
5
-A1
6
-A1
Digital Output MOTOR MAIN CONTACTOR NETZSCHÜTZ
2t
3t
DISTURBANCE RELAY Störungs-Kontakt
/5.2
A0.3
/5.2
A0.2
5t
REMOTE CONTROL ACTIVE Fernbedienung aktiv /5.2
A0.7 13t
A1
A1
-K4
50A A2 INCL. VAR.
Original 2011-06-21
Digital Output
4t
-K1
/5.9
-A1
Digital Output
COOLING WATER VALVE Kühlwasserabsperrventi
/5.2
A0.1
9
-A1
Digital Output
DRAIN VALVES Entwässerungs-Ventile
/5.2
A0.0
-A1
Digital Output
8
7
A1
-K5
INCL. A2 VAR.
INCL. A2 VAR.
1N1
1 3 5 13 21 51 /4.8 61 /4.9 /4.2 /4.2 /4.2 /7.8
2 4 6 14 22 52 62
/7.9 13
14
Störungskontakt DISTURBANCE RELAY
/7.7 13
14
Fernbedienung aktiv REMOTE CONTROL ACTIVE
Kompressor ein COMPRESSOR ON
-X1
17 1
-Y1
PE
17 1
-Y2
Entwässerungsventile DRAIN VALVES
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
18 1
PE
PE
-Y5 Kühlwasser-Absperrventil (optional) COOLING WATER SHUT OFF VALVE (OPTIONAL)
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 8 von 8 Bl.
0
2
1
3
4
5
6
8
7
9
Kompressor-Umschaltbox COMPRESSOR SEQUENCE SELECTION BOX Box de selection de guidage
200
VIEW FROM BEHIND: 200
120
Kompressor-Umschaltbox COMPRESSOR SEQUENCE SELECTION BOX Kompressor 1 = Führungskompressor COMPRESSOR 1 = LEADING COMPRESSOR
Schutzart: IP54 PROTECTION CLASS: IP54 200
2
200
1
Gewicht: ca. 3kg WEIGHT: APPR. 3kg
Kompressor 2 = Führungskompressor COMPRESSOR 2 = LEADING COMPRESSOR
ø8,7 20
Original 2011-06-21
3S1
20
3S1
Führungswahlschalter SEQUENCE SELECTOR SWITCH Commutateur de guidage
Stellung 1: Kompressor 1 = Führungskompressor Kompressor 2 = Folgekompressor
Stellung 2: Kompressor 2 = Führungskompressor Kompressor 1 = Folgekompressor
POSITION 1: COMPRESSOR 1 = LEADING COMPRESSOR COMPRESSOR 2 = FOLLOWING COMPRESSOR
POSITION 2: COMPRESSOR 2 = LEADING COMPRESSOR COMPRESSOR 1 = FOLLOWING COMPRESSOR
Position 1: Compresseur 1 = Compresseur de guidage Compresseur 2 = Compresseur de suivant
Position 2: Compresseur 2 = Compresseur de guidage Compresseur 1 = Compresseur de suivant
Datum french A texts 23.01.09 Zust. Änderung Datum
bre Name
20.02.08 Umschaltbox für Doppelkompressorsteuerung Bearb. Bre Gepr. cpu SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL Norm
Urspr.
330141
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
333392-44070 Blatt 1 von 2 Bl.
3
4
5
2
2
2
1
1
0
6
10
6
8
7
9
14
-3S1
Original 2011-06-21
Führungswahlschalter SEQUENCE SELECTOR SWITCH
-3X1
-1F4
1
2
5
PE
1
6
3
5
7
9
11 13 15
PE
7
8
3
PE
-2F4
P
Druckluftschalter für Führungskompressor AIR PRESSURE SWITCH FOR LEADING COMPRESSOR
4
PE
P
Druckluftschalter für Folgekompressor AIR PRESSURE SWITCH FOR FOLLOWING COMPRESSOR
A
B
C Druckluftwächter-Signal zum Schaltschrank Kompressor 1 AIR PRESSURE SIGNAL TO CONTACTOR CABINET COMPRESSOR 1
Druckluftwächter-Signal zum Schaltschrank Kompressor 2 AIR PRESSURE SIGNAL TO CONTACTOR CABINET COMPRESSOR 2
Datum
20.02.08 Umschaltbox für Doppelkompressorsteuerung Bearb. Bre Gepr. cpu SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL Zust. Änderung
Datum
Name
Norm
Urspr.
330141
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
D
333392-44070 Blatt 2 von 2 Bl.
0
2
1
3
4
5
Schaltschrank Not-Luft-Kompressor (5,5-7,5kW) STARTER / CONTROLLER EMERGENCY AIR COMPRESSOR (5,5-7,5kW)
6
8
7
9
(344184-44070) NO
NC
29 30
31 32
-X1 W
H1 H2
1
2
3
4
5
6
7
8
Brücke ! link !
M
3
P
Not-LuftKompressor L20 EMERGENCY AIR COMPRESSOR L20 6,3 kW
Heizung HEATING appr. 30W
-F4
P
13 14
19 20
21 22
23 24
T
-F2
25 26
Brücke ! link ! ø6-13
Entwässerungsventil Abscheider DRAIN VALVE SEPARATOR
ø6-13
Öldruckschalter OIL PRESSURE SWITCH
Druckluftwächter für Start/Stop in Automatik AIR PRESSURE SWITCH FOR START/STOP IN AUTOMATIC
HE1 HE2
W
24V DC
-M1
V
24V DC
U
ø6-13
11 12
Luftteemperatur-Wächter AIR TEMPERATURE SWITCH
ø6-13
10
24V DC
ø6-13
440V 60Hz 440V 60Hz
ø9-17
Einspeisung SHIP SUPPLY
Original 2011-06-21
ø9-17
9
NO
-F3
*
ø6-13
ø6-13
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
220-230V AC
L1 L2 L3
-Y4 Gleichstrom-Magnetspulen muß das Kabel * Bei am Gleichrichter im Stecker angeschlossen werden. * IN CASE OF DC SOLENOID COILS THE CABLE MUST BE CONNECTED TO THE RECTIFIER INSIDE THE PLUG.
Datum cable gla.08.12.10 A sizes Zust. Änderung Datum
bre
Bearb. Gepr.
Name
Norm
02.11.10 Bre cpu
Anschlußplan Kompressor L20 CONNECTION DIAGRAM COMPRESSOR L20 Urspr.
342530
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344183-44070 Blatt 1 von 1 Bl.
0
2
1
3
4
5
6
8
7
9
380 210
Schaltschrank Kompressor STARTER/CONTROLLER COMPRESSOR
P1
P1
Amperemeter (mit Markierungsanzeiger) AMMETER
P2
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
Q1
Hauptschalter (mit Türverriegelung) ISOLATING SWITCH
Q2
Hauptschalter Motor-Heizung MAIN SWITCH MOTOR HEATING
H2
Meldelampe "Motor-Heizung ein" INDICATING LIGHT "MOTOR HEATING HEATING ON"
A H2 P2 TD 200
HATLAPA 600
(BU)
Q1 Gewicht: ca. 30kg WEIGHT: APPR. 30kg Schutzart: IP54 PROTECTION CLASS: IP54 8 20
Original 2011-06-21
Q2
mit Türfeststeller
20
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 1 von 8 Bl.
0
2
1
3 P2
4
5
Original 2011-06-21
RESET
HATLAPA
SHIFT
black on red
STOP
8
9
TD 200
MAN
schwarz auf rot
7
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
SIEMENS
STOP
6
AUTO
schwarz auf hell-blau black on light blue
AUTO
ESC
schwarz auf grün
schwarz auf weiß
black on green
black on white
MAN
ENTER
RESET
HATLAPA dark blue on white dunkel-blau auf weiß
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 2 von 8 Bl.
Kurzbeschreibung für Kompressorsteuerung mit TD200
short description f.compressor control with TD200: ON / OFF:
The standard text on the text display is:
ready for operation / off Betriebsbereit / aus
Now you can start the compressor in manual or in automatic operation. When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4. Normallay the manual operation is only used for maintenance purposes. After a blackout the cmpressor will not start again in this manual mode. When You press the "STOP" push button the compressor stops again.
Original 2011-06-21
ALARMS:
Jetzt kann man den Kompressor in der Hand- oder in der Automatik-Betriebsart starten. compressor on / man Kompressor ein / Hand
ready for operation / off Betriebsbereit / aus
When You press the "AUTO" push button the compressor is switched to automatic mode. The compressor starts and stops automatically depending on the air pressure. Normally this should be the standard operation mode. When the pressure switch F4 is closed the compressor starts. When the pressure switch F4 is opened the compressor stops. After a blackout the compressor will start again in automatic mode. When you want to change the operation mode from manual to automatic or from automatic to manual you must press the "STOP" push button before. When there is any fault, the compressor stops and the belonging disturbance alarm is shown in the display. Not all possible disburbance texts are used for this compressor.
Now the fault must be eliminated. Then press the "RESET" push button and there should be the standard text on the display again. Now You can start the compressor again with the "AUTO" or "MAN" push button.
compressor on / auto Kompressor ein / Auto ready for operation / auto Betriebsbereit / Auto
make maintenance ! Wartung fällig ! motor overload Motor Überlast low oil pressure Oeldruck-Alarm high air temperature Lufttemperatur-Alarm high cooling water temperature Kühlwassertemperatur-Alarm no cooling water kein Kühlwasserfluß
Mit der Taste "MAN" wird der Kompressor in der Hand-Betriebsart gestartet. D.h. ohne Funktion des Druckluftschalters F4. Normalerweise wird diese Fuktion nur für Wartungszwecke benutzt. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Hand" nicht wieder selbsttätig starten. Mit dem Taster "STOP" kann der Kompressor wieder gestoppt werden. Mit dem Taster "AUTO" kann der Kompressor in die Betriebsart "Automatik" geschaltet werden. Der Kompressor startet und stopt dann selbstätig in Abhängigkeit des Druckluftschalters F4. Wenn der Druckluftschalter geschlossen ist, dann startet der Kompressor. Wenn der Druckluftschalter geöffnet ist, dann stopt der Kompressor. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Automatik" selbstständig wieder anlaufen.
ALARME
Wenn eine Störung vorliegt, dann stopt der Kompressor und es wird der zugehörige Alarm im Textdisplay angezeigt. Nicht alle hier dargestellten Alarm-Texte werden für diesen Kompressor benutzt. Jetzt must der entsprechende Fehler behoben werden und dann der "RESET"-Taster betätigt werden. Darauf sollte dann der Standart-Text wieder auf dem Display erscheinen. Jetzt kann der Kompressor wieder mit den Tasten "MAN" oder "AUTO" gestartet werden.
ready for operation / off Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS: When there are one or two arrows in the right side of the display, you can go to other display texts by pressing the belonging arrow push buttons The other texts can show more disturbance alarms, if there is more than one fault. Or you can watch the working hours. Or you can watch some special settings of the software. Normally all settings are done by HATLAPA for a normal purpose of the compressor. If you want to change any setting, you must press the "ENTER" push button one time. Now you can change the value with the arrow push buttons. After this you must quit the new value by pressing "ENTER" again.
workings hours xxxxx h Betriebsstunden drainage time 5sec Entwässerungsdauer drainage interval 20min Entwässerungsinterval star delta time 4sec Stern-Dreieck-Zeit delayed start 0sec verzögerter Anlauf cooling water delay 2min Kühlwassernachlauf continuous time 0min Durchlaufzeit
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
EIN / AUS
Dies ist der Standart-Text auf dem Display.
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
Wenn ganz rechts im Display ein oder zwei Pfeile dargestellt werden, dann kann mit d.entsprechenden Pfeil-Tasten zu anderen möglichen Texten gesprungen werden. Die weiteren Texte können weitere Alarme anzeigen, wenn mehr als eine Störung ansteht. Oder es werden die Betriebsstunden angezeigt. Oder es können einige variable Einstellungen der Software angezeigt werden. Normalerweise sind alle Einstellungen für einen normalen Kompressorbetrieb bereits durch HATLAPA festgelegt. Wenn Einstellungen geändert werden sollen, muß einmalig die "ENTER"-Taset betätigt werden. Dann kann man mit den Pfeil-Tasten den entsprechenden Wert verändern. Daraufhin muß der geänderte Wert nocheinmal mit der "ENTER"-Taste quittiert werden.
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 3 von 8 Bl.
0
2
1
3
4
5
6
8
7 -F2
9
2A
2
1
1L1
/5.0
4
6
4
11
6
1
3
5
-K1 3
5
12
/8.1
/8.9
1
4
2
0P ±5%
6
1
3
5
2
4
6
-F1
1
220V 250VA 0S
2A Heizungs-Spannung HEATING VOLTAGE
1
97 95
-Q2
98 96
2
3 Hauptschalter Heizung MAIN SWITCH 4 HEATING
Original 2011-06-21
/6.0
9-13A CLASS 20
-F3
-T1 440V
2
/5.0
2
0,63-1A GV2 RT05
-
-Q1
4
2
1N1
Trafo-Einspeisung TRANSFORMER SUPPLY
-Q3
A
20A
5
3
-P1
3
4
+
1
3
Steuerspannung CONTROL VOLTAGE
51
61
/8.1 52
62
-K1 X1
-H2
Heizung ein HEATING ON
220V X2
SHIP SUPPLY 440V
440V Zuleitung
U
V
W
U
V
W
H1 H2 PE
PE
60Hz
L1 L2 L3 PE
60Hz
-X1
-M1
HE1 HE2
M
3
Kompressor COMPRESSOR 5,5-7,5 kW
Heizung HEATING appr.25-50W
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 4 von 8 Bl.
0 /4.9
/4.9
2
1
3
4
5
6
7
8
9
1L1
1N1
1N1
1L+
+24V DC
/8.0
/6.0
0V DC
2 3 4 5 6 7 8 9
Original 2011-06-21
Softwareversion TD200_8
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
S7-CPU 222 Relais-Ausgänge 8 x Eingänge
/6.0 /6.2 /6.4 /6.6 /6.8 /7.1 /7.3 /7.5
MOTOR PROTECTION RE AIR PRESSURE SWITCH OIL PRESSURE SWITCH AIR TEMPERATURE SWI COOL.WATER TEMP.SWI COOL.WATER FLOW SWI SPARE SPARE
6 x Ausgänge Relais 2 3 5 6 8 9
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5
/8.1 /8.2 /8.5 /8.6
PE Vers N L1
M Erw L+
1M 2M Ein
1L Aus 2L
-A1
MOTOR MAIN CONTACTO DRAIN VALVES Entwäs DISTURBANCE RELAY COOLING WATER VALVE star contactor delta contactor
-P2 TD 200
HATLAPA Anzeige- und Bedieneinheit monitoring and operation panel
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 5 von 8 Bl.
0
/5.9
2
1
3
4
5
6
8
7
9
1L+
1L+
/7.0
95
-F1 /4.2 96
Original 2011-06-21
2
3
-A1
E0.0
/5.2
E0.1
MOTOR PROTECTION RELAY Motorschutzrelais
1
2
/5.2
5
-A1
E0.2
/5.2
AIR PRESSURE SWITCH Luftdruck-Wächter
OIL PRESSURE SWITCH Öldruckk-Wächter
Digitaler Eingang
Digitaler Eingang
Digitaler Eingang
-X1
4
-A1
3
PE
4
6
-A1
E0.3
/5.2
E0.4
AIR TEMPERATURE SWITCH Lufttemperatur-Wächter
5
Option mit Brücke OPTIONAL WITH LINK
6
/5.2
COOL.WATER TEMP.SWITCH Kühlwassertemp.Wächter
Digitaler Eingang
PE
-A1
Digitaler Eingang
7
PE
Option mit Brücke OPTIONAL WITH LINK
8
PE
Option mit Brücke OPTIONAL WITH LINK
Optional über KompressorUmschaltbox
-F4
1
P
-F2 P
2
OPTIONAL VIA COMPRESSOR SEQUENCE Luftdruck-Wächter SELECTION BOX für Auto Start/Stop AIR PRESSURE SWITCH FOR AUTO START/STOP
-F3
Öldruck-Wächter OIL PRESSURE SWITCH
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
-F5
T
Lufttemperatur-Wächter AIR TEMPERATURE SWITCH
HATLAPA
T
Kühlwasser-Temperatur-Wächter COOLING WATER TEMPERATURE SWITCH
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 6 von 8 Bl.
0
/6.9
2
1
3
4
5
6
7
8
9
1L+
7 E0.5
Original 2011-06-21
8
-A1 /5.2
E0.6
COOL.WATER FLOW SWITCH Kühlwasserdurchfl.Wäch
9
10 PE
/5.2
-A1
E0.7
SPARE Reserve
Digitaler Eingang
-X1
9
-A1
/5.2 SPARE Reserve
Digitaler Eingang
Digitaler Eingang
11 12 PE
13 14 PE
Option mit Brücke OPTIONAL WITH LINK
-F6 F
Kühlwasser-Durchfluß-Wächter OIL PRESSURE SWITCH
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 7 von 8 Bl.
0
2
1 -A1
3
4
5
-A1
Digitaler Ausgang MOTOR MAIN CONTACTOR NETZSCHÜTZ /5.2
A0.0
-A1
Digitaler Ausgang
DISTURBANCE RELAY Störungs-Kontakt
/5.2
A0.1
/5.2
A0.2
3
8
7
9
-A1
Digitaler Ausgang
DRAIN VALVES Entwässerungs-Ventile
2
6
5
Digitaler Ausgang COOLING WATER VALVE Kühlwasserabsperrventi
potentialfreie Kontakte FLOATING CONTACTS
/5.2
A0.3 6
11
-Q1 /4.1 12 A1
A1
-K2
-K1
Original 2011-06-21
18A A2 INCL. VAR.
/5.9
13
INCL. A2 VAR.
13
-K1
-K2
14 /8.1
14 /8.5
1N1 1 2 3 4 5 6 13 14 21 22 51 52 /4.8 61 62 /4.9 Kompressor ein COMPRESSOR ON
/8.9 13
/4.2 /4.2 /4.2 /8.8
14
Störungskontakt DISTURBANCE RELAY
-X1
19 20 PE
21 22 PE
23 24 PE
25 26 PE
29 30 PE Kompressor ein COMPRESSOR ON
(NO)
-Y1
-Y2
-Y3/4
Zust. Änderung
Datum
Name
Norm
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
(NC)
Kühlwasser-Absperrventil (optional) COOLING WATER SHUT OFF VALVE (OPTIONAL)
Datum 02.11.10 Bre cpu
STÖRUNG DISTURBANCE
-Y5
Entwässerungsventile (optional) DRAIN VALVES (OPTIONAL)
Bearb. Gepr.
31 32 PE
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 8 von 8 Bl.
Original 2011-06-21
ENGLISH READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR
RECEIVING CHECK Check if any damage has occured during transportation. üCheck nameplate data. üRemove shaft locking device (if any) before operating the motor. üTurn the shaft with the hand to make sure it is turning freely.
HANDLING AND TRANSPORTATION 1 - General
Insulation Resistance Check
MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYEBOLTS
Original 2011-06-21
In case the motors are stored for more than two years, the bearings must be replaced or the lubrication grease must be totally removed after cleaning. Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any). We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas. If motor is fitted with space heaters, these should be switched on.
Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices then a double chain must be used to lift it. Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged. DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE. THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN WHEN THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE.
STORAGE If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases, corrosive smokes, under constant temperature and in normal position free from other objects. Motor storage temperature must remain between 5ºC to 60ºC, with relative humidity not exceeding 50%.
Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding. The resistance measured at 25ºC must be: Ri ≥ (20 x U) / (1000 + 2P) [MΩ] (measured with a MEGGER at 500 V d.c.) where U = voltage (V); P = power (kW). If the insulation resistance is less than 2 megaohms, the winding must be dried according to the following: Warm it up inside an oven at a minimum temperature of 80ºC increasing 5ºC every hour until 105ºC, remaining under this temperature for at least one hour. Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be reimpregnated.
INSTALLATION 1 - Safety All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be well informed and updated concerning safety standards and principles that govern the work and carefully follow them. We strongly recommend that these jobs are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE. Motors must be protected against accidental starts. When performing any maintenance service, disconnect the motor from the power supply. Make sure all accessories have been switched off and disconnected. In order to prevent from penetrating dust and/or water into the terminal box, cable glands or threaded pipe in the lead holes must be installed. Do not change the regulation of the protecting devices to avoid damaging.
Original 2011-06-21
2 - Operating Conditions Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 0ºC and 40ºC. Any variation is stated on the nameplate. COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE. Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate. KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER. 3 - Foundation Motors provided with feet must be installed on solid foundations to avoid excessive vibrations. The purchaser is fully responsible for the foundation. Metal parts must be painted to avoid corrosion. The foundation must be uniform and sufficiently tough to support any schock. It must be
designed in such a way to stop any vibration originated from resonance. 4 - Drain Holes Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order. 5 - Balancing THE MOTORS ARE DYNAMICALLY BALANCED WITH HALF KEY, AT NO LOAD AND UNCOUPLED. Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before installation. Use always appropriate tools for installation and removal. 6 - Alignment ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE. Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings. When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings. Suitable assembly of half-coupling: Check that clearance Y is less than 0.05 mm and that the difference X1 to X2 is less than 0.05 mm, as well.
Note: Dimension X1 and X2 must be 3mm minimum Figure and alignment tolerances 7 - Belt Drive When using pulley or belt coupling, the following must be observed: Belts must be tighten just enough to avoid slippage when running, according to the
specifications stated on the belt supplier recommendation. WARNING: Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture. 8 - Connection WARNING: Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating. WARNING: The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even when the motor has reached standstill.
Original 2011-06-21
A WRONG CONNECTION CAN BURN THE MOTOR. Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ±10%; the acceptable frequency variation is ±5% and the total acceptable variation is ± 10%. 9 - Starting Methods The motor is rather started through direct starting. In case this is not possible, use compatible methods to the motor load and voltage. The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1, L2, L3. To change the rotation direction, interchange two of the connecting leads. THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION. AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED.
Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate. BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE CURRENT STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS. When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, termal protector, etc, connect their terminals to the corresponding devices on the control panel. 10 - Start-Up THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR. a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the connections and the mounting before starting it again. b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done. c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate.
MAINTENANCE WARNING: SAFETY CHECK LIST 1 - General Inspection üCheck the motor periodically. üKeep the motor clean and assure free air flow. üCheck the seals or V Ring and replace them, if required. üCheck the connections as well as supporting screws. üCheck the bearings and observe: Any excessive noise, vibration, bearing temperature and grease condition. üWhen a change, under normal conditions, is detected, check the motor and replace the required parts.
The frequency of the inspections depends on the motor type and on the application conditions.
LUBRICATION FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION. 1 - Machines without Grease Nipples Motors up to frame 200 are normally fitted without grease nipples. In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects: üDisassemble carefully the motors. üTake all the grease out. üWash the bearing with querosene or diesel. üRegrease the bearing immediately.
2 - Machines Fitted with Grease Nipples It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc) that offer some risk to the physical integrity of the operator, proceed as follows: üClean the area near the grease nipple. üPut approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off the motor and insert the rest of the grease. üThe injection of all the grease with the motor in standstill can make the grease penetrate into the motor, through the inner seal of the bearing housing. FOR LUBRICATION USE ONLY MANUAL GREASE GUN.
Original 2011-06-21
RELUBRICATION INTERVALS TABLE 1 - BALL BEARINGS - Series 62/63 II pole
Relubrication intervals (running hours horizontal position) IV pole
VI pole
Bearing 6209 6211 6212
60Hz 18400 14200 12100
50Hz 20000 16500 14400
60Hz 20000 20000 20000
50Hz 20000 20000 20000
60Hz 20000 20000 20000
Bearing 6309 6311 6312 6314 6316 6319 6322
60Hz 15700 11500 9800 3600 -
50Hz 18100 13700 11900 4500 -
60Hz 20000 20000 20000 9700 8500 7000 5100
50Hz 20000 20000 20000 11600 10400 9000 7200
60Hz 20000 20000 20000 14200 12800 11000 9200
Serie 62
VIII pole
50Hz 60Hz 20000 20000 20000 20000 20000 20000 Serie 63 50Hz 60Hz 20000 20000 20000 20000 20000 20000 16400 17300 14900 15900 13000 14000 10800 11800
X pole
XII pole
Grease
50Hz 20000 20000 20000
60Hz 20000 20000 20000
50Hz 20000 20000 20000
60Hz 20000 20000 20000
50Hz 20000 20000 20000
(g) 9 11 13
50Hz 20000 20000 20000 19700 18700 17400 15100
60Hz 20000 20000 20000 19700 18700 17400 15100
50Hz 20000 20000 20000 20000 20000 18600 15500
60Hz 20000 20000 20000 20000 20000 18600 15500
50Hz 20000 20000 20000 20000 20000 20000 19300
(g) 13 18 21 27 34 45 60
TABLE 2 - ROLLER BEARINGS - Series NU 3 Relubrication intervals (running hours horizontal position) II pole Bearing NU 309 NU 311 NU 312 NU 314 NU 316 NU 319 NU 322 NU 324
60Hz 9800 6400 5100 1600 -
50Hz 13300 9200 7600 2500 -
IV pole 60Hz 20000 19100 17200 7100 6000 4700 3300 2400
50Hz 20000 20000 20000 8900 7600 6000 4400 3500
VI pole 60Hz 20000 20000 20000 11000 9500 7600 5900 5000
50Hz 20000 20000 20000 13100 11600 9800 7800 6600
VIII pole 60Hz 20000 20000 20000 15100 13800 12200 10700 10000
50Hz 20000 20000 20000 16900 15500 13700 11500 10200
X pole 60Hz 20000 20000 20000 16900 15500 13700 11500 10200
50Hz 20000 20000 20000 19300 17800 15700 13400 12100
XII pole 60Hz 20000 20000 20000 19300 17800 15700 13400 12100
50Hz 20000 20000 20000 20000 20000 20000 17300 15000
Grease (g) 13 18 21 27 34 45 60 72
Note: üThe ZZ bearings from 6201 to 6307 do not require relubrication as its life time is about 20,000 hours. üTables 1 and 2 are intended for the lubrication period under bearing temperature of 70°C (for bearings up to 6312 and NU 312) and temperature of 85°C (for bearings 6314 and NU 314 and larger). üFor each 15°C of temperature rise, the relubrication period is reduced by half. üThe relubrication periods given above are for those cases applying Polyrex® EM grease. ü When motors are used on the vertical position, their relubrication interval is reduced by half if compared to horizontal position motors. WE RECOMENDED TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD.
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WARNING: EXCESS OF GREACE CAN CAUSE BEARNING OVERHEATING RESULTING IN COMPLETE DAMARGE. Compatibility of Polyrex® EM grease with other types of grease: Containing polyurea thickener and mineral oil, the Polyrex® EM grease is compatible with other types of grease that contain: üLithium base or complex of lithium or polyurea and highly refined mineral oil. üInhibitor additive against corrosion, rust and anti-oxidant additive. Notes: üAlthough Polyrex® EM is compatible with types of grease given above, we do not recommended to mix it with any other greases. ü If you intend to use a type of grease different than those recommended above , first contact HATLAPA. üOn applications (with high or low temperatures, speed variation, etc), the type of grease and relubrification interval are given on an additional nameplate attached to the motor. THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE MANUFACTURER OR HATLAPA
DISASSEMBLY AND ASSEMBLY Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated methods.
The stator grips must be applied over the side face of the inner ring to be disassembled or over an adjacent part. It is essential that bearings assembly be done under cleanning conditions to ensure good operation and to avoid damages. New bearings shall only be taken out from their cases when assembling them. Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals. For bearing assembly warm their inner parts withsuitable equipment - inductive pocess - or use suitable tools.
SPARE PARTS When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate. Please also inform the motor serial number stated on the nameplate.
MOTORS FOR HAZARDOUS LOCATIONS Besides the recommendations given previously, these ones must be also followed: THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY, WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS. Motors for hazardous locations are manufactured according to specific standards for such environments and they are certified by worldwide certifying entities. 1 - Installation The complete installation must follow procedures given by the local legislation in effect. THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT. 2 - Maintenance Maintenance must be carried out by repair shops authorized by HATLAPA. Repair shops and people without HATLAPA’s authorization who will perform any service on hazardous location motors will be fully responsible for such service as well as for any consequential damage.
ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION. When performing maintenance, installation or relubrication, follow these instructions: üCheck if all components are free of edges, knocks or dirt. üMake sure all parts are in perfect conditions. üLubricate the surfaces of the endshield fittings with protective oil to make the assembly easier. üUse only rubber hammer to fit the parts. üCheck for correct bolts tightening. üUse clearance calibrator for correct T-box fitting (smaller than 0.05mm). DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE FACTORY.
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MOTORS DRIVEN BY VFD Applications using VFD´s without filter can affect motor performance as follows:
üLower efficiency. üHigher vibration. üHigher noise level. üHigher rated current. ü Higher temperature rise. üReduced motor insulation. üReduced bearing life. 1- Standard Motors üVoltages lower than 440V do not require filter. üVoltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters. üVoltages equal or higher than 575V require filter for any size of power supply cables. IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY, MOTOR WARRANTY WILL BE VOID. 2- Inverter Duty Motors: üCheck power supply voltage of the forced cooling set. üFilters are not required.
Lubricating Instructions for V-Line Piston Compressors
178492 Rev. 01.06
1. General Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of the compressor. Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is advisable to contact him when making your choice. Ask only the lubricant manufacturer for his recommendation! He is the expert.
2. Lubrication Oil Quality
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Above all, compressor oils must have good lubrication properties for which their viscosity is highly important. HATLAPA recommends lubrication oils within the following range: viscosity at 100 °C: min. 9 cSt max. 15 cSt viscosity at 40 °C: min. 90 cSt max. 120 cSt The lubrication oils should have low tendency to ageing and coking in order to prevent oil carbon deposits on valves and pipelines. HATLAPA recommends to use oils of class VDL according to DIN 51 506.
3. Guarantee If lubrication oils are used which do not meet the requirements, damage to the compressor may occur. This damage is not covered by HATLAPA's guarantee obligations.
4. Lubricant Examples The following oils are examples which comply with the above specification: Mineral Oils Synthetic Oils BP ENERGOL RC100 ENERSYN RX100 CASTROL AIRCOL PD 100 AIRCOL SN 100 CHEVRON TEXACO (FAMM) COMPRESSOR OIL EP VDL100 CETUS DE 100 ELF TOTAL FINA (Lubmarine) DACNIS P100 BARELF CH 100 ESSO (ExxonMobil Marine) EXXCOLUB 100 SYNESSTIC 100 MOBIL (ExxonMobil Marine) RARUS 427 RARUS 827 SHELL CORENA P 100 CORENA AP 100 However, the oil properties are subject to change without notice by the oil manufacturer. Also, the oil characteristics may vary depending on the regional market. Therefore this list does not release the operator of the compressor from verifying that the selected oil complies with the above specification.
Service
Anleitung zur richtigen Bestellung von Ersatzteilen Für die Bestellung sind folgende Angaben unbedingt erforderlich: 1) Schiffsname (Ex-Name), Neubau-Nr. und Bauwerft 2) Fabriknummer und Typenbezeichnung (siehe Typenschild) 3) Ersatzteilnummer entsprechend Ersatzteilliste 4) Gewünschte Versandart, Versandadresse und Rechnungsanschrift
Instructions for correctly ordering spare parts When ordering spare parts, the following details must be given:
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1) Name of vessel (former name), Hull No. and building shipyard 2) Serial number and type of the machine (see name plate) 3) Part number from the Spare Parts List 4) Desired method of dispatch, invoice and consignee’s address
Instruction pour établir les commandes de pièces de rechange Les indications suivantes seront indispensables pour la commande: 1° Nom du navire (ex-nom), No. du navire et chantier de construction 2° Numéro d’usine et type (voir plaque d’identité) 3° Numéro de pièce suivant liste des pièces de rechange 4° Mode de transport désiré, adresses du destinataire et de la facture
Instrucciones para pedir correctamente piezas de repuesto. Cuando se piden piezas de repuesto, deben ser dados los – siguiéntes datos:
1) Número de serie y tipo (ver placa) . 2) Número de la pieza según la Lista de Piezas de Repuesto. 3) Forma de despacho así como consignación y dirección para la facturación. 4) Nombre del buque (nombre antígúo) ‚ número de construción y Astilliero.
Guida alla corretta ordinazione dei pezzi di ricambio Per ordinare rispettivi pezzi di ricambio sono assolutamente indispensabili i seguenti dati: 1) Nome della nave (ev. nome precedente), numero di Costruzione e nome del Cantiere Naval e 2) Numero di matricola e tipo del compressore (vedi targhetta) 3) Numero del pezzo di ricambio in base alla «Lista dei pezzi di ricambio» 4) Mezzo di trasporto, indirizzo di spedizione ed indirizzo di fatturazione desiderati
Service
Um Ersatzteile schnellstens zu erhalten, wenden Sie sich bitte direkt an
oder an unsere Vertretungen (x), Kundendienststellen (o) oder Lizenznehmer ( +) laut anliegender Liste. In order to receive spare parts with the least possible delay, please get in touch with us directly
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or with our representatives (x),service stations (o) or licensees/co-operators (+) as indicated in the enclosed list. Pour assurer une fourniture rapide, veuillez vous adresser á
ou á nos agences (x) , stations-service (o) ,licenciés/partenaires de cooperation (+) Per offenere i rispetti celermente rivolgersi direttamente alla:
od ai rappresentanti (x), centri d‘assistenza (o) o licenziatari/partner di cooperazione (+) delta HATLAPA indicati neIl‘elenco aliegato.
Service Stations Spare Parts Agencies OUR MANUFACTURING PROGRAMME: Deck machinery, compressors, steering gear
Headquarters:
HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 25436 Uetersen GERMANY Phone: +49 4122 711-0 Mobile: +49 172 9 813292 Fax: +49 4122 711-104 Sales 711-330 Service
[email protected], http://www.hatlapa.de
Subsidiary office for Hamworthy type compressors:
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HATLAPA Marine Equipment Ltd. Discovery Court Business Centre 551-553 Wallisdown Road POOLE, Dorset BH12 5AG UNITED KINGDOM Phone: +44 1202 8531-80 Fax: +44 1202 8531-91 Sales 8531-90 Spares
[email protected], http://www.hatlapa-uk.com
Vertretungen (x), Kundendienststellen (o) und Lizenznehmer (+) Representatives (x), service stations (o) and licensees/co-operators (+) Agencies (x), stations-service (o) et licenciés/partenaires de cooperation(+) o Australia
CJA Marine Technology Pty Ltd Unit 3, 136 Cochranes Road Moorabbin, Victoria 3189
Tel: +61 3 953213-97 / 953213-86 Fax: +61 3 953214-13
[email protected]
x Belgium
Marine & Industrie Div. of SA Aciers Marathon Staal NV Haven 138, Boterhamvaartweg 2 (Unit 1) B-2030 Antwerp
Tel: +32 3 82740-91 Fax: +32 3 82740-95
[email protected]
o Belgium/ Luxembourg
Service Hydro n.v. Haven 138, Boterhamvaartweg 2 B-2030 Antwerp
Tel: +32 3 54640-80 Fax: +32 3 54640-81
[email protected]
x Brazil
TRIDENTE Indústria Comércio Equip Ltda Rua Visc Inhaúma 134 – Centro, Rio de Janeiro RJ, 20091-007
Tel: +55 21 2233-1489 Cell: +55 21 9983-3190 Fax: +55 21 2516-7543
[email protected]
o Brazil
Metalock Brasil Ltda Rua Visconde do Rio Branco 20/26 Santos, SP 11013-030
Tel: +55 13 322646-86 Fax: +55 13 322646-80
[email protected]
Updated 14th December 2010
Page 1
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Service Stations Spare Parts Agencies
x Bulgaria
Ecatdan ApS 1, Studentska Str. 9010 Varna
Tel: +359 52 383476
[email protected]
xo Canada
Marine and Offshore Canada 29-113 Cushman Rd St. Catherines Ontario, L2M 6S9
Tel: +1 905 688 4922 (office) Fax: +1 905 688 9028 Cell: +1 905 650 3160
[email protected]
o Chile
Eurotecnica Ltda Lincoyán # 973 4030485 Conception
Tel: +56 41 22532-75 Fax: +56 41 22532-76
[email protected]
x+ China
HATLAPA Nanjing Representative Office Asia Pacific Pte Ltd Room 612, No 19, Zhanyuan Road Nanjing 210039
Tel: +86 25 52 26 27 90 Fax: +86 25 86 70 33 10
[email protected]
x China
HATLAPA Shanghai Asia Pacific Pte Ltd No. 1211 Chang De Road Room 1011, Baohua Building Shanghai 200060
Tel: +86 21 623296-71 Mobile: +86 137 0 17473 14 Fax: +86 21 623039-71
[email protected]
xo Croatia
Nava International d.o.o. Planciceva 4 21000 Split
Tel: +385 21 385267 Fax: +385 21 385267
[email protected]
x Cyprus
M.I.E. Services Ltd The Hawk Building 124 Gladstonos Str.. 3032 Limassol
Tel: +357 25 889801 Fax: +357 25 763902
[email protected]
x Cyprus
HATLAPA EastMed Ltd The Hawk Building 124 Gladstonos Str.. 3032 Limassol
Tel: +357 25 8897-00 Fax: +357 25 3660-88
[email protected]
x Denmark
A/S Kelvin Hughes Gøngehusvej 280 DK-2970 Horsholm
Tel: +45 8734 2270 Mobile: +45 2060 9405 Fax: +45 8611 2726
[email protected]
x Egypt
AMCO Alexandria Maritime 10 Ahmed Yehya Pasha St. Gleem P.O. Box 1424, Alexandria
Tel: +20 3 58585-70 Fax: +20 3 58285-87
[email protected]
x Finland
EPOMARE OY (from 1st January 2011) Perämiehenkatu 11 20810 Turku
Tel: +358 2 2749640 Fax: +358 2 2351499
[email protected]
x France
Wenex Equipments SA 49 Rue de Billancourt 92100 Boulogne
Tel: +33 1 411023-30 Fax: +33 1 411023-45
[email protected]
o Germany
Friedrich Jung Fa. König-Friedrich-Wilhelm-Str. 20
Tel: +49 203 82898 Fax: +49 203 57085-24
Updated 14th December 2010
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Service Stations Spare Parts Agencies
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47119 Duisburg xo Great Britain
HATLAPA Marine Equipment Ltd Discovery Court Business Centre 551-553 Wallisdown Road Poole, Dorset BH12 5AG
Tel: +44 1202 8531-80 Fax:+44 1202 8531-90
[email protected]
xo Greece
M.I.E. Co. Ltd. Kanari 1 18537 Piraeus
Tel: +30 210 4598-800 Fax: +30 210 4539-234
[email protected]
o Greece
INJEGOV Advanced Mechanical Services Ltd Vipa Shistou, Road 2, OT3 Perama 18863 Piraeus
Tel: +30 210 4323600/1-2 Fax: +30 210 43127-70
[email protected]
xo India
Dolphin Consultants 35 Mittal Chambers Nariman Point, Maharashtra State Mumbai 400021
Tel: +91 22 302877-11 to 15 (5 Lines) Fax:+91 22 302877-10
[email protected]
xo Indonesia
PT. Assindo Perniagaan Internasional Victoria Building, 3rd Floor Jl. Sultan Hasanuddin No. 47 - 51 Jakarta Selatan 12160
Tel: +62 21 72555-41 Fax: +62 21 72555-46
[email protected]
+ Indonesia
PT. Assindo Perniagaan Internasional Victoria Centre, 3rd Floor Jl. Sultan Hasanuddin No. 47-51 Jakarta 12160
Tel: +62 21 72555-41 Fax: +62 21 72555-46
[email protected]
xo Iran
Iran IMEXEN Co. No.4, Apt. 6, Morvarid Crossing Goldan St., Africa Ave. (Ex-Jordan) Tehran 19668
Tel: +98 21 22000008 Fax: +98 21 22004849
[email protected]
xo Italy
RTN Srl Loc. Cà Verde 29011 Borgonovo Val Tidone (PC)
Tel: +39 0523 869611 Fax: +39 0523 861077
[email protected]
xo Korea
Dong Sung Co. Room 1725, 21 Century City Building 55-1, Daeyeon 3-dong Nam Gu, Pusan 608-743
Tel: +82 51 61012-33 Fax: +82 51 61012-32
[email protected]
xo Korea
HATLAPA Korea Co. Ltd. 1212, Jisa-dong Gangseo-gu, Busan
Tel: +82 51 97292-66 Fax: +82 51 97292-70
[email protected]
x Lebanon
M.I.E. (Overseas) Ltd. The Hawk Building 124 Gladstonos Street 3312 Limassol, Cyprus
Tel: +357 25 889800 Fax : +357 25 346626
[email protected]
x Middle East
M.I.E. (Overseas) Ltd.
Tel: +357 25 366077 Fax.:+357 25 366088
[email protected]
for steering gear
Saudi Arabia, Oman The Hawk Building U.A.E., Qatar, Yemen 124 Gladstonos Street Bahrain, Kuwait, 3312 Limassol, Cyprus
Updated 14th December 2010
Page 3
Service Stations Spare Parts Agencies
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Jordan, Israel
xo Netherlands
Hamworthy KSE B.V. Aploniastraat 33 3084 CC Rotterdam
Tel: +31 10 46247-77 Fax.: +31 10 41590-46
[email protected]
xo Norway
Hatlapa Marine Equipment AS Frithjof Nansens Plass 7, 0117 Oslo
Tel: +47-918-08-546
[email protected]
xo Poland
SANGER METAL Sp-ka Z o.o. Mostnika Str.10-12 70-672 Szczecin
Tel: +48 91 4623236 / 4623383 Fax: +48 91 4623345
[email protected]
xo Portugal
Javier López-Alonso Morán Avda. San Luis 166 - 8° E 28033 Madrid
Tel/Fax: +34 91 3831577
[email protected]
x Romania
XEREX SRL 43 Alexandru Cernat str. 800087 Galati, Romania
Tel/Fax: +40 236 462056 Mobile: +40 723 533596
[email protected]
x Singapore
HATLAPA Asia Pacific Pte Ltd German Centre, Unit 02-25 25 International Business Park Jurong, Singapore 609916
Tel: +65 65 628086 / 628088 Mobile: +65 96 339381 Fax: +65 65 628099
[email protected]
xo Spain
Javier López-Alonso Morán Avda. San Luis 166 - 8° E 28033 Madrid
Tel/Fax: +34 91 3831577
[email protected]
xo Sweden
Bövik Marin AB Hälleflundregatan 12 42658 Västra Frölunda, Gothenburg
Tel: +46 31 290075
[email protected]
x Syria
M.I.E. (Overseas) Ltd. The Hawk Building, 124 Gadstonos Street 3312 Limassol, Cyprus
Tel : +357 25 889800 Fax : +357 25 346626
[email protected]
x Taiwan
SHIPCARE Co. Ltd. Rm1, 2nd fl., no.135, sec.1 Chungking South Road Taipei 10036
Tel: +886 2 2383-2255 Fax: +886 2 2383-1020
[email protected]
x U.S.A.
MarinSOLVE LLC PO Box 2176 Clifton, NJ 07015
Tel: +1 973 24657 26 Fax: +1 973 75503 33
[email protected]
x U.S.A.
CS Controls 101 Dickson Road Houma, LA 70363
Tel: +1 985 876 6040 Fax: +1 985 876 0751
[email protected]
x U.S.A.
Mariner Hub LLC 917 West 21st Street, Unit H Houston, TX 77008
Tel: +1 713 822 1252
[email protected]
Updated 14th December 2010
Page 4
Service Stations Spare Parts Agencies
TENAVAL Av. Fco. De Miranda, Edif. Bco del Orinoco 2°, Piso Ofic 2-B Caracas
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x Venezuela
Updated 14th December 2010
Page 5
Tel: +58 212 285-2344 +58 212 285-7822 +58 212 285-7631 Fax: +58 212 285-7776
Technical Documentation Piston Compressor
Technical Documentation for Piston Compressor Type L 20
of
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Uetersener Maschinenfabrik GmbH & Co. KG 25436 UETERSEN GERMANY Phone: +49-4122-711 0.. Telefax: +49-4122-711 330 Internet http://www.hatlapa.de E-Mail:
[email protected]
Ref.-No.:
10.2722 / 2
Serial-No.:
10.2722 - 2 - 0
This technical documentation belong NOT in the office, but in the hands of the operator
Technical Documentation Piston Compressor
Original 2011-06-21
Table of Contents 1
Important Information on this Documentation and Safety
2
Final Drawings / Specification
3
Operating Instructions
4
Technical Indications
5
Spare Parts List
6
E-Diagrams
7
E - Motor
8
Lubricating Instructions
9
Service
We recommend reading these instructions through carefully and becoming quite familiar with the design and operation of the piston compressor before putting it into operation, this will avoid damage through imporper handling.
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Important Information on this Documentation and Safety
Important Information on this Documentation and Safety
1
Information on Manuals ........................................................................................................................... 3
2
Copyright ................................................................................................................................................. 3
3
Guarantee................................................................................................................................................ 3
4
Designations ............................................................................................................................................ 4
5
Signs Used .............................................................................................................................................. 5
6
Intended Use ........................................................................................................................................... 5
7
Ban on Arbitrary Modifications................................................................................................................. 5
8
General Safety Instructions ..................................................................................................................... 6
9
Safety Equipment .................................................................................................................................... 6
10 Instruments for Operating Surveillance ................................................................................................... 6 11 Safety Instructions for Assembly ............................................................................................................. 7 12 Additional Safety Instructions for Electrical Installation........................................................................... 7 13 Safety Instructions for Operation and Service......................................................................................... 8
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14 Safety Instructions for Maintenance and Repairs ................................................................................... 9 15 Noise Protection .................................................................................................................................... 10 16 Waste Disposal...................................................................................................................................... 10
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Important Information on this Documentation and Safety
1 Information on Manuals This manual includes all information necessary for guaranteeing the safety as well as for the operation and maintenance of the equipment. It is directed at instructed and trained personnel who are responsible for the operation and maintenance of the equipment. Only knowledge of this manual can ensure faultless and correct functioning of the equipment, so its contents must be known to the responsible persons. The manual should be kept so that the operating and maintenance personnel have access to it at all times.
2 Copyright The copyright for this technical documentation remains with HATLAPA. This documentation is intended for the operator and their personnel only.
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All rights reserved.
3 Guarantee Guarantee and liability claims for damage to persons and/or objects are excluded, if caused by one or several of the following circumstances:
Techen, Kerstin
−
inappropriate use of the equipment,
−
neglect of the provisions of this documentation,
−
improper assembly, operation or maintenance,
−
operation of the equipment with ineffective protective devices,
−
arbitrary functional or constructive alteration of the equipment,
−
removal of parts or installation of spare parts or additional components, respectively, which have not been supplied or approved by HATLAPA,
−
repairs which have not been authorised by HATLAPA,
−
impact of foreign bodies in case of catastrophes or Force Majeure.
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Important Information on this Documentation and Safety
4 Designations
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Persons are defined as follows:
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−
The operator is the (natural or legal) person on whose behalf the equipment is used, e.g. the ship’s owner.
−
Operating personnel are personnel trained for the respective work, and who are authorised to operate the equipment and to remedy disturbances. The operating personnel must be trained for the tasks they are entrusted with, and meet the requirements necessary to handle the equipment.
−
Assembling personnel are personnel trained for the respective work, and who are authorised to assemble the equipment. They are able to carry out the tasks assigned to them and to recognise possible dangers because of their completed specialised training.
−
Maintenance personnel are personnel trained for the respective work, and who are authorised to maintain, adjust and modify the equipment. They are able to carry out the tasks assigned to then and to recognise possible dangers because of their completed specialist training.
−
An electrician has electro-technical skills gained by respective education, masters the legal regulations, and is assigned by the operator to carry out work on their electrical equipment and appliances.
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Techen, Kerstin
Important Information on this Documentation and Safety
5 Signs Used Sign for Danger Danger! This sign indicates specific behavioral patterns the non-observance of which is highly dangerous, or which may lead to permanent bodily injury. Sign for Caution Caution! This sign indicates specific behavioral patterns the non-observance of which may lead to injury to persons, severe damage, or severe malfunction of the equipment, or to damage to the environment.
Sign for 'Pay Attention' Pay Attention!
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This sign indicates specific behavioral patterns the non-observance of which may lead to damage or malfunction of the equipment.
Sign for Information Information! This sign indicates tips and useful information which facilitate the operation of the equipment or the understanding of the documentation.
6 Intended Use The compressor is exclusively designed for air compression. Any other use is deemed as not being in compliance with the intended use and requires express written approval from HATLAPA. The intended use also includes compliance with all the regulations contained in this technical documentation, the generally acknowledged rules of technology as well as all the relevant laws, standards and regulations.
7 Ban on Arbitrary Modifications Arbitrary modifications and changes to the machine/system are not permitted, as they may put persons in danger and result in damage to the machine/system. If you are planning modifications or changes, contact HATLAPA and request written authorisation.
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26.11.2009
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Important Information on this Documentation and Safety
8 General Safety Instructions Besides the specific safety-related technical notes contained in these instructions and the sub supplier's documentation, you must also observe the generally applicable safety and accident regulations, such as the: –
Recognised technical regulations for safe and professional work
–
Regional and internal regulations
–
Regulations from the responsible classification authority
–
Rules and regulations for the prevention of accidents from the professional organisation, in particular concerning compressors
–
Safety signs and indicator plates on the machine/system
–
Environmental protection regulations
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Incorrect handling or failure to comply with regulations concerning use can result in the risk of physical injury and death and/or damage to property. Observe the limits specified in the technical data. Find out about the fire detection and fire prevention options, and ensure that these are fully functional and sufficient.
9 Safety Equipment Danger! Faulty safety equipment may put lives and equipment at risk. All safety equipment must always be in a flawless and fully operational condition. You must not make the safety equipment inoperative in any way. If a piece of safety equipment is defective, the machine/system must not be operated. Only remove safety equipment if the machine/system has been isolated and secured. Perform regular checks on the safety equipment, in accordance with the regulations in this documentation and the sub suppliers' documentation.
10 Instruments for Operating Surveillance Caution! If instruments for operating surveillance are out of order, monitoring of the operating conditions of the machine/system may lead to incorrect analyses. This may put lives and/or equipment at risk. Never decommission any instruments for operating surveillance. If instruments for operating surveillance are defective, they must be changed as soon as possible. Take utmost care when operating the machine/system until the instruments are exchanged.
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26.11.2009
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Important Information on this Documentation and Safety
11 Safety Instructions for Assembly Danger! During assembly and installation, the functioning of the safety equipment is not guaranteed. Therefore, the safety of the assembling personnel is to a great extent dependent on the proper execution of work. Only trained and briefed personnel are permitted to carry out assembling and installation work. The personnel must have a specialised knowledge of compressed air and electrical engineering. Only use suitable and fully functioning tools. During torching or welding work, ensure that risks of fire or explosion are avoided.
12 Additional Safety Instructions for Electrical Installation All work on the electrical systems is only allowed to be performed by qualified electronics specialists. Danger!
Original 2011-06-21
Deadly voltage! Before starting to work on electrical equipment, the machine/system must be deenergized. Ensure that −
the mains supply is deactivated. Check that the disconnected parts are deenergized before commencing work.
−
the electricity supply cannot be reconnected unintentionally or without authorization while work is being performed on the electrical installation.
−
the electricity for parts which must remain connected for the maintenance and repair work only remains connected for as long as is absolutely necessary for the work in question.
Danger! The main switch remains energized even if it is deactivated. Work carried out on electrical systems must be done so in accordance with the valid safety regulations, as well as all other relevant state or local regulations. Under no circumstances repair or tide over defective fuses. Fuses must only be replaced by the same type of fuses. When working on electrical systems, only use permitted and suitable tools. Only use voltage-free tools. When taking measurements with the voltage supply of >65 V activated,
Techen, Kerstin
−
you must under no circumstances touch the electrical connection points,
−
the inspection equipment must be in good condition and safe to operate,
−
you must not wear any jewelry on fingers or wrists,
−
you must stand on insulated ground.
26.11.2009
7 / 10
Important Information on this Documentation and Safety
13 Safety Instructions for Operation and Service Danger! The machine/system must only be operated by trained and briefed operating personnel. New personnel may only use the machine/system under the constant supervision of trained and briefed operating personnel. Give regular briefings on accident regulations and the requirements stated in this documentation. Danger! Drawing in into moving parts! Body parts or clothing may get caught at the flywheel. Prior to start-up, check that the flywheel cover is fitted! Caution! Burn hazard! The compressor housing and the pressure pipes become hot during operation. Wear protective gloves!
Original 2011-06-21
Caution! Drawing in into moving parts! Long hair or loose clothing may get caught at the air intake filter. When the compressor is in operation, maintain a safe distance to the compressor housing! Caution! In automatic operation mode, the compressor starts automatically without warning.
8 / 10
26.11.2009
Techen, Kerstin
Important Information on this Documentation and Safety
14 Safety Instructions for Maintenance and Repairs Danger! The machine/system must only be maintained and repaired by trained and briefed maintenance personnel. The personnel must have a specialised knowledge of hydraulic and electrical engineering. Optionally, the compressed air pressure gauges can be equipped with gauge valves. In this case, the compressor may be under pressure although the compressed air pressure gauges show a pressure of 0 bar. Before starting any repair work, shutdown the machine/system and secure it against unintentional restarting. If the work can only be carried out while the machine/system is running, make the necessary safety arrangements. A second person must monitor the work, and be ready to intervene if needed. When carrying out maintenance and repair work, do not decommission more than one piece of safety equipment at a time. Only use suitable and fully functioning tools.
Original 2011-06-21
Caution! Burn hazard! The compressor housing and the pressure pipes become hot during operation. Before beginning maintenance work, allow the compressor to cool down for approx. 2 hours! Caution! Besides the information contained in this documentation, you must also observe the regulations of the classification authorities and professional organisations in order to determine the inspection and maintenance intervals. After disassembly, always exchange self-locking nuts and gaskets. They are not designed for repeat use. If leaks occur at couplings which are sealed with resilient joint gaskets, the leaks cannot be eliminated by retightening the coupling because the resilient joint gaskets are damaged or hardened. Exchange the resilient joint gaskets. Pay particular attention to cleanliness. Cover any openings to prevent the ingress of dirt. Ensure that tools, loose parts or cleaning cloths are not left in or on the compressor. Dispose of old oils and grease in an environmentally friendly manner in accordance with national regulations.
Techen, Kerstin
26.11.2009
9 / 10
Important Information on this Documentation and Safety
15 Noise Protection Refer to the technical data for information about the noise level. Caution! Make sure to wear ear protection in the vicinity of the compressor when it is in operation.
16 Waste Disposal The following substances which are caused by the operation of the machine/system must be disposed of in an environmentally friendly manner, in accordance with the applicable laws: used oils and grease as well as cloths with such substances on them;
−
cleaning agents, and cloths with cleaning agents on them.
Original 2011-06-21
−
10 / 10
26.11.2009
Techen, Kerstin
Final Drawings
Original 2011-06-21
for COSCO GUANGDONG SHIPYARD HULL No: N352 - N353 HATLAPA Order No.: 10.2722 - 23 / 2 1x EMERRGENCY AIR COMMPRESSOR L20
2011-06-21
1/1
INDEX
SECTION 1 .............................................. TECHNICAL SPECIFICATION
SECTION 2
CONTRACT SPECIFIC DRAWINGS
Original 2011-06-21
DRAWING No.
TITLE
179132049............................ GENERAL ARRANGEMENT – L20 – 30 BAR 450388................................... PIPING DIAGRAM .............................................. INSTRUMENT LIST D10183...................................COMP. AIR PRESSURE CONTROL SWITCH 177148...................................OIL AND WATER SEPARATOR 174502...................................FLEXIBLE HOSE FOR COMPRESSED AIR 174767...................................EMOTOR DATA SHEET 344183..................................CONNECTION DIAGRAM 344184...................................STARTER/CONTROLLER
STANDARD COMPRESSOR DRAWINGS DRAWING No.
TITLE
178483................................... FLEXIBLE HOSE INSTALLATION GUIDELINES 175694................................... LUBRICATING INSTRUCTIONS
SECTION 3 074608................................... SPARE PART LIST 176968................................... SPARE PART E-MOTOR 020244...................................AIR FILTER
Original 2011-06-21
SECTION 1
T E C H N I C A L S P E C I F I C A T I O N/2 Our Ref. 10.2722/2K EMERGENCY AIR COMPRESSOR 1 x ELECTRO-COMPRESSOR SET T y p e L 20 high pressure compressor, single acting, with 2 cylinder/s, 2-staged, air-cooled. F.A.D. compressed from 0-30 bar
25
m³/h (+/-5%)
(20°C, 1,013 bar)
Original 2011-06-21
Speed Final pressure Power need approx. Heat to be dissipated Direction of rotation when facing the driving side
1.750 min-1 30 bar 6,3 kW 5,1 kJ/sec. clockwise
SCOPE OF SUPPLY Compressor with flywheel and flexible coupling air-intake filter with silencer radial fan for cylinder cooling intermediate and after cooler force-feed lubrication by means of gearwheel pump pressure gauges with glycerine filling for 1st and 2nd stage as well as for oil pressure with root cocks condensate drain valves on 1st and 2nd stage safety valves on 1st and 2nd stage pipe connection for compressed-air outlet crankcase breather oil level inspection glass fusible plug AUTOMATIC CONTROL for starting without load, for automatic start/stop operation, with automatic drainage in "stop" position as per description and piping and wiring diagram, suitable for control current, consisting of: a) 1 solenoid valve, ref. Y4 relieving the compressed-air delivery pipe and for draining the 2nd stage as well as the oil and water separator ref. D4, fitted to the oil and water separator, open when not energised. b) 1 pressure control switch, ref. F4, separate, with 3-way test cock suitable for control current, switching-on pressure adjustable between 12 and 27 bar, switching-off pressure at 30 bar. 1 contactor cabinet with motor protection, consisting of steel casing, containing: main contactor for the electric motor transformer
overcurrent relay for the electric motor main switch PLC (programmable logic control) textdisplay for indication of operating modes, disturbances and service intervals with push buttons for operating the compressor potential free contacts for indicating "compressor on" and "collective alarm" with cable gland Oil pressure control switch, ref. F2, splash-tight, with 3-way test cock switching off the compressor set at insufficient oil pressure Compressed-air temperature control switch, ref. F3, splash-tight, switching off the compressor at excessive compressed-air temperature and making contact with the alarm Non-return valve, ref. RV, separate for mounting in the compressed-air delivery line.
Original 2011-06-21
Oil and water separator, ref. D4, separate, with solenoid valve for automatic drainage, for mounting in the compressed-air delivery line. AC squirrel cage induction motor for direct-on-line starting make of our choice, type B3/B5, flange diameter 300 mm, protection IP54 for 45°C ambient temperature according the rules of NK 6,3 kW nominal out-put at 1.750 min-1, 440 V, 60 Hz, with space heater and cable gland Compressor set, three-point mounted, assembly included. Resilient mounting, separate hose pipe for compressed-air included
FINAL PAINTING of compressor, electric motor and contactor cabinet: MUNSELL 7.5 BG 7/2 TESTING: by NK of compressor and oil-water separator 1 set of spare parts for compressor according to the rules of NK 1 set of spare parts for electric motor consisting of 1 set anti-friction bearings 1 set of spare parts for contactor cabinet consisting of 1 contactor 1 additional set of air filter inlets for compressor for SY’s purpose
Original 2011-06-21
SECTION 2
949 540 Temperature switch; F3
409 Air intake filter
Safety valve 2nd stage; SV2
Pressure gauge 1st stage; P1
536 510
Oil pressure gauge; P4 Pressure gauge 2nd stage; P2 Drainage 1st stage Comp. air outlet for pipe ø16x1,5
100
Foot print
70
649 100 130
158
222 262
Oil pressure switch; F2
Fusible plug; F Drainage 2nd stage G3/8 Oil level inspection glass Oil outlet
435
500 minimum distance for cooling air supply
215 227 382
465
Original 2011-06-21
12
5
159 241
621
Motor 132M
ø11
ø11
70
Safety valve 1st stage; SV1
weight: ~175 kg Komm.-Nr.:
E-compressor set L20
Datum : Bearb. 01.11.10
"Schutzvermerk nach DIN 34 beachten"
Freig.
01.11.10
Pitrowski Waldow
HATLAPA
Uetersener Maschinenfabrik D-25436 Uetersen
Masstab:
%
Zeichnungsnummer
179132-049 Klassennummer
06040
Index
-
Blatt
1
v. Blaetter
1
HATLAPA
Original 2011-06-21
Instrument list
Original 2011-06-21
Instrument:
range / setting point
1st stage air safety valve: 2nd stage air safety valve:
SV1 SV2
Set to: Set to:
7 32
bar bar
Oil pressure switch (alarm and trip):
F2
Adjusted to: 1
bar
F3
Adjusted to: 75
°C
Compressed air temperature switch (alarm and trip):
Pressure switch:
CMG 14.07.08
F4 Start: adjst. Stop: adjst.
bar bar
> -I'.
CROSS REFERENCE
151 75,5
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IIIM1 I II 212111...1 11,WFAIME 111
ALTERATIONS
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1
Original 2011-06-21
I
I
(A)
ORIGINAL ISSUE
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.-.
C) 7)
3
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z TI -I r-ri
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71
Fri
rfl rfl -1 --i --i (-)71= -I
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-17 --i
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.-,
"-z 1--) mi-i ,-,--1 p 1-- r- n = = -i rn (/) '-'
=
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1> '-' 1 - < < petti -1,--,,--,
(/) C
71 71 C) .__, 3> ' -1 _,
rfl P1 C-) C-) C7 (C7 -I Z = = 7> -1 P1 Z C-) -1 -
v) 'T_I c-) =
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0.,
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c , = ._, c ._ _, 1— X>
a>
Z
c,,,)
7
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C7 GI Irg 71
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(C7 = az
,,.. =
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DJ rt)
= <
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FIRST ANGLE PROJECTION ALL DIMENSIONS IN MILLIMETRES MACHINING SYMBOLS UNSTATED LIMITS TO T0103 PART NO.
SHT. 1 SH1S. 1
„D,1 ,0,1 83 „
ISS1
PATT. NO. MAT'L SPEC.
HATLAPA MARINE E QUIPMENT Ltd Copyrightand All Oth er Ri ghts R eserved
,--. k-,,
= rn z a"- i=i (-) ■-■ --I Z
7l3 Std
rfl
--,-,
,.. -pc-, ,,, ,. C)„
AIR PRESSURE SWITCH - 30 BAR WITH 3 WAY TEST COCK AND 40MM TEST FLANGE
71 Z 70 11 2 2 -1 ,--, 2 7 -1 ;-'7 GI cr c:,., 2 v.) Gl 5 = r- -i 71
__i
, z71
Original 2011-06-21
Original 2011-06-21
Original 2011-06-21
12.5 27 12.5
30
600
16
180
140
173986-5
0
2
1
3
4
5
Schaltschrank Not-Luft-Kompressor (5,5-7,5kW) STARTER / CONTROLLER EMERGENCY AIR COMPRESSOR (5,5-7,5kW)
6
8
7
9
(344184-44070) NO
NC
29 30
31 32
-X1 W
H1 H2
1
2
3
4
5
6
7
8
Brücke ! link !
M
3
P
Not-LuftKompressor L20 EMERGENCY AIR COMPRESSOR L20 6,3 kW
Heizung HEATING appr. 30W
-F4
P
13 14
19 20
21 22
23 24
T
-F2
25 26
Brücke ! link ! ø6-13
Entwässerungsventil Abscheider DRAIN VALVE SEPARATOR
ø6-13
Öldruckschalter OIL PRESSURE SWITCH
Druckluftwächter für Start/Stop in Automatik AIR PRESSURE SWITCH FOR START/STOP IN AUTOMATIC
HE1 HE2
W
24V DC
-M1
V
24V DC
U
ø6-13
11 12
Luftteemperatur-Wächter AIR TEMPERATURE SWITCH
ø6-13
10
24V DC
ø6-13
440V 60Hz 440V 60Hz
ø9-17
Einspeisung SHIP SUPPLY
Original 2011-06-21
ø9-17
9
NO
-F3
*
ø6-13
ø6-13
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
220-230V AC
L1 L2 L3
-Y4 Gleichstrom-Magnetspulen muß das Kabel * Bei am Gleichrichter im Stecker angeschlossen werden. * IN CASE OF DC SOLENOID COILS THE CABLE MUST BE CONNECTED TO THE RECTIFIER INSIDE THE PLUG.
Datum cable gla.08.12.10 A sizes Zust. Änderung Datum
bre
Bearb. Gepr.
Name
Norm
02.11.10 Bre cpu
Anschlußplan Kompressor L20 CONNECTION DIAGRAM COMPRESSOR L20 Urspr.
342530
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344183-44070 Blatt 1 von 1 Bl.
0
2
1
3
4
5
6
8
7
9
380 210
Schaltschrank Kompressor STARTER/CONTROLLER COMPRESSOR
P1
P1
Amperemeter (mit Markierungsanzeiger) AMMETER
P2
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
Q1
Hauptschalter (mit Türverriegelung) ISOLATING SWITCH
Q2
Hauptschalter Motor-Heizung MAIN SWITCH MOTOR HEATING
H2
Meldelampe "Motor-Heizung ein" INDICATING LIGHT "MOTOR HEATING HEATING ON"
A H2 P2 TD 200
HATLAPA 600
(BU)
Q1 Gewicht: ca. 30kg WEIGHT: APPR. 30kg Schutzart: IP54 PROTECTION CLASS: IP54 8 20
Original 2011-06-21
Q2
mit Türfeststeller
20
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 1 von 8 Bl.
0
2
1
3 P2
4
5
Original 2011-06-21
RESET
HATLAPA
SHIFT
black on red
STOP
8
9
TD 200
MAN
schwarz auf rot
7
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
SIEMENS
STOP
6
AUTO
schwarz auf hell-blau black on light blue
AUTO
ESC
schwarz auf grün
schwarz auf weiß
black on green
black on white
MAN
ENTER
RESET
HATLAPA dark blue on white dunkel-blau auf weiß
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 2 von 8 Bl.
Kurzbeschreibung für Kompressorsteuerung mit TD200
short description f.compressor control with TD200: ON / OFF:
The standard text on the text display is:
ready for operation / off Betriebsbereit / aus
Now you can start the compressor in manual or in automatic operation. When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4. Normallay the manual operation is only used for maintenance purposes. After a blackout the cmpressor will not start again in this manual mode. When You press the "STOP" push button the compressor stops again.
Original 2011-06-21
ALARMS:
Jetzt kann man den Kompressor in der Hand- oder in der Automatik-Betriebsart starten. compressor on / man Kompressor ein / Hand
ready for operation / off Betriebsbereit / aus
When You press the "AUTO" push button the compressor is switched to automatic mode. The compressor starts and stops automatically depending on the air pressure. Normally this should be the standard operation mode. When the pressure switch F4 is closed the compressor starts. When the pressure switch F4 is opened the compressor stops. After a blackout the compressor will start again in automatic mode. When you want to change the operation mode from manual to automatic or from automatic to manual you must press the "STOP" push button before. When there is any fault, the compressor stops and the belonging disturbance alarm is shown in the display. Not all possible disburbance texts are used for this compressor.
Now the fault must be eliminated. Then press the "RESET" push button and there should be the standard text on the display again. Now You can start the compressor again with the "AUTO" or "MAN" push button.
compressor on / auto Kompressor ein / Auto ready for operation / auto Betriebsbereit / Auto
make maintenance ! Wartung fällig ! motor overload Motor Überlast low oil pressure Oeldruck-Alarm high air temperature Lufttemperatur-Alarm high cooling water temperature Kühlwassertemperatur-Alarm no cooling water kein Kühlwasserfluß
Mit der Taste "MAN" wird der Kompressor in der Hand-Betriebsart gestartet. D.h. ohne Funktion des Druckluftschalters F4. Normalerweise wird diese Fuktion nur für Wartungszwecke benutzt. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Hand" nicht wieder selbsttätig starten. Mit dem Taster "STOP" kann der Kompressor wieder gestoppt werden. Mit dem Taster "AUTO" kann der Kompressor in die Betriebsart "Automatik" geschaltet werden. Der Kompressor startet und stopt dann selbstätig in Abhängigkeit des Druckluftschalters F4. Wenn der Druckluftschalter geschlossen ist, dann startet der Kompressor. Wenn der Druckluftschalter geöffnet ist, dann stopt der Kompressor. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Automatik" selbstständig wieder anlaufen.
ALARME
Wenn eine Störung vorliegt, dann stopt der Kompressor und es wird der zugehörige Alarm im Textdisplay angezeigt. Nicht alle hier dargestellten Alarm-Texte werden für diesen Kompressor benutzt. Jetzt must der entsprechende Fehler behoben werden und dann der "RESET"-Taster betätigt werden. Darauf sollte dann der Standart-Text wieder auf dem Display erscheinen. Jetzt kann der Kompressor wieder mit den Tasten "MAN" oder "AUTO" gestartet werden.
ready for operation / off Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS: When there are one or two arrows in the right side of the display, you can go to other display texts by pressing the belonging arrow push buttons The other texts can show more disturbance alarms, if there is more than one fault. Or you can watch the working hours. Or you can watch some special settings of the software. Normally all settings are done by HATLAPA for a normal purpose of the compressor. If you want to change any setting, you must press the "ENTER" push button one time. Now you can change the value with the arrow push buttons. After this you must quit the new value by pressing "ENTER" again.
workings hours xxxxx h Betriebsstunden drainage time 5sec Entwässerungsdauer drainage interval 20min Entwässerungsinterval star delta time 4sec Stern-Dreieck-Zeit delayed start 0sec verzögerter Anlauf cooling water delay 2min Kühlwassernachlauf continuous time 0min Durchlaufzeit
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
EIN / AUS
Dies ist der Standart-Text auf dem Display.
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
Wenn ganz rechts im Display ein oder zwei Pfeile dargestellt werden, dann kann mit d.entsprechenden Pfeil-Tasten zu anderen möglichen Texten gesprungen werden. Die weiteren Texte können weitere Alarme anzeigen, wenn mehr als eine Störung ansteht. Oder es werden die Betriebsstunden angezeigt. Oder es können einige variable Einstellungen der Software angezeigt werden. Normalerweise sind alle Einstellungen für einen normalen Kompressorbetrieb bereits durch HATLAPA festgelegt. Wenn Einstellungen geändert werden sollen, muß einmalig die "ENTER"-Taset betätigt werden. Dann kann man mit den Pfeil-Tasten den entsprechenden Wert verändern. Daraufhin muß der geänderte Wert nocheinmal mit der "ENTER"-Taste quittiert werden.
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 3 von 8 Bl.
0
2
1
3
4
5
6
8
7 -F2
9
2A
2
1
1L1
/5.0
4
6
4
11
6
1
3
5
-K1 3
5
12
/8.1
/8.9
1
4
2
0P ±5%
6
1
3
5
2
4
6
-F1
1
220V 250VA 0S
2A Heizungs-Spannung HEATING VOLTAGE
1
97 95
-Q2
98 96
2
3 Hauptschalter Heizung MAIN SWITCH 4 HEATING
Original 2011-06-21
/6.0
9-13A CLASS 20
-F3
-T1 440V
2
/5.0
2
0,63-1A GV2 RT05
-
-Q1
4
2
1N1
Trafo-Einspeisung TRANSFORMER SUPPLY
-Q3
A
20A
5
3
-P1
3
4
+
1
3
Steuerspannung CONTROL VOLTAGE
51
61
/8.1 52
62
-K1 X1
-H2
Heizung ein HEATING ON
220V X2
SHIP SUPPLY 440V
440V Zuleitung
U
V
W
U
V
W
H1 H2 PE
PE
60Hz
L1 L2 L3 PE
60Hz
-X1
-M1
HE1 HE2
M
3
Kompressor COMPRESSOR 5,5-7,5 kW
Heizung HEATING appr.25-50W
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 4 von 8 Bl.
0 /4.9
/4.9
2
1
3
4
5
6
7
8
9
1L1
1N1
1N1
1L+
+24V DC
/8.0
/6.0
0V DC
2 3 4 5 6 7 8 9
Original 2011-06-21
Softwareversion TD200_8
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
S7-CPU 222 Relais-Ausgänge 8 x Eingänge
/6.0 /6.2 /6.4 /6.6 /6.8 /7.1 /7.3 /7.5
MOTOR PROTECTION RE AIR PRESSURE SWITCH OIL PRESSURE SWITCH AIR TEMPERATURE SWI COOL.WATER TEMP.SWI COOL.WATER FLOW SWI SPARE SPARE
6 x Ausgänge Relais 2 3 5 6 8 9
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5
/8.1 /8.2 /8.5 /8.6
PE Vers N L1
M Erw L+
1M 2M Ein
1L Aus 2L
-A1
MOTOR MAIN CONTACTO DRAIN VALVES Entwäs DISTURBANCE RELAY COOLING WATER VALVE star contactor delta contactor
-P2 TD 200
HATLAPA Anzeige- und Bedieneinheit monitoring and operation panel
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 5 von 8 Bl.
0
/5.9
2
1
3
4
5
6
8
7
9
1L+
1L+
/7.0
95
-F1 /4.2 96
Original 2011-06-21
2
3
-A1
E0.0
/5.2
E0.1
MOTOR PROTECTION RELAY Motorschutzrelais
1
2
/5.2
5
-A1
E0.2
/5.2
AIR PRESSURE SWITCH Luftdruck-Wächter
OIL PRESSURE SWITCH Öldruckk-Wächter
Digitaler Eingang
Digitaler Eingang
Digitaler Eingang
-X1
4
-A1
3
PE
4
6
-A1
E0.3
/5.2
E0.4
AIR TEMPERATURE SWITCH Lufttemperatur-Wächter
5
Option mit Brücke OPTIONAL WITH LINK
6
/5.2
COOL.WATER TEMP.SWITCH Kühlwassertemp.Wächter
Digitaler Eingang
PE
-A1
Digitaler Eingang
7
PE
Option mit Brücke OPTIONAL WITH LINK
8
PE
Option mit Brücke OPTIONAL WITH LINK
Optional über KompressorUmschaltbox
-F4
1
P
-F2 P
2
OPTIONAL VIA COMPRESSOR SEQUENCE Luftdruck-Wächter SELECTION BOX für Auto Start/Stop AIR PRESSURE SWITCH FOR AUTO START/STOP
-F3
Öldruck-Wächter OIL PRESSURE SWITCH
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
-F5
T
Lufttemperatur-Wächter AIR TEMPERATURE SWITCH
HATLAPA
T
Kühlwasser-Temperatur-Wächter COOLING WATER TEMPERATURE SWITCH
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 6 von 8 Bl.
0
/6.9
2
1
3
4
5
6
7
8
9
1L+
7 E0.5
Original 2011-06-21
8
-A1 /5.2
E0.6
COOL.WATER FLOW SWITCH Kühlwasserdurchfl.Wäch
9
10 PE
/5.2
-A1
E0.7
SPARE Reserve
Digitaler Eingang
-X1
9
-A1
/5.2 SPARE Reserve
Digitaler Eingang
Digitaler Eingang
11 12 PE
13 14 PE
Option mit Brücke OPTIONAL WITH LINK
-F6 F
Kühlwasser-Durchfluß-Wächter OIL PRESSURE SWITCH
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 7 von 8 Bl.
0
2
1 -A1
3
4
5
-A1
Digitaler Ausgang MOTOR MAIN CONTACTOR NETZSCHÜTZ /5.2
A0.0
-A1
Digitaler Ausgang
DISTURBANCE RELAY Störungs-Kontakt
/5.2
A0.1
/5.2
A0.2
3
8
7
9
-A1
Digitaler Ausgang
DRAIN VALVES Entwässerungs-Ventile
2
6
5
Digitaler Ausgang COOLING WATER VALVE Kühlwasserabsperrventi
potentialfreie Kontakte FLOATING CONTACTS
/5.2
A0.3 6
11
-Q1 /4.1 12 A1
A1
-K2
-K1
Original 2011-06-21
18A A2 INCL. VAR.
/5.9
13
INCL. A2 VAR.
13
-K1
-K2
14 /8.1
14 /8.5
1N1 1 2 3 4 5 6 13 14 21 22 51 52 /4.8 61 62 /4.9 Kompressor ein COMPRESSOR ON
/8.9 13
/4.2 /4.2 /4.2 /8.8
14
Störungskontakt DISTURBANCE RELAY
-X1
19 20 PE
21 22 PE
23 24 PE
25 26 PE
29 30 PE Kompressor ein COMPRESSOR ON
(NO)
-Y1
-Y2
-Y3/4
Zust. Änderung
Datum
Name
Norm
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
(NC)
Kühlwasser-Absperrventil (optional) COOLING WATER SHUT OFF VALVE (OPTIONAL)
Datum 02.11.10 Bre cpu
STÖRUNG DISTURBANCE
-Y5
Entwässerungsventile (optional) DRAIN VALVES (OPTIONAL)
Bearb. Gepr.
31 32 PE
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 8 von 8 Bl.
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Use angle adaptors to eliminate tight bend radii and sharp twists occurring in the hose.
incorrect
correct
If the installation bend radius is less than the minimum allowed, use angle adaptors to eliminate tight bend radii.
16.01.2006 122/Pitrowski
2/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is installed with a smooth bend, avoiding any tight corners, which could cause the flexible part of the hose to collapse.
incorrect
correct
In a collinear application, do not install the hose in a straight line or with kinks, use angle adaptors.
16.01.2006 122/Pitrowski
3/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is kept away from hot surfaces by using suitable clamps. High ambient temperatures can reduce the life of the flexible part of the hose.
16.01.2006 122/Pitrowski
4/4
Safety Instructions for Hoses
1 General Hose pipes are safety relevant parts which may endanger persons and the environment in case of failure.
1.1 Installation and maintenance During installation the hoses must in no way be damaged, bent, twisted or exerted to pressure. They must not be painted or have contact with sharp objects! For cleaning hose pipes and hoses neither aggressive cleaning agents nor pressure cleaners may be used. They can damage the hose surface resp. hose line! Hose pipes must be inspected visually by the assembly/service personnel before commissioning and once a year. Inspection is carried out under the following aspects: Original 2011-06-21
• • • • • • •
Damage to the outer layer Decay of the outer layer Deformation of the hose or hose pipe (alteration of the geometry, layer separation, forming of blisters) Damage or deformation of the hose fitting Corrosion of the fitting (impairs function and strength) Installation (chafing at sharp edges or smooth surfaces) Exceeding the admissible storage resp. operational duration (stated below)
1.2 Storage and durability According to DIN 7716 proper storage is to be understood as follows: • • • • • •
max storage time 2 years dry, cool, dust-free no direct sunlight or UV light protection against ozone protect against heat store lying and without tension
According to EN 982 resp., DIN 20066 following must be observed: 1. Once installed, the hoses have a durability of 6 years and must be replaced after this period. 2. If the max. storage time of 2 years is exceeded, then the hose may no longer be used. If the hose is installed within this period, the durability of 6 years is reduced by the period of storage accordingly. It lies within the responsibility of the user that all hoses mentioned in this manual are checked at regular intervals, and to guarantee correct and safe function once the guarantee period has elapsed, thus preventing damage to persons and the environment.
date 18.04.2005 Created by Tanz
page 1 of 1
Lubricating Instructions for HATLAPA W- and L-type Piston Compressors
175694 Rev. 01.06
1. General Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of the compressor. Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is advisable to contact him when making your choice. Ask only the lubricant manufacturer for his recommendation! He is the expert.
Original 2011-06-21
2. Lubrication Oil Quality Above all, compressor oils must have good lubrication properties for which their viscosity is highly important. HATLAPA recommends lubrication oils within the following range: viscosity at 100 °C: min. 9.4 cSt max. 15 cSt viscosity at 40 °C: min. 90 cSt max. 120 cSt The lubrication oils should have low tendency to ageing and coking in order to prevent oil carbon deposits on valves and pipelines. HATLAPA recommends to use mineral oils of class VDL according to DIN 51 506. The use of synthetic oils is not recommended for HATLAPA W- and L-type compressors.
3. Guarantee If lubrication oils are used which do not meet the requirements, damage to the compressor may occur. This damage is not covered by HATLAPA's guarantee obligations.
4. Lubricant Examples The following mineral oils are examples which comply with the above specification: ARAL MOTANOL HE100 BP ENERGOL RC100 CASTROL AIRCOL PD100 CHEVRON TEXACO (FAMM) COMPRESSOR OIL EP VDL100 ELF TOTAL FINA (Lubmarine) DACNIS P100 ESSO (ExxonMobil Marine) EXXCOLUB 100 MOBIL (ExxonMobil Marine) RARUS 427 SHELL CORENA P100 However, the oil properties are subject to change without notice by the oil manufacturer. Also, the oil characteristics may vary depending on the regional market. Therefore this list does not release the operator of the compressor from verifying that the selected oil complies with the above specification.
Original 2011-06-21
SECTION 3
Komm.-Nr.:
Spare Parts
HATLAPA UETERSENER MASCHINENFABRIK
D-25436 Uetersen
Reserveteile L15/L20
074608 - 07083
(dent-no.
Qt
(according to manual)
Designation
Sketch
piston ring 1
20.30.10.40
r
94x1,5
..J
s
1
20.30.10.50
stepped scraper ring 94x1,75
1
20.30.10.60
s
oil scraper ring
r &..)
?„tr
..)
Original 2011-06-21
94x4
_
1
20.30.20.50
taper faced compr. ring
41 '
42x2
2
20.30.20.40
rm
..J
stepped scraper ring 42x2
1
20.20.10
_
compl. suction and pressure valve 1st stage
1
20.20.20
compl. suction and pressure valve 2nd stage
11 •••• 098
(NI
.n. 098
1
09.01.97
074610
set of packing rings
(see separate
(for valves)
sheet)
Sagroll 21.Juni 2008
16:52:16
HATLAPA
Set packing rings for valves
Komm.-Nr.:
UETERSENER MASCHINENFABRIK
D-25436 Uetersen
L15 / L20
Qt
(dent-no.
Designation
1
20.20.50
Gasket
074610 - 08004 Sketch
,, Ln ,
(cylinder head 2nd stage)
1
Original 2011-06-21
1
_
1
20.20.40
074610.30
074610.40
20.20.30
(cylinder head 2nd stage)
SERi
0)
Packing ring 68x55x1
co
4'-k
(Copper)
s WI,
Packing ring 42x32x1
Gasket
Krafft
"
[Tr*
s
_M-W
CD
(cylinder head 1st stage)
22.04.08
L.--/
t=1
Gasket
(Copper)
1
a' ,
21.Juni 2008 16:52:16
FP
%0
t=1
HATLAPA
Spare parts
Kamm —Nr
:
UETERSENER MASCHINENFABRIK
D-25436 Uetersen
Of
1
Ident-no.
084177-03400
for E-motor
Designation
grooved ball bearing
Original 2011-06-21
6308 ZZ
_
1
003549-03400
grooved ball bearing 6207 ZZ
Motor. WEG 132 M
20.03 01
Sagroll
176968 - 07080
Sketch
Original 2011-06-21
0115
CNJ
0 40
E
MaBe o hne Toleranzang abe
C
Andorung von
in
Ealwerhm Gezekkeet
24.9.69 Adas."---
Nr.
CT
Datum Name
L90 L13118
&miff
Uetersener Maschinenfabrik Nenecepr. Ail &orbit uag sutural! Havetail Auswirtstell
6
Diimpferfilter
HATLAPA
Ma/stab:
1:1
20244-04330 Ersatz tar
Uetersen / Holstein
O./m.11110Mo Rothe 2 DIN 3141 - zul. groBIe Rauh/Ude:
Ersotzt dunk
unboarbolle gktt
v----ostoo pv=0,025
0VV.0,006
Original 2011-06-21
Instruction manual
Piston compressor L15 - L20 - L35
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
INTRODUCTION: This Instructions Manual contains a brief technical description and important instructions on commissioning, maintenance and servicing of the compressor. We recommend to read this manual carefully in order to be able, in case of trouble, to detect the cause quickly and care for remedy and, in case of repairs, to make provisions for proper mounting acc. to the instructions. This manual assumes a general technical knowledge of piston compressors and does not claim to be complete. If repairs become necessary, only original HATLAPA spare parts must be used in order to maintain the operational reliability and efficiency of the machine. For identification and supply of spare parts, an order must contain the following information: 1. Serial No. and type designation (see name plate). 2. Ident No. from the spare parts list. 3. Method of the required dispatch, as well as consignee and address for the invoice.
Original 2011-06-21
4. Name of the vessel (ex-name), Yard No., and Shipyard. In order to receive spare parts with the least possible delay, get in touch direct with
Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 · D-25436 Uetersen / Germany D-2549 Uetersen / Germany Phone: Telex: Cable: Fax: E-mail: Internet:
(+49) 4122 / 711- 0 218510 htlu d HATLAPA Uetersen (+49) 4122 / 711 - 330
[email protected] http://www.hatlapa.de
or with our accredited agents, after-sales service stations or licensees/co-operators as per attached list. We wish to point out that repairs and/or modifications to the compressor which are carried out without our approval during the guarantee period, will release us from our guarantee obligations. The manufacturer cannot be rendered liable for damage to the compressor which can be shown to have been caused by the use of unsuitable lubricants or failure to comply with the operating instructions. Reprint of the text or illustrations, or even extracts therefrom is prohibited. Subject to alterations at all times due to technical development.
2
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
TABLE OF CONTENTS: Page: 1 Description ..................................................................................................................4 1.1 Design........................................................................................................................4 1.2 Specifications.............................................................................................................5 1.3 Working method.........................................................................................................5 1.4 Cooling.......................................................................................................................5 1.5 Lubrication of Working Parts......................................................................................6 1.6 Condensate Separation .............................................................................................6 1.7 Starting without Back-Pressure..................................................................................6
Original 2011-06-21
2 Setting-up and Installation.........................................................................................7 3 Commissioning...........................................................................................................8 3.1 Safety References .....................................................................................................8 3.2 Before Starting...........................................................................................................9 3.3 After Starting..............................................................................................................9 3.4 During Operation .......................................................................................................9 3.5 After Stopping ............................................................................................................9 4 Servicing and Maintenance......................................................................................10 4.1 General Servicing Instructions .................................................................................10 4.2 Servicing Schedule ..................................................................................................11 4.3 Overhaul of Valves ..................................................................................................13 4.4 Overhaul of Pistons and Cylinders...........................................................................13 4.5 Overhaul of crankshaft and connecting rod .............................................................14 4.6 Overhaul of Lubrication System...............................................................................15 4.7 Protection against Corrosion during prolonged Shut-Down .....................................16 5 Trouble Shooting ......................................................................................................17 6 Spare Parts................................................................................................................18 7 Instructions for Correctly Ordering Spare Parts....................................................19
Rev.: 15.09.1999
3
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
1 Description 1.1 Design
Original 2011-06-21
Two-stage, single acting, air-cooled, 2-cylinder trunk piston machine with 90°-V cylinder , arrangement.
The equalization of mass of the crank mechanism and the special arrangement of the two cylinders together with the use of trunk pistons guarantee low vibrations during operation. They enable a 3-point resilient mounting without any problems.. The large-dimensioned and slide bearings of the crankshaft and connecting rods,and force feed lubricated oil, make the machine insensitive to internal and external vibration loading in both standstill and operating modes. The use of trunk pistons at all stages guarantees low wear and an safe lubrication with high service life expectancy for pistons and cylinders.
4
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
Original 2011-06-21
1.2 Specifications Typ
L15 L20
L35
Number of Cylindersr
2
2
2
Cylinder Bore 1st Stage [mm]
94
94
94
Cylinder Bore 2nd Stage [mm]
42
42
42
Piston Stroke [mm]
52
52
71
Crankshaft-Axial Clearance [mm]
0,2- 0,20,3 0,3
0,20,3
Quantity of Lub. Oil min. [l]
1,75 1,75
1,75
Quantity of Lub. Oil max. [l]
2,25 2,25
2,25
Weight without E-Motor [approx. kg] 110 110
110
Setting Oil pressure Machine [approx. bar]
at
warm 4
4
4
Setting Oil Pressure Contol Switch 1 [approx. bar]
1
1
1.3 Working method The compressor compresses the ambient air sucked in through the air-intake filter with silencer in two stages to the selected final pressure. Combined concentric ring plate valves with large flow cross-sections control automatically the gas exchange in the compression chambers. After every stage the heated compressed air flows through a large-dimension cooler. To monitor the correct functioning of the compressor a pressure gauge is installed after each compression stage. Safety valves, installed after every compression stage, prevent the pressure from rising above the admissible limit.
1.4 Cooling The heat generated in the machine by air compression and mechanical friction is led off to the atmosphere. A radial-flow fan fixed directly on the shaft and a hood guide to suit the air flow guide the cooling air at high speed over the strongly ribbed cylinders, valves and cylinder heads and over the ribbed cooler of the first and second stages installed on the circumference.
Rev.: 15.09.1999
5
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
1.5 Lubrication of Working Parts Only compressor oils according to the enclosed oil specification chart may be used. Crankshaft and conn. rod bearings are force-feed lubricated by means of a gearwheel oil pump driven directly by the crankshaft. This pump sucks the oil from the crankcase through a sieve and forces it to the two main bearings of the crankshaft, as well as to the conn. rod bearings. The lub. oil pressure is limited by a spring-loaded pressure limiting valve and is indicated by a pressure gauge. The lub. oil pressure is monitored by a pressure switch, which switches off the compressor in case of insufficient oil pressure.
Original 2011-06-21
1.6 Condensate Separation Together with the moist ambient air which is sucked in, water enters the compressor in form of vapour. By compression and subsequent cooling of the compressed air, this water vapour condenses. The water separated from the compressed air blends with the oil which is entrained in very small quantities from the lubricated working surfaces of the cylinders. This water-oil mixture is extracted from the compressed-air stream in special condensate collector chambers. At regular intervals – after every 15 min. for about 10 sec. - as well as on starting and stopping of the compressor, the collector chambers must be drained by opening the manual valves or optionally by automatic devices. Such condensate separation reduces wear and tear due to corrosion in the compressor components, and in the connected pipelines and prevents the compressor from damage due to water shocks. Disposal of the condensate has to be carried out according to the locally valid prescriptions.
1.7 Starting without Back-Pressure During starting-up, the driving motor must be unloaded by opening the drain valves. In automatically controlled compressors, unloading is effected by time-lagged closing of these valves.
6
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
2 Setting-up and Installation The compressor is driven by a directly-coupled electric motor through a flexible coupling, the shaft centres of motor and compressor must lie in exactly the same axis. Under no circumstances may the shaft centres be offset. In case of resilient mounting there must be sufficient room for movement. All pipelines must then be connected to the consumer system by flexible hoses, strictly adhering to the installation instructions.
Original 2011-06-21
All drain pipelines are to be laid with constant descent and must discharge into an open funnel after the shortest possible distance. Each compression stage needs a separate drain pipeline in order to guarantee perfect drainage of the individual stages; stop valves are to be installed as closely as possible to the compressor. For sufficient supply of cooling air, the minimum distance to the cooler must be observed (see final drawing). The air inlets may not be influenced by the warm exhaust of other machinery. Further instructions on the installation of valves, pipelines, and control equipment are to be taken from the enclosed piping diagrams with their respective descriptions.
Rev.: 15.09.1999
7
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
3 Commissioning 3.1 Safety References The compressor has been produced according to the State-of-art and is operationally reliable.
Original 2011-06-21
The compressors are a source of danger if inexpertly or improperly used.
8
•
Only authorised and trained persons are allowed to operate and repair the machine or to do maintenance work. Make sure that these persons have read and understood the complete operating instructions and safety instructions.
•
The compressor may only be used for compressing air.
•
The compressor may not be operated without safety or protecting devices.
•
Only sealed safety valves may be used, readjustment is not allowed. They have to be replaced immediately when defective.
•
Before starting any maintenance work it is necessary to stop the compressor system and to prevent it from re-starting. The system has to be voltage–free, all parts containing compressed air have to be depressurized.
•
The compressor system may only be operated in perfect working condition. It must be free of foreign parts.
•
Rebuilding or any other changes to the compressor system that may influence the safety are strictly prohibited.
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
At initial commissioning, after a several months` interruption in operation, or after extensive repair work the operator must observe the following points (see also 4.7 Protection against corrosion during prolonged Shut-Down).
Original 2011-06-21
3.2 Before Starting •
The compressor must be filled to the upper oil level mark with prescribed compressor oil (see list of recommended oils).
•
Check that the crankshaft is moving easily by turning over the flywheel by hand; but make sure that the compressor set cannot be started unintentionally.
•
Open the shut-off valve in the pipeline leading to the compressed-air receiver.
•
Open drain valves.
3.3 After Starting •
Check the direction of rotation of the shaft (see also arrow).
•
Watch the pressure gauge for rise in oil pressure.
•
Close the drain valves and check for leakage.
3.4 During Operation •
Once the final pressure is attained, check the safety valves for proper functioning: Slightly turn the knurled nut until the valve blows off. After closure, check for leakage.
•
After fitting of new working parts (repair), run in the compressor for about one hour at low final pressure (5 to 10 bar).
3.5 After Stopping •
Open the drain valves at the condensate separators.
•
Check that the automatic drain valves open properly.
•
Check the non-return valve in the pipe to the compressed-air receiver for leakage.
Rev.: 15.09.1999
9
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
4 Servicing and Maintenance For trouble-free operation, it is necessary to check regularly and carefully the safety devices and the wear and tear parts of the compressor as well as the functioning of fitted valves and instruments. Regularly check the stock of spare parts and seals which must be protected against corrosion, and stock up to the specified quantity again after any servicing and overhaul work. The following maintenance and overhaul instructions must be adhered to. However, they do not claim to be complete. Observance of the servicing intervals as mentioned below guarantees great reliability and long service life of the compressor.
Original 2011-06-21
In this connection, reference is made to the requirements of the rules of the classification societies and seafarer unions. 4.1 General Servicing Instructions a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil, however, not exceeding the top oil level mark. Too much oil results in foaming due to immersion of rotating parts, with the compressor at extremely inclined position. Intense misting of the oil and uncontrolled cylinder lubrication would result in increased oil consumption and coking of the working valves. b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot from running - and fill in fresh compressor oil after having cleaned the oil sieve. c) Regularly and carefully check the oil pressure as well as the air pressure of all stages. Varying operating pressure values indicate anomalies in the lubricating system and valves, as well as leaks in the piping system. d) At regular intervals dismantle and strip down the combined suction and pressure valves and clean all parts. Packing rings between valve and cylinder head must be replaced in sets only. For details, see „4.3 Overhaul of Valves„. e) Check the safety valves on the compressor by slightly turning the knurled nut at short intervals.
10
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
4.2 Servicing Schedule After first commissioning, after a general overhaul, and after repairs to the crank mechanism or cylinder, the following maintenance work should be done: After 100 working hours 1.) Change the oil. 2.) Clean the oil suction sieve. 3.) Check the safety valves.
Original 2011-06-21
4.) Check the bolts and nuts on crankcase, cylinders, and pipelines for tightness (See list of tightening torques). 5.) Check the drainage system.
After that the following intervals are to be kept: After every 500 working hours: 1.) Check the safety valves 2.) Clean the air-intake filter 3.) Check the drainage system
After every 1000 working hours (however, at least once a year): 1.) Change the oil. 2.) Clean the oil suction sieve. 3.) Clean the ribbed coolers, the ribbed cylinders and the radial-flow fan
Rev.: 15.09.1999
11
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
After every 1000 working hours: 1.) Clean the combined suction and pressure valves and check for wear. 2.) Check parts which come into direct contact with hot compressed air, such as valves, cylinder heads and compressed-air pipelines for carbon residues and, if necessary, clean them with solvents.
Original 2011-06-21
The admissible servicing intervals of the valves are determined above all by the operating conditions and by the properties of the lubricant used. We recommend to reduce the servicing intervals in case of severe operating conditions.
12
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
4.3 Overhaul of Valves
Original 2011-06-21
The combined suction and pressure valves of the compressor require conscientious care and maintenance. Their springs and plates are the most intensely stressed parts of the compressor. For cleaning, the concentric valves have to be dismantled by removal of the fitting bolt. Soaking of the components in paraffin facilitates removal of coked deposits. Care should be taken that the ground sealing surfaces, and valve plates are neither scratched nor damaged. Springs and valve plates should be checked for damage and wear and replaced, if necessary. For reassembly, adhere strictly to the assembly diagram (parts list). Parts of different valves must not be mixed. Tighten the fitting bolt with the prescribed torque. After reassembling check the soft running of the valve plates against the spring pressure using a rounded pin. Valves and valve parts must be clamped in a vice with smooth jaws only. When fitting the valves, use new packing rings in sets and see that they are properly positioned. Cylinder head nuts and bolts for pipes should first be tightend by hand. Then nuts should be initially tightened cross-wise using a torque wrench at approx. 10 Nm (1 kpm) and then tightened securely in the same sequence to the necessary torque.
4.4 Overhaul of Pistons and Cylinders Pistons and cylinders can be removed for cleaning and checking of wear without dismantling the connecting rod and crankshaft. All components must first be marked so as to maintain pairings (assignment of pistons and cylinders) and the positioning of the parts for reassembly. To dismantle the pistons after pulling out the cylinders, firstly remove each of the retainer rings of the wrist pins using a pair of circlip pliers, and then push the wrist pin out of the piston with a set bolt or other suitable device. Heating the piston to between approx. 60°C and 80°C facilitates insertion of the wrist pin. Piston rings should be removed and inserted only using piston-ring pliers.Observe that the piston rings are correctly positioned (see parts list) and stagger the joints when fitting. On inclined cylinders, the oil scraper ring joint should point upwards when fitting. To measure clearance and wear, first of all, all parts must be cleaned and checked for damage. The measurement of the cylinder diameter is carried out using a precision internal gauge applied in the operational way of the piston rings. The nominal diameter of the piston is stamped on top of the piston head. The actual diameter should be checked at the bottom end of the piston stem, at right angles to the wrist pin axis. For fitting clearances and wear limits refer to the attached list. To check the joint clearance, the piston rings should be inserted at a right angle into
Rev.: 15.09.1999
13
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
the upper cylinder aperture and positioned at a location where the cylinder liner shows no signs of wear. The joint clearance is measured using a feeler gauge. Before fitting the pistons and cylinders, the seal-face on the crankcase and underside of the cylinder must be carefully cleaned. Use new cylinder gaskets. Apply oil to pistons and cylinders. Compress piston rings with a tensioning band and slip the cylinders over the pistons by hand. Take care that the cylinder head bolts do not touch the cooling ribs of the cylinders. Parts, which have reached or exceeded their service life (see List of Wear Limits), should be replaced.
Original 2011-06-21
4.5 Overhaul of crankshaft and connecting rod Crankshaft and connecting rods move in force-feed lubricated slide bearings. Connecting rods and bearing covers are identified by punched figures. Association and location of the covers must not be changed. Mark the individual parts to maintain correct positions during reassembly. After disassembly, clean all parts, check all bearings and journals for wear and damage and measure the wear. Check the axial and radial clearance by means of a precision gauge.
Refitting of the crankshaft
Clean the oil ducts and blow through compressed air. Thoroughly oil the bearings and journals as well as the associated components before assembly. Insert the crankshaft in the crankcase first without shaft seals and then screw on the housing cover with its gasket. Check whether the axial clearance of the crankshaft is within the admissible clearance. Fit the shaft seals and tighten the housing cover screws to the prescribed torque. When fastening the flywheel and the fan wheel, secure the crankshaft against rotation by inserting a rod from outside through the opening of the flywheel housing into the flywheel bore.
14
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
Refitting of the connecting rods
Oil the crank pin and bolt threads. Place the upper part of the connecting rod with bearing shell on the crank pin and see that the shell is correctly positioned in the connecting rod. Put the lower part of the connecting rod with bearing shell from the opposite side, pass through the fitting bolts and screw them into the upper part of the connecting rod. Tighten the fitting bolts to the prescribed torque. (Slight distortions between the bearing halves can be corrected by applying light blows to both connecting rod parts close to the joint.)
Original 2011-06-21
4.6 Overhaul of Lubrication System The lubrication oil pump driven directly by the crankshaft is located on the fan side in the bearing cover of the crankcase. The gearwheels are installed in a pump cover. Due to the symmetrical design this can be used in both clockwise and anticlockwise direction of the crankshaft. With clockwise running - normal design of the compressor with electric drive - this pump cover is to be installed in such a way that the internally toothed gear points in the direction of the 2nd stage cylinder (TOP-marking). The following instructions are to be observed for pump installation. Firstly insert the bearing cover with slide bearing into the crankcase and screw tight. Oil both gearwheels and insert into pump cover. The punched point markings on the wheels remain visible and point in the direction of the flywheel! Insert the pump cover together with the gearwheels into the bearing cover. Turn the crankshaft by hand until the internally toothed gear slides over the guide onto the shaft. After removing the cover screws check easymovement of the shaft. Replace damaged or hardened O-rings. The spring-loaded oil pressure limit valve is inserted into the crankcase from the bottom on the fan side. In the event of operational breakdowns this can be loosened directly for checking.
Rev.: 15.09.1999
15
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
4.7 Protection against Corrosion during prolonged Shut-Down Compressors must be stored in a dry room. In case of long storage a protection of all inner components should be carried out according to the manual at least every 8 months. Before first commissioning, the compressors must be checked by a trained engineer for damage which may result from long storage. A report of inspection must be sent to HATLAPA. Noticed damage during this check are not covered by our guarantee. The date of commissioning or supply of the vessel to owner must be advised to us. Compressors which will be put out of operation for several months must be protected against corrosion.
Original 2011-06-21
Internal protection: • Open drain valves of 1st and 2nd stage under pressure. • Run the compressor without pressure while the drain valves are open. • Close the drain valves. • Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the air-intake socket within approx. 2 minutes. • Shut down the compressor and open the drain valves.
External protection: • After cleaning, apply rust-preventive paint to all parts. • Components made of light alloy, copper or brass need no treatment.
16
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
5 Trouble Shooting The following details are intended to provide a brief guide to determining the cause of abnormal operation. We do not claim that this information is complete. It only deals with the faults most frequently encountered, as known from experience. a) Oil pressure too low: Too low oil level in the crankcase (oil pressure display fluctuating). Clogged suction sieve. Leaking oil pressure limiting valve (dirt). Damaged bearing (in general together with knocking noise).
Original 2011-06-21
b) Intermediate pressure too low and / or compressed-air delivery too low: Combined suction/pressure valve damaged or leaking. Leaking piston rings Leaking cooler or compressed-air delivery line. Still open or leaking drain valves. c) Intermediate pressure too high and / or compressed-air delivery too low: Combined suction/pressure valve damaged or leaking. Leaking cooler or compressed-air delivery line. d) Safety valve blowing off although pressure is normal: Defective safety valve. e) Safety valve 1st stage blowing off / Intermediate pressure too high sea c) f) Safety valve of final stage blowing off, final pressure too high : Closed valve on compressed-air receiver. Non-return valve does not open. Defective pressure control switch (of the automatic system).
Rev.: 15.09.1999
17
Type
Instruction manual
L15 - L20 - L35
Piston Compressors
6 Spare Parts We recommend to keep some spare parts in stock in order to allow quick remedy of minor failures due to the natural wear and tear.
1 set of valve plates and valve springs for each stage 1 set of piston rings incl. oil scraper ring for each stage 1 set of sealing rings and gaskets for each stage
If the compressor is intended for continuous operation, in addition stock:
Original 2011-06-21
1 combined suction and pressure valve for each stage 1 set of crankshaft bearings and connecting-rod bearings 1 piston with wrist pin and piston rings for each stage
18
Rev.: 15.09.1999
Instruction manual
Type
Piston Compressors
L15 - L20 - L35
7 Instructions for Correctly Ordering Spare Parts When ordering spare parts, the following details must be given: 1.) Serial No. and type designation (see name plate). 2.) Ident. No. from the spare parts list. 3.) Method of the required dispatch, as well as consignee and address for the invoice. 4.) Name of the vessel (ex-name), Yard No., and Shipyard.
Original 2011-06-21
In order to receive spare parts with the least possible delay, get in touch direct with
Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 · D-25436 Uetersen / Germany D-2549 Uetersen / Germany Phone: Telex: Cable: Fax: E-mail: Internet:
(+49) 4122 / 711- 0 218510 htlu d HATLAPA Uetersen (+49) 4122 / 711 - 330
[email protected] http://www.hatlapa.de
or with our accredited agents, after-sales service stations or licensees/cooperators as per attached list.
Rev.: 15.09.1999
19
Technische Hinweise Technical indication Indications techniques
Original 2011-06-21
Technische Hinweise Technical indication Indications techniques
Kolbenkompressor Piston compressor Compresseur à piston
Technische Hinweise Technical indication Indications techniques
Anzugsdrehmomente / tightening Torques Verschleißgrenzen / wearing limits
Original 2011-06-21
Sicherheitshinweise für Schlauchleitungen / Safety Instructions for Hoses Montagehinweise für Schlauchleitungen / flexible hose installation guidelines
Anzugsdrehmomente Tightening Torques Couples de serrage
Typ L15 - L20 - L35
Zylinderkopf
1. Stufe / 1st Stage / 1ère étage
32 Nm
cylinderhead
2. Stufe / 2nd stage / 2ème étage
32 Nm
Pleuel
1. Stufe / 1st Stage / 1ère étage
33 Nm
1)
connecting rod
2. Stufe / 2nd stage / 2ème étage
33 Nm
1)
Ventilzentralschraube
1. Stufe / 1st Stage / 1ère étage
19 Nm
valve fitting bolt
2. Stufe / 2nd stage / 2ème étage
10 Nm
culasse de cylindre
bielle
goujon de soupape Lagerdeckel Kurbelgeh. crankshaft bearing cover
45 Nm
Original 2011-06-21
couvercle palier/carter
1)
Kurbelzapfen und Gewinde einölen Oil crank pin and bolts threads Huilage tourillon de vilebr. et filetage
Stand: 24.09.1999
Verschleißgrenzen Wearing limits Limites d´usure Durchmesser Zylinder / Zylinderlaufbuchse diameter cylinder / cylinder liner diamètre du cylindre / chemise du cylindre
Original 2011-06-21
Kolbenringspaltmaß piston ring gap clearance jeu de joint des segments du piston
von oben nach unten from top to bottom de haut en bas
Typ L15 - L20 - L35 1. Stufe 1st stage 1ère étage
94,35 mm
2. Stufe 2nd stage 2ème étage
42,3 mm
1. Stufe 1st stage 1 ère étage
1,3 mm 1,3 mm 1,0 mm
2. Stufe 2nd stage 2ème étage
0,7 mm 0,7 mm 0,7 mm
radiales Lagerspiel Kurbelwellenhauptlager radial bearing clearence crank shaft main bearing jeu radial du palier principale de vilebrequin
1) 1) 1)
0,25mm
radiales Lagerspiel Pleuelhauptlager radial bearing clearence connecting rod main bearing jeu radial du palier principale de la bielle
1) 1) 1)
0,25 mm
radiales Lagerspiel Pleuelbuchse radial bearing clearence connecting rod wrist pin bushing jeu radial de la douille du pied de la bielle
1) 1) 1)
0,10 mm
1) Um das radiale Lagerspiel zu bestimmen, zieht man den gemessenen Zapfendurchmesser vom gemessenen Lagerdurchmesser ab. 1) In order to find out the radial bearing clearance, subtract the measured journal diameter from the measured bearing inside diameter. 1) Pour trouver le jeu du palier radial, déduire le diamètre mesuré du tourillon du diamètre d´alésage mesuré du palier.
Stand: 24.09.1999
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES Flexible hoses are used for connecting a flexible mounted compressor assembly to a rigid piping system. When a hose is installed, it must allow the compressor to move in all three directions. See typical applications below, which show a single bend, to achieve this. The diagrams apply to both air and water. Note: The following diagrams show flexible hoses with threaded end connections, however flanged end connections may be supplied. These guidelines apply to the flexible part of the hose, regardless of the type of end fitting supplied.
No pressure
Original 2011-06-21
High pressure
To allow the flexible part of the hose to move when pressurised, ensure no supporting clamps are located on the bends.
incorrect
correct
On installation, ensure that the flexible part of the hose is not twisted, this could result in hose damage and, when pressurised, it could untwist, loosening the connections.
16.01.2006 122/Pitrowski
1/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Use angle adaptors to eliminate tight bend radii and sharp twists occurring in the hose.
incorrect
correct
If the installation bend radius is less than the minimum allowed, use angle adaptors to eliminate tight bend radii.
16.01.2006 122/Pitrowski
2/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is installed with a smooth bend, avoiding any tight corners, which could cause the flexible part of the hose to collapse.
incorrect
correct
In a collinear application, do not install the hose in a straight line or with kinks, use angle adaptors.
16.01.2006 122/Pitrowski
3/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is kept away from hot surfaces by using suitable clamps. High ambient temperatures can reduce the life of the flexible part of the hose.
16.01.2006 122/Pitrowski
4/4
Safety Instructions for Hoses
1 General Hose pipes are safety relevant parts which may endanger persons and the environment in case of failure.
1.1 Installation and maintenance During installation the hoses must in no way be damaged, bent, twisted or exerted to pressure. They must not be painted or have contact with sharp objects! For cleaning hose pipes and hoses neither aggressive cleaning agents nor pressure cleaners may be used. They can damage the hose surface resp. hose line! Hose pipes must be inspected visually by the assembly/service personnel before commissioning and once a year. Inspection is carried out under the following aspects: Original 2011-06-21
• • • • • • •
Damage to the outer layer Decay of the outer layer Deformation of the hose or hose pipe (alteration of the geometry, layer separation, forming of blisters) Damage or deformation of the hose fitting Corrosion of the fitting (impairs function and strength) Installation (chafing at sharp edges or smooth surfaces) Exceeding the admissible storage resp. operational duration (stated below)
1.2 Storage and durability According to DIN 7716 proper storage is to be understood as follows: • • • • • •
max storage time 2 years dry, cool, dust-free no direct sunlight or UV light protection against ozone protect against heat store lying and without tension
According to EN 982 resp., DIN 20066 following must be observed: 1. Once installed, the hoses have a durability of 6 years and must be replaced after this period. 2. If the max. storage time of 2 years is exceeded, then the hose may no longer be used. If the hose is installed within this period, the durability of 6 years is reduced by the period of storage accordingly. It lies within the responsibility of the user that all hoses mentioned in this manual are checked at regular intervals, and to guarantee correct and safe function once the guarantee period has elapsed, thus preventing damage to persons and the environment.
date 18.04.2005 Created by Tanz
page 1 of 1
Original 2011-06-21
Ersatzteil-Verzeichnis List of spare parts Liste des pièces de rechange
Kolbenkompressor Piston compressor Compresseur à piston L 15 & L 20 zum Verzeichnis to the list vers la liste
Original 2011-06-21
Ersatzteilverzeichnis List of spare parts Liste des pièces de rechange
Benennung / designation / désignation
Kompressor L15-L20 Compressor L15-L20 Compresseur L15-L20
Tafel / table / planche
Schnittzeichnung / sectional drawing / plan de coupe Kurbelgehäuse / crank case / carter ................................................................1-1010-010 Kurbelwelle / crankshaft / arbre manivelle ......................................................2-501-010 Schmiersystem / lubricating system / système de lubrification .....................3-999-010 Fußschiene / support / support ........................................................................4-999-010 Zylinder und Zylinderkopf / cylinder and cylinder head / cylindre et culasse ...........................................................................................1-1006-020 Ventile / valves / soupapes...............................................................................2-999-020 Kolben / pistons / pistons .................................................................................3-999-020 Original 2011-06-21
Pleuelstangen / connecting rods / bielles ......................................................4-1102-020 Kühlsystem / cooling system / système de refroidissement ..........................1-807-030 Armaturen / fittings / robinetterie .....................................................................1-206-040 Schwungrad und Kupplung / flywheel and coupling / volant et accouplement ...................................................................................1-999-014 Ansaugsystem / suction system / système d’aspiration.................................1-999-032 Starre Lagerung Flanschdurchmesser 250mm / rigid mounting flange diameter 250mm / fixation rigide diamètre de la bride 250mm......................1-999-045 Starre Lagerung Flanschdurchmesser 300mm / rigid mounting flange diameter 300mm / fixation rigide diamètre de la bride 300mm......................2-999-045 Elastische Lagerung Motorgröße 112 / resilient mounting motor type 112 / suspension élastique type de moteur 112 .....................................................1-999-046 Elastische Lagerung Motorgröße 132 / resilient mounting motor type 132 / suspension élastique type de moteur 132 .....................................................2-999-046 Anbau Öldruckwächter / oil pressure control switch mounted on the compressor / contrôleur d´huile lubrifiante monté sur le compresseur .....1-1100-052 Automatische Entwässerung 1.Stufe / automatic drainage 1st stage / vidange automatique 1er étage.......................................................................1-303-053 Automatische Entwässerung 2.Stufe / automatic drainage 2nd stage / vidange automatique 2ème étage ...................................................................2-303-053
Stand: 10.10.2006
Original 2011-06-21
Kurbelgehäuse Crank case Carter
L 15 / L 20 Tafel / Table / Planche 1-1010-010
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
10.10.10.10
Kurbelgehäuse
1
Crank case Carter 2
10.10.10.20
Kurbelwellenlager
1
Crankshaft bearing Pallier d’arbre-manivelle 3
10.10.10.30
Ölsaugrohr
1
Pipe Tuyaux 4
10.10.10.40
Verschlußschraube
1
Screw plug
Original 2011-06-21
Vis de fermeture 5
10.10.10.50
Verschlußschraube
1
Screw plug Vis de fermeture 6
10.10.10.60
Verschlußschraube
1
Screw plug Vis de fermeture 7
10.10.20.10
Gehäusedeckel
1
Housing cover Couvercle de carter 8
10.10.20.20
Kurbelwellenlager
1
Crankshaft bearing Palier d’arbre-manivelle 9
10.10.30
Stiftschraube
6
Stud bolt Goujon prisonnier 10
10.10.40
Sechskantmutter
6
Hexagon nut Écrou hexagonal 11
10.10.50
Sicherung Securing ring Segment de sécurité
6
Kurbelgehäuse Crank case Carter
L 15 / L 20 Tafel / Table / Planche 1-1010-010
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
12
10.10.60
Wellendichtring
1
Radial packing ring Bague d’étanchéité radiale 13
10.10.70
O-Ring
1
O-ring Joint torique 14
10.10.110
Ölstandsauge
1
Oil level inspection glass Verre de regard de niveau d’huile 15
10.10.120
Öleinfüllstutzen
1
Filler tube for oil
Original 2011-06-21
Tuyau de remplissage d’huile 16
10.10.130
Gegenmutter
1
Counter nut Contre-écrou 17
10.10.140
Tragösenverschlußschraube
1
Eye bolt/screw plug Boulon àoeillet/vis de fermeture 18
10.10.150
Dichtring
1
Packing ring Rondelle de joint 19
10.10.160
Dichtring
1
Packing ring Rondelle de joint 20
10.10.170
Druckfeder
1
Pressure spring Ressort de pression 21
10.10.180
Kugel
1
Ball Boulet 22
10.10.190
Gewindestift Threaded pin Cheville filetée
1
Kurbelgehäuse Crank case Carter
L 15 / L 20 Tafel / Table / Planche 1-1010-010
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
23
10.10.200
Dichtring
2
Packing ring Rondelle de joint 24
10.10.210
Sechskantmutter
1
Hexagon nut Écrou hexagonal 25
10.10.220
Hutmutter
1
Cap nut Écrou borgne 26
10.10.230
Ölsaugsieb
1
Oil suction sieve
Original 2011-06-21
Tamis à huile 27
10.10.240
Dichtring
1
Packing ring Rondelle de joint 28
10.10.250
Schutzblech
1
Protection plate Protection 29
10.10.260
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 30
10.10.270
Schutzblech Protection plate Protection
1
Original 2011-06-21
Kurbelwelle Crank shaft Arbre manivelle
L 15 / L 20 Tafel / Table / Planche 2-501-010
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
10.20.10.10
Kurbelwelle
1
Crank shaft Arbre manivelle 2
10.20.10.30
Paßfeder
1
Fitting key Clavette d’ajustage 3
10.20.10.40
Paßfeder
1
Fitting key Clavette d’ajustage 4
10.20.20
Paßscheibe
1
Fitting disc
Original 2011-06-21
Disque d’ajustage 5
10.20.30
Paßscheibe Fitting disc Disque d’ajustage
1
Original 2011-06-21
Schmiersystem Lubricating system Système de lubrification
L 15 / L 20 Tafel / Table / Planche 3-999-010
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
10.30.10
Ölpumpendeckel
1
Oil pump cover Couvercle de la pompe à huile 2
10.30.20
Wellendichtring
1
Radial packing ring Bague d’étanchéité radiale 3
10.30.30
O-Ring
1
O-ring Joint torique 4
10.30.40
Ölpumpenzahnrad
1
Gear wheel for oil pump
Original 2011-06-21
Roue dentée de la pompe à huile 5
10.30.50
Ölpumpenzahnrad
1
Gear wheel for oil pump Roue dentée de la pompe à huile 6
10.30.60
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 7
10.30.70
Dichtscheibe Packing ring Rondelle de joint
4
Original 2011-06-21
Fußschiene Support Support
L 15 / L 20 Tafel / Table / Planche 4-999-010
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
10.40.10
Fußschiene
1
Support Support 2
10.40.20
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 3
10.40.30
Sicherungsring Securing ring
Original 2011-06-21
Segment de sécurité
4
Original 2011-06-21
Zylinder und Zylinderkopf Cylinder and cylinder head Cylindre et culasse
L 15 / L 20 Tafel / Table / Planche 1-1006-020
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
20.10.10
Zylinder 1. Stufe
1
st
Cylinder 1 stage Cylindre 1er étage 2
20.10.20
Dichtung
2
Gasket Joint 3
20.10.30
Zylinderkopf 1. Stufe
1
st
Cylinder head 1 stage Culasse 1er étage 4
20.10.40
Zylinder 2. Stufe
1
Cylinder 2nd stage
Original 2011-06-21
Cylindre 2ème étage 5
20.10.50
Zylinderkopf 2. Stufe
1
Cylinder head 2nd stage Culasse 2ème étage 6
20.10.60
Stiftschraube
8
Stud bolt Goujon prisonnier 7
20.10.70
Sechskantmutter
8
Hexagon nut Écrou hexagonal 8
20.10.80
Scheibe
8
Disc Disque 9
20.10.100
Distanzring (nur bei L15) Distance ring (for L15 only) Baque d´écartement (seulement pour L15)
1
Original 2011-06-21
L 15 / L 20
Ventile Valves Soupapes
Tafel / Table / Planche 2-999-020
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
20.20.10
Kombiniertes Saug- und Druckventil 1. Stufe
1
st
Comb. Suction and pressure valve 1 stage Soupape combinée d’aspiration et de refoulement 1er étage
2
20.20.10.10
1 Satz Ventilplatten und Federn
1
1 set of valveplates and springs 1 jeu de disques et ressorts de soupape 3
20.20.10.20
Zylinderstift
1
Pin Goupille 4
20.20.20
Kombiniertes Saug- und Druckventil 2. Stufe
1
Comb. Suction and pressure valve 2nd stage
Original 2011-06-21
Soupape combinée d’aspiration et de refoulement 2ème étage
5
20.20.20.10
1 Satz Ventilplatten und Federn
1
1 set of valveplates and springs 1 jeu de disques et ressorts de soupape 6
20.20.30
Dichtung
1
Gasket Joint 7
20.20.40
Dichtung
1
Gasket Joint 8
20.20.50
Dichtung Gasket Joint
1
Original 2011-06-21
L 15 / L 20
Kolben Pistons Pistons
Tafel / Table / Planche 3-999-020
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
20.30.10
Kolben 1. Stufe, komplett
1
st
Piston 1 stage, complete Piston 1er etage, compl. 2
20.30.10.10
Kolben
1
Piston Piston 3
20.30.10.20
Kolbenbolzen
1
Wrist pin Axe du piston 4
20.30.10.30
Sicherungsring
2
Securing ring
Original 2011-06-21
Segment de sécurité 5
20.30.10.40
Rechteckring
1
Piston ring Segment de piston 6
20.30.10.50
Nasenring
1
Stepped scraper ring Segment à talon 7
20.30.10.60
Schlauchfederring
1
Double-bevelled oil control ring Racleur d’huile 8
20.30.20
Kolben 2. Stufe, komplett
1
Piston 2nd stage, complete Piston 2ème étage, compl. 9
20.30.20.10
Kolben
1
Piston Piston 10
20.30.20.20
Kolbenbolzen
1
Wrist pin Axe du piston 11
20.30.20.30
Sicherungsring Securing ring Segment de sécurité
1
Kolben Pistons Pistons
L 15 / L 20 Tafel / Table / Planche 3-999-020
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
12
20.30.20.40
Nasenring
2
Stepped scraper ring Segment à talon 13
20.30.20.50
Minutenring Taper faced compression ring
Original 2011-06-21
Segment compresseur à face conique
1
Original 2011-06-21
Original 2011-06-21
Pleuelstangen Connecting rods Bielles
L 15 / L 20 Tafel / Table / Planche 4-1102-020
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
20.40.10.10
Pleuelstange 1. Stufe, komplett
1
st
Connecting rod 1 stage, complete Bielle 1er étage, compl. 2
20.40.10.20
Pleuellagerschale
2
Connecting rod bearing Coussinet de bielle 3
20.40.20.30
Pleuelstange 2. Stufe, komplett
1
Connecting rod 2nd stage, complete Bielle 2ème étage, compl. 4
20.40.20.30.20
Nadellager
1
Needle bearing
Original 2011-06-21
Pallier à aiguilles 5
20.40.20.20
Pleuellagerschale Connecting rod bearing Coussinet de bielle
2
Original 2011-06-21
Kühlsystem Cooling system Système de refroidissement
L 15 / L 20 Tafel / Table / Planche 1-807-030
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
30.10.10
Kühler 1. Stufe
1
st
Cooler 1 stage Refroidisseur 1er étage 2
30.10.20
Gerade Einschraubverschraubung
1
Straight male stud coupling Union simple mâle 3
30.10.30
Schwenkverschraubung
1
Banjo coupling Équerre orientable 4
30.10.40
Anschlußschraube
1
Connecting screw
Original 2011-06-21
Raccord 5
30.10.50
Dichtring
1
Packing ring Rondelle de joint 6
30.10.60
Kühler 2 Stufe
1
Cooler 2nd stage Refroidisseur 2ème étage 7
30.10.70
Gerade Einschraubverschraubung
2
Straight male stud coupling Union simple mâle 8
30.10.80
Luftauslaß
1
Compressed air outlet Sortie air comprimé 9
30.10.90
Zylinderschraube
2
Cylinder head bolt Vis à tête cylindrique 10
30.10.100
Verschlußschraube
1
Screw plug Vis de fermeture 11
30.10.110
Dichtring Packing ring Rondelle de joint
1
Kühlsystem Cooling system Système de refroidissement
L 15 / L 20 Tafel / Table / Planche 1-807-030
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
12
30.10.120
Befestigungsschelle
1
Double clamp Agrafe double de serrage 13
30.10.130
Halter
1
Fastener Support 14
30.10.140
Haltebügel
1
Double clamp Agrafe double de serrage 15
30.10.150
Senkschraube
2
Countersunk head screw
Original 2011-06-21
Vis à tête fraisée 17
30.10.170
Sicherheitsmutter
2
Safety nut Écrou de blocage 18
30.10.180
Gerade Einschraubverschraubung
1
Straight male stud coupling Union simple mâle 19
30.10.190
Lüfterhaube
1
Air blast housing Carter du ventilateur 20
30.10.200
Frontplatte
1
Front cover Couvercle avant 21
30.10.210
Haubenhalter
2
Fastening angle Équerre de fixation 22
30.10.220
Sechskantschraube
2
Hexagon head bolt Vis hexagonale 23
30.10.230
Scheibe Disc Disque
8
Kühlsystem Cooling system Système de refroidissement
L 15 / L 20 Tafel / Table / Planche 1-807-030
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
24
30.10.240
Sechskantschraube
6
Hexagon head bolt Vis hexagonale 25
30.10.250
Radiallüfterrad
1
Radial fan wheel Roue du ventilateur radiale 26
30.10.260
Scheibe
1
Disc Disque 27
30.10.270
Sechskantschraube
1
Hexagon head bolt
Original 2011-06-21
Vis hexagonale 28
30.10.280
Sicherungsring
1
Securing ring Segment de sécurité 29
30.10.290
Schutzschlauch
2
Protection hose Tuyau de protection 30
30.10.300
Schutzschlauch Protection hose Tuyau de protection
2
Original 2011-06-21
L 15 / L 20
Armaturen Fittings Robinetterie
Tafel / Table / Planche 1-206-040
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
40.10.10
Manometer 1. Stufe
1
st
Pressure gauge 1 gauge Manomètre 1er étage 2
40.10.20
Manometer 2. Stufe
1
Pressure gauge 2nd gauge Manomètre 2ème étage 3
40.10.30
Öldruckmanometer
1
Oil pressure gauge Manomètre de pression d’huile 4
40.10.40
Manometer-Anschlußstück
2
Coupling for pressure gauge connection
Original 2011-06-21
Raccord pour manomètre 5
40.10.50
Dichtring
2
Packing ring Rondelle de joint 6
40.10.60
Wika-Dichtring
3
Wika packing ring Rondelle de joint Wika 7
40.10.70
Manometerhalter
1
Pressure gauge holder Porte-manomètre 8
40.10.80
Sechskantschraube
2
Hexagon head bolt Vis hexagonale 9
40.10.90
Rohr
1
Pipe Tuyau 10
40.10.100
Gerade Einschraubverschraubung
1
Straight male stud coupling Union simple mâle 11
40.10.160
Sicherheitsventil 1. Stufe Safety valve 1st stage Soupape de sûreté 1er étage
1
Armaturen Fittings Robinetterie
L 15 / L 20 Tafel / Table / Planche 1-206-040
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
12
40.10.170
Sicherheitsventil 2. Stufe
1
Safety valve 2nd stage Soupape de sûreté 2ème étage 13
40.10.180
Dichtring
2
Packing ring Rondelle de joint 14
40.10.190
Einstellbare Winkelverschraubung
2
Adjustable elbow coupling Équerre orientable 15
40.10.200
Gerade Einschraubverschraubung
2
Straight male stud coupling
Original 2011-06-21
Union simple mâle 16
40.10.210
Muffenkugelhahn
2
Ball valve Robinet à boisseau sphérique 17
40.10.110
L-Verschraubung L- coupling T mâle renversé
1
Original 2011-06-21
Original 2011-06-21
Schwungrad und Kupplung Flywheel and coupling Volant et accouplement
L 15 / L 20 Tafel / Table / Planche 1-999-014
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
14.10
Kupplungsteil
1
Coupling part Partie d’accouplement 2
14.20
Scheibe
1
Disc Disque 3
14.30
Sechskantschraube
1
Hexagon head bolt Vis hexagonale 4
14.40
Sicherungsring
1
Securing ring
Original 2011-06-21
Segment de sécurité 5
14.50
Schwungrad
1
Flywheel Volant 6
14.60
Kupplungsstern Flexible gear rim Couronne dentée élastique
1
Original 2011-06-21
Ansaugsystem Suction system Système d’aspiration
L 15 / L 20 Tafel / Table / Planche 1-999-032
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
32.10
Ansaugfilter komplett
1
Suction filter complete Filtre d’aspiration complet 2
32.20
Schlauch
1
Hose Tuyau flexible 3
32.30
Schlauchschelle Hose clip
Original 2011-06-21
Agrafe de serrage
2
Original 2011-06-21
Starre Lagerung Rigid mounting Fixation rigide
L 15 / L 20 Tafel / Table / Planche 1-999-045
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
45.10
Kompressorfuß
2
Support for compressor Support pour compresseur 2
45.20
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 3
45.30
Sechskantmutter
4
Hexagon nut Écrou hexagonale 4
45.40
Fußschiene
1
Support
Original 2011-06-21
Support 5
45.50
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 6
45.60
Stiftschraube
4
Stud bolt Goujon prisonnier 7
45.70
Sechskantmutter
4
Hexagon nut Écrou hexagonale 8
45.80
Zwischenflansch
1
Intermediate flange Bride intermédiaire 9
45.90
Zylinderschraube Cylinder head bolt Vis à tête cylindrique
4
Original 2011-06-21
Starre Lagerung Rigid mounting Fixation rigide
L 15 / L 20 Tafel / Table / Planche 2-999-045
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
45.10
Kompressorfuß
2
Support for compressor Support pour compresseur 2
45.20
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 3
45.30
Sechskantmutter
4
Hexagon nut Écrou hexagonale 4
45.40
Fußschiene
1
Support
Original 2011-06-21
Support 5
45.50
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 6
45.60
Stiftschraube
4
Stud bolt Goujon prisonnier 7
45.70
Sechskantmutter Hexagon nut Écrou hexagonale
4
Original 2011-06-21
Elastische Lagerung Resilient mounting Suspension élastique
L 15 / L 20 Tafel / Table / Planche 1-999-046
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
46.10
Platte
1
Plate Plaque 2
46.20
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 3
46.30
Schwingmetallelement
2
Rubber to metall bonded foot Jointure métallo-caoutchouc 4
46.40
Sechskantschraube
4
Hexagon head bolt
Original 2011-06-21
Vis hexagonale 5
46.50
Sechskantmutter
4
Hexagon nut Écrou hexagonal 6
46.60
Schwingmetallpuffer
1
Rubber to metal bonded foot Pied en caoutchouc-métal 7
46.70
Grundplatte für Schwingmetallpuffer
1
Base plate for rubber to metal bonded foot Platine pour pied en caoutchouc-métal 8
46.80
Motorfuß
1
Support for electric motor Support pour moteur électrique 9
46.90
Stiftschraube
4
Stud bolt Goujon prisonnier 10
46.100
Sechskantmutter
4
Hexagon nut Écrou hexagonal 11
46.110
Sechskantschraube Hexagon head bolt Vis hexagonale
2
Elastische Lagerung Resilient mounting Suspension élastique
L 15 / L 20 Tafel / Table / Planche 1-999-046
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
12
46.120
Sechskantmutter
3
Hexagon nut Écrou hexagonal 13
46.130
Zwischenflansch
1
Intermediate flange Bride intermédiaire 14
46.140
Zylinderschraube Cylinder head bolt
Original 2011-06-21
Vis à tête cylindrique
4
Original 2011-06-21
Original 2011-06-21
Elastische Lagerung Resilient mounting Suspension élastique
L 15 / L 20 Tafel / Table / Planche 2-999-046
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
46.10
Platte
1
Plate Plaque 2
46.20
Sechskantschraube
4
Hexagon head bolt Vis hexagonale 3
46.30
Schwingmetallelement
2
Rubber to metall bonded foot Jointure métallo-caoutchouc 4
46.40
Sechskantschraube
4
Hexagon head bolt
Original 2011-06-21
Vis hexagonale 5
46.50
Sechskantmutter
4
Hexagon nut Écrou hexagonal 6
46.60
Schwingmetallpuffer
1
Rubber to metal bonded foot Pied en caoutchouc-métal 7
46.70
Grundplatte für Schwingmetallpuffer
1
Base plate for rubber to metal bonded foot Platine pour pied en caoutchouc-métal 8
46.80
Motorfuß
1
Support for electric motor Support pour moteur électrique 9
46.90
Stiftschraube
4
Stud bolt Goujon prisonnier 10
46.100
Sechskantmutter
4
Hexagon nut Écrou hexagonal 11
46.110
Sechskantschraube Hexagon head bolt Vis hexagonale
2
Elastische Lagerung Resilient mounting Suspension élastique
Tafel / Table / Planche 2-999-046
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
12
46.120
Sechskantmutter
3
Hexagon nut Écrou hexagonal
Original 2011-06-21
L 15 / L 20
Original 2011-06-21
Original 2011-06-21
Anbau Öldruckwächter Oil pressure switch mounted on compressor Contrôleur d’huile lubrifiante monté sur le compresseur
L 15 / L 20 Tafel / Table / Planche 1-1100-052
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
52.10
Rohr
1
Pipe Tuyau 2
52.20
Reduzierstutzen
1
Reducing socket Raccord de réduction 3
52.30
Öldruckwächter
1
Oil pressure control switch Contrôleur d’huile lubrifiante 4
52.40
Sechskantschraube
2
Hexagon head bolt
Original 2011-06-21
Vis hexagonale 5
52.50
Sicherungsring
2
Securing ring Segment de sécurité 6
52.60
Schwenkverschraubung Banjo coupling Équerre orientable
1
Original 2011-06-21
Automatische Entwässerung 1.Stufe Automatic drain 1st stage Vidange automatique 1er étage
L 15 / L 20 Tafel / Table / Planche 1-303-053
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
53.10
2/2-Wege-Magnetventil 1.Stufe
1
st
2/2-way solenoid valve 1 stage Soupape électro-magnetique à 2/2 orifices 1er étage 2
53.20
Verschraubung
1
Straight male stud coupling Union simple mâle 3
53.30
Dichtring Packing ring
Original 2011-06-21
Rondelle de joint
2
Original 2011-06-21
L 15 / L 20 Automatische Entwässerung 2.Stufe Automatic drain 2nd stage Vidange automatique 2ème étage
Tafel / Table / Planche 2-303-053
Teil-Nr. / Part-No.
Ident-Nr. / Ident-No.
Benennung / Designation
Menge / Qty.
No. de pièces
No. d´identific
Désignation
Qté.
1
53.10
2/2-Wege-Magnetventil 2.Stufe nd
2/2-way solenoid valve 2 stage
Original 2011-06-21
Soupape électro-magnetique à 2/2 orifices 2ème étage
1
ELECTRICAL DRAWINGS FOR COMPRESSORS Shipyard
Original 2011-06-21
Cosco Guangdong Shipyard Co., Ltd.
Newbuilding
N352 N353
Date
22.12.2010
Our ref.
10.2722 10.2723
ITEM
DESCRIPTION
DRAWING No.
1
Spare part list
2
Connection diagram compressors V105
344181-44070 1-2
3
Starter / controller compressor 22-30kW
344182-44070 1-8
4
Sequence selection box for double compr. control
333392-44070 1-2
5
Connection diagram compressor L20
344183-44070 1
6
Starter / controller compressor 5,5-7,5kW
344184-44070 1-8
1/1 Uetersener Maschinenfabrik GmbH & Co. KG Tornescher W eg 5-7 25436 Uetersen / Germany
Tel.: + 49-(0) 4122 / 711-0 Fax: + 49-(0) 4122 / 711-104
[email protected] www.hatlapa.de
Geschäftsführer / Managing Directors: Dr.-Ing. Alexander Nürnberg Jörg Tollmien
Amtsgericht Elmshorn: HRA 0499 Verwaltungsgesellschaft: HRB 1560 UST.ID-Nr. DE 134527127
ELECTRICAL SPARE PARTS FOR COMPRESSORS
Original 2011-06-21
Shipyard
Newbuilding
Date
02.11.2010
Our ref.
Cosco Guangdong Shipyard Co., Ltd.
N352 N353
10.2722 10.2723
ITEM: QUANTITY:
DESCRIPTION:
IDENT No.:
1
1
MAIN CONTACTOR LC1-D50
121496
2
1
MAIN CONTACTOR LC1-D18
334706
1/1 Uetersener Maschinenfabrik GmbH & Co. KG Tornescher W eg 5-7 25436 Uetersen / Germany
Tel.: + 49-(0) 4122 / 711-0 Fax: + 49-(0) 4122 / 711-104
[email protected] www.hatlapa.de
Geschäftsführer / Managing Directors: Dr.-Ing. Alexander Nürnberg Jörg Tollmien
Amtsgericht Elmshorn: HRA 0499 Verwaltungsgesellschaft: HRB 1560 UST.ID-Nr. DE 134527127
0
2
1
3
4
5
6
Schaltschrank Startluft-Kompressor 1 (22-30kW) STARTER / CONTROLLER MAIN AIR COMPRESSOR 1 (22-30kW)
8
7
9
(344182-44070) NO
NO
NC
26 27
20 21
22 25
-1X1
ø16-28
W
H1 H2
ø16-28
5
ø6-13
5
7
8
5
9
10
5
ø6-13
X1
5
11 12
1
17
1
17
1
18
13 14 15
ø16-28
ø16-28
6
KompressorUmschaltbox
cable glan 08.12.10 A sizes Zust. Änderung Datum
bre Name
Bearb. Gepr. Norm
02.11.10 Bre cpu
343260
NO
-1Y1 -1F13
Ers.f
NO
(Klemmenkasten Kompressor 1) (TERMINAL BOX COMPRESSOR 1)
13
14 15
13-21
ø6-13
ø6-13
24V DC
COM
F3W
COM
Entwässerungsventil letzte Stufe DRAIN VALVE FINAL STAGE
NC
T
1 18
220-230V AC
NC T
WARNING
L
220-230V AC
1
Werft-Lieferung SUPPLIED BY SHIPYARD
-1Y2
-1F3
Anschlußplan Kompressoren V105 CONNECTION DIAGRAM COMPRESSORS V105 Urspr.
1 17
Entwässerungsventil 1. Stufe DRAIN VALVE FIRST STAGE
Luft-TemperaturWächter AIR TEMPERATURE SWITCH
Ölstands-Wächter OIL LEVEL SWITCH
-1F4 CONTACTS SHOWN WITHOUT OIL
Datum
1 17
10
F3S
Heizung HEATING appr. 50W
L
9
SHUTDOWN
StartluftKompressor 1 MAIN AIR COMPRESSOR 1 V105 24 kW
2
5
24V DC
P
3
8
F13.1
M
3
7
SHUTDOWN
HE1 HE2
5
F13.2
W
24V DC
-1M1
V
Druckluftwächter für Führungskompressor AIR PRESSURE SWITCH F.LEADING COMPRESSOR
U
5 11 12
2
24V DC
1
WARNING
440V 60Hz 440V 60Hz
X1
5 9 10
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
5 7 8
COMPRESSOR SELECTION BOX
MAN 0 AUTO
(333392)
Einspeisung SHIP SUPPLY
Original 2011-06-21
6
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
potentialfreier Kontakt für Fernbedienung aktiv FLOATING CONTACT FOR REMOTE CONTROL ACTIVE
L1 L2 L3
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344181-44070 Blatt 1 von 2 Bl.
0
2
1
3
4
5
6
Schaltschrank Startluft-Kompressor 2 (22-30kW) STARTER / CONTROLLER MAIN AIR COMPRESSOR 2 (22-30kW)
8
7
9
(344182-44070) NO
NO
NC
26 27
20 21
22 25
-2X1
ø16-28
W
H1 H2
ø16-28
5
ø6-13
5
7
8
5
9
10
5
ø6-13
X1
7
11 12
1
17
1
17
1
18
13 14 15
ø16-28
ø16-28
8
KompressorUmschaltbox
Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
02.11.10 Bre cpu
343260
NO
-2Y1 -2F13
Ers.f
NO
(Klemmenkasten Kompressor 2) (TERMINAL BOX COMPRESSOR 2)
14 15
-2Y2
Ers.d
ø6-13
ø6-13
Werft-Lieferung SUPPLIED BY SHIPYARD
-2F3
HATLAPA
13
13-21
24V DC
COM
F3W
COM
Entwässerungsventil letzte Stufe DRAIN VALVE FINAL STAGE
NC
T
1 18
220-230V AC
NC T
WARNING
L
220-230V AC
1
Anschlußplan Kompressoren V105 CONNECTION DIAGRAM COMPRESSORS V105 Urspr.
1 17
Entwässerungsventil 1. Stufe DRAIN VALVE FIRST STAGE
Luft-TemperaturWächter AIR TEMPERATURE SWITCH
Ölstands-Wächter OIL LEVEL SWITCH
-2F4 CONTACTS SHOWN WITHOUT OIL
Datum
1 17
10
F3S
Heizung HEATING appr. 50W
L
9
SHUTDOWN
StartluftKompressor 2 MAIN AIR COMPRESSOR 2 V105 24 kW
2
24V DC
P
3
5
F13.1
M
3
8
SHUTDOWN
HE1 HE2
7
F13.2
W
24V DC
-2M1
V
5
24V DC
U
5 11 12
4
Druckluftwächter für Folgekompressor AIR PRESSURE SWITCH F.FOLLOWING COMPRESSOR
3
WARNING
440V 60Hz 440V 60Hz
X1
5 9 10
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
5 7 8
COMPRESSOR SELECTION BOX
MAN 0 AUTO
(333392)
Einspeisung SHIP SUPPLY
Original 2011-06-21
6
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
potentialfreier Kontakt für Fernbedienung aktiv FLOATING CONTACT FOR REMOTE CONTROL ACTIVE
L1 L2 L3
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344181-44070 Blatt 2 von 2 Bl.
0
2
1
3
4
5
600
6
8
7
9
210
Schaltschrank Kompressor STARTER/CONTROLLER COMPRESSOR
Amperemeter (mit Markierungsanzeiger) AMMETER
P2
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
Q1
Hauptschalter (mit Türverriegelung) ISOLATING SWITCH
Q2
Hauptschalter Motor-Heizung MAIN SWITCH MOTOR HEATING
H2
Meldelampe "Motor-Heizung ein" INDICATING LIGHT "MOTOR HEATING ON"
H2 P2
Q2
S2
TD 200
L
R
600
HATLAPA
(BU)
S2
Wahlschalter "Vorort / Fern" SELECTOR SWITCH "LOCAL / REMOTE"
Q1
Gewicht: ca. 50kg WEIGHT: APPR. 50kg 8
Schutzart: IP54 PROTECTION CLASS: IP54
20
Original 2011-06-21
P1
P1
mit Türfeststeller
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 1 von 8 Bl.
0
2
1
3 P2
4
5
Original 2011-06-21
RESET
HATLAPA
SHIFT
black on red
STOP
8
9
TD 200
MAN
schwarz auf rot
7
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
SIEMENS
STOP
6
AUTO
schwarz auf hell-blau black on light blue
AUTO
ESC
schwarz auf grün
schwarz auf weiß
black on green
black on white
MAN
ENTER
RESET
HATLAPA dark blue on white dunkel-blau auf weiß
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 2 von 8 Bl.
Kurzbeschreibung für Kompressorsteuerung mit TD200
short description f.compressor control with TD200: ON / OFF:
The standard text on the text display is:
ready for operation / off Betriebsbereit / aus
Now you can start the compressor in manual or in automatic operation. When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4. Normallay the manual operation is only used for maintenance purposes. After a blackout the cmpressor will not start again in this manual mode.
Original 2011-06-21
When You press the "AUTO" push button the compressor is switched to automatic mode. The compressor starts and stops automatically depending on the air pressure. Normally this should be the standard operation mode. When the pressure switch F4 is closed the compressor starts. When the pressure switch F4 is opened the compressor stops. After a blackout the compressor will start again in automatic mode.
ALARMS:
Jetzt kann man den Kompressor in der Hand- oder in der Automatik-Betriebsart starten. compressor on / man Kompressor ein / Hand
ready for operation / off Betriebsbereit / aus
When You press the "STOP" push button the compressor stops again.
When you want to change the operation mode from manual to automatic or from automatic to manual you must press the "STOP" push button before. When there is any fault, the compressor stops and the belonging disturbance alarm is shown in the display. Not all possible disburbance texts are used for this compressor.
Now the fault must be eliminated. Then press the "RESET" push button and there should be the standard text on the display again. Now You can start the compressor again with the "AUTO" or "MAN" push button.
compressor on / auto Kompressor ein / Auto ready for operation / auto Betriebsbereit / Auto
make maintenance ! Wartung fällig ! motor overload Motor Überlast oil level warning Öl-Level Voralarm low oil level Öl-Level Alarm air temperature warning Lufttemperatur Voralarm high air temperature Lufttemperatur-Alarm
Mit der Taste "MAN" wird der Kompressor in der Hand-Betriebsart gestartet. D.h. ohne Funktion des Druckluftschalters F4. Normalerweise wird diese Fuktion nur für Wartungszwecke benutzt. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Hand" nicht wieder selbsttätig starten. Mit dem Taster "STOP" kann der Kompressor wieder gestoppt werden. Mit dem Taster "AUTO" kann der Kompressor in die Betriebsart "Automatik" geschaltet werden. Der Kompressor startet und stopt dann selbstätig in Abhängigkeit des Druckluftschalters F4. Wenn der Druckluftschalter geschlossen ist, dann startet der Kompressor. Wenn der Druckluftschalter geöffnet ist, dann stopt der Kompressor. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Automatik" selbstständig wieder anlaufen.
ALARME
Wenn eine Störung vorliegt, dann stopt der Kompressor und es wird der zugehörige Alarm im Textdisplay angezeigt. Nicht alle hier dargestellten Alarm-Texte werden für diesen Kompressor benutzt. Jetzt must der entsprechende Fehler behoben werden und dann der "RESET"-Taster betätigt werden. Darauf sollte dann der Standart-Text wieder auf dem Display erscheinen. Jetzt kann der Kompressor wieder mit den Tasten "MAN" oder "AUTO" gestartet werden.
ready for operation / off Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS: When there are one or two arrows in the right side of the display, you can go to other display texts by pressing the belonging arrow push buttons The other texts can show more disturbance alarms, if there is more than one fault. Or you can watch the working hours. Or you can watch some special settings of the software. Normally all settings are done by HATLAPA for a normal purpose of the compressor. If you want to change any setting, you must press the "ENTER" push button one time. Now you can change the value with the arrow push buttons. After this you must quit the new value by pressing "ENTER" again.
workings hours xxxxx h Betriebsstunden drainage time 2sec Entwässerungsdauer drainage interval 5min Entwässerungsinterval star delta time 4sec Stern-Dreieck-Zeit delayed start 0sec verzögerter Anlauf cooling water delay 2min Kühlwassernachlauf continuous time 5min Durchlaufzeit
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
EIN / AUS
Dies ist der Standart-Text auf dem Display.
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
Wenn ganz rechts im Display ein oder zwei Pfeile dargestellt werden, dann kann mit d.entsprechenden Pfeil-Tasten zu anderen möglichen Texten gesprungen werden. Die weiteren Texte können weitere Alarme anzeigen, wenn mehr als eine Störung ansteht. Oder es werden die Betriebsstunden angezeigt. Oder es können einige variable Einstellungen der Software angezeigt werden. Normalerweise sind alle Einstellungen für einen normalen Kompressorbetrieb bereits durch HATLAPA festgelegt. Wenn Einstellungen geändert werden sollen, muß einmalig die "ENTER"-Taset betätigt werden. Dann kann man mit den Pfeil-Tasten den entsprechenden Wert verändern. Daraufhin muß der geänderte Wert nocheinmal mit der "ENTER"-Taste quittiert werden.
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 3 von 8 Bl.
0
2
1
3
4
5
6
8
7 -F2
9
2A
4
L
2
4
6
11
1
3
5
12
1
3
5
2
4
6
0P ±5%
-K1 /8.0
-F3
-T1 440V
-Q1
4
6
220V 250VA 0S
2A
2
-Q4
0,63-1A 2 GV2 RT05
l
Heizungs-Spannung HEATING VOLTAGE
/7.9
1 1
3
5
-Q2
97 95
2
-F1 37-50A
4
3 Hauptschalter Heizung MAIN SWITCH 4 HEATING
98 96
6
Original 2011-06-21
2
/5.0
4
75/1
1N1
Trafo-Einspeisung TRANSFORMER SUPPLY
1
k
-T2
5
3
-P1 75A + A -
K
3
/5.0
Steuerspannung CONTROL VOLTAGE 3
1
2
1
1L1
51
61
/8.0 52
62
-K1 X1
-H2
Heizung ein HEATING ON
220V X2
SHIP SUPPLY 440V
440V Zuleitung
U
V
W
U
V
W
H1 H2 PE
PE
60Hz
L1 L2 L3 PE
60Hz
-X1
-M1
9 10 HE1 HE2
M
3
Heizung HEATING 25-100W
Kompressor COMPRESSOR 22-30 kW Datum 02.11.10 Bearb. Gepr.
Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 4 von 8 Bl.
0 /4.9
/4.9
2
1
3
4
5
6
7
8
9
1L1
1N1
1N1
1L+
+24V DC
/8.0
/6.0
Original 2011-06-21
Softwareversion Hamw_7
16t 17t 18t
S7-CPU 224 Relay-Outputs 14 x Inputs
10 x Outputs Relay
2b 3b 4b 5b 6b 7b 8b 9b
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
/6.0 /6.4 /6.4 /6.5 /6.6 /6.7 /6.8 /6.2
MOTOR PROTECTION RE OIL LEVEL SW.WARNIN OIL LEVEL SW.SHUTDO AIR TEMPERAT.SHUTDO AIR TEMPERAT.WARNIN SPARE Reserve SPARE Reserve AIR PRESSURE SWITCH
2t 3t 4t 5t 8t 9t 10t 13t
11b 12b 13b 14b 15b 16b
E1.0 E1.1 E1.2 E1.3 E1.4 E1.5
/7.1 /7.3 /7.5
REMOTE CONTROL ON REMOTE CONTROL MANU REMOTE CONTROL AUTO
14t A1.0 15t A1.1
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5 A0.6 A0.7
/8.0 /8.5 /8.7 /8.6 /8.2 /8.3 /8.9
PE N L1
17b 18b
-A1
M Exp. L+
1L Out 2L 3L 1M In 2M
1t 7t 12t 1b 10b
0V DC
Supply
MOTOR MAIN CONTACTO DRAIN VALVES Entwäs DISTURBANCE RELAY COOLING WATER VALVE SPARE STAR CONTACTOR DELTA CONACTOR REMOTE CONTROL ACTI
-P2 TD 200
HATLAPA Anzeige- und Bedieneinheit monitoring and operation panel
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 5 von 8 Bl.
0 /5.9
2
1
3
4
5
6
8
7
1L+
9 1L+
-A1
-A1
3b
-A1
5b
E0.1
/5.2
/7.0
7b
E0.3
/5.2
E0.5
/5.2
95 OIL LEVEL SW.WARNING Ölstands-W. Voralarm
-F1
AIR TEMPERAT.SHUTDOWN Lufttemp.-Wächter Alarm
SPARE
Reserve
/4.2 96 Digital Input
-A1
AIR PRESSURE SWITCH Luftdruck-Wächter Digital Input
PE
Optional über KompressorUmschaltbox 2
OPTIONAL VIA COMPRESSOR SEQUENCE Luftdruck-Wächter SELECTION BOX für Auto Start/Stop AIR PRESSURE SWITCH FOR AUTO START/STOP
7
8
3
2
1
24V DC
1
P
5
L
ÖlStandsWächter OIL LEVEL SWITCH
L
Zust. Änderung
Datum
Name
Norm
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
SPARE
10
NC T
PE
/5.2 Reserve
Digital Input
5
11
12
PE
NC
T COM
COM
-F3
Datum 02.11.10 Bre cpu
9
LuftTemp.Wächter AIR TEMP. SWITCH
-F13 Bearb. Gepr.
E0.6
Digital Input
5
PE
/5.2
AIR TEMPERAT.WARNING Lufttemperatur Voralarm
24V DC
6
F13.1
5
E0.4
Digital Input
SHUTDOWN
-X1
/5.2
OIL LEVEL SW.SHUTDOWN Ölstands-Wächert Alarm
F13.2
Digital Input
-F4
E0.2
F3W
MOTOR PROTECTION RELAY Motorschutzrelais
/5.2
8b
WARNING
E0.7
-A1
6b
F3S
/5.2
Digital Input
-A1
4b
WARNING
E0.0
Original 2011-06-21
-A1
9b
SHUTDOWN
-A1 2b
Digital Input
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 6 von 8 Bl.
0 /6.9
2
1
3
4
5
6
8
7
9
1L+
13
potentialfreie Kontakte FLOATING CONTACTS
-S2 Vorort-Fern LOCAL-REMOTE
14
11
-Q1 /4.1 12 13 -A1
-A1
11b E1.0
/5.2
E1.1
REMOTE CONTROL ON Fernbedienung ein
Original 2011-06-21
13b /5.2
REMOTE CONTROL MANUAL Fernbedienung Hand ein
Digital Input
E1.2
-K5
-K1
-K4
14 /8.0
14 /8.4
13
/5.2
REMOTE CONTROL AUTO ON Fernbedienung Auto ein
Digital Input
-X1
13
14 /8.6
-A1
12b
13
Digital Input
14 15 PE
26 27 PE Fernbedienung aktiv REMOTE CONTROL ACTIVE
(NO)
22 25 PE STÖRUNG DISTURBANCE
(NC)
MAN 0 AUTO
(NO)
20 21 PE Kompressor ein COMPRESSOR ON
Fernbedienung Hand - Aus - Automatik REMOTE CONTROL MANUAL - OFF - AUTOMATIC
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 7 von 8 Bl.
0
2
1
3
4
5
-A1
6
-A1
Digital Output MOTOR MAIN CONTACTOR NETZSCHÜTZ
2t
3t
DISTURBANCE RELAY Störungs-Kontakt
/5.2
A0.3
/5.2
A0.2
5t
REMOTE CONTROL ACTIVE Fernbedienung aktiv /5.2
A0.7 13t
A1
A1
-K4
50A A2 INCL. VAR.
Original 2011-06-21
Digital Output
4t
-K1
/5.9
-A1
Digital Output
COOLING WATER VALVE Kühlwasserabsperrventi
/5.2
A0.1
9
-A1
Digital Output
DRAIN VALVES Entwässerungs-Ventile
/5.2
A0.0
-A1
Digital Output
8
7
A1
-K5
INCL. A2 VAR.
INCL. A2 VAR.
1N1
1 3 5 13 21 51 /4.8 61 /4.9 /4.2 /4.2 /4.2 /7.8
2 4 6 14 22 52 62
/7.9 13
14
Störungskontakt DISTURBANCE RELAY
/7.7 13
14
Fernbedienung aktiv REMOTE CONTROL ACTIVE
Kompressor ein COMPRESSOR ON
-X1
17 1
-Y1
PE
17 1
-Y2
Entwässerungsventile DRAIN VALVES
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 22-30kW (440V) STARTER / CONTROLLER COMPRESSOR 22-30kW (440V) Urspr.
343261
Ers.f
Ers.d
18 1
PE
PE
-Y5 Kühlwasser-Absperrventil (optional) COOLING WATER SHUT OFF VALVE (OPTIONAL)
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344182-44070 Blatt 8 von 8 Bl.
0
2
1
3
4
5
6
8
7
9
Kompressor-Umschaltbox COMPRESSOR SEQUENCE SELECTION BOX Box de selection de guidage
200
VIEW FROM BEHIND: 200
120
Kompressor-Umschaltbox COMPRESSOR SEQUENCE SELECTION BOX Kompressor 1 = Führungskompressor COMPRESSOR 1 = LEADING COMPRESSOR
Schutzart: IP54 PROTECTION CLASS: IP54 200
2
200
1
Gewicht: ca. 3kg WEIGHT: APPR. 3kg
Kompressor 2 = Führungskompressor COMPRESSOR 2 = LEADING COMPRESSOR
ø8,7 20
Original 2011-06-21
3S1
20
3S1
Führungswahlschalter SEQUENCE SELECTOR SWITCH Commutateur de guidage
Stellung 1: Kompressor 1 = Führungskompressor Kompressor 2 = Folgekompressor
Stellung 2: Kompressor 2 = Führungskompressor Kompressor 1 = Folgekompressor
POSITION 1: COMPRESSOR 1 = LEADING COMPRESSOR COMPRESSOR 2 = FOLLOWING COMPRESSOR
POSITION 2: COMPRESSOR 2 = LEADING COMPRESSOR COMPRESSOR 1 = FOLLOWING COMPRESSOR
Position 1: Compresseur 1 = Compresseur de guidage Compresseur 2 = Compresseur de suivant
Position 2: Compresseur 2 = Compresseur de guidage Compresseur 1 = Compresseur de suivant
Datum french A texts 23.01.09 Zust. Änderung Datum
bre Name
20.02.08 Umschaltbox für Doppelkompressorsteuerung Bearb. Bre Gepr. cpu SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL Norm
Urspr.
330141
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
333392-44070 Blatt 1 von 2 Bl.
3
4
5
2
2
2
1
1
0
6
10
6
8
7
9
14
-3S1
Original 2011-06-21
Führungswahlschalter SEQUENCE SELECTOR SWITCH
-3X1
-1F4
1
2
5
PE
1
6
3
5
7
9
11 13 15
PE
7
8
3
PE
-2F4
P
Druckluftschalter für Führungskompressor AIR PRESSURE SWITCH FOR LEADING COMPRESSOR
4
PE
P
Druckluftschalter für Folgekompressor AIR PRESSURE SWITCH FOR FOLLOWING COMPRESSOR
A
B
C Druckluftwächter-Signal zum Schaltschrank Kompressor 1 AIR PRESSURE SIGNAL TO CONTACTOR CABINET COMPRESSOR 1
Druckluftwächter-Signal zum Schaltschrank Kompressor 2 AIR PRESSURE SIGNAL TO CONTACTOR CABINET COMPRESSOR 2
Datum
20.02.08 Umschaltbox für Doppelkompressorsteuerung Bearb. Bre Gepr. cpu SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL Zust. Änderung
Datum
Name
Norm
Urspr.
330141
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
D
333392-44070 Blatt 2 von 2 Bl.
0
2
1
3
4
5
Schaltschrank Not-Luft-Kompressor (5,5-7,5kW) STARTER / CONTROLLER EMERGENCY AIR COMPRESSOR (5,5-7,5kW)
6
8
7
9
(344184-44070) NO
NC
29 30
31 32
-X1 W
H1 H2
1
2
3
4
5
6
7
8
Brücke ! link !
M
3
P
Not-LuftKompressor L20 EMERGENCY AIR COMPRESSOR L20 6,3 kW
Heizung HEATING appr. 30W
-F4
P
13 14
19 20
21 22
23 24
T
-F2
25 26
Brücke ! link ! ø6-13
Entwässerungsventil Abscheider DRAIN VALVE SEPARATOR
ø6-13
Öldruckschalter OIL PRESSURE SWITCH
Druckluftwächter für Start/Stop in Automatik AIR PRESSURE SWITCH FOR START/STOP IN AUTOMATIC
HE1 HE2
W
24V DC
-M1
V
24V DC
U
ø6-13
11 12
Luftteemperatur-Wächter AIR TEMPERATURE SWITCH
ø6-13
10
24V DC
ø6-13
440V 60Hz 440V 60Hz
ø9-17
Einspeisung SHIP SUPPLY
Original 2011-06-21
ø9-17
9
NO
-F3
*
ø6-13
ø6-13
potentialfreier Kontakt für Störung FLOATING CONTACT FOR DISTURBANCE
V
potentialfreier Kontakt für Kompressor ein FLOATING CONTACT FOR COMPRESSOR ON
U
220-230V AC
L1 L2 L3
-Y4 Gleichstrom-Magnetspulen muß das Kabel * Bei am Gleichrichter im Stecker angeschlossen werden. * IN CASE OF DC SOLENOID COILS THE CABLE MUST BE CONNECTED TO THE RECTIFIER INSIDE THE PLUG.
Datum cable gla.08.12.10 A sizes Zust. Änderung Datum
bre
Bearb. Gepr.
Name
Norm
02.11.10 Bre cpu
Anschlußplan Kompressor L20 CONNECTION DIAGRAM COMPRESSOR L20 Urspr.
342530
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344183-44070 Blatt 1 von 1 Bl.
0
2
1
3
4
5
6
8
7
9
380 210
Schaltschrank Kompressor STARTER/CONTROLLER COMPRESSOR
P1
P1
Amperemeter (mit Markierungsanzeiger) AMMETER
P2
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
Q1
Hauptschalter (mit Türverriegelung) ISOLATING SWITCH
Q2
Hauptschalter Motor-Heizung MAIN SWITCH MOTOR HEATING
H2
Meldelampe "Motor-Heizung ein" INDICATING LIGHT "MOTOR HEATING HEATING ON"
A H2 P2 TD 200
HATLAPA 600
(BU)
Q1 Gewicht: ca. 30kg WEIGHT: APPR. 30kg Schutzart: IP54 PROTECTION CLASS: IP54 8 20
Original 2011-06-21
Q2
mit Türfeststeller
20
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 1 von 8 Bl.
0
2
1
3 P2
4
5
Original 2011-06-21
RESET
HATLAPA
SHIFT
black on red
STOP
8
9
TD 200
MAN
schwarz auf rot
7
Anzeige- und Bedieneinheit MONITORING AND OPERATION PANEL
SIEMENS
STOP
6
AUTO
schwarz auf hell-blau black on light blue
AUTO
ESC
schwarz auf grün
schwarz auf weiß
black on green
black on white
MAN
ENTER
RESET
HATLAPA dark blue on white dunkel-blau auf weiß
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 2 von 8 Bl.
Kurzbeschreibung für Kompressorsteuerung mit TD200
short description f.compressor control with TD200: ON / OFF:
The standard text on the text display is:
ready for operation / off Betriebsbereit / aus
Now you can start the compressor in manual or in automatic operation. When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4. Normallay the manual operation is only used for maintenance purposes. After a blackout the cmpressor will not start again in this manual mode. When You press the "STOP" push button the compressor stops again.
Original 2011-06-21
ALARMS:
Jetzt kann man den Kompressor in der Hand- oder in der Automatik-Betriebsart starten. compressor on / man Kompressor ein / Hand
ready for operation / off Betriebsbereit / aus
When You press the "AUTO" push button the compressor is switched to automatic mode. The compressor starts and stops automatically depending on the air pressure. Normally this should be the standard operation mode. When the pressure switch F4 is closed the compressor starts. When the pressure switch F4 is opened the compressor stops. After a blackout the compressor will start again in automatic mode. When you want to change the operation mode from manual to automatic or from automatic to manual you must press the "STOP" push button before. When there is any fault, the compressor stops and the belonging disturbance alarm is shown in the display. Not all possible disburbance texts are used for this compressor.
Now the fault must be eliminated. Then press the "RESET" push button and there should be the standard text on the display again. Now You can start the compressor again with the "AUTO" or "MAN" push button.
compressor on / auto Kompressor ein / Auto ready for operation / auto Betriebsbereit / Auto
make maintenance ! Wartung fällig ! motor overload Motor Überlast low oil pressure Oeldruck-Alarm high air temperature Lufttemperatur-Alarm high cooling water temperature Kühlwassertemperatur-Alarm no cooling water kein Kühlwasserfluß
Mit der Taste "MAN" wird der Kompressor in der Hand-Betriebsart gestartet. D.h. ohne Funktion des Druckluftschalters F4. Normalerweise wird diese Fuktion nur für Wartungszwecke benutzt. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Hand" nicht wieder selbsttätig starten. Mit dem Taster "STOP" kann der Kompressor wieder gestoppt werden. Mit dem Taster "AUTO" kann der Kompressor in die Betriebsart "Automatik" geschaltet werden. Der Kompressor startet und stopt dann selbstätig in Abhängigkeit des Druckluftschalters F4. Wenn der Druckluftschalter geschlossen ist, dann startet der Kompressor. Wenn der Druckluftschalter geöffnet ist, dann stopt der Kompressor. Nach einem Spannungsausfall wird der Kompressor in der Betriebsart "Automatik" selbstständig wieder anlaufen.
ALARME
Wenn eine Störung vorliegt, dann stopt der Kompressor und es wird der zugehörige Alarm im Textdisplay angezeigt. Nicht alle hier dargestellten Alarm-Texte werden für diesen Kompressor benutzt. Jetzt must der entsprechende Fehler behoben werden und dann der "RESET"-Taster betätigt werden. Darauf sollte dann der Standart-Text wieder auf dem Display erscheinen. Jetzt kann der Kompressor wieder mit den Tasten "MAN" oder "AUTO" gestartet werden.
ready for operation / off Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS: When there are one or two arrows in the right side of the display, you can go to other display texts by pressing the belonging arrow push buttons The other texts can show more disturbance alarms, if there is more than one fault. Or you can watch the working hours. Or you can watch some special settings of the software. Normally all settings are done by HATLAPA for a normal purpose of the compressor. If you want to change any setting, you must press the "ENTER" push button one time. Now you can change the value with the arrow push buttons. After this you must quit the new value by pressing "ENTER" again.
workings hours xxxxx h Betriebsstunden drainage time 5sec Entwässerungsdauer drainage interval 20min Entwässerungsinterval star delta time 4sec Stern-Dreieck-Zeit delayed start 0sec verzögerter Anlauf cooling water delay 2min Kühlwassernachlauf continuous time 0min Durchlaufzeit
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
EIN / AUS
Dies ist der Standart-Text auf dem Display.
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
Wenn ganz rechts im Display ein oder zwei Pfeile dargestellt werden, dann kann mit d.entsprechenden Pfeil-Tasten zu anderen möglichen Texten gesprungen werden. Die weiteren Texte können weitere Alarme anzeigen, wenn mehr als eine Störung ansteht. Oder es werden die Betriebsstunden angezeigt. Oder es können einige variable Einstellungen der Software angezeigt werden. Normalerweise sind alle Einstellungen für einen normalen Kompressorbetrieb bereits durch HATLAPA festgelegt. Wenn Einstellungen geändert werden sollen, muß einmalig die "ENTER"-Taset betätigt werden. Dann kann man mit den Pfeil-Tasten den entsprechenden Wert verändern. Daraufhin muß der geänderte Wert nocheinmal mit der "ENTER"-Taste quittiert werden.
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 3 von 8 Bl.
0
2
1
3
4
5
6
8
7 -F2
9
2A
2
1
1L1
/5.0
4
6
4
11
6
1
3
5
-K1 3
5
12
/8.1
/8.9
1
4
2
0P ±5%
6
1
3
5
2
4
6
-F1
1
220V 250VA 0S
2A Heizungs-Spannung HEATING VOLTAGE
1
97 95
-Q2
98 96
2
3 Hauptschalter Heizung MAIN SWITCH 4 HEATING
Original 2011-06-21
/6.0
9-13A CLASS 20
-F3
-T1 440V
2
/5.0
2
0,63-1A GV2 RT05
-
-Q1
4
2
1N1
Trafo-Einspeisung TRANSFORMER SUPPLY
-Q3
A
20A
5
3
-P1
3
4
+
1
3
Steuerspannung CONTROL VOLTAGE
51
61
/8.1 52
62
-K1 X1
-H2
Heizung ein HEATING ON
220V X2
SHIP SUPPLY 440V
440V Zuleitung
U
V
W
U
V
W
H1 H2 PE
PE
60Hz
L1 L2 L3 PE
60Hz
-X1
-M1
HE1 HE2
M
3
Kompressor COMPRESSOR 5,5-7,5 kW
Heizung HEATING appr.25-50W
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 4 von 8 Bl.
0 /4.9
/4.9
2
1
3
4
5
6
7
8
9
1L1
1N1
1N1
1L+
+24V DC
/8.0
/6.0
0V DC
2 3 4 5 6 7 8 9
Original 2011-06-21
Softwareversion TD200_8
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
S7-CPU 222 Relais-Ausgänge 8 x Eingänge
/6.0 /6.2 /6.4 /6.6 /6.8 /7.1 /7.3 /7.5
MOTOR PROTECTION RE AIR PRESSURE SWITCH OIL PRESSURE SWITCH AIR TEMPERATURE SWI COOL.WATER TEMP.SWI COOL.WATER FLOW SWI SPARE SPARE
6 x Ausgänge Relais 2 3 5 6 8 9
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5
/8.1 /8.2 /8.5 /8.6
PE Vers N L1
M Erw L+
1M 2M Ein
1L Aus 2L
-A1
MOTOR MAIN CONTACTO DRAIN VALVES Entwäs DISTURBANCE RELAY COOLING WATER VALVE star contactor delta contactor
-P2 TD 200
HATLAPA Anzeige- und Bedieneinheit monitoring and operation panel
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 5 von 8 Bl.
0
/5.9
2
1
3
4
5
6
8
7
9
1L+
1L+
/7.0
95
-F1 /4.2 96
Original 2011-06-21
2
3
-A1
E0.0
/5.2
E0.1
MOTOR PROTECTION RELAY Motorschutzrelais
1
2
/5.2
5
-A1
E0.2
/5.2
AIR PRESSURE SWITCH Luftdruck-Wächter
OIL PRESSURE SWITCH Öldruckk-Wächter
Digitaler Eingang
Digitaler Eingang
Digitaler Eingang
-X1
4
-A1
3
PE
4
6
-A1
E0.3
/5.2
E0.4
AIR TEMPERATURE SWITCH Lufttemperatur-Wächter
5
Option mit Brücke OPTIONAL WITH LINK
6
/5.2
COOL.WATER TEMP.SWITCH Kühlwassertemp.Wächter
Digitaler Eingang
PE
-A1
Digitaler Eingang
7
PE
Option mit Brücke OPTIONAL WITH LINK
8
PE
Option mit Brücke OPTIONAL WITH LINK
Optional über KompressorUmschaltbox
-F4
1
P
-F2 P
2
OPTIONAL VIA COMPRESSOR SEQUENCE Luftdruck-Wächter SELECTION BOX für Auto Start/Stop AIR PRESSURE SWITCH FOR AUTO START/STOP
-F3
Öldruck-Wächter OIL PRESSURE SWITCH
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
-F5
T
Lufttemperatur-Wächter AIR TEMPERATURE SWITCH
HATLAPA
T
Kühlwasser-Temperatur-Wächter COOLING WATER TEMPERATURE SWITCH
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 6 von 8 Bl.
0
/6.9
2
1
3
4
5
6
7
8
9
1L+
7 E0.5
Original 2011-06-21
8
-A1 /5.2
E0.6
COOL.WATER FLOW SWITCH Kühlwasserdurchfl.Wäch
9
10 PE
/5.2
-A1
E0.7
SPARE Reserve
Digitaler Eingang
-X1
9
-A1
/5.2 SPARE Reserve
Digitaler Eingang
Digitaler Eingang
11 12 PE
13 14 PE
Option mit Brücke OPTIONAL WITH LINK
-F6 F
Kühlwasser-Durchfluß-Wächter OIL PRESSURE SWITCH
Datum 02.11.10 Bearb. Gepr. Zust. Änderung
Datum
Name
Norm
Bre cpu
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 7 von 8 Bl.
0
2
1 -A1
3
4
5
-A1
Digitaler Ausgang MOTOR MAIN CONTACTOR NETZSCHÜTZ /5.2
A0.0
-A1
Digitaler Ausgang
DISTURBANCE RELAY Störungs-Kontakt
/5.2
A0.1
/5.2
A0.2
3
8
7
9
-A1
Digitaler Ausgang
DRAIN VALVES Entwässerungs-Ventile
2
6
5
Digitaler Ausgang COOLING WATER VALVE Kühlwasserabsperrventi
potentialfreie Kontakte FLOATING CONTACTS
/5.2
A0.3 6
11
-Q1 /4.1 12 A1
A1
-K2
-K1
Original 2011-06-21
18A A2 INCL. VAR.
/5.9
13
INCL. A2 VAR.
13
-K1
-K2
14 /8.1
14 /8.5
1N1 1 2 3 4 5 6 13 14 21 22 51 52 /4.8 61 62 /4.9 Kompressor ein COMPRESSOR ON
/8.9 13
/4.2 /4.2 /4.2 /8.8
14
Störungskontakt DISTURBANCE RELAY
-X1
19 20 PE
21 22 PE
23 24 PE
25 26 PE
29 30 PE Kompressor ein COMPRESSOR ON
(NO)
-Y1
-Y2
-Y3/4
Zust. Änderung
Datum
Name
Norm
Schaltschrank Kompressor 5,5-7,5kW (440V) STARTER / CONTROLLER COMPRESSOR 5,5-7,5kW (440V) Urspr.
342531
Ers.f
(NC)
Kühlwasser-Absperrventil (optional) COOLING WATER SHUT OFF VALVE (OPTIONAL)
Datum 02.11.10 Bre cpu
STÖRUNG DISTURBANCE
-Y5
Entwässerungsventile (optional) DRAIN VALVES (OPTIONAL)
Bearb. Gepr.
31 32 PE
Ers.d
HATLAPA
Gruppe :
Uetersener Maschinenfabrik Ort D-25436 Uetersen
:
344184-44070 Blatt 8 von 8 Bl.
Original 2011-06-21
ENGLISH READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR
RECEIVING CHECK Check if any damage has occured during transportation. üCheck nameplate data. üRemove shaft locking device (if any) before operating the motor. üTurn the shaft with the hand to make sure it is turning freely.
HANDLING AND TRANSPORTATION 1 - General
Insulation Resistance Check
MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYEBOLTS
Original 2011-06-21
In case the motors are stored for more than two years, the bearings must be replaced or the lubrication grease must be totally removed after cleaning. Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any). We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas. If motor is fitted with space heaters, these should be switched on.
Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices then a double chain must be used to lift it. Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged. DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE. THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN WHEN THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE.
STORAGE If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases, corrosive smokes, under constant temperature and in normal position free from other objects. Motor storage temperature must remain between 5ºC to 60ºC, with relative humidity not exceeding 50%.
Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding. The resistance measured at 25ºC must be: Ri ≥ (20 x U) / (1000 + 2P) [MΩ] (measured with a MEGGER at 500 V d.c.) where U = voltage (V); P = power (kW). If the insulation resistance is less than 2 megaohms, the winding must be dried according to the following: Warm it up inside an oven at a minimum temperature of 80ºC increasing 5ºC every hour until 105ºC, remaining under this temperature for at least one hour. Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be reimpregnated.
INSTALLATION 1 - Safety All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be well informed and updated concerning safety standards and principles that govern the work and carefully follow them. We strongly recommend that these jobs are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE. Motors must be protected against accidental starts. When performing any maintenance service, disconnect the motor from the power supply. Make sure all accessories have been switched off and disconnected. In order to prevent from penetrating dust and/or water into the terminal box, cable glands or threaded pipe in the lead holes must be installed. Do not change the regulation of the protecting devices to avoid damaging.
Original 2011-06-21
2 - Operating Conditions Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 0ºC and 40ºC. Any variation is stated on the nameplate. COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE. Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate. KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER. 3 - Foundation Motors provided with feet must be installed on solid foundations to avoid excessive vibrations. The purchaser is fully responsible for the foundation. Metal parts must be painted to avoid corrosion. The foundation must be uniform and sufficiently tough to support any schock. It must be
designed in such a way to stop any vibration originated from resonance. 4 - Drain Holes Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order. 5 - Balancing THE MOTORS ARE DYNAMICALLY BALANCED WITH HALF KEY, AT NO LOAD AND UNCOUPLED. Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before installation. Use always appropriate tools for installation and removal. 6 - Alignment ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE. Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings. When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings. Suitable assembly of half-coupling: Check that clearance Y is less than 0.05 mm and that the difference X1 to X2 is less than 0.05 mm, as well.
Note: Dimension X1 and X2 must be 3mm minimum Figure and alignment tolerances 7 - Belt Drive When using pulley or belt coupling, the following must be observed: Belts must be tighten just enough to avoid slippage when running, according to the
specifications stated on the belt supplier recommendation. WARNING: Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture. 8 - Connection WARNING: Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating. WARNING: The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even when the motor has reached standstill.
Original 2011-06-21
A WRONG CONNECTION CAN BURN THE MOTOR. Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ±10%; the acceptable frequency variation is ±5% and the total acceptable variation is ± 10%. 9 - Starting Methods The motor is rather started through direct starting. In case this is not possible, use compatible methods to the motor load and voltage. The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1, L2, L3. To change the rotation direction, interchange two of the connecting leads. THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION. AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED.
Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate. BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE CURRENT STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS. When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, termal protector, etc, connect their terminals to the corresponding devices on the control panel. 10 - Start-Up THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR. a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the connections and the mounting before starting it again. b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done. c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate.
MAINTENANCE WARNING: SAFETY CHECK LIST 1 - General Inspection üCheck the motor periodically. üKeep the motor clean and assure free air flow. üCheck the seals or V Ring and replace them, if required. üCheck the connections as well as supporting screws. üCheck the bearings and observe: Any excessive noise, vibration, bearing temperature and grease condition. üWhen a change, under normal conditions, is detected, check the motor and replace the required parts.
The frequency of the inspections depends on the motor type and on the application conditions.
LUBRICATION FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION. 1 - Machines without Grease Nipples Motors up to frame 200 are normally fitted without grease nipples. In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects: üDisassemble carefully the motors. üTake all the grease out. üWash the bearing with querosene or diesel. üRegrease the bearing immediately.
2 - Machines Fitted with Grease Nipples It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc) that offer some risk to the physical integrity of the operator, proceed as follows: üClean the area near the grease nipple. üPut approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off the motor and insert the rest of the grease. üThe injection of all the grease with the motor in standstill can make the grease penetrate into the motor, through the inner seal of the bearing housing. FOR LUBRICATION USE ONLY MANUAL GREASE GUN.
Original 2011-06-21
RELUBRICATION INTERVALS TABLE 1 - BALL BEARINGS - Series 62/63 II pole
Relubrication intervals (running hours horizontal position) IV pole
VI pole
Bearing 6209 6211 6212
60Hz 18400 14200 12100
50Hz 20000 16500 14400
60Hz 20000 20000 20000
50Hz 20000 20000 20000
60Hz 20000 20000 20000
Bearing 6309 6311 6312 6314 6316 6319 6322
60Hz 15700 11500 9800 3600 -
50Hz 18100 13700 11900 4500 -
60Hz 20000 20000 20000 9700 8500 7000 5100
50Hz 20000 20000 20000 11600 10400 9000 7200
60Hz 20000 20000 20000 14200 12800 11000 9200
Serie 62
VIII pole
50Hz 60Hz 20000 20000 20000 20000 20000 20000 Serie 63 50Hz 60Hz 20000 20000 20000 20000 20000 20000 16400 17300 14900 15900 13000 14000 10800 11800
X pole
XII pole
Grease
50Hz 20000 20000 20000
60Hz 20000 20000 20000
50Hz 20000 20000 20000
60Hz 20000 20000 20000
50Hz 20000 20000 20000
(g) 9 11 13
50Hz 20000 20000 20000 19700 18700 17400 15100
60Hz 20000 20000 20000 19700 18700 17400 15100
50Hz 20000 20000 20000 20000 20000 18600 15500
60Hz 20000 20000 20000 20000 20000 18600 15500
50Hz 20000 20000 20000 20000 20000 20000 19300
(g) 13 18 21 27 34 45 60
TABLE 2 - ROLLER BEARINGS - Series NU 3 Relubrication intervals (running hours horizontal position) II pole Bearing NU 309 NU 311 NU 312 NU 314 NU 316 NU 319 NU 322 NU 324
60Hz 9800 6400 5100 1600 -
50Hz 13300 9200 7600 2500 -
IV pole 60Hz 20000 19100 17200 7100 6000 4700 3300 2400
50Hz 20000 20000 20000 8900 7600 6000 4400 3500
VI pole 60Hz 20000 20000 20000 11000 9500 7600 5900 5000
50Hz 20000 20000 20000 13100 11600 9800 7800 6600
VIII pole 60Hz 20000 20000 20000 15100 13800 12200 10700 10000
50Hz 20000 20000 20000 16900 15500 13700 11500 10200
X pole 60Hz 20000 20000 20000 16900 15500 13700 11500 10200
50Hz 20000 20000 20000 19300 17800 15700 13400 12100
XII pole 60Hz 20000 20000 20000 19300 17800 15700 13400 12100
50Hz 20000 20000 20000 20000 20000 20000 17300 15000
Grease (g) 13 18 21 27 34 45 60 72
Note: üThe ZZ bearings from 6201 to 6307 do not require relubrication as its life time is about 20,000 hours. üTables 1 and 2 are intended for the lubrication period under bearing temperature of 70°C (for bearings up to 6312 and NU 312) and temperature of 85°C (for bearings 6314 and NU 314 and larger). üFor each 15°C of temperature rise, the relubrication period is reduced by half. üThe relubrication periods given above are for those cases applying Polyrex® EM grease. ü When motors are used on the vertical position, their relubrication interval is reduced by half if compared to horizontal position motors. WE RECOMENDED TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD.
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WARNING: EXCESS OF GREACE CAN CAUSE BEARNING OVERHEATING RESULTING IN COMPLETE DAMARGE. Compatibility of Polyrex® EM grease with other types of grease: Containing polyurea thickener and mineral oil, the Polyrex® EM grease is compatible with other types of grease that contain: üLithium base or complex of lithium or polyurea and highly refined mineral oil. üInhibitor additive against corrosion, rust and anti-oxidant additive. Notes: üAlthough Polyrex® EM is compatible with types of grease given above, we do not recommended to mix it with any other greases. ü If you intend to use a type of grease different than those recommended above , first contact HATLAPA. üOn applications (with high or low temperatures, speed variation, etc), the type of grease and relubrification interval are given on an additional nameplate attached to the motor. THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE MANUFACTURER OR HATLAPA
DISASSEMBLY AND ASSEMBLY Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated methods.
The stator grips must be applied over the side face of the inner ring to be disassembled or over an adjacent part. It is essential that bearings assembly be done under cleanning conditions to ensure good operation and to avoid damages. New bearings shall only be taken out from their cases when assembling them. Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals. For bearing assembly warm their inner parts withsuitable equipment - inductive pocess - or use suitable tools.
SPARE PARTS When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate. Please also inform the motor serial number stated on the nameplate.
MOTORS FOR HAZARDOUS LOCATIONS Besides the recommendations given previously, these ones must be also followed: THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY, WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS. Motors for hazardous locations are manufactured according to specific standards for such environments and they are certified by worldwide certifying entities. 1 - Installation The complete installation must follow procedures given by the local legislation in effect. THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT. 2 - Maintenance Maintenance must be carried out by repair shops authorized by HATLAPA. Repair shops and people without HATLAPA’s authorization who will perform any service on hazardous location motors will be fully responsible for such service as well as for any consequential damage.
ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION. When performing maintenance, installation or relubrication, follow these instructions: üCheck if all components are free of edges, knocks or dirt. üMake sure all parts are in perfect conditions. üLubricate the surfaces of the endshield fittings with protective oil to make the assembly easier. üUse only rubber hammer to fit the parts. üCheck for correct bolts tightening. üUse clearance calibrator for correct T-box fitting (smaller than 0.05mm). DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE FACTORY.
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MOTORS DRIVEN BY VFD Applications using VFD´s without filter can affect motor performance as follows:
üLower efficiency. üHigher vibration. üHigher noise level. üHigher rated current. ü Higher temperature rise. üReduced motor insulation. üReduced bearing life. 1- Standard Motors üVoltages lower than 440V do not require filter. üVoltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters. üVoltages equal or higher than 575V require filter for any size of power supply cables. IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY, MOTOR WARRANTY WILL BE VOID. 2- Inverter Duty Motors: üCheck power supply voltage of the forced cooling set. üFilters are not required.
Lubricating Instructions for HATLAPA W- and L-type Piston Compressors
175694 Rev. 01.06
1. General Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of the compressor. Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is advisable to contact him when making your choice. Ask only the lubricant manufacturer for his recommendation! He is the expert.
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2. Lubrication Oil Quality Above all, compressor oils must have good lubrication properties for which their viscosity is highly important. HATLAPA recommends lubrication oils within the following range: viscosity at 100 °C: min. 9.4 cSt max. 15 cSt viscosity at 40 °C: min. 90 cSt max. 120 cSt The lubrication oils should have low tendency to ageing and coking in order to prevent oil carbon deposits on valves and pipelines. HATLAPA recommends to use mineral oils of class VDL according to DIN 51 506. The use of synthetic oils is not recommended for HATLAPA W- and L-type compressors.
3. Guarantee If lubrication oils are used which do not meet the requirements, damage to the compressor may occur. This damage is not covered by HATLAPA's guarantee obligations.
4. Lubricant Examples The following mineral oils are examples which comply with the above specification: ARAL MOTANOL HE100 BP ENERGOL RC100 CASTROL AIRCOL PD100 CHEVRON TEXACO (FAMM) COMPRESSOR OIL EP VDL100 ELF TOTAL FINA (Lubmarine) DACNIS P100 ESSO (ExxonMobil Marine) EXXCOLUB 100 MOBIL (ExxonMobil Marine) RARUS 427 SHELL CORENA P100 However, the oil properties are subject to change without notice by the oil manufacturer. Also, the oil characteristics may vary depending on the regional market. Therefore this list does not release the operator of the compressor from verifying that the selected oil complies with the above specification.
Service
Anleitung zur richtigen Bestellung von Ersatzteilen Für die Bestellung sind folgende Angaben unbedingt erforderlich: 1) Schiffsname (Ex-Name), Neubau-Nr. und Bauwerft 2) Fabriknummer und Typenbezeichnung (siehe Typenschild) 3) Ersatzteilnummer entsprechend Ersatzteilliste 4) Gewünschte Versandart, Versandadresse und Rechnungsanschrift
Instructions for correctly ordering spare parts When ordering spare parts, the following details must be given:
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1) Name of vessel (former name), Hull No. and building shipyard 2) Serial number and type of the machine (see name plate) 3) Part number from the Spare Parts List 4) Desired method of dispatch, invoice and consignee’s address
Instruction pour établir les commandes de pièces de rechange Les indications suivantes seront indispensables pour la commande: 1° Nom du navire (ex-nom), No. du navire et chantier de construction 2° Numéro d’usine et type (voir plaque d’identité) 3° Numéro de pièce suivant liste des pièces de rechange 4° Mode de transport désiré, adresses du destinataire et de la facture
Instrucciones para pedir correctamente piezas de repuesto. Cuando se piden piezas de repuesto, deben ser dados los – siguiéntes datos:
1) Número de serie y tipo (ver placa) . 2) Número de la pieza según la Lista de Piezas de Repuesto. 3) Forma de despacho así como consignación y dirección para la facturación. 4) Nombre del buque (nombre antígúo) ‚ número de construción y Astilliero.
Guida alla corretta ordinazione dei pezzi di ricambio Per ordinare rispettivi pezzi di ricambio sono assolutamente indispensabili i seguenti dati: 1) Nome della nave (ev. nome precedente), numero di Costruzione e nome del Cantiere Naval e 2) Numero di matricola e tipo del compressore (vedi targhetta) 3) Numero del pezzo di ricambio in base alla «Lista dei pezzi di ricambio» 4) Mezzo di trasporto, indirizzo di spedizione ed indirizzo di fatturazione desiderati
Service
Um Ersatzteile schnellstens zu erhalten, wenden Sie sich bitte direkt an
oder an unsere Vertretungen (x), Kundendienststellen (o) oder Lizenznehmer ( +) laut anliegender Liste. In order to receive spare parts with the least possible delay, please get in touch with us directly
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or with our representatives (x),service stations (o) or licensees/co-operators (+) as indicated in the enclosed list. Pour assurer une fourniture rapide, veuillez vous adresser á
ou á nos agences (x) , stations-service (o) ,licenciés/partenaires de cooperation (+) Per offenere i rispetti celermente rivolgersi direttamente alla:
od ai rappresentanti (x), centri d‘assistenza (o) o licenziatari/partner di cooperazione (+) delta HATLAPA indicati neIl‘elenco aliegato.
Service Stations Spare Parts Agencies OUR MANUFACTURING PROGRAMME: Deck machinery, compressors, steering gear
Headquarters:
HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 25436 Uetersen GERMANY Phone: +49 4122 711-0 Mobile: +49 172 9 813292 Fax: +49 4122 711-104 Sales 711-330 Service
[email protected], http://www.hatlapa.de
Subsidiary office for Hamworthy type compressors:
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HATLAPA Marine Equipment Ltd. Discovery Court Business Centre 551-553 Wallisdown Road POOLE, Dorset BH12 5AG UNITED KINGDOM Phone: +44 1202 8531-80 Fax: +44 1202 8531-91 Sales 8531-90 Spares
[email protected], http://www.hatlapa-uk.com
Vertretungen (x), Kundendienststellen (o) und Lizenznehmer (+) Representatives (x), service stations (o) and licensees/co-operators (+) Agencies (x), stations-service (o) et licenciés/partenaires de cooperation(+) o Australia
CJA Marine Technology Pty Ltd Unit 3, 136 Cochranes Road Moorabbin, Victoria 3189
Tel: +61 3 953213-97 / 953213-86 Fax: +61 3 953214-13
[email protected]
x Belgium
Marine & Industrie Div. of SA Aciers Marathon Staal NV Haven 138, Boterhamvaartweg 2 (Unit 1) B-2030 Antwerp
Tel: +32 3 82740-91 Fax: +32 3 82740-95
[email protected]
o Belgium/ Luxembourg
Service Hydro n.v. Haven 138, Boterhamvaartweg 2 B-2030 Antwerp
Tel: +32 3 54640-80 Fax: +32 3 54640-81
[email protected]
x Brazil
TRIDENTE Indústria Comércio Equip Ltda Rua Visc Inhaúma 134 – Centro, Rio de Janeiro RJ, 20091-007
Tel: +55 21 2233-1489 Cell: +55 21 9983-3190 Fax: +55 21 2516-7543
[email protected]
o Brazil
Metalock Brasil Ltda Rua Visconde do Rio Branco 20/26 Santos, SP 11013-030
Tel: +55 13 322646-86 Fax: +55 13 322646-80
[email protected]
Updated 14th December 2010
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Service Stations Spare Parts Agencies
x Bulgaria
Ecatdan ApS 1, Studentska Str. 9010 Varna
Tel: +359 52 383476
[email protected]
xo Canada
Marine and Offshore Canada 29-113 Cushman Rd St. Catherines Ontario, L2M 6S9
Tel: +1 905 688 4922 (office) Fax: +1 905 688 9028 Cell: +1 905 650 3160
[email protected]
o Chile
Eurotecnica Ltda Lincoyán # 973 4030485 Conception
Tel: +56 41 22532-75 Fax: +56 41 22532-76
[email protected]
x+ China
HATLAPA Nanjing Representative Office Asia Pacific Pte Ltd Room 612, No 19, Zhanyuan Road Nanjing 210039
Tel: +86 25 52 26 27 90 Fax: +86 25 86 70 33 10
[email protected]
x China
HATLAPA Shanghai Asia Pacific Pte Ltd No. 1211 Chang De Road Room 1011, Baohua Building Shanghai 200060
Tel: +86 21 623296-71 Mobile: +86 137 0 17473 14 Fax: +86 21 623039-71
[email protected]
xo Croatia
Nava International d.o.o. Planciceva 4 21000 Split
Tel: +385 21 385267 Fax: +385 21 385267
[email protected]
x Cyprus
M.I.E. Services Ltd The Hawk Building 124 Gladstonos Str.. 3032 Limassol
Tel: +357 25 889801 Fax: +357 25 763902
[email protected]
x Cyprus
HATLAPA EastMed Ltd The Hawk Building 124 Gladstonos Str.. 3032 Limassol
Tel: +357 25 8897-00 Fax: +357 25 3660-88
[email protected]
x Denmark
A/S Kelvin Hughes Gøngehusvej 280 DK-2970 Horsholm
Tel: +45 8734 2270 Mobile: +45 2060 9405 Fax: +45 8611 2726
[email protected]
x Egypt
AMCO Alexandria Maritime 10 Ahmed Yehya Pasha St. Gleem P.O. Box 1424, Alexandria
Tel: +20 3 58585-70 Fax: +20 3 58285-87
[email protected]
x Finland
EPOMARE OY (from 1st January 2011) Perämiehenkatu 11 20810 Turku
Tel: +358 2 2749640 Fax: +358 2 2351499
[email protected]
x France
Wenex Equipments SA 49 Rue de Billancourt 92100 Boulogne
Tel: +33 1 411023-30 Fax: +33 1 411023-45
[email protected]
o Germany
Friedrich Jung Fa. König-Friedrich-Wilhelm-Str. 20
Tel: +49 203 82898 Fax: +49 203 57085-24
Updated 14th December 2010
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Service Stations Spare Parts Agencies
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47119 Duisburg xo Great Britain
HATLAPA Marine Equipment Ltd Discovery Court Business Centre 551-553 Wallisdown Road Poole, Dorset BH12 5AG
Tel: +44 1202 8531-80 Fax:+44 1202 8531-90
[email protected]
xo Greece
M.I.E. Co. Ltd. Kanari 1 18537 Piraeus
Tel: +30 210 4598-800 Fax: +30 210 4539-234
[email protected]
o Greece
INJEGOV Advanced Mechanical Services Ltd Vipa Shistou, Road 2, OT3 Perama 18863 Piraeus
Tel: +30 210 4323600/1-2 Fax: +30 210 43127-70
[email protected]
xo India
Dolphin Consultants 35 Mittal Chambers Nariman Point, Maharashtra State Mumbai 400021
Tel: +91 22 302877-11 to 15 (5 Lines) Fax:+91 22 302877-10
[email protected]
xo Indonesia
PT. Assindo Perniagaan Internasional Victoria Building, 3rd Floor Jl. Sultan Hasanuddin No. 47 - 51 Jakarta Selatan 12160
Tel: +62 21 72555-41 Fax: +62 21 72555-46
[email protected]
+ Indonesia
PT. Assindo Perniagaan Internasional Victoria Centre, 3rd Floor Jl. Sultan Hasanuddin No. 47-51 Jakarta 12160
Tel: +62 21 72555-41 Fax: +62 21 72555-46
[email protected]
xo Iran
Iran IMEXEN Co. No.4, Apt. 6, Morvarid Crossing Goldan St., Africa Ave. (Ex-Jordan) Tehran 19668
Tel: +98 21 22000008 Fax: +98 21 22004849
[email protected]
xo Italy
RTN Srl Loc. Cà Verde 29011 Borgonovo Val Tidone (PC)
Tel: +39 0523 869611 Fax: +39 0523 861077
[email protected]
xo Korea
Dong Sung Co. Room 1725, 21 Century City Building 55-1, Daeyeon 3-dong Nam Gu, Pusan 608-743
Tel: +82 51 61012-33 Fax: +82 51 61012-32
[email protected]
xo Korea
HATLAPA Korea Co. Ltd. 1212, Jisa-dong Gangseo-gu, Busan
Tel: +82 51 97292-66 Fax: +82 51 97292-70
[email protected]
x Lebanon
M.I.E. (Overseas) Ltd. The Hawk Building 124 Gladstonos Street 3312 Limassol, Cyprus
Tel: +357 25 889800 Fax : +357 25 346626
[email protected]
x Middle East
M.I.E. (Overseas) Ltd.
Tel: +357 25 366077 Fax.:+357 25 366088
[email protected]
for steering gear
Saudi Arabia, Oman The Hawk Building U.A.E., Qatar, Yemen 124 Gladstonos Street Bahrain, Kuwait, 3312 Limassol, Cyprus
Updated 14th December 2010
Page 3
Service Stations Spare Parts Agencies
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Jordan, Israel
xo Netherlands
Hamworthy KSE B.V. Aploniastraat 33 3084 CC Rotterdam
Tel: +31 10 46247-77 Fax.: +31 10 41590-46
[email protected]
xo Norway
Hatlapa Marine Equipment AS Frithjof Nansens Plass 7, 0117 Oslo
Tel: +47-918-08-546
[email protected]
xo Poland
SANGER METAL Sp-ka Z o.o. Mostnika Str.10-12 70-672 Szczecin
Tel: +48 91 4623236 / 4623383 Fax: +48 91 4623345
[email protected]
xo Portugal
Javier López-Alonso Morán Avda. San Luis 166 - 8° E 28033 Madrid
Tel/Fax: +34 91 3831577
[email protected]
x Romania
XEREX SRL 43 Alexandru Cernat str. 800087 Galati, Romania
Tel/Fax: +40 236 462056 Mobile: +40 723 533596
[email protected]
x Singapore
HATLAPA Asia Pacific Pte Ltd German Centre, Unit 02-25 25 International Business Park Jurong, Singapore 609916
Tel: +65 65 628086 / 628088 Mobile: +65 96 339381 Fax: +65 65 628099
[email protected]
xo Spain
Javier López-Alonso Morán Avda. San Luis 166 - 8° E 28033 Madrid
Tel/Fax: +34 91 3831577
[email protected]
xo Sweden
Bövik Marin AB Hälleflundregatan 12 42658 Västra Frölunda, Gothenburg
Tel: +46 31 290075
[email protected]
x Syria
M.I.E. (Overseas) Ltd. The Hawk Building, 124 Gadstonos Street 3312 Limassol, Cyprus
Tel : +357 25 889800 Fax : +357 25 346626
[email protected]
x Taiwan
SHIPCARE Co. Ltd. Rm1, 2nd fl., no.135, sec.1 Chungking South Road Taipei 10036
Tel: +886 2 2383-2255 Fax: +886 2 2383-1020
[email protected]
x U.S.A.
MarinSOLVE LLC PO Box 2176 Clifton, NJ 07015
Tel: +1 973 24657 26 Fax: +1 973 75503 33
[email protected]
x U.S.A.
CS Controls 101 Dickson Road Houma, LA 70363
Tel: +1 985 876 6040 Fax: +1 985 876 0751
[email protected]
x U.S.A.
Mariner Hub LLC 917 West 21st Street, Unit H Houston, TX 77008
Tel: +1 713 822 1252
[email protected]
Updated 14th December 2010
Page 4
Service Stations Spare Parts Agencies
TENAVAL Av. Fco. De Miranda, Edif. Bco del Orinoco 2°, Piso Ofic 2-B Caracas
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x Venezuela
Updated 14th December 2010
Page 5
Tel: +58 212 285-2344 +58 212 285-7822 +58 212 285-7631 Fax: +58 212 285-7776
Technical Documentation Screw Compressors
Technical Documentation for Screw Compressors Type HSC 11
of
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Uetersener Maschinenfabrik GmbH & Co. KG 25436 UETERSEN GERMANY Phone: +49-4122-711 0.. Telefax: +49-4122-711 330 Internet http://www.hatlapa.de E-Mail:
[email protected]
Ref.-No.:
10.2722 / 3
Serial-No.:
10.2722 - 3 - 0
This technical documentation belong NOT in the office, but in the hands of the operator
Technical Documentation Screw Compressors
Original 2011-06-21
Table of Contents 1
Important Information on this Documentation and Safety
2
Final Drawings / Specification
3
Operating Instructions
4
Spare Parts List
5
E- Diagrams
6
Lubricating Instructions
7
Service
We recommend reading these instructions through carefully and becoming quite familiar with the design and operation of the piston compressor before putting it into operation, this will avoid damage through imporper handling.
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Important Information on this Documentation and Safety
Important Information on this Documentation and Safety
1
Information on Manuals ........................................................................................................................... 3
2
Copyright ................................................................................................................................................. 3
3
Guarantee................................................................................................................................................ 3
4
Designations ............................................................................................................................................ 4
5
Signs Used .............................................................................................................................................. 5
6
Intended Use ........................................................................................................................................... 5
7
Ban on Arbitrary Modifications................................................................................................................. 5
8
General Safety Instructions ..................................................................................................................... 6
9
Safety Equipment .................................................................................................................................... 6
10 Instruments for Operating Surveillance ................................................................................................... 6 11 Safety Instructions for Assembly ............................................................................................................. 7 12 Additional Safety Instructions for Electrical Installation........................................................................... 7 13 Safety Instructions for Operation and Service......................................................................................... 8
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14 Safety Instructions for Maintenance and Repairs ................................................................................... 9 15 Noise Protection .................................................................................................................................... 10 16 Waste Disposal...................................................................................................................................... 10
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Important Information on this Documentation and Safety
1 Information on Manuals This manual includes all information necessary for guaranteeing the safety as well as for the operation and maintenance of the equipment. It is directed at instructed and trained personnel who are responsible for the operation and maintenance of the equipment. Only knowledge of this manual can ensure faultless and correct functioning of the equipment, so its contents must be known to the responsible persons. The manual should be kept so that the operating and maintenance personnel have access to it at all times.
2 Copyright The copyright for this technical documentation remains with HATLAPA. This documentation is intended for the operator and their personnel only.
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All rights reserved.
3 Guarantee Guarantee and liability claims for damage to persons and/or objects are excluded, if caused by one or several of the following circumstances:
Techen, Kerstin
−
inappropriate use of the equipment,
−
neglect of the provisions of this documentation,
−
improper assembly, operation or maintenance,
−
operation of the equipment with ineffective protective devices,
−
arbitrary functional or constructive alteration of the equipment,
−
removal of parts or installation of spare parts or additional components, respectively, which have not been supplied or approved by HATLAPA,
−
repairs which have not been authorised by HATLAPA,
−
impact of foreign bodies in case of catastrophes or Force Majeure.
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Important Information on this Documentation and Safety
4 Designations
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Persons are defined as follows:
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−
The operator is the (natural or legal) person on whose behalf the equipment is used, e.g. the ship’s owner.
−
Operating personnel are personnel trained for the respective work, and who are authorised to operate the equipment and to remedy disturbances. The operating personnel must be trained for the tasks they are entrusted with, and meet the requirements necessary to handle the equipment.
−
Assembling personnel are personnel trained for the respective work, and who are authorised to assemble the equipment. They are able to carry out the tasks assigned to them and to recognise possible dangers because of their completed specialised training.
−
Maintenance personnel are personnel trained for the respective work, and who are authorised to maintain, adjust and modify the equipment. They are able to carry out the tasks assigned to then and to recognise possible dangers because of their completed specialist training.
−
An electrician has electro-technical skills gained by respective education, masters the legal regulations, and is assigned by the operator to carry out work on their electrical equipment and appliances.
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Techen, Kerstin
Important Information on this Documentation and Safety
5 Signs Used Sign for Danger Danger! This sign indicates specific behavioral patterns the non-observance of which is highly dangerous, or which may lead to permanent bodily injury. Sign for Caution Caution! This sign indicates specific behavioral patterns the non-observance of which may lead to injury to persons, severe damage, or severe malfunction of the equipment, or to damage to the environment.
Sign for 'Pay Attention' Pay Attention!
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This sign indicates specific behavioral patterns the non-observance of which may lead to damage or malfunction of the equipment.
Sign for Information Information! This sign indicates tips and useful information which facilitate the operation of the equipment or the understanding of the documentation.
6 Intended Use The compressor is exclusively designed for air compression. Any other use is deemed as not being in compliance with the intended use and requires express written approval from HATLAPA. The intended use also includes compliance with all the regulations contained in this technical documentation, the generally acknowledged rules of technology as well as all the relevant laws, standards and regulations.
7 Ban on Arbitrary Modifications Arbitrary modifications and changes to the machine/system are not permitted, as they may put persons in danger and result in damage to the machine/system. If you are planning modifications or changes, contact HATLAPA and request written authorisation.
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26.11.2009
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Important Information on this Documentation and Safety
8 General Safety Instructions Besides the specific safety-related technical notes contained in these instructions and the sub supplier's documentation, you must also observe the generally applicable safety and accident regulations, such as the: –
Recognised technical regulations for safe and professional work
–
Regional and internal regulations
–
Regulations from the responsible classification authority
–
Rules and regulations for the prevention of accidents from the professional organisation, in particular concerning compressors
–
Safety signs and indicator plates on the machine/system
–
Environmental protection regulations
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Incorrect handling or failure to comply with regulations concerning use can result in the risk of physical injury and death and/or damage to property. Observe the limits specified in the technical data. Find out about the fire detection and fire prevention options, and ensure that these are fully functional and sufficient.
9 Safety Equipment Danger! Faulty safety equipment may put lives and equipment at risk. All safety equipment must always be in a flawless and fully operational condition. You must not make the safety equipment inoperative in any way. If a piece of safety equipment is defective, the machine/system must not be operated. Only remove safety equipment if the machine/system has been isolated and secured. Perform regular checks on the safety equipment, in accordance with the regulations in this documentation and the sub suppliers' documentation.
10 Instruments for Operating Surveillance Caution! If instruments for operating surveillance are out of order, monitoring of the operating conditions of the machine/system may lead to incorrect analyses. This may put lives and/or equipment at risk. Never decommission any instruments for operating surveillance. If instruments for operating surveillance are defective, they must be changed as soon as possible. Take utmost care when operating the machine/system until the instruments are exchanged.
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Important Information on this Documentation and Safety
11 Safety Instructions for Assembly Danger! During assembly and installation, the functioning of the safety equipment is not guaranteed. Therefore, the safety of the assembling personnel is to a great extent dependent on the proper execution of work. Only trained and briefed personnel are permitted to carry out assembling and installation work. The personnel must have a specialised knowledge of compressed air and electrical engineering. Only use suitable and fully functioning tools. During torching or welding work, ensure that risks of fire or explosion are avoided.
12 Additional Safety Instructions for Electrical Installation All work on the electrical systems is only allowed to be performed by qualified electronics specialists. Danger!
Original 2011-06-21
Deadly voltage! Before starting to work on electrical equipment, the machine/system must be deenergized. Ensure that −
the mains supply is deactivated. Check that the disconnected parts are deenergized before commencing work.
−
the electricity supply cannot be reconnected unintentionally or without authorization while work is being performed on the electrical installation.
−
the electricity for parts which must remain connected for the maintenance and repair work only remains connected for as long as is absolutely necessary for the work in question.
Danger! The main switch remains energized even if it is deactivated. Work carried out on electrical systems must be done so in accordance with the valid safety regulations, as well as all other relevant state or local regulations. Under no circumstances repair or tide over defective fuses. Fuses must only be replaced by the same type of fuses. When working on electrical systems, only use permitted and suitable tools. Only use voltage-free tools. When taking measurements with the voltage supply of >65 V activated,
Techen, Kerstin
−
you must under no circumstances touch the electrical connection points,
−
the inspection equipment must be in good condition and safe to operate,
−
you must not wear any jewelry on fingers or wrists,
−
you must stand on insulated ground.
26.11.2009
7 / 10
Important Information on this Documentation and Safety
13 Safety Instructions for Operation and Service Danger! The machine/system must only be operated by trained and briefed operating personnel. New personnel may only use the machine/system under the constant supervision of trained and briefed operating personnel. Give regular briefings on accident regulations and the requirements stated in this documentation. Danger! Drawing in into moving parts! Body parts or clothing may get caught at the flywheel. Prior to start-up, check that the flywheel cover is fitted! Caution! Burn hazard! The compressor housing and the pressure pipes become hot during operation. Wear protective gloves!
Original 2011-06-21
Caution! Drawing in into moving parts! Long hair or loose clothing may get caught at the air intake filter. When the compressor is in operation, maintain a safe distance to the compressor housing! Caution! In automatic operation mode, the compressor starts automatically without warning.
8 / 10
26.11.2009
Techen, Kerstin
Important Information on this Documentation and Safety
14 Safety Instructions for Maintenance and Repairs Danger! The machine/system must only be maintained and repaired by trained and briefed maintenance personnel. The personnel must have a specialised knowledge of hydraulic and electrical engineering. Optionally, the compressed air pressure gauges can be equipped with gauge valves. In this case, the compressor may be under pressure although the compressed air pressure gauges show a pressure of 0 bar. Before starting any repair work, shutdown the machine/system and secure it against unintentional restarting. If the work can only be carried out while the machine/system is running, make the necessary safety arrangements. A second person must monitor the work, and be ready to intervene if needed. When carrying out maintenance and repair work, do not decommission more than one piece of safety equipment at a time. Only use suitable and fully functioning tools.
Original 2011-06-21
Caution! Burn hazard! The compressor housing and the pressure pipes become hot during operation. Before beginning maintenance work, allow the compressor to cool down for approx. 2 hours! Caution! Besides the information contained in this documentation, you must also observe the regulations of the classification authorities and professional organisations in order to determine the inspection and maintenance intervals. After disassembly, always exchange self-locking nuts and gaskets. They are not designed for repeat use. If leaks occur at couplings which are sealed with resilient joint gaskets, the leaks cannot be eliminated by retightening the coupling because the resilient joint gaskets are damaged or hardened. Exchange the resilient joint gaskets. Pay particular attention to cleanliness. Cover any openings to prevent the ingress of dirt. Ensure that tools, loose parts or cleaning cloths are not left in or on the compressor. Dispose of old oils and grease in an environmentally friendly manner in accordance with national regulations.
Techen, Kerstin
26.11.2009
9 / 10
Important Information on this Documentation and Safety
15 Noise Protection Refer to the technical data for information about the noise level. Caution! Make sure to wear ear protection in the vicinity of the compressor when it is in operation.
16 Waste Disposal The following substances which are caused by the operation of the machine/system must be disposed of in an environmentally friendly manner, in accordance with the applicable laws: used oils and grease as well as cloths with such substances on them;
−
cleaning agents, and cloths with cleaning agents on them.
Original 2011-06-21
−
10 / 10
26.11.2009
Techen, Kerstin
Final Drawings
Original 2011-06-21
for COSCO GUANGDONG SHIPYARD HULL No: N352 - N353 HATLAPA Order No.: 10.2722 - 23 / 3 1x WORKING AIR COMMPRESSOR HSC 11
2011-06-21
1/1
INDEX DRAWING No.
TITLE
SECTION 1 ................................................ TECHNICAL SPECIFICATION ................................................ TECHNICAL DESCRIPTION
Original 2011-06-21
SECTION 2 177572.................................... GENERAL ARRANGEMENT – HSC11 – 7 BAR 177470.................................... INTERNAL VIEW 178025.................................... PIPING DIAGRAM ................................................ OPERATIONAL DESCRIPTION 177934.................................... FLEXIBLE HOSE FOR COMPRESSED AIR AND DRAINAGE 178483.................................... FLEXIBLE HOSE INSTALLATION GUIDELINES 177469.................................... LUBRICATING INSTRUCTIONS ................................................ CONNECTION DIAGRAM
SECTION 3 177469.................................... SPARE PART LIST
Original 2011-06-21
SECTION 1
T E C H N I C A L S P E C I F I C A T I O N/2 Our Ref. 10.2722/3K WORKINGAIR COMPRESSOR
1 x SCREW COMPRESSOR T y p e HSC 11
Original 2011-06-21
fully automatic belt-driven screw compressor, built as compact unit, noise-protected and ready to connect, air cooled F.A.D. compressed from 0-7 bar (20°C, 1,013 bar) Operating pressure Max. pressure Min. pressure Power consumption approx. Voltage Residual oil content Cooling air flow Compressed air delivery connection Ambient temperature (min./max.) Length x width x height Noise level acc. to DIN 46653
105
m³/h (+/-5%)
7 bar 7,5 bar 5 bar 11 kW 440V/ 60 Hz 2-4 mg/m³ 36,6 m³/min 1” +3/+45 °C 805 x 695 x 1170 mm 71 (66) dB(A)
SCOPE OF SUPPLY Compressor HSC Screw Compressors are belt-driven by a marine type motor, protection IP 54, with PTCresistor and insulation class F. This facilitates smooth starting, absorbing the ensuing starting torques effectively. All components built on base frame (designed as oil pan) completely piped and wired, ready for installation, including: Air intake filter Compact aluminium after cooler Compression unit of robust design with low circumference speed and long life time Fixed internal pipe connections Oil level indication With air receiver (with oil plug) and integrated oil filtration unit for 3-step oil separation to guarantee the above oil content. Air outlet with external oil and water separator, automatic mechanical drainage valve – level control and flexible hose
Air-end with High-Tech Profile Modern, asymmetric profile as well as operation within a range of revolutions offering highest specific efficiency factor – that means you get more air with less energy compared to conventional profiles.
Original 2011-06-21
Microprocessor Control Unit HSC screw compressors are equipped as standard with an integrated microprocessor control system, unifying simplest operation with extraordinary performance features. All settings can be made conveniently on a control panel. Thanks to the modern microprocessor-based control unit operating costs are minimized. Numerous operating modes allow an optimum adjustment to the existing conditions: An integrated diagnostic system monitors all safety-relevant operating parameters System self-test before each start Service indicator to notify when maintenance work is due Automatic start-up after power failure Reaching final pressure control system calculates the actual follow-up time. This saves up to 60% of energy cost during idle operation The pressure sensor ensures precise operation in the adjusted pressure range (up to 0.2 bar difference) The motor only runs when necessary in automatic mode Galvanic isolated contacts for possible connection to a master control system/ remote control Switchable remote and local operation Alarm indication for high lub oil temperature and high discharge air temperature Potential free contacts for connection to ship’s alarm system
Compressor resiliently mounted Final coating shade: Munsell 7.5 BG 7/2 (blue green) TESTING: works certificate 1 set of spare parts consisting of: - 1 oil filter - 1 air filter - 1 fine filter - 1 set of belts 1 additional set of air filter for compressor for SY’s purpose
Hatlapa Screw Compressor Model: HSC 11 Belt-driven screw compressor built as compact unit, noise-protected and ready to connect, fully automatic control air cooled Compressor HSC Screw Compressors are belt-driven. This facilitates smooth starting, absorbing the ensuing starting torques effectively. Air intake filter Compact aluminium after cooler Compression unit of robust design with low circumference speed and long life time Fixed internal pipe connections Oil level indication Air-end with High-Tech Profile Modern, asymmetric profile as well as operation within a range of revolutions offering highest specific efficiency factor – that means you get more air with less energy compared to conventional profiles. Compressed air passes air receiver (with oil plug) and integrated oil filtration unit for 3-step oil separation to guarantee the above oil content. Air outlet with external oil and water separator, automatic mechanical drainage valve – level control and flexible hose (with DIN flange)
Original 2011-06-21
Microprocessor Control Unit HSC screw compressors are equipped as a standard with an integrated microprocessor control system, unifying the simplest operation with extraordinary performance features. All settings can be made conveniently on a control panel. Numerous operating modes allow an optimum adjustment to the existing conditions: • An integrated diagnostic system monitors all safety-relevant operating parameters • System self-test before each start • Service message indicates outstanding when maintenance work, • Automatic start-up after power failures • Reaching final pressure control system calculates the actual follow-up time. This saves up to 60% of energy cost during idle operation • The pressure sensor ensures precise operation in the adjusted pressure range (up to 0.2 bar difference) • The motor only runs when necessary in automatic mode • Galvanic isolated contacts make possible connection to a master control system • Switchable remote and local operation • Alarm indication for high lub oil temperature and high discharge air temperature • Potential free contacts for connection to ship’s alarm system
HSC_11_10
Motor IP 54, PTC-resistor and F-coiling offer complete control of the unit. Thanks to the modern microprocessor-based control unit operating costs are minimized. All components built on base frame (designed as oil pan) completely piped and wired, ready for installation. No special foundation is required.
HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen Telefon: ++49 4122 711- 0 Telefax: ++49 4122 711 - 104 eMail
[email protected] Internet www.hatlapa.de
2
Hatlapa Screw Compressor Model: HSC 11 Technical Data Sheet: Flow Capacity 0-7,5 bar Max. operating pressure Min. operating pressure Motor power at shaft Idle capacity requirement Oil contents Residual oil contents Cooling air flow Noise level acc. to DIN 46653 Ambient temperature (min./max.)
Motor Power Motor revolutions Voltage (option) Frequency (option) Protection Mode Insulation Class Mode of construction
105 7.5 5 11 2,8 6 2-4 2200 71 +3 /+45
Electric Motor acc. to IEC standard 11 3000 380 50 IP 54 F B3/B5
m3/h bar bar kW kW l mg/m3 m3/h dB(A) °C
kW min-1 V Hz
Dimensions Original 2011-06-21
Connection Length x Bright x Height Weight
1" 805 x 695 x 1170 334
i mm kg
HSC_11_10
Hatlapa Screw Compressor (opened)
HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen Telefon: ++49 4122 711- 0 Telefax: ++49 4122 711 - 104 eMail
[email protected] Internet www.hatlapa.de
3
Original 2011-06-21
SECTION 2
-
-
10 .= 071-
L o
,.1,. cNi
1_LL.
0
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2.4
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0
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with au to ma tic dra in
Original 2011-06-21
ru
HATLAPA Screw Compressor Internal view
177470
Original 2011-06-21
Equipment with V belt drive (example)
Equipment with direct drive (example) 1 2 3 4 5 6 8 10 14 15
Condenser Separator tank Separator cartridge Electric motor Fan wheel valve Operational controls Proportional controller(option) Rating plate Drainage pipe Pressure control device
02.12.2002
16 17 18 19 20 21 22 23 24
Safety valve Switch box Oil temperature regulator Electricity supply cable Oil and condensate drain valve Boiler plate Oil filler neck Pulley for V belt Drainage coil regulator
25 26 27 28 29 30 31 32 33
Intake regulator Control valve Relief valve Intake filter Oil filter Compressed air outlet with cut-off Aftercooler Oil cooler Super noise cover
Original 2011-06-21
Operational description of HATLAPA screw compressors HSC Basic air delivery: The screw compression stage (3) sucks in air through the suction filter (1), if the suction valve (2) is open. During the compression inside the screw compression stage (3) the air is mixed with an extensive amount of oil. The air and oil mixture flows through the air pressure pipe (4) to the primary cyclone (5) and then into the compressed air and oil reservoir (6). Most of the oil remains in the reservoir (6) and only a small content reaches the oil fine filter (7). After this filtration the oil content is minimized to 2-4 mg/m³. The compressed air passes through the minimum pressure valve (8) to the compressed air cooler (9).
Original 2011-06-21
Oil circuit: Due to the pressure inside the oil and air reservoir (6) the oil is pressed back to the suction side of the screw compression stage (3), passing through an oil filter (12). The thermostatic valve (11) switches to its open position when the oil has reached its working temperature. The temperature is held constant by regulating an oil flow through the largely designed oil cooler (10). The small amount of oil filtered from the compressed air inside of the oil fine filter (7) is sucked back into the screw compression stage (3) through the oil drainage line (17). The throttle (19) is installed to avoid a short circuit of the compressed air. The check valve (18) prevents oil being pressed back into the fine filter (7) from the compression stage when the compressor is shut off. Control and monitoring: The minimum and maximum network pressures are adjusted by setting the respective values of the electronic control system PROCON. The network pressure signal is taken from the pressure sensor (20) and is indicated under usual running conditions on the display. Furthermore the display of the PROCON indicates the temperature of the oil and air mixture inside of the oil and air reservoir (6). The temperature is taken from the sensor (21) which is installed behind the screw compression stage (3) or directly in the air/oil reservoir (6). If more than 105 °C are reached the PROCON will show an alarm, after reaching 110 °C the compressor will trip. In the unlikely case that the internal pressure becomes too high the safety valve (22) will protect the system by blowing off the air. For correct operation of the screw compression stage (3), of the oil flow and of the control valves there has to be a minimum pressure inside the system between screw compression stage (3) and minimum pressure valve (8). The minimum pressure valve (8) opens at approx. 4 bar(g). If the final pressure in the network is reached the PROCON will switch the solenoid valve (15) into the drawn position, as indicated in the piping diagram. This results in an open relief valve (14) and a closed suction valve (2), as shown in the piping diagram. The compressor will continue idle running for a certain period of time, as programmed in the PROCON (approx. 2 to 5 min.), without delivering compressed air to the network. To hold the minimum system pressure there is a small throttle inside of the suction valve (2), still allowing a small amount of air to be sucked in. The same amount of air is flowing to the suction line through the relief valve (14). If the minimum network pressure is not reached within the programmed time the PROCON stops the compressor. The internal pipings are made pressureless by the opened relief valve (14) – up to the minimum pressure valve (8) with check-valve. If the network pressure is falling under the minimum value the PROCON will switch the solenoid valve (15) which results in an open suction valve (2) and a closed relief valve (14). The compressor will then start delivering its full amount of air into the network. 21.06.2005
Original 2011-06-21
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES Flexible hoses are used for connecting a flexible mounted compressor assembly to a rigid piping system. When a hose is installed, it must allow the compressor to move in all three directions. See typical applications below, which show a single bend, to achieve this. The diagrams apply to both air and water. Note: The following diagrams show flexible hoses with threaded end connections, however flanged end connections may be supplied. These guidelines apply to the flexible part of the hose, regardless of the type of end fitting supplied.
No pressure
Original 2011-06-21
High pressure
To allow the flexible part of the hose to move when pressurised, ensure no supporting clamps are located on the bends.
incorrect
correct
On installation, ensure that the flexible part of the hose is not twisted, this could result in hose damage and, when pressurised, it could untwist, loosening the connections.
16.01.2006 122/Pitrowski
1/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Use angle adaptors to eliminate tight bend radii and sharp twists occurring in the hose.
incorrect
correct
If the installation bend radius is less than the minimum allowed, use angle adaptors to eliminate tight bend radii.
16.01.2006 122/Pitrowski
2/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is installed with a smooth bend, avoiding any tight corners, which could cause the flexible part of the hose to collapse.
incorrect
correct
In a collinear application, do not install the hose in a straight line or with kinks, use angle adaptors.
16.01.2006 122/Pitrowski
3/4
178483
FLEXIBLE HOSE INSTALLATION GUIDELINES
incorrect
correct
Original 2011-06-21
Ensure the hose is kept away from hot surfaces by using suitable clamps. High ambient temperatures can reduce the life of the flexible part of the hose.
16.01.2006 122/Pitrowski
4/4
Safety Instructions for Hoses
1 General Hose pipes are safety relevant parts which may endanger persons and the environment in case of failure.
1.1 Installation and maintenance During installation the hoses must in no way be damaged, bent, twisted or exerted to pressure. They must not be painted or have contact with sharp objects! For cleaning hose pipes and hoses neither aggressive cleaning agents nor pressure cleaners may be used. They can damage the hose surface resp. hose line! Hose pipes must be inspected visually by the assembly/service personnel before commissioning and once a year. Inspection is carried out under the following aspects: Original 2011-06-21
• • • • • • •
Damage to the outer layer Decay of the outer layer Deformation of the hose or hose pipe (alteration of the geometry, layer separation, forming of blisters) Damage or deformation of the hose fitting Corrosion of the fitting (impairs function and strength) Installation (chafing at sharp edges or smooth surfaces) Exceeding the admissible storage resp. operational duration (stated below)
1.2 Storage and durability According to DIN 7716 proper storage is to be understood as follows: • • • • • •
max storage time 2 years dry, cool, dust-free no direct sunlight or UV light protection against ozone protect against heat store lying and without tension
According to EN 982 resp., DIN 20066 following must be observed: 1. Once installed, the hoses have a durability of 6 years and must be replaced after this period. 2. If the max. storage time of 2 years is exceeded, then the hose may no longer be used. If the hose is installed within this period, the durability of 6 years is reduced by the period of storage accordingly. It lies within the responsibility of the user that all hoses mentioned in this manual are checked at regular intervals, and to guarantee correct and safe function once the guarantee period has elapsed, thus preventing damage to persons and the environment.
date 18.04.2005 Created by Tanz
page 1 of 1
Lubricating Instructions for HATLAPA HSC Screw Compressors
177469 Rev. 08.10
1. General Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of the compressor. Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is advisable to contact him when making your choice. Ask only the lubricant manufacturer for his recommendation! He is the expert.
2. Lubrication Oil Quality Above all, compressor oils must have good lubrication properties for which their viscosity is highly important. HATLAPA recommends lubrication oils within the following range: ambient temperature
0 .. +25 °C
constantly over 25 °C (engine room of sea going ships)
Original 2011-06-21
viscosity class
ISO VG 46
ISO VG 68 2
2
viscosity at 40°C
41 .. 51 mm /s
61 .. 75 mm /s
flash point
> 200 °C
> 200 °C
pourpoint
at least 5 °C under the lowest ambient temperature
The screw compressor oils should have low tendency to ageing and foaming. 3. Guarantee If lubrication oils are used which do not meet the requirements, damage to the compressor may occur. This damage is not covered by HATLAPA's guarantee obligations. 4. Lubricant Examples The following oils are examples which comply with the above specification: BP ENERSYN RC-S 68 CASTROL AIRCOL SR-68 CHEVRON TEXACO (FAMM) CETUS PAO 68 ELF TOTAL FINA (Lubmarine) BARELF SM-68 / DACNIS SH-68 ESSO (ExxonMobil Marine) RARUS SHC-1026 MOBIL (ExxonMobil Marine) SHELL CORENA AS-68 However, the oil properties are subject to change without notice by the oil manufacturer. Also, the oil characteristics may vary depending on the regional market. Therefore this list does not release the operator of the compressor from verifying that the selected oil complies with the above specification.
Schaltpläne Schraubenkompressoren Connection diagram - screw compressor
4 – 37
Original 2011-06-21
HSC
Jahr/Building Year: 200_____
Serien Nr/SerialNo.:______________
HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen ++49 4122 711- 0, FAX ++49 4122 711 – 104
E03071606 b - 06/05
1
2
3
4
Frequence 5G4
5G6
50A
5G10
29,3A
06.06.05
Datum
"a"
Änderung
Name
Küster
Hall
Bearb.
Norm
Gepr.
06/05
Datum
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW Ers.d.
Ben.
E990903
775089
22,0 kW
400-440V
5G10
50A
5G25
55,0A
63A
E990927
775024
30,0 kW
7
5G25
68,0A
80A
E990927
775024
37,0 kW
5G35
81,0A
100A
E990928
7750281
45,0 kW
8
4G50
99,0A
125A
E990929
7750281
55,0 kW
4G70
134,0A
160A
E030222
7750291
75,0 kW
9
Schaltschrank Daten Dates of control cabinet
EDV Nr.:
E03071606 b
SKP-E 4 - 75 kW
Ort:
Anlage:
Folge
Blatt
verknüpft mit Exel-Liste E03071608.xls
A t t ent i o n !
Le dimensionnement de la conduite d’alimentation, ainsi que de t ous les câblages externes, a lieu en propre responsabilit é de la société électrique exécutant ces travaux.
Avant mise en service et en cas de travaux d’entretien il f aut serrer les vis de contact, ou bien vérifier s’ils sont bien fixés.
Avant mise en service il faut vérifier la tension et f réquence ainsi que les valeurs de cosigne de la protection du moteur et du relais temporisé.
Inf o r mat io ns imp o r t ant es!
5G16
41,0A
50 - 60 Hz
36,0A
50A
230V / 19V / 10V
A t t ent io n !
5G2,5
35A 21,7A
6
3/PE 50-60Hz 400-440V
E990903
A cht ung !
5G2,5
25A 15,3A
E990701
775089
18,5 kW
The dimensioning of the conducting cable as well as all external cables are the responsibility of the electrician ef fect ing the wiring.
Câble d'alimentat ion
20A 11,3A
E990701
775087
15,0 kW
Die Dimensionierung der Zuleit ung sowie alle ext ernen Verkabelungen erfolgt in Eigenverantwortung der ausf ührenden Elekt rof irma.
Zuleitung
16A 8,5A
E990802
775087
11,0 kW
Before initial st arting and during maintenance works, all contact screws have t o be checked and retightened respectively.
Frequency
Supply line
Frequenz
Branchement de courant
Fusible de puissance
E990802
7,5 kW 775083
Vor Inbetriebnahme und bei Wartungsarbeiten sind alle Kontakt schrauben nachzuziehen bzw. auf festen Sitz zu kontrollieren.
Connecting current
Anschlußstrom
E990802
5,5 kW 775083
Before initial st arting, volt age and frequency as well as t he values at which motor protect ion and t ime relay are set have to be checked.
Preliminary locking device
max. Vorsicherung
Tension de gâchette
4 kW 775083
Vor Inbetriebnahme sind Spannung und Frequenz sowie die Einstellwerte der M ot orschut z und Zeitrelais zu prüfen.
Control voltage
Steuersspannung
Tension du moteur
Alimentat ion
C har g es d e co nnexi o n
Dessin No.
EDV No.
I mp o r t ant d i r ect io ns !
M otor volt age
M ot orspannung
Pr o jet d o nnées
Compresseur à hélice
5
W icht i g e Hinweise !
C o nnect ed lo ad
Zeichnung Nr
Power supply
Drawing No.
EDV - Nr
Einspeisung
EDV - No.
Schraubenverdichter
A nschl uß w er t e
Pr o ject D at a
screw compressor
Pr o jekt D at en
Schaltschrank Daten / dates of control cabinet / Données Armoire, instruments
0
Original 2011-06-21
1.1 2
06.06.05
Datum
"a"
Änderung
0
Name
Küster
Hall
Bearb.
Norm
Gepr.
06/05
Datum
1
PROCON A1
3
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
Gehäuse 01 housing 01 Carter 01
2
Ers.d.
4
620mm
S1
Ben.
5
Original 2011-06-21
Frontansicht front view
3P1
3Q1
6
EDV Nr.:
Amperemeter ammeter amperemeter
Hauptschalter Power switch interrupteur principal
7
E03071606 b
SKP-E 4 - 75 kW
290mm
Tiefe: 170mm
8
Anlage: Ort:
Folge
Blatt
9
2 3
06.06.05
Datum
"a"
3F0
Änderung
Bauseits at site
4
L3
6
L2
3
5
6
L3
5
PE
see attachment
siehe Anhang
PE
Name
Kuester
Hall
Bearb.
Norm
Gepr.
06/05
Datum
Alimentation voir annexe 3/PE 50-60Hz/400-440V Castouche fusible puissance de branchement nominale Courant en régime
power supply 3/PE 50-60Hz/400-440V back up fuse max. rating current rated
Einspeisung 3/PE 50-60Hz/400-440V Sicherungseinsatz max. Nennanschlußleistung Nennbetriebstrom
L1
1
4
L2
L1
2
3
1
2
Motorstromrelais motor power relais relais motorisé
Option
U1
2
1
V1
4
3
W1
6
5
A
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
*
* 3F6
7.7
7K1
3T2
5.2
96
95
~
M
PE
PE
Ers.d.
3M1
3
1X1
98
97
3P1
Commande compresseur à hélice
3
Alimentation
2 Antrieb Schraubenkompressor screw compressor drive
1
Einspeisung power supply
1X1
3Q1
Hauptschalter Power switch interrupteur principal
0 4
7.5
7K2
W2
2
1
U2
4
3
Ben.
V2
6
5
5
Original 2011-06-21
2
1 4
3 6
5
Einspeisung / Antrieb power supply / drive Alimentation / Commande
7.6
7K3
6
1X1
230
12
11
2
1
0
3F3
400 - 440
3F1
E03071606 b
SKP-E 4 - 75 kW
3F2
PE
3F5
3S1
3T1
EDV Nr.:
PE
Transformator transformer transformateur
7
19
2
1
2
1
8
0
3F4
10
2
1
0
Ort:
Anlage:
Transformator transformer transformateur
Folge
Blatt
3.1 4
/4.0
/7.0
/4.0
/4.0
/4.0
/4.0
PE /4.0
L10 L11
L50 L51
L60 L61
L3
L2
L1
9
L51
L50
L60
3.9/
3.9/
3.9/
Änderung
Datum
PE
L61
3.9/
3.9/
L11
3.9/
0
Name
Hall
Bearb.
Norm
Gepr.
5/03
Datum
0V / 10V AC
0V / 19V AC
19V AC
10V AC
230V 50Hz
4A1
32
33
31
11
0X7
12
13
0X3
30
10
9
3
29
28
Schnittestelle RS232/RS485 nicht auf Klemmen verdrahtet interface RS232/RS485 not wired on clamps interface RS232/RS485 pas câblé sur pinces
2
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
PROCON - Steuerelektronik PROCON - control electronic PROCON - électronique de commande
1
27
26
Ers.d.
0X6
8
7
25
0X2
4
6
24
23
22
Ben.
20
19
bl 18
5
6
3
ga 16
0X1
0X4
17
4
15
2
br
PROCON-control electronic PROCON-Steuerelektronik PROCON-électronique de commande
0X5
21
Typ / type / Type : PROCON Electronic électronique PROCON
5
sw
Original 2011-06-21
EDV Nr.:
14
1
gr-ge
7
E03071606 b
SKP-E 4 - 75 kW
8
Anlage: Ort:
Folge
Blatt
PE /5.0
L11
9
4 5
Änderung
4.9/
Datum
PE
Name
5/03
Hall
4
21
4.5
PE
23
0X6
défaut arrêt d'urgence
4.3
Urspr.
PE
Ers.f.
Ers.d.
6
24
PE
Option avertissement filtre à air
4.3
0X6
Warnung Luftfilter warning air filter
Option
1X1 8
25
PE
Ben.
10
26
PE
Option avertissement séparateur fin
4.3
0X6
Warnung Feinabscheider warning fine seperator
Option
1X1
Digital-Eingänge digital input entrées digitales
Option avertissement filtre à huile
4.3
0X6
Warnung Ölfilter warning oil filter
Option
1X1
12
27
PE
EDV Nr.:
14
28
PE
8
Option Xxx marche / arrêt
4.3
0X6
Fern Ein / Aus remote on / of
Option
1X1
E03071606 b
SKP-E 4 - 75 kW
Option GLW: charge / marche à vide
4.3
0X6
GLW: Last / Leerlauf load / unload
Option
1X1
4
25
3
13
4
1X1 3
11
2
1X1
1
9
2
1X1
1
7
4
1X1
7
3
5
6
32
1X1
5
31
Störung Not - Aus malfunction emergency stop
1X1
3S1
29
Versorg.spg. 24VDC Digital Eingänge supply voltage 24VDC digital inputs
4.3
0X6
tension d'alimentation 24VDC entrées numériques
Kompressor/compressor/compresseur PROCON 4 - 75 kW
défaut PTC température du moteur
0X5
Störung PTC Motortemperatur malfunction PTC temp. motor
1X1
2
1
96
95
3
4.5
PE
5R2
* 3F6
1X1
0X5
Option réserve défaut PTC
Bearb.
Norm
20
Reserve Störung PTC reserve malfunction PTC
Datum
Gepr.
2
2
1
1
Option
1X1
5R1
1X1
22
Versorg.spg. 12VDC Motortemperatur PTC supply voltage 12VDC motor temp. PTC
4.5
0X5
tension d'alimentation 12VDC température du moteur PTC
rt
rt
sw
4
gr-ge
3
rs
2
bl
1
vi
0
br
ws
Original 2011-06-21
ga
Anlage: Ort:
Folge
Blatt
PE /7.0
9
5 6
Änderung
0
Datum
Name
5/03
Hall
Norm
15
1X1
4.5
16
S
sonde de température KTY -20 à +150°C
4.5
0X4
Temperaturfühler KTY -20 bis +150°C temp. transductor KTY -20 bis +150°C
16
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
sonde de température KTY -20 à +150°C
0X4
4.5
15
2
-2
17
P
17
0X4
Netzdruck 4-20mA 0 bis 16 bar line pressure
18
Ers.d.
Ben.
A1
I
6
conduite d'alimentation capteur de pression 4-20mA
4.5
0X4
Zuleitg.Druckfühler 4-20mA feed line pressure transductor
19
Analog-Eingänge analog inputs entrée analogique
pression du réseau 4-20mA 0 à 16 bar
S
Option pression du système 4-20mA 0 à 16 bar
18
A2
P
4.5
+1
I
6A1
Druckfühler pressure transductor capteur de pression
5
4.5
0X4
Systemdruck 4-20mA 0 bis 16 bar system pressure
Option
1X1
6A0
Druckfühler pressure transductor capteur de pression
4
ws
1
3
ga
6R1
Temperaturfühler KTY -20 bis +150°C temp. transductor KTY -20 bis +150°C
2
br
0X4
blindage entrée analogique
Bearb.
Gepr.
14
gr-ge
Schirmung Analog Eingänge screening analog inputs
Datum
1
sw
Original 2011-06-21
bl
EDV Nr.:
7
E03071606 b
SKP-E 4 - 75 kW
8
Anlage: Ort:
Folge
Blatt
9
6 7
10.11.03
Datum
Änderung
L10 PE
Option 7Y2
5.9/
3.9/
0
Name
Küster
5/03
Hall
Bearb.
Norm
Gepr.
1X1
22
23
8
Urspr.
Ers.f.
Ers.d.
Steuerventil control valve soupape de distribution 45/55/75kW
(45/55/75kW)
* Option
* 7Y2
Sammelstörung Wechsler NO collective indicat. change over cont. NO
4.4
0X2
défaut collectif inverseur NO
3
Kompressor/compressor/compresseur PROCON 4 - 75 kW
21
7
6
4.4
4.4
Sammelstörung Wechsler NC collective indicat. change over cont. NC
0X2
0X2
Sammelstörung Wechsler C collective indicat. change over cont. C
défaut collectif inverseur NC
2
défaut collectif inverseur C
Datum
0V 50Hz
1 4
26
-
+
24
PE
Entlastungsventil relief valve soupape de décharge
1X1
7Y1
1X1
9
Lastventil load valve
4.2
0X3
soupape de charge
Ben.
1 3 5 21
7K2
.6
2 3.4 4 3.5 6 3.5 22 .6
A2
A1
22
21
Relais-Ausgänge relay outlets sortie de relais
10
Dreieckschütz delta contactor
4.2
0X3
contacteur en delta
7K3
5
Original 2011-06-21
1 3 5 21
7K3
.5
7K2
11
2 3.6 4 3.6 6 3.6 22 .5
A2
A1
22
21
Sternschütz star contactor
4.2
0X3
contacteur en étoile
6
EDV Nr.:
7K1
1 3 5
2 3.3 4 3.3 6 3.3
A2
A1
1X1
E03071606 b
26
27
8
Wasserstopventil water stop valve soupape d'arrêt d'eau
(Wasserkühlung) (water-cooling) (refroidissement à l'eau)
* Option
1X1
* 7Y3
SKP-E 4 - 75 kW
12
Netzschütz main contactor
4.2
0X3
contacteur principal
7
Anlage: Ort:
Folge
Blatt
PE
L10
9
7 8
06.06.05
10.11.03
Datum
Option 7Y2
Änderung
0V 50Hz
running/pot.free
3.9/
L10 5.9/ PE
0
Kuester
Name
Küster
30
7K1
31
Norm
Gepr.
Bearb.
Datum
Hall
5/03
Ein (Motor läuft) Pot.freie Kontakte on (running) potential-free contacts
29
4
3
1
7K1
28
14
11
7K4
Last (Leerlauf) Pot.freie Kontakte load (idle) potential-free contacts
* Option
27
3
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
32
4
3
2
Ers.d.
*7K4
4
A1
Steuerventil control valve soup de distribution
* Option (45/55/75kW)
A2
Ben.
1X1
1X1
26
24
5
Original 2011-06-21
Relais-Ausgänge relay outlets sortie de relais
PE
6
EDV Nr.:
Stillstandheizung Motor auxiliary heating motor
L11
7
26
230V
33
22
21
E03071606 b
SKP-E 4 - 75 kW
Stillstandheizung Motor auxiliary heating motor
* Option
7K1
8
Anlage: Ort:
Folge
Blatt
PE
L10
9
7-1 8
Änderung
Klemmenplan
/ terminal strip
HOP.KP02
W6A0
W6R1
W0X5
W0X4
W0X1
0
Leistenbezeichnung
Datum Name
Kabelname
Kabelname
1X1
Norm
Hall
Bearb.
Gepr.
5/03
Datum Kabeltyp
Zielbezeichnung
Anschluß
Klemmennummer
Zielbezeichnung
Anschluß
Kabeltyp
4mm²
Seite/Pfad
1
Funktionstext / function text Einspeisung power supply
6
3Q1
4
3Q1
2
3Q1
0/L1 0/L2 0/L3
0/PE
PE
0/N
N
Ers.f.
1
5R2
2
5R1
1
5R1
1 2
7K1
1
7K1
X
3
7K1
3.0
X
5
3T1
3.1
X
3.1
0
3.1 3.1
0X5
22
0X5
rt
20
5.1
sw
5.1 3
2
5R2
2
Kompressor / compressor PROCON 4 - 75 kW
Urspr.
Einspeisung power supply Einspeisung power supply Einspeisung power supply Einspeisung power supply
3 4
S
SH
W6R1
9
1
8
2
7
1
6
4
5
3 Ers.d.
SH
W6A0
5.2 0X5
21
3S1
br
5.2
31
0X6
5.4
24
gr-ge
5.4 5.5
0X6
25
rs
5.5 5.6
0X4
14
gr-ge
6.3
S
1
6R1
2
15
2
6R1
1
14
4
13
3
12
4
11
3
10
2
Ben.
SH
Druckfühler pressure transductor
4
1
Druckfühler pressure transductor
6.5 0X6
26
bl
5.6 5
1X1
16
-2
17
+1
18
EDV Nr.:
E03071606 b
SKP-E 4 - 75 kW
+
7Y1
24 25
5.7 0X6
27
vi
5.7 5.8
0X6
28
0X4
ga
15
0X4
5.8 br
16
0X4
6.3
sw
17
6A1
6.3
ws
6.4
A1
0X2
6.4
6
0X2
7.2
7
0X2
7.2 7
32
3S1
26
6
6A0 6A0
-
7Y1
8
0X3
7.2
9
0X6
7.4
23
A2
7K2
0
3T1
rt
5.3 7.4 3.4
3T1
8
PE
Antrieb Kolbenkompressor piston compressor drive
Original 2011-06-21
SH
2
Druckfühler pressure transductor
21 22 23
PE
3M1
PE
Transformator transformer
PE
4A1-0X1
3.7
1
gr-ge
Anlage:
Ort:
Folge
Blatt
5.5
PE
5.4
PE
5.3
PE
5.2
PE
5.2
PE
9
5.6
PE 8
Original 2011-06-21
SECTION 3
SPARE PARTS RESERVETEILE for screw compressor HSC 4 - HSC 75
Position
Qty.
Bezeichnung/Declaration
010
1
Ölfilter oil filter
Original 2011-06-21
020 2
Luftfilter-Element air filter element
030
1
Feinabscheider fine separator
040
1
Satz Keilriemen Set of V-belts HSC4, HSC5.5 HSC7.5, HSC11 HSC15, HSC18.5, HSC22 HSC30, HSC37 HSC45, HSC55 HSC75
16.04.2008
1 2 3 4 6 7
pc pcs pcs pcs pcs pcs
177982-06060
HSC Electronic Control: Procon Modification of Maintenance Intervals
Any alarm- or malfunction has to be acknowledged by below stated procedure 2. If the alarm indication is caused by a maintenance interval, the value of the respective parameter has to be re-adjusted to an appropriate value PRIOR to acknowledgement of the alarm. 1. Modification of Maintenance Intervals Back to basic mode Select Menu (press 3 seconds) Enter Menu-Code 020 Confirm Choose C1 air filter
Original 2011-06-21
Select edit mode, (blinking) Enter maintenance interval, e.g. 1500 h Confirm Choose C2 oil filter Choose C3 oil fine separator cartridge Choose C4 oil operating life time Confirm Back to basic mode 2. After this has been done the Alarm/Malfunction can be acknowledged by: • Press
to enter the basic mode.
• Then keep both keys
11.01.2007
pressed for at least 2 seconds.
Original 2011-06-21
Operating instructions HATLAPA Screw Compressors
Type Serial number
Date
Operating instructions Component overview
7
Original 2011-06-21
12
23
Fig. 1: 1 2 3 4 5 6 7 8 9 10 11
24 13
4
28
10
25
5
27 26
6
2
8
19
20
9
3
21
22 1
16 17 11 18 15 14
Component overview
Compressor Compressed air / oil reservoir Oil high-precision separator cartridge Electric motor Fan PROCON control Proportional controller (optional) Name plate Drain line Pressure detector Safety valve
12 Switch box 13 Oil thermostat 14 Temperature sensor
15 16 17 18 19 20 21 22 23 24 25
Oil and condensation water drain valve Pressure reservoir name plate Oil gauge Oil filler neck V-belt tensioning roller Suction stop valve Control valve Relief valve Suction filter Oil filter Compressed-air outlet with cut-off valve (optional) 26 Compressed-air aftercooler 27 Oil cooler 28 Super sound proofing hood
104482 HSC • 03/03
Operating instructions PROCON control
8
9
10
11
12
00 .
Original 2011-06-21
20
Fig. 2: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
104482 HSC • 03/03
5
14
bar
°C
4
13
6
7
1
2
3
Operating elements
Power switch Circuit-breaking key Emergency stop In the menu: Edit mode: In the menu: Edit mode: In the menu: Edit mode: In the menu: Edit mode: Permanent yellow: Permanent yellow: Permanent yellow: Permanent green: Green flashing: Blinking yellow: Blinking yellow: Red flashing:
One line up Increase value One line down Selection of the menu Call up information Cancel value input Selection of the menu Apply value Base load sequencer operating mode Remote operation Automatic restart Motor is running Standby, motor can start automatically at any time Maintenance Warning Type of malfunction
1
Original 2011-06-21
Operating instructions Table of contents PROCON control Table of contents
Technical annex
Original 2011-06-21
Component overview PROCON control 1 1.1 1.2 1.3
Fundamental safety instructions....... 2 Designated use ........................................ 2 Fundamental measures.......................... 2 Description of symbols and notes ........ 2
2 2.1 2.2
Transport and storage ......................... 2 Transport .................................................. 2 Storage...................................................... 2
3 3.1 3.2 3.3 3.4
Mounting ................................................ 3 Mounting conditions............................... 3 Compressed-air port ............................... 4 Electrical connection .............................. 4 Checking the rotating direction ............ 5
4 4.1 4.2 4.3 4.4 4.5 4.6 4.7
Operation................................................ 7 Safety instructions .................................. 7 Switching the unit on ............................. 7 Start-up after an extended idle time..... 7 Weekly check ........................................... 7 Switching the unit off ............................. 7 Remote control ........................................ 8 Original HATLAPA accessories ............ 8
5 5.1 5.2 5.3
PROCON control .................................. 9 Operating elements ................................ 9 Display features....................................... 9 Input of parameters................................. 9
6 6.1 6.2 6.3 6.4 6.5 6.6
Inspection and servicing ................... 13 Safety instructions ................................ 13 Checking and topping up the oil level 13 Changing the oil .................................... 14 Changing oil filter.................................. 14 Draining the condensation water ....... 15 Cleaning the oil cooler and the compressed-air aftercooler.................. 15 Checking safety valve ........................... 15 Changing oil high-precision separator cartridge.................................................. 15 Checking and changing the suction filter cartridge ........................................ 15 Clean proportional controller nozzle. . 16 Cleaning drain restrictor ...................... 16 Checking and adjusting the V-belt ..... 16 Notes on systems equipped with water cooling system....................................... 17 Tighten the screw connections. .......... 17 Checking electric terminals................. 17 Relubricating / replacing motor mounting ................................................ 17
6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16
104482 HSC • 03/03
7
Maintenance schedule....................... 18
8 8.1 8.2 8.3
Trouble shooting ................................ 20 Malfunction, compressor generally.... 20 Malfunction, PROCON control............ 24 Warnings, PROCON control ................ 25
1
Operating instructions Fundamental safety instructions 1
Fundamental safety instructions
1.1
Designated use
2
Transport and storage
2.1
Transport
The compressor system is intended exclusively for the generation of compressed air. Any other use shall be considered an undesignated use.
• •
1.2 • • • • • •
Original 2011-06-21
• •
• •
1.3
Fundamental measures Never point compressed air at persons. Observe these operating instructions. Keep these operating instructions available at the location of use at all times. Please observe the regular maintenance intervals (refer to chapter 7 “Maintenance schedule”). Use original HATLAPA parts and approved operating material only. Do not use compressed air for breathing without corresponding treatment. Do not modify the system. Use mounting parts and devices downstream from the compressor which have been designed for the maximum operating overpressure of the compressor. In your capacity as proprietor, please ensure that all safety regulations are observed by the operating staff. Do not use the compressor as a climbing aid.
Description of symbols and notes
• • • • •
2.2
Danger Mortal danger caused by incorrect transport. Do not hold the compressor at its cladding elements as you lift it. Only use suitable lifting gear with the corresponding weight-bearing capacity (for data on weight, please refer to chapter “Technical annex”). Fasten and secure the system with belts at the corresponding points. Secure swivelling and loose parts. Transport the compressor by means of crane hooks, fork-lift truck and elevating truck only. Never remain under suspended loads. Depressurise the compressor prior to any transport.
Storage
Store the compressor in a dry location protected against weather influence. Ambient temperature: -10°C to +50°C. Please order the HATLAPA conservation instructions in case of storage of over six months. For information on recommissioning after an extended idle time, please refer to chapter 4.3.
Danger Mortal danger and risk of injury. Caution Damage to property. Information and tips.
2
104482 HSC • 03/03
Operating instructions Mounting 3
Mounting
3.1
Mounting conditions
!
Cooling and exhaust air
Check the compressor for damage during transport.
•
Ambient conditions
•
Danger Mortal danger and explosion hazard when caustic, inflammable or poisonous gases are drawn in. Do not operate the compressor in explosive surroundings or in the vicinity of open flames and flying sparks.
•
Danger Mortal danger and explosion hazard during suction. Ensure that the compressor takes in only clean air which is free from noxious constituents. Noxious substances are liable to accumulate in the lubricating oil of the compressor. They may cause explosions in the system and heavy damages. Do not allow objects or pieces of clothing of persons going past to be sucked in by the intake air flow.
1
Caution Wrong mounting will cause damage to the compressor. Ensure sufficient ventilation of the compressor room. Do not operate the compressor in the open. Systems with a capacity exceeding 40 kW must be installed in such a way that no combustible objects or materials are in the immediate proximity. Systems with a capacity exceeding 100 kW should be installed in a separate room.
2
The space between the compressor and the wall has to be at least 60 cm (cf. Fig. 3: Location). The compressor has to be easily accessible from all sides. The ambient temperature has to be between 3°C and 40°C.
C
Original 2011-06-21
• • •
•
A
D
E
Fig. 4: > 60 cm
+3°C - +40 °C
Fig. 3:
104482 HSC • 03/03
B
1 2 A B C D E
A
A
Room ventilation
Intake air Exhaust air Air inlet Air outlet Ventilation duct Exhaust fan Elastic connecting piece
Location
3
Operating instructions Mounting The overall length of all air intake and exhaust ducts must not exceed 4m; one baffle is permissible. In case of conduits exceeding this length or in case of several baffles, a booster fan must be installed. In this case, please contact your technical adviser.
•
For further information on the required ventilation cross sections, please refer to the Technical Annex. •
Ground !
Place the compressor on a horizontal and plane surface.
The ground has to have a suitable loadbearing capacity. HATLAPA offers special solutions for inclined surfaces.
Original 2011-06-21
In order to reduce vibrations, HATLAPA recommends rubber-metal connections.
3.2
Compressed-air port
The connection to the compressed-air ductwork system may be carried out only by trained experts or by staff members of HATLAPA Company.
•
Danger Danger of injury by pressure in the pipes. Vent the pipes to which the compressor is connected. Use a flexible hose to connect the compressor to the supply network. Thus, stress cracks and sound bridges are prevented.
•
•
Compressed-air lines, filters, aftercoolers and vessels must at their lowest spots be equipped with an outlet for the condensation water accumulated. These outlets must allow to observe the draining condensation water. Condensation water may contain oil! In draining the condensation water, all applicable regulations on the disposal of waste water must be complied with. Remove all securing devices before you start to install the conduits. Use only suitable connecting lines and couplings which are designed for the intended working pressure. Do not use any defect component. Supply lines must not be subjected to stress or tension.
Observe the technical data for the connection of compressed air (cf. chapter “Technical annex”).
3.3
Electrical connection
The connection to the electrical power system may be carried out only by adequately trained expert.
•
Danger Mortal danger caused by electric voltage but also by rotating wheels, Vbelts, and fan blades. Test runs are permissible only if all parts of the casing are closed (exception: check of the rotating direction).
Compressor systems have to be fitted with a power switch or a plug connection to interrupt the power supply. Compressor systems with a motor capacity of more than 3 kW or 16 Amps have to be fitted with a lockable power switch and upstream fuses. In this respect, please refer to the circuit diagram in the chapter titled “Technical annex” or in the switch cabinet as well as to the following connection conditions. Check and retighten where appropriate all electric terminals before first commissioning.
4
104482 HSC • 03/03
Operating instructions Mounting 3.4
Checking the rotating direction
•
! ! !
Open side cladding of the compressor. Please refer to chapter 4.2 titled “Switching the unit on”. Press the power switch, and immediately after this the emergency stop (see fig. 2: Operating elements). The correct rotating direction of the fan has been marked by an arrow on the fan cover. Change the poles of the electric connection of the motor in case of a wrong rotating direction.
Original 2011-06-21
!
Caution Fire hazard and damage to compressor in case of wrong polarisation of the motor (5 revolutions maximum in the wrong direction of rotation!). Carry out the check of the rotating direction as described below:
104482 HSC • 03/03
5
Operating instructions Mounting Electrical connection conditions The connection to the electrical power system may be carried out only by adequately trained expert. Caution Overvoltages and undervoltages must not exceed the 10% mark.
Original 2011-06-21
This unit is intended for operation on a power supply network with a maximum system impedance Zmax at the interconnection point (house service line), which is listed in the table below in dependence of the performance. The user shall have to ensure that the unit is operated only on a power supply network which meets these requirements. If and when necessary, the local power supply company can provide information on the system impedance.
Motor performance
400V-50Hz 3 ph Protection Motor rated cur- – stardelta rent starting
Protection – direct starting A
Motor performance
230V-50Hz 1 ph Protection Motor rated cur- – stardelta rent starting
kW
A
kW
A
1.1 1.5 2.2
2.6 3.5/4.1 5.0/6.0
6 10 16
1.1 1.5 2.2
2.6 3.5/4.1 5.0/6.0
6 10 16
3.0
6.6/8.1
16
3.0
6.6/8.1
16
4.0
8.5
16
20
4.0
8.5
16
5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0
11.5 15.5 22.5 30.0 36.0 43.0 58.0 68 81 99 134
20 25 35 50 50 63 80 80 100 125 160
5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0
11.5 15.5 22.5 30.0 36.0 43.0 58.0 68 81 99 134
20 25 35 50 50 63 80 80 100 125 160
A
A
Protection – direct starting A
20
Tab. 1: Characteristic value for the electrical connection The supply line cross sections provided are recommended values for a maximum 50m line length at 30°C. For fuse protection, use “slow-to-blow” or “gL” fuses. • 220/240 V systems require a three-core 1P/N/PE cable. • 380/400 V systems require a four-core 3P/PE cable for direct start. • 380/400 V systems require for star-delta starting a five-core supply line 3P/N/PE.
6
104482 HSC • 03/03
Operating instructions Operation 4
Operation
4.2
4.1
Safety instructions
!
•
Danger Mortal danger caused by sudden startup of the system. Systems which are in the standby operating mode are liable to start automatically at any time.
! ! ! !
• • • • •
Original 2011-06-21
•
• •
• • • • • • • • • • •
104482 HSC • 03/03
All parts installed behind the check valve (e. g. aftercooler, pressure switch) are not released automatically from pressure. Not all transmission lines are de-energised when the system is switched off! Before commissioning, ensure that no person can be injured by the starting compressor. Never point compressed air at persons. Do not use compressed air for breathing without corresponding treatment. Use mounting parts and devices downstream from the compressor which have been designed for the maximum operating pressure of the compressor. Do not reach into the rotating wheels when the compressor is operational. Touch the compressor system at the on and off switch only during and shortly after operation. Hot surface can cause severe injuries. Switch the compressor off immediately in case of faults. Keep combustible materials away from the compressor system. Operate the compressor only with suction filter and if all parts of the casing are closed. Operate the compressor only at the permissible operating pressure of the pressure reservoir. Tighten the screw connections of the pressure pipes. Wear tight-fitting work cloths when handling the compressor. Wear goggles and ear muffs when working with compressed air. Wear a hair net to protect long hair and remove any lose jewellery. Check the cables for damage in regular intervals. Keep domestic animals and children away from the compressor system. Switch the compressor off when not needed.
!
Switching the unit on Check oil level through oil gauge and top up the oil if and when necessary (refer to chapter 6.2 “Checking and topping up the oil level”). Switch on the power switch. Press power switch (see fig. 2: operating elements). Signal lamp indicates readiness for operation. Compressor starts and after approx. 10sec. starts load operation. Open ball valve.
In case of faults, please refer to chapter 8 titled “Trouble shooting” for more help.
4.3
Start-up after an extended idle time.
During an extended idle time, the complete oil content flows into the compressed air / oil reservoir. If this has happened, the screw compressor is not any more lubricated. ! ! !
Dismount intake regulator. Fill approx. 1 litre compressor oil into the air intake fitting. Mount intake regulator. Do not mix different types of oil. In choosing the oil you want to use, refer to the corresponding HATLAPA specifications (refer to chapter 6.2 “Checking and topping up the oil level“).
4.4 •
4.5 ! !
Weekly check Check oil level of the compressor (refer to chapter 6.2 “Checking and topping up the oil level“).
Switching the unit off Press circuit-breaking key “0” (see fig. 2: operating elements). Switch off power switch.
7
Operating instructions Operation 4.6
Remote control
All systems which are equipped with remote control must bear a clearly visible label reading as follows: “Warning! This system is remotely controlled and is liable to start at any time." In addition, persons operating remotely controlled systems must ensure that the system is not started during maintenance or repair work. For this, a corresponding information sign must be affixed to the remote control unit. ! ! ! !
4.7
Open ball valve. Press power switch (see fig. 2: operating elements). Signal lamp indicates readiness for operation. System is now ready to be operated via remote control.
Original HATLAPA accessories
Original 2011-06-21
HATLAPA offers you the following accessories: For more information, please refer to the HATLAPA price list or directly to HATLAPA.
Compressed-air filter To clean the compressed air for special applications.
Refrigeration or adsorption dryer To prevent faults of the compressed air ductwork system, compressed-air tools, instruments and controls caused by humid air.
Top sound insulation To reduce noise emissions.
Base load sequencer Intelligent higher-order control system to control several compressors depending on the actual compressed air consumption.
Speed regulator Adapts speed and thus also energy consumption of the screw compressor to the actual compressed air consumption.
Water-cooling system For application conditions under which the standard fan cooling is not sufficient.
Heat exchanger Free of charge energy derived from heat produced by the compressor during operation which is then available to other consumers.
For more information on these and other pneumatic accessories, please refer to HATLAPA. Our address is on the last page of these operating instructions.
Automatic condensation water drain To spare you the daily draining of condensation water.
Oil and water separator Is fitted downstream of the condensation water drain. The separated water can be removed directly into the sewer system.
Rubber-metal connection To reduce vibrations.
8
104482 HSC • 03/03
Operating instructions PROCON control 5
PROCON control
5.1
Operating elements
See fig. 2 PROCON control
5.2
•
•
Display features
Basic display
•
During normal operation, the display indicates both network pressure and final compression temperature as three-digit figures. In the event of pressure or temperature measurement failure, the corresponding field shows “- - -”. The load operation of the system is indicated through a dot following the network pressure value.
Original 2011-06-21
In the event of malfunction reports or warnings occurring, these will alternate with the analogue quantities in the pressure display every three seconds. Malfunction reports in the display start with an “E” followed by a two-digit malfunction code (refer to chapter 8.2 “Malfunction, PROCON control” and chapter 8.3 “Warnings, PROCON control”) whereas warnings start with an “A”. In addition, in case of malfunction a malfunction LED will light up; in case of a warning a warning LED will light up.
•
•
•
•
Line 3: Load operation hours. Load operation hours are indicated as five-digit figures. “L.“ will appear on the left side of the display (e. g. “ L.12 345“ for 12345h). Line 4: Air filter operating life. In the display “F1” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 5: Oil filter operating life. In the display “F2” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 6: Oil separator operating life. In the display “F3” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 7: Oil operating life. In the display “OIL” alternates with the corresponding operating life value. In addition, the maintenance LED flashes. Line 8: V-belt operating life. In the display “BE.” alternates with the corresponding operating life value. This line will appear only in case the V-belt is activated in the option menu. In addition, the maintenance LED flashes. Line 9: Software version, e. g. “PRO 1.00“ for Version 1.00.
Information menu !
!
!
•
•
104482 HSC • 03/03
To call up the first line of the information menu, keep key 6 (→) pressed for one second. The keys 4 and 5 (↑/↓) allow you to navigate within the menu structure. Press key 6 (→) to exit the menu; alternatively, the menu is also exited if no key has been pressed for 3 minutes. Line 1: System pressure indicator. The system pressure is displayed in place of the network pressure. “P2” will appear on the left side of the display. This line will appear only in case the system pressure input is activated in the option menu. In case an incorrect system pressure value has been obtained, the display will show “- - -”. Line 2: Hours of operation. Hours of operation are indicated as five-digit figures. “R.“ will appear on the left side of the display (e. g. “R.23 456“ for 23456h).
5.3
Input of parameters
Selection menu !
!
!
!
In order to enter parameters, keep key 7 (↵) pressed for three seconds. “COD.000” will appear in the display. Enter the code for the desired menu using the keys 4 and 5 (↑/↓). Confirm by pressing key 7 (↵), and the first parameter of the selected menu is displayed. In case an invalid code has been entered, or key 6 (→) has been pressed, the routine returns to the initial display.
Selection of parameters within a menu !
The keys 4 and 5 (↑/↓) allow you to navigate within the menu structure in the display modus.
9
Operating instructions PROCON control !
Press key 6 (→) to exit the menu; alternatively, the menu is also exited if no key has been pressed for 5 minutes.
Editing parameters within a menu !
!
!
!
Press key 7 (↵) to modify parameters. You are then in the edit mode. This is indicated by the corresponding parameter value flashing. The keys 4 and 5 (↑/↓) allow you now to modify the value. Press key 6 (→) to return to the display mode, and retain the previous value. Press key 7 (↵) to save the current value and to enter the next value that can be modified.
Original 2011-06-21
In the event values have been modified within one menu, storage of the new values is signalled through a horizontal bar (for one second).
Pressure control menu (Code 010) Name
Message
Minimum A1. ##.# network pressure
Maximum network pressure
A2. ##.#
Setting range
Factory setting
Between 5.0 bar and maximum network pressure Between minimum network pressure and system pressure
8.5 bar
10.0 bar
Oil filter operating life Oil separator operating life Oil operating life V-belt operating life Shutdown maintenance
C2.# ###
0-9999h
500*
C3.# ###
0-9999h
2000
C4.# ###
0-9999h
500*
C5.# ###
0-9999h
C6.
0=No 1=Yes
0 (inactive) No
#
Tab. 3: Maintenance menu *
only first maintenance interval; the remaining intervals are 2000h
The maintenance intervals can be specified between 0-9999h while the input „0“ means that this interval should not be edited. In this place only the target values of the maintenance intervals are indicated; please infer the actual count from the information provided in the initial display (refer to initial display in chapter 5.2 “Display features”). After a maintenance interval has been modified, the corresponding count is reset while the new set value is being applied. Thus the respective interval can start again, for instance after maintenance work has been completed. Use the “C6” parameter to decide whether the compressor should be shut down after the maintenance interval has been exceeded by more than 100h. After the compressor has been shut down this way, the operator can acknowledge this error message and start the compressor for another 100h.
Tab. 2: Pressure control menu
Maintenance menu (Code 020) Name
Message
Air filter C1.# ### operating life
10
Setting range
Factory setting
0-9999h
2000
104482 HSC • 03/03
Operating instructions PROCON control
Original 2011-06-21
Operating parameter menu (Code 030) Name
Message
Setting range
Factory setting
Base load sequencer operating mode Continuous operation Remote operation Re-starts automatically after power failure Power failure time Re-start delay
B1.
#
0=No 1=Yes
No
B2.
#
0=No 1=Yes
No
0=No 1=Yes 0=No 1=Yes
No
B5. ##
0-60s
1s
B6. ##
0-60s
0s
B3.
#
B4.
#
Tab. 4: Operating parameter menu
104482 HSC • 03/03
No
The pressure control is effected via an external contact during programmed operation of the base load sequencer. In case the remote control is activated the start-up is effected via an external contact. The control system reacts only to the positive signal edge for start-up of the device. If there is no input signal this means that the compressor is switched off. In this case you cannot use the keyboard to switch on or off the device. The “continuous operation” parameter allows to operate the compressor in the no-load operation mode and thus to prevent it from being switched off. You can specify two periods if the automatic restart after voltage breakdown has been activated. The power failure time specifies the maximum allowable period of voltage breakdown after which it is permitted to restart the device. If this value is set to “0”, the device can be restarted at any time. The re-start delay allows to prevent the compressor from restarting immediately after voltage recovery. This may be necessary to prevent several compressors connected to the mains network from starting simultaneously.
11
Operating instructions PROCON control Menu structure, customer menu Pressure control
Information °C 3s
bar
p2
00 .
. r23
456
°C 3s
System pressure (Option)
345
F1.
999
F2.
999
F3.
999
oil
999
cod
010
a1.
90 .
A2.
100 .
Cut-in pressure
Hours of operation
. L12
Maintenance intervals Operating parameter
bar
M
Load operation hours
Shut-off pressure
bar
COD
020
. c11
500
Air filter operating life
c2.
500
Oil filter operating life
. c31
500
3s
°C
bar
Cod
030
b1 .
0
b2.
0
b3.
0
b4.
0
b5.
1
b6.
0
Base load sequencer operation Continuous operation
Oil separator operating life Remote operation
Air filter operating life
Oil filter operating life
C4.
500
C5.
0
C6.
0
Oil operating life
V-belt operating life
Oil separator operating life
Disable maintenance
Oil operating life
Original 2011-06-21
3s
°C
Automatic restart
Power failure time
Re-start delay
Edit:
be
999
V-belt operating life
Edit mode Increase values
pro
. 100
Software version
Fig. 1:
12
Decrease values Apply value
Cancel: Return to the basic mode without retaining all previous values
Menu structure, customer menu
104482 HSC • 03/03
Operating instructions Inspection and servicing 6
Inspection and servicing
6.1
Safety instructions
6.2
The inspection and servicing may be carried out by experts or trained persons only. • • • • • •
Switch the compressor off for all servicing work, and protect the unit against unintentional operation. Prior to any servicing work set the power switch to off or remove the mains plug. Use original HATLAPA parts and approved operating material only. After having completed the servicing work tighten all screws again. Depressurise the compressor prior to any servicing work. Touch the compressor system at the on and off switch only during and shortly after operation. Permit the compressor to cool down prior to any servicing work. Hot surfaces can cause severe injuries.
Original 2011-06-21
Before commencement of work, the following steps must always be carried out. ! ! ! !
! !
!
!
104482 HSC • 03/03
Close cut-off valve at compressed air outlet 25 (see fig. 1: component overview). Shut down the system. Switch off power switch. Open slowly the screw plug of the compressed air aftercooler 26 to release air pressure. Wait until no more air exits the postcooler, and tighten the screw plug. Wait until the remaining system is released from pressure and has cooled down. Unscrew oil filler neck 18 by approx. 1 turn to check whether pressure has been released completely. Wait until no more air exits the oil filler neck 18, and tighten again oil plug.
Checking and topping up the oil level
• •
Danger Scalding hazard by draining hot oil. Slowly open the oil filler neck. Avoid skin contact with hot oil
2
1
Fig. 5: 1 2
Oil level indication
min. mark max. mark
Checking the oil level ! !
!
! ! !
Switch the compressor off and depressurise. Drain off the condensation water before you check the oil level (refer to chapter 6.5 “Draining the condensation water”). Unscrew oil filler neck 18 (see fig. 1: Component overview) by approx. 1 turn to check whether pressure has been released completely. Check oil level through oil gauge 17 (see fig. 1: component overview). The oil level has to be within the min. / max. level. Check whether the oil has a milky discoloration or contains water drops (for measures, please refer to chapter 8 titled “Trouble shooting / Milky colour of the oil, water drops in the oil”).
13
Operating instructions Inspection and servicing Topping up oil
6.3
Do not mix different types of oil. Exclusively use types of oil specified by HATLAPA. ! ! ! !
!
Switch the compressor off and depressurise. Carry out the above steps as described in the “Checking oil level” section. Remove oil filler neck 18. Slowly fill in the oil until the oil level as indicated by the oil gauge 17 is within the min. / max. range. Screw on the oil filler neck.
• •
!
Types of oil
Original 2011-06-21
The degree of viscosity of the oil chosen should be based on the ambient temperature according to ISO 3448. Ambient temperature 0 up to +25°C Permanently higher than 25°C Viscosity class Viscosity at 40 °C Point of ignition Pour point
ISO VG 46
ISO VG 68
At least 5°C below lowest ambient temperature.
Tab. 5: Types of oil We assume no warranty unless the lubricants used in our screw compressors show these essential characteristics.
14
!
! ! !
!
Switch the compressor off and depressurise. Place a suitable collecting vessel under the oil and condensation water drain valve 15. Open oil and condensation water drain valve 15 while it is at operating temperature. Drain the oil into the vessel. Close oil and condensation water drain valve 15. Open oil filler neck 18 and fill in the new oil slowly (refer to chapter 6.2 “Types of oil”) until the oil level as indicated by the oil gauge 17 is within the min. / max. range. Screw on the oil filler neck.
6.4
Changing oil filter
• •
41 up to 51 61 up to 75 mm²/s mm²/s > 200°C
Danger Scalding hazard by draining hot oil. Slowly open the oil filler neck. Avoid skin contact with hot oil Used oil has to be disposed of according to the local environmental regulations.
!
On account of the high stress the lubricating oil is exposed to in screw compressors with oil injection cooling, we recommend to use HATLAPA special purpose oils with AFS (anti foam system) additives showing an extremely good aging and water-repellent behaviour; these oils do not foam, and they are anticorrosive.
Changing the oil
Danger Scalding hazard by draining hot oil. Carefully and slowly remove the oil filter. Avoid skin contact with hot oil Use only new oil filters; you cannot clean a used oil filter. If you replace the oil filter while the oil circuit is filled, up to 2l oil can escape the system. Dispose of the oil filter according to the applicable local environmental regulations.
104482 HSC • 03/03
Operating instructions Inspection and servicing ! ! ! ! !
6.5
Place a suitable collecting vessel under the oil filter 24. Turn the oil filter left using chain pliers to screw it off. Clean the oil filter holder. Screw down the new oil filter until the gasket is firmly in place. Replace oil that has escaped by new oil (refer to chapter 6.2 “Checking and topping up the oil level“).
Drain the condensation water every week.
Original 2011-06-21
!
! !
6.6 !
6.7
Place a suitable collecting vessel under the oil and condensation water drain valve 15. Open oil and condensation water drain valve 15 while it is at operating temperature. Drain the condensation water into the vessel until pure oil escapes. Close oil and condensation water drain valve 15.
Cleaning the oil cooler and the compressed-air aftercooler. Blow compressed air through the cooling fins of the oil cooler 27 and of the compressed-air aftercooler 26 (see fig. 1: Component overview) from the inside of the machine until dust and deposits have disappeared.
Changing oil high-precision separator cartridge Use only a new oil high-precision separator cartridge; you cannot clean a used high precision separator cartridge. A small amount of oil can escape as you change the oil high-precision separator cartridge. Dispose of the oil high-precision separator cartridge according to the applicable local environmental regulations.
Draining the condensation water The condensation water contains oil and has to be disposed of according to the local environmental regulations.
!
6.8
!
! !
!
6.9 ! !
!
Turn the oil high-precision separator cartridge 3 (see fig. 1: Component overview) left using chain pliers to screw it off. Clean the oil high-precision separator cartridge holder. Oil slightly the O-ring and the gasket of the new oil high-precision separator cartridge. Screw down the new oil high-precision separator cartridge until the gasket is firmly in place.
Checking and changing the suction filter cartridge Remove the cover of the suction filter 23 (see fig. 1: Component overview). In case of severe soiling, immediately replace the suction filter (cf. list of HATLAPA spare parts in the chapter titled “Technical annex”). Refit the cover of the suction filter.
Checking safety valve The safety valve 11 (see fig. 1: Component overview) is secured with a seal which must not be removed.
!
104482 HSC • 03/03
Lift slightly the valve cap to check the function.
15
Operating instructions Inspection and servicing 6.10 Clean proportional controller nozzle. Applies only to systems equipped with proportional control.
6.12 Checking and adjusting the Vbelt HSC up to 7.5 kW
5 1
F
2
Original 2011-06-21
Fig. 6:
Proportional controller
1 2
Nozzle Hose connection
!
Remove plastic hose connection of the proportional controller 7 (see. fig. 1: Component overview). Unscrew the nozzle behind. Clean nozzle, controller and hose. Screw in the nozzle. Fix the hose connection again.
! ! ! !
Fig. 7: Checking V-belt tension HSC up to 7.5 kW ! !
! ! ! !
Remove the drain line 9 from the drain restrictor. Unscrew the restrictor from the casing of the compressor 1. Clean the hole of the restrictor. Mount and connect the restrictor again.
3
1
Fig. 8: HSC V-belt tensioning device up to 7.5 kW 1 2 3 4
Motor flange screws Adjusting screw Lock nut Nut
!
Slightly loosen motor flange screws 1. Loosen lock nut 3 at adjusting screw 2. Adjust V-belt tension through adjusting screw 2 and tighten lock nut 3 again. Tighten motor flange screws 1.
! ! !
16
Apply a perpendicular force between 25 N and 35 N in point 1 using a dynamometer. In doing so, the belt must give approx. 5mm. 2
6.11 Cleaning drain restrictor The drain restrictor is where the drain line 9 enters the casing of the compressor 1 (see fig. 1: Component overview).
1
104482 HSC • 03/03
Operating instructions Inspection and servicing HSC up to 7.5 kW
6.14 Tighten the screw connections. After first commissioning, check and – if required – retighten all screws.
3 ! !
4 2
Tighten all screw connections in regular intervals. In doing so, observe the torque (cf. Tab.: 6: Torques).
Screw
Maximum torque
M8 M 10 M 12
25 Nm 50 Nm 85 Nm
1
Fig. 9: HSC V-belt tensioning device over 7.5 kW 1 2 3 4
Bottom adjusting nut Top adjusting nut Lock ring Square pin
Original 2011-06-21
The V-belt tension must be corrected if the lock ring 3 touches the square pin 4. ! !
!
Loosen the bottom adjusting nut 1. Unscrew the top adjusting nut 2 until the distance between the lock ring 3 and the square pin 4 is 10-12mm. Tighten the bottom adjusting nut 1.
Tab. 6: Torques
6.15 Checking electric terminals !
6.16 Relubricating / replacing motor mounting !
6.13 Notes on systems equipped with water cooling system
Check and – if required – tighten all electric terminals regularly.
Relubricate or replace the motor mounting as specified by the manufacturer (refer to the name plate of the motor).
In water-cooled screw compressors, the oil / air cooler is replaced by a plate heat exchanger, and the air-to-air cooler is replaced by a tube bundle heat exchanger. You can use fresh water as cooling water. It is recommended to install a sand and a dirt filter before the cooling water preliminary flow.
104482 HSC • 03/03
17
Operating instructions Maintenance schedule 7
Maintenance schedule
Every week
500 h1
2 000h1
4 000 h1
6 000h1
8 000 h1
10 000 h1
After first commissioning
!
!
!
!
!
–
Drain the condensation water (cf. chapter 6.5).
!
!
!
!
!
!
–
Check the oil level (cf. chapter 6.2).
!
!
!
!
!
!
–
!
!
!
!
!
!
–
"
!
!
!
!
!
–
!
!
!
!
!
–
!
–
Interval
!
Application
Check the rotating direction (cf. chapter 3.4).
Original 2011-06-21
Before first commissioning
The intervals mentioned are experimental values. They can differ considerably depending on the application conditions.
Check the V-belt (cf. chapter 6.12).
!
!
Clean the proportional controller nozzle (cf. chapter 6.12). Change oil (cf. chapter 6.3), mineral (factoryfilled). Change oil (cf. chapter 6.3), synthetic.
!
Replace oil filter (cf. chapter 6.4).
!
!
!
!
!
–
Check safety valves (cf. chapter 6.7).
!
!
!
!
!
–
!
!
!
!
–
"
!
!
!
!
–
"
!
Clean the drain restrictor (cf. chapter 6.11). Clean the oil-aftercooler (cf. chapter 6.6). Check the suction filter cartridge² (cf. chapter 6.9). Change the suction filter cartridge² (cf. chapter 6.9). Change the oil highprecision separator cartridge (cf. chapter 6.8). Tighten the screw connections (cf. chapter 6.14).
18
!
!
–
!
"
!
!
–
"
!
!
–
!
–
104482 HSC • 03/03
Operating instructions Maintenance schedule Check the electric terminals (cf. chapter 6.15) Relubricate/replace motor mounting (cf. chapter 6.16)
!
–
! !
–
Measures carried out on (date):
Original 2011-06-21
Measures carried out by (name):
Key: ! Measure to be carried out: " Measure to take whenever required. – Check at the manufacturer's works. 1 The required maintenance and inspection measures must be carried out on a yearly basis if the hours of operation provided are not reached within a year’s period. 2 Check daily in dusty conditions and replace, if and when necessary.
104482 HSC • 03/03
19
Operating instructions Trouble shooting 8
Trouble shooting
8.1
Malfunction, compressor generally Danger Trouble shooting may be carried out only by trained experts or by staff members of HATLAPA Company. In all actions, please observe the fundamental safety instructions (cf. chapter 1), the safety instructions for operation (cf. chapter 4), and the safety instructions for maintenance (cf. chapter 6).
The compressor does not start up. Potential reasons
Actions
No connection to network. Fuse has blown.
• •
Original 2011-06-21
Network pressure is over cut-in pressure. Defect in the pressure detector or cable break. The motor has broken down. Temperature detector of the motor gives a signal.
• • • • • • •
Check the connection to the mains. Check the electric cable, switching units and the motor. Use time-lag fuses only. Replace the fuse. Reduce the pressure in the network. Check cable, or replace pressure detector. Check the electric system and the cables. Replace the motor. Refer to table “Temperature detector of the motor gives a signal”.
Temperature detector of the motor gives a signal. Potential reasons
Actions
Fault at the electric connection.
•
Ambient temperature is too high. Damage on the compressor Motor gets too hot due to high switching frequency. Pressure detector has been set wrongly. The clamping connections have come lose.
20
•
Check the electric connection for undervoltage and phase failure. Check the conductor cross section. Improve the room ventilation. Select a cooler location. Check bearing of the compressor and gear set. Check the pressure switching points.
• •
Check the pressure switching points. Retighten the clamping connections.
• • • •
104482 HSC • 03/03
Operating instructions Trouble shooting The switching frequency of the motor is too high. Potential reasons
Actions
The compressed-air reservoir is too small. Pressure detector has been set wrongly. Too much condensation water in the compressed-air reservoir / compressed-air ductwork system.
• • • •
Use a larger compressed-air reservoir. Check the pressure switching points. Drain the condensation water (refer to chapter 6.5). As a preventive measure, fit an automatic condensation water drain system (HATLAPA accessories).
Low delivery – the setpoint pressure is not made. Potential reasons
Actions
The suction filter is soiled.
• • • • • • •
Pipes and fittings are leaking.
Original 2011-06-21
Pressure detector has been set wrongly. The air demand is higher than the delivery volume of the compressor.
Clean the suction filter. Change the filter cartridge. Tighten the screws and fittings. Replace the seals. Check the pressure switching points. Check the air demand. Expand the compressed air supply.
The compressor turns too hot. Potential reasons
Actions
Ambient temperature is too high.
• • •
The cooling air volume is not available or too low.
•
104482 HSC • 03/03
The ultimate pressure is too high. Oil level too low.
• •
Oil cooler is dirty. Oil thermostat / thermostat is defective (only in case of water cooling)
• •
Improve the room ventilation. Select a cooler location. The space between fan and wall is to small (cf. chapter 3.1 “Mounting conditions”). Check cooler for dirt, and clean if necessary. Check the pressure switching points. Top up oil (refer to chapter 6.2 'Checking and topping up the oil level'). Clean the oil cooler. Replace oil thermostat / thermostat.
21
Operating instructions Trouble shooting Milky colour of oil, water drops in the oil. Potential reasons
Actions
Water accumulation in the oil vessel (operating temperature is not reached because of too short operation time)
• • • • •
Water accumulation in the oil vessel (caused by humid conditions).
• •
Change the oil immediately. Retrofit a standby heating (HATLAPA accessory item). Select warmer location. Check design of the compressor. Contact manufacturer as to oil specifications. Change the oil immediately. Select dry location.
The oil consumption is too high. Potential reasons
Actions
The wrong oil has been used.
•
Original 2011-06-21
• The compressor is too hot. Oil escapes through oil high-precision separa- • tor cartridge. •
Check the type of oil (cf. chapter 6.2 “Types of oil”), and replace, if and when necessary. See Table “Compressor turns too hot”. Check suction – compressor stage. Check oil grade.
Air escapes when the compressor is at rest Potential reasons
Actions
Pressure control valve is defective.
•
Replace pressure control valve.
The compressor is not relieved when switched off. Potential reasons
Actions
Pressure detector or relief valve is defective.
•
Check pressure detector and relief valve at intake regulator and replace if necessary.
The system shuts suddenly down
22
Potential reasons
Actions
Oil level too low.
•
Oil filter is clogged.
•
Refill oil (refer to chapter 6.2 'Checking and topping up the oil level'). Replace oil filter cartridge.
104482 HSC • 03/03
Operating instructions Trouble shooting System fails to shift to no-load operation or fails to shut down. Potential reasons
Actions
Pressure control valve is defective.
•
Replace pressure control valve.
Original 2011-06-21
Safety valve blows off Potential reasons
Actions
Pressure detector is set at a too high rate. Pressure sensor is defect. Safety valve is defective. Suction stop valve does not close completely. Solenoid valve is defective. Oil high-precision separator cartridge is used up. Proportional controller nozzle is clogged (only with proportional control).
• • • • • • •
Correct settings of pressure sensor. Replace pressure sensor. Replace safety valve. Check springs of the suction stop valve. Replace solenoid valve. Replace oil high-precision separator cartridge. Clean proportional controller nozzle.
System is operating but is producing no pressure Potential reasons
Actions
Membrane in the adjust cylinder of the reduc- • ing damper is defective (depending on the type of compressor) • The relief valve is defective. • Pressure control valve is leaky.
Replace membrane and check control pressure in the pressure control valve. Replace relief valve. Replace pressure control valve.
Abnormal noises Potential reasons
Actions
“Whistling” sound caused by compressed air escaping the supply network, fittings etc.
• • • • •
The safety valve is “crackling”.
Fan is knocking. Grinding noises
• • •
104482 HSC • 03/03
Remedy leaking points. Replace the seals. Tighten the screw connections. Check pressure settings. Check and replace if necessary safety valve. Check whether the fan does not scrape. Damage in the mounting, compressor needs repair. Damage in the mounting, motor needs repair (HATLAPA service).
23
Operating instructions Trouble shooting 8.2
Malfunction, PROCON control Any malfunction will cause the compressor to shut down. This will last until the cause of the malfunction is eliminated and the corresponding message is acknowledged:
Original 2011-06-21
• •
24
Press key 6 (→) to enter the basic mode. Keep then both keys 4 and 5 (↑/↓) pressed for at least 2 seconds.
Message
Type of malfunction
Cause
E01
Final temperature
E02
Emergency stop
E03
Temperature of the motor.
E04 E05
Direction of rotation Start temperature
E06 E07
Development of system pressure Excess pressure
E08 E09
Temperature sensor Network pressure sensor
E10
System pressure sensor
E11
Shutdown maintenance
ErE
EEPROM parameter
ErA
EEPROM adjustment
The value set under “Final temperature error” has been reached or exceeded. Emergency stop key 4 has been pressed; or cable break. The temperature of the motor winding is too high; or cable break. Wrong direction of rotation; or cable break. The final temperature is not higher than the value set under “Start temperature”. The system pressure has not been developed within the set period. V-belt may have broken. The maximum allowable system pressure has been exceeded. Defect in the temperature sensor or cable break. Defect in the network pressure detector or cable break. When parameter “System pressure sensor” = 1 and system pressure sensor is defective; or cable break. At least one maintenance interval has been exceeded by more than 100h and parameter active. At least one parameter is outside the valid setting range or EEPROM is defective. Adjusted values of the analogue sensors are incorrect.
104482 HSC • 03/03
Operating instructions Trouble shooting 8.3
Warnings, PROCON control In case of a warning, the compressor is not shut down automatically. The message is acknowledged in the same fashion as with malfunction.
Message
Type of malfunction
Cause
A01
Final temperature
A021
Air filter differential pressure Oil filter differential pressure Separator differential pressure Air filter service life Oil service life Oil filter service life Separator service life V-belt service life
The value set under “Final temperature error” (-5°C) has been reached or exceeded. If Error final temperature is active the warning is reset automatically. Air filter is clogged; or cable break.
A03 A041
Original 2011-06-21
A11 A12 A13 A14 A15 1
104482 HSC • 03/03
Oil filter is clogged; or cable break. Defect in the oil separator; or cable break. Maintenance interval for the air filter has elapsed. Maintenance interval for the oil has elapsed. Maintenance interval for the oil filter has elapsed. Maintenance interval for the separator has elapsed. Maintenance interval for the V-belt has elapsed.
Optional
25
104482 HSC •
03/03 # We reserve the right for technical changes.
Original 2011-06-21 HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen Telefon: ++49 4122 711- 0 Telefax: ++49 4122 711 - 104 eMail
[email protected] Internet www.hatlapa.de
Parts List Screw Compressors
HSC 15
Original 2011-06-21
HSC 11
Building Year: 200_____
Serial No.:______________________________
HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen ++49 4122 711- 0, FAX ++49 4122 711 – 104
06/05
Abluft Outgoing air
Zuleitungsquerschnitt Cable cross section
N
mm2
23
35
5G6
HSC 15
30
50
5G10
Z Y
P S B
R L
M
D F
m
HSC 11
334
11
6
2200
4
HSC 15
346
15
6
3000
4
Ab einer Kanallänge von 4 m (Summe aus Ansaugkanal und Abluftkanal) wird der Einsatz eines Ventilators notwendig. Dieser muß ebenfalls bei dem vorgegebenen Kühlluftvolumenstrom eine Förderdifferenz von ca. 80-100 Pa erreichen. From a channel lenght of 4m (sum from intake port and air discharge channel) a ventilator will be necessary. This one must also reach, with the given air-cooling flow capacity, a delivery difference of approx. 80-100 Pa.
G-Druckluftanschluß Outlet compressed air Y-Netzanschluß Cable inlet Z-Kondensatablaß Condensation water drain
Abmessungen / Measurements
40 mm Rahmen
schallgedämpft Abmessungen / Noise protected Measurement
Type
A mm
C mm
805 x 695 x 1170 160
575
L mm
B mm
H mm
F mm
K mm
600 min.
m3/h
C
l
600 min.
Zuluft Incoming air
max. Kanallänge max. Channel lenght
kW
Kühlluftmenge Cool air flow
kg
Ölfüllung Oil filling
Type
Motorleistung Motor capacity
Kühlluftbedarf / Required cooling air
Gewicht Weight
Original 2011-06-21
Der elektrische Anschluß und die Schutzmaßnahmen sind nach VDE und gemäß den Zusatzvorschriften des jeweiligen Elektrizitätswerkes von einer autorisierten Fachkraft auszuführen. Die angegebenen Zuleitungsquerschnitte sind Richtwerte für eine max. Leitungslänge von 50m bei einer Temperatur von 30°C. The electric connection and the protecting measures have to be carried out by an authorized skilled specialist from the relevant power station, according to the VDE and the additional regulations. The mentioned sectional drawings of the incoming supply are guidelines for a max. line lenght of 50m with a temperature of 30°C.
T
HSC 11
U
A
G
I
A
E
H
Type
Sicherung (träge) Slow fuse
Nennstrom 400V (3) Rated current
Elektrischer Anschluß / Electrical connection
R mm
S mm
710
595
D mm
T mm
60
15
P mm
U mm
A
Werkstoff / Halbzeug / DIN
E mm
G
I mm
Y Pg
M mm
N mm
670
21
200
265 1/4"
Z Modell Nr. / Werkzeug Nr.
HSC 11 410
--
105 770
90
1"
Buchstabe
HSC 15
Maßstab
Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
17.2.03
Name
Zeichn.Nr.
Küster
HSC 11/15
6980000
Name
Original 2011-06-21
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 11/15
13.01.03
Name
Küster
Zeichn.Nr.
6980001
Compressor-motor cpl.
Name
Original 2011-06-21
Pos.
pcs.
101 101 102 103 105 106 107 108 109 111 113 113 116 117 117 118 119 119 120 121 130 131 131 132 134 134 135 136 137 137 139 140
1 1 4 4 4 4 1 2 2 2 1 1 1 1 1 3 3 3 3 3 1 1 1 4 1 1 1 1 1 1 1 1
Description DS-Motor 11kW DS-Motor 15kW vibration dampers Hexagon bolt Wheel disc Nut Motor plate Hexagon bolt Spring washer Nut Fan belt disc 11kW Fan belt disc 15kW Fan hub Fan complete 11kW Fan complete 15kW set screw Fan blade 11kW Fan blade 15kW Hexagon bolt Spring washer screw compressor block Clamping lever 11kW Clamping lever 15kW Cylinder screw Pin 11kW Pin 15kW Compression spring Screw Pin 11kW Pin 15kW Compressor disc 7,5 bar 11 kW Compressor disc 10bar 11kW
Order-No.
Pos.
pcs.
764038 764039 757102 700250 701407 703103 6980107 700243 7035070 703106 717601 717600 6980116 104743 104745 701350 104744 104746 700204 703512 765033 69151310 69271311 701018 6914134 6927134 6637480 6914136 6914137 69271371 6970139 6970140
140 141 141 142 142 145 145 145 145 145 145 145 151 155 155 155.9 155.9 156 156 157 157 160 161 161 162 163 164 165 166 166 168 169
1 1 1 1 1 2 2 2 2 3 3 3 1 1 1 1 1 2 2 1 1 3 1 1 1 1 1 1 1 1 1 1
Description
Order-No.
Compressor disc 10bar 15kW Compressor disc 13bar 11kW Compressor disc 13bar 15kW Compressor disc 15bar 11kW Compressor disc 15bar 15kW Fan belt 7,5bar 11kW Fan belt 10bar 11kW Fan belt 13bar 11kW Fan belt 15bar 11kW Fan belt 10bar 15kW Fan belt 13bar 15kW Fan belt 15bar 15kW Clamping Clamping roll 11kW Clamping roll 15kW Clamping roll complete 11kW Clamping roll complete 15kW Ball bearing 11kW Ball bearing 15kW Lock ring 11kW Lock ring 15kW Nut Disc 11kW Disc 15kW Wheel disc Under leg washer Lock nut Lock ring Lock ring 11kW Lock ring 15kW Cylinder screw Disc
6980140 6970141 6980141 6970142 6980142 707579 707524 707567 707467 707598 707593 707593 6927151 6613155 69141551 66131559 69141559 705062 705063 704109 704107 703104 705393 705383 701409 703413 703312 704011 704008 704018 700822 703423
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 11/15
13.01.03
Name
Küster
Zeichn.Nr.
6980001
Compressor-motor cpl.
Name
Original 2011-06-21
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 11/15
13.01.03
Name
Küster
Zeichn.Nr.
6980002
Frame and noise cover
Name
pcs.
10 201 210 211 212 213 214 215 216 217
1 1 1 4 4 4 4 1 1 1
Description Shield Frame complete Frame rubber base Cylinder screw Cylinder screw Spring disc Sidepanel front Sidepanel right Sidepanel left
Order-No.
Pos.
pcs.
15030014 6980201 6980210 708805 700820 700822 703604 6980215 6980216 6980217
218 219 220 221 222 222 223 224 228 230
1 1 1 1 1 1 6 6 4 1
Description
Order-No.
ventilation flap cover plate key to the control cubicle protective grid Wall ring 11kW Wall ring 15kW Nut Cylinder screw Cylinder screw Cable connection
6980218 6980219 770051 715814 6975224 6980224 703102 700822 701004 762014
Original 2011-06-21
Pos.
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 11/15
13.01.03
Name
Küster
Zeichn.Nr.
6980002
Frame and noise cover
Name
434
431 427 467
Original 2011-06-21
437 305 304 303
308 306
302
300 309 312
307
313
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
09.06.05
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
HSC 11/15
Name
Küster
Zeichn.Nr.
108966
Electric-control Procon
Name
pcs.
3 3 300 302 303 304 305 306 307
1 1 1 1 1 1 1 1 1
Description Assembly control PROCON kpl. 400V Assembly control PROCON kpl. 440V Control cubicle Emergency stop PROCON control Covering cap Cable form Front foil for Procon control Adhesive label
Order-No.
Pos.
pcs.
108971 108966 6980300 775105 775045 7750451 7750453 7750452 6970307
308 309 312 313 427 431 434 437 467
6 1 1 1 1 1 1 1 1
Description
Order-No.
Cylinder screw DIN 84 M4x10 Sealing rubber profile power switch ammeter Temperature sensor Coupling Screw connection Pressure detector Reducer plug
702012 708825 108864 107077 775050 775073 752003 775048 6913467
Original 2011-06-21
Pos.
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
09.06.05
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
HSC 11/15
Name
Küster
Zeichn.Nr.
108966
Electric-control Procon
Name
601 610 446 409 408
497
447 470 478 410
439
498
444
Original 2011-06-21
466
440
499 464 457
526 527
486
448
469 520
468
522
458 459
408
521
460 500 543 545 548 Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
7/97
Name
Küster
Zeichn.Nr.
Name
6980004
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
Armatures-tubing, Separation system, Cooling system HSC 11/15
pcs.
408 409 410 434 435 436 439 440 444 446 447 448 457 458 459 460 464 466 468
2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Description
Order-No.
Pos.
pcs.
752057 711801 6970410 752003 705526 101423 706807 752139 752040 706343 6980447 706800 751208 752017 752148 6970460 6613464 755237 721201
469 470 478 478 486 497 498 499 500 520 521 526 527 543 545 548 601 610
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Screw connection Pressure control valve Separator compl. Screw connection Screw connection Hose opt. Seal ring Cu Screw connection Screw connection Double nipple Pipe Ø18 Seal ring Cu G1/8" Non-return valve Screw connection Screw connection Screw connection Restrictor Hose non-return valve
Description
Order-No.
Screw connection Oil temperature controller compl. Oil filter - 7,5/10 bar Oil filter - 13 bar/ 15 bar Screw connection Pipe Pneumatic pipe Pneumatic pipe Container 8,5 l Screw connection Screw connection Oil filler plug Seal ring AI G1" Cone cock Angle G 3/(" oil drain hose Combi-Cooler Screw
752107 6613470 758101 758102 752094 6980497 6980498 6980499 6980500 6980520 752001 6633551 703705 751601 705833 107175 102521 702979
Original 2011-06-21
Pos.
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
7/97
Name
Küster
Zeichn.Nr.
Name
6980004
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
Armatures-tubing, Separation system, Cooling system HSC 11/15
539
455
Original 2011-06-21
405
454
406
421 424 465
443 467 468
411
442
449
443
463 462
452
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr.
423
Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 4-15
5.11.02
Name
Küster
Zeichn.Nr.
6970410
Separator cpl.
Name
pcs.
410 405 406 411 421 423 424 442 443 449
1 4 4 1 1 1 1 1 2 1
Description Separator Cylinder screw DIN912 M10x80 Wheel disc DIN6797 J10,5 Valve housing Lock ring DIN471 A16 Seal O-Ring Emergency valve Seal ring Screw connection
Order-No.
Pos.
pcs.
6970410 701027 701407 6913411 704007 6913505 707753 751032 703701 752001
452 454 455 462 463 465 467 468 539
1 1 1 1 1 1 1 1 1
Description
Order-No.
Screw connection Double nipple Pipe Screw Seal ring Screw Screw Seal ring air/oil separator box
752057 6913454 6913455 705500 703700 705522 705526 703702 758160
Original 2011-06-21
Pos.
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 4-15
5.11.02
Name
Küster
Zeichn.Nr.
6970410
Separator cpl.
Name
472 482
473
489
484
480 481
483
493
Original 2011-06-21
494 495
488
476
477
484 478
479
Werkstoff / Halbzeug / DIN
mit 55°-Einsatz Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 4-15
12.10.00
Name
Küster
Zeichn.Nr.
6613470
Oil-thermostat cpl.
Name
pcs.
470 472 473 476 477 478 478 479 480
1 1 1 1 1 1 1 4 1
Description Oil thermostat compl. O-ring Inlet for Oil thermostat compl. Valve housing Double nipple Oil filter 7,5/10 bar Oil filter 13/15 bar Cylinder screw DIN912 M6x75 Compression spring
Order-No.
Pos.
6613470 707703 757817 6613476 6633477 758102 758101 701020 6613480
481 482 483 484 488 489 493 494 495
Description
Order-No.
Piston Cylinder screw O-ring Spring disc Screw connection Screw connection Cap Screw Seal ring
6613481 701006 707753 703605 752107 752112 6613493 705500 703700
Original 2011-06-21
Pos.
Werkstoff / Halbzeug / DIN
mit 55°-Einsatz Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Die Maße werden besonders geprüft Ersatz für
Datum Datum
Gez. Gepr.
Benennung
Abmaß
Oberflächenbehandlung
Änderung
HSC 4-15
12.10.00
Name
Küster
Zeichn.Nr.
6613470
Oil-thermostat cpl.
Name
730 709 738
729 745
731
728 726.1 727 726
720
Original 2011-06-21
733
719
708
707
705
703
717
725 702
735
730
701 750
711
714
713
716
715
712
704
710
706
730 737 738 725
721
736
739
722
732
740
724 Werkstoff / Halbzeug / DIN
752
Modell Nr. / Werkzeug Nr.
718
Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
23.01.03
Name
Küster
Zeichn.Nr.
Name
6913700
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
Suction regulator without proportional control HSC 4-15kW
Original 2011-06-21
Pos.
pcs.
700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 718 717 719 720 721 722 724 725
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 1 2
Description Suction controller Suction body Cylinder Holder O-ring Compression spring Seal 15x22x5 Seal 20x30x7 Piston Restrictor Compression spring Lock ring Valve cone Valve ring O-Ring 10x2,5 O-Ring 31,35x3,53 Steel ball Seal Lock ring Cylinder screw Spring disc Hexagon bolt Spring disc Putting nipple Double nipple
Order-No.
Pos.
6913700 6913701 6613702 6613703 707622 6613705 707867 708439 66137081 6913709 6613710 704112 6613712 6633713 707608 707751 707304 6913505 704108 701016 703605 700203 703605 2707099 706340
726 7261 727 728 729 730 731 732 733 735 736 737 738 739 740 745 750 752 750 752 750 752 790
Description
Order-No.
Cap Relief valve complete Membrane Relief valve complete Cylinder screw Screw connection Screw connection Plastic pipe Plastic pipe Plastic pipe Tee coupling Sleeve Seal ring Solenoid valve Plastic pipe Spring disc Air filter with set Filter set Air filter with set Filter set Air filter Filter set Maintenance set incl. 704,705,706,707,710,715,718,727
66137254 69157260 66137252 66137251 701004 707322 707372 100874 100874 100874 707321 6633737 703700 7054071 100874 703606 708975 758198 708976 708977 708988 758022 69137901
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
23.01.03
Name
Küster
Zeichn.Nr.
Name
6913700
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
Suction regulator without proportional control HSC 4-15kW
736 724
740
730
739
732 733
730
731
709 738
745 Original 2011-06-21
742
731
741
729 728 727 726
726.1
738
724
734
720
705
719
723
735
708
746
725
702
725
724
730
731 750
711
714
713
716
715
712
704
703
717
707
710
706 748
747
721 722 Werkstoff / Halbzeug / DIN
701
Modell Nr. / Werkzeug Nr.
752 Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Buchstabe
718
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Maßstab Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
23.01.03
Name
Küster
Zeichn.Nr.
Name
69137001
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
Suction regulator with proportional control HSC 4-15kW
Original 2011-06-21
Pos.
pcs.
700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 7261
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 1 3 2 1 1
Description
Order-No.
Pos.
pcs.
Suction controller complete Suction body Cylinder Holder O-Ring 40x3 Compression spring Seal Seal Piston Restrictor Compression spring Emergency ring Valve cone Valve ring O-Ring 10x2,5 O-Ring 31,35x3,53 Steel ball Emergency ring Seal Cylinder screw Spring disc Hexagon bolt Spring disc Seal Putting nippple Double nipple Cap Relief valve complete
69137001 6913701 6613702 6613703 707622 6613705 707867 708439 66137081 6913709 6613710 704112 6613712 6633713 707608 707751 707304 704108 6913505 701016 703605 700203 703605 6633736 2707099 706340 66137254 69157260
727 728 729 730 731 732 733 734 735 736 738 739 740 741 742 745 746 747 748 750 752 750 752 750 752
1 1 4 4 3 1 1 1 1 1 2 1 1 1 1 4 1 1 1 1 1 1 1 1 1
790
1
Description
Order-No.
Membrane Relief valve complete Cylinder screw In screw connection Angle putting connection Plastic pipe Plastic pipe Plastic pipe Plastic pipe Tee coupling Seal ring Solenoid valve Plastic pipe Adapter Putting nippple Spring disc Reduce plug Connecting screw Seal ring Air filter with set Air filter with set Air filter Air filter with set Air filter Air filter with set Maintenance set incl. 704,705,706,707,710,715,718,727
66137252 66137251 701004 707322 707320 100874 100874 100874 100874 707321 703700 7054071 100874 6913741 27070991 703606 8759 705500 703700 708975 758198 708976 708977 708988 758022 69137901
Werkstoff / Halbzeug / DIN
Modell Nr. / Werkzeug Nr. Buchstabe
Maßstab Allgemeintoleranzen für Schweißkonstruktionen DIN 8570 für Längenmaße Genauigkeitsgrad
A B C
l in mm bis 30
±1 ±1 ±1
Winkelmaße
Nennbereich l über 30 bis 120
über 120 bis 315
über 315 bis 1000
±1 ±2 ±3
±1 ±2 ±4
±2 ±3 ±6
a in ° und ' für Schenkellänge
über 1000 bis 2000
über 2000 bis 4000
bis 315
über 315 bis 1000
±3 ±4 ±8
±4 ±6 ±11
±20' ±45' ±1°
±15' ±30' ±45'
über 1000
±10' ±20' ±30'
Diese Zeichnung darf nur zu den Zwecken benutzt werden, wozu sie dem Empfänger anvertraut ist, sie darf weder vervielfältigt, noch dritten Personen, insbesondere Konkurenzfirmen ohne unsere Erlaubnis mitgeteilt oder zugänglich gemacht werden.
Zerspanende Fertigung: Zulässige Abweichung für Maße ohne Toleranzangabe in mm DIN 2768 Genauigkeitsgrad fein mittel grob sehr grob
Nennbereiche (mm) der Freimaße über 3 bis 6 über 0,5 bis 3
±0,05 ±0,1 ±0,2
±0,05 ±0,1 ±0,3 ±0,5
über 6 bis 30
±0,1 ±0,2 ±0,5 ±1
über 30 bis 120
±0,15 ±0,3 ±0,8 ±1,5
über 120 bis 400
über 400 bis 1000
über 1000 bis 2000
über 2000 bis 4000
±0,2 ±0,5 ±1,2 ±2,5
±0,3 ±0,8 ±2 ±4
±0,5 ±1,2 ±3 ±6
±2 ±4 ±8
Paßmaß
Datum Datum
Gez. Gepr.
23.01.03
Name
Küster
Zeichn.Nr.
Name
69137001
Benennung
Abmaß
Oberflächenbehandlung
Änderung
Die Maße werden besonders geprüft Ersatz für
Suction regulator with proportional control HSC 4-15kW
Schaltpläne Schraubenkompressoren Connection diagram - screw compressor
4 – 37
Original 2011-06-21
HSC
Jahr/Building Year: 200_____
Serien Nr/SerialNo.:______________
HATLAPA Uetersener Maschinenfabrik GmbH & Co. Tornescher Weg 5 – 7, 25436 Uetersen ++49 4122 711- 0, FAX ++49 4122 711 – 104
E03071606 b - 06/05
1
2
3
4
Frequence 5G4
5G6
50A
5G10
29,3A
06.06.05
Datum
"a"
Änderung
Name
Küster
Hall
Bearb.
Norm
Gepr.
06/05
Datum
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW Ers.d.
Ben.
E990903
775089
22,0 kW
400-440V
5G10
50A
5G25
55,0A
63A
E990927
775024
30,0 kW
7
5G25
68,0A
80A
E990927
775024
37,0 kW
5G35
81,0A
100A
E990928
7750281
45,0 kW
8
4G50
99,0A
125A
E990929
7750281
55,0 kW
4G70
134,0A
160A
E030222
7750291
75,0 kW
9
Schaltschrank Daten Dates of control cabinet
EDV Nr.:
E03071606 b
SKP-E 4 - 75 kW
Ort:
Anlage:
Folge
Blatt
verknüpft mit Exel-Liste E03071608.xls
A t t ent i o n !
Le dimensionnement de la conduite d’alimentation, ainsi que de t ous les câblages externes, a lieu en propre responsabilit é de la société électrique exécutant ces travaux.
Avant mise en service et en cas de travaux d’entretien il f aut serrer les vis de contact, ou bien vérifier s’ils sont bien fixés.
Avant mise en service il faut vérifier la tension et f réquence ainsi que les valeurs de cosigne de la protection du moteur et du relais temporisé.
Inf o r mat io ns imp o r t ant es!
5G16
41,0A
50 - 60 Hz
36,0A
50A
230V / 19V / 10V
A t t ent io n !
5G2,5
35A 21,7A
6
3/PE 50-60Hz 400-440V
E990903
A cht ung !
5G2,5
25A 15,3A
E990701
775089
18,5 kW
The dimensioning of the conducting cable as well as all external cables are the responsibility of the electrician ef fect ing the wiring.
Câble d'alimentat ion
20A 11,3A
E990701
775087
15,0 kW
Die Dimensionierung der Zuleit ung sowie alle ext ernen Verkabelungen erfolgt in Eigenverantwortung der ausf ührenden Elekt rof irma.
Zuleitung
16A 8,5A
E990802
775087
11,0 kW
Before initial st arting and during maintenance works, all contact screws have t o be checked and retightened respectively.
Frequency
Supply line
Frequenz
Branchement de courant
Fusible de puissance
E990802
7,5 kW 775083
Vor Inbetriebnahme und bei Wartungsarbeiten sind alle Kontakt schrauben nachzuziehen bzw. auf festen Sitz zu kontrollieren.
Connecting current
Anschlußstrom
E990802
5,5 kW 775083
Before initial st arting, volt age and frequency as well as t he values at which motor protect ion and t ime relay are set have to be checked.
Preliminary locking device
max. Vorsicherung
Tension de gâchette
4 kW 775083
Vor Inbetriebnahme sind Spannung und Frequenz sowie die Einstellwerte der M ot orschut z und Zeitrelais zu prüfen.
Control voltage
Steuersspannung
Tension du moteur
Alimentat ion
C har g es d e co nnexi o n
Dessin No.
EDV No.
I mp o r t ant d i r ect io ns !
M otor volt age
M ot orspannung
Pr o jet d o nnées
Compresseur à hélice
5
W icht i g e Hinweise !
C o nnect ed lo ad
Zeichnung Nr
Power supply
Drawing No.
EDV - Nr
Einspeisung
EDV - No.
Schraubenverdichter
A nschl uß w er t e
Pr o ject D at a
screw compressor
Pr o jekt D at en
Schaltschrank Daten / dates of control cabinet / Données Armoire, instruments
0
Original 2011-06-21
1.1 2
06.06.05
Datum
"a"
Änderung
0
Name
Küster
Hall
Bearb.
Norm
Gepr.
06/05
Datum
1
PROCON A1
3
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
Gehäuse 01 housing 01 Carter 01
2
Ers.d.
4
620mm
S1
Ben.
5
Original 2011-06-21
Frontansicht front view
3P1
3Q1
6
EDV Nr.:
Amperemeter ammeter amperemeter
Hauptschalter Power switch interrupteur principal
7
E03071606 b
SKP-E 4 - 75 kW
290mm
Tiefe: 170mm
8
Anlage: Ort:
Folge
Blatt
9
2 3
06.06.05
Datum
"a"
3F0
Änderung
Bauseits at site
4
L3
6
L2
3
5
6
L3
5
PE
see attachment
siehe Anhang
PE
Name
Kuester
Hall
Bearb.
Norm
Gepr.
06/05
Datum
Alimentation voir annexe 3/PE 50-60Hz/400-440V Castouche fusible puissance de branchement nominale Courant en régime
power supply 3/PE 50-60Hz/400-440V back up fuse max. rating current rated
Einspeisung 3/PE 50-60Hz/400-440V Sicherungseinsatz max. Nennanschlußleistung Nennbetriebstrom
L1
1
4
L2
L1
2
3
1
2
Motorstromrelais motor power relais relais motorisé
Option
U1
2
1
V1
4
3
W1
6
5
A
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
*
* 3F6
7.7
7K1
3T2
5.2
96
95
~
M
PE
PE
Ers.d.
3M1
3
1X1
98
97
3P1
Commande compresseur à hélice
3
Alimentation
2 Antrieb Schraubenkompressor screw compressor drive
1
Einspeisung power supply
1X1
3Q1
Hauptschalter Power switch interrupteur principal
0 4
7.5
7K2
W2
2
1
U2
4
3
Ben.
V2
6
5
5
Original 2011-06-21
2
1 4
3 6
5
Einspeisung / Antrieb power supply / drive Alimentation / Commande
7.6
7K3
6
1X1
230
12
11
2
1
0
3F3
400 - 440
3F1
E03071606 b
SKP-E 4 - 75 kW
3F2
PE
3F5
3S1
3T1
EDV Nr.:
PE
Transformator transformer transformateur
7
19
2
1
2
1
8
0
3F4
10
2
1
0
Ort:
Anlage:
Transformator transformer transformateur
Folge
Blatt
3.1 4
/4.0
/7.0
/4.0
/4.0
/4.0
/4.0
PE /4.0
L10 L11
L50 L51
L60 L61
L3
L2
L1
9
L51
L50
L60
3.9/
3.9/
3.9/
Änderung
Datum
PE
L61
3.9/
3.9/
L11
3.9/
0
Name
Hall
Bearb.
Norm
Gepr.
5/03
Datum
0V / 10V AC
0V / 19V AC
19V AC
10V AC
230V 50Hz
4A1
32
33
31
11
0X7
12
13
0X3
30
10
9
3
29
28
Schnittestelle RS232/RS485 nicht auf Klemmen verdrahtet interface RS232/RS485 not wired on clamps interface RS232/RS485 pas câblé sur pinces
2
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
PROCON - Steuerelektronik PROCON - control electronic PROCON - électronique de commande
1
27
26
Ers.d.
0X6
8
7
25
0X2
4
6
24
23
22
Ben.
20
19
bl 18
5
6
3
ga 16
0X1
0X4
17
4
15
2
br
PROCON-control electronic PROCON-Steuerelektronik PROCON-électronique de commande
0X5
21
Typ / type / Type : PROCON Electronic électronique PROCON
5
sw
Original 2011-06-21
EDV Nr.:
14
1
gr-ge
7
E03071606 b
SKP-E 4 - 75 kW
8
Anlage: Ort:
Folge
Blatt
PE /5.0
L11
9
4 5
Änderung
4.9/
Datum
PE
Name
5/03
Hall
4
21
4.5
PE
23
0X6
défaut arrêt d'urgence
4.3
Urspr.
PE
Ers.f.
Ers.d.
6
24
PE
Option avertissement filtre à air
4.3
0X6
Warnung Luftfilter warning air filter
Option
1X1 8
25
PE
Ben.
10
26
PE
Option avertissement séparateur fin
4.3
0X6
Warnung Feinabscheider warning fine seperator
Option
1X1
Digital-Eingänge digital input entrées digitales
Option avertissement filtre à huile
4.3
0X6
Warnung Ölfilter warning oil filter
Option
1X1
12
27
PE
EDV Nr.:
14
28
PE
8
Option Xxx marche / arrêt
4.3
0X6
Fern Ein / Aus remote on / of
Option
1X1
E03071606 b
SKP-E 4 - 75 kW
Option GLW: charge / marche à vide
4.3
0X6
GLW: Last / Leerlauf load / unload
Option
1X1
4
25
3
13
4
1X1 3
11
2
1X1
1
9
2
1X1
1
7
4
1X1
7
3
5
6
32
1X1
5
31
Störung Not - Aus malfunction emergency stop
1X1
3S1
29
Versorg.spg. 24VDC Digital Eingänge supply voltage 24VDC digital inputs
4.3
0X6
tension d'alimentation 24VDC entrées numériques
Kompressor/compressor/compresseur PROCON 4 - 75 kW
défaut PTC température du moteur
0X5
Störung PTC Motortemperatur malfunction PTC temp. motor
1X1
2
1
96
95
3
4.5
PE
5R2
* 3F6
1X1
0X5
Option réserve défaut PTC
Bearb.
Norm
20
Reserve Störung PTC reserve malfunction PTC
Datum
Gepr.
2
2
1
1
Option
1X1
5R1
1X1
22
Versorg.spg. 12VDC Motortemperatur PTC supply voltage 12VDC motor temp. PTC
4.5
0X5
tension d'alimentation 12VDC température du moteur PTC
rt
rt
sw
4
gr-ge
3
rs
2
bl
1
vi
0
br
ws
Original 2011-06-21
ga
Anlage: Ort:
Folge
Blatt
PE /7.0
9
5 6
Änderung
0
Datum
Name
5/03
Hall
Norm
15
1X1
4.5
16
S
sonde de température KTY -20 à +150°C
4.5
0X4
Temperaturfühler KTY -20 bis +150°C temp. transductor KTY -20 bis +150°C
16
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
sonde de température KTY -20 à +150°C
0X4
4.5
15
2
-2
17
P
17
0X4
Netzdruck 4-20mA 0 bis 16 bar line pressure
18
Ers.d.
Ben.
A1
I
6
conduite d'alimentation capteur de pression 4-20mA
4.5
0X4
Zuleitg.Druckfühler 4-20mA feed line pressure transductor
19
Analog-Eingänge analog inputs entrée analogique
pression du réseau 4-20mA 0 à 16 bar
S
Option pression du système 4-20mA 0 à 16 bar
18
A2
P
4.5
+1
I
6A1
Druckfühler pressure transductor capteur de pression
5
4.5
0X4
Systemdruck 4-20mA 0 bis 16 bar system pressure
Option
1X1
6A0
Druckfühler pressure transductor capteur de pression
4
ws
1
3
ga
6R1
Temperaturfühler KTY -20 bis +150°C temp. transductor KTY -20 bis +150°C
2
br
0X4
blindage entrée analogique
Bearb.
Gepr.
14
gr-ge
Schirmung Analog Eingänge screening analog inputs
Datum
1
sw
Original 2011-06-21
bl
EDV Nr.:
7
E03071606 b
SKP-E 4 - 75 kW
8
Anlage: Ort:
Folge
Blatt
9
6 7
10.11.03
Datum
Änderung
L10 PE
Option 7Y2
5.9/
3.9/
0
Name
Küster
5/03
Hall
Bearb.
Norm
Gepr.
1X1
22
23
8
Urspr.
Ers.f.
Ers.d.
Steuerventil control valve soupape de distribution 45/55/75kW
(45/55/75kW)
* Option
* 7Y2
Sammelstörung Wechsler NO collective indicat. change over cont. NO
4.4
0X2
défaut collectif inverseur NO
3
Kompressor/compressor/compresseur PROCON 4 - 75 kW
21
7
6
4.4
4.4
Sammelstörung Wechsler NC collective indicat. change over cont. NC
0X2
0X2
Sammelstörung Wechsler C collective indicat. change over cont. C
défaut collectif inverseur NC
2
défaut collectif inverseur C
Datum
0V 50Hz
1 4
26
-
+
24
PE
Entlastungsventil relief valve soupape de décharge
1X1
7Y1
1X1
9
Lastventil load valve
4.2
0X3
soupape de charge
Ben.
1 3 5 21
7K2
.6
2 3.4 4 3.5 6 3.5 22 .6
A2
A1
22
21
Relais-Ausgänge relay outlets sortie de relais
10
Dreieckschütz delta contactor
4.2
0X3
contacteur en delta
7K3
5
Original 2011-06-21
1 3 5 21
7K3
.5
7K2
11
2 3.6 4 3.6 6 3.6 22 .5
A2
A1
22
21
Sternschütz star contactor
4.2
0X3
contacteur en étoile
6
EDV Nr.:
7K1
1 3 5
2 3.3 4 3.3 6 3.3
A2
A1
1X1
E03071606 b
26
27
8
Wasserstopventil water stop valve soupape d'arrêt d'eau
(Wasserkühlung) (water-cooling) (refroidissement à l'eau)
* Option
1X1
* 7Y3
SKP-E 4 - 75 kW
12
Netzschütz main contactor
4.2
0X3
contacteur principal
7
Anlage: Ort:
Folge
Blatt
PE
L10
9
7 8
06.06.05
10.11.03
Datum
Option 7Y2
Änderung
0V 50Hz
running/pot.free
3.9/
L10 5.9/ PE
0
Kuester
Name
Küster
30
7K1
31
Norm
Gepr.
Bearb.
Datum
Hall
5/03
Ein (Motor läuft) Pot.freie Kontakte on (running) potential-free contacts
29
4
3
1
7K1
28
14
11
7K4
Last (Leerlauf) Pot.freie Kontakte load (idle) potential-free contacts
* Option
27
3
Urspr.
Ers.f.
Kompressor/compressor/compresseur PROCON 4 - 75 kW
32
4
3
2
Ers.d.
*7K4
4
A1
Steuerventil control valve soup de distribution
* Option (45/55/75kW)
A2
Ben.
1X1
1X1
26
24
5
Original 2011-06-21
Relais-Ausgänge relay outlets sortie de relais
PE
6
EDV Nr.:
Stillstandheizung Motor auxiliary heating motor
L11
7
26
230V
33
22
21
E03071606 b
SKP-E 4 - 75 kW
Stillstandheizung Motor auxiliary heating motor
* Option
7K1
8
Anlage: Ort:
Folge
Blatt
PE
L10
9
7-1 8
Änderung
Klemmenplan
/ terminal strip
HOP.KP02
W6A0
W6R1
W0X5
W0X4
W0X1
0
Leistenbezeichnung
Datum Name
Kabelname
Kabelname
1X1
Norm
Hall
Bearb.
Gepr.
5/03
Datum Kabeltyp
Zielbezeichnung
Anschluß
Klemmennummer
Zielbezeichnung
Anschluß
Kabeltyp
4mm²
Seite/Pfad
1
Funktionstext / function text Einspeisung power supply
6
3Q1
4
3Q1
2
3Q1
0/L1 0/L2 0/L3
0/PE
PE
0/N
N
Ers.f.
1
5R2
2
5R1
1
5R1
1 2
7K1
1
7K1
X
3
7K1
3.0
X
5
3T1
3.1
X
3.1
0
3.1 3.1
0X5
22
0X5
rt
20
5.1
sw
5.1 3
2
5R2
2
Kompressor / compressor PROCON 4 - 75 kW
Urspr.
Einspeisung power supply Einspeisung power supply Einspeisung power supply Einspeisung power supply
3 4
S
SH
W6R1
9
1
8
2
7
1
6
4
5
3 Ers.d.
SH
W6A0
5.2 0X5
21
3S1
br
5.2
31
0X6
5.4
24
gr-ge
5.4 5.5
0X6
25
rs
5.5 5.6
0X4
14
gr-ge
6.3
S
1
6R1
2
15
2
6R1
1
14
4
13
3
12
4
11
3
10
2
Ben.
SH
Druckfühler pressure transductor
4
1
Druckfühler pressure transductor
6.5 0X6
26
bl
5.6 5
1X1
16
-2
17
+1
18
EDV Nr.:
E03071606 b
SKP-E 4 - 75 kW
+
7Y1
24 25
5.7 0X6
27
vi
5.7 5.8
0X6
28
0X4
ga
15
0X4
5.8 br
16
0X4
6.3
sw
17
6A1
6.3
ws
6.4
A1
0X2
6.4
6
0X2
7.2
7
0X2
7.2 7
32
3S1
26
6
6A0 6A0
-
7Y1
8
0X3
7.2
9
0X6
7.4
23
A2
7K2
0
3T1
rt
5.3 7.4 3.4
3T1
8
PE
Antrieb Kolbenkompressor piston compressor drive
Original 2011-06-21
SH
2
Druckfühler pressure transductor
21 22 23
PE
3M1
PE
Transformator transformer
PE
4A1-0X1
3.7
1
gr-ge
Anlage:
Ort:
Folge
Blatt
5.5
PE
5.4
PE
5.3
PE
5.2
PE
5.2
PE
9
5.6
PE 8
Lubricating Instructions for HATLAPA HSC Screw Compressors
177469 Rev. 08.10
1. General Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of the compressor. Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is advisable to contact him when making your choice. Ask only the lubricant manufacturer for his recommendation! He is the expert.
2. Lubrication Oil Quality Above all, compressor oils must have good lubrication properties for which their viscosity is highly important. HATLAPA recommends lubrication oils within the following range: ambient temperature
0 .. +25 °C
constantly over 25 °C (engine room of sea going ships)
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viscosity class
ISO VG 46
ISO VG 68 2
2
viscosity at 40°C
41 .. 51 mm /s
61 .. 75 mm /s
flash point
> 200 °C
> 200 °C
pourpoint
at least 5 °C under the lowest ambient temperature
The screw compressor oils should have low tendency to ageing and foaming. 3. Guarantee If lubrication oils are used which do not meet the requirements, damage to the compressor may occur. This damage is not covered by HATLAPA's guarantee obligations. 4. Lubricant Examples The following oils are examples which comply with the above specification: BP ENERSYN RC-S 68 CASTROL AIRCOL SR-68 CHEVRON TEXACO (FAMM) CETUS PAO 68 ELF TOTAL FINA (Lubmarine) BARELF SM-68 / DACNIS SH-68 ESSO (ExxonMobil Marine) RARUS SHC-1026 MOBIL (ExxonMobil Marine) SHELL CORENA AS-68 However, the oil properties are subject to change without notice by the oil manufacturer. Also, the oil characteristics may vary depending on the regional market. Therefore this list does not release the operator of the compressor from verifying that the selected oil complies with the above specification.
Service
Anleitung zur richtigen Bestellung von Ersatzteilen Für die Bestellung sind folgende Angaben unbedingt erforderlich: 1) Schiffsname (Ex-Name), Neubau-Nr. und Bauwerft 2) Fabriknummer und Typenbezeichnung (siehe Typenschild) 3) Ersatzteilnummer entsprechend Ersatzteilliste 4) Gewünschte Versandart, Versandadresse und Rechnungsanschrift
Instructions for correctly ordering spare parts When ordering spare parts, the following details must be given:
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1) Name of vessel (former name), Hull No. and building shipyard 2) Serial number and type of the machine (see name plate) 3) Part number from the Spare Parts List 4) Desired method of dispatch, invoice and consignee’s address
Instruction pour établir les commandes de pièces de rechange Les indications suivantes seront indispensables pour la commande: 1° Nom du navire (ex-nom), No. du navire et chantier de construction 2° Numéro d’usine et type (voir plaque d’identité) 3° Numéro de pièce suivant liste des pièces de rechange 4° Mode de transport désiré, adresses du destinataire et de la facture
Instrucciones para pedir correctamente piezas de repuesto. Cuando se piden piezas de repuesto, deben ser dados los – siguiéntes datos:
1) Número de serie y tipo (ver placa) . 2) Número de la pieza según la Lista de Piezas de Repuesto. 3) Forma de despacho así como consignación y dirección para la facturación. 4) Nombre del buque (nombre antígúo) ‚ número de construción y Astilliero.
Guida alla corretta ordinazione dei pezzi di ricambio Per ordinare rispettivi pezzi di ricambio sono assolutamente indispensabili i seguenti dati: 1) Nome della nave (ev. nome precedente), numero di Costruzione e nome del Cantiere Naval e 2) Numero di matricola e tipo del compressore (vedi targhetta) 3) Numero del pezzo di ricambio in base alla «Lista dei pezzi di ricambio» 4) Mezzo di trasporto, indirizzo di spedizione ed indirizzo di fatturazione desiderati
Service
Um Ersatzteile schnellstens zu erhalten, wenden Sie sich bitte direkt an
oder an unsere Vertretungen (x), Kundendienststellen (o) oder Lizenznehmer ( +) laut anliegender Liste. In order to receive spare parts with the least possible delay, please get in touch with us directly
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or with our representatives (x),service stations (o) or licensees/co-operators (+) as indicated in the enclosed list. Pour assurer une fourniture rapide, veuillez vous adresser á
ou á nos agences (x) , stations-service (o) ,licenciés/partenaires de cooperation (+) Per offenere i rispetti celermente rivolgersi direttamente alla:
od ai rappresentanti (x), centri d‘assistenza (o) o licenziatari/partner di cooperazione (+) delta HATLAPA indicati neIl‘elenco aliegato.
Service Stations Spare Parts Agencies OUR MANUFACTURING PROGRAMME: Deck machinery, compressors, steering gear
Headquarters:
HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 25436 Uetersen GERMANY Phone: +49 4122 711-0 Mobile: +49 172 9 813292 Fax: +49 4122 711-104 Sales 711-330 Service
[email protected], http://www.hatlapa.de
Subsidiary office for Hamworthy type compressors:
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HATLAPA Marine Equipment Ltd. Discovery Court Business Centre 551-553 Wallisdown Road POOLE, Dorset BH12 5AG UNITED KINGDOM Phone: +44 1202 8531-80 Fax: +44 1202 8531-91 Sales 8531-90 Spares
[email protected], http://www.hatlapa-uk.com
Vertretungen (x), Kundendienststellen (o) und Lizenznehmer (+) Representatives (x), service stations (o) and licensees/co-operators (+) Agencies (x), stations-service (o) et licenciés/partenaires de cooperation(+) o Australia
CJA Marine Technology Pty Ltd Unit 3, 136 Cochranes Road Moorabbin, Victoria 3189
Tel: +61 3 953213-97 / 953213-86 Fax: +61 3 953214-13
[email protected]
x Belgium
Marine & Industrie Div. of SA Aciers Marathon Staal NV Haven 138, Boterhamvaartweg 2 (Unit 1) B-2030 Antwerp
Tel: +32 3 82740-91 Fax: +32 3 82740-95
[email protected]
o Belgium/ Luxembourg
Service Hydro n.v. Haven 138, Boterhamvaartweg 2 B-2030 Antwerp
Tel: +32 3 54640-80 Fax: +32 3 54640-81
[email protected]
x Brazil
TRIDENTE Indústria Comércio Equip Ltda Rua Visc Inhaúma 134 – Centro, Rio de Janeiro RJ, 20091-007
Tel: +55 21 2233-1489 Cell: +55 21 9983-3190 Fax: +55 21 2516-7543
[email protected]
o Brazil
Metalock Brasil Ltda Rua Visconde do Rio Branco 20/26 Santos, SP 11013-030
Tel: +55 13 322646-86 Fax: +55 13 322646-80
[email protected]
Updated 14th December 2010
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Service Stations Spare Parts Agencies
x Bulgaria
Ecatdan ApS 1, Studentska Str. 9010 Varna
Tel: +359 52 383476
[email protected]
xo Canada
Marine and Offshore Canada 29-113 Cushman Rd St. Catherines Ontario, L2M 6S9
Tel: +1 905 688 4922 (office) Fax: +1 905 688 9028 Cell: +1 905 650 3160
[email protected]
o Chile
Eurotecnica Ltda Lincoyán # 973 4030485 Conception
Tel: +56 41 22532-75 Fax: +56 41 22532-76
[email protected]
x+ China
HATLAPA Nanjing Representative Office Asia Pacific Pte Ltd Room 612, No 19, Zhanyuan Road Nanjing 210039
Tel: +86 25 52 26 27 90 Fax: +86 25 86 70 33 10
[email protected]
x China
HATLAPA Shanghai Asia Pacific Pte Ltd No. 1211 Chang De Road Room 1011, Baohua Building Shanghai 200060
Tel: +86 21 623296-71 Mobile: +86 137 0 17473 14 Fax: +86 21 623039-71
[email protected]
xo Croatia
Nava International d.o.o. Planciceva 4 21000 Split
Tel: +385 21 385267 Fax: +385 21 385267
[email protected]
x Cyprus
M.I.E. Services Ltd The Hawk Building 124 Gladstonos Str.. 3032 Limassol
Tel: +357 25 889801 Fax: +357 25 763902
[email protected]
x Cyprus
HATLAPA EastMed Ltd The Hawk Building 124 Gladstonos Str.. 3032 Limassol
Tel: +357 25 8897-00 Fax: +357 25 3660-88
[email protected]
x Denmark
A/S Kelvin Hughes Gøngehusvej 280 DK-2970 Horsholm
Tel: +45 8734 2270 Mobile: +45 2060 9405 Fax: +45 8611 2726
[email protected]
x Egypt
AMCO Alexandria Maritime 10 Ahmed Yehya Pasha St. Gleem P.O. Box 1424, Alexandria
Tel: +20 3 58585-70 Fax: +20 3 58285-87
[email protected]
x Finland
EPOMARE OY (from 1st January 2011) Perämiehenkatu 11 20810 Turku
Tel: +358 2 2749640 Fax: +358 2 2351499
[email protected]
x France
Wenex Equipments SA 49 Rue de Billancourt 92100 Boulogne
Tel: +33 1 411023-30 Fax: +33 1 411023-45
[email protected]
o Germany
Friedrich Jung Fa. König-Friedrich-Wilhelm-Str. 20
Tel: +49 203 82898 Fax: +49 203 57085-24
Updated 14th December 2010
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Service Stations Spare Parts Agencies
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47119 Duisburg xo Great Britain
HATLAPA Marine Equipment Ltd Discovery Court Business Centre 551-553 Wallisdown Road Poole, Dorset BH12 5AG
Tel: +44 1202 8531-80 Fax:+44 1202 8531-90
[email protected]
xo Greece
M.I.E. Co. Ltd. Kanari 1 18537 Piraeus
Tel: +30 210 4598-800 Fax: +30 210 4539-234
[email protected]
o Greece
INJEGOV Advanced Mechanical Services Ltd Vipa Shistou, Road 2, OT3 Perama 18863 Piraeus
Tel: +30 210 4323600/1-2 Fax: +30 210 43127-70
[email protected]
xo India
Dolphin Consultants 35 Mittal Chambers Nariman Point, Maharashtra State Mumbai 400021
Tel: +91 22 302877-11 to 15 (5 Lines) Fax:+91 22 302877-10
[email protected]
xo Indonesia
PT. Assindo Perniagaan Internasional Victoria Building, 3rd Floor Jl. Sultan Hasanuddin No. 47 - 51 Jakarta Selatan 12160
Tel: +62 21 72555-41 Fax: +62 21 72555-46
[email protected]
+ Indonesia
PT. Assindo Perniagaan Internasional Victoria Centre, 3rd Floor Jl. Sultan Hasanuddin No. 47-51 Jakarta 12160
Tel: +62 21 72555-41 Fax: +62 21 72555-46
[email protected]
xo Iran
Iran IMEXEN Co. No.4, Apt. 6, Morvarid Crossing Goldan St., Africa Ave. (Ex-Jordan) Tehran 19668
Tel: +98 21 22000008 Fax: +98 21 22004849
[email protected]
xo Italy
RTN Srl Loc. Cà Verde 29011 Borgonovo Val Tidone (PC)
Tel: +39 0523 869611 Fax: +39 0523 861077
[email protected]
xo Korea
Dong Sung Co. Room 1725, 21 Century City Building 55-1, Daeyeon 3-dong Nam Gu, Pusan 608-743
Tel: +82 51 61012-33 Fax: +82 51 61012-32
[email protected]
xo Korea
HATLAPA Korea Co. Ltd. 1212, Jisa-dong Gangseo-gu, Busan
Tel: +82 51 97292-66 Fax: +82 51 97292-70
[email protected]
x Lebanon
M.I.E. (Overseas) Ltd. The Hawk Building 124 Gladstonos Street 3312 Limassol, Cyprus
Tel: +357 25 889800 Fax : +357 25 346626
[email protected]
x Middle East
M.I.E. (Overseas) Ltd.
Tel: +357 25 366077 Fax.:+357 25 366088
[email protected]
for steering gear
Saudi Arabia, Oman The Hawk Building U.A.E., Qatar, Yemen 124 Gladstonos Street Bahrain, Kuwait, 3312 Limassol, Cyprus
Updated 14th December 2010
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Service Stations Spare Parts Agencies
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Jordan, Israel
xo Netherlands
Hamworthy KSE B.V. Aploniastraat 33 3084 CC Rotterdam
Tel: +31 10 46247-77 Fax.: +31 10 41590-46
[email protected]
xo Norway
Hatlapa Marine Equipment AS Frithjof Nansens Plass 7, 0117 Oslo
Tel: +47-918-08-546
[email protected]
xo Poland
SANGER METAL Sp-ka Z o.o. Mostnika Str.10-12 70-672 Szczecin
Tel: +48 91 4623236 / 4623383 Fax: +48 91 4623345
[email protected]
xo Portugal
Javier López-Alonso Morán Avda. San Luis 166 - 8° E 28033 Madrid
Tel/Fax: +34 91 3831577
[email protected]
x Romania
XEREX SRL 43 Alexandru Cernat str. 800087 Galati, Romania
Tel/Fax: +40 236 462056 Mobile: +40 723 533596
[email protected]
x Singapore
HATLAPA Asia Pacific Pte Ltd German Centre, Unit 02-25 25 International Business Park Jurong, Singapore 609916
Tel: +65 65 628086 / 628088 Mobile: +65 96 339381 Fax: +65 65 628099
[email protected]
xo Spain
Javier López-Alonso Morán Avda. San Luis 166 - 8° E 28033 Madrid
Tel/Fax: +34 91 3831577
[email protected]
xo Sweden
Bövik Marin AB Hälleflundregatan 12 42658 Västra Frölunda, Gothenburg
Tel: +46 31 290075
[email protected]
x Syria
M.I.E. (Overseas) Ltd. The Hawk Building, 124 Gadstonos Street 3312 Limassol, Cyprus
Tel : +357 25 889800 Fax : +357 25 346626
[email protected]
x Taiwan
SHIPCARE Co. Ltd. Rm1, 2nd fl., no.135, sec.1 Chungking South Road Taipei 10036
Tel: +886 2 2383-2255 Fax: +886 2 2383-1020
[email protected]
x U.S.A.
MarinSOLVE LLC PO Box 2176 Clifton, NJ 07015
Tel: +1 973 24657 26 Fax: +1 973 75503 33
[email protected]
x U.S.A.
CS Controls 101 Dickson Road Houma, LA 70363
Tel: +1 985 876 6040 Fax: +1 985 876 0751
[email protected]
x U.S.A.
Mariner Hub LLC 917 West 21st Street, Unit H Houston, TX 77008
Tel: +1 713 822 1252
[email protected]
Updated 14th December 2010
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Service Stations Spare Parts Agencies
TENAVAL Av. Fco. De Miranda, Edif. Bco del Orinoco 2°, Piso Ofic 2-B Caracas
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x Venezuela
Updated 14th December 2010
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Tel: +58 212 285-2344 +58 212 285-7822 +58 212 285-7631 Fax: +58 212 285-7776
