Table of Contents. Air compressor Manual

Transcription

1 Table of Contents Safety Precautions utline Principle Items Structure and Performances of Compressor Main Unit Main Accessories Precautions for Installation Air Intake and Installation Site Cooling Water and Piping Lubrication il Air Reservoir and Piping Precautions before and after Start-up peration Inspection Manual Rotation After Start-up peration perational Precautions Air Tightness Lubrication il Sound Safety Valve Heat Precaution for Stopping peration Before Stopping peration Lubrication il Drainage Cooling Water External Inspection Disassembly Main Unit Valve Piston Air cooler Assembly Air cooler Piston Valve Main Unit Lubrication il Type of il Troubleshooting In Case a Pressure cannot be increased In Case There is an Abnormal Sound Motor-driven Automatic Air Feed Unit for Compressor Descriptions of performances Periodic Inspection Structural Drawings List of Clamping Nuts & Tightening Torques /21

2 Safety Precautions To ensure proper use of the compressor unit, read this manual and the other attached documents carefully before starting installation, operation, maintenance, and inspection. In this manual, safety precautions are ranked, in order of importance, as either "Danger" or "Caution". Danger- An operator may be killed or seriously injured by a hazardous condition resulting from improper operation. Caution- An operator may be experience minor injuries and/or equipment may be damaged by a hazardous condition resulting from improper operation. Under certain conditions, incorrect operation may result in serious injury and/or damage even if it is labeled only as "caution". Give attention to item indicated as Danger or Caution as these may be hazardous. Danger 1. General Read a manual and a safety precaution of the compressor accessories (piping, fitting, receiver, etc.) and the prime mover (motor, engine,, etc.). Transportation, installation, piping, operation, maintenance, and inspection of a compressor should be done by a specialist. Failure to do so may result in injury. The pressure rating of piping, fitting, etc. should be 4.41MPa (45kgf/cm 2 ) or greater. Failure to do so may result in injury and/or these equipments may be burst. 2. Precaution of high pressure The air is compressed to 2.94MPa (30kgf/cm 2 ) by the compressor. This compressed air has a strong destructive power. Pay attention to following points. Do not dismantle if the system is pressurised. Failure to do so may result in injury. If the compressor is run beyond the safe working pressure, 2.94MPa (30kgf/cm 2 ) the compressor unit may be ruptured and operator may be injured. Do not change set pressure of a safety valve to more than the initial set value. therwise, the pressure of the compressor unit will rise abnormally and the unit can rupture and operator can be injured. If pressure of the compressor unit rises abnormally, immediately stop the operation of the unit and check its cause. The unit can rupture and operator can be injured. 2/21

3 3. Precaution of rotating parts This compressor has rotary parts such as flexible coupling, pulley, belt, etc. Do not touch rotating parts while compressor is running. Failure to do so may result in injury. Before disassembly, make sure the following items: o The compressor has stopped. o The compressor can not run during disassembly. Failure to do so may result in injury. o Do not start the compressor without a guard on the rotating parts. o Failure to do so may result in injury. 4. Precaution of motor and starter To prevent electrical shock, turn off the electric power before starting maintenance or inspection. To prevent electrical shock, and fire, connect cable according to a manual and wiring diagram. If there is a malfunction, immediately stop the operation of the unit and turn off the electric power as it can result in electrical shock or fire. To prevent electrical shock electrical equipment must be earthed. To prevent electrical shock do not start the unit without a terminal cover. Caution Hot surfaces Following parts become very hot while compressor unit is running or just after it has stopped. Do not touch these parts. Failure to do so may result in burns. o Cylinder cover o LP air piping o HP suction valve cover o HP delivery valve cover o HP valve cover o HP air piping o Non-return valve Keep the exhaust pipe of a safety valve and drainage facing away from operator. An operator can get injured and his clothes may be soiled. The direction of rotation compressor should be as specified. The unit can get damaged and an operator may get injured. For wiring to motor and starter, select cable sizes suitable. Failure to do so may result in fire. Do not touch the sharp edge of screw. Failure to do so may result in injury. Do not make any modifications to compressor unit. This modification will invalidate guarantee. Maintenance and inspection of a compressor should be done by a specialist. Use original parts from manufacturer for replacement. 3/21

4 1. utline 1.1 Principle Items Model Type/ Pressure Cylinder bore (mm) LP HP Stroke (mm) RPM Capacity Inlet/outlet Temp diff 10 C Amount of CW required (l/min) Inlet/outlet Temp diff 5 C MH114A Vertical 2 stage, water cooled 2.9MPa/ 30kgf/cm Structure and Performances of Compressor Refer to Section 12: Structural drawing of compressor Main Unit This is a vertical 2-stage compressed water cooled type compressor. It is designed to work at a normal pressure of 2.94MPa (30 kgf/cm2.) The features of this compressor are simple structure, rigidity and good performances. For its structure, the upper part of a cylinder is a low pressure area and its lower part is a high pressure area. The stepped piston performs "suction" and "delivery" and compresses air by reciprocating vertically by means of a connecting rod. The air is compressed in the low pressure area for the first time after having passed the air strainer located at the inlet of the compressor. The compressed air is cooled while it is passing through an air cooler body, and it enters in the high pressure area, separating drainage. The air recompressed in the high pressure-area is set to a specified working pressure. However, it enters in the air cooler body once again due to a high temperature and is sent to an air reservoir after its temperature has been lowered. Since heat generation is of a considerable amount due to compression, cylinder, cylinder cover and air cooler body are cooled by cooling water Main Accessories (1) Low pressure suction and delivery valve In the L.P valve assembly suction valve seat is located at bottom and a delivery valve seat at top and function as combined suction and delivery valve. This is a feature of the Matsubara Compressor. Since a valve area is large, it requires a less lift of the valve. Consequently, it endures high-speed rotations and does not lower its efficiency. Since the valve consists of an unified body (combined suction & delivery), it can be easily removed for disassembly and repair. 4/21

5 (2) High pressure suction and delivery valve This high pressure valves can be easily removed for disassembly and repair. Suction valve and delivery valve are separate. (3) High pressure safety valve This valve is attached to prevent abnormally high pressure. When the pressure increases above 10% of the normal pressure, it is actuated and discharges the compressed air into the atmosphere to prevent a pressure rise. Its working pressure can be easily controlled by means of an adjusting bolt. (4) Air cooler This air cooler is installed to cool the high temperature compressed air and to separate the drainage. (5) Pressure gauge A low pressure gauge is attached to check whether the valves are correctly actuated. Although it depends on a compressor model, it will indicate 0.45MPa 0.7MPa (4.5-7kgf/cm2) when the compressor is normally operated at discharge pressure of 2.94MPa (30kgf/cm2). Be sure to close the pressure gauge cock when operating the compressor. pen the cock only when checking the pressure on the gauge. (6) il gauge The lubrication oil in crank case is scraped up (splashed) by oil scraper (splash plate) at the lower part of connecting rod to lubricate to cylinder (high pressure area), piston area, metal area, crankpin and main bearing. The oil mist from crank case is sent to lubricate cylinder (low pressure area) and low pressure valve area by oil pipe and oil flow can be observed from oil gauge. 2. Precautions for Installation 2.1 Air Intake and Installation Site Select a place with less dust and moisture for air intake. Install the unit at a well illuminated place for inspection, disassembly and repair. Its foundation must be firm and the unit shouldn t vibrate. 2.2 Cooling Water and Piping If the compressor is operated without cooling water, compressor may overheat and seize. Provide piping so that the cooling water may be flow in from the lower part of the cylinder and come out of its upper part. (Use pipes whose diameter is larger than the dimension below mentioned.) Take note of a leakage from the piping. For cooling water amount, refer to Section 1.1 Dimensions of pipes for Cooling Water Inlet and utlet Ports (Model: MH 114A, size of pipes: 015 C1220). 5/21

6 2.3 Lubrication il Since the compressor is delivered without its lubrication oil filled, be sure to supply it before operation. (Remove the cover of the crank case and supply the oil up to the upper line of the oil gauge.) For the types of lubrication oils, refer to Section Air Reservoir and Piping Mount the air reservoir as close to the compressor as possible. Use pipes whose diameter is larger than the dimension below mentioned and joint them securely lest the air should leak. Do not bend the piping at an acute angle. Dimensions of Pipes for High Pressure Air utlet Ports (Model: MH 114A, size of pipes: 15A STPG) 3. Precautions before and after Start-up peration 3.1 Inspection Inspect the whole unit thoroughly; check once again whether or not each part is properly tightened, whether or not the oil is sufficiently supplied, and whether or not the cooling water is available at the outlet of the compressor. 3.2 Manual Rotation Rotating calmly and flexible coupling or a pulley, check whether or not there is any abnormality inside the compressor. When a considerable force is required in compressing, or when a "honk-honk" or "pang-pang" sound is heard in sucking, it indicates a desirable condition. However, when it is felt that something is hit, it indicates a failure. Disassemble and inspect the unit. 3.3 After Start-up peration Supply few drops of oil from an oil supply cup located at the upper part of an air inlet case. (This procedure is required when there is no oil inside the cylinder after installation. It can be omitted when the unit has been always used.) Although a rattling sound may be heard immediately after the oil is supplied, it will stop in a short time because it is caused by the irregular movement of the valve due to the oil. Confirm the flow of cooling water flow, and whether or air is being compressed by opening the cock of the low pressure gauge. 6/21

7 4. perational Precautions 4.1 Air Tightness Check whether or not the air leaks from air passages (piping, joints, valve sealing areas, and so on), whether or not the water leaks from cooling water passages, whether or not the cooling water is flowing (it can be checked due to coldness by touching its passages.), or whether or not the oil leaks. 4.2 Lubrication il Monitor the oil consumption. Check the consumption rate of the oil, stopping the unit after having operated for 4-5 hours. For the oil amount, refer to Section Sound If there is any abnormal sound, immediately stop the unit and investigate as it may result in serious damage. 4.4 Safety Valve Be sure to check once whether or not it is actuated at a specified pressure. 4.5 Heat Although the temperature of each part keeps on increasing for approximately 20 minutes after having started the operation of the unit, if it still keeps on increasing, it indicates an abnormality. Although the temperature of a compression area may exceeds 100 o C, depending on a model, if other parts are too hot to touch by hand, check its cause immediately because it indicates an abnormality. 5. Precaution for Stopping peration 5.1 Before Stopping peration Supply few drops of oil at air inlet to prevent rust when the unit is stopped for long duration. This can be omitted if unit is on auto start and stop. 5.2 Lubrication il Check the oil gauge, if the oil level is close to a bottom line, supply the oil. il can also be topped up from a breather pipe by removing its cap. If the unit is operated for a long time, the oil is contaminated by the drainage or impurities. Replace the oil, depending on its condition. For details, refer to Section 8 and 11. 7/21

8 5.3 Drainage Drain moisture by opening the drain cock at the air cooler. 5.4 Cooling Water Drain the water inside the compressor when the unit is stopped for long duration. This procedure is required to prevent the clogging of the water passage caused by precipitated fur or the rust caused by water leakage. Drain the water if there is danger of freezing. 5.5 External Inspection Clean the unit from outside. It will prevent the ingress of foreign substances and corrosions. 6. Disassembly (Refer to Structural Drawing in Section 12) 6.1 Main Unit (1) Remove the pipes. (2) Remove the air cooler. (3) Remove the cylinder cover and take out the low pressure valve. When this is done, be sure to detach the packing without fail. (4) Remove the crank case cover and unscrew the bolt of a crank pin metal. (Make sure of the number of adjusting liners) (5) Detach the piston. (using an eye type bolt for detaching the piston) (6) Remove the high pressure suction and delivery valve. (It is not required to be removed unless it must be disassembled.) (7) Remove the cylinder. (The disassembly below mentioned can be carried out without removing the cylinder.) (8) Remove the flexible coupling or pulley. (9) Undo the nut of the main bearing case (where the crank shaft is detached). Detach the crank shaft, lightly hitting a crank shaft end with a wooden hammer. 6.2 Valve Apply a soft material such as a rag around the.valve seat and hold it with a stock vice. pen the nut and disassemble. Keep valve components securely lest they should be lost. Be careful not to damage the valve and its seat. 6.3 Piston (1) When removing piston ring don t stretch it too much because it may break. (2) Pull out a piston pin. For a taper air tightness type, remove a set-bolt first, and then, pull out the piston pin by means of a piston pin drawer. If the pin is stuck firmly hit the bolt of the jig hard. 8/21

9 6.4 Air cooler (1) Remove a drain separator located at the lower part. (2) Remove the pipes. (3) Remove the cover of the air cooler and take out the cooling pipe. 7. Assembly (Refer to Structural Drawings in Section 12) 7.1 Air Cooler (1) Mount the air cooler cover. (2) Check the packing of a cooling pipe joint and replace it if it is defective. Paint the cooling pipe joint and insert it in the air cooler body. (3) Tighten a joint nut firmly. (4) Mount the drain separator. 7.2 Piston (1) Mount the connecting rod. Apply oil to the piston pin metal area of the connecting rod and insert in the piston. For the taper air tightness type, the blind side of the piston pin should be on the left side with the timing mark of the connecting rod on this side, when this is done. For the taper air tightness type piston, insert the piston pin in the piston, paying attention to the notch of the set-bolt. After having inserted it, hit it hard and fix with the set-bolt. (2) Place the piston ring. 7.3 Valve Assemble the valve in the opposite order of its disassembly. Care should be fully taken lest dust should enter, when this is done. Check a valve lift in accordance with the table below mentioned to make it doubly sure. For an ideal valve contact, it should not be separated when the valve is calmly and vertically set in dry condition. Valve lift list Unit: mm L P Suction valve 1.1 L P Delivery valve 1.0 H P Suction valve 1.1 H P Delivery valve 1.0 9/21

10 7.4 Main Unit (1) Set one main bearing case to the crank shaft. Put this assembly in the crank case and set the crank shaft to the other main bearing case. When this is done, be careful lest the air tight oil seal of the main bearing case should be rolled in. If the oil seal is rolled in, it feels heavy when the unit is idled. (2) Mount the flexible coupling or pulley. This is intended to facilitate the rotation of the crank shaft and the assembly. (3) Mount the cylinder. (4) Mount the high pressure suction and delivery valve (5) Attach the piston to which the connecting rod is mounted. When this is done, apply oil fully to the cylinder, crank pin and the surface of the piston. Set the piston ring at the right position, and put the piston in the cylinder, hitting it lightly. If it is necessary to hit the piston hard to put it in the cylinder, it indicates that the piston ring is caught somewhere. Pull the piston out and check it. Forcing the piston in may break the piston ring. After having put the piston in, set the lower metal of the connecting rod. Then, set the crank pin metal bolt and liners, and tighten firmly. After having tightened the nut,-rotate the crank shaft and check whether or not it can be lightly done. Also, apply a long bar to the lower part of the connecting rod and check whether or not it can be moved to the right and left. If the number of liners is short, the crank pin will be over tightened by crank pin metal. Consequently, the crank shaft cannot be lightly rotated and the lower part of the connecting rod cannot be moved to the right and left. If the unit is operated when the number of the liners is short, the crank pin metal is easily sticked. (6) Mount the low pressure valve. After having applied oil to the valve fully, place the cylinder cover. Move the piston and check whether or not the top of the piston comes into contact with the bottom of the low pressure valve. When they come into contact with each other, increase the number of the packings used for the lower part of the low pressure valve. This clearance between the top of the piston and the bottom of the low pressure valve (top clearance) should be mm. If the clearance exceeds this range, the efficiency of the unit will be deteriorated. (7) Mount the crank case cover. (8) Mount the air cooler. (9) Mount the pipes. 10/21

11 8. Lubrication il 8.1 Type of il The oil below mentioned are recommended as the results of our experiments. NIPPN MITSUBISHI IL CRPRATIN FAIRCL SA100 FAIRCL A100 DIAMND MARINE T-103 DIAMND MARINE S-30P CSM IL C., LTD. CSM RECIPR SX 100 CSM MARINE 3000 CSM MARINE 3005 CSM MARINE 3010 JAPAN ENERGY CRPRATIN BER ELF CH-100 RESIC N-100 IDEMITSU KSAN C., LTD. DAPHNE MARINE CMPRESSR 100 ESS SEKIYU K.K. EXXMAR XA NEW REX DF100 MBIL IL C., LTD. RARUS 827 RARUS.429 SHWA-SHELL SEKIYU K.K. CRENA IL AP100 GADINIA IL 30 CRENA IL P100 FUJI KSAN C. LTD. FKKL MARINE 312 CMPRESSR S100 NTE: Do not use any turbine oil because it will cause an abnormal abrasion due to rust. Model Initial oil amount (up to the upper indication line) Replenishing amount (between the upper and-lower indication lines) MH114A 1.50 L 0.40L When the unit is operated for a long time, the oil is contaminated by the drainage or impurities. Replace the oil with a new one before it is too late. (Refer to Section 11) 11/21

12 9. Troubleshooting 9.1 In Case a Pressure cannot be increased (1) Leakage from the piping line The air may leak from the piping, joints and air reservoir more or less. Check a leak point with soap water and repair it. (2) Damage of the valve The valve may be worn out due to a long time of operation, or it may catch dust, or it may be damaged by heating. If the pressure cannot be increased at all, it indicates the damage of the valve. In this case, disassemble and check it immediately. If the pressure cannot be increased smoothly, it indicates that the valve seat is damaged by catching the dust, or that the valve contact is deteriorated by the deformation of the valve due to heating. In this case, check the following items, operat i ng the unit. Closing the air inlet case with hand, if the air is returned in this sucking condition, the low pressure suction valve is defective. If the low pressure gauge indicates a value lower than a test result, the 'low pressure delivery valve is defective. If the low pressure gauge indicates too high a value, the high pressure suction valve and delivery valve are defective. The suction valve is mainly defective when the unit is in operation, and the delivery valve is defective when the unit is not in operation. (3) Abrasion of the piston ring When the unit is operated for a long time, the piston ring is worn out. Replace with a new one. (4) Excess feeding of the lubrication oil An excess feeding of the lubrication oil in crank case brings excess scraping of the lubrication oil which may deteriorate the function of valve. Pay attention to a noise (lasting long) which can be heard in this case. (5) Insufficient tightening of the low pressure valve seat If the valve seat is not sufficiently tightened because the cylinder comes into contact with the cylinder cover, or because the 0-ring of a connection pipe is obstructive, the compressed air may flow reversely (through the clearance of the packing located at the upper part of the low pressure valve seat) or it may flow away in the atmosphere. Through the clearance of the packing located at the lower part of the low pressure valve seat. This can be found by covering the air inlet port with hand because the air is not sucked in. If the cylinder cover is removed, it can be confirmed that the valve does not come into firm contact with the packing. Increase the number of the packings on the upper part of the valve seat and tighten firmly. 12/21

13 9.2 In Case There is an Abnormal Sound Since this indicates a serious damage, immediately stop the operation of the unit and check its cause. (1) In case the top of the piston comes into contact with the bottom of the low pressure valve: ( Refer to Section (6) ) (2) In case a pulley or flexible coupling key is loosened: (3) In case a clearance is increased due to the abrasion of the piston pin metal: If an abnormal sound can be clearly heard, it indicates that the piston pin metal is considerably worn out. It can be found only by slowly moving the piston. In this case, since it is likely that the crank pin metal is worn out, remove the cylinder cover and check the movement of the piston. (4) In case a clearance is increased due to the abrasion of the crank pin metal: Remove the crank case cover. This cause can be confirmed by slowly rotating the crank shaft and viewing the very part. If it cannot be still confirmed, move the connecting rod vertically, using a long bar. (5) In case there is no clearance in the high pressure area: If a high pressure clearance (clearance of a stepped area) is extremely small, the compressor is hardly resisted when it is rotated by hand, and it causes a sound when it is operated. Take out the packing between the cylinder and crank case to increase the clearance in the high pressure area. When this is done, since the top clearance (between the Lop of the piston and the bottom of the low pressure valve) is also changed, increase the number of low pressure valve packings (large) for adjustment. 9.3 In Case the Unit is verheated: (1) Although some parts of the unit, such as the compressed air outlet, high pressure valve and air piping, may become too hot to touch by hand, it is not abnormal. (2) In case a V-pulley is hot: It is because a belt slips. If it is a V-belt, it smells of the burning of rubber. Check the tension of the belt. (3) In case the whole compressor is hot: (a) In case the cooling water is insufficient: If the cooling water is not sufficient or does riot exist at all, the compressor is overheated and it causes the sticking of the piston. Stop the compressor immediately and check the amount of the cooling water. (For the cooling water amount, refer to Section 1-1.1) When the compressor is overheated due to the shortage of the cooling water, operate tile unit after it has been completely cooled down. There was a case reported that the cylinder had been cracked by flowing the cooling water to an overheated cylinder. 13/21

14 (b) In case the cooling water amount is proper: Heat is generated because the compressed air is not properly sent to the air reservoir. Check whether or not the compressed air passages, such as the high and low pressure valves, non-return valve, and so on, are clogged by carbon. Since the heat may be generated when the diameter of the pipe between the compressed air outlet and air reservoir is too narrow, or when the non-return valve of the air reservoir malfunctions, check also these points. (For the diameter of the pipe, refer to Section 2-2.4) 10. Motor-driven Automatic Air Feed Unit for Compressor This unit feeds air automatically by "N /FF" switch of power source of motor by pressure switch Descriptions of performances (1) Automatic operation: (a) Starting operation: When the pressure inside the air reservoir reaches a specified lower limit, the contact of the pressure switch 1 is closed, and the magnetic switch 2 is actuated to start the motor. The timer 8 on delay works and the magnetic valve 3 is closed in approximately 10 seconds. The 1st stage compression area 4 is shut off from the atmosphere, and the operation of the compressor opens the nonreturn valve 5 to fill the air reservoir with the air. (b) Stopping operation: When the pressure inside the air reservoir reaches a specified upper limit, the contact of the pressure switch 1 is opened, and the magnetic switch 2 is actuated to stop the motor. At the same time, since the current to the magnetic valve 3 is shut off, the valve is opened, and the drainage and residual air inside the 1st stage compression area are discharged into the atmosphere. The non-return valve 5 is closed to prevent the reverse flow of the compressed air inside the air reservoir. (c) Adjustment: The working pressure can be easily adjusted by the spring of the pressure switch. (2) Manual operation: If the auto & manual exchange switch 7 is turned to manual, the unit can be arbitrarily started and stopped by the push button switch 6 apart from the air pressure. 14/21

15 15/21

16 11. Periodic Inspection Periodic inspection is recommended in order to use the compressor without a trouble at any time. Although it is difficult to standardize the periodic inspection due to the application of the compressor, its service conditions, quality of its lubrication oil and its handling, the contents of its inspection and their frequencies are as follows. Periodic Inspection List Inspection item peration hour (hr) Remarks Section Inspection part Job contents Everyday months months year years Lobe oil Crankcase Check of quantity of oil Change of lube oil Check and replacement of piston ring piston Removal and cleaning of piston Reciprocating motion parts Check of piston pin Check of piston pin metal Connecting rod Check of crankpin metal Check of crankpin metal bolt Rotating part Main bearing Check of main bearing Crankshaft Check for wear Zinc protector Check and replacement Sea water cooled Cooling water system Cooling water pump Check and replacement of mechanical seal Check of bearing Check of impeller double plate* Water jacket Cleaning Sea water cooled 16/21

17 Periodic Inspection List Inspection item peration hour (hr) Remarks Section Inspection part Job contents Everyday months months year years Valves Removal, check and cleaning f valves (Note) Replacement of valves Air system Safety valve Check of discharge pressure and cleaning (Note) Non-return Valve Check. Cleaning and replacement of valve seat (Note) Air passage Check and cleaning (Note) Check for leakage ther various pipes Appearance Check looseness of bolts and nuts check for oil leak (Note) Carbon deposition varies depending on quality of lube oil. Determine proper check period after checking carbon deposition. 17/21

18 12. Structural Drawings 18/21

19 19/21

20 Unit: mm A B C D MH114A /21

21 13. List of Clamping Nuts & Tightening Torques Model: MH114A Clamping Nut Tightening Torque Kgf.Cm N.m Remarks M M M UNF 3/ M HP Valve (Reference: Toothed L.W.) M LP Valve M M M M M /21