Compressor
Compressor
Compressor
CONTENTS
1. Compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Compressor unit main components . . . . . . . . . . . . . . . . . . . 3
1.4 Compressing principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Components of compressor circuit . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Operating principle of compressor circuit . . . . . . . . . . . . . . . . 7
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Compressor air circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Compressor oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Compressor regulating system . . . . . . . . . . . . . . . . . . . . . . . 8
4. Control instruments of the compressor . . . . . . . . . . . . . . . . . 12
4.1 Air circuit control instruments . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Compressor oil circuit control instruments . . . . . . . . . . . 13
5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Air circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Air circuit diagram and components . . . . . . . . . . . . . . . . . 16
6.2 Dust collector cleaning impulse . . . . . . . . . . . . . . . . . . . . . 17
2 ( 17) B 62800 ---1 GB 1091/PRa
1. COMPRESSOR UNIT
1 2 5
1. Housing
7
2. Screw rotor
3. Slide rotor
4. Inlet cover
5. Outlet cover
6. Shaft seal
7. Bearing housing cover
6
Fig. 1.
4 3
Fig. 2.
4 ( 17) B 62800 ---1 GB 1091/PRa
4.1
4
4.2
3
6 5
5.2
5.1
15.1
12 14 9
10 15
8
13.1 2
11
13
2. COMPONENTS OF COMPRESSOR
CIRCUIT
8. Oil separator
The oil separator separates the oil mixed with the pressurized air.
9. Minimum pressure valve
The valve keeps at least 3 bar pressure in the tank while the
compressor is running to ensure the oil circulation.
10. Safety relief valve
The valve restricts the maximum pressure in the receiver to 11,7
bar.
11. Thermostat
Cool oil flows through thermostat direct to the return oil filter. When
the oil temperature rises the thermostat closes and directs the oil to
the cooler.
12. Oil cooler
Including radiator cells for compressor oil circulation and hycraulic
oil.
13. Oil filter
The oil filter is a full---flow in---line unit with a built---in by---pass
valve. The by---pass valve (13.1) opens when the pressure
difference over the unit exceeds 3,5 bar.
14. Orifice plate (1 mm)
The orifice plate controls the oil flow to the inlet side of the
compressor coming from the oil separator.
15. Temperature gauge
The gauge indicates the temperature of the compressor output air.
The sensor (15.1) is located under the compressor unit.
B 62800 ---1 GB 1091/PRa 7 ( 17)
3. OPERATING PRINCIPLE OF
COMPRESSOR CIRCUIT
3.1. GENERAL
Figure 3 shows the components of the compressor circuit in a situation
where the compressor produces pressurized air.
The built---in compressor unit (3) produces the pressurized air used by
the drilling rig. The air flows from the compressor into the oil/air
receiver. (7), where the oil is separated from the air.
According to the air consumption, the pressure regulator (5) adjusts
the inlet valve (4) that regulates the inlet port. The temperature gauge
(15) indicates the output air temperature.
From the oil cooler the oil flows to the return filter (13). The filter has a
built---in by---pass valve (13.1) which lets the oil flow past the filter if the
filter is plugged or if the oil is too thick while it is not yet in operating
temperature. The opening pressure of the by---pass valve is 3,5 bar.
From the filter the oil flows into the lubricating ducts at the inlet side of
the compressor (3). At the beginning of the single phase compression,
oil is injected onto the rotors to cool down the air and to seal the
clearances. Oil flows also through the other ducts to lubricate the
bearings and the shaft seal.
After compression, the pressurized oil/air mixture flows from the screw
compressor into the spiral duct of the oil/air receiver (7) where most of
the oil is separated from the air to the bottom of the receiver. The rest of
the oil mixed with the air is separated when the air flows through the oil
separator element (8). The oil from the bottom of the separator
chamber is forced through the pipe to the inlet side of the compressor
unit. The pipe includes an orifice plate (14) (on top of the oil/air receiver)
which must be cleaned regularly.
Before starting
6 5
14
B 62800 ---1 GB 1091/PRa 9 ( 17)
Starting
When the compressor is started the screws generate suction that
opens the spring---loaded (4.2) inlet valve. The compressor starts
producing pressurized air.
4
4.2
7
Production
The inlet valve is fully open, and pressure in the oil/air receiver starts
rising. When pressure reaches 3 bar the minimum pressure valve (9) of
the receiver opens. The pressure regulator (5) is used to adjust desired
output pressure. Normally, the operation is adjusted so that the inlet
valve starts closing at 6 bar, and is fully closed at 7 bar. The inlet valve
will operate steplessly between 6...7 bar.
7
10 ( 17) B 62800 ---1 GB 1091/PRa
Output control
When the consumption of pressurized air is less than the compressor
output, the pressure in the receiver starts rising. When the pressure
reaches the set value, the diaphragm (5.1) of the pressure regulator
starts rising, compressing the spring (5.2). The diaphragm opens a
passage for the pressurized air to enter below the inlet valve piston
(4.1), moving the valve towards the closed position.
5.2
5.1
4.1
Idling
When no pressurized air is consumed and the pressure in the receiver
has reached the maximum set value, the intake valve (4) will be
completely closed.
4
B 62800 ---1 GB 1091/PRa 11 ( 17)
Stopping
When the compressor (3) is stopped, the pressure rises in the
compressor unit and closes the inlet valve (4) preventing air and oil
entering to the intake duct. The pressure in the compressor affects the
cone of the blow---down valve (6), and pushes the ball valve open. The
pressure in the receiver is released into the atmosphere. The inlet valve
(4) and the blow---down valve cone (6.1) will keep up the pressure in the
compressor unit until the receiver is pressureless.
6.1 6
3
12 ( 17) B 62800 ---1 GB 1091/PRa
15
H5
S16 H10
0
S11 S15
0
0
1
P1
S12 S2 S10.1
OFF ON
H
START
S1
H1 H2 H3 H4
22
Fig. 4.
5. TROUBLESHOOTING
COMPRESSOR OVERHEATS
Oil level too low.
D Check oil level and fill up if necessary. Avoid overfilling (1/3 of the
sight glass height is sufficient).
Faulty thermostat (11).
(Oil circulation through the cooler partly or completely obstructed.)
D Check operation and condition of the thermostat (11).
Dirty oil cooler (12).
D Clean the oil cooler.
Plugged oil filter (13).
(Poor oil circulation --- poor cooling efficiency)
D Replace the filter element (13). Also check the air filter (1.1) and
inlet duct for leaks.
Low output pressure.
(Low pressure --- poor oil circulation)
D Raise the pressure by adjusting the pressure regulator (5).
Low pressure may also be caused by excessive air consumption.
Oil viscosity too high (oil too thick).
(Poor oil circulation --- poor cooling efficiency)
D Check oil grade. Refer to oil recommendations.
Air in oil cooler.
(Poor circulation)
D Bleed oil cooler, and change oil type if foaming occurs.
Foaming oil.
D Check oil grade. Refer to oil recommendation. Check oil level.
7
14
21
4 3 15 18
16 20
19
Fig. 5.
B 62800 ---1 GB 1091/PRa 17 ( 17)
List of contents
To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Before starting the repair work . . . . . . . . . . . . . . . . . . . . . 1
Before starting the compressor . . . . . . . . . . . . . . . . . . . . . 1
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection and repair of components . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubricants and tools that you need . . . . . . . . . . . . . . . . . . . 6
To the user 01.02.1999
Enduro air end is an oil injected single stage screw, which is designed for industrial air
compressors.
Each Enduro air end is designed for its own capacity range.
Don’t exceed the max. pressure, power and rotation speed and don’t use lower than the
minimum rotation speed given in the technical data. The warranty of the air end is not
valid if these values are exceeded.
Only the use of original spare parts guarantees long and reliable lifetime.
This instruction makes you acquainted with the repair of Enduro air end.
Read these instructions carefully before starting the repair work.
When ordering spare parts, please, give the codenumber from the plate connected to the air
end.
Safety
Read always the safety instructions of the equipment, where the air end is used!
The cleanness in all repair work is of great importance. All the foreign particles in the air end
shorten the life time of the bearings and the rotors.
1
Technical data 01.02.1999
Rotor size
- male φ mm 120
- female φ mm 95,1
Lobe combination 4/5
Male rotor driven
Displacement volume l/rev 1,2191
Male rotor speed
- min rpm 1820
- max rpm 6300
Tip speed (male)
- min m/s 11
- max m/s 40
Input power
- max kW 45
Working pressure
- min bar 3
- max bar 13
Oil injection quantity l/min 50 - 70
Weight kg about 56
2
01.02.1999
On the repairing of the compressor air end use always special tools.
Disassembly
1. Clean the outside surfaces of the compressor unit from all dirt.
2. Place the compressor unit on a steady surface where the repair work can be carried out.
3. Remove the output end cover(18) mounting screws(24 and 25), and remove the cover.
4. Remove the sealing housing cover(2) screws(1), and remove the cover.
5. Mount a special tool to the drive shaft and lock it to the compressor unit body.
6. Open the shaft nuts(17 and 23) and make sure that the special tool prevents the shaft from
turning. Use special tool. Do not use pneumatic impact tool.
7. Remove the pressure flange(13) mounting screws(20).
8. Remove the tool mounted to the drive shaft.
9. Remove the pressure flange by using the threads in the flange.
(In older models remove the pressure flange by lightly tapping the drive shaft with a
copper drift.
Note! Do not use a screw driver to pry off the flange.)
10. Remove the rotors from the body.
Note! Handle the rotors with care.
11. Note the positions of the ball bearings(15 and 22).
12. Remove the outer bearing races (tap out with a drift) from the bearing housings.
Note! A puller must be used for the bearing(9).
13. Remove the inner ring(5) of the shaft seal (warm up to about 100 ... 150 °C).
14. Use a puller to remove the inner races of the bearings, or place the rotor vertically and
quickly heat up the race to make it fall off.
15. Remove the shaft seal(6) from its housing.
3
Inspection and repair of components 01.02.1999
Assembly
1. Install the bearings(7 and 9) to the body.
Use Loctite 601 to lock the bearings in place and use assembling tool.
Lubricate the bearings.
2. Using the special installing tool, mount the inner races of the bearings(14 and 21, and
7 and 9) onto the rotors (warm up the races to about 100 °C). Use Loctite 601.
3. Insert the rotors into the body and lock the drive shaft with the special tool.
4. Install the bearings(14 and 21) to the pressure flange. Use special tool.
Use Loctite 601 to lock the bearings in place.
Lubricate the bearings.
5. Use grease when installing the O-rings(12 and 19) into their grooves. Mount the pressure
flange.
6. Install the pins(11, 2 pcs) to the pressure flange.
7. Tighten the screws(20) to 180 Nm.
Tighten crosswise.
8. Install the pressure flange ball bearings(15 and 22). Use special tool.
Note! Thick side of inner race upwards.
9. Install the shaft nuts(17 and 23) with their own tools.
Apply Molykote 1000 to the threads.
4
28.02.2000
5
28.02.2000
Cement
Cement Loctite 601
Cement Loctite 542