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CAP-835

23

DIRECT COUPLED (45-185 kW Models)

Fig.12:Screw compressor 45

–185 kW with direct drive

1

Compressor airend

2

Oil separator tank

3

Oil filter

4

Cooling fan

5

Intake filter

6

Main motor

7

Electrical cabinet

8

Frequency converter

(optional)

9

Minimum pressure and non-return valve

10

Safety valve

11

Connection pipe

12

After cooler

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Summary of Contents for NX Series

Page 1: ...t by failing to pay attention to the vital safety information and instructions in this manual Carefully read understand and retain all safety information and instructions before operating this compressor NX Series Oil Injected Rotary Screw Compressor Operator Manual 18 185 kW 25 250 HP ...

Page 2: ......

Page 3: ...sumes no liability for damages caused by failure to adhere to these instructions improper use use of unqualified staff unauthorized conversions technical modifications use of non approved spare parts The actual scope of supply may differ from the descriptions and illustrations in these instructions in the case of special designs the inclusion of additional ordering options or as a result of the la...

Page 4: ...tion 15 3 3 1 Remove shipping spacers 15 3 3 2 Ventilation 15 3 3 3 Connection to the compressed air network 16 3 3 4 Connecting to the power supply 16 3 4 Checking the oil level 17 3 5 Start up lubrication of the compressor airend 17 3 6 Switching on after installation 18 3 7 Work after the initial commissioning 18 4 Design and function 20 4 1 Overview 20 4 2 Brief description 24 4 3 Assembly des...

Page 5: ...5 Checking the compressor temperature 38 7 5 6 Inspect clean coolers 38 7 5 7 Checking the drive unit 38 7 5 8 Re lubricating the electric motor 38 7 5 9 Replacing the oil changing the oil filter 39 7 5 10 Replacing the air oil separator 40 7 5 10 1 Spin on off separator style 40 7 5 10 2 Drop in style separator 40 7 5 11 Replacing the intake filter 40 7 6 Clean replace return line 41 7 7 Measures...

Page 6: ... Use compressed air properly Pressurized air can cause serious injury to personnel 9 Be sure that no tools rags or loose parts are left in or on the compressor or drive parts 10 Do not use flammable solvents for cleaning parts 11 Exercise cleanliness during maintenance and when making repairs Keep dirt away from parts and exposed openings by covering with clean rags or plastic to prevent cross con...

Page 7: ...ng markings are used in these instructions for emphasizing instructions for actions results lists cross references and other elements Marking Explanation Step by step instructions for actions Results of actions References to sections of these instructions and other applicable documents Lists without a set order Button Operating controls e g buttons switches display elements e g indicator lamps Dis...

Page 8: ...rom nonfunctional safety devices If safety devices are not functioning or are disabled there is a danger of injury or death Check that all safety devices are fully functional and correctly installed before starting work Never disable or bypass safety devices Ensure that all safety devices are always accessible ...

Page 9: ...ked by turning it so that the button is released The controller fault must be reset Refer to the controller documentation for information on fault displays WARNING Danger to life from an unauthorized restart An uncontrolled restart of the machine may cause serious injuries including death Before switching the machine back on make sure the cause of the emergency stop has been removed and all safety...

Page 10: ... They must not be allowed to escape into the environment Store oils in suitable containers and dispose of in accordance with applicable local state and federal regulations Lubricants Lubricants such as greases and oils can contain harmful substances They must not be allowed to escape into the environment Dispose of lubricants in accordance with applicable local state and federal regulations 1 5 Si...

Page 11: ...CAP 835 11 Hazardous Voltage Brief instructions for operation This sticker is on the enclosure and contains brief instructions for operation ...

Page 12: ...pect of each defect immediately following detection Damage compensation claims can only be asserted within the applicable complaint deadlines 2 3 Packaging About the packaging The individual screw compressors are packaged in cartons or sometimes on wooden frames and according to the anticipated transport conditions Only environmentally friendly materials are used for the packaging The packaging sh...

Page 13: ...e 4 Lift the package and begin transportation 2 6 Storage Storage of the packaged compressor Store the compressor under the following conditions Do not store outdoors Store dry and dust free Do not expose to any aggressive media Protect against solar radiation Avoid mechanical jolts Storage temperature 60 to 95F 15 to 35 C Relative humidity max 60 In case of storage for longer than 3 months check ...

Page 14: ... In the event of an unauthorized restart of the power supply during installation there is a danger of serious injuries or death for persons in the danger zone Switch off all power supplies before starting work and make sure they cannot be switched on again Follow lockout tagout procedure Improper installation and commissioning WARNING Risk of injury due to improper installation or commissioning Im...

Page 15: ...c disturbance 3 3 Installation 3 3 1 Remove shipping spacers To protect the vibration isolators underneath the motor airend assembly during transport there are red spacers that hold the assembly in place Make sure all of these spacers are removed before first startup of the compressor Failure to remove the spacers will result in excessive vibration and can cause damage to the compressor Fig 6 Ship...

Page 16: ...ty of the owner 1 Connect the compressed air 2 Ensure that the compressed air connection does not represent a stumbling hazard 3 Anchor and fasten the compressed air connection sufficiently Air piping requirements 1 Install required accessories 2 Main piping should have 1 2 slant away from the compressor to drain the condensate 3 Pressure drop of piping must not exceed 5 of discharge pressure Sele...

Page 17: ...ce will result in electri cal overload and the protective devices will shut down the machine 7 Power supply cable fuse and air break switch need to match the compressor power supply requirements to ensure the safety of all electrical components 8 It is necessary to confirm the correct voltage while performing power distribution of the air compressor 9 The grounding wire of a motor or system must b...

Page 18: ...tream of the discharge port between the screw compressor and the compressed air network The screw compressor is now connected to the compressed air network 5 Switch on the main switch 6 Start the screw compressor controller documentation The compressor is ready and may start up automatically at any time 3 7 Work after the initial commissioning WARNING Danger of injury from hot surfaces Surfaces of...

Page 19: ...too high compressor temperature If the compressor temperature is too low or too high the screw compressor may become damaged For detailed information contact the manufacturer If the compression temperature is sufficiently high this ensures that the air humidity taken in does not form condensation Frequent switching on and off of the screw compressor can prevent the compressor from reaching the req...

Page 20: ...essor 1 Controller 2 Emergency stop button 3 Enclosure panels 4 Air receiver optional on 18 22 kW models This chapter shows the screw compressors described in these instructions The compressors differ primarily in size and the installed drive However their basic design is the same ...

Page 21: ...h V belt optional air receiver on 18 22 kW models 1 Air receiver 2 Compressor airend 3 Oil separator tank 4 Oil filter 5 Air oil separator 6 Cooling air fan 7 Oil cooler 8 Air after cooler 9 Intake air filter 10 Drive motor 11 Belt guard 12 Electrical cabinet 13 Minimum pressure and non return valve ...

Page 22: ...rigeration dryer optional 1 Compressor airend 2 Oil separator tank 3 Oil filter 4 Refrigeration dryer optional 5 Cooling air fan 6 Oil cooler 7 Air after cooler 8 Intake air filter 9 Drive motor 10 Electrical cabinet 11 Frequency converter 12 Minimum pressure and non return valve 13 Safety valve 14 Air oil separator 15 Intake manifold ...

Page 23: ... 45 185 kW with direct drive 1 Compressor airend 2 Oil separator tank 3 Oil filter 4 Cooling fan 5 Intake filter 6 Main motor 7 Electrical cabinet 8 Frequency converter optional 9 Minimum pressure and non return valve 10 Safety valve 11 Connection pipe 12 After cooler ...

Page 24: ...ection and reduce the sound level emitted by the unit 4 3 2 Screw Compressor The compressor assembly is an oil flooded positive displacement single stage helical screw type unit consisting of two rotors or screws supported axially by roller bearings and enclosed in a housing or stator as depicted in the sectional view 4 3 2 1 Drive unit Belt and direct drive units are installed in the screw compre...

Page 25: ...the electric motor is speed controlled by the frequency converter in the electrical cabinet Actuation is also performed directly with a coupling 4 3 3 Intake filter Fig 15 Intake filter The intake air filter Fig 15 1 is fitted above the drive motor The air which the cooling air fan pulls into the enclosure is filtered by the intake filter and fed to the compressor airend through the inlet valve Fi...

Page 26: ... Sight glass 5 Drain 6 Separator tank The oil separator tank has several components The relief valve protects the oil separator tank from overpressure The level of the oil can be read through the sight glass The oil is topped up via the filler nozzle and removed via the oil drain 4 3 6 Air oil separator Fig 19 Air oil separator 18 37 kW models The air oil separator Fig 19 1 removes the residual oi...

Page 27: ... back out of the network into the oil separator tank 4 3 8 Coolers Fig 23 Air oil Coolers 18 37 kW models The compressed air is cooled in the air after cooler Fig 23 2 before it leaves the screw compressor via the discharge port Fig 23 1 The oil is cooled by the oil cooler Fig 23 3 and fed back into the oil circuit Fig 24 Air oil Coolers 45 185 kW models The compressed air is cooled in the after c...

Page 28: ...sor airend once again 160 185 kW units contain a second oil filter that requires periodic replacement 4 3 10 Cooling air fan Fig 27 Cooling air fan 18 37 kW models Fig 28 Cooling air fan 45 185 kW models The cooling of the air after cooler and of the oil cooler is performed by the cooling air fan The cooling air fan also supplies the intake filter Fig 28 1 with sufficient intake air ...

Page 29: ... diagram of screw compressor 18 37 kW with direct drive Fig 30 Flow diagram of screw compressor 45 185 kW with direct drive The following interfaces are found in the screw compressor Air supply Cooling air fan Intake filter Discharge port ...

Page 30: ...er to the technical data sheet 5 1 Serial tag Fig 31 Serial tag The serial tag can be found on the enclosure It includes the following details 1 Manufacturer 2 Part number 3 Serial number 4 Motor power HP 5 Voltage V 6 Lot number 7 Discharge pressure PSI ...

Page 31: ... Hours Below 185 F 185 F to 194 F Above 194 F Intervals 8000 6000 4000 5 2 2 Oil The following oils have been tested and approved for use in these compressors 5 2 3 Oil Capacity Screw compressor type 18 185 kW models Type Consumable Fill level 18 Oil 4 US GAL 22 Oil 4 US GAL 30 Oil 5 US GAL 37 Oil 5 US GAL 45 Oil 10 5 US GAL 55 Oil 10 5 US GAL 75 Oil 14 US GAL 90 Oil 14 US GAL 110 Oil 22 US GAL 16...

Page 32: ...ting the compressor from switching to unload When the system air demand falls below 50 of full flow the controller switches the compressor to unload Changing the setting of the modulation valve The modulation valve is not set at the factory The compressor will run load unload To set modulation control refer to the following paragraph Fig 32 Changing the modulating valve setting To change to modula...

Page 33: ...ufacturer or manufacturer approved spare parts If in doubt always contact the manufacturer Loss of warranty The use of non approved spare replacement parts will invalidate the warranty Obtain replacement parts from an authorized distributor Please refer to the Parts list for accurate part number information 7 3 Maintenance schedule The next sections describes the maintenance work that is required ...

Page 34: ...ating under 8000 h Lubricant may require more frequent changes depending on operating environment and running conditions For oil life versus operating temperature see chart on page 31 3 Do not tamper with safety valve setting it is factory set only check operation Tampering will void warranty and result may cause severe injury or death 4 Replace as necessary or every 5 years 5 Visual check weekly ...

Page 35: ...on Min Pressure Valve 110Kw 2104020058 1 Min Pressure Valve 160Kw 185Kw 2104020039 1 Inlet Valve 110Kw 2104050195 1 Inlet Valve 160Kw 185Kw 2104050196 1 Pressure Sensor 2105040250 2 Temperature Sensor 110Kw 2105040246 1 Temperature Sensor 160Kw 185Kw 2105040252 1 Maintenance Notes 1 Initial 500 hours only Follow regular intervals thereafter 2 Change oil yearly if operating under 8000 h Lubricant m...

Page 36: ...ntact with these components may result in serious or fatal injury Before working on the specified components ensure that they have been completely disconnected from the power supply Allow 10 minutes to elapse in order to ensure that the internal capacitors have been fully discharged 1 Close the shut off valve on the pressure network side and secure it to prevent it from being opened again 2 Open a...

Page 37: ...e compressor from reaching the required operating temperature NOTICE Risk of material damage from condensate in the oil circuit Condensate in the oil circuit can cause the destruction of the compressor airend In case of condensate in the oil separator tank contact your authorized distributor department immediately 1 Close the shut off valve on the pressure outlet side and secure it to prevent it f...

Page 38: ...r from inside and outside for dirt 4 Clean cooler surfaces Dirt can be removed by blowing it out While doing this make sure that the dirt from the device is blown out of rather than into the machine In case of severe dirt buildup consult your authorized distributor 7 5 7 Checking the drive unit 1 Close compressed air outlet side gate valve and secure against re opening 2 Open and remove the enclos...

Page 39: ... on the filler nozzle 10 Position the gasket and check that it is firmly in place 11 Insert the screw plug and tighten 12 Switch on the compressor and switch it off again without waiting any longer than one minute controller documentation 13 Check the oil level and top up as necessary Chapter 7 5 3 Checking the oil level topping up the oil on page 36 Replace the oil filter 1 Close the shut off val...

Page 40: ... compressor off and secure it to prevent it from being switched back on again 2 Close the shut off valve on the outlet side and secure it to prevent it from being opened 3 Open and remove the enclosure panels with the special wrench 4 Use a drip pan to make sure that the leaking oil is collected Fig 39 Unfastening the air oil separator 5 Use a wrench to unfasten the cover of air oil separator tank...

Page 41: ... necessary replace them with original spare parts Parts List 6 Place the nozzle and return line Fig 42 1 back in position and tighten the screw connections 7 7 Measures after maintenance has been performed After completion of the maintenance work and before switching the machine on carry out the following steps 1 Check all previously loosened hose connections and fittings to make sure they are tig...

Page 42: ...supply while tracking down and rectifying a fault there is a danger of serious injuries or death for persons in the danger zone Switch off all power supplies before starting work and make sure they cannot be switched on again Improperly executed troubleshooting work WARNING Danger of injury from improper troubleshooting Improperly executed troubleshooting work may result in serious injury and sign...

Page 43: ... during operation replaced by appropriate specialist personnel immediately Before all work make sure that the compressor is not under pressure wait at least 5 minutes Oil vapor CAUTION Danger of injury from oil vapor In case of high temperatures oil vapor can form Oil vapor can irritate eyes and the respiratory system When working on the oil system and if an oil vapor arises wear breathing protect...

Page 44: ...e valve blocked Clean or replace minimum pressure valve Safety valve faulty Check safety valve and replace if necessary Air oil separator clogged Change air oil separator Chapter 7 5 10 Replacing the air oil separator on page 40 Overpressure fault or Network pressure too high Air oil separator clogged Change air oil separator Chapter 7 5 10 Replacing the air oil separator on page 40 Higher outside...

Page 45: ... page 40 Wrong oil being used Refer to Chapter 5 2 2 Oil on page 31 System stops before reaching the final pressure Overheating or overpressure Remedy fault Controller documentation Interruption in the control power circuit Check power circuit Overload motor thermal overload relay tripping Press reset botton on overload Inspect motor circuit for over current condition Pressure drop Pressure differ...

Page 46: ... Filler nozzle 27 I Inspection at delivery 13 Installation Ventilation 16 Installation conditions 16 Installation location 16 Intake filter 26 Interfaces 30 Media 30 M Maintenance Changing the oil filter 41 Checking the build up of condensation 38 Checking the oil level 37 Oil change 41 Replacing the intake filter 42 Replacing the oil 41 Replacing the oil filter 41 Topping up the oil liquid 37 Min...

Page 47: ... ft Nm Lock screw nuts DIN 912 931 933 934 982 design or similar Thread Category 8 8 Unit Category 10 9 Unit M 5 4 43 6 lbf ft Nm 6 27 8 5 lbf ft Nm M 6 7 38 10 lbf ft Nm 10 33 14 lbf ft Nm M 8 18 44 25 lbf ft Nm 25 81 35 lbf ft Nm M 10 36 14 49 lbf ft Nm 50 89 69 lbf ft Nm M 12 63 43 86 lbf ft Nm 88 51 120 lbf ft Nm M 16 154 89 210 lbf ft Nm 217 58 295 lbf ft Nm 10 2 Oil change intervals at eleva...

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