ERVOR 8101000 Operating And Maintenance Manual Download

Page: 1 / 37

Rev. : A

Date : 05/05/20

Operating and Maintenance Manual for Air compressor G04

8_101_000

ERVOR

(SCA)

– Z.I. du Val d’Argent

6 rue Désiré Granet - 95100 ARGENTEUIL

– France



(33) 1 34 11 50 00



(33) 1 34 11 50 10

Web :

www.ervor.com

Page : 1/37

AIR COMPRESSOR G04

(Ref: 8101000)

OPERATING AND MAINTENANCE MANUAL

Summary of Contents for 8101000

Page 1: ...right We reserve the right to make technical modifications Illustrations are not contractual 8_101_000 ERVOR SCA Z I du Val d Argent 6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 1 37 AIR COMPRESSOR G04 Ref 8101000 OPERATING AND MAINTENANCE MANUAL ...

Page 2: ... of Ervor SCA The following information must be given when ordering spares a Compressor type and serial number are stamped on the compressor rating plate see fig 1 b Quantity description and parts numbers of the spares required See chapter of this manual or our web site www ervor com PERSONNEL SAFETY Whenever work is to be carried out on the compressor the electric current must be switched off or ...

Page 3: ...Checking oil level 12 3 2 2 Compressor lubrication 13 3 2 3 General characteristics of recommended oil 13 4 Warning symbols 14 5 Storage 15 5 1 Storage conditions 15 5 2 Under 3 months 15 5 2 1 Year maximum 15 5 3 Over 1 year and each successive year 15 6 Sens of rotation 16 6 1 Splash lubrification 16 6 2 Check sense of rotation 16 6 3 Definition of the sense of rotation 16 7 Starting 17 7 1 Safe...

Page 4: ...eb www ervor com Page 4 37 12 3 Every 200 hours 30 12 4 Every 500 hours or every year 30 12 5 Every 1000 hours 30 12 6 Every 2000 hours 30 12 7 Every 4000 hours 30 13 Tightening torque 31 14 Failures analysis 32 14 1 Start up failure 32 14 1 A Compressor does not start 32 14 2 Running failure 32 14 2 A Compressor start but trips 32 14 2 B Compressor runs but there is no delivery pressure 32 14 2 C...

Page 5: ...ngines or Gas engines and is not planned for a continuous usage The produced air is not breathable If the only compressor is bought it is necessary to install statutory safety valve For all other uses please consult us This compressor has been specifically designed for the compression of air with an optimal working ratio of 1 3 2 3 working stop and continuos operating time of two hours maximum It ...

Page 6: ... The lubrication is made by splash lubrication oil sight glass allow to verify the level of oil in the crankcase 1 3 Technical data G04 1 3 1 General description Capacity FAD 30 bar 7 2 m3 H 5 50Hz Capacity FAD 40 bar 6 5 m3 H 5 50Hz Working pressure 40 bar max Standard speed 600 to 1450 rpm 50Hz 1745 rpm 60Hz Nber of cylinders 2 Flat twin cylinders Nber of compression stages 2 Cylinder diameter L...

Page 7: ...100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 7 37 1 3 2 Limit conditions of use Temperatures of use with speed engine of 1450 rpm The indicated values are for a maximum ambient temperature of 40 C and delivery pressure of 40 bars Pressure air outlet LP stage Temperature air outlet LP stage Temperature air inlet HP stage Temperature air outlet HP stage According to...

Page 8: ... provided with shock absorber is in support on a flat ground to guarantee a correct functioning of the machine 2 1 Arrangement A well dimensioned fresh air duct must be provided to the location where the compressor is to be installed The mouth of the duct should be as close as practically to the suction side of the cooling fan 2 2 Coupling This coupling has been specially designed to absorb vibrat...

Page 9: ...hub Intermediate plate 2mm 0 3 Rrecommendations for assembly Fit the short hub coupling plate on the end of the compressor drive shaft Fit the long hub coupling plate on the end of the motor drive shaft Mount the drive motor onto the common frame Assemble the semi elastic blades between the intermediate plate and the plate on the motor drive side as shown below Align the compressor and motor by ad...

Page 10: ...ETWEEN THE DRIVE MOTOR AND THE COMPRESSOR ARE EFFECTED THROUGH SEMI ELASTIC BLADES It is absolutely necessary that after mounting both plates should move angularly in relation to each other The measurement between these two plates must be maintained while mounting Under no circumstances must the two plates be bonded together Breaking of semi flexible blades This is systematically due to a fault in...

Page 11: ...ar difficulties The ambient temperature should not exceed 40 C Excessively high temperatures of the intake air negatively affect thequality of the compressed air In addition the final compression temperature may rise excessively and which causes abnormal operation of the compressor If the compressor room is too small temperature regulation should be installed The temperature of the compressor room...

Page 12: ...gent 6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 12 37 3 2 Lubricating oil REGULARLY CHECK OIL LEVEL EVERY 8 HOURS OF USE THE VOLUME IN OIL OF THE CRANKCASE IS 1 LITRE MAX FIRST DRAINING AFTER 50 HOURS OF OPERATION AFTER EVERY 500 HOURS OF OPERATION OR EVERY 12 MONTHS vary depending on type of oil and the operating conditions 2 2 1 Checking ...

Page 13: ...mperative to maintain the oil level in the casing above the minimum level that the compressor runs over its minimum speed of 600 rpm to respect the indicated direction of rotation to respect a max inclination of 30 on the two axis 3 2 3 General characteristics of recommended oil Ambient temperature 0 to 30 C 15 to 45 C Type Mineral oil Synthetic oil Recoomended oil ERVOR AIRLUB REGULAR P ERVOR ULT...

Page 14: ...llustrations are not contractual 8_101_000 ERVOR SCA Z I du Val d Argent 6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 14 37 4 Warning symbols A QUALIFIED TECHNICIAN IS NECESSARY FOR ANY INTERVENTIONS Dangerous voltage Noise Hot parts Moving parts No breathable air High pressure Rotaring fan Fluid ejection ...

Page 15: ...vibration or pulsations emanating from e g nearby machinery Avoid extreme ambient temperature temperature and moisture Ambient temperature during storage 5 C 40 C with a relative humidity not exceeding 50 5 2 Under 3 months Close the inlet ports of the suction air intake filters with plastic plugs A sealed package eg heat sealed plastic to avoid dust and surface damage 5 2 1 Year maximum Dismount ...

Page 16: ...ght or left as well as the different situations of mounting of the oi pipe Inform us of any non standard mountings 6 2 Check sense of rotation Entraînement par moteur électrique alimentation triphasé Au moment du branchement de l alimentation du moteur d entraînement vérifier le sens derotation de celui ci Le sens de rotation d un moteur électrique triphasé s inverse en intervertissant deux des fi...

Page 17: ...ions are not contractual 8_101_000 ERVOR SCA Z I du Val d Argent 6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 17 37 RIGHT ROTATION LEFT HAND ROTATION Right hand oil filling ERVOR STANDARD Left hand oil filling Right hand oil filling Left hand oil filling Fig 1 Air outlet Arbre Pipe d huile LP HP LP HP LP HP LP HP ...

Page 18: ...at all the specified protective guards are in place Never clog air intake filter 7 2 Precautions Before first start and after all long term stop control Direction of rotation clockwise looking at the drive end Oil level Instrumentation optional Voltage Turn over the compressor by hand Equipments work correctly Every valves are opened before starting up the compressor 7 3 Monitoring system During o...

Page 19: ...e Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 19 37 7 4 Stopping No action is necessary before stop the compressor If the compressor is to remain unused for a long time drain oil and replace the oil by some oil of storage The compressor should be turned over from time to time Opening air intake filter and air outlet parts should be closed with plu...

Page 20: ...ef 3933024 10 Nm max Split pin ref 7436004 8 Maintenance Overhall Repairs The only ones of the spare parts of origin ERVOR must be used during the interventions at the risk of seeing the cancelled guarantee 8 1 LP cylinder head Suction Delivery Belleville washer x2 ref 7421009 Piston side Manifold side Tightening torque of the screws 25 Nm max Valve stem ref 3925002 Valve ref 3933003 Intake stop r...

Page 21: ...1 50 10 Web www ervor com Page 21 37 Nut ref 7933402 10 Nm max Split pin ref 7436004 Nut ref 7933402 10 Nm max Split pin ref 7436004 8 2 HP cylinder head Piston side Manifold side Tightening torque of the screws 25 Nm max Suction Delivery Valve stem ref 8925000 Intake stop ref 3936005 Valve spring x4 ref 3933011 Valve ref 3933002 Washer CS x2 ref 7423048 Cylinder head ref 3932002 Valve ref 3933002...

Page 22: ...ew one BE CARREFUL NEVER CLEAN VALVES WITH INFLAMMABLE LIQUIDS E G PETROLEUM Remonting of valves Remount valve on the cylinder head according to the figure on the previous page Do not forget the belleville washer and split pin which prevent the slackening of the valve stem nut Tightening of the valves nuts After tightening the castellated nut to a torque reading of 10 Nm continue to tighten the nu...

Page 23: ...ing of crankshaft Connecting rod Spacer Remove the crankshaft Box bearing Crankshaft Wth balance mass 9 Moving parts The moving parts of the compressor are 1 piston low pressure First stage and 1 piston high pressure Second stage in light alloyaxially opposed and connected by 4 arms made in foundry in order to form a monobloc set The monobloc piston containt a unique rod in light alloy bushed with...

Page 24: ...lock and thus enables the extraction of it Remove the single plummer block with a boss puller The monobloc piston with the connecting rod will be removed after dismounting thecylinders 9 2 Remounting of the crankshaft The monobloc piston with the rod being placed in the casing Mount the crankshaft on the single plummer block Fix the set on the casing with the excentric shaft in the correct directi...

Page 25: ...age Ø95mm 0 015 0 045mm High Pressure 2 ND stage Ø40mm 0 025 0mm Ovality of cylinders Disassemble cylinder heads Move the piston to its lowest point to free the cylinder to be checked Check for ovality and possible scratches inside the cylinder Change oval or scratched cylinder Piston rings pistons and cylinders must be checked every 4000 hours of operating Mounting of cylinders For remounting of ...

Page 26: ... adjusted right cut Manufacturing reading Low Pressure 1 st stage Anti leak 95mmm x 3 Qty 2 Scraper 95mmm x 4 Qty 2 High Pressure 2 ND stage Anti leak 40mmm x 2 5 Qty 3 Scraper 95mmm x 2 5 Qty 1 Diameterof pitonring Low Pressure 1 st stage play at cut Anti leak 95 mm 0 30 to 0 45mm Scraper 95 mm 0 45 to 0 60mm High Pressure 2 ND stage play at cut Anti leak 40 mm 0 15 à 0 30mm Scraper 40 mm 0 20 à ...

Page 27: ... 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 27 37 11 1 Mounting of rings Position of rings Pistons must be assembled with three new piston rings to run in good condition Before mounting cylinders make sure that each gap of the piston ring is rotated 120 approximately in relation to the gap of the preceeding piston ring Ø 95mm Ø 40mm Anti leak Anti leak Scraper...

Page 28: ... rings used for ERVOR compressors are conical ones wherefore it is absolutelynecessary to respect the direction of mounting A mark is engraved on one of the flanks of the anti leak piston rings The piston ring should be mounted so as to place this mark on the cylinder head side seehereunder Checking of piston rings in their grooves The piston rings fitted in their respective grooves must slide fre...

Page 29: ...ting of piston in cylinder Wearing of the groves of piston rings The efficiency of a compressor and its consumption depends mosity on the state of segmentation Piston rings must work perpendiculary to the cylinder axis and for this the side play between the piston ring and its groove should not be too large If the wear rate is reached change the pistons and piston rings Piston Ring Clearance for n...

Page 30: ...evel Drain decantor check valve separator not applicable for automatic drain Drain air receivers 12 2 After the first 50 hours Drain oil and refill with new oil Drain air receivers 12 3 Every 200 hours Replace air intake filter 12 4 Every 500 hours or every year Drain oil and refill with new oil Check intake and compression valves clean and grind if necessary 12 5 Every 1000 hours Replace air inta...

Page 31: ...e not contractual 8_101_000 ERVOR SCA Z I du Val d Argent 6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 31 37 13 Tightening torque Cylinder head LP HP 25 Nm Cylinder LP HP 25 Nm Oil pipe 10 Nm Intake pipe 10 Nm Bearing housing 25 Nm Valve LP Ø30mm nuts 25 Nm Valve HP Ø20mm nuts 10 Nm Coupling AC1 nuts 25Nm min 30 Nm max ...

Page 32: ...ssor does not start Source of errors Solution No power supply Check voltage Coupling broken Replace Piston jams Replace piston and fill with oil level 14 2 Running failure 14 2 A Compressor start but trips Source of errors Solution Airing broken Replace decompression device Loose cable Check the wiring 14 2 B Compressor runs but there is no delivery pressure Source of errors Solution Broken piston...

Page 33: ...V V C Intake filter mounting clip 1 8 200 000 U C C C C C C C C C C C C G04 LP cylinder head assembly set 1 8 970 156 C C G04 HP cylinder head assembly set 1 8 970 157 C C LP cylinder first stage standard version 1 3 931 001 V V V LPcylinder first stage Lloyd s Register of Shipping version 1 3 931 019 V V V LPcylinder first stage Bureau Véritas version 1 3 931 017 V V V HP cylinder second stage st...

Page 34: ...6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 34 37 080A 150A 300A 160A 310A 180A 500A 190A 200A 290A 120A 270A 280A 020A 010A 100A 030A 040A 050A 060A 070A 080A 090A 110A 340A 230A 250A 130A 130A 140A 330A 170A 210A 210A 220A 240A 260A 350A 320A 360A 370A 380A 390A 400A 410A 420A 430A 440A 450A 460A 490A 490A 470A 480A 16 Exploded view and pa...

Page 35: ...rew for cooling coil 3 409 501 040A 3 Cooling coil shock absorber 3 943 002 050A 1 plate shock absorber cap of cooling coil 3 943 006 060A 1 Fan 1 050 001 070A 1 Housing bearing 3 936 015 Set of gaskets 8 970 007 080A 2 Gasket cylinder LP HP 7500105 090A 1 Gasket cylinder head LP 7500200 100A 1 Gasket cylinder head HP 7500208 110A 1 Gasket compression cap LP 7500305 120A 1 Gasket HP collector 7500...

Page 36: ...Oil pipe plug 7 603 007 320A 1 Intake filter with clamp 8 200 000 330A 1 Intake pipe 1 934 006 340A 1 Compression cap 3 394 002 350A 1 Connecting rod 8 960 002 360A 1 Piston with rings 8 923 001 370A 1 Piston axis 8 925 001 380A 2 Circlips 7 430 002 1 Set of piston rings 8 970 086 390A 1 LP Cylinder standard version 3 931 001 400A 1 LPCylinder Lloyd s Register of Shipping version 3 931 019 410A 1 ...

Page 37: ...G04 All rights reserved copyright We reserve the right to make technical modifications Illustrations are not contractual 8_101_000 ERVOR SCA Z I du Val d Argent 6 rue Désiré Granet 95100 ARGENTEUIL France 33 1 34 11 50 00 33 1 34 11 50 10 Web www ervor com Page 37 37 Notes ...

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