ROTORCOMP NK 100 Operating Manual Download

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Operating Manual

SCREW COMPRESSOR COMPACT MODULE

NK 100 / NK 100 G

[en] 09/2008

Summary of Contents for NK 100

Page 1: ...Operating Manual SCREW COMPRESSOR COMPACT MODULE NK 100 NK 100 G en 09 2008...

Page 2: ...degree permitted by the applicable copyright laws is permitted without prior written approval The information contained in this document is subject to change without prior notice This document is not...

Page 3: ...NK 100 Screw Compressor Compact Module pneumatic 3 6 3 7 1 Standstill 3 6 3 7 2 Starting 3 7 3 7 3 Feed mode 3 7 3 7 4 Stopping 3 7 3 7 5 Switching off 3 7 3 8 Intake control valve for pneumatic contr...

Page 4: ...ntake air filter 7 6 7 6 1 Maintenance intervals 7 6 7 6 2 Replacing air filter element 7 6 7 7 Maintenance check sheet 7 7 7 8 Maintenance intervals 7 8 8 Lubricants and Operating Materials Maintenan...

Page 5: ...e Any missing parts and or transport damage must be reported immediately A damaged compressor module must not be put into operation under any circumstances Always have the operating manual available f...

Page 6: ...ny defects of these individual components for which it is respon sible within the scope of the warranty conditions Failure to comply with the following instructions and information shall void any and...

Page 7: ...specially trained personnel of the owner or to make it available at the operating loca tion prior to installation and commissioning Prior to installation and commissioning the entire oper ating manua...

Page 8: ...e with doors open or shrouding loose Warning Hot machine parts Warning Pressurized part or system Lifting point Warning High voltage Active environmental protection Warning on a danger point Warning D...

Page 9: ...Control unit electric 5 Transport eye 6 Oil filler opening 7 Oil level monitoring optional 8 Oil drain screw 9 Oil separation return line with oil extraction sight glass optional 10 Oil filter 11 Oil...

Page 10: ...e 13 Safety valve optional 14 Non return valve 3 3 Operating description for NK 100 Screw Compressor Compact Module electric The flow diagram shows a schematic view of the operating principle and the...

Page 11: ...he oil flow is routed directly via the oil cooler 10 or directly to the oil filter 9 by the oil thermostat valve The oil then flows via the oil filter 9 to the various injection points in the compress...

Page 12: ...electric control unit The NK 100 is equipped with an integrated intake valve mounted directly on the compressor hous ing Figure 3 3 A Intake valve opened B Intake valve closed 1 Air inlet 2 Air outle...

Page 13: ...rt eye 6 Oil filler opening 7 Oil level monitoring optional 8 Oil drain screw 9 Oil separation return line with oil extraction sight glass optional 10 Oil filter 11 Oil circulation On 12 Oil circulati...

Page 14: ...fety valve optional 3 7 Operating description for NK 100 Screw Compressor Compact Module pneumatic The flow diagram shows a schematic view of the operating principle and the arrangement of the main co...

Page 15: ...arated from the air The air then flows via the fine separator 6 and the minimum pressure valve 7 to the compressed air outlet In the fine separator 6 the oil is filtered out down to a residual content...

Page 16: ...ctly on the compressor housing Figure 3 7 A Intake valve closed B Intake valve opened 1 Air inlet 2 Air outlet 3 Spring of holding piston 4 Control piston 5 Valve plate 6 Holding piston 7 Spring of co...

Page 17: ...esult the air filter element is the ideal fine filter for the filtering of intake air of compressor system 3 9 2 Intake filter monitoring Maintenance indicator optical option Maintenance indicator ele...

Page 18: ...with oil extraction sight glass option 3 Minimum pressure valve 3 10 1 Oil intake non return valve Figure 3 11 The oil intake non return valve 1 prevents flooding of the fine separator cartridge with...

Page 19: ...recover the extremely finely distributed residual oil in the form of droplets following the pre separation The fine separator cartridge separates virtually the entire residual oil from the compressed...

Page 20: ...re the air recooler and serves as a Pressure holding valve It prevents the pressure drop in case of a lack of counter pressure under a minimum pressure of approx 5 5 bar This pressure is necessary to...

Page 21: ...ixture in the fine separator car tridge has been deoiled the compressed air flows through the air cooler and from there to the con sumer The oil flows via a thermostat see 3 11 2 to the oil cooler The...

Page 22: ...re The oil thermostat opens the connection to the oil cooler when the operating temperature is reached and controls the maintaining of the optimum tem perature of the system in the further process In...

Page 23: ...cold ambient air should be fed through the cooler with a fan A sufficient distance to the cooler must be chosen in order to achieve uniform cool ing air distribution over the entire effective cooling...

Page 24: ...ROTORCOMP VERDICHTER Operating Manual NK 100 3 16 en 09 2008...

Page 25: ...ed With rail transports a record of the facts must also be requested from the railroad With postal consignments the damage must be certified in writing by the postal service before accepting damaged p...

Page 26: ...orted Remove all loose or swinging parts before lift ing the screw compressor Remove drive or body components before hand Only transport the compressor module while depressurized When transported on a...

Page 27: ...ssor housing may be used for this purpose Consult ROTORCOMP beforehand if necessary 5 2 Safety precautions for installation and assembly e Caution To lift the compressor module suitable lifting equipm...

Page 28: ...be torsionally rigid and level The fastening of the compressor module on a base frame together with the drive motor can be designed in accordance with the following ver sions 5 3 1 Fastening on base...

Page 29: ...ammer as this can result in bearing damage When aligning the belt drive exact parallelism without vertical and horizontal angular errors must be ensured A torsionally rigid base frame for the belt dri...

Page 30: ...st be pointed out to the final customer 5 7 Oil cooling L Note The cooler connection lines must be connected torque free to the oil connections The following information on the design and exe cution o...

Page 31: ...g see chapter 7 Maintenance Check the position of the shut off valve Check all screw fitting and fastening screws for firm seating 6 2 Checking direction of rotation Direction of rotation Standard mod...

Page 32: ...te stop fill approx 0 2 liters of oil same oil type as in the oil separator tank into the oil intake hole with a syringe On models with a transmission pour 0 25 liters of oil into the transmission via...

Page 33: ...tem must be carried out Never use flammable solvents or carbon tetra chloride to clean parts Take precautions against toxic vapors or cleaning agents Always ensure absolute cleanliness during mainten...

Page 34: ...l filler opening With the system running the oil level must be vis ible in the oil hose If not conduct an oil level check via the oil filler opening 7 2 2 Oil level check via oil filler opening dWarni...

Page 35: ...till and with the screw compressor system com pletely discharged 7 3 1 Oil change intervals According to the specifications of the system man ufacturer For the reference values for the screw compresso...

Page 36: ...y only be carried out at a standstill and with the screw compressor sys tem completely discharged 7 4 1 Oil filter replacement intervals According to the specifications of the system man ufacturer For...

Page 37: ...intenance intervals With heavily soiled intake air or a poor oil quality the cartridge is heavily soiled making premature replacement necessary 7 5 2 Replacing fine separator cartridge Figure 7 5 L No...

Page 38: ...6 e Caution No dirt or dust particles may get into the air inlet of the screw compressor L Note It is not permissible to clean the filter element the filter element must always be replaced in case of...

Page 39: ...k work carried out with an X or enter mea sured values and confirm with your signature Elapsed time meter reading Replace air intake filter Replace oil filter cartridge Replace oil fine separator cart...

Page 40: ...w of the reference value for the NK 100 screw compressor module Maintenance intervals Bh operating hours Maintenance work See chapter Before commissioning Check oil level in separator tank 7 2 Once af...

Page 41: ...the oil type Corrosion and other material damage may not occur It is not permissible to mix different oils 8 1 2 Topping up oil Use the same manufacturer and the same oil type as is currently in use...

Page 42: ...nents thermostat cooler fan etc have been properly designed and the supply and exhaust air temperatures of the installation room and the compressor system make this pos sible The entire thermal econom...

Page 43: ...tigrade oil The use of multigrade oils can cause problems in the long run as viscosity improvers used are destroyed over time The oil is then no longer secured in the upper viscosity class and a therm...

Page 44: ...ROTORCOMP VERDICHTER Operating Manual NK 100 8 4 en 09 2008...

Page 45: ...sory components in accordance with the corre sponding data sheet of the manufacturer or sup plier Screw compressor model NK 100 NK 100 G Max operating gauge pressure bar 15 15 psi 218 218 Max deliver...

Page 46: ...orques must be used Always tighten screws bolts with a torque wrench Screw bolt type Thread Max torque Hexagonal head bolts Allen screws M 6 10 Nm 7 ft lbs Hexagonal head bolts Allen screws M 8 25 Nm...

Page 47: ...3 Oil filling too viscous Check viscosity 8 1 1 Pressure losses at filter cartridges Pressure loss at separator cartridges too high Replace separator cartridge 7 5 2 Combistat switches off due to exce...

Page 48: ...tch off automatically in case of intermittent operation i e safety valve blows off Upper switching point of network pressure monitor set too high Readjust network pressure monitor Solenoid valve defec...

Page 49: ...is of incorrect size Replace with different nozzle diameter Oil escapes during stop Sealing surfaces in control valve damaged spring in control valve broken Check parts and replace if necessary System...

Page 50: ...ROTORCOMP VERDICHTER Operating Manual NK 100 10 4 en 09 2008...

Page 51: ......

Page 52: ...A member of BAUER GROUP ROTORCOMP VERDICHTER GmbH Industriestra e 9 82110 Germering Germany Tel 49 89 724 09 0 Fax 49 89 724 09 38 info rotorcomp de www rotorcomp de...

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