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Installation and operating manual

[en] 02/2014

SCREW COMPRESSOR COMPACT MODULE

NK 31

Original operating manual

Содержание NK 31

Страница 1: ...Installation and operating manual en 02 2014 SCREW COMPRESSOR COMPACT MODULE NK 31 Original operating manual ...

Страница 2: ...eyond the 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 subject to the change service ROTORCOMP VERDICHTER GmbH Industriestraße 9 82110 Germering Germany ...

Страница 3: ...6 3 Switching off 3 6 3 7 Flow diagram of NK 31 START STOP controller 3 7 3 8 Operating description for NK 31 Screw Compressor Compact Module START STOP controller 3 7 3 8 1 Standstill 3 7 3 8 2 Load condition 3 8 3 8 3 Switching off 3 8 3 9 Intake valve 3 9 3 9 1 Installation position 3 9 3 10 Intake air filter 3 10 3 10 1 Micro air filter element 3 10 3 10 2 Intake filter monitoring 3 10 3 11 Fi...

Страница 4: ...dge 7 5 7 6 Intake 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 Maintenance Parts 8 1 8 1 Lubricants and operating materials 8 1 8 1 1 Oil recommendation 8 1 8 1 2 Topping up oil 8 1 8 1 3 Measures at low room temperature 8 1 8 1 4 Piping materials 8 1 8 1 5 P...

Страница 5: ...issing 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 for the operating personnel and make sure that op eration and maintenance are carried out accord ing to the instructions All instructions contained in this operating manu al must be observed in the specified ...

Страница 6: ...e for any defects of these individual components for which it is re sponsible within the scope of the warranty condi tions Failure to comply with the following instructions and information shall void any and all liability This liability disclaimer also results in the loss of claims for damages This applies in particular in case of Installation not approved by RC Improper use Operation of the compr...

Страница 7: ...ained personnel of the owner or to make it available at the operating location prior to installation and commissioning Prior to installation and commissioning the entire operating manual must be carefully read by the specially trained personnel and then kept in a safe place Failure to observe the safety precau tions can result in a serious hazard for the per sonnel the pressure vessel or the envir...

Страница 8: ... the system if the doors are open or the shrouding is loose Warning Hot machine parts Warning Part under pressure Lifting point Warning High voltage Active environmental protection Warning on a danger point Warning Danger of explosion and or detonation Warning Hazardous substances Warning Flammable substances 2 3 2 Instructions to use safety equipment Wear safety helmet Wear safety shoes Wear pers...

Страница 9: ...ht glass optional oil level control 9 Temperature probe connection 10 Oil Thermostat 3 Technical Description 4 5 6 7 19 18 12 11 10 8 16 17 14 15 13 9 1 3 2 Figure 3 1 3 1 General overview of NK 31 Screw Compressor Compact Module standard model with electric control unit 11 Oil circuit outlet 12 Oil circuit inlet 13 Oil filter 14 Oil drain plug 15 Oil filler 16 NK 31 basic module 17 Front cover 18...

Страница 10: ...gure 3 2 3 2 Flow diagram of NK 31 electric control unit 3 3 Operating description for NK 31 Screw Compressor Compact Module electric The flow diagram shows a schematic view of the operating principle and the arrangement of the main components of the NK 31 screw compres sor module with electrical control unit regardless of any other equipment 3 3 1 Standstill At standstill the solenoid valve 3 1 i...

Страница 11: ... opens due to the spring force and the vacuum in the intake cham ber of the compressor The air drawn in flows via the intake filter 1 through the intake valve 2 di rectly into the compression chamber of the screw compressor 4 There the intake air is compressed and oil for lubrication and cooling is injected The oil air mixture then enters the separator tank 5 in which the majority of the oil is se...

Страница 12: ...unit 1 Name plate 2 Control unit pneumatic 3 Intake valve with intake filter unit 4 Safety valve optional 5 Separator cartridge 6 Minimum pressure valve 7 Compressed air outlet 8 Oil sight glass optional oil level control 9 Temperature probe connection 10 Oil Thermostat 11 Oil circuit outlet 12 Oil circuit inlet 13 Oil filter 14 Oil drain plug 15 Oil filler 16 NK 31 basic module 17 Front cover 18 ...

Страница 13: ... the impulse pressure relief valve 3 2 are closed by the spring pretension The downstream devices are depres surized The minimum pressure valve 7 is set to approx 5 bar at the factory is tightly closed The propor tional regulator 3 1 is set to operating pressure 2 1 2 9 8 10 4 5 3 3 1 3 2 11 6 7 13 12 1 1 Intake filter 2 Intake valve 2 1 No load nozzle 3 Control unit pneumatic 3 1 Proportional con...

Страница 14: ...ed which is required for optimum lubrica tion and oil separation When the operating air pressure is reached the proportional regulator 3 1 opens and the pilot air flows under the piston of the intake valve 2 which begins to close The adjustable proportion al regulator 3 1 steplessly controls the pressure under the piston of the intake valve 2 in depen dence on the compressed air removal This pres ...

Страница 15: ...ription for NK 31 Screw Compressor Compact Module START STOP controller The flow diagram shows a schematic view of the operating principle and the arrangement of the main components of the NK 31 screw compres sor module with pneumatic control unit regard less of any other equipment In the start stop controller there is no magnet control or piston The start stop controller func tions only mechanica...

Страница 16: ...a non return function prevents backflow of the compressed air out of the system into the compression chamber in the discharge phase During startup a faster pressure buildup is also ensured which is required for optimum lubrica tion and oil separation The heat resulting during compression is dis sipated via the oil air mixture The oil circulation also results from the pressure difference between th...

Страница 17: ...e 3 6 3 9 Intake valve The NK 31 is equipped with an integrated intake valve mounted directly on the compressor hous ing 3 9 1 Installation position Figure 3 7 1 Different control units can be used for various operating modes the EMC electric control unit or the PMC pneumatic control unit Depending on the application various intake control valve systems can also be used A B 1 1 3 2 4 ...

Страница 18: ...service life As a result the micro air filter element is the ideal fine filter for the filtering of intake air of compressor system 1 3 10 2 Intake filter monitoring Maintenance indicator optical option Maintenance indicator electric option The micro air filter elements are recommended as a 1 stage filter with a low filter resistance for standard applications Attention Special applications e g sys...

Страница 19: ...il separation 3 11 1 Oil intake non return valve Figure 3 10 The oil intake non return valve 1 prevents flood ing of the fine separator cartridge with oil flow ing back out of the screw compressor due to the pressure difference in the system when the screw compressor system is switched off 1 Figure 3 9 3 11 Fine separator 1 3 2 ...

Страница 20: ... fine separator cartridge is used to 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 air An optimum pre separation in the separating tank is assumed the better the pre separation the better the fine separation The vertical cartridge is flowed again...

Страница 21: ... of the compressor before 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 ensure the oil supply of the compressor At the same time this is the condition for good oil sepa ration C Non return valve It prevents compressed air from flowing back out of th...

Страница 22: ...led the compressed air flows through the air cooler and from there to the consumer The oil flows via a thermostat located in the ther mostat head to the oil cooler The cooled oil flows from the oil cooler via the oil filter back into the internal oil air circuit of the compressor module Figure 3 13 3 12 Air oil circulation outside compressor module ...

Страница 23: ...ction to the oil cooler when the operating temperature is reached and controls the maintaining of the optimum temperature of the system in the fur ther process In the startup phase this parameter is reached faster and therefore the formation of condensate in the oil circulation is largely avoided Depending on the compressor operating data the temperature is to be between 70 C and 110 C 158 F and 2...

Страница 24: ...ters are assumed The 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 uni form cooling air distribution over the entire effec tive cooling surface 3 14 Safety valve SIV option Figure 3 15 1 Knurled screw for operating test 1 Warning The safety valve must be installed prior to com missioning Operation of the system w...

Страница 25: ... With rail transports a record of the facts must also be requested from the rail road With postal consignments the damage must be certified in writing by the postal service before accepting damaged packages etc B In case of damage which cannot be recognized immediately which are discovered during unpacking the carrier must be notified immediately and in writing If possible leave packing materials ...

Страница 26: ...be transported 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 pallet the compressor module must be securely fastened to it Do not transport the compressor module on the forks of a stacker or lift truck Transport eyes are only designed for transport ing...

Страница 27: ...he compres sor housing may be used for this purpose Consult ROTORCOMP beforehand if necessary 5 2 Safety precautions for installation and assembly Attention To lift the compressor module suitable lifting equipment must be used which complies with the local safety regulations All blind flanges plugs caps and bags with desiccant must be removed before mounting the pipes Screw fittings and pipe conne...

Страница 28: ...ions must 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 frame with screw fitting Figure 5 1 Attention The compressor module may only be fastened at the side holes on the compressor housing pro vided for this purpose The unit must be fastened torqu...

Страница 29: ...ith a hammer 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 drive must be installed so that it aligns exactly with the compressor module Fluttering of the belt of the belt drive should be prevented with construction measures axis spacing of pulleys belt te...

Страница 30: ...must be pointed out to the final customer Note 5 7 Oil cooling Note The cooler connection lines must be con nected torque free to the oil connections The following information on the design and execution of the oil cooling system must be ob served The oil cooling system must be designed so that the oil outlet temperature is a maximum of 105 C 220 F at the maximum intended ambi ent temperature The ...

Страница 31: ...elt tension and belt routing see chapter 7 Maintenance Check the position of the shut off valve Check all screw fitting and fastening screws for firm seating 6 Commissioning 6 2 Checking direction of rotation Direction of rotation Standard model rotating to the left counterclock wise looking at the shaft Attention The direction of rotation of the screw compres sor must be checked during first comm...

Страница 32: ...t a com plete stop pour approx 0 2 liters of oil same oil type as in oil separator tank into the filler neck after removing the intake filter To do this push down the valve plate and pour the oil directly into the intake opening Rotate the screw compressor again in the direction of rotation several times by hand Check the oil level in the separator tank and top up if necessary see chapter 7 Mainte...

Страница 33: ...m must be carried out Never use flammable solvents or carbon tetrachloride to clean parts Take precautions against toxic vapors or cleaning agents Always ensure absolute cleanliness during maintenance and when conducting repair work Keep dirt away from the system Cover parts and exposed openings with a clean cloth paper or strips of adhesive tape Do not carry out welding work or any other work req...

Страница 34: ... equipment With hot oil the oil level can be approx 10 mm higher than with cold oil shortly after discharg ing As a result oil may escape when the oil filler plug is opened at the maximum oil level In this case close the oil filler plug again imme diately and carefully remove the oil which has escaped Figure 7 1 Note The screw cap of the oil filler neck is provided with a safety hole on the side f...

Страница 35: ...stem completely discharged 7 3 1 Oil change intervals According to the specifications of the system manufacturer For the reference values for the screw compres sor compact module see chapter 7 8 Mainte nance intervals 7 3 2 Oil drain points The system should be at operating temperature in this case Figure 7 2 Note Dispose of the used oil according to the appli cable regulations Switch off the scre...

Страница 36: ...C 176 F danger of burns Wear personal safety equipment The oil filter replacement may only be carried out at a standstill and with the screw compressor system completely discharged 7 4 1 Oil filter replacement intervals According to the specifications of the system manufacturer For the reference values for the screw compres sor compact module see chapter 7 8 Mainte nance intervals 7 4 2 Oil filter...

Страница 37: ...er 7 8 Mainte nance 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 4 Note Dispose of the old fine separator cartridge ac cording to the applicable regulations Unscrew the fine separator cartridge 1 with a suitable tool e g oil filter strap wrench Oil the gasket o...

Страница 38: ...ent Figure 7 5 Attention No dirt or dust particles may get into the air inlet of the screw compressor Note It is not permissible to clean the filter element the filter element must always be replaced in case of soiling Dispose of the old air filter element according to the applicable regulations 3 1 2 Switch off the system and secure it against unauthorized switch on Screw off the nut 1 and remove...

Страница 39: ...k sheet Elapsed time meter reading Replace intake filter Replace oil filter cartridge Replace oil fine separator cartridge Retension V belts Replace V belt set System repair Date Mechanic Mark work carried out with an X or enter measured values and confirm with your signature ...

Страница 40: ...n overview of the reference value for the NK 31 screw com pressor module Maintenance intervals Bh operating hours Maintenance work See chapter Before commissioning Check oil level in separator tank 7 2 Once after 50 Bh Check oil level in separator tank Tighten all screw pipe fittings and electrical screw terminal fittings check all other connections for firm seating 7 2 Every 100 Bh Check oil leve...

Страница 41: ...age 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 in the screw compres sor 8 1 3 Measures at low room temperature Sufficient room heating At ambient temperatures below 0 C 32 F the system must be heated up to at least 20 C 68 F before start up with an integrated standstill heater 8 1 4 Piping ma...

Страница 42: ...ndensate from forming in the system 8 1 8 Cold starts During compressor cold starts the viscosity of the oil must enable the sufficient immediate supply of the compressor with lubricant following starting while taking into account the higher pres sure losses in the oil circulation which is still cold The higher cold starting power requirement must not overload the compressor drive 50 45 40 35 30 2...

Страница 43: ... 1 10 Multigrade 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 ther mal stability is no longer completely ensured Therefore multigrade oils are not approved for use in ROTORCOMP compressors Attention Only use oils approved for screw compressors ...

Страница 44: ...8 4 en 02 2014 Installation and operating manual NK 31 ROTORCOMP VERDICHTER ...

Страница 45: ...ents in accordance with the corresponding data sheet of the manufacturer or supplier 9 1 Technical data Screw compressor model RC NK 31 Max operating pressure bar g 15 psi 218 Max gauge pressure bar g 16 5 psi 239 Max delivered quantity according to DIN 1945 up to m3 min 1 18 cfm 42 Required output up to full load without fan kW 7 5 hp 10 Max speed of main rotor rpm 4200 Oil capacity approx l 3 Ma...

Страница 46: ...llowing torques 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 18 ft lbs Hexagonal head bolts Allen screws M 10 43 Nm 32 ft lbs Hexagonal head bolts Allen screws M 12 75 Nm 53 ft lbs Hexagonal head bolts Allen screws M 14 120 Nm 85 ft lbs Hexagonal head ...

Страница 47: ...too viscous Check viscosity 8 1 1 Differential pressure Pressure in separator cartridge too high with clogged or full separator cartridge Replace separator cartridge 7 5 2 Combistat switches off due to excessively high temperature Oil shortage Check oil level in oil reservoir and top up if necessary 7 2 Oil filter soiled Replace oil filter cartridge 7 4 2 Thermostat defective Replace thermostat 3 ...

Страница 48: ...s not dischar ged during continuous operation system does not switch off automatically in case of intermittent opera tion i e safety valve blows off Upper switching point of network pressure monitor set too high Readjust network pressure monitor Solenoid valve defective Relief valve defective Replace solenoid valve relief valve Minimum pressure valve jammed Check minimum pressure valve for smooth ...

Страница 49: ...trol valve broken Check parts and replace if necessary System does not relieve Solenoid valve electrical system Check Impulse pressure relief valve Check and replace parts if necessary Control valve constantly discharges Solenoid valve electrical system Check Oil escapes during discharging oil foam in fine separator cartridge Oil type incorrect Oil change 7 3 Oil foam forms during stop Install dis...

Страница 50: ...ROTORCOMP VERDICHTER GmbH Industriestraße 9 82110 Germering Germany phone 49 89 72 409 0 fax 49 89 72 409 38 info rotorcomp de www rotorcomp de A Member of BAUER GROUP ...

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