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Technical Documentation
Piston Compressor
Technical Documentation
for
Piston Compressor Type L 160
of
Uetersener Maschinenfabrik
GmbH & Co. KG
25436 UETERSEN
GERMANY
Ref.-No.: 08.5198
Serial-No.: 08.5198 - 0
This technical documentation belongs NOT in the office, but in the hands of the
operator
Technical Documentation
Piston Compressor
Table of Contents
1 General Comments
2 Description of Compressor
3 Installation Drawing
4 Operating Instructions
5 Technical Indications
7 E-Diagrams
8 E - Motor
9 Lubricating Instructions
10 Service
We recommend reading these instructions carefully and becoming quite familiar with the
design and operation of the piston compressor before putting it into operation.
This will avoid damage through improper handling.
General Comments
General Comments
Information on Instruction Manuals
This technical documentation includes all the information which is necessary for
guaranteeing the safety as well as for the operation and maintenance of the equipment.
It is directed at instructed and trained personnel who are responsible for the operation
and maintenance of the equipment.
Only knowledge of this technical documentation can guarantee faultless and correct
functioning of the equipment, and must be known by the responsible person. The
technical documentation should be kept on board so that the operating and maintenance
personnel have access at all times.
Copyright
The copyright for this technical documentation remains with Hatlapa.
This documentation is intended for the operator and their personnel only and may
neither be reproduced, copied, distributed in parts or as a whole without the written
permission of Hatlapa, nor be used for competitive purposes.
All rights reserved.
Guarantee
HATLAPA undertakes the guarantee that this technical documentation is in accordance
with the technical and functional parameters of the equipment supplied. HATLAPA
reserves the right to include additional information.
It is pointed out that guarantee claims cannot be derived from any lack of information
and details in case of incorrect operation, as operation and maintenance by trained
skilled workers is presupposed.
Guarantee claims will only be accepted in accordance with the conditions of the contract.
Guarantee and liability claims for damage to persons and/or objects are excluded when
caused by one or several of the following circumstances:
- inappropriate use of the equipment,
- neglecting the provisions of this documentation,
- faulty assembly, operation or maintenance,
- operation of the equipment with ineffective protective measures,
- arbitrary functional or constructive alteration of the equipment,
- removal of parts resp. installation of spare parts or additional components which
have not been supplied or approved by HATLAPA,
- repairs during the guarantee period which have not been authorized by
HATLAPA,
- effect of foreign bodies in case of catastrophes or Force Majeure.
Designations
Persons are defined as follows:
• Operator is the (natural or corporate) person, on whose behalf the equipment is
used, e.g. the ship’s owner.
• Operating personnel is personnel trained for the corresponding work who are
authorized to operate the equipment and to remedy disturbances. The operating
personnel must be trained in accordance with his tasks and meet the requirements of
handling the equipment. They must know the necessary protective devices and
protective measures, the relevant provisions, accident prevention rules, and
equipment conditions.
• Assembly personnel is personnel trained for the corresponding work and who are
authorized to assembly the equipment. The assembly personnel must have
knowledge of mechanical, hydraulic, and electric engineering. They are able to carry
out the tasks assigned to them and recognise possible danger because of their
specialized training. In addition they must know the necessary protective devices and
protective measures, the relevant provisions, accident prevention rules, and
equipment conditions.
• Maintenance personnel is personnel trained for the corresponding work and who are
authorized to maintain, adjust and modify the equipment. They are able to carry out
the tasks assigned to then and recognise possible danger because of their
specialized training. In addition they must know the necessary protective devices and
protective measures, the relevant provisions, accident prevention rules, and
equipment conditions.
An electrician has electro-technical knowledge gained by corresponding education,
masters the legal regulations, and is assigned by the operator to carry out work on their
electrical equipment and appliances.
description of compressor
174598-06060
Enddruck,
final pressure : 30 bar
Ventile: valves:
kombinierte konzentrische Saug- und combined concentric suction and pressure
Druckventile in allen Stufen valves in all stages
Lager: bearings:
Kurbelwelle : Gleitlager crankshaft : slide bearings
Pleuel: Gleitlager connecting rod: slide bearings
Kolbenbolzen: Nadellager wrist pin: needle roller bearing
20.12.1998
M. Fröse
Instruction manual
Piston compressor
To Introduction
Type Instruction manual
INTRODUCTION:
This Instructions Manual contains a brief technical description and important instructions
on commissioning, maintenance and servicing of the compressor.
We recommend to read this manual carefully in order to be able, in case of trouble, to
detect the cause quickly and care for remedy and, in case of repairs, to make provisions for
proper mounting acc. to the instructions.
This manual assumes a general technical knowledge of piston compressors and does not
claim to be complete. If repairs become necessary, only original HATLAPA spare parts
must be used in order to maintain the operational reliability and efficiency of the machine.
For identification and supply of spare parts, an order must contain the following
information:
In order to receive spare parts with the least possible delay, get in touch direct with
To Table of Contents
2 Rev.: 15.09.1999
Instruction manual Type
TABLE OF CONTENTS:
Page:
Introduction ................................................................................................................2
1 Description ...............................................................................................................4
1.1 Design.....................................................................................................................4
1.2 Specifications..........................................................................................................5
1.3 Working method .....................................................................................................5
1.4 Cooling....................................................................................................................5
1.5 Lubrication of Working Parts ..................................................................................6
1.6 Condensate Separation ..........................................................................................6
1.7 Starting without Back-Pressure...............................................................................6
3 Commissioning........................................................................................................8
3.1 Safety References ..................................................................................................8
3.2 Before Starting........................................................................................................9
3.3 After Starting...........................................................................................................9
3.4 During Operation ....................................................................................................9
3.5 After Stopping .........................................................................................................9
6 Spare Parts.............................................................................................................17
Rev.: 15.09.1999 3
Type Instruction manual
1 Description
1.1 Design
Three-stage, single acting, air-cooled, 3-cylinder trunk piston machine with 60° W
cylinder arrangement.
The equalization of mass of the crank mechanism and the special arrangement of
the three cylinders together with the use of trunk pistons guarantee low vibrations
during operation. They enable a 3-point resilient mounting without any problems..
The use of trunk pistons at all stages guarantees low wear and safe lubrication with
high service life expectancy for pistons and cylinders.
4 Rev.: 15.09.1999
Instruction manual Type
1.2 Specifications
The compressor compresses the ambient air sucked in through the air-intake filter
with silencer in three stages to the selected final pressure. Combined concentric
ring plate valves with large flow cross-sections control automatically the gas
exchange in the compression chambers. After every stage the heated compressed
air flows through a large-dimension cooler. To monitor the correct functioning of the
compressor a pressure gauge and a thermometer are installed after each
compression stage. Safety valves, installed after every compression stage, prevent
the pressure from rising above the admissible limit.
1.4 Cooling
The heat generated in the machine by air compression and mechanical friction is led
off to the atmosphere. An axial-flow fan fixed on the face of the crankshaft sucks
cooling air through a combined light alloy honeycomb radiator at the 1st, 2nd and
3rd stages and forces this to the cylinders installed downstream.
Rev.: 15.09.1999 5
Type Instruction manual
Only compressor oils according to the enclosed oil specification chart may be used.
Crankshaft and conn. rod bearings are force-feed lubricated by means of a
gearwheel oil pump driven directly by the crankshaft. This pump sucks the oil from
the crankcase through a sieve and forces it to the two main bearings of the
crankshaft, as well as to the conn. rod bearings. The lubrication oil pressure is
limited by a spring-loaded pressure limiting valve and is indicated by a pressure
gauge. The lub. oil pressure is monitored by a pressure switch, which switches off
the compressor in case of insufficient oil pressure.
Together with the moist ambient air which is sucked in, water enters the compressor
in form of vapour. By compression and subsequent cooling of the compressed air,
this water vapour condenses. The water separated from the compressed air blends
with the oil which is entrained in very small quantities from the lubricated working
surfaces of the cylinders. This water-oil mixture is extracted from the compressed-
air stream in special condensate collector chambers.
At regular intervals – after every 15 min. for about 10 sec. - as well as on starting
and stopping of the compressor, the collector chambers must be drained by opening
the manual valves or optionally by automatic devices. Such condensate separation
reduces wear and tear due to corrosion in the compressor components, and in the
connected pipelines and prevents the compressor from damage due to water
shocks. Disposal of the condensate has to be carried out according to the locally
valid prescriptions.
During starting-up, the driving motor must be unloaded by opening the drain valves.
In automatically controlled compressors, unloading is effected by time-lagged
closing of these valves.
6 Rev.: 15.09.1999
Instruction manual Type
In case of resilient mounting there must be sufficient room for movement. All
pipelines must then be connected to the consumer system by flexible hoses, strictly
adhering to the installation instructions.
All drain pipelines are to be laid with constant descent and must discharge into an
open funnel after the shortest possible distance. Each compression stage needs a
separate drain pipeline in order to guarantee perfect drainage of the individual
stages; stop valves are to be installed as closely as possible to the compressor.
Rev.: 15.09.1999 7
Type Instruction manual
3 Commissioning
• Only authorised and trained persons are allowed to operate and repair the
machine or to do maintenance work. Make sure that these persons have read
and understood the complete operating instructions and safety instructions.
• The compressor may only be used for compressing air.
• The compressor may not be operated without safety or protecting devices.
• Only sealed safety valves may be used, readjustment is not allowed. They
have to be replaced immediately when defective.
• Before starting any maintenance work it is necessary to stop the compressor
system and to prevent it from re-starting. The system has to be voltage–free,
all parts containing compressed air have to be depressurized.
• The compressor system may only be operated in perfect working condition. It
must be free of foreign parts.
• Rebuilding or any other changes to the compressor system that may
influence the safety are strictly prohibited.
8 Rev.: 15.09.1999
Instruction manual Type
• The compressor must be filled to the upper oil level mark with prescribed
compressor oil (see list of recommended oils).
• Check that the crankshaft is moving easily by turning over the flywheel by
hand; but make sure that the compressor set cannot be started
unintentionally.
• Open the shut-off valve in the pipeline leading to the compressed-air receiver.
• Open drain valves.
• Once the final pressure is attained, check the safety valves for proper
functioning: Slightly turn the knurled nut until the valve blows off. After
closure, check for leakage.
• Observe the compressed-air temperature at the thermometers.
• After fitting of new working parts (repair), run in the compressor for about one
hour at low final pressure (5 to 10 bar).
Rev.: 15.09.1999 9
Type Instruction manual
a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil,
however, not exceeding the top oil level mark. Too much oil results in foaming
due to immersion of rotating parts, with the compressor at extremely inclined
position. Intense misting of the oil and uncontrolled cylinder lubrication would
result in increased oil consumption and coking of the working valves.
b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot
from running - and fill in fresh compressor oil after having cleaned the oil sieve.
c) Regularly and carefully check the oil pressure as well as the air pressure of all
stages. Varying operating pressure values indicate anomalies in the lubricating
system and valves, as well as leaks in the piping system.
d) At regular intervals dismantle and strip down the combined suction and pressure
valves and clean all parts. Packing rings between valve and cylinder head must
be replaced in sets only. For details, see „4.3 Overhaul of Valves„.
e) Check the safety valves on the compressor by slightly turning the knurled nut at
short intervals.
10 Rev.: 15.09.1999
Instruction manual Type
After first commissioning, after a general overhaul, and after repairs to the crank
mechanism or cylinder, the following maintenance work should be done:
Rev.: 15.09.1999 11
Type Instruction manual
1.) Clean the combined suction and pressure valves and check for wear.
2.) Check parts which come into direct contact with hot compressed air, such as
valves, cylinder heads and compressed-air pipelines for carbon residues and,
if necessary, clean them with solvents.
The admissible servicing intervals of the valves are determined above all by the
operating conditions and by the properties of the lubricant used. We recommend
to reduce the servicing intervals in case of severe operating conditions.
12 Rev.: 15.09.1999
Instruction manual Type
The combined suction and pressure valves of the compressor require conscientious
care and maintenance. Their springs and plates are the most intensely stressed
parts of the compressor.
For cleaning, the concentric valves have to be dismantled by removal of the fitting
bolt. Soaking of the components in paraffin facilitates removal of coked deposits.
Care should be taken that the ground sealing surfaces, and valve plates are neither
scratched nor damaged. Springs and valve plates should be checked for damage
and wear and replaced, if necessary. For reassembly, adhere strictly to the assembly
diagram (parts list). Parts of different valves must not be mixed. Tighten the fitting
bolt with the prescribed torque. After reassembling check the soft running of the
valve plates against the spring pressure using a rounded pin. Valves or valve parts
must be clamped in a vice with smooth jaws only. When fitting the valves, use new
packing rings in sets and see that they are properly positioned.
Cylinder head nuts and bolts for pipes should first be tightend by hand. Then nuts
should be initially tightened cross-wise using a torque wrench at approx. 10 Nm
(1 kpm) and then tightened securely in the same sequence to the necessary torque.
Pistons and cylinders can be removed for cleaning and checking of wear without
dismantling the connecting rod and crankshaft. All components must first be marked
so as to maintain pairings (assignment of pistons and cylinders) and the positioning
of the parts for reassembly.
To dismantle the pistons after pulling out the cylinders, firstly remove each of the
retainer rings of the wrist pins using a pair of circlip pliers, and then push the wrist
pin out of the piston with a set bolt or other suitable device.
Heating the piston to between approx. 60°C and 80°C facilitates insertion of the wrist
pin. Piston rings should be removed and inserted only using piston-ring pliers.
Observe that the piston rings are correctly positioned (see parts list) and stagger the
joints when fitting. On inclined cylinders, the oil scraper ring joint should point
upwards when fitted.
To measure clearance and wear, first of all, all parts must be cleaned and checked
for damage. The measurement of the cylinder diameter is carried out using a
precision internal gauge applied in the operational way of the piston rings.
The nominal diameter of the piston is stamped on top of the piston head. The actual
diameter should be checked at the bottom end of the piston stem, at right angles to
the wrist pin axis. For fitting clearances and wear limits refer to the attached list.
Rev.: 15.09.1999 13
Type Instruction manual
To check the joint clearance, the piston rings should be inserted at a right angle into
the upper cylinder aperture and positioned at a location where the cylinder liner
shows no signs of wear. The joint clearance is measured using a feeler gauge.
Before fitting the pistons and cylinders, the seat-face on the crankcase and
underside of the cylinder must be carefully cleaned. Use new cylinder gaskets. Apply
oil to pistons and cylinders. Compress piston rings with a tensioning band and slip
the cylinders over the pistons by hand.
Parts, which have reached or exceeded their service life (see List of Wear Limits),
should be replaced.
Clean the oil ducts and blow through compressed air. Thoroughly oil the bearings
and journals as well as the associated components before assembly. Insert the
crankshaft in the crankcase first without shaft seals and then screw on the housing
cover with its gasket. Check wether the axial clearance of the crankshaft is within
the admissible clearance. Fit the shaft seals and tighten the housing cover screws to
the prescribed torque. When fastening the flywheel and the fan wheel, secure the
crankshaft against rotation by inserting a rod from outside through the opening of
the flywheel housing into the flywheel bore.
14 Rev.: 15.09.1999
Instruction manual Type
Compressors which will be put out of operation for several months must be
protected against corrosion.
Internal protection:
• Open drain valves of 1st and 2nd stage under pressure.
• Run the compressor without pressure while the drain valves are open.
• Close the drain valves.
• Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the
air-intake socket within approx. 2 minutes.
• Shut down the compressor and open the drain valves.
External protection:
• After cleaning, apply rust-preventive paint to all parts.
• Components made of light alloy, copper or brass need no treatment.
• Finned cylinders and cylinder heads should only be given an application of
aluminium bronce.
Rev.: 15.09.1999 15
Type Instruction manual
5 Trouble Shooting
The following details are intended to provide a brief guide to determining the
cause of abnormal operation. We do not claim that this information is complete.
It only deals with the faults most frequently encountered, as known from
experience.
e) Safety valve 1st stage / 2nd stage blowing off / Intermediate pressure too high
sea c)
f) Safety valve of final stage blowing off, final pressure too high :
Closed valve on compressed-air receiver.
Non-return valve does not open.
Defective pressure control switch (of the automatic system).
16 Rev.: 15.09.1999
Instruction manual Type
6 Spare Parts
We recommend to keep some spare parts in stock in order to allow quick remedy
of minor failures due to the natural wear and tear.
Rev.: 15.09.1999 17
Type Instruction manual
In order to receive spare parts with the least possible delay, get in touch direct
with
18 Rev.: 15.09.1999
Technische Hinweise
Technical Indications
Technische Hinweise
Technical Indications
Kolbenkompressor
Piston Compressor
Luft
Technische Hinweise
Technical Indications
Zeichnungs-Nr.:
Drawing No.:
Luft
Anzugsdrehmomente Typ
Tightening Torques L160 - L190
Couples de serrage L220 - L270
Zylinderkopf 1. Stufe / 1st Stage / 1ère étage 78 Nm
cylinderhead 2. Stufe / 2nd stage / 2ème étage 78 Nm
culasse de cylindre 3. Stufe / 3rd stage / 3ème étage 32 Nm
Zylinder 1. Stufe / 1st Stage / 1ère étage 185 Nm
cylinder 2. Stufe / 2nd stage / 2ème étage 185 Nm
cylindre 3. Stufe / 3rd stage / 3ème étage 185 Nm
Pleuel 1. Stufe / 1st Stage / 1ère étage 85 Nm 1)
connecting rod 2. Stufe / 2nd stage / 2ème étage 85 Nm 1)
bielle 3. Stufe / 3rd stage / 3ème étage 85 Nm 1)
Ventilzentralschraube 1. Stufe / 1st Stage / 1ère étage 91 Nm
valve fitting bolt 2. Stufe / 2nd stage / 2ème étage 35 Nm
goujon de soupape 3. Stufe / 3rd stage / 3ème étage 19 Nm
Lagerdeckel Kurbelgeh.
crankshaft bearing cover 78 Nm
couvercle palier/carter
Stand: 24.09.1999
Verschleißgrenzen Typ
Wearing limits
Limites d´usure L160 - L190
Durchmesser Zylinder / Zylinderlaufbuchse 1. Stufe
st
diameter cylinder / cylinder liner 1 stage 185,60 mm
diamètre du cylindre / chemise du cylindre 1ère étage
2. Stufe
nd
2 stage 110,4 mm
2ème étage
3. Stufe
rd
3 stage 60,3 mm
3ème étage
2. Stufe 1,5 mm
nd
2 stage 1,5 mm
2ème étage 1,5 mm
1,2 mm
3. Stufe 0,9 mm
rd
3 stage 0,9 mm
3ème étage 0,9 mm
1) Um das radiale Lagerspiel zu bestimmen, zieht man den gemessenen Zapfendurchmesser vom
gemessenen Lagerdurchmesser ab.
1) In order to find out the radial bearing clearance, detuct the measured journal diameter from the measured
bearing inside diameter.
1) Pour trouver le jeu du palier radial, déduire le diamètre mesuré du tourillon du diamètre d´alésage mesuré
du palier.
Stand: 24.09.1999
178483
FLEXIBLE HOSE
INSTALLATION GUIDELINES
Flexible hoses are used for connecting a flexible mounted compressor assembly to a rigid
piping system. When a hose is installed, it must allow the compressor to move in all three
directions. See typical applications below, which show a single bend, to achieve this. The
diagrams apply to both air and water.
Note:
The following diagrams show flexible hoses with threaded end connections, however
flanged end connections may be supplied. These guidelines apply to the flexible part of
the hose, regardless of the type of end fitting supplied.
No pressure
High pressure
To allow the flexible part of the hose to move when pressurised, ensure no supporting
clamps are located on the bends.
incorrect correct
On installation, ensure that the flexible part of the hose is not twisted, this could result in
hose damage and, when pressurised, it could untwist, loosening the connections.
16.01.2006
122/Pitrowski 1/4
178483
FLEXIBLE HOSE
INSTALLATION GUIDELINES
incorrect correct
Use angle adaptors to eliminate tight bend radii and sharp twists occurring in the hose.
incorrect correct
If the installation bend radius is less than the minimum allowed, use angle adaptors to
eliminate tight bend radii.
16.01.2006
122/Pitrowski 2/4
178483
FLEXIBLE HOSE
INSTALLATION GUIDELINES
incorrect correct
Ensure the hose is installed with a smooth bend, avoiding any tight corners, which could
cause the flexible part of the hose to collapse.
incorrect correct
In a collinear application, do not install the hose in a straight line or with kinks, use angle
adaptors.
16.01.2006
122/Pitrowski 3/4
178483
FLEXIBLE HOSE
INSTALLATION GUIDELINES
incorrect correct
Ensure the hose is kept away from hot surfaces by using suitable clamps. High ambient
temperatures can reduce the life of the flexible part of the hose.
16.01.2006
122/Pitrowski 4/4
Safety Instructions for Hoses
1 General
Hose pipes are safety relevant parts which may endanger persons and the environment
in case of failure.
1.1 Installation and maintenance
During installation the hoses must in no way be damaged, bent, twisted
or exerted to pressure. They must not be painted or have contact with
sharp objects!
For cleaning hose pipes and hoses neither aggressive cleaning agents
nor pressure cleaners may be used. They can damage the hose surface
resp. hose line!
Kolbenkompressor
Piston compressor
Compresseur à piston
L 160 - L 190
Zum Verzeichnis
To the List
vers la liste
Ersatzteilverzeichnis Kompressor L160-L190
List of spare parts Compressor L160-L190
Liste des pièces de rechange Compresseur L160-L190
Stand: 16.11.2005
L 160 / L 190
Kurbelgehäuse
crank case Tafel / Table / Planche
carter 1-999-010
1/1
Tel.: + 49-(0) 4122 / 711-0 Geschäftsführer / Amtsgericht Elmshorn:
Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49-(0) 4122 / 711-104 Managing Directors: HRA 0499
Tornescher W eg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
0 1 2 3 4 5 6 7 8 9
Brücke ! Brücke !
link ! link !
Entwässerungsventil 3. Stufe
FOR START/STOP IN AUTOMATIC
Entwässerungsventil 1.Stufe
Entwässerungsventil 1.Stufe
DRAIN VALVE SECOND STAGE
Start/Stop in Automatik
Luftteemperatur-Wächter
Druckluftwächter für
U V W
220-230V AC
220-230V AC
220-230V AC
24V DC
24V DC
24V DC
-1M1 3 NO
* NO
* NO
*
P P T
Kompressor L160
COMPRESSOR L160 -1F4 -1F2 -1F3
40,2 kW -1Y1 -1Y2 -1Y3
* Bei Gleichstrom-Magnetspulen muß das Kabel
am Gleichrichter im Stecker angeschlossen werden.
* IN CASE OF DC SOLENOID COILS THE CABLE MUST BE CONNECTED
TO THE RECTIFIER INSIDE THE PLUG.
HATLAPA
Datum 11.07.08
Anschlußplan Kompressor L160 Gruppe : 334887-44070
Bearb. Bre
Gepr. cpu CONNECTION DIAGRAM COMPRESSOR L160 Uetersener Maschinenfabrik Blatt 1
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333391 Ers.f Ers.d von 1 Bl.
0 1 2 3 4 5 6 7 8 9
600 210
Schaltschrank Kompressor
STARTER/CONTROLLER COMPRESSOR
P1 Amperemeter
P1 (mit Markierungsanzeiger)
AMMETER
ISOLATING SWITCH
HATLAPA
Schutzart: IP54
PROTECTION CLASS: IP54
8
20
mit Türfeststeller
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 1
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
0 1 2 3 4 5 6 7 8 9
SIEMENS TD 200
HATLAPA SHIFT
ESC ENTER
schwarz auf
schwarz auf rot hell-blau schwarz auf grün schwarz auf weiß
black on
black on red light blue black on green black on white
HATLAPA
dark blue on white
dunkel-blau auf weiß
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 2
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
short description f.compressor control with TD200: Kurzbeschreibung für Kompressorsteuerung mit TD200
ON / OFF: The standard text on the text display is: ready for operation / off Dies ist der Standart-Text auf dem Display. EIN / AUS
Betriebsbereit / aus
Now you can start the compressor in manual or Jetzt kann man den Kompressor in der Hand- oder
in automatic operation. in der Automatik-Betriebsart starten.
When You press the "MAN" push button the compressor on / man Mit der Taste "MAN" wird der Kompressor in der
compressor starts in maual operation without any Kompressor ein / Hand Hand-Betriebsart gestartet. D.h. ohne Funktion des
function of the air pressure switch F4. Druckluftschalters F4.
Normallay the manual operation is only used for Normalerweise wird diese Fuktion nur für
maintenance purposes. Wartungszwecke benutzt.
After a blackout the cmpressor will not start Nach einem Spannungsausfall wird der Kompressor in
again in this manual mode. der Betriebsart "Hand" nicht wieder selbsttätig
starten.
When You press the "STOP" push button the ready for operation / off
compressor stops again. Betriebsbereit / aus Mit dem Taster "STOP" kann der Kompressor wieder
gestoppt werden.
When You press the "AUTO" push button the
compressor is switched to automatic mode.
The compressor starts and stops automatically Mit dem Taster "AUTO" kann der Kompressor in die
depending on the air pressure. Betriebsart "Automatik" geschaltet werden.
Normally this should be the standard operation Der Kompressor startet und stopt dann selbstätig
mode. in Abhängigkeit des Druckluftschalters F4.
When the pressure switch F4 is closed the compressor on / auto Wenn der Druckluftschalter geschlossen ist, dann
compressor starts. Kompressor ein / Auto startet der Kompressor.
When the pressure switch F4 is opened the ready for operation / auto Wenn der Druckluftschalter geöffnet ist, dann
compressor stops. Betriebsbereit / Auto stopt der Kompressor.
After a blackout the compressor will start again Nach einem Spannungsausfall wird der Kompressor in
in automatic mode. der Betriebsart "Automatik" selbstständig wieder
anlaufen.
ALARMS: When you want to change the operation mode from ALARME
manual to automatic or from automatic to manual
you must press the "STOP" push button before. make maintenance ! Wenn eine Störung vorliegt, dann stopt der
Wartung fällig ! Kompressor und es wird der zugehörige Alarm im
When there is any fault, the compressor stops motor overload Textdisplay angezeigt.
and the belonging disturbance alarm is shown in Motor Überlast Nicht alle hier dargestellten Alarm-Texte werden
the display. low oil pressure für diesen Kompressor benutzt.
Not all possible disburbance texts are used Oeldruck-Alarm Jetzt must der entsprechende Fehler behoben werden
for this compressor. high air temperature und dann der "RESET"-Taster betätigt werden.
Lufttemperatur-Alarm
high cooling water temperature
Kühlwassertemperatur-Alarm Darauf sollte dann der Standart-Text wieder auf
Now the fault must be eliminated. Then press the no cooling water dem Display erscheinen.
"RESET" push button and there should be the kein Kühlwasserfluß Jetzt kann der Kompressor wieder mit den Tasten
standard text on the display again. "MAN" oder "AUTO" gestartet werden.
Now You can start the compressor again with ready for operation / off
the "AUTO" or "MAN" push button. Betriebsbereit / aus
EINSTELLUNGEN
SETTINGS:
When there are one or two arrows in the right Wenn ganz rechts im Display ein oder zwei Pfeile
side of the display, you can go to other display dargestellt werden, dann kann mit d.entsprechenden
texts by pressing the belonging arrow push buttons Pfeil-Tasten zu anderen möglichen Texten
gesprungen werden.
The other texts can show more disturbance alarms, Die weiteren Texte können weitere Alarme anzeigen,
if there is more than one fault. workings hours xxxxx h wenn mehr als eine Störung ansteht.
Or you can watch the working hours. Betriebsstunden Oder es werden die Betriebsstunden angezeigt.
Or you can watch some special settings of the drainage time 5sec
software. Entwässerungsdauer Oder es können einige variable Einstellungen der
Normally all settings are done by HATLAPA for drainage interval 20min Software angezeigt werden.
a normal purpose of the compressor. Entwässerungsinterval Normalerweise sind alle Einstellungen für einen
If you want to change any setting, you must star delta time 4sec normalen Kompressorbetrieb bereits durch HATLAPA
press the "ENTER" push button one time. Now you Stern-Dreieck-Zeit festgelegt.
can change the value with the arrow push buttons. delayed start 0sec Wenn Einstellungen geändert werden sollen, muß
After this you must quit the new value by pressing verzögerter Anlauf einmalig die "ENTER"-Taset betätigt werden. Dann
"ENTER" again. cooling water delay 2min kann man mit den Pfeil-Tasten den entsprechenden
Kühlwassernachlauf Wert verändern. Daraufhin muß der geänderte Wert
continuous time 0min nocheinmal mit der "ENTER"-Taste quittiert werden.
Durchlaufzeit
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 3
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
0 1 2 3 4 5 6 7 8 9
-P1 100A 1 3 5
K
k + A -
-T2
100/1 l -Q3
L 0,63-1A 2 4 6
GV2 RT05
-T1 -F2 2A
-Q1 2 4 6 11 1 3 5 1L1
/5.0
440V 220V
2
-K1 250VA
1 3 5 12 /8.1 2 4 6 0P 0S 1N1
4
/8.9
/5.0
1 3 5 ±5%
97 95
-F1 98 96
55-70A 2 4 6
CLASS 20
/6.0
-X1 L1 L2 L3 PE U V W PE
60Hz
60Hz
U V W
440V
-M1 M
3
Zuleitung
Kompressor
COMPRESSOR
37-44 kW
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 4
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
0 1 2 3 4 5 6 7 8 9
1L1
/4.9
1N1 1N1
/4.9 /8.0
+24V DC 1L+
/6.0
0V DC
-A1
1L
Aus 2L
1M
2M
M
Erw L+
PE
Vers N
L1
S7-CPU 222 Relais-Ausgänge
Ein
8 x Eingänge 6 x Ausgänge Relais
Softwareversion 2 E0.0 /6.0 MOTOR PROTECTION RE 2 A0.0 /8.1 MOTOR MAIN CONTACTO
TD200_8 3 E0.1 /6.2 AIR PRESSURE SWITCH 3 A0.1 /8.2 DRAIN VALVES E
4 E0.2 /6.4 OIL PRESSURE SWITCH 5 A0.2 /8.5 DISTURBANCE RELAY S
5 E0.3 /6.6 AIR TEMPERATURE SWI 6 A0.3 /8.6 COOLING WATER VALVE
6 E0.4 /6.8 COOL.WATER TEMP.SWI 8 A0.4 star contactor
7 E0.5 /7.1 COOL.WATER FLOW SWI 9 A0.5 delta contactor
8 E0.6 /7.3 spare
9 E0.7 /7.5 spare
-P2
TD 200
HATLAPA
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 5
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
0 1 2 3 4 5 6 7 8 9
1L+ 1L+
/5.9 /7.0
95
-F1
/4.2 96
E0.0 /5.2 E0.1 /5.2 E0.2 /5.2 E0.3 /5.2 E0.4 /5.2
MOTOR PROTECTION RELAY AIR PRESSURE SWITCH OIL PRESSURE SWITCH AIR TEMPERATURE SWITCH COOL.WATER TEMP.SWITCH
Motorschutzrelais Luftdruck-Wächter Öldruckk-Wächter Lufttemperatur-Wächter Kühlwassertemp.Wächter
Digitaler Eingang Digitaler Eingang Digitaler Eingang Digitaler Eingang Digitaler Eingang
-X1 1 2 PE 3 4 PE 5 6 PE 7 8 PE
OPTIONAL VIA
COMPRESSOR
SEQUENCE
Luftdruck-Wächter SELECTION BOX Öldruck-Wächter Lufttemperatur-Wächter Kühlwasser-Temperatur-Wächter
für Auto Start/Stop OIL PRESSURE SWITCH AIR TEMPERATURE SWITCH COOLING WATER TEMPERATURE SWITCH
AIR PRESSURE SWITCH
FOR AUTO START/STOP
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 6
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
0 1 2 3 4 5 6 7 8 9
1L+
/6.9
-X1 9 10 PE 11 12 PE 13 14 PE
-F6 F
Kühlwasser-Durchfluß-Wächter
OIL PRESSURE SWITCH
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 7
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
0 1 2 3 4 5 6 7 8 9
MOTOR MAIN CONTACTOR DRAIN VALVES DISTURBANCE RELAY COOLING WATER VALVE
NETZSCHÜTZ Entwässerungs-Ventile Störungs-Kontakt Kühlwasserabsperrventi
1N1
/5.9
/4.2 1 2 /8.9 13 14
3 4
/4.2
5 6 Störungskontakt
/4.2
13 14 DISTURBANCE RELAY
/8.8
21 22
Kompressor ein
COMPRESSOR ON
-X1 19 20 PE 21 22 PE 23 24 PE 25 26 PE 29 30 PE 31 32 PE
Kompressor ein STÖRUNG
COMPRESSOR ON DISTURBANCE
(NO) (NC)
HATLAPA
Datum 11.07.08
Bearb. Bre
Schaltschrank Kompressor 37-44kW (440V) Gruppe : 334888-44070
Gepr. cpu STARTER / CONTROLLER COMPRESSOR 37-44kW (440V) Uetersener Maschinenfabrik Blatt 8
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 333390 Ers.f Ers.d von 8 Bl.
ENGLISH
STORAGE 1 - Safety
If motors are not immediately installed, All personnel involved with electrical
they must be stored in dry places, free of installations, either handling, lifting, operation
dust, vibrations, gases, corrosive smokes, or maintenance must be well informed and
under constant temperature and in normal updated concerning safety standards and
position free from other objects. principles that govern the work and carefully
Motor storage temperature must remain follow them.
between 5ºC to 60ºC, with relative humidity not We strongly recommend that these jobs
exceeding 50%. are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC designed in such a way to stop any vibration
MOTORS ARE SWITCHED OFF originated from resonance.
BEFORE STARTING ANY
MAINTENANCE SERVICE. 4 - Drain Holes
Motors must be protected against acci- Make sure the drains are placed in the
dental starts. lower part of the motor when the mounting
When performing any maintenance configuration differs from that specified on the
service, disconnect the motor from the power motor purchase order.
supply. Make sure all accessories have been
switched off and disconnected. 5 - Balancing
In order to prevent from penetrating dust
and/or water into the terminal box, cable glands THE MOTORS ARE DYNAMICALLY
or threaded pipe in the lead holes must be BALANCED WITH HALF KEY, AT NO
installed. LOAD AND UNCOUPLED.
Do not change the regulation of the
protecting devices to avoid damaging. Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
2 - Operating Conditions with half key before installation.
Use always appropriate tools for installation and
Electric motors, in general, are designed removal.
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0ºC 6 - Alignment
and 40ºC. Any variation is stated on the
ALIGN THE SHAFT ENDS AND
nameplate.
USE FLEXIBLE COUPLING,
COMPARE THE CURRENT, VOLTAGE, WHENEVER POSSIBLE.
FREQUENCY, SPEED, OUTPUT AND
Ensure that the motor mounting devices
OTHER VALUES DEMANDED BY THE
do not allow modifications on the alignment and
APPLICATION WITH THE DATA GIVEN
further damages to the bearings.
ON THE NAMEPLATE.
When assembling a half-coupling, be sure
Motors supplied for hazardous locations to use suitable equipment and tools to protect
must be installed in areas that comply with that the bearings.
specified on the motor nameplate. Suitable assembly of half-coupling:
Check that clearance Y is less than
KEEP AIR INLET AND OUTLET FREE 0.05 mm and that the difference X1 to X2 is less
AND CLEAN. THE AIR BLOWN OUT than 0.05 mm, as well.
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
Motors provided with feet must be installed 3mm minimum
on solid foundations to avoid excessive Figure and alignment tolerances
vibrations.
The purchaser is fully responsible for the 7 - Belt Drive
foundation.
Metal parts must be painted to avoid When using pulley or belt coupling, the
corrosion. following must be observed:
The foundation must be uniform and suf- Belts must be tighten just enough to avoid
ficiently tough to support any schock. It must be slippage when running, according to the
specifications stated on the belt supplier Make sure to use the correct cable
recommendation. dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
Excessive tension on the pulleys will BEFORE ENERGIZING THE
damage the bearings and lead to a TERMINALS, CHECK IF THE
probable shaft rupture. GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
8 - Connection AGAINST ACCIDENT RISKS.
RELUBRICATION INTERVALS
1. General
Moving parts require the correct lubricant. Good quality lubrication oils increase the service life of
the compressor.
Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it is
advisable to contact him when making your choice.
Ask only the lubricant manufacturer for his recommendation! He is the expert.
Above all, compressor oils must have good lubrication properties for which their viscosity is highly
important. HATLAPA recommends lubrication oils within the following range:
viscosity at 100 °C: min. 9.4 cSt max. 15 cSt
viscosity at 40 °C: min. 90 cSt max. 120 cSt
The lubrication oils should have low tendency to ageing and coking in order to prevent oil carbon
deposits on valves and pipelines. HATLAPA recommends to use mineral oils of class VDL
according to DIN 51 506.
The use of synthetic oils is not recommended for HATLAPA W- and L-type compressors.
3. Guarantee
If lubrication oils are used which do not meet the requirements, damage to the compressor may
occur. This damage is not covered by HATLAPA's guarantee obligations.
4. Lubricant Examples
The following mineral oils are examples which comply with the above specification:
1) Nome della nave (ev. nome precedente), numero di Costruzione e nome del Cantiere
Naval e
2) Numero di matricola e tipo del compressore (vedi targhetta)
3) Numero del pezzo di ricambio in base alla «Lista dei pezzi di ricambio»
4) Mezzo di trasporto, indirizzo di spedizione ed indirizzo di fatturazione desiderati
Service
In order to receive spare parts with the least possible delay, please get in touch with us
directly
SUBSIDIARY OFFICE
FOR HAMWORTHY TYPE COMPRESSORS
HATLAPA Marine Equipment Ltd.
Discovery Court Business Centre
551-553 Wallisdown Road
POOLE, Dorset BH12 5AG
UNITED KINGDOM
Phone: +44 1202 8531-80
Fax.: +44 1202 8531-91 Sales
+44 1202 8531-90 Spares
x Canada St. Catherines, Ontario L2M 6S9 Tel.: +1 905 688 4922
o Marine & Offshore Inc Fax.: +1 905 688 9028
113 Cushman Road, Unit 60 hcl@vaxxine.com
x Great Britain POOLE, Dorset BH12 5AG Tel: +44 1202 8531-80
o for London and HATLAPA Marine Equipment Ltd Fax:+44 1202 8531-90
all U.K. ports Discovery Court Business Centre
551-553 Wallisdown Road info@hatlapa-uk.com
x Italy 29015 Castel San Giovanni (Piacenza) Tel.: +39 0523 843046
o Realizzazioni Tecniche Cable: Ratenav
Navalmeccaniche Srl (R.T.N. Srl) Fax: +39 0523 843040
Via Mozza 15 info@retenav.it