air compressor -hatlapa type v105

Technical Documentation

Deck Machinery - Compressors - Steering gears

Technical Documentation for HATLAPA Compressors

V 105 L20 HSC 11

Start Start Start

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Technical Documentation Piston Compressor

Technical Documentation for

Piston Compressor Type V105

of

Uetersener Maschinenfabrik

GmbH & Co. KG 25436 UETERSEN

GERMANY

Phone: +49-4122-711 0.. Telefax: +49-4122-711 330

Internet http://www.hatlapa.de E-Mail: [email protected]

Ref.-No.: 10.2722 / 1 Serial-No.: 10.2722 - 1 - 1 10.2722 - 1 - 2

This technical documentation belong NOT in the office, but in the hands of the

operator

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Technical Documentation Piston Compressor

Table of Contents

1 Important Information on this Documentation and Safety 2 Final Drawings / Specification 3 Operating Instructions 4 E-Diagrams 5 E - Motor 6 Lubricating Instructions 7 Service

We recommend reading these instructions through carefully and becoming quite familiar with the design and operation of the piston compressor before putting it into operation,

this will avoid damage through imporper handling.

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Important Information on this Documentation and Safety

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1 Information on Manuals ........................................................................................................................... 3 2 Copyright ................................................................................................................................................. 3 3 Guarantee................................................................................................................................................ 3 4 Designations............................................................................................................................................ 4 5 Signs Used .............................................................................................................................................. 5 6 Intended Use ........................................................................................................................................... 5 7 Ban on Arbitrary Modifications................................................................................................................. 5 8 General Safety Instructions ..................................................................................................................... 6 9 Safety Equipment .................................................................................................................................... 6 10 Instruments for Operating Surveillance ................................................................................................... 6 11 Safety Instructions for Assembly ............................................................................................................. 7 12 Additional Safety Instructions for Electrical Installation........................................................................... 7 13 Safety Instructions for Operation and Service......................................................................................... 8 14 Safety Instructions for Maintenance and Repairs ................................................................................... 9 15 Noise Protection .................................................................................................................................... 10 16 Waste Disposal...................................................................................................................................... 10

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1 Information on Manuals This manual includes all information 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 manual can ensure faultless and correct functioning of the equipment, so its contents must be known to the responsible persons. The manual should be kept so that the operating and maintenance personnel have access to it at all times.

2 Copyright The copyright for this technical documentation remains with HATLAPA.

This documentation is intended for the operator and their personnel only.

All rights reserved.

3 Guarantee Guarantee and liability claims for damage to persons and/or objects are excluded, if caused by one or several of the following circumstances:

inappropriate use of the equipment,

neglect of the provisions of this documentation,

improper assembly, operation or maintenance,

operation of the equipment with ineffective protective devices,

arbitrary functional or constructive alteration of the equipment,

removal of parts or installation of spare parts or additional components, respectively, which have not been supplied or approved by HATLAPA,

repairs which have not been authorised by HATLAPA,

impact of foreign bodies in case of catastrophes or Force Majeure.

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4 Designations Persons are defined as follows:

The operator is the (natural or legal) person on whose behalf the equipment is used, e.g. the ships owner.

Operating personnel are personnel trained for the respective work, and who are authorised to operate the equipment and to remedy disturbances. The operating personnel must be trained for the tasks they are entrusted with, and meet the requirements necessary to handle the equipment.

Assembling personnel are personnel trained for the respective work, and who are authorised to assemble the equipment. They are able to carry out the tasks assigned to them and to recognise possible dangers because of their completed specialised training.

Maintenance personnel are personnel trained for the respective work, and who are authorised to maintain, adjust and modify the equipment. They are able to carry out the tasks assigned to then and to recognise possible dangers because of their completed specialist training.

An electrician has electro-technical skills gained by respective education, masters the legal regulations, and is assigned by the operator to carry out work on their electrical equipment and appliances.

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5 Signs Used

Sign for Danger

Danger!

This sign indicates specific behavioral patterns the non-observance of which is highly dangerous, or which may lead to permanent bodily injury.

Sign for Caution

Caution!

This sign indicates specific behavioral patterns the non-observance of which may lead to injury to persons, severe damage, or severe malfunction of the equipment, or to damage to the environment.

Sign for 'Pay Attention'

Pay Attention!

This sign indicates specific behavioral patterns the non-observance of which may lead to damage or malfunction of the equipment.

Sign for Information

Information!

This sign indicates tips and useful information which facilitate the operation of the equipment or the understanding of the documentation.

6 Intended Use The compressor is exclusively designed for air compression. Any other use is deemed as not being in compliance with the intended use and requires express written approval from HATLAPA.

The intended use also includes compliance with all the regulations contained in this technical documentation, the generally acknowledged rules of technology as well as all the relevant laws, standards and regulations.

7 Ban on Arbitrary Modifications Arbitrary modifications and changes to the machine/system are not permitted, as they may put persons in danger and result in damage to the machine/system.

If you are planning modifications or changes, contact HATLAPA and request written authorisation.

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8 General Safety Instructions Besides the specific safety-related technical notes contained in these instructions and the sub supplier's documentation, you must also observe the generally applicable safety and accident regulations, such as the:

Recognised technical regulations for safe and professional work

Regional and internal regulations

Regulations from the responsible classification authority

Rules and regulations for the prevention of accidents from the professional organisation, in particular concerning compressors

Safety signs and indicator plates on the machine/system

Environmental protection regulations

Incorrect handling or failure to comply with regulations concerning use can result in the risk of physical injury and death and/or damage to property. Observe the limits specified in the technical data.

Find out about the fire detection and fire prevention options, and ensure that these are fully functional and sufficient.

9 Safety Equipment

Danger!

Faulty safety equipment may put lives and equipment at risk.

All safety equipment must always be in a flawless and fully operational condition.

You must not make the safety equipment inoperative in any way.

If a piece of safety equipment is defective, the machine/system must not be operated.

Only remove safety equipment if the machine/system has been isolated and secured.

Perform regular checks on the safety equipment, in accordance with the regulations in this documentation and the sub suppliers' documentation.

10 Instruments for Operating Surveillance

Caution!

If instruments for operating surveillance are out of order, monitoring of the operating conditions of the machine/system may lead to incorrect analyses. This may put lives and/or equipment at risk.

Never decommission any instruments for operating surveillance.

If instruments for operating surveillance are defective, they must be changed as soon as possible. Take utmost care when operating the machine/system until the instruments are exchanged.

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11 Safety Instructions for Assembly

Danger!

During assembly and installation, the functioning of the safety equipment is not guaranteed. Therefore, the safety of the assembling personnel is to a great extent dependent on the proper execution of work.

Only trained and briefed personnel are permitted to carry out assembling and installation work. The personnel must have a specialised knowledge of compressed air and electrical engineering.

Only use suitable and fully functioning tools.

During torching or welding work, ensure that risks of fire or explosion are avoided.

12 Additional Safety Instructions for Electrical Installation All work on the electrical systems is only allowed to be performed by qualified electronics specialists.

Danger!

Deadly voltage!

Before starting to work on electrical equipment, the machine/system must be de-energized. Ensure that

the mains supply is deactivated. Check that the disconnected parts are de-energized before commencing work.

the electricity supply cannot be reconnected unintentionally or without authorization while work is being performed on the electrical installation.

the electricity for parts which must remain connected for the maintenance and repair work only remains connected for as long as is absolutely necessary for the work in question.

Danger!

The main switch remains energized even if it is deactivated.

Work carried out on electrical systems must be done so in accordance with the valid safety regulations, as well as all other relevant state or local regulations.

Under no circumstances repair or tide over defective fuses. Fuses must only be replaced by the same type of fuses.

When working on electrical systems, only use permitted and suitable tools. Only use voltage-free tools.

When taking measurements with the voltage supply of >65 V activated,

you must under no circumstances touch the electrical connection points,

the inspection equipment must be in good condition and safe to operate,

you must not wear any jewelry on fingers or wrists,

you must stand on insulated ground.

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13 Safety Instructions for Operation and Service

Danger!

The machine/system must only be operated by trained and briefed operating personnel.

New personnel may only use the machine/system under the constant supervision of trained and briefed operating personnel.

Give regular briefings on accident regulations and the requirements stated in this documentation.

Danger! Drawing in into moving parts!

Body parts or clothing may get caught at the flywheel.

Prior to start-up, check that the flywheel cover is fitted!

Caution! Burn hazard!

The compressor housing and the pressure pipes become hot during operation.

Wear protective gloves!

Caution! Drawing in into moving parts!

Long hair or loose clothing may get caught at the air intake filter.

When the compressor is in operation, maintain a safe distance to the compressor housing!

Caution!

In automatic operation mode, the compressor starts automatically without warning.

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14 Safety Instructions for Maintenance and Repairs

Danger!

The machine/system must only be maintained and repaired by trained and briefed maintenance personnel. The personnel must have a specialised knowledge of hydraulic and electrical engineering.

Optionally, the compressed air pressure gauges can be equipped with gauge valves. In this case, the compressor may be under pressure although the compressed air pressure gauges show a pressure of 0 bar.

Before starting any repair work, shutdown the machine/system and secure it against unintentional restarting. If the work can only be carried out while the machine/system is running, make the necessary safety arrangements. A second person must monitor the work, and be ready to intervene if needed.

When carrying out maintenance and repair work, do not decommission more than one piece of safety equipment at a time.

Only use suitable and fully functioning tools.

Caution! Burn hazard!

The compressor housing and the pressure pipes become hot during operation.

Before beginning maintenance work, allow the compressor to cool down for approx. 2 hours!

Caution!

Besides the information contained in this documentation, you must also observe the regulations of the classification authorities and professional organisations in order to determine the inspection and maintenance intervals.

After disassembly, always exchange self-locking nuts and gaskets. They are not designed for repeat use.

If leaks occur at couplings which are sealed with resilient joint gaskets, the leaks cannot be eliminated by retightening the coupling because the resilient joint gaskets are damaged or hardened. Exchange the resilient joint gaskets.

Pay particular attention to cleanliness. Cover any openings to prevent the ingress of dirt.

Ensure that tools, loose parts or cleaning cloths are not left in or on the compressor.

Dispose of old oils and grease in an environmentally friendly manner in accordance with national regulations.

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15 Noise Protection Refer to the technical data for information about the noise level.

Caution!

Make sure to wear ear protection in the vicinity of the compressor when it is in operation.

16 Waste Disposal The following substances which are caused by the operation of the machine/system must be disposed of in an environmentally friendly manner, in accordance with the applicable laws:

used oils and grease as well as cloths with such substances on them;

cleaning agents, and cloths with cleaning agents on them.

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2011-06-21 1 / 1

Final Drawings

for COSCO GUANGDONG SHIPYARD

HULL No: N352 - N353

HATLAPA Order No.: 10.2722 - 23 / 1 2x MAIN AIR COMMPRESSORS V105

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SECTION 1 V105 MAIN STARTING AIR/ EQUIPMENT SPECIFICATION SHEET

BOTTLE CHARGING SECTION 2 CONTRACT SPECIFIC DRAWINGS DRAWING No. TITLE D10082 GENERAL ARRANGEMENT V105 30 BARMOTORDATASHEET D10183AIRPRESSURESWITCH D10408AIRHOSEASSEMBLYD10409WATERHOSEASSEMBLYD10102DRAINHOSEASSEMBLY 450241 PIPINGANDINSTRUMENTATION344181 CONNECTIONDIAGRAM333182STARTERCONTROLLER333392SEQUENCESELECTORSWITCH INSTRUMENT LIST

STANDARD COMPRESSOR DRAWINGS DRAWING No. TITLE T0401132 CONTROL AND OPERATING PHILOSOPHY T0401133 INSTALLATION RECOMMENDATIONS 178483 FLEXIBLE HOSE INSTALLATION GUIDELINES T0401121 COOLING WATER DATA T0401126 HEAT DISSIPATION DATA 178492 CRANKCASE LUBRICANTS

SECTION 3

DRAWING No. TITLE

94301002 ILLUSTRATED SPARES D10262MOTORBEARINGSD10201AIRFILTER

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SECTION 1

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T E C H N I C A L S P E C I F I C A T I O N/2 Our Ref. 10.2722/1K

MAIN AIR COMPRESSORS

2 x ELECTRO-COMPRESSOR SET T y p e V 105

Type: V 105

Description: Two stage, twin cylinder in a 90o V format.

Capacity: 105 m3/hr FAD

Pressure: 30 bar G

Speed: 1800 min-1

Shaft power: 22 kW

Unloading Automatic via 1st and 2

nd Stage Solenoid Valves.

Control Voltage: 220 V

Lubrication: Splash

Cooling type: Fresh water up to 7 bar maximum pressure.

Inspection: NK survey on mechanical portion only

Standard Compressor Fittings:

Low Oil Level switch with Alarm and Shutdown feature. High Air Temperature switch with Alarm and Shutdown feature. 1st & 2nd Stage Air Safety Valves. Water Jacket Safety Valve. 1st & 2nd Stage Centrifugal Condensate Separator. 1st & 2nd Stage Solenoid Drain / Unloading valves. Compressor electrical junction box pre-wired by HATLAPA with Cable glands. Suction Filter & Silencer 1st & 2nd Stage Pressure Gauges Graduated in Bar / MPa Integral interstage/ aftercooler with cast passageways for air and water. Fully guarded flywheel with aperture for barring over compressor. Flexible coupling. Combined oil filler / dipstick. `Asbestos-Free` gaskets. Anti Vibration Mounts

Loose Supply Items:

Air pressure control switch for auto Stop / Start of compressor with 3 way test cock and 40 mm test flange, control air connection fitted with tube coupling to suit

8 mm outer tube.

Final air delivery flexible hose & integral Final air delivery Non-Return Valve. Cooling water inlet flexible hose. Cooling water outlet flexible hose. First stage solenoid drain valve flexible hose. Second stage solenoid drain valve flexible hose.

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Prime Mover:

Manufacturer make of our choice 24 kW Motor Power 1800 RPM 440 V/ 3 ph/ 60 Hz Power Supply IP 55 Enclosure Horizontal Foot & Flange Mounting - B35 & IEC 72 Mechanical dimensions DIRECT ON LINE Starting Method Manufactured to NK Latest requirements Standard terminal box Anti condensation heater Cable gland

Starter / Controller:

1 contactor cabinet with motor protection,

consisting of steel casing, containing:

main contactor for the electric motor

transformer

overcurrent relay for the electric motor

main switch

PLC (programmable logic control)

textdisplay for indication of operating modes,

disturbances and service intervals

with push buttons for operating the compressor

potential free contacts for indicating

"compressor on" and "collective alarm"

twin control with separate sequence selection switch

selector switch for auto / manual and local / remote control with interface for

ECR and cable gland

FINAL PAINTING of compressor, electric motor and contactor cabinet:

MUNSELL 7.5 BG 7/2

TESTING: by NK of compressor

1 set of spare parts for compressor acc. to the rules of NK

1 set of spare parts for electric motor consisting of 1 set anti-friction bearings

1 set of spare parts for contactor cabinet consisting of 1 contactor

1 additional set of air filter inlets for each compressor for SYs purpose

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SECTION 2

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HATLAPA

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HATLAPANr.: 180L4

Date: 08-DEC-2010

DATA SHEETThree-phase Induction Motor - Squirrel Cage

Customer : Motor line : Multivoltage

Frame : 180LRated Output : 25,0 kWFrequency : 60 HzPoles : 4 polesFull load speed : 1765 rpmSlip : 1,94 %Voltage : 440 VFull load current : 41,3 ALocked rotor amps : 310 ALocked rotor current (Il/In) : 7,50No load current : 15,0 AFull load torque : 135 NmLocked rotor torque : 260 %Breakdown torque : 250 %Design : NInsulation class : FTemperature rise : 80 KLocked rotor time : 14 sService factor : 1,00Duty cycle : S1Ambient temperature : 45 CAltitude : 1000 m.a.s.lDegree of protection : IP55Aprox. weight : 183 kgMoment of inertia : 0,1973 kgmNoise level : 64 dB(A)

D.E. N.D.E. Load cos Efficiency(%)Bearings 6311-C3 6211-Z- C3 100% 0,86 92,3Regreasing int. 20000 h 20000 h 75% 0,82 92,4GGrreeaassee aammoouunntt 1188 gg 11 g 50% 0,73 91,5

output for compressor: 24kW with I=appr. 40A / with element type heating 220V, appr. 50W, terminal HE+HE2

*The values shown are subject to change without prior notice.

Performed: Checked:

Version 4.06

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HATLAPA

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0 1 2 3 4 5 6 7 8 9

nderung Datum Name

Bearb.Gepr.

Norm

Datum

Urspr. Ers.fZust. Bl.Ers.d

Gruppe :

Ort :

HATLAPAUetersener Maschinenfabrik

D-25436 UetersenBlatt 1

von 2

NCNO

20 21 22 2513 14 15

24V

DC

Fernbedienung

Hand

-Aus

-Automatik

REMOTE

CONTROL

MANUAL

-OFF

-AUTOMATIC

FLOATING

CONTACT

FOR

REMOTE

CONTROL

ACTIVE

potentialfreier

Kontakt

fr

Fernbedienung

aktiv

26 27

potentialfreier

Kontakt

fr

Strung

potentialfreier

Kontakt

fr

Kompressor

ein

FLOATING

CONTACT

FOR

COMPRESSOR

ON

FLOATING

CONTACT

FOR

DISTURBANCE

NO

1811

1 17 1 17 1 18

12115

5 11 12875

5 7 8 5 9 10

9 105

WARNING

SHUTDOWN

5 7 8

SHUTDOWN

5 9 10

WARNING

24V

DC

24V

DC

17117

lstands-Wchter

OIL

LEVEL

SWITCH

Luft-Temperatur-

Wchter

AIR

TEMPERATURE

SWITCH

220-230V

AC

220-230V

AC

3 2 1

L

F13.2

L

F13.1

T

NC

COM

F3S

T

NC

COM

F3W

-1F13 -1F3

NO

Entwsserungsventil

1.

Stufe

DRAIN

VALVE

FIRST

STAGE

-1Y1

NO

Entwsserungsventil

letzte

Stufe

DRAIN

VALVE

FINAL

STAGE

-1Y2

(KlemmenkastenKompressor 1)

(TERMINAL BOXCOMPRESSOR 1)

Werft-LieferungSUPPLIED BY SHIPYARD

0MAN

AUTO

13

14 15

65

21

24V

DC

P

Druckluftwchter

fr

Fhrungskompressor

AIR

PRESSURE

SWITCH

F.LEADING

COMPRESSOR

-1F4

5 6

X1

X1

Kompressor-Umschaltbox

COMPRESSORSELECTION BOX

(333392)

CONTACTSSHOWNWITHOUTOIL

L1 L2 L3

Einspeisung

440V

60Hz

SHIP

SUPPLY

440V

60Hz

-1X1

H1 H2

Heizung

HE2HE1

WVU

M3

U V W

-1M1

344181-44070Bre

Anschluplan Kompressoren V105cpu

343260

CONNECTION DIAGRAM COMPRESSORS V105

02.11.10

Schaltschrank Startluft-Kompressor 1 (22-30kW)STARTER / CONTROLLER MAIN AIR COMPRESSOR 1 (22-30kW)

(344182-44070)

Startluft-Kompressor 1MAIN AIRCOMPRESSOR 1V10524 kW

HEATINGappr.50W

6-13 6-13 6-13 6-1316-28 16-28 16-28 16-28 13-21

A cable glansizes 08.12.10 bre

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0 1 2 3 4 5 6 7 8 9

nderung Datum Name

Bearb.Gepr.

Norm

Datum


Gruppe :

Ort :



NCNO

20 21 22 25

-2X1

13 14 15

FLOATING

CONTACT

FOR

REMOTE

CONTROL

ACTIVE

potentialfreier

Kontakt

fr

Fernbedienung

aktiv

26 27

potentialfreier

Kontakt

fr

Strung

potentialfreier

Kontakt

fr

Kompressor

ein

FLOATING

CONTACT

FOR

COMPRESSOR

ON

FLOATING

CONTACT

FOR

DISTURBANCE

NO

1 17 1 17 1 185 11 12875 9 105H1 H2L1 L2 L3

Einspeisung

440V

60Hz

SHIP

SUPPLY

440V

60Hz

5 6

24V

DC

Fernbedienung

Hand

-Aus

-Automatik

REMOTE

CONTROL

MANUAL

-OFF

-AUTOMATIC

1811121155 7 8 5 9 10

WARNING

SHUTDOWN

5 7 8

SHUTDOWN

5 9 10

WARNING

24V

DC

24V

DC

17117

lstands-Wchter

OIL

LEVEL

SWITCH

Luft-Temperatur-

Wchter

AIR

TEMPERATURE

SWITCH

220-230V

AC

220-230V

AC

3 2 1

L

F13.2

L

F13.1

T

NC

COM

F3S

T

NC

COM

F3W

-2F13 -2F3

NO

Entwsserungsventil

1.

Stufe

DRAIN

VALVE

FIRST

STAGE

-2Y1

NO

Entwsserungsventil

letzte

Stufe

DRAIN

VALVE

FINAL

STAGE

-2Y2

(KlemmenkastenKompressor 2)(TERMINAL BOXCOMPRESSOR 2)

0MAN

AUTO

13

14 15

Werft-LieferungSUPPLIED BY SHIPYARD

von 2

Heizung

HE2HE1

24V

DC

7 8

3 4

X1

X1

Kompressor-Umschaltbox

COMPRESSORSELECTION BOX

(333392)

P

Druckluftwchter

fr

Folgekompressor

AIR

PRESSURE

SWITCH

F.FOLLOWING

COMPRESSOR

-2F4

CONTACTSSHOWNWITHOUTOIL

WVU

M3

U V W

-2M1

344181-44070Bre

Anschluplan Kompressoren V105cpu

343260

CONNECTION DIAGRAM COMPRESSORS V105

02.11.10

(344182-44070)Schaltschrank Startluft-Kompressor 2 (22-30kW)STARTER / CONTROLLER MAIN AIR COMPRESSOR 2 (22-30kW)

Startluft-Kompressor 2MAIN AIRCOMPRESSOR 2V10524 kW

HEATINGappr.50W

6-13 6-13 6-13 6-1316-28 16-28 16-28 16-28 13-21

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nderung Datum Name

Bearb.Gepr.

Norm

Datum


Gruppe :

Ort :



8

mit Trfeststeller

20

210

HATLAPA

TD 200

P1

P2

STARTER/CONTROLLER COMPRESSORSchaltschrank Kompressor

Amperemeter(mit Markierungsanzeiger)

Hauptschalter(mit Trverriegelung)

Anzeige- und Bedieneinheit

P1

P2

Q1

AMMETER

MONITORING AND OPERATION PANEL

ISOLATING SWITCH

Schutzart: IP54PROTECTION CLASS: IP54

S2SELECTOR SWITCH "LOCAL / REMOTE"Wahlschalter "Vorort / Fern"

von 8

Q1

H2

Q2 L RS2

H2(BU)

Q2

Gewicht: ca. 50kgWEIGHT: APPR. 50kg

600

600

Meldelampe "Motor-Heizung ein"INDICATING LIGHT "MOTOR HEATING ON"

344182-44070Bre

Schaltschrank Kompressor 22-30kW (440V)

cpu

343261

STARTER / CONTROLLER COMPRESSOR 22-30kW (440V)

02.11.10

Hauptschalter Motor-HeizungMAIN SWITCH MOTOR HEATING

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nderung Datum Name

Bearb.Gepr.

Norm

Datum


Gruppe :

Ort :


D-25436 Uetersen

STOP AUTO MAN RESET

Blatt 2

black on redblack onlight blue black on green

schwarz auf rot schwarz auf grn schwarz auf wei

black on white

dunkel-blau auf weidark blue on white

ENTERESCSHIFT

TD 200SIEMENS

STOP AUTO MAN RESET

HATLAPA

HATLAPA

schwarz aufhell-blau

Anzeige- und BedieneinheitP2MONITORING AND OPERATION PANEL

von 8

344182-44070Bre


cpu

343261


02.11.10

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nderung Datum Name

Bearb.Gepr.

Norm

Datum


Gruppe :

Ort :



EIN / AUS

ALARME

EINSTELLUNGENSETTINGS:

ALARMS:

ON / OFF:

nocheinmal mit der "ENTER"-Taste quittiert werden.Wert verndern. Daraufhin mu der genderte Wert kann man mit den Pfeil-Tasten den entsprechendeneinmalig die "ENTER"-Taset bettigt werden. Dann

normalen Kompressorbetrieb bereits durch HATLAPA Normalerweise sind alle Einstellungen fr einenSoftware angezeigt werden.Oder es knnen einige variable Einstellungen der

Darauf sollte dann der Standart-Text wieder aufdem Display erscheinen.Jetzt kann der Kompressor wieder mit den Tasten"MAN" oder "AUTO" gestartet werden.

Now the fault must be eliminated. Then press the"RESET" push button and there should be the standard text on the display again.Now You can start the compressor again withthe "AUTO" or "MAN" push button.

Wenn ganz rechts im Display ein oder zwei Pfeile

Pfeil-Tasten zu anderen mglichen Textengesprungen werden.Die weiteren Texte knnen weitere Alarme anzeigen,wenn mehr als eine Strung ansteht.Oder es werden die Betriebsstunden angezeigt.

anlaufen.

Nach einem Spannungsausfall wird der Kompressor inder Betriebsart "Automatik" selbststndig wieder

starten.

gestoppt werden.Mit dem Taster "STOP" kann der Kompressor wieder

in Abhngigkeit des Druckluftschalters F4.

Mit dem Taster "AUTO" kann der Kompressor in dieBetriebsart "Automatik" geschaltet werden.Der Kompressor startet und stopt dann selbsttig

und dann der "RESET"-Taster bettigt werden.Jetzt must der entsprechende Fehler behoben werdenfr diesen Kompressor benutzt.Nicht alle hier dargestellten Alarm-Texte werdenTextdisplay angezeigt.Kompressor und es wird der zugehrige Alarm imWenn eine Strung vorliegt, dann stopt der

stopt der Kompressor.Wenn der Druckluftschalter geffnet ist, dannstartet der Kompressor.Wenn der Druckluftschalter geschlossen ist, dann

Dies ist der Standart-Text auf dem Display.

Jetzt kann man den Kompressor in der Hand- oderin der Automatik-Betriebsart starten.

Mit der Taste "MAN" wird der Kompressor in derHand-Betriebsart gestartet. D.h. ohne Funktion desDruckluftschalters F4.Normalerweise wird diese Fuktion nur frWartungszwecke benutzt.Nach einem Spannungsausfall wird der Kompressor inder Betriebsart "Hand" nicht wieder selbstttig

can change the value with the arrow push buttons.

If you want to change any setting, you mustpress the "ENTER" push button one time. Now you

a normal purpose of the compressor.Normally all settings are done by HATLAPA for

make maintenance !Wartung fllig !

"ENTER" again.

When there is any fault, the compressor stops

you must press the "STOP" push button before.manual to automatic or from automatic to manual

ready for operation / autoBetriebsbereit / Auto

compressor on / autoKompressor ein / Auto

ready for operation / offBetriebsbereit / aus


compressor on / manKompressor ein / Hand


After this you must quit the new value by pressing

if there is more than one fault.The other texts can show more disturbance alarms,

software.Or you can watch some special settings of the Or you can watch the working hours.

texts by pressing the belonging arrow push buttonsside of the display, you can go to other displayWhen there are one or two arrows in the right

The standard text on the text display is:

Now you can start the compressor in manual or in automatic operation.

When You press the "MAN" push button the compressor starts in maual operation without any function of the air pressure switch F4.Normallay the manual operation is only used formaintenance purposes.

mode.Normally this should be the standard operation

When the pressure switch F4 is closed thecompressor starts.When the pressure switch F4 is opened the compressor stops.

depending on the air pressure.The compressor starts and stops automaticallycompressor is switched to automatic mode.When You press the "AUTO" push button the

compressor stops again.When You press the "STOP" push button the

After a blackout the cmpressor will not startagain in this manual mode.

After a blackout the compressor will start again in automatic mode.

When you want to change the operation mode from

and the belonging disturbance alarm is shown inthe display.Not all possible disburbance texts are used for this compressor.

dargestellt werden, dann kann mit d.entsprechenden

festgelegt.Wenn Einstellungen gendert werden sollen, mu

short description f.compressor control with TD200: Kurzbeschreibung fr Kompressorsteuerung mit TD200

motor overloadMotor berlast

oil level warningl-Level Voralarmlow oil levell-Level Alarm

high air temperatureLufttemperatur-Alarm

air temperature warningLufttemperatur Voralarm

star delta time 4secStern-Dreieck-Zeit

workings hours xxxxx hBetriebsstunden

cooling water delay 2minKhlwassernachlauf

delayed start 0secverzgerter Anlauf

drainage time 2secEntwsserungsdauerdrainage interval 5minEntwsserungsinterval

continuous time 5minDurchlaufzeit

von 8

344182-44070Bre


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0 1 2 3 4 5 6 7 8 9

nderung Datum Name

Bearb.Gepr.

Norm

Datum


Gruppe :

Ort :


D-25436 Uetersen

L2 L3

Blatt 4

L1-X1 PE

Zuleitung

440V

60Hz

SHIP

SUPPLY

440V

60Hz

0,63-1AGV2 RT05

1 3 5

2 4 6-Q4

Trafo-EinspeisungTRANSFORMER SUPPLY

SteuerspannungCONTROL VOLTAGE

2A

213 4

-F21L1

1N1

von 8

Heizung

9 10

H2H1 PE

/5.0

/5.0

5%

250VA0P

440V

0S

220V

-T1

Heizungs-SpannungHEATING VOLTAGE

2A

213 4

-F3

1

2

3

4-Q2

51

52-K1

61

62/8.0

HauptschalterHeizungMAIN SWITCHHEATING

11

12

2

1

4

3

6

5

-Q1

/7.9

1

2

3

4

5

6-K1/8.0

97

98

95

96

WVU

M3

U V W

-M1

PE

Heizung einHEATING ON220V

X1

X2

-H2

344182-44070Bre


cpu

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02.11.10

HEATING25-100W

KompressorCOMPRESSOR22-30 kW

37-50A

5

6

3

4

1

2-F1

75/1

K

L

k

l-T2 A

75A+ --P1

HE1 HE2

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nderung Datum Name

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Norm

Datum


Gruppe :

Ort :


D-25436 Uetersen

1N1

1L1

1N1

1L+

HATLAPA

TD 200

Anzeige- und Bedieneinheitmonitoring and operation panel

Blatt 5

+24V DC

0V DC

-P2

von 8

SoftwareversionHamw_7

/4.9

/4.9 /8.0

/6.0

Out

In

Exp.

Supply14 x Inputs 10 x Outputs Relay

S7-CPU 224 Relay-Outputs

MOTOR PROTECTION REOIL LEVEL SW.WARNINOIL LEVEL SW.SHUTDOAIR TEMPERAT.SHUTDOAIR TEMPERAT.WARNINSPARE ReserveSPARE ReserveAIR PRESSURE SWITCH

REMOTE CONTROL ON REMOTE CONTROL MANUREMOTE CONTROL AUTO

MOTOR MAIN CONTACTODRAIN VALVES EntwsDISTURBANCE RELAY COOLING WATER VALVESPARESTAR CONTACTORDELTA CONACTORREMOTE CONTROL ACTI

1t

1L

12t

3L

10b

2M

2b E0.03b E0.14b E0.25b E0.36b E0.47b E0.58b E0.69b E0.7

11b E1.012b E1.113b E1.214b E1.315b E1.416b E1.5

2t A0.03t A0.14t A0.25t A0.38t A0.49t A0.510t A0.613t A0.7

14t A1.015t A1.1

18t

L1

17t

N16t

PE

7t

2L

1b

1M

17b

M18b

L+

-A1

/6.0/6.4/6.4/6.5/6.6/6.7/6.8/6.2

/7.1/7.3

/8.0/8.5/8.7/8.6

/8.2/8.3/8.9

/7.5

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Norm

Datum


Gruppe :

Ort :



1L+

WARNING

SHUTDOWN

OILLEVELSWITCH

-F13

l-Stands-Wchter

24V

DC

3 2 1

L

F13.2

L

F13.1

7 8 PE

SHUTDOWN

AIRTEMP.SWITCH

-F3

WARNINGLuft-

Temp.-Wchter

24V

DC

T

NC

COM

F3S

T

NC

COM

F3W

5 9 10 PE

95

96-F1

6 PE5-X1 5 5 11 12 PE

Optional berKompressor-Umschaltbox

1 2

OPTIONAL VIACOMPRESSORSEQUENCESELECTION BOX

AIR PRESSURE SWITCHFOR AUTO START/STOP

Luftdruck-Wchterfr Auto Start/Stop

P-F4

von 8

1L+/5.9 /7.0

/4.2

Digital Input

MOTOR PROTECTION RELAYMotorschutzrelais

2b

E0.0

-A1

/5.2

Digital Input

AIR PRESSURE SWITCHLuftdruck-Wchter

9b

E0.7

-A1

/5.2

Digital Input

OIL LEVEL SW.WARNINGlstands-W. Voralarm

3b

E0.1

-A1

/5.2

Digital Input

OIL LEVEL SW.SHUTDOWNlstands-Wchert Alarm

4b

E0.2

-A1

/5.2

Digital Input

AIR TEMPERAT.SHUTDOWNLufttemp.-Wchter Alarm

5b

E0.3

-A1

/5.2

Digital Input

AIR TEMPERAT.WARNINGLufttemperatur Voralarm

6b

E0.4

-A1

/5.2

Digital Input

SPARE Reserve

7b

E0.5

-A1

/5.2

Digital Input

SPARE Reserve

8b

E0.6

-A1

/5.2

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Norm

Datum


Gruppe :

Ort :


D-25436 Uetersen von 8Blatt 7

FernbedienungHand - Aus - AutomatikREMOTE CONTROLMANUAL - OFF - AUTOMATIC

14 15

0MAN

AUTO

PE

Vorort-FernLOCAL-REMOTE

13

14-S2

1L+

13-X1Kompressor einCOMPRESSOR ON

STRUNGDISTURBANCE

(NO) (NC)(NO)

Fernbedienung aktivREMOTE CONTROL ACTIVE

/4.1

potentialfreie KontakteFLOATING CONTACTS

20 21 PE 22 25 PEPE26 27

11

12

-Q1

13

14

-K113

14

-K513

14

-K4

/6.9

/8.4/8.6 /8.0

Digital Input

REMOTE CONTROL ONFernbedienung ein

11b

E1.0

-A1

/5.2

Digital Input

REMOTE CONTROL MANUALFernbedienung Hand ein

12b

E1.1

-A1

/5.2

Digital Input

REMOTE CONTROL AUTO ONFernbedienung Auto ein

13b

E1.2

-A1

/5.2

344182-44070Bre


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Norm

Datum


Gruppe :

Ort :


D-25436 Uetersen

1N1

1 23 45 613 1421 2251 5261 62

von 8Blatt 8

-Y1 -Y2

17-X1 1 PE 17 1 PE

EntwsserungsventileDRAIN VALVES

-Y5

18 1 PE

Khlwasser-Absperrventil (optional)COOLING WATER SHUT OFF VALVE (OPTIONAL)

13 141413

INCL.VAR.

Fernbedienung aktivREMOTE CONTROL ACTIVE

A1

A2-K5

StrungskontaktDISTURBANCE RELAY

INCL.VAR.

A1

A2-K4

/5.9

/7.7/7.9/4.2/4.2/4.2

/4.8/4.9

/7.8

Digital Output

MOTOR MAIN CONTACTORNETZSCHTZ

2t

A0.0

-A1

/5.2

Digital Output

DRAIN VALVESEntwsserungs-Ventile

3t

A0.1

-A1

/5.2

Digital Output

COOLING WATER VALVEKhlwasserabsperrventi

5t

A0.3

-A1

/5.2

Digital Output

DISTURBANCE RELAYStrungs-Kontakt

4t

A0.2

-A1

/5.2

Digital Output

REMOTE CONTROL ACTIVEFernbedienung aktiv

13t

A0.7

-A1

/5.2

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INCL.VAR.

Kompressor einCOMPRESSOR ON

50A

A1

A2-K1

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Datum


Gruppe :

Ort :



8,7

200200

120

200

200

20

20

Gewicht: ca. 3kgWEIGHT: APPR. 3kg

Schutzart: IP54PROTECTION CLASS: IP54

3S1

Stellung 1: Kompressor 1 = FhrungskompressorKompressor 2 = Folgekompressor

Stellung 2: Kompressor 2 = FhrungskompressorKompressor 1 = Folgekompressor

POSITION 1: COMPRESSOR 1 = LEADING COMPRESSORCOMPRESSOR 2 = FOLLOWING COMPRESSOR

POSITION 2: COMPRESSOR 2 = LEADING COMPRESSORCOMPRESSOR 1 = FOLLOWING COMPRESSOR

VIEW FROM BEHIND:

Kompressor 1 = FhrungskompressorCOMPRESSOR 1 = LEADING COMPRESSOR

1 2

Kompressor 2 = FhrungskompressorCOMPRESSOR 2 = LEADING COMPRESSOR

3S1 FhrungswahlschalterSEQUENCE SELECTOR SWITCH

COMPRESSOR SEQUENCE SELECTION BOXKompressor-Umschaltbox

COMPRESSOR SEQUENCE SELECTION BOXKompressor-Umschaltbox

von 2

333392-44070Bre Umschaltbox fr Doppelkompressorsteuerung

cpu

330141

SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL

20.02.08

Box de selection de guidage

Commutateur de guidage

Position 1: Position 2:Compresseur 1 = Compresseur de guidage Compresseur 2 = Compresseur de guidageCompresseur 2 = Compresseur de suivant Compresseur 1 = Compresseur de suivant

A frenchtexts23.01.09 bre

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nderung Datum Name

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Norm

Datum


Gruppe :

Ort :


D-25436 Uetersen

1-3X1 2 5 6 7 8 3 4

A

B

C

D

Blatt 2

P

Druckluftschalter fr FhrungskompressorAIR PRESSURE SWITCH FOR LEADING COMPRESSOR

-1F4 P

AIR PRESSURE SWITCH FOR FOLLOWING COMPRESSORDruckluftschalter fr Folgekompressor

-2F4

Druckluftwchter-Signal zumSchaltschrank Kompressor 1

CONTACTOR CABINET COMPRESSOR 1AIR PRESSURE SIGNAL TO

Druckluftwchter-Signal zumSchaltschrank Kompressor 2AIR PRESSURE SIGNAL TOCONTACTOR CABINET COMPRESSOR 2

1 2

FhrungswahlschalterSEQUENCE SELECTOR SWITCH

2 6 10 14

1 3 5 7 9 11 13 15-3S1

von 2

PE PE PE PE

333392-44070Bre Umschaltbox fr Doppelkompressorsteuerung

cpu

330141

SEQUENCE SELECTION BOX FOR DOUBLE COMPRESSOR CONTROL

20.02.08

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T0401132 Sheet 1 of 4

CONTROL AND OPERATING PHILOSOPHY

V LINE COMPRESSOR FRESH WATER COOLED

ELECTRO-MECHANICAL VERSION

ECN No. Drawn WAH Issue No. 1 2 Checked Date: 08.05.02 16.01.06 Approved SK W:\Compressors\ENGINEERING\T Stds\T0401132-ISS2.doc

COPYRIGHT RESERVED

1. General Description 1.1 The V Line is a 2 stage, 2 cylinder reciprocating type air compressor direct coupled to

an electric motor, all mounted on Anti-Vibration mounts.

The equipment is designed to be operated via a remote mounted starter/control panel (supplied by either Hatlapa or the Customer). The compressor rotating and reciprocating elements are splash lubricated via dippers, integrally cast onto the con-rods, hitting the oil surface - the oil contained in the compressor crankcase. The compressor is arranged with a water cooling system, which is be suitable for fresh water only. This system cools both the air interstage and after coolers. An integrally mounted electric motor driven water circulating pump can be supplied by Hatlapa.

1.2 Pressure gauges are provided for monitoring the air interstage and final stage

pressures, P1 and P2. 1.3 The compressor has a number of safety features as follows:-

Safety valves are fitted to each air stage of the compressor, SV1 and SV2

A safety valve is fitted to the water jacket housing the coolers, SV5

1.4 The compressor is fitted with the following protection devices:- Minimum oil level, F13 shutdown (1) and optional alarm (2) High final delivery temperature, F3 shutdown (S) and optional alarm (W) High compressor motor current shutdown only High water pump motor current shutdown only (of water pump supplied) Note 1) Both the low oil level switch, F13, and the high air temperature switch, F3, are

closed under normal running conditions and open on fault. 2) The low oil level switch, F13, is connected to a timer delay to prevent spurious

operation due to ships motion, ie, pitch and roll.

1.5.1 The starter/ control panel should be capable of the following functions:-

Selection of manual mode local start/stop only Selection of automatic mode local or remote start/stop sequence

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T0401132 Sheet 2 of 4





COPYRIGHT RESERVED

Selection sequence of operation - if more than one compressor is charging the system a selector switch should be fitted enabling the sequence in which the compressors should work i.e. lead and follow. Emergency stop operation - shutdown only - local or remote

2. Operation

Note - If this is the first commissioning or a re-commission after a significant period out of service then refer to the commissioning procedure for guidance.

2.1 Normal Running Procedure (Automatic Control)

Note The manual drain valves (HV1) should be closed

2.1.1 Energise the starter panel via the main isolator Set mode switch S1 to AUTO Set local/remote switch S2 as required Set drain switch S3 to AUTO (S3 not fitted if only hand drains supplied) Press RESET push button.

2.1.2 On pressing the START button, the following events occur:-

The compressor starts and runs off load The water circulating pump (WP) starts and runs (when fitted) The water shut off valve (Y5) is energised to open (when fitted)

The compressor will run off load for 15 20 seconds after which solenoid valves Y1 and Y2 are energised to close to charge the air system. (Note - the solenoid valves will only close if the air system is not fully charged) Note If a visual flow indicator (F1) is fitted to the compressor cooling water outlet this should be checked to ensure that water is circulating through the compressor. In the event that there is no flow the compressor should be stopped and the cause investigated.

2.1.3 The compressor is now controlled by the air system pressure switch.

At 5 minute intervals (adjustable dependant on ambient conditions) solenoid valves Y1 and Y2 are de-energised to open for 2 seconds (adjustable) to drain moisture collected in the interstage and final stage separator bowls.

2.1.4 On air system charged signal, from the air system pressure switch, solenoid valves

Y1 and Y2 are de-energised to open to drain and unload the compressor and await a signal as follows:-

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T0401132 Sheet 3 of 4





COPYRIGHT RESERVED

On recharge signal the solenoid valves Y1 and Y2 close, energise, causing the compressor to charge the system. If the recharge signal is not received within 5 minutes (adjustable) of the charged signal, the compressor stops leaving the solenoid valves Y1 and Y2 open. On recharge signal the compressor starts as for pressing the START button.

2.1.5 On pressing the STOP button solenoid valves Y1 and Y2 are de-energised to open to

drain the separator bowls, the compressor continues to run on for 5 minutes (adjustable) before stopping. Simultaneously with the compressor stopping the water circulating pump (if fitted) stops and the water shut off valve Y5 (if fitted) is de-energised to close. Pressing the START button during this cycle brings the compressor back on line to charge the air system.

2.1.6 If the START button is pressed while the air system is fully charged, the compressor

starts as described in Paragraph 2.1.2. The compressor is then controlled by the air system pressure switch as described in Paragraphs 2.1.3 and 2.1.4.

2.2 Sequence Selector Switch 2.2.1 If more than one compressor is charging the receiver, the Sequence Selector Switch

changes which compressor is the lead and which is the follow machine. 2.3 Manual Mode Running 2.3.1 Energise the starter panel via the main isolator

Set the mode switch S1 to MAN Set local/remote switch S2 to LOCAL Set drain switch S3 to AUTO (S3 not fitted if only hand drain valves fitted) Press RESET push button. The compressor will start and run in this mode overriding the low oil level switch, F13, and high air temperature switch, F3. The emergency stop button and motor thermal overloads will still stop and unload the compressor. Starting, running and stopping cycles are as for Normal (Automatic) Running as described with the exception of the following:-

Oil level switch overridden High air temperature switch overridden Remote start/stop function disabled

2.4 Emergency Stop

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T0401132 Sheet 4 of 4





COPYRIGHT RESERVED

Upon pressing the emergency stop button, either local or remote (if fitted), the compressor stops immediately, solenoid valves Y1 and Y2 open, water circulating pump (if fitted) stops and the water shut off valve, Y5, (if fitted) closes.

3 General 3.1 It is recommended that individual volt-free change-over contacts and control panel

indicator lamps are provided as follows:- Compressor running Water pump running (if fitted) Low oil level shutdown Low oil level warning (if fitted) High air temperature shutdown High air temperature warning (if fitted) Compressor motor overload Water pump motor overload (if fitted)

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T0401133 Page 1 of 3

V-LINE COMPRESSOR

INSTALLATION RECOMMENDATIONS FRESH WATER COOLING

ECN No. - N0054647 Drawn RAVIssue No. 1 2 3 Checked RAV Date: 16.3.00 08.05.02 16.01.06 Approved AES W:\Compressors\ENGINEERING\T Stds\T0401133-iss3.DOC

COPYRIGHT RESERVED

1. LOCATION

The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as cool and dry as possible and there is adequate circulation to the drive motor integral cooling fan and all the compressor external surfaces. It is preferable that the compressor be positioned with the axis of the crankshaft and motor fore and aft in the vessel.

2. MOUNTING

The compressor should be mounted on support plates/pads and supported by a ribbed structure suitable for the type and weight of the compressor. The pads/plates must be clean and flat to within 1mm. Shims should be used if necessary. All V-Line compressors are supplied with AV mounts and flexible hoses. Refer to General Arrangement Drawing supplied with the compressor documentation package for anti-vibration mounts dimensions, positions and weight of the compressor. Refer to 178483 for flexible hose installation guidelines.

3. COOLING WATER SYSTEM General Comments

The Compressor is suitable for fresh water cooling only. The supply of water should be free of solids or any other foreign matter. The compressor coolers have been designed incorporating a fouling factor equivalent to 10%. There must be positive water circulation through the compressor. For optimum compressor performance the operating temperature of the compressor needs to be regulated by the combination of cooling water inlet temperature and flow rate. Note! A compressor running too cold will tend to generate condensation internally within the crankcase, leading to contamination of the lubricating oil with water. A compressor running too hot will have a high final air delivery temperature with an increased risk of mechanical failure. 3.1 Cooling Water Temperature For recommendations see T0401121 3.2 Cooling Water Quantity 3.2.1 When installing the V-Line compressor into the ship's cooling water system, consideration

must be given to the cooling water flow requirement for the compressor to operate efficiently. For the cooling water flow recommendations see T0401121. When a water circulating pump is supplied, see T0401131 (V105/150), T0401143 (V200/250), T0401144 (V375) for Pump Performance data. A means of measuring the pressure drop across the system should be provided. A visual flow indicator is fitted as standard.

3.2.2 The system must be designed to ensure a positive back pressure exists on the cooler outlet to prevent the first stage cylinder being starved of cooling water. For the pressure drop across the compressor see T0401121. The nominal cooling water flow rate through the compressor will normally give an acceptable heat transfer rate across the compressor resulting in a cooling water outlet temperature rise of 15C over water inlet temperature and a final air delivery temperature of 15C over the cooling water inlet temperature. It may be found necessary to vary the cooling water flow rate in order to achieve these temperature rises.

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T0401133 Page 2 of 3

V-LINE COMPRESSOR



COPYRIGHT RESERVED

3.2.3 A water shut off valve should be fitted, to the water inlet to the compressor, see

T0401115 figs 1 & 4 (supplied on request), when the temperature of the cooling water is significantly below the temperature of the air surrounding the compressor. In these circumstances it is necessary to avoid overcooling and the resultant generation of condensation. Where cooling water is at a higher temperature particularly with fresh water systems, it is less important to stop the water flow.

3.2.4 The fitting of a 3 way thermostatic valve on the outlet of the compressor is

recommended where overcooling problems may be envisaged or experienced. Overcooling occurs mainly when:- a) The cooling water inlet temperature is very low. b) The cooling water inlet temperature is low and compressor is running unloaded. c) Cooling water continues to flow through the compressor after the machine has

stopped running The effects of overcooling are excessive condensation in the compressor causing corrosion and emulsification of the lubricating oil. See T0401115 fig 6 (supplied on request) for a typical fresh water installation fitted with a heat exchanger.

3.3 Cooling System Pressure See T0401121 for limitations. 3.4 Water Pipe Sizing and Layout

In order to avoid excessive friction loss through piping, it should be kept as short as possible. See T0401121 for recommended pipe sizes. It should be noted that the compressor connections should not be used to establish the pipe size to be used. Should the pipe work be very long, the next larger size pipe than that recommended in T0401121 should be used. Refer to T0401115 for typical installations/layouts (supplied on request).

3.5 Venting of Air from the Compressor Cooling Water System The compressor is fitted with an air bleed valve on top of the cooler box and it is recommended (in the compressor Manual) that this is bled on a daily basis to ensure air is not trapped in the cooler box water chamber thus preventing hot spots in the machine.

4. MAIN AIR LINE

4.1 Vertical run-up direct from the compressor must be kept to a minimum and the horizontal run, incorporating the non return valve, should descend away from the compressor to prevent any moisture in the pipeline from running back to the compressor and non return valve.

4.2 See drawing A22002 for a typical 2 compressor installation (supplied on request).

5. DRAINAGE SYSTEM 5.1 Drain Sizing

Refer to recommendations made in T0401124 for typical installations (supplied on request).

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T0401133 Page 3 of 3

V-LINE COMPRESSOR



COPYRIGHT RESERVED

6. SUMMARY OF STANDARDS AND DATA SHEETS REFERENCED IN THIS PROCEDURE.

178483 - Flexible Hose Installation Guidelines T0401121 - Cooling Data

T0401131 - Pump performance Data V105/150 T0401143 - Pump performance Data V200/250 T0401144 - Pump performance Data V375

T0401115 - Typical Cooling Installation Diagrams (supplied on request) A22002 - Typical Air System 2 Compressors (supplied on request) T0401124 - Drain Sizing Recommendations (supplied on request)

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178483 FLEXIBLE HOSE

INSTALLATION GUIDELINES

16.01.2006

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.

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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.

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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.

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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.

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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!

Hose pipes must be inspected visually by the assembly/service personnel before commissioning and once a year. Inspection is carried out under the following aspects:

Damage to the outer layer Decay of the outer layer Deformation of the hose or hose pipe (alteration of the geometry, layer

separation, forming of blisters) Damage or deformation of the hose fitting Corrosion of the fitting (impairs function and strength) Installation (chafing at sharp edges or smooth surfaces) Exceeding the admissible storage resp. operational duration (stated below)

1.2 Storage and durability According to DIN 7716 proper storage is to be understood as follows:

max storage time 2 years dry, cool, dust-free no direct sunlight or UV light protection against ozone protect against heat store lying and without tension

According to EN 982 resp., DIN 20066 following must be observed: 1. Once installed, the hoses have a durability of 6 years and must be replaced after

this period. 2. If the max. storage time of 2 years is exceeded, then the hose may no longer be

used. If the hose is installed within this period, the durability of 6 years is reduced by the period of storage accordingly.

It lies within the responsibility of the user that all hoses mentioned in this manual are checked at regular intervals, and to guarantee correct and safe function once the guarantee period has elapsed, thus preventing damage to persons and the environment.

date 18.04.2005 page 1 of 1 Created by Tanz

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ECN No. - N0054732 Drawn RAVIssue No. 1 2 3 Checked RAV Date: 16.03.00 31.05.02 16.01.06 Approved AES W:\Compressors\ENGINEERING\T Stds\T0401121.DOC

T.0401121 Page 1of 1

V-LINE PERFORMANCE

WATER COOLED/AIR COOLED

1. COMPRESSOR

Model

Flow l/min

Pressure Drop Across

Compressor (P2 P1)*

Max. Water Jacket

Pressure

Inlet & Outlet Connections

Recommended Min. Pipe Bore

V105 20/25 0.5m 7 bar g G 19mm V150 20/25 0.5m 7 bar g G 19mm V200 60/70 2.5m 7 bar g G1 25mm V250 60/70 2.5m 7 bar g G1 25mm V375 110/120 4.4m 7 bar g G1 32mm

* See T0401115 for positions

Water jacket Safety Valve setting = 7.7barg Minimum cooling water inlet temperature = 5oC Maximum cooling water inlet temperature = 45oC For heat dissipation to cooling water see T0401126

2. WATER CIRCULATING PUMP (Option) See Data Sheets T0401125 (Sea Water All Models) T0401131 (Fresh Water V105/150) T0401143 (Fresh Water V200/250) T0401144 (Fresh Water V375) 2. THERMOSTATIC BY-PASS VALVE (Option)

2.1 Valve actuating temperature = 35C 2.2 Pressure drop across valve see table below

Model

Pressure Drop Across Valve Valve Connections

V105 0.68m G" V150 0.68m G" V200 2.38m G1" V250 2.38m G1" V375 5.78m G1"

3. WATER SHUT OFF VALVE - Solenoid Operated (Option)

4.1 Pressure drop across valve see table below

Model Pressure Drop Across Valve

Valve Connections V105 0.1m G" V150 0.1m G" V200 0.8m G1" V250 0.8m G1" V375 0.5m G1"

COPYRIGHT RESERVED

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T0401126 Page 1 of 2

V-LINE COMPRESSOR

HEAT DISSIPATION

pc COPYRIGHT RESERVED

WATER COOLED

BOTTLE CHARGING DUTY

33 25 14 14000

17.6 17600 21.6

Heat Dissipation Pres- sure Bar g

16 16000 21.6

21600 24 24000

1000 rpm 1200 rpm 1500 rpm 1800 rpm kW J/s kW J/s kW J/s kW J/s

33 25 9.6

15 8.2 8200 9.9 9900 12.7 12700 15.4 15400 V105

10 7

21600 24 24000

20 15 14400 18.4 18400 22.4 22400

10 7 10.4 10400 12.8 12800 16

21200 25.6 25600 30.4 30400

20 15 16 16000 19.2 19200

33 25 22.4 22400 26.4 41.2 41200

20 15 20.8 20800 24 24000 30.4 30400 36 36000 V250

31.2 31200

33 25 30.4 30400 39.2 39200 46.4 46400 58.4

V375

NOT AVAILABLE

9600 11 11000

16000 20 20000

10

14.9 14900 16.5 16500

33

V200

7 19.2 19200

20

25 17.6 17600 21.2

21.6 21600 26.4 26400

7.1 7100 8.8 8800

24 24000 28.8

58400

11 11000 13.8

28800

10

20 15 NOT AVAILABLE

13800

7 14.4 14400

10 7

12 12000 14.4

26400 33.6 33600

V150

ECN No. - N0054729 Drawn RAVIssue No. 1 2 Checked RAV Date: 22.3.00 31.5.02 Approved AES W:\Compressors\ENGINEERING\T Stds\T0401126.DOC

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T0401126 Page 2 of 2

V-LINE COMPRESSOR

HEAT DISSIPATION

pc COPYRIGHT RESERVED

WATER COOLED

FAD (NOZZLE) DUTY

Heat Dissipation Pres- sure Bar g J/s kW J/s kW J/s

V105 30 21 9.6 8.2

9600 8200

16500 15400

V150 12 14000 12000

16 14.4

16000 18400

24 22.4

24000 22400

V200 30 21 17.6 16

17600 16000

30400 28800

V250 30 21 22.4 20.8

22400 20800

26.4 24

26400

V375 NOT AVAILABLE

AIR COOLED

Heat Dissipation 1000 rpm 1200 rpm 1500 rpm 1800 rpm sure

Bar g kW

25 4.2 4200 5 5000 6.5 6500 7.3 7300

20 15 10 7 3.2 3200 4 4000 4.9 4900 5.9 5900

1000 rpm 1200 rpm 1500 rpm

21.2 19.2

21200

J/s kW J/s

1800 rpm

19200 25.6 24

kW J/s kW

kW J/s kW

25600 24000

30.4 28.8

J/s 33

VA40

11 9.9

11000

24000 33.6 30.4

3.9 3900 4.7

9900 14.9 12.7

14900

33600 30400

41.2 36

4700 6 6000 6.8

12700 16.5 15.4

41200 36000

6800

30 21

14 14400

21.6 18.4

21600

BOTTLE CHARGING DUTY Pres-

ECN No. - N0054729 Drawn RAVIssue No. 1 2 Checked RAV Date: 22.3.00 31.5.02 Approved AES W:\Compressors\ENGINEERING\T Stds\T0401126.DOC

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Lubricating Instructionsfor V-Line

Piston Compressors

178492Rev. 01.06

1. General

Moving parts require the correct lubricant. Good quality lubrication oils increase the service life ofthe compressor.Please note: only the lubrication oil manufacturer knows his products thoroughly. Therefore, it isadvisable to contact him when making your choice.

Ask only the lubricant manufacturer for his recommendation! He is the expert.

2. Lubrication Oil Quality

Above all, compressor oils must have good lubrication properties for which their viscosity is highlyimportant. HATLAPA recommends lubrication oils within the following range:

viscosity at 100 C: min. 9 cSt max. 15 cStviscosity 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 carbondeposits on valves and pipelines. HATLAPA recommends to use oils of class VDL according toDIN 51 506.

3. Guarantee

If lubrication oils are used which do not meet the requirements, damage to the compressor mayoccur. This damage is not covered by HATLAPA's guarantee obligations.

4. Lubricant Examples

The following oils are examples which comply with the above specification:

Mineral Oils Synthetic OilsBP ENERGOL RC100 ENERSYN RX100CASTROL AIRCOL PD 100 AIRCOL SN 100CHEVRON TEXACO (FAMM) COMPRESSOR OIL EP VDL100 CETUS DE 100ELF TOTAL FINA (Lubmarine) DACNIS P100 BARELF CH 100ESSO (ExxonMobil Marine)MOBIL (ExxonMobil Marine)

EXXCOLUB 100RARUS 427

SYNESSTIC 100RARUS 827

SHELL CORENA P 100 CORENA AP 100However, the oil properties are subject to change without notice by the oil manufacturer. Also,the oil characteristics may vary depending on the regional market. Therefore this list does notrelease the operator of the compressor from verifying that the selected oil complies with theabove specification.

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SECTION 3

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Instruction Manual V-Line Water Cooled Compressor

V105, V150, V200, V250, V375

PCH 1540

ISSUE 8 1105

Uetersener Maschinenfabrik GmbH & Co. KG Tornescher Weg 5-7 25436 Uetersen / Germany

Telephone: +49-4122-711 0.. Facsimile: +49-4122-711 330 Internet http://www.hatlapa.de E-Mail: [email protected]

Marine Equipment Ltd.Discovery Court Business Centre

551-553 Wallisdown Road,Poole, Dorset BH12 5AG, Great Britain

Telephone: +44 (0) 1202 853 180Facsimile: +44 (0) 1202 853 190Internet http://www.hatlapa.deE-Mail: [email protected]

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CAUTION

1. The following manual must be read before proceeding with installation, operation and maintenance of this equipment.

2. Health & Safety Act Compliance. Before working on this equipment personnel should be made aware of, and ensure compliance with, the Health and Safety Regulations appropriate to this class of work.

3. The handling points are indicated on the unit and must be used. The hooks of slings must be fitted to lifting eyebolts using shackles.

4. Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings, it must be stopped and isolated electrically and mechanically and the outlet valves closed. Some units on automatic standby duty, or isolators are remote from the unit and extra care is then necessary to ensure that isolation is complete.

HATLAPA MARINE EQUIPMENT reserves the right to make changes to the design of the machine without prior notice.

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CONTENTS

1 INSTALLATION ......................................................................................................................... 1-1

1.1 LOCATION ................................................................................................................................. 1-1 1.2 MOUNTING ................................................................................................................................ 1-1 1.3 COMMISSIONING ..................................................................................................................... 1-1

2 OPERATING PROCEDURE ...................................................................................................... 2-1 2.1 DESCRIPTION ........................................................................................................................... 2-1 2.2 CONTROL AND OPERATING PHILOSOPHY .......................................................................... 2-1 2.3 NORMAL RUNNING PROCEDURE (AUTOMATIC CONTROL) .............................................. 2-2 2.4 MANUAL MODE RUNNING ...................................................................................................... 2-4 2.5 GENERAL .................................................................................................................................. 2-5

3 MAINTENANCE ......................................................................................................................... 3-1 3.1 GENERAL .................................................................................................................................. 3-1 3.2 MAINTENANCE INSTRUCTIONS ............................................................................................. 3-3

3.2.1 Lubrication Oil Checking ............................................................................................................ 3-3 3.2.2 Lubrication Oil Changing ............................................................................................................ 3-3 3.2.3 Air Suction Filter/Silencer Removal and Replacement .............................................................. 3-3 3.2.4 First Stage Concentric Valve Removal/Servicing/Replacement ................................................ 3-4 3.2.5 Final Stage Concentric Valve Removal/Servicing/Replacement ............................................... 3-9 3.2.6 First Stage Cylinder and Piston Removal ................................................................................ 3-13 3.2.7 First Stage Cylinder and Piston Reassembly........................................................................... 3-15 3.2.8 Final Stage Cylinder and Piston Removal ............................................................................... 3-16 3.2.9 Final Stage Cylinder and Piston Reassembly .......................................................................... 3-17 3.2.10 Cooler Tubenest and Header Removal ................................................................................... 3-18 3.2.11 Tubenest Clean/Examine/Replace .......................................................................................... 3-18 3.2.13 Cooler box end cover ............................................................................................................... 3-21 3.2.14 Connecting Rod Removal ........................................................................................................ 3-21 3.2.15 Bearing Removal and Reassembly to Connecting Rods ......................................................... 3-21 3.2.16 Connecting Rod Reassembly to Compressor .......................................................................... 3-27 3.2.17 V105, V150, V200, and V250 Drive Motor and Coupling ........................................................ 3-28 3.2.18 V375 Drive Motor and Coupling ............................................................................................... 3-30 3.2.19 Flywheel and Drive End Oil Seals Removal from Compressor ............................................... 3-31 3.2.20 Flywheel and Drive End Oil Seal Reassembly to Compressor ................................................ 3-32 3.2.21 Crankshaft and Main Bearing Removal from Compressor ...................................................... 3-34 3.2.22 Crankshaft and Main Bearings Reassembly to Compressor ................................................... 3-35 3.2.23 Oil Level Switch Remove/Clean/Replace ................................................................................ 3-35 3.2.24 Air and Water Safety Valves .................................................................................................... 3-36 3.2.25 Separator and Diffuser Plate: Removal and Examination ....................................................... 3-36 3.2.26 Separator and Diffuser Plate: Reassembly .............................................................................. 3-37

3.3 WATER CIRCULATING PUMP (if supplied) ............................................................................ 3-38 3.3.1 General Overhaul ..................................................................................................................... 3-39

3.4 ELECTRICAL MAINTENANCE ................................................................................................ 3-39 3.5 FAULT FINDING CHART ......................................................................................................... 3-39 3.6 TOOLS REQUIRED FOR COMPRESSOR MAINTENANCE .................................................. 3-41

4 TECHNICAL DATA ................................................................................................................... 4-1 4.1 GENERAL .................................................................................................................................. 4-1 4.2 PERFORMANCE ....................................................................................................................... 4-1 4.3 OTHER DATA ............................................................................................................................ 4-1 4.4 CRANKCASE LUBRICANTS ..................................................................................................... 4-3

4.4.1 Approved Oils ............................................................................................................................. 4-3 4.4.2 Oil Company Equivalents ........................................................................................................... 4-3 4.4.3 Additional Maintenance for Machines Lubricated with Synthetic Oils ....................................... 4-3

5 DRAWINGS ............................................................................................................................... 5-1

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FIGURES

Figure 3.1 First Stage Concentric Valve V105/150 3-5 Figure 3.2 First Stage Concentric Valve V200/250 3-6 Figure 3.3 First Stage Concentric Valve V375 3-7 Figure 3.4 Final Stage Concentric Valve V105/150 3-10 Figure 3.5 Final Stage Concentric Valve V200/250 3-11 Figure 3.6 Final Stage Concentric Valve V375 3-12 Figure 3.7 Cooler Header 3-20 Figure 3.8 V105/V150 Fitting and Orientation of Big End Bearings/Con Rods 3-24 Figure 3.9 V200/V250 Fitting and Orientation of Big End Bearings/Con Rods 3-25 Figure 3.10 V375 Big End Bearings Fitting & Con Rod Orientation in the Crankcase 3-26 Figure 3.11 Coupling 3-28 Figure 3.12 Gap between Coupling and Flywheel 3-29 Figure 3.13 Coupling 3-30 Figure 3.14 Location of Angle Steel on Crankcase Rails 3-31 Figure 3.15 Water Circulating Pump 3-38 Figure 5.1 Typical Arrangement of V-Line Water Cooled Compressor with Gauges 5-1 Figure 5.2 Cooler 5-3 Figure 5.3 Crankshaft and Flywheel 5-4 Figure 5.4 First Stage Cylinder and Piston 5-5 Figure 5.5 Final Stage Cylinder and Piston 5-6 Figure 5.6 Separator 5-7 Figure 5.7 Gauges 5-8

TABLES

Table 3.1 Fastener Torque Settings (unlubricated) 3-1 Table 3.2 Maintenance Schedule 3-2 Table 3.3 Fixtures to Assist Flywheel Removal 3-31 Table 3.4 Items List - Water Circulating Pump 3-38 Table 3.5 Switch Settings 3-39 Table 3.6 Fault Finding Chart 3-39 Table 3.7 Tools Required for Compressor Maintenance 3-41 Table 4.1 Capacity and Power at 30 Bar 4-1 Table 4.2 Operating Parameters 4-1 Table 4.3 Recommended Maximum Wear Clearances 4-2 Table 5.1 List of Parts for Figure 5.1 5-1 Table 5.2 List Of Parts V-Line Compressors 5-9

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Spare Parts and Service

Spare Parts can be ordered direct from the following address:

HATLAPA Marine Equipment Ltd. Telephone: +44 (0) 1202 853180 Discovery Court Business Centre Facsimile: +44 (0) 1202 853190 551 553 Wallisdown Road e-mail [email protected] BH12 5AG England

When ordering spare parts, the following information is required to ensure that correct parts are supplied: Type and serial number of machine: Obtained from machine nameplate Item Number and full description of part required: Obtained from details in this publication

Technical Service and Advice:

Technical service and advice can be obtained during normal working hours from the above address, on the following contact numbers

Telephone: +44 (0) 1202 853175 Facsimile: +44 (0) 1202 853190 Email: [email protected]

Signs used

DANGER

This sign indicates behaviour which if not observed is highly dangerous, or which may lead to permanent bodily injury.

Observe the warning exactly and pass this to other operators of the equipment also.

CAUTION

This sign indicates behaviour which if not observed may lead to injury to persons, severe damage, or severe mal-function of the equipment, or to damage to the environment.

PAY ATTENTION

This sign indicates behaviour which if not observed may lead to damage or mal-function of the equipment.

INFORMATION

This sign indicates tips and useful information which makes the operation of the equipment or the understanding of the documentation easier.

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CHAPTER 1 INSTALLATION

Page 1-1

1 INSTALLATION

1.1 LOCATION

The suction inlet should be installed in a well ventilated position so that air drawn into the compressor is as cool and dry as possible and there is adequate circulation to the drive motor integral cooling fan and all the compressor external surfaces.

The compressor must be positioned with the axis of the crankshaft and motor fore and aft in the vessel to ensure adequate lubrication during the vessels normal roll, pitch, list and trim modes.

1.2 MOUNTING

The compressor should be mounted on support plates/pads and supported by a ribbed structure suitable for the type and weight of the compressor. The pads/plates must be clean and flat to within 0.5 mm (1 mm with anti-vibration mounts). Shims should be used if necessary. Refer to general arrangement drawing supplied with the compressor documentation package for mounting feet or anti-vibration mounts dimensions and positions and weight of the compressor.

1.3 COMMISSIONING

DANGER

Do not make any adjustments to the compressor, its connections or fittings whilst the compressor is running or on standby duty.

Do not run the compressor unless all protective guards fitted to it and its prime mover are in place.

1. Ensure compressor is isolated from its electrical supply.

2. Check lubricating oil level in crankcase sump.

3. Before initial start up, or after any servicing has been carried out, or when the compressor has not been run for 5 weeks or more, carry out the following procedures.

a. Remove the suction filter of the first stage (see chapter 3.2.3 Air Suction Filter/Silencer Removal and Replacement) and the plug from the second stage cylinder head.

b. Pour 20 m

air compressor -hatlapa type v105

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