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Tài liệu hướng dẫn sử dụng, bảo trì, bảo dưỡng máy nén khí mã hiệu WP206L của hãng Sauer compressor. Tài liệu bao gồm các mục chính: + General + Safety +Design and function +Technical specification +Transport and installation +Operating +Troubleshouting +Maintenance +Lubrication +Spare part
S a u e r C o m p r e s s o r Type: WP 206L Operating Manual High-pressure Compressor Stages, 2/1 flows Air-cooled Edition: 03 / 2009 Edited by: J.P Sauer & Sohn Maschinenbau – Technical Documentation WP206L_BA_Titel_en_09.fm WP206L_BA_Titel_en_09.fm Zertifikate_en_0.fm Sauer compressor Type Approvals Note! On this page only a few examples are shown FurtherType Approvals are available on request Genuine Sauer spare parts – certified safety Zertifikate_en_0.fm N E M I C SPE Table of Contents General Foreword Precautions Warrenty and Liability Type Approval and genuine Sauer spare parts 10 J.P SAUER & SOHN customer service 11 Specific instructions 12 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Safety Conditions of use Unauthorised moditifaction Safety information - Warning & Caution Safety warnings on the machine Safety and protection devices Noise protection Waste disposal Personal safety Personal protection 13 13 13 14 15 16 17 17 18 19 3.1 3.2 3.3 3.4 Design and Function Overview Functional description Indicators for the Sauer compressor Compressor Control System - Indicators and Control 20 20 24 26 27 4.1 4.2 Technical Specification 28 Specification data 28 P&I Diagram 30 WP206L_BA_en_09_IVZ.fm 1.1 1.2 1.3 1.4 1.5 1.6 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Transport and Installation Transport Storage before Installation Installation Connecting the Compressor Final pressure switch setting Filling with oil Installation checks and before the initial start 32 32 33 34 37 41 42 43 6.1 6.2 6.3 6.4 Operation Safe operation Operation modes Initial Operation Routine operation 44 44 45 46 47 Troubleshouting guide 49 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 Maintenance Maintenance and Service by J.P SAUER & SOHN Maintenance safety Maintenance schedule Table of tightening torques Oil change Checking screw connections Air Intake filter cartridge replacement Checking valves Checking the piston rings Replacing gudgeon pins / bearings Replacing valves Checking pistons and cylinders Checking the drive bearings Checking the coupling and replacing the coupling insert Checking the separator Checking the safety valves WP206L_BA_en_09_IVZ.fm 53 53 54 55 57 58 59 59 60 63 65 67 67 68 69 70 71 Storage, Preservation - “lay-up“ procedure Safety when storing and removing Temporary preservation & storage Removing 72 72 73 76 10 10.1 10.2 Lubricant table 77 Lubricating oils 78 Preservation oils 79 11 Spare Parts and Accessories 80 12 Annex 82 WP206L_BA_en_09_IVZ.fm 9.1 9.2 9.3 WP206L_BA_K1_12_en_09.fm General 1.1 Foreword This Operator Manual provides installation guidance, safe operation, maintenance and repair instructions with illustrated parts breakdown The following unique specification for the Sauer Compressor can be found on the nameplate affixed to the compressor: – compressor type – serial number – year of construction We recommend you record this information in Chapter 11, “Spare Parts and Accessories”, and always provide this data when requesting parts and any repair instructions 1.2 Precautions We recommend that only authorised and trained personnel Operate and Service the Sauer Compressor Such responsible personnel should be thoroughly familar with, and frequently review, the Operator Manual These instructions should always be readily available at the compressor installation Copyright The copyright for these instructions remains with J.P SAUER & SOHN These instructions, or parts thereof, shall not be copied, distributed or made available to third parties Contravention will result in prosecution WP206L_BA_K1_12_en_09.fm Specific precautions General 1.3 Warranty and Liability WP206L_BA_K1_12_en_09.fm Sauer can no longer cover warranty, be liable for any claims, if a failure is attributed to any of the following: – use of the machine not as specified; – substitution of parts not manufactured or approved by Sauer; – use of spare parts that are not genuine Sauer spare parts; – operation of the machine with faulty or improperly installed safety and/or protection devices; – disregard of the operating instructions; – unauthorised modification to the machine or its control system; – inadequate monitoring of machine parts subject to wear; – failure to maintain/repair in accordance with Sauer instructions; – force majeure 1.4 Type Approval and genuine Sauer spare parts • The Type Approval for the Sauer Compressor is valid under the condition that parts and components specified and qualified by J.P SAUER & SOHN are used The Type Approval is provided by the Classification Society and the EC Declaration of Conformity or EC Manufacturer's Declaration Disregard for the “specifications“ may cause the Type Approval to expire • Only the use of genuine Sauer spare parts will ensure compliance with these ’specfications’ and, therefore, reliable and safe operation of the Sauer Compressors • If non-genuine Sauer spare parts are used, we reserve the right of exclusion from liability for personal injury and material damage • Genuine Sauer spare parts are supplied with a Certificate of Conformity and a Certificate of Authenticity An example of this document is shown just before the Table of Contents in these instructions If spare parts are received without this certificate, there is a risk that these are not genuine Sauer spare parts In such an istance please contact our Customer Service Note! Be aware this is a high-pressure compressor, for your own safety and for reliable compressor operation, only unse genuine Sauer parts Correct Do not use parts from the “grey market“! WP206L_BA_K1_12_en_09.fm Only use genuine Sauer spare parts supplied with a Certificate! Incorrect 10 Item 053 727 Gudgeon pin 057 520 28 053 727 Gudgeon pin 057 520 22 053 727 Gudgeon pin 057 523 30 053 727 Gudgeon pin 057 523 24 054 164 Pressure spring 057 916 52 056 216 Cylinder 064 408 32 056 237 Gasket 064 408 32 056 239 Gasket 064 408 32 056 264 Fan keep-plate 065 187 20 056 272 Big-end bearing 064 568 22 056 272 Big-end bearing 064 848 24 056 316 Connecting rod bolt 064 352 22 056 316 Connecting rod bolt 068 353 24 056 318 Gasket 064 119 50 056 334 Gasket 068 355 43 056 335 Gasket 068 355 42 056 730 Gear wheel 064 119 50 057 519 Piston 057 520 28 057 520 Piston 2nd stage 068 350 057 522 Piston 057 523 30 057 523 Piston 3rd stage 068 350 057 916 Pressure relief valve 064 119 50 060 266 Gasket 064 409 36 060 342 Fusible plug 063 121 48 062 089 Safety valve 3rd stage 068 355 42 50 062 328 Baffle cone 063 121 48 062 375 Gasket 064 408 32 062 376 Gasket 064 409 36 062 376 Gasket 068 351 12 33 WP206L_ET_Index_en_09.fm Description E - 76 Assembly Page E- Ref No WP206L_ET_Index_en_09.fm Index Assembly Page E- Ref No Description Item 062 376 Gasket 068 386 38 062 908 Oil pump gear wheel 062 909 54 062 909 Gear oil pump 064 119 50 063 120 Oil/water manifold 068 423 58 063 121 Separator 3rd stage 068 350 13 063 228 Separator housing 063 121 48 063 229 Separator head 063 121 48 063 748 Gasket 068 351 12 063 824 Gasket 062 909 54 064 051 Gasket 068 386 38 064 064 Dipstick 068 351 12 064 075 Clamp 068 355 42 30 064 079 Bearing housing 068 351 13 064 095 Gasket 068 351 13 064 098 Gear wheel 064 119 50 064 119 Lubricating oil pump 068 350 14 064 135 Cylinder head 068 386 38 064 345 Flywheel 065 187 20 064 346 Cylinder 064 409 36 064 347 Cylinder head 064 409 36 064 352 Connecting rod 064 568 22 064 365 Stub 068 360 56 064 408 Cylinder with head and valve 1st stage 068 350 8 064 409 Cylinder with head and valve 2nd stage 068 350 064 420 Flywheel keep-plate 065 187 20 064 481 Cylinder head 064 408 32 064 501 Spacer ring 068 422 064 523 Double pipe nipple 065 177 40 064 568 Connecting rod 1st and 2nd stage 068 350 E - 77 Item 064 849 Connecting rod 064 848 24 065 117 Crankcase 068 351 13 065 120 Forced air duct 068 355 43 065 177 Crankcase vent 068 350 11 065 187 Crankshaft 068 350 065 190 Crankshaft 065 187 20 065 194 Pipe clamp 068 355 42 29 065 195 Spacer bush 068 355 42 26 065 196 Cooler 3rd stage 065 229 46 065 197 Pipe 068 355 42 14 065 200 Pipe 068 355 42 27 065 229 Cooler 3rd stage 068 355 42 33 065 230 Cooler 3rd stage 065 229 46 065 234 Clamp 068 355 42 32 065 235 Clamp 068 355 42 31 065 348 Oil filter / strainer 068 351 13 065 352 Screwed socket 068 360 56 065 353 Screwed socket 068 360 56 065 376 Spacer 068 355 43 28 065 388 Non-return valve 068 554 62 065 389 Spacer 068 355 43 25 065 478 Drain hose 068 423 58 066 885 Orifice 068 423 58 068 350 Compressor WP 206 L 068 422 068 351 Crankcase 068 350 068 352 Connecting rod 3rd stage 068 350 068 354 Cylinder 068 386 38 068 355 Cooler and air pipes 068 350 12 068 356 Pipe 068 355 42 WP206L_ET_Index_en_09.fm Description E - 78 Assembly Page E- Ref No Index Description Item 068 357 Pipe 068 355 42 12 068 358 Pipe 068 355 42 18 068 359 Pipe 068 355 42 23 068 360 Compressor monitoring and protection 068 350 15 068 385 Connection flange 068 351 12 32 068 386 Cylinder with head and valve 3rd stage 068 350 10 068 423 Automatic drainage system 068 422 068 521 Motor support 068 422 6 068 522 Spacer 068 554 62 11 068 523 Rail 068 554 62 068 544 Resilient mounts 068 422 068 706 Separator 2nd stage 068 355 42 17 WP206L_ET_Index_en_09.fm Assembly Page E- Ref No E - 79 Parts List by Description Description Assembly Page E- Item AC drive motor 068 422 14 036 394 Air filter 064 408 32 11 038 264 Angle pressure gauge 068 360 56 031 149 Anti-vibratuon resilient mount 068 554 62 068 423 Automatic drainage system 068 422 062 328 Baffle cone 063 121 48 064 079 Bearing housing 068 351 13 056 272 Big-end bearing 064 568 22 056 272 Big-end bearing 064 848 24 035 824 Cap 065 177 40 000 540 Cap screw 068 355 43 000 543 Cap screw 068 350 17 000 558 Cap screw 068 355 42 37 002 962 Circlip 057 916 52 002 984 Circlip 033 185 26 002 984 Circlip 057 520 28 002 984 Circlip 057 523 30 064 075 Clamp 068 355 42 30 065 234 Clamp 068 355 42 32 065 235 Clamp 068 355 42 31 037 941 Compressed-air hose 065 478 60 036 333 Compressor half coupling 068 350 66 036 333 Compressor half coupling 068 350 16 068 360 Compressor monitoring and protection 068 350 15 068 350 Compressor WP 206 L 068 422 037 460 Concentric valve 1st stage 064 408 32 12 064 352 Connecting rod 064 568 22 E - 80 WP206L_ET_Index_en_09.fm Ref No WP206L_ET_Index_en_09.fm Index Assembly Page E- Ref No Description Item 064 849 Connecting rod 064 848 24 064 568 Connecting rod 1st and 2nd stage 068 350 068 352 Connecting rod 3rd stage 068 350 056 316 Connecting rod bolt 064 352 22 056 316 Connecting rod bolt 068 353 24 068 385 Connection flange 068 351 12 32 037 776 Cooler 1st and 2nd stage 068 355 42 065 196 Cooler 3rd stage 065 229 46 065 229 Cooler 3rd stage 068 355 42 33 065 230 Cooler 3rd stage 065 229 46 068 355 Cooler and air pipes 068 350 12 033 531 Counter-sunk bolt 068 554 62 10 033 423 Coupling flexible insert 068 422 66 033 423 Coupling flexible insert 068 422 13 065 117 Crankcase 068 351 13 068 351 Crankcase 068 350 051 883 Crankcase inspection cover 068 351 12 065 177 Crankcase vent 068 350 11 065 187 Crankshaft 068 350 065 190 Crankshaft 065 187 20 034 575 Cxylindrical roller bearing - drive end 065 187 20 14 033 215 Cxylindrical roller bearing - outer end 065 187 20 15 056 216 Cylinder 064 408 32 064 346 Cylinder 064 409 36 068 354 Cylinder 068 386 38 064 135 Cylinder head 068 386 38 064 347 Cylinder head 064 409 36 064 481 Cylinder head 064 408 32 E - 81 Item 064 408 Cylinder with head and valve 1st stage 068 350 8 064 409 Cylinder with head and valve 2nd stage 068 350 068 386 Cylinder with head and valve 3rd stage 068 350 10 037 470 Delivery valve plate 037 460 34 037 471 Delivery valve spring 037 460 34 037 076 Dipstick 064 064 16 064 064 Dipstick 068 351 12 064 523 Double pipe nipple 065 177 40 065 478 Drain hose 068 423 58 037 790 Fan 065 187 20 056 264 Fan keep-plate 065 187 20 036 395 Filter element for air filter 036 394 32 13 036 081 Fitting 068 355 42 45 004 598 Fitting 068 360 56 004 635 Fitting 068 351 13 21 004 641 Fitting 068 351 12 27 004 641 Fitting 068 423 58 10 004 661 Fitting 065 388 64 004 694 Fitting 065 348 18 004 705 Fitting 065 229 46 004 707 Fitting 068 355 42 39 004 998 Fitting 068 423 58 12 006 055 Fitting 068 355 42 24 006 186 Fitting 068 355 42 41 006 193 Fitting 068 355 42 42 006 197 Fitting 068 355 42 13 006 205 Fitting 065 177 40 006 216 Fitting 068 423 58 13 006 224 Fitting 068 355 42 53 WP206L_ET_Index_en_09.fm Description E - 82 Assembly Page E- Ref No WP206L_ET_Index_en_09.fm Index Assembly Page E- Ref No Description Item 006 231 Fitting 068 355 42 16 030 510 Fitting 068 360 56 033 614 Fitting 065 177 40 033 912 Fitting 068 360 56 035 310 Fitting 068 351 12 28 036 157 Fitting 068 355 42 40 037 109 Fitting 068 355 42 21 037 649 Fitting 068 423 58 037 832 Fitting 068 355 42 52 037 851 Fitting 068 355 43 039 305 Fitting 068 355 43 10 039 306 Fitting 068 355 42 19 039 307 Fitting 068 355 42 51 064 345 Flywheel 065 187 20 064 420 Flywheel keep-plate 065 187 20 065 120 Forced air duct 068 355 43 060 342 Fusible plug 063 121 48 030 545 Gasket 064 119 50 035 061 Gasket 068 360 56 19 056 237 Gasket 064 408 32 056 239 Gasket 064 408 32 056 318 Gasket 064 119 50 056 334 Gasket 068 355 43 056 335 Gasket 068 355 42 060 266 Gasket 064 409 36 062 375 Gasket 064 408 32 062 376 Gasket 064 409 36 062 376 Gasket 068 351 12 33 062 376 Gasket 068 386 38 E - 83 Item 063 748 Gasket 068 351 12 063 824 Gasket 062 909 54 064 051 Gasket 068 386 38 064 095 Gasket 068 351 13 062 909 Gear oil pump 064 119 50 036 359 Gear wheel 062 909 54 056 730 Gear wheel 064 119 50 064 098 Gear wheel 064 119 50 033 187 Gudgeon pin 033 185 26 033 187 Gudgeon pin 033 185 22 053 727 Gudgeon pin 057 520 28 053 727 Gudgeon pin 057 520 22 053 727 Gudgeon pin 057 523 30 053 727 Gudgeon pin 057 523 24 000 010 Hexagon head screw 068 360 56 000 036 Hexagon head screw 068 423 58 000 054 Hexagon head screw 068 355 42 000 057 Hexagon head screw 065 187 20 000 123 Hexagon head screw 068 355 42 36 000 147 Hexagon head screw 068 355 42 35 000 162 Hexagon head screw 068 355 43 000 184 Hexagon head screw 068 355 42 43 000 184 Hexagon head screw 068 554 62 000 187 Hexagon head screw 068 422 000 197 Hexagon head screw 068 554 62 000 216 Hexagon head screw 065 187 20 000 220 Hexagon head screw 068 422 005 269 Hexagon head screw 068 554 62 036 041 Hexagon head screw 063 121 48 10 WP206L_ET_Index_en_09.fm Description E - 84 Assembly Page E- Ref No WP206L_ET_Index_en_09.fm Index Assembly Page E- Ref No Description Item 001 064 Hexagon nut 062 909 54 001 620 Hexagon nut 064 408 32 001 620 Hexagon nut 064 409 36 001 620 Hexagon nut 068 386 38 002 031 Hexagon nut 068 351 12 17 002 063 Hexagon nut 068 422 10 002 094 Hexagon nut 068 351 13 18 002 098 Hexagon nut 068 351 12 16 034 763 High pressure flexible hose 068 554 62 036 546 Insulation hose 065 177 40 001 925 Key 062 909 54 11 001 942 Key 064 119 50 032 430 Key 065 187 20 13 035 787 Lamellar valve 2nd stage 064 409 36 037 158 Lamellar valve 3rd stage 068 386 38 000 270 Lifting-eye bolt 068 351 13 037 942 Link bolt clamp 065 478 60 001 672 Lock plate 062 909 54 10 001 675 Lock plate 065 187 20 11 003 114 Lock washer 068 355 42 56 003 115 Lock washer 068 423 58 004 472 Locking pin 065 187 20 12 030 082 Low oil pressure switch 068 360 56 20 034 612 Low pressure hose 065 177 40 10 037 264 Low pressure hose 065 177 40 11 064 119 Lubricating oil pump 068 350 14 036 438 Motor half coupling 068 422 66 036 438 Motor half coupling 068 422 12 068 521 Motor support 068 422 6 E - 85 Item 037 883 Non-return valve 065 388 64 065 388 Non-return valve 068 554 62 002 544 Nose ring 057 523 30 033 188 Nose ring 033 185 26 034 213 Nose ring 057 520 28 005 016 O-ring 068 355 42 20 005 016 O-ring 068 360 56 10 030 340 O-ring 068 355 42 46 035 520 O-ring 064 064 16 036 171 O-ring 063 121 48 037 526 O-ring 068 386 38 12 036 897 Oil filter / strainer 065 348 18 065 348 Oil filter / strainer 068 351 13 033 212 Oil pump cover 062 909 54 062 908 Oil pump gear wheel 062 909 54 036 360 Oil pump housing 062 909 54 033 221 Oil scraper ring 057 520 28 035 200 Oil scraper ring 033 185 26 063 120 Oil/water manifold 068 423 58 066 885 Orifice 068 423 58 008 633 Pipe 068 360 56 22 008 633 Pipe 068 360 56 23 008 651 Pipe 065 348 18 008 663 Pipe 068 351 12 30 008 663 Pipe 068 423 58 17 008 663 Pipe 068 423 58 18 008 663 Pipe 068 423 58 19 012 766 Pipe 065 177 40 12 065 197 Pipe 068 355 42 14 WP206L_ET_Index_en_09.fm Description E - 86 Assembly Page E- Ref No WP206L_ET_Index_en_09.fm Index Assembly Page E- Ref No Description Item 065 200 Pipe 068 355 42 27 068 356 Pipe 068 355 42 068 357 Pipe 068 355 42 12 068 358 Pipe 068 355 42 18 068 359 Pipe 068 355 42 23 065 194 Pipe clamp 068 355 42 29 033 186 Piston 033 185 26 057 519 Piston 057 520 28 057 522 Piston 057 523 30 033 185 Piston 1st stage 068 350 057 520 Piston 2nd stage 068 350 057 523 Piston 3rd stage 068 350 002 663 Plain ring 057 523 30 033 220 Plain ring 057 520 28 035 199 Plain ring 033 185 26 000 970 Plug 064 119 50 000 972 Plug 064 409 36 11 001 007 Plug 063 121 48 11 001 009 Plug 068 351 13 13 001 021 Plug 068 351 12 15 030 744 Plug 068 351 12 14 030 744 Plug 068 355 42 38 030 744 Plug 068 423 58 16 037 596 Plug 068 355 42 57 038 288 Pressure gauge 1st stage 068 360 56 12 033 262 Pressure gauge 2nd stage 068 360 56 13 036 372 Pressure gauge 3rd stage 068 360 56 14 033 261 Pressure gauge oil 068 360 56 21 057 916 Pressure relief valve 064 119 50 E - 87 Item 054 164 Pressure spring 057 916 52 068 523 Rail 068 554 62 006 390 Reducing union 063 121 48 033 017 Reducing union 068 360 56 11 037 138 Reducing union 065 177 40 045 847 Reducing union 068 355 42 54 068 544 Resilient mounts 068 422 030 751 Safety valve 1st stage 068 355 42 48 035 862 Safety valve 2nd stage 068 355 42 49 062 089 Safety valve 3rd stage 068 355 42 50 065 352 Screwed socket 068 360 56 065 353 Screwed socket 068 360 56 003 496 Sealing washer 063 121 48 12 003 496 Sealing washer 064 119 50 005 029 Sealing washer 063 121 48 068 706 Separator 2nd stage 068 355 42 17 063 121 Separator 3rd stage 068 350 13 063 229 Separator head 063 121 48 063 228 Separator housing 063 121 48 007 123 Shaft seal 068 351 13 25 030 831 Shaft seal 068 351 13 26 033 213 Small-end bearing 064 568 22 033 213 Small-end bearing 064 568 26 033 213 Small-end bearing 064 568 28 033 213 Small-end bearing 068 352 30 034 552 Small-end bearing 064 848 24 037 681 Solenoid valve 1st and 2nd stage 068 423 58 15 037 837 Solenoid valve 3rd stage 068 423 58 20 WP206L_ET_Index_en_09.fm Description E - 88 Assembly Page E- Ref No WP206L_ET_Index_en_09.fm Index Assembly Page E- Ref No Description Item 065 376 Spacer 068 355 43 28 065 389 Spacer 068 355 43 25 068 522 Spacer 068 554 62 11 065 195 Spacer bush 068 355 42 26 064 501 Spacer ring 068 422 006 456 Stub 068 355 42 55 033 961 Stub 068 423 58 14 035 321 Stub 068 423 58 038 920 Stub 065 177 40 064 365 Stub 068 360 56 001 410 Stud screw 068 351 12 11 001 411 Stud screw 068 351 12 001 459 Stud screw 068 351 13 12 001 517 Stud screw 068 386 38 001 519 Stud screw 064 409 36 033 717 Stud screw 068 351 12 10 037 477 Stud screw 064 408 32 039 304 Stud screw 068 351 12 20 037 468 Suction valve plate 037 460 34 037 472 Suction valve plate 037 460 34 037 469 Suction valve spring 037 460 34 006 383 T-piece 065 177 40 033 223 Thermometer 1st stage 068 360 56 15 037 839 Thermometer 2nd and 3rd stage 068 360 56 24 001 637 Washer 068 554 62 001 638 Washer 068 422 11 002 144 Washer 068 360 56 002146 Washer 068 351 13 19 002 161 Washer 064 408 32 10 E - 89 Description Item 002 166 Washer 068 355 42 44 002 166 Washer 068 554 62 003 438 Washer 064 119 50 10 005 001 Washer 068 351 13 22 005 001 Washer 068 360 56 17 005 006 Washer 068 360 56 16 005 009 Washer 063 121 48 005 009 Washer 064 409 36 10 005 009 Washer 068 351 12 23 005 009 Washer 068 355 42 22 005 009 Washer 068 360 56 18 005 023 Washer 068 355 42, 43 11 035 254 Worm drive hose clip 065 177 40 13 037 137 Y-branch 065 177 40 WP206L_ET_Index_en_09.fm Assembly Page E- Ref No E - 90