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Compressed Air System Training

Atlas Copco Korea MFG

Compressor Technique Service

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Compressor Training Agenda

1. Compressor overview

2. Compressor component data

3. Compressor flow system

4. Compressor operation procedure

5. MKIV control module

6. Maintenance procedure

7. Air Dryer

8. Filters

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Compressor Overview (out side)

Emergency button

Principal : -. MK4 :

-. AF :

-. S2 :

-. SVl :

-. DRi :

-. SVh :

-. DRa :

-. AO :

-. WI :

-. WO :

Controller Module

Safety valve of Low pressure

Drain Receiver of Intercooler

Safety valve of High pressure

Drain Receiver of Aftercooler

Air outlet

Water inlet

Water outlet

Air Filter

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Compressor Overview (In side)

Principal.

AF : Air filter

BV : by-pass valve, oil cooler

Ca1 : Pre-Aftercooler

Ca2 : Aftercooler

Ci : Intercooler

Co : Oil cooler

EwDi : Electronic water drain, Intercooler

El : Low pressure element

Eh : High pressure element

FC : Oil filler cap

FN : Cooling fan

M1 : Drive motor

M25 : Fan motor

MTi : Moisture trap, Intercooler

Y1 : Loading solenoid valve

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Control module side

Emergency stopButton

Control Panel

Function Keys

Start Button

StopButton

Automatic operationLED

Warning/Shutdown LED

PowerOnLED

Scro

ll K

eys

DisplayTAB

UP

Down

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Motor side view

★ attention :

Never mix Greases of different brands or types.

(P/N : 2901 0338 03 Roto glide amber for 400g cartridges)

Stop the compressor before regreasing, and fill up to the unload running.

Purpose :

Element & Oil pump rotation.

Description.

Flange type connecting

Main motor is supporting by the vibration damper.

There is connected by the rubber coupling between motor & drive shaft .

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Element side view

Principal :

-. Main Drive shaft

-. LP Element

-. HP Element

-. Oil pump

-. Gear box & Sump tank

LP Element

HP Element

Main drive shaft Oil pump ★ Attention :

When machine Stop more than 2 weeks,

you have to turn the Air compressor for 2 ~3

minutes a week by hand or unloading condition.

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Air Inlet valve viewPurpose : Used to load and unload compressor by opening and closing a Plate valve located at the inlet to the LP element.

By-pass to adjust the IC pressure at unload

Description 1.

1) No load : Inlet valve disc :100% closed.

To protect element rotor, supply the air of about 12 ~15% through by-pass line of inlet valve.

At this time, Compressed air between check valve and Unload line is blown off through muffler(silencer)

(HP inlet pressure -0.6 ~ -0.7 bar)

Description 2.

1) Full load : Atmospheric pressure is allowed through solenoid valve to chamber of unloader. As this pressure is higher than the pressure in chamber, full load/no-load valve starts opening.

2) Intercooler pressure is building up causing diaphragm to switch to the right. As the pressure difference between chambers increases, plunger moves further against the spring force until full-load/no-load valve is fully open and unloading valve closed.

Muffler

Sol’ valve

By pass valve

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Element view Z Type Compressor is Oil free air type.

Component :

-. Rotor : Lobe combination Screw Type of 4 Male : 6 Female

-. Balancer piston : when pressing , prevent pushing the the male rotor.

-. Vent hole : eliminate the oil & air from the element seals

-. Water Jacket : be cooled the element rotors

-. Timing gear : to rotate between the Male rotor and Female rotor

Female Rotor

Female Rotor

Pinion gear

Pinion gear

Timing gearTiming gear

Balancer piston

Balancer piston

Male RotorMale Rotor

Vent holeVent hole

Principal of Rotor

Cooling jacketCooling jacket

LP Element – Raises atmospheric pressure to 1.8 ~ 2.7bar while loaded. During unloading raises pressure from unload the Inlet valve from about - 0.5~ -0.7bar.

HP Element – Raises the intercooler pressure to working pressure while loaded. While unloaded raises intercooler pressure to about 0.2bar that is blown-off.

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Cooler view

Description : -. Cooler is manufactured the aluminum

pre –cooler

Compressed air in the tubes

Cooling air around the tubes

Inter & after cooler

Fins on both sides

- Cross flow of cooling air & compressed air.

cooling air is supplied from cooling fan

Attention: -. Cooling efficiency is swayed room temperature.

because Compressor room’s temperature control below 40 ℃ and

have to prevent contamination of cooler from dust.

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Electronic Water drain (EWD)Purpose : To discharge the condensate water in the moisture trap.

Two condensate traps are installed: intercooler & aftercooler

Description: The condensate enters the EWD via inlet(1) and accumulates in collector(6). A capacitive sensor(5) continuously measures the liquid level.

On the EWD330, pilot valve(3) is activated as soon as the collector is filled up to a certain level. Diaphragm(4) opens outlet(8), discharging the condensate.

When the collector has been emptied, the outlet closes quickly without wasting compressed air.

When the controller registers a malfunction, the red alarm LED on the control panel of the EWD starts flashing, a warning appears on the display of the regulator and the electronic drain valve will automatically change to the alarm mode, opening and closing the valve according to a sequence shown above.

If the fault is not remedied automatically, maintenance is required.

Function test. (Checking the alarm signal)

1) Press and hold the test button for at least 1 minute.

2) Check that the alarm LED flashes

3) Check that a warning is generated on the display of the regulator

4) Release the test button

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Gear box & oil pump viewGear box’s component :

-. Connection between Drive motor & Element.

-. Vibration Prevention by Vibration damper

-. Oil pumping & supply line inclusion

-. Body with Oil sump tank

Oil pump (Rotaty Pump type)’ description : Driven by the Main Shaft in draws oil from the sump and Pump it into the oil cooler at between 1.8 ~ 3.0bar.

Oil is circulated by pump from the sump of the gear casing through cooler. The oil flows through the cooling jackets of the compressor elements. The oil passes through oil filters towards the dearings and timing gears. Valve opens if the oil pressure should rise above a given value.

Inlet hole

Outlet hole

CompressionSuction discharge

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Gearcase breather system

Purpose :

-. To create slight vacuum in the gearbox.

-. To remove oil and oil fumes

Description :

Driving medium is compressed air from compressor outlet.

Sucks the oil fumes out of the gearcase

Converts the oil fumes into drops

Oil drops flow back into the gearcase

Attention :

you have to check the Breather system at every day.

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Compressor Flow systemCompressed air

Oil

Full-load / no-loadregulator, blow-off valve & silencer

Oil filter

Oil bypass valve

Silencer

Check valve

Oil pump

Oil Thermostatic

OilSump Tank

Condensate drain for I/C

Condensate drain for A/C

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Compressor Operation procedure 1. Before Starting

1) The temperature of the intake air must be between 10 ℃ and 50 ℃ (HAT version)

2) Check the oil level, which must be in the upper field of the green Color.

3) Open the air outlet valve.

4) Switch on the voltage and check that voltage on LED lights up.

5) if you stopped compressor more than a week, you should turn the drive shaft to check the stick the rotor.

2. Starting and During operation

1) Press start button. The compressor starts running in unloaded condition and automatic operation LED lights up. Reading the measured data.

2) When the automatic operation LED is lit, the starting and stopping of the motor is controlled automatically.

3) in daily, Check the display. Press the ↓ key to call up the compressor status (Press, Temp’, etc,..)

4) Condensate drain & Gearbox breather system check, in every day.

3. Stopping

1) Press the test button on top of the EWD while the compressor is running loaded.

2) Press stop button : the compressor will run unloaded for a few seconds, and stop with LED go out

3) if necessary, close the Air outlet valve.

***. Refer the instruction manual for detail data.

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Compressor Problems relating & inspection 1. Do not start the Compressor.

1) check lighting on the LED and main power voltage.

2) check setting point of pressure band

2. Main Motor overload.

1) check the rotation of Main shaft by hands.

2) check the manually operation of Inlet valve.

3) check the leak of Air outlet Check valve.

4) check the cable connection and Bearing states of Main motor.

3. Fan motor overload.

1) check the cable connection and Bearing states of Fan motor

2) check the Q25 (circuit breaker).

4. Do not change the Loading. 1) check the pressure set point on MKIV control.

2) check the damage of Diaphragm of inlet valve.( if necessary, change the part.)

3) check the operation of Loading relay & Solenoid valve.

4) check the operation of Inlet valve (Piston & Plate).

5) check the supply line for Inlet valve

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Compressor Problems relating & inspection5. DP Air filter pressure too low (Normal < -0.038 bar, Service warning < - 0.044 bar)

1) check the Filter pollution.

2) check the DP Air filter sensor. (if become the pollution, replace the new part.)

6. Oil Pressure too low. (1.9 < Normal , shutdown < 1.2 bar)

1) check the Oil Level (if necessary, refill up the oil). (up to about 1/3 Indication on running)

2) check the pollution in Oil filter (if necessary, change the new part).

3) check the Oil by-pass valve (if release the tension, change the part).

4) check the Oil pressure sensor (if having the problem, change the part).

7. On Unloading, HP Inlet pressure low ( - 0.5 > Normal > - 0.7 bar) 1) check the pressure point on MKIV control module.

(if get out the range, regulate the by-pass valve on inlet valve)

2) Check the condensate drain line & trap.

8. Oil Temperature too High. ( Normal < 60 ℃ , 70 ℃ < shutdown ) 1) check the oil Cooler & Oil Level.

2) consult the Atlas Copco service center.

9. Condensate drain shut down. 1) check in the Solenoid valve and clean the Moisture trap.

2) push the test button on top the EWD.

***. If necessary, Consult the Atlas Copco service center

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Using the MKIV Control module 1. Main screen menu

2. Status data menu

3. Measured data menu

4. Counters menu

5. Test menu

6. Modify parameters menu

1) Parameters

2) Protections

3) Service Plan

4) Clock function

5) Configuration

6) Parameters MCC (only No.A machine)

7. Service

8. Saved data

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3. The first item “ Parameters” will be followed by a

horizontal arrow( ), Press the tabulator key( ).

3-1. The first item “ Loading pressure” is followed by

Tab icon( ), Press the “Modify”( ); the setting

will blink.

MKIV module (To modify the pressure band)

-. Starting from the Main screen

1. Press the key “Menu” ( ).

***. Consult the section procedure to select “ Loading pressure”

2. Press the arrow down key ( ) until “Modify

Parameters” is followed by a horizontal arrow( ).

2-1. Activate the menu by pressing the tabulator key.

( )

4. Use the scroll keys( ) to change the setting.

4-2. Press the key “Program” ( ) to program the

new value or the key “Cancel” ( ) to cancel

the modification operation.

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3. The option “Protection” is blinking.

3-1. Press the tabulator key ( ).

MKIV module (To reset the shut down message)

-. Starting from the Main screen

1. Press the key “Menu” ( ).

1) In case the compressor is shut down, LED( ) will blink.

2) The indicators(***) are blinking. The screen shows the actual reading.

2. Press the tabulator key ( ) to select the “ status

data” ( )

4. The option “ Shut downs” is blinking.

4-2. Press the tabulator key( ). “Shutdowns”

5. Switch off the voltage and remedy the trouble. After remedying and when the shut-down condition has disappeared, switch on the voltage and press the key “Reset” ( )

6. General alarm LED is out and the message on the display will indicate that “All conditions are OK”

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3. The first option is shown “ Last shutdown 1”

horizontal arrow( ), Press the tabulator key( ).

3-2. If desired, scroll through the other items

MKIV module (To check the saved data)

-. Starting from the Main screen

1. Press the key “Menu” ( ).2. Press the arrow down key ( ) until “Saved data”

is followed by a horizontal arrow( ).

2-1. Activate the menu by pressing the tabulator key.

( )

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3. The first item “ C.C.M ” is followed by

Tab icon( ), Press the “Modify”( ); the setting

will blink.

MKIV module (To Change the control mode)

-. Starting from the Main screen

1. Press the key “Menu” ( ).2. Press the arrow down key ( ) until “Configuration”

is followed by a horizontal arrow( ).

2-1. Activate the menu by pressing the tabulator key.

( )

4. Use the scroll keys( ) to change the setting.

(Local / Remote / LAN Control)

4-2. Press the key “Program” ( ) to program the

new value or the key “Cancel” ( ) to cancel

the modification operation.

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1. Loosen the 4 clip (A).

Maintenance procedure ( To change the air filter)

2. Remove the cover (A) 3. Remove the dirty filter element (A)

4. change the New filter element. 5. Reinstall the filter element and cover.

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1. Loosen the drain hose (A) from the beam.

2. Open the oil sump valve.

Maintenance procedure ( To Change the Breather pre-filter)

2. Remove the oil filler plug (A). 3. Remove the oil cooler drain plug and open the oil cooler drain valve (B)

4. Drain the oil out of the cooler 5. Close the oil sump valve and oil cooler valve.

6. Refill the gearcasing with Roto-Z up to green color of sight glass (about 40 l).7. Part no. 2908 8501 01 (20 l) 2908 8503 00 (5 l)

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1. Remove the oil filter (A).

Maintenance procedure ( To Change the oil filter)

2. Clean the gear casing (A) 3. Oil the gasket (A)

4. Install the oil filter (A) 5. Turn the filter by hand, at least half a turn after contact.

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1. Disconnect the air supply pipe (A).

Maintenance procedure ( To Change the Breather filter)

2. Loosen the 3 bolts (A) of the cover 3. Remove the cover (A)

4. Remove the breather filter (B)

4. Clean the cover.5. Check the breather nozzle (A) *. When compressed air is applied to the

nozzle, A suction force should be felt at the copper injector

6. Fit the new breather filter (A).7. Fit 2 new O-rings in the cover

8. Install the cover.9. Tighten the 3 bolts (A) of the cover.10. Connect the air supply pipe

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1. Remove the pre-filter outlet pipe (A).

Maintenance procedure ( To Change the Breather pre-filter)

2. Remove the pre-filter cover (A) 3. Remove the pre-filter housing (A) and pre-filter (B)

4. Clean the pre-filter housing.5. Install the new pre-filter (A) -. If necessary, tap carefully with plastic hammer to put the pre-filter correctly in

place.

6. Fit a new O-ring (A) in the pre-filter cover (B).

7. Fit the pre-filter cover and tighten bolt.8. Connect the pre-filter outlet pipe.

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1. Loosen the oil bypass valve plug (A) with a spanner.

Maintenance procedure (the oil bypass valve)Regulates the oil pressure from the pump by bypassing oil pressure back into the sump

2. Remove the oil pass valve

3. Clean the housing in the gear casing (A)

4. Remove the circlip (A) out of the oil bypass housing (B)

5. Remove all internal parts

6. Clean the plug.

7. Replace the washer.

8. Install a new part. → Spring, valve seat (A) , Circlip

9. Install the oil bypass (A) in the gearcasing (B).

10. Torque the plug with a spanner

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Air Dryer _ General View

3030

Air Dryer _ Control module

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Air Dryer _ Working principle

Description .

The dryer has two towers, containing the adsorbing material or desiccant. The desiccant is a very porous grain material which can adsorb large amounts of water vapour.

Operation_ by Eleckronikon regulator and a PDP sensor.

Recycle the tower A and B

A Tower – Drying

B Tower – Downward - Regenerating (expands to atmospheric pressure) - pressurization

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Air Dryer package quality

Description .

-. DD coalescing filter for general purpose protection, removing oil aerosol to 0.1 mg/ ㎥ (0.1 ppm) and particles down to 1 micron, Δp = 0.2 bar

-. DDP particulate filter for dust protection, removing particles down to 1 micron, Δp = 0.08 bar

-. PD high efficiency coalescing filter, removing oil aerosol to 0.01mg/ ㎥ (0.01 ppm) and particles down to 0.01 micron, Δp = 0.14 bar

-. QD active carbon filter for removal of oil vapour and hydrocarbon odours with a maximum remaining oil content of 0.003mg/ ㎥ ( 0.003 ppm), Δp = 0.07 bar

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Committed tosustainable productivity.

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