Compressed Air System Training

Atlas Copco Korea MFG Compressor Technique Service

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

Compressor Overview (out side)

Principal :
-. MK4 : Controller Module -. AF : Air Filter -. S2 : Emergency button -. SVl : Safety valve of Low pressure

-. DRi : Drain Receiver of Intercooler

-. SVh : Safety valve of High pressure -. DRa : Drain Receiver of Aftercooler -. AO : Air outlet -. WI : Water inlet -. WO : Water outlet

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

Control module side

Control Panel
Scroll Keys
Display
Start Button UP

TAB

Function Keys
Stop Button
Automatic Warning/ Power operation Shutdown On LED LED LED

Down

Emergency stop Button

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Motor side view

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 .

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.

Element side view

Principal :
-. Main Drive shaft -. LP Element -. HP Element -. Oil pump -. Gear box & Sump tank

LP 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.

HP Element

Air Inlet valve view

Purpose : Used to load and unload
By pass valve Muffler

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.
Sol valve

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.
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Element view
Cooling jacket Female Rotor

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
Pinion gear Vent hole

Timing gear

Male Rotor

Balancer piston

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 Principal of Rotor

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pressure while loaded. While unloaded raises intercooler pressure to about 0.2bar that is blown-off.

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 rooms 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 view

Gear boxs 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.

Outlet hole

Suction

Compression

discharge

Inlet hole

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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 system

Compressed air Oil

Oil bypass valve Oil filter Full-load / no-load regulator, blow-off valve & silencer

Oil pump Silencer Check valve Oil Sump Tank Oil Thermostatic

Condensate drain for A/C

Condensate drain for I/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 & inspection

5. 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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MKIV module

(To modify the pressure band)

-. Starting from the Main screen 1. Press the key Menu ( ).

2. Press the arrow down key (

) until Modify ).

3. The first item Parameters will be followed by a horizontal arrow( Tab icon( will blink. ), Press the tabulator key( ); the setting ). 3-1. The first item Loading pressure is followed by ), Press the Modify(

Parameters is followed by a horizontal arrow(

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

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

4. Use the scroll keys(

) to change the setting. ) to program the ) to cancel

4-2. Press the key Program (

new value or the key Cancel ( the modification operation.

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MKIV module

(To reset the shut down message)

-. Starting from the Main screen 1. Press the key Menu ( ). )

2. Press the tabulator key ( data ( )

) to select the status

3. The option Protection is blinking. 3-1. Press the tabulator key ( ).

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

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

4. The option Shut downs is blinking. 4-2. Press the tabulator key( ). Shutdowns

5. Switch off the voltage and remedy the trouble. 6. General alarm LED is out and the message on the After remedying and when the shut-down display will indicate that All condition has disappeared, switch on the voltage conditions are OK and press the key Reset ( )

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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 ).

3. The first option is shown Last shutdown 1 horizontal arrow( ), Press the tabulator key( ).

is followed by a horizontal arrow(

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

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

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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 3. The first item C.C.M is followed by ). Tab icon( will blink. ), Press the Modify( ); the setting

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. ) to program the ) to cancel

(Local / Remote / LAN Control) 4-2. Press the key Program ( new value or the key Cancel ( the modification operation.
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Maintenance procedure ( To change the air filter)

1. Loosen the 4 clip (A).

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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Maintenance procedure ( To Change the Breather pre-filter)

1. Loosen the drain hose (A) from the beam. 2. Open the oil sump valve.

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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Maintenance procedure ( To Change the oil filter)

1. Remove the oil filter (A).

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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Maintenance procedure ( To Change the Breather filter)

1. Disconnect the air supply pipe (A).

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
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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

Maintenance procedure ( To Change the Breather pre-filter)

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

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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Maintenance procedure (the oil bypass valve)

Regulates the oil pressure from the pump by bypassing oil pressure back into the sump

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

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

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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, p = 0.2 bar -. DDP particulate filter for dust protection, removing particles down to 1 micron, p = 0.08 bar

-. PD high efficiency coalescing filter, removing oil aerosol to 0.01mg/ (0.01 ppm) and particles down to 0.01 micron, p = 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), p = 0.07 bar

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Committed to sustainable productivity.

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