Tage aol Moat Tat Naat ae eee er ve ) AIR-COOLED HIGH-PRESSURE AIR COMPRESSOR WP 3232 TECHNICAL MANUAL 063 080 NUS. \40%b J.P. SAUER & SOHN & MASCHINENBAU GMBH & CO.: J.P. SAUER & SOHN - MASCHINERHAU GMBH & CO General Hints 7 General hints This maintenance and operation manual contains recommendations which are ‘ Aecessary for the unobjectable and troublefree operation of your Sauer-piston compressor. Read these instructions thoroughly before starting-up operation because damages resulting from inappropriate handling of the compressor are not 7 covered by the warranty, Hi ts for purchase of spare parts Saver & Sohn warrants a total spare part supply over the life time of the equipment, The Interchangeability of all parts of one compressor type is our highest principle. : However, technical development or quality improvement may cause technical i changes in favour of the user. Therefore, it is absolutely necessary to mention the production number, the year - sL-production and, if possible, the operation hours besides the compressor type in : ‘he spare part order, ~ You will find this information on the type label of the compressor, which is fixed : on the crankcase at the operator side, For your convenience we recommend that you : insert the information in the space below. ‘Compressor No. Year of production: Production Ni All our spare parts are subject to a permanent quality control and are in accordance with the latest state of engineering, : Only the use of original Sauer spare parts guarantees an unobjectionable function 5 of the compressor and the avoidance of larger follow-on damages.W Rgs =< ra CONTENTS Technical data General design Constructional features Operating instruction Trouble Shooting Maintenance Air flow plan Full view of compressor unit Cross section of the compressor Longitudinal view of the compressor E-Motor Illustrated parts catalogue Page 12 13-22 23 24 25 26 27Technical Dala and Description I Technical data Number of cylinder 3 Number of stages 3 Cylinder-O Ist Stage 95 mm Cylinder-O lind Stage 38 mm Cylinder-0 lid Stage = 18mm Piston stroke 45mm Maximum working pressure 230 bar Revolutions 1140 rpm maximum Output 11.2 mah + 5% UL General design Being of weight-saving construction, the compressor has been shaped so as to assume the form of a flange compressor. The three cylinders are arranged in fan shape. Cooling is ensured by a radial fan connected to the crankshaft, The air flow, produced by the radial fan, is directed to the recoolers grouped around the diameter of the fan. Fan and cooling coils are covered by a hood which directs the cooling air to the cylinders. To separate the residual condensate, reliable oil and water separators are installed behind the respective cooling coil of stage II and tlt For a maximum speed of 1140 rpm and by the use of an intermediate housing the compressor can be flexibly coupled directly with the prime driver. The flywheel has been adapted for use with a flexible pin coupling. Annotation: Description / drawings of air compressor system: see VIl page 23, and VIII page 24 1 Il Constructional features, drawings see IX page 25 Crankcase The completely closed crankcase, made of tough light metal casting, is provided with a mounting flange. The oil sump is fitted to its lower part. The crankcase is equipped with a dipstick, vent valve and oil drain plug. Crankshail The drop-forged highly tempered crankshaft runs in two roller bearings. The bearing at the fan wheel end has been shaped so as to form a tight bearing, while the counter-bearing has been designed to constitute a compensating bearing. The crank pin is hardened Connecting rod“ The connecting rods have been drop-forged and tempered. Lead bronze steel-backed bearings serve as connecting-rod bearings The piston pins run in needle bearings. The connecting rods travel together on a crank-pin of the crankshattLubrication Piston, Cylinders Valves Intercooler Separator the driving system is lubricated by circulating pressure oil fed to the lubricating points from the incorporated gear-type oil pump, via a filter. This type of compressor requires a balanced driving system. Therefore, all pistons have to be well compensated and of equal weight. To achieve this the stage | piston has been made of light metal while the stage Il piston, which consists of a guide and compression part, is made of of grey cast iron. The guide for the stage III piston is also made of giey cast iron, while the threaded compression part is made from chrome steel The piston of stage | is provided with rectangular, lug and an oil scrapper rings, the piston of stage II with four rectangular rings and one lug ring, while the piston of stage Ill is equipped with 10 highly stressed rectangular tings arranged in pairs The cylinders, made of high-quality grey cast iron, are provided with high cooling ribs. The cylinder of stage Ill is equipped with an inserted liner of particularly tough grey cast iron. All of the working surfaces are microdrilled and honed. The reliable and well proven concentric valves, which comply with even the severest demands, have been selected for stages | and Il Intemal inlet vaive and external outlet valve, combined with high cooling ribs fitted to the valve body, ensure good heat dissipation. The two valves lying between the cylinder and cylinder head are tightened together with the cylinder head. While the compression spring in the valve gap provides the sealing between the respective induction and delivery valve part of the stage | valve, the sealing between the respective induction and delivery valve part of the stage Il valve is secured by means of a clamping screw. Stage Ill is equipped with individual valves, which are tightly screwed in the cast steel cylinder head using valve cages The steel tube intercooler between stages | and Il as well as between stages II and Ill have been designed so as to form gilled- tube coolers, whereas multiply wound plain tube material have been used for the aftercoale!. All af the cooling coils lie in the full air flow of the radial fan An oil and water separator has been installed between the outlet of stage IN/lll intercooler and the inlet to stage Ill cylinder. Another oil and water separator Is located at the outlet of the aftercooler. The separatory effect of these centrifugal separators has been increased by the incorporation of a multiply wound fine mesh gauze sieve. The separated condensate car be lot off by opening the condensate drain cocks.Salely devices Pressure indication Safety valves connected with the pressure spaces of the individual stages, have been installed according to the respective reguiations. With the stage | safety valve being screwed into stage I cylinder head, the safety valves of stages I! and Ill have been similarly secured in the cap of the respective separator. The valves have been adjusted to the following blow-off pressures: Stage I 10 bar Stage 59 bar StageT 245 bar A central pressure gauge panel combines the pressure gauges of the 3 pressure stages and the pressure gauge for oil pressure, The pressure gauges for air pressure have red marks to indicate the maximum pressure in the individual stages. With the final pressure reaching 280 bar, the pressure in stage | will be of the order of 5.8 bar, while the stage Il pressure will reach approximately 45 bar.” The oil pressure has been set to 2 bar. The compressor is switched off by an oil pressure switch in case the oil pressure drops below 1 bar.IV Operating instruction V1. OPERATION - SAFETY INSTRUCTIONS, The compressor is built to the state of the art and is safe to operate The assembly can cause danger if it is used incorrectly or not according to spectlication Only authorised personnel are petmitied to be employed on maintenance, operation and repair work on the compressor. These employees have to read the complete operation instructions, including the safety instructions, before being emplayed on the compressor Work on the compressor is only permitted when it is switched off and free of potential hazards. The pressure must be released from all pressurised parts, The user has to make sure that the compressor is only used when it is in a satistactory condition, The whole assembly has to be clean and free of any foreign bodies. Particular care must be taken to ensure that no tools are left behind after working on the compressor, The compressor is only to be used for the purpose of compressing air. Re-building and changes which influence the safe operation of the compressor are not permitted The compressor must not be used without the safety devices. The safety valves must not be readjusted; only sealed valves are to be used Damaged valves have to be replaced by new ones. Only authorised personnel are permitted to readjust, repair or seal safety valves.IV 2. Installation information When installing the compressor assembly, free access for maintenance work as per the set up instructions has to be provided. If the compressor assembly is mounted on vibration mounts, no resonance in the natural frequency of the vibration mounts is permitted 1o be transferred from the foundation of the base frame of the compressor. The natural frequency of the vibration mounts delivered as standard with the compressor is approximately 12 Hz. If the frequency of excitation of the ships propeller, the main engine or auxiliary engines. nearby is near to the natural frequency, the vibration mounts have to be changed accordingly Installation of the compressor assembly without vibration mounts is possible, if there is a sufficient rigid foundation. When a compressor is supplied without a drive, a correct connection beiween the compressor and the drive has to be made. The drainage pipes of the single stages are joined in the moisture tanks The oil-water mixture can be drained to a sludge tank through pipe together with the purging air. During the installation provision for sufficient movement of air for both the inlet and outlet cooling air has to be considered. The compressor shou'd not be placed in a comer in such a way that the cooling air is being recirculated. When more than one compressor is likely to run at the same time, then the axial alignment of one or more compressors is to be avoided, this will prevent a compressor inducing the heated cooling air from another machine ‘The electrical connections of the compressor assembly varies according to the equipment used and customer's requirements. Paragraph 7 shows the standard arrangement for fully automatic operation. Decrease in pressure between the compressor and the air bottle, due to resistance to flow, has to be taken into account by setting the pressure switch at the air bottle lower than the operational pressure of the compressor, dangerous situation can arise if the safely valve of the compressor reacts earlier than the pressure switch, To assure a safe operation of the compressor the pressure switch has to be installed at the air bottle (avoiding pulsation) SAS SN sx \ Fresh air supply } correct \\_ Fresh air supply a 7 # 1 41 must point towards f cooling air intake > cooling air intake “ Fresh air supply for air cooled compressors WP 3232 LIV 3. Handling, operation and safety instruction 1, Safety instructions and checks When completing any work on the air compressor fo" maintenance, servicing or repair warning signs "Do not switch on ..." have to been placed on all starting controls. Only trained personnel are permitted to be employed on maintenance, operations and repair work on the compressor. It is especially important to ensure that residual pressures are discharged before commencing work on any pressurised components. The ball cocks of the IInd and IItrd stage as well as the solenoid and the pneumatic relief valve have to be open Start of operation of a air compressors (1) Check the air compressor and ensure that it is in a satisfactory condition (2) Unscrew relief valve. (3) Fill with recommended lubrication oil (4) Check oil level with dipstick. Note The oil level has to be at the upper mark of the dipstick. If necessary fill up with oil. The recommended cil is listed in the list for recommended oil (5) Insert the relief valve. 3. Cheoks before starting (1) Check oil level in the crankcase with the dipstick Note — The oil level has to be at the upper mark of the dipstick. If necessary fill up with the recommended cil (2) Open valve towards the air bottles (3) Supply electrical power. (4) Open ball cocks.4._Slart of operation Altention Valves towards the air bottle (s) must be open. Operation information The drainage of the compressor is achieved manually or automatically depending on the delivery standard. In manual operation mode the compressor should be started with open drainage valves, only after reaching the nominal revolutions should they be closed. Before switching off the compressor, the drainage valves should be opened first and then the compressor switched off..In automatic mode this sequence is achieved by the electrica! control of the drainage valves. When operating the compressor for longer duration it has to be drained periodically. The frequency of this periodic draining depends on the humidity and temperature of the ambient air. Stages equipped with pressure air drainage will drain the moisture continuously; therefore periodic drainage is not necessary. 230 100 20 ” 407.0% §0 bor Ist stage lind stage Tata yo Prof feBes concd pF Bey 6 teres po part bh tert vntnrne te bees 9 ‘< be5. Mon ‘oring of operation (1) Pressure of the 3 compressor stages has to be monitored at the pressure gauges. Attention The maximum pressures are marked in red on the scales of the pressure gauges and they must not be exceeded. Pressure gauge Ist stage 7 bar Pressure gauge lind stage 52 bar Pressure gauge Ilr. stage 230 bar (2) The pressure of the lubrication oit system has to be monitored at the Pressure gauge. The oil pressure should be approximately 2.5 bar Note If the oil pressure drops below 1 bar the electrical motor of the compressor is switched off (3) Monitor the function of the automatic drainage - In case of failure of the automatic drainage proceed as follows: Close ballcocks Slowly open the ball cocks, start with the stage | ball cock, in intervals of 10 minutes, drain the moisture from the separator. 6. Stopping the Compressor (1) Switch off the electrical power supply at the switch board of the compressor. (2) Close valves in the compressed air pipes towards the air bottle (s) 10Preservation / Inhibiting Inhibiting the compressor is necessary whenever the compressor operation is stopped for more than 12 weeks. To inhibit the compressor it} When the compressor is stopped, drain the lubrication oil using the tocking screw ‘on the oil sump drain After unscrewing of the relief valve, fill with approximately 2 | corrosion prevention oil Operate the compressor for approximately 5 minutes. Switch off the air compressor and close the compressed air pipes towards the air bottle(s). Protect the air compressor against unauthorised operation Note Check at the pressure gauges if the single stages are released. (5) (6) (7) (8) 19) ‘Take off the air filter and pipes between the separator of stage II and cylinder head Illrd stage. Open valve at the air pipes towards the air bottle(s) Start the air compressor. Slowly inject corrosion protection oil into the inlet opening of the cylinder head Ist stage (approximately 15 cm3) and into the screwing of the cylinder head llird stage (approximately 5 cm3). Stop the air compressor. Install air filter and pipes using new seals. {10} Drain the corrosion protection oil using the locking screw on the oil sump drain. Note The preservation of the air compressor with corrosion protection oil will only last for one year 11v No, 4 { t I 2 3 4 4 6 Iteml Trouble Trouble Shooting Trouble detection table Air compressor switched off ‘oll vapour is leaving at the irelieve valve, Safely-valve of the Ist stage is blowing | Safety valve of ‘the Ist and tind stage are blowing ' Pressure “gauges of Ist and lind stage indicate low pressure Pressure {| gauges indicate, no pressure Probable reason 1.1 No power supply, no control power supply 1.2 Motor overheated, Thermal engine protection did correspond 1.3 Oil pressure switch did correspond 2.1 Piston ring is detective. 3.1 Inlet valve of the lind stage is leaking. 4.4 Inlet valve of the Nird stage is leaking 4.2 Pressure valve of the Illrd stage is leaking. 5.1 Inlet valve of the Ist stage is leaking 5.2 Pneumatic valve is leaking 5.3 Airfiller very dirty 4. No current ai the solenoid valve, Remedy 1.1.1 Check fuses of air compressor. | Replace defect fuses. ! 1.2.1 Find reason for failure. By overheating of electrical motor, it can be re-startet alter a cooling period, Measure coil resistance 1.3.1 Check cil ievel in the crankcase, fill up if necessary. 3.1.1 Repair inlet valve of lind stage, see VI2.5, 4.1.1 Repair inlet vaive of lllrd stage, see Vi 2.5 4.1.1 Repair pressure valve of the Ilird stage, see VI2.5. 5.1.1 Repair inlet valve of the Ist stage, see VI2.5. 5.2.1 Clean pneumatic valve. For | drainage open ball cocks | 5.3.1 Change insert of air filter | 6.1.1 Check power supply of | solenoid valve. Close ball cocks and open for drainage the ball cocks 12oe VL Maintenance 1. Maintenance schedule 1.1 Maintenance afte 50 operating hours after insiallation and after main overhaul the oil must be changed (VI 2.2) . all fasteners (screws and nuts) have to be checked, and, if loose lightened (see VI 2.1) 1.2 Mainienance plan based on accumulated operation hours Operation Maintenance Operation Maintenance hours, routin' hours, routin 800 ry 4000 A 1600 B 4800 B 2400 A 5600 A 3200 G 6400 D Alter 6,400 operation hours the routine starts again with A after 800 hours HINTS: - Routine A has to be carried out at least once A year (see Vi 1.3) ~ The following maintenance routines have to be carried out according to paragraph VI 2, maintenance instruction. Routine A 4. Oil change (see Vi 2.2) 2. Cleaning the air filter (see VI 2.3) 3. Cleaning of air vent valve (see VI 2.4) 4. Check af the compressor valves (see Vi 2.5) Routine B: +. As required for Routine A 2. Check of the compressor valves and change valve plates and springs (see VI 2.5) 3. Check of the piston rings Ilird stage and change if necessary (see VI 2.6) Routine C; 1. As tequired for Routine B. 2. Check the piston rings IInd and Hllrd stage and change if necessary (see Vi 2.6) 3. Change the piston pins and piston pin bearings IInd and llrd stage (see VI 2.7) 4 Change compressor valve Illrd stage (see VI2.5) 5. Clean separator and change damaged parts (see VI 2.11) Routi eo +. As required for Routine C. 24 Change the piston rings ofall stages (soe VI 2.6) Change the piston pins and piston pin bearings (see VI 2.7) Gheck the thrust rod bearing {see Vi 2.8) Change the concentric valves of all stages (see VI2.5) 3 Gheck the piston and cylinder, change if necessary (see VI 2.9) * Check the elastic coupling (see VI 2.10) 131.3 Maintenance schedule according to time intervals Daily; Check the stage pressure and the oil pressure as well as ihe oil level, replenish the oil as necessary Yearly; Under 800 operating hour per year’ 2.4 Security of fasteners (Screws and Nuts] 50 operation hours after installation the tightness of all screws and nuls in the crank case, cylinders, pipes and connections have to be checked, and where loose they are to be tightened. The tightness of all screw connections loosened during maintenance work have again to be checked after 50 operation hours 2.2 Oi ange Oil change are to be carried out 50 hours after installation, cil changes every 800 hour or once a year, whichever is the sooner. A recommended lubrication oil should be used. | air filter When operating under normat conditions, the maintenance of the air filter is done by dismantling of the filter housing and washing it with an oil solvent liquid, such as petrol or kerosene. The insert should be replaced with a new one. Afterwards the filter can be reinstalled of vent vi The vent valves have to be cleaned in an oil solvent liquid. They have to be screwed! out of the crank case and taken apart. During assembly care has to be taken to ensure that the valve plate is in the correct location and has the correct freedom of movement (see figure 3). Vent valve valve catcher alve plate. stiffening downwards! 142.5 Removal of concentric valves Caution! Great care should be exercised in the mounting and dismounting of valves. Clean valve seats thoroughly, change damaged packings and packing rings. Dismounting Release cap nuts (1) and serew joints and remove cylinder head (2). Lift out vaive (3). Mounting In reverse:sequence Stage I Dismounting Release cap nuts (1) and screw joints, siacken back clamp screw (4) by 3 threads remove cylinder head (5) and lift out valve (6). In reverse sequence. When screwing on cylinder head (5). see to it that clamp screw (4) with cylinder head being tightened, continues to be lightly turnable. Tighten clamp screw. Moun 15Dismounting Stage I Unscrew lock nuts (5) tum out valve cage (4) with square box spanner (62). Take out inlet part of the delivery valve respectively, using auxiliary mandrel (47) To ensure correct valve installation, pay attention to marked indications. The mark indicated on the cylinder head (6) is similarly affixed on the outside diameter of the vaives in "S" and "D" (7). Valves should therefore be installed in this clearly defined fitting position. Complete the assembly as follows Inlet valve: (9) Screw valve on auxiliary mandrel (47), put packing ring (2) on collar of valve, introduce these components collectively into cylinder head pass valve cage (4) over auxiliary mandrel (47) and screw same in as far as the slop, using the auxiliary spanner (62). Turn out auxiliary mandrel, unscrew auxiliary spanner hentighten vaive cage withs uare bo x spanner! Insert packing ring (3) and screw on lock nut (5) Delivery valve (40): Put packing ring (2) on seat in cylinder head (8) screw delivery valve (10) on auxiliary mandrel (47) and insert valve into head, Pass valve cage (4) over auxiliary mandrel and screw same in as far as the stop, using the auxiliary spanner (62). Turn out auxiliary mandrel, unscrew auxiliary spanner hen tighten valve cage with square box Spanner! Insert packing } and screw on lock nut (8). 1626 1 3 Check of piston rings: Remove the cylinder head and valves as describe under VI 2.5 "Removal of concentric valves" Loosen the screws at the cylinder foot and remove the cylinder. Prevent the piston from hitting the crank case during this procedure, Take off the piston rings from the piston and put them into the cylinder. Measuring the gap with a slip gauge. If the following measurement are exceeded the piston rings have to be changed: ist Stage: 4.1mm lind Stage: 0.5 mm rd Stage: 0.4mm When changing the piston rings in stage Ill a new cylinder liner has to be installed in stage Ill The installation will be done in reverse order. At insertion of the rings notice the correct position. The mark *TOP" must show up. See Figure. Piston stage Lit see page 24 drawing 12 172, 7. Change of piston pin and piston pin bearing 1. Unscrew the compressor from the base plate, lift the compressor and put it on the flywheel side to enable ihe dismantling of the ail sump. 2. Removal of the cylinders as described under 4.2.6. "Check of the piston rings” Remove securing wire from connecting rod nuts, loosen screws and remove connecting rods with piston. 4. Remove securing ring from the piston pins and push out the piston pins. 5. Push piston pin bearing out of connecting rod eye, change bearing and piston pin. 6. _ Installation in reverse order. Thrust rod to be installed with plenty of oil and the lower part is to be screwed manually. Attention The upper and lower part of the connecting rod are marked near the parting line with numbers. These have to be the same on both parts! Example see drawing Connecting rod Hilrd stage PRN connecting rod bearing It should be possible to screw the thrust rod screws manually, only then the correct position on the crankshait is assured. Aiter fastening the screws, torque 50 Nm, the thivst rod must be easily able to be turned on the crankshaft 182:8. Check of the connecting rod bearing 1. Removal as described under VI 2.7. "Change of the piston pins and piston pin bearings" Change the connecting 10d bearing if there is heavy scoring or there is significant wear 10 be found. 5. Assembly in reverse orders Installation of the thrust bearing as described under paragraph VI 2.7. 2.9 Check of piston and cylinder - Removal of the cylinder as described under VI 2.6 "Check of the piston rings" ~ Check cylinder and piston for scoring and excessive wear. If found, these paris are to be changed. - Measure the cylinder, if the wear limits are exceeded (see table below) change the oylinder, Stage Wear limits for cylinder diameter 1 maximum diameter 95.1 mm i maximum diameter 38.1 mm Wr maximum diameter 18.1 mm ~ assemble in reverse order. the elastic coupling In order to check the spur gear in the coupling, the safety device between compressor and electric motor has to be removed. Check the elastic spur gear for damage. If necessary change coupling sleeve Procedure as follow Loosen the electric motor connecting screw and remove the motor. ~ The electric motor is to be lifted carefully, using the lifting eye, until the elastic coupling sleeves is freed. Change coupling sleeve Assemble in reversed order 2.44 Cleaning of separators and changing damaged pais Dismount all air pipes connected to the separators - Unscrew safety valves stage Il and Il - Open separator caver, dismount separator from the crankcase. - Clean the separator case with petroleum - Blow out the petroleum with air ~ Check the filter elements for damages. if necessary change it Clean the filter elements with fuel. blow out with air Assemble in reversed order 19J.P.SAUER & SOHN Concentric vaive stage I MIASCTIIE HE RDAU GMBH & CO. ARATE Delivery vaive spring Description of sequence/ valve mounting YJ. Maintenance, page 13-19 Unit Type > 030 060 Page: 20MASCHIENEWBAU GMBH & CO. J.P.SAUER & SOHN | Concentric valve stage Il 7 > Delivery valve spring Delivery valve plate ____— Inlet valve plate | C : f Iniet vatve spring ~{S—“// | ae ee ES - S oe QW) YY Description of sequence/ valve mounting see VI, Maintenance, page 13-19 Unit / Type : 030 061 | Page: 21J.P.GSAUER & SOHN Inlet and delivery valve stage IL MASCHIENENDAU GMBH & CO ow Delivery valve 4 AN / ae / \ Valve spring 4 ; ive plate ! \ Valve spring Valve plate Vice clan 72) and auxiliary spanner (71) serve to disassemble the valves of stage {ll When the clamp and valve are held in a vice the valve can be unscrewed or replaced with the aid of the auxiliary spanner. Description of sequence/ valve mounting see VI, Maintenance, page 13-19 I Unit / Type: 050 312vil Air flow plan W 2 Compressor 3-stages air-cooled 8 The compressor induces ambient stages to an output pressure of 230 ba mechanism 1 Moist air fitter 13 2 Cooler, stage | 14 33° Cooler, stage Il 20 F4 Séparator, stage Il 24 5 Cooler, stage Ill 23 & Separator, stage Il 24 7 Olt pressure gauge 3 Pressure gauge, stage I, Il, it 3 Gil pressure controller 10 Safety valve, stage 1 11 Safety valve, stage Il 12. Salety valve, stage Ill through a moist air filter and compressed in 3 For separating the condensate produced in compressing and recooling separators with automatic drain valves are insialted after IInd and llird stage. The additional hand valves are only for emergency operation in case of failure of the control non-return valve Flexible hose Manual drain valve, stage 1 Manual drain valve, stage Ill Solenoid drain vatve Pneumatic valve | Page: 23JLP.SAUER & SOHN | VIII Full view of compressor unit WASCHIENEHAU GMBH & CO, gauge Pressure gauge panel [ Unit Type ] Page: 24{| J.P.SAUER & SOHN MASCHIEHENGAY GMBH & CO. Attention when mounting stage Ill connecting rod: bore upwards! Safety vaive stage Connecting rod Valve stage Il \ Cylinder LF stage IT pe H a rs y vas Z Piston stage Il [+p Safety valve (Gia) stage Memes Noes Cylinder ~ stage 1 stage HI” Safety valve stage Il Crankcase Description: see Ill, page 3-5 Unit | Type | Page: 25J.P.SAUER & SOHN MASCHIENFNBAU GMBH & CO, 1X Longitudinal view of the compressor Cooler Stage 1 Crankshaft ul Gear type oll pump Sj} h Oil filter Y Description: see Ill, page 3-5 [Yat TypeX — E-Motor Immediately after receipt, the motor should be proofed to damages which perhaps ‘occured on transport. Installation The motor is fastened on a plane foundation. Bracing should be avoided. Unimpeded air flow is necessary. When the motor is installed in a dusty almosphere, the surface of the motor, the fan and the fan cowl should often be cleaned to grant a better thermal dissipation Starting The connection of the motor has to be made in accordance to the rules of VDE 0100 and under obeyance of the specifications of the local EVU (Energy Supply Enterprise). The dates given on the rating plate and the connection diagram in the terminal box should be absolutely obeyed. ATTENTION! Before first starting, it must be proofed if connection, earthing, and motor protection are in order. Bearing lubrication The motor frame sizes 56-200 have permanent lubrication. Maintenance interval 10000 - 20000 h Lubricant Operating conditions Temperature range Rolling bearing grease/ insulation max. Service range class temp. C° Normal B 430 Lithium based rolling bearing grease/ -35 to + 130°C Long-life or permanent F 155 High-temperature lubrication, stationary long-life grease/ shafts. high temperatures. -35 to + 155°C, high speeds briefly 200°C 27s winding Standard version insulation class "D" to VDE 0530 Ingulaiion class, Motors with class F insula:ion can to'erate 60 C coo ant temperature insiead of 40 C at rated oulpui ifthe maximum coolant temperature is 49°C the continuous cLipul ‘ating ean be increased for motors frame size 56 - 132 by approximately 15% F insulation. This does not anply to motars which rorma'ly have cla: Maximum temperature Max, continuous K temperature °C 3 80 130 F 150 185 The class of insulation is noted on the raiing plate. ire. tise ‘empere nV! The rated output is applicable ic continuous operation in accordencs = 0530 for @ maximum ambiet temperature of 49°C and installation at an allitude up to 1900m above seal level. The permissiole outputs for concitions deviating from ihese are gven in the following table Coolant permissible output Altitude permisailpe output temperature ass inm as % °C of rated output above sea level —_of rated output ac 100 1000 100 a5 96 2000 92 50 2 3000 Ba 55 87 40a 78 60 82