Compressor Manual
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
FOREWARD
1. DOCUMENTATION OBJECT AND LAYOUT
The documentation for SCI series compressors contains information and
instructions addressed to
with the aim to:
- Operative Staff:
using the system at its best, optimizing its
performances during operation;
- Workshop Staff:
perform emergency operations to assure service
continuity and quality in case of failure;
- Technical Staff:
keeping the apparatus at the best of its
performances
operating,
controlling
and
providing
its
preventive
and
corrective
maintenance, including the monitoring and tests
that are to be performed during the scheduled
interventions.
The operating and maintenance manual for SCI series compressors is laid out in a main
part (this volume), divided in 8 sections, common for all machines of the series, and some
additional volumes specific for each model, to which this part refers,
named
Supplementary Technical Manuals, or MTI.
To learn the basis of the operation of SCI series compressors it is sufficient to examine
the main manual, but to operate on a compressor model it is necessary to examine
both the main manual and the specific manual (MTI).
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
2.
MANUAL CONTENT
The main manual provides the following information:
–
–
a global view of the machine;
various functions of the single Unit and the related mode of operation;
The Supplementary Technical Manual provides the following information:
–
procedures, data, information regarding functional description, planned and corrective
maintenance, failure search.
NOTE
MAINTENANCE OPERATIONS MUST BE CARRIED OUT BY
SKILLED STAFF, CAREFULLY OBSERVING THE SPECIFIED
PROCEDURES AND MODALITIES.
Considering both the main and the technical manuals (MTI), all operations are widely
explained, to easily identify the interest issue.
The information in the manual provides a complete view of the machine. The main
arguments are:
a.
Description and Functioning
This subject describes sub-systems/components and their functioning. This argument
provides to the Staff in charge of maintenance a complete view of characteristics and
functionality of SCI series compressors, that are required to carry out the maintenance
operations.
b.
Failure identification
This subject enables the skilled technicians to identify the failed unit/apparatus or
component by means of the failure search procedures. For each failure, the
symptom, the probable cause and the cure are provided.
c.
Scheduled maintenance
This subject includes the materials that are to be inspected, as well as the
implementation procedures. Moreover, the recommended frequency, method and
materials are provided as well.
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
d.
Disassembly /Installation
This subject provides the procedures for disassembly and installation of
components, sets, subsets and combinations of parts. The procedures illustrate
All the operations in a logical sequence with a step-by-step method of
disassembly and installation.
e.
Adjustments/Tests
This subject provides all the procedures and the parameters required to assess the
running efficiency and the integrity of the system, subsystem, unit, component or
parts connected thereto contributing to the running efficiency thereof.
f.
Inspections/Monitoring
This subject provides the detailed procedures to assess the efficiency of a part,
set, system, component or parts connected thereto contributing to the running
efficiency thereof. If an adjustment/test is required, prior to an inspection, it is
provided.
g.
Special tools
This subject provides, for what may concern any special tool used in the
maintenance and repair activities, the following information:
1.
What it is for
2.
Operating instructions
3.
Instructions for adjustment
4.
Instructions for maintenance (e.g., inspections, lubrications,
scheduled maintenance, failure search, repair)
5.
Conservation instructions
6.
Replaceable parts
Every special tool is identified by a code and a description.
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
h.
Cleaning/Painting
This subject illustrates the methods and the processes required for the cleaning
and/or the painting of specific parts or areas. The instructions are provided in a
logical operation-by-operation sequence. The required directions and precautions
for the Staff safety and to prevent possible damages of the material are also
provided. The required material is identified.
3.
INSTRUCTIONS FOR THE INTERVENTION
The interventions must be carried out with tools that are specific and suitable for the
apparatus at issue.
The replacement of the machine or of components must exclusively be carried out using
original components.
The numeric values of the technical data are generally expressed by means of the
International System (I.S.). However, numeric expression of the traditional Technical
System, reported inside brackets when applicable.
The precautions to adopt are indicated throughout the text in two different ways:
a. With the word ATTENTION, for indications related to the maintenance and operative
Staff safety.
b. With the word NOTE, for indications that are useful to prevent damages to the
components, that might compromise the plant normal running.
4.
RELATED DOCUMENTATION
Technical specifications, item, equipment, parts list for a determined SCI compressor,
could be find in the Supplementary Technical Manuals, typical for each model.
5.
UPDATES
The content of this manual could be updated from TM.C. TERMOMECCANICA
COMPRESSORI S.p.A. with new information, drawings, modification.
TM.C. can include those modifications and/or add information necessary according to
eventual variance noticed in operation and confirmed by maintenance activities, or
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
succeeding any configuration changes on the machine.
Any updates or additional copies of this manual should be requested from the customer
contacting TM.C. to the following address:
TM.C. TERMOMECCANICA COMPRESSORI S.p.A.
Address:
Via del Molo 3
19126 LA SPEZIA
ITALIA
Phone:
+390187552286
Fax:
+390187552247
E-mail:
tmc.aftersales@termomeccanica.com
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
ADDITION AND VARIATION RECORD
VARIATION
N°
VARIATION
DATE OF
ISSUE
LIST OF
REMOVED
PAGES
1
2
3
4
5
6
7
8
9
10
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LIST OF
INSERTED
PAGES
VARIATION
DATE OF
INSERTION
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
TABLE OF CONTENTS
1. GENERAL DESCRIPTION
1.1.
Introduction
1.2.
Principles of the operation of the compressor
1.3.
Unit \ Apparatus of the compressor
1.3.1. Unit \ Apparatus internal to the compressor
1.3.2 Unit \ Apparatus external to the compressor
1.4.
Assembly/operation of the compressor
2. FUNCTIONAL DESCRIPTION
2.1.
Introduction
2.2.
Functional description of SCI with electric motor
2.3.
Functional description of SCI with heat engine motor
3. SAFETY RULES
3.1.
Introduction
3.2.
Precaution for installation and standard operation
3.3.
Use of an air blow
3.4.
Use of solvent
3.5.
Electric components
3.6.
Intervention safeguard
3.7.
Handling safeguard
3.8.
Testing safeguard
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4. OPERATION PROCEDURES
4.1.
Air flow adjustment on a SCI compressor
4.2.
Pressure adjustment on a SCI compressor
4.3.
Operation procedures with limited functionality
4.4.
Operation procedures in case of failure
4.5.
Cleaning and Storage
5. PREVENTIVE MAINTENANCE
5.1.
Introduction
5.1.1. Use of the maintenance procedure index
5.1.2. Use of the scheduled maintenance cards
5.1.3. Post - overhaul setting at work of the Compressor
6. FAILURE SEARCH
6.1.
Introduction
7. COMPLETE OVERHAUL
7.1.
Introduction
7.2.
Instructions on reference documents for complete overhaul of
a specific SCI model
7.3.
Lubricants
7.4.
Painting
7.5.
Handling
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Compressor SCI BM/FM
8. SPECIAL TOOLS
8.1.
Introduction
8.2.
Instructions on reference documents for description and use of
a specific special tool
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Compressor SCI BM/FM
LIST OF ILLLUSTRATIONS
Chapter 1
Fig. 1.1
Fig. 1.2
Fig. 1.3
Fig. 1.4
Fig. 1.5
Fig. 1.6
Fig. 1.7
Fig. 1.8
Fig. 1.9
Fig. 1.10
Fig. 1.11
Fig. 1.12
Fig. 1.13
Fig. 1.14
Fig. 1.15
Fig. 1.16
Fig. 1.17
Fig. 1.18
Fig. 1.19
PAGE
Integrated Compressors SCI
SCI Integrated Compressors – Rotors profile
SCI Integrated Compressor – Components identification
Inlet air filter
Suction Valve
Solenoid Valve
Safety Valve
Oil separator filter
Oil drainage sight glass
Minimum pressure valve
Oil filter
Thermostatic Valve
Oil level sight glass
Oil unload
Oil load
Belt driven assembly lay-out
BM compressor reference lay-out
FM compressor reference lay-out
SCI Integrated compressor assembly lay-out
12
13
16
17
18
19
20
21
21
22
23
24
25
26
27
28
30
31
32
Chapter 2
PAGE
Fig. 2.1 Functional lay-out of SCI with electric motor outline
Fig. 2.2 Functional lay-out of SCI with heat engine motor outline
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
LIST OF TABLES
Tables
Tab. 5-1
Tab. 6-1
Tab. 7-1
Tab. 7-2
Tab. 7-3
Tab. 7-4
Tab. 7-5
PAGE
Preventive Maintenance Index
SCI Compressor – Failure search
Driving Torques
Standard tools list for maintenance operations
Viscosity Grade
Mineral Oils
Synthetic Oils
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53-54-55
56
57
59
60
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
1. GENERAL DESCRIPTION
1.1. Introduction
In this Section a functional description of the SCI Compressors is provided.
The description is divided into sections and is completed with figures identifying all the
main components that take part in the functioning of the apparatus/unit.
The SCI compressor has been studied to be used in different applications, both coupled
with and electric motor and an heat engine motor.
The SCI compressor is composed by a casting in which a rotors pair, horizontally
positioned, can rotate. The pair is formed by a main rotor, named drive or male, and a
secondary rotor, named driven or female. The same casting has function of tank, with
integrated valves, filters, sight glasses and other components.
FIG.1.1 – Integrated Compressors SCI – a) SCI7, b) SCI8
The profile is the S.R.M. asymmetric, with 5 lobes on the male rotor and 6 lobes on the
female rotor. This solution can guarantee the optimal result regarding stiffness, air volume
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Operation and maintenance
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Compressor SCI BM/FM
per revolution and efficiency.
FIG.1.2 – SCI Integrated Compressors – Rotors profile
The advantages of lubricated screws compressor compared to alternative compressor are:
•
compressed air discharge without pulsation;
•
Noise reduction;
•
Vibration reduction;
•
High reliability;
•
Reduced maintenance;
•
Continuous operation allowed for long period;
•
Reduced spare parts stock;
•
Longer MTBF (mean time between failure);
•
Possibility to use smaller air tank.
1.2. Principles of the operation of the compressor
The air is suctioned in the rotor casing through the inlet port on the upper side and then
moved in axial direction between the lobes of the rotors.
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Compressor SCI BM/FM
Due to the rotation, the spaces between the lobes become larger, in the upper side of the
rotors, till the maximum opening for the entire length.
In this way it is possible to intake the air.
As the rotation continues, the space between the lobes, now full of air, becomes smaller
and after a first phase of simple axial delivery, the compression starts in the lower part of
the machine.
The compression phase is made by the meshing of the lobes of the male rotor in the
spaces of the female rotor.
The “V” chambers, formed by the closing of the spaces between the rotors, due to the
rotation, are constantly reducing their volume towards the discharge.
The air closed in each chamber is consequently compressed, during the axial movement ,
until the outlet port, where it is discharged.
The described process is repeated the same number of time as the number of lobes of the
male rotor.
During the operation, inside the SCI compressors it is necessary to inject a big quantity of
oil, to lubricate the mechanical parts (rotors, bearings, seal), to guarantee the seal between
the rotors and between the rotor casing and the rotors, to dissipate the heat.
All the oil is discharged with the air from the outlet port, and has to be separated from it
and then cooled to be used again.
The separated oil is collected in the lower part of the compressor tank and passing through
the thermostatic valve it flows to an internal circuit or the external cooling circuit.
In the first case the oil flows through the thermostatic valve, the oil filter and then injected
to the rotors.
In case the temperature raises over 70°C, the therm ostatic valve opens the external circuit
to the cooler. Then the oil flows back to the compressor, through the oil filter and then is
injected to the rotors. The discharge pressure must be high enough to guarantee the oil
circulation (> 3 bar).
The compressed air, with residual oil, is collected in the upper part of the tank of the SCI
compressor casing, and then delivered to the oil separator filter.
The oil residual, separated by the oil separator filter, are carried back to the suction area
through internal channels.
The clean air, in case of load running (solenoid valve energized and closed) is discharged
through the minimum pressure valve. In case of idle condition (solenoid valve not
energized and open), the clean air is discharged to atmosphere through the suction valve.
A small quantity of the air is used to close the suction valve and avoid further air is passing
through.
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Compressor SCI BM/FM
1.3. Unit \ Apparatus of the compressor
In this paragraph the main parts composing the SCI compressor and others necessary to
package it are listed.
1.3.1 Unit \ Apparatus internal to the compressor
In the SCI Integrated Compressors casings are present the seats for all main components
necessary to operate and regulate the compressor.
Internally are also present all the channels necessary to recover the oil separated in the oil
separator filter, to switch the compressor to idle condition and discharge the air, to
rubricate the machine, a part from the cooler.
The most relevant components of the SCI compressor are listed here:
1. Air filter
2. Suction valve
3. Solenoid valve
4. Safety valve
5. Oil separator filter
6. Oil drainage sight glass
7. Minimum pressure valve
8. Oil filter
9. Thermostatic valve
10. Oil level sight glasses
11. Pressure ports
12. Temperature port
13. Oil unload
14. Oil load
Components are illustrated in figure 1.3.
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Compressor SCI BM/FM
FIG.1.3 – SCI Integrated Compressor – Components identification
1. Air Filter
The air filter (figure 1.4) consists of a container in painted metal specifically designed to
reduce the noise generated by the air intake and by the paper cartridge having a filtration
grading of 0.010 mm.
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Compressor SCI BM/FM
The function performed by the intake air filter is crucial, as it prevents the contact between
the impurities of the environment in which the compressor is set with the parts in motion,
hence preventing the lubricating oil pollution.
A bad maintenance of the intake air filter entails a reduction of the working life of the
bearings, as the polluted oil does not perform its lubricating function correctly anymore,
and an overall decay in the performances of the compressor.
FIG.1.4 – Inlet air filter – a) SCI7, b) SCI8
2. Suction valve
The suction valve (figure 1.5) performs the double function of keeping the compressed air
and the oil present in the group of rotors from being discharged in the environment at the
moment of the compressor stopping under any discharge pressure condition closing the
intake during idle running in order to reduce the power consumption of the compressor.
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Compressor SCI BM/FM
According to operation condition it is necessary to ad just idle pressure, by the use of the
appropriate screw, already adjusted by TM.C..
FIG.1.5 – Suction valve – a) SCI7, b) SCI8
3. Solenoid valve
The solenoid valve (figure 1.6), normally open, is controlled with a pressure switch (not
included in the compressor) that keeps it closed during the loaded running phase.
Once the required pressure has been reached, the solenoid valve opens, discharging all
the suctioned air by the compressor inside the intake filter.
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Operation and maintenance
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Compressor SCI BM/FM
The solenoid valve automatically empties the compressor casing each time it is stopped, in
order to ensure the restarting thereof in absence of pressure.
In the standard configuration, the solenoid valve requires a 24V feeding, (a.c. 50/60 Hz).
On request, it is possible to purchase a solenoid valve fed with different voltages and
frequencies.
FIG.1.6 – Solenoid valve
4. Safety valve
The pneumatic safety valve (figure 1.7), protects the compressor casing from possible
overpressures caused by the oil separator cartridge clogging, the minimum pressure valve
blocking, and by an intervention failure of the external adjusting systems (pressure switch
control).
The safety valve is set to open at a 15 barg pressure.
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Operation and maintenance
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Compressor SCI BM/FM
FIG.1.7 – Safety valve
5. Oil separator filter
The oil coalescence separator cartridge (figure 1.8) completes the operation of separating
the oil from the compressed air which started inside the casing by means of a flapping
labyrinth and a successive speed change.
The filter is of the spin-on cartridge kind, easy to replace, ensuring a percentage of oil in
air lower than 5 ppm (at 80°C temperature).
A good functioning of the oil separator depends on the operative temperature of the
compressor, on the quality of the oil and on the general maintenance of the machine. It is
possible to check the clogging of the oil separator, by the use of the pressure ports (G
1/8”) upstream and downstream the separator. It is recommended to substitute the
cartridge as the differential pressure exceeds 0,5 bar.
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Operation and maintenance
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Compressor SCI BM/FM
FIG.1.8 – Oil separator filter
FIG.1.9 – Oil drainage sight glass
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Compressor SCI BM/FM
6. Oil drainage sight glass
By means of the oil reclaim sight glass (figure 1.9), it is possible to verify the amount of oil
reclaimed from the oil separator cartridge through the separator nipple and nozzle.
It is important to check periodically the correct drainage.
7. Minimum pressure valve
The task of the minimum pressure valve (figure 1.10), placed on the compressor discharge
side is that of maintaining a minimum pressure value of 3 - 4 bars inside the casing until
the network pressure equals the internal pressure of the compressor. The pressure value
is adjustable according to working condition, by the use of the appropriate screw.
At the same time, it performs a non return valve function, isolating the group from the
power network when the compressor is stopped.
FIG.1.10 – Minimum pressure valve
8. Oil filter
The oil filter (figure 1.11), placed at the beginning of the lubrication line, retains the solid
particles present inside the lubrication circuit that might damage rotors and bearings.
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Operation and maintenance
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Compressor SCI BM/FM
The filter, made of a wire net having a filtration grading of 0.025 mm, can be easily
inspected. Its replacement is closely related to the intake filter maintenance and to the oil
quality.
It is highly recommended to replace the oil filter cartridge after maximum 50 operating
hours for the first time. In fact according to our experience during first running hours all the
particles left in the entire oil circuit (especially from the cooler) are collected in the filter.
FIG.1.11 – Oil filter
9. Thermostatic valve
The thermostatic valve (figure 1.12), consists of a thermosensitive element, changing its
volume function of temperature changes, and of a sliding piston.
The sliding piston, operated by the thermosensitive element expansion, closes the internal
oil way as 71 °C temperature is reached and, at the same time, it starts opening the oil
way to the cooler. As the temperature reaches 85°C the oil is circulating only in the
external cooling circuit.
The function of the thermostatic valve is that of keeping the oil injection temperature to a
minimum value of 71 °C in order to avoid a condensi ng of the suctioned air moisture inside
the oil itself, that would modify the lubricating characteristics thereof and cause rust.
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Operation and maintenance
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Compressor SCI BM/FM
FIG.1.12 – Thermostatic valve
10. Oil level sight glasses
The minimum oil level can be checked by means of the oil level sight glass provided for
the purpose (figure 1.13), placed on the right of the thermostatic valve.
The oil level must not sink below the lower half of the oil level sight glass when the
compressor is not running.
The maximum oil level can be checked by means of the oil level sight glass provided for
the purpose placed above the thermostatic valve. The oil level must not exceed a half of
the oil level sight glass.
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Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
FIG.1.13 – Oil level sight glasses
11. Pressure ports
N°3 pressure ports G 1/8” are available on the casi ng. One is on the right of the oil
separator cartridge (seen from the discharge of the compressor). It can be used to
measure the pressure inside the air-oil tank.
The second one is on the left of the separator cartridge (seen from the discharge of the
compressor). With this two ports, one upstream and one downstream the oil separator
filter, it is possible to measure the differential pressure caused by clogging in the cartridge.
The third port i near the discharge, downstream the minimum pressure valve. It is
necessary to connect this port to the pressure switch to control the compressor.
12. Temperature port
The temperature port (thread through hole G 1/4") is positioned on the left of the maximum
oil level sight glass. It is recommended to install in this port a temperature pickpocket 60 to
80 mm long, inside the air/oil tank.
To measure the correct air/oil moisture temperature, it is recommended to maintain the oil
level higher than the minimum and the use of the appropriate pickpocket.
It is recommended to set the high temperature shut down at a temperature lower than
105°C.
By the measured temperature it is possible to control the electro fan of the cooler.
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Operation and maintenance
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Compressor SCI BM/FM
13. Oil unload
The oil unload plug (figure 1.14), placed directly on the compressor casing, eases the oil
change operations at the required maintenance intervals.
Removing the plug the periodical operations of checking the presence of condensate in
the oil can be carried out.
All the operations must be carried out in absence of internal pressure.
FIG.1.14 – Oil unload
14. Oil load
The oil load plug (figure 1.15), is placed directly on the compressor casing and is marked
by a filler cap.
The accessing to the filler cap must be carried out in only in absence of internal pressure.
The maximum level of the oil can be checked by means of the oil level sight glass placed
over the thermostatic valve. The maximum oil level must not exceed a half of the oil level
sight glass horizontal length.
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Operation and maintenance
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Compressor SCI BM/FM
FIG.1-15 Oil load
1.3.2. Unit \ Apparatus external to the compressor
1. Motor
It is possible to use both an electric motor and an heat engine motor (Diesel). The starting
torque of the motor has to be higher than the starting torque of the compressor during the
speedup phase.
2. Flexible coupling
In case of direct coupling of the SCI compressor, the flexible joint coupling the compressor
to the motor, has to compensate minimum 0.4 mm radial misalignment and 1° angular
misalignment. The joint has to be statically balanced and possibly also dynamically.
3. Belts and pulleys
In case of belt driven application it is necessary to verify the alignment of the pulleys and
the correct belt tension, which must be adjusted in order to not exceed the maximum
bending moment allowable on compressor shaft end.
The belt could be mounted with every orientation. However it is recommended to tension
the belt in the IV quadrant (seen from atmosphere, figure 1.16), to reduce stresses on
bearing.
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Compressor SCI BM/FM
FIG.1.16 – Belt driven assembly lay-out
4. Connections (air oil, water)
The piping used must be of the correct dimensions, to guarantee that the flow speed is
lower than admissible.
Reference values for flow speed are given here after:
Inlet line (air)
15 – 20
m/s
5–8
m/s
Discharge line (air without residual oil)
20 – 25
m/s
Oil line
0.5 – 2
m/s
2–3
m/s
Discharge line (air with residual oil)
Water line
5. Air cooler and condensate drainage
The air is discharged at a temperature of about 80 – 100 °C, than it could be necessary to
cool it down.
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Compressor SCI BM/FM
If an air cooler is used, the temperature could become lower than the dew point., so it is
necessary to mount on the line a condensate drainage system, to separate the water from
the air.
6. Electrical panel
The electrical panel controls the entire compressor package.
Correct setting must be carried out:
˘
˘
˘
˘
High temperature emergency stop (105°C);
Load/unload cycles timing according to ambient temperature and operation condition
to avoid condensate inside the compressor;
Hour counter and maintenance operation timer;
Alarms: high temperature, high pressure, high power absorption, etc...
1.4. Assembly/operation of the compressor
a) Assembly
SCI compressors are available in two different models:
BM to be used base mounted, fixing it by n°4 M10 r eference holes (named A in
figure 1.17);
FM to be used flange mounted, fixing it by n°6 M10 reference holes (named B in
figure 1.18); if necessary it is possible to mount it on the base too, by n°4 M10
reference holes (named A in figure 1.18)
It is possible to use the seal cover, machined in the external diameter with the g6 tolerance
range, for the centering of a bell housing or connection adaptor to the motor.
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Operation and maintenance
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Compressor SCI BM/FM
FIG.1.17 – BM compressor reference lay-out
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Operation and maintenance
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Compressor SCI BM/FM
FIG.1.18 – FM compressor reference lay-out
The SCI compressors can be tilted only in some positions as indicated in the following
drawing (figure 1.19) for maximum 10°.
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Compressor SCI BM/FM
FIG.1.19 – SCI Integrated compressor assembly lay-out
The compressor must be electrically isolated from the other parts of the plant, through its
dedicated ground cable. The lack of observance of this rule can cause the origin of
galvanic current, through the compressor itself, that could seriously damage the machine.
The lack of a ground cable in the compressor causes electrostatic charge storage inside it,
during the operation, with the risk of explosion and fire in the machine.
b) Operation
The operation of the SCI compressor is possible in two different solutions:
With direct driving, both belt driven or direct driven configuration
With internal Gear box (named with the suffix G)
SCI Compressor direct driving
The male rotor is driven by belt or directly from the motor. The rotor requested rotation
speed is achieved by the transmission ratio given by the selected pulleys in case of belt
driven, whereas it is exactly the same of the motor in case of direct driven.
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Compressor SCI BM/FM
SCI G Compressor
The male rotor is driven by a gear box, to ad just the motor speed to the requested rotation
speed of the rotor.
The coupling of the motor is to be realized by an appropriate flexible joint.
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Compressor SCI BM/FM
2. FUNCTIONAL DESCRIPTION
2.1
Introduction
In this Section a functional description of the SCI series compressors is provided.
The description is divided into sections and is complete with figures identifying all the main
components that concur to the functioning of the apparatus/unit.
Please refer to the Supplementary Technical Manual for technical data specific for each
compressor model.
2.2. Functional description of SCI with electric motor
This paragraph shows, with reference to the functional diagram in fig. 2.1, the SCI
compressor coupled to an electric motor.
a. Motor start/star connection
The suction valve (2) is closed,
The discharge valve is open.
The solenoid valve (5) is switched on idle running.
The electric motor (M) is started with star connection.
b. Motor star/delta switching
Electric motor (M) is switched to delta connection.
The solenoid valve (5) is switched to load running..
The discharge valve closes.
Suction valve (2) opens.
c. Load running
The minimum pressure valve (6) does not open till a pressure of 3.5-4 barg is reached
inside the tank. This pressure guarantees a sufficient lubrication of the compressor.
The compressor conveys the air to the user circuit as soon as the pressure upstream the
check valve (6) is higher than the pressure downstream.
The minimum pressure valve service and the check valve service are obtained by a single
valve.
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FIG.2.1 – Functional lay-out of SCI with electric motor outline
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d. Load running/idle running
As soon as the pressure switch (P) reaches the maximum switching point, the solenoid
valve (5) switches to idle running and the suction valve (2) closes.
The compressor is unloaded at the idle pressure through the discharge valve, the check
valve (6) closes and separates the compressor unit from the line.
The idle pressure must be higher than 1.5 barg.
As soon as the line air pressure reaches the minimum switching point of the switch (P), the
solenoid valve (5) switches to load and the suction valve (2) opens, The minimum pressure
valve (6) opens as described in the load running (point c).
e. Stop
The compressor stop should occur according to the procedure described hereinafter:
e.1.
The solenoid valve (5) switches to idle condition and the suction valve (2)
closes
e.2.
The discharge line opens and the unit is discharged to atmospheric pressure,
while it is separated from the line by the check valve (6)
e.3.
The motor (M) can be stopped
f. Emergency stop
Should the lack of power occur, or owing to the intervention of a safety device, the unit is
disconnected.
The check valve (6) closes to avoid a reflux of air and oil through the compressor,
preventing its inverted running.
The suction valve (2), which is working as check valve too, closes to avoid oil leakage from
inlet.
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2.3.
Functional description of SCI with heat engine motor
This paragraph shows, with reference to the functional diagram in fig. 2.2, the SCI
compressor coupled to an heat engine motor.
a. Compressor start up
While the compressor is in stand by:
The suction valve (2) is closed
The discharge valve (6) is open.
The solenoid valve (5) is switched to idle running
At start-up:
The motor (M) is stated at the minimum speed.
discharge valve (10) is closed.
b. Load running
The solenoid valve (5) is switched to load condition; the motor (M) runs at maximum speed
and the suction valve (2) opens.
The minimum pressure valve (6) does not open till the compressor unit reaches the 3.5-4
barg.
The compressor conveys the air to the user circuit as soon as the pressure upstream the
check valve (6) is higher than the pressure downstream.
The minimum pressure valve service and the check valve service are obtained by a single
valve.
c. Load running/idle running
As soon as the pressure switch (P) reaches the maximum switching point, the solenoid
valve (5) switches to idle running and the suction valve (2) closes. The motor (M) runs at
minimum speed.
As soon as the line air pressure reaches the minimum switching point of the switch (P), the
solenoid valve (5) switches to load and the suction valve (2) opens. The motor (M) runs at
maximum speed. The minimum pressure valve (6) opens as described in the load running
(point b).
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d. Stop
d.1.
d.2.
d.3.
The compressor is discharged at atmospheric pressure and separated from
the line by the check valve (6).
At the same time the solenoid valve (5) opens and the suction valve (2)
closes. The motor (M) runs at minimum speed.
Subsequently the motor (M) can be stopped
e. Emergency stop
Should the lack of power occur, or owing to the intervention of a safety device, the unit is
disconnected.
The check valve (6) closes to avoid a reflux of air and oil through the compressor,
preventing its inverted running.
The suction valve (2), which is working as check valve too, closes to avoid oil leakage from
inlet.
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FIG.2.2 – Functional lay-out of SCI with heat engine motor outline
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3. SAFETY RULES
3.1
Introduction
In this section general safety rules for the use of a compressor SCI are provided.
Particular safeguard, referred to specific operation for assembly, maintenance and check,
are specified in the MTI.
NOTE
The lack of observance of the safety rules can cause serious injuries to the personnel
working and/or to everyone in proximity.
3.2
Precaution for installation and standard operation
Position the compressor in a clean and cool air ambient.
If it is necessary to position the compressor in a dusty and/or hot ambient, must design a
suction line to convey clean and cool air.
The suctioned air must be free of inflammable gas and vapour, to eliminate any risk of fire
and explosion inside the compressor.
To prevent the temperature increase in the convey system, check and clean periodically
the heat exchange surfaces
Assure that the discharge line of the compressor, to the distribution line, is free to expand,
if an high temperature increase occurs, and it is not in contact with inflammable materials.
Preserve the compressor clean and remove dust and oil deposits as much as possible.
Design the lay-out of inlet line, in order to avoid any possible danger: contact with
prominent parts, entrapment of clothes or hair.
NOTE
The compressor must be electrically isolated from the other parts of the plant, through its
dedicated ground cable. The lack of observance of this rule can cause the origin of
galvanic current, through the compressor itself, that could seriously damage the machine.
The lack of a ground cable in the compressor causes electrostatic charge storage inside it,
during the operation, with the risk of explosion and fire in the machine.
3.3
Use of an air blow
The use of an air blow, that must be always lower than 8 bar, to dry parts after cleaning
with solvent, causes the dispersion in the ambient of dust particles or solvent drops; this
can cause irritation to skin, eyes or breathing apparatus.
While using an air blow, never direct it to the skin or another person.
Do not use the air blow to clean clothes.
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Improper use of an air blow can cause injuries or death.
While using an air blow, it is necessary to wear a safeplate.
3.4
Use of solvent
The use of solvent or chemical agents can affect health and safety.
Manufacturers of those kind of products should be contacted to obtain information on
safeguard and their precautions should be followed.
Never use inflammable liquids to clean valves, filters, tank connections, inlet and outlet
piping, air tank or any other component exposed to the airflow during the operation.
3.5
Electric components
The use of electric material must comply with the main characteristics indicated by the
manufacturer, to avoid any dangerous situation.
Components must be used to avoid temperature excess, electric arc, radiations.
To prevent electric shock during tests, do not touch electric components, connections and
bin and the operative staff do not touch the test bench.
NOTE
The lack of observance of the safety rules can cause serious injuries or death.
3.6
Intervention safeguard
Before executing any intervention on the compressor, check that the compressor is
disconnected from the motor.
Air delivery or electric current to the unit and/or any components must be shut before the
removal of the unit and/or any components from their seat.
After disconnecting the motor, check that the air inside the compressor has been
discharged, before proceeding to any intervention on it.
Follow the instructions to avoid starting unsought, sudden or out of control.
Disassemble with care, to avoid any components to cause injuries.
Assemble with care, positioning carefully all the components, even the small ones, to avoid
accidental disassembly during the compressor operation.
Be careful to not touch hot parts of the compressor: rotor casing, discharge casing,
minimum pressure valve, oil separator filter.
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3.7
Handling safeguard
A lift with the adequate capacity should be available during the execution of the removal,
installation and maintenance operations.
The SCI compressors are heavy(56kg SCI7; 57kg SCI8); take care during each operation.
While handling, take care particularly to the prominent parts (male shaft end, oil separator
filter, air filter), because the contact could cause serious injuries to the personnel and/or
people in proximity.
3.8
Testing safeguard
While executing any test on an equipment or components, if it is mounted on the plant
(during a plant test, etc.) check it is not possible to start the compressor accidentally, to
avoid injuries to the personnel or damages to the parts.
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4. OPERATION PROCEDURES
4.1. Air flow adjustment on a SCI compressor
The SCI compressor can be equipped with an air flow adjustment control system of these
types:
Full load – idle running
Full load – stop
It is possible to install both control types to be used alternate.
If the air delivery must be reduced or stopped for a short period, it is recommended to use
a control full load – idle running.
If the air delivery must be stopped for a long period, or if small air quantity is required, it is
recommended to use a control full load – stop, to avoid an extended idle running of the
unit. In this case it is important that the motor will not start more than 3 – 4 times per hour.
4.2. Pressure adjustment on a SCI compressor
Discharge pressure is adjusted by the use of a pressure switch on discharge line.
4.3. Operation procedures with limited functionality
Due to different reasons the SCI compressor and/or units/apparatus part of the
compressor or controlling its functions could fail.
In this case, assuming that the compressor will stop for lack of power or the intervention of
a safety system ( see Par.2.2 point f.), it is possible, due to operative reasons, to continue
operation in the following cases:
4.4.a
Oil leakage.
In this case check constantly the oil level and if it gets down under the minimum
level, STOP IMMEDIATELY THE COMPRESSOR.
4.3.b
Anomalous motor power absorption
If the power absorption is remaining 5 – 10 % higher than nominal, it is possible to
continue operation. If the power absorption exceeds 10 % higher than nominal
STOP IMMEDIATELY THE COMPRESSOR.
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3.4.c
Low air flow
If the actual air flow is lower than the nominal value of 5 to 20 %, and there are no
other fail as noise, high power absorption, etc, it is possible to continue operation.
If the air flow decreases under -20 % lower than nominal STOP IMMEDIATELY
THE COMPRESSOR
Follow safety rules while operating on equipments and/or components of SCI compressor
system.
Never exceed recommended pressure, speed, bending moment
4.4. Operation procedures in case of failure
In case of failure, execute the following intervention steps:
1. Obtain as much information as possible. Try to look for information essential to
understand what happened and in which conditions, and if the problem is “local” or
from the plant (affecting different units).
2. The first step before looking for the failure is to repeat it, if possible, and LEAVE
THE SYSTEM IN FAIL STATUS
This course of action allows the following:
2.1.
to verify the origin of the problem and to record the information in the failure
report.
2.2.
to start with targeted intervention to avoid any random trails to fix the failure.
3. As the failure has be repeated, it is important to avoid the use of the equipments in
this status, until full working condition is not achieved. The problem at first sight
could seems to be temporarily solved but it is possible to find it again.
4. Next step is to identify the problem and its reason. Proceed carefully, leaving the
plant in failure condition, and localize the problem by the failure search instructions.
It depends on the plant system and personal preference to isolate the plant. The
best way to proceed is to isolated monitoring, to avoid random trials. If the problem
is a breakage it is easy to isolate the broken component. But most of the reasons
for failure are not so evident. Every time a component is removed, substituted or
repaired, it is necessary to perform a functional operative test of the system, to be
sure the component is working correctly.
5. While the system is in failure it is recommended to refer to the information in the
manuals, to learn about how the system works, before to modify the failure status.
It is important to consider that the system is in failure condition and it is not working
correctly.
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6. Sometimes just intervening in a random way on the system in failure, could seem
to solve the problem, it is recommended to verify the identified component, under
suspicion, is really the cause of the failure, by installing it again on the system, to
verify the failure condition is still present. The procedure is the following:
6.1
6.2
6.3
As a component is identified to be in fail, substitute it with a new one, to
verify the correct working.
Install again the component not working and verify the failure condition is
present again.
If the check confirms the not working component, conclusively substitute it
and check again the system, to verify all the other isolated parts are
restored to standard working position.
7. As the work is completed, it is recommended to record all information useful for the
solution of the failure (description of the failure, intervention performed, description
of the failed component, etc.), to collect a document to refer to in case of a future
similar failure.
4.5. Cleaning and storage
It is important that the compressor be kept free of dirt, to reduce risks of malfunctioning.
The cleaning of the outer parts must be performed with water, but special attention should
be paid to the use of cleaning devices employing high pressure or steam, especially in the
housings of the electrical components (motor).
To remove grease use Varsol or similar.
After the cleaning operations the compressor needs to be dried.
If the compressor should be kept stored it is necessary to periodically fill with oil (0,2-0,5
dm3 from inlet) and rotate the shaft.
The compressor should be stored in a dry room and it is necessary to apply protective
matter on external surfaces after the first three months.
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Operation and maintenance
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Compressor SCI BM/FM
5. PREVENTIVE MAINTENANCE
5.1. Introduction
The purpose of this section is to provide to the maintenance staff procedures and data that
are required for a correct and swift execution of the maintenance operations for SCI
compressors.
The scheduled maintenance operations for the SCI Compressor correspond to the
carrying out of the following test:
a. Maintenance procedures
b. Performance checks
The scheduled maintenance procedures are reported as cards, and all the information
pertaining to each card are summarized in the maintenance procedures.
The section is divided as follows:
a.
Maintenance Card Index
b.
Maintenance Procedures
c.
Performance check
Explanations regarding the use of the maintenance procedure index and of the
maintenance cards are provided here below.
5.1.1. Use of the maintenance procedure index
The maintenance procedure index reported in table 4-1 of each Supplementary Technical
Manuals (MTI) provides the index and the cross references of all the maintenance
procedures, listed according to their periodicity. This index is the basic document on which
the maintenance program is realized and the tasks are assigned to the staff in charge.
The information provided by the maintenance procedure index are::
a.
The configuration of the apparatus to which the document refers;
b.
The list of the reference publications where further information on the
maintenance of the apparatus at issue can be found;
c.
A list of all the maintenance operations according to their periodicity, in a
decreasing order;
d.
The maintenance periodicity code;
e.
The level of the staff in charge of the maintenance;
f.
The man hours needed to carry out the procedure.
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Operation and maintenance
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5.1.2. Use of the scheduled maintenance cards
The scheduled maintenance cards reported in table 4-2 (available in each Supplementary
Technical Manuals) provide all the technical information required to perform the
maintenance procedure of interest.
Every scheduled maintenance card is divided into the following blocks:
a.
SYSTEM
The system to which the subsystem object of the maintenance belongs is
indicated.
b.
SUBSYSTEM
The Subsystem object of the maintenance is indicated.
c.
UNIT
The Unit object of the maintenance is indicated.
d.
PERIODICITY CODE
The abbreviations of the adopted periodicities are the following:
1/1 = corresponding to about 100 hrs of running
30/1 = corresponding to about 3000 hrs of running
200/1 = corresponding to about 20.000 hrs of running and to about 7 years.
e.
STAFF LEVEL
The competence level or the professional aptitude of the Staff in charge of
maintenance, is indicated with the following abbreviations:
B = Basic
I = Intermediate
f.
MANHOURS
The time expressed in man hours (hours and tenths of hours) needed to carry out
the maintenance is indicated.
g.
TOTAL MANHOURS
The total time needed to perform the maintenance is indicated.
h.
ENGAGEMENT OF APPARATUS
The time, expressed in hours and tenths of hours, during which the apparatus is
engaged for the maintenance is indicated.
i.
DESCRIPTION
The title assigned to the maintenance is indicated.
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l.
SAFETY PRECAUTIONS
Precautions for the safety of the staff in charge of the apparatus maintenance are
indicated.
m.
TOOLS AND CONSUMABLES
All the tools, materials and measures needed to perform the maintenance
procedure are listed.
n.
PROCEDURE
The procedure for the maintenance execution is described, and the precautions
needed to prevent harm to the staff or material damages are recalled case wise.
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Table 5-1 Preventive Maintenance Index – SCI Integrated Compressor
SYSTEM, SUBSYSTEM OR UNIT
REFERENCE MANUALS
SCI Integrated Compressor
Supplementary
Manual SCI
DATE
Technical
This document must apply to:
SCI Integrated Compressor
DESCRIPTION OF THE OPERATION
PERIOD.
CODE
STAFF
LEVEL
MANHOURS
Oil level check
1/1
B
0.05
Replace Oil separator filter
30/1
B
0.05
Replace Air filter
30/1
B
0.20
Replace Oil and Oil filter
30/1
I
0.50
Compressor Complete Overhaul
200/1
I
8
Page 1 of 1
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5.1.3. Post - overhaul setting at work of the Compressor
This section contains the operative directions concerning how to manage the various
functions and adjustments, after the disassembly and the complete overhaul of the SCI
Compressor.
a.
Compressor repositioning
Insert the corresponding joint or pulley on the compressor shaft end.
Position the compressor on the base after the insertion, when needed, of the joint spacer,
and lock it with the fixing screws
In case of belt driven application:
•
Insert the belt;
•
Ad just the compressor position to align the pulley on the compressor shaft end and
the pulley on the motor shaft;
•
Tension the belt following the instructions given by the belt manufacturer,
considering that the radial force on the compressor shaft end must never exceed
the maximum bending moment (allowable on the protrusion of the male rotor in
correspondence of the pulley beating surface section), indicated in each specific
MTI.
In case of direct driven application:
align the compressor and the motor so that the transversal, longitudinal and angular shaft
misalignments do not exceed the maximum ones that can be compensated by the
coupling, according to the instructions of the manufacturer.
b.
Filling with oil of the compressor
Before first start up it is necessary to fill the compressor with 3.5 dm3 of suitable mineral
or synthetic oil. 0.5 dm3 of oil must be filled directly from the inlet port of the compressor.
This operation must be repeated before starting, every time maintenance operations are
performed.
Refers to paragraph 7.3 of this manual to define the recommended oils.
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c.
Connection check
Make sure that all the connections with the apparatus and the compressor have been
completed.
d.
Direction of rotation check
Make sure that the driving rotor is operated in the direction of rotation indicated by the
arrow highlighted on the compressor casing.
e.
Electric isolation check
The compressor must be electrically isolated from the other parts of the plant, through its
dedicated ground cable. The lack of observance of this rule can cause the origin of
galvanic current, through the compressor itself, that could seriously damage the machine.
The lack of a ground cable in the compressor causes electrostatic charge storage inside it,
during the operation, with the risk of explosion and fire in the machine.
f.
Compressor starting
After having performed the operations described in the preceding points a.-d., the starting
can be performed, with the following steps:
f.1
Start the motor
f.2
Wait for the discharge pressure to reach the preset operative value
f.3
Make sure that anomalous vibration, noise values etc are not detectable
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6. Failure search
6.1. Introduction
This section contains directions and information required to locate failures or discharge
anomalies on the SCI Compressor.
A failure logical table is provided as an aid for the failure search.
This logical scheme is based on the failure indications observed in the process of failure
search.
The table includes the symptoms and the probable causes related to the failure isolation
Each cause implies a specific cure, thereby gradually reducing the uncertainty field.
Therefore, the functional area of the set wherein the failure is located will gradually be
reduced, and lastly the information needed to complete the isolation and to perform the
repair will be provided.
Table 6-1 indicates the inconvenient and the cures that can be applied to eliminate the
inconvenient found.
In particular, for each failure found the corresponding corrective actions are listed to locate
the damaged subsystems and/or components and restore the normal operative
conditions..
NOTE
In the realization of the logical failure schemes, the assumption was made that the
incoming feeds and signals be present and that the harness be in order. The technical
staff in charge of the failure search will have to make sure of the aforesaid
If, after having performed the indicated operations, the failure persists, contact the
TM.C. TERMOMECCANICA COMPRESSORI S.p.A. service center.
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Table 6-1 SCI Integrated Compressor – Failure Search (1 of 3)
UNIT
SYMPTOM
CAUSE
CURE
REFERENCE
Compressor
The compressor
doesn’t switch to
load condition
Losses in the
control air line
Solenoid valve
out of order.
Check and
replace.
Supplementary
Technical
Manual sect. 4.2
point 5
Air filter
Clogged air filter
Remove and
check the filter.
Replace if
needed.
Supplementary
Technical
Manual sect. 4.2
point 1
Solenoid Valve
Solenoid valve
out of order
Safety Valve
Air delivery or
pressure lower
than standard
value
Remove and
Supplementary
check the valve.
Technical
Replace if
Manual sect. 4.2
needed.
point 5
Remove and
Supplementary
Safety valve with check the safety
Technical
valve. Replace if Manual sect. 4.2
leakage
needed.
point 6
Oil separator
filter
Oil separator
filter clogged
Remove and
check the
cartridge.
Replace if
needed.
Compressor
Compressor out
of order
Contact TM.C.
Service Center.
Air filter
Air filter
During stop
operation too
much oil is
throwing through
the filter
Excessive oil
load
Oil separator
filter clogged
- 53 Rev. August ‘07
Supplementary
Technical
Manual sect. 4.2
point 7
Check the oil
Supplementary
level and restore
Technical
standard
Manual sect. 4.2
condition.
point 1 and 2
Remove and
check the
cartridge.
Replace if
needed.
Supplementary
Technical
Manual sect. 4.2
point 7
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
Table 6-1 SCI Integrated Compressor – Failure Search (2 of 3)
UNIT
Compressor
Oil filter
Thermostatic
valve
Minimum
pressure valve
Compressor
SYMPTOM
CAUSE
CURE
REFERENCE
Check and
Supplementary
adjust oil level.
Oil level low;
Technical
Check for
lack of
Manual sect. 3
obstructions in
table 3.1, sect.
lubrication
the external oil
4.2 point 5
circuit.
Remove and
Supplementary
The compressor Clogged oil filter;
check
the
filter.
Technical
is overheating
oil filter out of
Replace if
Manual sect. 4.2
order
needed.
point 4
Remove and
Supplementary
Thermostatic
check the valve.
Technical
valve out of
Replace if
Manual sect. 4.2
order
needed.
point 3
Remove and
Supplementary
check the
Minimum
Safety valve
Technical
minimum
pressure valve
intervenes
pressure valve. Manual sect. 4.2
out of order
point 8
Replace if
needed.
Remove oil in
Excessive oil
load.
excess.
High oil level
Remove
Excessive
condensate from Supplementary
condensate.
the oil unload.
Technical
Excessive oil
Remove oil in
Manual sect. 3
load.
excess.
table 3.2, sect.
Too much
Oil separator
Replace oil filter
4.2
residual oil in the filter out of order
separator.
delivered air
Oil quality not
Replace with
correct. Too
adequate oil.
much foam.
Check the oil
Insufficient oil level and restore Supplementary
load
standard
Technical
condition.
Manual sect. 3
Oil level
Oil leakage
Check the seals table 3.1, sect.
4.2
decreasing
(from the seal,
and replace if
gaskets)
necessary.
Supplementary
Oil separator
Replace oil filter
Technical
filter out of order
separator.
Manual sect. 4.2
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Table 6-1 SCI Integrated Compressor – Failure Search (3 of 3)
UNIT
SYMPTOM
CAUSE
Clogged air filter
Suction valve
doesn’t open
correctly
Low air delivery
Solenoid valve
doesn’t close
correctly
Compressor
Lack of
lubrication
Oil separator
filter clogged
High power
absorption
Rotors
Rotors are
locked
Minimum
pressure valve
doesn’t open
correctly
Foreign matter
entry.
Seizure.
Wrong
lubrication.
- 55 Rev. August ‘07
CURE
Remove and
check the filter.
Replace if
needed.
Remove and
check the
suction valve.
Replace if
needed.
Remove and
check the
solenoid valve.
Replace if
needed.
Check for
obstructions in
the external oil
circuit and
remove them.
Remove and
check the
cartridge.
Replace if
needed.
Remove and
check the
minimum
pressure valve.
Replace if
needed.
Contact TM.C.
Service Center.
REFERENCE
Supplementary
Technical
Manual sect. 4.2
point 1
Supplementary
Technical
Manual sect. 4.2
point 5
Supplementary
Technical
Manual sect. 4.2
point 7
Supplementary
Technical
Manual sect. 4.2
point 8
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
7. COMPLETE OVERHAUL
7.1. Introduction
The term complete overhaul implies the SCI Compressor disassembly, the thorough
cleaning and an accurate check of all the parts thereof; the replacement of all the rubber
parts and of other worn out or defective parts, the replacement of all the clamps. The rusty
parts must be replaced or repainted.
This section contains the instructions needed to disassemble, replace and overhaul all the
parts constituting the SCI Compressor.
The maintenance staff must strictly observe the maintenance procedures, and particularly
the general safety regulations.
In table 7-1 the driving torques recommended, function of the size of bolts having a 8.8
resistance rate are listed.
The list of the tools related to the standard equipment, needed to perform the scheduled
maintenance operations of the and the complete overhaul is shown in table 7-2.
Table 7-1 Driving torques
Class
Dimension
Driving torques [Nm]
8.8
M6
12
8.8
M8
30
8.8
M10
59
The following list reports the tools recommended to perform the majority of the
maintenance tasks. Maker names are listed exclusively as a reference.
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Table 7-2 Standard tools list for maintenance operations
Q.ty
Description
Manufacturer/type
1
Tool case
526.ABS/T6
1
Screwdriver set ( 0.5 – 6 )
USAG 326
1
Screwdriver set ( 0 – 3 )
USAG 326 TC4
1
Non metallic screwdriver for
compensator
USAG 322 C
1
Torque screwdriver
STAHLWILLE 76/25
1
Cutter
STANLEY 199
1
Scissors
USAG 207
1
Wrench set ( 6 – 22 )
USAG 252
1
Allen wrench set ( 3/64 - ¼ )
USAG 280”
1
Pliers
USAG 156 NT
1
Tweezer
USAG 40
1
45 degrees tweezer
USAG 41
1
Cutting pliers
BAHCO 2112
1
Articulated wrench set
USAG 613
1
Wrench 34
USAG 252
- 57 Rev. August ‘07
Note
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
7.2. Instructions on reference documents for complete overhaul of a
specific SCI model
It is necessary to complete the advice given in this manual with the information included in
the Supplementary Technical Manual (MTI) specific for each machine, before proceeding
with the complete overhaul of the compressor.
Ask for the specific Supplementary Technical Manual while purchasing a SCI compressor
model.
In the MTI, the user can find all the information related to the specific SCI compressor
model (technical data, maintenance card, reference drawings, etc.).
Together with this manual, the use of MTI is needed to operate on a SCI compressor.
The customer should refer to the specific MTI every time it is requested in this manual.
- 58 Rev. August ‘07
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
7.3. Lubricants
The use of a mineral lubricant having additives conferring antirust, antioxidant, anti wear
characteristics and having antifoam properties is recommended.
The selection of the viscosity grade depends on the conditions of use, refer to the data
reported in table 7.3.
ATTENTION
Strictly observe the use and the safety instructions of the manufacturer of the
lubricants.
ATTENTION
When contacting air, many lubricants produce aggressive fumes, and may irritate
the skin and the eyes. In case of contact, read and observe the instructions reported
on the tank.
Table 7.3 – Viscosity Grade
TEMPERATURE
VISCOSITY GRADE
0°C to 30°C
ISO VG 46
Constantly below 0°C
ISO VG 32
Constantly above30°C
ISO VG 68
- 59 Rev. August ‘07
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
7.3.1. Mineral oils
The use of one of the following mineral oils reported in table 7-4 is recommended.
Table 7.4 – Mineral Oils
Type
SHELL CORENA D 46
ISO
grade
Viscosity Index
46
44 / 6.7 cST (40° C\ 100°C)
(cinematic viscosity ASTM D 445)
SHELL CORENA D 68
68
68 / 9.0 cST (40° \ 100°)
(cinematic viscosity ASTM D 445)
AGIP DICREA 32
32
112
AGIP DICREA 46
46
112
AGIP DICREA 68
68
104
ERG COMPRESSOR 32
32
106
ERG COMPRESSOR 46
46
104
ERG COMPRESSOR 68
68
102
CASTROL 943 TRIBOL AW 32
32
116 (ASTM D 2270)
CASTROL 943 TRIBOL AW 46
46
112 (ASTM D 2270)
CASTROL 943 TRIBOL AW 68
68
106 (ASTM D 2270)
MOBIL RARUS 424
32
105
MOBIL RARUS 425
46
105
MOBIL RARUS 426
68
105
NOTE
The first oil change must be performed after no more than 50 hours of operation.
The successive changes must be performed every year or every 3000 hours of
operation.
- 60 Rev. August ‘07
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
7.3.2. Synthetic oils
Alternatively to the mineral oils, synthetic oils can be used as well, capable of prolonging
the time between oil changes and the working life of the various components (filters etc..).
The list is reported in table 7.5.
Table 7.5 - Synthetic Oils
Type
SHELL CORENA AS 46
ISO
grade
46
Viscosity Index
46 / 83 Cst (40° C / 100° C)
(cinematic viscosity ASTM D 445)
SHELL CORENA AS 68
68
68 / 11,1 Cst (40° C/ 100°C)
(cinematic viscosity ASTM D 445)
MOBIL RARUS SHC 1024
32
127 (ASTM D 2270)
MOBIL RARUS SHC 1025
46
131 (ASTM D 2270)
MOBIL RARUS SHC 1026
68
136 (ASTM D 2270)
- 61 Rev. August ‘07
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
7.4. Painting
The areas of the compressor where the paint is damaged must be repaired to prevent
further decay.
The areas to paint must be clean, dry and free of rust. If the rust is already present it will
be necessary to perform a sand blasting of the area at issue and an integral cleaning
thereof before applying the paint in accordance with the following directions.
Electrostatic painting
This is carried out by means of suitable equipment that permits atomization of the paint
product and brings the particles to a high electric potentiality by means of a high voltage
source.
These particles are attracted by means of the electrostatic field of the surface to be
painted that has a charge that is opposite to that of the particles.
Main features of this method are:
•
a complete coating effect;
•
a good distribution of the product;
•
limited product loss.
6.1. Handling
To handle the compressor it is necessary to use an eye bolt, fixed to the appropriate hole
on the machine. It is necessary to lock the compressor during handling to avoid any ranger
or touch.
- 62 Rev. August ‘07
Operation and maintenance
manual – Integrated
Compressor SCI BM/FM
8. SPECIAL TOOLS
8.1. Introduction
To proceed with the disassembly/assembly and to ad just the SCI compressor, it is
necessary to use in some phases some apposite special tools.
These tools are specifically designed to perform particular operations.
8.2. Instructions on reference documents for description and use of a
specific special tool
The specific information regarding the special tools are included in the Supplementary
Technical Manual (MTI) specific for each machine.
Ask for the specific Supplementary Technical Manual while purchasing a SCI compressor
model.
In the MTI, the user can find all the information related to the specific SCI compressor
model (technical data, maintenance card, reference drawings, etc.).
Together with this manual, the use of MTI is needed to operate on a SCI compressor.
The customer should refer to the specific MTI for the data regarding special tools.
- 63 Rev. August ‘07
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