Máy khoan hầm Boomer H282 (Phần 4) - P5

Shop manual máy khoan hầm Boomer H282 (Phần 4) Phần động cơ

Atlas Copco Stationary Air Compressors

Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium

Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks, model denominations, part numbers and drawings

This instruction book meets the requirements for instructions specified by the machinery directive 98/37/EC and is valid for CE as well as non-CE labelled machines

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life

Read this book before putting the machine into operation to ensure correct handling, operation and

proper maintenance from the beginning The maintenance schedule comprises measures for keeping the machine in good condition

Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according to the instructions Record all operating data, maintenance performed, etc in an operator's logbook available from Atlas Copco Follow all relevant safety precautions, including those mentioned on the cover of this book

Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further information

In all correspondence mention the type and the serial number, shown on the data plate

For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data"

The company reserves the right to make changes without prior notice

1 Leading particulars 5

1.1 General description 5

1.1.1 Compressor variants 8

1.2 Air flow 9

1.2.1 LE/LF2 up to -5, LE7 and LE10 50 Hz (Fig 1.10) 9

1.2.2 LE10 60 Hz, LE15, -20, LF7, -10 and LT (Fig 1.11) 9

1.3 Regulating system 12

1.3.1 LE/LF/LT2 up to -7 with DOL starter (Fig 1.10) 12

1.3.2 LE/LT5 up to -20, LF5 up to -10, each with Y/D starter (Fig 1.11) 12

1.3.3 LE/LF/LT Trolley (Fig 1.12) 13

2 Installation and handling 15

2.1 Dimension drawings 15

2.2 Installation proposals 36

2.2.1 LE/LF/LT 38

2.2.2 LE/LF/LT Trolley 39

2.3 Electrical connections 39

2.4 Settings of overload relay - fuses - cable size 43

2.4.1 Settings of overload relay - fuses of compressors with DOL starter 43

2.4.2 Settings of overload relay - fuses of compressors with Y-D starter 44

2.4.3 Cable size 45

2.5 Pictographs 46

3 Operating instructions 47

3.1 Initial start-up 47

3.2 Starting 47

3.3 Stopping 48

3.4 Taking out of operation at end of compressor service life 49

4 Maintenance 50

4.1 Petrol engine maintenance 50

4.2 Preventive maintenance schedule of the compressor 1) 50

4.3 Lubrication of LE/LT compressors 51

4.4 Service kits 51

5 Servicing and adjustment procedures 53

5.1 Unloader or check valve 53

5.2 Valves 53

5.2.1 Replacement of valve discs (Figs 5.1 and 5.2) 55

5.3 Air filter 56

5.4 Adjustment of MDR4S pressure switch (Figs 5.4 up to 5.6) 57

5.5 Adjustment of MDR3 pressure switch (Figs 5.7 and 5.8) 59

5.6 Adjustment of pilot valve on Trolley (Fig 5.9) 60

5.7 Safety valve (SV-Figs 1.4, 1.6 and 1.8) 1) 61

5.7.1 Testing on LE/LF/LT 61

5.7.2 Testing on LE/LF/LT Trolley 61

5.8 Relief valve (8-Fig 1.1) on LF7, -10, LE10 up to -20 and LT 61

6 Problem solving 62

7 Principal data 64

7.1 Reference conditions 64

7.2 Limitations 64

7.5.2 60 Hz 67

7.6 Compressor data for LT 20 bar 68

7.6.1 50 Hz 68

7.6.2 60 Hz 68

7.7 Compressor data for LT 30 bar 69

7.7.1 50 Hz 69

7.7.2 60 Hz 69

8 Conversion list of SI units into US/British units 70

9 PED (Pressure Equipment Directive) 70

9.1 Components subject to 97/23/EC Pressure Equipment Directive 70

9.2 Overall rating 70

2920 1585 00 - 4 -

1 Leading particulars

1.1 General description

LE, LF and LT are air-cooled, single-acting piston compressors LE and LT are lubricated compressors;

LF are oil-less compressors which deliver oil-free air LF2 up to LF5, LE2 up to LE7 and LE10 50 Hz are single-stage compressors; LE10 60 Hz, LE15, -20, LF7, -10 and LT are two-stage compressors

LT and LE/LF2 up to -7 and LE10 50 Hz are two-cylinder compressors, LE10 60 Hz, LF10, LE15, -20 are three-cylinder compressors

Note: Take care that three-cylinder compressors rotate in the direction as indicated by the arrow on the

fan housing (counter-clockwise seen from fan cowl side)

LE/LF are built for effective working pressures up to 10 bar LT are built for effective working pressures up

to 30 bar (LT2 only for 15 and 20 bar)

Fig 1.1 Compressor Block with unloading valve Fig 1.2 Power Pack with unloading valve

Fig 1.3 Power Pack

Figs 1.1 up to 1.3 General views, Compressor Block - Power Pack

Fig 1.4 Tank-mounted unit, LE/LT/LF2, -3,

horizontal receiver (standard receiver is

120 l)

Fig.1.5 Tank-mounted unit, LE10 60 Hz, LE5-20, LT15,

-20 and LT/LF5-10 (standard receiver is 250 l)

1 10 11

AF

FN

7 5

AR

Dm

D0656

Fig 1.6 Tank-mounted unit, LE/LT/LF2, -3, -5, vertical

receiver (standard receiver is 250 l)

Fig 1.7 Tank-mounted unit, three-cylinder

Fig 1.8 Base-mounted Fig 1.9 LE/LF/LT with CD dryer

The Compressor Block (Fig 1.1) includes:

- Crankcase (4) and cylinders (6)

- Air inlet filter (AF) and inlet silencer (3)

- Fan (FN)

- Air cooler piping (2) and (5)

- Unloader (7, as standard on LE/LF/LT5 up to -10, LE15, -20 and LT15 up to -20)

- Interstage relief valve (8, for LF7, -10, LE10 60 Hz, LE15, -20 and LT)

The Power Pack comprises (Figs 1.2/1.3):

- For LE/LF/LT2 and -3: the Compressor Block as described above, with flanged-on electric motor (M), check

valve (CV-Fig 1.4), and on 60 Hz air pressure switch with on/off switches (13-Fig 1.4)

- For LE/LF/LT5 up to -10, LT15 up to -20: the Compressor Block as described above, with flanged-on

electric motor (M) and solenoid valve (Y1-Fig 1.5)

The Tank-mounted unit comprises:

- For LE/LF/LT2 and -3: the Power Pack mounted on a horizontal (Fig 1.4) or vertical (Fig 1.6) air

receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV), air pressure switch with on/off switches (13) and condensate drain valve (Dm)

- For LE/LF/LT5 up to -10, LE15, -20 and LT15, -20 (Fig 1.5/1.7): the Power Pack mounted on an air

receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV) and condensate drain valve (Dm) An electric cubicle (6) includes the motor starter A separate air pressure switch (13) is provided

A silencing canopy (1-Fig 1.13) is available as an option The canopy has a hinged top to allow easy access for maintenance

The Base-mounted unit (Fig 1.8) is a fully operational unit with air pressure switch and on/off switches

mounted on a frame (no air receiver) A silencing hood can be added as an option

LE, LF and LT Trolley units (Figs 1.15 and 1.16) are mobile compressors They are equipped with either

a directly flanged electric motor (LE/LF/LT ETROL - Fig 1.15) or a petrol engine (LE/LF/LT PETROL - Fig 1.16) The compressors have two outlet connections:

- a connection for compressed air at working pressure

- a connection for compressed air at reduced pressure via a pressure regulator

The Full-Feature compressor is a Tank-mounted compressor additionally provided with an FX dryer and DD/PD filters

1.2 Air flow

1.2.1 LE/LF2 up to -5, LE7 and LE10 50 Hz (Fig 1.10)

Air drawn through air filter (AF) and inlet silencer (1) into cylinders (3) is compressed, then discharged through cooler piping (4) and (6) and check valve (CV) into air receiver (AR)

1.2.2 LE10 60 Hz, LE15, -20, LF7, -10 and LT (Fig 1.11)

Air drawn through air filter (AF) and inlet silencer (1) into LP (low-pressure) cylinder(s) (7) is compressed, then discharged to HP (high-pressure) cylinder (8) via intercooler (10)

The air is further compressed and discharged through cooler piping (6) and check valve (CV) into air receiver (AR)

MCOMPRESSED AIR (1)

FC

2

5AR

3

4

346

FN

AF

(1) Compressed air

Fig 1.10 Air flow of LE and regulating system of LE/LF/LT2 up to -7 with DOL starter and separate

air pressure switch

10FN6

107

AR

1213UV

UA9

115

50981D(1) Compressed air

Fig 1.11 Air flow of LT and regulating system of LE5 up to -20, LF5 up to -10, LT5 up to -10 and

LT15 up to -20 with Y/D starter and electric cabinet

6SG

UA

3

4

34FN

AF

PD

PD

AV1AV2

AV Air outlet valve

AV1/2 Air outlet valves

CV Check valve

Dm Condensate drain valve

DP Oil drain plug

FC Oil filler cap

1 Air inlet silencer

2 Pressure release valve

1.3 Regulating system

1.3.1 LE/LF/LT2 up to -7 with DOL starter (Fig 1.10)

The regulating system includes:

When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the air pressure switch close and pressure release valve (2) closes The motor restarts and compressed air is supplied to the receiver again

1.3.2 LE/LT5 up to -20, LF5 up to -10, each with Y/D starter (Fig 1.11)

The regulating system includes:

- Electric cubicle (11)

- Air pressure switch (MDR)

- On/off switch (5)

- Solenoid valve (Y1)

- Unloader (UA) with integrated check valve (CV)

Operation

Air pressure switch (MDR) opens and closes its contacts at pre-set pressures During loaded operation, the contacts are closed: the motor is running and solenoid valve (Y1) is energized preventing the compressed air from flowing to unloader (UA)

When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts of pressure switch (MDR) open The motor stops and solenoid valve (Y1) is de-energized Compressed air from the receiver will flow via the solenoid valve to plunger (12) which causes unloading valve (UV) to open The air at the delivery side of the compressor is blown through silencer (9) to atmosphere and check valve (CV) closes to prevent venting of the receiver

When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the pressure switch close The motor restarts and, after switching over from star to delta, solenoid valve (Y1)

is energized Control air from the unloader plunger chamber is vented to atmosphere Unloading valve (UV) closes and compressed air is supplied to the receiver again

Fig 1.13 Optional silencing hood Fig 1.14 Pack compressor with optional silencing

hood

AV Air outlet valve

Dm Condensate drain valve

1 Silencing hood (standard option)

2 Electric cabinet

3 On/off switch

4 Air pressure switch with on/off switches

Figs 1.13 and 1.14 Pack - silencing hood

1.3.3 LE/LF/LT Trolley (Fig 1.12)

The regulating system includes:

- Pilot valve (RV)

- Unloader (UA) with integrated check valve (CV)

- Electric cabinet (11) (only on electric motor driven Trolley compressors)

Fig 1.15 LE/LF/LT ETROL Fig 1.16 LE/LF/LT PETROL

AF Air filter

AV1 Air outlet valve

Dm Condensate drain valve

Gp Air pressure gauge

2 Installation and handling

2.1 Dimension drawings

(14)

(3)

(5) (1)

2 3 5 2 3 5

See page 35 for the text on this figure

Fig 2.1 Dimension drawing, LE/LT2 up to -5 and LF2, -3 Power Pack

9820 2239 02/3 55750D

(1) (14)

See page 35 for the text on this figure

Fig 2.2 Dimension drawing, LE/LT7, -10 and LF5, -7 Power Pack

10 10 15 20

See page 35 for the text on this figure

Fig 2.3 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Power Pack

15 20 15-30 20-30

See page 35 for the text on this figure

Fig 2.4 Dimension drawing, LT15, -20 and LT15-30, LT20-30 Power Pack

(1) (14)

(3)

(15)

(4)

9820 2239 42/1 55752D

2 3 5 2 3 5

mounted

Base-See page 35 for the text on this figure

Fig 2.5 Dimension drawing, LE/LT2 up to -5 and LF2 Base-mounted

5 7 10 7 7 10

Base -mounted

See page 35 for the text on this figure

Fig 2.6 Dimension drawing, LE/LT7 up to -10 and LF5, -7 Base-mounted

See page 35 for the text on this figure

Fig 2.7 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Base-mounted

20

See page 35 for the text on this figure

Fig 2.8 Dimension drawing, LT15, -20 Base-mounted

2 3 5 5 7 10

See page 35 for the text on this figure

Fig 2.9 Dimension drawing, LE/LF/LT2 up to -7 and LE/LT10 50 Hz Pack with optional silencing hood

10 15 10 20

See page 35 for the text on this figure

Fig 2.10 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Pack with optional silencing hood

(1) (14)

2-5 2-3

2 3 5 2 3 5

See page 35 for the text on this figure

Fig 2.11 Dimension drawing, Tank-mounted LE/LT2 up to -5 and LF2, -3 (horizontal 120 l receiver)

9820 2239 23/2 55760D

See page 35 for the text on this figure

Fig 2.12 Dimension drawing, Tank-mounted LE/LT2 up to -5 (vertical 250 l receiver)

5

5

See page 35 for the text on this figure

Fig 2.13 Dimension drawing, Tank-mounted LE/LT5 (horizontal 250/475 l receiver)

See page 35 for the text on this figure

Fig 2.14 Dimension drawing, Tank-mounted LE10 up to -20 and LF10 (horizontal 250/475 l receiver)

15/60 15

20

15/60 15 20

See page 35 for the text on this figure

Fig 2.15 Dimension drawing, Tank-mounted LT15, -20 (horizontal 250/475 l receiver)

9820 2239 24/5 55767D

2-5 2-3

2 3 5 2 3 5 2 3 5 2 3 5

See page 35 for the text on this figure

Fig 2.16 Dimension drawing, LE/LT2 up to -5 and LF2, -3 Tank-mounted with optional silencing hood

7 5 10

7 7 10

See page 35 for the text on this figure

Fig 2.17 Dimension drawing, LE/LT7, -10 and LF5, -7 Tank-mounted with optional silencing hood

2-3

2-3

5 7-10 7-10 15-20 7 10

See page 35 for the text on this figure

Fig 2.18 Dimension drawing, LE/LT/LF with CD dryer

2 3 5 5 7 10

See page 35 for the text on this figure

Fig 2.19 Dimension drawing, LE/LF/LT Trolley with electrical motor

3 5 5 7

See page 35 for the text on this figure

Fig 2.20 Dimension drawing, LE/LF/LT Trolley with petrol engine

(5) Compressed air outlet, G 1/2

(6) Manual condensate drain

(7) Hole, 15 x 25 (3x)

(8) Receiver

(9) Cooling air outlet

(10) Motor cooling air inlet

(11) Compressed air outlet

(12) Hole, 15 x 24 (4 x), can be used for fixing without rubber pads

(13) Compressor cooling air and air inlet

(14) For dismantling air filter

(15) Compressor air outlet with flexible (2 meter)

(16) Electric cable entry (on rear side)

(17) Hole (4x)

(18) EURO receiver

(19) Air outlet

2.2 Installation proposals

9820 2332 03 52790D

9820 2332 00 52791D

Fig 2.21 Installation proposal for Tank-mounted unit

(120 l receiver)

Fig 2.22 Installation proposal for Tank-mounted unit

(250/475 l receiver)

9820 2332 04 52792D

9820 2332 02 52794D

(1)

(2)

Fig 2.23 Installation proposal for Tank-mounted

unit (vertical 250 l receiver)

Fig 2.24 Installation proposal for Tank-mounted

unit with optional silencing hood

(1) Cooling air outlet

(2) Compressor air and cooling air inlet

9820 2332 01 52793D

(1)

(2)

(1) Cooling air outlet

(2) Compressor air and cooling air inlet

Fig 2.25 Installation proposal for Pack compressors

2.2.1 LE/LF/LT

Install the compressor horizontally, in a cool but frost-free and well-ventilated room Place the compressor

as level as possible; however, LE/LT can be operated with an angular deviation below 22.5 degrees in any direction, LF can operate with any angular deviation, in any direction The air should be clean

A Pack Unit must be installed away from walls to allow easy maintenance Keep the ventilation openings

free

It is recommended to install an automatic condensate drain (available as an option) on the air receiver to ensure continuous condensate removal