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Instruction Manual and Replacement Parts List

Low Pressure Compressor Block Screw Compressor


NK 60

September 2008
BAUER Compressors, Inc. 1328 Azalea Garden Road Norfolk, Virginia 23502-1944

MNL-0188
Phone: (757) 855-6006 Fax: (757) 855-6224 www.bauercomp.com

NK 60
This information is believed to be accurate by Bauer Compressors, Inc., as of its date of publication, but Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use of this information. All information supplied is in connection with sales of Bauers products, and is thus subject to Bauers standard terms and conditions of sale. Bauer reserves the right to change this information and has no obligation to update these materials. Bauer Compressors, Inc.reserves to itself all rights to this publication. Bauers customers have no right to reproduce, rewrite, modify, license or permit anyone elses use of this information, without the express written permission of Bauer Compressors, Inc.

NOTICE
This manual is a combined format of Rotorcomps Operating Manual NK 60 dated September 2008 and Spare Parts List NK 60 dated November 2008. Both were created on A4 (8.27 x 11.69) size paper. When printing adjust your settings appropriately.

Page i

Operating Manual
SCREW COMPRESSOR COMPACT MODULE NK 60

[en] 09/2008

Copyright ROTORCOMP VERDICHTER GmbH, 2008 All rights reserved. No duplication, modification or translation beyond the degree permitted by the applicable copyright laws is permitted without prior written approval. The information contained in this document is subject to change without prior notice. This document is not subject to the change service. Printed in Germany

ROTORCOMP VERDICHTER GmbH Industriestrae 9 82110 Germering, Germany

Operating Manual - NK 60

1 1.1 1.2 1.3 1.4 1.5

Foreword......................................... 1.1 General ............................................ 1.1 Scope............................................... 1.1 Change service ................................ 1.1 Abbreviations ................................... 1.1 Manufacturer's information .............. 1.1

3.8 3.9

Intake control valve for pneumatic control unit .......................................3.8 Intake air filter ..................................3.9

3.8.1 Installation position ............................... 3.8 3.9.1 Micro air filter element .......................... 3.9 3.9.2 Intake filter monitoring .......................... 3.9

1.5.1 General information................................1.1 1.5.2 Purpose..................................................1.2 1.5.3 Standard delivery scope.........................1.2

3.10 Fine separator ...............................3.10


3.10.1 Oil intake non-return valve.................. 3.10 3.10.2 Fine separator cartridge ..................... 3.11 3.10.3 Minimum pressure valve..................... 3.12

1.6 1.7 2 2.1 2.2 2.3

Warranty information, liability disclaimer ............................. 1.2 Nameplate........................................ 1.2 Safety precautions......................... 2.1 Marking of safety precautions .......... 2.1 Safety regulations ............................ 2.1 General safety precautions .............. 2.1

3.11 Air-oil circulation outside compressor module .......................3.13


3.11.1 Oil filter ............................................... 3.14 3.11.2 Oil thermostat (option) ........................ 3.14

3.12 Oil cooler/air after-cooler (option) ..3.15 3.13 Safety valve (SIV) (option).............3.15 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 Transport........................................4.1 Delivery and packing .......................4.1 Transport damage ...........................4.1 Transporting unpacked system .......4.2 Transport options.............................4.2 Installation/Assembly....................5.1 Connection thread/assembly ...........5.1 Safety precautions for installation and assembly ..................................5.1 Installation .......................................5.2

2.3.1 Special symbols .....................................2.2 2.3.2 Information on use of safety equipment ..............................................2.2

3 3.1

3.2 3.3

Technical Description.................... 3.1 General overview of NK 60 Screw Compressor Compact Module (standard model with electric control unit) ...................................... 3.1 Flow diagram of NK 60 (electric control unit)......................... 3.2 Operating description for NK 60 Screw Compressor Compact Module (electric) ........................................... 3.2
Standstill ................................................3.2 Relieved stating .....................................3.3 Feed phase ............................................3.3 Switching off...........................................3.3

5.1.1 Fastening screws.................................. 5.1 5.1.2 Pipe connections .................................. 5.1

3.3.1 3.3.2 3.3.3 3.3.4

5.3.1 Fastening on base frame with screw fitting ..................................................... 5.2 5.3.2 Drive ..................................................... 5.2

3.4 3.5

Intake valve for electric control unit ................................................... 3.4 General overview of NK 60 Screw Compressor Compact Module (pneumatic control unit) ................... 3.5 Flow diagram of NK 60 (pneumatic control unit) ................... 3.6 Operating description for NK 60 Screw Compressor Compact Module (pneumatic) ...................................... 3.6
Standstill ................................................3.6 Starting...................................................3.7 Feed mode .............................................3.7 Stopping .................................................3.7 Switching off...........................................3.7

3.4.1 Installation position ................................3.4

5.4 5.5 5.6 5.7 5.8 6 6.1 6.2 6.3 6.4

Belt drive..........................................5.3 Direct drive ......................................5.3 Air outlet ..........................................5.4 Oil cooling........................................5.4 Service.............................................5.4 Commissioning..............................6.1 Preparation for commissioning ........6.1 Checking direction of rotation ..........6.1 Test run ...........................................6.1 Recommissioning screw compressor system .........................6.2 Maintenance...................................7.1 Safety precautions...........................7.1 Oil level............................................7.2

3.6 3.7

3.7.1 3.7.2 3.7.3 3.7.4 3.7.5

7 7.1 7.2

7.2.1 Oil level check via oil hose (option) ...... 7.2 7.2.2 Oil level check via oil filler opening ....... 7.2
i.1

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ROTORCOMP VERDICHTER

Operating Manual - NK 60

7.3

Oil change....................................... 7.3

7.3.1 Oil change intervals ..............................7.3 7.3.2 Oil drain point ........................................7.3 7.3.3 Filling with oil.........................................7.4

7.4 7.5 7.6 7.7 7.8 8 8.1


8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 8.1.8 8.1.9 8.1.10

Oil filter............................................ 7.4 Fine separator cartridge.................. 7.5 Intake air filter ................................. 7.6 Maintenance check sheet ............... 7.7 Maintenance intervals..................... 7.8 Lubricants and Operating Materials Maintenance Parts ........................ 8.1 Lubricants and operating materials ......................................... 8.1
Oil recommendation ..............................8.1 Topping up oil .......................................8.1 Measures at low room temperature ......8.1 Piping materials ....................................8.1 Pressure dew point of compressed air..8.2 Temperatures........................................8.2 Condensate damage.............................8.2 Cold starts .............................................8.2 Oil separation ........................................8.3 Multigrade oil.........................................8.3

7.4.1 Oil filter replacement intervals...............7.4 7.4.2 Oil filter replacement .............................7.4 7.5.1 Maintenance intervals ...........................7.5 7.5.2 Replacing fine separator cartridge ........7.5 7.6.1 Maintenance intervals ...........................7.6 7.6.2 Replacing air filter element....................7.6

9 9.1 9.2 10

Technical Data and Tightening Torques ...................... 9.1 Technical data ................................ 9.1 Tightening torques .......................... 9.2 Troubleshooting ......................... 10.1

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Operating Manual - NK 60

Foreword

1.1 General
This manual contains information and regulations for the installation and operation of the NK 60 Screw Compressor Compact Module.

1.2 Scope
This documentation is applicable for the screw compressor of the type NK 60 Compact Module from the delivery date of 01/2008.

1.3 Change service


This document is not subject to the change service.

1.4 Abbreviations
bar (g) Bh DHV RC SIV Min. Max. V DC V AC Operating pressure (relative pressure in bar) Operating hours Minimum pressure valve ROTORCOMP Safety valve minimum maximum Direct voltage Alternating voltage

All instructions contained in this operating manual must be observed in the specified manner and sequence in order to prevent injuries and damage to the system. The screw compressor has been built according to the latest technology and the recognized safety rules. Danger may nevertheless result for the user or others or for the compressor system during its use. Any use other than described in the chapter "Purpose" is considered improper. ROTORCOMP shall not be liable for any damage or injuries resulting from such improper use. We shall not provide any guarantee whatsoever for malfunctions and damage resulting from failure to comply with the operating manual. The manufacturer reserves the right to carry out further technical developments without prior notice. Always specify the model and the complete serial number from the nameplate in all correspondence. ROTORCOMP shall assume no liability whatsoever for damage or injuries which occur during handling, operation, maintenance work or repairs due to a failure to comply with the safety instructions to proceed with the usual care and caution, even if this is not expressly mentioned in this operating manual.

1.5 Manufacturer's information


1.5.1 General information This operating manual provides information on the mode of operation, installation, operation and maintenance of the NK 60. It is must therefore always be consulted on the operation and maintenance of the NK 60. Read this operating manual carefully before commissioning the NK 60 for the first time in order to ensure proper handling, operation and maintenance from the outset. Pay particular attention to all warnings and safety precautions. ROTORCOMP screw compressors are carefully checked and tested prior to shipping. When your compressor arrives, the delivery scope must be checked for completeness and damage. Any missing parts and/or transport damage must be reported immediately. A damaged compressor module must not be put into operation under any circumstances. Always have the operating manual available for the operating personnel and make sure that operation and maintenance are carried out according to the instructions.

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1.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

1.5.2 Purpose The NK 60 is a screw compressor compact module designed for installation in a compressed-air generating station. The sole intended use of the system is the compression of atmospheric air. The NK 60 may only be used to compress gases or other media following written approval by ROTORCOMP. The NK 60 may only be installed by specialized companies with the corresponding know-how. The safety precautions, technical data, limits, installation guidelines and regulations for commissioning and operation specified in this operating manual must be observed and complied with. 1.5.3 Standard delivery scope With the NK 60, ROTORCOMP offers a completely equipped, compact compressor module. The components of the standard delivery scope are described in the following chapters. Optionally available components are marked with (optional).

1.7 Nameplate
For the location of the nameplate, see Figure 3-1 and 3-5. Should you have questions, please provide us with the data on the nameplate. This ensures that you receive the correct information.

5 6 7 9
Figure 1-1 Stamping for customers outside Germany (Europe) 1. 2. 3. 4. 5. 6. 7. 8. 9. Order No. Model Serial No. Year of manufacture Max. rpm Max. operating pressure in psi Max. operating temperature F Max. operating temperature C Max. operating pressure in bar

1.6 Warranty information, liability disclaimer


ROTORCOMP is a manufacturer of screw compressor components and not of ready-to-operate compressor systems. RC shall only be answerable for any defects of these individual components for which it is responsible within the scope of the warranty conditions. Failure to comply with the following instructions and information shall void any and all liability. This liability disclaimer also results in the loss of claims for damages. This applies in particular in case of: Installation not approved by RC Improper use Operation of the compressor outside the specified limits Failure to observe the safety precautions and the usual care and caution Unsuitable operating materials (gases, oils) Condensate in the screw compressor Corrosion as subsequent damage Improper operation Insufficient maintenance, missing proof of maintenance Use of unsuitable tools Failure to use genuine spare parts Unauthorized modifications to the screw compressor module and/or its components

1.2

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Operating Manual - NK 60

Safety precautions

2.3 General safety precautions


This operating manual contains important instructions and information on the installation, commissioning, operation and maintenance, which must be observed by the owner. As a result, it is absolutely necessary to turn over the entire documentation to the specially trained personnel of the owner or to make it available at the operating location prior to installation and commissioning. Prior to installation and commissioning, the entire operating manual must be carefully read by the specially trained personnel and then kept in a safe place. Failure to observe the safety precautions can result in a serious hazard for the personnel, the pressure vessel or the environment. Observe the chapter "Manufacturer's information" on page 1-1 of this operating manual. The following safety precautions only refer to the NK 60 screw compressor module and not to the entire compressor system. The applicable national safety and occupational safety regulations of the respective country in which the system is operated must be complied with. The manufacturer of the compressor system is responsible for including the necessary safety regulations for the operation of the compressor system in the operating manual of the compressor system. Installation, operation, maintenance and repair may only be carried out by authorized, trained and qualified personnel. The operating personnel is expected to safely use the working technology and follow all applicable local operating safety regulations and provisions. The owner bears the responsibility for always keeping the machine in safe operating condition. Limits (pressures, temperatures, time settings, etc.) must be permanently marked. Should a regulation contained in this list, especially with regard to safety, not comply with legal regulations, then the safer of the two applies.

2.1 Marking of safety precautions


Important instructions concerning hazards to persons, technical safety and their operational safety are especially highlighted in the following. They precede the measures to be taken and have the following meaning:

d Warning:

Indicates working and operating processes which must be exactly complied with in order to prevent endangering of persons. These include information on special dangers when handling the system.

Caution: Refers to working and operating processes which must be exactly complied with to prevent damage to or destruction of parts or all of the system.

L Note:

Indicates special information for better handling during operating, inspection and adjustment processes and care work.

2.2 Safety regulations


The regulations of the respective country for putting into service and operating pressure vessels must be observed. In Germany these include: Directive 97/23/EC (Pressure Vessel Directive DGRL) of 05/29/1997 Operating Safety Ordinance (BetrSichV) of 09/27/2002

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2.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

2.3.1 Special symbols


Do not operate the system without the safety device mounted Warning on a danger point

Do not inhale compressed air from this machine

Warning: Danger of explosion and/or detonation

Warning: System can be started automatically via remote control following a power failure

Warning: Hazardous substances

Warning: System runs on for 30 seconds after the "OFF" button is pressed

Warning: Flammable substances

Watch cooling air

2.3.2 Information on use of safety equipment


Warning: Do not operate with doors open or shrouding loose Wear safety helmet

Warning: Hot machine parts

Wear safety shoes

Warning: Pressurized part or system

Wear personal safety equipment (safety goggles, protective gloves, safety clothing, etc.) in accordance with the local safety egulations Read the operating manual before commissioning, maintenance, service and repairs.

Lifting point

Warning: High voltage

Active environmental protection

2.2

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Operating Manual - NK 60

Technical Description

3.1 General overview of NK 60 Screw Compressor Compact Module (standard model with electric control unit) 1 2

20 4 19 5 6 18 7 8

17
Figure 3-1

16

15

14

13

12

11 10

1. Air-oil separating element 2. Maintenance indicator for intake filter (optional) 3. Intake valve with air filter 4. Control unit, electric 5. Nameplate 6. Oil filler opening 7. Oil level monitoring (optional) 8. Oil drain screw 9. Return line of oil separation or return line of oil separation with oil-extraction sight glass (optional) 10. Separator head 11. Oil circulation/Off 12. Minimum pressure valve 13. Compressed air outlet 14. Oil filter 15. Oil circulation/On 16. Temperature sensor connection 17. Safety valve (optional) 18. NK 60 basic module 19. Drive shaft 20. End cover

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3.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.2 Flow diagram of NK 60 (electric control unit)

3 3.1

2.1 2 4 1 5 6 13 7 11

12

10

Figure 3-2 1. 2. 2.1 3. 3.1 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 Intake filter Intake valve No-load nozzle Control unit (electric) Solenoid valve Screw compressor Separator tank with pre-separation Fine separator Minimum pressure valve Oil thermostat Oil filter Oil cooler Air after-cooler Non-return valve Safety valve (optional)

3.3 Operating description for NK 60 Screw Compressor Compact Module (electric)


The flow diagram shows a schematic view of the operating principle and the arrangement of the main components of the NK 60 screw compressor module with electrical control unit, regardless of any other equipment. 3.3.1 Standstill At standstill the solenoid valve 3.1 is deenergized, the relief line is open and the downstream devices are depressurized. The minimum pressure valve 7 set to approx. 5.5 bar at the factory is tightly closed. The intake valve 2 is slightly open at standstill.

3.2

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Operating Manual - NK 60

3.3.2 Relieved stating During relieved starting a small air quantity is already drawn in at a minimum vacuum by the rotor rotation. This air quantity is then compressed and flows as pilot air via the deenergized, open solenoid valve 3.1 under the piston of the control valve. The intake valve 2 closes and remains in the no-load position. In this throttled position a corresponding air quantity is drawn in at a certain compressor rotational speed so that a residual pressure of 2 bar is maintained in the separator tank 5. The compressed air flows into the intake filter 1 via the no-load nozzle 2.1 of the intake valve 2 to relieve the system. 3.3.3 Feed phase During the feed phase the solenoid valve 3.1 is closed electrically. The control pressure of the intake valve 2 is released via the no-load nozzle 2.1. The intake valve 2 opens due to the spring force and the vacuum in the intake chamber of the compressor. The air drawn in flows via the intake filter 1 through the intake valve 2 directly into the compression chamber of the screw compressor 4. There the intake air is compressed and oil for lubrication and cooling is injected. The oil-air mixture then enters the separator tank 5 in which the majority of the oil is separated from the air. The air then flows via the fine separator 6 and the minimum pressure valve 7 to the compressed air outlet. In the fine separator 6 the oil is filtered out down to a residual content of < 3 mg/m3 and then routed back into the compressor housing via a nozzle and a non-return valve 12. When the compressor is switched off, the minimum pressure valve 7 with a non-return function prevents backflow of the compressed air out of the system into the compression chamber in the discharge phase. During startup a faster pressure buildup is also ensured, which is required for optimum lubrication and oil separation. The heat resulting during compression is dissipated via the oil-air mixture. The oil circulation also results from the pressure difference between the outlet and inlet pressure. The optimum operating temperature for the oil is adjusted by the oil thermostat 8. Depending on the oil temperature, the oil flow is routed directly via the oil cooler 10 or directly to the oil filter 9 by the oil thermostat valve. The oil then flows via the oil filter 9 to the various injection points in the compressor block.

3.3.4 Switching off When the system is switched off, the intake valve 2, operates, supported by spring pressure, as an independent non-return valve. Following switch-off, the deenergized solenoid valve 3.1 also opens and compressed air flows into the control piston of the intake valve 2. The intake opening is closed off oil-tight in the process, and then the system is completely relieved via the no-load nozzle 2.1.

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3.3

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.4 Intake valve for electric control unit

The NK 60 is equipped with an integrated intake valve mounted directly on the compressor housing.

A
1 1

4 3

Figure 3-3 A B 1. 2. 3. 4. Intake valve opened Intake valve closed Air inlet Air outlet Control line of intake valve No-load/relief nozzle

3.4.1 Installation position

Figure 3-4

3.4

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Operating Manual - NK 60

3.5 General overview of NK 60 Screw Compressor Compact Module (pneumatic control unit S3T)

4 21 20 6 19 7 8 9 18
Figure 3-5 1. Air-oil separating element 2. Maintenance indicator for intake filter (optional) 3. Air filter 4. Intake control valve 5. Control unit, pneumatic 6. Nameplate 7. Oil filler opening 8. Oil level monitoring (optional) 9. Oil drain screw 10. Return line of oil separation or return line of oil separation with oil-extraction sight glass (optional) 11. Separator head 12. Oil circulation/Off 13. Minimum pressure valve 14. Compressed air outlet 15. Oil filter 16. Oil circulation/On 17. Temperature sensor connection 18. Safety valve (optional) 19. NK 60 basic module 20. Drive shaft 21. End cover

17

16 15 14 13

12 11 10

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3.5

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.6 Flow diagram of NK 60 (pneumatic control unit S3T)

3.1

3.2

2 13 4 1 2.1 9 8 5 6 7 12 11

10

Figure 3-6 1. 2. 2.1 3. 3.1 3.2 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 Intake filter Intake control valve Nozzle Control unit (pneumatic) Proportional control valve (positive) Impulse-pressure relief valve Screw compressor Separator tank with pre-separation Fine separator Minimum pressure valve Oil thermostat Oil filter Oil cooler Air after-cooler Non-return valve Safety valve (optional)

3.7 Operating description for NK 60 Screw Compressor Compact Module (pneumatic)


The flow diagram shows a schematic view of the operating principle and the arrangement of the main components of the NK 60 screw compressor module with pneumatic control unit, regardless of its other equipment. 3.7.1 Standstill At standstill the intake control valve 2 is closed by the spring 3-7/3. The downstream devices up to minimum pressure valve 7 are depressurized. The minimum pressure valve is set to approx. 5.5 bar at the factory is tightly closed. The proportional control valve 3.1 is set to operating pressure.

3.6

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Operating Manual - NK 60

3.7.2 Starting In the startup phase the intake control valve is closed via the spring 3-7/3. The rotors in the screw compressor 4 intake air via a bypass hole with a non-return valve in the intake control valve and relief valve. This air is compressed and the pressure in the separator slowly increases. This pressure is routed via the control unit 3 before the holding piston 3-7/6. This presses the holding piston toward the rear and the control piston 3-7/4 opens the intake control valve with the spring. The desired final pressure can be set on the proportional control valve 3.1. When the set final pressure is almost reached, the proportional control valve 3.1 opens and compressed air is routed behind the control piston 3-7/4. As a result, the control piston is pressed toward the front and the valve plate 3-7/5 closes the intake control valve. If the operating pressure drops, the proportional control valve closes and the intake control valve opens again. The proportional control valve steplessly controls the opening of the intake control valve depending on the operating pressure. 3.7.3 Feed mode The air drawn in flows via the intake filter 1 through the intake control valve 2 directly into the compression chamber of the screw compressor 4. There the intake air is compressed and oil for lubrication and cooling is injected. The oil-air mixture then enters the separator tank 5 in which the majority of the oil is separated from the air. The air then flows via the fine separator 6 and the minimum pressure valve 7 to the compressed air outlet. In the fine separator 6 the oil is filtered out down to a residual content of < 3 mg/m3 and then routed back into the compressor housing via a nozzle and a non-return valve 12. When the compressor is switched off, the minimum pressure valve 7 with a non-return function prevents backflow of the compressed air out of the system into the compression chamber in the discharge phase. During startup a faster pressure buildup is also ensured, which is required for optimum lubrication and oil separation. The heat resulting during compression is dissipated via the oil-air mixture. The oil circulation also results from the pressure difference between the outlet and inlet pressure. The optimum operating temperature for the oil is adjusted by the oil thermostat 8. Depending on the oil temperature, the oil flow is routed directly via the oil cooler 10 or
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directly to the oil filter 9 by the thermostat valve. The oil then flows via the oil filter 9 to the various injection points in the compressor block. 3.7.4 Stopping When switching off the system, the valve plate 3-7/5 closes the intake control valve immediately with the spring 3-7/8. This causes pressure to build up in the intake chamber. This pressure actuates a piston in the relief valve 3.2 and the separator is discharged via holes in the relief valve and intake control valves in the intake filter 1. 3.7.5 Switching off When switching off the system, the intake control valve 2 operates, supported by spring pressure, as an independent non-return valve and closes the intake opening oil-tight.

3.7

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.8 Intake control valve for pneumatic control unit

The NK 60 is equipped with an integrated intake control valve mounted directly on the compressor housing.

B
1 1

5 3 4

2
Figure 3-7 A B 1. 2. 3. 4. 5. 6. 7. 8. Intake valve closed Intake valve opened Air inlet Air outlet Spring of holding piston Control piston Valve plate Holding piston Spring of control piston Spring of valve plate 3.8.1 Installation position

2 1

Figure 3-8 1. Impulse-pressure relief valve 2. Proportional control valve 3. Intake control valve

3.8

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Operating Manual - NK 60

3.9 Intake air filter

3.9.2 Intake filter monitoring Maintenance indicator, optical (option) Maintenance indicator, electric (option) The micro dry filter cartridges are recommended as a 1-stage filter with a low filter resistance for standard applications. Caution: Special applications, e.g. system installation in a heavily soiled environment, mobile systems, etc., require 2-stage filters with a somewhat higher filter resistance, however a better degree of separation for the protection of the compressor system. Filter Type/Order No.: on special request.

1
Figure 3-9 3.9.1 Micro air filter element The RC intake air filter is mounted directly over the intake valve. The micro air filter element with a fineness of 10 m is used for the filtering of intake air. The constant degree of separation of almost 100% on all loading levels, the resistance to heat, cold, water, oil and fuel and a large filter area permit a long service life. As a result, the air filter element is the ideal fine filter for the filtering of intake air of compressor system.

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3.9

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.10 Fine separator

3.10.1 Oil intake non-return valve

Figure 3-11 The oil intake non-return valve 1 prevents flooding of the fine separator cartridge with oil flowing back out of the screw compressor due to the pressure difference in the system when the screw compressor system is switched off.

Figure 3-10 1. Fine separator cartridge 2. Oil separation return line with oil-extraction sight glass (option) 3. Minimum pressure valve

3.10

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Operating Manual - NK 60

3.10.2 Fine separator cartridge

The fine separator cartridge is used to recover the extremely finely distributed residual oil in the form of droplets following the pre-separation. The fine separator cartridge separates virtually the entire residual oil from the compressed air. An optimum pre-separation in the separating tank is assumed - the better the pre-separation, the better the fine separation. The vertical cartridge is flowed against from below, while the residual oil is separated out while flowing through the special filter element. Then it is fed into the oil circulation again.

2 3 4

5 8

6
Figure 3-12 1. 2. 3. 4. 5. 6. 7. 8. 9. De-oiled compressed air Post-separator Fine separator Pressure-resistant support pipe Separated oil Outlet of de-oiled air Inlet of air-oil mixture Sealing off Pressure-resistant housing

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3.11

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.10.3 Minimum pressure valve

1 2

4 5 6

A
7

Figure 3-13 1. 2. 3. 4. 5. 6. 7. Non-return valve plate Non-return valve spring Pressure holding valve piston O-ring Pressure holding valve spring Pressure holding valve housing Adjustment screw for minimum pressure

b) Non-return valve It prevents compressed air from flowing back out of the system or the compressed-air reservoir into the screw compressor system. As a result, the system can be completely discharged when the separator reservoir is switched off. This valve operates automatically.

A Minimum pressure valve closed B Minimum pressure valve open The minimum pressure valve is located on the outlet of the compressor before the air recooler and serves as: a) Pressure holding valve It prevents the pressure drop, in case of a lack of counter-pressure, under a minimum pressure of approx. 5.5 bar. This pressure is necessary to ensure the oil supply of the compressor. At the same time this is the condition for good oil separation.

3.12

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Operating Manual - NK 60

3.11 Air-oil circulation outside compressor module

Figure 3-14 After the oil-air mixture in the fine separator cartridge has been deoiled, the compressed air flows through the air cooler and from there to the consumer. The oil flows via a thermostat (optional) to the oil cooler. The cooled oil flows from the oil cooler via the oil filter back into the internal oil-air circuit of the compressor module.

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3.13

ROTORCOMP VERDICHTER

Operating Manual - NK 60

3.11.1 Oil filter

3.11.2 Oil thermostat (option) The NK 60 can be equipped with an oil thermostat. This is located in the piping system between the basic module and the oil cooler/oil filter. The oil thermostat working element can be replaced and must be selected in accordance with the operating temperature. The oil thermostat opens the connection to the oil cooler when the operating temperature is reached and controls the maintaining of the optimum temperature of the system in the further process. In the startup phase this parameter is reached faster, and therefore the formation of condensate in the oil circulation is largely avoided. Depending on the compressor operating data, the temperature is to be between 70C and 110C/ 158F and 230F (measured at compressor outlet). When designing the cooling system, the pressure dew point graph (Figure 8-1) must be taken into account. If questions arise concerning the pressure dew point, please contact ROTORCOMP. The oil thermostat is maintenance-free. Operation of the compressor system with an impermissible overtemperature can result in a failure of the working element (in this case the working element must be replaced).

Figure 3-15 1. Oil filter 2. Separator head The oil filter 1 is screwed onto the separator head 2. The filter fineness is 20 m. The replacement filter has a bypass valve which opens with cold, high-viscosity oil or a heavily soiled filter with a pressure difference of 2.5 bar. This eliminates the undersupply of the screw compressor with oil, which results in the maximum permissible compression temperature being exceeded.

L Note:

When the system is operated at 15 bar, the thermostat working element must always be adapted to the increased requirements

3.14

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Operating Manual - NK 60

3.12 Oil cooler/air after-cooler (option)


With air-cooled screw compressor systems the circulating oil is cooled down from the compressor outlet temperature to the compressor injection temperature. As an option, ROTORCOMP offers combination coolers with aluminum fins, which are connected to the air and oil circulation of the respective compressor (see Figure 3-14). The corresponding coolers are dimensioned so that they ensure operating safety at an ambient temperature of up to 45C/113F. Sufficient cooling air parameters are assumed. The cold ambient air should be fed through the cooler with a fan. A sufficient distance to the cooler must be chosen in order to achieve uniform cooling air distribution over the entire effective cooling surface.

d Warning:

The safety valve must be installed prior to commissioning. Operation of the system without a safety valve can be hazardous! The safety valve is located on the basic module, and is provided with a test device. While taking the pressure loss in the oil separating system into account, the blow-off pressure is a maximum of 1.5 bar above the respective operating pressure (final pressure) of the system. The valve is type-tested and leaded (manufacturer's certificate available on request).

3.13 Safety valve (SIV) (option)

Figure 3-16 1. Knurled screw for operating test

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Operating Manual - NK 60

3.16

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Operating Manual - NK 60

Transport

The deadlines are as follows: a) GERMAN FEDERAL RAILWAY: within 7 days (Paragraph 81/82 of EVO - German Regulations Concerning Carriage by Rail) b) FORWARDING AGENT: within 7 days (Paragraph 60ADSp - General German Forwarders' Conditions) c) POSTAL SERVICE: immediately, at the latest 24 hours following delivery of the shipment

4.1 Delivery and packing


The system is delivered in suitable packing in accordance with the selected shipping method and delivery conditions.

4.2 Transport damage


Regardless of the care taken at the factory, the screw compressor module may be damaged during transport. Therefore, the screw compressor module should be checked for damage following each transport. Caution: A damaged module must not be put into operation under any circumstances. In case of transport damage, damage claims must be secured in your interest by calling in representatives of the transport company promptly for determination of damage, i.e.: A) Externally recognizable damage or losses must be certified with a corresponding note on the freight bill before the merchandise is accepted. With rail transports, a record of the facts must also be requested from the railroad. With postal consignments, the damage must be certified in writing by the postal service before accepting damaged packages etc. B) In case of damage which cannot be recognized immediately which are discovered during unpacking, the carrier must be notified immediately and in writing. If possible, leave packing materials and damaged products in an unaltered state until the facts are recorded. Above all, comply with the complaint deadlines.

L Note:

Each product is checked in accordance with the type and quantity prior to shipment. Should you nevertheless have a reason for complaint, please specify the Order No.

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ROTORCOMP VERDICHTER

Operating Manual - NK 60

4.3 Transporting unpacked system


The screw compressor can be moved with a crane or with a lift truck or forklift truck when fastened to a transport pallet.

4.4 Transport options

d Warning:

Death or serious injuries due to falling cargo! Observe the local safety regulations! Select the lifting equipment in accordance with the total weight to be transported! Remove all loose or swinging parts before lifting the screw compressor! Remove drive or body components beforehand! Only transport the compressor module while depressurized! When transported on a pallet, the compressor module must be securely fastened to it! Do not transport the compressor module on the forks of a stacker or lift truck! Transport eyes are only designed for transporting the compressor module! Do not stand or walk under cargo during transport!

To transport on a pallet, secure the screw compressor on the pallet with angle brackets.

Figure 4-1

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Operating Manual - NK 60

Installation/Assembly

5.2 Safety precautions for installation and assembly


Caution: To lift the compressor module, suitable lifting equipment must be used which complies with the local safety regulations. All blind flanges, plugs, caps and bags with desiccant must be removed before mounting the pipes. Screw fittings and pipe connections must be of the correct size and must be suitable for the respective operating pressure. The air drawn in may not contain any flammable, caustic, toxic or aggressive vapors or gases whatsoever. Make sure that the pressure line from the compressor to the recooler or air system can expand as a result of the heat and does not come into contact with flammable materials. The air intake opening must be positioned so that objects, e.g. loose clothing of passersby, cannot be drawn in. No external force may be exerted on the air outlet valve; the connected pipe connection must be mounted torque-free. The compressor block must be provided with a sufficiently dimensioned ground.

5.1 Connection thread/assembly


5.1.1 Fastening screws Female threads are provided on the NK housing which must be used for fastening. Only suitable screws with a METRIC THREAD are to be screwed into this female thread. 5.1.2 Pipe connections Pipe connections with a female thread for a compressed-air outlet, oil circulation, draining and control lines are provided on the NK housing. Only fittings or screw connections with a CYLINDRICAL INCH THREAD suitable for these female threads may be screwed in. CONICAL THREADS must be avoided, as damage to the NK housing can occur when screwing in (see installation drawing). Caution: The maximum permissible tightening torque for all screw connections may not be exceeded. VDI 2330 (see chapter 9.2 "Tightening torques") Only screws suitable for fastening the compressor housing may be used for this purpose. Consult ROTORCOMP beforehand if necessary.

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5.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

5.3 Installation
Caution: The system must be installed at a location at which the ambient air is as cool and clean as possible. Never block the air inlet. It must be ensured that the penetration of moisture with the intake air is kept to a minimum. Screw compressor must always be installed on a level surface and must be aligned with a level if necessary. In exceptional cases, e.g. with mobile systems, these may only be operated up to a maximum angle of inclination of 10. In these cases the inclined position must be taken into account when checking the oil level and must be carried out with particular care. The base frame for the following fastening versions must be torsionally rigid and level. The fastening of the compressor module on a base frame together with the drive motor can be designed in accordance with the following versions. 5.3.1 Fastening on base frame with screw fitting

5.3.2 Drive The compressor module is designed as an alternative for driving with electric motors, combustion motors, hydraulic motors, etc. The power can be transmitted indirectly via a belt drive (V-belt, toothed belt, etc.) or directly via a flexible coupling. The direction of rotation, looking at the shaft, is counterclockwise, i.e. to the left. On the model with a transmission, the direction of rotation, looking at the shaft, is clockwise, i.e. to the right.

1
Figure 5-1 Caution: The compressor module may only be fastened at the side holes on the compressor housing provided for this purpose. The unit must be fastened torque-free at the respective fastening points 1 on the left and right on the base frame.

5.2

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5.4 Belt drive


Improper design and/or installation of the V-belt drive can result in a considerable reduction of he bearing life and/or to breakage of the drive shaft. If the drive shaft breaks and/or in case of bearing damage, ROTORCOMP can only grant a warranty if the belt drive is properly designed and executed. The following information must be observed for this purpose. The belt drive must not be underdimensioned. The maximum design output for a belt drive is 15.0 kW at 8,500 rpm for this screw compressor. The belt pulley must be pushed onto the drive shaft as far as possible and secured. The V-belt pulleys must be balanced. It is not permissible to drive the belt pulley onto the drive shaft by striking it with a hammer, as this can result in bearing damage. When aligning the belt drive, exact parallelism without vertical and horizontal angular errors must be ensured. A torsionally rigid base frame for the belt drive must be installed so that it aligns exactly with the compressor module. "Fluttering" of the belt of the belt drive should be prevented with construction measures (axis spacing of pulleys, belt tension and stability of the base frame and tensioner).

5.5 Direct drive


Caution: Offset and angular errors result in damage to bearings and drive shaft! ROTORCOMP recommends installation with an elastic coupling. The alignment of the motor and compressor module must be carried out according to the instructions of the elastic coupling manufacturer. The compressor module is provided with a centering flange for directly coupled units. The flanged unit can be fastened stress-free on the base frame. The connection dimensions of the flange are contained in the offer drawing.

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ROTORCOMP VERDICHTER

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5.6 Air outlet


The pressure loss at the air outlet due to air aftercoolers, fittings, piping, etc.should be as small as possible.

5.7 Oil cooling

L Note:

L Note:

The cooler connection lines must be connected torque-free to the oil connections. The following information on the design and execution of the oil cooling system must be observed. The oil cooling system must be designed so that the oil outlet temperature is a maximum of 105C/220F at the maximum intended ambient temperature. The oil circulation quantity is dependent on the pressure difference between the outlet and the inlet pressure of your application. The oil cooler must be installed so that it can be cleaned easily.

Cross-sections of the outlet pipe must be generously dimensioned. Avoid pressure losses due to elbow screw fittings. The outlet pipe must be connected stress-free to the outlet.

d Warning:

Serious injuries and damage are possible in case of operation without a safety valve! Operation without a safety valve on the separator tank is not permitted.

5.8 Service
Ensure good accessibility to the service points when installing the compressor module in a housing: Oil filling point Oil drain point Removal of the separator cartridge (removal dimensions according to offer drawing) Removal of the oil filter cartridge (observe the removal dimensions specified in the offer drawing) Easy cleaning of the oil cooler Replacement of the shaft seal (removal and installation of the end cover and the bearing race) Belt drive (accessibility, specifications for correct belt tension)

L Note:

A possible compressed air temperature (at the outlet) of up to 110C/230F requires the components connected downstream, e.g. the compressed-air hose, pressure switch, air after-cooler, fittings, etc. to be designed for this temperature. We therefore recommend the installation of an air after-cooler. When used without an air after-cooler, the high outlet temperature must be pointed out to the final customer.

5.4

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Operating Manual - NK 60

Commissioning

6.2 Checking direction of rotation


Direction of rotation: Standard model rotating to the left (counterclockwise) looking at the shaft. Caution: The direction of rotation of the screw compressor must be checked during first commissioning and each time changes are made to the electrical supply line of the electric motor drive. For this purpose, switch on the drive motor briefly and then switch off again immediately. An incorrect direction of rotation for more than 2 seconds will result in destruction in the screw compressor. Reconnect the phases of the connection cable if necessary.

6.1 Preparation for commissioning


The components of the screw compressor are carefully checked and tested at the factory. These tests ensure that the required performance and checking data are complied with. Nevertheless, the screw compressor system should be observed during the initial operating hours. Caution: With regard to commissioning, the applicable regulations of the specific country must be observed. In Germany these include the Operating Safety Ordinance. The following points must be observed prior to first commissioning: Direction of rotation: be sure to observe (see chapter 6.2 "Checking direction of rotation"). The max. final pressure specified on the nameplate may not be exceeded. Do not switch off screw compressor systems running under load at the Emergency-Stop or main switch. Check the oil level (see chapter 7.2 "Oil level"). Before each first commissioning and when recommissioning after a longer shut-down of the screw compressor compact module, always carry out the activities described in chapter 6.4 "Recommissioning screw compressor system". With a belt drive: check the belt tension and belt routing (see chapter 7 "Maintenance"). Check the position of the shut-off valve. Check all screw fitting and fastening screws for firm seating.

6.3 Test run


Caution: The system is discharged extremely quickly down to the opening pressure "minimum pressure valve" in the Stop mode, "with shut-off valve opened"! This can result in the oil in the separating tank foaming up. The possible consequences include: Oil escaping with the discharge air Oil flooding the fine separator cartridges Compressed air containing oil when restarting the line Therefore, the following points must be observed during the test run: Only switch off the system with the shut-off valve closed! If possible, connect the system to a compressed-air reservoir!

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6.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

6.4 Recommissioning screw compressor system


Screw compressor systems switched off, shutdown or stored for longer than three months cannot be put into operation again until after the following measures have been carried out: Rotate the screw compressor in the direction of rotation several times by hand. With the screw compressor system at a complete stop, fill approx. 0.2 liters of oil (same oil type as in the oil separator tank) into the oil intake hole with a syringe. Rotate the screw compressor again in the direction of rotation several times by hand. Check the oil level in the separator tank and top up if necessary (see chapter 7 "Maintenance"). Test the running check function for the screw compressor system for at least 15 minutes.

d Warning:

The system may not be started with the feed chamber completely filled. There is a danger of considerable damage.

6.2

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Operating Manual - NK 60

Maintenance

7.1 Safety precautions


The owner must ensure that all maintenance, assembly and repair work is carried out by authorized, qualified, specially trained personnel, which has informed itself sufficiently in advance by studying the operating manual in detail. Following commissioning, the owner bears al responsibility and liability for equipment and assembly. Only use permissible or suitable tools for maintenance and repair work. Only use genuine spare parts. All maintenance and repair work must only be carried out with the machines shut down and the power supply switched off. In the process, the machine must be secured against accidental switch-on. Before removing pressurized parts, the unit must be effectively cut off from all pressure sources and a pressure relief of the entire system must be carried out. Never use flammable solvents or carbon tetrachloride to clean parts. Take precautions against toxic vapors or cleaning agents. Always ensure absolute cleanliness during maintenance and when conducting repair work. Keep dirt away from the system. Cover parts and exposed openings with a clean cloth, paper or strips of adhesive tape. Do not carry out welding work or any other work requiring or producing heat near the oil system. Make sure that no tools, loose parts or cleaning cloths are left behind in or on the system. Before releasing the unit for operation following maintenance or overhauling, check whether the operating pressures, temperatures, time settings and the oil level are correct, and whether the control and switch-off devices function properly. Electrical components, control devices, etc. must be protected against the penetration of moisture, e.g. from a steam jet.

d Warning: L Note:

During all maintenance work: ACCIDENT DANGER!

All maintenance work conducted must be entered immediately in the check sheet.

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7.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

7.2 Oil level


An important factor for the operating safety of the system is the oil level in the oil reservoir. The oil level check must be carried out before commissioning the screw compressor module and then repeated every 100 operating hours. There are two methods for performing the oil level check: Via the oil hose (option) Via the oil filler opening The exact oil level check can only be carried out via the oil filler opening.

7.2.2 Oil level check via oil filler opening

d Warning:

The unit parts, oil and oil filler plug 1 may be over 80C/176F; danger of burns! Wear personal safety equipment! With hot oil, the oil level can be approx. 10 mm higher than with cold oil shortly after discharging. As a result, oil may escape when the oil filler plug is opened at the maximum oil level. In this case, close the oil filler plug again immediately and carefully remove the oil which has escaped.

d Warning:

Rotating, pressurized and hot components, DANGER OF INJURY! 7.2.1 Oil level check via oil hose (option)

1 MAX MIN
MAX MIN

Figure 7-2

L Note:
Figure 7-1 The oil hose 1 is intended for an oil level check with the system running. If the oil level is correct at a standstill, the oil level must be within the imagined markings, i.e. the oil level is approximately equal to the oil level in the oil filler opening. With the system running, the oil level must be visible in the oil hose. If not, conduct an oil level check via the oil filler opening.

The screw cap of the oil filler neck is provided with a safety hole on the side from which oil or air escapes if there is any residual pressure in the separating tank. Wait briefly in this case.

Switch off the system and secure it against

unauthorized switch-on. Wait for one minute at standstill. Screw off the screw plug 1 of the filler neck by hand with the oil level depressurized. Check the oil level.

7.2

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Operating Manual - NK 60

If necessary, top up oil of the same oil type and


the same brand up to the maximum level.

7.3.2 Oil drain point The system should be at operating temperature in this case.

L Note:

The oil filler neck is positioned so that overfilling of the screw compressor system is not possible. Excess oil runs out of the filler neck again.

Screw on the screw plug 1 firmly by hand. Switch on the system. Check the oil filler plug for leaks and replace
the O-ring if necessary. Carefully remove escaped, excess oil.

7.3 Oil change

d Warning:

1
Figure 7-3

Rotating, pressurized and hot components, DANGER OF INJURY The oil change may only be carried out at a standstill and with the screw compressor system completely discharged. 7.3.1 Oil change intervals According to the specifications of the system manufacturer. For the reference values for the screw compressor compact module, see chapter 7.8 "Maintenance intervals".

L Note:

Dispose of the used oil according to the applicable regulations

Switch off the screw compressor and then

secure it against being switched on again by removing the main switch. Completely release the pressure in the screw compressor system. Slowly screw off the screw plug on the oil filler neck. Carefully unscrew the oil drain screw 1 and catch the used oil in a suitable container. Clean the oil drain screw 1 and screw in again.

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7.3

ROTORCOMP VERDICHTER

Operating Manual - NK 60

7.3.3 Filling with oil Caution: Observe the oil recommendation, see "Lubricants and Operating Materials". Add oil of the same oil type from the same manufacturer. Switching over to another oil type can require the compressor module to be flushed. ROTORCOMP recommends also replacing the oil filter during an oil change.

7.4.2 Oil filter replacement

2 1

Replace the oil filter if necessary Pour oil into the filler neck on the separator

tank up to the maximum level and screw the screw plug 1 onto the filler neck by hand (see Figure 7-2). Switch on the screw compressor and allow it to run for approx. three minutes. Oil level check: Top up the missing oil quantity again up to the maximum level. Check sheet entry (see chapter 7.7 "Maintenance check sheet").

Figure 7-4

Switch off the system and completely release

the pressure in the system. Remove the oil filter cartridge 1 with a suitable tool, e.g. oil filter strap wrench. Oil the gasket 2 on the new oil filter cartridge 1 with oil of the same oil type as in the compressor module.

7.4 Oil filter

d Warning:

L Note:

Rotating, pressurized and hot components, DANGER OF INJURY The unit parts, oil and oil filler plug may be over 80C/176F; danger of burns! Wear personal safety equipment! The oil filter replacement may only be carried out at a standstill and with the screw compressor system completely discharged. 7.4.1 Oil filter replacement intervals According to the specifications of the system manufacturer. For the reference values for the screw compressor compact module, see chapter 7.8 "Maintenance intervals".

Dispose of the old oil filter cartridge according to the applicable regulations

The new oil filter cartridge 1 must be held verti

cally and filled with oil of the same oil type as in the compressor module before screwing on. Screw the new oil filter cartridge onto the separator head 3 and tighten by hand. No tool is required. Switch on the screw compressor. The oil filter must then be checked for leaks with the system running. Oil level check: Top up the missing oil quantity again up to the maximum level. Check sheet entry (see chapter 7.7 "Maintenance check sheet").

7.4

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7.5 Fine separator cartridge

7.5.2 Replacing fine separator cartridge

d Warning:

Rotating, pressurized and hot components, DANGER OF INJURY The unit parts and oil may be over 80C/176F; danger of burns! Wear personal safety equipment! The fine separator cartridge may only be replaced at a standstill and with the screw compressor system completely discharged. 7.5.1 Maintenance intervals According to the specifications of the system manufacturer. For the reference values for the screw compressor compact module, see chapter 7.8 "Maintenance intervals". With heavily soiled intake air or a poor oil quality, the cartridge is heavily soiled, making premature replacement necessary.

Figure 7-5

L Note:

Dispose of the old fine separator cartridge according to the applicable regulations

Unscrew the fine separator cartridge 1 with a

suitable tool, e.g. oil filter strap wrench. Oil the gasket on the new fine separator cartridge 1 with oil of the same oil type as in the compressor module. Tighten the new fine separator cartridge by hand. No tool is required. Switch on the screw compressor system. The fine separator must be checked for leaks with the system running. Check sheet entry (see chapter 7.7 "Maintenance check sheet").

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7.5

ROTORCOMP VERDICHTER

Operating Manual - NK 60

7.6 Intake air filter


7.6.1 Maintenance intervals According to the specifications of the system manufacturer. For the reference values for the screw compressor compact module, see chapter 7.8 "Maintenance intervals". In case of heavily soiled intake air, an earlier replacement of the filter element is necessary when the optical or electric maintenance indicator (optional) indicates this (perm. vacuum up to 50 mbar). 7.6.2 Replacing air filter element

1 2

3
Figure 7-6 Caution: No dirt or dust particles may get into the air inlet of the screw compressor.

L Note:

It is not permissible to clean the filter element; the filter element must always be replaced in case of soiling! Dispose of the old air filter element according to the applicable regulations.

Switch off the system and secure it against


7.6

unauthorized switch-on. Screw off the wing nut 1 and remove the filter cover 2. Carefully remove dust from the filter housing. Remove the old filter element 3. Insert the new filter element in the filter housing. Lay on the filter cover, ensuring proper positioning during assembly. Tighten the wing nut. Switch on the screw compressor system. Conduct a test run and an operating test.
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Operating Manual - NK 60

7.7 Maintenance check sheet


Elapsed time meter reading Replace air intake filter Replace oil filter cartridge Replace oil fine separator cartridge Retension V-belts Replace V-belt set System repair Date Mechanic

Mark work carried out with an "X" or enter measured values and confirm with your signature.

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7.7

ROTORCOMP VERDICHTER

Operating Manual - NK 60

7.8 Maintenance intervals


Caution: The frequency of the maintenance intervals (oil change, replacement of oil filter, fine separator cartridge and air filter element) varies depending on the application and the operating parameters. Depending on the design of the system, maintenance interval should therefore be specified by the compressor manufacturer. These must be given priority. It is advisable to conclude a maintenance agreement. The following table provides an overview of the reference value for the NK 60 screw compressor module.

Maintenance intervals (Bh = operating hours) Before commissioning Once after 50 Bh

Maintenance work Check oil level in separator tank Check oil level in separator tank Tighten all screw pipe fittings and electrical screw terminal fittings; check all other connections for firm seating Check oil level in separator tank, top up in case of oil shortage Check maintenance indicator Replace fine separator cartridge Carry out oil change Replace oil filter Replace filter element in intake air filter Check system for leaks System inspection.

See chapter 7.2 7.2

Every 100 Bh

7.2

Every 1,000 - 6,000 Bh depending on application Recommendation: every 12 months

7.5.2 7.3 7.4.2 7.6.2

7.8

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Lubricants and Operating Materials Maintenance Parts

L Note:

See the information sheet! The requirements placed on the cooling oil in the screw compressor include the following: High resistance to aging High dispersive power Flash point: over 200C/392F Minimum foaming High corrosion protection Operating temperature: up to 110C/230F Select suitable viscosity class, e.g. ISO VG 68.

8.1 Lubricants and operating materials


8.1.1 Oil recommendation RC screw compressors must be operated with an oil suitable for special requirements. This oil must be approved by the manufacturer for screw compressors. It must even be suitable under unfavorable operating conditions, such as soiling of the intake air with gases, solvent vapors and exhaust gases and at high ambient temperatures. Suitable oil types and oil manufacturers can be specified for screw compressor on request. Refined oils (mineral oils) synthetic oils and bio oils (biodegradable) can be used as screw compressor oil. The materials and gaskets used in the screw compressor system must be taken into account when selecting the oil type. Corrosion and other material damage may not occur. It is not permissible to mix different oils. 8.1.2 Topping up oil Use the same manufacturer and the same oil type as is currently in use in the screw compressor. 8.1.3 Measures at low room temperature Sufficient room heating. At ambient temperatures below 0C/32F, the system must be heated up to at least 20C/68F before start-up with an integrated standstill heater. 8.1.4 Piping materials Plastic compressed-air piping systems can be attacked by the oil used in the screw compressor.

Caution: Be sure to comply with the oil viscosity, as otherwise there is a danger for the bearing service life.

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8.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

Figure 8-1 Pressure dew point graph 8.1.5 Pressure dew point of compressed air Example: 1*) Temperature of the intake air is 20C/68F, humidity is 50 %, resulting in an absolute humidity of approx. 8.6 g/m3 in the intake air. At a pressure of 10 bar, the pressure dew point is approx. 51C/124F. 2*) Temperature of the intake air is 40C/104F, humidity is 90 %, resulting in an absolute humidity of approx. 45.6 g/m3 in the intake air. At a pressure of 10 bar, the pressure dew point is approx. 92C/198F.

8.1.6 Temperatures

L Note:

The optimum operating temperatures for the screw compressor system can only be achieved if the oil circuit components (thermostat, cooler, fan, etc.) have been properly designed and the supply and exhaust air temperatures of the installation room and the compressor system make this possible. The entire thermal economy must be calculated. 8.1.7 Condensate damage The relative humidity and the final operating pressures must always be taken into account in accordance with the selection graph for the working temperature of the thermostat element and for the compressor operating temperature in order to prevent condensate from forming in the system. 8.1.8 Cold starts During compressor cold starts, the viscosity of the oil must enable the sufficient, immediate supply of the compressor with lubricant following starting while taking into account the higher pressure losses in the oil circulation which is still cold. The higher cold-starting power requirement must not overload the compressor drive.

8.2

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8.1.9 Oil separation The fine oil separation becomes poorer in the upper area with an increasing compressor outlet temperature. 8.1.10 Multigrade oil The use of multigrade oils can cause problems in the long run, as "viscosity improvers" used are destroyed over time. The oil is then no longer secured in the upper viscosity class and a thermal stability is no longer completely ensured. Therefore, multigrade oils are not approved for use in ROTORCOMP compressors.

Caution: Only use oils approved for screw compressors!

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8.3

ROTORCOMP VERDICHTER

Operating Manual - NK 60

8.4

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Operating Manual - NK 60

Technical Data and Tightening Torques

9.1 Technical data


Screw compressor model Max. operating gauge pressure. bar psi Max. delivered quantity according to DIN 1945 m3/min cfm Required output up to (full load without fan) Max. speed of main rotor Oil capacity, approx. Machine weight without oil, approx. kW hp rpm l kg lb Compressed-air connection Max. outlet temperature inch C F Max. room temperature C F NK 60 15 218 2.0 70 15 20 8,500 5 51 112 G " 110 230 45 115

L Note:

This sheet contains only general technical data for this screw compressor. The corresponding ROTORCOMP performance sheet applies for calculation, design and measurement. Technical data on the entire screw compressor system, drive motors, electrical system and accessory components in accordance with the corresponding data sheet of the manufacturer or supplier.

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9.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

9.2 Tightening torques


Caution: The maximum permissible tightening torque for all screw connections may not be exceeded. VDI 2230 Unless otherwise specified, the following torques must be used. Always tighten screws/bolts with a torque wrench.

Screw/bolt type Hexagonal head bolts Allen screws Hexagonal head bolts Allen screws Hexagonal head bolts Allen screws Hexagonal head bolts Allen screws Hexagonal head bolts Allen screws Hexagonal head bolts Allen screws

Thread M6 M8 M 10 M 12 M 14 M 16

Max. torque 10 Nm (7 ft.lbs) 25 Nm (18 ft.lbs) 43 Nm (32 ft.lbs) 75 Nm (53 ft.lbs) 120 Nm (85 ft.lbs) 180 Nm (126 ft.lbs)

9.2

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10 Troubleshooting
Fault Incorrect direction of rotation System does not start Possible cause Phases reversed No electricity Combistat switches off due to excessively high temperature System difficult to start Motor output insufficient Drive gear ratio "too fast" Star-delta switchover incorrect Compressor is flooded with oil System has not been discharged yet Oil filling too viscous Differential pressure Pressure in separator cartridge too high with clogged or full separator cartridge Oil shortage Remedy Reconnect 2 supply lines Check Check oil level, cooling, thermo-bypass Check Check Set Check Check Check viscosity Replace separator cartridge 8.1.1 7.5.2 See chapter

Combistat switches off due to excessively high temperature

Check oil level in oil reservoir and top up if necessary Replace oil filter cartridge Replace thermostat Clean oil cooler on air side, clean on oil side if necessary Observe recommendation on installing system

7.2

Oil filter soiled Thermostat defective Oil cooler soiled

7.4.2 3.11.2

Incorrect installation a) Room ventilation b) Exhaust air blocked c) Thermal short circuit Combistat faulty or incorrectly adjusted Fan has failed

5.3

Adjust combistat or replace Check

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10.1

ROTORCOMP VERDICHTER

Operating Manual - NK 60

Fault Safety valve blows off

Possible cause Safety valve defective Fine separator cartridge soiled System does not relieve Continuous operation System does not switch off automatically (drop-out mode)

Remedy Replace safety valve Replace cartridge

See chapter

7.5.2

Oil in compressed air

Oil extraction line with nozzle in oil sight glass soiled SA Fine separator cartridge defective Oil level in oil reservoir too high; possibly excessive condensate

Clean oil extraction system

Check cartridge and replace if necessary Observe oil level marking; drain and replace if necessary Readjust network pressure monitor Replace solenoid valve/ relief valve Check minimum pressure valve for smooth movement; ensure smooth movement if necessary Replace solenoid valve/ relief valve Eliminate break Replace filter insert Check oil level and top up if necessary Check control valve Check, seal off

7.5.2 7.2

System is not discharged during continuous operation, system does not switch off automatically in case of intermittent operation, i.e. safety valve blows off

Upper switching point of network pressure monitor set too high Solenoid valve defective Relief valve defective Minimum pressure valve jammed

System continually discharges, low feed quantity

Solenoid valve defective Relief valve defective Break in electric supply line to solenoid valve Intake filter soiled Oil shortage Intake control valve does not open Leaks in system

No or insufficient feed quantity

7.6.2 7.2

10.2

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Operating Manual - NK 60

Fault Control valve does not close Oil exits through intake control valve during stop

Possible cause Pressure switch, or control valve Sealing surface on intake control valve damaged, spring in intake control valve broken Solenoid valve/electrical system Impulse-pressure relief valve

Remedy Check setting Check parts and replace if necessary

See chapter

System does not relieve

Check Check and replace parts if necessary Check Oil change Install discharge delay valve, replace with different nozzle diameter Drain off oil 7.2 7.3

Control valve constantly discharges Oil escapes during discharging (oil foam in fine separator cartridge)

Solenoid valve/electrical system Oil type incorrect Oil foam forms during stop

Oil level too high

[en] 09/2008

10.3

ROTORCOMP VERDICHTER

Operating Manual - NK 60

10.4

[en] 09/2008

ROTORCOMP VERDICHTER GmbH


Industriestrae 9 82110 Germering Germany Tel.: +49 89 724 09-0 Fax: +49 89 724 09-38 info@rotorcomp.de www.rotorcomp.de

A member of BAUER GROUP

Ersatzteilliste mit Wartungsstzen


Spare parts list with maintenance kits Version - electric / pneumatic

Ausfhrung - elektrisch / pneumatisch NK 60

[de/en] 11/2008

Copyright ROTORCOMP VERDICHTER GmbH, 2008 Alle Rechte vorbehalten. ber das durch die Urheberrechtsgesetze erlaubte Ma hinaus sind keine Vervielfltigung, Anpassung oder bersetzung ohne vorherige schriftliche Genehmigung gestattet. Die in diesem Dokument enthaltenen Informationen knnen ohne vorherige Ankndigung gendert werden. Diese Unterlage unterliegt nicht dem nderungsdienst.

All rights reserved. Over the reproduction permitted through the copyright laws duplication, adaptation or translation without prior written permission is not allowable. The information in this document can be changed without notice. No update service for this document.
Printed in Germany

ROTORCOMP VERDICHTER GmbH Industriestrae 9 82110 Germering, Germany

Ersatzteilliste - NK 60

Inhaltsverzeichnis Table of contents


Filter Filter Filter Filter Komponenten Components Komponenten Components mit elektrische Steuereinheit ............................................................................................... 4 with Control Block Electric .......................................................................................................4 mit pneumatische Steuereinheit .......................................................................................... 6 with Control Block Pneumatic ..................................................................................................6 mit elektrische Steuereinheit ............................................................................................... 8 with Control Block Electric .......................................................................................................8 mit pneumatische Steuereinheit ........................................................................................ 10 with Control Block Pneumatic ................................................................................................10

Wartungssatz Lagerung, Wellendichtungssatz .............................................................................................. 12 Maintenance Kit Bearing and Shaft Sealing ........................................................................................................12 Wartungssatz Lagerung, Wellendichtungssatz .............................................................................................. 14 Maintenance Kit Bearing and Shaft Sealing ........................................................................................................14 Wartungssatz Ansaugventil, elektrische Steuereinheit ................................................................................. 16 Maintenance Kit Intake Valve, Control Block Electric .......................................................................................... 16 Wartungssatz Ansaugventil, pneumatische Steuereinheit ............................................................................ 18 Maintenance Kit Intake Valve, Control Block Pneumatic ......................................................................................18 Wartungssatz Abscheiderkopf ......................................................................................................................... 20 Maintenance Kit Separator head ..........................................................................................................................20 Einzelteile Single Parts Einzelteile Single Parts Einzelteile Single Parts Einzelteile Single Parts Einzelteile Single Parts Basismodul und Stirndeckel .............................................................................................. 22 Basic Module and Front Cover ..............................................................................................22 Abscheiderkopf, Druckhalteventil und lfilter ................................................................. 26 Separator head, Pressure valve and Oil filter ........................................................................26 Ansaugventil mit elektrische Steuereinheit...................................................................... 30 Intake valve with Control Block Electric .................................................................................30 pneumatische Steuereinheit .............................................................................................. 34 Control Block Pneumatic .......................................................................................................34 Ansaugregler fr pneumatische Steuereinheit ................................................................ 38 Intake Valve for Control Block Pneumatic .............................................................................38

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ROTORCOMP VERDICHTER

Ersatzteilliste - NK 60

Wichtige Hinweise fr den Benutzer Important recommendations for the user


Zur ordnungsgemen Bearbeitung Ihres Auftrages, bitten wir um Angabe der vollstndigen Bestelldetails. Ein Bestellvordruck steht Ihnen am Ende dieses Dokumentes zur Verfgung. To provide you with an accurate processing of your order, we appreciate it if you could supply us all the necessary information. A spare parts order form is available at the end of this document.

Erluterungen zum Aufbau und Symbolerklrung


Symbole 1 A [23] Definition Positionsnummer Markierung mit Buchstabe oder Zahl Position in eckigen Klammern Erklrung Einzelteil mit Positionsnummer Baugruppe oder Wartungssatz Nicht dargestellt in der Zeichnung

Structure of spare parts list and symbols


Symbols 1 A [23] Definition Position number Index with letter or cipher Position number with brackets Explanation part with position number assembly group or maintenance kit not shown in drawing

Beispiel/Example:
Pos. Pos. 11 A [13] Teilenummer Part number N17751 101104 102017 Benennung deutsch Erforderliche Stckzahl fr die Baugruppe Qty. Required for this Description german assembly group 2 1 1 Zylinderschraube Wartungssatz Dichtmittel Benennung englisch Description english Cylinder head screw Maintenance kit Silicone Bemerkungen Comments Neue Version New version

Adressfeld fr Rotorcomp-Vertriebspartner

ii

[de/en] 11/2008

Ersatzteilliste - NK 60

Schraubenverdichter Kompakt-Modul NK 60 / Screw compressor compact module NK 60 (elektrische Steuereinheit) / (electrical control block) 1 2

20 4 19 5 6 18 7 8

17

16

15

14

13 12

11 10

1. Luftentlelement 2. Wartungsanzeiger fr Ansaugfilter (optional) 3. Ansaugventil mit Luftfilter 4. Steuereinheit, elektrisch 5. Typenschild 6. leinfllffnung 7. berwachung lstand (optional) 8. lablassschraube 9. Rcklauf labscheidung 10. Abscheiderkopf 11. lkreislauf/Aus 12. Mindestdruckhalteventil 13. Druckluftauslass 14. lfilter 15. lkreislauf/Ein 16. Anschluss Temperaturfhler 17. Sicherheitsventil (optional) 18. NK 60 Basismodul 19. Antriebswelle 20. Stirndeckel

1. Separator cartridge 2. Maintenance indicator (optical) 3. Intake valve with intake filter unit 4. Control block, electric 5. Type plate 6. Oil filling screw 7. Oil Level monitoring (optical) 8. Oil drain screw 9. Oil feedback 10. Separator head 11. Oil circuit/out 12. Minimum pressure valve 13. Compressed air outlet 14. Oil filter 15. Oil circuit/in 16. Temperature probe connection 17. Safety valve (optical) 18. NK 60 basic module 19. Drive shaft 20. Front cover

[de/en] 11/2008

ROTORCOMP VERDICHTER

Ersatzteilliste - NK 60

[de/en] 11/2008

Ersatzteilliste - NK 60

Schraubenverdichter Kompakt-Modul NK 60 / Screw compressor compact module NK 60 (pneumatische Steuereinheit) / (pneumatic control block) 1 2

4 21 20 6 19 7 8 9 18 17 16 15 14 13 12 11 10 5

1. Luftentlelement 2. Wartungsanzeiger fr Ansaugfilter (optional) 3. Luftfilter 4. Ansaugregler 5. Steuereinheit, pneumatisch 6. Typenschild 7. leinfllffnung 8. berwachung lstand (optional) 9. lablassschraube 10. Rcklauf labscheidung 11. Abscheiderkopf 12. lkreislauf/Aus 13. Mindestdruckhalteventil 14. Druckluftauslass 15. lfilter 16. lkreislauf/Ein 17. Anschluss Temperaturfhler 18. Sicherheitsventil (optional) 19. NK 60 Basismodul 20. Antriebswelle 21. Stirndeckel

1. Separator cartridge 2. Maintenance indicator (optical) 3. Filter unit 4. Intake Valve 5. Control block, pneumatic 6. Type plate 7. Oil filling screw 8. Oil Level monitoring (optical) 9. Oil drain screw 10. Oil feedback 11. Separator head 12. Oil circuit/out 13. Minimum pressure valve 14. Compressed air outlet 15. Oil filter 16. Oil circuit/in 17. Temperature probe connection 18. Safety valve (optical) 19. NK 60 basic module 20. Drive shaft 21. Front cover

[de/en] 11/2008

Bild Figure

F Filter F Filter

mit elektrische Steuereinheit with Control Block Electric

4
[de/en] 11/2008

ROTORCOMP VERDICHTER

Ersatzteilliste Verdichter - NK 60

Bezug Bild / Reference Figure F


Pos. Item 1 2 3 Best.-Nr. Part No. 85483 102979 84606 Stck Qty 1 1 1 Benennung Luftentlelement lfilter Luftfilterpatrone Description Separator cartridge Oil filter Intake filter cartridge Bemerkung Comments alternativ 112476 alternative 112476

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

Bild Figure

FP Filter FP Filter

mit pneumatische Steuereinheit with Control Block Pneumatic

6
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ROTORCOMP VERDICHTER

Ersatzteilliste Verdichter - NK 60

Bezug Bild / Reference Figure FP


Pos. Item 1 2 3 Best.-Nr. Part No. 85483 102979 84605 Stck Qty 1 1 1 Benennung Luftentlelement lfilter Luftfilterpatrone Description Separator cartridge Oil filter Intake filter cartridge Bemerkung Comments alternativ 112476 alternative 112476

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

Bild Figure

K Komponenten K Components

mit elektrische Steuereinheit with Control Block Electric

8
[de/en] 11/2008

ROTORCOMP VERDICHTER

7c 3

5 4

2 7a

1
Ersatzteilliste Verdichter - NK 60

7b

Bezug Bild / Reference Figure K


Pos. Item 1 2 3 4 5 6 113879-KD 120070-KD 85483 102979 7 7a 7b 7c 110596 109954 Best.-Nr. Part No. 110582 111323 109566-KD 85461 Stck Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Stirndeckel Luftfilter elektrisch Ansaugventil kpl. Steuereinheit elektrisch Abscheiderkopf kpl. Abscheiderkopf Standard Abscheiderkopf mit lrcklaufkontrolle Luftentlelement lfilter Zubehr Sicherheitsventil berwachung lstand Wartungsanzeiger, optisch Benennung Basismodul kpl. Description Basic module cpl. Front cover Intake filter, electric Intake valve cpl. Control block, electric Pressure valve cpl. Pressure valve basic version Pressure valve with Oil return control Separator cartridge Oil filter Accessory parts Safety valve Oil Level monitoring Maintenance indicator, optical optional siehe Seite 25 see page 25 Variantenstckliste Versions Parts List Variantenstckliste Versions Parts List alternativ 112476 alternative 112476 siehe Seite 31 see page 31 Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

Bild Figure

KP Komponenten KP Components

mit pneumatische Steuereinheit with Control Block Pneumatic

10
[de/en] 11/2008

ROTORCOMP VERDICHTER

7c 3

5 2 7a

1
Ersatzteilliste Verdichter - NK 60

7b

Bezug Bild / Reference Figure KP


Pos. Item 1 2 3 4 5 6 113879-KD 120070-KD 85483 102979 7 7a 7b 7c 110596 109954 Best.-Nr. Part No. 110582 111323 102909 103505 103762 1 1 1 1 1 1 1 1 1 Stck Qty 1 1 1 1 Stirndeckel Luftfilter pneumatisch Ansaugventil kpl. Steuereinheit pneumatisch Abscheiderkopf kpl. Abscheiderkopf Standard Abscheiderkopf mit lrcklaufkontrolle Luftentlelement lfilter Zubehr Sicherheitsventil berwachung lstand Wartungsanzeiger, optisch Benennung Basismodul kpl. Description Basic module cpl. Front cover Intake filter, pneumatic Intake valve cpl. Control block, pneumatic Pressure valve cpl. Pressure valve basic version Pressure valve with Oil return control Separator cartridge Oil filter Accessory parts Safety valve Oil Level monitoring Maintenance indicator, optical optional siehe Seite 25 see page 25 alternativ 112476 alternative 112476 Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

11

Bild Figure

WL Wartungssatz Lagerung, Wellendichtungssatz WL Maintenance Kit Bearing and Shaft Sealing

Bestell-Nr.: 87530, 115611, 87534 Part-No 87530, 115611, 87534

12
[de/en] 11/2008

ROTORCOMP VERDICHTER

9 8 10 B 6 7 11

Ersatzteilliste Verdichter - NK 60

2 1

4 5

Bezug Bild / Reference Figure WL


Pos. Item Best.-Nr. Part No. 87530 Stck Qty 1 Benennung Wartungssatz Lagerung und Wellendichtungssatz Wartungssatz Lagerung Wellenmutter Wellenmutter Kegelrollenlager Kegelrollenlager O-Ring Nadellager Nadellager Montagematerial Wellendichtungssatz Standard Innenring O-Ring Wellendichtring Passscheibe Montagebuchse Dichtmittel Description Maintenance Kit Bearing and Shaft Sealing Maintenance Kit Bearing Shaft nut Shaft nut Taper roller bearing Taper roller bearing O-ring Needle bearing Needle bearing Installation material Maintenance Kit Shaft Sealing Basic version Inner ring O-ring Shaft sealing ring Shim ring Bush Silicone Bemerkung Comments 87534 + 115611

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
1 2 3 4 5 6 7 [12]

87534 101716 101717 101715 101714 111349 101008 101007 112188 115611 105295 113878 107917 111292 105640 102017

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

B
8 9 10 11 [13] [14]

13

Bild Figure

WL Wartungssatz Lagerung, Wellendichtungssatz WL Maintenance Kit Bearing and Shaft Sealing

Bestell-Nr.: 87509 Part-No 87509

14
[de/en] 11/2008

ROTORCOMP VERDICHTER

9 8 10 B 6 7 11

Ersatzteilliste Verdichter - NK 60

2 1

4 5

Bezug Bild / Reference Figure WL


Pos. Item Best.-Nr. Part No. 87509 105295 113878 110765 110753 105640 102017 Stck Qty 1 1 1 1 1 1 1 Benennung Wellendichtungssatz Staubschutz Innenring O-Ring Wellendichtring doppellippig Passscheibe Montagebuchse Dichtmittel Description Maintenance Kit Shaft Sealing Dust Cover Inner ring O-ring Shaft sealing ring double lip Shim ring Bush Silicone Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

[B]
8 9 10 11 [13] [14]

15

Bild Figure

WE Wartungssatz Ansaugventil, elektrische Steuereinheit Bestell-Nr.: 113606 WE Maintenance Kit Intake Valve, Control Block Electric Part-No 113606

16
[de/en] 11/2008

ROTORCOMP VERDICHTER

1 2 3 4 A

Ersatzteilliste Verdichter - NK 60

5 6 7 8

Bezug Bild / Reference Figure WE


Pos. Item Best.-Nr. Part No. 113606 113017 107447 110800 107625 109212 89760 85322 100571 Stck Qty 1 1 1 1 1 1 1 1 1 Benennung Wartungssatz Ansaugventil, elektrische Steuereinheit Kegelfeder Kegelfeder Kolben kpl. V-Ring O-Ring Ventilteller Gewicht O-Ring Description Maintenance Kit Intake Valve, Control Block Electric Conical spring Conical spring Piston cpl. V-ring O-ring Valve head Weight O-ring Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
1 2 3 4 5 6 7 8

17

Bild Figure

WP Wartungssatz Ansaugventil, pneumatische Steuereinheit Bestell-Nr.: 113604 WP Maintenance Kit Intake Valve, Control Block Pneumatic Part-No 113604

18
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ROTORCOMP VERDICHTER

A 14 9 10 15 16 11 7 1 6 5 8 13 12 17

Ersatzteilliste Verdichter - NK 60

Bezug Bild / Reference Figure WP


Pos. Item Best.-Nr. Part No. 113604 103779 102932 N15688 102815 102493 102527 102933 113778 104849 102373 107316 100837 102389 111366 102390 102067 102068 Stck Qty 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 Benennung Wartungssatz Ansaugventil, pneumatische Steuereinheit Flachdichtung Stufenkolben kpl. Verschluschraube Flachdichtung Flachdichtung Ventilplatte Membrane Dichtring Ventilsitz O-Ring Ventilteller Druckfeder Flachdichtung Kolben kpl. Flachdichtung O-Ring O-Ring Description Maintenance Kit Intake Valve, Control Block Pneumatic Gasket Stepped piston cpl. Plug bold Gasket Gasket Valve plate Diaphragm Sealing ring Valve seat O-ring Valve head Pressure spring Gasket Piston cpl. Gasket O-ring O-ring Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

19

Bild Figure

AS Wartungssatz Abscheiderkopf AS Maintenance Kit Separator head

Bestell-Nr.: 114330 Part-No 114330

20
[de/en] 11/2008

ROTORCOMP VERDICHTER

1 2 A 3 4 5 6 7 A

Ersatzteilliste Verdichter - NK 60

Bezug Bild / Reference Figure AS


Pos. Item Best.-Nr. Part No. 114330 107837 107447 107836 107582 104190 107581 111294 113946 Stck Qty 1 1 1 1 1 1 1 1 1 Benennung Wartungssatz Abscheiderkopf Standardausfhrung Ventilteller Kegelfeder Kolben mit O-Ring Druckfeder O-Ring O-Ring lrcklaufschlauch mit 1,0 mm Dse Dichtung Description Maintenance Kit Separator head basic version Valve head Conical spring Piston with O-ring Pressure spring O-ring O-ring Oil feedback pipe with 1,0 mm nozzle Seal Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
1 2 3 4 5 6 7 8

21

Bild Figure

E Einzelteile E Single Parts

Basismodul und Stirndeckel Basic Module and Front Cover

22
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ROTORCOMP VERDICHTER

24 26 23 25

27

28

29

30

31 32 33

22 18 16 14 15 19 20

35

36 34 38 22 23 37

12

15

17 21 22 23 41 40 39
Ersatzteilliste Verdichter - NK 60

9 8 7

10 11 13

6 2

Bezug Bild / Reference Figure E


Pos. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Best.-Nr. Part No. N61 N7171 N314 114268 113779 109174 N19549 101716 101717 101715 101714 113875 111349 109486 109201 113873 113872 103622 101008 101007 113871 N7171 N15688 Stck Qty 12 1 1 2 2 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 3 3 Dichtring Verschluschraube Zylinderschraube Dichtring Ring Zylinderschraube Nutmutter Mutter Kegelrollenlager Kegelrollenlager Lagerdeckel O-Ring Rotor, Paar B60/NK60 Innenring Ring/weiblich Ring/mnnlich Passfeder Nadellager Nadellager Verdichtergehuse Dichtring Verschluschraube Benennung Zylinderschraube Description Cylinder head screw Sealing ring Plug bold Cylinder head screw Sealing ring Ring Cylinder head screw Slotted round nut Nut Taper roller bearing Taper roller bearing Bearing cover O-ring Rotor, pair B60/NK60 Inner ring Ring/female Ring/male Key Needle bearing Needle bearing Housing Sealing ring Plug bold Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

23

Bild Figure

E Einzelteile E Single Parts

Basismodul und Stirndeckel Basic Module and Front Cover

24
[de/en] 11/2008

ROTORCOMP VERDICHTER

24 26 23 25

27

28

29

30

31 32 33

22 18 16 14 15 19 20

35

36 34 38 22 23 37

12

15

17 21 22 23 41 40 39
Ersatzteilliste Verdichter - NK 60

9 8 7

10 11 13

6 2

Bezug Bild / Reference Figure E


Pos. Item 24 100330 100331 100332 N7171 25 26 27 28 29 105295 113878 115374 N171 111292 110793 30 31 103632 107917 110765 32 33 34 35 36 37 38 39 40 41 109182 115100 115068 114898 103620 N314 N7171 110596 N7171 N314 Best.-Nr. Part No. Stck Qty 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 Benennung Sicherheitsventil Variantenstckliste Sicherheitsventil, 1/2, 8,5 bar Sicherheitsventil, 1/2, 11,5 bar Sicherheitsventil, 1/2, 14,5 bar Dichtring Innenring O-Ring Stirndeckel Zylinderschraube Passscheibe 50x62x1,8 Stirndeckel Standard Passscheibe 50x62x1,5 Stirndeckel WDR doppellippig Sicherungsring Wellendichtring 40x62x8 Standard Wellendichtring 40x62x8,5 doppellippig Dse 1,5 mm Verschlussschraube Dichtring Typschild Halbrundkerbnagel Verschlussschraube Dichtring berwachung lstand Dichtring Verschlussschraube Description Versions Parts List Safety valve Safety valve, 1/2, 8.5 bar Safety valve, 1/2, 11.5 bar Safety valve, 1/2, 14.5 bar Sealing ring Inner ring O-ring Front cover Cylinder head screw Shim ring basic version Shim ring Front cover shaft sending ring double lip Retaining ring Shaft sealing ring 40x62x8 basic version Shaft sealing ring 40x62x8,5 double lip Nozzle 1,5 mm Locking screw Sealing Ring Name plate Pin Locking screw Sealing Ring Oil level device Sealing Ring Locking screw Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

25

Bild Figure

AD Abscheiderkopf, Druckhalteventil und lfilter AD Separator head, Pressure valve and Oil filter

Bestell-Nr.: 113879-KD, 120070-KD Part-No 113879-KD, 120070-KD

26
[de/en] 11/2008

ROTORCOMP VERDICHTER

1 22 21 23 24

25 26

2 6

4 5 20

27

7 3 8 9 10 11 13 14 B 15 16 17

28 19 31 30 32 18 A 35 34 B 33 36 29
Ersatzteilliste Verdichter - NK 60

12

Bezug Bild / Reference Figure AD


Pos. Item Best.-Nr. Part No. 113879 - KD 120070 - KD 85483 106238 109180 115880 107516 107837 107447 107836 107516 107582 107493 104190 107581 107585 110805 115060 N57 102979 106366 N20003 N61 113930 103620 Stck Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 1 2 Benennung Abscheiderkopf Standard kpl. mit DHV und Filtern Abscheiderkopf mit lrcklaufkontrolle kpl. mit DHV und Filtern Luftentlelement Absaugrohr Doppelnippel Buchse O-Ring Ventilteller Feder Kolben O-Ring Druckfeder Federfhrung O-Ring O-Ring Verschraubung Gewindestift kpl. Gewindestift Sechskantmutter lfilter Verschraubung W-Einschraubstutzen Zylinderschraube Gehuse Halbrundkerbnagel Description Separator head basic version cpl. Separator head with oil return control Separator cartridge Suction pipe Double nipple Bushing O-ring Valve head Spring Piston O-ring Pressure spring Spring guide O-ring O-ring Screw connection Grub screw cpl. Grub screw Hexagon nut Oil filter Screw connection Elbow fitting Cylinder head screw Housing Pin Bemerkung Comments Pos/Item (1 - 31) + 32 ohne/without 18 Pos/Item (1 - 31) + (33 - 36) ohne/without 18 alternativ 112476 alternative 112476

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

27

Bild Figure

AD Abscheiderkopf, Druckhalteventil und lfilter AD Separator head, Pressure valve and Oil filter

Bestell-Nr.: 113879-KD, 120070-KD Part-No 113879-KD, 120070-KD

28
[de/en] 11/2008

ROTORCOMP VERDICHTER

1 22 21 23 24

25 26

2 6

4 5 20

27

7 3 8 9 10 11 13 14 B 15 16 17

28 19 31 30 32 18 A 35 34 B 33 36 29
Ersatzteilliste Verdichter - NK 60

12

Bezug Bild / Reference Figure AD


Pos. Item 24 25 26 27 28 29 30 31 Best.-Nr. Part No. 111213 113946 103663 N20237 N108 N57 N15688 113778 Stck Qty 1 1 1 1 1 1 1 1 Ventilplatte Flachdichtung Stiftschraube G-Einschraubstutzen Federring Sechskantmutter Verschlussschraube Dichtring Benennung Valve platte Sealing Stud bolt Connecting fitting Washer lock Hexagon nut Locking screw Sealing Ring Description Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
32 111294 110807 111525 N20405 103508 111524 1 1 1 1 1 1 lrcklaufschlauch mit 1,0 mm Dse lrcklaufkontrolle kpl. Rohr G-Aufschraubstutzen lrcklaufkontrolle Rohr Oil feeedback pipe with 1,0 mm nozzle Oil return control cpl. Pipe Connecting fitting Oil return control Pipe fr/for 113879 - KD fr/for 120070 - KD fr/for 120070 - KD fr/for 120070 - KD fr/for 120070 - KD fr/for 120070 - KD

B
33 34 35 36

29

Bild Figure

AV Einzelteile AV Single Parts

Ansaugventil mit elektrischer Steuereinheit Intake valve with Control Block Electric

30
[de/en] 11/2008

ROTORCOMP VERDICHTER

29 5 6 B 7 4 3 A 2 11 12 8 13 14 16 17 1 C 20 21 18 19 33 10 31 9 30

15 32 D

Ersatzteilliste Verdichter - NK 60

22 26 27 28 23 24 25

Bezug Bild / Reference Figure AV


Pos. Item Best.-Nr. Part No. Stck Qty 1 115497 114116 115498 115659 115660 115661 115662 115663 115664 85459 110638 103616 84684 104513 85730 N16543 85496 N15786 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 3 1 1 Benennung Steuereinheit elektrisch kpl. G-Aufschraubverschraubung Schlauch Dichtring Magnetventil Variantenstckliste 3/2-Wege-Magnetventil 12 V DC 3/2-Wege-Magnetventil 230 V AC 3/2-Wege-Magnetventil 110 V AC 3/2-Wege-Magnetventil 24 V AC 3/2-Wege-Magnetventil 48 V AC 3/2-Wege-Magnetventil 24 V DC Flansch kpl. O-Ring Zylinderschraube Flansch O-Ring Ansaugventil kpl. Zylinderschraube Deckel Luftfilterpatrone Description Control block, electric cpl. Straight union Tube Sealing Ring Versions Parts List Solenoid valve Solenoid valve 3/2-way 12 V DC Solenoid valve 3/2-way 230V AC Solenoid valve 3/2-way 110V AC Solenoid valve 3/2-way 24 V AC Solenoid valve 3/2-way 48V AC Solenoid valve 3/2-way 24 V DC Flange cpl. O-ring Cylinder head screw Flange O-ring Intake valve cpl. Cylinder head screw Cover Intake filter cartridge Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
1 2 3 4

B
5 6 7 8

C
9 10 11

31

Bild Figure

AV Einzelteile AV Single Parts

Ansaugventil mit elektrische Steuereinheit Intake valve with Control Block Electric

32
[de/en] 11/2008

ROTORCOMP VERDICHTER

29 5 6 B 7 4 3 A 2 11 12 8 13 14 16 17 1 C 20 21 18 19 33 10 31 9 30

15 32 D

Ersatzteilliste Verdichter - NK 60

22 26 27 28 23 24 25

Bezug Bild / Reference Figure AV


Pos. Item 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Best.-Nr. Part No. 113018 113017 103549 112996 107447 110800 100840 107625 110977 111374 109212 115465 89760 85322 85323 100571 115464 109954 109566-KD 109915 109640 84606 109568 Stck Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Federfhrung Feder Sechskantmutter Federfhrung Feder Kolben kpl. Dichtung V-Ring Dse Reglergehuse O-Ring Sicherungsscheibe Ventilteller Gewicht Tellersatz O-Ring Reglerstange Wartungsanzeiger, optisch Luftfilter elektrisch Flgelmutter Deckel Luftfilterpatrone Unterteil O-ring Control linkage Maintenance indicator, optical Intake filter, electric Wing nut Cover Intake filter cartridge Bottom Benennung Spring guide Spring Hexagon nut Spring guide Spring Piston cpl. Sealing V-ring Nozzle Governor housing O-ring Lock washer Valve head Weight Description Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

D
30 31 32 33

33

Bild Figure

PS Einzelteile PS Single Parts

pneumatische Steuereinheit Control Block Pneumatic

34
[de/en] 11/2008

ROTORCOMP VERDICHTER

4 1

2 3 9 20 21 22

7 8 13

14

15

10 11 12 38 37 24

39

19 19

17 18

16

23

36 25 26 27 28 35 45

29 32 33

34

Ersatzteilliste Verdichter - NK 60

30

31

43 41 42 44

40

Bezug Bild / Reference Figure PS


Pos. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Best.-Nr. Part No. N19498 N19532 102502 N287 102057 102503 102526 102933 102060 102062 102061 102064 102494 102501 N2773 N7430 N3663 N4530 N20237 N19528 102514 103779 102510 102932 102491 104652 105084 Stck Qty 1 4 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 2 4 1 1 1 1 1 1 1 Benennung Sechskantschraube Zylinderschraube Deckel Sechskantmutter Federfhrung Druckfeder Hlse Membrane Membrane Membrane Stift Ventilplatte Ventilgeuse Dse 0,8 Zylinderschraube berwurfmutter Schneidring Verschlustopfen G-Einschraubstutzen Zylinderschraube Platte Flachdichtung Deckel Stufenkolben kpl. Dichtung Kolben Dichtring Description Hexagon head screw Cylinder head screw Cover Hexagon nut Spring guide Pressure spring Sleeve Diaphragm Diaphragm Diaphragm Pin Valve plate Valve housing Nozzle 8,0 Cylinder head screw Retainer nut Cutting ring Plug Connecting fitting Cylinder head screw Platte Gasket Cover Stepped piston cpl. Sealing Piston Sealing ring Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

35

Bild Figure

PS Einzelteile PS Single Parts

pneumatische Steuereinheit Control Block Pneumatic

36
[de/en] 11/2008

ROTORCOMP VERDICHTER

4 1

2 3 9 20 21 22

7 8 13

14

15

10 11 12 38 37 24

39

19 19

17 18

16

23

36 25 26 27 28 35 45

29 32 33

34

Ersatzteilliste Verdichter - NK 60

30

31

43 41 42 44

40

Bezug Bild / Reference Figure PS


Pos. Item 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Best.-Nr. Part No. 102491 102513 N15688 113778 N2773 102509 N20211 102815 102493 102527 103522 104286 N20003 106699 113778 111269 N20211 111269 Stck Qty 1 1 1 1 3 1 1 2 2 1 1 2 1 1 1 1 1 1 Dichtung Ventilsitz Verschluschraube Dichtring Zylinderschraube Ventilgehuse G-Einschraubstutzen Flachdichtung Flachdichtung Ventilplatte Ventilplatte Zylinderschraube W-Einschraubstutzen Verschraubung Dichtring Schlauch mit Verschraubung G-Einschraubstutzen Schlauch mit Verschraubung Benennung Sealing Valve seat Plug bold Sealing Ring Cylinder head screw Valve housing Connecting fitting Gasket Gasket Valve plate Valve plate Cylinder head screw Elbow fitting Screw connection Sealing Ring Tube with fitting Connecting fitting Tube with fitting Description Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

37

Bild Figure

AP Einzelteile AP Single Parts

Ansaugregler fr pneumatische Steuereinheit Intake Valve for Control Block Pneumatic

38
[de/en] 11/2008

ROTORCOMP VERDICHTER

38 37 1 2 9 3 4 5 6 7 8 10 11 12 13 14 16 17 18 20 21 14 13 15 22 35 A 36

Ersatzteilliste Verdichter - NK 60

25 19 23 24 26 27 28 29 30 31 32 33 34

Bezug Bild / Reference Figure AP


Pos. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Best.-Nr. Part No. N19540 N15688 113778 N19534 102308 N57 103580 103663 104849 100200 102373 102301 113778 N15688 102389 107316 100837 105312 111366 109483 100840 100840 102390 102293 N2773 102067 102382 Stck Qty 2 1 1 1 1 4 4 4 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 3 1 1 Benennung Zylinderschraube Verschluschraube Dichtring Zylinderschraube Ansaugkrmmer Sechskantmutter Scheibe Stiftschraube Ventilsitz O-Ring O-Ring Reglergehuse Dichtring Verschluschraube Flachdichtung Ventilteller Druckfeder Druckfeder Steuerkolben kpl. Steuerkolben Dichtung Dichtung Flachdichtung Zylinder Zylinderschraube O-Ring Kolben Description Cylinder head screw Plug bold Sealing Ring Cylinder head screw Intake manifold Hexagon nut Washer Stud bolt Valve seat O-ring O-ring Governor housing Sealing Ring Plug bold Gasket Valve head Pressure spring Pressure spring Control piston cpl. Control piston Sealing Sealing Gasket Cylinder Cylinder head screw O-ring Piston Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

39

Bild Figure

AP Einzelteile AP Single Parts

Ansaugregler fr pneumatische Steuereinheit Intake Valve for Control Block Pneumatic

40
[de/en] 11/2008

ROTORCOMP VERDICHTER

38 37 1 2 9 3 4 5 6 7 8 10 11 12 13 14 16 17 18 20 21 14 13 15 22 35 A 36

Ersatzteilliste Verdichter - NK 60

25 19 23 24 26 27 28 29 30 31 32 33 34

Bezug Bild / Reference Figure AP


Pos. Item 28 29 30 31 32 33 34 Best.-Nr. Part No. 102068 102362 102528 102128 N2635 N287 N19534 102909 109915 105348 84605 105345 Stck Qty 1 1 1 1 1 1 1 1 1 1 1 1 O-Ring Druckfeder Druckstck Abschludeckel Sicherungring Sechskantmutter Zylinderschraube Luftfilter pneumatisch Flgelmutter Deckel Luftfilterpatrone Gehuse Benennung O-ring Pressure spring Spring catch Cover plate Retaining ring Hexagon nut Cylinder head screw Intake filter, pneumatic Wing nut Cover Intake filter cartridge Housing Description Bemerkung Comments

Ersatzteilliste Verdichter - NK 60

[de/en] 11/2008

A
35 36 37 38

41

ROTORCOMP VERDICHTER

Ersatzteilliste Verdichter - NK 60

42

[de/en] 11/2008

Bestellformular
To ROTORCOMP Fax: +49 (89) 72 409-38 info@rotorcomp.de oder Rotorcomp-Vertriebspartner

Firma

______________________

Kundennummer ______________________

Ansprechpartner______________________ Lieferadresse Strae ______________________ PLZ Ort Land Tel.-Nr. Fax-Nr. E-Mail ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ Rechnungsadresse Strae ______________________ PLZ Ort Land ______________________ ______________________ ______________________

Typ / Version _________/_________ Seriennummer ___________ Baujahr ________ Ersatzteilliste Ref-Nr. _________ nderungsindex ________ Ausgabedatum _____
Position Bestellnummer Menge Benennung Bemerkung

Datum _____________

Unterschrift Kunde _________________________

Bestellformular bitte vollstndig ausfllen. Bei Fragen wenden Sie sich bitte an uns oder den zustndigen Vertriebspartner. Soweit nicht anders vereinbart, gelten die Allgemeinen Geschftsbedingungen der ROTORCOMP VERDICHTER GmbH.

Bestell_20080102.fm

Erstelldatum 02. Januar 2008

Spare parts Order Form


To ROTORCOMP Fax: +49 (89) 72 409-38 info@rotorcomp.de or authorised distributor

Company Name ______________________ Contact person ______________________ Invoice Address Street ______________________ ZIP Code City Country Tel Number Fax Number E-Mail ______________________ ______________________ ______________________ ______________________ ______________________ ______________________

Customer-No.

______________________

Delivery Address Street ______________________ ZIP Code City Country ______________________ ______________________ ______________________

Type / Version _______/______ Serial number __________ Year of manufacture ____ Spare part list Ref. No. ___________ Revision index ___________ Date of issue ____
Pos. Part No. Qty Description Comments

Date _____________

Signature _________________________

Please make sure to fill in all sections of this form. If you require any help please contact us or your authorised distributor. Unless otherwise agreed, the General Terms and Conditions of the ROTORCOMP VERDICHTER GmbH apply. Bestell_eng_20080102.fm Creation data 02. January 2008

ROTORCOMP VERDICHTER GmbH


Industriestrae 9 82110 Germering Germany Tel.: +49 89 724 09-0 Fax: +49 89 724 09-38 info@ rotorcomp.de www.rotorcomp.de

A member of BAUER GROUP

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