1. Unscrew oil filler (red).
2. Fill with oil and check the oil level with the dipstick (red).
3. Put dipstick back and replace the oil filler plug.
Note!
Unless otherwise ordered, Sauer compressors are delivered without oil.
Dipstick Oil filler
Danger
The compressor's crankcase oil sump must be filled with oil be-fore initial operation!
Use recommended lubricating oil (see Chapter 10: “Lubricant Table”).
Note the amount of oil needed (see Chapter 4: “Technical Spe-cification”).
Note!
Only fill to the upper mark on the oil level indicator. If over-filled the oil consumption of the compressor will increase.
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5.7 Installation checks before the initial start
– Verify electrical connection corresponds with the nameplate?
– Check all air connections are propperly installed. Pay special attention to the compressed air outlet.
– Are drain lines properly connected? See section “Drainage”.
– Has the crankcase been filled with oil?
– Have all tools and foreign objects been removed from the com-pressor?
– Check cooling air intake is not restricted or blocked in any way.
– Air filter turned from transport position to operating position?
– Is the entire Unit clean?
Operation
1_12_en_08.fm
6 Operation
6.1 Safe operation
Danger!
Only authorised persons are permitted put into operation and operate the Sauer Compressor!
Danger!
Turn on and start the compressor only if
– it has been checked for proper working condition;
– all tools and foreign objects are removed from the machine.
Danger!
Immediately turn compressor off if personnel are endangered.
Start compressor only when there is no danger or possible da-mage.
Danger!
In Automatic Mode the compressor starts automatically without warning.
Danger!
Risk of burns from touching hot surfaces of the compressor du-ring operation. Wear protective gloves.
Danger!
Risk of hearing damage when the compressor is running! Wear ear protection near the compressor.
Note!
Turn compressor off if any fault condition exists or any irregula-rities. Refer to Chapter 7 “Troubleshooting” to correct any fault.
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6.2 Operation modes
When the power supply to the Sauer compressor is turned on, it can be started with one of the following two operational modes:
– Normal operation mode “Manual“:
The compressor starts and keeps running until it is stopped or turned off with either the operation mode selector or the main switch.
– Operation mode “Automatic“:
Starting and stopping of the compresssor is controlled by ex-ternal devices (e. g. by the pressure switch at the pressure vessel).
When the Sauer compressor starts, it starts without load with the drain valves open. Some seconds later the valves close and the compressor runs up against pressure.
Operation
Allow the Sauer compressor to run only for a few seconds to check the direction of rotation.
1. Turn the power supply on.
2. Set the operation mode selector to “Manual“ to start the com-pressor in manual mode.
3. Immediately check the compressor's direction of rotation. It must rotate in the direction indicated by the arrow on the crankcase.
4. Set the operation mode selector to “0“ to stop the compres-sor.
5. Turn the power supply off.
6. If the direction of rotation is incorrect, the polarity of the elec-tric motor should be changed by a qualified elecelec-trician.
Test run 1. Turn the power supply on.
2. Set the operation mode to “Manual” to start the compressor in manual mode.
If correct, the drain valves will close after approx. 15 seconds and the compressor then will run up against pressure.
3. Check the air pressure for each stage and the oil pressure, and compare with the nominal values (for nominal values see Chapter 6.4 “Routine operation”).
4. Check the function of the automatic periodic drainage, e. g. 15 seconds every 15 minutes, dependent upon opera-ting cycle. This is visible as a drop in stage pressures.
5. Set the operation mode to “0” to stop the compressor.
6. Turn the power supply off.
7. If necessary, correct any faults. See also Chapter 7 “Trouble-shooting“.
8. Complete the start up journal and send it to J.P. SAUER &
SOHN service department. The start up journal is in the Ap-pendix of this Manual.
Warning!
If the direction of rotation is incorrect, there is no oil pressure.
Risk of subsequent damage.
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6.4 Routine operation
Cleaning • Keep compressor area clean.
• Keep indicators and control elements clean.
Checks • Inspect connections, pipes and electric cables for damage.
• Check the oil level once a week before starting, top up, if nec-essary. Do not overfill with oil beyond the maximum mark.
Operation 1. Turn power supply on.
2. Set operation mode selector to “Auto“ to operate the com-pressor in Automatic mode.
Observation • Pay attention to abnormal operating noise.
• Pay attention to leaks (compressed air, oil, condensate).
• For any deviation see Chapter 7 "Troubleshooting”.
Troubleshooting guide
1_12_en_08.fm
7 Troubleshooting guide
Note!
• Should a malfunction occur, first check the ’User Interface’
display status on the compressor Control Panel (fault = RED).
• The following information tabulated below, provides help to correct any fault.
If the fault cannot be corrected, please contact J.P. SAUER &
SOHN customer service. The fault description journal is in the appendix of this manual..
Fault Probable cause Remedy
Operation with compressor control:
The compressor does not start or shuts down.
No supply voltage / no control voltage.
Check fuses. Replace blown fuses.
Operation with compressor control:
Compressor shut-down, fault indicator lamp “Oil level“ (option) illuminates.
The oil level is too low. Check the oil level, refill with oil if nec-essary. Check for oil leaks.
Oil too viscous. Fill oil in accordance to recommenda-tions.
Check ambient temperature is > + 5°C.
Operation with compressor control:
Compressor shut-down due to over-current relay, fault indicator lamp “Overcurrent“
illuminates.
Motor overheated. Excessive current drawn.
Check supply voltage and check for loose connections. The compressor can be started again after a cooling-down period.
Check if crankshaft can be easily rota-ted by hand. If not, disconnect coupling to determine if motor or compressor is at fault.
Piston seizure Check cylinders and pistons for any score marks, replace as necessary.
Safety valve of 1st stage blows:
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Pressure exceeds set
pressure (8 bar) 2nd stage valve malfunction. Check 2nd stage valve, replace if nec-essary.
Gasket between inlet and out-let at the 2nd stage is faulty.
Replace gasket.
Pressure below set pressure (8 bar)
Safety valve is faulty. Replace the safety valve.
2nd stage safety valve blows:
Pressure exceeds set pressure
(final pressure + 5%)
Valve in the air line to the com-pressed air storage closed.
Open the valve.
Pressure switch set too high. Reduce set pressure.
Pressure below set pressure
(final pressure + 5%)
Safety valve set too low or faulty.
Replace the safety valve.
Too much pressure loss in the air line to the compressed air receiver.
Correct pressure losses.
Pressure gauge of of 2nd stage indicates too low pressure.
Valve of 1st stage leaky. Check 1st stage valve, replace if neces-sary.
Air intake filter blocked. Clean or replace air intake filter cart-ridge.
No or, too low pressure indi-cated at 2nd stage stage pressure gauge.
No power at solenoid drain valve.
Check solenoid valve power supply.
Solenoid drain valve faulty. Check solenoid valve, replace if neces-sary.
Air escaping from com-pressed air lines.
Connection gaskets or seals leaking.
Replace faulty gasket or seal.
Cutting rings leaky. Turn compressor off. Wait until all parts are relieved of pressure, check pres-sure gauges. Then tighten connec-tions.
Air escaping from fuse of the final separator.
Outlet temperature of com-pressed air too high; insuffici-ent cooling by faulty fan.
Check fan, replace if necessary.
Check fuse, replace if necessary.
Blocked or dirty cooler;
insufficient ventilation.
Clean the cooler.
Check the room ventilation.
Replace the fuse.
Operation with compressor control:
Solenoid drain valve does not close.
No supply voltage. Check fuses, replace blown fuses.
Solenoid faulty. Replace solenoid.
Foreign matter in solenoid valve.
Clean solenoid valve.
Fault Probable cause Remedy
Troubleshooting guide
1_12_en_08.fm
Abnormal compressor noise.
Connecting rod bearing faulty.
(noise when off-load).
Check connecting rod bearing, replace if necessary. Check oil supply.
Gudgeon pin bearing faulty. Check gudgeon pin bearing, replace if necessary.
Crankshaft bearing faulty. Check crank shaft bearing, replace if necessary.
Motor bearing faulty. Check motor bearing, replace if neces-sary.
Oil leaking from crankcase. Gasket or shaft seal faulty.
Screws not tight.
Tighten all screws.
If there is significant leakage, check to see which gasket is faulty, then replace it.
Minor traces of oil on the crankcase or oil drops below the compressor are harmless. Wipe off with a lint-free rag.
Air leak between cylinder and valve cover.
Gasket or O-ring of the liner above the relief groove faulty.
Replace gasket or O-ring.
Oil leak at relief groove of cylinder flange.
O-ring of the liner beneath the relief groove faulty.
Replace O-ring.
Water in the oil Poor ventilation (compressor is overcooled).
Correct the room ventilation.
Poor drainage. Check drain lines and drain intervals.
No isolating hose at crankcase ventilation or isolating hose is broken.
Replace isolating hose.
Very short compressor run time.
Extend compressor running time.
Premature failure of valve plates, valve springs or valve discs.
Poor drainage. Check drain lines and drain interval.
Note: Indentation marks on the valve plate due to valve impact are normal.
Fault Probable cause Remedy
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8 Maintenance
8.1 Maintenance and Service by J.P. SAUER & SOHN
The J.P. SAUER & SOHN customer service offers differing main-tenance services – e.g. full mainmain-tenance or valve replacement service. Please contact:
J.P. SAUER & SOHN Maschinenbau GmbH Customer Service
P.O. Box 92 13 D-24157 Kiel
Technical information +49 431 39 40 -87
Spare parts orders +49 431 39 40 -86/886
Telefax (international): +49 431 39 40 -89 Emergency service (international): +49 172 4 14 63 94
E-Mail: [email protected]
Web: www.sauersohn.de
or contact a service partner close-by who is authorised by J.P.
SAUER & SOHN.
Maintenance
1_12_en_08.fm
8.2 Maintenance safety
Before Servicing 1. Disconnect the power supply to the compressor.
2. Post sign “Caution Maintenance Work!” at the power supply.
Danger!
Only authorised persons are permitted to Service and make ad-justments to the Sauer Compressor!
Danger!
Risk of injury from hot surfaces!
Let compressor cool down after turning OFF.
Danger!
Risk of injury from pressurised compressor components!
Check the pressure gauges before servicing to ensure the com-pressor is completely relieved of pressure.
Danger!
High voltage! Danger to life!
– Never assume that a circuit is de-energised – always check for your own safety!
– The main switch is energised, even when it is turned off.
– Components being worked on should only be energised if this is explicitly specified.
Danger!
Danger of death from missing safety devices and missing isola-ting protection devices!
Reinstall all safety devices and isolating protection devices after Servicing. This also applies to electrical protection devices (e.g.
earth wires).
52
• Use the maintenance schedule as a master template or copy the respective page from the document and save it as a sepa-rate file under a suitable name. Use the maintenance schedule as a guide for evidence that work has been carried out.
• Regularly check the maintenance schedule to see which main-tenance intervals, depending upon the number of operating hours, are due. The intervals are shown in the table's column headers.
• Check the column of each maintenance interval to see what maintenance work is to be carried out at the end of each main-tenance interval. The required tasks are indicated by check boxes. The description for the tasks is shown in the first co-lumn.
• Carry out all maintenance work for an interval and tick the ap-propriate check boxes of the maintenance schedule.
Then enter operating hours count, date and your signature.
• When beginning a new maintenance schedule
– enter: main specifications, date of commissioning, number of maintenance schedule, current date and operating hours count
– tick: beginning after commissioning/after major overhaul Danger!
For all maintenance work Chapter 8.4 “Table of tightening torques” must be observed for identified screws, bolts and nuts.
Note!
The maintenance intervals specified in the maintenance schedu-le must be adhered to. Shortening the maintenance intervals is of no advantage with regard to operating performance or service life of the Sauer compressor.
Note!
We recommend to carry out an inspection (functional check) by authorised persons at least once a year.
Note!
After 4,000 operating hours the maintenance schedule begins all over again.
The major overhaul after 8,000 operating hours shall be carried out by personnel authorised by Sauer.
Maintenance
1_12_en_08.fm
Maintenance Schedule No.: Compressor type:
Maintenance schedule beginning: Type series 2L
after commissioning Compressor number:
after major overhaul Factory No.:
Date: Year of construction:
Operating hours: Date of Commissioning:
1 000 2 000 3 000 4 000 periodically
8 000
Checking screwed connections
Air filter cartridge replacement
Oil change
Checking valves
Replace valves
Checking piston rings
Replace piston rings
Replace gudgeon pins and gudgeon pin bearings
Checking pistons and cylinders
Checking drive bearings
Checking connecting rod bearings
Checking coupling
Replace coupling flexible insert
Checking separator
Replace shaft seals
Checking safety valves
Major overhaul
Checking screwed connections
Oil change
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8.4 Table of tightening torques
Note!
Always check the compressor after 50 hours following any maintenance work. Check all screws affected by the mainte-nance work to see if they are tight.
Bolt(s) / Screw(s) Tightening torque Cylinder head screws 1st stage 38 Nm
Cylinder head screws 2nd stage 38 Nm Connecting rod screws 1st stage 50 Nm Connecting rod screws 2nd stage 50 Nm
Maintenance
1_12_en_08.fm
8.5 Oil change
1. Put oil catchpan of sufficient size under the Sump oil drain as-sembly (sufficient capacity to hold the complete oil fill, see Chapter 4 “Technical Specification”).
2. Remove the oil drain plug.
3. Wait until all oil is drained.
4. Replace the oil drain plug.
5. Unscrew oil filler (red).
6. Fill the oil and check the level with the dipstick.
The level should be between the upper and lower mark on the dipstick.
7. Put dipstick back and replace the oil filler.
Note!
Only use oil as recommended in the Lubricant Table (see Chap-ter 10).
Oil drain plug Dipstick Oil filler
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8.6 Checking screw connections
Check all unions and screw connections for tightness, re-tighten as necessary:
– cooler and gas lines;
– unions for pipe lines and flexible hose-lines;
– cylinder heads;
– cylinders;
– electric motor and bell-housing flange;
– monitoring and protective sensors;
– baseframe / foundation;
– accessories and ancillary equipment.
Maintenance
1_12_en_08.fm
8.7 Air Intake filter cartridge cleaning
1. Loosen clamp and remove air filter.
2. Unfasten the clips at the air filter and remove air filter cap.
3. Wipe out the cover with a lint-free cloth.
4. The air filter is part of the base of the air filter cage. Wash out the air filter with an oil dissolving fluid (e.g. kerosine).
5. Blow out the air filter with compresed air from inside to out-side.
6. Replace cap and mount the air filter on the cylinder head.
air filter
clamp
Danger!
Do not train compressed air on persons!
Note!
The air filter has to be replaced, if cleaning is not possible.
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8.8 Checking valves
Valve removal 1. Loosen all unions and hose lines at the cylinder heads.
2. Remove cylinder head nuts and remove the cylinder heads.
3. Take valves carefully out.
Checking the lamellar valves
4. Check the valves.
If the reed (lamellar) valves are heavily carboned or dama-ged, replace the complete valves.
Hinweis!
Reed (lamellar) valves, are those parts of a reciprocating com-pressor that are subjected to the most stress. In order to achieve the guaranteed maintenance intervals, these valves are high-quality precision parts, specially matched to the individual com-pression stages and their function carefully checked before deli-very. Repair by maintenance and operating personnel requires specialist knowledge, which may not be readily available. In such a case J.P. SAUER & SOHN can offer a valve replacement service; please contact the Sauer service department.
Note!
Install all valves with new gaskets and seals. Do not reuse the used old seals under any circumstances. Doing so leads to leakage within a short time.
Use only genuine Sauer spare parts. They are precision parts, designed, tested with special material characteristics for use in Sauer compressors. Installation of other gaskets may lead to leakage and may cause substantial damage to the compressor.
Note!
Reed (lamellar) valves require very little maintenance and function even when in the presence of small quantities of dirt in contrast to plate valves. Normally the plates have the same service life as the valve body which, due to its geometry, cannot be re-faced or lapped. Therefore, replacement of individual parts is not recommended.
Should a plate be broken prematurely (e.g. from foreign objects), please contact Sauer service.
Maintenance
1_12_en_08.fm
Valve installation
5. Fit reed (lamellar) valve and cylinder head of the 1st stage, use a new cylinder head gasket between valve and cylinder head.
6. Remove supports to separate the inner and outer ring of the cylinder head gasket.
7. Fit reed (lamellar) valve and cylinder of the 2nd stage, using a new cylinder head gasket between valve and cylinder head and a new O-ring.
Cylinder head gasket 1st stage
Lamellar valve
Note!
Do not reuse used seals under any circumstances. Doing so leads to leakage within a short time.
The supports of the gasket must be removed before assembly.
support
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8. Fit inner gasket ring between the pins.
9. Observe the tightening torques of the cylinder head nuts: 38 Nm.
10. Attach all unions and hose lines to the cylinder heads.
Cylinder head gasket 2nd stage
Lamellar valve
Maintenance
1_12_en_08.fm
8.9 Checking the piston rings
1. Remove cylinder heads and valves as described in Chapter 8.8 “Checking valves”.
2. Remove cylinder base nuts and pull off the cylinder carefully.
Hold the piston while the cylinder comes off.
3. Remove circlips to release gudgeon pins, push out gudgeon pin and take piston off.
4. Remove all piston rings from the respective pistons.
5. Insert the piston rings in the respective cylinder and measure the gap clearance with a feeler gauge.
6. Replace all piston rings if the gap clearance of one ring ex-ceeds the following limits.
7. Install piston rings to the respective piston. Make sure they are in the correct position: piston rings having an asymmetric cross section are marked on one of the surfaces with “TOP”.
The marked face must be at the top when the piston ring is installed. See illustration.
Note!
If the piston is not held, when pulling the cylinder off, it will fall against the crankcase.
1st stage all piston rings 0.90 mm
2nd stage Nose ring 0.55 mm
Plain ring 0.55 mm
Oil scraper ring 0.40 mm
Note!
Always replace all pistons rings of a piston when one of the pis-ton rings exceeds the limit.
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8. The piston ring gaps should be staggered.
9. Fit a new cylinder base gasket for each cylinder.
10. Push the piston up to the piston pin bore into the respective cylinder. Fit the cylinder together with the piston.
11. Mount pistons on the connecting rods. For this purpose,
11. Mount pistons on the connecting rods. For this purpose,