REMEZA SB4/C-100.LB75 Manuale utente

COMPRESSOR

SB4/C-100.LB75

SB4/F-270.LB75

SB4/F-500.LB75

SB4/F-270.LB75V

MANUAL

ISO 9001:2008

1. General data

1.1. The present manual is a document, containing the specification of the compressors

(hereinafter referred to as compressor) SB4/C-100.LB75, SB4/F-270.LB75, SB4/F-

500.LB75, SB4/F-270.LB75V (air compressors, piston-type compressors), as well as the

maintenance guidelines and technical characteristics, the adequacy of which is ensured by

the manufacturer.

1.2. The manufacturer has the right to make some minor constructive changes, which

may be not stated in this document.

2. Purpose

2.1. The compressor is a complex electromechanical production, which serves the pur-

pose of compressed air supply to the pneumatic systems, devices and instruments, used in

industry, automobile service centers and for other consumers’ purposes, after its rectification

with the auxiliary air treatment system, and adjustment to the standards, peculiar to each

branch. The compressor helps to save electric energy, to mechanize labor and to improve the

quality of production.

It is not allowed to use the compressor in the areas of high risk of explosion or fire ac-

cording, in the places, exposed to rain, and for household purposes.

2.2. The power supply of the compressor is provided by means of an alternate current

power supply source with the voltage 400 V and the frequency (50 ± 1.25) Hz.

2.3. The climatic construction –NF 3.1, by the ambient temperature 274 –313 K (from

+1 up to +40 ºC).

2.4. The compressor’s operating mode – intermittent.

2.5. Pressure regulation in the receiver –automatic.

2.6. The compressor has a thermal protection against the equipment overload (thermal

relay), short circuit or fault of one of the phases of the electricity supply network (automatic

cutout).

2.7. The compressor can be additionally equipped with a water and oil segregator.

2.8. The general view of the compressor is presented on pictures 1, 2, 3, 4, and the prin-

cipal electric scheme –on picture 5.

3. Performance specifications

3.1. The general safety requirements, concerning the compressor’s design and electric

equipment comply with EN 1012-1; EN 60204-1.

3.2. The compressor’s receiver is designed and manufactured in compliance with the

Directive of EEU Council "Certification of vessels under pressure 87/404/ЕEU".

3.3. The main technical characteristics of the compressor are listed in table 1.

3.4. The compressor’s electrical equipment is made with protection level not less than

IP41.

Table 1

Name of the parameter

Parameter’s value

SB4/C-

100.LB75

SB4/F-

270.LB75

SB4/F-

500.LB75

SB4/F-

270.LB75V

Number of compressor stages

Number of the compressor’s cyl-

inders

Capacity (in-draft), l/min, (m3/h)

880 (52,8)

Maximum compressed air pres-

sure, MPa, (kg/sm2)

1,0 (10)

Nominal capacity, kW

5,5

Supply voltage, V.

400

Receiver volume, l, no less than

100

270

500

270

Dimensions, mm, no more than:

length

width

height

1150

550

1150

1650

510

1150

2000

610

1250

650

700

1800

Weight, kg, not more than

143

195

230

195

3.5. The characteristics of wedge-type belt are listed in table 2.

Table 2

Name and marking

Quant.

Notes

Belt А1600

3.6. Characteristics of the electrical equipment are listed in table 3.

Table 3

Name and marking

Technical charac-

teristics

Quantity

Notes

Engine AIR100L2У3

50 Hz, 400/690 V,

5,5 kW, 10,2/5,9 А

Telepressostate MDR3

Рmах 1,1 MPa ,

400 V, 16 A

3.5. Characteristics of greasing substance.

Nominal filling volume for the oil amounts to 1,8 l.

For compressor’s module greasing it is recommended to use the following types of

compressor oils for piston-type air compressors, avoiding their mixing (or the oils, having

the similar quality and requirements).

SHELL Corena P 100

CASTROL Aircol PD 100

ESSO Kompressoroel 30 (VCL 100)

4. Complete set

4.1. The list of delivered components is given in table 4.

Table 4

Name

Quantity

Notes

Compressor

Manual

Wheels and shock absorbers

Shipping container

Notes: Complete set of wheels and shock absorbers for the compressor SB4/C-100.LB75 (pos. 15, see

pic. 1), complete set of shock absorbers for compressor SB4/F-270.LB75, SB4/F-500.LB75, SB4/F-

270.LB75V (pos. 15, see pic. 2, 3, 4), as well as the details for their fastening are packed separately.

5. System and the operation principal.

5.1. The compressor (pic. 1) consists of the following main assembly units and compo-

nents: compressor module LB75, receiver 1, bay 2, electric engine 3 with pulley 4, wedge-

type belts 5, protection enclosure 6, pressostate 7, manometer 8, air-outlet unloading pipe 9,

force air pipe 10, discharge cock 11, safety valve 12, check valve 13, overflow valve 14,

wheels and shock absorbers 15.

Compressor module –piston-type, single-stage, double-cylinder with air-cooling –is

made for compressed air production.

Greasing of rubbing surfaces of the compressor module’s components is made by

means of oil spraying. Oil pouring into the crater is accomplished through the carter’s port,

oil drain is accomplished through an aperture in the crater’s bottom, which is blanked with

the cap.

Receiver 1 (see pic. 1, 2, 3, 4) serves for collecting of compressed air, avoidance of

pressure pulsation, condensate and oil segregation. Receiver is also a body, on the base of

which other modules and compressor’s components are mounted.

Receiver has connecting pipes for telepressostate or pressostate 7, check valve 13, over-

flow valve 14, safety valve 12 and holders for mounting of the bay.

Bay 2 is meant for assembling of the compressor’s module, engine, wedge-belt trans-

mission and protection enclosure.

Electric engine 3 is meant for the compressor’s drive.

Telepressostate or pressostate 7 provides the operation of the compressor in automatic

mode and maintains the pressure in the receiver.

Unloading air channel 9 serves for unload of the compressed air out of the force air pipe

10 after the compressor’s shutdown, in order to make its subsequent start easier.

Spigot 11 with the pressure regulator serves for air supply.

Safety valve 12 serves for limiting of the maximum pressure in receiver and is set for

the pressure of the emergency response –(1,05+0,05) MPa.

Check valve 13 ensures the compressed air supply in the direction from the compres-

sor’s module to receiver only.

Discharge cock 14 serves for discharge of condensate from receiver.

Manometer 8 serves for pressure control in receiver.

General view of the compressor SB4/C-100.LB75

Рiс. 1

General view of the compressor SB4/F-270.LB75

LB75

1 2

4 567

15 15

1 2

5 6

14 15

LB75

Рic.2

General view of the compressor SB4/F-500.LB75

Pic. 4

Principal electric circuit

General view of the compressor SB4/F-270.LB75В

LB75

1 2

5 67

8 9

14 15

4 5

LB75

1415

Hz 400

6. Safety regulations

6.1. For the compressor’s control are allowed only those persons, who were previously

instructed about its system and maintenance regulations, and who were instructed on the

safety and first-aid measures.

6.2. In the process of running the compressor, the operator should use protective glasses

in order to protect eyes against the foreign particles, brought by the flow of air.

6.3. Compressor should be placed on the horizontal floor surface, in a stable position.

6.4. Do not expose the compressor to the influence of precipitation.

6.5. In the room, where the compressor is situated, it is necessary to ensure good venti-

lation (aeration), checking the ambient temperature, which should be between +5 and

+40 ºC.

6.6. The air sucked in by the compressor should not contain any dust, fumes of any

kind, dangerously explosive or flammable gases, solvent or dye spray, toxic smoke of any

type.

6.7. In case the compressor is situated in a room of critical condition (presence of dust

particle of different types) it is necessary to change filters more often. If the filters loose their

carrying capacity significantly, than it can lead to crash of the suction, force or check valve.

6.8. The usage of the compressor is limited to the air compression, that is why it can not

be used with other gases.

6.9. Utilization of compressed air for other stipulated purposes (supercharge, pneumatic

instrument, coloring, washing with the water-base means* etc.) is conditioned by the

knowledge and observance of the standards, provided for each occasion.

6.10. When the compressor is plugged to the connection line, or to the operation unit, it

is recommended to use pneumoapparatus and flexible lines of the same size and having the

same characteristics (pressure and temperature).

Pic. 5

Ì à ñ ñ à Ì à ñ ø ò à á

È ç ì .

Ë è ñ ò

¹ ä î ê ó ì . Ï î ä ï .

Ä à ò à

Ë è ò .

Ð à ç ð à á .

Ï ð î â .

Ò .ê î í ò ð . Ë è ñ ò Ë è ñ ò î â

Í .ê î í ò ð .

Ó ò â .

1:1

È í â . ¹ ï î ä ë . Ï î ä ï . è ä à ò à Â ç à ì . è í â . ¹ È í â . ¹ ä ó á ë . Ï î ä ï . è ä à ò à Ñ ï ð à â . ¹ Ï å ð â . ï ð è ì å í .

Ê î ï è ð î â à ë Ô î ð ì à ò A3

Ð Å À Â Ñ

< Ð Â Ð

3 ~ 50 Hz, 400 V

À , Â , Ñ - energized cable

PE- cable protector

BP - telepressostat

M- elektric motor

À N Ð Å

~ 50 Hz, 230 V

< Ð Â Ð

M Ê Ê

À , N, - energized cable

PE- cable protector

BP -pressostat

M- elektric motor

C- capacitor (50

F, 450 V)

XS - plug connector

KK - thermal relay 16 A, 250 VAC

Ð Å À Â Ñ

< Ð Â Ð

3 ~ 50 Ã ö , 380 Â

À , Â , Ñ - ï ð î â î ä à ï î ä ê ë þ ÷ å í è ÿ

ï è ò à þ ù å é ñ å ò è

PE-ï ð î â î ä ç à ù è ò û

BP - ò å ë å ï ð å ñ ñ î ñ ò à ò

M- ý ë å ê ò ð î ä â è ã à ò å ë ü

À N Ð Å

~ 50 Hz, 230 V

< Ð Â Ð

M Ê Ê

À , N, - ï ð î â î ä à ï î ä ê ë þ ÷ å í è ÿ

ï è ò à þ ù å é ñ å ò è

PE- ï ð î â î ä ç à ù è ò û

BP -ï ð å ñ ñ î ñ ò à ò

M- ý ë å ê ò ð î ä â è ã à ò å ë ü

C- ê î í ä å í ñ à ò î ð (50 ì ê Ô , 450 Â )

XS -â è ë ê à ì î ä å ë è 82

KK - ò å ï ë î â î å ð å ë å 16 À , 250 VAC

A, B, C –connection wires of the

power supply source

PE –protection wire

BP –telepressostate

M –electric engine

6.11. Compressed air is a flow of energy, and for this reason it is associated with a po-

tential danger. Pipelines, containing the compressed air, should be in working condition and

plugged correspondingly. Before increasing pressure in the flexible lines, one should make

sure, that their rags are well fixed.

6.12. Do not use the flexible lines for the instruments’ shift.

6.13. To move the compressor (switched off) the handle located on the receiver should

be used.

6.14. Before starting the device one should check up the following:

- accuracy of connection to the power supply source and to earth.

-integrity and reliability of the protection enclosure of the wedge-type drive fastening.

-reliability of the compressor’s supports fastening.

- integrity and good order of the safety valves and operating controls.

6.15. For technical testing one should use the present manual, as well as “Regula-

tions on the electric installations” and “Regulations on the safe exploitation of the vessels

under pressure”.

6.16. After completing the rehabilitation the operator should place the protective en-

closure and all other details, by this one should observe the same safety measures, as by the

first start.

6.17. Safety measures by operating of the receiver.

-Properly use the receiver within the limits of pressure and temperature, stated on the

shield with technical data of the manufacturer.

-Constantly control the serviceability and efficacy of the protective and controlling de-

vices (pressostate, safety valve, manometers).

-Do not place receiver in premises with poor ventilation facilities, and in zones, exposed

to heat and flammable materials.

-Do not expose the receiver to vibrations, which can lead to breakage of the welds, be-

cause of the metal’s fatigue strength.

-Every day one should discharge condensate, which is generated in receiver.

When operating the receiver, one should observe the requirements of “Regulations

on the system and safe exploitation of the vessels under pressure”.

6.18. The equivalent of the sound level in the operator’s working zone within 1,0 m

from the compressor, provided the coefficient of usage is 0,6, should not exceed 80 decibel.

6.19. When the noise level exceeds normal level, than it is necessary to use the means

of individual protection.

6.20. The cargo handling procedures should be carried out according to transport marks

on the container.

6.21. Recycling of the used oils and condensates should be carried out with observance

of the appropriate specifications, because these products pollute the environment.

6.22. While operating the compressor one should observe “General fire prevention rules

for the industrial enterprises … ".

It is forbidden:

- To operate the compressor with the faulty or switched - off protection against cur-

rents of short circuit and thermal protection;

- To bring in any changes to electrical or pneumatic circuits of the compressor or

their settings. In particular to change the value of the maximal pressure of compressed air

and settings of the safety valve;

-To turn on the compressor with removed protection of wedge-belt transmission;

-While operating the compressor to touch heated details (head and block of cylin-

ders, heat pump, details of the force air-pump, electric motor’s cooling fans);

-To carry out machining or welding of the receiver. In case of defects or corrosion it

is necessary to replace it completely, as it falls under the special norms of safety;

-to touch the compressor with wet hands or to work in wet footwear;

-To direct a jet of compressed air at oneself or other people around;

-To let children and animals into the working area;

-To carry out coloring in a non-aired premises or near open flame;

-To store kerosene, petrol and other inflammable liquids at the site of the com-

pressor’s installation;

-To leave the compressor, which is plugged to the mains, without supervision;

-To carry out repair works of the compressor, which is plugged to the mains,

and when the pressure in the receiver is not releived;

-To transport the compressor, which is under pressure.

7. Pre-starting and operating procedures

7.1. Study the instructions of the present passport attentively and follow them.

7.2. It is important, that the first start of the compressor should be made by the

trained personnel, which carries out various kinds of the control according to the instruc-

tions. 7.3. Accurately open the package, check up completeness, make sure of the absence

of damages.

7.4. Mount wheels and shock-absorbers onto the receiver, mount the compressor on

an even horizontal platform, ensuring in this way an easy approach to the switch and spigot

of air supply to the consumer. For good ventilation and effective cooling it is necessary that

the protections of belt transfer were at a minimum distance of 1 meter from a wall. The

floor of the premises at an installation site of the compressor should be made from a fire-

proof and oil proof material.

7.5. Check up the conformity of the instructions shields on the unit of the compres-

sor, receiver, electric motor and data of the present passport.

7.6. Check up on the oil indicator the level of oil in crank case of the compressor’s

module - it should be within the limits of a red mark on a watching glass. If necessary, add

some oil up to the average level, choose oil according recommendations in the present

instruction. Do not allow outflow of oil from junctures and onto the outside surfaces of the

compressor.

7.7. Check up conformity of the voltage of a power-supply mains with the re-

quirements of the paragraph 2.2 of the present operation manual.

In the case of electrical connection the sequence of phases is of importance, as it

determines the direction of rotation, which should correspond to the direction, speci-

fied by the pointer on a protection enclosure of the wedge-belt transmission.

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