ac 阿特拉斯 15-22kw 使用维护零件手册 说明书 tsc ga 15 - 22 modele

Main Menu,Course Content,Air / oil flow diagram,General description,Air filter,Vacuum unloader valve,Drive train,Element,Drive motor,Gear casing,Air / oil separation,Cooling system,Air receiver,Regulation,Elektronikon I,Dryer,Cubicle,Service matters,GA 15 22 Model 2006,After completing this module the student will demonstrate an understanding of:To know and understand the build up of the complete unit.Understand the operation of the compressor.Air / oil circuit , electrical diagramKnow the subjects which need special attention during assembly.Have a clear view on the Service Interventions and the service kits,Training objectives,Prod.start21 / 05 / 2006 API 450 000,General view,General description,GA15-22 FM,GA15-22 FF FM,Basic version,General description,GA15-22 TM,GA15-22 FF TM,Basic version,General description,Voltage: 230V / 400VApprovals: CE/Lloyds/ASME/DIR/UDT,Pressure variants,50 Hz : 200V/ 230V/400V/500V,60 Hz : 200-230-460V/ 380V/440-460V / 575V,Pressure variants,General description,500 l,Man. air receiver drain,ELEKTRONIKON I,Air outlet valve connection,Front view FF version,General description,Cooling air compressor,Air inlet compressor,Rear view FF version,General description,Dryer condensate drain,Dryer air inlet,Dryer FF version,General description,Dryer cooling air outlet,Compressor cooling air outlet,Roof view FF version,General description,General description,Service access ability FF,Cooling air flow,Inlet,Outlet,General description,Motor ductTo have better cooling capacityFoam to reduce the noise,Oil cooler duct ductTo have noise reduction,General description,Cooling air flow,As a part of our new GA+ and GA strategy above 11kW.Replace current GA11-30C ELI and GX15-22.Name current GA11-30CELII as GA11+-30 with improved performance.,Atlas Copco Family,General description,AML figures,General description,With 4-5% FAD differentiation between GA+ and GA,With 4-5% FAD differentiation between GA+ and GA,AML figures,General description,Operation limitsMax. Inlet temp : 46CMin.ambient temp : 0COil capacityGA15 : 6.75l / GA18 : 7.25l / GA22 : 7.75lOil content2 mg/m3Oil consumption at ref.conditionsGA15 : 0.017l/100hGA18 : 0.032l/100hGA22 : 0.049l/100h,General description,AML figures,FF version,Air / oil flow diagram,Air Flow1 Air intake filter2 Air intake valve3 Compression element4 Air/Oil separator vessel5 Oil separator6 Minimum pressure valve7 Aftercooler8 Air/air heat exchanger9 Integrated water separator10 Electronic automatic drain11 Air receiverOil flow12 Oil13 Thermostatic bypass valve14 Oil cooler15 Oil filter16 Scavenge line,Air Flow1 Air intake filter2 Air intake valve3 Compression element4 Air/Oil separator vessel5 Oil separator6 Minimum pressure valve7 Aftercooler9 Water separator11 Air receiverOil flow12 Oil13 Thermostatic bypass valve14 Oil cooler15 Oil filter16 Scavenge line,Pack version,Air / oil flow diagram,Build up,Air filterConnected with elbow to unloaderInside we have a metal bushingFilter element replacement :Loose the clamp and take off the complete filter assemblyRemove the cover of the filter assy and replace the air filter element.Remark : cover is hard to loosen,Loosen the clamp,Bushing,Air filter,Technical data : The same as GX15/22 GA11/30CAir filter ass y : 1613 8719 00Filter element ( paper) : 1613 8720 00Change interval : 4000 h(delta p : 5mbar)nominal air capacity: 50 l/s?efficiency on SAE fine contamination:particle size 0.001 mm: 98 % 0.003 mm: 99.9 %,Air filter,Technical data,Inlet system,Sol.valveBlow off valve1622 3694 80Vacuum unloader1622 1713 80,Elbow is mounted with Loctite 577,Vacuum unloader valve,Inlet system,Sol.valveHas smaller dimensions.Can be mounted in one position.See lip.110V/ 50Hz1089 0702 09 120V/ 60Hz1089 0702 10 Normally closed : NCOrifice : 0.8mm3/2 valveMax.p = 16bar,O-ring,Lip ?,Vacuum unloader valve,Inlet system,Blow off valve1622 3694 80Housing is made from PVC.No internal parts avialable as spare part.Mounted to unloader with 2 lock screws : Hand tightened.To prevent deformation of the housing.,Vacuum unloader valve,Denomination,3.BOV16.Lock screw: hand tightened11+12+13+14 .Non return valveAir Flow : from BOV to unloader9.squad ring : To hold the piston 78.Taper ring :to center the piston 7No sealing purposes.7.PistonScrewed in the piston 1Contains 2 xM6 for disassembly.6.Polyamide bushing.Act as bearing for the rod.3 000 000 cycle test : lab1.Rod :locked by the screw 18Has a central hole.2.Valve : contains vulcanisized rubberMoves freely over the rod 1.,Vacuum unloader valve,Vacuum unloader : 1622 1713 80,Air flow from BOV towards unloader,Seal,Allen key : 5mm,Non return valve,Vacuum unloader valve,Control air is divided in :1.Below the piston 7Upper positionValve 2 is closed2.To air filterSmallest openingUsed to blow off the air vessel via the air filter3.To elementBlow off to the element,1.,2.,3.,Control air,Vacuum unloader valve,Load condition.Sol.valve is energized.BOV pressure at both sidesBOV is closedNo control air at the check valveHow does the valve 2 opens?The under pressure of the element sucks open the inlet valve,P inlet element ?,Basic working principle,Vacuum unloader valve,UN Load condition.Sol.valve is not energized.BOV pressure at the bottomBOV is openControl air to unloaderHow does the valve 2 closes?We get pressure below the piston 7 and the valve will be closed.,Pressure ?,P inlet element ?,Basic working principle,Vacuum unloader valve,Cut away drawing : connections,Sol.valve NC,Air inlet from instrument block(oil vessel),Outlet side : is situated at the back sideIs connected to the unloader,Blow Off Valve,Vacuum unloader valve,Blow Off Valve,Outlet side.Is mounted against the unloader by 2 screws.Sealed of by the o-ring.,Vacuum unloader valve,Working principleLoad conditionSol.valve is open.Control air above piston.Piston is pushed down.Result : Opening towards unloader is closed,Blow Off Valve,Vacuum unloader valve,Working principleUN Load conditionSol.valve is closed.Not energisedControl air only below piston.Piston is pushed upwards.Result : Opening towards unloader is open.,Blow Off Valve,Vacuum unloader valve,Conclusion :In unload :Sol.valve is not energised = NCPiston in upper positionControl air to the unloader.In load :Sol.valve is energised = Contol air above piston.Piston in bottom positionNo Control air to the unloader.,Blow Off Valve,Vacuum unloader valve,We need control pressure to move the piston.Deformation of the BOV housing can result in a higher friction between the piston and the housing.When the unload pressure is not high enough to overwin this force , then the piston will not move and the unloader will get no control air = no load condition.Sol.valve does not perform well.We also get no movement of the piston = No proper function of the unloader.,Blow Off Valve,Vacuum unloader valve,Problem solvingSol.valve controls the BOV valveThe BOV controls the unloader.For problem solving NO LOADCheck first above parts for proper function.,Blow Off Valve,Vacuum unloader valve,Load to unloadSol.valve not energised.Control air to unloader.Press.below piston ?Pressure at inlet element?Compressure ratio ?p load+p atmP inlet element=160 = very high load to element bearings.How to solve ?Blow off channel to element,P inlet element ?,Vacuum unloader valve,Basic working principle,Blow off systemThe moment we go to unload we still have 7 bar in the oil vessel which need to blow off.This air volume comes via the BOV , the non return valve in the unloader.Air is partly blowed back to the elementAir is partly blowed via the air filter to the atmosphere.Total blow of time is about 40 secondsUnload pressure is about 0.8bar.,Vacuum unloader valve,Basic working principle,Advantage compair to previous unloader?Less parts More simplified build up.Easier to dismount and the assemble.No spring loaded piston used. Less danger during disassemblyLess risc to have wear out parts.,Vacuum unloader valve,Basic working principle,Another use of the non return valve in case of an emergency stop ?To avoid oil coming into air filter +contamination of the OSF.Explanation:When we go to unload then the air /oil vesel pressure wants to escape via :Instrument block : blow off line to unloaderSol.vlv: NC = opening to unloader + element + air filterInstrument block : scavenge line to elementNon return valve in al.conn.below element will close To element : HP sideAir/oil mixture from element can enter the unloader via the blow off channel towards the element. Thanks of the non return valve the air/oil mixture can not go via the BOV towards the OSF,Vacuum unloader valve,Basic working principle,1.Check valve replacement.4 x small part need to inserted at the unloader.Take off the unloader so you can mount the check valve in a vertical position.,Practical tips,Vacuum unloader valve,2.Conn.flex.instrument block to BOV.Max.torque is 7Nm.To avoid damage at the BOVUse two wrenches to mount the flexible.,Vacuum unloader valve,Practical tips,4.Dismounting of the rod.Revetted nut 1 is only used to unscrew the rod out of the piston 7.Rod into piston. handtightenedMount lock nut : 24NmNo loctite may be used.,Lock nut 18,Vacuum unloader valve,Practical tips,3.Two M6 screwsAre used to dismount the lock nut 18 off the rod.Also used to screw out the rod 1 out off the piston 7.,Lock nut,Vacuum unloader valve,Practical tips,5.Replacing of the polyamide bushing 7.This is a gliding fit.Need to be replaced in the direction from top to bottom.,Vacuum unloader valve,Practical tips,Which part determine the openings pressure ?What happens when the unit start up with an open unloader = at full load position?What in case we use the emergency stop?,Questions practical exersise,Vacuum unloader valve,General build up,Drive trainDirect drivenGear casingMotor SiemensElementC77/H06,Drive train,Gear casing,Production build upDrive train support to the frame2 x anti vibration pad to supportPreassembly motorGear casing to motorMotor + gear casing to the framePreassembly elementGearwheel to element.Connection part below elementElement to gear casing,General build up,Drive train,Element C77 HO6,Service stage : 1616 6712 90Also used at : GA 11-30C / GX 30-37Shaft seal kit :2901 5005 00Min. life time : 24 000 hElement overhaul kit : 2901 0709 00Element mounting kit : 2901 1639 00,Element,Direction of rotationCounter clock wise facing motor shaft end.A page is glued at the roof, which must blow upwards the moment we start up the unit.See arrow at the gear casingCasted arrow in the motor fanElement is not protected for wrong sense of rotationOption kit : Phase sequence realy,Element C77 HO6,Element,Service stage : 1616 6712 90C77 / HO6Used units :GA11/30C GX 30/37 O ring is mounted with vasalineBoth bearings are secured by the spacer+boltBelow , the lubrication nozzle for the gearsParallel key to mount the driven gear wheelElement shaft has a chamfer , where to we mount the gear wheel.,Lubrication nozzle,Chamfer for gear wheel position,Oil return hole,Element pre preparation,Element,Be sure there is no burr at the gear wheel and at the element shaft.Gear wheel is pre heated up to 150C.Slide the gaer wheel as far as possible. The special bushing contains the parallel key inside in order to hold the motor shaft during torque.Mount the spacer and the M10 bolt. Put Loctite 243 at the bolt to lock.M10 : 46+-5NmThe bushing has a flat surface to hold the motor shaft.,Special bushing,M10 46Nm +-5,Element pre preparation,Element,Brand : Siemens Single voltage 50Hz/60HzTri Voltage : 60Hz/CSA : 200V- 230V / 460V Rpm : 2940-50Hz /3540 60HzIP : 55Insulating class : FMax. delta T windings : 105KExpected life time : 24 000hBall bearings : D end : 6309-ZC5N end : 6209-ZC5Bearing kit : 2901 0716 00,Technical specifications,Drive motor,Service factor : 1.27 : 50Hz/60HzEfficiency : 90.2%Voltage difference : 10%Max.start/stops per hour : 30Bearings greased for life timeKlueberquiet.Weight : 84kg=15kW / 104kg=18kW /110kg=22kWCurrents : see motor data plateThe first 12 month : return the complete motor for investigation,Drive motor,Technical specifications,Longer motor due to : Cooling duct / cooling fan,Drive motor,Technical specifications,Drive motor,Be sure there is no burr at the motor shaft.Put Loctite 641 at the motor shaft.to prevent oil leakge between shaft/bushing.Remark : a conical bushing is used for easy centering of the bushing towards the motor shaft.,Heat up the bushing up to 130C.Slide bushing over the motor shaft in one go.As far as possible : against the chamfer.,Motor/gear casing pre preparation,Chamfer,Put Loctite 243 at the position of the shaft seal,Motor/gear casing pre preparation,Gear casing,Lipps are positioned towards the tool shaft,Element side,Motor side,Motor/gear casing pre preparation,Gear casing,Element side,Motor side,Compressor oil,Motor/gear casing pre preparation,Gear casing,At the motor side we have the spacer,4 x M16,Motor/gear casing pre preparation,Gear casing,Gear casing to motor.Put a teflon part over the motor shaft to prevent damage of the shaft seal.4 x M16 : Torque 171Nm.?,Motor/gear casing pre preparation,Gear casing,Mount the parallel keyThe gear wheel need to be mounted against the bushing.Gear wheel is pre - heated up to 150C (temporally heated up ) Engineering 130,Part number must be situated at the front as well as the two small holes.Slide the gear wheel against the bushingCheck if the gear wheel is in front of the motor shaft.,Motor/gear casing pre preparation,Gear casing,Tool is used to block the gear wheel and the motor shaft.The gear wheel is locked with a spacer and a M16 bolt.Loctite 243 to the bolt.Torque : 170Nm,Motor/gear casing pre preparation,Gear casing,Element to gear casing.A support with lifting eye is mounted at the inlet of the element.Slide the element in the bearing housing by hand force.8 x M10 bolt : 46+-5Nm,Element to gear casing,Gear casing,Gear wheel overview,Gear casing,Spares order gear wheel,Maintenace intervalSame interval as the element 24 000h ?Gears need to be replaced at the same momentGear sets are releasedNo separate gear wheels can be ordered.Why ?To prevent noise.,Gear casing,Connection part to element,Used at the GX30/37GA11/22/30C,Temp sensor:mounted with Loctite 577,Scavenge line with non return valve,Air/oil mixure:element outlet,Oil injection line,Gear casing,Oil injection point element,O-ring,From oil filter housing,Scavenge line,Connection part to element,Air/oil outlet element,Gear casing,Flow diagram,Air / oil pre separation,Oil separator vessel,Air/oil separation1.Cyclone action2.Gravity separation3.Change air flow direction,Inlet,Air outlet,Oil outlet,Oil drain,Air / oil pre separation,Oil sight glass,Oil filling plug G 3/4,No overfilling possible,Do never use this hole to fill the unit with oil.,Air / oil pre separation,Oil separtor vessel,Technical specificationsVolume : 13 literDesign pressure : 15 barTest pressure : 23 barWorking temperature : minus 10C up to 120CApprovals : ECC -87/404 and ASME,Air / oil pre separation,Oil separtor vessel,Oil sight glass :Sealed of with gasketNo Loctite used.Contact surface with the oil vessel must be clean.,Air / oil pre separation,Oil separtor vessel,Oil filling plugG 3/4Is sealed of by an o-ringCan be orderedAir relieve openingSafety issue.,Oil separtor vessel,O - ring,Air / oil pre separation,Oil separtor vessel,Other connectionsSafety valve : Mounted with Loctite 5772 x elbow at the bottom of the oil vessel :Mounted with Loctite 577,Air / oil pre separation,Instrument block,General build up:Connected to oil vessel.Sealed by o-ringFixed with 3 x boltAir outlet Is mounted with Loctite 577Air outlet flexible to air receiever or to dryer.Oil thermostat.Is screwed with two bolts.,O - ring,Air outlet,Oil thermostat,Air / oil pre separation,Instrument block,Air / oil flow.Inlet side,To oil vessel + sealed by o-ring,Inlet side,Inlet side,Mounting bolts,Oil sep.filter,Air / oil pre separation,Instrument block,Connections M22x1Pipe mounted with Loctite 577Purpose : to avoid oil consumptionM36x1.5Nipple : for OSF mounting.A : scavenge line connectionB : to unloader : to blow of valveC : min.press.valve positionD : air outlet connection,Air / oil pre separation,Instrument block,Air / oil separationM22x1Pipe mounted with Loctite 577Without Loctite , the collected oil comes in the air system.M36x1.5 NippleSeals off at the al.instrument block.Non return valve is mounted at the element side.Not in the instrument block.,Scavenge line opening is 4mm,Air / oil pre separation,Instrument block,Scavenge line connectionIs connected via :Nipple + seal washerFlexible 1622 4781 02Non return valve 1613 9005 01Mounted in al.conn.part,Air / oil pre separation,Instrument block,What happens when this hole is clogged ?,Air / oil pre separation,Instrument block,Oil vessel blow off line.Is connected via :Elbow 0581 1200 23Black PVC flex. 0070 6002 05To blow of valve at unloaderWorking principle : see unloader section,Air / oil pre separation,Instrument block,Min.pres.valveIs mounted at the bottom of the instrument block.Act as min.pr.valve and as non return valve.Idem as previous rangeOpen. pr. 7bar=13bar/175psi2901 1411 00 open.pr.4bar= 7.5 - 8.5 - 10bar= 100 125 - 150 psi.2901 1399 00,Air / oil pre separation,Sealing min.press.valve/check valveWhich position ?,G1 thread,Instrument bloc