High Pressure Breathing Air Compressors NAUTILUS MINI

Transcription

1 High Pressure Breathing Air Compressors NAUTILUS MINI

2 1. INTRODUCTION This manual contains operating instructions and maintenance schedule for the high pressure breathing air compressor unit NAUTILUS MINI NAUTILUS MINI series are newly designed high pressure air compressor to compress air for breathing. It comes in 3 different model variations: 3 phase motor Single phase motor Petrol Engine NAUTILUS MINI has 3-stage air compression, 2-layer of filtration. The compressed air is purified by activated carbon and molecular sieves to clean out oil and impurities. High pressure air compressor are suitable for diving operations, water sports, fishing, aqua farming, underwater construction, fire fighting, military and aerospace application, providing the user with high purity, clear, odorless, safe and reliable breathing air. NAUTILUS MINI high pressure air compressor produces breathing air the complied with National GB standards, and also European EN12021 standards. The high performance, durability, and value for money of NAUTILUS MINI make it a popular choice among the consumers. The breathing air product with the compressor units described in this manual is subject to strict quality standards. Ignoring the operating and maintenance instructions can lead to severe injury or death. The machine has been built according to the highest standard of technology and the generally acknowledged safety standards. Nevertheless, operation could still cause danger for the operating personnel or third parties, or result in damage to the machine and other values. The machine may only be used to produce compressed air as specified in this manual. Other use is strictly prohibited. All instructions should be observed and carried out in the order laid down to prevent damage and premature wear to the equipment. The manufacturer and the supplier void all responsibility for damage or injury resulting from failure to follow these instructions P a g e

3 2. CONTACTS AND CORRESPONDANCE We are happy to give you advice on any question regarding your NAUTILUS compressor and help as soon as possible with any arising problems. Do you want to order spare parts? Do you have problems with maintenance or repair work? Feel free to contact us. You can contact us Mondays to Fridays from 0830 till 1730 on phone no. (65) Or visit us on the internet at: Our international office location Nautilus International Pte Ltd 883 North Bridge Road #19-05 Southbank Singapore Telephone: FAX: P a g e

4 3. SAFETY MEASURES IDENTIFYING THE SAFETY NOTICES Important instructions concerning with possible endangerment of personnel, technical safety, and operating safety will be specially emphasized and highlighted in the manual with the use of the following signs. DANGER This notice must be complied with in order to avoid damage to or destruction of the machine or its equipment. WARNING This notice is used with maintenance work and operating procedures and must be adhered to exactly in order to avoid endangering personnel IMPORTANT This notice advises of technical requirements which the operator must take particular note of P a g e

5 NOTES AND WARNING LABELS WARNING LABELS DESCRIPTION WARNING DESCRIPTION LABELS Hot surface, do not touch! Removal of safety devices prohibited High Voltage Work on moving parts prohibited Risk of hand crushing Smoking Prohibited Danger of moving parts Gloves Compulsory Flammable Goggles Compulsory P a g e

6 Instruction must be read Helmet Compulsory by person operating the machinery P a g e

7 COMPRESSOR OPERATION IN BRIEF Read instruction manual before operating the unit. Check oil level on compressor and petrol engine before operating unit. Turn on the machine and ensure the direction of motor rotation is correct. Operation duration per session should NOT exceed 60 minutes. Drain condensate at least every 15 minutes (On all drainage locations) Release and purge gas and pressure after each use. Strictly forbidden to repair or inspect the compressor when it is connected to power supply and/or pressurized. Strictly forbidden to deform high pressure hose in pressurized state. Air filtration housing, Oil & Water separator housing and high pressure hose need to be replace every 7000 hours of usage. High pressure safety valve need to be inspected annually P a g e

8 IMPORTANT REMINDER Always ensure the charging pressure in below maximum pressure of gas cylinder. Always check the oil level before operating the machine, If any odd noise is produced, immediately stop the machine for inspection. Long duration usage will cause heating of equipment, which can severely reduce the equipment lifespan. Bleeding need to be done for the equipment after each running duration of 15 minutes Machine need to be disconnected from power supply and completely depressurized before troubleshooting or repairing. After each usage, bleed all the waste liquid and close up the bleeding valve. Store the machine in an airy and dry location. If the user is unable to confirm / identify issues or troubleshoot the equipment, please contact our customer support P a g e

9 4. COMPRESSOR DESIGN The main parts of the compressor are made up of: motor (electrical), multi-stage condenser, oil & water separator housing, air filtration housing, pressure display, pressure control and pressure safety mechanism. Electric Label Component 1 High pressure gauge 2 Motor terminal box 3 Single / Three-phase motor 4 Final pressure safety valve 5 Air intake 6 Compressor oil pipe 7 Filtration system 8 Handle 9 Fanwheel cover 10 Condensate drain valves P a g e

10 Petrol Label Component 1 Exhaust 2 Air filter 3 Tank 4 Throttle lever 5 Choke lever 6 Engine stop switch (ignition) 7 Starter rope 8 Safety valve, final pressure 9 High pressure gauge 10 Air intake 11 Compressor oil pipe 12 Filtration system 13 Condensate drain taps P a g e

11 Label Component 1 Final pressure safety valve 2 Filling valve with pressure gauge 3 Filling hose 4 International filling connector 5 Filtration system 6 Pressure maintaining valve 7 Condensation drain tap 8 Air filter 9 Petrol Tank 10 Exhaust 11 High pressure gauge 12 V-belt cover P a g e

12 AIR FLOW DIAGRAM Figure 1: Air flow diagram Fig. 1 shows the operation stages of the machine. When the motor drives the compressor via the triangle belt, free air enters the first stage cylinder through the filtration unit. When a certain level of pressure is achieved, the gas enters into first stage cooling coil, which the air are cooled and transferred to second stage cylinder. The gas will be further compressed and cooled in order to transfer the gas into the third stage cylinder, where the gas is to be further compressed to the final necessary pressure. Then, the compressed air is passed through oil and water separator unit, air filtration unit to further purify the air by removing unwanted impurities, condensate and vapor. Finally, the compressed air passes through the pressure maintenance valve to produce clean, pure and odorless air. Figure 2: Compressor block NAUTILUS MINI P a g e

13 TECHNICAL DATA Model No. Layout Delivery Rate Output Pressure NAUTILUS MINI Petrol NAUTILUS MINI Electric drive drive Three stage compression reciprocating active piston 125 L/min 225 / 330 Bar Drive Electric Motor Petrol Motor R.P.M Power 2.2kW 3 phase 2.2kW Single phase 5.5PS Lubrication Cooling Method Noise Splash Air Cooled <78dBA Dimension(L B H) cm 69x42x48 cm cm Weight 48kg 50g 44kg Lubricant Recommend use Nautilus compressor oil P a g e

14 5. LOCATION, SAFETY, OPERATION, BOTTLE FILLING LOCATION Keep unit away from flammable items. Do not smoke while petrol tank is open and while unit is in operation. Compressor should be parallel to the floor. Maximum allowable inclination is 5 degrees to ensure effective lubrication and operation. An air conditioner is required if the operation temperature exceeds 40 C Position the machine at a minimum distance of 1m from surrounding walls and 1.5 m from ceiling in order not to compromise the proper operation and cooling of the compressor. Do not operate unit in vicinity of open fire. Ensure adequate ventilation. Air must be free from exhaust fumes and hazardous vapors (e.g. smoke, solvent vapors, high concentration of dust, etc.) If possible, install unit for the compressor fan to be able to get fresh air. Ensure adequate exhaust air opening is provided. When operating in location where natural ventilation is not ensured, measures must be taken to provide artificial ventilation. SAFETY The compressor room should be kept tidy, the floor area clear of obstacles and doorways unobstructed. Eye protection should be worn when carrying out any mechanical operation, especially where rotating tools and compressed air are involved. Ear defenders should be used when operating compressed air tools, releasing compressed air, working near compressors or whenever the ambient noise level exceeds 90 decibels (dba) Shoes or boots with built in toe protection should be worn whilst handling heavy items. Barrier creams should be used when using oils, greases, solvents, adhesives, cleaning agents and chemicals. Rashes and dermatitis are not uncommon when working with these products. Diameter of copper core wire should not be less than 2.5cm 2, length not shorter than 10 meters for single phase power extension cord. (Wire connection not following the standards will cause an increase in operation temperature due to higher electrical resistance, increasing the risk of equipment failure) P a g e

15 If power supply cable is to be replaced, only use cable of the same type. The compressor needs to be earth effectively. OPERATION All compressor units are tested prior to delivery to the customer, so after correct installation of the unit there should be no problem putting it into operation. Prior to first operation, read the instruction manual carefully. Make sure that all persons handling the compressor and the filling station are familiar with the function of all controls and monitors. After a standstill period of 2 years or more, compressor oil need to be change before taking the unit into operation. When mineral oil is used, oil change is needed for every year. Prior to first operation or operation subsequent to repair work, operate unit for at least 5 minutes with open condensate valves (pressure-less state) to ensure proper lubrication of all parts before pressure is built up. Prior to each operation, check the compressor oil level and determine whether maintenance is necessary. Every time the unit is started up, check all systems for proper operation. If any malfunction is observed, stop unit immediately and find the cause for the fault or contact the customer service. For three phase current motor units, immediately after switching on the system for the first time, check the direction of rotation of the motor for compliance with the arrow on the unit. It motor turns in the wrong direction, the phases are not connected properly. Shut down unit immediately and interchange two of the three phase leads in the switch box. Never change leads at the motor terminal board. For the petrol engine units, o Check engine oil level. o Check fuel tank. Top up if necessary. o Open fuel shut-off valve Close condensate drain valves and run unit to final pressure. Check final pressure safety valve and pressure gauge. As soon as final pressure is reached and final pressure safety valve blows off, open condensate drain valves and drain condensate unit is ready for filling operation. Do not tamper with the safety valve, as it will result in serious damage and guarantee of the compressor will be voided P a g e

16 Instruction before start up 1. Pour in suitable compressor oil into the unit. Check the compressor oil level. The level should be around the middle line position (Refer to picture below) Figure 3: Position to check compressor oil Figure 4: Compressor oil positions Check and ensure that the oil level is between maximum and minimum line. If the oil is too high, air valves will carbonize, and too low will result in insufficient lubrication and cylinder sticking P a g e

17 2. Check the triangle belt s tension and all the connected parts for signs of loosening. 3. In order to start up and equipment, open up the oil water separator condensate drain valve and air filtration condensate drain valve. (Refer to the figure below) Figure 5: Opening of condensate drain valves 4. Check if the rotational direction of the mechanical belt follows the right direction. The cooled air should be blowing towards the equipment s direction. If rotational direction is wrong, it will cause the equipment to have insufficient cooling which could lead to excessive wear of cylinder and crank shaft fracture P a g e

18 BOTTLE FILLING Filling hoses must be in satisfactory condition and threads undamaged. Pay particular attention to damage on the interface from hose fitting to hose. If the rubber is scored, hose must be discarded otherwise water can enter and attack wire gauze casing it to rust and thus endangering pressure tightness Only use accredited air bottle with pressure indication. 1. Test run Open the oil vapor drain valve and condensate drain valve for free loading, connect air bottle and compressor outlet with flex hose. Turn off the charging valve. Start up the compressor and wait for the equipment to be stabilized. When it is stabilized, turn off the oil vapor drain valve and condensate drain valve for the pump to begin pressurize. When the pressure reaches the rating pressure, the safety valve will be triggered. Safety valve is mounted on the purification filter while pressure gauge is mounted on the oil vapor separator. There are 2 drain valves which manually drain after every refill operation. The compressor fills air bottle under 12L. Longtime continually running is not suggested, because it may results in temperature rising, parts damaged and the machine life shortened. Check the pressure gauge and if any abnormalities are observed, stop the equipment for inspection. 2. Connect the charging hose to the air bottle Use only certified high pressure cylinder. Maximum pressure must not be higher than cylinder safety working pressure. Check and ensure that the charging hose are in perfect condition without any signs of damage. Note that the adaptor needs to be closed. Open the condensate drain valve for free loading for a few minutes. After it runs well for a few minutes, turn off the drain valve and open the charging valve. 3. When the cylinder is charged to the expected pressure value, stop the equipment and cut the power supply. Close the charging valve. 4. After stopping the equipment, open the oil vapor separator drain valve immediately to depressurize. 5. After the release of high pressure air in the changing hose, remove the charged gas cylinder. Open the drain valves to purge high pressure gas and condensate after every refill operation P a g e

19 Do not disconnect charging hose before purging the pressure in the compressor. How to deal with emergencies during air filling If emergencies happened during the charging process Power failure Power cutoff due to overload Sudden halt of compressor 1. Shut off the main switch of the compressor immediately and bring the equipment to a total stop. 2. Simultaneously, shutoff the charging valve on the cylinder. Once the charging process has ended, the condensate drain valve need to be open to discharge the condensate. After purging, close the condensate drain valve to avoid moisture from entering the equipment, causing corrosion and rusting, which affects the equipment lifespan P a g e

20 6. MAINTENANCE AND REPAIR All maintenance tasks must be carried out with the compressor off and the power lead un-plugged from the mains socket Every Refill 5 h 25 h 30 h 50 h 100 h 1000 h Annually Oil level check Belt wear and tension Air intake filter Safety valve check Hose and fitting check Check Replace Oil level check and change Oil level must be checked every 25 hours. Oil must be replaced after 100 working hours or annually. For first time operation, change the oil after 50 working hours. Check drive belt tension and replace Figure 6: Check drive belt tension To check belt tension, remove the cover by removing the fixing screws and exert a pressure of approximately 10kg on the belt. Check that the belt does not flex by more than 1 cm with respect to its original position. Should it flex more than this: o Loosen the engine fixing screws and the cooling fan cover fixing screw o If the belt is worn or close to its scheduled time for replacement, change it with a new one o Remove the belt and withdraw the engine by about 5 mm o Fix the screw and tighten the cooling fan cover fixing screw o Re-fit the belt, re-check belt tension and re-fit the cover A mixture of different compressor oil cannot be used. The drive belt must be replaced annually or every 1000 working hours of the compressor. If the tension of the new belt still fails to comply with the necessary requirement, contact Nautilus customer service P a g e

21 Changing of air filter After putting the compressor into service the intake filter must be changed after the first 25 working hours. The air filter must then be changed every 100 working hours or annually. Compressor s air intake filter cartridge (10 mm paper air filter cartridge) should be kept clean. If it is found to be dirty / aged / blocked, it should be change periodically. Air Filter Figure 7: Removal of air filtration unit and changing of filter cartridge The breathing air quality is largely affected by the saturation and condition of activated carbon and molecular sieve, thus it needs to be regularly changed. If the air from the compressor is used for breathing air purpose, the activated carbon in the filtration unit need to be changed once for every 50 cylinder / 12L of charging. Early replacement is needed if the breathing air is found to have oil smell or other odor P a g e

22 Instructions to change filtration cartridge 1) For changing of filter cartridge, use customized tools and rotates following the anti-clockwise direction to remove the filter. 2) Use fingers to hook onto the filter cartridge unit. Pull it up to remove and change into the new filter cartridge. 3) Use fingers to press down on the new filter cartridge to lock it in place. Close the filtration unit lid by rotating it and close it firmly P a g e

23 Purging condensate of The compressor oil released from the separator of each stage goes through condensation and form water emulsion. Purge once for every minutes Periodically after charging (10 15 minutes), the condensate drain valve needs to be open. If purging is not done, it will affect the air quality, or even leads to equipment damage. Under normal condition, the bleed condensate should be in milky white or brown color. If the condensate shows to be dark brown in color and has strong oil smell, inspection of the lubricating oil quality and oil level is needed. 7. TROUBLESHOOTING P a g e