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Final-Documents
Chengxi SY
Hull No. CX4238 to 4247
Sauer Order-No. 41005407
2 x Main air compressor WP151L
1x Topping up air compressor WP22L
1x Emergency air compressor SCK22
Revision Changes Date Sign
0 initial issue 25-Oct-2007 DH
page 1/108
Transport and Installation
I_MO001_2A.fm
Transport and Installation
- Transport
Shipping The machine is packed suitable for shipping.
? Immediately on receipt of the Sauer Kompressor it should be
checked for completeness and damage.
? The transport company and J.P. SAUER & SOHN must be im-
mediately notified of any damage to the packing or the machi-
ne.
Transportation The Sauer Kompressor must must be transported by a forklift
truck or hoisted by crane.
Danger!
Suspended load when transported.
The forklift truck/crane must have sufficient load bearing capaci-
ty.
? Ensure that no persons stay within the danger area of the sus-
pended load and the forklift truck/crane.
? Sling the unpacked compressor at the two lifting eyes and at
the pipe (see illustration). Protect pipe sling location against
scratching.
? Lift, move, and set down carefully.
Lifting eyes
Pipe
sling location
page 2/108
I_MO001_2A.fm
- Storage before installation
If the Sauer Kompressor has to be stored before installation, do
not unpack and store at the following conditions:
– temperature: +5 to +40 °C;
– relative humidity 30 … 95%, not condensating;
– dry, under a roof and protected against dew;
– protected against soiling;
– protected against vibrations and shocks.
- Installation
For installation observe the installation instructions and the follo-
wing conditions.
Installation condi-
tions
– The place of installation must be dry and free of dust.
– The place of installation must be vented in such way that the
heat generated during operation is dissipated.
– Room temperature while the Sauer Kompressors is running:
+5 … +55 °C
(deviating temperatures only if confirmed in writing by
J.P. SAUER & SOHN)
Note!
The standard factory conservation is sufficient for a maximum
storage period of 12 months.
Note!
When in doubt if the intended place of installation and room are
suitable, contact J.P. SAUER & SOHN in time before the instal-
lation. There you will also get help with the design of a ventilating
system, if required at the place of installation.
page 3/108
Transport and Installation
I_MO001_2A.fm
Note!
The air temperature at the cooling air intake of the compressor
must not exceed +55 °C when the compressor is running. Room
conditions and the heat, generated by the compressor and other
machines installed in the room, must be taken into considerati-
on.
? If necessary, install a ventilation or exhaust system at the
place of installation.
? Install any ventilation system in such way that the fresh air
stream is not directly directed against the compressor. Other-
wise there is a risk of condensation of water inside the machi-
ne and subsequent damage.
Do not install fresh
air feed this way!
This way is correct!
page 4/108
I_MO001_2A.fm
Installation condi-
tions (cont''d)
– At a room temperature of below +5 °C the room needs to be
heated or the Sauer Kompressor must be equipped with a he-
ating system.
– Choose the location so that the Sauer Kompressor is acces-
sible and has sufficient clearance to walls and other machinery
(see installation documents).
– Do not position the motor side in a room niche, so the Sauer
Kompressor will not take in the warmed-up cooling air again.
– Do not position several compressors one after the other, to
prevent one compressor from taking in the warmed-up cooling
air of another compressor.
Foundation
1. Check early enough if there are foundation vibrations in the
10 Hz range.
2. If in doubt, check with J.P. SAUER & SOHN to see if a modi-
fied resilient-mount bedding can be used.
Note!
J.P. SAUER & SOHN is glad to advise you on the installation of
the compressors.
Note!
The standard delivery resilient-mount bedding has a resonant
frequency of approx. 10 Hz.
Generation of oscillations of the intended foundation by other ne-
arby machinery must not be at 10 Hz. Otherwise there is a risk
that the standard delivery resilient-mount bedding is destroyed
by sympathetic vibration.
page 5/108
Transport and Installation
I_MO001_2A.fm
- Connecting the compressor
Pipelines The compressed air outlet and the drain outlets of the Sauer
Kompressors must be connected to the stationary pipelines by
hose lines.
Danger!
The compressor should only be connected by qualified technici-
ans. Any work on the electrical installation must be carried out
by qualified electricians only.
Note!
The oil filler tube is insulated using a section of hose. Do not re-
move the insulating material.
Hose lines
Danger!
Compressed air escapes from the drain outlets when the com-
pressor starts and when the condensate is drained. Do not ope-
rate compressor without the hose lines connected.
page 6/108
I_MO001_2A.fm
Hose lines have to be installed free of tension and untwisted.
Drainage
Not this way!
This way is correct!
Note!
Condensate build-up is oil-saturated. It may only be disposed of
in compliance with applicable legal regulations.
J.P. SAUER & SOHN can supply condensate collecting pots for
separating condensate, as well as condensate treatment units
for separating the oil from the condensate.
Note!
We recommend connecting the compressor''s drainage separa-
tely.
When the drain lines of several compressors are to be connec-
ted to a common pipe, observe the following:
– Choose a sufficient nominal diameter for the common drain
line.
– Connect drain lines of the individual compressors at a sharp
angle to the common drain line, so no pressure can build up
in the drain line of a stopped compressor.
page 7/108
Transport and Installation
I_MO001_2A.fm
37
This way is correct!
Not this way!
page 8/108
I_MO001_2A.fm
Connections The illustration below shows the connections and armatures for
the operation of the standard versionSauer Kompressors.
13
456
2
7
Note!
For technical specifications of the individual items please refer to
Chapter 4
All selective switches are factory set.
As an option, the subsystems can be prewired in a terminal box.
Item Designation Type Function
1 Drain valve Solenoid valve Starting relief and drainage
2 Drain valve Solenoid valve Starting relief and drainage
3 Drive motor 3-phase motor Drive of the compressor
4
Ultimate pressure
switch
Selective switch Stops/starts the compressor
5 Oil pressure switch Selective switch Stops compressor when oil level is low
6
Temperature control
(optional)
Selective switch Stops compressor in case of excess tempera-
ture
7 Non-return valve Plate valve Prevent air backflow
page 9/108
Transport and Installation
I_MO001_2A.fm
- Filling in oil
The Sauer Kompressor is supplied without oil.
1. Unscrew oil filler plug (red).
2. Fill in oil and check level with the dipstick.
3. Put dipstick back in and replace the oil filler plug.
Danger!
Oil must be filled into the compressor''s crankcase before initial
operation!
Use lubricating oil (see chapter 10. “Lubricant Table”).
Observe filling amount (see chapter chapter 4. “Technical Speci-
fications”).
Oil filler plug
Dipstick
Note!
Fill only to the upper marking on the dipstick. Otherwise the oil
consumption of the compressor will increase.
page 10/108
Technical Specification Sauer Compressor Unit Type WP151 L
as per enclosed drawing B 151 – D 5984
Fill-up-Capacity 0 – 30 bar: 180 m3/h
Operation pressure/max operation pressure 30/40 bar
Speed: 1770 rpm
Required power: 38 kW
Stages / Cylinders: 3 / 3
Cooling: air-cooled
Heat dissipation: 42 kJ/sec
Ambient temperature up to: + 5 up to + 55 ° C
Permissible inclination each direction 22,5 °
Sound level in 1 m distance: 93 dB(A)
Unit weight: 700 kgs
Drive: direct drive
Lub.oil content crankcase 13,6 ltr.
Color Munsell 7.5BG7/2
All capacity data with 5 % tolerance
Standard Equipment:
- Sturdy rigid and weight saving design with flanged motor
- no bedplate necessary
- flexible coupling, fully covered inside compressor flange
- air intake and silencing filter
- oil- and water separator after 2nd and 3rd stage, mounted
- intercoolers and final recooler
- pressure oil lubrication with lifetime filtration by sieve
- crankshaft driven cooling air fan
- resilient mounts for the unit
- flex. hp-hose for drainage and air-outlet ( mounted non return valve)
- all hoses type approved by class
- safety valves after each stage
- air thermometer after each stage,
- Oil pressure gauge, stage pressure and final pressure gauge, glycerine filled
- name plates (symbols) for all gauges and thermometers
- solenoid valves 230 V/50/60 Hz for automatic and periodic drainage
- of all 3 stages
- starting relief integrated in condensate drain automation (unloaded start)
- oil pressure control switch for “alarm + stop”
- temperature switch at air outlet for supervision of compressor cooling, “alarm + stop”
- pressure switch start/stop, loose
- threephase motor size 225S with suitable marine cable glands (brass)
rated output acc ISO B: 43 kW
speed: 1770 rpm
voltage/frequency: 440/60 V/Hz
starting current: abt. 547 A
nominal current: abt. 72 A
efficiency/ starting time abt. 94 %/ 2-3 sec
weight: abt. 400 kg
protection/ISO class IP 55/ F
page 11/108
Additional Equipment for the 2 compressor unit (included):
- 1 spare part set “B+A” as per regulation
CCS for Hull CX4240 / 41 / 44 / 45. DNV for Hull CX4238 / 4239 / 4242 / 4243 / 4246 / 4247
Test and certificates:
- test and certificate for the compressor as per regulation
CCS for Hull CX4240 / 41 / 44 / 45. DNV for Hull CX4238 / 4239 / 4242 / 4243 / 4246 / 4247
- workstest for the motor
- certificate for motor
page 12/108
4.2 Compressed air wiring diagram
19 3425 43354210
6
5
12 11 13 8 7 8 258 7
Inlet
atm.
14
15
Outlet
Item Designation
1 Drive motor
2 Safety valve
3 Compressor stage
4 Intercooler and aftercooler
5 Pressure gauge
6 Oil pressure switch
7 Separator
8 Solenoid valve
9 Intake filter
10 Temperature switch (optional):
11 Oil pump
12 Overpressure valve
13 Oil filter
14 Non-return valve
15 Condensate collecting pot
page 13/108
Fundamentplan
mounting plan
?18
140
180
100
920
490
Ma?stab
Ers.f.
Ers.d.
Blatt
Bl.
Sach-Nr.
Code-Nr.
bearb. gepr. Freigabe
Werkstoff
Rohteil (Code- u.Sach-Nr.)
Datum
Name
J.P.SAUER SOHN
MASCHINENBAU GMBH CO.
&
&
Lft.Nr.
Fertiggewicht (kg)
Modell-Nr.
Freima?toleranz nach
WN 1340-1
Für diese Unterlage
wird jegl.Rechtsschutz
in Anspruch genommen
Index ?nderung ?nd.Nr. Datum Name
Kanten gratfrei
bis 0.3 mm gebrochen
B 151 - D 5984 .
.
1
1
1:10
064525/1-0148
700 Kg
Kompr.-Aggregat WP 151L
Mit Drehstrommotor 225S IP 54
17.06.
1997
Dahms
a
b
c
d
Dahms
Romeyke
Sukiennik
Romeyke
07.04.1998
15.04.1999
06.06.2003
05.11.2003
.
.
.
....Ma? 464 dazu; 925 in 960
Druckluftschlauch ge?ndert
Entw?sserungsschlauch
Ma? Kondensataustritt ge?nd.
C:00008016
Achtung: Installationshinweise AUT-E 22077
Attention: Instructions of installation AUT-E 22077
Mindestens 300mm Abstand bis zur n?chsten Wand einhalten
Keep at least 300mm distance to the next wall.
750
780
295
1575
787 1000
331
Schmelzsicherung
fusible plug
?ldruckschalter
oil pressure switch
Ansaugfilter
air intake filter
Kondensataustritt
Schlauch d
i
=60mm
condensate outlet
hose d=60mm
490
955
960
71
464
406
920
370
465355
593
6
?ldruckmanometer
oil pressure gauge
Druckluftaustritt
air outlet
Manometer I.Stufe
gauge stage I.
Manometer II. Stufe
gauge stage II.
Manometer III. Stufe
gauge stage III.
?labla?
oil outlet
?lpeilstab
dipstick
Rohr 22x1,5 Schneidringvers.
pipe 22x1,5 bite-type fitting
Thermometer I. Stufe
Thermometer II. Stufe
Thermometer III. Stufe
thermometer stage III.
thermometer stage II.
thermometer stage I.
flexibler Schlauch
flexible hose
1000 lang
1000 long
page 14/108
2 Compressor control panel for 2 compressor-unit WP 151L
Nominal motor rating 43 kW
Power supply 3x 440V / 60Hz
Isolation IP54
Material Steel
Labelling English
Colour Munsell 7.5 BG 7/2
For wall-mounting; with lockable front door and marine cable glands in a flanged base
plate at the bottom, "fail-safe" wiring with following standard-devices for the automatic
and unattended operation of the compressor-unit according to the rules and regulations
of the ship classification societies:
- automatically operated main contactor for direct-on-line starting (DOL)
- thermal overload relay with alarm and compressor shut-down
- control voltage internally transformed by built-in control voltage transformer 440V/230V
with fuses
- hourmeter
- oil pressure supervision with alarm and compressor shut-down
- temperature supervision with alarm and compressor shut-down
- intermediate drainage of the compressor-stages each 15 min for 15sec
- start-stop relief arrangement
- selector switch for operation mode: "On - Off/Reset - Remote Start/Stop"
- signal lamps for "Operation", "Overload", "Air temperature" and "Oil pressure" “ power
on”
- cage clamps for connecting power supply, motor, drain valves and start/stop signal
- cage clamps for potential-free contacts "Operation", "Off" and "Collective fault"
- Ammeter
1 Lead / lag control box for selecting the starting sequence of 2 compressors
(delivered loose)
Isolation IP54
Material Steel
Labelling English
Color Munsell 7.5 BG 7/2
- selector switch for selecting the starting sequence of the compressor-units
- ?stand by“ function by staggered pressure switch settings
- cage clamps for connecting pressure switches or equivalent start/stop signal
page 15/108
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page 48/108
Transport and Installation
I_MO008_1A.fm
Transport and Installation
- Transport
Shipping The machine is packed suitable for shipping.
? Immediately on receipt of the Sauer compressor it should be
checked for completeness and damage.
? The transport company and J.P. SAUER & SOHN must be im-
mediately notified of any damage to the packing or the machi-
ne.
Transportation The Sauer compressor must be transported by a forklift truck or
hoisted by crane.
Danger!
Suspended load when transported.
The forklift truck/crane must have sufficient load bearing capaci-
ty.
? Ensure that no persons stay within the danger area of the sus-
pended load and the forklift truck/crane.
? Sling the unpacked compressor at the two lifting eyes on the
crankcase and electric motor or diesel engine as the case
may be (see illustration).
? Lift, move, and set down carefully.
page 49/108
I_MO008_1A.fm
Lifting eyes on the
Sauer compressor
with electric motor
page 50/108
Transport and Installation
I_MO008_1A.fm
- Storage before installation
If the Sauer compressor has to be stored before installation, do
not unpack and store at the following conditions:
– temperature: +5 to +40 °C;
– relative humidity 30 … 95%, not condensating;
– dry, under a roof and protected against dew;
– protected against soiling;
– protected against vibrations and shocks.
Lifting eyes on the
Sauer compressor
with diesel engine
Note!
The standard factory conservation is sufficient for a maximum
storage period of 12 months.
page 51/108
I_MO008_1A.fm
- Installation
For installation observe the installation instructions and the follo-
wing conditions.
Installation condi-
tions
– The place of installation must be dry and free of dust.
– The place of installation must be vented in such way that the
heat generated during operation is dissipated.
– Room temperature while the Sauer compressor is running:
+5 … +55 °C
(deviating temperatures only if confirmed in writing by
J.P. SAUER & SOHN)
Note!
When in doubt if the intended place of installation and room are
suitable, contact J.P. SAUER & SOHN in time before the instal-
lation. There you will also get help with the design of a ventilating
system, if required at the place of installation.
Note!
The air temperature at the cooling air intake of the compressor
must not exceed +55 °C when the compressor is running. Room
conditions and the heat, generated by the compressor and other
machines installed in the room, must be taken into considerati-
on.
? If necessary, install a ventilation or exhaust system at the
place of installation.
? Install any ventilation system in such way that the fresh air
stream is not directly directed against the compressor. Other-
wise there is a risk of condensation of water inside the machi-
ne and subsequent damage.
page 52/108
Transport and Installation
I_MO008_1A.fm
Installation condi-
tions (cont''d)
– At a room temperature of below +5 °C the room needs to be
heated or the Sauer compressor must be equipped with a he-
ating system.
– Choose the location so that the Sauer compressor is accessib-
le and has sufficient clearance to walls and other machinery
(see installation documents).
– Do not position the motor side in a room niche, so the Sauer
compressor will not take in the warmed-up cooling air again.
– Do not position several compressors one after the other, to
prevent one compressor from taking in the warmed-up cooling
air of another compressor.
Do not install fresh
air feed this way!
This way is correct!
Note!
J.P. SAUER & SOHN is glad to advise you on the installation of
the compressors.
page 53/108
I_MO008_1A.fm
Foundation
1. Check early enough if there are foundation vibrations in the
10 Hz range.
2. If in doubt, check with J.P. SAUER & SOHN to see if a modi-
fied resilient-mount bedding can be used.
- Connecting the compressor
Pipelines The compressed air outlet and the drain outlet of the Sauer com-
pressor must be connected to the permanently fitted pipelines
using hose lines (see illustration).
Note!
The standard delivery resilient-mount bedding has a resonant
frequency of approx. 10 Hz.
Generation of oscillations of the intended foundation by other ne-
arby machinery must not be at 10 Hz. Otherwise there is a risk
that the standard delivery resilient-mount bedding is destroyed
by sympathetic vibration.
Danger!
The compressor should only be connected by qualified technici-
ans. Any work on the electrical installation must be carried out
by qualified electricians only.
Hose lines on the Sauer compressor with
electric motor
page 54/108
Transport and Installation
I_MO008_1A.fm
Hose lines on the Sauer compressor with
diesel engine
Danger!
Compressed air escapes from the drain outlets when the com-
pressor starts and when the condensate is drained. Do not ope-
rate compressor without the hose lines connected.
page 55/108
I_MO008_1A.fm
Hose lines have to be installed free of tension and untwisted.
Drain
Not this way!
This way is correct!
Note!
Condensate build-up is oil-saturated. It may only be disposed of
in compliance with applicable legal regulations.
J.P. SAUER & SOHN can supply condensate collecting pots for
separating condensate, as well as condensate treatment units
for separating the oil from the condensate.
Note!
We recommend connecting the compressor''s drainage separa-
tely.
When the drain lines of several compressors are to be connec-
ted to a common pipe, observe the following:
– Choose a sufficient nominal diameter for the common drain
line.
– Connect drain lines of the individual compressors at a sharp
angle to the common drain line, so no pressure can build up
in the drain line of a stopped compressor.
page 56/108
Transport and Installation
I_MO008_1A.fm
Connections The illustrations show the connections and fittings for the opera-
tion of the standard version Sauer compressor.
This way is correct!
Not this way!
page 57/108
I_MO008_1A.fm
5 26 3
14
Note!
For technical specifications of the individual items please refer to
Chapter 4
All toggle switches are factory set.
As an option, the subsystems can be prewired in a terminal box.
Item Name Type Function
1 Drain valve Solenoid valve Starting relief and draining
2 Drive motor 3-phase motor Drive of the compressor
3
Ultimate pressure
switch
Toggle switch Stops/starts the compressor
4
Oil level switch (opti-
onal)
Toggle switch Stops compressor in case of low oil level
5
Temperature control
(optional)
Toggle switch Stops compressor in case of excess tempera-
ture
6 Non-return valve Plug valve Prevent air backflow
page 58/108
Transport and Installation
I_MO008_1A.fm
56
21
3
4 7
Item Name Type Function
1 Drain valve Hand valve Starting relief and draining
2 Drive motor Diesel engine Drive of the compressor
3
Ultimate pressure
switch (optional):
Toggle switch Stops/starts the compressor
4
Oil level switch (opti-
onal)
Toggle switch Stops compressor in case of low oil level
5
Temperature control
(optional)
Toggle switch Stops compressor in case of excess tempera-
ture
6 Non-return valve Plug valve Prevent air backflow
7
Solenoid valve (opti-
onal)
Solenoid valve Starting relief and draining
page 59/108
I_MO008_1A.fm
- Filling in oil
The Sauer compressor is supplied without oil.
1. Unscrew oil filler plug (red).
2. Fill in oil and check level with the dipstick.
Danger!
Oil must be filled into the compressor''s crankcase before initial
operation!
Use lubricating oil (see chapter 10. “Lubricant table”).
Observe filling amount (see chapter 4. “Technical Specificati-
ons”).
Oil filler plug
Dipstick
page 60/108
Transport and Installation
I_MO008_1A.fm
3. Put dipstick back in and replace the oil filler plug.
- Setting the ultimate pressure switch
The pressure loss between the compressor and compressed air
receiver must be taken into account for selecting the maximum
set pressure. Too high a set pressure can cause the safety valve
of the final stage to blow off.
- Checks after installation and before the first start
– Electrical connection corresponds with the type label data?
– Are all connections between compressor and the pressurized
air unit supplied correctly installed? Pay special attention to
the compressed air outlet.
– Are drain lines properly connected? See section “Drainage”
– Oil filled into crankcase?
– Have all tools and foreign objects been removed from the com-
pressor?
– Entire unit clean?
Note!
Fill only to the upper marking on the dipstick. Otherwise the oil
consumption of the compressor will increase.
Note!
The ultimate pressure switch must be connected directly to the
compressed air receiver to ensure a quiet and uniform compres-
sor operation.
page 61/108
Technical Specification Sauer Compressor Unit Type WP 22 L
as per attached drawing B 22 - D 6123
Fill-up-Capacity: 25,3 m3/h
Operation pressure: 30 bar
Max. operation pressure: 40 bar
Speed: 1750 rpm
Required power: 5,4 kW
Stages / Cylinders: 2 / 2
Cooling: air-cooled
Heat dissipation: 4,8 kJ/sec
Drive: direct drive
Ambient temperature up to: + 5 - + 55 ° C
Permissible inclination each direction 22,5 °
Unit weight: 135 kgs
Noise level at 1 m distance: 85 dB(A)
Lub.oil content crankcase 1,5 ltr.
Color Munsell 7.5BG7/2
All capacity data with 5 % tolerance
Standard Equipment:
- Sturdy rigid and weight saving design with flanged motor
- no bedplate necessary
- flexible coupling, fully covered inside compressor flange
- air intake and silencing filter
- oil- and water separator after 2
nd
stage, mounted
- intercoolers and final recooler
- splasch oil lubrication
- crankshaft driven cooling air fan with integrated flywheel
- resilient mounts for the unit
- flex. hp-hose for drainage and air-outlet (mounted non return valve)
- all hoses type approved by class
- safety valves after each stage
- final pressure gauge, glycerine filled, with name plates (symbols)
- solenoid valve 230 V/50/60 Hz for automatic drainage
- pressure switch start/stop, loose
- Temperature switch
- Oil pressure switch
- threephase electrical motor size 132 S with suitable marine cable glands,(brass)
rated output acc ISO B: 6,3 kW
speed: 1770 rpm
voltage/frequency: 440/60 V/Hz
starting current: abt. 73 A
nominal current: abt 11,5 A
efficiency/ starting time abt.86 %/ 1-2 sec
weight: abt 60 kg
protection/ISO class IP 55/ F
page 62/108
Additional Equipment for the 2 compressor unit (included):
1 spare part set “B+A” as per regulation CCS for Hull CX4240 / 41 / 44 / 45. DNV for Hull CX4238 / 4239 / 4242
/ 4243 / 4246 / 4247
Test and certificates:
- test and certificate for the compressor as per regulation CCS for Hull CX4240 / 41 / 44 / 45. DNV for Hull
CX4238 / 4239 / 4242 / 4243 / 4246 / 4247
page 63/108
I_TD021_1A.fm
- Compressed air system plan
1
Outlet
23 4 35 4 6 7 8
12 11 2 10 9
Inlet atm.
Item Name
1 Drive motor
2 Compressor stage
3 Intercooler and aftercooler
4 Safety valve
5 Pressure gauge
6 Temperature switch (optional):
7 Non-return valve
8
Ultimate pressure switch (standard for operation with electric
motor; optional for operation with diesel engine):
9 Condensate separator
10
Drain valve (for operation with electric motor: solenoid valve; for
operation with diesel engine: hand valve)
11 Oil level switch (optional)
12 Intake filter
page 64/108
1 Compressor control panel for 1 compressor-unit WP 22L
Nominal motor rating 6,6 kW
Power supply 3x 440V / 60Hz
Isolation IP54
Material Steel
Labelling English
Colour Munsell 7.5 BG 7/2
For wall mounting; with lockable front door and marine cable glands in a flanged base
plate at the bottom, "fail-safe" wiring with following standard devices for the automatic
and unattended operation of the compressor-unit according to the rules and regulations
of the ship classification societies:
- automatically operated main contactor for direct-on-line starting (DOL)
- thermal overload relay with alarm and compressor shut-down
- control voltage internally transformed by built-in control voltage transformer 440V/230V
with fuses
- hourmeter
- start-Stop relief arrangement
- selector switch for operation mode: "On - Off/Reset - Remote Start/Stop" Power on
- signal lamps for "Operation" and "Overload" “Air temperature” “and oil pressure”
“power on”
- cage clamps for connecting power supply, motor, drain valves and start/stop signal
- cage clamps for potential-free contacts "Operation", "Off" and "Collective fault"
- ammeter
page 65/108
600
270
855
5
178
234
fusible plug
Schmelzpropfen
compressor
Kompressor
elrctric motor
E - Motor
163
323
246
387
132
382
543
air outlet
Rohr 12x1,5 Schneidringverschraubung
Rohr 12x1,5 Schneidringverschraubung
drainage
Peilstab
dipstick
?leinfüllstutzen
oil tank filler
?labla?
oil outlet
separator
Abscheider
safety valve 1. stage
Sicherheitsventil 1. Stufe Sicherheitsventil 2. Stufe
safety valve 2. stage
flexibler Schlauch 1000 lang
flexible hose 1000 long
flexibler Schlauch
flexible hose
500 lang
500 long
Druckluftaustritt
pipe 12x1,5 bite-type fitting
Entw?sserungsaustritt
pipe 12x1,5 bite-type fitting
non-return valve
Rückschlagventil
252
282
390
330
630
5
Manometer II. Stufe
gauge stage II
Ansaugfilter
air intake filter
330
Fundamentplan
mounting-plan
543
50
100
130
643
400
?11,5
70
Achtung: Installationshinweise AUT-E 22077
Attention: Instructions of installation AUT-E 22077
Mindestens 300mm Abstand bis zur n?chsten Wand einhalten
Keep at least 300mm distance to the next wall.
C:00006318
Ma?stab
Ers.f.
Ers.d.
Blatt
Bl.
Sach-Nr.
Code-Nr.
bearb. gepr. Freigabe
Werkstoff
Rohteil (Code- u.Sach-Nr.)
Datum
Name
J.P.SAUER SOHN
MASCHINENBAU GMBH
&
B 22 - D 6123
1
1
1:10
065 568 / 2-0209
065 582 / 1-0141 und
Kompr.-Aggregat WP 22 L
mit Drehstrommotor Bgr.132 S, IP 54
06.02.
2001
Romeyke
13.08.
Sukiennik
135.00
a sukiennik23.10.2002Grundplatten u. Rückschlagventil hinzu
Fertiggewicht (kg)
Modell-Nr.
Freima?toleranz nach
WN 1340-1
Für diese Unterlage
wird jegl.Rechtsschutz
in Anspruch genommen Index ?nderung ?nd.Nr. Datum Name
Kanten gratfrei
bis 0.3 mm gebrochen
Lft.Nr.
page 66/108
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page 80/108
page 81/108
page 82/108
page 83/108
Technical Specification Sauer - ALUP Screwcompressor SCK22-10 MA60
as per enclosed drawing B - SCK E - 6193
Capacity as per ISO 1217 121 m3/h
Operation pressure: 8 bar
Max. pressure: 10 bar
Required power: 16,8 kW
Cooling: aircooled
Drive: v-belt driven
Ambient temperature up to: 50 ° C
Heat dissipation: 18,5 kj/sec
Unit weight: 235 kgs
All capacity data with 5 % tolerance related to ambient conditions
Standard Equipment:
- air intake filter
- compressor rotors with asymmetric profile
- final air cooler
- non-return valve mounted on the compressor
- oil separator
- oil recooler
- safety valve
- starting relief
- self induced pressure lubrication with oil filter
- sound proof canopy
- automatic control unit
ALUP AIRCONTROL AC1(microprocessor control and monitoring unit)
combined load/unload and start/stop control by integrated press.transmitter
star-delta start
indication of pressure, compressed air temperature, running hours
supervision of oil- and air temperature, pressure and maintenance intervals
potentialfree contact for remote alarm indication
start/ stop push button
- resilient mounts incl. flexible hose for airoutlet
- threephase electrical motor:
nominal-rating: 18 kW
speed: 3520 rpm
voltage: 440 V
frequency: 60 Hz
protection / insulation: IP 54 / F
Additional Equipment for the compressor unit:
- Spare parts set “seagoing” as per regulation CCS for Hull CX4240 / 41 / 44 / 45. DNV for Hull CX4238 /
4239 / 4242 / 4243 / 4246 / 4247
Test and certificates:
- worktest certificate
- test and certificate for the compressor as per regulation CCS for Hull CX4240 / 41
/ 44 / 45. DNV for Hull CX4238 / 4239 / 4242 / 4243 / 4246 / 4247
page 84/108
page 85/108
page 86/108
page 87/108
page 88/108
page 89/108
page 90/108
page 91/108
page 92/108
page 93/108
page 94/108
page 95/108
page 96/108
page 97/108
Oil Recommendations
for
Sauer Compressors
page 98/108
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- Lubricating Oils
for Sauer Compressors
The following lubricating oil recommendations for Sauer piston
and screw-type compressors include:
- Mineral oils
- Synthetic oils
- Preservation oils
- Lubricating oils for Sauer screw-type compressors.
Scope The lubricant table applies to all Sauer compressors.
The lubricant table does not apply to temperature ranges outside
of +5 … +55°C.
In general, we recommend mineral oils of the viscosity class in
accordance with ISO VG 100 for the temperature range 5 …
55°C for air compressors. The lubricating oils should at least con-
form to the group VCL in accordance with DIN 51506.
Changing lubri-
cating oil types
from mineral to
synthetic oil
When changing lubricating oil types from mineral oil to synthetic
oil, or vice versa, we recommend to drain completely the existing
oil and to flush three times before re-filling with the new oil type.
Note!
The approved oils in these lists are based upon proven operati-
onal experience with Sauer piston compressors.
Lubricants ’bold’ referred to in the lubricant table may only be
used after approval by J.P. SAUER & SOHN. Otherwise the war-
ranty is void.
Please contact our Customer Service when selecting oils not
listed, or if operating conditions differ from those recommended.
page 99/108
Mineral Oils
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- Mineral Oils
Mineral-base oils are used for a wide range of applications provi-
ding exceptional equipment protection and reliability for compres-
sors by:
Mineral-base oil
general
properties
– Mineral oils have good lubricating qualities.
– Mineral oils are available with differing viscosities.
– Mineral oils can adsorb water.
– Mineral oils do not affect standard seals (NBR).
– Mineral oils are readily available, worldwide.
– Mineral oils are inexpensive in comparison to “special“ oil ty-
pes.
– Different mineral oils can be mixed together.
– The disposal of mineral oil is simpler compared to the disposal
needed for synthetic oils.
The range of application for mineral oils is limited by:
Application
limitations
– Mineral oils are limited by operating temperature.
– Mineral oil viscosity changes with temperature.
– Use of mineral oils may be restricted with high ambient
temperatures.
Standard
mineral oil
As a standard for industrial applications, Shell Corena P 100 is
used in Sauer compressors.
Note!
Unless otherwise ordered, Sauer compressors are delivered
without oil.
page 100/108
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Admitted
mineral oils
The approved list of mineral oils can be used in Sauer compres-
sors:
Brand Product Name Class
Agip Diesel Gamma 30 VCL-100
Dicrea 100 VDL-100
Acer 100 VCL-100
Motor Oil HD 30 SAE 30
Cladium 50 SAE 30
ARAL Kowal M30 VCL-100
AVIA Avilub Compressor oil VDL-100 VDL-100
BP Energol RC 100 VDL-100
Energol IC-DG 30 VCL-100
Vanellus C3 SAE 30 SAE 30
Aircol PD 100 VDL-100
CHEVRON HD Compressor Oil 100 VDL-100
Delo 1000 Marine 30 SAE 30
Veritas 800 Marine 30 SAE 30
ESSO Rarus 426 VDL-100
Rarus 427 VDL-100
Mobilgard 300 SAE 30
Mobilgard 312 SAE 30
Delvac 1230 SAE 30
Shell Corena P 100 VDL-100
Rimula X 30 SAE 30
Melina S Oil 30 SAE 30
Melina Oil 30 SAE 30
Gadinia Oil 30 SAE 30
Statoil MARWAY 1030 SAE 30
TEXACO Compressor Oil EP VDL 100 VDL-100
Regal EP 100 VCL-100
Ursatex 30 SAE 30
Veritas 800 Marine 30 SAE 30
TOTAL Dacnis P 100 VDL-100
Disola M 3015 SAE 30
page 101/108
Mineral Oils
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Mineral oils
for Naval
applications
The following alternative mineral oils can be used without restric-
tion for Naval applications:
Brand Product Name Class
NATO classified O - 278 VDL-120
NATO classified OMD 113 VDL-100
page 102/108
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- Synthetic Oils
Synthetic oils are used in applications for which special
properties are needed:
’Special’
properties
– Synthetic oils offer good oxidation resistance.
– Synthetic oils have improved viscosity-temperature behaviour.
– Synthetic oils are suitable for high and low temperature opera-
tion:
? they have a better flow behaviour at low temperatures;
? they have a slight tendency to vapourise at high
temperatures.
– Synthetic oils have a greater life span owing to lower aging.
– Synthetic oils have a lower combustibility tendency.
– Synthetic oils have an improved chemical compatibility.
The range of application for synthetic oils is limited by the fact as:
Application
limitations
– Synthetic oils display solubility of additives.
– Synthetic oils have hydrolytic properties (separation when wa-
ter is added).
– Synthetic oils have limited anti-corrosion properties.
– Synthetic oils have limited compatibility with elastomers.
– Synthetic oils are not always readily available.
– Synthetic oils are more costly compared to a mineral oil.
– Synthetic oils cannot be mixed with mineral oils.
Note!
We recommend for initial starting to use mineral oils.
Please consult our Customer Service, if you wish to use
synthetic oils.
page 103/108
Synthetic Oils
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The synthetic oils listed below can be used in Sauer
compressors:
Synthetic oils
for Naval
applications
The NATO classified synthetic oil OY 1230 can be used for Naval
applications.
Brand Product Name Class
Agip Dicrea SX 100 VDL-100
AVIA Dynasyth VDL 100 VDL-100
BP Enersyn RX 100 VDL-100
Enersyn RC 100 VDL-100
Tribol 890/100 VDL-100
CHEVRON Compressor Oil Tegra 100 VDL-100
DEA Xenic EP VDL 100 VDL-100
Synstar DE 100 VDL-100
ESSO Compressor Oil RS 100 VDL-100
Mobil Rarus 829 VDL-150
Shell Corena AP 100 VDL-100
Statoil COMPWAY 100 ISO VG 100
YUKONG Super Compressor Oil S 100 VDL-100
Brand Product name Class
NATO classified OY 1230 VDL-120
page 104/108
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Compression of
“dry“ gases
The favorable properties of synthetic oil make this oil type the re-
commended choice for Sauer ’dry’ gas compressors.
The absence of water, or oxygen, content in the ’dry’ gas can re-
sult in poor oil film adhesion and rapid internal wear.
To prevent premature wear, Sauer standard is Mobil Rarus 829
for all ’dry’ gas applications, such as Nitrogen, Helium, Argon,
etc.
Standard
Synthetic oil
As a standard synthetic oil, Mobil Rarus 829 is recommended for
the compression of ’dry’ gases in Sauer compressors.
Note!
As a standard, compressors for Helium- and Argon compression
are supplied by Sauer with a first filling of Mobil Rarus 829,
while compressors made for the compression of other gases are
supplied without first oil filling; for special requests, please con-
tact our Customer Service.
page 105/108
Preservation Oils
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- Preservation Oils
Sauer standard is to use preservation oil Mobilarma 524.
Alternatively, the following preservation or, flushing, oils can be
used:
Sauer standard is to deliver all compressors preserved with Mo-
bilarma 524 to guard against internal corrosion.
To avoid any possibility of downstream contamination on initial
start-up, it is recommended the compressor is run for 15 minutes
“unloaded“ with drain valves open.
Brand Product Name
Agip Rustica C SAE 30
ARAL Konit Engine Oil SAE 30
AVIA MK 1540 S
BP MEK 20 W-20
DEA Deamot EKM 642 SAE 30
Esso MZK Engine Oil HD 30
Antirust MZ 110
Mobil Mobilarma 524
Shell Ensis Motor Oil 30
page 106/108
Lubricating Oils for Screw-Type Compressors
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- Lubricating Oils
for Screw-Type Compressors
The following lubricating oils are recommended for screw-type
compressors:
Mineral oils
As a standard mineral lubricating oil Energol RC-R 46 is used
and required for screw-type compressors.
The use of other mineral oils for screw-type compressors is sub-
ject to special approval by J.P. SAUER & SOHN.
Brand Product Name
BP Energol RC-R 46
Energol RC-R 46-4000
Castrol Aircool PD 46
Chevron Texaco Auriga EP 46
Esso Compressor Oil 46 CA
Fuchs Renolin SC 46
Mobil Rarus 425
Shell Corena D 46
TOTAL / FINA / ELF DACNIS VS 46
Note!
Unless otherwise ordered, screw-type compressors are deliver-
ed with oil.
page 107/108
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Synthetic oils
As a standard synthetic lubricating oil Enersyn RC-S 46 is used
and required for screw-type compressors.
The use of other synthetic oils for screw-type compressors is
subject to special approval by J.P. SAUER & SOHN.
Brand Product Name
Anderol BV Anderol 496
Anderol 3046
BP Enersyn RC-S 46
Enersyn RC-S 46-8000
Castrol Aircol SR 46
Chevron Texaco CETUS PAO 46
SL10-046
ESSO Compressor Oil RS 46
Fuchs Unisyn Oil 46
Mobil Sental SHC 1025
Shell Corena AS 46
TOTAL / FINA / ELF DACNIS SH 46
Note!
Unless otherwise ordered, screw-type compressors are deliver-
ed without oil.
page 108/108
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