Service Manual

Page 1 of 24

Tecom Compressor AS Series:

Service Manual

Model Pressure Serial Number

: : :

Page 2 of 24

Ownership Information Compressor model:

Serial number:

Capacity:

Rated pressure:

Air dryer model:

Dryer serial number:

Capacity: Motor model:

Motor serial number:

Airend model:

Airend serial number:

Delivery date:

First startup date:

Selected Lubricant Information Compressor:

Capacity:

Motor bearing grease: Dryer gear box:

Capacity:

Local Tecom Representative Name: Address: Phone 1:

Email:

Phone 2:

Website:

Fax: Notes:

Page 3 of 24

Safety Precautions Read Safety Precautions before installing, operating, or repairing the unit. Failure to do so may result in severe injury or death. The unit operator must employ safe working practices and observe all related local work safety requirements and ordinances. The owner is responsible for maintaining the unit in safe operating conditions. Only authorized, trained and competent personnel should perform installation, operation maintenance and repair. Any modification on the compressor may only be performed in agreement with Tecom Compressor and under supervision of authorized competent personnel. If any statement in this book, especially with regard to safety, does not comply with local legislation, the stricter of the two shall apply. Installation 1. Compressor or air dryer must only be lifted in accordance with local safety rules. Loose or pivoting parts must be securely fastened before lifting. Before lifting the machine must be turned off and disconnected from the power source. 2. Remove any blanking flanges, plugs or caps from the compressor’s pipe connections. Be sure to use appropriate size connections and pipes, with suitable operating pressures. 3. Be sure to supply the unit with the cleanest coolest ambient air possible. If necessary, install a suction duct at the air intake panel of the unit. Be sure that exhaust air has no possibility to recirculate to the inlet. 4. Keep compressor area free of flammable substances during normal operation. 5. On units that have automatic start/stop, or are remotely controlled, additional warning signs must be placed in the units immediate area. 6. If using multiple compressors in the same system, use manual valves between the compressors to isolate each one from the system. Check valves are not sufficient for this task. 7. If the ground the compressor is being placed on, consult Tecom Compressor or Tecom Compressor’s local representative first. 8. Be sure the compressor is properly grounded and fuses to protect against short circuits are in place. 9. A padding material may be used between the unit and the floor to reduce noise if necessary. Operation 1. All air hoses must be of the appropriate size and they must be rated for an appropriate working pressure. Make sure system is completely depressurized before making any changes to the air piping system, or changing any hoses. 2. Your unit is not considered capable of producing breathing quality air. Additional filtering is needed for breathing quality air. See local regulations. 3. Do not operate unit in the presence of any flammable or combustible substances. 4. Do not operate unit below or in excess of the pressure limits indicated by the manufacturer. 5. Keep cabinet closed at all times. Before performing any work inside the unit, make sure it is shut down and disconnected from the main power supply. 6. Do not remove or alter sound damping material. 7. Keep grounded conductive objects such as tools away form the compressor while it is running. 8. Keep suitable BC or ABC fire extinguishers nearby the compressor at all times. Maintenance 1. Maintenance and repair work shall only be carried out by an authorized person(s). 2. Use only genuine spare parts. 3. Do not perform any maintenance work (other than a visual inspection) without first stopping the unit, and disconnecting it from the power supply. Wait until the compressor has cooled down before starting work. 4. Before removing any pressurized component, be sure the compressor is isolated from the system and that all stored compressed air is completely discharged. 5. Never use a flammable solvent for cleaning the compressor. Avoid using any cleaning solutions that produce toxic vapors. 6. Be careful to not allow any foreign particles to enter any of the exposed openings during maintenance. Covering openings with a cloth as often as possible is highly recommended. 7. Never do any heat operations (for example welding) near the oil system. The oil tanks must be completely purged before carrying such work.

Page 4 of 24 8. DO NOT MODIFY PRESSURE VESSEL in any way. 9. Before putting the unit back into service after maintenance, check the operating pressures, temperatures and time settings and check that the control and shutdown devices are functioning correctly. 10. When changing the separator element, examine the discharge pipe and the inside of the oil separator vessel for carbon deposits and remove them. 11. Be sure to use appropriate eye, hand and body protection when performing maintenance operations in accordance with work place regulations. This should include gloves and goggles where appropriate. 12. Keep area free of sparks and other ignition sources during oil change. In the event of an oil spill, clean immediately. 13. Keep electrical wiring in good condition. Replace any wiring that has cracked, severed, or otherwise degraded insulation. Replace any terminals that are worn, discolored or corroded. 14. Keep suitable BC or ABC fire extinguishers nearby the compressor at all times. Failure to adhere to these precautions, or by non-observance of ordinary caution and due care require in handling, operating, maintenance or repair – even if not expressly mention in this manual – may result in damage to the unit and injury or even death to operator. Tecom Compressor is not liable in this case.

Warranty Information: 1. The manufacturer guarantees their products free of material or manufacturing defects for 24 months from the delivery date, on the entire unit and all components contained within the unit. 2. Only an authorized service center or the manufacturer may carry out repairs or servicing claimed under warranty. 3. Products can only be delivered to the manufacturer for warranty claims only after receiving prior authorization from the manufacturer. 4. The warranty covers free-of-charge repairs/replacement of faulty machine parts. 5. The warranty becomes null and void in case of accidental damage due to negligence, incorrect/improper use, or failure to follow any other guidelines set forth by the manufacturer. 6. The warranty does not cover any transportation costs related to the warranty claim nor does it cover labor costs related to the warranty claim. 7. The warranty is only valid if the purchaser has met all contractual and payment requirements. 8. Only original spare parts supplied by the manufacturer may be used.

Page 5 of 24 Congratulations! You are the proud owner of a new Tecom Compressor rotary screw compressor, a truly wise investment in the future of your company. This instruction book describes what you need to know about your new investment to help ensure a safe, efficient, long life for your unit. Please take the time to read this book before putting the machine into operation to ensure correct handling, operation and maintenance. A proactive strategy to protect your investment guarantees the reliability and longevity of your unit. Be sure to keep this book available to the operator of the unit and make sure that the machine is operated according to the guidelines listed here. Be sure to record operating data and any maintenance performed on the unit. Repairs may only be carried out by personnel authorized to do so by the manufacturer. Do not attempt to perform maintenance yourself. Be sure to contact your local Tecom Compressor partner. If contacting the manufacturer be sure to give the serial number on the unit’s data plate. Tecom Compressor and its partner companies reserve the right to make changes without prior notice.

Table of Contents SECTION

PAGE(S)

1. Safety Precautions and Warranty

3-4

2. Getting Started

6-9

Principle of Operation

6

Installation Instructions

7

Initial Startup

8

3. Maintenance, Service and Spare Parts

10-15

Filter Changes

11

Periodic Maintenance Guide

13

4. Electric Circuit Diagram

16

APPENDICES A. Periodic Maintenance Table

17

B. Connections Sizes

18

C. Quality Control Report

19

D. Service Log

20

E. Declaration of Conformity (CE)

22

F. Initial Startup Checklist

23

G. Additional Useful Information

24

H. Compressor Technical Data

25

Page 6 of 24

Principle of Operation Rotary-screw compressors from Tecom Compressor use a pair of asymmetrical helical screws to compress ambient air. As the motor begins turning the screws, suction is created. The screw unit (airend) begins to pull in ambient air from within the compressor cabinet. Air enters the cabinet through large cartridge type panel filters on the compressor cabinet. These filters are cheap and easily replaced. Their primary function is to remove the largest of particles from the air. Large particles pose a serious a risk to the life of the screw unit. These panel filters therefore should be replaced periodically. Check the maintenance section for guidelines on replacing panel filters and all components discussed in this section. Air inside the compressor cabinet enters the screw unit through the air intake filter and the attached intake valve. The intake filter is of dry replaceable cartridge type, and it is located inside the filter housing, which is attached to the intake valve. The intake valve controls the intake of air into the screw unit and prevents the back flow of air. Air entering into the screw unit, is compressed by the rotating motion of the rotors. During the compression cycle, oil is injected into the system. This oil serves several purposes: 1. Filling the gap between rotors and casing, creating a liquid seal that prevents the compressed air from returning to the suction side. 2. Creating an oil film on the surface of the rotors, thus preventing metal-to-metal contact between the rotors. If lubricated properly, the two rotors should not touch each other during normal operation. 3. Lubricating the bearings in the screw unit. 4. By circulating through the after cooler, the oil also acts as a coolant. Air that is compressed creates heat. This heat is partly taken away by the oil injected into the screw unit. The oil that takes the heat is cooled in oil cooler. The constant circulation of a cooling fluid makes the compression cycle more efficient by making the cycle as close to isothermal compression as possible.. After leaving the screw unit, the compressed air and oil mixture passes to the oil tank and then up through the separator and minimum pressure valve assembly. The oil separator acts removes the majority of oil vapor from the compressed air to approximately 5 ppm. The minimum pressure valve keeps the pressure within the system above 4.5 barg. This is the minimum amount of pressure needed to keep oil circulating in the compressor and therefore the screw unit flooded with oil. If the compressor were to operate at a pressure below 4.5 barg, oil cannot circulate properly and the screw unit will be damaged. Clean air leaves the separator and passes through the after cooler before exiting the compressor to the system. The after cooler is cooled by air being blown over it from within the compressor cabinet. Compressed air enters the oil cooler at around 85-90°C, and exits at around above the ambient temperature 10°C. The cooler also acts to cool the oil. Oil leaves the oil tank through the bottom of the tank (a separate outlet from the compressed air) and circulates through an oil filter and then the cooler. Oil enters the cooler at around 85-90° C, and exits at about around 70°C. Temperature probes within the compressor monitor the temperature and display it either via an analog control or on the PLC screen. An alarm will sound when the compressor temperature rises above 100°C. Should the temperature hit 105°C, the compressor will stop.

2. Getting Started

Page 7 of 24

Air-oil circuit diagram

Installation Instructions Immediately upon receiving your compressor, check it for any damages acquired during delivery. If damaged, report immediately to your local Tecom Compressor agent or to Tecom Compressor, describing in detail the nature of the damage. Do this before installing the unit. 1. Apply all related safety precautions listed in the section of this manual relating to safety. Apply all local safety precautions as well. 2. Be sure to install the compressor on a level floor capable of supporting the weight of the compressor. The maximum acceptable incline of the floor is 5 degrees. 3. The pressure drop over the air outlet pipe can be calculated using the following formula

L ×450 ×Qc1.85 dp = d 5 ×p

Dp = pressure drop (recommended maximum = 0.1 bar) L= length of outlet pipe in meters d = the inside diameter of the outlet pipe in millimeters p = absolute pressure at the compressor outlet in bar(a) Qc = free air delivery of the compressor in liters per second

4. If not using a ventilation system make sure that there is at least 1000 mm between the top of the compressor and ceiling. Also be sure that there are at least 1000 mm of unobstructed space on all sides of the unit. 5. Ventilation system should be made in a way that ensures recirculation of cooling air does not occur. The fan capacity of the ventilation system should match the compressor fan capacity at a pressure head equal to the pressure drop caused by the coiling air outlet ducts. The maximum pressure drop over the ducts should not be more than 0.001 bar. The following formula can be used to calculate the required ventilation capacity. 2. Getting Started

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Qv =0.93 ×N dT

Qv = required ventilation capacity in m3/s N = shaft input power of the compressor in kW dt = temperature increase in compressor room.

6. Necessary steps should be taken to keep the ambient air temperature between 0 and 40 degrees Celsius. Otherwise consult your local Tecom Compressor Agent, or Tecom Compressor. 7. Be sure to place the compressor in a place that is free from all fumes or other hazardous materials. It is recommended to have a dedicated compressor room that has no risk of contamination by toxic, flammable, combustible or otherwise hazardous substances. 8. Inspect all air openings and make sure that there are no coverings, or other obstructions before connecting the compressor to the air distribution system. 9. Insert a manual isolation valve at the outlet of the compressor so that the compressor can be isolated from the system if necessary. 10. Do not install the compressor on the same piping or manifold with a reciprocating compressor. If there is a reciprocating compressor in the plant air system, connect all compressors with separate piping to a common air receive to damp the pulsations caused by the reciprocating compressor. 11. Consult appendix B for required cable sizes. Consult B for recommended outlet pipe diameters 12. Although the compressor is fitted with an after cooler and a moisture separator, it is recommended that a refrigerated air dryer be used in conjunction with your unit. Particle and oil removal filters are also recommended as complimentary products to your compressed air system, depending on your clean air requirements. Consult your local Tecom Compressor representative if there are any questions. 13. Be sure that grounding cable of the unit has a resistance of less than 5 Ohms 14. Be sure that the line voltage is within acceptable values (+/- 5% of nameplate voltage) The compressor is supplied with an oversized after cooler. A refrigerated or desiccant air dryer, particle and oil removal filters are recommended in air systems where various degrees of dry and clean air is required

Initial Startup Instructions Before starting your unit or if the unit has been unused for more than one year, be sure to go through the initial startup checklist and return a signed copy to Tecom Compressor. The checklist can be found in appendix A of this manual. This checklist outlines the procedure to be followed during the initial startup of the unit. Be sure that you have read through this manual and it’s entirety before attempting to start your unit. 1. Apply all related safety precautions listed in the section of this manual relating to safety. Apply all local safety precautions as well. 2. In the event that the compressor is installed at high altitude, outdoors, or is in below freezing temperatures (0 degrees Celsius) consult your local Tecom Compressor agent first. 3. Consult appendix B for electrical cable size. 4. Before starting the compressor check the following: i. Power is turned off. ii. All pipe connections are all tight and sturdy. iii. Check oil level indicator to make sure the oil is at an acceptable level. Add more if needed. iv. Dryer unit is setup and ready to run according to the dryer’s operating instructions. v. Compressor is at least one meter away from other working machinery. vi. Compressor is on a flat surface or a surface with an incline no greater than five degrees. vii. Line voltage is within acceptable values (380±10V). viii. Grounding cable’s resistance is below five ohms. ix. Check that the cable is of an appropriate length and thickness x. Unit’s doors are closed and locked. xi. Connect the power and turn it on. xii. Jog the compressor for about 4 to 6 seconds to allow the oil to fill all empty spaces. xiii. Make sure there are no oil leaks. xiv. Make sure the direction of rotation is correct. If not, turn off the main power, and reverse the phases. Start again at step (xii). xv. Run the compressor until the cooling fan turns on. When the oil temperature reaches about 70°C the cooling fan will start. The fan should blow air out of the cabinet. If air is flowing in the opposite direction, reverse the phases on the fan motor and check again. xvi. Be sure that the compressor loads to the appropriate pressure and that it enters standby (doesn’t produce air). The pressure inside the system should remain steady. After three minutes in standby the compressor should shut itself off. It is important to check that the automatic shutoff is working 2. Getting Started

Page 9 of 24 properly. xvii.Run the compressor and be sure that it unloads at the proper pressure. Open the manual isolation valve and be sure that the compressor loads again. xviii.While the compressor is under full load, check the supply voltage and the current draw of the main motor and the fan motor. Check the pressure inside the compressor. Make of a record of these readings. xix. Stop the compressor and check the oil level. After the initial startup, the oil level may drop. xx. Start the compressor again and let run for 15 minutes. Pay attention to any irregular sounds, or any error messages registering on the PLC (warning lights if the compressor has manual controls). If there are any problems and this manual does not address those problems, contact your local Tecom Compressor representative, or Tecom Compressor directly. If after running for 15 minutes the room is significantly warmer (10 degrees warmer), the circulation in the room is not sufficient and better circulation must be provided for.

2. Getting Started

Page 10 of 24

Maintenance, Service and Spare Parts In general, your local Tecom partner knows what’s best for your compressor. However there are a few steps that you can take yourself to help protect your investment even further. Please follow the few simple steps listed in this section. Remember DO NOT try to perform maintenance yourself. 1. Be sure to talk to your local Tecom Compressor partner about which oil is best for your compressor. There are several different options, and you will do well for yourself to take the time to learn about the different options. Remember that Tecom’s local partner knows best in the end. 2. Visually inspect the compressor everyday. Taking two minutes each day to open up the compressor and leak around inside for any leaks can be vital in catching problems early and minimizing downtime for maintenance. If any leaking oil is visible, call your local Tecom partner immediately. 3. Check the oil level of the compressor everyday. If the oil level drops too low, you can risk destroying your compressor’s air end. Checking the oil level regularly will be a good indication if your compressor has any oil leaks or other problems. 4. Ask your local Tecom partner to provide you with a schedule relating to the maintenance of your compressor. You can follow and make sure that maintenance is performed regularly in accordance with the schedule provided. Rotary screw compressors are designed to operate reliably at maximum output for long periods of time. To ensure that the compressor has a long product life with minimum down time, it is important that a regular service schedule be followed. This section outlines the important steps required to maintain your compressor. DO NOT try to perform maintenance unless you are a qualified service technician and employed by Tecom or a Tecom representative. Should service work be done on the machine by a technician not employed by Tecom or a Tecom representative, or by someone with no technical experience, the warranty on the machine will be voided. It is vital that before any maintenance work is performed that the compressor is switched off, and the compressor is allowed to come to a complete stop and to cool down, and the main power is disconnected. Follow all safety precautions listed in this manual in the section on safety. Oil Selection Oil selection is very important to the lifetime of your compressor. Please follow these guidelines when choosing an oil. 1. All Tecom Compressors ship with viscosity 46 mineral oil hydraulic oil. Tecom Compressor recommends using a viscosity 46 oil. Brand is no important, but the type of oil can make a difference. If different oil is desired for future orders, it is no problem for Tecom Compressor to ship your future units with a different oil. 2. If opening in cold climates (where temperatures drop below -10 oC, use a viscosity 32 oil. In colder weather your compressor will have a hard time starting with viscosity 46 oil and will put unnecessary strain on the air end and the motor. 3. Synthetic oil is recommended over mineral oil. Synthetic oil has about three times the lifetime of mineral oil and it has better heat transfer properties. If the compressor is experiencing problems with overheating, switching to synthetic oil will allow the compressor to work in higher temperatures. DO NOT mix synthetic and mineral oil. Doing so can damage the compressor. Be sure to drain the compressor completely of oil if switching between oil types. Oil Change Make sure the system is shut down before attempting to change the oil. Appropriate protection for eyes, hands and clothing, should be worn before attempting to change the oil. 1. Make sure the compressor is cooled down before trying to change the oil. If the compressor has been working, let it cool for 10 minutes before attempting to change the oil. 2. Depressurize the compressor by turning the compressor to standby and letting the pressure drop to zero. 3. Loosen the plug on top of the oil tank. 4. Drain the oil by opening the oil drain on the oil tank. Be sure to catch the draining oil in a pan. Be Appendix A: Periodic Maintenance Table

Page 11 of 24 careful incase the oil is still hot. 5. Allow the oil to drain for 10 minutes. It is advisable to do the other tasks of servicing the compressor while the oil is draining. Be sure to dispose of the oil according to local regulations. Close the oil drain. 6. Remove the oil filler plug and fill the oil tank with oil until the level reaches the desired level as indicated on the oil gauge. 7. Close the filler plug. Check all other plugs and valves are closed properly. 8. Run the compressor for five minutes. If the oil level drops, begin the process again at step 6.

Oil drain

Oil filler plug

Oil Filter Change The oil filter needs to be changed periodically as indicated in the periodic maintenance table in the appendices of this manual. 1. Stop the compressor, switch off the voltage and depressurize the air by turning the compressor off and letting it completely depressurize. Be sure to isolate the compressor from the main power supply to prevent accidental starting. 2. Place an oil pan or take other appropriate actions to prevent spills in the area of work. 3. Open the cartridge with the filter key. Be sure to apply the filter key at the bottom of the filter. 4. Get rid of the removed filter according to the local regulations. 5. Wipe down the oil filter connection. 6. Lightly oil the gaskets of the new filter. 7. Screw the new filter into place with the filter key and make sure the gaskets contact their seats and tighten by hand. 8. Tighten the filter plug.

The picture shows the filter key being used to tighten (turning clockwise) a separator. The chain of the filter key must be used on the metal lip around the edge of the separator. The same technique is used to remove the oil filter. In both cases, the filter is removed by turning counterclockwise, and turning clockwise tightens it.

Spin-on Separator Change The separator is disposable and should be replaced every year or every 2000 hours, whichever happens first. The separator should be immediately replaced if the pressure drop across the separator is high than 0.5 bar. 1. Stop the compressor, switch off the voltage and depressurize the air by turning the compressor off and letting it completely depressurize. Be sure to isolate the compressor from the main power supply to prevent accidental starting. 2. Remove the separator as indicated in the figure using the filter key. Be sure to apply the filter key at the bottom of the filter. 3. Insert the new separator and tighten it with the filter key. Visual inspect to make sure it is installed properly. 4. Get rid of the removed separator according to local regulations Appendix A: Periodic Maintenance Table

Page 12 of 24 Deep Separator Change The separator is disposable and should be replaced every year or every 2000 hours, whichever happens first. The separator should be immediately replaced if the pressure drop across the separator is high than 0.5 bar. Most of the same rules that apply to spin on separators apply to deep separators. However, the process of changing a deep separator takes more work, and more time. 1. Stop the compressor, switch off the voltage and depressurize the air by turning the compressor off and letting it completely depressurize. Be sure to isolate the compressor from the main power supply to prevent accidental starting. 2. Remove all piping connections and the minimum pressure valve from the separator tank. 3. Remove all of the bolts from the separator lid and remove the lid. 4. Remove the top seal (colored orange in the picture) and pull out the separator cartridge. 5. Place a new cartridge in place of the old one and dispose of the used cartridge properly. Reverse the steps to reassemble the separator tank. Make sure all connections are tightened properly. 6. DO NOT replace the seals. Be sure to reuse the seals. If the seals need to be replaced contact Tecom Compressor directly. Replacing the seals without taking certain measures could result in serious damage to your compressor.

Air Filter Change The air filter on the air intake valve should be replaced every 500-1000 hours depending on the surrounding environment. Regularly changing the air filter will ensure high quality compressed air and lead to a longer product life for all the components in the compressor. The better quality air you have going into the air intake valve, the longer your compressors life will be. 1. Stop the compressor, switch off the voltage and depressurize the stopping the compressor and making sure the pressure has dropped to zero. Be sure to isolate the compressor from the main power supply to prevent accidental starting. 2. Open the filter case and remove the cartridge. Clean the case with pressurized air no great than 5 bar. 3. Place the new filter in the case. 4. Dispose of the removed air filter cartridge according to local regulations and close the air filter case.

Appendix A: Periodic Maintenance Table

Page 13 of 24

Figure showing the air filter cartridge found inside the metal housing attached to the air intake valve. Different models will have different size and different style air filter. The red and beige cartridge is disposable. The metal housing is reausable.

After Cooler It is important to keep the after cooler clean to maintain cooling efficiency. The after cooler should be cleaned with low-pressure compressed air (no greater than 5 bar). This should be done as needed. Check the cooler every 1-3 months for dirt buildup. If there are overheating problems in your compressor, cleaning the after cooler is a good place to start. If a more through cleaning is needed, remove the cooler, seal any openings and clean it with pressurized water. Belt Tension and Alignment The tension of the belt on all belt drive machines needs to be controlled periodically. At the same time, the alignment of the pulleys needs to be controlled. Both can be altered by using the setscrews, as shown in the pictures below. Note that there are two different alignments. For the larger sizes of compressor, the airend and the motor are side by side in what is referred to as a horizontal alignment/compressor. For smaller sizes, the airend is above the motor in a vertical alignment.

Location of setscrews with vertical alignment.

Location of setscrews with horizontal alignment.

Close up of setscrews with horizontal alignment.

Periodic Maintenance: In the appendices of this manual is a chart outlining what maintenance needs to be performed on the compressor and at what intervals. Consult this chart in order to schedule maintenance. Other general steps that should be taken to ensure the well being of your compressor are: 1. Check display readings daily 2. Give the compressor a daily look over for any leaks. 3. Check the oil level daily 4. Clean the compressor with low-pressure compressed air (no greater than five bars) every 3 months or as needed. Pay specific attention to cleaning the cooler. If using a cleaning solution, use only nonflammable, non-corrosive one. Consult Tecom Compressor before using any cleaning solutions. 5. Check for air leaks in the compressor and the air distribution system every three months. Intake Group Intake Filter Panel Filter Intake Valve

Replace: The intake filter needs to be replaced every 2000 hours throughout the lifetime of the compressor. Replace: Replace the panel filters every 2,000 hours or as needed. Cleaning the filters periodically is not enough. They must be replaced after several cleanings. Control: Check it for leaks every 2,000 hours. Check the connections with the

Appendix A: Periodic Maintenance Table

Page 14 of 24 solenoid. Maintenance: Perform maintenance every 6000 hours using an intake valve maintenance kit. Screw Unit General Control Noise Overhaul

Control: Visually inspect the screw unit every 2000 hours for any obvious problems. These include, leaks, cracks or discoloration of the material. If anything is abnormal, consult your local Tecom representative or Tecom Compressor. Control: After each servicing of the compressor (every 2000 hours), let the compressor run for 10 minutes and listen for any abnormal sounds come from the screw unit. If anything is abnormal, consult Tecom Compressor. Maintenance: Every 20,000 hours use a certified maintenance kit to replace the included parts.

Air Circuits Air Leaks

Minimum Pressure Valve Safety Valves

Control: After each servicing of the compressor (every 2000 hours) inspect the air lines for any leaks. Since oil and air travel together in the compressor, oil will be visible if there are any leaks. Replace any damaged/nonfunctioning components Control: Check it for leaks every 2,000 hours. Check the connections with the solenoid. Maintenance: Perform maintenance every 6000 hours using an intake valve maintenance kit. Control: Visually inspect for leaks every 2,000 hours. Maintenance: Replace every 20,000 hours using only CE certified safety valves.

Oil Circuits Cleaning the Radiators Oil Oil Filter

Maintenance: Every 2,000 hours clean the air/oil after cooler or as needed. Use low-pressure compressed air (no greater than 5 bar). Replace: The oil in the system should be replaced every 2,000 hours if using mineral oil. If using synthetic oil, the oil should be replaced every 10,000 hours. Follow the guidelines listed earlier in this section. Replace: The oil filter should be replaced every 2000 hours, according to the guidelines given earlier in this section.

Control Lines Solenoid Valves Pressure Switch Thermostatic Gauge (AS15 and smaller) Pressure Gauges (AS15 and smaller)

Control: If there are any problems about late or incomplete discharges, replace this valve. Control: If there are any problems with this valve, replace it. Control: If compressor is operating at a different temperature than it should be, replace this piece. Control: If the compressor is operating at the wrong pressure, replace this piece.

Coupling/V-Belts Belt Alignment/Tension Motor Bearings

Control: Measure the belt tension and make sure it is within acceptable ranges. Replace: If a belt breaks, or is noticeable worn, replace it. Maintenance: If the compressor contains a Siemen’s motor, the bearings need to be greased every 10,000 hours. WAT motor bearings do not need to be greased. Replace: Both brands of motors need their bearings replaced every 20,000 hours.

Electrical Panel Contactors Current (loaded/unloaded) Separator and Receiver Separator

Maintenance: Remove the contactors’ covers and clean with low pressure air (less than 5 bar) every 4,000 hours or as needed. Control: Check the current at 6.5 bar and 8 bar for an 8 bar compressor. At 8.5 and 10 bar for a 10 bar compressor. And at 11.5 bar and 13 bar for a 13 bar compressor.

Replace: The separator element has to be replaced every 2,000 hours. Follow the

Appendix A: Periodic Maintenance Table

Page 15 of 24

Oil Level All Mechanical Connections All Piping Connections

guidelines listed earlier in this section. Control: Check to make sure there is enough oil in the compressor every 2,000 hours. Control: Visually inspect all mechanical connections every 2,000 hours for any obvious problems. These include, leaks, cracks or discoloration of the material. If anything is abnormal, consult your local Tecom representative or Tecom Compressor. Control: Visually inspect all piping connections every 2,000 hours for any obvious problems. These include, leaks, cracks or discoloration of the material. If anything is abnormal, consult your local Tecom representative or Tecom Compressor. Replace: Every 10,000 hours replace the piping connections to avoid any leakage problems from developing.

Appendix A: Periodic Maintenance Table

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Appendix A: Periodic Maintenance Table

Page 17 of 24

Periodic Maintenance Table Time Period

2,000 hrs C M R

4,000 hr C M R

10000 hr C M R

20,000 hr C M R

40,000 hr C M R

Intake Group • Intake Filter • Panel Filter • Intake Valve* Screw Unit • General Control • Noise • Overhaul Air Circuits • Air Leaks • Minimum Pressure Valve* • Safety Valves Oil Circuit • Clean Radiators • Oil* • Oil Filter Control Lines • Solenoid Valves • Pressure Switch • Thermostatic Switch/Gauge • Pressure Gauges V-Belts • Belt Alignment/Tension • Motor Bearings* Electrical Panel • Contactors and contacts • Current (loaded/unloaded) Separator and Receiver • Separator • Oil Level All Mechanical Connections All Piping Connections C – Control, M – Maintenance, R – Replace (change) * Reference the service section of this manual for the specific details of scheduling this part of the periodic maintenance.

Appendix A: Periodic Maintenance Table

Page 18 of 24

Connection Sizes Consult this section when installing the compressor. It describes the necessary cable length, fuse size and the connection size of each Tecom Compressor.

5.5

Air Outlet (inches) 1”

Mains Cable(mm²) (Length<15 m.) 2.5

Mains Cable (mm²) (Length>15 m.) 08

Isolation Switch Fuse (Amps) 25

5.5

7.5

1”

4

08

32

7.5

10

1”

4

10

40

11

15

1”

6

10

50

15

20

1”

6

10

63

18

25

1”

10

10

63

22

30

1”

10

16

65

30

40

11/4”

16

25

100

37

50

11/4”

25

35

100

45

60

11/2”

35

35

100

55

75

11/2”

35

70

125

75

100

11/2”

70

95

160

90

125

2”

95

120

200

110

150

2”

120

185

250

132

180

2”

185

240

400

160

220

2”

240

240

400

kW

HP

4

Appendix B: Connections Sizes

Page 19 of 24

Product Quality Control Final Test Compressor Model:

Serial #: Brand

Pressure: Type

BAR

Serial #

Airend Main Motor Fan Motor Mechanical Checks Check the oil level. Check that the compressor shuts down automatically when overheated. Check that the compressor run on both stand-by and at full load with no errors. Check all the hydraulic and pneumatic connections. Check all the assembly connections, nuts and bolts. Check for oil leakages. Check the cleanliness of the compressor. Check all the documentation and stickers of the compressor.

Result

Electrical Checks Check all the klemens connections and cables. Check the shut down timing of the compressor. Check the electrical fuses. Check that both the main motor and the fan motor turn in the right direction. Check the functionality of the emergency start/stop button. Check the compressor PLC system.

Result

Measurements Parameter Airend oil inlet oil temperature Airend oil outlet temperature Oil tank temperature Automatic turn off temperature Current drawn (loaded) Current drawn (stand-by) Fan motor current drawn (load) Voltage value Belt-pulley alignment Sound pressure level Vibration levels and report Air leakages

Test Device Infrared temperature probe Infrared temperature probe Infrared temperature probe PLC control system Control board Control board Control board Control board Laser level Sound measuring device Vibration detection device Ultrasonic leak detector

Ambient temperature during test Moisture level during test (%)

˚C %

Mechanical Quality Control

Electrical Quality Control

Hakan KENAR

Cüneyt ÖZMEN

Document No: 2100/FR/09

Unit °C °C °C °C Amp Amp Amp Volt mm db(A) mm/s-rms sensitive

Revision No:2

Appendix C: Quality Control Report

Date: 22/11/2006

Quality Manager

Neşe AŞCI Page No:1/1

Value

Page 20 of 24

Service Record This section is provided to keep track of service performed on the machine. This is only a suggestion. It is more than likely that your service provider will track this information as well. Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Appendix D: Service Log

Page 21 of 24 Notes: Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Date:_____________ Oil Filter Notes:

Separator

Oil Change

Air filter

Control belt tension

Appendix D: Service Log

Page 22 of 24

Declaration of Conformity We: TECOM COMPRESSOR Makina San. Tic. Ltd. Sti. Eski Silivri Yolu Cad. No. 44 Buyukcekmece Istanbul, Turkey Under our own responsibility herewith declare that the products: Model AS

Serial Number ( POWER

)

So as it has been manufactured by ourselves, complies to the following regulations specifically to: 98/37/EC 73/23/EEC 89/336/EEC 97/23/EC

Machinery Directive Low Voltage Directive Electro-Magnetically Compatibility Directive PED Directive

No improper use of this declaration is allowed.

Place and date

Authorized person responsible

İSTANBUL

Appendix E: Declaration of Conformity

NEŞE AŞCI

Signature and stamp

Page 23 of 24

Initial Startup Checklist It is important to execute the following steps in the order they are listed and that this document is returned, signed and stamp, to Tecom Compressor. Failure to do so will void the compressor’s warranty. These steps are to be followed in order and are in addition to the installation instructions section of this manual. Signing this document confirms that you have followed all of Tecom’s directives for installing and starting your compressor.. Date Compressor Model Compressor Serial Number CHECK Power is turned off. Compressor is isolated from both the power and the air system. All pipe connections are all tight and sturdy. Check oil level indicator to make sure the oil is at an acceptable level. Add more if needed. Dryer unit is setup and ready to run according to the dryer’s operating instructions. Compressor is at least one meter away from other working machinery. Compressor is on a flat surface or a surface with an incline no greater than five degrees. Line voltage is within acceptable values (380±10V). Grounding cable’s resistance is below five ohms. Check that the power cable is of an acceptable length and thickness. Unit’s doors are closed and locked. Connect the power and turn it on. Jog the compressor for about 4 to 6 seconds to allow the oil to fill all empty spaces. Make sure there are no oil leaks. Make sure the direction of rotation is correct. If not, turn off the main power, and reverse the phases. Run the compressor until the cooling fan turns on. When the oil temperature reaches about 70° C the cooling fan will start. The fan should blow air out of the cabinet. If air is flowing in the opposite direction, reverse the phases on the fan motor and check again. Make sure that the compressor enters standby mode and that it automatically shuts down after three minutes in standby mode. Run the compressor and be sure that it unloads at the proper pressure. Open the manual isolation valve and be sure that the compressor loads again. While the compressor is under full load, check the supply voltage and the current draw of the main motor and the fan motor. Check the pressure inside the compressor. Make of a record of these readings. Stop the compressor and check the oil level. After the initial startup, the oil level may drop. Start the compressor again and let run for 15 minutes. Pay attention to any irregular sounds, or any error messages registering on the PLC (warning lights if the compressor has manual controls). If there are any problems and this manual does not address those problems, contact your local Tecom Compressor representative, or Tecom Compressor directly. Be sure that the room is not heating up with the compressor. If the room is noticeably warmer (10 degrees) after running the compressor for 15 minutes, the air circulation is not adequate.

Stamp and signature of service

Stamp and signature of the customer

Printed Name

Printed Name

Date

Date

Appendix F: Initial Startup Checklist

Page 24 of 24

Other Useful Information Unit conversion list of SI (metric) units to American units: 1 Bar = 14.504 psi 1 g = 0.035 oz 1 kg = 2.205 lb 1 kW = 1.341 hp 1 l = 0.264 US gal 1 l = 0.220 Imperial gal 1 l = 0.035 cu.ft 1 l/s = 2.117 cfm 1 mm = 0.039 in 1 mbar = 0.401 in of water 1 N = 0.225 lbf 1 Nm = 0.738 ft-lbf 1 degrees Celsius = 32+1.8*C degrees Fahrenheit

Appendix G: Additional Useful Information