Doosan 7/20 User manual

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Small compressors
COMPRESSOR TRAINING
Company Confidential
SMALL COMPRESSORS RANGE
•7/20 - P65 - 7 bar (100 PSI), 1.9 m3/min (70 cfm)
•7/26E - P90 - 7 bar (100 PSI),2.5 m3/min (90 cfm)
•7/31E - P110 - 7 bar (100 PSI), 3.0 m3/min (105 cfm)
•7/41 - P135 -7 bar (100 PSI), 4.0 m3/min (140 cfm)
•7/51 - XP185 -7 bar (100 PSI), 5.0 m3/min (175 cfm)
•7/71 - P260 -7 bar (100 PSI), 7.1 m3/min (250 cfm)
•12/56 -12 bar (170 PSI), 5.6 m3/min (200 cfm)
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SUMMARY
•The compressor can be divided in the following subsystems
–ENGINE & AIREND
–LUBRICATION & COOLING SYSTEM
–AIR FLOW REGULATION SYSTEM
–SEPARATION SYSTEM
–BLOWDOWN SYSTEM
–INSTRUMENT/CONTROL PANEL
–ELECTRICAL WIRING
•Troubleshooting

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Company Confidential
ENGINE (7/20)
Compressor 7/20
IR Designation 3IRJ5N
Model D 1005
Cylinders 3
Displacement 1 L
Rated Output (kW@RPM) 17.5@3000
Aspiration Naturally aspirated
Fuel Pump Mechanical inline pump
Emissions Tier II certified
Electrics 12 Volts
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ENGINE Tier 2 (7/26E –7/51)
Compressor 7/26E 7/31E 7/41 7/51
IR
Designation 3IRH2NS 3IRH8N 4IRH8N 4IRI8N
Model 3TNV82A 3TNV88 4TNV88 4TNV98
Cylinders 3344
Displacement 1,3 1,6 2,2 3,3
Rated Output
(kW@RPM) 21,1@2800 25,8@2800 34,8@280 049,7@240 0
Aspiration Naturally aspirated
Fuel Pump Mono plunger mechanical pump
Emissions Tier II certified
Electrics 12 Volts
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ENGINE Tier 3(7/51) from September 2008
Compressor 7/51
IR Designation 4IRI8NE-2
Model 4TNV98
Cylinders 4
Displacement 3,3
Rated Output (kW@RPM) 50.2@2400
Aspiration Naturally aspirated
Fuel Pump Mono plunger
mechanical pump
Emissions Tier III certified
Electrics 12 Volts

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Company Confidential
ENGINE Tier 2 (7/71 –12/56)
Compressor 7/71 –12/56
IR Designation 4IRD5N
Model JD 4045DF270
Cylinders 4
Displacement 4.5 liter
Rated Output (kW@RPM) 60@2500
Aspiration NaturallyAspirated
Fuel Pump Rotary fuel pump
Emissions Tier II certified
Electrics 12 Volts
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ENGINE Tier 3 (7/71 –12/56) from October 2008
Compressor 7/71
IR Designation 4IRI8TE
Model 4TNV98T
Cylinders 4
Displacement 3,3
Rated Output (kW@RPM) 59.2@2300
Aspiration Turbocharged
Fuel Pump Mono plunger mechanical pump
Emissions Tier III certified
Electrics 12 Volts
Company Confidential
Eco-Governor is Yanmar unique electronics control governor
system which has been used for over 10 years mainly for
agricultural machine. Yanmar has renewed this system to
apply all equipment and named “2G Eco-Governor” which
means second generation Eco-Governor. In addition, EGR
valve for NV3 engine is controlled by this system.
MP type fuel Injection Pump
with ECO Governor
ECU
ECO-Governor system
EGR Valve
EGR Control system
ENGINE Tier 3 Improvements –YANMAR ECO

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Company Confidential
Speed
Rack
position
Eco-Governor
Fuel Pump CSD
Actuator
EGR
Starting Aid
CW Temp.
Starter
Display
Switch
Key Switch
OFF ON
START
Accelerator
CAN
ENGINE Tier 3 Improvements –YANMAR ECO
Company Confidential
EGR Control –exhaust gas re-circulation
Standard Function for >= 37kW
Intake Exhaust
ECU Speed,Load & Temp
ECU
EGR Valve
Piston
Inj.Nozzle
EGR Valve
Combustion temperature is reduced.
NOx Reduced
Exhaust Gas Re-Circulation
Speed, Load, &
Temp.
ENGINE Tier 3 Improvements –YANMAR ECO
Company Confidential
Intake
EGR-Valve
Piston
Liner
Inj.Nozzle
Exhaust
Turbo Charger
EGR Cooler
Reverse flow protection
Re-circulated Gas Cooling for
Low Emission
Cooled EGR system ECU Speed , Load & Temp.
ECU Speed , Load & Temp.
Re-circulation
One way valve
One way valve
ENGINE Tier 3 Improvements –YANMAR ECO

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Company Confidential
Fuel filter
Electric fuel
feed pump
Fuel tank
Engine crankcase
Accumulator
Overflow
orifice
Timer piston
Plunger
Distributor
shaft
Torochoid pump
Fuel return
Pressure control valve
Fuel injection pipe
Nozzle
Injection pump
tappet
Oil seal
joint
Engine oil
Cam
High pressure gallery
Low pressure gallery
orifice
Water separator
12/48
Engine coolant
Thermo-element
Engine oil
Cam
Trochoid pump
ENGINE Tier 3 Improvements –YANMAR ECO
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ENGINE Tier 3 Improvements –YANMAR ECO
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AIREND
•Casing houses two screw-type rotors mounted on ball and roller
bearings.
•Diesel engine drives the male rotor through heavy-duty coupling.
•Mechanical seal used to seal the shaft.
•Gear sets allow to change rotor speed and therefore air output.

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Company Confidential
CE55RW - AIREND
AIREND (7/20)
•Now used on 7/20 only, formerly used on 7/21 and 7/26.
•Cast iron body.
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AIREND (7/20)
•Now used on 7/20 only.
•Formerly used on 7/21 and 7/26.
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AIREND (7/26E - 7/51)
•85 mm Airend.
•Different gear sets permit to adjust air delivery.
•Cast aluminium body.
•Repair not advised.

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Company Confidential
AIREND CF 90 (7/71 - 12/56)
•Different gear sets permit
the use of this airend as 7/71
or 12/56.
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COMPRESSOR OIL SYSTEM
•Functions of the oil system:
–Lubricating the rotors, airend bearings and mechanical seals
–Sealing the clearances between the airend rotors
–Cooling of the airend. Heat is generated during air compression.
•The oil flows due to the air pressure. No oil pump is required.
Company Confidential
LUBRICATION & COOLING (7/20)

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Company Confidential
LUBRICATION & COOLING
•The Separator tank is also the
reservoir of compressor oil.
•Pressure in the tank is forcing
the oil through the system.
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LUBRICATION & COOLING
•Cool box design with pusher
type fan.
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LUBRICATION & COOLING

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Company Confidential
LUBRICATION & COOLING
•Compressor oil filter, 10
micron rating.
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LUBRICATION & COOLING (7/26E - 7/51)
Company Confidential
LUBRICATION & COOLING (7/26E - 7/51)
•Oil filter head integrated to airend.

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Company Confidential
LUBRICATION & COOLING (7/71 –12/56)
Company Confidential
LUBRICATION & COOLING (7/71 –12/56)
Company Confidential
LUBRICATION & COOLING (7/71 –12/56)

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Company Confidential
LUBRICATION & COOLING (7/71 –12/56)
•Allows to regulate the oil
temperature around 85°C.
•Keeping the oil hot enough
allows to reduce the water
condensation in the
compressor.
•Never remove the thermostat as
this would by-pass the oil
cooler!
Company Confidential
AIR REGULATION SYSTEM
•The air regulation system continuously adjusts the production of
compressed air to the consumption by controlling the engine
speed and unloader valve.
•The unloader and fuel pump throttle are pneumatically (on
mechanical engines) controlled through the pressure regulator.
•On the new electronic Yanmar engines the regulation pressure
signal is converted to a speed signal to the engine ECU.
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AIR FLOW & REGULATION (7/20)
Unit stopped

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Company Confidential
AIR FLOW & REGULATION (7/20)
Start-up
Service valve closed
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AIR FLOW & REGULATION (7/20)
Air demand
Service valve open
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AIR FLOW & REGULATION (7/20)
Off load
Service valve closed

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Company Confidential
AIR FLOW & REGULATION (7/20)
1. Fully open the service valve
until full speed.
2. Slowly close service valve
until speed starts to
decrease.
3. Read tank pressure, this is
the regulated pressure.
4. Increase by tightening
regulator screw B or
decrease by un-tightening.
Company Confidential
AIR FLOW & REGULATION (7/20)
•Orifice continuously
bleeds air from the
regulation circuit.
•Size of orifice
greatly affects
regulation and can
not be adjusted.
Regulation orifice
Company Confidential
AIR FLOW & REGULATION (7/20)
•Anti-rumble valve.
•Membrane opens and allows some air to enter to limit vacuum at
inlet.
High vacuum

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Company Confidential
REGULATOR VALVE - OPERATION
•Needle valve actuated by diaphragm and held closed by a spring.
•Controlled pressure preset in factory, can be adjusted by means of
adjusting screw.
•Pin hole allows to determine diaphragm condition.
Company Confidential
AIR FLOW & REGULATION (7/20)
•Mechanical engine - Spring loaded piston - Air pressure increase reduces
speed.
•Electronic engine –Regulating pressure sensor sends signal to SECU which
translates this to engine speed request to ECU.
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AIR FLOW & REGULATION (7/26E –7/51)
Start-up
Service valve closed

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Company Confidential
AIR FLOW & REGULATION (7/26E –7/51)
Air demand
Service valve open
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AIR FLOW & REGULATION (7/26E –7/51)
Off load
Service valve closed
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AIR FLOW & REGULATION (7/26E –7/51)

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Company Confidential
AIR FLOW & REGULATION (7/26E –7/51)
Company Confidential
AIR FLOW & REGULATION (7/26E –7/51)
•Connection on compressor inlet allows to reduce noise.
Regulation
Orifice
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AIR FLOW & REGULATION (7/71 –12/56)
Start up
Service valve closed

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Company Confidential
AIR FLOW & REGULATION (7/71 –12/56)
Load button pressed
Service valve closed
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AIR FLOW & REGULATION (7/71 –12/56)
Off load
Service valve closed
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AIR FLOW & REGULATION (7/71 –12/56)
UL99
Unloader

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Company Confidential
AIR FLOW & REGULATION (7/71 –12/56)
Regulation
Orifice
Company Confidential
SEPARATION SYSTEM
•Functions of the separation system:
–Removing the oil contained in the compressed air
•Most of the oil is removed from the air through a specially shaped
baffle in the separator tank.
•The remaining oil is removed by the separator element.
Company Confidential
SEPARATION SYSTEM
•The air and oil mixture discharges from the airend into the separator
receiver. Here most of the oil separates out from the mixture under
gravity when it impinges on the underside of the specially-shaped base of
the separator element. The separator element then removes any
remaining oil entrained in the air. The oil which flows down the inside
surfaces of the element and accumulates on the base is returned via the
Scavenge line (because of the pressure differential) to the airend.
•The orifice in the scavenge drop tube controls the flow rate through the
scavenge line.
•The minimum pressure valve (or sonic orifice) is located before the
service taps. It ensures that the pressure inside the separator receiver
never falls below 4.4-5.1 bar (65-75 psi). This ensures there is sufficient
oil circulation in the system at all times. It also limits the pressure drop
across the separator element, thereby protecting it.

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Company Confidential
SEPARATION SCHEMATIC (7/20)
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SEPARATOR/RECEIVER TANK (7/20)
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SCAVENGE LINE (7/20)
•Orifice is located in the elbow connector.
•It is designed to scavenge the oil while limiting the loss of air flow.
•Check valve prevents oil reverse flow during shutdown.

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Company Confidential
SCAVENGE LINE (7/20)
•Returns to air inlet.
•Look for clogged scavenge lines in case of oil carry over!
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SAFETY VALVE (7/20)
•Valve is on the oil side of the element where pressure is maximum
when the separator element is blocked.
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SONIC ORIFICE (7/20)
•Maintains a min. pressure (~5bar) in the receiver to:
–keep the oil flowing.
–limit pressure drop across the separator.
•Continuous operation at min pressure results in oil carry over due
to insufficient scavenge flow.