Sauer WP 33 L User manual

Sauer
Compressor
Type: WP 33 L
Operator Manual
High-pressure Compressor
2 Stages
Air-cooled

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Edition: 11 / 2008
Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation
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Zertifikate_en_0.fm
Sauer compressor Type Approvals
Note!
On this page only a few examples are shown. FurtherType Ap-
provals are available on request.

Zertifikate_en_0.fm
Genuine Sauer spare parts –
certified safety
SPECIMEN

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Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warrenty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Type Approval and genuine Sauer spare parts . . . . . . . . . . . . . . . . . . . . . 10
1.5 J.P. SAUER & SOHN customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Specific instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Conditions of use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Unauthorised moditifaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Safety information - Warning & Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Safety warnings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Safety and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.9 Personal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Indicators for the Sauer compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Compressor Control System - Indicators and Control . . . . . . . . . . . . . . . . . 27
4 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 P&I Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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5 Transport and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Storage before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4 Connecting the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.5 Stop/Start pressure switch setting(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.7 Installation checks and before the initial start . . . . . . . . . . . . . . . . . . . . . . . 42
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Troubleshouting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Maintenance and Service by J.P. SAUER & SOHN . . . . . . . . . . . . . . . . . . 50
8.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.4 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.5 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.6 Checking screw connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.7 Air Intake filter cartridge cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.8 Checking valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.9 Checking the piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.10 Replacing gudgeon pins / bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.11 Replacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.12 Checking pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.13 Checking the drive bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.14 Replacing the connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.15 Checking the coupling and replacing the coupling insert . . . . . . . . . . . . . . 70
8.16 Checking the oil / water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.17 Checking the safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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9 Storage, Preservation - “lay-up“ procedure . . . . . . . . . . . . . . . . . . . . . . 73
9.1 Safety when storing and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2 Temporary preservation & storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.3 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.2 Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11 Spare Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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1 General
1.1 Foreword
This Operator Manual provides installation guidance, safe oper-
ation, maintenance and repair instructions with illustrated parts
breakdown.
The following unique specification for the Sauer Compressor can
be found on the nameplate affixed to the compressor:
– compressor type
– serial number
– year of construction
We recommend you record this information in Chapter 11, “Spare
Parts and Accessories”, and always provide this data when re-
questing parts and any repair instructions.
1.2 Precautions
Specific
precautions
We recommend that only authorised and trained personnel Op-
erate and Service the Sauer Compressor. Such responsible per-
sonnel should be thoroughly familar with, and frequently review,
the Operator Manual.
These instructions should always be readily available at the com-
pressor installation.
Copyright The copyright for these instructions remains with J.P. SAUER &
SOHN. These instructions, or parts thereof, shall not be copied,
distributed or made available to third parties. Contravention will
result in prosecution.
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General
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1.3 Warranty and Liability
Sauer can no longer cover warranty, be liable for any claims, if a
failure is attributed to any of the following:
– use of the machine not as specified;
– substitution of parts not manufactured or approved by Sauer;
– use of spare parts that are not genuine Sauer spare parts;
– operation of the machine with faulty or improperly installed
safety and/or protection devices;
– disregard of the operating instructions;
– unauthorised modification to the machine or its control system;
– inadequate monitoring of machine parts subject to wear;
– failure to maintain/repair in accordance with Sauer instruc-
tions;
– force majeure.

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1.4 Type Approval and genuine Sauer spare parts
• The Type Approval for the Sauer Compressor is valid under
the condition that parts and components specified and quali-
fied by J.P. SAUER & SOHN are used. The Type Approval is
provided by the Classification Society and the EC Declaration
of Conformity or EC Manufacturer's Declaration. Disregard for
the “specifications“ may cause the Type Approval to expire.
• Only the use of genuine Sauer spare parts will ensure compli-
ance with these ’specfications’ and, therefore, reliable and
safe operation of the Sauer Compressors.
• If non-genuine Sauer spare parts are used, we reserve the
right of exclusion from liability for personal injury and material
damage.
• Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown just before the Table of Contents in these
instructions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such an istance please contact our Customer Service.
Note!
Be aware this is a high-pressure compressor, for your own safe-
ty and for reliable compressor operation, only unse genuine
Sauer parts.
Do not use parts from the
“grey market“!
Only use genuine Sauer spare parts
supplied with a Certificate!
Correct Incorrect

General
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1.5 J.P. SAUER & SOHN customer service
Should you have any technical questions relating to maintenance
or repair, please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH
Customer Service
P.O. Box 92 13
24157 Kiel
Telephone (international):
Technical information [phone]
Spare parts orders [phone]/886
Telefax (international): [phone]
Emergency service (international): [phone]
E-Mail: [email protected]
Web: www.sauersohn.de
Note!
If you have questions regarding your Sauer Compressor, please
state Compressor model and serial number (see chapter 11
“Spare Parts and Accessories” or nameplate on the compres-
sor).

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1.6 Specific instructions
Lists General lists are hyphenated.
e. g.:
Compressor cooling consists of
– fan wheel,
– fan wheel cage, and
– cooler assembly.
Instructions Individual instructions or multiple instructions requiring action but
where the sequence is of no importance are normally denoted by
a bullet-point.
e. g.:
• Check oil level.
Instructions to be carried out in a certain sequence are num-
bered.
e. g.:
1. Turn the main switch ON.
2. Choose the Operating mode.
3. Turn the control ON.
Results of actions carried out are denoted by a tick mark.
Example:
The control light is on.
Safety
instructions
Safety and warning instructions are presented pictorially with
clear instructions. The safety instructions are described in detail
in Chapter 2 “Safety”.

Safety
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2Safety
2.1 Conditions of use
This Sauer Compressor must be used for the compression of air.
The Sauer Compressor must not be used at ambient temperatu-
res below +5 °C. Any other use not as specified, requires the ex-
plicit consent in writing from J.P. SAUER & SOHN .
Observing operating instructions, the installation requirements
detailed in the instructions, and keeping maintenance records,
are all part of the specified conditions of use.
Most accidents which occur during operation and maintenance of
machinery result from failure to observe basic safety rules or pre-
cautions.
When handling, operating or carrying out maintenance, person-
nel must observe safe engineering working practices and local
regulations.
2.2 Unauthorised modification
Unauthorised modification of the Sauer Compressor is not per-
mitted. Modifications may lead to an accident that can be life-th-
reatening, cause personal injury or result in damage to the
equipment.
Contact J.P. SAUER & SOHN when planning any modification to
obtain written approval.

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2.3 Safety information - Warning & Caution
The safety information in these instructions is presented as ’high’
risk and ’lower’ risk, as follows:
Warning - Danger!
High risk.
Ignoring this safety information can cause personal injury, or
death, and significant equipment damage.
Caution - Note!
Less risk.
Disregarding this safety note may cause damage to the equip-
ment.

Safety
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2.4 Safety warnings on the machine
Sauer compressor models with an EC Manufacturer's Declarati-
on or EC Declaration of Conformity are marked with the following
safety labels:
Location of safety markings
Danger!
Safety labeling affixed to the machine must not be altered or re-
moved. Replace damaged or lost safety labels immediately with
an approved replacement.
Safety label Meaning Safety label Meaning
Danger! High voltage! Read Operator Manual!
Compressor starts auto-
matically without warning!
Wear hearing protection!
Hot surface! Rotational direction of
crankshaft

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2.5 Safety and protection devices
Safety valves Each compression stage of the Sauer compressor is equipped
with a safety valve, which will vent freely when the valve set pres-
sure is reached.
Safety valves are installed at the following locations:
–1
st compression stage: at the cylinder head of the 2nd stage;
–2
nd compression stage: in the final separator behind the 2nd
stage.
Fusible plug/
Temperature
sensor
A fusible plug is fitted in the condensate separator of the 2nd sta-
ge to monitor cooling. It melts at 121 °C and allows the com-
pressed air to escape, when its temperature exceeds the
threshold value.
The fusible plug can only be used once. If it blows, it needs to be
replaced with a new one.
As an alternative to the fusible plug, the Sauer compressor can
be fitted with a temperature sensor to protect against a compres-
sor cooling failure. This sensor will shutdown the compressor if
the temperature of the compressed air exceeds the pre-set limit.
Final pressure
sensor
The Sauer compressor is fitted with a final pressure sensor,
which activates if the final pressure is exceeded. This sensor is
factory-set according to the customer’s particular final pressure.
If the final pressure is exceeded, an alarm is displayed.
Danger!
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked.
Safety valves must be
– installed with a lock-seal
– should be replaced, adjusted and re-sealed only by autho-
rised personnel.

Safety
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2.6 Noise protection
Sound pressure level details are found in the Technical Specifica-
tion (see Chapter 4).
The Sauer compressor can be arranged with a sound-dampening
enclosure to reduce the noise. This sound-dampening enclosure
is available as optional accessory from J.P. SAUER & SOHN.
2.7 Waste disposal
Danger!
When the compressor is operated without sound-dampening en-
closure, hearing protection should be worn when working near
to the compressor.
Note!
While recyclable materials are used as far as possible, local en-
vironmental regulations, or laws, dictate that the following are
disposed of to avoid polluting the environment.
– condensate (oil and water saturated mixture) arising from in-
tercooling in the compression process;
– used oil and grease, and soiled materials;
– cleaning material and soiled rags.

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2.8 Personal safety
Only personnel authorised by J.P. SAUER & SOHN are permitted
to Service the Sauer Compressor! Before commencing work they
must have read and understood the instructions in the Manual,
and must be familiar with all safety devices and safety regulati-
ons.
In addition to the instructions in this Manual, and manufacturer
documentation, accepted engineering standards must be obser-
ved as well as local regulations and standards e.g.
– Equipment and Product Safety Act,
– Industrial Health and Safety,
– Regulations for accident prevention pertaining to compres-
sors,
– Regulations on environmental protection.
Additionally, where appropriate Classification Society and opera-
tional regulations must be observed.
Only those trained and thoroughly familar with the compressor
operation, should be authorised to operate the compressor.
Personnel authorised to service the compressor must be trained
’specialists’.

Safety
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2.9 Personal protection
The user should provide personal protection (e.g. hearing protec-
tion, safety boots, etc.) for the operator, or Service engineer car-
rying out any work on the Sauer compressor.

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3 Design and Function
3.1 Overview
Note!
Details of parts and spare parts can be found in the spare parts
catalogue.
12
3
4 5
67
8
9
10