COMPRESSOR ACADEMY

 

COMPRESSOR ACADEMY

 

WE PRODUCE QUALITY AND PROVIDE RELIABILITY


PISTON AIR COMPRESSORS FOR CEMENT TANKERS AND BLOWERS

 

PISTON AIR COMPRESSORS FOR CEMENT MODELS BNB 72 AND BNB102

 

MANUFACTURER COMPANY INFORMATION

The COMPRESSOR manufacturer’s information specified in this use and maintenance manual is as follows:

Manufacturer Company Title: CONFIDENCE  KOMPRESÖR  MAK.  İML.  SAN.            TİC.  LTD. ŞTİ

Manufacturer Company Address: ORGANİZE SANAYİ BÖLGESİ AHİ EVRAN Mh. 200. Cd. No : 116 Sincan – ANKARA / TÜRKİYE

Manufacturer Company Phone Number: 0312 274 0 

Manufacturer Company Fax Number : 444 – 445 – 447

e-mail                          : Contact@cementcompressor.com

Web                             : www.cementcompressor.com

 

 

CONTENTS

PRODUCT DESCRIPTION AND TECHNICAL SPECIFICATIONS

  1. TRANSPORT AND ASSEMBLY

     2.1 TRANSPORTATION

 

     2.2 ASSEMBLY

 

3.BASIC OPERATING PRINCIPLES

 

       3.1 Start-up

 

       3.2 Mode of operation

 

       3.3 Stopping

 

       3.4 Safety instructions

 

MAINTENANCE INFORMATION

 

  1. PERSONAL PROTECTIVE EQUIPMENT

     5.1 Equipment required during use

 

     5.2 Equipment required during maintenance

 

  1. POSSIBLE PROBLEMS AND RECOMMENDED SOLUTIONS

WARNINGS

  1. GENERAL MAINTENANCE AND RECOMMENDATIONS FOR THE COMPRESSOR

   8.1 Compressor oil change

 

   8.2 Filter cleaning procedures

 

  1. DIESEL ENGINE GENERAL MAINTENANCE AND RECOMMENDATIONS
  2. GENERAL MAINTENANCE AND RECOMMENDATIONS FOR THE ELECTRIC MOTOR
  3. PRODUCT DESCRIPTION AND TECHNICAL SPECIFICATIONS

 

 

1- WHAT IS A PISTON AIR COMPRESSOR FOR CEMENT?

 

A COMPRESSOR performs the function of air generation with the help of the power it receives from the motor and with the help of electrical-mechanical systems. In short, the COMPRESSOR is dedicated to the production of air in all sectors where air is needed.

 

Sector of use: It is used in all sectors where air is required. It should not be used in processes that exceed pressure values and in environments with fire risk, particularly with the use of diesel engine models.

 

The models and technical specifications of the Compressors are detailed below:

 

WHAT ARE THE TECHNICAL SPECIFICATIONS OF THE CEMENT PISTON AIR COMPRESSOR?

GENERAL TECHNICAL SPECIFICATIONS OF THE MACHINE
Operating Voltage 380 V
Number of Stages 1
Normal Working Pressure 2 Bar
Max Working Pressure 3 Bar
Cooling Air

 

Cooling                                                          Air-cooled

 

 

COMPARATIVE TABLE OF COMPRESSOR CHARACTERISTICS

FEATURE BNB 102 D BNB 72 E BNB 72 D
Number of Cylinders 2 2 3 3
Piston Diameter 220 mm 220 mm 160 mm 160 mm
Motor power 22 Kw,30 Kw 80 hp 18,5 Kw 80 hp
Compressor Revolution 1500 Revolution 1500 Revolution 1500 Revolution 1500 Revolution
Air Suction Power 10200Lt/min 10200 Lt/min 7200 Lt/min 7200 Lt/min
Course Length 90 mm 90 mm 80 mm 80 mm

 

HOW CAN I TRANSPORT AND ASSEMBLE THE AIR COMPRESSOR AND PISTON BLOWER FOR A CEMENT TANK?

 

TRANSPORT

 

A forklift or crane with sufficient capacity must be used to transport the machine safely.

Lifting with the crane is done by attaching the crane hook to the lifting ring on top of the machine.

Our company is not responsible for any damage caused by improper transportation.

The machine must always be transported in an upright position.

The shipment is made according to the method determined by the customer.

Before shipment, the machine is packed with wooden and plastic parts.

The packed product must not tilt during transport.

During transport, no cargo or other materials should be placed on the product.

Be careful not to bend, twist or bump the parts during transport.

 

5- WHAT TYPE OF BOLTS SHOULD BE USED WHEN INSTALLING THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

The machine must be connected to the chassis with M14-M16 bolts.

 

6- What space should there be in the trailer/ tanker where the cement piston air compressor is installed?

 

The compressor must be placed on the chassis so that there is at least 500 mm of space with the tank.

 

7- WHAT IS THE BASIC PRINCIPLE OF OPERATION OF AIR COMPRESSORS AND PISTON BLOWERS FOR CEMENT TANKS?

 

8- WHAT MUST BE DONE BEFORE STARTING UP THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

Start-up instructions

 

 

In order not to affect human health, the mains line used in the machine connection must be connected to a grounded line.

Check the mains and air line connections before starting the compressor.

Do not cover the compressor with cloth, nylon, etc. If it is, do not operate it.

Do not change the compressor pressure setting.

Check the oil level in the compressor crankcase. The sight glass or dipstick located on the crankcase body, allowing the oil level to be easily seen. Check the oil level when the compressor is stopped. Carrying out this check while the machine is running operation may show an inaccurate reading because the oil in the crankcase is moving during operation.

Before starting, check that the direction of rotation is in the direction of the indicator arrow.

Check the pressure of the pressure switch.

Be sure to read this information before operating the machine.

 

9- HOW TO OPERATE THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

 

 

Instructions

 

 

The machine must be operated with a star-delta switch.

The machine must always operate in triangular “Δ” mode.

The compressor should always operate at a level between 1.5 – 2 bar.

The 0-1-2 switch must always be actuated controlling that the rotation is in the direction of the indicator arrow.

Check with the pressure gauge if the pressure is at the desired bar level.

Check that the air outlet valve is open and make sure that air is coming out.

 

10- HOW SHOULD THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS BE TURNED OFF?

 

 

 Instructions

 

 

Turn off the machine with the star-delta switch at the end of the machine’s working period.

Unplug the machine until next use.

 

 

11- WHAT ARE THE SAFETY INSTRUCTIONS FOR AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

Carry out a general check of the machine before starting to use it.

Do not use the compressed air obtained from the compressor in the respiratory, underwater and food industries without first taking the necessary additional precautions.

The connecting tubes between the cylinder heads and the check valve as well as the cylinder heads must not be touched without wearing protective gloves.

The air coming from the compressor outlet valve must not be directed at a living being and a live flame.

Do not operate the compressor when the air filter is not in place.

Do not clean the compressor with flammable substances during maintenance.

The machine’s pressure gauge must not be transported over short or long distances while it is displaying a pressure value.

No one should use the machine except a trained operator.

Do not interfere with the machine while it is running.

The operator should not be left during the use of the machine.

Only authorized personnel should service the machine. Please inform our company in case of any problem or malfunction.

 

 

12- HOW TO MAINTAIN AND SERVICE THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

Maintenance and service

 

The machine should only be serviced by authorized persons.

Inadequate maintenance and service lead to malfunctions, prolonged product downtime and high repair costs. Therefore, regular service and maintenance is necessary.

Depending on different operating conditions, the frequency with which maintenance, wear monitoring and service will be required may vary. These processes should be scheduled based on your specific operating situation.

The mechanical and electrical circuits must not be tampered with by unauthorized persons. Please contact our authorized technical service in case of any adjustment problem.

 

13- HOW IS THE DAILY MAINTENANCE OF THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS PERFORMED?

 

Perform general external cleaning of the machine after use.

 

Check the oil level and top up if necessary.

 

14- HOW IS THE WEEKLY MAINTENANCE OF THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS PERFORMED?

 

Perform general external cleaning of the machine after use.

Check the oil level and top up if necessary.

Clean the intake filters.

 

14.i- HOW IS THE MONTHLY MAINTENANCE OF THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKERS CARRIED OUT?

 

Perform general external cleaning of the machine after use.

Check the oil level and top up if necessary.

Clean the intake filters.

Check for wear on machine parts.

 

14.ii- HOW IS ANNUAL MAINTENANCE OF AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKERS PERFORMED?

 

Perform general external cleaning of the machine after use.

Check the oil level and top up if necessary.

Clean the intake filters.

Change the machine oil every 3 months.

Check for wear on machine parts.

 

WHAT IS THE PERSONAL PROTECTIVE EQUIPMENT TO BE USED DURING THE OPERATION OF THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

5.1 Equipment required during operation

 

The operator must wear goggles, gloves, ear muffs, steel-toed shoes and a hard hat.

 

5.2 WHAT IS THE PERSONAL PROTECTIVE EQUIPMENT TO BE USED DURING MAINTENANCE OF THE AIR COMPRESSOR AND PISTON BLOWERS FOR CEMENT TANKS?

 

Protective gloves and goggles, steel-toed shoes and hard hat must be worn during maintenance.

 

  1. WHAT ARE THE POSSIBLE PROBLEMS AND RECOMMENDED SOLUTIONS FOR AIR COMPRESSORS AND PISTON BLOWERS FOR CEMENT TANKS?

 

COMPRESSOR TROUBLESHOOTING SCHEME
FAULT REASONS SUGGESTIONS

 

1-

What to do in case of low pressure? Check the suction and discharge valves. Wash and clean with air. If there are broken materials, replace them.
Check the piston, ring and liner for wear. Replace parts such as pistons, liners and rings.
Check the filter. Carry out filter maintenance frequently in dusty environments, change the oil. (20/50 engine oil)

 

2-

Which Maintenance and changes required in case of pressure drop in outlet pipe? Check the suction and discharge valves. Clean the valve plates.
Check if there is cracking or physical defect in the sleeve and welded parts . Change the defective bolts, nuts and welded material.

 

3-

What to do in case of pressure rise in the outlet pipe? Blockages in the cooler or valves Open or replace the clogged part.
Possible dents on the outlet pipe Replace the valve or pipes with a new one.

 

4-

What to do in case of overheating in the machine? Breakage of the cooling ribs  in the liner Changing the liner,
Lack of lubricating oil or loss of its properties Replacing the propeller with a new one,
Breakage of cooling fan Most importantly, the oil that has lost its properties must be changed. (20/50 engine oil)

 

5-

What to do If the machine is pumping oil into the system? Wear on the rings Replace the defective parts with new ones.
Expansion of the piston groove
Scratch or wear of the liner

 

6-

What to do If jolting or knocking occurs in the compressor? Flywheel rubber mounts are worn. Change the rubber mounts.
Arm bushings may be worn or the bearing may be scattered. Change the arm bushings and bearings.
If it creates knock as a result, If it works with a diesel engine, tighten the turbine belt.

 

 

7-

What are the reason Possible malfunctions of Safety valve?

A – If it opens prematurely,

B – if there is a leak,

C – if it does not open and does not drain the air,

 

 

 

Tighten the spring loaded mechanism a little,

 

 

The safety valve should be maintained at the end of each year, and defective ones should never be used.

  1. WARNINGS

 

Read the user manual carefully before opening the package.

The person or organization that purchased the machine is responsible for ensuring that it is used only by trained operators.

During operation, unauthorized persons and children should be kept away from the working area.

After taking the necessary safety precautions to start the machine , turn the ignition switch if it is diesel, and if it is electric, turn the star-delta switch.

 

To stop the machine, if it is diesel, turn off the ignition (turn off the engine), if it is electric, turn off the star-delta switch.

In the first gear after electrical connection, the direction of rotation must be checked, if it is reversed, the electrical connection must be changed.

The operator working on the machine must wear gloves, goggles, ear muffs, helmet and steel-toed shoes.

 

WHAT ARE THE GENERAL MAINTENANCE AND RECOMMENDATIONS FOR AIR COMPRESSORS AND PISTON BLOWERS FOR CEMENT TANKS?

 

Check the oil level before starting the compressor.

A transparent oil sight glass or dipstick is located in the compressor crankcase for easy viewing of the oil level. Check the oil level when the compressor is stopped. (The oil level may change during operation).

Refill if oil is missing in the compressor.

The compressor oil should be changed every 150 and 250 hours.

Use Mobil 20/50 motor oil.

If the compressor oil has been completely drained, put 2.5 liters of oil in BNB 72 models and 4.5 liters of oil in BNB 102 models.

Filter maintenance should be done daily in dusty environments and once a week in dust-free environments.

Mobil 20/50 motor oil should be used for the filter.

In case the filter operates without oil, all kinds of dust and harmful particles enter your compressor and stick to the working surfaces, causing excessive wear.

Do not disassemble any parts with the compressor running, disconnect the compressor from the main switch before servicing.

Perform general external cleaning of the machine after each use.

Follow the recommendations and rules for periodic maintenance.

Check the machine for worn parts.

Help us to improve, please share all your comments and suggestions about your compressor with our company.

 

 

8.1 HOW TO CHANGE THE OIL IN AIR COMPRESSORS AND PISTON BLOWERS FOR CEMENT TANKERS? WHAT TYPE OF OIL SHOULD BE USED FOR AIR COMPRESSORS AND PISTON BLOWERS FOR CEMENT TANKERS?

 

A transparent oil sight glass or dipstick is located in the compressor crankcase for easy viewing of the oil level. Check the oil level when the compressor is stopped. (The oil level may change during operation.) Top up if oil is missing.

 

Turn off the compressor. If the compressor was not running, first let the oil warm up during turning on the compressor for 5-10 minutes and then turn it off.

Wait 1-2 minutes for the oil to drip.

Drain the oil completely by removing the oil plug from the top of the crankcase and the drain plug from the bottom of the crankcase. Reinstall the drain plug when the oil flow is complete.

Fill new oil to the mid-level by checking the oil level sight glass on BNB 72 models. Be careful not to overfill or run out of oil. Fill the new oil by checking the dipstick in the range of the indicator line on BNB 102 models.

When oil filling is complete, replace the oil cap.

Run the compressor for several minutes and then turn it off, check the oil level after waiting for the oil to settle and top up if necessary.

 

 

8.2 HOW TO CLEAN THE FILTER OF AIR COMPRESSORS AND PISTON BLOWERS FOR CEMENT TANKS?

 

 Filter cleaning procedures

 

 

It is a completely closed type filter. It should be thoroughly cleaned at least once a month, depending on the degree of dust in the environment.

Open the tabs holding the front cover, take the cover and wipe the inside with a clean cloth. Slide the filter by rotating it.

Let the dust out by blowing compressed air in reverse into the filter.

Soak it in cleaning liquid and wash it for a while.

Dry it with compressed air.

Mount it correctly in place after it has dried.

 

 

WHAT ARE THE GENERAL MAINTENANCE AND RECOMMENDATIONS FOR THE DIESEL ENGINE?

 

The oil level should be checked before starting the engine.

If engine oil is missing, it must be refilled.

The engine oil should be changed every 150 and 250 hours.

Filter maintenance should be performed daily in dusty environments and once a week in dust-free environments.

Mobil 20/50 motor oil should be used for the engine.

Mobil 20/50 motor oil should be used for the filter.

 

WHAT ARE THE GENERAL MAINTENANCE AND RECOMMENDATIONS FOR THE ELECTRIC MOTOR?

 

The control panel should be close to the compressor and easily accessible.

Do not change the pressure and current values of the fuses related to the compressor operation. If the set values are exceeded, the load will increase and the motor current will increase. This can cause your motor to burn out.

Keep your motor’s cooling fan, ventilation ducts and fan guard grille clean.

Altitude above sea level and ambient temperature directly affect engine cooling performance. In its standard form, your engine operates properly up to 1000 meters altitude and 40°C ambient temperature. It is necessary to check the charge rate at higher altitudes and warmer locations.

ALTURA (metros) 1000 1500 2000 2500 3000 3500 4000
% 100 98 95 9 87 83 78
TEMPERATURA (0C) 30 35 40 45 50 55 60
% 105 102 100 97 93 87 82

NOTE: KEEP THIS MANUAL.