VEK 20-50 Screw Compressor: Maintenance and Spare Parts Guide

VEK 20-50
SCREW COMPRESSOR
MAINTENANCE AND
SPARE PARTS
GUIDE
Address and communication informations:
Ali Bey Köyü,Karasinan Asfaltı Telefon No: +90 212 728 43 43 (Pbx)
Mevkii,Silivri,İstanbul, Turkey Fax : +90 212 728 70 23
www.komsan.com.tr e-mail:info@komsan.com.tr
09 FRM 020 Rev 10

15.04.2005 14/04/2008
VEK 20-50 VİDALI KOMPRESÖR KATALOG FİHRİSTİ SAYFA NO
IMPORTANT SECURITY RULES IN OPARATING, MAINTANANCE AND REPAIR OF THE COMPRESSORS---------------------- 4

CARRYING THE COMPRESSOR ---------------------------------------------------------------------------------------------------------------------------- 5
IMPORTANT THINGS TO BE CHECKED AT THE FIRST START UP----------------------------------------------------------------------------- 6
PLACING OF THE COMPRESSOR-------------------------------------------------------------------------------------------------------------------------- 7
SAMPLE INSTALLATION-------------------------------------------------------------------------------------------------------------------------------------- 8
INLET AND OUTLET AIR FLOW OF THE COMPRESSOR ROOM--------------------------------------------------------------------------------- 9
SAMPLE ELECTRIC INSTALLATION SCHEME--------------------------------------------------------------------------------------------------------- 10
PLC-------------------------------------------------------------------------------------------------------------------------------------------------------------------- 11
COMPRESSOR DIMENSION---------------------------------------------------------------------------------------------------------------------------------- 12
PLACING OF THE AIR DRYER------------------------------------------------------------------------------------------------------------------------------- 13
PLACING OF THE AIR RECEIVER-------------------------------------------------------------------------------------------------------------------------- 14
PERIODICAL MAINTENANCE PROGRAM---------------------------------------------------------------------------------------------------------------- 15
PERIODIC MAINTENANCE INTERVALS------------------------------------------------------------------------------------------------------------------ 16
PROBABLE BREAKDOWNS AND REMOVING METHODS------------------------------------------------------------------------------------------ 17
THE MAINTENANCE THAT MUST BE DONE BY THE USER-------------------------------------------------------------------------------------- 18
FİRST OPERATING INSTRUCTIONS----------------------------------------------------------------------------------------------------------------------- 19
SPARE PART LIST----------------------------------------------------------------------------------------------------------------------------------------------- 20
MAIN ASSEMBLY DRAW-------------------------------------------------------------------------------------------------------------------------------------- 21
MAIN ASSEMBLY LIST----------------------------------------------------------------------------------------------------------------------------------------- 22
HYDROLIC GROUP DRAW----------------------------------------------------------------------------------------------------------------------------------- 23
HYDROLIC GROUP LIST-------------------------------------------------------------------------------------------------------------------------------------- 24
MOTOR GROUP DRAW----------------------------------------------------------------------------------------------------------------------------------------- 25
MOTOR GROUP LIST------------------------------------------------------------------------------------------------------------------------------------------- 26
AIREND GROUP DRAW---------------------------------------------------------------------------------------------------------------------------------------- 30
AIREND GROUP LIST------------------------------------------------------------------------------------------------------------------------------------------- 31
OIL RECEIVER DRAW------------------------------------------------------------------------------------------------------------------------------------------ 32
OIL RECEIVER LIST--------------------------------------------------------------------------------------------------------------------------------------------- 33
AIR INLET VALVE DRAW-------------------------------------------------------------------------------------------------------------------------------------- 34
AIR INLET VALVE LIST---------------------------------------------------------------------------------------------------------------------------------------- 35
MINUMUM PRESSURE VALVE DRAW-------------------------------------------------------------------------------------------------------------------- 36
MINUMUM PRESSURE VALVE LIST----------------------------------------------------------------------------------------------------------------------- 37
THERMOSTATIC VALVE DRAW---------------------------------------------------------------------------------------------------------------------------- 40
THERMOSTATIC VALVE LIST-------------------------------------------------------------------------------------------------------------------------------- 41
BONNET GROUP DRAW--------------------------------------------------------------------------------------------------------------------------------------- 42
BONNET GROUP LIST------------------------------------------------------------------------------------------------------------------------------------------ 43
PNEUMATIC GROUP DRAW---------------------------------------------------------------------------------------------------------------------------------- 44
PNEUMATIC GROUP LIST------------------------------------------------------------------------------------------------------------------------------------- 45
THE SCREW COMPRESSOR’S HYDRO-PNEUMATİC CYCLE AND WORKİNG PRİNCİPLE-------------------------------------------- 46
ELECTRICAL GROUP DRAW--------------------------------------------------------------------------------------------------------------------------------- 47
ELECTRICAL GROUP LIST------------------------------------------------------------------------------------------------------------------------------------ 48
INSTRUMENT PANEL GROUP DRAW--------------------------------------------------------------------------------------------------------------------- 49
INSTRUMENT PANEL GROUP LIST------------------------------------------------------------------------------------------------------------------------ 50

SERVICE INFORMATIONS------------------------------------------------------------------------------------------------------------------------------------- 51
COMPRESSOR MAINTENANCE OBSERVATION TABLE------------------------------------------------------------------------------------------- 52
2/68
VEK 20-50
SCREW COMPRESSOR
OPERATION
MAINTENANCE AND
SPARE PARTS
GUIDE
MOTOR POWER WORKING PRESSURE

VEK 20 – 50 7.5 – 10 - 13
Hp Bar
Adress And Communication Informations :
Ali Bey Köyü Karasinan Asfaltı Phone No :+90 212 728 43 43 (Pbx)
Mevkii TEM Otoyolu Gişeler Yanı
İstanbul, Turkey Fax :+90 212 728 70 23
www.komsan.com.tr e-mail :info@komsan.com.tr
3/68
FIRST SAFETY
IMPORTANT SECURITY RULES IN OPERATING, MAINTENANCE AND

REPAIR OF THE COMPRESSORS
1-) Use KOMSAN air receivers, equipments and KOMSAN original spare parts produced in compliance with the
norms of TSE 1613
2-) In case compressor is worked parallel with another compressor or is connected an air system with the same
pressure, do not use check valve in the compressor air outlet.
3-) The materials of the pressurized air, pipe and hoses must be in compliance with the pressure.
4-) Do not use scratched, spoilt , decayed and broken hoses. Store the hoses away from the heat source and
direct sun rays.Burst of a hose may harm a human.
5-) Fix the suitable connectors to the lip of the hose.
6-) If pressurized air is used to clean the tools and parts, it must be done carefully. Be careful with the dust while it
is cleaned from the machine. Use googles during cleaning.
7-) While air is used from the hose and installation directly, there must not be any foreign substance in hose. Hold
the hose tip tightly and securely. Otherwise, hose tip may be dangerous because it can hit in the directions of the
right and left like a whip. Open the air outlet valve carefully, check if air gets out of the hose freely. Clogged hose
could become an air rifle.
8-) Do not hold pressed air onto your skin. Do not hold tip of the hose onto another person. Do not clean dusts on
you with pressurized air.
9-) A pressure air system or tool must be operated in accordance with its designed pressure.
10-) Drain compressor pressure completely before dismantling hose and air line.
11-) Tips of the electrical cables must not be open
12-) Electrical connection must be done by authorized electrician.
13-) Pressure tests of the air receivers must be done each year.
14-) Manufacturer company will not be responsible for the damage and life loss caused by the misuse.
4/68
CARRYING THE COMPRESSOR :
Compressor must be carried in vertical position. All motions and collisions which may cause
damage must be avoided. Compressors must not be pushed or pulled through its canopy or doors. Compressors
must not be hung in any other way than it is shown in figure 2.
CARRYING BY MEANS OF FORKLIFT OR HYDRAULIC CARRIER:

When carrying the compressor with a forklift or hydraulic carrier the carrying the support forks of the forklift must
be inserted below the compressor as seen in picture 1.
CARRYING HANGED BY MEANS OF A HOIST:

When carrying the compressor by means of a hoist, insert iron rods to the gaps of the compressor bottom pallet
as seen in picture 2. Care must be given that the upper rod must not touch the compressor, nor the ropes rubbing
on the side of the compressor.
TAKE OUT THE WOODEN FOUNDATION

AFTER CARRYING THE COMPRESSOR
PICTURE-1 PICTURE-2
INSTALLATION:
1-) Install the compressor in a room as it is indicated in picture-4.
2-) Keep the compressor away from the sunlight or other devices which may increase ambient temperature such
as generator sets heating systems etc.
3-) Enough ventilation is absolutely necessary for a compressor. A sample ventilation diagram is presented in
picture-7. Inlet air of the compressor room must be clean and without any contamination of porous gases or
chemicals. If necessary , an appropriate filtration must be installed at the air entrances of compressor room.
4-) Compressor must be installed on the smooth ground, its feet must be put correctly to the ground. Compressor
must not be installed to the ground. Compressor must be seated on the concrete base. (Max. declination of the
floor, where the compressor is to be assembled, must not be more than ±2 degrees)
5-) If compressor is to be used with dryers, filters or receiver, please check picture-6 for how to connect these
instruments to your compressor.
CONNECTING TO MAINS:
1-) Compressor must be separately grounded according to your country’s requirements. (See picture-6) Neutral
connection is not ground . Compressor may burn because of the static charge if not grounded.
2-) Do not allow main supply cables to lay on the floor freely. D o secure them so that they may not cause any
dangerous accidents.
3-) Check all connections are done tight and secure on the mains supply.
4-) Suitable circuit breaker and delayed fuse must be placed on the mains supply (see table-2).
5-) There must be no temporary connection on the mains supply cables.
6-) Compressor operating voltage must be 380±19 volt, unless it is designed for other voltages, during the full
load operation.
7-) TTR type cable must be used with appropriate dimensioning (see table-2).
8-) Keep the compressor away from the moisture if it is not going to be used for a long time.
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IMPORTANT THINGS TO BE CHECKED AT THE FIRST START UP
1-) Check the earth, neutral and phases (R-S-T) if they are fit into system appropriately when compressor starts.
2-) Check the ambient temperature.
3-) Check the oil level.
Ask your dealer’s authorized personnel for the first start up. This will
prevent your compressor from any possible damages. If you start up
compressor on your own, ask your dealer the warranty conditions.
For some cases your start up may infringe guarantee claims.
IMPORTANT THINGS DURING OPERATION
1-) Covers must be kept close.

2-) Water and oil must not be poured onto compressor and foreign objects must not be put onto compressor.
3-) Do not touch the inside of the compressor or do not try to make any reparations by yourself.
STOPPING
To stop the compressor completely, push the ‘’STOP’’ button. Compressor will stop in a certain time. Push the
‘’EMERGENCY STOP’’ button when emergency situation may occur.
CONTROL PANEL
easy
AIREND OUTLET TEMP.

! ELECTRONIC CONTROL SYSTEM
VIDA CIKIS SICAKLIGI
ELEKTRONIK KONTROL SISTEMI
MAIN SCREEN SWITCH

ANA EKRAN BUTONU
STOP SWITCH
START SWITCH DURDURMA BUTONU
CALISTIRMA BUTONU
LOAD - UNLOAD SWITCH EMERGENCY STOP

YUK - BOS BUTONU SCREW COMPRESSOR
ACIL DURDURMA
VIDALI KOMPRESOR
VEK20/50
PICTURE-3
6/68
PLACING OF THE COPMPRESSOR:
~1000 mm ~1000 mm
COOLING AIR INLET

(CLEAN AIR)
~1000 mm
~1000 mm
WARM AIR
OUTLET
PICTURE-4
- DIMENSIONS ARE IN MM.

- ~: AVARAGE
NOT: You should leave 1000 mm 1500 mm
space in the both sides of the

compressor for service.
!
It is advised to use a water cooled COMPRESSOR
To Work ower 35ºC am bient

preaure.
PICTURE-5
7/68
SAMPLE INSTALLATION
REF
NO
PERT NAME
!
01 CHOOSE THE CORRECTLY SIZED
02 PIPING SO THET THE TOTAL
03 02
04
02 PRESSURE LOSS IN THE SYSTEM
05 WILL NOT EXCEED 1/10 BAR
06
07
08 09
09 07 01
8/68
10 06
10
03
08 03
09
09 09
04
08
09
05
OIL
WATER
PICTURE-6
INLET AND OUTLET AIR FLOW OF THE COMPRESSOR ROOM
HOT AIR
OUTLET
Max 15 mm
SU
ABSORBER CLEAN AIR

INLET
WATER
CONCRETE
FOUNDATION
PICTURE 5
PICTURE-7
AIR FLOW ENTERING TO THE COMPRESSOR ROOM
COMPRESSOR TYPE INTAKE AIR FLOW (m³ /s)

VEK 20 1,65
VEK 30 1,65
VEK 40 2,70
VEK 50 2,70
TABLE-1
- ∆P must not be more than 15 mm. If ∆P is more than 15 mm, a new ventilation system must be designed.
- This ventilation system must be designed in such a way that it can drain warm air from the system.
- Cool air inlet must be higher than 1,5 fold from the section area of the warm air outlet.
- Paddlebox weight must not be overlaped the compressor.
- Bellows must be placed between paddlebox and compressor to prevent warm air leakage.
- Paddlebox must not be installed to the compressor, in this purpose a hole must not be made on the
compressor.
9/68
SAMPLE ELECTRIC INSTALLATION SCHEME
CIRCUIT
BREAKER
FUSE
TTR
CABLE
GROUNDING
COMPRESSOR
COMPRESSO AIR DRYER
PICTURE-8
R
YOU MUST DO THE GROUNDING

NEUTRAL LINE IS NOT GROUNDING
FUSE AND CABLE TYPES WHICH ARE USED IN THE ELECTRIC INSTALLATION
COMPRESSOR TYPE FUSE CABLE (TTR)
VEK 20 63 A 4 x 10
VEK 30 80 A 4 x 16
VEK 40 100 A 4 x 16
VEK 50 100A 4 x 16
TABLE-2
USE AN UPPER CABLE SECTION IF THE DISTANCE IS OVER 50 M
NOT: FUSE SELECTION IS IN COMPLIANCE WITH DIN 42673
10/68
PIC: A (new type) PIC: B (old type)
In picture A, you can see EASY 819 used in your new type of compressors and in picture B, you can see EASY
412 used in our older type of compressors.
PLC (control relay) exists in the panel control. PLC has several properties such as LCD
screen, 24 volt, direct current and real time hourmeter. As seen in the panel control,
several functions are carried out with the buttons (see picture c)
Operate your compressor by pushing the ‘’<’’ button. In this case, your compressor
starts to produce air. In order for your compressor to stop, push the ‘’>’’ button. In this
PIC: C
case, your compressor firstly starts to work unload and after a very short time (30 seconds) stops. In
order for your compressor to work manually load and unload , push the ‘ ’’’ button. When your compressor
works on load , if you press ‘’ ’’ button, your compressor works unload. In another situation, when your
compressor works unload, if you press ‘’ ´´ button, your compressor works normally.
In case you press the ‘’ ’’ button, all the information on the screen changes. If you press ‘’ ’’ button when
compressor works on load; model properties, serial numbers, durations on total load and total unload come up. If
you press ‘’ ’’ button again previous information is seen on the screen.
Also, some failures regarding working system of your compressor are seen on the PLC screen. For example,
excessive temperature and high pressure on the compressor.
Do not use OK, ESC, DEL and ALT button because they are on the purpose of service and programming.
OK,ESC,DEL AND ALT BUTTONS ARE IN THE PURPOSE OF SERVICE

AND PROGRAMMING AND THESE BUTTONS MUST NOT BE USED.
11/68
COMPRESSOR DIMENSION
COMPRESSOR TYPE A B C
VEK 20 1845 880 720
VEK 30 1845 880 720
VEK 40 1845 880 720
VEK 50 1845 880 720
TABLE-3
ALL DIMENSIONS ARE IN MM.
PICTURE-9
12/68
PLACING OF THE AIR DRYER
~500 mm ~1000 mm
~500 mm
~1000 mm
COOLING AIR INLET

(CLEAN AIR)
WARM AIR
OUTLET
PICTURE 7
- DIMENSIONS ARE IN mm.

- ~: AVARAGE
NOT: YOU SHOULD LEAVE 1000 mm

SPACE IN THE BOTH SIDES OF THE
1500 mm ~1500 mm
AIR DRAYER FOR SERVICE.
! COMPRESSOR
AIR DRYER
YOU MUST SELECT THE SUITABLE AIR

DRYER ORDER TO WORK OVER 35°C
AMBIENT TEMPERATURE
13/68
PLACING OF THE YERLEŞTİRİLMESİ:
HAVA DEPOSUNUN AIR RECEIVER
~1000 mm
WATER
SUDRAINAGE
TAHLIYESİ
PICTURE-12
!
-- 1475
INSTALLATION OF THEGÖRE
SAYILI İŞ KANUNUNA RECEIVER MUST
BASINÇLI BE DONE
KAPLAR ACCORDING
MEVZUATI İÇ TÜZÜĞÜNETO
LOCAL
UYGUN PROTECTION
MEKANA GÜVENLİKLAWS FOR
ÖNLEMİ PRESSURIZED
ALACAK VESSEL
ŞEKİLDE YERLEŞTİRİLMELİDİR.
!
- -DRAIN
DEPO İÇİNDE BİRİKEN SU HER GÜN
THE ACCUMULATED BOŞALTILMALIDIR
WATER VEYA DEPO
IN THE RECEIVER İÇİNE BİRİKEN
EVERYDAY OR USE
SUYUAUTOMATIC
THE ALMAK İÇİN OTOMATİK
DRAIN FORTAHLİYE
THISKULLANILMALIDIR.
PURPOSE
14/68
PERIODICAL MAINTENANCE PROGRAM
CONTROLS AND MAINTENANCE THAT MUST BE DONE DAILY
1-) Compressor chamber

a-) Temperature
b-) Cleanliness
2-) Air pressure circuit

a-) Air leakage control
3-) Oil pressure circuit

a-) Oil leakage control
b-) Oil level control
4-) Electrical pneumatic circuit
a-) Heat control
5-) Airend
a-) Airend voice control
6-) Electrical motor

a-) Motor voice control
CONTROLS AND MAINTENANCES THAT MUST BE DONE DAILY
1-) Cleanliness of air filter ( from inside to outside with pressurized air)
2-) Inside cleanliness of compressor (*)
3-) Compressor cooler cleanliness (*)
4-) Control of working hourmeter (**)
5-) Control of current values
6-) Voltage control
7-) Control of belt tension
* Do not use water, thinner etc., abrasive or conductive cleanliness material.

** As soon as you realize that it is not working, inform to the Komsan Authorized
Service.
15/68
PERIODIC MAINTENANCE INTERVALS
Institutions working 8
Institutions working 16 hours a day Institutions working 24 hours a day
hours a day
6 Months or 1000 Hours 3 Months or 1000 Hours 2 Months or 1000 Hours
Maintenance A Maintenance A Maintenance A
6 Months or 2000 Hours
1 Year or 2000 Hours 4 Months or 2000 Hours
Maintenance A
Maintenance A Maintenance A
2 Years or 4000 Hours 12 Months or 4000 Hours 8 Months or 4000 Hours
Maintenance B Maintenance B Maintenance B
4 Years or 8000 Hours 24 Months or 8000 Hours 1 Year or 8000 Hours
Maintenance C Maintenance C Maintenance C
Maintenance B Maintenance B Maintenance B
Maintenance D Maintenance D Maintenance D
TABLE-4
- Maintenance A and B are done by KOMSAN’S Technical Service at the place that the compressor is situated.
- Maintenance C is done by KOMSAN in KOMSAN COMPRESSOR MANUFACTORING FACTORY or at the

place that the compressor is situated.
- Maintenance D is done by KOMSAN in KOMSAN COMPRESSOR MANUFACTORING FACTORY
- You should make your compressor to have maintenance on time for the most efficiently working without any
problems
- The user of the compressor must inform KOMSAN COMPRESSOR MANUFACTURING FACTORY or
KOMSAN TECHNICAL SERVICE about the related time intervals shown above ; that the compressor is being
used
- The time table that is given above is valid for normal conditions. The time table can differ according to the
working conditions and the working area
- The earlier occured working time intervals for montly or hourly working time will be taken in to consideration for
the maintanance duration time.
16/68
BREAKDOWN PROBABLE REASONS WAYS TO REPAIR
Overload relay is out of order Change
Electric engine or screw bearings are out of order Call service
Regulate and push the reset
Overload relay or fuse Star-delta transition time is short
button
burns
Off loading time is very short Regulate
Contactors are out of order or sticked Change
Fuses are burned Change
Working pressure interval is wrong Regulate
Pressure switch is out of order Change
Solenoid valve coil is burned Change
Call service
Electrical system is breakdown Change contactor
Compressor can not be Change contactor
loaded Change the cracked
Control air control hoses
or crushed ones
Air control hose connections could have been dirty
( After maintenance, sealing components could block Clean
the connections )
Solenoid valve is dirtied Clean
Air filter is blocked Change air filter
Separator is blocked Change separator
Air intake setting valve is breakdown Call service
Air efficiency is not
enough Control installation leakage and
Excessive air consumption exists. The cross-section of
air consumption of pneumatic
pipes of Air connection is narrow.
tools
Oil hoses are blocked Change

There is foam on oil Wrong oil usage
Expiry date of oil has long been passed Change
Cooler is blocked or dirty Clean cooler
Cooling air is not enough Change the inlet and outlet air
Termostatic valve does not work Call service
Compressor heats
excessively.
(Outlet air +100 C , Be careful about not being
warning lamp lights.) leakage in the suction and
Ambient temperature is very high (max 35 C) or pumping chimney-hoods. Make
ventilation is not enough. chimney-hood and ventilation
installation to make ambient
temperature decrease.
Lamp and relay are out of order Control

Fan blower blades are not strong Change
Oil turning pipe is blocked Open and clean
Separator is blocked or out of order Change
Excessive oil
consumption Wrong oil usage or oil expiry date has long been Change the oil with oil filter and
passed. use the suitable oil
Pressure switch is breakdown Change

Pressure is increasing
The setting of pressure switch has not been done Set
excessively.
Air intake setting valve is breakdown Call service
TABLE-5
If a cabinet filter mounted on the compressor you should change it free of charge.
17/68
THE MAINTENANCE THAT MUST BE DONE BY THE USER
1- To check the electrical connections; to check the connections whether they are loose or not, while the switch is
closed.
2- Air circuit problems; the control of the air leaks and the pneumatic circuit elements.
3- To protect your compressor against the outer effects; you should keep your compressor away from dirty
surroundings and if it is necessary you should build a separate compressor room.
4- To check the thermic, fuse and voltage.
5- To clean the cooler; the cooler must be cleaned with compressed air from its inner side to its outer side.
6- To clean the oil return line; to clean the filter in the oil return check valve.
7- To check the belt tightness; once a week you should check the belt tightness.
8- To arrange the pressure level
9- To clean the air filter; the air filter should be disassembled and cleaned with compressed air from its inner side
to its outer side.
10-To check the operating hour meter; whether the operating hour meter is working or not while the compressor
is working; if the hour meter is not working you must call immediately the KOMSAN technical service.
If the technical service is called, because of the reasons above and things stated in the breakdown
finding page, a service expense is paid to KOMSAN.If a brekdown occurs because of not doing the cleaning and
maintenance stated above, while your compressor is working your compressor will be out of guarantee.
The first start of the compressor process and all the maıntenance will be done in the guarantee period;
the maintenance except the things stated above and in the breakdown finding page must be done by KOMSAN
technical service. In an opposite occasion the compressor will be out of guarantee.
The adress that the compressor is situated : CUSTOMER/Cachet
PHONE NUM : DATE :

SIGNATURE :
18/68
ATTENTION TO THE SERVICE AFTER SALE
FIRST OPERATING INSTRUCTIONS
DATE : ......../......./ 200...

TYPE OF THE COMPRESSOR : ...................................................
SERI NO : ...................................................
KOMSAN A.Ş. FAX : +90 (212) 728 70 23
THE PROCESSES THAT MUST BE DONE BEFORE CALLING THE KOMSAN TECHNICAL SERVICE
FOR THE FIRST START OF THE COMPRESSOR
YES NO
1-1 Are the compressor and equipments installed as shown in the guide book?
1-2 Is the air installation correctly completed according to the type of the compressor?
1-3 Is the electrical installition completed as shown in the guide book?
1-4 Is the electrical volt value,cable type,quality.fuse,thermic switch;suitable to the

motor power and the empty space occupied between the compressor and the power
resource? (Please look at the maintenance guide)
1-4-1 Is the volt entrance suitable to compressor and the compressedair equipments
working with electric?
1-5 Is there a ventilation system established?
The processes stated above are done by us. We request the first start and the begin of guarantee applications of
the compressor to be done by KOMSAN compressor manufactorıng factory.
The adress that the compressor is situated : CUSTOMER/ Cachet
PHONE NUMBER : DATE :
SIGNATURE :
NOTE: If our service technician that will come to your institution, sees some uncompleted processes, then our
service will not do the first start. After the needed processes are completed the service will come to your institution
again and will do the first start by getting the service expences from you.
If you want to get detailed information about the things above, you can call; +90 212 728 43 43 or comminicate
with us by fax from +90 212 728 70 23 and reach us servis@komsan.com.tr.
19/68
YEDEK PARÇA
LİSTESİ
SPARE PART
LIST
20/68
21/68
VEK 20-50 ANA MONTAJ
VEK 20-50 MAIN ASSEMBLY
Sıra No/Ref. No Parça No/Series No Sayfa No/Page No Adı Name
01 154.66.904 34 Kaporta Grubu Bonnet Group

02 154.45.101 44 Gösterge Grubu Instrument Panel Group
03 154.47.102 36 Pnömatik Grubu Pneumatic Group
04 154.42.301 40 Elektrik Grubu Electrical Group
05 154.47.003 20 Hidrolik Grubu Hydrolic Group
06 154.00175.001 24 Vida Grubu Air End Group
07 154.10.820 22 Motor Grubu Motor Group
22/68
23/68
HİDROLİK GRUBU
HYDROLIC GROUP - 154.47.003
Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı Part Name
01 154.62.004 1 Soğutucu Cooler

02 154.28.210 5 Nipel Nipple
03 154.32.030 1 Boru Hose
04 154.32.030 1 Boru Hose
05 154.50.057 1 Termostatik Valf Thermostatic Valve
06 154.28.158 2 Nipel Nipple
07 154.03.601 1 Filtre Kapağı Filter Cover
08 154.32.301 1 Boru Hose
09 154.56.606 1 Filtre Filter
10 154.28.234 2 Rakor Nipple
11 154.32.903 2 Nipel Nipple
12 154.00175.001 1 Vida Ünitesi Airend
13 154.32.938 1 Vek 20-30 Boru Tak. Hose Team
154.32.939 1 Vek 40-50 Boru Tak. Hose Team
14 154.60.820 1 Yağ Deposu Montajı Oil Receiver Assembly
15 154.28.231 2 Rakor Nipple
16 154.56.111 1 Seperatör Separator
17 154.03.603 1 Seperatör kapağı Separator Cover
18 154.28.011 1 Nipel Nipple
Min. Basınç Valfi
19 154.50.014 1 Min. Presure Valve
(Vek 20-30)
Min. Basınç Valfi
154.50.022 1 Min. Presure Valve
(Vek 40-50)
24/68
25/68
MOTOR GRUBU
MOTOR GROUP - 154.10.820
Sıra No/Ref. Parça No/Series

Adet/Quant. Parça Adı Part Name
No No
01 154.00175.001 1 Vida Ünitesi Air End

02 154.19.023 1 Kama Wedge
03 154.10.026 1 Kama (Vek 20) Wedge (Vek 20)
154.10.022 1 Kama (Vek 30) Wedge (Vek 30)
04 154.23.061 4 Somun Nut
05 154.27.024 8 Pul Washer
06 154.22.097 4 Civata Bolt
07 154.04.006 1 Kasnak (Vek 20-7.5 bar) Pulley (Vek 20-7.5 bar)
154.04.006 1 Kasnak (Vek 20-10 bar) Pulley (Vek 20-10 bar)
154.04.062 1 Kasnak (Vek 30-7.5 bar) Pulley (Vek 30-7.5 bar)
Kasnak (Vek 50-10 bar –
154.04.115 1 Pulley (Vek 50-10 bar – 1500 rpm)
1500 dev/dak)
154.04.115 1 Pulley (Vek 50-13 bar – 1500 rpm)
1500 dev/dak)
08 154.15.119 1 Kas.Göb.(Vek 20-7.5 bar) Tapper Lock Bushing(Vek 20-7.5 bar)
154.15.119 1 Kas.Göb. (Vek 20-10 bar) Tapper Lock Bushing(Vek 20-10 bar)
154.15.807 1 Kas.Göb.(Vek 30-7.5 bar) Tapper Lock Bushing(Vek 30-7.5 bar)
Kas.Göb. (Vek 50-10 bar – Tapper Lock Bushing(Vek 50-10 bar
154.15.156 1
1500dev/dak) – 1500rpm)
26/68
MOTOR GRUBU
Sıra No/Ref. No Parça No/Series No Adet/Quant. Parça Adı Part Name
Kas.Göb. (Vek 50-13 bar – Tapper Lock Bushing (Vek

154.15.156 1
1500 dev/dak) 50-13 bar – 1500 rpm)
09 154.15.119 2 Setskur.(Vek 20-7.5 bar) Set Screw(Vek 20-7.5 bar)
154.15.119 2 Setskur. (Vek 20-10 bar) TSet Screw(Vek 20-10 bar)
154.15.119 2 Setskur. (Vek 20-13 bar) Set Screw(Vek 20-13 bar)
154.15.156 2 Setskur.(Vek 30-7.5 bar) Set Screw(Vek 30-7.5 bar)
10 154.22.007 5 Civata Bolt
11 154.21.040 1 Pervane Göbeği Fan Hub
12 154.21.043 2 Pervane Bağlantı Parçası Blade Assembly Tool
13 154.21.009 10 Kanat Blade
14 154.10.026 1 Motor (Vek 20) Motor (Vek 20)
154.10.022 1 Motor (Vek 30) Motor (Vek 30)
15 154.22.097 8 Civata Bolt
16 154.27.024 16 Pul Washer
17 154.66.423 1 Gönye Direği Montajı Gönye Direği Montajı
18 154.23.015 8 Somun Nut
19 154.04.060 1 Kasnak (Vek 20-7.5 bar) Pulley (Vek 20-7.5 bar)
Kasnak (Vek 50-10 bar – Pulley (Vek 50-10 bar –
154.04.137 1
1500 dev/dak) 1500 rpm)
27/68
MOTOR GRUBU
Sıra No/Ref. Parça No/Series

Adet/Quant. Parça Adı Part Name
No No

154.04.136 1 Pulley (Vek 50-13 bar – 1500rpm)
1500dev/dak)
20 154.15.155 1 Kas.Göb.(Vek 20-7.5 bar) Tapper Lock Bushing(Vek 20-7.5 bar)

Kas.Göb. (Vek 50-10 bar Tapper Lock Bushing(Vek 50-10 bar -
154.15.160 1
1500dev/dak) 1500rpm)
Kas.Göb. (Vek 50-13 bar - Tapper Lock Bushing(Vek 50-13 bar
154.15.160 1
1500dev/dak) – 1500 rpm)
21 154.15.155 2 Setskur.(Vek 20-7.5 bar) Set Screw(Vek 20-7.5 bar)
154.15.118 2 Setskur. (Vek 20-10 bar) TSet Screw(Vek 20-10 bar)
22 154.14.919 4 Kayış (Vek 20-7,5 bar) Belt (Vek 20-7,5 bar)
154.14.024 4 Kayış (Vek 20-10 bar) Belt (Vek 20-10 bar)
154.14.041 4 Kayış (Vek 30-7.5 bar) Belt (Vek 30-7.5 bar)
28/68
Kayış (Vek 50-10 bar –
154.14.025 5 Belt (Vek 50-10 bar – 1500 rpm)
1500 dev/dak)
Kayış (Vek 50-13 bar –
154.14.356 5 Belt (Vek 50-13 bar – 1500 rpm)
1500 dev/dak)
29/68
30/68
VİDA GRUBU
AIREND GROUP - 154.00175.800
01 154.23.023 1 Somun Nut

02 154.56.036 1 Filtre Kabı Cover
03 154.56.100 1 Filtre Fitler
04 154.32.301 1 Nipel Nipple
05 154.22.202 4 Civata Bolt
06 154.23.009 4 Somun Nut
07 154.27.043 4 Pul Washer
08 154.22.904 4 Civata Bolt
09 154.22.260 4 Civata Bolt
10 154.39.902 1 Emiş Valfi Montajı Intake Valve Assembly
11 154.16.919 1 O-Ring O-Ring
12 154.19.077 1 Kama Wedge
13 154.28.279 1 Nipel Nipple
14 154.28.279 1 Süzgeç Strainer
15 154.50.004 1 Çekvalf Check Valve
16 154.28.463 1 Dirsek Elbow
17 154.22.202 4 Cıvata Bolt
18 154.13.035 1 Termometer Orifice
19 154.22.008 10 Civata Bolt
21 154.28.106 1 Rakor Nipple
31/68
32/68
YAĞ DEPOSU
OIL RECEIVER - 154.60.820
01 154.28.295 1 Rakor Nipple

02 154.28.304 1 Nipel Nipple
03 154.28.065 2 Kör Tapa Plug
04 154.60.940 1 Yağ deposu Montajı Oil Receiver Assembly
05 154.52.012 1 Emniyet Subabı Safety Valve
06 154.35.004 2 Dirsek Elbow
07 154.00175.304 1 Conta Gasket
08 154.32.059 1 Hortum Hose
09 154.60.820 1 Dirsek Elbow
10 154.58.054 1 Boru Hose
11 154.28.253 1 Ayak Flange
33/68
34/68
HAVA EMİŞ VALFİ
AIR INLET VALVE - 154.39.902
01 154.01.046 1 Gövde Frame

02 154.16.919 1 O-Ring O-Ring
03 154.24.035 1 Yay Spring
04 154.23.016 1 Somun Nut
05 154.16.042 1 Halka Ring
06 154.49.023 1 Piston Piston
07 154.16.916 1 Keçe Seal
08 154.19.032 1 Mil Pin
09 154.16.321 1 O-Ring O-Ring
10 154.15.110 1 Yatak İnnerr Part
11 154.16.034 1 O-Ring O-Ring
12 154.15.137 1 Burç Bushing
13 154.46.022 1 Segman Piston Ring
14 154.24.010 1 Yay Spring
15 154.15.138 1 Burç Bushing
16 154.68.004 1 Klape Clamp
17 154.16.916 1 Conta Gasket
18 154.26.040 1 Segman Piston Ring
19 154.16.920 2 O-Ring O-Ring
20 154.28.061 1 Kovan Cover
21 154.28.072 1 Kovan Cover
22 154.28.920 2 O-Ring O-ring
35/68
36/68
MİNİMUM BASINÇ VALFİ
MINUMUM PRESSURE VALVE - 154.50.014
01 154.22.466 1 Setskur Set Screw

02 154.23.002 1 Somun Nut
03 154.26.026 1 Pul Washer
04 154.01.048 1 İç Gövde Cylinder
05 154.16.028 1 Oring O-ring
06 154.50.801 1 Stoper Stopper
07 154.24.046 1 Yay Spring
08 154.03.011 1 Kapak Cover
09 154.16.023 1 O-ring O-ring
10 154.24.045 1 Yay Spring
12 154.16.011 1 O-ring O-ring
13 154.22.449 1 Setskur Set Screw
14 154.01.049 1 Gövde Body
37/68
38/68
MİNİMUM BASINÇ VALFİ
MINUMUM PRESSURE VALVE - 154.50.022
01 154.22.171 1 Cıvata Bolt

02 154.23.018 1 Somun Nut
03 154.01.051 1 İç Gövde Cylinder
04 154.16.138 1 O-ring O-ring
05 154.50.802 1 Stoper Stopper
06 154.24.047 1 Yay Spring
07 154.24.048 1 Yay Spring
08 154.03.012 1 Kapak Cover
09 154.16.088 1 Keçe Seal
10 154.03.013 1 Piston Kapağı Piston Cover
11 154.22.118 1 Cıvata Bolt
12 154.24.049 1 Yay Spring
14 154.16.036 1 O-ring O-ring
15 154.01.052 1 Gövde Body
16 154.22.449 1 Setskur Fill Plug
39/68
40/68
TERMOSTATİK VALF
THERMOSTATIC VALVE - 154.50.057
Part
Sıra No/Ref. No Parça No/Series No Adet/Quantity Parça Adı
Name
01 154.26.906 1 Segman Circlip

02 154.03.071 1 Kapak Cover
03 154.16.061 1 O-ring O-ring
04 154.40.620 1 Müşür Gage
06 154.24.022 1 Yay Spring
07 154.50.057 1 Gövde Body
41/68
42/68
KAPORTA GRUBU
BONNET GROUP - 154.66.424
01 154.66.426 2 Yan Kapak Side Plate

02 154.66.444 1 Elektrik Panosu Electrical Panel Sheet
03 154.66.450 1 Tavan Sacı Cover Plate
04 154.64.116 1 Dav. Borusu (Vek 20) Chimney Hood (Vek 20)
154.64.116 1 Dav. Borusu (Vek 30) Chimney Hood (Vek 30)
154.64.116 1 Dav. Borusu (Vek 40-50) Chimney Hood (Vek 40-50)
05 154.64.115 1 Davlumbaz Borusu Göv. Scarfed Sheet Cover
06 154.66.447 1 Arka Kapama Sacı Back Cover Plate
07 154.66.433 1 Izgara Protecting Plate
08 154.66.435 1 Gövde Body
10 154.66.425 1 Pano Kapağı Panel Sheet Panel
11 154.28.290 7 Kapak Kilidi Cover Key
12 154.28.293 1 Kilit Anahtarı Lock Key
13 154.66.427 1 Ön Kapak Front Plate
14 154.28.248 4 Menteşe Hinge
15 154.66.449 1 Sol Direk Left Column
16 154.66.448 1 Sağ Direk Right Column
17 154.66.446 1 Ara Bağlantı Parçası Beam
18 154.66.418 1 Kapak Plate
19 154.22.033 4 Civata Bolt
20 154.22.005 8 Civata Bolt
21 154.27.305 8 Pul Washer
22 154.66.451 1 Taban Sacı Bottom Plate
23 154.28.030 4 Lastik Takoz Rubber Block
24 154.23.013 4 Somun Nut
25 154.66.445 4 Bağlantı Ayağı Rubber Block Holder
43/68
B
11
13 10
2
44/68
17
1
PNÖMATİK GRUBU
PNEUMATIC GROUP - 154.47.102

02 154.39.902 1 Emiş Valfi IntakeValve
03 154.50.004 2 Çek Valf Check Valve
04 154.40.023 1 Ters Dönüş Müşürü Anti Rotation Swich
05 154.40.037 1 Basınç Sensörü Pressure Sensor
06 154.42.050 1 Selenoid Valf 2NA Solenoid Valve 2NA
07 154.42.089 1 Selenoid Valf 2NK Solenoid Valve 2NA
08 154.42.024 1 Selenoid Valf 3NK Solenoid Valve 3NA
09 154.60.820 1 Yağ Deposu Oil Receiver
10 154.56.111 1 Seperatör Separator
Min Basınç Valfi Minumum Presure
154.50.014 1
(Vek 20-30) Valve
11
Min Basınc Valfi Minumum Presure
154.50.022 1
(Vek 40-50) Valve
12 154.28.278 1 Orifis (Vek 20-30-40) Orifice (Vek 20-30-40)
154.28.277 1 Orifis (Vek 50) Orifice (Vek 50)
13 154.52.012 1 Emniyet Subabı Safety Valve
14 154.50.057 1 Termostatik Valf Thermostatic Valve
16 154.62.004 1 Soğutucu Cooler
17 154.80.055 12 Lt Komsan Yağı Komsan Oil
45/68
The Screw Compressor’s Hydro-Pneumatic Cycle and Working Principle
Compressor working onload: The compressor starts with star contactor and then delta contactor and
required energy is provided in order for compressor to start. Airend (1) is driven by electrical motor. With the
rotation of the rotors in the airend , a vacuum environment is created. This vacuum environment enable the
compressed air goes through the rotors meshing each other to the outlet port.
The compressed air which is mixed with oil, inside the airend, leaves the airend with the impact of the
high pressure and is sprayed to the separator tank’s (oil receiver’s) (10) upper section. Inside the separator the oil
in the air is accumulated at the bottom of the oil receiver. Under the high pressure conditions, the oil leaves the
oil receiver and enters in the thermostatic valve. At this part of the cycle according to the oil’s temprature the oil
directly passes from the thermostatic valve(15) to the airend, through the oil filter or goes to the cooler (17) just
after passing the thermostatic valve. After the oil is cooled in the cooler, it enters in the oil filter (16) and returns
back to the rotors that are working together, to decrease the increasing heat produced by the rotors and to
prevent the compressed air escaping backwards.
In the separator tank(oil receiver) firstly the oil is partly separated. In the second step the oil passes to the
separator(11) in which the air is completely separated from oil. After the separation of the oil from air, the air
passes through the minimum pressure valve(12) and enters in the cooler in which air is cooled and be ready to be
served. On the other hand the oil inside the separator tank is pushed to the airend by passing through check
valve (3) and orifice (13) with the impact of the high pressure.
Compressor working unloading: As soon as the pressure level of the compressor reaches to the desired
level, solenoid valve (7) goes into closed position from open position after pressure switch (6) starts to work.
Then, air intake valve closes. As for pressurized air in separator tank, a little portion of pressurized air in
separator tank goes to the airend by passing through solenoid valve (7) , remaining part of the pressurized air
gets out of the system by passing through intake valve.
If any air demand emerges when the compressor works unload, pressure switch enable solenoid valve to open
position. Therefore, compressor again starts to produce compressed air.
Compressor’s stop: In case no need of compressed air in the system while the compressor working
unload , electrical motor stops after the time controlled by PLC.
Compressor resumes to work: When the compressor’s pressure decreases to designated level,
pressure switch starts to work. After a while, the compressor start to work again to produce compressed air after
getting current to its electrical motor from the system.
46/68
1
0,5/4,5
3
+24V
4
P
Selenoid
INPUTS
Valve
Transfer air
into Airend
Selenoid
Valve
8
Discharge
1
3
Selenoid
Valve No
Load
1
Delta
contactor
3
Star
contactor
1
2
Line
Contaactor
2
22
∆
~
POWER CIRCUIT
47/68
ELEKTRİK GRUBU
ELECTRICAL GROUP - 154.42.058
01 154.110.017 1 Acil Stop Butonu Emergency Stop Button

02 154.43.496 1 Besleme Kartı Supply Card
03 154.43.551 1 PLC PLC
04 154.100.019 1 Hat Kontaktörü (Vek 20) Line Contactor (Vek 20)
154.43.554 1 Hat Kontaktörü (Vek 30) Line Contactor (Vek 30)
154.43.004 1 Yıldız Kontaktör (Vek 20) Star Contactor (Vek 20)
05 154.100.019 1 Yıldız Kontaktör (Vek 30) Star Contactor (Vek 30)
154.100.019 1 Üçgen Kontaktör (Vek 20) Delta Contactor (Vek 20)
06 154.43.006 1 Üçgen Kontaktör (Vek 40) Delta Contactor (Vek 40)
07 154.42.011 1 Selenoid Valf Solenoid Valve
08 154.43.700 1 Termik Röle (Vek 20) Thermic Relay (Vek 20)
154.43.703 1 Termik Röle (Vek 30) Thermic Relay (Vek 30)
09 154.43.497 1 Trafo Transformer
10 154.41.336 2 Kontaktör Yardımcı Bloğu Contactor Auxiliary Block
11 154.100.018 1 alter Circuit Breaker
12 154.115.021 1 Sigorta Fuse
48/68
2
1
easy
AIREND OUTLET TEMP.

! ELECTRONIC CONTROL SYSTEM
VIDA CIKIS SICAKLIGI
ELEKTRONIK KONTROL SISTEMI

49/68
MAIN SCREEN SWITCH

ANA EKRAN BUTONU
STOP SWITCH
START SWITCH DURDURMA BUTONU
CALISTIRMA BUTONU
LOAD - UNLOAD SWITCH

YUK - BOS BUTONU EMERGENCY STOP
ACIL DURDURMA SCREW COMPRESSOR
VIDALI KOMPRESOR
VEK20/50
6
5
3
GÖSTERGE GRUBU
INSTRUMENT PANEL GROUP - 154.45.101
01 154.43.551 1 PLC PLC

02 154.13.035 1 Termometre Thermometer
03 154.45.004 1 Etiket Label
04 154.45.008 1 Etiket Label
05 154.110.017 1 Acil Stop Butonu Emergency Stop Button
06 154.43.551 1 Etiket Label
50/68
SERVİS
BİLGİLERİ
SERVICE
INFORMATIONS
51/68
09 FRM 017 Rev 00
29.04.2005
KOMPRESÖR BAKIM TAKİP KARTI

KOM PRES ÖR TİPİ : S ERİ NO :
TARİHLER YAPILAN PERİYODİK BAKIM

BAKIM I YAPAN
VEYA GİDERİLEN ARIZANIN RAPOR NO
BAŞ LANGIÇ BİTİŞ ARIZAYI GİDEREN
TANIM I
52/68
53/68

VEK 20-50 Screw Compressor: Maintenance and Spare Parts Guide

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VEK 20-50

Address and communication informations:

09 FRM 020 Rev 10

IMPORTANT SECURITY RULES IN OPARATING, MAINTANANCE AND REPAIR OF THE COMPRESSORS---------------------- 4

INSTRUMENT PANEL GROUP LIST------------------------------------------------------------------------------------------------------------------------ 50

MOTOR POWER WORKING PRESSURE

Adress And Communication Informations :

IMPORTANT SECURITY RULES IN OPERATING, MAINTENANCE AND

CARRYING BY MEANS OF FORKLIFT OR HYDRAULIC CARRIER:

CARRYING HANGED BY MEANS OF A HOIST:

TAKE OUT THE WOODEN FOUNDATION

IMPORTANT THINGS DURING OPERATION

1-) Covers must be kept close.

AIREND OUTLET TEMP.

ELEKTRONIK KONTROL SISTEMI

MAIN SCREEN SWITCH

LOAD - UNLOAD SWITCH EMERGENCY STOP

COOLING AIR INLET

- DIMENSIONS ARE IN MM.

NOT: You should leave 1000 mm 1500 mm

space in the both sides of the

To Work ower 35ºC am bient

ABSORBER CLEAN AIR

AIR FLOW ENTERING TO THE COMPRESSOR ROOM

COMPRESSOR TYPE INTAKE AIR FLOW (m³ /s)

YOU MUST DO THE GROUNDING

USE AN UPPER CABLE SECTION IF THE DISTANCE IS OVER 50 M

NOT: FUSE SELECTION IS IN COMPLIANCE WITH DIN 42673

OK,ESC,DEL AND ALT BUTTONS ARE IN THE PURPOSE OF SERVICE

COOLING AIR INLET

- DIMENSIONS ARE IN mm.

NOT: YOU SHOULD LEAVE 1000 mm

YOU MUST SELECT THE SUITABLE AIR

CONTROLS AND MAINTENANCE THAT MUST BE DONE DAILY

1-) Compressor chamber

2-) Air pressure circuit

3-) Oil pressure circuit

6-) Electrical motor

CONTROLS AND MAINTENANCES THAT MUST BE DONE DAILY

* Do not use water, thinner etc., abrasive or conductive cleanliness material.

- Maintenance C is done by KOMSAN in KOMSAN COMPRESSOR MANUFACTORING FACTORY or at the

- Maintenance D is done by KOMSAN in KOMSAN COMPRESSOR MANUFACTORING FACTORY

Oil hoses are blocked Change

Lamp and relay are out of order Control

Pressure switch is breakdown Change

4- To check the thermic, fuse and voltage.

8- To arrange the pressure level

The adress that the compressor is situated : CUSTOMER/Cachet

PHONE NUM : DATE :

FIRST OPERATING INSTRUCTIONS

DATE : ......../......./ 200...

1-3 Is the electrical installition completed as shown in the guide book?

1-4 Is the electrical volt value,cable type,quality.fuse,thermic switch;suitable to the

1-5 Is there a ventilation system established?

The adress that the compressor is situated : CUSTOMER/ Cachet

PHONE NUMBER : DATE :

Sıra No/Ref. No Parça No/Series No Sayfa No/Page No Adı Name