Starting Air Compressor hl2/140

Wärtsilä id: DBAB538460 -
Sperre Air Compressor Unit

Final Documentation
CUSTOMER: Wärtsilä Finland OY

Power Plant
YOUR ORDER NO.: PP4501290150
Powerstation: “Kipevu III”
SPERRE ORDER CONF.: 458027
A STARTING AIR UNIT w/ El.motor & diesel engine 3 x HL2/140

B GENERAL DRAWINGS & PROSPECTUS
C INSTRUCTION MANUALS: Air compressor HL2/140
El. Motor ABB M3AA 180
Diesel engine Deutz F3L 912F
Final 10.03.10 SF RD
Working
Approval 16.02.10 SF RD
ISSUE DATE PREP. BY CHECK
Sperre Industri AS Sperre Rotterdam BV Sperre Asia PTE LTD Sperre China
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 763 63 00 Tel +86 21 65070436
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11 Fax +86 21 65070402
E-mail:industri@sperre.com E-mail:rotterdam@sperre.com E-mail:asia@sperre.com E-mail:china@sperre.com
Sole suppliers of genuine spare parts - www.sperre.com
LIST OF DRAWINGS
Starting air unit 3 x HL2/140 w/ diesel & el.motor
No. Description Type /Dwg.
A1 Starting of compressor w/ diesel engine 4-2143

A2 General arrangement, Air compressor GW03-0126
A3 PI-diagram DW03-0126
A4 El. Motor data sheet M7384
A5 El. Wiring diagram E20167103 pg. 1-5
A6 El.wiring diagram, Program print out E20167 pg. 1-6
A7 Diesel Engine Deutz 7210
A8 Exhaust silencer w/ flex. hose 4-2106 4776
Electric Motor
Data Sheet
Part no. 7384
0DQXIDFWXUHU 7\SH &RQVWUXFWLRQ

Manufacturer ABB Size and dimentions according to IEC 60072
Model M2AA 180 LB4 Design (IEC 60034-7) IMB3
Frame size (IEC 60072) 180L
Protection (IEC 60034-5) IP55
6XSSO\ Insulation class (IEC 60085) / Temp. rise F/B
House material Aluminium
Volts/Cycles/Phases 400V/50Hz/3 Bearing greasing For life
Rated current, In 58.5 A Bearings DE/SPERRE part no. 6209ZC3/6332
Starting current 6.4 x In Bearings NDE/SPERRE part no. 6209ZC3/6332
Weight 145 kg
2XWSXW ,QVWDOODWLRQ
Rated power 28.0 kW Starting method DOL / Y-D
Power factor at FL (cosΦ) 0.86 Duty type S1
Efficiency at FL 91.8% Rotation (seen against shaft end) CW
Speed synchronous / FL 1500/1460RPM Wiring connection DELTA
Cable entries 2 x ∅40mm
Suitable for cable diameter 22-32mm
6SHUUH,QGXVWUL$6 6SHUUH5RWWHUGDP%9 6SHUUH$VLD37(/7' 6ROHVXSSOLHUVRI
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 763 63 00 JHQXLQHVSDUHSDUWV
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
E-mail:industri@sperre.com E-mail:rotterdam@sperre.com E-mail:asia@sperre.com
% (
) *' *+ ) ,
*' % - %( ) $ . (( $ ) # %% / %(
$ $ *' % $ ( % %( $ , $-# 0 % / $/ 1 #
% %( ) .., -$ ( ) #
*+ % %( -1 (( $ ) # ( % $ % . )
2$ , ( $ ) ) - ) %( % ( $ ) # ( / #
2$ (( ) %% % $ ($ % %( # % / .
( %% - ) %( % # % % ( . 3 $ ,
. $ #
) ( % ) / %
4 %( $ # %( $ 5 . %( $ ) %( ) ( %) - / #
%) % $ -$ ( # %( 4 64 ! !7* +7! ) ) % $
-$ ( # ( $ %( ) . ) %( / / #
3$- . $ # . 3$-# 0 / ( $ . $ . 3$-# 0 ) %( ) ( %) -
/ # %) % $ -$ ( # %( 3+8# 0 3 * 3+7! ) ) % $
-$ ( # ( $ %( ) . ) %( / / #
! 9% / # . % / 1 , %( ) ( %) - / # %) % $
% 1 # %( 0:!730*& ) ) % $ % 1 #
( $ %( ) . ) %( / / #
!% 1 (# . % 1 ( ($ -$ / , %( ) ( %) - / # %)
% $ % 1 ( ($ -$ -$ ( # %( 0:!730*& / .
) % . $ -$ ( #
3 ) ( $ # ( $ ) ) / %) ( $ . $ . ) # %(
30; * 7 7!<<+7! ) %) - / # %) % $ ( $ - / . ) #
( % $ . - $ . %( *+ % , % 8" ) 1 . %( #
) % 1 $ ) #; ) ( 3 / , % .$
. / #
) . % 1 $ 1 %( %$ - . $ $ #
$ %
& %' #
! " #
>= # ) @ 8 8
8 = >? # %( @
8 "
8 8 D
4 8
8 8 = >C # & : / @
7 % A ..
8
B 8 8
7 % A ..
> @ 8 8 D! 8 " B 8 = >4 # 7$ @
8
/
8
8 D 7 % A .. 7 % A ..
>*$ @ 8 B = >? # %( @
9
8 8 8 8 8
>= # ) @ 4 8 D 8 = >C # & : / @
8 " 8 8
7 % A ..
> # %(@ 8 8 " B 8 =" >4 # 7$ @
8 8 !
<
7
8 /
"
8 D 7 % A ..
7 %A0
> # %(@ 8 " 8 9
8
8 8
<
7
8
" 8
8
7 %A0
8 D
8 8
> # < < (@
8
< 8
7 8
7< 8
> # < < ( )@ 8
7 %A
8
$ %
& %' #
! " #
> # 0 / @
8 8 " 8 8 =
D >4 0/ @
7
8 " 8 8 D
7 % A .. <
8
7
B " 8
7 %A0.. 8 D
8
> # 0 / @ 8 8 =D >4 %(@
8 8 " 8
8 " 8
7
8
8 8
7 % A .. <
8
7
B "
8 8 = >4 3$- . $ @
7 %A0..
8
>3 %( @
>!% 1 (@ 8 " 8
" >7 @ 8 8
< 8 D
7 !
8 8 /
8
8 " 7 % A .. 8
8 7 % A ..
8 8 8 D
D> # 0/ @ 8 8 "! 9
8
8 8 = >* %@
8 8
> # 0/ @ 8
8 "!
8
8 D 8 " = >4" 3 ) ( $ @
"> 3 )( $ @
$ %
& %' #
! " #
!
" # $ % $ & # #& & ' + &,
( )' && '&*
- !
. $ $ & ' / )' && ' * 0 &,
' $ $ & * 0* & $&
2 3& ' #& 4# & 5 ' '

0 &
0 &
6 4# &
+ 3& ' #& 4# & 5 ' '

0 &
0 &
+-
1+ !
. $ $ & ' / )' && ' * 0 &,
' $ $ & * 0* & $&
10 !
#)' && ' #& $ ( ' # & / )' && ' * + &,
' $ $ & +* 0* & $&
1 3& ' #& 4# & 5 ' '

0 &
0 &
16 !
! % $ & # #& & ' + &,
( )' && '& 7 # & &7 $ 3.8 *
0+ !
#)' && ' #& $ ( ' # & / )' && ' * + &,
' $ $ & +* 0* & $&
$ %
& %' #
! " #
!% 1 (
= # )
= # )
*$
" 7
3 %(
D # 0/
# 0/
# < < (
# < < ( )
# %(
# %(
# 0 /
# 0 /
" 3 )( $
<
<
<
<
<
<"
<
<D
$ %
& %' #
! " #
*"
*D
= ? # %(
= ? # %(
= C # & : /
= C # & : /
= 4 # 7$
=" 4 # 7$
= 4 0/
=D 4 %(
= 4 3$- . $
= 4" 3 ) ( $
= * %
= "
*=
*=
E"
ED
$ %
& %' #
! " #
912. The engine for construction equipment.

.......................................................................................................................................................................................................................................................
....... -1
24 - 82 kW at 1500 - 2500 min
These are the characteristics of the 912:

Air-cooled 3-, 4-, 5-, 6-cylinder naturally aspirated in-line-engines.
Direct injection.
Advanced injection and combustion system.
PTOs via gear, V-belt and crankshaft.
Extremely compact design.
High torque at low speeds.
Modular system with single cylinder arrangement and high degree of parts commonality.
Customized component system with many different peripheral parts.
Cold-starting ability even under extreme climatic conditions.
These are the benefits for you:

E Fast response to load changes.
E Low noise emission, high cost savings thanks to less noise insulation requirement.
E Low operating costs thanks to lower fuel consumption and long maintenance intervals
with reduced maintenance requirement.
E Excellent smooth-running characteristics thanks to low engine vibrations.
E Minimal environmental impact. Meets exhaust regulation EU-RL 97/68.
E Extremely reliable and durable.
E Easy-to-install unit (engine with integrated cooling system).
Engine description
Cooling system:....................... Air-cooled with integrated axial-flow blower

Crankcase: .................................... Grey cast iron
Cylinder head:........................... Aluminium single cylinder heads
Valve arrangement/
timing: ............................................. Overhead valves in the cylinder head, one inlet and one exhaust valve per cylinder,
actuated from gear-driven camshaft via tappets, push-rods and rocker arms
Piston: ............................................... Three-ring piston: two compression rings and one oil scraper ring
Piston cooling: .......................... Oil spray via nozzle
Crankshaft: .................................. Drop-forged steel crankshaft with bolted counterweights
Connecting rod:....................... Drop-forged steel rod, diagonally split
Main and big end
bearings: ........................................ Ready-to-install tri-metal plain bearings
Camshaft:...................................... Steel, seated in bi-metal bearing on the blower side
Lubrication system:............. Forced-feed circulation lubrication with rotary pump which feeds both
lubricating and heating systems (if heating is fitted)
Engine oil cooler: .................... Integrated aluminium cooler
Oil cooler thermostat: ....... Oil cooler flow thermostatically controlled on engines with heating system
Lube oil filter:............................. Paper-type micro-filter as replaceable-cartridge full flow filter
Injection pump/
governor: ....................................... In-line injection pump with mechanical centrifugal governor
Injection nozzle: ...................... Five-hole-nozzle
Fuel filter: ...................................... Replaceable cartridge
Starter motor:............................ 12V; 2,7 kW (Standard)
Alternator: .................................... Three-phase alternator, 14 V; 55A (Standard)
Heating system:...................... Optional connection for cab heating
Options: .......................................... Intake manifold connections, exhaust manifold connections, compressors, hydraulic pumps,
engine mounts rigid and flexible, oil pans, SAE 1/2/3/4 flywheel housings, three-phase alter-
nators 12 and 24 Volt, integrated hydraulic oil cooler, cooling fans controlled by exhaust
thermostat
DEUTZ AG
Deutz-Mülheimer Str. 147-149
D-51057 Köln
Telephone: ++ 49 (0) 2 21-8 22 - 25 10
Fax: ++ 49 (0) 2 21-8 22 - 25 29
Internet: http://www.deutz.de
E Technical data
Engine type F3L912 F4L912 F5L912 F6L912
Number of cylinders 3 4 5 6
Bore/stroke mm 100/120 100/120 100/120 100/120

Displacement l 2.83 3.77 4.71 5.66
Compression ratio 18 18 18 18
Max. rated speed min - 1 2500 2500 2500 2500

Mean piston speed m/s 10 10 10 10
Power ratings for construction equipment engines1)
Power ratings for automotive engines2) kW 40 54 68 82

at speed3) min - 1 2500 2500 2500 2500
Mean effective pressure bar 6.79 6.88 6.93 6.96
Power ratings for industrial engines4)

highly intermittent operation kW 40 54 68 82
at speed min - 1 2500 2500 2500 2500
intermittent operation4) kW 38 51 65 78
at speed min - 1 2500 2500 2500 2500
Max. torque Nm 185 247 308 370

at speed min - 1 1450 1450 1450 1450
Minimum idle speed min - 1 650 650 650 650
Specific fuel consumption5) g/kWh 225 225 225 225
Weight to DIN 70020, Part 7A6) kg 270 300 380 410
E Model designation
1) Power ratings without deduction fan power requirement, incl. cooling system, meeting
exhaust emission limits of EU-RL 97/68.
F 3 L 912 2) Power ratings to DIN ISO 1585, EG-RL80/1269/EWG ECE-R 24
3) Power ratings for non-mentioned speeds upon request.
4) Power to DIN ISO 3046/1 (IFN). The fuel stop IFN power is an ISO net power at flywheel
under reference conditions with all essential auxiliaries driven by the engine.
Engine family designation 5) At optimal operating point. Specific fuel consumption based on diesel fuel with a specific
gravity of 0,835 kg/dm3 at 15°C.
L = Air-cooled
6) Without starter motor/alternator, radiator and liquids, however with flywheel and flywheel
housing and complete integrated cooling system.
Number of cylinders
F = High-speed four-stroke engine The values given in this data sheet are for information purposes only and not binding.
The information given in the offer is decisive.
E Standard engines
E Dimensions
Engine A B C D E F
F3L912 mm 589 679 796 329 268 108

F4L912 mm 719 679 796 329 268 88
*) with standard flywheel, incl. cooling system

**) with standard oil pan, oil sump central
LIST OF DRAWINGS
GENERAL DRAWINGS & PROSPECTUS
No. Description Type /Dwg. Part no.
B1 Non-return valve, KV-48 3-2828 4492

B2 Oil & water separator, V-23-1 3-3197 1941
B3 Vibration damper 4-1813 4546
B4 Flexible hose, 1 ¼” Bsp x 370 w/elbow 4-2193 8346
B5 Flexible hose 4595/ 4598
B6 Solenoid drain/ unloading valve 322 H 4332
B7 Pressure switch, alarm & start/ stop PRS-30 7756
B8 Thermo switch TMS-80 7746
B9 Oil level switch VH-600 4356
B10 Air filter AF4000 4756
B11 Reduction valve AR410 4321
B12 Manual stop valve Ball type 3840
B13 Safety valve, L.P. & H.P. ½” BSP 4420/ 4421
B14 Y-Strainer ½” BSP 3637
B15 Pressure gauges
Data Sheet
Flexible hoses
1. 2. 3.
Opening Minimum Sperre Sperre part no. Sperre part no.

A B C D E F of the bending part no. w/ one end flange w/ both end flange
(inch) (mm) (mm) (mm) (mm) (mm) spanner radius
(mm) (mm) (1) (2) (3)
½” 600 500 Ø 31 Ø 25 Ø 22 27 180 4595 4666 (DN15) 7495 (DN15)

¾” 600 470 Ø 38 Ø 33 Ø 29 33 240 4596 4667 (DN20) 7492 (DN20)
1” 800 670 Ø 43 Ø 38 Ø 38 38 300 4597 4668 (DN25) 7493 (DN25)
1 ¼” 800 600 Ø 57 Ø 50 Ø 50 50 420 4598 4669 (DN32) 7494 (DN32)
1 ½” 800 600 Ø 70 Ø 57 Ø 54 60 500 4599 4687 (DN40) 7496 (DN40)
2” 800 580 Ø 80 Ø 70 Ø 66 70 635 4601
Hose construction :
Tube : Oil resistant synthetic rubber
Reinforcement : Two high tensile steel wire braids
Cover : Abrasion and weather resistant synthetic rubber
Temperatur range : - 40°C to + 100°C
Flexible hoses acc. to SAE 100 R2
Sperre Industri AS Sperre Rotterdam BV Sperre Asia PTE LTD Sole suppliers of
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 67 63 63 00 genuine spare parts
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
E-mail: industri@sperre.com E-mail: rotterdam@sperre.com E-mail: asia@sperre.com
Data sheet
Solenoid drain valve Part no. 4332
2/2 shut of valve for unloading and drain of compressors.
Technical data
Function ............... : Open when de-energized
Valve design......... : Pilot operated diaphragm valve
Poppet type pilot.
Nominal diameter. : 14.5 mm
Port sizes .............. : ½” BSP
Mounting.............. : Direct pipe mounting
Unrestricted position
Working pressure . : Max 40 bar
Pressure drops ...... : ∆ p min. 0.3 bar for opening
∆ p min 0 bar for closing
∆ p max 40 bar
Flow factor ........... : Kv = 60
Weight.................. : 880 g (incl. coil)
For spare part orders

Sperre
Description
part no.
Valve body (without coil) 4332
Coil 220 V (50 and 60 Hz) 4345
Coil 110 V (50 and 60 Hz) 4343
Coil 24 V DC 4342
Coil 24 V AC 7898
Material specification Electrical data - Coil

Body......................: Forged brass Material......................: Encapsulated in synthetic material.
Internal parts .........: Stainless steel, Plug connection .........: 3 pin DIN 43650A, incl. Plug with
brass and nickel PG11 for cable conn.
Sealing ..................: Synthetic rubber (FKM) Voltage ......................: DC 24 V AC 110 V (50 and 60 Hz)
Valve sealing.........: Pressure/spring loaded AC 220 V (50 and 60 Hz) Other
seat disc (O-Ring) voltages on request.
against a carefully Voltage tolerance .......: -10% to +15% of nominal
machined nozzle provides Class of insulation......: F
bubble tight sealing. Solenoid duty .............: Continuos
Life expectancy.....: Hundreds of thousands Power rating...............: 8 W
of cycles. Protection class ..........: IP 65
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 763 63 00 genuine spare parts
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
Data Sheet
Pressure switch PRS-30 Part no. 7756
Adjustable pressure switch
for control of compressor's START and STOP.
Range: 3,5 - 35 bar
Construction: Adjustment:
Pressure switch type ........ : Diaphragm Range of switching point ... : 3,5 - 35 bar
Fluids controlled.............. : Hydraulic oils, fresh water, (50,75 - 507,5 psi)
sea water, air Min. diff. at low setting ...... : 1,7 bar (24,65 psi)
Weight ............................. : 0.75 kg Min. diff. at high setting ..... : 2,55 bar (36,97 psi)
Max. diff. at high setting .... : 20 bar (290 psi)
Design: Installation:
Max temperature.............. : 70°C Fluid connection.................. : ¼" BSP
Max. permissible pressure : El. connector type ............... : DIN 43650A, 4-pin male,
Per cycle 45 bar (652,5 psi) plug PG11
Occasional surge 80 bar (1160 psi) Enclosure............................. : IP65
Destruction pressure ........ : 160 bar (2320 psi)
6 Ship approvals:
Mechanical life.................: 5 x 10 operating cycles
DNV, LRS, GL, BV, RINA
CE marked acc. to 89/336/EC, 92/31EEC, 93/68/EEC
PRESSURE SWITCH
Range
Plage
350 50,8 3,5

1
2000 290 20
PH
3500 508 35
N6
3
PRS-30 Electrical wiring:

Part no. 7756
Differential
Ecart
2000 290 20
2
1
900 130,5 9
PB
13
11
170 24,7 1,7

3
3
IEC/EN60 947-5-1
Ui : 250V IP65IP65 1
PH- High setting point SPERRE
14
12
AC15
www.sperre.com Ue : 240V
0 PB- Low setting point Ie : 1,5A

Ie : 1,5A FranceFrance
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
Data Sheet
Temperature switch TMS-80 Part no. 7746
Adjustable temperature switch
for alarm indication and shut down of compressor
Alarm: S.P. 75°C, Shut down: S.P. 80°C
Construction: Performance:
Temperature switch type ............. : Rigid sensor Setting range ..................................: 50-100°C
Weight ......................................... : 0.35 kg Differential .....................................: 3°C
Permissible operating temp. ...........: 200°C
Environmental conditions:
Operation temperature ................. : -40 to +70°C Installation:
Enclosure ..................................... : IP65, IEC 529 Process connection.......................: ½" BSP
Vibration stability El. connector type ........................: DIN 43650A, PG11
Sinusoidal 20g, 25 Hz - 2 Hz ... : IEC 68-2-6
Shock resistance Material:
Shock 50 g/6 ms, 500 g/1 ms .. : IEC 68-2-27 Wetted Parts: Sensor pocket ...: Brass
Free fall ................................... : IEC 68-2-32 Enclosure Parts: Housing ...........: AlMGSi1
Plug fixture ......: Glass filled polyamid
Electrical specifications:
Switch.......................................... : SPDT Ship approvals:
Contact load: AC15 .................. : 0.5 A, 250 V DNV, ABS, LRS, GL, BV, RINA, MRS, KRS
DC13 .................. : 12 W, 125 V CE marked acc. to EN 60 947-5-1
Adjustment: When the top cover is removed, the

range can be set with the setting-screw.
The differential is non-adjustable
Electrical wiring:
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
Data Sheet
Oil level switch Part no. 4356
Technical data:
Nominal pressure ..................... : PN25
Weight ..................................... : 0.35 kg
Max. medium temp. ................. : 110°C
Max. ambient temp. ................. : 80°C
Switching hysteresis ................ : ca. 1-4 mm
Switching-on point reffered to
center position : ........................ : -4 to 0 mm
Electrical specifications:
Max. switching current .......: 1A
Max. switching voltage .......: 230 VAC/ 48 VDC
Max. rating .........................: 26 VA / 20 W
Protection class ...................: IP 65
Material:
Body ............................. : Brass (Cu Zn 39Pb)
Float ball ....................... : PVDF
Installation:
Process connection ....... : ¾" BSP
El. connector type .......... : Plug connector DIN 43650 type
A ISO 4400 including cable box, suitable for cables of
outside dia. 4.5 - 7 mm.
Adjustment of the switching unit

The contacts are normally set for "normally open" operation, The switching point is adjustable within the WHITE or
i.e. the contacts are closed when the lubricating oil level is the RED arrow. The direction of the arrow shows that
high enough. the switching unit switches at a lower level. After
For adjustment, the locking screw has to be released and the adjustment the locking screw has to be fastened again.
switching unit has to be moved, so that the RED arrow
(normally open operation) or the WHITE arrow (normally
closed operation) is located at the input of the cross drilling.
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
Data Sheet
Air Filter Part no. 4756
Specifications
Max. supply pressure ........ : 15 kgf/cm2
Max. operating pressure .... : 9.9 kgf/cm2
Ambient & media temp..... : 5~60°C
Port sizes ........................... : 1/2” BSP
Filtration............................ : 5 µm
Bowl capacity.................... : 45 cm3
Weight............................... : 550 g
Material specifications
1. Body...................: Aluminium die casting
2. Filter element .....: Bronze
3. Bafle...................: ABS
4. O-ring.................: NBR
5. Bowl assembly ...: Polycarbonate
6. Deflector ............: ABS
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
Data Sheet
Reduction valve H.P. Part no. 4321
Reduction valve for compressed air

Technical data
Connectionssure................ : ½” BSP
Max. in pressure................ : 30 bar
Out pressure ...................... : 0.2 – 15 bar
Manometer conn. .............. : ¼” bsp
Working temperature. ....... : 5~60°C
Weight............................... : 750 g
Material specifications
1. Pressure spring ...: Steel
2. Membrane ..........: NBR
3. Main valve seat ..: Copper Alloy
4. Valve spring .......: Stainless Steel
5. O-ring .................: NBR
6. O-ring .................: NBR
7. O-ring .................: NBR
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
Data Sheet
Ball valve
Dim DN L L1 H h R CH PN Handel Part no.

¼” 10 47 13 28 38 - 22 64 T-handle 3845
3/8” 10 47 13 28 38 - 22 64 T-handle 3844
½” 15 65 16 34 42 - 27 40 Lever 3840/ 7826
¾” 20 73 18 43 50 115 32 40 Lever 3841
1” 25 86 21 52 54 115 41 40 Lever 3842
1 ¼” 32 101 23 62 64 130 50 40 Lever 3848
1 ½” 40 118 24 76 75 150 55 64 Lever 3849
2” 50 137 28 93 86 170 70 64 Lever 3847
Full bore ball valve Materials

Services: Hot and cold water, Part no: 3845-3844-3840-3841
compressed air, oil, gases, Body: Nickle-plated OT58 brass
fuels, steem, gas oil, etc. Ball: Chrome-plated OT58 brass
Seals: P.T.F.E. (Teflon)
Anti blow-out The ball valve is bottom Stem: Nickle-plated brass
steam: loaded steam designed O-rings: Viton
providing two seals on the Lever: Galvanized steel, (Plastic coated)
packing to ensure safe and T-handle: Enameled aluminium
reliable thightness of the
valve and to prevent blow-
outs
End connections: Screwed BSP to BS21 Part no: 7826-3842-3848-3849-3847
parallel threads. Body: AISI 316
Ball: AISI 316
Working temp.: From –20°C to +170°C Seals: P.T.F.E. (Teflon)
Stem: AISI 316
Approvals: Type approved by DNV Lever: AISI 316, (Plastic coated)
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
Data Sheet
Safety valve L.P. Part no. 4421 & 7795
DIRECT SPRING LOADED ATMOSPHERIC DISCHARGE
SAFETY VALVE FOR COMPRESSED AIR OR GASES
8 mm Nominal Bore
APPROVALS
Ad-Merkblatt A2 1998: (TÜV Germany), Ref - TÜV.SV.02-893.8D/G.
P.E.D.97/23/EC
TYPE EXAMINATION, MODULE B, CERT. No. 01 202 111-B-00015
QUALITY MANAGEMENT SYSTEM, MODULE D, CERT. No. EDS 0002011/01
DESIGNED IN ACCORDANCE WITH I.S.O.4126 & BS6759 Part 2, but not approved
TECHNICAL DATA
Relieving pressure = Set pressure +10%
Reseating pressure = Set pressure -10%
Flow area = 50.27 mm2
Inlet bore diameter = 8 mm
Temperature range = -15ºC to 200ºC
TÜV Derated coefficient of discharge ad = 0.67 from 3 Bar.g
BS Minimum lift at 10% overpressure = 1.4 mm
APPROVED PRESSURE RANGE

Set pressure Bar g 8 9 10 11 12
Rated discharge capacity in
accordance with TÜV, Air at 0°C 225 250 275 300 326
3
and 1013 mbar Normal m /h
Sperre part no. 7795* 4421 7795* 7795* 7795*
PARTS LIST AND MATERIAL SPECIFICATION

1 Body Brass BS 2874 CZ12
2 Tutchitite seal Viton
3 Plunger Brass BS 2874 CZ121
4 Spring ST.STL BS2056 302S26
5 Adjuster Brass BS 2874 CZ132
6 Nameplate Alum. Alloy
7 Lifting Clip Baker & Finnemore Starl.
8 Lifting Cap Brass BS 2874 CZ121
9 Wire & Lead seal St.Stl. & Lead
Max.tightening torque 50Nm

*) Set pressure adjusted by SPERRE according to order.
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
Data Sheet
Safety valve H.P. Part no. 4420 & 7790
DIRECT SPRING LOADED ATMOSPHERIC DISCHARGE
SAFETY VALVE FOR COMPRESSED AIR OR GASES
8 mm Nominal Bore
APPROVALS
DESIGNED IN ACCORDANCE WITH I.S.O.4126 & BS6759 Part 2 & 3 1984 For steam & gas
Ad-Merkblatt A2 1993: (TÜV Germany), Ref - TÜV.SV.97-685.8,0.D/G.0,70.p.
P.E.D.97/23/EC
TYPE EXAMINATION, MODULE B, CERT. No. 01 202 111-B-00015
QUALITY MANAGEMENT SYSTEM, MODULE D, CERT. No. EDS 0002011/01
TECHNICAL DATA
Relieving pressure = Set pressure +10%
Reseating pressure = Set pressure -10%
Flow area = 50.27 mm2
Inlet bore diameter = 8 mm
BS Derated coefficient of discharge Kdr = 0.78
TÜV Derated coefficient of discharge ad = 0.70
BS Minimum lift at 10% overpressure = 2.5 mm
Temperature range = -20ºC to 200ºC
APPROVED PRESSURE RANGE

Set pressure Bar g 25 31,5 35 40 45
Rated discharge capacity in
accordance with TÜV, Air at 0°C 683 894 947 1079 1211
3
and 1013 mbar Normal m /h
Sperre part no. 7790* 4420 7790* 7790* 7790*
PARTS LIST AND MATERIAL SPECIFICATION

1 Inlet seat Brass BS 2874 CZ12
2 Tutchitite seal Viton
3 Seal retainer Brass BS 2874 CZ121
4 Plunger Brass BS 2874 CZ132
5 Body Brass BS 2874 CZ132
6 Spring ST.STL BS2056 302S26
7 Spindel ST.STL BS970 431S29
8 Adjuster Brass BS 2874 CZ121
9 Cap Brass BS 2874 CZ121
Max.tightening torque 14Nm *) Set pressure adjusted by SPERRE according to order.
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
Data Sheet
Y-Strainer
Y-strainer - PN40
For: Water, air, oil, steam
Dimmension mm Sperre
Dim A B Weight Part no.
½” 61 40 0.2 kg 3637
¾” 70 55 0.3 kg
1” 86 65 0.5 kg
Max. working pressure: 40 bar at 120°C

Working temperature: -20 °C to +120 °C
Material
Body Stainl. St 316 C16

Strainer Stainl. St 316 S15
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 6763 18 11
Data Sheet
Pressure gauge
Characteristics
Robust pressure gauge. Intended for adverse service
conditions where pulsation or vibration exists.
Nominal size .............................. : 63 mm
Accurancy class ......................... : 1.6 per DIN 16005
Design ....................................... : DIN 16063, DIN 16064
Working pressure ....................... : 2/3 of full scale value
Wether protection ...................... : IP 65 per EN 60 529/ IEC 529
Threaded entry .......................... : DIN 16 288 radial, ¼” BSP, 14 mm flats
Materials
Case .......................................... : One-piece brass forging
Pressure element ...................... : ≤ 40 bar, CU-alloy, C-type, soft soldered
> 40 bar, CU-alloy, helical type, brazed
Movement .................................. : Cu-alloy, wear parts argentan
Dial ............................................ : White alluminium/ black lettering
Pointer ....................................... : Black aluminium
Window ...................................... : Non-splinting clear plastic
Bezel ring ................................... : Roll formed stainless steel
Liquid filling ................................ : Glycerine 99.7 %
Scale range Bar/ Mpa

0 - 10 bar 0 - 1.0 Mpa Part no. 3771
0 - 16 bar 0 - 1.6 Mpa Part no. 4848
0 - 60 bar 0 - 6.0 Mpa Part no. 3773
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
INSTRUCTION MANUAL GB
AIR COMPRESSOR
HL2/140
SPERRE
Instruction manual for compressor type HL2/140
PREFACE
Sperre has produced this instruction manual in order to provide users of its compressor equipment
with information about the compressor’s construction and operation, as well as basic information about
inspection and maintenance.
It is important that the operator should familiarise himself with the contents of this instruction manual,
so as to ensure that installation, use and maintenance work is carried out in a correct and safe manner
from the outset.
The maintenance intervals and individual technical data are average values based on experience, and
may vary, depending on the compressor’s operational parameters.
The supplier accepts no responsibility for damage resulting from careless operation or inadequate
maintenance. Keep the compressor in good mechanical condition, and remember that preventive
maintenance of the equipment reduces the danger of damage and unnecessary operational
interruptions.
Sperre reserves the right to modify details without prior warning.
Ellingsøy, February 2006

Sperre Industri A/S
CONTENT
Content Page
Personal safety............................................................................................................................ 2
General description ..................................................................................................................... 2
Sketch.......................................................................................................................................... 3
Installation.................................................................................................................................... 4
Starting up ................................................................................................................................... 5
Operation ..................................................................................................................................... 5
Stopping....................................................................................................................................... 5
Maintenance – Overhaul – Repairs............................................................................................. 5
Valves....................................................................................................................................... 5
Piston and connecting rod........................................................................................................ 6
Bearings - Dismantling and Assembly ..................................................................................... 6
Coolers ..................................................................................................................................... 7
Gaskets .................................................................................................................................... 7
Recommended lubricating oil brands .......................................................................................... 8
Table of normal pressures and temperatures ............................................................................. 8
Maintenance routines .................................................................................................................. 9-10
Fault tracing chart........................................................................................................................ 11
Tolerances – wear limits.............................................................................................................. 12
Ordering spare parts.................................................................................................................... 13
Spare parts list............................................................................................................................. 14-15
Available spare part kits .............................................................................................................. 16
Illustration for spare parts list....................................................................................................... 17
Page 1
PERSONAL SAFETY
The installation, operation and maintenance of the compressor should be carried out by trained
personnel who are familiar with the contents of this instruction manual.
The compressor must only be used to compress air.
Unauthorised remodelling or modification of the compressor may result in a safety hazard, and are not
permitted.
Before any form of work is commenced on the compressor the electrical power must be turned off at
the starter panel and at the main switchboard, and the switch on the main switchboard must be
marked with a notice indicating that repair work is in progress. The discharge valve of the compressor
must be closed, and the pressure must be released in all pressurised parts of the compressor.
The safety valves for LP and HP air and any other safety equipment must be inspected regularly.
Damaged components should be replaced with new, original parts. Adjustment of the safety valves
shall only be carried out by authorised personnel. The compressor must never be used if the safety
equipment is defective.
GENERAL DESCRIPTION
This is a two cylinder, two stage compressor. The cylinders are fitted in a V-shape at 90° angle to
each other. Cylinders and compressed air coolers are air-cooled by a built in fan. Supply pressure is
determined by adjusting the safety valve.
Cooling air is supplied by a well-dimensioned fan fitted in flywheel.
The compressor and motor are normally supplied fitted together on a strong bedplate. The compressor
and motor are connected by means of a heavy duty flexible coupling.
All the materials used are of first class quality, thoroughly tested and in accordance with the
requirements of the classification societies.
Instrumentation is supplied in accordance with classification society requirements and if desired the
compressor can be fitted with equipment for fully automatic operation.
Bearings and cylinder walls are splash lubricated. The oil level in the sump can be checked through a
sight glass. An automatic low oil level alarm can be supplied as an optional extra.
The compressor is supplied with a manual relief mechanism for the LP cylinder suction valve.
The compressor unit can be supplied either for bolting directly to the foundation, or for flexible
installation by means of resilient mountings fitted under the bedplate.
Page 2
Page 3
INSTALLATION
When the compressor is being installed, it is of the greatest importance to ensure that there are no
distortion of the bedplate. The compressor and motor are normally supplied ready-fitted to the
bedplate. In cases where the motor is installed separately, alignment must be carried out with great
care.
Alignment should be carried out as follows:
1. Use vernier callipers to check that the distance between the coupling halves is equal around the
whole circumference. The distance between the coupling halves should be 37 ± 1 mm. The exact
distance is not important, but it must be the same all around the coupling.
2. When angular alignment has been checked as described above, check for parallel displacement,
using a dial gauge mounted on a magnetic base. Measure the parallel displacement around the
circumference. Displacement must not exceed ±0,05 mm.
In order to ensure trouble-free operation it is important that the foundation is well stiffened and free
from vibrations from other installed machinery. This applies to rigid mounting and flexible mounting
alike.
A well-dimensioned fresh air duct must be provided to the location where the compressor is installed.
The mouth of the duct should be as close as practically possible to the suction side of the cooling fan.
The ambient temperature should not exceed 45°C.
In principle the pipe from the compressor to the air reservoir should be arranged as shown in the
installation diagram supplied with the compressor. A non-return valve of strong construction and little
air resistance should be installed between oil and water separator and air receiver.
If the compressor unit is installed with resilient mountings, a flexible hose must be installed in the
compressed air pipe. An oil and water separator should be fitted at some distance from the
compressor, and arranged so that the line slopes downwards from the compressor to the separator. It
is recommended to provide the oil and water separator with both manual and automatic draining.
Equipment for automatic draining is available as an optional extra.
If the pipe from compressor to reservoir is longer than about 10 meters, the dimensions shown in the
installation diagram supplied with compressor should be somewhat increased to ensure the lowest
possible air resistance.
Arrange the piping so that condensate cannot collect in pockets.
All piping must be well clamped and free from vibration.
Page 4
STARTING UP
Before initial starting up and after long periods out of use, carry out the following operations in the
sequence given:
1. Check the oil level (sight glass).

2. If the compressor has been out of service for more than 6 months, remove valves and lubricate
cylinder walls.
3. Turn the compressor by hand.
4. Open valves on compressed air line, and start the unit.
5. Check that all components are running normally. Inspect instruments, check for air leaks.
OPERATION
During operation, pressures and temperatures must be within the recommended limits. Any deviation
is abnormal and it’s cause should be ascertained by means of the fault tracing chart. In the case of
pressure or temperature deviations, it is recommended first to check the values with new
thermometers and pressure gauges in order to ensure that the fault is not to be found in the
instruments.
STOPPING
If the compressor is to remain unused for a long period, lubricate valves and cylinder walls with oil.
The compressor should be turned over from time to time.
MAINTENANCE – OVERHAUL – REPAIRS

Only Sperre original spare parts should be used for overhauls and repairs. Before ordering spare parts,
please read the instructions given in chapter: “Ordering spare parts”.
Valves
LP valve
To dismantle the valve, proceed as follows:
1. Loosen cooler pipe connection at cylinder head.
2. Loosen and remove cylinder head.
3. The valve is now free and can be removed.
HP valve
To dismantle the valve, proceed as follows:
1. Loosen pipe connections at cylinder head.
2. Loosen cylinder head nuts and lift off cylinder head.
3. The valve is now free and can be removed.
Valve assembly sequence is the opposite of the above.

Worn and damaged parts should be replaced. Always replace valve gaskets.
Valve overhaul: Release the lock at the top of the valve, loosen the nuts and carefully open the valve.
Note the location of the parts, so that they can be correctly refitted.
Clean the valve parts, carbon deposits can best be removed by means of a good solvent, carbon
remover or similar, then flush with hot water.
Page 5
Important: The valves are an essential part of the compressor and it is important for
operational safety that all parts have the correct material specifications and machining
tolerances. Even the smallest defect in a valve component may lead to overheating and
consequent damage. The supplier accepts no responsibility for damage to the compressor
resulting from the use of non-original parts.
Only original Sperre copper gaskets can be used as valve seating gaskets. Exact dimensions
and correct hardness are of great importance for trouble free operation.
Cylinder head nuts should be tightened a little at a time, in sequence, to prevent unsymmetrical load
on the valve.
Piston and connection Rod

The procedure for dismantling and assembling the piston and connecting rod is as follows:
1. Loosen and remove the cylinder head.
2. Remove the crankcase front cover, and remove the locking plate at the end of the crankpin.
3. Remove the cylinder from the crankcase.
4. Turn the crankshaft until the piston is at TDC.
5. Slide the connecting rod off the crank pin.
Assembly sequence is the opposite order.
Bearings - Dismantling and Assembly
Important: Work on bearings requires great care and scrupulous cleanliness.
Worn or damaged crankshaft bearings should be replaced complete. Replacement of parts of

the bearings is not satisfactory. Bearings dismantled from shaft and/or connecting rod should
always be replaced with new bearings.
Crankshaft bearings
Dismantle as follows:
1. Remove the outer ring from the connecting rod, using a hydraulic press.
2. Remove the inner ring from the crankpin by heating it rapidly with a welding torch, then push it off
the pin by means of a screwdriver or the like. If necessary, grind a notch in it to reduce its tension.
3. Fit a new outer ring to the connecting rod by using a hydraulic press.
4. To fit the inner ring, heat it in an oil bath or on an electric hotplate to 80 – 100 °C before sliding it
onto the pin.
Gudgeon pin bearings
1. Remove seeger rings.
2. Press out the gudgeon pin. If necessary, heat the piston slightly.
3. Use a hydraulic press to remove and re-install the gudgeon pin bearing in the connecting rod.
Important: Check that there is axial play between connecting rod and piston after installation.
Page 6
Main bearings
1. Remove the grille from the front of the fan, loosen the air deflector from base and manifold and
pull the deflector backwards over the electric motor.
2. Remove fan and flywheel.
3. Loosen the cooler pipe from the manifold, cylinder head and lower clamps.
4. Dismantle cylinders, pistons and connecting rods as described under "Piston and connecting rod".
5. Loosen frame bearing housing nuts. Pull the bearing housing and crankshaft clear of the
crankcase.
6. Remove the internal seeger rings in the bearing housing and pull the crankshaft complete with
bearings out of the bearing housing.
7. Pull the bearings off the shaft.
8. Check that the oil sealing ring in the bearing housing is not damaged.
Before fitting the bearings, heat them in an oil bath to about 100°C. Ensure that the seeger rings are
correctly placed in their respective slots.
Assembly is done in the opposite sequence to dismantling.
Coolers
To ensure trouble-free operation it is of the greatest importance to ensure that the coolers are kept
clean and free of foreign matter at all times. If the coolers are not kept properly clean, high air
temperatures will result, with a consequent reduction of working life of valves and cylinders.
The coolers can be externally cleaned by spraying on a good grease solvent and then blowing them
clean with compressed air.
In the case of heavy deposits of dirt the coolers should be dismantled for external and internal
cleaning.
Any carbon deposits in the tubes can be removed by placing them in a bath of carbon remover or
similar solvent overnight, and then flushing with hot fresh water.
Important: Make sure that the cleaning products are suitable for use on copper pipes.
Gaskets
In order to achieve satisfactory operation it is recommended to replace gaskets at every overhaul.
Worn or damaged gaskets will reduce compressor capacity and cause faulty operation.
Use only original SPERRE gaskets.
Page 7
LUBRICATING OIL
The lubrication oil volume in the crank case is 10,0 liters.
The following lubricating oil brands are recommended:
Synthetic oil
ANDEROL 555
BP ENERSYN RX 100
CASTROL AIRCOL SN 100
COSMO RECIPRO SX 100
DAPHNE MARINE COMPR. 100
ESSO / EXXON ZERICE S 100
ESSO / EXXON SYNNESTIC 68
FAMM CETUS DE 100
MOBIL RARUS 827
NIPPON OIL CO. FAIRCOL SA 100
SHELL CORENA AP 68
STATOIL FRIDGEWAY S 100
TOTAL LUBMARINE BARELF AL 100
Ask SPERRE for advice before using lubricating oil of any other type.
TABLE OF NORMAL PRESSURES AND TEMPERATURES

Temperatures in service, with shaft speed 1450 rpm. The values are valid for ambient temperature
40°C and delivery pressure 30 bar.
Pressure after LP cylinder: 3-4 bar

Temperature after LP cylinder: 145-175°C
Temperature after LP cooler: 55-65°C
Temperature after HP cylinder: 195-235°C
Temperature after HP cooler: 55-65°C
At lower or higher ambient temperatures, the compressed air temperatures at the points indicated
above will be approximately an equal number of degrees lower or higher.
Temperatures will be lower at lower shaft speeds.
Page 8
MAINTENANCE ROUTINES
The following is a guideline for a normal maintenance schedule. However, the compressors operating
conditions vary widely from installation to installation and it is therefore important to adapt the
maintenance schedule to the experience of the individual operator.
The following schedule applies to automatically monitored and manually operated installations alike.
After the first 200 hour operation:

Change lubricating oil. Drain the sump while the oil is warm, clean the sump thoroughly before filling
with fresh oil.
Daily inspection:
Make a quick general inspection of the whole compressor (in normal operation) and specially check
the following:
1. Lubricating oil level.

2. Compressed air temperature and pressure.
3. Automatic equipment.
Overhaul routine A (1.000 running hours or every 2 years):

Make sure that overhaul kit no. 3034MK2 and 3035MK2 are in stock before starting overhaul of
compressor according to Routine A - 1.000 hour service. Please follow installation instructions
included in the kit.
1. Replace lubricating oil.
2. Remove the valves from both cylinders. Check for carbon deposits. Dismantle the valve for
cleaning and repair if necessary. Use spare part kit no. 3034MK2 and 3035MK2 to overhaul
valves. All valve gaskets should be replaced with new parts at assembly.
3. Inspect the flexible coupling between compressor and motor.
4. Check all bolts and nuts for proper tightness. Also check vibration dampers and hose connections
if the unit is flexibly mounted. Check that no oil has come in contact with the rubber elements in
the vibration dampers.
5. Function-test the safety valve. Start the compressor, and slowly close the stop valve on the
compressed air line. The air pressure should not exceed max. working pressure + 10%. The
safety valves are sealed and the setting should not be adjusted. If the valves are malfunctining or
open at wrong pressure, the safety valves should be replaced.
6. Check all pipe connections (compressor running).
7. Check that all automatic equipment is functioning correctly.
8. Clean suction air filter.
Page 9
Overhaul routine B (5.000 running hours):

Make sure that overhaul kit no. 7938 are in stock before starting overhaul of compressor
according to Routine B - 5.000 hour service. Please follow installation instructions included in
the kit.
1. Change lubricating oil.
2. Remove the valves from both cylinders. Check for carbon deposits. Overhaul valves. Use spare
part kit no. 3034MK2 and 3035MK2 to overhaul valves. All valve gaskets should be replaced
with new parts at assembly.
3. Replace the flexible coupling between compressor and motor.
8. Clean suction air filter.
9. Remove the compressors cooler tubes and clean the outside and inside. Spray the outside with a
good grease solvent, and wash clean with warm water. The inside is cleaned by letting the cooler
tube soak in a bath of carbon remover, and then flushing the tube with warm water. Make sure
that cleaning products suitable for copper tubes are used.
10. Remove cylinders, pistons and connecting rods. Inspect cylinder walls and piston. Replace the
piston rings (use a piston ring expander tool to fit the rings on the piston). Clean all parts. Replace
gudgeon pins with bearings and crank bearings. Rotate the shaft by hand, and check that the
main bearings are rotating smoothly and without any signs of excessive wear. Use overhaul kit
no. 7938.
Overhaul routine C (10.000 running hours):

Make sure that overhaul kit no. 7968 are in stock before starting overhaul of compressor
according to Routine C - 10.000 hour service. Please follow installation instructions included in
the kit.
1. Change lubricating oil.
2. Replace the LP and HP valves. Use spare part kit no. 3034MK and 3035MK. All valve gaskets
should be replaced with new parts at assembly.
3. Replace the flexible coupling between compressor and motor.
8. Clean suction air filter, or replace filter cartridge where possible. Replace crank case breather
valve.
9. Remove the compressors cooler tubes and clean the outside and inside. Spray the outside with a
good grease solvent, and wash clean with warm water. The inside is cleaned by letting the cooler
tube soak in a bath of carbon remover, and then flushing the tube with warm water. Make sure
that cleaning products suitable for copper tubes are used.
10. Remove cylinders, pistons and connecting rods. Inspect cylinder walls and piston. Replace the
piston rings (use a piston ring expander tool to fit the rings on the piston). Clean all parts. Replace
gudgeon pins with bearings, crank bearings and main bearings. Use overhaul kit no. 7968.
Page 10
FAULT TRACING CHART
1. Compressor capacity is low, or the compressor is not delivering full pressure

Possible causes Remedy
Clean and check all valve plates, springs and
Dirty, damaged or worn valves.
gaskets. Replace defective parts.
Piston rings are worn. Replace.
Carbon deposits on valves.
Unsuitable lubricating oil. Change oil brand.
Loosen and remove piston rings.
Piston rings are stuck.
Clean piston ring grooves and rings.
Air filter clogged. Clean filter.
Air leaking to surroundings or leaking inside the
Check for external leakages with soapy water.
compressor through valve gaskets and valve
Check valve gaskets and valves.
plates.
Faulty automatic control equipment. Inspect components and circuits.
2. Safety valve blows

Closed air line valve. Open the valve.
Carbon deposits in non-return valve. Clean the valve.
Faulty adjustment of automatic system.
Compressor does not stop when air reservoir is Check pressure switch and automatic circuitry.
full.
Safety valve damaged or defective (causing it to
Replace safety valve.
open at lower pressure).
3. Valves require maintenance too frequently

High ambient temperature. Improve fresh air
Overheating. supply. Carbon deposits in coolers.
Clean coolers.
Dirt or foreign matter in intake air. Air filter damaged. Improve suction air quality.
Cooler tubes dirty. Clean.
4. Bearings and bearing housings running hot. Lub. oil overheating. Noise from bearings
Damaged or worn bearings. Replace bearings.
Uneven wear on crankshaft bearings. Check crankshaft for straightness.
Low oil level. Refill lub. oil.
5. Piston running hot

Check little end bearing, piston rings and piston
Worn bearing on flywheel end.
clearance.
Ensure cool fresh air supply to cooling fan and
suction air filter. If the piston has completely
Piston and/or rings binding in cylinder. seized, wait a while before turning over the
compressor. Clean cylinder and piston, fit new
piston if necessary.
Page 11
TOLERANCES – WEAR LIMITS
1. End tolerances for piston rings
Push a piston without piston rings halfway into the cylinder, and place the piston ring in the cylinder so
that it presses against the top of the piston. Withdraw the piston and using a feeler gauge, measure
the clearance between the piston ring ends.
Piston Clearance for new Maximum

diameter rings in new cylinder Permissible clearance
77 mm 0,3 - 0,45 mm 0,8 mm
140 mm 0,5 - 0,7 mm 1,1 mm
2. Height clearance in piston ring grooves
Clean piston rings and ring grooves. Fit ring in groove and measure the height clearance of the ring in
the groove using a feeler gauge.
Clearance for new Maximum

rings in new piston Permissible clearance
Top ring 0,015 - 0,04 mm 0,06 mm
All other rings 0,00 - 0,025 mm 0,04 mm
These values apply to both piston diameters.
3. Clearance between piston and cylinder
Measure the clearance by means of a dial gauge, measuring the cylinder and piston separately.
Alternatively the piston can be placed in the cylinder and the clearance measured with thickness
gauges. The piston clearance should be measured in the area above the upper ring groove.
The clearance listed in the table below is the difference in diameter for the two parts.
Piston Clearance for new piston Maximum

diameter in new cylinder Permissible clearance
77 mm 0,20 mm 0,60 mm
140 mm 0,26 mm 0,66 mm
4. Clearance between piston top and cylinder head/valve.
The clearance between the top of the piston and the valve should be 1,0-1,5 mm.
Page 12
ORDERING SPARE PARTS
The following information must be given when ordering spares:
(A) Compressor type

(B) Compressor number
(C) Quantity, parts number and description of the spare parts required
(A) and (B) are stamped on the compressor rating plate, which is fixed to the side of the crankcase
and (C) will be found in the spare parts list in this instruction book.
SPERRE INDUSTRI AS reserves the right to amend technical specifications without prior notice and
disclaims all legal liability in connection with such amendments.
Address: SPERRE INDUSTRI AS

6057 ELLINGSØY
NORWAY
Phone: + 47 70 16 11 00
Fax: + 47 70 16 11 10
E-mail: industri@sperre.com
www.sperre.com
Page 13
SPARE PART LIST
Qty. Description Part no. Qty. Description Part no.
1 Crankcase.................................. 1020 1 Relief cylinder.............................3308

1 Crankcase cover........................ 1035 1 Relief piston................................3316
1 Bearing housing......................... 1054 2 Elbow..........................................3341
1 Flywheel..................................... 1082 1 Oil scoop ....................................33491
1 Cylinder, HP............................... 1141 Tubular pin .................................3350
1 Cylinder, LP ............................... 1145 1 Piston, LP ...................................3362
1 Cylinder head, HP...................... 1285 1 Piston, HP ..................................3423
1 Cylinder head, LP ...................... 1287 1 Gudgeon pin, HP........................3455
1 Flywheel nut............................... 1330 1 Gudgeon pin, LP ........................3457
1 Outlet manifold........................... 1334 2 Compression ring,stepped, LP...3492
1 Manifold ..................................... 1348 3 Compression ring, plain, HP ......3502
1 Drive coupling ............................ 1376 1 Oil ring, HP .................................3529
1 Crankshaft.................................. 1405 2 Oil ring, LP..................................3541
2 Piston rods ................................. 1426 1 Inspection glass .........................3634
1 Air filter support.......................... 1500 1 Intermediate cooler, complete....3661
1 Driven coupling, compressor ..... 1983 1 After cooler, complete ................3662
1 Coupling housing ....................... 1987 1 Flywheel key...............................3677
1 Fan............................................. 1997 1 Breather valve ............................3700
2 Right angle bracket.................... 2043 1 Air filter .......................................3715
1 Grille bracket.............................. 2044 1 Filter cartridge ............................3718
1 Support plate.............................. 2047 1 Pressure gauge, LP ...................3771
1 Valve, LP complete.................... 3034 1 Pressure gauge, HP...................3773
1 Valve, HP complete ................... 3035 1 Grille ...........................................3789
1 Gripper, complete ...................... 3047 1 Guard, outer ...............................3795
1 Upper valve section LP.............. 3081 1 Guard,inner ................................3796
1 Lower valve section LP.............. 3082 1 Seeger ring.................................3803
1 Upper valve section HP ............. 3083 1 Seeger ring.................................3805
1 Lower valve section HP ............. 3084 4 Seeger ring.................................3808
1 Valve seat, LP............................ 3118 1 Sealing ring ................................3861
1 Valve plate, LP........................... 3119 1 Ball bearing ................................3873
1 Valve plate, HP .......................... 3120 1 Ball bearing ................................3874
2 Valve plate, HP .......................... 3121 2 Needle bearing ...........................3879
2 Fixing pin.................................... 3142 2 Needle bearing ...........................3880
1 Fixing pin.................................... 3145 2 Bolt .............................................3883
2 Fixing pin.................................... 3146 2 Bolt .............................................3884
1 Valve bolt, HP. ........................... 3225 1 Plug ............................................3900
1 Valve bolt, LP............................. 3226 1 Copper gasket, HP.....................3914
1 Valve nut, HP ............................. 3236 2 Copper gasket, HP.....................3915
1 Valve nut, LP.............................. 3237 1 Copper gasket, LP .....................3916
1 Valve opener complete .............. 3245 2 Copper gasket, LP .....................3917
1 End plate, crankshaft ................. 3249 2 Copper gasket ............................3925
1 Locking plate, crankshaft ........... 3250 5 Copper gasket ............................3927
1 Valve spring, suction,LP ............ 3275 5 Copper gasket ............................3929
1 Valve spring, pressure, LP......... 3276 1 Copper gasket ............................3930
4 Valve spring, suction, HP........... 3277 16 Bolt .............................................3945
4 Valve spring, suction, HP........... 3278 1 Bolt .............................................3947
1 Guide ring, HP ........................... 3299 8 Bolt .............................................3949
1 Guide ring, LP ............................ 3300 1 Stud bolt .....................................3969
1 Relief cap ................................... 3302 1 O ring..........................................4019
Page 14
Qty. Description Part no.
2 Gasket........................................ 4081
1 Gasket........................................ 4097
2 Gasket........................................ 4098
1 Gasket........................................ 4100
1 Gasket kit ................................... 4124
1 Clamp, set.................................. 4129
1 Clamp, set.................................. 4148
1 Clamp, set.................................. 4149
1 Clamp, set.................................. 4150
1 Stud bolt..................................... 4189
22 Stud bolt..................................... 4192
2 Stud bolt..................................... 4196
1 Stud bolt..................................... 4198
4 Stud bolt..................................... 4200
4 Stud bolt..................................... 4202
8 Stud bolt..................................... 4207
29 Nut ............................................. 4238
8 Nut ............................................. 4240
10 Lock nut ..................................... 4251
14 Lock nut ..................................... 4253
2 Set screw ................................... 4268
2 Nipple muff................................. 4283
1 Reduction................................... 4292
3 Plug............................................ 4294
2 Plug............................................ 4296
1 Plug............................................ 4297
1 Flexible steel hose ..................... 4400
6 Bolt............................................. 4405
2 Nipple......................................... 4412
2 Nipple......................................... 4413
16 Washer....................................... 4414
14 Washer....................................... 4416
1 Safety valve, HP ........................ 4420
1 Safety valve, LP......................... 4421
2 Bolt............................................. 4431
1 Bolt............................................. 4446
1 Flexible coupling insert .............. 4516
2 Cone .......................................... 7880
2 Cone .......................................... 7881
2 Nut ............................................. 7882
2 Nut ............................................. 7883
2 Support tube for cone ................ 7884
2 Support tube for cone ................ 7885
Page 15
SPARE-PART & MAINTENANCE KITS
SPERRE’s kits of genuine spare-parts include the wear parts you must change when you overhaul the
compressor. For example, if you replace a valve, it is strongly recommended to replace the valve
gaskets at the same time. With a spare-part kit available, all necessary parts are at hand together with
clear installation instructions.
For model HL2/140 following kits are available:
Description Part no. Content of kit

Gasket kit 4124 All flat gaskets, O-rings, sealing rings, and valve gaskets.
Crankshaft with all bearings, flywheel key and nut, Seeger-
Crankshaft 1405MK
rings, endplate and screw.
Valve LP 3034MK Valve and necessary copper rings and/or gaskets.
Valve HP 3035MK Valve and necessary copper rings and/or gaskets.
Overhaul kit - LP valve 3034MK2 Valve springs, plates and gaskets.
Overhaul kit - HP valve 3035MK2 Valve springs, plates and gaskets.
Piston LP 3362MK Piston, gudgeon pin with Seeger-rings and piston rings.
Piston HP 3423MK Piston, gudgeon pin with Seeger-rings and piston rings.
Connecting rod with small- and big-end bearings, oil scoop
Connecting rod 1426MK
with set screw.
Cylinder LP 1145MK Cylinder with gaskets, stud bolts/nuts and fittings.
Cylinder HP 1141MK Cylinder with gaskets, stud bolts/nuts and fittings.
All parts needed for 5 000-hours’ maintenance: Overhaul

kits for valves complete with gaskets and guide rings, piston
Overhaul kit Routine B 7938
rings, connecting rod bearings, gudgeon pins, Seeger-rings,
gaskets and ventilator.
All parts needed for 10 000-hours’ maintenance: Same as

Overhaul kit Routine C 7968 kit B, plus complete valves, crankshaft bearings and seal
ring.
Maintenance kits:
• All necessary parts at hand when you need them
• With clear installation instructions enclosed
Genuine Sperre parts give you peace of mind at sea!
Page 16
Sole suppliers of genuine spare parts:

Sperre Asia PTE Ltd Sperre Industri AS Sperre Rotterdam BV
63 Hillview Avenue #09-13 N-6057 Ellingsøy Glasblazerstraat 12B
Lam Soon Industrial Building Norway NL-2984 BL Ridderkerk
Singapore 669569 Tel +47 70 16 11 00 The Netherlands
Tel +65 6763 6300 Tel +31 180 463 299
Fax + 65 6763 1811
Fax + 47 70 16 11 10 Fax + 31 180 463 264
asia@sperre.com industri@sperre.com rotterdam@sperre.com
www.sperre.com
English GB
Machine Instructions
Induction motor
ABB M3AA
Machine Instructions Insulation resistance check

Measure insulation resistance before commissioning and
NOTE! when winding dampness is suspected.
These instructions must be followed to ensure safe and Resistance, measured at 25°C, shall exceed the
proper installation, operation and maintenance of the reference value, i.e.
motor. They should be brought to the attention of
anyone who installs, operates or maintains this
10 M ohm (measured with 500 V dc Megger)
equipment. Ignoring the instruction may invalidate the
warranty.
WARNING
Windings should be discharged immediately after
measurement to avoid risk of electric shock.
Declaration of Conformity
Insulation resistance reference value is halved for each
Declarations of Conformity with respect to the Low 20°C rise in ambient temperature.
voltage Directive 73/23/EEC amended by Directive 93/68
EEC are issued separately with individual machines. If the reference resistance value is not attained, the
winding is too damp and must be oven dried.
The Declaration of Conformity also satisfies the Oven temperature should be 90°C for 12-16 hours
requirements of a Declaration of Incorporation with followed by 105°C for 6-8 hours.
respect to the Machinery Directive 89/392/EEC,
amended by 91/368/EEC, 93/44/EEC and 93/68/EEC. Drain hole plugs, if fitted, must be removed during
heating.
Validity
Windings drenched in seawater normally need to be
The instructions are valid for the following ABB electrical rewound.
machine types, in both motor and generator operation.
Direct-on-line or star/delta starting
series MT*, MBT*, MXMA, The terminal box on standard single speed machines
series M2A*/M3A*, M2B*/M3B*, M2C*/M3C*, M2F*/ normally contains 6 winding terminals and at least one
M3F*, M2L*/M3L*, M2M*/M3M*, M2R*/M3R*, earth terminal.
in frame sizes 63 - 400. Earthing m ust be carried out according to local
regulations before the machine is connected to the
(Additional information may be required for some
supply voltage.
machine types due to special application and/or design
considerations.)
The voltage and connection are stamped on the rating
plate.
Putting into service (starting)
Direct-on-line starting (DOL):
Y or ∆ winding connections may be used.
Reception check
eg 660 VY, 380 V∆ indicates Y-connection for 660 V and
Immediately upon receipt check the machine for external
∆-connection for 380 V.
damage and if found, inform the forwarding agent without
delay. ∆) :
Star/Delta starting (Y/∆
The supply voltage must be equal to the rated voltage of
Check all rating plate data, especially voltage and
the machine in ∆-connection.
winding connection (star or delta). The type of bearing is
Remove all connection links from the terminal block.
specified on the rating plate from size 112 and larger.
Turn shaft by hand to check free rotation, remove For two-speed, single phase and special machines,
transport locking if employed. supply connection must follow the instructions inside the
terminal box.
Motors equipped with roller bearings: Running the
motor with no radial force applied to the shaft may Terminals and direction of rotation
damage the roller bearing. Direction of rotation is clockwise when viewing the shaft
face at the machine drive end, when the line phase
Motors equipped with angular contact bearing: sequence L1, L2, L3 is connected to the terminals as
Running the motor with no axial force applied in the right shown in the figure 1.
direction to the shaft may damage the angular contact
bearing. To alter the direction of rotation, interchange the
connection of any two line cables.
Motors equipped with regreasing devices:
When starting the motor for the first time, apply at least If the machine has a uni-directional fan, ensure that the
the specified quantity of grease until new grease forced direction of rotation is according to the arrow marked on
out of the grease outlet. the machine.
For details see section “Machines with relubrication
system” on page 6.
LV Motors/Machine Instructions 00-10 2

needed the position of the eyebolt must be adjusted with

Use
suitable washers.
Ensure that proper lifting equipment is used and that the
Operating conditions sizes of the hooks are suitable for the lifting lugs.
The machines are intended for use in industrial drive Care must be taken not to damage auxiliary equipment
applications. and cables attached to the motor.
Normal ambient temperature limits are -25° to +40°C.
Maximum altitude 1000 m above sea level. Machine weights
Total machine weight can vary within the same frame
Safety considerations size (center height) depending on different output,
The machine is intended for installation and used by mounting arrangements and added features.
qualified personnel, familiar with relevant safety
requirements. The following table shows estimated maximum weights
for machines in their basic versions as a function of
Safety equipment necessary for the prevention of frame material.
accidents at the installation and operating site must be
provided in accordance with the local regulations. On machines weighing more than 25 kg, the actual
weight is stated on the rating plate.
WARNING
Small motors with supply current directly Aluminium Cast iron Steel
switched by thermally sensitive switches can Frame Weight Add. Weight Weight
start automatically. size kg for brake kg kg
Points to observe 63 6 - - -
1. Do not use the machine to step on 71 8 5 13 -
2. The temperature of the outer casing of the 80 12 8 20 -
machine may be hot to the touch during normal 90 17 10 30 -
operation. 100 25 16 40 -
3. Some special machine applications require 112 36 20 50 -
special instructions (e.g. using frequency 132 63 30 90 -
conver ter supplies) 160 110 55 175 -
4. Lifting lugs must only be used for lifting the motor. 180 160 65 250 -
They must not be used to lift the motor when it is 200 220 - 310 -
attached to other equipment. 225 295 - 400 -
250 370 - 550 -
Handling 280 - - 800 600
315 - - 1300 1000
Storage 355 - - 2300 2200
The machine should always be stored indoors, in dry, 400 - - 3500 3000
vibration free and dust free conditions.
Installation
Unprotected machined surfaces (shaft-ends and flanges)
should protected with anti-corrosive paint. Cooling
Normal ambient temperatures should not exceed 40°C
It is recommended that shafts be rotated periodically by (marine standard 50°C) if standard performance is to be
hand to prevent grease migration. achieve. Check that the motor has sufficient airflow.
Ensure that no nearby equipment or surfaces radiate
Anti condensation heaters, if fitted, should preferably be additional heat to the motor. For more information about
energised. higher ambient temperatures and cooling, see “the Motor
Guide” or contact ABB Sales Office.
The characteristics of electrolytic capacitors, if fitted to
single-phase motors, will require “reforming” following Foundation
periods of storage exceeding 1-2 years. The purchaser bears full responsibility for preparation of
Contact ABB Sales Office for details. the foundation.
Transportation Metal foundations should be painted to avoid corrosion.

Machines fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices Foundations must be even, and sufficiently rigid to
during transport. withstand possible short circuit forces. They shall be
dimensioned as to avoid the occurrence of vibration due
Lifting to resonance.
Only lift the motor using the lifting lugs.
The center of gravity of motors with the same frame
Foundation studs
Bolt the foundation studs to the feet of the motor and
may vary due to different outputs, mounting arrange-
place a 1-to-2 mm shim between the stud and the feet.
ments and auxiliary equipment.
Check that eyebolts or the lifting eyes integrated with Align the motor directly using appropriate means.
the motor frame are undamaged before lifting. Damaged
lifting eyes must not be used. Grout the studs with concrete, check, alignment and drill
Lifting eyebolts must be tightened before lifting. If holes for locating pins.
3
Drain holes
Always check that open drain holes face downward. This arrangement has no electrical safety function; the
Machines with closable plastic drain plugs are delivered purpose is to equalise the potentials. When the motor
with these open. and the gearbox are mounted on a common steel funda-
In extremely dusty environments, all drain holes should ment, no potential equalisation is required.
be closed.
Potential equalisation
Alignment
Correct alignment is essential to avoid bearing failures,
V1 Plate/strip Cables/wires
vibrations and possible fractured shaft extensions. U1 W1
PE
3~M
Slide rails and belt drives > 150 mm
0.75 mm
• Fasten the machine to the slide rails as shown in
figure 2. 70 mm
Driven machi nery min 50 mm
• Place the slide rails horizontally on the same level.
• Check that the machine shaft is parallel with driven, or
driving, shaft. To comply with EMC-requirements, only cables and connec-
• Any belt must be tensioned according to the supplier's tors approved for this purpose. (See instruction for frequency
instructions. converters.)
WARNING Assembly and dismantling

Excessive belt tension will damage bearings and
can cause shaft breakage. General
Dismantling and assembly of machines must be carried
Do not exceed the maximum belt forces (i.e. radial out by qualified personnel using only suitable tools and
bearing loading) stated in the relevant product working methods.
catalogues.
Bearings
Connection Special care should be taken with the bearings.
These must be removed using pullers and fitted by
The normal machine design is with the terminal box on heating or using special tools for the purpose. How
top and with cable entry possible from both sides. to replace bearings is described in detail in a separate
instruction leaflet available from ABB Sales Office.
Some machines are available, as a special option, with
top mounted terminal boxes rotatable 4 x 90°, and some Fitting coupling halves and pulleys
with side mounted terminal boxes. Coupling halves and pulleys must be fitted using suitable
equipment and tools that do not damage the bearings.
Availability of these solutions is described in the product
catalogues. Never fit a coupling half or pulley by hammering into
place or remove it using a lever pressed against the
Unused cable entries must be closed. body of the machine.
As well as main winding and ear thing terminals, the Mounting accuracy of coupling half :
terminal box can also contain connections for check that the clearance b is less than 0,05 mm and
thermistors, standstill heating elements, bimetallic, that the difference a1 to a2 is also less than 0,05 mm.
switches, or PT 100 resistance elements. See figure 3.
WARNING Balancing
Voltage may be connected at standstill inside the
terminal box for heating elements or direct The rotor of the machine is dynamically balanced.
winding heating.
As standard, balancing has been carried out using half
Connection diagrams for auxiliary elements are found key, and the shaft is mar ked with a RED tape, with the
inside the ter minal box cover. text “Balanced with half key”.
To a void vibration the coupling-half or pulley must be
WARNING balanced with half key after the keyway has been
The capacitor in single-phase motors can retain machined.
a charge that appears across the motor
terminals, even when the motor has reached In the event of balancing with full key the shaft is
standstill. marked with a YELLOW tape, with the text “Balanced
with full key”.
In frequency converter applications motor fr ame To a void vibration the coupling-half or pulley must be
external ear thing must be used for equalising the poten- balanced without a key after the keyway has been
tial between the motor frame and the driven machine, machined.
unless the two machines are mounted on the same
metallic base. For motor frame sizes above IEC 280, In case balancing without key, the shaft is marked with
use 0.75 x 70 mm flat conductor or at least two 50 mm² a BLUE tape, with the text “Balanced without key".
round conductors. The distance of the round conductors
must be at least 150 mm from each other.
Maintenance and lubrication ABB Motors policy is to have reliability as a vital issue
in bearing lubrication intervals. That is why we follow the
General inspection L1-principle (meaning that 99 % of the motors are sure
- Inspect the machine at regular intervals. to make the interval time). According to L1 policy the
- Keep the machine clean and ensure free lubrication intervals are as follows:
ventilation airflow.
- Check the condition of shaft seals (eg V-ring) and Frame Amount 3600 3000 1800 1500 1000 500-900
replace if necessary. size of grease r/min r/min r/min r/min r/min r/min
- Check the condition of connections and mounting g/bearing
and assembly bolts.
Ball bearings
- Check the bearing condition by listening for
Lubrication intervals in duty hours
unusual noise, vibration measurement, bearing
112 10 10000 13000 18000 21000 25000 28000
temperature, inspection of spent grease or SPM
132 15 9000 11000 17000 19000 23000 26500
bearing monitoring.
160 25 7000 9500 14000 17000 21000 24000
* When changes of condition occur,
180 30 6000 8000 13500 16000 20000 23000
dismantle the machine, chec k the parts
200 40 4000 6000 11000 13000 17000 21000
and replace if necessary.
225 50 3000 5000 10000 12500 16500 20000
250 60 2500 4000 9000 11500 15000 18000
Lubrication
280 70 2000 3500 8000 10500 14000 17000
315 90 2000 3500 6500 8500 12500 16000
Machines with permanently greased bearings
355 120 1200 2000 4200 6000 10000 13000
Machines up to frame size 180 are normally fitted with
400 120 1200 2000 4200 6000 10000 13000
permanently greased bearings of either Z or 2Z types.
Bearing types are specified in the respective product Roller bearings
catalogues and on the rating plate of each motor from Lubrication intervals in duty hours
size 112 and larger. 160 25 3500 4500 7000 8500 10500 12000
180 30 3000 4000 7000 8000 10000 11500
As a guide, adequate lubrication can be achieved for the 200 40 2000 3000 5500 6500 8500 10500
following duration, according to L1 at ambient 225 50 1500 2500 5000 6000 8000 10000
temperature of 25° C. 250 60 1300 2000 4500 5700 7500 9000
32 000 - 45 000 duty hours for 4 pole machines.1) 280 70 1000 1700 4000 5300 7000 8500
16 000 - 26 000 duty hours for 2 and 2/4 pole 315 90 1000 1700 3300 4300 6000 8000
machines.1) 355 120 400 1000 2000 3000 5000 6500
400 120 400 1000 2000 3000 5000 6500
The shorter times apply to larger frame sizes.
Lubrication intervals for vertical machines are half of the
1)
Depending on application and load conditions, see above values.
applicable product catalogue.
Hours of operation for vertical motors are half of the The amount of grease stated in the table should be
above values. doubled if an automatic regreasing system is used.
Machines with relubrication system The table values are based on the motor running at rated
output in an ambient temperature of about + 25° (approx.
WARNING 80°C bearing temperature).The values should be halved
Beware of all rotating parts! for 15°C increase in bearing temperature and may be
doubled for 15°C decrease in ambient temperature.
Relubrication procedure:
- Remove grease outlet plug if fitted. WARNING
- Press fresh grease into the bearing until all old grease The maximum operating temperature of the
has been forced out grease and bearings must not be exceeded.
- Let the motor run 1-2 hours to ensure that all excess
grease is forced out of the bearing. Close the grease Higher speed operation, eg in frequency converter
outlet plug if fitted. applications, or lower speed with heavy load will require
shorter lubrication intervals. Consult ABB Sales Office in
Regrease motors while running. If this is not possible, such cases.
lubrication can be carried out while the machine is at a
standstill. In this case, use only half the quantity of Typically a doubling of speed will require a reduction of
grease, then run the motor for a few minutes at full lubrication intervals to approx. 40 % of values tabulated
speed. When the motor has stopped, the remaining above.
quantity of grease can be forced in until the old grease
has been replaced. Suitability of bearings for high speed operation must also
After 1-2 running hours close the grease outlet plug (if be checked.
fitted).
The grease outlet plug must be removed permanently

with automatic lubrication.
If the machine is fitted with a lubrication information
plate, follow the values given, otherwise use the values
in table below.
5
Lubricants Environmental requirements

When regreasing, use only special ball bearing grease
with the following proper ties: Noise levels
- good quality grease with lithium complex soap and with Smaller machines have a sound pressure level that not
mineral- or PAO-oil exceeding 70 dB(A).
- base oil viscosity 100-150 cST at 40°C
- consistency NLGI grade 2 or 3 The following table shows catalogue values of sound
- temperature range -30°C - +120°C, continuously. pressure levels at 1 m from the machine surface.
Grease with the correct properties is available from all Frame Guideline sound pressure level, dB(A)
the major lubricant manufacturers. size 2 pole 4 pole 6 pole 8 pole
The following (or similar) high performance grease can
be used 132 69 59 61 56
• EssoUnirex N2 or N3 160 69 62 59 59
• Shell Albida EMS 2 180 69 62 59 59
• SKF LGHQ 3 200 72 63 63 60
• Mobil Mobilith SHC 100 225 74 66 63 63
• Klüber Kluberplex BEM 41-132 250 75 67 63 63
• BP Energrease LC2 280 77 68 66 65
315 80 71 68 72
NOTE! 355 83 80 75 75
Always use high speed grease for high speed machinens 400 83 80 - -
and some other models, e.g. M2_ 355 and 400 2-pole Values for specific machines can be found in the
machines, where the speed factor is higher than 400 000 relevant product catalogues. Tolerance acc ± 3 dB(A).
(calculated as Dm x n where Dm = average bearing
diameter, mm ; n = rotational speed, rpm). The follo wing, The table values refer to 50 Hz sinusoidal supply
or similar, types of grease can be used: conditions.
• Kluber Asonic GHY 72 For 60 Hz sin usoidal supply, add 4 dB(A) to the abo ve
• Kluber Asonic HQ 72-102 values.
• Shell Albida EMS 2
• Esso LT2 For sound pressure levels with non-sinusoidal supplies,
• Mobil Mobilith SHC 100 contact ABB Sales Office.
The following normal type of grease can be used if the Sound pressure levels for all machines in the above
regreasing interval is halved (these types of grease frame sizes having separate cooling systems and for
should not be used when bearing temperature is above series M2F*/M3F*, M2L*/M3L*, and M2R*/M3R*, are
100°C) indicated in separate specific Machine Instructions.
• Esso Beacon 2 or 3
• Shell Alvania RL2 or RL3 Rewinding
• SKF LGMT 2 or 3
• Mobil Mobilux 2 Rewinding should always be carried out by qualified
• Kluber Centoplex 2 repair shops.
• BP Energrease LS2
Smoke venting and other special motors should not be
If the make of grease is changed and compatibility is rewound without first contacting ABB Motors.
uncertain, consult ABB Sales Office.
Highly loaded and/or slowly rotating bearings require EP-
grease.
If the ambient temperature is below -25°C or above
+55°C, or bearing temperature is above 110°C, consult
ABB Sales Office regarding suitable grease.
WARNING
Grease can cause skin irritation and eye
inflammation.
Follow all safety precautions specified by the
manufacturer.
Spare parts
When ordering spare parts, the full type designation and
product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
number, this should also be given.

These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please contact
the nearest ABB Sales Office.
Motor trouble shooting chart

Your motor service and any trouble shooting must be handled by qualified persons with proper tools and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to star t Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in star ter.
Improper power supply Check to see that power supplied agrees with motor
name plate and load factor.
Improper line connections Check connections with diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is
switch closed. Check for loose wiring connections. Also,
ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound.
Poor stator coil connection Remove end bells, locate with test lamp.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult manufacturer.
Overload Reduce load.
Low voltage Ensure the name plate voltage is maintained.
Check connection.
Open circuit Fuses blown, check overload relay, stator and push
buttons.
Motor runs and then Power failure Check for loose connections to line, fuses and
dies down control.
Motor does not come Not applied properly Consult supplier for proper type.
up to speed Voltage too low at motor terminals Use higher voltage or transformer terminals or
because of line drop reduce load. Check connections. Check conductors
for proper size.
Starting load too high Check load motor is supposes to carry at start.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be
required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltage during start Check for high resistance. Adequate wire size.
high amp Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats while Overload Reduce load.
running underloaded Frame or bracket vents may be Open vent holes and check for a continuous stream
clogged with dirt and prevent proper of air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well
connected.
Grounded coil Locate and repair.
Unbalanced terminal voltage Check for faulty leads, connections and
transformers.

TROUBLE CAUSE WHAT TO DO

Motor vibrates Motor misaligned Realign.
Weak suppor t Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Line up properly.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor
rotor and coupling
(half key – full key)
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan r ubbing air shield Remove interference.
Fan str iking insulation Clear fan.
Loose on bedplate Tighten holding bolts.
Noisy operation Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance.
Hot bearings general Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Hot bearings ball Insufficient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in
contaminated kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be
more than 1/2 filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing thoroughly.

Figure 1. Connection diagram

Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio
Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figur 2. Remdrift
Kuva 2. Hihnakäyttö
9 LV Motors/Machine Instructions 00-10

Figure 3. Mounting of half-coupling or pulley

Bild 3. Anbau von Kupplungshälften und
Riemenscheiben
Figure 3. Montage des demi-accouplements et des
poulies
Figura 3. Montaje de mitades de acoplamiento y
poleas
Figura 3. Montaggio di semigiunti e pulegge
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus

LV Motors
Printed in Finland,Ykkös-Offset Oy Vaasa, 0009 20.000

Manufacturing sites (*) and some of the biggest sales companies.
Australia Finland* Japan Sweden*

ABB Industry Pty Ltd ABB Motors Oy ABB K.K. ABB Motors AB
2 Douglas Street P.O.Box 633 2-39, Akasaka 5-Chome S-721 70 Västerås
Port Melbourne, FIN-65101 Vaasa Minato-Ku Tel: +46 (0) 21 329 000
Victoria, 3207 Tel: +358 (0) 10 22 4000 Tokyo 107 Fax: +46 (0) 21 124 103
Tel: +61 (0) 3 9644 4100 Fax: +358 (0) 10 22 47372 Tel: +81 (0) 3 556 38605
Fax: +61 (0) 3 9646 9362 Fax: +81 (0) 3 556 38615 Switzerland
France ABB Normelec AG
Austria ABB Automation Korea Badenerstrasse 790
ABB AG 15, rue Sully ABB Ltd. Korea Postfach
Wienerbergstrasse 11 B F-69153 Décines Charpieu Cedex 513, Sungsung-dong, CH-8048 Zürich
A-1810 Wien Tel: +33 (0) 472 054 040 Chonan-SI Tel: +41 (0) 1 435 6666
Tel: +43 (0) 1 601 090 Fax: +33 (0) 472 020 345 Chungchongnam-Do Fax: +41 (0) 1 435 6603
Fax: +43 (0) 1 601 09 8305 Tel: +82 2 528 2327
Germany Fax: +82 2 546 8517 Taiwan
Belgium ABB Automation Products GmbH Asea Brown Boveri Ltd
Asea Brown Boveri S.A.-N.V. P.O.Bo x 10 02 61 Mexico P.O.Box 81-54
Hoge Wei 27 D-68002 Mannheim ABB México, S.A. de C.V. Taipei
B-1930 Zaventem Tel: +49 (0) 621 3810 Apartado Postal 111 Tel: +886 (0) 2 579 9340
Tel: +32 (0) 2 718 6311 Fax: +49 (0) 621 381 6820 CP 54000 Tlalnepantla Fax: +886 (0) 2 577 9434
Fax: +32 (0) 2 718 6657 Edo. de México, México
Hong Kong Tel: +52 5 328 1400 Thailand
Brazil ABB Automation Limited Fax: +52 5 390 3720 ABB Limited
Asea Brown Boveri Ltda 3 Dai Hei Street 5th Building, 322 Moo 4
P.O .Box 00975 Tai Po Industr ial Estate The Netherlands Bangpoo Industrial Estate Soi 6
06020-902 Osasco -SP Tai Po New Territories ABB B.V. Sukhumvit Road, Prekasa,
Tel: +55 (0) 11 7088 9526 Hong Kong Dept. LV motors (APP2R) Muang, Samutprakarn 10280
Fax: +55 (0) 11 7088 4523 Tel: +852 292 938 38 P.O.Box 301 Tel: +662 (0) 709 3346
Fax: +852 292 938 87 NL-3000 AH Rotterdam Fax: +662 (0) 709 3765
Canada Tel: +31 (0) 10 4078 879
Asea Brown Boveri, Inc. India* Fax: +31 (0) 10 4078 345 The United Kingdom
200 Chisholm Dr., Asea Brown Boveri Ltd ABB Automation Ltd
Milton, Ontario L9T 5E7 P.O.Box 16 New Zealand 9 The Towers , Wilmslo w Road
Tel: +1 905 875 4500 Faridabad 121 001 ABB Automation Didsbury
Fax: +1 905 875 0077 Tel: +91 (0) 129 5233 313 Motor Sales Manchester, M20 2AB
Fax: +91 (0) 129 5234 288 P.O .Box 22167 Tel: +44 (0) 161 445 5555
China* Otahuhu, Auckland Fax: +44 (0) 161 448 1016
ABB Yuejin Motors (Shanghai) Indonesia Tel: +64 (0) 9 276 6016
Company Limited P.T. Abdibangun Buana Fax: +64 (0) 9 276 1303 USA
8 Guang Xing Rd.,Rong Bei P.O.Box 3781 ABB Automation Inc.
Town, Songjiang County, Jakarta 10002 Norway AC Motors
Shanghai 201613 Tel: +62 (0) 21 314 9115 ABB Industri AS P.O.Box 372
Tel: +86 21 5778 0988 Fax: +62 (0) 21 315 3963 P.O.Bo x 6540 Rodelökka Milwaukee
Fax: +86 21 5778 1364 N-0501 Oslo 5 WI 53201-0372
Ireland Tel: +47 22 872 000 Tel: +1 262 785 8364
Chile Asea Brown Boveri Ltd Fax: +47 22 872 541 Fax: +1 262 785 8628
Asea Brown Boveri S.A. Components Division
P.O.Box 581-3 Belgard Road Singapore Venezuela
Santiago Tallaght, Dublin 24 ABB Industry Pte Ltd Asea Brown Boveri S.A.
Tel: +56 (0) 2 5447 100 Tel: +353 (0) 1 405 7300 P.O.Box 95 P.O.Box 6649
Fax: +56 (0) 2 5447 405 Fax: +353 (0) 1 405 7327 Pasir Panjang Post Office Carmelitas,
Singapore 9111 Caracas 1010A
Denmark* Italy* Tel: +65 775 3777 Tel: +58 (0) 2 238 2422
ABB Motors A/S ABB Industria S.p.a. Fax: +65 778 0222 Fax: +58 (0) 2 239 6383
Petersmindevej 1 Motor Division
DK-5000 Odense C Viale Edison 50 Spain*
Tel: +45 65 477 777 I-20099 Sesto S. Giovanni, Milano ABB Motores S.A.
Fax: +45 65 477 888 Tel: +39 02 262 321 P.O.Box 81
Fax: +39 02 262 32723 E-08200 Sabadell
Tel: +34 93 728 8500
Fax: +34 93 728 8554
LV MotorsM/M3000 Machine Instruction 00-10
ABB Motors
Marketing Communications
P.O.Box 633
FIN-65101 Vaasa Finland
tel. +358 (0) 10 22 4000
fax +358 (0) 10 22 43575
www.abb.com/motors&drives

Starting Air Compressor hl2/140

Uploaded by

Copyright:

Available Formats

You might also like

Starting Air Compressor hl2/140

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Starting Air Compressor hl2/140

Uploaded by

Copyright:

Available Formats

Wärtsilä id: DBAB538460 -

Sperre Air Compressor Unit

CUSTOMER: Wärtsilä Finland OY

A STARTING AIR UNIT w/ El.motor & diesel engine 3 x HL2/140

Starting air unit 3 x HL2/140 w/ diesel & el.motor

No. Description Type /Dwg.

A1 Starting of compressor w/ diesel engine 4-2143

0DQXIDFWXUHU 7\SH &RQVWUXFWLRQ

6SHUUH,QGXVWUL$6 6SHUUH5RWWHUGDP%9 6SHUUH$VLD37(/7' 6ROHVXSSOLHUVRI

>= # ) @ 4 8 D 8 = >C # & : / @

2 3& ' #& 4# & 5 ' '

+ 3& ' #& 4# & 5 ' '

1 3& ' #& 4# & 5 ' '

912. The engine for construction equipment.

These are the characteristics of the 912:

These are the benefits for you:

Cooling system:....................... Air-cooled with integrated axial-flow blower

Engine type F3L912 F4L912 F5L912 F6L912

Bore/stroke mm 100/120 100/120 100/120 100/120

Max. rated speed min - 1 2500 2500 2500 2500

Power ratings for construction equipment engines1)

Power ratings for automotive engines2) kW 40 54 68 82

Power ratings for industrial engines4)

Max. torque Nm 185 247 308 370

Minimum idle speed min - 1 650 650 650 650

Specific fuel consumption5) g/kWh 225 225 225 225

Weight to DIN 70020, Part 7A6) kg 270 300 380 410

F3L912 mm 589 679 796 329 268 108

*) with standard flywheel, incl. cooling system

GENERAL DRAWINGS & PROSPECTUS

No. Description Type /Dwg. Part no.

B1 Non-return valve, KV-48 3-2828 4492

Opening Minimum Sperre Sperre part no. Sperre part no.

½” 600 500 Ø 31 Ø 25 Ø 22 27 180 4595 4666 (DN15) 7495 (DN15)

For spare part orders

Material specification Electrical data - Coil

350 50,8 3,5

PRS-30 Electrical wiring:

170 24,7 1,7

0 PB- Low setting point Ie : 1,5A

Adjustment: When the top cover is removed, the

Adjustment of the switching unit

Reduction valve for compressed air

Dim DN L L1 H h R CH PN Handel Part no.

Full bore ball valve Materials

APPROVED PRESSURE RANGE

PARTS LIST AND MATERIAL SPECIFICATION

Max.tightening torque 50Nm

APPROVED PRESSURE RANGE

PARTS LIST AND MATERIAL SPECIFICATION

Max.tightening torque 14Nm *) Set pressure adjusted by SPERRE according to order.

For: Water, air, oil, steam

Max. working pressure: 40 bar at 120°C

Body Stainl. St 316 C16

Scale range Bar/ Mpa

Instruction manual for compressor type HL2/140

Sperre reserves the right to modify details without prior warning.

Ellingsøy, February 2006