Operating Manual: Edition: 01 / 2016
Operating Manual: Edition: 01 / 2016
Operating Manual: Edition: 01 / 2016
SV 2000 / 80
edition:
J.A. Becker & Söhne GmbH & Co. KG Neckarsulm 01 / 2016
1
Operating manual
© 2009
4 INTRODUCTION ................................................ 13
5.3 Oil level gauge / oil level eyes and/ or oil level dipstick . 14
7 MAINTENANCE ................................................. 32
8 TROUBLESHOOTING.......................................... 44
9 PRESERVATION................................................. 46
Please comply with the safety instructions specified below. Any non-
compliance can result in serious damage to life and health and/ or in ma-
terial damage. The following applies with regard to the safety instructions:
The safety instructions listed below will not be repeated in this manual.
Reference will only be made to these.
• valid regulations.
2. JAB does not accept any liability for cases of damage / malfunctions
This manual comprises the entire documentation required for your com-
pressor. It is aimed at all those who are in charge of the operation and
maintenance of the compressor and has to be read by them and complied
with in all points by them.
1. Storage:
2. Forwarding:
The operator shall ensure that only persons instructed in the opera-
tion and the safety measures use/ operate the machine.
2. Persons not expressly authorised to that end must not stay in the
danger zone of the compressor during operation.
In your capacity as the operator you ensure that all the laws, regulations
and standards in force in your country are taken into account and com-
plied with. For the territory of Germany and/ or Europe, this comprises
primarily EN1012-1, safety requirements for compressors as well as fur-
ther relevant standards and guidelines.
• Environmental legislation
Air-cooled piston compressors are used for diverse applications in the field
of commercial, industrial and private use.
Your JAB compressor is released for the following gasses/ gas mixtures:
The use of the system in accordance with the provisions also includes
compliance with the operating instructions and, first foremost, compliance
with the maintenance intervals.
The compressor systems are built in accordance with the valid safety-
related rules and correspond to the state of the art. Any use of the system
which is not in accordance with the provisions can result in risks for the
life and health of the operator and/ or damage to the compressors or
mounting parts in case these:
• The compressor must not be used for any other purposes than
those specified above.
4.1 General
• Piston compressors
• Two- to five-stage
• Single-acting
The oil pressure can be read off on this manometer. Normally, the oil
pressure amounts to approx. 3 to 4 bar.
5.3 Oil level gauge / oil level eyes and/ or oil level
dipstick
The following applies to compressors with oil level gauges: The oil level
has to lie between the MIN and the MAX labelling.
The following applies to compressors with oil level eyes: The oil
level has to lie in the area between the centre of the lower oil level eye
and the centre of the upper oil level eye.
one other (i.e. not exactly below each other as shown in the illustration).
• Unscrew dipstick.
• Screw dipstick into the oil container completely and unscrew again.
• Read off the oil level on the basis of the notches (Picture 3: Oil level
dipstick on page 16).
The oil level has to lie in the area between the MIN labelling and
the MAX labelling.
• checking the oil pressure monitor (cf. Function testing of the oil pres-
sure switch on page 28)
The oil pressure switch is used to monitor the oil pressure on compres-
sors. Upon starting-up, the NO contact of the oil pressure switch has to be
bridged for approx. 8 seconds. During this period of time the oil pressure
builds up from 0 to more than 2 bar. In a star-delta connection the pres-
sure switch is connected to the delta contactor. Because of this, a time
relay is not required.
• Ensures a good supply with lubricating oil right from the start
The 250 mm high compressor base facilitates the oil change and the
maintenance of the compressor. Moreover, it provides protection against
the accumulation of dirt on the compressor.
To that end, you either operate the emergency stop or the main switch
on the electrical control system.
Until the malfunction has been removed, the main switch has to
be protected against renewed switching-on! Only approach the
compressor once it has completed its relief (discernible through loud
hissing sound). After that, only approach the machine with the utmost
care until you have ascertained that the compressor is pressureless by
reading off all manometers.
If the machine stops under pressure: Close off danger zone and warn
other persons against approaching the machine. Contact your JAB
service partner in order to sort out the causes of the malfunction as
well as remedying of the malfunction.
Important:
• Electrical installations must only be carried out by skilled electri-
cians in any case.
6.1.1 Transport
• Only use equipment which is able to securely lift the weight of the
compressor. Information on the mass of your compressor is pro-
vided in the Technical Data.
2. Subgrade level, firm and suitable for the weight of the plant.
(A) Distance
at least 500 mm
(A) Distance
at least 500 mm
The following formula can be used for dimensioning any cooling air ducts
which might be required:
Please consider section 6 on page 24 with regard to this. The following has
to be taken into account during the installation of the electrical equip-
ment:
• Take the sense of rotation of the compressor into account upon con-
necting the system to the supply grid. (Arrow indicating the sense of
rotation on the fan wheel guard)
1. Check oil level: The oil level has to lie between the min-
imum and the maximum marking.
2. Turn fan wheel manually: It must be possible to turn
the wheel fully once easily and without any major re-
sistance.
container.
• Is the sealing on the safety valves there and is it free from damage?
Your compressor is delivered with an oil filling. However, you should still
check the following:
• Is sufficient oil available? Inspection (see Oil level gauge / oil level
eyes and/ or oil level dipstick on page 14)
Switch on compressor
after 6 to 8 seconds
Machine
switches
off.
YES NO
In case of a malfunction:
• Check integration and/ or wiring of the oil pressure switch within the
electrical control system with the help of the circuit diagram!
Turn off the valve spindle in a clockwise direction or close the oil ball valve
while the machine is running. This blocks automatic relieving. Switch off
the compressor and check piping connections for tightness. Turn on the
valve spindle or open the ball valve again after the check, the compressor
can relieve and is ready for operation again.
Ball valve
After 2000 operating hours respectively; in case of low running times, the
oil has to be replaced at the latest after 2 years, however.
1. Place an oil collection container under the oil drain screw. Make
sure that the volume of the collecting container is big enough to take
up your compressor’s oil filling.
2. Open the oil fill pipe.
3. Open the oil drain screw.
4. Wait until the oil has drained completely into the collecting contain-
er.
5. Screw out any oil screen which might exist and wash out and
blow out any contaminations with petroleum or a similar solvent.
6. Rinse out contamination in the oil sump with a little fresh oil!
7. Please note: In systems with external oil filter, the filter has to be
replaced upon every oil change!
8. Close the oil drain screw.
9. Fill in the prescribed quantity of fresh oil (see below for recom-
mendations regarding lubricating oil).
10. Close the oil fill pipe.
11. Introduce the waste oil collected into environmentally compati-
ble disposal.
Only the compressor oils released by us must be used in any case. Mixing
of different oil grades must be avoided at any rate.
We especially point to the use of synthetic lubricating oils which entail ad-
vantages in their viscosity behaviour and with regard to the formation of
oil carbon compared with mineral lubricating oils according to DIN 51 506.
Procedure:
Every filter cartridge should only be blown out once and replaced upon the
next maintenance.
The cooling ribs of the flat tubular radiator as well as the tube intercoolers
and after-coolers have to be cleaned in case they are contaminated in or-
der to ensure a flawless cooling effect. Shut down the compressor first of
all and protect it against renewed switching on. Consider the warnings in
the section entitled MAINTENANCE on page 32.
Procedure:
In the event of the optional equipment of the compressor with a fine filter,
the filter cartridge has to be replaced upon every maintenance (or every
2000 operating hours) as described below. Shut down the compressor and
protect it against switching on again before replacing the cartridge.
Procedure:
Unscrew cylinder head studs and/ or cylinder head cover studs and take
off cylinder heads and/ or head covers. Remove reed valves and/ or indi-
vidual valves, clean these if possible and check for damage or wear.
Residues of old gaskets on the cylinders, cylinder heads and valves have
to be removed cautiously without damaging the contact face.
If the valves are still free from wear and tear and undamaged, they can
be reused and re-installed with new gaskets. Worn or damaged valves
have to be renewed. Installation in reverse order.
Unscrew the screwed pipe connection on the inlet and outlet side on the
cylinder head, loosen and unscrew nut, SW,[width across flats] 55. Loosen
central pressure screw (width across flats 30) and unscrew by approx. 2
pitches. Unscrew 4 Allen screws on the cylinder head and take off cylinder
head.
Remove concentric valve from the cylinder seat, clean and check for dam-
age. Replace valve in case damage is found.
Remove all old gaskets and clean seal faces before re-assembling
the valve.
Insert new gaskets. In this context, pay close attention to make sure that
the gaskets are inserted precisely into the circumferential slot on the cyl-
inder and on the central screw. For better fixing in the position, the Cu
sealing rings have to be “glued“ into the groves with a little grease.
After that, insert valve and cautiously place cylinder head with the mount-
ed central pressure screw on the cylinder and screw tight. Consider tight-
ening moment!
In case the aluminium edge sealing ring on the outside of the central
screw is damaged, insert new ring.
Screw on cap nut (SW [width across flats] 55) and tighten carefully. After
that, tighten screwed pipe connection again.
Caution: Do not damage the seal faces. Replace O-rings before re-
assembly.
Check and clean the relief valves upon every oil change or every 2000 op-
erating hours.
Disconnect air or control air lines on the relief valves on the crankcase or
on the base of the separator.
Unscrew screws and remove relief valves from the crankcase and/ or from
the base of the separator.
Screw out screws and dismantle valves into their individual parts.
Check lip seals on the pistons for cleanness and damage, the same also
applies to the gaskets inserted on the face side of the pistons. If required,
renew parts.
Before assembly, grease pistons and lip seals with acid-free grease. Cover
gaskets and O-rings have to be replaced.
In case of a defect on the solenoid valve, unscrew cap nut of the screwed
pipe connections and electric supply cables.
Replace valve and fasten it again with the help of the screwed pipe con-
nection.
During every maintenance the elastic coupling has to be checked for cou-
pling clearance. To that end, “hold“ the axial fan on the compressor and
check whether any clearance is discernible by turning the motor shaft
(remove cover of the motor fan).
Recommendation:
The coupling buffers of the elastic coupling have to be replaced regularly,
however, at the latest every 10,000 operating hours in order to prevent
damage to the drive (as of SV 300/250).
Attention!
In case nothing to the contrary is specified, the following applies to piston
rings with the marking or designation“TOP“ on the ring joint: The “TOP“
marking has to point to the piston crown. Depending on the number of
rings, the ring joints should be arranged in a position offset from one an-
other by 90° to 120°. Lubricate cylinder, piston and rings well before as-
sembly.
In case pistons display signs of wear and tear, the entire pistons incl. the
piston rings have to be replaced.
After maintenance has been carried out, the compressor has to be turned
manually and checked for smooth running. Check all screws and screwed
pipe connections unscrewed during maintenance for tight seat. Switch on
machine and allow to warm up for approx. 10 to 15 min. Check oil pres-
sure and pressures of the stages and compare these with the set values.
After that, switch off machine and tighten all screws and screwed pipe
connections once again.
In order to provide fast access to all the information regarding your com-
pressor to all those persons involved in maintaining and operating the
compressor, we urgently recommend that you also keep a maintenance
log:
• Facilitating troubleshooting
• Air intake filter contaminated, the flow of air taken in is curbed. Clean
or replace filter cartridge.
• Cylinder head gasket of the 1st pressure stage or the reed valve is
damaged. Check and replace defective parts.
• Air is blown off on the oil and water separator via the relieving line
while the compressor is running. Relief valves leaky. Unscrew locking
screw as well as screwed connection on the relief valves. If air is dis-
charged from the opened drill hole while the compressor is in opera-
tion, the piston with its gasket does not seal perfectly on the valve
seat. Check the corresponding valve and replace defective parts.
• Worn piston rings after a very long running time. Replace piston
rings. See list of spare parts for placement of piston rings.
The cylinder head gasket or the suction and/ or pressure valve of the fol-
lowing pressure stage are damaged. Check and replace defective parts.
7.15.3 Air is blown off to the outside via the relieving line while
the machine is not running
(Air flows back to the compressor from the air pressure tank.) The non-
return valve or the pressure control valve is leaky on the compressed air
outlet. Gasket in the non-return valve, packing or O-ring of the pressure
control valve is defective. Replace defective interior parts or entire valve.
• Oil pressure drops to below 1.8 - 2 bar so that the oil pressure switch
switches off the machine. Pressure oil lubrication is interrupted.
• Oil screen on the oil drain plug is contaminated. Dismantle, wash out
and blow out with compressed air. The oil has to be drained to that
end.
Compressor does not reach the operating pressure set on the pressure
valve or the safety valve of the last pressure stage blows off.
• The adjustment of the valve has changed. The operating pressure can
be increased by turning down the pressure regulation hood (in a clock-
wise direction) or the operating pressure can be increased by turning
up the pressure regulating hood. After the desired operating pressure
has been set, the pressure regulation hood is secured against self-
adjustment by means of a locknut.
Hard metallic knocks instead of the normal working sounds indicate a run-
ning clearance of the connecting rods on the crank pin of the crankshaft or
on the gudgeon pins of the pistons which is too big. Such a defect has to
be remedied by means of the installation of new connecting rods forth-
with.
8 TROUBLESHOOTING
• under pressure
• Acoustically: Based on your hearing (To that end, only take off
your hearing protection for as long as is absolutely required and
make sure that the valve on the oil overpressure valve is closed at
all times throughout this period!)
5. Open the oil shut-off valve again: The compressor relieves (wear
hearing protection!).
The compressors are delivered with oil filling. No additional measures are
required upon commissioning. Normally, the machines can be stored for
up to 6 months in this version and under adequate storage conditions.
Compressor type:
unit
SV 2000/80
Cooling air
Number of stages 4/3
Displaced volume l/min 2394
Piston - Ø mm 120 / 120 / 70 / 40
Stroke mm 72
Rpm U/min 1470
Output acc. to VDMA 4362 (±5%) l/min 1965
max. working overpressure bar 80
Oil quantity in sump Liter 14,5
Stored oil quantity between max.
Liter 11
and min. oil level
Stored oil quantity between max.
h 2000
and min. oil level sufficient for approx.
Operating range (standard) °C +5 to +40
Operating range (with heating) °C -20 to +40
Noise level
at 1 mtr. distance dB(A) 95
at 7 mtr. distance dB(A) 88
E-motor 30kW / 50cycles, B5, IP55
Power requirement kW 27
Weight kg 590
Length mm 1460
Width mm 1080
Height mm 1085
Recommended spare parts for 2000, 4000, 6000 running hours and
also for complete overhaul and complete gasket set.
Fig/
Order- Gasket 2000 4000 6000
Item- Description Revision
No. set 1) h h h
No.
1/100 169118 silent blocks Ø 100x55 - - - - 3
2/34 157643 gasket ring R 1" 1 1 1 1 1
2/36 027871 gasket ring A 21x26 CU 1 1 1 1 1
2/62 072958 O-Ring 32x4 1 1 1 1 1
3/4 157740 retainer BA SL 32x56x10 1 - - 1 1
3/12 162429 retainer BA 70x100x10 1 - - 1 1
3/20 162449 coupling buffer - - - 10 10
4/2 162431 connecting rod 2. + 3. Stage - - - - 2
4/1 508622 connecting rod 1. Stage - - - - 2
4/5 502232 piston cpl. 1. Stage Ø 120 - - - - 2
4/7 511921 piston cpl. 3. Stage Ø 40/90 - - - - 1
4/10 031640 piston cpl. 2. Stage Ø 70 - - - 1 1
5/1 198332 gasket ring 142,47X3,53 2 - - 2 2
5/2 195517 cylinder 1. Stage Ø 120 - - - - 2
5/3 161554 cylinder gasket 2 2 2 2 2
5/4 510545 lamella valve 1. Stage - - 2 - 2
5/5 161555 cylinder head gasket 2 2 2 2 2
5/6 161556 cylinder head gasket 2 2 2 2 2
5/12 529421 filter cartridge - 2 2 2 2
6/1 198332 Di-Ri-Quad 142,47X3,53 1 - - 1 1
6/2 511063 cylinder 2. Stage Ø 70 - - - - 1
6/3 168850 cylinder gasket 1 1 1 1 1
6/4 511859 lamella valve 2. Stage - - 1 - 1
6/5 168848 cylinder head gasket 1 1 1 1 1
6/6 168849 cylinder head gasket 1 1 1 1 1
7/1 198332 Di-Ri-Quad 142,47X3,53 1 - - 1 1
7/2 161141 cylinder 2. Stage Ø 90 - - - - 1
7/3 073598 O-Ring 90x3 1 - - 1 1
7/5 193247 cylinder 3. Stage Ø 40 - - - - 1
7/8 168847 cylinder gasket 1 1 1 1 1
7/9 503218 lamella valve 3. Stage - - 1 - 1
7/16 197465 cylinder gasket 1 1 1 1 1
8/3 162242 gasket flange 3 3 3 3 3
11/4 167109 fan wheel cpl. - - - - 1
view
SV 2000 / 80
Pos. Benennung description
1+2
10-14 Abscheider, nackt 1 seperator, nacked
21+22
35+36
Sicherheitsventile und Druckwaechter
15 SV 2000 / 80
safety valves and pressure switches
Best.-Nr. Stück
Pos. Benennung description
order-No. quantity