NHP-1500WCU Portable Oil-Free Compressor Training

4/30/2009
NHP-1500WCU Portable Oil-Free Compressor

Service Training
DANNY POELMANS Product Service Manager Portable Compressors & Tools
NHP-1500WCU Portable Oil-Free Compressor
4/30/2009
Training Contents
Basic Component Layout Main Components Intellisys Controller Safety Labels Operation Components Electronic Control Sys. Troubleshooting using special tools Displays & Menus Unit Shutdowns and Alarms Warranty
MACHINE LAYOUT
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Machine Layout
Air In
Air In
Air In
Exhaust Through Ro oof
RAD
Fuel Top Hyd. Middle A/E Oil Bottom
Compressor
Diesel Engine
I/C Top A/C Bottom
CAC
Air In Air In
Machine Layout
Sealed Base 2270 Liters
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Machine Layout
Airflow Airflow
AIREND
ENGINE
Airflow
Airflow
Airflow
AIRFLOW~ 820m/min, ~29,000 cfm
MAIN COMPONENTS
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Main Components Cummins QSX15

600 HP @ 1800 RPM Full Load Speed 1200 RPM No Load Speed EPA Tier 3 and EEC Stage 3 emissions certified EFC and 15% hp margin for continuous duty operation
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Main Components Oil-Free Compressor
Working pressure range between 4.1 and 10.7 bar. Outlet air temp is A+11C
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HELICAL ROTARY SCREW SPECIAL MICRO COATING FOR PROTECTION FROM CORROSION AGMA 12 DRIVEN AND TIMING GEARS FOUR ROLLER BEARINGS AND TWO 4 POINT AIRCRAFT TYPE THRUST BEARINGS STAINLESS STEEL AIR SEALS VENTED TO ATMOSPHERE BRASS SPIRAL TYPE LABYRINTH SEALS FOR BEARING LUBRICATING OIL METRIC FASTENERS

Two-Stage A/E Highly efficient shaft sealing UltraCoat rotor and housing protection Stainless Steel high-pressure rotors
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Synchro gears
Labyrinth bearing seals
Main Components INTELLISYS Controller

Total Control at Your Fingertips Easy Operation Adjustable Operating Parameters Time-Saving Diagnostics Comprehensive Data Display
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Main Components INTELLISYS Controller

INTELLISYS Controller is the heart of the NHP 1500 machine monitor and control system. It provides data collection, alarming and control functions for compressor operations operations. It is an Intel micro-controller based unit with analog and digital inputs and outputs.
Main Components INTELLISYS Controller - Functions

First function of INTELLISYS is to scan all analog and digital inputs at a given time interval. The inputs are scanned every 100 milliseconds. The values are then compared against min. and max. values and an ALERT or SHUTDOWN is issued. d l d i i d Second function to monitor discharge press., and varies engine speed to maintain air press. at desired setpoint. Third function to retrieve diagnostic info from the engine.
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SAFETY
SAFETY This machine should not be used:

For direct or indirect human consumption of the compressed air. Outside the ambient temperature range -20F to 115F. (-20F ( 20F will need cold weather options) options). When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists. With guards, or controls or switches missing or disabled. For storage or transportation of materials inside or on the enclosure.
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SAFETY- Labels
COMPRESSOR OPERATION
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Compressor Operation
ATMOSPHERIC AIR IS DRAWN IN FROM THE RIGHT END OF THE CABINET VIA INTERNAL SOUND ATTENUATING DUCTING. WHEN THE INLET CONTROL BUTTERFLY VALVE IS OPEN THE AIR ENTERS THE 1st STAGE AIREND WHERE IT IS COMPRESSED TO 26 TO 31 PSIG. THE AIR DISCHARGES THE AIREND VIA A VENTURI USED TO DISSIPATE PRESSURE PULSATION. FROM THE VENTURI THE AIR MOVES THROUGH A STAINLESS STEEL FLEXIBLE SECTION AND ENTERS THE INTERCOOLER WHERE THE AIR IS COOLED TO 20 ABOVE AMBIENT TEMPERATURE. THE AIR EXITS THE INTERCOOLER AND PROCEEDS THROUGH STAINLESS STEEL PIPING TO A MOISTURE SEPARATOR ( WHICH INTERNALS ARE EPOXY COATED) WHERE CONDENSATE IS REMOVED BEFORE PROCEEDING TO THE 2nd STAGE AIREND. THE AIR EXITS THE 2nd STAGE AIREND DIRECTLY INTO A SILENCER BOTTLE AFTER WHICH BOTTLE, IT FLOWS INTO THE AFTERCOOLER. THE AIR TEMPERATURE IS LOWERED TO WITHIN 20F OF THE AMBIENT AIR TEMPERATURE BEFORE EXITING THROUGH A STAINLESS STEEL PIPE, INTO A CHECK VALVE AND THEN INTO A MOISTURE SEPARATOR . ANY MOISTURE THAT HAS CONDENSED DUE TO THE LOWERING OF THE TEMPERATURE IS REMOVED IN THE SEPARATOR AND THEN THE AIR FLOWS TO THE CUSTOMER SYSTEMS.
Hypothetical compression cycle 32oC, 65% Relative Humidity, 1 bar Dirt Water Air
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters
Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters Butterfly unloader - Hydraulic control
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters Butterfly unloader Compression (STAGE 1)
Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters Butterfly unloader Compression (STAGE 1) 1st stage discharge : 185oC, 100% RH, 3.5 bar
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters y Butterfly unloader Compression (STAGE 1) 1st stage discharge : 185oC, 100% RH, 3.5 bar Venturi
v1 v2
u1
u2
v1
v2
Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters y Butterfly unloader Compression (STAGE 1) 1st stage discharge : 185oC, 100% RH, 3.5 bar Venturi Intercooler
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters y Butterfly unloader Compression (STAGE 1) 1st stage discharge : 185oC, 100% RH, 3.5 bar Venturi Intercooler Water separator
Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters y Butterfly unloader Compression (STAGE 1) 1st stage discharge : 185oC, 100% RH, 3.5 bar Venturi Intercooler Water separator 2nd stage inlet : 44oC, 100% RH,3.5 bar
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar Filters Butterfly unloader Compression (STAGE 1) 1st stage discharge : 185oC, 100% RH, 3.5 bar Venturi Intercooler 2nd stage inlet : 44oC, 100% RH,3.5 bar Compression (STAGE 2) 2nd stage discharge 185oC, 100% RH, 10.3 bar
Ambient air / Inlet air : 32C, 65% RH, 1 bar 2nd stage discharge : , , 185oC, 100% RH, 10.3 bar Venturi
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar (abs vol = 42.5m/min) 2nd stage discharge : 185oC 100% RH 10 3 bar C, RH, 10.3 Venturi Aftercooler
Ambient air / Inlet air : 32oC, 65% RH, 1 bar (abs vol = 42.5m/min) 2nd stage discharge : 185oC 100% RH 10 3 bar C, RH, 10.3 Venturi Aftercooler Water separator
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Ambient air / Inlet air : 32oC, 65% RH, 1 bar (abs vol = 42.5m/min) 2nd stage discharge : 185oC 100% RH 10 3 bar C, RH, 10.3 Venturi Aftercooler Water separator Discharge
Ambient air / Inlet air : 32oC, 65% RH, 1 bar (abs vol = 42.5m/min) 2nd stage discharge : 185oC 100% RH 10 3 bar C, RH, 10.3 Venturi Aftercooler Water separator Discharge air : 43oC, 100% RH, 10.3 bar, (abs vol ~7.3m/min) CTD = C ld T Cold Temperature Diff t Difference or temperature above t t b ambient = 43oC - 32oC = 11oC
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Condensate burn-off, not
Mass of water precipitated @ 42.5m/min = 44.6 kg / hour = 1080 kg / day
GENERAL OPERATION
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General Operation - Transport
Compact design & 3 handling methods

Beaver tail
Flat bed
Hoisted by crane Towed Fork lifted

Long distance: 20ft Container
General Operation - Installation
Installation Example:
Manifold for multiple units or pressure sensor
Compressed air
Check valve
Dryer
Installation
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General Operation - Installation
This will limit turbulence and restriction in the airline thereby improving airflow.
Check and isolation valves in vital locations can help when the need arises to move part of the installation.
General Operation
Place unit in an open, well ventilated area. Position as level as possible, max. 5 degree out-of-level operation.
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General Operation - Fork Tubes

Place Drawbar in vertical stowing position. Size Fork Truck lifting capacity per gross weight of machine.
General Operation - Wheel Chocks

Located inside of front door. Secure unit with chocks before disconnecting drawbar from tow vehicle.
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General Operation - Fuel Tanks

Unit has on-board fuel tanks with a capacity of 300 gallons which provides 10-11 hours of full load operation. To minimize condensation re-fill the tank at the end of each day
General Operation - Compressor Oil Level

The proper oil level is labeled on the sump dipstick. The oil level is most consistent when checked NOT running.
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General Operation - Hydraulic Oil Level

The proper oil level is mid-way on the sight gauge. Check the oil level when the unit is warm and not running. Use IR Hydraulic Oil P/N 54758321- 5 gal. 54758339- 55 gal. 54758347- 275 gal.
General Operation - Controls & Instruments
Message Display Menu Selection Start Button U o d u o Unload Button Power On-Off Switch
Lamp & Switch Scroll Buttons Load Button Stop Button Either Inject Hour Meter
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General Operation - Controls & Instruments 4. Start 5. Load
1. ON
3. Etherstart
Manual operation: Starting the machine

Ingersoll -Rand
INTELLISYS
1) Switch Power to On
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2) Press the Start button
..10 seconds.
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3) Engine cranks and starts 4) Engine reaches idle speed
1200 rpm

5) Engine warms up. (Machine can go on load only once engine jacket temperature reaches 40oC)
1200 rpm pressure
6) Pressure adjustment / setting through scroll bar and menus
O O
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5) Machine up to temperature. Press load button
1200 rpm 40oC

6) Machine goes on load, revs climb
1800 rpm Pressure
O O
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7) Machine is operational. Settings can be changed if required.
1800 rpm Pressure
8) Take the machine off-load
O O
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9) Switch off the machine. Wait 3 minutes
119 s
Shut down
Ingersoll -Rand
INTELLISYS
10) Switch Power to Off
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General Operation Start Sequence

1. 2. 3. 4. Flip the Power button to the ON position. Display will alluminate. Check E stops and open the air outlet valve. In cold weather conditions press the Etherstart button twice. Press the Start button if a condition exists which would prevent a normal start sequence then the engine will not run and the failure will be displayed on the controller. Audible alarm will sound for 10 seconds. Unit will go through the warmup fase. After warmup fase Load button can be pushed.
5. 6.
General Operation - Emergency Stop Button

Press this button to immediately stop unit. Use this button ONLY during emergency conditions. The g y Stop button should be used for normal stops. Engine damage could occur Another Emergency Stop is located on the drawbar end of unit.
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General Operation - Service Valve

Open Service Valve before starting.
General Operation - Stopping The Unit

Press STOP button. The compressor will unload and engine speed will go to idle. A three minute cool down will begin. When the cool down is complete the engine will stop complete, stop. Switch the POWER switch to OFF.
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COMPONENTS
COMPONENTS - Cummins QSX-15

Engine speed varies between 1200 and 1800 RPM while compressor is loaded to match the required volume flow. Full flow at set point press. @ 1200 RPM is approx. 1000 CFM. Full flow at set point press. @ 1800 RPM is 1500 CFM
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COMPONENTS Heat Exchangers
Condensate burn-off
Stage 2
QSX - 15
Stage 1
Unloader
Air - Air : Air Intercooler Air - Air : Aftercooler Wtr - Air : Engine radiator
Oil - Air : Airend oil cooler Air - Air : Engine charge air cooler Oil - Air : Hydraulic oil Fuel - Air : Diesel return cooler
COMPONENTS Coolant System

Engine Charge Air Cooler
Clogged cooler will lead to engine high temp shutdown Clean from roof side
Exhaust
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COMPONENTS Coolant System Conditioner

Engine Coolant Conditioner Filter
Replace every coolant interval Switch valve to OFF position Replace filter Switch valve to ON position
COMPONENTS Air System
2nd MS
1st MS Safety Valve
After Cooler
Inter Cooler Inlet Valve
Air End
Engine
Check Valve
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COMPONENTS - Air System Unloaded
COMPONENTS Air System Loaded
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COMPONENTS - Inlet Butterfly - Blowdown Valve

Adjustable unit Can be rebuilt
COMPONENTS - Inlet Butterfly - Blowdown Valve

Compressor inlet butterfly valve and blowdown valve are controlled by a solenoid which directs oil to a cylinder by the y y Intellisys Controller. The compressor is either loaded (inlet valve fully open/BDV fully closed) or unloaded ( inlet valve fully closed/BDV fully open.)
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COMPONENTS Pulsation Dampers

On first and second stage outlet dampers have been placed to even out the p pulsations after air compression.
COMPONENTS - Inter-Cooler
Cools to Ambient Temp. plus 12 degrees C
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COMPONENTS - After-Cooler
Ambient Temp. plus 11degrees C Stainless Steel to protect the quality of air
COMPONENTS - Moisture Separator

First Stage Moisture Separator Solenoid drain valve located on bottom of the separator Moisture bleed-off to engine exhaust
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COMPONENTS - Moisture Separator

Second Stage Moisture Separator
Valve &Condensate Solenoid Orifice

Solenoid is normally open Only closes on machine start up
COMPONENTS - Check Valve

This valve will prevent backflow of plant air into the airend when the machine is idling or shutdown g
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COMPONENTS - Safety Valve

Valve setting 165 PSI Located on 2nd stage Inlet
COMPONENTS Lube Oil System

OIL FLOW SYSTEM THE PURPOSE OF THE OIL SYSTEM IS TO SUPPLY LUBRICATION TO THE BEARINGS IN THE AIREND AND FOR HOUSING COOLING ON THE 2nd STAGE AIREND. THE OIL IS DRAWN THROUGH A STRAINER, USED TO FILTER OUT LARGE CONTAMINANTS AND THEN THROUGH A SUCTION TUBE WHICH CONNECTS TO THE OIL PUMP. THE OIL PROCEEDS TO THE SUCTION PORT ON THE OIL PUMP AND IS THEN ELEVATED IN PRESSURE TO APPROXIMATELY 40 - 45PSIG. THERE IS A PRESSURE RELIEF VALVE ON THE PUMP DISCHARGE PIPING WHICH IS USED TO ADJUST SYSTEM OIL PRESSURE THE OIL IS DISCHARGED TO THE OIL COOLER WHERE THE OIL IS COOLED TO APPROXIMATELY 130 - 140F. A THERMALLY CONTROLLED MIXING VALVE IS LOCATED ON THE COOLER OUTLET. THIS VALVE MIXES HOT OIL, (WHICH BYPASSES THE COOLER) AND COOL OIL FROM THE OIL COOLER TO MAINTAIN THE OPTIMUM OIL TEMPERATURE. (APPROX. 130 - 140F). THE OIL LEAVES THE THERMAL MIXING VALVE AND PROCEEDS THROUGH A 10 MICRON OIL FILTER AND THEN IS DIVERTED TO MULTIPLE OIL FEED POINTS ON THE TWO AIRENDS. THE OIL PRESSURE IS CONTROLLED BY THE USE OF AN ORIFICE, SIZED BY THE FACTORY, LOCATED IN THE OIL OUT PIPING ON THE 2nd STAGE AIREND HOUSING. THE OIL THAT HAS BEEN FEED TO THE BEARINGS IS DRAINED FROM THE AIRENDS VIA OVERSIZED DRAIN PORTS LOCATED ON THE BOTTOM SIDE OF THE AIRENDS. PRESSURIZED OIL IS ALSO SUPPLIED TO THE 1SV SOLENOID FOR OPERATING THE CONTROL VALVE HYDRAULIC CYLINDER USED TO LOAD AND UNLOAD THE UNIT.
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COMPONENTS Compressor Oil Sump

Compressor Lubricate 25 gallons capacity Must be changed at 6 months or 1000 hrs of operation hrs. Use IR Hydraulic Oil P/N 54758321- 5 gal. 54758339- 55 gal. 54758347- 275 gal.
COMPONENTS Gear Case Breather

Clean breather every 2000 hours or 12 months of operation
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COMPONENTS Air End Oil Pump

PUMPS OIL UNDER PRESSURE TO ALL BEARINGS AND OIL FOR COOLING TO 2nd STAGE JACKET POSITIVE DISPLACEMENT GEAR TYPE. DRIVEN BY OLDHAM COUPLING ON BULL GEAR SHAFT
COMPONENTS Pressure Relief Valve

Valve Setting is 42-44 PSI at 1800 RPM Loaded
PREVENTS OIL SYSTEM FROM BEING OVER PRESSURIZED FACTORY SET AT 42 PSIG NORMAL OIL PRESSURE 40 - 45 PSIG (oil temp > 120 F - 49C) 120F 49 C)
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COMPONENTS Compressor Oil Filter

Spin-on filter element Has a internal bypass valve (opens @ 25psi) Filter must be changed at 6 months or 1000 hrs. of operation
COMPONENTS Oil Temp Control Valve

By-Pass Cooler to reach operating temp. at start-up Thermostat opens @ 135F 57 C 57C
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COMPONENTS Compressor Oil Cooler
LAT= 115 Degrees
COMPONENTS Engine Oil Replenishment

Eliminates the need for daily shutdown to check engine oil level. Tank holds 10 gal of engine gal. oil and the level should be visible in sight tube. This does not extend the engine oil change interval.
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COMPONENTS Hydraulic Fan System
COMPONENTS Hydraulic Oil Filter

Filter must be changed at 6 months or 1000 hrs. of operation Spin-on filter element Spin on Has a internal bypass valve (opens @ 25psi 1.7bar)
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COMPONENTS Hydraulic Sump Tank

Hydraulic oil capacity 27 gallons Must be changed at 6 months or 1000 hrs of operation hrs. Use IR Hydraulic Oil P/N 54758321- 5 gal. 54758339- 55 gal. 54758347- 275 gal.
COMPONENTS Hydraulic Oil Manifold

Hydraulic Press. Gauge (2250 PSI @ 1800 RPM Loaded 1150-1250 PSI @ 1200 RPM 1150 1250 Unloaded
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COMPONENTS Hydraulic Pump

Pump is driven off the engine flywheel
COMPONENTS Fan Motor

Fan Speed @ 1200 RPM Unloaded=1050-1150 RPM Fan Speed @ 1800 RPM Loaded 1630 1644 Loaded=1630-1644 RPM Grease fitting on top should be serviced each oil change
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COMPONENTS Hydraulic Cooler
LAT= 130 F 54C
COMPONENTS Fuel System
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COMPONENTS Fuel/Water Separator Filter

Drain the water from filters daily. These filter elements should be changed every 500 hrs or hrs. 3 months service.
Check for water
Change over valve one filter can be isolated to service with machine running
COMPONENTS Fuel Pump
Primary machine fuel feed pump
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COMPONENTS Fuel Cooler

Cools the fuel before return to fueltank
COMPONENTS Remote Fueling Connection

One 3/4 Female Connector(Supply) One 3/4 Male Connector (Return)
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COMPONENTS 3 Way Valve

Lever Handle in the horizontal(down) position allows for Remote Fueling
COMPONENTS Condensate System
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COMPONENTS Condensate Burn-Off System

Collects all the water from the after-cooler water separator and injects it into the engine exhaust where it is FLASH EVAPORATED.
COMPONENTS 24 Volt DC Heating
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COMPONENTS Fuel Heaters
COMPONENTS Stage One Moisture Separator
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COMPONENTS Stage Two Moisture Separator
COMPONENTS 115 Volts AC Heating Compressor Side

Hydraulic Oil Sump Tank Heater A/E Oil Sump Tank Heater Heat Trace Lines AC Pl I Plug-Ins
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COMPONENTS Hydraulic Oil Sump
COMPONENTS A/E Oil Sump Heater
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COMPONENTS Heat Trace Lines
COMPONENTS AC Plug-Ins
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COMPONENTS 115 Volts AC Heating Engine Side

Engine Coolant Heater Engine Oil Pan Heater Battery Pads

Engine Charge Air Cooler
Clogged cooler will lead to engine high temp shutdown Clean from roof side
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Engine Coolant Conditioner Filter
Replace every coolant interval Switch valve to OFF position Replace filter Switch valve to ON position
COMPONENTS Engine Coolant Heater 1500 W
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COMPONENTS Engine Oil Pan Heater 350 W
COMPONENTS Battery Pads
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COMPONENTS Pressure Transducers

The Electronics System contains Pressure Transducers to measure pressure changes. These devices have an output signal of .45 VDC, to 4.5 VDC, corresponding to 0 PSI and the maximum PSI for a selected transducer which will be 100,225, or 30 PSI. The 0-30 PSI transducer is a vacuum transducer and the 100-225 PSI units are gauge press.devices. A 5 VDC excitation signal is provided to power the transducers.

P7
L5 P4 P8
T4 T2 T3 V2 P3 P2
L4
Stage 2
T5
QSX - 15
Stage 1
T7
T1 P5 P6 T8 P1 IV T6 BDV MUF
FL V
Exhaust
V1
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COMPONENTS Pressure Transducers HYD Tank Located

PT1= Stg1 Inlet Vac PT2= Stg2 Inlet Press PT3= Stg2 Disch Press PT4 PT4= Package Disch Press
PT 1 PT 2 PT 3 PT 4
COMPONENTS Pressure Transducer 1

Stage 1 Inlet Vacuum 0-30 IN. Vacuum Transducer 0.3-0.6 Loaded 10.8-11.3 Unloaded 10 8 11 3 U l d d
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2nd Stage Inlet Press. 0-100 PSI Pressure Transducer 28 32 PSI Loaded 28-32 0 PSI Unloaded

2nd Stage Discharge Press. 0-225 PSI Pressure Transducer 152 PSI Loaded 0-4 PSI Unloaded
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Package Discharge Pressure 0-225 Pressure Transducer 150 PSI Loaded 0-2 0 2 PSI Unloaded U l d d

PT5= Oil Filter In Press PT6= Oil Filter Out Press PT7= Remote Press
PT PT 7 5/6
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COMPONENTS Pressure Transducer 5 & 6

PT5= Oil Pressure In PT6= Oil Pressure Out Both are 0-100 PSI Pressure Transducers 42-44 PSI For Oil Press. Out Loaded

Remote Pressure Signal 0-225 Pressure Transducer
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COMPONENTS Temperature Sensors

There are two types of temperature sensors, RTDS and Thermistors. Both of these devices exhibit a change in resistance as the temperature changes. g p g g This resistance change causes an input voltage change to the INTELLISYS Controller Input and is interpreted as a temperature change.
COMPONENTS RTD Locations

RT 1- 1st Stage Temperature Out RT 2- 2nd Stage Temperature IN RT 3- 2nd Stage Temperature Out RT 4- P k 4 Package Discharge Ai T Di h Air Temperature t RT 5- A/E Oil Injection Temperature RT 6- 1st Stage Inlet Temperature RT 7- Engine Coolant Temperature RT 8- Inter-cooler Temperature Out
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COMPONENTS RT 1
100 OHM RTD 1st Stage Temperature Out 350-370F /167-188C Loaded 180F / 82C Unloaded
COMPONENTS RT 2
100 OHM RTD 2nd Stage Temp. In Ambient Plus 25 Degree Loaded Ambient Plus 10 Degree Unloaded
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COMPONENTS RT 3
100 OHM RTD 2nd Stage Temp. Out 360-380 F / 182-193C Loaded 173F / 78C Unloaded
COMPONENTS RT 4
100 OHM RTD Package Discharge Air Temperature Ambient Plus 25 FLoaded 25FLoaded
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COMPONENTS RT 5
10K OHM Thermister A/E Oil Injection Temperature 136F / 58C Loaded 132F / 55.5C U l d d 55 5C Unloaded
COMPONENTS RT 6
10K OHM Thermister 1st Stage Inlet Temp Ambient Plus 10 Degree Loaded & Unloaded
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COMPONENTS RT 7
100 OHM RTD Engine Coolant Temp 179F / 81.5C Loaded
COMPONENTS RT 8
100 OHM RTD Inter-Cooler Temperature Out Ambient Plus 25 Degree Loaded
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Electronic Sys.Troubleshooting Procedures and Techniques Basic troubleshooting steps: Collect all facts concerning the problem Analyze the problem thoroughly C Consider any recent repairs th t could relate t th problem id t i that ld l t to the bl Double check before replacing components Determine the cause of the problem and make a thorough repair
MAINTENANCE - Engine
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MAINTENANCE - Compressor
MAINTENANCE Compressor Inlet valve
THREE MAJOR COMPONENTS INLET VALVE NOTHING SERVICEABLE ADJUST TO .012 / 3.05mm UNLOADED HYDRAULIC CYLINDER REBUILD KIT AVAILABLE BLOWDOWN VALVE REBUILD KIT AVAILABLE
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To atmosphere
Unloaded
2nd stage air
0.12 gap
Spring loaded closed

To atmosphere
Start to load
2nd stage air
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MAINTENANCE Compressor Inlet valve Fully Loaded
2nd stage air

To atmosphere
Start to unload
2nd stage air
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To atmosphere
Unloaded
2nd stage air
MAINTENANCE Diesel Fuel
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MAINTENANCE Oil Recommendation
OPTIONS
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OPTIONS
Options Without running gear Remote start, auto start systems & trickle charger S Special colour i l l Interior lights Spark arrestor Engine oil top-up system
OPTIONS Autostart on sensor input
Primary
Dryer
Installation
Pressure transducer on customer installation will trigger start and stop
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OPTIONS Autostart on switch

Electrical relay contact
Primary
Dryer
Installation
Customer control room switch will start /stop compressor
OPTIONS Special Colour
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OPTIONS Internal Lights
OPTIONS Auto Oil Top-up Tank
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WARRANTY
WARRANTY
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WARRANTY
WARRANTY
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WARRANTY
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NHP-1500WCU Portable Oil-Free Compressor Training

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NHP-1500WCU Portable Oil-Free Compressor Training

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4/30/2009

NHP-1500WCU Portable Oil-Free Compressor

DANNY POELMANS Product Service Manager Portable Compressors & Tools

NHP-1500WCU Portable Oil-Free Compressor

Exhaust Through Ro oof

Fuel Top Hyd. Middle A/E Oil Bottom

I/C Top A/C Bottom

Sealed Base 2270 Liters

AIRFLOW~ 820m/min, ~29,000 cfm

Main Components Cummins QSX15

Main Components Cummins QSX15

Main Components Cummins QSX15

Main Components Cummins QSX15

Main Components Cummins QSX15

Main Components Cummins QSX15

Main Components Cummins QSX15

Main Components Oil-Free Compressor

Main Components Oil-Free Compressor

Main Components Oil-Free Compressor

Main Components Oil-Free Compressor

Labyrinth bearing seals

Main Components INTELLISYS Controller

Main Components INTELLISYS Controller

Main Components INTELLISYS Controller - Functions

SAFETY This machine should not be used:

Condensate burn-off, not

Mass of water precipitated @ 42.5m/min = 44.6 kg / hour = 1080 kg / day

General Operation - Transport

Compact design & 3 handling methods

Hoisted by crane Towed Fork lifted

General Operation - Installation

General Operation - Installation

General Operation - Fork Tubes

General Operation - Wheel Chocks

General Operation - Fuel Tanks

General Operation - Compressor Oil Level

General Operation - Hydraulic Oil Level

General Operation - Controls & Instruments

General Operation - Controls & Instruments 4. Start 5. Load

General Operation - Controls & Instruments

Manual operation: Starting the machine

General Operation - Controls & Instruments

2) Press the Start button

General Operation - Controls & Instruments

General Operation - Controls & Instruments

General Operation - Controls & Instruments

1200 rpm pressure

6) Pressure adjustment / setting through scroll bar and menus

General Operation - Controls & Instruments

1200 rpm 40oC

General Operation - Controls & Instruments

1800 rpm Pressure

General Operation - Controls & Instruments

1800 rpm Pressure

General Operation - Controls & Instruments

8) Take the machine off-load

General Operation - Controls & Instruments

9) Switch off the machine. Wait 3 minutes

General Operation - Controls & Instruments

10) Switch Power to Off

General Operation Start Sequence

General Operation - Emergency Stop Button