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Installation standards and requirements of Atlas Copco air compressors
Computer room installation requirements
The ground is smooth and clean concrete, the inner surface of the wall should be white, the compressor base should be placed on the concrete floor, and the level of the plane should not be greater than 0.5/1000 (mm). There are grooves around 200mm away from the unit, so that oil and water can flow away from the groove when the unit is stopped for oil change, maintenance or scouring to clean the ground. The size of the groove is determined by the user.
The compressor unit is placed on the ground, and it should be ensured that the bottom of the box is in good contact with the ground to prevent vibration and increase noise.
For qualified users, sound-absorbing panels can be attached to the walls of the computer room to further reduce noise, but it is not advisable to use hard surface materials such as ceramic tiles to decorate the walls.
Since the air-cooled compressor is greatly affected by the ambient temperature, the ventilation of the machine room should be good and dry.
There is little dust in the computer room, the air is clean, and there is no harmful gas or corrosive medium. According to the nature of the products processed by your company, the air inlet should be equipped with a primary filter device. The effective area of window circulation should be greater than 3㎡
3 Requirements for power supply and peripheral wiring
The main power supply of the compressor is AC (380V/50Hz) three-phase, and the freeze dryer is AC (220V/50HZ). Please confirm the power supply.
The voltage drop cannot exceed 5% of the rated voltage, and the voltage difference of each phase is within 3%.
The compressor power supply must be equipped with an isolating switch to prevent the short circuit from causing phase loss operation.
Check the secondary circuit fuse, and select an appropriate no-fuse fuse switch according to the power of the compressor.
The compressor uses a separate power system to avoid parallel use with other different power consumption systems, especially when the power of the compressor is large, the compressor may be overloaded due to excessive voltage drop or unbalanced three-phase current, causing the protection device Action jump.
The grounding wire must be grounded to prevent danger caused by leakage, and must not be connected to the air delivery pipe or cooling water pipe.
4 Requirements for pipeline installation
The air supply port of the unit has a threaded pipe, which can be connected to your air supply pipeline. Please refer to the factory manual for installation dimensions.
In order to avoid affecting the operation of the whole station or other units during maintenance, and to reliably prevent the backflow of compressed air during maintenance, a shut-off valve must be installed between the unit and the gas storage tank.
In order to avoid affecting air consumption during filter maintenance, spare pipelines should be provided on each filter pipeline.
The branch pipeline must be connected from the top of the main pipeline to prevent the condensed water in the pipeline from flowing into the compressor unit.
The pipeline is as short and straight as possible, reducing elbows and various valves to reduce pressure loss.
5 Connection and arrangement of air lines
The main line of the compressed air pipeline is 4 inches, and the branch line uses the existing pipeline as much as possible.
The pipeline should generally have a slope greater than 2/1000, with a drain valve (screw plug) at the lower end, and the pipeline should be less curved, short, and straight.
When the underground pipeline passes through the main road surface, the buried depth of the pipe top shall not be less than 0.7m, and the secondary road surface shall not be less than 0.4m.
The installation position and surface size of the pressure and flow instruments should enable the operator to see the indicated pressure clearly, and the pressure scale range should be such that the working pressure is at 1/2 to 2/3 of the dial scale.
After the system is installed, the air pressure strength and air tightness test should be carried out, and the water pressure test should not be carried out. The pressure is 1.2 to 1.5 times that of the same gas, and no leakage is considered acceptable.
6 Anti-corrosion of air pipelines
After the installation is completed and the pressure test is qualified, after removing the dust, dirt, rust spots, welding slag and other objects on the surface, paint the anti-corrosion treatment. Pipe painting has the effect of anti-corrosion, prolonging the service life of the pipeline, and also easy to identify and beautiful. Generally, apply anti-rust paint on the surface first, and then apply the specified blending paint.
7 of the air line
Once the high-voltage electricity induced by lightning in the pipeline is introduced into the workshop pipeline system and gas equipment, it will cause equipment personal safety accidents. Therefore, the pipeline should be well grounded before entering the workshop.
8 Pipeline pressure loss
When the gas flows in the pipe, frictional resistance is generated in the straight pipe section; local resistance is generated at the valve, tee, elbow, reducing pipe, etc., resulting in gas pressure loss.
Note: The total pressure drop of the pipeline should also be added to the partial pressure loss caused by elbows, reducers, tee joints, valves, etc. These values can be found from the relevant manuals
Regardless of whether the user uses an oil-free machine or an oil-filled machine, or whether the user uses an air-cooled compressor or a water-cooled compressor, the ventilation problem of the air compressor room must be solved. According to our past experience, more than 50% of air compressor failures are due to neglect or misunderstanding of this aspect.
When the air is compressed, a large amount of heat will be emitted. If the heat cannot be discharged from the air compressor room in time, the room temperature of the air compressor room will gradually increase, so that the temperature of the air compressor suction port will increase. The higher it is, such a vicious cycle will cause the air compressor exhaust temperature to be high and alarm, and at the same time, due to the low density of the high-temperature air, the gas production will be reduced.
Remarks: For water-cooled compressors, most of the heat is transferred to the cooling water through the heat exchanger, and the heat is taken away by the cooling water. At this time, only a small ventilation fan needs to be set to send a small part of the main motor. Just take the heat away. For air-cooled compressors, a large amount of fresh air is required to exchange the heat generated during the compression process, so the inlet of the fresh air must be considered, which can be close to the cooling air intake of the air compressor (for the compression part the air inlet can also be close to the fresh air inlet).
If necessary, a separate air duct can be set to introduce fresh air, so as to avoid the hot air of the air compressor from affecting the cooling process. Of course, this depends on the structure of the air compressor and the customer’s situation. Generally speaking, it is necessary to set up air ducts to export the hot air after heat exchange out of the air compressor room, and if necessary, set up fans or fans at the outlet to enhance the export effect of hot air.
The fresh air inlet mentioned above needs to be set at the low position of the air compressor room, and the hot air outlet (including the corresponding fan or fan) should be set at the high position, because the density of the hot air is small, it will generally stay at the high position, so the setting will have It is conducive to the export of hot air, and at the same time, it will prevent the exhausted hot air from entering the air inlet again and short-circuit the air flow.
In addition, it should be noted that the fresh air inlet and the hot air outlet are respectively arranged on two opposite walls. The purpose of this is also to prevent the exhausted hot air from entering the air inlet again and short-circuiting the air flow. A dust-proof grid is set at the fresh air inlet to prevent more dust or catkins and other debris from entering the air compression room, and a rain cover is set at the outlet of the hot air to prevent rainwater from flowing into the hot air duct.
No matter the air duct of the air inlet or the air duct of the air outlet, a relatively large diameter reduction or elbow should be avoided, because it will cause relatively large ventilation resistance and affect the ventilation effect. Because the air in the compressed room is continuously used for compression and cooling, and the supplement of fresh air is generally passive, it is normal to maintain a certain negative pressure in the compressed room.
However, if the negative pressure value exceeds the allowable value, it means that the size of the air inlet or the air intake volume needs to be improved, because the negative pressure value will cause the cooling effect to deteriorate and the exhaust volume to decrease.
