CompAir EO40/0001, User Manual

Page 1: ...Compressors Serial numbers from GB BR1815BA 08 2004 V100 EO40 0001 V150 EO41 0001 VL200 EO42 0001 VL300 EO43 0001 VL200D V100D EO44 0001 VL400D V300D EO55 0001 VL300D V150D EO45 0001 V200 EO50 0001 V3...

Page 2: ...work of CompAir Distributors backed up by the AfterMarket division at Redditch If replacement parts are needed the user should contact the local Distributor in the first instance The information given...

Page 3: ...V150D EO45 0001 V200 EO50 0001 V300 EO51 0001 VL400 EO52 0001 V200D EO54 0001 Section Page 1 Safety Procedures 5 2 General Description 11 3 Leading Particulars 15 4 Installation 19 5 Operation 25 6 Ma...

Page 4: ...Delivery Date Compressor Lubricant Lubricant Capacity Motor Bearing Grease If applicable LOCAL COMPAIR DISTRIBUTOR Address Fax Contact Names Parts Service Model Serial Number Year Maximum Pressure kW...

Page 5: ...anual AC20160 1157 Parts Lists C20160 1143 V100A to V300A V100W to V300W C20160 1467 VL200A C20160 1468 VL300A C20160 1469 VL400A C20160 1470 VL200DA C20160 1471 VL300DA C20160 1472 VL400DA C20160 137...

Page 6: ...Air may lead to failures in service which would not be covered by warranty z Any unauthorised modifications or failure to maintain this equipment in accordance with the maintenance instructions may ma...

Page 7: ...anual Page General 6 Warnings Cautions and Notes 6 General Safety Precautions 7 Installation Precautions 7 Operational Precautions 7 Maintenance and Repair Precautions 8 Precautions in the Event of Fi...

Page 8: ...cedure an item of equipment or a method of working which is not specifically recommended by CompAir he must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons...

Page 9: ...eing sucked into the air intake Ensure that the air delivery pipe from the compressor to the user s pipework aftercooler or receiver is free to expand and that no flammable material is within the vici...

Page 10: ...wn The compressor must not be operated at pressures above the nominal pressure given on the data plate The compressor must not be operated in ambient temperatures outside of those given under Leading...

Page 11: ...ding work or other modification be carried out on the reclaimer or any other pressure vessel Before dismantling of any part of the compressor unit ensure that all heavy movable parts are secured After...

Page 12: ...CompAir Limited page 10...

Page 13: ...page 11 V100 VL400 User Manual Page Compressor 12 Safety Devices 12 Instrument Panel 12 Lubrication System 12 Regulation System 13 Air Governor Control 13 Control Panel 13 2 GENERAL DESCRIPTION...

Page 14: ...sshead carried on the connecting rod small end Ventilated distance pieces fitted between the crankcase and the cylinders incorporate the crosshead guide sleeves and gland assemblies which prevent oil...

Page 15: ...re switch solenoid valve runon timer and a solenoid timer It operates in conjunction with a separately mounted automatic contactor type starter for the compressor The panel carries a HAND OFF AUTO sel...

Page 16: ...CompAir Limited page 14...

Page 17: ...page 15 V100 VL400 User Manual 3 LEADING PARTICULARS...

Page 18: ...ure Running speed Working pressure V F2 VL200A F2 VL200DA F2 V300DA F3 All other VL300A F2 VL300DA F2 only V F3 VL400A F2 VL400DA F2 models 7 bar 3 5 bar 2 4 bar 8 6 bar 10 3 bar V150 V300 VL200 VL400...

Page 19: ...stage models V100 V150 V100W V150W VL200 VL300 4 VL400 8 8 4 V200 V300 VL400 18 Litres All other models 9 litres 1 2 5 inch 2 bar 14 litres min All water cooled intercooler models G1 2 A V200W V300W...

Page 20: ...793 658 796 728 V200DW V200W V200DA V200A V300DW V300W V300DA V300A Without motor 808 644 898 705 850 686 900 707 With motor F2 1092 875 1130 937 1245 1017 1232 1038 With motor F3 1151 913 1168 975 1...

Page 21: ...page 19 V100 VL400 User Manual 4 INSTALLATION Page General 20 Guidelines 20 Ventilation 23 Installation Procedure 24...

Page 22: ...ter cooled Baseplate with or without anti vibration mountings and Vee belt drive Control panel Acoustic enclosure Air receiver Refrigerant air dryer Air filter Non return valve desirable in multiple i...

Page 23: ...be installed in a position remote from the compressor an adaptor for the intake manifold will be required Consult the local CompAir distributor for advice regarding the dimensions of the extension pi...

Page 24: ...alves on the inlet pipes should be solenoid operated and the solenoids interconnected with the compressor starter This will ensure that the water supply is cut off when the compressor shuts down or is...

Page 25: ...4 VL200DA 29 57 0 4 V300A 85 128 1 3 1 5 0 8 V300W 85 1 3 1 5 V300DA 85 128 1 3 1 5 0 8 V300DW 85 1 3 1 5 VL300A 43 85 VL300DA 43 85 VL400A 57 114 VL400DA 57 114 Total area of ventilation inlet and o...

Page 26: ...n accordance with the diagram If an airblast aftercooler is installed the electrical wiring for the aftercooler fan motor should be interlocked with the compressor motor starter or the optional contro...

Page 27: ...page 25 V100 VL400 User Manual 5 OPERATION Page Commissioning Starting Procedures 26 Static Checks 26 Functional Checks 27 Routine Starting 27 Adjustments 28...

Page 28: ...e without entering the user s pipework 4 Fit the air intake silencer filter assembly 5 If the compressor has been in storage for a lengthy period remove all suction and delivery valves and inspect to...

Page 29: ...cylinders 7 Stop the compressor 8 Connect the air delivery manifold flange to the air receiver 9 Move the hand unloaders to the valve unloaded position start the compressor and when it is running even...

Page 30: ...ssure cut out point of the regulation system to a higher pressure than the nominal operating pressure of the compressor Operation at higher pressures than nominal will overload the drive motor and may...

Page 31: ...cording Pressures and Temperatures 30 Maintenance Record 30 Pressure Settings 30 Electrical Connections 30 Leaks 31 Regular Checks 31 Lubricating Oil 31 Maintenance Schedule 31 Maintenance Parts Two Y...

Page 32: ...regular daily record of operating pressures and temperatures The readings should be taken when conditions are stable and with the compressor running on full load 1 3 Maintenance Record Keep a careful...

Page 33: ...he correct level of oil and to change the oil completely at the specified intervals Details of the recommended oil are given in Leading Particulars 2 MAINTENANCESCHEDULE Regular maintenance should be...

Page 34: ...nternally Clean if required Every 2 500 hours Service A Air intake filter Check and clean Replace if necessary Suction and delivery valves Remove dismantle clean and inspect If necessary replace valve...

Page 35: ...contacts Inspect motor for cleanliness Check condition of cables and wiring Every 15 000 hours Service D Compressor Dismantle completely Inspect crankshaft journal bearings Check security of balance w...

Page 36: ...stage Pressure Ring 2 2 4 4 Oil Wiper Ring 2 2 4 4 Oil Scraper Ring 2 2 4 4 Seal 2 2 4 4 D 1st stage Suction Valves 2 2 4 4 1st stage Delivery Valves 2 2 4 4 2nd stage Suction Valves 1 1 2 2 2nd stag...

Page 37: ...er every 2 500 hours of service If the compressor is operating in adverse conditions such as high dust levels or the presence of chemical or other pollutants more frequent oil changes may be necessary...

Page 38: ...ssary 4 2 1 To Remove theAir Filter Element The compressor must be stopped 1 Unscrew the wingnut or slot headed nut securing the air intake cover and remove the cover 2 Remove the filter element 3 Cle...

Page 39: ...page 37 V100 VL400 User Manual 7 FAULT FINDING...

Page 40: ...alve necessary remove and clean Ball valve sticking in valve assembly open position Check seating Reset valve 6 Clogged oil filter element 6 Renew oil filter element 7 Broken or loose connections 7 Ch...

Page 41: ...ration of unloader compressor from coming mechanism on load 4 Valves faulty 4 Remove valves Inspect valve plates springs and seats Check condition of ring joints Renew as necessary 5 Leaks in user s p...

Page 42: ...ing Excessive oil 1 Incorrect oil in crankcase 1 Drain and refill with correct oil consumption 2 Oil level too high 2 Drain off surplus oil until correct level shows on dipstick 3 Worn cylinders and p...

Page 43: ...Compressor 5 Worn big end bearings 5 Remove and inspect bearings knocking cont Renew bearing shells if necessary 6 Insufficient clearance 6 Check clearance with lead strip between piston crown and an...

Page 44: ...CompAir Limited page 42...

Page 45: ...page 43 V100 VL400 User Manual APPENDIX 1 The Pressure Systems Safety Regulations 2000...

Page 46: ...components eg pressure vessels pressure relief valves etc will be defined by the competent person preparing the written scheme In defining these periods the competent person must take into account the...

Page 47: ...2 First Stage Compression Cylinder LP 3 Pressure Relief Valve 4 Intercooler 5 Auto Drain Trap 6 Second Stage Compression Cylinder HP 7 Pulsation Vessel 8 Pressure Relief Valve 9 Non return Valve 10 Af...

Page 48: ...CompAir Limited page 46...