CompAir L37S-75, Operating Instructions Manual

Page 1: ...ating instructions Issue December 2000 Ident no 100 00 2288 00 Screw compressor L37S 75 Operating instructions Issue December 2000 Ident no 100 00 2288 00 Screw compressor L37S 75 Umschlag aus Umschlag ein ...

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Page 3: ... ensures that your screw compressor can meet all the requirements placed upon it It is therefore indispen sable to adhere to prescribed servicing and mainte nance intervals and to carry out servicing and upkeep thoroughly especially in the case of harsh operating conditions 1 Foreword Servicing Please contact your authorized CompAir dealer in the case of malfunction or when spare parts are require...

Page 4: ...structions contain important notes on how to operate the compressor safely properly and cost effec tively Observing these instructions helps to avoid risks to reduce repair costs and downtimes and to increase the reliability and service life of the machine unit The operating instructions have to be supplemented by the respective national rules and regulations regard ing the prevention of accidents...

Page 5: ...ling air volume minimum cross sections 24 6 2 Compressed air connection 24 6 3 Water connection for W version 26 6 4 Electrical connection 27 6 5 Oil level check 29 6 6 Sound pressure level 29 7 Commissioning 30 7 1 First commissioning 30 7 2 Routine commissioning 30 7 3 Commissioning after malfunction 31 7 4 Operating modes 31 7 5 Setting of the operating pressure 31 7 6 Monitoring 31 8 Servicing...

Page 6: ...nces of operations personnel assigned to certain tasks are to be added to the operating manual The personnel entrusted with working on the machine must have read the operating instructions and in partic ular the chapter on safety regulations before starting work Reading the instructions after work has begun is too late This applies especially to persons working only occasionally on the machine e g...

Page 7: ...correct method of lifting according to the opera ting instructions of the load suspension device has to be ensured All blind flanges plugs caps and bags with drying agent have to be removed prior to the installation of the pipes Distributing pipes and pipe connections have to be of the proper size and suitable for the relevant ope rating pressure The system has to be installed in such a way that i...

Page 8: ...take air Pipes and or other parts with a surface temperature higher than 70 C have to be suitably identified and shielded against touching Electrical connections must meet the local regula tions Power units must be connected to earth and pro tected from short circuits by means of fuses all wires are connected correctly and are in good condition all safety valves and other pressure relief mecha nis...

Page 9: ...en left inside these units Be careful when the screw compressor system is in operation Maintenance rectification of faults The employer has to inform the employee of the dan gers possibly arising during the repair and mainte nance of the machine unit as well as on how to avoid them the employee has to observe all measures for safety at work Safety equipment for the prevention or elimination of dan...

Page 10: ...th the specific instructions 3 Safety regulations ously touched by the personnel must not be removed before these parts have cooled down to room tempera ture Check the accuracy of pressure and temperature indi cators at regular intervals If the admissible tolerance li mits have been exceeded these devices have to be re placed Before removing or overhauling a compressor a mo tor or another machine ...

Page 11: ...ed before carrying out any repair work Hydraulic and compressed air lines must be laid and fitted properly Ensure that no connections are ex changed The fittings lengths and quality of the hoses must comply with the technical requirements Oils greases and other chemical sub stances When handling oils greases and other chemical sub stances observe the safety regulations for this product Be careful ...

Page 12: ...anations Carefully read the operating manual before commissioning or servicing this compressor Never operate the machine without protective equipment fitted Never breath in compressed air from this system 3 Safety regulations ...

Page 13: ...13 Warning Hot surface 3 Safety regulations Warning Never operate the unit with open doors or loose access panels Warning Pressurized part or system ...

Page 14: ...system can start up by means of a remote control or automatically after a power failure 3 Safety regulations Warning The system continues to run for 30 seconds after pressing the O key Warning Danger of electric shock ...

Page 15: ...e after approximately 100 operating hours For further details see the operating instructions Attention Check and if required re tighten connection terminals For further details see the operating instructions Lifting point 3 Safety regulations ...

Page 16: ...16 Attention Only lubricate the system while the motor is running For further details see the operating instructions 3 Safety regulations ...

Page 17: ... 12 Panel 13 Switch cabinet 1 Pressure reservoir 2 Oil filter 3 Oil cooler 4 Pressure holding and check valve 5 Operating panel control 6 Screw compressor 7 Air cooler Fig 3 4 Design and functioning 4 1 Design of the air cooled unit 12 11 1 13 5 9 8 6 3 7 2 10 7 1 4 2 3 ...

Page 18: ...alve 5 Operating panel control 6 Screw compressor 7 Air cooler 8 Cooling water solenoid valve 9 Manual control valve 10 Pressure pipe to the mains 11 Support frame 12 Cooling water outlet 13 Cooling water inlet 14 Electric motor 15 Air filter 16 Cooling air ventilator 17 Switch cabinet Fig 4 4 Design and functioning ...

Page 19: ... pressure B3 Sensor outlet of the oil fine separator S3 Pressure monitor S5 Differential pressure oil filter S6 Differential pressure fine separator S7 Differential pressure air filter S8 Oil injection pressure S10 Direction of rotation monitor S12 Oil level S13 Bearing monitor SPM Y1 Regulating valve Y4 Blow off valve Y6 Cooling water sole noid valve WS only option Pressure holding check valve 16...

Page 20: ...ressure reservoir 6 is depressurized If the mains pressure does not fall to the minimum va lue set at pressure monitor 17 or at the sensor of the mains pressure B1 within 6 minutes the system shuts down The cooling water solenoid valve 29 only WS units de energizes and closes If the minimum value preset at pressure monitor 17 or at the sensor of the mains pressure B1 is reached in less than 6 minu...

Page 21: ...6 is bled via the solenoid valve 20 and actuating cylinder 2 1 into the in take channel Stopping of the system After pressing the OFF key on the operating panel the solenoid valves 19 20 are de energized The pressure control valve 2 2 in the intake regu lator 2 closes and the system is relieved After approximately 30 seconds the electric motors 3 25 shut down The cooling water solenoid valve 28 on...

Page 22: ...are approximate values they refer to a screw compressor unit including oil fill Version L34S approx 1165 kg L45 approx 1260 kg L55 approx 1370 kg L75 approx 1460 kg A A A B B B A 0 9 m B 0 9 m Fig 7 5 2 Installation Danger The foundation weight carrying capacity has to be taken into account Provide for a solid and plane base The intakes are to be located so that no hazar dous constituent solvent v...

Page 23: ...m mend a minimum cross section of approx 0 4 m2 Important The stated minimum cross section refers to a ma ximum duct length of 5 m and a maximum of one bend In case of differing values over 5 m more than one bend filter cartridges screens etc plea se contact your technical adviser CompAir screw compressors are rated for ambi ent temperatures and cooling air temperatures of 1 C to 40 C In the case ...

Page 24: ...o be fitted to allow the observan ce of the draining of such liquids Hand operated drain facilities have to be actuated in accordance with the operating instructions Automatic drain facilities have to be checked for pro per function at regular intervals When draining con densates into a collecting line which also collects the condensate from other machines make sure that the collecting line is fre...

Page 25: ... in order to avoid an increased precipitation of lime Important During danger of frost or extended periods of standstill of the screw compressor unit the cooling water is to be drained Maintenance and repair work must be carried out carefully Dismantled bundles of pipes have to be checked for damage prior to being reinstalled In the case of even the slightest damage the pipes have to be re placed ...

Page 26: ...ds on the individual ambient and instal lation conditions on site For safety reasons the exact setting values should be obtained from the manufactur er Isetting Inom x 1 15 x voltage correction if required Inom see nameplate Compressed air stations are finished in the factory ac cording to standard EN60204 industrial machinery Please observe the following notes Danger The customer has to connect a...

Page 27: ...ntrol power transformer jeopardizes the trouble free operation of compres sor units and can result in malfunction or damage The verification of the control power transformer setting is a must during commissioning and peri odic inspection maintenance as the voltage supply conditions may vary The correct setting should be checked in on load operation of the unit by measuring the control po wer trans...

Page 28: ... regular intervals The oil should have settled and the air entrapped should have been dispersed This procedure may take up to one hour depending on the conditions The max oil level is in the middle of the upper oil le vel sight glass the min oil level in the middle of the lower oil sight glass fig 14 If required top up oil See also chapter 8 Maintenance air cooled water cooled A W L37S 71 70 L45 7...

Page 29: ...e LCD displays will li ght up for a display test For testing purposes all LEDs and segments on the operating panel light up Danger Make sure before commissioning that nobody is in the danger zone of the motor screw compressor Only operate the screw compressor with closed access panels The safety valve can be hot as a result of prece ding operation A functional check must only be car ried out at op...

Page 30: ...ly be restarted when the Θ acknowledgement key has been pressed Start the screw compressor unit by pressing the I key Important The operating pressure is indicated on the name plate fig 2 A higher setting of the operating pressure is not permitted It is possible to reduce the operating pressure to a minimum of 5 bar The admissible maximum number of motor cycles is controlled by the DELCOS electron...

Page 31: ... any maintenance work by slowly opening the plug oil fill port with integral venting bore The customer installed main switch is set to O OFF Warning Electrical voltage Only work on the screw compressor unit when it is disconnected 8 Servicing and maintenance In order to facilitate this task the scope of supply of the screw compressor unit comprises the Maintenance and inspection manual for CompAir...

Page 32: ...minals in the switch cabinet electric motor and check the set ting of the control power transformer W 8 Check retighten bolted connections W 9 General maintenance cleaning in the case of a very dirty atmosphere short en the cleaning intervals as required W10 Replacement of V belt recommendation complete kits only Servicing and maintenance intervals These maintenane intervals have to be observed Af...

Page 33: ...etely if possible since used oil reduces the ser vice life of the new oil fill considerably Lubricants of different types should not be mixed When changing over to a new oil type the oil in the oil circuit must be drained completely Fig 21 Danger The oil must only be changed when the screw compressor is out of operation and depressurized Be careful when draining hot oil Danger of scal ding Note Co...

Page 34: ...tridges The operating conditions e g coolant temperatures the operating modes and the quality of the intake air e g content of dust content of gaseous foreign matter such as SO2 solvent vapours etc have a strong influ ence on the oil change intervals For such applications the required changing intervals could be shorter Note Dispose of the fine separator cartridge in line with the regulations spec...

Page 35: ...ctor lower part of the housing Attention Take note of the marking for the correct position Close the air filter with the lower part of the housing The spring latches must snap into place Changing intervals of oil fine separators The operating conditions e g coolant temperatures the operating modes and the quality of the intake air e g content of dust content of gaseous foreign matter such as SO2 s...

Page 36: ... g coolant temperatures the operating modes and the quality of the intake air e g content of dust content of gaseous foreign matter such as SO2 solvent vapours etc have a strong influ ence on the service life of the filters air filters oil filters fine separators For such applications the required changing intervals could be shorter 8 8 Safety valve Intermediate cleaning of the air filter by rinsi...

Page 37: ...djustment after the first installation or a repla cement of the V belt set the compression spring has be pretensioned For this purpose a blue marking is provi ded on the threaded rod Fig 27 8 10 Connecting terminals in the switch cabinet When replacing the V belt set the automatic tensioning system must be stressrelieved by means of the nut 14 fig 27 After the replacement of the V belts the nut 14...

Page 38: ...can be found on the in dividual motor nameplates Note In the case of 60 Hz drive strictly observe the infor mation on the nameplate For lubrication use lithium saponified roller bearing grease that meets the following requirements Consistence class NLGI 3 Worked penetration 220 250 Drop point 180 C Ash content 4 Water content 0 4 This corresponds to lubricating grease to DIN 51 825 part 1 KH 3R Ro...

Page 39: ...ns for station ary compressors Lubricant recommendation Please note that proper lubrication significantly ex tends the service life of your compressor system According to the regulations for the prevention of acci dents in connection with compressors issed by the German social insurance against occupational acci dents VBG 16 lubricants must be used whose proper ties comply with the operating condi...

Page 40: ... 3 Connecting terminals in the switch 3 Check and re tighten cabinet are loose 4 No or insufficient pressure builds up 4 Check the pressure holding valve and the in the pressure reservoir during the opening function of the intake regulator phase 5 Oil too viscous 5 Select the type of oil according to the ambient conditions or install an auxiliary heater 6 E appears on the display 6 Check sensors c...

Page 41: ...d solenoid valves 19 20 2 System not unloaded 2 Check solenoid valve 19 and lines Oil in the compressed air 1 Oil fine separator defective 1 Replace 2 Oil foams 2 Change oil blow off time too short 3 Oil level too high 3 Drain off oil 4 Opening pressure of the pressure 4 Check pressure holding valve control valve too low 5 Check valve 14 defective 4 Replace check valve Oil in the air filter 1 Pack...

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Page 44: ...5469 Simmern Deutschland Tel 49 0 6761 832 0 www compair com e mail sales compair com CompAir is an Invensys company CompAir UK Ltd High Wycombe Hughenden Avenue High Wycombe Buckinghamshire HP13 5SF United Kingdom Tel 44 01 1494 605 0 CompAir Drucklufttechnik GmbH Argenthaler Str 11 55469 Simmern Deutschland Tel 49 0 6761 832 0 www compair com e mail sales compair com ...