CompAir D50H RS Operating And Service Manual
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CompAir D50H RS Operating And Service Manual

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Original Operating and Service Manual
Screw Air Compressor
D50H RS - D110H RS
V2
●
GB
Id. no. ZS1098950 / 04 - June 2014

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Summary of Contents for CompAir D50H RS

  • Page 1 Original Operating and Service Manual Screw Air Compressor D50H RS - D110H RS ● Id. no. ZS1098950 / 04 - June 2014...
  • Page 3 Genuine CompAir parts will be used. Warranty The conditions of the CompAir Warranty are set out in the Companyʼs standard Conditions of Sale available from the Gardner Denver Company or Distributor supplying the machine. USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED OUT USING NON-GENUINE PARTS.
  • Page 4 Data sheet for users Fig. 1 Your CompAir distributor Name: Address: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Telephone: Fax: Contact: Spare Parts: Service:...

  • Page 5: Foreword

    Maintenance Notes on the compressor Carefully performed maintenance is imperative, this CompAir screw compressors are the result of many ensures that your screw compressor can meet all the years of research and development. These requirements placed upon it. It is therefore imperative to...
  • Page 6 Operating errors • Incorrect maintenance • Wrong auxiliary materials • Use of spare parts other than CompAir genuine • spare parts Modifications and changes to the installation • The warranty and liability conditions of the general terms and conditions of Gardner Denver will not be extended by the notes above.

  • Page 7: Table Of Contents

    4 Design and functioning ..............................17 4.1 Design of the unit ................................17 4.1.1 Design of the water-cooled D110H RS-W .....................17 4.1.2 Design of the water-cooled D50H RS-W - D75H RS-W................18 4.1.3 Design of the air-cooled D50H RS-A - D75H RS-A..................19 4.2 Schematic diagram ..............................20 4.2.1 Schematic diagram - D110H RS ........................20...
  • Page 8 11.1.1 Technical data EUROPE version water-cooled D110H RS-W ..............51 11.1.2 Technical data EUROPE version water-cooled D75H RS-W ...............52 11.1.3 Technical data EUROPE version air-cooled D75H RS-A ................53 11.1.4 Technical data EUROPE version water-cooled D50H RS-W ...............54 11.1.5 Technical data EUROPE version air-cooled D50H RS-A ................55 11.2 Layout plan..................................56 11.2.1 Layout plan D110H RS ...........................56...

  • Page 9: Safety Regulations

    3. Safety regulations Safety re gulations Identification of safety guidelines Danger Passages marked with this sign indicate a possible Gardner Denver is not liable for any damage or injury danger to persons. resulting from the non-observance of these safety instructions or negligence of the usual care and attention required during handling, operation, Important maintenance or repair, even if this is not explicitly...

  • Page 10: Particular Dangers Associated With Compressed Air

    3. Safety regulations 3.3 Particular dangers associated with compressed air Danger Safety measure required Compressed air is very powerful. It can Never play about with compressed air. be used for example to break open concrete but can also put lives at risk. Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution compressed air can penetrate the skin...
  • Page 11 3. Safety regulations Danger Safety measure required Compression results in high The system should be set up such that hazardous mixtures (inflammable solvent vapours etc. but also dusts and other dangerous or toxic materials) temperatures. cannot be drawn in. The same applies to flying sparks. Never use the machine in environments where the possibility cannot be ruled out that inflammable or toxic vapours may be taken in.

  • Page 12: Particular Dangers Associated With Machines

    3. Safety regulations 3.4 Particular dangers associated with machines Danger Safety measure required Risk of electric shock. Electrical connections must meet the local regulations. Power units must be connected to earth and protected from short-circuits by means of fuses. Insufficient power quality could have Always check a correct power supply to the compressor before commissioning.

  • Page 13: Dangers Present When Loading/Moving Machines

    3. Safety regulations 3.6 Dangers present when loading/moving machines Danger Safety measure required Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can turn like doors etc. must be secured and made immobile. Parts to be removed for transport purposes must be carefully refitted and fixed again before putting the machine / installation back into operation.

  • Page 14: Dangers Resulting From Neglecting To Perform Maintenance

    Contact your CompAir agent. removed. If you maintain the compressor and have not been trained by CompAir, you will put yourself and others at risk. Incorrectly configured spare parts may Spare parts must meet the technical requirements laid down by the jeopardise safety, e.g.
  • Page 15 3. Safety regulations Danger Safety measure required Risk of electric shock. Work on the electrical systems of the machine / installation may only be carried out by a trained electrician in accordance with electrical regulations. The system must be secured from being switched on. Seal off the main switch and remove the key and/or attach a warning sign to the main switch.

  • Page 16: Dangers Resulting From Conversion Work/Modifications On The Machine

    3. Safety regulations 3.10 Dangers resulting from conversion work/modifications on the machine Danger Safety measure required Genuine parts are designed especially No alterations, additions, or modifications to the machine may be carried out for the machine. Modifications may without the approval of the manufacturer. Unauthorized modifications to the interfere with safety equipment or give machine are prohibited for reasons of safety.

  • Page 17: Symbols And Explanations

    3. Safety regulations 3.11 Symbols and explanations Carefully read the operating manual before Never breathe in compressed air from this system. commissioning or servicing this compressor. Never operate the unit with open doors or loose access Warning: Hot surface panels. Warning: Pressurized part or system Warning: This system can start up by means of a remote control or automatically after a power failure.
  • Page 18 3. Safety regulations Warning: The system continues to run for 30 seconds Warning: Danger of electric shock after pressing the O-key Attention: Lifting point Attention: Check and, if required, re-tighten connection terminals. For further details, see the operating instructions. Attention: Danger of electric shock from loaded condensers! Please always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components.

  • Page 19: Design And Functioning

    4. Design and functioning Design a nd functioning Design of the unit 4.1.1 Design of the water-cooled D110H RS-W Fig. 2 1 Intake filter 12 Cooling air inlet filter mat 22 Cooling water outlet 2 Suction inlet 13 Compressed air outlet 23 Fan protection panel 3 Electric motor 14 Base frame...

  • Page 20: Design Of The Water-Cooled D50H Rs-W - D75H Rs-W

    4. Design and functioning 4.1.2 Design of the water-cooled D50H RS-W - D75H RS-W Fig. 3 1 Intake filter 12 Cooling air inlet filter mat 22 Cooling water outlet 2 Suction inlet 13 Compressed air outlet 23 Fan protection panel...

  • Page 21: Design Of The Air-Cooled D50H Rs-A - D75H Rs-A

    4. Design and functioning 4.1.3 Design of the air-cooled D50H RS-A - D75H RS-A Fig. 4 1 Intake filter 11 Cooling air ventilator 20 Water cooler 2 Suction inlet 12 Cooling air inlet filter mat 23 Fan protection panel 3 Electric motor...

  • Page 22: Schematic Diagram

    4. Design and functioning Schematic diagram 4.2.1 Schematic diagram - D110H RS Fig. 5 1. Intake filter 14. Throttle 26. Bypass valve (Y11) 2. Vacuum generator 15. RS inverter 27. Cooling-water solenoid valve (Y6) 3. Electric motor 16. Blow-off line orifice 28.

  • Page 23: Schematic Diagram - D50H Rs - D75H Rs

    4. Design and functioning 4.2.2 Schematic diagram - D50H RS - D75H RS Fig. 6 1. Intake filter 15. RS inverter 28. Solenoid valve (water in) (Y8) 2. Vacuum generator 16. Blow-off line orifice 29. Solenoid valve (water out) (Y9) 3.

  • Page 24: Water Circuit

    4. Design and functioning The water supply of the screw compressor (- 4 -) is • Water circuit provided by the drop in pressure between the pressure tank (-6-) and the injection site in the (see fig. 2, fig. 3, fig. 4) screw compressor.
  • Page 25 4. Design and functioning Automatic operation If the mains pressure achieves the preset maximum • value, then the electric motor (-3-) will have its speed lowered in order to allow for the delivery amount to adapt to the actual need for compressed air.

  • Page 26: Transport And Installation

    D110H RS-W: 2200 kg water-cooled D75H RS-W 1810 kg air-cooled D75H RS-A 1890 kg water-cooled D50H RS-W 1490 kg air-cooled D50H RS-A 1570 kg Fig. 8 Note Before transporting the unit, remove the doors. The doors must be removed before lifting from the control side.

  • Page 27: Installation

    5. Transport and installation Installation Fig. 9 Danger The weight carrying capacity of the foundation • has to be taken into account when installing the compressor. Provide for a solid and plane base. • The system may not be operated on the transport •...

  • Page 28: Preparations For Commissioning

    (over 5 m/16.4 ft, more than one bend, filter cartridges, screens, etc.), please contact your technical adviser. CompAir screw compressors are rated for ambient temperatures and cooling temperatures of +2°C (35.6°F) to +45°C (113°F). In the case of temperatures other than the above limiting values, please consult your technical adviser.

  • Page 29: Water Connection For W Type

    D50H RS W approx. 80 l/min This data is based on fresh water and the cooling-water quality recommended by CompAir (see Chapter 6.3.1). Please contact CompAir if the cooling-water data diverges from this. The flow of cooling-water for the water cooler at commissioning can be adjusted by means of a manual control valve.

  • Page 30: Limit Values Of The Constituent Elements In Water

    6. Preparations for commissioning 6.3.1 Limit values of the constituent Note elements in water Wherever possible, the cooling-water outlet temperature should be below 50 °C, in order to prevent Note excessive precipitation of limestone fur. The information set out below is intended for guidance and may differ under certain conditions of operation.

  • Page 31: Electrical Connection

    6. Preparations for commissioning To establish an electrical connection, proceed as Electrical connection follows: 6.4.1 Electrical connection (EUROPE- Route the supply cable through the cable gland Version only) (-1 - Fig. 14) on the control cabinet and tighten screws. Compressor units are finished in the factory according Connect the supply line to the connecting terminals as to standard EN60204 (industrial machinery).

  • Page 32: Check Setting Of The Fan Protection Switch

    3 x 95 PE 50 380V 3 x 50 PE 25 D75H RS 400V 3 x 50 PE 25 380V D50H RS 3 x 35 PE 164G25 400V 60 Hz Compressors 380V 3 x 95 PE 50 D110H RS 460V...

  • Page 33: Checking The Control Transformer Setting

    < 50 mg / L system. Ammonium (NH4+) < 0.5 mg / L The CompAir water analysis set can be used to determine the water quality. If values that deviate from these apply, any warranty claims may be invalidated and the relevant Gardner Denver representative must be consulted.

  • Page 34: Extraction Of Water Samples

    78 dB(A) water, the requisite level of water quality will be water-cooled D50H RS-W 75 dB(A) achieved over the course of time. air-cooled D50H RS-A (50 Hz) 75 dB(A) air-cooled D50H RS-A (60 Hz) 77 dB(A) Subject to technical revision.

  • Page 35: Commissioning

    Check the setting of the control-power transformer • Important (see also chapter 6.4.3) (Fig. 15). Although every CompAir screw compressor has Check and re-tighten all connecting terminals of the • been subjected to a test run at the factory and has electrical control.

  • Page 36: Putting A Decommissioned Compressor Back Into Operation

    7. Commissioning Display of the compressor control water-cooled units DELCOS XL Fig. 18 1. Touchscreen Display 2. Start push-button [ I ] air-cooled units 3. Stop push-button [ O ] 4. red LED Flashing slowly = Warning Flashing rapidly = fault 5.

  • Page 37: Routine Commissioning

    7. Commissioning Routine commissioning Commissioning after malfunction Danger Important Make sure before commissioning that nobody is in Do not switch the screw compressor on repeatedly the danger zone of the motor/screw compressor. without having rectified the malfunction, since this may cause considerable damage to the machine. After completion of maintenance work: Verify that all safety devices have been refitted and that all Re-start after an automatic shutdown due to a...

  • Page 38: Storage Of Compressors

    8. Storage of compressors Stora ge of com press ors Shutdown All compressors are protected against corrosion at the factory for transport and for brief storage before commissioning. If the compressors are to be stored for period exceeding six months, additional precautions must be taken.

  • Page 39: Service 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 compressors”, in which you can list your performed maintenance work at the specified intervals.

  • Page 40: Function Display On Lubricator

    (The decode switches are preset and locked in the factory. They must not be changed.) f) Place drive on new LC unit until the gears mesh. Only use completely filled genuine CompAir LC units. g) Screw down drive cover to LC unit (hand tight).

  • Page 41: Troubleshooting And Fault Rectification For Lubricator

    Troubleshooting and fault rectification for lubricator If faults occur when operating the lubricator, please check the possible causes of error using the following table. If an error occurs that isnʼt listed in the table, please contact CompAir customer service. Fault...
  • Page 42 These maintenance intervals must be observed! x For your own benefit, put a cross on the servicing schedule against maintenance work when performed.  We recommend that you have the work on these parts be performed by a CompAir company or by an authorised dealer.
  • Page 43 9. Service and maintenance                                                          ...

  • Page 44: Change Of Air Intake Filter

    9. Service and maintenance Changing intervals for air filter cartridge Change of air intake filter 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 SO , solvent vapours, etc.) have a strong influence on the service life of the filters (air filters,...

  • Page 45: Replace Prefilter Ro Unit

    9. Service and maintenance Perform the water filter change as follows: Note Switch the screw compressor unit off and ensure • Before the prefilter element can be installed, the that it is depressurized, electrically isolate and element should be rinsed out with clean water so that locked off.

  • Page 46: Safety Valve

    9. Service and maintenance Safety valve Connecting terminals in the switch cabinet/control transformer setting Danger Danger of electric shock! Work on the control cabinet may only be carried • out by electrotechnical specialist personnel. When carrying out adjustment work on the •...

  • Page 47: Fittings

    9. Service and maintenance Change the control transformer setting as follows if 9.12 Clean / change filter with cooling air the output voltage is not correct: inlet and control cabinet inlet Set the main power switch to "O" (OFF) and secure •...

  • Page 48: Cleaning Of The Bearing Flushing System

    9. Service and maintenance b) Control-cabinet inlet filter (-4- Fig. 25) 9.13 Cleaning of the bearing flushing system Fig. 26 Fig. 28 Danger Only ever clean the blow-off silencer and ejector nozzle with the compressor stopped and depressurized.. Check the blow-off silencer (-1+2- Fig. 28) and •...

  • Page 49: Inspection Of The Compressor Stage

    9. Service and maintenance 9.14 Inspection of the compressor stage 9.15 Inspection intervals for pressure vessels and electrical installations Pressure vessels As per the requirements of the 97/23/EC Pressure Equipment Directive, a qualified person must inspect the pressure vessel from inside every five years. As per the requirements of the 97/23/EC Pressure Equipment Directive, an appointed body must perform a strength test on the pressure vessel after ten years.

  • Page 50: Checking The Water Level Sensor

    9. Service and maintenance If one of these limit values is not reached, then the 9.16 Checking the water level sensor water level sensor will have to be replaced. After the checking and possible replacement of the water level sensor, adjust the water level in the pressure vessel again so that it is situated between both the fill level marks (-4- and -5- Fig.

  • Page 51: Trouble-Shooting

    10. Trouble-shooting Trouble-s hooting In the case of faults or warnings that are detected by the compressor control DELCOS XL, please refer to the chapter “Fault/warning table” in the operating instructions of the DELCOS XL. Malfunction Possible cause Remedy Unit cannot be started No operating or control voltage Check fuses, main switch and supply line Malfunction not acknowledged...
  • Page 52 10. Trouble-shooting Malfunction Possible cause Remedy Excessive idling System not unloaded Check intake regulator Check solenoid pressure valves Water in the air filter Water stop valve not closing Check/ replace water stop valve Safety valve opens Safety valve defective Replace Pressure holding valve defective Check / Replace Mains pressure sensor defective...

  • Page 53: Annex

    11. Annex Annex 11.1 Technical data 11.1.1 Technical data EUROPE version water-cooled D110H RS-W Maximum operating pressure bar g 10.0 Minimum operating pressure bar g Ambient temperature °C 2 … 45 at min. speed at max. speed 5 bar Flow /min 3.37 18.55...

  • Page 54: Technical Data Europe Version Water-Cooled D75H Rs-W

    11. Annex 11.1.2 Technical data EUROPE version water-cooled D75H RS-W Maximum operating pressure bar g 10.0 Minimum operating pressure bar g Ambient temperature °C 2 … 45 at min. speed at max. speed 5 bar Flow /min 1.91 11.87 8 bar Flow /min 1.82...

  • Page 55: Technical Data Europe Version Air-Cooled D75H Rs-A

    11. Annex 11.1.3 Technical data EUROPE version air-cooled D75H RS-A Maximum operating pressure bar g 10.0 Minimum operating pressure bar g Ambient temperature °C 2 … 40 at min. speed at max. speed 5 bar Flow /min 1.91 11.39 8 bar Flow /min 1.82...

  • Page 56: Technical Data Europe Version Water-Cooled D50H Rs-W

    11. Annex 11.1.4 Technical data EUROPE version water-cooled D50H RS-W Maximum operating pressure bar g 10.0 Minimum operating pressure bar g Ambient temperature °C 2 … 45 at min. speed at max. speed 5 bar Flow /min 1.30 7.64 8 bar...

  • Page 57: Technical Data Europe Version Air-Cooled D50H Rs-A

    11. Annex 11.1.5 Technical data EUROPE version air-cooled D50H RS-A Maximum operating pressure bar g 10.0 Minimum operating pressure bar g Ambient temperature °C 2 … 45 at min. speed at max. speed 5 bar Flow /min 1.30 7.64 8 bar...

  • Page 58: Layout Plan

    11. Annex 11.2 Layout plan 11.2.1 Layout plan D110H RS Fig. 32 (all dimensions in mm)
  • Page 59 11. Annex Fig. 33 (all dimensions in mm)

  • Page 60: Layout Plan D50H Rs-D75H Rs

    11. Annex 11.2.2 Layout plan D50H RS-D75H RS cooling air (all dimensions in mm) Fig. 34...
  • Page 61 11. Annex (all dimensions in mm) Fig. 35...

  • Page 62: Declaration Of Conformity

    Kompressor that the product: type: D15H; D15H RS; D22H; D22H RS; D37H; D37H RS; D50H RS; D75H RS; D110H RS trade mark: manufacturer no.: in the form as shipped by us complies with the following relevant provisions: 2009/ 105/ EG...
  • Page 64 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 www.compair.com e-mail: sales@compair.com...

This manual is also suitable for:

D110h rs

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