CompAir CL15SS Operation And Maintenance Manual
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CompAir CL15SS Operation And Maintenance Manual

CompAir CL15SS Operation And Maintenance Manual

Rotary screw stationary air compressor
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ROTARY SCREW
STATIONARY AIR COMPRESSOR
MODELS
CL15SS-CL20SS-CL25SS-CL30SS
CL15CUB-CL20CUB-CL25CUB-CL30CUB
OPERATION AND
MAINTENANCE MANUAL
CompAir LeROI
P.O. Box 927
211 E. Russell Road
Sidney, OH 45365-0927
Telephone: +01 (937) 498-2500
CL15SS-CL20SS-CL25SS-CL30SS
Facsimile: +01 (937) 492-3923
CL15CUB-CL20CUB-CL25CUB-CL30CUB
4391x,4393x,4394,x4395x,4396x

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  • Page 1 ROTARY SCREW STATIONARY AIR COMPRESSOR MODELS CL15SS-CL20SS-CL25SS-CL30SS CL15CUB-CL20CUB-CL25CUB-CL30CUB OPERATION AND MAINTENANCE MANUAL CompAir LeROI P.O. Box 927 211 E. Russell Road Sidney, OH 45365-0927 Telephone: +01 (937) 498-2500 CL15SS-CL20SS-CL25SS-CL30SS Facsimile: +01 (937) 492-3923 CL15CUB-CL20CUB-CL25CUB-CL30CUB 4391x,4393x,4394,x4395x,4396x...
  • Page 2 A Siebe Group Company 0897 THIS PAGE LEFT INTENTIONALLY BLANK.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ..........................4 FORWARD............................6 WARNINGS PERTAINING TO AIR SYSTEM..................7 SPARE PARTS........................... 8 SECTION I - GENERAL INFORMATION Air End............................9 Air and Oil Flow..........................9 Control Function.......................... 10 Modulating Control........................10 High Temperature Shutdown Switch ....................10 Safety Shutdown .........................
  • Page 4 Shut Down..........................27 Preventive Maintenance........................ 27 Daily ............................27 Every 200 Hours.......................... 28 Every 1000 Hours ........................28 SECTION VI - CONTROLS AND ADJUSTMENT PROCEDURES Controls............................29 Modulating Control - Control Pressure Regulator (CPR) Valve Adjustments........29 SECTION VII - SERVICE PROCEDURES - COMPONENTS Control Pressure Regulator Valve Service ..................

  • Page 5: Safety Notice

    SAFETY NOTICE CompAir LeROI strives through constant research and development to provide this equipment with every necessary safety device. This manual contains numerous “Warnings,” “Cautions” and “Notes” intended to protect the equipment from damage and the operator from injury. However, none of these is a substitute for safe operating procedures.
  • Page 6 Safety instructions in this manual will appear as follows: DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury, death or substantial property damage if the warning is ignored. WARNING Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored.

  • Page 7: Forward

    FORWARD This manual contains vital information for the safe use and efficient operation of this unit. It must be read carefully and understood before installing, operating or servicing the unit. Failure to adhere to the instructions and warnings will expose operator or service personnel to the risk of serious injury or death.
  • Page 8 WARNINGS RELATING TO AIR SYSTEMS 1. All service piping to and from the compressor must take into account pressure, temperature, vibration, corrosion and chemical resistance. Special attention should be given to the compatibility of the lubricant used and the system piping and accessories. 2.

  • Page 9: Warnings Pertaining To Air System

    CAUTION Use only genuine CompAir LeROI replacement parts. The use of other than genuine parts may cause machine malfunctions, exposing the operator to injury and the machine to damage. The use of other than genuine parts will also void the CompAir LeROI warranty.

  • Page 11: Section I - General Information

    AIR AND OIL FLOW Example: CL20 CUB Air circulates through the system beginning CL-CompAir LeROI at the air cleaner, passing through the intake valve and into the air end where it is 20 - Horsepower required to drive the air end compressed.

  • Page 12: Control Function

    The control pressure regulator valve will, at Final air/oil separation is obtained using a the maximum operating pressure, hold the composition material “can” type separator intake valve completely closed, fully element to provide nearly oil free air at the unloaded. separator out or service connection.

  • Page 13: Component Function

    occur when the discharge temperature The air receiver/oil reservoir provides an oil reaches the pre-set maximum discharge sump, primary oil separation and a mounting air temperature setting. location for the separator element. The separator element is mounted at the top of FIGURE 5 the air receiver/oil reservoir and held in place by the receiver/reservoir cover.

  • Page 14: Minimum Pressure/Check Valve

    minimum pressure of 60 to 70 psi in the air This normally closed valve is opened by receiver/oil reservoir regardless of service or control pressure when the unit is running distribution piping pressure. unloaded. In addition, this valve checks the return flow of When the unit is running unloaded (intake air from the system receiver (storage tank valve closed) a small amount of air is allowed...
  • Page 15 OPERATING PRESSURE BEFORE MAKING ADJUSTMENTS.

  • Page 16: Section Ii - Compairtroller

    SECTION II COMPAIR TROLLER The following is provided. • The Micro Controller used on the CL Indication that air filter needs service • compressors is designed to accept three (3) Indication that oil filter needs service • analog inputs and eight (8) digital inputs.

  • Page 17: Oil Cooler

    The “Select” Button will scroll through several parameters. This may be done any time if Settings may be changed by pressing UP or compressor is running or not running. The DOWN button until desired valve shows on parameters are displayed as follows: display.
  • Page 18 Filter Diff. OVERLOAD LOCATED Pressure STARTER ENCLOSURE. “dpOil” High Oil Filter Diff. Pressure *Oil Service Hrs Oil Life Expired *Fltrs. Service Hrs Filter Life Expired FEFLT Metal in Oil (Optional) * LED and Display flash alternately. The following faults will be indicated and cause unit to shut down or not start: DISPLAY CONDITION...

  • Page 19: Service Menu

    SERVICE MENU To set the service timers in the CompAirTroller (CAT) the service menu must be accessed. To access the menu and set times, proceed as follows. When the compressor is stopped, the service menu is accessed by holding in both “UP”↑ and “Down”↓...

  • Page 20: Factory Menu

    FACTORY MENU In the event that a CompAirTroller (CAT) has to be replaced additional programming to that done by user and service personnel is required. After the unit is powered up the “Factory Menu” is accessed by holding in both “UP”↑ and “DOWN”↓ arrow keys simultaneously for ten (10) seconds.
  • Page 21 COMPRESSOR CONFIGURATION MODELS (FACTORY PRESET PARAMETERS) TABLE B Unload Blow Time Design Starts Down Before Press. Accel. per Max. Model Time Time Stop Load Unload Limit Time Time Hour Temp...

  • Page 22: Section Iii - Specifications - General Specifications Chart

    SECTION III SPECIFICATIONS - GENERAL MODEL CL15SS,CUB CL20SS,CUB CL25SS,CUB CL30SS,CUB Type Rotary Screw Rotary Screw Rotary Screw Rotary Screw Stages Type of Drive Belt Belt Belt Belt Motor Shaft Speed, RPM 1750 1750 1750 1750 Male Rotor Speed, RPM (100 psi)

  • Page 23: Lubrication - Compressor

    CAUTION CONDITIONS IN WHICH THE UNIT IS RUNNING MAY REQUIRE CHANGING THE OIL FILTER MORE OFTEN. ALWAYS RENEW THE OIL FILTER AT EACH OIL CHANGE. An oil filter restriction indicator is provided so that the pressure drop across the filter, (filter condition) may be checked.
  • Page 24 TABLE 1 TYPICAL LUBRICANT SPECIFICATIONS Non-Detergent Turbine or Hydraulic Oil or Synthetic PAO (polyalphaolefin) Lubricant Viscosity at 100°F....................160-200 SSU Viscosity at 0°F ..................11,000 SSU or Less Minimum Viscosity Index ......................90 Pour Point, °F..20° lower than lowest expected starting temperature Minimum Flash Point, °F .. 400 Rust Inhibitor..SSTM, D665 (latest) No rust after 24 hours sea water Oxidation Inhibitor..ASTM, D943 (latest) Neutral No.

  • Page 25: Mounting And Space Requirements

    TABLE II DIMENSIONS AND WEIGHTS TANK MOUNT (120 GAL.) MODEL LENGTH, IN. WIDTH, IN. HEIGHT, IN. WEIGHT, LBS. CL15SS,CUB 69.0 33.43 62.43 1075 CL20SS,CUB 69.0 33.43 62.43 1125 CL25SS,CUB 69.0...

  • Page 26: Air Supply To Compressor (Cooling And Compression)

    MINIMUM COOLING AIR FLOW Air supplied to the compressor should be free MODEL FLOW, CFM of contaminants such as paint spray mist and vapors, and other chemical vapors as well as CL15SS,CUB 1900 normally air borne dust and dirt particles. CL20SS,CUB 2650 CL25SS,CUB...

  • Page 27: Checks To Be Made At Initial Start Up

    THIS IS A REQUIREMENT OF THE ASME air end for correct rotation. CODE AND STATE REGULATIONS TO PREVENT OVER PRESSURE NOTICE CONDITION WHICH COULD CAUSE ROTATION OF THE AIR END IS CORRECT PERSONAL INJURY OR DEATH. WHEN THE INPUT DRIVE SHAFT TURNS COUNTER CLOCKWISE WHEN VIEWING A tank mounted compressor should be THE AIR END FROM THE DRIVESHAFT...

  • Page 29: Section V - Operation And Preventive Maintenance

    SECTION V OPERATION AND PREVENTIVE MAINTENANCE Satisfactory performance of a stationary It is possible, however, to obtain information screw air compressor requires a good about the wear characteristics of the machine preventive maintenance program. with continued oil testing. The oil test performed should include...

  • Page 30: Every 200 Hours

    FILL UNTIL OIL REACHES THE BOTTOM OIL SAMPLES MAY BE OBTAINED FROM OF THE FILLER HOLE. OIL MUST BE THE OIL RESERVOIR (AT FILLER, NOT ADDED IF IT DOES NOT COVER THE DRAIN) OR FROM THE OIL SYSTEM SIGHT GAGE. SAMPLE VALVE LOCATED NEAR THE OIL FILTER.

  • Page 31: Section Vi - Controls And Adjustment Procedures

    SECTION VI CONTROLS AND ADJUSTMENT PROCEDURES CONTROLS 1. Install/connect pressure test gages (minimum pressure range 200 psi), if Adjustment to all controls are made very required, in place of the existing air carefully at the factory. However, it may be pressure gages.
  • Page 32 Observe that the CPR valve control pressure (modulated) rises and unloads the compressor at the rated full unload pressure. 8. Shut the unit down and remove all test equipment. Restart, check for and correct any leaks.

  • Page 33: Section Vii - Service Procedures - Components

    SECTION VII SERVICE PROCEDURES - COMPONENTS CONTROL PRESSURE REGULATOR The intake valve may be obtained as a VALVE SERVICE (Figure 11) complete assembly, if required. Service parts are available, however, to repair the intake The control pressure regulator valve is valve is desired.

  • Page 34: Minimum Pressure/Check Valve Service

    COVER THE AIR END INLET PORT TO deform the o-ring seal. PREVENT FOREIGN MATTER FROM 15. Install the two operating piston springs ENTERING THE CYLINDER. into the valve body. 16. Coat the threads of the piston (spring) 4. Using a flat bladed tool remove the valve retaining cap with Locktite 271 or plate seal ring (o-ring) retaining ring.

  • Page 35: Blow Down (Dump) Valve

    VALVE SERVICE piston, with the spring, in the large piston. minimum pressure valve 12. Lubricate the o-ring seal on the piston purchased as an assembly if required. with a silicone base lubricant. (Example, Service parts are available, however, to Dow Corning 55M). repair/overhaul this valve.

  • Page 36: Air End

    To install a new separator element, reverse input shaft. the above removal sequence. Make certain 5. Remove the oil seal face insert, with o- the flange and cover surfaces are clean. ring seal, from the seal retainer. Discard the face insert, with o-ring seal. Make certain the element flange gaskets 6.

  • Page 37: Fan Drive Shaft Oil Seal Replacement

    3. Shaft Seal Assembly 8. Lubricate the new seal face insert with 4. Spring clean compressor oil and install the seal 5. Spring Guide retainer. 6. Outer Seal 9. Lubricate the rotary seal assembly with clean compressor oil, including the 9.

  • Page 38: Belt Installation And Adjustment

    performance for specific combinations of motor horsepower and system pressure requirements. Initial belt tensioning will rapidly drop off during the first fifty to one hundred hours of compressor operation. Therefore, belt tension should be monitored daily during this period to minimize belt wear. A belt that is too loose will slip, causing excessive heat and accelerated wear.

  • Page 39: Section Viii - Service Diagnosis Service Diagnosis

    SECTION VIII SERVICE DIAGNOSIS MALFUNCTION POSSIBLE CAUSE REMEDY Motor will not run 1. Blown branch circuit fuse. 1. Renew fuse(s). 2. Blown line disconnect fuse 2. Renew fuse(s) or reset or tripped circuit breaker. circuit breaker. 3. Blown control circuit fuse(s). 3.
  • Page 40 MALFUNCTION POSSIBLE CAUSE REMEDY Compressor fails 4. Motor not running up to 4. Check power supply to motor continued. speed. and correct as required. 5. Drive belts loose and 5. Replace and/or retention slipping. drive belts. 6. Damaged or excessively 6.
  • Page 41 MALFUNCTION POSSIBLE CAUSE REMEDY Air receiver-oil control pressure or control lines continued regulator valve supply and control air lines. b. Incorrectly adjusted b. Adjust controls. control pressure regulator valve. c. Dirty, clogged, or c. Clean, repair or replace damaged control regulator valve.

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Cl20ssCl25ssCl30ssCl15cubCl20cubCl25cub ... Show all

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