CompAir L15 Operating And Service Manual
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CompAir L15 Operating And Service Manual

Screw air compressor
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Original Operating and Service Manual
Screw Air Compressor
L90 - L140
L90RS - L132RS
V3
●
GB
Id. no. ZS1068322 / 10 - November 2015

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  • Page 1 Original Operating and Service Manual Screw Air Compressor L90 - L140 L90RS - L132RS ● Id. no. ZS1068322 / 10 - November 2015...
  • Page 3 Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or Distributor who is supplied with revised and up-dated information.
  • Page 4 Data sheet for users Fig. 1 *) The values on the type plate are maximum values. 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

    2. Table of contents Tab le of co nte nt s 1 Foreword ....................................3 1.1 Notes on the compressor............................. 3 1.2 Intended use ................................. 3 1.3 Maintenance ................................. 3 1.4 Notes ..................................... 3 2 Table of contents ................................5 3 Safety regulations ................................
  • Page 8 2. Table of contents 9 Service and maintenance ..............................39 9.1 Maintenance recommendations ..........................39 9.2 Maintenance electric motor ............................39 9.2.1 Motor lubrication system ..........................39 9.2.2 Structure of the lubricators..........................39 9.2.3 Changing the LC unit ............................ 39 9.2.4 Special lubrication ............................

  • Page 9: Safety Regulations

    3. Safety regulations Safet y r eg ula tio ns Identification of safety guidelines Danger Gardner Denver is not liable for any damage or injury indicates a directly dangerous situation resulting from the non-observance of these safety which, if not protected against, could result instructions or negligence of the usual care and in death or serious (irreversible) injuries.

  • 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 temperatures. Risk of explosion from solvent vapours etc. but also dusts and other dangerous or toxic materials) drawn in materials. cannot be drawn 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: Particular Dangers Associated With Water-Cooled Units

    3. Safety regulations 3.5 Particular dangers associated with water-cooled units Danger Safety measure required If open cooling towers are used in the The growth and spread of bacteria must be prevented by corresponding service cooling water circuit, it is possible for and water treatment methods.

  • Page 14: General Workplace Dangers

    3. Safety regulations 3.7 General workplace dangers Danger Safety measure required This manual only describes how to work Please note and pass on general statutory and other binding regulations that safely with the compressor itself. But may supplement the operating manual for the prevention of accidents and the other dangers will arise during work.

  • Page 15: Dangers During Maintenance And Repairs

    Only persons with special knowledge and experience of hydraulics may work compressor and have not been trained on system elements, for example components under pressure. 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 16 3. Safety regulations Danger Safety measure required Risk of injury from pressurised or Only carry out inspection, maintenance, and repair work when the screw com- pressor system is at a standstill and is not under pressure. The system must moving parts. be secured from being switched on.

  • Page 17: 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 18: 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 19 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 20 3. Safety regulations Attention: Before disassembling the tube bundle, the intake union must be disassembled! (Only for Lxx W – water-cooled units)

  • Page 21: Design And Functioning

    4. Design and functioning Desig n a n d f un cti oni ng Design of the unit 4.1.1 Design of air-cooled units Fig. 2 1 Intake filter 13 Pressure holding and check valve 25 Final compression temperature 2 Intake regulator 14 Air cooler sensor 3 Electric motor...

  • Page 22: Design Of Water-Cooled Units

    4. Design and functioning 4.1.2 Design of water-cooled units Fig. 3 1 Intake filter 15 Oil fine separator extractor 28 Opening for lifting gear 2 Intake regulator 16 Oil temperature regulator 29 Fan protection panel 3 Electric motor 17 Cooling air ventilator 30 Pressure relief for cooler 4 Screw compressor 18 Cooling air inlet filter mat...

  • Page 23: Schematic Diagram L90 - L132

    4. Design and functioning Schematic diagram 4.2.1 Schematic diagram L90 - L132 Switching point: 50 mbar Switching point: 50 mbar Opening pressure: 4.5 bar Idling pressure approx. 1.5 bar Pressure regulator output pressure: 2.5 bar Orifice diameter: 1.2 mm Start of opening: 55°C, 70°C Compressed air line Oil line Control line...

  • Page 24: Schematic Diagram L140

    4. Design and functioning 4.2.2 Schematic diagram L140 Compressed air line Oil line Control line Cooling water line (only LxxW - water-cooled units) Fig. 5 Intake filter 11 Final compression pressure 24 Blow-off valve Intake regulator sensor 27 Choke valve 2.1 Actuator 12 Pressure holding and check 28 Intake monitor, visual...

  • Page 25: Oil Circuit

    4. Design and functioning Oil circuit System control The oil flows from the pressure reservoir (- 6 -) into the (See also operating instructions for the compressor oil thermostat (- 16 -). With oil temperatures < 55 °C control DELCOS XL) (131 °F) the oil flows via the by-pass of the oil cooler directly into the oil filter (- 17 -) and is then injected into Standstill of the system...
  • Page 26 4. Design and functioning Stopping the system Solenoid valve (-23-(Y1)) is deenergised when the • STOP button on the operating panel of the compressor control DELCOS XL is pressed. The upper control space of the adjusting cylinder • (2.1) is ventilated by the solenoid valve (-23-(Y1)), the pressure spring in the adjusting cylinder causes the choke valve (-2.2-) in the intake regulator to close.

  • Page 27: Transport And Installation

    5. Transport and installation Tr ans por t an d i ns tall ati on Transport Danger The compressor must be lifted using a suitable forklift truck which complies with the local safety regulations. The length of the forks must correspond at least to the width of the unit (see Chapter 11.2).

  • Page 28: Installation

    5. Transport and installation Installation A = 1.1m/43.3“ B = 1.1m/43.3“ Fig. 8 Warning Pipes and/or other parts with a surface temperature higher than 70 °C (158 °F) have to be suitably identified and secured against touching. See also the safety regulations in chapter 3 of the operating instructions.

  • Page 29: Preparations For Commissioning

    6. Preparations for commissioning Pr epar ati on s f or com m iss io nin g CompAir screw compressors are rated for ambient Cooling air volume/minimum cross temperatures and cooling temperatures of +1°C (33.8 °F) to +45°C (113 °F). In the case of temperatures other than the above limiting values, please consult your technical adviser.

  • Page 30: Compressed Air Connection

    6. Preparations for commissioning Compressed air connection Warning When connecting the compressor on the mains side to the compressed air system available at the customerʻs end, check the operating temperatures and operating pressures required and examine the required connecting flange or the connection thread for proper type, size and functioning.

  • Page 31: Limit Values Of The Constituent Elements In Water

    The values refer to fresh water quality without additives Manganese <0.1 mg/l <0.1 mg/l (e.g. anti-freeze). Should the cooling water data differ, please consult CompAir. Sulphide Ammoniac Adjust the cooling water flow for the air cooler during commissioning using a manual regulating valve.

  • Page 32: Electrical Connection (Europe-Version Only)

    6. Preparations for commissioning To establish an electrical connection, proceed as Electrical connection (EUROPE- follows: Version only) Route the supply cable through the cable gland Compressor units are finished in the factory according (-1 - Fig. 12) on the control cabinet and tighten screws. to standard EN60204 (industrial machinery).

  • Page 33: Check Setting Of The Fan Protection Switch (L90Rs-L132Rs Only)

    6. Preparations for commissioning Recommended supply cable cross-sections and fuses Installed nominal Fuse protection Line cross section Compressor type Supply voltage motor power (slow-blow fuse) at 30°C [kW] [AgL] 50-Hz-Compressors 220V 2x3x250 2x3x95PE50 380V 3x95PE50 400V 3x70PE35 220V 2x3x315 2x3x150PE70 L110 380V 3x95PE50...

  • Page 34: Checking The Control Transformer Setting

    6. Preparations for commissioning Before first commissioning set the measured supply 6.4.2 Checking the control transformer voltage on the control transformer. Fig. 13 shows an setting example. Warning Following first commissioning the setting of the control transformer must be inspected while operating under Danger of electric shock! load and corrected where necessary (see section 9.9).

  • Page 35: Oil Level Check

    6. Preparations for commissioning Check the oil level as follows: Oil level check Stop the compressor, with the stop button. • Warning Wait at least 5 minutes for the oil to settle and for • the air to disperse Only check the oil level when the screw compressor unit is out of operation and The oil level is checked with the help of the •...

  • Page 36: Commissioning

    DELCOS XL menu [Settings; Pressure range, p1] Although every CompAir screw compressor has (further information can be found in section 5 of the been subjected to a test run at the factory and has compressor control DELCOS XL operating manual).

  • Page 37: Putting A Decommissioned Compressor Back Into Operation

    (1) hour prior to it being started. This ensures the operability of the capacitors and prevents any damage from occurring. If the compressor has been in storage for longer than 2 years, please contact an authorised CompAir dealer prior to start-up. Fig. 15 b – Air-cooled units...

  • Page 38: Display Of The Compressor Control Delcos Xl

    7. Commissioning Routine commissioning Display of the compressor control DELCOS XL Warning Make sure before commissioning that nobody is in the danger zone of the motor/screw compressor. After completion of work: Verify that all safety devices have been refitted and that all tools have been removed.

  • Page 39: Commissioning After Malfunction

    7. Commissioning Commissioning after malfunction Important Do not switch the screw compressor on repeatedly without having rectified the malfunction, since this may cause considerable damage to the machine. Re-start after an automatic shutdown due to a malfunction as follows: Faults are shown as text in the compressor control •...

  • Page 40: Storage Of Compressors

    8. Storage of compressors Stor ag e o f c om pr es sor s 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 41: 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 42: Special Lubrication

    LED. These LEDs signal the following operating modes Place drive on new LC unit until the gears mesh. or faults to the operator. Only use completely filled genuine CompAir MLS 120 LC units. Screw down drive to LC unit (hand tight).

  • Page 43: 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. Error function and error...
  • Page 44 9. Service and maintenance Error function and error messages Description of error Cause of error Error rectification Display not visible, despite Internal drive error. Replace entire lubrication voltage being applied. system "Lo" message on the Weak drive back-up Replace back-up battery display.

  • Page 45: Maintenance And Inspection Schedule

    9. Service and maintenance Service packages Maintenance and inspection schedule Package C Oil filter cartridge, air filter cartridge Package D Oil separator element Package E Worn parts Warning When performing control, adjusting and maintenance work, be careful with hot Intervals are valid for normal industrial environments surfaces of machine parts.
  • Page 46    General maintenance/cleaning      Oil change when using CompAir - 4000 hours oil (only European version)      Oil change when using CompLube 4000 or CompLube 4000FG Food Grade  ...
  • Page 47 9. Service and maintenance                                     ...

  • Page 48: Oil Change

    9. Service and maintenance necessary. The specified oil change intervals refer to an Oil change intake air from a normal environment without a high content of foreign matter (dusts, vapours, gases). When changing the oil, the waste oil is to be drained completely, since used oil reduces the service life of the new oil fill considerably.

  • Page 49: Change Of Oil Filter Cartridge

    9. Service and maintenance Change the oil filter cartridge as follows: Change of oil filter cartridge Switch the screw compressor unit off and ensure that • it is depressurized, electrically isolate and locked off. Wait at least 5 minutes for the oil to settle and for •...

  • Page 50: Change Of The Oil Fine Separator

    9. Service and maintenance Change of the oil fine separator Fig. 22 Fig. 21 Change the oil fine separator as follows: 1 Oil fine separator 2 Oil extraction plastic tube Switch the screw compressor unit off and ensure • 3 Control air plastic tube that it is depressurized, electrically isolate and 4 Oil extractor locked off.

  • Page 51: Change Of Air Intake Filter

    9. Service and maintenance Swivel reservoir cover back to the initial position • Change of air intake filter Turn cheese head screw (- 8 - Fig. 21) • counterclockwise until the reservoir cover is loosely lying on the pressure reservoir flange Screw down all hexagonal head screws, with •...

  • Page 52: Safety Valve

    9. Service and maintenance Changing intervals for air filter cartridge Safety valve 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, oil filters, fine separators).

  • Page 53: Connecting Terminals In The Switch Cabinet/Control Transformer Setting

    9. Service and maintenance Check the control transformer setting as follows: Connecting terminals in the switch cabinet/control transformer setting Switch the unit on as described in Chapter 7.4. • Check the control transformer output voltages while • Danger operating under load. Several tapping points are provided for this purpose (see circuit diagram).

  • Page 54: Clean / Change Filter With Cooling Air Inlet And Control Cabinet Inlet

    9. Service and maintenance 9.12 Clean / change filter with cooling air Warning inlet and control cabinet inlet Only perform checks and carry out work on the screw compressor when the unit is out of operation, depressurized, and secured from being switched on again! Perform filter mat change as follows: a) Filter mat, cooling-air inlet •...

  • Page 55: Clean Dirt Interceptor (Only For Lxx W - Water-Cooled Units)

    9. Service and maintenance b) Control-cabinet inlet filter (L90RS - L132RS only) 9.13 Clean dirt interceptor (only for Lxx W – water-cooled units) • Open the louvred grilles of the inlet filter (Fig. 27). • Remove the filter pad. • Insert the new filter pad into the louvred grille. Ensure that the smooth side (-A- Fig.

  • Page 56: Inspection Intervals For Pressure Vessels And Electrical Installations

    CompLube 4000 b) CompLube 4000FG Food Grade (Optional) c) CompLube 8000 (Optional) d) CompLube 8000H1 (Optional) For further information, please contact your local CompAir Distributor or Gardner Denver-USA at (937) 498-2500. CANADA-Version: a) CS6000XL b) CSS20 Food Grade (Optional)

  • Page 57: Trouble-Shooting

    10. Trouble-shooting Tr ou ble -s ho oti ng 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...
  • Page 58 10. Trouble-shooting Malfunction Possible cause Remedy Unit switches off Ambient temperature too high Ventilate compressor room Electric motor defective Check electric motor and thermistor Fan defective Check/replace fan Sensor, connections or lines defective Check sensors, connections and lines Cross section of the electric supply Measure power requirement, lines too small if necessary, replace lines...

  • Page 59: Annex

    11. Annex Ann ex 11.1 Technical Data 11.1.1 EUROPE version L90-L110 50 Hz A - air-cooled W - water-cooled L110 Technical data 50Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C 1...45 Flow /min 17.45 15.47 13.45 20.77 18.63 16.21 A -°C After-cooler outlet temperature...

  • Page 60: Europe Version L90-L110 60 Hz A - Air-Cooled W - Water-Cooled

    11. Annex 11.1.2 EUROPE version L90-L110 60 Hz A - air-cooled W - water-cooled L110 Technical data 60Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C 1...45 Flow /min 17.76 16.24 13.37 20.60 19.35 16.13 A - °C After-cooler outlet temperature above ambient temp.

  • Page 61: Europe Version L132 - L140 50 Hz A - Air-Cooled W - Water-Cooled

    11. Annex 11.1.3 EUROPE version L132 - L140 50 Hz A - air-cooled W - water-cooled L132 L140 Technical data 50Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C 1...45 Flow / min 22.87 21.27 18.59 24.65 21.59 A - °C After-cooler outlet temperature above ambient temp.

  • Page 62: Europe Version L132 - L140 60 Hz A - Air-Cooled W - Water-Cooled

    11. Annex 11.1.4 EUROPE version L132 - L140 60 Hz A - air-cooled W - water-cooled L132 L140 Technical data 60Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C 1...45 Flow / min 22.63 21.32 18.36 24.78 23.44 A - °C After-cooler outlet temperature above ambient temp.

  • Page 63: Europe Version L90Rsa - Air-Cooled W - Water-Cooled

    11. Annex 11.1.5 EUROPE version L90RS A - air-cooled W - water-cooled Technical data 50 / 50Hz L90RS Maximum operating pressure 13.0 Minimum operating pressure Ambient temperature °C 1...45 at min. speed at max. speed 7.5 bar Flow / min 4.76 17.6 9 bar...

  • Page 64: Europe Version L110Rsa - Air-Cooled W - Water-Cooled

    11. Annex 11.1.6 EUROPE version L110RS A - air-cooled W - water-cooled Technical data 50 / 60Hz L110RS Maximum operating pressure 13.0 Minimum operating pressure Ambient temperature °C 1...45 at min. speed at max. speed 7.5 bar Flow / min 4.76 20.68 9 bar...

  • Page 65: Europe Version L132Rsa - Air-Cooled W - Water-Cooled

    11. Annex 11.1.7 EUROPE version L132RS A - air-cooled W - water-cooled Technical data 50 / 60Hz L132RS Maximum operating pressure 13.0 Minimum operating pressure Ambient temperature °C 1...45 at min. speed at max. speed 7.5 bar Flow / min 4.76 22.72 9 bar...

  • Page 66: Layout Plan

    11. Annex 11.2 Layout plan (all dimensions in mm) Fig. 30 A Compressed air connection Europe version: male screwed thread R 1 1/2“ DIN 2999 Canada USA version: male screwed thread NPT 1 1/2 - 11-1/2 B Cooling air inlet C Cooling air outlet D Cooling-air inlet, control cabinet (L90RS - L132RS only) E Openings for inlet cable...
  • Page 67 11. Annex Fig. 31...

  • Page 68: Declaration Of Conformity

    Argenthaler Str.11 D-55469 Simmern that the product: Kompressor L15; L18; L22; L23; L26; L29; L30; L37; L45; L50; L55; L75; L80; type: L90; L110; L132; L140; L160; L200; L250; L15RS; L18RS; L22RS; L23RS; L26RS; L29RS; L30RS; L37RS; L45RS; L55RS; L75RS; L90RS; L110RS; L132RS; L160RS; L200RS; L250RS;...
  • Page 72 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 Fax ++49 (0)6761 832-409 www.compair.com e-mail: sales@compair.com...

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