L&W SC-180 ES Operating Instructions Manual
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L&W SC-180 ES Operating Instructions Manual

Breathing air compressor
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C H A P T E R O V E R V I E W
Operating Instructions
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Attachment
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Manufacturer in terms of 97/23/EC
The full name and address of the manufacturer is:
Lenhardt & Wagner GmbH
An der Tuchbleiche 39
68623 Hüttenfeld / Germany
Phone: +49 (0) 62 56 - 85 88 0 - 0
Fax: +49 (0) 62 56 - 85 88 0 - 14
E-Mail: service@lw-compressors.com
Internet: www.lw-compressors.com
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  • Page 1 C H A P T E R O V E R V I E W Operating Instructions ....................................................................................................................Attachment ............................ Manufacturer in terms of 97/23/EC The full name and address of the manufacturer is: Lenhardt & Wagner GmbH An der Tuchbleiche 39 68623 Hüttenfeld / Germany Phone: +49 (0) 62 56 - 85 88 0 - 0...
  • Page 2 S E R V I C E I N F O R M A T I O N / W A R R A N T Y Compressor information Type designation Serial number Date of construction Purchase information Purchase date First commissioned on Warranty period Dealer's stamp...
  • Page 3 Operating Instructions Breathing Air Compressor LW SC-180 ES / LW SC-250 ES Version: 12/2022...

  • Page 4: Table Of Contents

    Check V-belt tension / Tension V-belt ....................43 Compressor lubrication / Check oil level ..................44 Oil change ............................45 Final pressure switch ........................46 Automatic condensation dump system ................... 47 Seite A - 2 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 5 Pressure gas vessel test ........................62 Maintenance records ....................... 64 - 68 Storage Conservation / storage of the compressor ..................69 De-conservation, commissioning ....................69 Transportation instructions / Disposal ..................... 70 Seite A - 3 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 6: General Information / Description Of Warning Symbols

    Indicates a potentially hazardous situation which, if not avoided, could result in physical injury or damage to the product or environment. Note Indicates additional information on how to use the unit. Seite A - 4 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 7: Scope Of Delivery

    • Additional high pressure outlet • Oil pressure gauge • CEE plug • Intermediate pressure gauges • Special voltages / frequencies on request • Oil pressure monitoring c/w auto shut down Seite A - 5 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 8: Technical Data

    Noise level from a distance of 1 m [dB(A)]: Dimensions W x D x H [mm]: 900 x 1085 x 1330 Weight [kg]: ca. 263 ca. 265 Content Volume Filter housing [l]: 0,69 0,69 Seite A - 6 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 9: Unit Assembly

    Switchboard Filling pressure gauge (200 bar) Filling valve (200 bar) c/w Filling Hose Filling pressure gauge (300 bar) Filling valve (300 bar) c/w Filling Hose Filter Housing Seite A - 7 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 10: Switchboard

    D E S C R I P T I O N Switchboard Designation Emergency shut-off switch Hour counter ON button OFF button Drain test button Seite A - 8 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 11: Flow Chart

    20. Öl-/Wasserabscheider / Oil-/Water Separator 41. Kreuzventil (Option) / Filling Valve „Cross Design“ (Option) 21. Druckhalteventil / Pressure Maintaining Valve 42. Hochdruckschlauch (Option) / HP-Hose (Option) 22. Rückschlagventil / Non-Return Valve Seite A - 9 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 12 S I C H E R H E I T S H I N W E I S E...

  • Page 13: Safety Precautions

    Only trained personnel are permitted to work on the unit! Warning Work on the electrical equipment on / with the machine / unit may only be carried out by qualified electricians. Seite A - 11 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 14: Safety Instructions On The Unit

    Importance of notes and warning signs that are affixed to the compressor according to the application or its equipment. Warning Note High voltage! Ensure correct direction of rotation! Seite A - 12 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 15: General Safety Precautions

    • Do not use the product in areas prone to explosion or in the presence of flammable gases. The product is not designed for these applications. An explosion might be the result if certain conditions apply. Seite A - 13 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 16: Unit Customised Safety Notices

    • Soundproofing equipment on the compressor has to be activated in safety function during operation. • When handling with fats, oils and other chemical agents, observe the note for the product- related safety. Seite A - 14 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 17: Maintenance Instructions

    • Only personnel with particular knowledge and experience with pneumatics may carry out work on pneumatic equipment. • Only personnel with particular knowledge and experience in gas equipment may carry out work on gas equipment. Seite A - 15 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 18: Transportation Instructions / Safety Regulations

    No guarantees whatsoever are valid for damage caused or favoured by the non-consideration of these directions for use. Seite A - 16 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 19: Installation

    I N S T A L L A T I O N...

  • Page 20: Installation In Closed Rooms

    Pos. Length of Intake Hose [m] Diameter of Intake Hose [mm] ≤ 03 Ø 30 ≤ 10 Ø 80 ≤ 15 Ø 100 ≤ 20 Ø 120 Seite A - 18 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 21: Dimensions

    I N S T A L L A T I O N Dimensions Fig. Dimensions Seite A - 19 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 22: Minimum Distances

    Front side min. 1500 mm, sides min. 500 mm, rear side min. 500 mm. Avoid anything in this area which can restrict the cooling air flow. Fig. Minimum distances Seite A - 20 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 23: Ventilation

    • The fan capacity for fresh air and warm air must meet at least the required cooling air flow. The fans must have the same capacity. Fig. Ventilation through facade Fig. Ventilation via ventilation stack Seite A - 21 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 24: Electrical Installation

    • Fuse the motor correctly (see table; use slow-blow fuses). Fig. Compressor name plate Designation Circuit diagram number Compressor type Power supply Frequency Motor current consumption Nominal motor power Seite A - 22 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 25 Recommended fuses for 220 - 240 V operating voltage Nominal motor power Fusing start A Connection in mm² [kw] Direct Star/Delta Contactor supply Motor S/D 14.8 19.6 26.4 18.5 Seite A - 23 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 26: Operation

    O P E R A T I O N...

  • Page 27: Important Operation Instructions

    Ensure that all persons handling the compressor are familiar with function and operation of the unit. Wear hearing protection When working on a running machine, always wear hearing protection. Seite A - 25 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 28: First Commissioning

    - Drain test - press the test button - If correct, air escapes Stop the compressor by pushing the OFF button. 10. Open all filling valves carefully to vent. Seite A - 26 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 29 The V-belts could lose tension during transportation. Please check the V-belt tension before starting the compressor. Tension V-belts / Correct V-belt tension See chapter "Service and Maintenance" -> "Tension V-belts" Seite A - 27 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 30 2nd and 3rd stages can not be sufficiently lubricated, with the consequence that the pistons will be damaged. Furthermore, cooling air flow will not be sufficient. Rotation direction arrow Seite A - 28 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 31: Daily Commissioning

    • Check compressor oil level by the oil sight glass. • Check if filter cartridge is in place / observe filter cartridge life! • Ensure toxic-free, pure intake air. Seite A - 29 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 32: Filling Procedure

    Fill compressed air cylinders to the desired pressure, subsequently close the filling valves slowly. Close and vent all filling valves. Disconnect all compressed air cylinders from filling valves. Seite A - 30 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 33: Switch Off The Compressor

    (only in case of emergency!). Note After automatic or manual switching off, all pressure vessels and filter housings of the compressor will be automatically vented. Seite A - 31 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 34: Remedying Faults

    R E M E D Y I N G F A U L T S...
  • Page 35 Cylinder(s), piston(s) or piston ring(s) used up Replace V-belt slips Tension V-belt See chapter "Final pressure can not be reached" See chapter "Final pressure can not be reached" Seite A - 33 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 36 Mole carbon filter cartridge saturated Replace Compressor oil unsuitable Use prescribed oil quality Filter cartridge unsuitable Use prescribed filter type Cylinder(s), piston(s) or piston ring(s) defective Replace Seite A - 34 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 37 Check fusing of the power supply / observe Valid only for E models regulations Emergency stop switch has tripped Unlock emergency stop switch, close compressor housing door correctly Seite A - 35 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 38 Operating temperature too high Observe prescribed operating temperatures Oil leak at the compressor block Tighten corresponding mounting screws, if necessary replace corresponding paper sealing / o-ring / shaft seal Seite A - 36 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 39: Maintenance And Service

    M A I N T E N A N C E A N D S E R V I C E...

  • Page 40: Service, Repair And Maintenance

    Carry out maintenance or service work when the unit is switched off and protected against unexpected restart. Warning Risk of burns! Carry out maintenance or service work when the unit has cooled down. Seite A - 38 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 41: Maintenance Lists / Maintenance Intervals

    Check automatic condensate drain, open manual condensate taps Check/Retorque all connections and bolts Check V-belt tension and condition LW SC-180 ES (50Hz) 011839 LW SC-250 ES (50Hz) 011839 Seite A - 39 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 42 Check V-belt tension and condition see above see above see above Change intake filter 001708 Check pressure maintaining/non-return valve Check all connections for leaks Clean oil/water separators Seite A - 40 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 43 001255 Replace sintered metal filter of condensate stop 000188 Replace o-rings of the filter housing 001769 Oil change ( at least once a year!) 0,8 l 000001 Seite A - 41 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 44 Upper gasket 1st 003651 Lower gasket 1st 011103 Note All stated quantities are parts of our 2000h service kits. You can find an overview on page Service Kits. Seite A - 42 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 45: Check V-Belt Tension / Tension V-Belt

    Settings Motor Type Initial Installation Operation after running in Electric motors 50Hz 500 N 400 N Electric motors 60Hz 400 N 300 N Seite A - 43 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 46: Compressor Lubrication / Check Oil Level

    Refill new compressor oil at least when the oil level reached the middle of the indicated area. Oil sight glass Warning • First oil change after 25 operating hours. Seite A - 44 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 47: Oil Change

    Approx. 800 ml synthetic compressor oil is necessary for one oil change. Only use synthetic compressor oil which is recommended as suitable from L&W (L&W Article no.: 000001). Seite A - 45 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 48: Final Pressure Switch

    Example settings: Safety valve Max. Operating Pressure 225 bar 215 bar 250 bar 240 bar 330 bar 320 bar Seite A - 46 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 49: Automatic Condensation Dump System

    All oil / water separators have an integrated sinter filter which has to be replaced every 1,000 operating hours. Oil / water separators final stage Seite A - 47 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 50: Oil / Water Separators 2Nd Stage - Maintenance

    The oil / water separator maintenance is now completed. Fig. 2 - Remove sinter filter holder Fig. 3 - Change sinter filter Fig. 4 - Change o-ring Seite A - 48 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 51: Filter Housing / Filter Cartridge

    Breathing air filter cartridges should be changed at the following intervals, at +20°C or more often, depending on humidity and ambient temperature: • 46.3 hours for LW SC-180 ES • 33.3 hours for LW SC-250 ES Seite A - 49 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 52: Filter Cartridge Change

    Abb. 2 - Filtergehäusedeckel entnehmen Fig. 3 - Pull out the filter cartridge by the catch and insert a new cartridge Seite A - 50 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 53: Filter Housing - Maintenance

    • Mount the filter housing. • Mount the bracket (Abb. 3). The filter housing maintenance is now completed. Fig. 2 - Change o-ring Fig. 3 - Mounting bracket Seite A - 51 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 54: Pneumatic Condensate Valve - Maintenance

    • Tighten pipe connections and mounting screws. Pneumatic Condensate Valve Pneumatic condensate valve maintenance is now completed. Fig. 2 - Loosen connection Fig. 3 - Change sinter filter Seite A - 52 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 55: Inlet Filters / Inlet Filter Cartridge Change

    Fig. 4 - Place o-ring into the groove Fig. 5 - Place and align filter housing Fig. 6 - Connect ventilation hose at carefully the oil fill port Seite A - 53 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 56: Cylinder Heads And Valves

    There are no special tools required to replace these valves. Available special tools Special tools are not necessary for dismounting inlet and outlet valves but make work easier. Order number: 006847 Special tool Seite A - 54 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 57: Replace Inlet And Outlet Valve 1St Stage

    • Remove upper valve head gasket and inlet / outlet valve. Install inlet / outlet valve - see following page Fig. 2 - Remove in– and outlet valve Fig. 1 - Remove spring wire clamps Seite A - 55 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 58 Fig. 2 - Correct position of inand Fig. 3 - Correct position of in-and Fig. 4 - Take care to kkeep valve in outlet valve outlet valve place Seite A - 56 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 59: Replace Inlet And Outlet Valves 2Nd And 3Rd Stage

    • Tighten valve head screws crosswise. • Tighten pipe connections. Inlet and outlet valves change 2nd stage / 3rd stage is now completed. Fig. 1 - Ensure correct valve position (centre pin) Seite A - 57 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 60: Safety Valves

    If a safety valve blows off, it indicates problems with either inlet or outlet valve of the following stage. Note Replace defective safety valves immediately! Safety valve 1st stage Safety valve 2nd stage Safety valve 3rd stage Seite A - 58 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 61: Pressure Maintaining / Non Return Valve

    / condensate drain valves. After compressor stop, the indicated filling pressure remains constant, if the non return valve is working correctly. Seite A - 59 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 62: Safety Valve Test

    • Turn the adjusting screw of the final pressure switch back (one turn counterclockwise). Pressure switch • Check the cut-out pressure. Adjust if necessary! The safety valve test is now completed. Seite A - 60 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 63: Leak Test

    • Verify the compressor for release noises. (A slight hiss of the air inlet filter nozzle can be ignored). If release noises occur, localise blow off position(s). • Release the OFF-switch. The leak test is now completed. OFF-switch Seite A - 61 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 64: Pressure Gas Vessel Test

    Max. numbers of load cycles for operation with max. allowable pressure variation Final pressure [bar] Load cycles Operating hours [h] 35.000 8.750 Caution The filter container (P/N: 011281) has to be replaced after 15 years! Seite A - 62 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 65: Maintenance Records

    M A I N T E N A N C E R E C O R D S...
  • Page 66 By adding themselves to this list, the person that signs it confirms having been given a yearly introduction/instruction about the function and operation of the compressor unit.Furthermore, they have be informed about the relevant safety rules and regualtions (TRG, DGRL, BetrSichV, GSG, GSGV). Seite A - 64 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 67 M A I N T E N A N C E R E C O R D S Top up oil, oil change Date Operating hours Oil quantity [l] Name Seite A - 65 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 68 M A I N T E N A N C E R E C O R D S Cartridge change Date Operating hours Difference Name Seite A - 66 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 69 M A I N T E N A N C E R E C O R D S Maintenance work Description Date, signature Seite A - 67 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 70 M A I N T E N A N C E R E C O R D S Replaced Parts Designation Part number Date, signature Seite A - 68 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 71: Conservation / Storage Of The Compressor

    Check safety valve relief pressure of final stage and/or pressure switch setting. • Check all connections and pipe work for leaks. Once all above steps are completed, compressor unit is now ready for use. Seite A - 69 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...

  • Page 72: Transportation Instructions / Disposal

    The device can be returned to L&W. Please do not hesitate to contact us if you have any further questions on this issue. Seite A - 70 LW SC-180 ES / LW SC-250 ES Version: 09.12.2022...
  • Page 73 A T T A C H M E N T Version: 11/12-E...
  • Page 74 OPERATING INSTRUCTION FOR SAFETY VALVE Lenhardt & Wagner GmbH An der Tuchbleiche 39 D-68623 Lampertheim – Hüttenfeld www.lw-compressors.com Operating Instruction Safety valve Typ: SiV2 BKZ TÜV.SV.19-1140.5.G.V.P CE 0091 AlMgSi1 F31 1100* Lenhardt & Wagner Set pressure: see mark (hand wheel on top of valve) Maximum outflow: Set pressure 100-159 bar: 750 l / min...
  • Page 75 OPERATING INSTRUCTION FOR SAFETY VALVE In order to prevent manipulation of the set pressure, all safety valves are factory fitted with a seal. A safety valve on which the seal has been removed, must be returned to the manufacturer for repair / adjustment before further use.
  • Page 76 OPERATING INSTRUCTION FOR SAFETY VALVE Manufacturer: Lenhardt & Wagner GmbH An der Tuchbleiche 39 D-68623 Lampertheim – Hüttenfeld Contact: E-Mail: service@lw-compressors.com Web: www.lw-compressors.com Tel.: +49 (0) 6256 – 85880 0 Fax: +49 (0) 6256 – 85880 14 Note: Only use safety valves which are in a technically perfect condition, for its intended purpose, safety and danger awareness, in compliance with the operating instructions! Faults which could affect safety must be rectified immediately! Notes:...
  • Page 77 INFORMATION ON THE SERVICE LIFE OF L&W HIGH PRESSURE HOSES...
  • Page 78 CONTENTS Testing hose lines Testing hose lines ............................3 Testing after assembly and before commissioning ................3 Recurring test ............................... 4 Procedure for hose lines found to be "defective" ................. 4 Test intervals ..............................4 Persons qualified to test hose lines ......................5 Maintenance Replacing hose lines ...........................

  • Page 79: Testing Hose Lines

    TESTING HOSE LINES Testing hose lines An essential factor in ensuring operational safety when handling L&W compressors is the proper testing of the hose lines used. Tests are necessary:   After assembly and before commissioning the hose line.  After accidents, changes (modifications) to the compressor system, longer periods of non- ...

  • Page 80: Recurring Test

    TESTING HOSE LINES Recurring test Since hose lines are subject to influences that cause damage during operation and can lead to dangerous situations, they must be tested recurrently at fixed intervals. The aim of recurring tests is to detect and repair damage in good time. The objective is to ensure that the system remains in a safe condition.

  • Page 81: Persons Qualified To Test Hose Lines

    TESTING HOSE LINES Persons qualified to test hose lines A qualified person is a person who, through his or her professional training, professional experience and recent professional activity, has the necessary specialist knowledge required for testing work equipment - in this case for testing hose lines. These requirements are defined in the Technical Rules for Industrial Safety TRBS 1203 "Qualified persons - general requirements"...

  • Page 82: Replacing Hose Lines

    MAINTENAN Replacing hose lines As a general rule, even when stored properly and subjected to permissible stress during use, all hose lines are subject to natural aging, which changes the material and composite properties and reduces the performance of the hose lines. This limits the service life of a hose line and the operator must ensure that hose lines are replaced at appropriate intervals.

  • Page 83: Service Life

    SERVICE LIFE Service life of L&W high pressure hoses When determining the service life or the replacement interval of the individual hose lines, the concrete specifications and recommendations of the hose line or machine manufacturer must be observed. Furthermore, empirical values resulting from previous tests done under the prevailing operating conditions on site are also relevant.

  • Page 84: Storage

    STORAGE Storing hose lines When storing hose lines, storage conditions must be aimed at minimizing the natural aging that occurs over time and the associated change in material and composite properties. For this purpose, the following information must be provided: ...
  • Page 85 ANNEX...
  • Page 86 ANNEX SCOPE OF TESTING; TEST CRITERIA Recommended scope of testing "visual inspection" (before initial commissioning or recommissioning)  Is all user information required for safe operation of the system available (e.g. flow chart, operating instructions)?  Do the hose lines comply with the flow chart or parts list? ...
  • Page 87 ANNEX SCOPE OF TESTING; TEST CRITERIA Recommended scope of testing "Functional test" (before initial or recommissioning) Note: Visual inspection must be carried out before the functional test  All parts of the system must be tested at least at the maximum working pressure that could be achieved taking into account all intended applications:...

This manual is also suitable for:

Sc-250 es

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