Related Manuals for CompAir AirStation L15RS FS
Summary of Contents for CompAir AirStation L15RS FS
- Page 1 Original Operating and Service Manual Screw Air Compressor L15 - L22, L15RS - L22RS L15FS-L22FS, L15RS FS - L22RS FS ● ● ● Id. no. ZS1062654 / 04 - April 2013...
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Page 3: General Information
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:...
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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... - 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.
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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 ................................7 3.1 Identification of safety guidelines ..........................7 3.2 General safety instructions............................7 3.3 Changes and modifications to the machine ........................8 3.4 Installation and normal operation..........................8... - Page 8 2. Table of contents 8 Control system...................................37 8.1 General..................................37 8.2 Keys.....................................37 8.3 Status indicator (display / light signals) ........................37 8.4 Displaying / changing values............................38 8.4.1 Selecting values ..............................38 8.4.2 Changing values .............................38 8.5 Default settings ................................38 8.5.1 Selecting language............................38 8.5.2 Setting network pressure (apart from L15RS-L22RS) ..................38 8.5.3 Setting line pressure (only L15RS-L22RS)....................39 8.5.4 Setting time/date (timer) ..........................39 8.6 Starting the unit ................................39...
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Page 9: Safety Regulations
3. Safety regulations Safet y r eg ula tio ns General safety instructions Identification of safety guidelines Organizational measures Gardner Denver is not liable for any damage or injury resulting from the non-observance of these safety The operating instructions must always be at hand at instructions or negligence of the usual care and the place of operation of the machine/unit! attention required during handling, operation,... -
Page 10: Changes And Modifications To The Machine
3. Safety regulations For the execution of maintenance work, tools and The manufacturer is not liable for damage resulting workshop equipment adapted to the task on hand are from the use of non-original parts or special accessories. This applies also to the installation and absolutely indispensable. - Page 11 3. Safety regulations If a remote control is used, the system must carry a If the room temperature can fall below zero, the clearly visible sign with the following note: Attention! condensation drain system must be protected from This installation is operated by remote control and can freezing, e.g.
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Page 12: Special Work/Maintenance
3. Safety regulations Before blowing through a hose or an air pipe ensure Maintenance and repair work may only be carried out that the open end is positively held. A free end whips under the supervision of a person who is qualified for and can cause injuries. - Page 13 3. Safety regulations Avoid damage to the safety valves and other pressure Maintenance/rectification of faults reducing components. Check in particular for clogging The employer has to inform the employee of the caused by paint, oil carbon or the accumulation of dust, dangers possibly arising during the repair and which could deteriorate the effectiveness of these maintenance of the machine/unit as well as on how to...
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Page 14: Warning Of Special Dangers
3. Safety regulations If the set-up, maintenance or repair require the Before carrying out welding, flame-cutting and grinding demounting of safety equipment, this equipment has to operations, clean the machine/unit and its surroundings be remounted and checked immediately after these from dust and other inflammable substances and make activities. -
Page 15: Storage Of Compressors
3. Safety regulations Oils, greases and other chemical substances When handling oils, greases and other chemical substances, observe the safety regulations for this product! Be careful when handling hot fuels and consumables (danger of burning or scalding)! Rooms subject to explosion hazards Danger Compressor units must never be operated in areas subject to explosion hazards! -
Page 16: Symbols And Explanations
3. Safety regulations Symbols and explanations Carefully read the operating manual before commissioning or servicing this compressor. Never breathe in compressed air from this system. Never operate the unit with open doors or loose access panels. - Page 17 3. Safety regulations Warning: Hot surface 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 after pressing the O-key Warning: Danger of electric shock Attention: Lifting point...
- Page 19 3. Safety regulations Attention: Check and, if required, re-tighten connection terminals. For further details, see the operating instructions. Attention: Electric motor fasteners Electric motor fasteners used for securing the unit during transportation have to be removed prior to commissioning (see also chapter 6.4).
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Page 20: 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 the unit - L15-L22 Fig. 2 a L15-L22 1 Intake filter 12 Oil cooler 24 EMERGENCY OFF push-button 2 Intake regulator 13 Safety valve 25 Control cabinet 3 Electric motor... -
Page 21: Design Of The Unit - Airstation L15Fs-L22Fs
4. Design and functioning 4.1.2 Design of the unit - AirStation L15FS-L22FS Fig. 2 b AirStation L15FS-L22FS 1 Compressor L15-L22 5 Opening for fork lift 9 Manometer 2 Pressure vessel 500 L 6 Operating panel controller 10 Compressor hood 3 Dryer 7 EMERGENCY-Stop button 11 Stands 4 Condensate drain... -
Page 22: Schematic Diagram
4. Design and functioning Schematic diagram 4.2.1 Schematic diagram L15-L22 Residual pressure: 1,5 - 2,0 bar Opening pressure: Opening pressure: 4,5 bar 1,0 bar Opening pressure: 0,14 bar Opening temperature: 55 °C Fig. 3 L15-L22 1 Intake filter 11 Oil filter 22 Frequency converter 2 Intake regulator 12 Oil cooler... -
Page 23: Oil Circuit
4. Design and functioning Oil circuit System control The oil flows from the pressure reservoir (- 6 - Fig. 3) into the oil thermostat (- 17 - Fig. 3). With oil tempera- tures < 55 °C/131 °F the oil flows via the by-pass of the oil cooler directly into the oil filter (- 11 - Fig. -
Page 24: System Control L15Rs-L22Rs / L15Rs Fs-L22Rs Fs
4. Design and functioning Automatic operation (open-close operation) 4.5.2 System control L15RS-L22RS / L15RS FS-L22RS FS When the pressure reaches the upper switching point • set on the network pressure sensor (-7 - Fig. 4), (See also operating instructions for the compressor solenoid valve (Y1 Fig. -
Page 25: Hood (Opening/Closing)
4. Design and functioning Speed control operation Hood (opening/closing) Speed is controlled using a software-implemented PI The compressor is provided with a detachable plastic regulator that adapts the RPMs according to the need hood that allows easy access to all parts that are for compressed air. -
Page 26: Transport And Installation
5. Transport and installation Tr ans por t an d i ns tall ati on It is strictly prohibited to work or stand in the Transport danger zone of a lifted load. The proper lifting of the load (according to the operating instructions of the load suspension device) has to be ensured. -
Page 27: Installation
5. Transport and installation Installation A = 0.5 m B = 0.8 m Fig. 7 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. •... -
Page 28: Preparations For Commissioning
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 +1°C/ 33.8°F to +45°C/113°F. In the case of temperatures other than the above limiting values, please consult... -
Page 29: Compressed Air Connection
6. Preparations for commissioning Compressed air connection Note After-coolers, separators, collecting reservoirs and the compressed air lines must be equipped with drain facilities at their lowest points to drain collected liquids. These facilities have to be fitted to allow the observance of the draining of such liquids. -
Page 30: Electrical Connection
6. Preparations for commissioning Electrical connection 6.3.1 Electrical connection (EUROPE-Version only) 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] [AgG] 50-Hz-Compressors 4G25 L15, L15FS 4G25 L18, L18FS 18.5... - Page 31 6. Preparations for commissioning Compressor units are finished in the factory according To establish an electrical connection, proceed as to standard EN60204 (industrial machinery). Please follows: observe the following important notes: Guide in supply cable at cable entry ( - 1 - Fig. 10) and tighten screw connection.
- Page 32 6. Preparations for commissioning Checking the setting of the control-power transformer The control-power transformer is factory-preset to the rated voltage. However, practice has shown that the actual supply voltage often differs from this value. In order to adjust the unit to the local conditions, the setting of the control-power transformer must be checked by measuring the control-power transformer output voltages during under load operation and, if...
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Page 33: Electrical Connection (Usa/Canada-Version Only)
6. Preparations for commissioning 6.3.2 Electrical connection (USA/CANADA-Version only) Recommended supply cable cross-sections and fuses for multi-wire cables or three current-carrying conductors in raceway based on 86 °F ambient temperature Compressor type Supply Installed Fuse(s) Line cross section voltage nominal motor protection conductor rated power... - Page 34 6. Preparations for commissioning To establish an electrical connection, proceed as Checking the setting of the control-power follows: transformer Route the supply cable through the cable gland The control-power transformer is factory-preset to the (- 1 - Fig. 10) on the control cabinet and tighten screws. rated voltage.
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Page 35: Electric Motor Fasteners For Secure Transportation
6. Preparations for commissioning Electric motor fasteners for secure transportation Fasteners used for securing the electric motor (- 1 - Fig. 12) during transportation must be removed prior to commissioning. To remove the fasteners, proceed as follows: After the panel has been removed, support the •... -
Page 36: Sound Pressure Level
6. Preparations for commissioning Sound pressure level Sound pressure level measured in dB(A) according to PN8NTC 2.2 under full load at a distance of 1 m (tolerance: ± 3 dB(A)): 50 Hz compressors dB(A) 60 Hz compressors dB(A) Speed-controlled compressors dB(A) 50 Hz/ 60 Hz L15RS... -
Page 37: Commissioning
The access panels may temporarily be opened for Important checking the direction of rotation (wear ear protectors). Although every CompAir screw compressor has been subjected to a test run at the factory and has Danger again been thoroughly inspected before shipment, damage during shipment cannot be excluded. -
Page 38: Routine Commissioning
7. Commissioning Temperature start-up protection Commissioning after malfunction The screw compressor unit will not start up if the Important ambient temperature is lower than + 1 °C/33.8 °F. Do not switch the screw compressor on repeatedly without having rectified the malfunction, since this may cause considerable damage to the machine. -
Page 39: Control System
8. Control system Contr ol s yst em Status indicator (display / light General signals) This chapter is used to quickly commission the unit. The control system is explained in detail in the separate The control system is fitted with a three-row display. DELCOS Pro operating instructions. -
Page 40: Displaying / Changing Values
8. Control system Displaying / changing values Default settings 8.4.1 Selecting values Danger You can display values, e.g. total hours, and set the When programming in standby, the machine may control system, e.g. cut-in and cut-out times, in the sub- start up at any time. -
Page 41: Setting Line Pressure (Only L15Rs-L22Rs)
8. Control system 8.5.4 Setting time/date (timer) 8.5.3 Setting line pressure (only L15RS- L22RS) The DELCOS Pro accumulator can bridge a loss of power lasting between around two to three weeks. If Speed is controlled with the aid of a PI controller power is lost for longer periods, the timer's time and implemented in the software and is matched to the date are lost and have to be entered anew. -
Page 42: Emergency Off Button
8. Control system Emergency off button The emergency off button is situated next the DELCOS Pro. It is used to immediately shut down the unit. Only use the emergency off button to shut down the unit in emergencies. When shutting down normally, always ... -
Page 43: Menu Structure (Apart From L15Rs-L22Rs) (Values Are Examples)
8. Control system 8.10 Menu structure (apart from L15RS-L22RS) (values are examples) + TOTAL RUNNING 12345h [MAINTENANCE SCHED.] LOADED HOURS 10987h + AIR FILTER IN 2000h OIL FILTER IN 2000h ... -
Page 44: Menu Structure (Only L15Rs-L22Rs) (Values Are Examples)
8. Control system 8.11 Menu structure (only L15RS-L22RS) (values are examples) + TOTAL RUNNING 12345h [MAINTENANCE SCHED.] LOADED HOURS 10987h + AIR FILTER IN 2000h OIL FILTER IN 2000h ... -
Page 45: Service And Maintenance
In order to facilitate this task, the scope of supply of the screw compressor unit comprises the “Maintenance Checks and maintenance work may only be carried and inspection manual for CompAir compressors”, in out when the following points are observed: which you can list your performed maintenance work at Press the STOP button on the control panel and •... - 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 ...
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Page 48: Oil Change
9. Service and maintenance in the intake air and the formation of condensate within Oil change the machine affect the service life of the lubricant oil so that a reduction in the oil change intervals may become necessary. The specified oil change intervals refer to an intake air from a normal environment without a high content of foreign matter (dusts, vapours, gases). -
Page 49: Change Of Oil Filter Cartridge
9. Service and maintenance Screw on the new oil filter cartridge and tighten • Change of oil filter cartridge manually (take notice of the instructions on the oil filter cartridge) Check for leakage • Check oil level (see chapter 6.5) •... -
Page 50: Change Of Air Intake Filter
9. Service and maintenance Note Dispose of the fine separator cartridge in line with the regulations - special waste! Check for leakage! For the changing intervals, see the maintenance schedule. Change the oil fine separator as follows: Switch the screw compressor unit off and make sure •... -
Page 51: Safety Valve
9. Service and maintenance Safety valve Changing V-belts/automatic tensioning system Danger Only perform checks and carry out work when the screw compressor unit is out of operation and depressurized, electrically isolated and locked off. Any safety equipment which had to be removed for the replacement of the V-belt set must be remounted after completion of this work. -
Page 52: Connecting Terminals In The Switch Cabinet/Control Transformer Setting
9. Service and maintenance Changing the V-belt is carried out as follows: 9.12 General maintenance and cleaning Open front panel • Important Remove the cover cap ( - 1 - Fig. 21) from the • Remove oil residues and other deposits from unit access panel parts and from the coolers of compressors, which Lift the motor by turning the motion screw... -
Page 53: Clean / Change Filter With Cooling Air Inlet And Control Cabinet Inlet
9. Service and maintenance Cleaning: 9.13 Clean / change filter with cooling air inlet and control cabinet inlet Clean the filter mat by brushing or washing. Important Never install the filter mat in a wet or moist state! b) Inlet filter and outlet filter of control cabinet (only L15RS-L22RS): •... -
Page 54: 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 55: Trouble-Shooting
10. Trouble-shooting Tr ou ble -s ho oti ng Malfunction Possible cause Remedy Unit cannot be started No operating or control voltage Check fuses, main switch and supply line Malfunction not acknowledged Acknowledge fault message Pressure reservoir not depressurized Wait until depressurized Electric motor defective Check connections, winding, etc. - Page 56 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 Cross section of the electric supply Measure power requirement, lines too small if necessary, replace lines Power requirement too high Oil fine separator clogged,...
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Page 57: Annex
11. Annex Ann ex 11.1 Technical data EUROPE version L15-L22 50 Hz Technical Data L15-L22 ; 50 Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C + 1 / + 45 Flow /min 2.70 2.26 1.80 3.25 2.74 2.34 3.65 3.21 2.61... -
Page 58: Technical Data Europe Version L15-L22 60 Hz
11. Annex 11.2 Technical data EUROPE version L15-L22 60 Hz Technical Data L15-L22 ; 60 Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C + 1 / + 45 Flow /min 2.59 2.42 1.84 3.21 2.97 2.34 3.66 3.40 2.68 Final compression temperature above ambient temp. -
Page 59: Technical Data Europe Version L15Rs
11. Annex 11.3 Technical data EUROPE version L15RS Technical data 50Hz / 60Hz L15RS Maximum operating pressure 13.0 Minimum operating pressure Ambient temperature °C + 1 / + 45 Operating pressure 7.5 bar 9 bar 10 bar 13 bar min. max. -
Page 60: Technical Data Europe Version L18Rs
11. Annex 11.4 Technical data EUROPE version L18RS Technical data 50Hz / 60Hz L18RS Maximum operating pressure 13.0 Minimum operating pressure Ambient temperature °C + 1 / + 45 Operating pressure 7.5 bar 9 bar 10 bar 13 bar min. max. -
Page 61: Technical Data Europe Version L22Rs
11. Annex 11.5 Technical data EUROPE version L22RS Technical data 50Hz / 60Hz L22RS Maximum operating pressure 13.0 Minimum operating pressure Ambient temperature °C + 1 / + 45 Operating pressure 7.5 bar 9 bar 10 bar 13 bar min. max. -
Page 62: Technical Data Usa/Canada Version L15-L22 60 Hz
11. Annex 11.6 Technical data USA/Canada version L15-L22 60 Hz Technical data L15-L22 ; 60 Hz Maximum operating pressure psi g Minimum operating pressure psi g 73.0 Ambient temperature °F + 34 / + 113 Flow 91.5 85.5 65.1 113.3 104.9 82.6 129.4... -
Page 63: Technical Data Usa/Canada Version L15Rs
11. Annex 11.7 Technical data USA/Canada version L15RS Technical data 50Hz / 60Hz L15RS Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature °F + 34 / + 113 Operating pressure psi g min. max. min. max. min. -
Page 64: Technical Data Usa/Canada Version L18Rs
11. Annex 11.8 Technical data USA/Canada version L18RS Technical data 50Hz / 60Hz L18RS Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature °F + 34 / + 113 Operating pressure psi g min. max. min. max. min. -
Page 65: Technical Data Usa/Canada Version L22Rs
11. Annex 11.9 Technical data USA/Canada version L22RS Technical data 50Hz / 60Hz L22RS Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature °F + 34 / + 113 Operating pressure psi g min. max. min. max. min. -
Page 66: Layout Plan L15-L22
11. Annex 11.10 Layout plan L15-L22 Fig. 23 A = Compressed air connection G 1“ B = Cooling air inlet C = Cooling-air outlet D = Oil drain E = Cooling-air outlet of control cabinet (only L15RS-L22RS) F = Cooling-air inlet of control cabinet (only L15RS-L22RS) H = Cable entry CM = Center of gravity... -
Page 67: Layout Plan Airstation L15Fs-L22Fs
11. Annex 11.11 Layout plan AirStation L15FS-L22FS PLUG 2” Fig. 24 A = Compressed air connection G 1“ B = Cooling air inlet dryer C = Dryer D = Cooling-air outlet compressor E = Condensate drain G 3/8“ F = Forklift truck guidance G = Center of gravity... -
Page 68: Declaration Of Conformity
EN 61000-6-4 EN 14121-1 EN 29001 EN 60204-1 EN 61000-6-2 5. National engineering standards and specifications applied AD-S1/2000 BetrSichV DIN 3230 VDE 0298 6. Recording agency: CompAir Drucklufttechnik - Zweigniederlassung der Gardner Denver Deutschland GmbH Qualitätsmanagement: Christian Mair Simmern, Date Signature... - Page 72 Garrdner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 ++49 (0)6761 832-409 www.compair.com e-mail: sales@compair.com...
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