CompAir D15H Operating And Service Manual

Screw air compressor

Hide thumbs

page of 64

/ 64
Bookmarks

Quick Links

Download this manual

Original Operating and Service Manual

Screw Air Compressor

D15H - D22H

D15HRS - D22HRS

●

Id. No. ZS1093090 / 03 - June 2014

Need help?

Do you have a question about the D15H and is the answer not in the manual?

Questions and answers

Summary of Contents for CompAir D15H

Page 1 Original Operating and Service Manual Screw Air Compressor D15H - D22H D15HRS - D22HRS ● Id. No. ZS1093090 / 03 - 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 CompAir 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 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 prerequisites requirements placed upon it. It is therefore imperative to...
Page 6 Modifications and changes to the installation • The warranty and liability conditions of the general terms and conditions of CompAir will not be extended by the notes above. Any unauthorized change to the compressor unit/ station, or the installation of components not accepted by the manufacturer (e.g.
Page 7 6.3.1 Limit values of the constituent elements in water..................30 6.4 Electrical connection..............................31 6.4.1 Electrical connection (EUROPE-Version only)....................31 6.4.2 Check setting of the motor protection switch (only D15H RS-D22H RS).............32 6.4.3 Checking the setting of the control-power transformer .................33 6.5 Water supply ................................33 6.5.1 First-time water filling ............................33...
Page 8 10 Trouble-shooting ................................48 11 Annex....................................50 11.1 Technical data................................50 11.1.1 Technical data D15H - D22H 50 Hz (air-cooled)...................50 11.1.2 Technical data D15H - D22H 50 Hz (water-cooled)..................51 11.1.3 Technical data D15HRS - D22HRS (air-cooled) ...................52 11.1.4 Technical data D15HRS - D22HRS (water-cooled) ..................53 11.2 Layout plans................................54...
Page 9 3. Safety regulations Safet y r eg ula tio ns Identification of safety guidelines Gardner Denver is not liable for any damage or injury resulting from the non-observance of these safety instructions or negligence of the usual care and attention required during handling, operation, maintenance or repair, even if this is not explicitly mentioned in these operating instructions.
Page 10 3. Safety regulations 3.2 General safety regulations Danger Safety measure required Working with compressors involves Everyone working with the machine must have first read and understood the dangers that are not immediately operating manual. Donʼt leave this until you start work – itʼs too late. apparent.
Page 11 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 12 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 13 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 14 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 15 3. Safety regulations 3.8 Dangers resulting from neglecting to perform maintenance Danger Safety measure required Components of importance to safety Observe the setting, maintenance, and inspection work and intervals wear over time. stipulated in the operating manual, including information about the replacement of parts / partial sections.
Page 16 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 17 3. Safety regulations Danger Safety measure required Modifications to the machine impair After completing repair work, always check to see whether any tools, loose parts or cloths have been left in or on the machine, driving engine or driving safety. equipment.
Page 18 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 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 D15H - D22H Fig. 2 1 Intake filter 11 Cooling air ventilator 21 Fan protection panel 2 Intake controller...
Page 21 4. Design and functioning 4.1.2 Design of the unit D15HRS - D22HRS Fig. 3 1 Intake filter 11 Cooling air ventilator 21 Fan protection panel 2 Suction inlet 12 Cooling air inlet filter mat 22 Water level indicator 3 Electric motor 13 Compressed air outlet 23 Water level sensor 4 Screw compressor...
Page 22 4. Design and functioning 4.1.3 Design of the unit D15H - D22H - W Fig. 4 1 Intake filter 11 Cooling air ventilator 21 Fan protection panel 2 Intake controller 12 Cooling air inlet filter mat 22 Water level indicator...
Page 23 4. Design and functioning 4.1.4 Design of the unit D15HRS - D22HRS - W Fig. 5 1 Intake filter 11 Cooling air ventilator 21 Fan protection panel 2 Suction inlet 12 Cooling air inlet filter mat 22 Water level indicator 3 Electric motor 13 Compressed air outlet 23 Water level sensor...
Page 24 4. Design and functioning 4.1.5 Schematic diagram - fix speed - air-cooled and water-cooled Fig. 6 1. Intake filter 13. Water cooler 28. 2/2-directional solenoid valve 2. Intake controller 15. Blow-off valve (water in Y8) 2.1 Actuator 16. Pressure holding valve 29.
Page 25 4. Design and functioning 4.1.6 Schematic diagram - regulated speed - air-cooled and water-cooled Fig. 7 1. Intake filter 15. Blow-off valve 27. 2/2-directional solenoid valve 2. Intake controller 16. Pressure holding valve (water stop Y6) 3. Electric motor (residual pressure) 28.
Page 26 (Please also see the operating instructions for the compressor control DELCOS XL) Speed control operation Speed is controlled using a software-implemented PI 4.4.1 Control D15H RS-D22H RS (Fig. 7) regulator that adapts the RPMs according to the need for compressed air. System downtime...
Page 27 (-20-) are shut down. The system will then go into load runs. • Automatic operation (open-close operation) 4.4.2 Control D15H-D22H (Fig. 6) When the pressure reaches the upper switching • point set on the network pressure sensor (-31-(B1)), (Please also see the operating instructions for the solenoid valve (-25- (Y1)) is deenergised.
Page 28 Only use the identified lifting points. Do not slide the unit when it is standing on the floor. Weights The values listed below are approximate values, they refer to a screw compressor unit including water fill: air-cooled unit D15H: 672 kg D15HRS: 687 kg D22H: 691 kg...
Page 29 5. Transport and installation Installation A = 1m/39.4” B = 1m/39.4” 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 30 (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 +40°C (104°F). In the case of temperatures other than the above limiting values, please consult your technical adviser.
Page 31 6. Preparations for commissioning Automatic drain facilities have to be checked for proper Compressed air connection function at regular intervals. When draining conden- sates into a collecting line, which also collects the condensate from other machines, make sure that the collecting line is free from back pressure at all lines.
Page 32 Δ t = 10 °C, is approx. 60 l/min Note This data is based on fresh water and the cooling-water quality recommended by CompAir (see Chapter 6.3.1). The information set out below is intended for guidance Please contact CompAir if the cooling-water data and may differ under certain conditions of operation.
Page 33 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. 15) on the base frame and the control cabinet and tighten screws. Compressor units are finished in the factory according to standard EN60204 (industrial machinery).
Page 34 DIN VDE 0298, part 4 or BS7671 taking into account the cable type. 6.4.2 Check setting of the motor protection switch (only D15H RS- D22H RS) Check the setting of the motor protection switch in accordance with the enclosed circuit diagram for the compressor.
Page 35 < 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 36 By mixing circulation water, drinking water and treated (tolerance: ± 3 dB(A)): water, the requisite level of water quality will be achieved over the course of time. air-cooled unit D15H(RS) 50Hz 68 dB(A) D15H(RS) 60Hz 70 dB(A) D22H(RS) 50Hz 68 dB(A)
Page 37 DELCOS XL operating manual). power supply, check the direction of rotation of the drive motor! Only D15H-D22H: To check the drive direction, • temporarily open the enclosure. The direction of If the direction of rotation is incorrect, immediately...
Page 38 7. Commissioning Display of the compressor control DELCOS XL Fig. 19 1. Touchscreen Display 2. Start push-button [ I ] 3. Stop push-button [ O ] 4. red LED Flashing slowly = Warning Flashing rapidly = fault Fig. 18 5. yellow LED Flashing slowly = Maintenance required Note 6.
Page 39 [O] key. compression pressure is more than 0.4 bar / 5.8 PSI for the D15H-D22H and 1.0 bar / 14.5 PSI for the D15H RS-D22H RS. Temperature start-up protection The screw compressor unit will not start up if the ambi-...
Page 40 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 • Warning: Electrical voltage: Only work on the screw compressor unit when it is disconnected. For D15H RS-D22H RS only: 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 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 9. Service and maintenance Change of air intake filter Change water filter Fig. 20 Fig. 21 1 Air intake filter 1 Water filter 2 Extraction site for water sample Danger Danger Only perform checks and carry out work on the screw compressor when the unit is out of Only change water filter when the unit is out of operation, depressurized, and secured from being...
Page 45 9. Service and maintenance Insert a new filter element and hand tighten the filter Changing times for the water filter • housing. The operating conditions (e.g. cooling medium temperatures), the operating modes and the quality of Re-open the main water supply and the storage tank •...
Page 46 9. Service and maintenance Safety valve Important A wrong setting of the control-power transformer jeopardizes the trouble-free operation of compressor units and can result in malfunction or damage. The verification of the control-power transformer • setting is a must during commissioning and periodic inspection/ maintenance, as the voltage supply conditions may vary.
Page 47 9. Service and maintenance 9.10 Fittings 9.12 Clean / change filter mats The fittings of the air and water circuits have to be Danger checked and, if required, re-tightened according to the Only perform filter mat change when the unit is out maintenance schedule.
Page 48 9. Service and maintenance b) Switch cabinet filter (D15HRS-D22HRS only) 9.13 Inspection of the compressor stage Fig. 26 Fig. 28 Danger 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! Caution when draining hot water: risk of scalding! Allow the unit to cool down first.
Page 49 9. Service and maintenance Caution when draining hot water: risk of scalding! 9.14 Inspection intervals for pressure vessels and electrical installations Allow the unit to cool down first. Check if the water level indicator on the DELCOS XL Pressure vessels display deviates greatly from the water level indicator As per the requirements of the 97/23/EC Pressure (-1- Fig.
Page 50 > 1.0 bar/14.5 PSI (for the D15HRSD22H RS) or > 0.4 bar/5.8 PSI (for the D15H-D22H) 4. Electric motor defective 4. Check connections, winding, etc. 5. Compressor defective 5. Turn the compressor manually;...
Page 51 10. Trouble-shooting Malfunction Possible cause Remedy Unit switches off 1. Ambient temperature too high 1. Ventilate compressor room 2. Electric motor defective 2. Check electric motor and thermistor 3. Fan defective 3. Check/replace fan 4. Sensor, connections or lines defective 4.
Page 52 11. Annex Ann ex 11.1 Technical data 11.1.1 Technical data D15H - D22H 50 Hz (air-cooled) D15H D22H Maximum operating pressure Minimum operating pressure Ambient temperature min./max. °C 2 to 45 2 to 40 Flow /min 2.30 1.80 3.50 2.89 Outlet temperature above ambient temp.
Page 53 11. Annex 11.1.2 Technical data D15H - D22H 50 Hz (water-cooled) D15H D22H Operating pressure max. Operating pressure min. Ambient temperature min./max. °C 2 to 45 Flow /min 2.30 1.80 3.50 2.89 Outlet temperature above ambient temp. °C Sound pressure level...
Page 54 11. Annex 11.1.3 Technical data D15HRS - D22HRS (air-cooled) D15HRS D22HRS Working pressure max. Working pressure min. Ambient temperature min./max. °C 2 to 45 2 to 40 min. 0.32 0.43 0.68 0.77 Flow /min max. 2.21 1.83 3.34 2.93 Discharge temp. of air above ambient temp. °C Sound pressure level 50Hz/60Hz dB(A)
Page 55 11. Annex 11.1.4 Technical data D15HRS - D22HRS (water-cooled) D15HRS D22HRS Working pressure max. Working pressure min. Ambient temperature min./max. °C 2 to 45 2 to 40 min. 0.32 0.43 0.68 0.77 Flow /min max. 2.21 1.83 3.34 2.93 Discharge temp. of air above ambient temp. °C Sound pressure level 50Hz/60Hz dB(A)
Page 56 Water inlet inner thread G 3/8” (3/8” NPT) Water outlet inner thread G 3/8” (3/8” NPT) Drain water separator inner thread G 1/4” (1/4” NPT) (only for D15H-D22H) Drain RO unit inner thread G 1/4” (1/4” NPT) Compressed air connection: external threaded connector R 1” (1” NPT)
Page 57 Water inlet inner thread G 3/8” (3/8” NPT) Water outlet inner thread G 3/8” (3/8” NPT) Drain water separator inner thread G 1/4” (1/4” NPT) (only for D15H-D22H) Drain RO unit inner thread G 1/4” (1/4” NPT) Compressed air connection: external threaded connector R 1” (1” NPT)
Page 58 11. Annex (all dimensions in mm) Fig. 33...
Page 59 11. Annex water-cooled (all dimensions in mm) Fig. 34 L Cooling-water inlet G1" (G1" NPT) M Cooling-water outlet G1" (G1" NPT)
Page 60 Argenthaler Str.11 D-55469 Simmern that the product: Kompressor 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:...
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:

D22h D15hrs D22hrs