Professional Documents
Culture Documents
Compair L22 Compressor
Compair L22 Compressor
●
GB ●
CDN ●
USA Id. no. ZS1062654 / 04 - April 2013
General Information
These compressors are for compressing atmospheric air and are not suitable for compressing any other gas. They are
designed and manufactured to give optimum performance with long life and reliability.
This manual gives the user all the information required to install and operate the compressors and carry out the regular
schedules for servicing and maintenance, which will ensure the maximum satisfactory service life.
Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of CompAir
Companies and Distributors. If replacement parts are needed, the user should, in the first instance, contact the local
CompAir Company or Distributor.
The information given in this manual was correct at the time of printing, however, as part of continuous development,
modifications to parts and procedures may be made without notice which could affect the servicing requirements of the
compressors. 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.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL NUMBER and where
possible the YEAR of MANUFACTURE.
All pressure data given in this manual refer to overpressures (pressure gauge pressures) unless specified otherwise.
Maintenance
To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenance and
servicing is carried out in accordance with the information given in the ʻMaintenanceʼ section of this manual. To assist in
this matter your local CompAir Company or Distributor can provide a number of optional maintenance agreements to suit
your requirements. These agreements provide the user with the expertise of our factory trained technicians and the
guarantee that only Genuine CompAir parts will be used.
Warranty
The conditions of the Gardner Denver Warranty are set out in the Companyʼs standard Conditions of Sale available from
the Gardner Denver Company or Distributor supplying the machine.
*)
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Fig. 1
Name:
Address: ______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Telephone: Fax:
Service:
2
1. Foreword
1 For ew or d
3
1. Foreword
Guarantee
• Operating errors
• Incorrect maintenance
• Wrong auxiliary materials
• Use of spare parts other than CompAir genuine
spare parts
• Modifications and changes to the installation
Safety regulations
Danger
Technical changes
In the course of technical development we reserve the
right to modify the units without further notice.
4
2. Table of contents
2 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
3.5 Special work/maintenance .........................................................................................................................................10
3.6 Warning of special dangers........................................................................................................................................12
3.7 Storage of compressors .............................................................................................................................................13
3.8 Symbols and explanations .........................................................................................................................................14
4 Design and functioning ....................................................................................................................................................18
4.1 Design of the unit ........................................................................................................................................................18
4.1.1 Design of the unit - L15-L22 ...........................................................................................................................18
4.1.2 Design of the unit - AirStation L15FS-L22FS ................................................................................................19
4.2 Schematic diagram .....................................................................................................................................................20
4.2.1 Schematic diagram L15-L22...........................................................................................................................20
4.3 Oil circuit......................................................................................................................................................................21
4.4 Air circuit......................................................................................................................................................................21
4.5 System control ............................................................................................................................................................21
4.5.1 System control L15-L22 / L15FS-L22FS........................................................................................................21
4.5.2 System control L15RS-L22RS / L15RS FS-L22RS FS.................................................................................22
4.6 Hood (opening/closing)...............................................................................................................................................23
5 Transport and installation ................................................................................................................................................24
5.1 Transport .....................................................................................................................................................................24
5.2 Installation ...................................................................................................................................................................25
6 Preparations for commissioning ....................................................................................................................................26
6.1 Cooling air volume/minimum cross ............................................................................................................................26
6.2 Compressed air connection........................................................................................................................................27
6.3 Electrical connection...................................................................................................................................................28
6.3.1 Electrical connection (EUROPE-Version only)..............................................................................................28
6.3.2 Electrical connection (USA/CANADA-Version only) .....................................................................................31
6.4 Electric motor fasteners for secure transportation ....................................................................................................33
6.5 Oil level check .............................................................................................................................................................33
6.6 Sound pressure level ..................................................................................................................................................34
7 Commissioning ..................................................................................................................................................................35
7.1 First commissioning ....................................................................................................................................................35
7.2 Routine commissioning ..............................................................................................................................................36
7.3 Commissioning after malfunction...............................................................................................................................36
5
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
8.7 Switching off the unit...................................................................................................................................................39
8.8 Emergency off button..................................................................................................................................................40
8.9 Acknowledging warning / fault messages .................................................................................................................40
8.9.1 Warning messages .........................................................................................................................................40
8.9.2 Fault messages...............................................................................................................................................40
8.10 Menu structure (apart from L15RS-L22RS) (values are examples).........................................................................41
8.11 Menu structure (only L15RS-L22RS) (values are examples)...................................................................................42
9 Service and maintenance.................................................................................................................................................43
9.1 Maintenance recommendations.................................................................................................................................43
9.2 Maintenance electric motor ........................................................................................................................................43
9.3 Maintenance schedule................................................................................................................................................43
9.4 Oil change ...................................................................................................................................................................46
9.5 Change of oil filter cartridge .......................................................................................................................................47
9.6 Change of the fine separator cartridge ......................................................................................................................47
9.7 Change of air intake filter............................................................................................................................................48
9.8 Safety valve.................................................................................................................................................................49
9.9 Changing V-belts/automatic tensioning system ........................................................................................................49
9.10 Connecting terminals in the switch cabinet/control transformer setting...................................................................50
9.11 Fittings .........................................................................................................................................................................50
9.12 General maintenance and cleaning ...........................................................................................................................50
9.13 Clean / change filter with cooling air inlet and control cabinet inlet..........................................................................51
9.14 Inspection intervals for pressure vessels and electrical installations.......................................................................52
9.15 Maintenance information and lubricant recommendations for stationary compressors..........................................52
10 Trouble-shooting ...............................................................................................................................................................53
11 Annex...................................................................................................................................................................................55
11.1 Technical data EUROPE version L15-L22 50 Hz .....................................................................................................55
11.2 Technical data EUROPE version L15-L22 60 Hz .....................................................................................................56
11.3 Technical data EUROPE version L15RS ..................................................................................................................57
11.4 Technical data EUROPE version L18RS ..................................................................................................................58
11.5 Technical data EUROPE version L22RS ..................................................................................................................59
11.6 Technical data USA/Canada version L15-L22 60 Hz ...............................................................................................60
11.7 Technical data USA/Canada version L15RS ............................................................................................................61
11.8 Technical data USA/Canada version L18RS ............................................................................................................62
11.9 Technical data USA/Canada version L22RS ............................................................................................................63
11.10 Layout plan L15-L22 ................................................................................................................................................64
11.11 Layout plan AirStation L15FS-L22FS .....................................................................................................................65
11.12 Declaration of conformity .........................................................................................................................................66
6
3. Safety regulations
7
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
absolutely indispensable. accessories. This applies also to the installation and
setting of safety equipment and valves as well as to
The personnel must be made familiar with the location welding on structural or pressurized parts.
and operation instructions of fire extinguishers !
Observe all fire-warning and fire-fighting procedures!
Limit values (pressures, time settings, etc.) have to be 3.4 Installation and normal operation
permanently identified!
Installation
Selection and qualification of personnel; In addition to the general technical operation in
basic responsibilities accordance with the stipulations of the local authorities,
we would like to refer in particular to the following
Work on/with the machine/unit must be carried out by
regulations.
reliable personnel only. Statutory minimum age limits
must be observed! For the lifting of a compressor, a suitable lifting
mechanism is to be used, which meets the local safety
Employ only trained or instructed personnel and clearly
regulations. All loose or slew able parts must be safely
set out the individual responsibilities of the personnel
fixed before the machine can be lifted. It is strictly
for operation, set-up, maintenance and repair!
prohibited to stay in the danger zone of a lifted load.
Ensure that only authorized personnel work on or with
The correct method of lifting (according to the operating
the machine!
instructions of the load suspension device) has to be
Define the machine operator's responsibilities giving the ensured.
operator the authority to refuse instructions by third
All blind flanges, plugs, caps and bags with drying
persons that are contrary to safety regulations. agent have to be removed prior to the installation of the
Do not allow persons to be trained or instructed or pipes. Distributing pipes and pipe connections have to
persons taking part in a general training course to work be of the proper size and suitable for the relevant
on or with the machine/unit without being permanently operating pressure.
supervised by an experienced person!
The system must be set up on a level surface with full
Work on the electrical equipment of the machine/unit contact between its base frame and the supporting
must be carried out only by a skilled electrician in surface.
accordance with electrical engineering rules and
The system has to be installed in such a way that it is
regulations. adequately accessible and the required cooling is
Work on system elements such as hoses may only be guaranteed. Never block the air intake. Make sure that
carried out by personnel with special knowledge and the ingress of humidity via the intake air is kept to a
experience of hydraulics! minimum.
The air intake is to be located so that no hazardous
constituent (solvent vapour, etc., but also dusts and
3.3 Changes and modifications to the other hazardous material) can be sucked in. This
machine applies also to flying sparks.
The air intake is to be positioned so that no loose
Do not make any changes, modifications or
clothing of persons can be sucked in. Make sure that
attachments to the machine/unit, which could affect
the pressure line from the compressor to the after
safety, without the supplier's prior permission!
cooler or the air circuit can expand under heat and does
Unauthorized changes to the machine are not permitted not come into contact with inflammable material.
for safety reasons.
The pressure line connected to the air outlet of the
Original parts were especially designed for this system must be fitted stress-free. When connecting the
machine. We would like to point out that we have not compressor on the mains side to the compressed air
released and will not release parts and special system available at the customerʻs end, check the
accessories which have not been supplied by us. The operating temperatures and operating pressures
installation and/or use of such products can therefore required and examine the required connecting flange or
affect the active and/or passive safety. the connection thread for proper functioning.
In the case of connections by means of connecting
hoses, take appropriate measures to prevent whipping
of the loose end in the event that the hose connection
tears off.
8
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. by means of a steam heater.
start up without prior warning!
If it is possible that the intake temperature of the air will
As an additional safety measure, persons, who start exceed, from time to time, the admissible maximum
remotely controlled systems, have to take sufficient specified in the operating instructions, a precooler with
safety precautions in order to ensure that nobody is condensate drain is to be installed before the dryer.
checking the system or working on it. For this, a label
with a corresponding warning notice has to be attached Tests or repair work on the coolant circuit may only be
to the remote control equipment. carried out in a well vented room. Never breath in
coolant vapour; if necessary, wear a breathing mask.
Compressed air and cooling water lines have to be Always wear protective goggles and gloves. If skin
clearly marked in line with the local regulations. comes into contact with coolants, rinse well with water.
Never take off or tear up clothes but rinse them well
If a system comprises several compressors, hand with water until the coolant is washed off; then see a
operated isolator valves have to be installed in order to doctor.
be able to shut off each machine individually. When
operating pressure systems, do not rely on the
effectiveness of start valves alone to isolate these Condensate drain
systems.
The drain hose for condensate discharge is to be
Safety equipment, protective covers or insulation must connected to the drains or to a collecting reservoir, if
not be removed or modified. Any pressure reservoir, local regulations prohibit direct discharge to the drains.
which is located outside the system, the permissible In connection with this, it must be taken into account
operating pressure of which is higher than the that the condensate from compressors with oil-
atmospheric pressure and which is fitted with two or lubricated pressure chambers can contain oil.
more pressure supply lines, has to be equipped with
additional safety equipment, which will automatically
prevent the admissible operating pressure from rising Normal operation
by more than 10%. Take the necessary precautions to ensure that the
The installed unit-specific safety valves only assume machine is used only when in a safe and reliable state!
the pressure safeguarding function of the compressor Operate the machine only when all protective
unit provided in currently valid standards and equipment, emergency shut-off equipment, sound-
regulations. proofing elements and extraction devices are in place
and fully functional!
For pressure components/systems mounted to the
connecting flange on the pressure side, a pressure Check regularly that
safety device (safety valve or similar) has to be installed • all means of protection are correctly fitted and fixed,
taking into account the weakest pressurized
component. • all hoses and/or pipes within the system are in good
condition, firmly fixed and do not chafe,
The min. and max. temperatures of +1 °C/33.8 °F and
+45 °C/113°F are also valid for the intake air. Pipes • there are no leakages (fuel, oil or coolant),
and/or other parts with a surface temperature higher
• all fittings are firmly tightened,
than 70 °C/158 °F have to be suitably identified and
shielded against touching. • all wires are connected correctly and are in good
condition,
Electrical connections must meet the local regulations.
Power units must be connected to earth and protected • all safety valves and other pressure relief
from short-circuits by means of fuses. mechanisms are in good order and not blocked by
e.g. dirt or paint,
Cold dryer • the safety mechanisms are fully functional.
Wherever possible, the cold dryer should be installed in If compressed air hoses are used, they must be of the
a place where the ambient air is as clean as possible proper size and suitable for the relevant operating
and where the temperatures never rise above or fall pressure. Do not use chafed, damaged or poor-quality
below the respective limit values as indicated in the hoses.
operating instructions. If required, the cooling air is to
be taken from a cleaner, cooler or warmer area via an Only use hose couplings and fittings of the right type
intake channel; depending on the size of the machine, and the correct size.
an additional fan could turn out to be necessary.
9
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. this work.
Before decoupling a hose ensure that it is pressureless. Oil losses result in a slippery floor. Therefore, always
clean the floor and the outside of the machine prior to
Refrain from any working method which is doubtful in starting the maintenance work.
terms of safety.
Checks, maintenance and repair work may only be
Never play around with compressed air! carried out with the screw compressor being at rest and
Never aim compressed air at your skin or at other depressurized. Protective equipment to be removed for
persons! this work, has to be refitted after completion of these
activities. Operation of the machine without protective
Never use compressed air to clean your clothing. equipment is not permitted. When working on a running
screw compressor system, working clothes have to be
When using compressed air to clean equipment take
close-fitting.
the utmost care and always wear protective goggles.
If the machine/unit is completely shut down for
The compressed air generated by these compressors
maintenance and repair work, it must be secured
must never be used for breathing unless it has been
against inadvertent restarting:
conditioned for those applications in line with the “safety
requirements for respiratory air”. • Lock the main command elements and remove the
key and/or
Never use the machine in an environment where
inflammable or poisonous vapour can be sucked in. • attach a warning sign to the main switch.
Never operate the system at pressures and Always use the correct tools for maintenance and repair
temperatures below or above the values indicated in the work.
technical data sheet.
Never use inflammable solvents or carbon tetrachloride
The access panels, etc. have to be closed during to clean parts. Take precautions against poisonous
operation. vapours from cleaning agents.
Check the machine/unit at least once per shift for visible In any work concerning the operation, conversion or
damage and faults! Report any changes (including adjustment of the machine and its safety-oriented
changes in the machineʼs operating behaviour) to the devices or any work related to maintenance, inspection
responsible department/person immediately. If and repair, always observe the start-up and shutdown
necessary, stop and lock the machine immediately! procedures set out in the operating instructions and the
information on maintenance work.
In the case of malfunction, stop the machine/unit
immediately and lock it! Have any defects rectified Ensure that the maintenance area is adequately
immediately! secured.
Observe the start-up and stopping procedures and the To lower the risk of accidents, individual parts and large
control displays according to the operating instructions. assemblies being moved for replacement purposes
Before starting up or setting the machine in motion, should be carefully attached to lifting tackle and
ensure that nobody is at risk. secured. Use only suitable and technically correct lifting
gear and only utilize suspension systems with adequate
Do not cut off or remove extraction or venting facilities
lifting capacity. Never work or stand under suspended
while the machine is running.
loads!
During maintenance and when carrying out repair work,
cleanliness is very important. Avoid the ingress of dirt
3.5 Special work/maintenance
by covering parts and free openings with a clean cloth,
Carefulness paper or adhesive tape.
Observe the adjusting, maintenance and inspection After the completion of each repair, check that tooling or
activities and intervals set out in the operating loose parts have not been left in the or on top of the
instructions, including information on the replacement of machine, drive motor or drive equipment and ensure
parts and equipment. These activities may be carried that no cloth has been left inside these units.
out by skilled personnel only. Be careful when the screw compressor system is in
Brief the operating personnel prior to starting special operation.
operations or maintenance work! Appoint a person to
supervise the activities!
10
3. Safety regulations
Maintenance/rectification of faults Avoid damage to the safety valves and other pressure
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 components.
avoid them; the employee has to observe all measures
for safety at work. Safety equipment for the prevention Insulation or protective shielding, the temperature of
or elimination of danger has to be maintained regularly which may exceed 70 °C/158 °F and which could be
and functionally checked at least once a year. Faults erroneously touched by the personnel, must not be
observed have to be immediately rectified and/or removed before these parts have cooled down to room
reported to the responsible person. temperature.
Use only original spare parts. Check the accuracy of pressure and temperature
indicators at regular intervals. If the admissible
Only carry out maintenance and repair work when the tolerance limits have been exceeded, these devices
system is not in operation and the power supply have to be replaced.
disconnected. Ensure that the power unit cannot be
switched on inadvertently. Before removing or overhauling a compressor, a motor
or another machine, ensure that all moveable parts of a
Before removing or opening pressurized components, mass of more than 15 kg cannot move or roll away.
positively isolate any source of pressure and
depressurize the entire system. After completion of repair work, always verify that no
tools, loose parts or cloths have been left in or on the
Never weld near oil systems or carry out any other work machine, drive motor or drive equipment. Machines
requiring heat. Pressure reservoirs or components and performing a back and forward main movement have to
pipes containing oil have to be drained completely and be cycled at least once, rotating machines have to be
cleaned, for example by means of a steam jet, before cycled several times in order to ensure that there are no
beginning such work. mechanical faults in the machine or the drive member.
Never weld any pressure reservoir or change it in any Check the direction of rotation of the electric motors
way. during first commissioning and after each modification
of the electrical connections in order to prevent the
If work which produces heat, flames or sparks has to be compressor from being damaged.
carried out on a machine, the adjacent components
have to be protected by means of non inflammable The fastening of loads and the instructing of crane
material. operators should be entrusted to experienced persons
only. The person giving the instructions must be within
Before releasing the power unit for operation after sight or voice contact with the operator.
maintenance or overhaul, check that the operating
pressures, temperatures and time settings are correct For carrying out overhead assembly work always use
and that the regulating and shut-down equipment specially designed or otherwise safety-orientated
function properly. ladders and working platforms. Never use machine
parts as a climbing aid. Wear a safety harness when
Every six months, check the pressure pipe and carrying out maintenance work at greater heights.
pressure vibration damper for carbon deposits. If
excessive deposits are found, they should be removed. Keep all steps, handles, handrails, platforms, landings
and ladders free from dirt, snow and ice! Clean the
Motor, air filter, electrical components and regulating machine, especially connections and threaded unions,
equipment have to protected from the ingress of of any traces of oil, fuel or preservatives before carrying
humidity, e.g. when cleaning the system by means of a out maintenance or repair work! Never use aggressive
steam jet. detergents! Use lint-free cleaning rags!
Under no circumstance must the sound-proofing Before cleaning the machine with water or steam jet
material be removed or modified. (high pressure cleaner) or other cleaning agents,
cover/mask all openings which have to be protected
Never use etching solvents which could attack the
from the ingress of water, steam or detergents for
materials used.
safety and/or functional reasons, in particular electric
If indicated or if there is any suspicion that an internal motors and switch cabinets.
part of the machine has run hot, the machine has to be
After cleaning, remove the covers/masking completely !
shut down.
Check all hydraulic oil lines for leakage, loose fittings,
In order to avoid an increase in the operating
abrasion and damage after cleaning. Any defect must
temperature, check and clean the heat transfer surfaces
be rectified immediately!
(cooling fins, intermediate cooler, water cooling jackets,
etc.) at regular intervals. Prepare a plan of the most Always re-tighten screwed connections which have
favourable cleaning intervals for each machine. been loosened for maintenance and repair work.
11
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. sure that the premises are adequately ventilated (risk of
explosion)!
Ensure that consumables and replacement parts are
disposed of in a safe and environmentally friendly Adhere to the regulations valid for the place of operation!
manner.
Observe any existing national regulations if work is to
be carried out in small rooms.
12
3. Safety regulations
Danger
Note
13
3. Safety regulations
14
3. Safety regulations
15
3. Safety regulations
16
3. Safety regulations
17
4. Design and functioning
Fig. 2a L15-L22
18
4. Design and functioning
19
4. Design and functioning
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
20
4. Design and functioning
21
4. Design and functioning
Fig. 5
1 Turnbuckle
2 Hood
23
5. Transport and installation
Important
Weights
The values listed below are approximate values, they
refer to a screw compressor unit including oil fill:
Compressor L15-L22:
AirStation L15FS-L22FS:
Fig. 6 b
Danger
24
5. Transport and installation
5.2 Installation
A = 0.5 m
B = 0.8 m
Fig. 7
Danger
Important
25
6. Preparations for commissioning
Fig. 8
Important
26
6. Preparations for commissioning
Fig. 9
Danger
27
6. Preparations for commissioning
50-Hz-Compressors
220 80 4G25
L15, L15FS 15
400 35 4G6
220 80 4G25
L18, L18FS 18.5
400 50 4G10
220 100 4G35
L22, L22FS 22
400 50 4G10
60-Hz-Compressors
220 63 4G16
230 63 4G16
L15, L15FS 15
380 50 4G10
460 35 4G6
380 50 4G10
L15RS, L15RS FS 400 15 50 4G10
460 40 4G6
220 80 4G25
230 80 4G25
L18, L18FS 18.5
380 50 4G10
460 50 4G10
380 63 4G16
L18RS, L18RS FS 400 18,5 63 4G16
460 50 4G10
220 100 4G35
230 100 4G35
L22, L22FS 22
380 63 4G16
460 50 4G10
380 63 4G16
L22RS, L22RS FS 400 22 63 4G16
460 50 4G10
28
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
Danger tighten screw connection.
The power supply to the compressor side has to be Connect the supply line to the connecting terminals as
fitted for industrial equipment and fulfilling the shown in the circuit diagram.
requirements of EN60204-1/IEC60204-1. To avoid
strong damages and fire on the power electric
components, any kind of operation outside of the
stated limits of EN60204-1/IEC60204-1 is
inadmissible.
The customer has to connect a main switch in the
incoming line of the compressor unit (unless
factory-mounted as special accessories)
(DIN EN 1012 - 1).
If this switch does not provide short-circuit and
overload protection for the system, suitable
back-up fuses have to be installed according to
EN 60269-1 (low voltage directive ) (see table).
The main switch must meet the requirements of the
safety standard EN 60 204-1 (electrical equipment of
machinery) as well as of EN 60947-2 (low- voltage
switchgear and control gear (circuit-breakers)).
The electrical connection and protective measures
have to be installed in accordance with VDE, BS or
local regulations. As a rule, additional instructions
of the relevant power supplier have also to be
adhered to.
The electrical connections must be made by an Fig. 10
authorized specialist.
29
6. Preparations for commissioning
Fig. 11
Danger
Important
30
6. Preparations for commissioning
An adequate electrical power supply of the correct When installing a unit in a "Hazardous Location"; that is
voltage must be provided. All control enclosure wiring in a location where fire or explosion is a definite hazard,
has been completed at the factory. refer to the appropriate section of the National Electrical
Code for further information.
The electrical supply should be equipped with a fused
line disconnect switch or circuit breaker so that Caution
electrical power may be disconnected while the unit is
being serviced. IN ALL CASES, THE LOCAL, STATE, AND
NATIONAL ELECTRICAL CODES MUST BE
The fuse line disconnect should be located and moun- STRICTLY FOLLOWED.
ted in accordance with all state, local, and national
regulations. Danger
The unit must be properly grounded to provide adequa- The power supply to the compressor side has to be
te ground fault protection. As a guide, it is suggested fitted for industrial equipment and fulfilling the
that the ground wire be equal in size to one of the requirements of NFPA 79. To avoid strong damages
conductors which feeds the compressor motor circuit. and fire on the power electric components, any kind
Make certain the ground wire connections are clean of operation outside of the stated limits of NFPA 79
and tight. is inadmissible.
The wire used to feed the compressor circuit should be
selected and sized based on the following conditions:
1. Motor full load amperage plus service factor.
2. Ambient temperature in the area where the wire is
located.
3. Length of wire
4. Insulation type
This information may be found in the latest edition of
the National Electrical Code.
31
6. Preparations for commissioning
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. However, practice has shown that the
actual supply voltage often differs from this value. In
Connect the supply line to the connecting terminals as order to adjust the unit to the local conditions, the
shown in the circuit diagram. setting of the control-power transformer must be
checked by measuring the control-power transformer
output voltages during under load operation and, if
required, re-set. Several tapping points are provided for
this purpose (see circuit diagram).
Fig. 11
Danger
Important
32
6. Preparations for commissioning
Fig. 13
Important
Fig. 12 • Wait at least 5 minutes for the oil to settle and for
the air to disperse
• The oil level is checked with the help of the
6.5 Oil level check transparent plastic tube at the pressure reservoir
(- 2 - Fig. 13) after every stop and at regular
Danger intervals. If required, top up oil
Only check the oil level when the screw Also see chapter 8 “Service and maintenance”
compressor unit is out of operation and
depressurized!
The pressure reservoir can be under pressure and
the oil hot. Warning: Danger of scalding!
33
6. Preparations for commissioning
50 Hz compressors dB(A)
L15 70
L18 71
L22 71
60 Hz compressors dB(A)
L15 73
L18 74
L22 74
Speed-controlled
compressors dB(A)
50 Hz/ 60 Hz
L15RS 72
L18RS 73
L22RS 73
34
7. Commissioning
7 Com m issio ni ng
If the screw compressor is newly connected to a check the direction of rotation. With a wrong direction
power supply, check the direction of rotation of the of rotation, press the red emergency STOP button
drive motor! (-24- Fig. 2) immediately and correct the direction of
rotation.
35
7. Commissioning
36
8. Control system
8 Contr ol s yst em
When supplied, the display language is set to English. Final compression temperature: is the temperature
To set another language, see chapter 8.5.1. measured downstream of the compressor stage.
Final compression pressure: is the pressure measured
downstream of the compressor stage.
Network pressure: is the pressure within the system
connected downstream of the compressor.
2nd row:
73ºC 10,4bar 10,3bar The second row is reserved for the menu. You can view
TOTAL RUNNING 4711h
ON-LOAD values like the total service hours and set values like
the nominal pressure in the menu.
3rd row:
Switch off unit Flashing rapidly: fault, unit is stopped until fault has
been rectified
The three keys on the right next to the display have a
dual function: The red light signal only goes out once the warning or
fault has been remedied properly.
+
Call up or exit menu,
at the same exit menu / sub-menu Green light signal:
time
Flashing: system is ready, i.e. the motor
may start up automatically at any
time.
Switch to next sub-menu / menu item,
or reduce a value Lit up permanently: the drive motor is running
Switch to previous sub-menu / menu
item, or increase a value
Acknowledgement key,
37
8. Control system
To then fully exit the main menu, you must again press sub-menu. Then please press the key.
the
+ keys at the same time.
The CUT-OUT POINT menu item now appears on the
display. Again pressing the – key causes the value to
flash. You can now correct (increase or decrease) this
8.4.2 Changing values value using or
. Then confirm the value set by
pressing the key.
Enter the sub-menu and then the menu item containing
the value you wish to change. Note
Then press the key, the value flashes. You can now The control system checks whether the value set can
press or
to change the value. You must then
be used. The maximum network pressure CUT-
press the key again to confirm the value. OUT POINT must be at least 0.2 more than the
minimum network pressure CUT-IN POINT. You may
therefore have to first set the minimum network
pressure point. To prevent your compressor suffering
from excess wear, the difference between the CUT-
OUT POINT and CUT-IN POINT should not be too
small.
Example:
38
8. Control system
8.5.3 Setting line pressure (only L15RS- 8.5.4 Setting time/date (timer)
L22RS) The DELCOS Pro accumulator can bridge a loss of
Speed is controlled with the aid of a PI controller power lasting between around two to three weeks. If
implemented in the software and is matched to the power is lost for longer periods, the timer's time and
demand for compressed air. In the [ CONTROL MENU ] date are lost and have to be entered anew.
menu you have to set the maximum line pressure
Press the + keys at the same time. Use to go
switching point (CUT-OUT POINT) and the TARGET
to the [ TIMER CONTROL ] sub-menu and press the
PRESSURE.
key. The date and time are displayed there in the
When the maximum line pressure switching point is following format:
reached, the machine switches to off-load.
TU 30.10.07 12:10:34
In the range between TARGET PRESSURE and CUT-
OUT POINT the speed of the machine is regulated If you press the key, the left-hand value (day of the
according to the compressed air requirement. week) starts to flash. You can now use the or
keys to set this. Then confirm the value by pressing the
Example: key.
CUT-OUT POINT 10.0bar All values can now be set in succession using this
TARGET PRESSURE 9.5bar procedure. When the last value (seconds) has been set,
The speed of the machine is regulated according to the the timer is fully set and you can exit the menu by twice
need for compressed air so that the set pressure of pressing the + keys at the same time.
Note
Target pressure: The unit may only be shut down using the emergency
off button in real emergencies. When shutting down
In the [ CONTROL MENU ] sub-menu please use
normally, please use the key.
to go to the TARGET PRESSURE menu item.
39
8. Control system
40
8. Control system
+
TIMER CONTROL
p2 TIMER CONTROL
OFF
OFF
AUTO RESTART
POWER LOSS TIME
OFF
2s
START-UP DELAY 5s
DRYER PRE-RUN 0min
RS485-ProTOCOL ModBus
RS485-BAUDRATE 19200
RS485-ADDRESS 1
+
:
:
TH 08.02.07 13:55:41
[ TIMER CONTROL ] 1 ____________ 00:00 00:00
+
:
7 ____________ 00:00 00:00
:
p2 1 __________ 00:00 00:00
:
p2 7 __________ 00:00 00:00
MIN START TEMP
RUN-ON TIME
1°C
90s
SOFT STOP 30s
STAR/DELTA TIME 6s
SOFTWARE: DPro-L-x.xx
41
8. Control system
+
+
:
:
TH 08.02.07 13:55:41
[ TIMER CONTROL ] 1 ____________ 00:00 00:00
+
:
7 ____________ 00:00 00:00
:
p2 1 __________ 00:00 00:00
:
p2 7 __________ 00:00 00:00
MIN START TEMP
RUN-ON TIME
1ºC
90s
SOFT STOP
VOL.MAX.
30s
2.8m3/min
VOL.MIN. 1.0m3/min
SOFTWARE: DPro-LRS-x.xx
42
9. Service and maintenance
• Warning:
Electrical voltage: Only work on the screw
9.2 Maintenance electric motor
compressor unit when it is disconnected.
The maintenance of the electric motor is to be • Only L15RS-L22RS / L15RS FS-L22RS FS:
performed in line with the motor operating instructions. 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. The
power condensers require this time in order to
discharge!
Service packages
Package C Oil filter cartridge, air filter cartridge
Package D Oil separator element
Package E Worn parts
Package V V-belt set (recommendation)
43
9. Service and maintenance
2,000 h
4,000 h
6,000 h
8,000 h
30 m 10,000 h
36 m 12,000 h
42 m 14,000 h
48 m 16,000 h
54 m 18,000 h
60 m 20,000 h
Commissioning
Due at x service hours
6m
12 m
18 m
24 m
At the latest after x months
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
(only USA version)
Oil change when using CSS20 Food Grade oil (only Canadian version)
Oil change when using CompLube 8000H1 oil (only USA version)
44
66 m 22,000 h
72 m 24,000 h
78 m 26,000 h
84 m 28,000 h
90 m 30,000 h
96 m 32,000 h
102 m 34,000 h
108 m 36,000 h
114 m 38,000 h
9. Service and maintenance
120 m 40,000 h
126 m 42,000 h
132 m 44,000 h
138 m 46,000 h
144 m 48,000 h
150 m 50,000 h
156 m 52,000 h
162 m 54,000 h
168 m 56,000 h
174 m 58,000 h
180 m 60,000 h
186 m 62,000 h
192 m 64,000 h
198 m 66,000 h
204 m 68,000 h
210 m 70,000 h
216 m 72,000 h
222 m 74,000 h
228 m 76,000 h
234 m 78,000 h
45
240 m 80,000 h
9. Service and maintenance
9.4 Oil change in the intake air and the formation of condensate within
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
Collect the waste oil, do not allow it to seep into the Changing intervals for lubricants
ground! The operating conditions (e.g. coolant temperatures),
Disposal in accordance with the regulations! Do not spill the operating modes and the quality of the intake air
oil! Check for leakage! (e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours) have a strong influence
With these compressors, the oil change intervals on the oil change intervals.
strongly depend on the degree of contamination of the
circulating oil. It must therefore be taken care that no In this case the oil must be analyzed to check the
oil-deteriorating matter (dusts, vapours, gases) are permissible length of time that the oil can be used (see
transported through the air intake filter into the oil circuit also chapter 9.15). Under no circumstances should the
of the compressor unit. Also a high content of humidity oil be used beyond its design life.
46
9. Service and maintenance
9.5 Change of oil filter cartridge • Screw on the new oil filter cartridge and tighten
manually (take notice of the instructions on the oil
filter cartridge)
Fig. 17
Danger
Note
• Wait at least 5 minutes for the oil to settle and for 1 Oil fine separator
the air to disperse.
Danger
• Unscrew the oil filter cartridge ( - 1 - Fig. 17) using
The pressure reservoir is under pressure! Only
an appropriate tool
work on the screw compressor unit when it is out of
• Dispose of the oil filter cartridge according to the operation and depressurized!
regulations Be careful with hot oil: Danger of scalding!
• Oil the gasket of the new oil filter cartridge slightly Do not spill oil!
47
9. Service and maintenance
Note
Changing intervals for oil fine separator cartridge 1 Air filter housing cover
2 Air filter housing
The operating conditions (e.g. coolant temperatures), 3 Air filter element
the operating modes and the quality of the intake air 4 Fixing clip
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong
influence on the service life of the filters (air filters, oil Change the air filter as follows:
filters, fine separators).
• Loosen and remove the air filter housing cover
Where such conditions exist the filter element may ( - 1 - Fig. 19)
require changing more frequently.
• Remove the air filter ( - 3 - Fig. 19) and replace it
with a new one
• Insert the air filter cartridge into the air filter housing
9.7 Change of air intake filter (- 2 - Fig. 19)
Danger • Screw the air filter housing cover on to the air filter
housing
Only perform checks and carry out work on the
screw compressor when the unit is out of operation
and depressurized! Changing intervals for air filter cartridge
Important The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air
Never operate the screw compressor unit without (e.g. content of dust, content of gaseous foreign matter
the air filter (even a short operating time without such as SO2, solvent vapours, etc.) have a strong
this filter can result in considerable damage to the influence on the service life of the filters (air filters, oil
machine)! filters, fine separators).
A clogged air filter must be cleaned or replaced when Where such conditions exist the filter element may
the maintenance point has been reached. require changing more frequently.
Check the air filter for accumulated dust at least once a
week or, if required, daily.
48
9. Service and maintenance
Danger
Important
Fig. 20
1 Safety valve
Danger Fig. 21
49
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
access panel Remove oil residues and other deposits from unit
parts and from the coolers of compressors, which
• Lift the motor by turning the motion screw are exposed to hot compressed air, according to
(- 2 - Fig. 21) clockwise until the V-belts are the operating instructions.
released
Blow off the screw compressor unit with
• Clean/degrease the V-belt pulleys compressed air at the specified intervals (never
• Replace the V-belt set (- 5 - Fig. 21) direct compressed air towards persons) paying
particular attention to:
• Screw the motion screw back in until the lock nut
(- 3 - Fig. 21) reaches the holder (- 4 - Fig. 21); • Regulating elements
securely fasten the motion screw (anti-clockwise) • Fittings
• Compressor block
• Replace the cover cap and the panel • Cooler
• Electric motor
• Pressure tank (L15FS-L22FS)
• Dryer (L15FS-L22FS)
9.10 Connecting terminals in the switch • Filter (option)
cabinet/control transformer setting
The maintenance of the electric motor is to be
performed in line with the motor operating instructions.
Danger
The electric motor is permanently lubricated.
In the case of electric voltage:
9.11 Fittings
The fittings of the air and oil circuits have to be checked
and, if required, re-tightened according to the
maintenance schedule.
50
9. Service and maintenance
Important
Fig. 22
Danger
51
9. Service and maintenance
European version
CompAir „4000“
USA-Version:
a) 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)
For further information, please contact your local
CompAir Distributor or Gardner Denver-Canada at
(905) 847-0688.
52
10. Trouble-shooting
10 Tr ou ble -s ho oti ng
Unit cannot be started 1. No operating or control voltage 1. Check fuses, main switch and supply
line
6. Ambient temperature less than 6. Make sure that the ambient temperature
+1 °C/ 33.8 °F is not less than +1 °C/ 33.8 °F; install an
auxiliary heater, if required
8. Mains pressure is above the lower 8. Wait until the mains pressure has fallen
switch set point below the lower switch set point
Unit stops during the 1. Intake regulator only closes partly, 1. Fix intake regulator or, if required,
start-up phase pressure builds up too quickly in the replace; check solenoid valves
pressure reservoir
Unit does not reach the 1. Mains pressure sensor set too low 1. Check, re-set
set mains pressure
2. Intake regulator opens only partly 2. Fix intake regulator or, if required,
replace; check solenoid valves
8. Mains pressure exceeds the lower 8. Wait until the mains pressure has fallen
switching point below the lower switching point
53
10. Trouble-shooting
Unit switches off 1. Ambient temperature too high 1. Ventilate compressor room
Excessive idling 1. Intake regulator does not close correctly 1. Check intake regulator
pressure
2. System not unloaded 2. Check intake regulator
Oil in the compressed air 1. Oil fine separator defective 1. Replace oil fine separator cartridge
2. Oil foams 2. Change oil
3. Oil level too high 3. Drain off oil
4. Minimum pressure valve defective 4. Check minimum pressure valve
Oil in the air filter 1. Intake regulator setback function 1. Check intake regulator
defective
2. Intake regulator does not close correctly 2. Check intake regulator
3. Frequent emergency shutdown 3. The emergency shutdown may only be
activated in the case of safety-relevant
functional problems
Safety valve opens 1. Safety valve defective 1. Replace
2. Oil fine separator clogged and final 2. Replace oil fine separator cartridge and
compression pressure sensor defective change final compression pressure
sensor
3. Intake regulator closes too slowly 3. Check intake regulator and solenoid
valve
Danger
54
11. Annex
11 Ann ex
55
11. Annex
Ambient temperature °C + 1 / + 45
3
Flow m /min 2.59 2.42 1.84 3.21 2.97 2.34 3.66 3.40 2.68
56
11. Annex
Weight kg 365
Dimensions L x W x H mm 787 x 698 x 1202
57
11. Annex
Weight kg 381
Dimensions L x W x H mm 787 x 698 x 1202
58
11. Annex
Weight kg 386
Dimensions L x W x H mm 787 x 698 x 1202
59
11. Annex
60
11. Annex
61
11. Annex
62
11. Annex
63
11. Annex
Fig. 23
64
11. Annex
PLUG 2”
Fig. 24
65
11. Annex
1. EC Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A
type: L07; L11; L15; L18; L22; L23; L26; L29; L30; L37; L45; L50; L55;
L75; L80; L90; L110; L132; L160; L200; L250; L07RS; L11RS;
L15RS; L18RS; L22RS; L23R; L26R; L29R; L30RS; L37RS;
L45RS; L55RS; L75RS; L90RS; L110RS; L132RS; L160RS;
L200RS; L250RS; L07FS; L11FS; L15FS; L18FS; L22FS
trade mark:
manufacturer no.:
This machine is exempt from the Pressure Equipment Directive. Please refer to Article 1, clauses 3.3
and 3.6 for information on this exemption.
3. If the machine is modified in a way not agreed upon with us, this statement will be void.
Simmern,
Date Signature
66
Garrdner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland
www.compair.com
e-mail: sales@compair.com