Compair компрессор инструкция на панель управления

User Manual
Screw Air Compressor
L07-L22
CDN ●
USA
GB ●
●
Id. Nr. 100013552 / 00 - Dezember 2007
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 ‘Maintenance’ 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 CompAir Warranty are set out in the Company’s 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.
Deutsche Basis-BA: 100013551/00
3
Data sheet for users
*)
*)
*)
*) The values on the type plate are maximum values.
Your CompAir distributor
Name:
Address: ______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Telephone:
Fax:
Contact:
Spare Parts:
Service:
4
1. Foreword
1
For ew or d
1.1
Notes on the compressor
CompAir screw compressors are the result of many
years of research and development. These
prerequisites combined with high quality standards
guarantee the manufacture of screw compressors
providing a long service life, high reliability and costeffective operation. It stands to reason that all
requirements concerning environmental protection are
met.
Certificate of conformity
The compressor and its accessories as supplied by
CompAir conform to the basic health and safety
requirements included in the EC Machinery Directive
89/392/EWG, version 93/44/EWG. The compliance with
these directives is confirmed by the "CE mark" (fig. 1).
In addition,
•
•
•
relevant accident prevention regulations,
generally recognized safety regulations and
national regulations
have to be observed.
The machine/unit must only be used in technically
perfect condition and in accordance with its intended
use and the instructions set out in the operating
manual, and only by safety-conscious persons who are
fully aware of the risks involved in operating the
machine/unit! Any functional defects, especially those
affecting safety, have to be rectified immediately (or
rectified by others)!
The machine/unit is designed exclusively for the
generation of compressed air to power air-driven
devices. Using the machine/unit for purposes other than
those mentioned above is considered contrary to its
intended use. The manufacturer/supplier cannot be held
responsible for damage resulting from such use. The
risk of such misuse lies solely with the user.
Operating the machine within the limits of its intended
use also involves observing the instructions set out in
the operating manual and complying with the inspection
and maintenance directives.
1.3
Fig. 1
1.2
Intended use
The machine/unit has been constructed in accordance
with state-of-the-art technology and the recognized
safety regulations. Nevertheless, its use may constitute
a risk to life and limb of the user or third persons or
cause damage to the machine or to other material
property, if
•
•
•
•
it is not used as intended,
it is operated by unqualified personnel,
it is improperly modified or changed,
the safety regulations are not observed.
Therefore, any person entrusted with the operation,
maintenance or repair of the machine must read and
follow the safety regulations. If required, this has to be
acknowledged by signature.
Maintenance
Carefully performed maintenance is imperative, this
ensures that your screw compressor can meet all the
requirements placed upon it. It is therefore imperative to
adhere to the specified maintenance intervals and to
carry out the maintenance work with particular care,
especially when the unit is utilized under harsh
operating conditions.
Servicing
Please contact your authorized CompAir dealer in the
case of malfunctions or when spare parts are required.
In the case of damage, our fully trained personnel will
ensure that a quick and proper repair is carried out
using genuine CompAir spare parts. Genuine CompAir
spare parts are manufactured utilizing state-of-the-art
technology, thus guaranteeing the further reliable
operation of the unit.
In case of queries
Please enter the data on the nameplate of your
compressor into the nameplate shown in (fig. 2). In the
case of queries or spare parts orders, please refer to
the compressor type indicated on the nameplate, the
identification no. and the year of construction. With this
information at hand it can be guaranteed that you will
receive the right information or required spare parts.
5
1. Foreword
Guarantee
Operate this compressor only if you have an exact
knowledge of the machine taking into respect these
instructions.
CompAir cannot be held responsible for the safe
operation of the machine/unit if it is used in a manner
which does not correspond to the intended use, or for
other applications which are not mentioned in these
instructions.
Warranty claims will not be accepted in the case of
•
•
•
•
•
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 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. fine separator) will result in
the withdrawal of the CE mark. As a consequence, any
liability and warranty claims will not be accepted by the
manufacturer.
Fig. 2
Safety regulations
1.4
Notes
General
These operating instructions are intended to familiarize
the user with the machine/unit and its intended use. The
instructions contain important notes on how to operate
the compressor safely, properly and cost-effectively.
Observing these instructions helps to avoid risks, to
reduce repair costs and downtimes and to increase the
reliability and service life of the machine/unit.
The operating instructions have to be supplemented by
the respective national rules and regulations regarding
the prevention of accidents and environmental
protection. They must always be available at the
location of the machine/unit. The operating instructions
must be read and followed by any person carrying out
work in connection with the machine/unit, e.g.
operation, including setting up, trouble-shooting in the
operation cycles, disposal of production waste, care,
service, and disposal of waste fuels and consumables,
upkeep (maintenance, inspection, repair), transport.
Besides the operating instructions and the binding
regulations for the prevention of accidents, which are
valid in the country and place of operation of the
machine/unit, the generally recognized technical
regulations for safe and proper working have also to be
observed.
6
Danger
The safety regulations in chapter 3 of the operating
instructions have to be strictly observed.
Technical changes
In the course of technical development we reserve the
right to modify the units without further notice.
2. Table of contents
2
1
2
3
4
5
6
7
8
Tab le of co nte nt s
Foreword .............................................................................................................................................................................. 5
1.1 Notes on the compressor............................................................................................................................................. 5
1.2 Intended use ................................................................................................................................................................. 5
1.3 Maintenance ................................................................................................................................................................. 5
1.4 Notes ............................................................................................................................................................................. 6
Table of contents ................................................................................................................................................................ 7
Safety regulations ............................................................................................................................................................... 9
3.1 Identification of safety guidelines................................................................................................................................. 9
3.2 General safety instructions .......................................................................................................................................... 9
3.3 Changes and modifications to the machine .............................................................................................................. 10
3.4 Installation and normal operation .............................................................................................................................. 10
3.5 Special work/maintenance ......................................................................................................................................... 12
3.6 Warning of special dangers ....................................................................................................................................... 14
3.7 Storage of compressors ............................................................................................................................................. 15
3.8 Symbols and explanations ......................................................................................................................................... 16
Design and functioning .................................................................................................................................................... 20
4.1 Design of the unit........................................................................................................................................................ 20
4.1.1 Design of the unit L07-L11 ............................................................................................................................. 20
4.1.2 Design of the unit L15-L22 ............................................................................................................................. 21
4.2 Schematic diagram..................................................................................................................................................... 22
4.2.1 Schematic diagram L07-L11 .......................................................................................................................... 22
4.2.2 Schematic diagram L15-L22 .......................................................................................................................... 23
4.3 Oil circuit ..................................................................................................................................................................... 24
4.4 Air circuit ..................................................................................................................................................................... 24
4.5 System control ............................................................................................................................................................ 24
4.5.1 System control L07-L11 ................................................................................................................................. 24
4.5.2 System control L15-L22 ................................................................................................................................. 25
4.6 Hood (opening/closing) .............................................................................................................................................. 26
Transport and installation................................................................................................................................................ 27
5.1 Transport..................................................................................................................................................................... 27
5.2 Installation................................................................................................................................................................... 27
Preparations for commissioning .................................................................................................................................... 28
6.1 Cooling air volume/minimum cross............................................................................................................................ 28
6.2 Compressed air connection ....................................................................................................................................... 28
6.3 Electrical connection .................................................................................................................................................. 29
6.4 Electric motor fasteners for secure transportation.................................................................................................... 31
6.5 Oil level check............................................................................................................................................................. 31
6.6 Sound pressure level.................................................................................................................................................. 32
Commissioning.................................................................................................................................................................. 33
7.1 First commissioning.................................................................................................................................................... 33
7.2 Routine commissioning .............................................................................................................................................. 34
7.3 Commissioning after malfunction .............................................................................................................................. 34
Control system .................................................................................................................................................................. 35
8.1 General ....................................................................................................................................................................... 35
8.2 Keys ............................................................................................................................................................................ 35
8.3 Status indicator (display / light signals) ..................................................................................................................... 35
8.4 Displaying / changing values ..................................................................................................................................... 36
8.4.1 Selecting values.............................................................................................................................................. 36
8.4.2 Changing values ............................................................................................................................................. 36
8.5 Default settings ........................................................................................................................................................... 36
8.5.1 Selecting language ......................................................................................................................................... 36
8.5.2 Setting network pressure................................................................................................................................ 36
8.5.3 Setting time/date (timer) ................................................................................................................................. 37
8.6 Starting the unit........................................................................................................................................................... 37
8.7 Switching off the unit .................................................................................................................................................. 37
8.8 Emergency off button ................................................................................................................................................. 37
8.9 Acknowledging warning/fault messages ................................................................................................................... 37
8.9.1 Warning messages......................................................................................................................................... 37
8.9.2 Fault messages .............................................................................................................................................. 37
8.10 Menu structure (values are examples) ...................................................................................................................... 38
7
2. Table of contents
9
Service and maintenance ................................................................................................................................................ 39
9.1 Maintenance recommendations ................................................................................................................................ 39
9.2 Maintenance electric motor........................................................................................................................................ 39
9.3 Maintenance schedule ............................................................................................................................................... 39
9.4 Oil change................................................................................................................................................................... 41
9.5 Change of oil filter cartridge ....................................................................................................................................... 42
9.6 Change of the fine separator cartridge...................................................................................................................... 42
9.7 Change of air intake filter ........................................................................................................................................... 43
9.7.1 Change of air intake filter L07-L11................................................................................................................. 43
9.7.2 Changing of air intake filter L15-L22.............................................................................................................. 44
9.8 Safety valve ................................................................................................................................................................ 44
9.9 Changing V-belts/automatic tensioning system........................................................................................................ 45
9.10 Connecting terminals in the switch cabinet/control transformer setting .................................................................. 45
9.11 Fittings......................................................................................................................................................................... 45
9.12 General maintenance and cleaning........................................................................................................................... 46
9.13 Clean / change filter with cooling air inlet and control cabinet inlet ......................................................................... 46
9.14 Maintenance information and lubricant recommendations for stationary compressors ......................................... 46
10 Trouble-shooting............................................................................................................................................................... 47
11 Annex .................................................................................................................................................................................. 49
11.1 Technical data EUROPE version L07-L22 50 Hz..................................................................................................... 49
11.2 Technical data EUROPE version L07-L22 60 Hz..................................................................................................... 50
11.3 Layout plan L07-L11................................................................................................................................................... 51
11.4 Layout plan L15-L22................................................................................................................................................... 52
8
3. Safety regulations
3
Safet y r eg ula tio ns
3.1
Identification of safety guidelines
CompAir 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.
If any of the regulations contained in these instructions
-especially with regard to safety - does not correspond
to the local legal provisions, the stricter of both shall
prevail.
These safety regulations are general and valid for
various types of machines and equipment. It is
therefore possible that some references do not apply to
the unit(s) described in these instructions.
Danger
Passages marked with this sign indicate a possible
danger to persons.
Important
Passages marked with this sign indicate a possible
danger to machines or part of machines.
Note
Passages marked with this sign provide technical
information on an optimal cost-effective use of the
machine.
3.2
General safety instructions
Organizational measures
The operating instructions must always be at hand at
the place of operation of the machine/unit!
In addition to the operating instructions, all other
generally applicable legal and other mandatory
regulations relevant to accident prevention and
environmental protection must be adhered to and
passed on to others! These compulsory regulations
may also deal with the handling of hazardous materials
or the issuing/wearing of personal protective equipment,
or traffic regulations.
Instructions, including supervisory responsibility and
duty of notification for taking into account in-plant
factors, for example regarding work organization,
sequences of operations, personnel assigned to certain
tasks, are to be added to the operating manual.
The personnel entrusted with working on the machine
must have read the operating instructions and in
particular the chapter on safety regulations before
starting work. Reading the instructions after work has
begun is too late. This applies especially to persons
working only occasionally on the machine, e.g. for
setting up or maintenance.
Check on a regular basis that the personnel are
carrying out the work in compliance with the operating
instructions and that they are paying attention to the
safety requirements!
For safety reasons, long hair must be tied back or
otherwise secured, garments must be close-fitting and
no jewellery - such as rings - may be worn. Injury may
result from being caught up in the machinery or from
rings catching on moving parts! As necessary or as
required by regulations, personal protective equipment
should be used.
Observe all safety and warning notices attached to the
machine/unit!
See to it that safety instructions and warnings attached
to the machine are always complete and perfectly
legible.
In the case of safety-relevant changes to the machine/
unit or its operating behaviour, stop the machine/unit
immediately and report the fault to the responsible
department/person!
Spare parts have to comply with the technical
requirements specified by the manufacturer. This can
always be ensured by using original spare parts.
Hydraulic hoses have to be changed within stipulated
and periodic intervals, even if no safety-relevant faults
have been detected!
Adhere to prescribed intervals or those specified in the
operating instructions for routine checks and
inspections!
9
3. Safety regulations
For the execution of maintenance work, tools and
workshop equipment adapted to the task on hand are
absolutely indispensable.
The personnel must be made familiar with the location
and operation instructions of fire extinguishers !
Observe all fire-warning and fire-fighting procedures!
Limit values (pressures, time settings, etc.) have to be
permanently identified!
The manufacturer is not liable for damage resulting
from the use of non-original parts or special
accessories. This applies also to the installation and
setting of safety equipment and valves as well as to
welding on structural or pressurized parts.
3.4
Installation and normal operation
Installation
Selection and qualification of personnel;
basic responsibilities
Work on/with the machine/unit must be carried out by
reliable personnel only. Statutory minimum age limits
must be observed!
Employ only trained or instructed personnel and clearly
set out the individual responsibilities of the personnel
for operation, set-up, maintenance and repair!
Ensure that only authorized personnel work on or with
the machine!
Define the machine operator's responsibilities giving the
operator the authority to refuse instructions by third
persons that are contrary to safety regulations.
Do not allow persons to be trained or instructed or
persons taking part in a general training course to work
on or with the machine/unit without being permanently
supervised by an experienced person!
Work on the electrical equipment of the machine/unit
must be carried out only by a skilled electrician in
accordance with electrical engineering rules and
regulations.
Work on system elements such as hoses may only be
carried out by personnel with special knowledge and
experience of hydraulics!
3.3
Changes and modifications to the
machine
Do not make any changes, modifications or
attachments to the machine/unit, which could affect
safety, without the supplier's prior permission!
Unauthorized changes to the machine are not permitted
for safety reasons.
Original parts were especially designed for this
machine. We would like to point out that we have not
released and will not release parts and special
accessories which have not been supplied by us. The
installation and/or use of such products can therefore
affect the active and/or passive safety.
In addition to the general technical operation in
accordance with the stipulations of the local authorities,
we would like to refer in particular to the following
regulations.
For the lifting of a compressor, a suitable lifting
mechanism is to be used, which meets the local safety
regulations. All loose or slew able parts must be safely
fixed before the machine can be lifted. It is strictly
prohibited to stay in the danger zone of a lifted load.
The correct method of lifting (according to the operating
instructions of the load suspension device) has to be
ensured.
All blind flanges, plugs, caps and bags with drying
agent have to be removed prior to the installation of the
pipes. Distributing pipes and pipe connections have to
be of the proper size and suitable for the relevant
operating pressure.
The system must be set up on a level surface with full
contact between its base frame and the supporting
surface.
The system has to be installed in such a way that it is
adequately accessible and the required cooling is
guaranteed. Never block the air intake. Make sure that
the ingress of humidity via the intake air is kept to a
minimum.
The air intake is to be located so that no hazardous
constituent (solvent vapour, etc., but also dusts and
other hazardous material) can be sucked in. This
applies also to flying sparks.
The air intake is to be positioned so that no loose
clothing of persons can be sucked in. Make sure that
the pressure line from the compressor to the after
cooler or the air circuit can expand under heat and does
not come into contact with inflammable material.
The pressure line connected to the air outlet of the
system must be fitted stress-free. When connecting the
compressor on the mains side to the compressed air
system available at the customer‘s end, check the
operating temperatures and operating pressures
required and examine the required connecting flange or
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.
10
3. Safety regulations
If a remote control is used, the system must carry a
clearly visible sign with the following note: Attention!
This installation is operated by remote control and can
start up without prior warning!
As an additional safety measure, persons, who start
remotely controlled systems, have to take sufficient
safety precautions in order to ensure that nobody is
checking the system or working on it. For this, a label
with a corresponding warning notice has to be attached
to the remote control equipment.
Compressed air and cooling water lines have to be
clearly marked in line with the local regulations.
If a system comprises several compressors, hand
operated isolator valves have to be installed in order to
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
systems.
Safety equipment, protective covers or insulation must
not be removed or modified. Any pressure reservoir,
which is located outside the system, the permissible
operating pressure of which is higher than the
atmospheric pressure and which is fitted with two or
more pressure supply lines, has to be equipped with
additional safety equipment, which will automatically
prevent the admissible operating pressure from rising
by more than 10%.
The installed unit-specific safety valves only assume
the pressure safeguarding function of the compressor
unit provided in currently valid standards and
regulations.
For pressure components/systems mounted to the
connecting flange on the pressure side, a pressure
safety device (safety valve or similar) has to be installed
taking into account the weakest pressurized
component.
If the room temperature can fall below zero, the
condensation drain system must be protected from
freezing, e.g. by means of a steam heater.
If it is possible that the intake temperature of the air will
exceed, from time to time, the admissible maximum
specified in the operating instructions, a precooler with
condensate drain is to be installed before the dryer.
Tests or repair work on the coolant circuit may only be
carried out in a well vented room. Never breath in
coolant vapour; if necessary, wear a breathing mask.
Always wear protective goggles and gloves. If skin
comes into contact with coolants, rinse well with water.
Never take off or tear up clothes but rinse them well
with water until the coolant is washed off; then see a
doctor.
Condensate drain
The drain hose for condensate discharge is to be
connected to the drains or to a collecting reservoir, if
local regulations prohibit direct discharge to the drains.
In connection with this, it must be taken into account
that the condensate from compressors with oillubricated pressure chambers can contain oil.
Normal operation
Take the necessary precautions to ensure that the
machine is used only when in a safe and reliable state!
Operate the machine only when all protective
equipment, emergency shut-off equipment, soundproofing elements and extraction devices are in place
and fully functional!
Check regularly that
•
all means of protection are correctly fitted and fixed,
•
all hoses and/or pipes within the system are in good
condition, firmly fixed and do not chafe,
•
there are no leakages (fuel, oil or coolant),
•
all fittings are firmly tightened,
•
Electrical connections must meet the local regulations.
Power units must be connected to earth and protected
from short-circuits by means of fuses.
all wires are connected correctly and are in good
condition,
•
all safety valves and other pressure relief
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
a place where the ambient air is as clean as possible
and where the temperatures never rise above or fall
below the respective limit values as indicated in the
operating instructions. If required, the cooling air is to
be taken from a cleaner, cooler or warmer area via an
intake channel; depending on the size of the machine,
an additional fan could turn out to be necessary.
If compressed air hoses are used, they must be of the
proper size and suitable for the relevant operating
pressure. Do not use chafed, damaged or poor-quality
hoses.
The min. and max. temperatures of +1 °C/33.8 °F and
+45 °C/113°F are also valid for the intake air. Pipes
and/or other parts with a surface temperature higher
than 70 °C/158 °F have to be suitably identified and
shielded against touching.
Only use hose couplings and fittings of the right type
and the correct size.
11
3. Safety regulations
Before blowing through a hose or an air pipe ensure
that the open end is positively held. A free end whips
and can cause injuries.
Brief the operating personnel prior to starting special
operations or maintenance work! Appoint a person to
supervise the activities!
Before decoupling a hose ensure that it is pressureless.
Maintenance and repair work may only be carried out
under the supervision of a person who is qualified for
this work.
Refrain from any working method which is doubtful in
terms of safety.
Never play around with compressed air!
Never aim compressed air at your skin or at other
persons!
Never use compressed air to clean your clothing.
When using compressed air to clean equipment take
the utmost care and always wear protective goggles.
The compressed air generated by these compressors
must never be used for breathing unless it has been
conditioned for those applications in line with the “safety
requirements for respiratory air”.
Never use the machine in an environment where
inflammable or poisonous vapour can be sucked in.
Never operate the system at pressures and
temperatures below or above the values indicated in the
technical data sheet.
Oil losses result in a slippery floor. Therefore, always
clean the floor and the outside of the machine prior to
starting the maintenance work.
Checks, maintenance and repair work may only be
carried out with the screw compressor being at rest and
depressurized. Protective equipment to be removed for
this work, has to be refitted after completion of these
activities. Operation of the machine without protective
equipment is not permitted. When working on a running
screw compressor system, working clothes have to be
close-fitting.
If the machine/unit is completely shut down for
maintenance and repair work, it must be secured
against inadvertent restarting:
•
Lock the main command elements and remove the
key and/or
•
attach a warning sign to the main switch.
The access panels, etc. have to be closed during
operation.
Always use the correct tools for maintenance and repair
work.
Persons in an environment or areas in which the sound
pressure is 85 dB(A) or higher have to wear ear
protectors.
Never use inflammable solvents or carbon tetrachloride
to clean parts. Take precautions against poisonous
vapours from cleaning agents.
Check the machine/unit at least once per shift for visible
damage and faults! Report any changes (including
changes in the machine’s operating behaviour) to the
responsible department/person immediately. If
necessary, stop and lock the machine immediately!
In any work concerning the operation, conversion or
adjustment of the machine and its safety-oriented
devices or any work related to maintenance, inspection
and repair, always observe the start-up and shutdown
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
immediately!
Observe the start-up and stopping procedures and the
control displays according to the operating instructions.
Before starting up or setting the machine in motion,
ensure that nobody is at risk.
Do not cut off or remove extraction or venting facilities
while the machine is running.
3.5
Special work/maintenance
Carefulness
Observe the adjusting, maintenance and inspection
activities and intervals set out in the operating
instructions, including information on the replacement of
parts and equipment. These activities may be carried
out by skilled personnel only.
12
Ensure that the maintenance area is adequately
secured.
To lower the risk of accidents, individual parts and large
assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and
secured. Use only suitable and technically correct lifting
gear and only utilize suspension systems with adequate
lifting capacity. Never work or stand under suspended
loads!
During maintenance and when carrying out repair work,
cleanliness is very important. Avoid the ingress of dirt
by covering parts and free openings with a clean cloth,
paper or adhesive tape.
After the completion of each repair, check that tooling or
loose parts have not been left in the or on top of the
machine, drive motor or drive equipment and ensure
that no cloth has been left inside these units.
Be careful when the screw compressor system is in
operation.
3. Safety regulations
Maintenance/rectification of faults
The employer has to inform the employee of the
dangers possibly arising during the repair and
maintenance of the machine/unit as well as on how to
avoid them; the employee has to observe all measures
for safety at work. Safety equipment for the prevention
or elimination of danger has to be maintained regularly
and functionally checked at least once a year. Faults
observed have to be immediately rectified and/or
reported to the responsible person.
Use only original spare parts.
Only carry out maintenance and repair work when the
system is not in operation and the power supply
disconnected. Ensure that the power unit cannot be
switched on inadvertently.
Before removing or opening pressurized components,
positively isolate any source of pressure and
depressurize the entire system.
Never weld near oil systems or carry out any other work
requiring heat. Pressure reservoirs or components and
pipes containing oil have to be drained completely and
cleaned, for example by means of a steam jet, before
beginning such work.
Never weld any pressure reservoir or change it in any
way.
If work which produces heat, flames or sparks has to be
carried out on a machine, the adjacent components
have to be protected by means of non inflammable
material.
Before releasing the power unit for operation after
maintenance or overhaul, check that the operating
pressures, temperatures and time settings are correct
and that the regulating and shut-down equipment
function properly.
Every six months, check the pressure pipe and
pressure vibration damper for carbon deposits. If
excessive deposits are found, they should be removed.
Motor, air filter, electrical components and regulating
equipment have to protected from the ingress of
humidity, e.g. when cleaning the system by means of a
steam jet.
Under no circumstance must the sound-proofing
material be removed or modified.
Never use etching solvents which could attack the
materials used.
If indicated or if there is any suspicion that an internal
part of the machine has run hot, the machine has to be
shut down.
In order to avoid an increase in the operating
temperature, check and clean the heat transfer surfaces
(cooling fins, intermediate cooler, water cooling jackets,
etc.) at regular intervals. Prepare a plan of the most
favourable cleaning intervals for each machine.
Avoid damage to the safety valves and other pressure
reducing components. Check in particular for clogging
caused by paint, oil carbon or the accumulation of dust,
which could deteriorate the effectiveness of these
components.
Insulation or protective shielding, the temperature of
which may exceed 70 °C/158 °F and which could be
erroneously touched by the personnel, must not be
removed before these parts have cooled down to room
temperature.
Check the accuracy of pressure and temperature
indicators at regular intervals. If the admissible
tolerance limits have been exceeded, these devices
have to be replaced.
Before removing or overhauling a compressor, a motor
or another machine, ensure that all moveable parts of a
mass of more than 15 kg cannot move or roll away.
After completion of repair work, always verify that no
tools, loose parts or cloths have been left in or on the
machine, drive motor or drive equipment. Machines
performing a back and forward main movement have to
be cycled at least once, rotating machines have to be
cycled several times in order to ensure that there are no
mechanical faults in the machine or the drive member.
Check the direction of rotation of the electric motors
during first commissioning and after each modification
of the electrical connections in order to prevent the
compressor from being damaged.
The fastening of loads and the instructing of crane
operators should be entrusted to experienced persons
only. The person giving the instructions must be within
sight or voice contact with the operator.
For carrying out overhead assembly work always use
specially designed or otherwise safety-orientated
ladders and working platforms. Never use machine
parts as a climbing aid. Wear a safety harness when
carrying out maintenance work at greater heights.
Keep all steps, handles, handrails, platforms, landings
and ladders free from dirt, snow and ice! Clean the
machine, especially connections and threaded unions,
of any traces of oil, fuel or preservatives before carrying
out maintenance or repair work! Never use aggressive
detergents! Use lint-free cleaning rags!
Before cleaning the machine with water or steam jet
(high pressure cleaner) or other cleaning agents,
cover/mask all openings which have to be protected
from the ingress of water, steam or detergents for
safety and/or functional reasons, in particular electric
motors and switch cabinets.
After cleaning, remove the covers/masking completely !
Check all hydraulic oil lines for leakage, loose fittings,
abrasion and damage after cleaning. Any defect must
be rectified immediately!
Always re-tighten screwed connections which have
been loosened for maintenance and repair work.
13
3. Safety regulations
If the set-up, maintenance or repair require the
demounting of safety equipment, this equipment has to
be remounted and checked immediately after these
activities.
Ensure that consumables and replacement parts are
disposed of in a safe and environmentally friendly
manner.
3.6
Warning of special dangers
Electric energy
Use only original fuses with the specified current rating.
Switch off the machine/unit immediately if trouble
occurs in the electric system.
Work on the electrical system or equipment may only
be carried out by a skilled electrician or by specially
instructed personnel under the control and supervision
of such an electrician and in line with the relevant
electrical engineering rules.
If regulations require, the power supply to parts of
machines and plants on which inspection, maintenance
and repair work is to be carried out must be cut off.
Before starting any work, check the deenergized parts
for the presence of power and ground or short-circuit
them in addition to insulating adjacent live parts and
elements.
The electrical equipment of the machines/units is to be
inspected and checked at regular intervals. Defects
such as loose connections or scorched cables must be
rectified immediately.
Necessary work on live parts and elements must be
carried out in the presence of a second person who can
cut off the power supply in case of danger by operating
the emergency shutdown or main power switch. Secure
the working area with a red-and-white safety chain and
a warning sign. Use insulated tools only.
Observe any existing national regulations if work is to
be carried out in small rooms.
Hydraulics, pneumatics
Work on hydraulic equipment may only be carried out
by persons with special knowledge and experience of
hydraulics.
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair
damage immediately. High pressure jets of oil may
cause injury and fire.
Depressurize all system sections and pressure pipes
(hydraulic system, compressed-air system) which are to
be removed in accordance with the specific instructions
for the assemblies concerned before carrying out any
repair work.
Hydraulic and compressed-air lines must be laid and
fitted properly. Ensure that no connections are
exchanged. The fittings, lengths and quality of the
hoses must comply with the technical requirements.
Noise
Sound-proofing elements on the machine/unit have to
be active during operation (i.e. sound-proofing panels
closed, etc.).
Wear personal ear protection as prescribed.
Noise, even at a low level, can cause nervousness and
annoyance; over a longer period of time, our nervous
system can suffer serious damage. We therefore
recommend a separate machine room in order to keep
the noise of the machine away from the workshop.
Depending on the number of machines in a machine
room, the noise can be quite loud. In accordance with
the sound pressure level at manned posts, the following
precautions have to be taken:
•
Below 70 dB(A): no special measures
•
Above 70 dB(A): persons who stay permanently in
this room have to wear ear protectors
•
Below 85 dB(A): in the case of occasional visitors
who stay in this room only for a short while, no
special precautions are to be taken
Carry out welding, flame-cutting and grinding work on
the machine/unit only if this has been expressly
authorized, as there may be a risk of explosion and fire.
•
Before carrying out welding, flame-cutting and grinding
operations, clean the machine/unit and its surroundings
from dust and other inflammable substances and make
sure that the premises are adequately ventilated (risk of
explosion)!
Above 85 dB(A): hazardous noise zone! A warning
sign has to be attached to each entrance indicating
that everybody who enters the room - even for a
short time only - has to wear ear protectors.
•
Above 95 dB(A): the warning signs have to contain
the recommendation that occasional visitors also
have to wear ear protectors.
Before starting work on high-voltage assemblies and
after having cut out the power supply, the feeder cable
must be grounded, and components, such as
capacitors, short-circuited with a grounding rod.
Gas, dust, steam and smoke
Adhere to the regulations valid for the place of
operation!
14
3. Safety regulations
•
Above 105 dB(A): special ear protectors, which are
suitable for the noise level and the spectral
composition of the noise must be available. A
corresponding warning sign must be fixed to each
entrance door.
3.7
Storage of compressors
All compressors are protected against corrosion at the
factory for transport and for brief storage before
commissioning.
Take care that the noise transmission through walls and
frames does not result in too high a noise level in the
surrounding areas.
If the compressors are to be stored for period
exceeding six months, additional precautions must be
taken.
Oils, greases and other chemical substances
Compressors which are to be shut down for a lengthy
period must also be protected from corrosion.
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)!
Since corrosion occurs more quickly in damp
atmospheres than in dry conditions, it is not possible to
specify a maximum permissible standstill time which will
apply in all cases.
Rooms subject to explosion hazards
Danger
Compressor units must never be operated in areas
subject to explosion hazards!
(Exception: Special units with the corresponding
technical modifications)
Note
The following aspects must be taken into account for
storage of storing compressors.
The compressor should be stored in a dry building
which should be heated if possible.
This is particularly true during the months of winter.
If there is a risk that the temperature will fall or rise
above the limits of -10 °C/14 °F to +65 °C/149 °F , the
electrical controller must be removed and stored in
ambient temperatures of +5 °C/41 °F to +30 °C/86 °F.
Before commissioning the compressor all the electrical
and electronic components and units should be
checked for the ingress of water or condensation.
15
3. Safety regulations
3.8
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.
16
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.
17
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
18
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).
19
4. Design and functioning
4
Desig n a n d f un cti oni ng
4.1
Design of the unit
4.1.1
Design of the unit L07-L11
Fig. 3a L07-L11
1
2
3
4
5
6
7
8
9
10
11
20
Intake filter
Intake regulator
Electric motor
Screw compressor
Belt drive
Pressure reservoir
Oil fine separator
Oil filling port
Oil drain
Oil level indicator
Oil filter
12
13
14
15
16
17
18
19
20
21
22
Oil cooler
Safety valve
Pressure holding and check valve
Air cooler
Oil fine separator extractor
Oil temperature regulator
Cooling air ventilator
Cooling air inlet filter mat
Compressed air outlet
Base frame
Lock hood
23
24
25
26
27
Control keypad
EMERGENCY OFF push-button
Control cabinet
Supply cable gland
Final compression temperature
sensor
28 Network pressure sensor
29 Final compression pressure
sensor
30 Opening for lifting gear
4. Design and functioning
4.1.2
Design of the unit L15-L22
Fig. 3 b L15-L22
1
2
3
4
5
6
7
8
9
10
11
Intake filter
Intake regulator
Electric motor
Screw compressor
Belt drive
Pressure reservoir
Oil fine separator
Oil filling port
Oil drain
Oil level indicator
Oil filter
12
13
14
15
16
17
18
19
20
21
22
Oil cooler
Safety valve
Pressure holding and check valve
Air cooler
Oil fine separator extractor
Oil temperature regulator
Cooling air ventilator
Cooling air inlet filter mat
Compressed air outlet
Base frame
Lock hood
23
24
25
26
27
Control keypad
EMERGENCY OFF push-button
Control cabinet
Supply cable gland
Final compression temperature
sensor
28 Network pressure sensor
29 Final compression pressure
sensor
30 Opening for lifting gear
21
4. Design and functioning
4.2
4.2.1
Schematic diagram
Schematic diagram L07-L11
Residual pressure
2 bar
Opening
pressure
4.5 bar
Opening temp. 55 °C
Fig. 4 a L07-L11
1 Intake filter
2 Intake regulator
2.1 Actuator
2.2 Intake valve
2.3 Check valve
3 Electric motor
4 Compressor block
5 Belt drive
6 Pressure reservoir
7 Fine separator
8 Oil filler cap
9 Oil drain
10 Oil-level indicator
22
11
12
13
14
15
16
17
18
19
R1
R2
Oil filter
Oil cooler
Safety valve
Pressure holding and check valve
(opening pressure 4.5 bar)
Air cooler
Oil fine separator extractor
Oil temperature regulator
(opening temperature 55 °C)
Cooling air ventilator
Filter mat cooling air inlet
Motor temperature
Final compression temperature
B1 Network pressure sensor
B2 Final compression pressure
sensor
Y1 3/2-way solenoid valve
Compressed air line
Oil line
Control line
4. Design and functioning
4.2.2
Schematic diagram L15-L22
Residual pressure
1,5 bar
Opening
pressure
4,5 bar
Opening temperature 55 °C
Fig. 4 b
1 Intake filter
2 Intake regulator
2.1 Actuator
2.2 Intake valve
2.3 Check valve
3 Electric motor
4 Compressor block
5 Belt drive
6 Pressure reservoir
7 Fine separator
8 Oil filler cap
9 Oil drain
10 Oil-level indicator
11
12
13
14
15
16
17
18
19
R1
R2
Oil filter
Oil cooler
Safety valve
Pressure holding and check valve
(opening pressure 4.5 bar)
Air cooler
Oil fine separator extractor
Oil temperature regulator
(opening temperature 55 °C)
Cooling air ventilator
Filter mat cooling air inlet
Motor temperature
Final compression temperature
B1 Network pressure sensor
B2 Final compression pressure
sensor
Y1 3/2-way solenoid valve
Compressed air line
Oil line
Control line
23
4. Design and functioning
4.3
Oil circuit
The oil flows from the pressure reservoir (- 6 - Fig. 40)
into the oil thermostat (- 17 - Fig. 4). With oil temperatures < 55 °C/131 °F the oil flows via the by-pass of the
oil cooler directly into the oil filter (- 11 - Fig. 4) and is
then injected into the screw compressor (- 4 - Fig. 4).
4.5
4.5.1
System control
System control L07-L11
With oil temperatures of between 55 °C/131 °F and
70 °C/ 158 °F the oil flow is divided and fed into the oil
cooler (- 12 - Fig. 4) and the by-pass.
With oil temperatures above 70 °C/158 °F the entire oil
flow is directed via the oil cooler through the oil filter into
the screw compressor.
The oil separated by the oil separator element
(- 7 - Fig. 4) is fed through an oil scavage line to the
screw compressor.
The entire oil circulation is based on a differential
pressure in the system. Considering the pressure
difference of approx. 2 bar/29 PSI within the oil circuit,
the oil is then injected into the screw compressor with
approx. 8 bar/116 PSI at a reservoir pressure of e.g.
10 bar/145 PSI.
When the screw compressor is in the off-load mode, a
sufficiently high pressure differential and thus the
required oil injection quantity is achieved owing to the
fact that when the intake regulator (- 2 - Fig. 4) is
closed, a vacuum pressure occurs in the intake
connection.
Excess pressure of approx. 2 bar/ 29 PSI (L07-L11
residual pressure) or 1.5 bar/22 PSI (L15-L22 residual
pressure) is produced in the pressure reservoir at the
same time.
4.4
Air circuit
The intake air passes through the intake filter (- 1 - Fig.
4) and the intake regulator (- 2 - Fig. 4) into the screw
compressor (- 4 - Fig. 4). During the compression
process, the intake air is cooled via the injected oil, and
the developed air/oil mixture flows tangentially into the
pressure reservoir (oil reservoir) (- 6 - Fig. 4). After preseparation and subsequent fine separation by the
separator element (- 7 - Fig. 4), the compressed air with
a low oil content is fed via the minimum pressure valve
(- 15 - Fig. 4) and the air cooler (- 16 - Fig. 4) into the
consumer network.
24
Fig. 5 a L07-L11
Standstill of the system
•
When the system is at rest the intake regulator
(- 2 - Fig. 5a) is opened.
•
The solenoid valve (Y1 Fig. 5a) is de-energised.
•
The pressure reservoir (- 5 - Fig. 5a) is bled via the
blow-off line (- 2.-1 and -2.3- Fig. 5a) into the
suction channel.
Starting the system
•
The motor (- 3 - Fig. 5b) starts up in the Y-mode.
•
The compressor extracts a certain volume of air via
a start valve (- 2.2 - Fig. 5a). Pressure builds up in
the reservoir and closes the regulator.
•
When changing over to Δ operation, the solenoid
valve (- Y1 - Fig. 5a) is energised, which blocks the
connection between pressure vessel and intake
regulator.
•
The intake regulator opens due to the intake
vacuum pressure.
•
The minimum pressure valve (- 8 - Fig. 5a) opens
when the pressure reservoir is approx. 4.5 bar.
•
Compressed air is now delivered into the consumer
network.
4. Design and functioning
Automatic operation (open-close operation)
Standstill of the system
•
When the pressure reaches the upper switching
point set on the network pressure sensor (-7 - Fig.
5a), solenoid valve (Y1 Fig. 5a) is de-energised.
•
When the system is at rest the intake regulator
(- 2 - Fig. 5b) is closed.
•
•
The solenoid valve (Y1 Fig. 5b) is de-energised.
The intake regulator (- 2 - Fig. 5a) is vented and
closed.
•
•
The pressure reservoir (- 5 - Fig. 5a) is
depressurised via the intake filter.
The pressure reservoir (- 6 - Fig. 5b) is bled via the
blow-off line (- 2.1- and -2.3- Fig. 5b) into the
suction channel.
•
The compressor is now running in idle mode.
Starting the system
•
If the mains pressure does not fall within 90
seconds (adjustable) to the lower switching point,
the system shuts down.
•
The motor (- 3 - Fig. 5b) starts up in the Y-mode.
•
The compressor extracts a certain volume of air via
a start valve (- 2.2 - Fig. 5b). Pressure builds up in
the reservoir.
•
When changing over to Δ-operation, the solenoid
valve (- Y1 - Fig. 5b) is energised and a connection
is then established between the pressure reservoir
and the intake regulator.
•
The intake regulator opens.
•
The minimum pressure valve (- 8 - Fig. 5b) opens
when the pressure reservoir is approx. 4.5 bar.
•
Compressed air is now delivered into the consumer
network.
•
•
If the lower switching point is reached in less than
90 seconds, the solenoid valve (- Y1 - Fig. 5a) is
energised again.
The unit now changes over to on-load operation.
Stopping the system
•
 (Fig. 16) on the
After pressing the OFF button 
operating panel, the solenoid valve (- Y1 - Fig. 5a)
is de-energised.
•
The intake regulator (-2- Fig. 5a) closes and the
tank (-5- Fig. 5a) is relieved.
•
After 30 seconds, the drive motor (- 3 - Fig. 5a) is
shut down.
4.5.2
Automatic operation (open-close operation)
•
When the pressure reaches the upper switching point
set on the network pressure sensor (-28 -(B1)),
solenoid valves (- 19 -(Y1) and - 20 - (Y4)) are deenergised.
•
The intake regulator (- 2 - Fig. 5b) is bled and closed.
•
The pressure reservoir (- 5 - Fig. 5b) is
depressurised via the intake filter.
•
The compressor is now running in idle mode.
•
If the mains pressure does not fall within
90 seconds (adjustable) to the lower switching point,
the system shuts down.
•
If the lower switching point is reached in less than
90 seconds, the solenoid valve (- Y1 - Fig. 5b) is
energised again.
•
The unit now changes over to on-load operation.
System control L15-L22
Stopping the system
Fig. 5b L15-L22
•
 (Fig. 16) on the
After pressing the OFF button 
operating panel, the solenoid valve (- Y1 - Fig. 5b)
is de-energised.
•
The intake regulator (-2- Fig. 5b) closes and the
tank (-5- Fig. 5b) is relieved.
After 30 seconds, the drive motor (- 3 - Fig. 5b) is shut
down.
25
4. Design and functioning
4.6
Hood (opening/closing)
The compressor is provided with a detachable plastic
hood that allows easy access to all parts that are
subject to servicing.
Opening / closing the hood (Fig. 6)
•
Open the lock ( - 1 - Fig. 6)
•
Remove the hood ( - 2 - Fig. 6) and put it down at a
safe place
•
Close the hood in the reverse order
Fig. 6
1
2
26
Lock
Hood
5. Transport and installation
5
Tr ans por t an d i ns tall ati on
5.1
5.2
Transport
Installation
A = 0.5 m
B = 0.8 m
Fig. 7
Fig. 8
Note
Danger
Before transporting the unit, remove the doors.
•
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 intakes are to be located so that no
hazardous constituent (solvent vapour, etc., but
also dusts and other hazardous material) can be
sucked in. This applies also to flying sparks.
•
Pipes and/or other parts with a surface
temperature higher than 70 °C/158 °F have to be
suitably identified and secured against
touching.
Danger
The compressor must be lifted using a suitable
forklift truck which complies with the local safety
regulations.
Before lifting, all loose or slewable parts of the
machine have to be firmly secured.
It is strictly prohibited to work or stand in the
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.
See also the safety regulations in chapter 3 of the
operating instructions.
Important
Never lift or lash the compressor and its hood via
the enclosure. The screw compressor is lifted with
the help of a fork lift truck (Fig. 7). The separation
of the forks and their length must be taken into
account for transportation.
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 oil fill:
50-Hz- compressors:
L07
L11
215 kg
233 kg
L15
L18
L22
327 kg
353 kg
359 kg
L15
L18
L22
351 kg
356 kg
365 kg
Important
The operator has to provide adequate ventilation
for the compressor station.
The screw compressor unit has to be levelled. A
minimum distance from walls, other machines, etc.
should be maintained so that there is sufficient
clearance for maintenance and repair work (Fig. 8).
During operation of the screw compressor unit, heat is
generated by the electric motor and the compression
process. The screw compressor radiates a part of this
heat into the surroundings.
Proper ventilation has a considerable effect on the
service life and the performance of a compressor.
60-Hz- compressors:
L07
L11
218 kg
233 kg
27
6. Preparations for commissioning
6
Pr epar ati on s f or com m iss io nin g
6.1
Cooling air volume/minimum cross
6.2
Fig. 9
Fig. 10
1
2
1
Cooling air intake
Cooling air outlet
For this you should use a flexible connection
(e.g. compressed air hose, compensator).
50-Hz-compressors:
ca. 34 m 3/min
ca. 37 m 3/min
L15
L18
L22
ca. 59 m 3/min
ca. 56 m 3/min
ca. 56 m 3/min
60-Hz- compressors:
L07
L11
3
ca. 34 m /min
ca. 37 m 3/min
L07-L11
L15-L22
sleeve G 3/4"
sleeve G 1"
Note
L15
L18
L22
3
ca. 48 m /min
ca. 54 m 3/min
ca. 54 m 3/min
Under unfavourable local conditions, we recommend
the installation of venting ducts. However, the velocity
of the cooling air should not exceed 5 m/s. We
recommend a minimum duct cross-section of approx.
0.15 m2 for L07-L11, 0.2 m 2 for L15-L22.
Important
The stated minimum cross-section refers to a
maximum duct length of 5 m/16.4 ft and a maximum
of one bend. In the event of differing values (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 +1°C/
33.8°F to +45°C/113°F. In the case of temperatures
other than the above limiting values, please consult
your technical adviser.
Note
In order to ensure a good heat dissipation, auxiliary
fans should be rated to process approximately 15 to
20% more air volume than the total cooling air
quantity required by the compressors installed in the
compressed air station.
28
Compressed air connection
The compressed air line system is connected at the
compressed air supply of the screw compressor
( - 1 - Fig. 10).
The cooling air volume required by these screw
compressors is as follows:
L07
L11
Compressed air connection
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.
Hand-operated drain facilities have to be actuated in
accordance with the operating instructions.
Automatic drain facilities have to be checked for proper
function at regular intervals. When draining
condensates 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.
Condensate may contain oil! When draining
condensate, observe the corresponding regulations for
waste water disposal.
6. Preparations for commissioning
6.3
Electrical connection
Recommended supply cable cross-sections and fuses
Compressor type
Supply voltage
[V]
Installed nominal
motor power
[kW]
Fuse protection
(slow-blow fuse)
[AgL]
Line cross section
at 30°C
[mm2]
50-Hz-Compressors
L07
L07
L11
L11
L15
L15
L18
L18
L22
L22
220
400
220
400
220
400
220
400
220
400
7,5
7,5
11,0
11,0
15,0
15,0
18,5
18,5
22,0
22,0
35
20
50
35
63
35
80
50
100
50
4G6
4G2,5
4G10
4G6
4G16
4G6
4G25
4G10
4G35
4G10
220
230
460
220
230
460
220
230
460
220
230
460
220
230
460
7,5
7,5
7,5
11,0
11,0
11,0
15,0
15,0
15,0
18,5
18,5
18,5
22,0
22,0
22,0
35
35
20
50
50
35
63
63
35
80
80
35
80
80
50
4G6
4G6
4G2,5
4G10
4G10
4G4
4G16
4G16
4G6
4G25
4G25
4G6
4G25
4G25
4G10
60-Hz- Compressors
L07
L07
L07
L11
L11
L11
L15
L15
L15
L18
L18
L18
L22
L22
L22
Notes on the table:
We do not know the cable type used by you, its length
and the installation conditions (temperatures, grouping).
The table above can therefore only be regarded as a
guideline.
The supply cable cross-sections given in the table
comply with VDE 0298, part 4 - table 13, column 7.
(Rubber hose line at 30 °C/86 °F and max. line length of
50 m). In the case of differing conditions (line length,
temperature and grouping), establish the cross sections
in accordance with DIN VDE 0298, part 4 or BS7671
taking into account the cable type.
Important
If local regulations are stricter than the values
specified above, observe the stricter regulations.
Compressor units are finished in the factory according
to standard EN60204 (industrial machinery). Please
observe the following important notes:
Danger
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 (lowvoltage switchgear and control gear (circuitbreakers)).
29
6. Preparations for commissioning
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
authorized specialist.
Attention: Interference voltage!
If external electric circuits, which cannot be cut out
via the main switch, are connected to the control,
these have to be identified according to EN60204.
Warning signs have to be fixed near the main
switch and near these electric circuits. In addition,
these conductors have to be laid separately and/or
identified by colors. Work on control cabinets may
only be carried out by electrotechnical specialists.
If the installation conditions of the system differ
from the conditions described in EN60204, please
contact your technical adviser.
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
required, re-set. Several tapping points are provided for
this purpose (see circuit diagram). Fig. 12 illustrates an
example.
To establish an electrical connection, proceed as
follows:
Guide in supply cable at cable entry ( - 1 - Fig. 11) (cut
slit in cable entry to match cable diameter), guide
through clamp ( - 2 - and - 3 - Fig. 11) and through
cable screw connection on switch cabinet
(- 4 - Fig. 11) and tighten screw connection.
Connect the supply line to the connecting terminals as
shown in the circuit diagram.
Fig. 12
Danger
When carrying out adjustment work on the control
power transformer, the unit must be electrically
isolated and locked off.
Work on the control cabinet may only be carried
out by electrotechnical specialist personnel.
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.
The correct setting should be checked during
under load operation of the unit by measuring the
control power transformer output voltages.
Fig. 11
30
6. Preparations for commissioning
6.4
Electric motor fasteners for secure
transportation
6.5
Oil level check
Danger
Fasteners used for securing the electric motor (- 1 - Fig.
13) during transportation must be removed prior to
commissioning.
To remove the fasteners, proceed as follows:
•
After the panel has been removed, support the
motor by screwing the belt adjusting bolt (- 2 - Fig.
13) clockwise until it touches the motor.
•
Loosen the fastening screws (- 3 - and - 4 -Fig. 13)
and remove the fasteners
•
Check V-belt (- 5 -Fig. 13) is correctly placed in the
in V-belt pulleys
•
Screw the belt adjusting bolt back until it reaches
the lock nut (- 6 -Fig. 13) on the holder (- 7-Fig. 13);
securely fasten the motion screw (anti-clockwise)
Only check the oil level when the screw
compressor unit is out of operation and
depressurized!
The pressure reservoir can be under pressure and
the oil hot. Warning: Danger of scalding!
Do not spill oil! Check for leakage!
Fig. 14
1
2
3
4
Oil filler cap R1"
Oil-level indicator
Maximum oil level
Minimum oil level
Important
Do not mix oils of different specifications.
Fig. 13
Machines which are delivered without oil must first
be filled to the max. mark in the pressure reservoir
sight glass (see also chapters 9.4 and 9.14)
Check the oil level as follows:
•
Switch off the screw compressor unit by pressing
 (Fig. 16).
the button 
•
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
transparent plastic tube at the pressure reservoir
(- 2 - Fig. 14) after every stop and at regular
intervals. If required, top up oil
Also see chapter 8 “Service and maintenance”
31
6. Preparations for commissioning
6.6
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)
L07
68
L11
69
L15
69
L18
70
L22
70
60 Hz compressors
dB(A)
L07
72
L11
72
L15
73
L18
73
L22
73
Subject to technical revision.
32
7. Commissioning
7
Com m issio ni ng
7.1
First commissioning
Danger
Make sure before commissioning that nobody is in
the danger zone of the screw compressor.
Only operate the screw compressor with closed
access panels.
Important
Although every CompAir screw compressor has
been subjected to a test run at the factory and has
again been thoroughly inspected before shipment,
damage during shipment cannot be excluded. For
this reason, every screw compressor should be
checked once again for damage before being commissioned. In addition, it should be observed
during the first operating hours.
If the screw compressor is newly connected to a
power supply, check the direction of rotation of the
drive motor!
Important
If the direction of rotation is incorrect, immediately
shut down the unit using the large emergency
STOP button on the control panel (-24- Fig. 3) and
 key (Fig. 16), as otherwise you
not using the 
may cause serious damage to the compressor,
even if only operated briefly.
The access panels may temporarily be opened for
checking the direction of rotation (wear ear
protectors).
Danger
Beware of rotating parts!
Rotating parts can lead to injuries. Stay at a safe
distance away from rotating machine parts!
I (- 2 - Fig. 16) and
Press the START button 
check the direction of rotation. With a wrong direction
of rotation, press the red emergency STOP button
(-24- Fig. 3) immediately and correct the direction of
rotation.
First commissioning is carried out as follows:
•
Remove transport guards (see chapter 6.4, Fig. 13)
•
Fill oil in the pressure vessel up to “maximum oil
level” mark. (This applies to compressor systems
which are delivered without having been filled with
oil). (Refer to Chapter 9.4 and 9.14 for information
on filling oil).
•
Check the oil level in the pressure reservoir (see
also chapter 6.5). (Fig. 14)
•
Check the setting of the control-power transformer
(see also chapter 6.3). (Fig. 12)
•
Check and re-tighten all connecting terminals of the
electrical control.
•
Open isolator valves between the screw compressor, reservoir and pipe.
•
Operate main power supply switch.
•
Once the power supply has been switched on, the
POWER LOSS fault appears. This fault must be
acknowledged using the
key (Fig. 16). You will
find more information about the control in chapter 8.
•
•
Fig. 15
1
Drive motor‘s direction of rotation
Note
The factory setting of the setpoint value for the
network pressure (upper and lower switching point)
is saved in the compressor control DELCOS Pro
and depends on the relevant pressure variant of the
compressor (see nameplate fig. 2, stage pressures
= maximum operating pressure). Chapter 8.5.2
describes how you check these settings or change
the values.
For switching the compressor off “normally”, use only
 (Fig. 16), but not the
the stop push-button 
EMERGENCY STOP push-button (-24- Fig. 3). After
having been switched off, the compressor is aftercooled
for 30 seconds (soft stop).
Temporarily open the hood to check the direction of
rotation, for specified direction, see (- 1 - Fig. 15)
The screw compressor unit will not start up if the
ambient temperature is lower than + 1 °C/33.8 °F.
Temperature start-up protection
33
7. Commissioning
7.2
Routine commissioning
Danger
Make sure before commissioning that nobody is in
the danger zone of the motor/screw compressor.
After completion of work: Verify that all safety
devices have been refitted and that all tools have
been removed.
Only operate the screw compressor unit with
closed access panels.
7.3
Commissioning after malfunction
Important
Do not switch the screw compressor on repeatedly
without having rectified the malfunction, since this
may cause considerable damage to the machine.
Re-start after an automatic shutdown due to a
malfunction as follows:
•
Turn master switch off.
•
Eliminate fault.
For routine commissioning, proceed as follows:
•
Turn master switch on.
•
Check oil level in the pressure reservoir (see also
chapter 6.5).
•
Press acknowledgement push-button
•
Open shut-off valves between the screw
compressor, reservoir and pipe.
•
Start the screw compressor unit by pressing the
I (Fig. 16).
START button 
•
Switch on the power supply master switch.
•
Once the power supply has been switched on, the
POWER LOSS fault appears. This fault must be
acknowledged using the
key (Fig. 16).
•
I (Fig. 16).
Press START button 
•
To switch off the compressor in the usual way use
 (Fig. 16) and not the emergency
the STOP button 
STOP button. After shutdown the compressor has a
run on time of 30 seconds (soft-stop).
Start-up protection of the electric motor
The screw compressor unit will not start up if the final
compression pressure is more than 0,8 bar / 11, 6 PSI.
Temperature start-up protection
The screw compressor unit will not start up if the ambient temperature is lower than + 1 °C/33.8 °F.
34
(Fig. 16)
8. Control system
8
Contr ol s yst em
8.1
8.3
General
Status indicator (display / light
signals)
This chapter is used to quickly commission the unit. The
control system is explained in detail in the separate
DELCOS Pro operating instructions.
The control system is fitted with a three-row display.
When the unit has been switched on for the first time,
the POWER LOSS fault appears on the display. This fault
must be acknowledged using . This is a routine
message, the compressor is not defective.
The final compression temperature, final compression pressure and network pressure are permanently
displayed here.
When supplied, the display language is set to English.
To set another language, see chapter 8.5.1.
Final compression temperature: is the temperature
measured downstream of the compressor stage.
1st row:
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.
The following symbols may also be used in the 1st row:
73°C 10.4bar 10.3bar
TOTAL RUNNING
4711h
ON-LOAD
p2
Second pressure range / timer active
Remote start / stop activated
2nd row:
The second row is reserved for the menu. You can view
values like the total service hours and set values like
the nominal pressure in the menu.
Fig. 16
3rd row:
8.2
The third row shows status, fault and warning messages.
Keys
I
Switch on unit


Switch off unit
The three keys on the right next to the display have a
dual function:
 +


at the same
time


Call up or exit menu,
exit menu / sub-menu
Switch to next sub-menu / menu item,
or reduce a value
Light signals
The DELCOS Pro is fitted with two light signals (red,
green).
Red light signal:
Flashing slowly:
warning, maintenance due
Flashing rapidly:
fault, unit is stopped until fault has
been rectified
The red light signal only goes out once the warning or
fault has been remedied properly.
Green light signal:
Flashing:


Switch to previous sub-menu / menu
item, or increase a value
system is ready, i.e. the motor
may start up automatically at any
time.
Lit up permanently: the drive motor is running
Acknowledgement key,
if you are in a menu / sub-menu, the
acknowledgement key functions as an
Enter key [↵].
35
8. Control system
8.4
8.4.1
Displaying / changing values
Selecting values
8.5
Default settings
Danger
You can display values, e.g. total hours, and set the
control system, e.g. cut-in and cut-out times, in the submenu.
When programming in standby, the machine may
start up at any time.
 +

To reach the main menu, you must press the 
keys at the same time.
 or 
 keys to switch between the
You can use the 
following sub-menus:
[MAINTENANCE SCHED.]
[ CONTROL MENU ]
[ FAULT MEMORY ]
[ TIMER CONTROL ]
[ LIMIT VALUES ]
[OPTIONAL IN-/OUTPUTS]
Enter a sub-menu by pressing the
Selecting language

You can change the language by pressing the
+
 keys. Press these keys at the same time
or
+
until the right language appears.
8.5.2 Setting network pressure
key.
 or 
 keys to go to a
Again here you can use the 
menu item.
 +
 keys
To exit the sub-menu, you must press the 
at the same time.
To then fully exit the main menu, you must again press
 +
 keys at the same time.
the 
8.4.2
8.5.1
Changing values
Enter the sub-menu and then the menu item containing
the value you wish to change.
Then press the
key, the value flashes. You can now
 or 
 to change the value. You must then
press 
press the
key again to confirm the value.
Max. network pressure:
The network pressure is set in the [ CONTROL MENU ]
 +
 keys have to be pressed at the
sub-menu. The 
same time to do this. You are then taken to the main
 to switch to the [ CONTROL MENU ]
menu. Use 
key.
sub-menu. Then please press the
The CUT-OUT POINT menu item now appears on the
– key causes the value to
display. Again pressing the 
flash. You can now correct (increase or decrease) this
 or 
 . Then confirm the value set by
value using 
pressing the
key.
Note
The control system checks whether the value set can
be used. The maximum network pressure CUTOUT 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 CUTOUT POINT and CUT-IN POINT should not be too
small.
Example:
CUT-OUT POINT 10.0bar
CUT-IN POINT
9.8bar
Min. network pressure:

In the [ CONTROL MENU ] sub-menu please use 
to go to the CUT-IN POINT menu item.
Pressing the
key causes the value to flash.
You can now correct (increase or decrease) this value
 or 
 . Then confirm the value set by pressing
using 
the
key.
36
8. Control system
8.5.3 Setting time/date (timer)
The DELCOS Pro accumulator can bridge a loss of
power lasting between around two to three weeks. If
power is lost for longer periods, the timer's time and
date are lost and have to be entered anew.
 +
 keys at the same time. Use 
 to go
Press the 
to the [ TIMER CONTROL ] sub-menu and press the
key. The date and time are displayed there in the
following format:
TU 30.10.07 12:10:34
If you press the
key, the left-hand value (day of the
 or 

week) starts to flash. You can now use the 
keys to set this. Then confirm the value by pressing the
key.
All values can now be set in succession using this
procedure. When the last value (seconds) has been set,
the timer is fully set and you can exit the menu by twice
 +
 keys at the same time.
pressing the 
8.8
The emergency off button is located above 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,
 key.
always use the 
8.9
Starting the unit
Danger
If the unit is ready, i.e. the green LED is flashing,
the compressor may automatically start at any time.
Acknowledging warning /
fault messages
Warning and fault messages are shown in the third row
of the display. The red light signal flashes at the same
time.
You will find a table containing messages and
suggested ways of remedying problems in the separate
DELCOS Pro operating instructions.
8.9.1
8.6
Emergency off button
Warning messages
When there are warnings, the red light signal flashes
slowly. The unit does not automatically shut down when
there are warnings. However ignored warnings may
cause faults.
Rectify what is causing the warning and press the
key to hide the warning.
Use the main switch to switch the unit on.
If warning or fault messages appear in the third row of
the display, these first have to be rectified and
confirmed using the
key.
I key on the
Then start the unit by pressing the 
DELCOS Pro.
8.7
8.9.2
Fault messages
Fault messages result in the unit automatically shutting
down or do not permit the unit to be started.
Once you have rectified the problem, you still have to
confirm by pressing the
key.
Switching off the unit
 key on the
The unit is switched off by pressing the 
DELCOS Pro. However the unit will only stop after a 30second soft-stop.
The soft-stop is preset to protect the compressor.
Note
The unit may only be shut down using the emergency
off button in real emergencies. When shutting down
 key.
normally, please use the 
37
8. Control system
8.10 Menu structure (values are examples)
 +


[MAINTENANCE SCHED.]




 +


[ CONTROL MENU ]
 +






[ FAULT MEMORY ]




 +


[ TIMER CONTROL ]




 +


[ LIMIT VALUES ]
 +






[OPTIONAL IN-/OUTPUTS]
12345h
10987h
2000h
2000h
4000h
4000h
OFF




CUT-OUT POINT
13.0bar
CUT-IN POINT
12.5bar
p2 CUT-OUT POINT
10.5bar
p2 CUT-IN POINT
10.0bar
AUTOMATIC OPERATION
ENABLE REMOTE-START
OFF
TIMER CONTROL
OFF
p2 TIMER CONTROL
OFF
AUTO RESTART
OFF
POWER LOSS TIME
2s
START-UP DELAY
5s
DRYER PRE-RUN
0min
RS485-ProTOCOL
ModBus
RS485-BAUDRATE
19200
RS485-ADDRESS
1




01!EM-STOP
01!EM-STOP
:
:
12345h
12300h




TH 08.02.07
13:55:41
1 _____________00:00 00:00
:
7 _____________00:00 00:00
:
p2 1 ___________00:00 00:00
:
p2 7 ___________00:00 00:00




DESIGN PRESS
13.0bar
START ProTECT
0.8bar
HEAVY STARTUP
3.5bar
FINAL TEMP WARN
110°C
FINAL TEMP MAX
120°C
MIN START TEMP
1°C
RUN-ON TIME
90s
SOFT STOP
30s
STAR/DELTA TIME
6s
SOFTWARE:
DPro-L-x.xx




INPUT 1:
 +


38
TOTAL RUNNING
LOADED HOURS
AIR FILTER IN
OIL FILTER IN
SEPARATOR IN
OIL CHANGE IN
SHUTDOWN
OUTPUT 1:
OUTPUT 2:
:
OFF
FAULT
OFF




9. Service and maintenance
9
Ser vice an d m ai nte na nce
9.1
Maintenance recommendations
9.3
Maintenance schedule
Danger
Note
The screw compressor unit can only operate to your
complete satisfaction when the maintenance work is
carefully carried out at the specified intervals.
When performing control, adjusting and maintenance work, be careful with hot surfaces of
machine parts.
In order to facilitate this task, the scope of supply of the
screw compressor unit comprises the “Maintenance and
inspection manual for CompAir compressors”, in which
you can list your performed maintenance work at the
specified intervals.
Checks and maintenance work may only be carried
out when the following points are observed:
You can also have this maintenance work performed by
our trained technicians. Please ask your CompAir
distributor for a maintenance contract.
9.2
Maintenance electric motor
•
Press the STOP button on the control panel and
wait until the screw compressor unit has come
to rest and the screw compressor unit is
depressurized
•
The pressure display does no longer indicate
pressures < 0.3 bar/4.4 PSI.
•
Shortly after switching the screw compressor
off, the system can contain a low residual
pressure.
•
The screw compressor unit must therefore be
depressorized prior to any maintenance work by
slowly opening the lock (oil filler cap) with
integral vents
•
The customer-installed main switch is set to "O"
(OFF) and locked off
•
Warning:
Electrical voltage: Only work on the screw
compressor unit when it is disconnected.
The maintenance of the electric motor is to be
performed in line with the motor operating instructions.
39
9. Service and maintenance
Service packages
Package C
Package D
Package E
Package V
Oil filter cartridge, air filter cartridge
Oil separator element
Worn parts
V-belt set (recommendation)
Intervals are valid for normal industrial environments
and operating conditions.
For order numbers see the spare parts list.
Maintenance items
W1 European-version
Oil change (CompAir - 4000 hours oil)
Valid for normal industrial environments (when in
doubt, check the oil change intervals by carrying
out an oil analysis) Minimum oil change = 1 x year
W7 Checking/tightening of connecting terminals in
the switch cabinet/ and checking of the
“control transformer” setting
W8 Checking/tightening screw connections
W9 General maintenance/cleaning
(In the case of a very dirty atmosphere, the
cleaning intervals have to be shortened as
required)
W2 Replacement of oil filter cartridge
Valid for normal industrial environments
W3 Replacement of oil fine separator cartridge
Valid for normal industrial environments
W10 Replacing the V-belt (recommendation)
(only complete sets)
W4 Replacement of air filter cartridge
Valid for normal industrial environments
W11 Cleaning/replacement of cooling air inlet filter
(In the case of a very dirty atmosphere, the
cleaning intervals have to be shortened as
required)
W5 Safety valve / functional test
at least once a year
W6 V-belt
(only visual check)
Intervals
Operating
hours
Required service
package
No later than
x months
During
comm.
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
3M
6M
9M
12 M
15 M
18 M
21 M
24 M
27 M
30 M
33 M
36 M

Package C


Package D





Package V


W2




W3

W4
W5














W6




W7




W8







W9

W10
W11

These maintenance intervals must be adhered to!
40


Package E
W1
Maintenance






9. Service and maintenance
9.4
Oil change
intake air from a normal environment without a high
content of foreign matter (dusts, vapours, gases).
When changing the oil, the waste oil is to be drained
completely, since used oil reduces the service life of the
new oil fill considerably.
Do not mix lubricating oils of different makes. When
changing over to a new oil type, the oil in the oil circuit
must be drained completely.
For the oil change intervals, see maintenance schedule.
When changing the oil, proceed as follows:
Fig. 17
1
2
3
4
5
6
Oil reservoir
Oil filler cap R1"
Oil-level indicator
Max. oil level
Min. oil level
Oil drain R1/2"
Danger
Only change the oil when the screw compressor
unit is not in operation and is depressurized!
Be careful when draining hot oil:
Danger of scalding!
Important
Remove oil residues and other deposits from unit
parts and from the coolers of compressors, which
are exposed to hot compressed air, according to
the operating instructions.
•
Switch the screw compressor unit off and ensure
that it is depressurized, electrically isolate and
locked off.
•
Slowly open the oil filler cap (- 2 - Fig. 17), to
depressurize the screw compressor by releasing
any residual pressure in the unit
•
Remove the oil filler cap
•
Open the oil drain (- 6 - Fig. 17) for the pressure
reservoir and the oil cooler
•
Drain oil at operating temperature
•
Close the oil drain
•
Fill in oil up to the marking “maximum oil level”
(- 4 - Fig. 17) (L07-L11 approx. 5 litres,
L15-L22 approx. 6 litres)
•
Close the oil filler cap
•
Let the screw compressor unit run for approx.
2 minutes
•
Check for leakages
•
Switch the screw compressor unit off
•
Wait at least 5 minutes for the oil to settle and for
the air to disperse
•
Check oil level (see chapter 6.5)
•
The oil level must be between the maximum level (4 - Fig. 17) and minimum level (- 5 - Fig. 17) marked
on the oil reservoir.
•
If required, top up oil
Note
Collect the waste oil, do not allow it to seep into the
ground!
Disposal in accordance with the regulations! Do not spill
oil! Check for leakage!
With these compressors, the oil change intervals
strongly depend on the degree of contamination of the
circulating oil. It must therefore be taken care that no
oil-deteriorating matter (dusts, vapours, gases) are
transported through the air intake filter into the oil circuit
of the compressor unit. Also a high content of humidity
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
Changing intervals for lubricants
The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours) have a strong influence
on the oil change intervals.
In this case the oil must be analyzed to check the
permissible length of time that the oil can be used (see
also chapter 9.14). Under no circumstances should the
oil be used beyond its design life.
41
9. Service and maintenance
9.5
Change of oil filter cartridge
•
Check oil level (see chapter 6.5)
•
If required, top up oil.
Changing intervals for oil filter cartridge
The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong
influence on the service life of the filters (air filters, oil
filters, fine separators).
Where such conditions exist the filter element may
require changing more frequently.
9.6
Change of the fine separator
cartridge
Fig. 18
1
Oil filter cartridge
Danger
Only replace the oil filter cartridge when the screw
compressor unit is out of operation and
depressurized!
Be careful with hot oil: Danger of scalding! Do not
spill oil!
Note
Dispose of the oil filter cartridge in line with the
regulations - special waste ! Check for leakage!
For the changing intervals, see the maintenance
schedule.
Fig. 19
Change the oil filter cartridge as follows:
•
Switch the screw compressor unit off and ensure
that it is depressurized, electrically isolate and
locked off.
•
Wait at least 5 minutes for the oil to settle and for
the air to disperse.
•
Unscrew the oil filter cartridge ( - 1 - Fig. 18) using
an appropriate tool
•
Dispose of the oil filter cartridge according to the
regulations
•
Oil the gasket of the new oil filter cartridge slightly
•
Screw on the new oil filter cartridge and tighten
manually (take notice of the instructions on the oil
filter cartridge)
•
Check for leakage
42
1
Oil fine separator
Danger
The pressure reservoir is under pressure! Only
work on the screw compressor unit when it is out
of operation and depressurized!
Be careful with hot oil: Danger of scalding!
Do not spill oil!
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.
9. Service and maintenance
Change the oil fine separator as follows:
•
Switch the screw compressor unit off and make sure
that it is depressurised and no voltage is supplied.
•
Unscrew the fine separator cartridge (-1- Fig. 19)
using an appropriate tool
•
Dispose of the fine separator cartridge according
tothe regulations
•
Oil the gasket of the new fine separator cartridges
lightly
•
Screw on the new fine separator cartridge and
tighten manually (take notice of the instructions on
the fine separator cartridge)
•
Check for leakage
•
Check oil level (see chapter 6.5)
•
If required, top up oil.
9.7
Change of air intake filter
Danger
Only perform checks and carry out work on the
screw compressor when the unit is out of operation
and depressurized!
Important
Never operate the screw compressor unit without
the air filter (even a short operating time without
this filter can result in considerable damage to the
machine)!
A clogged air filter must be cleaned or replaced when
the maintenance point has been reached.
Check the air filter for accumulated dust at least once a
week or, if required, daily.
Changing intervals for oil fine separator cartridge
During maintenance work, take care that no dirt enters
the clean air side of the air filter.
The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong
influence on the service life of the filters (air filters, oil
filters, fine separators).
9.7.1
Change of air intake filter L07-L11
Fig. 20
L07-L11
Where such conditions exist the filter element may
require changing more frequently.
1
2
Air intake filter
Fixing clip
Change the air filter as follows:
•
Loosen the fixing clamp ( - 2 - Fig. 20)
•
Pull off the air filter ( - 1 - Fig. 20) and replace it with
a new one
•
Put the air filter on and tighten the fixing clamp
( - 2 - Fig. 20)
43
9. Service and maintenance
9.7.2 Changing of air intake filter L15-L22
Fig. 21
1
2
3
4
L15-L22
Air filter housing cover
Air filter housing
Air filter element
Fixing clip
9.8
Safety valve
Fig. 22
1
Safety valve
Testing the safety valve
The valve should be tested on a separate compressed
air line in accordance with local legislation.
Change the air filter as follows:
•
Loosen and remove the air filter housing cover
( - 1 - Fig. 21)
•
Remove the air filter ( - 3 - Fig. 21) and replace it
with a new one
•
Insert the air filter cartridge into the air filter housing
(- 2 - Fig. 21)
•
Screw the air filter housing cover on to the air filter
housing
Changing intervals for air filter cartridge
The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong
influence on the service life of the filters (air filters, oil
filters, fine separators).
Where such conditions exist the filter element may
require changing more frequently.
44
Operate the safety valve depending on the type of
valve:
•
by unscrewing the cap one or two turns and
retightening it
•
or by pulling the valve lifting lever
Danger
Never operate a screw compressor system with a
defective safety valve or without safety valve!
9. Service and maintenance
9.9
Changing V-belts/automatic
tensioning system
Danger
Changing the V-belt is carried out as follows:
•
Remove the panel (- 5 - Fig. 23) by loosening the
capscrews (- 6 - fig. 34)
•
Only perform checks and carry out work when the
screw compressor unit is out of operation and
depressurized, electrically isolated and locked off.
Remove the cover cap ( - 1 - Fig. 23) from the
access panel
•
Any safety equipment which had to be removed for
the replacement of the V-belt set must be
remounted after completion of this work.
Lift the motor by turning the motion screw
(- 2 - Fig. 23) clockwise until the V-belts are
released
•
Clean/degrease the V-belt pulleys
•
Replace the V-belt set (- 7 - Fig. 23)
•
Screw the motion screw back in until the lock nut
(- 3 - Fig. 23) reaches the holder (- 4 - Fig. 23);
securely fasten the motion screw (anti-clockwise)
•
Replace the cover cap and the panel
Important
The replacement of a single V-belt is not permitted,
always replace a complete V-belt set.
During the entire service life of the V-belt set, no
readjustment of the automatic V-belt tensioning
system will be necessary.
9.10 Connecting terminals in the switch
cabinet/control transformer setting
Danger
In the case of electric voltage:
•
•
 at the operating panel
Actuate STOP button 
Set the customer-fitted main power switch to
"O" (OFF).
The connecting terminals in the switch cabinet have to
be checked and, if required, re-tightened during first
commissioning and later on in line with the maintenance
schedule.
The setting of the control transformer must be checked
according to chapter 6.3 “Electrical connection”.
Fig. 23
1
2
3
4
5
6
7
8
Cover cap
Motion screw
Lock nut
Holder
Panel
Capscrew
V-belt set
Rotational axis
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.
Check the hose and piping for unsealed areas.
The V-belt preload needed is specified by the weight of
the motor, which is mounted in a rotary fashion ( - 8 Fig. 23).
45
9. Service and maintenance
9.12 General maintenance and cleaning
Important
Remove oil residues and other deposits from unit
parts and from the coolers of compressors, which
are exposed to hot compressed air, according to
the operating instructions.
Blow off the screw compressor unit with
compressed air at the specified intervals (never
direct compressed air towards persons) paying
particular attention to:
•
•
•
•
•
Regulating elements
Fittings
Compressor block
Cooler
Electric motor
The maintenance of the electric motor is to be
performed in line with the motor operating instructions.
The electric motor is permanently lubricated.
9.13 Clean / change filter with cooling air
inlet and control cabinet inlet
Perform filter mat change as follows:
•
Remove mounting bolt (- 1 - Fig. 24).
•
Remove filter mat (- 1 - Fig. 24) and clean,
exchange if damaged.
•
Re-insert filter mat in the bottom access panel
(- 3 - Fig. 24).
•
Secure filter mat by means of the mounting bolt.
Cleaning:
Clean the filter mat by brushing or washing.
Important
Never install the filter mat in a wet or moist state!
Changing times for the filter mat
The operating modes and the quality of the suctioned
air (e.g. dust content) has a strong influence on the filter
service life.
The filter should be checked on a weekly basis,
eventually daily basis, for dust build-up.
In these operational cases, shorter change intervals are
possible.
9.14 Maintenance information and
lubricant recommendations for
stationary compressors
Lubricant recommendations
Please note that proper lubrication will considerably
increase the service life of your compressor unit.
According to regulations relating to the prevention of
accidents, use lubricants the properties of which meet
the requirements of the operating conditions on site.
Do not mix lubricating oils of different makes. When
changing over to a new oil type, drain the old oil
completely from the system.
Fig. 24
1
2
3
Filter mat cooling air inlet
Mounting bolt
Bottom access panel
Danger
Only perform filter mat change after the
compressor system has been shut down and
depressurized!
If final compression temperatures of more than 90 °C/
195 °F occur continually, the oil change intervals given
in section 9.3 (maintenance schedule) are halved.
The oil change intervals should be calculated more
accurately in accordance with the actual operating
conditions by analyzing the oil.
Use the following oil type:
European version
CompAir „4000“
46
10. Trouble-shooting
10
Tr ou ble -s ho oti ng
Malfunction
Possible cause
Remedy
Unit cannot be started
1.
No operating or control voltage
1.
Check fuses, main switch and supply
line
2.
Malfunction not acknowledged
2.
Acknowledge fault message
3.
Pressure reservoir not depressurized
3.
Wait until depressurized
4.
Electric motor defective
4.
Check connections, winding, etc.
5.
Compressor defective
5.
Turn the compressor manually;
if required, replace
6.
Ambient temperature less than
+1 °C/ 33.8 °F
6.
Make sure that the ambient temperature
is not less than +1 °C/ 33.8 °F; install an
auxiliary heater, if required
7.
Remote control has been activated via
terminal strip
7.
Deactivate remote control/timer
8.
Mains pressure is above the lower
switch set point
8.
Wait until the mains pressure has fallen
below the lower switch set point
1.
Intake regulator only closes partly,
pressure builds up too quickly in the
pressure reservoir
1.
Fix intake regulator or, if required,
replace; check solenoid valves
2.
Short-circuit in the unit
2.
Determine and eliminate cause; replace
defective fuses
3.
Connecting terminals in the switch
cabinet are loose
3.
Check and re-tighten
4.
Oil too viscous
4.
Select the type of oil according to the
ambient conditions or install an auxiliary
heater
5.
Maximum motor switching cycles
exceeded due to too frequent manual
on and off-switching
5.
Avoid frequent manual on and offswitching, let electric motor cool down
1.
Mains pressure sensor set too low
1.
Check, re-set
2.
Intake regulator opens only partly
2.
Fix intake regulator or, if required,
replace; check solenoid valves
3.
Excessive air consumption
3.
Reduce consumption or cut in a further
compressor
4.
V-belt slips
4.
Replace the V-belt set
5.
Fine separator clogged
5.
Replace fine separator cartridge
6.
Air filter clogged
6.
Replace air filter cartridge
7.
Heavy leakage in the compressor
system
7.
Check unit
8.
Mains pressure exceeds the lower
switching point
8.
Wait until the mains pressure has fallen
below the lower switching point
Unit stops during the
start-up phase
Unit does not reach the
set mains pressure
47
10. Trouble-shooting
Malfunction
Unit switches off
Possible cause
Remedy
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.
Cross section of the electric supply
lines too small
4.
Measure power requirement,
if necessary, replace lines
5.
Power requirement too high
5.
Oil fine separator clogged,
replace, if necessary
6.
Oil level too low
6.
Top up oil in the pressure reservoir
7.
Oil injection pressure too low
7.
Replace oil filter cartridge,
clean oil system
8.
Excessive oil temperature
8.
Check oil cooler and fan/
Check oil thermostat
Excessive idling
pressure
1.
Intake regulator does not close correctly
1.
Check intake regulator
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
1.
Intake regulator setback function
defective
1.
Check intake regulator
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
1.
Safety valve defective
1.
Replace
2.
Oil fine separator clogged and final
compression pressure sensor defective
2.
Replace oil fine separator cartridge and
change final compression pressure
sensor
3.
Intake regulator closes too slowly
3.
Check intake regulator and solenoid
valve
4.
Mains pressure sensor defective
4.
Replace mains pressure sensor
5.
Electronics defective
5.
Replace electronics
Oil in the air filter
Safety valve opens
Danger
Never operate the screw compressor with defective safety valve!
48
11. Annex
11
Ann ex
11.1 Technical data EUROPE version L07-L22 50 Hz
Technical Data L07-L11 50Hz
L07
Maximum operating pressure
Minimum operating pressure
bar
bar
Ambient temperature
Flow
°C
m3/min
Final compression temperature above ambient temp.
Sound pressure level (to Cagi Pneurop PN8NTC2)
Nominal motor rating
°C
dB(A)
kW
Full-load current max. IP55 (220V)
Full-load current max. IP55 (400V)
7,5
1,14
0,93
10
9
68
7,5
Cooling air outlet temperature above ambient temp.
Max. allowable pressure drop in duct at ambient 35°C/45°C
Compressor oil fill
Residual oil capacity
Compressed air delivery connection
12
1,41
1,14
11
69
11
10
4G10 / 4G6
50 / 35
37
17
5
3-5
EN 10226 Rp 3/4" (DIN 2999 - Rp 3/4)
215
233
687 x 585 x 1000
L18
Minimum operating pressure
Ambient temperature
Flow
bar
°C
m3/min
2,47
2,10
1,68
°C
9
8
7
Recommended cable cross-section
220V / 400V
Recommended fuse size 220V / 400V
12
30
bar
Motor protection type
Nominal speed
Nominal fan motor power
10
13
52
26
°C
Pa
Maximum operating pressure
Full-load current max. IP55 (220V)
Full-load current max. IP55 (400V)
8
4G6 / 4G2,5
35 / 20
34
L15
7,5
+ 1 / + 45
0,69
1,68
mm2
A
m3/min
kg
mm
Technical Data L15-L22 ; 50 Hz
10
IP55
3000
no separate fan motor
l
mg/m³
Weight
Dimensions L x W x H
7,5
32
16
rpm
kW
Recommended cable cross-section 220V / 400V
Recommended fuse size 220V / 400V
Cooling air flow through ventilator
Final compression temperature above
ambient temp.
Sound pressure level (to Cagi Pneurop
PN8NTC2)
Nominal motor rating
13
5,0
A
A
Motor protection type
Nominal speed
Nominal fan motor power
L11
10
13
7,5
10
L22
13
5,0
+ 1 / + 45
3,07
2,60
2,22
12
11
10
7,5
10
13
3,46
3,04
2,58
13
12
11
dB(A)
69
70
70
kW
15
18,5
22
A
A
60
30
72
36
88
44
IP55
3000
no separate fan motor
rpm
kW
mm2
4G16 / 4G6
4G25 / 4G10
4G35 / 4G10
A
63 / 35
80 / 50
100 / 50
Cooling air flow through ventilator
Cooling air outlet temperature above
ambient temp.
Max. allowable pressure drop in duct at
ambient 35°C/45°C
Compressor oil fill
m3/min
59
56
56
°C
14
18
21
l
8
Residual oil capacity
Compressed air delivery connection
Weight
mg/m³
3-5
EN 10226 Rp 1" (DIN 2999 - Rp 1)
353
Dimensions L x W x H
Pa
kg
mm
20
327
359
823 x 696 x 1162
49
11. Annex
11.2 Technical data EUROPE version L07-L22 60 Hz
Technical Data L07-11 ; 60 Hz
Maximum operating pressure
Minimum operating pressure
L07
bar
bar
Ambient temperature
Flow
Final compression temperature above ambient temp.
°C
m3/min
°C
Sound pressure level (to Cagi Pneurop PN8NTC2)
Nominal motor rating
dB(A)
kW
Full-load current max. IP55 (220V)
Full-load current max. IP55 (400V)
Motor protection type
Nominal speed
Nominal fan motor power
Recommended cable cross-section 220V / 400V
Recommended fuse size 220V / 400V
Cooling air flow through ventilator
Cooling air outlet temperature above ambient temp.
Max. allowable pressure drop in duct at ambient
35°C/45°C
Compressor oil fill
Residual oil capacity
Compressed air delivery connection
Weight
Dimensions L x W x H
7,5
9
L11
13
7,5
9
13
1,53
11
1,14
10
5,0
1,15
10
1,00
9
+ 1 / + 45
0,69
1,61
8
12
72
7,5
A
A
11
IP55
3600
no separate fan motor
rpm
kW
4G6 / 4G2,5
35 / 20
4G10 / 4G4
50 / 35
mm2
A
m3/min
34
12
37
17
30
°C
5
Pa
3-5
l
EN 10226 Rp 3/4" (DIN 2999 - Rp 3/4)
mg/m³
218
233
687 x 585 x 1000
kg
mm
Technical Data L15-22 ; 60 Hz
L15
Maximum operating pressure
bar
Minimum operating pressure
Ambient temperature
Flow
bar
°C
m3/min
Final compression temperature above ambient temp.
Sound pressure level (to Cagi Pneurop PN8NTC2)
°C
dB(A)
7,5
9
L18
13
2,31
2,14
1,54
9
8
7
7,5
9
L22
13
5,0
+ 1 / + 45
2,96
2,71
2,13
12
11
73
10
7,5
9
13
3,43
3,12
2,50
13
12
11
Nominal motor rating
Full-load current max. IP55 (220V)
Full-load current max. IP55 (400V)
kW
A
A
15
Motor protection type
Nominal speed
rpm
4G16 / 4G6
no separate fan motor
4G25 / 4G6
4G25 / 4G10
Nominal fan motor power
Recommended cable cross-section 220V / 400V
Recommended fuse size 220V / 400V
kW
mm2
A
63 / 35
48
17
80 / 35
54
19
80 / 50
54
22
Cooling air flow through ventilator
Cooling air outlet temperature above ambient temp.
Max. allowable pressure drop in duct at ambient
35°C/45°C
Compressor oil fill
Residual oil capacity
Compressed air delivery connection
Weight
Dimensions L x W x H
50
18,5
IP55
3600
m3/min
°C
20
8
Pa
3-5
l
mg/m³
kg
mm
351
EN 10226 Rp 1" (DIN 2999 - Rp 1)
356
823 x 696 x 1162
22
365
11. Annex
11.3 Layout plan L07-L11
FRONT VIEW
REMOVABLE
HOOD
Compressed air connection
R3/4“
View “X”
Electrical connection
Air inlet
Cooling-air outlet
Access panel
Service aperture (V-belt relief)
Oil drain R1/2“
Fig. 25
51
11. Annex
11.4 Layout plan L15-L22
FRONT VIEW
REMOVABLE
HOOD
Compressed air connection
R1“ (1“ NPT/USA)
Electrical connection
View “X”
Air inlet
Cooling-air outlet
Access panel
Service aperture (V-belt relief)
Oil drain R1/2“
Fig. 26
52
CompAir Drucklufttechnik GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland
Tel. ++49 (0)6761 832-0
Fax ++49 (0)6761 832-409
w w w.compair.com
e-mail: [email protected]

Table of Contents for CompAir L07RS:

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