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Screw Air Compressor L02 – L03 – L04 – L05

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1. 2 3 L AutoCAD Unrerlage N LA 1 205 COMPRESSOR WEIGHT KG L04 kW 4 L05 kW 5 5 1 2 GAS E N 4 HOLES 9 11 680 SIA Datum Aend Zustand Tolerierung DIN 7167 Allgemeintoleranzen ISO 2768 mH Datum Rauhtiefe Rz Reihe 2 DIN 3141 Name AM Nr Ma stab 1 10 Gewicht Rohteil Nr Arte Nr 04 06 07 M Belegott Copyright reserved nach DIN 34 beachten Material Nr Format Blatt Blatter A CompAir Coma O 1 1 varit GmbH n Entstanden auss aus Modell Nr Werkstoff Benennung Aufstellplan General Arrangement Description 104 105 500LT Lo RN Nr Codestelle AutoCAD Unterlage de I 2 5 550 AIR B D Se 1335 IAA a au COMPRESSOR WEIGHT KG 1450 1 2 GAS 1 145 Keg Reviser Date Reviser State Tolerance DIN 7167 surface Roughness General Tolerance une 2 DIN 3141 ISO 2768 mH Description of revision 1 10 Weight achined part no Order no Dyright reserved Attention to protection mark
2. _ N d EE AO kJ O gt gt VDE More AT DAQSIO J Wye A SADIO L 4 ID N SIO VOI TAGE N0V 50 EOLH MPIAN RMA RD COMM DISEGNO N N NSION r4 VOLTAGE 400V 50 VA DUHZ Drucklufttechnik GmbH RAVING N SHEET N INT A INWED e R 1 A ES OTENZA POWER 4 0 5 5 kW CAZIDN N ES ALANANSA S RAE EZE U Wet Mort 2 er Gardner Denver Deutschland GmbH Argenthaler Str 11 55469 Simmern Hunsr ck Deutschland Tel 49 0 6761 832 0 Fax 49 0 6761 832 409 WWW compair com e mail sales compair com
3. 5 O N lt ES N lt Tol erierung DIN 71 Rauhtiefe RZ Gewicht Allgemeintoleranze ISO 2768 mH Reihe 2 DIN 3141 Rohteil Nr Auftr Nr ell Nr Werkstoff Datum Na ne Benennung 06 06 07 Bellegoffi Aufstellplan General Arrangement Descri phion Dyrig Klass Schutzvermerk nach DIN 34 beachten A CompAir 2012180 Drucklufttechnik GmbH l Entstanden aus ht reserved 107 103 L04 L05 UA SDE Forma I att Bla Codestelle tter EIS Brito Per erer 670 L 94 550 O S S 158 pe Kd S d COMPRESSOR WEIGHT KG L02 kW 2 2 L03 kW 3 SIA Datum LOL KW d E05 RW gt Tolerierung DIN 71 Rauhtiefe Rz aBstab 1 10 Gewicht Allgemeintoleranze Reihe 2 DIN 3141 Rohteil Nr SN ISO 2768 mH odell Nr Werkstoff Benennung Aufstellplan General Arrangment Description ii sa L02 L03 L04 L05 200LT Schutzvermerk nach DIN 34 beachten AC Ai NP SK Al Format Blatt Blatter A VOMPAIr 2012183 Drucklufttechnik GmbH
4. 6 2 PERFORMANCE COMPRESSOR FREE AIR MAXIMUM NOISE DELIVERY PRESSURE BAR dB A Capacity and power measurements according to ISO 1217 ed 3 ANNEX C 1996 test code Pneurop Cagi PN 2 CPTC2 Noise values determined according to ISO 2151 and ISO 3744 7 ELECTRIC MOTORS Technical Features Universal Voltage according to DIN IEC 38 Norms 400 690 230 400 Voltage tolerance of connection 5 Network voltages admissible with nominal power at 50Hz Nominal current indicated on the data plate referred to 400 230 REMARK 1 The control of the electrical input is to be carried out only by skilled staff 2 The value of current absorbed by the motor is meant measured on the cables of the N motor after the start up breakers the transformer and the fans in case there are any 8 LIFTING TRANSPORTATION RT mm 8 mom K 510 MAX Centre of gravity 9 DIMENSIONS WEIGHTS di z M z z E 1 2 GAS rf Ei b A C KN 62 1 I TE a al S m f 28 11 200 LT
5. AIR INTAKE VALVE OIL RETURN PRESSURE GAUGE DISCHARGE VALVE IP PRESSURE SWITCH PRESSURE TRANSDUCER 6 OIL FILTER OIL RADIATOR THERMOSTAT VALVE AIR INTAKE FILTER oo MINIMUM PRESSURE NON RETURN VAL COOLING FAN OIL TANK 12 REGULATION SYSTEM only for version with AIRBASIC 2 controller The compressor is specifically designed to operate automatically according to the control algorithm implemented into the AIR BASIC 2 controller When the button ON is pushed the compressor starts off in sequence with the Wye Delta function Once the Why Delta transition has been completed the timer counts a 1 second delay at the end of which the electric valve in activated and the compressor passes to the load phase The pressure is measured by a pressure transducer linked to the controller When the pressure reaches the Pmax operation value the controller deactivates the electric valve leaving the compressor in unload phase at most for three minutes If during the unload phase the pressure decreases at the Pmin value of the pressure switch the controller sends the input to restart the compressor If the pressure remains at a higher value than the Pmin the motor is switched off after the unload phase As soon as the pressure decrease below the Pmin value the motor is started to load phase AN 13 WORKING PRESSURE SETTING VERSIONS WITH OVERLOAD CUT OUT The pressure switch controls the load unload operat
6. TEST TEST TEST C NO NC NES Function available from 0 10 firmware version of controller COMPRESSORE COMPRESSOR mo Schema elettrico TIPO TYPE Wye Delta AirBASIC2 EE EE E ISSN TENSIONE VOLTAGE 400V 50 60H IMPIANTO FIRMA DISEGNO N runs II Drucklufttechnik GmbH pem iS DRAWING N POTENZA POWER 4 0 5 5 KW er KA0405A2B400 5 6 A N N N m N A N N TIT MODEL DENOMINAZIONE m DESIGNATION FABRICANTE 2 MANUFACTURER P N 400V 50 60Hz _ o s eer j _ em alba es pa e fen bass feses base vissa somesen om LI jonna bass percer somenen om BD D TRASFORMATORE TRASFORMER TRASFORMATEUR TRANSFORMATOR TRAFO Vout 0 12V 30VA 0 24V DK4Q 35 MORSETTO TERMINAL BOARD BORNIERA KLEMMENBRETT BORNERA WEIDMULLER RELAY SEQ FASI PHASES MONIT REL RELAIS RELAIS RELAIS SUPERVISION 200 500Vac os AIRBASIC2 CENTRALINA CONTROLLER CONTROLLER CONTROLLER CENTRALITA ELECTR Vin 0 230 400V TR1 3 14 TR 80 VA JINGDA CC1070151 1 CC1065055 1 NT D A G C c n n m m D P ai ai I ISTO comoone A SEV CAR I A J o NN a m EEA FN FL ADD e LU M IKE D DJK J COUMFREDSDUR E PP A OAO NOA lt leq
7. 500LT kW 3 100 kW 2 2 3 4 0 1 m s 30 Pa kw4 105 kW 5 5 0 2 m3 s 50 Pa kW55 105 ELECTRICAL LINE INLET kW22 165 3 PHASES sa MEME MI ELECTRICAL LINE INLET 2 kW4 170 255 PHASES lt 4 AIR OUTLET an SYMBOLS LABEL 10 OPERATING PRINCIPLES The air end is a single stage asymmetrical screw type driven by an electric motor The air is compressed through the rotation of a male and female rotors which mate perfectly along their parallel axes and are housed in a cast iron case Oil is injected into the air end housing for the double purpose of cooling the unit as well as lubricating the parts in movement The air once compressed enters a receiver where the remaining oil is separated to a residual of about 2 3ppm At this point it is ready to be delivered Should the oil temperature be above the desired running temperature the separated oil will pass through a thermostat controlled oil cooler should not this be the case it will be bypassed directly into the air end to start a new cycle of lubrication and cooling The air for the cooler used to cool the motor it is led into the compressor case through a fan driven directly by the motor 11 COMPRESSOR DIAGRAM A 13 1 ow EZ M16 10 N gt lt 12 bd Y 1L 9 ELECTRIC MOTOR AIR END DISCHARGE OIL OIL SEPARATION FILTER TEMPERATURE CONTROL DEVICE SAFETY VALVE
8. PROTEZIONE INGRESSO LINEA L re DI LINEA DEVONO ESSERE INSTALLATI A CURA DI UN 400 5 50 60Hz NSTALLATORE QUALIFICATO D 4 0 4x2 5 m MOTORE COMPRESSORE 55 4x2 5 INPUT LINE MAIN DISCONNECT SWITCH AND BRANCH CIRCUIT COMPRESSOR MOTOR SCARE LEITUNG PROTECTIVE DEVICE S SHALL BE PROVIDED BY A MOTEUR COMPRESSEUR G QUALIFIED INSTALLER KOMPRESSOR MOTOR LINEA MOTOR N COMPRESSORE Z COMPRESSOR TIPO TYPE 400V 50 60Hz KW 2 zie DE Aengd Zusta Tolerierung DIN 16Yauh ti asstak Gewicht AllgemeintoleranzenReihe hteil Nh AUF tr Nr Z 6 IS SEN ell Nnl Werkstoff onnung Schaltplan tlectrical Diagram Description Copyright reserved LUS LU4 05 Klass Nr JA Spr Schutzvermerk nach DIN 34 beachten ACompAir e Drucklufttechnik GmbH XP ee D 010 l terlaae 2 3 4 COMPRESSORE COMPRESSOR TIPO TYPE Wye Delta AirBASIC2 TENSIONE VOLTAGE 400V 50 60Hz POTENZA POWER 4 0 5 5 kW QUADRO CONTROLLO ELETTRO COMPRESSORE E COMPRESSOR CONTROL PANEL IABLEAU DE CONTROLE POUR E COMPRESSEUR PANEEL KONTROLLE E KOMPRESSOR TABLERO DE CONTROLE ELECTROCOMPRESOR 1 e S3 4 5 6 7 8S 9 A ie i3 14 1 5 1 VQ QA AG 1222222
9. ana s a R ate n m 17 22 ELECTRONIC CONTROLLER FOR SPECIFIC VERSION J J 17 23 Ry i elm 18 24 MAINTENANCE PROGRAM nase ee 19 20 25 OIL RECOMMENDATION FOR COMPAIR SCREW INDUSTRIAL COMPRESSOR 21 22 20 BELE TENSIONING uu uu DT 23 27 MAINTENANCE OF THE AUTOMATIC CONDENSATION DRAINER FOR SPECIFIC VERSION 24 28 TROUBLESHOOTING eene 25 26 2 27 USER S MANUAL AIRBASIC 2 CONTROLLER FOR SPECIFIC VERSION SPARE PARTS UE 1 GRAPHICS AND WARNING SYMBOLS An adhesive label visibly placed on the cover of the compressor reports a series of symbols pictograms to Inform anyone about risks and residual dangers contained in the compressor itself Description of pictograms following to norms EN 1012 1 ISO 7000 CE 245 24 O READ OPERATOR S INSTRUCTIONS BEFORE STARTING THE COMPRESSOR AN DANGER MAINTENANCE WORK CONSULT INSTRUCTION MANUAL WARNING RISK OF ELECTRIC SHOCK FORBIDDEN TO REMOVE PROTECTIVE COVERING AND SAFETY DEVICES WARNING HOT SURFACE DANGER LOW TEMPERATURE FOLLOW INSTRUCTION MANUAL DANGER COMPONENTS EQUIPMENT UNDER HIGH PRESSURE DANGER AUTOMATIC MODE START UP WITHOUT WARNING DANGER HOT OR NOXIOUS GASES OUTLET UNBREATHABLE ON START UP SWITCH OFF STOP SWITCH 2 GENERAL INFORMATION This manual is aimed for the compressor user and specifically for Ha
10. box Cf electric diagrams and technical data Connecting the protective earth lead correctly is highly important N Power supply connections are only allowed to gualified electricians No computers should be installed near the compressor Make sure that any computers is connected to an electrical circuit separate from that of the compressor 15 4 RECOMMENDATIONS a The air drawn into the compressor must be completely free from toxic tumes and inflammable vapours from solvents paints etc which would cause fire or explosions and pollute the working area b The usage of the compressor without a proper air reservoir will jeopardise its functionality Overloading the electrical control system may cause too many starts per hour lead to motor damage and shorten the life of the unit c Never dismantle or modify guards and isolating materials fitted to the compressor d Never tamper with the pressure regulator and or pressure switch or set working pressure higher than that the one set for the compressor model and for the reservoir Maximum available pressure must always be below the blow off pressure level for the safety valve fitted to reservoirs built to current safety standards 13 16 INSTALLATION DIAGRAM THREE PHASES ELECTRICAL SUPPLY 3 ke THREE PHASES ELECTRICAL SUPPLY MONO PHASE ELECTRICAL SUPPLY DESCRIPTION L COMPRESSOR E TANK AR AIR DRYER FLEXIBLE HOSE OIL WATER SEPARATOR CENTRIFUGA
11. positioned before the drainer pos 10 c unscrew the filter container pos 9 clean the filter carefully pos 8 and remount 24 28 TROUBLESHOOTING NOTE a operations must be carried out exclusively by suitably trained technical personnel or by a service centre b before attempting any operation take all the due safety precautions as stated in the MAINTENANCE chapter Problem Possible cause and repair check fuses and voltage No power supply check that the protection devices of the THE COMPRESSOR FAILS voltage supply safety switch fault current TO START protection or fuses are suitable to be used as protection of the freguency converter Contact the sales advisor Find out the possible cause of overheating Compressor stopped due to oil mixing valve or sensor faulty overheating recirculation of hot cooling air cooling air volume insufficient ambient temperature too high cooler clogged wrong oil type or oil level too low oil separator clogged oil filter blocked check the main switch Electrical fault check the motor wiring and the frequency wiring converter as well as the tightness of the cable connectors check that the maximum pressure is not Over loaded motor exceeding check the inlet temperature and flow of the cooling air check the oil level check the pressure drop of the separator check that the shut off valve between Compressor stopped due to compressor and
12. to clean the cooler Cf Technical specifications N Please note that in case of an air cooled compressor almost the whole compressor input power is transferred to the cooling air as heat The compressor should not be installed in location with concrete silica or other dust in the atmosphere without special intake pre filtering IN CASE OF DOUBTS PLEASE CONTACT COMPAIR AUTHORIZED DISTRIBUTOR Outside installation is not allowed A oc DEF 6 15 2 INITIAL CHECKS After removing the compressor from its packaging before proceeding with installation please verify that no damages occurred during transportation Packaging materials such as wood nails and plastic sheet could be dangerous for children and should not be left within their reach a Check that all the fuses in the electrical board are properly fitted and tightened b Check that the protection main nuts are tightened and the screw fixed 15 3 ELECTRICAL CONNECTIONS The electric connections must be made according to the EC standards All local safety regulations must also be observed Make sure that the operating voltage is correct The voltage must be as rated 5 Check that each phase has an equal voltage The customer must provide supply cable short circuit protection The fuse type refers to the electric diagrams and technical data If the compressor is eguipped with an integrated dryer a separate 230V supply must be connected to the el
13. 222022 COMPRESSORE COMPRESSOR an Vista lamiera A CompAir TIPO TYPE Wye Delta AirBASIC2 PARA VIO SE SEN e IMPIANTO V NNI DISEGND N FOGLIO N 1 TENSIONE VOLTAGE 400V 50 60Hz w mm n POTENZA POWER 4 0 5 5 kW re fe KA0405AeB400 1276 L 1 1 eG 3 4 5 6 7 8 9 10 Hl je 1 15 1 INGRESSO LINEA 400V 5 50 60Hz INPUT LINE ENTREE LIGNE EINGABE LEITUNG ENTRADA LINEA L1 L2 L3 400V 50 60Hz L max 10m UA CompAir Drucklufttechnik GmbH SUGGESTED K4 SETTINGS ow A _40 55 _55 70 MOTORE COMPRESSORE COMPRESSOR MOTOR MOTEUR COMPRESSEUR KOMPRESSOR MOTOR MOTOR COMPRESOR COMPRESSORE COMPRESSOR TIPO TYPE Wye Delta AirBASIC2 TENSIONE VOLTAGE 400V 50 60Hz POTENZA POWER 4 0 5 5 kW IMPIANTO W1V1U1 V2U2W2 R1 S1 1 400V L3 L2 L1 oh TR1 80VA 24v 12V 4 13 K3 45 NA 23 FS 24 27 F6 50VA 30VA E 4 3 8 S01 3 4 3 4 1 4 1 21 4 1 5s ba5 025 Schema elettrico ume Electrical wiring diagram Lo ea m 2 Ka0a0sa2Ba00 3 6 31 1 SONDA aan me NR RELE RELE RELE ELETTROVALV RELE TEMP PRESS TANDEM RELE TERMICO SEQUENZA FASI ARRESTO LINEA STELLA TRIANGOLO SCARICO ALLARME TEMP PRESS CONNECTION OVERLOAD PHASES EXTERNAL DESCH
14. ARGE ALARM SENSOR BEER TANDEM CONTACT ur da START STOP CONTACTOR CONTACTOR CONTACTOR SOLENOID VALV RELAY SONDE CONNEXION CONTACT NEN DEMAR ARRET CONTACTEUR CONTACTEUR CONTACTEUR ELECTROVALV RELAIS TEMP PRESS TANDEM SURCHARGE PHASE EXTERNE OILE TRIANGLE DECHARGE ALARME SONDE SHALTUNG KONTAKT UMSCHALT SN ECK RELAY TEMP DRUCK TANDEM UBERLASTET RELAIS STERNE FERNSCHALTER FERNSCHALTER FERNSCHALTER ELEKTROVENTIL WARNUNG SENSOR BORNERA CONTACT RELE ARRANOUE CONTACTOR CONTACTOR CONTACTOR ELECTROVALV RELAY TEMP PRES TANDEM SOBRECARGA PASE EXTERNO LINEA ESTRELLA TRIANGULO DE DESCARGA ALARMAR 24 3 16 Ja E 21 21 84 X1 18 L 83 X1 17 Le 82 X1 16 Le Function available from 0 10 firmware version of controller e Eer Ps Ps 3 16 COMPRESSORE COMPRESSOR PRS WEE TA TIPO TYPE Wye Delta AirBASIC2 ca VOLTAGE 400V 50 60Hz SE EE de 7 ne m je 15 POTENZA POWER 4 0 5 5 kW KA0405A2B400 4 6 START STOP ELETTROVALV am p RE SCARICO ALLARME DESCHARGE ALARM VALVE DEMAR 4 ARRET ELECTROVALV CONNEXION RELAIS EXTERNE DECHARGE TANDEM ALARME ANLASSEN u EH LI EXTERNE ELEKTROVENTIL ARRANQUE ELECTROVALV BORNERA RELAY ed DE DESCARGA TANDEM ALARMAR 64 24 21 52 24 61 21 58 57 82 83 84 ERES 9 A6 X119 13 14 15 16 17 18 SA X
15. DIN 34 A CompAir Drucklufttechnik GmbH ell no Materia Part Document Descripfion Aufstellplan General Arrangement Description ED ER II Hl fend ZE EE Format Sheet Sheets ZU 2103 A3 1 1 AutoCAD 620 e 530 o o LA 1 2 GAS LOMPRESSOR AIR DRYER C 3 1 025 410 680 LOMPRESSOR LO4 kW L05 kW 5 5 5 v O N lt n C E AM Nr Tolerierung DIN 7167 Rauhtiefe Rz Ma stab 1 10 Gewicht Allgemeintoleranzen Reihe 2 DIN 3141 Rohteil Nr Auftr Nr ISO 2768 mH Modell Nr Werkstoff Datum Name Benennung 21 09 07 MBellegotti Aufstellplan General Arrangement Description LOL L05 AirStation 500lT Klass Nr UA Spr Codestelle Schufzvermerk nach DIN 34 beachten Al Format Blatt Blatter SK J L Material Nr A CompAir 2012192 A2 1 4 Drucklufttechnik GmbH Copyright reserved AutoCAD Unterlage MOTOR PROTECTIVE CIRCUIT BREAKER __FLUSH MOUNTED IP55 ENCLOSURE END FREE SHUNT TRIP RELEASE LINKING CABLE CABLE MARKING 111213 MOTOR P C BREAKER PRESSURE SWITCH sect 4X2 5mm2 5 LENGTH 1200mm L1 TYPE FROR 450 750V SUPPLY CABLE e sect 4x2 5 mm2 length 3500 mm TYPE FG7OR 0 6 1kV END
16. L SEPARATOR AUT COND DISCHARGE CERAMIC FILTER COALESCING FILTER 0 1m 10 COALESCING FILTER 0 01m 4 11 ACTIVE CARBON FILTER 12 DIFFERENTIAL MANOMETER NOTE MIN DISTANCE TO REAR WALL 1000 MM gt AIR EXIT J Oo 74 O O Q I L 750 e 14 17 FIRST START UP OPERATION Recommendations a Before starting the compressor for the first time make sure that the flexible hoses are in good condition and efficient and do not show any signs of abrasion or cracks the electrical power phases are connected properly A phase reversal protection does not allow the compressor to start and prevents damages to the air end The compressor must not be operated on with the door open all protections are in place and fixed properly all the electrical wiring is in good conditions and that the earth is properly connected there are no oil or air leaks b Before opening the valve and letting the air into the connecting hose make sure that its end is fixed This is to prevent whip lashing of the hose that could cause injuries c Attheendof each working session switch the power off using the off button on the controller d The air generated contains oil vapour and cannot be breathed therefore the compressor should be placed in a separate room 18 FIRST START NOT VALID FOR VERSION WITH AIRBASIC 2 CONTROLLER For starting the compressor push ON 1 button BLACK color positioned on the frontal pan
17. M CompAir User Manual Screw Air Compressor L02 103 L04 L05 Translation of the original instructions Version 03 June 2011 TABLE OF CONTENTS IDENTIFICATION DATA En en EE 1 T GRAPHICS AND WARNING SYMBOLS uuu ee 4 2 GENERAL INFORMATION 2 5 3 CORRECT COMPRESSOR OPERATING 5 4 IMPROPER USE OF COMPRESSOR u uu ce oEEES EE 6 X ig cha lzc 6 S TEGHNIGAL CHARACTERISTICS au 7 7 ELECTRIC MOTORS TECHNICAL FEATURES eiae RR ha p le aa cuv vu ccv cae eue vds 8 8 LIETING TRASPORTATION ee 8 9 DIMENSIONS en NK 9 10 OPERATION PHINUIPLEBES ee 10 IT GOMPRESSOR DIAGRAM Bree neet 10 12 REGULATION SYSTEM ONLY FOR ELECTRONIC CONTROLLER 11 13 WORKING PRESSURE SETTING uuu lu ee 11 TA AIR CONNECTION m EE 12 15 INSTALLATION HE 12 13 IO INSTALLATION DIAGRAM WE 14 T FIRST START UP OPERATIONS 15 18 FIRST START UP NO FOR VERSION WITH ELECTRONIC CONTROLLER 15 19 START UP AFTER LONG STORAGE PERIODS eene nennen nnn nnn nnn nnn nnn nnn 16 20 STARTING AT LOW TEMPERATURES erate vance tes tec 16 2 SHUT DOWN DUE TO POWER FAILURE nee uu Ts an
18. WITH 4 LINKING BAR T END FREE FORK TERMINAL n 2 FASTON 6 3X0 8 FORK TERMINAL TIPO 2 EXTERNAL JACKET UNWRAPPED FOR 20mm EXTERNAL JACKET UNWRAPPED FOR 50mm O N FORK TERMINAL lt EARTH CABLE YELLOW GREEN THERMOSTAT CABLE Fons fmm EE YPE 1 sect 2 x 1 5 mm2 END FREE N 9 3 9mm B 5 5mm d 3 2mm LENGTH 300 mm HOLE 5 ve TO REN TYPE FROR 450 150V mm mm mm SECOND END CONNECTED IN THE FOLLING MODE BLUE wired at motor p c breaker END SIDE PRESSURE SWITCH BROWN wired in series at shunt trip 4 FORK TERMINAL END SIDE MOTOR release FIRST END FORK TERMINAL TYPE 2 4 RING TERMINAL HOLE 85mm N 2 RING TERMINAL 5mm EXTERNAL JACKET UNWRAPPED FOR 50mm EXTERNAL JACKET UNWRAPPED FOR 100mm EXTERNAL JACKET UNWRAPPED FOR 40mm CABLE MARKING 1 T2 T3 CABLE MARKING W1 V1 U1 SECOND END WITH 2 FORK TERMINAL HOUR METER CABLE SUPPLIED SEPARATELY FORK TERMINAL TYPE 1 sect 2x1 5 mm2 EXTERNAL JACKET UNWRAPPED FOR 30mm LENGTH 800 mm TYPE FROR 450 750V LINKING CABLE PRESSURE SWITCH MOTOR SEPARATELY sect 4x2 5mm2 LENGTH 800mm TYPE FROR 450 750V SIA Datum Aend Zustand AM Nr Ma stab 1 5 Gewicht Tolerierung DIN 7167 Rauhtiefe Rz Allgemeintoleranzen Reihe 2 DIN 3141 Rohteil Nr Auftr Nr ISO 2768 mH Modell Nr Werkstoff Datum Name 23 07 07 M Malnafi 23 01 07 F Guarnaccia Benennung Kabelbaum Wiring diag
19. by service personnel authorized by CompAir e Always fill in the log DRM KI ES EJ EJEJKI KAKI Check fault indicator lights and alarms only for AIRBASIC controller Discharge air tank drain Eni strainer Chekollwl ll Change o1 see Oirecommendatons _ Replace oil fiter ll Replace separator carage _ Replace are _ eaneoderetmay I Oneckoperatonotpressurereleivae LL Repicosealkisotmetvave Il ohella x Eu Olean inside compressor oeann Fepcesasedkt f Clean air tter rr T T T ll Check ana reighton main motorcables _ V BELTS Replace the belts and check drive pulleys B replace if worn out 1 Daily 5 Once a year 2 Weekly Every 50 h 6 Every 6 000 h 6 years MAX 3 Every 500 h 7 Every 9 000 h 6 years MAX 4 Every 1 500 h 8 Every 4 500 h 4 years MAX Stop the compressor before checking the oil level Wait until the oil is separated from the air about 10 min SERVICE KIT TIMINGS 1 500 hours 6 000 hours 6 000 hours 9 000 hours KIT NUMBERS KIT DESCRIPTION CC1045817 HOSES SERVICE KIT CC1046311 SEAL AIR END SCA7L 20 25 OIL RECOMMENDIATION FOR COMPAIR SCREW INDUSTRIAL COMPRESSORS 25 1 Recommended lubricant CompAir compressors have been tested and authorized to be used only with CompAir 4000 lubricants These lubricants are formulated according to the highest quality standards and are factory authorized tested and approve
20. compressed air system is too high pressure open aftercooler is frozen pressure sensor faulty line filters clogged Doesn t start although the wait network pressure exceeds the Start button has been adjusted pressure pressed Air filter clogged replace the air filter LOW AIR DELIVERY Oil separator clogged replace the oil separator Intake valve faulty 25 x Problem x Possible cause and repair x Discharge valve or clean or replace LOW AIR DELIVERY condensate drainage is fault x Leaks in the compressed check and repair the leaks air system Broken coupling Pressure limits incorrectly set correctly set Ambient temperature too make cooling air circulation sufficient ensure that the intake air is from the coolest possible place prevent the flow of cold cooling air to the compressor Pressure relief valve open close the valve Clogged cooler clean the cooler COMPRESSOR Ambient temperature too check cooling air circulation OVERHEATS high Intake valve faulty Oil level too low Wrong oil type Oil filter clogged replace the oil filter Faulty discharge replace temperature transducer Cooling air canalization too check the dimensioning and pressure drop small or pressure drop too of the canalization and repair high OIL CONSUMPTION TOO HIGH Discharge temperature too find out and eliminate the cause high Shaft seal leaking replace the shaft seal Oil level too
21. d for use in rotary screw compressors The lubricants are available from your authorized CompAir compressor distributor 25 2 General guidelines for oil change intervals If final compression temperatures of more than 90 C occur continually the oil change intervals given in section 24 maintenance schedule are halved The oil change intervals should be calculated more accurately in accordance with the actual operating conditions by analyzing the oil A Specific CompAir lubricants are recommended for use in this equipment Other lubricants may cause shorter life span of oil filters oil separators and oil varnishing and blockage of oil circuit higher oil consumption excessive carryover and compressor damage Do not mix different types of oil Please Note If a wrong oil type has been used or the oil circuit is varnished contact CompAir specialists for oil circuit cleaning instructions 21 OIL TANK CAPACITY Kg 2 22 1 OIL FILLING PLUG 2 GASKET 3 OIL LEVEL GAUGE 4 WATER DRAIN OIL DISCHARGING TAP 26 BELT TENSIONING L 02 03 04 05 AN The belts tension is guaranteed by the horizontal sliding of the air end pulley bracket fig 1 n 3 after having loosened the screws fig 1 n 4 The correct tensioning is operated by adjusting the position of this bracket with the regulation screw fig 1 n 1 In order to check the correct belt tension value apply a F Force 30 N with a dynamometer positioned in
22. el The compressor is automatically regulated by a pressure switch that cuts off the power to the motor when air pressure in the tank reaches MAXIMUM and starts it up again when the pressure drops to MINIMUM For switch off the compressor push OFF 0 button RED color positioned on the frontal panel The pressure range is fixed to MIN 8 bar MAX 10bar NOTE The compressor should work at least 3 minutes before switching it off Shorter working periods can damage the compressor in long term and are not recommended 19 START UP AFTER LONG STORAGE PERIODS IF THE COMPRESSOR REMAIN SWITCHED OFF FOR MORE THEN TWO MONTHS PLEASE PROCEED AS FOLLOWS a reach the intake valve A by detaching cover B and removing the air intake filter cartridge C put in 100 cc of proper oil run compressor for ten seconds repeat stage b an other time replace the parts and start unit 20 STARTING AT LOW TEMPERATURES Warning if the room temperature may fall below 0 C it is essential to protect all pipe hosework and condensate drains with suitable insulation This will prevent blockage due to ice which can cause dangerous damages to the air reservoir If the room temperature remains constant around 0 it is recommended to use a synthetic oil as the one indicated on the table Recommended procedure for start up with cold temperature below 0 Start the motor up for 5 seconds then switch off before the pressure rises R
23. epeat phase a c Temporarily start the compressor checking that the pressure rises to a value close to the maximum working pressure for example 9BAR for 10 BAR working pressure models d Switch off the compressor immediately when pressure at phase c is reached e Repeatphasesc d Finally start the compressor making sure that the pressure is not exceeded due to the formation of ice in the hoses and or icing up of the retaining valve h A 21 SHUT DOWN DUE TO POWER FAILURE a Turn off the power from the main switch and make sure that the compressor cannot be accidentally started b The blow down function empties the receveir after stopping wait 2 minutes c Turnthe power on from the main switch end start up the compressor VERSIONS WITH OVERLOAD CUT OUT If a cut out occurs the compressor will stop Once the power is back again the compressor will resume operation automatically with no delay N B For safety reasons it is absolutely recommended to affix a sign near the machine to alert people that the compressor may come back into operation automatically and without prior notice It is also mandatory to check that the automatic re start of the compressor will not pose any hazards whatsoever ONLY FOR VERSIONS WITH AIRBASIC 2 CONTROLLER In the event of transient power failure the compressor will shut down and re start in automatic after 10 sec the set time to unload the oil separation tank to guarantee a correct res
24. high lower the oil level INTAKE VALVE LEAKS OIL Intake valve seal is leaking replace the intake valve seal AFTER EMERGENCY STOP COMPRESSOR STOPS Volume of compressed air observe the min pipe size correct TOO OFTEN system too small Blockage in network search the blockage repair Please Note See also the error messages listed in the controller user s manual for specific version 26 29 DISPOSAL IMPORTANT INFORMATION More than 90 of the components of this compressor are manufactured with recyclable material In the event that compressor is withdrawn from service and destined to be dismantled the following materials must be disposed of as follows lubricating oil to be collected and taken to authorized re cycling centers rubber hosing electrical cable and plastic parts to be collected separately from to the other materials filters to be disposed as special refuse metal components motor air end frame etc recycle in authorized centers KEEP THIS HANDBOOK SAFE FOR FUTURE REFERENCE THIS MANUAL IS SUBJECT TO REVISION AND MODIFICATION 27 3 O LINE 50 120 Lom lu 160 350 670 1 2 GAS N 4 M8 50 d d 5 m 50 Mm 5 10 50 2 LINE L02 L03 L04 0 1 m3 sec 10 1 2 GAS L05 0 2 m3 sec 20Pa COMPRESSOR WEIGHT KG 102 103 100 104 105 105 2052 E J 4 ay
25. imbol N 4 IMPROPER USE OF COMPRESSOR The manufacturer shall waive all responsibility in case of Incorrect use by untrained or negligent personnel Use in violation of current laws Incorrect installation Installation without suitable reservoir Installation in dust filled environments i e cement silica etc Incorrect electrical connection Serious lack of proper maintenance Use of non original spares for the model Total or partial failure to observe the instructions Damage due to natural or exceptional events Tampering with the safety valve Exceeding maximum pressure rating through tampering Operation of compressor without panels and guards 5 SAFETY MEASURES 3 zum Tae tO An TD Read carefully to avoid potential risks DANGER MEASURES Handing EE Base designed for use with forklift and transpallet forklift Electrical Connection Built in full load AC23 filled circuit breaker Electrical Board Bolted on with door interlock switch Built in yellow red warning light Built in line fuses Motor Magneto thermal cut out Electrostatic Discharge De oiling filter with electrical continuity Compressor Overheat 110 C thermostat with cut
26. ion of the compressor The set up of the pressure switch is done by CompAir If itis necessary to modify the pressure switch setting contact CompAir authorized distributor Its prohibited setting the pressure switch at pressure over 10 bar ONLY FOR VERSIONS WITH AIRBASIC 2 CONTROLLER The controller controls the load unload operation of the compressor measuring the pressure at output and comparing it with Pmax and Pmin value set The set up of the compressor is done by CompAir If itis necessary to modify the set value of Pmin and Pmax contact CompAir authorized distributor Its prohibited setting the pressure switch at pressure over 10 bar 14 AIR CONNECTION IMPORTANT CONNECTION PIPING Use a flexible hose to connect the compressor to the network not included in the delivery 15 INSTALLATION 15 1 INSTALLING LOCATION a compressor must be installed on an even surface bearing mind the compressor s weight Cf Technical specifications A The water drain contains traces ofoil b Study the dimensional drawing for the required minimum distances to walls and other machines c Make sure that the compressor room is properly ventilated The cooling air temperature must be lower than 45 or higher than 0 Prevent recirculation of cooling air If the compressor is provided with air ducts observe the reguired air volume and the max pressure loss of the ducting Observe also the possibility
27. ndling and lifting personnel Installation personnel A Electrical installation technicians Operation and surveillance personnel Maintenance staff Specialised service and repair technicians This instruction manual should be considered as part of the compressor itself It should be kept as a reference for the entire life of the unit until its disposal or handed over in the event of sale The manual is usually supplied inside a plastic envelope attached to the outside of the compressor it should always be kept properly and be available for consultation near the unit itself If lost or damaged a new copy may be obtained from the manufacturer specifying the details on the compressor information plate The manual exclusively concerns the compressor itself and does not concern any other components or accessories in an installation for which reference must be made to the appropriate manuals The manual is based on the state of the technology at the moment of sale of the compressor The manufacturer retains the right to review it following new developments at any time without any duty to update previous manuals Any suggestions for improvements or modifications to the manual may be made directly to manufacturer The identification data for the compressor is shown on the first page of this manual and is identical to those shown on the COMPRESSOR IDENTIFICATION PLATE as in compliance with EEC directive on the issue Other data c
28. oncerning noise level and weight is shown in the technical specifications table TECHNICAL CHARACTERISTICS In this manual the model of the compressor is identified by its code and by the motor power expressed in kW as indicated in the page TECHNICAL CHARACTERISTICS 3 CORRECT COMPRESSOR OPERATING CONDITIONS The compressor described in this manual is only suitable for the compression of air at the atmospheric pressure and may deliver air up to the maximum pressure stated on the identification plate MAX PRESS bar The compressor is a industrial type to be used in accordance with the technical specifications of the compressor itself The compressor works automatically and no specific operator is required The unit must however be supervised in use and must have a routine maintenance by an expert technician who should be familiar with all the aspects of its operation and safety outlined in this manual The compressor is designed exclusively for operation connected to an approved air reservoir of suitable capacity at least 200 It and having pressure rating of at least 1096 higher than the unit itself The air delivered from the compressor is not sufficiently treaded for human use It may never be used as breathing air The compressor is designed only to be operated complete with closed enclosure for the purposes of cooling protection and sound proofing NOTE The instruction concerning safety are marked with this s
29. out Insufficient Lubrication 110 C thermostat for adiabatic compression Starting Under Load 10 sec delay from energizing Overpressure Approved safety valve Back Pressure Non return valve Residual Pressure Descharge tap and internal air gauge Phase Reversal wrong direction of rotation Indicator arrow or R S F electronic relay Temperature Max Environment gt 45 C 110 C thermostat Min Environment lt 2 C See starting recommendations Pressure PANS EE Built to EEC 87 404 standards Flexible Hoses High pressure hose used 4 6 times working pressure Seier Parts reaching 70 marked with warnings NOTE only for version with AIRBASIC 2 controller 6 TECHNICAL CHARACTERISTICS GAS COMPRESSED TYPE AIR GAS COMPRESSED IL WE AR INLET PRESSURE INSTALLATION ROOM ROOM TEMPERATURE MAX MIN WORKING TEMPERATURE k I AIR OUTLET TEMPERATURE 140 50 ROOM TEMP PPM C C C RESIDUAL OIL CONTENT 2 MAX ROOM HUMIDITY 9 89 O MAX ALTITUDE m J A 100 9 4J9 MAX STARTING Hour N 6 ELECTRICAL SUPPLY Volt Hz SEE DATA PLATE RATING HOURS 24 24
30. ramm Description Netztrennschalter Circuit Breaker L02 03 04 05 Copyright reserved SALVAMOTORE BOBINA SGANCIO CUSTODIA 400V INCASSO Material Nr Format ZEE A CompAir 2012147 A3 5 2 Codestelle Klass Nr UA Spr Schutzvermerk nach DIN 34 beachten Blatt Blatter E 10 60 5 5 55kw Gees v cos ms _ Drucklufttechnik GmbH Entstanden aus Ersetzt durch AutoCAD Unterlage c 8 4 6 BOBINA DI SGANCIO SHUNT TRIP RELEASE 400V TERMOSTATO THERMOSTAT a CONTAORE HOURMETER 400V 2 2 4x2 5 A 3 0 4x2 5 4 0 4x2 5 949 4x2 5 PRESSOSTATO OV PRESSURE SWITCH PRESSOSTAT DRUCKWACHTER HH PRESOSTATO B T5 T2 T1 O 70 h U1 V1 Wi kW mmq h 2 2 4x2 5 3 0 4x2 5 ALLA PORTINA 4 0 4 2 5 TO DOOR 5 5 4x2 5 U1 V1 WI ES E bcm 400V 50 60H ye N M N L max 10m NOTA NOTE kW mmg 2 227 L SEZIONATORE ED IL I DISPOSITIVO I DI
31. tart WARNING Take extra care when in this situation in order to avoid any damage to persons or property caused by the drop in air pressure in the distribution installation 22 ELECTRONIC CONTROLLER FOR SPECIFIC VERSION All compressor settings are made by using the electronic controller AIRBASIC 2 For detailed instructions for the controller please refer to the AIRBASIC 2 Controller User s Manual Controller regulates the output of the compressor The following variables have been set in to the controller target unload and load pressures service intervals programmable I O operational parameters alarm and shutdown limits x10 x100 i e ES PRG m ac ep SA 23 MAINTENANCE Only authorized CompAir personnel is to carry out maintenance operations that are not included in this manual N Always wear protective clothes and gloves during the maintenance 23 1 BEFORE MAINTENANCE N Caution Hot surfaces inside the compressor cabinet immediately after stopping a Stop the compressor b Turn the power off from the main switch and make sure that the compressor cannot be accidentally started Theblow down function empties the receiver after stopping wait 20 seconds 23 2 AFTER MAINTENANCE a the power on from the main switch b Startup the compressor 24 MAINTENANCE PROGRAM N e Maintenance and service operations other than those described in item n 4 8 must carried out
32. the middle of the belts see fig 2 if the tension is correct the measure of the camber is f 5 1 mm If f gt 7 mm the tension is too low and the regulation screws must be screwed then the measure of f should be done again to verify if the correct value is reached If f lt 3mm the tension is too high and the regulation screws must be unscrewed then the measure of f should be done again to verify if the correct value is reached NOTE 1 Once the belt has been replaced and the belt tensioned following the procedures just described the compressor should run for 20 30 min Check the tension by measuring the f value should this not be within the standard range tension the belt should be tensioned again NOTE 2 Check the perfect alignment of the pulleys and if necessary correct it to set the misalignment to 2 mm for XPA belts 1 mm for poly V belts fig 1 1 TENSIONING SCREW 2 BLOCKING NUT SLIDING PLATE 4 SLIDING PLATE SCREW 5 AIR END PULLEY 6 MOTOR PULLEY 7 AIR END SUPPORT 8 ELECTRIC MOTOR 9 AIR END 10 BELT TOOL FOR ALIGNMENT CONTROL 23 27 MAINTENANCE OF THE AUTOMATIC CONDENSATION DRAIN OPTIONAL CLOSED Clean after the first 10 working hrs and then every 500 hrs Clean the tap filter pos 8 following the instructions given below a disconnect power and disconnect the connection at pos 2 b close the tap

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