User Manual

V-Compact Series
Stationary Air Compressors
Serial numbers from:V100 V150 VL200 VL300 VL200D/V100D VL400D/V300D EO40/0001 EO41/0001 EO42/0001 EO43/0001 EO44/0001 EO55/0001 VL300D/V150D V200 V300 VL400 V200D EO45/0001 EO50/0001 EO51/0001 EO52/0001 EO54/0001

GB

BR1815BA - 08/2004

FOREWORD
These compressors are intended 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, commission 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 Distributors, backed up by the AfterMarket division at Redditch. If replacement parts are needed, the user should contact the local Distributor in the first instance. The information given in this manual was correct at the time of printing but 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 Distributor who is supplied with revised and up-dated information. In any communication concerning the compressor it is essential to quote the MODEL and SERIAL NUMBER. Throughout this manual all pressures quoted are gauge pressure unless otherwise specified.

V100-VL400 User Manual

BR1815BA - 08/2004

V100, V150, V200, V300, VL200, VL300 & VL400 AIR COMPRESSORS Serial Numbers from: V100 V150 VL200 VL300 VL200D/V100D VL400D/V300D EO40/0001 EO41/0001 EO42/0001 EO43/0001 EO44/0001 EO55/0001 VL300D/V150D V200 V300 VL400 V200D EO45/0001 EO50/0001 EO51/0001 EO52/0001 EO54/0001

CONTENTS

Section 1. Safety Procedures 2. General Description 3. Leading Particulars 4. Installation 5. Operation 6. Maintenance 7. Fault Finding Appendix 1 The Pressure Systems Safety Regulations 2000

Page 5 11 15 19 25 29 37 43

Illustration Typical Installation/General Arrangement Pressure System Diagram - 1 st Stage Pressure System Diagram - 2nd Stage

Page 21 44 45

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OWNERSHIP DATA
TECHNICAL DATA Model: Serial Number: Year: Maximum Pressure: kW: Motor rpm: V. Ph. Hz. M /min:
3

Motor Serial Number: Delivery Date:

Compressor Lubricant: Lubricant Capacity: Motor Bearing Grease: (If applicable)

LOCAL COMPAIR DISTRIBUTOR Name: Address:

Telephone: Contact Names: Parts: Service:

Fax:

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V100-VL400 User Manual

ASSOCIATED PUBLICATIONS

Title Automatic Air Governor: Regulating Panel Mk.5: Repair Manual: Parts Lists:

Part No. C20160-014 C20160-040 AC20160-1157 C20160-1143 C20160-1467 C20160-1468 C20160-1469 C20160-1470 C20160-1471 C20160-1472 C20160-1374 C20160-1375 C20160-1376 C20160-1377 C20160-1378 C20160-1379 C20160-1380 C20160-1381 V100A to V300A V100W to V300W VL200A VL300A VL400A VL200DA VL300DA VL400DA V100DA V150DA V200DA V300DA V100DW V150DW V200DW V300DW

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WARRANTY The conditions of the CompAir Warranty are set out in the company's standard Conditions of Sale available from the Distributor supplying the machine. MAINTENANCE To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenance and servicing are carried out in accordance with the information given in the 'Maintenance' section of this manual. If any replacement or repair is needed use only CompAir Genuine Parts.

WARNING
The use of replacement parts or lubricating oils not supplied or approved by CompAir may lead to failures in service which would not be covered by warranty. Any unauthorised modifications or failure to maintain this equipment in accordance with the maintenance instructions may make it unsafe. The use of replacement parts not supplied or approved by CompAir may create hazardous conditions over which CompAir has no control. Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury or result in damage to the equipment. CompAir can bear no responsibility for equipment in which unapproved replacement parts are included.

USE ONLY

GENUINE PARTS AUTHORISED SERVICE AGENTS

USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED OUT USING NON-GENUINE PARTS.

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V100-VL400 User Manual

1
SAFETY PROCEDURES
Page General Warnings, Cautions and Notes General Safety Precautions Installation Precautions Operational Precautions Maintenance and Repair Precautions Precautions in the Event of Fire 6 6 7 7 7 8 9

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SAFETY PROCEDURES
1. GENERAL 2. WARNINGS, CAUTIONS AND NOTES

Most accidents which occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. An accident can often be avoided by recognising a situation that is potentially hazardous. When handling, operating or carrying out maintenance on the unit, personnel must use safe engineering practices and observe all relevant local health and safety requirements and regulations. The attention of users in the UK is drawn to the Health and Safety at Work Act, 1974, and to the Regulations of the Institution of Electrical Engineers. CompAir cannot anticipate every possible circumstance which might represent a potential hazard. The WARNINGS in this manual are therefore not all-inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by CompAir he must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property. Failure to observe the precautions given under 'Safety Procedures' may be considered dangerous practice or misuse of the compressor unit.

2.1 Warnings Warnings call attention to operations or procedures involving specific hazards which could cause injury or death and are identified by the following symbols on the unit and in the text of the manual.

WARNING: RISK OF DANGER

WARNING: RISK OF ELECTRIC SHOCK

WARNING: RISK OF HIGH PRESSURE

WARNING: CONSULT MANUAL

2.2 Cautions Incorrect operational procedures causing possible damage to the compressor unit are identified by a 'CAUTION' in the text of this manual.

2.3 Notes Methods to make the job easier and points which require particular attention are identified by a 'Note' in the text of the manual.

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V100-VL400 User Manual Safety Procedures

3.

GENERAL SAFETY PRECAUTIONS

If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing and eye protection is worn. Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing. Before releasing compressed air through a hose make sure that the free end is held securely so that it cannot whip and cause injury. Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct capacity . They must be tested and approved according to local safety regulations. Cables, chains or ropes must never be applied directly to lifting eyes. Always use an appropriate shackle or hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles. When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary. 4. INSTALLATION PRECAUTIONS

Ensure that the air delivery pipe from the compressor to the user's pipework aftercooler, or receiver is free to expand and that no flammable material is within the vicinity. A shut-off valve must be fitted in the delivery air line to enable the compressor unit to be isolated. This is particularly important if more than one unit is to be coupled in parallel or connected to an existing air supply system. Non-return valves must not be relied upon for isolating parts of the pressure system. In addition, it may be necessary to install shut-off valves elsewhere in the system to allow a dryer or other equipment to be bypassed. A safety relief valve must be installed between any compressor unit and the shut-off valve/s. A safety relief valve is fitted on the reclaimer vessel as standard equipment. A pressure relieving device must be fitted to every pressure vessel, or equipment containing air at above atmospheric pressure, when installed downstream of the unit. In order to control the risk of Legionnaires Disease, CompAir strongly advise against the use of water cooling tower systems for water cooled compressors. A closed circuit radiator system is preferred (see Bulletin CBB 2083). 5. OPERATIONAL PRECAUTIONS

Installation work must only be carried out by competent personnel under a qualified supervisor. A fused isolating switch must be fitted between the main power supply and the compressor. Ensure that air drawn into the air intake will not be contaminated with flammable fumes or vapours, since this could cause an internal fire or explosion. Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into the air intake.

The compressor unit must only be operated by competent personnel under a qualified supervisor. Do not run the compressor with covers removed. Never remove or tamper with the safety devices, guards or insulation materials fitted to the unit. The compressor must only be operated at the supply voltage and/or frequency for which it is designed. When mains power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the electrical system. Do not open the starter compartment or touch

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electrical components while voltage is applied unless it is necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the proper tools and wearing appropriate body protection against electrical hazards. On a unit equipped with an Automatic Start/Stop system, attach a sign stating 'THIS UNIT MAY START WITHOUT WARNING' next to the display panel. On a unit equipped with an Automatic Restart device, attach a warning notice stating 'THIS UNIT HAS BEEN MODIFIED AND WILL START AUTOMATICALLY ON APPLICATION OF POWER' next to the display panel and on the inside of the unit next to the starter contactors. If the unit is equipped with a Remote Control device, attach warning notices stating 'THIS UNIT CAN BE STARTED REMOTELY' in prominent locations, one on the outside of the unit, the other inside the control compartment. As a further safeguard, take adequate precautions to make sure there is no one checking or working on the unit before attempting to switch on remotely controlled equipment. Attach a 'CHECK THAT ALL PERSONNEL ARE CLEAR OF THE UNIT BEFORE STARTING' or similar warning notice to the remote start equipment. Parts of the compressor, auxiliary equipment and pipework with a working temperature in excess of 80C must be insulated or guarded and clearly marked in accordance with the local safety code. If there is any indication that the compressor is overheating it must be shut down and the cause investigated. Beware of burns from hot metal parts, hot oil and water when working on a unit which has recently been shut down. The compressor must not be operated at pressures above the nominal pressure given on the data plate. The compressor must not be operated in ambient temperatures outside of those given under 'Leading Particulars'.

The 'Noise at Work Regulations 1989' suggest that ear protectors should be worn where noise levels are 85 dB(A) or higher. Be aware that high noise levels can interfere with communication. 6. MAINTENANCE AND REPAIR PRECAUTIONS

Maintenance, repairs or modifications must only be carried out by competent personnel under a qualified supervisor. If replacement parts are needed use only CompAir Genuine Parts. Before removing any panels from the enclosure, if fitted, or dismantling any part of the unit, carry out the following preparatory operations:1. Isolate the compressor unit from the main electrical power supply. Lock the isolator in the 'OFF' position and remove the fuses. Attach a label to the isolator switch and display panel carrying the warning 'WORK IN PROGRESS - DO NOT APPLY VOLTAGE'. Do not switch on electrical power or attempt to start the unit if a warning label is attached. Close the isolating valve between the compressor unit and the users pipework. Close the isolating valve in the cooling water inlet pipe. Attach a label to each valve carrying the warning 'WORK IN PROGRESS - DO NOT OPEN' Check that all pressurised air trapped in the system is released to atmosphere. Check that all pressure gauges on the display panel register zero. Ensure that the cooling water system has been drained on water cooled models. Check that the drain valve on the delivery manifold is clear and air pressure released. Open the manual drain cock to ensure that pressurised air trapped between the first and second stages has been released. Stand clear of the valve covers when removing the securing screws.

2.

3.

4.

5. 6. 7.

8.

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V100-VL400 User Manual Safety Procedures

Use only lubricating oils and greases approved by CompAir. Make sure that the selected lubricants comply with all relevant safety regulations, especially with regard to the risk of explosion or fire and the possibility of decomposition or the generation of hazardous gases. Always clean up oil spills from the surrounding floor and outside of the compressor unit before and after maintenance work. Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good running order . The accuracy of pressure and temperature gauges and switching thermometers must be regularly checked. They must be renewed when acceptable tolerances are exceeded. Protection devices must be tested as described in the 'Maintenance' section of this manual. Keep the compressor unit clean at all times. Protect components and exposed openings by covering with clean cloth or tape during maintenance and repair work. Protect the motor, air intake, electrical and regulation components against the entry of moisture, e.g. when steam cleaning. Precautions must be taken when carrying out welding or any repair operation which generates heat, flames or sparks. The adjacent components must always be screened with non-flammable material and if the operation is to be carried out near any part of the oil system, or close to a component which may contain oil, the system must first be thoroughly purged, preferably by steam cleaning. Never use a light source with an open flame to inspect any part of the unit. In no circumstances must any welding work or other modification be carried out on the reclaimer or any other pressure vessel. Before dismantling of any part of the compressor unit ensure that all heavy movable parts are secured.

After completion of repair or maintenance work ensure that no tools, loose items or rags are left on or inside any part of the machine. Check the direction of rotation of the motor when starting up the compressor initially and after any work on the electrical connections or switch gear. Do not use any flammable liquid to clean valves, filter elements, cooler air passages, air pipes or any component carrying a flow of air during normal operation. If chlorinated hydrocarbon nonflammable fluids are used for cleaning, safety precautions must be taken against any toxic vapours which may be released. Do not use carbon tetrachloride. Precautions must be taken when using acids, alkalis and chemical detergents for cleaning machine parts and components. These materials cause irritation and are corrosive to the skin, eyes, nose and throat. Avoid splashes and wear suitable protective clothing and goggles. Do not breathe mists. Ensure that water and soap are readily available. When disposing of condensate, old oil, used filter elements and other parts and waste material of any kind make sure that there is no pollution of any drain or natural water-course and that no burning of waste takes place which could cause pollution of the air. Protect the environment by using only approved methods of disposal. 7. PRECAUTIONS IN THE EVENT OF FIRE

Use extreme caution when handling components that have been subjected to fire or very high temperatures. Some components may contain fluoroelastomer materials which decompose under these conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage.

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2
GENERAL DESCRIPTION
Page Compressor Safety Devices Instrument Panel Lubrication System Regulation System Air Governor Control Control Panel 12 12 12 12 13 13 13

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GENERAL DESCRIPTION
1. COMPRESSOR Two suction and two delivery valves are fitted in each first stage cylinder head and one suction and one delivery valve in each second stage cylinder head. The delivery manifold is designed as a pulsation vessel to minimise valve pressure peaks in the air delivery pipe to the aftercooler or receiver . 2. SAFETY DEVICES

CompAir V-Compact reciprocating compressors are single-acting units with two or four cylinders arranged in a 90-Vee formation for complete primary balance. The standard version has two compression stages while the Low Pressure version is a single-stage machine. These compressors are available in 'oil-free' or 'lubricated' versions. Two-stage compressors are fitted with an air-cooled or water-cooled intercooler. The cylinders, crankcase and air-cooled intercoolers are cooled by air blast from a cowled fan fitted on the non-drive end of the crankshaft. The cylinders and cylinder heads are furnished with cooling fins. The normal drive method is by electric motor flangemounted to the compressor driving the crankshaft directly through a flexible coupling. Alternative drive arrangements include direct drive via a separately mounted electric motor and flexible coupling and an electric motor or diesel engine mounted with the compressor on a common base-plate and driving through multiple Vee-belts and pulleys. The crankcase is a single iron casting provided with large access doors. Two detachable bearing housings carry the crankshaft main journal white metal bearing shells. The counterbalanced crankshaft has either one or two crankpins, each crankpin carrying two forged steel connecting rods on plain steel backed aluminium/tin big-end bearings. Each 1st stage piston of the oil-free compressors carries a single two-piece pressure ring and one guide ring. The 2nd stage pistons are fitted with two pressure rings and one guide ring. All the rings are of PTFE. Each piston is driven by a rod attached to a crosshead carried on the connecting-rod small end. Ventilated distance pieces fitted between the crankcase and the cylinders incorporate the crosshead guide sleeves and gland assemblies which prevent oil from entering the cylinders. In the lubricated compressors no distance pieces are required and the pistons are attached directly to the connecting rod small ends by hardened steel gudgeon pins.

The standard compressors have a safety switch mounted on the crankcase which operates to shut down the compressor if oil pressure falls too low. Two switching thermometers protect the compressor against high 1 st stage and 2nd stage air temperature. An interstage safety valve provides protection to the 1 st stage pressure system. On low pressure versions the safety switch provides protection against low oil pressure and high air temperature. 3. INSTRUMENT PANEL

On standard machines an instrument panel mounted on the compressor carries 1 st stage and 2nd stage air pressure gauges, two switching thermometers and an oil pressure gauge. On low pressure models the panel carries a delivery air pressure gauge and an oil pressure gauge. 4. LUBRICATION SYSTEM

An externally-mounted gear type pump is belt driven from the fan end of the crankshaft. Oil is drawn into the pump through a submerged strainer in the crankcase and is circulated through the lubrication system via a full-flow oil filter. An adjustable pressure relief valve is incorporated in the pump and a dipstick is fitted in the crankcase oil filler tube.

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V100-VL400 User Manual General Description

5.

REGULATION SYSTEM

Each suction valve is fitted with an unloader which incorporates an air operated diaphragm and springloaded fork to hold the suction valves off their seats and cause the compressor to run unloaded. The unloader forks are actuated by the regulation system to provide the required control of the compressor. The unloaders may also be operated manually to enable the compressor to be started up initially in an off-load condition. The normal method of regulation is by Air Governor Control. An alternative method using an additional control panel is available which allows the compressor to be operated in either the Continuous mode or the Automatic Start/Stop mode. The panel can also control a stand-by compressor or a multiple installation. 5.1 Air Governor Control Air Governor Control provides continuous running control in which the air governor responds to air pressure in the receiver to operate the suction valve unloaders. If the pressure rises to the set point of the governor the valve unloaders are operated. The compressor continues to run, but in the unloaded condition. When the air pressure in the receiver falls to the pre-set level the unloaders are released, allowing the suction valves to close and the compressor comes on load. The air governor also operates a valve in the base of the intercooler to drain accumulated condensate and relieve interstage pressure. Refer to Publication C20160-014 for details of the Air Governor. 5.2 Control Panel The optional wall-mounted control panel incorporates a pressure switch, solenoid valve, runon timer and a solenoid timer. It operates in conjunction with a separately mounted automatic contactor type starter for the compressor. The panel carries a 'HAND/OFF/AUTO' selector switch.

Selector switch in 'HAND' position: The compressor starts and then runs continuously, responding to system air demand by unloading at the upper pressure switch setting and loading at the lower pressure switch setting. Selector switch in' AUTO' position: The compressor starts when receiver pressure is less than the low setting of the pressure switch. It then runs on load until receiver pressure reaches the upper setting of the pressure switch which then operates the solenoid valve to actuate the unloaders and also initiates the run-on timer. The compressor continues to run off-load for the time period set by the run-on timer. If receiver pressure falls during this period to the lower setting of the pressure switch, the switch opens, allowing the solenoid valve to close and the unloaders to release the suction valves. The compressor then comes on load. If receiver pressure does not fall to the lower setting of the pressure switch during the run-on period the run-on timer will cause the compressor to be shut down automatically. It will re-start automatically when receiver pressure falls sufficiently to operate the pressure switch. The unloader solenoid valve in the control panel also operates the intercooler condensate drain/ pressure relief valve. Should the compressor shut down automatically through the operation of the low oil pressure/high air temperature safety device it cannot be restarted until the fault has been rectified and the 'SET RUN/ FAULT RESET' push button on the control panel is pressed. Refer to Publication C20160-040 for details of the Control Panel.

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V100-VL400 User Manual

3
LEADING PARTICULARS

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LEADING PARTICULARS
Note: There are detail differences depending on the compressor concerned. The designations are as follows:
Basic designation: V100 V150 V200 V300 VL200 VL300 VL400 Low pressure model prefix: Oil-free model suffix: Air-cooled suffix: Water-cooled suffix: Motor rating suffix: L D A W F2 or F3 VL 200 V200D VL300DA V100W V100DW-F3

In the tables below the models are identified by the appropriate prefix or suffix.
Model: Type: Model: Intercooler: Ambient Temperature: minimum: maximum: Running speed: normal : maximum: Working pressure: minimum: Working pressure: V-F2 V 4.1 bar VL200A-F2 VL300A-F2 VL400A-F2 maximum: Motor rotation: 7 bar 3.5 bar VL200DA-F2 VL300DA-F2 VL400DA-F2 2.4 bar All Models: Clockwise, viewed from motor end. Cylinder bore: 1st stage: 2nd stage: Piston stroke: V100/V200 196.9 mm 114.3 mm 85.5 mm V150/V300 222.3 mm 133.4 mm 98.4 mm VL200/VL400 196.9 mm 85.5 mm VL300 222.3 mm 98.4 mm 8.6 bar V 2-Stage, single acting A Air-cooled V 0C 55C All Models: 1,460 rev/min 1 ,500 rev/min VL 1.4 bar V300DA-F3 only All other V-F3 models 10.3 bar VL 1-Stage, single acting W Water-cooled VL 0C 50C

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V100-VL400 User Manual Leading Particulars

V100/V150 Suction valves Delivery valves 1st stage: 2nd stage: 1st stage: 2nd stage: 2 1 2 1

V200/V300 4 2 4 2

VL200/VL300 4 4 -

VL400 8 8

V200/V300/VL400 Crankcase oil capacity: Oil pressure: Recommended Oil: 18 Litres All Models: 1.7 bar All Models: Shell Corena P100 V200A/V200W /V300A/V300W Intercooler air pressure: V100/V150 Air delivery connection flange: (to BS 101962 Table D) W/DW Cooling water pressure, maximum: V100W/V150W Cooling water flow, nominal: Intercooler water connections:
V100 Motor rating suffix F2: suffix F3: 18.5 kW 22kW VL200A (1.4-2 bar) V150 30kW 37kW VL200A (2-3.5 bar) VL200DA

All other models 9 litres

All other 2-stage models 1.8 bar VL200/VL300 4 inch VL400 4 inch (>2 bar) 5 inch (<2 bar)

2.2 bar V200/V300 2.5 inch 2 inch

4.8 bar V200W 9 litres/min G1/ 2 A

V200 37kW 45kW VL300A VL300DA VL400A (1.4-2.7 bar) VL400DA V300 55kW 63kW VL400A (2.3-3.5 bar)

V300W 14 litres/min

4.5 litres/min

All water-cooled intercooler models

Motor rating VL Models:

22kW

30kW

37kW

45kW

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LEADING PARTICULARS (contd)

Weights, Kg: V100DW Without motor: With motor (F2): With motor (F3): Without motor With motor (F2): With motor (F3): Without motor: With motor (lower range): With motor (higher range): 503 641 720 V200DW 808 1092 1151 V100W 421 550 593 V200W 644 875 913 V100DA 506 655 724 V200DA 898 1130 1168 VL200DA 544 717 V100A 455 581 622 V200A 705 937 975 VL200A 442 615 635 V150DW 509 745 793 V300DW 850 1245 1418 VL300DA 549 780 V150W 421 620 658 V300W 686 1017 1121 VL300A 445 678 V150DA 513 748 796 V300DA 900 1232 1345 VL400DA 852 1108 V150A 494 687 728 V300A 707 1038 1150 VL400A 658 928 989

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4
INSTALLATION
Page General Guidelines Ventilation Installation Procedure 20 20 23 24

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INSTALLATION
WARNING
Refer to the safety procedures before installation of the compressor unit. Lethal voltages are used in this equipment.Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. Control panel. Acoustic enclosure. Air receiver. Refrigerant air dryer. Air filter. Non-return valve (desirable in multiple installations). 2. GUIDELINES

1.

GENERAL

Standard V-Compact compressors are supplied with the following equipment: Intercooler, air- or water-cooled (two-stage units only). Instrument panel carrying: 1st and 2nd stage air pressure gauges. Two air temperature switching thermometers. Oil pressure gauge. Interstage air pressure relief valve (2-stage models only). Delivery manifold/pulsation vessel. Air governor. Safety devices. Low oil pressure. On low pressure (single stage) models the instrument panel carries only two gauges showing delivery air pressure and oil pressure respectively and the safety switch gives protection against low oil pressure and high air temperature. The following optional equipment is available: Flange mounted electric motor. Diesel engine. Steam turbine. Starter. Aftercooler (air- or water-cooled). Baseplate (with or without anti-vibration mountings) and Vee-belt drive.

Before despatch from the factory all compressors are inhibited against the effects of moisture. If all blanking covers and protective tapes remain secure and undamaged the effective life of this process is 12 months from the date shown on the test card with the machine. In the case of oil-free compressors, one delivery valve is removed from each cylinder head and a desiccant bag put in its place. The loose valves are wrapped and placed inside the distance pieces for shipping. It is unnecessary under normal conditions to construct a special foundation for the compressor. The usual standards and limits of building design are adequate to allow the compressor to be placed directly on the floor, but the floor must have a loading capacity sufficient to support the weight (see 'Leading Particulars'). The anti-vibration mountings MUST NOT be removed and solid mountings substituted, as this will place undue stress on the compressor. Air and water pipework should preferably be fabricated in galvanised steel to prevent corrosion.

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V100-VL400 User Manual Installation

1. Compressor 2. Safety Relief Valve 3. Non-Return Valve 4. Air-Blast Aftercooler

5. Isolating Valve 6. Receiver 7. By-Pass Valve 8. Refrigerant Dryer

TYPICAL INSTALLATION/GENERAL ARRANGEMENT The only connections required to the compressor are as follows: 1. 2. 3. 4. 5. 6. Air delivery outlet to the aftercooler/receiver. Electrical power supply to drive motor: 3-phase plus earth. Electrical connections to the safety switch. Air pipe from the air governor to the receiver. Cooling water pipes (water cooled intercooler/ aftercooler models only). Condensate drain to the users disposal system. If the air intake filter is to be installed in a position remote from the compressor an adaptor for the intake manifold will be required. Consult the local CompAir distributor for advice regarding the dimensions of the extension pipe. If the air intake filter is to be positioned on the outside of the building it must be protected from the weather. An air receiver of appropriate size should be installed with a manually operated valve between the compressor and the air receiver. A safety pressure relief valve must also be fitted between the compressor delivery outlet and the isolating valve. Providing the compressor is arranged for normal speed running, any air pipework between the compressor delivery flange and the air receiver must on no account be smaller than the delivery flange.

The compressor should be installed in a cool and clean location and positioned to allow the necessary access and headroom for the removal of components. A minimum of 1 m all round and clear headroom of 1.5 m is recommended. Walkways, passages and doorways must not be obstructed.

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When the compressor is piped into an existing rigidly fixed compressed air main the length of pipe between the compressor delivery flange and the nearest fixed support should be at least 3 m. This connecting pipe must include a 90 bend of 0.3 m minimum radius with a straight vertical length of pipe of at least 1.2 m between the compressor delivery flange and the bend. When an aftercooler is installed in a system incorporating an air receiver, the aftercooler should be between the compressor and the receiver. If a non-return valve is incorporated, this should be upstream of the aftercooler. If the aftercooler is positioned close to the compressor the connecting pipework will normally be in the form of an inverted U loop and one vertical leg of the loop must be at least 1.2 m in length. The connection between the aftercooler and the air receiver must be arranged as in the previous paragraph. It is essential that all pipework is made and installed so that it is not constrained or distorted when connected to the compressor, aftercooler or user's pipework. Use 90 bends with 0.3 m minimum radius. Do NOT use elbows. Where the installation includes a water cooled intercooler and/or aftercooler, valves must be installed in the water inlet and outlet pipes to allow the compressor and the aftercooler to be isolated from the water supply. If the compressor is to operate under automatic start/stop control the isolating valves on the inlet pipes should be solenoid operated and the solenoids interconnected with the compressor starter. This will ensure that the water supply is cut off when the compressor shuts down or is on standby. If the compressor is operating under air governor control fit 'Iockshield' valves in the water inlet pipes to the intercooler and aftercooler to allow control of cooling water flow. This is particularly important in multiple installations. Where necessary the cooling water system must be protected to prevent freezing. If the compressor is connected into a central cooling system check that the cooling water is of good quality.

Whenever cooling towers are used in the water cooling system expert advice must be sought regarding the precautions to be taken to prevent the development of harmful bacterial growth which could cause a health hazard. On installations equipped with individual cooling towers the power supply to the water pump and the cooling tower fan must be interlocked with the compressor starter. The operation of the cooling tower fan should also be controlled by a suitable thermostat fitted in the cooling tower sump. It is recommended that the pipe from the condensate valve should lead to the disposal system by way of an open drain or tundish so that valve operation may be observed. If an air dryer is installed with the compressor it should be located downstream of the air receiver. Bypass valves and piping should be fitted so that the dryer may be isolated for servicing. If the dryer is of the desiccant type a prefilter and an afterfilter must be incorporated, particularly if used with a lubricated compressor.

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V100-VL400 User Manual Installation

3.

VENTILATION

In operation the compressor will release heat into the surroundings and therefore the compressor room should be of adequate size and have good ventilation. The recommended minimum sizes of room and ventilation openings are as below:
Total area of ventilation Room volume Model Room volume m V100A V100W V100DA V100DW V150A V150W V150DA V150DW V200A V200W V200DA V200DW VL200A VL200DA V300A V300W V300DA V300DW VL300A VL300DA VL400A VL400DA
3

inlet and outlet openings 7 bar 10.5 bar m

2

Additional area to inlet opening for aftercooler m 0.25 0.4 0.4 0.5 0.5 0.4 0.4 0.8 0.8 2

with aftercooler m 43 64 64 85 85 57 57 128 128 85 85 114 114

3

29 29 29 29 43 43 43 43 57 57 57 57 29 29 85 85 85 85 43 43 57 57

43

0.45 0.45 0.45 0.45 0.7 0.7 0.7 0.7 0.9 0.9 0.9 0.9

0.55 0.55 0.55 0.55 0.8 0.8 0.8 0.8 1.05 1.05 1.05 1.05

0.25

0.4 (up to 2.5 bar only) 0.4 (up to 2.5 bar only) 1.3 1.3 1.3 1.3 1.5 1.5 1.5 1.5 -

If any difficulties are anticipated or if there are space limitations on site consult the local CompAir distributor before installation is commenced.

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4.

INSTALLATION PROCEDURE

When using the compressor lifting bracket and the motor eyebolt as the slinging attachment points, it is essential that a spreader of the correct length is used. The lift should always be made vertically as inclined loading severely reduces the safe working load of the eyebolt. A 16 mm diameter shackle pin is required for V1 00 and V150 units and a 19 mm diameter shackle pin for V200, V300 and V400 units. When the compressor is in position check that it is clean and undamaged. Check that no blanking covers and tapes are missing or damaged. Make sure that the power supply to the compressor is taken from an isolator incorporating suitable high rupture current (HRC) fuses and that the switch is locked 'OFF' and the fuses removed. Connect the power supply to the compressor drive motor in accordance with the diagram provided, using cables which comply with the standards of the International Electrotechnical Commission (I.E.C.). The cables must be suitably protected and clamped. Connect the electrical wiring link between the safety switch and the motor starter contactor in accordance with the diagram. If an airblast aftercooler is installed the electrical wiring for the aftercooler fan motor should be interlocked with the compressor motor starter or the optional control panel, if fitted. Following the guidelines above, make up the necessary pipes to connect the air delivery flange of the compressor to the air receiver or aftercooler but leave the connection open. If appropriate, connect the aftercooler and intercooler to the water cooling system. Make up and fit a connecting pipe between the air governor and the receiver. This pipe should have a minimum internal diameter of 6 mm unless the pipe length is more than 7.5 m, when the minimum internal diameter should be 9 mm. The pipe should be blown through with compressed air before being fitted.

On oil-free models fit the delivery valves in the compressor cylinder heads as follows: Remove the labelled gauze covers from the distance pieces and take out the wrapped valves from the cavity. Replace the gauze covers. Remove the paper tape from all the gauze covers. Remove the valve retaining covers from the cylinder heads, withdraw the delivery valve retainers and remove the desiccant bags. Fit the delivery valves on the valve seats, ensuring that the copper joint rings are in place and undamaged. Refit the valve retainers and covers.

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5
OPERATION
Page Commissioning/Starting Procedures Static Checks Functional Checks Routine Starting Adjustments 26 26 27 27 28

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OPERATION

WARNING
Refer to the safety procedures before operating the compressor unit. Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

1.

COMMISSIONING/STARTING PROCEDURES

4. 5.

Fit the air intake silencer/filter assembly. If the compressor has been in storage for a lengthy period, remove all suction and delivery valves and inspect to ensure that they are in good condition. Check that ambient temperatures are within limits and that ventilation of the compressor is satisfactory. Check that the cooling water supply is adequate and clean and that any water treatment equipment is in order. Check that the aftercooler and air receiver are correctly installed and that the air pressure relief valves operate correctly. Prime the lubrication system as follows: Disconnect the oil pipe between the crankcase and the oil pressure switch at the switch end. Connect a pressure oil can to the free end of the pipe. Remove one of the crankcase doors so that the connecting rods are visible. With the recommended oil in the can, pump oil into the pipe until oil is seen to flow from the small end bushes. Disconnect the oil can and reconnect the pipe to the oil pressure switch. Refit the crankcase door.

When commissioning a new compressor or one which has been overhauled or out of service for an extended period, carry out the following procedure. 1.1 Static Checks 1. Check that the isolator switch is locked 'OFF' and that all electrical connections are tight and correctly made and comply with the wiring diagram. In the case of Vee-belt drive, check the belts for condition, tension and alignment. Check that all blanking covers and protective tapes have been removed. With oil-free models ensure that the delivery valves have been taken from their shipping locations inside the distance pieces and fitted in the cylinder heads. Check that all air intake piping is clean, free from corrosion and contains no loose debris. Note: If the main air system is being used to supply delicate instrumentation it is permissible, for the initial run only, to fit gauze filters in the air intake line and the downstream line from the receiver to trap small particles which may be present, particularly in extended intake lines. Ensure that all gauze filters are removed on completion of the initial run. Do not connect the delivery manifold flange to the pipework at this stage. The initial run will allow the cylinder inhibitor, which is slightly toxic, to disperse without entering the users pipework.

6.

7.

8.

2.

9.

3.

10. Remove the oil filler cap and pour in the correct quantity of the recommended oil (9 or 18 litres, depending on model). Check that the oil level is at the maximum level on the dipstick. Refit the oil filler cap.

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V100-VL400 User Manual Operation

1.2 Functional Checks 1. 2. Insert the isolator fuses and switch on the power supply to the compressor. Hand unload each 1st stage cylinder of the compressor by moving the spring loaded cam levers to the valve unloaded position. Open cooling water valves to water-cooled intercooler and aftercooler, if fitted and open the intercooler vent/drain cock. Close the cock when a full, air-free flow emerges. Check the direction of rotation of the motor by observing the direction in which the motor kicks over when started. This may be conveniently done by removing the clip-on inspection panel in the top of the flywheel housing and viewing the drive coupling. Correct rotation is clockwise viewed from the motor end of the compressor, as indicated by the direction arrow on the housing. Check for correct rotation of the fan motor on the air blast aftercooler, if fitted. If rotation is incorrect, stop the compressor immediately, switch off the power supply at the isolator and rectify the cable connections. 5. When the direction of rotation is correct, start the compressor and allow to run for 10 - 15 minutes in the unloaded condition. Check that the oil pressure is more than 1.7 bar, settling to 1.7 bar when the compressor reaches operating temperature. On lubricated compressors only, close the hand unloaders and run the compressor for a further 10 - 15 minutes to clear all traces of inhibitor from the cylinders. Stop the compressor . Connect the air delivery manifold flange to the air receiver. Move the hand unloaders to the valve unloaded position, start the compressor and when it is running evenly close the hand unloaders.

11 . Check the setting of the switching thermometers as follows:Using the trip needle adjusting knob on the face of each thermometer, set the trip needles to 15C above the normal running temperatures indicated. Note: The minimum oil pressure switch is preset at 1 bar and should not require adjustment. 12. Check the complete installation for leaks and excessive temperatures. 13. Close the receiver valve and check that the compressor runs correctly under the influence of the air governor or pressure switch. If adjustment is necessary , refer to section below headed 'Adjustments'. 14. Run the compressor for 1 hour, checking continually for correct loading and unloading, temperatures and pressures. Record temperature and pressure readings to provide a basis for assessing future performance. 1.3 Routine Starting 1.3.1 Air Governor Control 1. 2. 3. 4. 5. Check crankcase oil level. Operate hand unloaders on 1st. stage cylinder heads. Open cooling water flow, if applicable. Switch the power supply 'ON' at the isolator and operate starter. When the compressor is running steadily, close hand unloaders.

3.

4.

6.

7. 8. 9.

1.3.2 Optional Control Panel 1. 2. 3. Check crankcase oil level. Operate hand unloaders on 1st. stage cylinder heads. Open cooling water valves, if applicable.

10. Run the compressor on load with a receiver valve open to maintain the running loaded condition until full operating temperature is reached (approximately 20 minutes from cold).

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4. 5. 6. 7.

Switch power supply on at the isolator . Press 'SET RUN/FAULT RESET' button. Turn selector switch to 'AUTO' or 'HAND' as required. When compressor is running steadily, close hand unloaders.

1.4.2 Oil Pressure When the oil pressure is not within the correct limits it should be adjusted as follows: Remove the cap nut and locknut on the side of the oil pump and turn the adjusting screw clockwise to increase the oil pressure and counter-clockwise to reduce the oil pressure. If the pressure is too low and cannot be corrected by utilising the full adjustment, check the following possible causes: 1. 2. 3. 4. 5. 6. Insufficient oil in the crankcase. Dirty oil suction strainer. Dirt under ball valve. Gauge faulty. Pipe connections loose. Excessive bearing clearance.

1.4 Adjustments 1.4.1 Air Governor and Optional Control Panel. If the pressure settings at which the compressor regulation system operates to bring it on-load or offload require alteration adjustments may be made to the air governor or the pressure switch, as appropriate. For details of the procedures refer to publications C20160-014 (air governor) or C20160-040 (control panel). CAUTION: Do not set the high pressure cut out point of the regulation system to a higher pressure than the nominal operating pressure of the compressor. Operation at higher pressures than nominal will overload the drive motor and may cause damage. Such action may invalidate the Warranty.

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V100-VL400 User Manual

6
MAINTENANCE
Page Routine Maintenance Cleanliness Recording Pressures and Temperatures Maintenance Record Pressure Settings Electrical Connections Leaks Regular Checks Lubricating Oil Maintenance Schedule Maintenance Parts (Two Years Operation) Maintenance Procedures Lubrication System Air Intake Filter 30 30 30 30 30 31 31 31 31 34 35 35 36

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MAINTENANCE

WARNING
Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit. Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

1.

ROUTINE MAINTENANCE

1.2 Recording Pressures and Temperatures Keep a regular daily record of operating pressures and temperatures. The readings should be taken when conditions are stable and with the compressor running on full load. 1.3 Maintenance Record Keep a careful record of all servicing, maintenance and repair work carried out on the compressor. The record will form a useful reference and any variation from normal operation will be noticeable immediately, alerting the user to a possible need for servicing or maintenance. Frequent recurrence of a particular repair could reveal an unsatisfactory operating condition which must be corrected. 1.4 Pressure Settings Pressure switch settings and adjustments must be maintained correctly to prevent faults occurring which could reduce the efficiency of the compressor. Refer to 'Adjustments' in the 'Operation' section of this manual for details. 1.5 Electrical Connections Avoid damage to electrical wiring when working on the compressor installation and inspect wires and cables before refitting. Ensure no damage will be caused by chafing or contact with hot surfaces when the unit is in service. Do not fasten wiring directly to a line carrying fluid.

To ensure the efficient operation of the compressor installation the user must check performance regularly and carry out the necessary adjustments to maintain correct settings. This section gives the information needed by the user for this purpose. Personnel accustomed to servicing and maintaining mechanical equipment should have no difficulty in carrying out these tasks but if assistance is needed the user should refer to the local CompAir Distributor . Routine maintenance and regular servicing must be carried out as recommended in the 'Maintenance Schedule'. A condition of the Warranty cover is that the user must ensure that the compressor and auxiliary equipment are properly maintained and adjusted, that all checks and services listed in the Schedule are carried out at the specified intervals and an accurate record is kept of the work. 1.1 Cleanliness The installation must be kept in clean condition at all times. Inspect regularly for signs of damage, excessive wear and security of fittings. Ensure that any oil spillage is wiped up immediately and any residual oil cleaned from external surfaces.

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1.6 Leaks Inspect the unit for leaks, loose pipe connections and dirt build-up prior to carrying out routine maintenance. Tighten loose connections and repair or replace damaged pipes immediately. 1.7 Regular Checks The 'Maintenance Schedule' lists the routine checks and services which are important for the efficient running of the compressor. The user should ensure that the Daily and Weekly Checks become an integral part of planned maintenance, even if the major servicing work is contracted to a CompAir Distributor. 1.8 Lubricating Oil It is essential to maintain the correct level of oil and to change the oil completely at the specified intervals. Details of the recommended oil are given in 'Leading Particulars'. 2. MAINTENANCE SCHEDULE Hours 2,500 5,000 7,500 10,000 12,500 15,000 Service A A+B A+C A+B A A+B+C+D

The above cycle from 2,500 hours should then be repeated.

Regular maintenance should be carried out as recommended in the Schedule below. The Schedule is appropriate to most normal circumstances but in some instances, changes in detail may be required. The Schedule should always be used as an initial guide, but if experience shows that an alteration is necessary, advice should be sought from the local CompAir distributor. The services for lubricated and oil free compressors are almost identical. Any variations are indicated in the schedule and should be observed.

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It is expected that service items marked * in the Schedule below will normally be carried out by a CompAir distributor. Users who wish to carry our these services themselves will find the procedures in the Repair Manual, part number C20160-1157.

Item Daily checks Pressure gauges Thermometers Condensate drains Water cooling system Airblast aftercooler Weekly checks Lubrication system After first 1000 hours Water cooled intercooler Every 2,500 hours (Service A) Air intake filter *Suction and delivery valves Unloader valve Air governor Lubrication system *Low oil pressure/high air temperature switch Intercooler Aftercooler

Action

Note/record readings. Note/record readings. Check for correct operation. Check water flow. Drain condensate (manual tap).

Check oil level in crankcase. Top up as necessary.

Examine internally. Clean if required.

Check and clean. Replace if necessary. Remove, dismantle, clean and inspect. If necessary replace valve plates. Renew all valve springs. Inspect diaphragm. Renew if necessary. Clean and inspect. Renew filter pads if necessary. Drain crankcase oil. Remove and clean oil strainer. Renew oil filter element. Refill crankcase with new oil. Remove and check operation on bench. Clean externally with low pressure air jet, 0.5 bar maximum. Clean externally with low pressure air jet, 0.5 bar maximum.

Every 5,000 hours (Service B) *Pressure gauges Intercooler Air intake Check calibration. Check operation of blowdown valves. Renew filter element.

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V100-VL400 User Manual Maintenance

Item Every 7,500 hours (Service C) *Compressor cylinders *Pistons

Action

*Connecting rods

Electrical components Check condition of cables and wiring. Every 15,000 hours (Service D) *Compressor

Remove cylinder heads and cylinders. Check piston ring gaps. Renew rings if necessary. Inspect small end bushes /gudgeon pins. Renew if necessary. Check guide ring 'stand out'. Inspect big end bearings. Renew if necessary. Note: if new big end bearing shells are fitted, the big end bolts must also be renewed. Check gland packings. Renew if excessive oil is being passed. Inspect starter contacts. Inspect motor for cleanliness.

Dismantle completely. Inspect crankshaft journal bearings. Check security of balance weights. Renew main bearing shells. Renew oil seals. Renew big end bearing shells. Renew big end bolts. Inspect crossheads and guides. Renew small end bushes. Inspect piston rods. Renew piston rod gland packings. Inspect cylinder bores. Renew piston rings. Strip and inspect oil pump. Renew worn parts. Renew drive belt. Inspect relief valves and check operation. Inspect all protection devices and check operation. Remove motor. Check coupling bolts for security. Inspect main starter contacts.

Items marked refer to oil-free compressors only.

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3.

MAINTENANCE PARTS (TWO YEARS OPERATION)

Quantities required Service Description V100 'A' Oil Filter Element 2nd stage Valve Plates 2nd stage Valve Springs 1st stage Valve Springs Diaphragms (unloader) Valve Joint Ring Valve Lanterns 'O' Ring Oil Filter Element 1 2 6 12 3 6 6 1 V150 1 2 6 12 3 6 6 1 V200 1 4 12 24 6 12 12 1 V300 1 4 12 24 6 12 12 1

'B'

Air Filter Element

'C'

1st stage Guide Ring 1st stage Pressure Ring 2nd stage Guide Ring 2nd stage Pressure Ring Oil Wiper Ring Oil Scraper Ring Seal

1 1 1 2 2 2 2

1 1 1 2 2 2 2

2 2 2 4 4 4 4

2 2 2 4 4 4 4

'D'

1st stage Suction Valves 1st stage Delivery Valves 2nd stage Suction Valves 2nd stage Delivery Valves Diaphragms (unloader) Main Bearing Bushes Oil Seals Big End Bearing, Half Liners Big End Bolts Small End Bushes Gudgeon Pins 1st stage Piston Rings 1st stage Conformable Rings 2nd stage Piston Rings 2nd stage Conformable Ring Shakeproof Washers Set of Gaskets and 'O' Seals Oil Pump Belt

2 2 1 1 3 2 2 4 4 2 2 2 1 2 1 2 1 1

2 2 1 1 3 2 2 4 4 2 2 2 1 2 1 2 1 1

4 4 2 2 6 2 2 8 8 4 4 4 2 4 2 4 1 1

4 4 2 2 6 2 2 8 8 4 4 4 2 4 2 4 1 1

Items marked refer to oil-free compressors only.

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4.

MAINTENANCE PROCEDURES

WARNING
Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit. Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. Where a maintenance procedure below includes the warning 'The compressor must be stopped' the following steps must be taken before work is commenced: 1. Close the isolating shut-off valve to the receiver. 2. Switch the power supply 'OFF' at the isolator. 3. Check that all pressurised air trapped in the system is released to atmosphere. 4. Check that all pressure gauges on the display panel register zero. 5. Ensure that the cooling water system has been drained on water cooled models. 6. Check that the drain valve on the delivery manifold is clear and air pressure released. 7. Open the manual drain cock to ensure that pressurised air trapped between the first and second stages has been released.

4.1 Lubrication System 4.1.1 Recommended Oil At ambient temperatures from 0 to 30C, the recommended oil for the 3000 Series V-Compact is Shell Corena P68. Where temperatures are consistently in excess of 30C, use 100 viscosity rating of the selected brand. For alternative lubricants consult your local distributor. In normal circumstances the oil should be changed after every 2,500 hours of service. If the compressor is operating in adverse conditions, such as high dust levels or the presence of chemical or other pollutants, more frequent oil changes may be necessary. 4.1.2 To Check the Oil Level The oil level is indicated on the dipstick housed inside the oil filler tube. The oil level is correct when it reaches the 'MAX' mark.

The compressor must be stopped. Remove the oil filler cap, withdraw the dipstick and check the level. If topping up is required, pour in the appropriate quantity of the correct oil to bring the level up to the 'MAX' mark on the dipstick. Refit the oil filler cap. 4.1.3 To Change the Oil Filter Element The full-flow oil filter has a disposable cartridge type element. The compressor must be stopped. 1. 2. 3. 4. Remove the old filter element by unscrewing it from the housing and discard it. Carefully clean out the filter housing. Apply a light film of oil to the seal of the new element. To fit the new element, screw it into the housing until it contacts the gasket and then tighten it a further quarter turn.

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4.1.4 To Drain the Oil The compressor must be stopped. Drain the oil while the compressor is hot. The hot oil will run freely and carry out any suspended particles. 1. 2. Remove the oil filler cap. Place a container beneath the crankcase drain, remove the drain plug and allow the oil to drain into the container for disposal. Clean and refit the drain plug. Refit the oil filler cap.

4.2.2 To Clean the Element by Air Blast The compressor must be stopped. 1. Using an air line supplying dry, low-pressure air (max. 5 bar) carefully blowout the inner cavity of the element, ensuring that the air stream passes through the element from inside to outside. When all contamination has been removed, inspect the element for cracks, holes or other damage by viewing the light from a hand lamp through the element or holding the element up against a light source. If any damage is evident the element must be discarded and a new one fitted. Re-install the clean/new element in the intake silencer.

2.

3.

3. 4.

4.2 Air Intake Filter In normal circumstances the air intake filter element should be checked after every 2,500 hours service. If the compressor is operating in adverse conditions, such as high dust levels, more frequent attention may be necessary . 4.2.1 To Remove the Air Filter Element The compressor must be stopped. 1. Unscrew the wingnut or slot-headed nut securing the air intake cover and remove the cover. Remove the filter element. Clean out the inside of the intake silencer.

2. 3.

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7
FAULT FINDING

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CompAir Limited

FAULT FINDING

WARNING
Refer to the safety procedures before carrying out any fault finding investigation on the compressor unit.
Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

Indication Low oil pressure. (1) (2) (3) (4) (5)

Possible Cause Low oil level. Incorrect grade of oil in crankcase. Oil pump drive belt or pulley loose. Oil pressure gauge faulty. Incorrect setting of oil pressure relief valve. Ball valve sticking in open position. Clogged oil filter element. Broken or loose connections on oil pipework. Oil pump gears faulty. Worn main bearings. (1) (2) (3) (4) (5)

Remedy Check/top up oil. Drain crankcase and refill with correct oil. Check drive belt and pulley. Rectify or renew as necessary. Check gauge calibration. Renew gauge if defective. Check setting of valve. If necessary remove and clean valve assembly. Check seating. Reset valve. Renew oil filter element. Check condition of oil pipes and filter. Renew if necessary. Renew oil pump gears. Inspect bearings and small end bushes. Renew if necessary.

(6) (7) (8) (9)

(6) (7) (8) (9)

Compressor overheating.

(1)

Inadequate ventilation of compressor room. Incorrect positioning of compressor or aftercooler. Valves faulty.

(1)

(2)

(2)

(3)

(3)

(4)

Intercooler passages obstructed (usually only after very long service).

(4)

Check ventilation meets the recommendations in the 'Installation' section of this manual. Check positioning meets the recommendations in the 'Installation' section of this manual. Remove valves. Inspect valve plates, springs and seats. Check condition of ring joints. Renew as necessary . Clean intercooler internally and externally.

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V100-VL400 User Manual Fault Finding

Indication Compressor overheating (cont.) (5) (6)

Possible Cause Main delivery pipework blocked or restricted. Faulty unloading (particularly on 2nd stage cylinders). 1st stage temperature gauge reading will increase when compressor is running unloaded. (5) (6)

Remedy Remove pipework and inspect. Rectify if necessary. Check that bore is of adequate diameter. Check operation of unloader mechanism. Ensure that unloader fork travels its full distance to open suction valve plate completely.

Compressor fails to maintain working pressure.

(1) (2) (3)

Incorrect setting of governor or pressure switch. Compressor air intake blocked or partially obstructed. Faulty unloading preventing compressor from coming on load. Valves faulty.

(1) (2) (3)

Adjust settings to achieve correct pressure. Inspect air intake filter for cleanliness and serviceability. Renew element if necessary. Check operation of unloader mechanism. Remove valves. Inspect valve plates, springs and seats. Check condition of ring joints. Renew as necessary. Check for leaks. Check compressor is in good condition. (A slow fall in delivery pressure when running on full load indicates that the compressor is not large enough for the installation). Check drive motor speed. Rectify as necessary . Inspect piston rings and cylinders.

(4)

(4)

(5) (6)

Leaks in user's pipework. The air demand of the installation exceeds the rating of the compressor.

(5) (6)

(7) (8)

Compressor running under speed. Worn or broken piston rings.

(7) (8)

Interstage pressure reading too high (1st stage relief valve exhausting).

(1) (2)

1st stage safety valve faulty. 2nd stage valves faulty.

(1) (2)

(3)

Intercooler passages obstructed (usually only after very long service).

(3)

Check setting of safety valve. Adjust as necessary. Setting should be 3.1 bar. Remove valves. Inspect valve plates, springs and seats. Check condition of ring joints. Renew as necessary. Clean intercooler internally and externally.

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Indication Intercooler pressure reading low. (1) (2)

Possible Cause Air pressure gauge faulty. 1st stage valves faulty. (1) (2)

Remedy Check gauge for accuracy. Renew if necessary. Remove valves. Inspect valve plates, springs and seats. Check condition of ring joints. Renew as necessary. Check air intake. Inspect filter. Clean or renew as necessary.

(3)

Compressor air intake blocked.

(3)

Intercooler condensate valve fails to exhaust.

(1)

Ball valve faulty .

(1)

Dismantle condensate valve. Check condition of ball and spring. Clean or renew as necessary . Check for free operation.

Excessive carbon deposits in compressor.

(1) (2)

Excessive oil consumption. Compressor overheating.

(1) (2)

See following action on 'Excessive Oil Consumption'. See previous action on overheating.

Excessive oil consumption.

(1) (2) (3) (4)

Incorrect oil in crankcase. Oil level too high. Worn cylinders and piston rings. Excessive small end clearance.

(1) (2) (3) (4)

Drain and refill with correct oil. Drain off surplus oil until correct level shows on dipstick. Check all piston ring gaps. Inspect cylinder bores for wear. Renew components as required. Inspect small end bushes for wear. Renew if necessary. Inspect gudgeon pins for wear.

Compressor knocking.

(1)

Loose flywheel. (Will be heard when compressor is on full load). Broken valve plates or springs. Broken valve spring contacting piston crown. Worn small end bearings.

(1)

(2) (3) (4)

(2) (3) (4)

Remove flywheel. Check that crankshaft and flywheel are not damaged. Refit flywheel with new key and tighten retaining bolt to correct torque. Remove and inspect valve plates. Renew as necessary. Remove and inspect valve springs. Rectify and renew as necessary. Remove and inspect bearings. Renew bearings and fit new gudgeon pins if required.

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V100-VL400 User Manual Fault Finding

Indication Compressor knocking (cont.) (5) (6)

Possible Cause Worn big end bearings. Insufficient clearance between piston crown and cylinder head. (5) (6)

Remedy Remove and inspect bearings. Renew bearing shells if necessary. Check clearance with lead strip and if insufficient fit joint between cylinder base and crankcase.

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V100-VL400 User Manual

APPENDIX 1
The Pressure Systems Safety Regulations 2000

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APPENDIX 1
Note: The intervals between examination and calibration of components, eg pressure vessels, pressure relief valves etc, will be defined by the 'competent person' preparing the written scheme. In defining these periods the 'competent person' must take into account the recommendations of the component part manufacturer, the Health and Safety Executive (H & SE) and the British Compressed Air Society (BCAS).

THE PRESSURE SYSTEMS SAFETY REGULATIONS 2000 The circuit diagram shown below is provided to assist a 'competent person' in preparing a written scheme of examination for a system incorporating the air compressor(s).

1. Intake Air Filter 2. Compression Cylinder 3. Pulsation Vessel 4. Pressure Relief Valve

5. Non-return Valve 6. Aftercooler 7. Auto Drain Trap

PRESSURE SYSTEM DIAGRAM 1ST STAGE

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V100-VL400 User Manual Appendix 1

1. Intake Air Filter 2. First Stage Compression Cylinder LP 3. Pressure Relief Valve 4. Intercooler 5. Auto Drain Trap 6. Second Stage Compression Cylinder HP

7. Pulsation Vessel 8. Pressure Relief Valve 9. Non-return Valve 10. Aftercooler 11. Auto Drain Trap

PRESSURE SYSTEM DIAGRAM 2ND STAGE

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