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User Manual V-Compact Series Stationary Air Compressors Serial numbers from:- GB BR1815BA - 08/2004 V100 EO40/0001 V150 EO41/0001 VL200 EO42/0001 VL300 EO43/0001 VL200D/V100D EO44/0001 VL400D/V300D EO55/0001 VL300D/V150D EO45/0001 V200 EO50/0001 V300 EO51/0001 VL400 EO52/0001 V200D EO54/0001

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User Manual

V-Compact SeriesStationary Air CompressorsSerial 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

FOREWORDThese 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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CompAir Limited

OWNERSHIP DATATECHNICAL 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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CompAir Limited

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.

WARNINGThe 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

1SAFETY PROCEDURESPage 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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CompAir Limited

SAFETY PROCEDURES1. 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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CompAir Limited

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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CompAir Limited

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V100-VL400 User Manual

2GENERAL DESCRIPTIONPage 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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CompAir Limited

GENERAL DESCRIPTION1. 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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CompAir Limited

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V100-VL400 User Manual

3LEADING PARTICULARS

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CompAir Limited

LEADING PARTICULARSNote: 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 (