compair v-compact serie user manual.pdf

48
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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Page 1: Compair V-Compact serie user manual.pdf

User Manual

V-Compact SeriesStationary Air Compressors

Serial numbers from:-

GB BR1815BA - 08/2004

V100 EO40/0001V150 EO41/0001VL200 EO42/0001VL300 EO43/0001VL200D/V100D EO44/0001VL400D/V300D EO55/0001

VL300D/V150D EO45/0001V200 EO50/0001V300 EO51/0001VL400 EO52/0001V200D EO54/0001

Page 2: Compair V-Compact serie user manual.pdf

FOREWORD

These compressors are intended for compressing atmospheric airand are not suitable for compressing any other gas. They aredesigned and manufactured to give optimum performance, with longlife and reliability.

This manual gives the user all the information required to install,commission and operate the compressors and carry out the regularschedules for servicing and maintenance which will ensure themaximum satisfactory service life.

Servicing facilities and the supply of genuine replacement parts areprovided through a worldwide network of CompAir Distributors,backed up by the AfterMarket division at Redditch. If replacementparts are needed, the user should contact the local Distributor in thefirst instance.

The information given in this manual was correct at the time ofprinting but modifications to parts and procedures may be madewithout notice which could affect the servicing requirements of thecompressors. Before any servicing or maintenance work isundertaken the user is advised to contact the local CompAirDistributor who is supplied with revised and up-dated information.

In any communication concerning the compressor it is essential toquote the MODEL and SERIAL NUMBER.

Throughout this manual all pressures quoted are gauge pressureunless otherwise specified.

Page 3: Compair V-Compact serie user manual.pdf

page 1

V100-VL400 User Manual

BR1815BA - 08/2004

V100, V150, V200, V300, VL200, VL300 & VL400 AIR COMPRESSORS

Serial Numbers from:

V100 EO40/0001V150 EO41/0001VL200 EO42/0001VL300 EO43/0001VL200D/V100D EO44/0001VL400D/V300D EO55/0001

VL300D/V150D EO45/0001V200 EO50/0001V300 EO51/0001VL400 EO52/0001V200D EO54/0001

Section Page

1. Safety Procedures 5

2. General Description 11

3. Leading Particulars 15

4. Installation 19

5. Operation 25

6. Maintenance 29

7. Fault Finding 37

Appendix 1 The Pressure Systems 43Safety Regulations 2000

CONTENTS

Illustration Page

Typical Installation/General Arrangement 21

Pressure System Diagram - 1 st Stage 44

Pressure System Diagram - 2nd Stage 45

Page 4: Compair V-Compact serie user manual.pdf

CompAir Limited

page 2

TECHNICAL DATA

Motor Serial Number:

Delivery Date:

Compressor Lubricant:

Lubricant Capacity:

Motor Bearing Grease:(If applicable)

LOCAL COMPAIR DISTRIBUTOR

Address:

Fax:

Contact Names: Parts:

Service:

Model:

Serial Number:

Year:

Maximum Pressure:

kW:

Motor rpm:

V. Ph. Hz.

M3/min:

Telephone:

Name:

OWNERSHIP DATA

Page 5: Compair V-Compact serie user manual.pdf

page 3

V100-VL400 User Manual

ASSOCIATED PUBLICATIONS

Title Part No.

Automatic Air Governor: C20160-014

Regulating Panel Mk.5: C20160-040

Repair Manual: AC20160-1157

Parts Lists: C20160-1143 V100A to V300AV100W to V300W

C20160-1467 VL200AC20160-1468 VL300AC20160-1469 VL400AC20160-1470 VL200DAC20160-1471 VL300DAC20160-1472 VL400DA

C20160-1374 V100DAC20160-1375 V150DAC20160-1376 V200DAC20160-1377 V300DAC20160-1378 V100DWC20160-1379 V150DWC20160-1380 V200DWC20160-1381 V300DW

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CompAir Limited

page 4

WARRANTY

The conditions of the CompAir Warranty are set outin the company's standard Conditions of Saleavailable from the Distributor supplying themachine.

MAINTENANCE

To ensure the continued trouble-free operation of thecompressor unit it is important that periodicmaintenance and servicing are carried out inaccordance with the information given in the'Maintenance' section of this manual. If anyreplacement or repair is needed use only CompAirGenuine Parts.

The use of replacement parts or lubricatingoils not supplied or approved by CompAirmay lead to failures in service which wouldnot be covered by warranty.

Any unauthorised modifications or failure tomaintain this equipment in accordance withthe maintenance instructions may make itunsafe. The use of replacement parts notsupplied or approved by CompAir maycreate hazardous conditions over whichCompAir has no control.

Such hazardous conditions may lead toaccidents that can be life threatening,cause substantial bodily injury or result indamage to the equipment. CompAir canbear no responsibility for equipment inwhich unapproved replacement parts areincluded.

WARNING

USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTYCOULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIEDOUT USING NON-GENUINE PARTS.

GENUINE PARTSAUTHORISED SERVICE AGENTS

USE ONLY

Page 7: Compair V-Compact serie user manual.pdf

page 5

V100-VL400 User Manual

Page

General 6

Warnings, Cautions and Notes 6

General Safety Precautions 7

Installation Precautions 7

Operational Precautions 7

Maintenance and Repair Precautions 8

Precautions in the Event of Fire 9

1SAFETY PROCEDURES

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CompAir Limited

page 6

1. GENERAL

Most accidents which occur during the operationand maintenance of machinery are the result offailure to observe basic safety rules or precautions.An accident can often be avoided by recognising asituation that is potentially hazardous.

When handling, operating or carrying outmaintenance on the unit, personnel must use safeengineering practices and observe all relevant localhealth and safety requirements and regulations.The attention of users in the UK is drawn to theHealth and Safety at Work Act, 1974, and to theRegulations of the Institution of Electrical Engineers.

CompAir cannot anticipate every possiblecircumstance which might represent a potentialhazard. The WARNINGS in this manual aretherefore not all-inclusive. If the user employs anoperating procedure, an item of equipment or amethod of working which is not specificallyrecommended by CompAir he must ensure that theunit will not be damaged or made unsafe and thatthere is no risk to persons or property.

Failure to observe the precautions given under'Safety Procedures' may be considered dangerouspractice or misuse of the compressor unit.

2. WARNINGS, CAUTIONS AND NOTES

2.1 Warnings

Warnings call attention to operations or proceduresinvolving specific hazards which could cause injuryor death and are identified by the following symbolson the unit and in the text of the manual.

WARNING: RISK OF DANGER

WARNING: RISK OFELECTRIC SHOCK

WARNING: RISK OF HIGHPRESSURE

WARNING: CONSULTMANUAL

2.2 Cautions

Incorrect operational procedures causing possibledamage 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 whichrequire particular attention are identified by a 'Note'in the text of the manual.

SAFETY PROCEDURES

Page 9: Compair V-Compact serie user manual.pdf

page 7

V100-VL400 User Manual – Safety Procedures

3. GENERAL SAFETY PRECAUTIONS

If using compressed air for cleaning purposes,ensure safety regulations are complied with andappropriate clothing and eye protection is worn.

Never direct compressed air onto your skin or atother people.

Never use compressed air to clean loose dirt fromclothing.

Before releasing compressed air through a hosemake sure that the free end is held securely so thatit cannot whip and cause injury.

Avoid injury by using a hoist to lift heavy loads.Check that all chains, hooks, shackles and slingsare in good condition and are of the correct capacity. They must be tested and approved according tolocal safety regulations.

Cables, chains or ropes must never be applieddirectly to lifting eyes. Always use an appropriateshackle or hook, properly positioned. Arrange liftingcables 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 dangerarea beneath and around it. Keep lifting accelerationand speed within safe limits and never leave a loadhanging on a hoist for longer than is necessary.

4. INSTALLATION PRECAUTIONS

Installation work must only be carried out bycompetent personnel under a qualified supervisor.

A fused isolating switch must be fitted between themain power supply and the compressor.

Ensure that air drawn into the air intake will not becontaminated with flammable fumes or vapours,since this could cause an internal fire or explosion.

Precautions must be taken to ensure that no injuryis caused to passers-by through loose clothingbeing sucked into the air intake.

Ensure that the air delivery pipe from thecompressor to the user's pipework aftercooler, orreceiver is free to expand and that no flammablematerial is within the vicinity.

A shut-off valve must be fitted in the delivery air lineto enable the compressor unit to be isolated. This isparticularly important if more than one unit is to becoupled in parallel or connected to an existing airsupply system.

Non-return valves must not be relied upon forisolating parts of the pressure system. In addition, itmay be necessary to install shut-off valveselsewhere in the system to allow a dryer or otherequipment to be bypassed.

A safety relief valve must be installed between anycompressor unit and the shut-off valve/s. A safetyrelief valve is fitted on the reclaimer vessel asstandard equipment.

A pressure relieving device must be fitted to everypressure vessel, or equipment containing air atabove atmospheric pressure, when installeddownstream of the unit.

In order to control the risk of Legionnaires Disease,CompAir strongly advise against the use of watercooling tower systems for water cooledcompressors. A closed circuit radiator system ispreferred (see Bulletin CBB 2083).

5. OPERATIONAL PRECAUTIONS

The compressor unit must only be operated bycompetent 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 thesupply voltage and/or frequency for which it isdesigned.

When mains power is switched on, lethal voltagesare present in the electrical circuits and extremecaution must be exercised whenever it is necessaryto carry out any work on the electrical system.Do not open the starter compartment or touch

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CompAir Limited

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electrical components while voltage is appliedunless it is necessary for measurements, tests oradjustments. Such work should be carried out onlyby a qualified electrician equipped with the propertools and wearing appropriate body protectionagainst electrical hazards.

On a unit equipped with an Automatic Start/Stopsystem, attach a sign stating 'THIS UNIT MAYSTART WITHOUT WARNING' next to the displaypanel.

On a unit equipped with an Automatic Restartdevice, attach a warning notice stating 'THIS UNITHAS BEEN MODIFIED AND WILL STARTAUTOMATICALLY ON APPLICATION OF POWER'next to the display panel and on the inside of theunit next to the starter contactors.

If the unit is equipped with a Remote Control device,attach warning notices stating 'THIS UNIT CAN BESTARTED REMOTELY' in prominent locations, oneon the outside of the unit, the other inside thecontrol compartment.

As a further safeguard, take adequate precautionsto make sure there is no one checking or workingon the unit before attempting to switch on remotelycontrolled equipment. Attach a 'CHECK THAT ALLPERSONNEL ARE CLEAR OF THE UNIT BEFORESTARTING' or similar warning notice to the remotestart equipment.

Parts of the compressor, auxiliary equipment andpipework with a working temperature in excess of80°C must be insulated or guarded and clearlymarked in accordance with the local safety code.

If there is any indication that the compressor isoverheating it must be shut down and the causeinvestigated. Beware of burns from hot metal parts,hot oil and water when working on a unit which hasrecently been shut down.

The compressor must not be operated at pressuresabove the nominal pressure given on the data plate.

The compressor must not be operated in ambienttemperatures outside of those given under 'LeadingParticulars'.

The 'Noise at Work Regulations 1989' suggest thatear protectors should be worn where noise levels are85 dB(A) or higher.

Be aware that high noise levels can interfere withcommunication.

6. MAINTENANCE AND REPAIR PRECAUTIONS

Maintenance, repairs or modifications must only becarried out by competent personnel under a qualifiedsupervisor.

If replacement parts are needed use only CompAirGenuine Parts.

Before removing any panels from the enclosure, iffitted, or dismantling any part of the unit, carry outthe following preparatory operations:-

1. Isolate the compressor unit from the mainelectrical power supply. Lock the isolator in the'OFF' position and remove the fuses.

2. Attach a label to the isolator switch anddisplay panel carrying the warning 'WORK INPROGRESS - DO NOT APPLY VOLTAGE'. Donot switch on electrical power or attempt tostart the unit if a warning label is attached.

3. Close the isolating valve between thecompressor unit and the users pipework. Closethe isolating valve in the cooling water inletpipe. Attach a label to each valve carrying thewarning 'WORK IN PROGRESS - DO NOTOPEN'

4. Check that all pressurised air trapped in thesystem is released to atmosphere. Check thatall pressure gauges on the display panelregister zero.

5. Ensure that the cooling water system hasbeen drained on water cooled models.

6. Check that the drain valve on the deliverymanifold is clear and air pressure released.

7. Open the manual drain cock to ensure thatpressurised air trapped between the first andsecond stages has been released.

8. Stand clear of the valve covers when removingthe securing screws.

Page 11: Compair V-Compact serie user manual.pdf

page 9

V100-VL400 User Manual – Safety Procedures

Use only lubricating oils and greases approved byCompAir. Make sure that the selected lubricantscomply with all relevant safety regulations,especially with regard to the risk of explosion or fireand the possibility of decomposition or thegeneration of hazardous gases.

Always clean up oil spills from the surrounding floorand outside of the compressor unit before and aftermaintenance work.Make sure that all instructions concerning operationand maintenance are strictly followed and that thecomplete unit, with all accessories and safetydevices, is kept in good running order .

The accuracy of pressure and temperature gaugesand switching thermometers must be regularlychecked. They must be renewed when acceptabletolerances are exceeded.

Protection devices must be tested as described inthe 'Maintenance' section of this manual.

Keep the compressor unit clean at all times. Protectcomponents and exposed openings by covering withclean cloth or tape during maintenance and repairwork.

Protect the motor, air intake, electrical andregulation components against the entry ofmoisture, e.g. when steam cleaning.

Precautions must be taken when carrying outwelding or any repair operation which generatesheat, flames or sparks. The adjacent componentsmust always be screened with non-flammablematerial and if the operation is to be carried out nearany part of the oil system, or close to a componentwhich may contain oil, the system must first bethoroughly purged, preferably by steam cleaning.

Never use a light source with an open flame toinspect any part of the unit.

In no circumstances must any welding work or othermodification be carried out on the reclaimer or anyother pressure vessel.

Before dismantling of any part of the compressorunit ensure that all heavy movable parts aresecured.

After completion of repair or maintenance workensure that no tools, loose items or rags are left onor inside any part of the machine.

Check the direction of rotation of the motor whenstarting up the compressor initially and after anywork on the electrical connections or switch gear.

Do not use any flammable liquid to clean valves,filter elements, cooler air passages, air pipes or anycomponent carrying a flow of air during normaloperation. If chlorinated hydrocarbon nonflammablefluids are used for cleaning, safety precautions mustbe taken against any toxic vapours which may bereleased.

Do not use carbon tetrachloride.

Precautions must be taken when using acids,alkalis and chemical detergents for cleaningmachine parts and components. These materialscause irritation and are corrosive to the skin, eyes,nose and throat. Avoid splashes and wear suitableprotective clothing and goggles. Do not breathemists. Ensure that water and soap are readilyavailable.

When disposing of condensate, old oil, used filterelements and other parts and waste material of anykind make sure that there is no pollution of anydrain or natural water-course and that no burning ofwaste takes place which could cause pollution ofthe air. Protect the environment by using onlyapproved methods of disposal.

7. PRECAUTIONS IN THE EVENT OF FIRE

Use extreme caution when handlingcomponents that have been subjected to fire orvery high temperatures. Some components maycontain fluoroelastomer materials which decomposeunder these conditions to form highly corrosiveresidues. Skin contact can cause painful andpenetrating burns resulting in permanent skin andtissue damage.

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CompAir Limited

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V100-VL400 User Manual

Page

Compressor 12

Safety Devices 12

Instrument Panel 12

Lubrication System 12

Regulation System 13 Air Governor Control 13 Control Panel 13

2GENERAL DESCRIPTION

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CompAir Limited

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1. COMPRESSOR

CompAir V-Compact reciprocating compressors aresingle-acting units with two or four cylindersarranged in a 90°-Vee formation for completeprimary balance. The standard version has twocompression stages while the Low Pressure versionis a single-stage machine.

These compressors are available in 'oil-free' or'lubricated' versions. Two-stage compressors arefitted with an air-cooled or water-cooled intercooler.

The cylinders, crankcase and air-cooledintercoolers are cooled by air blast from a cowledfan fitted on the non-drive end of the crankshaft. Thecylinders and cylinder heads are furnished withcooling fins.

The normal drive method is by electric motor flange-mounted to the compressor driving the crankshaftdirectly through a flexible coupling. Alternative drivearrangements include direct drive via a separatelymounted electric motor and flexible coupling and anelectric motor or diesel engine mounted with thecompressor on a common base-plate and drivingthrough multiple Vee-belts and pulleys.

The crankcase is a single iron casting provided withlarge access doors. Two detachable bearinghousings carry the crankshaft main journal whitemetal bearing shells. The counterbalancedcrankshaft has either one or two crankpins, eachcrankpin carrying two forged steel connecting rodson plain steel backed aluminium/tin big-endbearings.

Each 1st stage piston of the oil-free compressorscarries a single two-piece pressure ring and oneguide ring. The 2nd stage pistons are fitted with twopressure rings and one guide ring. All the rings areof PTFE. Each piston is driven by a rod attached toa crosshead carried on the connecting-rod smallend. Ventilated distance pieces fitted between thecrankcase and the cylinders incorporate thecrosshead guide sleeves and gland assemblieswhich prevent oil from entering the cylinders.

In the lubricated compressors no distance piecesare required and the pistons are attached directly tothe connecting rod small ends by hardened steelgudgeon pins.

GENERAL DESCRIPTION

Two suction and two delivery valves are fitted in eachfirst stage cylinder head and one suction and onedelivery valve in each second stage cylinder head.

The delivery manifold is designed as a pulsationvessel to minimise valve pressure peaks in the airdelivery pipe to the aftercooler or receiver .

2. SAFETY DEVICES

The standard compressors have a safety switchmounted on the crankcase which operates to shutdown the compressor if oil pressure falls too low.Two switching thermometers protect the compressoragainst high 1 st stage and 2nd stage airtemperature. An interstage safety valve providesprotection to the 1 st stage pressure system.

On low pressure versions the safety switch providesprotection against low oil pressure and high airtemperature.

3. INSTRUMENT PANEL

On standard machines an instrument panelmounted on the compressor carries 1 st stage and2nd stage air pressure gauges, two switchingthermometers and an oil pressure gauge. On lowpressure models the panel carries a delivery airpressure gauge and an oil pressure gauge.

4. LUBRICATION SYSTEM

An externally-mounted gear type pump is belt drivenfrom the fan end of the crankshaft. Oil is drawn intothe pump through a submerged strainer in thecrankcase and is circulated through the lubricationsystem via a full-flow oil filter. An adjustablepressure relief valve is incorporated in the pump anda dipstick is fitted in the crankcase oil filler tube.

Page 15: Compair V-Compact serie user manual.pdf

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V100-VL400 User Manual – General Description

5. REGULATION SYSTEM

Each suction valve is fitted with an unloader whichincorporates an air operated diaphragm and spring-loaded fork to hold the suction valves off their seatsand cause the compressor to run unloaded. Theunloader forks are actuated by the regulationsystem to provide the required control of thecompressor.

The unloaders may also be operated manually toenable the compressor to be started up initially inan off-load condition.

The normal method of regulation is by Air GovernorControl. An alternative method using an additionalcontrol panel is available which allows thecompressor to be operated in either the Continuousmode or the Automatic Start/Stop mode. The panelcan also control a stand-by compressor or amultiple installation.

5.1 Air Governor Control

Air Governor Control provides continuous runningcontrol in which the air governor responds to airpressure in the receiver to operate the suction valveunloaders. If the pressure rises to the set point ofthe governor the valve unloaders are operated. Thecompressor continues to run, but in the unloadedcondition. When the air pressure in the receiver fallsto the pre-set level the unloaders are released,allowing the suction valves to close and thecompressor comes on load.

The air governor also operates a valve in the base ofthe intercooler to drain accumulated condensateand relieve interstage pressure.

Refer to Publication C20160-014 for details of the AirGovernor.

5.2 Control Panel

The optional wall-mounted control panelincorporates a pressure switch, solenoid valve,runon timer and a solenoid timer. It operates inconjunction with a separately mounted automaticcontactor type starter for the compressor. The panelcarries a 'HAND/OFF/AUTO' selector switch.

Selector switch in 'HAND' position: The compressorstarts and then runs continuously, responding tosystem air demand by unloading at the upperpressure switch setting and loading at the lowerpressure switch setting.

Selector switch in' AUTO' position: The compressorstarts when receiver pressure is less than the lowsetting of the pressure switch. It then runs on loaduntil receiver pressure reaches the upper setting ofthe pressure switch which then operates thesolenoid valve to actuate the unloaders and alsoinitiates the run-on timer. The compressor continuesto run off-load for the time period set by the run-ontimer. If receiver pressure falls during this period tothe lower setting of the pressure switch, the switchopens, allowing the solenoid valve to close and theunloaders to release the suction valves. Thecompressor then comes on load.

If receiver pressure does not fall to the lower settingof the pressure switch during the run-on period therun-on timer will cause the compressor to be shutdown automatically. It will re-start automaticallywhen receiver pressure falls sufficiently to operatethe pressure switch.

The unloader solenoid valve in the control panel alsooperates the intercooler condensate drain/ pressurerelief valve.

Should the compressor shut down automaticallythrough the operation of the low oil pressure/high airtemperature safety device it cannot be restarteduntil the fault has been rectified and the 'SET RUN/FAULT RESET' push button on the control panel ispressed.

Refer to Publication C20160-040 for details of theControl Panel.

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CompAir Limited

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V100-VL400 User Manual

3LEADING PARTICULARS

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CompAir Limited

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LEADING PARTICULARS

Note: There are detail differences depending on the compressor concerned. The designations are as follows:

Basic V100 VL200 Low pressure model prefix: L VL200designation: V150 VL300 Oil-free model suffix: D V200D V200 VL400 Air-cooled suffix: A VL300DA V300 Water-cooled suffix: W V100W Motor rating suffix: F2 or F3 V100DW-F3

In the tables below the models are identified by the appropriate prefix or suffix.

Ambient Temperature:

Running speed:

Working pressure:

V-F2 VL200A-F2 VL200DA-F2 V300DA-F3 All other VL300A-F2 VL300DA-F2 only V-F3 VL400A-F2 VL400DA-F2 models

7 bar 3.5 bar 2.4 bar 8.6 bar 10.3 bar

V150/V300 VL200/VL400 VL300222.3 mm 196.9 mm 222.3 mm133.4 mm - -98.4 mm 85.5 mm 98.4 mmPiston stroke:

V100/V200 196.9 mm 114.3 mm 85.5 mm

Cylinder bore:

2nd stage:

4.1 bar

Working pressure:

maximum:

Motor rotation: Clockwise, viewed from motor end.

1st stage:

normal : maximum:

All Models:

1.4 barminimum: V VL

All Models: 1,460 rev/min 1 ,500 rev/min

VL 0°C 50°C

minimum: maximum:

V 0°C

55°C

VL 1-Stage, single acting

W Water-cooled

V 2-Stage, single acting

A Air-cooled

Model: Type: Model: Intercooler:

Page 19: Compair V-Compact serie user manual.pdf

page 17

V100-VL400 User Manual – Leading Particulars

Suction valves 1st stage:

2nd stage: Delivery valves 1st stage:

2nd stage:

Crankcase oil capacity: Oil pressure: Recommended Oil:

Intercooler air pressure: Air delivery connection flange: (to BS 101962 Table D)

Cooling water pressure, maximum: Cooling water flow, nominal: Intercooler water connections:

Shell Corena P100

V200A/V200W /V300A/V300W 2.2 bar 1.8 bar

All other 2-stage models

V100/V150

V100W/V150W

VL200/VL300 4-

VL4008 84

-

V200/V300/VL400 18 Litres

All other models9 litres

1 2

5 inch (<2 bar)

14 litres/minAll water-cooled intercooler models

G1/2 A

V200W V300W

W/DW 4.8 bar

4.5 litres/min 9 litres/min

VL4004 inch (>2 bar)

All Models: 1.7 bar

All Models:

2 inch V200/V300

2.5 inch VL200/VL300

4 inch

V200/V300 424

V100/V150 212

V100 V150 V200 V300 Motor rating suffix F2: 18.5 kW 30kW 37kW 55kW

suffix F3: 22kW 37kW 45kW 63kW VL200A (1.4-2 bar) VL200A (2-3.5 bar) VL300A VL400A (2.3-3.5 bar) VL200DA VL300DA VL400A (1.4-2.7 bar) VL400DA Motor rating VL Models: 22kW 30kW 37kW 45kW

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CompAir Limited

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Weights, Kg:

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

LEADING PARTICULARS (cont’d)

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V100-VL400 User Manual

4INSTALLATION

Page

General 20

Guidelines 20

Ventilation 23

Installation Procedure 24

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CompAir Limited

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Refer to the safety procedures beforeinstallation of the compressor unit.

WARNING

Lethal voltages are used in thisequipment.Use extreme caution whencarrying out electrical checks. Isolate thepower supply before starting anymaintenance work.

INSTALLATION

1. GENERAL

Standard V-Compact compressors are supplied withthe following equipment:

Intercooler, air- or water-cooled (two-stageunits only).

Instrument panel carrying:

1st and 2nd stage air pressure gauges.

Two air temperature switchingthermometers.

Oil pressure gauge.

Interstage air pressure relief valve (2-stagemodels only).

Delivery manifold/pulsation vessel.

Air governor.

Safety devices.

Low oil pressure.

On low pressure (single stage) models theinstrument panel carries only two gauges showingdelivery air pressure and oil pressure respectivelyand the safety switch gives protection against lowoil 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-vibrationmountings) and Vee-belt drive.

Control panel.

Acoustic enclosure.

Air receiver.

Refrigerant air dryer.

Air filter.

Non-return valve (desirable in multipleinstallations).

2. GUIDELINES

Before despatch from the factory all compressorsare inhibited against the effects of moisture. If allblanking covers and protective tapes remain secureand undamaged the effective life of this process is12 months from the date shown on the test cardwith the machine.

In the case of oil-free compressors, one deliveryvalve is removed from each cylinder head and adesiccant bag put in its place. The loose valves arewrapped and placed inside the distance pieces forshipping.

It is unnecessary under normal conditions toconstruct a special foundation for the compressor.The usual standards and limits of building designare adequate to allow the compressor to be placeddirectly on the floor, but the floor must have aloading capacity sufficient to support the weight(see 'Leading Particulars').

The anti-vibration mountings MUST NOT be removedand solid mountings substituted, as this will placeundue stress on the compressor.

Air and water pipework should preferably befabricated in galvanised steel to prevent corrosion.

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page 21

V100-VL400 User Manual – Installation

The only connections required to the compressorare as follows:

1. Air delivery outlet to the aftercooler/receiver.

2. Electrical power supply to drive motor: 3-phase plus earth.

3. Electrical connections to the safety switch.

4. Air pipe from the air governor to the receiver.

5. Cooling water pipes (water cooled intercooler/aftercooler models only).

6. Condensate drain to the users disposalsystem.

The compressor should be installed in a cool andclean location and positioned to allow the necessaryaccess and headroom for the removal ofcomponents. A minimum of 1 m all round and clearheadroom of 1.5 m is recommended. Walkways,passages and doorways must not be obstructed.

If the air intake filter is to be installed in a positionremote from the compressor an adaptor for theintake manifold will be required. Consult the localCompAir distributor for advice regarding thedimensions of the extension pipe. If the air intakefilter is to be positioned on the outside of thebuilding it must be protected from the weather.

An air receiver of appropriate size should beinstalled with a manually operated valve between thecompressor and the air receiver. A safety pressurerelief valve must also be fitted between thecompressor delivery outlet and the isolating valve.

Providing the compressor is arranged for normalspeed running, any air pipework between thecompressor delivery flange and the air receiver muston no account be smaller than the delivery flange.

1. Compressor2. Safety Relief Valve3. Non-Return Valve4. Air-Blast Aftercooler

5. Isolating Valve6. Receiver7. By-Pass Valve8. Refrigerant Dryer

TYPICAL INSTALLATION/GENERAL ARRANGEMENT

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When the compressor is piped into an existingrigidly fixed compressed air main the length of pipebetween the compressor delivery flange and thenearest fixed support should be at least 3 m. Thisconnecting pipe must include a 90° bend of 0.3 mminimum radius with a straight vertical length of pipeof at least 1.2 m between the compressor deliveryflange and the bend.

When an aftercooler is installed in a systemincorporating an air receiver, the aftercooler shouldbe between the compressor and the receiver. If anon-return valve is incorporated, this should beupstream of the aftercooler. If the aftercooler ispositioned close to the compressor the connectingpipework will normally be in the form of an inverted Uloop and one vertical leg of the loop must be at least1.2 m in length. The connection between theaftercooler and the air receiver must be arranged asin the previous paragraph.

It is essential that all pipework is made and installedso that it is not constrained or distorted whenconnected to the compressor, aftercooler or user'spipework. Use 90° bends with 0.3 m minimumradius. Do NOT use elbows.

Where the installation includes a water cooledintercooler and/or aftercooler, valves must beinstalled in the water inlet and outlet pipes to allowthe compressor and the aftercooler to be isolatedfrom the water supply. If the compressor is tooperate under automatic start/stop control theisolating valves on the inlet pipes should be solenoidoperated and the solenoids interconnected with thecompressor starter. This will ensure that the watersupply is cut off when the compressor shuts downor is on standby.

If the compressor is operating under air governorcontrol fit 'Iockshield' valves in the water inlet pipesto the intercooler and aftercooler to allow control ofcooling water flow. This is particularly important inmultiple installations.

Where necessary the cooling water system must beprotected to prevent freezing.

If the compressor is connected into a central coolingsystem check that the cooling water is of goodquality.

Whenever cooling towers are used in the watercooling system expert advice must be soughtregarding the precautions to be taken to prevent thedevelopment of harmful bacterial growth which couldcause a health hazard.

On installations equipped with individual coolingtowers the power supply to the water pump and thecooling tower fan must be interlocked with thecompressor starter. The operation of the coolingtower fan should also be controlled by a suitablethermostat fitted in the cooling tower sump.

It is recommended that the pipe from thecondensate valve should lead to the disposalsystem by way of an open drain or tundish so thatvalve operation may be observed.

If an air dryer is installed with the compressor itshould be located downstream of the air receiver.Bypass valves and piping should be fitted so thatthe dryer may be isolated for servicing. If the dryer isof the desiccant type a prefilter and an afterfiltermust be incorporated, particularly if used with alubricated compressor.

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V100-VL400 User Manual – Installation

Room volume Additional area

Model Room volume with aftercooler to inlet opening 7 bar 10.5 bar for aftercooler m3 m3 m2 m2 m2

V100A 29 43 0.45 0.55 0.25V100W 29 - 0.45 0.55 -V100DA 29 43 0.45 0.55 0.25V100DW 29 - 0.45 0.55 -V150A 43 64 0.7 0.8 0.4V150W 43 - 0.7 0.8 -V150DA 43 64 0.7 0.8 0.4V150DW 43 - 0.7 0.8 -V200A 57 85 0.9 1.05 0.5V200W 57 - 0.9 1.05 -V200DA 57 85 0.9 1.05 0.5V200DW 57 - 0.9 1.05 -VL200A 29 57 0.4VL200DA 29 57 0.4V300A 85 128 1.3 1.5 0.8V300W 85 - 1.3 1.5 -V300DA 85 128 1.3 1.5 0.8V300DW 85 - 1.3 1.5 -VL300A 43 85 - - -VL300DA 43 85 - - -VL400A 57 114 - - -VL400DA 57 114 - - -

Total area of ventilation inlet and outlet openings

0.4 (up to 2.5 bar only) 0.4 (up to 2.5 bar only)

3. VENTILATION

In operation the compressor will release heat into the surroundings and therefore the compressor room shouldbe of adequate size and have good ventilation. The recommended minimum sizes of room and ventilationopenings are as below:

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

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4. INSTALLATION PROCEDURE

When using the compressor lifting bracket and themotor eyebolt as the slinging attachment points, itis essential that a spreader of the correct length isused. The lift should always be made vertically asinclined loading severely reduces the safe workingload of the eyebolt. A 16 mm diameter shackle pinis required for V1 00 and V150 units and a 19 mmdiameter shackle pin for V200, V300 and V400units.

When the compressor is in position check that it isclean and undamaged. Check that no blankingcovers and tapes are missing or damaged.

Make sure that the power supply to the compressoris taken from an isolator incorporating suitable highrupture current (HRC) fuses and that the switch islocked 'OFF' and the fuses removed. Connect thepower supply to the compressor drive motor inaccordance with the diagram provided, using cableswhich comply with the standards of the InternationalElectrotechnical Commission (I.E.C.).The cables must be suitably protected andclamped.

Connect the electrical wiring link between the safetyswitch and the motor starter contactor inaccordance with the diagram.

If an airblast aftercooler is installed the electricalwiring for the aftercooler fan motor should beinterlocked with the compressor motor starter or theoptional control panel, if fitted.

Following the guidelines above, make up thenecessary pipes to connect the air delivery flange ofthe compressor to the air receiver or aftercooler butleave the connection open. If appropriate, connectthe aftercooler and intercooler to the water coolingsystem.

Make up and fit a connecting pipe between the airgovernor and the receiver. This pipe should have aminimum internal diameter of 6 mm unless the pipelength is more than 7.5 m, when the minimuminternal diameter should be 9 mm. The pipe shouldbe blown through with compressed air before beingfitted.

On oil-free models fit the delivery valves in thecompressor cylinder heads as follows:

Remove the labelled gauze covers from the distancepieces and take out the wrapped valves from thecavity. Replace the gauze covers.Remove the paper tape from all the gauze covers.

Remove the valve retaining covers from the cylinderheads, withdraw the delivery valve retainers andremove the desiccant bags. Fit the delivery valveson the valve seats, ensuring that the copper jointrings are in place and undamaged.Refit the valve retainers and covers.

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V100-VL400 User Manual

5OPERATION

Page

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

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OPERATION

1. COMMISSIONING/STARTINGPROCEDURES

When commissioning a new compressor or onewhich has been overhauled or out of service for anextended 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 andcorrectly made and comply with the wiringdiagram. In the case of Vee-belt drive, checkthe belts for condition, tension and alignment.

2. Check that all blanking covers and protectivetapes have been removed. With oil-free modelsensure that the delivery valves have been takenfrom their shipping locations inside thedistance pieces and fitted in the cylinderheads.

3. Check that all air intake piping is clean, freefrom corrosion and contains no loose debris.

Note: If the main air system is being used tosupply delicate instrumentation it ispermissible, for the initial run only, to fit gauzefilters in the air intake line and the downstreamline from the receiver to trap small particleswhich may be present, particularly in extendedintake lines. Ensure that all gauze filters areremoved on completion of the initial run. Donot connect the delivery manifold flange to thepipework at this stage. The initial run will allowthe cylinder inhibitor, which is slightly toxic, todisperse without entering the user’s pipework.

4. Fit the air intake silencer/filter assembly.

5. If the compressor has been in storage for alengthy period, remove all suction and deliveryvalves and inspect to ensure that they are ingood condition.

6. Check that ambient temperatures are withinlimits and that ventilation of the compressor issatisfactory.

7. Check that the cooling water supply isadequate and clean and that any watertreatment equipment is in order.

8. Check that the aftercooler and air receiver arecorrectly installed and that the air pressurerelief valves operate correctly.

9. Prime the lubrication system as follows:

Disconnect the oil pipe between the crankcaseand the oil pressure switch at the switch end.Connect a pressure oil can to the free end ofthe pipe. Remove one of the crankcase doorsso that the connecting rods are visible. Withthe recommended oil in the can, pump oil intothe pipe until oil is seen to flow from the smallend bushes. Disconnect the oil can andreconnect the pipe to the oil pressure switch.Refit the crankcase door.

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

Refer to the safety procedures beforeoperating the compressor unit.

WARNING

Lethal voltages are used in this equipment.Use extreme caution when carrying outelectrical checks. Isolate the power supplybefore starting any maintenance work.

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V100-VL400 User Manual – Operation

1.2 Functional Checks

1. Insert the isolator fuses and switch on thepower supply to the compressor.

2. Hand unload each 1st stage cylinder of thecompressor by moving the spring loaded camlevers to the valve unloaded position.

3. Open cooling water valves to water-cooledintercooler and aftercooler, if fitted and openthe intercooler vent/drain cock. Close the cockwhen a full, air-free flow emerges.

4. Check the direction of rotation of the motor byobserving the direction in which the motorkicks over when started. This may beconveniently done by removing the clip-oninspection panel in the top of the flywheelhousing and viewing the drive coupling. Correctrotation is clockwise viewed from the motorend of the compressor, as indicated by thedirection arrow on the housing.

Check for correct rotation of the fan motor onthe air blast aftercooler, if fitted. If rotation isincorrect, stop the compressor immediately,switch off the power supply at the isolator andrectify the cable connections.

5. When the direction of rotation is correct, startthe compressor and allow to run for 10 - 15minutes in the unloaded condition. Check thatthe oil pressure is more than 1.7 bar, settlingto 1.7 bar when the compressor reachesoperating temperature.

6. On lubricated compressors only, close thehand unloaders and run the compressor for afurther 10 - 15 minutes to clear all traces ofinhibitor from the cylinders.

7. Stop the compressor .

8. Connect the air delivery manifold flange to theair receiver.

9. Move the hand unloaders to the valve unloadedposition, start the compressor and when it isrunning evenly close the hand unloaders.

10. Run the compressor on load with a receivervalve open to maintain the running loadedcondition until full operating temperature isreached (approximately 20 minutes from cold).

11 . Check the setting of the switchingthermometers as follows:-

Using the trip needle adjusting knob on theface of each thermometer, set the trip needlesto 15°C above the normal running temperaturesindicated.

Note: The minimum oil pressure switch ispreset at 1 bar and should not requireadjustment.

12. Check the complete installation for leaks andexcessive temperatures.

13. Close the receiver valve and check that thecompressor runs correctly under the influenceof the air governor or pressure switch. Ifadjustment is necessary , refer to sectionbelow headed 'Adjustments'.

14. Run the compressor for 1 hour, checkingcontinually for correct loading and unloading,temperatures and pressures. Recordtemperature and pressure readings to provide abasis for assessing future performance.

1.3 Routine Starting

1.3.1 Air Governor Control

1. Check crankcase oil level.

2. Operate hand unloaders on 1st. stage cylinderheads.

3. Open cooling water flow, if applicable.

4. Switch the power supply 'ON' at the isolatorand operate starter.

5. When the compressor is running steadily,close hand unloaders.

1.3.2 Optional Control Panel

1. Check crankcase oil level.

2. Operate hand unloaders on 1st. stage cylinderheads.

3. Open cooling water valves, if applicable.

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4. Switch power supply on at the isolator .

5. Press 'SET RUN/FAULT RESET' button.

6. Turn selector switch to 'AUTO' or 'HAND' asrequired.

7. When compressor is running steadily, closehand unloaders.

1.4 Adjustments

1.4.1 Air Governor and Optional Control Panel.

If the pressure settings at which the compressorregulation system operates to bring it on-load or off-load require alteration adjustments may be made tothe air governor or the pressure switch, asappropriate. For details of the procedures refer topublications C20160-014 (air governor) orC20160-040 (control panel).

CAUTION: Do not set the high pressure cut outpoint of the regulation system to a higher pressurethan the nominal operating pressure of thecompressor. Operation at higher pressures thannominal will overload the drive motor and may causedamage. Such action may invalidate the Warranty.

1.4.2 Oil Pressure

When the oil pressure is not within the correct limitsit should be adjusted as follows:

Remove the cap nut and locknut on the side of theoil pump and turn the adjusting screw clockwise toincrease the oil pressure and counter-clockwise toreduce the oil pressure.

If the pressure is too low and cannot be correctedby utilising the full adjustment, check the followingpossible causes:

1. Insufficient oil in the crankcase.

2. Dirty oil suction strainer.

3. Dirt under ball valve.

4. Gauge faulty.

5. Pipe connections loose.

6. Excessive bearing clearance.

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V100-VL400 User Manual

6MAINTENANCE

Page

Routine MaintenanceCleanliness 30Recording Pressures and Temperatures 30Maintenance Record 30Pressure Settings 30Electrical Connections 30Leaks 31Regular Checks 31Lubricating Oil 31

Maintenance Schedule 31

Maintenance Parts (Two Years Operation) 34

Maintenance Procedures 35Lubrication System 35Air Intake Filter 36

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MAINTENANCE

1. ROUTINE MAINTENANCE

To ensure the efficient operation of the compressorinstallation the user must check performanceregularly and carry out the necessary adjustmentsto maintain correct settings. This section gives theinformation needed by the user for this purpose.

Personnel accustomed to servicing and maintainingmechanical equipment should have no difficulty incarrying out these tasks but if assistance is neededthe user should refer to the local CompAirDistributor .

Routine maintenance and regular servicing must becarried out as recommended in the 'MaintenanceSchedule'.

A condition of the Warranty cover is that the usermust ensure that the compressor and auxiliaryequipment are properly maintained and adjusted,that all checks and services listed in the Scheduleare carried out at the specified intervals and anaccurate record is kept of the work.

1.1 Cleanliness

The installation must be kept in clean condition atall times. Inspect regularly for signs of damage,excessive wear and security of fittings. Ensure thatany oil spillage is wiped up immediately and anyresidual oil cleaned from external surfaces.

1.2 Recording Pressures and Temperatures

Keep a regular daily record of operating pressuresand temperatures. The readings should be takenwhen conditions are stable and with the compressorrunning on full load.

1.3 Maintenance Record

Keep a careful record of all servicing, maintenanceand repair work carried out on the compressor. Therecord will form a useful reference and any variationfrom normal operation will be noticeableimmediately, alerting the user to a possible need forservicing or maintenance. Frequent recurrence of aparticular repair could reveal an unsatisfactoryoperating condition which must be corrected.

1.4 Pressure Settings

Pressure switch settings and adjustments must bemaintained correctly to prevent faults occurringwhich could reduce the efficiency of the compressor.Refer to 'Adjustments' in the 'Operation' section ofthis manual for details.

1.5 Electrical Connections

Avoid damage to electrical wiring when working onthe compressor installation and inspect wires andcables before refitting. Ensure no damage will becaused by chafing or contact with hot surfaceswhen the unit is in service. Do not fasten wiringdirectly to a line carrying fluid.

Refer to the safety procedures before carryingout any maintenance or servicing work on thecompressor unit.

WARNING

Lethal voltages are used in this equipment.Use extreme caution when carrying outelectrical checks. Isolate the power supplybefore starting any maintenance work.

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V100-VL400 User Manual – Maintenance

1.6 Leaks

Inspect the unit for leaks, loose pipe connectionsand dirt build-up prior to carrying out routinemaintenance. Tighten loose connections and repairor replace damaged pipes immediately.

1.7 Regular Checks

The 'Maintenance Schedule' lists the routine checksand services which are important for the efficientrunning of the compressor. The user should ensurethat the Daily and Weekly Checks become anintegral part of planned maintenance, even if themajor servicing work is contracted to a CompAirDistributor.

1.8 Lubricating Oil

It is essential to maintain the correct level of oil andto change the oil completely at the specifiedintervals. Details of the recommended oil are givenin 'Leading Particulars'.

2. MAINTENANCE SCHEDULE

Regular maintenance should be carried out asrecommended in the Schedule below. The Scheduleis appropriate to most normal circumstances but insome instances, changes in detail may be required.The Schedule should always be used as an initialguide, but if experience shows that an alteration isnecessary, advice should be sought from the localCompAir distributor.

The services for lubricated and oil free compressorsare almost identical. Any variations are indicated inthe schedule and should be observed.

Hours Service

2,500 A5,000 A + B7,500 A + C

10,000 A + B12,500 A15,000 A + B + C + D

The above cycle from 2,500 hours should then berepeated.

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

Item Action

Daily checks

Pressure gauges Note/record readings.Thermometers Note/record readings.Condensate drains Check for correct operation.Water cooling system Check water flow.Airblast aftercooler Drain condensate (manual tap).

Weekly checks

Lubrication system Check oil level in crankcase. Top up as necessary.

After first 1000 hours

Water cooled intercooler Examine internally. Clean if required.

Every 2,500 hours (Service A)

Air intake filter Check and clean. Replace if necessary.*Suction and delivery valves Remove, dismantle, clean and inspect.

If necessary replace valve plates.Renew all valve springs.

Unloader valve Inspect diaphragm. Renew if necessary.Air governor Clean and inspect. Renew filter pads if necessary.Lubrication system Drain crankcase oil. Remove and clean oil strainer.

Renew oil filter element. Refill crankcase with new oil.*Low oil pressure/high air Remove and check operation on bench.temperature switchIntercooler Clean externally with low pressure air jet, 0.5 bar

maximum.Aftercooler Clean externally with low pressure air jet, 0.5 bar

maximum.

Every 5,000 hours (Service B)

*Pressure gauges Check calibration.Intercooler Check operation of blowdown valves.Air intake Renew filter element.

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V100-VL400 User Manual – Maintenance

Item Action

Every 7,500 hours (Service C)

*Compressor cylinders Remove cylinder heads and cylinders.*Pistons Check piston ring gaps. Renew rings if necessary.

Inspect small end bushes /gudgeon pins. Renew ifnecessary.Check guide ring 'stand out'. §

*Connecting rods Inspect big end bearings. Renew if necessary.Note: if new big end bearing shells are fitted, the bigend bolts must also be renewed.Check gland packings. Renew if excessive oil is beingpassed. §

Electrical components Inspect starter contacts.Inspect motor for cleanliness.

Check condition of cables and wiring.

Every 15,000 hours (Service D)

*Compressor 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. Renewdrive 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)

Items marked § refer to oil-free compressors only.

'A' Oil Filter Element 1 1 1 1 2nd stage Valve Plates 2 2 4 4 2nd stage Valve Springs 6 6 12 12 1st stage Valve Springs 12 12 24 24 Diaphragms (unloader) 3 3 6 6 Valve Joint Ring 6 6 12 12 Valve Lanterns 'O' Ring 6 6 12 12 Oil Filter Element 1 1 1 1

'B' Air Filter Element 1 1 1 1

'C' §1st stage Guide Ring 1 1 2 2 §1st stage Pressure Ring 1 1 2 2 §2nd stage Guide Ring 1 1 2 2 §2nd stage Pressure Ring 2 2 4 4 §Oil Wiper Ring 2 2 4 4 §Oil Scraper Ring 2 2 4 4 Seal 2 2 4 4

'D' 1st stage Suction Valves 2 2 4 4 1st stage Delivery Valves 2 2 4 4 2nd stage Suction Valves 1 1 2 2 2nd stage Delivery Valves 1 1 2 2 Diaphragms (unloader) 3 3 6 6 Main Bearing Bushes 2 2 2 2 Oil Seals 2 2 2 2 Big End Bearing, Half Liners 4 4 8 8 Big End Bolts 4 4 8 8 Small End Bushes 2 2 4 4 Gudgeon Pins 2 2 4 4 1st stage Piston Rings 2 2 4 4 1st stage Conformable Rings 1 1 2 2 2nd stage Piston Rings 2 2 4 4 2nd stage Conformable Ring 1 1 2 2 Shakeproof Washers 2 2 4 4 Set of Gaskets and 'O' Seals 1 1 1 1 Oil Pump Belt 1 1 1 1

Service Description Quantities required

V100 V150 V200 V300

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V100-VL400 User Manual – Maintenance

4. MAINTENANCE PROCEDURES

The compressor must be stopped.

Remove the oil filler cap, withdraw the dipstick andcheck the level. If topping up is required, pour in theappropriate quantity of the correct oil to bring thelevel up to the 'MAX' mark on the dipstick. Refit theoil filler cap.

4.1.3 To Change the Oil Filter Element

The full-flow oil filter has a disposable cartridge typeelement.

The compressor must be stopped.

1. Remove the old filter element by unscrewing itfrom the housing and discard it.

2. Carefully clean out the filter housing.

3. Apply a light film of oil to the seal of the newelement.

4. To fit the new element, screw it into thehousing until it contacts the gasket and thentighten it a further quarter turn.

4.1 Lubrication System

4.1.1 Recommended Oil

At ambient temperatures from 0° to 30°C, therecommended oil for the 3000 Series V-Compact isShell Corena P68. Where temperatures areconsistently in excess of 30°C, use 100 viscosityrating of the selected brand.

For alternative lubricants consult your localdistributor. In normal circumstances the oil shouldbe changed after every 2,500 hours of service. If thecompressor is operating in adverse conditions, suchas high dust levels or the presence of chemical orother pollutants, more frequent oil changes may benecessary.

4.1.2 To Check the Oil Level

The oil level is indicated on the dipstick housedinside the oil filler tube. The oil level is correct whenit reaches the 'MAX' mark.

Refer to the safety procedures before carryingout any maintenance or servicing work on thecompressor unit.

Lethal voltages are used in this equipment.Use extreme caution when carrying outelectrical checks. Isolate the power supplybefore starting any maintenance work.

Where a maintenance procedure belowincludes the warning 'The compressor mustbe stopped' the following steps must betaken before work is commenced:

1. Close the isolating shut-off valve to thereceiver.

2. Switch the power supply 'OFF' at theisolator.

3. Check that all pressurised air trapped in thesystem is released to atmosphere.

4. Check that all pressure gauges on thedisplay panel register zero.

5. Ensure that the cooling water system hasbeen drained on water cooled models.

6. Check that the drain valve on the deliverymanifold is clear and air pressure released.

7. Open the manual drain cock to ensure thatpressurised air trapped between the firstand second stages has been released.

WARNING

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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 oilwill run freely and carry out any suspendedparticles.

1. Remove the oil filler cap.

2. Place a container beneath the crankcasedrain, remove the drain plug and allow the oil todrain into the container for disposal. Clean andrefit the drain plug.

3. Refit the oil filler cap.

4.2 Air Intake Filter

In normal circumstances the air intake filter elementshould be checked after every 2,500 hours service.If the compressor is operating in adverse conditions,such as high dust levels, more frequent attentionmay be necessary .

4.2.1 To Remove the Air Filter Element

The compressor must be stopped.

1. Unscrew the wingnut or slot-headed nutsecuring the air intake cover and remove thecover.

2. Remove the filter element.

3. Clean out the inside of the intake silencer.

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 cavityof the element, ensuring that the air streampasses through the element from inside tooutside.

2. When all contamination has been removed,inspect the element for cracks, holes or otherdamage by viewing the light from a hand lampthrough the element or holding the element upagainst a light source.

3. If any damage is evident the element must bediscarded and a new one fitted.

4. Re-install the clean/new element in the intakesilencer.

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V100-VL400 User Manual

7FAULT FINDING

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Refer to the safety procedures before carryingout any fault finding investigation on thecompressor unit.

WARNING

Lethal voltages are used in this equipment.Use extreme caution when carrying outelectrical checks. Isolate the power supplybefore starting any maintenance work.

FAULT FINDING

Indication Possible Cause Remedy

Low oil pressure. (1) Low oil level. (1) Check/top up oil.(2) Incorrect grade of oil in (2) Drain crankcase and refill with

crankcase. correct oil.(3) Oil pump drive belt or pulley (3) Check drive belt and pulley.

loose. Rectify or renew as necessary.(4) Oil pressure gauge faulty. (4) Check gauge calibration.

Renew gauge if defective.(5) Incorrect setting of oil (5) Check setting of valve. If

pressure relief valve. necessary remove and cleanBall valve sticking in valve assembly.open position. Check seating. Reset valve.

(6) Clogged oil filter element. (6) Renew oil filter element.(7) Broken or loose connections (7) Check condition of oil pipes

on oil pipework. and filter. Renew if necessary.(8) Oil pump gears faulty. (8) Renew oil pump gears.(9) Worn main bearings. (9) Inspect bearings and small

end bushes. Renew if necessary.

Compressor (1) Inadequate ventilation of (1) Check ventilation meetsoverheating. compressor room. the recommendations in the

'Installation' section of thismanual.

(2) Incorrect positioning of (2) Check positioning meetscompressor or aftercooler. the recommendations in the

'Installation' section of thismanual.

(3) Valves faulty. (3) Remove valves. Inspect valveplates, springs and seats.Check condition of ring joints.Renew as necessary .

(4) Intercooler passages (4) Clean intercooler internally andobstructed (usually only externally.after very long service).

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V100-VL400 User Manual – Fault Finding

Indication Possible Cause Remedy

Compressor (5) Main delivery pipework (5) Remove pipework and inspect.overheating (cont.) blocked or restricted. Rectify if necessary. Check that

bore is of adequate diameter.(6) Faulty unloading (6) Check operation of unloader

(particularly on 2nd stage mechanism. Ensure thatcylinders). 1st stage unloader fork travels its fulltemperature gauge reading distance to open suction valvewill increase when plate completely.compressor is runningunloaded.

Compressor fails to (1) Incorrect setting of governor (1) Adjust settings to achievemaintain working or pressure switch. correct pressure.pressure. (2) Compressor air intake (2) Inspect air intake filter for

blocked or partially cleanliness and serviceability.obstructed. Renew element if necessary.

(3) Faulty unloading preventing (3) Check operation of unloadercompressor from coming mechanism.on load.

(4) Valves faulty. (4) Remove valves. Inspect valveplates, springs and seats.Check condition of ring joints.Renew as necessary.

(5) Leaks in user's pipework. (5) Check for leaks.(6) The air demand of the (6) Check compressor is in good

installation exceeds the condition. (A slow fall in deliveryrating of the compressor. pressure when running on full

load indicates that thecompressor is not large enoughfor the installation).

(7) Compressor running under (7) Check drive motor speed.speed. Rectify as necessary .

(8) Worn or broken piston rings. (8) Inspect piston rings andcylinders.

Interstage pressure (1) 1st stage safety valve faulty. (1) Check setting of safety valve.reading too high Adjust as necessary. Setting(1st stage relief valve should be 3.1 bar.exhausting). (2) 2nd stage valves faulty. (2) Remove valves. Inspect valve

plates, springs and seats.Check condition of ring joints.Renew as necessary.

(3) Intercooler passages (3) Clean intercooler internally andobstructed (usually only externally.after very long service).

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Indication Possible Cause Remedy

Intercooler pressure (1) Air pressure gauge faulty. (1) Check gauge for accuracy.reading low. Renew if necessary.

(2) 1st stage valves faulty. (2) Remove valves. Inspect valveplates, springs and seats.Check condition of ring joints.Renew as necessary.

(3) Compressor air intake (3) Check air intake. Inspect filter.blocked. Clean or renew as necessary.

Intercooler condensate (1) Ball valve faulty . (1) Dismantle condensate valve.valve fails to exhaust. Check condition of ball and

spring. Clean or renew asnecessary . Check for freeoperation.

Excessive carbon (1) Excessive oil consumption. (1) See following action ondeposits in compressor. 'Excessive Oil Consumption'.

(2) Compressor overheating. (2) See previous action onoverheating.

Excessive oil (1) Incorrect oil in crankcase. (1) Drain and refill with correct oil.consumption. (2) Oil level too high. (2) Drain off surplus oil until correct

level shows on dipstick.(3) Worn cylinders and piston (3) Check all piston ring gaps.

rings. Inspect cylinder bores for wear.Renew components as required.

(4) Excessive small end (4) Inspect small end bushesclearance. for wear. Renew if necessary.

Inspect gudgeon pins for wear.

Compressor knocking. (1) Loose flywheel. (Will be (1) Remove flywheel. Check thatheard when compressor is crankshaft and flywheel are noton full load). damaged. Refit flywheel with new

key and tighten retaining bolt tocorrect torque.

(2) Broken valve plates or (2) Remove and inspect valvesprings. plates. Renew as necessary.

(3) Broken valve spring (3) Remove and inspect valvecontacting piston crown. springs. Rectify and renew as

necessary.(4) Worn small end bearings. (4) Remove and inspect bearings.

Renew bearings and fit newgudgeon pins if required.

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V100-VL400 User Manual – Fault Finding

Indication Possible Cause Remedy

Compressor (5) Worn big end bearings. (5) Remove and inspect bearings.knocking (cont.) Renew bearing shells if

necessary.(6) Insufficient clearance (6) Check clearance with lead strip

between piston crown and and if insufficient fit jointcylinder head. 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

THE PRESSURE SYSTEMS SAFETYREGULATIONS 2000

The circuit diagram shown below is provided toassist a 'competent person' in preparing a writtenscheme of examination for a system incorporatingthe air compressor(s).

Note: The intervals between examination andcalibration 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 thecomponent part manufacturer, the Health and SafetyExecutive (H & SE) and the British Compressed AirSociety (BCAS).

1. Intake Air Filter2. Compression Cylinder3. Pulsation Vessel4. Pressure Relief Valve

5. Non-return Valve6. Aftercooler7. Auto Drain Trap

PRESSURE SYSTEM DIAGRAM – 1ST STAGE

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V100-VL400 User Manual – Appendix 1

1. Intake Air Filter2. First Stage Compression Cylinder LP3. Pressure Relief Valve4. Intercooler5. Auto Drain Trap6. Second Stage Compression Cylinder HP

7. Pulsation Vessel8. Pressure Relief Valve9. Non-return Valve10. Aftercooler11. Auto Drain Trap

PRESSURE SYSTEM DIAGRAM – 2ND STAGE

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