CompAir V-Compact Series Manual de usuario
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
FOREWORD
These compressors are intended for compressing atmospheric air
and are not suitable for compressing any other gas. They are
designed and manufactured to give optimum performance, with long
life and reliability.
This manual gives the user all the information required to install,
commission and operate the compressors and carry out the regular
schedules for servicing and maintenance which will ensure the
maximum satisfactory service life.
Servicing facilities and the supply of genuine replacement parts are
provided through a worldwide network of CompAir Distributors,
backed up by the AfterMarket division at Redditch. If replacement
parts are needed, the user should contact the local Distributor in the
first instance.
The information given in this manual was correct at the time of
printing but modifications to parts and procedures may be made
without notice which could affect the servicing requirements of the
compressors. Before any servicing or maintenance work is
undertaken the user is advised to contact the local CompAir
Distributor who is supplied with revised and up-dated information.
In any communication concerning the compressor it is essential to
quote the MODEL and SERIAL NUMBER.
Throughout this manual all pressures quoted are gauge pressure
unless otherwise specified.
page 1
V100-VL400 User Manual
BR1815BA - 08/2004
V100, V150, V200, V300, VL200, VL300 & VL400 AIR COMPRESSORS
Serial Numbers from:
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
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 43
Safety Regulations 2000
CONTENTS
Illustration Page
Typical Installation/General Arrangement 21
Pressure System Diagram - 1 st Stage 44
Pressure System Diagram - 2nd Stage 45
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 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 V300A
V100W to V300W
C20160-1467 VL200A
C20160-1468 VL300A
C20160-1469 VL400A
C20160-1470 VL200DA
C20160-1471 VL300DA
C20160-1472 VL400DA
C20160-1374 V100DA
C20160-1375 V150DA
C20160-1376 V200DA
C20160-1377 V300DA
C20160-1378 V100DW
C20160-1379 V150DW
C20160-1380 V200DW
C20160-1381 V300DW
CompAir Limited
page 4
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.
zThe 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.
zAny 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.
zSuch 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.
WARNING
USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY
COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED
OUT USING NON-GENUINE PARTS.
GENUINE PARTS
AUTHORISED SERVICEAGENTS
USE ONLY
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
1
SAFETY PROCEDURES
CompAir Limited
page 6
1. GENERAL
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. WARNINGS, CAUTIONS AND NOTES
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.
SAFETY PROCEDURES
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 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
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.
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
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
CompAir Limited
page 8
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
80°C 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.
2. 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.
3. 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'
4. Check that all pressurised air trapped in the
system is released to atmosphere. Check that
all pressure gauges on the display panel
register zero.
5. Ensure that the cooling water system has
been drained on water cooled models.
6. Check that the drain valve on the delivery
manifold is clear and air pressure released.
7. Open the manual drain cock to ensure that
pressurised air trapped between the first and
second stages has been released.
8. Stand clear of the valve covers when removing
the securing screws.
Este manual sirve para los siguientes modelos
25
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