User ManualV-Compact Series Stationary Air Compressors Serial numbers from:V100 V150 VL200 VL300 VL200D/V100D VL400D/V300D EO40/0001 EO41/0001 EO42/0001 EO43/0001 EO44/0001 EO55/0001 VL300D/V150D V200 V300 VL400 V200D EO45/0001 EO50/0001 EO51/0001 EO52/0001 EO54/0001 GB BR1815BA - 08/2004 FOREWORD These compressors are intended for compressing atmospheric air and are not suitable for compressing any other gas. They are designed and manufactured to give optimum performance, with long life and reliability. This manual gives the user all the information required to install, commission and operate the compressors and carry out the regular schedules for servicing and maintenance which will ensure the maximum satisfactory service life. Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of CompAir Distributors, backed up by the AfterMarket division at Redditch. If replacement parts are needed, the user should contact the local Distributor in the first instance. The information given in this manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressors. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Distributor who is supplied with revised and up-dated information. In any communication concerning the compressor it is essential to quote the MODEL and SERIAL NUMBER. Throughout this manual all pressures quoted are gauge pressure unless otherwise specified. V100-VL400 User Manual BR1815BA - 08/2004 V100, V150, V200, V300, VL200, VL300 & VL400 AIR COMPRESSORS Serial Numbers from: V100 V150 VL200 VL300 VL200D/V100D VL400D/V300D EO40/0001 EO41/0001 EO42/0001 EO43/0001 EO44/0001 EO55/0001 VL300D/V150D V200 V300 VL400 V200D EO45/0001 EO50/0001 EO51/0001 EO52/0001 EO54/0001 CONTENTS Section 1. Safety Procedures 2. General Description 3. Leading Particulars 4. Installation 5. Operation 6. Maintenance 7. Fault Finding Appendix 1 The Pressure Systems Safety Regulations 2000 Page 5 11 15 19 25 29 37 43 Illustration Typical Installation/General Arrangement Pressure System Diagram - 1 st Stage Pressure System Diagram - 2nd Stage Page 21 44 45 page 1 CompAir Limited OWNERSHIP DATA TECHNICAL DATA Model: Serial Number: Year: Maximum Pressure: kW: Motor rpm: V. Ph. Hz. M /min: 3 Motor Serial Number: Delivery Date: Compressor Lubricant: Lubricant Capacity: Motor Bearing Grease: (If applicable) LOCAL COMPAIR DISTRIBUTOR Name: Address: Telephone: Contact Names: Parts: Service: Fax: page 2 V100-VL400 User Manual ASSOCIATED PUBLICATIONS Title Automatic Air Governor: Regulating Panel Mk. 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 page 3 .5: Repair Manual: Parts Lists: Part No. 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. 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. YOUR WARRANTY COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED OUT USING NON-GENUINE PARTS. WARNING The use of replacement parts or lubricating oils not supplied or approved by CompAir may lead to failures in service which would not be covered by warranty. Such hazardous conditions may lead to accidents that can be life threatening. The use of replacement parts not supplied or approved by CompAir may create hazardous conditions over which CompAir has no control. Any unauthorised modifications or failure to maintain this equipment in accordance with the maintenance instructions may make it unsafe. If any replacement or repair is needed use only CompAir Genuine Parts. cause substantial bodily injury or result in damage to the equipment. page 4 .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. V100-VL400 User Manual 1 SAFETY PROCEDURES Page General Warnings. Cautions and Notes General Safety Precautions Installation Precautions Operational Precautions Maintenance and Repair Precautions Precautions in the Event of Fire 6 6 7 7 7 8 9 page 5 . The WARNINGS in this manual are therefore not all-inclusive. An accident can often be avoided by recognising a situation that is potentially hazardous. 2. and to the Regulations of the Institution of Electrical Engineers. 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. CompAir cannot anticipate every possible circumstance which might represent a potential hazard.2 Cautions Incorrect operational procedures causing possible damage to the compressor unit are identified by a 'CAUTION' in the text of this manual.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. When handling. Failure to observe the precautions given under 'Safety Procedures' may be considered dangerous practice or misuse of the compressor unit. 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. WARNINGS.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. 2. GENERAL 2. 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. 1974. page 6 .CompAir Limited SAFETY PROCEDURES 1. The attention of users in the UK is drawn to the Health and Safety at Work Act. If the user employs an operating procedure. WARNING: RISK OF DANGER WARNING: RISK OF ELECTRIC SHOCK WARNING: RISK OF HIGH PRESSURE WARNING: CONSULT MANUAL 2. The compressor unit must only be operated by competent personnel under a qualified supervisor. Never direct compressed air onto your skin or at other people. INSTALLATION PRECAUTIONS Ensure that the air delivery pipe from the compressor to the user's pipework aftercooler. In addition. Cables. 4. it may be necessary to install shut-off valves elsewhere in the system to allow a dryer or other equipment to be bypassed. chains or ropes must never be applied directly to lifting eyes. Do not open the starter compartment or touch page 7 . Arrange lifting cables so that there are no sharp bends. eyes and shackles. The compressor must only be operated at the supply voltage and/or frequency for which it is designed. Non-return valves must not be relied upon for isolating parts of the pressure system. GENERAL SAFETY PRECAUTIONS If using compressed air for cleaning purposes. properly positioned. Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary. CompAir strongly advise against the use of water cooling tower systems for water cooled compressors. Do not run the compressor with covers removed. A safety relief valve must be installed between any compressor unit and the shut-off valve/s. Never use compressed air to clean loose dirt from clothing. or receiver is free to expand and that no flammable material is within the vicinity. Before releasing compressed air through a hose make sure that the free end is held securely so that it cannot whip and cause injury. When mains power is switched on. A fused isolating switch must be fitted between the main power supply and the compressor. Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into the air intake. 5. Never remove or tamper with the safety devices. 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. In order to control the risk of Legionnaires Disease. Use a spreader bar to avoid side loads on hooks. A shut-off valve must be fitted in the delivery air line to enable the compressor unit to be isolated. They must be tested and approved according to local safety regulations. ensure safety regulations are complied with and appropriate clothing and eye protection is worn. Always use an appropriate shackle or hook. When a load is on a hoist stay clear of the danger area beneath and around it. since this could cause an internal fire or explosion. Check that all chains. Ensure that air drawn into the air intake will not be contaminated with flammable fumes or vapours. when installed downstream of the unit. OPERATIONAL PRECAUTIONS Installation work must only be carried out by competent personnel under a qualified supervisor. hooks. A closed circuit radiator system is preferred (see Bulletin CBB 2083).V100-VL400 User Manual – Safety Procedures 3. shackles and slings are in good condition and are of the correct capacity . or equipment containing air at above atmospheric pressure. Avoid injury by using a hoist to lift heavy loads. This is particularly important if more than one unit is to be coupled in parallel or connected to an existing air supply system. A pressure relieving device must be fitted to every pressure vessel. guards or insulation materials fitted to the unit. A safety relief valve is fitted on the reclaimer vessel as standard equipment. if fitted. Stand clear of the valve covers when removing the securing screws. Parts of the compressor. Open the manual drain cock to ensure that pressurised air trapped between the first and second stages has been released. tests or adjustments. attach a sign stating 'THIS UNIT MAY START WITHOUT WARNING' next to the display panel. take adequate precautions to make sure there is no one checking or working on the unit before attempting to switch on remotely controlled equipment. Beware of burns from hot metal parts. carry out the following preparatory operations:1. 3. Be aware that high noise levels can interfere with communication. Ensure that the cooling water system has been drained on water cooled models. If the unit is equipped with a Remote Control device. Do not switch on electrical power or attempt to start the unit if a warning label is attached.CompAir Limited electrical components while voltage is applied unless it is necessary for measurements. As a further safeguard. Check that all pressure gauges on the display panel register zero. Close the isolating valve between the compressor unit and the users pipework. 6.DO NOT OPEN' Check that all pressurised air trapped in the system is released to atmosphere. Attach a label to each valve carrying the warning 'WORK IN PROGRESS . 4. If there is any indication that the compressor is overheating it must be shut down and the cause investigated. 2. repairs or modifications must only be carried out by competent personnel under a qualified supervisor. Lock the isolator in the 'OFF' position and remove the fuses. 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. 5. attach warning notices stating 'THIS UNIT CAN BE STARTED REMOTELY' in prominent locations. or dismantling any part of the unit.DO NOT APPLY VOLTAGE'. Such work should be carried out only by a qualified electrician equipped with the proper tools and wearing appropriate body protection against electrical hazards. hot oil and water when working on a unit which has recently been shut down. 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. The compressor must not be operated in ambient temperatures outside of those given under 'Leading Particulars'. If replacement parts are needed use only CompAir Genuine Parts. The compressor must not be operated at pressures above the nominal pressure given on the data plate. 6. 7. The 'Noise at Work Regulations 1989' suggest that ear protectors should be worn where noise levels are 85 dB(A) or higher. Attach a 'CHECK THAT ALL PERSONNEL ARE CLEAR OF THE UNIT BEFORE STARTING' or similar warning notice to the remote start equipment. 8. the other inside the control compartment. Before removing any panels from the enclosure. Close the isolating valve in the cooling water inlet pipe. MAINTENANCE AND REPAIR PRECAUTIONS Maintenance. Isolate the compressor unit from the main electrical power supply. Attach a label to the isolator switch and display panel carrying the warning 'WORK IN PROGRESS . On a unit equipped with an Automatic Start/Stop system. page 8 . Check that the drain valve on the delivery manifold is clear and air pressure released. one on the outside of the unit. On a unit equipped with an Automatic Restart device. Before dismantling of any part of the compressor unit ensure that all heavy movable parts are secured. electrical and regulation components against the entry of moisture. Make sure that the selected lubricants comply with all relevant safety regulations. or close to a component which may contain 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. page 9 . Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit. Ensure that water and soap are readily available. filter elements. 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. When disposing of condensate. The accuracy of pressure and temperature gauges and switching thermometers must be regularly checked.g. 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. Some components may contain fluoroelastomer materials which decompose under these conditions to form highly corrosive residues. PRECAUTIONS IN THE EVENT OF FIRE Use extreme caution when handling components that have been subjected to fire or very high temperatures. with all accessories and safety devices. Precautions must be taken when carrying out welding or any repair operation which generates heat. Protection devices must be tested as described in the 'Maintenance' section of this manual. If chlorinated hydrocarbon nonflammable fluids are used for cleaning. nose and throat. preferably by steam cleaning. air intake. These materials cause irritation and are corrosive to the skin. when steam cleaning. Protect the motor. Do not use carbon tetrachloride. is kept in good running order . safety precautions must be taken against any toxic vapours which may be released.V100-VL400 User Manual – Safety Procedures Use only lubricating oils and greases approved by CompAir. 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. loose items or rags are left on or inside any part of the machine. flames or sparks. Keep the compressor unit clean at all times. Do not use any flammable liquid to clean valves. e. air pipes or any component carrying a flow of air during normal operation. eyes. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage. In no circumstances must any welding work or other modification be carried out on the reclaimer or any other pressure vessel. old oil. Protect the environment by using only approved methods of disposal. the system must first be thoroughly purged. cooler air passages. 7. alkalis and chemical detergents for cleaning machine parts and components. Protect components and exposed openings by covering with clean cloth or tape during maintenance and repair work. After completion of repair or maintenance work ensure that no tools. Never use a light source with an open flame to inspect any part of the unit. Avoid splashes and wear suitable protective clothing and goggles. Precautions must be taken when using acids. Do not breathe mists. They must be renewed when acceptable tolerances are exceeded. CompAir Limited page 10 . V100-VL400 User Manual 2 GENERAL DESCRIPTION Page Compressor Safety Devices Instrument Panel Lubrication System Regulation System Air Governor Control Control Panel 12 12 12 12 13 13 13 page 11 . The cylinders. An interstage safety valve provides protection to the 1 st stage pressure system. 2. The cylinders and cylinder heads are furnished with cooling fins. 3. 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 2nd stage pistons are fitted with two pressure rings and one guide ring. 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. 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. page 12 . Each 1st stage piston of the oil-free compressors carries a single two-piece pressure ring and one guide ring. two switching thermometers and an oil pressure gauge. 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. Two switching thermometers protect the compressor against high 1 st stage and 2nd stage air temperature. each crankpin carrying two forged steel connecting rods on plain steel backed aluminium/tin big-end bearings. The delivery manifold is designed as a pulsation vessel to minimise valve pressure peaks in the air delivery pipe to the aftercooler or receiver . crankcase and air-cooled intercoolers are cooled by air blast from a cowled fan fitted on the non-drive end of the crankshaft. All the rings are of PTFE. Each piston is driven by a rod attached to a crosshead carried on the connecting-rod small end. The standard compressors have a safety switch mounted on the crankcase which operates to shut down the compressor if oil pressure falls too low. On low pressure models the panel carries a delivery air pressure gauge and an oil pressure gauge. 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. LUBRICATION SYSTEM An externally-mounted gear type pump is belt driven from the fan end of the crankshaft. 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. An adjustable pressure relief valve is incorporated in the pump and a dipstick is fitted in the crankcase oil filler tube. Two-stage compressors are fitted with an air-cooled or water-cooled intercooler. The counterbalanced crankshaft has either one or two crankpins. The standard version has two compression stages while the Low Pressure version is a single-stage machine. INSTRUMENT PANEL On standard machines an instrument panel mounted on the compressor carries 1 st stage and 2nd stage air pressure gauges.CompAir Limited GENERAL DESCRIPTION 1. On low pressure versions the safety switch provides protection against low oil pressure and high air temperature. 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. These compressors are available in 'oil-free' or 'lubricated' versions. 4. allowing the solenoid valve to close and the unloaders to release the suction valves. Selector switch in 'HAND' position: The compressor starts and then runs continuously.V100-VL400 User Manual – General Description 5. The compressor then comes on load. The compressor continues to run. The compressor continues to run off-load for the time period set by the run-on timer.2 Control Panel The optional wall-mounted control panel incorporates a pressure switch.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. 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. 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. The unloader forks are actuated by the regulation system to provide the required control of the compressor. The panel carries a 'HAND/OFF/AUTO' selector switch. Refer to Publication C20160-014 for details of the Air Governor. runon timer and a solenoid timer. 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. It operates in conjunction with a separately mounted automatic contactor type starter for the compressor. 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. 5. the switch opens. page 13 . The panel can also control a stand-by compressor or a multiple installation. 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. When the air pressure in the receiver falls to the pre-set level the unloaders are released. The air governor also operates a valve in the base of the intercooler to drain accumulated condensate and relieve interstage pressure. responding to system air demand by unloading at the upper pressure switch setting and loading at the lower pressure switch setting. Refer to Publication C20160-040 for details of the Control Panel. The normal method of regulation is by Air Governor Control. The unloaders may also be operated manually to enable the compressor to be started up initially in an off-load condition. but in the unloaded condition. solenoid valve. 5. If the pressure rises to the set point of the governor the valve unloaders are operated. It will re-start automatically when receiver pressure falls sufficiently to operate the pressure switch. allowing the suction valves to close and the compressor comes on load. The unloader solenoid valve in the control panel also operates the intercooler condensate drain/ pressure relief valve. If receiver pressure falls during this period to the lower setting of the pressure switch. Selector switch in' AUTO' position: The compressor starts when receiver pressure is less than the low setting of the pressure switch. CompAir Limited page 14 . V100-VL400 User Manual 3 LEADING PARTICULARS page 15 . 3 mm 133.3 mm 98.1 bar VL200A-F2 VL300A-F2 VL400A-F2 maximum: Motor rotation: 7 bar 3. viewed from motor end.4 bar All Models: Clockwise. single acting A Air-cooled V 0°C 55°C All Models: 1. 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.500 rev/min VL 1.4 mm 8.5 mm V150/V300 222.CompAir Limited LEADING PARTICULARS Note: There are detail differences depending on the compressor concerned. single acting W Water-cooled VL 0°C 50°C page 16 .3 bar VL 1-Stage.5 mm VL300 222.5 bar VL200DA-F2 VL300DA-F2 VL400DA-F2 2.3 mm 85.4 mm 98.9 mm 114.6 bar V 2-Stage.4 bar V300DA-F3 only All other V-F3 models 10.9 mm 85. Model: Type: Model: Intercooler: Ambient Temperature: minimum: maximum: Running speed: normal : maximum: Working pressure: minimum: Working pressure: V-F2 V 4. Cylinder bore: 1st stage: 2nd stage: Piston stroke: V100/V200 196.460 rev/min 1 .4 mm VL200/VL400 196. 2 bar V200/V300 2.4-2.5 kW 22kW VL200A (1. maximum: V100W/V150W Cooling water flow.7 bar) VL400DA V300 55kW 63kW VL400A (2.5 bar) V300W 14 litres/min 4.3-3.5 litres/min All water-cooled intercooler models Motor rating VL Models: 22kW 30kW 37kW 45kW page 17 . nominal: Intercooler water connections: V100 Motor rating suffix F2: suffix F3: 18.7 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.8 bar VL200/VL300 4 inch VL400 4 inch (>2 bar) 5 inch (<2 bar) 2.8 bar V200W 9 litres/min G1/ 2 A V200 37kW 45kW VL300A VL300DA VL400A (1.5 bar) VL200DA All other models 9 litres All other 2-stage models 1.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: 1.5 inch 2 inch 4.4-2 bar) V150 30kW 37kW VL200A (2-3. CompAir Limited LEADING PARTICULARS (cont’d) Weights. Kg: V100DW Without motor: With motor (F2): With motor (F3): Without motor With motor (F2): With motor (F3): Without motor: With motor (lower range): With motor (higher range): 503 641 720 V200DW 808 1092 1151 V100W 421 550 593 V200W 644 875 913 V100DA 506 655 724 V200DA 898 1130 1168 VL200DA 544 717 V100A 455 581 622 V200A 705 937 975 VL200A 442 615 635 V150DW 509 745 793 V300DW 850 1245 1418 VL300DA 549 780 V150W 421 620 658 V300W 686 1017 1121 VL300A 445 678 V150DA 513 748 796 V300DA 900 1232 1345 VL400DA 852 1108 V150A 494 687 728 V300A 707 1038 1150 VL400A 658 928 989 page 18 . V100-VL400 User Manual 4 INSTALLATION Page General Guidelines Ventilation Installation Procedure 20 20 23 24 page 19 . Before despatch from the factory all compressors are inhibited against the effects of moisture. page 20 . If all blanking covers and protective tapes remain secure and undamaged the effective life of this process is 12 months from the date shown on the test card with the machine. Acoustic enclosure.Use extreme caution when carrying out electrical checks. Lethal voltages are used in this equipment. The usual standards and limits of building design are adequate to allow the compressor to be placed directly on the floor. Starter. Baseplate (with or without anti-vibration mountings) and Vee-belt drive. Control panel. but the floor must have a loading capacity sufficient to support the weight (see 'Leading Particulars'). Interstage air pressure relief valve (2-stage models only). Air filter. Aftercooler (air. Delivery manifold/pulsation vessel. Safety devices. Oil pressure gauge. Air receiver.CompAir Limited INSTALLATION WARNING Refer to the safety procedures before installation of the compressor unit. as this will place undue stress on the compressor. air. one delivery valve is removed from each cylinder head and a desiccant bag put in its place.or water-cooled (two-stage units only). 2.or water-cooled). In the case of oil-free compressors. Diesel engine. The anti-vibration mountings MUST NOT be removed and solid mountings substituted. Steam turbine. Isolate the power supply before starting any maintenance work. Refrigerant air dryer. Air governor. Instrument panel carrying: 1st and 2nd stage air pressure gauges. It is unnecessary under normal conditions to construct a special foundation for the compressor. The following optional equipment is available: Flange mounted electric motor. Air and water pipework should preferably be fabricated in galvanised steel to prevent corrosion. GENERAL Standard V-Compact compressors are supplied with the following equipment: Intercooler. Two air temperature switching thermometers. The loose valves are wrapped and placed inside the distance pieces for shipping. Low oil pressure. On low pressure (single stage) models the instrument panel carries only two gauges showing delivery air pressure and oil pressure respectively and the safety switch gives protection against low oil pressure and high air temperature. Non-return valve (desirable in multiple installations). GUIDELINES 1. Refrigerant Dryer TYPICAL INSTALLATION/GENERAL ARRANGEMENT The only connections required to the compressor are as follows: 1. 2. The compressor should be installed in a cool and clean location and positioned to allow the necessary access and headroom for the removal of components. Providing the compressor is arranged for normal speed running. Non-Return Valve 4. Isolating Valve 6. If the air intake filter is to be installed in a position remote from the compressor an adaptor for the intake manifold will be required. 3. passages and doorways must not be obstructed. A minimum of 1 m all round and clear headroom of 1. If the air intake filter is to be positioned on the outside of the building it must be protected from the weather. Walkways. An air receiver of appropriate size should be installed with a manually operated valve between the compressor and the air receiver. any air pipework between the compressor delivery flange and the air receiver must on no account be smaller than the delivery flange. By-Pass Valve 8. 6. 4. A safety pressure relief valve must also be fitted between the compressor delivery outlet and the isolating valve. Air delivery outlet to the aftercooler/receiver.5 m is recommended. Electrical power supply to drive motor: 3-phase plus earth. Compressor 2. Receiver 7. 5. page 21 . Air-Blast Aftercooler 5. Air pipe from the air governor to the receiver. Electrical connections to the safety switch. Consult the local CompAir distributor for advice regarding the dimensions of the extension pipe.V100-VL400 User Manual – Installation 1. Cooling water pipes (water cooled intercooler/ aftercooler models only). Condensate drain to the users disposal system. Safety Relief Valve 3. This connecting pipe must include a 90° bend of 0. Where necessary the cooling water system must be protected to prevent freezing. If the dryer is of the desiccant type a prefilter and an afterfilter must be incorporated. valves must be installed in the water inlet and outlet pipes to allow the compressor and the aftercooler to be isolated from the water supply. The operation of the cooling tower fan should also be controlled by a suitable thermostat fitted in the cooling tower sump. the aftercooler should be between the compressor and the receiver. If the compressor is to operate under automatic start/stop control the isolating valves on the inlet pipes should be solenoid operated and the solenoids interconnected with the compressor starter. page 22 . Bypass valves and piping should be fitted so that the dryer may be isolated for servicing. Whenever cooling towers are used in the water cooling system expert advice must be sought regarding the precautions to be taken to prevent the development of harmful bacterial growth which could cause a health hazard. this should be upstream of the aftercooler. If the compressor is connected into a central cooling system check that the cooling water is of good quality. particularly if used with a lubricated compressor.3 m minimum radius. It is recommended that the pipe from the condensate valve should lead to the disposal system by way of an open drain or tundish so that valve operation may be observed.3 m minimum radius with a straight vertical length of pipe of at least 1.CompAir Limited When the compressor is piped into an existing rigidly fixed compressed air main the length of pipe between the compressor delivery flange and the nearest fixed support should be at least 3 m.2 m between the compressor delivery flange and the bend. It is essential that all pipework is made and installed so that it is not constrained or distorted when connected to the compressor. Use 90° bends with 0. If the aftercooler is positioned close to the compressor the connecting pipework will normally be in the form of an inverted U loop and one vertical leg of the loop must be at least 1. If a non-return valve is incorporated. If the compressor is operating under air governor control fit 'Iockshield' valves in the water inlet pipes to the intercooler and aftercooler to allow control of cooling water flow.2 m in length. If an air dryer is installed with the compressor it should be located downstream of the air receiver. The connection between the aftercooler and the air receiver must be arranged as in the previous paragraph. On installations equipped with individual cooling towers the power supply to the water pump and the cooling tower fan must be interlocked with the compressor starter. aftercooler or user's pipework. This is particularly important in multiple installations. Where the installation includes a water cooled intercooler and/or aftercooler. When an aftercooler is installed in a system incorporating an air receiver. Do NOT use elbows. This will ensure that the water supply is cut off when the compressor shuts down or is on standby. 4 0.5 bar m 2 Additional area to inlet opening for aftercooler m 0.5 1.25 0.55 0.4 0.8 1.05 0.45 0.8 2 with aftercooler m 43 64 64 85 85 57 57 128 128 85 85 114 114 3 m 2 29 29 29 29 43 43 43 43 57 57 57 57 29 29 85 85 85 85 43 43 57 57 43 0.5 0.4 0.3 1.05 1.55 0.55 0. page 23 .7 0.45 0.4 (up to 2.9 0.3 1. The recommended minimum sizes of room and ventilation openings are as below: Total area of ventilation Room volume Model Room volume m V100A V100W V100DA V100DW V150A V150W V150DA V150DW V200A V200W V200DA V200DW VL200A VL200DA V300A V300W V300DA V300DW VL300A VL300DA VL400A VL400DA 3 inlet and outlet openings 7 bar 10.8 0.05 1.7 0.4 0.V100-VL400 User Manual – Installation 3. VENTILATION In operation the compressor will release heat into the surroundings and therefore the compressor room should be of adequate size and have good ventilation.5 1.7 0.05 1.55 0.5 1.9 0.5 0.9 0.25 0.8 0.3 1.7 0.5 bar only) 1.5 - If any difficulties are anticipated or if there are space limitations on site consult the local CompAir distributor before installation is commenced.4 (up to 2.5 bar only) 0.3 1.8 0.8 0.45 0.9 0.45 0. A 16 mm diameter shackle pin is required for V1 00 and V150 units and a 19 mm diameter shackle pin for V200. Fit the delivery valves on the valve seats. if fitted. it is essential that a spreader of the correct length is used. Connect the electrical wiring link between the safety switch and the motor starter contactor in accordance with the diagram. On oil-free models fit the delivery valves in the compressor cylinder heads as follows: Remove the labelled gauze covers from the distance pieces and take out the wrapped valves from the cavity.CompAir Limited 4.E. Connect the power supply to the compressor drive motor in accordance with the diagram provided. If an airblast aftercooler is installed the electrical wiring for the aftercooler fan motor should be interlocked with the compressor motor starter or the optional control panel. make up the necessary pipes to connect the air delivery flange of the compressor to the air receiver or aftercooler but leave the connection open. The pipe should be blown through with compressed air before being fitted.5 m. Replace the gauze covers. Make sure that the power supply to the compressor is taken from an isolator incorporating suitable high rupture current (HRC) fuses and that the switch is locked 'OFF' and the fuses removed.). If appropriate. This pipe should have a minimum internal diameter of 6 mm unless the pipe length is more than 7. INSTALLATION PROCEDURE When using the compressor lifting bracket and the motor eyebolt as the slinging attachment points. When the compressor is in position check that it is clean and undamaged. Check that no blanking covers and tapes are missing or damaged. connect the aftercooler and intercooler to the water cooling system. using cables which comply with the standards of the International Electrotechnical Commission (I. Following the guidelines above. V300 and V400 units. Refit the valve retainers and covers. Make up and fit a connecting pipe between the air governor and the receiver. when the minimum internal diameter should be 9 mm. The cables must be suitably protected and clamped. Remove the valve retaining covers from the cylinder heads. page 24 . ensuring that the copper joint rings are in place and undamaged. The lift should always be made vertically as inclined loading severely reduces the safe working load of the eyebolt. Remove the paper tape from all the gauze covers. withdraw the delivery valve retainers and remove the desiccant bags.C. V100-VL400 User Manual 5 OPERATION Page Commissioning/Starting Procedures Static Checks Functional Checks Routine Starting Adjustments 26 26 27 27 28 page 25 . 5. tension and alignment. Remove the oil filler cap and pour in the correct quantity of the recommended oil (9 or 18 litres. Refit the oil filler cap. If the compressor has been in storage for a lengthy period. 3. Check that all air intake piping is clean. 1. 10. 6. particularly in extended intake lines. Remove one of the crankcase doors so that the connecting rods are visible. 9. Check that all blanking covers and protective tapes have been removed. Ensure that all gauze filters are removed on completion of the initial run. Refit the crankcase door. for the initial run only. to fit gauze filters in the air intake line and the downstream line from the receiver to trap small particles which may be present. 2. depending on model). Note: If the main air system is being used to supply delicate instrumentation it is permissible. In the case of Vee-belt drive. page 26 . 8. check the belts for condition. The initial run will allow the cylinder inhibitor. 1. which is slightly toxic. Check that the cooling water supply is adequate and clean and that any water treatment equipment is in order.1 Static Checks 1. Connect a pressure oil can to the free end of the pipe. COMMISSIONING/STARTING PROCEDURES 4.CompAir Limited OPERATION WARNING Refer to the safety procedures before operating the compressor unit. free from corrosion and contains no loose debris. to disperse without entering the user’s pipework. Fit the air intake silencer/filter assembly. Prime the lubrication system as follows: Disconnect the oil pipe between the crankcase and the oil pressure switch at the switch end. pump oil into the pipe until oil is seen to flow from the small end bushes. Disconnect the oil can and reconnect the pipe to the oil pressure switch. Check that the aftercooler and air receiver are correctly installed and that the air pressure relief valves operate correctly. Check that ambient temperatures are within limits and that ventilation of the compressor is satisfactory. With the recommended oil in the can. 7. Check that the isolator switch is locked 'OFF' and that all electrical connections are tight and correctly made and comply with the wiring diagram. With oil-free models ensure that the delivery valves have been taken from their shipping locations inside the distance pieces and fitted in the cylinder heads. When commissioning a new compressor or one which has been overhauled or out of service for an extended period. Isolate the power supply before starting any maintenance work. carry out the following procedure. Check that the oil level is at the maximum level on the dipstick. Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Do not connect the delivery manifold flange to the pipework at this stage. remove all suction and delivery valves and inspect to ensure that they are in good condition. 2. Check crankcase oil level. When the compressor is running steadily. Correct rotation is clockwise viewed from the motor end of the compressor. air-free flow emerges. Open cooling water valves. Stop the compressor . stage cylinder heads. Run the compressor on load with a receiver valve open to maintain the running loaded condition until full operating temperature is reached (approximately 20 minutes from cold).3 Routine Starting 1.15 minutes in the unloaded condition.2 Functional Checks 1. 1. 1. 9. 11 . 6. Check crankcase oil level. temperatures and pressures. Check for correct rotation of the fan motor on the air blast aftercooler. if applicable. 4. refer to section below headed 'Adjustments'. Open cooling water valves to water-cooled intercooler and aftercooler. if fitted and open the intercooler vent/drain cock. This may be conveniently done by removing the clip-on inspection panel in the top of the flywheel housing and viewing the drive coupling. 3.V100-VL400 User Manual – Operation 1.3. as indicated by the direction arrow on the housing. checking continually for correct loading and unloading.1 Air Governor Control 1. if fitted. 2. When the direction of rotation is correct. switch off the power supply at the isolator and rectify the cable connections. Check that the oil pressure is more than 1. Note: The minimum oil pressure switch is preset at 1 bar and should not require adjustment. close hand unloaders. 12. 7.3.7 bar. 10. Switch the power supply 'ON' at the isolator and operate starter. If adjustment is necessary . Connect the air delivery manifold flange to the air receiver. Operate hand unloaders on 1st. 3. 5. Insert the isolator fuses and switch on the power supply to the compressor. stop the compressor immediately. 8. Close the cock when a full. 3. Check the setting of the switching thermometers as follows:Using the trip needle adjusting knob on the face of each thermometer.15 minutes to clear all traces of inhibitor from the cylinders. 5. Check the complete installation for leaks and excessive temperatures. if applicable. 2. Open cooling water flow. On lubricated compressors only. Run the compressor for 1 hour. settling to 1. Move the hand unloaders to the valve unloaded position. close the hand unloaders and run the compressor for a further 10 . start the compressor and allow to run for 10 . Check the direction of rotation of the motor by observing the direction in which the motor kicks over when started. 14. If rotation is incorrect. stage cylinder heads. Record temperature and pressure readings to provide a basis for assessing future performance. page 27 . Close the receiver valve and check that the compressor runs correctly under the influence of the air governor or pressure switch.7 bar when the compressor reaches operating temperature. set the trip needles to 15°C above the normal running temperatures indicated. Operate hand unloaders on 1st. 13.2 Optional Control Panel 1. Hand unload each 1st stage cylinder of the compressor by moving the spring loaded cam levers to the valve unloaded position. 4. start the compressor and when it is running evenly close the hand unloaders. 6. CAUTION: Do not set the high pressure cut out point of the regulation system to a higher pressure than the nominal operating pressure of the compressor. 5.CompAir Limited 4. For details of the procedures refer to publications C20160-014 (air governor) or C20160-040 (control panel). Switch power supply on at the isolator . 6.2 Oil Pressure When the oil pressure is not within the correct limits it should be adjusted as follows: Remove the cap nut and locknut on the side of the oil pump and turn the adjusting screw clockwise to increase the oil pressure and counter-clockwise to reduce the oil pressure. When compressor is running steadily. 1. 1. Excessive bearing clearance. close hand unloaders. 2. Insufficient oil in the crankcase. 5. Dirt under ball valve. Such action may invalidate the Warranty. check the following possible causes: 1. If the pressure settings at which the compressor regulation system operates to bring it on-load or offload require alteration adjustments may be made to the air governor or the pressure switch. Turn selector switch to 'AUTO' or 'HAND' as required. 7. 4. Gauge faulty. Pipe connections loose. 3.4 Adjustments 1. Press 'SET RUN/FAULT RESET' button.4. Dirty oil suction strainer. page 28 . as appropriate.1 Air Governor and Optional Control Panel. If the pressure is too low and cannot be corrected by utilising the full adjustment. Operation at higher pressures than nominal will overload the drive motor and may cause damage.4. V100-VL400 User Manual 6 MAINTENANCE Page Routine Maintenance Cleanliness Recording Pressures and Temperatures Maintenance Record Pressure Settings Electrical Connections Leaks Regular Checks Lubricating Oil Maintenance Schedule Maintenance Parts (Two Years Operation) Maintenance Procedures Lubrication System Air Intake Filter 30 30 30 30 30 31 31 31 31 34 35 35 36 page 29 . Personnel accustomed to servicing and maintaining mechanical equipment should have no difficulty in carrying out these tasks but if assistance is needed the user should refer to the local CompAir Distributor .2 Recording Pressures and Temperatures Keep a regular daily record of operating pressures and temperatures. Use extreme caution when carrying out electrical checks. 1. maintenance and repair work carried out on the compressor. Ensure that any oil spillage is wiped up immediately and any residual oil cleaned from external surfaces.3 Maintenance Record Keep a careful record of all servicing.5 Electrical Connections Avoid damage to electrical wiring when working on the compressor installation and inspect wires and cables before refitting. page 30 . Lethal voltages are used in this equipment. This section gives the information needed by the user for this purpose. The readings should be taken when conditions are stable and with the compressor running on full load. alerting the user to a possible need for servicing or maintenance.CompAir Limited MAINTENANCE WARNING Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit. Refer to 'Adjustments' in the 'Operation' section of this manual for details. Inspect regularly for signs of damage. Frequent recurrence of a particular repair could reveal an unsatisfactory operating condition which must be corrected.1 Cleanliness The installation must be kept in clean condition at all times. The record will form a useful reference and any variation from normal operation will be noticeable immediately. 1. that all checks and services listed in the Schedule are carried out at the specified intervals and an accurate record is kept of the work. 1. Ensure no damage will be caused by chafing or contact with hot surfaces when the unit is in service. Isolate the power supply before starting any maintenance work. ROUTINE MAINTENANCE 1. To ensure the efficient operation of the compressor installation the user must check performance regularly and carry out the necessary adjustments to maintain correct settings. 1. 1.4 Pressure Settings Pressure switch settings and adjustments must be maintained correctly to prevent faults occurring which could reduce the efficiency of the compressor. excessive wear and security of fittings. Do not fasten wiring directly to a line carrying fluid. A condition of the Warranty cover is that the user must ensure that the compressor and auxiliary equipment are properly maintained and adjusted. Routine maintenance and regular servicing must be carried out as recommended in the 'Maintenance Schedule'. 500 10. Regular maintenance should be carried out as recommended in the Schedule below. Details of the recommended oil are given in 'Leading Particulars'.000 Service A A+B A+C A+B A A+B+C+D The above cycle from 2.500 15. Tighten loose connections and repair or replace damaged pipes immediately.V100-VL400 User Manual – Maintenance 1. even if the major servicing work is contracted to a CompAir Distributor. MAINTENANCE SCHEDULE Hours 2.8 Lubricating Oil It is essential to maintain the correct level of oil and to change the oil completely at the specified intervals. loose pipe connections and dirt build-up prior to carrying out routine maintenance.000 12. changes in detail may be required.6 Leaks Inspect the unit for leaks. page 31 . The Schedule should always be used as an initial guide.500 5.7 Regular Checks The 'Maintenance Schedule' lists the routine checks and services which are important for the efficient running of the compressor.500 hours should then be repeated. 1. advice should be sought from the local CompAir distributor.000 7. Any variations are indicated in the schedule and should be observed. but if experience shows that an alteration is necessary. The services for lubricated and oil free compressors are almost identical. 2. The Schedule is appropriate to most normal circumstances but in some instances. The user should ensure that the Daily and Weekly Checks become an integral part of planned maintenance. 1. dismantle. Item Daily checks Pressure gauges Thermometers Condensate drains Water cooling system Airblast aftercooler Weekly checks Lubrication system After first 1000 hours Water cooled intercooler Every 2.5 bar maximum. Users who wish to carry our these services themselves will find the procedures in the Repair Manual. Renew filter element. Note/record readings. Clean and inspect. page 32 . Renew if necessary. Check oil level in crankcase.5 bar maximum. Every 5. Clean externally with low pressure air jet. If necessary replace valve plates. Top up as necessary. Remove and check operation on bench. Remove and clean oil strainer. part number C20160-1157. Check water flow. Renew oil filter element. Renew filter pads if necessary. Refill crankcase with new oil. Replace if necessary. clean and inspect.000 hours (Service B) *Pressure gauges Intercooler Air intake Check calibration. Clean if required.CompAir Limited It is expected that service items marked * in the Schedule below will normally be carried out by a CompAir distributor. Check for correct operation. Drain crankcase oil. Check operation of blowdown valves. Remove. Examine internally. Check and clean. Renew all valve springs. 0. Clean externally with low pressure air jet.500 hours (Service A) Air intake filter *Suction and delivery valves Unloader valve Air governor Lubrication system *Low oil pressure/high air temperature switch Intercooler Aftercooler Action Note/record readings. Drain condensate (manual tap). 0. Inspect diaphragm. Renew piston rod gland packings. Renew if excessive oil is being passed. page 33 . the big end bolts must also be renewed. Renew big end bolts. Inspect all protection devices and check operation. Renew main bearing shells. § Inspect big end bearings. Inspect relief valves and check operation. Renew rings if necessary. Check piston ring gaps. Renew if necessary. Check guide ring 'stand out'. Inspect piston rods.000 hours (Service D) *Compressor Remove cylinder heads and cylinders. § Renew small end bushes. Items marked § refer to oil-free compressors only. Renew big end bearing shells. Dismantle completely. Inspect main starter contacts. § Inspect cylinder bores. Inspect crankshaft journal bearings. Every 15. Strip and inspect oil pump. Note: if new big end bearing shells are fitted. § Inspect starter contacts. Inspect small end bushes /gudgeon pins. Inspect crossheads and guides. Renew worn parts. Check coupling bolts for security.500 hours (Service C) *Compressor cylinders *Pistons Action *Connecting rods Electrical components Check condition of cables and wiring. Remove motor. Renew drive belt. Renew oil seals. Renew if necessary. Inspect motor for cleanliness.V100-VL400 User Manual – Maintenance Item Every 7. Check gland packings. Renew piston rings. Check security of balance weights. CompAir Limited 3. MAINTENANCE PARTS (TWO YEARS OPERATION) Quantities required Service Description V100 'A' Oil Filter Element 2nd stage Valve Plates 2nd stage Valve Springs 1st stage Valve Springs Diaphragms (unloader) Valve Joint Ring Valve Lanterns 'O' Ring Oil Filter Element 1 2 6 12 3 6 6 1 V150 1 2 6 12 3 6 6 1 V200 1 4 12 24 6 12 12 1 V300 1 4 12 24 6 12 12 1 'B' Air Filter Element 1 1 1 1 'C' §1st stage Guide Ring §1st stage Pressure Ring §2nd stage Guide Ring §2nd stage Pressure Ring §Oil Wiper Ring §Oil Scraper Ring Seal 1 1 1 2 2 2 2 1 1 1 2 2 2 2 2 2 2 4 4 4 4 2 2 2 4 4 4 4 'D' 1st stage Suction Valves 1st stage Delivery Valves 2nd stage Suction Valves 2nd stage Delivery Valves Diaphragms (unloader) Main Bearing Bushes Oil Seals Big End Bearing. page 34 . Half Liners Big End Bolts Small End Bushes Gudgeon Pins 1st stage Piston Rings 1st stage Conformable Rings 2nd stage Piston Rings 2nd stage Conformable Ring Shakeproof Washers Set of Gaskets and 'O' Seals Oil Pump Belt 2 2 1 1 3 2 2 4 4 2 2 2 1 2 1 2 1 1 2 2 1 1 3 2 2 4 4 2 2 2 1 2 1 2 1 1 4 4 2 2 6 2 2 8 8 4 4 4 2 4 2 4 1 1 4 4 2 2 6 2 2 8 8 4 4 4 2 4 2 4 1 1 Items marked § refer to oil-free compressors only. page 35 . In normal circumstances the oil should be changed after every 2. The compressor must be stopped. 2. Remove the oil filler cap.1 Recommended Oil At ambient temperatures from 0° to 30°C.V100-VL400 User Manual – Maintenance 4.500 hours of service. 5.1. Check that all pressure gauges on the display panel register zero. 7. 1.2 To Check the Oil Level The oil level is indicated on the dipstick housed inside the oil filler tube. To fit the new element. Ensure that the cooling water system has been drained on water cooled models. Isolate the power supply before starting any maintenance work. Close the isolating shut-off valve to the receiver. Where a maintenance procedure below includes the warning 'The compressor must be stopped' the following steps must be taken before work is commenced: 1. Check that the drain valve on the delivery manifold is clear and air pressure released. 4. If the compressor is operating in adverse conditions. the recommended oil for the 3000 Series V-Compact is Shell Corena P68. Lethal voltages are used in this equipment.1. 2. Remove the old filter element by unscrewing it from the housing and discard it. Where temperatures are consistently in excess of 30°C. Use extreme caution when carrying out electrical checks. The oil level is correct when it reaches the 'MAX' mark. 3.3 To Change the Oil Filter Element The full-flow oil filter has a disposable cartridge type element. 4. MAINTENANCE PROCEDURES WARNING Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit. screw it into the housing until it contacts the gasket and then tighten it a further quarter turn. Apply a light film of oil to the seal of the new element. 4. The compressor must be stopped. such as high dust levels or the presence of chemical or other pollutants. For alternative lubricants consult your local distributor.1. Check that all pressurised air trapped in the system is released to atmosphere. If topping up is required. 4. Refit the oil filler cap. 6. 3. more frequent oil changes may be necessary. use 100 viscosity rating of the selected brand. pour in the appropriate quantity of the correct oil to bring the level up to the 'MAX' mark on the dipstick. withdraw the dipstick and check the level. Open the manual drain cock to ensure that pressurised air trapped between the first and second stages has been released. 4. Switch the power supply 'OFF' at the isolator.1 Lubrication System 4. Carefully clean out the filter housing. Clean and refit the drain plug.CompAir Limited 4. 1. holes or other damage by viewing the light from a hand lamp through the element or holding the element up against a light source. Drain the oil while the compressor is hot. When all contamination has been removed. ensuring that the air stream passes through the element from inside to outside. 1. The hot oil will run freely and carry out any suspended particles. more frequent attention may be necessary . 1. such as high dust levels. 2. low-pressure air (max.1. 2. If the compressor is operating in adverse conditions.2. Unscrew the wingnut or slot-headed nut securing the air intake cover and remove the cover. Clean out the inside of the intake silencer. 4. 2.500 hours service. Refit the oil filler cap. remove the drain plug and allow the oil to drain into the container for disposal. Place a container beneath the crankcase drain.1 To Remove the Air Filter Element The compressor must be stopped.2 To Clean the Element by Air Blast The compressor must be stopped. Re-install the clean/new element in the intake silencer. Remove the oil filler cap. 4. 5 bar) carefully blowout the inner cavity of the element. 3.4 To Drain the Oil The compressor must be stopped. 3. 4. 3. 4. inspect the element for cracks. Remove the filter element.2 Air Intake Filter In normal circumstances the air intake filter element should be checked after every 2. Using an air line supplying dry.2. If any damage is evident the element must be discarded and a new one fitted. page 36 . V100-VL400 User Manual 7 FAULT FINDING page 37 . Oil pump drive belt or pulley loose. Indication Low oil pressure. (1) Inadequate ventilation of compressor room. (1) (2) (2) (3) (3) (4) Intercooler passages obstructed (usually only after very long service). Renew if necessary. Use extreme caution when carrying out electrical checks. Oil pump gears faulty. Lethal voltages are used in this equipment. Rectify or renew as necessary.CompAir Limited FAULT FINDING WARNING Refer to the safety procedures before carrying out any fault finding investigation on the compressor unit. Oil pressure gauge faulty. Inspect bearings and small end bushes. Isolate the power supply before starting any maintenance work. Renew oil filter element. Incorrect setting of oil pressure relief valve. Valves faulty. Check condition of oil pipes and filter. Renew gauge if defective. Check seating. Check condition of ring joints. (6) (7) (8) (9) (6) (7) (8) (9) Compressor overheating. Renew if necessary. Renew as necessary . Remove valves. Renew oil pump gears. (1) (2) (3) (4) (5) Remedy Check/top up oil. Incorrect grade of oil in crankcase. Clean intercooler internally and externally. Check setting of valve. Ball valve sticking in open position. Inspect valve plates. (1) (2) (3) (4) (5) Possible Cause Low oil level. Incorrect positioning of compressor or aftercooler. Drain crankcase and refill with correct oil. If necessary remove and clean valve assembly. Check gauge calibration. page 38 . springs and seats. Reset valve. Check positioning meets the recommendations in the 'Installation' section of this manual. (4) Check ventilation meets the recommendations in the 'Installation' section of this manual. Check drive belt and pulley. Broken or loose connections on oil pipework. Worn main bearings. Clogged oil filter element. Renew element if necessary. 1st stage temperature gauge reading will increase when compressor is running unloaded. Check that bore is of adequate diameter. Check condition of ring joints. Compressor air intake blocked or partially obstructed. (1) (2) 1st stage safety valve faulty. Check operation of unloader mechanism. Remove valves. Check compressor is in good condition. (3) Check setting of safety valve. Setting should be 3. (5) (6) Remedy Remove pipework and inspect. Renew as necessary. Inspect valve plates. Ensure that unloader fork travels its full distance to open suction valve plate completely. (1) (2) (3) Intercooler passages obstructed (usually only after very long service). Inspect valve plates. springs and seats. Worn or broken piston rings. (7) (8) Interstage pressure reading too high (1st stage relief valve exhausting). (1) (2) (3) Incorrect setting of governor or pressure switch. Faulty unloading (particularly on 2nd stage cylinders). Check condition of ring joints. (1) (2) (3) Adjust settings to achieve correct pressure. Adjust as necessary.1 bar. The air demand of the installation exceeds the rating of the compressor. (A slow fall in delivery pressure when running on full load indicates that the compressor is not large enough for the installation). page 39 .V100-VL400 User Manual – Fault Finding Indication Compressor overheating (cont. Rectify if necessary. Faulty unloading preventing compressor from coming on load. Check drive motor speed. springs and seats. Remove valves. Renew as necessary. Check operation of unloader mechanism. Clean intercooler internally and externally. Check for leaks. 2nd stage valves faulty. Valves faulty. Compressor fails to maintain working pressure. (5) (6) (7) (8) Compressor running under speed. Inspect piston rings and cylinders. Inspect air intake filter for cleanliness and serviceability. Rectify as necessary .) (5) (6) Possible Cause Main delivery pipework blocked or restricted. (4) (4) (5) (6) Leaks in user's pipework. Renew as necessary. springs and seats. Oil level too high. Renew as necessary. Inspect cylinder bores for wear. page 40 . Worn small end bearings. Clean or renew as necessary. Compressor overheating. Check that crankshaft and flywheel are not damaged. Compressor knocking. Inspect small end bushes for wear. Check condition of ring joints. Renew if necessary.CompAir Limited Indication Intercooler pressure reading low. (1) (2) Excessive oil consumption. Check condition of ball and spring. (1) (2) (3) (4) (2) (3) (4) Remove flywheel. 1st stage valves faulty. Remove and inspect bearings. Broken valve spring contacting piston crown. Inspect filter. Renew if necessary. (1) (2) (3) (4) Incorrect oil in crankcase. Clean or renew as necessary . See previous action on overheating. (1) Dismantle condensate valve. (1) (2) Remedy Check gauge for accuracy. Drain off surplus oil until correct level shows on dipstick. Check air intake. Excessive small end clearance. Inspect gudgeon pins for wear. Remove and inspect valve springs. (Will be heard when compressor is on full load). Rectify and renew as necessary. Inspect valve plates. Renew bearings and fit new gudgeon pins if required. (3) Intercooler condensate valve fails to exhaust. (1) (2) (3) (4) Drain and refill with correct oil. Worn cylinders and piston rings. Excessive oil consumption. Broken valve plates or springs. (3) Compressor air intake blocked. Refit flywheel with new key and tighten retaining bolt to correct torque. (1) (2) See following action on 'Excessive Oil Consumption'. (1) (2) Possible Cause Air pressure gauge faulty. (1) Loose flywheel. Renew components as required. Remove valves. Check all piston ring gaps. (1) Ball valve faulty . Excessive carbon deposits in compressor. Remove and inspect valve plates. Check for free operation. Renew bearing shells if necessary. Check clearance with lead strip and if insufficient fit joint between cylinder base and crankcase.) (5) (6) Possible Cause Worn big end bearings. (5) (6) Remedy Remove and inspect bearings. Insufficient clearance between piston crown and cylinder head.V100-VL400 User Manual – Fault Finding Indication Compressor knocking (cont. page 41 . CompAir Limited page 42 . V100-VL400 User Manual APPENDIX 1 The Pressure Systems Safety Regulations 2000 page 43 . Aftercooler 7.CompAir Limited APPENDIX 1 Note: The intervals between examination and calibration of components. In defining these periods the 'competent person' must take into account the recommendations of the component part manufacturer. pressure relief valves etc. the Health and Safety Executive (H & SE) and the British Compressed Air Society (BCAS). Compression Cylinder 3. will be defined by the 'competent person' preparing the written scheme. Intake Air Filter 2. Pressure Relief Valve 5. eg pressure vessels. Non-return Valve 6. Pulsation Vessel 4. THE PRESSURE SYSTEMS SAFETY REGULATIONS 2000 The circuit diagram shown below is provided to assist a 'competent person' in preparing a written scheme of examination for a system incorporating the air compressor(s). Auto Drain Trap PRESSURE SYSTEM DIAGRAM – 1ST STAGE page 44 . 1. V100-VL400 User Manual – Appendix 1 1. Pulsation Vessel 8. Auto Drain Trap 6. Pressure Relief Valve 9. Pressure Relief Valve 4. Second Stage Compression Cylinder HP 7. Intake Air Filter 2. First Stage Compression Cylinder LP 3. Non-return Valve 10. Intercooler 5. Auto Drain Trap PRESSURE SYSTEM DIAGRAM – 2ND STAGE page 45 . Aftercooler 11. CompAir Limited page 46 .