CompAir H5211 User manual

OPERATOR MANUAL
For a
H5211
Air Cooled Air Compressor
In any correspondence please quote; COMPAIR JOB NUMBER:-
CUSTOMER:-
CUSTOMER ORDER NUMBER:-
MACHINE NUMBER:-
PUBLICATION NUMBER:- 98407.1050
ISSUE DATE:-JAN 2009 – issue 2
CompAir UK Ltd
CompAir UK Ltd. Reavell House
53-56 White House Road IPSWICH ENGLAND IP1 5PB
Telephone: [phone] Fax: [phone] Parts Fax: [phone] Service [phone]
www.compair.com e-mail:- [email protected]

CompAir UK Ltd PUBLICATION 98407/1050
Page 1
OPERATOR HANDBOOK FOR A
5211.2.IA.
AIR-COOLED COMPRESSOR
1SAFETY....................................................................................................................................................... 3
1.1 OWNERSHIP DATA............................................................................................................................. 4
1.2 FOREWORD......................................................................................................................................... 5
1.3 CAUTION.............................................................................................................................................. 6
1.4 SAFETY PROCEDURES...................................................................................................................... 6
1.4.1 GENERAL...................................................................................................................................... 7
1.4.2 WARNINGS, CAUTIONS & NOTES ............................................................................................. 7
1.4.3 GENERAL SAFETY PRECAUTIONS ........................................................................................... 8
1.4.4 INSTALLATION PRECAUTIONS.................................................................................................. 8
1.4.5 OPERATIONAL PRECAUTIONS.................................................................................................. 8
1.4.6 MAINTENANCE & REPAIR PRECAUTIONS................................................................................ 9
1.4.7 PRECAUTIONS IN THE EVENT OF FIRE.................................................................................. 10
2AMENDMENTS ......................................................................................................................................... 11
3LOGSHEET................................................................................................................................................ 13
4GENERAL DESCRIPTION AND OPERATION ........................................................................................ 15
4.1 GENERAL........................................................................................................................................... 15
4.2 BEARINGS.......................................................................................................................................... 15
4.3 VALVES.............................................................................................................................................. 15
4.4 LUBRICATION.................................................................................................................................... 16
4.5 DRIVE................................................................................................................................................. 16
4.6 INSTRUMENTATION ......................................................................................................................... 16
4.7 AUTOMATIC STOP/START CONTROL ............................................................................................ 16
4.7.1 ELECTRIC DRIVEN SETS.......................................................................................................... 16
4.7.2 ENGINE DRIVEN SETS.............................................................................................................. 16
4.8 NON-RETURN VALVE....................................................................................................................... 16
4.9 FUSIBLE PLUG .................................................................................................................................. 16
5LEADING PARTICULARS........................................................................................................................ 17
5.1 UNIT DESIGNATION.......................................................................................................................... 17
5.2 TECHNICAL DATA............................................................................................................................. 17
5.3 PRESSURES...................................................................................................................................... 17
5.4 SAFETY VALVE SET PRESSURES.................................................................................................. 17
5.5 GENERAL........................................................................................................................................... 17
5.6 DIMENSIONS ..................................................................................................................................... 17
5.7 WEIGHT.............................................................................................................................................. 17
5.8 SPEED................................................................................................................................................ 17
5.9 TEMPERATURES .............................................................................................................................. 18
5.10 LUBRICANTS.................................................................................................................................. 18
5.11 TORQUE SETTINGS...................................................................................................................... 18
5.12 RUNNING CLEARANCES.............................................................................................................. 19
6INSTALLATION......................................................................................................................................... 21
6.1 GENERAL........................................................................................................................................... 21

CompAir UK Ltd PUBLICATION 98407/1050
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6.2 UNPACKING.......................................................................................................................................22
6.3 HANDLING..........................................................................................................................................22
6.4 MOUNTING.........................................................................................................................................22
6.5 DRIVE..................................................................................................................................................22
6.6 CONNECTIONS, PIPEWORK AND FITTINGS..................................................................................22
6.7 ELECTRICAL......................................................................................................................................23
6.8 SITING REQUIREMENTS..................................................................................................................23
6.9 TYPICAL CONTROL WIRING DIAGRAM..........................................................................................24
7COMMISSIONING OR RECOMMISSIONING...........................................................................................25
7.1 LUBRICATION....................................................................................................................................25
7.2 BEFORE STARTING ..........................................................................................................................25
7.3 START-UP PROCEDURE..................................................................................................................25
7.4 MAINTENANCE..................................................................................................................................26
8OPERATION AND ROUTINE MAINTENANCE........................................................................................27
8.1 OPERATION AND GENERAL MAINTENANCE.................................................................................27
8.2 STARTING UP....................................................................................................................................27
8.3 RUNNING ON LOAD ..........................................................................................................................27
8.4 STOPPING..........................................................................................................................................27
8.5 STANDING IDLE.................................................................................................................................28
9MAINTENANCE SCHEDULE....................................................................................................................29
9.1 GENERAL...........................................................................................................................................29
9.2 DAILY..................................................................................................................................................29
9.3 WEEKLY .............................................................................................................................................29
9.4 RECOMMENDED MAINTENANCE SCHEDULE...............................................................................31
10 REMOVAL AND REPLACEMENT OF VALVES...................................................................................33
10.1 GENERAL........................................................................................................................................33
10.2 VALVE CLEANING – ALL STAGES................................................................................................33
10.3 1ST STAGE VALVE ........................................................................................................................33
10.3.1 REMOVAL................................................................................................................................33
10.3.2 REPLACEMENT.......................................................................................................................33
10.4 2ND STAGE VALVE........................................................................................................................34
10.4.1 REMOVAL................................................................................................................................34
10.4.2 REPLACEMENT.......................................................................................................................34
11 FAULT GUIDE........................................................................................................................................35
12 PARTS LIST...........................................................................................................................................39
13 ANCILLARY EQUIPMENT.....................................................................................................................53
13.1 ELECTRIC MOTOR – APP034.......................................................................................................53
13.2 HIGH AIR PRESSURE SWITCH – APP086...................................................................................54
13.3 DIRECT DRIVE – APP011B............................................................................................................56
13.4 SOLENOID VALVE – APP171........................................................................................................57

CompAir UK Ltd PUBLICATION 98407/1050
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1 SAFETY
5000 SERIES COMPRESSORS
WARNING
The use of replacement parts or lubricating oils not supplied,
recommended or approved by CompAir UK Ltd Ipswich, or the failure to
maintain this equipment in accordance with the maintenance instructions,
may invalidate the WARRANTY, cause equipment failure, create unsafe or
hazardous conditions or result in damage to the equipment.
CompAir UK Ltd Ipswich cannot accept responsibility for damage,
injury or failure caused by these situations.
USE ONLY
CompAir UK Ltd Ipswich
GENUINE PARTS
AND
AUTHORISED SERVICE AGENTS

CompAir UK Ltd PUBLICATION 98407/1050
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1.1 OWNERSHIP DATA
TECHNICAL DATA
It is recommended that details taken from the compressor and motor nameplates are recorded below.
CompAir UK Ltd Ipswich CONTACT DETAILS
Contact Name: Sales Telephone: [phone]
Notes:
Address:
CompAir UK Ltd
Reavell House
53-56 White House Road
Ipswich IP1 5PB
ENGLAND
Telephone: [phone] Fax: [phone]
Contact Names: Parts Telephone: [phone]
Parts Fax: [phone]
Contact Names: Service: [phone]
For any comments or queries about the contents of this manual, please write to CompAir UK Ltd. at
the above address, marked for the attention of Mr. Owen Dale, Technical Author.

CompAir UK Ltd PUBLICATION 98407/1050
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1.2 FOREWORD
SPECIAL ATTENTION
The STANDARD BUILD of all CompAir UK Ltd (Ipswich Operations) products are not intended for use in
either Explosive or Potentially Explosive Atmospheres as defined in Directive 95/9/EC.
An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours,
hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture
and may cause a hazard.
A Potential Explosive atmosphere is an atmosphere, which could become explosive due to local
conditions.
CompAir UK Ltd Ipswich H5000 Series compressors are designed and manufactured to give optimum
performance, with long life and reliability.
This Manual will help you to obtain the best performance from your compressor. It provides the information
required to install, commission and operate the compressor and carry out regular maintenance schedules,
which will ensure the maximum satisfactory service life.
Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing.
Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network
of CompAir companies and CompAir UK Ltd. distributors, backed by the Service tel[phone]
and Parts department tel [phone]) Fax [phone] and Sales (+44 (0) 1473
242000 Fax [phone] at CompAir UK Ltd., Ipswich (UK)
The information 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 compressor. Before any
servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or
CompAir UK Ltd Distributor for revised or up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No.
and any CONTRACT Ref.
It is important this Manual is retained with the compressor for reference and should remain with the
compressor if it is sold or transferred to another user. Ensure that the new user is made fully aware of the
need to study the Safety Section and any Warnings for safe operation given throughout the text.
Protect the environment by using only approved method of disposal of condensates lubricating oil etc.
Please note: a. Throughout the Manual all pressures quoted are gauge pressures.
b. Whilst recyclable materials are used as far as possible, please ensure when
disposing of condensate, spent oil, used filter elements and any discarded parts or
waste material of any kind make sure that there is no pollution to any natural water-
course, drain system and that no burning waste takes place which could cause
pollution of the atmosphere.

CompAir UK Ltd PUBLICATION 98407/1050
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1.3 CAUTION
Use only CompAir UK Ltd Ipswich Genuine Parts when carrying out routine maintenance or repair. The
use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd Ipswich can
lead to expensive failures, which will not be covered by warranty.
Substitution of parts not manufactured or approved by CompAir UK Ltd Ipswich can create a potential
personnel hazard.
This is a High Pressure Compressor, for safe and reliable operation use only
genuine CompAir UK Ltd Ipswich Parts
To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance
with the information given in this manual - refer to the “Maintenance Section”.
Conditions of CompAir UK Ltd Ipswich warranty are stated in our Conditions of Sale. Details of warranty for
a particular unit may be obtained from the local CompAir Company or authorised Distributor.
1.4 SAFETY PROCEDURES
•WARRANTY
The Conditions of the CompAir UK Ltd Ipswich Warranty are set out in the Standard Conditions of
Sale.
•MAINTENANCE
To ensure continued trouble free operation of the compressor 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 genuine CompAir UK Ltd Ipswich parts.
∗WARNING
The use of replacement parts or lubricating oils not supplied or approved by
CompAir UK Ltd Ipswich may lead to failures in service which would not be
covered by warranty.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance
instructions may make it unsafe. The use of replacement parts not supplied by CompAir UK Ltd
Ipswich may create hazardous conditions over which CompAir UK Ltd Ipswich has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury
or result in damage to the equipment. CompAir UK Ltd Ipswich can bear no responsibility for
equipment for which unapproved replacement parts are included.
SPECIAL NOTE:
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH
ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.

CompAir UK Ltd PUBLICATION 98407/1050
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1.4.1 GENERAL
CompAir UK Ltd Ipswich compressor safety relates to the document BS EN1012-1 Compressors and
Vacuum Pumps - Safety requirements and the UK Pressure Systems Health & Safety Regulations S.I. No.
128.
•Most accidents which occur during the operation and maintenance of machinery result of failure to
observe basic safety rules or precautions. Recognising a situation that is potentially hazardous can often
prevent an accident.
•When handling, operating or carrying out maintenance on the unit, personnel must observe safe
engineering practices and all relevant local regulations. The attention of users is drawn to the Health and
Safety at Work Act 1974, and the regulations of the Institution of Electrical Engineers.
•CompAir UK Ltd 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 UK Ltd then they 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 these precautions given under "Safety Precautions" may be considered dangerous
practice or misuse of the compressor
•Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the unit before
operating or carrying out maintenance or servicing.
1.4.2 WARNINGS, CAUTIONS & NOTES
The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in
Machinery Directive 89/392/EEC, Amended 91/286/EEC.
∗Warnings call for attention to operating procedures involving specific hazards which could cause injury
or death and are identified by the following
RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST
RISK OF ELECTRIC SHOCK RISK OF HOT SURFACE CONSULT MANUAL

CompAir UK Ltd PUBLICATION 98407/1050
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1.4.3 GENERAL SAFETY PRECAUTIONS
•When using cleaning solvents, local Health and Safety Regulations must be complied with. Provide good
ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and
gloves.
•Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any risk
of falling objects.
•If using compressed air for cleaning purposes, ensure safety regulations are complied with and
appropriate clothing 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 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 should never be applied 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 and never leave a heavy load unattended.
•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.
1.4.4 INSTALLATION PRECAUTIONS
•Competent personnel under a qualified supervisor must only carry out installation work.
•A fused isolator 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 compressor intake.
•Ensure that the discharge pipe from the compressor to the user pipework, receiver or storage is free to
expand and that no flammable material is within the vicinity. If any such material is close-by take steps to
preclude ignition.
•A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated. Non
return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must be
installed between any compressor unit and the isolating valve.
•A pressure-reliving device must be fitted to every pressure vessel, or equipment containing air or gas
above atmospheric pressure. Never remove or tamper with safety devices, guards or insulation fitted. In
order to limit the risk of Legionnaires Disease, CompAir UK LTD advise caution with the use of cooling
towers for water cooling the compressor. Closed circuit or direct mains cooling is preferred.
•Pipework or other parts with a surface temperature above 70°C, which may be accidentally touched in
normal operation, must be guarded or insulated. Other high temperature pipework should be clearly
marked and all pipework should be clearly marked.
1.4.5 OPERATIONAL PRECAUTIONS
•Competent personnel under a qualified supervisor must only operate the compressor.
•Do not operate compressor with any removable inspection cover removed e.g. crankcase doors, valve
covers etc.
•Never remove or tamper with safety devices, guards or insulation materials.
•The compressor must only be operated at the supply voltage and frequency for which it is designed.
Always isolate power before maintenance or servicing.
•When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is
need when essential work is carried out on the electrical system. ALWAYS CONSULT A QUALIFIED
ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK.