Comprag RECOM RCW Series User manual

OPERATING MANUAL
Version 2.3
RECOM RCW-Series
RCW-3 - RCW-11
EN
BEDIENUNGSANLEITUNG
Kolbenkompressoren RECOM RCW-Serie
Version 2.3
DE
Seite. 25
Руководство по эксплуатации
и техническому обслуживанию
Версия 2.3
стр. 44
Установка компрессорная
поршневая RECOM RCW
RU

© 2015 Comprag ®. All rights reserved.
No part of the text and /or diagram may be reprinted or used without the prior written
permission of Comprag.
The manufacturer reserves the right to make changes to a product design in order to
enhance its technological and operational parameters without notifying the user.
The product type may considerably differ to that displayed in documents.

3
COMPRAG RECOM RCW series
Table of contest
1 Safety guidelines 4
1.1 Symbols used in the instructions 4
1.2 General safety guidelines 4
1.3 Safety precautions for start-up 5
1.4 Safety precautions during operation 6
1.5 Safety precautions for maintenance and repair 7
2 Technical data and functional description 9
2.1 Technical data 9
2.2 General description 9
2.3 Function diagram and main components 10
2.4 Pneumatic diagram 10
2.5 Electrical diagram and main components 11
2.6 Functional description 12
3 Start-up 13
3.1 Lifting and carrying 13
3.2 Dimensions 13
3.3 Requirements on installation facility 14
3.4 Connection to the compressed airline 14
3.5 Connecting to power supply 15
3.6 Checking compressor’s oil level 15
3.7 Checking drive belt 15
3.8 Symbols and indications 16
4 Operation 17
4.1 Starting the Compressor 17
4.2 Switching off the compressor 18
5 Maintenance 18
5.1 Changing compressor oil 18
5.2 Changing air intake lters 19
5.3 Changing drive belt 20
5.4 Servicing bearings of electric motor 20
6 Fault handling 21
6.1 Faults and corrective actions 21
7 Storage and disposal 21
7.1 Storage conditions 21
7.2 Disposal of oils and process condensate 21
EN

4Version 2.3
1. Safety guidelines
1.1 Symbols used in the instructions
Lethal hazard
Warning
Attention
1.2 General safety guidelines
Carefully familiarise yourself with the technical documentation,
operating instructions and safety guidelines. Most accidents as-
sociated with the use of compressor equipment occur as a result
of non-compliance with safety guidelines. Prevent hazards from
developing and adhere to the safety guidelines. The main rules
are given in the following section.
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. The operator must stringently adhere to safety guidelines provided for by these instruc-
tions and local legislation!
2. When choosing between these safety guidelines and the regulations provided for by local
legislation, those rules which provide for more stringent requirements shall apply.
3. Only trained maintenance personnel with the relevant level of professional training are
permitted to operate, service and repair Comprag equipment.
4. Compressed air owing immediately from the compressor may contain oil and impurities
and is not suitable for breathing! Compressed air has to be puried to an air purity grade suit-

5
COMPRAG RECOM RCW series
able for breathing, in accordance with the standards prescribed by local legislation.
5. Compressed air is an extremely hazardous energy source. Compressed air must not be
used for unintended purposes! Do not use it to clean clothing and footwear and never point
compressed air hoses at people and animals! When using air to clean equipment, take
extra caution and wear safety goggles!
6. All maintenance, repair, setup and installation work etc. must be performed while the
equipment is turned off, disconnected from the power source, with compressed-air hoses
disconnected from the equipment, and with the use of safety goggles! Ensure that equip-
ment is disconnected from the compressed air system and is not under pressure.
1.3 Safety precautions for start-up
The user is solely liable for injuries or damages which occur due
to non-compliance with safety guidelines during installation, op-
eration or servicing, as well as unauthorised use of equipment!
1. Equipment must only be unloaded/loaded using the appropriate handling devices or
hoisters. Equipment must not be manually lifted or moved. Do not leave equipment sus-
pended. Use a helmet during unloading operations.
2. Arrange the equipment in a dry and clean facility which provides shelter from precipitation.
The facility must be well ventilated, and forced ventilation should be provided if necessary.
3. Worn, damaged or spoiled compressed-air hoses should not be used. Ensure that hoses
correspond to the equipment in terms of nominal diameter and working pressure.
4. When using several compressor stations in a system, each compressor must have a
manually operated valve for cutting off any of the compressors in the case of emergency.
5. Explosive and re-hazardous admixtures such as solvent vapours and carbon dust etc.
must not be released into the atmosphere.
6.Ensure unrestricted access to the compressed-air hose from the compressor. Do not clut-
ter it and do not store ammable materials in its immediate vicinity.
7. Do not pinch or deform the compressed-air feed hoses.
8. Do not cover holes used to provide equipment with air for cooling. Ensure the facility is
well ventilated.
9. When using remote control, the equipment must give a legible and clear warning of this: ‘AT-
TENTION: this machine is being controlled remotely and may start operating without warning!’
An operator who is remotely controlling equipment must ensure that no installation or other
work is being performed with the equipment at that moment. Once the equipment is turned
off remotely, the operator must ensure that the equipment is actually turned off!
10. Equipment must be earthed. Provide short-circuit protection. The starting knife switch must
be in the immediate vicinity of the equipment and protect against unauthorised start-up.

6Version 2.3
The user bears full responsibility for compliance with the operating con-
ditions of the electrical motor installed in the equipment.
Equipment must be used with protection devices.
The protection devices must protect the electric motor from short cir-
cuits, overloading (systematic and start-up) and open-phase conditions.
Installation of protection devices is the responsibility of the user.
11. There must be an information plate afxed next to the control panel on equipment with
an independent control system featuring an automatic restart function: ‘ATTENTION: This
machine may start operating without warning!’
12. Any tanks and vessels working under pressure must be tted with safety-relief valves!
Unauthorised installation, disassembly or adjustment of attached safety-relief valves is not
allowed.
1.4 Safety precautions during operation
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. Ensure that hoses correspond to the equipment in terms of nominal diameter and working
pressure. Check the attachment of every hose coupling before start-up. An insecurely fastened
hose may cause serious injury.
2. Never turn on equipment if you suspect the presence of highly ammable impurities in the
air!
3. The operator remotely controlling equipment must ensure that no installation or other work
is being performed with the equipment at that moment! An information plate must be afxed
to the equipment in relation to this: ‘ATTENTION: this machine is being controlled remotely and
may start operating without warning!’
4. An operator is not allowed to operate equipment if the operator is fatigued, in a state of intoxi-
cation from alcohol, drugs or medicine that reduces the body’s reaction time.
5. The equipment must not be operated if parts of the casing have been removed. Doors or
panels may be opened for short durations for inspection and scheduled checks. It is advisable
to wear hearing protection.
In some types of equipment, open doors or removal of panels
during operation may lead to overheating.

7
COMPRAG RECOM RCW series
6. Personnel in conditions or a facility where the sound pressure level reaches or exceeds 90
dB (A), must wear ear protectors.
7. If the air used for cooling equipment is used while the facility is being heated, undertake
measures for it to be ltered so that it is suitable for breathing.
8. Regularly check that:
• safety devices and attachments are in place;
• all hoses and pipes are in good condition and sealed;
• there are no leaks;
• brackets and structural components are tightened;
• all electrical cables and contacts are in good condition and safe to use;
• safety devices are fully functional and there is no contamination etc;
• all structural components are in working order, with no signs of wear and tear.
1.5 Safety precautions for maintenance and repair
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, operati-
on or servicing, as well as unauthorised use of equipment!
1. Only original spare parts and ancillary items may be used. Using spare parts from other
manufactures may lead to unpredictable results and consequently accidents.
2. When performing installation and repair work, always wear goggles!
3. Before connecting or disconnecting equipment, disconnect it from the main pneumatic
system. Ensure that the hoses aren’t under pressure!
4. Before beginning installation or other work, ensure that equipment is not pressurised.
Installation work must not be carried out on equipment under pressure.
5. All maintenance work should be carried out only when the temperature of all structural
elements falls to room temperature.
6.Never use highly ammable solvents or carbon tetrachloride for cleaning structural ele-
ments. When wiping, take precautions against the poisonous vapours of cleaning uids.
7. When carrying out installation and repair work, an information plate should be afxed to
the control panel to warn against unauthorised start-up. For example, “Do not turn on. Per-
sonnel operating!”
8. The operator remotely controlling equipment must ensure that no installation or other
work is being performed with the equipment at that moment! An information plate must be
afxed to the equipment in relation to this: See 1.3.9.
9. Maintain cleanliness in the facility where the equipment is installed. Close open inlets and
outlets during installation with dry clothes or paper to prevent rubbish entering the equip-
ment.
10. Welding or other similar operations must not be carried out in the immediate vicinity of
the equipment and vessels under pressure.
11. If there is any suspicion of overheating, combustion or other emergency, turn off the

8Version 2.3
equipment. Immediately disconnect it from the power supply. Do not open the doors of equip-
ment until the temperature falls to room temperature, in order to prevent burns or injury.
12. Naked ames must not be used as a light source for inspecting and checking equipment.
13. Never use caustic solvents, which may damage materials of the pneumatic system.
14. After performing installation or other work, ensure that no instruments, rags or spare
parts have been left inside the equipment.
15. Pay particular attention to the safety-relief valves. Thoroughly inspect them and remove
any dust and dirt. They must not be allowed to suffer any loss in function under any circum-
stances. Remember that your safety depends on their functionality!
16. Before beginning work in normal mode after maintenance or repair work, check that the
working pressure, temperature and other characteristics are correctly set. Ensure that all
control devices are installed and functioning properly.17. When replacing lters, separators
etc., wipe away dust, dirt and oil residue from the area where they are installed with a dry
cloth.
18. Protect the motor, air lter, electrical components and control components etc. from com-
ing into contact with condensate. For instance, blow down with dry air.
19. Safety precautions for operation with refrigerants:
• Never inhale refrigerant vapours. Ensure that the work zone is properly ventilated;
use a respirator if necessary.
•Always wear special-purpose gloves. If the refrigerant comes into contact with skin,
rinse the area of contact with plenty of water. If refrigerant comes into contact with
skin through clothing, do not try to remove clothing. Thoroughly rinse clothing with
fresh water until the refrigerant is washed off. Then seek medical assistance.
20. Use protective gloves during installation and repair work in order to avoid burns and injury
(for instance, during oil change).

9
COMPRAG RECOM RCW series
2. Technical data and functional description
Entitlement to free handling of faults arising during the guaran-
tee period is forfeited when:
- No warranty service coupon for the compressor or it is lled out
incorrectly
- No records for the compressor’s scheduled maintenance are
entered in the compressor’s service book
- Unoriginal parts and lubricants are used
2.1 Technical data
Tab. 1 Technical data
Article
Model
Drive power (kW)
Max. working
pressure (bar)
Capacity *
(m³/min)
Sound pressure
Level** (dB)
Rated Voltage
(Phase/V/Hz)
Air receiver
capacity (liter)
Screw
connection
11200301 RCW-3-100 3,0 10 0,52 74 3/380/50 100 1/2"
11200302 RCW-3-270 3,0 10 0,52 74 3/380/50 250 1/2"
11200401 RCW-4-100 4,0 10 0,70 74 3/380/50 100 1/2"
11200402 RCW-4-270 4,0 10 0,70 74 3/380/50 270 1/2"
11200501 RCW-5,5-100 5,5 10 0,82 76 3/380/50 100 1/2"
11200502 RCW-5,5-270 5,5 10 0,82 76 3/380/50 270 1/2"
11200503 RCW-5,5-500 5,5 10 0,82 76 3/380/50 500 1/2"
11200702 RCW-7,5-270 7,5 10 1,20 78 3/380/50 270 1/2"
11200703 RCW-7,5-500 7,5 10 1,20 78 3/380/50 500 1/2"
11201102 RCW-11-270 11 10 1,70 79 3/380/50 270 1/2"
11201103 RCW-11-500 11 10 1,70 79 3/380/50 500 1/2"
* Measured according to ISO 1217
** Measured according to ISO 3744
2.2 General description
RECOM RCW series compressors comprise a one-to-two-stage cast iron unit with low speed
and low operating temperature.
All RECOM RCW compressors are tted with an industrial three-phase electric motor and an
electromechanical pressure control relay.

10 Version 2.3
2.3 Function diagram and main components
Fig. 1 Main components RCW.
1 Pump unit 10 Check valve
2 Electric motor 11 Oil drain plug
3 Air receiver 12 Oil filling plug
4 Pressure switch 13 Air filter
5 Pressure gauge 14 Air outlet ball valve
6 Oil sight glass 15 Condensate drain ball valve
7 Flywheel 16 Plate compressor
8 Belt 17 Plate receiver
9 Filter-regulator 18 Belt guard
2.4 Functional description
In one-stage models, air is fed into the cylinder along the discharge pipe, and then into the
pressure vessel.
In two-stage models, air is fed into the low-pressure cylinder and then into the pre-compres-
3
6
15
14
5
17
2 18
4
87, 13
13
16
10111
9
12

11
COMPRAG RECOM RCW series
sion cylinder.
Pre-compressed air is fed into the high-pressure cylinder, and then along the discharge pipe
into the pressure vessel.
Once the working pressure is reached, the compressor stops and surplus air in the compres-
sor pump and delivery pipe is discharged through the dump valve under the pressure switch.
During air consumption, pressure falls in the pressure vessel and when the lower limit is
reached, the electric motor turns on again. The performance is controlled automatically after
the compressor is started up by means of the periodic starting and stopping of the compres-
sor.
The regular running time is 20 minutes and the downtime is 5 minutes (in order to avoid
overheating).
2.5 Pneumatic diagram
Fig. 2 Pneumatic diagram RCW
1Air intake lter 6Safety valve
2Pump unit 7Manometer
3Electric motor 8Pressure switch
4Check valve 9Air outlet ball valve
5Air receiver 10 Filter-regulator
1
2
3
4
5
6
8
7
9
9

12 Version 2.3
2.6 Electrical diagram and main components
Fig. 3 Electrical diagram RCW
L1, L2, L3 Power lines
Kd Pressure switch
M1 Electric motor

13
COMPRAG RECOM RCW series
3. Start-up
3.1 Lifting and carrying
All lifting should be carried out using a forklift truck with a carry-
ing capacity suited to the compressor.
Lifting may be carried out with loading cranes, winches and other
machinery, using a crossbeam with the right length.
Local safety guidelines for lifting have to be implemented.
3.2 Dimensions
Fig. 4 Dimension drawing RCW
Model Compressor dimensions
Length L, mm Width D, mm Height H, mm Weight, kg
RCW-3-100 1250 490 949 139
RCW-3-270 1614 607 1179 222
RCW-4-100 1205 490 949 161
RCW-4-270 1614 607 1179 244
RCW-5,5-100 1205 490 949 187
RCW-5,5-270 1614 607 1179 278

14 Version 2.3
RCW-5,5-500 1953 650 1243 312
RCW-7,5-270 1614 607 1179 282
RCW-7,5-500 1953 650 1243 324
RCW-11-270 1614 607 1179 373
RCW-11-500 1953 650 1243 405
Tab. 2 Compressor dimensions
3.3 Requirements on installation facility
Ensure that the oor of the facility can withstand the weight of the compressor. Install the
compressor on a level surface that is able to bear its weight.
Adjust the horizontal axis of the compressor using a levelling instrument.
If the compressor is not anchored to the base on which it is installed, the tilt angle with re-
spect to the horizontal surface must not exceed 3°.
If the compressor is anchored to the base on which it is installed, the tilt angle with respect
to the horizontal surface must not exceed 7°.
Install the compressor in a facility where precipitation cannot reach.
Choose a facility for installing the compressor with a minimum level of dust.
Install the compressor at least 1.5 m from walls.
If multiple compressors are installed, there should be a 1.5 m minimum distance between
each compressor.
There should be a 4 m safety distance from the area of the operated equipment connected
to the compressor.
The facility in which the compressor is installed must be tted with a combined extract-and-
input ventilation system.
The facility where the compressor is installed should be provid-
ed with air inow equivalent to twice the compressor’s capacity.
The volume of extraction ventilation must not exceed 40% of the air inow capacity of the
input ventilation in a facility where the compressor is installed and tted with an extract-
and-input ventilation system.
The compressor should not be installed in a facility where the temperature may drop below
+5°С.
3.4 Connection to the compressed airline
Provide the throughput capacity of the compressed-air line in accordance with the perfor-
mance of the compressor.
In order to avoid damage associated with seal failure of the compressed-air line, the com-

15
COMPRAG RECOM RCW series
pressor should be connected via a exible hose.
All components of the compressed-air line must have a working pressure no less than the
compressor’s nominal pressure.
Use a pressure vessel with a capacity corresponding to the compressor’s performance and
the compressed air consumer.
3.5 Connecting to power supply
Connect the compressor to the electric mains: the plug of the compressor’s power cable into
380 V socket.
Ensure that your electric power grid can withstand the starting current of the compressor.
An isolating switch must be tted within reach of the compressor to facilitate connection and
maintenance.
The compressor must be earthed and protected against short
circuits in each phase, impermissible voltage uctuation and
phase failure.
3.6 Before use and on a weekly basis
Ensure the compressor’s power cable is intact.
Ensure the oil level using the sight glass (point 3.7). Fill up with oil if necessary (point 5.1).
Fig. 5 Checking compressor’s oil level

16 Version 2.3
The oil level in the compressor should be viewed via the oil level glass when the compres-
sor has stopped.
The oil level glass is arranged in the lower section of the compressor pump.
Oil level in the compressor pump should be always between H and L.
If oil level is low or oil cannot be seen in the level glass, then oil needs to be added.
3.7 Checking drive belt
Check on a daily basis drive belts condion and the
tension on drive belts.
Check on a daily basis drive belts condion and the tension on drive belts (1).
Fig. 6 Checking drive belt
Unscrew the 4 bolts (2) of the belt guard (1), removing the guard’s clips (3) and the guard
itself.
Inspect belts for wear of side edges and cracks. If belts are damaged, then they should be
replaced.
Using belt tension gauge, check the tensile load of the compressor belts.
The tensile loads of belts are given in the table for various models. Set the belt guard into
place, tighten the bolts and replace the clips which were removed.
Model Tension force F, N
RCW-3-100 250
RCW-3-270 250
RCW-4-100 250
1
3
21

17
COMPRAG RECOM RCW series
RCW-4-270 250
RCW-5,5-100 250
RCW-5,5-270 250
RCW-5,5-500 250
RCW-7,5-270 250
RCW-7,5-500 250
RCW-11-270 250
RCW-11-500 250
Tab. 7 Tensile loads of belt
4. Operation
Non-qualified personnel must not be allowed to operate the
compressor.
4.1 Starting the compressor
Before starng check oil level
Switch on the voltage.
Turn the pressure switch 90 degrees clockwise from the OFF position to the AUTO position
Fig. 7 Switch on the voltage

18 Version 2.3
The compressor starts running in an automac operaon mode
4.2 Switching off the compressor
Turn the pressure switch 90 degrees counterclockwise from the AUTO position to the OFF
position.
After usage
Disconnect the plug of the compressor’s power cable from the 380 V socket and open the
air outlet valve for pressure release in pressure vessel.
5. Maintenance
5.1 Changing compressor oil
Fig. 8 Changing compressor oil
Bleed the pressure in the system by opening the air outlet ball valve.
Unscrew the drain plug (1) from the compressor pump and bleed the oil into a special
container.
Screw drain plug (1) into its initial position.
Unscrew the fill plug (2) from the compressor pump and pour in 2 l of Comprag RecLub oil.
Screw the fill plug into its initial position.
Start the compressor and let it run idly for several minutes in order for the oil to circulate
and air to be extracted from the oil system.
Wait several minutes until the oil settles and the inner pressure is bled.
Unscrew the fill plug and add oil, if necessary, until oil enters the red circle of the sight glass.
Place the fill plug into its initial position.
122
122
11

19
COMPRAG RECOM RCW series
5.2 Changing air intake lters
Fig. 9 Changing intake air filters
Unscrew the wing nut holding the filter lid (1) and remove the nut.
Remove the filter lid (1) and the dirty air filter (2).
Install the new air filter in place of the dirty one.
Set the filter lid into place and tighten the wing nut.
5.3 Changing drive belt
Fig. 10 and 11 Changing drive belt
2
1
1
22
2

20 Version 2.3
Remove the belt guard.
Loosen the two bolts of the motor and the two corresponding nuts (1) on the left and right
sides of the motor.
Move the electric motor towards the compressor pump until tension in the belt wanes.
Remove the old belt (2) from the flywheel of the compressor pump and pulley of the electric
motor.
Install the new belt and tighten the belt with the appropriate tension force F (see table in §
3.7 Checking drive belt)
Set the belt guard into place.
Check the belt tension within four hours of the compressor’s operation.
5.4 Servicing bearings of electric motor
When the compressor is used, fresh viscous lubricant (formulated for rolling bears) should
be added to the motor’s bearings. Lubricant should be added using a special syringe for
viscous lubricants through lubricators accommodated in the motor’s bearing caps. The
volume of lubricant added can be calculated using the formula:
Do not over-lubricate the bearings beyond the standard level as all excess lubricant will
be squeezed out of the bearings into the motor when the motor is running.
6. Fault handling
6.1 Faults and corrective actions
Problem. Possible faults. Corrective action.
The compressor starts up with
lag. There is a slow build up in
the electric motor’s speed.
Tighten the belt with the rel-
evant load.
The oil is thick. Replace the oil.
There’s a whistling during the
compressor’s operation.
Tighten the belt with the appro-
priate tensile force
The compressor won’t start.
The ambient air temperature in
the facility does not meet the
required temperature (below
+5°C or above +40°C).
Ensure the necessary ambient
air temperature where the com-
pressor is installed.