L&W Compressors LW 230 ES User manual

C H A P T E R O V E R V I E W
Operating Instructions
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ECC - Electronic Compressor Control (if equipped
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Spare Parts Lists
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Options (if equipped
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Attachment
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A
B
C
D
E
Manufacturer in terms of 97/23/EC
The full name and address of the manufacturer is:
Lenhardt & Wagner GmbH
An der Tuchbleiche 39
686 3 Hüttenfeld / Germany
Phone: +49 (0) 6 56 - 85 88 0 - 0
Fax: +49 (0) 6 56 - 85 88 0 - 14
E-Mail: [e-mail]
Internet: www.lw-compressors.com
Version: 1.06. 013

S E R V I C E I N F O R M A T I O N / W A R R A N T Y
Compressor information
Type designation
Serial number
Date of construction
Purchase information
Purchase date
First commissioned on
Warranty period
Dealer's stamp
Warranty
L&W will uphold warranty claims made during a period of 1 months from the invoice date.
If the compressor was purchased from an official L&W dealer, the date on the dealer's invoice is
valid. Warranty claims can only be made on presentation of the original invoice.
Should verifiably defective parts have been delivered, we will decide to either replace the parts or
repair them. The resulting transport and assembly costs will be invoiced.
No reduction of the purchase price or changes to the contract can be made. The parts for which a
claim is being made should be kept safe by the purchaser and, when requested, sent to us at their
cost. Replaced parts become the property of L&W. If maintenance work is carried out without our
knowledge or permission by the purchaser or a third party, we are absolved from any liability for
warranty claims. As a matter of principle, warranty claims can only be made by the initial purchaser.
Version: 1.06. 013

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Operating Instructions
Breathing Air Compressor
LW 230 ES / LW 280 ES / LW 320 ES
Version: 02.01.2017

LW 230 ES / LW 280 ES / LW 320 ES Page A - 2
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T A B L E O F C O N T E N T S
General nformation and Technical Data
General Informa ion / Descrip ion of Warning Symbols .................................................................... 4
Scope of Delivery .............................................................................................................................. 5
Technical Da a .................................................................................................................................. 6
Uni Assembly ................................................................................................................................... 7
Swi chboard ..................................................................................................................................... 8
Flow char ......................................................................................................................................... 9
Safety Precautions
In ended Use / Opera ors ................................................................................................................ 11
Safe y ins ruc ions on he uni ........................................................................................................ 12
General Safe y Precau ions ............................................................................................................. 13
Uni cus omised safe y no ices ....................................................................................................... 14
Main enance ins ruc ions ............................................................................................................... 15
Transpor a ion ins ruc ions / Safe y regula ions .............................................................................. 16
nstallation
Ins alla ion in closed rooms ............................................................................................................ 18
Dimensions ...................................................................................................................................... 19
Minimum dis ances ........................................................................................................................ 20
Ven ila ion ...................................................................................................................................... 21
Elec rical Ins alla ion ................................................................................................................ 22 - 23
Operation
Impor an opera ion ins ruc ions .................................................................................................... 25
Firs commissioning ................................................................................................................. 26 - 28
Daily commissioning ....................................................................................................................... 29
Filling procedure ............................................................................................................................. 30
Swi ch off he compressor .............................................................................................................. 31
Remedying faults
............................................................................................................. 32 - 36
Maintenance and Service
Service, Repair and Main enance .................................................................................................... 38
Main enance Lis s / Main enance In ervals ............................................................................... 39 - 42
Service Ki s ..................................................................................................................................... 43
Check V-bel ension / Tension V-bel .............................................................................................. 44
Compressor lubrica ion / Check oil level .......................................................................................... 45
Oil change ...................................................................................................................................... 46
Oil fil er main enance ..................................................................................................................... 47
Final pressure swi ch ...................................................................................................................... 48
Version: 121212-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 3
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T A B L E O F C O N T E N T S
Maintenance and Service
Au oma ic condensa ion dump sys em ........................................................................................... 49
Oil / Wa er separa ors 1s and 2nd s age - main enance ................................................................ 50
Oil / wa er separa ors final s age - main enance ............................................................................. 51
Pneuma ic condensa e valve - main enance ................................................................................... 52
Fil er housing / Fil er car ridge ........................................................................................................ 53
Fil er car ridge change ..................................................................................................................... 54
Fil er housing - Main enance ........................................................................................................... 55
Inle fil ers / Inle fil er car ridge change ......................................................................................... 56
Cylinder heads and valves ............................................................................................................... 57
Replace inle and ou le valve 1s s age ................................................................................... 58 - 59
Replace inle and ou le valves 2nd and 3rd s age .......................................................................... 60
Safe y valves ................................................................................................................................... 61
Pressure main aining / non re urn valve .......................................................................................... 62
Safe y valve es .............................................................................................................................. 63
Leak es ......................................................................................................................................... 64
Pressure gas vessel es ................................................................................................................... 65
Main enance records ............................................................................................................... 66 - 71
Storage
Conserva ion / s orage of he compressor ....................................................................................... 72
De-conserva ion, commissioning .................................................................................................... 72
Transpor a ion ins ruc ions / Disposal ............................................................................................. 73
Version: 111212-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 4
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Warning
Indica es a po en ially hazardous si ua ion which, if no avoided, could resul in physical
injury or damage o he produc or environmen .
Caution
Indica es an imminen ly hazardous si ua ion which, if no avoided, could resul in serious
injury, physical injury or dea h.
General nformation
We s rongly recommend reading his manual horoughly prior o opera ion and follow all he safe y
precau ions precisely. Damage resul ing from any devia ion from hese ins ruc ions is excluded from
warran y and liabili y for his produc . Carry ou o her commissioning s eps only if you have fully
unders ood he following con en s.
Before commissioning and using he uni , carry ou all he essen ial preliminary work and measures
concerning legal regula ions and safe y. These are described on he following pages of his
opera ion manual.
G E N E R A L N F O R M A T O N
!
!
Note
Indica es addi ional informa ion on how o use he uni .
i
Description of marks and warning signs
The following warning signs are used in his documen o iden ify he corresponding warning no es
which require par icular a en ion by he user. The warning signs are defined as follows:
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 5
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D E S C R P T O N
Version: 121212-001 E
Scope of Delivery
Compressors are provided in differen equipped versions.
Versions
Filling pressure versions:
• PN 225 bar
• PN 330 bar
• PN 225 / 330 bar
Specifications
Options
• Au o s ar sys em
• Up o 6 addi ional hoses available
• 200 and 300 bar parallel filling pressures
• Oil pressure gauge
• In ermedia e pressure gauges
• Oil pressure moni oring c/w au o shu down
• Cylinder head empera ure moni oring wi h
au o shu down
• Oil empera ure display wi h au o shu down
• Puracon fil er moni oring (Au o shu down
also available)
• ECC con rol
• Phase moni oring c/w shu down a wrong
direc ion of ro a ion
• Addi ional high pressure ou le
• Power cable and plug
• Sound insula ed housing
• Au oma ic condensa e drain
• Au oma ic s op a final pressure
• Hour coun er
• Opera ing panel wi h s ar /s op and
condensa e es bu on, as well emergency
s op swi ch
• 2 x Filling hose c/w filling valve
• Mo or pro ec ion swi ch (LW 230 Op ional)
• Pressure main aining and non re urn valve
• All pis ons c/w s eel pis on rings
• Low pressure oil pump and fil er
• Oil- / Wa er separa ors in s ainless s eel
• Safe y valves af er each s age
• 3 x concen ric suc ion/pressure valves
• Filling pressure o your choice (200 or 300
bar)

LW 230 ES / LW 280 ES / LW 320 ES Page A - 6
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D E S C R P T O N
Technical Data
Version: 020117-001 E
Technical Data LW 230 ES LW 280 ES LW 320 ES
Capaci y [l/min]: 230 280 320
Max. Opera ing Pressure [bar]: 350 350 350
RPM [min
-1
]: 1080 1300 1450
Number of Pressure S ages: 3 3 3
Cylinder Bore 1s S age [mm]: Ø 95 Ø 95 Ø 95
Cylinder Bore 2nd S age [mm]: Ø 40 Ø 40 Ø 40
Cylinder Bore 3rd S age [mm]: Ø 18 Ø 18 Ø 18
Medium: Compressed Air / Brea hing Air
In ake Pressure: a mospheric
Oil Pressure [bar]: +0.6 o +4.0 +0.6 o +4.0 +0.6 o +4.0
Oil Capaci y [l]: 1.8 1.8 1.8
In ake Tempera ure [°C]: 0 < +45 0 < +45 0 < +45
Ambien Tempera ure [°C]: +5 < +45 +5 < +45 +5 < +45
Cooling Air Volume [m³/h]: > 1650 > 2250 > 2250
Vol age: 400 V / 3 phase / 50 Hz
Pro ec ion Class Drive Mo or: IP 54 IP 54 IP 54
Drive Power [kW]: 5.5 7.5 7.5
RPM Mo or [min
-1
]: 2890 2890 2890
S ar : S ar/Del a
Noise level from a dis ance of 1 m [dB(A)]: 61 61 61
Dimensions W x D x H [mm]:
Weigh [kg]: approx. 330 approx. 330 approx. 330
Con en Volume Fil er housing [l]: 1.7 1.7 1.7
760 x 1030 x 1630

LW 230 ES / LW 280 ES / LW 320 ES Page A - 7
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Unit Assembly
D E S C R P T O N
Version: 131212-001
1
4
3
2 5
6
7
No. Designation
1 Filling pressure gauge
2 Swi chboard
3 Fil er Housing
4 Pressure main aining / non re urn valve
5 Lever filling valve
6 Filling hoses
7 Filling connec or

LW 230 ES / LW 280 ES / LW 320 ES Page A - 8
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Switchboard
D E S C R P T O N
1 2
3 4 5
No. Designation
1 Emergency shu -off swi ch
2 Hour coun er
3 ON bu on
4 OFF bu on
5 Drain es bu on
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 9
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Flow chart
D E S C R P T O N
Version: 121212-001 E
1. Ansaugfil er / Air In ake Fil er
2. 1. Verdich ers ufe / 1s Pressure S age
3. Kondensa ablaßschlauch / Condensa e Drain Hose
4. Sicherhei sven il 1. S ufe / Safe y Valve 1s S age
5. Wärme auscher / Hea Exchanger
6. Magne ven il / Solenoid Valve
7. Öl-/Wasserabscheider / Oil-/Wa er Separa or
8. 2. Verdich ers ufe / 2nd Pressure S age
10. Sicherhei sven il 2. S ufe / Safe y Valve 2nd S age
11. Wärme auscher / Hea Exchanger
12. Pneuma isches Kondensa ven il / Pneuma ic Condensa e
Valve
13. Öl-/Wasserabscheider / Oil-/Wa er Separa or
14. 3. Verdich ers ufe / 3rd Pressure S age
15. S euer- / En lüf uf ungslei ung 2. S ufe /
Con rol pressure / Condensa e drain 2nd s age
16. Sicherhei sven il 3. S ufe / Safe y Valve 3rd S age
17. Wärme auscher / Hea Exchanger
18. Öl-/Wasserabscheider / Oil-/Wa er Separa or
19. Druckmanome er (Fülldruck) / Pressure Gauge
(Filling Pressure)
20. Magne ven il / Solenoid Valve
21. Öl-/Wasserabscheider / Oil-/Wa er Separa or
22. Schalldämpfer / Silencer
23. Druckhal even il / Pressure Main aining Valve
24. Rückschlagven il / Non-Re urn Valve
25. Hochdruckschlauch / HP-Hose
26. Kondensa ablaßschlauch / Condensa e Drain Hose
28. Kondensa ablaßschlauch / Condensa e Drain Hose
1s s age 2nd s age 3rd s age

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S A F E T Y P R E C A U T O N S

LW 230 ES / LW 280 ES / LW 320 ES Page A - 11
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ntended Use
Only use he uni in perfec condi ion for i s in ended purpose, safe y and in ended use and observe
he opera ing ins ruc ions! In par icular disorders ha may affec safe y have o be elimina ed
immedia ely!
Use he uni exclusively for he de ermined medium (see "Technical Da a"). Any o her use ha is no
specified is no au horized. The manufac urer/supplier shall no be liable for any damages resul ing
from such use. Such risk lies en irely wi h he user. Au horiza ion for use is also under he condi ion
ha he ins ruc ion manual is complied wi h and inspec ion and main enance requiremen s are
enforced.
No change and modifica ion o he uni can be made wi hou he wri en agreemen of he
manufac urer. The manufac urer is no liable for damage o persons or proper y resul ing from
unau horised modifica ions.
Operators
Targe groups in hese ins ruc ions;
Operators
Opera ors are persons who are au horized and briefed for he use of he compressor.
Qualified personnel
Qualified personnel are persons who are en i led o repair, service, modify and main ain he sys em.
S A F E T Y P R E C A U T O N S
Warning
Only rained personnel are permi ed o work on he uni !
!
Warning
Work on he elec rical equipmen on / wi h he machine / uni may only be carried ou by
qualified elec ricians.
!
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 12
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Safety instructions on the unit
Impor ance of no es and warning signs ha are affixed o he compressor according o he
applica ion or i s equipmen .
S A F E T Y P R E C A U T O N S
Warning
High voltage!
Note
Ensure correct direction of
rotation!
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 13
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S A F E T Y P R E C A U T O N S
General Safety Precautions
• Read he Opera ing Ins ruc ions of his produc carefully prior o use.
• S ric ly follow he ins ruc ions. The user mus fully unders and and s ric ly observe he
ins ruc ions. Use he produc only for he purposes specified in he in ended use sec ion of his
documen .
• Do no dispose he opera ing ins ruc ions. Ensure ha hey are re ained and appropria ely used
by he produc user.
• Only rained and compe en personnel are permi ed o use his produc .
• Comply wi h all local and na ional rules and regula ions associa ed wi h his produc .
• Only rained and compe en personnel are permi ed o inspec , repair and service he produc .
• Only au hen ic L&W par s and accessories may be used for main enance work. O herwise, he
proper func ioning of he produc may be impaired.
• Do no use faul y or incomple e produc s. Do no modify he produc .
• Inform L&W in he even of any produc or componen faul or failure.
• The quali y of he air supply mus mee EN 12021 specifica ions for brea hing air.
• Do no use he produc in areas prone o explosion or in he presence of flammable gases. The
produc is no designed for hese applica ions. An explosion migh be he resul if cer ain
condi ions apply.
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 14
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S A F E T Y P R E C A U T O N S
Unit customised safety notices
Organisational measures
• In addi ion o he ins ruc ion manual, observe and comply wi h universally valid legal and o her
obliga ory regula ions regarding acciden preven ion and environmen pro ec ion.
• In addi ion o he ins ruc ion manual, provide supplemen ary ins ruc ions for supervision and
moni oring du ies aking in o considera ion excep ional fac ors e.g. wi h regard o organisa ion
of work, produc ion, personnel employed.
• Supervise personnel’s work in accordance wi h he ins ruc ion manual, aking in o accoun safe y
and danger fac ors.
• Observe all safe y and danger no ices on he compressor and check readabili y and
comple eness.
Safety instructions operation
• Take measures o ensure ha he machine is only aken in o opera ion under safe and func ional
condi ions. Only opera e he compressor if all pro ec ive and safe y equipmen , e.g. de achable
pro ec ive equipmen , are provided and in good working order.
• Check he compressor a leas once per day for obvious damage and defec s. Inform he
responsible depar men / person immedia ely if any hing is no as is should be (including
opera ion performance). Shu down he machine immedia ely if necessary and lock i .
• In case of malfunc ion, s op he compressor immedia ely and lock i . Repair malfunc ions
immedia ely.
• If here is a failure in he elec ric energy supply, shu he machine / uni down immedia ely.
• Ensure safe and environmen ally friendly disposal of consumables and old par s.
• The s ipula ed hearing pro ec ors mus be worn.
• Soundproofing equipmen on he compressor has o be ac iva ed in safe y func ion during
opera ion.
• When handling wi h fa s, oils and o her chemical agen s, observe he no e for he produc -
rela ed safe y.
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 15
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S A F E T Y P R E C A U T O N S
Maintenance instructions
• Hoses have o be checked by he opera or (pressure and visual inspec ion) a reasonable
in ervals, even if no safe y-rela ed defec s have been de ec ed.
• Immedia ely repair any damage. Escaping compressed air can cause injury.
• Depressurise sys em and pressure lines before beginning repair work.
• Pressurised air lines mus be laid and moun ed by qualified personnel. Connec ions mus no be
mixed up. Fi ings, leng h and quali y of he piping mus correspond o requiremen s.
• Adjus men , main enance and inspec ion ac ivi ies and keep appoin men s, including
informa ion on replacemen par s / equipmen , prescribed in he opera ing ins ruc ions have o
be respec ed.
• If he machine / equipmen is comple ely off during main enance and repair work, i mus be
pro ec ed agains unexpec ed res ar . Turn off main con rol device and remove he key and/or
display a warning sign on he main swi ch.
• The machine and especially he connec ions and fi ings should be cleaned from oil, fuel and
main enance produc s a he beginning of he main enance / repair. Do no use aggressive
cleaning agen s. Use fibre-free cleaning clo hs.
• Swi ch off compressor and clean wi h a sligh ly damp clo h. Remove dir from cooling pipes by
using a brush.
• Af er cleaning, examine all pipes for leaks, loose connec ions, chafing and damage. Immedia ely
elimina e any faul s.
• Always re igh en any screw connec ions loosened for main enance or repair work.
• If i is necessary o remove safe y devices for main enance and repair work, hese mus be
replaced and checked immedia ely af er comple ion of he main enance or repair work.
• The elec rical equipmen of he compressor mus be regularly checked. Defec s, such as loose
screw connec ions or burn wires, mus be immedia ely rec ified by elec rically skilled personnel.
• Only personnel wi h par icular knowledge and experience wi h pneuma ics may carry ou work
on pneuma ic equipmen .
• Only personnel wi h par icular knowledge and experience in gas equipmen may carry ou work
on gas equipmen .
Version: 261012-001 E

LW 230 ES / LW 280 ES / LW 320 ES Page A - 16
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S A F E T Y P R E C A U T O N S
Transportation instructions
• Par s which need o be disman led for ranspor purposes mus be carefully replaced and secured
before aking in o opera ion.
• The ranspor may only be carried ou by rained personnel.
• For ranspor a ion, only use lif ing devices and equipmen wi h sufficien lif ing power.
• Do no s and or work under suspended loads.
• Also separa e from minor reloca ion machinery / sys em of any ex ernal energy supply. Before
recommissioning, reconnec he machine o he mains according o regula ions.
• When recommissioning, proceed according o he opera ing ins ruc ions..
Safety regulations
• Inspec ions according o legal and local obliga ory regula ions regarding acciden preven ion are
carried ou by he manufac urer or by au horised exper personnel. No guaran ees wha soever
are valid for damage caused or favoured by he non-considera ion of hese direc ions for use.
Version: 261012-001 E

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N S T A L L A T O N

LW 230 ES / LW 280 ES / LW 320 ES Page A - 18
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N S T A L L A T O N
Version: 261012-001 E
nstallation in closed rooms
For installation in closed rooms, observe the following:
• Ins all he uni horizon ally and level. The floor mus be vibra ion-free and capable of aking he
load of he sys em weigh .
• The compressor room mus be clean, dry, dus free and as cool as possible. Avoid direc exposure
o sunligh . If possible, ins all uni in such a manner ha he compressor fan can in ake fresh air
from ou side. Ensure adequa e ven ila ion and exhaus air opening.
• When loca ing he compressor in rooms of less han 30 m³ space where na ural ven ila ion is no
ensured or o her sys ems having high radia ion are opera ing in he same room, measures mus
be aken o provide ar ificial ven ila ion.
• In ake air mus be free from noxious gas e.g. smoke, solven vapours, exhaus fumes e c.
• Observe he specified opera ing empera ure (see "Technical Da a")!
•
•
•
•
Appro imate value - Diameter of intake hose depending on the length of the intake hose
Danger
No opera ion in explosion-hazard areas.
The uni is no approved for opera ion in areas prone o explosion.
!
Hinweis
• In ake air mus be free from noxious gas e.g. smoke, solven vapours and exhaus
fumes. We recommend no o use he in ake air inside he compressor housing. An
in ake hose would be recommendable!
i
Pos. Length of Intake Hose [m] Diameter of Intake Hose [mm]
1 ≤ 03 Ø 30
2 ≤ 10 Ø 80
3 ≤ 15 Ø 100
4 ≤ 20 Ø 120