L&W Compressors LW 300 EC III 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
....................................................................................................................................
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

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.

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Operating Instructions
Breathing Air Compressor
LW 300 EC III / LW 450 EC III
Version: 04/18-E

Page A - 2
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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
T A B L E O F C O N T E N T S
Genera Information and Technica Data
General Infor ation / Description of Warning Sy bols .................................................................... 4
Scope of Delivery .............................................................................................................................. 5
Technical Data .................................................................................................................................. 6
Unit Asse bly ................................................................................................................................... 7
Switchboard ..................................................................................................................................... 8
Flow chart ......................................................................................................................................... 9
Safety Precautions
Intended Use / Operators ................................................................................................................ 11
Safety instructions on the unit ........................................................................................................ 12
General Safety Precautions ............................................................................................................. 13
Unit custo ised safety notices ....................................................................................................... 14
Maintenance instructions ............................................................................................................... 15
Transportation instructions / Safety regulations .............................................................................. 16
Insta ation
Installation in closed roo s ............................................................................................................ 18
Di ensions ...................................................................................................................................... 19
Mini u distances ........................................................................................................................ 20
Ventilation ...................................................................................................................................... 21
Electrical Installation ................................................................................................................ 22 - 23
Operation
I portant operation instructions .................................................................................................... 25
First co issioning ................................................................................................................. 26 - 28
Daily co issioning ....................................................................................................................... 29
Filling procedure ............................................................................................................................. 30
Switch off the co pressor .............................................................................................................. 31
Remedying fau ts
............................................................................................................. 32 - 36
Maintenance and Service
Service, Repair and Maintenance .................................................................................................... 38
Maintenance Lists / Maintenance Intervals ............................................................................... 39 - 42
Service Kits ..................................................................................................................................... 43
Check V-belt tension / Tension V-belt .............................................................................................. 44
Co pressor lubrication / Check oil level .......................................................................................... 45
Oil change ...................................................................................................................................... 46
Oil sieve change .............................................................................................................................. 47

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
T A B L E O F C O N T E N T S
Maintenance and Service
Auto atic condensation du p syste ........................................................................................... 48
Oil / water separator 1st stage - aintenance ......................................................................... 49 - 50
Oil / water separators 2nd stage - aintenance ....................................................................... 51 - 52
Filter housing 1.7ltr / 0.8ltr ............................................................................................................. 53
1.7ltr filter cartridge change ............................................................................................................ 54
1.7ltr filter housing - aintenance ................................................................................................. 55
Inlet filter / Inlet filter cartridge change .......................................................................................... 56
Cylinder heads and valves ............................................................................................................... 57
Replace inlet and outlet valves 1st and 2nd stage .................................................................... 58 - 59
Replace inlet and outlet valve 3rd stage ......................................................................................... 60
Replace piston rings and needle bearings of the 2nd and 3rd stage ......................................... 61 - 62
Safety valves ................................................................................................................................... 63
Pressure aintaining / non return valve .......................................................................................... 64
Safety valve test .............................................................................................................................. 65
Leak test ......................................................................................................................................... 66
Pressure gas vessel test ................................................................................................................... 67
Maintenance records ............................................................................................................... 69 - 73
Storage
Conservation / storage of the co pressor ....................................................................................... 74
De-conservation, co issioning .................................................................................................... 74
Transportation instructions / Disposal ............................................................................................. 75

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
Warning
Indicates a potentially hazardous situation which, if not avoided, could result in physical
injury or da age to the product or environ ent.
Caution
Indicates an i inently hazardous situation which, if not avoided, could result in serious
injury, physical injury or death.
Genera Information
We strongly reco end reading this anual thoroughly prior to operation and follow all the safety
precautions precisely. Da age resulting fro any deviation fro these instructions is excluded fro
warranty and liability for this product. Carry out other co issioning steps only if you have fully
understood the following contents.
Before co issioning and using the unit, carry out all the essential preli inary work and easures
concerning legal regulations and safety. These are described on the following pages of this operati-
on anual.
G E N E R A L I N F O R M A T I O N
!
!
Note
Indicates additional infor ation on how to use the unit.
i
Description of marks and warning signs
The following warning signs are used in this docu ent to identify the corresponding warning notes
which require particular attention by the user. The warning signs are defined as follows:

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
D E S C R I P T I O N
• Auto atic du p syste
• Auto atic stop at final pressure
• Auto start syste
• Up to 3 extra filling hoses
• 200 and 300 bar parallel filling operation
• Oil pressure gauge and inter ediate pressure
gauge
• Oil pressure onitoring c/w auto shut down
• Cylinder head te perature onitoring with
auto shut down
• Puracon filter onitoring
• Direction of rotation onitoring
• Power cable and plug
• Painted steel fra e and V-belt guard (RAL
6026)
• Hour counter
• Start/ Stop and e ergency stop switch
• Manual condensate drain
• 1 filling hose c/w filling valve
• Motor protection switch
• Pressure aintaining and non-return valve
• All pistons c/w steel piston rings
• Low pressure oil pu p and filter
• Oil / water separators after each stage
• Safety valves after each stage
• 3 concentric suction/pressure valves
Scope of De ivery
Co pressors are provided in different equipped versions.
Versions
Filling pressure versions:
• PN 225 bar
• PN 330 bar
• PN 225 / 330 bar
Specifications
Options

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
D E S C R I P T I O N
Technica Data
Technica Data LW 300 E III LW 450 E III
Capacity [l/ in]: 300 450
Max. Operating Pressure [bar]: 350 350
RPM [ in
-1
]: 730 1,100
Nu ber of Pressure Stages: 3 3
Cylinder Bore 1st Stage [ ]: Ø 95 Ø 95
Cylinder Bore 2nd Stage [ ]: Ø 42 Ø 42
Cylinder Bore 3rd Stage [ ]: Ø 18 Ø 18
Mediu :
Co pressed Air / Breathing Air Co pressed Air / Breathing Air
Intake Pressure: at ospheric at ospheric
Oil Pressure (at operating te perature)
[bar]: +1.5 (-0,2) +1.5 (-0,2)
Oil Capacity [l]: 2.7 2.7
Intake Te perature [°C]: 0 < +45 0 < +45
A bient Te perature [°C]: +5 < +45 +5 < +45
Cooling Air Volu e [ ³/h]: > 2,250 > 3,300
Voltage: 400 V / 3 phase / 50 Hz 400 V / 3 phase / 50 Hz
Protection Class Drive Motor: IP 54 IP 54
Drive Power [kW]: 7.5 11
RPM Motor [ in
-1
]: 2,890 2,890
Start: Star/Delta Star/Delta
Noise level [dB(A)]: 82 fro a distance of 1 83 fro a distance of 1
Di ensions W x D x H [ ]: 1335 x 705 x 910 1335 x 705 x 910
Weight [kg]: ca. 365 ca. 365
Content Volu e Filter housing [l]: 1.7 1.7
Content Volu e Filter Housing (Option)
[l]: 0.8 0.8

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
Unit Assemb y
D E S C R I P T I O N
No. Designation
1 Switch box
2 Filling hose
3 Filling valve with pressure gauge
4 Filter housing 1.7 litres
5 Final pressure safety valve
1
2 3
4 5

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
Switchboard
D E S C R I P T I O N
No. Designation
1 ON button
2 OFF button
3 E ergency shut-off switch
4 Motor protection warning light
5 Hour counter
1
2
3
4
5

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
F ow chart
D E S C R I P T I O N
1. Ansaugfilter / Intake Filter
2. 1. Verdichterstufe / 1st Pressure Stage
3. Kondensat-Ablassschlauch / Condensate Drain Hose
4. Sicherheitsventil 1. Stufe / Safety Valve 1st Stage
5. Wär etauscher / Heat Exchanger
6. Kondensat-Ablassventil / Condensate Release Valve
7. Öl- / Wasserabscheider / Oil- / Water Separator
8. 2. Verdichterstufe / 2nd Pressure Stage
9. Kondensat-Ablassschlauch / Condensate Drain Hose
10. Sicherheitsventil 2. Stufe / Safety Valve 2nd Stage
11. Wär etauscher / Heat Exchanger
12. Öl- / Wasserabscheider / Oil- / Water Separator
13. Kondensat-Ablassventil / Condensate Release Valve
14. 3. Verdichterstufe / 3rd Pressure Stage
15. Kondensat-Ablassschlauch / Condensate Drain Hose
16. Sicherheitsventil 3. Stufe / Safety Valve 3rd Stage
17. Wär etauscher / Heat Exchanger
18. Öl- / Wasserabscheider / Oil- / Water Separator
19. Kondensat-Ablassventil / Condensate Release Valve
20. Druckhalteventil / Pressure Maintaining Valve
21. Rückschlagventil / Non-Return Valve
22. Hochdruckschlauch / HP-Hose
23. Baueinheit Füllventil / Filling Valve Unit
24. Flaschenanschlussstutzen / Tank Connector (DIN, CGA or
INT Yoke)
25. Füllventil / Filling Valve
26. Fülldruck ano eter / Pressure Gauge
27. Entlüftungsventil / Vent Valve)
1st stage 2nd stage 3rd stage

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

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
Intended Use
Only use the unit in perfect condition for its intended purpose, safety and intended use and observe
the operating instructions! In particular disorders that ay affect safety have to be eli inated i -
ediately!
Use the unit exclusively for the deter ined ediu (see "Technical Data"). Any other use that is not
specified is not authorized. The anufacturer/supplier shall not be liable for any da ages resulting
fro such use. Such risk lies entirely with the user. Authorization for use is also under the condition
that the instruction anual is co plied with and inspection and aintenance require ents are en-
forced.
No change and odification to the unit can be ade without the written agree ent of the anu-
facturer. The anufacturer is not liable for da age to persons or property resulting fro unauthori-
sed odifications.
Operators
Target groups in these instructions;
Operators
Operators are persons who are authorized and briefed for the use of the co pressor.
Qualified personnel
Qualified personnel are persons who are entitled to repair, service, odify and aintain the syste .
S A F E T Y P R E C A U T I O N S
Warning
Only trained personnel are per itted to work on the unit!
!
Warning
Work on the electrical equip ent on / with the achine / unit ay only be carried out by
qualified electricians.
!

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
Safety instructions on the unit
I portance of notes and warning signs that are affixed to the co pressor according to the applica-
tion or its equip ent.
S A F E T Y P R E C A U T I O N S
Warning
High voltage!
Note
Ensure correct direction of
rotation!

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
S A F E T Y P R E C A U T I O N S
Genera Safety Precautions
• Read the Operating Instructions of this product carefully prior to use.
• Strictly follow the instructions. The user ust fully understand and strictly observe the instruc-
tions. Use the product only for the purposes specified in the intended use section of this
docu ent.
• Do not dispose the operating instructions. Ensure that they are retained and appropriately used
by the product user.
• Only trained and co petent personnel are per itted to use this product.
• Co ply with all local and national rules and regulations associated with this product.
• Only trained and co petent personnel are per itted to inspect, repair and service the product.
• Only authentic L&W parts and accessories ay be used for aintenance work. Otherwise, the
proper functioning of the product ay be i paired.
• Do not use faulty or inco plete products. Do not odify the product.
• Infor L&W in the event of any product or co ponent fault or failure.
• The quality of the air supply ust eet EN 12021 specifications for breathing air.
• Do not use the product in areas prone to explosion or in the presence of fla able gases. The
product is not designed for these applications. An explosion ight be the result if certain conditi-
ons apply.

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
S A F E T Y P R E C A U T I O N S
Unit customised safety notices
Organisationa measures
• In addition to the instruction anual, observe and co ply with universally valid legal and other
obligatory regulations regarding accident prevention and environ ent protection.
• In addition to the instruction anual, provide supple entary instructions for supervision and
onitoring duties taking into consideration exceptional factors e.g. with regard to organisation
of work, production, personnel e ployed.
• Supervise personnel’s work in accordance with the instruction anual, taking into account safety
and danger factors.
• Observe all safety and danger notices on the co pressor and check readability and co pleten-
ess.
Safety instructions operation
• Take easures to ensure that the achine is only taken into operation under safe and functional
conditions. Only operate the co pressor if all protective and safety equip ent, e.g. detachable
protective equip ent, are provided and in good working order.
• Check the co pressor at least once per day for obvious da age and defects. Infor the respon-
sible depart ent / person i ediately if anything is not as is should be (including operation per-
for ance). Shut down the achine i ediately if necessary and lock it.
• In case of alfunction, stop the co pressor i ediately and lock it. Repair alfunctions i e-
diately.
• If there is a failure in the electric energy supply, shut the achine / unit down i ediately.
• Ensure safe and environ entally friendly disposal of consu ables and old parts.
• The stipulated hearing protectors ust be worn.
• Soundproofing equip ent on the co pressor has to be activated in safety function during ope-
ration.
• When handling with fats, oils and other che ical agents, observe the note for the product-
related safety.

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
S A F E T Y P R E C A U T I O N S
Maintenance instructions
• Hoses have to be checked by the operator (pressure and visual inspection) at reasonable inter-
vals, even if no safety-related defects have been detected.
• I ediately repair any da age. Escaping co pressed air can cause injury.
• Depressurise syste and pressure lines before beginning repair work.
• Pressurised air lines ust be laid and ounted by qualified personnel. Connections ust not be
ixed up. Fittings, length and quality of the piping ust correspond to require ents.
• Adjust ent, aintenance and inspection activities and keep appoint ents, including infor ati-
on on replace ent parts / equip ent, prescribed in the operating instructions have to be respec-
ted.
• If the achine / equip ent is co pletely off during aintenance and repair work, it ust be
protected against unexpected restart. Turn off ain control device and re ove the key and/or
display a warning sign on the ain switch.
• The achine and especially the connections and fittings should be cleaned fro oil, fuel and
aintenance products at the beginning of the aintenance / repair. Do not use aggressive
cleaning agents. Use fibre-free cleaning cloths.
• Switch off co pressor and clean with a slightly da p cloth. Re ove dirt fro cooling pipes by
using a brush.
• After cleaning, exa ine all pipes for leaks, loose connections, chafing and da age. I ediately
eli inate any faults.
• Always retighten any screw connections loosened for aintenance or repair work.
• If it is necessary to re ove safety devices for aintenance and repair work, these ust be re-
placed and checked i ediately after co pletion of the aintenance or repair work.
• The electrical equip ent of the co pressor ust be regularly checked. Defects, such as loose
screw connections or burnt wires, ust be i ediately rectified by electrically skilled personnel.
• Only personnel with particular knowledge and experience with pneu atics ay carry out work
on pneu atic equip ent.
• Only personnel with particular knowledge and experience in gas equip ent ay carry out work
on gas equip ent.

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
S A F E T Y P R E C A U T I O N S
Transportation instructions
• Parts which need to be dis antled for transport purposes ust be carefully replaced and secured
before taking into operation.
• The transport ay only be carried out by trained personnel.
• For transportation, only use lifting devices and equip ent with sufficient lifting power.
• Do not stand or work under suspended loads.
• Also separate fro inor relocation achinery / syste of any external energy supply. Before
reco issioning, reconnect the achine to the ains according to regulations.
• When reco issioning, proceed according to the operating instructions..
Safety regu ations
• Inspections according to legal and local obligatory regulations regarding accident prevention are
carried out by the anufacturer or by authorised expert personnel. No guarantees whatsoever
are valid for da age caused or favoured by the non-consideration of these directions for use.

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I N S T A L L A T I O N

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LW 300 EC III / LW 450 EC III
Version: 24.04.18-001 E
I N S T A L L A T I O N
Insta ation in c osed rooms
For installation in closed rooms, observe the following:
• Install the unit horizontally and level. The floor ust be vibration-free and capable of taking the
load of the syste weight.
• The co pressor roo ust be clean, dry, dust free and as cool as possible. Avoid direct exposure
to sunlight. If possible, install unit in such a anner that the co pressor fan can intake fresh air
fro outside. Ensure adequate ventilation and exhaust air opening.
• When locating the co pressor in roo s of less than 30 ³ space where natural ventilation is not
ensured or other syste s having high radiation are operating in the sa e roo , easures ust
be taken to provide artificial ventilation.
• Intake air ust be free fro noxious gas e.g. s oke, solvent vapours, exhaust fu es etc.
• Observe the specified operating te perature (see "Technical Data")!
enchmarks - Diameter of the suction hose as a function of the suction hose length
Danger
No operation in explosion-hazard areas.
The unit is not approved for operation in areas prone to explosion.
!
Note
The intake air ust be free of har ful gases.
We reco end to use an intake hose in order to get fresh air fro the outside.
i
Pos. Length of suction hose [m] Diameter suction hose [mm]
1 ≤ 3 Ø 30
2 ≤ 10 Ø 80
3 ≤ 15 Ø 100
4 ≤ 20 Ø 120