L&W LW 450 E User manual

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Operating Instructions
Breathing Air Compressor
LW 300 E / LW 450 E
www.uebler.net
Version: 11/12-E

LW 300 E / LW 450 E Page A - 2
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TABLE OF CONTENTS
General Information and Technical Data
General Information / Description of Warning Symbols .................................................................... 4
Scope of Delivery .............................................................................................................................. 5
Technical Data .................................................................................................................................. 6
Unit Assembly ................................................................................................................................... 7
Switchboard ..................................................................................................................................... 8
Flow chart ......................................................................................................................................... 9
Safety Precautions
Intended Use / Operators ................................................................................................................ 11
Safety instructions on the unit ........................................................................................................ 12
General Safety Precautions ............................................................................................................. 13
Unit customised safety notices ....................................................................................................... 14
Maintenance instructions ............................................................................................................... 15
Transportation instructions / Safety regulations .............................................................................. 16
Locating the unit
Installation in closed rooms ............................................................................................................ 18
Dimensions...................................................................................................................................... 19
Minimum distances ........................................................................................................................ 20
Ventilation ...................................................................................................................................... 21
Electrical Installation ................................................................................................................ 22 - 23
Operation
Important operation instructions .................................................................................................... 25
First commissioning ................................................................................................................. 26 - 28
Daily commissioning ....................................................................................................................... 29
Filling procedure ............................................................................................................................. 30
Switch off the compressor .............................................................................................................. 31
Remedying faults ............................................................................................................. 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
Compressor lubrication / Check oil level .......................................................................................... 45
Oil change ...................................................................................................................................... 46
Oil sieve change .............................................................................................................................. 47
Final pressure switch ...................................................................................................................... 48
Version: 261012-001 E

LW 300 E / LW 450 E Page A - 3
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TABLE OF CONTENTS
Maintenance and Service
Automatic condensation dump system ........................................................................................... 49
Oil / water separator 1st stage - maintenance ................................................................................ 50
Oil / water separators 2nd stage - maintenance .............................................................................. 51
Oil / water separators final stage - maintenance ............................................................................. 52
Pneumatic condensate valve - maintenance ................................................................................... 53
Filter housing / Filter cartridge ........................................................................................................ 54
Filter cartridge change..................................................................................................................... 55
Filter housing - Maintenance ........................................................................................................... 56
Inlet filters / Inlet filter cartridge change ......................................................................................... 57
Cylinder heads and valves ............................................................................................................... 58
Replace inlet and outlet valves 1st and 2nd stage .................................................................... 59 - 60
Replacement inlet and outlet valves 3rd stage ................................................................................ 61
Safety valves ................................................................................................................................... 62
Pressure maintaining / non return valve .......................................................................................... 63
Safety valve test .............................................................................................................................. 64
Leak test ......................................................................................................................................... 65
Pressure gas vessel test ................................................................................................................... 66
Maintenance records ............................................................................................................... 67 - 72
Storage
Conservation / storage of the compressor ....................................................................................... 73
De-conservation, commissioning .................................................................................................... 73
Transportation instructions / Disposal ............................................................................................. 74
Version: 261012-001 E

LW 300 E / LW 450 E Page A - 4
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Warning
Indicates a potentially hazardous situation which, if not avoided, could result in physical
injury or damage to the product or environment.
Caution
Indicates an imminently hazardous situation which, if not avoided, could result in serious
injury, physical injury or death.
General Information
We strongly recommend reading this manual thoroughly prior to operation and follow all the safety
precautions precisely. Damage resulting from any deviation from these instructions is excluded from
warranty and liability for this product. Carry out other commissioning steps only if you have fully
understood the following contents.
Before commissioning and using the unit, carry out all the essential preliminary work and measures
concerning legal regulations and safety. These are described on the following pages of this operati-
on manual.
GENERAL INFORMATION
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!
Note
Indicates additional information on how to use the unit.
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Description of marks and warning signs
The following warning signs are used in this document to identify the corresponding warning notes
which require particular attention by the user. The warning signs are defined as follows:
Version: 261012-001 E

LW 300 E / LW 450 E Page A - 5
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DESCRIPTION
Scope of Delivery
Compressors are provided in different equipped versions.
Versions
Filling pressure versions:
• PN 225 bar
• PN 330 bar
• PN 225 / 330 bar
Specifications
Options
• Auto start system
• 200 and 300 bar parallel filling operation
• Oil pressure display
• Intermediate pressure gauges
• Oil pressure monitoring c/w auto shut down
• Cylinder head temperature monitoring with
auto shut down
• Oil temperature display with auto shut down
• Puracon filter monitoring
• ECC control in remote control box
• Additional high pressure outlet
• Direction of rotation monitoring
• Power cable and plug
• Automatic condensate drain
• Automatic stop at final pressure
• Hour counter
• Start/Stop and emergency stop switch, con-
densate test buttons
• Motor protection switch, emergency stop
switch
• Pressure maintaining and non-return valve
• All pistons c/w steel piston rings
• Low pressure oil pump and filter
• Oil / water separators after each stage
• Safety valves after each stage
• 3x concentric suction/pressure valves
Version: 261012-001 E

LW 300 E / LW 450 E Page A - 6
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DESCRIPTION
Technical Data
Technical Data LW 300 E LW 450 E
Capacity [l/min]: 300 450
Max. Operating Pressure [bar]: 350 350
RPM [min-1]: 730 1,100
Number of Pressure Stages: 3 3
Cylinder Bore 1st Stage [mm]: Ø 95 Ø 95
Cylinder Bore 2nd Stage [mm]: Ø 42 Ø 42
Cylinder Bore 3rd Stage [mm]: Ø 18 Ø 18
Medium: Compressed Air / Breathing Air Compressed Air / Breathing Air
Intake Pressure: atmospheric atmospheric
Oil Pressure [bar]: +2.0 +2.0
Oil Capacity [l]: 2.2 2.2
Intake Temperature [°C]: 0 < +45 0 < +45
Ambient Temperature [°C]: +5 < +45 +5 < +45
Cooling Air Volume [m³/h]: > 3,300 > 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 [min-1]: 2,890 2,890
Start: Star/Delta Star/Delta
Noise level [dB(A)]: 82 from a distance of 1 m 83 from a distance of 1 m
Dimensions L x W x H [mm]: 1150 x 680 x 1000 1150 x 680 x 1000
Weight [kg]: ca. 280 ca. 280
Content Volume Filter housing [l]: 1.7 1.7
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Unit Assembly
DESCRIPTION
No. Designation
1 Filling pressure gauge
2 Switchboard
3 Filling hoses (optional: without filling hoses)
4 Filling valves
1 2
Version: 260912-001
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LW 300 E / LW 450 E Page A - 8
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Switchboard
DESCRIPTION
1 2
3 4
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No. Designation
1 Emergency shut-off switch
2 Hour counter
3 ON button
4 OFF button
5 Drain test button
Version: 261012-001 E

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Flow chart
DESCRIPTION
1. Ansaugfilter / Air Intake Filter
2. 1. Verdichterstufe / 1st Pressure Stage
3. Kondensatablassschlauch / Condensate Release Hose
4. Sicherheitsventil 1.Stufe / Safety Valve 1st Stage
5. Wärmetauscher / Heat Exchanger
6. Kondensatventil / Condensate Valve
7. Öl-/Wasserabscheider / Oil Water Separator
8. 2. Verdichterstufe / 2nd Pressure Stage
9. Kondensatablassschlauch / Condensate Release Hose
10. Sicherheitsventil 2.Stufe / Safety Valve 2nd Stage
11. Wärmetauscher / Heat Exchanger
12. Kondensatventil / Condensate Valve
13. Öl-/Wasserabscheider / Oil-/Water Separator
14. 3. Verdichterstufe / 3rd Pressure Stage
15. Kondensatablassschlauch / Condensate Release Hose
16. Sicherheitsventil 3.Stufe / Safety Valve 3rd Stage
17. Wärmetauscher / Heat Exchanger
18. Öl-/Wasserabscheider / Oil-/Water Separator
19. Pneum. Kondensatventil / Pneumatic Condensate Valve
20. Magnetventil / Solenoid Valve
21. Kondensatabscheider Endstufe / Condensate Separator
22. Schalldämpfer / Silencer
23. Druckhalteventil / Pressure Maintaining Valve
24. Rückschlagventil / Non-Return Valve
25. Hochdruckschläuche / HP Hose
26. Druckmanometer / Pressure Gauge
27. Steuerleitung 2.Stufe / Control Cable 2nd Stage
28. Füllanschlüsse / Filling Connections
29. Hochdruckabgang (Option) / HP Outlet (option)
Version: 261012-001 E
1st stage 2nd stage 3rd stage

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SAFETY PRECAUTIONS