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

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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

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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
!
!
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

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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
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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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Switchboard
DESCRIPTION
1 2
3 4
5
No. Designation
1 Emergency shut-off switch
2 Hour counter
3 ON button
4 OFF button
5 Drain test button
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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

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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 may affect safety have to be eliminated im-
mediately!
Use the unit exclusively for the determined medium (see "Technical Data"). Any other use that is not
specified is not authorized. The manufacturer/supplier shall not be liable for any damages resulting
from such use. Such risk lies entirely with the user. Authorization for use is also under the condition
that the instruction manual is complied with and inspection and maintenance requirements are en-
forced.
No change and modification to the unit can be made without the written agreement of the manu-
facturer. The manufacturer is not liable for damage to persons or property resulting from unauthori-
sed modifications.
Operators
Target groups in these instructions;
Operators
Operators are persons who are authorized and briefed for the use of the compressor.
Qualified personnel
Qualified personnel are persons who are entitled to repair, service, modify and maintain the system.
SAFETY PRECAUTIONS
Warning
Only trained personnel are permitted to work on the unit!
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Warning
Work on the electrical equipment on / with the machine / unit may only be carried out by
qualified electricians.
!
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Safety instructions on the unit
Importance of notes and warning signs that are affixed to the compressor according to the applica-
tion or its equipment.
SAFETY PRECAUTIONS
Warning
High voltage!
Note
Ensure correct direction of
rotation!
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SAFETY PRECAUTIONS
General Safety Precautions
• Read the Operating Instructions of this product carefully prior to use.
• Strictly follow the instructions. The user must fully understand and strictly observe the instructi-
ons. Use the product only for the purposes specified in the intended use section of this docu-
ment.
• Do not dispose the operating instructions. Ensure that they are retained and appropriately used
by the product user.
• Only trained and competent personnel are permitted to use this product.
• Comply with all local and national rules and regulations associated with this product.
• Only trained and competent personnel are permitted to inspect, repair and service the product.
• Only authentic L&W parts and accessories may be used for maintenance work. Otherwise, the
proper functioning of the product may be impaired.
• Do not use faulty or incomplete products. Do not modify the product.
• Inform L&W in the event of any product or component fault or failure.
• The quality of the air supply must meet EN 12021 specifications for breathing air.
• Do not use the product in areas prone to explosion or in the presence of flammable gases. The
product is not designed for these applications. An explosion might be the result if certain conditi-
ons apply.
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SAFETY PRECAUTIONS
Unit customised safety notices
Organisational measures
• In addition to the instruction manual, observe and comply with universally valid legal and other
obligatory regulations regarding accident prevention and environment protection.
• In addition to the instruction manual, provide supplementary instructions for supervision and
monitoring duties taking into consideration exceptional factors e.g. with regard to organisation
of work, production, personnel employed.
• Supervise personnel’s work in accordance with the instruction manual, taking into account safety
and danger factors.
• Observe all safety and danger notices on the compressor and check readability and complete-
ness.
Safety instructions operation
• Take measures to ensure that the machine is only taken into operation under safe and functional
conditions. Only operate the compressor if all protective and safety equipment, e.g. detachable
protective equipment, are provided and in good working order.
• Check the compressor at least once per day for obvious damage and defects. Inform the respon-
sible department / person immediately if anything is not as is should be (including operation per-
formance). Shut down the machine immediately if necessary and lock it.
• In case of malfunction, stop the compressor immediately and lock it. Repair malfunctions imme-
diately.
• If there is a failure in the electric energy supply, shut the machine / unit down immediately.
• Ensure safe and environmentally friendly disposal of consumables and old parts.
• The stipulated hearing protectors must be worn.
• Soundproofing equipment on the compressor has to be activated in safety function during ope-
ration.
• When handling with fats, oils and other chemical agents, observe the note for the product-
related safety.
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SAFETY PRECAUTIONS
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.
• Immediately repair any damage. Escaping compressed air can cause injury.
• Depressurise system and pressure lines before beginning repair work.
• Pressurised air lines must be laid and mounted by qualified personnel. Connections must not be
mixed up. Fittings, length and quality of the piping must correspond to requirements.
• Adjustment, maintenance and inspection activities and keep appointments, including informati-
on on replacement parts / equipment, prescribed in the operating instructions have to be respec-
ted.
• If the machine / equipment is completely off during maintenance and repair work, it must be
protected against unexpected restart. Turn off main control device and remove the key and/or
display a warning sign on the main switch.
• The machine and especially the connections and fittings should be cleaned from oil, fuel and
maintenance products at the beginning of the maintenance / repair. Do not use aggressive clea-
ning agents. Use fibre-free cleaning cloths.
• Switch off compressor and clean with a slightly damp cloth. Remove dirt from cooling pipes by
using a brush.
• After cleaning, examine all pipes for leaks, loose connections, chafing and damage. Immediately
eliminate any faults.
• Always retighten any screw connections loosened for maintenance or repair work.
• If it is necessary to remove safety devices for maintenance and repair work, these must be repla-
ced and checked immediately after completion of the maintenance or repair work.
• The electrical equipment of the compressor must be regularly checked. Defects, such as loose
screw connections or burnt wires, must be immediately rectified by electrically skilled personnel.
• Only personnel with particular knowledge and experience with pneumatics may carry out work
on pneumatic equipment.
• Only personnel with particular knowledge and experience in gas equipment may carry out work
on gas equipment.
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SAFETY PRECAUTIONS
Transportation instructions
• Parts which need to be dismantled for transport purposes must be carefully replaced and secured
before taking into operation.
• The transport may only be carried out by trained personnel.
• For transportation, only use lifting devices and equipment with sufficient lifting power.
• Do not stand or work under suspended loads.
• Also separate from minor relocation machinery / system of any external energy supply. Before
recommissioning, reconnect the machine to the mains according to regulations.
• When recommissioning, proceed according to the operating instructions..
Safety regulations
• Inspections according to legal and local obligatory regulations regarding accident prevention are
carried out by the manufacturer or by authorised expert personnel. No guarantees whatsoever
are valid for damage caused or favoured by the non-consideration of these directions for use.
Version: 261012-001 E

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LOCATING THE UNIT

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LOCATING THE UNIT
Installation in closed rooms
For installation in closed rooms, observe the following:
• Install the unit horizontally and level. The floor must be vibration-free and capable of taking the
load of the system weight.
• The compressor room must be clean, dry, dust free and as cool as possible. Avoid direct exposure
to sunlight. If possible, install unit in such a manner that the compressor fan can intake fresh air
from outside. Ensure adequate ventilation and exhaust air opening.
• When locating the compressor in rooms of less than 30 m³ space where natural ventilation is not
ensured or other systems having high radiation are operating in the same room, measures must
be taken to provide artificial ventilation.
• Intake air must be free from noxious gas e.g. smoke, solvent vapours, exhaust fumes etc.
• Observe the specified operating temperature (see "Technical Data")!
Danger
No operation in explosion-hazard areas.
The unit is not approved for operation in areas prone to explosion.
!
Version: 261012-001 E

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LOCATING THE UNIT
Version: 261012-001 E
Dimensions
494
600
1040
1140
997
1317
Fig. Dimensions

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LOCATING THE UNIT
Minimum distances
• Make sure that the compressor always has a sufficient amount of fresh air available.
• To prevent serious damage, ensure that the cooling air flow can flow freely.
• The following minimum distances must be adhered:
Front side min. 1500 mm, sides min. 500 mm, rear side min. 500 mm.
Avoid anything in this area which can restrict the cooling air flow.
Version: 291112-001 E
Fig. Minimum distances
500500
500
1500
Note
Minimum distances must be adhered!
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