L&W LW 450 E Operating Instructions Manual Download

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Operating Instructions

Breathing Air Compressor

LW 300 E / LW 450 E

www.uebler.

net

Version: 11/12-E

Summary of Contents for LW 450 E

Page 1: ...A Operating Instructions Breathing Air Compressor LW 300 E LW 450 E www uebler net Version 11 12 E...

Page 2: ...n 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 ins...

Page 3: ...e 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 Replac...

Page 4: ...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...

Page 5: ...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...

Page 6: ...r 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 m h 3 300 3 300 Voltage 400...

Page 7: ...0 E LW 450 E Page A 7 A Unit Assembly D E S C R I P T I O N No Designation 1 Filling pressure gauge 2 Switchboard 3 Filling hoses optional without filling hoses 4 Filling valves 1 2 Version 260912 001...

Page 8: ...LW 300 E LW 450 E Page A 8 A Switchboard D E S C R I P T I O N 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 Version 261012 001 E...

Page 9: ...13 l Wasserabscheider Oil Water Separator 14 3 Verdichterstufe 3rd Pressure Stage 15 Kondensatablassschlauch Condensate Release Hose 16 Sicherheitsventil 3 Stufe Safety Valve 3rd Stage 17 W rmetausch...

Page 10: ...A S A F E T Y P R E C A U T I O N S...

Page 11: ...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...

Page 12: ...on the unit Importance of notes and warning signs that are affixed to the compressor according to the applica tion or its equipment S A F E T Y P R E C A U T I O N S Warning High voltage Note Ensure c...

Page 13: ...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 an...

Page 14: ...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 worki...

Page 15: ...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...

Page 16: ...rk 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 reco...

Page 17: ...A LO C A T I N G T H E U N I T...

Page 18: ...at 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 m space where natural ventilation is n...

Page 19: ...LW 300 E LW 450 E Page A 19 A L O C A T I N G T H E U N I T Version 261012 001 E Dimensions 494 600 1040 1140 997 1317 Fig Dimensions...

Page 20: ...able 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 anyth...

Page 21: ...n flow freely The necessary cooling air flow can be calculated by using the following formula 300 x drive power kW required cooling air flow m h Example 11kW motor 300 x 11kW 3300 m h required cooling...

Page 22: ...r The fusing should be done in accordance with the valid regulations of the responsible electricity supply company When connecting the unit to the electrical supply check the compressor direction of r...

Page 23: ...minal motor power Fusing start A Connection in mm kw A Direct Star Delta Contactorsupply Motor S D 2 2 5 10 1 5 1 5 4 8 5 20 2 5 1 5 5 5 11 3 25 20 2 5 1 5 7 5 15 2 30 25 2 5 1 5 11 21 7 35 4 2 5 15 2...

Page 24: ...A O P E R AT I O N...

Page 25: ...mportant operation instructions Note Ensure that all persons handling the compressor are familiar with function and operation of the unit i Wear hearing protection When working on a running machine al...

Page 26: ...tact an authorised electrician 3 Check oil pressure if oil pressure gauge is installed 4 Run the compressor for about 2 minutes 5 Close the open filling valve carefully 6 Run the compressor up to maxi...

Page 27: ...ose tension during transportation Please check the V belt tension before starting the compressor Tension V belt To tighten V belt tension loosen 4 mounting nuts of the drive motor Use the tensioning s...

Page 28: ...tation is wrong the guide pistons of the 2nd and 3rd stages can not be sufficiently lubricated with the consequence that the pistons will be damaged Further more cooling air flow will not be sufficien...

Page 29: ...I N G Prior to daily operation observe the following Ensure cooling air can flow freely Check compressor oil level by the oil sight glass Check if filter cartridge is in place observe filter cartridge...

Page 30: ...ast test date are rated for the final pressure are free from humidity i 1 Close all filling valves 2 Connect the closed compressed air cylinders 3 Open cylinder valves 4 Start compressor by pushing th...

Page 31: ...s down the system when the corresponding final pressure is reached During filling process you can shut down the system at any time by pushing the red button OFF or the emergency stop only in case of e...

Page 32: ...A R E M E D Y I N G FA U LT S...

Page 33: ...s heat exchanger broken Replace Condensate drain valves leaky Unscrew valves check sealing surfaces clean replace if necessary Final pressure switch stop unit Verify settings replace if necessary Pist...

Page 34: ...direction Ensure correct phase rotation observe rotation direction arrow Inlet and outlet valves contaminated defective Clean replace if necessary Safety valve leaks Cause of fault Remedy Inlet and ou...

Page 35: ...re not as prescribed control pressure of pneumatic condensate valve too low Check corresponding inlet and outlet valve replace if necessary Piston sealing of pneumatic condensate valve contaminated us...

Page 36: ...y saturated before change Store filter cartridges properly dispose defective cartridges Cylinder s piston s or piston ring s defective Replace Operating temperature too high Ensure sufficient ventilat...

Page 37: ...A M A I N T E N A N C E A N D S E R V I C E...

Page 38: ...trained personnel This is necessary because all maintenance work can not be explained exactly and detailed in this manual Only use authentic spare parts for service work Danger Components under pressu...

Page 39: ...of final pressure switch Every 3 months or as required Maintenance work Type Quantity Order No Check Retorque all connections and bolts Annually Maintenance work Type Quantity Order No Oil change if l...

Page 40: ...I N T E N A N C E A N D S E R V I C E Every 500 operating hours Maintenance work Type Quantity Order No Change intake filter 1 000170 Check pressure maintaining non return valve Check V belt tension a...

Page 41: ...tage 1 000184 2nd stage 1 000173 1st stage 1 001294 2nd stage 3 001272 Replace o ring of oil separator 1 001294 Replace silencer 1 000178 Replace sintered metal filter of oil separators 1 000184 Repla...

Page 42: ...ets of 1st 2nd and 3rd stage gasket 3 000240 o ring 1 001274 1st stage 1 000259 2nd stage 1 000256 3rd stage 1 000510 Upper gasket 1st 1 000257 Upper gasket 2nd 1 000254 Lower gasket 1st 1 000258 Lowe...

Page 43: ...el and interval the service kits include parts such as O Rings Sinter Filter Inlet Filter V Belts Silencers In Outlet Valve Valve Seals and Compressor oil Service Kits Compressor Frequency Operating H...

Page 44: ...rew to move the electric motor until the V belt tension is sufficient Then tighten mounting nuts and check V belt tension We recommend using a V belt tension gauge Correct V belt tension Do not tensio...

Page 45: ...drain hose with oil drain valve Oil sight glass Lubricating System Oil Pressure Switch Check oil level Check oil before each operation of the system The oil level should be between the middle and uppe...

Page 46: ...funnel Check oil level The oil level should be between the middle and upper end of the oil sight glass Screw oil fill port manually in and tighten with the adjustable wrench The oil change is now com...

Page 47: ...ce the gaskets Soak the gaskets with oil before placing respect mounting direction Be sure to position the arrow see Fig Pos 1 from the new oil sieve opposite to inlet and return ports of the pump see...

Page 48: ...ng cut out pressure Turn the adjusting screw anti clockwise Adjust the pressure switch in steps of a quarter turn Restart the compressor after every adjustment step to verify the actual cut out pressu...

Page 49: ...itch box and activates the dump valves about every 15 minutes To release the complete condensate through the black plastic hoses we recommend using an 20 l container at least The drain noise can be ke...

Page 50: ...Fig 3 Reassemble all parts and tighten nut Change o ring previously grease new o ring Fig 4 Place separator top and tighten ring nut manually Mount oil water separators Tighten pipe connections and mo...

Page 51: ...ange o ring previously grease new o ring Fig 4 Place separator top and tighten manually Remove bottom part Fig 5 Change o ring previously grease new o ring Press in bottom part Mount oil water separat...

Page 52: ...ove separator top Fig 1 Loosen nut at the separator top Change sinter filter Fig 2 Reassemble all parts and tighten nut Change o ring previously grease new o ring Fig 3 Place separator top and tighten...

Page 53: ...onnections and mounting screws Remove pneumatic condensate valve Loosen connection Fig 2 Change sinter filter Fig 3 Tighten horizontal screw Mount pneumatic condensate valve Tighten pipe connections a...

Page 54: ...reathing air purification system Air is compressed up to 330 bar dried and odour and tasteless purified Oil residues are bounded The breathing air filter cartridge consists of a molecular sieve and ac...

Page 55: ...acking of the new filter cartridge and place it with the filter tool in the filter housing Screw the new filter cartridge hand tight in by using the filter tool Screw the cover of the filter housing f...

Page 56: ...Loosen pipe connections and nuts Fig 3 Remove filter housing Dismount filter housing base Change o ring and back up ring previously grease both Fig 4 Screw filter base tight in Mount filter housing Co...

Page 57: ...y 1 000 working hours depending on pollution grade Inlet filter cartridge change Inlet filter cartridge change as follows Loosen cover by pushing the three clips apart Remove inlet filter cartridge an...

Page 58: ...valve heads to change valves The three valves are combined inlet and outlet valves The first and second stage valves are plate valves The third stage con tains a spring operated piston which acts ins...

Page 59: ...Loosen valve head screws Fig 1 Remove valve head Pull out inlet and outlet valve Fig 2 CAUTION Observe that the lower copper valve ring is also pulled out It can still stick inside the cylinder Check...

Page 60: ...let and outlet valve CAUTION Observe the correct paper gasket position centre inlet and outlet channels Fig 4 Note Valve head screws can be inserted into the valve head to secure the upper valve gaske...

Page 61: ...re pin Mount valve gasket on inlet and outlet valve CAUTION Ensure correct mounting position of the upper valve gasket Fig 4 Insert new inlet and outlet valve into valve head CAUTION Observe correct p...

Page 62: ...ation of the limit value settings Safety valves with removed seals have to be immediately che cked for the prescribed settings and replaced if necessary The safety valve of the final stage is furtherm...

Page 63: ...alve prevents the compressed air from blowing off final pressure gauge 0 bar When the adjusted opening pressure is reached 150 and 180 bar the purified compressed air flows via pressure maintai ning a...

Page 64: ...he final pressure gauge The safety valve should open when reaching working pressure of the compressor If not switch off the unit and take out of service until the safety valve has been replaced Switch...

Page 65: ...f the compressor at a pressure of approx 150 bar Verify the compressor for release noises A slight hiss of the air inlet filter nozzle can be ignored If release noises occur localise blow off position...

Page 66: ...smaller than 999 result Test is applicable Example Filter housing 2 3 l Maximum operating pressure 350 bar Content volume 2 3 litres 350 bar x 2 3 litres 805 805 is smaller than 999 result Test is ap...

Page 67: ...A M A I N T E N A N C E R E C O R D S...

Page 68: ...Signature Instructor By adding themselves to this list the person that signs it confirms having been given a yearly introduction instruction about the function and operation of the compressor unit Fu...

Page 69: ...LW 300 E LW 450 E Page A 69 A M A I N T E N A N C E R E C O R D S Top up oil oil change Date Operating hours Oil quantity l Name Version 161012 001E...

Page 70: ...LW 300 E LW 450 E Page A 70 A M A I N T E N A N C E R E C O R D S Cartridge change Date Operating hours Difference Name Version 161012 001E...

Page 71: ...LW 300 E LW 450 E Page A 71 A M A I N T E N A N C E R E C O R D S Maintenance work Description Date signature Version 161012 001E...

Page 72: ...LW 300 E LW 450 E Page A 72 A M A I N T E N A N C E R E C O R D S Replaced Parts Designation Part number Date signature Version 161012 001E...

Page 73: ...ation commissioning After the compressor has been stored the following steps are to be taken Replace the final purification filter Check oil level replace oil if necessary Fuel Driven Units only Fill...

Page 74: ...ceed according to the operating instructions Disposal The product must be disposed in accordance with national waste disposal regulations and by an appropriate waste disposal company Electric and elec...

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