L&W SC-180 ES Operating Instructions Manual Download

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C H A P T E R O V E R V I E W

Operating Instructions

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Attachment

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Manufacturer in terms of 97/23/EC

The full name and address of the manufacturer is:

Lenhardt & Wagner GmbH

An der Tuchbleiche 39
68623 Hüttenfeld / Germany

Phone: +49 (0) 62 56 - 85 88 0 - 0
Fax: +49 (0) 62 56 - 85 88 0 - 14

E-Mail: [email protected]
Internet: www.lw-compressors.com

Summary of Contents for SC-180 ES

Page 1: ...E Manufacturer in terms of 97 23 EC The full name and address of the manufacturer is Lenhardt Wagner GmbH An der Tuchbleiche 39 68623 H ttenfeld Germany Phone 49 0 62 56 85 88 0 0 Fax 49 0 62 56 85 88...

Page 2: ...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 reductio...

Page 3: ...A Operating Instructions Breathing Air Compressor LW SC 180 ES LW SC 250 ES Version 12 2022...

Page 4: ...tructions 15 Transportation instructions Safety regulations 16 Installation Installation in closed rooms 18 Dimensions 19 Minimum distances 20 Ventilation 21 Electrical Installation 22 23 Operation Im...

Page 5: ...ondensate valve maintenance 52 Inlet filters Inlet filter cartridge change 53 Cylinder heads and valves 54 Replace inlet and outlet valve 1st stage 55 56 Replace inlet and outlet valves 2nd and 3rd st...

Page 6: ...ntial preliminary work and measures concerning legal regulations and safety These are described on the following pages of this operation manual Warning Indicates a potentially hazardous situation whic...

Page 7: ...7l filter housing Puracon filter monitoring Auto shut down also available Remote Tab Control RTC Additional high pressure outlet CEE plug Special voltages frequencies on request Elektro motor Powder c...

Page 8: ...r Breathing Air Intake Pressure atmospheric Oil Pressure bar 2 0 4 2 0 4 Oil Capacity l 0 8 0 8 Intake Temperature C 0 45 0 45 Ambient Temperature C 5 45 5 45 Cooling Air Volume m h 1200 1440 1650 198...

Page 9: ...12 2022 Unit Assembly D E S C R I P T I O N No Designation 1 Switchboard 2 Filling pressure gauge 200 bar 3 Filling valve 200 bar c w Filling Hose 4 Filling pressure gauge 300 bar 5 Filling valve 300...

Page 10: ...ite A 8 A LW SC 180 ES LW SC 250 ES Version 09 12 2022 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 butto...

Page 11: ...69 ltr 20 l Wasserabscheider Oil Water Separator 21 Druckhalteventil Pressure Maintaining Valve 22 R ckschlagventil Non Return Valve 23 Sicherheitsventil 3 Stufe Safety Valve 3rd Stage 24 Hochdrucksc...

Page 12: ...A S I C H E R H E I T S H I N W E I S E...

Page 13: ...hat 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 t...

Page 14: ...2022 S A F E T Y P R E C A U T I O N S Safety instructions on the unit Importance of notes and warning signs that are affixed to the compressor according to the application or its equipment Warning Hi...

Page 15: ...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 Onl...

Page 16: ...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...

Page 17: ...isplay 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...

Page 18: ...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...

Page 19: ...A I N S TA L L AT I O N...

Page 20: ...ce 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...

Page 21: ...Seite A 19 A LW SC 180 ES LW SC 250 ES Version 09 12 2022 I N S T A L L A T I O N Dimensions Fig Dimensions...

Page 22: ...or 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...

Page 23: ...e cooling air flow can 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...

Page 24: ...plate on the compressor 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 com...

Page 25: ...inal motor power Fusing start A Connection in mm kw A Direct Star Delta Contactor supply 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 26: ...A O P E R AT I O N...

Page 27: ...2022 O P E R A T I O N 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 always wear...

Page 28: ...iately stop the compressor by pushing the OFF button and contact an authorised electrician 3 Check oil pressure if oil pressure gauge is installed 4 Run the compressor for about 2 minutes 5 Close the...

Page 29: ...he oil level reached the middle of the indicated area Warning Check oil level daily Never start the compressor with a too low oil level Risk of accidental loss destruction or deterioration Check V bel...

Page 30: ...or If the direction of rotation 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 Furthermore cooling air fl...

Page 31: ...L Y C O M M I S S I O N 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...

Page 32: ...ydrostatic tested check last 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...

Page 33: ...which automatically shuts 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 emergen...

Page 34: ...A R E M E D Y I N G FA U LT S...

Page 35: ...valve leaky Replace Pipes heat exchanger broken Replace Condensate drain valves leaky Unscrew valves check sealing surfaces clean replace if necessary Final pressure switch stop unit Verify settings r...

Page 36: ...diameter Wrong compressor rotation direction Ensure correct phase rotation observe rotation direction arrow Inlet and outlet valves contaminated defective Clean replace if necessary Safety valve leak...

Page 37: ...Remedy Pressure stages are not as prescribed control pressure of pneumatic condensate valve too low Check corresponding inlet and outlet valve replace if necessary Piston sealing of pneumatic condensa...

Page 38: ...r cartridge already partly saturated before change Store filter cartridges properly dispose defective cartridges Cylinder s piston s or piston ring s defective Replace Operating temperature too high E...

Page 39: ...A M A I N T E N A N C E A N D S E R V I C E...

Page 40: ...only be carried out by 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...

Page 41: ...all connections and bolts Check V belt tension and condition LW SC 180 ES 50Hz 1 011839 LW SC 250 ES 50Hz 1 011839 Daily before taking unit into operation Maintenance work Type Quantity Order No Check...

Page 42: ...SC 250 ES 50Hz 1 011839 Check opening pressure of final safety valve Clean coolers Clean all oil water separators if less than 500 operating hours Service intake filter depends on condition if less t...

Page 43: ...No Replace o ring of the DIN filling connector 2 001237 Replace o ring of the revolvable filling hose 2 001224 Replace sintered metal filter of oil separator 2nd Stage 1 002123 Replace o ring of the w...

Page 44: ...No Replace o rings and gaskets of 1st 2nd and 3rd stage O Ring 1st stage 1 011104 O Ring 2nd 3rd stage 2 011105 Replace all inlet and outlet valves incl Gaskets 1st stage 1 003652 2nd stage 1 000551...

Page 45: ...1 Tighten V belt by the lock nuts Fig 2 3 Tighten mounting screws Fig 1 ATTENTION Motor plate A and motor B must be mounted in parallel Fig 4 Correct V belt tension Do not tension V belts too tight T...

Page 46: ...rning First oil change after 25 operating hours Compressor Lubrication Pistons cylinders crankshaft and connecting rods are provided with oil by splash lubrication Check oil level Check oil before eac...

Page 47: ...oil level should be between the middle and upper end of the oil sight glass Screw oil fill port manually in and tighten by hand The oil change is now completed Maintenance intervals First oil change...

Page 48: ...g screw clockwise Reducing 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 t...

Page 49: ...ids The timer is located in the switch box and activates the dump valves about every 15 minutes To release the complete condensate through the black plastic hoses we recommend using an 10 l container...

Page 50: ...er Remove sinter filter holder Fig 2 Change sinter filter Fig 3 screw in new sinter filter by using a suitable screwdriver Change o ring previously grease new o ring Fig 4 Place sinter filter holder i...

Page 51: ...s purified Oil residues are bounded The breathing air filter cartridge consists of a molecular sieve and activated carbon filter All breathing air filter cartridges are factory vacuum sealed We recomm...

Page 52: ...tool The housing can not be opened if still under pressure After opening the housing pull out the filter cartridge Fig 3 Open the vacuum sealed packet of the new filter cartridge and carefully place...

Page 53: ...over by using the filter tool Fig 1 Change o ring previously grease new o ring Fig 2 Screw the filter housing cover in by using the filter tool and turn it back turn This avoids tightening of the cove...

Page 54: ...as follows Loosen pipe connections and mounting screws Remove pneumatic condensate valve Loosen connection Fig 2 Change sinter filter Fig 3 Tighten horizontal screw Mount pneumatic condensate valve Ti...

Page 55: ...rtridge and assemble the housing Place o ring into the groove Fig 4 Place and align the filter housing carefully inlet port up hose connector 90 turned to the left Fig 5 Tighten mounting screw and con...

Page 56: ...ions Dismount valve heads to change valves The three valves are combined inlet and outlet valves The first stage is a plate valve The stages two and three are made of a spring operated piston which ac...

Page 57: ...t valve Remove spring wire clamps of the crankcase ventilation hose Fig 1 Remove hose Loosen pipe connections Loosen valve head screws Remove valve head and check if defective Remove upper valve head...

Page 58: ...hole and valve head locating pin Fig 2 3 Place valve head carefully on top of the cylinder take care to keep valve in place Fig 4 Tighten valve head screws crosswise Set tight connecting nut and fix...

Page 59: ...out It can still stick inside the cylinder head Remove inlet outlet valve Check valve head if defective check locating pin Change upper valve gasket Change lower valve gasket aluminium gasket Insert...

Page 60: ...y seals to avoid manipulation of the limit value settings Safety valves with removed seals have to be immediately checked for the prescribed settings and replaced if necessary The safety valve of the...

Page 61: ...ents the compressed air from blowing off final pressure gauge 0 bar When the adjusted opening pressure is reached 160 bar the purified compressed air flows via pressure maintaining and non return valv...

Page 62: ...e A 46 Start the compressor Watch the 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 sa...

Page 63: ...mpressor Press the OFF switch and hold on the button 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 posi...

Page 64: ...ar x content volume litres from 200 up to 1000 Example Filter housing 0 69 l Maximum operating pressure 350 bar Content volume 0 69 litres 350 bar x 0 69 litres 241 5 241 5 is bigger than the minimum...

Page 65: ...A M A I N T E N A N C E R E C O R D S...

Page 66: ...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 Furthermore they have be i...

Page 67: ...Seite A 65 A LW SC 180 ES LW SC 250 ES Version 09 12 2022 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...

Page 68: ...Seite A 66 A LW SC 180 ES LW SC 250 ES Version 09 12 2022 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...

Page 69: ...Seite A 67 A LW SC 180 ES LW SC 250 ES Version 09 12 2022 M A I N T E N A N C E R E C O R D S Maintenance work Description Date signature...

Page 70: ...Seite A 68 A LW SC 180 ES LW SC 250 ES Version 09 12 2022 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...

Page 71: ...d drain valves Store the compressor in a cool dry place free from dust and contamination A dust cover is recommended as long as condensation can be avoided If compressor unit should be stored for a pe...

Page 72: ...s When recommissioning proceed according to the operating instructions Disposal The product must be disposed in accordance with national waste disposal regulations and by an appropriate waste disposal...

Page 73: ...E A T T A C H M E N T Version 11 12 E...

Page 74: ...350 bar 1 100 l min Suitable media Media resistant non corrosive gases The safety valve is used for protection of pressurized components eg pipelines pressure vessels or the compressor itself The han...

Page 75: ...e problem is on the system A constant blowing of the safety valve is not permitted the sealing seat of the valve can be damaged The error on the system must be detected and repaired before further fil...

Page 76: ...ately Notes The safety valve must be installed directly on the protected pressure vessel and or the plant The safety valve must be installed in an upright position The flow area of the port must be gr...

Page 77: ...INFORMATIONON THE SERVICE LIFE OF L W HIGH PRESSURE HOSES...

Page 78: ...bly and before commissioning 3 Recurring test 4 Procedure for hose lines found to be defective 4 Test intervals 4 Persons qualified to test hose lines 5 Maintenance Replacing hose lines 6 Immediate re...

Page 79: ...regarding type scope and deadlines as well as the replacement intervals must be documented in writing as occupational health and safety measures The results of the tests must also be recorded e g tog...

Page 80: ...replaced at the same time precautions must be taken to prevent mix ups of the connections or the installation points Test intervals Deadlines for the recurring tests of the hose lines should already b...

Page 81: ...t be sufficiently familiar with the conditions that demand the performance of tests such as the result of the risk assessment or observations during the working day there is proof of recent profession...

Page 82: ...ite properties and reduces the performance of the hose lines This limits the service life of a hose line and the operator must ensure that hose lines are replaced at appropriate intervals Immediate re...

Page 83: ...e guideline given above for a replacement interval of six years for hose lines meeting normal requirements includes a maximum storage period of two years The guideline value of two years for hose line...

Page 84: ...void storage temperatures below 10 C for elastomers Do not use ozone generating light fittings or electrical devices that may produce sparks in the immediate vicinity Ozone generating light fittings a...

Page 85: ...ANNEX...

Page 86: ...he hose is routed via a kink protector if necessary on the connecting element sufficient clearance prevents external mechanical influences or abrasion on the edges hose bridges prevent damage being ca...

Page 87: ...arried out before the functional test All parts of the system must be tested at least at the maximum working pressure that could be achieved taking into account all intended applications Are the hose...

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