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4. Design and functioning

17

4

Design a nd functioning

4.1

Design of the unit

4.1.1

Design of the water-cooled D110H RS-W

Fig. 2

1  Intake filter
2  Suction inlet
3  Electric motor
4  Screw compressor
5  Pressure reservoir
6  Water filter
7  RO-Unit
8  Safety valve
9  Pressure holding and check valve
10  Water connection
11  Cooling air ventilator

12  Cooling air inlet filter mat
13  Compressed air outlet
14  Base frame
15  Control keypad
16  EMERGENCY OFF

push-button

17  Control cabinet
18  Supply cable gland
19  Opening for lifting gear
20  Water cooler
21  Cooling water inlet

22  Cooling water outlet
23  Fan protection panel
24  Water level indicator
25  Water level sensor
26  Network pressure sensor
27  Final compression

pressure sensor

28 Final compression temperature

sensor

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Содержание D110H RS

Страница 1: ...Original Operating and Service Manual Screw Air Compressor D50H RS D110H RS V2 GB Id no ZS1098950 04 June 2014...

Страница 2: ......

Страница 3: ...ken the user is advised to contact the local CompAir Company or Distributor who is supplied with revised and up dated information In any communication concerning the compressor it is essential to quot...

Страница 4: ..._____________________________________________________________________ _____________________________________________________________________________________ ____________________________________________...

Страница 5: ...set out in the operating manual and complying with the inspection and maintenance directives 1 3 Maintenance Carefully performed maintenance is imperative this ensures that your screw compressor can m...

Страница 6: ...ill not be accepted in the case of Operating errors Incorrect maintenance Wrong auxiliary materials Use of spare parts other than CompAir genuine spare parts Modifications and changes to the installat...

Страница 7: ...esign of the air cooled D50H RS A D75H RS A 19 4 2 Schematic diagram 20 4 2 1 Schematic diagram D110H RS 20 4 2 2 Schematic diagram D50H RS D75H RS 21 4 3 Water circuit 22 4 4 Air circulation 22 4 5 C...

Страница 8: ...11 General maintenance and cleaning 45 9 12 Clean change filter with cooling air inlet and control cabinet inlet 45 9 13 Cleaning of the bearing flushing system 46 9 14 Inspection of the compressor s...

Страница 9: ...tely apparent Everyone working with the machine must have first read and understood the operating manual Don t leave this until you start work it s too late Please keep this operating manual handy at...

Страница 10: ...st be fitted with a safety wire for operating pressures above 7 bars it is in fact recommended that this safety device should be used for pressures above 4 bars The steel wire has a diameter of 8 mm a...

Страница 11: ...p make sure that nobody can be injured by the machine installation as it starts up Compressed air may contain substances that may damage your health if inhaled The compressed air produced by these com...

Страница 12: ...checking the system or working on it For this a label with a corresponding warning notice has to be attached to the remote control equipment Noise even when it is not very loud can make us nervous and...

Страница 13: ...e isolated from external lines and hoses The system must be set up on a level surface with full contact between its base frame and the supporting surface 3 7 General workplace dangers Danger Safety me...

Страница 14: ...e for damaged parts to be replaced Risk of electric shock Have the electrical equipment on a machine system checked regularly Have defects like loose connections or charred cables rectified immediatel...

Страница 15: ...r change it in any way If work which produces heat flames or sparks has to be carried out on a machine the adjacent components have to be protected by means of non inflammable material Motor air filte...

Страница 16: ...that parts and special accessories not supplied by us are not approved by us Installing or using such products may thus adversely affect active and or passive safety The manufacturer accepts no liabil...

Страница 17: ...sioning or servicing this compressor Never breathe in compressed air from this system Never operate the unit with open doors or loose access panels Warning Hot surface Warning Pressurized part or syst...

Страница 18: ...loaded condensers Please always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components The power condensers require this time in order...

Страница 19: ...eck valve 10 Water connection 11 Cooling air ventilator 12 Cooling air inlet filter mat 13 Compressed air outlet 14 Base frame 15 Control keypad 16 EMERGENCY OFF push button 17 Control cabinet 18 Supp...

Страница 20: ...onnection 11 Cooling air ventilator 12 Cooling air inlet filter mat 13 Compressed air outlet 14 Base frame 15 Control keypad 16 EMERGENCY OFF push button 17 Control cabinet 18 Supply cable gland 19 Op...

Страница 21: ...check valve 10 Water connection 11 Cooling air ventilator 12 Cooling air inlet filter mat 13 Compressed air outlet 14 Base frame 15 Control keypad 16 EMERGENCY OFF push button 17 Control cabinet 18 S...

Страница 22: ...RS inverter 16 Blow off line orifice 17 Silencer 18 Manual valve 19 Mud flap 20 Ventilator 21 Nozzle 22 Non return valve 23 Choke valve adjustable 24 Dirt trap 25 Blow off valve Y4 26 Bypass valve Y11...

Страница 23: ...er 13 Water cooler 14 Throttle 15 RS inverter 16 Blow off line orifice 17 Silencer 18 Manual valve 19 Mud flap 20 Ventilator 1 all versions 21 Ventilator 2 only air cooled version 22 Non return valve...

Страница 24: ...Y11 and via the orifice 21 fig 5 or 5 fig 6 This way constant pressure of approx 4 to 4 5 bar is maintained in the pressure tank 6 as the pressure holding non return valve 7 still remains closed at t...

Страница 25: ...25 Y4 is deenergized opened and solenoid valve 26 Y11 continues energized open Reservoir pressure is reduced to approx 4 to 4 5 bar and the pressure maintenance valve 7 closes This way no more compre...

Страница 26: ...ictly prohibited to work or stand in the danger zone of a lifted load The proper lifting of the load according to the operating instructions of the load suspension device has to be ensured Important N...

Страница 27: ...r than 70 C 158 F have to be suitably identified and secured against touching See also the safety regulations in chapter 3 of the operating instructions Important The operator has to provide adequate...

Страница 28: ...imum duct length of 5 m 16 4 ft and a maximum of one bend In the event of differing values over 5 m 16 4 ft more than one bend filter cartridges screens etc please contact your technical adviser CompA...

Страница 29: ...Water connection for W type Danger If open cooling towers are used in the cooling water circuit it is possible for legionella Legionella pneumophila and other bacteria to grow and spread The growth an...

Страница 30: ...e derived from this Constituent elements of water characteristic values Circulating water Pass through water pH value at 25 C 77 F 6 9 6 9 Carbonate hardness CaCO3 100 mg l 5 6 dH 50 mg l 2 8 dH Total...

Страница 31: ...chgear and control gear circuit breakers The electrical connection and protective measures have to be installed in accordance with VDE BS or local regulations As a rule additional instructions of the...

Страница 32: ...o not know the cable type used by you its length and the installation conditions temperatures grouping The table above can therefore only be regarded as a guideline The supply cable cross sections giv...

Страница 33: ...oning the setting of the control transformer must be inspected while operating under load and corrected where necessary see section 9 9 6 5 Water supply 6 5 1 First time water filling Important When t...

Страница 34: ...it By mixing circulation water drinking water and treated water the requisite level of water quality will be achieved over the course of time 6 6 Extraction of water samples Danger Water samples must...

Страница 35: ...f the electrical control Open isolator valves between the screw compressor reservoir and pipe Ensure cooling water supply in accordance with Chapter 6 3 only water cooled units Operate main power supp...

Страница 36: ...it must be re installed Then proceed as described in chapter 7 1 First commissioning 7 3 Display of the compressor control DELCOS XL Fig 18 1 Touchscreen Display 2 Start push button I 3 Stop push butt...

Страница 37: ...f the electric motor The screw compressor unit will not start up if the final compression pressure is more than 1 0 bar 14 5 PSI Temperature start up protection The screw compressor unit will not star...

Страница 38: ...to specify a maximum permissible standstill time which will apply in all cases Note The following aspects must be taken into account for storage of storing compressors The compressor should be stored...

Страница 39: ...s are powered 24 V DC via the compressor control when the drive motor is running The volume of grease set on the lubricator is dispensed over several cycles depending on the motor runtime measured An...

Страница 40: ...e transparent cover The function display is only active if the screw air compressor unit s drive motor is running The lubricators are fitted with one red and one green LED These LEDs signal the follow...

Страница 41: ...en replaced with a partly filled one Fit full LC unit MLS120 9 3 Maintenance and inspection schedule Danger When performing control adjusting and mainte nance work be careful with hot surfaces of mach...

Страница 42: ...nnecting terminals in the switch cabinet and checking of the control transformer setting Checking tightening screw connections Checking cleaning water level sensor Replace O ring of pressure holding n...

Страница 43: ...44 000 h 46 000 h 48 000 h 50 000 h 52 000 h 54 000 h 56 000 h 58 000 h 60 000 h 62 000 h 64 000 h 66 000 h 68 000 h 70 000 h 72 000 h 74 000 h 76 000 h 78 000 h 80 000 h 33 m 36 m 39 m 42 m 45 m 48 m...

Страница 44: ...When carrying out maintenance work make sure that no dirt gets to the clean air side of the air filter Changing intervals for air filter cartridge The operating conditions e g coolant temperatures the...

Страница 45: ...been removed Perform the prefilter change as follows Switch the screw compressor unit off and ensure that it is depressurized electrically isolate and locked off Close the main water supply connection...

Страница 46: ...c shock from loaded condensers Please always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components The power condensers require this t...

Страница 47: ...d intervals never direct compressed air towards persons paying particular attention to Regulating elements Fittings Compressor block Cooler Electric motor Remove and clean the dirt trap strainer W ver...

Страница 48: ...the quality of the suctioned air e g dust content has a strong influence on the filter service life The filter should be checked on a weekly basis eventually daily basis for dust build up In these op...

Страница 49: ...ess the condition of the compressor The inspection plan describes everything you need to consider Attach the side cover with a new seal Insert the screws to a torque of 25 Nm Check the water level on...

Страница 50: ...ows Raise the water level to approx 50mm above the upper mark of the water display indicator 5 Fig 16 of the pressure vessel The resistance value of both the sensor connections 1 and 2 Fig 31 must lie...

Страница 51: ...has fallen below the lower switching point Unit stops during the start up phase 1 Short circuit in the unit 1 Determine and eliminate cause replace defective fuses 2 Connecting terminals in the switc...

Страница 52: ...e air filter 1 Water stop valve not closing 1 Check replace water stop valve Safety valve opens 1 Safety valve defective 1 Replace 2 Pressure holding valve defective 2 Check Replace 3 Mains pressure s...

Страница 53: ...A Qualifying Nominal speed min max rpm 750 3700 Nominal fan motor power kW 1 x 0 37 50Hz IP 54 1 x 0 66 60Hz IP 54 Recommended cable cross section mm 2 3 x 95 PE 50 Recommended fuse size 380V 400V 460...

Страница 54: ...nal speed min max rpm 750 3550 Nominal fan motor power kW 0 37 IP 54 Recommended cable cross section 380V 400V 460V mm 2 3x50 PE25 3x50 PE25 3x35 PE16 Recommended fuse size 380V 400V 460V A 160 160 12...

Страница 55: ...Motor protection type IP 55 IE2 IEC 60034 2 1 ECA Qualifying Nominal speed min max rpm 750 3550 Nominal fan motor power kW 2 x 2 25 IP 54 Recommended cable cross section 380V 400V 460V mm 2 3x50 PE25...

Страница 56: ...speed min max rpm 750 3700 Nominal fan motor power kW 0 37 IP 54 Recommended cable cross section 380V 400V 460V mm 2 3x35 PE16 4G25 4G25 Recommended fuse size 380V 400V 460V A 125 100 100 Cooling Cool...

Страница 57: ...nt Motor protection type IP 55 IE2 IEC 60034 2 1 ECA Qualifying Nominal speed min max rpm 750 3700 Nominal fan motor power kW 2 x 2 25 IP 54 Recommended cable cross section 380V 400V 460V mm 2 3x35 PE...

Страница 58: ...11 Annex 56 11 2 Layout plan 11 2 1 Layout plan D110H RS Fig 32 all dimensions in mm...

Страница 59: ...11 Annex 57 Fig 33 all dimensions in mm...

Страница 60: ...11 Annex 58 11 2 2 Layout plan D50H RS D75H RS Fig 34 all dimensions in mm cooling air cooling air...

Страница 61: ...11 Annex 59 Fig 35 all dimensions in mm...

Страница 62: ...t provisions 2009 105 EG 2006 42 EG 2006 95 EG This machine is exempt from the Pressure Equipment Directive Please refer to Article 1 clauses 3 3 and 3 6 for information on this exemption 3 If the mac...

Страница 63: ......

Страница 64: ...Gardner Denver Deutschland GmbH Argenthaler Str 11 55469 Simmern Deutschland Tel 49 0 6761 832 0 www compair com e mail sales compair com...

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