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Operation manual

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OPERATION MANUAL

MODEL: V120103-RS11

Rotary Screw Stationary

Air Compressor

7502 Mesa Road Houston, TX77028
Telephone: (713) 635-6331
E-mail: [email protected]

Web Site:

www.laplantecompressor.com

Содержание V120103-RS11

Страница 1: ...ation manual 1 OPERATION MANUAL MODEL V120103 RS11 Rotary Screw Stationary Air Compressor 7502 Mesa Road Houston TX77028 Telephone 713 635 6331 E mail service lapante com Web Site www laplantecompressor com ...

Страница 2: ...APLANTE WARRANTY Please refer to the attached LaPlante Compressor LTD Warranty Manual for full details of the LPRS Express Warranty versus the Extended Air End Warranty options that are available for 3 and 5 year terms plus LaPlante s lines of Proprietary Lubricants The Warranty Manual also provides details of the LaPlante Oil Monitoring and Oil Sampling Program The LaPlante Extended Air End Warra...

Страница 3: ...rawings Recommended 3 0 SPECIFICATION GENERAL 3 1 Compressor Specification Sheet 3 2 Lubrication Specification 3 3 Electric specification sheet 4 0 CONTROLLER 4 1 Introduction 4 2 Controller Panel 4 3 Symbol Meaning 4 4 Start and Loading 4 5 Stop 4 5 1 Manual Stop 4 5 2 Un loading Stop 4 5 3 Emergency Stop 4 5 4 Malfunction Stop 4 6 Warning 4 7 Calling Up the Display 4 8 Change the Timer 4 9 Progr...

Страница 4: ...ystem and Components 6 6 Modulation System 6 7 Safety System 7 0 PREVENTATIVE MAINTENANCE 7 1 Preventative Maintenance 7 2 Oil Testing 7 3 Oil Replacement 7 4 Oil Filter Replacement 7 5 Air Filter Replacement 7 6 V belts Replacement 7 7 Electrical Motor 7 8 Fan 7 9 Minimum Pressure Check Valve 7 10 General Maintenance and Clearings 8 0 TROUBLESHOOTING TABLE 9 0 PARTS LIST 9 1 LPRS11 230V the P N o...

Страница 5: ...ing quality the compressed air must be adequately purified according to local legislation and standards 5 Before any maintenance repair work adjustment or any other non routine check stop the compressor press the emergency stop button switch off the voltage and depressurize the compressor In addition the power isolating switch must be opened and locked 6 Never play with compressed air Do not apply...

Страница 6: ...st be earthed and protected against short circuits by fuses in all phases A lockable power isolating switch must be installed near the compressor 12 On machines with automatic start up system or if the automatic restart function after voltage failure is activated a sign stating This machine may start without warning must be affixed near the instrument panel 13 In multiple compressor system Manual ...

Страница 7: ...y the manufacturer PRECAUTIONS DURING OPERATION 1 Use only the correct type and size of hose end fittings and connections When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury or death Make sure that a hose is fully depressurized before disconnecting it 2 Persons switching on remotely controlled machines shall take adequate prec...

Страница 8: ...he two shall apply 3 Installation operation maintenance and repair work must only be performed by authorized trained specialized personnel 4 The compressor is not considered capable of producing air other non routing check stop the compressor press the emergency stop button switch off the voltage and depressurize the compressor in addition the power isolating switch must be opened and locked 5 Bef...

Страница 9: ...e machine for use after maintenance or overhaul check that operating pressures temperatures and time setting are correct Check that all control and shut down devices are fitted and that their function correctly If removed check that the coupling guard of the compressor drive shaft has been reinstalled 17 Every time the separator element is renewed examine the discharge pipe and the inside of the o...

Страница 10: ...ce of a hazard that will or can cause personal injury or equipment and property damage if the warning is ignored Notice is used to notify people of installation operation or maintenance of information that is important but not hazard related 1 4 Symbols and Warnings An adhesive label visibly placed on the cover of the compressor reports a series of symbols pictograms to inform anyone about risks a...

Страница 11: ...Operation manual 11 Rotation In Direction Of Arrow Emergency Stop Switch Stop Switch Start up Switch ...

Страница 12: ...ghted area that will not have an ambient air temperature below 40 degree F or exceed 105 degree F Provisions must be made for proper ventilation so that the temperature of the room will not exceed 105 degree F Foundation Your LaPlante s rotary screw compressor does not require a special foundation However it is necessary that the floor is level and the frame adequately supported Consult the Specif...

Страница 13: ...led Generally most adverse conditions may be overcome by regular servicing of the filter furnished with the unit When bringing in outside air into the compressor building for cooling and or compression the air inlet to the compressor building should be located away from contaminants such as engines exhaust gases steam and other harmful vapors Also the opening to the building must be protected from...

Страница 14: ...should do all electrical wiring Be sure to investigate the local requirements before installing the compressor The power supply should be adequate and free of parasitic loads that will cause an under voltage condition during the operation of the compressor otherwise there will be nuisance electrical shutdowns Though the unit has a disconnect we recommend that one be installed away from the machine...

Страница 15: ...or opposite side of the loop Locate runs away from the main header close to the point of application This limits the pressure drop through hose Take air off the top of the header to prevent carryover of condensed moisture to tools Slope pipe so that it drains toward a drop let or moisture trap away from the compressor 2 4 Unpacking and Handling Occasionally damage will occur during shipping Be sur...

Страница 16: ...ate materials used and cost of materials 2 5 Storage In some cases it may necessary to store the compressor for extended periods of several months before placing the unit in operation When this is required do the following 1 Cover and seal all machine openings to prevent the entrance of water and dirt 2 Cover all openings in open drip proof motors to prevent the entrance of rodents 3 If the storag...

Страница 17: ...Operation manual 17 Figure 2 2 Installation Drawings ...

Страница 18: ...O68 SAE30 Oil Capacity Gal L 1 32 5 NOTE Control Electro Pneumatic Volume Flow CFM are ratings for full package performance in accordance test standard PN2CPTC2 Package sound level based on CAGI PNEUROP ANSI S51 3 dB A Maximum ambient temperature 105 degrees F 3 2 Lubrication Specification The useful life of compressor oil depends on the quality of the oil the maintenance of the Product and the co...

Страница 19: ...Wire 460 11 8 13 6 60 No 14 Wire Inlet Cable Size No 575 10 2 11 8 60 No 14 Wire 230 60 22 30 460 60 12 5 18 Main Overload Relay A 575 60 8 5 12 5 As a general rule take the motors full load amp FLA X1 25 or 25 to determine your breaker wire size CAUTION All electrical work must be performed by a qualified electrician and must conform to national state and local electrical code in your area NOTE T...

Страница 20: ...eeds the programmed shut down level the compressor will be stopped The compressor will also be stopped in case of overload of the drive motor Shut down warning A shut down warning level is a programmable level below the shut down level If one of the measurements exceeds the programmed shut down warning level this will also be indicated on the display to warn the operator before the shut down level...

Страница 21: ... 30 seconds Start Push button to start the compressor status symbol lighted indicate the controller is operative Reset Key to reset the service timer a shut down condition etc or to return to a previous display Enter Key to select or validate a parameter to open a sub display Down or Decrement Value Key to scroll downwards through the screens or to decrease a setting Up or Increment Value Key to s...

Страница 22: ...in seconds While a countdown is being displayed normal User items can still be viewed press Down The display will default back to the User Temperature item after a short period of no key activity or after a timer event has completed If operating in Pressure Switch Mode the main display will show the detected temperature and the default User Menu item will be total run hours Pressure is not display...

Страница 23: ...n negative hours The service countdown timer can be reset using the menu routine when the required service has been carried out Set to any value greater than 0 zero hours before reset The Service Due countdown timer can be reset to any hour s value dependant on the required service interval The timer will countdown dependant on total run hours Start and Loading Start press the button start the mac...

Страница 24: ...gency Stop In the especially urgency press the emergency stop button the alarm signal will flash compressor will automatically un load the motor will stopped and the air end will ceased user menu item display area will show the err code more detail show as figure 4 7 After deal with all the trouble twist and loose the emergency stop button press the reset button the controller will back to start f...

Страница 25: ...Operation manual 25 Figure 4 8 Trouble Display ...

Страница 26: ... different is bigger than set point Replace filter press the controller s reset button the controller will back to start state If necessary change the pressure different switch E 0115 Pressure transmitter fault Pressure transmitter malfunction wire loose or part failure Inspect the transmitter s wire or replace one transmitter Press the controller s reset button the controller will back to start s...

Страница 27: ...Operation manual 27 Figure 4 9 Alarming Display Figure 4 10 Parameter Display ...

Страница 28: ... Inspect the machine s pressure or the pressure transmitter press the controller s reset button the controller will back to start state A 2128 Excess temperature alarm High discharge temperature Resolve high discharge temperature cause more detail see Section VIII Press the controller s reset button the controller will back to start state A 2816 Power failure alarm low Inlet controller power or po...

Страница 29: ... the access code is incorrect the display will return to the normal operational display To select a menu item for adustement press Up or Down until the menu item is displayed To adjust an item setting press Enter the value or option will flash Press Up or Down to adjust as required then press Enter to store in memory Figure 4 11 shows how to change the timer Figure 4 11 Time Change After change th...

Страница 30: ...rature Trip Fault Level 2 tF o F 126 248 482 Digital Input C2 configuration 2 d2 2 Eno Shutdown Trip 24Vac 0Vac OK 3 Enc Shutdown Trip 0Vac 24Vac OK 3 Digital Input C3 configuration 2 d3 2 Eno Shutdown Trip 24Vac 0Vac OK 3 Enc Shutdown Trip 0Vac 24Vac OK 3 Digital Input C4 configuration 2 d4 2 Eno Shutdown Trip 24Vac 0Vac OK 3 Enc Shutdown Trip 0Vac 24Vac OK 3 Digital Input C5 configuration 2 d5 0...

Страница 31: ...mitted Set to 0 zero seconds if not required Stop Time When the Stop button is pressed the compressor will unload and the main motor will continue to run for the set Stop Time This time is intended to allow internal pressure or sump pressure to reduce before the compression element is stopped preventing potential oil blow back through the compression element and air filter The stop time is initiat...

Страница 32: ... switch for compressor 5 2 4 Check transformer for correct connection 5 2 5 Check that the motor overload relay is set for manual resetting 5 2 6 Open the air outlet valve 5 2 7 Connect the condensate drain outlet to a drain collector 5 2 8 Check the oil level and oil type as required 5 2 9 Provide labels warning the other operator 5 2 10 Checking the main motor rotation direction 5 2 11 Jog the c...

Страница 33: ... emergency stop button wait until the compressor has stopped depressurize the oil system by unscrewing oil filler plug one turn and wait a few minutes Remove the plug and top up oil until the sight glass is full Fit and tighten the plug Observe the oil filter and element of air filter when they have exceeded the normal replacement interval stated in this manual 5 5 Checking the Display Checking th...

Страница 34: ...em to escape 5 7 5 Shut off and depressurize the part of the air net which is connected to the discharge valve Disconnect the compressor air discharge pipe from the air net 5 7 6 Drain oil Air escaping to atmosphere is noisy Always wear ear protection to protect hearing against high intensity noise ...

Страница 35: ...valve Air end Motor and Belts Pulley Assembly Tank Air Oil Separator and Minimum Pressure Value Lubrication System Oil Cooler oil filter and thermostatic valve Intelligent controller and electrical Components Safety Devices pressure sensor temperature sensor Sub base Main Frame and solenoid valve 6 2 Airend The compressor assembly is an oil flooded positive displacement single stage helical screw ...

Страница 36: ...m Air enters the air end through the air filter and air inlet valve where it is mixed with oil After compression the air oil mixture is discharged into the oil separator where its velocity is reduced causing most of the oil to drop to the bottom The remaining oil is removed as the air passes through separator element Oil collected at the bottom of the separator element is returned to the inlet of ...

Страница 37: ...ler 3 Intake Valve 12 Minimum Pressure and NON Return Valve 4 Air Filter 13 Air Tank 5 Solenoid Valve 14 Drain Water Valve 6 Air Oil Separator 15 Discharge Valve 7 Safety Valve System 16 Pressure Sensor 8 Temperature Sensor 17 Safety Valve Network 9 Oil Filter 18 Pressure Gauge Figure 6 3 Compressor Flow System ...

Страница 38: ... back flow to separator and air end 6 4 Oil System In the LaPlante Screw Compressor oil flow is driven by the pressure in the air oil separator and flow through oil cooler and be cooled a thermal mixing valve the cooled oil pass oil filter to the airend where it provides cooling sealing and lubrication The oil mixed with compressed air is returned to separator from the airend through the discharge...

Страница 39: ... inlet air control valve solenoid valve and piping There are 3 various operation statuses 1 Load When you press the start button the motor drives the air end through belts The inlet air valve is opened by light vacuum A little air is sucked into air end and pressure in separator is setup When the pressure reaches 29 Psig partial air is delivered into inlet valve to close it to stop air inlet feedi...

Страница 40: ...ve system is set on the air end the safety valve network is set on the air receiver When the pressure exceeds setpoint the safety valve will release the pressure to keep the compressor safety When the motor working current exceeds upper preset value a current protection device overload protection will automatically turn off main power and the unit is stopped immediately Unless the device is manual...

Страница 41: ...Operation manual 41 ...

Страница 42: ...Operation manual 42 Figure 6 5 a the Electrical Drawing 230 Voltage ...

Страница 43: ...Operation manual 43 ...

Страница 44: ...Operation manual 44 Figure 6 5 b the Electrical Drawing 575 Voltage ...

Страница 45: ...ction 5 Clean the external filter if applicable 6 Belts first check after 50 hours for proper tension Initial 30days or 500 hours 1 Replace oil filter element 2 Check cooler clean it if necessary Every 6 months or 1000 hours 1 Replace air filter element 2 Check the belts for sign of wear and replace as necessary 3 Clean motor and ventilation operation 4 Check the temperature sensor 5 Take oil samp...

Страница 46: ... sheet table 7 2 Table 7 2 oil analysis Viscosity increase 10 over new oil Neutral number increase 0 5 over new oil Total solids by weight 0 21 Oxidation by weight oxidized material 11 Sediment by volume 0 21 Water by volume 0 5 7 3 Oil Change Only change the oil when the unit is not in operation and is depressurized When change the oil proceed as flows Figure 7 1 oil sight glass 1 Switch off the ...

Страница 47: ...eplacement The oil filter in the compressor system is a full flow replaceable canister type Initially the filter should replaced after 500 hours of operation then every 2000 hours This element protects the compressor bearings from grit and dirt ingression throughout the system A dirty filter will cause an oil flow restriction that can result in high oil temperature and a unit shutdown Hot oil unde...

Страница 48: ... air side of the air filter In accordance with the provisions the exchange cartridge of the intake air filter shall be replaced after every 1000 hours of running time If intake air is strongly polluted an earlier exchange or cleaning of the cartridge is required whenever the optical or electronically maintenance indicator shows it Only perform checks and carry out work on the screw compressor when...

Страница 49: ...pressure to relieve 3 Remove the belt guard 4 Inspect for any fraying or cracking of the belts If there is any replace the belts 5 Check the tension The deflection should be about 1 64 per inch of span between the sheaves with about 4 5 pounds of force perpendicular to the belt To Change The Belts 1 Switch off the unit disconnect the power lockout and tag circuit breaker to prevent accidental rest...

Страница 50: ...te straight edge 1 Switch off the unit disconnect the power and lockout and tag to prevent accidental restarting 2 Allow one minute after stopping the compressor for settling and the pressure relieve 3 Remove the belt guard 4 Lay the straight edge across the face of the motor sheave and check the alignment with the air end sheave 5 Then lay the straight edge across the face of the air end sheave a...

Страница 51: ...check that the motor is clean and ventilation openings are clear The second area to maintain to insure long motor life is bearing lubrication Bearing grease will lose its lubricating ability over time not suddenly But for these motors the motor use the double sealed deep groove ball bearing so the electric motors are permanently lubricated 7 8 Fan Check the fan for cracking and bent or loose blade...

Страница 52: ...ear Replace as required This check valve assembly is furnished only as a complete assembly Check the plastic Teflon seat on the valve assembly carefully for damage Replace valve assembly as required 10 Install a new O ring on the larger piston 11 Re assemble the check valve piston with the spring in the large piston 12 Lubricate the O seal ring on the piston with a silicone based lubricant 13 Re i...

Страница 53: ...on Operate the safety valve depending on the type of valve 1 by unscrewing the cap one or two turns and retightening it 2 or by pulling the valve Lifting lever Never operate a screw compressor system with a defective valve or without safety valve 8 2 Connecting terminals in the switch cabinet control transformer setting The connecting terminals in the switch cabinet have to be checked and if requi...

Страница 54: ...ssed air according to the operating instructions Blow off the screw compressor unit with compressed air at the specified intervals never aim compressed air at persons paying particular attention to Regulating elements Fittings Compressor block Cooler Electric motor ...

Страница 55: ...ircuit fuse s 4 Reset overload relay s 5 Check and repair or replace broken wire s and connection s 6 Check components Renew as required 7 Repair or replace motor Air end will not rotate 1 Defective or damaged air end 1 Replace air end Motor will not rotate 1 Defective or damaged motor 1 Replace or repair motor Air end motor will not come up to full speed before starter overload trips 1 Low line v...

Страница 56: ...arator element 1 Clean or replace line and or filler 2 Inspect for and correct all external oil leaks 3 Refer to oil specifications Drain unit and install correct oil 4 Drain to correct oil level 5 Operate at correct pressure 80 psi minimum 6 Renew separator element Oil blows out blow down valve when blow down valve actuates 1 Clogged or restricted separator drain line or filter 2 Defective blow d...

Страница 57: ...t down switch 3 Low compressor oil flow 4 Solenoid valve fault 5 Separator element blocked 6 Minimum pressure valve fault 1 a Fill reservoir to correct level with recommended oil b Adjust to correct pressure c Clean or replace oil cooler 2 Renew high temperature shut down switch 3 a Check for restricted oil filter Change element as required b Check for and correct cause of restriction in oil syste...

Страница 58: ...Operation manual 58 9 0 PARTS LIST 9 1 LPRS11 230V the P N of LaPlante is 001117 001117 Exploded Drawing 001117 Parts List ...

Страница 59: ...Operation manual 59 ...

Страница 60: ...Operation manual 60 Electrical Main Parts List ...

Страница 61: ...Operation manual 61 9 2 LPRS11 575V the P N of LaPlante is 001118 001118 Exploded Drawing ...

Страница 62: ...Operation manual 62 001118 Parts List ...

Страница 63: ...Operation manual 63 Electrical Main Parts List ...

Страница 64: ...anual 64 10 0 Main Wearable Parts List Item LP P N Description Qty 36 420055 Belt XPZ1312Lp 2 54 280001 Element of Air Filter 1 59 071000 Gasket Intake Valve 1 61 900002 Oil Air Separator 1 62 900003 Oil Filter 1 ...

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