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Related Manuals for CompAir V-Compact Series
Summary of Contents for CompAir V-Compact Series
- Page 1 User Manual V-Compact Series Stationary Air Compressors Serial numbers from:- V100 EO40/0001 VL300D/V150D EO45/0001 V150 EO41/0001 V200 EO50/0001 VL200 EO42/0001 V300 EO51/0001 VL300 EO43/0001 VL400 EO52/0001 VL200D/V100D EO44/0001 V200D EO54/0001 VL400D/V300D EO55/0001 BR1815BA - 08/2004...
- Page 2 Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Distributor who is supplied with revised and up-dated information. In any communication concerning the compressor it is essential to quote the MODEL and SERIAL NUMBER.
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Page 3: Table Of Contents
V100-VL400 User Manual BR1815BA - 08/2004 V100, V150, V200, V300, VL200, VL300 & VL400 AIR COMPRESSORS Serial Numbers from: V100 EO40/0001 VL300D/V150D EO45/0001 V150 EO41/0001 V200 EO50/0001 VL200 EO42/0001 V300 EO51/0001 VL300 EO43/0001 VL400 EO52/0001 VL200D/V100D EO44/0001 V200D EO54/0001 VL400D/V300D EO55/0001 CONTENTS Section... - Page 4 TECHNICAL DATA Model: Motor Serial Number: Serial Number: Delivery Date: Year: Maximum Pressure: Compressor Lubricant: Lubricant Capacity: Motor Bearing Grease: Motor rpm: (If applicable) V. Ph. Hz. /min: LOCAL COMPAIR DISTRIBUTOR Name: Address: Telephone: Fax: Contact Names: Parts: Service: page 2...
- Page 5 V100-VL400 User Manual ASSOCIATED PUBLICATIONS Title Part No. Automatic Air Governor: C20160-014 Regulating Panel Mk.5: C20160-040 Repair Manual: AC20160-1157 Parts Lists: C20160-1143 V100A to V300A V100W to V300W C20160-1467 VL200A C20160-1468 VL300A C20160-1469 VL400A C20160-1470 VL200DA C20160-1471 VL300DA C20160-1472 VL400DA C20160-1374 V100DA C20160-1375...
- Page 6 CompAir Limited WARRANTY WARNING The conditions of the CompAir Warranty are set out in the company's standard Conditions of Sale The use of replacement parts or lubricating available from the Distributor supplying the oils not supplied or approved by CompAir machine.
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Page 7: Safety Procedures
V100-VL400 User Manual SAFETY PROCEDURES Page General Warnings, Cautions and Notes General Safety Precautions Installation Precautions Operational Precautions Maintenance and Repair Precautions Precautions in the Event of Fire page 5... -
Page 8: General
WARNING: RISK OF HIGH recommended by CompAir he must ensure that the PRESSURE unit will not be damaged or made unsafe and that there is no risk to persons or property. -
Page 9: General Safety Precautions
Use a spreader bar to avoid side loads on hooks, In order to control the risk of Legionnaires Disease, eyes and shackles. CompAir strongly advise against the use of water cooling tower systems for water cooled When a load is on a hoist stay clear of the danger compressors. -
Page 10: Maintenance And Repair Precautions
'THIS UNIT HAS BEEN MODIFIED AND WILL START If replacement parts are needed use only CompAir AUTOMATICALLY ON APPLICATION OF POWER' Genuine Parts. next to the display panel and on the inside of the unit next to the starter contactors. -
Page 11: Precautions In The Event Of Fire
V100-VL400 User Manual – Safety Procedures Use only lubricating oils and greases approved by After completion of repair or maintenance work CompAir. Make sure that the selected lubricants ensure that no tools, loose items or rags are left on comply with all relevant safety regulations, or inside any part of the machine. - Page 12 CompAir Limited page 10...
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Page 13: General Description
V100-VL400 User Manual GENERAL DESCRIPTION Page Compressor Safety Devices Instrument Panel Lubrication System Regulation System Air Governor Control Control Panel page 11... - Page 14 Two suction and two delivery valves are fitted in each first stage cylinder head and one suction and one delivery valve in each second stage cylinder head. CompAir V-Compact reciprocating compressors are single-acting units with two or four cylinders arranged in a 90°-Vee formation for complete The delivery manifold is designed as a pulsation primary balance.
- Page 15 V100-VL400 User Manual – General Description REGULATION SYSTEM Selector switch in 'HAND' position: The compressor starts and then runs continuously, responding to Each suction valve is fitted with an unloader which system air demand by unloading at the upper incorporates an air operated diaphragm and spring- pressure switch setting and loading at the lower loaded fork to hold the suction valves off their seats pressure switch setting.
- Page 16 CompAir Limited page 14...
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Page 17: Leading Particulars
V100-VL400 User Manual LEADING PARTICULARS page 15... - Page 18 CompAir Limited LEADING PARTICULARS Note: There are detail differences depending on the compressor concerned. The designations are as follows: Basic V100 VL200 Low pressure model prefix: VL 200 designation: V150 VL300 Oil-free model suffix: V200D V200 VL400 Air-cooled suffix: VL300DA...
- Page 19 V100-VL400 User Manual – Leading Particulars V100/V150 V200/V300 VL200/VL300 VL400 Suction valves 1st stage: 2nd stage: Delivery valves 1st stage: 2nd stage: V200/V300/VL400 All other models 18 Litres 9 litres Crankcase oil capacity: All Models: 1.7 bar Oil pressure: All Models: Shell Corena P100 Recommended Oil: V200A/V200W /V300A/V300W...
- Page 20 CompAir Limited LEADING PARTICULARS (cont’d) Weights, Kg: V100DW V100W V100DA V100A V150DW V150W V150DA V150A Without motor: With motor (F2): With motor (F3): V200DW V200W V200DA V200A V300DW V300W V300DA V300A Without motor With motor (F2): 1092 1130 1245 1017...
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Page 21: Installation
V100-VL400 User Manual INSTALLATION Page General Guidelines Ventilation Installation Procedure page 19... - Page 22 CompAir Limited INSTALLATION WARNING Refer to the safety procedures before Lethal voltages are used in this installation of the compressor unit. equipment.Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. Control panel.
- Page 23 Consult the local Air delivery outlet to the aftercooler/receiver. CompAir distributor for advice regarding the dimensions of the extension pipe. If the air intake Electrical power supply to drive motor: filter is to be positioned on the outside of the 3-phase plus earth.
- Page 24 CompAir Limited When the compressor is piped into an existing Whenever cooling towers are used in the water rigidly fixed compressed air main the length of pipe cooling system expert advice must be sought between the compressor delivery flange and the regarding the precautions to be taken to prevent the nearest fixed support should be at least 3 m.
- Page 25 VL200A 0.4 (up to 2.5 bar only) VL200DA V300A V300W V300DA V300DW VL300A VL300DA VL400A VL400DA If any difficulties are anticipated or if there are space limitations on site consult the local CompAir distributor before installation is commenced. page 23...
- Page 26 CompAir Limited INSTALLATION PROCEDURE On oil-free models fit the delivery valves in the compressor cylinder heads as follows: When using the compressor lifting bracket and the motor eyebolt as the slinging attachment points, it Remove the labelled gauze covers from the distance...
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Page 27: Operation
V100-VL400 User Manual OPERATION Page Commissioning/Starting Procedures Static Checks Functional Checks Routine Starting Adjustments page 25... -
Page 28: Commissioning/Starting Procedures
CompAir Limited OPERATION WARNING Refer to the safety procedures before Lethal voltages are used in this equipment. operating the compressor unit. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. COMMISSIONING/STARTING Fit the air intake silencer/filter assembly. -
Page 29: Functional Checks
V100-VL400 User Manual – Operation 1.2 Functional Checks 11 . Check the setting of the switching thermometers as follows:- Insert the isolator fuses and switch on the power supply to the compressor. Using the trip needle adjusting knob on the face of each thermometer, set the trip needles Hand unload each 1st stage cylinder of the to 15°C above the normal running temperatures... -
Page 30: Adjustments
CompAir Limited Switch power supply on at the isolator . 1.4.2 Oil Pressure Press 'SET RUN/FAULT RESET' button. When the oil pressure is not within the correct limits it should be adjusted as follows: Turn selector switch to 'AUTO' or 'HAND' as required. -
Page 31: Maintenance
V100-VL400 User Manual MAINTENANCE Page Routine Maintenance Cleanliness Recording Pressures and Temperatures Maintenance Record Pressure Settings Electrical Connections Leaks Regular Checks Lubricating Oil Maintenance Schedule Maintenance Parts (Two Years Operation) Maintenance Procedures Lubrication System Air Intake Filter page 29... -
Page 32: Routine Maintenance
Keep a careful record of all servicing, maintenance the user should refer to the local CompAir and repair work carried out on the compressor. The Distributor . -
Page 33: Leaks
The user should ensure that the Daily and Weekly Checks become an integral part of planned maintenance, even if the major servicing work is contracted to a CompAir Distributor. 1.8 Lubricating Oil It is essential to maintain the correct level of oil and to change the oil completely at the specified intervals. - Page 34 CompAir Limited It is expected that service items marked * in the Schedule below will normally be carried out by a CompAir distributor. Users who wish to carry our these services themselves will find the procedures in the Repair Manual, part number C20160-1157.
- Page 35 V100-VL400 User Manual – Maintenance Item Action Every 7,500 hours (Service C) *Compressor cylinders Remove cylinder heads and cylinders. *Pistons Check piston ring gaps. Renew rings if necessary. Inspect small end bushes /gudgeon pins. Renew if necessary. Check guide ring 'stand out'. § *Connecting rods Inspect big end bearings.
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Page 36: Maintenance Parts (Two Years Operation)
CompAir Limited MAINTENANCE PARTS (TWO YEARS OPERATION) Quantities required Service Description V100 V150 V200 V300 Oil Filter Element 2nd stage Valve Plates 2nd stage Valve Springs 1st stage Valve Springs Diaphragms (unloader) Valve Joint Ring Valve Lanterns 'O' Ring Oil Filter Element Air Filter Element §1st stage Guide Ring... -
Page 37: Maintenance Procedures
V100-VL400 User Manual – Maintenance MAINTENANCE PROCEDURES WARNING 3. Check that all pressurised air trapped in the Refer to the safety procedures before carrying system is released to atmosphere. out any maintenance or servicing work on the compressor unit. 4. Check that all pressure gauges on the display panel register zero. -
Page 38: Air Intake Filter
CompAir Limited 4.1.4 To Drain the Oil 4.2.2 To Clean the Element by Air Blast The compressor must be stopped. The compressor must be stopped. Drain the oil while the compressor is hot. The hot oil Using an air line supplying dry, low-pressure air will run freely and carry out any suspended (max. -
Page 39: Fault Finding
V100-VL400 User Manual FAULT FINDING page 37... - Page 40 CompAir Limited FAULT FINDING WARNING Refer to the safety procedures before carrying Lethal voltages are used in this equipment. out any fault finding investigation on the Use extreme caution when carrying out compressor unit. electrical checks. Isolate the power supply before starting any maintenance work.
- Page 41 V100-VL400 User Manual – Fault Finding Indication Possible Cause Remedy Compressor Main delivery pipework Remove pipework and inspect. overheating (cont.) blocked or restricted. Rectify if necessary. Check that bore is of adequate diameter. Faulty unloading Check operation of unloader (particularly on 2nd stage mechanism.
- Page 42 CompAir Limited Indication Possible Cause Remedy Intercooler pressure Air pressure gauge faulty. Check gauge for accuracy. reading low. Renew if necessary. 1st stage valves faulty. Remove valves. Inspect valve plates, springs and seats. Check condition of ring joints. Renew as necessary.
- Page 43 V100-VL400 User Manual – Fault Finding Indication Possible Cause Remedy Compressor Worn big end bearings. Remove and inspect bearings. knocking (cont.) Renew bearing shells if necessary. Insufficient clearance Check clearance with lead strip between piston crown and and if insufficient fit joint cylinder head.
- Page 44 CompAir Limited page 42...
- Page 45 V100-VL400 User Manual APPENDIX 1 The Pressure Systems Safety Regulations 2000 page 43...
- Page 46 CompAir Limited APPENDIX 1 Note: The intervals between examination and THE PRESSURE SYSTEMS SAFETY calibration of components, eg pressure vessels, REGULATIONS 2000 pressure relief valves etc, will be defined by the 'competent person' preparing the written scheme. The circuit diagram shown below is provided to...
- Page 47 V100-VL400 User Manual – Appendix 1 1. Intake Air Filter 7. Pulsation Vessel 2. First Stage Compression Cylinder LP 8. Pressure Relief Valve 3. Pressure Relief Valve 9. Non-return Valve 4. Intercooler 10. Aftercooler 5. Auto Drain Trap 11. Auto Drain Trap 6.
- Page 48 CompAir Limited page 46...
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