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CompAir L07RS User Manual

CompAir L07RS
68 pages
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Original Operating and Service Manual
Screw Air Compressor
L07 - L11, L07RS - L11RS
L07FS - L11FS, L07RS FS - L11RS FS
V2
GB
CDN
USA
Id. no. ZS1066273 / 03 - December 2011

Table of Contents

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CompAir L07RS Specifications

General IconGeneral
BrandCompAir
ModelL07RS
CategoryAir Compressor
LanguageEnglish

Summary

General Information and Warranty

Maintenance Overview

Importance of periodic maintenance for trouble-free operation and optional maintenance agreements.

Warranty Conditions

Conditions for warranty are set out in the Company's standard Conditions of Sale.

Foreword and Compressor Notes

Compressor Notes and R&D

Highlights the result of years of R&D, high quality standards, reliability, and environmental compliance.

Intended Use and Safety

Specifies the machine's construction according to state-of-the-art technology and safety regulations.

Maintenance Importance

Emphasizes the importance of carefully performed maintenance for optimal compressor performance.

General Operating Notes

General notes on operating instructions, safety, cost-effectiveness, and compliance with regulations.

Foreword Details and Safety

Guarantee and Liability

Defines responsibility and conditions under which Gardner Denver is not liable for operation.

Foreword Safety Regulations

Highlights the importance of observing safety regulations in chapter 3.

Safety Regulations - Identification and General

Safety Guideline Identification

Explains liability for non-observance of safety instructions and local regulation precedence.

General Safety Instructions

Details organizational measures, personnel responsibilities, and adherence to safety notices.

Safety Regulations - Modifications and Installation

Machine Modifications and Safety

Prohibits unauthorized changes affecting safety and warns about using non-original parts.

Installation and Normal Operation

Covers lifting, pipe installation, leveling, air intake location, and pressure line stress.

Safety Regulations - Operation and Environment

Remote Control and Line Safety

Covers remote control operation, line marking, isolator valves, and safety equipment requirements.

Dryer and Condensate Drain Safety

Guidance for cold dryer installation, protection, and condensate drain connection.

Normal Operation Safety Checks

Lists regular checks for protective equipment, hoses, leakages, fittings, wiring, and safety mechanisms.

Safety Regulations - Personnel and Electrical

Personnel and Electrical Safety

Covers personnel qualifications, electrical work by skilled electricians, and hydraulic safety.

Safety Regulations - System Operation

System Operation and Safety Checks

Details safety during operation, including remote control, line marking, safety valves, and dryer operation.

Safety Regulations - Special Work

Special Work and Maintenance Safety

Emphasizes carefulness, supervision, and use of correct tools for maintenance and repair work.

Safety Regulations - Maintenance Procedures

Maintenance Safety Procedures

Covers safety during maintenance, cleaning, post-maintenance checks, and handling of hot parts.

Safety Regulations - Special Dangers

Warning of Special Dangers

Details dangers related to electric energy, gas/dust/steam/smoke, hydraulics, pneumatics, and noise.

Safety Regulations - Substances and Storage

Chemical Substance Safety

Emphasizes observing safety regulations when handling oils, greases, and chemicals, especially hot fuels.

Compressor Storage Guidelines

Provides guidelines for storing compressors, including temperature limits and protection from corrosion.

Safety Regulations - Symbols

Symbols and Explanations

Explains various symbols used in the manual, such as reading the manual and avoiding breathing compressed air.

Safety Regulations - Warning Symbols

Warning Symbols Explained

Explains warning symbols for hot surfaces, pressurized parts, and automatic start-up.

Safety Regulations - Operational Warnings

Operational Warning Symbols

Explains warning symbols for continued operation after pressing O-key and danger of electric shock.

Safety Regulations - Terminal Warnings

Terminal and Fastener Warnings

Covers warnings for re-tightening terminals, electric motor fasteners, and danger from loaded condensers.

Design and Functioning Overview

Unit Design L07-L11 (RS)

Details the design of the L07-L11 (RS) unit with component identification.

Design - AirStation Unit

Unit Design AirStation L07FS-L11FS (RS)

Illustrates the design of the AirStation unit with component identification.

Design - Schematic Diagram

Schematic Diagram

Presents a schematic diagram of the compressor system with component labels.

Design - System Circuits

Oil Circuit Explanation

Explains the oil circulation path, including the oil thermostat, cooler, and injection into the compressor.

Air Circuit Explanation

Describes the air intake path, compression, cooling, and delivery to the consumer network.

System Control Introduction

Introduces the system control and details the standstill and starting procedures for L07-L11/L07FS-L11FS.

Design - System Control Operations

Automatic Operation Control

Explains automatic operation, including pressure control, idle mode, and shutdown conditions.

System Control for RS Models

Details standstill, starting, and stopping procedures for specific models.

Design - Speed Control and Hood

Speed Control Operation

Describes speed control using a PI regulator to adapt RPMs to compressed air demand.

Hood Opening and Closing

Provides instructions for opening and closing the detachable plastic hood for servicing access.

Transport and Installation Overview

Transport Procedures and Weights

Covers safe lifting practices, identification of lifting points, and weight specifications for different models.

Installation Requirements

Installation Guidelines

Details installation requirements, including foundation capacity, leveling, air intake location, and ventilation.

Preparations for Commissioning - Cooling

Cooling Air Volume and Ducts

Specifies cooling air requirements and minimum duct cross-sections for various compressor models.

Preparations for Commissioning - Air Connection

Compressed Air Connection

Details compressed air connection points, flexible connections, and flange/thread checks.

Preparations for Commissioning - Electrical (Europe)

Electrical Connection (Europe Version)

Provides recommended cable cross-sections and fuses for Europe-version compressors.

Preparations for Commissioning - Electrical Details

Electrical Connection Details

Explains electrical connection, protective measures, interference voltage, and control-power transformer settings.

Preparations for Commissioning - Electrical (USA/Canada)

Electrical Connection (USA/Canada Version)

Lists recommended supply cable sizes and fuses for USA/Canada versions based on temperature.

Preparations for Commissioning - Motor Fasteners

Control Transformer Setting Check

Details checking and adjusting the control-power transformer setting for local voltage conditions.

Electric Motor Fasteners Removal

Instructs on removing electric motor fasteners used for transportation before commissioning.

Preparations for Commissioning - Oil and Sound

Oil Level Check Procedure

Provides instructions for checking the oil level in the pressure reservoir, emphasizing safety precautions.

Sound Pressure Level Data

Lists sound pressure levels for different compressor models according to ISO 2151.

Commissioning Overview

First Commissioning Steps

Details steps for first commissioning, including safety checks, oil filling, and motor rotation check.

Commissioning Procedures

Start-up Protection Measures

Explains start-up protection related to temperature and pressure.

Routine Commissioning Steps

Outlines procedures for routine commissioning, including safety checks and system startup.

Commissioning After Malfunction

Provides steps for re-starting the unit after an automatic shutdown due to malfunction.

Control System Overview

Control System Basics

Introduces the control system and its commissioning, mentioning the POWER LOSS fault and language setting.

Control Panel Keys

Explains the functions of the control panel keys, including dual functions.

Status Indicators and Signals

Describes the three-row display, light signals (red/green), and their meanings.

Control System - Value Management

Displaying and Changing Values

Details how to navigate menus to display and change values like total hours and cut-out times.

Default Settings Configuration

Covers setting default parameters, including language selection and network pressure.

Control System - Pressure and Timer Settings

Setting Line Pressure

Explains setting maximum line pressure and target pressure for speed-controlled compressors.

Setting Time and Date (Timer)

Details how to set the timer for date and time after a power loss.

Starting, Stopping, and Emergency Off

Combines procedures for starting, stopping, and emergency shutdown of the unit.

Control System - Message Handling

Acknowledging Warning/Fault Messages

Explains how warning and fault messages are displayed and how to acknowledge them.

Control System - Menu Structure (Standard)

Menu Structure (Excluding RS Models)

Provides a menu structure diagram for controlling the compressor unit.

Control System - Menu Structure (RS Models)

Menu Structure (RS Models Only)

Illustrates the menu structure for L07RS-L11RS models, showing control parameters.

Service and Maintenance Overview

Maintenance Recommendations

Stresses performing maintenance at specified intervals for optimal unit satisfaction.

Electric Motor Maintenance

States that electric motor maintenance should follow the motor's operating instructions.

Maintenance and Inspection Schedule

Lists safety precautions and required conditions for checks and maintenance work.

Service and Maintenance - Schedules

Detailed Maintenance Schedule

Details service intervals for packages, filter replacements, oil changes, and inspections.

Service and Maintenance - Oil Change

Oil Change Procedure

Provides step-by-step instructions for changing the oil, including safety warnings.

Service and Maintenance - Filter Changes

Oil Filter Cartridge Replacement

Guides on replacing the oil filter cartridge, including safety and interval information.

Fine Separator Cartridge Replacement

Details the process for changing the fine separator cartridge with safety precautions.

Service and Maintenance - Air Filter

Air Intake Filter Replacement

Instructs on changing the air intake filter, emphasizing the importance of not operating without it.

Service and Maintenance - Safety Valve

Safety Valve Testing

Explains how to test the safety valve and warns against operating with a defective valve.

Service and Maintenance - Belts and Terminals

V-Belt and Tensioning System

Provides instructions for changing V-belts and notes about automatic tensioning.

Switch Cabinet Terminals

Covers checking and re-tightening switch cabinet terminals and control transformer settings.

Service and Maintenance - Fittings and Cleaning

Fittings and Hoses Check

Instructs to check and re-tighten fittings of air and oil circuits and check hoses for leaks.

General Maintenance and Cleaning

Outlines general maintenance and cleaning procedures for various unit parts.

Service and Maintenance - Filter Mats

Cooling Air Filter Mat Cleaning

Details how to clean or change the cooling air filter mat and inlet/outlet filters for the control cabinet.

Service and Maintenance - Inspections and Lubricants

Inspection Intervals

Specifies inspection intervals for pressure vessels (5/10 years) and electrical installations (4 years).

Lubricant Recommendations

Provides lubricant recommendations and discusses factors affecting oil change intervals.

Trouble-shooting - Unit Start Issues

Unit Cannot Be Started

Lists possible causes and remedies for the unit failing to start, covering voltage, faults, and temperature.

Trouble-shooting - Start-up and Pressure Issues

Unit Stops During Start-up

Identifies causes and remedies for the unit stopping during the start-up phase, such as intake regulator issues.

Failure to Reach Mains Pressure

Lists causes and remedies for the unit failing to reach the set mains pressure, including sensor issues.

Trouble-shooting - Operational and Oil Issues

Unit Switches Off

Details causes and remedies for the unit switching off unexpectedly, like high ambient temperature.

Excessive Idling and Oil Contamination

Combines causes for excessive idling and oil in air/compressed air, suggesting checks and replacements.

Safety Valve Issues

Addresses potential causes for the safety valve opening, including valve defects or clogged components.

Annex - Technical Data (Europe)

Technical Data L07-L11 (50 Hz)

Provides detailed technical specifications for the L07-L11 compressor at 50 Hz.

Annex - Technical Data (Europe 60 Hz)

Technical Data L07-L11 (60 Hz)

Provides detailed technical specifications for the L07-L11 compressor at 60 Hz.

Annex - Technical Data (Europe L07RS)

Technical Data L07RS (50/60 Hz)

Provides detailed technical specifications for the L07RS compressor at 50/60 Hz.

Annex - Technical Data (Europe L11RS)

Technical Data L11RS (50/60 Hz)

Provides detailed technical specifications for the L11RS compressor at 50/60 Hz.

Annex - Technical Data (USA/Canada L07-L11)

Technical Data USA/Canada L07-L11 (60 Hz)

Provides detailed technical specifications for the L07-L11 compressor in USA/Canada (60 Hz).

Annex - Technical Data (USA/Canada L07RS)

Technical Data USA/Canada L07RS (60 Hz)

Provides detailed technical specifications for the L07RS compressor in USA/Canada (60 Hz).

Annex - Technical Data (USA/Canada L11RS)

Technical Data USA/Canada L11RS (60 Hz)

Provides detailed technical specifications for the L11RS compressor in USA/Canada (60 Hz).

Annex - Layout Plans

Layout Plan L07-L11 and L07RS-L11RS

Shows layout plan with dimensions for L07-L11 and L07RS-L11RS models.

Annex - AirStation Layout Plan

Layout Plan AirStation L07FS-L11FS/L07RS FS-L11RS FS

Shows layout plan with dimensions for AirStation L07FS-L11FS and L07RS FS-L11RS FS models.

Annex - Declaration of Conformity

EC Declaration of Conformity

Contains the EC Declaration of Conformity for the compressor unit.

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