L&W Compressors LW 100 E, LW 100 E ECO, LW 100 B ECO, LW 100 B, LW 100 E1 Operating Instructions Manual
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C H A P T E R O V E RV I EW
Operating Instructions
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Spare Parts Lists
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Options
(if equipped)
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Attachment
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A
B
C
D
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: service@lw-compressors.com
Internet: www.lw-compressors.com
Version: 11/12-E
S E R V IC E I N F O R M A T I O N / W A R R A N T Y
Compressor information
Type designation
Serial number
Date of construction
Purchase information
Purchase date
First commissioned on
Warranty period
Dealer's stamp
Warranty
L&W will uphold warranty claims made during a period of 12 months from the invoice date.
If the compressor was purchased from an official L&W dealer, the date on the dealer's invoice is
valid. Warranty claims can only be made on presentation of the 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 reduction of the purchase price or changes to the contract can be made. The parts for which a
claim is being made should be kept safe by the purchaser and, when requested, sent to us at their
cost. Replaced parts become the property of L&W. If maintenance work is carried out without our
knowledge or permission by the purchaser or a third party, we are absolved from any liability for
warranty claims. As a matter of principle, warranty claims can only be made by the initial purchaser.
Version: 171012-001E
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Operating Instructions
Breathing Air Compressor
LW 100 series
Version: 29.03.2016
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LW 100 Series
Version: 29.03.2016
T A B L E O F C O N T E N T S
General Information and Technical Data
General Information / Description of Warning Symbols .................................................................... 4
Drive motors ...................................................................................................................................... 5
Scope of Delivery LW 100 E (ECO) / LW 100 E1 (ECO) ........................................................................ 6
Scope of Delivery LW 100 B ECO / LW 100 B ...................................................................................... 7
Technical Data .................................................................................................................................. 8
Unit Assembly LW 100 E / E1 ............................................................................................................ 9
Unit Assembly LW 100 B ................................................................................................................. 10
Flow chart ....................................................................................................................................... 11
Safety Precautions
Intended Use / Operators ................................................................................................................ 13
Safety instructions on the unit ........................................................................................................ 14
General Safety Precautions ............................................................................................................. 15
Unit customised safety notices ....................................................................................................... 16
Maintenance instructions ............................................................................................................... 17
Transportation instructions / Safety regulations .............................................................................. 18
Installation
Installation in closed rooms - LW 100 E / E1 ................................................................................... 20
Installation LW 100 B ...................................................................................................................... 21
Dimensions ...................................................................................................................................... 22
Minimum distances ........................................................................................................................ 23
Ventilation LW 100 E / E1 ............................................................................................................... 24
Electrical Installation LW 100 E / E1 ......................................................................................... 25 - 26
Operation
Important operation instructions .................................................................................................... 28
First commissioning LW 100 E / E1 ........................................................................................... 29 - 30
First commissioning LW 100 B ......................................................................................................... 31
Daily commissioning ....................................................................................................................... 32
Filling procedure ............................................................................................................................. 33
Switch off the compressor .............................................................................................................. 34
Remedying faults
............................................................................................................. 35 - 39
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LW 100 Series
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T A B L E O F C O N T E N T S
Maintenance and Service
Service, Repair and Maintenance .................................................................................................... 41
Maintenance Lists / Maintenance Intervals ............................................................................... 42 - 44
Service Kits ..................................................................................................................................... 45
Check V-belt tension / Tension V-belt / Settings ............................................................................... 46
Compressor lubrication / Check oil level .......................................................................................... 47
Oil change ...................................................................................................................................... 48
Manual condensation dump system ............................................................................................... 49
Oil / water separators 2nd stage - maintenance .............................................................................. 50
Filter housing / Filter cartridge ......................................................................................................... 51
Filter cartridge change .................................................................................................................... 52
Filter housing - maintenance ........................................................................................................... 53
Inlet Filter ....................................................................................................................................... 54
Check or change filter inlet ............................................................................................................. 55
Valve heads and valves / Pistons and Cylinders / Cooling ................................................................ 56
Replace inlet and outlet valve 1st stage .................................................................................... 57 - 58
Replace inlet and outlet valves 2nd and 3rd stage ........................................................................... 59
Safety valves ................................................................................................................................... 60
Pressure maintaining / non return valve .......................................................................................... 61
Adjust pressure maintaining valve .................................................................................................. 62
O-rings - filling valve and filling hose .............................................................................................. 63
Motor change ................................................................................................................................. 64
Pressure gas vessel test ................................................................................................................... 65
Maintenance records ............................................................................................................... 66 - 71
Storage
Conservation / storage of the compressor ....................................................................................... 72
De-conservation, commissioning .................................................................................................... 73
Transportation instructions / Disposal / Electric and electronic components ................................... 74
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LW 100 Series
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Warning
Indicates a potentially hazardous situation which, if not avoided, could result in physical
injury or damage to the product or environment.
Caution
Indicates an imminently hazardous situation which, if not avoided, could result in serious
injury, physical injury or death.
General Information
We strongly recommend reading this manual thoroughly prior to operation and follow all the safety
precautions precisely. Damage resulting from any deviation from these instructions is excluded from
warranty and liability for this product. Carry out other commissioning steps only if you have fully
understood the following contents.
Before commissioning and using the unit, carry out all the essential preliminary work and measures
concerning legal regulations and safety. These are described on the following pages of this
operation manual.
G E N E R A L I N F O R M A T IO N
!
!
Note
Indicates additional information on how to use the unit.
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Description of marks and warning signs
The following warning signs are used in this document to identify the corresponding warning notes
which require particular attention by the user. The warning signs are defined as follows:
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LW 100 Series
Version: 29.03.2016
Drive motors
Special Honda - Gasoline Motor
LW 100 B ECO / LW 100 B
High performance Briggs & Stratton 4 gear motor (4.5 kW) with integrated
fuel tank.
Pull start, auto cut off at low oil level
LW 100 E ECO / LW 100 E
2.2 kW E-Motor / 400V (230V/440V as an option) / 3 phase /
50 Hz (60 Hz as an option).
Start/Stop switch, fully wired with cable and 16A CEE plug.
LW 100 E1 ECO / LW 100 E1
2.2 kW E-Motor / 230 V AC / 50 Hz (as an option 60 Hz).
Start/Stop switch, fully wired with cable and two-pin earthed plug 230V.
D E S C R I P T I O N
LW 100 B ECO / LW 100 B
High performance Honda 4 gear motor (3.6 kW) with integrated fuel tank.
Pull start, auto cut off at low oil level
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LW 100 Series
Version: 29.03.2016
Scope of Delivery LW 100 E (ECO) / LW 100 E1 (ECO)
Compressors are provided in different equipped versions.
Versions
Filling pressure versions:
• PN 225 bar
• PN 330 bar
• PN 225 / 330 bar
Differences ECO to the Standard-Model
Specifications
Options
• Carrying handles (ECO only)
• Filling valve holder (ECO only)
• Additional filling hose c/w filling valve
• Automatic condensate drain
• Automatic stop at final pressure c/w hour
counter
• Switch over device for 200 or 300 bar
• Motor protection switch
• Conversion set: Petrol-/electro version
• 60 Hz Version
• 230V / 440V Version (LW 100 E / E ECO only)
• Power cable with plug
• Start/Stop Switch
• Stainless steel frame / aluminium frame (ECO)
• Manual condensate drain
• Pressure maintaining and non return valve
• 1 x Filling hose c/w f lling valve and pressure
gauge
• Intermediate coolers
• Oil- / Water separators after 2nd and 3rd stage
• Safety valves after for each stage
• All pistons with piston rings
• Filling pressure to your choice
(200 or 300 bar)
• Connections to your choice
(DIN 200 bar or 300 bar, CGA 200 bar or 300
bar and INT)
• Frame in a aluminium
• No carrying handles
• Unpainted compressor block
• No filling valve holder
D E S C R I P T I O N
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LW 100 Series
Version: 29.03.2016
Scope of Delivery LW 100 B ECO / LW 100 B
Compressors are provided in different equipped versions.
Versions
Filling pressure versions:
• PN 225 bar
• PN 330 bar
• PN 225 / 330 bar
Differences ECO to the Standard-Model
Specifications
Options
• Carrying handles (ECO ony)
• Filling valve holder (ECO only)
• Additional filling hose c/w filling valve
• Automatic stop at final pressure c/w hour
counter
• Switch over device for 200 or 300 bar
• Conversion set: Petrol-/electro version
• Stainless steel frame / aluminium frame (ECO)
• Manual condensate drain
• Pressure maintaining and non return valve
• 1 x Filling hose c/w f lling valve and pressure
gauge
• Intermediate coolers
• Oil- / Water separators after 2nd and 3rd
stage
• Safety valves after for each stage
• All pistons with piston rings
• Filling pressure to your choice
(200 or 300 bar)
• Connections to your choice
(DIN 200 bar or 300 bar, CGA 200 bar or 300
bar and INT)
• Frame in a aluminium
• No carrying handles
• Unpainted compressor block
• No filling valve holder
D E S C R I P T I O N
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LW 100 Series
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Technical Data
Technical Data
LW 100 E / (ECO) LW 100 E1 / (ECO) LW 100 B / (ECO)
Capacity [l/min]: 100 100 100
Max. Operating Pressure [bar]: 350 350 350
RPM [min-1]: 2300 2300 2300
Number of Pressure Stages: 3 3 3
Cylinder Bore 1st Stage [mm]: Ø 60 Ø 60 Ø 60
Cylinder Bore 2nd Stage [mm]: Ø 30 Ø 30 Ø 30
Cylinder Bore 3rd Stage [mm]: Ø 12 Ø 12 Ø 12
Medium: Compressed Air / Breathing Air
Intake Pressure: atmospheric
Oil Capacity [l]: 0,5 0,5 0,5
Intake Temperature [°C]: 0 < +45 0 < +45 0 < +45
Ambient Temperature [°C]: +5 < +45 +5 < +45 +5 < +45
Cooling Air Volume [m³/h]: > 660 > 660 > 1350
Voltage: -
Protection Class Drive Motor: IP 55 IP 55 -
Drive Power [kW]: 2.2 2.2 4.5
RPM Motor [min-1]: 2890 2890 2890
Start: Start / Stop switch Hand start
Noise level [dB(A)]: 82 82 93
Dimensions L x W x H [mm]: 650 x 390 x 400 650 x 390 x 400 780 x 380 x 400
Weight [kg]: approx. 43 / (39) approx. 43 / (39) approx. 46 / (42)
Content Volume Filter housing [l]: 0.37 0.37 0.37
400V / 3-Phase /
50 Hz
230V / 1-Phase /
50Hz
D E S C R I P T I O N
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LW 100 Series
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Unit Assembly LW 100 E / E1
No. Designation
1 Pressure gauge
2 Filling hose with filling valve
3 Carrying handles (ECO Optional)
4 E-Motor / 400V / 3 Phase / 50 Hz or E-Motor / 230V / single phase / 50Hz
D E S C R I P T I O N
3
2
1
4
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LW 100 Series
Version: 29.03.2016
No. Designation
1 Pressure gauge
2 Intake telescopic pipe
3 Filling hose with filling valve
4 Carrying handles (ECO Optional)
5 4 stroke gasoline engine, hand start
D E S C R I P T I O N
4
3
1
5
2
Unit Assembly LW 100 B
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LW 100 Series
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1. Air Intake Filter
2. 1st Pressure Stage
3. Safety Valve 1st Stage
4. Cooling Pipe 1st Stage
5. 2nd Pressure Stage
6. Safety Valve 2nd Stage
7. Cooling Pipe 2nd Stage
8. Condensate Release Hose
9. Condensate Release Valve
10. Oil-/Water Separator
11. 3rd Pressure Stage
12. Endpressure-Safety Valve
13. Cooling Pipe Final Stage
14. Condensate Release Hose
15. Condensate Release Valve
16. Oil-/Water Separator
17. Pressure Maintaining Valve
18. Non-Return Valve
19. Filling Hose
20. Filling Connector
21. Filling Valve
22. Pressure Gauge (Filling Pressure)
23. Vent Valve
24. Unit Filling Valve "Cross Design"
D E S C R I P T I O N
Flow chart
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S A F E T Y P R E C A U T I O N S
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LW 100 Series
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Intended Use
Only use the unit in perfect condition for its intended purpose, safety and intended use and observe
the operating instructions! In particular disorders that may affect safety have to be eliminated
immediately!
Use the unit exclusively for the determined medium (see "Technical Data"). Any other use that 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 the condition
that the instruction manual is complied with and inspection and maintenance requirements are
enforced.
No change and modification to the unit can be made without the written agreement of the
manufacturer. The manufacturer is not liable for damage to persons or property resulting from
unauthorised modifications.
Operators
Target groups in these instructions;
Operators
Operators are persons who are authorized and briefed for the use of the compressor.
Qualified personnel
Qualified personnel are persons who are entitled to repair, service, modify and maintain the system.
S A F E T Y P R E C A U T I O N S
Warning
Only trained personnel are permitted to work on the unit!
!
Warning
Work on the electrical equipment on / with the machine / unit may only be carried out by
qualified electricians.
!
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LW 100 Series
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Safety instructions on the unit
Importance of notes and warning signs that are affixed to the compressor according to the
application or its equipment.
S A F E T Y P R E C A U T I O N S
Warning
High voltage!
Note
Ensure correct direction of
rotation!
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LW 100 Series
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S A F E T Y P R E C A U T I O N S
General Safety Precautions
• Read the Operating Instructions of this product carefully prior to use.
• Read the Operating Instructions of the petrol engine carefully prior to use. (LW 100 B Versions)
• Strictly follow the instructions. The user must fully understand and strictly observe the
instructions. Use the product only for the purposes specified in the intended use section of this
document.
• Do not dispose the operating instructions. Ensure that they are retained and appropriately used
by the product user.
• Only trained and competent personnel are permitted to 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.
• Only authentic L&W parts and accessories may be used for maintenance work. Otherwise, the
proper functioning of the product may be impaired.
• Do not use faulty or incomplete products. Do not modify the product.
• Inform L&W in the event of any product or component fault or failure.
• The quality of the air supply must meet EN 12021 specifications for breathing air.
• Do not use the product in areas prone to explosion or in the presence of flammable gases. The
product is not designed for these applications. An explosion might be the result if certain
conditions apply.
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LW 100 Series
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S A F E T Y P R E C A U T I O N S
Unit customised safety notices
Organisational measures
• In addition to the instruction manual, observe and comply with universally valid legal and other
obligatory regulations regarding accident prevention and environment protection.
• In addition to the instruction manual, provide supplementary instructions for supervision and
monitoring duties taking into consideration exceptional factors e.g. with regard to organisation
of work, production, personnel employed.
• Supervise personnel’s work in accordance with the instruction manual, taking into account safety
and danger factors.
• Observe all safety and danger notices on the compressor and check readability and
completeness.
Safety instructions operation
• Take measures 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 provided and in good working order.
• Check the compressor at least once per day for obvious damage and defects. Inform the
responsible department / person immediately if anything is not as is should be (including
operation performance). Shut down the machine immediately if necessary and lock it.
• In case of malfunction, stop the compressor immediately and lock it. Repair malfunctions
immediately.
• If there is a failure in the electric energy supply, shut the machine / unit down immediately.
• Ensure safe and environmentally friendly disposal of consumables and old parts.
• The stipulated hearing protectors must be worn.
• Soundproofing equipment on the compressor has to be activated in safety function during
operation.
• When handling with fats, oils and other chemical agents, observe the note for the productrelated safety.
• Check all additional safety notices for the petrol engine in the specific handbook
(LW 100 B Versions)
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LW 100 Series
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S A F E T Y P R E C A U T I O N S
Maintenance instructions
• Hoses have to be checked by the operator (pressure and visual inspection) at reasonable
intervals, even if no safety-related defects have been detected.
• Immediately repair any damage. Escaping compressed air can cause injury.
• Depressurise system and pressure lines before beginning repair work.
• Pressurised air lines must be laid and mounted by qualified personnel. Connections must not be
mixed up. Fittings, length and quality of the piping must correspond to requirements.
• Adjustment, maintenance and inspection activities and keep appointments, including
information on replacement parts / equipment, prescribed in the operating instructions have to
be respected.
• If the machine / equipment is completely off during maintenance and repair work, it must be
protected against unexpected restart. Turn off main control device and remove the key and/or
display 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 not use aggressive
cleaning agents. Use fibre-free cleaning cloths.
• Switch off compressor and clean with a slightly damp cloth. Remove dirt from cooling pipes by
using a brush.
• After cleaning, examine all pipes for leaks, loose connections, chafing and damage. Immediately
eliminate any faults.
• Always retighten any screw connections loosened for maintenance or repair work.
• If it is necessary to remove safety devices for maintenance and repair work, these must be
replaced and checked immediately after completion of the maintenance or repair work.
• The electrical equipment of the compressor must be regularly checked. Defects, such as loose
screw connections or burnt wires, must be immediately rectified by electrically skilled personnel.
• Only personnel with particular knowledge and experience with pneumatics may carry out work
on pneumatic equipment.
• Only personnel with particular knowledge and experience in gas equipment may carry out work
on gas equipment.
• Any work on the petrol engine should be done in accordance with ist specific handbook.
(LW 100 B Versions)
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S A F E T Y P R E C A U T I O N S
Transportation instructions
• Parts which need to be dismantled for transport purposes must be carefully replaced and secured
before taking into operation.
• The transport may only be carried out by trained personnel.
• For transportation, only use lifting devices and equipment with sufficient lifting power.
• Do not stand or work under suspended loads.
• Even minor relocation please disconnect the machine / system from any external energy supply.
• Before recommissioning, reconnect the machine to the mains according to regulations.
• When recommissioning, proceed according to the operating instructions..
Safety regulations
• Inspections according to legal and local obligatory regulations regarding accident prevention are
carried out by the manufacturer or by authorised expert personnel. No guarantees whatsoever
are valid for damage caused or favoured by the non-consideration of these directions for use.
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I N S T A L L A T I O N
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LW 100 Series
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Installation in closed rooms - LW 100 E / E1
For installation in closed rooms, observe the following:
• Install the unit horizontally and level. The floor must be vibration-free and capable of taking the
load of the system weight.
• The compressor room must be clean, dry, dust free and as cool as possible. Avoid direct exposure
to sunlight. If possible, install unit in such a manner that the compressor fan can intake fresh air
from outside. Ensure adequate ventilation and exhaust air opening.
• When locating the compressor in rooms of less than 30 m³ space 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 noxious gas e.g. smoke, solvent vapours, exhaust fumes etc.
• Observe the specified operating temperature (see "Technical Data")!
Danger
No operation in explosion-hazard areas.
The unit is not approved for operation in areas prone to explosion.
!
I N S T A L L A T I O N
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LW 100 Series
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Installation LW 100 B
For outside installation observe the following:
• Install the unit horizontally and level. The floor must be vibration-free and capable of taking the
load of the system weight.
• On units employing petrol or diesel motors, it is most important that only clean air is used.
Position compressor in direction of wind so that exhaust fumes are blown away from the unit.
• Intake air must be free from noxious gas e.g. smoke, solvent vapours, exhaust fumes etc.
• Observe the specified operating temperature (see "Technical Data")!
Danger
Compressors with petrol or diesel motors must only be located outdoors, never indoors,
not even in partially closed rooms however large they may be.
!
Wind
WindWind
Wind
Exhaust gases
Exhaust gasesExhaust gases
Exhaust gases
Intake air
Intake airIntake air
Intake air
I N S T A L L A T I O N
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LW 100 Series
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Dimensions LW 100 E / E1
400 650
390
Fig. Dimensions
450
180
Dimensions LW 100 B
400 780
380
Fig. Dimensions
450
180
I N S T A L L A T I O N
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LW 100 Series
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Fig. Minimum distances LW 100 E / E1
300 mm 300 mm
Fig. Minimum distances LW 100 B
300 mm 300 mm
I N S T A L L A T I O N
Note
Minimum distances must be adhered!
i
Minimum distances
• Make sure that the compressor 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. 300 mm, rear side min. 300 mm. Avoid anything in this area which can restrict
the cooling air flow.
• No minimum distances are required at the side panels.
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LW 100 Series
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Ventilation LW 100 E / E1
• Make sure that the compressor always has a sufficient amount of fresh air available for cooling.
• To prevent serious damage, ensure that the 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 [m³/h]
Example 11kW motor: 300 x 11kW = 3300 m³/h = required cooling air flow.
• The fan capacity for fresh air and warm air must meet at least the required cooling air flow.
The fans must have the same capacity.
Fig. Ventilation through facade
Fig. Ventilation via ventilation stack
I N S T A L L A T I O N
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LW 100 Series
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Electrical Installation LW 100 E / E1
For installation of electrical equipment, observe the following:
• If control devices are delivered by the factory, refer to the appropriate wiring diagram.
• Ensure correct installation of protective conductors.
• Check conformity of motor and control device tension and frequency with those of the electric
network (see name 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 compressor direction of rotation
(see chapter "Operation -> First commisioning - LW 100 E/E1).
• Fuse the motor correctly (see table; use slow-blow fuses).
I N S T A L L A T I O N
Warning
Work on the electrical equipment on / with the machine / unit may only be carried out by
qualified electricians.
!
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LW 100 Series
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Recommended fuses for 360 - 500 V operating voltage
Nominal motor power Fusing start A Connection in mm²
[kw] [A] Direct Star/Delta Contactor supply S/D* to Motor
2.2 5 10 - 1.5 1.5
4 8.5 20 - 2.5 1.5
Electrical Installation LW 100 E / E1
The compressor comes fully wired with cable and plug. An installation is not necessary.
Recommended fuses for 220 - 240 V operating voltage
Nominal motor power Fusing start A Connection in mm²
[kw] [A] Direct Star/Delta Contactor supply S/D* to Motor
2.2 8.7 20 - 1.5 1.5
4 14.8 25 - 2.5 1.5
Fig. 1 - Connections LW 100 E Fig. 2 - Connections LW 100 E1
Terminal Box Wiring
I N S T A L L A T I O N
* S/D - Star / Delta.
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O P E R A T I O N
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LW 100 Series
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O P E RA T I O N
Important operation instructions
Danger
On petrol or diesel engines, operation unit must only be located outdoors, never indoors,
not even in partially closed rooms however large they may be.
!
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 hearing protection.
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