LW 1300 E

Instruction Manual

LW 1300 E
CNG Compressor

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 1 of 13
 LW 1300 E

SAFETY PRECAUTIONS

General Notice

This instruction manual contains the operation and maintenance procedures

necessary to safely run your L&W gas compressor.
We strongly recommend to read 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. Be sure to pay
attention to the following points:

Fill only tanks with a valid hydrostatic test date

Never exceed the working-pressure rating indicated on the tank
Carry out proper maintenance on the compressor and filtration system
Care must be taken to avoid the intake of contaminated air in to the compressor
Do not exceed maximum operating temperatures

Safety Precautions

Read the operation manual of your compressor carefully

Allow only qualified personnel to run the compressor
Do not place any objects on compressor while in operation
Make sure no person or object can accidentally touch any moving parts while
running
Take care that the intake-air is pure and free of toxic gases
All work on compressor must be carried out while compressor is disconnected for
the power supply and depressurized
Check unit regularly for air- & oil leaks
Never weld damaged high-pressure tubes
Filling-hoses must be in perfect condition; special attention should be paid to the
connecting fittings
Do not touch any hot compressor / engine parts while doing maintenance work as
these may cause injury by burning. Wait until unit has cooled down.

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 2 of 13
 LW 1300 E

Technical Data LW 1300 VD 4 / 300Nm/h / 75 KW (/400V/50hz)

Delivery Capacity: 3,000 l/min

Max. Pressure: 350 bar
RPM Compressor: 985 min-1
No of Pressure Stages: 4
Cylinder Bore 1st Stage:: 135 mm
Cylinder Bore 2nd Stage: 70 mm
Cylinder Bore 3rd Stage: 32 mm
Cylinder Bore 4th Stage: 16 mm
Stroke: 120 mm
Medium: CNG
Working Pressure 1st Stage: 2.8 bar (at 290 bar final pressure)
Working Pressure 2nd Stage: 17 bar (at 290 bar final pressure)
Working Pressure 3rd Stage: 76 bar (at 290 bar final pressure)
Relief Pressure Safety Valve 1st Stage: 8 bar
Relief Pressure Safety Valve 2nd Stage: 25 bar
Relief Pressure Safety Valve 3rd Stage: 95 bar
Relief Pressure Safety Valve Final Stage: depents on application
Intake Pressure: 4,0 bar
Oil Pressure: +1.5 bar (+/- 0.3 bar)
Oil Capacity: 3.9 ltr
Air Intake Temperature: -30C < +55C
Ambient Temperature: -5 C < +55C
Cooling Air Requirement: > 11,000 m/h
Voltage:
400 V / 3-Phase / 50 Hz
(special windings on request)

Protection Class Drive Motor IP 55

Motor Power: 75 kW
RPM Motor: 1,185 min-1
Start: Star / Delta

Dimensions:
Depth:
1,590 mm (62.6)
Length: 1,210 mm (47.6)
Height: 1,260 mm (49.6)
Weight: approx. 1,000 kg
Breathing Air Quality according to:
DIN 3188 - EN 12021 - ISO 2533 - BS 4001 & BS 4275

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 3 of 13
 LW 1300 E

Application:
4-stage breathing air compressor.
Large capacity, slow running stationary compressor
- ideal for professional applications.

Specifications:
Ready to connect, fully wired with pneumatic/electric compressor control and start/delta
start cycle, automatic stop and automatic condensation drain
Operating panel with start/stop buttons and drain test button, final pressure gauge and
hours counter
Sturdy steel housing, powder coated in RAL 6026
All pistons with piston rings
Low pressure oil pump
Oil/water separators after each stage, safety valve for each stage
Inlet pressure control and cut-off (ECC version only)
Pressure maintaining and non-return valve
HP-Outlet

Options:

ECC Control
Motor overload protection switch
Special windings for electric motor and control (e.g. 220V / 60Hz)
Oil pressure control
420 bar version
HP-Outlet

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 4 of 13
 LW 1300 E

Method of Operation

Air comes through a micro filter into

the first stage, gets compressed and
leaves trough the heat exchanger
into a water / oil separator. A short
pipe leads the air into the second
cylinder and is further compressed,
leaving again through a heat
exchanger and the second water /oil
separator and then compressed in
the third stage to the final pressure.
The air then goes through the after
cooler and into the mole carbon
filter. The purified air passes a
safety valve and into the pressure
maintaining valve, there to the air 4-stage Compressor Block

manifold and filling hoses or, if

required, into an external filling
panel.

Electric Motor / Universal Joint

Standard 50 Hz specification: 75 kW / 3-phase / 1,185 rpm
Standard 60 Hz specification: 75 kW / 3-phase / 985 rpm
- Special windings on request

Compressor block is direct driven via universal joint (rotation ratio 1:1)
Drive motor is free of maintenance
Universal joint: lubricate grease nipples every 1500 hours, at least once a year

Universal Joint

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 5 of 13
 LW 1300 E

Installation

The compressor should only be connected by a qualified licensed electrician.

NOTE: Check direction of rotation immediately after the first start !
If the direction of rotation is wrong, the oil pump will not lubricate the 3rd & 4th stage
pistons which may cause them to overheat / cease.
Furthermore the unit would not get the required cooling air flow.
When facing the front of the compressor cover, the direction of rotation should be
anticlockwise (check arrow on drive motor).
Dont place compressor closer than 1 meter to any walls and ensure good
ventilation.

Automatic Condensation Dump System

The L&W 1300 E comes with an auto dump system as standard.

Each pressure stage has its own oil- / waterseparator.
Solenoids open and drain all four condensate separators about every 15 minutes.

Standard Version: all four separators have solenoids which were controlled by an
electronic timer. The timer is located in the switchboard compartment and activates
the dump valves every 15 minutes - interval is adjustable - to release the condensate
through hoses. We recommend the use of a 20 litre container to collect all
condensate. It can then be deposed of like discarded oil.
The drain noise is kept to a minimum with a silencer.
Operation can be check by the blue push button on the dash panel.

ECC Version: all four separators have solenoids which were controlled by the ECC.
It activates the dump valves every 15 minutes to release the condensate through.
We recommend the use of a 20 litre container to collect all condensate. It can then
be deposed of like discarded oil.
The drain noise is kept to a minimum with a silencer.
Operation of the solenoids can be check at Test Menu (* 4)

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 6 of 13
 LW 1300 E

Intake Filter

A micro filter cartridge is used as an

intake filter.
We recommend to replace filter
cartridges every
1000 working hours.
A dirty, contaminated filter restricts the
intake flow,
reduces the compressors delivery
capacity and
causes overheating.

Cylinder Heads and Valves

Inlet and outlet valves are located

inside the cylinder heads.
Inlet valves opens on the down stroke,
outlet valve opens on the upstroke.
Valves should be replaced after 2000
working hours due to normal wear and
tear.
To replace valves the cylinder heads
have to be removed. All four valves
are combinated valves (inlet and outlet
valves form one unit).
First and second stage valves are of
plate valve design, third an fourth
stage usees spring operated pistons
which act inside brass cylinders.
These valves sit loose inside the
cylinder head, alloy rings are used as
high temperature seals.
There are no special tools required to
do any service work.

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 7 of 13
 LW 1300 E

Lubrication

LW 1300 compressor is equipped with

an directly
driven, low pressure oil pump.

Crankshaft is lubricated by oil spray /

oil slinger.
1st and 2nd stages are lubricated by
spray oil.
3rd & 4th stages are lubricated by
mechanical oil pump

The oil pump is protected by a plastic

sieve which
is located under the oil pump cover.
It has to be cleaned every 1000 working
hours.

NOTE:
Check oil level daily.
It never should be lower than the red marking on the oil level indicator glass
(located on right hand side of compressor crankcase).

Safety Valves

Every pressure-stage is equipped

with a separate safety valve.
They protect the unit from over -
pressure / load.

Safety Valves Settings:

1st Stage: 8 bar
2nd Stage: 25 bar
3rd Stage: 95 bar
4th stage: final pressure

If a safety valve blows it indicates problems with either inlet or outlet valve of the
following stage (valid for 1st, 2nd & 3rd stage compression stages).

NOTE: Faulty safety valves should always be replaced!

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 8 of 13
 LW 1300 E

Filter cartridge change

Unscrew the filter housing cap anti-

clockwise, first with the
special cartridge key and later by hand (1)
Place the other end of the cartridge key in
the filter cartridge
in the filter housing (2)
Unscrew the filter cartridge anti-clockwise
and pull the
cartridge out of the housing (3)
Check O-ring for wear and grease thread
of top cap
Open the sealing of the new filter cartridge
and use the
cartridge key to place it in the filter housing
(3)
Screw in the new filter cartridge clockwise
with the cartridge
key hand tight (2)
Refit the cap of the filter housing clockwise,
first by hand and
than by the filter key, hand tight (1)
Close the drain valve of the separator /
filter housing if only
the hand operated drain is mounted.
The filter cartridge replacement is now
completed, ensure
that the saturated filter cartridge is disposed
of correctly at an
approved waste point.

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 9 of 13
 LW 1300 E

Service, repair and maintenance

All repair, service and maintenance work is to be carried out when the compressor is
stopped, isolated from the power supply and pressure free.
The unit is to be regularly checked for leaks of air/oil, air leaks can be localised using
a leak detector or spray
It is recommended that only authorised L&W service technicians carry our repair and
service on the bearing of the compressor (crankshaft and connecting rods)

Conservation / storage of the compressor:

If the compressor is not to be used for an extended period of time, we recommend
the following conservation work is carried out before the storage:
Run the compressor at 200 bar for approx 10 mins (control the flow with the
filling valve to maintain the pressure).
Replace the oil with new oil.
Open the filling valve(s) and run the compressor for a few minutes .
Stop the compressor and open the drain valves.
Close the filling valves
Open the final filter housing and lubricate the O Ring with a food grade grease
or silicone grease.
Store the compressor in a cool dry place free from dust and contamination. A
cover is recommended as long as condensation can be avoided.

De-conservation, commissioning:
After the compressor has been stored, the following Steps are to be taken:
If the compressor has been stored for more than 12 Months, we recommend
replacing the oil before use.
Replace the final purification filter.
Check oil level.
Inspect the condition of the vee belts, replace if necessary
Inspect the filling hoses visually for signs of deterioration, replace as
necessary.
Open the filling valves and run the compressor for approx 10 minutes with the
filling valves open.
Close the filing valves and allow the compressor to build up to working
pressure.
Check the correct safety valve setting and/or pressure switch setting (option).
Check all connections and pipe work for leaks.

Once the above Stepps are completed to satisfaction, the unit is ready to use.

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 10 of 13
 LW 1300 E

OIL CHANGE INSTRUCTIONS

For the periodic oil change, please follow the
time schedule of the
instruction manual;
Only use the original L&W synthetic oil
9001/01
(1 ltr bottle) or 9001/12 (12 x 1 ltr bottle
packing).
Before changing the oil, be sure the
compressor is swithed off and
cannot be inadvertantly started. Disconnect
it from the power supply or
by switch off the starter of the gasoline or
Diesel engine.

To conduct an oil change, the tem perature of the oil must be at least +20C to allow it to flow
easily. In cold climates, the compressor should run first for about 15 minutes, dependent on
the ambient temperature;

The picture above is showing the easy

way of oil refilling by using a funnel
placed on the oil drain hose.

Oil change
Unscrew the filling cap anti-clockwise (1)
Remove the oil drain hose from its holder (2)
Unscrew the drain hose cap anti-clockwise (3)
Hold the drain hose over a container for waste oil and open the drain valve (4)
Let the oil drain completely, close valve (4), screw on plug (3) and relocate the hose
Refill the block with original L&W compressor oil (approx. 1.8 ltr) by using a funnel
The indicator glass (5) should be filled up to the top level - DO NOT OVERFILL WITH OIL!!
Refit the oil filler cap

The oil change is now completed, ensure the filling cap (1) is securely refitted.
The schedule in the maintenance manual will indicate the next oil change or the ECC
display.
Ensure the waste oil is disposed of correctly at an approved waste oil point.
To conduct an oil change, the tem perature of the oil must be at least +20C to allow it to flow
easily.

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 11 of 13
 LW 1300 E

Pressure maintaining and non-return valve

The combined pressure maintaining

non-return valve is located in the
system directly after the final filter
housing

Pressure maintaining valve

The pressure maintaining valve serves to keep the pressure in the final filter housing
at a minimum of 150 - 180 bar. This high pressure creates more condensation in the
separator/housing that can be mechanically removed (opening the drain valve)
before the air is finally purified in the final filter, thus extending the life of the filter
cartridge.
When the compressor is started, the pressure will build up in each stage as the
compressor runs. The pressure in the final filter housing will increase until the
pressure maintaining valve set pressure is reached. As a result of this function, the
filling pressure gauge will not show any pressure for approx 1 min after the
compressor is started and no air will flow out of the filling valve if opened.
Once the pressure maintaining valve opens, the pressure gauge will respond by
climbing quite rapidly (within a few seconds) to the set pressure of the pressure
maintaining valve (default 150 180 bar).

Adjusting the pressure maintaining valve:

Open the filling valve to vent the system completely, close the filling valve
(Pressure gauge reads 0 bar)
Start the compressor
Monitor the pressure gauge
The valve will open and the pressure the gauge climbs to quickly to the set
pressure, this should be 150 180 bar
If the pressure setting is outside this valve, adjust the pressure maintaining
valve as follows:

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 12 of 13
 LW 1300 E

Increase the pressure setting:

Stop the compressor and open the drain valves

Open the filling valve to vent the system after the pressure maintaining valve
(Pressure gauge reads 0 bar)
Loosen the locking screw on the pressure maintain valve
Using a suitable tool, screw the valve setting screw clockwise to increase the
spring tension
Start the compressor and check the pressure setting, adjust as necessary
Re-tighten the locking screw
Check the pressure maintaining opening pressure once again

Decrease the pressure setting:

Stop the compressor and open the drain valves

Open the filling valve to vent the system after the pressure maintaining valve
(Pressure gauge reads 0 bar)
Loosen the locking screw on the pressure maintain valve
Using a suitable tool, screw the valve setting screw anti-clockwise to decrease
the spring tension
Start the compressor and check the pressure setting, adjust as necessary
Re-tighten the locking screw
Check the pressure maintaining opening pressure once again

Warning:
If the pressure maintaining valve is set at a higher pressure than the maximum
working pressure, the final safety valve will blow off before the pressure maintaining
valve opens, the pressure gauge will read 0 bar!
After repair work where the pressure maintaining valve is not yet adjusted, the basic
setting is the setting screw approx 3 turns in to the housing.

Non-return valve
The non-return valve is located in the system after the pressure maintaining valve
and prevent air from flowing back from the filling lines into the final filter
housing/compressor block. The non-return valve is operating correctly if the
pressure gauge on the filling valve remains constant when the drain valves on the
compressor are opened.

LW 1300 / VD 4 / 75 KW / 300 Nm/h

Michael Knabe 13 of 13