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Repair Manual

D55-08A to D150-10A
Oil Free, Rotary Screw Air Compressors

Air-Cooled

GB DL051AAA – 12/2008
CompAir Contents

Repair Manual

D55-08A to D150-10A
Oil Free, Rotary Screw Air Compressors

Air-Cooled

GB DL051AAA – 12/2008

DL051AAA 3
Contents CompAir

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.4 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.5 Where To Contact Us . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Warnings, Cautions And Notes . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 General Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Operational Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Maintenance and Repair Precautions . . . . . . . . . . . . . . . . . . . 13
2.7 Precautions In The Event Of Fire . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 50Hz Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 60Hz Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Thermal Overload Settings . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 MCB Q101 (MMS) Settings . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 About the Cable Sizes and Fuse Ratings Table . . . . . . . . . . . . . . 20
3.6 Cable Sizes and Fuse Ratings Table . . . . . . . . . . . . . . . . . . . . 21
4 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Air End - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Air End - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 Air System - Description . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 Air System - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Regulation System - Description . . . . . . . . . . . . . . . . . . . . . . 28
4.7 Regulation System - Operation . . . . . . . . . . . . . . . . . . . . . . 28
4.8 Cooling System - Description . . . . . . . . . . . . . . . . . . . . . . . . 32
4.9 Cooling System - Operation . . . . . . . . . . . . . . . . . . . . . . . . 32
4.10 Lubrication System - Description . . . . . . . . . . . . . . . . . . . . . . 34
4.11 Lubrication System - Operation . . . . . . . . . . . . . . . . . . . . . . . 34
4.12 Powered Breather - Description . . . . . . . . . . . . . . . . . . . . . . 36
4.13 Powered Breather - Operation . . . . . . . . . . . . . . . . . . . . . . . 36
4.14 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1 Compressor Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 Air and Condensate Pipework . . . . . . . . . . . . . . . . . . . . . . . 44
5.4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Storage - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.6 During Long-Term Storage (Up To 12 Months) . . . . . . . . . . . . . . 46
5.7 During Short-Term Storage (Up To One Month) . . . . . . . . . . . . . . 46
5.8 Long-Term Storage - Preparation . . . . . . . . . . . . . . . . . . . . . 46
5.9 Long-Term Storage Procedure - Power Connected to Compressor . . . . 47
5.10 Long-Term Storage Procedure - Compressor Disconnected from Power . 47
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1 Preliminary Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . 48
6.2 SureScan Controller - Entering the Access Code . . . . . . . . . . . . . 48
6.3 System Checks and Calibration . . . . . . . . . . . . . . . . . . . . . . 49
6.4 Checking/Altering Commissioning Parameters . . . . . . . . . . . . . . . 52

4 DL051AAA
CompAir Contents

6.5 Checking/Altering Operating Parameters. . . . . . . . . . . . . . . . . . 54


6.6 Re-setting Service Interval Timer . . . . . . . . . . . . . . . . . . . . . 55
6.7 Final Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.8 Commissioning Parameters (Compressor Running On-Load) . . . . . . . 58
6.9 Powered Breather System - Check Vacuum.. . . . . . . . . . . . . . . . 58
6.10 Commissioning Check List . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Operation and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.2 Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.3 Displaying the Number of Hours Run . . . . . . . . . . . . . . . . . . . 62
7.4 Changing the Displayed Value . . . . . . . . . . . . . . . . . . . . . . . 62
7.5 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.6 Emergency Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.7 Condensate Drain Operation . . . . . . . . . . . . . . . . . . . . . . . . 63
7.8 Service Interval Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.9 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.10 Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.11 Fault History Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.12 Stand-by Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.13 Using The Menu Routines . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.14 Menu Structure Quick Reference . . . . . . . . . . . . . . . . . . . . . . 74
7.15 Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.16 Glossary Of Display Messages . . . . . . . . . . . . . . . . . . . . . . . 76
7.17 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.18 Index of Shutdown and Warning Messages . . . . . . . . . . . . . . . . 80
8 Components (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.1 Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.2 Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.3 Air Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.4 Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.5 Condensate Drains and Manifold . . . . . . . . . . . . . . . . . . . . . . 91
8.6 Discharge Silencer (Second Stage) . . . . . . . . . . . . . . . . . . . . 92
8.7 Dump Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.8 Intercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.9 Moisture Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.10 Oil Breather (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . 96
8.11 Oil Removal Filter (Current Models) . . . . . . . . . . . . . . . . . . . . 96
8.12 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.13 Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.14 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.15 Shuttle Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.16 Suction Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9 Components (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.1 Air and Oil Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . 103
9.2 Oil Pressure Switches and Sensors . . . . . . . . . . . . . . . . . . . . 103
9.3 Phase Rotation Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.4 Drive Motor Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.5 Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.6 Oil Filter Differential Pressure Switch . . . . . . . . . . . . . . . . . . . 105
9.7 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.8 Unloader Solenoid Valve (3 Way) . . . . . . . . . . . . . . . . . . . . . 107
9.9 Condensate Drain Solenoid Valve (2-Way N/C) . . . . . . . . . . . . . 108
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 112

DL051AAA 5
Contents CompAir

10.3 Recommended Maintenance Parts . . . . . . . . . . . . . . . . . . . . 112


10.4 Torque Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10.5 Enclosure Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.6 Intake Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.7 Condensate Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.8 Condensate Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.9 Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.10 Power Breather Oil Removal Filter . . . . . . . . . . . . . . . . . . . . 117
10.11 Balance Piston Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . 118
10.12 Non-Return Check Valve (NRV). . . . . . . . . . . . . . . . . . . . . . 118
10.13 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.14 Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.15 Interstage and Discharge Moisture Separators . . . . . . . . . . . . . . 120
10.16 Flexible Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 121
10.17 Air End Bearing Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . 121
11 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.2 Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.3 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
11.4 Control Function Option - Condensate Drain . . . . . . . . . . . . . . . 130
11.5 Control Function Option - Inputs . . . . . . . . . . . . . . . . . . . . . 130
11.6 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
11.7 Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11.8 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11.9 Cage-Clamp Screwless Terminals . . . . . . . . . . . . . . . . . . . . 143
11.10 Displayed Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . 144
11.11 Observed Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . 145
11.12 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
11.13 Motors and Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 147
11.14 Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.15 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11.16 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
11.17 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12 Dismantling & Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 171
12.1 Air Intake Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 171
12.2 Suction Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
12.3 Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
12.4 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
12.5 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
12.6 Cleaning Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
12.7 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
12.8 Condensate Drain Solenoid Valve (2 Way Normally Closed) . . . . . . . 184
12.9 Main Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
12.10 Drive Coupling Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
12.11 Air-Ends and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
12.12 Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 198
12.13 Air End Special Tools Diagrams. . . . . . . . . . . . . . . . . . . . . . 200
13 Appendix 1 - The Pressure Systems Safety Regulations 2000. . . . . . 210
13.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
13.2 P & I Diagram - Current Machines . . . . . . . . . . . . . . . . . . . . 210
13.3 P & I Diagram - Early Machines . . . . . . . . . . . . . . . . . . . . . . 212
14 Appendix 2 - Commissioning Checklist Form. . . . . . . . . . . . . . . 214
14.1 Instructions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

6 DL051AAA
CompAir Introduction 1

1 Introduction
1.1 Foreword which unapproved replacement parts are
included.
1.1.1 Worldwide service and parts facilities are
provided by CompAir. The AfterMarket
department at Redditch is available should USE ONLY
any difficulty be experienced.
1.1.2 It is essential to quote the compressor
MODEL and SERIAL numbers in all
communications.
GENUINE PARTS
AUTHORISED
1.1.3 All pressures shown are gauge pressures.
SERVICE AGENTS
1.1.4 The substitution of parts not manufactured or
approved by CompAir can reduce
performance or service life and create 1.4 Scope
potential mechanical or personnel hazards.
1.4.1 This manual covers all models with German
1.1.5 The right is reserved to modify the contents of Dataplate and UK built models with the
this publication without notice and the data following serial numbers:
given is in no way binding on the
manufacturers. 50Hz Models From Serial Number
1.1.6 Where approximate figures are shown, D75-08A F220-0103
specific details are available on request. D75-10A F221-0201
D90-08A F222-0307
1.2 Maintenance and Servicing D90-10A F223-0403
1.2.1 Maintenance, repairs and/or modifications D110-08A F224-0502
must only be carried out by competent D110-10A F225-0603
personnel under a CompAir trained and D132-08A F226-0703
qualified supervisor.
D132-10A F227-0801
D150-08A F228-0904
1.3 Warranty
D150-10A F229-1002
1.3.1 The conditions of the CompAir Warranty are
set out in the company's standard Conditions
of Sale available from the Distributor
supplying the machine.
60Hz Models From Serial Number
Warning: The use of replacement parts or D55-08A F230-0101
lubricating oils not supplied or approved
by CompAir may lead to failures in service D75-08A F232-0301
which would not be covered by warranty . D75-10A F233-0401

Any unauthorised modifications or failure D90-08A F234-0502


to maintain this equipment in accordance D90-10A F235-0601
with the maintenance instructions may D110-08A F236-0701
make it unsafe. The use of replacement D110-10A F237-0801
parts not supplied or approved by
CompAir may create hazardous conditions D150-08A F238-0904
over which CompAir has no control. D150-10A F239-1001

Such hazardous conditions may lead to


accidents that can be life threatening,
cause substantial bodily injury or result in
damage to the equipment. CompAir can
bear no responsibility for equipment in

DL051AAA 7
1 Introduction CompAir

1.5 Where To Contact Us CompAir Canada Inc., CompAir France SA,


871 Cranberry Court, 70 avenue Albert Einstein,
While these details were Oakville, Z.A. du Château d'Eau,
correct at time of printing, Ontario, BP 50061,
please check the L6L 6J7, 77551 Cramayel Cedex,
secureCompAir website at Canada France
info.compair.com for the Tel: +1 905 847 0688 Tel: +33 (0) 1.64.13.89.13
latest information. Fax: +1 905 847 8124 Fax: +33 (0) 1.64.13.37.00
info@compair.ca compair.france@compair.com
CompAir Australasia Ltd. www.compair.ca
13-17 Progress Street, CompAir Drucklufttechnik
Dandenong, Shanghai CompAir GmbH
Vic 3175, Compressor Co. Ltd., Argenthaler Straße 11
PO Box 4508, (CompAir SCCC) D-55469
Victoria 3164, 3501 Nan Zheng Building, Simmern/Hunsrück
Australia. 580 Nanjing Road (W), Germany
Tel: +61 (0)3 9212 5800 Shanghai, Tel: +49 6761 8320
enquiries@compair.com.au China 200041 Fax:+49 6761 832409
Tel: +86 21 5109 5030 info@compair.de
CompAir Austria GmbH, Fax: +86 21 6272 9910
Westbahnstrasse 5, -------------------------------------- CompAir Italia S.r.l
4490 St. Florian, Shanghai CompAir-Dalong via Archimede 31
Austria High Pressure Equipment 20041 Agrate Brianza
Tel: +43 (0) 7224 67660 Co. Ltd., Milan
Fax: +43 (0) 7224 67660-100 850 Changjiang Road (W), Italy
office@compair.at Shanghai, Tel: +39 039 6551 1
China 200431 Fax: +39 039 605 6458
CompAir do Brasil, Tel: +86 21 6615 2883 compair@compair.it
Rua Alvaro de Oliveira Fax:+86 21 6615 2633
Marcondes, CompAir Kointec Ltd,
36, Jardim das Tulipas, CompAir Hong Kong Ltd., #201-2 Ma,
Jundiaí Room 406, 4th Floor, Shihwa Industrial Complex,
São Paulo, Wing Ming Industrial Centre, 1703, Chungwang-dong
Brasil No 15, Cheung Yue Street, Shiheung-si,
CEP 13201-973 Lai Chi Kok, Kyungki-do,
CP2181-4 Kowloon, Korea 429-925
Tel: +55 11 4815 8150 Hong Kong Tel: +82 31 433 6307
Fax: +55 11 4815 8173 Tel: +852 2307 0872 Fax: +82 31 433 6317
compair@compair.com.br Fax: +852 2307 0371 kwonho.kim@compair.com
thomas.ma@compair.com.hk
CompAir Canada Inc., CompAir Polska SP z.o.o,
4875 Rue Bourg, CompAir Far East Pte Ltd. ul.Pachonskiego 65,
Ville St Laurent, 5 Toh Guan Road East, 31-223 Kraków,
Quebec, Unit # 03-00, Poland
H4T 1H9, Freight Links Express Tel: +48 (0) 12 618 99 00
Canada Distripark, Fax: +48 (0) 12 618 99 02
Tel: +1 514 341 3432 Singapore 608831, office@compair.com.pl
Fax: +1 514 342 0512 Tel:+65 6665 5610 www.compair.com.pl
compair@compair.ca Fax:+65 6562 1577
www.compair.ca sales@compair.com.sg
--------------------------------------

8 DL051AAA
CompAir Introduction 1

CompAir Representative CompAir Middle East, CompAir USA,


Office CIS Post Office Box 61146, 130 Fox Drive,
Kubinskaya str., 75-1, Jebel Ali free zone, Piqua,
196240 St.Petersburg, Dubai, Ohio,
Russia United Arab Emirates OH 45356,
Tel: +7 812 7025211 For Courier Service: USA
Fax: +7 812 6001069 CompAir Middle East, Tel: +1 (937) 778 2500
sales@compair.com.ru LOB16, Office 503, Fax: +1 (937) 778 4123
www.compair.com.ru Jebel Ali free zone, --------------------------------------
CompAir South East Europe doo, Dubai, CompAir LeROI,
Jaroslava Cermaka 2, United Arab Emirates 211 East Russell Road
1185 Zemun, Belgrade, Tel: +971 4 8811744 Sidney,
Serbia, Fax: +971 4 8811898 Ohio,
Tel +381 (0) 11 377 45 33 compair.middleeast@compair.com OH 45365,
Fax +381 (0) 11 377 45 44 USA
nikolas.luketic@compair.com CompAir UK Ltd., Tel: +1 (937) 498 2500
Reavell House 53-56, Fax: +1 (937) 492 3923
CompAir South Africa Ltd. White House Road, --------------------------------------
Private Bag, Ipswich, CompAir Houston,
X029, Suffolk, 1603 W Main Street,
Berrange Road, IP1 5PB, Laporte,
Wadeville 1422, United Kingdom Texas 77571,
South Africa Tel: +44 (0)1473 242 000 USA
Tel: +27 (0) 11345 2200 Fax: +44 (0) 1473 745 451 Tel: +281 471 7800
Fax: +27 (0) 11345 2204 sales@compair.com Fax: +280 471 7803
compair@iafrica.com cht@compair.com
CompAir UK Ltd.,
CompAir Iberia S.L., Compair Head Office, CompAir Ocala (Mako)
Ctra. De Andalucia KM18, Claybrook Drive, 1634 SW 17th Street
Poligono Industrial, Washford Industrial Estate, Ocala
Las Arenas 28320 Pinto, Redditch, Florida 34478
Madrid, Worcestershire, USA
Spain B98 0DS, Tel: +1 (352) 732 2268
Tel: +34 91 649 9200 United Kingdom Fax: +1(352) 351 5211
Fax:+34 91 649 9249 Tel +44 (0)1527 838200 email@compairmako.com
compair@compair-iberia.es Fax +44 (0)1527 521140 www.compairmako.com
sales@compair.com
CompAir Aeberhardt AG, CompAir UK Ltd.,
Zürcherstraße 254, CompAir California, Holman House,
CH - 8406 Winterthur, 12630 Allard Street, Jon Davey Drive,
Switzerland Santa Fe Springs, Treleigh Industrial Estate,
Tel: +41(0) 52 208 0200 CA 90670, Redruth
Fax:+41 (0) 52 208 0210 USA TR16 4AX
aeberhardt@compair.com Tel: +1 (562) 406-8881 United Kingdom
Fax: +1 (562) 406-8887 Tel+44 (0)1209 315800
CompAir Taiwan compairusa@yahoo.com fax+44 (0)1209 313846
10F-3
No146 Wunsing Street,
Last up-dated Dec 08
Gueishan Township
Taoyuan County 333
Taiwan R.O.C.
Tel:+886-03-3282299
Fax:+886-03-2115655
richard@compair.com.tw

DL051AAA 9
2 Safety Procedures CompAir

2 Safety Procedures
2.1 General 2.2 Warnings, Cautions And Notes
2.1.1 Most accidents which occur during the 2.2.1 Warnings
operation and maintenance of machinery are
Warnings call attention to operations or
the result of failure to observe basic safety
procedures involving specific hazards which
rules or precautions.
could cause injury or death and are identified
2.1.2 An accident can often be avoided by by the following symbols on the unit and in the
recognising a situation that is potentially text of the manual.
hazardous.
2.1.3 When handling, operating or carrying out
maintenance on the unit, personnel must use WARNING: RISK OF DANGER
safe engineering practices and observe all
relevant local health and safety requirements
and regulations.
2.1.4 The attention of users in the UK is drawn to
the Health and Safety at Work Act, 1974, the WARNING: RISK OF ELECTRIC
Regulations of the Institution of Electrical SHOCK
Engineers and the Pressure Systems and
Transportable Gas Container Regulations
1989.
WARNING: RISK OF HOT
2.1.5 CompAir cannot anticipate every possible SURFACES
circumstance which might represent a
potential hazard. The WARNINGS in this
manual are therefore not all-inclusive. If the
user employs an operating procedure, an item WARNING: CONSULT MANUAL
of equipment or a method of working which is
not specifically recommended by CompAir he
must ensure that the unit will not be damaged
or made unsafe and that there is no risk to
persons or property. WARNING: RISK OF HIGH
PRESSURE
2.1.6 The standard builds of all CompAir products
are not intended for use in either explosive or
potentially explosive atmospheres as defined
2.2.2 Cautions
in Directive 94/9/ EC. An explosive
atmosphere is a mixture with air, under Incorrect operational procedures causing
atmospheric conditions, of flammable gases, possible damage to the compressor unit are
vapours, hazes or dust in which, after ignition identified by a ‘Caution’ in the text of this
has occurred, combustion propagates to the manual.
entire unburned mixture and may cause a
2.2.3 Notes
hazard. A potentially explosive atmosphere is
an atmosphere which could become explosive Methods to make the job easier and points
due to local conditions. which require particular attention are identified
by a ‘Note’ in the text of the manual.
2.1.7 Failure to observe the precautions given
under ‘Safety Procedures’ may be considered
dangerous practice or misuse of the
compressor unit.

10 DL051AAA
CompAir Safety Procedures 2

2.3 General Safety Precautions 2.4.4 Precautions must be taken to ensure that no
injury is caused to passers-by through loose
2.3.1 If using compressed air for cleaning purposes, clothing being sucked into the air intake.
ensure safety regulations are complied with
and appropriate clothing and eye protection is 2.4.5 Ensure that the air delivery pipe from the
worn. compressor to the user’s pipework or receiver
is free to expand and that no flammable
2.3.2 Never direct compressed air onto your skin or material is within the vicinity.
at other people.
2.4.6 The discharge piping must connect into the
2.3.3 Never use compressed air to clean loose dirt top of the distribution header to prevent
from clothing. condensed water from running back into the
2.3.4 Before releasing compressed air through a compressor during periods of standby
hose make sure that the free end is held operation. The pipe must not be connected
securely so that it cannot whip and cause into either the side or bottom of the header.
injury. 2.4.7 A shut-off valve must be fitted in the delivery
2.3.5 Avoid injury by using a hoist to lift heavy air line to enable the compressor unit to be
loads. Check that all chains, hooks, shackles isolated. This is particularly important if more
and slings are in good condition and are of the than one unit is to be coupled in parallel or
correct capacity. They must be tested and connected to an existing air supply system.
approved according to local safety 2.4.8 The non-return valve is not intended as an
regulations. isolating valve and should not be relied upon
2.3.6 Cables, chains or ropes must never be for this purpose. In addition, it may be
applied directly to lifting eyes. Always use an necessary to install shut-off valves elsewhere
appropriate shackle or hook, properly in the system to allow a dryer or other
positioned. Arrange lifting cables so that there equipment to be by-passed.
are no sharp bends. 2.4.9 A pressure relief valve must be installed
2.3.7 Use a spreader bar to avoid side loads on between any compressor unit and the shut-off
hooks, eyes and shackles. When a load is on valve/s. Pressure relief valves (safety valves)
a hoist stay clear of the danger area beneath are fitted to the air pipework, as standard
and around it. Keep lifting acceleration and equipment, between the intercooler and
speed within safe limits and never leave a compressor delivery. The set pressures of
load hanging on a hoist for longer than is these relief valves (pressure at which they will
necessary. open) are indicated by the following label,
attached to the exterior of the machine:-

2.4 Installation Precautions


Warning: Set pressure safety valve
2.4.1 Installation work must only be carried out by xx bar
competent personnel under a trained and
qualified supervisor.
2.4.2 A fused isolating switch must be fitted Note: The set pressures for these valves can
between the main power supply and the be found in section 8.3 of this manual.
compressor. Warning: These valves are factory set and
2.4.3 Ensure that air drawn into the air intake will should never be adjusted.
not be contaminated with flammable fumes or 2.4.10 A pressure relieving device must be fitted to
vapours, since this could cause an internal fire every pressure vessel, or equipment
or explosion. containing air at above atmospheric pressure,
when installed downstream of the unit.

DL051AAA 11
2 Safety Procedures CompAir

2.5 Operational Precautions 2.5.9 During normal operation no internal part of the
compressor unit should reach a temperature
2.5.1 The compressor unit must only be operated above 220°C and protection devices are fitted
by competent personnel under a qualified to prevent excessive temperatures occurring.
supervisor.
2.5.10 If there is any indication that the compressor
2.5.2 Do not run the compressor with doors open or is overheating it must be shut down and the
covers removed. cause investigated. Beware of burns from hot
2.5.3 Never remove or tamper with the safety metal parts or hot oil when working on a unit
devices, guards or insulation materials fitted which has recently been shut down.
to the unit. 2.5.11 The compressor must not be operated at
2.5.4 The compressor must only be operated at the pressures above the nominal pressure given
supply voltage and/or frequency for which it is on the data plate.
designed. 2.5.12 The compressor must not be operated in
2.5.5 On a unit equipped with an Automatic ambient temperatures outside of those given
Start/Stop system, attach a sign stating ‘THIS under ‘Technical data’.
UNIT MAY START WITHOUT WARNING’ 2.5.13 The ‘Noise at Work Regulations 1989’
next to the display panel. suggest that ear protectors should be worn
2.5.6 On a unit equipped with an Automatic Restart where noise levels are 85 dB(A) or higher.
device, attach a warning notice stating ‘THIS With all covers in place, the noise levels of the
UNIT HAS BEEN MODIFIED AND WILL compressors described in the manual are
START AUTOMATICALLY ON substantially lower than this figure unless
APPLICATION OF POWER’ next to the installed in an already noisy environment.
display panel and on the inside of the unit 2.5.14 Be aware that high noise levels can interfere
next to the starter contactors. with communication.
2.5.7 If the unit is equipped with a Remote Control
device, attach warning notices stating ‘THIS
UNIT CAN BE STARTED REMOTELY’ in
prominent locations, one on the outside of the
unit, the other inside the control compartment.
2.5.8 As a further safeguard, take adequate
precautions to make sure there is no one
checking or working on the unit before
attempting to switch on remotely controlled
equipment. Attach a ‘CHECK THAT ALL
PERSONNEL ARE CLEAR OF THE UNIT
BEFORE STARTING’ or similar warning
notice to the remote start equipment.

12 DL051AAA
CompAir Safety Procedures 2

2.6 Maintenance and Repair accessories and safety devices, is kept in


Precautions good running order.
2.6.9 The accuracy of pressure and temperature
2.6.1 Maintenance, repairs or modifications must
sensors must be regularly checked. They
only be carried out by competent personnel
must be renewed when unacceptable
under a qualified supervisor
tolerances are exceeded.
2.6.2 Lethal voltages are present in the electrical
2.6.10 Protection devices must be tested as
circuits and extreme caution must be
described in the ‘Maintenance’ section of this
exercised whenever it is necessary to carry
manual.
out any work on the electrical system.
2.6.11 Keep the compressor unit clean at all times.
2.6.3 If replacement parts are needed use only
Protect components and exposed openings
CompAir Genuine Parts.
by covering with clean cloth or tape during
2.6.4 Do not open the starter compartment or touch maintenance and repair work.
electrical components while voltage is applied
2.6.12 Protect the motor, air intake, electrical and
unless it is necessary for measurements, tests
regulation components against the entry of
or adjustments. Such work should be carried
moisture, e.g. when steam cleaning.
out only by a qualified electrician equipped
with the proper tools and wearing appropriate 2.6.13 Precautions must be taken when carrying out
body protection against electrical hazards. welding or any repair operation which
generates heat, flames or sparks. The
2.6.5 Before removing any panels from the
adjacent components must always be
enclosure, if fitted, or dismantling any part of
screened with non-flammable material and if
the unit, carry out the following preparatory
the operation is to be carried out near any part
operations:-
of the oil system, or close to a component
a) Isolate the compressor unit from the main which may contain oil, the system must first
electrical power supply. Lock the isolator in be thoroughly purged, preferably by steam
the ‘OFF’ position and remove the fuses. cleaning.
b) Attach a label to the isolator switch and 2.6.14 Never use a light source with an open flame
display panel carrying the warning ‘WORK IN to inspect any part of the unit.
PROGRESS – DO NOT APPLY VOLTAGE’.
2.6.15 In no circumstances must any welding work or
Do not switch on electrical power or attempt to
other modification be carried out on the
start the unit if a warning label is attached.
pressure vessels.
c) Close the isolating valve between the
2.6.16 Before dismantling of any part of the
compressor unit and the user’s pipework.
compressor unit ensure that all heavy
Attach a label to each valve carrying the
movable parts are secured.
warning ‘WORK IN PROGRESS – DO NOT
OPEN’. 2.6.17 After completion of repair or maintenance
work ensure that no tools, loose items or rags
d) Ensure that the blowdown system has
are left on or inside any part of the machine.
operated to release all pressure from the
compressor. 2.6.18 Check the direction of rotation of the motor
when starting up the compressor initially and
2.6.6 Use only lubricating oils and greases
after any work on the electrical connections or
approved by CompAir. Make sure that the
switchgear.
selected lubricants comply with all relevant
safety regulations, especially with regard to 2.6.19 Do not use any flammable liquid to clean
the risk of explosion or fire and the possibility valves, filter elements, cooler air passages, air
of decomposition or the generation of pipes or any component carrying a flow of air
hazardous gases. during normal operation. If chlorinated
hydrocarbon nonflammable fluids are used for
2.6.7 Always clean up oil spills from both the inside
cleaning, safety precautions must be taken
and outside of the compressor unit before and
against any toxic vapours which may be
after maintenance work.
released.
2.6.8 Make sure that all instructions concerning
2.6.20 Do not use carbon tetrachloride.
operation and maintenance are strictly
followed and that the complete unit, with all

DL051AAA 13
2 Safety Procedures CompAir

2.6.21 Precautions must be taken when using acids, 2.8 Disposal


alkalis and chemical detergents for cleaning
machine parts and components. These 2.8.1 When items of equipment are taken out of
materials cause irritation and are corrosive to service for disposal it is recommended that
the skin, eyes, nose and throat. Avoid the following instructions are adhered to:
splashes and wear suitable protective clothing a) In order to prohibit the ‘bringing back into
and goggles. Do not breathe mists. Ensure service’ of equipment by persons unknown, it
that water and soap are readily available. should be rendered unusable in order to avoid
2.6.22 When disposing of condensate, old oil, used improper re-use.
filter elements and other parts and waste b) Alternatively all such items of equipment
material of any kind make sure that there is no should be stripped into their component form
pollution of any drain or natural water-course for ‘material composition disposal’ e.g. base
and that no burning of waste takes place metals, plastics, fabrics etc and be subject to
which could cause pollution of the air. Protect normal industrial waste re-cycling processes.
the environment by using only approved
methods of disposal. c) Bio-degradable items should be subject to
normal industrial waste disposal processes.
Ensure that no plastic, rubber or composite
2.7 Precautions In The Event Of Fire materials are disposed of by incineration.
2.7.1 Use extreme caution when handling d) Ensure that all fluid waste e.g. lubricating oils
components that have been subjected to fire and greases, anti-freeze agents, refrigerant
or very high temperatures. Some components fluids or corrosive inhibitors should be
may contain fluoroelastomer materials which separated and disposed of by authorised
decompose under these conditions to form salvage disposal or recycling systems
highly corrosive residues. Skin contact can ensuring that none is permitted to enter a
cause painful and penetrating burns resulting waste water system.
in permanent skin and tissue damage.

14 DL051AAA
CompAir Safety Procedures 2

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DL051AAA 15
3 Technical Data CompAir

3 Technical Data
3.1 50Hz Models
Performance Data D75 D90 D110 D132 D150
08A 10A 08A 10A 08A 10A 08A 10A 08A 10A
Maximum working pressure bar g 8.0 10.0 8.0 10.0 8.0 10.0 8.0 10.0 8.0 10.0
Minimum working pressure bar g 4.0
Ambient temperature - min °C 0
Ambient temperature - max °C 45 38 45 40 45 40 45 40 45 40
3
Maximum FAD min/max m /min 11.13 9.46 13.81 12.12 16.75 14.83 19.93 17.67 22.87 20.99
working
pressure Total package input power kW 86.35 87.06 101.23 102.96 124.5 123.91 146.61 144.52 169.88 170.94
3
FAD* m /min 11.39 9.84 14.12 12.58 16.94 15.12 20.22 18.11 23.21 21.50
4 bar g Shaft Power kW 57.82 50.13 71.41 64.19 88.07 76.79 107.89 94.38 126.57 114.34
Total input power IP55 kW 68.62 60.46 82.55 74.94 101.91 90.02 122.43 108.24 142.05 129.20
3
FAD* m /min 11.32 9.78 14.04 12.51 16.89 15.07 20.15 18.04 23.12 21.41
5 bar g Shaft Power kW 62.00 54.31 75.84 68.62 93.43 82.15 113.64 100.14 133.20 120.96
Total input power IP55 kW 73.05 64.90 87.22 79.61 107.56 95.67 128.47 114.29 149.01 136.16
3
FAD* m /min 11.26 9.71 13.96 12.43 16.85 15.02 20.07 17.96 23.04 21.33
6 bar g Shaft Power kW 66.18 58.49 80.27 73.05 98.79 87.51 119.40 105.89 139.82 127.58
Total input power IP55 kW 77.48 69.33 91.89 84.28 113.20 101.32 134.52 120.33 155.97 143.12
3
FAD* m /min 11.20 9.65 13.89 12.35 16.80 14.97 20.00 17.89 22.95 21.24
7 bar g Shaft Power kW 70.36 62.67 84.71 77.49 104.15 92.87 125.16 111.65 146.44 134.21
Total input power IP55 kW 81.91 73.76 96.56 88.95 118.85 106.96 140.57 126.38 162.92 150.07
3
FAD* m /min 11.13 9.59 13.81 12.28 16.75 14.92 19.93 17.82 22.87 21.16
8 bar g Shaft Power kW 74.54 66.85 89.14 81.92 109.51 98.23 130.91 117.41 153.06 140.83
Total input power IP55 kW 86.35 78.19 101.23 93.62 124.50 112.61 146.61 132.43 169.88 157.03
3
FAD* m /min 9.52 12.20 14.87 17.74 21.07
9 bar g Shaft Power kW 71.03 86.35 103.59 123.16 147.45
Total input power IP55 kW 82.63 98.29 118.26 138.47 163.99
3
FAD* m /min 9.46 12.12 14.83 17.67 20.99
10 bar g Shaft Power kW 75.21 90.78 108.95 128.92 154.07
Total input power IP55 kW 87.06 102.96 123.91 144.52 170.94
Total input power at no load kW 20.3 18.4 23.1 22.1 29.3 26.5 34.5 31.2 40.0 37.0
1st Stage Male rotor speed rpm 7827 7008 9381 8531 11337 10231 13433 12061 15234 14164
2nd Stage Male rotor speed rpm 12784 10062 14557 12264 17478 13983 20149 17163 21762 19091
Compressed air discharge temp*** °C 27 28 25 27 28
Free field noise level @ 1metre** dB(A) 73 74 75 76 77

16 DL051AAA
CompAir Technical Data 3

50Hz Models (cont'd)

Performance Data D75 D90 D110 D132 D150


08A 10A 08A 10A 08A 10A 08A 10A 08A 10A
Electrical Data
Nominal Motor Rating kW 75 90 110 132 160
Standard drive motor detail IP55, totally enclosed fan ventilated, service factor 1.1, motor speed 2975 rpm
Oil pump motor detail 1.5kW, IP55, totally enclosed
Cooling Fan motor detail 2 x 4kW, IP55, totally enclosed 2 x 5.5kW, IP55, totally enclosed
Full load current - 220volts amps 280 327 396 467 567
Starting current - 220volts amps 650 785 814 997 1973
Full load current - 400volts amps 161 188 227 268 343
Starting current - 400volts amps 378 458 473 567 1141
Cooling Data
3
Cooling air flow at outlet grille m /min 376 544
Heat rejected by cooling fans kW 86 103 124 147 171
Cooling air temp. rise °C 11 14 11 13 16
Max. pressure drop in cooling air outlet ducting 15mm H2O
Maximum length of cooling air outlet ducting 3 metres of straight duct plus 1 right angle bend
Minimum cooling air outlet duct dimensions 1470mm x 590mm or equivalent cross section area
Weights Dimensions and Capacities Data
Compressor oil capacity litres 40
Compressed air delivery connection Flanged DN80 BS4504 PN16 (DIN2633)
3
Condensate drain connections Automatic: 2 x G /8 Manual: 2 x G½
Weight - package kg 2490 2565 2758 2816 2986
Weight - compression element kg 499
Weight - IP55 motor kg 430 505 650 730 900
Package dimensions - LxWxH mm 2895 x 1600 x 2050
Additional Data
TIS D75/10 - 12 / 02
* Measured and stated in accordance with ISO1217 Annex C and Pneurop/Cagi PN2CPTC2 at reference conditions
** +/- 3db(A) according to Pneurop/Cagi test code
*** At reference conditions - Air Intake Pressure - 1 bar a (14.5 psi a ), Air Intake Temperature - 20° C (68°F), Humidity - 0% (dry)

DL051AAA 17
3 Technical Data CompAir

3.2 60Hz Models


Performance Data D55 D75 D90 D110 D150
08A 08A 10A 08A 10A 08A 10A 08A 10A
Maximum working pressure bar g 8.6 8.6 10.0 8.6 10.0 8.6 10.0 8.6 10.0
Minimum working pressure bar g 4.0
Ambient temperature - min °C 0
Ambient temperature - max °C 40 40 45 40 40 45 40 45 40
3
Maximum FAD min/max m /min 7.53 11.35 9.88 14.72 13.07 17.85 16.39 22.54 21.74
working
pressure Total package input power kW 70.64 92.38 91.26 112.99 111.36 138.72 137.13 174.99 180.17
3
FAD* m /min 7.86 11.69 10.31 15.05 13.52 18.26 16.83 23.09 22.27
4 bar g Shaft Power kW 40.21 54.11 54.31 77.03 65.15 91.66 90.84 124.22 122.55
Total input power IP55 kW 50.94 65.51 65.73 89.22 76.64 106.99 106.13 140.75 139.00
3
FAD* m /min 7.79 11.62 10.24 14.98 13.44 18.17 16.75 22.97 22.18
5 bar g Shaft Power kW 44.20 59.58 58.30 81.92 70.62 98.18 95.73 131.29 129.07
Total input power IP55 kW 55.22 71.35 69.98 94.39 82.43 113.89 111.30 148.20 145.86
3
FAD* m /min 7.72 11.54 10.17 14.91 13.37 18.08 16.68 22.85 22.09
6 bar g Shaft Power kW 48.18 65.05 62.28 86.80 76.09 104.70 100.61 138.36 135.59
Total input power IP55 kW 59.51 77.19 74.24 99.55 88.21 120.79 116.46 155.64 152.72
3
FAD* m /min 7.65 11.47 10.10 14.84 13.30 17.99 16.61 22.73 22.00
7 bar g Shaft Power kW 52.16 70.51 66.26 91.69 81.55 111.22 105.49 145.43 142.11
Total input power IP55 kW 63.79 83.04 78.49 104.72 94.00 127.69 121.63 163.08 159.58
3
FAD* m /min 7.53 11.35 9.98 14.72 13.18 17.85 16.50 22.54 21.86
8 bar g Shaft Power kW 58.53 79.27 72.63 99.50 90.30 121.64 113.31 156.74 152.54
Total input power IP55 kW 70.64 92.38 85.30 112.99 103.26 138.72 129.90 174.99 170.56
3
FAD* m /min 9.95 13.15 16.47 21.83
9 bar g Shaft Power kW 74.23 92.49 115.26 155.14
Total input power IP55 kW 87.00 105.58 131.97 173.31
3
FAD* m /min 9.88 13.07 16.39 21.74
10 bar g Shaft Power kW 78.21 97.96 120.14 161.66
Total input power IP55 kW 91.26 111.36 137.13 180.17
Total input power at no load kW 16.6 21.8 20.1 26.6 24.4 32.6 30.5 41.1 40.1
1st Stage Male rotor speed rpm 5894 8059 7253 10441 9161 12079 11234 15044 14627
2nd Stage Male rotor speed rpm 8970 11985 10289 14605 12777 17910 15447 21940 20252
Compressed air discharge temp*** °C 26 27 28 26 28
Free field noise level @ 1metre** dB(A) 73 74 75 76 77
Electrical Data
Nominal Motor Rating kW 55 75 90 110 150
Standard drive motor detail IP55, totally enclosed fan ventilated, service factor 1.15, motor speed 3585 rpm
Oil pump motor detail 1.5kW, IP55, totally enclosed
Cooling Fan motor detail 2 x 4kW, IP55, totally enclosed 2 x 5.5kW, IP55, totally enclosed
Full load current - 220volts amps 217 273 327 418 538
Starting current - 220volts amps 500 560 730 1018 1358
Full load current - 380volts amps 131 164 197 253 325
Starting current - 380volts amps 303 339 442 616 822
Full load current - 440volts amps 109 137 164 210 270
Starting current - 440volts amps 250 280 365 509 679

18 DL051AAA
CompAir Technical Data 3

60Hz Models (cont'd)


Performance Data D55 D75 D90 D110 D150
08A 08A 10A 08A 10A 08A 10A 08A 10A
Cooling Data
3
Cooling air flow at outlet grille m /min 376 544
Heat rejected by cooling fans kW 71 92 91 113 111 139 137 175 180
Cooling air temp. rise °C 9 12 12 15 15 13 13 16 16
Max. pressure drop in cooling air outlet ducting 15mm H2O
Maximum length of cooling air outlet ducting 3 metres of straight duct plus 1 right angle bend
Minimum cooling air outlet duct dimensions 1470mm x 590mm or equivalent cross section area
Weights Dimensions and Capacities Data
Compressor oil capacity litres 40
Compressed air delivery connection Flanged DN80 BS4504 PN16 (DIN2633)
Condensate drain connections Automatic: 2 x G 3/8 / Manual 2 x G 1/2
Weight - package kg 2290 2490 2560 2790 2948
Weight - compression element kg 499
Weight - IP55 motor kg 230 430 500 650 830
Package dimensions - LxWxH mm 2895 x 1600 x 2050
Additional Data
TIS D55/12 - 12 / 02
* Measured and stated in accordance with ISO1217 Annex C and Pneurop/Cagi PN2CPT2 at reference conditions
** +/- 3db(A) according to Pneurop/Cagi test code
*** At reference conditions - Air intake Pressure - 1 bar a (14.5 psi a), Air Intake Temperature - 20° C (68°F), Humidity - 0% (dry)

3.3 Thermal Overload Settings


Oil Pump and Fan Motors Thermal Overload Settings, Amps
Motor 220V 50Hz 400V 50Hz 220V 60Hz 380V 60Hz 440/460V 60Hz 575V 60Hz
Oil Pump 6.5 3.5 6.3 3.7 3.3 2.5
Fans
14.9 8.2 12.1 7.3 6.3 4.8
(D55-D90)
Fans
20.9 11.5 22 13.3 11.5 8.8
(D110-D150)

Main Motor Thermal Overload Settings, Amps


Model 220V 50Hz 400V 50Hz 220V 60Hz 380V 60Hz 440/460V 60Hz 575V 60Hz
D55 110 65 55 45
D75 130 75 140 85 70 55
D90 155 90 170 105 85 70
D110 205 110 215 130 110 85
D132 220 130
D150 290 170 285 170 140 115

3.4 MCB Q101 (MMS) Settings


MCB Q101 (MMS) Settings, Amps
Model 220V 50Hz 400V 50Hz 220V 60Hz 460V 60Hz 575V 60Hz
D55-D90 32 19.9 30.5 18.3 12.1
D110-D150 45 25 45 25 21

DL051AAA 19
3 Technical Data CompAir

3.5 About the Cable Sizes and Fuse


Ratings Table
(See section 3.6)
3.5.1 The following assumptions have been made
in compiling the table of cable sizes and fuse
ratings:
a) PVC insulated, 3-core non-armoured copper
cable with a rated conductor operating
temperature of 70°C (where more than 3
conductors are specified, they are assumed to
be in separate 3-core cables).
b) Cables for any given machine are run
separately from the supply cables to other
equipment.
c) Cables are clipped directly to insulated walls.
d) Cables are shaded from direct sunlight and
other sources of external heat.
Notes: (i) Where any of these assumptions is
invalid, or regulations other than BS7671
apply, cable sizes should be calculated for the
actual conditions.
(ii) The voltage at the machine connections
should not be less than nominal voltage less
6%, except 400V 50Hz models which should
be no less than 360V.
(iii) Earth conductors should not be less than
half the cross section of the main conductors,
and may be separate or a fourth conductor in
the main cable.
(iv) ISO 269 fuses or equivalents (EN 60269,
BS 88) must conform to gG characteristics.

20 DL051AAA
CompAir Technical Data 3

3.6 Cable Sizes and Fuse Ratings Table


Model 220V 50Hz 220V 60Hz 380V 60Hz 400V 50Hz 440/460V 60Hz 575V 60Hz
D55 Main Overload Setting 110 65 55 45
Fuse (ISO 269 gG) 250 160 125 100
2 2 2 2
Cable Size @ 30°C (BS 6231) 3x120mm 3x70mm 3x50mm 3x35mm
2 2 2 2
Cable Size @ 45°C (BS 6231) 3x185mm 3x95mm 3x70mm 3x50mm
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)
D75 Main Overload Setting 140 140 85 85 70 55
Fuse (ISO 269 gG) 315 315 200 200 160 125
2 2 2 2 2 2
Cable Size @ 30°C (BS 6231) 3x185mm 3x185mm 3x95mm 3x95mm 3x70mm 3x50mm
2 2 2 2 2 2
Cable Size @ 45°C (BS 6231) 3x240mm 3x240mm 3x120mm 3x120mm 3x95mm 3x70mm
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)
D90 Main Overload Setting 170 170 105 100 85 70
Fuse (ISO 269 gG) 400 400 200 200 200 160
2 2 2 2 2 2
Cable Size @ 30°C (BS 6231) 3x240mm 3x240mm 3x95mm 3x95mm 3x95mm 3x70mm
2 2
6x150mm or 6x150mm or 2 2 2 2
Cable Size @ 45°C (BS 6231) 2 2 3x120mm 3x120mm 3x120mm 3x95mm
3x400mm 3x400mm
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)
D110 Main Overload Setting 200 215 130 120 110 85
Fuse (ISO 269 gG) 400 500 315 250 250 200
2
2 6x150mm or 2 2 2 2
Cable Size @ 30°C (BS 6231) 3x240mm 2 3x185mm 3x120mm 3x120mm 3x95mm
3x400mm
2
6x150mm or 2 2 2 2 2
Cable Size @ 45°C (BS 6231) 2 6x300mm 3x240mm 3x185mm 3x185mm 3x120mm
3x400mm
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)
D132 Main Overload Setting 245 140
Fuse (ISO 269 gG) 500 315
2
6x150mm or 2
Cable Size @ 30°C (BS 6231) 2 3x185mm
3x400mm
2 2
Cable Size @ 45°C (BS 6231) 6x300mm 3x240mm
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)
D150 Main Overload Setting 320 285 170 185 140 115
Fuse (ISO 269 gG) 630 630 400 400 315 250
2 2 2 2 2 2
Cable Size @ 30°C (BS 6231) 6x240mm 6x240mm 3x240mm 3x240mm 3x185mm 3x120mm
2 2
2 2 6x150mm or 6x150mm or 2 2
Cable Size @ 45°C (BS 6231) 6x400mm 6x400mm 2 2 3x240mm 3x185mm
3x400mm 3x400mm
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)

DL051AAA 21
4 General Description CompAir

4 General Description
4.1 Introduction 4.1.5 Removable panels or hinged doors allow
access for routine maintenance.
4.1.1 The unit is a fully enclosed, oil-free, 2 stage,
air-cooled, rotary screw compressor package 4.1.6 The compressor is controlled by an electronic
(see fig. 4.1). controller which monitors and acts on
information translated from pneumatic,
4.1.2 The compressor air-ends are driven by an electrical and mechanical devices. Delivery
electric squirrel cage motor via a flexible pressure is monitored by a pressure sensor to
coupling to a gearbox. regulate on-load and off-load running via a
4.1.3 The gearbox contains a helical main gear solenoid-operated unloader valve (1). A visual
mounted on a central shaft which drives a display on the control panel provides
pinion fitted to the male rotor of each stage. information on compressor performance and
condition.
4.1.4 The unit consists of a drive motor (13), first
and second stage air-ends (3 & 2), intercooler
(7), aftercooler (6), oil cooler (8), oil pump
(10), air intake and filter assembly (12), first
and second stage moisture separators (9 &
4), electronic controller (14) and ventilation
fans. It is mounted on a free standing, steel
fabricated sub frame supported on vibration
absorbing mounts and enclosed in an
acoustic steel-panelled enclosure.

22 DL051AAA
CompAir General Description 4

Fig. 4.1 - General Arrangement


1. Suction Regulator 6. Aftercooler 11. Powered Breather
2. 2nd Stage Air End 7. Intercooler System
3. 1st Stage Air End 8. Oil Cooler 12. Air Intake Filter
4. Moisture Separator 9. Moisture Separator 13. Main Drive Motor
(Aftercooler) (Intercooler) 14. Electronic Controller
5. Automatic Drain Valves 10. Oil Pump

DL051AAA 23
4 General Description CompAir

4.2 Air End - Description 4.3 Air End - Operation


4.2.1 The air is compressed by two oil-free, positive 4.3.1 Compression takes place between the lobes
displacement, rotary screw air-ends in series. on the male rotor, the flutes on the female
Each air-end comprises an intermeshing pair rotor and the air-end casing. When the
of helical screw rotors, male and female, compressor is running the helically cut timing
driven by a pinion fitted to the male rotor shaft gear on the male rotor inlet end provides the
which meshes with the helical main gear. The drive for the female rotor.
main gear shaft is carried in matched ball
4.3.2 As the rotors turn, air at atmospheric pressure
bearing races at the coupling end, and a
enters the inlet port of the first stage air-end
single roller bearing at the oil filler end.
and fills the space between the lobes of the
4.2.2 Helically cut timing gears are fitted at the inlet male rotor and the flutes of the female rotor.
end of each rotor to ensure that minimal As rotation continues the pressure of the
clearance between the rotors is maintained, trapped air progressively increases until the
thus avoiding rotor contact and optimising discharge port is uncovered and air is then
reliability and efficiency. Each rotor is discharged into the second stage air-end via
supported at both ends by a duplex bearing to the intercooler. The air is compressed in a
sustain the axial loading and a single roller similar manner in the second stage from
bearing for radial loads. A diaphragm- where it passes through a silencer, check
operated balance piston is fitted at the suction valve, aftercooler and moisture separator, into
end of the male rotor to offset a proportion of the user’s pipework.
the thrust load applied to the duplex bearing.
4.2.3 Ventilated stainless steel air seals and alloy
labyrinth oil seals are fitted between the
helical rotors and each pair of bearings, to
prevent air passing into the oil system and oil
passing into the compression chambers.
Rotors and shafts within the compression
space and seals are coated with an
anti-corrosive/anti-wear material to prolong
rotor life and efficiency. The rotor casing is
similarly coated within the compression space
envelope.

24 DL051AAA
CompAir General Description 4

Fig. 4.2 - Air End General Arrangement


1. First Stage Air-end 7. Duplex Bearing 13. Second Stage Inlet
2. First Stage Inlet 8. Thrust Balance Pistons 14. Flexible Coupling
3. First Stage Discharge 9. Oil Returns 15. Helical Main Gear
4. Labyrinth Seal 10. Oil Sump 16. Second Stage Discharge
5. Roller Bearings 11. Oil Pressure Relief Valve
6. Helical Timing Gear 12. Second Stage Air-end

DL051AAA 25
4 General Description CompAir

4.4 Air System - Description


4.4.1 The air system consists of an air intake filter, Key to Fig. 4.3 - Air System
suction regulator, first and second stage
1. Switch - Air Intake Filter Diff. Press.
air-ends, intercooler, aftercooler, associated
2. Air Intake Filter
moisture separators and safety valves,
3. Suction Regulator
silencers, check valve, shuttle valve and
4. Silencer - Blowdown
solenoid valves.
5. Solenoid Valves - Unloader
6. First Stage Air-end
4.5 Air System - Operation 7. Balance Piston
8. Shuttle Valve
4.5.1 Air enters the compressor unit through the
9. Silencer - First Stage
intake filter (2) and suction regulator (3) to the
10. Transmitter - Temperature (High)
inlet port of the first stage air-end (6) where it
11. Intercooler
is trapped by the turning rotors and
12. Transmitter - Temperature (Low)
compressed. The air increases in pressure
13. Pressure Relief Valve - Interstage
and temperature and passes through the
14. Sensor - Pressure
discharge port of the air-end into the
15. Moisture Separator - Interstage
intercooler (11) and moisture separator (15).
16. Second Stage Air End
As the air cools, condensate is automatically
17. Silencer - Discharge
ejected through electronically operated
18. Transmitter - Temperature (High)
solenoid valves (27). The cooled air then
19. Non-return Valve
passes to the second stage air-end (16)
20. Aftercooler
where compression is increased to the final
21. Transmitter - Temperature (Low)
delivery pressure.
22. Transducer - Pressure
4.5.2 After final compression, the air passes 23. Pressure Relief Valve - Discharge
through a silencer (17) and check valve (19), 24. Ball Valve (Screwdriver-Operated)
the latter being fitted to safeguard the air flow 25. Moisture Separator - Discharge
system when the unit is off-load. It then 26. Strainer - Condensate
passes through an aftercooler (20) and 27. Solenoid Valves - Condensate
moisture separator (25), where final cooling
takes place before passing to the delivery
outlet.
4.5.3 On shutting down, compressed air within the
machine is vented to atmosphere via a
blowdown valve and silencer (4).
4.5.4 The air flow system is protected from
excessive pressure build up by safety relief
valves. One (or two, depending on model)
valve (13) is fitted to the pipework between
the intercooler and moisture separator and
another (23) is fitted to the discharge manifold
attached to the aftercooler. If the air pressure
becomes excessive, the valve(s) will open
and vent to atmosphere.
4.5.5 The temperature of the compressed air is
monitored by temperature sensors located at
the first stage air-end discharge (10),
intercooler discharge (12), second stage
air-end discharge (18) and the delivery outlet
(21).

26 DL051AAA
CompAir General Description 4

Fig. 4.3 - Air System

DL051AAA 27
4 General Description CompAir

4.6 Regulation System - Description 4.7.3 Starting

(see fig. 4.4) a) When START is pressed, ventilation fans and


oil pump motors start. When the controller
4.6.1 Control of the compressor is achieved through detects the oil pressure is correct, the main
the combined operation of pneumatic, motor start sequence begins. The display
electronic and mechanical devices. message shows STARTING.
4.6.2 Pressure regulation is controlled by a sensor b) To minimise starting current the motor runs up
(8) situated at the compressor delivery into to speed in Star mode. After the pre-set
the user's pipework. The compressor runs Star/Delta time the motor drive circuit
continuously, going fully on-load and fully switches to Delta mode, drawing full load
off-load at pre-set delivery pressures. The current at full motor speed.
system does not incorporate progressive
loading/unloading. c) The compressor always starts off-load and
remains in this condition until the main motor
4.6.3 Pressure is maintained between the upper start sequence is complete and the pre-set
(P1) and lower (P2) pressure set points. Load Delay time has elapsed.
4.6.4 If air demand is low, the compressor will shut d) When the Load Delay time has elapsed, the
down into Standby mode after the pre-set controller energises the unloader solenoid
run-on time. The compressor will valves (7) and the machine goes on-load.
automatically re-start as demand increases.
4.7.4 Running On-Load
4.7 Regulation System - Operation a) When the pressure is below the (P2) lower
pressure set point, the controller energises
(see fig. 4.4) the unloader solenoid valves (7).
4.7.1 The suction regulator (2) is controlled by two b) The solenoid valves then switch to connect
unloader solenoid valves (7). The function of the diaphragm chamber - RH to the inlet end
the solenoid valves is to connect the left side of the 1st stage rotors and the diaphragm
(3) and right side (4) of the diaphragm chamber - LH to the interstage. Suction
chamber to positive or negative pressures, created by the 1st stage air-end creates a
depending on whether the machine is off-load depression in the diaphragm chamber - RH
or on-load. (4). The pressure differential across the
4.7.2 Power First Switched ON diaphragm causes the valve spindle to move
against the springs and the inlet valve (14)
a) When power is switched on, the control begins to open.
system checks that all pre-set conditions are
correct and the emergency circuits are in c) As pressure builds in the interstage, it first
order. The display shows the control program acts on the shuttle valve (11) which closes
identification and part number. When the and so prevents the interstage pressure from
internal checks are complete the display escaping to atmosphere. It then passes
message changes to READY TO START. through the unloader solenoids to pressurise
the diaphragm chamber - LH, thus opening
b) At this stage, the unloader solenoid/s (7) are the inlet valve fully and closing the blowdown
de-energised and the inlet valve in the suction valve.
regulator is held closed by the suction
regulator springs. The diaphragm chamber -
RH (4) is connected to atmosphere via
unloader solenoids (7), airline filter (10) and
shuttle valve (11). The diaphragm chamber -
LH (3) is connected to the inlet end of the first
stage rotors.
c) The 2nd stage air-end delivery is connected to
atmosphere (5) via the open blowdown valve
(6).

28 DL051AAA
CompAir General Description 4

2 3 4 5 2 3 4 5

1 6 6
1
Z1

14 14

13
13
7 7

12 10 10
11 8 11 8
12

A 9 B
SM 0887 9

Fig. 4.4 - Regulation System


1. Inlet Air 6. Blowdown Valve 12. Second Stage Air-end
2. Suction Regulator 7. Unloader Solenoid Valve x 2 13. First Stage Air-end
3. Diaphragm Chamber (LH) 8. Mains Pressure Sensor 14. Inlet Valve
4. Diaphragm Chamber (RH) 9. Non-return Valve
5. Blowdown Valve to 10. Regulation Line Filter A UNLOADED
Atmosphere 11. Shuttle Valve B LOADED

DL051AAA 29
4 General Description CompAir

4.7.5 Running Off-Load 4.7.6 Stopping


a) The compressor continues to run on-load until a) The compressor may be stopped manually by
the upper (P1) pressure set point is reached. pressing the STOP button. When STOP is
The controller then de-energises the unloader pressed the compressor unloads and the
solenoid valves. main motor stops. The cooling fans and oil
pump motor continue to run for a further 30
b) The diaphragm chamber - LH is now
seconds cooling down period.
connected to the inlet end of the first stage
rotors so the interstage pressure, which has b) If EMERGENCY STOP is pressed, the main
been acting within the chamber, escapes into motor, cooling fans and oil pump motor will
the first stage inlet. stop immediately.
c) With the drop in pressure in the diaphragm Caution: Do not stop the compressor
chamber - LH, the springs begin to close the during a motor start sequence.
inlet valve, assisted by the interstage pressure
Caution: Emergency Stop should only be
which is now connected to the diaphragm
used in a genuine emergency situation.
chamber - RH.
d) The interstage pressure assists the springs
until it decreases below atmospheric, at which
time the shuttle valve will move to isolate the
interstage (2nd stage inlet) from atmosphere.
This allows the unloader valve to close fully
and the blowdown valve to open.
e) The blowdown valve exhausts all compressed
air within the compressor to atmosphere and
the compressor runs off-load. A non-return
valve in the delivery line (9) prevents system
air from exhausting through the blowdown
valve.
f) If the compressor is started with the pressure
above the lower (P2) pressure set point, the
compressor will immediately enter Standby
mode and will automatically start when the
pressure falls.

30 DL051AAA
CompAir General Description 4

SM 1053

+
+++ +
+

Z1 Z1 +
+ + +
+ +

C1 C1
Depression from Inlet Depression from Inlet

Atmospheric Pressure Atmospheric Pressure

To - 1st stage To - 1st stage


Balance Piston Balance Piston
Diaphragm Diaphragm

B1 A1 X B1 A1 X
C C
A A
Z Z

P P

Interstage B Interstage B

Off Load On Load (Solenoids Energised)

Fig. 4.5 - Regulation System Control Manifold Connections (D-Series)

DL051AAA 31
4 General Description CompAir

4.8 Cooling System - Description 4.9 Cooling System - Operation


4.8.1 The cooling system consists of the air end 4.9.1 Two cooling fans within the machine draw
cooling jackets, intercooler, aftercooler and oil ambient air, via the enclosure filter, through
cooler. the cooling fins of the three coolers into the
enclosure. At the opposite end of the
4.8.2 Oil circulates through passages cast into the
machine, a cooling fan, which is integral with
air ends to help remove the heat of
the main drive motor, also draws cool ambient
compression but at no time do the air and oil
air over the motor into the enclosure. All
mix.
cooling air is then exhausted through the top
4.8.3 The compressed air is cooled by being of the enclosure to atmosphere.
passed through an intercooler and aftercooler,
4.9.2 The intercooler (2) and aftercooler (1) cool the
and the lubricating oil by being passed
hot compressed air delivered from the first
through an oil cooler. All coolers are air
and second stage air-ends. Hot compressed
cooled.
air passes through tubes in the coolers, which
1 in turn are cooled by the air being drawn
SM 1035 through the integral fins. This allows the
temperature of the compressed air to be
maintained at acceptable levels. The oil is
cooled in the same way, passing through
finned tubes in the oil cooler (3).
4.9.3 The intercooler and aftercooler have
associated moisture separators, which extract
the condensate resulting from cooling the
compressed air. The condensate is then
automatically ejected by electronically
controlled solenoid drain valves.
4.9.4 The cooling fans run constantly whenever the
compressor unit is in operation and continue
running for 30 seconds after the compressor
has shut down.

2
3

Fig. 4.6 - Arrangement of Cooler Elements


1. Aftercooler
2. Intercooler
3. Oil Cooler

32 DL051AAA
CompAir General Description 4

SM 1036 5

4
11 F
M

11 10
F
M
1

8
7
6 3

Fig. 4.7 - Oil Cooling System


1. Aftercooler 7. Oil Filter
2. Intercooler 8. Oil Pressure Relief Valve
3. Oil Cooler 9. To Gearbox
4. 1st Stage Air End 10. 2nd Stage Air End
5. Cooling Fans 11. To Bearings and Gears
6. Motor Driven Oil Pump

DL051AAA 33
4 General Description CompAir

4.10 Lubrication System - Description 4.11 Lubrication System - Operation


4.10.1 The lubrication system is a fully enclosed and (see fig. 4.8)
pressurised oil lubricating system. It consists
4.11.1 The oil is drawn from the sump (1) by the oil
of an oil sump, oil pump, oil cooler, oil filter,
pump (5) and is first passed under pressure to
gearbox, driven gears and bearings, timing
an air blast oil cooler (6). It then enters the air
gears and bearings and oil inlet manifold. The
end cooling jackets (9, 10) after which it
lubricant should be a good quality high grade
enters the oil filter (15). After filtration, the oil
turbine oil containing corrosion inhibitors.
passes to the drive gears (11), air-end
bearings and timing gears.
4.11.2 Pressure in the oil circuit is controlled by a
relief valve (14). If the oil pressure should
exceed 2.5 bar, the relief valve will open and
relieve the pressure by allowing oil to by-pass
the circuit and return direct to the oil sump via
the gearbox.
4.11.3 Oil is prevented from entering the
compression space by vented labyrinth seals
fitted to both ends of the rotor shafts. On
completion of the lubrication cycle the oil is
returned to the sump by gravity drainage.
4.11.4 To ensure that no oil escapes to atmosphere,
a powered breather system (13) extracts any
oil mist from the gearbox under vacuum,
liquefies it and returns it to the oil sump (see
section 4.12).
4.11.5 The system incorporates various control and
safety devices to monitor oil level, pressure
and temperature. Oil temperature and, on
later machines, oil pressure can be displayed
on the control panel. Also, the monitoring
system displays alarm and trip information if
danger levels are approached regarding filter
blockage, low level, low pressure, high
temperature and oil pump motor fault.

34 DL051AAA
CompAir General Description 4

Fig. 4.8 - Lubrication System


1. Oil sump 9. 1st Stage Air End
2. Oil Drain 10. 2nd Stage Air End
3. Oil Level Indicator / Switch 11. Gearbox
4. Oil Strainer 12. Oil Filler
5. Oil Pump 13. Oil Breather System
6. Oil Cooler 14. Oil Pressure Relief Valve
7. Temperature Sensor 15. Oil Filter
8. Oil Pressure Transmitter 16. Differential Pressure Switch

DL051AAA 35
4 General Description CompAir

4.12 Powered Breather - Description Caution: It is important that the air supply
to the powered breather (3), is moisture
4.12.1 The powered breather system is designed to free. If the installation is such that
prevent any oil mist emission from the condensation from the customer's air
compressor. network forms in the delivery pipe, then
the air supply must be taken from a new
4.13 Powered Breather - Operation location that is moisture free.

See fig. 4.9. Caution: Do not use pressure gauge (6) to


set up powered breather system, as
4.13.1 The system works by tapping the plant damage could result. For correct
discharge for an air supply (3) which is fed adjustment procedure, refer to section 6.9.
through a control filter/pressure regulator (4)
to a vacuum generator (7).
4.13.2 The vacuum generator creates a depression
which is utilised to remove any oil mist (8)
from the gearbox. The air/oil mist passes
through an oil removal filter (10) after which
the filtered air exhausts to atmosphere (9).
The recovered oil (11) then returns to the
sump tank.

36 DL051AAA
CompAir General Description 4

Fig. 4.9 - Powered Breather System


1. 2nd Stage Moisture Separator
2. Air Outlet to Customer's Network
3. Elbow
4. Pressurised Air to Vacuum Generator
5. Pressure Reducing Valve/Line Filter
6. Pressure Adjuster
7. Pressure Gauge (see "Caution" note)
8. Vacuum Generator
9. Oil Mist from Gearcase
10. Vacuum Generator Exhaust Air to Atmosphere
11. Oil Removal Filter
12. Removed Oil Returned to Gearcase

DL051AAA 37
4 General Description CompAir

4.14 Electrical System


4.14.1 Introduction 4.14.2 Electrical Cabinet
The compressor is controlled via a See fig. 4.10
touch-sensitive control panel (see section 11)
The electrical cabinet contains the major
which communicates with an electronic
control components of the electrical system.
controller unit mounted behind it within a
The control panel/controller assembly (1) is
protective enclosure.
built into the access door and communicate
The controller unit controls starting and with the interface assembly (2) via cable runs
stopping sequences, compressor loading and carried within trunking secured to the
unloading in response to customer air enclosure panels.
demand, and automatic draining of
The interface assembly in turn communicates
condensate which accumulates during normal
with the heavier electrical equipment and
operation of the machine. It also continuously
carries slightly heavier control equipment such
monitors various temperatures, pressures and
as relays, contactors, transformers, fuses etc.
fluid levels within the machine during
operation and checks power supply Power cables enter the cabinet via low level
parameters. In addition, the controller keeps entry points in the rear panel where they are
track of scheduled servicing intervals and connected to the star/delta starter assembly
retains a record of fault occurrences. (3) and thermal overload relay (7).
To facilitate this, certain control and
monitoring equipment is integrated into the
design of the machine to individually monitor
and control the various operating systems.
Details of this monitoring equipment and items
protected are shown in para 4.14.3 and fig.
4.11, together with an overview of their
function.

38 DL051AAA
CompAir General Description 4

Fig. 4.10 - Electrical Cabinet


1. Controller Assembly 5. Delta Contactor
2. Interface Assembly 6. Main Contactor
3. Star/Delta Starter Assembly 7. Thermal Overload Relay
4. Star Contactor 8. Earth Bar

DL051AAA 39
4 General Description CompAir

4.14.3 Overview of Electrical System Plant Air Delivery (14) - Monitors temperature
of the compressed air leaving the aftercooler
a) Major Components
(located in elbow above 2nd stage moisture
Motors separator).
Main Drive Motor (11) - Drives the Plant Oil (15) - Monitors temperature of the
compressor units via the gearbox and flexible circulating oil (located in tapped boss on face
drive. of oil cooler).
Fan Motors (10) - Drive the two cooling fans in Pressure
the roof of the machine.
Plant Air Delivery (5) - Monitors pressure of
Oil Pump Motor (8) - Drives the oil circulating the compressed air leaving the aftercooler
pump. (located in elbow above 2nd stage moisture
separator).
Controllers/Starters
Interstage (7) - Monitors pressure of the
Electronic Controller/Control Panel (1) -
compressed air within the intercooler (located
Contains the central processor chip which
on side of intercooler above exit port).
controls the operation of the whole machine.
Receives signals from the control panel and Plant Oil (6) - Monitors pressure of the
Interface Assembly, processes them and circulating oil (located on top of gearbox).
returns resulting messages/commands.
Fluid Level
Interface Assembly (19) - Acts as the interface
Plant Oil (4) - Monitors level of the circulating
between Electronic Controller and electrical
oil within the oil sump (located on side of oil
system components and contains the relays,
level sight glass).
switches etc. which control the operation of
the motors, solenoids.
d) Switches
Starter (Star/Delta, (12)) - Controls the
Air Filter (2) - Monitors the differential
starting of the Main Drive Motor.
pressure across the air inlet filter and if
b) Solenoids excessive, the switch operates, causing a
message to be shown on the control panel
Unloader (20) - Controls the loading and
(located on acoustic enclosure adjacent to
unloading of the machine in response to
filter).
customer's demand for air.
Oil Filter (3) - Monitors the differential
Condensate Drains (9) - Controls the opening
pressure across the circulating oil filter and if
and closing of condensate drain valves.
excessive, the switch operates, causing a
message to be shown on the control panel
c) Sensors
(located on top of filter).
Temperature
Ambient (13) - Monitors temperature of the
inlet air to the 1st stage compressor unit
(located on bracket in front of oil cooler).
1st Stage Delivery (16) - Monitors
temperature of the compressed air leaving the
1st stage air end (located in 1st stage
silencer).
2nd Stage Intake (18) - Monitors temperature
of the compressed air entering the 2nd stage
air end (located on side of intercooler below
exit port).
2nd Stage Delivery (17) - Monitors
temperature of the compressed air leaving the
2nd stage air end (located in 2nd stage
delivery silencer).

40 DL051AAA
CompAir General Description 4

Fig. 4.11 - Overview of Electrical System


1. Control Panel/Controller Assy 8. Oil Pump and Motor 15. Plant Oil Temp Sensor
2. Air Filter Press Diff Switch 9. Condensate Drain Solenoids 16. 1st Stage Dely Temp Sensor
3. Oil Filter Press Diff Switch 10. Cooling Fans and Motors 17. 2nd Stage Dely Temp Sensor
4. Plant Oil Level Sensor 11. Main Drive Motor 18. 2nd Stage Intake Temp
5. Plant Air Del Press Sensor 12. Star/Delta Starter Sensor
6. Plant Oil Press Sensor 13. Ambient Temp Sensor 19. Interface Assembly
7. Interstage Press Sensor 14. Plant Air Dely Temp Sensor 20. Unloader Solenoids

DL051AAA 41
5 Installation and Storage CompAir

5 Installation and Storage


a) DUCTING
WARNING Allowable length of duct, 2 metres plus one
bend. If duct is longer then a booster fan
should be fitted.
• Refer to the safety procedures before
installation of the compressor unit. b) FANS

• Lethal voltages are used in this Fans should be wired to run when the
equipment. Use extreme caution when compressor cooling fans are running. Inlet
carrying out electrical checks. Isolate the opening(s) and ventilation fan(s) should be
power supply before starting any sized to prevent the build up of heat within the
maintenance work. building, to limit the temperature rise to an
acceptable level and to ensure that the
maximun allowable ambient is not exceeded.
The fan(s) should be sized to handle the total
5.1 Compressor Room
cooling air flow of the compressor(s).
5.1.1 The compressor unit is supplied as a
Note: See section 3 'Technical Data' for
complete package and does not require
airflow figures.
securing to a foundation. However, the
supporting floor must have a loading capacity 5.2.3 If temperature in compressor room can fall
sufficient to support the weight of the unit (see below 0°C / 32°F then heating must be
Technical Data). provided.
5.1.2 In operation the unit will release heat into the 5.2.4 Service connections are required as follows:
surroundings. The compressor room should
a) Air delivery outlet to the user’s pipework.
therefore be of adequate size and have good
ventilation. The recommended minimum size b) Electrical power supply: 3-phase plus earth.
of room is 50 m3. The inlet and outlet
c) Condensate drain to the user’s disposal
ventilation openings should each have a
system.
minimum area of 0·5 m2.
5.2.5 If the compressor is to be coupled in parallel
5.1.3 The ventilation inlet opening should be
with another compressor or connected to an
positioned as low down as possible. The
existing air supply system, additional steps
outlet opening should be positioned as high
must be taken as set out in section 2 ‘Safety
up as possible, preferably in the roof or
Procedures’.
ceiling.
5.2.6 If the compressor is coupled to a header used
5.1.4 A minimum of 1·5 m is recommended above
by other compressors, ensure that
the compressor and a minimum of 1.2 m
condensate from the header cannot flow back
clearance on all sides for air circulation and to
into the compressor.
give access for servicing. Do not obstruct
doorways, passages or walkways. 5.2.7 If air usage fluctuates rapidly or if the volume
of the user’s pipework is less than 4·25 m3 for
5.1.5 Lifting facilities should be provided over the
each unit, a receiver of appropriate capacity
compressor to enable the heaviest
should be installed between the compressor
components to be lifted during maintenance.
and the user’s pipework.

5.2 Ventilation 5.2.8 Compressor units are inhibited against the


effects of moisture before shipment. If all
5.2.1 The compressor room must be ventilated. The blanking covers and protective tapes remain
maximum temperature in the compressor secure and undamaged the effective life of
room must not exceed the maximum ambient this process is 12 months from the date
capability of the plant. shown on the test card with the machine.
Refer to Section 5.5, ‘Storage Procedures’, for
5.2.2 Hot cooling air from the compressor must be
details of attention required during storage
removed from the room by a duct or fan.
and for the procedure to be followed if the
storage period is longer than 12 months.

42 DL051AAA
CompAir Installation and Storage 5

1.5m min
1.2m min

1.2m min

1.2m min
1.2m min

SM 0955

Fig. 5.1 - Installation Space

C C
B
B

A A

SM 0973 SM 0974

Fig. 5.2 - Typical Ducted Ventilation Fig. 5.3 - Typical Fan Ventilation
A. Cool Air Inlet A. Cool Air Inlet
B. Warm Air Outlet B. Warm Air Outlet
C. Booster Fan C. Ventilation Fan
(required if ducting
exceeds 2m in length)

DL051AAA 43
5 Installation and Storage CompAir

5.3 Air and Condensate Pipework


5.3.1 The air discharge flange should be connected
to the distribution header or air receiver using
piping with a minimum nominal bore of
80mm/3in. The discharge piping must connect
into the top of the distribution header to
prevent condensed water from running back
into the compressor during periods of standby
operation. The pipe must not be connected
into either the side or bottom of the header.
An isolating valve should be incorporated in
the discharge piping as shown in fig. 5. 4 to
enable the compressor to be isolated for
maintenance purposes.
SM 1048

Fig. 5.5 - Baseframe Connections


1. Condensate Strainers
2. Manual Condensate Drains
3. Automatic Condensate Drains

5.3.5 In order to minimise pressure drops, all valves


should be either gate or ball full flow type and
all bends should have a minimum radius of at
least 1.5 times the pipe diameter.
Caution: All pipework is to be adequately
Fig. 5.4 - Recommended Location for supported outside of the compressor. The
Discharge Piping Isolating Valve compressor connections must not carry
any load.

5.3.2 A suitably sized air receiver should be Caution: It is important that the air supply
installed between the compressor and to the powered breather, which is taken
distribution system. As a guide the receiver from the delivery pipe, is moisture free. If
capacity should be 10% of the compressor the installation is such that condensation
output e.g. a 10m3/min compressor will require from the customer's air network forms in
a 1m3 / 35ft3 air receiver. the delivery pipe, then the air supply must
be taken from a new location that is
5.3.3 See fig. 5.5 for connections detailed in the moisture free.
following paragraph.
5.3.6 When connecting the compressor to the
5.3.4 The two automatic condensate drain and two customer’s distribution network, ensure all
manual drain connections should all be pipework and hoses are of the correct size
separately piped into a drain gulley or open and suitable for the working pressures and
tundish. The four drains must not be temperatures involved. If connection is by
connected together. Piping from the drain means of hoses, ensure that they incorporate
connections should not exceed 3 metres / safety wires to prevent the free end from
118in. in length and must fall towards the whipping in the event of failure of the hose or
drain gulley or open tundish.

44 DL051AAA
CompAir Installation and Storage 5

connection. Ensure connecting flanges and 5.4.6 Remove the plain gland plates from the
threads are in good condition. baseframe and the starter compartment. Drill
the plates to take the power cable and fit
Caution: Do not install a non-return valve
suitable plates and grommets.
on the outlet side of the compressor.
5.4.7 Ensure the power supply to the unit is taken
5.4 Installation from a fused isolator, the switch is locked
‘OFF’ and fuses removed. Connect the supply
The following procedure is a guide for in accordance with the electrical connection
installing a standard compressor unit. For the diagram. Use cables complying with the
installation of non-standard units or units fitted standards of the International Electrotechnical
with optional equipment refer to your local Commission (IEC) or of the Institution of
CompAir office. Electrical Engineers (IEE) (latest edition) for
U.K. users. The cables must be correctly
5.4.1 The compressor package may be lifted by fork
sized for the total input kW of the plant and
lift using the slots provided in the baseframe
suitably protected and clamped.
or by a spreader bars and lifting frame with
slings or chains attached to lifting brackets 5.4.8 Refit the starter compartment door.
bolted to the baseframe. To prevent damage,
Caution: After installation of the isolating
spreader bars or frames should be wide
valve between the air delivery pipe flange
enough to keep slings and chains clear of the
and the user’s pipework as shown in Fig.
enclosure.
5.4, do not connect the flange permanently
at this stage. The connection must not be
secured until the corrosion inhibitor has
been dispersed by the initial run at the
correct stage in the commissioning
procedure.

5.5 Storage - General


Warning: refer to the safety procedures
before carrying out any work on the
compressor unit.
5.5.1 All compressors are inhibited against
corrosion before leaving the CompAir factory
to give protection during transportation and
storage before installation, for a maximum of
12 months. Proper precautions should be
taken if the storage period is longer than 12
months.
SM 0978

5.5.2 Similarly, any compressor taken out of service


Fig 5.6 - Lifting Compressor or put into temporary storage must be
protected against corrosion. The rate at which
corrosion in storage occurs will be more rapid
5.4.2 Remove the transportation feet from the in a humid climate than in dry conditions,
compressor. making it impossible to recommend a
maximum safe storage time applicable to all
5.4.3 Lower the unit into position, ensuring that the
cases.
weight is evenly supported. Remove the four
lifting brackets. Check that the baseframe is 5.5.3 This section details the procedures to be
level to within 3 mm. Use packing pieces followed in preparing the compressor for
under the baseframe if necessary. storage and the periodic attention required
during the storage phase. It will be
5.4.4 Remove all protective blanking covers and
satisfactory for most storage situations.
tapes.
5.4.5 Remove the starter compartment door.

DL051AAA 45
5 Installation and Storage CompAir

5.6 During Long-Term Storage (Up To 5.7 During Short-Term Storage (Up To
12 Months) One Month)
5.6.1 This procedure makes provision for 5.7.1 The compressor should be started and run for
circumstances where a compressor is 10 to 15 minutes at least once each week.
delivered to site and is not immediately This procedure applies to (i) a compressor
installed, but stored. It should also be followed which is shut down for a short period but
if a compressor is to be put into long term remains connected to power and (ii) a
storage after a period of operation. compressor which remains on ‘Standby’ duty
in a multiple unit installation.
5.6.2 The compressor should be stored in a dry
building, preferably heated, particularly during 5.7.2 If power is disconnected, rotate the drive
the winter months. If the ambient temperature coupling by hand at weekly intervals as
is likely to fall below 0°C, it is important that described in para 5.6.5.
the electronic controller is removed and stored
separately in a temperature above 0°C. 5.8 Long-Term Storage - Preparation
Mechanical stress due to excessive
contraction (slackening of flange bolts, etc.) Warning: The chemical solutions used in
should also be monitored. these procedures are slightly toxic. Ensure
that there is adequate ventilation and that
5.6.3 In the case of a new compressor, inspect the
all personnel involved wear protective
crate on arrival and ensure that there is no
gloves and breathing filter masks and do
water in the packing, the base of the
not smoke while working. Observe full fire
compressor or the protective plastic covering.
and safety precautions.
If there is evidence of moisture, dry out any
damp areas and also ensure that the packing 5.8.1 Inhibitor solution
and plastic covering is dry before replacing.
a) VPI 280 solution is used to protect the air
5.6.4 The shaft of the drive motor must be turned pipework.
manually at least once a week, to prevent the
b) For the solution, mix 64 gm of VPI 280
bearings developing brinelling and/or sticking,
(dicychlorohexyl ammonium nitrite) with
particularly if the package is subject to
2 litres of acetone.
vibration.
Quantity required: 2 litres of solution
5.6.5 The motor shaft can be rotated by turning the
per compressor.
drive coupling which can be reached through
the opening in the drive coupling housing. The Note: This inhibitor solution is not oil-based.
coupling should be turned by HAND, using the
c) When using VPI 280 agitate the solution by
minimum of force, in an ANTI-CLOCKWISE
shaking the spray can during application.
direction (as viewed from the motor non-drive
end). One and a quarter turns is sufficient. 5.8.2 Equipment Required:
5.6.6 If resistance is experienced, the coupling may a) One spray gun with standard nozzle and
be freed by alternating the HAND torque baffle plate nozzle.
between CLOCKWISE and
ANTI-CLOCKWISE. Then continue turning in b) One plastic storage container.
an ANTI-CLOCKWISE direction for one and a c) Waterproof adhesive tape, as required.
quarter turns.
d) Plastic caps.
5.6.7 If this is not effective and the coupling is still
not free, contact the local CompAir distributor.
5.6.8 In the case of a new compressor, replace
protective covering.
5.6.9 At the end of each 12 month storage period
the full inhibition procedure must be carried
out.

46 DL051AAA
CompAir Installation and Storage 5

5.9 Long-Term Storage Procedure - 5.10 Long-Term Storage Procedure -


Power Connected to Compressor Compressor Disconnected from
If the compressor has already been Power
disconnected from power, see para 5.10. Use the same equipment and inhibitor as
5.9.1 Stop compressor. described in para 5.8.

5.9.2 Disconnect delivery pipework at baseframe 5.10.1 Disconnect the delivery pipework at the
connection. baseframe connection.

5.9.3 Remove inlet filter element. 5.10.2 Remove the inlet air filter element.

5.9.4 Re-start compressor. 5.10.3 Remove the first stage moisture separator top
flange complete with the air pressure safety
5.9.5 LOAD the compressor. This will open the valve.
suction regulator inlet valve.
5.10.4 Disconnect the regulation air pipe at the
5.9.6 While the compressor is running, spray Shell unloader solenoid valve and connect a low
VPI 280 solution through inlet silencer until it pressure air line (2 bar max.) to the pipe.
appears at the delivery connection. Apply air pressure to open the inlet valve of
5.9.7 UNLOAD the compressor. the suction regulator.

5.9.8 Spray VPI 280 solution into intake silencer for 5.10.5 Rotate the compressor by turning the drive
10 seconds (approx. 10 ml). coupling which can be reached through the
opening in the drive coupling housing. The
5.9.9 Stop compressor. coupling should be turned by HAND in an
5.9.10 Spray VPI 280 solution into delivery ANTI-CLOCKWISE direction (as viewed from
connection for 10 seconds (approx. 10 ml). the motor non-drive end).

5.9.11 Replace inlet filter element, fit a plastic bag 5.10.6 While the shaft is being turned, inhibit the first
over the filter body and seal with waterproof stage air-end by spraying VPI 280 solution
tape. through the inlet valve of the suction regulator
until it appears at the first stage moisture
5.9.12 Seal air delivery connection with a waterproof separator top flange.
plug.
5.10.7 Continue turning the compressor shaft and
5.9.13 Place the following warning statement on inhibit the second stage air-end by spraying
instrument panel:- VPI 280 solution into the first stage moisture
"CAUTION: BEFORE STARTING THE separator through the top flange opening until
COMPRESSOR, REMOVE WATERPROOF it appears at the blowdown silencer.
SEALING TAPE FROM AIR INTAKE 5.10.8 Disconnect the slave air line from the
FILTER." regulation pipe to close the suction regulator
5.9.14 Paint all bare metal and exposed machined inlet valve and bleed off pressurised air.
surfaces with one coat of Croda CS 1033A 5.10.9 Spray VPI 280 solution into the first stage
preservative. moisture separator through the top flange
5.9.15 After completion of this procedure the opening for one minute.
compressor may be left in store for up to 12 5.10.10 Refit the regulation air supply pipework at the
months but should be inspected regularly as unloader solenoid valve.
detailed in para 5.6 ‘During long-term
storage’. 5.10.11 Refit the filter element and first stage moisture
separator top flange.
5.10.12 Complete the procedure by carrying out items
11 to 15 of para 5.9.
Note: Storage procedures and attention to the
compressor during storage should comply
with ‘During long-term storage (up to 12
months)’ in para 5.6.

DL051AAA 47
6 Commissioning CompAir

6 Commissioning
6.1.10 Ensure fan motor and oil pump motor thermal
WARNING overloads are set correctly for supply voltage
(See 'Technical Data', section 3.3).
6.1.11 Remove panels as required to gain access to
• Refer to the safety procedures before motor connections.
commissioning the compressor unit.
6.1.12 Inspect the motor and control wiring
• Lethal voltages are used in this connections to make sure they are correct
equipment. Use extreme caution when and secure. Replace all panels.
carrying out electrical checks. Isolate the
power supply before starting any 6.1.13 Check that all protection blanks, air filter
maintenance work. covers and tapes have been removed. Ensure
the blanking plugs have been removed from
the Air End vents.
When commissioning a new compressor or
re-commissioning a compressor which has 6.1.14 Remove the four air-end/motor transportation
been overhauled or out of service, carry out bolts (if fitted). These are coloured red for
the following procedures before attempting to identification.
start: 6.1.15 Open the isolating valve to the user’s
Note: We recommend that commissioning is pipework.
carried out by a trained and qualified CompAir 6.1.16 Check that the air end and motor rotate freely.
commissioning engineer.
6.1.17 Check oil level and top up if required.
6.1 Preliminary Mechanical Checks
6.2 SureScan Controller - Entering the
6.1.1 Remove air filter covers and silica gel bags. Access Code
6.1.2 Check that the isolator switch is locked ‘OFF’
When an attempt to alter a parameter or
and that all pipework and electrical power
option is made for the first time after entering
connections are correct and secure.
the menu routines, the controller will request
6.1.3 Open the access panel to the starter an access code. When this occurs, the
compartment. Check all screws and starter following procedure should be followed:-
connections for security. Check all electrical
6.2.1 Press SERVICE, HOURS, SERVICE, HOURS
connections are correct and secure.
buttons.
6.1.4 Ensure the controller to Extension module unit
Note: A guide to using the menu routines and
interface cable connections are correct and
control unit menu structure diagrams is shown
secure.
in Section 7, 'Operation'.
6.1.5 Ensure the main supply cables and fuse
ratings comply with regulations. (See
'Technical Data', section 3.6).
6.1.6 Ensure the control transformer primary
tapping connections are correct for supply
voltage.
6.1.7 Ensure main motor thermal overload is set
correctly for motor F.L.C. and supply voltage,
as shown on the motor data plate.
6.1.8 Ensure MCB Q101 (MMS) is set correctly.
(See 'Technical Data', section 3.4)
6.1.9 Ensure phase rotation relay voltage
adjustment is correct (where fitted).

48 DL051AAA
CompAir Commissioning 6

6.3 System Checks and Calibration


Note: The values shown throughout these
procedures are examples only.

No. Action Reason Display


1 Switch power supply ‘ON’. C20619/nn/xx/nn
SF3LFnnUN ddmmmyy

Note: The POWER ON indicator


lights.

The REMOTE and AUTO RESTART


indicators will light if these facilities
have been selected in the installation
procedure.

After several seconds the status


display changes to:

Ready to start
Oil temperature 20°C

Note: If ‘Rotation fault’ is displayed,


isolate the power and change over
any two of the 3 phase incoming
supply cable connections.
2 Press ENTER. To display the main menu Main menu
Operational settings
3 Press DOWN until the To scroll through the menu options. Main menu
message shown on the right Commissioning - config.
is displayed.
4 Press ENTER. To choose the Commissioning - Commissioning - config. Language
configuration menu English
5 Press (+) or (-) and repeat To select the displayed language. Commissioning - config. Language
until the required language is Option
displayed.
(Pulsing display)
6 Press ENTER. To confirm the displayed language. Commissioning - config.
Language Option

(Steady display)
7 Press DOWN and repeat until To select the required option. Commissioning - config.
the display shown on the Return to previous menu
right is obtained.
8 Press ENTER. To display the main menu. Main menu
Operational settings
9 Press DOWN and repeat until To scroll through the menu. Main menu
the option shown on the right Service diagnostics
is displayed.
10 Press ENTER. To choose the Service diagnostics Service diagnostics
menu Reset service hours

DL051AAA 49
6 Commissioning CompAir

No. Action Reason Display


11 Press DOWN and repeat until To scroll to the required option. Service diagnostics
the option shown on the right Test digital outputs
is displayed.
12 Press ENTER To choose the Test digital outputs Test digital outputs
option. Main contactor 0
13 Press DOWN and repeat until To scroll to the required option. Test digital outputs
the option shown on the right Fan contactor 0
is displayed.
14 Press (+). To turn on the fan and oil pump. Test digital outputs
Fan contactor 1
15 Check that air is being To check the direction of rotation of
expelled from the enclosure the fan .
fan exhaust.
16 Check that oil pressure rises. To check the direction of rotation of
the oil pump.
17 Press (-). To turn off the Fan/oil pump. Test digital outputs
Fan contactor 0
18 If the fan or oil pump rotation To reverse rotation.
is incorrect, switch power
‘OFF’ and change any two
Incoming Power Supply
cables. Switch power ‘ON’
and return to step 8.
19 Press UP and repeat until the To scroll to option required. Test digital outputs
option shown on the right is Return to previous menu
displayed.
20 Press ENTER. To return to the service diagnostics Service diagnostics
menu. Reset service hours
21 Press DOWN once then To choose the calibrate pressure Set pressure at 0 bar
ENTER. menu Press enter when ready
22 If the zero pressure display is To by-pass the first part of the
known to be correct then calibration procedure.
press DOWN and go to step
25.
23 Disconnect the air connection To ensure zero pressure on the Set pressure at 0 bar
to the delivery pressure transmitter. Press enter when ready
transmitter.
24 Press ENTER. To set the zero pressure Set pressure > 5.51bar
measurement in the controller.
25 Connect a slave air supply of To establish a known calibration Adjust +/- :- 6.9bar
more than 5.51 bar to the pressure. Press enter when ready
delivery pressure transmitter.

Note: If the air pressure is


not above 5.51 bar, the
message shown in step 24 is
displayed.

50 DL051AAA
CompAir Commissioning 6

No. Action Reason Display


26 If the slave air supply is not The alternative calibration procedure
constant then press UP or is more suitable for use with an
DOWN to enter the unstable reference pressure.
alternative calibration routine
and go to step 30.
27 Press (+) or (-) as required to To adjust the LCD Adjust +/- :- 7.0bar
adjust the value shown on display reading to match the slave air Press enter when ready
the display gauge.
(Pulsing display)
28 When the gauge and display To store the pressure calibration Commissioning - config.
pressures are equal, press value in the controller.
ENTER. (After a delay the display reverts to:)

Service diagnostics
Reset service hours
29 Go to step 31 To by-pass the alternative calibration
procedure.
30 Press UP or DOWN as To adjust the control panel display. Adjust pressure up/down
required to make the LED Press enter when ready
display follow the slave
gauge display.
31 When the gauge and display To calibrate the pressure display. Calibration complete
track the pressure together,
press ENTER.
(After a delay the display returns to:)

Service diagnostics
Reset service hours
32 Press RESET. To exit menu routine. Ready to start
Oil temperature 20°C

DL051AAA 51
6 Commissioning CompAir

6.4 Checking/Altering Commissioning Refer to the Control Unit Menu Structure


Parameters diagrams and check/set the commissioning
parameters
Note: The values shown throughout these
procedures are examples only.

No. Action Reason Display


1. Press ENTER. To display the Main menu. Main menu.
Operational settings.
2. Press DOWN and repeat To display the Commissioning - Main menu.
until the display shown on config menu. Commissioning - config.
the right is obtained.
3. Press ENTER. To choose the Commissioning - Commissioning - config. Language
config menu. English
4. Press DOWN. To display the next option. Commissioning - config.
Unit of pressure bar
5. Press DOWN. To display the next option. Commissioning - config.
Unit of temperature °C
6. Press DOWN. To display the next option. (On multi Commissioning - config.
unit installations). Compressor number 1
7. Press ENTER. To display the Main menu. Main menu.
Operational settings.
8. Press DOWN and repeat To scroll through the menu options. Main menu.
until the display shown on Commissioning - values.
the right is displayed.
9. Press ENTER. To select the commissioning values Commissioning - values
menu. Max. pressure 7.0bar
10. Press DOWN. To choose the next option. Commissioning - values
Max. overpress 7.5bar
11. Press DOWN. To choose the next option. Commissioning - values
Star/delta time 15sec
12. Press DOWN. To choose the next option. Commissioning - values
Load delay time 2sec
13. Press DOWN. To choose the next option. Commissioning - values
Max. service hours 4000
14. Press DOWN. To choose the next option. Commissioning - values
Auto-restart delay 10sec
15. Press DOWN. To choose the next option. Commissioning - values
Interstage trip 3.5bar
16. Press DOWN. To choose the next option. Commissioning - values
Interstage alarm 3.0bar
17. Press DOWN. To choose the next option. Commissioning - values
Oil temp trip 70°C
18. Press DOWN. To choose the next option. Commissioning - values
Oil temp alarm 65°C

52 DL051AAA
CompAir Commissioning 6

No. Action Reason Display


19. Press DOWN. To choose the next option. Commissioning - values
St1 delivery trip 210°C
20. Press DOWN. To choose the next option. Commissioning - values
St1 delivery alarm 200°C
21. Press DOWN. To choose the next option. Commissioning - values
St2 intake trip 55°C
22. Press DOWN. To choose the next option. Commissioning - values
St2 intake alarm 50°C
23. Press DOWN. To choose the next option. Commissioning - values
St2 delivery trip 220°C
24. Press DOWN. To choose the next option. Commissioning - values
St2 delivery alarm 210°C
25. Press DOWN. To choose the next option. Commissioning - values
Plant del trip 70°C
26. Press DOWN. To choose the next option. Commissioning - values
Plant del alarm 60°C
27. Press RESET. To exit menu routines. Ready to start.
Oil temperature 20°C.

DL051AAA 53
6 Commissioning CompAir

6.5 Checking/Altering Operating Note: The values shown throughout these


Parameters procedures are examples only.

No. Action Reason Display


1. Press ENTER. To display main menu. Main menu.
Operational settings.
2. Press DOWN and repeat To scroll through the main menu. Main menu
until the display shown on Operational settings
the right is obtained.
3. Press ENTER. To display the Operational settings Operational settings
menu. P1 set point 7.0bar
4. Press DOWN. To choose the next option. Operational settings
P2 set point 7.3bar
5 Press DOWN. To choose the next option. Operational settings
Run on time 10min
6. Press DOWN. To choose the next option. Operational settings
Drain open time 5sec
7. Press DOWN. To choose the next option. Operational settings
Drain shut time 30sec
8. Press RESET. To exit the menu routines. Ready to start
Oil temperature 20°C

54 DL051AAA
CompAir Commissioning 6

6.6 Re-setting Service Interval Timer


Note: The values shown throughout these
procedures are examples only.

No. Action Reason Display


1. Press ENTER. To display the Main menu. Main menu.
Operational settings
2. Press DOWN and repeat To scroll through the menu. Main menu.
until the display shown on Service diagnostics
the right is obtained.
3. Press ENTER. To display the service diagnostics Service diagnostics
menu. Reset service hours
4. Press ENTER. To reset the service hours Service diagnostics
countdown timer to maximum Service hours to run 4000
programmed hours.
(After a delay, changing to:)

Service diagnostics
Reset service hours
5. Press RESET. To exit the menu routines Ready to start
Oil temperature 20°C

DL051AAA 55
6 Commissioning CompAir

6.7 Final Mechanical Checks (ii) Ensure that the air discharge pipe is
disconnected from the user’s system.
Notes:
(iii)Ensure that the discharge air is directed
(i) The values shown throughout these away from all persons in the area.
procedures are examples only.

No. Action Reason Display


1. Switch power supply ‘ON’. C20619/nn/UN/xx
SF3LFnnUN ddmmmyy
2. After a few seconds the Ready to start
display becomes: Oil temperature 20°C
3. Press START. To start the compressor. Starting
Oil temperature 20°C
4. If the compressor does NOT The compressor will not start if:
start a message should be (a) A menu routine has been Menu selected
displayed. selected. Menu option displayed
(b) Remote operation has been Ready to start
enabled. Remote start enabled
(c) A trip fault condition exists. Status
Fault message
(See fault rectification.)
5. If electrical work has to be
carried out switch power to
the compressor ‘OFF’.
Establish the correct starting
conditions. Go to step 1.
6. Following start-up of the motor the Offload
display becomes: Oil temperature 20°C
7. Provided the delivery pressure is Onload
below the P2 set point the Oil temperature 20°C
compressor loads and the display
becomes:
8. Run the compressor for 10 To disperse corrosion inhibitor from
minutes. the system.
9. Press STOP. To stop the compressor for Ready to start
connection to the air system. Oil temperature 20°C
10. Check that the blowdown
valve has released all
pressure from the
compressor.

56 DL051AAA
CompAir Commissioning 6

No. Action Reason Display


11. Connect the compressor
delivery flange to the user’s
pipework via an isolating
shut-off valve. Ensure that
the valve is fully open.
12. Press START. To operate the compressor to check (See the displays in steps 4 to 10).
operating conditions and parameters.
WARNING: RISK OF HIGH
PRESSURE

Do not use hands to locate


leaks in the system. Always
use a piece of paper or card
for this purpose.
13. Examine compressor
pipework for oil or air leaks. If
a leak is found, stop the
compressor, rectify the fault
and go to step 3.
14. Simulate a constant air To provide a normal operating air
demand by opening a valve demand.
in the user’s pipework.
15. Check that the compressor
loads and unloads at the
selected P1 and P2 pressure
set points.
16. Run the compressor under To achieve stable operating
these conditions for an hour. conditions.
17. Examine all pipework again
for oil or air leaks.
18. Check operation of automatic
condensate drains.
19. Press STOP. Switch power
to the compressor ‘OFF’ at
the isolator. Allow several
minutes for the oil to settle.
Top up the oil level if
necessary.
20. Replace all covers and
panels.
21. Record all set points and
operating parameters from
the ‘operational settings’,
‘commissioning Config’ and
‘commissioning values’
sub-menus for future
reference.

DL051AAA 57
6 Commissioning CompAir

6.8 Commissioning Parameters 6.9.3 Check the reading on the vacuum gauge (5)
(Compressor Running On-Load) and, if necessary, adjust the pressure
regulator (2) to obtain a reading of approx
6.8.1 During the 1-hour test running period detailed 50mm / 2in w.g. when the machine is on load.
in item 16 of the table in previous section 6.7,
Caution: It is not possible to adjust the
temperatures and pressures should stabilise
vacuum in the sump accurately by setting
between the figures given below:-
a specific pressure reading on the
Note: The temperature guidelines are for pressure regulator gauge (1). Inaccurate
compressors working in an ambient adjustment of the breather system will
temperature of approximately 20°C. In higher result in pressure in the oil sump, which
ambient temperatures, the temperatures given could create oil leakages at the air end
may be higher. In this case the temperature venting holes.
alarm and trip levels may need to be raised.
First stage delivery 150°C to 185°C
Second stage intake 35°C to 45°C
Second stage delivery 155°C to 190°C
2
Lubricating oil 40°C to 50°C
1
Oil Pressure 2 bar approximately 2
40

0
80

lbf/in2
bar
6

120
8

3
0 10

Stage 1 Air Delivery 1.8–2.8 bar 4


(Depending on model)

6.9 Powered Breather System - Check 5


Vacuum.
6.9.1 With the machine stopped, connect a vacuum
gauge (5) or U-tube/manometer capable of
reading a vacuum of 50mm / 2in w.g. into the
oil mist suction line between pressure vacuum
generator and filler pipe as shown in fig. 6.1.
6.9.2 Start the machine and check that air is being
discharged from the vacuum generator/oil
removal filter vent (4).

SM 0811

Fig. 6.1 - Vacuum Gauge Connection


1. Pressure Gauge
2. Pressure Adjuster
3. Vacuum Generator
4. Vent
5. Vacuum Gauge

58 DL051AAA
CompAir Commissioning 6

6.10 Commissioning Check List


6.10.1 A master Commissioning Checklist Form is
contained in Appendix 2 (section 14). This
checklist form must be completed during, and
on completion of, the commissioning
procedure. The completed form must then be
returned to the CompAir AfterMarket Dept. at
Redditch.

Commissioning Check List – D-Series Air Cooled

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Commissioning
Engineer's Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . c 23 All temperature and


pressure trip limits set . . . . . . . . . . . . . . . . c
2 Cable, fuse ratings OK . . . . . . . . . . . . . . . c
24 All temperature and pressure
3 Control transformer alarm limits set . . . . . . . . . . . . . . . . . . . . . c
input voltage set correctly . . . . . . . . . . . . . c
25 Star/delta time set . . . . . . . . . . . . . . . . . . . c
4 Main motor, fan motor, oil pump motor
overloads and MCB Q102 set correctly. . . c 26 Load delay time set . . . . . . . . . . . . . . . . . . c
5 Phase rotation relay voltage set . . . . . . . . c 27 Reset service hours timer . . . . . . . . . . . . . c
6 Starter connections OK . . . . . . . . . . . . . . . c 28 Starting sequence correct . . . . . . . . . . . . . c
7 Motor connections OK. . . . . . . . . . . . . . . . c 29 Compressor blows down OK. . . . . . . . . . . c
8 Protection blanks and tapes . . . . . . . . . . . c 30 Corrosion inhibitor dispersed. . . . . . . . . . . c
9 Fill compressor with oil . . . . . . . . . . . . . . . c 31 Connected to user’s pipework . . . . . . . . . . c
10 Air end and motor freely rotate . . . . . . . . . c 32 Oil and air leaks check ..........c
11 Select language . . . . . . . . . . . . . . . . . . . . c 33 Compressor loads, unloads,
stands by and stops correctly . . . . . . . . . . c
12 Fan/Oil pump rotation OK . . . . . . . . . . . . . c
34 Emergency stop correct . . . . . . . . . . . . . . c
13 Main Motor rotation OK . . . . . . . . . . . . . . . c
35 Temperatures and pressures in limits . . . . c
14 Pressure transducer calibrated . . . . . . . . . c
36 Oil level topped up . . . . . . . . . . . . . . . . . . c
15 Display units set . . . . . . . . . . . . . . . . . . . . c
37 All parameters recorded from
16 Compressor number set controller menu routines . . . . . . . . . . . . . . c
(if comms facility available/fitted). . . . . . . . c
38 Plugs removed from air end vents. . . . . . . c
17 Pressure control set points set . . . . . . . . . c
39 Powered oil breather system
18 Run-on time set . . . . . . . . . . . . . . . . . . . . . c operating correctly. . . . . . . . . . . . . . . . . . . c
19 Drain open time set . . . . . . . . . . . . . . . . . . c 40 Motor auto greaser set (if fitted) . . . . . . . . c
20 Drain shut time set . . . . . . . . . . . . . . . . . . c 41 Commissioning check list
21 Maximum compressor pressure set. . . . . . c complete and signed . . . . . . . . . . . . . . . . . c

22 Maximum overpressure set . . . . . . . . . . . . c

Customer Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning
Engineer's Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

This form must be completed and returned to CompAir AfterMarket Dept. at Redditch.
Please make 2 copies of this form. Copy 1: Customer – Copy 2: Commissioning Engineer.

Fig. 6.2 - Sample Commissioning


Checklist Form

DL051AAA 59
7 Operation and Fault Finding CompAir

7 Operation and Fault


Finding
Notes:
WARNING
(i) Oil temperature is used as an example
only. Actual display can be any of the
• Refer to the safety procedures before displayed values in para 7.4.
operating the compressor unit. (ii) See ‘Fault Messages’ for possible start-up
• Lethal voltages are used in this faults. If a fault exists and a repair is
equipment. Use extreme caution when necessary, power to the compressor must be
carrying out electrical checks. Isolate the isolated and the fault rectified.
power supply before starting any (iii) If the reset indicator is lit, RESET must be
maintenance work. pressed following rectification of the fault,
before the compressor will start.
Notes: 7.1.3 To start the compressor press START (4).
(i) If the compressor has been out of operation Provided pressure at the delivery point is
for a prolonged period it is advisable to check below P2 set point the compressor will start. It
performance and all regulation functions by will otherwise enter Standby mode. The oil
carrying out the full commissioning procedure pump and fans will start but the main motor
before starting. will not start until the oil pressure has reached
its set point. The compressor will not start
(ii) The temperatures and pressures given in if:
the procedures are shown as examples only.
a) Certain menu routines are in use.
7.1 Starting b) The remote starting facility has been enabled.
In this instance the display panel REMOTE
See fig. 7.1. CONTROL indicator (20) will be lit and the
7.1.1 Switch mains power to the compressor ‘ON’ at display will show:
the isolator. The front panel is now in the Unable to start
following state:
Remote start enabled
a) The POWER ON indicator (22) is lit.
7.1.4 During the initial starting period, the drive
b) The status display (5) shows: motor starts in Star connection and the status
C20627/nn/xx/nn display will show:
SF3LFnnUN_ddmmmyy Starting
c) Either or both the REMOTE (20) and AUTO Oil temperature 20°C
RESTART (21) indicators are lit if these 7.1.5 Following the motor Star/Delta switch-over
facilities have been selected. and during the subsequent load delay period,
7.1.2 After a few seconds, provided no fault exists, the status display will show:
the status display will show: Offload
Ready to start Oil temperature 20°C
Oil temperature 20°C 7.1.6 Provided the delivery pressure is below the
lower set point (P2) the compressor runs on
load.
Onload
Oil temperature 25°C

60 DL051AAA
CompAir Operation and Fault Finding 7

7.1.7 Fault conditions and service requirements are 7.1.9 To interrogate the hours run and service
continuously monitored (from start-up) and hours information press HOURS. (See para
warning and the appropriate status messages 7.13 'Using The Menu Routines').
are displayed.
7.1.10 To show operating parameters, fault history,
7.1.8 To interrogate other temperature or interstage etc. or to alter programmed settings, press
pressure information press VALUE (see para ENTER (10) to access the menu routine (see
7.13 'Using The Menu Routines'). para 7.13 'Using The Menu Routines').

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

bar

psi

36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
PI/97/067

Fig. 7.1 - SureScan Control Panel


1. Psi Units Indicator 19. Remote Control Legend
2. Bar Units Indicator 20. Remote Control Indicator
3. Delivery Pressure Display 21. Auto Restart Indicator
4. Start Button 22. Power On Indicator
5. Status and Message Display 23. Compressor Delivery Fault Indicator
6. Plus Button 24. Oil System Fault Indicator
7. Minus Button 25. Change Oil Filter Indicator
8. Up Button 26. 2nd Stage Delivery Fault Indicator
9. Down Button 27. Low Oil Level Indicator
10. Enter Button 28. Main Motor Fault Indicator
11. Mimic Diagram 29. Oil Pump Motor Fault Indicator
12. Intake Filter Change Indicator 30. Hours Button
13. Incorrect Phase Rotation Indicator 31. Reset Button
14. 1st Stage Delivery Fault Indicator 32. Reset Indicator (LED)
15. 2nd Stage Intake Fault Indicator 33. Values Button
16. Fan Motor Fault Indicator 34. Service Button
17. Emergency Stop Button 35. Service Indicator (LED)
18. Auto Restart Legend 36. Stop Button

DL051AAA 61
7 Operation and Fault Finding CompAir

7.2 Pressure Control 7.3 Displaying the Number of Hours


7.2.1 The compressor will unload and load in Run
response to varying air demand when the 7.3.1 The HOURS button (30) is used to display the
upper and lower set points P1 and P2 are hours run by the compressor and the hours to
reached. When the compressor goes off-load run before a service is due.
the system blows down. The controller loads
and unloads the compressor by fully opening 7.3.2 Successive presses of the HOURS button
or fully closing the suction regulator inlet give the following display sequence:
valve. The display alternates, as appropriate, Total hours 1000
between:
Hours on load 800
Offload
Service hrs to run 3000
Oil temperature 45°C
7.3.3 The display will cancel itself after a short
and period or it can be cancelled immediately by
Onload pressing RESET.

Oil temperature 45°C


7.4 Changing the Displayed Value
7.2.2 If the compressor is off-load for longer than
the ‘Run-on Time’, the compressor will stop 7.4.1 The VALUE button (33) is used to step
and the status display will change to: through the compressor operating
temperatures and interstage pressure
Stopping displays.
Oil temperature 40°C 7.4.2 Successive presses of the VALUE button give
7.2.3 After the stopping period the display will the following display sequence.
change to: Oil Pressure 2.0 bar
Standby Oil temperature 45°C
Oil temperature 40°C St1 Delivery temp 160°C
Note: If the START button is pressed whilst St2 Intake temp 40°C
the compressor is stopping the display
changes to ‘Standby’ immediately. St2 Delivery temp 165°C

7.2.4 When air demand lowers the pressure below Plant delivery temp 35°C
the lower set point P2 the compressor will Interstage press 2.0 bar
restart and run on-load. The display will show:
7.4.3 The selected value will remain on the display
Starting until a new value is selected.
Oil temperature 20°C
changing to:
Offload
Oil temperature 20°C
during load delay time, then:
On load
Oil temperature 25°C

62 DL051AAA
CompAir Operation and Fault Finding 7

7.5 Stopping 7.8 Service Interval Timer


7.5.1 To stop the compressor press STOP (36). 7.8.1 The control system uses a count-down timer
This initiates a controlled shut down which can be reset to programmed maximum
sequence. The main motor will continue to run each time a service is carried out. The
for 8 seconds and the display will briefly show: maximum service hours can be adjusted to
suit site conditions and/or service schedule
Offload
requirements.
Oil temperature 45°C
7.8.2 When the timer reaches zero hours a service
changing to: due advice message is displayed. When the
service has been completed, the reset service
Stopping
hours function should be selected from the
Oil temperature 45°C service diagnostics sub-menu and the service
advice message reset.
7.5.2 The oil pump motor and cooling fans will
continue to run for 30 seconds after the main 7.8.3 When the compressor has reached the
motor has stopped. running hours at which a service is required,
the SERVICE indicator (35) will flash. If
7.5.3 After the 30 second cooling down period the
SERVICE (34) is now pressed the SERVICE
display will change to:
indicator (35) will stop flashing and remain lit.
Ready to start The RESET indicator (32) will then flash
continuously and the status display will show
Oil temperature 40°C the service advice message below:
Onload
7.6 Emergency Stopping
Service due
7.6.1 When the EMERGENCY STOP (17) is
pressed, the compressor will stop immediately 7.8.4 The compressor must be stopped and
and the system will blow down. isolated to carry out the required service (see
‘Safety Procedures’). On completion of the
7.6.2 The RESET indicator will pulse and the service the ‘service hrs to run’ value must be
display will show: reset to maximum by using the Service
Fault shut down Diagnostics menu routine.
Emergency stop 7.8.5 It may not be convenient to respond to the
service due message immediately. In this
Caution: The emergency stop button case press RESET (31) to cancel the flashing
should be used only in a genuine RESET indicator and restore the status and
emergency and must not be used as the selected value display. The service indicator
normal method of stopping the will remain lit to indicate that a service is
compressor. required.

7.7 Condensate Drain Operation


7.7.1 When running on-load the intercooler and
aftercooler condensate drains will operate
according to the programmed drain shut and
drain open times. The drain will open and the
timer cycle will begin every time the
compressor loads.
7.7.2 When the compressor is in ‘off-load’, ‘standby’
or ‘ready to start’, the drains will continue to
operate with a two second ‘open’ time and an
extended ‘shut’ time. This prevents any
build-up of condensate when the compressor
is stopped or running ‘off-load’.

DL051AAA 63
7 Operation and Fault Finding CompAir

7.9 Warnings 7.10 Shutdowns


7.9.1 If a service is required, the SERVICE indicator 7.10.1 If a shutdown occurs, the compressor will
(35) and the appropriate mimic diagram stop. This can occur at any time after the
indicator will flash continuously. If SERVICE compressor has been started.
(34) is pressed the SERVICE indicator will
7.10.2 Both RESET and the appropriate mimic
stop flashing and stay lit in acknowledgement.
diagram indicator will flash continuously and
The RESET indicator (32) will flash
the SERVICE indicator will light. If the menu
continuously and the display will show the
routine is in use when a shutdown occurs the
required action (e.g. an air filter change) as
appropriate panel and mimic diagram
below:
indicators will light and flash as normal. The
Onload current message will not be overwritten until
RESET is pressed or the display reverts to the
Change Air filter
fault message after a period of time.
7.9.2 Pressing SERVICE repeatedly during this
7.10.3 The display will show:
period will recall any earlier stored warnings in
chronological order (most recent first) that Fault shutdown
have not been corrected and reset.
Relevant shutdown message
7.9.3 When pressing SERVICE is discontinued, the
(See Display messages)
fault/service display will be shown for several
seconds after which it reverts to the selected
value display message. 7.11 Fault History Recall
7.9.4 The occurrence of another warning after any 7.11.1 Selecting ‘Fault History Recall’ on the Main
previous warning has been acknowledged will Menu will show the compressor status at the
again cause the SERVICE indicator to flash last fault. The following parameters can be
continuously and the mimic diagram indicator displayed showing the conditions at the last
appropriate to the second fault will also light. fault.
7.9.5 It may not be convenient to respond to a 7.11.2 The fault history will retain the last 25 faults
warning immediately. In this case press (see table of fault history messages below).
RESET to cancel the flashing service indicator
and to restore the status and selected value
displays. The mimic diagram indicator will
remain lit to indicate that attention is required.

Fault History Message Meaning


Hours run 1000 Hours run at time of fault.
Onload, Offload, Standby, Ready to start etc. State of compressor at time of fault.
Delivery Press 7.0 bar Delivery Pressure at time of fault.
Interstage press 2.0 bar Interstage pressure at time of fault.
Oil temperature 45°C Oil temperature at time of fault.
St1 delivery temp 160°C Stage 1 delivery temperature at time of fault.
St2 intake temp 40°C Stage 2 intake temperature at time of fault.
St2 delivery temp 165°C Stage 2 delivery temperature at time of fault.
Plant delivery temp 30°C Plant delivery temperature at time of fault.

64 DL051AAA
CompAir Operation and Fault Finding 7

7.12 Stand-by Operations 7.13 Using The Menu Routines


7.12.1 A compressor on stand-by duty must be 7.13.1 The menu routines are used to access, view
started and run for 10 minutes per week. and/or alter the operating parameters and
options stored in the memory of the controller.
7.12.2 If the user’s air usage is insufficient to allow
the compressor to run for 10 minutes the 7.13.2 With the mains power on and ENTER
compressor should be run Off-load as follows: pressed, the text display on the control panel
will show two lines of text. The top line
a) Ensure the Run On time on the controller is
indicates the menu in use and the bottom line
set to 10 minutes.
the parameters in use.
b) At the remote inputs, ensure Remote Load
7.13.3 The diagrams at the end of this section show
Input is open, then close the Remote Load
the sequence of messages available and the
Enable.
buttons to press to obtain the required
c) If the compressor is not already in standby, message.
start the compressor which will then go into
7.13.4 In the diagrams the solid line boxes represent
stand by.
the message window and the broken line
d) Momentarily close the Remote Load input. boxes are reader information or instructions.
The compressor will start .
Notes referred to within the following
Note:Ensure that the Remote Load input is SureScan menu diagrams
opened before the delta contact is closed or
(1) Test digital inputs – Test routine for each
the compressor may load.
individual input.
e) Open the Remote Load Enable to put control
(2) Test analogue inputs – Test routine for
back to the transducer.
pressure and temperature inputs.
f) The compressor will now run for the time set.
(3) Test keypad – Keypad test routine. Each
key pressed will be displayed to establish
operation. Press RESET to exit routine.
(4) Test Display – Control panel LED, LCD
and indicator test. When selected all LED’s
and indicators will light and all LCD text
display elements will turn on for 15 seconds.
The routine will self cancel.

DL051AAA 65
7 Operation and Fault Finding CompAir

Status Message

Oil temperature 25ºC


Main Menu Go to 2 of 8

Intake temp 20ºC Total hours 1000

St1 delivery temp 160ºC Hours on load 800

When first attempt is made to adjust


any value, the prompt will appear:

St2 intake temp 40ºC Service hrs to run 3000

Enter code: ????


St2 delivery temp 165ºC

Plant del temp 35ºC


To continue

Interstage press 2.0 bar

Oil pressure 2.3 bar

Press at any time in any


menu to return to initial display

SM 1060

Fig 7.2 - SureScan Control Unit Menu Structure (1 of 8)


"STATUS"

66 DL051AAA
CompAir Operation and Fault Finding 7

Fig 7.3 - SureScan Control Unit Menu Structure (2 of 8)


"MAIN MENU"

DL051AAA 67
7 Operation and Fault Finding CompAir

Fig 7.4 - SureScan Control Unit Menu Structure - (3 of 8)


"OPERATIONAL SETTINGS" and "SERVICE DIAGNOSTICS"

68 DL051AAA
CompAir Operation and Fault Finding 7

Note: The calibration procedure corrects for zero


offset of all transducers but only corrects the range
of the delivery pressure. Therefore all pressures
(delivery, interstage and oil) must be zero for the
first stage of this routine or the routine will be
aborted with a probe error message. For
subsequent stages, only the delivery pressure
needs to be adjusted.
From 3 of 8
'Calibrate pressure'

Set pressure at 0bar See note


Press enter when ready

Disconnect delivery

Set pressure > 5.51bar

Connect known air pressure supply


to delivery pressure transmitter

Adjust +/-: 5.6bar Adjust until display shows


Press enter when ready correct pressure

Adjust pressure up/down Adjust until display tracks


Press enter when ready pressure variations correctly

Calibration complete

2 sec

To 3 of 8
'Service diagnostics'
Press at any time in any
menu to return to initial display

SM 1063

Fig 7.5 - SureScan Control Unit Menu Structure (4 of 8)


"CALIBRATE PRESSURE" Sub-menu

DL051AAA 69
7 Operation and Fault Finding CompAir

From 3 of 8
Service diagnostics

Test digital outputs


Main contactor 0 Running 0

Star contactor 0 On load 0

Delta contactor 0 Group trip 0

Unloader solenoid 0 Service due 0

Drain solenoids 0 Remote fault 1 0

Fan contactor 0 Remote fault 2 0

Channel 7 0 Remote fault 3 0 Remote fault 3 1

Oil pump contactor 0 Remote fault 4 0

For each parameter

Available 0 Remote fault 5 0

0 indicates not energised


1 indicates energised
Group fault 0 Extension XO6/7 0

Return to previous menu

To 3 of 8
Service diagnostics

Press at any time in any


menu to return to initial display

SM 1064

Fig 7.6 - SureScan Control Unit Menu Structure (5 of 8)


"TEST DIGITAL OUTPUTS" Sub-menu

70 DL051AAA
CompAir Operation and Fault Finding 7

From 2 of 8

Commissioning-Config
Language: English Language: Option

Unit of pressure bar Unit of pressure psi

Unit of temperature C Unit of temperature F

Machine model To 7 of 8

Machine number 1 Compressor number 10

Communications config. To 7 of 8

Fault input config.


Fault input config.
Remote fault 1
Remote fault 1
Disabled
Return to previous menu

Remote fault 2

Trip type 1, 2 or 3

Remote fault 5

Alarm type 1, 2 or 3

Return to previous menu

Start inhibit

Press at any time in any


menu to return to initial display

Fig 7.7 - SureScan Control Unit Menu Structure (6 of 8)


"COMMISSIONING CONFIG" Sub-menu

DL051AAA 71
7 Operation and Fault Finding CompAir

From 6 of 8

Enter code ????

Machine model
Machine model
Model message
Machine model
see list below

Return to previous menu

To 6 of 8
Commissioning-Config.

Communications config.
Communications config.
Config. message
Communications config.
Disabled

Return to previous menu

SmartAir control

To 6 of 8
Commissioning-Config.
Communications control

MACHINE MODELS
“ 6504/6604” “Dryclon 507W/607W”
“ 6505/6605” “Dryclon 508W/608W”
“ 6506/6606” “Dryclon 509W/609W”
“ 6507/6607” “Dryclon 510W/610W”
“ 6508/6608” “Dryclon 512W/612W”
“ 6509/6609” “Dryclon 515W/615W” default setting
“ 6510/6610”
“ 6512/6612” D55-08/10A
“ 6515/6615” D75-08/10A
D90-08/10A
“Dryclon 504W/604W” D110-08/10A
“Dryclon 505W/605W” D132-08/10A
“Dryclon 506W/606W” D150-08/10A

SM 1066

Fig 7.8 - SureScan Control Unit Menu Structure (7 of 8)


"MACHINE MODEL" and "COMMUNICATIONS CONFIG" Sub-menus

72 DL051AAA
CompAir Operation and Fault Finding 7

From 2 of 8

Commissioning-Values
Max. pressure 10.5 bar St1 delivery alarm 180ºC

Max. overpress 10.6 bar St2 intake trip 65ºC

Star/delta time 25 sec St2 intake alarm 60ºC

Load delay time 60 sec St2 delivery trip 200ºC

Max. service hrs 4000 St2 delivery alarm 180ºC

Autorestart delay 100sec Plant del trip 55ºC Plant del trip 45ºC

Interstage trip 4.0 bar Plant del alarm 40ºC

For each parameter

Interstage alarm 3.8 bar Load default values

Default values loaded 2 sec


Oil pressure alarm 1.7bar Return to previous menu

Oil pressure trip 1.5 bar


To 2 of 8
Main Menu

Oil temp trip 75ºC

Oil temp alarm 70ºC

St1 delivery trip 200ºC

Press at any time in any


menu to return to initial display

SM 1067

Fig. 7.9 - SureScan Control Unit Menu Structure (8 of 8)


"COMMISSIONING VALUES" Sub-menu

DL051AAA 73
7 Operation and Fault Finding CompAir

7.14 Menu Structure Quick Reference

Control Panel Menus


Entry Menu Sub Menu

Main Selection Menu Operational settings Commissioning - Values

Operational settings P1 setpoint **.*bar Max. pressure **.*bar


Fault history recall P2 setpoint **.*bar Max. overpress **.*bar
Service diagnostics Run on time **min Star/delta time **sec
Commissioning - config. Drain open time **sec Load delay time ***sec
Commissioning - values Drain shut time ***sec Max service hours ****
Show program variant Return to previous menu Autorestart delay ***sec
Return to previous menu Interstage trip **.*bar
Service Diagnostics Interstage alarm **.*bar
Oil pressure alarm **.*bar
Reset service hours
Oil pressure trip **.*bar
Calibrate pressure
Oil temp trip ***˚C
Fault History Recall Test digital outputs
Oil temp alarm ***˚C
Test digital inputs
Scroll up/down last 25 St1 delivery trip ***˚C
faults in chronological Test analogue inputs
order. St1 delivery alarm ***˚C
Test keypad
St2 intake trip ***˚C
Shows status of Test display
compressor at time of St2 intake alarm ***˚C
displayed fault. Return to previous menu
St2 delivery trip ***˚C
St2 delivery alarm ***˚C
Commissioning - Config
Plant del trip ***˚C
Language: English Plant del alarm ***˚C
Unit of pressure bar Load default values
Unit of temperature ˚C
Machine model
Machine number **
Communications config
Fault input config ****
Return to previous menu Return to previous menu

SM 0985

Fig. 7.10 - SureScan Menu Quick Reference

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CompAir Operation and Fault Finding 7

7.15 Default Values 7.15.3 The compressor may be re-programmed with


different values at any time, and the controller
7.15.1 Default values for a number of the operational settings may be restored to the default values,
settings are stored in the controller. These are by choosing the ‘Load default values’ option in
suitable for operating the compressor in most the ‘Commissioning - values’ sub-menu.
normal situations. Alteration of the working setting values
requires the use of the access code.
7.15.2 The compressor can use these values as
operational settings. Unless the compressor is 7.15.4 The following is a list of default values
reprogrammed during commissioning, the together with the range and size of the
default values will be those used by the increments/decrements available for each
compressor. setting.
Note: The ‘Max. Pressure’ and ‘Star/Delta time’
must be set according to compressor model.

Setting Unit Minimum Maximum Step Default Value


P1 setpoint bar 4.0 10·5 0·1 7·0
P2 setpoint bar 3.9 10·4 0·1 6·3
Run on time minute 5 240 1 10
Drain open time second 1 20 1 5
Drain shut time second 10 120 1 30
Star delta time second 3 30 1 15
Comms baud rate * baud 110 9600 options 9600
Compressor number number 1 99 1 1
Max. working pressure bar 8/8.6/10·5 options 8.0
Max. overpress bar 6·0 11·0 0·1 7·5
Load delay time second 2 60 1 2
Max. service hours hour 1000 8000 100 8000
Auto restart Delay second 10 240 1 10
Interstage trip bar 2·5 4·0 0·1 3·5
Interstage alarm bar 2·5 4·0 0·1 3·0
Oil temp trip °C 50 75 1 70
Oil temp alarm °C 50 75 1 65
St1 delivery trip °C 180 225 1 225
St1 delivery alarm °C 180 220 1 215
St2 intake trip °C 40 75 1 60
St2 intake alarm °C 40 75 1 50
St2 delivery trip °C 180 235 1 235
St2 delivery alarm °C 180 230 1 225
Plant del trip °C 30 90 1 70
Plant del alarm °C 30 90 1 60
Low oil press trip bar 1·5 3.0 – 1.5
Low oil press alarm bar 1.7 3.0 – 1.7
Intake filter blockage mbar – – fixed 65
Oil filter blockage bar – – fixed 2

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7 Operation and Fault Finding CompAir

7.16 Glossary Of Display Messages


7.16.1 Operator Advice Messages

Message Displayed Meaning

Invalid access code The access code entered is not acceptable.


No reset indicated The ‘Reset’ button has been pressed when there is no reset required.
No service indicated The ‘Service’ button has been pressed when there is no service action
required.
Remote start enabled Starting has been attempted via the Control Panel when the remote start
facility is enabled (Panel starting is disabled).
Remote stopped Starting is inhibited by the remote stop input.
Stop compressor first The compressor is running and a menu selection has been attempted
which can only be used when the compressor is stopped.

7.16.2 Shutdown Messages

Message displayed Meaning

Extension fault Extension module unit is not responding.


Emergency stop An emergency stop has been made.
Power supply fault Main supply phase rotation is detected to be incorrect or voltage is below
acceptable limits.
Main motor fault The compressor has shut down because of main motor overcurrent or
high temperature.
Fan motor fault The compressor has shut down because of fan motor overcurrent.
Oil pump fault The compressor has shut down because of oil pump motor overcurrent.
MPCB Q101 tripped The protection circuit breaker Q101 is in the tripped condition.
High air pressure The compressor has shut down because the delivery pressure has
exceeded the maximum pressure setting.
Interstage press trip The interstage pressure has exceeded the maximum set pressure limit.
Oil pressure trip The compressor has shut down because the oil pressure has fallen
below the minimum pressure limit.
Oil temperature trip The compressor has shut down because the oil temperature has
exceeded the upper (trip) limit.

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CompAir Operation and Fault Finding 7

Shutdown Messages (contd)

Message displayed Meaning

St1 delivery temp trip The compressor has shut down because the first stage delivery
temperature has exceeded the upper (trip) limit.
St2 intake temp trip The compressor has shut down because the second stage intake
temperature has exceeded the upper (trip) limit.
St2 delivery temp trip The compressor has shut down because the second stage delivery
temperature has exceeded the upper (trip) limit.
Plant delivery t trip The compressor has shut down because the plant air delivery
temperature has exceeded the upper (trip) limit.
Del press probe fault * The delivery pressure transducer resistance is outside the limits as
defined in section 11.16.
Intake temp probe fault The temperature sensor resistance is outside the limits as defined in
section 11.16.
Int.St press probe fault The delivery pressure transducer resistance is outside the limits as
defined in section 11.16.
Oil pressure probe fault The Oil Pressure sensor resistance is outside the limits as defined in
section 11.16.
Oil temp probe fault The temperature sensor resistance is outside the limits as defined in
section 11.16.
St1 del temp probe fault * The temperature sensor resistance is outside the limits as defined in
section 11.16.
St2 in temp probe fault * The temperature sensor resistance is outside the limits as defined in
section 11.16.
St2 del temp probe fault * The temperature sensor resistance is outside the limits as defined in
section 11.16.
Plant del t probe fault * The temperature sensor resistance is outside the limits as defined in
section 11.16.
Remote fault 1 (2,3,4,5) The compressor has shutdown because one of the remote fault inputs
has been activated.
Oil level low The sump oil level is detected to be low while the compressor is stopped.
(start inhibit)

* Temperature & Pressure probe faults will cause associated pressure & temperature history to be
displayed as – – – – –

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7.16.3 Warning Messages

Message displayed Meaning

Change air filter A high differential pressure has been detected across the air filter
indicating the need for an air filter element change. Note: Switch must be
reset manually after tripping.
Change oil filter A high differential pressure has been detected across the oil filter
indicating the need for an oil filter change.
Interstage press alarm The interstage pressure has reached the programmed warning value.
Oil pressure alarm The oil pressure has dropped to the programmed warning value.
Oil temperature alarm The oil temperature has reached the programmed warning value.
St1 delivery temp alarm The first stage delivery temperature has reached the programmed
warning value.
St2 intake temp alarm The second stage intake temperature has reached the programmed
warning value.
St2 delivery temp alarm The second stage delivery temperature has reached the programmed
warning value.
Plant delivery t alarm The plant air delivery temperature has reached the programmed warning
value.
Oil level low Indicates that oil level is low
Remote fault 1 (2,3,4,5) One of the remote alarm inputs has been activated.
Service due The service interval countdown timer has reached zero hours indicating a
service is now due.
Start inhibit The remote start inhibit input is open circuit.

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7.16.4 Service Messages

Message displayed Meaning

Total hours Shows the recorded total number of compressor running hours on and off
load.
Hours on load Shows the recorded total number of compressor running hours on load
only.
Max. service hrs Shows the maximum programmed hours before a service is required.
Service hrs to run Indicates the number of running hours remaining before a service is
required.
Reset service hours Invitation to reset the service interval hours to the maximum programmed
service hours.

7.16.5 Status Messages

Message displayed Meaning

Auto restarting The compressor is about to automatically restart following restoration of


power.
Fault shutdown The compressor has stopped due to a fault.
Offload The compressor is running off load (the run-on time has not expired).
Onload The compressor is running on load.
Ready to start The compressor is waiting for a start signal (keypad or external) and no
fault has been detected.
Remote stopped Starting is inhibited by the remote stop input being open circuit.
Standby The compressor has been ‘started’ but is waiting for the delivery pressure
to fall below the lower setpoint, before the motor is energised.
Starting Motor starting.
Unable to start A remote shutdown fault or start inhibit is present.
Stopping The stop button has been pressed but the oil pump motor and cooling
fans will remain energised for 30 seconds.
Start Inhibited Displayed in place of 'Ready To Start' if a remote fault input is open
circuit.

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7.17 Fault Finding


WARNING Message Category Index No.
2nd Stage - Messages
- St2 intake temp alarm 29
• Refer to the safety procedures before
- St2 intake temp trip 8
installation of the compressor unit.
- St2 intake temp probe fault 17
• Lethal voltages are used in this - St2 delivery temp alarm 30
equipment. Use extreme caution when
- St2 delivery temp trip 9
carrying out electrical checks. Isolate the
power supply before starting any - St2 del temp probe fault 18
maintenance work. Plant Delivery - Messages
- High air pressure 13
The controller has a memory facility that - Plant delivery t alarm 31
retains a fault history. Details of 25 previous - Plant delivery t trip 10
situations can be displayed, including the fault - Plant del t probe fault 19
message together with recorded hours,
- Del press probe fault 14
compressor state (standby, on-load, off-load
etc.), plant temperatures and pressures. Interstage - Messages
- Interstage press alarm 32
When in operation, the compressor is
protected by circuits which are triggered when - Interstage press trip 11
a fault arises and either cause the compressor - Int.St press probe fault 15
to shut down or indicate that a servicing action Electrical - Messages
is required.
- Emergency stop 1
- Main motor fault 2
7.18 Index of Shutdown and Warning - Fan motor fault 3
Messages - Oil pump fault 4
7.18.1 The following index table is designed to group - St1 del temp probe fault 16
the messages detailed in paras. 7.18.2 and - St2 del temp probe fault 18
7.18.3 into categories to assist the user in - Plant del t probe fault 19
quickly finding the possible cause and action
- Int.St press probe fault 15
to be taken in the event of a shutdown /
- MPCB Q101 tripped 5
warning message appearing.
- Extension fault 21
Message Category Index No. - Remote fault 20
Oil - Messages - Power supply 22
- Oil temperature alarm 27 - Remote alarm 33
- Oil temperature trip 6 - Start inhibit 34
- Oil pressure low 12 General - Messages
- Oil level low (start inhibit) 23 - Change air filter 25
- Oil pump fault 4 - Change oil filter 26
- Change oil filter 26 - Service due 24
1st Stage - Messages
- St1 delivery temp alarm 28
- St1 delivery temp trip 7
- St1 del temp probe fault 16

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CompAir Operation and Fault Finding 7

7.18.2 Shutdown Messages

Index Message Displayed Possible Cause Action required


1 Emergency stop (1) Emergency Stop switch operated. (1) Check cause of fault and rectify.
Turn Emergency Stop switch to
release latch. Press RESET.
(2) Starter circuit fuse F5 blown. (2) Check cause and rectify.
2 Main motor fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure filter;
ducting; motor cooling air intake.
(3) Fan operation/rotation incorrect. (3) Check and rectify electrical circuit.
(4) Low voltage/high current. (4) Check power supply.
(5) Thermal overload F101 incorrectly (5) Check setting and reset.
set.
(6) Excessive starting of main motor (6) Check setting of the run-on timer
3 Fan motor fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure filter;
ducting; motor cooling air intake;
auxiliary cooling fan (if fitted).
(3) Low voltage/high current. (3) Check power supply.
(4) Overloads F102/F103 incorrectly set. (4) Check setting and reset.
4 Oil pump fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure filter;
ducting; motor cooling air intake.
(3) Low voltage/high current. (3) Check power supply.
(4) Overload F104 incorrectly set. (4) Check setting and reset.
(5) Pressure control incorrectly set (5) Check setting and reset.
(6) Oil pump relief valve seized (6) Check and rectify/renew
5 MPCB Q101 tripped (1) Circuit breaker incorrectly set. (1) Check setting and reset.
(2) Oil pump/fan motor circuit fault. (2) Check cause and rectify.
6 Oil temperature trip (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
filters. Inspect/clean cooler matrix.
(3) Temperature sensor/switch fault. (3) Rectify/renew.
(4) Sensor/switch wiring fault. (4) Check wiring.
(5) Low oil level. (5) Investigate for oil leaks, top up oil
level.
(6) Oil flow restriction. (6) Investigate and rectify.
(7) Incorrect grade of oil. (7) Drain/flush oil system. Refill oil
system to the correct level with the
recommended oil.
(8) Incorrect setting of controller (8) Reset the alarm/trip to default
alarm/trip values. values.

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7 Operation and Fault Finding CompAir

Shutdown Messages (continued)

Index Message Displayed Possible Cause Action required


7 St1 delivery temp trip (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
filters. Inspect/clean air coolers.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) High interstage pressure. (4) Inspect/clean air coolers.
(5) Incorrect setting of controller (5) Reset the alarm/trip to default
alarm/trip values. values.
(6) Air flow restriction within intercooler. (6) Check differential pressure across
intercooler. Clean or renew
intercooler.
(7) 2nd stage air end fault. (7) Renew 2nd stage air end.
8 St2 intake temp trip (1) Insufficient cooling air flow. (1) Check fan operation and enclosure
filters. Inspect/clean cooler matrix.
(2) High ambient temperature. (2) Check room ventilation.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) Incorrect setting of controller (4) Reset the alarm/trip to default
alarm/trip values. values.
(5) Air flow restriction within intercooler. (5) Check differential pressure across
intercooler. Clean or renew
intercooler.
(6) High 1st stage temperature. (6) Investigate and rectify.
(7) 1st stage air end fault. (7) Renew 1st stage air end.
9 St2 delivery temp trip (1) High ambient temperature (1) Check room ventilation
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
filters. Inspect/clean intercooler.
(3) Air flow restriction within aftercooler. (3) Check differential pressure across
aftercooler/clean aftercooler
(4) Temperature sensor fault. (4) Rectify/renew.
(5) Incorrect setting of controller (5) Reset the alarm/trip to default
alarm/trip values. values.
(6) High 2nd stage intake temperature. (6) Investigate and rectify.
(7) 2nd stage air end fault. (7) Renew 2nd stage air end.
10 Plant delivery t trip (1) High ambient temperature. (1) Check room ventilation
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
air filter.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) Incorrect setting of controller (4) Reset the alarm/trip to default
alarm/trip values. values.
(5) Air flow restriction within aftercooler. (5) Check differential pressure across
aftercooler. Clean or renew
aftercooler.
(6) High 2nd stage delivery temperature. (6) Investigate and rectify.
(7) 2nd stage air end fault. (7) Renew 2nd stage air end.

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Shutdown Messages (continued)

Index Message Displayed Possible Cause Action required


11 Interstage press trip (1) Air flow restriction within intercooler (1) Check differential pressure across
intercooler. Clean intercooler/renew
intercooler.
(2) Faulty interstage pressure sensor (2) Rectify/renew.
(3) Incorrect setting of controller (3) Reset the alarm/trip to default
alarm/trip values. values.
(4) 1st stage air end fault. (4) Renew 1st stage air end.
(5) 2nd stage air end fault. (5) Renew 2nd stage air end.
12 Oil pressure low (1) Low oil level. (1) Investigate for oil leaks, top up oil
level.
(2) Oil pump fault. (2) Investigate and rectify.
(3) Relief valve failure. (3) Adjust/Renew valve.
(4) Pressure sensor/switch fault. (4) Renew pressure sensor/switch.
(5) Oil cooler restriction. (5) Clean cooler.
(6) Oil filter blocked. (6) Renew oil filter element.
(7) Incorrect setting of controller (7) Reset the alarm/trip to default
alarm/trip values. values.
13 High air pressure (1) Compressor is failing to unload. (1) (a) Check/renew solenoid operated
unloader valve
(b) Check suction regulator inlet
valve closing fully. Rectify if
necessary.
(c) Check/renew shuttle valve.
(d) Check/renew suction valve
diaphragm.
(e) Check air signal supply to suction
regulator.
(2) Pressure transmitter fault. (2) Check/renew pressure transmitter.
(3) Incorrect setting of controller (3) Reset the alarm/trip to default
alarm/trip values. values.
14 Del press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
(2) Transmitter wiring fault. (2) Check and rectify fault.
15 Int.St press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
(2) Transmitter wiring fault. (2) Check and rectify fault.
16 St1 del temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Sensor wiring fault. (2) Check and rectify fault.
17 St2 in temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.
18 St2 del temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Sensor wiring fault. (2) Check and rectify fault.
19 Plant del t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.
20 Remote fault (1) Remote fault loop open circuit. (1) Find cause and rectify.
21 Extension fault (1) Fuse F3/F4 failed. (1) Check cause and rectify.
(2) Interface cable insecure. (2) Check interface cable.
(3) Extension module failure. (3) Renew Extension module.

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Shutdown Messages (continued)

Index Message Displayed Possible Cause Action required


22 Power supply (1) Supply wiring configuration incorrect, (1) Check supply wiring connections U,
motor rotation will be incorrect. V and W.
(2) Supply voltage low. (2) Check supply voltage.
23 Oil level low 1) Low oil level. (1) Check for oil leaks and rectify. Top
(start inhibit) up sump to correct level.
2) Oil level sensor fault. (2) Find cause and rectify.
3) Sensor wiring fault. (3) Check and rectify.

7.18.3 Warning Messages

Index Message Displayed Possible Cause Action required


24 Service due (1) Service countdown time expired. (1) Service compressor then reset timer.
25 Change air filter (1) Intake air filter blocked. (1) Check/renew element.
(2) Filter pressure switch fault. (2) Check operation. Renew if
(3) Filter pressure switch wiring fault. necessary.
(3) Check and rectify.
26 Change oil filter (1) Oil filter element blocked. (1) Renew oil filter.
(2) Differential pressure switch fault. (2) Check operation. Renew if
(3) Filter pressure switch wiring fault. necessary.
(3) Check and rectify.
27 Oil temperature alarm (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
filters. Inspect/clean cooler matrix.
(3) Temperature sensor/switch fault. (3) Rectify/renew.
(4) Sensor/switch wiring fault. (4) Check wiring.
(5) Low oil level. (5) Investigate for oil leaks, top up oil
level.
(6) Oil flow restriction. (6) Investigate and rectify.
(7) Incorrect grade of oil. (7) Drain/flush oil system. Refill oil
system to the correct level with the
recommended oil.
(8) Incorrect setting of controller (8) Reset the alarm/trip to default
alarm/trip values. values.
28 St1 delivery temp alarm (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
filters. Inspect/clean air coolers.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) High interstage pressure. (4) Inspect/Clean air coolers.
(5) Incorrect setting of controller (5) Reset the alarm/trip to default
alarm/trip values. values.
(6) Air flow restriction within intercooler. (6) Check differential pressure across
intercooler. Clean or renew
intercooler.
(7) 2nd stage air end fault. (7) Renew 2nd stage air end.

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CompAir Operation and Fault Finding 7

Warning Messages (continued)

Index Message Displayed Possible Cause Action required


29 St2 intake temp alarm (1) Insufficient cooling air flow. (1) Check fan operation and enclosure
filters. Inspect/clean cooler matrix.
(2) High ambient temperature. (2) Check room ventilation.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) Incorrect setting of controller (4) Reset the alarm/trip to default
alarm/trip values. values.
(5) Air flow restriction within intercooler. (5) Check differential pressure across
intercooler. Clean or renew
intercooler.
(6) High 1st stage temperature. (6) Investigate and rectify.
(7) 1st stage air end fault. (7) Renew 1st stage air end.
30 St2 delivery temp alarm (1) High ambient temperature 1) Check room ventilation
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
filters. Inspect/clean intercooler.
(3) Air flow restriction within aftercooler. (3) Check differential pressure across
aftercooler. Clean or renew
aftercooler.
(4) Temperature sensor fault. (4) Rectify/renew.
(5) Incorrect setting of controller (5) Reset the alarm/trip to default
alarm/trip values. values.
(6) High 2nd stage intake temperature. (6) Investigate and rectify.
(7) 2nd stage air end fault. (7) Renew 2nd stage air end.
31 Plant delivery t alarm (1) High ambient temperature. (1) Check room ventilation
(2) Insufficient cooling air flow. (2) Check fan operation and enclosure
air filter.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) Incorrect setting of controller (4) Reset the alarm/trip to default
alarm/trip values. values.
(5) Air flow restriction within aftercooler. (5) Check differential pressure across
aftercooler. Clean or renew
aftercooler.
(6) High 2nd stage delivery temperature. (6) Investigate and rectify.
(7) 2nd stage air end fault. (7) Renew 2nd stage air end.
32 Interstage press alarm (1) Air flow restriction within intercooler. (1) Check differential pressure across
intercooler.
(2) Faulty interstage pressure sensor. (2) Rectify/renew.
(3) Incorrect setting of controller (3) Reset the alarm/trip to default
alarm/trip values. values.
(4) 1st stage air end fault. (4) Renew 1st stage air end.
(5) 2nd stage air end fault. (5) Renew 2nd stage air end.
33 Remote Alarm (1) Remote alarm loop open circuit. (1) Find cause and rectify.
34 Start inhibit (1) Remote start inhibit loop open circuit. (1) Find cause and rectify.

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8 Components (Mechanical) CompAir

8 Components (Mechanical)
Note: Routine maintenance instructions are
given in Chapter 10, dismantling and
assembly instructions are given in Chapter 12.
Before working on any component, read the
appropriate chapter and section.

8.1 Air Intake Filter

Fig 8.1 - Typical Air Intake Filter Assembly


1. Inlet to Filter 4. Filter Element
2. Filter Body 5. Dust Box Release Clip
3. Outlet to Suction 6. Dust Dump Valve
Regulator 7. Dust Box

8.1.1 Description 8.1.2 Operation


a) The air intake filter assembly consists of a a) Intake air is drawn into the filter body via a
body (2), element (4), dust box (7) and dust tangential connection (1), passes through the
dump valve (6). element (4) from outside to inside and exits to
the suction regulator via connection (3).
b) The element can be cleaned using
compressed air but it is preferable to fit a new b) The rotary motion imparted to the air by the
one. Access to the element is obtained by tangential connection causes most of the
unclipping the dust box and pulling the heavy dust particles to be centrifuged out to
element firmly out. be collected in the dust box (7). When a
sufficient weight of dust has collected, it is
ejected via the rubber dump valve (6).

For dismantling and assembly


details, see section 12.1.1

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CompAir Components (Mechanical) 8

8.2 Aftercooler
8.2.1 Description
a) The aftercooler is fitted in the air circuit
between the second stage discharge silencer
and moisture separator, and is the uppermost
of the three cooling elements. Its function is to
cool the second stage delivery air to an
acceptable temperature prior to final delivery
from the compressor plant.
b) The air to be cooled passes through tubes in
the aftercooler which are separated by a
series of cooling fins. Cool ambient air is
drawn through the cooling fins by two fans in
the enclosure.

For dismantling and assembly


details, see section 12.3

Fig 8.2 - Aftercooler


1. Air outlet
2. Air inlet

A. Hot compressed air


B. Cooled compressed air
C. Ambient cooling airflow

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8 Components (Mechanical) CompAir

8.3 Air Pressure Relief Valve

1 1

2 2
3
3 4
5
5
7
6

7
8
8
9

10
10
11
11

SM 0757

Fig 8.3 - Typical Air Pressure Relief Valves


1. Knob 7. Spindle
2. Locknut 8. Body
3. Adjuster 9. Shroud
4. Domed nut 10. Valve head
5. Spring 11. Valve seat
6. Spring Pad

8.3.1 Description
a) Relief valves are used to prevent excessive Note: Several types of relief valve are used
pressures from damaging the compressor throughout the Oil Free Screw series. For
unit. One (D55-D90) or two (D110-D150) correct type and application, refer to the
is/are fitted to the 2nd stage inlet pipe at the relevant parts catalogue.
interstage moisture separator and the other is
d) Air pressure relief valves are factory set and
fitted in the discharge manifold.
should not be adjusted. In the event of failure,
b) When the valve operates, pressure is the valve should be removed from the
released to atmosphere through holes in the compressor and serviced in accordance with
valve body. the manufacturer's instructions.
c) The valve comprises a body (9) and plunger 8.3.2 Operation
assembly. The plunger assembly consists of a
a) When air pressure exceeds the relief setting,
spindle (7), knob (1), locknut (2) and valve
the plunger is forced off its seat against spring
head (10). A spring (5) holds the plunger
pressure, allowing the air to vent to
assembly against the valve seat (11) when
atmosphere through holes in the valve body.
the valve is not operating. An adjuster (3) is
When pressure in the line falls below the relief
threaded into the valve body to allow for
setting, spring pressure acts on the plunger to
adjustments to the relief settings.
re-seat the valve.

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8.3.3 Description - valves with knurled top cover


a) This valve is comprised of an upper body (7)
which is screwed into a lower body (9). The
upper body contains a knurled top cover (2),
threaded adjuster (3), spring retainer (4),
spring (5), spring plate (8) and valve stem
(12). Atmospheric vents (6) allow the valve
parts to move.
b) The lower body contains the valve head (11)
and main vents (10).
c) To ensure that the valve does not become
stuck shut, the knurled top cover (2) is
threaded so that when it is turned by hand, it
lifts the stem and valve against the pressure
of spring (5). The valve re-seats when the
cover is turned back again.
d) An adjuster (3) is threaded into the valve body
to allow for adjustments to the relief settings at
the factory.
e) Safety valves are factory set and must not be
adjusted. In the event of failure, the valve
should be removed from the compressor and
serviced in accordance with the
Fig. 8.4 - Air Pressure Relief Valve
manufacturer's instructions.
with Knurled Top Cover
8.3.4 Operation - valves with knurled top cover
1. End Cap 7. Upper Body
a) When air pressure exceeds the lift setting, the 2. Knurled Cover 8. Spring Plate
valve head is forced off its seat against spring 3. Adjuster 9. Lower Body
pressure, allowing the air to vent to 4. Spring Retainer 10. Main Vents
atmosphere through holes in the valve body. 5. Spring 11. Valve Head
When pressure in the system falls below the 6. Atmospheric Vent 12. Valve Stem
re-seat setting, spring pressure acts on the
valve stem to close the valve.
8.3.5 Air Pressure Relief Valve Settings

Interstage Final Delivery


Model Relief Valve Relief Valve
Lifts At (bar) Lifts At (bar)
D55 to D150 3.5 11.4

DL051AAA 89
8 Components (Mechanical) CompAir

8.4 Check Valve

SM 1004

2
1

Direction
3 of Flow

Fig. 8.5 - Check Valve


1. Spring 3. Circlip
2. Valve Plate 4. Housing

8.4.1 Description 8.4.2 Operation


a) A check (non-return) valve is fitted within the a) When the compressor is on load, air pressure
second stage discharge silencer. beneath the valve plate overcomes the spring
and the valve lifts to allow full air flow.
b) The purpose of the valve is to prevent air in
the user’s system from exhausting back b) When the compressor runs off load or shuts
through the air-ends when the compressor down (whether on standby or at the end of the
runs off load or shuts down. workshift), air pressure is removed from
beneath the valve plate. The combination of
c) The check valve components within the
spring pressure plus back pressure from the
silencer consist of a spring (1) and valve plate
customer's air main then returns the valve
(2), the spring being retained in the housing
plate to its seat and isolates the compressor
(4) by a circlip (3).
from any back pressure from the customer's
air main.

90 DL051AAA
CompAir Components (Mechanical) 8

8.5 Condensate Drains and Manifold


8.5.1 Description
a) The condensate manifold assembly allows
condensate collected from the two moisture
separators to be drained from the machine at
programmed intervals.
8.5.2 Operation
a) The manifold incorporates 12 ports (six for
each drain). Condensate enters the manifold
(1) at port A and passes through a strainer (2)
and port B to the solenoid valve (4). When the
solenoid is energised, the valve opens and
the condensate is then allowed to pass
through port C to drain at port D.
b) Access to the condensate strainer (2) is
achieved by removing the brass plug (3)
located at the service port E. A manual drain
(5), which is normally closed, allows
condensate to drain from the manifold,
by-passing the solenoid valve and is also
used for servicing purposes.
c) The two condensate strainers prevent any
foreign matter from blocking the solenoid
drain valves.

Fig. 8.6 - Condensate Drains and Manifold


1. Body
2. Strainer
3. Brass Plug
4. Solenoid Valves
5. Manual Drain

A. From Moisture Separator


B. To Solenoid Valve
C. From Solenoid Valve
D. Automatic Drain Point
E. Access To Strainer

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8 Components (Mechanical) CompAir

8.6 Discharge Silencer (Second Stage)

SM 0813
A

Fig. 8.7 - Second Stage Discharge Silencer

8.6.2 Operation
8.6.1 Description
a) Air from the second stage air-end enters the
a) The discharge silencer fitted to the second silencer at port (A) and passes through the
stage air delivery pipe reduces the noise and check valve at port (B) to the aftercooler at a
pulsations from the second stage delivery much reduced noise level.
outlet.
b) A regulation system connection is fitted to port
b) The silencer consists of a welded body (C), which provides pressure to a diaphragm
containing a perforated tube which is operated balance piston fitted to the male
surrounded by two layers of steel mesh and rotor of the second stage compression
steel wool. element.
c) The discharge end (B) incorporates a check c) In the off-load condition, air at low pressure
(non-return) valve. enters the silencer through port A. As its
pressure is not great enough to open the
check valve, the air passes through port D
which is connected to the suction regulator
exhaust or the by-pass valve.
d) A temperature probe is fitted to the discharge
silencer at E.

92 DL051AAA
CompAir Components (Mechanical) 8

8.7 Dump Silencer 8.7.3 Current models


Current models contain a wire gauze silencing
element retained within the body by a
perforated plate.
1 2 3 4

5 5

6
7

Fig. 8.9 - Dump Silencer (Current Models)

SM 1099

Fig 8.8 - Dump Silencer (Earlier Models)


1. Body 5. End Plate
2. Perforated Tube 6. Perforated Body
3. Solid Baffle 7. Gauze Silencing
4. Mineral Wool Element

8.7.1 Early models


a) The dump silencer is fitted to the blow down
line of the suction regulator by-pass valve. It is
used during the off-load condition to decrease
the noise of air discharging from the air-ends.
b) The silencer is cylindrical, and consists of a
body (1) fitted with an internal perforated tube
(2). A solid baffle (3) is positioned in the
middle of the perforated tube to divert the air
flow. The rounded end plates (5) are designed
to assist the air to escape from the silencer.
8.7.2 Later models
Silencers used on later machines are simpler
in construction and consist of a hollow
perforated body (6) inside which is secured a
wire gauze silencing element (7).

DL051AAA 93
8 Components (Mechanical) CompAir

8.8 Intercooler
8.8.1 Description
a) The intercooler is fitted between the first stage
air-end and the interstage moisture separator.
Its function is to cool the first stage delivery air
prior to second stage compression.
b) The air to be cooled passes through tubes in
the intercooler which are separated by a
series of cooling fins. Cool ambient air is
drawn through the cooling fins by two fans in
the enclosure.

For dismantling and assembly


details, see section 12.4

5
4
3

2 SM 1051

Fig. 8.10 - Intercooler


1. Air inlet
2. Temperature sensor
(D55-D90)
3. Air outlet
4. Temperature sensor
(D110-D150)
5. Pressure sensor

A. Hot compressed air


B. Cooled compressed air
C. Ambient cooling airflow

94 DL051AAA
CompAir Components (Mechanical) 8

8.9 Moisture Separator 8.9.3 Moisture held in suspension in the


compressed air passing through the separator
is removed using the principles of centrifugal
force, impingement separation and laminar
and turbulent flow.
8.9.4 The condensate collects in the bottom of the
housing and is released automatically through
a solenoid valve operated drain connected to
the bowl.

7 2

HW 0300
3
Fig. 8.11 - Moisture Separator - Second
Stage (Top Entry)

8.9.1 The compressor is equipped with two


moisture separators to remove contamination
from the delivery air. The interstage moisture
separator is installed at the inlet to the second
stage air end, with the second stage moisture
separator being installed at the aftercooler
outlet, below the discharge manifold.
8.9.2 While the moisture separators vary slightly in
external appearance, their method of
operation is identical.

4
SM 0994

Fig. 8.12 - Moisture Separator -


Interstage (Side Entry)
1. Housing 4. Bowl
2. Inlet Port 5. Spinner
3. Impinger Cone 6. Outlet Port

DL051AAA 95
8 Components (Mechanical) CompAir

8.10 Oil Breather (Earlier Models) 8.11 Oil Removal Filter (Current Models)

3,4 SM 1038
2

2 6
5

SM 0743

Fig. 8.13 - Oil Breather


1. Perforated gauze
4
2. Cover
7
3. Screw
4. Washer
5. Cage nut
5
8.10.1 Description
8
The oil breather consists of several layers of
nylon bonded material surrounded by a Fig. 8.14 - Oil Removal Filter
cylindrical perforated gauze (1). The top is 1. Filter Body
closed by a cover (2) which is secured by the 2. Filter Inlet
screw (3) and washer (4). The bottom plate 3. Carbon Filter Element
contains the inlet/outlet port and the cage nut 4. Automatic Drain Valve
(5). 5. Bleed Valve
8.10.2 Operation 6. Oil Free Air Outlet
7. Sight Glass
This device is used to condense the oil mist 8. Oil Return Pipe.
formed above the oil level in the reservoir.

8.11.1 Description
a) The oil removal filter utilised in the powered
breather system is a coalescing filter
consisting of a filter body, Grade D activated
carbon filter element, automatic oil drain and
sight glass.
b) The carbon in the filter element is of a fine
granular form which offers maximum surface
area. A layer of high efficiency filter material
then traps any carbon dust which may have
been released. Grade D activated carbon
filters operate on the absorption principle.

96 DL051AAA
CompAir Components (Mechanical) 8

8.11.2 Operation:-
a) The air and oil vapour mix enters the filter
body and passes, from the inside of the filter
element to the outside, through a deep bed of
activated carbon where the oil vapour is
filtered from the air.
b) The oil vapour liquifies and drops to the
bottom of the filter body and is returned to the
oil sump via the auto drain and reclaiming
pipe. The oil free air exhausts through the
side of the filter body vent into the machine's
enclosure.
c) The sight glass gives an indication of the
current oil level within the filter base and
provides a visual check of correct auto drain
operation.
d) The bleed valve enables rapid
depressurisation of the filter. 1

For more details of how this component is


2
utilised within the powered breather system,
please refer to section 4.12.

8.12 Oil Cooler


8.12.1 Description
The oil cooler is fitted in the circuit between 4
the oil pump and first stage air end, and is the
lowermost of the three cooling elements. Its
function is to cool the circulating oil. 3 SM 1052
8.12.2 Operation
Fig. 8.15 - Oil Cooler
The oil to be cooled passes through tubes in
the oil cooler which are separated by a series 1. Oil outlet
of cooling fins. Cool ambient air is drawn 2. Temperature sensor
through the cooling fins by two fans in the 3. Oil drain point
enclosure. 4. Oil inlet

A. Hot oil
For dismantling and assembly B. Cooled oil
details, see section 12.5 C. Ambient cooling airflow

DL051AAA 97
8 Components (Mechanical) CompAir

8.13 Oil Pressure Relief Valve

A
B

11

10

9
8
7
6
5
4
3
2
1
SM 0986

Fig. 8.16 - Oil Pressure Relief Valve


1. Adjusting Screw Cap 7. ‘O’ Ring A. Oil From Filter
2. Washer 8. Spring B. Feeds To Oil Circuit
3. Adjusting Screw 9. Spool C. Oil To Relief Valve
4. Nut 10. Body D. Pressure Relief to Sump
5. Relief Valve Cap 11. Joint
6. Retaining Spring Cap

8.13.1 Description 8.13.3 If oil pressure rises above 2.5 bar (when the
compressor starts up from cold, for example),
The relief valve is attached to the air-end gear
it overcomes the pressure of spring (8). The
casing and ensures that system pressure is
spool then moves to progressively uncover
maintained at 2·0 bar to 2·5 bar (all models).
the "outlet" port from the valve, thereby
8.13.2 Operation allowing excess pressure to be relieved back
into the sump (D).
a) Oil from the oil pump is delivered at (A), from
where it branches off to feed the various oil
circuits within the machine (B). It can also For dismantling and assembly
pass to the "inlet" end of the relief valve at (C) details, see section 12.12
via internal porting, where it acts against the
face of the spring-loaded valve spool (9)

98 DL051AAA
CompAir Components (Mechanical) 8

8.14 Oil Pump

2
3
4
5
6
7
8
9
10

11
12
13
18

17
16

15
14
SM 0980

Fig. 8.17 - Oil Pump


1. Adaptor plates 7. Needle bearing 13. Pump cover
2. Motor half coupling 8. Pump body 14. Capscrew
3. Coupling insert 9. Drive key 15. Washer
4. Pump half coupling 10. Inner/outer gearotor 16. Capscrew
5. Circlip 11. Needle bearing 17. Washer
6. Oil seal 12. 'O' ring 18. Dowel pin

8.14.1 Description
The pump is part of a closed oil system which
supplies oil under pressure to the driving
gears, timing gears, jacket cooling and
bearings of the two stage air-end. The pump
is driven by a 1·5 kW, 3 phase electric motor
which is operated from the main power
supply.

For dismantling and assembly


details, see section 12.7

DL051AAA 99
8 Components (Mechanical) CompAir

8.15 Shuttle Valve

C2

C3

C1
C3
A
C2
2
C1
1

A B

Fig. 8.18 - Shuttle Valve

8.15.1 Description 8.15.2 Operation


a) The shuttle valve is an integral part of the a) When pressure is passed to ports (A) & (B),
suction regulator body. the higher of the two pressures acting upon
the diaphragm closes the opposing port and
b) Its purpose is to connect the higher of two
directs that pressure to chamber (C). This is
pressures to a third connection.
then ported, within the manifold, to a further
c) The shuttle valve is housed in an 8 port three airways (C1), (C2) and (C3).
control manifold. It consists of a coupling (1),
b) For more detail on the operation of the shuttle
seal (2) and shuttle valve diaphragm (3). The
valve within the context of the regulation
diaphragm can move freely to connect port
system, please refer to section 4.7.
(C - common) to inlet port (A) or (B),
depending on which of these two ports is
passing the highest pressure.

100 DL051AAA
CompAir Components (Mechanical) 8

8.16 Suction Regulator 8.16.2 Operation

See fig. 8.21 a) ON LOAD

8.16.1 Description Atmospheric pressure is passed from the


shuttle valve via the energised unloader
a) The suction regulator assembly comprises solenoid valve to the diaphragm chamber. A
three separate compartments, the regulator depression is created in the spring end of the
body (1), diaphragm chamber (2) and by-pass chamber via the air intake and unloader
valve box (3). Each compartment is solenoid valve. The pressure differential
connected by a common sliding stem (11) across the diaphragm causes the valve stem
mounted in sealing sleeves (5 & 10) and to move, opening the inlet valve and closing
containing the inlet valve (12), diaphragm the by-pass valve.
assembly (7) and by-pass valve (4).
b) The regulator body contains the inlet valve
(12) which is held against its seat by spring
pressure during offload running or when the
compressor is stopped. This pressure is the
result of two springs (6) mounted one inside
the other on the stem in the diaphragm
chamber. The inlet valve plate is fitted with
'metered orifice' plugs (13) which provide the
first stage air-end with a reduced air supply.
This causes a depression within regulator
body (1) which is utilised by the system
regulation components during start and Fig. 8.19 - Suction Regulator (On-Load)
off-load running.
c) The diaphragm chamber consists of a
diaphragm (7) attached to the valve stem (11) b) OFF LOAD
and sandwiched at its perimeter, between two The unloader solenoid is de-energised,
flanges. Each side of the diaphragm chamber directing pressure to the spring end of the
is connected to the unloader solenoid valve, chamber and connecting the diaphragm
by ports in the two flanges (8 & 9). chamber to suction at the air intake. As the
d) The by-pass valve box contains a by-pass inlet valve begins to close, pressure from the
valve (4) assembly attached to the end of the first stage air-end decreases. This in turn
valve stem by a screw and washer. With the allows atmospheric pressure to overcome first
compressor in the stopped or unloaded stage pressure at the shuttle valve.
condition, spring pressure acting on the Atmospheric pressure is now directed via the
diaphragm support holds the by-pass valve off shuttle valve to the spring end, thus further
its seat, allowing compressed air trapped assisting the springs to close the inlet valve
between the air-ends to escape to and open the by-pass valve.
atmosphere.

For dismantling and assembly


details, see section 12.2

Fig. 8.20 - Suction Regulator (Off-Load)

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FIG. 8.21 - Suction Regulator


1. Regulator Body 8. Port
2. Diaphragm Chamber 9. Port
3. By-Pass Valve Box 10. Seal
4. By-Pass Valve 11. Valve Stem
5. Seal 12. Valve Plate
6. Springs 13. Metered Orifices
7. Diaphragm Assembly

102 DL051AAA
CompAir Components (Electrical) 9

9 Components (Electrical)
9.1 Air and Oil Pressure Sensors 9.2 Oil Pressure Switches and Sensors

SM 0755

Fig 9.1 - Air Pressure Sensor

9.1.1 Description
The system oil pressure and the air pressure
at the interstage and in the user’s pipework is
continuously monitored by 4-20 mA pressure
sensors which convert pressure into an
electrical signal.
9.1.2 Operation
Fig. 9.2 - Oil Pressure Switch
a) A sensor converts air pressure into a linear
change of electrical current flowing in the two
power supply wires. Typically, the current will
Two types of oil pressure switch have been
change from 4 mA at 0·0 bar to 20 mA at 13·8
fitted to this range of compressors; type A was
bar.
used on early machines with type B being
b) The controller detects the current flowing in used on current machines
the 24 Volt DC power supply wires to the
9.2.1 Type A (early machines)
sensor, then processes and converts this
signal into a displayed pressure reading. a) Two normally open (NO) oil pressure switches
are fitted in the oil circulating system. The
c) The controller can recognise an ‘out of range’
switches provide lubricating oil pressure
signal from the pressure sensors. This will be
protection for the compressor.
displayed as a pressure probe fault.
b) When oil pressure is above 1.5 bar, the switch
Pressure (Bar) D.C. Current (mA) contacts will close. If the pressure in the
0·0 4·00 system falls below 1.5 bar, the switches will
1·0 5·16 open and signal the controller to stop the
compressor and a shutdown message 'Oil
2·0 6·32 Pressure Low' will be displayed on the
3·0 7·48 control panel.
4·0 8·64 9.2.2 Type B (later machines)
5·0 9·80 a) One oil pressure sensor is fitted in the oil
6·0 10·96 circulating system. The sensor provides
lubricating oil pressure protection for the
7·0 12·12
compressor.
8·0 13·27
b) When oil pressure is above 1.5 bar, the
9·0 14·44 controller can start the motor. If the pressure
10·0 15·60 in the system falls below 1.5 bar, the
controller will stop the compressor and a
11·0 16·75
shutdown message 'Oil Pressure Low' will be
12·0 17·91 displayed on the control panel.
13·0 19·07

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9.3 Phase Rotation Relay 9.3.2 Operation


a) If the phase rotation U-V-W (Red-Yellow-Blue)
of the main incoming three phase power
supply is detected to be incorrect, the output
contact of the relay opens circuit. The open
circuit contact switches off input I9 on Input
card 1 which signals a reverse rotation fault
condition to the controller. Incorrect phase
rotation of the main incoming power supply
will cause the main motor, fan motor and oil
pump motor to rotate in the wrong direction.
b) In correct running conditions, the green LED
status indicator (5) is lit continuously, whereas
shutdown due to a fault is indicated by the
LED flashing.

9.4 Drive Motor Thermistors


9.4.1 Description
The drive motor is equipped with a set of
three thermistors of the PTC type to protect
the compressor against motor
over-temperature. A thermistor is buried in the
windings of each coil. These are connected in
Fig 9.3 - Phase Rotation Relay series so that the motor will stop if any one of
the thermistors is activated.
1. U (Red) Phase connection terminal
2. V (Yellow) Phase connection terminal 9.4.2 Operation
3. W (Blue) Phase connection terminal If the temperature of any of the coil windings
4. Output contact connections exceeds a set temperature, the resistance of
5. Status indicator the thermistor in that coil will increase sharply.
6. Voltage selector (Type A only) The increase in resistance affects the input
state to the preconditioner card. This activates
the fault input on the input card which shuts
Two types of relay are used on this range of down the compressor.
compressors; type A and type B. The purpose
of the phase rotation relay is to monitor for
correct incoming supply phase rotation
sequence and phase-to-phase voltage. If any
is found to be incorrect, the relay trips and the
machine will stop.
Caution: The device will reset itself when
the incoming supply fault has been
corrected.
9.3.1 Description
a) The phase rotation relay monitors the phase
rotation and voltage of the three phase main
incoming power supply to the compressor.
The output of the relay is a volt free contact
which changes state if the rotation is detected
to be incorrect.
b) The voltage selector (6) must be adjusted to
suit the main power supply voltage (type A
only).

104 DL051AAA
CompAir Components (Electrical) 9

9.5 Oil Level Sensor 9.6 Oil Filter Differential Pressure


Switch

1 2

Minimum Oil level


50mm

SM 1068

Fig. 9.4 - Oil Level Indicator/Sensor Fig. 9.5 - Oil Filter Differential Pressure Switch
1. Differential Pressure Switch
2. Filter Head

9.5.1 Description 9.6.1 Description


a) This component is mounted on a bracket in a) The microswitch is located on top of the filter
front of the intercooler. Two pipes connect this head and monitors pressure drop across the
sensor to ports in the wall of the oil storage oil filter element. When the differential
tank. Its purpose is to give a visual indication reaches a pre-set value, the switch will
of the oil level within the tank and to operate and ‘Change oil filter’ will be
continuously monitor that oil level. displayed.
b) In addition, the sensor is electrically b) If a switch fault develops, a new switch should
connected into the control system, to which it be fitted as there are no user-serviceable
will pass a signal in the event of the oil parts inside.
quantity dropping to a pre-determined level
(50mm above the centre of the lower banjo
bolt).
9.5.2 Operation
a) The oil level sensor incorporates electrical
contacts which are closed during normal
operation (N/C).
b) Should the oil level drop to the pre-determined
level, the contacts open and a signal is thus
passed to the machine's control system.

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9.7 Temperature Sensors

KTY PT1000

SM 0741

Fig. 9.6 - Temperature Sensors

Resistance (ohms)
9.7.1 Description Temp °C
KTY PT1000
a) Two types of silicon temperature sensors of
0 1640 1000
the ‘spreading resistance’ type are used in
these plants. 10 1784 1039

b) The KTY type covers a temperature range 20 1928 1077.9


from below 0°C to 150°C and are installed in 30 2080 1116.7
the plant delivery, intercooler exit, oil cooler 40 2240 1155.4
exit and cool air intake.
50 2400 1194
c) The PT1000 type covers a temperature range
60 2584 1232.4
from below 0°C to 250°C and are installed in
the 1st & 2nd Stage delivery silencers. 70 2768 1270.8

d) The electrical resistance of both sensors 80 2960 1309


increases with temperature as indicated in the 90 3160 1347.1
following table. 100 3360 1385.1
9.7.2 Operation 110 3576 1422.9
The resistance of the temperature sensors is 120 3792 1460.7
processed within the controller and displayed 130 – 1498.3
as a temperature reading. A high temperature
alarm and/or compressor shut-down is 140 – 1535.8
activated if the temperature reaches the 150 – 1573.3
programmed alarm/trip settings. 160 – 1610.5
170 – 1647.7
180 – 1684.8
190 – 1721.7
200 – 1758.6
210 – 1795.3
220 – 1831.9

106 DL051AAA
CompAir Components (Electrical) 9

9.8 Unloader Solenoid Valve (3 Way)

A A

C B C B

De-energised Energised

Fig. 9.7 - Unloader Solenoid Valve (3 Way)

9.8.1 Description 9.8.2 Operation


a) The two unloader solenoid valves, part of the a) When the valves are in their normal
regulation system, are both identical in (un-energised) state, port B is closed and air
appearance and operation. However, the can only be passed to and from ports
valve connecting directly to interstage A and C.
(mounted on the left of the manifold above the
b) When the valves are in their switched
shuttle valve) is designed to operate at higher
(energised) state, port A is closed and air can
pressures than the valve connecting to the
then only be passed to and from ports
inlet port (mounted on the right) so they are
B and C.
not interchangeable.
c) For information on how these valves operate
b) The valves incorporate 3 ports, A, B and C
in the context of the regulation system, please
(common).
refer to section 4.7.
Note: These letters refer only to fig 9.6 and
9.8.3 These solenoid valves are not serviceable
not to letters that may appear on the valve
and should be renewed if a fault occurs.
body.

For dismantling and assembly


details, see section 12.11

DL051AAA 107
9 Components (Electrical) CompAir

9.9 Condensate Drain Solenoid Valve


(2-Way N/C)
9.9.1 Description
The valve assembly consists of a body (1) to
which the armature guide and tube containing
the plunger (5), seals (2, 3) and springs (6) is
attached. The coil is pushed over the guide
tube and thus isolated from the medium. The
medium is only in contact with the valve
internals and body.
9.9.2 Operation
a) At pre-determined intervals, the controller
opens the condensate drain valves to drain
any accumulation of moisture which will build
up within the machine, particularly in humid
climates.
b) During normal running, spring (6) holds the
seal and plunger (2, 5) closed on the valve
seat so no condensate moisture can pass
through the valve to drain. Fig. 9.8 - Condensate Drain Solenoid Valve
(2 Way Normally Closed)
9.9.3 When a drainage interval occurs, the
controller passes a current through the 1. Body 7. Shading Ring
contacts (10) and coil. This sets up a 2. Plunger-seal 8. Stopper
magnetic field which acts on the plunger (5) 3. '0' Ring 9. Locknut
and causes it to open against the pressure of 4. Armature 10 Electrical
spring (6). Any accumulated moisture can Guide Tube Contacts
then pass through the valve body to drain. 5. Plunger 11 Bonnet
6. Spring 12 Flange

108 DL051AAA
CompAir Components (Electrical) 9

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DL051AAA 109
10 Maintenance CompAir

10 Maintenance
10.1 Routine Maintenance c) It is recommended that service and
maintenance is carried out by your local
WARNING CompAir Distributor.
d) All CompAir compressors are fitted with high
performance filtration equipment. However, if
• Refer to the safety procedures before the working environment is particularly hostile
carrying out any maintenance or
the filter elements and the heat exchangers
servicing work on the compressor unit. .
will require attention at more frequent intervals
• Lethal voltages are used in this than specified in the schedule.
equipment. Use extreme caution when
10.1.2 Cleanliness
carrying out electrical checks. Isolate the
power supply before starting any The compressor unit must be kept in a clean
maintenance work. condition at all times. Make regular
inspections for signs of damage, excessive
• Where a maintenance procedure below wear and security of fittings. Ensure that any
includes the warning ‘The compressor
oil spillage is wiped up immediately and any
must be stopped’ the following steps
residual oil cleaned from external surfaces.
must be taken before work is
commenced: Caution: Do not allow oil to enter the air
intake, air system components or air
1. Close the isolating shut-off valve to the
system pipework.
user’s pipework. Attach a label carrying
the warning ‘WORK IN PROGRESS – 10.1.3 Recording Pressures and Temperatures
DO NOT OPEN’.
Keep a regular record of the compressor
2. Switch the power supply ‘OFF’ at the operating pressures and temperatures by
isolator. noting the value readings, together with
ambient air temperature, in a record book.
3. Attach a label carrying the warning
The readings should be taken when
‘WORK IN PROGRESS – DO NOT
conditions are stable and with the compressor
APPLY VOLTAGE’ to the isolator switch
running on full load.
and to the display panel. Do not switch
on electrical power or attempt to start the 10.1.4 Maintenance Record
unit if such a warning label is attached.
Keep a careful record of all servicing,
4. Bleed down all air pressure in the maintenance and repair work carried out on
delivery pipe between the non-return the compressor. This record will form a useful
valve and the shut-off valve by opening reference. Any variation from normal
the manual condensate drain valves. operation will be noticeable immediately,
alerting the user to a possible need for
servicing or maintenance. The frequency of
10.1.1 General
recurrence of a particular repair task could
a) To ensure the efficient operation of the reveal an unsatisfactory operating condition
compressor unit the user must check which should be corrected.
performance regularly and carry out the
10.1.5 Electrical Connections
necessary adjustments to maintain correct
settings. This section gives the information a) Regularly check the compressor unit for loose
needed by the user for this purpose. connections or frayed wiring. Clean and
tighten all connections and repair or renew all
b) It is a condition of the Warranty cover that the
frayed or damaged wires and cables before
unit is properly maintained and adjusted, that
starting up.
all checks, routine maintenance and regular
servicing listed in the Maintenance Schedule b) Take care not to damage the wiring when
are carried out at the specified intervals and working on the unit. When refitting wires and
that an accurate record is kept of the work. cables make sure they are not damaged and
that they will not be damaged in service by
chafing or contact with a hot surface.

110 DL051AAA
CompAir Maintenance 10

10.1.6 Leaks 10.1.8 Regular Checks


Warning: Risk of high pressure The ‘Maintenance Schedule’ lists the routine
checks and services which are important to
a) Do NOT use hands to locate leaks in the
the efficient running of the unit. The user
system. Always use a piece of paper or card
should ensure that the Weekly Checks
for this purpose.
become an integral part of planned
b) Inspect the unit as a matter of course when maintenance, even if the major servicing work
carrying out servicing or maintenance for any is contracted to a CompAir Distributor.
sign of leaking pipe connections, a build-up of
10.1.9 Lubricating Oil
dirt or debris and oil leaks. Repair or replace
damaged or leaking pipe or hose connections It is essential to maintain the correct level of
immediately. oil and to change the oil completely at the
specified intervals.
10.1.7 Prestolok Instant Pipe Connection System
Control air flexible pipes and Prestolok pipe
connections are used throughout the
compressor. Prestolok pipe connections are a
compact instant brass fitting for flexible pipes,
specially designed for pneumatic installations.
a) Assembly
(i) Push the cover ring onto the pipe.
(ii) Insert the pipe into the fitting until the pipe
bottoms.
(iii) Pull the pipe to ensure secure engagement
of the grip ring teeth.
(iv) Clip the cover ring onto the fitting.
b) Dismantling
(i) To remove a pipe, disengage the cover
and disengage the grip ring teeth by
manually applying pressure on the push
ring sleeve and withdrawing the pipe and
cover ring from the fitting.

DL051AAA 111
10 Maintenance CompAir

10.2 Maintenance Schedule motor bearings may need to be lubricated


more often than the recommended service
10.2.1 Regular maintenance should be carried out as period (see motor nameplate for details).
recommended in the Schedule below. The
Schedule is appropriate to most
circumstances but, in some instances, 10.3 Recommended Maintenance Parts
changes in detail may be required. The Covering 2 years average operation or 16000
Schedule should always be used as a guide hours running.
initially, but if experience shows that an
alteration is necessary, advice should be Note: For the latest kit contents refer to the
sought from the local CompAir office. 'Oil Free Screw Parts Guide' which can be
downloaded from the secure website (After
10.2.2 In conditions of high ambient Market Division) at https://info.compair .com
temperature/humidity and/or dirty conditions
all filters may need to be renewed more often Every Kit Description / Part No.
than the recommended service period. Renew
the filters when 'CHANGE AIR FILTERS' is 4000 Hours Balance Piston Diaphragms
indicated on the control system. 8000 Hours Minor S/Kit CK3100-3
10.2.3 In conditions of high ambient 16000 Hours Major S/Kit CK7100-4
temperature/humidity and/or dirty conditions

Note: The oil change period can be extended to 16000 hours or 24 months if oil condition monitoring indicates this to be satisfactory.

112 DL051AAA
CompAir Maintenance 10

Fig. 10.1 - Servicing Points


1. Drive Coupling 6. Intercooler 11. Oil Filler
2. Check Valve 7. Oil Cooler 12. Oil Removal Filter - Powered Breather
3. Unloader Valve 8. Balance Piston Diaphragm 13. Press. Reg. - Powered Breather
4. Aftercooler 9. Oil Filter 14. Intake Air Filter
5. Condensate Drains 10. Oil Reservoir 15. Motor Bearings

DL051AAA 113
10 Maintenance CompAir

10.4 Torque Schedule


10.4.1 Incorrect tightening of air pipework flange
bolts may cause premature failure of the
gaskets. All flange bolts should be tightened
in accordance with the torque schedules
below and re-checked at every 4000 hour
service. The bolts should be tightened in a
sequence of diametrically opposite pairs to
ensure even loading.

Location Bolt Size Qty Tightening Torque, Nm


Suction regulator to 1st stage inlet M12x1.75 4 50
1st stage outlet to silencer M16x2 4 125
Flexible pipe(s) to pipework (3 positions) M16x2 4 125
Flexible pipe(s) to coolers (3 positions) M16x2 4 125
2nd stage inlet pipe to separator M12x1.75 4 50
Separator to 2nd stage inlet adaptor M12x1.75 4 50
2nd stage inlet adaptor to 2nd stage inlet M12x1.75 4 50
2nd stage outlet to silencer M12x1.75 4 50
2nd stage outlet pipe to silencer M16x2 4 125
Discharge manifold to cooler M16x2 4 125
Expansion joint to manifold M16x2 4 125
Expansion joint to separator M16x2 4 125
Blowdown elbow to 2nd stage silencer M8x1.25 2 15
Non-pipework fastenings M16x2 - 125
Non-pipework fastenings M12x1.75 - 50
Non-pipework fastenings M10x1.5 - 29
Non-pipework fastenings M8x1.25 - 15
Non-pipework fastenings M6x1 - 6
Non-pipework fastenings M5x0.8 - 3.4

114 DL051AAA
CompAir Maintenance 10

10.5 Enclosure Filters 10.6.7 To clean the element by air blast:

10.5.1 The compressor is provided with five coarse Caution: Do not use high pressure air
screen filters in the panels of the enclosure. supply.
These act as pre-filters for the intake, a) Using an air line supplying dry, low-pressure
ventilation and cooling air. air (maximum 0·5 bar) carefully blow out the
10.5.2 Carry out a regular visual check of the inner cavity, ensuring that the air stream
condition of the enclosure filter elements. If passes through the element from the clean
the elements are seen to be heavily side.
contaminated they should be cleaned as b) When all contamination has been removed,
follows: inspect the element for cracks, holes or other
a) Open the enclosure door complete with damage by holding the element up against a
integral filter. light source. If any damage is evident the
element must be discarded and a new one
b) Remove the filter element and wash carefully fitted.
in a mild detergent solution. Rinse thoroughly
and allow to dry. 10.6.8 Re-install the clean element in the filter body
and refit the dust box.
c) Refit the element to the panel and close the
door.
10.7 Condensate Drains
10.6 Intake Air Filter 10.7.1 Moisture present in the compressed air
condenses in the interstage and second stage
10.6.1 The servicing intervals required by the intake moisture separators and is drained by
air filter will depend on the dust conditions solenoid operated valves.
prevailing on site.
10.7.2 To check the operation of the condensate
10.6.2 It is always better to renew the intake air filter drain valves:
element rather than to try to clean it. In any
cleaning operation, however carefully done, With the compressor running on load,
there is a risk of critical damage to filter disconnect the condensate drain connection
efficiency and dirt particles remaining on the at the baseframe and check visually that
element or being carried over to the clean condensate is being released automatically
side. according to the drain open and shut times
programmed into the controller. If no
10.6.3 Whenever the intake air filter element is condensate is being released, stop the
removed, check the sealing surfaces for signs compressor, switch power off at the isolator,
of dust tracking and rectify if necessary. clean the strainer and check the wiring.
Check that the rubber dust valve is in good
condition and is operating correctly.
10.6.4 Before carrying out any work on the intake air
filter the compressor must be stopped.
10.6.5 To change the element (see fig. 8.1):
a) Remove panels as required to gain access to
the intake air filter.
b) Remove the intake air filter dust box, take out
the element and discard.
c) Clean the inside of the filter body and dust
box.
d) Fit the new element in the filter body and refit
the dust box.
10.6.6 Always fit a new filter element at the specified
service intervals. However, if cleaning must
be resorted to, carry out the following
procedure.

DL051AAA 115
10 Maintenance CompAir

10.8 Condensate Strainers c) If the oil level is low, remove the cap from the
filler pipe and gradually top up the reservoir
4 until the float reaches the top of the indicator.
3 2 After each small quantity has been added
allow time for the change in level to be
indicated on the sightglass. This will prevent
overfilling.
4
d) Refit the cap to the oil filler pipe.
e) Close the service door.
10.9.2 To change the oil:
The compressor must be stopped
Drain the oil while the compressor is hot to
1
allow the oil to run freely and carry out any
2 suspended particles.
3
a) Remove enclosure doors as required.

SM 1041
b) Position suitable containers under the drain
hoses.
Fig. 10.2 - Manual Drain Valves and c) Enter ‘Test digital outputs’ mode on control
Strainer Gauzes panel, fit handle to 2 way valve and move to
drain position(fig. 10.3). Run pump until sump
is empty.
10.8.1 To clean the strainers: Caution: Do not run pump dry.
The compressor must be stopped Feed from
Oil pump
a) Manually drain condensate from the manifold
via the two manual drain valves (3).
b) Unscrew brass plugs and washers (1, 2) from
to drain pipe
the manifold and remove strainer gauzes (4).
c) Clean the strainer gauzes under running
water or renew if badly contaminated or
damaged. Rotate quarter turn
anticlockwise to
d) Refit gauzes and plugs to manifold and check drain position
operation. SM 2002

10.9 Oil System Fig. 10.3 - Valve in Drain Position

10.9.1 To check the oil level:


d) On earlier machines, remove and clean the oil
The compressor must be stopped breather canister (see para 10.9.4 ‘To Clean
Note: Allow a minimum of 30 minutes after the Oil Breather Element’). Machines
stopping for the oil in the system to settle. incorporating a powered breather system do
not have this item fitted.
a) Open the enclosure to gain access to the oil
filler and sightglass. e) Open oil cooler drain tap and drain oil into a
container. Close drain tap and move 2 way
b) Check the sightglass visually. The oil level valve back to normal running position (fig. 10.5).
should be above halfway on the indicator.
f) Remove valve handles and store.
Caution: Do not mix oils of different types;
always refill with the oil type in current g) Replace the oil filter element (see para 10.9.3
use. ‘To Change the Oil Filter Element’).
h) Close all drain valves and plugs.

116 DL051AAA
CompAir Maintenance 10

Feed from 10.10 Power Breather Oil Removal Filter


Oil pump

to oil cooler

Rotate quarter turn


clockwise to normal
running position
SM 2001

Fig. 10.5 - Valve in Running Position

i) Fill reservoir with recommended oil until the


float reaches the top of the indicator.
j) Ensure that breather is dry and refit to filler
pipe (earlier machines).
k) Run pump for one minute, check level and top
up as necessary.
l) Reset control panel, start and run unit for 60
seconds to circulate oil, check for leaks, then
press STOP button.
m) Check the oil level and top up if necessary.
n) Close doors.
Fig. 10.4 - Oil Removal Filter - Powered
10.9.3 To change the oil filter element: Breather
Note: The oil filter element should be renewed 1. Filter Head 4. 'O' ring
after every 8000 operating hours or every 2. Stud 5. Filter Body
year, whichever is sooner or when indicated 3. Filter Element
by the control system CHANGE OIL FILTER
message
The compressor must be stopped. 10.10.1 To change the oil removal filter (powered
breather system):
a) Unscrew and discard the old oil filter element.
a) Unscrew the filter body (4) from the head (5).
b) Carefully clean out the filter housing.
b) Unscrew the filter element (2). Dispose of in
c) Apply a thin film of clean oil to the element accordance with local regulations.
seal.
c) Apply a thin film of approved oil to the seal on
d) Screw in the new element by hand until seal the new element. Fit new filter element and
contact is made and then continue tightening tighten hand tight.
by hand for a further quarter of a turn.
d) Refit the body.
10.9.4 To clean the oil breather element (earlier
models): e) After changing the oil removal filter it is
recommended that the powered breather
a) Remove the canister from oil filler/breather system is checked for correct operation.
pipe. Please refer to section 6.9 - ‘Powered
b) Wash the element in warm (50°C) mild Breather System‘ in the Commissioning
detergent solution. section of this manual.

c) Rinse thoroughly and dry.


d) Refit the canister to oil filler/breather pipe.

DL051AAA 117
10 Maintenance CompAir

10.11 Balance Piston Diaphragms 10.12 Non-Return Check Valve (NRV)


SM 1004

2
1

Direction
3 of Flow

4
SM 1008

Fig. 10.6 - Balance Piston Diaphragms


Fig. 10.7 - Check Valve
1. Spring 3. Circlip
10.11.1 To renew the diaphragms: 2. Valve Plate 4. Housing
a) Remove the rear fill-in panel from the
enclosure.
10.12.1 To inspect the valve:
b) Remove the regulation air pipe from the first
a) Stop the compressor, isolate from air main
stage diaphragm cover. Disconnect the
and release all pressure.
regulation air pipe from the second stage
diaphragm cover. b) Remove the enclosure side panel.
c) Remove the screws and washers securing the c) Slacken and remove the 4 screws and
covers to the casing. Remove the covers. washers securing the 2nd stage discharge
Remove and discard the diaphragms. pipe to the discharge silencer.
d) Ensure that all mating faces are clean. d) Gently lower the discharge pipe, which
remains attached to the flexible pipe.
e) Position a new diaphragm on the first stage
air end. Locate the cover and secure with the e) Remove the 'O' ring from the discharge
screws and washers. Carry out the same silencer.
procedure on the second stage air end.
f) Remove the circlip retaining the check valve
f) Refit the regulation air pipe to the first stage within the silencer.
diaphragm cover. Re-connect the regulation
Warning: This circlip retains the check
air pipe to the second stage diaphragm cover.
valve spring so care should be taken
g) Refit the enclosure panel.
g) Remove the valve and renew any worn or
damaged parts.
Caution: Do not lubricate.
h) Reassemble the valve and fit new 'O' ring to
the discharge silencer.
i) Reattach discharge pipe and refit the screws
and washers. Tighten using the correct torque
loading.
j) Start and run the compressor until working
temperatures are reached. Stop and
re-tighten the screws.
k) Refit the enclosure panel.

118 DL051AAA
CompAir Maintenance 10

10.13 Electrical System d) The cooling fan and oil pump motors are fitted
with sealed bearings and should not need
Warning: Lethal voltages are used in this attention.
equipment. Use extreme caution when
carrying out electrical checks. Isolate the e) If a non-standard motor is fitted the user
power supply before starting any should take advice from the local CompAir
maintenance work. distributor before the compressor is put into
extended operation.
10.13.1 To check the electrical connections:
10.14.4 Pre-Packed Bearings
Carefully examine the electrical wiring and
check the security of all connections and Where no grease nipples are provided the
terminals. bearings are either single or double shielded
and pre-packed with grease. These bearings
do not require periodic re-lubrication but
10.14 Electric Motors should be renewed after 25000 hours of
10.14.1 Maintenance and lubricant recommendations operation in normal environments.

Note : The compressor unit can only operate Note: We recommend that this work is carried
to your complete satisfaction when out by a CompAir trained and qualified
maintenance work is carefully carried out at supervisor.
the specified intervals. 10.14.5 Bearings with automatic lubricators
a) In order to help with this task, the scope of (earlier models)
supply of the compressor unit includes a
"Maintenance and Inspection Manual for
CompAir Compressors”, in which you can
keep a record of what maintenance work was
carried out at which specified intervals.
b) The operating hours quoted in this manual are
recommended maintenance intervals for
average operating conditions. Depending on
your local intake conditions, the operating
hours may differ.
c) You can also have this maintenance work
carried out by our trained technicians. Please
ask your technical adviser for a maintenance
contract.
10.14.2 Maintenance Fig. 10.8 - Automatic Lubricators

The maintenance of the electric motor is to be


performed in line with the motor operating a) Automatic lubricators are fitted to the main
instructions. drive motor to provide continuous bearing
10.14.3 Lubrication lubrication for 8000 hours operation or one
year, whichever is the sooner, in accordance
a) The two bearings of the electric motor must with the Maintenance Schedule.
be lubricated at specified intervals, which are
determined by the type of motor. b) On commissioning, the lubricators are set to a
dispense rate of 12 months. If the compressor
b) The lubricating points, intervals and quantities is taken out of service for more than one week
specific to each motor can be found on the the lubricators should be switched off (zero
motor's nameplate. position) and reset to 12 months on
Note: In the case of 60 Hz drive, strictly re-commissioning.
observe the information on the nameplate !
c) In order to check the required for lubrication,
weigh the grease gun before and after
lubrication of the individual electric motor
bearings.

DL051AAA 119
10 Maintenance CompAir

10.14.6 To renew automatic lubricators (see fig. 10.9) 10.14.7 Dust contamination
a) Open service doors to gain access to the If the compressor is operating in a dusty
motor. Unscrew the discharged dispensers atmosphere it may be necessary to clean the
from the fittings and discard. motors periodically to remove accumulated
dust from the windings. This applies
WARNING: Do not attempt to dismantle
particularly to IP22 class motors. Service
discharged dispensers.
personnel should inspect the motors visually
b) Cut off the lubricator tip with a sharp knife. at the regular servicing intervals to determine
the frequency of cleaning required.
c) Screw the lubricator into the lubrication point
until hand tight.
10.15 Interstage and Discharge Moisture
d) Use a 3mm Allen key to set the dispense rate
at 12 months.
Separators
Note: Used lubricators containing grease 1
must be disposed of in accordance with local
regulations. Dispose of empty lubricators by
recycling with normal plastic waste.

7 2

4
SM 0994

Fig. 10.10 - Moisture Separator


1. Housing 5. Spinner
2. Inlet Port 6. 'O' ring
3. Impinger Cone 7. Outlet Port
4. Bowl

10.15.1 Whilst these items differ slightly in external


appearance, their method of operation and
internal construction is identical.
a) Unscrew the bowl (4) from the housing (1).
Remove 'O' ring (6) if it remains lodged in the
housing.
Fig. 10.9 - Fitting and Setting Automatic
Lubricators b) Unscrew the impinger cone (3). Dispose of in
accordance with local regulations.

120 DL051AAA
CompAir Maintenance 10

c) Fit new impinger cone and tighten hand tight. 10.17.5 One of the advantages of this method is that
peaks in the envelope spectrum, indicating a
d) Refit the bowl using a new 'O' ring and tighten
damage, can be clearly assigned to rolling
securely.
element bearing frequencies. Also, these
10.15.2 If a fault develops in the condensate drain rolling element bearing frequencies can be
valve, replace the condensate valve with a assigned to a bearing type and to a part of
serviceable component. this bearing (inner ring, outer ring, rolling
element and cage).
10.16 Flexible Drive Coupling 10.17.6 The rolling element bearing frequencies are
dependent on bearing geometry (pitch
10.16.1 To check the coupling backlash:
diameter, number and diameter of the rolling
a) The compressor must be stopped and elements, contact angle) and the speed.
isolated from both the electrical supply and air
10.17.7 Fig. 10.11 shows the formula to calculate the
pipework.
rolling element bearing frequencies.
b) Reach through the access opening in the
10.17.8 For measuring of the envelope curve
bellhousing and hold the drive shaft on each
spectrum a FFT vibration analyser is required.
side of the coupling. Check the coupling
Measuring and diagnosis should be done by
backlash which should not exceed 6 mm. If
trained service personnel, experienced in
the backlash is excessive it will be necessary
interpreting vibration spectra of screw air
to change the coupling inserts.
ends.
10.16.2 To renew the inserts:
10.17.9 The bearing condition measurements should
Refer to Chapter 12, para 12.10, ‘Drive be taken on the bearing vibration monitoring
Coupling Inserts’. points given in Fig 10.13. There are 9
measuring points on the air end unit,
numbered from 3 to 11 (considering that 1
10.17 Air End Bearing Diagnosis
(NDE) and 2 (DE) are the measuring points
10.17.1 In general, roller bearing damage cannot be on the drive motor).
detected by low-frequency vibration
10.17.10 As a minimum, one bearing condition
measurement. The shock pulses, created by
measurement should be taken on the LP
over-rolling of a damaged area of a bearing
stage, one on the HP stage and one on the
element, can be detected only in the
drive gear.
high-frequency range.
10.17.11 Additional information is available from
10.17.2 Some bearing condition measurements for
CompAir such as bearing data and the
roller bearings have been in use for the last
calculation of typical frequencies of a certain
25 years, measuring special bearing
type of compressor. An example of such a
characteristic overall values (e.g. SPM) and
spread sheet is shown in Fig. 10.12.
watching the trend of these values over a
period of time. However, a high shock pulse
reading is not necessarily an indication of
bearing failure as it may be influenced by
interference from other components within the
unit.
10.17.3 This is the case for screw-type compressors.
The meshing of the rotors and the tooth
engagement of gears dominate also the
vibration signals in the high-frequency range
and can cover up a bearing failure, especially
when the failure is in an early stage.
10.17.4 This is the reason why, for complex machines,
a method for in-depth bearing diagnosis was
developed - the so-called envelope curve
spectrum analysis.

DL051AAA 121
10 Maintenance CompAir

Fig. 10.11 - Formula for Calculation of Rolling Element Bearing Frequencies


BEARING ARRANGEMENT

AIR END-TYPE: DRYCLON LP-Stage DIA-Male [mm] : 135.6 4/5 Combination


HP-Stage DIA-Male [mm] : 89.7 4/6 Combination
BEARING BEARING NUMBER ROLLER DIA PITCH DIA CONTACT
NO: TYPE SIZE IDENT-NO. SUPPLIER LOCATION of [mm] [mm] ANGLE [°]
ROLLERS
1 Cylindr. Roller NU306 98076-41 SKF LP-Stage,Male 12 11.000 51.50 0
2 4-Point QJ206 98076-51 SKF LP-Stage,Male 13 9.525 46.00 35
3 Cylindr. Roller NU306 98076-41 SKF LP-Stage,Female 12 11.000 51.50 0
4 4-Point QJ206 98076-51 SKF LP-Stage,Female 13 9.525 46.00 35
1 Cylindr. Roller NU305 98076-42 SKF HP-Stage,Male 11 10.000 44.00 0
2 4-Point QJ304 98076-53 SKF HP-Stage,Male 10 9.525 36.00 35
3 Cylindr. Roller NU305 98076-42 SKF HP-Stage,Female 11 10.000 44.00 0
4 4-Point QJ304 98076-53 SKF HP-Stage,Female 10 9.525 36.00 35
1 Angular Contact 7211 SKF Gear, DE 16 14.290 77.50 40
98076-28
2 Deep Groove Ball 6211 SKF Gear, DE 10 14.290 77.50 0
3 Cylindr. Roller NU211 A93573910 SKF Gear, NDE 17 12.000 78.00 0
AIR END DATA
LP-Stage n-Male [1/min]: 13598 f-Male [Hz]: 226.63 f-Output [Hz] : 906.50 z Timing Gear 36
n-Female [1/min]: 10878 f-Female[Hz]: 181.30 Tip Speed, u-Male [m/s] : 96.54 z Timing Gear 45
HP-Stage n-Male [1/min]: 18918 f-Male[Hz]: 315.30 f-Output [Hz] : 1261.22 z Timing Gear 34
n-Female [1/min]: 12612 f-Female[Hz]: 210.20 Tip Speed, u-Male [m/s] : 88.85 z Timing Gear 51
BEARING DIAGNOSIS ( ENVELOPE CURVE SPECTRUM ) ROLLING ELEMENT BEARING FREQUENCIES P = 55 ... 155 kW
BEARING Inner Race Outer Race Roller/Ball Cage Relative Compressor Type
NO: SIZE f-IR [Hz] f-OR [Hz] f-Ball [Hz] f-C [Hz] Speed LOCATION D150-10W, 50 Hz
IR [1/min] LP z1 = 32
1 NU306 1650.18 1069.32 1012.61 89.11 13598 LP-Stage,Male HP z2 = 23
2 QJ206 1722.92 1223.20 1062.97 94.09 13598 LP-Stage,Male z Bullgear = 147
3 NU306 1320.15 855.45 848.81 71.29 10878 LP-Stage,Female LP i1 = 4.594
4 QJ206 1378.34 978.56 850.38 75.27 10878 LP-Stage,Female HP i2 = 6.391
1 NU305 2128.30 1340.04 1315.68 121.82 18918 HP-Stage,Male nDriv e [1/min] : 2960
2 QJ304 1918.21 1234.84 1135.72 123.48 18918 HP-Stage,Male
3 NU305 1418.87 893.36 877.12 81.21 12612 HP-Stage,Female Gear Drive Data:
4 QJ304 1278.81 823.22 757.15 82.32 12612 HP-Stage,Female fDriv e [Hz] : 49.33
1 7211 450.41 338.92 262.22 21.18 2960 Gear, DE fz,Driv e [Hz] : 7252.00
2 6211 292.15 201.18 258.46 20.12 2960 Gear, DE LP fz,Timing Gear 8158.50
3 NU211 483.85 354.82 313.08 21.65 2960 Gear, NDE HP fz,Timing Gear 10720.35

Fig. 10.12 - Typical Diagnosis Data Spreadsheet

122 DL051AAA
CompAir Maintenance 10

11

10

6
9

8 5
11
7

3
4

6 F 5
1st Stage
4 M 3
11 12
1 2

8 M 7
2nd Stage
10 F 9

Fig. 10.13 - Bearing Frequency Check Points

DL051AAA 123
11 Electrical Systems CompAir

11 Electrical Systems
11.1 Controller
11.1.1 The electronic control system is
microprocessor-based. On the front of the
electronic controller enclosure is the control
panel, which consists of a liquid crystal
display (LCD), mimic diagram, touch switches
and dedicated light-emitting diode (LED)
pressure display, incorporating many
advanced control and monitoring features.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

bar

psi

36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
PI/97/067

Fig. 11.1 - Control Panel


1. PSI Units Indicator 19. Remote Control Legend
2. Bar Units Indicator 20. Remote Control Indicator
3. Delivery Pressure Display 21. Auto Restart Indicator
4. Start Button 22. Power On Indicator
5. Status and Message Display 23. Compressor Delivery Fault Indicator
6. Plus Button 24. Oil System Fault Indicator
7. Minus Button 25. Change Oil Filter Indicator
8. Up Button 26. 2nd Stage Delivery Fault Indicator
9. Down Button 27. Low Oil Level Indicator
10. Enter Button 28. Main Motor Fault Indicator
11. Mimic Diagram 29. Oil Pump Motor Fault Indicator
12. Intake Filter Change Indicator 30. Hours Button
13. Incorrect Phase Rotation Indicator 31. Reset Button
14. 1st Stage Delivery Fault Indicator 32. Reset Indicator (LED)
15. 2nd Stage Intake Fault Indicator 33. Values Button
16. Fan Motor Fault Indicator 34. Service Button
17. Emergency Stop Button 35. Service Indicator (LED)
18. Auto Restart Legend 36. Stop Button

124 DL051AAA
CompAir Electrical Systems 11

11.1.2 Behind the control panel, within the same


enclosure, is the controller assembly
consisting of three circuit boards. The lower
board communicates with the control panel,
the centre one carries the microprocessor and
associated memory chip and the upper one
communicates with the Interface Assembly.

Control Program IC

bar

psi

PI/97/122

Fig. 11.2 - Controller Assembly

1 2 6 7 9

PI/97/124

5 8 4 3

Fig. 11.3 - Controller (Rear Connections)


1. Controller Assembly 4. Plug X06 7. Plug X09
2. Controller Enclosure 5. Plug X01 8. Plug X04
3. Plug X03 6. Plug X02 9. Plug X08

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11 Electrical Systems CompAir

11.2 Interface Assembly


11.2.1 The interface assembly consists of an Key to Fig. 11.4 - Interface Assembly
extension module, power supply transformer,
F1 to F5 Fused Terminals
fan and oil pump motor relays and contactors,
F102 & F103 Fan Overload Relays
circuit breakers and electrical terminal blocks.
F104 Oil Pump Overload Relay
11.2.2 This assembly is connected by cables and
trunking to the rear of the electronic K101 Phase Rotation Relay
controller/control panel. It forms the interface K201 Fan Relays
between the electronic controller, the motor K202 Oil Pump Relay
starter and the various sensors and solenoids K401 Available Relay
which monitor and control the compressor. K402 Group fault relay
K403 Running Relay
11.2.3 Wiring
K404 On Load Relay
a) Each control or signal wire is labelled with an K405 Group Trip Relay
individual wire number. Wires which have a K406 Service Due Relay
common function, power supply wires for
example, are labelled with the same number KM204 & KM 205 Fan Contactors
and originate from the same terminal block. KM206 Oil Pump Contactor
b) The wiring for low voltage control, signal and
Q101 MCB - Fan & Oil Pump
24V power supply is 1·0 mm2 in size. Starter
Motors Power Supply
control wiring, which carries main power
Circuit
supply voltage is 2·5mm2 in size and is
Q201 MCB - Control
coloured black.
Transformer
11.2.4 Power Supply Circuit Breakers and Fuses
T201 Control Transformer
a) The main power supply is connected to MCBs
Q101 and Q201. MCB Q201 protects the
power supply circuit to transformer T201 and
MCB Q101 protects the power supply circuit
to the fan motors M102/M103 and oil pump
motor M104.
b) The control transformer T201 has three 24V
ac outputs. Each output is individually
protected by fused terminal blocks F1 to F5.
Fuses F1 and F2 protect the controller power
supply circuit, fuses F3 and F4 protect the
extension module power supply circuit and
fuse F5 protects the controller relay output
circuits.

126 DL051AAA
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Fig. 11.4 - Interface Assembly

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11 Electrical Systems CompAir

11.3 Starter STAR DELTA MAIN


CONTACTOR CONTACTOR CONTACTOR
11.3.1 The compressor motor has a Star/Delta
starter system to reduce starting current. On
starting, the Star contactor is energised and
starts the main drive motor under reduced
power. As the motor approaches its rated
speed, a timer within the controller switches
the motor to full power by energising the Delta
contactor and de-energising the Star
contactor.
11.3.2 The starter assembly consists of three
contactors, Main (KM201), Star (KM202) and
THERMAL
Delta (KM203), and a main motor thermal
OVERLOAD
overload relay (F101). The coils of the three RELAY
contactors are rated for 24V ac, 50/60 Hz
SM 1056
11.3.3 The supply to the coil of the main contactor
(KM201) is connected to the thermal overload
(F101). If the thermal overload trips, the main Fig. 11.5 - Layout of Starter Assembly -
contactor is de-energised, the main motor Physical
stops and a ‘main motor fault’ signal is
activated. The supplies to the star and delta
contactor coils are interconnected by auxiliary
contacts. This is a safety feature designed to
prevent the two contactors energising at the
same time if a control fault occurs.

X2/2 L3 L2 L1
208
CL1/4
308
CL1/2 B Y R
214
CL1/3 216

A2 5 3 1 A2 5 3 1 A2 5 3 1
Delta KM203

Main KM201
Star KM202

N/C

N/O
N/C

A1 6 4 2
A1 6 4 2 A1 6 4 2

213

96 5 3 1
217
F101

215

95 6 4 2

CL1/1
212

104
Motor
Thermistor Clockwise U2 W2 V2 W1 V1 U1
Anti-Clockwise V2 W2 U2 W1 U1 V1
SM 1114

Fig. 11.6 - Layout of Starter Assembly - Schematic

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11.3.4 Starter Contactor Auxiliary Contacts b) Auxiliary Contact Type 2


All CompAir motor contactors have clip-on This type of auxiliary contact (2) clips onto the
auxiliary contacts which are designed to side of the contactor (1). The operation of the
operate in N/O (normally open) or N/C contact is determined by the N/O or N/C
(normally closed) mode, depending on pictorial symbols shown on the top when
orientation. Two types of auxiliary contact are fitted. Each contact block consists of three
used throughout the range, depending on the contacts.
type of contactor.
a) Auxiliary Contact Type 1
This type of auxiliary contact (2) clips onto the
front face of the contactor (1). The operation
of the contact is determined by the N/O or N/C
symbol furthest from the contactor face when
fitted. To remove the contact, pull the release
catches (3), (located top and bottom of the
contact) away from the contactor and slide the
contact sideways.
SM 0712

1
4 2
SM 0982 3

Fig. 11.8 - Auxiliary Contact Type 2


Shown Fitted To Operate As
Two N/C (Normally Closed)
And One N/O (Normally Open)

1. Contactor
2. Auxiliary Contacts
1 3. Electrical Connections
2

Fig. 11.7 - Auxiliary Contact Type 1


Shown Fitted To Operate In The N/C
(Normally Closed) Mode

1. Contactor
2. Auxiliary Contact
3. Release Catches
4. Electrical Connections

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11.4 Control Function Option - 11.5 Control Function Option - Inputs


Condensate Drain 11.5.1 Description
WARNING Two sets of eight inputs are available on
extension module terminal connections X01
and X02. Each input is designated a particular
• Refer to the safety procedures before function which may be used as required. Each
carrying out any of the following function is activated by connecting the
operations. appropriate terminal pin to the input terminal
common connection X5/1 or X5/2. This can be
• Lethal voltages are used in this achieved by connecting the input pin and the
equipment. Use extreme caution when common terminal to a remote switch, relay
carrying out electrical checks. Isolate the contact, PLC output or any switching device.
power supply before starting any
maintenance work. Note 1: Remote input cables must be at least
1.0 mm2 in size. The maximum cable length
from the compressor to a remote device must
Note: We recommend that the following not exceed 800 meters.
procedures are carried out by CompAir.
Note 2: To activate an input function, only
11.4.1 Operation connect an input terminal pin to the common
a) When running on-load the condensate drain terminal connection X5/1 for X01 inputs or
will operate according to the programmable X5/2 for X02 inputs.
drain shut and drain open times. The drain will
open and the timer cycle will begin every time
the compressor loads. When the compressor
is in ‘off-load’, ‘standby’ or ‘ready to start’, the
drain will continue to operate with a two
second ‘open’ time and an extended ‘shut’
time. This prevents any build-up of
condensate when the compressor is stopped
or unloaded.
b) If it is preferable for the drain to operate only
while the compressor is running, the following
starter wiring change can be made:
(i) Remove and discard the wire from
controller terminal X08/9 to terminal block
X2/1.
(ii) Connect a wire between terminal X08/9
and terminal block X2/6.

130 DL051AAA
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X01

1 2 3 4 5 6 7 8 9

REMOTE LOAD
COMMS CONTROL ENABLE

START

STOP
500

REMOTE START ENABLE


AUTO RESTART ENABLE

REMOTE LOAD ENABLE


20V D.C. COMMON

X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1

PRESSURE SWITCH
OR CASCADE
SM 0758 PANEL CONNECTION

Fig. 11.9 - Remote Input Connection

11.5.2 Input Designations


a) Input Terminal X01 b) Input Terminal X02

Pin No. Function Pin No. Function


X01-1 Common (20V dc) for X01 inputs X02-1 Common (20V dc) for X02 inputs
X01-2 Comms Control Enable X02-5 Remote Fault Input 1
X01-3 Auto Restart Enable X02-6 Remote Fault Input 2
X01-4 Remote Load Enable X02-7 Remote Fault Input 3
X01-5 Remote Load/Unload X02-8 Remote Fault Input 4
X01-6 Remote Start Enable X02-9 Remote Fault Input 5
X01-7 Remote Start
X01-8 Remote Stop
X01-9 No Standard Function

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11.5.3 Input Functions b) Input X01-3 Auto Restart Enable


a) Input X01-2 RS485 Communications Control (i)Automatic re-start will allow the compressor
Enable to start automatically after a break or failure in
the mains power supply. When this facility is
(i) The SureScan controller is equipped with
enabled the AUTOMATIC RE-START
an RS485 communications facility on terminal
indicator will be lit.
X06. The facility is activated when this input
(X01-2) is connected to the common terminal (ii) An automatic restart will not be initiated if
X5/1. the compressor was stopped when the power
failure occurred.
Note: The RS 485 terminal X03 on the
extension module has no standard function. (iii) When power is restored the following
message is displayed and the Auto Restart
(ii) The communications link can either be
enable lamp will flash.
connected point-to-point or networked with up
to 31 compressors and one master. Auto restarting
(iii) The controller network communications —————* *
protocol is a single master system.
The time before the compressor automatically
Communication is always between network
restarts, the auto restart delay time, is
master and controller. Only one
indicated by dashes on the lower display line.
communication protocol is used. Point-to-point
This time can be adjusted using the auto
links are considered to be networks with only
restart delay time setting of the
two nodes, master and controller. Each
‘Commissioning - values’ sub-menu of the
compressor controller on a network can be
SureScan menu routines.
assigned a unique identification number from
1 to 99, the master always being node 0. (iv) In multiple compressor installations
staggered re-starting can be achieved by
(iv) When connected, a master can read
adjusting the delay time of each compressor
status, fault, service, pressure and
temperature data from any controller in the Example four compressor installation:-
network.
(v) If the ‘Comms control enable’ input X01-1 Comp Autorestart Delay Time
and ‘Remote start enable’ input X01-6 are 1 10 seconds
activated, the compressor Remote control
lamp will light and the compressor will 2 70 seconds
respond to RS485 Start, Stop and Reset 3 150 seconds
commands.
4 210 seconds
Note: The control panel Start button and the
Remote start function will be inhibited. The
c) Input X01-4 Remote Load Enable
control panel stop button and remote stop
function remain active. (i) Remote control of loading and unloading
allows the pressure control routines of the
(vi) If the ‘Comms control enable’ and the
SureScan controller to be overridden in
‘Remote pressure control enable’ input X01-2
multiple compressor/cascade control
is activated, the compressor will respond to
installations. The facility allows control by any
RS485 load and unload commands.
of the I.C.C. range of multi compressor
(vii) Contact your local CompAir office for controllers available from CompAir.
details.
(ii) When the remote load enable input is
activated the compressor will load and unload
in response to the remote load/unload input
X01-5.

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d) Input X01-5 Remote Load/Unload f) Input X01-7 Remote Start


(i) If input X01-5 is activated, via a remote (i) When the remote start enable and remote
pressure switch, relay, programmable logic stop inputs are activated the compressor will
controller (P.L.C.) output etc, the compressor start when the remote start input is activated.
will load. When the input is de-activated the This input requires a single pulse of at least
compressor will unload. 0.5 seconds to activate it. The pulse length
can be between 0.5 seconds and continuous.
(ii) The compressor will shutdown and the
display will show a High air pressure trip if the (ii) When the remote start input is
Max overpress setting of the Commissioning continuously activated the SureScan panel
values menu is exceeded while using this stop button or the remote stop input will
facility. The compressor ‘Max overpress’ override the remote start signal and the
setting must be set above the working compressor will stop.
pressure of the remote pressure control
When the compressor is stopped, the remote
system. Where the remote pressure control
start signal must be de-activated before the
system is detecting air system pressure
compressor can be re-started.
downstream of dryers, filters or long lengths of
pipework, an allowance for any pressure Note: This facility is inhibited if the RS485
differential should be taken into account. communications control input is activated.
e) Input X01-6 Remote Start Enable (iii) Remote Timer Control
(i) The compressor can be connected to The remote start/stop facility can also be used
accept a remote start signal. When this input to achieve automatic seven day timer control.
is activated the REMOTE CONTROL indicator Any commercially available timer with a single
will be lit and the SureScan panel START switching contact can be used for this
button is disabled. purpose. Alternatively a timer with a 24v ac
power supply can be mounted within the
(ii) The SureScan panel stop button and the
starter area. A 24v ac power supply for this
remote stop input are always active,
purpose is available on compressors
regardless of remote start enable being
terminals X2/1 and X2/2. The timer unit should
activated.
be battery backed.

EXTENSION MODULE
7 DAY TIMER

X01
1 2 3 4 5 6 7 8 9
REMOTE START ENABLE

X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 CLOSED - START
OPEN - STOP
PI/97/136

Fig. 11.10 - Timer Control

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g) Input X01-8 Remote Stop i) Inputs X02-5 to 9 - Remote Faults 1 to 5


(i) The remote stop input is always active, (i) There are five remote fault input functions
regardless of remote start enable being available that can be individually programmed
activated. to function as remote alarm, remote trip or
start inhibit inputs. A remote fault input can be
(ii) The remote stop input must be active to
connected to a remote switch, relay contact,
enable the compressor to be started. The
programmable logic controller (PLC) output or
compressor will stop when the remote stop
any switching contact device. Each input
input is de-activated.
function will operate when the connection
(iii) A remote stop signal will override a remote between the appropriate input terminal, X02-5
start signal. When the remote stop input is to X02-9, and the common terminal X5/2 is
de-activated the display will show: broken.
Remote stopped (ii) When a remote fault input is de-activated
the appropriate remote fault number will be
Oil temperature 20°C
displayed by the SureScan controller and the
(iv) The STOP button on the SureScan panel fault will be stored in the fault history. The
is not affected and will remain active at all remote fault can be reset normally using the
times. RESET button.
(v) If this facility is not used the input must be Remote Fault Input Configuration
continuously activated by connecting a wire
Each remote fault input can be
from the input pin to terminal connection X5/1,
pre-programmed using the SureScan
to enable the compressor to be started and
controller menu routines to function as a
run.
remote alarm, remote shutdown trip or start
h) Inputs X01-9 and X02-2 to 4 inhibit when the fault input is de-activated.
Remote alarm and shutdown trip functions
Caution: These inputs are used by the
can also be pre-programmed to operate only
controller to monitor the operation of the
under pre-determined conditions to suit a
compressor and must not be used for any
particular application depending on the
other function.
remote fault input type selected.
Note: When a remote fault input is configured
to any option other than ‘Disabled’ the input
must, under normal circumstances, be
continuously activated to enable the
compressor to operate without indicating a
remote alarm, trip or start inhibit condition.

134 DL051AAA
CompAir Electrical Systems 11

11.5.4 Remote Fault Input Configuration Options

Option Function Description

Disabled Input not active


Trip type 1 Trip - active at all times
Trip type 2 Trip - active when the main motor is running
Trip type 3 Trip - active only when status is ‘Onload’ or ‘Offload’
Alarm type 1 Alarm - active at all times
Alarm type 2 Alarm - active when the main motor is running
Alarm type 3 Alarm - active only when status is ‘Onload’ or ‘Offload’
Start inhibit Will prevent a compressor from starting but will not stop a compressor if
already started. When activated the display will show ‘Start inhibited’.
This function is not a shutdown trip or alarm and will only function while
the input is de-activated.

11.5.5 Configuring the SureScan Controller Remote Fault Inputs


All remote fault inputs will be ‘Disabled’ when the compressor is first commissioned. To enable a remote
fault input, and select a required fault input function from the Configuration Options table , use the
SureScan menu routines procedure as described below :-

No. Action Reason Display

1. Press ENTER. To display the main menu. Main menu


Operational settings.
2. Press UP or DOWN To scroll through the Main menu
repeatedly until the menu options. Commissioning - config
message shown on the
right is displayed.
3. Press ENTER. To select the Commissioning - config
Commissioning - config Language English
sub menu.
4. Press UP or DOWN To scroll through the Commissioning - config
repeatedly until the sub menu options. Fault input config
message shown on the
right is displayed.
5. Press ENTER To select the fault input Fault input config
config sub menu. Remote fault 1
6. Press UP or DOWN To scroll through the Fault input config
repeatedly to select fault inputs available. Remote fault 2
fault input.

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11 Electrical Systems CompAir

No. Action Reason Display

7. Press ENTER To select the fault Remote fault 2


input to configure. Disabled
8. Press PLUS or MINUS. To select the required Remote fault 2
fault input function. Trip type 2
(pulsing display)
9. Press ENTER. To enter the selected fault Remote fault 2
input configuration option. Trip type 2
The display will automatically return to the fault input selection menu.
10. Repeat steps 6 to 9 for
each of the remote fault
inputs. If a remote
fault input is not required
select ‘Disabled’ from the
configuration options menu.
11. When all five remote fault Ready to start
inputs are configured press Oil temperature 20°C
RESET to exit the menu routine

136 DL051AAA
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11.5.6 Extension Module - Digital Inputs c) Inputs X02–1 to X02–4


When the extension module is connected, A remote signal from the MPCB auxiliary
remote stop and three digital input signals are contact Q101 (X02–4) is available for use.
available for use. There are also nine Contact X02–1 is the common 20V dc supply
additional inputs available if required. (see fig. 11. 11).
a) Inputs X01–1 and X01–8 d) Inputs X02–5 to X02–9
Contact X01–1 is the common 20V dc supply These contacts are available for additional
and the remote stop is linked to X01–8. remote fault input signals if required. If any of
these contacts are used the controller will
b) Inputs X01–2 to X01–7
require reprogramming from the touch panel
These contacts are available for linking to enable the functions selected.
operational signals. The comms control
enable must be linked to X01–2 and the auto
restart to X01–3. Contacts X01–4 and X01–5
must both be used to link the remote load
enable (X01–4) and remote load/unload
switched (X01–5) signals. Contacts X01–6
and X01–7 must both be used to link the
remote start enable (X01–6) and remote stop
switched (X01–7) signals.

Fig. 11.11 - Extension Module Digital Inputs

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11.6 Outputs c) Relay Specification

11.6.1 Description Single switching contact with a common,


normally open (N/O) and normally closed
Two sets of six outputs are available on (N/C) connection rated at 250V - 5 Amps
extension module terminal connections X05 maximum.
and X06. Each output is designated a
particular function which may be used if Note: The relay 24V dc coil is not
required. Outputs which are not used should bi-directional and must be connected to an
be left unconnected. extension module output as follows :-

11.6.2 Output Relay (i) Relay terminal ‘5’ must be connected to pin
‘1’ of the appropriate output terminal.
a) Extension module outputs are 24V dc
transistor switched with a maximum rating of (ii) Relay terminal ‘1’ must be connected to
25mA. Each output must be connected the pin of the output terminal appropriate for
directly to a relay module, as specified below, the required output function.
in order to achieve a relay contact output The relay base can be screw mounted or
suitable for remote applications external to the secured to a standard type DIN rail (available
compressor starter enclosure. Six relays, from CompAir).
K401 to K406 are supplied as standard for
this purpose.
b) Parts required for each additional output:-

Qty Description Part Number


1 Relay - 24 V dc 98475-64
1 Relay Base 98475-65

X4/1 X4/1 X4/1 X4/1 X4/1 X4/1 X4/1


COMMON 24V D.C.
K406

K405

K404

K403

K402

K401

5 3
+ 2
5 5 5 5 5 5
24V d.c.
- 4
1 1 1 1 1 1 1
406

405

404

403

402

401

400

7 6 5 4 3 2 1

X05 SM 0759

Fig. 11.12 - Remote Output Connection

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CompAir Electrical Systems 11

11.6.3 Output Designations c) Output X05-4 Running


a) Output Terminal X05 The running output will energise when the
compressor main motor is running.
Pin No. Function The contacts of relay K403 must be used for
X05-1 Common (20V dc) for X05 outputs remote connections to this facility.
X05-2 Available d) Output X05-5 On Load
X05-3 Group Fault The on load output will energise when the
compressor is on load.
X05-4 Running
The contacts of relay K404 must be used for
X05-5 On Load
remote connections to this facility.
X05-6 Group Trip
e) Output X05-6 Group Trip
X05-7 Service Due
The group trip output will de-energise when a
shutdown trip or power loss occurs.
b) Output Terminal X06
The output will be energised when power is
applied and no trip conditions are detected.
Pin No. Function
X06-1 Common (20V dc) for X06 outputs
The contacts of relay K405 must be used for
remote connections to this facility.
X06-2 Remote Fault 1
f) Output X05-7 Service Due
X06-3 Remote Fault 2
The service due output will energise when the
X06-4 Remote Fault 3 service hours countdown timer has reached
X06-5 Remote Fault 4 zero hours and a routine service is due.
X06-6 Remote Fault 5 The contacts of relay K406 must be used for
remote connections to this facility.
X06-7 No Standard Function
g) Outputs X06-2 to 6
11.6.4 Output Functions Remote fault outputs 1 to 5 will be normally
energised and will de-energise if a fault
a) Output X05-2 Available condition on the appropriate remote fault
The compressor available output will energise input, 1 to 5, is detected or a power loss
when the compressor is ‘running’ or in the occurs. The output will remain de-energised
‘standby’ state. This output indicates that the until the SureScan controller is reset. See
compressor has been started and is available remote fault inputs.
to automatically respond to a fall in system If start inhibit is selected, the output will
pressure without manual intervention. de-energise when the input is de-activated
The contacts of relay K401 must be used for and automatically re-set when the input is
remote connections to this facility. re-activated.
b) Output X05-3 Group Fault Note: An additional relay module as specified
in para 11.6.2 must be added if these outputs
The group fault output will de-energise when are used.
an alarm, shutdown trip or power loss occurs.
The output will be energised when power is
applied and no alarm or trip conditions are
detected.
The contacts of relay K402 must be used for
remote connections to this facility.

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11.6.5 Extension Module (Typical Example) 11.6.6 Extension Module - Digital Outputs
The example below shows the extension With an extension module fitted all
module kit connected to give the following connections and functions are the same as
facilities:- the analogue signal conditions detailed in
paras 11.6.1 to 11.6.4.
a) Remote start/stop using a normally open
(N/O) remote start button and a normally
closed (N/C) remote stop button.
b) Automatic restart of the compressor when
power is reinstated after a power failure.
c) A remote compressor available lamp
indication showing that the compressor has
been started and is in the offload, onload or
standby condition.
d) A group trip lamp indication to show if a
compressor shutdown trip occurs.
e) A group alarm lamp indication to show if a
compressor alarm occurs.
Note: This example of a typical installation is
intended to demonstrate how some of the
features of the extension module can be used
and the method of connection.
Each installation will be particular to the
requirements of the user. Additional parts
required, if any, and the installation
connections should be established as detailed
in the input and output descriptions contained
in the text of this manual.

140 DL051AAA
CompAir Electrical Systems 11

410
406
405
404
403
402
401
400 410

X08 X07 X06


X05
6 54 3 2 1 6 54 3 2 1 7 6 54 3 2 1 7 6 54 3 2 1

X4/1

X4/2

X5/1

X5/2

K401

K402

K403

K404

K405

K406
X03
21

1 23 4 56 7 8 9 1 23 4 56 7 8 9 21
N/O

X01 X02 X03


COM
N/C
510
500

REMOTE START ENABLE

AUTO RESTART ENABLE

STOP

START

24V
L
F1 0á5A
AVAILABLE
E
20VA
ALARM

TRIP
N
0V

REMOTE STATUS/CONTROL PANEL


PI/97/139

Fig. 11.13 - Extension module (Typical Installation)

DL051AAA 141
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11.7 Fault Diagnosis 11.8.1 Test Meter


A multimeter (preferably digital) is required for
WARNING
the tests carried out in this section. If an
analogue meter is used it should be 20,000
ohms/V minimum. The resistance range test
• Refer to the safety procedures before voltage should not exceed 1·5V. The following
carrying out any checks on the electrical ranges, as provided by an AVO 8 Mk7, are
circuits or components. suitable and are quoted in the tests. If a
• Lethal voltages are used in this different meter is used or a digital meter the
equipment. Use extreme caution when nearest higher ranges should be used. A
carrying out electrical checks. Isolate the digital meter (say a Fluke 179 series) will also
power supply before starting any give an alternative lower range of (0 -300
maintenance work. ohms) which will give more accurate
continuity and solenoid coil measurements.

Caution: Fault finding by substitution of dc volts: 0-30V (for 24V


cards without following correct fault measurements)
finding procedures is not recommended as ac volts 0-30V (for 24V
a machine fault may exist which would measurements)
damage the substitute card.
0-600V (for main supply
measurements)
11.8 Test Equipment
Resistance: 0-2 kohms
To carry out the checks on the electrical
components and the circuit cards inputs and 11.8.2 Clip-on Ammeter
outputs the following test equipment will be This should be suitable for measuring currents
required. up to 600 amps.
Caution: Do not use a test meter with less 11.8.3 Insulation Tester
than a 20,000 ohm/V specification to avoid
loading effects and to prevent damage to The tester should have a 1000V test voltage.
IC’s during testing. 11.8.4 Slave Air Supply
Caution: The circuit boards carry CMOS The air supply should be capable of
devices. When replacing circuit boards generating a pressure above 5.51 bar and be
avoid touching connector pins and devices fitted with an accurately calibrated gauge.
on the boards to prevent static damage to
components. Take anti-static precautions
as far as possible such as transporting the
circuit boards in anti-static bags.
Caution: When using an analogue
multimeter to check continuity or measure
resistance, particularly low resistances
such as solenoid coils, ensure that the
meter has been adjusted to read zero
ohms correctly with its test probes
connected together, before any
measurement is made.

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CompAir Electrical Systems 11

11.9 Cage-Clamp Screwless Terminals 11.9.1 Cable Connection or Removal

The connections on the interface assembly a) Strip the insulation from the end of the cable
and controller terminal blocks are fitted with to leave approximately 7 mm of bare wire.
cage-clamp screwless terminals. The b) Insert a screwdriver with a blade end width of
cage-clamp design ensures that the clamping 3 mm into the terminal slot and push fully
force adjusts to sizes of cable between 1 mm2 home.
2
and 2·5 mm . This results in a corrosion free
contact area and compensates for any c) Inset (or remove) the cable.
deformation of the cable end due to d) Withdraw the screwdriver to leave the cable
temperature or vibration. clamped.
e) Check the connection by lightly pulling on the
cable.

2
1

Fig. 11.14 - Cable Connection Or Removal


1. Terminal Jumper Connection
2. Cable
3. Terminal Block

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11.10 Displayed Fault Conditions


11.10.1 Warning Faults

Ref. Message Displayed Possible Fault See Section:

1. Change air filter Air Filter Differential Pressure Switch. 11.14.1


2. Change oil filter Oil Filter Differential Pressure Switch. 11.14.2
3. Interstage press Interstage Pressure Sensor 11.16.1
4. Oil temperature Oil Temperature Sensor 11.16.2
5. St1 delivery temp St1 Delivery Temperature Sensor 11.16.3
6. St2 intake temp St2 Intake Temperature Sensor 11.16.2
7. St2 delivery temp St2 Delivery Temperature Sensor 11.16.3
8. Plant delivery temp Plant Delivery Temperature Sensor 11.16.2
9. Oil level low Oil Level Sensor 11.14.5
10. Max. overpress Remote Pressure Control Circuit –

11.10.2 Shutdown Faults

Ref. Message Displayed Possible Fault See Section:

1. Emergency stop Emergency Stop Circuit 11.14.6


2. Power supply fault a) Main Power Supply Connection 11.12.2
b) Phase Rotation Relay 11.14.7
3. Main motor fault a) Main Motor. 11.13.1
b) Main Motor Thermistors 11.16.4
c) Main Power Supply 11.12.2
4. Fan motor a) Fan Motor Overload 11.15.2
b) Fan Motor 11.13.4
c) Contactor Coil Circuits 11.15.2
5. Oil pump motor a) Oil Pump Motor Overload 11.15.2
b) Oil Pump Motor 11.13.4
c) Contactor Coil Circuits 11.15.2
6. High air pressure Delivery Pressure Sensor 11.16.1
7. Interstage press Interstage Pressure Sensor 11.16.1
8. Oil pressure low Oil Pressure Switches 11.14.3
9. Oil temperature Oil Temperature Sensor 11.16.2
10. St1 delivery temp St1 Delivery Temperature Sensor 11.16.3
11. St2 intake temp St2 Intake Temperature Sensor 11.16.2
12. St2 delivery temp St2 Delivery Temperature Sensor 11.16.3
13. Plant delivery temp St2 Delivery Temperature Sensor 11.16.2
14. Air delivery probe Delivery Pressure Sensor. 11.16.1
15. Int.St press probe Interstage Pressure Sensor 11.16.1

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Shutdown Faults (continued)

Ref. Message Displayed Possible Fault See Section:

16. Oil temp probe Oil Temperature Sensor. 11.16.2


17. St1 del temp probe St1 Delivery Temperature Sensor 11.16.3
18. St2 in temp probe St2 Intake Temperature Sensor 11.16.2
19. St2 del temp probe St2 Delivery Temperature Sensor 11.16.3
20. Plant del t probe St2 Delivery Temperature Sensor 11.16.3
21. Remote fault Remote Fault Circuits –
22. Oil level low Oil Level Sensor 11.14.5

11.11 Observed Fault Conditions

Ref. Symptom Possible Fault See Section:

1. High main motor temperature. a) Fan circuit. 11.13.4


b) Main power supply. 11.12.2
2. Low discharge air pressure. a) Pressure Sensor circuit. 11.16.1
b) Unloader Solenoid circuit. 11.15.1
3. High discharge air pressure. a) Pressure Sensor circuit. 11.16.1
b) Unloader Solenoid circuit. 11.15.1
4. Power to machine on but a) Power cable connections. 11.12.2
Power On indicator not lit b) Transformer circuit. 11.12.1
and all displays blank. c) Circuit breaker. 11.12.1

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Observed Fault Conditions (continued)

Ref. Symptom Possible Fault See section:

5. Compressor unit will not start a) Remote starting has been enabled. Operate the compressor
The display will show: remotely or remove the
Ready to start remote start enable
Remote start enabled. connection.
b) The emergency stop button has Reset the emergency
not been reset. The display stop button by turning
will show: anti-clockwise, then
Unable to start press RESET
Emergency stop
c) A start inhibit exists. Conditions
which can inhibit starting are listed
in the ‘Operation’ section of
chapter 7.
d) Contactor circuit fault. 11.15.1
6. Machine will not run onload – a) Pressure Sensor circuit. 11.16.1
pressure display is incorrect. b) Unloader Solenoid circuit. 11.15.1
7. Machine will not run offload – a) Pressure Sensor circuit. 11.16.1
pressure display is incorrect. b) Unloader Solenoid circuit. 11.15.1

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11.12 Power Supplies 11.13 Motors and Motor Circuits


Caution: The high voltage (primary) and WARNING
low voltage (secondary) circuits must NOT
be connected in any way (e.g. via test
probes, wiring etc.)
• Refer to the safety procedures before
11.12.1 To Check the 24V ac Supply Circuits carrying out electrical checks.
(Connection Diagram 2 of 6)
a) Measure the ac voltage of the three 24V 11.13.1 To Check the Main Motor (Connection
secondary outputs of transformer T201. Diagram 1 of 6)
Always measure across the transformer 11.13.2 Motor Insulation
output terminals and NOT between each
terminal and earth. a) Ensure that the main power supply to the
compressor is isolated.
b) The voltage of each output should be in the
range 20V to 28V. If one or two of the Note: Use a calibrated 1000V insulation tester
voltages are incorrect, renew the transformer. for insulation resistance tests.
If all the voltages are incorrect see 5.2 ‘To
b) Measure the insulation resistance between
Check the Main Power Supply’.
each motor winding phase, i.e. cables V1-U1,
c) Check the fuses contained in the fused V1-W1 and U1-W1.
terminal blocks F1 to F5. Renew any fuse
c) The readings between each of the phases
found to be blown. If a fuse blows repeatedly
should be greater than 2 megohms.
continue to check along the circuit for any
short circuits or failed devices, as explained in d) If the insulation resistance is zero an
detail throughout this Chapter. inter-winding short circuit exists.
Renew/service the main motor.
d) Disconnect each 24V power supply circuit at
the device end and measure the voltage. If e) If the insulation resistance is below 2
the voltage is different from that measured at megohms conductive material or moisture is
the transformer, or the voltage is zero, renew present in the motor. Service the main motor.
the power supply circuit wiring.
f) Measure the insulation resistance between
11.12.2 To Check the Main Power Supply each motor winding phase cable (U1, V1 and
W1) and earth.
a) Measure and record the voltage between the
Red and Yellow, the Red and Blue, and the g) If the insulation resistance is below 2
Yellow and Blue incoming phases. The megohms renew/service the main motor.
readings should be within 10% of the
h) Carry out the motor current tests below.
specified working voltage on the motor
nameplate. Note: DO NOT apply power to a motor which
has an insulation resistance of less than 2
b) Measure and record any voltage drop during a
megohms.
motor start sequence. Any voltage drop will
cause an increase in normal starting current. 11.13.3 Motor Current
Excessive increases will cause tripping
a) Check that the motor nameplate shows the
problems.
correct working voltage for the compressor
c) If tripping occurs on start-up check the mains supply. Record the details given on the
connections in the remote isolator or fuse box plate, i.e.:
enclosure. If the connections are good check
Motor type
the main supply cable sizes.
Motor serial number
Working voltage
Full load line current (FLC) figure.
Note: Motors which operate over a voltage
band will give full load line current figures for
both the minimum and maximum working
voltages.

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b) Switch power on and start the compressor. 11.13.4 To Check the Fan/Oil Pump Motor
(Connection Diagram 1 of 6)
c) Using a calibrated pressure gauge ensure that
the compressor delivery pressure does not 11.13.5 Motor Insulation
exceed its rated working pressure.
This procedure is the same as in para 11.13.1
d) Measure and record the ac mains supply ‘To Check the Main Motor’ above.
voltage. If this is incorrect recheck the mains
11.13.6 Motor Current
power supply, see para 11.12.2 ‘To Check the
Mains Power Supply’ and power cables. a) If the supply voltage is correct, use a
calibrated clip-on ammeter to measure and
e) If the supply voltage is correct use a
record the currents in the cables to the fan
calibrated clip-on ammeter to measure and
motor terminals U1, V1 and W1. The readings
record the currents in the motor cables U1, V1
relate directly to the motor F.L.C. and should
and W1.
not exceed 5.6% above the figure given on
f) Add together the three motor (delta loop) the motor plate.
currents and divide by three to get the
b) Typical FLC figures for 3-phase, standard
average. If any one of the currents is more
production, squirrel cage compressor motors
than 5% different from the average it is more
are:
likely that a phase voltage imbalance exists
rather than a motor fault, see para 11.12.2 ‘To
Check the Mains Power Supply’. Motor FLC

g) Multiply the average motor current by 1.732 to kW 400V 220V


get a ‘line’ current figure. This is the full load 1.5 3.4 6.5
current (FLC) of the motor (provided the
compressor is on load).
The currents quoted above are typical values
h) If the measured working FLC figure exceeds for standard motors of the specified rating.
5.6% above the figure given on the motor Full load currents will vary from motor to
plate, renew/service the motor. motor and the FLC for a particular motor
should be established from the motor
For reference, typical FLC figures for 3-phase,
nameplate.
standard production, squirrel cage
compressor main motors are:

Motor FLC
hp kW 415V 220V
100 75 131 240
125 90 166 285
150 110 192 350
250 185 315 575

The currents quoted above are typical values


for standard IP22 motors of the specified
rating. Full load currents will vary from motor
to motor and the FLC for a particular motor
should be established from the motor
nameplate.

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11.14 Control Inputs c) Renew the pressure switch if open circuit.


d) Check the continuity between plug pins
WARNING
ML1/11 and ML1/12. Renew cables if open
circuit.

• Refer to the safety procedures before e) Check continuity between terminal X01/4 and
carrying out electrical checks. socket pin ML1/11 and between terminal X3/1
and socket pin ML1/12.
Caution: The high voltage (primary) and f) Renew any open circuit cable.
low voltage (secondary) circuits must NOT 11.14.3 To Check the Oil Pressure Switches
be connected in any way (e.g. via test S501/S502 - Early Machines (Current
probes, wiring etc.) Machine has an Oil Pressure Sensor)
11.14.1 To Check the Air Filter Differential Pressure See Connection Diagram 5 of 6 (fig. 11.30)
Switch (S301)
The oil pressure switch contacts are normally
(Connection Diagram 3 of 6) open. This indicates that the pressure in the
The air filter differential pressure switch oil system is below 1.5 bar. When the oil
contacts are normally open. This indicates pump is running the contacts will close.
that the air filter element differential pressure a) With the oil pump running, disconnect the
is within limits. When the filter requires cables from the pressure switch.
changing the inlet valve suction exceeds 65
mbar below atmospheric pressure and the b) Check that the pressure switch is closed by
contacts of switch S301 close. checking continuity between the switch
terminals.
a) Disconnect the cables from the pressure
switch. c) Renew the pressure switch if open circuit.
b) Check that the pressure switch is open circuit d) Check the continuity between plug pins
by checking continuity between the switch ML1/30 and ML1/31 or ML1/32 and ML1/33.
terminals. Renew cables if required.
c) Renew the pressure switch if closed circuit. e) Check continuity of all wires in the oil pressure
switch circuits.
d) Check the continuity between plug pins ML1/9
and ML1/10. Renew cables if closed circuit. f) Renew any open-circuit cable.
e) Check continuity between terminal X01/3 and 11.14.4 To Check the Oil Pressure Sensor P303 -
socket pin ML1/9 and between terminal X3/1 Current Machines
and socket pin ML1/10. See Connection Diagram 3 of 6 (fig. 11. 22)
f) Renew any open circuit cable. a) Fit an ammeter in line cable no. 323 (X02/5) -
11.14.2 To Check the Oil Filter Differential Pressure see section 11.16.
Switch (S302) b) Start the oil pump running and check that the
(Connection Diagram 3 of 6) minimum current is 5.23 Amp.
The oil filter differential pressure switch c) Check the continuity between ML2/5 and
contacts are normally closed. This indicates P303/1 and ML2/6 and P303/2.
that the oil filter element differential pressure d) Renew pressure sensor if no current is
is within limits. When the oil filter requires measured.
changing the pressure drop across the filter
exceeds 2 bar and the contacts of switch e) Renew any open-circuit cable.
S302 open. 11.14.5 To Check the Oil Level Sensor
a) Disconnect the cables from the pressure The oil level sensor is an optical liquid level
switch. sensing device. When oil covers the sensor
b) Check that the pressure switch is closed by the output is 0v. When the oil level drops and
checking continuity between the switch the sensor is exposed to air the output will
terminals. switch high (20v dc) and the SureScan will
display low oil level. To check the sensor:

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a) Measure the dc voltage between terminal by more than 15% of the relay voltage, the
block X3/1 and earth. The reading should be relay contacts will open circuit and the
between 18 and 24 volts. If the voltage is low controller will display a phase rotation fault.
see para 5.1 'To check the 24V ac supply An incorrect phase rotation will be detected as
circuits'. soon as power is applied to the compressor. If
a phase rotation fault is displayed during a
b) Measure the dc voltage between SureScan
start sequence check that the voltage
terminal X01, pin 5 and earth. If the reading is
adjustment setting is correct.
above 2V and the oil level is correct, renew
the sensor. c) Persistent phase rotation faults during the
start sequence is an indication that the main
c) If the oil level sensor fails to operate when the
power supply voltage is falling below
oil level is low, check the resistance between
acceptable limits as the main motor is
the terminals of resistor block R301. The
accelerating. If this occurs check the main
resistance should be 2·2k ohms ±10%.
power supply voltage.
11.14.6 To Check the Emergency Stop Circuit
11.14.8 Using the Menu Routine ‘Service Diagnostics’
The emergency stop button has two normally Test Facility
closed contacts. One contact is connected to
The Emergency Stop input is tested using the
the 24V ac power supply to controller relay
’Service diagnostics’ test inputs menu routine,
output circuits and the other is connected to
the display will report a closed circuit condition
the SureScan controller.
under normal circumstances. If the
a) To Check the 24V ac circuit. Emergency Stop button is activated or an
open circuit fault exists, the display will report
(i) Measure the voltage between terminal
an open circuit condition. This facility, as with
block X2/1 and X2/2. The reading should be
all the inputs, can be used to quickly identify
between 20 and 28V. If the voltage is low see
and diagnose a fault with the circuit.
5.1 'To check the 24V ac supply circuits'.
(ii) If the reading is zero, measure the voltage 11.15 Control Outputs
between fused terminal F5 and terminal block
X2/2. If this reading is zero check fuse F5. If WARNING
the reading is between 20 and 28V renew the
emergency stop contact.
b) To Check the Emergency Stop Circuit. • Refer to the safety procedures before
carrying out electrical checks.
(i) Check the continuity between the contacts
of the emergency stop button, wires 300 and
301. Caution: The high voltage (primary) and
low voltage (secondary) circuits must NOT
(ii) If the contact is open circuit, renew the be connected in any way (e.g. via test
emergency stop contact block. probes, wiring etc.)
(iii) If the contact is closed circuit, measure the 11.15.1 Main Motor Contactor, Drain and Load
continuity between terminal block X3/1 and Solenoid (Connection Diagrams 1 and 2 of 6)
pin 2 of SureScan terminal X01. If the
continuity is open circuit, renew wire No. 300 a) Ensure the Emergency Stop input has not
from the emergency stop button contact to been operated before checking the outputs,
terminal block X3/1 and wire No. 301 from the see para 7.5 ‘To Check the Emergency Stop
emergency stop button to controller X01 pin 2. Circuit’
11.14.7 Phase Rotation Relay b) The motor contactor, drain and load solenoid
controller outputs are all relay contacts.
a) The phase rotation relay monitors the phase
sequence of the main power supply. If the c) When checking an output ensure the 24V ac
phase sequence (U, V and W) is incorrect the supply to each output channel is good.
relay contacts will open circuit and the d) Measure the voltage of the output, while the
controller will display a phase rotation fault. output is operated, using the Service
b) The phase rotation relay also monitors the Diagnostic – test outputs function.
main power supply voltage. If the voltage falls

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e) If an output fails to function renew the a) Ensure the Emergency Stop input has not
controller. been operated before checking the outputs
(see para 11.14.6 ‘To Check the Emergency
f) Continue to check the output voltage along
Stop Circuit’).
the circuit being tested. Renew any
connections or wiring as necessary. b) Check that the fan motor overload relays
F102 and F103 and the oil pump motor
g) If the voltage across the terminals of the
overload relay F104 have not tripped.
contactor or solenoid coil being tested is
within the range 20V to 28V ac when the c) Operate the fan output, using the Service
controller output is switched on, renew the Diagnostics ‘Test Outputs’ function.
contactor or solenoid.
d) Measure the dc voltage across the coil of fan
11.15.2 Fan Contactors KM204/KM205 and Oil Pump relays K201 and K202. The voltage should be
Contactor KM 206 (see figs. 11.16, 11.20 and in the range 18V to 28V.
11.21)
e) If the voltage is incorrect or zero, check the
Caution: The controller fan contactor and wiring to relays K201and K202. Renew as
oil pump outputs are NOT relay contacts. necessary.
The output is a low current transistor type
f) If the voltage is correct and relay K201or
and can only operate the relay specified by
K202 fails to operate, renew the relay.
CompAir. Do NOT use any other device or
connect any other circuit to the controller g) If the relay operates satisfactorily, check the
fan contactor output. voltage between terminal blocks X2/1 and
X2/2. The voltage should be in the range 20V
The fan contactor output operates an auxiliary
to 28V ac.
fan relay K201. Relay K201 switches 24V ac
which operates the fan contactors KM204 and h) If the voltage is incorrect, check the 24V
KM205 simultaneously. The oil pump power supplies (see para 11.12.1 ‘To Check
contactor output operates an auxiliary relay The 24V ac Supply Circuits’).
K202. Relay K202 switches 24V ac which
operates the oil pump contactor KM 206.

CONTROLLER

X08
1 2 3 4 5 6 7 8 9 10

24V a.c.
X2/1 X2/1 X2/1 X2/1 X2/1

MAIN STAR DELTA LOAD DRAIN

0V a.c.
X2/2 X2/2 X2/2 X2/2 X2/2 SM 0716

Fig. 11.15 - Controller Relay Contact Outputs

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i) If the voltage is correct, check the voltage k) After a fan or oil pump contactor failure, check
across the coil of fan contactors KM204 and the continuity of the fan/oil pump overload
K205 or oil pump contactor KM 206. relay auxiliary switch. Renew the overload as
necessary.
j) If the voltage is incorrect check the contactor
wiring and the contact of relay K201 or K202. l) If the voltage is correct renew the fan or oil
Renew as necessary. pump contactor as necessary.

24Va.c. X2/1

X09/4
(232**) (225)

K202
CONTROLLER
24Va.c. X2/1

*20V +ve
X09/1 X2/6
(230) (223)
(225)

K201

(220)
X09/2 X2/5 X2/5
(231)

F102 F103 F104

INCOMING FAN FAN OIL


SUPPLY PUMP
KM204 KM205 KM206
* 20V -ve ON EARLIER MODELS
** 233 ON EARLIER MODELS
(208) (208) (208)
0Va.c.
SM 1102 X2/2 X2/2 X2/2

Fig. 11.16 - Fan/Oil Pump Contactor Circuit

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11.16 Sensors a) Remove the plug from the pressure sensor,


switch power ON and ignore any displayed
WARNING fault message.
b) Measure the dc voltage across the two plug
terminals. The reading should be between
• Refer to the safety procedures before 18V and 24V.
carrying out electrical checks.
c) If the voltage is incorrect see para 5.1 ‘To
Check The 24V ac Supply Circuits’.
Caution: The high voltage (primary) and
low voltage (secondary) circuits must NOT d) Re-connect the pressure sensor plug and
be connected in any way (e.g. via test disconnect one of the plug wires.
probes, wiring etc.) e) Connect the multimeter between the
11.16.1 To Check the Delivery and Interstage disconnected end of the cable and the plug
Pressure Sensors (P301/302) (Connection terminal.
Diagram 3 of 6) f) Measure the dc current. The reading should
The pressure sensors are 4-20 mA, 0-200 psi be as given in the pressure sensor output
type. The current in the 24V dc sensor power table below.
supply cables will change in proportion to the g) If the current is not within ± 5% of the figure
pressure acting on the pressure sensors. given check the wiring and connections of the
pressure sensor circuit.

CONTROLLER
PRESSURE
SENSOR
PLUG
1 ML2/1
X02/1
2 ML2/2
X02/2

INTERSTAGE
PRESSURE
SENSOR X02/4

PI/97/114

Fig. 11.17 - Measuring The Sensor Current

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h) Renew the pressure sensor if no wiring or b) The sensor resistance depends on the
connection faults can be found. temperature (see the Temperature/Sensor
resistance table below). If the resistance
i) If the current is NOT within ± 5% of the figure
varies by more than ± 5% from the figure
given, renew the controller
given in the table, renew the sensor.
Sensor Sensor c) If the resistance is correct re-connect the
Pressure Pressure sensor cables and remove plug ML1.
Output Output
(bar) (bar)
(mA) (mA)
d) Measure the resistance between the
0·0 4·00 7·5 12·70 appropriate pins of plug ML1. If the resistance
is not as given in the table renew the sensor
0·5 4·58 8·0 13·27
cables.
1·0 5·16 8·5 13·86
e) If the resistance is correct re-connect plug
1·5 5·74 9·0 14·44 ML1 and disconnect the sensor cable from the
2·0 6·32 9·5 15·02 extension module terminal X08.

2·5 6·90 10·0 15·60 f) Measure the resistance between the


disconnected cable end and terminal X6/1. If
3·0 7·48 10·5 16·18 the resistance is not as given in the table
3·5 8·06 11·0 16·75 renew the sensor cables as necessary.
4·0 8·64 11·5 17·33 Temp Sensor Res. Temp Sensor Res.
(°C) (ohms) (°C) (ohms)
4·5 9·22 12·0 17·91
-10 1512 65 2676
5·0 9·80 12·5 18·49
-5 1576 70 2768
5·5 10·38 13·0 19·07
0 1640 75 2860
6·0 10·96 13·5 19·65
5 1712 80 2960
6·5 11·54 13·8 20·00
10 1784 85 3060
7·0 12·12
15 1856 90 3160
11.16.2 To Check the Plant Delivery/Stage 2 Intake or 20 1928 95 3260
Oil Temperature Sensor - R601, R602 and
25 2000 100 3360
R603 (Connection Diagram 6 of 6)
30 2080 105 3468
The Temperature Sensor is a spreading
resistance type thermistor. The resistance of 35 2160 110 3576
the thermistor will increase as the applied
40 2240 115 3684
temperature increases.
45 2320 120 3792
a) Switch power off. Disconnect the cables from
the temperature sensor and measure its 50 2400 125 3900
resistance.
55 2492 130 4000
60 2584

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11.16.3 To check the PT1000 temperature sensors - 11.16.4 To Check the Main Motor Thermistors
R605 to R608 (Connection Diagram 6 of 6) (Connection Diagrams 1 and 3 of 6)
The PT1000 temperature sensors exhibit a) Switch power off and disconnect the main
different resistance characteristics from low motor thermistor cables. Measure the
temperature spreading resistance type resistance between the cable ends. The
sensors. resistance should be between 50 and 300
ohms.
a) Switch power off. Disconnect the cables from
the temperature sensor and measure its b) If the resistance is not within the limits given
resistance. renew/service the main motor thermistors.
b) The sensor resistance depends on the c) If the resistance is within the limits given
temperature (see the Temperature/Sensor check the continuity and connections of cable
resistance table below). If the resistance 308 and connector CL1/4. Renew cables and
varies by more than ± 5% from the figure remake connections as necessary.
given in the table, renew the sensor.
d) Check the continuity of auxiliary contact KM
c) If the resistance is correct re-connect the 201.
sensor cables and remove plug ML1.
d) Measure the resistance between the
appropriate pins of plug ML1. If the resistance
is not as given in the table renew the sensor
cables.
e) If the resistance is correct re-connect plug
ML1 and disconnect the sensor cable from the
extension module terminal X07.
f) Measure the resistance between the
disconnected cable end and terminal X6/2. If
the resistance is not as given in the table
renew the sensor cables as necessary.
Temp Sensor Res. Temp Sensor Res.
(°C) (ohms) (°C) (ohms)
-10 960.86 110 1422.9
0 1000 120 1460.7
5 1019.5 130 1498.3
10 1039 140 1535.8
15 1058.5 150 1573.3
20 1077.9 160 1610.5
25 1097.3 170 1647.7
30 1116.7 180 1684.8
40 1155.4 190 1721.7
50 1194 200 1758.6
60 1232.4 210 1795.3
70 1270.8 220 1831.9
80 1309 230 1868.4
90 1347.1 240 1904.7
100 1385.1 250 1941

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11.17 Controller 11.17.5 LCD Text Display Contrast

The Controller contains three cards: The text display contrast is set in the factory
to give clear visibility and definition. The
The Controller runs the control program contrast of the display can be re-adjusted to
contained in the program IC and is suit particular circumstances by means of an
responsible for the control and monitoring of adjustment on the control card within the
the compressor system. controller.
11.17.1 To Check the Control Panel a) If the text display is faint and difficult to see,
11.17.2 The Control Panel LED indicators and the adjust the contrast adjustment one tenth of a
Control Panel buttons can be tested by using turn clockwise.
the test routines in the ‘Service Diagnostics’ b) If the text display is too dark, adjust the
sub-menu. contrast adjustment one tenth of a turn
11.17.3 The ‘Power On’ indicator should be lit anti-clockwise.
whenever power is applied to the compressor. c) Repeat as necessary.
The ‘Remote Control Enabled’ and ‘Auto
Re-start Enabled’ indicators can be tested Note: Do not attempt to re-adjust any other
using the ‘Test Output’ routine in the ‘Service setting. There are several adjustments on the
Diagnostics’ sub-menu. control cards which are pre-set and, if altered,
would affect accuracy and performance.
11.17.4 All input and output functions can be tested
using the test facilities of the ‘Service
Diagnostics’ sub-menu

CAUTION

• When working with static sensitive


components, ie, circuit cards and
memory IC’s etc, always take antistatic
precautions.

1. Always transport static sensitive


components in anti-static bags or containers.

2. Never touch the metal pins of electronic IC


devices.

3. Never place static sensitive components


onto a metal surface. Always place directly
into an anti-static bag or container.

4. Always ensure any body static is


discharged before handling static sensitive
components by touching an earthed surface
at regular intervals.

156 DL051AAA
CompAir Electrical Systems 11

SM 0711

Fig. 11.18 - Arrangement Of Controller Cards

11.17.6 Control Program IC


Instructions for renewing the control program f) The control program IC can be removed
IC within a C20606-130 SureScan controller. without dismantling the three circuit Cards. To
eliminate the possibility of re-connection
a) Remove the controller from the compressor.
errors, it is recommended that the circuit
b) Remove the six screws located adjacent to cards are not dismantled .
the electrical plug connections on the rear of
Note: Before removal of the control program
the controller.
IC, make a note, or pencil sketch, of the
c) Using a spanner, remove the two (plug orientation and position of the IC in its socket.
securing) nuts adjacent to the Note the orientation marks on the IC, socket
communications connection X04 and circuit board. Also note the position of the
four unused holes on the IC socket.
d) Remove the four rear controller enclosure
securing screws. g) Using a small screwdriver, or similar tool,
carefully remove the control program IC from
e) Remove the rear controller cover.
its socket.

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11 Electrical Systems CompAir

h) Insert the new control program IC. Check the c) All input and output functions on the
orientation and ensure that each pin enters Extension module can be checked by using
the socket correctly. (The pins may bend the 'Service Diagnostic Routines'. An
underneath the IC during insertion.) 'Extension module fault' display on the
controller indicates that the complete
Note: The IC socket has four extra holes
Extension module is faulty and must be
which are not used. Ensure none of the
renewed. Individual input or output faults will
control program IC pins are inserted into
be reported separately by the SureScan, in
these holes.
the normal manner.
i) When re-assembling the controller, replace
11.17.8 To Check the Extension Module Power
the four rear cover securing screws first to
Supply Circuits
hold the cover in place. Then insert and
tighten the six screws and two nuts, adjacent a) Measure the dc voltage between pins 1 and 6
to the electrical plug connections, before on terminal X08 of the Extension Module. The
finally tightening the rear cover screws. voltage should be between 18V and 22V.
j) Re-connect to compressor and test. b) If the voltage is within limits check/renew the
data cable and connections from the
11.17.7 To Check the Extension Module
Extension module to the SureScan controller.
a) The extension module is connected to the
11.17.9 If the voltage is low, measure the ac voltage
SureScan controller via a screened data cable
between pins 1 and 2 on terminal X04. The
and integrates with the controller in operation
voltage should be between 20V and 28V.
to form a single control unit.
Check the control transformer output and
b) If the Extension module fails to respond wiring if the voltage is low or check fuses F3
correctly the SureScan will display 'Extension and F4 if the voltage is zero.
module fault'.

6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1
X08 X07 X06 X05

X09 Extension Module C20606-71

RS 485
X01 X02 X03
X04 2
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 24Vac 1

SM 0886

Fig. 11.19 - Extension Module

158 DL051AAA
CompAir Electrical Systems 11

Fig. 11.20 - Electrical Connection Diagram - Current Machines - (1 of 6)

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11 Electrical Systems CompAir

Fig. 11.21 - Electrical Connection Diagram - Current Machines - (2 of 6)

160 DL051AAA
CompAir Electrical Systems 11

Fig. 11.22 - Electrical Connection Diagram - Current Machines - (3 of 6)

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11 Electrical Systems CompAir

Fig. 11.23 - Electrical Connection Diagram - Current Machines - (4 of 6)

162 DL051AAA
CompAir Electrical Systems 11

Fig. 11.24 - Electrical Connection Diagram - Current Machines - (5 of 6)

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11 Electrical Systems CompAir

Fig. 11.25 - Electrical Connection Diagram - Current Machines - (6 of 6)

164 DL051AAA
CompAir Electrical Systems 11

Fig. 11.26 - Electrical Connection Diagram - Early Machines - (1 of 6)

DL051AAA 165
11 Electrical Systems CompAir

Fig. 11.27 - Electrical Connection Diagram - Early Machines - (2 of 6)

166 DL051AAA
CompAir Electrical Systems 11

Fig. 11.28 - Electrical Connection Diagram - Early Machines - (3 of 6)

DL051AAA 167
11 Electrical Systems CompAir

Fig. 11.29 - Electrical Connection Diagram - Early Machines - (4 of 6)

168 DL051AAA
CompAir Electrical Systems 11

Fig. 11.30 - Electrical Connection Diagram - Early Machines - (5 of 6)

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11 Electrical Systems CompAir

Fig. 11.31 - Electrical Connection Diagram - Early Machines - (6 of 6)

170 DL051AAA
CompAir Dismantling & Assembly 12

12.1 Air Intake Filter Assembly


12 Dismantling &
12.1.1 To remove air intake filter assembly
Assembly a) Ensure electrical power is switched off at the
WARNING main isolator, fuses are removed and
appropriate warning notices are displayed
b) Remove acoustic enclosure panels as
• Refer to the safety procedures before required.
carrying out any dismantling or assembly
c) Slacken hose clamp (1).
work on the compressor unit.
d) Remove cable tie (3).
• Lethal voltages are used in this
equipment. Use extreme caution when e) Release the two retaining clips (2).
carrying out electrical checks. Isolate the
f) Remove the air intake filter assembly.
power supply before starting any
maintenance work. 12.1.2 To install air intake filter assembly
The installation of the air intake filter assembly
Note: For information regarding the renewal is a reversal of the removal procedure.
of electrical components, see Chapter 11.
For further information about this
component, see section 8.1

For maintenance details, see


section 10.6

SM 1007

Fig. 12.1 - Air Intake Filter Assembly


1. Hose Clamp 4. Inlet Hose
2. Quick-Release Clip 5. Outlet to Suction Regulator
3. Cable Tie

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12.2 Suction Regulator

1
2
3
4 5
6
7 8 9 8
10

21

11 24
12

23 22 20
19 18
SM 1026 17 16
15 14
13

Fig. 12.2 - Suction Regulator


1. Suction Regulator Body 9. Diaphragm 17. Locator
2. Locknut 10. Locknut 18. Joint
3. Valve Plate 11. Springs 19. Screw
4. Stem 12. Screw 20. Washer
5. Joint 13. By-pass Valve Box * 21. Seal
6. Valve Seat Support Flange 14. Screw 22. Washer
7. Seal 15. Support 23. Nut
8. Diaphragm support 16. By-pass Valve 24. By-pass Seat Support Flange

* Note: Orientation of item 13 can vary


through 90° depending on silencer fitted.

172 DL051AAA
CompAir Dismantling & Assembly 12

12.2.1 Remove suction regulator (see fig. 12.3) i) Remove screws and washers securing
suction regulator body to compressor inlet.
a) Ensure electrical power is switched off at the
main isolator, fuses are removed and SM 1023
appropriate warning notices are displayed.
b) Remove acoustic enclosure panels as
required.
c) Slacken the clamps (2) securing the air intake
hose (1) to suction regulator (3) and move the
hose away from the suction regulator. If
necessary, remove the air intake filter (see
para 12.1.1 ‘Remove Air Intake Filter
Assembly’).
d) Disconnect all regulation system pipes from
the suction regulator.
Fig. 12.4 - Suction Regulator
e) Remove two screws (8) and washers securing
Securing Screws
blowdown elbow (7) to discharge silencer and
remove, together with 'O' ring (9).
j) Attach lifting gear and sling to suction
f) Unscrew flexible blowdown pipe (6) from
regulator and remove.
valve box and remove.
g) On earlier machines, remove the blowdown
silencer (4) from the valve box.
h) On current machines, disconnect the solid
blowdown silencer pipe (5) from the side of
the valve box and tie back securely out of the
way.

4
1 2 3

6
7

9 8 Fig. 12.5 - Removing Suction Regulator

SM 1009 k) Finally, blank off the air-end inlet aperture


using adhesive tape.
Fig. 12.3 - Suction Regulator
1. Regulator Body 6. Blowdown Pipe
2. Hose Clamp 7. Elbow
3. Suction Regulator 8. Screw
4. Silencer (early m/c's) 9. 'O' Ring
5. Silencer (current m/c's)

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12 Dismantling & Assembly CompAir

12.2.2 Dismantle Suction Regulator Caution: Ensure the diaphragm does not
rotate, otherwise it will be damaged. Use a
Warning: Do not attempt to dismantle the
backing spanner behind the locator.
suction regulator before removal from the
air-end.
a) Remove the suction regulator from the air end
as described in Section 12.2.1 - ‘Remove
Suction Regulator’.
b) Remove four screws (12) securing the
by-pass valve box (13) to the by-pass seat
support flange (24).
SM 1027

Fig. 12.8 - Ensuring Diaphragm Does Not


Rotate

12 Warning: Do not attempt to remove the


by-pass seat support flange before
releasing compression on the diaphragm
springs. Failure to heed this warning could
result in personal injury.
13
24 e) Remove TWO DIAMETRICALLY OPPOSED
SCREWS from the by-pass seat support
Fig. 12.6 - Removing By-pass Valve Box flange (24 or 27). Select two x 270 mm
(minimum) lengths of 12 mm studding and
screw into holes. Screw a nut down each stud
c) On removal of by-pass valve box, until it contacts the cover face.
check/examine:-
f) Remove the remaining screws and washers
(i) unloader seat. from the by-pass seat support flange.
(ii) plunger seal surface. g) Remove valve assembly.
Loosen the stud nuts. The valve will separate
(iii) for proper seat alignment.
either (1) at the gasket or (2) at the diaphragm
d) Remove screw (14), support (15), by-pass surface. Use a soft-faced hammer if
valve (16) and locator (17) from valve stem necessary.
(4).

4 17
16 15 14

24 SM 1029

Fig. 12.7 - Dismantling By-pass Valve

174 DL051AAA
CompAir Dismantling & Assembly 12

(1) If the valve separates at the gasket, carefully Separate the valve seat support flange from
retain spring cavity with two diametrically the face of the regulator body using a
opposed bolts and nuts as shown in fig. 12.9. soft-faced hammer.
Note: Where difficulty is experienced in
separating the valve seat support flange from
the regulator body, a knife-edge wedge may
be used. Take care to avoid damaging the
castings.
h) Remove the operating springs and the two
studs/nuts.
i) See Fig. 12.11. Remove the locknut (10)
securing the diaphragm supports (8) (between
which the diaphragm (9) is sandwiched).
1 2 3
6 7 4 8 9
8 10 11
Fig. 12.9 - Spring Cavity Retained With
Bolts/Nuts

Continue unscrewing the two stud nuts until


the valve assembly can be withdrawn over the
studs and removed from the regulator body.
Remove the two studs from the face of the
regulator body and re-insert them into the
holes in the valve assembly which they
occupied previously. Assemble the studs with
nuts and washers each side of the valve
assembly. Remove the bolts and nuts
indicated in fig. 12.9, then unscrew the stud
nuts evenly until the operating springs (A) are Fig. 12.11 - Suction Regulator
fully extended.
j) Remove the diaphragm support, diaphragm
SM 0963
and stem complete with valve plate (3) from
the valve seat support flange.
k) Remove locknut (2) and valve plate (3) from
stem.
12.2.3 Examine/Renew Worn Parts
Clean and examine all parts for wear or
damage. Renew all worn or damaged parts.
Note: It is recommended that all seals and
A sleeves are renewed before re-assembling
the component.

Fig. 12.10 - Releasing Spring Pressure

(2) If the valve separates at the diaphragm,


continue unscrewing each stud nut equally
until the operating springs (A) are fully
extended.

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12.2.4 Assemble Suction Regulator Caution: When assembled, the seal lips
must not protrude outside the housings
See Fig. 12.11.
b) See fig.12.11. Refit valve plate (3) to stem (4)
a) Apply ‘Loctite 620’ to housing bores and new
and secure with locknut (2).
seals. Fit new seals (7 & 21) into the valve
seat support flange (6) and by-pass seat c) Apply special grease ‘Autol-Top 2000’ (Part
support flange (24). Ensure that the seals are No. 100006579) to new seals and carefully
fitted in the direction of arrows shown on pass stem (4) through the valve seat support
Valve Seat Support Seal and By-pass Seat flange.
Support Seal on Figs. 12.12 and 12.13.
d) Position new joint (5) on valve seat support
flange and locate the suction regulator
body (1).
e) Screw two studs used in the dismantling
sequence, into two diametrically opposed
holes in the valve seat support flange and
suction regulator body.
Caution: During the following steps,
ensure that the diaphragm is not twisted
SM 0728 during assembly.

Fig. 12.12 - Valve Seat Support Seal f) Locate the diaphragm supports (8) and
diaphragm (9) on stem (4). Position the
diaphragm carefully over the two studs and
secure with locknut (10).
Note: Allow ‘Loctite 620’ a curing time of 24
hours minimum before inserting the stem (see g) Position springs inside the by-pass seat
manufacturer's instructions). support flange, locate the by-pass seat
support flange on the studs and attach the
nuts.
h) Ensure that the springs are correctly located
on the diaphragm support and progressively
tighten the two nuts until the securing screws
and washers can be fitted.
i) When the securing screws are tight, replace
the two nuts and studs with the remaining two
screws and washers.
SM 0729 j) Position joint (18) and fit locator (17), by-pass
valve (16) and support (15) to stem (4) and
Fig. 12.13 - By-pass Seat Support Seal secure with screw (14).

176 DL051AAA
CompAir Dismantling & Assembly 12

k) See Fig. 12.14. Fit by-pass valve box (A) to 12.3 Aftercooler
by-pass seat support flange (B) and secure
with screw (C), washer (D) and nut (E). 12.3.1 To remove the aftercooler
Ensure valve box is orientated correctly for a) Make sure the machine is isolated of all power
silencer fitted (see fig. 12.3). and all pressure released from the system.
SM 1030 b) Disconnect discharge port from customer's air
network.
c) Remove the two side doors closest to the
delivery end, via the upper release hinge.

E
D
A
B C

Fig. 12.14 - By-pass Valve Box

12.2.5 Install Suction Regulator


Fitting the suction regulator is a reversal of the
removal procedure.

For further information about this


component, see section 8.16
SM 0951

Fig. 12.15 - Removing Side Access Panels

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12 Dismantling & Assembly CompAir

d) Remove the 2 retaining capscrews from the g) Remove the four retaining screws (2) and
top edge of the central panel. washers (3) fixing the moisture separator (4)
to the discharge column.
e) It should now be possible to tilt the top edge of
the panel forward and lift it off the locating
pins at the base.

SM 1017

Fig. 12.18 - Discharge Column Fixings

h) Remove 4 screws (1) attaching the drain


valve manifold (2) to the lower portion of
discharge column.

Fig. 12.16 - Removing Front Access Panel

f) Insert screws in opposing holes of the delivery


flange and, with the help of a metal bar or
similar, unscrew the flange from the delivery
port.

Fig. 12.19 - Removing Valve Manifold


Fixings
SM 1010

Fig. 12.17 - Unscrewing Delivery Flange

178 DL051AAA
CompAir Dismantling & Assembly 12

i) Remove fixings from the top and bottom of k) Remove four screws and spring washers
both left and right column panels and remove (2 & 3) fixing the discharge assembly to
from compressor. aftercooler. Remove and discard 'O' ring (5)
(renew on re-fitting - see parts manual for
details).

7 1

2
3
6 5

SM 0954 SM 1018/1

Fig. 12.20 - Removing Column Panels Fig. 12.21 - Temperature/Pressure Sensors


1. Sensor cable 6. Aftercooler
j) Disconnect cables from temperature and 2. Washer 7. Sensor cable
pressure sensors (1 & 7)) on the delivery 3. Screw 8. Breather
elbow. Disconnect flexible pipe from bottom of 4. Moisture separator supply line
moisture separator and, if applicable, powered 5. 'O' ring
breather supply line (8) from side of discharge
port. l) Remove four screws and spring washers (10
& 11) fixing the flexible pipe to the entry port
of the aftercooler. Remove 'O' ring.

11
10

12

SM 1019

Fig. 12.22 - Aftercooler Inlet Fittings

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m) To allow access to the fixings at the rear of o) With assistance, carefully lift the aftercooler
the cooler, loosen the 6 quick-release fixings clear of the compressor.
(1) securing the duct access panel (2) and
Warning: Aftercooler weighs approx. 80kg
remove.
1
1

2
1
1 SM 1020

Fig. 12.25 - Removing Aftercooler


1 SM 0971

For further information about this


Fig. 12.23 - Cooler Access Panel Fixings component, see section 8.2

n) Remove the 6 screws, washers and nuts,


securing the base of the aftercooler (three of
these screws can be accessed via the
previously removed access panel).

Fig. 12.24 - Aftercooler Fixings

180 DL051AAA
CompAir Dismantling & Assembly 12

12.4 Intercooler d) Remove the 6 screws, washers and nuts


securing the base of the intercooler to the oil
12.4.1 To remove intercooler cooler (or spacer on models up to and
a) Carry out procedure for removing aftercooler. including D90).

b) Unplug the cables from their sensors on the e) With assistance, carefully lift the intercooler
side of the intercooler (D110-D150 shown, clear of the compressor.
D55-D90 one sensor above and below inlet Warning: Intercooler weighs 50kg approx.
flange).
SM 0968

SM 1021

Fig. 12.28 - Removing Intercooler

For further information about this


component, see section 8.8

Fig. 12.26 - Intercooler Temperature


Sensor

c) Remove the 4 screws and spring washers (10


& 11) securing the 1st stage discharge pipe to
the intercooler inlet. Remove 'O' ring (12).
Similarly, remove the 4 screws and spring
washers securing the 2nd stage inlet pipe to
the intercooler outlet.

11
10

12

SM 1019

Fig. 12.27 - Intercooler Inlet Fixings

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12.5 Oil Cooler 12.6 Cleaning Coolers


12.5.1 To remove oil cooler WARNING
a) Carry out procedure for removing intercooler.
b) Unplug the temperature sensor cable. • Cleaning these items is a specialised
c) Using a suitable container capable of holding function and should be entrusted to
50 litres, drain the machine of oil as detailed qualified contractors. The following
in section 10.9.2 instructions are a general guide only.
d) Place a suitable container capable of holding
20 litres under the oil cooler drain and operate 12.6.1 External
the switch-activated oil cooler drain valve. Clean the radiator and cooler fins using a
e) Remove flexible hoses from the coned unions compressed air or water jet parallel to the fins.
at the oil cooler inlet and outlet points. If using cleaning additives with the water
ensure they are compatible with aluminium.
f) Remove hose from oil cooler drain
12.6.2 Internal
g) Remove the 6 screws, washers and nuts,
fixing the base of the intercooler to the spacer Due to the nature of the materials necessary
attached to the compressor's base. to clean the tanks and tubes successfully,
CompAir recommend internal cleaning be
h) With assistance, carefully lift the oil cooler entrusted to qualified contractors.
clear of the compressor .
Warning: Oil cooler weighs 30kg

SM 1022

Fig. 12.29 - Removing Oil Cooler

For further information about this


component, see section 8.12

182 DL051AAA
CompAir Dismantling & Assembly 12

12.7 Oil Pump 12.7.2 Dismantle Oil Pump

12.7.1 Remove Oil Pump At the time of going to print, no further details
were available. Please contact CompAir
a) Ensure electrical power is switched off at the AfterMarket.
main isolator, fuses are removed and
appropriate warning notices are displayed
b) Remove acoustic panel, drain oil and For further information about this
disconnect cables/pipework as described in component, see section 8.14
para. 12.9.1.
c) Remove the 4 bolts securing the motor and
pump to the baseframe and lift unit clear.

2
3
4
5
6
7
8
9
10

11
12
13
18

17
16

15
14
SM 0980

Fig. 12.30 - Oil Pump (Current Models)


1. Adaptor Plates 10. Inner/Outer Gearotor
2. Shaft Half Coupling 11. Needle Bearing
3. Coupling Insert 12. O-ring
4. Pump Half Coupling 13. Pump Cover
5. Circlip 14. Capscrew
6. Seal 15. Washer
7. Needle Bearing 16. Capscrew
8. Pump Body 17. Washer
9. Drive key 18. Dowel Pin

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12.8 Condensate Drain Solenoid Valve 12.9 Main Drive Motor


(2 Way Normally Closed) 12.9.1 Remove Main Drive Motor
12.8.1 Dismantle Solenoid Valve a) Ensure electrical power is switched off at the
a) Remove the four screws and securing the main isolator, fuses are removed and
body (1) to the base (7). appropriate warning notices are displayed.

b) Remove the spring loaded poppet valve (5) b) Remove acoustic panels and enclosure
and spring (6). framework as required.

12.8.2 Examine/Renew Worn Parts c) Disconnect electrical cables and conduit at


starter box, remove cable tie wraps and stow
Clean and examine all parts for wear or cables at a convenient position on motor.
damage. Renew the valve if wear or damage
is apparent. d) Disconnect earthing bolt (Fig. 12.32 (1)).

12.8.3 Assemble Solenoid Valve


a) Place the spring loaded-poppet valve (5)
complete with spring (6) inside body (1 )).
b) Position the base (7) on body (1) and secure
with four screws.

SM 0772
1
2
3

SM 1040 1
5
6 Fig. 12.32 - Earthing Bolt
Main Drive Motor
7

8
10
9

Fig. 12.31 - Condensate Drain Solenoid Valve


(2 Way N/C) - Early Machines
1. Body 6. Spring
2. Plug 7. Base
3. Coil 8. Valve Seat
4. Electrical Connections 9. Inlet Port
5. Poppet Valve 10. Outlet Port

184 DL051AAA
CompAir Dismantling & Assembly 12

e) Fit lifting equipment to motor lifting points 12.9.2 Install Main Drive Motor
(Fig. 12.33 (1)).
a) Ensure mounting feet are fitted
f) Remove 8 screws securing motor to
b) Position motor on frame using lifting
bellhousing (2).
equipment.
g) Remove 4 screws securing mounting feet to
Note: During step c), the flexible drive
frame (3).
clearance is measured through the bell
1 housing aperture.

2 c) Align the flexible drive and push motor into


position, ensuring a clearance of 2 to 6 mm is
maintained between the two drive halves.
d) Secure mounting feet to frame, using 4
screws.
e) Remove lifting equipment and ‘eye’ bolt.
f) Secure motor to bellhousing using 8 screws.
g) Reconnect earthing bolt.
h) Reconnect electrical cables at starter box.
3 i) Check for correct rotation of motor as follows:
(i) Switch electrical power on.

SM 1031
(ii) Touch START and as soon as the motor
rotates, touch STOP.
Fig. 12.33 - Removing Main Drive Motor (iii) Viewing from the front of the compressor,
check the rotation of the main drive
coupling through the bell housing
h) Move motor away from bellhousing to aperture. An arrow showing the correct
disengage the flexible drive and lift clear. direction of rotation can be found on the
i) Remove mounting feet from motor as bell housing.
necessary. j) Refit enclosure framework and acoustic
Note: Servicing of the motor should be done panels.
by experienced personnel.

For maintenance details, see


section 10.14

DL051AAA 185
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12.10 Drive Coupling Inserts


12.10.1 To Renew Drive Coupling Inserts (see fig.
12.34)
a) Using an 8mm allen key through an access
aperture in the bell-housing, remove the 1
coupling bolts (1) securing the coupling ring
(2) in position.
b) Slide the coupling ring towards the gearbox to
expose the coupling inserts (3). Remove the
inserts.
c) Fit new inserts and refit coupling ring. Refit
the coupling bolts and torque tighten to 44
Nm.

For maintenance details, see


section 10.16

3 SM 1074

Fig. 12.34 - Drive Coupling


1. Coupling Bolts
2. Coupling Ring
3. Coupling Inserts

186 DL051AAA
CompAir Dismantling & Assembly 12

12.11 Air-Ends and Gearbox 12.11.2 Install Balance Piston Diaphragms

12.11.1 Remove Balance Piston Diaphragms a) Ensure all mating surfaces are clean.

a) Ensure electrical power is switched off at the b) Position a new diaphragm on the first stage
main isolator, fuses are removed and casing , locate the cover (2) and secure with
appropriate warning notices are displayed screws and washers.

b) Remove acoustic enclosure panels as c) Tighten the screws to 29Nm


required. d) Repeat the procedure at steps 1 and 2 for the
c) Disconnect the regulation air pipe (1) from the second stage casing.
first stage diaphragm cover (2). e) Refit the regulation pipes (1 & 3) to the first
d) Disconnect the regulation air pipe (3) from the and second stage diaphragm covers.
second stage diaphragm cover (4). f) Refit enclosure panels.

2
3
4

Fig. 12.35 - Diaphragm Regulation


Pipework Connections

e) Remove screws and washers securing the


covers to the casing and remove covers.
f) Remove and discard the diaphragms.

DL051AAA 187
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12.11.3 Remove Air Ends/Gearbox/Oil Tank Assembly i) Support the 2nd stage inlet pipework/moisture
separator (fig. 12.37 (3, 4)). Remove 4 screws
a) Ensure electrical power is switched off at the
and separate the 2nd stage inlet pipe (3) from
main isolator, fuses are removed and
the intercooler outlet flexible pipe (2). Remove
appropriate warning notices are displayed.
4 screws and remove adaptor (5) complete
b) Remove acoustic panels and framework as with moisture separator/inlet pipe assembly
required. from 2nd stage inlet.
c) Drain the system of oil as detailed in section SM 1044
10.9.2 - 'To Change the Oil'.
d) Remove the air intake filter assembly as 4
detailed in section 12.1.1 - ‘Remove Air Intake
Filter Assembly’.
e) Remove the suction regulator as detailed in
section 12.2.1 - ‘Remove Suction Regulator’.
f) Remove pipework and electrical connections
from 1st stage discharge silencer 5
(Fig. 12.36 (1)).
g) Support the 1st stage discharge silencer and
separate silencer from intercooler inlet flexible
pipe (2).
3
h) Remove 4 screws securing 1st stage
discharge silencer to first stage air-end outlet
and remove silencer. 2

Fig. 12.37 - Removing 2nd Stage Inlet


Pipework

SM 1043

Fig. 12.36 - Removing 1st Stage


Discharge Silencer
1. 1st Stage Discharge Silencer
2. Intercooler Inlet Flexible Pipe
3. Intercooler

188 DL051AAA
CompAir Dismantling & Assembly 12

j) Remove pipework and electrical connections n) Separate the drive motor from the air end
from 2nd stage discharge silencer (fig. 12.38 bellhousing sufficiently to disengage the
(1)). flexible drive as detailed in section 12.9 -
'Main Drive Motor'.
k) Support 2nd stage discharge silencer
assembly and remove 4 screws attaching the o) Blank off the air-end inlet and outlet apertures,
2nd stage discharge pipe (4) to aftercooler fit lifting ‘eye’ bolts (fig. 12.39 (1)) and attach
inlet flexible pipe (2). lifting equipment.
l) Remove 4 screws securing the 2nd stage p) Remove the two screws (2) attaching the oil
delivery silencer to the air end and remove tank to the base.
silencer/discharge pipe assembly.
1
1

2
3

Fig. 12.38 - Removing 2nd Stage Discharge


Pipework SM 1033

Fig. 12.39 - Air End Lifting Points


m) Disconnect all relevant cables and pipework
(including the powered breather system and
sump oil filler pipe) to allow removal of the air q) Remove airends/gearbox/oil tank assembly
ends/gearbox/oil tank assembly. complete with bell housing.
12.11.4 Install Air Ends/Gearbox/Oil tank assembly
Note: If removed previously, ensure that the
bellhousing is attached prior to positioning on
the base frame.
a) Using lifting equipment, locate the air-end on
the two anti-vibration mounts and secure with
screws and washers.
b) Remove lifting equipment and ‘eye’ bolts.

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c) Push the drive motor towards the air-end and k) Re-connect the silencer to the intercooler inlet
carefully engage the flexible drive. Ensure flexible pipe (??) and secure with 4
clearance between flexible drive halves is 2 to screws/washers.
6 mm.
l) Re-connect pipework and electrical
connections to 1st stage discharge silencer
clearance (1).
min 2mm m) Refit suction regulator in accordance with
max 6mm para 12.2.5 ‘Install Suction Regulator’.
n) Re-connect all remaining cables and pipework
(including powered breather system).
o) Re-fill the oil system with approved
compressor oil.
p) Refit the air intake filter assembly in
accordance with para 12.1.2 ‘Install Air Intake
Assembly’.
q) Ensure oil system is filled to the correct level
SM 1113
(see para 10.9.1 - ‘To Check the Oil Level’ in
Chapter 10).
Fig. 12.40 - Drive Motor & Bell Housing r) Switch on electrical power.
Note: The next two steps apply only to
d) Secure drive motor to bellhousing using 8 air-ends which have been inhibited against
screws. corrosion.

e) Secure the motor mounting feet with 4 s) Disconnect the air delivery line from the user
screws. system.

Note: When refitting components, it is t) Run the unit for 15 minutes to disperse
recommended that all joints and ‘O’ ring seals corrosion inhibitor from the air-end and check
are renewed. for leaks. Stop the compressor.

f) Re-position the 2nd stage delivery u) Reconnect the air delivery line to the user
silencer/discharge pipe assembly and secure system
the silencer to the air end with 4 v) Refit enclosure panels.
screws/washers.
12.11.5 Remove 1st Stage Air End from Gearbox
g) Re-connect 2nd stage discharge pipe (??) to
aftercooler inlet flexible pipe (3) and secure Caution: Ensure that adequate lifting,
with 4 screws/washers. pulling and heating equipment is available
before carrying out the following
h) Reconnect pipework and electrical procedures.
connections to 2nd stage discharge silencer
(1). Air-End Stage Weight Table
i) Refit adaptor (??) complete with moisture Stage Weight
separator/ inlet pipe assembly to 2nd stage
inlet and secure with 4 screws/washers. Still First 135 Kg
supporting the inlet pipework/moisture Second 75 Kg
separator assembly, re-connect the 2nd stage
inlet pipe (??) to the intercooler outlet flexible a) Remove air intake filter.
pipe (??). Secure with 4 screws/washers.
Remove lifting gear. b) Disconnect air pipework/electrical connections
to suction regulator. Remove suction regulator
j) Refit 1st stage discharge silencer to first stage assembly.
air-end outlet and secure with 4
screws/washers. c) Remove sufficient control air pipework,
including balance piston pipe, to allow
removal of first stage.

190 DL051AAA
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d) Disconnect all relevant pipework necessary to g) Remove second stage delivery silencer using
allow removal of 1st stage air end. suitable lifting gear.
e) Remove and discard first stage oil drain hose. h) Support the 2nd stage inlet pipework/moisture
Remove oil drain stub pipe from air-end. separator. Remove 4 screws and separate the
2nd stage inlet pipe (??) from the intercooler
f) Remove electrical cables from first stage
outlet flexible pipe (??). Remove 4 screws and
delivery temperature probe.
remove adaptor (??) complete with moisture
g) Disconnect 1st stage delivery silencer at separator/ inlet pipe assembly from 2nd stage
intercooler inlet flexible pipe. Remove silencer inlet.
from air end and store.
i) Fit two M12 eyebolts diagonally in second
h) Fit two M16 eyebolts diagonally in first stage stage delivery flange. Prepare to sling air end
suction flange. Prepare to sling air end from from suitably rated lifting gear (see air end
suitably rated lifting gear (see stage weight weight chart).
table).
j) Remove two screws securing second stage to
i) Remove two screws retaining first stage to gearbox eccentric ring, adjacent to dowels. Fit
gearbox flange, adjacent to dowels. Fit two two M8 X 80 mm plain guide studs at the two
M10 X 100 mm plain guide studs at the two screw positions and remove remaining
screw positions and remove remaining screws. Fit one M6 X 35 mm jacking screw
screws. Fit two M6 X 35 mm jacking screws into the hole provided and tighten the screw to
into the holes provided and tighten the screws jack the air-end away from the gearbox. Slide
to jack the air-end stage away from the air end horizontally away from gearbox and
gearbox. Slide the air-end stage horizontally dowels, ensuring pinion does not impact gear
away from the gearbox and dowels, ensuring casing, and lift from plant. Remove studs and
pinion does not impact gear casing, and lift eyebolts.
from plant. Remove studs and eyebolts.
k) Examine drive pinion.
j) Examine drive pinion.
Caution: If drive pinion teeth are deformed,
Caution: If drive pinion teeth are deformed, chipped or missing, the gear SET must be
chipped or missing, the gear SET must be renewed.
renewed.
l) Refer to para 12.11.7 ‘Removal Procedure -
k) Refer to para 12.11.7 ‘Removal Procedure - First and Second Stage Drive Pinion.’ and
First and Second Stage Drive Pinion’ and para 12.11.11 'Dismantle Gearbox'.
para 12.11.11 'Dismantle Gearbox'.
12.11.7 Removal Procedure - First and Second Stage
12.11.6 Remove 2nd Stage Air End from Gearbox Drive Pinion
a) Remove air pipe from second stage delivery a) For air-end stages where pinion is retained by
silencer to dump silencer. a capscrew, lock the rotors, using a spanner
on flats of pinion retainer, and remove central
b) Remove and store second stage delivery
retaining capscrew.
temperature probe.
b) For air-end stages where the pinion is
c) Remove sufficient control air pipework,
retained by two locking nuts, the nuts should
including balance piston pipe, to allow
be removed one at a time using tool 288097
removal of 2nd stage.
for the first stage, or tool 288098 for the
d) Remove and discard second stage oil drain second stage.
hose. Remove oil drain stub pipe from air-end.
Caution: When carrying out the next step,
e) Support 2nd stage discharge silencer ensure that the pinion is withdrawn parallel
assembly and remove 4 screws attaching the to the shaft or permanent scoring and
2nd stage discharge pipe (??) to aftercooler distortion may occur.
inlet flexible pipe (3).
c) Using suitable pulling equipment, and
f) Remove 4 screws securing the 2nd stage ensuring shaft end is protected, carefully
delivery silencer to the air end and remove remove pinion from drive shaft.
silencer/discharge pipe assembly.
d) Carefully remove and discard the taper lock
rings in the pinion bore. The rings can be

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released by lightly tapping their internal d) Remove and discard drive shaft collar from
diameter with a small soft drift. drive shaft end. Clean shaft end and pinion.
Check for burrs.
e) Suitably protect pinion until required for
refitting. Note: Where burrs are found during item 1.3,
remove carefully using an oil stone (DO NOT
f) Refit pinion spacer/retainer and
use other abrasives).
nuts/capscrew to air-end shaft.
Caution: Ensure adequate protective
12.11.8 Refitting Procedure - First and Second Stage
clothing is worn before handling the
Drive Pinion
heated pinion.
Caution: The drive pinion must be
e) Heat pinion by induction or in an oven to
correctly installed on the air-end shaft .The
130°C -150°C.
shaft is spring-loaded into the air-end and
has to be correctly positioned axially to Note: Prior to the next operation, a retaining
achieve specified rotor clearances. tool will be required. (See section 12.13).
a) During storage and transportation, the male f) When pinion has reached correct
rotor is positioned correctly by a temporary temperature, quickly remove from oven and
collar which replaces the pinion. When the slide fully on to drive shaft. IMMEDIATELY
collar is removed and discarded during retain pinion in position by fitting appropriate
air-end installation, the shaft may move retaining tool (as detailed below), secure with
inward and the rotor clearance may be original pinion capscrew (previously removed)
disturbed. To ensure that the shaft is pulled or retaining nut and torque tighten (see
outward by the pinion retaining nut or bolt Torque Table). At this point DO NOT rotate
before the pinion cools onto the shaft it is the air-end, or place wedges between rotors
essential that the drive pinion installation to prevent rotation. Allow pinion to cool in air
procedure (1.4 below) is followed exactly. It is for approximately 5 minutes - DO NOT
not possible to move the shaft inward through ACCELERATE COOLING.
the pinion after it has cooled and in no
g) Pinion Retaining Tools
circumstances should this be attempted.
First Stage 288093
b) Remove air-end stage from packaging and
remove silica gel bag from delivery port. Second Stage 288094
Remove blanking plugs/plates from all
h) When the pinion has cooled to hand heat,
connections and ports. Ensure all machined
check run-out of pinion face using a dial test
faces are clean.
indicator, measured just below root diameter
c) Using a suitable long feeler gauge through the of teeth (see Fig. 12.42). Run-out must not
delivery port, check the male rotor delivery exceed 0.010 mm T.I.R. Remove retaining
end clearance (see Fig. 12.41). Note and tool and discard capscrew.
record the actual clearance.

Fig. 12.41 - Checking Delivery End


Clearance

192 DL051AAA
CompAir Dismantling & Assembly 12

Note: Where run-out is excessive in item h), j) Second stage pinion only - Lightly oil two
gear position relative to the shaft should be pairs of split rings using new compressor oil
marked, the gear removed and rotated and fit them as shown in Fig. 12.44. Each pair
through 180°, refitted, and the run-out of split rings must have the gaps at 180° and
procedure repeated. each pair of rings must be spaced at 90° to
the other pair.

Fig. 12.44 - Correct Orientation of


Second Stage Pinion Rings

k) For those air-ends where the drive shaft has a


male thread and the pinion is retained by two
locknuts, the fitting procedure is as follows: -
Fig. 12.42 - Checking Pinion Run-out
Clean pinion spacer and fit over shaft to
locate against taper-Iock rings. Clean and
Note: A new capscrew, supplied in the parts
degrease shaft thread and fit the plain nut
kit, must be used for final assembly. The
using Loctite 222. Torque tighten nut (see
locking nuts used on some air-ends, however,
Torque Table) using the appropriate tool - see
may be re-used. The capscrew is made from
item g). Fit locknut (which has a spring insert)
a special high tensile material and must not
to shaft, with Loctite 222, ensuring that the
be exchanged for another of a different grade.
insert face is orientated away from the pinion.
Once this capscrew has been subjected to the
Torque tighten nut (see Torque Table) using
final tightening torque it must not be re-used if
the appropriate tool.
removed.
l) For air-ends where the drive shaft has a
i) First stage pinion only - Lightly oil two pairs
tapped hole and the pinion is retained by a
of rings using new compressor oil, and fit into
capscrew and cap, the fitting procedure is as
pinion recess, ensuring correct orientation
follows: -
(see Fig. 12.43).
Clean and degrease new capscrew and shaft
threads. Thoroughly oil capscrew with new
compressor oil. Fit retaining cap to shaft,
secure with capscrew and torque tighten (see
Torque Table). Using a dial test indicator,
check pinion run-out in accordance with item
h),
Note: Where the correct run-out is not
achieved, repeat item k) using new capscrew
Fig. 12.43 - Correct Orientation of and locking rings.
First Stage Pinion Rings

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m) Check that the air-end rotates freely with no f) Fit first stage discharge silencer between air
tight spots. Re-check male rotor delivery end end and intercooler inlet flexible pipe. Use
clearance, which should be the same as new joints. Tighten all screws.
measured in 1.2 within +/- 0.013 mm.
g) Fit all control air pipework previously
Note: Where the tolerance above is not removed.
achieved, incorrect pinion fitment should be
h) Fit suction regulator assembly and a new
suspected. The drive pinion must be removed
joint, to first stage suction flange and secure
and re-installed following the above
with screws/washers. Re-connect control
procedures.
pipework and electrical connections to suction
Caution: The air-end must not be installed regulator.
and operated until a satisfactory clearance
i) Fit air pipe from second stage delivery
has been established.
silencer to dump silencer.
n) Torque Table
j) Fit air intake filter assembly.
1ST STAGE
12.11.10 Fit 2nd Stage Air End to Gearbox
Pinion Retaining Nut 148Nm (109Ibf.ft)
a) Ensure face of gearbox is clean and apply
Pinion Lock Nut 167Nm (123Ibf.ft) Loctite 574.
Pinion Retaining Capscrew b) Fit two M10 guide studs loosely into top of
First Assembly 73Nm (54Ibf.ft) eccentric ring to aid location of the air-end.
Final torque 73Nm (54Ibf.ft)
c) Fit two M12 eyebolts diagonally in second
2ND STAGE stage delivery flange. Sling air end from
suitably rated lifting gear (see air end weight
Pinion Retaining Nut 98Nm (72Ibf.ft)
table) and lift into position in front of gearbox.
Pinion Lock Nut 118Nm (87Ibf.ft)
d) Fit oil drain stub pipe to air-end and new drain
Pinion Retaining Capscrew hose from air-end to gearbox, retain with hose
First Assembly 38Nm (28Ibf.ft) clips.
Final torque 35Nm (26Ibf.ft)
e) Using previously fitted studs, align stage with
12.11.9 Fit First Stage Air End to Gearbox gearbox and slide horizontally into position on
dowels. Ensure that pinion is engaged
a) Ensure face of gearbox is clean. Fit large ‘O’
correctly with drive gear. Retain air end with
ring and retain with a light coat of silicon
fixing screws tightened by hand. Remove
grease.
guide studs and replace with fixing screws.
b) Fit two M10 guide studs loosely into top of air Tighten screws using a torque of 56 Nm (41
end flange to aid location of the air-end. lbf.ft). Check that main gear drives the air-end
pinion.
c) Fit two M16 eyebolts diagonally in first stage
suction flange. Sling air end from suitably f) Fit second stage delivery silencer/pipe
rated lifting gear (see stage weight table) and assembly using new 'O' ring seals and secure
lift into position in front of gearbox. with screws/washers.
d) Fit oil drain stub pipe to air-end and new drain g) Refit all oil pipework previously removed.
hose from air-end to gearbox, retain with hose
h) Fit all control air pipework previously
clips.
removed.
e) Using previously fitted studs, align air end with
i) Re-connect all electrical cables previously
gearbox and slide horizontally into position on
removed.
dowels. Ensure that pinion is engaged
correctly with drive gear and that ‘O’ rings are j) Fit air pipe from second stage delivery
not distorted. Retain air end with fixing screws silencer to dump silencer.
tightened by hand. Remove guide studs and
k) Install air-end (see para 12.11.4 ‘Install
replace with fixing screws. Tighten screws
Air-ends').
using a torque of 56 Nm (41 lbf.ft). Check that
main gear drives the air-end pinion. 12.11.11 Dismantle Gearbox (Fig. 12.47)

194 DL051AAA
CompAir Dismantling & Assembly 12

Note: The following instructions are intended g) Secure support fixture (288084) to the input
for the maintenance of Dryclon gearboxes shaft end, using three M10 x 25mm screws.
using the appropriate parts kit. Using a suitable hoist, invert the input casing
and shaft assembly and secure the support
a) Remove bellhousing from drive side of
fixture in a suitable vice.
gearbox. The bellhousing is located by two
dowels. h) Remove screws (23) and washers (24)
securing labyrinth seal (19) to input casing
b) Using a suitable puller, remove coupling half
(13). Using jacking screws as necessary,
(22) from gear shaft (5). Remove coupling
remove labyrinth seal (19) parallel with shaft.
spacer (20) and ensure the shaft is clean.
i) Slide seal inner ring (6) from input shaft using
c) Remove capscrews (41) and washers (37)
M6 studding in the tapped holes provided.
(40) securing eccentric ring (42) to gearbox
Remove and discard ‘O’ ring (7).
face. Remove eccentric ring. Discard ‘O’ rings
(38) and (43). j) Lift out the four wave springs (18) and bearing
outer race spacer (9). Ensure that input shaft
Note: When carrying out step d) ensure that
is secure in vice and, using tool 288086,
the gear does not drop and contact the input
remove bearing retaining nut (4).
casing as the shaft is drawn from the inboard
bearing. Note: Some early gearboxes have a tab
washer securing the retaining nut.
d) Sling input casing (13) from suitably rated
lifting gear. Remove two screws (15) and k) Pull the input casing (13) over the shaft using
washers (14) adjacent to dowels and insert tool 288085, taking care to support the casing
two M10 X 100 mm plain studs. Remove as the bearings leave the shaft. Remove gear
remaining screws and using jacking holes and shaft assembly from the support fixture.
provided, remove input casing horizontally
from gearbox. Support the casing and shaft SM 0788
assembly on suitable timber blocks with the
gear uppermost.
e) Remove three capscrews (34) and washers
(33) securing the bearing retaining plate (32)
to input shaft (5) and remove retaining plate.
f) Using suitable pulling equipment or splitting
as necessary, and taking care not to score
shaft, remove bearing inner race (31) from
shaft (5) and discard.

Fig. 12.46 - Removing Input Casing

l) Lift out angular contact bearing (3) and


Support remove spacer rings (2) (10). Invert input
Fixture casing (13) and remove deep groove ball
bearing (1) from casing bore using a suitable
tool.
m) Remove circlip (36) from gearbox bearing
bore then remove bearing outer race spacer
(35) and bearing outer race (31).
n) Remove bolts (30) and washers (29) securing
SM 0785
gearbox (26) to oil sump (27) and remove
Fig. 12.45 - Support Fixture gearbox. Remove joint (28) and discard.

DL051AAA 195
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SM 0786

Fig. 12.47 - Gearbox (Sectional Arrangement)

196 DL051AAA
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12.11.12 Examine/Renew Worn Parts f) Heat the inner race of roller bearing (31) by
induction or in an oven, to 100°-120°C and fit
a) Clean oil sump (27) and gearbox casing (26)
onto the non-drive end of input shaft (5),
paying particular attention to all oil ways and
ensuring that the ring is hard against the
jets.
shoulder. Allow to cool in air, DO NOT
b) Remove and clean magnetic plugs. ACCELERATE COOLING. Mount input shaft
on support fixture (288084) and secure with
c) Remove and discard all joints and ‘O’ rings,
three M10 X 25 mm setscrews. Position
and clean joint faces.
fixture in vice.
d) Clean input shaft assembly (5), paying
g) Fit spacer ring (11) (large chamfer upwards).
particular attention to bearing journals.
Position spacer tool 288088 to gear face (25).
e) Examine the drive gear for tooth damage. Lower input casing (13) over shaft (5) and
jack casing over shaft using tool (288091)
Caution: Where teeth are deformed,
until the deep groove ball bearing (1) is
chipped or missing the gear set must be
seated on spacer ring (11).
renewed.
h) Blow through oil jets in outer bearing spacer
Caution: Abrasives are NOT to be used
(2), using a low pressure air supply, ensuring
when carrying out the next step.
all oil jets are clear. Position inner spacer (10)
f) Clean all bores and oil ways in input casing on inner race of installed bearing (1), and
(13). Ensure oil ways are clear by blowing outer spacer (2) so that etched ‘V’ on outer
through using a low pressure air supply. diameter points down towards drive gear (25).
g) Clean the labyrinth seal (6) (19) carefully, Note: When the angular contact bearing is
avoiding damage to the seal form and PTFE fitted during step i), the bearing outer race (3)
coating. will be a clearance fit in the bore.
12.11.13 Assemble Gearbox (See fig. 12.47). i) Position angular contact bearing (3) over shaft
(5) ensuring that the etched ‘V’ on outer
a) Fit gasket (28) to oil sump (27), lower gearbox diameter points down towards drive gear (25).
(26) into position and secure with screws (30) Press bearing onto shaft to meet spacers (2)
and washers (29). Tighten screws using a (10) using tool ( 288091). Secure bearings
torque of 98 Nm (72 lbf.ft). with lock nut (4) and tab washer (where fitted).
b) Apply Loctite 641 to outer race of roller Tighten lock nut using tool 288086 and a
bearing (31) and gently tap into gearbox torque of 363 Nm (268 lbf.ft), Then turn up
bearing bore using tool 288089. Pre-lubricate appropriate tab. Pre-lubricate bearings using
bearing using new compressor oil. new compressor oil.
c) Blow through oil jets in bearing spacer (35), j) Position complete Duplex bearing (3) on shaft
using a low pressure air supply, ensuring all (5). Press bearing to meet spacers, using tool
oil jets are clear. Position spacer ensuring that (288092). Secure bearings with lock nut (4)
oil hole in spacer face is towards installed and tighten using tool (288087) and a torque
bearing (31), and gently tap spacer into bore of 549 Nm (405 lbf.ft). Pre-lubricate bearings
against bearing. using new compressor oil.
d) Fit circlip (36) into gearbox bearing bore k) Lightly grease ‘O’ ring (7) and fit into the input
groove to retain bearing (31) and spacer (35), shaft seal (6). Carefully slide seal over shaft
ensuring that circlip gap is at bottom of bore. (5) ensuring ‘O’ ring is not damaged on the
keyway.
e) Position input casing (13) with input side
uppermost. Press in the deep groove ball l) Fit bearing outer race spacer (9) into input
bearing (1) using tool (288091), ensuring that casing bearing bore, followed by the wave
etched ‘V’ on outer diameter of matched springs (18). Ensure that wave springs are
bearing set points down towards drive gear ‘nested’ correctly.
(25). m) Lightly grease ‘O’ ring (8) and fit around
Warning: When carrying out step 6, ensure labyrinth seal (19). Carefully slide seal into
adequate protective clothing is worn position on input shaft (5), ensuring that
before handling the heated bearing race. angled drilling will point towards oil sump.
Secure seal with four screws (23) and

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washers (24), diagonally tighten using a 12.12 Oil Pressure Relief Valve
torque of 56 Nm (41 lbf.ft).
n) Remove assembly from vice and remove
support fixture. Degrease retaining plate
capscrews (34) and apply Loctite 222. Fit
retaining plate (32), secure using capscrews
(34) and washers (33). Torque tighten to 56
Nm (41 lbf.ft). 12
o) Fit two dowels to input casing (13) (tapered 11
end downwards), until plain ends are flush
with joint face. 10

p) Lightly grease ‘O’ rings (12) (39) and fit to


recess on gearbox location face and input 9
casing. 8
7
q) Fit two alignment studs adjacent to dowel 6
5
holes in gearbox face and hoist input casing 4
3
assembly into position over studs, ensuring 2
that shaft is aligned with gearbox bearing (31). SM 0979 1
Use a lever to align the dowel holes and tap
dowels fully in. Fit bolts (15) and washers Fig. 12.48 - Oil Pressure Relief Valve
(14). Remove location studs and fit remaining 1. Adjusting Screw Cap 7. 'O' Ring
bolts and washers. Tighten bolts sequentially 2. Washer 8. Spring
using a torque of 56 Nm (41 lbf.ft). 3. Adjusting Screw 9. Spool
r) Fit coupling spacer (20), where applicable, 4. Nut 10. Body
insert key (21) in keyway and heat the 5. Relief Valve Cap 11. Bolt
coupling half (22) in oven (150°C minimum - 6. Retaining Spring Cap 12. Joint
180°C maximum) for one hour.
Warning: When carrying out the next step, 12.12.1 Dismantle Oil Pressure Relief Valve
ensure adequate protective clothing is a) Remove bolts and washers securing relief
worn before handling the heated coupling valve assembly to gearbox. Remove and
half. discard joint.
s) Fit coupling half (22) to shaft (5) and hold in b) Remove adjusting screw cap (1) and washer
position against spacer (20) while cooling. DO (2) but do not alter position of adjusting screw
NOT ACCELERATE COOLING. (3).
t) Fit dowels to bellhousing. Position bellhousing c) Unscrew spring housing (5) and remove
to gearbox and retain with screws (17) and complete with spring cap (6) and spring (8).
washers (16). Align dowel holes and tap Remove ‘O’ ring (7) from spring housing and
dowels fully in. Tighten screws. discard. Remove spring cap (6) from housing.
u) Lightly grease ‘O’ rings (38) (43) and fit to d) Remove spool (9) from valve body (10) using
recess in second stage gearbox face. Fit one of the assembly fixing screws as required
eccentric ring (42) to gearbox face ensuring
‘O’ rings are not displaced, and secure using 12.12.2 Assemble Oil Pressure Relief Valve
five capscrews (41) and spring washers (40), a) Clean joint face of relief valve body (10) and
and one capscrew (41) with a copper washer mating surface of gearbox. Clean valve body
(37) fitted with Loctite 222 to seal thread. internally. Examine bore for burrs or surface
imperfections, dressing out as necessary
using an oil stone. Lubricate bore with new
compressor oil.
b) Examine outer surface of spool (9) for scores
For maintenance details, see or surface imperfections, dressing out as
section 10.17 necessary using an oil stone. Lightly lubricate
spool with new compressor oil and install into

198 DL051AAA
CompAir Dismantling & Assembly 12

bore of valve body (10), flat face innermost.


Ensure spool slides freely in bore.
c) Position spring (8) into spool (9). Check that
oil hole in spring cap (6) is clear and lubricate
cap with new compressor oil. Install cap (6)
into spring housing (5), flat face innermost.
d) Lubricate ‘O’ ring (7) with new compressor oil
and fit to spring housing (5). Position spring
housing (5) to valve body (10), ensure that
spring (8) is located in spool (9) and spring
cap (6). Screw spring housing into valve body.
e) Without disturbing adjusting screw (3), ensure
that locknut (4) is secure. Fit washer (2) and
adjusting screw cap (1) to spring housing (5)
and secure.
f) Using a new joint, fit relief valve to gearbox so
that end cap (1) is towards first stage side of
gearbox. Secure valve with bolts and spring
washers.

For further information about this


component, see section 8.13

DL051AAA 199
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12.13 Air End Special Tools Diagrams

Fig. 12.49 - Support Fixture 288084

200 DL051AAA
CompAir Dismantling & Assembly 12

Fig. 12.50 - Input Casing Removal Tool 288085

DL051AAA 201
12 Dismantling & Assembly CompAir

Fig. 12.51 - Locknut Tool 288086

202 DL051AAA
CompAir Dismantling & Assembly 12

Fig. 12.52 - Locknut Tool 288087

DL051AAA 203
12 Dismantling & Assembly CompAir

Fig. 12.53 - Support Tool 288088

204 DL051AAA
CompAir Dismantling & Assembly 12

Fig. 12.54 - Inboard Bearing - Outer Race Installation Tool 288089

Tool No. Machine A B C D E F


288089 D55 - D155 50Hz/60 Hz 19.5 15 100 30 65.87/65.84 98.5

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Fig. 12.55 - Bearing Installation Tool 288091

Tool No. Machine A B C D


288091 D55 - D155 50Hz/60 Hz 75 51.5 57 98.5

206 DL051AAA
CompAir Dismantling & Assembly 12

Fig. 12.56 - Pinion Retaining Tool 288093/94

Tool No. Machine A B C D E F G H J K


288093 D55 - D155 50Hz/60 Hz 75 40 10.5 35 20 2 13 18 36 30
288094 D55 - D155 50Hz/60 Hz 50 25 8.5 35 20 2 13 15 26 19

DL051AAA 207
12 Dismantling & Assembly CompAir

Fig. 12.57 - Pinion Locknut Tool - 1st Stage Air End 288097

208 DL051AAA
CompAir Dismantling & Assembly 12

Fig. 12.58 - Pinion Locknut Tool - 2nd Stage Air End 288098

DL051AAA 209
210 DL051AAA
CompAir Appendix 1 - The Pressure Systems Safety Regulations 2000 13

Fig. 13.1 - P & I Diagram for D55-D150 Air Cooled - Current Machines

DL051AAA 211
13 Appendix 1 - The Pressure Systems Safety Regulations 2000 CompAir

13.3 P & I Diagram - Early Machines

A AIR OUTLET GRILLE


B COOLING AIR INLET GRILLE
C DELIVERY AIR OUTLET R3
D 2nd STAGE CONDENSATE DRAIN G 1/2
(VALVE PACKED SEPARATELY)
E 2nd STAGE SOLENOID DRAIN G 3/8
F 1st STAGE CONDENSATE DRAIN G 1/2
(VALVE PACKED SEPARATELY)
G 1st STAGE SOLENOID DRAIN G 3/8
H OIL DRAIN G 3/4
J MOTOR AIR INLET GRILLE
K MAIN AIR INLET GRILLE
MAIN AIR LINES
CONDENSATE DRAIN LINES
CONTROL LINES
LUBE OIL LINES
BOUNDARY
WATER LINES
ELECTRICAL LINKS
MECHANICAL LINKAGES
CAPILLARY LINES
LIMIT OF SUPPLY
LOCALLY MOUNTED INSTRUMENT

LOCAL PANEL MOUNTED INSTRUMENT

CONTROL PANEL MOUNTED INSTRUMENT

PI PRESSURE INDICATOR
PA PRESSURE ALARM
PC PRESSURE CONTROL
PE PRESSURE TRANSMITTER
PDS DIFFERENTIAL PRESSURE SWITCH
PDA DIFFERENTIAL PRESSURE ALARM
PDI DIFFERENTIAL PRESSURE INDICATOR
LI LEVEL INDICATOR
RRS REVERSE ROTATION SWITCH
LS LEVEL SWITCH
LA LEVEL ALARM
TT TEMPERATURE THERMISTOR
TI TEMPERATURE INDICATOR
TA TEMPERATURE ALARM
TE TEMPERATURE TRANSMITTER
TO THERMAL OVERLOAD
RRA REVERSE ROTATION SWITCH
RR REVERSE ROTATION SHUTDOWN
RRA REVERSE ROTATION ALARM
L LOW ALARM
LL LOW SHUTDOWN
H HIGH ALARM
HH HIGH SHUTDOWN SM 1037

Key to Fig. 13.2

212 DL051AAA
CompAir Appendix 1 - The Pressure Systems Safety Regulations 2000 13

F
B

G
E
A

SM 1046
K

Fig. 13.2 - P & I Diagram for D55-D150 Air Cooled - Early Machines

DL051AAA 213
14 Appendix 2 - Commissioning Checklist Form CompAir

14 Appendix 2 - Commissioning Checklist Form


14.1 Instructions For Use
14.1.1 First, two copies should be made of the
template form on the following page. Both
copies should then be filled out during, and on
completion of, the commissioning procedure
detailed in Section 6.
14.1.2 Each completed copy should be signed by the
commissioning engineer and the customer.
One completed and signed copy should be
retained by the customer and the other should
be retained by the commissioning engineer for
forwarding to the CompAir After Market Dept.
at Redditch, U.K.

214 DL051AAA
Commissioning Check List – D-Series Air Cooled

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Commissioning
Engineer's Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . c 22 Maximum overpressure set . . . . . . . . . . . . c


2 Cable, fuse ratings OK . . . . . . . . . . . . . . . c 23 All temperature and
pressure trip limits set . . . . . . . . . . . . . . . . c
3 Control transformer
input voltage set correctly . . . . . . . . . . . . . c 24 All temperature and pressure
alarm limits set. . . . . . . . . . . . . . . . . . . . . . c
4 Main motor, fan motor, oil pump motor
overloads and MCB Q102 set correctly . . c 25 Star/delta time set . . . . . . . . . . . . . . . . . . . c
5 Phase rotation relay voltage set . . . . . . . . c 26 Load delay time set . . . . . . . . . . . . . . . . . . c
6 Starter connections OK . . . . . . . . . . . . . . . c 27 Reset service hours timer . . . . . . . . . . . . . c
7 Motor connections OK . . . . . . . . . . . . . . . . c 28 Starting sequence correct . . . . . . . . . . . . . c
8 Protection blanks and tapes . . . . . . . . . . . c 29 Compressor blows down OK . . . . . . . . . . . c
9 Fill compressor with oil . . . . . . . . . . . . . . . c 30 Corrosion inhibitor dispersed. . . . . . . . . . . c
10 Air end and motor freely rotate . . . . . . . . . c 31 Connected to user’s pipework . . . . . . . . . . c
11 Select language . . . . . . . . . . . . . . . . . . . . . c 32 Oil and air leaks check . . . . . . . . . . . . . . . c
12 Fan/Oil pump rotation OK . . . . . . . . . . . . . c 33 Compressor loads, unloads,
stands by and stops correctly . . . . . . . . . . c
13 Main Motor rotation OK . . . . . . . . . . . . . . . c
34 Emergency stop correct. . . . . . . . . . . . . . . c
14 Pressure transducer calibrated . . . . . . . . . c
35 Temperatures and pressures in limits . . . . c
15 Display units set . . . . . . . . . . . . . . . . . . . . c
36 Oil level topped up. . . . . . . . . . . . . . . . . . . c
16 Compressor number set
(if comms facility available/fitted). . . . . . . . c 37 All parameters recorded from
controller menu routines . . . . . . . . . . . . . . c
17 Pressure control set points set . . . . . . . . . c
38 Plugs removed from air end vents. . . . . . . c
18 Run-on time set . . . . . . . . . . . . . . . . . . . . . c
39 Powered oil breather system
19 Drain open time set . . . . . . . . . . . . . . . . . . c operating correctly . . . . . . . . . . . . . . . . . . . c
20 Drain shut time set. . . . . . . . . . . . . . . . . . . c 40 Motor auto greaser set (if fitted) . . . . . . . . c
21 Maximum compressor pressure set. . . . . . c

Customer Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning
Engineer's Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

This form must be completed and returned to CompAir AfterMarket Dept. at Redditch.
Please make 2 copies of this form. Copy 1: Customer – Copy 2: Commissioning Engineer.