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Technical Manual

L02 - L05
Rotary Screw Compressors

Oil Injected, Air-Cooled


DL105AA - 10/2009

GB fred
CompAir Contents

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 About The L02 - L05 Range . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4 Correct Compressor Operating Conditions . . . . . . . . . . . . . . . . . 6
1.5 Improper Use Of Compressor . . . . . . . . . . . . . . . . . . . . . . . .6
2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Warnings, Cautions and Notes. . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Operational Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Maintenance and Repair Precautions . . . . . . . . . . . . . . . . . . . . 9
2.7 Precautions In The Event Of Fire . . . . . . . . . . . . . . . . . . . . . . 10
2.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Performance Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Dimensions, Weights, Cooling Airflow Requirements . . . . . . . . . . . 12
3.3 Approved Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Refrigerant Dryer (Where Fitted) . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Safety Measures Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Air BASIC Electronic Controller Specifications (Where Fitted) . . . . . . . 14
3.8 General Arrangement Drawings . . . . . . . . . . . . . . . . . . . . . . 15
3.9 Electrical Diagrams - Compressor . . . . . . . . . . . . . . . . . . . . . 20
3.10 Electrical Diagrams - AirBasic Controller . . . . . . . . . . . . . . . . . . 22
4 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Compressor Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Regulation System (Only for Version with AirBASIC Controller) . . . . . . 28
4.4 Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Lifting and Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Connection Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.6 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8 After Prolonged Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2 To Start (Not Valid For Version With “Airbasic” Controller). . . . . . . . . 32
6.3 To Stop (Not Valid For Version With “Airbasic” Controller) . . . . . . . . . 32
6.4 Shut-Down Due To Power Failure . . . . . . . . . . . . . . . . . . . . . 32
6.5 Starting At Low Temperatures (below 0°C). . . . . . . . . . . . . . . . . 33
6.6 Electronic Controller (Where Fitted) . . . . . . . . . . . . . . . . . . . . 33
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Service Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3 Before Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.4 After Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

DL105AA 3
Contents CompAir

7.5 Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36


7.6 Guidelines For Oil Change Intervals . . . . . . . . . . . . . . . . . . . . 36
7.7 Belt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.8 Automatic Condensate Drain (Where Fitted) . . . . . . . . . . . . . . . . 38
7.9 Routine Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9 AirBASIC Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . 41
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.4 Compressor Operation with the AirBASIC Controller. . . . . . . . . . . . 41
9.5 Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.6 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.7 Error Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.8 Transducer Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10 Compressor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11 Compressed Air Dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.2 Safety - Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.3 Technical Data - Dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11.5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.6 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.7 "iDRY" Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . . 79
11.8 Timed Condensate Discharge Unit . . . . . . . . . . . . . . . . . . . . . 85
11.9 Operation And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 86
11.10 Troubleshooting Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4 DL105AA
CompAir Introduction 1

1 Introduction
1.1 General
Worldwide service and parts facilities are Due to the low noise level of the L02-l05
provided by CompAir. If you experience any range, the compressor can be installed at the
difficulty, please inform your local CompAir point of use, requiring no additional cost for a
office. separate compressor room or expensive
pipework.
It is essential to quote the compressor
MODEL and SERIAL numbers in all The Start/Stop operation ensures no idling
communications. time and no idling energy costs.
All pressures shown are gauge pressures. The L02-L03 as standard are equipped with
Start/Stop control and a direct start relay.
CompAir reserves the right to modify the Working hour indicator and pressure display
contents of this publication without notice and are also Included.
the data given is in no way binding on the
manufacturers. The L04 - L05 compressors as standard are
equipped with Star/Delta starting and the
Where approximate figures are shown, electronic AirBasic controller, which provides
specific details are available on request. the user with data on total hours of operation,
operating temperature and additional
1.2 Maintenance and Servicing information such as:
Maintenance, repairs and/or modifications - Air filter replacement
must only be carried out by competent - Oil filter replacement
personnel who have completed the
relevant training. - Separator filter replacement
- Oil change
USE ONLY - Regular maintenance advice
1.3.1 Standard Equipment:
Star/Delta starting (L04-L05)
GENUINE PARTS AirBasic controller (L04-L05)
DOL starting (L02-L03)
1.3 About The L02 - L05 Range
Overload relay protection
These compressors can be combined with
different options to provide everything from a Start/Stop control with pressure switch
stand alone compressor to a complete (L02 - L03)
compressor station. Main On/Off switch
Options include: Electric motor, IP5S, F-class insulation
- Compressor base mounted Oil level monitoring, sight glass
- Compressor mounted on an air receiver Belt transmission
- Airstation solution Safety devices for:
(includes compressor and refrigerant dryer,
both mounted on an air receiver) - Motor over temperature

Ease of maintenance is enhanced by the - Compressor over temperature, trip at 110 °C


removable side doors which provide quick and - Compressor over pressure (safety valve)
generous access to all service points.
Running condition indicators:
The compressors incorporate high reliability V
belts, designed for the highest performance - - Pressure
providing hours of reliable operation. - Hour-meter

DL105AA 5
1 Introduction CompAir

Epoxy powder coated enclosure and having a pressure rating at least 10%
higher than the unit itself.
Oil thermostat
The air delivered from these compressors is
1.3.2 Options Available
not suitable for human use. It must never be
a) Air Receiver-mounted used as breathing air.
High quality air receiver built to the highest The compressor is designed only to be
standard EN87/404 and AD2000. operated complete with closed enclosure, for
Inspection-free for 5 years. the purposes of cooling, protection and sound
proofing.
- 200 Litre capacity, suitable for L02 to L05
- 500 Litre capacity, L04 - L05 only 1.5 Improper Use Of Compressor
b) Refrigerant Dryer, L02FS - L05FS The manufacturer shall waive all responsibility
High performance combined with low in case of:
pressure losses a) Incorrect use by untrained or negligent
3°C dew point at 25°C ambient temperature personnel.
(ISO 7183) b) Use in violation of current laws.
Environmentally friendly refrigerant R134a c) Incorrect installation.
Digital controller displaying: d) Installation without suitable reservoir.
- Dew point indication e) Installation in dust-filled environments (i.e.
- Additional energy saving mode cement, silica etc.....).

- Maintenance display f) Incorrect electrical connection.

- Fault memory g) Serious lack of proper maintenance.

c) Other h) Use of non-original spares for the model.

L04 - L05 available with DOL starting i) Total or partial failure to observe the
instructions.
Prefilter and microfilter combination
j) Damage due to natural or exceptional events.
Timed or float condensate drains for
receiver-mounted units. k) Tampering with the safety valve.
l) Exceeding maximum pressure rating through
1.4 Correct Compressor Operating tampering.
Conditions m) Operation of compressor without panels and
guards.
The compressor described in this manual is
only suitable for the compression of
atmospheric air up to the maximum pressure
stated on the identification plate.
The compressor is an 'industrial' type, to be
used in accordance with the technical
specifications of the compressor itself.
The compressor works automatically and no
specific operator is required. However, the
unit must be supervised in use and must have
all routine maintenance carried out by an
expert technician, who should be familiar with
all aspects of its operation and safety outlined
in this manual.
The compressor is designed exclusively for
operation connected to an approved air
reservoir of suitable capacity (at least 200 lt.)

6 DL105AA
CompAir Safety Procedures 2

2 Safety Procedures
2.1 General 2.2 Warnings, Cautions and Notes
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
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 this manual.
hazardous.
When handling, operating or carrying out
WARNING: RISK OF DANGER
maintenance on the unit, personnel must use
safe engineering practices and observe all
relevant local health and safety requirements
and regulations. WARNING: RISK OF ELECTRIC SHOCK
The attention of users in the UK is drawn to
the Health and Safety at Work Act, 1974, the
Regulations of the Institution of Electrical
Engineers and the Pressure Systems and WARNING: RISK OF HOT SURFACES
Transportable Gas Container Regulations
1989.
CompAir cannot anticipate every possible WARNING: CONSULT MANUAL
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: COMPONENTS AND SYSTEMS
of equipment or a method of working which is UNDER HIGH PRESSURE
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 WARNING: REMOTE START - MACHINE
persons or property. MAY START WITHOUT WARNING
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 Incorrect operational procedures causing
atmosphere is a mixture with air, under possible damage to the compressor unit are
atmospheric conditions, of flammable gases, identified by a ‘Caution’ in the text of this
vapours, hazes or dust in which, after ignition manual.
has occurred, combustion propagates to the
entire unburned mixture and may cause a 2.2.3 Notes
hazard. A potentially explosive atmosphere is Methods to make the job easier and points
an atmosphere which could become explosive which require particular attention are identified
due to local conditions. by a ‘Note’ in the text of the manual.
Failure to observe the precautions given
under ‘Safety Procedures’ may be considered
dangerous practice or misuse of the
compressor unit.

DL105AA 7
2 Safety Procedures CompAir

2.3 General Safety Precautions The minimum pressure/non-return valve is not


intended as an isolating valve and should not
If using compressed air for cleaning purposes, be relied upon for this purpose. In addition, it
ensure safety regulations are complied with may be necessary to install shut-off valves
and appropriate clothing and eye protection is elsewhere in the system to allow a dryer or
worn. other equipment to be by-passed.
Never direct compressed air onto your skin or
at other people. 2.5 Operational Precautions
Never use compressed air to clean loose dirt The compressor unit must only be operated
from clothing. by competent personnel under a trained and
Before releasing compressed air through a qualified supervisor.
hose make sure that the free end is held Do not run the compressor with doors open or
securely so that it cannot whip and cause covers removed except when checking for
injury. leaks.
Avoid injury by using a hoist to lift heavy Never remove or tamper with the safety
loads. Check that all chains, hooks, shackles devices, guards or insulation materials fitted
and slings are in good condition and are of the to the unit.
correct capacity. They must be tested and
approved according to local safety The compressor must only be operated at the
regulations. supply voltage and/or frequency for which it is
designed.
Cables, chains or ropes must never be
applied directly to lifting eyes. Always use an On a unit equipped with an Automatic
appropriate shackle or hook, properly Start/Stop system, attach a sign stating ‘THIS
positioned. Arrange lifting cables so that there UNIT MAY START WITHOUT WARNING’
are no sharp bends. next to the display panel.

Use a spreader bar to avoid side loads on On a unit equipped with an Automatic Restart
hooks, eyes and shackles. When a load is on device, attach a warning notice stating ‘THIS
a hoist stay clear of the danger area beneath UNIT HAS BEEN MODIFIED AND WILL
and around it. Keep lifting acceleration and START AUTOMATICALLY ON
speed within safe limits and never leave a APPLICATION OF POWER’ next to the
load hanging on a hoist for longer than is display panel and on the inside of the unit
necessary. next to the starter contactors.
If the unit is equipped with a Remote Control
2.4 Installation Precautions device, attach warning notices stating ‘THIS
UNIT CAN BE STARTED REMOTELY’ in
Installation work must only be carried out by prominent locations, one on the outside of the
competent personnel under a trained and unit, the other inside the control compartment.
qualified supervisor.
As a further safeguard, take adequate
A fused isolating switch must be fitted precautions to make sure there is no one
between the main power supply and the checking or working on the unit before
compressor. attempting to switch on remotely controlled
Ensure that air drawn into the air intake will equipment. Attach a ‘CHECK THAT ALL
not be contaminated with flammable fumes or PERSONNEL ARE CLEAR OF THE UNIT
vapours. BEFORE STARTING’ or similar warning
notice to the remote start equipment.
Ensure that the air delivery pipe from the
compressor to the user’s pipework or receiver If there is any indication that the compressor
is free to expand. is overheating it must be shut down and the
cause investigated. Beware of burns from hot
A shut-off valve must be fitted in the delivery
metal parts or hot water when working on a
air line to enable the compressor unit to be
unit which has recently been shut down.
isolated. This is particularly important if more
than one unit is to be coupled in parallel or The compressor must not be operated at
connected to an existing air supply system. pressures above the nominal pressure given
on the data plate.

8 DL105AA
CompAir Safety Procedures 2

The compressor must not be operated in warning ‘WORK IN PROGRESS – DO NOT


ambient temperatures outside of those given OPEN’.
under ‘Technical data’.
Ensure that the blowdown system has
The ‘Noise at Work Regulations 1989’ operated to release all pressure from the unit.
suggest that ear protectors should be worn
Check that the pressure display registers
where noise levels are 85 dB(A) or higher.
zero. Release any remaining pressure from
With all covers in place, the noise levels of the
the compressor side of the non-return and
compressors described in the manual are
isolation valve by slackening a pipe
substantially lower than this figure unless
connection.
installed in an already noisy environment.
Use only greases (where used) approved by
Be aware that high noise levels can interfere
CompAir. Make sure that the selected
with communication.
lubricants comply with all relevant safety
regulations, especially with regard to the risk
2.6 Maintenance and Repair of explosion or fire and the possibility of
Precautions decomposition or the generation of hazardous
gases.
Before commencing any work on the
compressor, switch the power supply OFF at Always clean up any spills from both the
isolator unless directed otherwise in the text of inside and outside of the compressor unit
this manual. before and after maintenance work.
Maintenance, repairs or modifications must Make sure that all instructions concerning
only be carried out by competent personnel operation and maintenance are strictly
under a trained and qualified supervisor. followed and that the complete unit, with all
accessories and safety devices, is kept in
Lethal voltages are present in the electrical good running order.
circuits and extreme caution must be
exercised whenever it is necessary to carry The accuracy of pressure and temperature
out any work on the electrical system. sensors must be regularly checked. They
must be renewed when acceptable tolerances
If replacement parts are needed use only are exceeded.
CompAir Genuine Parts.
Protection devices must be tested as
Do not open the starter compartment or touch described in the ‘Maintenance’ section of this
electrical components while voltage is applied manual.
unless it is necessary for measurements, tests
or adjustments. Such work should be carried Keep the compressor unit clean at all times.
out only by a qualified electrician equipped Protect components and exposed openings
with the proper tools and wearing appropriate by covering with clean cloth or tape during
body protection against electrical hazards. maintenance and repair work.
Before removing any panels from the Protect the motor, air intake, electrical and
enclosure, if fitted, or dismantling any part of regulation components against the entry of
the unit, carry out the following preparatory moisture, e.g. when steam cleaning.
operations:- Precautions must be taken when carrying out
Isolate the compressor unit from the main welding or any repair operation which
electrical power supply. Lock the isolator in generates heat, flames or sparks. The
the ‘OFF’ position and remove the fuses. adjacent components must always be
screened with non-flammable material.
Attach a label to the isolator switch and
display panel carrying the warning ‘WORK IN Never use a light source with an open flame
PROGRESS – DO NOT APPLY VOLTAGE’. to inspect any part of the unit.
Do not switch on electrical power or attempt to In no circumstances must any welding work or
start the unit if a warning label is attached. other modification be carried out on any part
Close the isolating valve between the of the pressurised system.
compressor unit and the user’s pipework. Before dismantling of any part of the
Attach a label to each valve carrying the compressor unit ensure that all heavy
movable parts are secured.

DL105AA 9
2 Safety Procedures CompAir

After completion of repair or maintenance for ‘material composition disposal’ e.g. base
work ensure that no tools, loose items or rags metals, plastics, fabrics etc and be subject to
are left on or inside any part of the machine. normal industrial waste re-cycling processes.
Check the direction of rotation of the HSU and c) Bio-degradable items should be subject to
fans when starting up the compressor initially normal industrial waste disposal processes.
and after any work on the electrical Ensure that no plastic, rubber or composite
connections or switchgear. materials are disposed of by incineration.
Do not use any flammable liquid to clean d) The batteries associated with the back-up
valves, filter elements, cooler air passages, air power for the AMBs must be disposed of in
pipes or any component carrying a flow of air accordance with local guidelines.
during normal operation. If chlorinated
hydrocarbon nonflammable fluids are used for
cleaning, safety precautions must be taken
against any toxic vapours which may be
released.
Do not use carbon tetrachloride.
Precautions must be taken when using acids,
alkalis and chemical detergents for cleaning
machine parts and components. These
materials cause irritation and are corrosive to
the skin, eyes, nose and throat. Avoid
splashes and wear suitable protective clothing
and goggles. Do not breathe mists. Ensure
that water and soap are readily available.
When disposing of used filter elements and
other parts and waste material of any kind,
make sure that there is no pollution and that
no burning of waste takes place which could
cause pollution of the air. Protect the
environment by using only approved methods
of disposal.

2.7 Precautions In The Event Of Fire


Use extreme caution when handling
components that have been subjected to fire
or very high temperatures. Some components
may contain fluoroelastomer materials which
decompose under these conditions to form
highly corrosive residues. Skin contact can
cause painful and penetrating burns resulting
in permanent skin and tissue damage.

2.8 Disposal
When items of equipment are taken out of
service for disposal it is recommended that
the following instructions are adhered to:
a) In order to prohibit the ‘bringing back into
service’ of equipment by persons unknown, it
should be rendered unusable in order to avoid
improper re-use.
b) Alternatively all such items of equipment
should be stripped into their component form

10 DL105AA
CompAir Technical Information 3

3 Technical Information
3.1 Performance Figures
Performance Data L02 L03 L04 L05
Maximum pressure bar g 10
FAD * @ max. pressure m3/min 0.24 0.36 0,53 0,67
Total package input power * kW 3.20 4.15 5.33 6.69
Total input power at no load kW 0 0 0 0
Male rotor speed rpm 2160 2840 3950 5150
Ambient temperature - min/max °C from 1 to 40
Discharge temperature of air above ambient °C 16 21 26 34
Free field noise level ** dB(A) 61 61 62 66
Electrical Data
Nominal motor rating kW 2.2 3 4 5.5
Full load current max. (400V) Amp 6 7 9 11
Starting current max. IP55 (400V) direct online DOL Approx. 7 times full load current
Starting current max. IP55 (400V) star delta SD Approx. 2.5 times full load current
Standard drive motor detail IP IP55
Drive motor speed rpm 3000
Suggested cable size (400V) direct online mm 2 4 x 2,5 4 x 2,5 4x4 4x4
2
Suggested cable size (400V) star delta mm N/A N/A 4x4 4x4
Suggested fuse rating (400V) direct online, time delay Amp 16 aM 16 aM 16 aM 16 aM
Suggested fuse rating (400V) star delta, time delay Amp N/A N/A 16 aM 16 aM
Cooling Data
Ventilating fan capacity m3/min 6 6 12 12
Heat rejected by ventilating fan % 70
Size of cooling air inlet aperture mm 127 x 478
Size of cooling air outlet aperture mm 114 x 296
Cooling air temp above ambient approx. °C 30 35 38 42
Max. allowable pressure drop in duct at amb. 40°C Pa 20
Weights, Dimensions and Capacities
Compressor oil capacity litres 2
3
Approx. oil carry over mg/m <3
Compressed air delivery connection 1/2"
Weight kg 100 100 105 105
Package dimensions L x W x H mm 620 x 600 x 840
* Data measured and stated in accordance with ISO 1217 3rd Edition Annex C and at the following conditions:
Air Intake Pressure: 1 bar a / 14.5 psia
Air Intake Temperature: 20oC / 68oF
Humidity: 0%(dry)
** Measured in free field conditions in accordance with ISO 2151, tolerance ± 3dB.
CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications without prior notice. Rev 05/09

DL105AA 11
3 Technical Information CompAir

3.2 Dimensions, Weights, Cooling Airflow Requirements

1/2" GAS

S
E U
B

95

95
A C

620
40

A B C
296

kW 2.2-3-4-5.5 / 200 1450 1355 600


kW 2.2-3-4-5.5 / 270 1540 1400 600
C

kW 2.2-3-4-5.5 / 500 1950 1520 680


50

28 114
S
COOLING AIR QUANTITIES
500 LT. kW 2.2, 3, 4:- 0.1 m3/s (212 ft3/min)
200 LT.
kW 5.5:- 0.2 m3/s (424 ft3/min)
kW 2.2 100
kW 3 100
kW 4 105 S ELECTRICAL LINE INLET
kW 5.5 105 (3 PHASE)
kW 2.2 165
kW 3 165 M ELECTRICAL LINE INLET
Kg kW 4 170 255 (2 PHASE)
kW 5.5 170 255
AIR OUTLET
kW 2.2 212
kW 3 212
kW 4 213 290 SYMBOLS LABEL
kW 5.5 217 295 SM 1576

12 DL105AA
CompAir Technical Information 3

3.3 Approved Lubricant


• CompAir 4000 Lubricant
CompAir compressors have been tested and authorised to be used only with CompAir 4000 lubricants.
These lubricants are formulated according to the highest quality standards and are factory authorised,
tested and approved for use in rotary screw compressors.

3.4 Reference

Item Unit Value


Gas compressed Type Air
Inlet pressure Bar (A) 1 (Atmospheric)
Installation room Type Indoor
Room temperature - max/min °C Max. +40 / Min. + 2
Working temperature °C 50-65 + Room temp
Air outlet temperature °C 40-50 + Room temp
Residual oil content PPM 2-3
Max room humidity % 80
Max altitude m 1000
Max no. of starts per hour N° 6
Electrical supply Volt / Hz / A See data plate
Rating Hours 24 / 24

3.5 Refrigerant Dryer (Where Fitted)

Item Unit L02 L03 L04 L05


3
Flow Rate @ 35 °C m /min 0.4 0.4 0.6 0.9
Dew Point * °C +3 +3 +3 +3
Power Supply Ph / V / Hz 1 / 230 / 50 1 / 230 / 50 1 / 230 / 50 1 / 230 / 50
Nominal Power Consumption kW 0.22 0.22 0.22 0.22

* At ambient air temperature of +25 °C, Inlet air at 7 bar and 35 °C ( ISO 7183 Part 2)

3.6 Safety Measures Fitted

Danger Measures
Handling Base designed for use with forklift and transpallet forklift.

Electrical Connection Built-in full load AC23-filled circuit-breaker. *


Electrical Board Bolted on, with door interlock switch. *
Emergency Built- in yellow/red warning light. *
Short Circuit Built-in line fuses. *
Motor Overload Magneto-thermal cut-out. *
Electrostatic Discharge De-oiling filter with electrical continuity.

DL105AA 13
3 Technical Information CompAir

Safety Measures Fitted (cont'd)

Danger Measures
Compressor Overheat 110 °C thermostat with cut-out. *
Insufficient Lubrication 110 °C thermostat for 'adiabatic' compression.
Starting Under Load 20 sec. delay from energising *

Overpressure Approved safety valve.


Back-Pressure Non-return valve
Residual Pressure Descharge tap and internal air gauge.

Phase Reversal (wrong direction of rotation) Indicator arrow or R.S.F. electronic relay *

Temperature
Max. Environment > 45° C 110 °C thermostat.
Min Environment < 2° C See starting recommendations.
Pressure Parts Built to EEC 87/404 standards.
Flexible Hoses High pressure hose used (4-6 times working pressure).
Hot Surfaces Parts reaching 70 °C + marked with warnings

* only for versions with “AIRBASIC” controller

3.7 Air BASIC Electronic Controller Specifications (Where Fitted)

Power Supply 24Vac ±10%


Note: The controller goes OFF if duration of power failure exceeds 400 ms.
Memory Non-volatile for set data, compressor status and operating time data storage.
Hardware 4 optically isolated digital inputs for:
• line pressure switch
• motor overload thermal relay
• phase-sequence relay
• remote START/STOP
1 analog input for:
• KTY type temperature probe (range -10 to +130°C, resolution 1°C, precision ±1°C).
5 relay outputs [MAX 8(2)A-250Vac] for:
• line contactor
• star contactor
• delta contactor
• load/unload solenoid valve
• alarm remoting relay (N.O contact)
Operating • Operating temperature 0 to +55°C with 90% relative humidity (non-condensating)
Conditions • Storage temperature -20 to +70°C

14 DL105AA
CompAir Technical Information 3

3.8 General Arrangement Drawings


3.8.1 Stand Alone

DL105AA 15
3 Technical Information CompAir

3.8.2 Receiver-mounted (200 Ltr)

16 DL105AA
CompAir Technical Information 3

3.8.3 Receiver-mounted (200 Ltr) With Dryer

DL105AA 17
3 Technical Information CompAir

3.8.4 Receiver-mounted (500 Ltr) - L04, L05

18 DL105AA
CompAir Technical Information 3

3.8.5 Receiver-mounted (500 Ltr) With Dryer - L04, L05

DL105AA 19
3 Technical Information CompAir

3.9 Electrical Diagrams - Compressor


3.9.1 Wiring Harness

20 DL105AA
CompAir Technical Information 3

3.9.2 Electrical Schematic

DL105AA 21
3 Technical Information CompAir

3.10 Electrical Diagrams - AirBasic Controller

22 DL105AA
CompAir Technical Information 3

Electrical Diagrams - AirBasic Controller (cont'd)

DL105AA 23
3 Technical Information CompAir

Electrical Diagrams - AirBasic Controller (cont'd)

24 DL105AA
CompAir Technical Information 3

Electrical Diagrams - AirBasic Controller (cont'd)

DL105AA 25
26
REF. POS. MODEL DENOMINAZIONE NAME DESIGNATION BENENNUNG FABRICANTE SIZE MANUFACTURER 400V 50/60Hz
kW kW
4.0 5.5
SEZIONATORE BLOCCO MAIN DISCONNECT INTERRUPTEUR
S01 3\2 SE32003B HAUPSCHALTER INTERRUPTOR 3P 32A GIOVENZANA 1 1
PORTA SWITCH GENERAL

S01 3\2 012/0001 MANIGLIA HANDLE POIGNÉE HANDGRIFF MANIJA GIOVENZANA 1 1

S01 3\2 20401089 ALBERO SHAFT ARBRE ANTRIEB EJE GIOVENZANA 1 1

K1 4\4 3RT1015-1AB01 CONTATTORE CONTACTOR CONTACTEUR FERNSCHALTER CONTACTOR 3P+1NO 24Vac SIEMENS 1 1

K2 4\6 3RT1015-1AB02 CONTATTORE CONTACTOR CONTACTEUR FERNSCHALTER CONTACTOR 3P+1NC 24Vac SIEMENS 1 1
3 Technical Information

K3 4\5 3RT1015-1AB02 CONTATTORE CONTACTOR CONTACTEUR FERNSCHALTER CONTACTOR 3P+1NC 24Vac SIEMENS 1 1

K4 3\6 3RU1116-1HB0 TERMICA THERMAL RELAY RELAIS THERMIQUE THERMISCHES REL. INTER. SOBRECARGA 3P 5,5-8A SIEMENS 1

K4 3\6 3RU1116-1JB0 TERMICA THERMAL RELAY RELAIS THERMIQUE THERMISCHES REL. INTER. SOBRECARGA 3P 7-10A SIEMENS 1
PCH 3x38
F1 3\2 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 3P (10,3x38) ITALWEBER 1 1
2403038S
F1 3\2 1422020 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 20AaM (10,3x38) ITALWEBER 3 3

F2 3\12 FPC.10 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 1P (6,3x32) CABUR 1 1
Electrical Diagrams - AirBasic Controller (cont'd)

F2 3\12 0307200 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 2A (6,3x32) ITALWEBER 1 1

F3-F4 3\13-14 FPC.10 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 1P (6,3x32) CABUR 2 2

F3-F4 3\13-14 0307200 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 2A (6,3x32) ITALWEBER 2 2

F5-F6 3\14-15 FPC.10 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 1P (6,3x32) CABUR 2 2

F5 3\14 0307205 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 6A (6,3x32) ITALWEBER 1 1

F6 3\15 0307200 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 2A (6,3x32) ITALWEBER 1 1


0-230-400Vin
TR1 3\14 4TM36-1Y (80VA) TRASFORMATORE TRASFORMER TRASFORMATEUR TRANSFORMATOR TRAFO SIEMENS 1 1
0-24\0-24\0-110
X1 5 DAS.4 MORSETTO TERMINAL BOARD BORNIERA KLEMMENBRETT BORNERA 4mmq CABUR 7 7

RSF 3\12 RSF RELAY SEQ, FASI PHASES MONIT. REL. RELAIS RELAIS RELAIS SUPERVISION 400Vac CPE 1 1

A1 4 AIRBASIC CENTRALINA CONTROLLER CONTROLLER CONTROLLER CENTRALITA ELECTR. 24Vac GD 1 1

DL105AA
CompAir
CompAir General Description 4

4 General Description
4.1 Operating Principle Oil is injected into the air-end housing for the
dual purpose of cooling the unit and
The air end is a single-stage asymmetrical lubricating the moving parts.
screw type, driven by an electric motor. The
air is compressed through the rotation of a The air, once compressed, enters a receiver
male and female rotors which mate perfectly where the remaining oil is separated to a
along their parallel axes, and are housed in a residual of about 2-3ppm.
cast-iron case. At this point it is ready to be delivered.
Should the oil temperature be above the
desired running temperature, the separated oil
will pass through a thermostat-controlled
air-blast oil cooler. Should this not be the
case, it will be bypassed directly into the air
end to start a new cycle of lubrication and
cooling.
The air for the cooler is also used to cool the
motor. It is drawn through the compressor
canopy via a fan driven directly by the motor.
SM 1578

Fig. 4.1 - Rotary Screw Operating Principle


4.2 Compressor Diagram
See fig 4.2

13

16

15

8
10
4
6
12
9
14
18

11

7
3

17 M
5
1 2
SM 1579

Fig. 4.2 - Compressor Diagram


1. Electric Motor 7. Oil Filter 14. Discharge Valve
2. Air-End 8. Oil Radiator 15. Pressure Switch
3. Discharge Oil 9. Thermostat Valve 16. Minimum Pressure /
4. Oil Separation Filter 10. Air Intake Filter Non Return Valve
5. Temperature Control 11. Air Intake Valve 17. Cooling Fan
Device 12. Oil Return 18. Oil Tank
6. Safety Valve 13. Pressure Gauge

DL105AA 27
4 General Description CompAir

4.3 Regulation System (Only for


Version with AirBASIC Controller)
The compressor is specifically designed to
operate automatically according to the control
algorithm implemented into the AirBASIC
controller.
When the button ON is pushed, the
compressor starts off in sequence with the
“Star/Delta” function.
Once the “Star/Delta” transition has been
completed, the timer counts a 2 seconds
delay at the end of which the electric valve in
activated and the compressor passes to the
load phase.
When the pressure reaches the Pmax,
intervenes the pressure switch and the
controller turns off the motor.
If the pressure goes below the Pmin, the
controller makes the motor re-start.

4.4 Pressure Switch Setting


The pressure switch controls the load/unload
operation of the compressor.
The set-up of the pressure switch is done by
CompAir.
If it is necessary to modify the pressure switch
setting, contact CompAir authorised
distributor.
It’s prohibited setting the pressure switch at
pressure over 10 bar.

28 DL105AA
CompAir Installation and Storage 5

5 Installation and Storage


5.1 Lifting and Transportation

A B

C D

NO A  
B   
C  
D   


    

 

Fig. 5.3 - Lifting and Transportation

DL105AA 29
5 Installation and Storage CompAir

5.2 Installation Diagram

THREE PHASE 2
ELECTRICAL SUPPLY 9 10 11
12 12 12
1 4 6

MIN 750 MIN 750


7 8 7 3 7 5

REF. DESCRIPTION
THREE PHASE MONO PHASE
1 COMPRESSOR ELECTRICAL SUPPLY ELECTRICAL SUPPLY
2 TANK
3 AIR DRYER
4 FLEXIBLE HOSE
5 OIL-WATER SEPARATOR
6 CENTRIFUGAL SEPARATOR
7 AUT. COND. DISCHARGE
8 CERAMIC FILTER 1 3
9 COALESCING FILTER 0.1m
10 COALESCING FILTER 0.01m
11 ACTIVE CARBON FILTER 2
12 DIFFERENTIAL MANOMETER

AIR EXIT
MIN 750 MIN 750

SM 1580 NOTE: MIN. DISTANCE TO REAR WALL = 1000MM

Fig. 5.4 - Installation Diagram

5.3 Connection Piping 5.4.4 Prevent recirculation of cooling air. If the


Always use a flexible hose to connect the compressor is fitted with cooling air ducts,
compressor to the air distribution network. ensure they are of sufficient size for the
required cooling air volume including the
pressure loss within the ducting.
5.4 Installation Location
5.4.5 Ensure there is adequate access for cleaning
5.4.1 The compressor must be installed on a level the cooler.
surface capable of bearing the weight of the
compressor (see section 3 "Technical Please note that in the case of an
Information"). air-cooled compressor, almost the whole
compressor input power is transferred to
Caution: The condensate drain will contain the cooling air as heat.
traces of oil.
5.4.6 The compressor should not be installed in a
5.4.2 Refer to the installation diagram (fig. 5.4) for dusty location without special intake
the required minimum clearances around the pre-filtering. In case of doubt, contact
machine. CompAir Technical Support.
5.4.3 Make sure that the compressor room is 5.4.7 Outside installation is not permitted.
properly ventilated. The cooling air
temperature must be lower than + 45°C or
higher than 0°C.

30 DL105AA
CompAir Installation and Storage 5

5.5 Initial Checks 5.7.4 Never tamper with the pressure regulator
and/or pressure switch, or set working
5.5.1 After removing the compressor from its pressure higher than the one set for the
packaging and before proceeding with compressor model and for the reservoir.
installation, ensure that no damage has Maximum available pressure must always be
occurred during transportation. below the lift pressure of the safety valve fitted
5.5.2 Packaging materials such as wood, nails and to the reservoir.
plastic sheet could be dangerous for children
and should not be left within their reach. 5.8 After Prolonged Storage
5.5.3 Check that all the fuses in the electrical board If the compressor has remained switched off
are properly fitted and tightened. for longer than two months, the following
5.5.4 Check that the protection main nuts are procedure must be carried out before putting
tightened and the screw fixed. the machine back into service:

5.6 Electrical Connections


5.6.1 The electrical connections must be to EC
standards. All local safety regulations must
also be observed.
5.6.2 Make sure that the operating voltage is
B
correct. The voltage must be as rated, ± 5 %.
Check that each phase has an equal voltage.
C
5.6.3 The customer must provide supply cable short
circuit protection. The fuse type is given in the
electrical diagrams and technical data.
5.6.4 If the compressor is equipped with an
integrated dryer, a separate 230V supply must
be connected to the electrical cabinet (see
electric diagrams and technical data).
5.6.5 It is imperative that the earth cable is
connected correctly.
Only qualified electricians are permitted to
A
connect the power supply. No computer
should be installed near the compressor.
Make sure that any computer is connected
to an electrical circuit separate from that of
the compressor.

5.7 Recommendations SM 1581

5.7.1 The air drawn into the compressor must be Fig. 5.5 - Priming With Oil After Prolonged
completely free from toxic fumes and Storage
inflammable vapours from solvents, paints
etc, which would cause fire or explosions and
a) Access the intake valve (A) by detaching
pollute the working area.
cover (B) and removing the air intake filter
5.7.2 Using the compressor without a suitable air cartridge (C)
reservoir will jeopardise its functionality.
b) Pour 100 cc of approved compressor oil into
Overloading the electrical control system may
the valve
cause an excessive number of starts per hour,
leading to motor damage and shortening the c) Run compressor for ten seconds then stop
life of the unit.
d) Repeat step b
5.7.3 Never dismantle or modify guards or isolating
materials fitted to the compressor. e) Replace the parts and start unit.

DL105AA 31
6 Operation CompAir

6 Operation
6.1 Before Starting 6.3 To Stop (Not Valid For Version With
6.1.1 Before starting the compressor for the first “Airbasic” Controller)
time, make sure that: 6.3.1 To stop the compressor, push the “OFF-0”
- the flexible hoses are in good condition and button (RED colour) on the front panel.
efficient and do not show any signs of Caution: The compressor should be
abrasion or cracks allowed to run for at least 3 minutes before
- the electrical power phases are connected switching it off. Shorter running periods
properly. A phase reversal protection device is than this can damage the compressor in
fitted which will prevent the compressor being the long term and are not recommended.
started in this instance, thus avoiding damage
to the air end 6.4 Shut-Down Due To Power Failure
- all compressor access doors are closed 6.4.1 For standard machines:
- all guards are in place and properly secured a) Turn off the power from the main switch and
- all the electrical wiring is in good condition make sure that the compressor cannot be
and that the earth is properly connected accidentally started.

- there are no oil or air leaks b) Open the front panel.

6.1.2 Before opening the valve and letting c) Press down the red button on the pressure
compressed air into the connecting hose, switch to blow down the pressure. Pull up the
make sure that the hose end is securely fixed. red button again afterwards to restore the
This is to prevent the hose from whipping, pressure switch to normal working mode.
which could cause injury. d) Close the front panel end start up the
6.1.3 At the end of each working session, switch the compressor.
power off using the off button on the 6.4.2 For versions with overload cut-out:
controller.
a) If a cut-out occurs, the compressor will stop.
6.1.4 The air produced by this machine contains oil Once the power is back again, the
vapour and cannot be breathed, therefore the compressor will automatically resume
compressor should be placed in a separate operation immediately.
room.
Warning: For safety reasons, it is strongly
recommended that a sign be displayed
6.2 To Start (Not Valid For Version With near the machine indicating that the
“Airbasic” Controller) compressor may re-start without warning.
Caution: If the compressor has remained b) It is also imperative to check that the
switched off for more then two months, automatic re-start of the compressor will not
ensure that the procedure detailed in pose any hazards whatsoever.
section 5.8 is carried out before starting.
6.4.3 For versions with "Airbasic" controller:
6.2.1 To start the compressor, push the “ON-1”
a) The blow down function empties the receiver
button (BLACK colour) on the front panel.
after stopping; wait 2 minutes.
The compressor is controlled by a pressure
b) In the event of transient power failure, the
switch which stops the machine when air
compressor will shut-down and re-start in
pressure in the reservoir reaches MAXIMUM
automatic after 20 seconds (the set time to
and starts it up again when the pressure
unload the oil separation tank to guarantee a
drops to MINIMUM. The pressure range is set
correct restart).
to MIN 8 bar / MAX 10bar
Warning: Take extra care when in this
situation in order to avoid any damage to
persons or property caused by the drop in
air pressure in the distribution installation.

32 DL105AA
CompAir Operation 6

6.5 Starting At Low Temperatures 6.6 Electronic Controller (Where Fitted)


(below 0°C) 6.6.1 All compressor settings are programmed
Warning: If there is a possibility that the using the "AirBasic" electronic controller. For
room temperature may fall below 0°C, it is detailed instructions for the controller, please
essential to protect all pipes, hoses and refer to Chapter 9.
condensate drains with suitable insulation. 6.6.2 The controller regulates the output of the
This will prevent blockage due to ice, compressor. The following variables have
which can cause serious damage to the air been set in to the controller:
reservoir.
• target, unload and load pressures
Recommended procedure for start-up with
cold temperature (below 0 °C): • service intervals
a) Start the motor for 5 seconds then switch off • programmable I/O
before the pressure rises. • operational parameters
b) Repeat step a. • alarm and shutdown limits
c) Temporarily start the compressor, checking
that the pressure rises to a value close to the
maximum working pressure, for example 9
bar for 10 bar working pressure models ON
x10 x100
d) Switch off the compressor immediately when
pressure at step c is reached. OFF

e) Repeat steps c and d.


Reset
f) Finally, start the compressor, making sure that
the air pressure is not exceeded due to the
formation of ice in the hoses and/or icing up of
the non-return valve or the minimum pressure a03 A01 A03 A04 S.
valve.

SM 1574

Fig. 6.1 - "AirBasic" Electronic Controller


Display

DL105AA 33
7 Maintenance CompAir

7 Maintenance
Maintenance and service operations other than those described in this manual must be left to
service personnel authorised by CompAir.
Always wear suitable protective clothes, gloves and footwear while carrying out maintenance
work.

7.1 Maintenance Schedule

Maintenance Task Every

50 4,500 6,000 9,000


Hours Hours Hours Hours
500 1,500
Day or 1 Year or 4 or 6 or 6
Hours Hours
Week Years Years Years
Max Max Max Max

Check fault indicator lights and alarms


4 4 4 4 4 4 4 4
(only for “AIRBASIC” controller)

Check operation of condensate drain and clean strainer 4 4 4 4 4 4 4 4


Discharge air tank drain 4 4 4 4 4 4 4
Check oil level ** 4 4 4 4 4 4 4
Check for oil leaks 4 4 4 4 4 4
Clean inside compressor 4 4 4 4 4 4
Clean air filter 4 4 4 4 4 4
Change oil, see “Oil recommendations” 4 4 4 4 4
Renew oil filter 4 4 4 4 4
Renew oil separator cartridges 4 4 4 4 4
Renew air filter 4 4 4 4 4
Clean oil return line 4 4 4 4 4
Check V-belt tension 4 4 4 4 4
Clean cooler externally 4 4 4 4
Check operation of pressure relief valve 4 4 4 4
V-BELTS: Renew the belts. Check drive pulleys and renew if
4
worn.

Fit new seal kit in inlet valve 4


Renew oil hoses 4
Check and re-tighten main motor cables 4
Fit new shaft seal kit 4

** Stop the compressor before checking oil level. Wait until the oil has separated from the air - about 10 min)

34 DL105AA
CompAir Maintenance 7

7.2 Service Points


1 2

SM 1607 4

Fig. 7.1 - Service Points


1. Oil Filter 5. Oil Level Sight Glass
2. Air/Oil Separation Filter 6. Oil Filling Point
3. Inlet Air Filter 7. Drive Belt/s
4. Oil Drain Point

DL105AA 35
7 Maintenance CompAir

7.3 Before Maintenance The oil change intervals can be calculated


more accurately for the actual operating
Warning: Hot surfaces inside the conditions by analysing the oil.
compressor cabinet immediately after
stopping. Specific CompAir lubricants are
recommended for use in this equipment.
a) Stop the compressor. Other lubricants may cause :
b) Turn the power off from the main switch and - shorter life span of oil filters, oil separators
make sure that the compressor cannot be and oil
accidentally started.
- lacquering and blockage of oil circuit
c) Open the front panel.
- higher oil consumption
d) Ensure all air pressure released from machine
as follows: - excessive carryover and compressor
damage
- Standard versions: Push the red button on
the pressure switch to blow down the Caution: Do not mix different types of oil.
pressure. Afterwards pull the “RED” button to Caution: If a wrong oil type has been used
restore the pressure switch to normal working or the oil circuit is lacquered, contact
mode. CompAir specialists for oil circuit cleaning
instructions.
- "AirBasic" controller versions: The blow
down function automatically empties the
receiver after stopping; wait 20 seconds.
1
7.4 After Maintenance
2
a) Close the front panel.
b) Turn the power on from the main switch.
c) Start up the compressor.
d) CompAir recommends that a maintenance log
be kept as a record of all work carried out on
the compressor. Fill in the log.

7.5 Service Kits

Timing Kit No. Kit Description MAX


1,500
CK2302-1-KA Filters Service Kit
hours
6,000 Oil Separator Body
CK6300-1-KA
hours Service Kit
6,000 3
CC1045817 Hoses Service Kit
hours
9,000 Seal - Air End 4
CC1046311
hours SCA7L
SM 1582

7.6 Guidelines For Oil Change Intervals Fig. 7.2 - Changing the Oil
If final compression temperatures of more 1. Oil Filler Plug
than 90 °C occur continually, the oil change 2. Seal
intervals given in the maintenance schedule 3. Oil Level Gauge
are halved. 4. Oil and Condensate Drain Point

Note: Oil Tank Capacity 2kG

36 DL105AA
CompAir Maintenance 7

7.7 Belt Tensioning

1 2 3 3 1 2
2 MAX

9
5

7 10
5
8
TOOL FOR
ALIGNMENT CONTROL
6

6
SM 1584

Fig. 7.3 - Belt Adjustment Mechanism


1. Adjusting Screw 5. Air End Pulley 9. Air End
2. Locknut 6. Motor Pulley 10. Drive Belt
3. Air End/Pulley Bracket 7. Air End Mounting Plate
4. Securing Screws 8. Main Drive Motor

Belt tension is adjusted by slackening off the re-checked. Should it not be correct, the belt
air-end/pulley bracket securing screws should be tensioned again.
(fig. 7.3 (4)) and then moving the bracket (3)
(ii) Check the alignment of the pulleys. If
vertically using the adjusting screw (1).
necessary, correct it so that it is within 2 mm
a) To check the belt tension, apply a force (F) of for XPA belts, or 1 mm for poly-V belts (see
30 N with a dynamometer, positioned in the fig. 7.3).
middle of the belts (see fig. 7.4). If the tension
= =
is correct the belt deflection (f) should be
5±1 mm.
f
b) If (f) > 7 mm the tension is too low. Adjust the
position of the air end using adjusting screw
(fig. 7.3 (1)) then check the belt deflection (f)
again to confirm the tension is now correct.
c) If (f) < 3mm the tension is too high. Adjust the
position of the air end using adjusting screw F
(fig. 7.3 (1)) then check the belt deflection (f)
again to confirm the tension is now correct. S SM 1587
Notes:
Fig. 7.4 - Belt Adjustment
(i) If the belt has been renewed and the belt
tensioned following the procedures just
described, the compressor should be run for
20-30 minutes, then the tension (f) should be

DL105AA 37
7 Maintenance CompAir

7.8 Automatic Condensate Drain 7.9 Routine Maintenance Guide


(Where Fitted)

H0
2
50 h

50 h

OIL 1500 h

1 2
3 1500 h
4 ON OFF

5
1500 h
SM 1583 SM 1585

Fig. 7.6 - Cleaning Automatic Condensate Fig. 7.5 - Routine Maintenance Guide
Drain Filter

Clean after the first 10 working hours and


then every 500 hours.
7.8.1 Clean the tap filter (fig. 7.6 (4)) as follows :
a) Disconnect power and disconnect the
connection (1).
b) Close the tap (3).
SM 1608

OPEN CLOSED

c) Unscrew the gauze filter retainer (5) and


remove filter (4). Clean carefully and refit.

38 DL105AA
CompAir Troubleshooting 8

8 Troubleshooting
Warning: All operations must be carried out exclusively by suitably trained technical personnel or
by a service centre.
Warning: Before commencing any work, take all the due safety precautions as detailed in
chapter 7 - “Maintenance” .

Symptom Possible Cause Corrective Action


Compressor Fails To Start 1 No power supply a Check fuses and voltage
b Check that the protection devices of the voltage supply
(safety switch, current fault protection or fuses) are suitable
to be used as protection of the frequency converter.
c Contact the sales advisor.
2 Compressor stopped due Find out the possible cause of overheating
to overheating a Oil temperature control valve or sensor faulty
b Recirculation of hot cooling air
c Cooling air volume insufficient
d Ambient temperature too high
e Cooler clogged
f Wrong oil type or oil level too low
g Oil separator clogged
h Oil filter blocked
3 Electrical fault a Check the main switch
b Check wiring of the motor and frequency converter
c Check tightness of the cable connectors.
4 Over-loaded motor a Check that the maximum pressure is not being exceeded
b Check the inlet temperature and flow of the cooling air
c Check the oil level
d Check the pressure drop of the separator
5 Compressor stopped due a Check that the shut-off valve between compressor and
to excessively high compressed air system is open
pressure b Aftercooler is frozen
c Pressure sensor faulty
d Line filters clogged
6 Doesn't start, although the Wait (network pressure exceeds the adjusted pressure)
Start" button has been
pressed
Low Air Delivery 1 Air filter clogged Renew the air filter
2 Oil separator clogged Renew the oil separator
3 Intake valve faulty Repair or renew
4 Discharge valve or Clean or renew
condensate drainage is
faulty
5 Leaks in the compressed Check and repair the leaks
air system
6 Broken coupling Renew the coupling
7 Pressure limits incorrectly Set correctly
set

DL105AA 39
8 Troubleshooting CompAir

Symptom Possible Cause Corrective Action


Low Air Delivery (cont'd) 8 Ambient temperature too a Ensure sufficient cooling air circulation
high b Ensure that the intake air is from the coolest possible place
9 Aftercooler frozen Prevent the flow of cold cooling air to the compressor
10 Pressure relief valve open Close the valve
Compressor Overheats 1 Clogged cooler Clean the cooler
2 Ambient temperature too Check cooling air circulation
high
3 Intake valve faulty Repair or renew
4 Oil level too low Add oil
5 Wrong oil type See oil recommendation
6 Oil filter clogged Renew the oil filter
7 Faulty discharge Renew
temperature transducer
8 Cooling air ducting too Check the dimensioning and pressure drop of the
small or pressure drop too ventilation ducting and correct
high
9 Clogged oil separator Renew the oil separator
Oil Consumption Too High 1 Clogged oil return line Clean the oil return line
2 Faulty oil separator Renew the oil separator
3 Clogged oil separator Renew the oil separator
4 Wrong oil type See oil recommendation
5 Discharge temperature too Investigate and eliminate the cause
high
6 Shaft seal leaking Renew the shaft seal
7 Oil level too high Lower the oil level
Intake Valve Leaks Oil After Intake valve seal is leaking Renew the intake valve seal
Emergency Stop
Compressor Stops Too Often 1 Volume of compressed air Check the minimum pipe size. Correct if necessary.
system too small
2 Blockage in network Search for the blockage and repair

Note: See also the error messages listed in the controller user’s manual (for specific version)

40 DL105AA
CompAir AirBASIC Electronic Controller 9

9 AirBASIC Electronic Controller


9.1 Introduction 9.3.1 Display
The AirBASIC Controller is designed a) When the compressor is powered, the display
specifically for use in CompAir rotary screw air on the controller shows the “OFF” message.
compressors. These instructions will enable b) If a remote control is connected to the remote
you to operate the AirBASIC controller START/STOP input and its contact is open,
correctly and safely. that is, in a STOP condition, the display
shows the “---” message.
9.2 Safety
c) In normal operation, the controller display
Always read the safety instructions in shows the oil temperature value.
section 2 of this manual before starting work.
Note: The AirBASIC controller display can
In addition to these instructions, the local only show up to 3 digits. Numbers with 4 or 5
regulations in your country may impose digits are indicated by the illumination of LEDs
additional requirements that must be x10 or x100, which are termed "10 multiplying
observed. factor" and "100 multiplying factor"
respectively. The following examples show
how the LEDs work.
9.3 Description
1 2 Value to
Example Display LED LED
be
No. shows x10 x100
displayed

ON 3 1 697 697 OFF OFF


x10 x100
2 6970 697 ON OFF
OFF
3 69700 697 OFF ON

Reset
9.3.2 Button Functions
• ON: Switches on the compressor.
a03 A01 A03 A04 S. • OFF: Switches off the compressor.
• RESET: Resets alarms and displays hour
meter.
SM 1588 9.3.3 Indicator Functions
• x10 LED (green): indicates that the 10
Fig. 9.1 - AirBASIC Control Panel
multiplying factor is active.
1. LCD Display (3 Digits/7 Segments)
• x100 LED (green): indicates that the 100
2. LED Status Indicators (3 Green)
multiplying factor is active.
3. Control Pushbuttons (3)
• LED (green), steadily on: indicates load
The Control Panel is mounted on the operation mode.
compressor. It is used to operate the
compressor and observe system status using • LED (green), flashing: indicates unload
the LCD display, LED status indicators and operation mode.
buttons.
The Control Panel displays a comprehensive
9.4 Compressor Operation with the
overview of the compressor status and allows AirBASIC Controller
access to operational parameters such as 9.4.1 Starting The Compressor
alarm set points.
The starting procedure depends on the
current status of the compressor.
a) Starting the compressor in “OFF” status

DL105AA 41
9 AirBASIC Electronic Controller CompAir

The “OFF” message on the controller display When the compressor is started (either locally
indicates that the compressor is properly via the ON button or from a remote location),
powered, waiting to be started, and that the the controller performs a number of checks at
last switch-off was caused by pressing the the inputs to make sure that there are no
“OFF” push button on the controller (local conditions likely to pose hazards to the
switch-off). machine and/or the operators.
To start the compressor, use local controls, If abnormalities are found, the compressor
that is, press the “ON” button on the control start-up is inhibited and an error message
unit. appears on the controller display. If no
abnormality is found, the compressor is
Note: In this condition, opening and closing
allowed to start.
the remote contact will produce no effect
whatsoever. When start-up is initialised (and no alarms are
active), the controller checks the status of the
b) Starting the compressor in “---” status
line pressure switch contact. If the pressure
The “---” message on the controller display switch contact is closed, the motor is started
indicates that the compressor is properly according to the star/delta start-up sequence.
powered, waiting to be started, and that the If the pressure switch contact is open
remote START/STOP contact is in the OPEN (pressure in the network ), the compressor
position (STOP position). goes into stand-by mode and the motor is not
started until the network pressure drops to the
To start the compressor, use the relevant
load value level.
procedure described below, depending on
how the last switchoff occurred. When the load value level is reached, the
pressure switch contact closes. The relay
- If the compressor was running (no matter
outputs relating to the line and star contactors
whether loaded, unloaded or in stand-by) and
are energised for the equivalent of the star
was then switched off remotely, the “---”
time (parameter P06 - default 5 s). When the
message appears. To restart the compressor,
star time has elapsed, the controller switches
close the remote contact again.
from star to delta with a ‘safety’ delay (applied
- If the compressor was switched off locally, between the release of the star contactor and
that is, by pressing the OFF button on the the coming into operation of the delta
controller, and the remote contact was then contactor). This delay is equivalent to the time
opened AFTER the switch-off, the “---” value set up on the star/delta switching timer
message appears. (parameter P07 - default 20 ms). When the
switching timer has elapsed, the outputs
1. To restart the compressor, close the remote relating to the line and delta contactors are
contact. energised.
2. Press the ON button on the controller. In order to stabilise the motor’s rotation
This feature allows the operation of the speed, the load solenoid valve is energised
compressor to be disabled from a remote with a delay that is equivalent to the time
position in order to prevent unauthorised value set up on the “launch timer” parameter
personnel from starting the compressor with (parameter P08 - default 2s). The delay is in
the push buttons on the controller. relation to the closure of the delta contactor.
Once the solenoid valve has been energised,
Warning: If the remote control feature is to the compressor enters into load-operation
be used with the START/STOP contact stage.
connected to the controller, it is strongly
advisable to affix a sign by the machine 9.4.2 Controlling The Compressor Load/Unload
warning that the compressor may be Operation
started at any time from a remote location.
When the compressor is on load, the LED
Note: Machine start and machine restart on the right hand side of the display lights
operations can be performed via a control steadily. When the pressure reaches the set
device other than the one provided, as long as value of the pressure switch, the pressure
this does not pose any hazards. switch contact opens and the compressor
switches to unload operation for a period of
c) Compressor Start-up Process
time that is equivalent to the time value set up

42 DL105AA
CompAir AirBASIC Electronic Controller 9

on the “unload time” timer (parameter P09 - 9.4.3 Switching Off The Compressor
default 3 min).
The compressor can be switched off locally or
During the unload phase, the LED flashes remotely (if a remote contact is connected to
to indicate that the compressor is running in the appropriate terminals). In both cases,
unload mode. When the timer has elapsed, when the machine is commanded OFF, the
the motor is stopped. As soon as the pressure controller de-energises all the relay outputs
drops to the load value that is set up on the controlling the contactors as well as the
pressure switch, the motor is restarted solenoid valve, thereby causing the
automatically via a star/delta sequence. When compressor to stop immediately.
the motor is stopped, the LED is turned off The control unit activates a safety (“blowdown
and if no alarms are active, the value of the oil time”) timer (parameter P10 - default 20 s) to
temperature appears on the display. prevent the compressor from restarting with
If the pressure drops to the load value level pressure in the inner tank when the OFF
before the unload timer has elapsed, the button is pressed (or when the remote
compressor immediately switches back to start/stop contact is opened). Compressor
load mode without any stopping of the motor. restart is inhibited throughout the count down
When the “Unload time” timer elapses, the of the blowdown time. Pressing the ON button
motor stops. The oil temperature remains or closing back the remote start/stop contact
steady on the display to indicate that the during blow-down produces no effect
machine is not OFF but is still in stand-by whatsoever.
condition. The blow-down stage is indicated by the
Warning: Be very careful, as in this flashing of LED x10. When the count down of
condition, the compressor will restart the “blow-down time” is over, LED x10 is
without prior notice as soon as the turned off. At that point, you can restart the
pressure drops to the load value level. compressor.
See fig. 9.2 for an example of the operating
cycle.

Motor running
pressure
Network pressure

UNLOAD UNLOAD STOP

Unload pressure

Load pressure

LOAD LOAD

START
UNLOAD TIME
Motor running

Motor OFF

SM 1575 time

Fig. 9.2 - Example Of The Operating Cycle

DL105AA 43
9 AirBASIC Electronic Controller CompAir

9.5 Timers Note: When a maintenance pre-alarm


message is manually reset, it will no longer
The AirBASIC Controller has two kinds of appear as long as the compressor is ON.
control information: timers and parameters.
There are two kinds of timers: maintenance Maintenance timers can only be reset when
timers (for viewing and resetting) and the compressor is OFF. When the compressor
operation timers (for viewing only). is OFF, the display shows an “OFF” or “---”
message, depending on the conditions
9.5.1 Viewing maintenance timers described in section 11.7.1 a) - "Display".
Maintenance timers count the time until the a) To view the first maintenance code (S01),
next maintenance operation on the following press and hold RESET button for about 3
items (maintenance code number and seconds.
meaning):
b) To reset the first maintenance code, press
• S01 = oil change and hold the RESET button for about 3
• S02 = air filter replacement seconds. The value is replaced by the default
value and the second maintenance code will
• S03 = oil filter replacement be displayed.
• S04 = separator filter replacement c) If you do not wish to reset the first hour meter,
• S06 = general maintenance. but want to switch immediately to the second
one instead, press and release the RESET
The maintenance timers can be viewed when button. The second maintenance code
the compressor is ON. When the compressor appears on the display, and its timer value will
is ON, the display will normally show the oil be visible after 1 second. To reset the value,
temperature value, unless an alarm is ON. press and hold the RESET button for about 3
a) To view the first maintenance code, S01 (oil seconds.
change), press and release the RESET d) Scroll through all maintenance timers as
button. The value for remaining hours will be described above, resetting their values if
displayed automatically after about 1 second. necessary, until the “OFF” or “---” message is
b) To view the second maintenance code, S02 displayed again.
(air filter replacement), press and release the 9.5.3 Viewing operating timers
RESET button again. The value for remaining
hours will be displayed automatically after Operating timers count the total operating
about 1 second. hours (h-t) and total hours on load (h-L) of the
compressor. The operating timers are
c) To view the rest of the maintenance codes, available for viewing when the compressor is
press and release the RESET button again. ON.
d) To return to the oil temperature display, scroll a) To view the “h-t” message, press and hold the
through the remaining maintenance codes RESET button for 3 seconds. Total operating
(S03, S04, S06). hours will be displayed.
Notes: b) To view the “h-L” message, press and release
(i) Maintenance timer counting (parameters the RESET button again. Total hours on load
P12 - P 16) is based on motor running hours. will be displayed.
It works like a countdown; when the
countdown is at 0, it will continue with the Notes:
negative sign, and the first display will show (i) The counting of hours on load is based on
the “-” symbol. the length of time for which the relay
supplying the load/unload solenoid valve is
(ii) Maintenance hours are stored to the closed; the counting of total operating hours is
memory every 15 minutes; if a power failure based on the length of time for which the line
occurs during compressor operation, the contactor supplying the motor is closed.
entire 15 minute fraction will be lost.
(ii) Operating time is stored to the memory
9.5.2 Resetting maintenance timers every 15 minutes; if a power failure occurs
during compressor operation, the entire 15
minute fraction will be lost.

44 DL105AA
CompAir AirBASIC Electronic Controller 9

9.6 Parameters e) To edit the value of another parameter, scroll


up or down the list until the ID Code of the
The parameters allow the user to change the desired parameter is displayed, and repeat
operating parameters of the compressor, such step d).
as the maintenance pre-alarm hours or
maximum restarts per hour. The default f) To exit the programming mode after adjusting
values for the adjustable parameters are listed all the desired parameters, press and hold the
in the table on the next page. RESET button for about 3 seconds. At this
stage, the OFF or “---” message appears on
The parameters can only be adjusted when the display and all the changes made to the
the compressor is stopped. parameters are activated.
a) To enter the parameter programming mode, Notes:
simultaneously press and hold the OFF and (i) If no button is pressed for 60 seconds
RESET buttons for 3 seconds. After 3 during the programming procedure, the
seconds, the code of the first parameter, P01, controller will automatically exit the
will appear on the display. programming mode, switch back to OFF and
b) To scroll up or down the parameter list, press store all the changes.
ON or OFF buttons respectively. (ii) If the upper or lower threshold of a
c) To view the current value of a parameter, parameter is reached when editing a
press the RESET button. parameter, the value that appears on the
display will flash to warn that the min. or max.
d) To edit the displayed value, press ON value for that parameter has been reached.
(increase) or OFF (decrease) buttons. Once
the desired value has been entered, press The following table (fig. 9.3) contains all the
RESET button to store the value and to return available parameters with their respective
to the parameter list. codes, descriptions, units of measurement,
possible values and default values.

Param.code Description Unit Range Default


P01 MAX probe temperature range °C 130 - (P02+2) 130
P02 High oil temperature alarm threshold °C (P01-2) - (P03+2) 110
P03 High oil temperature pre-alarm threshold °C (P02-2) - (P04+2) 105
P04 Low oil temperature alarm threshold °C (P03-2) - -10 -10
P05 Oil temperature probe calibration °C -10 - +10 0
P06 Star time s 2 - 10 5
P07 Star-delta switch timer ms 10 - 50 20
P08 Launch timer s 1-5 2
P09 Unload time min 0 - 10 0
P10 Blow-down time s 1 - 60 20
P11 Max restarts per hour / 1 - 60 60
P12 Air filter maintenance pre-alarm hours h 100 - 3000 1500
P13 Oil filter maintenance pre-alarm hours h 100 - 9900 1500
P14 Separator filter maintenance pre-alarm hours h 100 - 9900 1500
P15 Oil maintenance pre-alarm hours h 100 - 9900 1500
P16 General maintenance pre-alarm hours h 100 - 1000 500
P17 Automatic restart status / 0-1 0
P18 Alarm relay function / 0-2 0

Fig. 9.3 - Table of Parameters

DL105AA 45
9 AirBASIC Electronic Controller CompAir

9.6.1 Parameter descriptions the motor’s rotation speed subsequent to


the star-delta switching.
P01 - MAX probe temperature range
– In normal conditions, this parameter needs
– Provides the highest value for oil
no adjustment.
temperature reading.
P09 - Unload time
– No adjustment is necessary.
– Defines the duration of the unload operation
P02 - High oil temperature alarm threshold
interval, at the end of which the controller
– Defines the high oil temperature alarm will power off the motor.
value. As soon as this value is reached, a
– Unload operation is identified by a flashing
dedicated alarm message (A01) appears on
LED.
the display.
P10 - Blow-down time
P03 - High oil temperature pre-alarm
threshold – Defines the duration of the blow-down
interval after the compressor has been
– Defines the high oil temperature pre-alarm
powered off. Its purpose is to prevent any
value. As soon as this value is reached, the
restarts of the compressor while pressure is
compressor stops and a dedicated alarm
still in the tank.
message (a03) appears on the display, but
the normal operation of the compressor is – The blow-down condition is identified by a
not interrupted. flashing x10 LED. In this condition, motor
start-up is inhibited for the set time interval.
P04 - Low oil temperature alarm threshold
P11 - Max restarts/hour
– Defines the low oil temperature alarm value.
Under this value, compressor start-up is – Defines the maximum number of permitted
inhibited and a dedicated alarm message start-ups per hour. Its purpose is to protect
(A34) appears on the display. the motor from damage. When the set
number of restarts is reached, the motor will
P05 - Oil temperature probe calibration
not stop for the rest of the following hour
– Compensates for possible reading errors and the compressor will work without
(either by excess or by defect) of the interruption, switching from load to unload
temperatureprobe due to a defective probe. and vice versa.
– In normal conditions, this parameter needs – This condition is identified by the
no adjustment. simultaneous flashing of LEDs x10, x100
and .
P06 - Star time
– At the end of the hour period, the counter is
– Defines how long the system should run in
reset and the motor will be able to stop at
star configuration during motor start-up.
the end of the unload phase.
– In normal conditions, this parameters needs
P12 - Air filter maintenance pre-alarm
no adjustment.
hours
P07 - Star-delta switch timer
– Defines the air filter change countdown
– Defines the delay between the release of timer value.
the star contactor and the coming into
– When the set timer has elapsed, the
operation of the delta contactor, during the
controller will warn the operator that
switching stage.
maintenance is needed by showing a
– In normal conditions, this parameter needs dedicated warning message (S02) on the
no adjustment. display.
P08 - Launch timer P13 - Oil filter maintenance pre-alarm
hours
– Defines the delay between the coming into
operation of the delta contactor and the – Defines the oil filter change countdown
energisingof the load/unload solenoid valve; timer value.
such delay stabilises as much as possible
– When the set timer has elapsed, the
controller will warn the operator that

46 DL105AA
CompAir AirBASIC Electronic Controller 9

maintenance is needed by showing a restart automatically after a delay that is


dedicated warning message (S03) on the equivalent to blow down time delay.
display.
P18 - Alarm relay function
P14 - Separator filter maintenance
– Defines which function is to be assigned to
pre-alarm hours
the alarm remoting relay contact, in
– Defines the separator filter change accordance with the following arrangement:
countdown timer value.
P18=0
– When the set timer has elapsed, the Relay is energised in any alarm condition and
controller will warn the operator that in any pre-alarm condition.
maintenance is needed by showing a
P18=1
dedicated warning message (S04) on the
Relay is energised only in alarm conditions
display.
that will stop the compressor.
P15 - Oil maintenance pre-alarm hours
P18=2
– Defines the oil change countdown timer Relay is energised only when one of the
value. maintenance timers has elapsed.
– When the set timer has elapsed, the
controller will warn the operator that
maintenance is needed by showing a
dedicated warning message (S01) on the
display.
P16 - Overall maintenance pre-alarm hours
– Defines the general maintenance
countdown timer value.
– When the set timer has elapsed, the
controller will warn the operator that
maintenance is needed by showing a
dedicated warning message (S06) on the
display.
P17 - Automatic restart status
Warning: If the automatic restart feature is
to be used, it is strongly adviced to affix a
warning sign by the machine to alert
bystanders that the compressor may come
back into operation automatically and
without prior notice. It is also mandatory to
check that the automatic re-start of the
compressor will not pose any hazards
whatsoever.
– Enables or disables the automatic restart of
the compressor as soon as current is back
after a power failure.
P17=0 automatic restart is disabled.
When current is back after a power failure has
halted the compressor, the compressor will
NOT restart automatically and the controller
will display a dedicated alarm message (A33).
P17=1 automatic restart is enabled.
When current is back after a power failure has
halted the compressor, the compressor will

DL105AA 47
9 AirBASIC Electronic Controller CompAir

9.7 Error Management 9.7.2 Shutdown Faults

9.7.1 Advisory Alarms The shutdown faults in the controller are


designed to protect the compressor from
The advisory alarms alert the user that component failure or extreme environmental
maintenance is needed, or that certain conditions. These alarms will stop the
parameters may be approaching their compressor and/or inhibit its start-up. To reset
shutdown level. Advisory alarms can be reset an alarm message, eliminate the cause of the
while the compressor is running or stopped by concern and press RESET.
pressing the RESET button. If the error
condition still exists after resetting the See the following table for shutdown faults
advisory alarm, the advisory alarm will occur that can occur in the AirBASIC Controller
again after the compressor is powered ON
Shutdown Faults
again after it has been powered OFF.
Code Meaning
See the following tables for advisory alarms
that can occur in the controller. A01 high oil temperature
A03 motor thermal overload relay trip
Pre-Alarms
A04 phase inversion/phase loss
Code Meaning
A07 temperature probe is faulty
a03 High oil temperature pre-alarm (message
alternates with temperature display). set data loss and acquisition of default
A26
data
Alarm automatically resets when
temperature drops below the set value power failure (only applicable if automatic
A33
of -2 °C. restart is disabled)
A34 low oil temperature
Maintenance Alarms
Code Meaning
S01 Oil change
S02 Air filter replacement
S03 Oil filter replacement
S04 Separator filter replacement
S06 General maintenance

Note: It is recommended that maintenance be


performed as soon as possible after a
maintenance message appears.

48 DL105AA
CompAir AirBASIC Electronic Controller 9

9.8 Transducer Locations


9.8.1 See fig. 9.4





 

  
 
 



     
Fig. 9.4 - Wiring Diagram

9.8.2 Key to codes in fig. 9.4

Input
Pin Function Status
connector
M1 power supply connector 24 Vac
M2 digital input connector, type: 5 poles Combicon 5 mm
C3 1 Common digital inputs
l1 2 Line pressure switch Closed=loaded Open=unloaded
l2 3 Motor thermal relay Alarm if open
l3 4 Phase-sequence relay Alarm if open
l4 5 Remote Start/Stop Closed=start Open=stop
M3 alarm relay connector, type: 2 poles Combicon 5 mm
C2 1 Common relay
R 2 Auxiliary alarm relay Energised=closed De-energised=open
M4 output relay connector, type: 5 poles Combicon 5 mm
C1 1 Common relay
K1 2 Line contactor Energised=closed De-energised=open
K2 3 Star contactor Energised=closed De-energised=open
K3 4 Delta contactor Energised=closed De-energised=open
EV 5 Solenoid valve Energised=closed De-energised=open
M5 temperature probe connector, type: screw terminals welded on the I.C.
1 Temperature probe
2 Temperature probe

DL105AA 49
10 Compressor Parts List CompAir

10 Compressor Parts List

Parts List Contents


Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor and Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Oil Separation Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Parts Kit/s - Oil Separation Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Parts Kit/s - Air Intake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

50 DL105AA
CompAir Compressor Parts List 10

Frame

9 5

10

7
1

11

SM 1593

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1044365 1 Frame
2 CC1044366 1 Panel (2.2/3/4-5.5kW)
CC1044373 1 Panel (4-5.5kW Premium)

3 CC1044367 1 Panel R.H.


4 CC1044368 1 Panel
5 CC1044312 1 Plate Belt Tightening
6 CC1044314 1 Motor Bracket
7 150008 4 Vibration Damper
8 CC1044369 1 Cover
9 CC1044370 1 Panel L.H.
10 150093 1 Adhesive Gasket 12x2
11 CC1044371 1 Panel Front

DL105AA 51
10 Compressor Parts List CompAir

Motor and Compressor Unit

11 10 9 7

16 15
6
5
8 3

2
12
14 13 4

SM 1594

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1026216 1 Electric Motor 9 CC1045111 1 Compressor Pulley -
(3kW B3 2P 230/400V) 132 Dia. PBT-1SPA (2.2kW)
CC1026212 1 Electric Motor CC1045110 1 Compressor Pulley -
(2.2kW B3 2P 230V/50-60Hz) 100 Dia. PBT-1SPA
CC1026210 1 Electric Motor (3kW,5.5kW & 5.5kW Premium)
(4kW B3 2P 400/690V) CC1045109 1 Compressor Pulley -
CC1026211 1 Electric Motor (4-5.5kW incl. 95 Dia. PBT-1SPA
Premium B3 2P 230/400V) (4kW & 4kW Premium)
CC1026218 1 Electric Motor (4-5.5kW incl. CC1045112 1 Compressor Pulley -
Premium B3 2P 400/690V) 140 Dia. PBT-1SPA (mon.) 2.2kW
2 CC1043038 1 Compressor SCA7L 10 CC1033626 1 Belt XPA 957
3 CC1043986 1 Air Intake Valve RH30 + GHS100 (2.2kW, 4kW & 4kW Premium)
(2.2-5.5kW) CC1033624 1 Belt XPA 907 (3kW)
CC1046515 1 Air Intake Valve RH30E 220842 1 Belt XPA 1032
(4-5.5kW Premium) (5.5kW & 5.5kW Premium)
4 CC1044309 1 Oil Separation Body VTDM15 11 CC1043966 1 Compressor Pulley Bush
5 250112 1 Clamp Wire D.44-47 (2.2kW,3kW,5.5kW
6 CC1044252 1 Air Intake Filter & 5.5kW Premium)
CC1044253 1 Air Intake Filter Cartridge CC1043967 1 Compressor Pulley Bush
(4kW & 4kW Premium)
7 221055B 1 Separation Cartridge
8 220977 1 Oil Cartridge Continued

52 DL105AA
CompAir Compressor Parts List 10

Motor and Compressor Unit - (cont'd)

11 10 9 7

16 15
6
5
8 3

2
12
14 13 4

SM 1594

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
12 CC1026592 1 Holder Fan
13 CC1033618 1 Motor Pulley 100 Dia.-1SPA
(2.2 & 3kW)
CC1033621 1 Motor Pulley 132 Dia.-1SPA
(4kW & 4kW Premium)
CC1033623 1 Motor Pulley 180 Dia.-1SPA
(5.5kW & 5.5kW Premium)
CC1033613 1 Motor Pulley 95 Dia.-PBT-1SPA
(monof.) 2.2kW
CC1026691 1 Compressor Pulley Bush (monof.)
2.2kW

14 CC1026685 1 Fan (2.2-4kW & 4kW Premium)


CC1026591 1 Fan (5.5kW & 5.5kW Premium)

15 180926 1 Screw M8x50


16 180549 1 Nut M6

DL105AA 53
10 Compressor Parts List CompAir

Oil Separation Body

6
5

4
5

4
5 10
8
7
1
3

SM 1595
2 5 4 5 4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1041791 1 Oil Separation Body
2 160240 1 Nipple 1" - 1/2"
3 180535 1 Copper Washer 33.5x40x1.5
4 160242 4 Nipple 1/2" - 3/8"
5 120377 5 Copper Washer 21.5x28x1.5
6 160268 1 Nipple 1/2"
7 120374 1 Copper Washer 17x23x1.5
8 160812 1 Plug 3/8"
9 160409 1 T Joint M1/8"x6
10 160510 2 Joint 1/8"x6

54 DL105AA
CompAir Compressor Parts List 10

Oil Tank

14

5
8 2

13

4
5

12
13
11
9

10
SM 1596

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1026595 1 Oil Tank
2 160806A 1 Oil Plug
3 CC1026596 1 Level Oil Plug
4 160268 1 Nipple 1/2"
5 120377 2 Copper Washer 21x28x1.5
6 120376 1 Copper Washer 27x33x1.5
7 150175 1 Oil Plug Gasket
8 221525 1 Safety Valve 1/4"-12bar
9 160299 1 Nipple 3/8"-1/4"
10 B160434 1 Tee 1/4" Copper Union
11 160811 1 Plug 1/4"
12 B160730 1 Ball Gate 1/4"
13 240014 2 Copper Washer 13.5x318x1.5
14 120812 1 Nipple 3/4"-1/2"

DL105AA 55
10 Compressor Parts List CompAir

Oil Circuit

10
7

10
4

6
9

11

SM 1597

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1044308 1 GAS Joint 3/4"
120376 1 Copper Washer 27x33x1.5

2 CC1039965 1 Probe Joint


3 150718A 1 Flexible Hose 3/4"x520
4 120812 1 Nipple 3/4"-1/2"
120377 1 Copper Washer 21.5x28x1.5

5 150835 2 Flexible Hose 3/8"x730-180D


6 150816A 1 Flexible Hose 1/2"x600
7 CC1026441 1 Oil Cooling Radiator
8 150408 1 Flexible Hose 1/2"x1900-180A
9 CC1027010 2 Flexible Hose 3/8"x450-180A
10 160245 2 Nipple 3/8"
120374 2 Copper Washer 17x23x1.5

11 210102 1 Cable Gland D.45

56 DL105AA
CompAir Compressor Parts List 10

Air Circuit

4
7

SM 1598

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1046670 1 Pressure Switch
2 210397 1 Support Pressure Switch
3 160512 1 Joint 1/4"x6
4 250180 2 Nylon Tube D.6
5 121233 1 Nozzle Whole M5 D.0.5
CC1045371 1 Joint 1/4"x6

6 250179 0.4 Rilsan Tube D.6


7 160459 1 Joint 90° 1/4"x6
8 221396 1 Air Gauge

DL105AA 57
10 Compressor Parts List CompAir

Electrical Components

7
8

4
ON
5 x10 x100

OFF
6
Reset

a03 A01 A03 A04 S.

SM 1599 9

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
400V/50Hz 230V/50-60Hz
1 CC1036610 1 Kit Overload Cutout + Coil 1 CC1036612 1 Kit Overload Cutout + Coil
6.3-10A (2.2 & 3-4kW) 6.3-10A (2.2-3kW)
CC1036611 1 Kit Overload Cutout + Coil CC1036613 1 Kit Overload Cutout + Coil
10-16A (5.5kW) 10-16A (4kW)
CC1035840 1 Coil 400V (2.2, 3-4 & 5.5kW) CC1036614 1 Kit Overload Cutout + Coil
20-25A (5.5kW)
2 CC1031508 1 Hours Counter
3 180948 2 Screw D.3.5x16 (2.2, 3-4 &5.5kW) CC1035841 1 Coil 230V (2.2-3, 4 & 5.5kW)
4 210102 1 Cable Gland D.45
5 210159 1 Cable Gland 2 CC1031508 1 Hours Counter
6 210179 1 Lock Nut 3 180948 2 Screw D.3.5x16 (2.2, 3-4 &5.5kW)
7 CC1027036 1 Thermostat 110°C + Probe 4 210102 1 Cable Gland D.45
(2.2, 3-4 & 5.5kW) 5 210159 1 Cable Gland
6 210179 1 Lock Nut
8 CC1033416 1 Controller AIRBASIC 7 CC1027036 1 Thermostat 110°C + Probe
(4-5.5kW Premium) (2.2, 3-4 & 5.5kW)

9 CC1028375 1 Panel Kit (4-5.5kW Premium) 8 CC1033416 1 Controller AIRBASIC


(4-5.5kW Premium)

9 CC1028375 1 Panel Kit (4-5.5kW Premium)

58 DL105AA
CompAir Compressor Parts List 10

Air Receiver

2.2 - 3 - 4 kW

5 2 3 4 17 EDX 4-6
1 EDX 4-6

E
4
1/2" GAS 18 13
7
6 6
A

12
12
11

9 10

5.5 kW

5 2 3 4 17
EDX 9 1/2" GAS
EDX 9

E U 1

18 13 4
7
6
A 6

12
12

11

9 10
16 15 14 8 13

VIEW A SM 1600

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 160207 1 Junction 1/2"
2 160731 1 Gate Valve 1/2"
3 160268 2 Nippe 1/2"
4 150497 1 Flexible Hose 1/2"x1100
5 CC1028206 1 Joint M/F 1/2"
6 CC1046496 1 Base Dryer
7 133107A 1 Angle Bar - Dryer Fixing
8 160333 1 Extension 1/4"
9 120812 1 Nipple 3/4"-1/2"
10 CC1046361 1 Tank LT200 CE 11bar (AD2000)
11 160736 1 Water Drain Tap
12 160817 2 Plug 2"
120340 2 Copper Washer 2"

13 223252 1 Air Gauge


14 160670 1 Junction 3/8"-1/4"
15 160446 1 Copper Union T 3/8"
16 221638 1 Safety Valve 3/8"-11bar PED
17 150408 1 Flexible Hose 1/2"x1900-180A
18 210102 1 Cable Gland D.45

DL105AA 59
10 Compressor Parts List CompAir

Parts Kit/s - Oil Separation Body

SM 1601

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A CC1045721 1 Minimum Pressure Valve Kit
B CC1041338 1 Thermostatic Valve Kit 71°C
C CC1041339 1 Nipple O-ring Kit
D CC1047123 1 Non Return Valve Kit

60 DL105AA
CompAir Compressor Parts List 10

Parts Kit/s - Air Intake Valve

B
4-5.5kW PREMIUM

2.2, 3, 4 & 5.5kW PREMIUM


SM 1602

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A CC1045722 1 Body Spare Parts Kit
B CC1045723 1 Discharge Valve GHS100 -
Spare Parts Kit

DL105AA 61
11 Compressed Air Dryers CompAir

11 Compressed Air Dryers


11.1 General SYMBOL DESCRIPTION

The units described in this chapter are


termed “dryers”. Unit air inlet

They are designed to remove the moisture


from a flow of “compressed gas”.
The dryers are equipped with a refrigerant
circuit that is designed to cool the compressed Condensate drain
air to a temperature designated “pressurised
dew point”.
Since, in the majority of applications, the gas
to be dried is compressed air, hereinafter the Direction of fan rotation
(air-cooled models)
term “compressed air” is used for the sake of
simplicity, even though the specific gas in an
individual application may be different. Do not use fork lift truck
Hereinafter the expression “pressure” is used where this symbol appears
to indicate relative (gauge) pressure.
General symbols are to be found on the
decals affixed to the unit and also in the
dimensional drawings and refrigerant circuit Electric shock hazard
diagrams in this manual. The meaning of each
symbol is indicated in fig. 11.1.
This manual, which is addressed to users,
installers, and service personnel, supplies all
the technical information required to install Unit air outlet
and work with the dryer and to perform the
routine maintenance operations required to
ensure a long working life.
11.1.1 If spare parts are needed use exclusively
genuine original components. Flow of cooling air
(air-cooled models)
11.1.2 Requests for SPARE PARTS and any
INFORMATION concerning the dryer must be
made to the nearest dealer or service centre,
Direction of flow
specifying the SERIAL NUMBER shown on
of refrigerant gas
the unit's dataplate.

Lifting point

SM 1589

Fig. 11.1 - Symbols Used On Dryers

62 DL105AA
CompAir Compressed Air Dryers 11

11.2 Safety - Dryers Caution: The gas being compressed must


not lead to corrosion that could impair the
Warning condition of pressurised containers, nor
must they be able to cause fire or
explosions in the event of leakage or
expulsion.
This plant is designed for safety in its
intended use, provided it is installed, b) Precautions during lifting and transport
commissioned, and serviced in When a load is lifted from the ground keep
compliance with the instructions given in well clear of the area beneath the load and
the present manual. the immediately surrounding area.
The unit contains electrical components Keep accelerations and lifting speed well
that operate at mains voltage and also within safety limits and never leave a
moving parts such as fans, it must suspended load attached to a hoist any longer
therefore normally be disconnected from than strictly necessary.
the electrical power supply before it is
opened. Handling of dryers must be carried out in
compliance with the diagrams given (see
Operation, overhauls or repair of the unit section 11.3 - "Technical Data - Dryer").
or any maintenance operations that call for
access to the plant must be executed by The manufacturer does not supply bars, belts
skilled or suitably qualified personnel who or lifting hooks with the unit.
are fully aware of all the necessary Caution: The unit's weight is shown on the
precautions, preferably under the dataplate and on the label affixed to the
guidance of a qualified supervisor. crate.
11.2.1 General c) Precautions to be adopted during installation
and operation
The user must ensure that all personnel
involved in operating and servicing the dryer For connection to the mains power supply
and the auxiliary equipment have read and follow the guidelines in section 11.5 -
understood all the warnings, precautions, “Installation” and the electrical diagrams in
prohibitions and notes given in this manual section 11.3 - "Technical Data - Dryer".
and affixed to the unit.
All pipelines must be painted and marked
If the user adopts operational procedures or clearly in compliance with local safety
uses tools or working procedures that are not prescriptions in force in the place of
specifically recommended, care must be installation.
taken to ensure that the dryer and the
Do not remove or tamper with safety devices,
auxiliary equipment are not damaged or made
protections or the insulating materials installed
unsafe and that no risks emerge in relation to
in the unit or in the auxiliary equipment.
persons or property.
The dryer and its auxiliary equipment must be
Any improper use of the machine will relieve
connected to earth and protected against
the manufacturer from any liability for possible
short circuits and overloads.
personal injury or property damage.
When the unit is powered, the voltage in the
Arbitrary modifications made to the unit will
electrical circuit assumes potentially lethal
automatically invalidate all forms of guarantee
values so the maximum precautions must be
provided by the manufacturer.
adopted if work is to be carried out on the
11.2.2 General precautions electrical circuit.
a) Type of compressed gases to be dried Do not open the electrical equipment
enclosure panels while the electrical system is
The compressed gases that can be dried
powered unless this is strictly necessary for
must be compatible with the unit's
the execution of tests, measurements or
construction materials (carbon steel, cast iron,
settings.
copper and copper alloys) and can be, for
example air, nitrogen, argon and helium. This work must be carried out exclusively by
qualified personnel equipped with suitable

DL105AA 63
11 Compressed Air Dryers CompAir

tools and wearing all the relevant protective When a repair has been completed make sure
equipment to safeguard against electrical that no tools, detached parts or rags are left in
hazards. the dryer.
d) Precautions for maintenance and repair All the protections must be refitted following
maintenance or repair work.
If spare parts are required, use exclusively
genuine original parts. Do not use inflammable liquids to clean
components while the dryer is running.
Keep a written record of all work carried out
on the unit and the auxiliary equipment. If non-inflammable hydrocarbons containing
chlorine are used all the relevant safety
The frequency and nature of the work
precautions must be adopted to protect
required in a certain period can reveal
against the toxic fumes that may be given off.
abnormal operating conditions that require
correction. Before removing any panels or dismantling
any parts of the unit, perform the following
Use exclusively the refrigerant specified on
steps:
the machine dataplate.
• Isolate the unit from the electrical power
Make sure that all the instructions concerning
supply by disconnecting the supply upstream
operation and maintenance are followed
of the power feeding line.
scrupulously and that the entire unit and all
the accessories and safety devices are • Lock out the breaker (if present) in the “OFF”
maintained in proper working order. position by fitting a padlock.
Always keep the plant clean. • Attach a warning label to the main switch (if
present) reading: "WORK IN PROGRESS -
Protect components and exposed openings
DO NOT SWITCH ON".
by plugging them, for example, with clean
rags during maintenance and repair work. • Do not set the electrical power switch to ON
or attempt to start the unit if the warning label
Precautions must be taken before welding or
is attached.
performing repair operations that may
generate heat, flames or sparks. Coloured tracers can be used in
service-maintenance operations.
Components in the vicinity must be protected
with non-inflammable material. Inspect all refrigerant circuit joints including
connectors, flanges, and more generally all
Do not weld or perform work that generates
critical points (open joints) in order to prevent
heat close to a system that contains oil.
possible leakage of refrigerant gas.
Systems that may contain oil must be
11.2.3 Refrigant gases
completely drained and flushed, for example,
with steam, before performing any operation. The plants can be charged only with R134a.
Do not weld or modify a container that may be The use and storage of cylinders containing
subject to pressurisation. refrigerants must be in compliance with the
prescriptions of the manufacturers of the
To prevent an increase in working
cylinders and in compliance with the
temperature and pressure values check and
applicable safety laws and prescriptions in
clean the heat exchange surfaces (e.g. the
force in the place of installation.
fins of condensers) regularly.
a) Characteristics of R134a refrigerant
For all dryers establish a convenient time
interval for cleaning procedures. At normal temperature and pressure
conditions, this is a class A1 colourless gas
Never use an open flame as a light source to
(classification EN 378-1).
inspect parts of the dryer.
Concentrations significantly above 1000 ppm
Before dismantling parts of a plant ensure that
v/v can cause narcotic effects.
all mobile and heavy parts are securely fixed,
and ensure electrical power has been In the event of leakages provide adequate
disconnected. ventilation of the room before entering.

64 DL105AA
CompAir Compressed Air Dryers 11

11.3 Technical Data - Dryers


11.3.1 Dataplate and meaning of abbreviations
The main technical data of the unit are indicated on the data plate as follows:

MODEL and CODE Identify the size of the unit and its type of construction.
MANUAL Code number of the present manual.
SERIAL NUMBER Unit serial number or manufacturing number.
YEAR OF CONSTRUCTION Year of unit's final testing.
VOLTAGE/PHASES/FREQUENCY Power supply characteristics.
Unit current input in limit operation conditions (refrigerant condensing and
MAX CURRENT DRAW (I max)
evaporation temperature of 70°C/158°F and 10°C/50°F respectively).
Unit power input in limit operation conditions (refrigerant condensing and
INSTALLED POWER (P max)
evaporation temperature of 70°C/158°F and 10°C/50°F respectively).
PROTECTION RATING According to European standard EN 60529 .
REFRIGERANT Type of refrigerant charge with which the unit is filled.
REFRIGERANT CHARGE Quantity of refrigerant supplied to circuit.
MAX. REFRIGERANT PRESS. Refrigerant circuit design pressure.
MAX REFRIGERANT TEMP. Refrigerant circuit design temperature.
USER CIRC. FLUID Fluid cooled by the machine.
MAX. WORKING PRESSURE User circuit maximum design pressure.
User circuit maximum design temperature - not to be confused with the
MAX TEMPERATURE
maximum working temperature, which is specified at the time of the offer.
Free field sound pressure level in hemispherical radiation conditions (open
SOUND PRESSURE LEVEL field) at a distance of 1m (39.37in) from the condenser side of the unit and a
height of 1.6m (63.0in) from the ground.
AMBIENT TEMPERATURE Cooling air minimum and maximum temperature values.
WEIGHT Approximate weight of the unit without packaging.
Fluid used by the machine to cool the condenser (this information is not
CONDENSER COOLING FLUID
given if the machine condenser is air-cooled).
Condenser cooling circuit maximum design pressure (this information is not
MAX. WORKING PRESSURE
given if the machine condenser is air-cooled).
Condenser cooling circuit maximum design temperature (this information is
MAX TEMPERATURE
not given if the machine condenser is air-cooled).
IMAX * Full load amperage
PMAX * Maximum power
ILR * Locked rotor current

* also present on wiring diagram

11.3.2 Performance data


a) The performance of the dryer (dew point, power consumption, pressure drops, etc.) depends mainly on
the flow rate and pressure of the compressed gas to be dried and on the condenser cooling fluid
temperature (ambient temperature). These data, which are usually defined at the time of the offer,
constitute the basic point of reference in relation to dryer performance.
b) Sound Level Measurements
The noise emission values measured are below 70 dB(A).

DL105AA 65
11 Compressed Air Dryers CompAir

11.3.3 Overall Dimensions

66 DL105AA
CompAir Compressed Air Dryers 11

11.3.4 Refrigeration Circuit

DL105AA 67
11 Compressed Air Dryers CompAir

11.3.5 Electrical Data

68 DL105AA
CompAir Compressed Air Dryers 11

Electrical Data (cont'd)

DL105AA 69
11 Compressed Air Dryers CompAir

11.3.6 Power Circuit

70 DL105AA
CompAir Compressed Air Dryers 11

11.3.7 Control Circuit

DL105AA 71
11 Compressed Air Dryers CompAir

11.3.8 Components Layout

72 DL105AA
11.3.9

DL105AA
CompAir

Notes
DYENHTYYZZ PFOBNF JN GTHTUHEPJR

RJYLTYCJJNDJLXBR GJ DHTVTYB EGHFDKZTVSQ RJYNHJKKTHJV = GHJUHFVVBHETVSQ RJLYLTYCJJNDJLXBR DYTIYBQ = GJGKFDRJDSQ RJYLTYCJJNDJLXBR


Compressed Air Dryers 11

73
74
11.3.10 Nomenclature
11 Compressed Air Dryers

CJRHFOTYBT GJKJ:TYBT YFPDFYBT


"KTRNHJC{TVF
GKFNF LFNXBRF CKBDF RJYLTYCFNF
LFNXBR $NJXRB HJCS$
RJYLTYCFNJH
RJYLTYCFNJH
RJVGHTCCJH
DTYNBKZNJH
GHTCCJCNFN DSCJRJUJ LFDKTYBZ
DBKRF
"KTRNHJRKFGFY RJYLTYCJJNDJLXBRF
RKTVVYBR PFPTVKTYBZ

DL105AA
CompAir
CompAir Compressed Air Dryers 11

11.3.11 Electrical Devices

DL105AA 75
11 Compressed Air Dryers CompAir

11.4 Description section of the thermal mass, where it absorbs


the heat of the warm and humid compressed
11.4.1 Operating principle air entering the dryer and thereby cools the
A refrigerant circuit cools a patented “thermal inlet flow.
mass” through which the humid compressed This air/air exchanger both reduces the
air to be dried flows. amount of energy required to dry a given flow
The air cools, resulting in condensation of the of air and also has the benefit of reducing the
water vapour it contains, which is relative humidity thereby avoiding the risk of
subsequently separated and discharged. the formation of condensate at the dryer
outlet.
The temperature of the thermal mass is
regulated by an electronic controller, which b) Refrigerant circuit
stops the refrigerant compressor when the The high pressure compressed refrigerant gas
programmed setpoint is reached. flows into the condenser.
11.4.2 Air and refrigerant circuits In the condenser, the refrigerant changes
(Also see refrigerant circuit diagrams from the gaseous to the liquid phase.
insection11.3 - "Technical Data - Dryer") The condenser is a heat exchanger of the
a) Air circuit finned core type and it is cooled by an air flow
provided by fan.
The warm and humid compressed air entering
the dryer flows through the air/air exchanger The condenser is generously sized in such a
section of the thermal mass. way that it can function partially also as a
liquid receiver.
Here the air is precooled by the cold and dry
compressed air leaving the air/refrigerant or Downline from the condenser the refrigerant
evaporator section of the thermal mass. enters a drier filter and a capillary tube where
refrigerant pressure is reduced to lower its
The precooled air then enters the evaporator boiling pressure.
section of the thermal mass where it is cooled
(in most applications to a temperature of The refrigerant then enters the tubes of the
approximately 3°C/37.4 °F) exchanging heat evaporator section of the thermal mass,
with the refrigerant fluid and the silica thermal cooling both the compressed air and the
mass. thermal mass itself.

Heat is exchanged by a process of conduction The refrigerant at the dryer outlet is now in the
through the aluminium fins that join the copper form of a cold vapour, which is returned to the
tubes through which the compressed air compressor to repeat the cycle.
flows, to the copper tubes in which the Since the heat provided by the compressed
refrigerant fluid evaporates. air to cause the refrigerant to evaporate varies
The aluminium fins exchange heat also with significantly because of fluctuations in the
the silica thermal mass keeping it at a compressed air temperature and flow rate, the
temperature of approximately 0°C (32°F). dryer is equipped with an electronic system to
control the temperature of the thermal mass.
At this point the compressed air is saturated
and conveys with it the condensation This system fulfils 3 important roles:
produced during the cooling process. • it ensures an almost constant pressurised
The precooled air then enters a high efficiency dew point (approx. +3°C (+37.4°F));
condensate separator (demister type with • it prevents the compressed air temperature
stainless steel mesh) where the condensate is from falling below 0°C (32°F) with consequent
precipitated and collected on the bottom of the freezing of the condensate;
enclosure.
• it ensures that all the refrigerant is evaporated
A condensate discharger opens periodically in the evaporator, thus avoiding the risk of any
and drains the condensate which is expelled liquid entering the compressor suction side.
by compressed air pressure.
When the load is low or zero, the temperature
The dry cold air at the outlet of the separator of the thermal mass tends to fall. When it
flows for the second time through the air/air

76 DL105AA
CompAir Compressed Air Dryers 11

reaches 0°C (32°F) the electronic controller b) The dryer should be installed upline from the
stops the compressor. tank when it is sized in order to allow wide
fluctuations of the air flow rate utilised with
The compressed air that continues to flow in
peak values that are significantly higher than
the evaporator is cooled by the cooling energy
the maximum flow rate of the compressor.
stored in the silica.
When the silica temperature starts to rise, the A SM 1605

refrigerant compressor is started automatically


so that it can cool it down again. 5

This system offers the benefit of reducing


3
average energy consumption of the dryer in
such a way as to make it approximately
proportional to demands. 2
1 4 7 6
11.5 Installation
Warning: Before installing or operating
these dryers, ensure that all personnel
involved have read and understood B
section 11.2 - “Safety - Dryers”.
11.5.1 Location 3 5
1) Install the dryer in a well-ventilated place,
where the ambient air is clean and free from 2
flammable gases or solvent vapours. 1 7 6 4
2) Avoid installing the dryer in excessively cold
places; this could cause the discharged Fig. 11.2 - Dryer Location
condensate to freeze in the drainage systems.
1. Compressed air compressor
The minimum ambient temperature for
2. Final refrigerant
installation of these dryers is shown in the
3. Condensate separator
dataplate affixed to the unit.
4. Compressed air tank
3) The dryer can be positioned on any flat 5. Prefilter
surface that is sufficiently solid to support its 6. Dryer
weight. Leave free space around the dryer as 7. By-pass
indicated in the installation drawings to allow
unimpeded access during servicing A. Dryer Downstream (most common)
operations and to avoid obstructing or B. DryerUpstream
disturbing the condenser cooling air flow.
Position the dryer in such a way that the 11.5.2 Pipelines
cooling air can not recirculate to the intake (see fig. 11.2)
grilles. Ensure that the dryer is not subject to
hot air flows deriving from systems for cooling, 1) The inlet and outlet connections are clearly
for example, the air compressor, the marked (see fig. 11.1). The pipelines and
refrigerant compressor, or any other connections must be correctly sized and
equipment in the vicinity. suitable for the working pressure of the
application. Remember to remove the
4) The position of the dryer in the compressed protective caps from the connections and
air distribution system depends on the ensure that no debris or other material enters
methods of use of the compressed air (see the connections during installation
fig. 11.2). procedures. Any foreign material that enters
a) The dryer must be installed downline of the the connections can result in clogging of the
tank when the air compressor runs filter or jamming of the condensate discharge
intermittently and the maximum compressed valve.
air working flow rate is no higher than the flow 2) All pipelines must be equipped with suitable
rate delivered by the compressor (this is the supports. Flexible couplings should be
most common type of installation).

DL105AA 77
11 Compressed Air Dryers CompAir

installed to prevent the transmission of a) Connect the unit (terminal in the electrical
vibration. panel) to the electrical earthing system of the
building
3) Connect the condensate discharge hose to a
suitable drain point. The drain line of the dryer b) Adopt means to ensure automatic
should not be connected to the drain lines of disconnection of the power supply in the
other equipment; ideally the line should end in presence of a ground fault (protection against
an open funnel type drain. Do not route the indirect contacts in compliance with the
condensate to a common drain header prescriptions of IEC 364) by means of a
because of the possibility of oil contents. residual current device (normally with rated
Oil/water separators should be installed to trip current of 0.03 A)
separate any oil out of the condensate. Make
c) Make sure the level of protection against
sure that the drainage system complies with
indirect contact at the source of the power
local regulations and bylaws.
feeding cable is equivalent at least to IP2X or
4) It is advisable to install a prefilter up-line of the IPXXB
dryer and, if necessary, a coalescent deoiler
d) At the start of the power feeding cable or the
filter down-line of the dryer. Install shut-off
power cable supplied with the unit install a
valves on the compressed air inlet and outlet
device that protects the cable from
connections so that the dryer can be isolated
overcurrent (short circuits) (refer to the
if necessary. Fit a suitably sized pressure
indications in the electrical diagram).
relief valve upline from the shut-off valves.
Caution: Protection devices must be
5) Install a bypass line with shut-off valves so
installed to limit the short circuit current to
that dryer maintenance operations can be
peaks of 17 kA corresponding to the
carried out without interfering with the
specified interruption power if the short
compressed air supply.
circuit current envisaged at the point of
6) Pipelines and other parts whose temperature installation is greater than an effective
may exceed 60°C (140°F) and that may be value of 10 kA.
accidentally touched by personnel must be
e) Use connectors rated for the maximum
protected or insulated.
required voltage at the maximum operating
7) In order to discharge the compressed air from ambient temperature, according to the chosen
the dryer so that the unit can be installation type (IEC 364-5-523) (see the
depressurised prior to maintenance indications on the electrical diagram).
operations, fit a venting valve in the pipe
2) Indications on the electrical diagram:
between the dryer and one of the shut-off
valves. a) Maximum permissible size of the fuse type
gG. In general, fuses can be replaced by an
11.5.3 Electrical connections
automatic switch adjusted in relation to the
The unit's connection to the power supply machine maximum current input (consult the
must be made in compliance with laws and manufacturer if necessary);
prescriptions in force in the place of
b) Section and type of power cable (if not
installation, after having consulted the
already supplied):
electrical diagram supplied with the plant.
– A Installation: insulated conductors,
The voltage, frequency and number of phases
multicore cable in a cable duct, installed
must comply with the data on the unit's
overhead, or fixed to a masonry structure
dataplate.
(type C in compliance with IEC 364-5-523
The power supply voltage must not be outside 1983) or without any other cables in
the tolerances shown on the electrical contact;
diagram, even in terms of transients.
– B working temperature: maximum working
Unless otherwise specified, the frequency ambient temperature for the unit;
tolerance is +/-1% of the nominal value (+/-2%
– C cable type: copper conductors, 70°C /
for short periods).
158°F PVC insulation (unless otherwise
1) For the electrical power supply: specified) or EPR 90°C/ 194°F insulation.

78 DL105AA
CompAir Compressed Air Dryers 11

Voltage must be supplied between phase and 11.7 "iDRY" Electronic Controller
neutral and the neutral conductor must be
connected to earth in the factory substation 11.7.1 User interface
(TN system to IEC 364) or by the electricity
company (TT system to IEC 364).
The line conductor and neutral conductor are
not interchangeable and their positions cannot
be switched.

11.6 Start-Up
Caution: Before starting this type of dryer, SM 1603
ensure that all personnel involved have
read and understood section 11.2 - “Safety Fig. 11.3 - "iDRY" Electronic Controller
- Dryers”.
a) Display
a) Check that the dryer shut-off valves are
closed and the by-pass valve is open. The controller displays the unit status with
messages shown on the LCD display. The
b) Check that the ambient temperature is within display messages can be:
the range indicated on the unit's dataplate.
c) Power the dryer by means of the line OFF Unit OFF
protection device.
d) When the unit is powered the control unit drY Unit running (normal operation)
display switches on (see section 11.7 - “iDRY
Electronic Controller”). hdp High Dew Point temperature
e) Press button of the control unit. Once the
programmed delay has elapsed the b) Buttons
compressor and fan will start.
f) Wait for the compressor to stop when the Button Function
thermal mass has reached the programmed
temperature. Displays or edits the set-point.
During programming, selects a
g) Slowly open the dryer inlet valve to pressurise parameter or confirms a value.
the unit.
h) Slowly open the dryer outlet valve. Displays data of a temperature
alarm. During programming,
i) Close the dryer by-pass valve. scrolls through parameter codes
or increases the relative value.
j) Press the manual condensate discharge
button to check that the discharge solenoid
valve opens. Displays data of a temperature
alarm. During programming,
k) If the unit is equipped with timer controlled scrolls through parameter codes
condensate discharge, check that the or decreases the relative value.
discharge solenoid valve opens again after
the time interval set on the control panel. Turns the unit on or off.
The dryer is now ready for normal operation
Condensate drain test.
(see section 11.9 - “Operation and
Maintenance”).
+ Locks or unlocks the keypad.

+ Enters programming mode.

+ Exits programming mode.

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c) Icons In the event of sudden power failure when the


unit is running, the unit will resume operation
Icon automatically when the power is restored
Icon Function
Status according to the procedure described above.
Off Compressor OFF Note: The electronic controller can be
On Compressor ON programmed with the unit ON or OFF.
Compressor stopped at 2) Unit shutdown
Flashing
timed intervals
With the unit ON, press for the unit to set
Condensate drain
Off to stand-by, indicated by the message OFF.
deactivated
On Condensate drain activated 3) Condensate drain test
On Winter set point in use Press to activate the condensate drain
Winter set point function relay (if the condensate drain is set in timed
Off mode). The relay is deactivated when the
disabled
button is released.
Off No alarm condition
4) Dual set point management
Flashing Indicates an alarm condition
Unit of measurement in The controller has a dual set point:
On
degrees Centigrade • Summer
Flashing Unit in programming • Winter
Unit of measurement in
On To select the set point to use, set the
degrees Fahrenheit
parameter “SSt” (For more information, see
Flashing Unit in programming section 11.7.4 - "Description of settings and
parameters”).
11.7.2 Main functions
Setting parameter “SSt” to "d" serves to
1) Unit start-up enable switching from a digital input (see
section 5) e) - "Dual set point from digital
After having made the electrical connections,
input”).
the message “---” appears on the display
showing that the board is powered, after 5) Digital input
which the message “OFF” appears (see
section 11.7.1 a) - "Display") showing that the A digital input is present with different
unit and the refrigerant compressor are off. configurations settable via parameter “|IF”.
The image below shows the electronic
To turn on the unit, press .
controller wiring diagram. Terminals 9 and 11
The unit starts to operate automatically indicate the digital input.
according to the temperature read by probe
Thermostat

-BDPT and according to the temperature


Digital
probe

control logic. not


input used
Note that when the temperature detected by 9 10 11 12
the probe reaches a value such that calls for 8(3)A250V 20(8)A250V

the compressor to start, instead of starting


immediately the compressor will start only 1 2 3 4 5 6 7 8
after the time lag set on the electronic Hot Key
Power supply
controller (see section 11.7.4 - "Description of N.C.
230V~
Comp
settings and parameters”). Line SM 1606

When the unit starts the message “hdP” will


appear on the display (see section 11.7.1 a) - Fig. 11.4 - Electronic Controller
"Display”) to indicate a high dew point Wiring Diagram
temperature; once the unit has reached
The maximum control range is 20m with a
steady-state operating conditions the display
Belden type shielded cable. If control from
will show the message “drY”. The icon more than 20 metres is required, a support
indicates compressor operation. relay must be installed.

80 DL105AA
CompAir Compressed Air Dryers 11

a) External alarm function (|IF = EAL) Contact Function |IP


After the timeout set in parameter “dId” has Open ON CL
elapsed after activation of the input, an alarm Closed OFF CL
is generated, the message “EA” is displayed
and the output status remains unchanged. Open OFF oP
The alarm is reset automatically when the Closed ON oP
digital input is deactivated.
f) Digital input polarity
b) External shutdown alarm function (|IF = bAL)
The polarity of the digital input depends on the
After the timeout set in parameter “dId ” has parameter “|IP”:
elapsed after activation of the input, a
shutdown alarm is generated, the message “ |IP = CL: active on contact closed;
CA ” is displayed and the compressor output |IP = oP: active on contact open.
is deactivated.
6) Compressor operating hours alarm
The alarm is reset automatically when the
digital input is deactivated. The controller memorises the compressor
operating hours.
c) Pressure switch trip function (|IF = PAL)
It is also possible to set a threshold value for
If the number of pressure switch trips as set in
the operating hours in the relative parameter
parameter “dId” is reached within the time
“AhF”.
interval set in parameter “nP5”, the alarm is
activated. The message “CA” is displayed, the When the operating hours exceed the set
compressor is shut down and control is threshold, an alarm message is displayed to
suspended. To resume normal operation, the notify the user of the need for prompt routine
device must be switched off and on again. maintenance intervention (alarm “H-C”). The
When the input is active, the compressor alarm message does not shut down the unit.
remains switched off. Note: On completion of routine maintenance,
d) Remote On / Off from digital input the operator must reset the compressor
(|IF = OFn) operating hour counter timers. To reset the
compressor operating hours alarm, press
If the parameter is set as “OFn”, the input is . The device displays the message
configured for remote on/off control of the “rSt” and, after 2 seconds, the text “hF”
device (see section f). starts flashing. This resets the alarm.
Contact Function |IP 11.7.3 Programming
Open ON CL 1) Editing parameters PR1
Closed OFF CL To edit a parameter value:
Open OFF oP
a) Press and hold buttons + to access
Closed ON oP programming mode ( flashes).
b) Select the required parameter.
Only if Sst is different from d .
c) Press the button to display the value.
e) Dual set point from digital input
d) Modify the value by means of or .
If the parameter “Sst” is set to d, none of
the above functions can be selected for the e) Press to save the new value and go to
digital input. the next parameter.

The input serves to set which of the two set To quit the programming procedure, display a
points is to be used for temperature control parameter and then press + .
(see section f). You can also quit the procedure by waiting for
15 seconds without pressing any buttons.
2) Keypad lock/unlock function

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Press and hold buttons and for a Press and hold buttons and for a
few seconds until the message “POF” flashes few seconds until the message “POn” flashes
on display. on display.
The keypad is now locked: only display of the The keypad is now unlocked:
set point, maximum and minimum
Note: The new value entered is saved to the
temperatures is possible.
memory also when you quit programming
If a button is pressed for more than 3s, the mode without pressing button.
text “POF” is displayed.
11.7.4 Description of settings and parameters

Parameter Level Description Range Setting


Selection of set point type: (E, I, d): selects whether the unit
operates with the summer set-point (SSt = E), winter set-point
SSt Pr1
(SSt = I) or whether the selection is to be made by the digital
E, I, d I
input (SSt = d).
Compressor output activation delay from start-up. Compressor
odS Pr1 activation is inhibited for the preset time interval from the time of 0 – 255 sec 10
unit startup.
Anti-hunting delay; identifies the minimum time interval between
AC Pr1
compressor shutdown and subsequent restart.
0 – 50 sec 2

Compressor running with faulty probe; time for which the


compressor remains active in the presence of a probe fault. With
Con Pr1 “Con” = 0 the compressor always remains stopped. 0 – 255 sec 0
Note: If “Con”= 0 and “COF”= 0, the compressor remains stopped.
Compressor off with faulty probe; time for which the compressor
COF Pr1 remains stopped in the event of a probe fault. With “COF”= 0, the 0 – 255 sec 0
compressor is always on.
CF Pr1 Temperature unit of measurement: °C = Celsius; °F = Fahrenheit. °C – °F °C
tSC Pr1 Condensate drain type: tP = timed; FI = fixed tP – FI tP
Condensate drain activation: S = always active; O = active only
tSO Pr1
when machine is ON.
S–O S

Condensate drain ON time, sets the condensate drain valve


tdS Pr1
opening time.
0 – 255 sec 2

Condensate drain ON time with compressor running, sets the


tdA Pr1
condensate drain valve opening time with compressor running.
0 – 255 sec 4

Condensate drain OFF time, sets the condensate drain valve


tdO Pr1
closing time.
0 – 255 sec 120

Temperature alarm configuration:


ALC Pr1 Ab – rE Ab
Ab = absolute temperatures; rE = related to SET POINT.
Temperature alarm delay; time interval between detection and
ALd Pr1
display of a temperature alarm.
0 – 255 sec 120

Temperature alarm inhibition from start; the temperature alarm is


dAO Pr1 inhibited from unit start-up for the time interval set in this 0 – 255 sec 15
parameter.
Compressor operating hours: calculates the compressor operating
hF Pr1
hours. Read-only parameter. Each unit is equivalent to 10 hours.
0 – 999 –

82 DL105AA
CompAir Compressed Air Dryers 11

Description of settings and parameters (cont'd)

Parameter Level Description Range Setting


Compressor maintenance alarm; compressor maintenance alarm
set-point.
AhF Pr1 0 – 999 0
Each unit is equivalent to 10 hours. “AhF” when set to 0 shuts off
the alarm.
Digital input polarity:
|IP Pr1 oP = the digital input is activated on opening of the contact; oP – CL CL
CL = the digital input is activated on closure of the contact.
Digital input configuration:
EAL = external alarm;
EAL, bAL,
BAL = external shutdown alarm;
|IÂ Pr1 PAL, OFn, EAL
PAL = pressure switch;
Htr
OFn = remote On/Off.
Htr = disabled;
Alarm delay from digital input:
|IÂ = EAL or BAL : alarm signal delay from digital input : delay
between detection and signalling of an external alarm.
dId Pr1 0 – 255 sec 5
|IÂ = PAL time for pressure switch function: if “nPS” starts in
time interval “dId” are reached, restarting is manual only and is
performed by switching the unit off and then on.
Number of starts for pressure switch function: At each activation of
the digital input, the control is blocked; if “nPS” activations are
nPS Pr1
reached in time “dId”, restarting is manual only by powering off
1 – 15 15
the unit and then powering it on again.
PbC Pr1 Probe type selection. PtC – ntc ntc
rEL Pr1 Software release (read-only). – –
Parameters table (read-only) serves to identify the factory set
Ptb Pr1
parameters map.
– –

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11.7.5 Alarms
1) Alarm display
When flashes, the unit sets to alarm
status and the display shows an alarm code,
which can be:

Code Meaning Cause Output


Probe -BDPT faulty or resistive Compressor output according to
PI Thermostat probe faulty
value out of range parameters “Con” and “COF”
Dew Point Temperature above
AdP High temperature alarm
alarm set point
Not modified

Dew Point Temperature below


LdP Low temperature alarm
alarm set point
Compressor output OFF

EA External alarm Not modified


CA External alarm (|IÂ = bAL) Compressor output OFF
PA External alarm (|IÂ = PAL) Compressor output OFF
When the number of compressor
operating hours exceeds the
H-C Compressor maintenance alarm maintenance threshold value of Not modified
parameter “hF”, the maintenance
request signal is activated

Caution: Alarms are displayed exclusively with the unit ON.


Notes: a) To check the type of alarm and its duration:-
(i) Probe alarm "PI" trips a few seconds after
– Press either or .
the probe develops a fault; this alarm is reset
automatically few seconds after the probe The display shows:
resumes normal operation. Before replacing "HAL" for the high temperature alarm ("LAL"
the probe, check the connections. for the low temperature alarm), followed by
the "Duration" (tiM) in h.mm.
(ii) The "AdP" and "LdP" temperature
alarms are reset automatically as soon as the The device then resumes the normal display
thermostat temperature returns to normal presentation as set.
values.
Note: The duration is to be considered as a
(iii) The external alarms "EA" and "CA" partial value if the alarm is still in progress.
(|IÂ = bAL) are reset as soon as the digital b) To delete saved or currently active alarms:-
input is deactivated.
– With the alarm shown on the display, press
(iv) If the digital input is configured as and hold .
pressure switch (|IÂ = PAL), the alarm
must be reset manually by switching the The message "rSt" will appear immediately
instrument off. and then, after 2 seconds, it will start flashing
to confirm that the values have been deleted.
2) High and low temperature alarm memorisation
If is pressed again, the display shows
When illuminates, the unit is in alarm the text "noA" (no alarm present).
status as follows:
3) Serial line for monitoring systems
Flashing = Alarm active
The TTL serial line, available via the HOT
Steady = Temperature alarm reset and KEY connector, enables interface with a
memorised. compatible ModBUS-RTU monitoring system.

84 DL105AA
CompAir Compressed Air Dryers 11

11.8 Timed Condensate Discharge Unit b) Press the manual condensate discharge
button to check that the filter is not
The timed condensate drain system is pressurised.
controlled automatically by the electronic
controller, on which the intervals between c) Set the line switch to OFF in order to
condensate discharge cycles can be disconnect the power supply to the dryer.
programmed (see Section 11.7 - “iDRY d) Carefully unscrew filter cap [1] retaining seal
Electronic Controller“). [2] and remove strainer mesh [3].
The condensate discharge unit must be e) Once cleaned, refit the mesh making sure it is
checked and serviced carefully to ensure that properly seated, and refit and tighten cap [1].
the condensate produced and separated is
not entrained in the compressed air stream f) Renew seal [2] if it is damaged.
into the distribution network. g) After re-opening the shut-off valve or the
11.8.1 Filter Cleaning Filterstop valve, power on the unit again and
restart it.
When a dryer is installed for the first time, it is
common for particles of rust, pipe scale, metal 11.8.2 Solenoid valve maintenance
filings, etc. to find their way into the separator
and then into the filter protecting the
discharge solenoid valve. This component
should therefore be removed and cleaned
approximately one month after installation.
Thereafter it should be cleaned once every
three months and in certain cases more
frequently.
Depending on the type of discharge unit fitted,
either a standard mechanical filter or a
Filterstop valve with integral filter (see fig.
11.5 ) may be installed.

3
3
2 2
1 Fig. 11.6 - Condensate Discharge Unit
Solenoid Valve
SM 1604 1
1. Body 7. Shading Ring
Fig. 11.5 - Condensate Drains 2. Plunger-seal 8. Stopper
3. '0' Ring 9. Locknut
1. Plug 4. Armature 10. Electrical
2. Seal Guide Tube Contacts
3. Metal Mesh Strainer 5. Plunger 11. Bonnet
a) Close the shut-off valve upline from the dryer 6. Spring 12. Flange
to remove strainer mesh [3]. If the timed
condensate discharge unit is equipped with The solenoid valve must always be protected
Filterstop valve, it is sufficient to simply close by an appropriate filter to prevent solid
the valve. particles preventing it from opening and
closing properly.

DL105AA 85
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However, if these particles manage to pass 11.9 Operation And Maintenance


through the filter and cause the valve to
malfunction, all its internal components must 11.9.1 General operation
be cleaned. Do not switch the dryer off in the absence
Proceed as follows: of a flow of compressed air.
a) Isolate and depressurise the dryer The dryer will switch on and off automatically.
The number of starts/stops depend mainly on
b) Open the line switch to disconnect the power the flow rate and temperature of the
supply to the dryer compressed air and the ambient temperature.
c) Undo the screw in the centre of the cap for the As explained in section 11.7 - “iDRY
valve power supply Electronic Controller”, the control unit will
d) Lift and remove the cap switch the compressor off automatically in the
absence of a flow of compressed air. In this
e) Remove the solenoid valve from the pipe and case the refrigerant compressor will run
clamp the body tightly in a vice occasionally and for short periods to
f) Unscrew nut [9] securing solenoid valve and compensate for heat losses between the
withdraw the latter from tie-rod thermal mass and the external atmosphere. In
this way the dryer will be ready to dry the air
g) Unscrew the tie-rod from the valve seat when the flow is restored.
h) Check the condition of the valve seal [2], If so desired, the user can switch off the dryer
O-rings [3] and of all other components and overnight or during weekend breaks without
clean thoroughly any problem. When the compressor unit is
i) Re-assemble the components by performing required for duty again, remember to
the above procedures in reverse sequence switch the dryer on at least 10-15 minutes
before the air compressor.
j) Make sure that the valve is re-installed with
the arrow pointing in the right direction 11.9.2 Maintenance
Caution: Do not tighten nut [9] excessively Warning: Before installing or operating
as it could obstruct movement of the valve these dryers, ensure that all personnel
element and cause the valve to open and involved have read and understood
close incorrectly. section 11.2 - “Safety - Dryers”.
These dryers will give many years of
trouble-free duty if they are properly
maintained and serviced.
a) Access to the dryer
To access the electrical panel, remove the
lateral screws fixing the top cover to the side
panels of the cabinet.
Once the top cover has been removed,
access the electrical panel components by
unscrewing the nuts fixing the protective cover
to the front panel.

86 DL105AA
CompAir Compressed Air Dryers 11

11.9.3 Maintenance Schedule - Dryers

Every

6 Months
Month

Year
Task

Day
Check to ensure there are no alarm signals. 4 4 4 4
Press the manual condensate discharge button to check that the valve drains properly. 4 4 4 4
If the dryer is equipped with a timed condensate discharge unit, check for possible excessive
production of condensate; in this case increase the valve opening time (ON). Check that the 4 4 4 4
solenoid valve opens properly, in compliance with the times set on control unit.
Check that compressed air inlet temperature is lower than the limit for which the dryer was
4 4 4
selected (normally 35-40°C (95-104°F)).
Remove, clean and refit the condensate discharge unit filter.If the filter is always clogged with
4 4 4
material, it may be necessary to dismantle and clean the solenoid valve.
Check that ambient air temperature is lower than the limit value used to select the dryer (normally
4 4 4
25-30°C / 77-86°F). Check that the area in which the dryer is installed is well ventilated.
When the compressor is running, check that its upper part is not too hot (more than approximately
4 4
50°C / 122°F). Check that the dryer's current draw is within the rated values.
Make a visual inspection of the refrigerant circuit to make sure the piping has not deteriorated and
4 4
there are no traces of oil, which may indicate a leak of refrigerant.
Check the condition and soundness of piping connections. 4 4
Check the condition and soundness of the electrical connections. 4 4
Check that the fan switches on automatically and does not produce excessively high noise levels.
Clean the condenser fins with a jet of clean compressed air. Make sure the grilles are free from dirt 4 4
and any other obstructions.
Clean the condenser fins with mild detergent. 4

Caution: The above maintenance schedule is based on average operating conditions. In some
cases it may be necessary to increase maintenance frequency.

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11.10 Troubleshooting Dryers


SM 1590
Dew point temperature
higher than
prescribed value

Compressed
air flow rate or Pressure of Circuit has
No compressed air No insufficient No Contact CompAir
temperature too high /
ambient to be dried refrigerant Technical Support
temperature too low ? charge ?
too high ?

Yes Yes Yes

Contact refrigeration
engineer to check
Restore values
circuit for
to within
refrigeration leaks.
preset limits
Recharge

SM 1591
Compressed air
excessive
pressure drop

Icing up
due to incorrect
Exchanger setting or faulty
tubes blocked operation or variation of Pressure of
by impurities conveyed No set-point value. No No Contact CompAir
compressed air
by compressed air ? Temperature probe to be dried Technical Support
not calibrated.
too low ?
Probe
positioning ?

Yes Yes
Yes

Clean surfaces of pipes Switch dryer off and Restore values


with descaling solution restart only after having: to within
that does not react positioned probe correctly. preset limits
with steel or copper If these actions fail to solve
the problem, renew control
board or probe

88 DL105AA
CompAir Compressed Air Dryers 11

Troubleshooting dryers (cont'd)

SM 1592
Presence of condensate
downline from dryer

Relay on
Clogged Solenoid electronic board Contact
strainer upline valve element controlling solenoid No CompAir
from solenoid blocked ? valve not Technical
valve ? No No No No functioning ? Support
Solenoid
Condensate
valve opening
discharge
time too short or
solenoid valve
closing time
coil burnt
too long ?
Yes out ?
Yes Yes

Yes Yes
Clean mechanical Use tester to check if
Isolate dryer terminal contacts of relay
filter by closing
Renew from air network, Edit open and controlling solenoid valve
valve upline from
solenoid dismantle closed times fail to close when manual
filter or isolating
valve solenoid valve, (if required by discharge button is pressed.
dryer from
clean components control unit) If relay not functioning,
compressed
refit valve renew control board
air network

DL105AA 89