lsr cyclon repair manual

CompAir

AC20160-1822, Issue 1, November 2002

CYCLON SR, and LSR

AIR COMPRESSORS

REPAIR MANUAL

Serial Numbers from:

F180-0106 (Cyclon 345SR)

F170-0112 (Cyclon 475SR)

F180-0101 (L45SR)

F170-0112 (L75SR)

F171-0100 (L120SR)

CompAir


GENERAL INFORMATION

These compressors are intended for compressing atmospheric air and are not suitable for compressing anyother gas. They are designed and manufactured to give optimum performance, with long life and reliability.

This manual gives the user all the information required to install and operate the compressors and carry out theregular schedules for servicing and maintenance which will ensure the maximum satisfactory service life.

Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network ofCompAir companies and distributors. If replacement parts are needed, the user should contact the localCompAir company or distributor in the first instance.

The information given in this manual was correct at the time of printing but modifications to parts andprocedures may be made without notice which could affect the servicing requirements of the compressors.Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAircompany or distributor who is supplied with revised and up-dated information.

In any communication concerning the compressor it is essential to quote the MODEL and SERIAL NUMBER.

Throughout this manual all pressures quoted are gauge pressure unless otherwise specified.

WARRANTY

The conditions of the CompAir Warranty are set out in the Company's standard Conditions of Sale availablefrom the CompAir company or distributor supplying the machine.

MAINTENANCE

To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenanceand servicing are carried out in accordance with the information given in the ‘Maintenance’ section of thismanual. If any replacement or repair is needed use only CompAir Genuine Parts.

USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTYCOULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIEDOUT USING NON-GENUINE PARTS.

CompAir


CONTENTS

Chapter Title

1 Safety Procedures

2 Product Improvements

3 General Description

4 Technical Data

5 Mechanical Fault Finding

6 Components

7 Maintenance

8 Electrical Systems and Fault Diagnosis

9 Disassembly and Assembly (Mechanical)

Appendix 1 Dimensions

Appendix 2 Diagrams

Associated Publications

Title Part Number

Cyclon 345SR Parts List C20160-1736

Cyclon 475SR Parts List C20160-1615

L45SR Parts List C20160-1790

L75SR Parts List C20160-1759

L120SR Parts List C20160-1811AX

Cyclon 345SR and 475SR User Manual C20160-1726

L45SR, L75SR and L120SR User Manual (English) C20160-1726

Power Converter Parts Manual T.B.A.

CompAir


AC20160-1822, Issue 1, November 2002 Chapter 1, page 1

LSR Repair Manual – Safety Procedures

CHAPTER

1SAFETY PROCEDURES

1. GENERAL2. WARNINGS, CAUTIONS AND NOTES2.1 Warnings2.2 Cautions2.3 Notes3. GENERAL SAFETY PRECAUTIONS 4. INSTALLATION PRECAUTIONS5. OPERATIONAL PRECAUTIONS6. MAINTENANCE AND REPAIR PRECAUTIONS7. PRECAUTIONS IN THE EVENT OF FIRE8. DISPOSAL

CompAir

Chapter 1, page 2 AC20160-1822, Issue 1, November 2002

2. WARNINGS, CAUTIONS AND NOTES

2.1 Warnings

Warnings call attention to operations or proceduresinvolving specific hazards which could cause injuryor death and are identified by the following symbolson the unit and in the text of the manual.

WARNING: RISK OF DANGER

WARNING: RISK OF ELECTRICSHOCK

WARNING: RISK OF HOTSURFACES

WARNING: CONSULT MANUAL

WARNING: RISK OF HIGHPRESSURE

WARNING: ENTRY DELAY –ENERGISEDCAPACITORS

2.2 Cautions

Incorrect operational procedures causing possibledamage to the compressor unit are identified by a‘CAUTION’ in the text of this manual.

Most accidents which occur during the operationand maintenance of machinery are the result offailure to observe basic safety rules or precautions.An accident can often be avoided by recognising asituation that is potentially hazardous.

When handling, operating or carrying outmaintenance on the unit, personnel must use safeengineering practices and observe all relevant localhealth and safety requirements and regulations.The attention of users in the UK is drawn to theHealth and Safety at Work Act, 1974, theRegulations of the Institution of Electrical Engineersand the Pressure Systems and Transportable GasContainer Regulations 1989.

CompAir cannot anticipate every possiblecircumstance which might represent a potentialhazard. The WARNINGS in this manual aretherefore not all-inclusive. If the user employs anoperating procedure, an item of equipment or amethod of working which is not specificallyrecommended by CompAir he must ensure that theunit will not be damaged or made unsafe and thatthere is no risk to persons or property.

The standard builds of all CompAir products are notintended for use in either explosive or potentiallyexplosive atmospheres as defined in Directive 94/9/EC. An explosive atmosphere is a mixture with air,under atmospheric conditions, of flammable gases,vapours, hazes or dust in which, after ignition hasoccurred, combustion propagates to the entireunburned mixture and may cause a hazard. Apotentially explosive atmosphere is an atmospherewhich could become explosive due to localconditions.

Failure to observe the precautions given under‘Safety Procedures’ may be considered dangerouspractice or misuse of the compressor unit.

1. GENERAL

SAFETY PROCEDURES



2.3 Notes

Methods to make the job easier and points whichrequire particular attention are identified by a ‘Note’in the text of the manual.

3. GENERAL SAFETY PRECAUTIONS

If using compressed air for cleaning purposes,ensure safety regulations are complied with andappropriate clothing and eye protection is worn.

Never direct compressed air onto your skin or atother people.

Never use compressed air to clean loose dirt fromclothing.

Before releasing compressed air through a hosemake sure that the free end is held securely so thatit cannot whip and cause injury.

Avoid injury by using a hoist to lift heavy loads.Check that all chains, hooks, shackles and slingsare in good condition and are of the correctcapacity. They must be tested and approvedaccording to local safety regulations.

Cables, chains or ropes must never be applieddirectly to lifting eyes. Always use an appropriateshackle or hook, properly positioned. Arrange liftingcables so that there are no sharp bends.

Use a spreader bar to avoid side loads on hooks,eyes and shackles.

When a load is on a hoist stay clear of the dangerarea beneath and around it. Keep liftingacceleration and speed within safe limits and neverleave a load hanging on a hoist for longer than isnecessary.

4. INSTALLATION PRECAUTIONS

Installation work must only be carried out bycompetent personnel under a qualified supervisor.

A fused isolating switch must be fitted between themain power supply and the compressor.

Ensure that air drawn into the air intake will not becontaminated with flammable fumes or vapours,since this could cause an internal fire or explosion.

Precautions must be taken to ensure that no injuryis caused to passers-by through loose clothingbeing sucked into the air intake.

Ensure that the air delivery pipe from thecompressor to the user’s pipework or receiver isfree to expand and that no flammable material iswithin the vicinity.

A shut-off valve must be fitted in the delivery air lineto enable the compressor unit to be isolated. This isparticularly important if more than one unit is to becoupled in parallel or connected to an existing airsupply system.

The minimum pressure/non-return valve is notintended as an isolating valve and should not berelied upon for this purpose. In addition, it may benecessary to install shut-off valves elsewhere in thesystem to allow a dryer or other equipment to beby-passed.

A pressure relief valve must be installed betweenany compressor unit and the shut-off valve/s. Apressure relief valve is fitted on the reclaimervessel as standard equipment.

A pressure relieving device must be fitted to everypressure vessel, or equipment containing air atabove atmospheric pressure, when installeddownstream of the unit.

5. OPERATIONAL PRECAUTIONS

The compressor unit must only be operated bycompetent personnel under a qualified supervisor.

Do not run the compressor with doors open orcovers removed except when checking reclaimeroperation.

Never remove or tamper with the safety devices,guards or insulation materials fitted to the unit.

The compressor must only be operated at thesupply voltage and/or frequency for which it isdesigned

On a unit equipped with an Automatic Start/Stopsystem, attach a sign stating ‘THIS UNIT MAYSTART WITHOUT WARNING’ next to the displaypanel.

CompAir


6. MAINTENANCE AND REPAIRPRECAUTIONS

● Before opening the door of the powerconverter compartment, switch the powersupply OFF at isolator and wait for 12minutes to allow the dc link capacitors todischarge to a safe level. Check that thedc link capacitors have fully dischargedbefore starting work on the compressor.

Maintenance, repairs or modifications must only becarried out by competent personnel under a qualifiedsupervisor

Lethal voltages are present in the electrical circuitsand extreme caution must be exercised whenever itis necessary to carry out any work on the electricalsystem.

If replacement parts are needed use only CompAirGenuine Parts.

Do not open the starter compartment or touchelectrical components while voltage is appliedunless it is necessary for measurements, tests oradjustments. Such work should be carried out onlyby a qualified electrician equipped with the propertools and wearing appropriate body protectionagainst electrical hazards.

Before removing any panels from the enclosure, iffitted, or dismantling any part of the unit, carry outthe following preparatory operations:-

1. Isolate the compressor unit from the mainelectrical power supply. Lock the isolator inthe ‘OFF’ position and remove the fuses.

2. Attach a label to the isolator switch anddisplay panel carrying the warning ‘WORK INPROGRESS – DO NOT APPLY VOLTAGE’Do not switch on electrical power or attempt tostart the unit if a warning label is attached.

On a unit equipped with an Automatic Restartdevice, attach a warning notice stating ‘THIS UNITHAS BEEN MODIFIED AND WILL STARTAUTOMATICALLY ON APPLICATION OFPOWER’ next to the display panel and on the insideof the unit next to the starter contactors.

If the unit is equipped with a Remote Control device,attach warning notices stating ‘THIS UNIT CAN BESTARTED REMOTELY’ in prominent locations, oneon the outside of the unit, the other inside thecontrol compartment.

As a further safeguard, take adequate precautionsto make sure there is no one checking or workingon the unit before attempting to switch on remotelycontrolled equipment. Attach a ‘CHECK THAT ALLPERSONNEL ARE CLEAR OF THE UNITBEFORE STARTING’ or similar warning notice tothe remote start equipment.

During normal operation no internal part of thecompressor unit should reach a temperature above120°C and protection devices are fitted to preventexcessive temperatures occurring.

If there is any indication that the compressor isoverheating it must be shut down and the causeinvestigated. Beware of burns from hot metal partsor hot oil when working on a unit which hasrecently been shut down.

The compressor must not be operated atpressures above the nominal pressure given onthe data plate.

The compressor must not be operated in ambienttemperatures outside of those given under ‘LeadingParticulars’.

The ‘Noise at Work Regulations 1989’ suggest thatear protectors should be worn where noise levelsare 85 dB(A) or higher. With all covers in place, thenoise levels of the compressors described in themanual are substantially lower than this figureunless installed in an already noisy environment.

Be aware that high noise levels can interfere withcommunication.

WARNING



3. Close the isolating valve between thecompressor unit and the user’s pipework.Attach a label to each valve carrying thewarning ‘WORK IN PROGRESS – DO NOTOPEN’

4. Ensure that the blowdown system hasoperated to release all pressure from thereclaimer.

5. Check that the pressure gauge registers zero.Release any remaining pressure from thedelivery side of the reclaimer element byslackening a pipe connection to thedifferential pressure indicator. Release anyresidual pressure from the upstream side ofthe reclaimer element by slowly slackeningthe oil filler plug on the reclaimer. Releaseany pressure in the aftercooler by slackeningthe pipe at the bottom of the moistureseparator. Tighten the plug and pipeconnections.

Use only lubricating oils and greases approved byCompAir. Make sure that the selected lubricantscomply with all relevant safety regulations,especially with regard to the risk of explosion or fireand the possibility of decomposition or thegeneration of hazardous gases.

Always clean up oil spills from both the inside andoutside of the compressor unit before and aftermaintenance work.

Make sure that all instructions concerning operationand maintenance are strictly followed and that thecomplete unit, with all accessories and safetydevices, is kept in good running order.

The accuracy of pressure and temperature gaugesand switching thermometers must be regularlychecked. They must be renewed when acceptabletolerances are exceeded.

Protection devices must be tested as described inthe ‘Maintenance’ section of this manual.

Keep the compressor unit clean at all times. Protectcomponents and exposed openings by coveringwith clean cloth or tape during maintenance andrepair work.

Protect the motor, air intake, electrical andregulation components against the entry ofmoisture, e.g. when steam cleaning.

Precautions must be taken when carrying outwelding or any repair operation which generatesheat, flames or sparks. The adjacent componentsmust always be screened with non-flammablematerial and if the operation is to be carried outnear any part of the oil system, or close to acomponent which may contain oil, the system mustfirst be thoroughly purged, preferably by steamcleaning.

Never use a light source with an open flame toinspect any part of the unit.

In no circumstances must any welding work orother modification be carried out on the reclaimeror any other pressure vessel.

Before dismantling of any part of the compressorunit ensure that all heavy movable parts aresecured.

After completion of repair or maintenance workensure that no tools, loose items or rags are left onor inside any part of the machine.

Check the direction of rotation of the motor whenstarting up the compressor initially and after anywork on the electrical connections or switchgear.

Do not use any flammable liquid to clean valves,filter elements, cooler air passages, air pipes or anycomponent carrying a flow of air during normaloperation. If chlorinated hydrocarbon non-flammable fluids are used for cleaning, safetyprecautions must be taken against any toxicvapours which may be released.

Do not use carbon tetrachloride.

Precautions must be taken when using acids,alkalis and chemical detergents for cleaningmachine parts and components. These materialscause irritation and are corrosive to the skin, eyes,nose and throat. Avoid splashes and wear suitableprotective clothing and goggles. Do not breathemists. Ensure that water and soap are readilyavailable.

When disposing of condensate, old oil, used filterelements and other parts and waste material of anykind make sure that there is no pollution of anydrain or natural water-course and that no burning ofwaste takes place which could cause pollution ofthe air. Protect the environment by using onlyapproved methods of disposal.

CompAir


7. PRECAUTIONS IN THE EVENT OF FIRE

Use extreme caution when handling componentsthat have been subjected to fire or very hightemperatures. Some components may containfluoroelastomer materials which decompose underthese conditions to form highly corrosive residues.Skin contact can cause painful and penetratingburns resulting in permanent skin and tissuedamage.

8. DISPOSAL

When items of equipment are taken out of servicefor disposal it is recommended that the followinginstructions are adhered to:

1. In order to prohibit the ‘bringing back intoservice’ of of equipment by persons unknown,it should be rendered unusable in order toavoid improper re-use.

2. Alternatively all such items of equipmentshould be stripped into their component formfor ‘material composition disposal’ e.g. basemetals, plastics, fabrics etc and be subject tonormal industrial waste re-cycling processes.

3. Bio-degradable items should be subject tonormal industrial waste disposal processes.Ensure that no plastic, rubber or compositematerials are disposed of by incineration.

4. Ensure that all fluid waste e.g. lubricating oilsand greases, anti-freeze agents, refrigerantfluids or corrosive inhibitors should beseparated and disposed of by authorisedsalvage disposal or recycling systemsensuring that none is permitted to enter awaste water system.


LSR Repair Manual – Product Improvements

CHAPTER

2PRODUCT IMPROVEMENTS

1. SUMMARY

MACHINE/S SERIAL NUMBERS IMPROVEMENT BULLETIN PAGE

475SR F170-0111 to F170-0145 Cold Start Inhibit. 773 3475SR all Compressors Transport Packaging. 785 5345SR, 475SR - Obsolete Gate Drive Board. 798 6475SR All Motor cable routing. 803 8345SR All Failure of EMC filters 804 10345SR - Phase Failure Kit (400V) 805 11475SR - Phase Failure Kit (440/460V) 806 16345SR - Power Converter Ventilation Kit 810 21475SR - Power Converter Ventilation Kit 811 26L45SR, L75SR F170 - 850 onwards Enhancements 812 31

F180 - 650 onwards475SR, L75SR All Single Pass Air/Oil Cooler Retrofit 822 33

- Kit

2. NEW BULLETINS

Insert when issued.

MACHINE/S SERIAL NUMBERS IMPROVEMENT BULLETIN PAGE

CompAir




WARNING

! Refer to the safety procedures in the UserManual before carrying out any maintenanceor servicing work on the compressor unit.

! Lethal voltages are used in this equipment.Use extreme caution when carrying outelectrical checks. Isolate the power supplybefore starting any maintenance work

1. INTRODUCTION

If an oil injected compressor is started when the oiltemperature is below the specified minimum of 0°C,serious damage to the air end may result. The lowoil temperature will result in high oil viscosity leadingto insufficient oil flow.

To ensure that a compressor cannot be startedduring below zero conditions, a Cold Start Inhibitfeature has been added to the control program ofcurrent production compressors, The improvedprogram. is also available for installation to existingcompressors.

If there is a possibility that the ambient temperaturearound the compressor is likely to fall below zero, aheater kit is available for fitting to the compressor.Please contact Product Management at CompAirUK for further details.

2. REPLACEMENT PROGRAM

The replacement program for the Surescan Mk.3 isnumber C20620/10/**/B3

COLD START INHIBIT

3. REPLACEMENT PROGRAM INSTALLATION

CAUTION

When working wfth static sensitive componentsi.e.. circuit cards and memory IC’s etc., alwaystake aniti-static precautions.

1. Always transport static sensitive componentsin anti-static bags or containers.

2. Never touch the rnetal pins of electronic ICdevices.

3. Never place static sensifive components ontoa metal surface. Always place directly into ananti-static bag or container.

4. Always ensure any body static is dischargedbefore handling static sensitive componentsby touching an earthed surface at regularintervals.

1 Switch off and isolate the power supply to thecompressor.

2. Remove the canopy panel as required and thestarter area access panel.

3. Remove the controller from the compressor.

4. Remove the screws located adjacent to theelectrical plug connections on the rear of thecontroller.

5. Using a spanner, remove the plug securingnuts adjacent to the ‘D’ type connector(s).

6. Remove the rear controller enclosure securingscrews.

7. Remove the rear controller cover.

8. The control program IC can be removedwithout dismantling the circuit cards. Toeliminate the possibility of re-connectionerrors, it is recommended that the circuitcards are not dismantled.

CompAir


Before removal of the control program IC,make a note or pencil sketch of the orientationand position of the IC in its socket. Note theorientation marks on the 1C, socket andcircuit board.

9. Using a srnall screwdriver or similar tool,carefully remove the control program IC fromits socket.

10. Insert the new control prograrn 1C. Check theorientation and ensure that each pin entersthe socket correctly. (The pins must not bendunderneath the IC during insertion.)

11. When re-assembling the controller, replacethe rear cover securing screws first to hold thecover in place. Then insert and tighten thescrews and nuts adjacent to the electricalplug connections before finally tightening therear cover screws.

12. Re-connect to compressor and test.

Fig. 1 SureScan Controller

4. OPERATION

Note: refer to the compressor User Manual foroperating details.

When the temperature in the air end is 1°C or less,

a) The High Delivery Temperature indicator on thecontroller will flash with a double pulse.

b) The message ‘Start Inhibited’ will be shown onthe controller display (unless the compressoris on Standby or Remote Stopped).

c) The start inhibit will not be recorded on theFault History Record or affect the Group FaultOutput.

The inhibit circuit will be automatically reset as thetemperature rises above 1°C.

HW 0274

bar

psi



INTRODUCTION

The Cyclon 475SR compressor may be secured toa pallet to reduce the chances of damage in transit.

Cardboard packing may also be fitted to the threeremovable panels and the service door of thecompressor.

This bulletin advises distributors and installers ofrecommended handling procedures.

METHOD

WARNING

LIFTING OPERATIONS MUST BE DONE BYQUALIFIED PERSONNEL USING APPROVEDEQUIPMENT.

CAUTION: The preferred method of handling thecompressor is by a forklift. The compressor is notdesigned for overhead lifting. If a forklift is notavailable, the compressor may be lifted using jacksand suitable spreader bars through the fork tunnelson the compressor.

COMPRESSORS TRANSPORT PACKAGING

1. Locate the compressor close to theinstallation position using a forklift to lift thepallet.

2. Remove the four nuts and washers securingthe compressor to the pallet.

3. Raise the compressor, using the forklift, untilit is clear of the locating studs on the pallet.

4. Place the compressor in the designatedposition.

5. Remove the plastic cover from thecompressor.

6. Remove the cardboard packing from the threeremovable panels and the service door on thecompressor.

7. Install and commission the compressor asdetailed in the User Manual.

CompAir


1. INTRODUCTION

The Gate Drive Board, part number C20606-83, asfitted to some Cyclon 345SR and Cyclon 475SRcompressors is now obsolete.

Gate Drive Board, part number C20606-143, may besupplied when C20606-83 is ordered.

When fitting the new Gate Drive Board, part numberC20606-143, some wiring connection changes arerequired.

2. METHOD

1. Remove the old gate drive board from thecompressor and install the new one.

2. Rewire the compressor to gate drive boardconnectors as detailed in Table 1.

3. Attach the connectors to the gate drive board.

OBSOLETE DRIVE BOARD

WARNING

● Refer to the safety procedures in theUser Manual before carrying out anyMaintenance work on the compressorunit.

● Lethal voltages are used in thisequipment. Use extreme caution whencarrying out electrical checks. Isolate thepower supply before starting anymaintenance work.

● Before opening the door of the powerconverter compartment, switch the powersupply OFF at isolator and wait for 12minutes to allow the dc link capacitors todischarge to a safe level. Check that the dclink capacitors have fully discharged beforestarting any maintenance work.



Connector Pin C20606-83 C20606-143 C20606-183 C20606-283

A1 1 - - 150 1502 - 151 151 1513 150 150 - -4 151 - - -5 152 152 152 -6 - - - -7 - - - 152

A2 1 - - 156 1562 - 157 157 1573 156 156 - -4 157 - - -5 158 158 158 -6 - - - -7 - - - 158

B1 1 - - 153 1532 - 154 154 1543 153 153 - -4 154 - - -5 155 155 155 -6 - - - -7 - - - 155

B2 1 - - 159 1592 - 160 160 1603 159 159 - -4 160 - - -5 161 161 161 -6 - - - -7 - - - 161

Table 1 Gate Drive Board Connector Wiring

When a C20606-283 board is used fourPhoenix 7-way Combicom connectors arerequired, Ref: MSTB 2,5/7 - ST5,08

CompAir


DETAIL

This is to advise that on a limited number ofmachines two of the four motor leads have beenrouted too close to the auxiliary contactor block ofthe main contactor.

The heat from these cables has caused thecontactor block to distort and lock, thus preventingthe main contactor from operating correctly and insome cases causing the contactor coil to failtogether with the 5 amp fuse.

Indication of this is a DC link charge fault on theSureScan display.

SOLUTION

Re-route the two cables that are adjacent to theauxiliary contactor block and fit heat shieldC27399-289.

METHOD

MOTOR CABLE ROUTING

1. Stop the compressor, isolate from the mainsupply and allow sufficient time for thecapacitors to discharge (refer to WARNING).

2. Open the controller enclosure door and checkthat the red LEDs on gate drive board are notilluminated.

3. Remove protective screen.

4. Slacken the two upper motor cables at the IGBTterminal point.

5. Fit heat shield (if required) and re-route theaffected cables away from the contactor (refer toillustrations).

6. Secure motor cables at the IGBT terminal point.

7. Re-fit protective shield, close enclosure door,apply power to the machine and test.

WARNING






CONTACTOR HEAT SHIELD ASSEMBLY AND WIRE ROUTING

1. Heatshield C27399-289 fitted using existing fixings

2. Contactor Block

3. Motor Leads (route as shown).

CompAir


DETAIL

This is to advise that a limited number of EMC filtershave failed due to the incoming power supply cablesnot being properly secured at the terminal block.

Use the following set of instructions for:

1. All new installations.

2. As a guide when examining existinginstallations.

EMC FILTER FAILURE

METHOD

1. Remove 17mm of insulation from the end ofeach of the three incoming phase cables.

2. If finely stranded wire is used then the correctsize of ferrule must be crimped to the cablebefore locating into the terminal block.

3. Locate each cable into the terminal block andtighten the clamp to a torque of 5Nm.

Note: The terminal will accept the following cablessizes:

Rigid conductors up to 50 sq mm.Flexible conductors up to 35 sq mm.Conductors with ferrules up to 35 sq mm.

WARNING






PHASE FAILURE KITS 400V (± 10%)

345SR MODELS

Purpose of the kit

The kit is supplied to constantly monitor the 3phase a.c. supply to the compressor. It monitorsboth phase sequence and voltage level. If the supplyvoltage on one of the phases drops, the current willrise in the other two phases to counteract theimbalance. This can lead to overloading of thesemiconductor fuses.

The phase failure relay will monitor the supply andstop the compressor when one or more of thephases drops below 70% of the set voltage. At thesame time, a ‘Main Contactor Fault’ will bedisplayed.

Kit Contents

98161-32 Phase Failure Relay

98140-361 110C Black Cable



98140-364 137B Blue Cable

98140-365 170 Blue Cable

98150-1 Cable Ties (5 off)

98241-31 Din Rail 210mm

C20775-19 Electrical Schematic Diagram

Fitting Instructions

The phase failure relay is designed to be fitted onthe auxiliary control plate.

1. Remove the finger guard.

2. Loosen the end stops at both ends of the dinrail.

3. Remove the third stop from the centre of theplate and discard.

4. Replace the existing din rail with the railsupplied, leaving space on the left hand sidefor the phase failure relay. Ensure allconnections are tight.

5. Drill a 6mm dia hole 15mm below the existingearth on the auxiliary control plate.

CAUTION: Make provision to ensure that nometal particles enter the machine whendrilling.

6. Remake the earth connection using the newhole.

7. Mount the phase failure relay on the din rail tothe left hand side of the manual motor starterMCB2 (10A).

8. Once mounted, ensure the two remaining endstops are secured.

WARNING




CompAir


9. Connect wire number 110C from terminalT1(2) on MCB2 and run to the left hand sideof the plate to terminal U of the phase failurerelay.

10. Repeat the instruction above for:

a) 111C from MCB2 T2(4) to the phasefailure relay terminal V.

b) 112C from MCB2 T3(6) to the phasefailure relay terminal W.

11. Connect pin of wire number 137B to terminal14 of the phase failure relay.

12. Connect pin of wire number 170 to terminal11 of the phase failure relay.

13. Run the cables 137B and 170 along thetrunking and down towards the maincontactor (RLA) located behind the auxiliaryplate.

14. Undo the two fixing screws and remove theauxiliary plate. Put to one side.

15. Disconnect the blue wire number 137 fromthe main contactor (RLA) auxiliary. Connectto the new wire 137B.

16. Connect wire number 170 to main contactor(RLA) auxiliary.

17. Replace the auxiliary control plate and tidythe new wiring.

18. Replace the finger guard.

Adjustment

The level of the monitored voltage can be adjustedon the front of the phase failure relay using apotentiometer. The arrow on the potentiometershould point to the national a.c. supply voltage.When power is applied to the machine a green LEDwill indicate the power supply is ON. An orangeLED will indicate that the machine is in asatisfactory condition.

If the orange LED does not light:

a) Isolate the power and allow the d.c. link todischarge.

b) Connect wire number 110C from terminalT1(2) on MCB2 to terminal V of the phasefailure relay.

c) Connect wire number 111C from terminalT2(4) on MCB2 to terminal U of the phasefailure relay.

d) Apply power - the orange LED should nowlight.



ELECTRICAL CONNECTION DIAGRAM - 1 OF 3(SUPERSEDES DIAGRAM IN USER MANUAL)

HW 0316

CompAir



HW 0317




HW 0318

CompAir


475SR MODELS

Purpose of the kit

The kit is supplied to constantly monitor the 3phase a.c. supply to the compressor. It monitorsboth phase sequence and voltage level. If the supplyvoltage on one of the phases drops, the current willrise in the other two phases to counteract theimbalance. This can lead to overloading of thesemiconductor fuses.

The phase failure relay will monitor the supply andstop the compressor when one or more of thephases drops below 70% of the set voltage. At thesame time, a ‘Main Contactor Fault’ will bedisplayed.

Kit Contents

98161-32 Phase Failure Relay




98140-359 140B Red Cable

98140-360 170 Red Cable

98150-1 Cable Ties 5 off

C20775-20 Electrical Schematic Diagram


The phase failure relay is designed to be fitted onthe din rail at the top left hand side of the enclosure.

1. Remove the finger guard.

2. Loosen the end stops at both ends of the dinrail.

3. Remove the third stop from the centre of thedin rail and discard.

4. Mount the phase failure relay on the din railbetween the manual motor starter (MCB 10A)and charging contactor (RLB).

5. Once mounted, ensure the two remaining endstops are secured.

6. Connect wire number 110C from terminalT1(2) on RLB, then run the wire to the righthand side of the phase failure relay andconnect to terminal U.

7. Repeat the instruction above for:

a) 111C from RLB T2(4) to the phasefailure relay terminal V.

b) 112C from RLB T3(6) to the phasefailure relay terminal W.

8. Connect pin of wire number 140B to terminal14 of the phase failure relay.

WARNING






9. Connect pin of wire number 170 to terminal11 of the phase failure relay.

10. Run the cables 140B and 170 along thetrunking and down the left hand side of of theenclosure towards the main contactor (RLA).

11. Disconnect the red wire number 140 from themain contactor (RLA) coil A1. Connect thenew wire 140B to wire 140.

12. Connect wire number 170 to main contactor(RLA) coil A1.

13. Replace the finger guard.

Adjustment

The level of the monitored voltage can be adjustedon the front of the phase failure relay using apotentiometer. The arrow on the potentiometershould point to the national a.c. supply voltage.

When power is applied to the compressor, a greenLED will indicate the power supply is ON. Anorange LED will indicate that the machine is in asatisfactory condition.

If the orange LED does not light:

a) Isolate the power and allow the d.c.link to discharge.

b) Connect wire number 110C fromterminal T1(2) on MCB2 to terminal Vof the phase failure relay.

c) Connect wire number 111C fromterminal T2(4) on MCB2 to terminal Uof the phase failure relay.

d) Apply power - the orange LED shouldnow light.

CompAir



HW 0319




HW 0320

CompAir



HW 0321



PRODUCT IMPROVEMENT

Purpose of the Kit

This kit is supplied to combat high temperatureswithin the power converter assembly. It is notnecessary to introduce this kit to all units, howeverit is recommended that the modification beperformed on machines operating in a high ambienttemperature or which have experienced failure dueto high ambient temperatures within the powerconverter cubicle.

POWER CONVERTER VENTILATION KIT

The ventilation kit uses the machine cooling fan todraw cool air through the power converter cubicleand exhaust it via the machines cooling airdischarge, therefore allowing the components withinthe cubicle to operate in free air.

Kit Contents

C27349-155 Kit – Power Converter VentilationC27349-136 Cover, Filter Retaining 1 off Inlet PanelC27349-137 Filter 1 off Inlet PanelC27349-157 Grille, Filter Retaining 1 off Inlet PanelC27349-158 Grille, Box Inlet 1 off Power Converter EnclosureC27349-159 Grille, Box Outlet 1 off Power Converter EnclosureC20089-557 Label, CE Electrical 1 off Power Converter EnclosureA6455-64 Pop Rivet 8 off Inlet Panel95001-230 Screw, Hex Head M6x25 4 off Inlet Panel95179-5 Washer, Spring M6 4 off Inlet Panel95149-13 Washer, Plain M6 8 off Inlet Panel95112-4 Nut, Plain M6 4 off Inlet Panel

Tools Required

60mm Diameter Hole Saw Knife8mm Diameter Drill Bit 10mm Spanner / socket4mm Diameter Drill Bit RulePop Rivet Gun SquareHalf Round File

WARNING




CompAir



1. Remove the Inlet Panel

2. Remove the foam from the inside of the topsection of the inlet panel and cut horizontallyacross the foam approximately 420mm fromthe top of the panel.

3. Clean the remaining foam from the surfacearea of the inlet panel ensuring that debrisdoes not enter the enclosure.

4. Mark the centres of the four fixing and sixventilation holes on the outside of the inletpanel ( FIG. 1)

5. Pilot drill both sets of holes and finish the fourfixing holes to 8mm diameter and the sixventilation holes to 60mm diameter. De-burrall holes and treat to prevent corrosion.

6. Cut the filter material (C27349-137) to sizeand place in filter retaining cover (C27349-136).

7. Align the assembly with the four fixing holeson the outside of the inlet panel and using theM6 fixings and the filter retaining grill(C27349-157), clamp the assembly to theinlet panel.

8. With the inlet panel removed from themachine, mark the centres of the fixing andventilation holes on the outside of the powerconverter cubicle. (FIG. 2)

9. Ensuring a safe drill length to avoid damageto the electrical components within the powerconverter pilot drill both sets of holes. Finishthe four fixing holes to 4mm diameter and thefour ventilation holes to 60mm diameter. De-burr all holes and treat to prevent corrosion.

10. Align the grille, box inlet (C27349-158) withthe four fixing holes. Pop rivet the grille intoplace and replace the inlet panel.

11. Move the hinged auxiliary control plate to gainaccess for marking out and drilling.

12. Mark the centres of the fixing and ventilationholes on the bottom of the power convertercubicle (FIG. 3).

13. Ensuring a safe drill length to avoid damageto the filter maifold assembly, pilot drill bothsets of holes.

Finish the four fixing holes to 4mm diameterand the three ventilation holes to 60mmdiameter. De-burr all holes and treat toprevent corrosion.

14. Align the grille, box outlet (C27349-159) withthe four fixing holes. Pop rivet the grille intoplace and replace the auxiliary control plateand the finger guards.

15. Apply power to the machine, enter servicediagnostics menu and through the digitaloutputs run the cooling fan. Ensure a good airflow through the power converter cubicle.



FIG. 1 SIDE PANEL

HW 0322

CompAir


FIG. 2 INLET BOX

HW 0322



FIG. 3 OUTLET BOX

HW 0323

CompAir


PRODUCT IMPROVEMENT

Purpose of the Kit

This kit is supplied to combat high temperatureswithin the power converter assembly. It is notnecessary to introduce this kit to all units, howeverit is recommended that the modification beperformed on machines operating in a high ambienttemperature or which have experienced failure dueto high ambient temperatures within the powerconverter cubicle.

POWER CONVERTER VENTILATION KIT

The ventilation kit uses the machine cooling fan todraw cool air through the power converter cubicleand exhaust it via the machines cooling airdischarge, therefore allowing the components withinthe cubicle to operate in free air.

Kit Contents

C27399-320 Kit – Power Converter VentilationC27399-290 Grille, Inlet Power Converter 1 off Door outsideC27399-305 Filter 1 off Door outsideC27399-324 Grille, Filter Retaining 1 off Door insideC27399-323 Guard, Bottom Finger 1 offC27399-304 Outlet Cover 1 off Backplate rearC27399-322 Outlet Grille 1 off Backplate rearC20089-557 Label, CE Electrical 1 off Power Converter Enclosure95001-230 Screw, Hex Head M6x25 4 off Door inlet filter95179-5 Washer, Spring M6 4 off Door inlet filter95149-13 Washer, Plain M6 8 off Door inlet filter95001-229 Screw, Hex Head M6x20 2 off Outlet grille and cover95149-13 Washer, Plain M6 2 off Outlet grille and cover95179-5 Washer, Spring M6 2 off Outlet grille and cover95001-229 Screw, Hex Head M6x20 2 off Finger GuardA10308-10 Washer, conical M6 2 off Finger Guard98140-366 Earth Cable 1 off Finger Guard95001-231 Screw, Hex Head M6x30 1 off Earth Cable to Finger Guard95149-13 Washer, Plain M6 2 off Earth Cable to Finger Guard95149-18 Washer, shakeproof M6 1 off Earth Cable to Finger Guard95179-5 Washer, Spring M6 1 off Earth Cable to Finger Guard95112-4 Nut, Plain M6 3 off Earth Cable to Finger Guard

WARNING






Tools Required

44mm Diameter Hole Saw Half Round File60mm Diameter Hole Saw 10mm Spanner / socket8mm Diameter Drill Bit RulePilot Drill Bit SquareDrill.


1. Disconnect and remove the SureScancontroller. Remove the power converter door.

2. Mark the centres of the four fixing and nineventilation holes on the inside of the powerconverter door (FIG. 1).

3. Pilot drill both sets of holes and finish the fourfixing holes to 8mm diameter and the sixventilation holes to 60mm diameter. De-burrall holes and treat to prevent corrosion.

4. Cut the filter material (C27399-305) to sizeand place in the inlet grill (C27399-290) of thepower converter.

5. Align the assembly with the four fixing holeson the outside of the power converter doorand using the M6 fixings (95001-230, 95149-13, 95179-5) and the filter retaining grill(C27399-324), clamp the assembly to thedoor.

6. Mark the centres of the fixing and ventilationholes on the back of the power converterbackplate (refer to FIG. 2 or 3 according toserial number)

Note: To avoid damage to components withinthe power converter cubicle note the followingserial numbers:-

Post serial number F170-0354 - refer toFIG.2.

Pre serial number F170-0353 - refer to FIG.3.

7. Ensuring a safe drill length to avoid damageto the electrical components within the powerconverter pilot drill both sets of holes. Finishthe four fixing holes to 8mm diameter and thefour ventilation holes to 44mm diameter. De-burr all holes and treat to prevent corrosion.

Note: Ensure no swarf or debris enters thepower converter or main drive motor whendrilling.

8. Align the grille outlet (C27399-322) and cover(C27399-304) with the four fixing holes to therear of the power converter backplate. Secureusing the M6 fixings (95001-229, 95149-13,95179-5) from within the power convertercubicle.

9. Remove the perspex guard from the bottom ofthe power converter cubicle and connect theearth cable (98140-366) to the main earth bar.

10. Fit the earth fixings to the replacement fingerguard (C27399-323).

Order of fitting:

95001-231 Screw, Hex Head M6x3095149-18 Washer, Shakeproof M6C27399-323 Finger Guard95112-4 Nut, Plain M695112-4 Nut, Plain M695149-13 Washer, Plain M698140-366 Terminate Earth Cable95149-13 Washer, Plain M695179-5 Washer, Spring M695112-4 Nut, Plain M6

Then secure the new finger guard in thebottom of the power converter cubicle usingthe M6 fixings (95001-229, A10308-10).

11. Replace the power converter door, refit andconnect the SureScan controller.

12. Apply power to the machine, enter servicediagnostics menu and through the digitaloutputs run the cooling fan. Ensure a good airflow through the power converter cubicle.

CompAir


HW 0325

FIG. 1 - HOLE CENTRES - POWER CONVERTER DOOR



HW 0326

FIG. 2 - HOLE CENTRES - POWER CONVERTER BACKPLATEAFTER SERIAL NUMBER F170-0354

CompAir


HW 0327

FIG. 3 - HOLE CENTRES - POWER CONVERTER BACKPLATEBEFORE SERIAL NUMBER F170-0353



We are pleased to announce the introduction of anumber of enhancements to the LSR-Series SpeedRegulated Rotary Screw Compressors.Modifications have been made to the powerconverter, software features and compressorprotection recommendations and are effective fromthe above serial nos.

This Bulletin explains the newly developed featuresand improvements, the installation requirements andincludes the technical documents considerednecessary.

This information below must be read in conjunctionwith the existing User Manual.

Phase Monitor Relay Protection with AutoRestart

A phase monitor relay is fitted to all models to tripthe machine in event of a power supply fault. Thiscovers situations not detected by the built-incontroller power detect circuit. ln particular, thisincludes loss of the single phase not supplying thecontroller or low incoming voltage and protects thepower converter and motor against drawingexcessive currents that could cause subsequentdamage.

The configuration of the phase monitor relay has nowbeen altered such that, if the auto restart function isenabled, the compressor wilt restart when power isrestored after phase toss or lowvoltage. Thisremoves the need for the user to manually reset thefault and start the compressor.

Power Supply Failure Detection

The control system has two methods of power failuredetection. Within the controller, an internal circuitmonitors two phases of the incoming ac voltage andwill trigger the power failure routine if two successivecycles are not detected. ]External to the controller,a phase monitor relay, connected to a controllerinput, monitors each phase and will signal to thecontroller input if any phase goes below 70% of theset voltage or the phase order is reversed. Thephase monitor relay will automatically reset within500ms when correct supply conditions are restored.

The controller itself is designed to operate for about0.5 secs following loss of incoming power. Thus ithas time to take action and store essential dataprior to shutdown.

The action taken following power failure detectionfrom either source is the same. The compressor willbe shut down and then the controller will shut down.When power to the controller is restored it willreboot. The recovery action when power is restoreddepends on the status of the machine at time ofpower faiture.

Compressor Stopped ('Ready to Start')

In this condition, the controller will reboot to display'Ready to Start'. These occurrences will not belogged as it has no consequence to the system andwould normally occur in a routine power off situation.

Should the controller remain powered (in the eventthat the failure was on a phase not supplyingcontroller) then on rebooting, the display will show'Start Inhibited - Power supply fault' and the chargingcircuits wilt not be actioned. On reset of the phasemonitor relay, the controller will again reboot toensure correct charging sequence.

Compressor Running or in Standby

Again, should the controller remain powered, then onrebooting the display will show 'Start Inhibited -Power supply fault' and the charging circuits will notbe actioned. The fault in this case will be stored inthe history. When the phase monitor relay resets,the controller will reboot again to ensure the correctcharging sequence.

If power to the controller is lost, then after reboot -depending on which circuit triggered first - an alarmwill be displayed either with message 'PowerfailFault' (controller internal circuit) or message 'Powersupply fault' (phase monitor relay) and the faultlogged.

Manual reset will not be required (except to cleardisplay and 'service' led) and, if enabled, themachine will auto restart to previous state.

L45SR & L75SR SPEED REGULATED ROTARY SCREW COMPRESSORENHANCEMENTS

From serial nos: F170-850 onwards, F180-650 onwards

CompAir


Note: Because this feature is only operable whilethe machine is 'available', any powerdip or failureoccurring after a controlled stop, but before themotor is switched off, will result in a reboot to 'Readyto Start' without the 'Power fail/supply fault'indicated. This is the standard machine action.

SR Motor Overcurrent Protection

The power converter incorporates motor overcurrentprotection. To prevent repeated starts that coulddamage components in the power converter, thesoftware has been altered to inhibit restart of thecompressor after two successive overcurrent tripsduring starting. In this case the controller will displayan operator advice message, 'Reset Inhibited' andrestart of the unit will be prevented. To ensure thatthe source of the fault is rectified, the controller canonly be reset by a CompAir authorised serviceengineer using the special access code: view,spanner, spanner, spanner. Entering this code willreset the fault and return the machine to 'Ready to

Start' state. This access code should be consideredconfidential and is only for the use of CompAircompany or authorised distributor service engineers.

Power Supply Fusing

In order to increase reliability, the incoming powersupply fuses have been removed from the powerconverter. These fuses were previously fitted toprotect the power converter components in the eventof a current surge resulting from a short circuit or lowvoltage condition. Due to improvements in thecurrent carrying capacity of the power convertercomponents these fuses are no longer required.

There is, however, still a requirement for thecustomer to fit correctly rated fuses in the incomingpower supply. These fuses should comply withBS88 Part 1, IEC269-1 and EN60269-1 and conformto gG characteristics. The following table providesthe recommended fuse ratings to be fitted by thecustomer.

Compressor Voltage Cable Size Fuse RatingModel 50/60Hz

L45SR All voltages 3 x 35mm2 gG125A



.Note: Cable size is valid for PVC insulated, 3 core cable with a conductor operating temperature of 70°C inaccordance with EN60204.

Commissioning

The commissioning engineer should check that boththe cable and fuses fitted are of the correct rating.The compressor must not be commissioned untilthis has been verified.



475SR & L75SR COMPRESSORS - ALL SERIAL NUMBERS

FITTING INSTRUCTIONS FOR SINGLE PASS AIR/OIL COOLERRETROFIT KIT NO. C27399-332

1. introduction

1.1 The single pass airloil cooler retrofit kit is intended to eliminate the past issues regarding the originalcooler system.

2. Kit Contents

ITEM No. DRAWING No. NAME OF PART No. OFF PART LOCATION

1 C11607-5 1" TO 3/4" REDUCING BUSH 1 ORIGINAL COOLER OIL INLET

2 A3764-6 3/4" PLUG 1 ORIGINAL COOLER OIL INLET

3 98418-61 ANTI VIBRATION MOUNTS 4 COOLER TO SUPPORTS

4 95148-14 WASHERS 8 COOLER TO SUPPORTS

5 95179-6 SPRING WASHER 8 COOLER TO SUPPORTS

6 95111-5 NUT M8 8 COOLER TO SUPPORTS

7 98154-337 OIL/AIR COOLER 1 ON SUPPORTS VIA AVMS

8 95635-8 COPPER WASHER 4 NIPPLES

9 C11605-25 NIPPLE 1” BSP 4 COOLER AND AMOT VALVE

10 95635-6 COPPER WASHER 1 COOLER DRAIN PORT

11 98650-109 DRAIN COCK 1 COOLER DRAIN PORT

12 A3764-6 PLUG 1 DRAIN COCK

13 95406-801 1 “ NIPPLE TAPER THREAD 1 RECLAIMER OUT

14 98650-390 AMOT VALVE 1 RECLAIMER OUT

15 98156-308 TEE 1" BSP 1 FILTER

16 98504-92 RUBBER SEALING STRIP 0.25M PROTECTS HOSE C27399-331

17 C27399-331 ASSY, FLEXIBLE HOSE 1 OIL COOLER TO FILTER VIA TEE

18 C27399-330 ASSY, FLEXIBLE HOSE 1 AMOT TO OIL COOLER INLET

19 C27399-343 ASSY, FLEXIBLE HOSE 1 TEE TO AMOT

20 C27399-334 BAFFLE, FOAM EXHAUST 1 INSIDE EXHAUST DUCT

21 C27399-335 ASSY, EXHAUST DUCT 1 TOP OF AIR/OIL COOLER

22 95251-276 STUD SCREWED METRIC 2 AIR/OIL COOLER AIR INLET

23 A3753-36 WASHERS 16 PLENUM CHAMBER TO COOLER

24 95602-85 “O” RING 1 AIR/OIL COOLER AIR INLET

CompAir


3. Procedure

3.1 Drain the compressor system of oil.

3.2 Remove the original cooler. Use C11607-5 (1”To 3/4” Reducing Bush) and A3764-6 (3/4”Plug) to plug the cooler oil inlet port beforeremoval to reduce oil spillage.

3.3 Install new Air/Oil Cooler 98154-337 using 4off 98418-61 (Anti Vibration Mounts) securedin place with 95148-14 (Washers), 95179-6(Spring Washers) and 95111-5 (M8 Nuts).See Fig 1.

3.4 Assemble 98650-390 (Amot Valve) onto thereclaimer via 95406-801 (Nipple 1“ TaperThread) with the Amot side port orientatedhorizontally and facing towards the inside ofthe machine. See fig 3.

3.5 Connect one end of hose C27399-331 (Assy,Flexible Hose) to the outlet port of the oilcooler section via C11605-25 (Nipple 1 “ BSP)and a 95635-8 (Copper Washer). See fig 2.

Note: Fig 2 also shows edges on whichC27399-331 (Assy, Flexible Hose) rests. Thiswill cause hose chafing so apply 98504-92(Rubber Sealing Strip) to these edges.

3.6 Assemble 98156-308 (Tee 1“ BSP) onto theoil filter using the original production fittedNipple. To the horizontal port of this Tee,connect C27399-331 (Assy, Flexible Hose).To the downward port of the Tee, connect oneend of C27399-343 (Assy, Flexible Hose).

3.7 Connect the other end of C27399-343 (Assy,Flexible Hose) to side port of 98650-390(Amot Valve) via C11605-25 (Nipple 1“ BSP)and 95635-8 (Copper Washer).

Note: Hose C27399-343 now has the 90 Deg.connector removed and replaced with astraight connector.

3.8 Connect one end of C27399-330 (Assy,Flexible Hose) to the inlet port of the OilCooler using C11605-25 (Nipple 1“ BSP) and95635-8 (Copper Washer). Connect the otherend to the exit port of the Amot Valve usingC11605-25 (Nipple 1“ BSP) and 95635-8(Copper Washer).

3.9 Assemble 98650-109 (3/4" Drain Cock) intothe cooler drain port using 95635-6 (CopperWasher).

Fig 1 - Securing new cooler

Fig 2 - Cooler outlet hose run

3.10 Finally, screw A3764-6 (3/4" Plug) into theDrain Cock.

3.11 There is no change from the originalassembly procedure of the Exhaust Baffleand Exhaust Duct Assy to the new. Amongthe design changes made are:-

• The thermostat clearance has been removed

• Four clearance apertures have been added toallow for the Air/Oil cooler securing bolts.



1 95635-8 Copper Washer 10. 95635-8 Copper Washer2. C11605-25 Nipple 1“ BSP 11. C11605-25 Nipple 1“ BSP3. C27399-331 Hose Assy 12. C27399-330 Hose Assy4. 98156-308 Tee 1“ BSP 13. C11605-25 Nipple 1” BSP5. C27399-331 Hose Assy 14. 95635-8 Copper Washer6. C11605-25 Nipple 1“ BSP 15. A3764-6 Plug 3/4”7. 95635-8 Copper Washer 16, 95635-6 Copper Washer8. 95406-801 Nipple 1" B5P Taper 17. 98650-109 Drain Cock 3/4”9. 98650-390 Amot Valve

Fig 3 - New pipework circuit

891011

1 2 3

4

5

67

12

13

14

15

16

17

HW 0109

CompAir


Fig 4 - Original pipework circuit

HW 0297

15

14

2 2 23 4 45 6 7

8

8

8 9

1211

13

161716

16

10

1

4

2

4

21

18

1920 22

27

2

2

1

23

1

24

25

26

SP4(2)WP2(2)NL1(2)

SH6(2)WS4(2)

Chapter 3, page 1

LSR Repair Manual – General Description


CHAPTER

31. COMPRESSOR2. AIR-END2.1 Description2.2 Operation3. SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT4. PROTECTION AND SAFETY EQUIPMENT4.1 Pressure Relief Valve4.2 Blowdown System4.3 Minimum Pressure Non-return Valve4.4 Emergency Stop4.5 Overpressure Switch4.6 Scavenge Sight Tube5. AIR/OIL SYSTEM (345SR, L45SR)5.1 Description5.2 Operation6. AIR/OIL SYSTEM (475SR, L75SR)6.1 Description6.2 Operation7. AIR/OIL SYSTEM (L120SR)7.1 Description7.2 Operation8. REGULATION SYSTEM8.1 Description8.2 Automatic Mode8.3 Manual Mode

FIGURESFIG. 3.1 CYCLON 3, 4 and 5 AIR-END - GENERAL ARRANGEMENTFIG. 3.2 CONTROL PANELFIG. 3.3 AIR/OIL SYSTEM - 345SR, L45SRFIG. 3.4 AIR/OIL SYSTEM - 475SR, L75SR old styleFIG. 3.5 AIR/OIL SYSTEM - L75SR new styleFIG. 3.6 AIR/OIL SYSTEM - L120SRFIG. 3.7 REGULATION SCHEMATIC - 345SR, L45SRFIG. 3.8 REGULATION SCHEMATIC - 475SR, L75SRFIG. 3.9 REGULATION SCHEMATIC - L75SR (Where Single Pass Cooler fitted)FIG. 3.10 REGULATION SCHEMATIC - (L120SR)

GENERAL DESCRIPTION

CompAir

AC20160-1822, Issue 1, November 2002Chapter 3, page 2

GENERAL DESCRIPTION

1. COMPRESSOR

The unit is an air cooled, single-stage, rotary screwcompressor. The compressor air-end is driventhrough a flexible coupling by an electric SwitchedReluctance Drive (SR Drive®) motor manufacturedunder licence from SR Drives Ltd.

The Compressor unit consists of the drive motor,air-end, reclaimer, oil cooler, after cooler, fan, starterassembly and control unit. The completecompressor unit is mounted on a baseframe and ishoused in a steel panelled acoustic enclosure.Removable panels or hinged access doors allowaccess for routine maintenance.

2. AIR-END

2.1 Description

The air is compressed in a single-stage, positivedisplacement, oil injected rotary screw air-end. Theair-end is of the Cyclon type and comprises anintermeshing pair of helical screw rotors, male andfemale, mounted horizontally within an enclosedcasing with drive being applied to the male rotor.

The male air-end rotor is larger in diameter than thefemale rotor and has four lobes which mesh withfive flutes on the female rotor. The rotors areasymmetric in profile to reduce blowback betweenthe lobes on the compression cycle to a minimum,thus maximising the overall sealing and efficiency.

The rotors are fitted with bearings at each end toprovide radial and axial support, maintain adequateshaft stiffness and to give minimum clearance andlow leakage between the rotor tip diameter and thecasing.

At the delivery end the male rotor is fitted with asingle taper roller bearing and the female rotor isprovided with a matched pair of taper roller bearings.These bearings provide axial and radial support ofboth rotors and control the very fine end clearancesbetween the rotors and the casing.

Heavy duty parallel roller bearings are fitted to bothrotors at the inlet end to provide radial support andto sustain the drive load of the male rotor.

2.2 Operation

Compression takes place between the lobes on themale rotor, the flutes on the female rotor and the air-end casing. When the compressor is running thehelical engagement of the rotors provides the drivefor the female rotor.

As the rotors turn, air at atmospheric pressureenters the inlet port and fills the space between thelobes of the male rotor and the flutes of the femalerotor. Oil is injected into the air at this point and thetrapped air/oil mixture is progressively compressedby the reduction in space created by continuousrotation of the rotors within the air-end casing.

Continued rotation brings the compressed air/oilmixture to the discharge port of the air-end, where itpasses into a reclaimer. The oil is separated fromthe air/oil mixture in the reclaimer and the air passesthrough a cooler into the user’s pipework.

Oil is continually injected into the low pressureregion of the air-end and mixes with the air duringthe compression process. The oil carries out threefunctions; lubrication, cooling and sealing. The oillubricates the rotors and bearings, acts as a coolantby absorbing the heat of compression and seals thefine clearances that exist between the rotors andbetween the rotors and casing. The compressed air/oil mixture is discharged from the air-end and intothe reclaimer where the oil is separated and returnedto the system.

Chapter 3, page 3



FIG. 3.1 CYCLON 3, 4 AND 5 AIR-END - GENERAL ARRANGEMENT

1. Parallel Roller Bearing2. Male Rotor3. Casing4. Taper Roller Bearing5. Outer Taper Roller Bearing6. Inner Taper Roller Bearing7. Female Rotor8. Parallel Roller Bearing

CompAir


3. SWITCHED RELUCTANCE DRIVE ANDELECTRONIC CONTROL UNIT

The SR Drive® system regulates the volume of airdelivered by the compressor by adjusting therotational speed of the air-end so that the outputfrom the compressor always matches the demandfrom the user’s system.

This method of regulation can reduce energyconsumption as the compressor produces only theamount of air demanded by the system and isequally efficient at high or low output volumes. Off-load idling is also eliminated and when there is nodemand for compressed air the SR motor stopsautomatically with no limit to the number of timesthat it can be started. Pressure in the user’s systemis accurately maintained to further improve thequality of the compressed air supply.

The motor operates on the principle of magneticattraction. The stator has eight poles and the rotorfour poles, the stator poles being wound with coils toform electromagnets. The electromagnets areconnected in two groups (phase A and B) of fourcoils which attract the poles on the rotor causingthem to rotate into alignment with the stator poles.

The SR stator is an insulated tube formed by thestator poles and coils vacuum impregnated in resinto form a ‘Sealed Insulation System’ which is highlyresistant to dust and corrosion. The rotor is a 4 poleiron shaft with no current carrying coils whichensures cool running and therefore extends bearinglife.

Continuous rotation is achieved by switching thestator phases in the correct sequence. A positiontransmitter on the rotor sends positional informationto the SR Drive® controller to ensure that theswitching of the motor phases is correctly timed.

The microprocessor based compressor controllerand the SR Drive® controller are housed in a singlecontrol unit which also contains the operator keypadand displays. The control unit is mounted on thedoor of the control panel.

A gate drive board isolates the microelectronics inthe control unit from the power electronic circuitsand provides monitoring and protection for the fourinsulated gate bi-polar transistor (IGBT) powerswitches.

The IGBTs are used to turn the motor phases onand off and, in conjunction with the electroniccontroller, to control the motor phase current and inturn the torque and speed of the SR motor.

4. PROTECTION AND SAFETY EQUIPMENT

In addition to the protection and warning circuitslinked to the controller the following protectionequipment is fitted:

4.1 Pressure Relief Valve

A pressure relief valve is mounted on the reclaimer.If a fault occurs, causing pressure to build up in thereclaimer, the relief valve will open at a pre-setpressure and vent to atmosphere.

4.2 Blowdown System

When the compressor stops, either automatically orby operation of the ‘STOP’ switch, all pressure inthe reclaimer is automatically released by ablowdown system which vents the pressure toatmosphere. This ensures that the compressor isrestarted in a ‘no-load’ condition.

4.3 Minimum Pressure Non-return Valve

Fitted on the reclaimer cover in the delivery air line,the minimum pressure valve remains closed untilminimum pressure is reached. This ensures a rapidbuild-up of pressure when the compressor firststarts and also prevents high velocity, low pressureair reaching the user’s pipework during the start-upperiod and carrying over excessive amounts of oil.When the compressor shuts down it functions as anon-return valve which prevents the pressure in theuser’s pipework feeding back into the reclaimer andventing through the blowdown system.

4.4 Emergency Stop

An emergency stop button, complying withinternational safety requirements, is fitted on thedisplay panel.

Chapter 3, page 5



1. Bar Units Indicator2. Psi Units Indicator3. Delivery Pressure Display4. Status and Message Display5. Plus6. Minus7. Up8. Down9. Enter

10. Mimic Diagram11. Intake Filter Change Lamp12. High Delivery Temperature Lamp13. Reclaimer Element Check Lamp14. Excess Pressure Lamp15. Emergency Stop16. Auto Restart Legend

FIG. 3.2 CONTROL PANEL

17. Remote Control Legend18. Remote Control Lamp19. Auto Restart Lamp20. Power on Lamp21. Fan Motor Overload Lamp22. Power Converter Fault Lamp

23. Main Motor Fault Lamp24. Reset25. Hours26. Reset Lamp27. Data View28. Service29. Service Lamp30. Stop31. Start

4.5 Overpressure Shutdown

An overpressure shutdown is present on allmachines. This shutdown setting is belowthe pressure relief valve setting and will stopthe compressor in the event of an overpressure condition.

BarPSI

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

16171819202122232425262728293031

4.6 Scavenge Sight Tube

A transparent nylon tube is incorporated in thescavenge oil line to allow a visual check of the flowof scavenge oil from the reclaimer to the air-end.

CompAir


5. AIR/OIL SYSTEM (345SR, L45SR)5.1 Description

The air/oil system comprises an air intake filter, inletnon-return valve, air-end, oil separator vessel, oilseparator filters, minimum pressure/non-returnvalve, aftercooler, oil cooler with thermostaticbypass valve and an oil filter. The flow of oil throughthe circuit is achieved through the pressuredifferential existing between the primary oilseparator and the oil injection point in the air-end.

5.2 Operation

Air enters the compressor unit through the intakefilter (2) and inlet non-return valve (1) to the inlet portof the air-end (7). The air is trapped by the turningrotors and mixes with the oil which enters the casingthrough the oil injection point.

Continued rotor rotation increases the pressure andtemperature of the air/oil mixture which passes fromthe air-end discharge pipe into the oil separator (4)where primary separation takes place by centrifugalforce. Most of the oil is separated at this stage anddrops to the bottom of the vessel.

The remaining air/oil mixture then passes throughoil separator elements (5) where final separationtakes place. The separated oil collects in the bottomof the elements and is scavenged back into theair-end through a small diameter pipe (13).

The filtered air then passes from the oil separatorelements by way of the minimum pressure/ non-return valve (3). Provided the air pressure at thisstage is above 3.5 to 4·0 bar the air passes throughthe aftercooler (9) where it is cooled before passingto the delivery outlet (12).

If the air pressure in the primary separator vesselfalls below 3.5 to 4·0 bar the minimum pressurevalve will close. The valve also incorporates a non-return valve which operates to prevent delivery airpassing back into the separator when thecompressor is running off-load.

Oil from the bottom of the primary separator flowsunder pressure to the oil cooler (10) and duringnormal running the oil passes through the cooler tomaintain the correct temperature. A thermostaticbypass valve (14) is installed in the inlet manifold ofthe oil cooler.

When the compressor is started, the cold oil in thesystem bypasses the cooler and flows through theoil filter (8) directly to the air-end. As the oil and airmixture is compressed by the rotors in the air-end,the temperature of the oil increases.

When the oil has reached its normal operatingtemperature the bypass valve closes and the oil isdirected through the oil cooler. The cooled oil thenflows to the oil filter where it is cleaned beforeentering the air-end.

The quantity of oil injected into the air-end iscontrolled by a restrictor orifice in the air-end casing.Oil is injected under pressure through the restrictororifice into the rotors and a gallery supplies oil to theair-end bearings.

Chapter 3, page 7



8. Oil Filter9. Aftercooler

10. Oil Cooler11. Fan12. Delivery Air Outlet13. Scavenge Line14. Thermostatic Bypass Valve

1. Inlet Non-Return Valve2. Intake Air Filter3. Minimum Pressure Valve4. Primary Oil Separator5. Separator Filter Element6. Discharge Pipe7. Air-end

15. Scavenge NR Valve16. Blow down solenoid

valve.

FIG. 3.3 AIR/OIL SYSTEM - 345SR, L45SR

12

3

45

6

7

8

9

10

11

12 13

14

15

16

CompAir


6. AIR/OIL SYSTEM(475SR, L75SR)

6.1 Description

The air/oil system comprises an air intake filter, air-end, reclaimer, reclaimer filter element, minimumpressure non-return valve, oil cooler and aftercooler,thermostatic bypass valve and oil filter. The flow ofoil through the system is achieved by means of thepressure differential existing between the reclaimerand the air-end inlet.

6.2 Operation

Air enters the compressor through the air intakefilter (19) to the inlet port of the air-end (18). The airis trapped by the turning rotors and mixes with theoil which enters the casing through a restrictororifice. Continued rotation increases the pressureand temperature of the air/oil mixture which passesthrough the discharge port of the air-end and, via thenon-return valve (15), into the reclaimer (12) where itis centrifugally separated and the oil drops to thebottom of the reclaimer vessel. The remaining air/oilmixture then passes through the two stages of thereclaimer element (6) where final separation takesplace.

The separated oil is collected in the bottom of theelement and is scavenged back into the air-endthrough a strainer (8) and scavenge line (11). Asolenoid operated valve (10), fitted in the scavengeline, prevents any oil loss through the air intake filterwhen the compressor is stopped.

Filtered air then passes out of the reclaimer throughthe minimum pressure valve (7). Provided the airpressure at this stage is above 4 bar the air will bepassed to the air cooler (3) where the warm air iscooled. The cooled, filtered air then passes througha moisture separator to the delivery air outlet (1).The condensate in the moisture separator (2) isautomatically removed by the operation of anelectronically controlled solenoid valve (20).

If the air pressure in the reclaimer is at any time lessthan 4 bar the minimum pressure valve will close.The valve also incorporates a non-return valve whichoperates to prevent delivery air passing back into thereclaimer when the compressor is running off-load.

Earlier oil circuit (Fig. 3.4). Oil from the reclaimerflows to the oil cooler. During normal running the oilpasses through the cooler to maintain itstemperature at a correct level. A thermostaticbypass valve (5) is installed in the oil cooler. Whenthe compressor is started, the cold oil in the systembypasses the cooler and flows through the oil filters(9) directly to the air-end. As the oil and air mixtureis compressed by the rotors in the air-end, thetemperature of the oil increases. Once the oil hasreached its normal operating temperature the 3-waythermostatic bypass valve directs oil throughcooler. The cooled oil then flows to the oil filterwhere it is cleaned before entering the air-end.

Later oil circuit (Fig. 3.5). Oil flows to the oilcooler (4) via a 3-way thermostatic bypass valve (6)installed in the reclaimer. During normal running theoil passes through the cooler to maintain itstemperature at the correct level. When thecompressor is started, the cold oil in the systembypasses the cooler and flows through the oil filters(9) directly to the air-end. As the oil and air mixtureis compressed by the rotors in the air-end, thetemperature of the oil increases. Once the oil hasreached its normal operating temperature the 3-waythermostatic bypass valve directs oil through thecooler. The cooled oil then flows to the oil filterwhere it is cleaned before entering the air-end.

The quantity of oil injected into the air-end rotors iscontrolled by a restrictor orifice in the rotor casing.Oil is injected under pressure through the restrictororifice into the rotors and a separate gallery suppliesoil to the air-end bearings.

Chapter 3, page 9



FIG. 3.4 AIR/OIL SYSTEM - 475SR, L75SR (WITH EARLIER OIL CIRCUIT)

9. Oil Filters10. Scavenge Solenoid11. Scavenge line12. Reclaimer13. Oil Drain14. Oil Level Tube15. Non-return Valve

1. Delivery Air Outlet2. Moisture Separator3. Air/Oil Cooler4. Fan5. Thermostatic Bypass Valve6. Reclaimer Element7. Minimum Pressure Valve8. Scavenge Strainer

16. Oil Drain17. Oil Stop Valve18. Air-end19. Air Intake Filter20. Drain Solenoid21. Strainer22. Air In

1

2 3 4 5 6 7 8 9

10

11

12

14

13

15

16

1718

19

20

21

22

Oil flow

Air flowAir/oil mixture

CompAir


FIG. 3.5 AIR/OIL SYSTEM - L75SR (WITH LATER OIL CIRCUIT)

1. Delivery Air Outlet2. Moisture Separator3. Drain Cock4. Air/Oil Cooler5. Fan6. 3-way Thermostatic Bypass Valve7. Reclaimer Element8. Minimum Pressure Valve9. Scavenge Strainer10. Oil Filters11. Scavenge Solenoid12. Scavenge Line

13. Reclaimer14. Oil Drain15. Oil Level Tube16. Non-return Valve17. Oil Drain18. Oil Stop Valve19. Air-end20. Air Intake Filter21. Drain Solenoid22. Strainer23. Air In

Chapter 3, page 11



7. AIR/OIL SYSTEM (L120SR)

7.1 Description

The air/oil system comprises an air intake filter, air-end, reclaimer, reclaimer filter element, minimumpressure non-return valve, oil cooler and aftercooler,thermostatic mixing valve and oil filters. The flow ofoil through the system is achieved by means of thepressure differential existing between the reclaimerand the air-end inlet.

7.2 Operation (fig. 3.6)

Air enters the compressor through the air intakefilter (1) and intake non-return valve (2) to the inletport of the air-end (3). The air is trapped by theturning rotors and mixes with the oil which entersthe casing through a restrictor orifice. Continuedrotation increases the pressure and temperature ofthe air/oil mixture which passes through thedischarge port of the air-end and into the reclaimer(5) where it is centrifugally separated and the oildrops to the bottom of the reclaimer vessel. Theremaining air/oil mixture then passes through thetwo stages of the reclaimer element where finalseparation takes place.

The separated oil is collected in the bottom of theelement and is scavenged back into the air-endthrough a strainer (n), non-return valve (n) andscavenge line (n). The non-return valve preventsany oil loss through the air intake filter when thecompressor is stopped.

Filtered air then passes out of the reclaimer throughthe minimum pressure valve (8). Provided the airpressure at this stage is above 4 bar the air will bepassed to the aftercooler (9) where the warm air iscooled. The cooled, filtered air then passes througha moisture separator (15) to the delivery air outlet(10). The condensate in the moisture separator (15)is automatically removed via the condensate drainport (17) by the operation of electronically controlledno loss drain (16).

If the air pressure in the reclaimer is at any timeless than 4 bar the minimum pressure valve willclose. The valve also incorporates a non-returnvalve which operates to prevent delivery air passingback into the reclaimer when the compressor isrunning off-load.

Oil from the reclaimer flows to the oil cooler (23).During normal running the oil passes through thecooler to maintain its temperature at a correct level.A thermostatic bypass valve (21) is installed in theoutlet side of the oil cooler.

If the unit is fitted with a heat recovery option athermostatic mixing valve (35) diverts the flow of oilto the cooler to first pass through the heat recoveryheat exchanger (36). This heats the water supplypassing between the water inlet and outletconnections (37).

When the compressor is started, the cold oil in thesystem bypasses the cooler via the coolewr bypasspipe (n) and flows through the oil filters (6) directly tothe air-end. As the oil and air mixture is compressedby the rotors in the air-end, the temperature of theoil increases and the oil starts to flow through thecooler. Once the oil has reached its normaloperating temperature the bypass valve (21) directsoil through the cooler. The cooled oil then flows tothe oil filter where it is cleaned before entering theair-end.

The quantity of oil injected into the air-end rotors iscontrolled by a restrictor orifice in the rotor casing.Oil is injected under pressure through the restrictororifice into the rotors and a separate gallery suppliesoil to the air-end bearings.

Cooling fan/motor (24) extracts air from theenclosure through the air outlet grille (20), which isreplenished by cool air entering air inlet grille (13).Cooling of the power converter heat sink is carriedout by a separate cooling fan/motor (25).

CompAir


FIG. 3.6 AIR/OIL SYSTEM - L120SR

1. Switched Reluctance Drive Controller 8. Separator Filtration Element

2. Switched Reluctance Drive Motor 9. Minimum Pressure NonReturn Valve

3. Air Intake Filter 10. Oil Cooler

4. Intake Non Return Valve 11. Air Cooler

5. Temperature Sensor 12. Oil Filter

6. Compression Element 13. Pressure Transmitter

7. Separator Vessel

A Intake Air C Air/Oil Mixture

B Compressed Air D Oil

Chapter 3, page 13



8. REGULATION SYSTEM(See figures 3.7 to 3.9)

8.1 Description

The compressor delivery pressure can be controlledin either ‘Automatic’ (AUTO) or ‘Manual’ (MAN)modes. The normal method of operation is the‘Automatic’ mode which varies the volume of airdelivered by the compressor by adjusting therotational speed of the air-end to match the demandon the user’s system and maintain a targetpressure.

‘Manual’ mode controls the pressure between twoset points, the rotational speed of the air-end beingcontrolled by the operator.

8.2 Automatic Mode

This is the normal mode of operation. A pressuretransmitter (18),(32) or (28) measures the deliverypressure which is compared with the target pressure(P2) programmed into the control unit.

If the delivery pressure is lower than the targetpressure, the rotational speed of the air-end, andtherefore the delivered air volume, increases untileither the target pressure is reached or the air-end isrunning at maximum speed. If the delivery pressureis above the target pressure the rotational speed ofthe air-end is reduced until either the target pressureis reached or the air-end is running at minimumspeed.

An unload pressure setpoint (P1) is also providedand is always set above the target set point. If theunload pressure is reached, a bypass/blowdownvalve (21), (12) or (14) opens and because the air-end is running at minimum speed all of the airproduced is re-circulated in the bypass piperesulting in zero delivered air volume. The bypasscondition will continue until:

a) the delivery pressure falls below the targetpressure and the bypass valve shuts, or

b) the SR motor run-on timer expires causing themotor to stop and the compressor to enter‘Standby’ condition. Subsequently, if thedelivery pressure falls below the targetpressure the SR motor will re-start.

8.3 Manual Mode

The ‘Manual’ mode should only be used if thecompressor is to be run at a fixed speed and,therefore, fixed rate of air delivery. A pressuretransmitter measures the delivery pressure which iscompared with upper and lower set pointsprogrammed into the control unit.

If the delivery pressure is below the upper setpointthe air-end will run at a pre-determined speed whichcan be set at any point between maximum andminimum. If the delivery pressure exceeds theupper setpoint the rotational speed of the air-end willreduce to minimum and the bypass valve will openresulting in zero delivered air volume. The bypasscondition will continue until:

a) the delivery pressure falls below the lowersetpoint. At this point the bypass valve willshut and the speed will be re-set to the pre-setvalue, or

b) the SR motor run-on timer expires causing themotor to stop and the compressor to enter‘Standby’ condition. Subsequently, if thedelivery pressure falls below the lower setpointthe SR motor will re-start and run at the pre-setspeed.

CompAir


FIG. 3.7 REGULATION SCHEMATIC - 345SR, L45SR

1. Intake Air Filter2. Non-return Valve3. Air-end4. SR Drive® Motor5. Reclaimer6. Separator Filters7. Pressure Gauge8. Minimum Pressure Non-return

Valve9. Aftercooler

10. Compressor Delivery11. Oil Filler12. Oil Level Sight Glass13. Temperature Thermistor (TE1)14. Overcurrent Trip

15. Position Sensor Fault Trip16. Overspeed17. Stall Trip18. Pressure Transducer19. Differential Pressure Switch20. Temperature Thermistor (TE2)21. Bypass Valve22. Pressure Relief Valve23. Oil Cooler24. Oil Filter25. Thermal Overload26. Temperature Thermistor (TE3)27. Cooling Fan28. Thermostatic Bypass Valve29. Control Panel

30. Pressurised Oil Drain Valve31. Oil Drain Valve32. Emergency Stop33. SR Current Sensor Trip34. DC Link Overvoltage Trip35. DC Link Undervoltage Trip36. Capacitor Charge Volt Trip37. Heatsink Sensor Fault Trip38. Heatsink Temperature Alarm39. Heatsink Temperature Trip40. Main Contactor Fault Trip

OIL SCAVENGE LINES

M4

24

3

2

1

20

13

14

15

16

17

19

21

22

11

5

28

7

30

32 33 34 35

29

36 37 38 39 40

8

M

9

18

106

A B

23

27

25

26

12

31

HW 0009

3 PHASE POWER SUPPLY

Chapter 3, page 15



19. Relief Valve20. Diff. Pressure Indicator21. Oil Filter22. Oil Drain Valve23. Oil Stop Valve24. Non-return Valve25. Oil Drain Valve26. Minimum Pressure Non-

return Valve27. Thermal Overload28. Temperature Thermistor

(TE3)29. Cooling Fan Motor30. Oil Cooler31. Aftercooler32. Pressure Transmitter33. Moisture Separator34. Strainer

1. Intake Air Filter2. Differential Pressure Switch3. Air Inlet Connection4. Air-end5. SR Drive® Motor6. Temperature Thermistor (TE1)7. Overcurrent Trip8. Position Transmitter Fault Trip9. Over Speed Trip

10. Stall Trip11. Temperature Thermistor (TE2)12. Bypass Valve13. Scavenge Solenoid14. Overpressure Switch15. Pressure Gauge16. Oil Filler17. Reclaimer18. Oil Level Tube

35. Drain Solenoid36. Compressor Delivery37. Condensate Drain38. Control Panel39. Emergency Stop40. SR Current Sensor Trip41. DC Link Overvoltage Trip42. DC Link Undervoltage Trip43. Capacitor Charge Volt Trip44. Heatsink Sensor Fault Trip45. Heatsink Temperature

Alarm46. Heatsink Temperature Trip47. Main Contactor Fault Trip48. Scavenge Strainer

49. Thermostatic Bypass Valve 50. Pressurised Oil Drain Valve

FIG. 3.8 REGULATION SCHEMATIC - 475SR, L75SR

M

M

39 40 41 42 43 44 45 46 47

38

32

33

35

36

37

31

30

29

28

27

49

1817

19

20

26

16

14

15

2522

21

23

24

4

5

48

6

7

8

9

10

1113

3

2

1

12

50

400V ± 10%, 50 Hz, 3-Phase400V-460V ± 10%, 60 Hz, 3-Phase

34

HW 0010

CompAir


FIG. 3.9 REGULATION SCHEMATIC - L120SR

17. Condensate Drain Point18. Oil Drain (Cooler)19. Oil Drain (Reclaimer)20. Air Outlet Grille21. Thermostatic Mixing

Valve22. Pressure Relief Valve23. Oil Cooler24. Fan Motor25. Power Converter Heat

Sink - Cooling Fan26. Position Sensor27. Pressure Transmitter

(Reclaimer)28. Pressure Transmitter

(Air Delivery)29. Inlet Non-Return Valve30. Scavenge Restrictor31. Scavenge NRV

32. Motor Thermistor33. Temperature Transmitter

(Air End Delivery)34. Differential Pressure

Indicator and Switch35. Thermostatic Mixing

Valve (Heat Recovery)36. Heat Recovery Heat

Exchanger37. Water Inlet and

Outlet Connection(Heat RecoveryOption Only)

1. Intake Air Filter2. Air Inlet Grille3. Air End4. SR Drive® Motor5. Reclaimer6. Oil Filters7. Pressure Gauge8. Minimum Pressure /

Non-Return Valve9. Aftercooler10. Compressor Delivery11. Oil Filler12. Oil Level Sight Glass13. Air Inlet Grille14. Solenoid Valve

(Blowdown)15. Moisture Separator16. Level Controlled

Condensate Valve

25

12

7

27

33

4

26

32

21

15

28

24

34

1

2

3

5

6

8

9

10

11

1314

16 17

18

20

22

23

36

37

HW 0013

30

2931

19

35


LSR Repair Manual - Technical Data

CHAPTER

41. LEADING PARTICULARS2. CABLE SIZES AND FUSE RATINGS3. APPROXIMATE FULL LOAD CURRENTS4. FAN MOTORS THERMAL OVERLOAD SETTINGS

TECHNICAL DATA

CompAir


MODEL 345SR 475SR L120SRand and

L45SR L75SR

Air-end: Single Stage Oil InjectedScrew

Cooling: Air Cooled

Oil Capacity: litres (US gal) 18.5 (4.9) 45 (11.9) 80 (21.1)

Recommended Oil: CompAir 4000HRCompAir FG (Food Grade)

Air Delivery Connection: G11/2 or R 21/2 or flanged11/2in NPTM 21/2in NPTM BS 4504/

DIN 2633DN80 PN16or 3” ASA-150lb RF

Condensate Connection: - 10mm/ 3/8 in G 1/2 orOD tube 1/2in NPT

Delivery Air Pressure: Minimum bar (psig) 5 (72) 5 (72) 5 (72)Maximum bar (psig) 13 (189) 13 (189) 11.5 (167)

or 13 (189)

★ Delivery Air Temperature Full load operation (7 bar) °C (°F) 10 (18) 11 (20) 10 (18) above ambient:

Ambient Temperature Range: Minimum °C (°F) 0 (32) 0 (32) 0 (32) Maximum °C (°F) 45 (113) 43 (109) 45 (113)

Typical Cooling Air OutletTemperature at MaximumOperating Pressure °C (°F) 19 (34) 14 (25) 21 (38)above ambient:

Main Drive Motor: Nominal Rating kW (HP) 50 (67) 75 (100) 128 (172)

Motor Rotation Clockwise viewed from drive end

Motor Speed Maximum rpm 5000 4800 3750

Fan Motor Power kW (HP) 2.2 (3) 4 (5.45) 5.5 (7.5)

Fan Motor Rotation viewed from Anti-clockwisenon-drive end Clockwise

Total Power Input (Typical) kW 56 88 144

Approx. Nett. Weight: kg (lbs) 955 (2101) 1243 (2735) 2100 (4620)

Dimensions: Length mm (ins) 1420 (55.9) 2050 (80.7) 2500 (98.5)Width mm (ins) 990 (39) 1200 (47.2) 1400 (55.2)Height mm (ins) 1650 (65) 1702 (67) 2020 (79.6)

Average Sound level at 1m 50Hz - 76(CAGI PNEUROP) dB(A) +/- 3dB(A) 77 77 60Hz - 79

★ The air temperature is a typical figure and relates to an inlet air temperature of 20°C and standard atmosphericpressure of 1 bar a. Specific values for particular operating conditions can be supplied on request.

TECHNICAL DATA1. LEADING PARTICULARS


LSR Repair Manual - Technical Data

2. Cable Sizes and Fuse Ratings

Model Voltage Cable Size Fuse Rating50/60Hz

345SR, L45SR All voltages 3 x 35mm2 gG125A474SR, L75SR All voltages 3 x 70mm2 gG200A


3. Approximate Full Load Current, Amps

Model 380V 400V 415V 460V

345SR, L45SR 107 102 98 87475SR, L75SR 160 155 151 139

L120SR 261 248 238 234

4. Fan Motors Thermal Overload Settings, Amps

Model 380V 400V 415V 460V

345SR, L45SR 6.0 5.5 5.4 5.0475SR, L75SR 9.5 9.0 8.9 8.5

L120SR 16.0 16.0 16.0 16.0

CompAir



LSR Repair Manual – Operation

CHAPTER

5MECHANICAL FAULT FINDING

DEFAULT SETTINGS

FAULT FINDING 1. SHUTDOWN MESSAGES2. WARNING MESSAGES3. FAULT FINDING CHART

CompAir


1. Default settings for a number of theoperational settings are stored in thecontroller. These are suitable for operating thecompressor in most normal situations.

2. The compressor can use these settings asoperational settings. Unless the compressor isreprogrammed during commissioning, thedefault settings will be those used by thecompressor.

3. The compressor may be re-programmed withdifferent settings at most times, and theoperational settings may be restored to thedefault values, by choosing the ‘Load defaultvalues’ option in the ‘Commissioning – values’sub-menu.

Alteration of the working setting valuesrequires the use of the access code.

DEFAULT SETTINGS

4. It is not possible to change any parameterswhile the Emergency Stop button is pressed.This is because when Emergency Stop ispressed (input open circuit) the power failuredetection is inhibited. The controller thereforeassumes a power failure possibility andsuspends all data storage to preventcorruption should the power fail during storageoperation. A message ‘Emergency Stop’ isshown if a change is attempted.

5. The following is a list of default settingstogether with the range and size of theincrements/decrements available for eachsetting.


LSR Repair Manual – Operation

Setting Unit Minimum Maximum Step DefaultValue

P1 for AUTO mode bar 5·1 13·4 (11.9)* 0·1 7·4

P2 for AUTO mode bar 5·0 13·0 (11.5)* 0·1 7·0

*P1 for AUTO mode bar 5·1 13·4 (11.9)* 0·1 7·4

*P2 for AUTO mode bar 5·0 13·0 (11.5)* 0·1 7·0

P1 for MAN mode bar 5·1 13·3 (11.8)* 0·1 7·0

P2 for MAN mode bar 5·0 13.0 (11.5)* 0·1 6·3

Max. overpress (L120SR) bar 6·0 14.3 (12·8)* 0·1 7·7

Max. overpress (L45SR, L75SR) 6·0 13·6 0·1 7·7

Acceleration time second 0 240 1 10

Cooler run-on time minute 4 12 1 4

Run on time second 20 240 1 20

Drain open time second 1 20 1 5

Drain shut time second 10 120 1 30

Oil t trip limit °C 85 125 1 110

Oil t alarm limit °C 85 125 1 105

Max. service hours hour 1000 2000 100 2000

Machine number number 1 99 1 1

Auto restart delay second 10 240 1 10

Auto restart Enabled – Disabled option disabled

Remote start/stop (see Chapter 8, 1.2.2) Enabled - Disabled option disabled

Pressure P factor 1 100 1 30

Pressure I factor 1 100 1 15

Input X01/4 (see Chapter 8, 1.2) Disabled to Start Inhibit option disabled

Input X01/6 (see Chapter 8, 1.2) Disabled to Start Inhibit option Pressureplus Pressure Range select Range sel

Input X01/7 (see Chapter 8, 1.2) Disabled to Start Inhibit option Remoteplus Remote Start/Stop start/stop

Output X08/6 (see Chapter 8, 1.3) Group Fault to Low Temp alarm option disabled

Output X08/10 (see Chapter 8, 1.3) Group Fault to Low Temp alarm option disabled

Output X09/2 (see Chapter 8, 1.3) Group Fault to Low Temp alarm option Group Fault

Output X09/3 (see Chapter 8, 1.3) Group Fault to Low Temp alarm option Available

Output X09/4 (see Chapter 8, 1.3) Disabled to Start Inhibit option Group Trip

Communications config Disabled-SmartAir control- option disabledCommunications control

* Figures in brackets are for L120SR-11 machines only.

Note: The ‘Max. overpressure’ must be set above P1 settings.

1. L45SR, L75SR, L120SR models.

CompAir


2. 345SR, 475SR models.

Setting Unit Minimum Maximum Step DefaultValue

*P1 for AUTO mode bar 5·1 13·4 0·1 7·4

*P2 for AUTO mode bar 5·0 13·0 0·1 7·0

P1 for AUTO mode bar 5·1 13·4 0·1 7·4

P2 for AUTO mode bar 5·0 13·0 0·1 7·0

P1 for MAN mode bar 5·1 13·4 0·1 7·0

P2 for MAN mode bar 5·0 13.2 0·1 6·3

Max. overpress bar 6·0 13·6 0·1 7·7

Acceleration time second 0 240 1 10

Cooler run-on time minute 4 12 1 4

Run on time second 20 240 1 20

Drain open time second 1 20 1 5

Drain shut time second 10 120 1 30

Oil t trip limit °C 85 125 1 110

Oil t alarm limit °C 85 125 1 105

Max. service hours hour 1000 2000 100 2000

Machine number number 1 99 1 1

Comms baud rate 110 9600 options 9600

Auto restart delay second 10 240 1 10

Remote control config Start/Stop Comms. option disabledControl

Auto restart Enabled – Disabled option disabled

Pressure P factor 1 100 1 30

Pressure I factor 1 100 1 15

Note: The ‘Max. overpressure’ must be set above P1 settings.


LSR Repair Manual – Fault Finding

FAULT FINDING

WARNING

The controller has a memory facility that retains afault history. Details of 15 previous situations canbe displayed, including the fault message togetherwith recorded hours, compressor state (standby, on-load, off-load etc.), oil temperature and air pressure.

In operation the compressor is protected by circuitswhich are triggered when a fault arises and eithercause the compressor to shut down or indicate thata servicing action is required.

! Refer to the safety procedures beforecarrying out any fault findinginvestigation on the compressor unit.

! Lethal voltages are used in thisequipment. Use extreme caution whencarrying out electrical checks. Isolate thepower supply before starting anymaintenance work.

! Before opening the door of the startercompartment, switch the power supply OFFat isolator and wait for 12 minutes to allowthe dc link capacitors to discharge to a safelevel. Check that the dc link capacitorshave fully discharged before starting workon the compressor.

1. SHUTDOWN MESSAGES

Message Displayed Possible Cause Action required

Emergency stop (1) Emergency stop switch (1) Check cause of fault andoperated. rectify. Turn Emergency Stop

switch to release latch. PressRESET.

(2) Starter circuit fuse F2 blown. (2) Check cause and rectify.

Fan motor fault (1) Insufficient cooling air flow. (1) Inspect/clean: enclosurefilter; ducting; air/oil coolermatrix; motor cooling air

intake.(2) High ambient temperature. (2) Check room ventilation.(3) Low voltage/high current. (3) Check power supply.(4) Circuit breaker MCB2 (4) Check setting and reset.

incorrectly set.(5) Starter circuit breaker (5) Check starter circuit breaker.

MCB2 open.(6) Fan motor thermistor fault. (6) Check thermistor.

(all models except L120SR).(7) Fan motor overload (L120SR). (7) Check motor/fan. replace if

necessary.

CompAir



Heat sink temp HI ** (1) Panel filters blocked (1) Clean/renew filters(2) Heat sink dirty (2) Clean heat sink(3) Heat sink fan faulty (L120SR) (3) Check motor/fan. replace if

necessary.

High air pressure (1) High pressure in user system (1) Check settings of othercompressors in system.

(2) Compressor fails. (2) Check operation of ventingvalve and solenoid operatedbypass valve. Renew ifnecessary.

(3) Pressure transmitter fault. (3) Check/renew pressureTransmitter.

(4) Controller fault. (4) Renew controller.

High oil temp fault (1) Fan rotation incorrect. (1) Check/rectify wiring.

(2) Insufficient cooling air flow. (2) Inspect/clean: enclosurefilter; ducting; air/oil coolermatrix.

(3) High ambient temperature. (3) Check room ventilation.(4) Poor electrical connection or (4) Rectify/renew.

Air/oil thermistor fault.(5) Low oil level. (5) Check for leaks and rectify.

Top up reclaimer to correctlevel.

(6) Incorrect grade of oil. (6) Drain/flush oil system. Cleanscavenge strainer. Renewreclaimer separator and oilfilter elements. Refill thesystem with therecommended oil.

(7) Oil stop valve not opening. (7) Rectify or renew valve.(8) Oil cooler bypass valve fault. (8) Rectify or renew valve.(9) L120SR only - Enclosure door (9) Close door.

open.

Press probe fault * (1) Pressure transmitter fault. (1) Renew pressure transmitter.Del pressure probe fault ** (2) Sensor wiring fault. (2) Check and rectify fault.Reclaimer P probe fault ** (3) Controller fault. (3) Renew controller.

Remote fault 1, 2 or 3 ** Appropriate input was open Check conditions (Type 1, 2circuit whilst conditions met. or 3) are appropriate.

Check auxiliary equipmentCheck/rectify wiring.

* 345SR and 475SR models ** L120SR models




SR motor high temp fault (1) Insufficient cooling air flow. (1) Inspect/clean: enclosure filter;ducting; motor cooling airintake.

(2) High ambient temperature. (2) Check room ventilation.(3) Fan operation/rotation incorrect. (3) Check and rectify electrical

circuit.(4) Controller fault. (4) Renew controller.

Temperature probe fault. (1) Temperature sensor fault. (1) Renew temperature sensor.Temp probe fault. (2) Temperature sensor wiring fault. (2) Check and rectify.

(3) Controller fault. (3) Renew controller.

2. WARNING MESSAGES

Message Displayed Possible Cause Action Required

Change air filter (1) Intake air filter blocked. (1) Check/renew element.(2) Filter pressure switch fault. (2) Check operation. Renew if

necessary.(3) Filter pressure switch wiring (3) Check and rectify.

fault.

Change reclaimer (1) Reclaimer filter blocked. (1) Check/renew elementelement (2) Pressure transmitter fault (2) Check and rectify.

Check reclaimer (1) Service interval expired (1) Check reclaimer differentialCheck reclaimer dp pressure.

(2) Renew element if required.

High oil temp alarm See High Oil Temp Fault

Remote fault 1, 2 or 3 An input was open circuit Check conditions (Type 4, 5whilst conditions met. or 6) are appropriate.

Check auxiliary equipment.Check/rectify wiring.

Service due Service countdown time Service compressor thenexpired. reset timer.

Start inhibited A start inhibit function is active. An input configured for startinhibit is open circuit.

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REMThe following chart will enable the user to identify other faults which may occur.

3. FAULT FINDING CHART

Indication Possible Cause Action

Compressor fails to run (1) Pressure transmitter faulty. (1) Adjust to correct setting.off-load. Renew if necessary.

(2) Solenoid bypass/blowdown valve (2) Find cause and rectify orfaulty. renew.

(3) Electrical wiring fault. (3) Find cause and rectify orrenew.

Compressor fails to (1) Solenoid bypass/blowdown valve (1) Rectify/renew valve.run on-load. faulty.

(2) Pressure transmitter faulty. (2) Adjust to correct setting.Renew if necessary.

(3) Electrical wiring fault. (3) Find cause and rectify.

Excessive oil (1) Leaks in oil system. (1) Examine system. Rectify ifconsumption. necessary.

(2) Oil carried into user’spipework caused by:

(a) Reclaimer element (2) (a) Check pressure dropdefective. across element. Renew

element if necessary.(b) Scavenge oil orifice (b) Clean scavenge strainer

adaptor restricted. and orifice adaptor.(c) Incorrect grade of oil. (c) Drain the system, flush and

re-fill with an approved oil.(d) Constant running at high (d) Check/clean enclosure ambient temperature. filter. Improve room

ventilation.(e) Minimum pressure valve (e) Check valve seating. not closing. Renew spring if

necessary.



Indication Possible Cause Action

Low delivery air (1) Pressure transmitter (1) Adjust to correct setting.pressure. incorrectly set or faulty. Renew if necessary.

(2) Pressure relief valve leaking. (2) Check/renew seals.Renew valve if necessary.

(3) Demand exceeds compressor (3) Check for system leaks andrating. rectify. Review user’s air

requirements.(4) Compressor speed reduced (4) Clean panel filters.

owing to high heat sink L120SR only: Check paneltemperature. fan.

Reclaimer pressure does (1) Minimum pressure valve not (1) Check valve seating. Renewnot fall to 4 bar when closing. spring if necessary.compressor runs off-load. (2) Venting valve faulty. (2) Check and renew if

necessary.

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This page is intentionally left blank

LSR Repair Manual – Components


CHAPTER

6COMPONENTS

1. PRIMARY OIL SEPARATOR AND SEPARATOR FILTER ELEMENT(345SR, L45SR)

1.1 Description1.2 Operation2. RECLAIMER (475SR, L75SR, L120SR)2.1 Description (475SR, L75SR2.2 Description (L120SR)2.3 Operation3. MINIMUM PRESSURE VALVE (475SR, L75SR) 3.1 Description3.2 Operation4. MINIMUM PRESSURE VALVE (345SR, L45SR)4.1 Description4.2 Operation5. MINIMUM PRESSURE/NON RETURN VALVE (L120SR)5.1 Description5.2 Operation6. DIFFERENTIAL PRESSURE INDICATOR (L75SR)7. EXCESS PRESSURE SWITCH (L75SR)8. AIR FILTER PRESSURE SWITCH (L45SR and L75SR)9. AIR FILTER PRESSURE SWITCH/INDICATOR (L120SR)10. AIR AND OIL COOLERS (345SR, L45SR)10.1 Air Cooler10.2 Oil Cooler11. AIR/OIL COOLER (475SR, L75SR)11.1 Description11.2 Operation12. AIR COOLER (L120SR)12.1 Description12.2 Operation13. OIL COOLER (L120SR)13.1 Description13.2 Operation14. THERMOSTATIC BYPASS VALVE (L45SR)14.1 Description14.2 Operation

(continued)

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CONTENTS (continued)

15. THERMOSTATIC BYPASS VALVE (Earlier L75SR Models, L120SR)15.1 Description15.2 Operation16. THERMOSTATIC BYPASS VALVE (Later L75SR Models)16.1 Description16.2 Operation17. MOISTURE SEPARATOR (475SR, L75SR, L120SR)18. STRAINERS18.1 Condensate Strainer (L75SR)18.2 Scavenge Strainer (L75SR)19. FILTER MANIFOLD19.1 Description20. OIL STOP VALVE (475SR, L75SR)20.1 Description20.2 Operation21. PRESSURE TRANSMITTER (L45SR, L75SR)21.1 Description21.2 Operation22. SILICON TEMPERATURE SENSOR22.1 Description22.2 Operation23. DRIVE AND FAN MOTOR THERMISTORS23.1 Description23.2 Operation24. DELIVERY NON-RETURN VALVE (475SR, L75SR)24.1 Description24.2 Operation25. BY-PASS VALVE25.1 Description (L45SR, L75SR)25.2 Description (L120SR)25.3 Operation26. INLET NON-RETURN VALVE (345SR, L45SR)26.1 Description26.2 Operation27. INLET NON-RETURN VALVE (L120SR)27.1 Description27.2 Operation28 BEKO DRAIN (L120SR)28.1 Description28.2 Operation29. SCAVENGE NRV ASSEMBLY (L120SR)29.1 Description29.2 Operation



FIGURES

FIG. 6.1 SEPARATOR FILTER ELEMENTFIG. 6.2 RECLAIMER (475SR, L75SR)FIG. 6.3 RECLAIMER (L120SR)FIG. 6.5 MINIMUM PRESSURE VALVE (475SR, L75SR)FIG. 6.4 MINIMUM PRESSURE VALVE (345SR, L45SR)FIG. 6.6 MINIMUM PRESSURE/NON RETURN VALVE (L120SR)FIG. 6.7 DIFFERENTIAL PRESSURE INDICATOR (L75SR)FIG. 6.8 EXCESS PRESSURE SWITCH (L75SR)FIG. 6.9 AIR COOLER (345SR, L45SR)FIG. 6.10 OIL COOLER (345SR, L45SR)FIG. 6.11 AIR/OIL COOLER (475SR, Earlier L75SR Models)FIG. 6.12 AIR/OIL COOLER (Later L75SR Models)FIG. 6.13 AIR AND OIL COOLERS (L120SR)FIG. 6.14 THERMOSTATIC MIXING ARRANGEMENTFIG. 6.15 THERMOSTATIC BYPASS VALVE (L45SR)FIG. 6.16 THERMOSTATIC BYPASS VALVEFIG. 6.17 THERMOSTATIC BYPASS VALVE (LATER L75SR MODELS)FIG. 6.18 MOISTURE SEPARATOR (475SR, L75SR)FIG. 6.19 MOISTURE SEPARATOR (L120SR)FIG. 6.20 FILTER MANIFOLDFIG. 6.21 CONDENSATE STRAINERFIG. 6.22 OIL STOP VALVEFIG. 6.23 PRESSURE TRANSMITTERFIG. 6.24 SILICON TEMPERATURE SENSORFIG. 6.25 NON-RETURN VALVE (475SR, L75SR)FIG. 6.26 BY-PASS VALVEFIG. 6.27 INLET NON-RETURN VALVE (345SR, L45SR)FIG. 6.28 INLET NON-RETURN VALVE (L120SR)FIG. 6.29 BEKO DRAIN (L120SR)FIG. 6.30 SCAVENGE NRV ASSEMBLY (L120SR)

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COMPONENTS

1. PRIMARY OIL SEPARATOR ANDSEPARATOR FILTER ELEMENT(345SR AND L45SR)

1. Filter Body2. Fine Filter Layer3. Supporting Tube4. Second Filter Layer5. Seal Ring

FIG. 6.1 SEPARATOR FILTER ELEMENT

1.1 Description

Primary separation of oil from the air/oil mixturetakes place in the separator vessel which ispositioned between the air-end and aftercooler.

The separator comprises a steel pressure vesselwith a welded cover.

The cover carries the pipe connections for the airand oil pipework and a safety relief valve. An oilfiller pipe and oil level sightglass assembly arefitted to the wall of the separator vessel.

The separator vessel operates in conjunction with aseparator filter element (Fig. 5.3) where finalseparation takes place. The separator element islocated on the manifold block and is fabricated fromlayers of micro fine glass fibre, supported by tubesand protected externally by a perforated steelsheath. A scavenge pipe, located on the undersideof the manifold block, passes through the centre ofthe element which screws into position against amachined face.

1.2 Operation

The air/oil mixture passes from the air-enddischarge pipe into the primary oil separator vesselwhere initial separation takes place by centrifugalforce. Most of the oil is separated at this stage anddrops to the bottom of the vessel.

The remaining air/oil mixture then passes throughtwo separator filter elements where final separationtakes place. The separator element functions withthe principle of coalescence. The micro glass fibrelayers separate the oil droplets which collect in thebottom of the filter and are scavenged back into theair-end through a small diameter pipe

The filtered air then passes from the oil separationelement by way of the minimum pressure/ non-return valve. Provided the air pressure at this stageis above 3.5 to 4·0 bar the air passes through theaftercooler where it is cooled before passing to thedelivery outlet.

If the air pressure in the primary oil separator fallsbelow 3.5 to 4·0 bar the minimum pressure valvewill close. The valve also incorporates a non-returnvalve which operates to prevent delivery airpassing back into the separator when thecompressor is running off-load.

Oil from the bottom of the primary oil separatorflows under pressure to the oil cooler and duringnormal running the oil passes through the cooler tomaintain the correct temperature. A thermostaticbypass valve is installed in the inlet manifold of theoil cooler.

1

2

3

4

5

HW 0275

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FIG. 6.3 RECLAIMER (L120SR)

2. RECLAIMER (475SR, L75SR, L120SR)

1. Pressure Vessel2. Joint3. Cover4. Scavenge Pipe5. Minimum Pressure Valve6. Air Outlet7. Pressure Relief Valve8. Filter Element9. Oil Outlet

10. Air/Oil Inlet11. Oil Reservoir12. Drain Connection13. Oil Level Sight Tube14. Oil Filler15. Excess Pressure Switch

FIG. 6.2 RECLAIMER (475SR, L75SR)

1. Pressure Vessel2. Joint3. Cover4. Scavenge Pipe5. Minimum Pressure Valve6. Air Outlet7. Pressure Relief Valve8. Filter Element9. Oil Outlet

10. Air/Oil Inlet11. Oil Reservoir12. Drain Connection13. Oil Level Sight Tube14. Oil Filler15. Pressure Transducer

5

2

3 4

1

15

6

7

8

9

10

12

13

14

11

HW 0276

54

13

12 HW 0277

3

7

15

11

2

1

8

9

14

10

6



2.1 Description (475SR and L75SR) - fig. 6.2

Separation of oil from the oil/air mixture takes placein the reclaimer which is positioned between theair-end and air/oil cooler.

The reclaimer comprises a steel pressure vessel(1) with a removable cover (3). A filter element (8)is contained within the pressure vessel.

The filter element is fabricated from layers of microfine glass fibre, supported by tubes and protectedexternally by a perforated steel sheath wrapped ina pre-filter element. The element is suspended by aflange from the top of the pressure vessel. Theassembly is sealed with a joint (2) and secured inposition by the cover.

The cover carries the minimum pressure valve (5),scavenge oil pipe (4) and air connections for theregulation system. A drain connection (12), oil filler(14), pressure relief valve (7), oil level sight glass(13) and excess pressure switch (15) are fitted tothe wall of the pressure vessel. The lower portion ofthe pressure vessel forms an oil reservoir (11).

2.2 Description (L120SR) - fig. 6.3

Separation of oil from the oil/air mixture takes placein the reclaimer which is positioned between theair-end and air/oil cooler.

The reclaimer comprises a steel pressure vessel(1) with a removable cover (3). A filter element (8)is contained within the pressure vessel.

The filter element is fabricated from layers of microfine glass fibre, supported by tubes and protectedexternally by a perforated steel sheath wrapped ina pre-filter element. The element is suspended by aflange from the top of the pressure vessel. Theassembly is sealed with a joint (2) which is bondedto the filter element (8) and secured in position bythe cover.

The cover carries the minimum pressure valve (5),scavenge oil pipe (4) and air connections for theregulation system. A drain connection (12), oil filler(14), pressure relief valve (7), oil level sight glass(13) and pressure transducer (5) are fitted to thewall of the pressure vessel. The lower portion of thepressure vessel forms an oil reservoir (11).

2.3 Operation

The air/oil mixture passes from the discharge portof the air-end into the reclaimer inlet (10).Centrifugal primary separation of the oil occurs andmost of the oil droplets fall into the oil reservoir.

The differential pressure between the inside andthe outside of the element causes the remaining oildroplets to pass through the two stages of thereclaimer element where final separation takesplace.

The reclaimer element functions on the principle ofcoalescence. The micro glass fibre layers separatethe small oil droplets from the compressed air/oilmixture to form larger droplets which drain down tocollect inside the bottom of the element. Theaccumulation of oil in the element is returned to theair end through the scavenge system.

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7. Guide Pin8. Spring9. ‘O’ Ring Seal

10. Piston11. Spring12. Valve Body

1. Locknut2. Washer3. Retainer4. ‘O’ Ring5. Valve Head6. ‘O’ Ring Seal

FIG. 6.4 MINIMUM PRESSURE VALVE (345SR, L45SR)

3. MINIMUM PRESSURE VALVE (345SR, L45SR)

3.1 Description

The minimum pressure valve fits inside themanifold block and performs the following mainfunctions:

1. It ensures a rapid pressure build-up in thereclaimer during initial start-up. The minimumpressure valve is held closed until thepressure in the reclaimer reaches 3.5 to 4 bar.

2. It prevents high velocity, low pressure aircarrying over excessive amounts of oil intothe delivery air pipe during start-up.

3. The minimum pressure valve alsoincorporates a non-return valve. This preventspressurised air in the user’s pipework passingback into the reclaimer when the compressorunit stops or runs off-load.

The minimum pressure valve consists of a valvebody (12), valve assembly, and piston (10).

The valve assembly comprises a guide pin (7),valve head (5), retainer (3) and two ‘O’ ring seals(4, 6) secured by a washer (2) and a locknut (1).The guide pin houses a spring (8) and is locatedinside the piston.

The valve head is seated against a face machinedin the manifold block. The piston moves inside thebore of the valve body and two springs (11) forcethe piston against the rear face of the valveassembly. An ‘O’ ring seal (9) fitted to the outsideof the piston prevents any pressure leakage pastthe piston.

The piston and valve assembly move to control theflow of air through the valve.

13 4 5 6 7 8

910

1112

HW 0278

2



3.2 Operation

When the compressor starts, the minimum pressurevalve is held in the closed position by the effect of aspring against the top of the piston and by the faceof the piston holding the valve assembly against theseat. The valve remains closed until the pressure inthe separator vessel reaches a set minimumpressure (3.5 to 4 bar). When the pressure in theseparator vessel overcomes the force exerted bythe two springs, the valve assembly and pistonmove up allowing full air flow past the open valve,through the outlet port and into the main deliverypipe to the aftercooler.

When the compressor off-loads the flow of airceases between the separator vessel and theuser’s pipework. Pressure in the compressorsystem acts to hold the minimum pressure valvepiston in the raised position against the effect of thespring and at the same time the valve spring closesthe non-return valve onto its seat.

When the compressor reverts to on-load running,the valve assembly will stay closed against the seatuntil the pressure in the separator vessel exceedsthe pressure in the user’s pipework. The plungerwill not return to close the outlet until the pressurein the user’s pipework falls below the force of thesprings.

4. MINIMUM PRESSURE VALVE(475SR, L75SR)

1. Piston Housing 9. Retainer2. Outer Piston Spring 10. 'O' Ring3. Inner Piston Spring 11. Body4. Piston 12. Guide Pin5. Valve Head 13. 'O' Ring6. 'O' Ring 14. Spring7. Washer 15. 'O' Ring8. Locknut

FIG. 6.5 MINIMUM PRESSURE VALVE(475SR, L75SR)

4.1 Description

The minimum pressure valve is mounted on thereclaimer cover and performs the followingfunctions:

1. It ensures a rapid pressure build-up in thereclaimer during initial start-up. The minimumpressure valve is held closed until thepressure in the reclaimer reachesapproximately 4 bar.

HW 0279 1

8910

11

7

12

13

14

3

2

4

56

15

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2. It prevents high velocity, low pressure aircarrying over excessive amounts of oil into thedelivery air pipe during start-up.

3. It acts as a non-return valve preventingpressurised air in the user’s pipework passingback into the reclaimer when the compressorunit stops or runs off-load.

The minimum pressure valve consists of a valvebody (11), a valve assembly and a piston housing(1). The valve assembly comprises a piston (4) and'O' ring (13), guide pin (12) and valve spring (14), avalve head (5) with ‘O’ ring seal (10) and retainer(9) secured by a washer (7) and locknut (8). An 'O'ring (6) provides a seal between the valve head andguide pin. The guide pin and spring are locatedinside the piston. The valve head and ‘O’ ring sealoperates against a seat formed in the valve body(11). The piston moves inside the bore of the pistonhousing and two piston springs (2,3) force thepiston against the rear face of the valve assembly.The piston and valve assembly move to control theflow of air through the valve.

A tapped hole in the base of the valve bodyprovides a connection to the differential pressureindicator.

4.2 Operation

When the compressor starts, the minimum pressurevalve is held in the closed position by the pistonsprings. The valve remains closed until the pressurein the reclaimer reaches a set minimum pressure (4bar). When the pressure in the reclaimer overcomesthe force exerted by the two piston springs, thevalve assembly and piston move up allowing full airflow past the open valve, through the outlet port andinto the main delivery pipe to the aftercooler.

When the compressor comes off-load the flow of airceases between the reclaimer and the user’spipework. Downstream pressure in the system actsto hold the minimum pressure valve piston (4) in theraised position against the effect of the pistonsprings and at the same time the valve spring (14)closes the non-return valve head (5) on to its seat.The piston will not return to close the outlet until thepressure in the user’s pipework falls below the setpressure of 4 bar.

When the compressor reverts to on-load running,the valve will stay closed against the seat untilreclaimer pressure again exceeds 4 bar.

5. MINIMUM PRESSURE/NON RETURN VALVE(L120SR)

5.1 Description

The minimum pressure valve is mounted on thereclaimer cover and performs the followingfunctions:

1. It ensures a rapid pressure build-up in thereclaimer during initial start-up. The minimumpressure valve is held closed until thepressure in the reclaimer reachesapproximately 4 bar.

2. It prevents high velocity, low pressure aircarrying over excessive amounts of oil into thedelivery air pipe during start-up.

3. It acts as a non-return valve preventingpressurised air in the user’s pipework passingback into the reclaimer when the compressorunit stops or runs off-load.

The minimum pressure valve consists of a valvebody (8), a valve assembly and a piston housing(1). The valve assembly comprises piston (4), 'O'ring (6) and valve head (5). The valve head stem islocated inside the piston and has a moulded sealwhich operates against a seat formed in the valvebody (8). The piston moves inside the bore of thepiston housing. The piston moves inside the bore ofthe piston housing and two piston springs (2,3)force the piston against the rear face of the valveassembly. The piston and valve assembly move tocontrol the flow of air through the valve.

5.2 Operation

When the compressor starts, the minimum pressurevalve is held in the closed position by the pistonsprings. The valve remains closed until the pressurein the reclaimer reaches a set minimum pressure (4bar). When the pressure in the reclaimer overcomesthe force exerted by the two piston springs, thevalve assembly and piston move up allowing full airflow past the open valve, through the outlet port andinto the main delivery pipe to the aftercooler.

When the compressor comes off-load the flow of airceases between the reclaimer and the user’spipework. Downstream pressure in the system actsto hold the minimum pressure valve piston (4) in theraised position against the effect of the pistonsprings and at the same time the valve head stem



moves out from the piston and the valve headcloses onto its seat to act as a non-return valve.The piston will not return to close the outlet until thepressure in the user’s pipework falls below the setpressure of 4 bar.

When the compressor reverts to on-load running,the valve will stay closed against the seat untilreclaimer pressure again exceeds 4 bar.

6. DIFFERENTIAL PRESSURE INDICATOR(L75SR)

The differential pressure indicator monitors thepressure drop across the reclaimer element. Thescale on the dial of the indicator is divided into twosectors, green and red. As the differential pressureacross the reclaimer element rises the needlemoves across the green sector (0-1 bar range)towards the red sector. If the needle passes into thered sector (1-2 bar range) the differential pressure istoo high indicating that the reclaimer element shouldbe replaced.

The differential pressure indicator is a sealed unitand no attempt should be made to tamper with it. Ifa fault is suspected the complete indicator must bereplaced.

The low pressure inlet port is connected to thedownstream side (inside) of the reclaimer elementvia a tapping in the base of the minimum pressurevalve. The high pressure inlet port is connected tothe upstream side of the element via a tapping inthe wall of the reclaimer pressure vessel.

FIG. 6.6 MINIMUM PRESSURE/NON RETURNVALVE (L120SR)

1. Piston Housing2. Outer Piston Spring3. Inner Piston Spring4. Piston5. Valve Head6. 'O' Ring7. 'O' Ring8. Body9. Bolt10 Washer

1. Body2. Adjusting screw3. Dial4. Low pressure inlet port5. High pressure inlet port6. Mounting holes

FIG. 6.7 DIFFERENTIAL PRESSURE INDICATOR(L75SR)

9,10

1

8

4

6

9

5

3

2

HW 0280

HW 0281

6

3

1

5

4

2

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7. EXCESS PRESSURE SWITCH(L75SR)

The excess pressure switch is a normally closed(N.C.) switch, connected to the primary separatorside of the reclaimer.

If the pressure in the reclaimer exceeds 14 bar theswitch contacts open and a signal from thecontroller stops the compressor. A shutdownmessage ‘High air pressure’ will be displayed onthe control panel.

The switch contacts will close again when thepressure downstream of the switch falls below 14bar and allows the fault to be reset.

8. AIR FILTER PRESSURE SWITCH(L45SR and L75SR)

A pressure switch is fitted to the air intake filter todetect filter element blockage. The switch signalsthe controller to display the warning ‘Change airfilter’ when the differential pressure across the filterexceeds a pre-set value.

9. AIR FILTER PRESSURE SWITCH/INDICATOR (L120SR)

A pressure switch/indicator is fitted to the air intakefilter to detect filter element blockage. The switchsignals the controller to display the warning‘Change air filter’ when the differential pressureacross the filter exceeds a pre-set value.

FIG. 6.8 EXCESS PRESSURE SWITCH(L75SR)

10. AIR AND OIL COOLERS (345SR, L45SR)

10.1 Air Cooler - fig. 6.9

10.1.1 Description

The air cooler cools the dicharge air before itpasses into the main distribution pipework. Thecooler is mounted vertically and comprises a bankof finned tubes, connected to inlet and dischargeheaders, attached to mounting points on the frameadjacent to the air intake panel.

A connection (1) for the inlet air is provided in theupper header whilst a similar discharge connection(2) is fitted in the lower header.

10.1.2 Operation

Compressed air from the reclaimer enters the upperheader of the aftercooler, passes downwardsthrough the finned tubes to the lower header andout into the user's pipework.

The cooling fan runs continuously drawing air inthrough the inlet grilles and through the aftercoolerand then discharging it vertically upwards throughthe oil cooler and some acoustic baffles to theexhaust outlet.

HW 0282

FIG. 6.9 AIR COOLER (345SR, L45SR)

HW 0283

IN

OUT



10.2 Oil Cooler

10.2.1 Description

FIG. 6.10 OIL COOLER (345SR, L45SR)

The oil cooler cools the oil from the separatorvessel before it returns to the air-end via the oilfilter. The cooler comprises a two pass matrix,connected to an inlet and outlet header, mountedhorizontally at the top of the unit. A thermoststicbypass valve is installed in the inlet header.

10.2.2 Operation

Oil from the bottom of the separator vessel flowsunder pressure to the oil cooler and during normalrunning the oil passes through the cooler tomaintain the correct temperature. A thermostaticbypass valve is installed in the inlet manifold of theoil cooler.

When the compressor is started, the cold oil in thesystem bypasses the oil cooler and flows throughthe oil filter directly to the air-end. As the oil and airmixture is compressed by the rotors in the air-end,the temperature of the oil increases.

When the oil has reached its normal operatingtemperature the bypass valve closes and the oil isdirected through the oil cooler. The cooled oil thenflows to the oil filter where it is cleaned beforeentering the air-end.

The cooling fan runs continuously drawing air inthrough the inlet grilles and through the aftercoolerand then discharging it vertically upwards throughthe oil cooler and some acoustic baffles to theexhaust outlet.

Out

In

Thermostat

HW 0284

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HW 0285

18

36

7

45

2

9

11. AIR/OIL COOLER (457SR, L75SR)

11.1 Description

The air/oil cooler cools the discharge air before itpasses into the main distribution pipework and alsocools the oil from the reclaimer before it returns tothe air-end via the oil filter. The cooler sections areseparate and comprise a matrix of cooling tubescarried between inlet and outlet headers which arewelded together and mounted horizontally betweensupports at the top of the compressor. On earliermodels the air cooler section is single pass and theoil section double pass. On later models both theair and oil coolers are single pass.

On earlier models a thermostatic bypass valve isinstalled in the oil inlet header. On later models a3-way thermostatic valve is fitted to the outlet port ofthe reclaimer.

A moisture separator fitted with an automaticcondensate drain is installed between the airsection of the cooler and the discharge connectionto the user’s pipework.

1. Air/Oil Cooler2. Cooling Fan3. Oil Inlet4. Thermostatic Bypass Valve5. Cooler Matrix6. Oil Outlet7. Air inlet8. Air Outlet9. Moisture Separator

Cooling is provided by a cooling fan, comprising afan and motor assembly, attached to a cowl andsupport plate and secured to the underside of the oilcooler.

11.2 Operation

Compressed air from the reclaimer enters the airsection of the inlet header of the cooler, passesthrough the finned tubes to the outlet header,through the moisture separator and out into theuser’s pipework. Separated moisture collects in themoisture separator, passes to the automaticcondensate drain and is expelled via the baseframeconnection and drain pipe.

On earlier models oil from the reclaimer enters theoil section of the cooler header and makes adouble pass through the cooling matrix back intothe header before passing to the air-end via thefilter. On later models oil from the reclaimer entersthe cooler oil section via a 3-way thermostatic valveand makes a single pass through the cooling matrixto the air-end via the filter.

FIG. 6.11 AIR/OIL COOLER (475SR, Earlier L75SR Models))



HW 0286

18

3

7

5

2

4

6

FIG. 6.12 AIR/OIL COOLER (Later L75SR Models)

On earlier models When the compressor is startedfrom cold, the thermostatic valve allows the cold oilin the system to by-pass the cooler and flowdirectly through the oil filter to the air-end. Once theoil has reached its normal operating temperaturethe by-pass valve directs the oil through the cooler.

On Later models, when the compressor is startedthe 3-way thermostatic valve allows the cold oil inthe system to by-pass the cooler and flow directlythrough the oil filters to the air-end. Once the oilhas reached its normal operating temperature thethermostatic valve directs the oil to the oil coolersection header.

The cooling fan runs continuously, drawing airthrough the inlet grille and discharging it verticallyupwards through the air/oil cooler and an array ofacoustic baffles to the exhaust outlet.

1. Air/Oil Cooler2. Cooling Fan3. Oil Inlet4. Moisture Separator5. Cooler Matrix6. Oil Outlet7. Air inlet8. Air Outlet

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12. AIR COOLER (L120SR)

12.1 Description

The air cooler cools the discharge air before itpasses into the main distribution pipework. Thecooler comprises a matrix of cooling tubes carriedbetween inlet and outlet headers which are weldedtogether and mounted vertically between coolersupports at the cooling air inlet end of thecompressor. It is a single pass cooler.

A moisture separator is fitted with a pipe that takesthe condensate to the Beko no loss drain. It isinstalled between the outlet of the air cooler and thedischarge connection to the User's pipework.

Cooling is provided by a cooling fan comprising afan and motor assembly inside a cowl, situatedcentrally inside the machine.

FIG. 6.13 AIR AND OIL COOLERS (L120SR)

1. Air In2. Oil Inlet3. Air Out4. Oil Outlet

5. Air Cooler6. Oil Cooler7. Moisture Separator8. Thermostatic Bypass Valve

1

2



12.2 Operation

Compressed air from the reclaimer enters the airsection of the inlet header of the cooler and passesthrough finned tubes to the outlet header, throughthe moisture separator and then out to the User'spipework.

Separated moisture collects in the moistureseparator, passes to the Beko no loss drain and isexpelled via the connection in the cooler endcolumn.

The cooling fan runs continuously, drawing airthrough the inlet grilles and discharging it verticallyupwards through the exhaust duct.

13. OIL COOLER (L120SR)

13.1 Description

The oil cooler cools the oil from the reclaimerbefore returning it to the air end via the oil filter.

The cooler comprises a matrix of cooling tubescarried between inlet and outlet headers which arewelded together. These are mounted verticallyunderneath the air cooler, between the coolersupports at the cooling air inlet end of thecompressor.

It is a single pass cooler with a bypass pipemounted between inlet and outlet headers. Athermostatic valve is installed in the oil outletheader which is controlled by the temperature ofthe mixed oil outlet.

Cooling is provided by a cooling fan comprising afan and motor assembly inside a cowl, situatedcentrally inside the machine.

13.2 Operation

Oil from the reclaimer enters the oil cooler andpasses through the cooler matrix back into theheader before passing to the air end via the oilfilters.

When the compressor is started from cold all of theoil flows through the bypass pipe and out throughthe oil filters to the air end.

As the temperature increases to 55°C thethermostatic valve will begin to open allowing someoil to flow through the cooler and some through thebypass pipe. When the oil temperature reaches68°C all of the oil will flow through the cooler

FIG. 6.14 THERMOSTATIC MIXINGARRANGEMENT

OIL INOIL OUT

OIL COOLER

THERMOSTATICVALVE

HW 0288

CompAir


14. THERMOSTATIC BYPASS VALVE(L45SR Models Not Having ExternalThermostat)

14.1 Description

The oil cooler is equipped with a thermostaticbypass valve which allows the oil in the system toreach operating temperature rapidly. The valve isinstalled in the inlet connection of the cooler headerand is held closed when the oil is cold. The cold oilbypasses the cooler tube block until the operatingtemperature (70°C) is reached.

The thermostatic bypass valve consists of theoperating element (7), thrust pin (8), valve housing(5) and spring (4). The operating element is asealed capsule containing wax into which isinserted the thrust pin. The valve body (3) isattached to the operating element. When the oil iscold the valve is held in position by the spring (4).Oil enters the valve through the inlet (1) and leavesby way of the bypass manifold (2).

14.2 Operation

When the temperature of the oil increases to the setpoint of the thermostat, the expansion of the meltingwax in the capsule forces the thrust pin out of thecapsule and moves the valve body (3) to close theoutlet to the bypass manifold (2) and open the inletto the cooler manifold (6). The hot oil is thendirected through the cooler tube block. A cap (9),installed in the cooler header, holds the valve inposition and allows access for servicing purposes.

FIG. 6.15 THERMOSTATIC BYPASS VALVE (L45SR)

1. Inlet2. Bypass Manifold3. Valve Body4. Spring5. Valve Housing

6. Cooler Inlet Manifold7. Operating Element8. Thrust Pin9. Cap



15. THERMOSTATIC BY-PASS VALVE(Earlier L75SR and all L120SR Models)

15.1 Description

The thermostatic by-pass valve comprises theoperating element (5), thrust pin (6), valve housing(2) and spring (3). The operating element is asealed capsule containing wax into which isinserted the thrust pin. The valve body (4) isattached to the operating element.

A cap (7) holds the valve in position in the coolerheader and allows access for servicing purposes.

FIG. 6.16 THERMOSTATIC BY-PASS VALVE

15.2 Operation

When the oil is cold the valve is held in position bythe spring (3). Oil enters the valve through theinlet (1) and leaves by way of the by-pass manifoldport (9).

When the temperature of the oil increases to theset point of the thermostat, the expansion of themelting wax in the capsule forces the thrust pin outof the capsule and moves the valve body (4) toclose the port to the by-pass manifold (9) and openthe port to the cooler manifold (10). The hot oil isthen directed through the cooler tube block.

1. Inlet2. Valve Housing3. Spring4. Valve Body5. Operating Element6. Thrust Pin7. Cap8. 'O' Ring9. By-pass Manifold Port

10. Cooler Manifold Port

16. THERMOSTATIC BYPASS VALVE(Later L45SR and L75SR Models)

16.1 Description

The thermostatic bypass valve is a fully automaticthree-way fluid temperature controller. The valve isconnected upstream of the oil cooler to allow the oilsystem to reach normal operating temperaturerapidly. The valve is closed when the compressor isstarted and the oil is cold. The cold oil bypasses thecooler until the normal operating temperature (70°C)is reached.The thermostatic bypass valve consists of the valvebody (6), cover (1), operating element (3), housing(7), inner and outer springs (4) and ‘0’ ring seals (8).The operating element is a sealed capsulecontaining wax which, together with the spring, iscontained within the brass housing. The upper partof the housing is flanged and is retained in the valvebody by the cover. The lower part is free to moveinside the valve body.

16.2 Operation

When the oil is cold, the valve is held in the bypassposition by the springs. Oil enters the valve throughthe inlet and leaves by way of the bypass outlet.When the temperature of the oil increases to the setpoint of the thermostatic valve, the expansion of themelting wax in the operating element causes thelower part of the housing to move away from theupper part, allowing the hot oil to flow through theoutlet to the coolers.

��yy

��yyyy��

98 10 3

17 5 4 2116

HW 0291

CompAir


FIG. 6.17 THERMOSTATIC BYPASS VALVE (LATER L45SR AND L75SR MODELS)

1. Cover2. Bypass Outlet3. Operating Element4. Inner and Outer Springs5. Inlet from Reclaimer

6. Valve Body7. Housing8. 'O' Ring seals9. Outlet to Cooler

1

2

3

4

5

6

7

8

8

9

HW 0298



17. MOISTURE SEPARATOR(475SR, L75SR, L120SR)

1. Housing2. Inlet Port3. Impinger Cone4. Bowl5. Spinner6. Outlet Port

FIG. 6.18 MOISTURE SEPARATOR(475SR, L75SR)

L75SR and L120SR compressors are equippedwith a moisture separator to remove contaminationfrom the delivery air. The moisture separator isinstalled in the delivery air pipe, downstream of theaftercooler.

Moisture held in suspension in the delivery air isremoved from the compressed air passing throughthe moisture separator by mechanical separation.

The moisture separator used on L120SR machinesis shown in FIG. 6.19.

The moisture separator uses the principles ofcentrifugal force, impingement separation, andlaminar and turbulent flow.

The condensate collects in the bottom of thehousing and is released automatically through asolenoid valve operated drain connected to thebowl (L75SR) or through a Beko no-loss drain(L120SR).

FIG. 6.19 MOISTURE SEPARATOR (L120SR)

HW 0300

CompAir


Oilfromcooler

Oil toair end

Air to air cooler

Oil Scavengereturn to Air Endand NRV

Air/oil inlet

3

56

1

8

2

7

4

1. Control Air Isolating Valve2. Unloader Solenoid Valve3. Minimum Pressure Valve4. Separator Filter - Qty 2 on L45SR

5. Differential Pressure Gauge (primary position)6. Differential Pressure Gauge (secondary position)7. Oil Filter8. Oil Drain Valve

HW 0301

19. FILTER MANIFOLD

FIG. 6.20 FILTER MANIFOLD

19.1 Description

A cast aluminium filter manifold is screwed to thebulkhead panel to provide ease of maintenance forthe serviceable components.

The manifold is ported and machined to provide ahousing for the separator filters, oil filter, scavengepipe, minimum pressure valve and differentialpressure gauge.

Primary and secondary connections are providedfor the gauge which measures the differentialpressure across the separator filter element.

Pipework connections are provided for the air/oilinlet and the air outlet from the separator element,oil filter inlet and outlet, unloader solenoid valve andscavenge oil return to the air-end.

18. STRAINERS

18.1 Condensate Strainer (L75SR)

A 'Y' type strainer is fitted in the condensate drainline between the moisture separator and thesolenoid operated condensate drain valve, toprevent blockage of the valve.

The strainer consists of a body (1), screen (2) andcap (3). The removable screen is made of a finewire mesh held in position by machined recesses inthe body and cap.

Condensate from the moisture separator enters thestrainer body and passes through the screen beforepassing to the drain valve.

The screen filters out any large particles whichthen collect in the lower part of the body. The cap isremovable to allow the screen to be cleaned orreplaced.

18.2 Scavenge Strainer (L75SR)

A simple gauze disc strainer is installed in thescavenge line between the reclaimer and theair-end to provide protection for the air-endcomponents and to prevent blockage of thescavenge restrictor orifice. The screen removesany solid particles from the oil being scavengedfrom the bottom of the reclaimer element before itenters the air-end.



20.1 Description

The purpose of the oil stop valve is to prevent anyoil entering the air-end when the compressor isstopped.

The oil stop valve is fitted at the oil inlet to the air-end and comprises a valve body (1) and cover (2),incorporating a diaphragm assembly (3), spindle (6)and valve head (5). The valve head is fitted with areturn spring (4) and operates against a seat (7) inthe valve body.

20.2 Operation

Discharge air pressure from the air-end acts on thediaphragm to open the oil stop valve against thespring during start up and holds it open while thecompressor is running. When the compressor stopsthis pressure falls to zero allowing the return springto close the valve.

FIG. 6.21 CONDENSATE STRAINER

1. Body 2. Screen 3. Cap

20. OIL STOP VALVE (475SR, L75SR)

1. Valve Body2. Cover3. Diaphragm Assembly4. Spring5. Valve Head6. Spindle7. Seat

6.22 OIL STOP VALVE (475SR, L75SR

1 32

4 5 7

6

HW 0303

CompAir


21.1 Description

The air pressure in the user’s pipework iscontinuously monitored by a 4-20 mA pressuretransmitter which converts the pressure into anelectrical signal.

21.2 Operation

The transmitter converts air pressure into a linearchange of electrical current flowing in the two powersupply wires to the transmitter. Typically, thecurrent will change from 4 mA at zero bar to 20 mAat 13·8 bar (L45SR, L75SR) or 4 mA at zero bar to20 mA at 16 bar (L120SR).

21. PRESSURE TRANSMITTER (L45SR, L75SR)

FIG. 6.23 PRESSURE TRANSMITTER

The controller detects the current flowing in thepower supply wires to the transmitter and convertsthis into a pressure reading.

The controller can recognise an ‘out of range’signal if the current is less than 4 or greater than20mA. This will be displayed as a pressure probefault.

Refer to the table in chapter 8 para. 6.0

4-20 mA PRESSURETRANSMITTER

1

2

4 to 20mA

+

-

X02-1 24V D.C.

0V D.C.

X02-2

CONTROLLER

DETECTIONCIRCUITRY

HW 0304



22. SILICON TEMPERATURE SENSOR

22.1 Description

A silicon temperature sensor of the ‘spreadingresistance’ type is installed in the air-end adjacentto the delivery port. The sensor protects thecompressor unit against excessive dischargetemperature by sensing the temperature of thecompressed air/oil mixture discharged from the air-end. The resistance of the sensor increases withtemperature

22.2 Operation

The resistance of the temperature sensor isprocessed within the controller and displayed as anair/oil temperature reading. A high oil temperaturewarning and/or compressor shut-down is activatedif the temperature of the air/oil mixture reaches thetrip setting.

FIG. 6.24 SILICON TEMPERATURE SENSOR

1. Probe2. Body3. Electrical Connectors

7. Locknut8. Retainer9. 'O' Ring

10. Guide Pin11. Spring

FIG. 6.25 NON-RETURN VALVE(475SR, L75SR)

23. DRIVE AND FAN MOTOR THERMISTORS

From June 2002 L45SR, L75SR do not have fanthermistors fitted. All L120SR models do nothave fan thermistors.

23.1 Description

The drive and fan motors are each equipped withthermistors of the PTC type which are buried in thewindings to protect the compressor against motorover-temperature.

23.2 Operation

If the temperature of the coil windings exceeds aset temperature, the resistance of the thermistorwill increase sharply. The sudden increase inresistance will be detected by the controller,causing the compressor to shut down and display amotor fault.

24. DELIVERY NON-RETURN VALVE(475SR, L75SR)

1. Body2. Cover3. 'O' Ring4. Valve Head5. 'O' Ring6. Washer

1

2

3

S

HW 0305

HW 0306

1

789 6

10

11

3

2

45

CompAir


1. Body2. Inlet Port3. Valve4. Spring5. Solenoid Coil6. 'O' Ring (not illustrated)

FIG. 6.26 BY-PASS VALVE

24.1 Description

The non-return valve is mounted on the dischargeoutlet of the air-end. Its function is to isolate the air-end from reclaimer pressure when the compressoris stopped. This prevents oil from being blown backthrough the air-end after stopping and ensures thatthe air end always re-starts in the unloadedcondition.

The non-return valve consists of a valve body (1)and cover (2) sealed by an 'O' ring (6) and a valveassembly. The valve assembly comprises a guidepin (10) and spring (11), a valve head (4) with 'O'ring seal (9) and retainer (8), secured by a washer(6) and locknut (7). An 'O' ring (5) provides a sealbetween the valve head and the guide pin. Twostuds secure the flange of the discharge pipe.

24.2 Operation

When the compressor is running and the pressurein the reclaimer is below the discharge pressure ofthe air-end the non-return valve is held open. Whenthe discharge pressure of the air-end falls, acondition is reached where pressure on each sideof the non-return valve is the same. The valvespring will then lift the valve head and close itagainst the seat. Reclaimer pressure will hold thevalve closed until air-end pressure rises toovercome the effect of reclaimer pressure and thevalve spring.

25. BY-PASS VALVE

25.1 Description (L45SR, L75SR)

The by-pass valve comprises a valve body (1),valve (3), solenoid coil (5), spring (4) and ‘O’ Ringseal (6). The function of the valve is to re-circulateair produced by the air-end when the compressor isrunning off-load at minimum speed. The by-passvalve is a solenoid operated, normally open, valvemounted on the air-end inlet connector (L75SR) oron the intake NRV (L45SR). The inlet port (2) islinked to the reclaimer cover by a pipe.

25.2 Description (L120SR)

The by-pass valve comprises a valve body (1),valve (3), solenoid coil (5), spring (4) and ‘O’ Ringseal (6). The function of the valve is to re-circulateair produced by the air-end when the compressor isrunning off-load at minimum speed. The by-passvalve is a solenoid operated, normally open, valvemounted on the reclaimer lid. The outet port islinked to the non-return valve by a flexible hose.

25.3 Operation

During normal running, when the delivery pressureis below the programmed off-load pressure, thesolenoid is energised and the by-pass valve is heldclosed. If delivery pressure rises above the offloadpressure the valve solenoid is de-energised andthe by-pass valve is opened. Delivered air volumethen falls to zero.

If delivery pressure falls below the target pressurethe solenoid is energised allowing delivered airvolume to rise and reclaimer pressure to build upagain towards the target pressure.



26. INLET NON-RETURN VALVE(345SR, L45SR)

FIG. 6.27 INLET NON-RETURN VALVE(345SR, L45SR)

26.1 Description

The non-return valve is mounted on the air-endinlet and secured by four screws. A pipe connectedto the air intake filter is secured to the top of thevalve by a clip.

The inlet non-return valve consists of a valve body(1) with an integral seat (2) and a valve assembly.The valve assembly comprises a valve head (3),spring (6) and a valve stem (5) with retaining bar(4). The retaining bar secures the valve assemblyto the valve body using two screws.

26.2 Operation

When the compressor starts the depressioncreated by the turning rotors causes a partialvacuum at the intake which lifts the valve head offthe seat against the light load of the spring. Thisallows air to be drawn through the air-end topressurise the separator vessel.

4. Retaining Bar5. Valve Stem6. Spring

1. Body2. Valve Seat3. Valve Head

FIG. 6.28 INLET NON-RETURN VALVE (L120SR)

1. Body2. Air Inlet Valve3. Stem4. Bush5. Spring

6. Washer7. Nut8. Washer9. Plug

When the compressor is stopped the valve headreturns to its seat and prevents the air/oil mixturefrom blowing back through the air intake.

27. INLET NON-RETURN VALVE (L120SR)

27.1 Description

The non-return valve is mounted on the air end inletand secured by 4 screws. A pipe connected to theair intake filter is secured to the inlet of the valvewith a jubilee clip.

The inlet non-return valve consists of a body (1)with an integral seat and a valve assemblycomprising a valve head (2), valve stem (3) andspring (5). The valve stem is secured to the body byan external domed nut (7).

27.2 Operation

See section 26.1.

1

3

2

5

6

7

984

HW 0309

CompAir


28. BEKO DRAIN (L120SR)

28.1 Description

FIG. 6.29 BEKO DRAIN (L120SR)

The Beko drain is positioned by the delivery sidecooler column. A pipe from the moisture separatoris connected to the inlet of the drain. A pipe from theoutlet of the drain is then connected to thedischarge end column via a bulkhead couplingwhich is the customer’s condensate connection.

28.2 Operation

The condensate accumulates in the container. Acapacitive sensor registers when the container istotally filled. It then passes a signal to the electroniccontrol within the valve to activate. The pilot valve isactivated which opens the diaphragm on the outletline. Every time the condensate is discharged thetime the valve is opened is calculated exactly toensure minimum compressed air wastage.

29. SCAVENGE NRV ASSEMBLY (L120SR)

FIG. 6.30 SCAVENGE NRV ASSEMBLY(L120SR)

29.1 Description

The scavenge NRV assemble is located in the lid ofthe reclaimer. It consists of a scavenge pipe braisedto a coupling with a steel ball placed within thecoupling and then a scavenge NRV swivel elbowscrewed into the top of the coupling.

29.2 Operation

When the machine is running the ball inside thescavenge moves up in the coupling and acts as arestrictor to the scavenge line but allows the oil toflow back down in to the air-end. Upon stopping ofthe compressor the ball drops down and acts as anNRV to the oil in the scavenge line.

HW 0311

HW 0312

LSR Repair Manual – Maintenance


CHAPTER

7MAINTENANCE

1. MAINTENANCE SCHEDULE1.1 Service Kit Part Numbers1.2 Oil Drain Kit (475SR, L75SR, L120SR)2. MAINTENANCE PROCEDURES2.1 Enclosure Filter2.2 Control Panel Filter2.3 Air Intake Filter2.4 Oil Separator Filters (345SR, L45SR)2.5 Reclaimer (475SR, L75SR, L120SR)2.6 Reclaimer Element (475SR, L75SR, L120SR)2.7 Scavenge Strainer (475SR, L75SR if fitted)2.8 Automatic Condensate Drain (475SR, L75SR)2.9 Oil System2.10 Minimum Pressure Valve2.11 Oil Cooler and Aftercooler2.12 Flexible Hoses2.13 Scavenge Tube2.14 Electrical System2.15 Electric Motors2.16 Non-return Valve

FIGURESFIG. 7.1 GENERAL ARRANGEMENT AND SERVICING POINTS (345SR, L45SR)FIG. 7.2 GENERAL ARRANGEMENT AND SERVICING POINTS (475SR, L75SR)FIG. 7.3 GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

CompAir


1. MAINTENANCE SCHEDULE

Regular maintenance should be carried out by your local CompAir distributor as detailed in the MaintenanceSchedule. The Schedule should be used as a general guide only.

Item Action

Weekly

Oil System Check oil level. Top up if necessary.Separator/Reclaimer Element(s) Check element(s). Renew if:

(345SR, L45SR) - pressure differential exceeds 1 bar.(475SR, L75SR) - indicator in red zone.(L120SR) - message on screen.

Aftercooler/Oil cooler/Control Panel Check condition of pre-filters and clean as necessary.

Minor Service – Every 2000 hours or 6 months (whichever is sooner)

Minor Service Use correct Service kit for model.Oil System Check oil level/top up.Blowdown System Check operation.Electrical Wiring Check connections and condition.Drain Solenoid Valve Check operation (475SR, L75SR only).Control Panel Check connectionsAftercooler and Oil Cooler Clean externallyOil Filter Renew Oil Filter.Air Filter Renew Air Filter (345SR, L45SR, 475SR, L75SR).Electrical Cabinet Filters Check and clean heatsink ducting if necessary.

Interim Service – Every 4000 hours or 1 year (whichever is sooner)

Service Carry out Minor Service.Oil system Change oil.Separator Filters Renew Separator Filters/Reclaimer Element.Air Filter (L120SR) Renew Air Filter.

MAINTENANCE



Major Service – Every 8000 hours or 2 years (whichever is sooner)

Major Service Use correct Major Service Kit for modelService Carry out Interim Service.Minimum Pressure Valve Service valve (not L120SR).Non-return valve Service valve (not L120SR).Motor Drive Check condition of flexible coupling inserts. Fit new inserts

if necessary.Air Pipe Couplings Renew ‘O’ rings.Condensate Auto Drain Valve Service valve. (L120SR only).Blowdown Valve Renew.Scavenge Tube Renew.

1.1 Service Kit Part Numbers

MODEL Minor Service Kit Interim Service Kit Major Service Kit(2000 hrs or 6 mths) (4000 hrs or 1 yr) (8000 hrs or 2 yrs)

345SR, L45SR CK2003 - 2 98262-223 (2) CK8003 - 4

475SR, L75SR CK2004 - 2 CK6004 - 197 CK8004 - 5

L120SR CK2007 - 1 CK6007-1 CK8007-1

1.2 Oil Drain Kit (457SR, L75SR)

Part number C27399-173

CompAir


1. Oil Cooler2. Cooling Fan3. Intake Air Filter4. Non-return Valve5. Cyclon 3 Air-end6. SR Drive® Motor7. Separator Element8. Oil Filter9. Air Delivery Connection

10. Minimum Pressure Valve

FIG. 7.1 GENERAL ARRANGEMENT AND SERVICING POINTS (345SR, L45SR)

11. Aftercooler12. Inlet Air Flow13. Inlet Air Baffle14. Inlet Air Pre-filter15. Primary Separator16. Control Panel17. Pressure Relief Valve18. Oil Filler Cap19. Cooling Air Exhaust Flow20. Exhaust Air Baffle21. Control Panel Filter



FIG. 7.2 GENERAL ARRANGEMENT AND SERVICING POINTS (475SR, L75SR)

11. SR Drive® Motor12. Cooling Air Inlet13. Cooling Fan14. Moisture Separator15. Air Delivery Connection16. Air and Oil Cooler17. Exhaust Air Baffles18. Control Panel19. Control Panel Filter

1. Oil Filters2. Minimum Pressure Valve3. Air/Oil Separator4. Pressure Relief Valve5. Oil Filler Cap6. Intake Air Filter7. Oil Sight Tube8. Air-End Intake9. Oil Drain Valve

10. Air-End

CompAir


FIG. 7.3 GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

1. Exhaust Duct2. Inlet/Non-Return Valve3. Aftercooler4. Oil Filters5. Safety Valve6. Oil Cooler7. Moisture Separator8. Condensate Drain Valve9. Air End

10. Drive Coupling Access11. SR Drive® Motor12. Power Converter

Cabinet Filters

13. Minimum Pressure Valve14. Blowdown Solenoid Valve15. Cooling Fan16. Control Panel17. Intake Air Filter18. Fork Lift Points19. Oil Filler20. Air/Oil Separator21. Oil Level Sight Glass22. Oil Drain23. Cooling Air Inlet Grille

1 23

4

5

6

7

8

9

1011

12

HW 0016

13 14 15

16

17

18192021

22

23



1. Close the shut-off valve to the user’spipework.

2. Switch the power supply ‘OFF’ at theisolator.

3. Ensure that the blowdown system hasoperated to release all pressure from thereclaimer.

Check that the pressure gauge registerszero. Release any remaining pressure fromthe delivery side of the reclaimer elementby slackening the pipe connection to thedifferential pressure switch at the reclaimerend. Release any residual pressure fromthe upstream side of the reclaimer elementby slowly slackening the oil filler plug onthe reclaimer. Tighten the plug.

WARNING

! Refer to the safety procedures beforecarrying out any maintenance orservicing work on the compressor unit.


! Before opening the door of the powerconverter compartment switch thepower supply OFF at isolator and waitfor 12 minutes to allow the DC linkcapacitors discharge to a safe level.Check that the dc link capacitors havefully discharged before starting work onthe compressor.

! Where a maintenance procedure belowincludes the warning ‘The compressormust be stopped’ the following stepsmust be taken before work iscommenced:

2.1 Enclosure Filter

The compressor is provided with a coarse screenfilter which acts as a pre-filter for the intake air.

Carry out a regular check on the condition of thepre-filter and if necessary remove the material fromthe enclosure and wash in a mild detergent solutionbefore refitting.

2.2 Control Panel Filter

Filters are provided to clean the cooling air for thepower electronic circuits. These should be cleanedat specific intervals or before scheduled if ‘Heatsink temp high’ is displayed.

2.3 Air Intake Filter

Clean intake air is essential for satisfactoryoperation of the unit. Any ingress of unfiltered airwill result in a reduction in the service life of theseparator element.

Particular care should be taken during routineservicing to ensure that unfiltered air cannot bypassthe air intake filter element via unsound joints anddefective trunking, etc.

L120SR only

A visual indicator is fitted which shows the conditionof the filter. In dirty conditions this may indicate areduction in element life.

2. MAINTENANCE PROCEDURES

CompAir


2.3.1 To Change the Air Filter Element:

The compressor must be stopped.

1. Remove the side panel or open the hingeddoor (according to model) to gain access tothe intake air filter.

2. Remove the clips from the air intake filter andwithdraw the element.

3. Clean out the inside of the filter body

3. Fit the new element , secure the clips and refitthe side panel or close the door.

2.4 Oil Separator Filters (345SR, L45SR)

The separator filter has a nominal service life of4000 hours under normal operating conditions.

Adverse operating conditions or failure to carry outregular maintenance and/or correct operatingprocedures will affect the service life of theelement.

2.4.1 To Check the Differential Pressure acrossthe Separator Filters

1. Ensure the compressor is running at workingpressure and temperature.

2. Open the access door to the service area.

3. Note the reading on the pressure gauge(s)fitted to the manifold block.

4. 345SR models: Using the bayonet fitting,change the pressure gauge over to the fittingon the other side of the manifold block andnote reading.

5. If the pressure difference exceeds 1 barrenew the separator filters.

2.4.2 To Change the Separator Filters:


1. Open the door to the service area to gainaccess to the manifold block.

Note: Models 345SR and L45SR have twoseparate filters both of which must bechanged at the same time.

2. Unscrew the old separator filters from themanifold block and discard the filters andsealing rings.

3. Apply a light film of oil to the seal of the newfilters.

4. To fit the new filters, screw into the manifoldblock until the gasket contacts the sealingsurface. Then tighten a further 1/3 turn.

5. Close the service area door.

1 Manifold block2 Pressure gauges3 Separator filters4 Oil filter

5 Plug6 Oil drain valve7 Control air

isolating valve

FIG. 7.4 MANIFOLD BLOCK AND FITTINGS(345SR, L45SR)

1 2

3

4

5

HW 0046

6

7



2.5 Reclaimer (475SR, L75SR, L120SR)

Condensate will collect in the reclaimer as thecompressor cools after shut-down and should bedrained off at the intervals specified in theSchedule. Draining the condensate must be carriedout only when the compressor is cold.

CAUTION: Regular draining of condensate fromthe reclaimer is essential in order to avoid oilcontamination and eventual problems in the user’ssystem

2.5.1 To Drain the Condensate


To drain the condensate from the reclaimer, slowlycrack open the reclaimer drain point (1) untilcondensate starts to flow out. As soon as the flowbecomes clear oil, close off the drain.

If the compressor is operating in conditions of highhumidity experience may show that it is necessaryto drain the condensate more frequently thanspecified.

2.6 Reclaimer Element (475SR, L75SR andL120SR)

A filter element within the reclaimer recovers oilcarried in the delivery air before it is passed to theaftercooler and the user’s pipework. The elementhas a maximum service life of 8000 hours. Thisfigure is based on ideal operating conditions and ifconditions are not ideal it will be necessary tochange the element more frequently.

The service life of the element can be prolonged bycarrying out regular maintenance and correctoperational procedures, but must always bechanged after 8000 hours.

2.6.1 To Check the Differential Pressure Acrossthe Reclaimer.

475SR, L75SR

1. Ensure the compressor is running at workingpressure and temperature.

2. Open the hinged access door.

3. The needle of the Differential Pressureindicator should be in the green zone of thescale.

4. If the needle is in the red zone, renew thereclaimer element.

NB. At service intervals the controller will display‘Check Reclaimer DP’ warning which will be resetwhen the service hours are reset.

L120SR

A lamp lights on the panel and the message‘Change separator’ is displayed when the reclaimerelement is blocked.

2.6.2 To Change the Reclaimer Element


1. Open the hinged access doors and/or roofpanel to gain access to the reclaimer.

2. Drain the oil from the reclaimer. Thisprocedure is described under 2.9.5 ‘NormalOil Change’.

3. Disconnect all pipes from the reclaimer cover.Disconnect and withdraw the scavenge pipe.

FIG. 7.5 RECLAIMER CONDENSATE DRAIN

1HW 0017

CompAir


4. Disconnect couplings and remove the airdischarge pipe from the minimum pressurevalve.

5. Release the reclaimer cover securing boltsand remove the cover. If necessary, use threeof the cover bolts in the jacking holes andtighten down to break the seal. Withdraw thereclaimer element. Discard the old joint andelement.

The element may be withdrawn through theaccess panel in the roof.

L120SR: One bolt may be loosened and leftin position and used to hinge the cover.

Discard the old joint and element.

6. Inspect the underside of the reclaimer cover.The cover has been treated and should be ingood condition. If not, remove any loose paintor rust by shot blasting or wire brushtreatment to leave a clean, oil free surface.Apply one coat of zinc phosphate paint,ensuring complete coverage to a minimumthickness of 0·1 mm (0.004”). Allow to drythoroughly.

7. Fit the new element and joint and replace thecover (the L120SR joint is glued to theelement). Replace all the reclaimer coverbolts and tighten by hand to position the jointcorrectly.

8. Tighten the bolts evenly, following thetightening sequence, to an initial torque of110 Nm / 81 ft.lbf. Check the ‘O’ ring

9. Tighten the bolts, following the tighteningsequence, to a final torque of 160 Nm / 118ft.lbf (475SR, LS75SR) or 200Nm / 148 ft.lbf(L120SR).

FIG. 7.8 RELAIMER COVER BOLTTIGHTENING SEQUENCE

(475SR, L75SR)FIG. 7.7 RECLAIMER ELEMENT

1. Scavenge pipe2. Air discharge pipe3. Minimum pressure valve4. Cover5. Jacking holes

FIG. 7.6 OIL RECLAIMER

1

2

3

4

5 HW 0018

HW 0313



FIG. 7.9 RECLAIMER COVER BOLTTIGHTENING SEQUENCE (L120SR)

10. Insert the scavenge pipe through the couplingin the reclaimer cover and lower it carefullyuntil it contacts the base of the element.Withdraw the pipe a distance of 3 mm (1/

8”)

and tighten the coupling. The couplings arefixed length on the L120SR model.

11. Re-connect the pipes to the reclaimer cover.Fit new ‘O’ rings to delivery pipe joints andretighten the bolts to 100 Nm / 74 ft.lbf.

12. Refill the compressor with new oil by followingthe procedures under 2.9.5 ‘Normal OilChange’.

13. Close the access doors and refit theenclosure panels.

CAUTION: When the compressor has reachednormal operating temperature, re-tighten the boltsto the correct torque in the sequence shown.

2.7 Scavenge Strainer (475SR, L75SR)

If the scavenge strainer becomes restricted orblocked it may cause oil to be carried over into theuser’s pipework. It is most important that thestrainer is regularly serviced to allow the scavengesystem to operate correctly.

2.7.1 To Clean the Scavenge Strainer


1. Remove the scavenge strainer.

2. Remove the strainer screen and clean itthoroughly, using a proprietary cleaning agent.

3. Refit the clean strainer screen.

2.8 Automatic Condensate Drain (475SR,L75SR, L120SR)

Moisture in the delivery air condenses in theaftercooler or moisture separator and is drainedautomatically by the action of a solenoid operatedvalve (L75SR) or level control valve ((L120SR).

2.8.1 To Check the Operation of the CondensateDrain Valve (475SR, L75SR)


Disconnect the users condensate drain connectionat the baseframe and connect a length of tubing tothe base frame connection. Run the tubing to asuitable container and visually check thatcondensate is being released automatically fromthe solenoid operated drain valve according to the‘drain open’ and ‘drain shut’ times set at thecontroller.

If no condensate is being released check theelectrical circuit and the solenoid valve asdescribed in the ‘Electrical’ section of the manual.Dispose of any condensate in accordance withlocal regulations. Reconnect the condensate drainline to the compressor.

The L120SR model displays a level controlled faultsignal on the panel if the valve is not functioningcorrectly. Maintenance should be carried out by aCompAir Distributor.

1

2

3

45

6

7

8

9

10

11

12

13

14

15

16

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CompAir


2.9 Oil System

2.9.1 Recommended Oil

The compressor is factory filled with CompAir4000 HR Oil or CompAir FG Lubricant.

1. CompAir 4000 HR OilThis is a high performance oil with excellentlubrication and cooling characteristicsformulated to maintain internal cleanliness,reduce the build-up of deposits on filterelements and extend component life.

2. CompAir FG LubricantA synthetic hydrocarbon based lubricantwhich has been specially developed for usewhere discharge air may come into contactwith foodstuffs or for reasons of health orenvironment. CompAir FG Lubricant meetsthe requirements of FDA regulation 21 CFR178.3570 and is USDA H-1 approved.

The local CompAir distributor will assist in theselection of an appropriate lubricant and in manycases will also be able to arrange for regularsampling of the oil to monitor the condition of thecompressor, and to determine the oil changeintervals to ensure optimum performance.

2.9.2 To Check the Oil Level: (345SR, L45SR)

To view the oil level sightglass (1), remove the sidepanel.

When stopped the mimimum level is indicatedwhen the sightglass is less than half full. Themaximum level is indicated when the sightglass isfull and the oil reaches the bottom threads in thefiller neck.

When running on-load the minimum level isindicated when oil is no longer visible in thesightglass.

FIG. 7.10 CHECKING OIL LEVEL(345SR, L45SR)

If necessary top up the separator with oil as follows:


1. Remove the side panel.

2. Unscrew the filler plug (2).

3. Fill to the correct level with CompAir approvedlubricant.

4. Refit the filler plug and tighten by hand.

5. Refit side panel.

1

2

HW 0022

WARNING

● Risk of injury from hot oil under pressure.



CAUTION: Always use the correct grade of oil anddo not mix oils of different types.

2.9.3 To Check the Oil Level (475SR, Tornado 75,L75SR, L120SR)

With the compressor shut down, the minimum oillevel is indicated when the level is just visible in theoil level tube on the reclaimer. The maximum levelis indicated when the level reaches the top of the oillevel tube.


Note: Check the oil level with the compressor cold.Allow a minimum of 30 minutes after stopping forthe oil in the system to settle.

1. Open the enclosure to gain access to thereclaimer.

2. Check the oil level tube (1). If the oil surfaceis not visible it is too low.

FIG. 7.11 CHECKING OIL LEVEL(475SR, L75SR, L120SR)

3. If topping up is required, ensure that thereclaimer pressure is zero, remove the oil fillerplug (2) and fill the reclaimer withrecommended oil to the correct level.

4. Replace the oil filler plug, making sure thatthe ‘O’ ring is undamaged and the plug fullytight.

2.9.4 To Change the Oil Filter:


1. Open the door to the service area or open theenclosure according to model.

2. Unscrew the old oil filter(s) (3) from themanifold block or filter housing and discard.

FIG. 7.12 OIL FILTERS (L75SR, L120SR)

3. Apply a light film of oil to the seal of the newelement(s) and prime the new filter(s) with oil.

4. To fit the new element, screw it into themanifold block or filter housing until the gasketcontacts the sealing surface. Then tighten afurther 1/3 turn.

5. Close the service area door.

6. Check oil level during initial run and top up ifnecessary.

3

HW 0024

3 Oil filters

1

2

HW 0023

1. Sight glass2. Filler plug

CompAir


2.9.5 Normal Oil Change


1. CompAir 4000 HR OilProvided the air-end discharge temperaturedoes not normally exceed 85°C CompAir4000 HR Oil should be changed every 4000hours service or 1 year, whichever is sooner.

Where the air-end discharge temperatureregularly exceeds 85°C then a change periodof 2000 Hours or 6 months is recommended.

2. CompAir FG LubricantProvided the air-end discharge temperaturedoes not regularly exceed 85°C CompAir FGLubricant should be changed every 4000hours service or 1 year, whichever is sooner.

Where the air-end discharge temperatureregularly exceeds 85°C then a change periodof 2000 Hours or 6 months is recommended.

Note: Where high dust levels and/or pollution arepresent the oil must be changed more frequentlyand the condition of the intake filtration systemexamined regularly.

2.9.6 To Change the Oil and Oil Filter: (345SR, L45SR)

To drain the oil, the system must (a) be pressurisedor (b) an alternative source of compressed air mustbe available.


Method (a)

1. Run the compressor on load to pressurise thesystem.

2. Open the door to the service area.

3. Close the control air isolating valve (7), fittedto the side of the manifold block (lever to thevertical position) and the isolating valve in theuser's system.

Note: A minimum of 4 bar (60 psi) must bemaintained in the compressor unit prior to carryingout the oil drain procedure.

FIG. 7.13 MANIFOLD BLOCK AND FITTINGS(345SR, Tornado 45, L45SR)

4. Stop the compressor. Wait until the motor hasstopped rotating before proceeding.

5. Remove the drain tap plug (5) and connect ahose (minimum 10 mm/ 3/8” bore) to the draintap (6) and place the open end into a suitablecontainer.

6. Slowly open the drain tap and allow the oil todrain into the container for disposal.

7. Close the drain tap, disconnect the hose, andremove the container. Refit the drain tap plug.

8. Open the control air isolating valve (7) (leverto the horizontal position) and allow anypressure to be released through the normalblowdown process.

1 Manifold block2 Pressure gauges3 Separator filters4 Oil filter

5 Plug6 Oil drain valve7 Control air

isolating valve

1 2

3

4

5

HW 0046

6

7

WARNING




9. Remove and discard the old oil filter element(4).

10. Prime the new filter with oil.

11. Apply a film of clean oil to the seal of a newoil filter element. Screw the element into thehousing until it contacts the gasket andtighten a further 1/3 turn.

12. Fill the separator to the correct level withCompAir approved lubricant, refit the filler capand tighten by hand.

13. Open the isolating valve to the user's system.

14. Run the compressor until it reaches workingtemperature to ensure full circulation of the oil.

15. Check the oil level and top up as necessary.

Method (b)

1. Open the door to the service area.

2. Close the control air isolating valve, fitted tothe side of the manifold block (lever to thevertical position) and the isolating valve in theuser's system.

3. Ensure that all pressure has been releasedfrom the oil separator, remove the filler plugand fit a suitable connector to the neck of thefiller pipe for the air supply.

4. Apply pressure to the compressor unit(minimum of 4 bar or 60 psi).

5. Remove the plug and connect a hose(minimum 10 mm / 3/8” bore) to the drain tapand place the open end into a suitablecontainer.


7. Close the drain tap, disconnect the hose andremove the container. Refit the drain tap plug.

8. Close the air supply through the filler tube,open the control air isolating valve (lever tothe horizontol position) and allow anypressure to be released through the normalblowdown process.

9. Remove the air supply and fitting from thefiller tube.

10. Remove and discard the old oil filter element(4).

11. Prime the new filter with oil.

12. Apply a film of clean oil to the seal of a newoil filter element. Screw the element into thehousing until it contacts the gasket andtighten a further 1/3 turn.

13. Fill the separator to the correct level withCompAir approved lubricant, refit the filler capand tighten by hand.

14. Open the isolating valve to the user’s system.


16. Check the oil level and top up as necessary.

WARNING


CompAir


5. Remove the plug and connect the Oil DrainPipe Kit and a hose (minimum 15 mm / 5/8”bore) to the drain tap and place the open endinto a suitable container.


FIG. 7.15 OIL DRAIN TAP(475SR, L75SR)

7. Close the reclaimer drain tap, disconnect theOil Drain Pipe Kit and hose, remove thecontainer and refit the plug.

8. Open the control air isolating valve and allowany pressure to be released through thenormal blowdown process.

9. Remove and discard the old oil filterelements.

10. Apply a film of clean oil to the seal of a newoil filter elements. Screw the elements into thehousing until they contact the gasket andtighten a further 1/

3 turn.

11. Fill the reclaimer to the correct level withCompAir approved lubricant, refit the filler capand tighten securely.



14. Stop the compressor, check the oil level andtop up as necessary.

To Change the Oil and Oil Filter: (475SR, L75SR)

To drain the oil, the system must be pressurised.



1. Open the door to the service area

2. Close the control air isolating valve (fitted tothe top of the reclaimer) (fitted on the top ofthe air-end).

FIG. 7.14 CONTROL AIR ISOLATING VALVE(475SR, L75SR)

3. Run the compressor for a short time topressurise the reclaimer to a minimum of 4bar (60 psi) prior to carrying out the oil drainprocedure. Stop the compressor and close theisolating valve between the compressor andthe user system.

4. Ensure that the reclaimer drain tap is closed.

WARNING


1HW 0017

1

HW 0026

2

3

1. Control air isolating valve2. Air end3. Intake air filter



To Change the Oil and Oil Filter: L120SR

To drain the oil, it is recommended that the systembe pressurised. However, the L120SR may be alsodrained under gravity.



3. The oil may be drained under pressure or bygravity. To drain under pressure, run thecompressor up to 7 bar/102 lbf/in2 and stop.Immediately open access door and closehand valve adjacent to blowdown (seeillustration), then proceed as for gravity drain.Beware of hot surfaces. Beware of hotpressurised oil. On completion, openblowdown hand valve.

FIG. 7.16 CONTROL AIR ISOLATING VALVE(L120SR)

1. Open the door to the service area

2. Close the control air isolating valve (paintedred and fitted to the top of the reclaimer).

6. Close the reclaimer and cooler drain taps,replace the hoses and remove the container.

7. Open the control air isolating valve and allowany pressure to be released through thenormal blowdown process.

8. Remove and discard the old oil filterelements.

9. Apply a film of clean oil to the seal of the newoil filter elements. Screw the elements into thehousing until they contact the gasket andtighten a further 1/

3 turn.

10. Fill the reclaimer to the correct level withCompAir approved lubricant, refit the filler capand tighten securely.



13. Stop the compressor, check the oil level andtop up as necessary.

4. Ensure that the reclaimer and oil cooler draintaps are closed.

5. Put reclaimer and cooler drain hoses into acontainer, open taps and allow oil to drain.

WARNING


1

HW 0025

1. Reclaimer oil drain2. Oil cooler drain

FIG. 7.17 OIL DRAIN POINTS (L120SR)

1

2

HW 0027

CompAir


2.9.6 To Change the Oil Type

No special precautions are required when changingfrom a detergent mineral oil to CompAir 4000 HROil or CompAir FG Lubricant or changing withinthese grades. The system should be drained andrefilled as described under 2.9.5 ‘Normal OilChange’.

2.10 Minimum Pressure Valve

The servicing of the Minimum Pressure Valveshould be carried out by a CompAir Distributor.(See Section 9.)

2.11 Oil Cooler and Aftercooler

To Clean Coolers Externally

The condition of the cooler fins must be checkedregularly. To clean the fins proceed as follows:Thecompressor must be stopped

1. Allow the compressor to cool for 30 minutes.

2. 345SR, L45SR:

Open enclosure service door and removeaccess panel on cooling duct. Removeenclosure panel in front of coolers.

Clean the cooler fins from inside the ductusing an air hose and oil-free compressed airfrom inside the machine.

If it is required to wash the coolers, they mustfirst be removed from the machine.

3. 475SR, L75SR:

Clean cooler fins with an air hose as follows:

(a) Ensure power is isolated and locked off.

(b) Remove fan guard and use low pressureair to clean coolers from inside themachine.

(c) Replace fan guard.

(d) Replace panels.

If it is required to wash the coolers, they mustfirst be removed from the machine.

4. L120SR: Clean cooler fins using low pressureair or water as follows.

(a) Remove cooler end panel and both sidepanels.

(b) Open access doors as necessary andclean coolers from inside the plant usinglow pressure air (up to 2 bar / 29 lbf/in2) orwater. Don not use excessive pressure ascooler tubes may be damaged.

5. Remove any dirt or liquid from the baseframe.

6. Replace access and enclosure panels andclose door(s).

The servicing of the Oil and After Coolers should becarried out by a CompAir Distributor.(See section 9.)

2.12 Flexible Hoses

When fitting flexible hoses the nuts should betightened using the torque appropriate to the nutsizes.

BSP Size Torque

0.5 in 44 Nm/32 ft.lbf0.75 in 84 Nm/62 ft.lbf1.0 in 115 Nm/85 ft.lbf1.25 in 189 Nm/139 ft.lbf1.5 in 244 Nm/180 ft.lbf2.0 in 297 Nm/219 ft.lbf

2.13 Scavenge Tube

The translucent tube should be changed at the8000 hour service interval.



2.14 Electrical System

! Refer to the safety procedures beforeoperating the compressor unit.


! Before opening the door of the powerconverter compartment, switch thepower supply OFF at isolator and waitfor 12 minutes to allow the dc linkcapacitors to discharge to a safe level.Check that the dc link capacitors havefully discharged before starting work onthe compressor.

Carefully inspect all the electrical wiring and checkthe security of all connections and terminals

WARNING

2.15 Electric Motors

2.15.1 Motor Bearings

The main drive motor and cooling fan motor arefitted with sealed bearings which are doubleshielded and pre-packed with grease. Thesebearings do not require periodic re-lubrication butshould be renewed after 32000 hours of operationin normal environments.

Note: This work should be carried out by aCompAir distributor. (See section 9.)

2.15.2 Motor Cooling

Ensure that the motor cooling intake grille is keptclear of debris at all times.

2.16 Non-Return Valve

The servicing of the Non-Return Valve should becarried out by a CompAir Distributor.(See section 9.)

CompAir




LSR Repair Manual – Electrical Systems

CHAPTER

8ELECTRICAL SYSTEMS AND FAULT DIAGNOSIS

CONTROL SYSTEM1. CONTROLLERELECTRICAL SYSTEM1. REMOTE CONTROL AND MONITORING CONNECTIONS1.1 Inputs1.2 Configurable Input Functions1.3 Outputs1.4 Configurable Output Functions1.5 4–20mA Compressor Speed Output1.6 RS485 CommunicationsFAULT DIAGNOSIS1. TEST EQUIPMENT1.1 Test Meter1.2 Clip-on Ammeter1.3 Insulation Tester1.4 DC Voltage Generator1.5 IGBT Tester1.6 Slave Air Supply1.7 Inductance Tester2. CAGE-CLAMP SCREWLESS TERMINALS2.1 Cable Connection or Removal 3. POWER SUPPLIES3.1 To Check the 24V ac Supply Circuits3.2 To Check the Main Power Supply4. CONTROL INPUTS4.1 To Check the Air Filter Differential Pressure Switch 4.2 To Check the Emergency Stop Circuit5. CONTROL OUTPUTS5.1 Relay Output (connector XO8)6. SENSORS6.1 To Check the Pressure Sensor 6.2 To Check the Air/oil Temperature Sensors

Continued

CompAir


Contents (Continued)

7. CONTROLLER7.1 Application Control Program IC7.2 Motor Drive Program IC7.3 FPGA Data IC8. SR FAULT LOCATION8.1 SR Current Sensor Fault8.2 SR Motor High Temperature Fault8.3 SR Motor Overcurrent8.4 DC Link High Voltage Fault8.5 DC Link Low Voltage Fault8.6 SR Position Sensor Fault8.7 SR Motor Overspeed Fault8.8 SR Motor Stall Fault8.9 DC Link Charge Fault8.10 Heatsink Temperature Sensor Fault8.11 Heatsink High Temperature Fault8.12 Main Contactor Fault8.13 SR Control Power Fault8.14 Internal Comms Fault8.15 SR PCB Internal Fault8.16 Start Inhibit8.17 SR Fault Location Charts9. SR TEST PROCEDURES9.1 Diode Device Test Procedures9.2 IGBT (Insulated Gate Bipolar Transistor)9.2.1 Dual IGBT (Insulated Gate Bipolar Transistor)9.2.2 Latest Semikron IGBTs9.2.3 IGBT Removal and Fitting Instructions9.3 Electrolytic Capacitor Test Procedures9.3.1 Electrolytic Capacitor Test9.3.2 Electrolytic Capacitor Measurement9.3.3 Capacitor Removal and Refiiting Instructions9.4 To Check Capacitor Bank Voltage Imbalance 9.5 To Check Capacitor Bank Balance Resistors9.6 To Check VDR/Resistor Board (L45SR and L75SR)9.7 To Check the SR Motor 9.7.1 Motor Insulation Test9.7.2 Motor Inductance Test


LSR Repair Manual – Control System

Contents (Continued)

FIGURESFIG. 8.1 CONTROL PANELFIG. 8.2-8.4 ELECTRICAL CONNECTION DIAGRAM 345SR, L45SRFIG. 8.5-8.7 ELECTRICAL CONNECTION DIAGRAM 475SR, L75SRFIG. 8.8-8.10 ELECTRICAL CONNECTION DIAGRAM L45SR WITH POWER FAIL RELAYFIG. 8.11-8.13 ELECTRICAL CONNECTION DIAGRAM L75SR WITH POWER FAIL RELAYFIG. 8.14-8.17 ELECTRICAL CONNECTION DIAGRAM L120SRFIG. 8.18 CABLE CONNECTION OR REMOVALFIG. 8.19 AIR FILTER INDICATOR SWITCH (L120SR)FIG. 8.20 MEASURING THE PRESSURE SENSOR CURRENTFIG. 8.21 PRESSURE SENSOR OUTPUT TABLEFIG. 8.22 TEMPERATURE SENSOR RESISTANCE TABLEFIG. 8.23 ARRANGEMENT OF CONTROLLER CARDSFIG. 8.24-8.25 SR CURRENT SENSOR FAULTFIG. 8.26 SR MOTOR OVERCURRENT FAULTFIG. 8.27-28 DC LINK HIGH VOLTAGE FAULTFIG. 8.29-30 DC LINK LOW VOLTAGE FAULTFIG. 8.31 SR MOTOR STALL FAULTFIG. 8.32 DC LINK CHARGE FAULTFIG. 8.33 CONNECTING TESTER TO IGBT TYPE GALFIG. 8.34 CONNECTING TESTER TO IGBT TYPE GARFIG. 8.35 CIRCUIT OF IGBT TYPE GALFIG. 8.36 CIRCUIT OF IGBT TYPE GALFIG. 8.37 L45SR POWER CONVERTER ASSEMBLYFIG. 8.38 L75SR POWER CONVERTER ASSEMBLYFIG. 8.39 L120SR POWER CONVERTER ASSEMBLY

CompAir


CONTROL SYSTEM

1. CONTROLLER

The microprocessor based compressor controller andthe SR Drive® controller are housed in a singlecontrol unit which also contains the operator keypadand displays. The control unit is mounted on thedoor of the control panel.

A gate drive board isolates the microelectronics inthe control unit from the power electronic circuits andprovides monitoring and protection for the fourinsulated gate bi-polar transistor (IGBT) powerswitches. The IGBTs are used to turn the motorphases on and off and, in conjunction with theelectronic controller, to control the motor phasecurrent and in turn the torque and speed of the SRmotor.

1. Bar Units Indicator2. Psi Units Indicator3. Delivery Pressure Display4. Status and Message

Display5. Plus6. Minus7. Up8. Down9. Enter

10. Mimic Diagram11. Intake Filter Change Lamp

12. High DeliveryTemperature Lamp

13. Reclaimer ElementCheck Lamp

14. Excess Pressure Lamp15. Emergency Stop16. Auto Restart Legend17. Remote Control Legend18. Remote Control Lamp19. Auto Restart Lamp20. Power on Lamp21. Fan Motor Overload

Lamp

22. Power Converter FaultLamp

23. Main Motor Fault Lamp24. Reset25. Hours26. Reset Lamp27. Data View28. Service29. Service Lamp30. Stop31. Start

FIG. 8.1 CONTROL PANEL

BarPSI

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

16171819202122232425262728293031

HW 0012


LSR Repair Manual – Electrical System

1. REMOTE CONTROL AND MONITORINGCONNECTIONS

Three remote input options and three (five onL120SR) remote output options are available. Thecable connections required are shown as brokenlines on the controller digital inputs and outputs onthe electrical connection diagrams on pages 40 to66.

1.1 Inputs

CAUTION: Do not connect any input terminal pin toa voltage source other than X3/1 as this will result inpermanent damage to the module.

Each of the three inputs is activated by connectingthe appropriate terminal pin to the input terminal X3/1.

This can be achieved by connecting the input pinand the common terminal to a volt free remoteswitch, relay contact, PLC output or any switchingdevice.

Note: Remote input cables must be at least 1.0 mm2

in size. The maximum cable length from thecompressor to a remote device must not exceed 800metres.

1.1.1 The function of some digital inputs areconfigurable. These are:

Input X01/6 Message: ‘Remote Fault 1’ unlessPressure Range Select selected

Input X01/7 Message: ‘Remote Fault 2’ unlessRemote Start/Stop selected

Input X01/4 Message: ‘Remote Fault 3’

The functions available are defined below and maybe selected using the Remote Control Config menuwithin the Commissioning Config Menu.

Default functions are assigned to each input andsome functions are only available on specifiedinputs.

1.2 Configurable Input Functions

1.2.1 Pressure Range Select

This is available on input X01/6 only and is thedefault function for this input.

Connecting to the pressure range select inputenables the selection of a secondary set of Targetand Off-load pressure set points. Using a suitableexternal timer this input can be used to vary theoperating pressure of the compressor at differenttimes. This facility enables energy savings to bemade during periods when a lower compressed airnetwork pressure can be used.

1.2.2 Remote Start/Stop

This is available on input X01/7 only and is thedefault function for this input.

ELECTRICAL SYSTEM

! Refer to the safety procedures beforeoperating the compressor unit.

! Lethal voltages are used in thisequipment. Use extreme caution whencarrying out electrical checks. Isolatethe power supply before starting anymaintenance work.

! Before opening the door of the powerconverter compartment, switch thepower supply OFF at isolator and waitfor 12 minutes to allow the dc linkcapacitors to discharge to a safe level.Check that the dc link capacitors havefully discharged before starting work onthe compressor.

WARNING

Note: Any work on the electrical system should be carried out by a CompAir Distributor

CompAir


When this function is selected an open connectionon this input will cause a remote stop and a link isnecessary for keypad start. However the RemoteStart function is by default disabled and needs to beenabled (separate menu item) for the remote startfunction to operate.

With Remote Start enabled, the keypad start buttonis disabled and needs to be enabled (separate menuitem) for the remote start function to operate. WithRemote Start enabled, the keypad start button isdisabled and a closing contact on this input willcause a machine start.

Also note that selecting another function for thisinput will automatically disable the Remote Start andRemote Stop functions; an open connection will notcause a stop.

1.2.3 Trip Type 1

An open connection will cause a trip at all times.

1.2.4 Trip Type 2

An open connection will cause a trip when the motoris running.

1.2.5 Trip Type 3

An open connection will cause a trip when status is‘Onload’ or ‘Offload’.

1.2.6 Alarm Type 1

An open connection will cause an alarm at all times.

1.2.7 Alarm Type 2

An open connection will cause an alarm when themotor is running.

1.2.8 Alarm Type 3

An open connection will cause an alarm when statusis ‘Onload’ or ‘Offload’.

1.2.9 Start Inhibit

Will prevent a compressor from starting when a faultis sensed but will not stop a compressor if alreadystarted. When activated the display will show ‘StartInhibited’. This function is not a shutdown trip oralarm and will only function while the connection isopen. It is not recorded in the Fault History log.

1.3 Outputs

1.3.1 Configurable Outputs

(a) Outputs on pins X09/2, 3 & 4These three configurable outputs are transistorswitched and only suitable for driving low current(50mA each max) 24v DC devices. A DC interfacerelay must be used (see 1.3.2)

(b) Outputs on pins X08/5 & 6 and X08/9 & 10(L120SR only)These two additional outputs are relay outputsproviding a normally open contact only. Note,therefore, that some functions (e. g. Group Trip) areenergised for healthy and the relay will present aclosed contact for OK.

As supplied, these contacts are connected to the24v AC ancillary equipment system supply and aresuitable for driving 24v AC devices subject to thetotal load on the transformer. It is, therefore,recommended that 24v AC interface relays are usedconnected between X08/6 or X08/10 and terminalX1/1.

If VOLT FREE contacts are required for use with anexternally supplied device, then the power supplylink between X08/5 or X08/9 and terminal X2/1MUST be removed. The external monitor should beconnected directly to the appropriate contact pair(X08/5 & 6 or X08/9 & 10). Contacts are rated at250V AC 8A.

1.3.2 Output Relays

The outputs are 24v dc transistor switched with amaximum rating of 25mA and an interface relaymust be used. Each output must be connecteddirectly to a relay module, as specified below, inorder to achieve a relay contact output suitable forremote applications external to the compressorstarter enclosure.

Parts required for each additional output:

Qty Description Part Number

1 Relay - 24 V dc 98475-64

1 Relay Base 98475-65



1.4 Configurable Output Functions

1.4.1 Group Fault

This is the default for output X09/2.

A group fault output will be energised when power isapplied and no alarm or trip conditions are detected.

The output will de-energise when an alarm includingservice due, a shutdown trip or power loss occurs.

1.4.2 Available

This is the default for output X09/3

A compressor available output will energise whenthe compressor is ‘running’ or in the ‘standby’ state.This output indicates that the compressor has beenstarted and is available to automatically respond toa fall in system pressure without manualintervention.

1.4.3 Group Alarm

A group alarm output will be energised when poweris applied and no alarm condition is detected. Theoutput will de-energise when an alarm or power lossoccurs.

1.4.6 Group Alarm + Trip

A group trip + alarm output will be energised whenpower is applied and no alarm or trip conditions aredetected.

The output will de-energise when an alarm excludingservice due, a shutdown trip or power loss occurs.

1.4.7 Running

A running output will energise when the compressormain motor is running.

1.4.8 On Load

The on load output will energise when thecompressor is on load.

1.4.9 Low Temperature Alarm

A Low Temperature Alarm output will energise whenthe Low Temperature Alarm is active.

1.5 4 - 20mA Compressor Speed Output

An output is provided to enable remote monitoring ofcompressor speed. The output range is from 4mA(0 rev/min) to 20mA (5000 rev/min).

1.6 RS485 Communications

The SureScan control unit is compatible with theelectrical RS485 communications standard. Thecommunication parameters are: 9600 baud, 8 data bits, no parity and 1 stop bit.

The message protocol is a proprietary multimasterprotocol compatible with the SmartAir Air SystemsControl Units and with the Active Network Interfacefor connection to PCs etc.

1.4.4 Group Trip

This is the default for output X09/4A group trip output will be energised when power isapplied and no trip conditions are detected.

The output will de-energise when a shutdown trip orpower loss occurs.

1.4.5 Service Due

The service due output will energise when theservice hours countdown timer has reached zerohours and a routine service is due.

1.3.3 Relay Specification

Single switching contact with a common, normallyopen (N/O) and normally closed (N/C) connectionrated at 250V - 5 Amps maximum.

Note: The relay 24V dc coil is not bi-directional andmust be connected to controller output as follows :

1. Relay terminal ‘5’ must be connected to pinX09/1.

2. Relay terminal ‘1’ must be connected to pinX09/2, 3 or 4 as appropriate.

The functions available are defined below and maybe selected using the Remote Control Config menuwithin the Commissioning Config Menu.

Default functions are assigned to each output. Aninterface relay must be used with these outputs -see following diagrams for connection information.

Com

pAir

Ch

apter 8, p

age 8

AC

20160-1822, Issue 1, Novem

ber 2002

FIG

. 8.2 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- 345SR

, L45S

R (1 O

F 3)

HW 032

MCB2

NO NC< > <1/06>

<1/06> <1/07> <3/15>

MCB1

NO NC< > <1/09>

<1/09>

RLA

NO NC<1/11 > <1/24><1/11> < > <1/11><1/26>

RLB

NO NC<1/14 > <1/14> <1/15>< >

R

M1013~(E)

0V(E)

50VA24V

0V

T101280VA

400V

200VA

30VA24V

0V

24V

0V

2AF1

3.15A

5AF2

F3

RESISTOR/VDRP.C.B

C5C1

(E)

24V

0V

24V

0V

24

0V

CUR

GATE DRIVE BOARD

TEMP SENSHEATSINK

LINK

SENS

POWER SWITCHING ASSY

C8

B1A1

C4

A2 B2

A1B2 B1A2

22

5

4M102

(E)

<3/

15>

<3/

15>

T1 T2

1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106)

NOTES:-

[PK] = PINK

WHERE [R] = RED; [BL] = BLUE; [BK] = BLACK,2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]

[G/Y] = GREEN/YELLOW; [CR] = CLEAR;

[BK](113) [R](128)

[R](127)

[BK](114) [R](123)

(111B)

[R](124)

(125) [R]

(126D) [R]

[R](133)

[R](132)

[R](131)

[BK

](1

10A

)M

CB

2 10

A

MC

B1

3A

[BK

](1

13)

[BK

](1

12A

)

(111

A)

[BK

]

OM CUSTOMERSCOMING SUPPLY

USED ISOLATOR

V

PE

W

U

(103) [BK]

(102) [BK]

[BK](101)

[BK

]

[BK](112B)[BK]

(110B)[BK]

(114

)

RLB

[BK]

(115

)

RLC

(117

)

(116

)

[BK](106)

(105)[BK]

[BK

](1

07)

[BK](104) F5 150A

F6 150A

F7 150A

(108)

(ON HEATSINK)

[BK]

(109) [BK]

[BK

](1

09)

[BK

](1

08)

(107) [BK]

STARTER BOX

SAFETY GUARD

BASE FRAME

GATE DRIVE P.C.B

CAPACITOR TRAYHEATSINK

2/02

[G/Y]

[G/Y][G/Y][G/Y]

DOOREARTHBAR

[G/Y][R]

[R]

[R]

[R]

[R](128)

[R](133)2/02

2/02

[R](126)

[R](132)

[R](124)

[R](131)

[R](139) 2/02

2/02

2/02

2/02

2/02

(140

)

[R]

(144

)

RLA

(126

A)

(126

B)

RLA

RLA

RLB

[R]

(139

)[R

]

(138

)[R

]

(141)(142)

(149)(148)R101

(134

)

(135

)

(137

)[B

L]

(136

)[B

L]

(ON HEATSINK)

(143)

(152

)

(150

)(1

51)

(153

)

(158

)

(156

)(1

57)

(155

)

(154

)

(161

)

(160

)(1

59)

2/03

2/03

(B1)

(A1)

(B2)

(A2)

X1/1

X1/1 X1/1

(126E)

1 2 3 4 5

11

23

2

1234567

1 2 3 4 51 2 3 4 5 1 2 3 4 5

G E C G E C G E CG E C

E

AC

20160-1822, Issue 1, Novem

ber 2002C

hap

ter 8, pag

e 9

LSR

Repair M

anual – Electrical S

ystems

FIG

. 8.3 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- 345SR

, L45S

R (2 O

F 3) 0V~

CONTROLLER

X22

X23SR

E)

24V~

0V~

24V~

4V~

0V~

X20

X21 X08

X1/1 X1/1

RELAY OUTPUTCONTROLLER

X03CONTROLLER

DIGITAL OUTPUT

X09

<1/34>39) [R]

<1/34>[R]26)

[R]

4

34

34

34

34

34

34

[R](132)

[R](128)

[R](133)

4[R](131)

[R](124)

(210

A)

(210

B)

(210

C)

(210

E)

S20

1/1

[R]

[R]

[R]

(211

)R

LC

Y20

2

R1

X2/1 X2/1 X2/1

R2 R3 R4 R5

[R]

[R]

[R]

(139

)

(126

C)

(126

F)

[R]

[R]

(213

)

AC1AC2

~

1

4

22

1 2 3 4 5 6 7 8 9 10 1 2 3 4

2

1 2 3 4

PI/98/697aRLC

NO NC<1/06>


NOTES:-

WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,

2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]

[G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PIN

Com

pAir

Ch

apter 8, p

age 10

AC

20160-1822, Issue 1, Novem

ber 2002

FIG

. 8.4 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- 345SR

, L45S

R (3 O

F 3) HW 0330

CONTROLLERDIGITAL INPUTS

CONTROLLERANALOG INPUTS

VCONT CONT1 CONT2 CONT3 CONT4

X01 X02

CONT5 CONT6 CONT7 CONT81 2

VA+1

ANA12

ANA23

ANA34

ANA45

VA-6 EE

(E) (E)

3 4 5 6 7 8 9

X3/120V-

X3/1 X3/1 X3/1 X3/1 X3/1 X3/1

S20

1/2

S30

2

MC

B2

P30

1

R30

1

(309

)

(301

E)

(301

C)

(310

)

(311

)

(312

)

(313

)

(303

)

(302

)

(301

)

(301

B)

(301

D)

X3/1

T1

T2

1

2

[BL]

(301

A)

[BL]

[BL]

[BL]

[BL]

[BL]

[BL]

[BL]

[BK

]

[CR

]

[BK

]

[CR

]

[BL]

(301

E)

[BL]

<1/

06>

<1/

07>


NOTES:-

[PK]=PINK.

WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]

[G/Y]=GREEN/YELLOW, [CR]=CLEAR,

AC

20160-1822, Issue 1, Novem

ber 2002C

hap

ter 8, pag

e 11

LSR

Repair M


ystems

FIG

. 8.5 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- 475SR

, L75S

R (1 O

F 3)

HW 033

MCB2

<3/15> <1/07> <1/06>

< > <1/06> NCNO

MCB1

<1/09>< > <1/09>

NCNO

RLA NO NC<1/11 > <1/24><1/11> < > <1/11><1/26>

R

M1013~(E)

0V(E)

50VA24V

0V

T101280VA

400V

200VA

30VA24V

0V

24V

0V

2AF1

3.15A

5AF2

F3

RESISTOR/VDRP.C.B

C6

C1

(E)

24

0V

24

0V

24

0V

CUR

GATE DRIVE BOARD

TEMP SENSHEATSINK

LINK

SENS

POWER SWITCHING ASSY

C10

B1A1

C5

A2 B2

A2B1 B2A1

22

5

E

4M102

(E)

<3/

15>

<3/

15>

T1 T2


NOTES:-

WHERE [R] = RED; [BL] = BLUE; [BK] = BLACK,2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]

[G/Y] = GREEN/YELLOW; [CR] = CLEAR;

[BK](113) [R](128)

[R](127)

[BK](114) [R](123)

(111B)

[R](124)

(125) [R]

(126D) [R]

[R](133)

[R](132)

[R](131)

[BK

](1

10A

)M

CB

2 10

A

MC

B1

3A

[BK

](1

13)

[BK

](1

12A

)

(111

A)

[BK

]

FR

OM

CU

ST

OM

FU

SE

D IS

OLA

TO

V

PE

W

U

(103) [BK]

(102) [BK]

[ ]( )

[BK

][BK]

(112B)[BK]

(110B)[BK]

(114

)

RLB

[BK]

(115

)

RLC

(117

)

(116

)

[BK](106)

(105) [BK]

[BK

](1

07)

[ ]( )

F6 180A

F7 180A

(108)

(ON HEATSINK)

[BK]

(109) [BK]

[BK

](1

09)

[BK

](1

08)

( ) [ ]

STARTER BOX

SAFETY GUARD

BASE FRAME

GATE DRIVE P.C.B

CAPACITOR TRAYHEATSINK

2/02

[G/Y]

[G/Y][G/Y][G/Y]

DOOR

EARTHBAR

[G/Y][R]

[R]

[R]

[R]

[R](128)

[R](133)2/0

2/0

[R](126)

[R](132)

[R](124)

[R](131)

[R](139) 2/02

2/0

2/0

2/0

2/0

(140

)

[R]

(144

)

RLA

(126

A)

(126

B)

RLA

RLA

RLB

[R]

(139

)[R

]

(138

)[R

]

(141)(142)

(149)(148)R101

(134

)

(135

)

(137

)[B

L]

(136

)[B

L]

(ON HEATSINK)

(143)

(152

)

(150

)(1

51)

(153

)

(158

)

(156

)

(157

)

(155

)(1

54)

(161

)(1

60)

(159

)

2/03

2/03

(B2)

(A2)

(B1)

(A1)

X1/1

X1/1 X1/1

(126E)

1 2 3 4 5

11

23

2

1234567

1 2 3 4 51 2 3 4 5 1 2 3 4 5

G E C G E C G E CG E C

E

RLB NO NC<1/14 > <1/14> <1/15>< >

Com

pAir

Ch

apter 8, p

age 12

AC

20160-1822, Issue 1, Novem

ber 2002

FIG

. 8.6 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- 475SR

, L75S

R (2 O

F 3) 0V~

CONTROLLER

X22

X23SR

E)

24V~

0V~

24V~

4V~

0V~

X20

X21 X08

X1/1 X1/1 X1/1 X1/1

RELAY OUTPUTCONTROLLER

X03CONTROLLER

DIGITAL OUTPUT

X09

<1/34>39) [R]

<1/34>[R]26)

[R]

[R]

34

34

34

34

34

34

34

[R](132)

[R](128)

[R](133)

34[R](131)

[R](124)

(210

A)

(210

B)

(210

C)

(210

D)

(210

E)

(210

F)

S20

1/1

[R]

[R]

(211

)R

LC

Y20

1

Y20

2

Y20

3

R1

X2/1 X2/1 X2/1 X2/1 X2/1

R2 R3 R4 R5

[R]

[R]

[R]

[R]

[R]

(139

)

(126

C)

(126

D)

(126

E)

(126

F)

[R]

(212

)

[R]

[R]

[R]

(213

)

[R]

(214

)

AC1 AC2

~

1

4

22

1 2 3 4 5 6 7 8 9 10 1 2 3 4

2

1 2 3 4

RLC<1/06>

/

+

-

COMPRESSORSPEED4 - 20 mA

3. TOTAL CURRENT TO X09/2, 3 & 4 MUST NOTEXCEED 150mA


NOTES:-

WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,

2. WIRE COLOURS ARE SHOWN IN BRACKETS THUS [R]

[G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PINK

GROUPFAULT RELAY20V dc

150mA (max)

AC

20160-1822, Issue 1, Novem

ber 2002C

hap

ter 8, pag

e 13

LSR

Repair M


ystems

FIG

. 8.7 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- 475SR

, L75S

R (3 O

F 3)

HW 0330




X01 X02

CONT5 CONT6 CONT7 CONT81 2

VA+1

ANA12

ANA23

ANA34

ANA45

VA-6 EE

(E) (E)

3 4 5 6 7 8 9

X3/120V-

X3/1 X3/1 X3/1 X3/1 X3/1 X3/1

S20

1/2

S30

2

MC

B2

P30

1

R30

1

(309

)

(301

E)

(301

C)

(310

)

(311

)

(312

)

(313

)

(303

)

(302

)

(301

)

(301

B)

(301

D)

X3/1

T1

T2

1

2

[BL]

(301

A)

[BL]

[BL]

[BL]

[BL]

[BL]

[BL]

[BL]

[BK

]

[CR

]

[BK

]

[CR

]

[BL]

(301

E)

[BL]

<1/

06>

<1/

07>


NOTES:-

[PK]=PINK.

WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]

[G/Y]=GREEN/YELLOW, [CR]=CLEAR,

CompAir


FIG. 8.8 ELECTRICAL CONNECTION DIAGRAM - L45SR (1 OF 3)WITH PHASE FAILURE RELAY

[PK](154)

(110C)

(111C)

(112C)(112B)

(111B)

[VLT]

[VLT]

[PK]

L2

[BL] SW1/A

CE

GC

EG

CE

GC

EG

76

54

32

1

23 2 1 1

54

32

1

(A2)

(B2)

(A1)

(B1)

2/03

2/03

(159)(160)

(161)

(155)

(157)(156)

(158)

(153)

(151)(150)

(152)

(143

)

(136)

[BL] (137)

(135)

(134)

R10

1(1

48)

(149

)

(142

)

(141

)

[R] (138)

[R] (139)

[R]

RLB(126B)

(126A)RLA

(144)[R]

(140)

2/02

2/02

2/02

2/02

2/02

(139

)[R

]

(131

)[R

]

(124

)[R

]

(132

)[R

]

(126

)[R

]

2/02

2/02

(133

)[R

]

(128

)[R

]

[R]

[R]

[R]

[G/Y

]

EA

RT

H

DO

OR

[G/Y

]

[G/Y

]

[G/Y

]

[G/Y

]

2/02

HE

AT

SIN

K

CA

PA

CIT

OR

TR

AY

GA

TE

DR

IVE

P.C

.B

BA

SE

FR

AM

E

SA

FE

TY

GU

AR

D

ST

AR

TE

R B

OX

(108)[BK]

(109)[BK]

(107)[BK]

(116)

(117)

(115)RLB

(E)

M10

24

5 22

A2

B1

B2

A1

B2

A2

C4

A1

B1

C8

SE

NS

LIN

KH

EA

TS

INK

TE

MP

SE

NS

GA

TE

DR

IVE

BO

AR

D

CU

R

0V~

24V

~

0V~

24V

0V~

24V

~

(E)

C1

C5

P.C

.BR

ES

IST

OR

/VD

R

[126

E]

SW1/B

PC

B2

54

32

15

43

21

54

32

1

PO

WE

R S

WIT

CH

ING

IGB

T'S

[PK]

[PK]

[PK]

[PK]

[PK]

[PK]

[VLT]

[VLT]

HW

0028

PC

B1

[BK]

[BK]

[BK]

[BK]

[BK]

[BK](110B)

[BK]

[BK]

[BK]




HW

002

9

24V

~<

1/34

>[R

](1

31)

<1/

34>

<1/

34>

<1/

34>

<1/

34>

<1/

34>

24V

~

24V

~

0V~

0V~

(E)

[R]

(124

)

[R]

(132

)

[R]

(133

)

[R]

(128

)

4<

1/34

>

<1/

34>

22C

ON

TR

OL

LE

R

X22

X23

SR

0V~

<1/

34>

(139

)[R

]

<1/

34>

[R]

(126

)

X20

X21

12

12

34

(210A)

S201/1

[R]

X08

RE

LA

YO

UT

PU

TC

ON

TR

OL

LE

RX

03

R1

R2

R3

R4

R5

AC

1A

C2

12

34

56

78

910

12

(210B)

(210C)

(211)

(210E)

(213)

[R]

[R]

[R]

[R]

[R]

[R](139)

X2/

1X

2/1

X2/

1

X1/

1X

1/1

[R]

RLC

Y202

(126C)

(126F)[R]

CO

NT

RO

LL

ER

DIG

ITA

LO

UT

PU

T

X09

12

34

Com

pAir

Ch

apter 8, p

age 16

AC

20160-1822, Issue 1, Novem

ber 2002

FIG

. 8.10 EL

EC

TR

ICA

L C

ON

NE

CT

ION

DIA

GR

AM

- L45S

R (3 O

F 3)

WIT

H P

HA

SE

FA

ILU

RE

RE

LA

Y

HW 0030



X01

CONT5 CONT6 CONT7 CONT81 2 3 4 5 6 7 8 9

(309

)

(301

C)

[BL]

[BL]

(301

E)

[BL]

(302

)

(301

)

[BL]

[BL]

(303

)

[BL]

S20

1/2

S30

2 K10

1

SW

2

T1

T2

<1/

06>

<1/

07>

(301

B)

(301

D)

[BL]

[BL]

(301

E)

[BL]

X3/1

20V-

X3/1 X3/1 X3/1 X3/1 X3/1

(301

A)

[BL]

P30

1

R30

1

1

2


X02VA+ ANA1 ANA2 ANA3 ANA4 VA-1 2 3 4 5 EE 6

(E)(E)

(310

)

(311

)

(312

)

(313

)

[BK

]

[CR

]

[BK

]

[CR

]

Reference

Key to Components (diagrams 1 to 3)

NameEMC1 EMC FILTERF1 FUSE, 2A TYPE TF2 FUSE, 5A ANTI-SURGEF3 FUSE, 3.15A SEMI-DELAYK101 PHASE FAILURE RELAYL1 LINE REACTORL2 CURRENT TRANSDUCERL208 SPEED SENSOR - MOTORM102 MOTOR - MAIN DRIVEMCB1 CIRCUIT BREAKER - TRANSFORMER PRIMARY 3AMCB2 CIRCUIT BREAKER - FAN 10AP301 PRESSURE TRANSMITTER - DELIVERY PRESSUREPCB1 RESISTOR/VDR PCBR101 TEMPERATURE SENSOR - HEATSINKR301 SENSOR - OIL TEMPERATURERLA CONTACTOR - MAINRLB CONTACTOR DC LINK CHARGINGRLC CONTACTOR - FANS302 SWITCH - AIR FILTER DP

T101 CONTROL TRANSFORMERY202 VALVE SOLENOID - BYPASS

Note:- Details of Control Panel components are supplied inside the Power Converter Box

AUXILIARY CONTACTSSW1




HW

003

1

PO

WE

R S

WIT

CH

ING

IGB

T'S

CC

CC

CE

EE

EG

GG

(150)

[VLT](151)

[PK](152)[PK](153)[VLT]

[PK](154)

[PK]

[PK]

(155)

[VLT](156)

(157)

[PK]

[PK]

[VLT]

(158)

(159)

(160)

[PK](161)

12

34

5

5C

UR

SE

NS

B2

12

34

51

23

45

12

34

5B

1A

2A

1

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AR

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PC

B2

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MP

SE

NS

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AT

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KLI

NK

22

12

34

57

6

(140)

(139)

(138)

(137)

(136)

(135)

(134)

[R]

[R]

[R]

[BL]

[BL]

[R](144)SW1

SW1

[R]

[R]

RLA

RLB(126B)

(126A)

X1/

1

X1/

1X

1/1

(126

E)

[R]

[R]

[R]

[G/Y

]

[G/Y

]

[G/Y

]

[G/Y

]

[G/Y

]

(E)

<2/

02>

SA

FE

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AR

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P.C

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OR

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STA

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FR

AM

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RT

HB

AR

[R]

[R]

[R]

[R]

[R]

[R]

[R]

(139

)<

2/02

>

<2/

02>

<2/

02>

<2/

02>

<2/

02>

<2/

02>

<2/

02>

(131

)

(124

)

(132

)

(126

)

(133

)

(128

)

24V

~

24V

~

24V

~

0V~

0V~

0V~

(E)

M10

24

<2/

03>

<2/

03>

A1

A2

B1

B2

L2

(A1)

(A2)

(B1)

(B2)

C1

C5

C6

C10

POWERBRIDGERECTIFYER

VD

R1

(104

)

[BK

]

[BK

]

[BK

]

(105

)

(106

)

(107)

[BK]

[BK]

[BK]

(108)

(109)

RLA

RE

SIS

TO

R/V

DR

P.C

.B

PC

B1

(115)

[BK]

[BK]

[BK]

(116)

(117)

RLB

(113)

[BK]

[BK]

(114)

[BK]

[BK]

[BK](110A)

(111A)

(112A)

MCB2 10A

MCB1 3A

[BK

]

[BK

]

[BK

](1

10B

)

(111

B)

(112

B)

(110C)

[BK]

[BK]

[BK]

(111C)

(112C)

m<

3L1

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L3

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AIL

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24V

30V

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200V

A

[R]

(123

)

[R]

(124

)

[R]

(125

)

[R]

(126

)

F1

[R]

(131

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[R]

(132

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2A

F2

5A

F2

5A

[R]

(132

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33.

15A

24V

OV

50V

A[R

](1

27)

[R]

(128

)

(E)

[BK

](1

13)

OV

M10

13~ R

(E)

<3/15>

<3/15>

T1

T2

FUSED ISOLATORFROM CUSTOMERSINCOMING SUPPLY

U V W PE

L1(1

01)

[BK

]

[BK

]

[BK

]

(102

)

(103

)

R10

1

(143

)

(142

)

(141

)

(148

)

(149

)

1 23 12

RLC

CompAir



HW

003

2

DIG

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PU

TC

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TR

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12

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R3

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12

43

56

78

910

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X2/

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X2/

1

(210D)

[R]

(210B)

[R]

(210C)

[R]

(210E)

[R]

(210F)

[R]

(214)

[R]

(213)

[R]

(212)

[R]

(211)

[R]

(139)

[R]

(126D)

[R]

(126C)

[R]

(126E)

[R]

(126F)

[R]

Y201

Y202

Y203

RLC

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X1/

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(210A)

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X21

X22

X23

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12

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)[R

]

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(132

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HW

003

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CO

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12

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56

E

(E)

E

(E)

(310)

[BK]

(311)

(313)

(312)

[BK]

[CR]

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R301

1 2

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ON

TC

ON

T1

CO

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2C

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T3

CO

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4C

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T5

CO

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6C

ON

T7

CO

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81

23

45

67

89 (309)

[BL]

[BL]

[BL]

[BL]

[BL]

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(308)

(301C)

(305)

(303)

(302)X

01

S201/2

S302

S304

K101

(301B)

(301D)

[BL]

(301A)[BL]

[BL]

(301E)[BL]

[BL]

(301F)

(301H)[BL]

<1/06> <1/07>

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T2

X3/

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to

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mp

on

ents

(d

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)

CompAir


FIG. 8.14 ELECTRICAL CONNECTION DIAGRAM - L120SR (1 OF 4)

HW

003

4




HW

003

5

CompAir



HW

003

6




Ref

eren

ce

Key

to

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mp

on

ents

(d

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WA

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TP

CO

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101

CO

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R1

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RIS

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VA

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VA

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RA

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ontr

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com

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are

supp

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ox

Ref

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HW

003

7

CompAir


This page has been intentionally left blank

LSR Repair Manual – Fault Diagnosis

AC20160-1822, Issue 1, August 2002 Chapter 8, page 25

FAULT DIAGNOSIS

● Refer to the safety procedures beforecarrying out fault diagnosis or testingany circuit on the compressor unit.


CAUTION: Fault finding by control card substitutionwithout following the correct fault findingprocedures is not recommended. A fault may existwhich could cause damage to the substitute card.

1. TEST EQUIPMENT

To carry out checks on the electrical componentsand the circuit cards inputs and outputs thefollowing test equipment will be required.

CAUTION: Do not use a test meter with less than a20,000 ohm/V specification to avoid loading effectsand to prevent damage to IC’s during testing.

CAUTION: The circuit boards carry CMOSdevices. When replacing circuit boards avoidtouching connector pins and devices on the boardsto prevent static damage to components. Take anti-static precautions as far as possible such astransporting the circuit boards in anti-static bags.

1.1 Test Meter

A digital multimeter with diode and capacitor testfunctions is required for the tests carried out in thissection. The meter resistance test voltage shouldnot exceed 1·5V. Always ensure that the meter andtest leads are rated for the voltage being measured:

DC - 0-1000V is normally sufficient.AC - 0-600V rms.

A suitable test meter is the Fluke 79-III.

1.2 Clip-on Ammeter

This should be suitable for measuring currents upto 600 amps. A suitable ammeter is the Heme 6-200 A model.

1.3 Insulation Tester

The tester should have a 1000V test voltage. Asuitable tester is the Megger BM222.

1.4 DC Voltage Generator

The generator should provide a maximum of 30VDC at a maximum current of up to 1 A. A suitablegenerator is the Thurlby Thandar InstrumentsPL310.

1.5 IGBT Tester

IGBT Tester part number 98506-24 can be orderedfrom CompAir UK Ltd.

1.6 Slave Air Supply

The air supply should be capable of generating apressure above 5.5 bar and be fitted with anaccurately calibrated gauge.

1.7 Inductance Tester

WARNING

● Before opening the door of the startercompartment, switch the power supplyOFF at isolator and wait for 12 minutes toallow the DC link capacitors to discharge toa safe level. Check that the DC linkcapacitors have fully discharged beforestarting any maintenance work.

The tester should be capable of measuring in theuF and mH ranges.

A suitable tester is the AVO Megger B131, RSstock number 230-6546.

CompAir

Chapter 8, page 26 AC20160-1822, Issue 1, August 2002

2. CAGE-CLAMP SCREWLESS TERMINALS

The connections on the controller terminal blocksare fitted with cage-clamp screwless terminals. Thecage-clamp design ensures that the clamping forceadjusts to sizes of cable between 1 mm2 and 2·5mm2. This results in a corrosion free contact areaand compensates for any deformation of the cableend due to temperature or vibration.

2.1 Cable Connection or Removal

1. Strip the insulation from the end of the cableto leave approximately 8 mm of bare wire.

2. Insert a screwdriver with a blade end width of3 mm into the terminal slot and push to theend stop.

3. Insert (or remove) the cable.

4. Withdraw the screwdriver to leave the cableclamped.

5. Check the connection by lightly pulling on thecable.

1. Terminal Jumper Connection2. Cable3. Terminal Block

FIG. 8.18 CABLE CONNECTION OR REMOVAL

1

2

3

HW 0333



4. CONTROL INPUTS

CAUTION: The high voltage (primary) and lowvoltage (secondary) circuits must NOT beconnected in any way (e.g. via test probes, wiringetc.)

4.1 To Check the Air Filter DifferentialPressure Switch

4.1.1 L45SR and L75SR models

The air filter differential pressure switch contactsare normally open. This indicates that the air filterelement differential pressure is within limits. Whenthe filter requires changing the contacts of theswitch close.

1. Disconnect the cables from the pressureswitch.

2. Check that the pressure switch is open circuitby checking continuity between the switchterminals.

3. Renew the pressure switch if closed circuit.

4. Refer to the electrical connection diagrams toverify the wiring connections from thecontroller to the pressure switch.

4.1.2 L120SR model

A visual filter condition indicator is fitted adjacent tothe air intake filter. This is also a switch.

The indicator is a vacuum indicator and when theset point of 65 mbar vacuum is reached it will senda signal to the controller to flag up a warning. Theswitch is normally open and can be checked in thenormal manner as above.

Note: The indicator has to be manually reset bypressing the yellow button (1) on the bottom (seefigure 8.19).

3. POWER SUPPLIES


3.1 To Check the 24V AC Supply Circuits(Refer to Electrical Connection Diagrams)

1. Measure the AC voltages of all the secondaryoutputs of the control transformer. Alwaysmeasure across the transformer outputterminals and NOT between each terminaland earth.

2. The voltage of each output should be asindicated ±10%. If one of the voltages isincorrect, renew the transformer. If all thevoltages are incorrect see 3.2 ‘To Check theMain Power Supply’.

3. Check the fuses contained in the fusedterminal blocks F1, F2 and F3. Renew anyblown fuse. If a fuse blows repeatedlycontinue to check along the circuit for anyshort circuits or failed devices, as explained indetail throughout this Chapter.

4. Measure the AC voltage between pins 1 and 2of controller terminal X03. The voltage shouldbe the same as measured in 2 above. Checkthe wiring if the voltage is incorrect.

5. Measure the AC voltage between pins 1 and 2of controller terminal X20. The voltage shouldbe the same as measured in point 2. Checkthe wiring if the voltage is incorrect.

3.2 To Check the Main Power Supply

1. Measure and record the voltage between theRed and Yellow, the Red and Blue, and theYellow and Blue incoming phases. In additionmeasure the AC voltage between the primaryconnections of control transformer T101. Thereadings should be within 10% of thespecified working voltage on the compressornameplate.

2. Measure and record any voltage drop during amotor start sequence. Excessive voltage dropwill cause tripping problems.

CompAir


4.2 To Check the Emergency Stop Circuit

The Emergency Stop button has two contacts whichwill open if the Emergency Stop button is pressed.One contact is connected to the 24V AC powersupply circuit to the controller outputs. This contactwill interrupt the power supply to the motorcontactors and control solenoids in the event of anEmergency Stop. The other contact is connected tothe DC input circuits of the controller. The twocircuits must NOT be connected in any way, e.g. viatest probes, wiring etc.

Refer to the electrical connection diagrams tocheck the continuity of the emergency stop wiring.

5. CONTROL OUTPUTS


5.1 Relay Output (connector X08)

1. Ensure the Emergency Stop input has notbeen operated before checking the outputs,see para. 4.2 ‘To Check the Emergency StopCircuit’

2 The motor contactors and load solenoidcontroller outputs are all relay contacts.

3. When checking an output ensure the ACsupply to X08/1,3,5,7 & 9 is within 10% of thenominal voltage.

4. Measure the voltage between the transformersecondary 0V terminal and the outputterminal, while the output is operated usingthe Test Digital Outputs function.

5. If an output fails to function renew thecontroller.

6. Continue to check the output voltage alongthe circuit being tested. Renew anyconnections or wiring as necessary.

7. If the voltage across the terminals of thecontactor or solenoid coil being tested iscorrect when the controller output is switchedon, but the device fails to function, renew thecontactor coil or solenoid.

6. SENSORS


6.1 To Check the Pressure Sensors

The Pressure Sensors are 4-20 mA types,0-13.8 Bar (L45SR and L75SR) and 0-16 Bar(L120SR). The current in the sensor 24V DCsupply wires will change in proportion to thepressure acting on the Pressure Sensor. Thecontroller monitors the current signal andprocesses the information to give a pressuredisplay.

FIG. 8.19 AIR FILTER INDICATOR SWITCH(L120SR)

1. Switch power OFF.

2. Remove the plug from the pressure sensor,switch power ON and ignore any displayedfault message.

3. Measure the DC voltage between terminals 1and 2 of the plug. The reading should bebetween 20V and 28V.

4. If the voltage is incorrect see 3.1 ‘To CheckThe 24V AC Supply Circuits’.

5. Re-connect the pressure sensor plug anddisconnect one of the plug wires.

1

2

3

HW 0334



6. Connect the multimeter between thedisconnected end of the wire and the plugterminal.

Pressure Sensor Sensor Pressure Sensor Sensor(bar) Output (mA) Output (mA) (bar) Output (mA) Output (mA)

L45SR, L75SR L120SR L45SR, L75SR L120SR

0.0 4.00 4.00 8·5 13.86 12.50

0·5 4.58 4.50 9·0 14.44 13.00

1·0 5.16 5.00 9·5 15.02 13.50

1·5 5.74 5.50 10·0 15.60 14.00

2·0 6.32 6.00 10·5 16.18 14.50

2·5 6.90 6.50 11·0 16.75 15.00

3·0 7.48 7.00 11·5 17.33 15.50

3·5 8.06 7.50 12·0 17.91 16.00

4·0 8.64 8.00 12·5 18.49 16.50

4·5 9.22 8.50 13·0 19.07 17.00

5·0 9·80 9.00 13·5 19.65 17.50

5·5 10·38 9.50 13.8 20.00 17.80

6·0 10·96 10.00 14.0 n/a 18.00

6·5 11·54 10.50 14.5 n/a 18.50

7·0 12·12 11.00 15.0 n/a 19.00

7·5 11.50 11.50 15.5 n/a 19.50

8·0 12.00 12.00 16.0 n/a 20.00

FIG. 8.21 PRESSURE SENSOR OUTPUT TABLE

FIG. 8.20 MEASURING THE PRESSURESENSOR CURRENT

7. Apply a calibrated known pressure to thesensor and measure the dc current in thesensor circuit. The reading should be asgiven in the Pressure Sensor output tablebelow.

8. If the current is not within ± 5% of the figuregiven check the wiring and connections ofthe pressure sensor circuit.

9. Renew the pressure sensor if no wiring orconnection faults can be found.

HW 0335

PRESSURESENSOR PLUG

12

ML1/7

ML1/8

CONTROLLER

X02/1X02/2

CompAir


6.2 To Check the Air/Oil TemperatureSensors

The temperature sensors are spreading resistancetype thermistors. The resistance of the thermistorswill increase as the applied temperature increases.The controller monitors the resistance andprocesses the information to give a temperaturedisplay.

1. Switch power OFF. Disconnect the cablesfrom the temperature sensor and measure itsresistance.

Note: Drain the air-end, remove the temperaturesensor and the sensing tip and place in a calibratedoil temperature bath if an accurate measurement isrequired.

WARNING

. Risk of injury from hot oil under pressure.

2. The sensor resistance depends on thetemperature, see the Temperature/Sensorresistance table below. If the measuredresistance equates to an error of more than± 2°C different from the figure given belowrenew the sensor.

3. If the resistance is correct re-connect thesensor cables.

4. Disconnect temperature sensor cables fromcontroller terminal plug.

5. Measure the resistance between thedisconnected cable ends. If the resistance isnot as given in the table renew cables asnecessary.

6. If the resistance is correct, renew thecontroller.

Temperature Sensor Temperature Sensor(°C) Res. (ohms) (°C) Res. (ohms)

0 1605 50 2448

5 1678 60 2638

10 1762 70 2844

15 1848 80 3058

20 1927 90 3282

25 2008 100 3520

30 2092 110 3772

40 2263 120 4043

FIG. 8.22 TEMPERATURE SENSOR RESISTANCE TABLE



7. CONTROLLER

The controller consists of two microprocessor units,the application subcontroller, and the motor drivesubcontroller.

The application subcontroller contains three cardswhich together run the application program tocontrol and monitor the compressor and keypadfunctions of the controller. An application programIC is fitted to this unit.

The motor drive subcontroller contains two cardsand is mounted adjacent to the applicationsubcontroller and connected by a three wire internalserial link. Motor drive program ICs, which are fittedto this unit, control the speed of the motor drive asrequired by the application program and returncondition and fault data from the drive circuits to theapplication program.

7.1 Application Control Program IC

Instructions for renewing the control program ICwithin a SureScan controller:

1. Remove the controller from the compressor.

2. Remove the screws located adjacent to theelectrical plug connections on the rear of thecontroller.

3. Using a spanner, remove the (plug securing)nuts adjacent to the sub-D connections.

4. Remove the six rear controller enclosuresecuring screws (do not remove the earth tagand stud adjacent to X03).

5. Remove the rear controller cover.

6. The control program IC can be removedwithout dismantling the three circuit cards. Toeliminate the possibility of re-connectionerrors, it is recommended that the circuit cardsare not dismantled.

Before removal of the control program IC,make a note of the orientation and position ofthe IC in its socket. Note the orientationmarks on the IC, socket and circuit board.

7. Using a small screwdriver, or similar tool,carefully remove the control program IC fromits socket.

8. Insert the new control program IC. Check theorientation and ensure that each pin enters thesocket correctly. (The pins must not bendunderneath the IC during insertion.)

9. When re-assembling the controller, refit the sixrear cover securing screws first to hold thecover in place but do not tighten. Then refitthe remaining screws and nuts before finallytightening the rear cover screws.

Note: Ensure that the ribbon cable is not trapped ordisplaced when replacing the cover.

10. Re-connect to compressor and test.

CAUTION

● When working with static sensitivecomponents, ie, circuit cards andmemory IC’s etc, always take antistaticprecautions.

1. Always transport static sensitivecomponents in anti-static bags orcontainers.

2. Never touch the metal pins of electronicIC devices.

3. Never place static sensitive componentsonto a metal surface. Always placedirectly into an anti-static bag orcontainer.

4. Always ensure any body static isdischarged before handling staticsensitive components by touching anearthed surface at regular intervals.

CompAir


FIG. 8.21 ARRANGEMENT OF CONTROLLER CARDS

7.2 Motor Drive Program IC

Normally it is not necessary to change the motordrive program IC. However some control programsalso require the drive program to be updated. If oneof these control programs is installed without thecorresponding drive IC change, the message’Wrong SR Drive program’ will be displayed.

To change this IC follow the basic instructions forthe control program. However to gain access it willbe necessary to fold the upper card to one side. Noconnections need to be disturbed. Note also theposition of the unused sockets at the notch end.

7.3 FPGA Data IC

A need to change this IC is not anticipated.However, if required, use the same procedure asabove.



8. SR FAULT LOCATION

8.1 SR Current Sensor Fault (Figs. 8.23/8.24)

The SR drive current sensor circuit has detected afault.

Refer to the flow chart in Figs. 8.23/8.24 for the faultfinding procedure.

FIG. 8.22 CURRENT SENSOR PIN

8.2 SR Motor High Temperature Fault

Under normal operating conditions the resistance ofthe thermistors in the SR motor windings should be50 to 500 ohms. Possible causes of hightemperature are:

1. High ambient temperature.

2. Motor cooling air intake grille blocked.

3. Pre-filter blocked.

4. Open circuit in thermistor cables.

5. Recirculation of exhaust air from cooler withinthe compressor.

8.3 SR Motor Overcurrent (Fig. 8.25)

Occurs if the current sensor signal indicatesexcessive SR motor phase current.

Refer to the flow chart in Fig. 8.25 for the faultfinding proceedure.

Attempting to repeatedly start a compressor with anSR motor overcurrent fault will produce a startinhibit.

8.4 DC Link High Voltage Fault(Figs. 8.26/8.27)

This fault occurs when the DC link voltage isexcessive.

Refer to the flow chart in Figs. 8.26/8.27 for the faultfinding procedure.

CAUTION: When measuring the DC link voltageuse a suitable test meter and leads (1000V testvoltage) and attach the leads to the DC link using‘crocodile’ clips.

Route the leads to ensure that the enclosure doorcan be closed and fastened before applying power.

8.5 DC Link Low Voltage Fault (Figs. 8.28/8.29)

This fault occurs when the DC link voltage is belowoperating level.

Refer to the flow chart in Figs. 8.28/8.29for the faultfinding procedure.

8.6 SR Position Sensor Fault

This fault occurs when the SR motor positionsensor cable is disconnected or the position sensoris faulty.

8.7 SR Motor Overspeed Fault

This fault occurs when the SR motor measuredspeed exceeds the normal operating speed.Possible causes are:

1. Fault in speed control harness, eg broken wireor cable screen.

2. Fault in controller.

8.8 SR Motor Stall Fault (Fig. 8.30)

This fault occurs when the SR motor speed remainsbelow 300rpm for 1 second.

Refer to the flow chart in Fig. 8.30 for the faultfinding procedure.

6 7 8 9

1 2 3 4 5

Current Sensor Pin Connection (X22)See Electrical Connection Diagrams

HW 0337

CompAir


8.9 DC Link Charge Fault(See Fig. 8.31)

This fault occurs during the 5 second charge periodif the voltage does not exceed expected level. At 5seconds the voltage should exceeed the followingfigure.

420V Serial Nos F170-0112 to F170-0353485V Serial Nos F170-0354 onwards485V Serial Nos F171-0100 onwards485V Serial Nos F180-0106 onwards

Refer to the flow chart in Fig. 8.31 for the faultfinding procedure.

8.10 Heatsink Temperature Sensor Fault

This fault occurs when the resistance of theheatsink temperature sensor is outside of it’sworking range. Possible causes are:

1. Broken wire.

2. Faulty sensor.

8.11 Heatsink High Temperature Fault

This fault occurs when the measured heatsinktemperature is above 90°C (L45SR and L75SR) or95°C (L120SR). Possible causes are:

1. High ambient temperature.

2. Pre-filter blocked.

3. Heatsink cooling duct blocked.

4. Heatsink cooling duct missing.

5. Heatsink dirty.

6. Power converter filters blocked.

Note: When the heatsink temperature is above85°C (L45SR and L75SR) or 90°C (L120SR) thedrive will start to limit the speed to try to limit theheat in the heatsink.

7. Heatsink cooling fan faulty (L120SR only)

8.12 Main Contactor Fault

This fault occurs if the main contactor auxiliarycontact is open when the contactor output isenergised.

A main contactor fault condition can also beproduced with the fitting of a phase failure retrofitkit. This occurs when the incoming phases aretransposed.

Possible causes are:

1. The potentiometer is set incorrectly for thenational AC supply voltage.

2. An imbalance in the national AC supplyvoltage.

3. A faulty phase failure relay auxiliary contact.

4. A faulty main contactor coil.

8.13 SR Power Supply Fault

There has been an interruption in the power supply.

8.14 Internal Comms Fault

This condition exists when there is a fault on theSurescan controller or there has been a briefinterruption in the power supply.

8.15 SR PCB Internal Fault

This condition occurs when there is a fault on theSurescan controller or there has been a briefinterruption in the power supply.

8.16 Start Inhibit

This fault condition has two possible causes.

1. Initial power up with incoming phasestransposed.

2.* Excessive starting of machine with SR motorovercurrent fault.

* An access code is required to reset the fault.



8.17 SR FAULT LOCATION CHARTS

FIG 8.23 SR CURRENT SENSOR FAULT (1 OF 2)

CompAir


FIG 8.24 SR CURRENT SENSOR FAULT (2 OF 2)



FIG 8.25 SR MOTOR OVERCURRENT FAULT

CompAir


FIG 8.26 DC LINK HIGH VOLTAGE FAULT (1 OF 2)



FIG 8.27 DC LINK HIGH VOLTAGE FAULT (2 OF 2)

CompAir


FIG 8.28 DC LINK LOW VOLTAGE FAULT ( 1 OF 2)



FIG 8.29 DC LINK LOW VOLTAGE FAULT (2 OF 2)

CompAir


FIG. 8.30 SR MOTOR STALL FAULT



FIG. 8.31 DC LINK CHARGE FAULT

CompAir


9. SR TEST PROCEDURES

9.1 Diode Device Test Procedures

Fast diodes as separate modules are only fitted tomachines with serial numbers:

F170/0112 to F170/0353 andF180/0101 to F180/0168

To carry out a functional test on any diode deviceproceed as follows:

CAUTION: All electrical connections andconnection bars must be removed from a devicebefore it can be tested.

Use a digital multimeter equipped with a diode testfunction (fig. 8.32). If the forward voltage does not

compare with the value shown in figs. 8.33-8.35,,the device is faulty.

Note: Each diode should also be tested for reverseconduction. No diode should conduct in reverse.

9.1.1 Fast Diode Module (Common Cathode)

Note: This diode is fitted near the top of the heatsink, in between IGBTs A2 and B2. Check theterminal numbers before carrying out a test.

9.1.2 Fast Diode Module (Common Anode)

Note: From serial numbers F170-0354 and F180-0106 onwards the fast diode is located within theIGBT (see 9.3.1)

! Refer to the safety procedures beforecarrying out fault diagnosis or testingany circuit on the compressor unit.


! Before opening the door of the startercompartment, switch the power supplyOFF at isolator and wait for 12 minutes toallow the dc link capacitors to discharge toa safe level. Check that the dc linkcapacitors have fully discharged beforestarting any maintenance work.

WARNING

BLA

CK

RE

D

OFF

~Hz

V

A

V

mV

COM

V

HW 0347

FIG. 8.32

HW 0348

1 2 3

0.30V 0.30V

HW 0349 0.30V 0.30V

1 2 3

FIG. 8.33

FIG. 8.34



9.1.3 Rectifier Diode Module

Note: There are three rectifier diodes fitted at thetop of the heatsink (L75SR) or the bottom of theheatsink (L45SR and L75SR). There is a diagramon the rectifier diode module(s) to indicate thecircuit. Test accordingly.

9.2 IGBT (Insulated Gate Bipolar Transistor)


Using IGBT tester, CompAir part number 98506-24,connect as shown below. In the illustrations belowthe two ends of the same connecting wire areshown by ‘a’ or ‘b’.

1. In normal operation the lamp will light whenthe test button is switched ON.

2. If the lamp does not light when the test buttonis switched ON an open circuit is indicated.

3. If the lamp remains lit with the button ON orOFF a short circuit is indicated.

Use IGBT tester, CompAir part number 98506-24.

9.2.1 Dual IGBT (Insulated Gate BipolarTransistor)

These devices contain two IGBTs and are fitted tomachines from serial numbers F170-0354 andF180-0106 onwards.

One of the IGBTs is forced open circuit by linking itsgate connection to the emitter enabling the internalfast diode to be tested.

On the right hand side of the IGBT there are four tabterminals, two of which are linked together. Tolocate the diode circuit it is necessary to determinewhich of these terminals are linked.

If the link is made between tab terminals E1 and G1the diode can be measured between screwterminals C2E1 and C1.

If the link is made between tab terminals E2 and G2the diode can be measured between screwterminals C2E1 and E2.

Note: Refer to 9.1 Diode Test Procedures.

The IGBT can now be located and tested.FIG. 8.36 CONNECTING TESTER TO IGBT

TYPE GAL

FIG. 8.37 CONNECTING TESTER TO IGBTTYPE GAR

FIG. 8.35

HW 0350

0.45V 0.45V

CompAir


If the link is made between tab terminals E1 and G1the transistor connections are:

Gate - G2 Emitter - E2 Collector - C2E1

If the link is made between tab terminals E2 and G2the transistor connections are:

Gate - G1 Emitter - C2E1 Collector - C1

Note: Refer to 9.3 IGBT Test Procedures.

CAUTION: Always ensure the correct tab terminalsare linked when replacing an IGBT.

9.2.2 Latest Semikron IGBTs

Test as in 9.2 and then test with diode testeraccording to the diagram on the IGBT.

FIG. 8.38 CIRCUIT OF IGBT TYPE GAL

FIG. 8.39 CIRCUIT OF IGBT TYPE GAR



FIG. 8.40 L45SR POWER CONVERTER ASSEMBLY

1 Rectifier Diodes 5 Gate Drive Board2 IGBTs 6 VDR/Resistor Board3 Snubber Capacitors 7 Capacitor Box4 Busbars

C9 C10 C12C11

HW 0357

1 2

3

4

5

6

7

CompAir



1 Rectifier Diodes 6 Earth2 Capacitor Box 7 Snubber Capacitors3 Balance Resistors 8 Busbars4 Capacitors 9 IGBTs5 Gate Drive Board

12 3

4

5

6

7

8

9

HW 0358



1

2

3

4

5

67

8

9

1

HW 0359

MOTOR CABLES A2 B2

THROUGH SENSOR

C10C10

C18C18

R105R105

R106R106

R107R107

R108R108

R109R109R114R114

R113R113

R112R112

R111R111

R110R110

137137136136

138138

140140139139

160

160

159

159

519

519

520

520

161161

157

157

156

156

158 158

516

516

517

517

154154 153153

513

513

514

514

155 155

510

510

511

511

151

151

150

150

152

152

R101

R101


1 Laminated Busbar 6 Capacitors2 Gate Drive Board 7 Lift-off Hinges3 Earth Lead 8 IGBTs4 Balance Resistors 9 Snubber Capacitors5 Capacitor Box

CompAir


9.2.3 IGBT Removal and Fitting Instructions

Removal (L45 and 75SR)

1. Open power converter door and remove allelectrical guards.

2. Disconnect motor cables from IGBTs.

3. Disconnect vertical bus bars / snubbercapacitors from IGBTs and remove.

4. Carefully disconnect the pink and violet wiresfrom the IGBTs.

5. Undo mounting screws for IGBTs andremove. Remove IGBTs from heatsink.

6. Clean residue compound from heatsink with amild degreaser. Ensure that there is nospillage on to other components.

Refitting (L45 and 75SR)

1. Clean the back of the IGBT’s from anyremaining thermal compound.

2. Uniformly coat the back of the IGBT withthermal compound (DOW CORNING DC340). Use a rubber roller for this process toensure an even coating of approx0.02-0.03mm thick.

3. Refit the IGBT’s in the correct order as shownhand tightening the screws in a diagonalsequence.

4. Tighten the screws again in a diagonalsequence to a torque of 5Nm maximum.

5. Refit wires from gate drive board

6. Refit busbars and snubber capacitors to atorque of 5Nm.

7. Refit motor cables.

8. Refit electrical guards.

Removal (L120SR)


2. Disconnect motor cables from IGBTs.

3. Disconnect wires and leads from gate driveboard.

4. Remove gate drive board

5. Disconnect pink and violet wires from IGBTs

6. Remove laminated bus bars, all balanceresistors and snubber capacitors.

7. Undo mounting screws for IGBTs andremove.

8. Clean residue compound from heatsink with amild degreaser. Ensure that there is nospillage on to other components.

Refitting (L120SR)

1. Clean the back of the IGBT’s from anyremaining thermal compound.

2. Uniformly coat the back of the IGBT withthermal compound (DOW CORNING DC340). Use a rubber roller for this process toensure an even coating of approx0.02-0.03mm thick.

3. Refit the IGBT’s in the correct order as shownhand tightening the screws in a diagonalsequence. Tighten to a maximum of 5Nm.

4. Refit laminated busbars, balance resistorsand snubber capacitors. Tighten IGBTconnections to 5Nm maximum and capacitorconnections to 2Nm maximum.

5. Refit Gate Drive Board.

6. Refit wires to Gate Drive Board and IGBTs.

7. Refit motor cables.

8. Refit Electrical Guard.



9.3 Electrolytic Capacitor Test Procedures

9.3.1 Electrolytic Capacitor Test


1. Check that the blow-hole plug (fig. 8.43) isintact. If the plug has blown the capacitor isfaulty. Check for distortion of the case.

2. Measure the voltage across the terminals ofthe capacitor. Although the DC link voltagehas been completely discharged to 0V beforeremoving the bus bars, it is possible for thecapacitors to recover a small charge voltage.If any voltage exists, hold one of the balanceresistors across the terminals until the voltageis dissipated to zero.

CAUTION: The resistor may become warm whenheld across the terminals.

3. Using the recommended digital multimeterswitched to the resistance/capacitanceposition ( ) (fig. 8.44), hold the red probeon the positive terminal of the capacitor andthe black probe on the unmarked terminal.

4. If the capacitor is good the meter reading willstart to increase slowly from an initial lowresistance level. This is due to the small testvoltage generated by the multimeter slowlycharging the the capacitor.

5. If the capacitor is open circuit (faulty) themeter will immediately indicate a very highresistance in excess of 1000k ohms or OL(over range).

Note: The tests described above are intended as an‘on site’ diagnostic aid only, and will enable atechnician to identify a capacitor fault in most cases.Refer to 9.3.2 for a more thorough test.

9.3.2 Electrolytic Capacitor Measurement

1. Use the recommended digital multimeterswitched to the resistance/capacitancemeasuring range ( ). Press the yellowbutton (1) to select capacitancemeasurements.

2. Hold the red probe on the positive terminal ofthe capacitor and the black probe on theunmarked terminal. Note: the meter willindicated overload if there is a residualcharge in the capacitor. The capacitor shouldthen be discharged using a balance resistor.

HW 0364

ElectrolyticCapacitor

Blow-Hole Plug

FIG. 8.43 CAPACITOR

BLA

CK

RE

D

OFF

~Hz

V

A

V

mV

COM

V

HW 0366

1

FIG. 8.44 MULTIMETER

CompAir


3. Wait until a steady reading is obtained,themeter will take a little time to switch to thecorrect range.

4. The reading for a good capacitor should bein the range 2640 to 3960 uF.

9.3.3 Capacitor Removal and Refitting Instructions

Removal (L45SR AND L75SR)


2. Disconnect all the leads to the gate driveboard and remove gate drive board.

3. L45SR only: Disconnect and remove VDRResistor Board

4. Remove all busbars from the IGBTs and therectifier diodes to the capacitors, includingbalance resistors.

5. Remove earth wire from capacitor box at theearth bar.

6. Remove capacitor housing box.

7. Remove capacitor plate from housing box.

8. Unscrew nylon back nuts holding capacitorsto plate.

Refitting (L45SR AND L75SR)

1. Refitting is the reversal of removal.

2. Ensure busbars to capacitors are onlytightened to 2Nm max.

Removal (L120SR)

1. Remove all electrical guards.

2. Disconnect all leads to the gate drive boardand remove gate drive board.

3. Remove both laminated bussbars fromIGBT’s /capacitors including balance resistorsand snubber capacitors.

4. Remove both earth wires at the earth barfrom capacitor boxes.

5. Remove screws from right hand side ofcapacitor boxes.

6. Swing capacitor boxes out on hinges and liftoff.

7. Unscrew nylon back nuts holding capacitorsto boxes.

Refitting (L120SR)

1 . Refitting is the reversal of removal.

2. Ensure screws securing bussbars are onlytightened to 5Nm on IGBTs and 2Nrn oncapacitors.

9.4 To Check Capacitor Bank VoltageImbalance

1. With the compressor stopped, isolated and theDC link discharged, connect a 30V dc powersupply to the dc link busbars. The powersupply should have a current limit of not morethan 2A. connect the supply +ve to the +ve onthe dc link. Switch on the 30V supply.

2. Check that both the dc link LEDs on the gatedrive board are dimly lit.

3. Using a digital multimeter check that the dclink is charged to the voltage of the dc powersupply.

4. Check that the dc link is balanced to within ±0.4V, ie each bank of series connectedcapacitors are charged to the same voltagewithin ± 0.4V.

5. If this fails disconnect the capacitor sensingconnections from the gate drive board (3 pinconnector) and repeat 1, 3 and 4. If the dc linkis now balanced the gate drive board is faulty.

6. If this test fails check the capacitor bankbalance resistors (see 9.6).

9.5 To Check Capacitor Bank BalanceResistors

Disconnect each balance resistor from the capacitorbefore measuring it’s resistance. The resistanceshould compare with the marking on the resistor.



9.6 To Check VDR/Resistor Board (L45SR and(L75SR)

1. Isolate AC power supply.

2. Measure resistance across terminals A to A1,B to B1 and C to C1 on the board. Theresistance should be 33 ohms ± 3 ohms ineach case.

FIG. 8.45 VDR/RESISTOR BOARD(L45SR,L75SR)

9.6.1 L120SR Resistors

Check the resistor values are within the rangeshown on the side of the resistors.

FIG. 8.46 Resistor (L120SR)

9.7 To Check the SR Motor

9.7.1 Motor Insulation Test(Test for end turn faults and faults to ground)

1. Ensure that the main power supply to thecompressor is isolated.

Note: Use a calibrated 1000V insulation tester forinsulation resistance tests.

2. Open starter door and remove upper andlower safety guards.

3. Disconnect all of the SR motor leads frompower converter, including the SR motorthermistor cables.

4. Measure the insulation resistance betweeneach motor winding phase, i.e. cables A1 andB1.

Measure the insulation resistance betweeneach motor winding phase cable (A1 and B1)and earth.

5. The resistance reading in each case shouldbe greater than 20 megohms.

6. If the insulation resistance is below 20megohms renew/service the main motor.

CAUTION: DO NOT apply power to a motor whichhas an insulation resistance of less than 20megohms.

WARNING

! Before removing the safety guards ordisconnecting or connecting the motorleads, switch the AC power supply OFFat isolator and wait for 12 minutes toallow the dc link capacitors to dischargeto a safe level. Check that the dc linkcapacitors have fully discharged beforestarting work on the compressor.

WARNING

! Before removing the safety guards ordisconnecting or connecting the motorleads, switch the AC power supply OFFat isolator and wait for 12 minutes toallow the dc link capacitors to dischargeto a safe level. Check that the dc linkcapacitors have fully discharged beforestarting work on the compressor.

HW 0367

115107108109

116117

ABC

A1

C1B1

CompAir


Acceptable ranges for motors

L45SR

Lmin (mH) Lmax (mH) Lmax/Lmin Ratio

1.30 min 13.00 min > 8.501.65 max 18.00 max

L75SR

Lmin (mH) Lmax (mH) Lmax/Lmin Ratio

0.95 min 9.50 min > 8.501.20 max 16.00 max

L120SR

Lmin (uH) Lmax (mH) Lmax/Lmin Ratio

595 min 5.60 min > 8.50730 max 7.50 max

9.7.2 Motor Inductance Test(Test for turn to turn faults)

1. Ensure that the main power supply to thecompressor is isolated.

2. Open the converter door and remove allguards.

3. Disconnect all SR motor leads from the powerconverter .

4. Use the meter specified in test equipment(para. 1).

5. Set the meter to measure 120Hz inductance(L).

6. Clip leads to phase A of the motor. Rotate themotor very slowly and note the lowest readingon the meter (this is Lmin). Rotate the motoragain and note the highest reading on themeter (this is Lmax).

7. Repeat step 6. for phase B.

8. Calculate the Lmax/Lmin ratio from thereadings taken for each phase.

9. Compare the readings with the table below.The motor is deemed to be faulty if the valuesfor Lmin and Lmax fall outside the ranges inthe table and/or if the Lmax/Lmin ratio is lessthan 8.5

SR Repair Manual – Disassembly & Assembly


CHAPTER

9DISASSEMBLY & ASSEMBLY

Page

A - 345SR, L45SR ...................................................................................................................................... 2

B - 475SR, L75SR ..................................................................................................................................... 19

C - L120SR ................................................................................................................................................. 35

CompAir


A - 345SR, L45SR

1. INLET NON-RETURN VALVE1.1 Remove Inlet Non-Return Valve1.2 Install Inlet Non-Return Valve1.3 Disassemble Inlet Non-Return Valve1.4 Inspect/Replace Worn Parts1.5 Assemble Inlet Non-Return Valve2. MINIMUM PRESSURE VALVE 2.1 Remove Minimum Pressure Valve 2.2 Install Minimum Pressure Valve 2.3 Disassemble Minimum Pressure Valve 2.4 Inspect/Replace Worn Parts 2.5 Assemble Minimum Pressure Valve3. OIL SCAVENGE PIPE3.1 Remove Oil Scavenge Pipe3.2 Install Oil Scavenge Pipe4. DRIVE MOTOR & COUPLING4.1 Remove Coupling Rubber Inserts4.2 Install Coupling Rubber Inserts4.3 Remove Drive Motor 4.4 Install Drive Motor 5. AIR-END5.1 Remove Air-End5.2 Install Air-End5.3 Remove Air-End Oil Seal5.4 Install Air-End Oil Seal 6. OIL COOLER6.1 Remove Oil Cooler6.2 Clean Oil Cooler 6.3 Install Oil Cooler7. AFTER COOLER7.1 Remove After Cooler7.2 Clean After Cooler 7.3 Install After Cooler8. FAN & FAN MOTOR8.1 Remove Fan and Fan Motor8.2 Install Fan and Fan Motor9. THERMOSTATIC BYPASS VALVE9.1 Remove Thermostatic Bypass Valve9.2 Install Thermostatic Bypass Valve

FIGURESFIG. 9.1 SCAVENGE COUPLING TOOLFIG. 9.2 AIR-END OIL SEAL INSTALLATION SLEEVE

DISASSEMBLY AND ASSEMBLY



1.1 Remove Inlet Non-Return Valve (fig. 9.1)

1. Remove right hand side panel.

2. Disconnect the air inlet pipe from the non-return valve [1].

3. Disconnect the wiring loom from the differentialpressure switch on the side of the non-returnvalve [2].

4. Disconnect the nylon pipe from the solenoidvalve [3]. Disconnect the wiring loom plug.

5. Remove the fourscrews securing the non-return valve to the air-end inlet [4].

1. INLET NON-RETURN VALVE

WARNING: RISK OF HIGH

DISASSEMBLY & ASSEMBLY (345SR, L45SR)

PRESSURE

6. Remove the non-return valve assembly fromthe air-end and discard the joint.

7. Cover the hole in the air-end to preventcontamination.

1.2 Install Inlet Non-Return Valve

Installation is a reversal of the removal procedure.

Note: Fit a new joint between the non-return valveand the air-end.

WARNING

! Refer to the safety procedures beforecarrying out fault diagnosis or testing anycircuit on the compressor unit.


! Before opening the door of the startercompartment, switch the power supplyOFF at the isolator and wait for 12minutes to allow the dc link capacitors todischarge to a safe level. Check that thedc link capacitors have fully dischargedbefore starting any maintenance work.

FIG. 9.1 INLET NON-RETURN VALVE

CompAir


1.3 Disassemble Inlet Non-Return Valve

1. Remove the solenoid valve.

2. Place the valve upside down on a flat surface.

3. Remove the two cap screws securing thevalve cover (fig. 9.2).

4. Remove the valve assembly, comprising thevalve head, spring and valve stem withretaining bar.

1.4 Inspect/Replace Worn Parts

1. Clean and inspect all parts for wear or damage.

2. Inspect valve head for signs of wear.

3. Renew spring.

4. Change all worn or damaged components fornew items.

1.5 Assemble Inlet Non-Return Valve

Parts required:

Major Service Kit, Part No CK8003-4

Assembly is a reversal of the disassemblyprocedure.

FIG. 9.2 REMOVING VALVE COVER

FIG. 9.3 VALVE ASSEMBLY INTERNAL

FIG. 9.4 VALVE KIT COMPONENTS



2. MINIMUM PRESSURE VALVE

2.1 Remove Minimum Pressure Valve

1. Remove the front service panel.

2. Screw the bolt, supplied with the repair kit,through the valve body into the piston (fig.9.5).

! Do not attempt to remove the valveassembly from the manifold block beforetaking up the compression on the pistonspring. Failure to heed this warning couldresult in personal injury.

3. Fully unscrew the valve body and remove theminimum pressure valve assembly from themanifold block.

2.2 Install Minimum Pressure Valve

1. Push the piston towards the valve body andscrew the bolt supplied in the repair kit throughthe valve body into the piston. Turn the bolt todraw the piston into the valve body (fig. 9.8).

2. Fit the minimum pressure valve assembly intothe manifold block using a new sealing washersupplied in the repair kit.

3. Unscrew and remove the bolt from the valvebody (fig. 9.9).

WARNING

HW 0405

FIG. 9.5 SECURING PISTON SPRING

HW 0406

FIG. 9.6 REMOVING VALVE BODY

4. Unscrew the bolt carefully to release thecompression on the piston spring.

5. Cover the hole in the manifold block to preventcontamination (fig. 9.7).

HW 0407

HW 0408

HW 0405

FIG. 9.7 PROTECTIVE COVER

FIG. 9.8 SECURING PISTON SPRING

FIG. 9.9 RELEASING PISTON SPRING

CompAir


4. Disassemble the valve assembly and discardthe ‘O’ ring seals (fig 9.12 (7) and (8)).


Clean and inspect all the parts for wear or damage.Inspect the surface of the piston for scratches.Clean and inspect the valve body for any scoring orcorrosion inside the bore. If the bore of the valvebody is corroded, remove all traces of corrosionusing a fine emery paper until the surface is smoothand clean. Apply a light coating of a silicone basedgrease to the bore of the valve body beforereassembling the valve. Change all worn ordamaged components for new items.

2.3 Disassemble Minimum Pressure Valve

1. Remove the minimum pressure valve. Refer topara. 2.1 ‘Remove Minimum Pressure Valve’.

2. Remove the valve body (fig. 9.10(1)) andpiston spring (2).

3. Remove the valve assembly (3), smallspring (4) and piston (6). Remove and discardthe ‘O’ ring seal (5) from the outer groove ofthe piston.

HW 04091

6

2

5

3

4

FIG. 9.10 MINIMUM PRESSURE VALVE

HW 0410

FIG. 9.11 DISMANTLING VALVE

HW 04117

8

FIG. 9.12 VALVE COMPONENTS



3. Fit a new ‘O’ ring seal (fig. 9.14 (5)) supplied inthe repair kit to the outer groove of the piston(6).

4. Insert the small spring (4) into the guide pinand insert the valve assembly (3) into the boreof the piston.

5. Insert piston spring (2) into the valve body (1)followed by the piston and valve assembly.

6. Install the valve. Refer to para. 2.2 ‘InstallMinimum Pressure Valve’ in this chapter.

2.5 Assemble Minimum Pressure Valve

Parts Required:

Major Service Kit.

1. Fit new ‘O’ ring seals (fig. 9.13 (7) and (8)),supplied in the service kit, to the guide pin andvalve head.

2. Assemble the valve using a new washer andlocknut supplied in the repair kit.

HW 0412

8

7

FIG. 9.13 MIN PRESS VALVE 'O' RING SEALS

HW 04091

6

2

5

3

4


CompAir


FIG. 9.15 SCAVENGE COUPLING TOOL

3. OIL SCAVENGE PIPE

3.1 Remove Oil Scavenge Pipe

Tooling Required: Scavenge Coupling Tool

WARNING

! Ensure all air pressure is released fromthe system in accordance with'Dismantling Precautions' in Chapter 1

HW 0413

12 A/FHEX

Ø3 Holes permissiblein corners of hexagonfor manufacture

17 A/F HEX Ø20.5Ø9.5 17 A/F HEX

13

17

207

27 2717

17

Ø3 Holes permissiblein corners of hexagonfor manufacture

14 A/FHEX

Material: EN 33

FIG. 9.16 OIL SEPARATOR FILTERS

HW 0414

1

2

1. Open the service door to gain access to themanifold block.

2. Close the control air isolating valve (fig. 9.16(1)).

3. Unscrew and remove the oil separator filters(2).



4. Fit the scavenge coupling tool (fig 9.15) overthe oil scavenge pipe as shown in fig. 9.17.Undo and remove the coupling and oilscavenge pipe assembly from the manifoldblock (fig. 9.18)).

3.2 Install Oil Scavenge Pipe

Installation is a reversal of the removal procedure.Fit a new scavenge pipe and coupling to themanifold block.

Note: Fit the scavenge pipe to the coupling beforeinstalling it into the manifold block.

HW 0415

HW 0416

FIG. 9.18 REMOVING OIL SCAVENGE PIPE

FIG. 9.17 USING SCAVENGE COUPLING TOOL

CompAir


4. DRIVE MOTOR & COUPLING

4.1 Remove Coupling Rubber Inserts

1. Remove motor side panel and open servicedoor.

2. Remove motor baffle (fig. 9.19 (1)).

3. Disconnect earth strap (2) from motor. Releaseand remove bolts/washers securing motor toAVMs (3).

4. Place suitable temporary supports under theair-end.

5. Remove nuts securing the motor to the air-end(fig. 9.20)

6. Using suitable blocks to support the motorfeet, slide the motor away from the air-end toallow access to the flexible coupling(fig. 9.21(4)).

Note: Take care not to move the motor beyond theextent of the motor cable conduit.

7. Remove coupling rubber inserts and discard.

4.2 Install Coupling Rubber Inserts

Fit new set of rubber inserts (fig. 9.21(5)) if required.


Note: Remove temporary supports from under theair-end after refitting the drive motor.

FIG. 9.19 REMOVING DRIVE MOTOR

FIG. 9.20 REMOVING MOTOR SECURING NUTS

FIG. 9.21 DRIVE COUPLING



1. Carry out procedures under 4.1 ‘RemoveCoupling Rubber Inserts’.

2. Remove side panels on reclaimer side.

3. Open power converter door and remove leftand right safety guards.

4. Disconnect all of the SR motor leads (fig 9.22(1)) from the power converter, including thethermistor cables (2). Release the motorconduit and rpt sensor lead.

5. Use suitable lifting equipment to slide themotor clear of unit. The motor can be pulledout through the service door.

Approximate weight of motor: 340kg.

4.3 Remove Drive Motor

4.4 Install Drive Motor


WARNING



! Before opening the door of the startercompartment, switch the power supply OFFat the isolator and wait for 12 minutes toallow the DC link capacitors to discharge toa safe level. Check that the dc linkcapacitors have fully discharged before starting any maintenance work.

FIG. 9.22 POWER CONVERTER

CompAir


5. AIR-END

5.1 Remove Air-End

1. Remove motor side and end panels.

2. Disconnect oil injection pipe and drain oil fromthe air-end.

3. Remove inlet non-return valve. (see para.1.1)

4. Disconnect the discharge pipe flange from theair-end (oil may still be present in the pipe).Discard the ‘O’ ring from the pipe flange.

5. Disconnect cables at the temperature sensor(fig. 9.23 (1)) and disconnect the scavenge oilpipe (2) from the air-end.

6. Remove nuts/washers securing the air-end tothe anti-vibration mounting (fig. 9.24 (1)).

7. Using suitable lifting gear, carefully raise air-end to clear anti-vibration mounting stud. Placetemporary supports under drive motor.

8. Remove bolts securing air-end to couplinghousing and remove air-end clear of the unit.

Approximate weight: 83kg

5.2 Install Air-End


Note 1: Replace all 'O' ring seals and self centeringbonded seals.

Note 2: Prime the air-end with 1 litre of BroomWade4000 HR oil or an approved alternative.

Note 3: Check oil level after running machine for 5minutes and top up if necessary.

WARNING


FIG. 9.24 ANTI-VIBRATION MOUNT

FIG. 9.23 AIR END CONNECTIONS

FIG. 9.25 REMOVING MOTOR SECURING NUTS



5.3 Remove Air-End Oil Seal

1. Remove the air-end.

2. Using a suitable puller, remove the flexiblecoupling.

3. Remove the oil seal housing by removing the 8bolts and using two jacking screws.

4. Remove the oil seal and gasket from the oilseal housing and discard.

5.4 Install Air-End Oil Seal

Tooling Required: Air-End Oil SealInstallation Sleeve (see fig. 9.26).

1. Ensure that the end bearings are undamagedand that all debris has been removed from theAir-End and oil seal housing before installing anew oil seal.

2. Fit the new oil seal into the oil seal housing.Ensure that the seal is seated firmly in therecess.

3. Place the oil seal installation sleeve onto therotor drive shaft. The installation sleeve shouldfit over the end of the shaft sleeve (fig. 9.27).

4. Install a new gasket to the Air-End.

5. Carefully lower the oil seal housing onto theAir-End, ensuring that the new oil seal fullyengages the shaft sleeve without twisting.

6. Fit the bolts and washers, tighten themprogressively as shown using a torque of57 Nm (42 lb.ft.) to secure the oil seal housing

7. Remove the installation sleeve.

8. Refit coupling.

9. Install air-end. Refer to para. 5.2 ‘Install Air-End’.

FIG. 9.26 AIR-END OIL SEAL INSTALLATIONSLEEVE

FIG. 9.27 INSTALLATION SLEEVE IN POSITION

CompAir


6. OIL COOLER

6.1 Remove Oil Cooler

1. Remove the end panel, roof panel, side panelsand exhaust baffle from the compressor unit.

2. Disconnect oil inlet and outlet pipes (fig 9.28)from cooler and let the oil drain from thecooler.

4. Remove the air inlet filter (fig. 9.31 (1)) and airinlet pipe (2) from non-return valve (3).

WARNING

! Ensure electrical power is isolated inaccordance with 'DismantlingPrecautions' in Chapter 1

3. Disconnect the fan motor cables from the fancontactor (RLC) and earth bar. Disconnectthermistors where fitted (fig. 9.29). Disconnectfan motor conduit from the power converterenclosure (fig. 9.30).

FIG. 9.30 FAN MOTOR CONDUIT

INLET

OUTLET

INLET OUTLET

98154-300

98154-350

HW 0432

FIG. 9.28 OIL COOLER CONNECTIONS

FIG. 9.29 FAN MOTOR CABLES

FIG. 9.31 AIR INLET CONNECTIONS



5. Remove the six screws securing the plenum chamber to the side frames.

6. Remove the fan assembly through the end ofthe machine.

7. Remove the rail at the top of the end frame.

8. Remove cross brace at rear of machine.

9. Remove the rail at the top of the end frame.

10. Remove cross brace at rear of machine.

11. Remove the exhaust duct plate (if fitted).

12. Secure the oil cooler using straps or ropes sothat it will not fall when the screws areremoved.

13. Loosen four nuts and bolts securing the oilcooler.

Note: Approximate weight of oil cooler: 52Kg

14. Loosen the screws securing the side frames to the base frame and power converter.

15. Remove four nuts and bolts securing the oilcooler.

16. Use two people to lift the cooler or cooler/support assembly out of the unit.

6.2 Clean Oil Cooler

The cooler should be removed and cleaned asnormal practice during Routine Maintenance.

Cleaning of the oil cooler should be carried out byflushing through with a suitable degreaser, detergentor vapour solvent.

6.3 Install Oil Cooler


FIG. 9.32 REMOVING FAN ASSEMBLY

CompAir


7. AFTER COOLER

7.1 Remove After Cooler

1. Open the service door from the front of thecompressor unit.

2. Remove inlet baffle (fig. 9.33(1)).

3. Loosen air delivery pipe between cooler andfilter block.

4. Disconnect cooler from user’s pipework.

5. Disconnect plastic pipe to pressure transducer.

4. Disconnect regulation air pipe from cooler topressure transducer.

5. Remove two screws securing cooler tobaseframe (2).

6. Remove air delivery pipe between cooler andfilter block.

7. Lift the cooler out of the unit.

Note: Approximate weight of after cooler: 23Kg

WARNING


7.2 Clean After Cooler

The cooler should be removed and cleaned asnormal practice during Routine Maintenance.

Accumulated dirt in the fins of the air cooler cannormally be removed using compressed air or asteam cleaner. Cleaning should be carried out fromthe reverse side to the air flow.

7.3 Install After Cooler

Installation is a reverse of the removal procedure.

FIG. 9.33 REMOVING AFTERCOOLER



8. FAN & FAN MOTOR

8.1 Remove Fan and Fan Motor

1. Remove side and end panels.

2. Disconnect the fan motor cables from the fancontactor (RLC) and earth bar. Disconnectthermistors where fitted (fig. 9.29). Disconnectfan motor conduit from the power converterenclosure (fig. 9.30).

3. Remove the air filter (fig. 9.34 (1)) anddisconnect air inlet pipe (2) from the non-returnvalve (3).

4. Remove six screws and washers securing theplenum chamber to the side frames.

5. Slide the plenum chamber and fan assembly(fig. 9.35) through the end of the machine.

6. Lay the fan/motor/cowling assembly on a flatsurface with the fan guard and motoruppermost.

7. Remove the fan guard.

8. Support fan/motor assembly with suitable liftinggear and remove four nuts/washers/bolts (fig.9.36) securing fan arms to fan cowling. Lift fan/motor and arms clear. Remove fan arms frommotor.

WARNING

! Ensure electrical power is isolated inaccordance with 'DismantlingPrecautions' in Chapter 1

8.2 Install Fan and Motor



FIG. 9.35 FAN ASSEMBLY

FIG. 9.36 FAN MOTOR RETAINING BOLTS

CompAir


9. THERMOSTATIC BYPASS VALVE

9.1 Remove Thermostatic Bypass Valve

1. Remove the reclaimer side panel, roof paneland exhaust baffle assembly.

2. Unscrew valve plug from pocket in coolerheader (fig. 9.37).

3. Remove the valve from the cooler completewith return spring (fig. 9.38).

9.2 Install Thermostatic Bypass Valve

Installation is a reversal of the removal procedure.Install a new sealing washer when fitting the plug.

Note: The thermostatic valve is supplied as acomplete unit and must be changed if defective.

4. Check the thermostat element by immersingit in a water bath at approximately 6°C abovethe nominal setting. Bypass port ‘B’ shouldclose. The nominal setting of the valve willbe found stamped on the end of the element.

FIG. 9.37 REMOVING THERMOSTATIC BYPASSVALVE

FIG. 9.38 THERMOSTATIC BYPASS VALVE


AC20160-1822, Issue 1, October 2002 Chapter 9, page 19

B - 475SR, L75SR

1. MINIMUM PRESSURE VALVE1.1 Remove Minimum Pressure Valve1.2 Install Minimum Pressure Valve1.3 Disassemble Minimum Pressure Valve1.4 Inspect/Replace Worn Parts1.5 Assemble Minimum Pressure Valve2. RECLAIMER2.1 Remove Reclaimer Element2.2 Install Reclaimer Element2.3 Remove Reclaimer2.4 Install Reclaimer3. NON-RETURN VALVE3.1 Remove Non-Return Valve3.2 Install Non-Return Valve3.3 Disassemble Non-Return Valve3.4 Inspect/Replace Worn Parts3.5 Assemble Non-Return Valve4. DRIVE MOTOR & COUPLING4.1 Remove Coupling Rubber Inserts4.2 Install Coupling Rubber Inserts4.3 Remove Drive Motor4.4 Install Drive Motor5. AIR-END5.1 Remove Air-End5.2 Install Air-End5.3 Remove Air-end Oil Seal5.4 Install Air-end Oil Seal6. AIR/OIL COOLER6.1 Remove Air/Oil Cooler Assembly6.2 Clean Air/Oil Cooler6.3 Install Air/Oil Cooler7. FAN & FAN MOTOR7.1 Remove Fan & Fan Motor7.2 Install Fan & Fan Motor8. THERMOSTATIC BYPASS VALVE8.1 Remove Thermostatic Bypass Valve8.2 Install Thermostatic Bypass Valve

FIGURES

FIG. 9.3 SCAVENGE PIPEFIG. 9.4 AIR-END OIL SEAL INSTALLATION SLEEVEFIG. 9.5 THERMOSTATIC BYPASS VALVEFIG. 9.6 THERMOSTATIC BYPASS VALVE - LATER COOLER

DISASSEMBLY AND ASSEMBLY

CompAir

Chapter 9, page 20 AC20160-1822, Issue 1, October 2002


1. Open the service door of the compressor. Removethe reclaimer side panel.

2. Remove the two bolts/washers from the deliverypipe coupling flange on the minimum pressure valveDisconnect the pipe to the differential pressureindicator and remove. If the valve is to bedisassembled, loosen the piston housing from valvebody by two threads (fig. 9.39).

3. Release the four nuts/washers securing the minimumpressure valve to the reclaimer cover. Remove thevalve. Remove the ‘O’ ring seals from the reclaimercover and the delivery pipe flange and discard(fig. 9.40).

4. Cover the hole in the reclaimer cover to preventcontamination.



Note: Fit new ‘O’ rings between the valve and reclaimercover and between the valve and delivery pipe flange.Apply Autol ‘Top 2000’ grease to the ‘O’ rings beforefitting.



DISASSEMBLY & ASSEMBLY (475SR, L75SR)

PI/98/023

WARNING


● Lethal voltages are used in thisequipment. Use extreme caution whencarrying out electrical checks. Isolatethe power supply before starting anymaintenance work.

● Before opening the door of the startercompartment, switch the power supplyOFF at isolator and wait for 12 minutes toallow the dc link capacitors to discharge toa safe level. Check that the dc linkcapacitors have fully discharged beforestarting any maintenance work.


FIG. 9.40 REMOVING MINIMUM PRESSUREVALVE




1. Remove the minimum pressure valve. Refer to para.1.1 ‘Remove Minimum Pressure Valve’.

2. Take a 250mm length of M8 x 1·25 threaded rodand insert through hole in top face of piston housing.Screw the rod into the piston to the bottom of thethread. Run a washer and nut down the exposed rodand turn the nut 2 full turns against the pistonhousing to compress the springs.

3. Using a suitable vice unscrew the valve body fromthe piston housing (fig. 9.41).

4. Remove the valve assembly, comprising the valvehead, guide pin and spring, from the piston. Removeand discard the ‘O’ ring from the piston housingmating face. Unscrew the 8mm nut on the threadedrod until the springs are fully relaxed. Remove anddiscard the ‘O’ ring from the piston diameter (fig.9.42). Remove the threaded rod, nut and washer andlift the piston and springs from the housing.

5. Hold the stem of the guide pin across the flat in softvice jaws. Do not overtighten the vice. Unscrew thelocknut from the guide pin and remove the washer,valve head, ‘O’ ring and retainer. Discard the ‘O’ring. Remove and discard the ‘O’ ring from the guidepin stem (fig. 9.43).



2. Inspect all surfaces of the piston for scratches.

3. Clean and inspect the valve body for any scoring orcorrosion inside the piston bore.

Note: If the piston bore of the valve body is corrodedremove all traces of corrosion using a fine emery paperuntil the surface is smooth and clean.

4. Change all worn or damaged components for newitems.

FIG. 9.41 REMOVING VALVE BODY FROMPISTON HOUSING

FIG. 9.42 PISTON DIAMETER WITH 'O' RINGREMOVED

FIG. 9.43 VALVE HEAD ASSEMBLY

CompAir



Parts required:


1. Hold the piston housing in a suitable vice and applyAutol ‘Top 2000’ grease to the bore of the housing.Apply Shell Abida R2 grease to the valve springsand locate in the bore of the housing.

2. Screw a 250mm length of M8x1·25 threaded rod intothe piston and insert through the springs andhousing to enter the piston into the bore. Take careto locate the springs correctly against the rear faceof the piston. Run a washer and nut on the exposedthreaded rod and tighten until the springs are justcompressed.

3. Apply Autol ‘Top 2000’ grease to the new ‘O’ ringseal and fit to the groove of the piston. Tighten nuton threaded rod to compress the springs and drawthe piston into the housing, taking care to avoiddamage to the ‘O’ ring (fig. 9.44).

4. Apply Autol ‘Top 2000’ grease to the new ‘O’ ringseals and assemble the valve head, ‘O’ rings andretainer with the guide pin using a new washer andlocknut. Tighten the locknut to a torque of 20Nm (15lb.ft.). Do not overtighten (fig. 9.45).

5. Apply Shell Abida R2 grease to the valve spring andinsert into the guide pin. Insert the valve assemblyinto the bore of the piston. Apply Autol ‘Top 2000’grease to the new ‘O’ ring and locate in the groove inthe mating face of the piston housing. Apply lightcoating of Loctite 577 to the threads of the pistonhousing (fig. 9.46).

6. Screw the valve body to the piston housing andtighten to compress the ‘O’ ring.

7. Release the nut on the threaded rod and remove rodfrom valve.

FIG. 9.46 FITTING VALVE HEAD TO PISTON

FIG. 9.45 ASSEMBLING VALVE HEAD

FIG. 9.44 ASSEMBLING PISTON



2. RECLAIMER

2.1 Remove Reclaimer Element


2. Remove the minimum pressure valve (see para.1.1).

3. Disconnect and withdraw the oil scavenge pipe.Disconnect and remove the regulation air pipe fromthe reclaimer cover (fig. 9.47).

4. Remove 10 bolts securing the reclaimer cover.

5. Use jacking screws to break the seal between thecover and reclaimer body (fig. 9.48).

6. Carefully remove the cover complete with old joint.Discard the old joint.

7. Remove and discard the old reclaimer element (fig.9.49).

Note: Inspect underside of reclaimer cover for any signs ofcorrosion. Remove any loose paint or rust by shot blastingor wire brush treatment to leave a clean, oil free surface.Apply one coat of zinc phosphate paint, ensuring completecoverage to a minimum thickness of 0·1 mm.


PRESSURE

FIG. 9.47 DISCONNECTING REGULATIONAIR PIPE

FIG. 9.48 REMOVING RECLAIMER COVER

FIG. 9.49 REMOVING RECLAIMERELEMENT

CompAir


2.2 Install Reclaimer Element


Note: Fit new joint to the reclaimer joint face and tightenthe reclaimer cover bolts in sequence to a torque setting of410Nm (fig. 9.50). Re-tighten bolts after 8 hours running.

CAUTION: The scavenge pipe must be fitted so that itcurves towards the centre of the reclaimer element (seeFig. 9.51). When fitted correctly there should be no gapbetween the pipe couplings. Failure to position the pipecorrectly will result in high oil carry over.

2.3 Remove Reclaimer

1. Remove the roof panel above the reclaimer.

2. Drain oil from the reclaimer.

3. Disconnect electrical wiring from excess pressureswitch (fig. 9.52) and remove the plastic pipe to thedifferential pressure switch.

4. Remove minimum pressure valve (see para. 1.1).

5. Disconnect the plastic scavenge pipe and theregulation air pipe.

6. Disconnect the coupling flange of the air inlet pipe atthe side of the reclaimer and secure the pipe toprovide clearance. Remove and discard the ‘O’ ringfrom the pipe flange (fig. 9.53).

FIG. 9.50 BOLT TIGHTENING SEQUENCE

FIG. 9.51 SCAVENGE PIPE

FIG. 9.52 DISCONNECTING EXCESSPRESSURE SWITCH

FIG. 9.53 DISCONNECTING AIR INLET PIPE



7. Disconnect the oil pipe between reclaimer and coolerat the reclaimer end and secure the pipe to provideclearance (fig. 9.54).

Note: Some oil may drain out of the cooler.

8. Remove the screws securing the intake air filter to thereclaimer. Move the filter aside and secure to provideclearance.

9. Fit eyebolts in the jacking holes on reclaimer coverand using a suitable hoist, support the reclaimer.

10. Release and remove three reclaimer mounting bolts(fig. 9.55).

11. Lift the reclaimer clear of the unit.

2.4 Install Reclaimer


Note: Refill the reclaimer with oil (refer to 2.8.5 in Chapter 6under ‘Normal Oil Change’).

3. NON-RETURN VALVE

3.1 Remove Non-Return Valve


2. Drain oil from air-end and place suitable catch trayunder non-return valve.

3. Remove the two nuts/washers from the dischargepipe coupling flange on the non-return valve (fig.9.56). Remove and discard the ‘O’ ring from the pipeflange. If the valve is to be disassembled loosen thecover from the valve body by about two threads.

Note: Oil may still be present in the pipe.

4. Disconnect the plastic pipe to the oil stop valve.

5. Remove the four nuts/washers securing the non-returnvalve to the air-end. Remove the valve. Remove anddiscard the ‘O’ ring.


FIG. 9.56 DISCONNECTING DISCHARGEPIPE

FIG. 9.55 RECLAIMER MOUNTING BOLTS

FIG. 9.54 OIL PIPE - COOLER/RECLAIMER

CompAir


3.2 Install Non-Return Valve


Note 1: Fit new ‘O’ rings between the valve and air-end andbetween the valve and discharge pipe flange. Apply Autol‘Top 2000’ grease to the ‘O’ rings before fitting.

Note 2: After installing the non-return valve prime the air-end as follows:

Remove the air intake filter and pour into the air-end 1 litreof BroomWade 4000HR oil or an approved alternative.Replace the intake filter.

3.3 Disassemble Non-Return Valve

1. Remove the non-return valve. Refer to 3.1 ‘RemoveNon-Return Valve’.

2. Using a suitable vice, unscrew the valve body fromthe cover (fig. 9.57). Remove the valve assembly,comprising the valve head, guide pin and spring, fromthe cover. Remove and discard the ‘O’ ring from thecover mating face.

3. Hold the stem of the guide pin across the flat in softvice jaws (fig. 9.58). Do not overtighten the vice.Unscrew the locknut from the guide pin and removethe washer, valve head, ‘O’ ring and retainer. Discardthe ‘O’ ring. Remove and discard the ‘O’ ring from theguide pin stem.


1. Clean and inspect all parts for wear or damage.Change all worn or damaged components for newitems.

3.5 Assemble Non-Return Valve

Parts required:


1. Assemble the valve head, ‘O’ rings and retainer withthe guide pin using a new washer and locknut.Tighten the locknut to a torque of 20Nm (15 lb.ft.). Donot overtighten.

2. Hold the valve cover in the vice across the flats ofthe hexagon. Apply Shell Albida R2 grease to the

FIG. 9.58 DISMANTLING VALVE HEAD

FIG. 9.59 FITTING VALVE ASSY TO COVER

FIG. 9.57 REMOVING VALVE COVER



new valve spring and insert the spring into the guidepin. Insert the valve assembly into the cover (fig.9.59).

3. Apply Autol ‘Top 2000’ grease to the new ‘O’ ring andlocate in groove in the mating face of the valve cover.

4. Screw the valve body to the valve cover and tightento compress the ‘O’ ring.

5. Install the valve. Refer to 3.2, ‘Install Non-ReturnValve’.



1. Remove two side panels at motor end.

2. Disconnect earth strap from motor. Release andremove bolts/washers securing motor to feet (fig.9.60). Unclip control harness from motor foot.

3. Disconnect motor and thermistor leads (refer toChapter 8 para 9.7).

4. Unscrew gland nut from motor cable conduit in side ofstarter box and ease motor power cables out of thestarter box and secure.

5. Place suitable temporary supports under the air-end.

6. Remove bolts securing the motor to the air-end (fig.9.61).

7. Using suitable blocks to support the motor pedestal,slide the motor away from the air-end to allow accessto the flexible coupling (fig. 9.62).



Fit new set of rubber inserts (12) if required.


Note: Remove temporary supports from under the air-endafter removing the drive motor.

FIG 9.60 MOTOR MOUNTING FEET

FIG 9.61 MOTOR/AIR END SECURING BOLTS

FIG 9.62 DRIVE COUPLING

CompAir


1. Carry out procedures under 4.1 ‘Remove CouplingRubber Inserts’.

2. Disconnect the RPT lead from the controller (fig.9.63).

3. Unscrew gland plate from converter.

4. Disconnect delivery air pipe from the moistureseparator.

5. Remove delivery panel, inlet grille and inlet panel.

6. Remove inlet baffle complete with sound insulation(fig 9.64).

7. Use a suitable piece of steel plate to slide the motorclear of unit.

Approximate weight: 340kg.




FIG. 9.63 CONTROLLER

WARNING


● Lethal voltages are used in thisequipment. Use extreme caution whencarrying out electrical checks. Isolatethe power supply before starting anymaintenance work.

● Before opening the door of the startercompartment, switch the power supplyOFF at isolator and wait for 12 minutes toallow the dc link capacitors to discharge toa safe level. Check that the dc linkcapacitors have fully discharged beforestarting any maintenance work.

FIG. 9.64 INLET BAFFLE



1. Open compressor service door and lift from hinges.Remove roof panel and reclaimer side panel.

2. Drain oil from the air-end and disconnect the oil drainpipe.

3. Disconnect the discharge pipe flange from the non-return valve end (oil may still be present in the pipe)(fig. 9.65). Discard the ‘O’ ring from the pipe flange.Disconnect the non-return valve.

4. Disconnect cables at the inlet air filter switch.Disconnect cables at the temperature sensor anddisconnect the scavenge oil pipe from the air-end (fig.9.66).

5. Disconnect the regulation air pipe from the oil stopvalve (fig. 9.67). Remove the oil stop valve andsecure to provide clearance.

5.1 Remove Air-End

● Ensure all air pressure is released from thesystem and electrical power is isolated inaccordance with ‘Dismantling Precautions’ inChapter 1.

5. AIR-END

WARNING

FIG. 9.65 DISCONNECTING DISCHARGEPIPE

FIG. 9.66 AIR END CONNECTIONS

FIG. 9.67 OIL STOP VALVE

CompAir



6. Remove intake air filter.

7. Remove flexible hose from the bypass valve andremove air inlet elbow/bypass assembly. Block air-end inlet to ensure no debris falls in.

8. Remove nuts/washers securing the air-end to theanti-vibration mounting (fig. 9.68).

9. Using suitable lifting gear, carefully raise air-end toclear anti-vibration mounting stud. Place temporarysupports under drive motor.

10. Remove bolts securing air-end to coupling housingand remove air-end clear of the unit.


5.2 Install Air-End


Note 1: Replace all 'O' ring seals, copper and Dowty seals.

Note 2: Prime the air-end with 1 litre of BroomWade 4000HR oil or an approved alternative.


1. Remove the air-end.

2. Using a suitable puller, remove the flexible coupling.

3. Remove the oil seal housing by removing the 8 boltsand using two jacking screws.

4. Remove the oil seal and gasket from the oil sealhousing and discard.


Tooling Required: Air-End Oil Seal InstallationSleeve

1. Ensure that the end bearings are undamaged and thatall debris has been removed from the Air-End and oilseal housing before installing a new oil seal.

2. Fit the new oil seal into the oil seal housing. Ensurethat the seal is seated firmly in the recess.

3. Place the oil seal installation sleeve onto the rotor

FIG. 9.68 AIR END A.V.M.

FIG. 9.69 INSTALLATION SLEEVE INPOSITION



drive shaft. The installation sleeve should fit over theend of the shaft sleeve.


5. Carefully lower the oil seal housing onto the Air-End,ensuring that the new oil seal fully engages the shaftsleeve without twisting.

6. Fit the bolts and washers, tighten them progressivelyas shown using a torque of 57 Nm (42 lb.ft.) to securethe oil seal housing


8. Refit coupling.

9. Install air-end. Refer to para. 5.2 ‘Install Air-End’.

6. AIR/OIL COOLER

6.1 Remove Air/Oil Cooler Assembly

1. Remove two side panels at motor end.

2. Remove fan guard from fan cowling and disconnectfan motor cables and thermistor cables from fanmotor terminal box and remove cables (fig. 9.71).

3. Disconnect air delivery pipe from moisture separator.

4. Remove delivery panel, inlet grille and inlet panel.

5. Remove exhaust panel and grille from roof andremove acoustic baffle assembly.

6. Position suitable funnel and container beneath oil pipeconnections at cooler. Disconnect oil inlet and outletpipes from cooler and drain oil from pipes and cooler(fig. 9.72). Secure pipes to provide clearance. Fittemporary plugs to pipe connections at cooler.

7. Disconnect and remove reclaimer discharge pipe fromcooler and minimum pressure valve (fig. 9.73).

! Ensure all air pressure is released from thesystem and electrical power is isolated inaccordance with ‘Dismantling Precautions’ inChapter 1.

WARNING

FIG. 9.71 REMOVING FAN GUARD

FIG. 9.72 OIL COOLER INLET AND OUTLETPIPES

FIG. 9.73 RECLAIMER DISCHARGE PIPE

CompAir


8. Disconnect drain pipe from moisture separator andsecure to provide clearance. Disconnect wiring plugfrom drain solenoid valve. Remove solenoid valve andstrainer from moisture separator.

9. Remove three screws securing heat sink duct to fansupport and starter box backplate and remove duct(fig. 9.74).

FIG. 9.76 HOISTING COOLER

10. Remove 4 nuts/bolts/washers securing cooler tocooler supports (fig. 9.75).

11. Position rope or webbing slings under cooler sidesand hoist cooler clear complete with moistureseparator, fan support and fan motor/cowling (fig.9.76).

12. Transfer to flat surface to stand on fan cowling.Position on blocks to give clearance for fan motor(fig. 9.77).

13. Remove moisture separator from cooler. Remove 16bolts/washers securing cooler to fan supports and liftcooler clear.

6.2 Clean Air/Oil Cooler

The cooler should be removed and cleaned as normalpractice during Routine Maintenance.

Externally. Accumulated dirt in the fins of the air side ofthe cooler can normally be removed using compressed airor a steam cleaner. Cleaning should be carried out from thereverse side to the air flow (top of the cooler).

Internally. Cleaning of the oil side only should be carriedout by flushing through with a suitable degreaser, detergentor vapour solvent.

FIG. 9.74 HEAT SINK DUCT

FIG. 9.75 RELEASING COOLER FIXINGS

FIG. 9.77 COOLER/FAN ASSY.



6.3 Install Air/Oil Cooler


Note 1: Replace all ‘O’ ring seals and copper washers withnew items.

Note 2: After installation replenish reclaimer with oil (referto Chapter 7, para 2.9.5 under ‘Normal Oil Change’).

7. FAN & FAN MOTOR

7.1 Remove Fan & Fan Motor

1. Remove Cooler as in para. 6.1.

2. Remove 8 bolts/washers securing fan cowling to fansupport fig. 9.78). Lift fan support clear.

3. Invert fan/motor/cowling assembly.

4. Support fan/motor assembly with suitable lifting gearand remove four nuts/washers/bolts securing fanarms to fan cowling fig. 9.79). Lift fan/motor and armsclear. Remove fan arms from motor.

7.2 Install Fan & Fan Motor


! Ensure all air pressure is released from thesystem and electrical power is isolated inaccordance with ‘Dismantling Precautions’ inChapter 1.

WARNING

FIG. 9.79 FAN MOTOR FIXINGS

FIG. 9.78 FAN COWL FIXINGS

CompAir



1. Open the service door.

2. Unscrew valve cap from pocket in cooler header (fig.9.80). Remove and discard the 'O' ring.

3. Remove the valve and return spring.

Note: The thermostatic valve is supplied as a completeunit and must be changed if defective.



Note: Fit a new ‘O’ ring seal and install the valve thecorrect way up in the cooler pocket as shown in Fig. 9.81,i.e. with the spring underneath and the wax element facingdownwards.

8.3 Remove AMOT Valve (Later model coolers)

1. Open service door.

2. Remove Amot valve from reclaimer.

8.2 Install Amot Valve

FIG. 9.81 THERMOSTATIC BYPASS VALVE(Earlier model coolers)

FIG. 9.82 THERMOSTATIC BYPASS VALVE(Later model coolers)

8. THERMOSTATIC BYPASS VALVE(Earlier model coolers)

! Ensure all air pressure is released from thesystem and electrical power is isolated inaccordance with ‘Dismantling Precautions’in Chapter 1.

WARNING

FIG. 9.80 REMOVING VALVE CAP



C - L120SR

1. INLET NON-RETURN VALVE1.1 Remove Inlet Non-Return Valve1.2 Install Inlet Non-Return Valve1.3 Disassemble Inlet Non-Return Valve1.4 Inspect/Replace Worn Parts1.5 Assemble Inlet Non-Return Valve2. MINIMUM PRESSURE VALVE 2.1 Remove Minimum Pressure Valve 2.2 Install Minimum Pressure Valve 2.3 Disassemble Minimum Pressure Valve 2.4 Inspect/Replace Worn Parts 2.5 Assemble Minimum Pressure Valve3. RECLAIMER3.1 Remove Reclaimer Element3.2 Install Reclaimer Element3.3 Remove Reclaimer3.4 Install Reclaimer4. DRIVE MOTOR & COUPLING4.1 Remove Coupling Rubber Inserts4.2 Install Coupling Rubber Inserts4.3 Remove Drive Motor 4.4 Install Drive Motor 5. AIR-END5.1 Remove Air-End5.2 Install Air-End5.3 Remove Air-End Oil Seal5.4 Install Air-End Oil Seal 6. COOLERS6.1 Remove After Cooler 6.2 Install After Cooler6.3 Clean After Cooler6.4 Remove Oil Cooler6.5 Install Oil Cooler6.6 Clean Oil Cooler7. FAN & FAN MOTOR7.1 Remove Fan and Fan Motor7.2 Install Fan and Fan Motor8 THERMOSTATIC BYPASS VALVE8.1 Remove Thermostatic Bypass Valve8.2 Install Thermostatic Bypass Valve9. BEKO DRAIN9.1 Removal and Servicing9.2 Installation

FIGURESFIG. 9.7 RECLAIMER COVER BOLT TIGHTENING SEQUENCEFIG. 9.8 AIR-END OIL SEAL INSTALLATION SLEEVE

DISASSEMBLY & ASSEMBLY

CompAir


1.1 Remove Inlet Non-Return Valve

1. Open access doors on the motor side.

2. Disconnect the air filter outlet hose (fig. 9.83(5)) from the non-return valve (1) by releasinghose clips (3).

3. Disconnect the air filter switch pipe elbow (2)from the non-return valve.

4. Disconnect the blowdown flexible hose (10).

5. Remove the four screws (6) and springwashers (7) securing the non-return valve tothe air end assembly (9). Discard joint (8).

6. Cover the hole in the air-end with tape toprevent contamination.

1.2 Install Inlet Non-Return Valve


Note: Fit a new joint between the non-return valveand the air-end.

1. INLET NON-RETURN VALVE


PRESSURE

DISASSEMBLY & ASSEMBLY (L120SR)

WARNING

● Refer to the safety procedures beforecarrying out fault diagnosis or testing anycircuit on the compressor unit.


● Before opening the door of the startercompartment, switch the power supplyOFF at the isolator and wait for 12minutes to allow the dc link capacitors todischarge to a safe level. Check that thedc link capacitors have fully dischargedbefore starting any maintenance work.

6, 7

1

8

45

2

9




1.3 Disassemble Inlet Non-Return Valve

1. Place the valve assembly (fig. 9.84 (10)) on aflat surface.

2. Remove the domed screw (11) and seal (12).

3. The valve stem assembly, comprises the airinlet valve head (13), bush (14), spring (15) andvalve stem (16). Remove the valve stemassembly by moving the valve head tocompress the spring and pushing the stemforward and driving the assembly out throughthe bottom of the valve.



2. Inspect air inlet valve head for signs of wear.


1.5 Assemble Inlet Non-Return Valve

1. Assembly is a reversal of the disassemblyprocedure.

10

16

13

15

12

11

14

FIG. 9.84 INLET/NON-RETURN VALVE

CompAir




1. Remove the left front service door and'reclaimer access' roof panel.

2. Remove the four bolts and washers securingthe aftercooler inlet pipe (1) to the minimumpressure valve (2). Discard Viton 'O' ring.

4. Remove the four nuts (fig. 9.86(4)) andwashers securing the minimum pressure valve(2) to the reclaimer cover (5) together with theseal. Discard the seal (6).

5. Cover the hole in the reclaimer cover toprevent contamination.


1. Fitting the minimum pressure valve is thereverse of the removal procedure given in 2.1.

Note: Fit a new seal on installation.


FIG. 9.86 M. P. VALVE & RECLAIMER




1. Remove the minimum pressure valve. Refer topara. 2.1 ‘Remove Minimum Pressure Valve’.

2. Take a 250mm length of M8 x 1·25 threadedrod and insert through hole in top face ofpiston housing (fig. 9.87 (1)). Screw the rodinto the piston to the bottom of the thread. Runa washer and nut down the exposed rod andturn the nut 2 full turns against the pistonhousing to compress the springs.

3. Remove the four screws (2) and washers (3)securing the piston housing (1) to the MPVbody (4). Collect warning label (5).

4. Remove the piston housing and pistonassembly complete from the MPV body.Collect 'O' ring (8).

5. Remove valve head (11) from piston (10).

5. Unscrew the 8mm nut on the threaded rod untilsprings (6 and 7) are fully relaxed.

6. Remove threaded rod and remove piston (10)and springs (6 and 7) from piston housing.

7. Remove the 'O' ring from the piston.


1. Clean and inspect all the parts for wear ordamage.

2. Inspect the surfaces of the piston and valvehead ) for scratches.

3. Clean and inspect the valve body for anyscoring or corrosion inside the bore.

Note: If the bore of the piston housing (1) or thevalve seat (12) of the valve body are corroded,remove all traces of corrosion using a fine emerypaper until the surface is smooth and clean.



1. Apply Shell Albida R2 grease to the springsand insert them into place in the pistonhousing.

2. Apply Autol 'Top 2000' grease to a new 'O' ring(9) and locate in groove in piston (10).Assemble piston (10) and valve head (11).

3. Apply a small amount of Autol 'Top 2000'grease to the piston housing bore and positionthe piston/valve head assembly in pistonhousing.

FIG. 9.87 DISMANTLING M. P. VALVE

FIG. 9.88 SECTIONAL ARRANGEMENT -M. P. VALVE

CompAir


4. Insert threaded rod through the hole in thepiston housing (1) and screw it into piston (10).

5. Run a washer and nut down the exposed rodand turn the nut 2 full turns against the pistonhousing to compress the springs.

6. Position a new 'O' ring (8) on the valve body (4)and mount the piston cover assembly on thevalve body with four screws and washers (2and 3). Ensure that warning label (5) iscorrectly in position as shown.

6. Install the valve. Refer to para. 2.2 ‘InstallMinimum Pressure Valve’ in this chapter.

3. RECLAIMER

3.1 Remove Reclaimer Element

1. Open the hinged access doors and/or roofpanel to gain access to the reclaimer.

2. Disconnect all pipes from the reclaimer cover(fig. 9.89 (1)). Disconnect and withdraw thescavenge pipe(2).

3. Remove four screws and spring washers (3) atboth ends of the air discharge pipe (4) from theminimum pressure valve (5). Remove pipe anddiscard joints.

HW 0019

4. Release the reclaimer cover securing bolts andremove the cover. If necessary, use three ofthe cover bolts in the jacking holes and tightendown to break the seal. Withdraw the reclaimerelement.

The element may be withdrawn through theaccess panel in the roof.

One bolt may be loosened and left in positionand used to hinge the cover.

Discard the element.

5. Inspect the underside of the reclaimer cover.The cover has been treated and should be ingood condition. If not, remove any loose paintor rust by shot blasting or wire brush treatmentto leave a clean, oil free surface. Apply onecoat of zinc phosphate paint, ensuring com-plete coverage to a minimum thickness of 0·1mm (0.004”). Allow to dry thoroughly.

3.2 Install Reclaimer Element

1. Fit the new element and joint and replace thecover (the joint is glued to the element). Re-place all the reclaimer cover bolts and tightenby hand to position the joint correctly.

2. Tighten the bolts evenly, following the tighten-ing sequence in fig. 9.91 to an initial torque of110 Nm / 81 ft.lbf. Check the ‘O’ ring.

3. Tighten the bolts, following the tighteningsequence, to a final torque of 200 Nm/148ft.lbf.

FIG. 9.89 RECLAIMER AND FITTINGS

FIG. 9.90 REMOVING RECLAIMER ELEMENT



FIG. 9.91 RECLAIMER COVER BOLT TIGHTENING SEQUENCE

4. Insert the scavenge pipe assembly and tighten.

5. Re-connect the pipes to the reclaimer cover.Fit new ‘O’ rings to delivery pipe joints andretightened the bolts to 100 Nm/74 ft.lbf.

6. Close the access door and roof.

CAUTION: When the compressor has reachednormal operating temperature, re-tighten the bolts tothe correct torque in the sequence shown.

1

2

3

45

6

7

8

9

10

11

12

13

14

15

16

HW 0021

3.3 Remove Reclaimer

1. Follow steps 1 to 4 in para 3.1 and remove theroof.

2. Remove the minimum pressure valve (seepara 2.1).

3. Disconnect electrical wiring from the reclaimerpressure transducer (fig. 9.92 (1)).

4. Disconnect the coupling flange of the air inletpipe (2) at the rear of the reclaimer. Discardthe 'O' ring.

5. Disconnect the oil pipe (3) between thereclaimer and oil cooler and secure the pipe toprovide clearance.

6. Fit eyebolts in the jacking holes on reclaimercover and using a suitable hoist support thereclaimer.

8. Release and remove three reclaimer mountingbolts (4).

9. Lift the reclaimer clear of the unit.

FIG. 9.92 RECLAIMER PIPEWORK & FITTINGS

CompAir




1. Remove motor end panel and open the motorside access doors.

2. Remove the fill in panel (fig. 9.93 (1)) in thebulkhead.

6. Remove coupling covers from the motor.

7. Remove nuts (fig. 9.94 (3)) and washers (4)securing the motor to the air-end.

8. Slide the motor (1) away from the air-end (2) toallow access to the flexible coupling (5).

Note: Take care not to move the motor beyond theextent of the motor cable conduit.


3. Disconnect earth strap (2) from motor. Releaseand remove bolt/washers securing AVM (3) tothe base. Use suitable blocks to support themotor.

4. Open the power converter door and removeguard. Disconnect main motor and motorthermistor leads.

5. Place suitable temporary supports under theair-end.

1

2

3

WARNING



! Before opening the door of the startercompartment, switch the power supply OFFat the isolator and wait for 12 minutes toallow the dc link capacitors to discharge to asafe level. Check that the dc link capacitorshave fully discharged before starting anymaintenance work.

FIG. 9.93 DRIVE MOTOR & MOUNTINGS

FIG. 9.94 DRIVE MOTOR & AIR END




1. Carry out procedures under 4.1 ‘RemoveCoupling Rubber Inserts’, steps 1 to 7.

2. Disconnect main motor leads (fig. 9.96 (1)),thermistor leads (2) and RPT Sensor lead fromthe back of the Surescan.

3. Disconnect motor conduit from powerconverter and withdraw the motor leads.

4. Remove 4 screws to disconnect the RPTflange from the back of the converter.

5. Use suitable lifting equipment to slide themotor clear of unit.

Approximate weight of motor: 340kg.




Fit new set of rubber inserts if required (fig. 9.95).


Note: Remove temporary supports from under theair-end and drive motor when fitting is completed.

FIG. 9.95 DRIVE COUPLING

FIG. 9.96 DRIVE MOTOR CABLES

CompAir


5. AIR-END

5.1 Remove Air-End

1. Remove motor side access doors.

2. Disconnect oil injection pipe (fig. 9.97 (1)) todrain oil from the air-end. Tie pipe up out of theway to stop oil draining down from the cooler.

3. Remove inlet non-return valve (2). (Refer to1.1)

4. Disconnect the discharge pipe flange (3) fromthe air-end (oil may still be present in the pipe).Discard the ‘O’ ring from the pipe flange.

5. Disconnect the scavenge oil pipe (4) from theair-end (5).

6. Remove bolts/washers securing the air-end (5)to the anti-vibration mountings (6).

7. Using suitable lifting gear take the weight ofthe air-end. Place temporary supports underdrive motor.

8. Take covers off the motor and remove boltssecuring air-end to the motor.

9. Remove air-end clear of unit.


5.2 Install Air-End


Note 1: Replace all 'O' ring seals and self centeringbonded seals.

Note 2: Prime the air-end with 1 litre of BroomWade4000 HR oil or an approved alternative.

2

5

6

3

4

1

WARNING

! Ensure electrical power is isolated inaccordance with ‘DismantlingPrecautions’ in Chapter 1.

FIG. 9.97 AIR END AND PIPEWORK




1. Remove the air-end (refer to 5.1).

2. Undo Taperlock bush and remove the flexiblecoupling.

3. Remove the oil seal housing by removing the 8bolts and using two jacking screws.

4. Remove the oil seal and gasket from the oilseal housing and discard.


Tooling Required: Air-End Oil SealInstallation Sleeve

1. Ensure that the end bearings are undamagedand that all debris has been removed from theAir-End and oil seal housing before installing anew oil seal.

2. Fit the new oil seal into the oil seal housing.Ensure that the seal is seated firmly in therecess.

3. Place the oil seal installation sleeve onto therotor drive shaft (fig. 9.99). The installationsleeve should fit over the end of the shaftsleeve.



5. Carefully lower the oil seal housing onto the Air-End, ensuring that the new oil seal fullyengages the shaft sleeve without twisting.

6. Fit the bolts and washers, tighten themprogressively as shown using a torque of57 Nm (42 lb.ft.) to secure the oil seal housing


8. Install air-end. Refer to 5.2, ‘Install Air-End’.

FIG. 9.99 INSTALLATION SLEEVE IN POSITION

CompAir


6. COOLERS

6.1 Remove After Cooler

1. Remove cooler end panels and side panelsfrom the compressor unit.

2. Disconnect and remove pipe (fig. 9.100 (1))between MPV and after cooler by removingflange nuts (2) and spring washers. Discard 'O'rings.

3. Remove after cooler discharge flexible pipe (3)by removing flange nuts (4) and washers.Discard 'O' rings.

4. Disconnect plug on delivery pressure probe.

5. Support after cooler (5) and remove fixingsfrom cooler columns (6).

5. Remove aftercooler from unit.

Note: Approximate weight of after cooler: 25 Kg

6.2 Install After Cooler


Note: Replace all 'O' rings with new items.

6.3 Clean After Cooler

The cooler should be cleaned as normal practiceduring Routine Maintenance.

1. Remove cooler end panel and both sidepanels.

2. Open access doors as necessary and cleancoolers using low pressure air (2 bar) or water.Do not use excess pressure as this mightdamage the coolers.

WARNING


FIG. 9.100 COOLERS & FITTINGS

3. Remove any dirt or liquid from base andreplace panels.

Accumulated dirt in the fins of the air cooler cannormally be removed using compressed air or asteam cleaner. Cleaning should be carried out fromthe reverse side to the air flow.

6.4 Remove Oil Cooler

1. Remove cooler end panel and end panel fromthe compressor unit.

2. Drain the oil from the oil cooler (11).

3. Disconnect and remove pipe (7) betweenreclaimer and oil cooler.

4. Disconnect swivel coupling (8) on oil cooleroutlet and remove oil filter assembly (9) byremoving screws (10).

5. Support oil cooler (12) and remove fixings fromcooler rear columns (6).

6. Remove oil cooler (12) from unit.

Note 1: Approximate weight of after cooler: 47 Kg

Note 2: Oil cooler will still contain some oil.



6.5 Install Oil Cooler


Note: Replace all 'O' rings and bonded seals withnew items.

6.6 Clean Oil Cooler

The cooler should be cleaned as normal practiceduring Routine Maintenance.

1. Remove cooler end panel and both sidepanels.

2. Open access doors as necessary and cleancoolers using low pressure air or water. Do notuse excess pressure as this might damage thecoolers.

3. Remove any dirt or liquid from base andreplace panels.Accumulated dirt in the fins ofthe oil cooler can normally be removed usingcompressed air or a steam cleaner. Cleaningshould be carried out from the reverse side tothe air flow.

Cleaning of the oil side should be carried out byflushing through with a suitable degreaser, detergentor vapour solvent.

CompAir


7. FAN & FAN MOTOR

7.1 Remove Fan and Fan Motor

1. Remove side access panels.

2. Disconnect fan motor cables in powerconverter.

3. Support Fan/Duct assembly (fig. 9.101).

4. Release fan grille (2) by removing 12 screws(3), washers (4) and nuts (5).

5. Release fan assembly from fan bracket (6) andduct (7) by removing 12 screws (8) andwashers (9).

6. Remove fan from motor. Lay fan assemblydown as shown in fig. 9.102 using blocks toprevent the fan rolling around.

Remove 4 nuts/washers/bolts (11) from plate(12) securing motor to fan assembly (13). Liftmotor from fan assembly.

7. Remove fan/motor assembly from the unit.

7.2 Install Fan and Fan Motor


Note: Replace fan seal if damaged.

WARNING


45

89

76

10

3

2

FIG. 9.101 FAN/DUCT ASSY.

FIG. 9.102 FAN & FAN MOTOR ASSY.



8. THERMOSTATIC BYPASS VALVE


1. Remove side panel on discharge side (filter)panel to gain access to the cooler assemblies(fig. 9.103 (1)).

2. Unscrew valve cap (3) from the pocket (2) inthe oil cooler. Remove and discard 'O' ring.

3. Remove the valve complete with return spring.

Note: The thermostatic valve is supplied as acomplete unit and must be changed ifdefective.

4. Check the thermostat element by immersing itin a water bath at approximately 6°C above thenominal setting. Bypass port ‘B’ should close.The nominal setting of the valve will be foundstamped on the end of the element.


Installation is a reversal of the removal procedure.Install a new 'O' ring when fitting the plug.

FIG. 9.103 THERMOSTATIC BYPASS VALVE

FIG. 9.104 THERMOSTATIC BYPASS VALVECOMPONENTS

CompAir


9. BEKOMAT DRAIN

Ensure that the device is pressureless andde-energised

9.1 Removal and servicing

1. Disconnect inlet and outlet pipes from the unit.

2. Undo the screws on the top of the Bekomatunit and disconnect the compressor wiringloom.

3. Replace the top on the Bekomat unit andremove from the compressor.

4. Unscrew the 6 pan head screws (fig. 9.105 (3))on the bottom of the unit until the heads arelevel with the outer edge and take offdiaphragm seat (4).

5. Replace worn parts (x).

9.2 Installation

Reasemble the Bekomat unit in reverse order.

9.3 Testing

1. Briefly press the test button (fig 9.106).

2. Valve opens for condensate discharge.

9.4 Checking the Alarm Signal

1. Shut off condensate inflow.

2. Press test button for at least 1 minute.

3. Red LED flashes (after 1 minute).

4. Alarm signal is being relayed.

FIG. 9.105 BEKOMAT DRAIN

FIG. 9.106 TESTING BEKOMAT DRAIN

lsr cyclon repair manual

Documents

compair genuine parts

parts andprocedures

nongenuine parts

cyclon sr

power converter parts

servicing facilities

servicing requirements

general safety precautions