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MANUAL DEL COMPRESOR COMPAIR

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  • CompAir

    AC20160-1822, Issue 1, November 2002

    CYCLON SR, and LSRAIR COMPRESSORS

    REPAIR MANUALSerial Numbers from:

    F180-0106 (Cyclon 345SR)F170-0112 (Cyclon 475SR)

    F180-0101 (L45SR)F170-0112 (L75SR)F171-0100 (L120SR)

  • CompAir

    AC20160-1822, Issue 1, November 2002

    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

    AC20160-1822, Issue 1, November 2002

    CONTENTS

    Chapter Title1 Safety Procedures2 Product Improvements

    3 General Description4 Technical Data

    5 Mechanical Fault Finding6 Components7 Maintenance

    8 Electrical Systems and Fault Diagnosis9 Disassembly and Assembly (Mechanical)

    Appendix 1 DimensionsAppendix 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

  • 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 aCAUTION 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 underSafety Procedures may be considered dangerouspractice or misuse of the compressor unit.

    1. GENERAL

    SAFETY PROCEDURES

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

    LSR Repair Manual Safety Procedures

    2.3 Notes

    Methods to make the job easier and points whichrequire particular attention are identified by a Notein 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 users 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

    Chapter 1, page 4 AC20160-1822, Issue 1, November 2002

    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 VOLTAGEDo 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 above120C 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

  • AC20160-1822, Issue 1, November 2002 Chapter 1, page 5

    LSR Repair Manual Safety Procedures

    3. Close the isolating valve between thecompressor unit and the users 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

    Chapter 1, page 6 AC20160-1822, Issue 1, November 2002

    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.

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

    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 BULLETINSInsert when issued.

    MACHINE/S SERIAL NUMBERS IMPROVEMENT BULLETIN PAGE

  • CompAir

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

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

    LSR Repair Manual Product Improvements

    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 0C,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 ICs 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

    Chapter 2, page 4 AC20160-1822, Issue 1, November 2002

    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 1C 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 1C.

    HW 0274

    bar

    psi

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 5

    LSR Repair Manual Product Improvements

    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 PACKAGING1. Locate the compressor close to the

    installation 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

    Chapter 2, page 6 AC20160-1822, Issue 1, November 2002

    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.

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 7

    LSR Repair Manual Product Improvements

    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

    Chapter 2, page 8 AC20160-1822, Issue 1, November 2002

    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

    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.

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 9

    LSR Repair Manual Product Improvements

    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

    Chapter 2, page 10 AC20160-1822, Issue 1, November 2002

    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

    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.

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 11

    LSR Repair Manual Product Improvements

    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 Contents98161-32 Phase Failure Relay98140-361 110C Black Cable98140-362 111C Black Cable98140-363 112C Black Cable98140-364 137B Blue Cable98140-365 170 Blue Cable98150-1 Cable Ties (5 off)98241-31 Din Rail 210mmC20775-19 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

    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.

  • CompAir

    Chapter 2, page 12 AC20160-1822, Issue 1, November 2002

    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.

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

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    ELECTRICAL CONNECTION DIAGRAM - 2 OF 3(SUPERSEDES DIAGRAM IN USER MANUAL)

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    Chapter 2, page 16 AC20160-1822, Issue 1, November 2002

    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 Contents98161-32 Phase Failure Relay98140-356 110C Black Cable98140-357 111C Black Cable98140-358 112C Black Cable98140-359 140B Red Cable98140-360 170 Red Cable98150-1 Cable Ties 5 offC20775-20 Electrical Schematic Diagram

    Fitting Instructions

    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

    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.

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 17

    LSR Repair Manual Product Improvements

    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.

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  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 21

    LSR Repair Manual Product Improvements

    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

    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.

  • CompAir

    Chapter 2, page 22 AC20160-1822, Issue 1, November 2002

    Fitting Instructions

    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.

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    LSR Repair Manual Product Improvements

    FIG. 1 SIDE PANEL

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    Chapter 2, page 24 AC20160-1822, Issue 1, November 2002

    FIG. 2 INLET BOX

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    LSR Repair Manual Product Improvements

    FIG. 3 OUTLET BOX

    HW 0323

  • CompAir

    Chapter 2, page 26 AC20160-1822, Issue 1, November 2002

    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

    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.

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 27

    LSR Repair Manual Product Improvements

    Tools Required

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

    Fitting Instructions

    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

    Chapter 2, page 28 AC20160-1822, Issue 1, November 2002

    HW 0325

    FIG. 1 - HOLE CENTRES - POWER CONVERTER DOOR

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

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    HW 0327

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

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 31

    LSR Repair Manual Product Improvements

    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

    Chapter 2, page 32 AC20160-1822, Issue 1, November 2002

    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 50/60HzL45SR All voltages 3 x 35mm2 gG125AL75SR All voltages 3 x 70mm2 gG200AL120SR All voltages 3 x 120mm2 gG315A

    .

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

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 33

    LSR Repair Manual Product Improvements

    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 INLET2 A3764-6 3/4" PLUG 1 ORIGINAL COOLER OIL INLET3 98418-61 ANTI VIBRATION MOUNTS 4 COOLER TO SUPPORTS4 95148-14 WASHERS 8 COOLER TO SUPPORTS5 95179-6 SPRING WASHER 8 COOLER TO SUPPORTS6 95111-5 NUT M8 8 COOLER TO SUPPORTS7 98154-337 OIL/AIR COOLER 1 ON SUPPORTS VIA AVMS8 95635-8 COPPER WASHER 4 NIPPLES9 C11605-25 NIPPLE 1 BSP 4 COOLER AND AMOT VALVE

    10 95635-6 COPPER WASHER 1 COOLER DRAIN PORT11 98650-109 DRAIN COCK 1 COOLER DRAIN PORT12 A3764-6 PLUG 1 DRAIN COCK13 95406-801 1 NIPPLE TAPER THREAD 1 RECLAIMER OUT14 98650-390 AMOT VALVE 1 RECLAIMER OUT15 98156-308 TEE 1" BSP 1 FILTER16 98504-92 RUBBER SEALING STRIP 0.25M PROTECTS HOSE C27399-33117 C27399-331 ASSY, FLEXIBLE HOSE 1 OIL COOLER TO FILTER VIA TEE18 C27399-330 ASSY, FLEXIBLE HOSE 1 AMOT TO OIL COOLER INLET19 C27399-343 ASSY, FLEXIBLE HOSE 1 TEE TO AMOT20 C27399-334 BAFFLE, FOAM EXHAUST 1 INSIDE EXHAUST DUCT21 C27399-335 ASSY, EXHAUST DUCT 1 TOP OF AIR/OIL COOLER22 95251-276 STUD SCREWED METRIC 2 AIR/OIL COOLER AIR INLET23 A3753-36 WASHERS 16 PLENUM CHAMBER TO COOLER24 95602-85 O RING 1 AIR/OIL COOLER AIR INLET

  • CompAir

    Chapter 2, page 34 AC20160-1822, Issue 1, November 2002

    3. Procedure

    3.1 Drain the compressor system of oil.

    3.2 Remove the original cooler. Use C11607-5 (1To 3/4 Reducing Bush) and A3764-6 (3/4Plug) 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.

  • AC20160-1822, Issue 1, November 2002 Chapter 2, page 35

    LSR Repair Manual Product Improvements

    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 3/47. 95635-8 Copper Washer 16, 95635-6 Copper Washer8. 95406-801 Nipple 1" B5P Taper 17. 98650-109 Drain Cock 3/49. 98650-390 Amot Valve

    Fig 3 - New pipework circuit

    891011

    1 2 3

    4

    5

    67

    12

    1314

    15

    16

    17

    HW 0109

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    Chapter 2, page 36 AC20160-1822, Issue 1, November 2002

    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

    AC20160-1822, Issue 1, November 2002

    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 users 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.

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    LSR Repair Manual General Description

    AC20160-1822, Issue 1, November 2002

    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

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    AC20160-1822, Issue 1, November 2002Chapter 3, page 4

    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 users 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 users 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 users 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 theusers 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.

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    LSR Repair Manual General Description

    AC20160-1822, Issue 1, November 2002

    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

    AC20160-1822, Issue 1, November 2002Chapter 3, page 6

    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 40 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 40 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.

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    LSR Repair Manual General Description

    AC20160-1822, Issue 1, November 2002

    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

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    AC20160-1822, Issue 1, November 2002Chapter 3, page 8

    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.

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    LSR Repair Manual General Description

    AC20160-1822, Issue 1, November 2002

    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

    1112

    14

    13

    15

    16

    1718

    19

    20

    21

    22

    Oil flowAir flowAir/oil mixture

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    AC20160-1822, Issue 1, November 2002Chapter 3, page 10

    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

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    LSR Repair Manual General Description

    AC20160-1822, Issue 1, November 2002

    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

    AC20160-1822, Issue 1, November 2002Chapter 3, page 12

    FIG. 3.6 AIR/OIL SYSTEM - L120SR

    1. Switched Reluctance Drive Controller 8. Separator Filtration Element2. Switched Reluctance Drive Motor 9. Minimum Pressure NonReturn Valve3. Air Intake Filter 10. Oil Cooler4. Intake Non Return Valve 11. Air Cooler5. Temperature Sensor 12. Oil Filter6. Compression Element 13. Pressure Transmitter7. Separator Vessel

    A Intake Air C Air/Oil MixtureB Compressed Air D Oil

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    LSR Repair Manual General Description

    AC20160-1822, Issue 1, November 2002

    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 theAutomatic mode which varies the volume of airdelivered by the compressor by adjusting therotational speed of the air-end to match the demandon the users 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 enterStandby 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 enterStandby condition. Subsequently, if thedelivery pressure falls below the lower setpointthe SR motor will re-start and run at the pre-setspeed.

  • CompAir

    AC20160-1822, Issue 1, November 2002Chapter 3, page 14

    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

    1314151617

    19

    21

    22

    11

    5

    28

    7

    30

    32 33 34 35

    29

    36 37 38 39 40

    8

    M

    918

    106

    A B

    23

    27

    2526

    12

    31

    HW 0009

    3 PHASE POWER SUPPLY

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    LSR Repair Manual Ge