Technical Manual l03

Technical Manual

L02 - L05 Rotary Screw Compressors 9 0 0 /2 0 1 A A 5 0 1 L D

Oil Injected, Air-Cooled

GB

fred

Contents

CompAir

Contents 1 1.1 1.2 1.3 1.4 1.5

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 5 About The L02 - L05 Range . . . . . . . . . . . . . . . . . . . . . . . . . 5 Correct Compressor Operating Conditions . . . . . . . . . . . . . . . . . 6 Improper Use Of Compressor . . . . . . . . . . . . . . . . . . . . . . . . 6

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Warnings, Cautions and Notes. . . . . . . . . . . . . . . . . . . . . . . . 7 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operational Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance and Repair Precautions . . . . . . . . . . . . . . . . . . . . 9 Precautions In The Event Of Fire. . . . . . . . . . . . . . . . . . . . . . 10 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Performance Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dimensions, Weights, Cooling Airflow Requirements . . . . . . . . . . . 12 Approved Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Refrigerant Dryer (Where Fitted) . . . . . . . . . . . . . . . . . . . . . . 13 Safety Measures Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Air BASIC Electronic Controller Specifications (Where Fitted) . . . . . . . 14 General Arrangement Drawings . . . . . . . . . . . . . . . . . . . . . . 15

3.9 3.10 4 4.1 4.2 4.3 4.4

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Compressor Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Regulation System (Only for Version with AirBASIC Controller) . . . . . . 28 Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lifting and Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . 29 Installation Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Connection Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installation Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 After Prolonged Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 7.2 7.3 7.4

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Electrical Diagrams - Compressor . . . . . . . . . . . . . . . . . . . . . 20 Electrical Diagrams - AirBasic Controller . . . . . . . . . . . . . . . . . . 22

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 To Start (Not Valid For Version With “Airbasic” Controller). . . . . . . . . 32 To Stop (Not Valid For Version With “Airbasic” Controller). . . . . . . . . 32 Shut-Down Due To Power Failure . . . . . . . . . . . . . . . . . . . . . 32 Starting At Low Temperatures (below 0°C). . . . . . . . . . . . . . . . . 33 Electronic Controller (Where Fitted) . . . . . . . . . . . . . . . . . . . . 33 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . Service Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Maintenance . . . . . . . . . . . . . . . . . . . . . . . . After Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 34 . . . . 34 . . . . 35 . . . . 36 . . . . 36

3

Contents

7.5 7.6 7.7 7.8 7.9

Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Guidelines For Oil Change Intervals . . . . . . . . . . . . . . . . . . . . 36 Belt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Automatic Condensate Drain (Where Fitted) . . . . . . . . . . . . . . . . 38 Routine Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . 38

8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9 9.1

AirBASIC Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . 41 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9.2 9.3 9.4 9.5 9.6 9.7 9.8

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Compressor Operation with the AirBASIC Controller. . . . . . . . . . . . 41 Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Error Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Transducer Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

10

Compressor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8

Compressed Air Dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Safety - Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Technical Data - Dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 "iDRY" Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . . 79 Timed Condensate Discharge Unit . . . . . . . . . . . . . . . . . . . . . 85

11.9 11.10

4

CompAir

Operation And Maintenance Troubleshooting Dryers . . . .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . .. .. .. .. .86 88

DL105AA

Introduction 1

CompAir

1

Introduction

1.1

General Worldwide service and parts facilities are provided by CompAir. If you experienc e any difficulty, please inform your local CompAir office.

Due to the low noise level of the L02-l05 range, the compressor can be installed at the point of use, requiring no additional cost for a separate compressor room or expensive pipework.

It is essential to quote the compressor MODEL and SERIAL numbers in all communications.

The Start/Stop operation ensures no idling time and no idling energy costs. The L02-L03 as standard are equipped with Start/Stop control and a direct start relay. Working hour indicator and pressure display are also Included.

All pressures shown are gauge pressures. CompAir reserves the right to modify the contents of this publication without notice and the data given is in no way binding on the manufacturers.

The L04 - L05 compressors as standard are equipped with Star/Delta starting and the electronic AirBasic controller, which provides the user with data on total hours of operation, operating temperature and additional information such as:

Where approximate figures are shown, specific details are available on request.

1.2

Maintenance a nd S ervicing

- Air filter replacement

Maintenance, repairs and/or modifications must only be carried out by competent personnel who have completed the relevant training.

- Oil filter replacement - Separator filter replacement - Oil change

USE ONLY

- Regular maintenance advice 1.3.1

Standard Equipment: Star/Delta starting (L04-L05)

GENUINE PARTS 1.3

About The L02 - L05 Range These compressors can be combined with different options to provide everything from a stand alone compressor to a complete compressor station.

DOL starting (L02-L03) Overload relay protection Start/Stop control with pressure switch (L02 - L03) Main On/Off switch

Options include:

Electric motor, IP5S, F-class insulation

- Compressor base mounted

Oil level monitoring, sight glass

- Compressor mounted on an air receiver - Airstation solution (includes compressor and refrigerant dryer, both mounted on an air receiver)

Belt transmission Safety devices for:

Ease of maintenance is enhanced by the removable side doors which provide quick and generous access to all service points.

- Compressor over temperature, trip at 110 °C

The compressors incorporate high reliability V belts, designed for the highest performance providing hours of reliable operation.

DL105AA

AirBasic controller (L04-L05)

- Motor over temperature

- Compressor over pressure (safety valve) Running condition indicators: - Pressure - Hour-meter

5

1 Introduction

CompAir

Epoxy powder coated enclosure

and having a pressure rating at least 10% higher than the unit itself.

Oil thermostat 1.3.2 a)

Air Receiver-mounted

The air delivered from these compressors is not suitable for human use. It must never be used as breathing air.

High quality air receiver built to the highest standard EN87/404 and AD2000. Inspection-free for 5 years.

The compressor is designed only to be operated complete with closed enclosure, for the purposes of cooling, protection and sound

- 200 Litre capacity, suitable for L02 to L05

proofing.

Options Available

- 500 Litre capacity, L04 - L05 only b)

1.5

Improper U se O f C ompressor

Refrigerant Dryer, L02FS - L05FS

The manufacturer shall waive all responsibility in case of:

High performance combined with low pressure losses

a)

3°C dew point at 25°C ambient temperature (ISO 7183)

Incorrect use by untrained or negligent personnel.

b)

Use in violation of current laws.

Environmentally friendly refrigerant R134a

c)

Incorrect installation.

Digital controller displaying:

d)

Installation without suitable reservoir.

- Dew point indication

e)

Installation in dust-filled environments (i.e. cement, silica etc.....).

f)

Incorrect electrical connection.

g)

Serious lack of proper maintenance.

- Fault memory Other

h)

Use of non-original spares for the model.

L04 - L05 available with DOL starting

i)

Total or partial failure to observe the instructions.

j)

Damage due to natural or exceptional events.

k)

Tampering with the safety valve.

l)

Exceeding maximum pressure rating through tampering.

m)

Operation of compressor without panels and guards.

- Additional energy saving mode - Maintenance display

c)

Prefilter and microfilter combination Timed or float condensate drains for receiver-mounted units.

1.4

Correct C ompressor O perating Conditions The compressor described in this manual is only suitable for the compression of atmospheric air up to the maximum pressure stated on the identification plate. The compressor is an 'industrial' type, to be used in accordance with the technical specifications of the compressor itself. The compressor works automatically and no specific operator is required. However, the unit must be supervised in use and must have all routine maintenance carried out by an expert technician, who should be familiar with all aspects of its operation and safety outlined in this manual. The compressor is designed exclusively for operation connected to an approved air reservoir of suitable capacity (at least 200 lt.)

6

DL105AA

Safety Procedures 2

CompAir

2

Safety Procedures

2.1

General

2.2

Warnings, Cautions and Notes

Most accidents which occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions.

2.2.1

Warnings Warnings call attention to operations or procedures involving specific hazards which could cause injury or death and are identified

An accident can often be avoided by recognising a situation that is potentially hazardous.

by the following symbols on the unit and in the text of this manual.

When handling, operating or carrying out maintenance on the unit, personnel must use safe engineering practices and observe all relevant local health and safety requirements and regulations.

WARNING: RISK OF DANGER

WARNING: RISK OF ELECTRIC SHOCK

The attention of users in the UK is drawn to the Health and Safety at Work Act, 1974, the Regulations of the Institution of Electrical Engineers and the Pressure Systems and Transportable Gas Container Regulations 1989.

WARNING: RISK OF HOT SURFACES

CompAir cannot anticipate every possible circumstance which might represent a potential hazard. The WARNINGS in this manual are therefore not all-inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by CompAir he must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property. The standard builds of all CompAir products are not intended for use in either explosive or potentially explosive 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 has occurred, combustion propagates to the entire unburned mixture and may cause a hazard. A potentially explosive atmosphere is an atmosphere which could become explosive due to local conditions.

WARNING: CONSULT MANUAL

WARNING: COMPONENTS AND SYSTEMS UNDER HIGH PRESSURE

WARNING: REMOTE START - MACHINE MAY START WITHOUT WARNING

2.2.2

Cautions Incorrect operational procedures causing possible damage to the compressor unit are identified by a ‘Caution’ in the text of this manual.

2.2.3

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

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

DL105AA

7

2 Safety Procedures

2.3

CompAir

The minimum pressure/non-return valve is not intended as an isolating valve and should not be relied upon for this purpose. In addition, it may be necessary to install shut-off valves elsewhere in the system to allow a dryer or other equipment to be by-passed.

General Safety Precautions If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing and eye protection is worn. Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing. Before releasing compressed air through a hose make sure that the free end is held securely so that it cannot whip and cause injury. Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to local safety regulations.

2.4

Operational Precautions The compressor unit must only be operated by competent personnel under a trained and qualified supervisor. Do not run the compressor with doors open or covers removed except when checking for leaks. Never remove or tamper with the safety devices, guards or insulation materials fitted to the unit. The compressor must only be operated at the supply voltage and/or frequency for which it is designed.

Cables, chains or ropes must never be applied directly to lifting eyes. Always use an appropriate shackle or hook, properly positioned. Arrange lifting cables so that there are no sharp bends.

On a unit equipped with an Automatic Start/Stop system, attach a sign stating ‘THIS UNIT MAY START WITHOUT WARNING’ next to the display panel.

Use a spreader bar to avoid side loads on hooks, eyes and shackles. When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary.

On a unit equipped with an Automatic Restart device, attach a warning notice stating ‘THIS UNIT HAS BEEN MODIFIED AND WILL START AUTOMATICALLY ON APPLICATION OF POWER’ next to the display panel and on the inside of the unit next to the starter contactors.

Installation P recautions Installation work must only be carried out by competent personnel under a trained and qualified supervisor. A fused isolating switch must be fitted between the main power supply and the compressor. Ensure that air drawn into the air intake will not be contaminated with flammable fumes or vapours. Ensure that the air delivery pipe from the compressor to the user’s pipework or receiver is free to expand. A shut-off valve must be fitted in the delivery air line to enable the compressor unit to be isolated. This is particularly important if more than one unit is to be coupled in parallel or connected to an existing air supply system.

8

2.5

If the unit is equipped with a Remote Control device, attach warning notices stating ‘THIS UNIT CAN BE STARTED REMOTELY’ in prominent locations, one on the outside of the unit, the other inside the control compartment. As a further safeguard, take adequate precautions to make sure there is no one checking or working on the unit before attempting to switch on remotely controlled equipment. Attach a ‘CHECK THAT ALL PERSONNEL ARE CLEAR OF THE UNIT BEFORE STARTING’ or similar warning notice to the remote start equipment. If there is any indication that the compressor is overheating it must be shut down and the cause investigated. Beware of burns from hot metal parts or hot water when working on a unit which has recently been shut down. The compressor must not be operated at pressures above the nominal pressure given on the data plate.

DL105AA

Safety Procedures 2

CompAir

The compressor must not be operated in ambient temperatures outside of those given under ‘Technical data’. The ‘Noise at Work Regulations 1989’ suggest that ear protectors should be worn where noise levels are 85 dB(A) or higher. With all covers in place, the noise levels of the compressors described in the manual are substantially lower than this figure unless installed in an already noisy environment. Be aware that high noise levels can interfere with communication.

2.6

Maintenance a nd R epair Precautions Before commencing any work on the compressor, switch the power supply OFF at isolator unless directed otherwise in the text of this manual. Maintenance, repairs or modifications must only be carried out by competent personnel under a trained and qualified supervisor. Lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the electrical system. If replacement parts are needed use only CompAir Genuine Parts. Do not open the starter compartment or touch electrical components while voltage is applied unless it is necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the proper tools and wearing appropriate body protection against electrical hazards. Before removing any panels from the enclosure, if fitted, or dismantling any part of the unit, carry out the following preparatory operations:Isolate the compressor unit from the main electrical power supply. Lock the isolator in the ‘OFF’ position and remove the fuses. Attach a label to the isolator switch and display panel carrying the warning ‘WORK IN PROGRESS – DO NOT APPLY VOLTAGE’. Do not switch on electrical power or attempt to start the unit if a warning label is attached. Close the isolating valve between the compressor unit and the user’s pipework. Attach a label to each valve carrying the

DL105AA

warning ‘WORK IN PROGRESS – DO NOT OPEN’. Ensure that the blowdown system has operated to release all pressure from the unit. Check that the pressure display registers zero. Release any remaining pressure from the compressor side of the non-return and isolation valve by slackening a pipe connection. Use only greases (where used) approved by CompAir. Make sure that the selected lubricants comply with all relevant safety regulations, especially with regard to the risk of explosion or fire and the possibility of decomposition or the generation of hazardous gases. Always clean up any spills from both the inside and outside of the compressor unit before and after maintenance work. Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good running order. The accuracy of pressure temperature sensors must be regularly and checked. They must be renewed when acceptable tolerances are exceeded. Protection devices must be tested as described in the ‘Maintenance’ section of this manual. Keep the compressor unit clean at all times. Protect components and exposed openings by covering with clean cloth or tape during maintenance and repair work. Protect the motor, air intake, electrical and regulation components against the entry of moisture, e.g. when steam cleaning. Precautions must be taken when carrying out welding or any repair operation which generates heat, flames or sparks. The adjacent components must always be screened with non-flammable material. Never use a light source with an open flame to inspect any part of the unit. In no circumstances must any welding work or other modification be carried out on any part of the pressurised system. Before dismantling of any part of the compressor unit ensure that all heavy movable parts are secured.

9

2 Safety Procedures

CompAir

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

for ‘material composition disposal’ e.g. base metals, plastics, fabrics etc and be subject to normal industrial waste re-cycling processes.

Check the direction of rotation of the HSU and fans when starting up the compressor initially and after any work on the electrical connections or switchgear.

c)

Bio-degradable items should be subject to normal industrial waste disposal processes. Ensure that no plastic, rubber or composite materials are disposed of by incineration.

Do not use any flammable liquid to clean

d)

The batteries associated with the back-up

valves, filter elements, cooler air passages, air pipes or any component carrying a flow of air during normal operation. If chlorinated hydrocarbon nonflammable fluids are used for cleaning, safety precautions must be taken against any toxic vapours which may be released.

power for the AMBs must be disposed of in accordance with local guidelines.

Do not use carbon tetrachloride. Precautions must be taken when using acids, alkalis and chemical detergents for cleaning machine parts and components. These materials cause irritation and are corrosive to the skin, eyes, nose and throat. Avoid splashes and wear suitable protective clothing and goggles. Do not breathe mists. Ensure that water and soap are readily available. When disposing of used filter elements and other parts and waste material of any kind, make sure that there is no pollution and that no burning of waste takes place which could cause pollution of the air. Protect the environment by using only approved methods of disposal.

2.7

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

2.8

Disposal When items of equipment are taken out of service for disposal it is recommended that the following instructions are adhered to:

10

a)

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

b)

Alternatively all such items of equipment should be stripped into their component form

DL105AA

Technical Information 3

CompAir

3

Technical Information

3.1

Performance F igures L02

Performance Data

Maximum pressure

L03

L04

m /min

3

0.24

0.36

kW

3.20

4.15

FAD * @ max. pressure Total package input power * Totalinputpoweratnoload

0 , 53

0,67

5.33

6.69

0000

kW

Male rotor speed

2160

rpm

Ambient temperature - min/max

2840

3950

Dischargetemperature ofairabove ambient

5150

from 1 to 40

°C 16

°C

Freefieldnoiselevel**

L05

10

bar g

21

26

34

dB(A)

61

61

62

66

kW

2.2

3

4

5.5

Amp

6

7

9

11

Electrical Data

Nominal motor rating Fullloadcurrentmax.(400V) Starting current max. IP55 (400V) direct online

Approx. 7 times full load current

DOL

Starting current max. IP55 (400V) star delta

Approx. 2.5 times full load current

SD

Standarddrivemotordetail

IP55

IP

Drive motor speed

rpm

3000

Suggestedcablesize(400V)directonline

mm

Suggested cable size (400V)stardelta

2 mm N/A

Suggested fuse rating (400V) direct online, time delay

Amp

Suggestedfuserating(400V)stardelta,timedelay

Amp N/A

2

4x2,5

4x2,5

4x4

N/A 16 aM

4x4 4x

4x

16aM N/A

16aM 16aM

16 aM 16aM

Cooling Data 3

Ventilating fan capacity

m /min

6

6

Heatrejectedbyventilatingfan

%

70

Sizeofcoolingairinletaperture

mm

127 x 478

Sizeofcoolingairoutletaperture

mm

Coolingairtempaboveambientapprox.

12

38

42

105

105

114 x 296 30

°C

Max.allowablepressuredropinductatamb.40°C

12

35 20

Pa

Weights, Dimensions and Capacities

Compressor capacity oil

2

litres

Approx. oil carry over

mg/m

3

<3

Compressed air delivery connection

1/2"

Weight

kg

PackagedimensionsLxWxH

100

mm

100

620 x 600 x 840

rd

* Data measured and stated in accordance with ISO 1217 3 Edition Annex C and at the following conditions: Air Intake Pressure: 1 bar a / 14.5 psia Air Intake Temperature: 20oC / 68oF Humidity: 0%(dry) ** Measured in free field conditions in accordance with ISO 2151, tolerance ± 3dB. CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications without prior notice.

DL105AA

Rev 05/09

11

3 Technical Information

3.2

CompAir

Dimensions, Weights, Cooling Airflow Requirements

M

1/2" GAS

S

U

E

B

5 9

5 9

C

A 620 0 4

A 6 9 2

C

kW 2.2-3-4-5.5 / 200 1450 kW 2.2-3-4-5.5 / 270 1540 kW 2.2-3-4-5.5 / 500 1950

B 1355 1400 1520

C 600 600 680

0 5

S

114

28

COOLING AIR QUANTITIES 200 LT.

Kg

12

kW 2.2 kW 3

100 100

kW 4 kW 5.5

105 105

kW 2.2, 3, 4:- 0.1 m3/s (212 ft3/min)

500 LT.

3

3

kW 5.5:- 0.2 m /s (424 ft /min)

kW 2.2 kW 3

165

kW 4 kW 5.5

170 170

kW 2.2

212

kW 3

212

kW 4 kW 5.5

213

290

217

295

165 255 255

S

ELECTRICAL LINE INLET (3 PHASE)

M

ELECTRICAL LINE INLET (2 PHASE) AIR OUTLET SYMBOLS LABEL SM 1576

DL105AA


CompAir

3.3

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

3.4

Reference Item

Unit

Gas compressed

Type

Inlet pressure

Air

Bar (A)

Installation room

(Atmospheric) 1

Type

Roomtemperaturemax/min -

Indoor

°C

Working temperature

Max.+40Min. / +2 C °

Air outlet temperature

50-65 + Room temp

C °

Residual content oil

40-50 + Room temp

PPM

Max room humidity

3-2

%

altitude Max

80 m

Max no. starts of per hour

1000

N°

6

Electricalsupply

Volt Hz / A/

Rating

3.5

Value

Seedataplate

Hours

24 / 24

Refrigerant Dryer (Where Fitted) Item

Unit

FlowRate@35°C

m

Dew Point *

3

/min

°C

PowerSupply

L03

L04

0.4

0.4

0.6

+3 Ph/V/Hz

NominalPowerConsumption

L02

kW

+3

1/230/50

+3

1/230/50

0.22

0.9 +3

1/230/50 0.22

L05

1/230/50 0.22

0.22

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

3.6

Safety Measures Fitted Danger Handling

Basedesignedforusewithforkliftandtranspalletforklift.

Electrical Connection

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

ElectricalBoard

Boltedon,withdoorinterlockswitch.*

Emergency

DL105AA

Measures

Built-inyellow/redwarninglight.*

ShortCircuit

Built-inlinefuses.*

MotorOverload

Magneto-thermalcut-out.*

Electrostatic Discharge

De-oiling filter with electrical continuity.

13


CompAir

Safety Measures Fitted (cont'd) Danger Compressor Overheat

Measures 110 °C thermostat with cut-out. *

Insufficient Lubrication

110 °C thermostat for 'adiabatic' compression.

StartingUnderLoad

20sec.delayfromenergising*

Overpressure Back-Pressure

Approvedsafetyvalve. Non-returnvalve

ResidualPressure

Deschargetapandinternalairgauge.

Phase Reversal (wrong direction of rotation)

Indicator arrow or R.S.F. electronic relay *

Temperature Max. Environment > 45°C

110 °Cthermostat.

Min Environment < 2° C

See starting recommendations.

PressureParts

BuilttoEEC87/404standards.

Flexible Hoses

High pressure hose used (4-6 times working pressure).

HotSurfaces

Partsreaching70°C+markedwithwarnings

* only for versions with “AIRBASIC” controller

3.7

Air BA SIC E lectronic C ontroller Sp ecifications (Where F itted) Power Supply

24Vac ±10% Note: The controller goes OFF if duration of power failure exceeds 400 ms.

Memory

Non-volatile for set data, compressor status and operating time data storage.

Hardware

4 optically isolated digital inputs for: • line pressure switch • motor overload thermal relay • phase-sequence relay • remote START/STOP 1 analog input for: • KTY type temperature probe (range -10 to +130°C, resolution 1°C, precision ±1°C). 5 relay outputs [MAX 8(2)A-250Vac] for: • line contactor • star contactor • delta contactor • load/unload solenoid valve • alarm remoting relay (N.O contact)

Operating Conditions

14

• Operating temperature 0 to +55°C with 90% relative humidity (non-condensating) • Storage temperature -20 to +70°C

DL105AA


CompAir

3.8

General A rrangement D rawings

3.8.1

Stand Alone

DL105AA

15


3.8.2

16

CompAir

Receiver-mounted (2 00 Ltr)

DL105AA


CompAir

3.8.3

DL105AA

Receiver-mounted (200 Ltr) With Dryer

17


3.8.4

18

CompAir

Receiver-mounted (500 Ltr) - L04, L05

DL105AA


CompAir

3.8.5

DL105AA

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

19


3.9

Electrical Diagrams - Compressor

3.9.1

Wiring Harness

20

CompAir

DL105AA


CompAir

3.9.2

DL105AA

Electrical S chematic

21


3.10

22

CompAir

Electrical D iagrams - AirBasic Controller

DL105AA


CompAir

Electrical Diagrams - AirBasic Controller (cont'd)

DL105AA

23


CompAir


24

DL105AA


CompAir


DL105AA

25


CompAir


z W .5 H 0 k 5 /6 0 5 V 0 0 4

R E R U T C A F U N A M

E IZ S

E T N A IC R B A F

G N U N N E N E B

N O I T A N IG S E D

E M A N

E N IO Z A N I M O N E D

1

1

1

1

1

1

1

1

1

1

1

1

S N E M E I S

S N E M E I S

S N E M E I S

S N E M E I S

c a V 4 2 O N 1 + P 3

c a V 4 2 C N 1 + P 3

c a V 4 2 C N 1 + P 3

A

A

A

A N Z N E V IO G

A N Z N E V IO G

A N Z N E V IO G

A 2 3 P 3

R O T P U R R E T IN

R E T L A H C S P U A H

R U E T P U R R E T IN

T C E N N O C S I D N I A M

L A R E N E G

H C T I W S

O C C O L B E R O T A N A IO T Z R E O S P

A IJ N A M

F IF R G D N A H

E É N IG O P

E L D N A H

A I L G I N A M

1

1

3

1

1

2

2

2

1

1

1

7

1

1

1

3

1

1

2

2

2

1

1

1

7

1

1

S N E M E I S

R E B E W L A IT

R E B E W L A IT

R U B A C

R E B E W L A IT

R U B A C

R E B E W L A IT

R U B A C

R E B E W L A IT

R E B E W L A IT

S N E M E I S

R U B A C

E P C

D G

A -8 5 , 5 P 3

A 0 -1 7 P 3

) 8 3 x 3 , 0 1 ( P 3

) 8 3 x 3 , 0 (1 M a A 0 2

) 2 3 x ,3 (6 P 1

) 2 3 x ,3 (6 A 2

) 2 3 x ,3 (6 P 1

) 2 3 x ,3 (6 A 2

) 2 3 x ,3 (6 P 1

) 2 3 x ,3 (6 A 6

) 2 3 x ,3 (6 A 2

q m m 4

c a V 0 0 4

c a V 4 2

A G R A C E R B O S . R E T IN

. R T C E L E A T I L A R T N E C

R E L L O R T N O C

E J E

R O T C A T N O C

R O T C A T N O C

R O T C A T N O C

A G R A C E R B O S . R E T IN

B IE R T N A

R E T L A H C S N R E F



. L E R S E H C IS M R E H T

. L E R S E H C IS M R E H T

E R B R A

R U E T C A T N O C

R U E T C A T N O C

R U E T C A T N O C

E U Q I M R E H T S I A L E R

E U Q I M R E H T S I A L E R

E L IB S U F E T R O P

A IC M R E T

A IC M R E T

2 0 B A 1 5 1 0 1 T R 3

0 B H 1 6 1 1 1 U R 3

0 B J 1 6 1 1 1 U R 3

O R E B L A

E R O T T A T N O C

E R O T T A T N O C

E R O T T A T N O C

2 0 B A 1 5 1 0 1 T R 3

B 3 0 0 2 3 E S

1 0 0 0 / 2 1 0

9 8 0 1 0 4 0 2

. S O P

2 \ 3

\2 3

\2 3

\4 4

\6 4

\5 4

6 \ 3

\6 3

. F E R

1 0 S

1 0 S

1 0 S

1 K

2 K

3 K

4 K

4 K

G N U R E H C I S

N U R E H C I S

E IL B I S U F A T R O P

T F A H S

R O T C A T N O C

E L B I S U F

R E T L A H S G

R E D L O H E S U F

R O T C A T N O C

Y A L E R L A M R E H T

E L B I S U F A V E L L

Y A L E R L A M R E H T

R O T C A T N O C

1 0 B A 1 5 1 0 1 T R 3

L E D O M

26

. W 0 k 4

1

E L B I S U F

E L B I S U F A V E L L R E T L A H S G N U R E H C I S


E S U F

R E D L O H E S U F

E L I B I S U F


E L B I S U F

G N U R E H C I S

E L B I S U F



E S U F

R E D L O H E S U F

E L I B I S U F


E L B I S U F

G N U R E H C I S

E L B I S U F



E S U F

R E D L O H E S U F

E L I B I S U F


in V 0 0 -4 0 3 -2 0

0 1 -1 \0 4 2 \0 4 -2 0

E L B I S U F

E L B I S U F

O F A R T

A R E N R O B

N O I IS V R E P U S IS A L E R

G N U R E H C I S

G N U R E H C I S

R O T A M R O F S N A R T

T T E R B N E M M E L K

IS A L E R

E L B I S U F

R U E T A M R O F S A R T

A R E I N R O B

IS A L E R

D R A O B L A N I M R E T

. L E R . T I N O M S E S A H P

O T T E S R

I S A F , Q E S Y A L

O M

E R

A N I L A R T N E C

.4 S A D

F S R

IC S A B IR A

E L B I S U F

E S U F

E IL B I S U F

E S U F

R E M R O F S A R T

E IL B I S U F

E R O T A M R O F S A R T

R E L L O R T N

O C

R E L L O R T N O C

0 2 0 2 2 4 1

0 1 . C P F

0 0 2 7 0 3 0

0 1 . C P F

0 0 2 7 0 3 0

0 1 . C P F

5 0 2 7 0 3 0

0 0 2 7 0 3 0

) A V 0 8 ( Y 1 6 3 M T 4

\2 3

\2 3

2 \1 3

2 \1 3

4 -1 3 \1 3

4 1 3 \1 3

5 1 4 \1 3

4 \1 3

5 \1 3

4 \1 3

5

2 \1 3

4

1 F

1 F

2 F

2 F

4 F 3 F

4 F 3 F

6 F 5 F

5 F

6 F

1 R T

1 X

F S R

1 A

8 3 x 3 H C P

S 8 3 0 3 0 4 2

DL105AA

General Description 4

CompAir

4

General Description

4.1

Operating P rinciple

Oil is injected into the air-end housing for the dual purpose of cooling the unit and lubricating the moving parts.

The air end is a single-stage asymmetrical screw type, driven by an electric motor. The air is compressed through the rotation of a male and female rotors which mate perfectly

The air, once compressed, enters a receiver where the remaining oil is separated to a residual of about 2-3ppm.

along their parallel axes, and are housed in a cast-iron case.

At this point it is ready to be delivered. Should the oil temperature be above the desired running temperature, the separated oil will pass through a thermostat-controlled air-blast oil cooler. Should this not be the case, it will be bypassed directly into the air end to start a new cycle of lubrication and cooling. The air for the cooler is also used to cool the motor. It is drawn through the compressor canopy via a fan driven directly by the motor.

SM 1578

4.2

Fig. 4.1 - Rotary Screw Operating Principle

Compressor Diagram See fig 4.2

13 16

15

8

10

4 6

12 9 14

18 11 7 17

M 1

3 5

2

SM 1579

Fig. 4.2 - Comp ressor Dia gram 1. 2. 3. 4. 5. 6.

DL105AA

Electric Motor Air-End Discharge Oil Oil Separation Filter Temperature Control Device Safety Valve

7. 8. 9. 10. 11. 12. 13.

Oil Filter Oil Radiator Thermostat Valve Air Intake Filter Air Intake Valve Oil Return Pressure Gauge

14. 15. 16. 17. 18.

Discharge Valve Pressure Switch Minimum Pressure / Non Return Valve Cooling Fan Oil Tank

27

4 General D escription

4.3

CompAir

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

4.4

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

28

DL105AA

Installation a nd Storage 5

CompAir

5

Installation and Storage

5.1

Lifting and Transportation

Fig. 5.3 - Lifting and Transportation

DL105AA

29

5 Installation and Storage

5.2

CompAir

Installation Diagram

2

THREE PHASE ELECTRICAL SUPPLY

1

9 4

12

6

10 11 12 12

MIN 750

MIN 750

8

7

R EF. 1 2 3 4 5 6 7 8 9 10 11 12

7

7

3

5

D E S C R I P T I ON THREE PHASE ELECTRICAL SUPPLY

COMPRESSOR TANK AIRDRYER FLEXIBLE HOSE OIL-WATER SEPARATOR CENTRIFUGAL SEPARATOR AUT. COND. DISCHARGE CERAMIC FILTER COALESCING FILTER 0.1m COALESCING FILTER 0.01m ACTIVE CARBON FILTER DIFFERENTIAL MANOMETER

1

MONO PHASE ELECTRICAL SUPPLY

3 2

AIR EXIT MIN 750

SM 1580

MIN 750

NOTE: MIN. DISTANCE TO REAR WALL = 1000MM

Fig. 5.4 - Installation Diagram

5.3

Connection Piping

5.4.4

Prevent recirculation of cooling air. If the compressor is fitted with cooling air ducts, ensure they are of sufficient size for the required cooling air volume including the pressure loss within the ducting.

5.4.5

Ensure there is adequate access for cleaning the cooler.

Always use a flexible hose to connect the compressor to the air distribution network.

5.4

Installation L ocation

5.4.1

The compressor must be installed on a level surface capable of bearing the weight of the compressor (see section 3 "Technical Information"). Caution: The condensate drain will contain traces of oil.

5.4.2

Refer to the installation diagram (fig. 5.4) for the required minimum clearances around the machine.

5.4.3

Make sure that the compressor room is properly ventilated. The cooling air temperature must be lower than + 45°C or higher than 0°C.

30

Please note that in the case of an air-cooled compressor, almost the whole compressor input power is transferred to the cooling air as heat. 5.4.6

The compressor should not be installed in a dusty location without special intake pre-filtering. In case of doubt, contact CompAir Technical Support.

5.4.7

Outside installation is not permitted.

DL105AA

Installation a nd Storage 5

CompAir

5.5

Initial Checks

5.5.1

After removing the compressor from its packaging and before proceeding with installation, ensure that no damage has occurred during transportation.

5.5.2

Packaging materials such as wood, nails and plastic sheet could be dangerous for children and should not be left within their reach.

5.5.3

Check that all the fuses in the electrical board are properly fitted and tightened.

5.5.4

Check that the protection main nuts are tightened and the screw fixed.

5.6

Electrical Connections

5.6.1

The electrical connections must be to EC standards. All local safety regulations must also be observed.

5.6.2

Make sure that the operating voltage is correct. The voltage must be as rated, ± 5 %. Check that each phase has an equal voltage.

5.6.3

The customer must provide supply cable short circuit protection. The fuse type is given in the electrical diagrams and technical data.

5.6.4

If the compressor is equipped with an integrated dryer, a separate 230V supply must be connected to the electrical cabinet (see electric diagrams and technical data).

5.6.5

It is imperative that the earth cable is connected correctly.

5.7.4

Never tamper with the pressure regulator and/or pressure switch, or set working pressure higher than the one set for the compressor model and for the reservoir. Maximum available pressure must always be below the lift pressure of the safety valve fitted to the reservoir.

5.8

After Prolonged Storage If the compressor has remained switched off for longer than two months, the following procedure must be carried out before putting the machine back into service:

B C

Only qualified electricians are permitted to connect the power supply. No computer should be installed near the c ompressor. Make sure that any computer is connected to an electrical circuit separate from that of the compressor.

5.7

Recommendations

5.7.1

The air drawn into the compressor must be completely free from toxic fumes and inflammable vapours from solvents, paints etc, which would cause fire or explosions and pollute the working area.

5.7.2

5.7.3

DL105AA

Using the compressor without a suitable air reservoir will jeopardise its functionality. Overloading the electrical control system may cause an excessive number of starts per hour, leading to motor damage and shortening the life of the unit. Never dismantle or modify guards or isolating materials fitted to the compressor.

A

SM 1581

Fig. 5.5 - Priming With Oil After Prolonged Storage a)

Access the intake valve (A) by detaching cover (B) and removing the air intake filter cartridge (C)

b)

Pour 100 cc of approved compressor oil into the valve

c)

Run compressor for ten seconds then stop

d)

Repeat step b

e)

Replace the parts and start unit.

31

6 Operation

CompAir

6

Operation

6.1

Before Starting

6.3

6.1.1

Before starting the compressor for the first time, make sure that:

To Stop (Not Valid For Version With “Airbasic” Controller)

6.3.1

To stop the compressor, push the “ OFF-0” button (RED colour) on the front panel.

- the flexible hoses are in good condition and efficient and do not show any signs of

Caution: The compressor should be allowed to run for at least 3 minutes before switching it off. Shorter running periods than this can damage the compressor in the long term and are not recommended.

abrasion or cracks - the electrical power phases are connected properly. A phase reversal protection device is fitted which will prevent the compressor being started in this instance, thus avoiding damage to the air end

6.4

- all compressor access doors are closed

6.4.1

- all guards are in place and properly secured

Shut-Down Due To P ower F ailure Turn off the power from the main switch and make sure that the compressor cannot be accidentally started.

- there are no oil or air leaks

b)

Open the front panel.

Before opening the valve and letting compressed air into the connecting hose, make sure that the hose end is securely fixed. This is to prevent the hose from whipping,

c)

Press down the red button on the pressure switch to blow down the pressure. Pull up the red button again afterwards to restore the pressure switch to normal working mode.

which could cause injury. At the end of each working session, switch the power off using the off button on the controller.

d)

Close the front panel end start up the compressor.

- all the electrical wiring is in good condition and that the earth is properly connected

6.1.2

6.1.3

6.1.4

The air produced by this machine contains oil vapour and cannot be breathed, therefore the compressor should be placed in a separate room.

6.2

To Start (Not Valid For Version With “Airbasic” Controller) Caution: If the compressor has remained switched off for more then two months, ensure that the procedure detailed in section 5.8 is carried out before starting.

6.2.1

For standard machines:

a)

To start the compressor, push the “

ON-1”

button (BLACK colour) on the front panel. The compressor is controlled by a pressure switch which stops the machine when air pressure in the reservoir reaches MAXIMUM and starts it up again when the pressure drops to MINIMUM. The pressure range is set to MIN 8 bar / MAX 10bar

6.4.2 a)

For versions with overload cut-out: If a cut-out occurs, the compressor will stop. Once the power is back again, the compressor will automatically resume operation immediately. Warning: For safety reasons, it is strongly recommended that a sign be displayed near the machine indicating that the compressor may re-start without warning.

b)

6.4.3

It is also imperative to check that the automatic re-start of the compressor will not pose any hazards whatsoever. For versions with "Airbasic" controller:

a)

The blow down function empties the receiver after stopping; wait 2 minutes.

b)

In the event of transient power failure, the compressor will shut-down and re-start in automatic after 20 seconds (the set time to unload the oil separation tank to guarantee a correct restart). Warning: Take extra care when in this situation in order to avoid any damage to persons or property caused by the drop in air pressure in the distribution installation.

32

DL105AA

Operation 6

CompAir

6.5

Starting At Low Temperatures (below 0°C) Warning: If there is a possibility that the room temperature may fall below 0°C, it is essential to protect all pipes, hoses and condensate drains with suitable insulation. This will prevent blockage due to ice, which can cause serious damage to the air reservoir. Recommended procedure for start-up with cold temperature (below 0 °C):

6.6

Electronic Controller (W here F itted)

6.6.1

All compressor settings are programmed using the "AirBasic" electronic controller. For detailed instructions for the controller, please refer to Chapter 9.

6.6.2

The controller regulates the output of the compressor. The following variables have been set in to the controller: • target, unload and load pressures • service intervals

a)

Start the motor for 5 seconds then switch off before the pressure rises.

• programmable I/O

b)

Repeat step a.

• alarm and shutdown limits

c)

Temporarily start the compressor, checking that the pressure rises to a value close to the maximum working pressure, for example 9 bar for 10 bar working pressure models

d)

Switch off the compressor immediately when pressure at step c is reached.

e)

Repeat steps c and d.

f)

Finally, start the compressor, making sure that the air pressure is not exceeded due to the formation of ice in the hoses and/or icing up of the non-return valve or the minimum pressure valve.

• operational parameters

ON x10 x100

OFF

Reset

a03

A01

A03

A04

S.

SM 1574

Fig. 6.1 - "AirBasic" Electronic Controller Display

DL105AA

33

7 Maintenance

7

CompAir

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

7.1

Maintenance Schedule MaintenancTeask

Every

Day

Check fault indicator lights and alarms (only for “AIRBASIC” controller)













4,500 6,000 9,000 Hours Hours Hours or 4 or 6 or 6 Years Years Years Max Max Max

















Discharge air tank drain















Check oil level **















Check operation of condensate drain and clean strainer





50 Hours 500 1,500 or 1 Year Hours Hours Week Max

Check for oil leaks













Clean inside compressor













Clean air filter Change oil, see “Oil recommendations”





 

  

Renew oil filter Renew oil separator cartridges

 







 



Renew air filter

 













Check V-belt tension













Clean cooler externally

V-BELTS: Renew the belts. Check drive pulleys and renew if worn.















Clean oil return line

Check operation of pressure relief valve

 





 

Fit new seal kit in inlet valve



Renew oil hoses



Check and re-tighten main motor cables



Fit new shaft seal kit



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

34

DL105AA

Maintenance 7

CompAir

7.2

Service Points 1

2

3

7

6 5 4

SM 1607

Fig. 7.1 - Service Points 1. 2. 3. 4.

DL105AA

Oil Filter Air/Oil Separation Filter Inlet Air Filter Oil Drain Point

5. 6. 7.

Oil Level Sight Glass Oil Filling Point Drive Belt/s

35

7 Maintenance

7.3

CompAir

Before Maintenance Warning: Hot surfaces inside the compressor cabinet immediately after stopping.

The oil change intervals can be calculated more accurately for the actual operating conditions by analysing the oil.

a)

Stop the compressor.

Specific CompAir lubricants are recommended for use in this equipment. Other lubricants may cause :

b)

Turn the power off from the main switch and make sure that the compressor cannot be

- shorter life span of oil filters, oil separators and oil

accidentally started. Open the front panel.

- lacquering and blockage of oil circuit

c) d)

Ensure all air pressure released from machine as follows: - Standard versions: Push the red button on the pressure switch to blow down the pressure. Afterwards pull the “RED” button to restore the pressure switch to normal working mode. - "AirBasic" controller versions: The blow down function automatically empties the receiver after stopping; wait 20 seconds.

- higher oil consumption - excessive carryover and compressor damage Caution: Do not mix different types of oil. Caution: If a wrong oil type has been used or the oil circuit is lacquered, contact CompAir specialists for oil circuit cleaning instructions.

1 7.4

7.5

After Maintenance

2

a)

Close the front panel.

b)

Turn the power on from the main switch.

c)

Start up the compressor.

d)

CompAir recommends that a maintenance log be kept as a record of all work carried out on the compressor. Fill in the log.

Service Kits Timing

KitNo.

1,500 hours

KitDescription

CK2302-1-KA

Filters Service Kit

6,000 hours

CK6300-1-KA

Oil Separator Body Service Kit

6,000 hours

CC1045817

Hoses Service Kit

9,000 hours

CC1046311

Seal - Air End SCA7L

MAX

3 4 SM 1582

7.6

Guidelines F or O il C hange Intervals If final compression temperatures of more than 90 °C occur continually, the oil change intervals given in the maintenance schedule are halved.

Fig. 7.2 - Changing the Oil 1. 2. 3. 4.

Oil Filler Plug Seal Oil Level Gauge Oil and Condensate Drain Point Note: Oil Tank Capacity 2kG

36

DL105AA

Maintenance 7

CompAir

7.7

Belt Tensioning 2

1

2 MAX

3

3

2

1

4 9 5 5

10

7 8

TOOL FOR ALIGNMENT CONTROL

6 7

SM 1584

6

Fig. 7.3 - Belt Adjustment Mechanism 1. 2. 3. 4.

Adjusting Screw Locknut Air End/Pulley Bracket Securing Screws

5. 6. 7. 8.

Air End Pulley Motor Pulley Air End Mounting Plate Main Drive Motor

Belt tension is adjusted by slackening off the air-end/pulley bracket securing screws (fig. 7.3 (4)) and then moving the bracket (3) vertically using the adjusting screw (1). a)

To check the belt tension, apply a force (F) of 30 N with a dynamometer, positioned in the middle of the belts (see fig. 7.4). If the tension is correct the belt deflection (f) should be 5±1 mm.

b)

If (f) > 7 mm the tension is too low. Adjust the position of the air end using adjusting screw (fig. 7.3 (1)) then check the belt deflection (f) again to confirm the tension is now correct.

c)

If (f) < 3mm the tension is too high. Adjust the position of the air end using adjusting screw (fig. 7.3 (1)) then check the belt deflection (f) again to confirm the tension is now correct.

9. 10.

Air End Drive Belt

re-checked. Should it not be correct, the belt should be tensioned again. (ii) Check the alignment of the pulleys. If necessary, correct it so that it is within 2 mm for XPA belts, or 1 mm for poly-V belts (see fig. 7.3). =

= f

F S

SM 1587

Notes: (i) If the belt has been renewed and the belt tensioned following the procedures just described, the compressor should be run for 20-30 minutes, then the tension (f) should be

DL105AA

Fig. 7.4 - Belt Adjustment

37

7 Maintenance

7.8

CompAir

Automatic Condensate Drain (Where Fitted)

7.9

Routine M aintenance G uide

H 0 2

50 h 50 h

OIL

2

1

1500 h

3 4

1500 h

ON

OFF

5

SM 1583

1500 h SM 1585

Fig. 7.6 - Cleaning Automatic Condensate Drain Filter

Fig. 7.5 - Routine Maintenance Guide

Clean after the first 10 working hours and then every 500 hours. 7.8.1

Clean the tap filter (fig. 7. 6 (4)) as follows :

a)

Disconnect power and disconnect the connection (1).

b)

Close the tap (3). SM 1608

OPEN

c)

38

CLOSED

Unscrew the gauze filter retainer (5) and remove filter (4). Clean carefully and refit.

DL105AA

Troubleshooting 8

CompAir

8

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

Compressor Fails To Start

PossibleCause 1

No power supply

CorrectiveAction a

Check fuses and voltage Check that the protection devices of the voltage supply (safety switch, current fault protection or fuses) are suitable to be used as protection of the frequency converter. c Contact the sales advisor. b

2

3

4

5

6

LowAirDelivery

DL105AA

1

Compressor stopped due to overheating

Electricalfault

Over-loaded motor

Compressor stopped due to excessively high pressure

Doesn't start, although the Start" button has been pressed Airfilterclogged

Find out the possible cause of overheating a Oil temperature control valve or sensor faulty b Recirculation of hot cooling air c d e f g h

Cooling air v olume insufficient Ambient temperature too high Cooler clogged Wrong oil type or oil level too low Oil separator clogged Oil filter blocked

a

Checkthe main switch

b c

Check wiring of the mo tor and frequency converter Check tightness of the cable connectors.

a Check that the maximum pressure is not being exceeded b Check the inlet temperature and flow of the cooling air c d

Check the oil level Check the pressure drop of the separator

a b c

Check that the shut-off valve between compressor and compressed air system is open Aftercooler is f rozen Pressure sensor faulty

d

Line filters clogged Wait (network pressure exceeds the adjusted pressure)

Renewtheairfilter

2

Oil separator clogged

Renew the oil separator

3

Intake valve faulty

Repair or renew

4

Discharge valve or condensate drainage is faulty

Clean or renew

5

Leaks in the compressed air system

Check and repair the leaks

6

Brokencoupling

Renewthecoupling

7

Pressure limits incorrectly set

Set correctly

39

8 Troubleshooting

CompAir

Symptom Low Air Delivery (cont'd)

PossibleCause 8 9

CompressorOverheats

Ensure sufficient cooling air circulation Ensure that the intake air is from the coolest possible place Prevent the flow of cold cooling air to the compressor

10 Pressure relief valve open

Close the valve

Cloggedcooler

Cleanthecooler

2

Ambient temperature too high

3

Intake valve faulty

4

Oilleveltoolow

5

Wrongoiltype

Seeoilrecommendation

6

Oil filter clogged

Renew the oil filter

7

Faulty discharge temperature transducer

Renew

8

Cooling air ducting too small or pressure drop too high

Check the dimensioning and pressure drop of the ventilation ducting and correct

1

Clogged oil separator Clogged oil return line

Check cooling air circulation Repair or renew Addoil

Renew the oil separator Clean the oil return line

2

Faulty oil separator

3

Clogged oil separator


4

Wrongoiltype

Seeoilrecommendation

5

Discharge temperature too high

6

Shaft seal leaking

7

Oilleveltoo high

Intake Valve Leaks Oil After Emergency Stop Compressor Stops Too Often

Aftercooler frozen

CorrectiveAction a b

1

9 Oil Consumption Too High

Ambient temperature too high


Investigate and eliminate the cause Renew the shaft seal Lower the oillevel

Intake valve seal is leaking

Renew the intake valve seal

1

Volume of compressed air system too small

Check the minimum pipe size. Correct if necessary.

2

Blockage in network

Search for the blockage and repair

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

40

DL105AA

AirBASIC Electronic Controller 9

CompAir

9

AirBASIC Electronic Controller

9.1

Introduction

9.3.1

The AirBASIC Controller is designed specifically for use in CompAir rotary screw air compressors. These instructions will enable you to operate the AirBASIC controller

Display

a)

When the compressor is powered, the display on the controller shows the “OFF” message.

b)

If a remote control is connected to the remote START/STOP input and its contact is open,

correctly and safely.

9.2

that is, in a STOP condition, the display shows the “---” message.

Safety

c)

In normal operation, the controller display shows the oil temperature value.

Always read the safety instructions in section 2 of this manual before starting work.

Note: The AirBASIC controller display can only show up to 3 digits. Numbers with 4 or 5 digits are indicated by the illumination of LEDs x10 or x100, which are termed "10 multiplying factor" and "100 multiplying factor" respectively. The following examples show how the LEDs work.

In addition to these instructions, the local regulations in your country may impose additional requirements that must be observed.

9.3

Description 1

2

Value to be displayed

Display shows

LED x10

LED x100

1

697

697

OFF

OFF

2

6970

697

ON

OFF

3

69700

697

OFF

ON

Example No. 3

ON x10 x100

OFF

Reset

9.3.2

Button Functions • ON: Switches on the compressor.

a03

A01

A03

A04

• OFF: Switches off the compressor.

S.

• RESET: Resets alarms and displays hour meter. SM 1588

9.3.3

• x10 LED (green): indicates that the 10 multiplying factor is active.

Fig. 9.1 - AirBASIC Control Pan el 1. 2. 3.

LCD Display (3 D igits/7 Segments) LED Status Indicators (3 Green) Control Pushbuttons (3)

• x100 LED (green): indicates that the 100 multiplying factor is active.

The Control Panel is mounted on the compressor. It is used to operate the compressor and observe system status using the LCD display, LED status indicators and buttons. The Control Panel displays a comprehensive overview of the compressor status and allows access to operational parameters such as alarm set points.

Indicator Functions

•

LED (green), steadily on: indicates load operation mode.

•

LED (green), flashing: indicates unload operation mode.

9.4

Compressor O peration w ith the AirBASIC Controller

9.4.1

Starting The Compressor The starting procedure depends on the current status of the compressor.

a)

DL105AA

Starting the compressor in “OFF” status

41

9 AirBASIC Electronic C ontroller

CompAir

The “OFF” message on the controller display indicates that the compressor is properly powered, waiting to be started, and that the last switch-off was caused by pressing the “OFF” push button on the controller (local switch-off).

When the compressor is started (either locally via the ON button or from a remote location), the controller performs a number of checks at the inputs to make sure that there are no conditions likely to pose hazards to the machine and/or the operators.

To start the compressor, use local controls, that is, press the “ON” button on the control unit.

If abnormalities are found, the compressor start-up is inhibited and an error message appears on the controller display. If no abnormality is found, the compressor is allowed to start.

Note: In this condition, opening and closing the remote contact will produce no effect whatsoever. b)

When start-up is initialised (and no alarms are active), the controller checks the status of the line pressure switch contact. If the pressure switch contact is closed, the motor is started according to the star/delta start-up sequence. If the pressure switch contact is open (pressure in the network ), the compressor goes into stand-by mode and the motor is not started until the network pressure drops to the load value level.

Starting the compressor in “---” status The “---” message on the controller display indicates that the compressor is properly powered, waiting to be started, and that the remote START/STOP contact is in the OPEN position (STOP position). To start the compressor, use the relevant procedure described below, depending on how the las t switchoff occurred.

When the load value level is reached, the pressure switch contact closes. The relay outputs relating to the line and star contactors are energised for the equivalent of the star time (parameter P06 - default 5 s). When the

- If the compressor was running (no matter whether loaded, unloaded or in stand-by) and was then switched off remotely, the “---” message appears. To restart the compressor, close the remote contact again.

star time has elapsed, the controller switches from star to delta with a ‘safety’ delay (applied between the release of the star contactor and the coming into operation of the delta contactor). This delay is equivalent to the time value set up on the star/delta switching timer (parameter P07 - default 20 ms). When the switching timer has elapsed, the outputs relating to the line and delta contactors are energised.

- If the compressor was switched off locally, that is, by pressing the OFF button on the controller, and the remote contact was then opened AFTER the switch-off, the “---” message appears. 1. To restart the compressor, close the remote contact. 2. Press the ON button on the controller.

In order to stabilise the motor’s rotation speed, the load solenoid valve is energised with a delay that is equivalent to the time value set up on the “launch timer” parameter (parameter P08 - default 2s). The delay is in relation to the closure of the delta contactor. Once the solenoid valve has been energised, the compressor enters into load-operation

This feature allows the operation of the compressor to be disabled from a remote position in order to prevent unauthorised personnel from starting the compressor with the push buttons on the controller. Warning: If the remote control feature is to be used with connected to the the START/STOP controller, it iscontact strongly advisable to affix a sign by the machine warning that the compressor may be started at any time from a remote location. Note: Machine start and machine restart operations can be performed via a control device other than the one provided, as long as this does not pose any hazards. c)

42

Compressor Start-up Process

stage. 9.4.2

Controlling The Compressor Load/Unload Operation When the compressor is on load, the LED on the right hand side of the display lights steadily. When the pressure reaches the set value of the pressure switch, the pressure switch contact opens and the compressor switches to unload operation for a period of time that is equivalent to the time value set up

DL105AA


CompAir

on the “unload time” timer (parameter P09 default 3 min).

9.4.3

Switching Off The Compressor The compressor can be switched off locally or remotely (if a remote contact is connected to the appropriate terminals). In both cases, when the machine is commanded OFF, the controller de-energises all the relay outputs controlling the contactors as well as the solenoid valve, thereby causing the compressor to stop immediately.

During the unload phase, the LED flashes to indicate that the compressor is running in unload mode. When the timer has elapsed, the motor is stopped. As soon as the pressure drops to the load value that is set up on the pressure switch, the motor is restarted automatically via a star/delta sequence. When the motor is stopped, the LED is turned off and if no alarms are active, the value of the oil temperature appears on the display.

The control unit activates a safety (“blowdown time”) timer (parameter P10 - default 20 s) to prevent the compressor from restarting with pressure in the inner tank when the OFF button is pressed (or when the remote start/stop contact is opened). Compressor restart is inhibited throughout the count down of the blowdown time. Pressing the ON button or closing back the remote start/stop contact during blow-down produces no effect whatsoever.

If the pressure drops to the load value level before the unload timer has elapsed, the compressor immediately switches back to load mode without any stopping of the motor. When the “Unload time” timer elapses, the motor stops. The oil temperature remains steady on the display to indicate that the machine is not OFF but is still in stand-by condition.

The blow-down stage is indicated by the flashing of LED x10. When the count down of the “blow-down time” is over, LED x10 is turned off. At that point, you can restart the compressor.

Warning: Be very careful, as in this condition, the compressor will restart without prior notice as soon as the pressure drops to the load value level.

See fig. 9.2 for an example of the operating cycle.

Motor running

pressure

Network pressure UNLOAD

STOP

UNLOAD

Unload pressure Load pressure LOAD

LOAD

START UNLOAD TIME Motor running Motor OFF time

SM 1575

Fig. 9.2 - Example Of The Operating Cycle

DL105AA

43


9.5

CompAir

Note: When a maintenance pre-alarm message is manually reset, it will no longer appear as long as the compressor is ON.

Timers The AirBASIC Controller has two kinds of control information: timers and parameters. There are two kinds of timers: maintenance timers (for viewing and resetting) and operation timers (for viewing only).

9.5.1

Maintenance timers can only be reset when the compressor is OFF. When the compressor is OFF, the display shows an “OFF” or “---” message, depending on the conditions described in section 11.7.1 a) - "Display".

Viewing maintenance timers Maintenance timers count the time until the next maintenance operation on the following items (maintenance code number and meaning): • S01 = oil change

a)

To view the first maintenance code (S01), press and hold RESET button for about 3 seconds.

b)

To reset the first maintenance code, press and hold the RESET button for about 3 seconds. The value is replaced by the default value and the second maintenance code will be displayed.

c)

If you do not wish to reset the first hour meter, but want to switch immediately to the second one instead, press and release the RESET button. The second maintenance code appears on the display, and its timer value will be visible after 1 second. To reset the value, press and hold the RESET button for about 3 seconds.

d)

Scroll through all maintenance timers as

• S02 = air filter replacement • S03 = oil filter replacement • S04 = separator filter replacement • S06 = general maintenance. The maintenance timers can be viewed when the compressor is ON. When the compressor is ON, the display will normally show the oil temperature value, unless an alarm is ON. a)

To view the first maintenance code, S01 (oil change), press and release the RESET button. The value for remaining hours will be displayed automatically after about 1 second.

b)

To view the second maintenance code, S02 (air filter replacement), press and release the RESET button again. The value for remaining hours will be displayed automatically after about 1 second.

9.5.3

Viewing operating timers Operating timers count the total operating hours (h-t) and total hours on load (h-L) of the compressor. The operating timers are available for viewing when the compressor is ON.

c)

To view the rest of the maintenance codes, press and release the RESET button again.

d)

To return to the oil temperature display, scroll through the remaining maintenance codes (S03, S04, S06).

a)

To view the “h-t” message, press and hold the RESET button for 3 seconds. Total operating hours will be displayed.

Notes: (i) Maintenance timer counting (parameters P12 - P 16) is based on motor running hours. It works like a countdown; when the

b)

To view the “h-L” message, press and release the RESET button again. Total hours on load will be displayed.

countdown is at 0, itthe willfirst continue negative sign, and displaywith will the show the “-” symbol. (ii) Maintenance hours are stored to the memory every 15 minutes; if a power failure occurs during compressor operation, the entire 15 minute fraction will be lost. 9.5.2

44

described above, resetting their values if necessary, until the “OFF” or “---” message is displayed again.

Resetting maintenance timers

Notes: (i) The counting of hours on load is based on the length of time for which the relay supplying the load/unload solenoid valve is closed; the counting of total operating hours is based on the length of time for which the line contactor supplying the motor is closed. (ii) Operating time is stored to the memory every 15 minutes; if a power failure occurs during compressor operation, the entire 15 minute fraction will be lost.

DL105AA


CompAir

9.6

Parameters

e)

The parameters allow the user to change the operating parameters of the compressor, such as the maintenance pre-alarm hours or maximum restarts per hour. The default values for the adjustable parameters are listed in the table on the next page.

To edit the value of another parameter, scroll up or down the list until the ID Code of the desired parameter is displayed, and repeat step d).

f)

To exit the programming mode after adjusting all the desired parameters, press and hold the RESET button for about 3 seconds. At this stage, the OFF or “---” message appears on the display and all the changes made to the parameters are activated.

The parameters can only be adjusted when the compressor is stopped. a)

To enter the parameter programming mode, simultaneously press and hold the OFF and RESET buttons for 3 seconds. After 3 seconds, the code of the first parameter, P01, will appear on the display.

b)

To scroll up or down the parameter list, press ON or OFF buttons respectively.

c)

To view the current value of a parameter, press the RESET button.

d)

To edit the displayed value, press ON (increase) or OFF (decrease) buttons. Once the desired value has been entered, press RESET button to store the value and to return to the parameter list.

Param.code

Notes: (i) If no button is pressed for 60 seconds during the programming procedure, the controller will automatically exit the programming mode, switch back to OFF and store all the changes. (ii) If the upper or lower threshold of a parameter is reached when editing a parameter, the value that appears on the display will flash to warn that the min. or max. value for that parameter has been reached. The following table (fig. 9.3) contains all the available parameters with their respective codes, descriptions, units of measurement, possible values and default values.

Description

Unit

Range

°C

Default

P01

MAXprobetemperaturerange

130-(P02+2)

P02

Highoiltemperaturealarmthreshold

°C

(P01-2)-(P03+2)

P03

Highoiltemperaturepre-alarmthreshold

°C

(P02-2)-(P04+2)

P04

Lowoiltemperaturealarmthreshold

°C

130 110 105

(P03-2)--10

-10

P05

Oiltemperatureprobecalibration

°C

P06

time Star

s

-10-+10

P07

Star-delta switch timer

ms

P08

Launch timer

s

5 - 1

P09

Unload time

min

10- 0

P10

Blow-down time

P11

Max restarts per hour

P12

Airfiltermaintenancepre-alarmhours

h

100-3000

1500

P13

Oilfiltermaintenancepre-alarmhours

h

100-9900

1500

P14

Separatorfiltermaintenancepre-alarmhours

P15

Oilmaintenancepre-alarmhours

P16

Generalmaintenancepre-alarmhours

P17

Automatic restart status

P18

Alarm relay function

10 -

s /

2

0 5

10 50 -

h h / /

0

60- 1 60 -1

h

20 2

20 60

100-9900

1500

100-9900

1500

100-1000

500

1-0 2-0

0 0

Fig. 9.3 - Table of Parameters

DL105AA

45


9.6.1

Parameter descriptions P01 - MAX probe temperature range – Provides the highest value for oil temperature reading. – No adjustment is necessary.

the motor’s rotation speed subsequent to the star-delta switching. – In normal conditions, this parameter needs no adjustment. P09 - Unload time

P02 - High oil temperature alarm threshold

– Defines the duration of the unload operation interval, at the end of which the controller

– Defines highasoilthis temperature alarm a value. Asthe soon value is reached, dedicated alarm message (A01) appears on the display.

will power off the motor. – Unload operation is identified by a flashing LED.

P03 - High oil temperature pre-alarm threshold – Defines the high oil temperature pre-alarm value. As soon as this value is reached, the compressor stops and a dedicated alarm message (a03) appears on the display, but the normal operation of the compressor is not interrupted. P04 - Low oil temperature alarm threshold – Defines the low oil temperature alarm value. Under this value, compressor start-up is inhibited and a dedicated alarm message (A34) appears on the display. P05 - Oil temperature probe calibration – Compensates for possible reading errors (either by excess or by defect) of the temperatureprobe due to a defective probe . – In normal conditions, this parameter needs no adjustment. P06 - Star time – Defines how long the system should run in star configuration during motor start-up. – In normal conditions, this parameters needs no adjustment. P07 - Star-delta switch timer – Defines the delay between the release of the star contactor and the coming into operation of the delta contactor, during the switching stage. – In normal conditions, this parameter needs no adjustment. P08 - Launch timer – Defines the delay between the coming into operation of the delta contactor and the energisingof the load/unload solenoid valve; such delay stabilises as much as possible

46

CompAir

P10 - Blow-down time – Defines the duration of the blow-down interval after the compressor has been powered off. Its purpose is to prevent any restarts of the compressor while pressure is still in the tank. – The blow-down condition is identified by a flashing x10 LED. In this condition, motor start-up is inhibited for the set time interval. P11 - Max restarts/hour – Defines the maximum number of permitted start-ups per hour. Its purpose is to protect the motor from damage. When the set number of restarts is reached, the motor will not stop for the rest of the following hour and the compressor will work without interruption, switching from load to unload and vice versa. – This condition is identified by the simultaneous flashing of LEDs x10, x100 and . – At the end of the hour period, the counter is reset and the motor will be able to stop at the end of the unload phase. P12 - Air filter maintenance pre-alarm hours – Defines the air filter change countdown timer value. – When the set timer has elapsed, the controller will warn the operator that maintenance is needed by showing a dedicated warning message (S02) on the display. P13 - Oil filter maintenance pre-alarm hours – Defines the oil filter change countdown timer value. – When the set timer has elapsed, the controller will warn the operator that

DL105AA


CompAir

maintenance is needed by showing a dedicated warning message (S03) on the display. P14 - Separator filter maintenance pre-alarm hours – Defines the separator filter change countdown timer value. – When the will set warn timer the hasoperator elapsed,that the controller maintenance is needed by showing a dedicated warning message (S04) on the display. P15 - Oil maintenance pre-alarm hours – Defines the oil change countdown timer value.

restart automatically after a delay that is equivalent to blow down time delay. P18 - Alarm relay function – Defines which function is to be assigned to the alarm remoting relay contact, in accordance with the following arrangement: P18=0 Relay energised in any alarm condition and in any is pre-alarm condition. P18=1 Relay is energised only in alarm conditions that will stop the compressor. P18=2 Relay is energised only when one of the maintenance timers has elapsed.

– When the set timer has elapsed, the controller will warn the operator that maintenance is needed by showing a dedicated warning message (S01) on the display. P16 - Overall maintenance pre-alarm hours – Defines the general maintenance countdown timer value. – When the set timer has elapsed, the controller will warn the operator that maintenance is needed by showing a dedicated warning message (S06) on the display. P17 - Automatic restart status Warning: If the automatic restart feature is to be used, it is strongly adviced to affix a warning sign by the machine to alert bystanders that the compressor may come back into operation automatically and without prior notice. It is also mandatory to check that the automatic re-start of the compressor will not pose any hazards whatsoever. – Enables or disables the automatic restart of the compressor as soon as current is back after a power failure. P17=0 automatic restart is disabled. When current is back after a power failure has halted the compressor, the compressor will NOT restart automatically and the controller will display a dedicated alarm message (A33). P17=1 automatic restart is enabled. When current is back after a power failure has halted the compressor, the compressor will

DL105AA

47


9.7

Error Management

9.7.1

Advisory Alarms The advisory alarms alert the user that maintenance is needed, or that certain parameters may be approaching their shutdown level. Advisory alarms can be reset while the compressor is running or stopped by pressing the RESET button. If the error condition still exists after resetting the advisory alarm, the advisory alarm will occur again after the compressor is powered ON again after it has been powered OFF. See the following tables for advisory alarms that can occur in the controller. Pre-Alarms Code Meaning a03

High oil temperature pre-alarm (message alternates with temperature display). Alarm automatically resets when temperature drops below the set value of -2 °C.

CompAir

9.7.2

Shutdown F aults The shutdown faults in the controller are designed to protect the compressor from component failure or extreme environmental conditions. These alarms will stop the compressor and/or inhibit its start-up. To reset an alarm message, eliminate the cause of the concern and press RESET. See the following table for shutdown faults that can occur in the AirBASIC Controller Shutdown Faults Code Meaning A01

high oil temperature

A03

motor thermal overload relay trip

A04

phase inversion/phase loss

A07

temperature probe is faulty

A26

set data loss and acquisition of default data

A33

power failure (only applicable if automatic restart is disabled)

A34

low oil temperature

Maintenance Alarms Code Meaning S01 Oil change S02

Air filter replacement

S03

Oil filter replacement

S04

Separator filter replacement

S06

General maintenance

Note: It is recommended that maintenance be performed as soon as possible after a maintenance message appears.

48

DL105AA


CompAir

9.8

Transducer Locations

9.8.1

See fig. 9. 4

Fig. 9.4 - Wiring Diagram 9.8.2

Key to codes in fig. 9. 4 Input connector

Pin

Function

Status

M1 power supply connector 24 Vac M2 digital input connector, type: 5 poles Combicon 5 mm C3

1

Commondigitalinputs

l1

2

Linepressureswitch

l2

3

Motorthermalrelay

l3

4

Phase-sequencerelay

Alarmifopen

l4

5

RemoteStart/Stop

Closed=startOpen=stop

Closed=loadedOpen=unloaded Alarmifopen

M3 alarm relay connector, type: 2 poles Combicon 5 mm C2

1

Common relay

R

2

Auxiliaryalarmrelay

Energised=closedDe-energised=open

M4 output relay connector, type: 5 poles Combicon 5 mm C1

1

Common relay

K1

2

Linecontactor


K2

3

Starcontactor


K3

4

Deltacontactor


EV

5

Solenoidvalve


M5 temperature probe connector, type: screw terminals welded on the I.C.

DL105AA

1

Temperatureprobe

2

Temperatureprobe

49

10 Compressor Parts List

10

CompAir

Compressor Parts List

Parts List Contents

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

50

DL105AA

Compressor Parts List 10

CompAir

Frame

8

2 5

9

4 10 3

6 7 1

11 SM 1593

DL105AA

51


CompAir

Motor and Compressor Unit

11

10

9

7 16

8

13

6 5 3 2

12 14

15

4

1

SM 1594

52

DL105AA


CompAir

Motor and Compressor Unit - (cont'd )

11

10

9

7 16

8

13

6 5 3 2

12 14

15

4

1

SM 1594

DL105AA

53


CompAir

Oil Separation Body

6 5

4 5

9

4 10

5 8 7 1 3 SM 1595

54

2

5

4

5

4

DL105AA


CompAir

Oil Tank 14 5 8

2

13

7

4 5

1

6 3

12 13 11 9 10 SM 1596

DL105AA

55


CompAir

Oil Circuit 9 10 7

2 3

1

5 10

4

6

9

11

8

SM 1597

56

DL105AA


CompAir

Air Circuit

4 7 8

5

6 4

1

2

3 4

SM 1598

DL105AA

57


CompAir

Electrical Components

1

3 2

7

8

4 ON x10 x100

5

OFF

6

Reset

a03

SM 1599

58

A01

A03

A04

S.

9

DL105AA


CompAir

Air Receiver 2.2 - 3 - 4 kW 3

2

5

1

4

17

EDX 4-6

EDX 4-6 E

4 1/2" GAS

18

13

7 6 A

6 3

12 12 11 9

10

5.5 kW 5

2

3

4

17 E

18

1/2" GAS

EDX 9

EDX 9

U

1 4

13

7 6 6

A

3

12 12 11 9 16

15 14 8

VIEW A

DL105AA

10

13

SM 1600

59


CompAir

Parts Kit/s - Oil Separation Body

A

C

B

D

SM 1601

60

DL105AA


CompAir

Parts Kit/s - Air Intake Valve

A

A

B 4-5.5kW PREMIUM

SM 1602

DL105AA

2.2, 3, 4 & 5.5kW PREMIUM

61

11 Compressed Air Dryers

11

Compressed Air Dryers

11.1

General The units described in this chapter are termed “dryers”.

CompAir

SYMBOL

DESCRIPTION

Unit air inlet

They are designed to remove the moisture from a flow of “compressed gas”. The dryers are equipped with a refrigerant circuit that is designed to cool the compressed air to a temperature designated “pressurised dew point”. Since, in the majority of applications, the gas to be dried is compressed air, hereinafter the term “compressed air” is used for the sake of simplicity, even though the specific gas in an individual application may be different. Hereinafter the expression “pressure” is used to indicate relative (gauge) pressure. General symbols are to be found on the decals affixed to the unit and also in the dimensional drawings and refrigerant circuit diagrams in this manual. The meaning of each symbol is indicated in fig. 11.1. This manual, is addressed users, all installers, andwhich service personnel, to supplies the technical information required to install and work with the dryer and to perform the routine maintenance operations required to ensure a long working life. 11.1.1

If spare parts are needed use exclusively genuine srcinal components.

11.1.2

Requests for SPARE PARTS and any INFORMATION concerning the dryer must be made to the nearest dealer or service centre, specifying the SERIAL NUMBER shown on the unit's dataplate.

Condensate drain

Direction of fan rotation (air-cooled models)

Do not use fork lift truck where this symbol appears

Electric shock hazard

Unit air outlet

Flow of cooling air (air-cooled models)

Direction of flow of refrigerant gas

Lifting point

SM 1589

Fig. 11.1 - Symbols Used On Dryers

62

DL105AA

Compressed Air Dryers 11

CompAir

11.2

Caution: The gas being compressed must not lead to corrosion that could impair the condition of pressurised containers, nor must they be able to cause fire or explosions in the event of leakage or expulsion.

Safety - Dryers Warning

This plant is designed for safety in its intended use, provided it is installed, commissioned, and serviced in

b)

When a load is lifted from the ground keep

compliance with the instructions given in the present manual.

well clear of the area beneath the load and the immediately surrounding area.

The unit contains electrical components that operate at mains voltage and also moving parts such as fans, it must therefore normally be disconnected from the electrical power supply before it is opened.

Keep accelerations and lifting speed well within safety limits and never leave a suspended load attached to a hoist any longer than strictly necessary. Handling of dryers must be carried out in compliance with the diagrams given (see section 11.3 - "Technical Data - Dryer").

Operation, overhauls or repair of the unit or any maintenance operations that call for access to the plant must be executed by skilled or suitably qualified personnel who are fully aware of all the necessary precautions, preferably under the guidance of a qualified supervisor. 11.2.1

General The userin must ensureand thatservicing all personnel involved operating the dryer and the auxiliary equipment have read and understood all the warnings, precautions, prohibitions and notes given in this manual and affixed to the unit. If the user adopts operational procedures or uses tools or working procedures that are not specifically recommended, care must be taken to ensure that the dryer and the auxiliary equipment are not damaged or made unsafe and that no risks emerge in relation to persons or property. Any improper use of the machine will relieve the manufacturer from any liability for possible personal injury or property damage. Arbitrary modifications made to the unit will automatically invalidate all forms of guarantee provided by the manufacturer.

11.2.2 a)

General precautions Type of compressed gases to be dried The compressed gases that can be dried must be compatible with the unit's construction materials (carbon steel, cast iron, copper and copper alloys) and can be, for example air, nitrogen, argon and helium.

DL105AA

Precautions during lifting and transport

The manufacturer does not supply bars, belts or lifting hooks with the unit. Caution: The unit's weight is shown on the dataplate and on the label affixed to the crate. c)

Precautions to be adopted during installation and operation For connection to the mains power supply follow the guidelines in section 11.5 “Installation” and the electrical diagrams in section 11.3 - "Technical Data - Dryer". All pipelines must be painted and marked clearly in compliance with local safety prescriptions in force in the place of installation. Do not remove or tamper with safety devices, protections or the insulating materials installed in the unit or in the auxiliary equipment. The dryer and its auxiliary equipment must be connected to earth and protected against short circuits and overloads. When the unit is powered, the voltage in the electrical circuit assumes potentially lethal values so the maximum precautions must be adopted if work is to be carried out on the electrical circuit. Do not open the electrical equipment enclosure panels while the electrical system is powered unless this is strictly necessary for the execution of tests, measurements or settings. This work must be carried out exclusively by qualified personnel equipped with suitable

63


d)

CompAir

tools and wearing all the relevant protective equipment to safeguard against electrical hazards.

When a repair has been completed make sure that no tools, detached parts or rags are left in the dryer.

Precautions for maintenance and repair

All the protections must be refitted following maintenance or repair work.

If spare parts are required, use exclusively genuine srcinal parts.

Do not use inflammable liquids to clean components while the dryer is running.

Keep a written record of all work carried out on the unit and the auxiliary equipment. The frequency and nature of the work required in a certain period can reveal abnormal operating conditions that require correction.

If non-inflammable containing chlorine are used allhydrocarbons the relevant safety precautions must be adopted to protect against the toxic fumes that may be given off. Before removing any panels or dismantling any parts of the unit, perform the following steps:

Use exclusively the refrigerant specified on the machine dataplate.

• Isolate the unit from the electrical power supply by disconnecting the supply upstream of the power feeding line.

Make sure that all the instructions concerning operation and maintenance are followed scrupulously and that the entire unit and all the accessories and safety devices are maintained in proper working order.

• Lock out the breaker (if present) in the “OFF” position by fitting a padlock.

Always keep the plant clean.

• Attach a warning label to the main switch (if present) reading: "WORK IN PROGRESS DO NOT SWITCH ON".

Protect components and exposed openings by plugging them, for example, with clean rags during maintenance and repair work.

• Do not set the electrical power switch to ON

Precautions must be taken before welding or performing repair operations that may generate heat, flames or sparks.

or attempt to start the unit if the warning label is attached. Coloured tracers can be used in service-maintenance operations.

Components in the vicinity must be protected with non-inflammable material.

Inspect all refrigerant circuit joints including connectors, flanges, and more generally all critical points (open joints) in order to prevent possible leakage of refrigerant gas.

Do not weld or perform work that generates heat close to a system that contains oil. Systems that may contain oil must be completely drained and flushed, for example, with steam, before performing any operation.

11.2.3

The plants can be charged only with R134a.

Do not weld or modify a container that may be subject to pressurisation.

The use and storage of cylinders containing refrigerants must be in compliance with the prescriptions of the manufacturers of the cylinders and in compliance with the applicable safety laws and prescriptions in force in the place of installation.

To prevent an increase in working temperature and pressure values check and clean the heat exchange surfaces (e.g. the fins of condensers) regularly. For all dryers establish a convenient time interval for cleaning procedures. Never use an open flame as a light source to inspect parts of the dryer. Before dismantling parts of a plant ensure that all mobile and heavy parts are securely fixed, and ensure electrical power has been disconnected.

64

Refrigant gases

a)

Characteristics of R1 34a refrigerant At normal temperature and pressure conditions, this is a class A1 colourless gas (classification EN 378-1). Concentrations significantly above 1000 ppm v/v can cause narcotic effects. In the event of leakages provide adequate ventilation of the room before entering.

DL105AA


CompAir

11.3

Technical Data - Dryers

11.3.1

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

Identify the size of the unit and its type of construction.

MANUAL

Codenumberofthepresentmanual.

SERIAL NUMBER

Unit serial number or manufacturing number.

YEAR OF CONSTRUCTION

Year of unit's final testing.

VOLTAGE/PHASES/FREQUENCY

Power supply characteristics.

MAX CURRENT DRAW (I max)

Unit current input in limit operation conditions (refrigerant condensing and evaporation temperature of 70°C/158°F and 10°C/50°F respectively).

INSTALLED POWER (P max)

Unit power input in limit operation conditions (refrigerant condensing and evaporation temperature of 70°C/158°F and 10°C/50°F respectively).

PROTECTION RATING

According to European standard EN 60529 .

REFRIGERANT

Type of refrigerant charge with which the unit is filled.

REFRIGERANT CHARGE

Quantity of refrigerant supplied to circuit.

MAX. REFRIGERANT PRESS.

Refrigerant circuit design pressure.

MAX REFRIGERANT TEMP.

Refrigerant circuit design temperature.

USERC IRC. FLUID

Fluid cooled by the machine.

MAX. WORKING PRESSURE

User circuit maximum design pressure. User circuit maximum design temperature - not to be confused with the

MAX TEMPERATURE

maximum working temperature, which is specified at the time of the offer. Free field sound pressure level in hemispherical radiation conditions (open field) at a distance of 1m (39.37in) from the condenser side of the unit and a height of 1.6m (63.0in) from the ground.

SOUND PRESSURE LEVEL AMBIENT TEMPERATURE

Cooling air minimum and maximum temperature values.

WEIGHT

Approximateweightoftheunitwithoutpackaging.

CONDENSER COOLING FLUID

Fluid used by the machine to cool the condenser (this information is not given if the machine condenser is air-cooled).

MAX. WORKING PRESSURE

Condenser cooling circuit maximum design pressure (this information is not given if the machine condenser is air-cooled).

MAX TEMPERATURE

Condenser cooling circuit maximum design temperature (this information is not given if the machine condenser is air-cooled).

IMAX*

Fullloadamperage

PMAX *

Maximum power

ILR *

Lockedrotorcurrent * also present on wiring diagram

11.3.2

Performance da ta

a)

The performance of the dryer (dew point, power consumption, pressure drops, etc.) depends mainly on the flow rate and pressure of the compressed gas to be dried and on the condenser cooling fluid temperature (ambient temperature). These data, which are usually defined at the time of the offer, constitute the basic point of reference in relation to dryer performance.

b)

Sound Level Measurements The noise emission values measured are below 70 dB(A).

DL105AA

65


11.3.3

66

CompAir

Overall Dimensions

DL105AA


CompAir

11.3.4

DL105AA

Refrigeration Circuit

67


11.3.5

68

CompAir

Electrical Data

DL105AA


CompAir

Electrical Data (cont'd)

DL105AA

69


11.3.6

70

CompAir

Power Ci rcuit

DL105AA


CompAir

11.3.7

DL105AA

Control Circuit

71


11.3.8

72

CompAir

Components Layout

DL105AA


CompAir

11.3.9

Notes

R XB L J D N J J C Y T L Y J R

Q S D J R D F K G J G =

Q B Y I T Y D  R XB L J D N J J C Y T L Y L J R Q S V T HE B V V HF U J H G =

R J P HE U HT T G N J F N B O PF Z Z Y TY H N E Y D

DL105AA

V HJ T K K J H N Y J R Q S V T Z K D F H G E  B Y T V HT D J G R XB L J D N J J C Y T L Y J R

73


CompAir

11.3.10 Nomenclature

T B Y F D P F Y

F V T { C HJ N R T K "

F N F C Y T L Y J R F D B K C F R B X N F L F N F K G

$ S C HJ B R X J $N R XB N F L

H J N F C Y T L Y J R

H J N F C TY L Y J R

H J C C TH G V J R

H J N Z K B N Y T D

F R XB Z L B Y J T D K N D J F J L C Y J T Z U L B J Y Y R J T J R K C Y TV S D F P G F F P N K R F R B N J Y C J F HN V C R R V C K T T HT B K K G D " R

T B Y T : J K J G T B Y T O F H R J C

74

DL105AA

CompAir


11.3.11 Electrical Devices

DL105AA

75


11.4

Description

11.4.1

Operating principle

CompAir

section of the thermal mass, where it absorbs the heat of the warm and humid compressed air entering the dryer and thereby cools the inlet flow.

A refrigerant circuit cools a patented “thermal mass” through which the humid compressed air to be dried flows.

This air/air exchanger both reduces the amount of energy required to dry a given flow of air and also has the benefit of reducing the relative humidity thereby avoiding the risk of the formation of condensate at the dryer outlet.

The air cools, resulting in condensation of the water vapour it contains, which is subsequently separated and discharged. The temperature of the thermal mass is regulated by an electronic controller, which stops the refrigerant compressor when the programmed setpoint is reached. 11.4.2

Air and refrigerant circuits (Also see refrigerant circuit diagrams insection11.3 - "Technical Data - Dryer")

a)

Air circuit The warm and humid compressed air entering the dryer flows through the air/air exchanger section of the thermal mass. Here the air is precooled by the cold and dry compressed air leaving the air/refrigerant or evaporator section of the thermal mass. The precooled air then enters the evaporator section of the thermal mass where it is cooled (in most applications to a temperature of approximately 3°C/37.4 °F) exchanging heat with the refrigerant fluid and the silica thermal mass. Heat is exchanged by a process of conduction through the aluminium fins that join the copper tubes through which the compressed air flows, to the copper tubes in which the refrigerant fluid evaporates. The aluminium fins exchange heat also with the silica thermal mass keeping it at a temperature of approximately 0°C (32°F). At this point the compressed air is saturated and conveys with it the condensation produced during the cooling process. The precooled air then enters a high efficiency condensate separator (demister type with stainless steel mesh) where the condensate is precipitated and collected on the bottom of the enclosure. A condensate discharger opens periodically and drains the condensate which is expelled by compressed air pressure. The dry cold air at the outlet of the separator flows for the second time through the air/air

76

b)

Refrigerant circuit The high pressure compressed refrigerant gas flows into the condenser. In the condenser, the refrigerant changes from the gaseous to the liquid phase. The condenser is a heat exchanger of the finned core type and it is cooled by an air flow provided by fan. The condenser is generously sized in such a way that it can function partially also as a liquid receiver. Downline from the condenser the refrigerant enters a drier filter and a capillary tube where refrigerant pressure is reduced to lower its boiling pressure. The refrigerant then enters the tubes of the evaporator section of the thermal mass, cooling both the compressed air and the thermal mass itself. The refrigerant at the dryer outlet is now in the form of a cold vapour, which is returned to the compressor to repeat the cycle. Since the heat provided by the compressed air to cause the refrigerant to evaporate varies significantly because of fluctuations in the compressed air temperature and flow rate, the dryer is equipped with an electronic system to control the temperature of the thermal mass. This system fulfils 3 important roles: • it ensures an almost constant pressurised dew point (approx. +3°C (+37.4°F)); • it prevents the compressed air temperature from falling below 0°C (32°F) with consequent freezing of the condensate; • it ensures that all the refrigerant is evaporated in the evaporator, thus avoiding the risk of any liquid entering the compressor suction side. When the load is low or zero, the temperature of the thermal mass tends to fall. When it

DL105AA


CompAir

reaches 0°C (32°F) the electronic controller stops the compressor.

b)

The compressed air that continues to flow in the evaporator is cooled by the cooling energy stored in the silica.

The dryer should be installed upline from the tank when it is sized in order to allow wide fluctuations of the air flow rate utilised with peak values that are significantly higher than the maximum flow rate of the compressor. A

When the silica temperature starts to rise, the refrigerant compressor is started automatically so that it can cool it down again.

5

This system offers the benefit of reducing average energy consumption of the dryer in such a way as to make it approximately proportional to demands.

3

2

1)

2)

B

Location

3

Install the dryer in a well-ventilated place, where the ambient air is clean and free from flammable gases or solvent vapours.

4)

a)

DL105AA

5

2 7

1

6

4

Avoid installing the dryer in excessively cold places; this could cause the drainage discharged condensate to freeze in the systems. The minimum ambient temperature for installation of these dryers is shown in the dataplate affixed to the unit.

3)

6

Installation Warning: Before installing or operating these dryers, ensure that all personnel involved have read and understood section 11.2 - “Safety - Dryers”.

11.5.1

7

4

1

11.5

SM 1605

The dryer can be positioned on any flat surface that is sufficiently solid to support its weight. Leave free space around the dryer as indicated in the installation drawings to allow unimpeded access during servicing operations and to avoid obstructing or disturbing the condenser cooling air flow. Position the dryer in such a way that the cooling air can not recirculate to the intake grilles. Ensure that the dryer is not subject to hot air flows deriving from systems for cooling, for example, the air compressor, the refrigerant compressor, or any other

11.5.2

Fig. 11.2 - Dryer Location Compressed air compressor Final refrigerant Condensate separator Compressed air tank Prefilter Dryer By-pass

A. B.

Dryer Downstream (most common) DryerUpstream

Pipelines (see fig. 11.2)

1)

equipment in the vicinity. The position of the dryer in the compressed air distribution system depends on the methods of use of the compressed air (see fig. 11.2). The dryer must be installed downline of the tank when the air compressor runs intermittently and the maximum compressed air working flow rate is no higher than the flow rate delivered by the compressor (this is the most common type of installation).

1. 2. 3. 4. 5. 6. 7.

The inlet and outlet connections are clearly marked (see fig. 11.1). The pipelines and connections must be correctly sized and suitable for the working pressure the application. Remember to removeofthe protective caps from the connections and ensure that no debris or other material enters the connections during installation procedures. Any foreign material that enters the connections can result in clogging of the filter or jamming of the condensate discharge valve.

2)

All pipelines must be equipped with suitable supports. Flexible couplings should be

77


installed to prevent the transmission of vibration. 3)

4)

Connect the condensate discharge hose to a suitable drain point. The drain line of the dryer should not be connected to the drain lines of other equipment; ideally the line should end in an open funnel type drain. Do not route the condensate to a common drain header because of the possibility of oil contents. Oil/water separators should be installed to separate any oil out of the condensate. Make sure that the drainage system complies with local regulations and bylaws. It is advisable to install a prefilter up-line of the dryer and, if neces sary, a coalescent deoiler filter down-line of the dryer. Install shut-off valves on the compressed air inlet and outlet connections so that the dryer can be isolated if necessary. Fit a suitably sized pressure relief valve upline from the shut-off valves.

5)

Install a bypass line with shut-off valves so that dryer maintenance operations can be carried out without interfering with the compressed air supply.

6)

Pipelines and other parts whose temperature may exceed touched 60°C (140°F) and thatmust may be be accidentally by personnel protected or insulated.

7)

11.5.3

In order to discharge the compressed air from the dryer so that the unit can be depressurised prior to maintenance operations, fit a venting valve in the pipe between the dryer and one of the shut-off valves.

The voltage, frequency and number of phases must comply with the data on the unit's dataplate. The power supply voltage must not be outside the tolerances shown on the electrical diagram, even in terms of transients. Unless otherwise specified, the frequency tolerance is +/-1% of the nominal value (+/-2% for short periods).

78

a)

Connect the unit (terminal in the electrical panel) to the electrical earthing system of the building

b)

Adopt means to ensure automatic disconnection of the power supply in the presence of a ground fault (protection against indirect contacts in compliance with the prescriptions of IEC 364) by means of a residual current device (normally with rated trip current of 0.03 A)

c)

Make sure the level of protection against indirect contact at the source of the power feeding cable is equivalent at least to IP2X or IPXXB

d)

At the start of the power feeding cable or the power cable supplied with the unit install a device that protects the cable from overcurrent (short circuits) (refer to the indications in the electrical diagram). Caution: Protection devices must be installed to limit the short circuit current to peaks of 17 kA corresponding to the specified interruption power if the short circuit current envisaged at the point of installation is greater than an effective

e)

2)

For the electrical power supply:

value of 10 kA. Use connectors rated for the maximum required voltage at the maximum operating ambient temperature, according to the chosen installation type (IEC 364-5-523) (see the indications on the electrical diagram). Indications on the electrical diagram:

a)

Maximum permissible size of the fuse type gG. In general, fuses can be replaced by an automatic switch adjusted in relation to the machine maximum current input (consult the manufacturer if necessary);

b)

Section and type of power cable (if not already supplied):

Electrical connections The unit's connection to the power supply must be made in compliance with laws and prescriptions in force in the place of installation, after having consulted the electrical diagram supplied with the plant.

1)

CompAir

– A Installation: insulated conductors, multicore cable in a cable duct, inst alled overhead, or fixed to awith masonry structure (type C in compliance IEC 364-5-523 1983) or without any other cables in contact; – B working temperature: maximum working ambient temperature for the unit; – C cable type: copper conductors, 70°C / 158°F PVC insulation (unless otherwise specified) or EPR 90°C/ 194°F insulation.

DL105AA


CompAir

Voltage must be supplied between phase and neutral and the neutral conductor must be connected to earth in the factory substation (TN system to IEC 364) or by the electricity company (TT system to IEC 364).

11.7

"iDRY" E lectronic C ontroller

11.7.1

User interface

The line conductor and neutral conductor are not interchangeable and their positions cannot be switched.

11.6

Start-Up Caution: Before starting this type of dryer, ensure that all personnel involved have read and understood section 11.2 - “Safety - Dryers”.

SM 1603

Fig. 11.3 - "iDRY" Electronic Controller a)

Display

a)

Check that the dryer shut-off valves are closed and the by-pass valve is open.

b)

Check that the ambient temperature is within the range indicated on the unit's dataplate.

c)

Power the dryer by means of the line protection device.

OFF

Unit OFF

d)

When the unit is powered the control unit display switches on (see section 11.7 - “iDRY Electronic Controller”).

drY

Unit running (normal operation)

hdp

High Dew Point temperature

e)

Press button delay ofhas the control programmed elapsedunit. theOnce the compressor and fan will start.

f)

Wait for the compressor to stop when the thermal mass has reached the programmed temperature.

g)

Slowly open the dryer inlet valve to pressurise the unit.

h)

Slowly open the dryer outlet valve.

i)

Close the dryer by-pass valve.

j)

Press the manual condensate discharge button to check that the discharge solenoid valve opens.

k)

b)

Buttons Button

Function Displays or edits the set-point. During programming, selects a parameter or confirms a value. Displays data of a temperature alarm. During programming, scrolls through parameter codes or increases the relative value. Displays data of a temperature alarm. During programming, scrolls through parameter codes or decreases the relative value.

If the unit is equipped with timer controlled condensate discharge, check that the discharge solenoid valve opens again after the time interval set on the control panel. The dryer is now ready for normal operation (see section 11.9 - “Operation and Maintenance”).

DL105AA

The controller displays the unit status with messages shown on the LCD display. The display messages can be:

Turns the unit on or off. Condensate drain test.

+

Locks or unlocks the keypad.

+

Enters programming mode.

+

Exits programming mode.

79


c)

CompAir

Icons Icon

Icon Status

Function

Off

Compressor OFF

On

Compressor ON

Flashing

Compressor stopped at timed intervals

Off

Condensate drain deactivated

On

Condensate drain activated

On

Winter set point in use

Off

Winter set point function disabled

Off

No alarm condition

Flashing Indicates an ala rm condition On

In the event of sudden power failure when the unit is running, the unit will resume operation automatically when the power is restored according to the procedure described above. Note: The electronic controller can be programmed with the unit ON or OFF. 2)

With the unit indicated ON, pressby theformessage the unit to set. to stand-by, OFF 3)

4)

• Summer • Winter

Unit of measurement in degrees Fahrenheit

To select the set point to use, set the parameter “SSt” (For more information, see section 11.7.4 - "Description of settings and parameters”). Setting parameter “SSt” to "d" serves to enable switching from a digital input (see section 5) e) - "Dual set point from digital input”).

Main functions Unit start-up After having made the electrical connections, the message “---” appears on the display showing that the board is powered, after which the message “OFF” appears (see section 11.7.1 a) - "Display") showing that the unit and the refrigerant compressor are off. To turn on the unit, press

.

The unit starts to operate automatically according to the temperature read by probe -BDPT and according to the temperatu re control logic.

Dual set point management The controller has a dual set point:

Unit of measurement in degrees Centigrade

Flashing Unit in programming

11.7.2 1)

Condensate drain test Press to activate the condensate drain relay (if the condensate drain is set in timed mode). The relay is deactivated when the button is released.

Flashing Unit in programming On

Unit shutdown

5)

Digital input A digital input is present with different configurations settable via parameter “|IF”. The image below shows the electronic controller wiring diagram. Terminals 9 and 11 indicate the digital input. Digital input

Note that when the temperature detected by the probe reaches a value such that calls for the compressor to start, instead of starting immediately the compressor will start only after the time lag set on the electronic controller (see section 11.7.4 - "Description of settings and parameters”). When the unit starts the message “hdP” will appear on the display (see section 11.7.1 a) "Display”) to indicate a high dew point temperature; once the unit has reached steady-state operating conditions the display will show the message “drY”. The icon indicates compressor operation.

80

not used 9

8(3)A250V

1

2

3

10

e b ro p

11 12

20(8)A250V

4

5

N.C. Comp Line

t ta s o rm e h T

6

7

8

Power supply 230V~

Hot Key

SM 1606

Fig. 11.4 - Electronic Controller Wiring Diagram The maximum control range is 20m with a Belden type shielded cable. If contro l from more than 20 metres is required, a support relay must be installed.

DL105AA


CompAir

a)

External alarm function ( |IF = EAL) After the timeout set in parameter “dId” has elapsed after activation of the input, an alarm is generated, the message “EA” is displayed and the output status remains unchanged. The alarm is reset automatically when the digital input is deactivated.

b)

|IF

bAL

The alarm is reset automatically when the digital input is deactivated. c)

f)

External shutdown alarm function ( = ) After the timeout set in parameter “ dId ” has elapsed after activation of the input, a shutdown alarm is generated, the message “ CA ” is displayed and the compressor output is deactivated.

e)

|IP CL

Closed

OFF

CL

Open

OFF

oP

Closed

ON

oP

OFF

oP

Closed

ON

oP

Digital input polarity

Compressor operating hours alarm

When the operating hours exceed the set threshold, an alarm message is displayed to notify the user of the need for prompt routine maintenance intervention (alarm “H-C”). The alarm message does not shut down the unit. Note: On completion of routine maintenance, the operator must reset the compressor operating hour counter timers. To reset the compressor operating hours alarm, press . The device displays the message “rSt” and, after 2 seconds, the text “ hF” starts flashing. This resets the alarm. 11.7.3 1)

Programming Editing parameters PR1 To edit a parameter value: + to access flashes).

a)

Press and hold buttons programming mode (

Only if Sst is different from d .

b)

Select the required parameter.

c)

Press the

Dual set point from digital input If the parameter “Sst” is set to d, none of the above functions can be selected for the digital input.

d)

Modifythevaluebymeansof

e)

Press to save the new value and go to the next parameter.

button to display the value. or

.

To quit the programming procedure, display a parameter and then press + .

The input serves to set which of the two set points is to be used for temperature control (see section f).

You can also quit the procedure by waiting for 15 seconds without pressing any buttons. 2)

DL105AA

CL

Open

It is also possible to set a threshold value for the operating hours in the relative parameter “AhF”.

If the parameter is set as “OFn”, the input is configured for remote on/off control of the device (see section f).

ON

OFF

The controller memorises the compressor operating hours.

Remote On / Off from digital input (|IF = OFn)

Function

CL

Closed

|IP = oP: active on contact open. 6)

When the input is active, the compressor remains switched off.

Open

|IP

ON

|IP = CL: active on contact closed;

Pressure switch trip function ( |IF = PAL)

Contact

Function

Open

The polarity of the digital input depends on the parameter “|IP”:

If the number of pressure switch trips as set in parameter “dId” is reached within the time interval set in parameter “nP5”, the alarm is activated. The message “CA” is displayed, the compressor is shut down and control is suspended. To resume normal operation, the device must be switched off and on again.

d)

Contact

Keypad lock/unlock function

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CompAir

Press and hold buttons and for a few seconds until the message “POF” flashes on display.

Press and hold buttons and for a few seconds until the message “POn” flashes on display.

The keypad is now locked: only display of the set point, maximum and minimum temperatures is possible.

The keypad is now unlocked:

If a button is pressed for more than 3s, the text “POF” is displayed. ParameterL evel

Note: The new value entered is saved to the memory also when you quit programming mode without pressing button. 11.7.4

Description of settings and parameters

Description

Range

Setting

SSt

Pr1

Selection of set point type: ( E, I , d ): selects whether the unit operates with the summer set-point (SSt = E ), winter set-point (SSt = I ) or whether the selection is to be made by the digital input (SSt = d ).

odS

Pr1

Compressor output activation delay from start-up. Compressor activation is inhibited for the preset time interval from the time of unit startup.

0–255sec

10

AC

Pr1

Anti-hunting delay; identifies the minimum time interval between compressor shutdown and subsequent restart.

0–50sec

2

Con

Pr1

Compressor running with faulty probe; time for which the compressor remains active in the presence of a probe fault. With “Con” = 0 the compressor always remains stopped. Note: If “Con”= 0 and “COF”= 0, the compressor remains stopped.

0–255sec

0

COF

Pr1

remains stopped in the event of a probe fault. With “ COF”= 0, the compressor is always on.

0–255sec

0

E, dI,

I

Compressor off with faulty probe; time for which the compressor

82

CF

Pr1

Temperature unit of measurement: °C = Celsius; °F = Fahrenheit.

°C – °F

tSC

Pr1

Condensate drain type: tP = timed; FIfixed =

tPFI–

tSO

Pr1

Condensate drain activation: S = always active; O = active only when machine is ON.

O–S

tdS

Pr1

Condensate drain ON time, sets the condensate drain valve opening time.

0–255sec

2

tdA

Pr1

Condensate drain ON time with compressor running, sets the condensate drain valve opening time with compressor running.

0–255sec

4

tdO

Pr1

Condensate drain OFF time, sets the condensate drain valve closing time.

0–255sec

120

Ab– rE

Ab

Temperature alarm configuration:

°C tP S

ALC

Pr1

ALd

Pr1

Temperature alarm delay; time interval between detection and display of a temperature alarm.

0–255sec

120

dAO

Pr1

Temperature alarm inhibition from start; the temperature alarm is inhibited from unit start-up for the time interval set in this parameter.

0–255sec

15

hF

Pr1

Compressor operating hours: calculates the compressor operating hours. Read-only parameter. Each unit is equivalent to 10 hours.

Ab = absolute temperatures; rE = related to SET POINT.

0 999 –

–

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CompAir

Description of settings and parameters (cont'd) ParameterL evel

AhF

Pr1

|IP

Pr1

Description Compressor maintenance alarm; compressor maintenance alarm set-point. Each unit is equivalent to 10 hours. “ AhF” when set to 0 shuts off the alarm.

Range

Setting

0 – 999

0

Digital input polarity: oP –CL

Pr1

Digital input configuration: EAL = external alarm; BAL = external shutdown alarm; PAL = pressure switch; OFn = remote On/Off. Htr = disabled;

EAL, bAL, PAL, OFn, Htr

dId

Pr1

Alarm delay from digital input: |IÂ = EAL or BAL : alarm signal delay from digital input : delay between detection and signalling of an external alarm. |IÂ = PAL time for pressure switch function: if “ nPS” starts in time interval “dId” are reached, restarting is manual only and is performed by switching the unit off and then on.

0–255sec

nPS

Pr1

|IÂ

DL105AA

oP = the digital input is activated on opening of the contact; CL = the digital input is activated on closure of the contact.

Number of starts for pressure switch function: At each activation of the digital input, the control is blocked; if “nPS” activations are reached in time “dId”, restarting is manual only by powering off

PbC

Pr1

the unit and then powering it on again. Probe type selection.

rEL

Pr1

Software release (read-only).

Ptb

Pr1

Parameters table (read-only) serves to identify the factory set parameters map.

1 15 –

PtC ntc –

CL

EAL

5

15

ntc

–

– –

–

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11.7.5 1)

CompAir

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

Meaning

Cause

Output

PI

Thermostat probe faulty

Probe -BDPT faulty or resistive value out of range

Compressor output according parameters “Con ” and “COF” to

AdP

High temperature alarm

Dew Point Temperature above alarm set point

Not modified

Low temperature alarm

Dew Point Temperature below alarm set point

Compressor output OFF

LdP EA

External alarm

CA

External alarm (|IÂ = bAL)

PA

External alarm (|IÂ = PAL)

H-C

Compressor maintenance alarm

Not modified Compressor output OFF Compressor output OFF When the number of compressor operating hours exceeds the maintenance threshold value of Not modified parameter “hF”, the maintenance request signal is activated

Caution: Alarms are displayed exclusively with the unit ON. Notes : alarm "PI" trips a few seconds after (i) Probe the probe develops a fault; this alarm is reset automatically few seconds after the probe resumes normal operation. Before replacing the probe, check the connections.

a)

The display shows: "HAL" for the high temperature alarm ("LAL" for the low temperature alarm), followed by the "Duration" (tiM) in h.mm.

(ii) The "AdP" and "LdP" temperature alarms are reset automatically as soon as the thermostat temperature returns to normal values. (iii) The external alarms "EA" and " CA" (|IÂ = bAL) are reset as soon as the digital input is deactivated.

The device then resumes the normal display presentation as set. Note: The duration is to be considered as a partial value if the alarm is still in progress. b)

The message "rSt" will appear immediately and then, after 2 seconds, it will start flashing to confirm that the values have been deleted.

High and low temperature alarm memorisation

If is pressed again, the display shows the text "noA" (no alarm present).

When illuminates, the unit is in alarm status as follows: Flashing = Alarm active Steady = Temperature alarm reset and memorised.

84

To delete saved or currently active alarms:– With the alarm shown on the display, press andhold .

(iv) If the digital input is configured as pressure switch (|IÂ = PAL), the alarm must be reset manually by switching the instrument off. 2)

To check the type of alarm and its duration:–P resseither or .

3)

Serial line for monitoring systems The TTL serial line, available via the HOT KEY connector, enables interface with a compatible ModBUS-RTU monitoring system.

DL105AA


CompAir

11.8

Timed Condensate Discharge Unit The timed condensate drain system is controlled automatically by the electronic controller, on which the intervals between condensate discharge cycles can be programmed (see Section 11.7 - “iDRY Electronic Controller“). The condensate discharge unit must be checked and serviced carefully to ensure that the condensate produced and separated is not entrained in the compressed air stream into the distribution network.

11.8.1

b)

Press the ma nual condensate discharge button to check that the filter is not pressurised.

c)

Set the line switch to OFF in order to disconnect the power supply to the dryer.

d)

Carefully unscrew filter cap [1] retaining seal [2] and remove strainer mesh [3].

e)

Once cleaned, the mesh it is properly seated,refit and refit andmaking tighten sure cap [1].

f)

Renew seal [2] if it is damaged.

g)

After re-opening the shut-off valve or the Filterstop valve, power on the unit again and restart it.

Filter Cleaning When a dryer is installed for the first time, it is common for particles of rust, pipe scale, metal filings, etc. to find their way into the separator and then into the filter protecting the discharge solenoid valve. This component should therefore be removed and cleaned approximately one month after installation. Thereafter it should be cleaned once every three months and in certain cases more frequently.

11.8.2

Solenoid valve maintenance

Depending on the type of discharge unit fitted, either a standard mechanical filter or a Filterstop valve with integ ral filter (see fig. 11.5 ) may be installed. B

A

3 3

2

2

Fig. 11.6 - Condensate Discharge Unit Solenoid Valve

1 1

SM 1604

Fig. 11.5 - Cond ensate Dra ins 1. 2. 3. a)

DL105AA

Plug Seal Metal Mesh Strainer

Close the shut-off valve upline from the dryer to remove strainer mesh [3]. If the timed condensate discharge unit is equipped with Filterstop valve, it is sufficient to simply close the valve.

1. 2. 3. 4. 5. 6.

Body Plunger-seal '0' Ring Armature Guide Tube Plunger Spring

7. 8. 9. 10. 11. 12.

Shading Ring Stopper Locknut Electrical Contacts Bonnet Flange

The solenoid valve must always be protected by an appropriate filter to prevent solid particles preventing it from opening and closing properly.

85


However, if these particles manage to pass through the filter and cause the valve to malfunction, all its internal components must be cleaned.

CompAir

11.9

Operation And Maintenance

11.9.1

General operation Do not switch the dryer off in the absence of a flow of compressed air.

Proceed as follows: a)

Isolate and depressurise the dryer

b)

Open the line switch to disconnect the power

c)

supply to the dryer Undo the screw in the centre of the cap for the valve power supply

d)

Lift and remove the cap

e)

Remove the solenoid valve from the pipe and clamp the body tightly in a vice

f)

Unscrew nut [9] securing solenoid valve and withdraw the latter from tie-rod

g)

Unscrew the tie-rod from the valve seat

h)

Check the condition of the valve seal [2], O-rings [3] and of all other components and clean thoroughly

i)

Re-assemble the components by performing the above procedures in reverse sequence

j)

Make sure that the valve is re-installed with the arrow pointing in the right direction

The dryer will switch on and off automatically. The number of starts/stops depend mainly on the flow rate and temperature of the compressed air and the ambient temperature. As explained in section 11.7 - “iDRY Electronic Controller”, the control unit will switch the compressor off automatically in the absence of a flow of compressed air. In this case the refrigerant compressor will run occasionally and for short periods to compensate for heat losses between the thermal mass and the external atmosphere. In this way the dryer will be ready to dry the air when the flow is restored. If so desired, the user can switch off the dryer overnight or during weekend breaks without any problem. When the compressor unit is required for duty again, remember to switch the dryer on at least 10-15 minutes before the air compressor. 11.9.2

Caution: Do not tighten nut [9] excessively as it could obstruct movement of the valve element and cause the valve to open and close incorrectly.

Maintenance Warning: Before installing or operating these dryers, ensure that all personnel involved have read and understood section 11.2 - “Safety - Dryers”. These dryers will give many years of trouble-free duty if they are properly maintained and serviced.

a)

Access to the dryer To access the electrical panel, remove the lateral screws fixing the top cover to the side panels of the cabinet. Once the top cover has been removed, access the electrical panel components by unscrewing the nuts fixing the protective cover to the front panel.

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CompAir

11.9.3

Maintenance Schedule - Dryers Every s th n o M 6

h t n o M

y a D

Task

r a e Y

   

Check to ensure there are no alarm signals. Press the manual condensate discharge button to check that the valve drains properly. If the dryer is equipped with a timed condensate discharge unit, check for possible excessive production of condensate; in this case increase the valve opening time (ON). Check that the solenoid valve opens properly, in compliance with the times set on control unit.

   



Check that compressed air inlet temperature is lower than the limit for which the dryer was selected (normally 35-40°C (95-104°F)).







Remove, clean and refit the condensate discharge unit filter.If the filter is always clogged with material, it may be necessary to dismantle and clean the solenoid valve.







Check that ambient air temperature is lower than the limit value used to select the dryer (normally 25-30°C / 77-86°F). Check that the area in which the dryer is installed is well ventilated.







When the compressor is running, check that its upper part is not too hot (more than approximately 50°C / 122°F). Check that the dryer's current draw is within the rated values.





Make a visual inspection of the refrigerant circuit to make sure the piping has not deteriorated and there are no traces of oil, which may indicate a leak of refrigerant.





Check the condition and soundness of piping connections.





Check the condition and soundness of the electrical connections. Check that the fan switches on automatically and does not produce excessively high noise levels. Clean the condenser fins with a jet of clean compressed air. Make sure the grilles are free from dirt and any other obstructions.









Clean the condenser fins with mild detergent.



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

DL105AA

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11.10

CompAir

Troubleshooting Dryers SM 1590

Dew point temperature higher than prescribed value

Compressed air flow rate or temperature too high / ambient temperature too high ?

No

Yes

Pressure of compressed air to be dried too low ?

No

Yes

Circuit has insufficient refrigerant charge ?

No

Yes

Contact refrigeration engineer to check circuit for refrigeration leaks. Recharge

Restore values to within preset limits

SM 1591

Compressed air excessive pressure drop

Exchanger tubes blocked by impurities conveyed by compressed air ?

Contact CompAir Technical Support

No

Icing up due to incorrect setting or faulty operation or variation of set-point value. Temperature probe not calibrated. Probe positioning ?

Yes

No

Pressure of compressed air to be dried too low ?

No


Yes Yes

Clean surfaces of pipes with descaling solution that does not react with steel or copper

88

Switch dryer off and restart only after having: positioned probe correctly. If these actions fail to solve the problem, renew control board or probe

Restore values to within preset limits

DL105AA


CompAir

Troubleshooting dryers (cont'd) SM 1592

Presence of condensate downline from dryer

Clogged strainer upline from solenoid valve ?

Yes

Clean mechanical filter by closing valve upline from filter or isolating dryer from compressed air network

DL105AA

No

No Condensate discharge solenoid valve coil burnt out ?

Solenoid valve element blocked ?

No Solenoid valve opening time too short or closing time too long ?

Yes Isolate dryer from air network, dismantle solenoid valve, clean components refit valve

No


Yes

Yes

Yes Renew solenoid valve

No

Relay on electronic board controlling solenoid valve not functioning ?

Edit open and closed times (if required by control unit)

Use tester to check if terminal contacts of relay controlling solenoid valve fail to close when manual discharge button is pressed. If relay not functioning, renew control board

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Technical Manual l03

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