LSR Cyclon Repair Manual

CompAir

CYCLON SR, and LSR AIR COMPRESSORS

REPAIR MANUAL Serial Numbers from: F180-0106 (Cyclon 345SR) F170-0112 (Cyclon 475SR) F180-0101 (L45SR) F170-0112 (L75SR) F171-0100 (L120SR)

AC20160-1822, Issue 1, November 2002

CompAir

GENERAL INFORMATION These compressors are intended for compressing atmospheric air and are not suitable for compressing any other gas. They are designed and manufactured to give optimum performance, with long life and reliability. This manual gives the user all the information required to install and operate the compressors and carry out the regular schedules for servicing and maintenance which will ensure the maximum satisfactory service life. Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of CompAir companies and distributors. If replacement parts are needed, the user should contact the local CompAir company or distributor in the first instance. The information given in this manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressors. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir company or distributor who is supplied with revised and up-dated information. In any communication concerning the compressor it is essential to quote the MODEL and SERIAL NUMBER. Throughout this manual all pressures quoted are gauge pressure unless otherwise specified.

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

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

USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED OUT USING NON-GENUINE PARTS.

AC20160-1822, Issue 1, November 2002

CompAir

CONTENTS

Chapter

Title

1

Safety Procedures

2

Product Improvements

3

General Description

4

Technical Data

5

Mechanical Fault Finding

6

Components

7

Maintenance

8

Electrical Systems and Fault Diagnosis

9

Disassembly and Assembly (Mechanical)

Appendix 1

Dimensions

Appendix 2

Diagrams

Associated Publications Title

Part Number

Cyclon 345SR Parts List

C20160-1736

Cyclon 475SR Parts List

C20160-1615

L45SR Parts List

C20160-1790

L75SR Parts List

C20160-1759

L120SR Parts List

C20160-1811AX

Cyclon 345SR and 475SR User Manual

C20160-1726

L45SR, L75SR and L120SR User Manual (English)

C20160-1726

Power Converter Parts Manual

T.B.A.

AC20160-1822, Issue 1, November 2002

CompAir

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Safety Procedures

CHAPTER

1 SAFETY PROCEDURES

1. 2. 2.1 2.2 2.3 3. 4. 5. 6. 7. 8.

GENERAL WARNINGS, CAUTIONS AND NOTES Warnings Cautions Notes GENERAL SAFETY PRECAUTIONS INSTALLATION PRECAUTIONS OPERATIONAL PRECAUTIONS MAINTENANCE AND REPAIR PRECAUTIONS PRECAUTIONS IN THE EVENT OF FIRE DISPOSAL

AC20160-1822, Issue 1, November 2002

Chapter 1, page 1

CompAir

SAFETY PROCEDURES 1.

GENERAL

Most accidents which occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. An accident can often be avoided by recognising a situation that is potentially hazardous. 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. 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. 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. Failure to observe the precautions given under ‘Safety Procedures’ may be considered dangerous practice or misuse of the compressor unit.

2.

WARNINGS, CAUTIONS AND NOTES

2.1

Warnings

Warnings call attention to operations or procedures involving specific hazards which could cause injury or death and are identified by the following symbols on the unit and in the text of the manual.

WARNING: RISK OF DANGER

WARNING: RISK OF ELECTRIC SHOCK

WARNING: RISK OF HOT SURFACES

WARNING: CONSULT MANUAL

WARNING: RISK OF HIGH PRESSURE

WARNING: ENTRY DELAY – ENERGISED CAPACITORS

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

Chapter 1, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Safety Procedures

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.

3.

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. 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.

Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into the air intake. Ensure that the air delivery pipe from the compressor to the user’s pipework or receiver is free to expand and that no flammable material is within the vicinity. 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. 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. A pressure relief valve must be installed between any compressor unit and the shut-off valve/s. A pressure relief valve is fitted on the reclaimer vessel as standard equipment. A pressure relieving device must be fitted to every pressure vessel, or equipment containing air at above atmospheric pressure, when installed downstream of the unit.

5. 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.

OPERATIONAL PRECAUTIONS

The compressor unit must only be operated by competent personnel under a qualified supervisor. Do not run the compressor with doors open or covers removed except when checking reclaimer operation. Never remove or tamper with the safety devices, guards or insulation materials fitted to the unit.

4.

INSTALLATION PRECAUTIONS

Installation work must only be carried out by competent personnel under a 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, since this could cause an internal fire or explosion.

AC20160-1822, Issue 1, November 2002

The compressor must only be operated at the supply voltage and/or frequency for which it is designed 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.

Chapter 1, page 3

CompAir

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.

6.

WARNING

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. During normal operation no internal part of the compressor unit should reach a temperature above 120°C and protection devices are fitted to prevent excessive temperatures occurring. 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 oil 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. The compressor must not be operated in ambient temperatures outside of those given under ‘Leading Particulars’. 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.

Chapter 1, page 4

MAINTENANCE AND REPAIR PRECAUTIONS

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting work on the compressor.

Maintenance, repairs or modifications must only be carried out by competent personnel under a 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:1.

Isolate the compressor unit from the main electrical power supply. Lock the isolator in the ‘OFF’ position and remove the fuses.

2.

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.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Safety Procedures

3.

Close the isolating valve between the compressor unit and the user’s pipework. Attach a label to each valve carrying the warning ‘WORK IN PROGRESS – DO NOT OPEN’

4.

Ensure that the blowdown system has operated to release all pressure from the reclaimer.

5.

Check that the pressure gauge registers zero. Release any remaining pressure from the delivery side of the reclaimer element by slackening a pipe connection to the differential pressure indicator. Release any residual pressure from the upstream side of the reclaimer element by slowly slackening the oil filler plug on the reclaimer. Release any pressure in the aftercooler by slackening the pipe at the bottom of the moisture separator. Tighten the plug and pipe connections.

Use only lubricating oils and greases 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 oil 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 and temperature gauges and switching thermometers must be regularly 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.

AC20160-1822, Issue 1, November 2002

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 and if the operation is to be carried out near any part of the oil system, or close to a component which may contain oil, the system must first be thoroughly purged, preferably by steam cleaning. 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 the reclaimer or any other pressure vessel. Before dismantling of any part of the compressor unit ensure that all heavy movable parts are secured. 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. Check the direction of rotation of the motor when starting up the compressor initially and after any work on the electrical connections or switchgear. Do not use any flammable liquid to clean 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. 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 condensate, old oil, used filter elements and other parts and waste material of any kind make sure that there is no pollution of any drain or natural water-course 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.

Chapter 1, page 5

CompAir

7.

PRECAUTIONS IN THE EVENT OF FIRE

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

8.

DISPOSAL

When items of equipment are taken out of service for disposal it is recommended that the following instructions are adhered to: 1.

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

2.

Alternatively all such items of equipment should be stripped into their component form for ‘material composition disposal’ e.g. base metals, plastics, fabrics etc and be subject to normal industrial waste re-cycling processes.

3.

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.

4.

Ensure that all fluid waste e.g. lubricating oils and greases, anti-freeze agents, refrigerant fluids or corrosive inhibitors should be separated and disposed of by authorised salvage disposal or recycling systems ensuring that none is permitted to enter a waste water system.

Chapter 1, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

CHAPTER

2 PRODUCT IMPROVEMENTS 1.

SUMMARY

MACHINE/S

SERIAL NUMBERS

IMPROVEMENT

475SR 475SR 345SR, 475SR 475SR 345SR 345SR 475SR 345SR 475SR L45SR, L75SR

F170-0111 to F170-0145 all All All F170 - 850 onwards F180 - 650 onwards All -

Cold Start Inhibit. Compressors Transport Packaging. Obsolete Gate Drive Board. Motor cable routing. Failure of EMC filters Phase Failure Kit (400V) Phase Failure Kit (440/460V) Power Converter Ventilation Kit Power Converter Ventilation Kit Enhancements

773 785 798 803 804 805 806 810 811 812

3 5 6 8 10 11 16 21 26 31

Single Pass Air/Oil Cooler Retrofit Kit

822

33

475SR, L75SR

2.

BULLETIN PAGE

NEW BULLETINS

Insert when issued. MACHINE/S

SERIAL NUMBERS

AC20160-1822, Issue 1, November 2002

IMPROVEMENT

BULLETIN PAGE

Chapter 2, page 1

CompAir

Chapter 2, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

COLD START INHIBIT WARNING !

!

1.

3.

Refer to the safety procedures in the User Manual before carrying out any maintenance or servicing work on the compressor unit.

CAUTION When working wfth static sensitive components i.e.. circuit cards and memory IC’s etc., always take aniti-static precautions.

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work

INTRODUCTION

If an oil injected compressor is started when the oil temperature is below the specified minimum of 0°C, serious damage to the air end may result. The low oil temperature will result in high oil viscosity leading to insufficient oil flow. To ensure that a compressor cannot be started during below zero conditions, a Cold Start Inhibit feature has been added to the control program of current production compressors, The improved program. is also available for installation to existing compressors. If there is a possibility that the ambient temperature around the compressor is likely to fall below zero, a heater kit is available for fitting to the compressor. Please contact Product Management at CompAir UK for further details.

2.

1.

Always transport static sensitive components in anti-static bags or containers.

2.

Never touch the rnetal pins of electronic IC devices.

3.

Never place static sensifive components onto a metal surface. Always place directly into an anti-static bag or container.

4.

Always ensure any body static is discharged before handling static sensitive components by touching an earthed surface at regular intervals.

1

Switch off and isolate the power supply to the compressor.

2.

Remove the canopy panel as required and the starter area access panel.

3.

Remove the controller from the compressor.

4.

Remove the screws located adjacent to the electrical plug connections on the rear of the controller.

5.

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

6.

Remove the rear controller enclosure securing screws.

7.

Remove the rear controller cover.

8.

The control program IC can be removed without dismantling the circuit cards. To eliminate the possibility of re-connection errors, it is recommended that the circuit cards are not dismantled.

REPLACEMENT PROGRAM

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

AC20160-1822, Issue 1, November 2002

REPLACEMENT PROGRAM INSTALLATION

Chapter 2, page 3

CompAir

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

4.

OPERATION

Note: refer to the compressor User Manual for operating details. When the temperature in the air end is 1°C or less,

9.

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

10.

Insert the new control prograrn 1C. Check the orientation and ensure that each pin enters the socket correctly. (The pins must not bend underneath the IC during insertion.)

11.

When re-assembling the controller, replace the rear cover securing screws first to hold the cover in place. Then insert and tighten the screws and nuts adjacent to the electrical plug connections before finally tightening the rear cover screws.

12.

a) The High Delivery Temperature indicator on the controller will flash with a double pulse. b) The message ‘Start Inhibited’ will be shown on the controller display (unless the compressor is on Standby or Remote Stopped). c) The start inhibit will not be recorded on the Fault History Record or affect the Group Fault Output. The inhibit circuit will be automatically reset as the temperature rises above 1°C.

Re-connect to compressor and test.

bar psi

HW 0274

Fig. 1 SureScan Controller

Chapter 2, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

COMPRESSORS TRANSPORT PACKAGING 1.

Locate the compressor close to the installation position using a forklift to lift the pallet.

2.

Remove the four nuts and washers securing the compressor to the pallet.

3.

Raise the compressor, using the forklift, until it is clear of the locating studs on the pallet.

This bulletin advises distributors and installers of recommended handling procedures.

4.

Place the compressor in the designated position.

METHOD

5.

Remove the plastic cover from the compressor.

WARNING

6.

Remove the cardboard packing from the three removable panels and the service door on the compressor.

LIFTING OPERATIONS MUST BE DONE BY QUALIFIED PERSONNEL USING APPROVED EQUIPMENT.

7.

Install and commission the compressor as detailed in the User Manual.

INTRODUCTION The Cyclon 475SR compressor may be secured to a pallet to reduce the chances of damage in transit. Cardboard packing may also be fitted to the three removable panels and the service door of the compressor.

CAUTION: The preferred method of handling the compressor is by a forklift. The compressor is not designed for overhead lifting. If a forklift is not available, the compressor may be lifted using jacks and suitable spreader bars through the fork tunnels on the compressor.

AC20160-1822, Issue 1, November 2002

Chapter 2, page 5

CompAir

OBSOLETE DRIVE BOARD WARNING

1.

●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

INTRODUCTION

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

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

2.

METHOD

1.

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

2.

Rewire the compressor to gate drive board connectors as detailed in Table 1.

3.

Attach the connectors to the gate drive board.

Gate Drive Board, part number C20606-143, may be supplied when C20606-83 is ordered. When fitting the new Gate Drive Board, part number C20606-143, some wiring connection changes are required.

Chapter 2, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

Connector

Pin

C20606-83

C20606-143 C20606-183 C20606-283

A1

1 2 3 4 5 6 7

150 151 152 -

151 150 152 -

150 151 152 -

150 151 152

A2

1 2 3 4 5 6 7

156 157 158 -

157 156 158 -

156 157 158 -

156 157 158

B1

1 2 3 4 5 6 7

153 154 155 -

154 153 155 -

153 154 155 -

153 154 155

B2

1 2 3 4 5 6 7

159 160 161 -

160 159 161 -

159 160 161 -

159 160 161

Table 1 Gate Drive Board Connector Wiring

When a C20606-283 board is used four Phoenix 7-way Combicom connectors are required, Ref: MSTB 2,5/7 - ST5,08

AC20160-1822, Issue 1, November 2002

Chapter 2, page 7

CompAir

MOTOR CABLE ROUTING

WARNING ●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

DETAIL

SOLUTION

This is to advise that on a limited number of machines two of the four motor leads have been routed too close to the auxiliary contactor block of the main contactor.

Re-route the two cables that are adjacent to the auxiliary contactor block and fit heat shield C27399-289.

The heat from these cables has caused the contactor block to distort and lock, thus preventing the main contactor from operating correctly and in some cases causing the contactor coil to fail together with the 5 amp fuse. Indication of this is a DC link charge fault on the SureScan display.

METHOD 1. Stop the compressor, isolate from the main supply and allow sufficient time for the capacitors to discharge (refer to WARNING). 2. Open the controller enclosure door and check that the red LEDs on gate drive board are not illuminated. 3. Remove protective screen. 4. Slacken the two upper motor cables at the IGBT terminal point. 5. Fit heat shield (if required) and re-route the affected cables away from the contactor (refer to illustrations). 6. Secure motor cables at the IGBT terminal point. 7. Re-fit protective shield, close enclosure door, apply power to the machine and test.

Chapter 2, page 8

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

CONTACTOR HEAT SHIELD ASSEMBLY AND WIRE ROUTING 1. Heatshield C27399-289 fitted using existing fixings 2. Contactor Block 3. Motor Leads (route as shown).

AC20160-1822, Issue 1, November 2002

Chapter 2, page 9

CompAir

EMC FILTER FAILURE

WARNING ●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

DETAIL

METHOD

This is to advise that a limited number of EMC filters have failed due to the incoming power supply cables not being properly secured at the terminal block.

1.

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

2.

If finely stranded wire is used then the correct size of ferrule must be crimped to the cable before locating into the terminal block.

3.

Locate each cable into the terminal block and tighten the clamp to a torque of 5Nm.

Use the following set of instructions for: 1.

All new installations.

2.

As a guide when examining existing installations.

Note: The terminal will accept the following cables sizes: Rigid conductors up to 50 sq mm. Flexible conductors up to 35 sq mm. Conductors with ferrules up to 35 sq mm.

Chapter 2, page 10

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

PHASE FAILURE KITS 400V (± 10%)

WARNING ●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

345SR MODELS Fitting Instructions Purpose of the kit The kit is supplied to constantly monitor the 3 phase a.c. supply to the compressor. It monitors both phase sequence and voltage level. If the supply voltage on one of the phases drops, the current will rise in the other two phases to counteract the imbalance. This can lead to overloading of the semiconductor fuses. The phase failure relay will monitor the supply and stop the compressor when one or more of the phases drops below 70% of the set voltage. At the same time, a ‘Main Contactor Fault’ will be displayed. Kit

Contents

98161-32

Phase Failure Relay

98140-361

110C Black Cable

98140-362

111C Black Cable

98140-363

112C Black Cable

98140-364

137B Blue Cable

98140-365

170 Blue Cable

98150-1

Cable Ties (5 off)

98241-31

Din Rail 210mm

C20775-19

Electrical Schematic Diagram

AC20160-1822, Issue 1, November 2002

The phase failure relay is designed to be fitted on the auxiliary control plate. 1.

Remove the finger guard.

2.

Loosen the end stops at both ends of the din rail.

3.

Remove the third stop from the centre of the plate and discard.

4.

Replace the existing din rail with the rail supplied, leaving space on the left hand side for the phase failure relay. Ensure all connections are tight. Drill a 6mm dia hole 15mm below the existing earth on the auxiliary control plate.

5.

CAUTION: Make provision to ensure that no metal particles enter the machine when drilling. 6.

Remake the earth connection using the new hole.

7.

Mount the phase failure relay on the din rail to the left hand side of the manual motor starter MCB2 (10A).

8.

Once mounted, ensure the two remaining end stops are secured.

Chapter 2, page 11

CompAir

9.

10.

Connect wire number 110C from terminal T1(2) on MCB2 and run to the left hand side of the plate to terminal U of the phase failure relay.

If the orange LED does not light: a)

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

Repeat the instruction above for:

b)

Connect wire number 110C from terminal T1(2) on MCB2 to terminal V of the phase failure relay.

c)

Connect wire number 111C from terminal T2(4) on MCB2 to terminal U of the phase failure relay.

d)

Apply power - the orange LED should now light.

a)

111C from MCB2 T2(4) to the phase failure relay terminal V.

b)

112C from MCB2 T3(6) to the phase failure relay terminal W.

11.

Connect pin of wire number 137B to terminal 14 of the phase failure relay.

12.

Connect pin of wire number 170 to terminal 11 of the phase failure relay.

13.

Run the cables 137B and 170 along the trunking and down towards the main contactor (RLA) located behind the auxiliary plate.

14.

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

15.

Disconnect the blue wire number 137 from the main contactor (RLA) auxiliary. Connect to the new wire 137B.

16.

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

17.

Replace the auxiliary control plate and tidy the new wiring.

18.

Replace the finger guard.

Adjustment The level of the monitored voltage can be adjusted on the front of the phase failure relay using a potentiometer. The arrow on the potentiometer should point to the national a.c. supply voltage. When power is applied to the machine a green LED will indicate the power supply is ON. An orange LED will indicate that the machine is in a satisfactory condition.

Chapter 2, page 12

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

HW 0316

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

AC20160-1822, Issue 1, November 2002

Chapter 2, page 13

CompAir

HW 0317

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

Chapter 2, page 14

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

HW 0318

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

AC20160-1822, Issue 1, November 2002

Chapter 2, page 15

CompAir

475SR MODELS

WARNING ●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

Purpose of the kit

Fitting Instructions

The kit is supplied to constantly monitor the 3 phase a.c. supply to the compressor. It monitors both phase sequence and voltage level. If the supply voltage on one of the phases drops, the current will rise in the other two phases to counteract the imbalance. This can lead to overloading of the semiconductor fuses.

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

The phase failure relay will monitor the supply and stop the compressor when one or more of the phases drops below 70% of the set voltage. At the same time, a ‘Main Contactor Fault’ will be displayed. Kit

Contents

98161-32

Phase Failure Relay

98140-356

110C Black Cable

98140-357

111C Black Cable

98140-358

112C Black Cable

98140-359

140B Red Cable

98140-360

170 Red Cable

98150-1

Cable Ties 5 off

C20775-20

Electrical Schematic Diagram

1.

Remove the finger guard.

2.

Loosen the end stops at both ends of the din rail.

3.

Remove the third stop from the centre of the din rail and discard.

4.

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

5.

Once mounted, ensure the two remaining end stops are secured.

6.

Connect wire number 110C from terminal T1(2) on RLB, then run the wire to the right hand side of the phase failure relay and connect to terminal U.

7.

Repeat the instruction above for:

8.

Chapter 2, page 16

a)

111C from RLB T2(4) to the phase failure relay terminal V.

b)

112C from RLB T3(6) to the phase failure relay terminal W.

Connect pin of wire number 140B to terminal 14 of the phase failure relay.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

9.

Connect pin of wire number 170 to terminal 11 of the phase failure relay.

10.

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

11.

Disconnect the red wire number 140 from the main contactor (RLA) coil A1. Connect the new wire 140B to wire 140.

When power is applied to the compressor, a green LED will indicate the power supply is ON. An orange LED will indicate that the machine is in a satisfactory condition. If the orange LED does not light:

12.

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

13.

Replace the finger guard.

a)

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

b)

Connect wire number 110C from terminal T1(2) on MCB2 to terminal V of the phase failure relay.

c)

Connect wire number 111C from terminal T2(4) on MCB2 to terminal U of the phase failure relay.

d)

Apply power - the orange LED should now light.

Adjustment The level of the monitored voltage can be adjusted on the front of the phase failure relay using a potentiometer. The arrow on the potentiometer should point to the national a.c. supply voltage.

AC20160-1822, Issue 1, November 2002

Chapter 2, page 17

CompAir

HW 0319

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

Chapter 2, page 18

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

HW 0320

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

AC20160-1822, Issue 1, November 2002

Chapter 2, page 19

CompAir

HW 0321

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

Chapter 2, page 20

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

POWER CONVERTER VENTILATION KIT PRODUCT IMPROVEMENT Purpose of the Kit This kit is supplied to combat high temperatures within the power converter assembly. It is not necessary to introduce this kit to all units, however it is recommended that the modification be performed on machines operating in a high ambient temperature or which have experienced failure due to high ambient temperatures within the power converter cubicle.

The ventilation kit uses the machine cooling fan to draw cool air through the power converter cubicle and exhaust it via the machines cooling air discharge, therefore allowing the components within the cubicle to operate in free air.

WARNING ●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

Kit Contents C27349-155 C27349-136 C27349-137 C27349-157 C27349-158 C27349-159 C20089-557 A6455-64 95001-230 95179-5 95149-13 95112-4

Kit – Power Converter Ventilation Cover, Filter Retaining 1 off Filter 1 off Grille, Filter Retaining 1 off Grille, Box Inlet 1 off Grille, Box Outlet 1 off Label, CE Electrical 1 off Pop Rivet 8 off Screw, Hex Head M6x25 4 off Washer, Spring M6 4 off Washer, Plain M6 8 off Nut, Plain M6 4 off

Inlet Panel Inlet Panel Inlet Panel Power Converter Enclosure Power Converter Enclosure Power Converter Enclosure Inlet Panel Inlet Panel Inlet Panel Inlet Panel Inlet Panel

Tools Required 60mm Diameter Hole Saw 8mm Diameter Drill Bit 4mm Diameter Drill Bit Pop Rivet Gun Half Round File

Knife 10mm Spanner / socket Rule Square

AC20160-1822, Issue 1, November 2002

Chapter 2, page 21

CompAir

Fitting Instructions 1.

Remove the Inlet Panel

2.

Remove the foam from the inside of the top section of the inlet panel and cut horizontally across the foam approximately 420mm from the top of the panel.

3.

Clean the remaining foam from the surface area of the inlet panel ensuring that debris does not enter the enclosure.

4.

Mark the centres of the four fixing and six ventilation holes on the outside of the inlet panel ( FIG. 1)

5.

Pilot drill both sets of holes and finish the four fixing holes to 8mm diameter and the six ventilation holes to 60mm diameter. De-burr all holes and treat to prevent corrosion.

6.

Cut the filter material (C27349-137) to size and place in filter retaining cover (C27349136).

7.

Align the assembly with the four fixing holes on the outside of the inlet panel and using the M6 fixings and the filter retaining grill (C27349-157), clamp the assembly to the inlet panel.

8.

With the inlet panel removed from the machine, mark the centres of the fixing and ventilation holes on the outside of the power converter cubicle. (FIG. 2)

9.

Ensuring a safe drill length to avoid damage to the electrical components within the power converter pilot drill both sets of holes. Finish the four fixing holes to 4mm diameter and the four ventilation holes to 60mm diameter. Deburr all holes and treat to prevent corrosion.

10.

Align the grille, box inlet (C27349-158) with the four fixing holes. Pop rivet the grille into place and replace the inlet panel.

11.

Move the hinged auxiliary control plate to gain access for marking out and drilling.

Chapter 2, page 22

12.

Mark the centres of the fixing and ventilation holes on the bottom of the power converter cubicle (FIG. 3).

13.

Ensuring a safe drill length to avoid damage to the filter maifold assembly, pilot drill both sets of holes. Finish the four fixing holes to 4mm diameter and the three ventilation holes to 60mm diameter. De-burr all holes and treat to prevent corrosion.

14.

Align the grille, box outlet (C27349-159) with the four fixing holes. Pop rivet the grille into place and replace the auxiliary control plate and the finger guards.

15.

Apply power to the machine, enter service diagnostics menu and through the digital outputs run the cooling fan. Ensure a good air flow through the power converter cubicle.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

HW 0322

FIG. 1 SIDE PANEL

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Chapter 2, page 23

CompAir

HW 0322

FIG. 2 INLET BOX

Chapter 2, page 24

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

HW 0323

FIG. 3 OUTLET BOX

AC20160-1822, Issue 1, November 2002

Chapter 2, page 25

CompAir

POWER CONVERTER VENTILATION KIT PRODUCT IMPROVEMENT Purpose of the Kit This kit is supplied to combat high temperatures within the power converter assembly. It is not necessary to introduce this kit to all units, however it is recommended that the modification be performed on machines operating in a high ambient temperature or which have experienced failure due to high ambient temperatures within the power converter cubicle.

The ventilation kit uses the machine cooling fan to draw cool air through the power converter cubicle and exhaust it via the machines cooling air discharge, therefore allowing the components within the cubicle to operate in free air.

WARNING ●

Refer to the safety procedures in the User Manual before carrying out any Maintenance work on the compressor unit.

●

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

●

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting any maintenance work.

Kit Contents C27399-320 C27399-290 C27399-305 C27399-324 C27399-323 C27399-304 C27399-322 C20089-557 95001-230 95179-5 95149-13 95001-229 95149-13 95179-5 95001-229 A10308-10 98140-366 95001-231 95149-13 95149-18 95179-5 95112-4

Chapter 2, page 26

Kit – Power Converter Ventilation Grille, Inlet Power Converter 1 off Filter 1 off Grille, Filter Retaining 1 off Guard, Bottom Finger 1 off Outlet Cover 1 off Outlet Grille 1 off Label, CE Electrical 1 off Screw, Hex Head M6x25 4 off Washer, Spring M6 4 off Washer, Plain M6 8 off Screw, Hex Head M6x20 2 off Washer, Plain M6 2 off Washer, Spring M6 2 off Screw, Hex Head M6x20 2 off Washer, conical M6 2 off Earth Cable 1 off Screw, Hex Head M6x30 1 off Washer, Plain M6 2 off Washer, shakeproof M6 1 off Washer, Spring M6 1 off Nut, Plain M6 3 off

Door outside Door outside Door inside Backplate rear Backplate rear Power Converter Enclosure Door inlet filter Door inlet filter Door inlet filter Outlet grille and cover Outlet grille and cover Outlet grille and cover Finger Guard Finger Guard Finger Guard Earth Cable to Finger Guard Earth Cable to Finger Guard Earth Cable to Finger Guard Earth Cable to Finger Guard Earth Cable to Finger Guard

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

Tools Required 7. 44mm Diameter Hole Saw 60mm Diameter Hole Saw 8mm Diameter Drill Bit Pilot Drill Bit Drill.

Half Round File 10mm Spanner / socket Rule Square

Fitting Instructions 1.

Disconnect and remove the SureScan controller. Remove the power converter door.

2.

Mark the centres of the four fixing and nine ventilation holes on the inside of the power converter door (FIG. 1).

3.

Pilot drill both sets of holes and finish the four fixing holes to 8mm diameter and the six ventilation holes to 60mm diameter. De-burr all holes and treat to prevent corrosion.

4.

5.

6.

Cut the filter material (C27399-305) to size and place in the inlet grill (C27399-290) of the power converter.

Note: Ensure no swarf or debris enters the power converter or main drive motor when drilling. 8.

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

9.

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

10.

Fit the earth fixings to the replacement finger guard (C27399-323).

Align the assembly with the four fixing holes on the outside of the power converter door and using the M6 fixings (95001-230, 9514913, 95179-5) and the filter retaining grill (C27399-324), clamp the assembly to the door.

Order of fitting: 95001-231 95149-18 C27399-323 95112-4 95112-4 95149-13 98140-366 95149-13 95179-5 95112-4

Mark the centres of the fixing and ventilation holes on the back of the power converter backplate (refer to FIG. 2 or 3 according to serial number) Note: To avoid damage to components within the power converter cubicle note the following serial numbers:Post serial number F170-0354 - refer to FIG.2.

Ensuring a safe drill length to avoid damage to the electrical components within the power converter pilot drill both sets of holes. Finish the four fixing holes to 8mm diameter and the four ventilation holes to 44mm diameter. Deburr all holes and treat to prevent corrosion.

Screw, Hex Head M6x30 Washer, Shakeproof M6 Finger Guard Nut, Plain M6 Nut, Plain M6 Washer, Plain M6 Terminate Earth Cable Washer, Plain M6 Washer, Spring M6 Nut, Plain M6

Then secure the new finger guard in the bottom of the power converter cubicle using the M6 fixings (95001-229, A10308-10). 11.

Replace the power converter door, refit and connect the SureScan controller.

12.

Apply power to the machine, enter service diagnostics menu and through the digital outputs run the cooling fan. Ensure a good air flow through the power converter cubicle.

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

AC20160-1822, Issue 1, November 2002

Chapter 2, page 27

CompAir

HW 0325

FIG. 1 - HOLE CENTRES - POWER CONVERTER DOOR

Chapter 2, page 28

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

HW 0326

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

AC20160-1822, Issue 1, November 2002

Chapter 2, page 29

CompAir

HW 0327

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

Chapter 2, page 30

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

L45SR & L75SR SPEED REGULATED ROTARY SCREW COMPRESSOR ENHANCEMENTS From serial nos: F170-850 onwards, F180-650 onwards We are pleased to announce the introduction of a number of enhancements to the LSR-Series Speed Regulated Rotary Screw Compressors. Modifications have been made to the power converter, software features and compressor protection recommendations and are effective from the above serial nos. This Bulletin explains the newly developed features and improvements, the installation requirements and includes the technical documents considered necessary. This information below must be read in conjunction with the existing User Manual.

The controller itself is designed to operate for about 0.5 secs following loss of incoming power. Thus it has time to take action and store essential data prior to shutdown. The action taken following power failure detection from either source is the same. The compressor will be shut down and then the controller will shut down. When power to the controller is restored it will reboot. The recovery action when power is restored depends on the status of the machine at time of power faiture. Compressor Stopped ('Ready to Start')

Phase Monitor Relay Protection with Auto Restart

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

A phase monitor relay is fitted to all models to trip the machine in event of a power supply fault. This covers situations not detected by the built-in controller power detect circuit. ln particular, this includes loss of the single phase not supplying the controller or low incoming voltage and protects the power converter and motor against drawing excessive currents that could cause subsequent damage.

Should the controller remain powered (in the event that the failure was on a phase not supplying controller) then on rebooting, the display will show 'Start Inhibited - Power supply fault' and the charging circuits wilt not be actioned. On reset of the phase monitor relay, the controller will again reboot to ensure correct charging sequence. Compressor Running or in Standby

The configuration of the phase monitor relay has now been altered such that, if the auto restart function is enabled, the compressor wilt restart when power is restored after phase toss or lowvoltage. This removes the need for the user to manually reset the fault and start the compressor. Power Supply Failure Detection The control system has two methods of power failure detection. Within the controller, an internal circuit monitors two phases of the incoming ac voltage and will trigger the power failure routine if two successive cycles are not detected. ]External to the controller, a phase monitor relay, connected to a controller input, monitors each phase and will signal to the controller input if any phase goes below 70% of the set voltage or the phase order is reversed. The phase monitor relay will automatically reset within 500ms when correct supply conditions are restored.

AC20160-1822, Issue 1, November 2002

Again, should the controller remain powered, then on rebooting the display will show 'Start Inhibited Power supply fault' and the charging circuits will not be actioned. The fault in this case will be stored in the history. When the phase monitor relay resets, the controller will reboot again to ensure the correct charging sequence. If power to the controller is lost, then after reboot depending on which circuit triggered first - an alarm will be displayed either with message 'Powerfail Fault' (controller internal circuit) or message 'Power supply fault' (phase monitor relay) and the fault logged. Manual reset will not be required (except to clear display and 'service' led) and, if enabled, the machine will auto restart to previous state.

Chapter 2, page 31

CompAir

Note: Because this feature is only operable while the machine is 'available', any powerdip or failure occurring after a controlled stop, but before the motor is switched off, will result in a reboot to 'Ready to Start' without the 'Power fail/supply fault' indicated. This is the standard machine action. SR Motor Overcurrent Protection The power converter incorporates motor overcurrent protection. To prevent repeated starts that could damage components in the power converter, the software has been altered to inhibit restart of the compressor after two successive overcurrent trips during starting. In this case the controller will display an operator advice message, 'Reset Inhibited' and restart of the unit will be prevented. To ensure that the source of the fault is rectified, the controller can only be reset by a CompAir authorised service engineer using the special access code: view, spanner, spanner, spanner. Entering this code will reset the fault and return the machine to 'Ready to

Start' state. This access code should be considered confidential and is only for the use of CompAir company or authorised distributor service engineers. Power Supply Fusing In order to increase reliability, the incoming power supply fuses have been removed from the power converter. These fuses were previously fitted to protect the power converter components in the event of a current surge resulting from a short circuit or low voltage condition. Due to improvements in the current carrying capacity of the power converter components these fuses are no longer required. There is, however, still a requirement for the customer to fit correctly rated fuses in the incoming power supply. These fuses should comply with BS88 Part 1, IEC269-1 and EN60269-1 and conform to gG characteristics. The following table provides the recommended fuse ratings to be fitted by the customer.

Compressor Model

Voltage

Cable Size 50/60Hz

Fuse Rating

L45SR

All voltages

3 x 35mm2

gG125A

L75SR

All voltages

3 x 70mm2

gG200A

L120SR

All voltages

2

3 x 120mm

gG315A

. Note: Cable size is valid for PVC insulated, 3 core cable with a conductor operating temperature of 70°C in accordance with EN60204. Commissioning The commissioning engineer should check that both the cable and fuses fitted are of the correct rating. The compressor must not be commissioned until this has been verified.

Chapter 2, page 32

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

475SR & L75SR COMPRESSORS - ALL SERIAL NUMBERS FITTING INSTRUCTIONS FOR SINGLE PASS AIR/OIL COOLER RETROFIT KIT NO. C27399-332 1.

introduction

1.1

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

2.

Kit Contents

ITEM No.

DRAWING No.

NAME OF PART

1

C11607-5

1" TO 3/4" REDUCING BUSH

1

ORIGINAL COOLER OIL INLET

2

A3764-6

3/4" PLUG

1

ORIGINAL COOLER OIL INLET

3

98418-61

ANTI VIBRATION MOUNTS

4

COOLER TO SUPPORTS

4

95148-14

WASHERS

8

COOLER TO SUPPORTS

5

95179-6

SPRING WASHER

8

COOLER TO SUPPORTS

6

95111-5

NUT M8

8

COOLER TO SUPPORTS

7

98154-337

OIL/AIR COOLER

1

ON SUPPORTS VIA AVMS

8

95635-8

COPPER WASHER

4

NIPPLES

9

C11605-25

NIPPLE 1” BSP

4

COOLER AND AMOT VALVE

10

95635-6

COPPER WASHER

1

COOLER DRAIN PORT

11

98650-109

DRAIN COCK

1

COOLER DRAIN PORT

12

A3764-6

PLUG

1

DRAIN COCK

13

95406-801

1 “ NIPPLE TAPER THREAD

1

RECLAIMER OUT

14

98650-390

AMOT VALVE

1

RECLAIMER OUT

15

98156-308

TEE 1" BSP

1

FILTER

16

98504-92

RUBBER SEALING STRIP

17

C27399-331

ASSY, FLEXIBLE HOSE

1

OIL COOLER TO FILTER VIA TEE

18

C27399-330

ASSY, FLEXIBLE HOSE

1

AMOT TO OIL COOLER INLET

19

C27399-343

ASSY, FLEXIBLE HOSE

1

TEE TO AMOT

20

C27399-334

BAFFLE, FOAM EXHAUST

1

INSIDE EXHAUST DUCT

21

C27399-335

ASSY, EXHAUST DUCT

1

TOP OF AIR/OIL COOLER

22

95251-276

STUD SCREWED METRIC

2

AIR/OIL COOLER AIR INLET

23

A3753-36

WASHERS

16

PLENUM CHAMBER TO COOLER

24

95602-85

“O” RING

1

AIR/OIL COOLER AIR INLET

AC20160-1822, Issue 1, November 2002

No. OFF

0.25M

PART LOCATION

PROTECTS HOSE C27399-331

Chapter 2, page 33

CompAir

3.

Procedure

3.1

Drain the compressor system of oil.

3.2

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

3.3

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

3.4

Assemble 98650-390 (Amot Valve) onto the reclaimer via 95406-801 (Nipple 1“ Taper Thread) with the Amot side port orientated horizontally and facing towards the inside of the machine. See fig 3.

3.5

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

3.9

Assemble 98650-109 (3/4" Drain Cock) into the cooler drain port using 95635-6 (Copper Washer).

Fig 1 - Securing new cooler

Note: Fig 2 also shows edges on which C27399-331 (Assy, Flexible Hose) rests. This will cause hose chafing so apply 98504-92 (Rubber Sealing Strip) to these edges. 3.6

Assemble 98156-308 (Tee 1“ BSP) onto the oil filter using the original production fitted Nipple. To the horizontal port of this Tee, connect C27399-331 (Assy, Flexible Hose). To the downward port of the Tee, connect one end of C27399-343 (Assy, Flexible Hose).

3.7

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

Note: Hose C27399-343 now has the 90 Deg. connector removed and replaced with a straight connector. 3.8

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

Chapter 2, page 34

Fig 2 - Cooler outlet hose run 3.10

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

3.11

There is no change from the original assembly procedure of the Exhaust Baffle and Exhaust Duct Assy to the new. Among the design changes made are:-

• The thermostat clearance has been removed • Four clearance apertures have been added to allow for the Air/Oil cooler securing bolts.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Product Improvements

4

1

2

5

3

17 14

16

13 15

12

6 7

HW 0109

1 2. 3. 4. 5. 6. 7. 8. 9.

95635-8 C11605-25 C27399-331 98156-308 C27399-331 C11605-25 95635-8 95406-801 98650-390

11 10

Copper Washer Nipple 1“ BSP Hose Assy Tee 1“ BSP Hose Assy Nipple 1“ BSP Copper Washer Nipple 1" B5P Taper Amot Valve

9

8

10. 11. 12. 13. 14. 15. 16, 17.

95635-8 C11605-25 C27399-330 C11605-25 95635-8 A3764-6 95635-6 98650-109

Copper Washer Nipple 1“ BSP Hose Assy Nipple 1” BSP Copper Washer Plug 3/4” Copper Washer Drain Cock 3/4”

Fig 3 - New pipework circuit

AC20160-1822, Issue 1, November 2002

Chapter 2, page 35

CompAir

SH6(2) WS4(2)

1

3

2

1

8

2

11

2

9

4

5

6

4

2

7

10

12

8

13 14

27

15

16

16

17

8

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

16 2 1

4

18

2 4

23

19 20 21

22

24 25 26 HW 0297

Fig 4 - Original pipework circuit

Chapter 2, page 36

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

CHAPTER

3 GENERAL DESCRIPTION 1. 2. 2.1 2.2 3. 4. 4.1 4.2 4.3 4.4 4.5 4.6 5. 5.1 5.2 6. 6.1 6.2 7. 7.1 7.2 8. 8.1 8.2 8.3

COMPRESSOR AIR-END Description Operation SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT PROTECTION AND SAFETY EQUIPMENT Pressure Relief Valve Blowdown System Minimum Pressure Non-return Valve Emergency Stop Overpressure Switch Scavenge Sight Tube AIR/OIL SYSTEM (345SR, L45SR) Description Operation AIR/OIL SYSTEM (475SR, L75SR) Description Operation AIR/OIL SYSTEM (L120SR) Description Operation REGULATION SYSTEM Description Automatic Mode Manual Mode

FIGURES FIG. 3.1 FIG. 3.2 FIG. 3.3 FIG. 3.4 FIG. 3.5 FIG. 3.6 FIG. 3.7 FIG. 3.8 FIG. 3.9 FIG. 3.10

CYCLON 3, 4 and 5 AIR-END - GENERAL ARRANGEMENT CONTROL PANEL AIR/OIL SYSTEM - 345SR, L45SR AIR/OIL SYSTEM - 475SR, L75SR old style AIR/OIL SYSTEM - L75SR new style AIR/OIL SYSTEM - L120SR REGULATION SCHEMATIC - 345SR, L45SR REGULATION SCHEMATIC - 475SR, L75SR REGULATION SCHEMATIC - L75SR (Where Single Pass Cooler fitted) REGULATION SCHEMATIC - (L120SR)

AC20160-1822, Issue 1, November 2002

Chapter 3, page 1

CompAir

GENERAL DESCRIPTION 1.

COMPRESSOR

The unit is an air cooled, single-stage, rotary screw compressor. The compressor air-end is driven through a flexible coupling by an electric Switched Reluctance Drive (SR Drive®) motor manufactured under licence from SR Drives Ltd. The Compressor unit consists of the drive motor, air-end, reclaimer, oil cooler, after cooler, fan, starter assembly and control unit. The complete compressor unit is mounted on a baseframe and is housed in a steel panelled acoustic enclosure. Removable panels or hinged access doors allow access for routine maintenance.

2.

AIR-END

2.1

Description

The air is compressed in a single-stage, positive displacement, oil injected rotary screw air-end. The air-end is of the Cyclon type and comprises an intermeshing pair of helical screw rotors, male and female, mounted horizontally within an enclosed casing with drive being applied to the male rotor. The male air-end rotor is larger in diameter than the female rotor and has four lobes which mesh with five flutes on the female rotor. The rotors are asymmetric in profile to reduce blowback between the lobes on the compression cycle to a minimum, thus maximising the overall sealing and efficiency. The rotors are fitted with bearings at each end to provide radial and axial support, maintain adequate shaft stiffness and to give minimum clearance and low leakage between the rotor tip diameter and the casing.

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

2.2

Operation

Compression takes place between the lobes on the male rotor, the flutes on the female rotor and the airend casing. When the compressor is running the helical engagement of the rotors provides the drive for the female rotor. As the rotors turn, air at atmospheric pressure enters the inlet port and fills the space between the lobes of the male rotor and the flutes of the female rotor. Oil is injected into the air at this point and the trapped air/oil mixture is progressively compressed by the reduction in space created by continuous rotation of the rotors within the air-end casing. Continued rotation brings the compressed air/oil mixture to the discharge port of the air-end, where it passes into a reclaimer. The oil is separated from the air/oil mixture in the reclaimer and the air passes through a cooler into the user’s pipework. Oil is continually injected into the low pressure region of the air-end and mixes with the air during the compression process. The oil carries out three functions; lubrication, cooling and sealing. The oil lubricates the rotors and bearings, acts as a coolant by absorbing the heat of compression and seals the fine clearances that exist between the rotors and between the rotors and casing. The compressed air/ oil mixture is discharged from the air-end and into the reclaimer where the oil is separated and returned to the system.

At the delivery end the male rotor is fitted with a single taper roller bearing and the female rotor is provided with a matched pair of taper roller bearings. These bearings provide axial and radial support of both rotors and control the very fine end clearances between the rotors and the casing.

Chapter 3, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

1. 2. 3. 4. 5. 6. 7. 8.

Parallel Roller Bearing Male Rotor Casing Taper Roller Bearing Outer Taper Roller Bearing Inner Taper Roller Bearing Female Rotor Parallel Roller Bearing

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

AC20160-1822, Issue 1, November 2002

Chapter 3, page 3

CompAir

3.

SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT

The SR Drive® system regulates the volume of air delivered by the compressor by adjusting the rotational speed of the air-end so that the output from the compressor always matches the demand from the user’s system. This method of regulation can reduce energy consumption as the compressor produces only the amount of air demanded by the system and is equally efficient at high or low output volumes. Offload idling is also eliminated and when there is no demand for compressed air the SR motor stops automatically with no limit to the number of times that it can be started. Pressure in the user’s system is accurately maintained to further improve the quality of the compressed air supply. The motor operates on the principle of magnetic attraction. The stator has eight poles and the rotor four poles, the stator poles being wound with coils to form electromagnets. The electromagnets are connected in two groups (phase A and B) of four coils which attract the poles on the rotor causing them to rotate into alignment with the stator poles. The SR stator is an insulated tube formed by the stator poles and coils vacuum impregnated in resin to form a ‘Sealed Insulation System’ which is highly resistant to dust and corrosion. The rotor is a 4 pole iron shaft with no current carrying coils which ensures cool running and therefore extends bearing life. Continuous rotation is achieved by switching the stator phases in the correct sequence. A position transmitter on the rotor sends positional information to the SR Drive® controller to ensure that the switching of the motor phases is correctly timed. The microprocessor based compressor controller and the SR Drive® controller are housed in a single control unit which also contains the operator keypad and displays. The control unit is mounted on the door of the control panel. A gate drive board isolates the microelectronics in the control unit from the power electronic circuits and provides monitoring and protection for the four insulated gate bi-polar transistor (IGBT) power switches.

Chapter 3, page 4

The IGBTs are used to turn the motor phases on and off and, in conjunction with the electronic controller, to control the motor phase current and in turn the torque and speed of the SR motor.

4.

PROTECTION AND SAFETY EQUIPMENT

In addition to the protection and warning circuits linked to the controller the following protection equipment is fitted:

4.1

Pressure Relief Valve

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

4.2

Blowdown System

When the compressor stops, either automatically or by operation of the ‘STOP’ switch, all pressure in the reclaimer is automatically released by a blowdown system which vents the pressure to atmosphere. This ensures that the compressor is restarted in a ‘no-load’ condition.

4.3

Minimum Pressure Non-return Valve

Fitted on the reclaimer cover in the delivery air line, the minimum pressure valve remains closed until minimum pressure is reached. This ensures a rapid build-up of pressure when the compressor first starts and also prevents high velocity, low pressure air reaching the user’s pipework during the start-up period and carrying over excessive amounts of oil. When the compressor shuts down it functions as a non-return valve which prevents the pressure in the user’s pipework feeding back into the reclaimer and venting through the blowdown system.

4.4

Emergency Stop

An emergency stop button, complying with international safety requirements, is fitted on the display panel.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

4.5

Overpressure Shutdown

4.6

An overpressure shutdown is present on all machines. This shutdown setting is below the pressure relief valve setting and will stop the compressor in the event of an over pressure condition.

1

2

3

4

5

Scavenge Sight Tube

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

6

7

8

9

10

11

12

13 14

15

18

17

Bar PSI

31

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

30

29

28

27

26

Bar Units Indicator Psi Units Indicator Delivery Pressure Display Status and Message Display Plus Minus Up Down Enter Mimic Diagram Intake Filter Change Lamp High Delivery Temperature Lamp Reclaimer Element Check Lamp Excess Pressure Lamp Emergency Stop Auto Restart Legend

25

24 23

22 21

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

20

19

16

Remote Control Legend Remote Control Lamp Auto Restart Lamp Power on Lamp Fan Motor Overload Lamp Power Converter Fault Lamp Main Motor Fault Lamp Reset Hours Reset Lamp Data View Service Service Lamp Stop Start

FIG. 3.2 CONTROL PANEL

AC20160-1822, Issue 1, November 2002

Chapter 3, page 5

CompAir

5. 5.1

AIR/OIL SYSTEM (345SR, L45SR) Description

The air/oil system comprises an air intake filter, inlet non-return valve, air-end, oil separator vessel, oil separator filters, minimum pressure/non-return valve, aftercooler, oil cooler with thermostatic bypass valve and an oil filter. The flow of oil through the circuit is achieved through the pressure differential existing between the primary oil separator and the oil injection point in the air-end.

5.2

Operation

Air enters the compressor unit through the intake filter (2) and inlet non-return valve (1) to the inlet port of the air-end (7). The air is trapped by the turning rotors and mixes with the oil which enters the casing through the oil injection point. Continued rotor rotation increases the pressure and temperature of the air/oil mixture which passes from the air-end discharge pipe into the oil separator (4) where primary separation takes place by centrifugal force. Most of the oil is separated at this stage and drops to the bottom of the vessel.

Oil from the bottom of the primary separator flows under pressure to the oil cooler (10) and during normal running the oil passes through the cooler to maintain the correct temperature. A thermostatic bypass valve (14) is installed in the inlet manifold of the oil cooler. When the compressor is started, the cold oil in the system bypasses the cooler and flows through the oil filter (8) directly to the air-end. As the oil and air mixture is compressed by the rotors in the air-end, the temperature of the oil increases. When the oil has reached its normal operating temperature the bypass valve closes and the oil is directed through the oil cooler. The cooled oil then flows to the oil filter where it is cleaned before entering the air-end. The quantity of oil injected into the air-end is controlled by a restrictor orifice in the air-end casing. Oil is injected under pressure through the restrictor orifice into the rotors and a gallery supplies oil to the air-end bearings.

The remaining air/oil mixture then passes through oil separator elements (5) where final separation takes place. The separated oil collects in the bottom of the elements and is scavenged back into the air-end through a small diameter pipe (13). The filtered air then passes from the oil separator elements by way of the minimum pressure/ nonreturn valve (3). Provided the air pressure at this stage is above 3.5 to 4·0 bar the air passes through the aftercooler (9) where it is cooled before passing to the delivery outlet (12). If the air pressure in the primary separator vessel falls below 3.5 to 4·0 bar the minimum pressure valve will close. The valve also incorporates a nonreturn valve which operates to prevent delivery air passing back into the separator when the compressor is running off-load.

Chapter 3, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

11 14 10 8

3

6

9

16

15 12

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

7

2

Inlet Non-Return Valve Intake Air Filter Minimum Pressure Valve Primary Oil Separator Separator Filter Element Discharge Pipe Air-end

8. 9. 10. 11. 12. 13. 14.

1

5

Oil Filter Aftercooler Oil Cooler Fan Delivery Air Outlet Scavenge Line Thermostatic Bypass Valve

13

4

15. Scavenge NR Valve 16. Blow down solenoid valve.

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

AC20160-1822, Issue 1, November 2002

Chapter 3, page 7

CompAir

6.

AIR/OIL SYSTEM (475SR, L75SR)

6.1

Description

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

6.2

Earlier oil circuit (Fig. 3.4). Oil from the reclaimer flows to the oil cooler. During normal running the oil passes through the cooler to maintain its temperature at a correct level. A thermostatic bypass valve (5) is installed in the oil cooler. When the compressor is started, the cold oil in the system bypasses the cooler and flows through the oil filters (9) directly to the air-end. As the oil and air mixture is compressed by the rotors in the air-end, the temperature of the oil increases. Once the oil has reached its normal operating temperature the 3-way thermostatic bypass valve directs oil through cooler. The cooled oil then flows to the oil filter where it is cleaned before entering the air-end.

Operation

Air enters the compressor through the air intake filter (19) to the inlet port of the air-end (18). The air is trapped by the turning rotors and mixes with the oil which enters the casing through a restrictor orifice. Continued rotation increases the pressure and temperature of the air/oil mixture which passes through the discharge port of the air-end and, via the non-return valve (15), into the reclaimer (12) where it is centrifugally separated and the oil drops to the bottom of the reclaimer vessel. The remaining air/oil mixture then passes through the two stages of the reclaimer element (6) where final separation takes place. The separated oil is collected in the bottom of the element and is scavenged back into the air-end through a strainer (8) and scavenge line (11). A solenoid operated valve (10), fitted in the scavenge line, prevents any oil loss through the air intake filter when the compressor is stopped.

Later oil circuit (Fig. 3.5). Oil flows to the oil cooler (4) via a 3-way thermostatic bypass valve (6) installed in the reclaimer. During normal running the oil passes through the cooler to maintain its temperature at the correct level. When the compressor is started, the cold oil in the system bypasses the cooler and flows through the oil filters (9) directly to the air-end. As the oil and air mixture is compressed by the rotors in the air-end, the temperature of the oil increases. Once the oil has reached its normal operating temperature the 3-way thermostatic bypass valve directs oil through the cooler. The cooled oil then flows to the oil filter where it is cleaned before entering the air-end. The quantity of oil injected into the air-end rotors is controlled by a restrictor orifice in the rotor casing. Oil is injected under pressure through the restrictor orifice into the rotors and a separate gallery supplies oil to the air-end bearings.

Filtered air then passes out of the reclaimer through the minimum pressure valve (7). Provided the air pressure at this stage is above 4 bar the air will be passed to the air cooler (3) where the warm air is cooled. The cooled, filtered air then passes through a moisture separator to the delivery air outlet (1). The condensate in the moisture separator (2) is automatically removed by the operation of an electronically controlled solenoid valve (20). If the air pressure in the reclaimer is at any time less than 4 bar the minimum pressure valve will close. The valve also incorporates a non-return valve which operates to prevent delivery air passing back into the reclaimer when the compressor is running off-load.

Chapter 3, page 8

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

2

3

4

5

6

7 8

9

1

21 22

10

20

14 19 11 12 13 16 18

1. 2. 3. 4. 5. 6. 7. 8.

17

Delivery Air Outlet Moisture Separator Air/Oil Cooler Fan Thermostatic Bypass Valve Reclaimer Element Minimum Pressure Valve Scavenge Strainer

15

9. 10. 11. 12. 13. 14. 15.

Oil Filters Scavenge Solenoid Scavenge line Reclaimer Oil Drain Oil Level Tube Non-return Valve

Air flow Air/oil mixture Oil flow

16. 17. 18. 19. 20. 21. 22.

Oil Drain Oil Stop Valve Air-end Air Intake Filter Drain Solenoid Strainer Air In

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

AC20160-1822, Issue 1, November 2002

Chapter 3, page 9

CompAir

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

Delivery Air Outlet Moisture Separator Drain Cock Air/Oil Cooler Fan 3-way Thermostatic Bypass Valve Reclaimer Element Minimum Pressure Valve Scavenge Strainer Oil Filters Scavenge Solenoid Scavenge Line

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Reclaimer Oil Drain Oil Level Tube Non-return Valve Oil Drain Oil Stop Valve Air-end Air Intake Filter Drain Solenoid Strainer Air In

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

Chapter 3, page 10

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

7.

AIR/OIL SYSTEM (L120SR)

7.1

Description

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

7.2

Operation (fig. 3.6)

Air enters the compressor through the air intake filter (1) and intake non-return valve (2) to the inlet port of the air-end (3). The air is trapped by the turning rotors and mixes with the oil which enters the casing through a restrictor orifice. Continued rotation increases the pressure and temperature of the air/oil mixture which passes through the discharge port of the air-end and into the reclaimer (5) where it is centrifugally separated and the oil drops to the bottom of the reclaimer vessel. The remaining air/oil mixture then passes through the two stages of the reclaimer element where final separation takes place. The separated oil is collected in the bottom of the element and is scavenged back into the air-end through a strainer (n), non-return valve (n) and scavenge line (n). The non-return valve prevents any oil loss through the air intake filter when the compressor is stopped. Filtered air then passes out of the reclaimer through the minimum pressure valve (8). Provided the air pressure at this stage is above 4 bar the air will be passed to the aftercooler (9) where the warm air is cooled. The cooled, filtered air then passes through a moisture separator (15) to the delivery air outlet (10). The condensate in the moisture separator (15) is automatically removed via the condensate drain port (17) by the operation of electronically controlled no loss drain (16).

AC20160-1822, Issue 1, November 2002

If the air pressure in the reclaimer is at any time less than 4 bar the minimum pressure valve will close. The valve also incorporates a non-return valve which operates to prevent delivery air passing back into the reclaimer when the compressor is running off-load. Oil from the reclaimer flows to the oil cooler (23). During normal running the oil passes through the cooler to maintain its temperature at a correct level. A thermostatic bypass valve (21) is installed in the outlet side of the oil cooler. If the unit is fitted with a heat recovery option a thermostatic mixing valve (35) diverts the flow of oil to the cooler to first pass through the heat recovery heat exchanger (36). This heats the water supply passing between the water inlet and outlet connections (37). When the compressor is started, the cold oil in the system bypasses the cooler via the coolewr bypass pipe (n) and flows through the oil filters (6) directly to the air-end. As the oil and air mixture is compressed by the rotors in the air-end, the temperature of the oil increases and the oil starts to flow through the cooler. Once the oil has reached its normal operating temperature the bypass valve (21) directs oil through the cooler. The cooled oil then flows to the oil filter where it is cleaned before entering the air-end. The quantity of oil injected into the air-end rotors is controlled by a restrictor orifice in the rotor casing. Oil is injected under pressure through the restrictor orifice into the rotors and a separate gallery supplies oil to the air-end bearings. Cooling fan/motor (24) extracts air from the enclosure through the air outlet grille (20), which is replenished by cool air entering air inlet grille (13). Cooling of the power converter heat sink is carried out by a separate cooling fan/motor (25).

Chapter 3, page 11

CompAir

1. Switched Reluctance Drive Controller

8. Separator Filtration Element

2. Switched Reluctance Drive Motor

9. Minimum Pressure NonReturn Valve

3. Air Intake Filter

10. Oil Cooler

4. Intake Non Return Valve

11. Air Cooler

5. Temperature Sensor

12. Oil Filter

6. Compression Element

13. Pressure Transmitter

7. Separator Vessel

A Intake Air

C Air/Oil Mixture

B Compressed Air

D Oil

FIG. 3.6 AIR/OIL SYSTEM - L120SR

Chapter 3, page 12

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

8.

REGULATION SYSTEM (See figures 3.7 to 3.9)

8.1

Description

The compressor delivery pressure can be controlled in either ‘Automatic’ (AUTO) or ‘Manual’ (MAN) modes. The normal method of operation is the ‘Automatic’ mode which varies the volume of air delivered by the compressor by adjusting the rotational speed of the air-end to match the demand on the user’s system and maintain a target pressure. ‘Manual’ mode controls the pressure between two set points, the rotational speed of the air-end being controlled by the operator.

8.2

8.3

The ‘Manual’ mode should only be used if the compressor is to be run at a fixed speed and, therefore, fixed rate of air delivery. A pressure transmitter measures the delivery pressure which is compared with upper and lower set points programmed into the control unit. If the delivery pressure is below the upper setpoint the air-end will run at a pre-determined speed which can be set at any point between maximum and minimum. If the delivery pressure exceeds the upper setpoint the rotational speed of the air-end will reduce to minimum and the bypass valve will open resulting in zero delivered air volume. The bypass condition will continue until: a)

the delivery pressure falls below the lower setpoint. At this point the bypass valve will shut and the speed will be re-set to the pre-set value, or

b)

the SR motor run-on timer expires causing the motor to stop and the compressor to enter ‘Standby’ condition. Subsequently, if the delivery pressure falls below the lower setpoint the SR motor will re-start and run at the pre-set speed.

Automatic Mode

This is the normal mode of operation. A pressure transmitter (18),(32) or (28) measures the delivery pressure which is compared with the target pressure (P2) programmed into the control unit. If the delivery pressure is lower than the target pressure, the rotational speed of the air-end, and therefore the delivered air volume, increases until either the target pressure is reached or the air-end is running at maximum speed. If the delivery pressure is above the target pressure the rotational speed of the air-end is reduced until either the target pressure is reached or the air-end is running at minimum speed.

Manual Mode

An unload pressure setpoint (P1) is also provided and is always set above the target set point. If the unload pressure is reached, a bypass/blowdown valve (21), (12) or (14) opens and because the airend is running at minimum speed all of the air produced is re-circulated in the bypass pipe resulting in zero delivered air volume. The bypass condition will continue until: a)

the delivery pressure falls below the target pressure and the bypass valve shuts, or

b)

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

AC20160-1822, Issue 1, November 2002

Chapter 3, page 13

CompAir

32 33 34 35 36 37 38 39 40

3 PHASE POWER SUPPLY

29

1 19

30 21

17

OIL SCAVENGE LINES

16

7

15

B

A

18

14 8

13 2

20

9 10

6

22

28

M

23

3 4

5 27 M

11

24 12

HW 0009

25 26 31

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

Intake Air Filter Non-return Valve Air-end SR Drive® Motor Reclaimer Separator Filters Pressure Gauge Minimum Pressure Non-return Valve Aftercooler Compressor Delivery Oil Filler Oil Level Sight Glass Temperature Thermistor (TE1) Overcurrent Trip

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Position Sensor Fault Trip Overspeed Stall Trip Pressure Transducer Differential Pressure Switch Temperature Thermistor (TE2) Bypass Valve Pressure Relief Valve Oil Cooler Oil Filter Thermal Overload Temperature Thermistor (TE3) Cooling Fan Thermostatic Bypass Valve Control Panel

30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.

Pressurised Oil Drain Valve Oil Drain Valve Emergency Stop SR Current Sensor Trip DC Link Overvoltage Trip DC Link Undervoltage Trip Capacitor Charge Volt Trip Heatsink Sensor Fault Trip Heatsink Temperature Alarm Heatsink Temperature Trip Main Contactor Fault Trip

FIG. 3.7 REGULATION SCHEMATIC - 345SR, L45SR

Chapter 3, page 14

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – General Description

39 40 41 42 43 44 45 46 47

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

38

12 20

50

13

32

1

31

26

11 2

33 36

48

37

4

3

34 35

19

16

30

24

5 M

14 6

M

17

28

18

7

15

23

29

27

8 9

49 21

10

22

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

25

Intake Air Filter Differential Pressure Switch Air Inlet Connection Air-end SR Drive® Motor Temperature Thermistor (TE1) Overcurrent Trip Position Transmitter Fault Trip Over Speed Trip Stall Trip Temperature Thermistor (TE2) Bypass Valve Scavenge Solenoid Overpressure Switch Pressure Gauge Oil Filler Reclaimer Oil Level Tube

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Relief Valve Diff. Pressure Indicator Oil Filter Oil Drain Valve Oil Stop Valve Non-return Valve Oil Drain Valve Minimum Pressure Nonreturn Valve Thermal Overload Temperature Thermistor (TE3) Cooling Fan Motor Oil Cooler Aftercooler Pressure Transmitter Moisture Separator Strainer

HW 0010

35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

Drain Solenoid Compressor Delivery Condensate Drain Control Panel Emergency Stop SR Current Sensor Trip DC Link Overvoltage Trip DC Link Undervoltage Trip Capacitor Charge Volt Trip Heatsink Sensor Fault Trip Heatsink Temperature Alarm Heatsink Temperature Trip Main Contactor Fault Trip Scavenge Strainer Thermostatic Bypass Valve Pressurised Oil Drain Valve

FIG. 3.8 REGULATION SCHEMATIC - 475SR, L75SR

AC20160-1822, Issue 1, November 2002

Chapter 3, page 15

CompAir

20

24 34 14 13 8 28

9

30

15

1 33

10

35 22

2 29

7

31

36

26 27

5

16

23 32

4

3

17

11 12 6 21

25

37

19

HW 0013

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

Intake Air Filter Air Inlet Grille Air End SR Drive® Motor Reclaimer Oil Filters Pressure Gauge Minimum Pressure / Non-Return Valve Aftercooler Compressor Delivery Oil Filler Oil Level Sight Glass Air Inlet Grille Solenoid Valve (Blowdown) Moisture Separator Level Controlled Condensate Valve

18

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Condensate Drain Point Oil Drain (Cooler) Oil Drain (Reclaimer) Air Outlet Grille Thermostatic Mixing Valve Pressure Relief Valve Oil Cooler Fan Motor Power Converter Heat Sink - Cooling Fan Position Sensor Pressure Transmitter (Reclaimer) Pressure Transmitter (Air Delivery) Inlet Non-Return Valve Scavenge Restrictor Scavenge NRV

32. 33. 34. 35. 36. 37.

Motor Thermistor Temperature Transmitter (Air End Delivery) Differential Pressure Indicator and Switch Thermostatic Mixing Valve (Heat Recovery) Heat Recovery Heat Exchanger Water Inlet and Outlet Connection (Heat Recovery Option Only)

FIG. 3.9 REGULATION SCHEMATIC - L120SR

Chapter 3, page 16

AC20160-1822, Issue 1, November 2002

LSR Repair Manual - Technical Data

CHAPTER

4 TECHNICAL DATA

1. 2. 3. 4.

LEADING PARTICULARS CABLE SIZES AND FUSE RATINGS APPROXIMATE FULL LOAD CURRENTS FAN MOTORS THERMAL OVERLOAD SETTINGS

AC20160-1822, Issue 1, November 2002

Chapter 4, page 1

CompAir

TECHNICAL DATA 1.

LEADING PARTICULARS MODEL

345SR and L45SR

475SR and L75SR

L120SR

Air-end:

Single Stage Oil Injected Screw

Cooling:

Air Cooled

Oil Capacity: litres (US gal)

18.5 (4.9)

Recommended Oil:

45 (11.9)

80 (21.1)

CompAir 4000HR CompAir FG (Food Grade) G11/2 or R 21/2 or 11/2in NPTM 21/2in NPTM

Air Delivery Connection:

Condensate Connection:

-

10mm/ 3/8 in OD tube

flanged BS 4504/ DIN 2633 DN80 PN16 or 3” ASA150lb RF 1

G 1/2 or /2in NPT

Delivery Air Pressure:

Minimum bar (psig) Maximum bar (psig)

5 (72) 13 (189)

5 (72) 13 (189)

5 (72) 11.5 (167) or 13 (189)

★

Full load operation (7 bar) °C (°F)

10 (18)

11 (20)

10 (18)

0 (32) 45 (113)

0 (32) 43 (109)

0 (32) 45 (113)

°C (°F)

19 (34)

14 (25)

21 (38)

Nominal Rating kW (HP)

50 (67)

75 (100)

128 (172)

Delivery Air Temperature above ambient:

Ambient Temperature Range: Minimum °C (°F) Maximum °C (°F) Typical Cooling Air Outlet Temperature at Maximum Operating Pressure above ambient: Main Drive Motor: Motor Rotation

Clockwise viewed from drive end

Motor Speed

Maximum rpm

Fan Motor Power

kW (HP)

Fan Motor Rotation

viewed from non-drive end

Total Power Input (Typical) kW Approx. Nett. Weight:

kg (lbs)

Dimensions:

Length mm (ins) Width mm (ins) Height mm (ins)

Average Sound level at 1m (CAGI PNEUROP) dB(A) +/- 3dB(A)

5000

4800

3750

2.2 (3)

4 (5.45)

5.5 (7.5)

Anti-clockwise Clockwise 56

88

144

955 (2101)

1243 (2735)

2100 (4620)

1420 (55.9) 2050 (80.7) 990 (39) 1200 (47.2) 1650 (65) 1702 (67)

2500 (98.5) 1400 (55.2) 2020 (79.6)

77

77

50Hz - 76 60Hz - 79

★

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

Chapter 4, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual - Technical Data

2.

3.

4.

Cable Sizes and Fuse Ratings

Model

Voltage 50/60Hz

Cable Size

Fuse Rating

345SR, L45SR 474SR, L75SR L120SR

All voltages All voltages All voltages

3 x 35mm2 3 x 70mm2 3 x 120mm2

gG125A gG200A gG315A

Approximate Full Load Current, Amps

Model

380V

400V

415V

460V

345SR, L45SR 475SR, L75SR L120SR

107 160 261

102 155 248

98 151 238

87 139 234

Fan Motors Thermal Overload Settings, Amps

Model

380V

400V

415V

460V

345SR, L45SR 475SR, L75SR L120SR

6.0 9.5 16.0

5.5 9.0 16.0

5.4 8.9 16.0

5.0 8.5 16.0

AC20160-1822, Issue 1, November 2002

Chapter 4, page 3

CompAir

Chapter 4, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Operation

CHAPTER

5 MECHANICAL FAULT FINDING

DEFAULT SETTINGS FAULT FINDING 1. 2. 3.

SHUTDOWN MESSAGES WARNING MESSAGES FAULT FINDING CHART

AC20160-1822, Issue 1, November 2002

Chapter 5, page 1

CompAir

DEFAULT SETTINGS 1.

Default settings for a number of the operational settings are stored in the controller. These are suitable for operating the compressor in most normal situations.

2.

The compressor can use these settings as operational settings. Unless the compressor is reprogrammed during commissioning, the default settings will be those used by the compressor.

3.

The compressor may be re-programmed with different settings at most times, and the operational settings may be restored to the default values, by choosing the ‘Load default values’ option in the ‘Commissioning – values’ sub-menu.

4.

It is not possible to change any parameters while the Emergency Stop button is pressed. This is because when Emergency Stop is pressed (input open circuit) the power failure detection is inhibited. The controller therefore assumes a power failure possibility and suspends all data storage to prevent corruption should the power fail during storage operation. A message ‘Emergency Stop’ is shown if a change is attempted.

5.

The following is a list of default settings together with the range and size of the increments/decrements available for each setting.

Alteration of the working setting values requires the use of the access code.

Chapter 5, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Operation

1.

L45SR, L75SR, L120SR models.

Setting

Unit

Minimum

Maximum

Step

Default Value

P1 for AUTO mode

bar

5·1

13·4 (11.9)*

0·1

7·4

P2 for AUTO mode

bar

5·0

13·0 (11.5)*

0·1

7·0

*P1 for AUTO mode

bar

5·1

13·4 (11.9)*

0·1

7·4

*P2 for AUTO mode

bar

5·0

13·0 (11.5)*

0·1

7·0

P1 for MAN mode

bar

5·1

13·3 (11.8)*

0·1

7·0

P2 for MAN mode

bar

5·0

13.0 (11.5)*

0·1

6·3

Max. overpress (L120SR)

bar

6·0

14.3 (12·8)*

0·1

7·7

6·0

13·6

0·1

7·7

Max. overpress (L45SR, L75SR) Acceleration time

second

0

240

1

10

Cooler run-on time

minute

4

12

1

4

Run on time

second

20

240

1

20

Drain open time

second

1

20

1

5

Drain shut time

second

10

120

1

30

Oil t trip limit

°C

85

125

1

110

Oil t alarm limit

°C

85

125

1

105

1000

2000

100

2000

Max. service hours

hour

Machine number

number

1

99

1

1

Auto restart delay

second

10

240

1

10

Auto restart

Enabled – Disabled

option

disabled

Remote start/stop (see Chapter 8, 1.2.2)

Enabled - Disabled

option

disabled

Pressure P factor

1

100

1

30

Pressure I factor

1

100

1

15

Input X01/4 (see Chapter 8, 1.2)

Disabled to Start Inhibit

option

disabled

Input X01/6 (see Chapter 8, 1.2)

Disabled to Start Inhibit plus Pressure Range select

option

Pressure Range sel

Input X01/7 (see Chapter 8, 1.2)

Disabled to Start Inhibit plus Remote Start/Stop

option

Remote start/stop

Output X08/6 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

disabled

Output X08/10 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

disabled

Output X09/2 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

Group Fault

Output X09/3 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

Available

Output X09/4 (see Chapter 8, 1.3)

Disabled to Start Inhibit

option

Group Trip

Disabled-SmartAir controlCommunications control

option

disabled

Communications config

* Figures in brackets are for L120SR-11 machines only. Note: The ‘Max. overpressure’ must be set above P1 settings.

AC20160-1822, Issue 1, November 2002

Chapter 5, page 3

CompAir

2.

345SR, 475SR models.

Setting

Unit

Minimum

Maximum

Step

Default Value

*P1 for AUTO mode

bar

5·1

13·4

0·1

7·4

*P2 for AUTO mode

bar

5·0

13·0

0·1

7·0

P1 for AUTO mode

bar

5·1

13·4

0·1

7·4

P2 for AUTO mode

bar

5·0

13·0

0·1

7·0

P1 for MAN mode

bar

5·1

13·4

0·1

7·0

P2 for MAN mode

bar

5·0

13.2

0·1

6·3

Max. overpress

bar

6·0

13·6

0·1

7·7

Acceleration time

second

0

240

1

10

Cooler run-on time

minute

4

12

1

4

Run on time

second

20

240

1

20

Drain open time

second

1

20

1

5

Drain shut time

second

10

120

1

30

Oil t trip limit

°C

85

125

1

110

Oil t alarm limit

°C

85

125

1

105

1000

2000

100

2000

1

99

1

1

110

9600

options

9600

10

240

1

10

Start/Stop

Comms. Control

option

disabled

option

disabled

Max. service hours Machine number

hour number

Comms baud rate Auto restart delay Remote control config Auto restart

second

Enabled – Disabled

Pressure P factor

1

100

1

30

Pressure I factor

1

100

1

15

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

Chapter 5, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Fault Finding

FAULT FINDING The controller has a memory facility that retains a fault history. Details of 15 previous situations can be displayed, including the fault message together with recorded hours, compressor state (standby, onload, off-load etc.), oil temperature and air pressure.

In operation the compressor is protected by circuits which are triggered when a fault arises and either cause the compressor to shut down or indicate that a servicing action is required.

WARNING

1.

!

Refer to the safety procedures before carrying out any fault finding investigation on the compressor unit.

!

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

!

Before opening the door of the starter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting work on the compressor.

SHUTDOWN MESSAGES

Message Displayed

Emergency stop

Possible Cause

(1) Emergency stop switch operated.

(2) Starter circuit fuse F2 blown.

Fan motor fault

Action required

(1) Check cause of fault and rectify. Turn Emergency Stop switch to release latch. Press RESET. (2) Check cause and rectify.

(1) Insufficient cooling air flow.

(1) Inspect/clean: enclosure filter; ducting; air/oil cooler matrix; motor cooling air

(2) High ambient temperature. (3) Low voltage/high current. (4) Circuit breaker MCB2 incorrectly set. (5) Starter circuit breaker MCB2 open. (6) Fan motor thermistor fault. (all models except L120SR). (7) Fan motor overload (L120SR).

(2) Check room ventilation. (3) Check power supply. (4) Check setting and reset.

intake.

AC20160-1822, Issue 1, November 2002

(5) Check starter circuit breaker. (6) Check thermistor. (7) Check motor/fan. replace if necessary.

Chapter 5, page 5

CompAir

Message Displayed

Possible Cause

Action required

Heat sink temp HI **

(1) Panel filters blocked (2) Heat sink dirty (3) Heat sink fan faulty (L120SR)

(1) Clean/renew filters (2) Clean heat sink (3) Check motor/fan. replace if necessary.

High air pressure

(1) High pressure in user system

(4) Controller fault.

(1) Check settings of other compressors in system. (2) Check operation of venting valve and solenoid operated bypass valve. Renew if necessary. (3) Check/renew pressure Transmitter. (4) Renew controller.

(1) Fan rotation incorrect.

(1) Check/rectify wiring.

(2) Insufficient cooling air flow.

(2) Inspect/clean: enclosure filter; ducting; air/oil cooler matrix. (3) Check room ventilation. (4) Rectify/renew.

(2) Compressor fails.

(3) Pressure transmitter fault.

High oil temp fault

(3) High ambient temperature. (4) Poor electrical connection or Air/oil thermistor fault. (5) Low oil level.

(6) Incorrect grade of oil.

(7) Oil stop valve not opening. (8) Oil cooler bypass valve fault. (9) L120SR only - Enclosure door open.

Press probe fault * Del pressure probe fault ** Reclaimer P probe fault **

Remote fault 1, 2 or 3 **

* 345SR and 475SR models

Chapter 5, page 6

(1) Pressure transmitter fault. (2) Sensor wiring fault. (3) Controller fault.

Appropriate input was open circuit whilst conditions met.

(5) Check for leaks and rectify. Top up reclaimer to correct level. (6) Drain/flush oil system. Clean scavenge strainer. Renew reclaimer separator and oil filter elements. Refill the system with the recommended oil. (7) Rectify or renew valve. (8) Rectify or renew valve. (9) Close door.

(1) Renew pressure transmitter. (2) Check and rectify fault. (3) Renew controller.

Check conditions (Type 1, 2 or 3) are appropriate. Check auxiliary equipment Check/rectify wiring.

** L120SR models

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Fault Finding

Message Displayed

SR motor high temp fault

Possible Cause

(1) Insufficient cooling air flow.

(4) Controller fault.

(1) Inspect/clean: enclosure filter; ducting; motor cooling air intake. (2) Check room ventilation. (3) Check and rectify electrical circuit. (4) Renew controller.

(1) Temperature sensor fault. (2) Temperature sensor wiring fault. (3) Controller fault.

(1) Renew temperature sensor. (2) Check and rectify. (3) Renew controller.

(2) High ambient temperature. (3) Fan operation/rotation incorrect.

Temperature probe fault. Temp probe fault.

2.

Action required

WARNING MESSAGES

Message Displayed

Change air filter

Possible Cause

(1) Intake air filter blocked. (2) Filter pressure switch fault. (3) Filter pressure switch wiring fault.

Action Required

(1) Check/renew element. (2) Check operation. Renew if necessary. (3) Check and rectify.

Change reclaimer element

(1) Reclaimer filter blocked. (2) Pressure transmitter fault

(1) Check/renew element (2) Check and rectify.

Check reclaimer Check reclaimer dp

(1) Service interval expired

(1) Check reclaimer differential pressure. (2) Renew element if required.

High oil temp alarm

See High Oil Temp Fault

Remote fault 1, 2 or 3

An input was open circuit whilst conditions met.

Check conditions (Type 4, 5 or 6) are appropriate. Check auxiliary equipment. Check/rectify wiring.

Service due

Service countdown time expired.

Service compressor then reset timer.

Start inhibited

A start inhibit function is active.

An input configured for start inhibit is open circuit.

AC20160-1822, Issue 1, November 2002

Chapter 5, page 7

CompAir

REM The following chart will enable the user to identify other faults which may occur. 3.

FAULT FINDING CHART

Indication

Compressor fails to run off-load.

Compressor fails to run on-load.

Possible Cause

(1) Pressure transmitter faulty.

(1) Adjust to correct setting. Renew if necessary.

(2) Solenoid bypass/blowdown valve faulty.

(2) Find cause and rectify or renew.

(3) Electrical wiring fault.

(3) Find cause and rectify or renew.

(1) Solenoid bypass/blowdown valve faulty.

(1) Rectify/renew valve.

(2) Pressure transmitter faulty.

(2) Adjust to correct setting. Renew if necessary. (3) Find cause and rectify.

(3) Electrical wiring fault.

Excessive oil consumption.

Action

(1) Leaks in oil system.

(1) Examine system. Rectify if necessary.

(2) Oil carried into user’s pipework caused by: (a) Reclaimer element defective. (b) Scavenge oil orifice adaptor restricted. (c) Incorrect grade of oil. (d) Constant running at high ambient temperature. (e) Minimum pressure valve not closing.

Chapter 5, page 8

(2) (a) Check pressure drop across element. Renew element if necessary. (b) Clean scavenge strainer and orifice adaptor. (c) Drain the system, flush and re-fill with an approved oil. (d) Check/clean enclosure filter. Improve room ventilation. (e) Check valve seating. Renew spring if necessary.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Fault Finding

Indication

Low delivery air pressure.

Possible Cause

(1) Pressure transmitter incorrectly set or faulty. (2) Pressure relief valve leaking. (3) Demand exceeds compressor rating. (4) Compressor speed reduced owing to high heat sink temperature.

Reclaimer pressure does not fall to 4 bar when compressor runs off-load.

(1) Minimum pressure valve not closing. (2) Venting valve faulty.

AC20160-1822, Issue 1, November 2002

Action

(1) Adjust to correct setting. Renew if necessary. (2) Check/renew seals. Renew valve if necessary. (3) Check for system leaks and rectify. Review user’s air requirements. (4) Clean panel filters. L120SR only: Check panel fan.

(1) Check valve seating. Renew spring if necessary. (2) Check and renew if necessary.

Chapter 5, page 9

CompAir

This page is intentionally left blank

Chapter 5, page 10

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Components

CHAPTER

6 COMPONENTS 1. 1.1 1.2 2. 2.1 2.2 2.3 3. 3.1 3.2 4. 4.1 4.2 5. 5.1 5.2 6. 7. 8. 9. 10. 10.1 10.2 11. 11.1 11.2 12. 12.1 12.2 13. 13.1 13.2 14. 14.1 14.2

PRIMARY OIL SEPARATOR AND SEPARATOR FILTER ELEMENT (345SR, L45SR) Description Operation RECLAIMER (475SR, L75SR, L120SR) Description (475SR, L75SR Description (L120SR) Operation MINIMUM PRESSURE VALVE (475SR, L75SR) Description Operation MINIMUM PRESSURE VALVE (345SR, L45SR) Description Operation MINIMUM PRESSURE/NON RETURN VALVE (L120SR) Description Operation DIFFERENTIAL PRESSURE INDICATOR (L75SR) EXCESS PRESSURE SWITCH (L75SR) AIR FILTER PRESSURE SWITCH (L45SR and L75SR) AIR FILTER PRESSURE SWITCH/INDICATOR (L120SR) AIR AND OIL COOLERS (345SR, L45SR) Air Cooler Oil Cooler AIR/OIL COOLER (475SR, L75SR) Description Operation AIR COOLER (L120SR) Description Operation OIL COOLER (L120SR) Description Operation THERMOSTATIC BYPASS VALVE (L45SR) Description Operation

(continued)

AC20160-1822, Issue 1, November 2002

Chapter 6, page 1

CompAir

CONTENTS (continued) 15. 15.1 15.2 16. 16.1 16.2 17. 18. 18.1 18.2 19. 19.1 20. 20.1 20.2 21. 21.1 21.2 22. 22.1 22.2 23. 23.1 23.2 24. 24.1 24.2 25. 25.1 25.2 25.3 26. 26.1 26.2 27. 27.1 27.2 28 28.1 28.2 29. 29.1 29.2

THERMOSTATIC BYPASS VALVE (Earlier L75SR Models, L120SR) Description Operation THERMOSTATIC BYPASS VALVE (Later L75SR Models) Description Operation MOISTURE SEPARATOR (475SR, L75SR, L120SR) STRAINERS Condensate Strainer (L75SR) Scavenge Strainer (L75SR) FILTER MANIFOLD Description OIL STOP VALVE (475SR, L75SR) Description Operation PRESSURE TRANSMITTER (L45SR, L75SR) Description Operation SILICON TEMPERATURE SENSOR Description Operation DRIVE AND FAN MOTOR THERMISTORS Description Operation DELIVERY NON-RETURN VALVE (475SR, L75SR) Description Operation BY-PASS VALVE Description (L45SR, L75SR) Description (L120SR) Operation INLET NON-RETURN VALVE (345SR, L45SR) Description Operation INLET NON-RETURN VALVE (L120SR) Description Operation BEKO DRAIN (L120SR) Description Operation SCAVENGE NRV ASSEMBLY (L120SR) Description Operation

Chapter 6, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Components

FIGURES FIG. 6.1 FIG. 6.2 FIG. 6.3 FIG. 6.5 FIG. 6.4 FIG. 6.6 FIG. 6.7 FIG. 6.8 FIG. 6.9 FIG. 6.10 FIG. 6.11 FIG. 6.12 FIG. 6.13 FIG. 6.14 FIG. 6.15 FIG. 6.16 FIG. 6.17 FIG. 6.18 FIG. 6.19 FIG. 6.20 FIG. 6.21 FIG. 6.22 FIG. 6.23 FIG. 6.24 FIG. 6.25 FIG. 6.26 FIG. 6.27 FIG. 6.28 FIG. 6.29 FIG. 6.30

SEPARATOR FILTER ELEMENT RECLAIMER (475SR, L75SR) RECLAIMER (L120SR) MINIMUM PRESSURE VALVE (475SR, L75SR) MINIMUM PRESSURE VALVE (345SR, L45SR) MINIMUM PRESSURE/NON RETURN VALVE (L120SR) DIFFERENTIAL PRESSURE INDICATOR (L75SR) EXCESS PRESSURE SWITCH (L75SR) AIR COOLER (345SR, L45SR) OIL COOLER (345SR, L45SR) AIR/OIL COOLER (475SR, Earlier L75SR Models) AIR/OIL COOLER (Later L75SR Models) AIR AND OIL COOLERS (L120SR) THERMOSTATIC MIXING ARRANGEMENT THERMOSTATIC BYPASS VALVE (L45SR) THERMOSTATIC BYPASS VALVE THERMOSTATIC BYPASS VALVE (LATER L75SR MODELS) MOISTURE SEPARATOR (475SR, L75SR) MOISTURE SEPARATOR (L120SR) FILTER MANIFOLD CONDENSATE STRAINER OIL STOP VALVE PRESSURE TRANSMITTER SILICON TEMPERATURE SENSOR NON-RETURN VALVE (475SR, L75SR) BY-PASS VALVE INLET NON-RETURN VALVE (345SR, L45SR) INLET NON-RETURN VALVE (L120SR) BEKO DRAIN (L120SR) SCAVENGE NRV ASSEMBLY (L120SR)

AC20160-1822, Issue 1, November 2002

Chapter 6, page 3

CompAir

This page is intentionally left blank

Chapter 6, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Components

COMPONENTS 1.

PRIMARY OIL SEPARATOR AND SEPARATOR FILTER ELEMENT (345SR AND L45SR)

5 4 3

The separator vessel operates in conjunction with a separator filter element (Fig. 5.3) where final separation takes place. The separator element is located on the manifold block and is fabricated from layers of micro fine glass fibre, supported by tubes and protected externally by a perforated steel sheath. A scavenge pipe, located on the underside of the manifold block, passes through the centre of the element which screws into position against a machined face.

2 1.2

1

Operation

The air/oil mixture passes from the air-end discharge pipe into the primary oil separator vessel where initial separation takes place by centrifugal force. Most of the oil is separated at this stage and drops to the bottom of the vessel.

HW 0275 1. 2. 3. 4. 5.

Filter Body Fine Filter Layer Supporting Tube Second Filter Layer Seal Ring

FIG. 6.1 SEPARATOR FILTER ELEMENT

1.1

Description

Primary separation of oil from the air/oil mixture takes place in the separator vessel which is positioned between the air-end and aftercooler. The separator comprises a steel pressure vessel with a welded cover. The cover carries the pipe connections for the air and oil pipework and a safety relief valve. An oil filler pipe and oil level sightglass assembly are fitted to the wall of the separator vessel.

AC20160-1822, Issue 1, November 2002

The remaining air/oil mixture then passes through two separator filter elements where final separation takes place. The separator element functions with the principle of coalescence. The micro glass fibre layers separate the oil droplets which collect in the bottom of the filter and are scavenged back into the air-end through a small diameter pipe The filtered air then passes from the oil separation element by way of the minimum pressure/ nonreturn valve. Provided the air pressure at this stage is above 3.5 to 4·0 bar the air passes through the aftercooler where it is cooled before passing to the delivery outlet. If the air pressure in the primary oil separator falls below 3.5 to 4·0 bar the minimum pressure valve will close. The valve also incorporates a non-return valve which operates to prevent delivery air passing back into the separator when the compressor is running off-load. Oil from the bottom of the primary oil separator flows under pressure to the oil cooler and during normal running the oil passes through the cooler to maintain the correct temperature. A thermostatic bypass valve is installed in the inlet manifold of the oil cooler.

Chapter 6, page 5

CompAir

2.

RECLAIMER (475SR, L75SR, L120SR)

5

3

4

5

4

6

6

3

2

7 2

7

15 10

1

8

14

9

8

1

9

10

15

11

13

14

11 13

12 HW 0276

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

Pressure Vessel Joint Cover Scavenge Pipe Minimum Pressure Valve Air Outlet Pressure Relief Valve Filter Element Oil Outlet Air/Oil Inlet Oil Reservoir Drain Connection Oil Level Sight Tube Oil Filler Excess Pressure Switch

FIG. 6.2 RECLAIMER (475SR, L75SR)

Chapter 6, page 6

12

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

HW 0277

Pressure Vessel Joint Cover Scavenge Pipe Minimum Pressure Valve Air Outlet Pressure Relief Valve Filter Element Oil Outlet Air/Oil Inlet Oil Reservoir Drain Connection Oil Level Sight Tube Oil Filler Pressure Transducer

FIG. 6.3 RECLAIMER (L120SR)

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Components

2.1

Description (475SR and L75SR) - fig. 6.2

Separation of oil from the oil/air mixture takes place in the reclaimer which is positioned between the air-end and air/oil cooler. The reclaimer comprises a steel pressure vessel (1) with a removable cover (3). A filter element (8) is contained within the pressure vessel. The filter element is fabricated from layers of micro fine glass fibre, supported by tubes and protected externally by a perforated steel sheath wrapped in a pre-filter element. The element is suspended by a flange from the top of the pressure vessel. The assembly is sealed with a joint (2) and secured in position by the cover. The cover carries the minimum pressure valve (5), scavenge oil pipe (4) and air connections for the regulation system. A drain connection (12), oil filler (14), pressure relief valve (7), oil level sight glass (13) and excess pressure switch (15) are fitted to the wall of the pressure vessel. The lower portion of the pressure vessel forms an oil reservoir (11). 2.2

2.3

Operation

The air/oil mixture passes from the discharge port of the air-end into the reclaimer inlet (10). Centrifugal primary separation of the oil occurs and most of the oil droplets fall into the oil reservoir. The differential pressure between the inside and the outside of the element causes the remaining oil droplets to pass through the two stages of the reclaimer element where final separation takes place. The reclaimer element functions on the principle of coalescence. The micro glass fibre layers separate the small oil droplets from the compressed air/oil mixture to form larger droplets which drain down to collect inside the bottom of the element. The accumulation of oil in the element is returned to the air end through the scavenge system.

Description (L120SR) - fig. 6.3

Separation of oil from the oil/air mixture takes place in the reclaimer which is positioned between the air-end and air/oil cooler. The reclaimer comprises a steel pressure vessel (1) with a removable cover (3). A filter element (8) is contained within the pressure vessel. The filter element is fabricated from layers of micro fine glass fibre, supported by tubes and protected externally by a perforated steel sheath wrapped in a pre-filter element. The element is suspended by a flange from the top of the pressure vessel. The assembly is sealed with a joint (2) which is bonded to the filter element (8) and secured in position by the cover. The cover carries the minimum pressure valve (5), scavenge oil pipe (4) and air connections for the regulation system. A drain connection (12), oil filler (14), pressure relief valve (7), oil level sight glass (13) and pressure transducer (5) are fitted to the wall of the pressure vessel. The lower portion of the pressure vessel forms an oil reservoir (11).

AC20160-1822, Issue 1, November 2002

Chapter 6, page 7

CompAir

3.

MINIMUM PRESSURE VALVE (345SR, L45SR)

1 2 3 4

5

6

7

8

11 9

12

10

HW 0278

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

Locknut Washer Retainer ‘O’ Ring Valve Head ‘O’ Ring Seal

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

Guide Pin Spring ‘O’ Ring Seal Piston Spring Valve Body

FIG. 6.4 MINIMUM PRESSURE VALVE (345SR, L45SR) 3.1

Description

The minimum pressure valve fits inside the manifold block and performs the following main functions: 1.

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

2.

It prevents high velocity, low pressure air carrying over excessive amounts of oil into the delivery air pipe during start-up.

3.

The minimum pressure valve also incorporates a non-return valve. This prevents pressurised air in the user’s pipework passing back into the reclaimer when the compressor unit stops or runs off-load.

Chapter 6, page 8

The minimum pressure valve consists of a valve body (12), valve assembly, and piston (10). The valve assembly comprises a guide pin (7), valve head (5), retainer (3) and two ‘O’ ring seals (4, 6) secured by a washer (2) and a locknut (1). The guide pin houses a spring (8) and is located inside the piston. The valve head is seated against a face machined in the manifold block. The piston moves inside the bore of the valve body and two springs (11) force the piston against the rear face of the valve assembly. An ‘O’ ring seal (9) fitted to the outside of the piston prevents any pressure leakage past the piston. The piston and valve assembly move to control the flow of air through the valve.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Components

3.2

Operation

4.

When the compressor starts, the minimum pressure valve is held in the closed position by the effect of a spring against the top of the piston and by the face of the piston holding the valve assembly against the seat. The valve remains closed until the pressure in the separator vessel reaches a set minimum pressure (3.5 to 4 bar). When the pressure in the separator vessel overcomes the force exerted by the two springs, the valve assembly and piston move up allowing full air flow past the open valve, through the outlet port and into the main delivery pipe to the aftercooler.

MINIMUM PRESSURE VALVE (475SR, L75SR) 1

HW 0279

2

3

15

4 14

When the compressor off-loads the flow of air ceases between the separator vessel and the user’s pipework. Pressure in the compressor system acts to hold the minimum pressure valve piston in the raised position against the effect of the spring and at the same time the valve spring closes the non-return valve onto its seat.

13 12 11

When the compressor reverts to on-load running, the valve assembly will stay closed against the seat until the pressure in the separator vessel exceeds the pressure in the user’s pipework. The plunger will not return to close the outlet until the pressure in the user’s pipework falls below the force of the springs.

10

1. 2. 3. 4. 5. 6. 7. 8.

9

8

7 6

Piston Housing Outer Piston Spring Inner Piston Spring Piston Valve Head 'O' Ring Washer Locknut

5

9. 10. 11. 12. 13. 14. 15.

Retainer 'O' Ring Body Guide Pin 'O' Ring Spring 'O' Ring

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

4.1

Description

The minimum pressure valve is mounted on the reclaimer cover and performs the following functions: 1.

AC20160-1822, Issue 1, November 2002

It ensures a rapid pressure build-up in the reclaimer during initial start-up. The minimum pressure valve is held closed until the pressure in the reclaimer reaches approximately 4 bar.

Chapter 6, page 9

CompAir

2.

It prevents high velocity, low pressure air carrying over excessive amounts of oil into the delivery air pipe during start-up.

3.

It acts as a non-return valve preventing pressurised air in the user’s pipework passing back into the reclaimer when the compressor unit stops or runs off-load.

5. MINIMUM PRESSURE/NON RETURN VALVE (L120SR) 5.1

The minimum pressure valve consists of a valve body (11), a valve assembly and a piston housing (1). The valve assembly comprises a piston (4) and 'O' ring (13), guide pin (12) and valve spring (14), a valve head (5) with ‘O’ ring seal (10) and retainer (9) secured by a washer (7) and locknut (8). An 'O' ring (6) provides a seal between the valve head and guide pin. The guide pin and spring are located inside the piston. The valve head and ‘O’ ring seal operates against a seat formed in the valve body (11). The piston moves inside the bore of the piston housing and two piston springs (2,3) force the piston against the rear face of the valve assembly. The piston and valve assembly move to control the flow of air through the valve. A tapped hole in the base of the valve body provides a connection to the differential pressure indicator. 4.2

Operation

When the compressor starts, the minimum pressure valve is held in the closed position by the piston springs. The valve remains closed until the pressure in the reclaimer reaches a set minimum pressure (4 bar). When the pressure in the reclaimer overcomes the force exerted by the two piston springs, the valve assembly and piston move up allowing full air flow past the open valve, through the outlet port and into the main delivery pipe to the aftercooler. When the compressor comes off-load the flow of air ceases between the reclaimer and the user’s pipework. Downstream pressure in the system acts to hold the minimum pressure valve piston (4) in the raised position against the effect of the piston springs and at the same time the valve spring (14) closes the non-return valve head (5) on to its seat. The piston will not return to close the outlet until the pressure in the user’s pipework falls below the set pressure of 4 bar. When the compressor reverts to on-load running, the valve will stay closed against the seat until reclaimer pressure again exceeds 4 bar.

Chapter 6, page 10

Description

The minimum pressure valve is mounted on the reclaimer cover and performs the following functions: 1.

It ensures a rapid pressure build-up in the reclaimer during initial start-up. The minimum pressure valve is held closed until the pressure in the reclaimer reaches approximately 4 bar.

2.

It prevents high velocity, low pressure air carrying over excessive amounts of oil into the delivery air pipe during start-up.

3.

It acts as a non-return valve preventing pressurised air in the user’s pipework passing back into the reclaimer when the compressor unit stops or runs off-load.

The minimum pressure valve consists of a valve body (8), a valve assembly and a piston housing (1). The valve assembly comprises piston (4), 'O' ring (6) and valve head (5). The valve head stem is located inside the piston and has a moulded seal which operates against a seat formed in the valve body (8). The piston moves inside the bore of the piston housing. The piston moves inside the bore of the piston housing and two piston springs (2,3) force the piston against the rear face of the valve assembly. The piston and valve assembly move to control the flow of air through the valve. 5.2

Operation

When the compressor starts, the minimum pressure valve is held in the closed position by the piston springs. The valve remains closed until the pressure in the reclaimer reaches a set minimum pressure (4 bar). When the pressure in the reclaimer overcomes the force exerted by the two piston springs, the valve assembly and piston move up allowing full air flow past the open valve, through the outlet port and into the main delivery pipe to the aftercooler. When the compressor comes off-load the flow of air ceases between the reclaimer and the user’s pipework. Downstream pressure in the system acts to hold the minimum pressure valve piston (4) in the raised position against the effect of the piston springs and at the same time the valve head stem

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LSR Repair Manual – Components

moves out from the piston and the valve head closes onto its seat to act as a non-return valve. The piston will not return to close the outlet until the pressure in the user’s pipework falls below the set pressure of 4 bar. When the compressor reverts to on-load running, the valve will stay closed against the seat until reclaimer pressure again exceeds 4 bar.

6.

DIFFERENTIAL PRESSURE INDICATOR (L75SR)

1 6

5 3

1

2 3

4 9,10

HW 0281 8

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

9 6 4

2 Body Adjusting screw Dial Low pressure inlet port High pressure inlet port Mounting holes

FIG. 6.7 DIFFERENTIAL PRESSURE INDICATOR (L75SR)

5

HW 0280

1. 2. 3. 4. 5. 6. 7. 8. 9. 10

Piston Housing Outer Piston Spring Inner Piston Spring Piston Valve Head 'O' Ring 'O' Ring Body Bolt Washer

FIG. 6.6 MINIMUM PRESSURE/NON RETURN VALVE (L120SR)

AC20160-1822, Issue 1, November 2002

The differential pressure indicator monitors the pressure drop across the reclaimer element. The scale on the dial of the indicator is divided into two sectors, green and red. As the differential pressure across the reclaimer element rises the needle moves across the green sector (0-1 bar range) towards the red sector. If the needle passes into the red sector (1-2 bar range) the differential pressure is too high indicating that the reclaimer element should be replaced. The differential pressure indicator is a sealed unit and no attempt should be made to tamper with it. If a fault is suspected the complete indicator must be replaced. The low pressure inlet port is connected to the downstream side (inside) of the reclaimer element via a tapping in the base of the minimum pressure valve. The high pressure inlet port is connected to the upstream side of the element via a tapping in the wall of the reclaimer pressure vessel.

Chapter 6, page 11

CompAir

7.

EXCESS PRESSURE SWITCH (L75SR)

10.

AIR AND OIL COOLERS (345SR, L45SR)

10.1 Air Cooler - fig. 6.9 The excess pressure switch is a normally closed (N.C.) switch, connected to the primary separator side of the reclaimer.

10.1.1 Description The air cooler cools the dicharge air before it passes into the main distribution pipework. The cooler is mounted vertically and comprises a bank of finned tubes, connected to inlet and discharge headers, attached to mounting points on the frame adjacent to the air intake panel. A connection (1) for the inlet air is provided in the upper header whilst a similar discharge connection (2) is fitted in the lower header.

IN

HW 0282

FIG. 6.8 EXCESS PRESSURE SWITCH (L75SR) If the pressure in the reclaimer exceeds 14 bar the switch contacts open and a signal from the controller stops the compressor. A shutdown message ‘High air pressure’ will be displayed on the control panel. The switch contacts will close again when the pressure downstream of the switch falls below 14 bar and allows the fault to be reset.

8.

AIR FILTER PRESSURE SWITCH (L45SR and L75SR)

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

9.

AIR FILTER PRESSURE SWITCH/ INDICATOR (L120SR)

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

Chapter 6, page 12

OUT

HW 0283

FIG. 6.9 AIR COOLER (345SR, L45SR) 10.1.2 Operation Compressed air from the reclaimer enters the upper header of the aftercooler, passes downwards through the finned tubes to the lower header and out into the user's pipework. The cooling fan runs continuously drawing air in through the inlet grilles and through the aftercooler and then discharging it vertically upwards through the oil cooler and some acoustic baffles to the exhaust outlet.

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10.2 Oil Cooler

10.2.2 Operation

10.2.1 Description

Oil from the bottom of the separator vessel flows under pressure to the oil cooler and during normal running the oil passes through the cooler to maintain the correct temperature. A thermostatic bypass valve is installed in the inlet manifold of the oil cooler.

Thermostat

Out In

HW 0284

FIG. 6.10 OIL COOLER (345SR, L45SR) The oil cooler cools the oil from the separator vessel before it returns to the air-end via the oil filter. The cooler comprises a two pass matrix, connected to an inlet and outlet header, mounted horizontally at the top of the unit. A thermoststic bypass valve is installed in the inlet header.

AC20160-1822, Issue 1, November 2002

When the compressor is started, the cold oil in the system bypasses the oil cooler and flows through the oil filter directly to the air-end. As the oil and air mixture is compressed by the rotors in the air-end, the temperature of the oil increases. When the oil has reached its normal operating temperature the bypass valve closes and the oil is directed through the oil cooler. The cooled oil then flows to the oil filter where it is cleaned before entering the air-end. The cooling fan runs continuously drawing air in through the inlet grilles and through the aftercooler and then discharging it vertically upwards through the oil cooler and some acoustic baffles to the exhaust outlet.

Chapter 6, page 13

CompAir

11.

AIR/OIL COOLER (457SR, L75SR)

Cooling is provided by a cooling fan, comprising a fan and motor assembly, attached to a cowl and support plate and secured to the underside of the oil cooler.

11.1 Description The air/oil cooler cools the discharge air before it passes into the main distribution pipework and also cools the oil from the reclaimer before it returns to the air-end via the oil filter. The cooler sections are separate and comprise a matrix of cooling tubes carried between inlet and outlet headers which are welded together and mounted horizontally between supports at the top of the compressor. On earlier models the air cooler section is single pass and the oil section double pass. On later models both the air and oil coolers are single pass.

11.2 Operation Compressed air from the reclaimer enters the air section of the inlet header of the cooler, passes through the finned tubes to the outlet header, through the moisture separator and out into the user’s pipework. Separated moisture collects in the moisture separator, passes to the automatic condensate drain and is expelled via the baseframe connection and drain pipe.

On earlier models a thermostatic bypass valve is installed in the oil inlet header. On later models a 3-way thermostatic valve is fitted to the outlet port of the reclaimer.

On earlier models oil from the reclaimer enters the oil section of the cooler header and makes a double pass through the cooling matrix back into the header before passing to the air-end via the filter. On later models oil from the reclaimer enters the cooler oil section via a 3-way thermostatic valve and makes a single pass through the cooling matrix to the air-end via the filter.

A moisture separator fitted with an automatic condensate drain is installed between the air section of the cooler and the discharge connection to the user’s pipework.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Air/Oil Cooler Cooling Fan Oil Inlet Thermostatic Bypass Valve Cooler Matrix Oil Outlet Air inlet Air Outlet Moisture Separator

1

8

2

9

4

5 7

6 3

HW 0285

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

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On earlier models When the compressor is started from cold, the thermostatic valve allows the cold oil in the system to by-pass the cooler and flow directly through the oil filter to the air-end. Once the oil has reached its normal operating temperature the by-pass valve directs the oil through the cooler. On Later models, when the compressor is started the 3-way thermostatic valve allows the cold oil in the system to by-pass the cooler and flow directly through the oil filters to the air-end. Once the oil has reached its normal operating temperature the thermostatic valve directs the oil to the oil cooler section header. The cooling fan runs continuously, drawing air through the inlet grille and discharging it vertically upwards through the air/oil cooler and an array of acoustic baffles to the exhaust outlet.

1. 2. 3. 4. 5. 6. 7. 8.

Air/Oil Cooler Cooling Fan Oil Inlet Moisture Separator Cooler Matrix Oil Outlet Air inlet Air Outlet

8

1

2

6

4

5 7

3 HW 0286

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

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Chapter 6, page 15

CompAir

12.

AIR COOLER (L120SR)

12.1 Description The air cooler cools the discharge air before it passes into the main distribution pipework. The cooler comprises a matrix of cooling tubes carried between inlet and outlet headers which are welded together and mounted vertically between cooler supports at the cooling air inlet end of the compressor. It is a single pass cooler.

A moisture separator is fitted with a pipe that takes the condensate to the Beko no loss drain. It is installed between the outlet of the air cooler and the discharge connection to the User's pipework. Cooling is provided by a cooling fan comprising a fan and motor assembly inside a cowl, situated centrally inside the machine.

1

2

1. 2. 3. 4.

Air In Oil Inlet Air Out Oil Outlet

5. 6. 7. 8.

Air Cooler Oil Cooler Moisture Separator Thermostatic Bypass Valve

FIG. 6.13 AIR AND OIL COOLERS (L120SR)

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12.2 Operation Compressed air from the reclaimer enters the air section of the inlet header of the cooler and passes through finned tubes to the outlet header, through the moisture separator and then out to the User's pipework. Separated moisture collects in the moisture separator, passes to the Beko no loss drain and is expelled via the connection in the cooler end column.

As the temperature increases to 55°C the thermostatic valve will begin to open allowing some oil to flow through the cooler and some through the bypass pipe. When the oil temperature reaches 68°C all of the oil will flow through the cooler

OIL OUT

OIL IN

THERMOSTATIC VALVE

The cooling fan runs continuously, drawing air through the inlet grilles and discharging it vertically upwards through the exhaust duct.

13.

OIL COOLER (L120SR)

HW 0288

OIL COOLER

13.1 Description The oil cooler cools the oil from the reclaimer before returning it to the air end via the oil filter.

FIG. 6.14 THERMOSTATIC MIXING ARRANGEMENT

The cooler comprises a matrix of cooling tubes carried between inlet and outlet headers which are welded together. These are mounted vertically underneath the air cooler, between the cooler supports at the cooling air inlet end of the compressor. It is a single pass cooler with a bypass pipe mounted between inlet and outlet headers. A thermostatic valve is installed in the oil outlet header which is controlled by the temperature of the mixed oil outlet. Cooling is provided by a cooling fan comprising a fan and motor assembly inside a cowl, situated centrally inside the machine.

13.2 Operation Oil from the reclaimer enters the oil cooler and passes through the cooler matrix back into the header before passing to the air end via the oil filters. When the compressor is started from cold all of the oil flows through the bypass pipe and out through the oil filters to the air end.

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Chapter 6, page 17

CompAir

14.

14.1

THERMOSTATIC BYPASS VALVE (L45SR Models Not Having External Thermostat) Description

The oil cooler is equipped with a thermostatic bypass valve which allows the oil in the system to reach operating temperature rapidly. The valve is installed in the inlet connection of the cooler header and is held closed when the oil is cold. The cold oil bypasses the cooler tube block until the operating temperature (70°C) is reached.

14.2

Operation

When the temperature of the oil increases to the set point of the thermostat, the expansion of the melting wax in the capsule forces the thrust pin out of the capsule and moves the valve body (3) to close the outlet to the bypass manifold (2) and open the inlet to the cooler manifold (6). The hot oil is then directed through the cooler tube block. A cap (9), installed in the cooler header, holds the valve in position and allows access for servicing purposes.

The thermostatic bypass valve consists of the operating element (7), thrust pin (8), valve housing (5) and spring (4). The operating element is a sealed capsule containing wax into which is inserted the thrust pin. The valve body (3) is attached to the operating element. When the oil is cold the valve is held in position by the spring (4). Oil enters the valve through the inlet (1) and leaves by way of the bypass manifold (2).

1. 2. 3. 4. 5.

Inlet Bypass Manifold Valve Body Spring Valve Housing

6. 7. 8. 9.

Cooler Inlet Manifold Operating Element Thrust Pin Cap

FIG. 6.15 THERMOSTATIC BYPASS VALVE (L45SR)

Chapter 6, page 18

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LSR Repair Manual – Components

15.

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

16.

THERMOSTATIC BYPASS VALVE (Later L45SR and L75SR Models)

15.1 Description

16.1 Description

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

The thermostatic bypass valve is a fully automatic three-way fluid temperature controller. The valve is connected upstream of the oil cooler to allow the oil system to reach normal operating temperature rapidly. The valve is closed when the compressor is started and the oil is cold. The cold oil bypasses the cooler until the normal operating temperature (70°C) is reached. The thermostatic bypass valve consists of the valve body (6), cover (1), operating element (3), housing (7), inner and outer springs (4) and ‘0’ ring seals (8). The operating element is a sealed capsule containing wax which, together with the spring, is contained within the brass housing. The upper part of the housing is flanged and is retained in the valve body by the cover. The lower part is free to move inside the valve body.

;; yy ; ;;; ;; yy ; ;;; ; ;; ;; yy A cap (7) holds the valve in position in the cooler header and allows access for servicing purposes. 8

9

10

3

HW 0291

7

6

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

5

11

4

2

1

Inlet Valve Housing Spring Valve Body Operating Element Thrust Pin Cap 'O' Ring By-pass Manifold Port Cooler Manifold Port

16.2 Operation When the oil is cold, the valve is held in the bypass position by the springs. Oil enters the valve through the inlet and leaves by way of the bypass outlet. When the temperature of the oil increases to the set point of the thermostatic valve, the expansion of the melting wax in the operating element causes the lower part of the housing to move away from the upper part, allowing the hot oil to flow through the outlet to the coolers.

FIG. 6.16 THERMOSTATIC BY-PASS VALVE 15.2 Operation When the oil is cold the valve is held in position by the spring (3). Oil enters the valve through the inlet (1) and leaves by way of the by-pass manifold port (9). When the temperature of the oil increases to the set point of the thermostat, the expansion of the melting wax in the capsule forces the thrust pin out of the capsule and moves the valve body (4) to close the port to the by-pass manifold (9) and open the port to the cooler manifold (10). The hot oil is then directed through the cooler tube block.

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Chapter 6, page 19

CompAir

1

7 4

6

9

5

3 8 HW 0298

1. 2. 3. 4. 5.

Cover Bypass Outlet Operating Element Inner and Outer Springs Inlet from Reclaimer

8

2

6. 7. 8. 9.

Valve Body Housing 'O' Ring seals Outlet to Cooler

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

Chapter 6, page 20

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17.

MOISTURE SEPARATOR (475SR, L75SR, L120SR)

The moisture separator used on L120SR machines is shown in FIG. 6.19. The moisture separator uses the principles of centrifugal force, impingement separation, and laminar and turbulent flow. The condensate collects in the bottom of the housing and is released automatically through a solenoid valve operated drain connected to the bowl (L75SR) or through a Beko no-loss drain (L120SR).

HW 0300 1. 2. 3. 4. 5. 6.

Housing Inlet Port Impinger Cone Bowl Spinner Outlet Port

FIG. 6.19 MOISTURE SEPARATOR (L120SR)

FIG. 6.18 MOISTURE SEPARATOR (475SR, L75SR) L75SR and L120SR compressors are equipped with a moisture separator to remove contamination from the delivery air. The moisture separator is installed in the delivery air pipe, downstream of the aftercooler. Moisture held in suspension in the delivery air is removed from the compressed air passing through the moisture separator by mechanical separation.

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Chapter 6, page 21

CompAir

18.

STRAINERS

18.1 Condensate Strainer (L75SR)

Condensate from the moisture separator enters the strainer body and passes through the screen before passing to the drain valve.

A 'Y' type strainer is fitted in the condensate drain line between the moisture separator and the solenoid operated condensate drain valve, to prevent blockage of the valve.

The screen filters out any large particles which then collect in the lower part of the body. The cap is removable to allow the screen to be cleaned or replaced.

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

18.2 Scavenge Strainer (L75SR) A simple gauze disc strainer is installed in the scavenge line between the reclaimer and the air-end to provide protection for the air-end components and to prevent blockage of the scavenge restrictor orifice. The screen removes any solid particles from the oil being scavenged from the bottom of the reclaimer element before it enters the air-end.

19. FILTER MANIFOLD 2

Oil to air end

Oil from cooler

1

3 Oil Scavenge return to Air End and NRV

Air to air cooler Air/oil inlet 8 4 7

HW 0301

1. 2. 3. 4.

6

Control Air Isolating Valve Unloader Solenoid Valve Minimum Pressure Valve Separator Filter Qty 2 on L45SR

5. 6. 7. 8.

5

Differential Pressure Gauge (primary position) Differential Pressure Gauge (secondary position) Oil Filter Oil Drain Valve

FIG. 6.20 FILTER MANIFOLD 19.1 Description A cast aluminium filter manifold is screwed to the bulkhead panel to provide ease of maintenance for the serviceable components.

Primary and secondary connections are provided for the gauge which measures the differential pressure across the separator filter element.

The manifold is ported and machined to provide a housing for the separator filters, oil filter, scavenge pipe, minimum pressure valve and differential pressure gauge.

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

Chapter 6, page 22

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20.1 Description The purpose of the oil stop valve is to prevent any oil entering the air-end when the compressor is stopped. The oil stop valve is fitted at the oil inlet to the airend and comprises a valve body (1) and cover (2), incorporating a diaphragm assembly (3), spindle (6) and valve head (5). The valve head is fitted with a return spring (4) and operates against a seat (7) in the valve body.

20.2 Operation 1. Body 2. Screen 3. Cap FIG. 6.21 CONDENSATE STRAINER

20.

OIL STOP VALVE (475SR, L75SR) 2

1

Discharge air pressure from the air-end acts on the diaphragm to open the oil stop valve against the spring during start up and holds it open while the compressor is running. When the compressor stops this pressure falls to zero allowing the return spring to close the valve.

3

6 5

HW 0303

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

4

7

Valve Body Cover Diaphragm Assembly Spring Valve Head Spindle Seat

6.22 OIL STOP VALVE (475SR, L75SR

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Chapter 6, page 23

CompAir

21.

PRESSURE TRANSMITTER (L45SR, L75SR)

4 to 20mA 1

+

2

-

X02-1

X02-2 4-20 mA PRESSURE TRANSMITTER HW 0304

24V D.C.

DETECTION CIRCUITRY

0V D.C.

CONTROLLER

FIG. 6.23 PRESSURE TRANSMITTER 21.1 Description The air pressure in the user’s pipework is continuously monitored by a 4-20 mA pressure transmitter which converts the pressure into an electrical signal. 21.2 Operation The transmitter converts air pressure into a linear change of electrical current flowing in the two power supply wires to the transmitter. Typically, the current will change from 4 mA at zero bar to 20 mA at 13·8 bar (L45SR, L75SR) or 4 mA at zero bar to 20 mA at 16 bar (L120SR).

Chapter 6, page 24

The controller detects the current flowing in the power supply wires to the transmitter and converts this into a pressure reading. The controller can recognise an ‘out of range’ signal if the current is less than 4 or greater than 20mA. This will be displayed as a pressure probe fault. Refer to the table in chapter 8 para. 6.0

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LSR Repair Manual – Components

22.

SILICON TEMPERATURE SENSOR

HW 0305

23.

DRIVE AND FAN MOTOR THERMISTORS

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

23.1 Description

1

2

The drive and fan motors are each equipped with thermistors of the PTC type which are buried in the windings to protect the compressor against motor over-temperature.

S 23.2 Operation

3 1. 2. 3.

Probe Body Electrical Connectors

If the temperature of the coil windings exceeds a set temperature, the resistance of the thermistor will increase sharply. The sudden increase in resistance will be detected by the controller, causing the compressor to shut down and display a motor fault.

FIG. 6.24 SILICON TEMPERATURE SENSOR 24.

DELIVERY NON-RETURN VALVE (475SR, L75SR)

22.1 Description 2

A silicon temperature sensor of the ‘spreading resistance’ type is installed in the air-end adjacent to the delivery port. The sensor protects the compressor unit against excessive discharge temperature by sensing the temperature of the compressed air/oil mixture discharged from the airend. The resistance of the sensor increases with temperature

3 1 11

10

22.2 Operation The resistance of the temperature sensor is processed within the controller and displayed as an air/oil temperature reading. A high oil temperature warning and/or compressor shut-down is activated if the temperature of the air/oil mixture reaches the trip setting.

9

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

8

7

6 5

Body Cover 'O' Ring Valve Head 'O' Ring Washer

4

7. 8. 9. 10. 11.

HW 0306

Locknut Retainer 'O' Ring Guide Pin Spring

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

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Chapter 6, page 25

CompAir

24.1 Description The non-return valve is mounted on the discharge outlet of the air-end. Its function is to isolate the airend from reclaimer pressure when the compressor is stopped. This prevents oil from being blown back through the air-end after stopping and ensures that the air end always re-starts in the unloaded condition. The non-return valve consists of a valve body (1) and cover (2) sealed by an 'O' ring (6) and a valve assembly. The valve assembly comprises a guide pin (10) and spring (11), a valve head (4) with 'O' ring seal (9) and retainer (8), secured by a washer (6) and locknut (7). An 'O' ring (5) provides a seal between the valve head and the guide pin. Two studs secure the flange of the discharge pipe.

24.2 Operation When the compressor is running and the pressure in the reclaimer is below the discharge pressure of the air-end the non-return valve is held open. When the discharge pressure of the air-end falls, a condition is reached where pressure on each side of the non-return valve is the same. The valve spring will then lift the valve head and close it against the seat. Reclaimer pressure will hold the valve closed until air-end pressure rises to overcome the effect of reclaimer pressure and the valve spring.

25.

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

Body Inlet Port Valve Spring Solenoid Coil 'O' Ring (not illustrated)

FIG. 6.26 BY-PASS VALVE 25.2 Description (L120SR) The by-pass valve comprises a valve body (1), valve (3), solenoid coil (5), spring (4) and ‘O’ Ring seal (6). The function of the valve is to re-circulate air produced by the air-end when the compressor is running off-load at minimum speed. The by-pass valve is a solenoid operated, normally open, valve mounted on the reclaimer lid. The outet port is linked to the non-return valve by a flexible hose.

BY-PASS VALVE 25.3 Operation

25.1 Description (L45SR, L75SR) The by-pass valve comprises a valve body (1), valve (3), solenoid coil (5), spring (4) and ‘O’ Ring seal (6). The function of the valve is to re-circulate air produced by the air-end when the compressor is running off-load at minimum speed. The by-pass valve is a solenoid operated, normally open, valve mounted on the air-end inlet connector (L75SR) or on the intake NRV (L45SR). The inlet port (2) is linked to the reclaimer cover by a pipe.

Chapter 6, page 26

During normal running, when the delivery pressure is below the programmed off-load pressure, the solenoid is energised and the by-pass valve is held closed. If delivery pressure rises above the offload pressure the valve solenoid is de-energised and the by-pass valve is opened. Delivered air volume then falls to zero. If delivery pressure falls below the target pressure the solenoid is energised allowing delivered air volume to rise and reclaimer pressure to build up again towards the target pressure.

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LSR Repair Manual – Components

26.

INLET NON-RETURN VALVE (345SR, L45SR)

When the compressor is stopped the valve head returns to its seat and prevents the air/oil mixture from blowing back through the air intake.

27.

INLET NON-RETURN VALVE (L120SR)

27.1 Description The non-return valve is mounted on the air end inlet and secured by 4 screws. A pipe connected to the air intake filter is secured to the inlet of the valve with a jubilee clip. The inlet non-return valve consists of a body (1) with an integral seat and a valve assembly comprising a valve head (2), valve stem (3) and spring (5). The valve stem is secured to the body by an external domed nut (7). 27.2 Operation 1. Body 2. Valve Seat 3. Valve Head

4. Retaining Bar 5. Valve Stem 6. Spring

See section 26.1.

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

8

9

4

1 2

6

26.1 Description 7

The non-return valve is mounted on the air-end inlet and secured by four screws. A pipe connected to the air intake filter is secured to the top of the valve by a clip. The inlet non-return valve consists of a valve body (1) with an integral seat (2) and a valve assembly. The valve assembly comprises a valve head (3), spring (6) and a valve stem (5) with retaining bar (4). The retaining bar secures the valve assembly to the valve body using two screws.

26.2 Operation When the compressor starts the depression created by the turning rotors causes a partial vacuum at the intake which lifts the valve head off the seat against the light load of the spring. This allows air to be drawn through the air-end to pressurise the separator vessel.

AC20160-1822, Issue 1, November 2002

3

5 HW 0309

1. 2. 3. 4. 5.

Body Air Inlet Valve Stem Bush Spring

6. 7. 8. 9.

Washer Nut Washer Plug

FIG. 6.28 INLET NON-RETURN VALVE (L120SR)

Chapter 6, page 27

CompAir

28.

BEKO DRAIN (L120SR)

29. SCAVENGE NRV ASSEMBLY (L120SR)

28.1 Description

HW 0312 FIG. 6.30 SCAVENGE NRV ASSEMBLY (L120SR) 29.1 Description The scavenge NRV assemble is located in the lid of the reclaimer. It consists of a scavenge pipe braised to a coupling with a steel ball placed within the coupling and then a scavenge NRV swivel elbow screwed into the top of the coupling. HW 0311

FIG. 6.29 BEKO DRAIN (L120SR) The Beko drain is positioned by the delivery side cooler column. A pipe from the moisture separator is connected to the inlet of the drain. A pipe from the outlet of the drain is then connected to the discharge end column via a bulkhead coupling which is the customer’s condensate connection.

29.2 Operation When the machine is running the ball inside the scavenge moves up in the coupling and acts as a restrictor to the scavenge line but allows the oil to flow back down in to the air-end. Upon stopping of the compressor the ball drops down and acts as an NRV to the oil in the scavenge line.

28.2 Operation The condensate accumulates in the container. A capacitive sensor registers when the container is totally filled. It then passes a signal to the electronic control within the valve to activate. The pilot valve is activated which opens the diaphragm on the outlet line. Every time the condensate is discharged the time the valve is opened is calculated exactly to ensure minimum compressed air wastage.

Chapter 6, page 28

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

CHAPTER

7 MAINTENANCE

1. 1.1 1.2 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16

MAINTENANCE SCHEDULE Service Kit Part Numbers Oil Drain Kit (475SR, L75SR, L120SR) MAINTENANCE PROCEDURES Enclosure Filter Control Panel Filter Air Intake Filter Oil Separator Filters (345SR, L45SR) Reclaimer (475SR, L75SR, L120SR) Reclaimer Element (475SR, L75SR, L120SR) Scavenge Strainer (475SR, L75SR if fitted) Automatic Condensate Drain (475SR, L75SR) Oil System Minimum Pressure Valve Oil Cooler and Aftercooler Flexible Hoses Scavenge Tube Electrical System Electric Motors Non-return Valve

FIGURES FIG. 7.1 FIG. 7.2 FIG. 7.3

GENERAL ARRANGEMENT AND SERVICING POINTS (345SR, L45SR) GENERAL ARRANGEMENT AND SERVICING POINTS (475SR, L75SR) GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

AC20160-1822, Issue 1, November 2002

Chapter 7, page 1

CompAir

MAINTENANCE 1.

MAINTENANCE SCHEDULE

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

Item

Action

Weekly

Oil System Separator/Reclaimer Element(s)

Aftercooler/Oil cooler/Control Panel

Check oil level. Top up if necessary. Check element(s). Renew if: (345SR, L45SR) - pressure differential exceeds 1 bar. (475SR, L75SR) - indicator in red zone. (L120SR) - message on screen. Check condition of pre-filters and clean as necessary.

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

Minor Service Oil System Blowdown System Electrical Wiring Drain Solenoid Valve Control Panel Aftercooler and Oil Cooler Oil Filter Air Filter Electrical Cabinet Filters

Use correct Service kit for model. Check oil level/top up. Check operation. Check connections and condition. Check operation (475SR, L75SR only). Check connections Clean externally Renew Oil Filter. Renew Air Filter (345SR, L45SR, 475SR, L75SR). Check and clean heatsink ducting if necessary.

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

Service Oil system Separator Filters Air Filter (L120SR)

Chapter 7, page 2

Carry out Minor Service. Change oil. Renew Separator Filters/Reclaimer Element. Renew Air Filter.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

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

Major Service Service Minimum Pressure Valve Non-return valve Motor Drive Air Pipe Couplings Condensate Auto Drain Valve Blowdown Valve Scavenge Tube

1.1

1.2

Use correct Major Service Kit for model Carry out Interim Service. Service valve (not L120SR). Service valve (not L120SR). Check condition of flexible coupling inserts. Fit new inserts if necessary. Renew ‘O’ rings. Service valve. (L120SR only). Renew. Renew.

Service Kit Part Numbers

MODEL

Minor Service Kit (2000 hrs or 6 mths)

Interim Service Kit (4000 hrs or 1 yr)

Major Service Kit (8000 hrs or 2 yrs)

345SR, L45SR

CK2003 - 2

98262-223 (2)

CK8003 - 4

475SR, L75SR

CK2004 - 2

CK6004 - 197

CK8004 - 5

L120SR

CK2007 - 1

CK6007-1

CK8007-1

Oil Drain Kit (457SR, L75SR) Part number C27399-173

AC20160-1822, Issue 1, November 2002

Chapter 7, page 3

CompAir

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil Cooler Cooling Fan Intake Air Filter Non-return Valve Cyclon 3 Air-end SR Drive® Motor Separator Element Oil Filter Air Delivery Connection Minimum Pressure Valve

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Aftercooler Inlet Air Flow Inlet Air Baffle Inlet Air Pre-filter Primary Separator Control Panel Pressure Relief Valve Oil Filler Cap Cooling Air Exhaust Flow Exhaust Air Baffle Control Panel Filter

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

Chapter 7, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil Filters Minimum Pressure Valve Air/Oil Separator Pressure Relief Valve Oil Filler Cap Intake Air Filter Oil Sight Tube Air-End Intake Oil Drain Valve Air-End

11. 12. 13. 14. 15. 16. 17. 18. 19.

SR Drive® Motor Cooling Air Inlet Cooling Fan Moisture Separator Air Delivery Connection Air and Oil Cooler Exhaust Air Baffles Control Panel Control Panel Filter

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

AC20160-1822, Issue 1, November 2002

Chapter 7, page 5

CompAir

1

2

3

4 5 6 12 7

8

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

Exhaust Duct Inlet/Non-Return Valve Aftercooler Oil Filters Safety Valve Oil Cooler Moisture Separator Condensate Drain Valve Air End Drive Coupling Access SR Drive® Motor Power Converter Cabinet Filters

9 10 11

14

13

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

15

Minimum Pressure Valve Blowdown Solenoid Valve Cooling Fan Control Panel 23 Intake Air Filter Fork Lift Points Oil Filler Air/Oil Separator Oil Level Sight Glass 22 Oil Drain Cooling Air Inlet Grille

16

17

21

20

19

HW 0016

18

FIG. 7.3 GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

Chapter 7, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

2.

MAINTENANCE PROCEDURES

WARNING !

Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit.

!

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

!

Before opening the door of the power converter compartment switch the power supply OFF at isolator and wait for 12 minutes to allow the DC link capacitors discharge to a safe level. Check that the dc link capacitors have fully discharged before starting work on the compressor.

!

Where a maintenance procedure below includes the warning ‘The compressor must be stopped’ the following steps must be taken before work is commenced:

2.1

Enclosure Filter

The compressor is provided with a coarse screen filter which acts as a pre-filter for the intake air. Carry out a regular check on the condition of the pre-filter and if necessary remove the material from the enclosure and wash in a mild detergent solution before refitting.

2.2

1.

Close the shut-off valve to the user’s pipework.

2.

Switch the power supply ‘OFF’ at the isolator.

3.

Ensure that the blowdown system has operated to release all pressure from the reclaimer. Check that the pressure gauge registers zero. Release any remaining pressure from the delivery side of the reclaimer element by slackening the pipe connection to the differential pressure switch at the reclaimer end. Release any residual pressure from the upstream side of the reclaimer element by slowly slackening the oil filler plug on the reclaimer. Tighten the plug.

2.3

Air Intake Filter

Clean intake air is essential for satisfactory operation of the unit. Any ingress of unfiltered air will result in a reduction in the service life of the separator element. Particular care should be taken during routine servicing to ensure that unfiltered air cannot bypass the air intake filter element via unsound joints and defective trunking, etc.

Control Panel Filter L120SR only

Filters are provided to clean the cooling air for the power electronic circuits. These should be cleaned at specific intervals or before scheduled if ‘Heat sink temp high’ is displayed.

AC20160-1822, Issue 1, November 2002

A visual indicator is fitted which shows the condition of the filter. In dirty conditions this may indicate a reduction in element life.

Chapter 7, page 7

CompAir

2.3.1 To Change the Air Filter Element: 1

2

The compressor must be stopped. 1.

Remove the side panel or open the hinged door (according to model) to gain access to the intake air filter.

2.

Remove the clips from the air intake filter and withdraw the element.

3.

Clean out the inside of the filter body

3.

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

2.4

Oil Separator Filters (345SR, L45SR)

7

6

3

5

4

1 2 3 4

The separator filter has a nominal service life of 4000 hours under normal operating conditions. Adverse operating conditions or failure to carry out regular maintenance and/or correct operating procedures will affect the service life of the element.

2.4.1 To Check the Differential Pressure across the Separator Filters 1.

Ensure the compressor is running at working pressure and temperature.

2.

Open the access door to the service area.

3.

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

4.

345SR models: Using the bayonet fitting, change the pressure gauge over to the fitting on the other side of the manifold block and note reading.

5.

If the pressure difference exceeds 1 bar renew the separator filters.

Chapter 7, page 8

Manifold block Pressure gauges Separator filters Oil filter

HW 0046

5 Plug 6 Oil drain valve 7 Control air isolating valve

FIG. 7.4 MANIFOLD BLOCK AND FITTINGS (345SR, L45SR) 2.4.2 To Change the Separator Filters:

The compressor must be stopped. 1.

Open the door to the service area to gain access to the manifold block. Note: Models 345SR and L45SR have two separate filters both of which must be changed at the same time.

2.

Unscrew the old separator filters from the manifold block and discard the filters and sealing rings.

3.

Apply a light film of oil to the seal of the new filters.

4.

To fit the new filters, screw into the manifold block until the gasket contacts the sealing surface. Then tighten a further 1/3 turn.

5.

Close the service area door.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

2.5

Reclaimer (475SR, L75SR, L120SR)

Condensate will collect in the reclaimer as the compressor cools after shut-down and should be drained off at the intervals specified in the Schedule. Draining the condensate must be carried out only when the compressor is cold. CAUTION: Regular draining of condensate from the reclaimer is essential in order to avoid oil contamination and eventual problems in the user’s system

2.5.1 To Drain the Condensate

2.6

Reclaimer Element (475SR, L75SR and L120SR)

A filter element within the reclaimer recovers oil carried in the delivery air before it is passed to the aftercooler and the user’s pipework. The element has a maximum service life of 8000 hours. This figure is based on ideal operating conditions and if conditions are not ideal it will be necessary to change the element more frequently. The service life of the element can be prolonged by carrying out regular maintenance and correct operational procedures, but must always be changed after 8000 hours.

The compressor must be stopped.

2.6.1 To Check the Differential Pressure Across the Reclaimer.

To drain the condensate from the reclaimer, slowly crack open the reclaimer drain point (1) until condensate starts to flow out. As soon as the flow becomes clear oil, close off the drain.

475SR, L75SR 1.

Ensure the compressor is running at working pressure and temperature.

2.

Open the hinged access door.

3.

The needle of the Differential Pressure indicator should be in the green zone of the scale.

4.

If the needle is in the red zone, renew the reclaimer element.

NB. At service intervals the controller will display ‘Check Reclaimer DP’ warning which will be reset when the service hours are reset. L120SR

1 HW 0017

FIG. 7.5 RECLAIMER CONDENSATE DRAIN

A lamp lights on the panel and the message ‘Change separator’ is displayed when the reclaimer element is blocked. 2.6.2 To Change the Reclaimer Element

The compressor must be stopped. If the compressor is operating in conditions of high humidity experience may show that it is necessary to drain the condensate more frequently than specified.

AC20160-1822, Issue 1, November 2002

1.

Open the hinged access doors and/or roof panel to gain access to the reclaimer.

2.

Drain the oil from the reclaimer. This procedure is described under 2.9.5 ‘Normal Oil Change’.

3.

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

Chapter 7, page 9

CompAir

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

3 2

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

1

Discard the old joint and element.

4

5

1. 2. 3. 4. 5.

6.

Inspect the underside of the reclaimer cover. The cover has been treated and should be in good condition. If not, remove any loose paint or rust by shot blasting or wire brush treatment to leave a clean, oil free surface. Apply one coat of zinc phosphate paint, ensuring complete coverage to a minimum thickness of 0·1 mm (0.004”). Allow to dry thoroughly.

7.

Fit the new element and joint and replace the cover (the L120SR joint is glued to the element). Replace all the reclaimer cover bolts and tighten by hand to position the joint correctly.

8.

Tighten the bolts evenly, following the tightening sequence, to an initial torque of 110 Nm / 81 ft.lbf. Check the ‘O’ ring

9.

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

HW 0018

Scavenge pipe Air discharge pipe Minimum pressure valve Cover Jacking holes FIG. 7.6 OIL RECLAIMER

4.

Disconnect couplings and remove the air discharge pipe from the minimum pressure valve.

5.

Release the reclaimer cover securing bolts and remove the cover. If necessary, use three of the cover bolts in the jacking holes and tighten down to break the seal. Withdraw the reclaimer element. Discard the old joint and element.

HW 0313

FIG. 7.7 RECLAIMER ELEMENT

Chapter 7, page 10

FIG. 7.8 RELAIMER COVER BOLT TIGHTENING SEQUENCE (475SR, L75SR)

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

2.7.1 To Clean the Scavenge Strainer 7

The compressor must be stopped.

1 9

13

6

3

12 4 10

14 2

8

HW 0021

FIG. 7.9 RECLAIMER COVER BOLT TIGHTENING SEQUENCE (L120SR) Insert the scavenge pipe through the coupling in the reclaimer cover and lower it carefully until it contacts the base of the element. Withdraw the pipe a distance of 3 mm (1/8”) and tighten the coupling. The couplings are fixed length on the L120SR model.

11.

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

12.

Refill the compressor with new oil by following the procedures under 2.9.5 ‘Normal Oil Change’. Close the access doors and refit the enclosure panels.

CAUTION: When the compressor has reached normal operating temperature, re-tighten the bolts to the correct torque in the sequence shown.

2.7

2.

Remove the strainer screen and clean it thoroughly, using a proprietary cleaning agent.

3.

Refit the clean strainer screen.

2.8

Automatic Condensate Drain (475SR, L75SR, L120SR)

16 5

13.

Remove the scavenge strainer.

11

15

10.

1.

Moisture in the delivery air condenses in the aftercooler or moisture separator and is drained automatically by the action of a solenoid operated valve (L75SR) or level control valve ((L120SR).

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

The compressor must be stopped. Disconnect the users condensate drain connection at the baseframe and connect a length of tubing to the base frame connection. Run the tubing to a suitable container and visually check that condensate is being released automatically from the solenoid operated drain valve according to the ‘drain open’ and ‘drain shut’ times set at the controller. If no condensate is being released check the electrical circuit and the solenoid valve as described in the ‘Electrical’ section of the manual. Dispose of any condensate in accordance with local regulations. Reconnect the condensate drain line to the compressor. The L120SR model displays a level controlled fault signal on the panel if the valve is not functioning correctly. Maintenance should be carried out by a CompAir Distributor.

Scavenge Strainer (475SR, L75SR)

If the scavenge strainer becomes restricted or blocked it may cause oil to be carried over into the user’s pipework. It is most important that the strainer is regularly serviced to allow the scavenge system to operate correctly.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 11

CompAir

2.9

Oil System

2.9.1 Recommended Oil The compressor is factory filled with CompAir 4000 HR Oil or CompAir FG Lubricant. 1.

2.

2

CompAir 4000 HR Oil This is a high performance oil with excellent lubrication and cooling characteristics formulated to maintain internal cleanliness, reduce the build-up of deposits on filter elements and extend component life. CompAir FG Lubricant A synthetic hydrocarbon based lubricant which has been specially developed for use where discharge air may come into contact with foodstuffs or for reasons of health or environment. CompAir FG Lubricant meets the requirements of FDA regulation 21 CFR 178.3570 and is USDA H-1 approved.

The local CompAir distributor will assist in the selection of an appropriate lubricant and in many cases will also be able to arrange for regular sampling of the oil to monitor the condition of the compressor, and to determine the oil change intervals to ensure optimum performance.

1

HW 0022

FIG. 7.10 CHECKING OIL LEVEL (345SR, L45SR) If necessary top up the separator with oil as follows:

WARNING ●

Risk of injury from hot oil under pressure.

The compressor must be stopped.

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

1.

Remove the side panel.

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

2.

Unscrew the filler plug (2).

3.

Fill to the correct level with CompAir approved lubricant.

4.

Refit the filler plug and tighten by hand.

5.

Refit side panel.

When stopped the mimimum level is indicated when the sightglass is less than half full. The maximum level is indicated when the sightglass is full and the oil reaches the bottom threads in the filler neck. When running on-load the minimum level is indicated when oil is no longer visible in the sightglass.

Chapter 7, page 12

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

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

2.9.4 To Change the Oil Filter:

The compressor must be stopped. 2.9.3 To Check the Oil Level (475SR, Tornado 75, L75SR, L120SR) With the compressor shut down, the minimum oil level is indicated when the level is just visible in the oil level tube on the reclaimer. The maximum level is indicated when the level reaches the top of the oil level tube.

1.

Open the door to the service area or open the enclosure according to model.

2.

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

HW 0024

The compressor must be stopped. Note: Check the oil level with the compressor cold. Allow a minimum of 30 minutes after stopping for the oil in the system to settle. 1.

Open the enclosure to gain access to the reclaimer.

2.

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

2 1

3 3 Oil filters FIG. 7.12 OIL FILTERS (L75SR, L120SR) 3.

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

4.

To fit the new element, screw it into the manifold block or filter housing until the gasket contacts the sealing surface. Then tighten a further 1/3 turn.

5.

Close the service area door.

6.

Check oil level during initial run and top up if necessary.

HW 0023

1. Sight glass 2. Filler plug FIG. 7.11 CHECKING OIL LEVEL (475SR, L75SR, L120SR) 3.

4.

If topping up is required, ensure that the reclaimer pressure is zero, remove the oil filler plug (2) and fill the reclaimer with recommended oil to the correct level. Replace the oil filler plug, making sure that the ‘O’ ring is undamaged and the plug fully tight.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 13

CompAir

2.9.5 Normal Oil Change 1

2

CAUTION: Always use the correct grade of oil and do not mix oils of different types. 1.

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

7

Where the air-end discharge temperature regularly exceeds 85°C then a change period of 2000 Hours or 6 months is recommended. 2.

6

3

5

CompAir FG Lubricant Provided the air-end discharge temperature does not regularly exceed 85°C CompAir FG Lubricant should be changed every 4000 hours service or 1 year, whichever is sooner.

4

1 2 3 4

Where the air-end discharge temperature regularly exceeds 85°C then a change period of 2000 Hours or 6 months is recommended.

HW 0046

Manifold block Pressure gauges Separator filters Oil filter

5 Plug 6 Oil drain valve 7 Control air isolating valve

Note: Where high dust levels and/or pollution are present the oil must be changed more frequently and the condition of the intake filtration system examined regularly.

4.

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

Stop the compressor. Wait until the motor has stopped rotating before proceeding.

5.

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

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

To drain the oil, the system must (a) be pressurised or (b) an alternative source of compressed air must be available. CAUTION: Always use the correct grade of oil and do not mix oils of different types. Method (a) 1.

Run the compressor on load to pressurise the system.

2.

Open the door to the service area.

3.

Close the control air isolating valve (7), fitted to the side of the manifold block (lever to the vertical position) and the isolating valve in the user's system.

Note: A minimum of 4 bar (60 psi) must be maintained in the compressor unit prior to carrying out the oil drain procedure.

Chapter 7, page 14

WARNING ●

Risk of injury from hot oil under pressure.

6.

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

7.

Close the drain tap, disconnect the hose, and remove the container. Refit the drain tap plug.

8.

Open the control air isolating valve (7) (lever to the horizontal position) and allow any pressure to be released through the normal blowdown process.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

9.

Remove and discard the old oil filter element (4).

10.

Prime the new filter with oil.

11.

Apply a film of clean oil to the seal of a new oil filter element. Screw the element into the housing until it contacts the gasket and tighten a further 1/3 turn.

8.

Close the air supply through the filler tube, open the control air isolating valve (lever to the horizontol position) and allow any pressure to be released through the normal blowdown process.

9.

Remove the air supply and fitting from the filler tube.

10. Fill the separator to the correct level with CompAir approved lubricant, refit the filler cap and tighten by hand.

Remove and discard the old oil filter element (4).

11.

Prime the new filter with oil.

13.

Open the isolating valve to the user's system.

12.

14.

Run the compressor until it reaches working temperature to ensure full circulation of the oil.

Apply a film of clean oil to the seal of a new oil filter element. Screw the element into the housing until it contacts the gasket and tighten a further 1/3 turn.

15.

Check the oil level and top up as necessary.

13.

Fill the separator to the correct level with CompAir approved lubricant, refit the filler cap and tighten by hand.

12.

Method (b) 1.

Open the door to the service area.

14.

Open the isolating valve to the user’s system.

2.

Close the control air isolating valve, fitted to the side of the manifold block (lever to the vertical position) and the isolating valve in the user's system.

15.

Run the compressor until it reaches working temperature to ensure full circulation of the oil.

16.

Check the oil level and top up as necessary.

3.

Ensure that all pressure has been released from the oil separator, remove the filler plug and fit a suitable connector to the neck of the filler pipe for the air supply.

4.

Apply pressure to the compressor unit (minimum of 4 bar or 60 psi).

5.

Remove the plug and connect a hose (minimum 10 mm / 3/8” bore) to the drain tap and place the open end into a suitable container.

WARNING ●

Risk of injury from hot oil under pressure.

6.

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

7.

Close the drain tap, disconnect the hose and remove the container. Refit the drain tap plug.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 15

CompAir

To Change the Oil and Oil Filter: (475SR, L75SR)

5.

Remove the plug and connect the Oil Drain Pipe Kit and a hose (minimum 15 mm / 5/8” bore) to the drain tap and place the open end into a suitable container.

6.

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

To drain the oil, the system must be pressurised. CAUTION: Always use the correct grade of oil and do not mix oils of different types.

The compressor must be stopped.

WARNING ●

Risk of injury from hot oil under pressure.

1.

Open the door to the service area

2.

Close the control air isolating valve (fitted to the top of the reclaimer) (fitted on the top of the air-end).

1 HW 0017

1 FIG. 7.15 OIL DRAIN TAP (475SR, L75SR)

2

7.

Close the reclaimer drain tap, disconnect the Oil Drain Pipe Kit and hose, remove the container and refit the plug.

8.

Open the control air isolating valve and allow any pressure to be released through the normal blowdown process.

9.

Remove and discard the old oil filter elements.

10.

Apply a film of clean oil to the seal of a new oil filter elements. Screw the elements into the housing until they contact the gasket and tighten a further 1/3 turn.

11.

Fill the reclaimer to the correct level with CompAir approved lubricant, refit the filler cap and tighten securely.

12.

Open the isolating valve to the user's system.

13.

Run the compressor until it reaches working temperature to ensure full circulation of the oil.

14.

Stop the compressor, check the oil level and top up as necessary.

3

HW 0026

1. Control air isolating valve 2. Air end 3. Intake air filter FIG. 7.14 CONTROL AIR ISOLATING VALVE (475SR, L75SR) 3.

4.

Run the compressor for a short time to pressurise the reclaimer to a minimum of 4 bar (60 psi) prior to carrying out the oil drain procedure. Stop the compressor and close the isolating valve between the compressor and the user system. Ensure that the reclaimer drain tap is closed.

Chapter 7, page 16

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

To Change the Oil and Oil Filter: L120SR

4.

Ensure that the reclaimer and oil cooler drain taps are closed.

To drain the oil, it is recommended that the system be pressurised. However, the L120SR may be also drained under gravity.

5.

Put reclaimer and cooler drain hoses into a container, open taps and allow oil to drain.

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

HW 0027

1

The compressor must be stopped. 2

WARNING ●

Risk of injury from hot oil under pressure.

1.

Open the door to the service area

2.

Close the control air isolating valve (painted red and fitted to the top of the reclaimer).

1

1. Reclaimer oil drain 2. Oil cooler drain

FIG. 7.17 OIL DRAIN POINTS (L120SR) 6.

Close the reclaimer and cooler drain taps, replace the hoses and remove the container.

7.

Open the control air isolating valve and allow any pressure to be released through the normal blowdown process.

8.

Remove and discard the old oil filter elements.

9.

Apply a film of clean oil to the seal of the new oil filter elements. Screw the elements into the housing until they contact the gasket and tighten a further 1/3 turn.

10.

Fill the reclaimer to the correct level with CompAir approved lubricant, refit the filler cap and tighten securely.

11.

Open the isolating valve to the user's system.

12.

Run the compressor until it reaches working temperature to ensure full circulation of the oil.

13.

Stop the compressor, check the oil level and top up as necessary.

HW 0025

FIG. 7.16 CONTROL AIR ISOLATING VALVE (L120SR) 3. The oil may be drained under pressure or by gravity. To drain under pressure, run the compressor up to 7 bar/102 lbf/in2 and stop. Immediately open access door and close hand valve adjacent to blowdown (see illustration), then proceed as for gravity drain. Beware of hot surfaces. Beware of hot pressurised oil. On completion, open blowdown hand valve.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 17

CompAir

2.9.6 To Change the Oil Type

4.

No special precautions are required when changing from a detergent mineral oil to CompAir 4000 HR Oil or CompAir FG Lubricant or changing within these grades. The system should be drained and refilled as described under 2.9.5 ‘Normal Oil Change’.

L120SR: Clean cooler fins using low pressure air or water as follows. (a) Remove cooler end panel and both side panels. (b) Open access doors as necessary and clean coolers from inside the plant using low pressure air (up to 2 bar / 29 lbf/in2) or water. Don not use excessive pressure as cooler tubes may be damaged.

2.10 Minimum Pressure Valve 5.

Remove any dirt or liquid from the baseframe.

The servicing of the Minimum Pressure Valve should be carried out by a CompAir Distributor. (See Section 9.)

6.

Replace access and enclosure panels and close door(s).

2.11 Oil Cooler and Aftercooler

The servicing of the Oil and After Coolers should be carried out by a CompAir Distributor. (See section 9.)

To Clean Coolers Externally The condition of the cooler fins must be checked regularly. To clean the fins proceed as follows:The compressor must be stopped 1.

Allow the compressor to cool for 30 minutes.

2.

345SR, L45SR: Open enclosure service door and remove access panel on cooling duct. Remove enclosure panel in front of coolers. Clean the cooler fins from inside the duct using an air hose and oil-free compressed air from inside the machine.

3.

2.12 Flexible Hoses When fitting flexible hoses the nuts should be tightened using the torque appropriate to the nut sizes. BSP Size

Torque

0.5 in 0.75 in 1.0 in 1.25 in 1.5 in 2.0 in

44 Nm/32 ft.lbf 84 Nm/62 ft.lbf 115 Nm/85 ft.lbf 189 Nm/139 ft.lbf 244 Nm/180 ft.lbf 297 Nm/219 ft.lbf

If it is required to wash the coolers, they must first be removed from the machine.

2.13 Scavenge Tube

475SR, L75SR:

The translucent tube should be changed at the 8000 hour service interval.

Clean cooler fins with an air hose as follows: (a) Ensure power is isolated and locked off. (b) Remove fan guard and use low pressure air to clean coolers from inside the machine. (c) Replace fan guard. (d) Replace panels. If it is required to wash the coolers, they must first be removed from the machine.

Chapter 7, page 18

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Maintenance

2.14 Electrical System

2.15 Electric Motors 2.15.1 Motor Bearings

WARNING !

Refer to the safety procedures before operating the compressor unit.

!

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

The main drive motor and cooling fan motor are fitted with sealed bearings which are double shielded and pre-packed with grease. These bearings do not require periodic re-lubrication but should be renewed after 32000 hours of operation in normal environments. Note: This work should be carried out by a CompAir distributor. (See section 9.) 2.15.2 Motor Cooling

!

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting work on the compressor.

Ensure that the motor cooling intake grille is kept clear of debris at all times.

2.16

Non-Return Valve

The servicing of the Non-Return Valve should be carried out by a CompAir Distributor. (See section 9.)

Carefully inspect all the electrical wiring and check the security of all connections and terminals

AC20160-1822, Issue 1, November 2002

Chapter 7, page 19

CompAir

This page is intentionally left blank

Chapter 7, page 20

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Electrical Systems

CHAPTER

8 ELECTRICAL SYSTEMS AND FAULT DIAGNOSIS

CONTROL SYSTEM 1.

CONTROLLER

ELECTRICAL SYSTEM 1. 1.1 1.2 1.3 1.4 1.5 1.6

REMOTE CONTROL AND MONITORING CONNECTIONS Inputs Configurable Input Functions Outputs Configurable Output Functions 4–20mA Compressor Speed Output RS485 Communications

FAULT DIAGNOSIS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2. 2.1 3. 3.1 3.2 4. 4.1 4.2 5. 5.1 6. 6.1 6.2

TEST EQUIPMENT Test Meter Clip-on Ammeter Insulation Tester DC Voltage Generator IGBT Tester Slave Air Supply Inductance Tester CAGE-CLAMP SCREWLESS TERMINALS Cable Connection or Removal POWER SUPPLIES To Check the 24V ac Supply Circuits To Check the Main Power Supply CONTROL INPUTS To Check the Air Filter Differential Pressure Switch To Check the Emergency Stop Circuit CONTROL OUTPUTS Relay Output (connector XO8) SENSORS To Check the Pressure Sensor To Check the Air/oil Temperature Sensors

Continued

AC20160-1822, Issue 1, November 2002

Chapter 8, page 1

CompAir

Contents (Continued) 7. CONTROLLER 7.1 Application Control Program IC 7.2 Motor Drive Program IC 7.3 FPGA Data IC 8. SR FAULT LOCATION 8.1 SR Current Sensor Fault 8.2 SR Motor High Temperature Fault 8.3 SR Motor Overcurrent 8.4 DC Link High Voltage Fault 8.5 DC Link Low Voltage Fault 8.6 SR Position Sensor Fault 8.7 SR Motor Overspeed Fault 8.8 SR Motor Stall Fault 8.9 DC Link Charge Fault 8.10 Heatsink Temperature Sensor Fault 8.11 Heatsink High Temperature Fault 8.12 Main Contactor Fault 8.13 SR Control Power Fault 8.14 Internal Comms Fault 8.15 SR PCB Internal Fault 8.16 Start Inhibit 8.17 SR Fault Location Charts 9. SR TEST PROCEDURES 9.1 Diode Device Test Procedures 9.2 IGBT (Insulated Gate Bipolar Transistor) 9.2.1 Dual IGBT (Insulated Gate Bipolar Transistor) 9.2.2 Latest Semikron IGBTs 9.2.3 IGBT Removal and Fitting Instructions 9.3 Electrolytic Capacitor Test Procedures 9.3.1 Electrolytic Capacitor Test 9.3.2 Electrolytic Capacitor Measurement 9.3.3 Capacitor Removal and Refiiting Instructions 9.4 To Check Capacitor Bank Voltage Imbalance 9.5 To Check Capacitor Bank Balance Resistors 9.6 To Check VDR/Resistor Board (L45SR and L75SR) 9.7 To Check the SR Motor 9.7.1 Motor Insulation Test 9.7.2 Motor Inductance Test

Chapter 8, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Control System

Contents (Continued) FIGURES FIG. 8.1 FIG. 8.2-8.4 FIG. 8.5-8.7 FIG. 8.8-8.10 FIG. 8.11-8.13 FIG. 8.14-8.17 FIG. 8.18 FIG. 8.19 FIG. 8.20 FIG. 8.21 FIG. 8.22 FIG. 8.23 FIG. 8.24-8.25 FIG. 8.26 FIG. 8.27-28 FIG. 8.29-30 FIG. 8.31 FIG. 8.32 FIG. 8.33 FIG. 8.34 FIG. 8.35 FIG. 8.36 FIG. 8.37 FIG. 8.38 FIG. 8.39

CONTROL PANEL ELECTRICAL CONNECTION DIAGRAM 345SR, L45SR ELECTRICAL CONNECTION DIAGRAM 475SR, L75SR ELECTRICAL CONNECTION DIAGRAM L45SR WITH POWER FAIL RELAY ELECTRICAL CONNECTION DIAGRAM L75SR WITH POWER FAIL RELAY ELECTRICAL CONNECTION DIAGRAM L120SR CABLE CONNECTION OR REMOVAL AIR FILTER INDICATOR SWITCH (L120SR) MEASURING THE PRESSURE SENSOR CURRENT PRESSURE SENSOR OUTPUT TABLE TEMPERATURE SENSOR RESISTANCE TABLE ARRANGEMENT OF CONTROLLER CARDS SR CURRENT SENSOR FAULT SR MOTOR OVERCURRENT FAULT DC LINK HIGH VOLTAGE FAULT DC LINK LOW VOLTAGE FAULT SR MOTOR STALL FAULT DC LINK CHARGE FAULT CONNECTING TESTER TO IGBT TYPE GAL CONNECTING TESTER TO IGBT TYPE GAR CIRCUIT OF IGBT TYPE GAL CIRCUIT OF IGBT TYPE GAL L45SR POWER CONVERTER ASSEMBLY L75SR POWER CONVERTER ASSEMBLY L120SR POWER CONVERTER ASSEMBLY

AC20160-1822, Issue 1, November 2002

Chapter 8, page 3

CompAir

CONTROL SYSTEM 1.

CONTROLLER

A gate drive board isolates the microelectronics in the control unit from the power electronic circuits and provides monitoring and protection for the four insulated gate bi-polar transistor (IGBT) power switches. The IGBTs are used to turn the motor phases on and off and, in conjunction with the electronic controller, to control the motor phase current and in turn the torque and speed of the SR motor.

The microprocessor based compressor controller and the SR Drive® controller are housed in a single control unit which also contains the operator keypad and displays. The control unit is mounted on the door of the control panel.

1

2

3

4

5

6

7

8

9

10

11

12

13 14

15

HW 0012

Bar PSI

31 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

30

29

28

27

Bar Units Indicator Psi Units Indicator Delivery Pressure Display Status and Message Display Plus Minus Up Down Enter Mimic Diagram Intake Filter Change Lamp

26

25

24 23

22 21

12. High Delivery Temperature Lamp 13. Reclaimer Element Check Lamp 14. Excess Pressure Lamp 15. Emergency Stop 16. Auto Restart Legend 17. Remote Control Legend 18. Remote Control Lamp 19. Auto Restart Lamp 20. Power on Lamp 21. Fan Motor Overload Lamp

20

19

18

17

16

22. Power Converter Fault Lamp 23. Main Motor Fault Lamp 24. Reset 25. Hours 26. Reset Lamp 27. Data View 28. Service 29. Service Lamp 30. Stop 31. Start

FIG. 8.1 CONTROL PANEL

Chapter 8, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Electrical System

ELECTRICAL SYSTEM WARNING !

Refer to the safety procedures before operating the compressor unit.

!

Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work.

!

Before opening the door of the power converter compartment, switch the power supply OFF at isolator and wait for 12 minutes to allow the dc link capacitors to discharge to a safe level. Check that the dc link capacitors have fully discharged before starting work on the compressor.

Note: Any work on the electrical system should be carried out by a CompAir Distributor 1.

REMOTE CONTROL AND MONITORING CONNECTIONS

Input X01/7

Message: ‘Remote Fault 2’ unless Remote Start/Stop selected

Input X01/4

Message: ‘Remote Fault 3’

Three remote input options and three (five on L120SR) remote output options are available. The cable connections required are shown as broken lines on the controller digital inputs and outputs on the electrical connection diagrams on pages 40 to 66.

The functions available are defined below and may be selected using the Remote Control Config menu within the Commissioning Config Menu.

1.1

Default functions are assigned to each input and some functions are only available on specified inputs.

Inputs

CAUTION: Do not connect any input terminal pin to a voltage source other than X3/1 as this will result in permanent damage to the module. Each of the three inputs is activated by connecting the appropriate terminal pin to the input terminal X3/ 1. This can be achieved by connecting the input pin and the common terminal to a volt free remote switch, relay contact, PLC output or any switching device. Note: Remote input cables must be at least 1.0 mm2 in size. The maximum cable length from the compressor to a remote device must not exceed 800 metres. 1.1.1

The function of some digital inputs are configurable. These are:

Input X01/6

Message: ‘Remote Fault 1’ unless Pressure Range Select selected

AC20160-1822, Issue 1, November 2002

1.2

Configurable Input Functions

1.2.1 Pressure Range Select This is available on input X01/6 only and is the default function for this input. Connecting to the pressure range select input enables the selection of a secondary set of Target and Off-load pressure set points. Using a suitable external timer this input can be used to vary the operating pressure of the compressor at different times. This facility enables energy savings to be made during periods when a lower compressed air network pressure can be used. 1.2.2 Remote Start/Stop This is available on input X01/7 only and is the default function for this input.

Chapter 8, page 5

CompAir

When this function is selected an open connection on this input will cause a remote stop and a link is necessary for keypad start. However the Remote Start function is by default disabled and needs to be enabled (separate menu item) for the remote start function to operate. With Remote Start enabled, the keypad start button is disabled and needs to be enabled (separate menu item) for the remote start function to operate. With Remote Start enabled, the keypad start button is disabled and a closing contact on this input will cause a machine start. Also note that selecting another function for this input will automatically disable the Remote Start and Remote Stop functions; an open connection will not cause a stop. 1.2.3 Trip Type 1 An open connection will cause a trip at all times. 1.2.4 Trip Type 2 An open connection will cause a trip when the motor is running. 1.2.5 Trip Type 3 An open connection will cause a trip when status is ‘Onload’ or ‘Offload’.

1.3

Outputs

1.3.1 Configurable Outputs (a) Outputs on pins X09/2, 3 & 4 These three configurable outputs are transistor switched and only suitable for driving low current (50mA each max) 24v DC devices. A DC interface relay must be used (see 1.3.2) (b) Outputs on pins X08/5 & 6 and X08/9 & 10 (L120SR only) These two additional outputs are relay outputs providing a normally open contact only. Note, therefore, that some functions (e. g. Group Trip) are energised for healthy and the relay will present a closed contact for OK. As supplied, these contacts are connected to the 24v AC ancillary equipment system supply and are suitable for driving 24v AC devices subject to the total load on the transformer. It is, therefore, recommended that 24v AC interface relays are used connected between X08/6 or X08/10 and terminal X1/1. If VOLT FREE contacts are required for use with an externally supplied device, then the power supply link between X08/5 or X08/9 and terminal X2/1 MUST be removed. The external monitor should be connected directly to the appropriate contact pair (X08/5 & 6 or X08/9 & 10). Contacts are rated at 250V AC 8A.

1.2.6 Alarm Type 1 1.3.2 Output Relays An open connection will cause an alarm at all times. 1.2.7 Alarm Type 2 An open connection will cause an alarm when the motor is running. 1.2.8 Alarm Type 3 An open connection will cause an alarm when status is ‘Onload’ or ‘Offload’. 1.2.9 Start Inhibit Will prevent a compressor from starting when a fault is sensed but will not stop a compressor if already started. When activated the display will show ‘Start Inhibited’. This function is not a shutdown trip or alarm and will only function while the connection is open. It is not recorded in the Fault History log.

Chapter 8, page 6

The outputs are 24v dc transistor switched with a maximum rating of 25mA and an interface relay must be used. Each output must be connected directly to a relay module, as specified below, in order to achieve a relay contact output suitable for remote applications external to the compressor starter enclosure. Parts required for each additional output:

Qty

Description

Part Number

1

Relay - 24 V dc

98475-64

1

Relay Base

98475-65

AC20160-1822, Issue 1, November 2002

LSR Repair Manual – Electrical Systems

1.3.3 Relay Specification

1.4.4 Group Trip

Single switching contact with a common, normally open (N/O) and normally closed (N/C) connection rated at 250V - 5 Amps maximum.

This is the default for output X09/4 A group trip output will be energised when power is applied and no trip conditions are detected.

Note: The relay 24V dc coil is not bi-directional and must be connected to controller output as follows :

The output will de-energise when a shutdown trip or power loss occurs.

1.

Relay terminal ‘5’ must be connected to pin X09/1.

1.4.5 Service Due

2.

Relay terminal ‘1’ must be connected to pin X09/2, 3 or 4 as appropriate.

The functions available are defined below and may be selected using the Remote Control Config menu within the Commissioning Config Menu. Default functions are assigned to each output. An interface relay must be used with these outputs see following diagrams for connection information. 1.4

The service due output will energise when the service hours countdown timer has reached zero hours and a routine service is due. 1.4.6 Group Alarm + Trip A group trip + alarm output will be energised when power is applied and no alarm or trip conditions are detected. The output will de-energise when an alarm excluding service due, a shutdown trip or power loss occurs.

Configurable Output Functions 1.4.7 Running

1.4.1 Group Fault This is the default for output X09/2. A group fault output will be energised when power is applied and no alarm or trip conditions are detected. The output will de-energise when an alarm including service due, a shutdown trip or power loss occurs.

A running output will energise when the compressor main motor is running. 1.4.8 On Load The on load output will energise when the compressor is on load. 1.4.9 Low Temperature Alarm

1.4.2 Available This is the default for output X09/3 A compressor available output will energise when the compressor is ‘running’ or in the ‘standby’ state. This output indicates that the compressor has been started and is available to automatically respond to a fall in system pressure without manual intervention.

A Low Temperature Alarm output will energise when the Low Temperature Alarm is active. 1.5

4 - 20mA Compressor Speed Output

An output is provided to enable remote monitoring of compressor speed. The output range is from 4mA (0 rev/min) to 20mA (5000 rev/min). 1.6

RS485 Communications

1.4.3 Group Alarm A group alarm output will be energised when power is applied and no alarm condition is detected. The output will de-energise when an alarm or power loss occurs.

The SureScan control unit is compatible with the electrical RS485 communications standard. The communication parameters are: 9600 baud, 8 data bits, no parity and 1 stop bit. The message protocol is a proprietary multimaster protocol compatible with the SmartAir Air Systems Control Units and with the Active Network Interface for connection to PCs etc.

AC20160-1822, Issue 1, November 2002

Chapter 8, page 7

CompAir

AC20160-1822, Issue 1, November 2002

T1 T2

(113) [BK]

0V

(131) [R]

3

NO NC NO NC < > < >

2

(A2) (B2) (A1) (B1)

(161)

(159) (160)

5

LINK

22

2/03

1

A2 B2

A1 B1

E 4 M102

RLB

(139) [R] (131) [R] (124) [R]

(125) [R] 24V 200VA (126D) [R] 0V

F2 5A

(127) [R] 24V 50VA (128) [R] 0V (E)

F3 3.15A

(132) [R]

(132) [R] X1/1

(133) [R]

(126) [R] X1/1

1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106) 2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R] WHERE [R] = RED; [BL] = BLUE; [BK] = BLACK, [G/Y] = GREEN/YELLOW; [CR] = CLEAR; [PK] = PINK

(133) [R]

X1/1

(128) [R]

[G/Y] [G/Y] [G/Y] [G/Y] [G/Y]

RLA NO NC < >

2/03

(E)

NOTES:MCB1

B2 CUR SENS

(134)

4

(126E) [R]

MCB2

(158)

(156) (157)

(155) 5

(126A) [R]

RLA

M101 3~ R

(E)

6

(135)

7

F1 2A

1 2 3 4 5

A2

HEATSINK TEMP SENS

(112B) [BK]

T101 280VA (123) [R] (114) 400V 24V 30VA [BK] (124) [R] 0V

1 2 3 4 5

C

GATE DRIVE BOARD

(139) [R]

(108) [BK]

B1

C GE

RLA (136) [BL]

(117)

(148) (149)

1 2 3 4 5

A1

(140) [R]

(111B) [BK]

R101

C GE

1 2 3 4 5

RLC

(110B) [BK]

(116)

RLB (115)

[BK]

C GE

(150) (151)

(143) (142) (141)

RESISTOR/VDR P.C.B

(114) [BK]

(113) [BK]

(112A) [BK]

(111A) [BK]

MCB1 3A

MCB2 10A (110A) [BK]

COMING SUPPLY OM CUSTOMERS USED ISOLATOR

(ON HEATSINK)

GE

(144) RLA (138)[R] [R] (137) [BL]

(109) [BK]

(126B) [R]

F7 150A

(152)

(106) [BK]

(153) (154)

(103) [BK]

POWER SWITCHING ASSY (ON HEATSINK)

3

W

C4 C8

C1 C5

2

(108) [BK]

1

F6 150A

2

(107) [BK]

V

1

F5 150A

(105) [BK]

(109) [BK]

(104)[BK]

(107) [BK]

(101) [BK] (102) [BK]

PE

FIG. 8.2 ELECTRICAL CONNECTION DIAGRAM - 345SR, L45SR (1 OF 3)

Chapter 8, page 8

U

RLB NO < >

NC

2/02 24V 2/02 0V 2/02 24 2/02 0V 2/02 24V 2/02 0V 2/02

(E) [R] 2/02 SAFETY GUARD GATE DRIVE P.C.B HEATSINK CAPACITOR TRAY STARTER BOX BASE FRAME DOOR EARTH BAR

HW 032

(132) [R]

S201/1

(133) [R] (128) [R]

4

4

X20

R1

2

3

R2

4

5

R3

6

7

R4

8

(210E) [R]

1

X2/1

X2/1

X2/1

1

2

3

4

Chapter 8, page 9

(126F) [R]

RLC (126C) [R]

X1/1 RLC NO

NC

X1/1 PI/98/697a

NOTES:1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106) 2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R] WHERE [R]=RED, [BL]=BLUE, [BK]=BACK, [G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PIN

LSR Repair Manual – Electrical Systems

39) [R] 0V~ 26) [R]

X09

R5

9 10

(213) [R]

4

Y202

3

(139) [R]

2

CONTROLLER DIGITAL OUTPUT

X03

X08

X21 1

AC1 AC2

CONTROLLER RELAY OUTPUT

(210C) [R]

X23

2

(211) [R]

34 22

1

SR CONTROLLER

(210B) [R]

X22

(210A) [R]

24V~ 34 0V~ 34

(131) [R] (124) [R]

~

FIG. 8.3 ELECTRICAL CONNECTION DIAGRAM - 345SR, L45SR (2 OF 3)

AC20160-1822, Issue 1, November 2002

4V~ 4 0V~ 34 E) 34 24V~ 34

CompAir

CONTROLLER ANALOG INPUTS

X3/1

X3/1

ANA4 5

VA6

[CR]

ANA3 4

(313)

[BK]

[CR]

(312)

[BK]

(309)

[BL]

X3/1

X3/1

X3/1

1 2

R301

P301



[BL]

(301E)

[BL]

(301D)

[BL]

T2

X3/1

(E)

ANA2 3

MCB2

[BL]

(301C)

[BL]

(301E)

[BL]

[BL]

S302

(303)

[BL]

(302)

(301)

S201/2 (301B)

[BL]

(301A)

T1

20VX3/1

E

ANA1 2 (311)

X02 VA+ 1 (310)

X01 VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8 1 2 3 4 5 6 7 8 9



AC20160-1822, Issue 1, November 2002

FIG. 8.4 ELECTRICAL CONNECTION DIAGRAM - 345SR, L45SR (3 OF 3)

Chapter 8, page 10

CONTROLLER DIGITAL INPUTS

X3/1

NOTES:1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106) 2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R] WHERE [R]=RED, [BL]=BLUE, [BK]=BACK, [G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PINK.

HW 0330

E

(E)

T1 T2

(125) [R] 24V 200VA (126D) [R] 0V 24V (113) [BK]

0V

0V (E)

(127) [R] 50VA (128) [R]

(A1) (B1) (A2) (B2)

E

5

2/03

22

1

(134)

2

3

A1 B1

A2 B2 E 4 M102

2/03

(E)

RLB

(135)

4

RLA (136) [BL]

5

(138) [R]

(139) [R]

6

(126B) [R]

(139) [R]

2/02

(131) [R]

24 2/0 0V 2/0 24 2/0 0V 2/0 24 2/0 0V 2/0

(124) [R] F2 5A

(132) [R]

(132) [R] X1/1

F3 3.15A

(133) [R]

(126) [R] X1/1

1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106) 2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R] WHERE [R] = RED; [BL] = BLUE; [BK] = BLACK, [G/Y] = GREEN/YELLOW; [CR] = CLEAR;

(133) [R]

X1/1

(128) [R]

[G/Y] [G/Y] [G/Y] [G/Y] [G/Y]

NOTES:MCB1 NO NC < >

(159) (160) (161)

(157) (158)

(156)

LINK

(126E) [R]

MCB2 NO NC < >

B2

HEATSINK TEMP SENS

RLA (126A) [R]

(131) [R]

1 2 3 4 5

A2

(144) [R]

M101 3~ R

F1 2A

1 2 3 4 5

CUR SENS

(112B) [BK]

T101 280VA (123) [R] (114) 400V 24V 30VA [BK] (124) [R] 0V

GEC

GATE DRIVE BOARD

7

RLC

(E)

(154) (155)

B1

(137) [BL]

(117)

(148) (149)

1 2 3 4 5

A1

RLA

(111B) [BK]

R101

1 2 3 4 5

(140) [R]

(110B) [BK]

(152)

(150) (151)

(143) (142) (141)

1 2 3

[BK] RLB (115)

(113) [BK]

(ON HEATSINK)

(153)

(109) [BK]

POWER SWITCHING ASSY (ON HEATSINK) GEC GEC GEC

C5 C10

C1 C6

RESISTOR/VDR P.C.B

(114) [BK]

(112A) [BK]

]

(108) [BK]

2

(106) [BK]

F7 180A

MCB1 3A

MCB2 10A (111A) [BK]

(110A) [BK]

)[

( F6 180A

1

]

(109) [BK]

)[

(105) [BK]

(107) [BK]

W PE

(103) [BK]

(

]

(108) [BK]

) [

(116)

(102) [BK]



FROM CUSTOM FUSED ISOLATO

(

V

RLA NO NC < >

RLB NO NC < >

(E) [R] 2/02 SAFETY GUARD GATE DRIVE P.C.B HEATSINK CAPACITOR TRAY STARTER BOX BASE FRAME DOOR EARTH BAR

HW 033

LSR Repair Manual – Electrical Systems

Chapter 8, page 11

FIG. 8.5 ELECTRICAL CONNECTION DIAGRAM - 475SR, L75SR (1 OF 3)

AC20160-1822, Issue 1, November 2002

U

CompAir

(132) [R] (133) [R] (128) [R] 4

R1

3

R2

4

6

7

R4

R5

8

9 10

X2/1

RLC /

(139)

X09 3

4

GROUP FAULT RELAY 20V dc 150mA (max)

X1/1

NOTES:-

[R]

[R]

(126F)

(126E)

X1/1

2

Y203

Y202

(126D) [R]

X1/1

1

(214) [R]

X2/1

(213) [R]

X2/1

(212) [R]

X2/1

RLC 0V~ 26) [R]

R3

X2/1

(126C) 39) [R]

5

(210F) [R]

2

(210E) [R]

1

+ COMPRESSOR SPEED 4 - 20 mA

CONTROLLER DIGITAL OUTPUT

X03

X08 4

[R]

X21 2 3

AC1 AC2

CONTROLLER RELAY OUTPUT

(210D) [R]

1

X20

Y201

X23

2

(210C) [R]

34 22

1 SR CONTROLLER

(211) [R]

X22

(210B) [R]

34

(210A) [R]

S201/1

24V~ 34 0V~ 34

(131) [R] (124) [R]

~

AC20160-1822, Issue 1, November 2002

FIG. 8.6 ELECTRICAL CONNECTION DIAGRAM - 475SR, L75SR (2 OF 3)

Chapter 8, page 12

4V~ 34 0V~ 34 E) 34 24V~ 34

X1/1

1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106) 2. WIRE COLOURS ARE SHOWN IN BRACKETS THUS [R] WHERE [R]=RED, [BL]=BLUE, [BK]=BACK, [G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PINK 3. TOTAL CURRENT TO X09/2, 3 & 4 MUST NOT EXCEED 150mA

CONTROLLER ANALOG INPUTS VA6

[CR]

ANA4 5

(313)

[BK]

[CR]

(312)

[BK]

[BL]

(309)

ANA3 4

X3/1

X3/1

X3/1

X3/1

X3/1

E

(E)

2

R301

P301



1



[BL]

(301E)

[BL]

(301D)

[BL]

T2

X3/1

(E)

ANA2 3

MCB2

[BL]

(301C)

[BL]

(301E)

[BL]

[BL]

S302

(303)

[BL]

(302)

(301)

S201/2 (301B)

[BL]

(301A)

T1

20VX3/1

E

ANA1 2 (311)

X02 VA+ 1 (310)

X01 VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8 1 2 3 4 5 6 7 8 9

X3/1

NOTES:1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106) 2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R] WHERE [R]=RED, [BL]=BLUE, [BK]=BACK, [G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PINK.

HW 0330

LSR Repair Manual – Electrical Systems

Chapter 8, page 13

FIG. 8.7 ELECTRICAL CONNECTION DIAGRAM - 475SR, L75SR (3 OF 3)

AC20160-1822, Issue 1, November 2002

CONTROLLER DIGITAL INPUTS

(108) [BK]

RLB

(107) [BK]

PCB1

RESISTOR/VDR P.C.B

(109) [BK]

(115) [BK] (116) [BK] (117) [BK] (110B) [BK] (111B) [BK] (112B) [BK] (110C) [BK] (111C) [BK] (112C) [BK]

R101 (149)

(148)

(141)

(142)

(143)

1

3

A1

4

5

7

HEATSINK TEMP SENS

2

[PK]

1

6

3 4

5

G E

1

2

3

A2

4

5 4

PCB2

3

GATE DRIVE BOARD

B1

[PK]

2

C C

POWER SWITCHING IGBT'S

(154)

G E

[PK]

C

2

G E

1

1

[G/Y]

[G/Y]

[G/Y]

[G/Y]

[G/Y]

[126E] [R]

5

(158) [PK]

G E

(150) [VLT] (151) 3 2 1

3

B2

4

LINK

5

C

22

5

L2

(A1)

(A2)

GATE DRIVE P .C.B

DOOR

BASE FRAME

STARTER BOX

CAPACITOR TRAY

HEATSINK

(B1)

24V 2/02 0V~ 2/02 24V~ 2/02 0V~ 2/02 24V~ 2/02 0V~ 2/02

HW 0028

(128) [R]

(133) [R]

(126) [R]

(132) [R]

(124) [R]

2/02

2/03

(139) [R]

4

2/03

(131) [R]

(E)

M102

A2 B2 A1 B1

(B2)

(E) 2/02 SAFETY GUARD

(161)

EARTH

CUR SENS

2

[PK]

C8

RLA

2 1

(152) [PK] (140) [R] (126A) [R]

[PK]

(155)

RLB (126B) (144) SW1/B (138) [R] [R] [R] (137) [BL]

(153) [VLT] (139) [R]

(156) [VLT] (157) (136) [BL] SW1/A

(159)[VLT] (160)

C4

(135)

Chapter 8, page 14 (134)

C1

[PK]

C5

CompAir

FIG. 8.8 ELECTRICAL CONNECTION DIAGRAM - L45SR (1 OF 3) WITH PHASE FAILURE RELAY

AC20160-1822, Issue 1, November 2002

(139) [R] (126) [R]





0V~



22

X23

4

X22

1

SR CONTROLLER 2

2

3

X21 4

X20

1

1

R1

X2/1

(210B) [R]

(133) [R] (128) [R]

2

(139) [R]

24V~ 0V~

3

R2

X2/1

(210C) [R] RLC

(132) [R]

4

X1/1

[R]

24V~

5

R3

X08 6

CONTROLLER RELAY OUTPUT

7

R4

X2/1

8

(213) [R]

(131) [R] (124) [R]

(211) [R] (126C)

(210E) [R] Y202

AC20160-1822, Issue 1, November 2002 X1/1

(126F) [R]

24V~ 0V~ (E)

1 2 AC1 AC2

9

R5 10

X03

1

2

X09 3

HW 0029

4

CONTROLLER DIGITAL OUTPUT

LSR Repair Manual – Electrical Systems

FIG. 8.9 ELECTRICAL CONNECTION DIAGRAM - L45SR (2 OF 3) WITH PHASE FAILURE RELAY

Chapter 8, page 15

(210A) [R]

S201/1

CompAir

Chapter 8, page 16 X02 3

4

5

VA6

[CR]

ANA4

2

[BK]

ANA3

1

(312)

ANA2

(311)

ANA1

[CR]

(E)

VA+

[BK]

9

E

(310)

8

[BL]

7

CONT8

E (E)

SW2

[BL]

6

CONT7

(309)

5

CONT6

[BL]

4

CONT5

(301C)

3

[BL]

2

(301E)

CONT4

[BL]

CONT3

(303)

CONT2

(302)

[BL]

(301)

1

CONT1

(313)

X01 VCONT

R301

1

2

[BL]

(301E)

[BL]

(301D)

[BL]

(301B)

[BL]

T2



P301

T1



K101

S302

S201/2

Key to Components (diagrams 1 to 3)

(301A)

AC20160-1822, Issue 1, November 2002

FIG. 8.10 ELECTRICAL CONNECTION DIAGRAM - L45SR (3 OF 3) WITH PHASE FAILURE RELAY

CONTROLLER ANALOG INPUTS

CONTROLLER DIGITAL INPUTS

Reference EMC1 F1 F2 F3 K101 L1 L2 L208 M102 MCB1 MCB2 P301 PCB1 R101 R301 RLA RLB RLC S302 SW1 T101 Y202

Name EMC FILTER FUSE, 2A TYPE T FUSE, 5A ANTI-SURGE FUSE, 3.15A SEMI-DELAY PHASE FAILURE RELAY LINE REACTOR CURRENT TRANSDUCER SPEED SENSOR - MOTOR MOTOR - MAIN DRIVE CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A CIRCUIT BREAKER - FAN 10A PRESSURE TRANSMITTER - DELIVERY PRESSURE RESISTOR/VDR PCB TEMPERATURE SENSOR - HEATSINK SENSOR - OIL TEMPERATURE CONTACTOR - MAIN CONTACTOR DC LINK CHARGING CONTACTOR - FAN SWITCH - AIR FILTER DP AUXILIARY CONTACTS CONTROL TRANSFORMER VALVE SOLENOID - BYPASS

Note:- Details of Control Panel components are supplied inside the Power Converter Box

20VX3/1

X3/1

X3/1

X3/1

X3/1

X3/1

HW 0030

INCOMING SUPPLY FROM CUSTOMERS FUSED ISOLATOR

HW 0031

PE

(114) [BK]

(110B) [BK]

(E)

T2

T1

R

M101 3~

(113) [BK]

(111B) [BK]

OV (E)

OV

24V

OV

24V

OV

T101 280VA 460V 24V

(112B) [BK]

50VA

PCB1

RESISTOR/VDR P.C.B

L1

L2

(128) [R]

(127) [R]

(126) [R]

(125) [R]

(124) [R]

(123) [R]

POWER BRIDGE RECTIFYER (132) [R]

(132) [R]

F3 3.15A

F2 5A

F2 5A

(131) [R]

K101

F1 2A

L3

PHASE FAILURE RELAY

L3

m