Documenti di Didattica
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L02 - L05
Rotary Screw Compressors
GB fred
CompAir Contents
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 About The L02 - L05 Range . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4 Correct Compressor Operating Conditions . . . . . . . . . . . . . . . . . 6
1.5 Improper Use Of Compressor . . . . . . . . . . . . . . . . . . . . . . . .6
2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Warnings, Cautions and Notes. . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Operational Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Maintenance and Repair Precautions . . . . . . . . . . . . . . . . . . . . 9
2.7 Precautions In The Event Of Fire . . . . . . . . . . . . . . . . . . . . . . 10
2.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Performance Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Dimensions, Weights, Cooling Airflow Requirements . . . . . . . . . . . 12
3.3 Approved Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Refrigerant Dryer (Where Fitted) . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Safety Measures Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Air BASIC Electronic Controller Specifications (Where Fitted) . . . . . . . 14
3.8 General Arrangement Drawings . . . . . . . . . . . . . . . . . . . . . . 15
3.9 Electrical Diagrams - Compressor . . . . . . . . . . . . . . . . . . . . . 20
3.10 Electrical Diagrams - AirBasic Controller . . . . . . . . . . . . . . . . . . 22
4 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Compressor Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Regulation System (Only for Version with AirBASIC Controller) . . . . . . 28
4.4 Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Lifting and Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Connection Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.6 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8 After Prolonged Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2 To Start (Not Valid For Version With Airbasic Controller). . . . . . . . . 32
6.3 To Stop (Not Valid For Version With Airbasic Controller) . . . . . . . . . 32
6.4 Shut-Down Due To Power Failure . . . . . . . . . . . . . . . . . . . . . 32
6.5 Starting At Low Temperatures (below 0C). . . . . . . . . . . . . . . . . 33
6.6 Electronic Controller (Where Fitted) . . . . . . . . . . . . . . . . . . . . 33
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Service Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3 Before Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.4 After Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DL105AA 3
Contents CompAir
4 DL105AA
CompAir Introduction 1
1 Introduction
1.1 General
Worldwide service and parts facilities are Due to the low noise level of the L02-l05
provided by CompAir. If you experience any range, the compressor can be installed at the
difficulty, please inform your local CompAir point of use, requiring no additional cost for a
office. separate compressor room or expensive
pipework.
It is essential to quote the compressor
MODEL and SERIAL numbers in all The Start/Stop operation ensures no idling
communications. time and no idling energy costs.
All pressures shown are gauge pressures. The L02-L03 as standard are equipped with
Start/Stop control and a direct start relay.
CompAir reserves the right to modify the Working hour indicator and pressure display
contents of this publication without notice and are also Included.
the data given is in no way binding on the
manufacturers. The L04 - L05 compressors as standard are
equipped with Star/Delta starting and the
Where approximate figures are shown, electronic AirBasic controller, which provides
specific details are available on request. the user with data on total hours of operation,
operating temperature and additional
1.2 Maintenance and Servicing information such as:
Maintenance, repairs and/or modifications - Air filter replacement
must only be carried out by competent - Oil filter replacement
personnel who have completed the
relevant training. - Separator filter replacement
- Oil change
USE ONLY - Regular maintenance advice
1.3.1 Standard Equipment:
Star/Delta starting (L04-L05)
GENUINE PARTS AirBasic controller (L04-L05)
DOL starting (L02-L03)
1.3 About The L02 - L05 Range
Overload relay protection
These compressors can be combined with
different options to provide everything from a Start/Stop control with pressure switch
stand alone compressor to a complete (L02 - L03)
compressor station. Main On/Off switch
Options include: Electric motor, IP5S, F-class insulation
- Compressor base mounted Oil level monitoring, sight glass
- Compressor mounted on an air receiver Belt transmission
- Airstation solution Safety devices for:
(includes compressor and refrigerant dryer,
both mounted on an air receiver) - Motor over temperature
DL105AA 5
1 Introduction CompAir
Epoxy powder coated enclosure and having a pressure rating at least 10%
higher than the unit itself.
Oil thermostat
The air delivered from these compressors is
1.3.2 Options Available
not suitable for human use. It must never be
a) Air Receiver-mounted used as breathing air.
High quality air receiver built to the highest The compressor is designed only to be
standard EN87/404 and AD2000. operated complete with closed enclosure, for
Inspection-free for 5 years. the purposes of cooling, protection and sound
proofing.
- 200 Litre capacity, suitable for L02 to L05
- 500 Litre capacity, L04 - L05 only 1.5 Improper Use Of Compressor
b) Refrigerant Dryer, L02FS - L05FS The manufacturer shall waive all responsibility
High performance combined with low in case of:
pressure losses a) Incorrect use by untrained or negligent
3C dew point at 25C ambient temperature personnel.
(ISO 7183) b) Use in violation of current laws.
Environmentally friendly refrigerant R134a c) Incorrect installation.
Digital controller displaying: d) Installation without suitable reservoir.
- Dew point indication e) Installation in dust-filled environments (i.e.
- Additional energy saving mode cement, silica etc.....).
L04 - L05 available with DOL starting i) Total or partial failure to observe the
instructions.
Prefilter and microfilter combination
j) Damage due to natural or exceptional events.
Timed or float condensate drains for
receiver-mounted units. k) Tampering with the safety valve.
l) Exceeding maximum pressure rating through
1.4 Correct Compressor Operating tampering.
Conditions m) Operation of compressor without panels and
guards.
The compressor described in this manual is
only suitable for the compression of
atmospheric air up to the maximum pressure
stated on the identification plate.
The compressor is an 'industrial' type, to be
used in accordance with the technical
specifications of the compressor itself.
The compressor works automatically and no
specific operator is required. However, the
unit must be supervised in use and must have
all routine maintenance carried out by an
expert technician, who should be familiar with
all aspects of its operation and safety outlined
in this manual.
The compressor is designed exclusively for
operation connected to an approved air
reservoir of suitable capacity (at least 200 lt.)
6 DL105AA
CompAir Safety Procedures 2
2 Safety Procedures
2.1 General 2.2 Warnings, Cautions and Notes
Most accidents which occur during the 2.2.1 Warnings
operation and maintenance of machinery are
Warnings call attention to operations or
the result of failure to observe basic safety
procedures involving specific hazards which
rules or precautions.
could cause injury or death and are identified
An accident can often be avoided by by the following symbols on the unit and in the
recognising a situation that is potentially text of this manual.
hazardous.
When handling, operating or carrying out
WARNING: RISK OF DANGER
maintenance on the unit, personnel must use
safe engineering practices and observe all
relevant local health and safety requirements
and regulations. WARNING: RISK OF ELECTRIC SHOCK
The attention of users in the UK is drawn to
the Health and Safety at Work Act, 1974, the
Regulations of the Institution of Electrical
Engineers and the Pressure Systems and WARNING: RISK OF HOT SURFACES
Transportable Gas Container Regulations
1989.
CompAir cannot anticipate every possible WARNING: CONSULT MANUAL
circumstance which might represent a
potential hazard. The WARNINGS in this
manual are therefore not all-inclusive. If the
user employs an operating procedure, an item WARNING: COMPONENTS AND SYSTEMS
of equipment or a method of working which is UNDER HIGH PRESSURE
not specifically recommended by CompAir he
must ensure that the unit will not be damaged
or made unsafe and that there is no risk to WARNING: REMOTE START - MACHINE
persons or property. MAY START WITHOUT WARNING
The standard builds of all CompAir products
are not intended for use in either explosive or
potentially explosive atmospheres as defined 2.2.2 Cautions
in Directive 94/9/ EC. An explosive Incorrect operational procedures causing
atmosphere is a mixture with air, under possible damage to the compressor unit are
atmospheric conditions, of flammable gases, identified by a Caution in the text of this
vapours, hazes or dust in which, after ignition manual.
has occurred, combustion propagates to the
entire unburned mixture and may cause a 2.2.3 Notes
hazard. A potentially explosive atmosphere is Methods to make the job easier and points
an atmosphere which could become explosive which require particular attention are identified
due to local conditions. by a Note in the text of the manual.
Failure to observe the precautions given
under Safety Procedures may be considered
dangerous practice or misuse of the
compressor unit.
DL105AA 7
2 Safety Procedures CompAir
Use a spreader bar to avoid side loads on On a unit equipped with an Automatic Restart
hooks, eyes and shackles. When a load is on device, attach a warning notice stating THIS
a hoist stay clear of the danger area beneath UNIT HAS BEEN MODIFIED AND WILL
and around it. Keep lifting acceleration and START AUTOMATICALLY ON
speed within safe limits and never leave a APPLICATION OF POWER next to the
load hanging on a hoist for longer than is display panel and on the inside of the unit
necessary. next to the starter contactors.
If the unit is equipped with a Remote Control
2.4 Installation Precautions device, attach warning notices stating THIS
UNIT CAN BE STARTED REMOTELY in
Installation work must only be carried out by prominent locations, one on the outside of the
competent personnel under a trained and unit, the other inside the control compartment.
qualified supervisor.
As a further safeguard, take adequate
A fused isolating switch must be fitted precautions to make sure there is no one
between the main power supply and the checking or working on the unit before
compressor. attempting to switch on remotely controlled
Ensure that air drawn into the air intake will equipment. Attach a CHECK THAT ALL
not be contaminated with flammable fumes or PERSONNEL ARE CLEAR OF THE UNIT
vapours. BEFORE STARTING or similar warning
notice to the remote start equipment.
Ensure that the air delivery pipe from the
compressor to the users pipework or receiver If there is any indication that the compressor
is free to expand. is overheating it must be shut down and the
cause investigated. Beware of burns from hot
A shut-off valve must be fitted in the delivery
metal parts or hot water when working on a
air line to enable the compressor unit to be
unit which has recently been shut down.
isolated. This is particularly important if more
than one unit is to be coupled in parallel or The compressor must not be operated at
connected to an existing air supply system. pressures above the nominal pressure given
on the data plate.
8 DL105AA
CompAir Safety Procedures 2
DL105AA 9
2 Safety Procedures CompAir
After completion of repair or maintenance for material composition disposal e.g. base
work ensure that no tools, loose items or rags metals, plastics, fabrics etc and be subject to
are left on or inside any part of the machine. normal industrial waste re-cycling processes.
Check the direction of rotation of the HSU and c) Bio-degradable items should be subject to
fans when starting up the compressor initially normal industrial waste disposal processes.
and after any work on the electrical Ensure that no plastic, rubber or composite
connections or switchgear. materials are disposed of by incineration.
Do not use any flammable liquid to clean d) The batteries associated with the back-up
valves, filter elements, cooler air passages, air power for the AMBs must be disposed of in
pipes or any component carrying a flow of air accordance with local guidelines.
during normal operation. If chlorinated
hydrocarbon nonflammable fluids are used for
cleaning, safety precautions must be taken
against any toxic vapours which may be
released.
Do not use carbon tetrachloride.
Precautions must be taken when using acids,
alkalis and chemical detergents for cleaning
machine parts and components. These
materials cause irritation and are corrosive to
the skin, eyes, nose and throat. Avoid
splashes and wear suitable protective clothing
and goggles. Do not breathe mists. Ensure
that water and soap are readily available.
When disposing of used filter elements and
other parts and waste material of any kind,
make sure that there is no pollution and that
no burning of waste takes place which could
cause pollution of the air. Protect the
environment by using only approved methods
of disposal.
2.8 Disposal
When items of equipment are taken out of
service for disposal it is recommended that
the following instructions are adhered to:
a) In order to prohibit the bringing back into
service of equipment by persons unknown, it
should be rendered unusable in order to avoid
improper re-use.
b) Alternatively all such items of equipment
should be stripped into their component form
10 DL105AA
CompAir Technical Information 3
3 Technical Information
3.1 Performance Figures
Performance Data L02 L03 L04 L05
Maximum pressure bar g 10
FAD * @ max. pressure m3/min 0.24 0.36 0,53 0,67
Total package input power * kW 3.20 4.15 5.33 6.69
Total input power at no load kW 0 0 0 0
Male rotor speed rpm 2160 2840 3950 5150
Ambient temperature - min/max C from 1 to 40
Discharge temperature of air above ambient C 16 21 26 34
Free field noise level ** dB(A) 61 61 62 66
Electrical Data
Nominal motor rating kW 2.2 3 4 5.5
Full load current max. (400V) Amp 6 7 9 11
Starting current max. IP55 (400V) direct online DOL Approx. 7 times full load current
Starting current max. IP55 (400V) star delta SD Approx. 2.5 times full load current
Standard drive motor detail IP IP55
Drive motor speed rpm 3000
Suggested cable size (400V) direct online mm 2 4 x 2,5 4 x 2,5 4x4 4x4
2
Suggested cable size (400V) star delta mm N/A N/A 4x4 4x4
Suggested fuse rating (400V) direct online, time delay Amp 16 aM 16 aM 16 aM 16 aM
Suggested fuse rating (400V) star delta, time delay Amp N/A N/A 16 aM 16 aM
Cooling Data
Ventilating fan capacity m3/min 6 6 12 12
Heat rejected by ventilating fan % 70
Size of cooling air inlet aperture mm 127 x 478
Size of cooling air outlet aperture mm 114 x 296
Cooling air temp above ambient approx. C 30 35 38 42
Max. allowable pressure drop in duct at amb. 40C Pa 20
Weights, Dimensions and Capacities
Compressor oil capacity litres 2
3
Approx. oil carry over mg/m <3
Compressed air delivery connection 1/2"
Weight kg 100 100 105 105
Package dimensions L x W x H mm 620 x 600 x 840
* Data measured and stated in accordance with ISO 1217 3rd Edition Annex C and at the following conditions:
Air Intake Pressure: 1 bar a / 14.5 psia
Air Intake Temperature: 20oC / 68oF
Humidity: 0%(dry)
** Measured in free field conditions in accordance with ISO 2151, tolerance 3dB.
CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications without prior notice. Rev 05/09
DL105AA 11
3 Technical Information CompAir
1/2" GAS
S
E U
B
95
95
A C
620
40
A B C
296
28 114
S
COOLING AIR QUANTITIES
500 LT. kW 2.2, 3, 4:- 0.1 m3/s (212 ft3/min)
200 LT.
kW 5.5:- 0.2 m3/s (424 ft3/min)
kW 2.2 100
kW 3 100
kW 4 105 S ELECTRICAL LINE INLET
kW 5.5 105 (3 PHASE)
kW 2.2 165
kW 3 165 M ELECTRICAL LINE INLET
Kg kW 4 170 255 (2 PHASE)
kW 5.5 170 255
AIR OUTLET
kW 2.2 212
kW 3 212
kW 4 213 290 SYMBOLS LABEL
kW 5.5 217 295 SM 1576
12 DL105AA
CompAir Technical Information 3
3.4 Reference
* At ambient air temperature of +25 C, Inlet air at 7 bar and 35 C ( ISO 7183 Part 2)
Danger Measures
Handling Base designed for use with forklift and transpallet forklift.
DL105AA 13
3 Technical Information CompAir
Danger Measures
Compressor Overheat 110 C thermostat with cut-out. *
Insufficient Lubrication 110 C thermostat for 'adiabatic' compression.
Starting Under Load 20 sec. delay from energising *
Phase Reversal (wrong direction of rotation) Indicator arrow or R.S.F. electronic relay *
Temperature
Max. Environment > 45 C 110 C thermostat.
Min Environment < 2 C See starting recommendations.
Pressure Parts Built to EEC 87/404 standards.
Flexible Hoses High pressure hose used (4-6 times working pressure).
Hot Surfaces Parts reaching 70 C + marked with warnings
14 DL105AA
CompAir Technical Information 3
DL105AA 15
3 Technical Information CompAir
16 DL105AA
CompAir Technical Information 3
DL105AA 17
3 Technical Information CompAir
18 DL105AA
CompAir Technical Information 3
DL105AA 19
3 Technical Information CompAir
20 DL105AA
CompAir Technical Information 3
DL105AA 21
3 Technical Information CompAir
22 DL105AA
CompAir Technical Information 3
DL105AA 23
3 Technical Information CompAir
24 DL105AA
CompAir Technical Information 3
DL105AA 25
26
REF. POS. MODEL DENOMINAZIONE NAME DESIGNATION BENENNUNG FABRICANTE SIZE MANUFACTURER 400V 50/60Hz
kW kW
4.0 5.5
SEZIONATORE BLOCCO MAIN DISCONNECT INTERRUPTEUR
S01 3\2 SE32003B HAUPSCHALTER INTERRUPTOR 3P 32A GIOVENZANA 1 1
PORTA SWITCH GENERAL
K1 4\4 3RT1015-1AB01 CONTATTORE CONTACTOR CONTACTEUR FERNSCHALTER CONTACTOR 3P+1NO 24Vac SIEMENS 1 1
K2 4\6 3RT1015-1AB02 CONTATTORE CONTACTOR CONTACTEUR FERNSCHALTER CONTACTOR 3P+1NC 24Vac SIEMENS 1 1
3 Technical Information
K3 4\5 3RT1015-1AB02 CONTATTORE CONTACTOR CONTACTEUR FERNSCHALTER CONTACTOR 3P+1NC 24Vac SIEMENS 1 1
K4 3\6 3RU1116-1HB0 TERMICA THERMAL RELAY RELAIS THERMIQUE THERMISCHES REL. INTER. SOBRECARGA 3P 5,5-8A SIEMENS 1
K4 3\6 3RU1116-1JB0 TERMICA THERMAL RELAY RELAIS THERMIQUE THERMISCHES REL. INTER. SOBRECARGA 3P 7-10A SIEMENS 1
PCH 3x38
F1 3\2 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 3P (10,3x38) ITALWEBER 1 1
2403038S
F1 3\2 1422020 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 20AaM (10,3x38) ITALWEBER 3 3
F2 3\12 FPC.10 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 1P (6,3x32) CABUR 1 1
Electrical Diagrams - AirBasic Controller (cont'd)
F3-F4 3\13-14 FPC.10 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 1P (6,3x32) CABUR 2 2
F3-F4 3\13-14 0307200 FUSIBILE FUSE FUSIBLE SICHERUNG FUSIBLE 2A (6,3x32) ITALWEBER 2 2
F5-F6 3\14-15 FPC.10 PORTAFUSIBILE FUSE HOLDER PORTE FUSIBLE SICHERUNGSHALTER LLEVAFUSIBLE 1P (6,3x32) CABUR 2 2
RSF 3\12 RSF RELAY SEQ, FASI PHASES MONIT. REL. RELAIS RELAIS RELAIS SUPERVISION 400Vac CPE 1 1
DL105AA
CompAir
CompAir General Description 4
4 General Description
4.1 Operating Principle Oil is injected into the air-end housing for the
dual purpose of cooling the unit and
The air end is a single-stage asymmetrical lubricating the moving parts.
screw type, driven by an electric motor. The
air is compressed through the rotation of a The air, once compressed, enters a receiver
male and female rotors which mate perfectly where the remaining oil is separated to a
along their parallel axes, and are housed in a residual of about 2-3ppm.
cast-iron case. At this point it is ready to be delivered.
Should the oil temperature be above the
desired running temperature, the separated oil
will pass through a thermostat-controlled
air-blast oil cooler. Should this not be the
case, it will be bypassed directly into the air
end to start a new cycle of lubrication and
cooling.
The air for the cooler is also used to cool the
motor. It is drawn through the compressor
canopy via a fan driven directly by the motor.
SM 1578
13
16
15
8
10
4
6
12
9
14
18
11
7
3
17 M
5
1 2
SM 1579
DL105AA 27
4 General Description CompAir
28 DL105AA
CompAir Installation and Storage 5
A B
C D
NO A
B
C
D
DL105AA 29
5 Installation and Storage CompAir
THREE PHASE 2
ELECTRICAL SUPPLY 9 10 11
12 12 12
1 4 6
REF. DESCRIPTION
THREE PHASE MONO PHASE
1 COMPRESSOR ELECTRICAL SUPPLY ELECTRICAL SUPPLY
2 TANK
3 AIR DRYER
4 FLEXIBLE HOSE
5 OIL-WATER SEPARATOR
6 CENTRIFUGAL SEPARATOR
7 AUT. COND. DISCHARGE
8 CERAMIC FILTER 1 3
9 COALESCING FILTER 0.1m
10 COALESCING FILTER 0.01m
11 ACTIVE CARBON FILTER 2
12 DIFFERENTIAL MANOMETER
AIR EXIT
MIN 750 MIN 750
30 DL105AA
CompAir Installation and Storage 5
5.5 Initial Checks 5.7.4 Never tamper with the pressure regulator
and/or pressure switch, or set working
5.5.1 After removing the compressor from its pressure higher than the one set for the
packaging and before proceeding with compressor model and for the reservoir.
installation, ensure that no damage has Maximum available pressure must always be
occurred during transportation. below the lift pressure of the safety valve fitted
5.5.2 Packaging materials such as wood, nails and to the reservoir.
plastic sheet could be dangerous for children
and should not be left within their reach. 5.8 After Prolonged Storage
5.5.3 Check that all the fuses in the electrical board If the compressor has remained switched off
are properly fitted and tightened. for longer than two months, the following
5.5.4 Check that the protection main nuts are procedure must be carried out before putting
tightened and the screw fixed. the machine back into service:
5.7.1 The air drawn into the compressor must be Fig. 5.5 - Priming With Oil After Prolonged
completely free from toxic fumes and Storage
inflammable vapours from solvents, paints
etc, which would cause fire or explosions and
a) Access the intake valve (A) by detaching
pollute the working area.
cover (B) and removing the air intake filter
5.7.2 Using the compressor without a suitable air cartridge (C)
reservoir will jeopardise its functionality.
b) Pour 100 cc of approved compressor oil into
Overloading the electrical control system may
the valve
cause an excessive number of starts per hour,
leading to motor damage and shortening the c) Run compressor for ten seconds then stop
life of the unit.
d) Repeat step b
5.7.3 Never dismantle or modify guards or isolating
materials fitted to the compressor. e) Replace the parts and start unit.
DL105AA 31
6 Operation CompAir
6 Operation
6.1 Before Starting 6.3 To Stop (Not Valid For Version With
6.1.1 Before starting the compressor for the first Airbasic Controller)
time, make sure that: 6.3.1 To stop the compressor, push the OFF-0
- the flexible hoses are in good condition and button (RED colour) on the front panel.
efficient and do not show any signs of Caution: The compressor should be
abrasion or cracks allowed to run for at least 3 minutes before
- the electrical power phases are connected switching it off. Shorter running periods
properly. A phase reversal protection device is than this can damage the compressor in
fitted which will prevent the compressor being the long term and are not recommended.
started in this instance, thus avoiding damage
to the air end 6.4 Shut-Down Due To Power Failure
- all compressor access doors are closed 6.4.1 For standard machines:
- all guards are in place and properly secured a) Turn off the power from the main switch and
- all the electrical wiring is in good condition make sure that the compressor cannot be
and that the earth is properly connected accidentally started.
6.1.2 Before opening the valve and letting c) Press down the red button on the pressure
compressed air into the connecting hose, switch to blow down the pressure. Pull up the
make sure that the hose end is securely fixed. red button again afterwards to restore the
This is to prevent the hose from whipping, pressure switch to normal working mode.
which could cause injury. d) Close the front panel end start up the
6.1.3 At the end of each working session, switch the compressor.
power off using the off button on the 6.4.2 For versions with overload cut-out:
controller.
a) If a cut-out occurs, the compressor will stop.
6.1.4 The air produced by this machine contains oil Once the power is back again, the
vapour and cannot be breathed, therefore the compressor will automatically resume
compressor should be placed in a separate operation immediately.
room.
Warning: For safety reasons, it is strongly
recommended that a sign be displayed
6.2 To Start (Not Valid For Version With near the machine indicating that the
Airbasic Controller) compressor may re-start without warning.
Caution: If the compressor has remained b) It is also imperative to check that the
switched off for more then two months, automatic re-start of the compressor will not
ensure that the procedure detailed in pose any hazards whatsoever.
section 5.8 is carried out before starting.
6.4.3 For versions with "Airbasic" controller:
6.2.1 To start the compressor, push the ON-1
a) The blow down function empties the receiver
button (BLACK colour) on the front panel.
after stopping; wait 2 minutes.
The compressor is controlled by a pressure
b) In the event of transient power failure, the
switch which stops the machine when air
compressor will shut-down and re-start in
pressure in the reservoir reaches MAXIMUM
automatic after 20 seconds (the set time to
and starts it up again when the pressure
unload the oil separation tank to guarantee a
drops to MINIMUM. The pressure range is set
correct restart).
to MIN 8 bar / MAX 10bar
Warning: Take extra care when in this
situation in order to avoid any damage to
persons or property caused by the drop in
air pressure in the distribution installation.
32 DL105AA
CompAir Operation 6
SM 1574
DL105AA 33
7 Maintenance CompAir
7 Maintenance
Maintenance and service operations other than those described in this manual must be left to
service personnel authorised by CompAir.
Always wear suitable protective clothes, gloves and footwear while carrying out maintenance
work.
** Stop the compressor before checking oil level. Wait until the oil has separated from the air - about 10 min)
34 DL105AA
CompAir Maintenance 7
SM 1607 4
DL105AA 35
7 Maintenance CompAir
7.6 Guidelines For Oil Change Intervals Fig. 7.2 - Changing the Oil
If final compression temperatures of more 1. Oil Filler Plug
than 90 C occur continually, the oil change 2. Seal
intervals given in the maintenance schedule 3. Oil Level Gauge
are halved. 4. Oil and Condensate Drain Point
36 DL105AA
CompAir Maintenance 7
1 2 3 3 1 2
2 MAX
9
5
7 10
5
8
TOOL FOR
ALIGNMENT CONTROL
6
6
SM 1584
Belt tension is adjusted by slackening off the re-checked. Should it not be correct, the belt
air-end/pulley bracket securing screws should be tensioned again.
(fig. 7.3 (4)) and then moving the bracket (3)
(ii) Check the alignment of the pulleys. If
vertically using the adjusting screw (1).
necessary, correct it so that it is within 2 mm
a) To check the belt tension, apply a force (F) of for XPA belts, or 1 mm for poly-V belts (see
30 N with a dynamometer, positioned in the fig. 7.3).
middle of the belts (see fig. 7.4). If the tension
= =
is correct the belt deflection (f) should be
51 mm.
f
b) If (f) > 7 mm the tension is too low. Adjust the
position of the air end using adjusting screw
(fig. 7.3 (1)) then check the belt deflection (f)
again to confirm the tension is now correct.
c) If (f) < 3mm the tension is too high. Adjust the
position of the air end using adjusting screw F
(fig. 7.3 (1)) then check the belt deflection (f)
again to confirm the tension is now correct. S SM 1587
Notes:
Fig. 7.4 - Belt Adjustment
(i) If the belt has been renewed and the belt
tensioned following the procedures just
described, the compressor should be run for
20-30 minutes, then the tension (f) should be
DL105AA 37
7 Maintenance CompAir
H0
2
50 h
50 h
OIL 1500 h
1 2
3 1500 h
4 ON OFF
5
1500 h
SM 1583 SM 1585
Fig. 7.6 - Cleaning Automatic Condensate Fig. 7.5 - Routine Maintenance Guide
Drain Filter
OPEN CLOSED
38 DL105AA
CompAir Troubleshooting 8
8 Troubleshooting
Warning: All operations must be carried out exclusively by suitably trained technical personnel or
by a service centre.
Warning: Before commencing any work, take all the due safety precautions as detailed in
chapter 7 - Maintenance .
DL105AA 39
8 Troubleshooting CompAir
Note: See also the error messages listed in the controller users manual (for specific version)
40 DL105AA
CompAir AirBASIC Electronic Controller 9
Reset
9.3.2 Button Functions
ON: Switches on the compressor.
a03 A01 A03 A04 S. OFF: Switches off the compressor.
RESET: Resets alarms and displays hour
meter.
SM 1588 9.3.3 Indicator Functions
x10 LED (green): indicates that the 10
Fig. 9.1 - AirBASIC Control Panel
multiplying factor is active.
1. LCD Display (3 Digits/7 Segments)
x100 LED (green): indicates that the 100
2. LED Status Indicators (3 Green)
multiplying factor is active.
3. Control Pushbuttons (3)
LED (green), steadily on: indicates load
The Control Panel is mounted on the operation mode.
compressor. It is used to operate the
compressor and observe system status using LED (green), flashing: indicates unload
the LCD display, LED status indicators and operation mode.
buttons.
The Control Panel displays a comprehensive
9.4 Compressor Operation with the
overview of the compressor status and allows AirBASIC Controller
access to operational parameters such as 9.4.1 Starting The Compressor
alarm set points.
The starting procedure depends on the
current status of the compressor.
a) Starting the compressor in OFF status
DL105AA 41
9 AirBASIC Electronic Controller CompAir
The OFF message on the controller display When the compressor is started (either locally
indicates that the compressor is properly via the ON button or from a remote location),
powered, waiting to be started, and that the the controller performs a number of checks at
last switch-off was caused by pressing the the inputs to make sure that there are no
OFF push button on the controller (local conditions likely to pose hazards to the
switch-off). machine and/or the operators.
To start the compressor, use local controls, If abnormalities are found, the compressor
that is, press the ON button on the control start-up is inhibited and an error message
unit. appears on the controller display. If no
abnormality is found, the compressor is
Note: In this condition, opening and closing
allowed to start.
the remote contact will produce no effect
whatsoever. When start-up is initialised (and no alarms are
active), the controller checks the status of the
b) Starting the compressor in --- status
line pressure switch contact. If the pressure
The --- message on the controller display switch contact is closed, the motor is started
indicates that the compressor is properly according to the star/delta start-up sequence.
powered, waiting to be started, and that the If the pressure switch contact is open
remote START/STOP contact is in the OPEN (pressure in the network ), the compressor
position (STOP position). goes into stand-by mode and the motor is not
started until the network pressure drops to the
To start the compressor, use the relevant
load value level.
procedure described below, depending on
how the last switchoff occurred. When the load value level is reached, the
pressure switch contact closes. The relay
- If the compressor was running (no matter
outputs relating to the line and star contactors
whether loaded, unloaded or in stand-by) and
are energised for the equivalent of the star
was then switched off remotely, the ---
time (parameter P06 - default 5 s). When the
message appears. To restart the compressor,
star time has elapsed, the controller switches
close the remote contact again.
from star to delta with a safety delay (applied
- If the compressor was switched off locally, between the release of the star contactor and
that is, by pressing the OFF button on the the coming into operation of the delta
controller, and the remote contact was then contactor). This delay is equivalent to the time
opened AFTER the switch-off, the --- value set up on the star/delta switching timer
message appears. (parameter P07 - default 20 ms). When the
switching timer has elapsed, the outputs
1. To restart the compressor, close the remote relating to the line and delta contactors are
contact. energised.
2. Press the ON button on the controller. In order to stabilise the motors rotation
This feature allows the operation of the speed, the load solenoid valve is energised
compressor to be disabled from a remote with a delay that is equivalent to the time
position in order to prevent unauthorised value set up on the launch timer parameter
personnel from starting the compressor with (parameter P08 - default 2s). The delay is in
the push buttons on the controller. relation to the closure of the delta contactor.
Once the solenoid valve has been energised,
Warning: If the remote control feature is to the compressor enters into load-operation
be used with the START/STOP contact stage.
connected to the controller, it is strongly
advisable to affix a sign by the machine 9.4.2 Controlling The Compressor Load/Unload
warning that the compressor may be Operation
started at any time from a remote location.
When the compressor is on load, the LED
Note: Machine start and machine restart on the right hand side of the display lights
operations can be performed via a control steadily. When the pressure reaches the set
device other than the one provided, as long as value of the pressure switch, the pressure
this does not pose any hazards. switch contact opens and the compressor
switches to unload operation for a period of
c) Compressor Start-up Process
time that is equivalent to the time value set up
42 DL105AA
CompAir AirBASIC Electronic Controller 9
on the unload time timer (parameter P09 - 9.4.3 Switching Off The Compressor
default 3 min).
The compressor can be switched off locally or
During the unload phase, the LED flashes remotely (if a remote contact is connected to
to indicate that the compressor is running in the appropriate terminals). In both cases,
unload mode. When the timer has elapsed, when the machine is commanded OFF, the
the motor is stopped. As soon as the pressure controller de-energises all the relay outputs
drops to the load value that is set up on the controlling the contactors as well as the
pressure switch, the motor is restarted solenoid valve, thereby causing the
automatically via a star/delta sequence. When compressor to stop immediately.
the motor is stopped, the LED is turned off The control unit activates a safety (blowdown
and if no alarms are active, the value of the oil time) timer (parameter P10 - default 20 s) to
temperature appears on the display. prevent the compressor from restarting with
If the pressure drops to the load value level pressure in the inner tank when the OFF
before the unload timer has elapsed, the button is pressed (or when the remote
compressor immediately switches back to start/stop contact is opened). Compressor
load mode without any stopping of the motor. restart is inhibited throughout the count down
When the Unload time timer elapses, the of the blowdown time. Pressing the ON button
motor stops. The oil temperature remains or closing back the remote start/stop contact
steady on the display to indicate that the during blow-down produces no effect
machine is not OFF but is still in stand-by whatsoever.
condition. The blow-down stage is indicated by the
Warning: Be very careful, as in this flashing of LED x10. When the count down of
condition, the compressor will restart the blow-down time is over, LED x10 is
without prior notice as soon as the turned off. At that point, you can restart the
pressure drops to the load value level. compressor.
See fig. 9.2 for an example of the operating
cycle.
Motor running
pressure
Network pressure
Unload pressure
Load pressure
LOAD LOAD
START
UNLOAD TIME
Motor running
Motor OFF
SM 1575 time
DL105AA 43
9 AirBASIC Electronic Controller CompAir
44 DL105AA
CompAir AirBASIC Electronic Controller 9
DL105AA 45
9 AirBASIC Electronic Controller CompAir
46 DL105AA
CompAir AirBASIC Electronic Controller 9
DL105AA 47
9 AirBASIC Electronic Controller CompAir
48 DL105AA
CompAir AirBASIC Electronic Controller 9
Fig. 9.4 - Wiring Diagram
Input
Pin Function Status
connector
M1 power supply connector 24 Vac
M2 digital input connector, type: 5 poles Combicon 5 mm
C3 1 Common digital inputs
l1 2 Line pressure switch Closed=loaded Open=unloaded
l2 3 Motor thermal relay Alarm if open
l3 4 Phase-sequence relay Alarm if open
l4 5 Remote Start/Stop Closed=start Open=stop
M3 alarm relay connector, type: 2 poles Combicon 5 mm
C2 1 Common relay
R 2 Auxiliary alarm relay Energised=closed De-energised=open
M4 output relay connector, type: 5 poles Combicon 5 mm
C1 1 Common relay
K1 2 Line contactor Energised=closed De-energised=open
K2 3 Star contactor Energised=closed De-energised=open
K3 4 Delta contactor Energised=closed De-energised=open
EV 5 Solenoid valve Energised=closed De-energised=open
M5 temperature probe connector, type: screw terminals welded on the I.C.
1 Temperature probe
2 Temperature probe
DL105AA 49
10 Compressor Parts List CompAir
50 DL105AA
CompAir Compressor Parts List 10
Frame
9 5
10
7
1
11
SM 1593
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1044365 1 Frame
2 CC1044366 1 Panel (2.2/3/4-5.5kW)
CC1044373 1 Panel (4-5.5kW Premium)
DL105AA 51
10 Compressor Parts List CompAir
11 10 9 7
16 15
6
5
8 3
2
12
14 13 4
SM 1594
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1026216 1 Electric Motor 9 CC1045111 1 Compressor Pulley -
(3kW B3 2P 230/400V) 132 Dia. PBT-1SPA (2.2kW)
CC1026212 1 Electric Motor CC1045110 1 Compressor Pulley -
(2.2kW B3 2P 230V/50-60Hz) 100 Dia. PBT-1SPA
CC1026210 1 Electric Motor (3kW,5.5kW & 5.5kW Premium)
(4kW B3 2P 400/690V) CC1045109 1 Compressor Pulley -
CC1026211 1 Electric Motor (4-5.5kW incl. 95 Dia. PBT-1SPA
Premium B3 2P 230/400V) (4kW & 4kW Premium)
CC1026218 1 Electric Motor (4-5.5kW incl. CC1045112 1 Compressor Pulley -
Premium B3 2P 400/690V) 140 Dia. PBT-1SPA (mon.) 2.2kW
2 CC1043038 1 Compressor SCA7L 10 CC1033626 1 Belt XPA 957
3 CC1043986 1 Air Intake Valve RH30 + GHS100 (2.2kW, 4kW & 4kW Premium)
(2.2-5.5kW) CC1033624 1 Belt XPA 907 (3kW)
CC1046515 1 Air Intake Valve RH30E 220842 1 Belt XPA 1032
(4-5.5kW Premium) (5.5kW & 5.5kW Premium)
4 CC1044309 1 Oil Separation Body VTDM15 11 CC1043966 1 Compressor Pulley Bush
5 250112 1 Clamp Wire D.44-47 (2.2kW,3kW,5.5kW
6 CC1044252 1 Air Intake Filter & 5.5kW Premium)
CC1044253 1 Air Intake Filter Cartridge CC1043967 1 Compressor Pulley Bush
(4kW & 4kW Premium)
7 221055B 1 Separation Cartridge
8 220977 1 Oil Cartridge Continued
52 DL105AA
CompAir Compressor Parts List 10
11 10 9 7
16 15
6
5
8 3
2
12
14 13 4
SM 1594
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
12 CC1026592 1 Holder Fan
13 CC1033618 1 Motor Pulley 100 Dia.-1SPA
(2.2 & 3kW)
CC1033621 1 Motor Pulley 132 Dia.-1SPA
(4kW & 4kW Premium)
CC1033623 1 Motor Pulley 180 Dia.-1SPA
(5.5kW & 5.5kW Premium)
CC1033613 1 Motor Pulley 95 Dia.-PBT-1SPA
(monof.) 2.2kW
CC1026691 1 Compressor Pulley Bush (monof.)
2.2kW
DL105AA 53
10 Compressor Parts List CompAir
6
5
4
5
4
5 10
8
7
1
3
SM 1595
2 5 4 5 4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1041791 1 Oil Separation Body
2 160240 1 Nipple 1" - 1/2"
3 180535 1 Copper Washer 33.5x40x1.5
4 160242 4 Nipple 1/2" - 3/8"
5 120377 5 Copper Washer 21.5x28x1.5
6 160268 1 Nipple 1/2"
7 120374 1 Copper Washer 17x23x1.5
8 160812 1 Plug 3/8"
9 160409 1 T Joint M1/8"x6
10 160510 2 Joint 1/8"x6
54 DL105AA
CompAir Compressor Parts List 10
Oil Tank
14
5
8 2
13
4
5
12
13
11
9
10
SM 1596
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1026595 1 Oil Tank
2 160806A 1 Oil Plug
3 CC1026596 1 Level Oil Plug
4 160268 1 Nipple 1/2"
5 120377 2 Copper Washer 21x28x1.5
6 120376 1 Copper Washer 27x33x1.5
7 150175 1 Oil Plug Gasket
8 221525 1 Safety Valve 1/4"-12bar
9 160299 1 Nipple 3/8"-1/4"
10 B160434 1 Tee 1/4" Copper Union
11 160811 1 Plug 1/4"
12 B160730 1 Ball Gate 1/4"
13 240014 2 Copper Washer 13.5x318x1.5
14 120812 1 Nipple 3/4"-1/2"
DL105AA 55
10 Compressor Parts List CompAir
Oil Circuit
10
7
10
4
6
9
11
SM 1597
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1044308 1 GAS Joint 3/4"
120376 1 Copper Washer 27x33x1.5
56 DL105AA
CompAir Compressor Parts List 10
Air Circuit
4
7
SM 1598
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 CC1046670 1 Pressure Switch
2 210397 1 Support Pressure Switch
3 160512 1 Joint 1/4"x6
4 250180 2 Nylon Tube D.6
5 121233 1 Nozzle Whole M5 D.0.5
CC1045371 1 Joint 1/4"x6
DL105AA 57
10 Compressor Parts List CompAir
Electrical Components
7
8
4
ON
5 x10 x100
OFF
6
Reset
SM 1599 9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
400V/50Hz 230V/50-60Hz
1 CC1036610 1 Kit Overload Cutout + Coil 1 CC1036612 1 Kit Overload Cutout + Coil
6.3-10A (2.2 & 3-4kW) 6.3-10A (2.2-3kW)
CC1036611 1 Kit Overload Cutout + Coil CC1036613 1 Kit Overload Cutout + Coil
10-16A (5.5kW) 10-16A (4kW)
CC1035840 1 Coil 400V (2.2, 3-4 & 5.5kW) CC1036614 1 Kit Overload Cutout + Coil
20-25A (5.5kW)
2 CC1031508 1 Hours Counter
3 180948 2 Screw D.3.5x16 (2.2, 3-4 &5.5kW) CC1035841 1 Coil 230V (2.2-3, 4 & 5.5kW)
4 210102 1 Cable Gland D.45
5 210159 1 Cable Gland 2 CC1031508 1 Hours Counter
6 210179 1 Lock Nut 3 180948 2 Screw D.3.5x16 (2.2, 3-4 &5.5kW)
7 CC1027036 1 Thermostat 110C + Probe 4 210102 1 Cable Gland D.45
(2.2, 3-4 & 5.5kW) 5 210159 1 Cable Gland
6 210179 1 Lock Nut
8 CC1033416 1 Controller AIRBASIC 7 CC1027036 1 Thermostat 110C + Probe
(4-5.5kW Premium) (2.2, 3-4 & 5.5kW)
58 DL105AA
CompAir Compressor Parts List 10
Air Receiver
2.2 - 3 - 4 kW
5 2 3 4 17 EDX 4-6
1 EDX 4-6
E
4
1/2" GAS 18 13
7
6 6
A
12
12
11
9 10
5.5 kW
5 2 3 4 17
EDX 9 1/2" GAS
EDX 9
E U 1
18 13 4
7
6
A 6
12
12
11
9 10
16 15 14 8 13
VIEW A SM 1600
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 160207 1 Junction 1/2"
2 160731 1 Gate Valve 1/2"
3 160268 2 Nippe 1/2"
4 150497 1 Flexible Hose 1/2"x1100
5 CC1028206 1 Joint M/F 1/2"
6 CC1046496 1 Base Dryer
7 133107A 1 Angle Bar - Dryer Fixing
8 160333 1 Extension 1/4"
9 120812 1 Nipple 3/4"-1/2"
10 CC1046361 1 Tank LT200 CE 11bar (AD2000)
11 160736 1 Water Drain Tap
12 160817 2 Plug 2"
120340 2 Copper Washer 2"
DL105AA 59
10 Compressor Parts List CompAir
SM 1601
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A CC1045721 1 Minimum Pressure Valve Kit
B CC1041338 1 Thermostatic Valve Kit 71C
C CC1041339 1 Nipple O-ring Kit
D CC1047123 1 Non Return Valve Kit
60 DL105AA
CompAir Compressor Parts List 10
B
4-5.5kW PREMIUM
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A CC1045722 1 Body Spare Parts Kit
B CC1045723 1 Discharge Valve GHS100 -
Spare Parts Kit
DL105AA 61
11 Compressed Air Dryers CompAir
Lifting point
SM 1589
62 DL105AA
CompAir Compressed Air Dryers 11
DL105AA 63
11 Compressed Air Dryers CompAir
tools and wearing all the relevant protective When a repair has been completed make sure
equipment to safeguard against electrical that no tools, detached parts or rags are left in
hazards. the dryer.
d) Precautions for maintenance and repair All the protections must be refitted following
maintenance or repair work.
If spare parts are required, use exclusively
genuine original parts. Do not use inflammable liquids to clean
components while the dryer is running.
Keep a written record of all work carried out
on the unit and the auxiliary equipment. If non-inflammable hydrocarbons containing
chlorine are used all the relevant safety
The frequency and nature of the work
precautions must be adopted to protect
required in a certain period can reveal
against the toxic fumes that may be given off.
abnormal operating conditions that require
correction. Before removing any panels or dismantling
any parts of the unit, perform the following
Use exclusively the refrigerant specified on
steps:
the machine dataplate.
Isolate the unit from the electrical power
Make sure that all the instructions concerning
supply by disconnecting the supply upstream
operation and maintenance are followed
of the power feeding line.
scrupulously and that the entire unit and all
the accessories and safety devices are Lock out the breaker (if present) in the OFF
maintained in proper working order. position by fitting a padlock.
Always keep the plant clean. Attach a warning label to the main switch (if
present) reading: "WORK IN PROGRESS -
Protect components and exposed openings
DO NOT SWITCH ON".
by plugging them, for example, with clean
rags during maintenance and repair work. Do not set the electrical power switch to ON
or attempt to start the unit if the warning label
Precautions must be taken before welding or
is attached.
performing repair operations that may
generate heat, flames or sparks. Coloured tracers can be used in
service-maintenance operations.
Components in the vicinity must be protected
with non-inflammable material. Inspect all refrigerant circuit joints including
connectors, flanges, and more generally all
Do not weld or perform work that generates
critical points (open joints) in order to prevent
heat close to a system that contains oil.
possible leakage of refrigerant gas.
Systems that may contain oil must be
11.2.3 Refrigant gases
completely drained and flushed, for example,
with steam, before performing any operation. The plants can be charged only with R134a.
Do not weld or modify a container that may be The use and storage of cylinders containing
subject to pressurisation. refrigerants must be in compliance with the
prescriptions of the manufacturers of the
To prevent an increase in working
cylinders and in compliance with the
temperature and pressure values check and
applicable safety laws and prescriptions in
clean the heat exchange surfaces (e.g. the
force in the place of installation.
fins of condensers) regularly.
a) Characteristics of R134a refrigerant
For all dryers establish a convenient time
interval for cleaning procedures. At normal temperature and pressure
conditions, this is a class A1 colourless gas
Never use an open flame as a light source to
(classification EN 378-1).
inspect parts of the dryer.
Concentrations significantly above 1000 ppm
Before dismantling parts of a plant ensure that
v/v can cause narcotic effects.
all mobile and heavy parts are securely fixed,
and ensure electrical power has been In the event of leakages provide adequate
disconnected. ventilation of the room before entering.
64 DL105AA
CompAir Compressed Air Dryers 11
MODEL and CODE Identify the size of the unit and its type of construction.
MANUAL Code number of the present manual.
SERIAL NUMBER Unit serial number or manufacturing number.
YEAR OF CONSTRUCTION Year of unit's final testing.
VOLTAGE/PHASES/FREQUENCY Power supply characteristics.
Unit current input in limit operation conditions (refrigerant condensing and
MAX CURRENT DRAW (I max)
evaporation temperature of 70C/158F and 10C/50F respectively).
Unit power input in limit operation conditions (refrigerant condensing and
INSTALLED POWER (P max)
evaporation temperature of 70C/158F and 10C/50F respectively).
PROTECTION RATING According to European standard EN 60529 .
REFRIGERANT Type of refrigerant charge with which the unit is filled.
REFRIGERANT CHARGE Quantity of refrigerant supplied to circuit.
MAX. REFRIGERANT PRESS. Refrigerant circuit design pressure.
MAX REFRIGERANT TEMP. Refrigerant circuit design temperature.
USER CIRC. FLUID Fluid cooled by the machine.
MAX. WORKING PRESSURE User circuit maximum design pressure.
User circuit maximum design temperature - not to be confused with the
MAX TEMPERATURE
maximum working temperature, which is specified at the time of the offer.
Free field sound pressure level in hemispherical radiation conditions (open
SOUND PRESSURE LEVEL field) at a distance of 1m (39.37in) from the condenser side of the unit and a
height of 1.6m (63.0in) from the ground.
AMBIENT TEMPERATURE Cooling air minimum and maximum temperature values.
WEIGHT Approximate weight of the unit without packaging.
Fluid used by the machine to cool the condenser (this information is not
CONDENSER COOLING FLUID
given if the machine condenser is air-cooled).
Condenser cooling circuit maximum design pressure (this information is not
MAX. WORKING PRESSURE
given if the machine condenser is air-cooled).
Condenser cooling circuit maximum design temperature (this information is
MAX TEMPERATURE
not given if the machine condenser is air-cooled).
IMAX * Full load amperage
PMAX * Maximum power
ILR * Locked rotor current
DL105AA 65
11 Compressed Air Dryers CompAir
66 DL105AA
CompAir Compressed Air Dryers 11
DL105AA 67
11 Compressed Air Dryers CompAir
68 DL105AA
CompAir Compressed Air Dryers 11
DL105AA 69
11 Compressed Air Dryers CompAir
70 DL105AA
CompAir Compressed Air Dryers 11
DL105AA 71
11 Compressed Air Dryers CompAir
72 DL105AA
11.3.9
DL105AA
CompAir
Notes
DYENHTYYZZ PFOBNF JN GTHTUHEPJR
73
74
11.3.10 Nomenclature
11 Compressed Air Dryers
DL105AA
CompAir
CompAir Compressed Air Dryers 11
DL105AA 75
11 Compressed Air Dryers CompAir
Heat is exchanged by a process of conduction The refrigerant at the dryer outlet is now in the
through the aluminium fins that join the copper form of a cold vapour, which is returned to the
tubes through which the compressed air compressor to repeat the cycle.
flows, to the copper tubes in which the Since the heat provided by the compressed
refrigerant fluid evaporates. air to cause the refrigerant to evaporate varies
The aluminium fins exchange heat also with significantly because of fluctuations in the
the silica thermal mass keeping it at a compressed air temperature and flow rate, the
temperature of approximately 0C (32F). dryer is equipped with an electronic system to
control the temperature of the thermal mass.
At this point the compressed air is saturated
and conveys with it the condensation This system fulfils 3 important roles:
produced during the cooling process. it ensures an almost constant pressurised
The precooled air then enters a high efficiency dew point (approx. +3C (+37.4F));
condensate separator (demister type with it prevents the compressed air temperature
stainless steel mesh) where the condensate is from falling below 0C (32F) with consequent
precipitated and collected on the bottom of the freezing of the condensate;
enclosure.
it ensures that all the refrigerant is evaporated
A condensate discharger opens periodically in the evaporator, thus avoiding the risk of any
and drains the condensate which is expelled liquid entering the compressor suction side.
by compressed air pressure.
When the load is low or zero, the temperature
The dry cold air at the outlet of the separator of the thermal mass tends to fall. When it
flows for the second time through the air/air
76 DL105AA
CompAir Compressed Air Dryers 11
reaches 0C (32F) the electronic controller b) The dryer should be installed upline from the
stops the compressor. tank when it is sized in order to allow wide
fluctuations of the air flow rate utilised with
The compressed air that continues to flow in
peak values that are significantly higher than
the evaporator is cooled by the cooling energy
the maximum flow rate of the compressor.
stored in the silica.
When the silica temperature starts to rise, the A SM 1605
DL105AA 77
11 Compressed Air Dryers CompAir
installed to prevent the transmission of a) Connect the unit (terminal in the electrical
vibration. panel) to the electrical earthing system of the
building
3) Connect the condensate discharge hose to a
suitable drain point. The drain line of the dryer b) Adopt means to ensure automatic
should not be connected to the drain lines of disconnection of the power supply in the
other equipment; ideally the line should end in presence of a ground fault (protection against
an open funnel type drain. Do not route the indirect contacts in compliance with the
condensate to a common drain header prescriptions of IEC 364) by means of a
because of the possibility of oil contents. residual current device (normally with rated
Oil/water separators should be installed to trip current of 0.03 A)
separate any oil out of the condensate. Make
c) Make sure the level of protection against
sure that the drainage system complies with
indirect contact at the source of the power
local regulations and bylaws.
feeding cable is equivalent at least to IP2X or
4) It is advisable to install a prefilter up-line of the IPXXB
dryer and, if necessary, a coalescent deoiler
d) At the start of the power feeding cable or the
filter down-line of the dryer. Install shut-off
power cable supplied with the unit install a
valves on the compressed air inlet and outlet
device that protects the cable from
connections so that the dryer can be isolated
overcurrent (short circuits) (refer to the
if necessary. Fit a suitably sized pressure
indications in the electrical diagram).
relief valve upline from the shut-off valves.
Caution: Protection devices must be
5) Install a bypass line with shut-off valves so
installed to limit the short circuit current to
that dryer maintenance operations can be
peaks of 17 kA corresponding to the
carried out without interfering with the
specified interruption power if the short
compressed air supply.
circuit current envisaged at the point of
6) Pipelines and other parts whose temperature installation is greater than an effective
may exceed 60C (140F) and that may be value of 10 kA.
accidentally touched by personnel must be
e) Use connectors rated for the maximum
protected or insulated.
required voltage at the maximum operating
7) In order to discharge the compressed air from ambient temperature, according to the chosen
the dryer so that the unit can be installation type (IEC 364-5-523) (see the
depressurised prior to maintenance indications on the electrical diagram).
operations, fit a venting valve in the pipe
2) Indications on the electrical diagram:
between the dryer and one of the shut-off
valves. a) Maximum permissible size of the fuse type
gG. In general, fuses can be replaced by an
11.5.3 Electrical connections
automatic switch adjusted in relation to the
The unit's connection to the power supply machine maximum current input (consult the
must be made in compliance with laws and manufacturer if necessary);
prescriptions in force in the place of
b) Section and type of power cable (if not
installation, after having consulted the
already supplied):
electrical diagram supplied with the plant.
A Installation: insulated conductors,
The voltage, frequency and number of phases
multicore cable in a cable duct, installed
must comply with the data on the unit's
overhead, or fixed to a masonry structure
dataplate.
(type C in compliance with IEC 364-5-523
The power supply voltage must not be outside 1983) or without any other cables in
the tolerances shown on the electrical contact;
diagram, even in terms of transients.
B working temperature: maximum working
Unless otherwise specified, the frequency ambient temperature for the unit;
tolerance is +/-1% of the nominal value (+/-2%
C cable type: copper conductors, 70C /
for short periods).
158F PVC insulation (unless otherwise
1) For the electrical power supply: specified) or EPR 90C/ 194F insulation.
78 DL105AA
CompAir Compressed Air Dryers 11
Voltage must be supplied between phase and 11.7 "iDRY" Electronic Controller
neutral and the neutral conductor must be
connected to earth in the factory substation 11.7.1 User interface
(TN system to IEC 364) or by the electricity
company (TT system to IEC 364).
The line conductor and neutral conductor are
not interchangeable and their positions cannot
be switched.
11.6 Start-Up
Caution: Before starting this type of dryer, SM 1603
ensure that all personnel involved have
read and understood section 11.2 - Safety Fig. 11.3 - "iDRY" Electronic Controller
- Dryers.
a) Display
a) Check that the dryer shut-off valves are
closed and the by-pass valve is open. The controller displays the unit status with
messages shown on the LCD display. The
b) Check that the ambient temperature is within display messages can be:
the range indicated on the unit's dataplate.
c) Power the dryer by means of the line OFF Unit OFF
protection device.
d) When the unit is powered the control unit drY Unit running (normal operation)
display switches on (see section 11.7 - iDRY
Electronic Controller). hdp High Dew Point temperature
e) Press button of the control unit. Once the
programmed delay has elapsed the b) Buttons
compressor and fan will start.
f) Wait for the compressor to stop when the Button Function
thermal mass has reached the programmed
temperature. Displays or edits the set-point.
During programming, selects a
g) Slowly open the dryer inlet valve to pressurise parameter or confirms a value.
the unit.
h) Slowly open the dryer outlet valve. Displays data of a temperature
alarm. During programming,
i) Close the dryer by-pass valve. scrolls through parameter codes
or increases the relative value.
j) Press the manual condensate discharge
button to check that the discharge solenoid
valve opens. Displays data of a temperature
alarm. During programming,
k) If the unit is equipped with timer controlled scrolls through parameter codes
condensate discharge, check that the or decreases the relative value.
discharge solenoid valve opens again after
the time interval set on the control panel. Turns the unit on or off.
The dryer is now ready for normal operation
Condensate drain test.
(see section 11.9 - Operation and
Maintenance).
+ Locks or unlocks the keypad.
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CompAir Compressed Air Dryers 11
The input serves to set which of the two set To quit the programming procedure, display a
points is to be used for temperature control parameter and then press + .
(see section f). You can also quit the procedure by waiting for
15 seconds without pressing any buttons.
2) Keypad lock/unlock function
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11 Compressed Air Dryers CompAir
Press and hold buttons and for a Press and hold buttons and for a
few seconds until the message POF flashes few seconds until the message POn flashes
on display. on display.
The keypad is now locked: only display of the The keypad is now unlocked:
set point, maximum and minimum
Note: The new value entered is saved to the
temperatures is possible.
memory also when you quit programming
If a button is pressed for more than 3s, the mode without pressing button.
text POF is displayed.
11.7.4 Description of settings and parameters
82 DL105AA
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11 Compressed Air Dryers CompAir
11.7.5 Alarms
1) Alarm display
When flashes, the unit sets to alarm
status and the display shows an alarm code,
which can be:
84 DL105AA
CompAir Compressed Air Dryers 11
11.8 Timed Condensate Discharge Unit b) Press the manual condensate discharge
button to check that the filter is not
The timed condensate drain system is pressurised.
controlled automatically by the electronic
controller, on which the intervals between c) Set the line switch to OFF in order to
condensate discharge cycles can be disconnect the power supply to the dryer.
programmed (see Section 11.7 - iDRY d) Carefully unscrew filter cap [1] retaining seal
Electronic Controller). [2] and remove strainer mesh [3].
The condensate discharge unit must be e) Once cleaned, refit the mesh making sure it is
checked and serviced carefully to ensure that properly seated, and refit and tighten cap [1].
the condensate produced and separated is
not entrained in the compressed air stream f) Renew seal [2] if it is damaged.
into the distribution network. g) After re-opening the shut-off valve or the
11.8.1 Filter Cleaning Filterstop valve, power on the unit again and
restart it.
When a dryer is installed for the first time, it is
common for particles of rust, pipe scale, metal 11.8.2 Solenoid valve maintenance
filings, etc. to find their way into the separator
and then into the filter protecting the
discharge solenoid valve. This component
should therefore be removed and cleaned
approximately one month after installation.
Thereafter it should be cleaned once every
three months and in certain cases more
frequently.
Depending on the type of discharge unit fitted,
either a standard mechanical filter or a
Filterstop valve with integral filter (see fig.
11.5 ) may be installed.
3
3
2 2
1 Fig. 11.6 - Condensate Discharge Unit
Solenoid Valve
SM 1604 1
1. Body 7. Shading Ring
Fig. 11.5 - Condensate Drains 2. Plunger-seal 8. Stopper
3. '0' Ring 9. Locknut
1. Plug 4. Armature 10. Electrical
2. Seal Guide Tube Contacts
3. Metal Mesh Strainer 5. Plunger 11. Bonnet
a) Close the shut-off valve upline from the dryer 6. Spring 12. Flange
to remove strainer mesh [3]. If the timed
condensate discharge unit is equipped with The solenoid valve must always be protected
Filterstop valve, it is sufficient to simply close by an appropriate filter to prevent solid
the valve. particles preventing it from opening and
closing properly.
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Every
6 Months
Month
Year
Task
Day
Check to ensure there are no alarm signals. 4 4 4 4
Press the manual condensate discharge button to check that the valve drains properly. 4 4 4 4
If the dryer is equipped with a timed condensate discharge unit, check for possible excessive
production of condensate; in this case increase the valve opening time (ON). Check that the 4 4 4 4
solenoid valve opens properly, in compliance with the times set on control unit.
Check that compressed air inlet temperature is lower than the limit for which the dryer was
4 4 4
selected (normally 35-40C (95-104F)).
Remove, clean and refit the condensate discharge unit filter.If the filter is always clogged with
4 4 4
material, it may be necessary to dismantle and clean the solenoid valve.
Check that ambient air temperature is lower than the limit value used to select the dryer (normally
4 4 4
25-30C / 77-86F). Check that the area in which the dryer is installed is well ventilated.
When the compressor is running, check that its upper part is not too hot (more than approximately
4 4
50C / 122F). Check that the dryer's current draw is within the rated values.
Make a visual inspection of the refrigerant circuit to make sure the piping has not deteriorated and
4 4
there are no traces of oil, which may indicate a leak of refrigerant.
Check the condition and soundness of piping connections. 4 4
Check the condition and soundness of the electrical connections. 4 4
Check that the fan switches on automatically and does not produce excessively high noise levels.
Clean the condenser fins with a jet of clean compressed air. Make sure the grilles are free from dirt 4 4
and any other obstructions.
Clean the condenser fins with mild detergent. 4
Caution: The above maintenance schedule is based on average operating conditions. In some
cases it may be necessary to increase maintenance frequency.
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11 Compressed Air Dryers CompAir
Compressed
air flow rate or Pressure of Circuit has
No compressed air No insufficient No Contact CompAir
temperature too high /
ambient to be dried refrigerant Technical Support
temperature too low ? charge ?
too high ?
Contact refrigeration
engineer to check
Restore values
circuit for
to within
refrigeration leaks.
preset limits
Recharge
SM 1591
Compressed air
excessive
pressure drop
Icing up
due to incorrect
Exchanger setting or faulty
tubes blocked operation or variation of Pressure of
by impurities conveyed No set-point value. No No Contact CompAir
compressed air
by compressed air ? Temperature probe to be dried Technical Support
not calibrated.
too low ?
Probe
positioning ?
Yes Yes
Yes
88 DL105AA
CompAir Compressed Air Dryers 11
SM 1592
Presence of condensate
downline from dryer
Relay on
Clogged Solenoid electronic board Contact
strainer upline valve element controlling solenoid No CompAir
from solenoid blocked ? valve not Technical
valve ? No No No No functioning ? Support
Solenoid
Condensate
valve opening
discharge
time too short or
solenoid valve
closing time
coil burnt
too long ?
Yes out ?
Yes Yes
Yes Yes
Clean mechanical Use tester to check if
Isolate dryer terminal contacts of relay
filter by closing
Renew from air network, Edit open and controlling solenoid valve
valve upline from
solenoid dismantle closed times fail to close when manual
filter or isolating
valve solenoid valve, (if required by discharge button is pressed.
dryer from
clean components control unit) If relay not functioning,
compressed
refit valve renew control board
air network
DL105AA 89