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Профессиональный Документы
Культура Документы
REPAIR MANUAL
Serial Numbers from:
F180-0106 (Cyclon 345SR)
F170-0112 (Cyclon 475SR)
F180-0101 (L45SR)
F170-0112 (L75SR)
F171-0100 (L120SR)
CompAir
GENERAL INFORMATION
These compressors are intended for compressing atmospheric air and are not suitable for compressing 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.
CompAir
CONTENTS
Chapter
Title
Safety Procedures
Product Improvements
General Description
Technical Data
Components
Maintenance
Appendix 1
Dimensions
Appendix 2
Diagrams
Associated Publications
Title
Part Number
C20160-1736
C20160-1615
C20160-1790
C20160-1759
C20160-1811AX
C20160-1726
C20160-1726
T.B.A.
CompAir
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
Chapter 1, page 1
CompAir
SAFETY PROCEDURES
1.
GENERAL
2.
2.1
Warnings
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
2.3
Notes
3.
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
4.
INSTALLATION PRECAUTIONS
Chapter 1, page 3
CompAir
6.
WARNING
Chapter 1, page 4
2.
3.
4.
5.
Chapter 1, page 5
CompAir
7.
8.
DISPOSAL
2.
3.
4.
Chapter 1, page 6
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
-
773
785
798
803
804
805
806
810
811
812
3
5
6
8
10
11
16
21
26
31
822
33
475SR, L75SR
2.
BULLETIN PAGE
NEW BULLETINS
SERIAL NUMBERS
IMPROVEMENT
BULLETIN PAGE
Chapter 2, page 1
CompAir
Chapter 2, page 2
1.
3.
CAUTION
When working wfth static sensitive components
i.e.. circuit cards and memory ICs etc., always
take aniti-static precautions.
INTRODUCTION
2.
1.
2.
3.
4.
2.
3.
4.
5.
6.
7.
8.
REPLACEMENT PROGRAM
Chapter 2, page 3
CompAir
4.
OPERATION
9.
10.
11.
12.
bar
psi
HW 0274
Chapter 2, page 4
2.
3.
4.
METHOD
5.
WARNING
6.
7.
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.
Chapter 2, page 5
CompAir
1.
INTRODUCTION
2.
METHOD
1.
2.
3.
Chapter 2, page 6
Connector
Pin
C20606-83
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
Chapter 2, page 7
CompAir
WARNING
DETAIL
SOLUTION
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
Chapter 2, page 9
CompAir
WARNING
DETAIL
METHOD
1.
2.
3.
2.
Chapter 2, page 10
WARNING
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
98140-361
98140-362
98140-363
98140-364
98140-365
98150-1
98241-31
C20775-19
2.
3.
4.
5.
7.
8.
Chapter 2, page 11
CompAir
9.
10.
b)
c)
d)
a)
b)
11.
12.
13.
14.
15.
16.
17.
18.
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
HW 0316
Chapter 2, page 13
CompAir
HW 0317
Chapter 2, page 14
HW 0318
Chapter 2, page 15
CompAir
475SR MODELS
WARNING
Fitting Instructions
Contents
98161-32
98140-356
98140-357
98140-358
98140-359
98140-360
98150-1
C20775-20
1.
2.
3.
4.
5.
6.
7.
8.
Chapter 2, page 16
a)
b)
9.
10.
11.
12.
13.
a)
b)
c)
d)
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.
Chapter 2, page 17
CompAir
HW 0319
Chapter 2, page 18
HW 0320
Chapter 2, page 19
CompAir
HW 0321
Chapter 2, page 20
WARNING
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
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
Chapter 2, page 21
CompAir
Fitting Instructions
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Chapter 2, page 22
12.
13.
14.
15.
HW 0322
Chapter 2, page 23
CompAir
HW 0322
Chapter 2, page 24
HW 0323
Chapter 2, page 25
CompAir
WARNING
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
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
Tools Required
7.
44mm Diameter Hole Saw
60mm Diameter Hole Saw
8mm Diameter Drill Bit
Pilot Drill Bit
Drill.
Fitting Instructions
1.
2.
3.
4.
5.
6.
9.
10.
Order of fitting:
95001-231
95149-18
C27399-323
95112-4
95112-4
95149-13
98140-366
95149-13
95179-5
95112-4
12.
Chapter 2, page 27
CompAir
HW 0325
Chapter 2, page 28
HW 0326
Chapter 2, page 29
CompAir
HW 0327
Chapter 2, page 30
Chapter 2, page 31
CompAir
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
3 x 120mm
gG315A
.
Note: Cable size is valid for PVC insulated, 3 core cable with a conductor operating temperature of 70C 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
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
C11607-5
A3764-6
3/4" PLUG
98418-61
COOLER TO SUPPORTS
95148-14
WASHERS
COOLER TO SUPPORTS
95179-6
SPRING WASHER
COOLER TO SUPPORTS
95111-5
NUT M8
COOLER TO SUPPORTS
98154-337
OIL/AIR COOLER
95635-8
COPPER WASHER
NIPPLES
C11605-25
NIPPLE 1 BSP
10
95635-6
COPPER WASHER
11
98650-109
DRAIN COCK
12
A3764-6
PLUG
DRAIN COCK
13
95406-801
RECLAIMER OUT
14
98650-390
AMOT VALVE
RECLAIMER OUT
15
98156-308
FILTER
16
98504-92
17
C27399-331
18
C27399-330
19
C27399-343
TEE TO AMOT
20
C27399-334
21
C27399-335
22
95251-276
23
A3753-36
WASHERS
16
24
95602-85
O RING
No. OFF
0.25M
PART LOCATION
Chapter 2, page 33
CompAir
3.
Procedure
3.1
3.2
3.3
3.4
3.5
3.9
3.7
Chapter 2, page 34
3.11
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
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
Chapter 2, page 35
CompAir
SH6(2)
WS4(2)
11
10
12
13
14
27
15
16
16
17
SP4(2)
WP2(2)
NL1(2)
16
2
1
18
2
4
23
19
20 21
22
24
25
26
HW 0297
Chapter 2, page 36
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
Chapter 3, page 1
CompAir
GENERAL DESCRIPTION
1.
COMPRESSOR
2.
AIR-END
2.1
Description
2.2
Operation
Chapter 3, page 2
1.
2.
3.
4.
5.
6.
7.
8.
Chapter 3, page 3
CompAir
3.
Chapter 3, page 4
4.
4.1
4.2
Blowdown System
4.3
4.4
Emergency Stop
4.5
Overpressure Shutdown
4.6
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
25
24 23
22 21
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
20
19
16
Chapter 3, page 5
CompAir
5.
5.1
5.2
Operation
Chapter 3, page 6
11
14
10
8
16
15
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Oil Filter
Aftercooler
Oil Cooler
Fan
Delivery Air Outlet
Scavenge Line
Thermostatic Bypass Valve
13
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
Operation
Chapter 3, page 8
7 8
21
22
10
20
14
19
11
12
13
16
18
1.
2.
3.
4.
5.
6.
7.
8.
17
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)
Chapter 3, page 9
CompAir
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
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
Chapter 3, page 10
7.
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
Chapter 3, page 11
CompAir
5. Temperature Sensor
6. Compression Element
7. Separator Vessel
A Intake Air
C Air/Oil Mixture
B Compressed Air
D Oil
Chapter 3, page 12
8.
REGULATION SYSTEM
(See figures 3.7 to 3.9)
8.1
Description
8.2
8.3
b)
Automatic Mode
Manual Mode
b)
Chapter 3, page 13
CompAir
32 33 34 35 36 37 38 39 40
29
1 19
30
21
17
16
15
18
14
8
13
2
20
9
10
22
28
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.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Chapter 3, page 14
39 40 41 42 43 44 45 46 47
38
12
20
50
13
32
31
26
11
2
33
36
48
37
34 35
19
16
30
24
5 M
14
6
17
28
18
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
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
Chapter 3, page 15
CompAir
20
24
34
14
13
8
28
30
15
1
33
10
35
22
2
29
31
36
26
27
16
23
32
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.
18
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
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)
Chapter 3, page 16
CHAPTER
4
TECHNICAL DATA
1.
2.
3.
4.
LEADING PARTICULARS
CABLE SIZES AND FUSE RATINGS
APPROXIMATE FULL LOAD CURRENTS
FAN MOTORS THERMAL OVERLOAD SETTINGS
Chapter 4, page 1
CompAir
TECHNICAL DATA
1.
LEADING PARTICULARS
MODEL
345SR
and
L45SR
475SR
and
L75SR
L120SR
Air-end:
Cooling:
Air Cooled
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
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
5 (72)
13 (189)
5 (72)
13 (189)
5 (72)
11.5 (167)
or 13 (189)
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)
50 (67)
75 (100)
128 (172)
Motor Speed
Maximum rpm
kW (HP)
viewed from
non-drive end
kg (lbs)
Dimensions:
Length mm (ins)
Width mm (ins)
Height mm (ins)
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)
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 20C and standard atmospheric
pressure of 1 bar a. Specific values for particular operating conditions can be supplied on request.
Chapter 4, page 2
2.
3.
4.
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
Model
380V
400V
415V
460V
345SR, L45SR
475SR, L75SR
L120SR
107
160
261
102
155
248
98
151
238
87
139
234
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
Chapter 4, page 3
CompAir
Chapter 4, page 4
CHAPTER
5
MECHANICAL FAULT FINDING
DEFAULT SETTINGS
FAULT FINDING
1.
2.
3.
SHUTDOWN MESSAGES
WARNING MESSAGES
FAULT FINDING CHART
Chapter 5, page 1
CompAir
DEFAULT SETTINGS
1.
2.
3.
4.
5.
Chapter 5, page 2
1.
Setting
Unit
Minimum
Maximum
Step
Default
Value
bar
51
134 (11.9)*
01
74
bar
50
130 (11.5)*
01
70
bar
51
134 (11.9)*
01
74
bar
50
130 (11.5)*
01
70
bar
51
133 (11.8)*
01
70
bar
50
13.0 (11.5)*
01
63
bar
60
14.3 (128)*
01
77
60
136
01
77
second
240
10
minute
12
Run on time
second
20
240
20
second
20
second
10
120
30
85
125
110
85
125
105
1000
2000
100
2000
hour
Machine number
number
99
second
10
240
10
Auto restart
Enabled Disabled
option
disabled
Enabled - Disabled
option
disabled
Pressure P factor
100
30
Pressure I factor
100
15
option
disabled
option
Pressure
Range sel
option
Remote
start/stop
option
disabled
option
disabled
option
Group Fault
option
Available
option
Group Trip
option
disabled
Communications config
Chapter 5, page 3
CompAir
2.
Setting
Unit
Minimum
Maximum
Step
Default
Value
bar
51
134
01
74
bar
50
130
01
70
bar
51
134
01
74
bar
50
130
01
70
bar
51
134
01
70
bar
50
13.2
01
63
Max. overpress
bar
60
136
01
77
Acceleration time
second
240
10
minute
12
Run on time
second
20
240
20
second
20
second
10
120
30
85
125
110
85
125
105
1000
2000
100
2000
99
110
9600
options
9600
10
240
10
Start/Stop
Comms.
Control
option
disabled
option
disabled
hour
number
second
Enabled Disabled
Pressure P factor
100
30
Pressure I factor
100
15
Chapter 5, page 4
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.
WARNING
1.
SHUTDOWN MESSAGES
Message Displayed
Emergency stop
Possible Cause
Action required
intake.
Chapter 5, page 5
CompAir
Message Displayed
Possible Cause
Action required
Remote fault 1, 2 or 3 **
Chapter 5, page 6
** L120SR models
Message Displayed
Possible Cause
2.
Action required
WARNING MESSAGES
Message Displayed
Possible Cause
Action Required
Change reclaimer
element
Check reclaimer
Check reclaimer dp
Remote fault 1, 2 or 3
Service due
Start inhibited
Chapter 5, page 7
CompAir
REM
The following chart will enable the user to identify other faults which may occur.
3.
Indication
Compressor fails to
run on-load.
Possible Cause
Excessive oil
consumption.
Action
Chapter 5, page 8
Indication
Possible Cause
Action
Chapter 5, page 9
CompAir
Chapter 5, page 10
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
(continued)
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
Chapter 6, page 2
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
Chapter 6, page 3
CompAir
Chapter 6, page 4
COMPONENTS
1.
5
4
3
2
1.2
Operation
HW 0275
1.
2.
3.
4.
5.
Filter Body
Fine Filter Layer
Supporting Tube
Second Filter Layer
Seal Ring
1.1
Description
Chapter 6, page 5
CompAir
2.
7
2
15
10
14
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
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
2.1
2.3
Operation
Chapter 6, page 7
CompAir
3.
1 2
3 4
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
Description
2.
3.
Chapter 6, page 8
3.2
Operation
4.
HW 0279
15
4
14
13
12
11
10
1.
2.
3.
4.
5.
6.
7.
8.
7 6
Piston Housing
Outer Piston Spring
Inner Piston Spring
Piston
Valve Head
'O' Ring
Washer
Locknut
9.
10.
11.
12.
13.
14.
15.
Retainer
'O' Ring
Body
Guide Pin
'O' Ring
Spring
'O' Ring
4.1
Description
Chapter 6, page 9
CompAir
2.
3.
Operation
Chapter 6, page 10
Description
2.
3.
Operation
6.
1
6
5
3
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
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
Chapter 6, page 11
CompAir
7.
10.
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
8.
9.
Chapter 6, page 12
OUT
HW 0283
10.2.2 Operation
10.2.1 Description
Thermostat
Out
In
HW 0284
Chapter 6, page 13
CompAir
11.
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
users pipework. Separated moisture collects in the
moisture separator, passes to the automatic
condensate drain and is expelled via the baseframe
connection and drain pipe.
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
5
7
6
3
HW 0285
Chapter 6, page 14
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
5
7
3
HW 0286
Chapter 6, page 15
CompAir
12.
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.
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
Chapter 6, page 16
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.
OIL OUT
OIL IN
THERMOSTATIC
VALVE
13.
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.
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.
Chapter 6, page 17
CompAir
14.
14.1
14.2
Operation
1.
2.
3.
4.
5.
Inlet
Bypass Manifold
Valve Body
Spring
Valve Housing
6.
7.
8.
9.
Chapter 6, page 18
15.
16.
15.1 Description
16.1 Description
;;
yy
;
;;;
;;
yy
;
;;;
;
;;
;;
yy
A cap (7) holds the valve in position in the cooler
header and allows access for servicing purposes.
8
10
HW 0291
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
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.
Chapter 6, page 19
CompAir
7
4
3
8
HW 0298
1.
2.
3.
4.
5.
Cover
Bypass Outlet
Operating Element
Inner and Outer Springs
Inlet from Reclaimer
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
17.
MOISTURE SEPARATOR
(475SR, L75SR, L120SR)
HW 0300
1.
2.
3.
4.
5.
6.
Housing
Inlet Port
Impinger Cone
Bowl
Spinner
Outlet Port
Chapter 6, page 21
CompAir
18.
STRAINERS
Oil to
air end
Oil
from
cooler
3
Oil Scavenge
return to Air End
and NRV
HW 0301
1.
2.
3.
4.
5.
6.
7.
8.
Chapter 6, page 22
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.
6
5
HW 0303
1.
2.
3.
4.
5.
6.
7.
Valve Body
Cover
Diaphragm Assembly
Spring
Valve Head
Spindle
Seat
Chapter 6, page 23
CompAir
21.
4 to 20mA
1
X02-1
X02-2
4-20 mA PRESSURE
TRANSMITTER
HW 0304
24V D.C.
DETECTION
CIRCUITRY
0V D.C.
CONTROLLER
Chapter 6, page 24
22.
HW 0305
23.
23.1 Description
S
23.2 Operation
3
1.
2.
3.
Probe
Body
Electrical Connectors
22.1 Description
2
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.
1.
2.
3.
4.
5.
6.
6 5
Body
Cover
'O' Ring
Valve Head
'O' Ring
Washer
7.
8.
9.
10.
11.
HW 0306
Locknut
Retainer
'O' Ring
Guide Pin
Spring
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)
BY-PASS VALVE
25.3 Operation
Chapter 6, page 26
26.
27.
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
1
2
26.1 Description
7
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.
5
HW 0309
1.
2.
3.
4.
5.
Body
Air Inlet Valve
Stem
Bush
Spring
6.
7.
8.
9.
Washer
Nut
Washer
Plug
Chapter 6, page 27
CompAir
28.
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
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
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
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)
Minor Service
Oil System
Blowdown System
Electrical Wiring
Drain Solenoid Valve
Control Panel
Aftercooler and Oil Cooler
Oil Filter
Air Filter
Electrical Cabinet Filters
Service
Oil system
Separator Filters
Air Filter (L120SR)
Chapter 7, page 2
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
MODEL
345SR, L45SR
CK2003 - 2
98262-223 (2)
CK8003 - 4
475SR, L75SR
CK2004 - 2
CK6004 - 197
CK8004 - 5
L120SR
CK2007 - 1
CK6007-1
CK8007-1
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
Chapter 7, page 4
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
Chapter 7, page 5
CompAir
4
5
6
12
7
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
16
17
21
20
19
HW 0016
18
Chapter 7, page 6
2.
MAINTENANCE PROCEDURES
WARNING
!
2.1
Enclosure Filter
2.2
1.
2.
3.
2.3
Chapter 7, page 7
CompAir
2.
3.
3.
2.4
1
2
3
4
2.
3.
4.
5.
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
2.
3.
4.
5.
2.5
2.6
475SR, L75SR
1.
2.
3.
4.
1
HW 0017
1.
2.
3.
Chapter 7, page 9
CompAir
3
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
HW 0018
Scavenge pipe
Air discharge pipe
Minimum pressure valve
Cover
Jacking holes
FIG. 7.6 OIL RECLAIMER
4.
5.
HW 0313
Chapter 7, page 10
1
9
13
12
4
10
14
2
HW 0021
11.
12.
2.7
2.
3.
2.8
16
5
13.
11
15
10.
1.
Chapter 7, page 11
CompAir
2.9
Oil System
2.
HW 0022
WARNING
1.
2.
3.
4.
5.
Chapter 7, page 12
1.
2.
HW 0024
2.
2
1
3
3 Oil filters
FIG. 7.12 OIL FILTERS (L75SR, L120SR)
3.
4.
5.
6.
HW 0023
1. Sight glass
2. Filler plug
FIG. 7.11 CHECKING OIL LEVEL
(475SR, L75SR, L120SR)
3.
4.
Chapter 7, page 13
CompAir
CompAir FG Lubricant
Provided the air-end discharge temperature
does not regularly exceed 85C CompAir FG
Lubricant should be changed every 4000
hours service or 1 year, whichever is sooner.
1
2
3
4
HW 0046
Manifold block
Pressure gauges
Separator filters
Oil filter
5 Plug
6 Oil drain valve
7 Control air
isolating valve
4.
5.
2.
3.
Chapter 7, page 14
WARNING
6.
7.
8.
9.
10.
11.
8.
9.
10.
Fill the separator to the correct level with
CompAir approved lubricant, refit the filler cap
and tighten by hand.
11.
13.
12.
14.
15.
13.
12.
Method (b)
1.
14.
2.
15.
16.
3.
4.
5.
WARNING
6.
7.
Chapter 7, page 15
CompAir
5.
6.
WARNING
1.
2.
1
HW 0017
1
FIG. 7.15 OIL DRAIN TAP
(475SR, L75SR)
7.
8.
9.
10.
11.
12.
13.
14.
HW 0026
4.
Chapter 7, page 16
4.
5.
HW 0027
WARNING
1.
2.
7.
8.
9.
10.
11.
12.
13.
HW 0025
Chapter 7, page 17
CompAir
4.
6.
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.
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
475SR, L75SR:
Chapter 7, page 18
WARNING
!
2.16
Non-Return Valve
Chapter 7, page 19
CompAir
Chapter 7, page 20
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
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
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
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
Chapter 8, page 3
CompAir
CONTROL SYSTEM
1.
CONTROLLER
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
26
25
24 23
22 21
20
19
18
17
16
Chapter 8, page 4
ELECTRICAL SYSTEM
WARNING
!
Note: Any work on the electrical system should be carried out by a CompAir Distributor
1.
Input X01/7
Input X01/4
1.1
Inputs
Input X01/6
1.2
Chapter 8, page 5
CompAir
1.3
Outputs
Chapter 8, page 6
Qty
Description
Part Number
Relay - 24 V dc
98475-64
Relay Base
98475-65
1.
2.
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.
RS485 Communications
Chapter 8, page 7
CompAir
T1 T2
(113)
[BK]
0V
(131) [R]
NO
NC NO
NC
< > <1/06>
< > <1/09>
<1/06>
<1/09>
<1/07>
<3/15>
(A2)
(B2)
(A1)
(B1)
(161)
(159)
(160)
LINK
22
2/03
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
(133) [R]
X1/1
(128) [R]
[G/Y]
[G/Y]
[G/Y]
[G/Y]
[G/Y]
RLA
NO
NC
<1/11 > <1/24>
<1/11> < >
<1/11>
<1/26>
2/03
(E)
NOTES:MCB1
B2
CUR
SENS
(134)
(126E)
[R]
MCB2
(158)
(156)
(157)
(155)
5
(126A)
[R]
RLA
<3/15>
M101
3~
R
<3/15>
(E)
(135)
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
(139) [R]
(108) [BK]
B1
C GE
(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
(109) [BK]
(126B)
[R]
F7 150A
(152)
(106) [BK]
(153)
(154)
(103) [BK]
C4
C8
C1
C5
(108) [BK]
F6 150A
(107) [BK]
F5 150A
(105) [BK]
(109) [BK]
(104)[BK]
(107) [BK]
(101) [BK]
(102) [BK]
PE
Chapter 8, page 8
RLB
NO
<1/14 >
<1/14>
<1/15>
< >
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]
X20
R1
R2
R3
R4
(210E)
[R]
X2/1
X2/1
X2/1
Chapter 8, page 9
(126F)
[R]
RLC
(126C)
[R]
X1/1
RLC
NO
<1/06>
NC
X1/1
PI/98/697a
39) [R]
<1/34>
0V~
26) [R] <1/34>
X09
R5
9 10
(213)
[R]
Y202
(139)
[R]
CONTROLLER
DIGITAL OUTPUT
X03
X08
X21
1
AC1 AC2
CONTROLLER
RELAY OUTPUT
(210C)
[R]
X23
(211)
[R]
34 22
SR
CONTROLLER
(210B)
[R]
X22
(210A)
[R]
24V~
34
0V~
34
(131) [R]
(124) [R]
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
<1/06>
[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
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
<1/07>
Chapter 8, page 10
CONTROLLER
DIGITAL INPUTS
X3/1
HW 0330
(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)
2/03
22
(134)
A1 B1
A2 B2
E
4
M102
2/03
(E)
RLB
(135)
(138) [R]
(139) [R]
(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
(133) [R]
X1/1
(128) [R]
[G/Y]
[G/Y]
[G/Y]
[G/Y]
[G/Y]
NOTES:MCB1
NO
NC
< > <1/09>
<1/09>
(159)
(160)
(161)
(157)
(158)
(156)
LINK
(126E)
[R]
MCB2
NO
NC
< > <1/06>
<1/06>
<1/07>
<3/15>
B2
HEATSINK
TEMP SENS
RLA
(126A)
[R]
(131) [R]
1 2 3 4 5
A2
(144)
[R]
<3/15>
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
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]
C5
C10
C1
C6
RESISTOR/VDR
P.C.B
(114) [BK]
(112A) [BK]
(108) [BK]
(106) [BK]
F7 180A
MCB1 3A
MCB2 10A
(111A) [BK]
(110A) [BK]
)[
(
F6 180A
(109) [BK]
)[
(105) [BK]
(107) [BK]
W
PE
(103) [BK]
(108) [BK]
) [
(116)
(102) [BK]
<3/15>
FROM CUSTOM
FUSED ISOLATO
RLA
NO
NC
<1/11 > <1/24>
<1/11> < >
<1/11>
<1/26>
RLB
NO
NC
<1/14 >
<1/14>
<1/15>
< >
(E)
[R] 2/02
SAFETY GUARD
GATE DRIVE P.C.B
HEATSINK
CAPACITOR TRAY
STARTER BOX
BASE FRAME
DOOR
EARTH
BAR
HW 033
Chapter 8, page 11
CompAir
(132) [R]
(133) [R]
(128) [R]
4
R1
R2
R4
R5
9 10
X2/1
RLC
<1/06>
/
(139)
X09
3
GROUP
FAULT
RELAY
20V dc
150mA (max)
X1/1
NOTES:-
[R]
[R]
(126F)
(126E)
X1/1
Y203
Y202
(126D)
[R]
X1/1
(214)
[R]
X2/1
(213)
[R]
X2/1
(212)
[R]
X2/1
RLC
<1/34>
0V~
26) [R] <1/34>
R3
X2/1
(126C)
39) [R]
(210F)
[R]
(210E)
[R]
+
COMPRESSOR
SPEED
4 - 20 mA
CONTROLLER
DIGITAL OUTPUT
X03
X08
4
[R]
X21
2 3
AC1 AC2
CONTROLLER
RELAY OUTPUT
(210D)
[R]
X20
Y201
X23
(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]
Chapter 8, page 12
4V~
34
0V~
34
E)
34
24V~
34
X1/1
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)
R301
P301
<1/06>
<1/07>
[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
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
HW 0330
Chapter 8, page 13
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)
A1
HEATSINK
TEMP SENS
[PK]
3
4
G E
A2
5
4
PCB2
B1
[PK]
C
C
(154)
G E
[PK]
G E
[G/Y]
[G/Y]
[G/Y]
[G/Y]
[G/Y]
[126E]
[R]
(158) [PK]
G E
(150) [VLT]
(151)
3
2
1
B2
LINK
22
L2
(A1)
(A2)
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]
2/03
(131) [R]
(E)
M102
A2 B2 A1 B1
(B2)
(E)
2/02
SAFETY GUARD
(161)
EARTH
CUR
SENS
[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
(139)
[R]
(126)
[R]
<1/34>
<1/34>
0V~
<1/34>
<1/34>
22
X23
X22
SR
CONTROLLER
2
X21
4
X20
R1
X2/1
(210B)
[R]
(133)
[R]
(128)
[R]
(139)
[R]
24V~
<1/34>
0V~
<1/34>
R2
X2/1
(210C)
[R]
RLC
(132)
[R]
X1/1
[R]
24V~
<1/34>
R3
X08
6
CONTROLLER
RELAY OUTPUT
R4
X2/1
(213)
[R]
(131)
[R]
(124)
[R]
(211)
[R]
(126C)
(210E)
[R]
Y202
(126F)
[R]
24V~
<1/34>
0V~
<1/34>
(E)
<1/34>
1
2
AC1 AC2
R5
10
X03
X09
3
HW 0029
CONTROLLER
DIGITAL OUTPUT
Chapter 8, page 15
(210A)
[R]
S201/1
CompAir
Chapter 8, page 16
X02
3
VA6
[CR]
ANA4
[BK]
ANA3
(312)
ANA2
(311)
ANA1
[CR]
(E)
VA+
[BK]
(310)
[BL]
CONT8
E
(E)
SW2
[BL]
CONT7
(309)
CONT6
[BL]
CONT5
(301C)
[BL]
(301E)
CONT4
[BL]
CONT3
(303)
CONT2
(302)
[BL]
(301)
CONT1
(313)
X01
VCONT
R301
[BL]
(301E)
[BL]
(301D)
[BL]
(301B)
[BL]
T2
<1/07>
P301
T1
<1/06>
K101
S302
S201/2
(301A)
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
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
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<3
L2
200VA
30VA
(106)
[BK]
(105)
[BK]
(114)
[BK]
(102)
[BK]
(110A)
[BK]
(107)
[BK]
(115)
[BK]
(110C)
[BK]
R101
(149)
(148)
(141)
(142)
(143)
C10
C6
C E
X1/1
(150)
(103)
[BK]
MCB2 10A
RLC
(108)
[BK]
(116)
[BK]
(111C)
[BK]
RLB
MCB1 3A
(113)
[BK]
(109)
[BK]
(117)
[BK]
(112C)
[BK]
A1
4
5
1
X1/1
B1
5
1
2
3
A2
X1/1
PCB2
(126E)
[R]
C G E
[G/Y]
[G/Y]
[G/Y]
[G/Y]
[G/Y]
[R]
C G E
HEATSINK
TEMP SENS
[VLT]
(151)
3
2
1
(111A)
[BK]
<3/15>
(140)
[R]
RLA
C5
(139)
[R]
C1
RLB
(104)
[BK]
(112A)
[BK]
<3/15>
(138)
[R]
SW1
(144)
[R]
(126B)
[R]
VDR1
(137)
[BL]
(101)
[BK]
RLA
(136)
[BL]
2
1
[PK]
(152)
[PK]
(153)
[VLT]
(154)
[PK]
(126A)
[R]
(155)
[PK]
(156)
[VLT]
(157)
[PK]
SW1
2
4
B2
(E)
<2/02>
22
L2
(A1)
DOOR
BASE FRAME
STARTER BOX
CAPACITOR TRAY
HEATSINK
(A2)
(B2)
(B1)
(E)
M102
A1 B1 A2 B2
SAFETY GUARD
EARTH
BAR
[R]
LINK
CUR
SENS
(158)
[PK]
(159)
[VLT]
(160)
[PK]
(135)
(161)
[PK]
L1
24V~
<2/02>
0V~
<2/02>
0V~
<2/02>
(128)
[R]
24V~
<2/02>
(126)
[R]
(133)
[R]
0V~
<2/02>
(132)
[R]
24V~
<2/02>
<2/02>
<2/03>
(124)
[R]
(131)
[R]
(139)
[R]
<2/03>
Chapter 8, page 17
<1/34>
0V~
<1/34>
(126)
[R]
22
(139)
[R]
<1/34>
<1/34>
0V~
<1/34>
(133)
[R]
(128)
[R]
X23
X22
SR
CONTROLLER
1
X21
X20
R1
X2/1
(210B)
[R]
21V~
<1/34>
(139)
[R]
(132)
[R]
R2
X2/1
(210C)
[R]
RLC
24V~
<1/34>
(211)
[R]
R3
X2/1
X08
CONTROLLER
RELAY OUTPUT
X1/1
(126C)
[R]
(210D)
[R]
Y201
(E)
<1/34>
(212)
[R]
X1/1
(126D)
[R]
R4
X2/1
(210E)
[R]
Y202
[R]
X1/1
R5
X2/1
10
2
AC2
1
X03
AC1
(210F)
(124)
[R]
(214)
(131)
[R]
(213)
(126E)
[R]
[R]
Y203
0V~
<1/34>
[R]
X1/1
[R]
Chapter 8, page 18
(126F)
24V~
<1/34>
X09
3
CONTROLLER
DIGITAL OUTPUT
HW 0032
CompAir
(210A)
[R]
S201/1
20V-
X3/1
(302)
[BL]
X3/1
(301B)
[BL]
(303)
[BL]
X3/1
(301D)
[BL]
CONT4
X3/1
CONT6
CONT5
X3/1
[BL]
S302
S201/2
X01
CONT3
(301F)
CONT2
(301C)
[BL]
CONT1
CONT7
K101
VCONT
(301A)
[BL]
(308)
[BL]
X3/1
(301H)
[BL]
(305)
[BL]
S304
(301E)
[BL]
CONT8
X3/1
T2
T1
SW2
(309)
[BL]
<1/06>
<1/07>
(E)
VA+
1
(310)
[BK]
2
X02
ANA2
ANA3
4
3
ANA1
2
(311)
[CR]
R301
(312)
[BK]
ANA4
5
CONTROLLER
ANALOG INPUTS
VA6
(313)
[CR]
CONTROLLER
DIGITAL INPUTS
(E)
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
SWITCH - EXCESS PRESSURE
AUXILIARY CONTACTS
CONTROL TRANSFORMER
SOLENOID VALVE - SCAVENGE
VALVE SOLENOID - BYPASS
SOLENOID VALVE - CONDENSATE DRAIN
Reference
EMC1
F1
F2
F3
K101
L1
L2
L208
M102
MCB1
MCB2
P301
PCB1
R101
R301
RLA
RLB
RLC
S302
S304
SW1
T101
Y201
Y202
Y203
Chapter 8, page 19
P301
HW 0034
CompAir
Chapter 8, page 20
HW 0035
Chapter 8, page 21
HW 0036
CompAir
Chapter 8, page 22
HW 0037
H101
IGBT 1 TO IGBT 4
IGBT 5 TO IGBT 8
K1
K101
K2
K3
K4
L1
L2
L208
Reference
BR1 TO BR3
C1 TO C18
C19 TO C22
EMC1
F1
F2
F3
F4
Chapter 8, page 23
CompAir
Chapter 8, page 24
FAULT DIAGNOSIS
WARNING
1.2
Clip-on Ammeter
1.
1.3
TEST EQUIPMENT
Test Meter
Insulation Tester
DC Voltage Generator
IGBT Tester
Inductance Tester
Chapter 8, page 25
CompAir
2.
2.1
1.
2.
3.
4.
5.
2
1
HW 0333
Chapter 8, page 26
3.
POWER SUPPLIES
4.
CONTROL INPUTS
3.1
4.1
1.
2.
3.
4.
5.
2.
2.
3.
4.
Chapter 8, page 27
CompAir
3.
4.
5.
6.
7.
6.
SENSORS
HW 0334
5.
CONTROL OUTPUTS
2.
5.1
3.
1.
4.
5.
Chapter 8, page 28
6.
7.
8.
9.
CONTROLLER
PRESSURE
SENSOR
PLUG
1
2
ML1/7
ML1/8
X02/1
X02/2
HW 0335
Pressure
(bar)
Sensor
Output (mA)
L45SR, L75SR
Sensor
Output (mA)
L120SR
Pressure
(bar)
Sensor
Output (mA)
L45SR, L75SR
Sensor
Output (mA)
L120SR
0.0
4.00
4.00
85
13.86
12.50
05
4.58
4.50
90
14.44
13.00
10
5.16
5.00
95
15.02
13.50
15
5.74
5.50
100
15.60
14.00
20
6.32
6.00
105
16.18
14.50
25
6.90
6.50
110
16.75
15.00
30
7.48
7.00
115
17.33
15.50
35
8.06
7.50
120
17.91
16.00
40
8.64
8.00
125
18.49
16.50
45
9.22
8.50
130
19.07
17.00
50
980
9.00
135
19.65
17.50
55
1038
9.50
13.8
20.00
17.80
60
1096
10.00
14.0
n/a
18.00
65
1154
10.50
14.5
n/a
18.50
70
1212
11.00
15.0
n/a
19.00
75
11.50
11.50
15.5
n/a
19.50
80
12.00
12.00
16.0
n/a
20.00
Chapter 8, page 29
CompAir
6.2
WARNING
2.
3.
4.
5.
6.
Temperature
(C)
Sensor
Res. (ohms)
Temperature
(C)
Sensor
Res. (ohms)
1605
50
2448
1678
60
2638
10
1762
70
2844
15
1848
80
3058
20
1927
90
3282
25
2008
100
3520
30
2092
110
3772
40
2263
120
4043
Chapter 8, page 30
7.
CONTROLLER
CAUTION
7.1
2.
3.
2.
4.
3.
5.
6.
1.
4.
8.
9.
Chapter 8, page 31
CompAir
7.2
7.3
FPGA Data IC
Chapter 8, page 32
8.
SR FAULT LOCATION
8.1
8.4
8.5
8.2
2.
3.
Pre-filter blocked.
4.
5.
8.3
8.6
8.7
2.
Fault in controller.
8.8
Chapter 8, page 33
CompAir
8.9
2.
3.
4.
Broken wire.
2.
Faulty sensor.
1.
2.
Pre-filter blocked.
3.
4.
5.
Heatsink dirty.
6.
1.
2.*
Chapter 8, page 34
Chapter 8, page 35
CompAir
Chapter 8, page 36
Chapter 8, page 37
CompAir
Chapter 8, page 38
Chapter 8, page 39
CompAir
Chapter 8, page 40
Chapter 8, page 41
CompAir
Chapter 8, page 42
Chapter 8, page 43
CompAir
9.
SR TEST PROCEDURES
WARNING
9.1
HW 0348
0.30V
0.30V
OFF
RED
BLACK
V
Hz
HW 0349
0.30V
0.30V
FIG. 8.34
COM
HW 0347
FIG. 8.32
Chapter 8, page 44
Note: From serial numbers F170-0354 and F1800106 onwards the fast diode is located within the
IGBT (see 9.3.1)
0.45V
1.
2.
3.
0.45V
Use IGBT tester, CompAir part number 98506-24.
9.2.1 Dual IGBT (Insulated Gate Bipolar
Transistor)
HW 0350
FIG. 8.35
9.2
Chapter 8, page 45
CompAir
Emitter - E2
Collector - C2E1
Emitter - C2E1
Collector - C1
Chapter 8, page 46
C9
C10
C11
C12
HW 0357
1
2
3
4
Rectifier Diodes
IGBTs
Snubber Capacitors
Busbars
Chapter 8, page 47
CompAir
2
1
5
9
6
HW 0358
1
2
3
4
5
Rectifier Diodes
Capacitor Box
Balance Resistors
Capacitors
Gate Drive Board
6
7
8
9
Earth
Snubber Capacitors
Busbars
IGBTs
Chapter 8, page 48
C10
159
160
R110
R105
R111
R106
R112
R107
1
519
520
161
516
517
158
R101
MOTOR CABLES A2 B2
THROUGH SENSOR
156
157
15
15 3
4
140
139
138
137
136
513
514
155
1
4
152
150
151
R113
R108
5
R114
R109
510
511
C18
HW 0359
1
2
3
4
5
Laminated Busbar
Gate Drive Board
Earth Lead
Balance Resistors
Capacitor Box
6
7
8
9
Capacitors
Lift-off Hinges
IGBTs
Snubber Capacitors
Chapter 8, page 49
CompAir
8.
Removal (L120SR)
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.
6.
7.
8.
6.
2.
Refitting (L120SR)
3.
4.
5.
6.
7.
Chapter 8, page 50
1.
2.
3.
4.
5.
6.
7.
8.
9.3
4.
5.
2.
2.
Blow-Hole Plug
1
mV
~
V
OFF
RED
Hz
BLACK
Electrolytic
Capacitor
HW 0364
COM
HW 0366
Chapter 8, page 51
CompAir
3.
4.
5.
6.
7.
Refitting (L120SR)
1.
1.
2.
2.
3.
9.4
4.
1.
5.
6.
2.
7.
8.
4.
5.
6.
9.5
2.
Removal (L120SR)
1.
2.
3.
4.
Chapter 8, page 52
9.6
9.7
WARNING
!
WARNING
!
1.
2.
A
B
C
115
116
117
2.
HW 0367
3.
4.
A1
B1
C1
6.
Chapter 8, page 53
CompAir
1.
Lmin (mH)
Lmax (mH)
Lmax/Lmin Ratio
2.
1.30 min
1.65 max
13.00 min
18.00 max
> 8.50
3.
4.
Lmin (mH)
Lmax (mH)
Lmax/Lmin Ratio
5.
0.95 min
1.20 max
9.50 min
16.00 max
> 8.50
6.
Lmin (uH)
Lmax (mH)
Lmax/Lmin Ratio
595 min
730 max
5.60 min
7.50 max
> 8.50
L75SR
7.
8.
9.
Chapter 8, page 54
L120SR
CHAPTER
9
DISASSEMBLY & ASSEMBLY
Page
A - 345SR, L45SR ...................................................................................................................................... 2
B - 475SR, L75SR ..................................................................................................................................... 19
C - L120SR ................................................................................................................................................. 35
Chapter 9, page 1
CompAir
FIGURES
FIG. 9.1 SCAVENGE COUPLING TOOL
FIG. 9.2 AIR-END OIL SEAL INSTALLATION SLEEVE
Chapter 9, page 2
1.
6.
7.
1.1
1.
1.2
2.
Disconnect the air inlet pipe from the nonreturn valve [1].
3.
4.
5.
Remove the fourscrews securing the nonreturn valve to the air-end inlet [4].
Chapter 9, page 3
CompAir
1.3
1.4
1.
1.
2.
2.
3.
3.
Renew spring.
4.
1.5
Parts required:
Major Service Kit, Part No CK8003-4
Assembly is a reversal of the disassembly
procedure.
4.
Chapter 9, page 4
2.
4.
2.1
5.
1.
2.
HW 0407
HW 0405
1.
WARNING
!
3.
HW 0408
3.
Chapter 9, page 5
CompAir
2.3
1.
2.
3.
4.
HW 0409
HW 0410
HW 0411
6
5
Chapter 9, page 6
2.4
2.5
3.
Parts Required:
HW 0409
8
7
6
5
HW 0412
4.
5.
6.
Chapter 9, page 7
CompAir
3.
3.1
WARNING
!
3 Holes permissible
in corners of hexagon
for manufacture
17 A/F HEX
12 A/F
HEX
3 Holes permissible
in corners of hexagon
for manufacture
20.5
17 A/F HEX
9.5
13
27
17
17
17
27
14 A/F
HEX
207
Material: EN 33
1.
2.
3.
HW 0413
HW 0414
Chapter 9, page 8
4.
HW 0415
Chapter 9, page 9
CompAir
4.
4.1
1.
2.
3.
4.
5.
6.
4.2
Chapter 9, page 10
4.3
WARNING
!
1.
2.
4.4
4.
5.
Chapter 9, page 11
CompAir
5.
AIR-END
WARNING
!
5.1
Remove Air-End
1.
2.
3.
4.
5.
5.2
Install Air-End
7.
Chapter 9, page 12
5.3
1.
2.
3.
4.
5.4
1.
2.
Fit the new oil seal into the oil seal housing.
Ensure that the seal is seated firmly in the
recess.
3.
5.
6.
7.
8.
Refit coupling.
9.
Chapter 9, page 13
CompAir
6.
OIL COOLER
6.1
WARNING
!
1.
2.
98154-300
OUTLET
4.
Remove the air inlet filter (fig. 9.31 (1)) and air
inlet pipe (2) from non-return valve (3).
98154-350
OUTLET
INLET
HW 0432
Chapter 9, page 14
5.
6.
7.
8.
9.
6.3
10.
6.2
12.
13.
15.
16.
Chapter 9, page 15
CompAir
7.
AFTER COOLER
7.2
7.1
WARNING
!
7.3
1.
2.
4.
5.
4.
5.
6.
7.
Chapter 9, page 16
8.
5.
WARNING
!
8.1
1.
2.
3.
7.
8.
8.2
Chapter 9, page 17
CompAir
9.
9.1
1.
2.
3.
4.
9.2
Chapter 9, page 18
FIGURES
FIG. 9.3
FIG. 9.4
FIG. 9.5
FIG. 9.6
SCAVENGE PIPE
AIR-END OIL SEAL INSTALLATION SLEEVE
THERMOSTATIC BYPASS VALVE
THERMOSTATIC BYPASS VALVE - LATER COOLER
Chapter 9, page 19
CompAir
WARNING
1.
1.1
1.
2.
3.
4.
1.2
PI/98/023
Chapter 9, page 20
2.
3.
4.
5.
Hold the stem of the guide pin across the flat in soft
vice jaws. Do not overtighten the vice. Unscrew the
locknut from the guide pin and remove the washer,
valve head, O ring and retainer. Discard the O
ring. Remove and discard the O ring from the guide
pin stem (fig. 9.43).
1.4
1.
2.
3.
Chapter 9, page 21
CompAir
1.5
Parts required:
Major Service Kit, Part No CK8004-5
1.
2.
3.
4.
5.
6.
7.
Chapter 9, page 22
2.
RECLAIMER
2.1
1.
2.
3.
4.
5.
6.
7.
Chapter 9, page 23
CompAir
2.2
2.3
Remove Reclaimer
1.
2.
3.
4.
5.
6.
Chapter 9, page 24
7.
8.
9.
10.
11.
2.4
Install Reclaimer
3.
NON-RETURN VALVE
WARNING: RISK OF HIGH
PRESSURE
FIG. 9.55 RECLAIMER MOUNTING BOLTS
3.1
1.
2.
3.
5.
Chapter 9, page 25
CompAir
3.2
3.3
1.
2.
3.
Hold the stem of the guide pin across the flat in soft
vice jaws (fig. 9.58). Do not overtighten the vice.
Unscrew the locknut from the guide pin and remove
the washer, valve head, O ring and retainer. Discard
the O ring. Remove and discard the O ring from the
guide pin stem.
3.4
1.
3.5
Parts required:
Major Service Kit, Part No CK8004-5
1.
2.
Chapter 9, page 26
new valve spring and insert the spring into the guide
pin. Insert the valve assembly into the cover (fig.
9.59).
3.
4.
5.
4.
4.1
1.
2.
3.
4.
5.
6.
7.
8.
4.2
Chapter 9, page 27
CompAir
WARNING
1.
2.
3.
4.
5.
6.
7.
Chapter 9, page 28
5.
AIR-END
WARNING
5.1
Remove Air-End
1.
2.
Drain oil from the air-end and disconnect the oil drain
pipe.
3.
Disconnect the discharge pipe flange from the nonreturn valve end (oil may still be present in the pipe)
(fig. 9.65). Discard the O ring from the pipe flange.
Disconnect the non-return valve.
4.
5.
Chapter 9, page 29
CompAir
6.
7.
8.
9.
10.
5.2
Install Air-End
5.3
1.
2.
3.
4.
Remove the oil seal and gasket from the oil seal
housing and discard.
5.4
2.
Fit the new oil seal into the oil seal housing. Ensure
that the seal is seated firmly in the recess.
3.
Chapter 9, page 30
5.
6.
7.
8.
Refit coupling.
9.
6.
AIR/OIL COOLER
WARNING
!
6.1
1.
2.
3.
4.
5.
6.
7.
Chapter 9, page 31
CompAir
8.
9.
11.
12.
13.
6.2
Chapter 9, page 32
6.3
7.
WARNING
!
7.1
1.
2.
3.
4.
7.2
Chapter 9, page 33
CompAir
8.
WARNING
!
8.1
1.
2.
3.
Note: Fit a new O ring seal and install the valve the
correct way up in the cooler pocket as shown in Fig. 9.81,
i.e. with the spring underneath and the wax element facing
downwards.
8.3
1.
2.
8.2
Chapter 9, page 34
FIGURES
FIG. 9.7 RECLAIMER COVER BOLT TIGHTENING SEQUENCE
FIG. 9.8 AIR-END OIL SEAL INSTALLATION SLEEVE
Chapter 9, page 35
CompAir
1.
1.1
1.
2.
3.
4.
5.
6.
1.2
2
1
4
5
6, 7
9
Chapter 9, page 36
1.3
1.
2.
3.
13
11
16
15
1.
2.
3.
1.5
1.
Chapter 9, page 37
CompAir
2.
2.1
1.
2.
5.
2.2
1.
Chapter 9, page 38
2.3
1.
2.
4.
5.
5.
6.
7.
2.4
1.
2.
3.
2.5
1.
2.
3.
Chapter 9, page 39
CompAir
4.
5.
6.
6.
HW 0019
RECLAIMER
Remove Reclaimer Element
1.
2.
3.
4.
3.2
1.
2.
Tighten the bolts evenly, following the tightening sequence in fig. 9.91 to an initial torque of
110 Nm / 81 ft.lbf. Check the O ring.
3.
Chapter 9, page 40
3.3
Remove Reclaimer
1.
2.
1
9
13
3
15
11
12
16
5
4
10
14
2
HW 0021
5.
6.
4.
5.
6.
8.
9.
Chapter 9, page 41
CompAir
WARNING
!
4.
6.
4.1
7.
1.
8.
2.
2
1
4.
5.
Chapter 9, page 42
4.2
4.3
1.
2.
4.
5.
4.4
Chapter 9, page 43
CompAir
5.
AIR-END
7.
8.
9.
WARNING
!
Remove Air-End
1.
5.2
2.
3.
4.
5.
6.
Install Air-End
2
4
5
6
1
Chapter 9, page 44
5.3
1.
2.
3.
4.
5.4
1.
2.
Fit the new oil seal into the oil seal housing.
Ensure that the seal is seated firmly in the
recess.
3.
5.
Carefully lower the oil seal housing onto the AirEnd, ensuring that the new oil seal fully
engages the shaft sleeve without twisting.
6.
7.
8.
Chapter 9, page 45
CompAir
6.
COOLERS
WARNING
!
6.1
1.
2.
3.
4.
5.
5.
6.4
1.
2.
3.
4.
5.
6.
6.3
2.
Chapter 9, page 46
6.5
6.6
2.
3.
Chapter 9, page 47
CompAir
7.
6.
WARNING
!
7.1
1.
2.
3.
4.
5.
7
9
7.2
3
10
Chapter 9, page 48
8.
8.1
1.
2.
3.
8.2
Chapter 9, page 49
CompAir
9.
BEKOMAT DRAIN
9.1
1.
2.
9.3
Testing
1.
2.
1.
2.
3.
4.
3.
4.
5.
9.2
Installation
Chapter 9, page 50