Original User Manual

D75-08A/10A, D90-08A/10A
D110-08A/10A, D132-08A/10A
D150-08A/10A
D110RS-10A
Oil Free Rotary Screw Air Compressors
(Air Cooled)

GB 100008775 / 07 - October 2011

DL054CA - 07/2011
 Foreword
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.
CompAir Contents

Contents

1 Ownership Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Local CompAir Representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Warnings, Cautions And Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Operational Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Maintenance and Repair Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Precautions in the event of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Models D55 to D155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Storage Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Cable Sizes And Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Cable Sizes and Fuse Rating Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 System Checks and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Checking/Altering Commissioning Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 Checking/Altering Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5 Re-setting Service Interval Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6 Final Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.7 Commissioning Parameters (compressor running on-load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8 Powered Breather - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.9 Powered Breather - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.10 Powered Breather System - Check Vacuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.11 Commissioning Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Routine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Altering Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3 Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4 Glossary of Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Torque Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.4 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1 Shutdown and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

DL054CA 3
Contents CompAir

10 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11 Appendix 1 – Sample Log Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.2 Values At Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.3 Commissioning Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11.4 Operational Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11.5 Weekly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11.6 Performance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.7 4000 hr Service (Service A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.8 8000 hr Service (Service B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.9 16000 hr Service (Service C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.10 Compressor History Log Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12 Appendix 2 – The Pressure Systems And Gas Regulations 2000 No. 128. . . . . . . . . . . . . . . . . . . . . . 76
12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4 DL054CA
CompAir Ownership Data 1

1 Ownership Data
1.1 Technical Data
1st Stage
Model:
Air-end Serial
2nd Stage
Numbers:
Serial Number:
Gearbox

Year: Motor Serial Number:

Delivery Date: Intercooler Serial Number:

Maximum Pressure: Intercooler Certificate Number:

kW/hp: Aftercooler Serial Number:

Motor rpm Aftercooler Certificate Number:

V. Ph. Hz. Oil cooler Serial Number:

Oil cooler Certificate Number:

Compressor lubricant:

1.2 Local CompAir Representative

Name:

Address:

Telephone: Fax:

Contact Names: Parts:

Service:

DL054CA 5
2 Safety Procedures CompAir

2 Safety Procedures 2.2 Warnings, Cautions And Notes

2.2.1 Warnings
Warnings call attention to operations or procedures
2.1 General
involving specific hazards which could cause injury
2.1.1 Most accidents which occur during the operation and or death and are identified by the following symbols
maintenance of machinery are the result of failure to on the unit and in the text of the manual.
observe basic safety rules or precautions. An
accident can often be avoided by recognising a WARNING:
situation that is potentially hazardous. Risk Of Danger
2.1.2 When handling, operating or carrying out
maintenance on the unit, personnel must use safe WARNING:
engineering practices and observe all relevant local Risk Of Electric Shock
health and safety requirements and regulations. The
attention of users in the UK is drawn to the Health
and Safety at Work Act, 1974, and to the WARNING:
Regulations of the Institution of Electrical Engineers. Risk Of Hot Surfaces

2.1.3 CompAir cannot anticipate every possible

circumstance which might represent a potential WARNING:
hazard. The WARNINGS in this manual are Consult Manual
therefore not all-inclusive. If the user employs an
operating procedure, an item of equipment or a
method of working which is not specifically WARNING:
recommended by CompAir he must ensure that the Risk Of High Pressure
unit will not be damaged or made unsafe and that
there is no risk to persons or property. 2.2.2 Cautions
2.1.4 The standard build of all CompAir products are not Incorrect operational procedures causing possible
intended for use in either explosive or potentially damage to the compressor unit are identified by a
explosive atmospheres as defined in ‘CAUTION’ in the text of this manual.
Directive 94/9/EC. 2.2.3 Notes
2.1.5 An explosive atmosphere is a mixture with air, under Methods to make the job easier and points which
atmospheric conditions, of flammable gases, require particular attention are identified by a ‘Note’
vapours, hazes, or dust in which, after ignition has in the text of the manual.
occurred, combustion propagates to the entire
unburned mixture and may cause a hazard.
2.1.6 A potentially explosive atmosphere is an
atmosphere which could become explosive due to
local conditions.
2.1.7 Failure to observe the precautions given under
'Safety Procedures' may be considered dangerous
practice or misuse of the compressor unit.

6 DL054CA
CompAir
2.3 General Safety Precautions
2.3.1 If using compressed air for cleaning purposes,
ensure safety regulations are complied with and
appropriate clothing and eye protection is worn.
2.3.2 Never direct compressed air onto your skin or at
other people.
2.3.3 The compressed air generated by these
compressors must never be used for breathing
unless it has been conditioned for those applications
in line with the “Safety Requirements For
Respiratory Air”.
2.3.4 Never use compressed air to clean loose dirt from
clothing.
2.3.5 Before releasing compressed air through a hose
make sure that the free end is held securely so that
it cannot whip and cause injury.
2.3.6 Avoid injury by using a hoist to lift heavy loads.
Check that all chains, hooks, shackles and slings are
in good condition and are of the correct capacity.
They must be tested and approved according to
local safety regulations.
2.3.7 Cables, chains or ropes must never be applied
directly to lifting eyes. Always use an appropriate
shackle or hook, properly positioned. Arrange lifting
cables so that there are no sharp bends.
2.3.8 Use a spreader bar to avoid side loads on hooks,
eyes and shackles.
2.3.9 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. Never leave a load
hanging on a hoist for longer than is necessary.
2.4 Installation Precautions
2.4.1 Installation work must only be carried out by
competent personnel under a qualified supervisor.
2.4.2 A fused isolating switch must be fitted between the
main power supply and the compressor.
2.4.3 Ensure that air drawn into the air intake will not be
contaminated with flammable fumes or vapours
since this could cause an internal fire or explosion.
2.4.4 Precautions must be taken to ensure that no injury is
caused to passers-by through loose clothing being
sucked into the air intake.
2.4.5 Ensure that the air delivery pipe from the
compressor to the user’s pipework or receiver is free
to expand and that no flammable material is in the
vicinity.
DL054CA
Safety Procedures 2
2.4.6 A shut-off valve must be fitted in the delivery air line
to enable the compressor unit to be isolated. This is
particularly important if more than one unit is to be
coupled in parallel or connected to an existing air
supply system.
2.4.7 The non-return valve is not intended as an isolating
valve and should not be relied upon for this purpose.
In addition, it may be necessary to install shut-off
valves elsewhere in the system to allow a dryer or
other equipment to be by-passed.
2.4.8 A pressure relief valve must be installed between
any compressor unit and the shut-off valve/s.
Pressure relief valves (safety valves) are fitted to the
air pipework, as standard equipment, between the
intercooler and compressor delivery. The set
pressures of these relief valves (pressure at which
they will open) are indicated by the following label,
attached to the exterior of the machine:-
Warning: Set pressure safety valve xx
bar (value 'xx' will be shown on the
label on the compressor)
Note: The set pressures for these valves can be
found in the ‘Technical Data’ section of this manual.
2.4.9 If raised platforms are required to provide access to
the unit they must not interfere with normal operation
or obstruct access for lifting or dismantling
components. Platforms and stairs should be of grid
or plate construction with safety rails on all open
sides.
2.5 Operational Precautions
2.5.1 The compressor unit must only be operated by
competent personnel under a qualified supervisor.
2.5.2 Do not run the compressor with doors open or
covers removed.
2.5.3 Never remove or tamper with the safety devices,
guards or insulation materials fitted to the unit.
2.5.4 The compressor must only be operated at the supply
voltage and/or frequency for which it is designed.
2.5.5 When mains power is switched on, lethal voltages
are present in the electrical circuits and extreme
caution must be exercised whenever it is necessary
to carry out any work on the electrical system.
2.5.6 Do not open the starter compartment or touch
electrical components while voltage is applied
unless it is necessary for measurements, tests or
adjustments. Such work should be carried out only
by a qualified electrician equipped with the proper
tools and wearing appropriate body protection
against electrical hazards.
7
2 Safety Procedures
2.5.7 When the unit is running under automatic control,
attach a sign stating ‘THIS UNIT MAY START
WITHOUT WARNING’ next to the display panel.
2.5.8 If the unit is equipped with a Remote Start device,
attach warning notices stating ‘THIS UNIT CAN BE
STARTED REMOTELY’ in prominent locations, one
on the outside of the unit, the other inside the control
compartment.
2.5.9 As a further safeguard, take adequate precautions to
make sure there is no one checking or working on
the unit before attempting to operate remote start
equipment. Attach a notice stating ‘CHECK THAT
ALL PERSONNEL ARE CLEAR OF THE UNIT
BEFORE STARTING’ or similar wording to the
remote start equipment.
2.5.10 Some parts of the compressor reach extremely high
temperatures. If panels are removed from the
enclosure take precautions against burns.
2.5.11 If there is any indication that the compressor is
overheating it must be shut down and the cause
investigated. Beware of burns from hot metal parts
or hot oil when working on a unit which has recently
been shut down.
2.5.12 The ‘Noise at Work Regulations 1989’ suggest that
ear protectors should be worn where noise levels
are 85 dB(A) or higher. With all covers in place, the
noise levels of the compressors described in the
manual are substantially lower than this figure
unless installed in an already noisy environment.
2.5.13 Be aware that high noise levels can interfere with
communication.
2.6 Maintenance and Repair Precautions
2.6.1 Maintenance, repairs or modifications must only be
carried out by competent personnel under a qualified
supervisor.
2.6.2 If replacement parts are needed use only CompAir
Genuine Parts.
2.6.3 Carry out the following operations before removing
any panels from the enclosure or dismantling any
part of the unit.
1) Isolate the compressor unit from the main
electrical power supply. Lock the isolator in the
‘OFF’ position and remove the fuses.
2) Attach a label to the isolator switch and to the
display panel carrying the warning ‘WORK IN
PROGRESS – DO NOT APPLY VOLTAGE’. Do
not switch on electrical power or attempt to
start the unit if such a warning label is
attached.
8 DL054CA
CompAir
3) Close the isolating valve between the
compressor unit and the user’s pipework.
Attach a label to each valve carrying the
warning ‘WORK IN PROGRESS – DO NOT
OPEN’.
4) Bleed down all air pressure in the delivery pipe
between the non-return valve and the shut-off
valve by carefully slackening the aftercooler
condensate drain connection at the strainer
inlet.
5) First and second stage pressure will be
exhausted through the dump silencers by the
action of the unloader solenoid valve. As an
additional precaution, open the manual
condensate drain valves.
6) Allow compressor to cool for 30 minutes.
2.6.4 Use only lubricating oils and greases approved by
CompAir. Make sure that the selected lubricants
comply with all relevant safety regulations,
especially with regard to the risk of explosion or fire
and the possibility of decomposition or the
generation of hazardous gases.
2.6.5 Always clean up oil spills from the surrounding floor
and outside of the compressor unit before and after
maintenance work. Make sure that no oil is left on or
near the air intake components, including the suction
regulator, which could be drawn into the compressor
and contaminate the delivered air.
2.6.6 Make sure that all instructions concerning the
operation and maintenance are strictly followed and
that the complete unit, with all accessories and
safety devices, is kept in good running order.
2.6.7 The accuracy of pressure and temperature gauges
and switching thermometers must be regularly
checked. They must be renewed when acceptable
tolerances are exceeded.
2.6.8 Protection devices must be tested as described in
the Repair manual.
2.6.9 Keep the compressor unit clean at all times. Protect
components and exposed openings by covering with
clean cloth or tape during maintenance or repair
work.
2.6.10 Protect the motor, air intake, electrical and
regulation components against the entry of
moisture, e.g., when steam cleaning.
2.6.11 Precautions must be taken when carrying out
welding or any repair operation which generates
heat, flames or sparks. The adjacent components
must always be screened with non-flammable
CompAir Safety Procedures 2

material and if the operation is to be carried out near Warning

any part of the oil system, or close to a component
which may contain oil, the system must first be
thoroughly purged, preferably by steam cleaning.
• The use of replacement parts or lubricating oils
2.6.12 Never use a light source with an open flame to not supplied or approved by CompAir may lead
inspect any part of the unit. to failures in service which would not be
2.6.13 In no circumstances must any welding work or other covered by warranty.
modification be carried out on any pressure vessel.
2.6.14 Before dismantling any part of the compressor unit • Any unauthorised modifications or failure to
ensure that all heavy movable parts are secured. maintain this equipment in accordance with the
maintenance instructions may make it unsafe.
2.6.15 After completion of repair or maintenance work The use of replacement parts not supplied or
ensure that no tools, loose items or rags are left on approved by CompAir may create hazardous
or inside any part of the machine. Turn the motor conditions over which CompAir has no control.
over by hand several times to ensure there is no
mechanical interference.
• Such hazardous conditions may lead to
2.6.16 Check the direction of rotation of the fan motors, oil accidents that can be life threatening, cause
pump motor and main drive motor when starting up substantial bodily injury or result in damage to
the compressor initially and after any work on the the equipment. CompAir can bear no
electrical connections or switchgear (refer to the responsibility for equipment in which
Installation and Commissioning manual). unapproved replacement parts are included.
2.6.17 Do not use any flammable liquid to clean valves,
filter elements, air pipes or any component carrying
a flow of air during normal operation. If chlorinated
hydrocarbon non-flammable fluids are used for
cleaning, safety precautions must be taken against
any toxic vapours which may be released.
2.6.18 Do not use carbon tetrachloride.
2.6.19 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 soap
and water are readily available.
2.6.20 When disposing of condensate, old oil, used filter
elements and other parts and waste material of any
kind make sure that there is no pollution of any drain
or natural water-course and that no burning of waste
takes place which could cause pollution of the air.
Protect the environment by using only approved
methods of disposal.

DL054CA 9
2 Safety Procedures CompAir

2.7 Precautions in the event of fire

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

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

1) In order to prohibit the ‘bringing back into

service’ of equipment by persons unknown, it
should be rendered unusable in order to avoid
improper re-use.

2) Alternatively all such items of equipment

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

3) Bio-degradable items should be subject to

normal industrial waste disposal processes.
Ensure that no plastic, rubber or composite
materials are disposed of by incineration.

4) Ensure that all fluid waste e.g. lubricating oils

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

10 DL054CA
CompAir General Description 3

3 General Description 3.3 Electronic Controller

3.3.1 The electronic control system is microprocessor
based with liquid crystal display (LCD), mimic
3.1 Introduction
diagram, tactile membrane switches and dedicated
3.1.1 The unit is a fully enclosed, oil-free, two-stage, air- (LED) pressure display, incorporating many
cooled, rotary screw compressor package. It advanced control and monitoring features.The
comprises a drive motor, first and second stage air- controller is Year 2000 compliant.
ends, intercooler, aftercooler, oil cooler, first and
second stage moisture separators, air intake and 3.4 Regulation System
filter assembly, control panel and cooling fans. The
unit is mounted on a baseframe in an acoustic steel- 3.4.1 The compressor runs continuously, loading and
panelled enclosure. Opening doors give access for unloading at preset delivery pressures (P1 and P2
routine maintenance. set points). If air pressure remains above the P2 set
point for the run-on time the compressor will shut
3.1.2 The air-ends are driven by an electric motor via a down into Stand-by mode. The compressor will
flexible coupling and a gearbox in which the single automatically restart as demand increases and the
main gear drives the male rotor of both stages. pressure drops to the P2 set point.
3.1.3 The compressor is controlled by an electronic
controller which monitors and acts on information
translated from pneumatic, electrical and
mechanical devices. Delivery pressure is monitored
by a pressure transmitter to regulate on-load and off-
load running via a solenoid operated unloader valve.
A visual display provides information on compressor
performance and condition.

3.2 Compressor
3.2.1 Description
Air is compressed by two rotary screw air-ends.
Each comprises an intermeshing pair of helical
screw rotors driven by a pinion fitted to the male
rotor shaft which meshes with the main gear.
3.2.2 Timing gears on each male rotor drive the female
rotors and maintain correct clearance. Seals
between the rotors and bearings prevent air passing
into the oil system and oil passing into the
compression chambers. The rotors, shafts, seals
and the internal surface of the rotor casing are
coated with an anti-corrosive/anti-wear material.
3.2.3 Operation
Compression takes place between the lobes on the
male rotor, the flutes on the female rotor and the air-
end casing. As the rotors turn, the trapped air is
progressively compressed until the discharge port is
uncovered and is then discharged at first stage
pressure. Further compression takes place in a
similar manner in the second stage air-end and air,
at delivery pressure, passes into the user’s
pipework.

DL054CA 11
4 Technical Data CompAir

4 Technical Data
4.1 Models D55 to D155
Oil capacity (approx.): 40 litres/10.57 US gal

Recommended oils: Fuchs Renolin AC68; Shell Turbo T68; Mobil Rarus 426
Esso Teresso 68; Castrol Perfecto T68
Note: Compressors are factory filled with Fuchs Renolin AC68

Air delivery connection: Flange DN80 BS4504 PN16 (DIN 2633)

or Flange 3 in. ASA 150lb R/F

Condensate drain connections: (manual) G 1/2 or 1/2 in. NPT Female

Condensate drain connections: (auto) G 3/8 or 3/8 in. NPT Female

Lifting points: Forklift slots and positions for four lifting brackets

Delivery air pressure: minimum 4·0 bar g/58psi g

maximum Refer to Compressor data plate

Delivery air temperature (continuous operation): Typically 10°C/18°F above ambient air temperature

Ambient temperature: minimum 0°C/32°F

maximum (see note) 40°C/104°F
Note: Some models are available for higher ambient air temperatures.

Main motor rotation: Anticlockwise viewed from non-drive end

Fan motor rotation: Clockwise viewed from non-drive end

Oil pump motor rotation: Clockwise viewed from non-drive end

Approx. weight of heaviest component (compressor air-ends/gearbox, all models), Kg/lb: 499/1098

Fan assembly weight, Kg/lb (all models): 53/117

Dimensions (approx), L x W x H, mm/inches: 2895 x 1600 x 2050/113.98 x 64 x 80.71

Air Pressure Relief Valve Settings Interstage: 3.5 bar

Final Delivery: 11.4 bar

Full Load Current See vehicle identification plate

Compressor Weight See vehicle identification plate

All data relates to the following reference conditions:

Air intake pressure: 1bar a/14.5psi a

Air intake temperature: 20°C/68°F

Humidity: 0% dry

12 DL054CA
CompAir Technical Data 4

Oil Pump and Fan Motors Thermal Overload Settings, Amps

Model 220V, 50Hz 400V, 50Hz 220V, 60Hz 380V, 60Hz 440V, 460V 575V, 60Hz
60Hz
Oil Pump 6.5 3.5 6.3 3.7 3.3 2.5
Fans (D55-D90) 14.9 8.2 12.1 7.3 6.3 4.8
Fans (D110-D150) 20.9 11.5 22 13.3 11.5 8.8

Main Motor Thermal Overload Settings, Amps

Model 220V, 50Hz 400V, 50Hz 220V, 60Hz 380V, 60Hz 440V, 460V 575V, 60Hz
60Hz
D55 - - 110 65 55 45
D75 130 75 140 85 70 55
D90 155 90 170 105 85 70
D110 205 110 215 130 110 85
D132 220 130 - - - -
D150 290 170 285 170 140 115

DL054CA 13
5 Installation
5 Installation
Warning
5.1.4
• Refer to the safety procedures before
installation of the compressor unit.
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical
checks. Isolate the power supply before starting
any maintenance work.
5.1 Installation Procedure
The following procedure is a guide for
installing a standard compressor unit. For the
installation of nonstandard units or units fitted
with optional equipment refer to the local
CompAir distributor.
5.1.1 Foundations
The compressor is supplied as a free standing
package and does not require securing to a
foundation. However, the supporting floor must
have a loading capacity sufficient to support
the weight of the unit (see “Technical Data”).
5.1.2 Unpacking, Lifting and Handling
a) The compressor package may be lifted by fork
lift using the slots provided in the baseframe or
by spreader bars and lifting frame with slings or
chains attached to lifting brackets bolted to the
baseframe. To prevent damage, spreader bars
or frames should be wide enough to keep
slings clear of the enclosure.
b) Remove the polythene cover and lift the
compressor off the pallet. Lower the unit into
position, ensuring that the weight is evenly
supported. Check that the baseframe is level to
within 3 mm / 1/8 in. Use packing pieces under
the baseframe if necessary.
c) Remove all protective blanking covers and
tapes.
5.1.3 Compressor Building
a) The compressor building should be sized to
provide 1200mm / 47in of free space on all
sides and 1500mm / 59in above the unit. In
14
CompAir
addition, consideration should be given to
providing adequate access for maintenance.
b) Lifting facilities should be provided over the
compressor to enable the heaviest
components to be lifted during maintenance.
Ventilation
a) A ventilation inlet opening must be provided at
the cooling air inlet end of the unit to allow cool
air to enter the building. Hot air should be
exhausted from the building either by means of
a duct connected to the outlet grille of the
compressor or a suitably sized ventilation fan
located in the building. The fan should be sized
to handle the total cooling air flow of the
compressor(s). The inlet opening and
ventilation fans should be sized to prevent build
up of heat within the building, limiting the
temperature rise to an acceptable level.
b) The minimum duct dimensions are 1470mm x
590mm / 58in x 23in or an equivalent cross
sectional area. The maximum duct length
without fan assistance is 3 metres / 118in of
straight duct plus one right angled bend.
c) If an exhaust duct is fitted a 1 metre / 39in
removable section should be provided
immediately above the compressor for
maintenance purposes.
d) The temperature of the air at the air intake
grilles should be between 0°C / 32°F and
40°C / 104°F. If the air temperature is below
0°C / 32°F heaters should be installed inside
the compressor and precautions should be
taken to prevent freezing of the condensate
drains. Refer to your CompAir distributor for
further details.
e) Ventilation openings should be screened to
prevent the ingress of debris into the
compressor room.
DL054CA
CompAir Installation 5

f) Recommended ventilation arrangements are b) A suitably sized air receiver should be installed
shown below: between the compressor and distribution
system. As a guide the receiver capacity
should be 10% of the compressor output. e.g.
DUCT
a 10m³/min compressor will require a 1m³ /
35ft³ air receiver.
INLET c) The two automatic condensate drain and two
OPENING
manual drain connections should all be
separately piped into a drain gulley or open
tundish. The four drains must not be connected
SM 1049 GB together. Piping from the drain connections
should not exceed 3 metres / 118in in length
and must fall towards the drain gulley or open
FAN tundish.
d) In order to minimise pressure drops all valves
INLET should be either gate or ball full flow type and
OPENING all bends should have a minimum radius of at
least 1.5 times the pipe diameter.

CAUTION: All pipework is to be adequately

5.1.5 Air and Condensate Pipework supported outside of the compressor. The
compressor connections must not carry any
a) The air discharge flange should be connected
load.
to the distribution header or air receiver using
piping with a minimum nominal bore of 80mm/
CAUTION: It is important that the air supply to
3in. The discharge piping must connect into the
the powered breather, which is taken from the
top of the distribution header to prevent
delivery pipe, is moisture free. If the
condensed water from running back into the
installation is such that condensation from the
compressor during periods of standby
customer's air network forms in the delivery
operation. The pipe must not be connected into
pipe, then the air supply must be taken from a
either the side or bottom of the header. An
new location that is moisture free.
isolating valve should be incorporated in the
discharge piping as shown below to enable the
e) When connecting the compressor on the mains
compressor to be isolated for maintenance
side to the compressed air system available at
purposes.
the customer's end, check the operating
SM 1048 temperatures and operating pressures
required and examine the required connecting
flange or the connection thread for correct
functioning. In the case of connections by
means of connecting hoses, take appropriate
measures to prevent whipping of the loose end
in the event that the hose connection tears off.

CAUTION: Do not install a non-return valve on

the outlet side of the compressor.

DL054CA 15
 5

16
2895 45
MOTOR COOLING AIR & [113.98"] [1.77"]
6-M6 CAPTIVE NUTS FOR SUCTION AIR
657
[25.87"] FIXING COOLING AIR OUTLET 1200 INLET COOLING AIR INLET
DUCT [47.24"]
23
[0.91"]
605 ALL AROUND

65
C

[2.56"]
[23.82"]
49

322
307
DUCTED ENTRY OF

[12.69"]
[1.93"]

[12.10"]
SUCTION AIR
Installation

163.5
[6.44"]
148.5
[5.85"]
[0.20"]

143
[5.63"]

1600

1554
[62.99"]

[61.18"]
1470
[57.87"]
227

10
[0.39"]
[8.94"]
CENTRE OF GRAVITY

895
[35.24"]
C 10 237
[0.39"] [9.34"]

827

727
[32.56"]

[28.62"]
6 HOLES M6

GLAND PLATE FIXING DETAILS

60 590

23
925
FOR SUCTION AIR INLET DUCT

[0.91"]
[36.42"]
[2.36"] [23.23"] SCALE 1:4
C D
DETAILS OF FIXING FOR
EXHAUST DUCT 1297
COOLING AIR INLET
[51.06"]

RECOMMENDED PIPING
ARRANGEMENT ( NOT IN COMPAIR SUPPLY)
MINIMUM
NOTE IT IS IMPORTANT THAT CONNECTING PIPEWORK/VALVES
MUST NOT IMPART ANY LOADS TO COMPRESSOR AND MUST BE
CLEARANCE
ADEQUATELY HELD BY INDEPENDENTLY MOUNTED SUPPORTS.

80 -3" DIA.MINIMUM C
NOMINAL BORE
FOR MAINTENANCE REASONS GLAND PLATE 352 x 267 [13.86 x 10.51"]
1500

COOLING AIR OUTLET

[59.06"]

A 1000-39.37" REMOVABLE D55-D75-D90. 376 M3/MIN.-13276 Ft3/MIN FOR INDEPENDANT SUCTION AIR INLET
SECTION MUST BE ALLOWED DUCTED ENTRY

1000
D110-D132-D150. 543.7 M3/MIN.- 19198 Ft3/MIN.

[39.37"]
FOR, IF INSTALLING COOLING
AIR DUCTWORK. SUCTION AIR INLET.
(GLAND PLATE FITTED IN THIS POSN. WHEN DUCTED INLET IN USE).

06 06

Hughenden Avenue High Wycombe

Buckinghamshire England HP13 5SF

TECHNICAL DATA
MODEL

SERIAL No.
TP1 MAX PRESSURE
YEAR

MOTOR RPM

V.Ph.Hz.
kW
C
m3/min

C20089-548

CONNECTI0N POINT FOR

2050
[80.71"]

DUCTED ENTRY OF
SUCTION AIR
D
(SEE DETAIL)
1041

1012
1017.5
[40.98"]

[39.84"]
[40.06"]

COOLING
AIR INLET E

DIMENSIONS AND INSTALLATION DETAILS

85.6 D
SEE SEPARATE VIEW DOCUMENT HOLDER [3.37"] 225
1080 757 FOR DETAILS OF CONDENSATE DRAINS INSIDE STARTER BOX [8.86"]
[42.52"] [29.80"] DOOR
FORKLIFT LIFTING 35
[1.38"] MOTOR COOLING AIR INLET
POINTS GLAND PLATE 298-11.73"x198-7.80"
& POSITION OF OPTIONAL FOR CUSTOMER ELECTRICAL
34
BRACKETS [1.34"] CABLE ENTRY

35
[1.38"]

189
[7.44"]
TP3 MANUAL CONDENSATE DRAIN (2 OFF, VALVES SUPPLIED LOOSE TO BE FITTED OUTSIDE MACHINE) G1/2 1/2" NPTF
TP2 AUTOMATIC CONDENSATE DRAIN (2 OFF) G3/8 3/8" NPTF
TP1 AIR DISCHARGE BS4504/DIN2633 DN80 PN16 ASA 3" RF-150#
DESCRIPTION 50 Hz BUILD 60 Hz BUILD
TP2 C C
101 TERMINAL POINT DETAILS
[3.98"]
TP3
DETAILS OF CONDENSATE DRAINS SM 0995

DL054CA
CompAir
CompAir Installation 5

5.1.6 Electrical Connections 3 conductors are specified, they are assumed

a) Remove the plain gland plate from the starter
compartment. Drill the plate to take the power
cable and fit suitable cable glands.
b) It is important that the sealing and IP rating of
the starter compartment is maintained by the
use of glands of the correct type and size in
order to seal the compartment against the
ingress of dust.
c) Ensure the power supply to the unit is taken
from a fused isolator, the switch is locked ‘OFF’
and fuses removed. Connect the supply in
accordance with the electrical connection
diagram. Use cables complying with the
standards of the International Electrotechnical
Commission (IEC) or of the Institution of
Electrical Engineers (IEE) (latest edition) for
U.K. users. The cables must be correctly sized
for the total input kW of the plant and suitably
protected and clamped.
to be in separate 3-core cables)
b) Cables for any given machine are run
separately from the supply cables to other
equipment.
c) Cables are clipped directly to insulated walls
d) Cables are shaded from direct sunlight and
other sources of external heat.
Notes:
1) Where any of these assumptions is invalid, or
regulations other than BS7671 apply, cable
sizes should be calculated for the actual
conditions.
2) The voltage at the machine connections
should not be less than nominal voltage less
6%, except 400V 50Hz models which should
be no less than 360V.

5.2 Storage Procedures 3) Earth conductors should not be less than half
the cross section of the main conductors, and
5.2.1 All compressors are inhibited against corrosion may be separate or a fourth conductor in the
before leaving the CompAir factory to give main cable.
protection during transportation and storage
before installation, for a maximum of 4) ISO 269 fuses or equivalents (EN 60269,
12 months. Proper precautions should be BS 88) must conform to gG characteristics.
taken if the storage period is longer than
12 months.
5.2.2 Similarly, any compressor taken out of service
or put into temporary storage must be
protected against corrosion. The rate at which
corrosion in storage occurs will be more rapid
in a humid climate than in dry conditions,
making it impossible to recommend a
maximum safe storage time applicable to all
cases.
5.2.3 Refer to your local distributor for advice on
carrying out procedures for short or long term
storage.

5.3 Cable Sizes And Fuse Ratings

(refer to following table)

5.3.1 The following assumptions have been made in

compiling the table of cable sizes and fuse
ratings:
a) PVC insulated, 3-core non-armoured copper
cable with a rated conductor operating
temperature of 70°C (where more than

DL054CA 17
5 Installation CompAir

5.4 Cable Sizes and Fuse Rating Table

Model 220V 50Hz 220V 60Hz 380V 60Hz 400V 50Hz 440/460V 60Hz 575V 60Hz

D55 Main Overload Setting 110 65 55 45

Fuse (ISO 269 gG) 250 160 125 100
Cable Size @ 30°C (BS 6231) 3x120mm2 3x70mm2 3x50mm2 3x35mm2
2 2 2
Cable Size @ 45°C (BS 6231) 3x185mm 3x95mm 3x70mm 3x50mm2
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)

D75 Main Overload Setting 140 140 85 85 70 55

Fuse (ISO 269 gG) 315 315 200 200 160 125
Cable Size @ 30°C (BS 6231) 3x185mm2 3x185mm2 3x95mm2 3x95mm2 3x70mm2 3x50mm2
Cable Size @ 45°C (BS 6231) 3x240mm2 3x240mm2 3x120mm2 3x120mm2 3x95mm2 3x70mm2
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)

D90 Main Overload Setting 170 170 105 100 85 70

Fuse (ISO 269 gG) 400 400 200 200 200 160
Cable Size @ 30°C (BS 6231) 3x240mm2 3x240mm2 3x95mm2 3x95mm2 3x95mm2 3x70mm2
6x150mm2 or 6x150mm2 or
Cable Size @ 45°C (BS 6231) 3x120mm2 3x120mm2 3x120mm2 3x95mm2
3x400mm2 3x400mm2
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)

D110 Main Overload Setting 200 215 130 120 110 85

Fuse (ISO 269 gG) 400 500 315 250 250 200

6x150mm2 or
Cable Size @ 30°C (BS 6231) 3x240mm2 3x185mm2 3x120mm2 3x120mm2 3x95mm2
3x400mm2
6x150mm2 or
Cable Size @ 45°C (BS 6231) 6x300mm2 3x240mm2 3x185mm2 3x185mm2 3x120mm2
3x400mm2
D110RS
Fuse (ISO 269 gG) 315
Cable Size @ 30°C(BS6231) 3x150mm2
Cable Size @ 45°C(BS6231) 3x240mm2

D132 Main Overload Setting 245 140

Fuse (ISO 269 gG) 500 315
6x150mm2 or
Cable Size @ 30°C (BS 6231) 3x185mm2
3x400mm2
Cable Size @ 45°C (BS 6231) 6x300mm2 3x240mm2
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)

D150 Main Overload Setting 320 285 170 185 140 115
Fuse (ISO 269 gG) 630 630 400 400 315 250
Cable Size @ 30°C (BS 6231) 6x240mm2 6x240mm2 3x240mm2 3x240mm2 3x185mm2 3x120mm2
2 2
6x150mm or 6x150mm or
Cable Size @ 45°C (BS 6231) 6x400mm2 6x400mm2 3x240mm2 3x185mm2
3x400mm2 3x400mm2
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)
Cable Size @ 45°C(UL/CSA)

18 DL054CA
CompAir Commissioning 6

6 Commissioning 9) Ensure fan motor and oil pump motor thermal

overloads are set correctly for supply voltage.
Warning Oil Pump and Fan Motors Thermal Overload Settings,
Amps
Motor 220V/ 400V/ 220V/ 380V/ 440/460V/ 575V/
50Hz 50Hz 60Hz 60Hz 60Hz 60Hz
Oil Pump 6.5 3.5 6.3 3.7 3.3 2.5
• Refer to the safety procedures before Fans
14.9 8.2 12.1 7.3 6.3 4.8
commissioning the compressor unit. (D55-D90)
Fans
• Lethal voltages are used in this equipment. Use (D110-D150)
20.9 11.5 22 13.3 11.5 8.8
extreme caution when carrying out electrical
checks. Isolate the power supply before starting Main Motor Thermal Overload Settings, Amps
any maintenance work. Model 220V/ 400V/ 220V/ 380V/ 440/460V/ 575V/
50Hz 50Hz 60Hz 60Hz 60Hz 60Hz
D55 110 65 55 45
D75 130 75 140 85 70 55
D90 155 90 170 105 85 70
6.1 Commissioning Procedure D110 205 110 215 130 110 85
D132 220 130
When commissioning a new compressor or
D150 290 170 285 170 140 115
recommissioning a compressor which has been
overhauled or out of service, carry out the following MCB Q101 (MMS) Settings, Amps
procedures before attempting to start: Motor 220V/ 400V/ 220V/ 460V/ 575V/
50Hz 50Hz 60Hz 60Hz 60Hz
Note: We recommend that commissioning is carried D55-D90 32 19.9 30.5 18.3 12.1
out by a CompAir distributor. D110-D150 45 25 45 25 21

6.1.1 Preliminary Mechanical Checks 10) Remove panels as required to gain access to motor
connections.
1) Remove air filter cover.
11) Inspect the motor and control wiring connections to
2) Check that the isolator switch is locked ‘OFF’ and
make sure they are correct and secure. Replace all
that all pipework and electrical power connections
panels.
are correct and secure.
12) Check that all protection blanks, air filter covers and
3) Open the access panel to the starter compartment.
tapes have been removed.
Check all screws and starter connections for
security. Check all electrical connections are correct 13) Remove the four air-end/motor transportation bolts
and secure. (if fitted). These are coloured red for identification.
4) Ensure the controller to Extension module unit 14) Open the isolating valve to the user’s pipework.
interface cable connections are correct and secure.
15) Check that the air end and motor rotate freely.
5) Ensure the main supply cables and fuse ratings
16) Check oil level and top up if required.
comply with regulations.
6) Ensure the control transformer primary tapping
connections are correct for supply voltage.
7) Ensure main motor thermal overload is set correctly
for motor F.L.C. and supply voltage, as shown on the
motor data plate.
8) Ensure MCB Q101 (MMS) is set correctly.

DL054CA 19
6 Commissioning CompAir

6.2 System Checks and Calibration
Note: The values shown throughout these
procedures are examples only.
6.2.1 When an attempt to alter a parameter or option is
made for the first time after entering the menu
routines, the controller will request an access code.
When this occurs, the following procedure should be
followed:
a) Press SPANNER, CLOCK, SPANNER, CLOCK
symbols
Note: A guide to using the menu routines and control
unit menu structure diagrams is shown in Section 7
– Operation
CAUTION: The fan, oil pump and main motor are
tested for correct rotation during manufacture. Do
not rewire any motor as reverse rotation may result
causing air-end seizure.

No. Action Reason Display

1. Switch power supply ‘ON’. C20619/nn/xx/nn

SF3LnnUN ddmmmyy

Note: The POWER ON indicator

lights.

The REMOTE and AUTO RESTART

indicators will light if these facilities
have been selected in the installation
procedure.

After several seconds the status

display changes to:

Ready to start
Oil temperature 20°C

Note: If ‘Power supply fault’ is

displayed, isolate the power and
change over any two of the 3 phase
incoming supply cable connections.

2. Press ENTER. To display the main menu. Main menu

Operational settings

3. Press DOWN until the message To scroll through the menu options. Main menu
shown on the right is displayed. Commissioning - config.

4. Press ENTER. To choose the Commissioning - Commissioning - config.

configuration menu. Language English

5. Press (+) or (-) and repeat until the To select the Commissioning - config.
required language is displayed. displayed language. Language Option

(Pulsing display)

6. Press ENTER. To confirm the displayed Commissioning - config.

language. Language Option

(Steady display)

7. Press DOWN and repeat until the To select the required option. Commissioning - config.
display shown on the right is obtained. Return to previous menu

8. Press ENTER. To display the main menu. Main menu

Operational settings

20 DL054CA
CompAir Commissioning 6

No. Action Reason Display

9. Press DOWN and repeat until the To scroll through the menu. Main menu
option shown on the right is displayed. Service diagnostics

10. Press ENTER. To choose the Service diagnostics Service diagnostics

menu. Reset service hours

11. Press DOWN and repeat until the To scroll to the required option. Service diagnostics
option shown on the right is displayed. Test digital outputs

12. Press ENTER. To choose the Test digital outputs Test digital outputs
option. Main contactor 0

13. Press DOWN and repeat until the To scroll to the required option. Test digital outputs
option shown on the right is displayed. Fan contactor 0

14. Press (+). To turn on the fan and oil pump. Test digital outputs
Fan contactor 1

15. Check that air is being expelled from To check the direction of rotation of the
the enclosure fan exhaust. fan.

16. Check that oil pressure rises. To check the direction of rotation of the
oil pump.

17. Press (-). To turn off the Fan/oil pump. Test digital outputs
Fan contactor 0

18. If the fan or oil pump rotation is To reverse rotation.

incorrect, contact your CompAir
distributor

19. Press UP and repeat until the option To scroll to option required Test digital outputs
shown on the right is displayed Return to previous menu

20. Press ENTER. To return to the service diagnostics Service diagnostics

menu. Reset service hours

21. Press DOWN once then ENTER. To choose the calibrate pressure Set pressure at 0 bar
menu. Press enter when ready

22. If the zero pressure display is known to To by-pass the first part of the
be correct then press DOWN and go to calibration procedure.
step 25.

23. Disconnect the air connection to the To ensure zero pressure on the Set pressure at 0 bar
delivery pressure transmitter. transmitter. Press enter when ready

24. Press ENTER. To set the zero pressure Set pressure > 5.51bar
measurement in the controller.

25. Connect a slave air supply of more
than 5.51 bar to the delivery pressure
transmitter.
To establish a known calibration Adjust +/- :- 6.9bar
pressure. Press enter when ready
Note: If the air pressure is not above
5.51 bar the message shown in step
24 is displayed.

DL054CA 21
6 Commissioning CompAir

No. Action Reason Display

26. If the slave air supply is not constant The alternative calibration procedure
then press UP or DOWN to enter the is more suitable for use with an
alternative calibration routine and go unstable reference pressure.
to step 30.

27. Press (+) or (-) as required to adjust To adjust the LCD display reading to Adjust +/- :- 7.0bar
the value shown on the display. match the slave air gauge. Press enter when ready

(Pulsing display)

28. When the gauge and display To store the pressure calibration value Commissioning - config.
pressures are equal press ENTER. in the controller.
(After a delay the display reverts to:)

Service diagnostics
Reset service hours

29. Go to step 31 To by-pass the alternative calibration

procedure.

30. Press UP or DOWN as required to To adjust the control panel display. Adjust pressure up/down
make the LED display follow the slave Press enter when ready
gauge display.

31. When the gauge and display track the To calibrate the pressure display. Calibration complete
pressure together, press ENTER.
(After a delay the display returns to:)

Service diagnostics
Reset service hours

32. Press RESET. To exit menu routine. Ready to start

Oil temperature 20°C

33. Re-connect the air line to the delivery

pressure transmitter.

22 DL054CA
CompAir Commissioning 6

6.3 Checking/Altering Commissioning Parameters

Note: The values shown throughout these procedures are examples only.
Refer to the Control Unit Menu Structure diagrams and check/set the commissioning parameters

No. Action Reason Display

1. Press ENTER. To display the Main menu. Main menu.

Operational settings.

2. Press DOWN and repeat until the To display the Commissioning - config Main menu.
display shown on the right is obtained. menu. Commissioning - config.

3. Press ENTER. To choose the Commissioning - config Commissioning - config.

menu. Language English

4. Press DOWN. To display the next option. Commissioning - config.

Unit of pressure bar

5. Press DOWN. To display the next option. Commissioning - config.

Unit of temperature °C

6. Press DOWN. To display the next option. (On multi Commissioning - config.
unit installations). Machine number 1

7. Press ENTER. To display the Main menu. Main menu.

Operational settings.

8. Press DOWN and repeat until the To scroll through the menu options. Main menu.
display shown on the right is obtained. Commissioning - values.

9. Press ENTER. To select the commissioning values Commissioning - values

menu. Max. pressure 10.5bar

10. Press DOWN. To choose the next option. Commissioning - values

Max. overpress 10.6bar

11. Press DOWN. To choose the next option. Commissioning - values

Star/delta time 25sec

12. Press DOWN. To choose the next option. Commissioning - values

Load delay time 60sec

13. Press DOWN. To choose the next option. Commissioning - values

Max. service hours 4000

14. Press DOWN. To choose the next option. Commissioning - values

Auto-restart delay 100sec

15. Press DOWN. To choose the next option. Commissioning - values

Interstage trip 4.0bar

16. Press DOWN. To choose the next option. Commissioning - values

Interstage alarm 3.8bar

17. Press DOWN. To choose the next option. Commissioning - values

Oil press alarm 1.7bar

18. Press DOWN. To choose the next option. Commissioning - values

Oil press trip 1.5bar

DL054CA 23
6 Commissioning CompAir

No. Action Reason Display

19. Press DOWN. To choose the next option. Commissioning - values

Oil temp trip 75°C

20. Press DOWN. To choose the next option. Commissioning - values

Oil temp alarm 70°C

21. Press DOWN. To choose the next option. Commissioning - values

St1 delivery trip 225°C

22. Press DOWN. To choose the next option. Commissioning - values

St1 delivery alarm 220°C

23. Press DOWN. To choose the next option. Commissioning - values

St2 intake trip 60°C

24. Press DOWN. To choose the next option. Commissioning - values

St2 intake alarm 50°C

25. Press DOWN. To choose the next option. Commissioning - values

St2 delivery trip 235°C

26. Press DOWN. To choose the next option. Commissioning - values

St2 delivery alarm 225°C

27. Press DOWN. To choose the next option. Commissioning - values

Plant del trip 55°C

28. Press DOWN. To choose the next option. Commissioning - values

Plant del alarm 40°C

29. Press RESET. To exit menu routines Ready to start

Oil temperature 20°C

24 DL054CA
CompAir Commissioning 6

6.4 Checking/Altering Operating Parameters

Note: The values shown throughout these procedures are examples only.

No. Action Reason Display

1. Press ENTER. To display main menu. Main menu

Operational settings

2. Press DOWN and repeat until the To scroll through the main menu. Main menu
display shown on the right is obtained. Operational settings

3. Press ENTER. To display the Operational settings Operational settings

menu. P1 set point 7.0bar

4. Press DOWN. To choose the next option. Operational settings

P2 set point 7.3bar

5. Press DOWN. To choose the next option. Operational settings

Run on time 10min

6. Press DOWN. To choose the next option. Operational settings

Drain open time 5sec

7. Press DOWN. To choose the next option. Operational settings

Drain shut time 30sec

8. Press RESET. To exit the menu routines. Ready to start

Oil temperature 20°C

6.5 Re-setting Service Interval Timer

Note: The values shown throughout these procedures are examples only.

No. Action Reason Display

1. Press ENTER. To display the Main menu. Main menu

Operational settings

2. Press DOWN and repeat until the To scroll through the menu. Main menu
display shown on the right is obtained. Service diagnostics

3. Press ENTER. To display the service diagnostics Service diagnostics

menu. Reset service hours

4. Press ENTER. To reset the service hours countdown Service diagnostics

timer to maximum programmed hours. Service hours to run 4000

(After a delay, changing to:)

Service diagnostics
Reset service hours

5. Press RESET. To exit the menu routines. Ready to start

Oil temperature 20°C

DL054CA 25
6 Commissioning CompAir

6.6 Final Mechanical Checks

Notes:
1) The values shown throughout these procedures are examples only.
2) Ensure that the air discharge pipe is disconnected from the user’s system.
3) Ensure that the discharge air is directed away from all persons in the area.

No. Action Reason Display

1. Switch power supply ‘ON’. C20619/nn/UN/xx

SF3LnnUN_ddmmmyy

2. After a few seconds the display Ready to start

becomes: Oil temperature 20°C

3. Press START. To start the compressor. Starting

Oil temperature 20°C

4. If the compressor does NOT start a The compressor will not start if:
message should be displayed.
(a) A menu routine has been selected. Menu selected
Menu option displayed
(b) Remote operation has been Ready to start
enabled. Remote start enabled

(c) A trip fault condition exists. Status

(See fault rectification.) Fault message

5. If electrical work has to be carried out,

switch power to the compressor ‘OFF’.
Establish the correct starting
conditions. Go to step 1.

6. Following start-up of the motor the Offload

display becomes: Oil temperature 20°C

7. Provided the delivery pressure is Onload

below the P2 set point the compressor Oil temperature 20°C
loads and the display becomes:

8. Run the compressor for 10 minutes. To disperse corrosion inhibitor from

the system.

9. Press STOP. To stop the compressor for connection Ready to start

to the air system. Oil temperature 20°C

10. Check that the blowdown valve has

released all pressure from the
compressor.

11. Connect the compressor delivery

flange to the user’s pipework via an
isolating shut-off valve. Ensure that
the valve is fully open.

26 DL054CA
CompAir Commissioning 6

No. Action Reason Display

12. Press START. To operate the compressor to check (See the displays in steps 3 to 9).
operating conditions and parameters.
WARNING: RISK OF HIGH
PRESSURE

Do not use hands to locate leaks in the

system. Always use a piece of paper
or card for this purpose.

13. Examine compressor pipework for oil,

water or air leaks. If a leak is found,
stop the compressor, rectify the fault
and go to step 3.

14. Simulate a constant air demand by To provide a normal operating air

opening a valve in the user’s pipework. demand.

15. Check that the compressor loads and

unloads at the selected P1 and P2
pressure set points.

16. Run the compressor under these To achieve stable operating

conditions for an hour. conditions.

17. Examine all pipework again for oil or

air leaks.

18. Check operation of automatic

condensate drains.

19. Press STOP. Switch power to the

compressor ‘OFF’ at the isolator. Allow
several minutes for the oil to settle.
Top up the oil level if necessary.

20. Replace all covers and panels.

21. Record all setpoints and operating

parameters from the ‘Operational
settings’, ‘Commissioning Config’ and
‘Commissioning values’ sub-menus
for future reference.

6.7 Commissioning Parameters (compressor running on-load)

First stage delivery 170°C to 200°C
Second stage intake 30°C to 40°C
Second stage delivery 170°C to 200°C
Lubricating oil 40°C to 50°C
Air differential 10°C
Oil Pressure 2 bar approximately
Stage 1 Air Delivery 1.8–2.5 bar (Depending on model)
Note: The temperature guidelines are for compressors working in an ambient temperature of approximately 20°C.
In higher ambient temperatures, the temperatures given may be higher. In this case the temperature alarm and trip
levels may need to be raised.

DL054CA 27
6 Commissioning CompAir

6.8 Powered Breather - Description 6.9.2 The vacuum generator creates a depression
which is utilised to remove any oil mist (8) from
6.8.1 The powered breather system is designed to the gearbox. The air/oil mist passes through an
prevent any oil leakage from the bearings or oil oil removal filter (10) after which the filtered air
mist emission from the compressor. exhausts to atmosphere (9). The recovered oil
(11) then returns to the sump tank.
6.9 Powered Breather - Operation
Caution: it is important that the air supply to
6.9.1 The system works by tapping the plant the powered breather (3) is moisture free. If
discharge for an air supply (3) which is fed the installation is such that condensation
through a control filter/pressure regulator (4) to from the customer’s air network forms in
a vacuum generator (7). the delivery pipe, then the air supply must
be taken from a new location that is
moisture free.

5 6
7
9
4 6

80

40 8
2 120

0 lbf/in2
bar

0 10

10
4

11

2
1
SM 0810/1

Powered Breather System

1. 2nd Stage Moisture Separator 7. Vacuum Generator

2. Tee 8. Oil Mist from Gearbox
3. Pressurised Air to Vacuum Generator 9. Vacuum Generator Exhaust Air to Atmosphere
4. Pressure Reducing Valve/Line Filter 10. Oil Removal Filter
5. Pressure Adjuster 11. Removed Oil Returned to Gearbox
6. Pressure Gauge

28 DL054CA
CompAir Commissioning 6

6.10 Powered Breather System - Check

Vacuum.
6.10.1 With the machine stopped, connect a vacuum
gauge or U-tube/manometer (5) capable of
reading a vacuum of 50mm (2") w.g. into the oil
2
mist suction line between pressure vacuum
generator and filler pipe as shown. 1
6.10.2 Start the machine and check that air is being 3
6

80

40 8
2 120

0 lbf/in2
bar

discharged from the vacuum generator/oil

0 10

removal filter vent (4).

4
6.10.3 Check the reading on the vacuum gauge (5)
and, if necessary, adjust the pressure regulator
(2) to obtain a reading of approx 50mm w.g.
when the machine is on load. 5
Caution: It is not possible to adjust the
vacuum in the sump accurately by setting a
specific pressure reading on the pressure
regulator gauge (1). Inaccurate adjustment
of the breather system will result in
pressure in the oil sump, which could
create oil leakages at the air end venting
holes and gearbox drive end seal.

SM 0811

Vacuum Gauge Connection

1. Pressure Gauge
2. Pressure Adjuster
3. Vacuum Generator
4. Vent
5. Vacuum Gauge

DL054CA 29
6 Commissioning CompAir

6.11 Commissioning Check List 19. Drain open time set ...................

1. Pipework ................... 20. Drain shut time set ...................

2. Cable, fuse ratings OK ................... 21. Maximum compressor pressure set ...................

3. Control transformer input voltage 22. Maximum overpressure set. ...................

set correctly ................... 23. All temperature and pressure trip
4. Main motor, fan motor, oil pump limits set ...................
motor overloads and 24. All temperature and pressure
MCB Q102 set correctly ................... alarm limits set ...................
5. Phase rotation relay voltage set ................... 25. Star/delta time set ...................
6. Starter connections OK ................... 26. Load delay time set ...................
7. Motor connections OK ................... 27. Reset service hours timer ...................
8. Protection blanks and tapes ................... 28. Starting sequence correct ...................
9. Fill compressor with oil ................... 29. Compressor blows down OK. ...................
10. Air end and motor freely rotate ................... 30. Corrosion inhibitor dispersed ...................
11. Select language ................... 31. Connected to user’s pipework ...................
12. Fan/Oil pump rotation OK ................... 32. Oil, air and water leaks check. ...................
13. Main Motor rotation OK ................... 33. Compressor loads, unloads,
14. Pressure transducer calibrated ................... stands by and stops correctly ...................

15. Display units set ................... 34. Emergency stop correct. ...................

16. Compressor number set. (if comms 35. Temperatures and pressures in limits ...................
facility available/fitted) ................... 36. Oil level topped up ...................
17. Pressure control set points set ................... 37. All parameters recorded from
18. Run-on time set ................... controller menu routines ...................

30 DL054CA
CompAir
7 Operation
Warning
• Refer to the safety procedures before operating
the compressor unit.
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical
checks. Isolate the power supply before starting
any maintenance work.
Note: If the compressor has been out of operation
for a prolonged period it is advisable to check
performance and all regulation functions by carrying
out the full commissioning procedure before starting.
The commissioning procedure should be carried out
by a CompAir company or distributor.
7.1 Routine Operation
(Refer to Control Panel diagram in this section of the
manual)
Note: The temperatures and pressures given in the
procedures are shown as examples only.
7.1.1 Starting
1) Switch mains power to the compressor ‘ON’ at the
isolator. The front panel is now in the following state.
a) The POWER ON indicator (22) is lit.
b) The status display (5) shows:
C20627/nnn/UN/nn
SF3PnnUN_ddmmmyy
c) Either or both the REMOTE (20) and AUTO
RESTART (21) indicators are lit if these facilities
have been selected. See also ‘Control/Remote
Options’ under ‘Electrical System’.
2) After a few seconds, provided no fault exists, the
status display will show:
Ready to start
Oil temperature 20°C
Note: Oil temperature is used as an example only.
See ‘Fault Messages’ for possible start-up faults. If a
fault exists and a repair is necessary, power to the
compressor must be isolated and the fault rectified.
DL054CA
Operation 7
If the reset indicator is lit, RESET must be pressed
following rectification of the fault, before the
compressor will start.
3) To start the compressor press START (4). Provided
pressure at the delivery point is below P2 set point
the compressor will start. It will otherwise enter
Stand-by mode.
The oil pump will energise but the main motor will not
start until the oil pressure has reached its set point.
The compressor will not start if:
a) Certain menu routines are in use.
b) The remote starting facility has been enabled. In this
instance the display panel REMOTE CONTROL
indicator (20) will be lit and the display will show:
Ready to start
Remote start enabled
4) During the initial starting period, the drive motor
starts in Star connection and the status display will
show:
Starting
Oil temperature 20°C
5) Following the motor Star/Delta switch-over and
during the subsequent load delay period, the status
display will show:
Offload
Oil temperature 20°C
6) Provided the delivery pressure is below the lower set
point (P2) the compressor runs on load.
Onload
Oil temperature 25°C
7) Fault conditions and service requirements are
continuously monitored (from start-up) and warning
and the appropriate status messages are displayed.
8) To interrogate other temperature or pressure
information press VALUE (see para 2, Using The
Menu Routines).
The selected value will remain on the display until a
new value is selected.
9) To interrogate the hours run press HOURS. (see
para 2, Using The Menu Routines).
The display will cancel itself after a short period or it
can be cancelled immediately by pressing RESET.
10) To show operating parameters, fault history, etc. or
to alter programmed settings, press ENTER (10) to
access the menu routine (see para 2, Using The
Menu Routines).
31
7 Operation CompAir

7.1.2 Pressure Control changing to:

1) The compressor will unload and load in response to Stopping
varying air demand when the upper and lower set
Oil temperature 45°C
points P1 and P2 are reached. When the
compressor goes off-load the system blows down. The oil pump motor, enclosure cooling fan will
The controller loads and unloads the compressor by remain energised for 30 seconds after the main
fully opening or fully closing the suction regulator motor has stopped.
inlet valve. The display alternates, as appropriate,
2) After the 30 second cooling down period the display
between:
will change to:
Offload
Ready to start
Oil temperature 45°C
Oil temperature 40°C
and 7.1.4 Emergency Stopping
Onload 1) When the EMERGENCY STOP (17) is pressed, the
compressor will stop immediately and the system
Oil temperature 45°C
will blow down.
2) If the compressor is off-load for longer than the ‘Run- 2) The RESET indicator will pulse and the display will
on Time’, the compressor will stop and the status show:
display will change to:
Fault shut down
Stopping Emergency stop
Oil temperature 40°C Note: The emergency stop button should be used
only in a genuine emergency and must not be used
3) After the stopping period the display will change to:
as the normal method of stopping the compressor.
Standby 7.1.5 Condensate Drain Operation
Oil temperature 40°C 1) With speed adjusted compressores the condensate
drain over Bekomaten is regulated.
Note: If the START button is pressed whilst the
compressor is stopping the display changes to 2) If no condensate flows off, top the compressor,
‘Standby’ immediately. switch the current supply off at the disconnecting
switch, clean the filter and examine the wiring.
4) When air demand reduces the pressure below the
3) When running on-load the intercooler and
lower set point P2 the compressor will restart and
aftercooler condensate drains will operate according
run on-load. The display will show:
to the programmed drain shut and drain open times.
Starting The drain will open and the timer cycle will begin
every time the compressor loads.
Oil temperature 20°C
4) When the compressor is in ‘off-load’, ‘standby’ or
changing to: ‘ready to start’, the drains will continue to operate
Offload with a two second ‘open’ time and an extended ‘shut’
time. This prevents any build-up of condensate
Oil temperature 20°C when the compressor is stopped or running ‘off-
during load delay time, then: load’.
5) Manual valves are fitted to enable the user to bypass
On load
the condensate system if required.
Oil temperature 25°C 7.1.6 Service Interval Timer
7.1.3 Stopping 1) The control system uses a count-down timer which
can be reset to programmed maximum each time a
1) To stop the compressor press STOP (36). This
service is carried out. The maximum service hours
initiates a controlled shut down sequence. The main
can be adjusted to suit site conditions and/or service
motor will continue to run for 8 seconds and the
schedule requirements.
display will briefly show:
When the timer reaches zero hours a service due
Offload advice message is displayed. When the service has
Oil temperature 45°C been completed, the reset service hours function

32 DL054CA
CompAir Operation 7

should be selected from the service diagnostics sub-
menu and the service advice message reset.
2) When the compressor has reached the running
hours at which a service is required, the SERVICE
indicator (35) will flash. If SERVICE (34) is now
pressed the SERVICE indicator (35) will stop flashing
and remain lit. The RESET indicator (32) will then
flash continuously and the status display will show
the service advice message below:
Onload
Service due
3) The compressor must be stopped and isolated to
carry out the required service (see ‘Safety
Procedures’). On completion of the service the
‘service hrs to run’ value must be reset to maximum
by using the Service Diagnostics menu routine.
4) It may not be convenient to respond to the service
due message immediately. In this case press
RESET (31) to cancel the flashing RESET indicator
and restore the status and selected value display.
The service indicator will remain lit to indicate that a
service is required.
7.1.7 Warnings
1) If a service is required, the SERVICE indicator (35)
and the appropriate mimic diagram indicator will
flash continuously. If SERVICE (34) is pressed the
SERVICE indicator will stop flashing and stay lit in
acknowledgement. The RESET indicator (32) will
flash continuously and the display will show the
required action (e.g. an air filter change) as below:
Onload
Change Air filter
2) Pressing SERVICE repeatedly during this period will
recall any earlier stored warnings in chronological
order (most recent first) that have not been corrected
and reset.
3) When pressing SERVICE is discontinued, the fault/
service display will be shown for several seconds
after which it reverts to the selected value display
message.
4) The occurrence of another warning after any
previous warning has been acknowledged will again
cause the SERVICE indicator to flash continuously
and the mimic diagram indicator appropriate to the
second fault will also light.
5) It may not be convenient to respond to a warning
immediately. In this case press RESET to cancel the
flashing service indicator and to restore the status
and selected value displays. The mimic diagram
indicator will remain lit to indicate that attention is
required.
7.1.8 Shutdowns
1) If a shutdown message occurs, the compressor will
stop. This event can occur at any time after the
compressor has been started.
Both RESET and the appropriate mimic diagram
indicator will flash continuously and the SERVICE
indicator will light. If the menu routine is in use when
a shutdown occurs the appropriate panel and mimic
diagram indicators will light and flash as normal. The
current message will not be overwritten until RESET
is pressed or the display reverts to the fault message
after a period of time.
2) The display will show:
Fault shutdown
(Relevant shutdown message) See Display
messages
7.1.9 Fault History Recall
Selecting ‘Fault History Recall’ on the Main Menu
will show the compressor status at the last fault. The
following parameters can be displayed showing the
conditions at the last fault. The fault history will retain
the last 25 faults.

Fault History Message Meaning

Onload, Offload, Standby, Ready to start etc. State of compressor at time of fault.
Hours run 1000 Hours run at time of fault.
Delivery Press 7·0 bar Delivery Pressure at time of fault.
Interstage press 2·0 bar Interstage pressure at time of fault.
Oil pressure 2·3 bar Oil pressure at time of fault
Oil temperature 45°C Oil temperature at time of fault.
St1 delivery temp 160°C Stage 1 delivery temperature at time of fault.
St2 intake temp 28°C Stage 2 intake temperature at time of fault.
St2 delivery temp 165°C Stage 2 delivery temperature at time of fault.
Plant delivery temp 30°C Plant delivery temperature at time of fault.
Intake temp 20°C Intake temperature at time of fault.

DL054CA 33
7 Operation CompAir

7.1.10 Stand-by Operations Notes for use with SureScan menu diagrams
CAUTION: A stand-by compressor must be 1) Show program variant – Displays a reference
started and run for 10 minutes per week. Failure number for the controller program variant, for
to follow these instructinos may result in reference only. Press Return to return to main menu.
damage to the compressor.
2) Test digital inputs – Test routine for each individual
If the user’s air usage is insufficient to allow the input. Input cards test routine.
compressor to run for 10 minutes the compressor
3) Test analogue inputs – Test routine for pressure and
should be run Off-load as follows:
temperature inputs. Pressure transmitters test
If on active stand-by (State: Stand-by) routine.
1) Ensure the Run On time on the controller is set to 4) Test keypad – Keypad test routine. Each key
10 minutes. pressed will be displayed to establish operation.
Press RESET to exit routine.
2) At the remote inputs, ensure Remote Load Input is
open, then close the Remote Load Enable. 5) Test Display – Control panel LED, LCD and indicator
test. When selected all LED’s and indicators will light
3) Momentarily close the Remote Load input. The
and all LCD text display elements will turn on for
compressor will start and enter Offload state.
15 seconds. The routine will self cancel.
Note: Ensure that the Remote Load input is opened
before the delta contact is closed or the compressor
may load.
If not on active duty (Ready to start)
1) Ensure the Run On time on the controller is set to
10 minutes.
2) At the remote inputs, ensure Remote Load Input is
open, then close the Remote Load Enable.
3) Start the compressor - the compressor will enter
Standby.
4) Momentarily close the Remote Load input. The
compressor will start and enter Offload state.
5) Allow the compressor to run for the set time, it will
then revert to Standby state.
6) Stop the compressor (Ready to start).
7) Open the Remote Load Enable to put control back to
the transducer.

7.2 Altering Control Settings

The menu routines are used to access, view and/or
alter the operating parameters and options stored in
the memory of the controller.
With the mains power on and ENTER pressed, the
text display on the control panel will show two lines
of text. The top line indicates the menu in use and
the bottom line the parameters in use.
The diagrams at the end of this section show the
sequence of messages available and the buttons to
press to obtain the required message.
In the diagrams the solid line boxes represent the
message window and the broken line boxes are
reader information or instructions.

34 DL054CA
CompAir Operation 7

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

bar

psi

36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
PI/97/067

1. Psi Units Indicator 19. Remote Control Legend

2. Bar Units Indicator 20. Remote Control Indicator
3. Delivery Pressure Display 21. Auto Restart Indicator
4. Start Button 22. Power On Indicator
5. Status and Message Display 23. Compressor Delivery Fault Indicator
6. Plus Button 24. Oil System Fault Indicator
7. Minus Button 25. Change Oil Filter Indicator
8. Up Button 26. 2nd Stage Delivery Fault Indicator
9. Down Button 27. Low Oil Level Indicator
10. Enter Button 28. Main Motor Fault Indicator
11. Mimic Diagram 29. Oil Pump Motor Fault Indicator
12. Intake Filter Change Indicator 30. Hours Button
13. Phase Monitor Fault Indicator 31. Reset Button
14. 1st Stage Delivery Fault Indicator 32. Reset Indicator (LED)
15. 2nd Stage Intake Fault Indicator 33. Values Button
16. Fan Motor Fault Indicator 34. Service Button
17. Emergency Stop Button 35. Service Indicator (LED)
18. Auto Restart Legend 36. Stop Button

CONTROL PANEL

Note: Please check for speed adjusted compressors

in the operating instructions "Touchpanel Pro-face".

DL054CA 35
7 Operation CompAir

Control Panel Menus

Entry Menu Sub Menu

Main Selection Menu Operational settings Commissioning - Values

Operational settings P1 setpoint **.*bar Max. pressure **.*bar

Fault history recall P2 setpoint **.*bar Max. overpress **.*bar
Service diagnostics Run on time **min Star/delta time **sec
Commissioning - config. Drain open time **sec Load delay time ***sec
Commissioning - values Drain shut time ***sec Max service hours ****
Show program variant Return to previous menu Autorestart delay ***sec
Return to previous menu Interstage trip **.*bar
Service Diagnostics Interstage alarm **.*bar
Oil pressure alarm **.*bar
Reset service hours
Oil pressure trip **.*bar
Calibrate pressure
Oil temp trip ***˚C
Fault History Recall Test digital outputs
Oil temp alarm ***˚C
Test digital inputs
Scroll up/down last 25 St1 delivery trip ***˚C
faults in chronological Test analogue inputs
order. St1 delivery alarm ***˚C
Test keypad
St2 intake trip ***˚C
Shows status of Test display
compressor at time of St2 intake alarm ***˚C
displayed fault. Return to previous menu
St2 delivery trip ***˚C
St2 delivery alarm ***˚C
Commissioning - Config
Plant del trip ***˚C
Language: English Plant del alarm ***˚C
Unit of pressure bar Load default values
Unit of temperature ˚C
Machine model
Machine number **
Communications config
Fault input config ****
Return to previous menu Return to previous menu

SM 0985

CONTROL PANEL MENUS – QUICK REFERENCE GUIDE

36 DL054CA
CompAir Operation 7

Status Message
Oil temperature 25˚C
Main Menu Go to 2 of 8

Intake temp 20˚C Total hours 1000

St1 delivery temp 160˚C Hours on load 800

When first attempt is made to adjust

any value, the prompt will appear:

St2 intake temp 40˚C Service hrs to run 3000

Enter code: ????

St2 delivery temp 165˚C

Plant del temp 35˚C

To continue

Interstage press 2.0bar

Oil pressure 2.3bar

Press at any time in any

menu to return to initial display

PI/97/094A

SURESCAN CONTROL UNIT MENU STRUCTURE (1 OF 8)

DL054CA 37
7 Operation CompAir

From 1 of 8

Main Menu
Operational settings
Go to 3 of 8

Fault history recall

Fault history recall 1 Fault message
Fault message Status Message

Service diagnostics
Go to 3 of 8
Fault history recall 2 Total hours 1000
Fault message
Commissioning - config
Go to 6 of 8
Pressure 7.0bar

Commissioning - values
Go to 8 of 8
Interstage Press 2.0bar

Show program variant See note 1 Fault history recall 25

Fault message Oil pressure 2.3bar ★

Return to previous menu To 1 of 8

Fault history recall 0 Oil temperature 45˚C

To 2 of 8 Return to previous menu

St1 delivery temp 160˚C

Main Program Number St2 intake temp 45˚C

Name & Date

St2 delivery temp 165˚C

Extension Module Prog No.

Name & Date
Plant del temp 30˚C

Intake temp 20˚C

Return to previous menu
Press at any time in any
menu to return to initial display
To 2 of 8

PI/97/095A

SURESCAN CONTROL UNIT MENU STRUCTURE (2 OF 8)

38 DL054CA
CompAir Operation 7

Operational settings
P1 setpoint 7.5bar P1 set point 8.1bar

P2 setpoint 6.9bar P2 set point 7.2bar

Run on time 15min Run on time 20min

Drain open time 25sec Drain open time 15sec

Drain shut time 125sec Drain shut time 200sec

Return to previous menu

Service diagnostics
Reset service hours Service hours to run 8000 2 sec

To 2 of 8

Calibrate pressure
Go to 4 of 8

Test digital outputs

Go to 5 of 8

Test digital inputs

See Note 2

Test analogue inputs

See Note 3

Test keypad
See Note 4

Test display
See Note 5

Press at any time in any

menu to return to initial display
Return to previous menu Go to 2 of 8
1 of 8

PI/97/096A

SURESCAN CONTROL UNIT MENU STRUCTURE (3 OF 8)

DL054CA 39
7 Operation CompAir

Note: The calibration procedure corrects for zero

offset of all transducers but only corrects the range
of the delivery pressure. Therefore all pressures
(delivery, interstage and oil) must be zero for the
first stage of this routine or the routine will be
aborted with a probe error message. For
From 3 of 8 subsequent stages, only the delivery pressure
needs to be adjusted.

Set pressure at 0bar See note

Press enter when ready

Disconnect delivery pipe from

pressure transmitter

Set pressure > 5.51bar

Connect known air pressure supply

to delivery pressure transmitter

Adjust +/-: 5.6bar Adjust until display shows

Press enter when ready correct pressure

Adjust pressure up/down Adjust until display tracks

Press enter when ready pressure variations correctly

Calibration complete

2 sec

Press at any time in any

To 3 of 8
menu to return to initial display

PI/97/097A

SURESCAN CONTROL UNIT MENU STRUCTURE (4 OF 8)

40 DL054CA
CompAir Operation 7

From 3 of 8

Test digital outputs

Main contactor 0 Running 0

Star contactor 0 On load 0

Delta contactor 0 Group trip 0

Unloader solenoid 0 Service due 0

Drain solenoids 0 Remote fault 1 0

Fan contactor 0 Remote fault 2 0

Channel 7 0 Remote fault 3 0 Remote fault 3 1

Oil pump contactor 0 Remote fault 4 0

For each parameter

Available 0 Remote fault 5 0

0 indicates not energised

1 indicates energised
Group fault 0 Extension XO6/7 0

Return to previous menu

To 3 of 8

Press at any time in any

menu to return to initial display

PI/97/098A

SURESCAN CONTROL UNIT MENU STRUCTURE (5 OF 8)

DL054CA 41
7 Operation CompAir

From 2 of 8

Commissioning-Config
Language: English Language: Option

Unit of pressure bar Unit of pressure psi

Unit of temperature ¡C Unit of temperature ¡F

Machine model Go to menu structure 7 of 8

Machine number 1 Compressor number 10

Go to menu structure 7 of 8
Communications config.
Fault input config
Remote fault 1
Remote fault 1
Disabled
Fault input config
Remote fault 2

Trip type 1, 2 or 3
Return to previous menu
Remote fault 5

Alarm type 1, 2 or 3
To 2 of 8
Return to previous menu

Start inhibit

To 6 of 8

Press at any time in any

menu to return to initial display

PI/97/099A

SURESCAN CONTROL UNIT MENU STRUCTURE (6 OF 8)

42 DL054CA
CompAir Operation 7

Enter code ????

Machine model
Machine model
Model message
Machine model
see list below

Return to previous menu

To 6 of 8

Communications config.
Communications config.
Config. message
Communications config.
Disabled

Return to previous menu

SmartAir control

To 6 of 8

Communications control

MACHINE models
6504 / 6604 Dryclon 508W/608W
6505 / 6605 Dryclon 509W/609W
6506 / 6606 Dryclon 510W/610W
6507 / 6607 Dryclon 512W/612W
6508 / 6608 Dryclon 515W/615W default setting
6509 / 6609 D55-08/10A
6510 / 6610 D75-08/10A
6512 / 6612 D90-08/10A
6515 / 6615 D110-08/10A
Dryclon 504W/604W D132-08/10A
Dryclon 505W/605W D150-08/10A
Dryclon 506W/606W
Dryclon 507W/607W

PI/97/099B

SURESCAN CONTROL UNIT MENU STRUCTURE (7 OF 8)

DL054CA 43
7 Operation CompAir

From 2 of 8

Commissioning-Values
Max. pressure 10.5bar St1 delivery alarm 180˚C

Max. overpress 10.6bar St2 intake trip 65˚C

Star/delta time 25sec St2 intake alarm 60˚C

Load delay time 60sec St2 delivery trip 200˚C

Max. service hrs 4000 St2 delivery alarm 180˚C

Autorestart delay 100sec Plant del trip 55˚C Plant del trip 45˚C

Interstage trip 4.0bar Plant del alarm 40˚C

For each parameter

Interstage alarm 3.8bar Load default values Default values loaded 2 sec

Oil pressure alarm 1.7bar Return to previous menu

Oil pressure trip 1.5bar From 2 of 8

Oil temp trip 75˚C

Oil temp alarm 70˚C

St1 delivery trip 200˚C

Press at any time in any

menu to return to initial display

PI/97/100A

SURESCAN CONTROL UNIT MENU STRUCTURE (8 OF 8)

44 DL054CA
CompAir Operation 7

7.3 Default Values choosing the ‘Load default values’ option in the
‘Commissioning - values’ sub-menu. Alteration of
7.3.1 Default values for a number of the operational the working setting values requires the use of the
settings are stored in the controller. These are access code.
suitable for operating the compressor in most normal
situations. 7.3.4 The following is a list of default values together with
the range and size of the increments/ decrements
7.3.2 The compressor can use these values as available for each setting.
operational settings. Unless the compressor is
reprogrammed during commissioning, the default Note: The ‘Model’ and ‘Max. Pressure’ must be set
values will be those used by the compressor. according to the compressor data plate. The default
‘Star/Delta Time’ for the model is set when the model
7.3.3 The compressor may be re-programmed with is set.
different values at any time, and the controller
settings may be restored to the default values, by
Setting Unit Minimum Maximum Step Default Value
P1 setpoint bar 4·0 10·5 0·1 7·0
P2 setpoint bar 3·9 10·4 0·1 6·3
Run on time minute 5 240 1 10
Drain open time second 1 20 1 5
Drain shut time second 10 120 1 30
Star delta time second 3 30 1 by model
Comms baud rate baud 110 9600 options 9600
Compressor number number 1 99 1 1
Max. working pressure bar 8/8.6/10·5 options 8·0
Max. overpress bar 6·0 11·0 0·1 7·5
Load delay time second 2 60 1 2
Max. service hours hour 1000 8000 100 8000
Auto restart Delay second 10 240 1 10
Interstage pressure trip bar 2·5 4·0 0·1 3·5
Interstage pressure alarm bar 2·5 4·0 0·1 3·0
Oil temp trip °C 50 75 1 70
Oil temp alarm °C 50 75 1 65
St1 delivery trip °C 180 225 1 225
St1 delivery alarm °C 180 220 1 215
St2 intake trip °C 40 75 1 60
St2 intake alarm °C 40 75 1 50
St2 delivery trip °C 180 235 1 235
St2 delivery alarm °C 180 230 1 225
Plant del trip °C 30 90 1 70
Plant del alarm °C 30 90 1 60
Low oil press trip bar 1·5 3·0 – 1·5
Low oil press alarm bar 1·7 3·0 – 1·7
Oil filter blockage bar – – fixed 2
Intake filter blockage mbar – – fixed 65

DL054CA 45
7 Operation CompAir

7.4 Glossary of Display Messages

Note: Check for speed adjusted compressors please in the operating instructions "Touchpanel Pro-face".

7.4.1 Operator Advice Messages

Message displayed Meaning

Invalid Access Code The access code entered is not acceptable.

No reset indicated
No service indicated
Remote start enabled
Remote stopped
Stop compressor first
The ‘Reset’ button has been pressed when there is no reset required.
The ‘Service’ button has been pressed when there is no service action required.
Starting has been attempted via the Control Panel when the remote start facility
is enabled (Panel starting is disabled).
Starting is inhibited by the remote stop input.
The compressor is running and a menu selection has been attempted which can
only be used when the compressor is stopped.

7.4.2 Shutdowns

Message displayed Meaning

Extension Fault Extension module unit is not responding.

Emergency stop An emergency stop has been made.
Power supply fault Main supply phase rotation is detected to be incorrect or voltage is below
acceptable limits.
Main motor fault The compressor has shut down because of main motor overcurrent or high
temperature.
Fan motor fault The compressor has shut down because of fan motor overcurrent.
Oil pump fault The compressor has shut down because of oil pump motor overcurrent.
MPCB Q101 tripped The protection circuit breaker Q101 is in the tripped condition.
High air pressure The compressor has shut down because the delivery pressure has exceeded
the maximum pressure setting.
Interstage press trip The interstage pressure has exceeded the maximum set pressure limit.
Oil pressure trip The compressor has shut down because the oil pressure has fallen below the
minimum pressure limit.
Oil temperature trip The compressor has shut down because the oil temperature has exceeded the
upper (trip) limit.
St1 delivery temp trip The compressor has shut down because the first stage delivery temperature
has exceeded the upper (trip) limit.
St2 intake temp trip The compressor has shut down because the second stage intake temperature
has exceeded the upper (trip) limit.
St2 delivery temp trip The compressor has shut down because the second stage delivery temperature
has exceeded the upper (trip) limit.
Plant delivery t trip The compressor has shut down because the plant air delivery temperature has
exceeded the upper (trip) limit.

46 DL054CA
CompAir
Message displayed
Del Press probe fault
Int.St Press probe fault
Oil pressure probe fault
Oil temp probe fault
St1 del temp probe fault
St2 in temp probe fault
St2 del temp probe fault
Plant del t probe fault
Remote fault 1 (2, 3, 4, 5)
Oil level low (start inhibit)
7.4.3 Warnings
Message displayed
Change air filter
Change oil filter
Interstage press alarm
Oil temperature alarm
St1 delivery temp alarm
St2 intake temp alarm
St2 delivery temp alarm
Plant delivery t alarm
Oil level low
Remote fault 1(2, 3, 4, 5)
Service due
Oil pressure alarm
Start inhibit
DL054CA
Operation 7
Meaning
The compressor has shut down because the air delivery pressure transmitter is
indicating a pressure outside of normal limits.
The compressor has shutdown because the interstage pressure transmitter is
indicating a pressure outside of normal limits.
The compressor has shutdown because the oil pressure transmitter is indicating
a pressure outside of normal limits.
The temperature sensor is indicating a temperature outside of normal limits.
The temperature sensor is indicating a temperature outside of normal limits.
The temperature sensor is indicating a temperature outside of normal limits.
The temperature sensor is indicating a temperature outside of normal limits.
The temperature sensor is indicating a temperature outside of normal limits.
The compressor has shutdown because one of the remote fault inputs
configured as a trip has been activated.
The sump oil level is detected to be low while the compressor is stopped.
Meaning
A high differential pressure has been detected across the air filter indicating the
need for an air filter element change. Note: Switch must be reset manually after
tripping.
A high differential pressure has been detected across the oil filter indicating the
need for an oil filter change.
The interstage pressure has reached the programmed warning value.
The oil temperature has reached the programmed warning value.
The first stage delivery temperature has reached the programmed warning
value.
The second stage intake temperature has reached the programmed warning
value.
The second stage delivery temperature has reached the programmed warning
value.
The plant air delivery temperature has reached the programmed warning value.
Indicates that oil level is low.
One of the remote fault inputs configured as an alarm has been activated.
The service interval countdown timer has reached zero hours indicating a
service is now due..
The oil pressure has dropped to the programmed warning value.
The remote start inhibit input is open circuit.
47
7 Operation CompAir

7.4.4 Service Messages

Message displayed Meaning

Total hours Shows the recorded total number of compressor running hours on and off load.
Hours on load Shows the recorded total number of compressor running hours on load only.
Max. service hrs Shows the maximum programmed hours before a service is required.
Service hrs to run Indicates the number of running hours remaining before a service is required.
Reset service hours Invitation to reset the service interval hours to the maximum programmed
service hours.

7.4.5 Status Messages

Message displayed Meaning

Auto restarting The compressor is about to automatically restart following restoration of power.
Fault shutdown The compressor has stopped due to a fault.
Offload The compressor is running off load (the run-on time has not expired).
Onload The compressor is running on load.
Ready to start The compressor is waiting for a start signal (keypad or external) and no fault has
been detected.
Remote stopped Starting is inhibited by the remote stop input being open circuit.
Standby The compressor has been ‘started’ but is waiting for the delivery pressure to fall
below the lower setpoint, before the motor is energised.
Starting Motor starting.
Start Inhibited A start inhibit is present.
Stopping The stop button has been pressed but the oil pump motor and cooling fans will
remain energised for 30 seconds.

48 DL054CA
CompAir
8 Maintenance
8.1 Routine Maintenance
Warning
• Refer to the safety procedures before carrying
out any maintenance or servicing work on the
compressor unit.
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical
checks. Isolate the power supply before starting
any maintenance work.
To ensure the efficient operation of the compressor
unit the user must check performance regularly and
carry out the necessary adjustments to maintain
correct settings. This section gives the information
needed by the user for this purpose.
It is a condition of the Warranty cover that the unit is
properly maintained and adjusted, that all checks,
routine maintenance and regular servicing listed in
the Maintenance Schedule are carried out at the
specified intervals and that an accurate record is
kept of the work.
It is recommended that service and maintenance is
carried out by your local CompAir Distributor.
All CompAir compressors are fitted with high
performance filtration equipment. However, if the
working environment is particularly hostile the filter
elements and the heat exchangers will require
attention at more frequent intervals than specified in
the schedule.
8.1.1 Cleanliness
The compressor unit must be kept in a clean
condition at all times. Make regular inspections for
signs of damage, excessive wear and security of
fittings. Ensure that any oil spillage is wiped up
immediately and any residual oil cleaned from
external surfaces.
Caution: Do not allow oil to enter the air intake, air
system components or air system pipework.
8.1.2 Recording Pressures and Temperatures
Keep a regular record of the compressor operating
pressures and temperatures by noting the value
readings, together with ambient air temperature, in a
record book. The readings should be taken when
DL054CA
Maintenance 8
conditions are stable and with the compressor
running on full load.
8.1.3 Maintenance Record
Keep a careful record of all servicing, maintenance
and repair work carried out on the compressor. This
record will form a useful reference.
8.1.4 Electrical Connections
Regularly check the compressor unit for loose
connections or frayed wiring. Clean and tighten all
connections and repair or renew all frayed or
damaged wires and cables before starting up.
Take care not to damage the wiring when working on
the unit. When refitting wires and cables make sure
they are not damaged and that they will not be
damaged in service by chafing or contact with a hot
surface.
8.1.5 Leaks
Warning
• Risk of high pressure
Do NOT use hands to locate leaks in the system.
Always use a piece of paper or card for this purpose.
Inspect the unit as a matter of course when carrying
out servicing or maintenance for any sign of leaking
pipe connections, a build-up of dirt or debris and oil
leaks. Repair or replace damaged or leaking pipe or
hose connections immediately.
8.1.6 ‘Push-in’ Instant Pipe Connection System
Push-in pipe connections are used throughout the
compressor on small diameter pipework.
1) Assembly
a) Insert the pipe into the fitting until the pipe bottoms.
b) Pull the pipe to ensure secure engagement of the
grip ring teeth.
2) Disassembly
To remove a pipe, disengage the grip ring teeth by
manually applying pressure on the push ring sleeve
and withdrawing the pipe and cover ring from the
fitting.
49
8 Maintenance CompAir

8.1.7 Regular Checks 8.2 Maintenance Schedule

The ‘Maintenance Schedule’ lists the routine checks
and services which are important to the efficient
running of the unit. The user should ensure that the
Weekly Checks become an integral part of planned
maintenance, even if the major servicing work is
contracted to a CompAir Distributor.
8.1.8 Lubricating Oil
It is essential to maintain the correct level of oil and
to change the oil completely at the specified
intervals.
Regular maintenance should be carried out as
recommended in the Schedule below. The Schedule
is appropriate to most circumstances but, in some
instances, changes in detail may be required. The
Schedule should always be used as a guide initially,
but if experience shows that an alteration is
necessary, advice should be sought from the local
CompAir distributor.
In conditions of high ambient temperature/humidity
and/or dirty conditions the air filter may need to be
renewed more often than the recommended service
period. Renew the filter when ‘CHANGE AIR
FILTER’ is indicated on the control system.

ITEM ACTION PART DESCRIPTION PART NO

WEEKLY CHECKS
Enclosure filters Inspect and clean if necessary - -
Condensate drain solenoid valves Check condensate drain operation - -
Oil level Check oil level - -
Control system Check for indicated service requirements - -
SERVICE A - Every 4000 Hours or 6 months, weekly checks plus the following:
Customer operating log Review operating parameters - -
Control system Review fault history - -
Intake air filter Check condition, clean if necessary - -
Hoses and pipework Check for leaks - -
Electrical wiring Check connections and condition - -
Compressor internals and enclosure Clean compressor - -
SERVICE B - Every 8000 Hours or 12 months, weekly checks plus Service A plus the following:
Intake air filter Replace element Service kit CK3100-4
Oil Filter Replace element " "
Breather Filter Replace element " "
Balance piston diaphragms Replace diaphragm - low pressure element " "
Replace diaphragm - high pressure element " "
Motor bearing lubricators Replace automatic lubricator - drive end " "
Replace automatic lubricator - non drive end " "
Condensate drain strainer Replace strainer - interstage drain " "
Replace strainer - discharge drain " "
Oil Change oil (see note) - -
Oil cooler, intercooler and aftercooler Clean cooler fins - -
Control system Check for satisfactory operating parameters - -
Control system Test displays and operating buttons - -
SERVICE C - Every 16000 Hours or 24 months, weekly checks plus Service A and B plus the following:
Suction regulator Replace diaphragm Service kit CK7100-6
Shuttle valve disc Replace disc “ “
Condensate drain solenoid valves Replace complete valve - interstage drain “ “
Replace complete valve - discharge drain “ “
Unloader solenoid valves Replace complete valves - valve no 1 “ “
Replace complete valves - valve no 2 “ “
Flexible drive coupling Check backlash and replace inserts if necessary Drive coupling inserts See parts list
Note: The oil change period can be extended to 16000 hours or 24 months if oil condition monitoring indicates this to be
satisfactory.

50 DL054CA
CompAir Maintenance 8

8.3 Torque Schedule

Incorrect tightening of air pipework flange bolts may CAUTION: All bolts into aluminium coolers and
result in premature failure. All flange bolts should be pipes must be tightened to the specified torque. A
tightened in accordance with the torque schedules serious failure may result if the values are exceeded.
below. The bolts should be tightened in a sequence
of diametrically opposite pairs to ensure even
loading.

Tightening
Location Bolt size Qty
torque, Nm
Suction regulator to 1st stage inlet M12x1.75 4 50
1st stage outlet to silencer M16x2 4 125
Flexible pipe(s) to pipework (3 positions) M16x2 4 125
Flexible pipe(s) to coolers (3 positions) M16x2 4 125
2nd stage inlet pipe to separator M12x1.75 4 50
Separator to 2nd stage inlet adaptor M12x1.75 4 50
2nd stage inlet adaptor to 2nd stage inlet M12x1.75 4 50
2nd stage outlet to silencer M12x1.75 4 50
2nd stage outlet pipe to silencer M16x2 4 125
Discharge manifold to cooler M16x2 4 125
Expansion joint to manifold M16x2 4 125
Expansion joint to separator M16x2 4 125
Blowdown elbow to 2nd stage silencer M8x1.25 2 15
Non-pipework fastenings M16x2 - 125
Non-pipework fastenings M12x1.75 - 50
Non-pipework fastenings M10x1.5 - 29
Non-pipework fastenings M8x1.25 - 15
Non-pipework fastenings M6x1 - 6
Non-pipework fastenings M5x0.8 - 3.4

DL054CA 51
8 Maintenance CompAir

8.4 Maintenance Procedures 3) Refit the element to the panel and close the
door.
Warning SM 1702

• Refer to the safety procedures before carrying

out any maintenance or servicing work on the
compressor unit.
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical
checks. Isolate the power supply before starting
any maintenance work.
• Where a maintenance procedure below includes
the warning ‘The compressor must be stopped’
the following steps must be taken before work is
commenced:
1) Close the isolating shut-off valve to the user’s
pipework. Attach a label carrying the warning
‘WORK IN PROGRESS – DO NOT OPEN’ to
each isolating valve.
2) Switch the power supply ‘OFF’ at the isolator.
3) Attach a label carrying the warning ‘WORK IN
PROGRESS – DO NOT APPLY VOLTAGE’ to
the isolator switch and to the display panel. Do Enclosure Filter Removal
not switch on electrical power or attempt to 8.4.2 Condensate Drains
start the unit if such a warning label is
attached. Moisture present in the compressed air condenses
in the interstage and second stage moisture
4) Bleed down all air pressure in the delivery pipe separators and is drained by solenoid operated
between the non-return valve and the shut-off valves.
valve by opening the manual condensate drain
valves. 1) To Check the Operation of the Condensate Drain
Valves:
a) With the compressor running on load, check visually
that condensate is being released automatically ac-
8.4.1 Enclosure Filters cording to the drain open and shut times pro-
The compressor is provided with five coarse screen grammed into the controller. If no condensate is
filters in the panels of the enclosure. These act as being released open the manual drain valve. If con-
pre-filters for the intake, ventilation and cooling air. densate is present stop the compressor, switch pow-
er off at the isolator, clean the strainer, check the
Carry out a regular visual check of the condition of wiring and operation of the solenoid operated
the enclosure filter elements. If the elements are valves.
seen to be heavily contaminated they should be
cleaned as follows: b) If the fault persists, refer to the local CompAir distrib-
utor.
1) Open the enclosure door complete with
integral filter.
2) Remove the filter element and wash carefully
in a mild detergent solution. Rinse thoroughly
and allow to dry.

52 DL054CA
CompAir Maintenance 8

8.4.3 Condensate Strainers 8.4.4 Intake Air Filter

SM 1700
Manual Drain Valves and Strainer Gauze
1) To Change the Strainer
1)
a) Isolate intercooler and aftercooler condensate sys-
tem from the moisture separators using in-line taps
b) Unscrew plugs from manifold and remove strainer
gauzes.
c) Fit new gauzes and refit plugs to manifold.
d) Open in-line taps and check operation.
The servicing intervals required by the intake air filter
will depend on the dust conditions prevailing on site.
A visual filter condition indicator is fitted adjacent to
the air intake filter.
It is always better to renew the intake air filter
element rather than to try to clean it. In any cleaning
operation, however carefully done, there is a risk of
critical damage to filter efficiency and dirt particles
remaining on the element or being carried over to
the clean side.
Whenever the intake air filter element is removed,
check the sealing surfaces for signs of dust tracking
and rectify if necessary.
Before carrying out any work on the intake air filter
the compressor must be stopped.
To Change the Element:
SM 1701

Intake Air Filter

a) Open door to gain access to the intake air filter.
b) Remove the cover of the intake air filter, take out the
element and discard.
c) Clean the inside of the filter body.
d) Fit the new element in the filter body and refit the
cover.

DL054CA 53
8 Maintenance
e) Reset filter condition switch by pressing yellow reset
button.
SM 1696
Air Filter Condition Switch
2) To Clean the Element by Air Blast:
Always fit a new filter element at the specified
service intervals. However, if cleaning must be
resorted to, carry out the following procedure.
Caution: Do not use high pressure air supply.
a) Using an air line supplying dry, low-pressure air
(maximum 0·5 bar) carefully blow out the inner cavi-
ty, ensuring that the air stream passes through the
element from the clean side.
b) When all contamination has been removed, inspect
the element for cracks, holes or other damage by
holding the element up against a light source. If any
damage is evident the element must be discarded
and a new one fitted.
c) Re-install the clean element in the filter body and re-
fit the cover.
8.4.5 Oil System
1) To Check the Oil level:
The compressor must be stopped
Note: Allow a minimum of 30 minutes after stopping
for the oil in the system to settle.
a) Open the enclosure to gain access to the oil filler and
sightglass.
b) Check the sightglass visually. The oil level should be
above halfway on the indicator.
54
CompAir
Caution: Do not mix oils of different types – always
refill with the oil type in current use.
SM 1697
Oil Level Indicator
c) If the oil level is low, remove the cap from the oil filler
pipe and gradually top up the reservoir until the float
reaches the top of the indicator. After each small
quantity has been added allow time for the change
in level to be indicated on the sightglass. This will
prevent overfilling.
d) Refit the cap to the oil filler pipe.
e) Close the service door.
2) To Change the Oil:
The compressor must be stopped
Drain the oil while the compressor is hot to allow the
oil to run freely and carry out any suspended
particles.
a) Open the enclosure doors as required.
b) Position suitable containers under the drain hoses.
c) Enter ‘Test digital outputs’ mode on control panel, fit
handle to 2 way valve and turn valve fully anti-clock-
wise to the drain position (1/4 turn). Run pump until
sump is empty.
DL054CA
CompAir
CAUTION: Do not run pump dry.
A h) Fill reservoir with recommended oil until the float
B
Typical Oil Pump and Drain Valve
A - Normal Running Position (Fully Clockwise)
B - Drain Position (Fully Anti-Clockwise)
d) Open oil cooler drain tap and drain oil into a contain-
er. Close drain tap on completion.
SM 1699
A b) Carefully clean the face of the filter housing.
Typical Oil Cooler Drain Valve
A - Drain Position (Fully Anti-Clockwise)
B - Normal Running Position (Fully Clockwise)
e) Turn 2 way valve back to the normal running position
(fully clockwise).
f) Remove valve handles and store.
DL054CA
Maintenance 8
g) Renew the oil filter element - see para 8.4.5 (3) ‘To
Change the Oil Filter Element’.
reaches the top of the indicator.
i) Run pump for one minute, check level and top up as
necessary.
j) Reset control panel, start and run unit for
60 seconds to circulate oil, check for leaks, then
press STOP button.
k) Check the oil level and top up if necessary.
l) Close doors.
3) To Change the Oil Filter Element:
Note: The oil filter element should be renewed after
every 8000 operating hours or every year, whichever
is sooner or when indicated by the control system
CHANGE OIL FILTER message
The compressor must be stopped.
a) Unscrew and discard the old oil filter element.
c) Apply a thin film of clean oil to the element seal.
d) Screw in the new element by hand until seal contact
is made and then continue tightening for a further
quarter of a turn.
SM 1695
Oil Filter
55
8 Maintenance CompAir

4) To Change the Oil Removal Filter: you can keep a record of what maintenance
work was carried out at which specified
a) Unscrew the filter cover (2) from the housing.
intervals. The operating hours quoted in this
b) Remove the filter element. manual are recommended maintenance
intervals for average operating conditions.
c) Fit new filter element.
Depending on your local intake conditions, the
d) Reattach the cover. operating hours may differ. You can also have
this maintenance work carried out by our
e) After changing the oil removal filter it is recommend-
trained technicians. Please ask your technical
ed that the powered breather system is checked for
adviser for a maintenance contract.
correct operation. Please refer to the section ‘Pow-
ered Breather System’ in the Commissioning section b) Maintenance electric motor
of this manual.
3) The maintenance of the electric motor is to be
performed in line with the motor operating
instructions.

2
4

40

0
80

lbf/in2
bar
6

120
8
a) Lubrication of electric motors
0 10

2
The two bearings of the electric motor must be
lubricated at specified intervals, which are
determined by the type of motor. The lubricating
1
points, intervals and quantities, specific to each
motor, can be found on the motor's nameplate.
Note: In the case of 60 Hz drive, strictly observe the
information on the nameplate !
In order to check the required for lubrication, weigh
SM 2000/1
the grease gun before and after lubrication of the
individual electric motor bearings.
Oil Removal Filter - Powered Breather
The cooling fan and oil pump motors are fitted with
8.4.6 Electrical System sealed bearings and should not need attention.
If a non-standard motor is fitted the user should take
Warning advice from the local CompAir distributor before the
compressor is put into extended operation.
8.4.7 Flexible Drive Coupling
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical 1) To Check the Coupling Backlash:
checks. Isolate the power supply before starting The compressor must be stopped and isolated from
any maintenance work. both the electrical supply and air pipework.
Remove the cover and reach through the access
opening in the bellhousing. Hold the drive shaft on
1) To Check the Electrical Connections: each side of the coupling and check the coupling
backlash which should not exceed 6 mm. If the
Carefully examine the electrical wiring and check the backlash is excessive it will be necessary to change
security of all connections and terminals. the coupling inserts.
2) Electric Motors 2) To Renew the Inserts:
a) Maintenance and lubricant recommendations We recommend that this work is carried out by a
Note: The compressor unit can only operate to CompAir distributor.
your complete satisfaction when maintenance
work is carefully carried out at the specified
intervals. In order to help with this task, the
scope of supply of the compressor unit
includes a "Maintenance and Inspection
Manual for CompAir Compressors”, in which

56 DL054CA
CompAir Maintenance 8

8.4.8 Coolers
1) To Clean Coolers Externally
The condition of the air cooler fins must be checked
regularly. To clean the fins procede as follows:
The compressor must be stopped
a) Allow the compressor to cool for 30 minutes and
loosen 6 quarter turn fasteners.
b) Open enclosure door and remove access panel on
cooling duct.
c) Remove enclosure panel in front of coolers.
d) Clean the cooler fins from inside the duct using one
of the following methods:-
• Hose with mains water.
• Air hose using oil free compressed air.
• Pressure wash with water or a water/detergent
mixture.
e) Replace access and enclosure panels and close
door.
f) Remove any dirt or liquid from the baseframe.
8.4.9 We recommend that work on the following items is
carried out by a CompAir distributor:-
• Balance Piston Diaphragms
• Suction Regulator
• Shuttle Valve Disc
• Condensate Drain Solenoid Valves
• Unloader Solenoid Valves

DL054CA 57
8 Maintenance CompAir

58 DL054CA
CompAir
9 Fault Finding
The controller has a memory facility that retains a
fault history. Details of 25 previous situations can be
displayed, including the fault message together with
recorded hours, compressor state (standby, on-
load, off-load etc.), plant temperatures and
pressures.
In operation the compressor is protected by circuits
which are triggered when a fault arises and either
cause the compressor to shut down or indicate that
a servicing action is required.
9.1 Shutdown and Warning Messages
Message Displayed Possible Cause
Emergency stop (1) Emergency Stop switch operated.
(2) Starter circuit fuse F5 blown.
Main motor fault (1) High ambient temperature.
(2) Insufficient cooling air flow.
(3) Low voltage/high current.
(4) Thermal overload F101 incorrectly set.
(5) Fan operation/rotation incorrect.
Fan motor fault (1) High ambient temperature.
(2) Insufficient cooling air flow.
(3) Low voltage/high current.
(4) Overloads F102/F103 incorrectly set.
Oil pump fault (1) High ambient temperature.
(2) Insufficient cooling air flow.
(3) Low voltage/high current.
(4) Overloads F104 incorrectly set.
(5) Pressure control incorrectly set
(6) Oil pump relief valve siezed
MCB Q101 tripped (1) Oil pump/fan motor circuit fault.
Oil temperature trip/ (1) High ambient temperature.
alarm (2) Insufficient cooling air flow.
(3) Temperature sensor fault.
(4) Sensor wiring fault.
DL054CA
Fault Finding 9
Warning
• Refer to the safety procedures before carrying
out any fault finding investigation.
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical
checks. Isolate the power supply before starting
any maintenance work.
Action required
(1) Check cause of fault and rectify. Turn
Emergency Stop switch to release latch.
Press RESET.
(2) Check cause and rectify.
(1) Check room ventilation.
(2) Inspect/clean: enclosure filter; ducting;
motor cooling air intake.
(3) Check power supply.
(4) Check setting and reset.
(5) Check and rectify electrical circuit.
(1) Check room ventilation.
(2) Inspect/clean: enclosure filter; ducting;
auxiliary cooling fan (if fitted)
(3) Check power supply.
(4) Check setting and reset.
(1) Check room ventilation.
(2) Inspect/clean: enclosure filter; ducting;
motor cooling air intake.
(3) Check power supply.
(4) Check setting and reset.
(5) Check setting and reset.
(6) Check and rectify/renew.
(1) Check cause and rectify.
(1) Check room ventilation.
(2) Check fan operation and enclosure filters.
Inspect/clean cooler matrix.
(3) Rectify/renew.
(4) Check wiring.
59
9 Fault Finding
Message Displayed Possible Cause
St1 delivery temp trip/ (1) High ambient temperature.
alarm (2) Insufficient cooling air flow.
(3) Temperature sensor fault.
(4) High interstage pressure.
(5) Sensor wiring fault.
St2 intake temp trip/ (1) Insufficient cooling air flow.
alarm
(2) High ambient temperature.
(3) Temperature sensor fault.
(4) Sensor wiring fault.
St2 delivery temp trip/ (1) Insufficient cooling air flow.
alarm
(2) High ambient temperature.
(3) Temperature sensor fault.
(4) Pressure too high.
(5) Sensor wiring fault.
Plant delivery temp trip/ (1) Insufficient cooling air flow.
alarm (2) Condensate build up.
(3) Temperature sensor fault.
(4) Sensor wiring fault
Interstage press trip/ (1) Air flow restriction.
alarm (2) Fault in HP compression element.
(3) Pressure transmitter fault.
Oil pressure low (1) Low oil level.
(2) Oil pump fault.
(3) Relief valve adjustment/failure.
(4) Pressure transmitter fault .
(5) Oil flow restriction.
(6) Oil filter blocked.
High air pressure (1) Compressor fails to unload.
(2) Pressure transmitter fault.
Del press probe fault (1) Pressure transmitter fault.
(2) Transmitter wiring fault.
Int.St press probe fault (1) Pressure transmitter fault.
(2) Transmitter wiring fault.
St1 del temp probe fault (1) Temperature sensor fault.
(2) Sensor wiring fault.
St1 in temp probe fault (1) Temperature sensor fault.
St2 in temp probe fault (2) Temperature sensor wiring fault.
St2 del temp probe fault (1) Temperature sensor fault.
(2) Sensor wiring fault.
60
CompAir
Action required
(1) Check room ventilation.
(2) Check fan operation and enclosure filters.
Inspect/clean air coolers.
(3) Rectify/renew.
(4) Inspect/clean air coolers.
(5) Check wiring.
(1) Check fan operation and enclosure filters.
Inspect/clean intercooler matrix.
(2) Check room ventilation.
(3) Rectify/renew.
(4) Check wiring.
(1) Check fan operation and enclosure filters.
Inspect/clean intercooler.
(2) Check room ventilation.
(3) Rectify/renew.
(4) Check pressure against rating.
Check transmitter calibration.
(5) Check wiring.
(1) Check fan operation and enclosure filter.
(2) Check drain operation.
Inspect/clean aftercooler.
(3) Rectify/renew.
(4) Check wiring
(1) Check fan operation and enclosure filters.
(2) Check and renew if necessary.
(3) Check/renew pressure transmitter. Check
wiring.
(1) Investigate for leaks, top up oil level.
(2) Investigate and rectify.
(3) Adjust/Renew valve.
(4) Renew pressure transmitter.
(5) Locate and clear obstruction.
(6) Renew oil filter element.
(1) (a) Check/renew solenoid operated
unloader valves.
(b) Check suction regulator inlet valve
closing fully. Rectify if necessary.
(2) Check/renew pressure transmitter. Check
wiring
(1) Renew pressure transmitter.
(2) Check and rectify fault.
(1) Renew pressure transmitter.
(2) Check and rectify fault.
(1) Renew temperature sensor.
(2) Check and rectify fault.
(1) Renew temperature sensor.
(2) Check and rectify.
(1) Renew temperature sensor.
(2) Check and rectify fault.
DL054CA
CompAir Fault Finding 9

Message Displayed Possible Cause Action required

Plant del t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.

Oil press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
(2) Transmitter wiring fault. (2) Check and rectify fault.

Remote fault/alarm (1) Remote fault loop open circuit. (1) Find cause and rectify.

Extension fault (1) Fuse F3/F4 failed. (1) Check cause and rectify.
(2) Interface cable insecure. (2) Check interface cable.
(3) Extension module failure. (3) Renew Extension module.

Power supply fault (1) Supply wiring configuration incorrect, (1) Check supply wiring connections U, V
motor rotation will be incorrect. and W.
(2) Supply voltage low. (2) Check supply voltage.
(3) Supply fault. (3) Check supply.

Oil level low (1) Low oil level. (1) Check for oil leaks and rectify. Top up
(start inhibit) sump to correct level.
(2) Oil level switch fault. (2) Find cause and rectify.
(3) Switch wiring fault. (3) Check and rectify.

9.2 Warning Messages

Message Displayed Possible Cause Action required

Service due (1) Service countdown time expired. (1) Service compressor then reset timer.

Change air filter (1) Intake air filter or intake blocked.
(2) Filter pressure switch not reset.
(3) Filter pressure switch fault.
(4) Filter pressure switch wiring fault.
(1) Check/renew element.
Check intake for obstruction.
(2) Press reset button on switch.
(3) Check operation. Renew if necessary.
(4) Check and rectify.

Change oil filter (1) Oil filter element blocked. (1) Renew oil filter.
(2) Differential pressure switch fault. (2) Check operation. Renew if necessary.
(3) Differential pressure switch wiring fault. (3) Check and rectify.

Start inhibit (1) Remote start inhibit loop open circuit. (1) Find cause and rectify.

DL054CA 61
10 Electrical System CompAir

10 Electrical System Note 1: Remote input cables must be at least

Warning
• Refer to the safety procedures before carrying
out any of the following operations.
1.0 mm2 in size. The maximum cable length from the
compressor to a remote device must not exceed
800 meters/875 yards.
Note 2: To activate an input function, only connect
an input terminal pin to the common terminal
connection X5/1 for X01 inputs or X5/2 for X02
inputs.

• Lethal voltages are used in this equipment. Use

extreme caution when carrying out electrical
checks. Isolate the power supply before starting
any maintenance work.

The electrical system is housed in an IP54 enclosure

and includes the controller and motor starters.
All of the functions are monitored by sensors
connected to the controller. Digital inputs are switch
contacts and analogue inputs are from pressure and
temperature sensors with signal conditioning from
within the controller.
An RS 485 communications port and a range of
remote control and monitoring facilities are
available.
Control/Remote Options
Note: Any work on the electrical system should be
carried out by a CompAir distributor.

10.1 Inputs
10.1.1 Description
Caution: Do not connect any extension module
input terminal pin to a voltage source as this will
result in permanent damage to the module.
Two sets of eight inputs are available on extension
module terminal connections X01 and X02. Each
input is designated a particular function which may
be used as required. Each function is activated by
connecting the appropriate terminal pin to the input
terminal common connection X5/1 or X5/2. This can
be achieved by connecting the input pin and the
common terminal to a remote switch, relay contact,
PLC output or any switching device.

62 DL054CA
CompAir Electrical System 10

X01

1 2 3 4 5 6 7 8 9

LOAD
REMOTELOAD
ENABLE

START

STOP
500

START
ENABLE

STOP
ENABLE
ENABLE

ENABLE

ENABLE
REMOTE
ENABLE
ENABLE
COMMON

CONTROL
COMMON

START
CONTROL

RESTART

LOAD

REMOTESTART
LOAD
RSTART

REMOTE
D.C.

COMMS

REMOTE
REMOTE
D.C.

COMMS

AUTO
AUTO
20V
20V

X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1

PRESSURESWITCH
PRESSURE SWITCH
ORCASCADE
OR CASCADE
PANELCONNECTION
PANEL CONNECTION

HW 0446

REMOTE INPUT CONNECTION

10.1.2 Input Designations 2) Input Terminal X02
1) Input Terminal X01 Pin No. Function
X02-1 Common (20V dc) for X02 inputs
Pin No. Function
X02-5 Remote Fault Input 1
X01-1 Common (20V dc) for X01 inputs
X02-6 Remote Fault Input 2
X01-2 Comms Control Enable
X02-7 Remote Fault Input 3
X01-3 Auto Restart Enable
X02-8 Remote Fault Input 4
X01-4 Remote Load Enable
X02-9 Remote Fault Input 5
X01-5 Remote Load/Unload
X01-6 Remote Start Enable 10.1.3 Input Functions
X01-7 Remote Start
1) Input X01-2
X01-8 Remote Stop
RS485 Communications Control Enable
X01-9 No Standard Function
a) The SureScan controller is equipped with an RS485
communications facility on terminal X06. The facility
is activated when this input is connected to the
common terminal X5/1.
Note: The RS 485 terminal X03 on the extension
module has no standard function.
b) If the ‘Comms control enable’ input X01-1 and
‘Remote start enable’ input X01-5 are activated, the
compressor Remote control indicator will light and

DL054CA 63
10 Electrical System CompAir

the compressor will respond to RS485 Start, Stop 3) Input X01-4 Remote Load Enable
and Reset commands.
a) Remote control of loading and unloading allows the
Note: The control panel Start button and the Remote pressure control routines of the SureScan controller
start function will be inhibited. The control panel stop to be overridden in multiple compressor/cascade
button and remote stop function remain active. control installations. The facility allows control by
any of the I.C.C. range of multi compressor
c) If the ‘Comms control enable’ and the ‘Remote
controllers available from CompAir.
pressure control enable’ input X01-3 is activated, the
compressor will respond to RS485 load and unload b) When the remote load enable input is activated the
comands. compressor will load and unload in response to the
remote load/unload input X01-5.
d) Contact your local CompAir distributor for details.
4) Input X01-5 Remote Load/Unload
2) Input X01-3 Auto Re-start Enable
a) If input X01-5 is activated, via a remote pressure
a) Automatic re-start will allow the compressor to start
switch, relay, programmable logic controller (P.L.C.)
automatically after a break or failure in the mains
output etc, the compressor will load. When the input
power supply. When this facility is enabled the
is de-activated the compressor will unload.
AUTOMATIC RE-START indicator will be lit.
b) The compressor will shutdown and the display will
b) An automatic re-start will not be initiated if the
show a High air pressure trip if the Max overpress
compressor was stopped when the power failure
setting of the Commissioning - values menu is
occurred.
exceeded while using this facility. The compressor
c) When power is restored the following message is ‘Max overpress’ setting must be set above the
displayed and the Auto Re-start enable indicator will working pressure of the remote pressure control
flash. system. Where the remote pressure control system
is detecting air system pressure downstream of
Auto restarting
dryers, filters or long lengths of pipework, an
—————* * allowance for any pressure differential should be
taken into account.
The time before the compressor automatically re-
starts, the auto re-start delay time, is indicated by 5) Input X01-6 Remote Start Enable
dashes on the lower display line. This time can be
a) The compressor can be connected to accept a
adjusted using the auto re-start delay time setting of
remote start signal. When this input is activated the
the ‘Commissioning - values’ sub-menu of the
REMOTE CONTROL indicator will be lit and the
SureScan menu routines.
SureScan panel START button is disabled.
d) In multiple compressor installations staggered re-
b) The SureScan panel stop button and the remote
starting can be achieved by adjusting the delay time
stop input are always active, regardless of remote
of each compressor
start enable being activated.
Example four compressor installation:-
Comp Auto re-start Delay Time
1 10 seconds
2 70 seconds
3 150 seconds
4 210 seconds

64 DL054CA
CompAir Electrical System 10

6) Input X01-7 Remote Start be de-activated before the compressor can be re-
started.
a) When the remote start enable and remote stop
inputs are activated the compressor will start when Note: This facility is inhibited if the RS485
the remote start input is activated. This input reqires communications control input is activated.
a single pulse of at least 0·5 seconds to activate it.
c) Remote Timer Control
The pulse length can be between 0·5 seconds and
continuous. The remote start/stop facility can also be used to
achieve automatic seven day timer control. Any
b) When the remote start input is continuously
commercially available timer with a single switching
activated the SureScan panel stop button or the
contact can be used for this purpose. Alternatively a
remote stop input will override the remote start
timer with a 24v ac power supply can be mounted
signal and the compressor will stop. When the
within the starter area A 24vac power supply for this
compressor is stopped, the remote start signal must
purpose is available on compressors terminals X2/1
and X2/2. The timer unit should be battery backed.

EXTENSION MODULE
7 DAY TIMER

X01
1 2 3 4 5 6 7 8 9
REMOTE START ENABLE

X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 CLOSED - START
OPEN - STOP
PI/97/136

TIMER CONTROL

DL054CA 65
10 Electrical System
7) Input X01-8 Remote Stop
a) The remote stop input is always active, regardless of
remote start enable being activated.
b) The remote stop input must be active to enable the
compressor to be started. The compressor will stop
when the remote stop input is de-activated.
c) A remote stop signal will override a remote start
signal. When the remote stop input is de-activated
the display will show:
Remote stopped
Oil temperature 20°C
d) The STOP button on the SureScan panel is not
affected and will remain active at all times.
e) If this facility is not used the input must be
continuously activated by connecting a wire from the
input pin to terminal connection X5/1, to enable the
compressor to be started and run.
8) Inputs X01-9 and X02-2 to 4
Caution: These inputs are used by the controller to
monitor the operation of the compressor and must
not be used for any other function.
66
CompAir
9) Inputs X02-5 to 9 - Remote Faults 1 to 5
There are five remote fault input functions available
that can be individually programmed to function as
remote alarm, remote trip or start inhibit inputs. A
remote fault input can be connected to a remote
switch, relay contact, programmable logic controller
(PLC) output or any switching contact device. Each
input function will operate when the connection
between the appropriate input terminal, X02-5 to
X02-9, and the common terminal X5/2 is broken.
When a remote fault input is de-activated the
appropriate remote fault number will be displayed by
the SureScan controller and the fault will be stored
in the fault history. The remote fault can be reset
normally using the RESET button.
a) Remote Fault Input Configuration
Each remote fault input can be pre-programmed
using the SureScan controller menu routines to
function as a remote alarm, remote shutdown trip or
start inhibit when the fault input is de-activated.
Remote alarm and shutdown trip functions can also
be pre-programmed to operate only under pre-
determined conditions to suit a particular application
depending on the remote fault input type selected.
Note: When a remote fault input is configured to any
option other than ‘Disabled’ the input must, under
normal circumstances, be continuously activated to
enable the compressor to operate without indicating
a remote alarm, trip or start inhibit condition.
DL054CA
CompAir Electrical System 10

b) Remote Fault Input Configuration Options

Option Function Description

Disabled Input not active.

Trip type 1 Trip - active at all times.
Trip type 2 Trip - active when the main motor is running.
Trip type 3 Trip - active only when status is ‘Onload’ or ‘Offload’.
Alarm type 1 Alarm - active at all times.
Alarm type 2 Alarm - active when the main motor is running.
Alarm type 3 Alarm - active only when status is ‘Onload’ or ‘Offload’.
Start inhibit Will prevent a compressor from starting but will not stop a compressor if already
started. When activated the display will show ‘Start inhibited’. This function is
not a shutdown trip or alarm and will only function while the input is de-activated.

c) Configuring the SureScan Controller Remote Fault Inputs

Refer to the SureScan menu structure in the OPERATION section of the manual.

DL054CA 67
10 Electrical System CompAir

10.2 Outputs c) Relay Specification

10.2.1 Description • Single switching contact with a common,

normally open (N/O) and normally closed
a) Two sets of six outputs are available on extension (N/C) connection rated at 250V - 5 Amps
module terminal connections X05 and X06. Each maximum.
output is designated a particular function which may
be used if required. Outputs which are not used Note: The relay 24V dc coil is not bi-directional and
should be left unconnected. must be connected to an extension module output
as follows :-
10.2.2 Output Relay
• Relay terminal ‘5’ must be connected to pin
a) Extension module outputs are 24V dc transistor ‘1’ of the appropriate output terminal.
switched with a maximum rating of 25mA. Each
output must be connected directly to a relay module, • Relay terminal ‘1’ must be connected to the
as specified below, in order to achieve a relay pin of the output terminal appropriate for the
contact output suitable for remote applications required output function.
external to the compressor starter enclosure. Six The relay base can be screw mounted or secured to
relays, K401 to K406 are supplied as standard for a standard type DIN rail (available from CompAir).
this purpose.
b) Parts required for each additional output:-

Qty Description Part Number

1 Relay - 24 V dc 98475-64

1 Relay Base 98475-65

X4/1 X4/1 X4/1 X4/1 X4/1 X4/1 X4/1

D.C.
24VD.C.

5
K406

K405

K404

K403

K402

K401

3
+ 2
5 5 5 5 5 5
COMMON24V

24v
24V d.c
d.c.
COMMON

- 4
1 1 1 1 1 1 1
406

405

404

403

402

401

400

7 6 5 4 3 2 1

X05
HW 0447
REMOTE OUTPUT CONNECTION

68 DL054CA
CompAir Electrical System 10

10.2.3 Output Designations b) Output X05-3 Group Fault

a) Output Terminal X05 The group fault output will de-energise when an
alarm, shutdown trip or power loss occurs. The
Pin No. Function output will be energised when power is applied and
no alarm or trip conditions are detected.
X05-1 Common (20V dc) for X05 outputs
The contacts of relay K402 must be used for remote
X05-2 Available connections to this facility.
X05-3 Group Fault c) Output X05-4 Running

X05-4 Running The running output will energise when the

compressor main motor is running.
X05-5 On Load
The contacts of relay K403 must be used for remote
X05-6 Group Trip connections to this facility.
d) Output X05-5 On Load
X05-7 Service Due
The on load output will energise when the
b) Output Terminal X06 compressor is on load.

Pin No. Function The contacts of relay K404 must be used for remote
connections to this facility.
X06-1 Common (20V dc) for X06 outputs
e) Output X05-6 Group Trip
X06-2 Remote Fault 1 Repeat The group trip output will de-energise when a
shutdown trip or power loss occurs.
X06-3 Remote Fault 2 Repeat
The output will be energised when power is applied
X06-4 Remote Fault 3 Repeat and no trip conditions are detected.
X06-5 Remote Fault 4 Repeat The contacts of relay K405 must be used for remote
connections to this facility.
X06-6 Remote Fault 5 Repeat
f) Output X05-7 Service Due
X06-7 No Standard Function
The service due output will energise when the
service hours countdown timer has reached zero
10.2.4 Output Functions
hours and a routine service is due.
a) Output X05-2 Available
The contacts of relay K406 must be used for remote
The compressor available output will energise when connections to this facility.
the compressor is ‘running’ or in the ‘standby’ state.
g) Outputs X06-2 to 6
This output indicates that the compressor has been
started and is available to automatically respond to Remote fault repeat outputs 1 to 5 will be normally
a fall in system pressure without manual energised and will de-energise if a fault condition on
intervention. the appropriate remote fault input, 1 to 5, is detected
or a power loss occurs. The output will remain de-
The contacts of relay K401 must be used for remote
energised until the SureScan controller is reset. See
connections to this facility.
remote fault inputs.
If start inhibit is selected, the output will de-energise
when the input is de-activated and automatically re-
set when the input is re-activated.
Note: An additional relay module, as specified in
para 2.2, must be added if these outputs are used.

DL054CA 69
11 Appendix 1 – Sample Log Sheets CompAir

11 Appendix 1 – Sample Log

Sheets
11.1 Introduction
11.1.1 The following sample log sheets are issued as a
guide to the user and can be used along with the
Ownership Data sheet to form a compressor log
book.
11.1.2 If these sample log sheets are used, they MUST be
used in conjunction with the User Manual, not as a
replacement.

11.2 Values At Commissioning

Note: All readings to be taken from SureScan.

Item Value Unit Inspection Date

Max. pressure bar

Max. overpressure bar

Star/delta time sec.

Load delay time sec.

Max. service hours hrs

Auto re-start delay sec.

Interstage trip bar

Interstage alarm bar

Oil temp. trip °C

Oil temp. alarm °C

St. 1 delivery trip °C

St. 1 delivery alarm °C

St. 2 intake trip °C

St. 2 intake alarm °C

St. 2 delivery trip °C

St. 2 delivery alarm °C

Plant del trip °C

Plant del alarm °C

Oil pressure bar

Interstage pressure bar

70 DL054CA
CompAir Appendix 1 – Sample Log Sheets 11

11.3 Commissioning Configurations

Item Setting Inspection Date

Language

Unit of Pressure

Unit of Temperature

Compressor Number

Comms Baud Rate

Fault Input Config.

Return to Previous Menu

11.4 Operational Settings

Item Setting Inspection Date

P1 Set Point

P2 Set Point

Run On Time

Drain Open Time

Drain Shut Time

11.5 Weekly Checks

Item Week 1 Week 2 Week 3 Week 4

Date

Running Hours Total

Hours On Load

Enclosure Filters

Intercooler Condensate Drains

Aftercooler Condensate Drain

Status Display

DL054CA 71
11 Appendix 1 – Sample Log Sheets CompAir

11.6 Performance Log

11.6.1 This log is provided to enable the user to keep a written record of compressor performance and as an aid to fault
diagnostics. It is recommended that the readings are recorded regularly, as part of the weekly service, with the
compressor in normal operating condition.

Item Value Unit Inspection Date

Delivery pressure bar

Interstage pressure bar

Total hours Std

Hours on load Std

Service hours to run

Oil Temp Std

St 1 delivery temp. °C

St 2 intake temp. °C

St 2 delivery temp. °C

Plant del temp. °C

Oil pressure bar

11.7 4000 hr Service (Service A)

Item Value/Completed

Date

Total Hours

Hours On Load

Hoses and Pipework

Flange Bolts/Screws Torque

72 DL054CA
CompAir Appendix 1 – Sample Log Sheets 11

11.8 8000 hr Service (Service B)

A 4000 hr (Service A) plus the following:

Item Value/Completed

Date

Total Hours

Off Load Hours

Oil Removal Filter (powered

breather)

Oil Change

Oil Filter Element

Intake Air Filter Element

Balance Piston Diaphragms

Reg. Air Line Filter Element

Intercooler Tubestack

Aftercooler Tubestack

Oil Cooler

Drive Motor Connections

Starter Connections

2nd Stage non-return Valve

11.9 16000 hr Service (Service C)

An 8000 hr (Service B) plus the following:

Item Value/Completed

Date

Total Hours

Hours On Load

Suction Reg. Valve Diaphragm

Drive Coupling Inserts

Starter Contacts

DL054CA 73
11 Appendix 1 – Sample Log Sheets CompAir

11.10 Compressor History Log Sheet

It is recommended that a written log be kept of the compressor fault history.

Model Memory Log Number

Serial 1 2 3 4 5 6 7 8 9 10 11

Date

By

Fault Message

Status Message

Total Hours

Discharge P bar

Interstage P bar

Oil Temp °C

LP Dely Temp °C

HP Inlet Temp °C

HP Dely Temp °C

Plant Dely Temp °C

Oil Pressure bar

74 DL054CA
CompAir Appendix 1 – Sample Log Sheets 11

12 13 14 15 16 17 18 19 20 21 22 23 24 25

DL054CA 75
12 Appendix 2 – The Pressure Systems And Gas Regulations 2000 No. 128 CompAir

12 Appendix 2 – The Pressure Systems And Gas Regulations

2000 No. 128
12.1 Introduction pressure relief valves etc., will be defined by the
‘competent person’ preparing the written scheme.
12.1.1 The circuit diagram shown below is provided to
assist a ‘competent person’ in preparing a written 12.1.2 In defining these periods the ‘competent person’
scheme of examination for a system incorporating must take into account the recommendations of the
the air compressor(s). component part manufacturer, the Health and Safe-
ty Executive (H & SE) and the British Compressed
Note: The intervals between examination and Air Society (BCAS).
calibration of components, e.g. pressure vessels,

NO
To 1st stage balance
12 To 1st stage
Y piston
balance piston

Z 13
P B

NC

12
C
X A

1 2
Z1 C1 B1 A1 15

14

16
17 5 6
3 4
+ -

11
18
M 20
+ -
19

10
7 8 9
15
SM 0996 14
1. Intake Air Filter

}
2. Suction Regulator 12. Unloader Solenoid Valve (2)
3. First Stage Air-end 13. Shuttle Valve
4. Intercooler 1st Stage 14. Strainer (2)
5. Pressure Relief Valve 15. Condensate Drain Valve (2)

}
6. Pressure Transmitter 16. Air Filter Switch
7. Second Stage Air-end 17. Temperature Sensor
8. Non-return Valve 18. Temperature Sensor
9. Aftercooler 2nd Stage 19. Temperature Sensor
10. Pressure Relief Valve 20. Temperature Sensor
11. Pressure Transmitter

Air Compressor Circuit Diagram

76 DL054BA
Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland

Tel. ++49 (0)6761 832-0

Fax ++49 (0)6761 832-409

www.compair.com
e-mail: sales@compair.com