50Hz/60Hz A21 A26 A31

OPERATION AND MAINTENANCE MANUAL

A21 SERIAL No : 2182000 –>

This manual contains
important safety information A26 SERIAL No : 2202000 –>
and must be made available to
personnel who operate and A31 SERIAL No : 2225002 –>
maintain this machine.

C.C.N. : 89267983 GB
DATE : FEBRUARY 2001
 Machine models represented in this manual may be used in various locations worldwide. Machines sold and
shipped into European common market countries requires that the machine display the EC Mark and conform
to various directives. In such cases, the design specification of this machine has been certified as complying
with EC directives. Any modification to any part is absolutely prohibited and would result in the CE certification
and marking being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC

WE,

ECOAIR
GEWERBEALLE 17
D–45478 MÜLHEIM
DEUTSCHLAND

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,
THE PRODUCT(S)

50Hz/60Hz A21 A26 A31

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS
OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012, EN50081, EN50082

ISSUED AT MÜLHEIM ON 01/01/2001 BY G BAUER, GENERAL MANAGER

GEORG BAUER
1 CONTENTS & ABBREVIATIONS
ABBREVIATIONS & SYMBOLS
CONTENTS
#### Contact ECOAIR for serial number
1 CONTENTS
–>#### Up to Serial No.
####–> From Serial No.
2 FOREWORD * Not illustrated
 Option
3 ISO SYMBOLS NR Not required
AR As required
SM Sitemaster/Sitepack
8 SAFETY HA High ambient machine
WC Watercooled machine
9 GENERAL INFORMATION AC Aircooled machine
ERS Energy recovery system
T.E.F.C.Totally enclosed fan cooled motor (IP54)
12 INSTALLATION / HANDLING
O.D.P. Open drip proof (motor)

18 OPERATING INSTRUCTIONS
D Germany
DK Denmark
21 MAINTENANCE E Spain
F France
GB Great Britain
24 FAULT FINDING
I Italy
N Norway
NL Netherlands
P Portugal
S Sweden
SF Finland

50Hz/60Hz A21 A26 A31


The contents of this manual are considered to be proprietary and
confidential to ECOAIR and should not be reproduced without the prior
written permission of ECOAIR.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding
the ECOAIR products described herein. Any such warranties or other
terms and conditions of sale of products shall be in accordance with the
standard terms and conditions of sale for such products, which are
available upon request.
This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised ECOAIR service
department.
The design specification of this machine has been certified as
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid.
All components, accessories, pipes and connectors added to the
compressed air system should be:
. of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by ECOAIR.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and
maintenance.
Details of approved equipment are available from ECOAIR Service
departments.
The use of non–genuine spare repair parts other than those
included within the ECOAIR approved parts list may create hazardous
conditions over which ECOAIR has no control. Therefore ECOAIR
cannot be held responsible for equipment in which non–approved
repair parts are installed. Standard warranty conditions may be
affected.
ECOAIR reserves the right to make changes and improvements to
products without notice and without incurring any obligation to make
such changes or add such improvements to products sold previously.
FOREWORD 2
The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however ECOAIR cannot
anticipate every application or work situation that may arise.
IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.
The use of the machine in any of the situation types listed in
table 1:–
a) Is not approved by ECOAIR,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against ECOAIR.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of
hazardous levels of flammable gases or vapours.
Use of the machine fitted with non ECOAIR approved components.
Use of the machine with safety or control components missing or
disabled.
The company accepts no responsibility for errors in translation of
this manual from the original English version.
ECOOL is a registered trademark of ECOAIR Company.
 COPYRIGHT 2001
INGERSOLL–RAND COMPANY
50Hz/60Hz A21 A26 A31
3 ISO SYMBOLS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.

X,X BAR

WARNING – Maintain correct tyre pressure.

WARNING – Pressurised component or
WARNING – Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION
system.
section of this manual).

0
C

WARNING – Before connecting the tow bar WARNING – For operating temperature
WARNING – Flammable liquid. or commencing to tow consult the below 0
C, consult the operation and
operation and maintenance manual. maintenance manual.

50Hz/60Hz A21 A26 A31

 ISO SYMBOLS 4

WARNING – Do not undertake any

WARNING – Consult the operation and
maintenance on this machine until the Do not breathe the compressed air from this
maintenance manual before commencing
electrical supply is disconnected and the air machine.
any maintenance.
pressure is totally relieved.

Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.

Do not stand on any service valve or other Do not operate with the doors or enclosure
Do not use fork lift truck from this side.
parts of the pressure system. open.

XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

50Hz/60Hz A21 A26 A31

5 ISO SYMBOLS

Lifting point. On (power). Off (power).

a
Read the Operation and Maintenance manual
When parking use prop stand, handrake and
before operation or maintenance of this Contains asbestos.
wheel chocks.
machine is undertaken.

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER SOILED FILTER

POWER INLET ELECTRIC MOTOR HOURS

50Hz/60Hz A21 A26 A31

 ISO SYMBOLS 6

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURISED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

50Hz/60Hz A21 A26 A31

7 ISO SYMBOLS

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

50Hz/60Hz A21 A26 A31


WARNINGS
Warnings call attention to instructions which must be followed
precisely to avoid injury or death.
CAUTIONS
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its
surroundings.
NOTES
Notes are used for supplementary information.
General Information
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual, and the
manual holder, are not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all
pressure.
All persons positioned near to operating machinery should be
equipped with hearing protection and given instructions on its use in
accordance with workplace safety legislation.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
The specification of this machine is such that the machine is not
suitable for use in flammable gas risk areas.
Installation of this compressor must be in accordance with
recognised electrical codes and any local Health and Safety Codes.
The use of plastic bowls on line filters without metal guards can be
hazardous. Their safety can be affected by either synthetic lubricants,
or the additives used in mineral oils. Metal bowls should be used on a
pressurised system.
Compressed air
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated
pressure.
If more than one compressor is connected to one common
downstream plant, effective isolation valves must be fitted and
controlled by work procedures, so that one machine cannot accidently
be pressurised / over pressurised by another.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
The discharged air contains a very small percentage of compressor
lubricating oil and care should be taken to ensure that downstream
equipment is compatible.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
When using compressed air always use appropriate personal
protective equipment.
SAFETY 8
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Avoid bodily contact with compressed air.
All safety valves located in the separator tank must be checked
periodically for correct operation.
Materials
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
. preservative grease
. rust preventative
. compressor coolant
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
For further information, consult Material Data Sheets ECO P006/95
(ECOOL) and EAA105 (food grade coolant).
Transport
When loading or transporting machines ensure that the specified
lifting and tie down points are used.
Electrical
Keep all parts of the body and any hand–held tools or other
conductive objects, away from exposed live parts of the compressor
electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the compressor
electrical system.
Close and lock all access doors when the compressor is left
unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
Condensate disposal
Condensate cannot be discharged into fresh/surface water drains.
In some regions compressor condensate containing ECOOL can be
fed directly into a drainage system that has downstream sewerage
treatment.
Condensate contaminated with mineral oil cannot be discharged
into fresh/surface water drains, whereas In some regions compressor
condensate containing ECOOL can be fed directly into a drainage
system that has downstream sewerage treatment.
As waste water regulations vary by country and region it is the
responsibility of the user to establish the limitations and regulations in
their particular area. ECOAIR and its associated distributors are happy
to advise and assist in these matters.
For further information, consult Material Data Sheets ECO P006/95
(ECOOL) and EAA105 (food grade coolant).
The above information contains data supplied in support of United
Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)
regulations.
50Hz/60Hz A21 A26 A31
9 GENERAL INFORMATION

Revision C
89265151

50Hz/60Hz A21 A26 A31

 GENERAL INFORMATION 10
KEY

CABLE SP Pushbutton, stop

L1 – L3 Mains terminals K2 Relay, stop
B Earth point, Sub–base TM3 Stop timer
PE Main earth terminal h Hourmeter
E1 Earth terminal, Main motor LT2 Auto restart lamp
E2 Earth terminal, Sub–base TM1 Star Delta Timer
E3 Earth terminal, Control transformer KM1 Contactor (main)
E4 Earth terminal, Instrument panel KM2 Delta contactor
E5 Earth terminal, PS KM3 Star contactor
E6 Earth terminal, 1SV PS Pressure switch
E7 Earth terminal, FM1 TM2 Run–on Timer
E8 Earth terminal, FM2 1SV Load solenoid
MCB1Miniature circuit breaker, Transformer supply 3SV Valve, solenoid
T1 Transformer, control supply LT3 Fault lamp
MCB2Miniature circuit breaker, 110V control circuit K3 Relay, fault 1
LT1 Power on lamp K4 Relay, fault 2
HAT Temperature switch, Discharge MM Main motor
MOL Motor overload FF1–3Fuse, fan motor
ES Switch, emergency stop FM1 Fan motor
RST Remote start (Optional) FM2 Fan motor
PORO Power out restart (Optional) LK Link
RSP Remote stop (Optional) RT Reset
OPT Optional AS Auto–stop
ST Pushbutton, start MOD Modulation
K1 Relay, control

50Hz/60Hz A21 A26 A31

11 GENERAL INFORMATION

89268098
Revision E

KEY

1. Filter, air 16 Relay, overload

Motor
2. Valve, inlet
17 Valve, safety
3. Valve, solenoid 1SV (load)
18 Valve, drain
4. Airend assembly
19 Screen, scavenge
5. Motor
20 Valve, solenoid 3SV (blowdown)
6. Tank, separator, Coarse
21 Orifice
7. Tank, separator, Fine
22 Gauge, temperature
8. Valve, minimum pressure
9. Aftercooler
23 Indicator, separator differential

10. Gauge, pressure

24 Indicator, air restriction

11. Switch, Discharge pressure

Air/Coolant
12. Switch, temperature
Air
13. Filter, coolant Coolant
14 Thermostat Condensate
15 Cooler Component boundary

50Hz/60Hz A21 A26 A31

INSTALLATION / HANDLING 12

50Hz/60Hz A21 A26 A31

13 INSTALLATION / HANDLING
NOTE
All dimensions are in millimetres unless otherwise stated.
Ensure that the correct fork lift truck slots or marked lifting / tie down
points are used whenever the machine is lifted or transported.
UNPACKING
The compressor will normally be delivered with a polythene cover.
If a knife has to be used to remove this cover ensure that the exterior
paintwork of the compressor is not damaged.
Ensure that all transport and packing materials are discarded.
LOCATION IN THE PLANT
The compressor can be installed on any level floor capable of
supporting it. A dry, well ventilated area where the atmosphere is as
clean as possible is recommended. A minimum of 0,45m should be left
at the rear and 1m at the sides of the machine for adequate service
access and ventilation.
50Hz/60Hz A21 A26 A31
Adequate clearance needs to be allowed around and above the
machine to permit safe access for specified maintenance tasks.
Ensure that the machine is positioned securely and on a stable
foundation. Any risk of movement should be removed by suitable
means, especially to avoid strain on any rigid discharge piping.
CAUTION
Screw type compressors [1] should not be installed in air systems
with reciprocating compressors without means of isolation such as a
common receiver tank. It is recommended that both types of
compressor be piped to a common receiver using individual air lines.
CAUTION
The use of plastic bowls on line filters and other plastic air line
components without metal guards can be hazardous. Their safety can
be affected by either synthetic coolants or the additives used in mineral
oils. From a safety standpoint, metal bowls should be used on any
pressurised system.
 INSTALLATION / HANDLING 14

NOTE It is essential when installing a new compressor [1], to review the

Items [2] to [5] are optional or may be existing items of plant. Refer total air system. This is to ensure a safe and effective total system. One
to your ECOAIR distributor / representative for specific item which should be considered is liquid carryover. Installation of air
recommendations. dryers [3] is always good practice since properly selected and installed
they can reduce any liquid carryover to zero.

DISCHARGE PIPING
It is good practice to locate an isolation valve close to the
Discharge piping should be at least as large as the discharge compressor and to install line filters [4].
connection of the compressor. All piping and fittings should be suitably
rated for the discharge pressure.

50Hz/60Hz A21 A26 A31

15 INSTALLATION / HANDLING
50Hz A21 A26 A31
COMPRESSOR
Maximum operating 7,5 bar 8,5 bar 10 bar 7,5 bar 8,5 bar 10 bar 7,5 bar 8,5 bar 10 bar
pressure
Normal operating 7 bar 8 bar 9,5 bar 7 bar 8 bar 9,5 bar 7 bar 8 bar 9,5 bar
pressure
Maximum Pressure ratio 7,5:1 8,5:1 10:1 7,5:1 8,5:1 10:1 7,5:1 8,5:1 10:1
Flow rate 2,4 2,2 2,0 2,9 2,7 2,5 3,3 3,2 2,9
m3/min
Maximum airend 109
C 109
C 109
C
discharge temperature
Ambient operating (+2
C ) » (+46
C) (+2
C ) » (+46
C) (+2
C ) » (+46
C)
temperature
MOTOR
Nominal power 15kW 18,5kW 22kW
Speed 2950 RPM 2945 RPM 2950 RPM
IP rating IP55 IP55 IP55
Frame B3 B3 B3
Insulation class F F F
COOLING SYSTEM
Air cooled
Cooling air flow 33m3 33m3 43m3
Maximum ∆P in air ducts 3 Pa/mm WG 3 Pa/mm WG 3 Pa/mm WG
Compressed air outlet ∆T 8
C 8
C 8
C
GENERAL DATA
Residual coolant content 3 mg/m3 3 mg/m3 3 mg/m3
Separator vessel 19 l 19 l 19 l
capacity
Coolant capacity 12 l 12 l 12 l
Sound pressure level to 72 dB(A) 72 dB(A) 73 dB(A)
CAGI–PNEUROP
Weight 410 kg 415 kg 421 kg
Discharge connection G1 G1 G1
Dimensions (L x W x H) 1140mm x 963mm x 970mm 1140mm x 963mm x 970mm 1140mm x 963mm x 970mm
ELECTRICAL DATA
Standard voltage 3–400V 3–400V 3–400V
Drive motor
Power 15 kW 18,5 kW 22 kW
Full load current 31A 40A 47A
(maximum)
Starting current (approx.) 96A 113A 130A
Starting time 3–5 S 3–5 S 3–5 S
Starts per hour 10 (IP54) 10 (IP54) 10 (IP54)
(maximum)
ELECTRICAL DATA
Fan motor
Power 0,2kW 0,3kW 0,3kW
Control voltage
Star/delta combination 110VAC 110VAC 110VAC
Minimum fuse rating 1&2 50A 50A 63A
Minimum cable size 3 10/16mm2 16/35mm2 25/35mm2
FCB/Fuse FCB/Fuse FCB/Fuse

50Hz/60Hz A21 A26 A31

 INSTALLATION / HANDLING 16
60Hz A21 A26 A31
COMPRESSOR
Maximum operating 103 128 143 203 103 128 143 203 103 128 143
pressure
PSIG
Normal operating 100 125 140 200 100 125 140 200 100 125 140
pressure
Maximum Pressure ratio 7,5:1 8,5:1 10:1 14:1 7,5:1 8,5:1 10:1 14:1 7,5:1 8,5:1 10:1
Flow rate 89 79 73 61 108 97 91 78 123 112 106
CFM
Maximum airend 109
C 109
C 109
C
discharge temperature
Ambient operating (+2
C ) » (+46
C) (+2
C ) » (+46
C) (+2
C ) » (+46
C)
temperature
MOTOR
Nominal power 20HP 25HP 30HP
Speed 3520 RPM 3520 RPM 3520 RPM
IP rating IP55 IP55 IP55
Frame 254T / B3 256T / B3 256T / B3
Insulation class F F F
COOLING SYSTEM
Air cooled
Cooling air flow 42m3 58m3 58m3
m3/Min
Maximum ∆P in air ducts 3 Pa/mm WG 3 Pa/mm WG 3 Pa/mm WG
Compressed air outlet ∆T 8
C 8
C 8
C
GENERAL DATA
Residual coolant content 3 mg/m3 3 mg/m3 3 mg/m3
Separator vessel 19 l 19 l 19 l
capacity
Coolant capacity 12 l 12 l 12 l
Sound pressure level to 72 dB(A) 72 dB(A) 73 dB(A)
CAGI–PNEUROP
Weight 410 kg 415 kg 421 kg
Discharge connection G1 G1 G1
Dimensions (L x W x H) 1140mm x 963mm x 970mm 1140mm x 963mm x 970mm 1140mm x 963mm x 970mm
ELECTRICAL DATA
Standard voltage 3–380V60 3–380V60 3–380V60
Drive motor
Power 20HP 25HP 30HP
Full load current 31A 40A 48A
(maximum)
Starting current (approx.) 96A 113A 130A
Starting time 3–5 S 3–5 S 3–5 S
Starts per hour 10 10 10
(maximum)
ELECTRICAL DATA
Fan motor
Power 0,3HP 0,4HP 0,4HP
Control voltage
Star/delta combination 110VAC 110VAC 110VAC
Minimum fuse rating 1&2 50A 50A 63A
Minimum cable size 3 10/16mm2 16/35mm2 25/35mm2
FCB/Fuse FCB/Fuse FCB/Fuse

50Hz/60Hz A21 A26 A31

17 INSTALLATION / HANDLING
1. If a circuit breaker is selected it should preferably be one with
magnetic trip only, set above the anticipated starting current of the
machine, but below the maximum prospective fault current for the
circuit. The circuit breaker must be capable of breaking the prospective
fault current at its terminals.
2. High breaking capacity, enclosed type gG.
3. PVC/PVC Type Calculated using the following conditions:
ELECTRICAL DATA
An independent electrical isolator should be installed adjacent to the
compressor.
Feeder cables should be sized by the customer/electrical
contractor to ensure that the circuit is balanced and not overloaded by
other electrical equipment. The length of wiring from a suitable
electrical feed point is critical as voltage drops may impair the
performance of the compressor. Cable sizes may vary considerably
so the mains terminals will accept up to 16mm2 cable.

i) PVC insulated cable, armoured, copper conductors.

ii) Cable clipped to a wall, in free air. Feeder cable connections to studs L1–L2–L3 on isolator should be
iii) Ambient temperature of 46
C. tight and clean.
iv) 20m cable run.
v) Volt drop limited to –10% during starting, –4% during normal The applied voltage must be compatible with the motor and
running. compressor data plate ratings.
vi) Protected by the circuit breaker listed above.

The control circuit transformer has different voltage tappings.

If there are any deviations from the above, or special regulations Ensure that these are set for the specific applied voltage prior to
apply, the installation must be planned by a competent, qualified starting.
engineer.

NOTE
All data applies to standard product only.

50Hz/60Hz A21 A26 A31

 OPERATING INSTRUCTIONS 18
GENERAL OPERATION The power transmission from the drive motor to the airend male
rotor is by pulley and belts. The constant auto tensioning system, using
The compressor is an electric motor driven, single stage screw
airend mass torque and gas arm, ensures that the belts are always
compressor, complete with accessories piped, wired and baseplate
under the correct tension, eliminating the need for adjustment and
mounted. It is a totally self contained air compressor package.
maximising the life of the belts.

The standard compressor is designed to operate in an ambient

By cooling the discharge air, much of the water vapour naturally
range of 1,7
C to 46
C. The standard maximum temperature of 46
C
contained in the air is condensed and may be drained from the
is applicable up to an elevation of 1000m (3280ft) above sea level.
downstream piping and equipment.
Above this altitude significant reductions in ambient temperature are
required if a standard motor is to be used.
The coolant system consists of a sump, cooler, thermostatic valve
and a filter. When the unit is operating, the coolant is pressurised and
Compression in the screw type air compressor is created by the
forced to the compressor bearings.
meshing of two (male & female) helical rotors.

The compressor load control system is automatic ’On–Off line’. The

The air/coolant mixture discharges from the compressor into the
compressor will operate to maintain a set discharge line pressure and
separation system. This system removes all but a few PPM of the
is provided with an autorestart system for use in plants where the air
coolant from the discharge air. The coolant is returned to the cooling
demand varies widely.
system and the air passes through the aftercooler and out of the
compressor.
Safety of operation is provided for as the compressor will shut down
if excessive temperatures or electrical overload conditions should
Ventilation air is moved through the coolers by the cooling fans and
occur.
discharged from the machine.

ELECTRO–PNEUMATIC CONTROL AND INSTRUMENTATION

50Hz/60Hz A21 A26 A31

19 OPERATING INSTRUCTIONS
PRIOR TO STARTING
1. Check coolant level. Add if necessary.
The reservoir is designed to prevent overfill. With warm unit stopped
in the normal way, the sight tube level should be within 15mm of the top
of the green strip. The level should not drop beyond the bottom of the
sight tube when running with a steady load.
2. Make sure main discharge valve is open.
3. Turn on electrical isolator. The ‘Power On’ (7) L.E.D. will light,
indicating that line and control voltages are available.
4. Check direction of rotation.
WARNING
Make sure that all protective covers are in place.
STARTING
1. Press ‘Start’ [5]. The compressor will start and then load
automatically.
NORMAL/EMERGENCY STOPPING
1. Press ‘Unloaded Stop’[6]. The compressor will unload then stop.
2. Press ‘Emergency stop button’ [4] and the compressor will stop
immediately.
3. Turn off electrical isolator.
50Hz/60Hz A21 A26 A31
1 PRESSURE GAUGE
Indicates the pressure immediately after the aftercooler. DO NOT
operate the compressor at discharge pressures over the rated
pressure.
2 TEMPERATURE GAUGE
Indicates the airend discharge temperature. DO NOT operate the
compressor at indicated temperatures above 109
C.
3 HOURMETER
Records the total running time of the compressor.
4 EMERGENCY STOP
When depressed will stop the compressor immediately. The ’Power
on’ L.E.D. will remain illuminated. The emergency stop button must be
released before the compressor can be restarted.
5 START
When depressed will cause the unit to start and run in a loaded
condition if there is a demand for air. If there is no demand, the machine
will run unloaded.
6 NORMAL STOPPING
The compressor will unload then stop.
7 POWER ON (Green)
Indicates the presence of control voltage at the controller.
8 AUTO RESTART (Amber)
Will illuminate when the machine has shut-down due to low air
demand. The machine will restart and load automatically as soon as the
demand for air returns.
9 COMMON ALARM
Turn off electrical Isolator. Investigate cause of fault.
 OPERATING INSTRUCTIONS 20
MODULATION OPTION – ELECTRO–PNEUMATIC CONTROL

SETTING PROCEDURE 5. Bring in the modulation using the rotary switch.

This option is either factory fitted or purchased as a kit with full
installation instructions. The modulation feature is brought in and out 6. Check for leaks.
with a rotary switch located under the canopy on the starter cabinet
wall.
7. Allow the machine to run, observing the rise in pressure.

1. This system is designed to modulate the machine capacity in the

range 100% – 60% of full capacity. It is possible to modulate to below
50% by setting a large differential at the pressure switch (1PS). Below
60% capacity it is recommended that the machine be set up to unload
for best efficiency.
2. Firstly, with the machine running in the ON/OFF line mode, check
the setting of the machine pressure switch 1PS (located under the
canopy).
3. The pressure switch upper trip point must not exceedthe rated
machine pressure. If in doubt, check the machine data plate Adjust the
set point if necessary.
8. Adjust the regulator clockwise, as required, so that the line pressure
holds steady approximately 2psi (0,3 bar) before the offline pressure.
9. If the pressure switch differential is set greater than 10psi (0,7bar),
this will result in the machine modulating to less than 60% capacity and
make unloading less likely.
10. Check that the unload (offline) pressure has not changed unduly
from that set with the modulation out of circuit.
11. Press the modulation pressure regulator knob down to lock the
setting. The system is now complete.

4. Allow the machine to load/unload according to the system demand.

Check and record the off–line pressure. Pull up the knob and turn the
pressure regulator anti–clockwise until all the adjustment is taken up.
The pressure regulator is located on the valve bracket, under the
canopy.

50Hz/60Hz A21 A26 A31

21 MAINTENANCE

ECOAIR CARE PROGRAMS 16000 hours / 4 Replace all hoses.

years
BRONZE Machine Diagnostic Report
SERVICE ECOOL Condition Monitoring 6 years/6000 hours Separator tank.
PLAN Critical Vibration Monitoring or as defined by Remove the cover plate and any necessary
Every 2000 local or national fittings. Clean the interior thoroughly and
Hours legislation. inspect all internal surfaces and welds.

SILVER ECOAIR recommendations for regular service ROUTINE MAINTENANCE

SERVICE schedule including genuine parts requirements.
This section refers to the various components which require
PLAN Service Plan also contains schedules for
150 & EVERY downstream accessories e.g. Dryers and Filtration. periodic maintenance and replacement.
2000 HOURS
The SERVICE/MAINTENANCE CHART indicates the various
GOLD Fixed 5 year service plan under contract with components’ descriptions and the intervals when maintenance has to
SERVICE ECOAIR or Distributor. take place. Oil capacities, etc., can be found in the GENERAL
PLAN Customer benefits include replacement of defective INFORMATION section of this manual.
5 YEAR parts in the event of failure during contract period.
CARE PLAN
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.

PERIOD MAINTENANCE CAUTION: Before beginning any work on the compressor, open,
Daily Check the coolant level and replenish if lock and tag the main electrical disconnect and close the isolation
necessary. (See “Prior to starting”) valve on the compressor discharge. Vent pressure from the unit
by slowly unscrewing the coolant fill cap one turn. Unscrewing
When the separator Check the pressure differential when the unit
service indicator is operating on full load at rated pressure. the fill cap opens a vent hole, drilled in the cap, allowing pressure
shows red before to release to atmosphere. Do not remove the fill cap until all
the 4000 hour Change the separator element if the pressure has vented from the unit. Also vent piping by slightly
change out period pressure drop is zero or exceeds 1 bar (15 opening the drain valve. When opening the drain valve or the
p.s.i.g.) coolant fill cap, stand clear of the valve discharge and wear
When the air filter Change the air filter. appropriate eye protection.
indicator shows red
before the 4000
h
hour/1
/ year change
h
out period Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
First 250 hours Change the coolant filter.

Each week Check that the safety valve easing gear

Ensure that maintenance personnel are adequately trained,
moves freely.
competent and have read the Maintenance Manuals.
1 month Check the cooler(s) for build up of foreign
matter. Clean if necessary by blowing out
with air or by pressure washing. Prior to attempting any maintenance work, ensure that:–

Each 3 months Check all hoses for signs of deterioration, . all air pressure is fully discharged and isolated from the system. If
cracks, hardening etc. the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.
Each 2000 hours Change the coolant filter.
2000 hours / 6 Check the operation of the high temperature
months protection switch (109
C). . the machine cannot be started accidently or otherwise, by posting
warning signs and/or fitting appropriate anti–start devices.
8000 hours / 1 year Check the scavenge screen for blockage,
clean if required.
. all residual electrical power sources (mains and battery) are
1 year Remove the safety valve from the
isolated.
compressor, inspect and re–calibrate.
1 year/1000 hours or Separator tank.
as defined by local Fully inspect all external surfaces, welds and Prior to opening or removing panels or covers to work inside
or national fittings. Report any excessive corrosion, a machine, ensure that:–
legislation. mechanical or impact damage, leakage or
other deterioration.
. anyone entering the machine is aware of the reduced level of
2000 hours Check the separator element. protection and the additional hazards, including hot surfaces and
Change if high pressure differential. intermittently moving parts.

1 year / 4000 hours Change the air filter element.

. the machine cannot be started accidently or otherwise, by posting
8000 hours / 2 years Change drive belt and gas spring. warning signs and/or fitting appropriate anti–start devices.
8000 hours / 2 years Replace the ECOOL at whichever interval
occurs first.
Prior to attempting any maintenance work on a running
Also replace the separator element and machine, ensure that:–
coolant filter.

50Hz/60Hz A21 A26 A31

 MAINTENANCE 22
. the work carried out is limited to only those tasks which require the 8. See “Prior to start” for refill level check method.
machine to run.

COOLANT FILTER CHANGE PROCEDURE

. the work carried out with safety protection devices disabled or
. Loosen filter element with the correct tool.
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
. Remove the element from the housing.
. all hazards present are known (e.g. pressurised components,
electrically live components, removed panels, covers and guards, . Place the old element in a sealed bag and dispose of in a safe way.
extreme temperatures, inflow and outflow of air, intermittently moving
parts, safety valve discharge etc.).
. Clean the mating face of the housing.

. appropriate personal protective equipment is worn.

. Remove the new ECOAIR replacement element from its protective
package.
. loose clothing, jewellery, long hair etc. is made safe.

. Apply a small amount of lubricant to the element seal.

. warning signs indicating that Maintenance Work is in Progress are
posted in a position that can be clearly seen.
. Screw the new element down until the seal makes contact with the
housing, then hand tighten a further half turn.
Upon completion of maintenance tasks and prior to returning
the machine into service, ensure that:–
. Start the compressor and check for leaks.
. the machine is suitably tested.
. all guards and safety protection devices are refitted. AIR FILTER CHANGE PROCEDURE
. all panels are replaced, canopy and doors closed. 1. Unscrew the retaining cap and withdraw the old element.
. hazardous materials are effectively contained and disposed of.
2. Fit the new element ensuring that the retaining nut is secured.

SEPARATOR ELEMENT CHANGE PROCEDURE

WARNING
Do not under any circumstances open any drain valve or remove 1. Disconnect the hose at the top of the separator tank.
components from the compressor without first ensuring that the
compressor is FULLY SHUT– DOWN, power isolated and all air
2. Disconnect the blow–down tube.
pressure relieved from the system.

3. Remove the setscrews securing the cover to the tank and remove
the complete cover assembly with the separator element.

COOLANT CHANGE PROCEDURE
The compressor features a ’no drip’ coolant drain feature which
requires no special tools and minimises the risk of coolant spillage.
4. Withdraw the used element, place it in a sealed bag and dispose of
it safely.
5. Clean the gasket surface on both the tank and the cover.

It is better to drain the coolant immediately after the compressor has

been operating as the liquid will drain more easily and any contaminant 6. Install the replacement element onto the flange using new ‘O’ ring
will still be in suspension. supplied if needed.

CAUTION
1. Remove the cap from the drain valve located at the front of the
Do not use any form of sealant on either the separator tank or the
separator vessel.
separator tank cover faces.

2. Place a suitable container close to the drain valve.

7. Carefully replace the flange/element assembly centrally.
Re–assemble the components in reverse order.
3. Screw the coolant drain hose onto the drain valve. As the threads
engage, the valve will automatically open and the coolant will drain. The maximum torque for the tank cover bolts is 60Nm (43 ft.lb).

4. Remove the drain hose. The valve will automatically close and seal. 8. Start the compressor and check for leaks.

5. Swing out the cooler as described below and, using a suitable

receptacle, remove the drain cap at the bottom tee of the cooler.

6. Replace the cap on the drain valve. WARNING

Do not remove the staple from the anti–static gasket on the
separator element since it serves to ground any possible static
7. Replace the cooler drain cap and secure the cooler and covers. build–up.

50Hz/60Hz A21 A26 A31

23 MAINTENANCE
AIREND BEARINGS BELT CHANGE / DRIVE SYSTEM ACCESS
Airend bearings are lubricated by the compressor coolant and 1. Swing out the cooler as described in the ‘COOLER CLEANING
require no maintenance. PROCEDURE’ section above.

COOLER CLEANING PROCEDURE 2. Fit a 1/2” square drive wrench or tommy bar in the tension cam
located above the belt and turn clockwise half a turn.
1. Stop the machine, electrically isolate and vent all trapped pressure.

3. The belt can be eased off the sheaves/pulleys and removed.

2. Remove the rear box by lifting off the keyhole fasteners.

4. To remove the tension gas strut, support the airend cradle with a
3. Remove the inverted ’L’ shaped cooler cover by unfastening the M6 suitable block of wood or similar.
taptite screws.

5. Using a small screwdriver under the spring clip, ease the ball ends
4. Disconnect the air discharge steel tube at the top of the aftercooler. off the spherical studs at the ends of the gas strut.

5. Disconnect the air discharge external to the package. 6. The gas strut and studs should be replaced at the same time.

6. Remove the fasteners holding the cooler extension plate to the 7. Replacement is done in reverse but great care should be taken that
cooler box. the ribs are not damaged when replacing the belt.

7. Swing the cooler outwards to clean, taking care not to stress the oil 8. Spin the drive to check alignment of the belt ribs on the pulleys
hoses. (sheaves).

8. Rebuild in reverse order.

50Hz/60Hz A21 A26 A31

 FAULT FINDING 24
FAULT CAUSE Pressure relief valve Compressor operating above rated
opens pressure.
Compressor fails to Control voltage not available.
start Incorrect pressure switch setting.
Defective starter.
Minimum pressure valve malfunction.
Machine shutsdown High airend temperature.
periodically Load solenoid valve defective.
Motor overload.
Blowdown valve defective.
Defective starter.
Inlet valve malfunction.
Line voltage variation.
Black residue on belt Drive belt slipping.
High current draw Compressor operating above rated g ard/cooler box
guard/cooler
pressure. Pulleys misaligned.

Separator filter element contaminated. Worn pulleys.

Low voltage. Gas strut failed.

Unbalanced voltage.
Damaged airend.
Low current draw Air filter contaminated.
Compressor operating unloaded.
High voltage.
Defective inlet valve.
High discharge Incorrect pressure switch setting.
press re
pressure
Load solenoid valve defective.
Blowdown valve defective.
Inlet valve malfunction.
Incorrectly set sequence panel.
Low system air Separator filter element contaminated.
press re
pressure
Incorrect pressure switch setting.
Minimum pressure valve malfunction.
Load solenoid valve defective.
Drive belt slipping.
Air system leaks.
Inlet valve malfunction.
System demand exceeds compressor
delivery.
Compressor overheats Compressor operating above rated
pressure.
Cooler blocked.
Low coolant level.
High ambient temperature.
Restricted cooling air flow.
Excessive coolant Separator element leak.
cons mption
consumption
Blocked separator element drain.
Compressor operating below rated
pressure.
Coolant system leak.
Excessive noise level Air system leaks.
Airend defective.
Motor defective.
Loose components.
Shaft seal leaking Defective shaft seal.

50Hz/60Hz A21 A26 A31

Printed in the United Kingdom