Avelair OM Instruction Manual 2020

ROTARY SCREW AIR COMPRESSOR
INSTRUCTION MANUAL
For all Compressors from serial no. R4213E
EVO fixed speed compressors

VSD variable speed compressors
Avelair Ltd Fred Castle Way Rougham Industrial Estate

Bury St Edmunds, Suffolk, IP30 9ND. United Kingdom
Tel: 00 44 (0)1359 272828

Fax: 00 44 (0) 1359 272829
Email : info@Avelair.co.uk
Web : www.Avelair.co.uk
For further information, or genuine spares requirements please contact Avelair Ltd on 00 44 (0) 1359 272828
Web site:- www.avelair.co.uk, E-mail:- info@avelair.co.uk 1
CONTENTS
1. INTERNATIONAL DIRECTIVES
2. MACHINE DESIGN PARAMETERS
3. SAFETY AND PREVENTION OF ACCIDENTS
4 EXPLANATION OF SAFETY SYMBOLS
5 GENERAL COMPRESSED AIR SAFETY
6. TRANSPORT, HANDLING AND PACKING
7. INSTALLATION
8. GENERAL DESCRIPTION
9. CONTROLLERS
10. START-UP AND STOPPING
11. NORMAL OPERATION
12. DECOMMISSIONING
13. TECHNICAL DESCRIPTION
14. MAINTENANCE
15. MAINTENANCE SCHEDULE
This Instruction Manual gives all the necessary information required to install, start and
operate the AVELAIR Rotary Screw Air Compressor. Maintenance instructions are also
included and must be observed. Failure to adhere to the operating and maintenance
instructions or unauthorised changes to the compressor may invalidate the warranty and
result in an unsafe operating condition.
The unit must be installed and commissioned by authorised technicians. For compliance
with the Machinery Directive and Safety of Machinery Standard the equipment must be
electrically connected via a suitable disconnector and breaker device. Guidance can be
provided from the Manufacturer. We advise that you request a scheduled Maintenance
Agreement. For further information on your nearest AVELAIR agent, please contact our
Customer Service Department on Tel +44: (0) 1359 272828
1 INTERNATIONAL DIRECTIVES
The compressor to which this instruction manual relates and the instruction manual itself
have been revised to satisfy the requirements of the European directives as indicated below
and associated harmonised standards.
2006/42/EC Machinery Directive 2006*

2014/30/EU EMC Directive
2014/68/EU Pressure Equipment Directive
*For compliance with the Machinery Directive the equipment MUST be electrically connected via a suitable disconnection device and installed in
accordance with BS EN 60204 and BS7671 (Latest revisions).
2 MACHINE DESIGN PARAMETERS

2.1. The compressor is designed for compressing air.
2.2. The compressor is designed for continuous use between +1° and +35°C and with
intermittent temperature increase to +40°C. For constant use in temperatures of below
+1°C or above +35°C additional design features are required.
2.3. The inlet pressure must be atmospheric pressure.
2.4. The environment should be free from air borne contamination such as dust, litter, hazardous
gases, fumes etc.
2.5. The unit should only be used in a dry, sheltered frost-free environment and free from
condensation and extreme changes in temperature.
2.6. The normal design voltage is 400V / 3Ph + earth / 50 Hz or 230V / 1Ph + earth / 50 Hz for
single phase units. Dependant on the specification a neutral supply may be required.
2.7. The discharge pressure, pressure settings, inverter controls and settings are factory
pre-set and may only be adjusted having first gained written agreement from the
manufacturer.
2.8. The speed of rotation can be fixed or variable dependant on unit.
2.9. The compressor must not be used in a potentially hazardous atmosphere.
2.10 The compressed air must not be used as breathing air unless it has been suitably
treated by external equipment.
2.11 The compressor is air cooled, the air flow into and out of the environment should be
20% more than the cooling air requirement specified on the specific data sheet.
2.12 The paint finish is suitable for internal industrial non-coastal environment.
3 SAFETY AND PREVENTION OF ACCIDENTS
Introduction
As the user / operator of the Avelair compressed air equipment it is essential that you familiarise
yourself with the contents of this manual with respect to safe operation, construction, function
and maintenance.
A requirement for safe working is a knowledge of the safety features of the equipment
These provisions apply to the Avelair Rotary Screw Air Compressor. Components
supplied by other manufacturers are to be used in accordance with their own safety
provisions.
The operation manual is to be followed by ALL personnel working with the equipment and must
be made freely available at the point of use. Read the following safety instructions carefully and
act accordingly when the compressor is transported, installed, operated, serviced, repaired or
decommissioned. These instructions are in addition to the usual safety regulations to be
observed for rotary screw air compressors, components and accessories. They support, not
replace general Health and Safety legislation such as the Provision and Use of Work Equipment
Regulations, (PUWER).
3.1 The operating personnel must employ safe practices and observe all
relevant safety regulations and operating instructions.
3.2 The operator is responsible for the machine to be kept in a safe

operating condition. If parts and accessories are considered not to be in
a suitable condition for safe operation, the machine must be taken out
of service until the fault or potential fault has been rectified.
3.3 The unit must only be transported, installed, operated, serviced,

repaired or decommissioned by authorised, trained and qualified
personnel.
3.4 Limits i.e. pressure and temperature values, timer settings etc. must not
be altered without written consent from the manufacturer.
If any of the above provisions (especially concerning safety) does not comply with local
provisions of law, the safer provision must be applied.
4 EXPLANATION OF SAFETY SYMBOLS
Hazard from entrapment, the equipment must be isolated prior to removal

of any guards.
Hazard from inhalation of untreated air from compressor.
Hazard from hot surfaces.
Risk of electric shock, isolate compressor prior to removal of any guards.
Hazard from release of pressurised air.
Risk of electric shock access to 400 volt supply.

(Voltage may vary)
The equipment must be isolated by safe isolation methods prior to removal

of any guards, maintenance, or repair.
Ear defenders should be worn when appropriate during maintenance and

repair.
Safety goggles should be worn during maintenance and repair.
Suitable hand protection should be worn during maintenance and repair.
This warns that if the compressor is not
fully isolated the unit may start without
warning.
Slip hazard from oil spills. Ensure all spills are cleaned thoroughly.
The emergency stop when operated removes power from the main drive
motor and fan motor (if fitted) the motors will coast to stop.
The emergency stop does NOT isolate the power from the unit.
A suitably sized disconnector and breaker should be fitted adjacent to the

compressor and any ancillary equipment to ensure full compliance with the
Machinery Directive and Safety of Machinery Standard. Failure to do this
could result in risk of electric shock.
It is highly recommended that an isolator is always fitted local to the
compressor to assist in two point isolation for ‘safe working practices’.
Waste oil, condensate and oil contaminated products must be disposed of

in accordance with legislation.
An Avelair trained engineer is required for this operation.
4.1 IMPORTANT NOTES
This instruction manual is a general manual for all Avelair compressors from serial №
R4213E. The manual includes instructions for different controllers, fixed speed and variable
speed compressors. Ensure that the correct section is selected. The manual describes how
the Avelair rotary screw air compressor must be operated in order to achieve safe operation,
maximum efficiency and long, reliable service life.
Read the manual before starting the machine, so that safe and appropriate procedures are
followed from the start. The maintenance schedule contains all the necessary measures
required to keep the machine in good condition. Maintenance is simple but must be carried
out regularly and by a competent person.
It is important to ensure that a copy of the instruction manual is kept available for the
operators of the compressor. All operating data, maintenance and service work should be
entered into a service log book.
Repairs and service should be carried out by authorised, Avelair trained, competent
personnel only.
Always specify the model and the serial number in all communication and correspondence,
this ensures that the correct spares appertaining to the specific machine are specified.
The manufacturer reserves the right to make technical changes without prior notice.
The compressor must always be operated with the guards in position as they form the
essential safety guarding of the machine. Only one key to open the cabinet for servicing is
included, a further key is provided for the electrical cabinet these keys must be guarded
against improper use and only issued to the competent personnel via a permit to work
procedure.
The manufacturer assumes no responsibility for any damage or injury caused by ignoring
these safety provisions, or by failing to exercise due care and attention during handling,
installation, operation, maintenance, repair or decommissioning, even if hazards are not
expressly mentioned in this operating manual.
5 GENERAL COMPRESSED AIR SAFETY
The following notes support the publication HS (G) 39 'Compressed Air Safety' published by
the United Kingdom Health and Safety Executive a copy of which can be obtained from the
HSE web site.
5.1 Never allow any part of the body e.g. (hand) to interrupt a flow of
compressed air, even at low pressure.
5.2 Never open valves when under pressure and disconnected, always think
ahead and find a safe route for the discharge of compressed air.
5.3 Check the complete system from time to time for air leaks and repair
where necessary. A hose or component failure may cause injury.
5.4 Always shut down and depressurise the complete system before carrying
out any maintenance work on the system or the compressor.
5.5 Always isolate the electrical supply before working on the compressor.
5.6 Never repair pressure lines or pressure vessel by soldering or welding.
5.7 Always use hose fittings and clamps designed for use with compressed
air and which have the correct thread to mate with other connectors.
5.8 Avoid releasing large volumes of air quickly, as icing may occur which
will result in ice particles being expelled at high velocity.
5.9 Use eye protection when operating or servicing pneumatic equipment.
5.10 Use protective gloves when performing maintenance operations that may
involve contact with the mineral oil lubricant.
NOISE EMISSION
At final test, the noise level of each machine is measured and recorded within our test area.
The measurement is made with the machine running in its noisiest condition with a noise
level meter. A measured 4dB (A) offset is allowed for test room acoustics. The measuring
probe is held 1 metre from the machine at a height of 1.6 metres. The typical values can be
seen on our technical information sheets.
6 TRANSPORTATION, HANDLING AND PACKING
The Avelair Rotary Screw Air Compressor is despatched in packing suitable for the chosen
mode of delivery. Even though great care is taken at the factory, damage can occur to the
compressor during transit. We therefore recommend that the unit is checked for damage.
If damage has occurred during transportation we suggest the following:
6.1 Outwardly visible damage must be officially noted on the carrier paperwork, and then
the carrier should immediately be informed by telephone and confirmed in writing.
6.2 If damage becomes apparent during unpacking, contact the carrier immediately and
follow up the notification in writing.
6.3 Do not alter the condition of the damaged compressor until the carrier has been to
inspect the damage or has declined to do so.
In all cases, inform the manufacturer immediately; do not commission a damaged machine.
When the compressor has been unpacked it should be transported by one of the following
methods:-
1. Fork - lift truck
2. Pallet truck
In all cases, the compressor should be lifted from below. The baseplate is designed to
accept the forks of a fork-lifting device. The compressor must be transported with the
flexible feet removed.
The approximate weight of the machine is given in the technical information sheets
available from Avelair Ltd.
7 INSTALLATION
The compressor must be installed on a solid, flat base. If it is installed on a floor of a multi-
storey building, the bearing capacity of the floor must be assessed. It is essential that a
minimum distance from walls, other machines, etc., be observed. Fit the anti-vibration feet
supplied and ensure the unit is level. For compressors of 30 kW and above, we would
recommend that the customer supply and position their own anti-vibration pads. Check that
all screw and clamp connections in the control cabinet are tight.
The heat that is generated during the compression process must be dissipated, and cool,
clean air supplied to allow the cooling process to continue. It is possible to use the hot air
generated to heat buildings provided local building regulations are observed, other legislation
complied with and insurers informed.
If the compressor room cannot be ventilated by natural means, then it is necessary to provide
forced ventilation by alternative means. In order to ensure good ventilation, the air volume
moved by these means should be at least 20% greater than the total of the cooling air
volumes of all the compressors located in the room.
It is essential that adequate attention is given to ensure that the heated cooling air does not
get drawn in or re-circulated back into the compressors and any necessary measures
implemented to stop this occurring.
The compressor is designed for continuous use between +1°C and +35°C and with
intermittent temperature increase to +40°C. For constant use in temperatures exceeding
+40°C additional design features will be required.
The required cooling air volume can be calculated by the following formula:
V= Q
Cp.dt
Where: Q : heat volume to be carried off (kJ s kW ), -1 -1
Cp: 1.3 kJ m . K -3
dt : Temperature rise (K),

V : Volume flow (m s ) 3 -1
The compressor should be kept frost-free when the machines are not in operation. In
installations where freezing is a possibility, suitable measures such as installing trace
heating, panel heaters and tube heaters or other means should be used.
INSTALLATION CONTINUED
In addition to operation according to general technical regulations of the local authorities,
the following guide- lines must be strictly observed.
7.1. The compressor must be installed in a place where the ambient air is as cool and
clean as possible. Never obstruct admission of air to the compressor. Ensure that
dust and moisture in the air is kept to a minimum.
7.2. Intake air must not contain any corrosive or flammable vapours or exhaust vapours
such as paint solvents. The presence of these gases could cause an internal fire or
malfunction.
7.3. Ensure that an adequate flow of clean cooling air is provided and that the warm air
discharged is not re-circulated into the cooling air inlet.
7.4. Ensure that the compressed air discharge pipe from the compressor to the air system
can expand with heating and does not have contact with any flammable material. The
connection must be able to withstand compressor vibration throughout the foreseen
life of the system.
7.5. If a remote control unit is fitted, the compressor must be equipped with a clearly
visible plate with the following lettering.
WARNING: THIS UNIT IS OPERATED BY REMOTE CONTROL

AND COULD START WITHOUT ANY WARNING.
As an additional protective measure, persons who start a compressor by remote

control must make sure that no person is checking or operating the unit. For this
purpose, a corresponding plate must be provided at the remote control unit.
7.6. Connection must be made to the compressor discharge point via the fitting shown in
the specification section.
7.7. During installation, the disconnector must be locked in its off position.
ELECTRICAL CONNECTION
The compressor must be connected to a suitable electrical supply including a local
disconnector adjacent to the machine, this will then comply with the Machinery Directive and
should be installed in accordance with the latest edition of BS 7671. The supply and earth
conductors must be sized accordingly by a qualified electrician considering site specific
measured values.
The incoming supply shall be protected against over-current externally to the compressor by
means of a motor rated overcurrent protective device. The suggested current rating and type
of protective device for each machine can be provided by the manufacturer.
Connection to the compressor is made via a suitably sized isolator to be installed by others
adjacent to the machine to comply with safe installation practices, and compliance with
Machinery Directive. A neutral connection is only required if the machine has ancillary
equipment; this requirement would be outlined on machine electrical drawings.
COMPRESSED AIR CONNECTION
The compressor must be connected to solid pipe-work via a flexible hose to ensure there is
no transmission of vibration from the compressor.
We also recommend the installation of a shut-off valve so that the compressor can be
isolated from pressurised pipe-work during maintenance. For multiple compressor systems,
it must be possible to pneumatically isolate each machine via a lockable valve during
maintenance work
ANCILLARY EQUIPMENT
Dependant on the application, it may be necessary to install ancillary such as air receiver / s,
filtration, moisture removal equipment and condensate management equipment to comply
with waste disposal requirements. As each installation has its’ own specific requirements, we
would recommend that you contact Avelair or your local Avelair distributor to discuss the
requirements and provide a cost effective solution. We can also provide compressor
management systems for use with multiple compressor installations to minimise energy
requirements along with bespoke control systems.
8 GENERAL DESCRIPTION
The compressors are enclosed in a fabricated enclosure, which, when assembled form a
rigid structure to house the compressor air end, motor, drive assembly, cooler and electrical
controls. The enclosure is complete with sound attenuation to reduce the noise level to well
within industry standards. The enclosure is painted with a highly durable industrial quality
leatherette finish power coating. The enclosure can be accessed for maintenance via the
removal of the guards using a specialist tool that should only be issued to competent
personnel.
The compressors have an integrated combination cooler to allow cooling for the oil and air.
The cooling air is drawn into the enclosure by a suitably sized fan pressurising the fan
plenum and forcing air through the cooler resulting in keeping the rotary screw at the
optimum temperature and reducing the air discharge temperature to approximately 10°C
above ambient.
The rotary screw is belt driven by an over specified drive train using a high quality drive belts
resulting in minimising any losses. The main drive motor is of proprietary manufacture and is
as a minimum IE3 high efficiency motor with IP55 protection rating ensuring longevity of the
motor in arduous conditions.
The compressor control panel will be the standard control panel protected against water
ingress. The compressor controller takes care of all the compressor functions and provides
operating information on the LCD display. The controller can supply a volt free contact for
external for alarms with the specific fault indicated as a failure alarm or shut down displayed
on the LCD display.
9. CONTROLLERS
There are currently two different types of compressor controller fitted to the Avelair standard
type machines please ensure that reference is made to the correct controller. For
distinction we will refer to the first controller as the standard controller and the following
controller as the advanced controller.
9.1 STANDARD CONTROLLER
USER DISPLAY
Main Display Value; Pressure (bar/psi menu selectable)
Default User Menu Item; Temperature (°C/°F menu selectable)
To view alternative User Menu Items, press Up or Down
Total Hours Run
Loaded Hours
Hour Until Service Due (countdown timer based on total run
hours)
RS485 Communication Network Address

(*only show if RS485 option is installed)
If a Timer event occurs (Run-On, Stop, Blowdown or Auto Restart time) the
User item display will show the time countdown in seconds. While a
countdown is being displayed normal User items can still be viewed; press
Down.
The display will default back to the User Temperature item after a short
period of no key activity or after a Timer event has completed.
If operating in “Pressure Switch Mode” the main display will show the
detected temperature and the default User Menu item will be total run hours.
Pressure is not displayed in pressure switch mode.
Pressure Switch Mode
9.1.1 Status Display:
Stand By:- The compressor is in a started state but not running. The
compressor will automatically re-start when the pressure falls to the lower
pressure set point or a remote Load signal
Running off Load:- The Run-On-Timer is active
Loaded:- The compressor is running on Load.
9.1.2 Fault Codes:
If a Fault condition occurs, the Fault triangle symbol will switch on steady
(Alarm/Warning) or flash (Trip/Shutdown). The User menu display item will
show a ‘Fault Code’ dependent on type of fault.
Fault Codes
Positive Displacement Air Compressor Application (E03 onwards):

If the Service Due countdown timer reaches 0 (zero) hours, the Service and
Alarm symbols will flash and the service Alarm (Warning) code will be
displayed. The alarm code can be reset but the service symbol will remain on
the display until the Service Due timer is reset; the service hours will continue
to decrement in negative hours. The service countdown timer can be reset
using the Menu routine, once the required service has been carried out. Set
to any value greater than 0 (zero) hours before reset.
The Service Due countdown timer can be reset to any hour value, dependent
on the required service interval. The timer will countdown dependent on total
run hours.
9.1.3 Menu Routine:
Parameters, Values and Options can be adjusted and set using the Menu Routines.
Operational Menu - Access Code “0009”
To access a Menu, first stop the compressor. Press the Up & Down buttons
simultaneously. After several seconds the display will show four “0”
characters; the first character will flash. Press Up or Down to adjust the first
character to match the first character of the required Access code. Press
Enter to increment to the second code character.
When all four access code characters have been set and the last code
character is flashing, press Enter. If the access code is correct for access to
one of the two menus, the first menu item of the appropriate menu will be
displayed. If the access code is incorrect, the display will return to the normal
operational display.
To select a menu item for adjustment, press Up or Down until the menu item
is displayed. To adjust an item setting, press Enter the value of option will
flash. Press Up or Down to adjust as required then press Enter to store in
memory.
To exit a menu and return to the normal operational display at any time, press
Reset. Any adjustment not been entered into Memory will be abandoned and
the previous default setting maintained.
9.1.4 Operational Menu:
Item Description Range Default

1: 1.Sh Service Interval Hours -999 to 9999 hours 2000 Hours
2: 1.Pu Upper Pressure Set Point 1 to 68bar 7.0bar
3: 1.PL Lower Pressure Set Point 0.8 to 67.8bar 6.8bar
4: 1.rt Run-On-Time 0 to 600 seconds 300 seconds (5 minutes)
5: 1.bt Blow-down Time 0 to 120 seconds 30 seconds
6: 1.St Stop Time 0 to 30 seconds 10 seconds
7: 1.P Pressure Display Units bar/psi bar
8: 1.t Temperature Display Units °C / °F °C
9: 1.At Auto Restart Time 0 to 120 seconds 10 seconds
Operational Menu Items:

9.1.5 Pressure Control
The compressor will maintain pressure between the set Pu (Unload Pressure Set Point) and
PL (Load Pressure Set Point).
When pressure reaches the set ‘Pu’ level, the compressor will unload. When pressure falls
to the ‘PL’ level, the compressor will load.
9.1.6 Run-On-Time:
When the compressor unloads, the Run-On-Timer is initiated. If the set run-on-time
expires before the compressor loads again, the main motor will stop and the compressor
will enter a Standby state.
9.1.7 Blowdown Timer:

When the main motor stops, the compressor will allow a period of blowdown (the
Blowdown Time) before a motor start can be re-initiated. A motor restart is inhibited
during this time period. This time is intended to allow internal pressure (or sump pressure)
to be vented before a motor start sequence is permitted. Set to 0 (zero) seconds if not
required.
9.1.8 Stop Time:

When the Stop button is pressed, the compressor will unload and the main motor will
continue to run for the set Stop Time. This time is intended to allow internal pressure (or
sump pressure) to reduce before the compression element is stopped; preventing
potential oil blow-back through the compression element and air filter. The stop time is
initiated from the moment the compressor is unloaded. If the compressor has been
offload for a period of time prior to a stop command, the time is automatically reduced
accordingly. If the compressor is stopped after the compressor has been running offload
for the stop time, or longer, the compressor is stopped immediately; no stop time is
applied. Set to 0 (zero) seconds if not required.
9.1.9 Auto Restart Time:

The controller is equipped with low voltage (<19.8Vac) and power failure detection
(>40ms). If a power disturbance or failure occurs while the controller is in a Started state
(running or in Standby mode), the compressor will automatically restart when power is
restored. The controller will display a Power Failure Detected alarm code to indicate this
event has occurred. To enable this function, select an Auto Restart time greater than 0
(zero) seconds.
When power is restored the controller will wait for the set Auto Restart Time before
initiating a motor start sequence. This time is intended as a warning period and/or a
method of stagger starting a number of compressors on the same power supply
distribution system. To disable (inhibit) the Auto Restart function; set the time to 0 (zero)
seconds.
Fault conditions are separated into two categories:-
A: Alarm (Warning) symbol illuminated on ‘Steady’; the compressor will continue

to operate.
A:2050 C4 (if set for alarm warning function).
A:2060 C5 (if set for alarm warning function).
A:2118 High Pressure: alarm limit exceeded.
A:2128 High Temperature: alarm limit exceeded.
A:2816 Power Failure Detected
A:3123 Limit
(will self-reset when temperature increases above the set temperature limit;
cannot be manually reset).
A:3423 Load Inhibited
Temperature is below set low temperature load inhibit.
A:3423 Limit
(will self-reset when temperature increases above the set temperature limit;
cannot be manually reset).
A:4804 Service Due
Service interval hours counter has reduced to zero.
E: Shutdown (Trip) symbol will flash; the compressor will stop.

E:0010 Process Stop - 24Vac in not being detected on terminal R1C
E:0020 C2 - fault condition detected on digital input C2
E:0050 C5 (if set for shutdown trip function)
E:0060 C6 (if set for shutdown trip function)
E:0115 Pressure Sensor Fault: signal out-of-range (<3.8mA or >20.8mA)
E:0119 Excess Pressure: shutdown limit exceeded
E:0125 Temperature Sensor Fault: signal out-of-range (<-50°C or >250°C)
E:0129 Excess Temperature: shutdown limit exceeded
9.2 ADVANCED CONTROLLER
Keypad
© Escape:- Go back one menu Start:- Enter started
navigation level condition
+Up Arrow:- Scroll up Stop:- Exit start condition.
- Down Arrow:- Scroll down

Reset:- Reset and clear fault
Enter:- Confirm selection conditions.
Start and Stop have one defined function and are not used for any other purpose.
Reset will initiate a display jump to the fault code item if a fault condition remains active or
initiate a display jump to the information item if no active faults exist in normal display mode.
If pressed and held for longer than two seconds in menu mode will exit menu mode to the
normal operational display mode, page 00.
Enter will lock a selected value display preventing return, after a short delay, to the default Td
value display. When locked the ‘key’ symbol will flash. To unlock press Escape.
Escape will initiate a display jump to the information item in normal display mode, page 00.
Plus +, Minus -, These buttons are used to navigate move to the next item or previous item
within the selected menu mode and adjust menu parameters.
Led Indicators
STATUS: Green, adjacent to Start and

Stop buttons
FAULT: Red, adjacent to Stop and

Reset buttons
Indicator States:
ON: Illuminated continuously.

FF: Fast Flash: on/off four times per
second.
SF: Slow Flash: on/off once per
second.
IF: Intermittent Flash: on/off every four
Machine
Machine State Status Fault
State №
1 Shutdown Error OFF FF
2 Start - up Inhibit OFF OFF **
Start Inhibit Check OFF **
3 OFF
Start inhibit condition SF
4 Ready to Start OFF OFF **
5 Blowdown if (load_request) FF else IF OFF **
6 Standby IF OFF **
7 Start Motor in Star/Delta if (load_request) FF else IF OFF **
8 Load Delay if (load_request) FF else IF OFF **
9 Load ON OFF **
10 Reload Delay if (load_request) FF else IF OFF **
11 Standby Run on Time IF OFF **
12 Stop Run on Time SF OFF **
**SF for Alarm condition
The Display is divided into 4 areas.
Top, Left: Display Field:-

4 character numeric display, with unit symbols, used to continuously show delivery
pressure in normal operating mode or menu page number in menu mode
Top, Right: Fault Symbol Field:-
Symbolic displays used to indicate

common general fault conditions.
Middle: Symbolic displays used to
reinforce meaning of selected item,
fault condition.
Symbolic status information in normal
operational mode ‘Information Screen’
item.
Bottom: Item and Value Field:-

Item identification: 2 character alphanumeric, 14 segment
Item Value: 4 character numeric, 7 segment

Item Unit: 3 character alphanumeric, 14 segment
Display Character Examples, Units:
Operational Display Symbols:
Main motor running
Compressor on load
Amount of time, timer
Pressure set point inidcation (upper and lower set point indicators
displayed independently
Condensate drain active (optional function)
Power failure auto-restart enables (optional function)
Remote load or remote pressure regulation active
Remote start/stop
Normal Operational: Selected item locked as temporary default display

Menu Mode: Page item locked (adjustment inhibited)
10 START-UP AND STOPPING
10.1 PREPARATION FOR START UP

Each rotary screw air compressor is operated in the factory and carefully tested before
delivery. The test ensures that the compressor functions correctly, meets its specification
and that all safety features are operable.
It is essential that the compressor is commissioned by a trained competent engineer who

will carry out all the necessary safety checks required to ensure that your compressor will
operate satisfactorily. If this is not done the manufacturer will not be held responsible for the
safety or reliability of the machine.
The commissioning details should be filled out on the commissioning sheet and returned to
the manufacturer. Failure to do this within 14 days will invalidate any warranty.
10.1.1
For AVELAIR compressors 4 - 55 kW it is essential that the correct rotation is observed.
This is done by pressing the Start button and then immediately pressing the Emergency
Stop button.
Running the compressor in reverse for more than 2 seconds will result in air-end
deterioration. The removable panels form part of the protective guarding of the
machine. Whilst the panels are open, no tool or body part may be allowed to enter
the confines of the enclosure.
AVELAIR compressors 55 - 160 kW are fitted with a sense of rotation protection device. If
the electrical phases are wired incorrectly, the compressor will not start.
10.1.2
If the sense of rotation is correct as indicated by the decal on the air-end, close and lock the
door before proceeding to the next step. If the sense of rotation is incorrect, electrically
isolate the machine, and allow a suitably qualified compressor engineer to make the
necessary changes prior to operation 1.
Close and lock the guards and return the keys to a controlled access store. The
machine must always be operated with the guards in place.
10.1.3
Operate the Emergency Stop button and attempt to start the machine; the machine should
not start.
If the machine should start, then a fault has occurred in the stopping circuit. Contact a
qualified compressor engineer to rectify the fault before proceeding further. Release the
Emergency Stop button by turning the E-Stop clockwise.
Failure to correct a fault with the Emergency Stop control will result in that feature
not being available during an emergency.
10.2 START-UP
The machine is now ready for its first run. Release the Emergency Stop button by rotating
the red mushroom headed button. Press Start and follow the HMI screen instructions.
After a short delay, the machine will start compressing air.
10.3 STOPPING
The Stop function should normally be performed by pressing the red soft stop button
displayed on the HMI screen. The Emergency Stop is a button of last resort and should
only be used in case of an emergency or when carrying out periodic checking of its
function. The correct functioning of the Emergency Stop control must be tested at least
once every month.
10.4 RESTART AFTER STOPPING

The internal pressure in the compressor must be allowed to fall below 1 Bar before an
attempt is made to restart the machine. This will take approximately 3 minutes. The internal
electronic functions that feed display information via the HMI panel automatically cover this
function.
10.5 START-UP AFTER EXTENDED SHUTDOWN

A compressor which has been out of service for an extended period of time (3 months or
more) must only be started after the following points have been observed:
• It is the users’ responsibility to ensure that all operators and personnel working on this
unit are fully trained and competent to do so.
• No work should not be carried out unless the compressor is isolated electrically and
pneumatically and locked off. A permit to work procedure should be used to ensure
safe working practices.
• The guards must not be removed unless the compressor has been isolated electrically
and pneumatically.
• Electrical isolation of the compressor should be via the local disconnector switch and
by means of secondary isolation on the supply line using the safe working practice of
double isolation.
10.5.1
Rotate the air-end manually several times in the correct direction of rotation.
10.5.2
Remove the air intake filter and pour a ¼ litre of oil (the same oil as already in the
compressor) into the top of the air-end.
10.5.3
Rotate the air-end again manually in the correct direction of rotation.
10.5.4
Check the oil level in the separator container and top it up if required as described in the
section 'MAINTENANCE'.
10.5.5
Start the compressor, ensuring that the correct direction of rotation is achieved and continue
monitoring it for at least the first 15 minutes.
11. NORMAL OPERATION
CAUTION:
11.1. The compressor is automatically controlled and may start without notice.
11.2. Under all running conditions; all guards must be kept closed as they fulfil
part of the protective guarding and noise reduction requirements.
11.3. The cooler will become hot during use: care must therefore be taken to avoid
bodily contact.
In normal operation, the detected delivery pressure controls regulation of the compressor
once the compressor has been started by pushing the start button, or by a remote start
command if enabled. The controller will perform safety checks and start the compressor if
no inhibiting conditions are detected.
11.4. On line, Off line Control
If a start inhibiting condition exists, the compressor will not enter the started condition and a
‘start inhibit’ message is displayed. If a run inhibiting condition exists, the compressor will
enter the started condition but a main motor start is inhibited. The compressor will remain
in the standby condition and a ‘run inhibit’ message is displayed. If a load request is
present in accordance with internal pressure settings, the main motor is started in one of
the following methods:-
a. Direct On Line The start signal energises the main contactor starting the
motor and the unit goes on load drawing air through the inlet valve.
b. Star Delta Sequence When running in delta configuration, after the star/delta
time (adjustable) has expired, the load delay time (adjustable) prevents
loading for a period to allow motor speed to stabilise. The load delay time can
be set to one second if required. When the load delay time has expired, the
load valve output is energised and the compressor will load.
c. Variable Speed Control Using the ADVANCED compressor controller, the
start signal energises the inverter and ramps up the motor to full speed, the
intake valve is bypassed drawing in a small volume of air to cause internal
operating pressure to be attained allowing the intake valve to open fully and go
on load.
In ON Line / Off Line mode; if the unload pressure setting is reached, the load valve output
is de-energised and the compressor will run offload for the standby run on time (adjustable)
before the main motor stops and the compressor enters Standby mode. The compressor
will load again if pressure falls below the load setting before the standby run on time
expires. If in Standby mode, a motor start sequence followed by the load delay time is
executed before loading.
In Variable Speed; mode the motor will maintain full speed until the discharge pressure
attains the target pressure, at this point, the inverter adjusts the motor speed to the degree
that the target pressure is maintained. If no air is being used the motor will shut down after
300 seconds and the unit will remain in standby mode until the pressure drops and the start
signal is renewed.
In the event of a motor stop initiated by a stop command or when entering standby mode,
a blow down timer (adjustable) is started. If a start request is made during the blow down
time, the compressor will enter standby mode until the blow down time expires. If already
in ‘standby’ mode and a ‘load’ request present, the compressor will remain in standby
mode until the blow down time has expired. For units with internal pressure detection
enabled, a minimum internal re-start pressure can also be set to prevent a motor start
sequence before internal pressure is vented. In the event internal pressure fails to fall
below the set minimum re-start pressure within two minutes after the set blow down time
has expired, a blow down fault is generated and the compressor will shut down. After an
unload event, a re-load timer (adjustable) is initiated that will prevent re-loading; this time
can be adjusted to a minimum of one second if required. Normal automated operations
are ended by pushing the Stop button, a Remote stop command or in the event of a
shutdown fault.
When stopped manually, the load value is de-energised and the main motor allowed to
run-on for the stop run on time (adjustable). This time can be adjusted to a minimum of
one second if required. Safety checks are made continuously, if there is a condition
detected that presents a hazardous or damaging situation an immediate stop is performed
and the reason displayed as a shutdown error message. If a warning condition is detected
an Alarm message is displayed and normal operation continues.
11.5. Normal Operational Mode
At controller initialisation, all display elements are switched on for three seconds, and the
normal operating display is shown. In ‘Normal Operational’ display mode the Display Field
will show the final delivery pressure continuously and the Item and Value Fields will initially
show the Information Item display for 35 seconds before reverting to the default
temperature display item.
All available item and value field option displays (temperatures, pressures, hours counters)
can be selected using the Up or Down buttons at any time. The item display will revert to
the default item after 35 seconds if no further selection is made. Pressing the Enter button
will lock any selected Item display and inhibit return to the default display. When an Item
display is locked the lock key symbol will slow flash. To unlock an item display press Up
or Down to view an alternative Item display or press Reset or Escape. Reset will select
any active fault code display or the Status Information Item display if no faults are active.
Unless a selected Item display is locked, the display will automatically jump to the Status
Information Item display at key status change events.
The timeout period before returning to the default Item display is modified in some
instances to enable the full range of a set countdown timer to be shown. If a fault
condition occurs, the fault code becomes the first list item and the display will automatically
jump to display the fault code. More than one active fault code item can exist at any one
time.
12 DECOMMISIONING
Before attempting to decommission the compressor it is essential that the internal

pressure has fallen to atmospheric and the machine has been electrically and
pneumatically isolated.
Remove the electrical supply wiring from the machine and ensure that the free ends are
insulated or removed back to the wall isolator. Remove the pneumatic connection. Raise
the machine and remove the four anti-vibration feet.
Move the machine to its destination using the safe practices described in section 1.
If the machine is to be stored, then a cover should be placed over the whole machine to
reduce the likelihood of corrosion.
At the end of the machine's lifetime it should be returned to the manufacturer for disposal or
recycling.
13 TECHNICAL DESCRIPTION
CONTENTS
13.1 Pneumatic & oil systems block diagram

13.2 Air/oil circuit diagram
13.3 Electrical circuit
13.4 Air filter
13.5 Oil filter
13.6 Drive train
13.7 Air/Oil Separator system
13.8 Airend
13.9 Thermovalve
13.10 Cooler
13.11 Fan
13.12 Temperature transmitter
13.13 Pressure reading
13.14 Hour counter
13.15 Minimum pressure valve
13.16 Pressure transmitter
13.17 Intake control
13.18 Safety devices
13.19 Enclosure and latch key
13.20 Oil filler cap
13.21 Safety valves
13.22 Thermal overload
13.1 PNEUMATIC AND OIL SYSTEMS
Compressed
6 7 Air Out
Atmospheric 2
Air In 10A
1
4 5
3 8
10
The flow chart above shows the complete Pneumatic and Oil systems. References are:-
1 Intake filter
2 Intake control
3 Control for item 2
4 Airend (Note: The airend and separator vessel are as indicated on the 55 -160kW units
only on the 2.2 - 55 kW the airends are encapsulated).
5 Separator tank
6 Cartridge separator
7 Minimum pressure valve
8 Oil thermo-valve
9 Oil filter
10 Oil cooler
10A Air after-cooler
13.2 AIR / OIL CIRCUIT

Cartridge
Separator
Cooler
MPV
Compressed Air
Separator
Tank Airend
Thermovalve
Oil Filter
The Air-End draws in air through the intake valve which is compressed by the rotary screw
action of the rotors and is mixed with lubricating oil. The mixture of compressed air and oil is
transported into the air end casing (separator tank) where it hits a baffle. The subsequent
decreasing of flow speed and change of direction causes most of the oil to be separated from
the air and it drops to the bottom of the casing. The pressure within the casing causes the oil
to flow around the cooling circuit, first passing through the thermovalve and the either straight
back through the oil filter to the air end if the oil is cool, or if it is hot and has caused the
thermo-valve to open, it is released to the oil cooler before passing through the oil filter and
back to the air-end.
Meanwhile, the compressed air passes out of the air end casing (separator tank) into the
cartridge separator where the remaining oil mist is removed from the air. The clean air is then
passed through the minimum pressure valve and into the air after-cooler before being
discharged to the point of use.
13.3 ELECTRICAL CIRCUIT
The compressor is powered by a three phase 380/415 Volt supply, this voltage is used across
the motor via a star delta or direct on line starter with overload protection, and via three
protective fuses across the electric fan. The control circuit operates at 24/110 Volts, this
voltage being achieved by the use of a step down transformer placed across two of the main
supply phases. The primary and secondary windings of the transformer are all fuse protected;
it is therefore possible to isolate the control circuit by removing the secondary fuses.
The emergency stop switch is normally closed; this is connected in series with the main
start/stop switch. The start and stop switching actions are an integral part of the compressor
controller. All process safety sensors are monitored within the compressor controller. Provided
there are no faults detected the controller will then initiate the start sequence for the direct on
line or star delta process for the starting of the motor.
Over-temperature protection is provided by the temperature sensor, and motor over-current is

provided by an overload. Continuous monitoring of these ensures that in the event of an over
temperature or over current situation the control voltage to the contactors is cut.
When contactor KM3 becomes energised; the controller then allows current to pass to the
solenoid valve on the intake control.
Once the compressor has reached pressure the controller will cut the power to the intake
solenoid closing the intake valve and will initiate a run on timer, this will allow the compressor
to run in an unloaded mode for a pre-set period before cutting the control voltage to the
contactors subsequently stopping the compressor.
The compressor is then in a waiting state, indicated by a green light flashing on the controller;
when there is a demand for air, the controller falls below its minimum setting, energises the
solenoid and allows control voltage to the contactors and the machine back on line and
producing compressed air.
All models are set to a pre-set time which is activated when the stop button is depressed and
allows the compressor to come off load before it is shut down.
An hours’ run meter within the controller logs total hours run by the machine on and off load.
13.4 AIR FILTER ELEMENT
The air intake filter is situated within the housing on top of the airend, directly above the air
intake control unit on all encapsulated air ends and on 55 - 160 kW units the air filter housing
is mounted remotely via a flexible tube, A micro-dry-filter cartridge with a filtration level of 10µ
is used for intake filtering.
The cartridge is replaceable and should be regularly checked in accordance with the
maintenance schedule.
13.5 OIL FILTER CARTRIDGE
The oil filter removes impurities from the compressor oil. The filtration level is 5-10µ.
The oil filter also has a bypass valve which opens if the oil viscosity increases due to its
temperature or if the filter becomes very contaminated. This ensures that if the filter
becomes blocked or severely restricted, the oil will continue to circulate to the airend
protecting it from the possibility of serious damage.
The oil filter is mounted directly on encapsulated air ends and remotely on 55 - 160 kW units.
13.6 DRIVE TRAIN
The drive system used on the compressors are high specification drive belts and once
bedded in and tensioned should not require re-tensioning in the correct environment. On
direct drive units a maintenance free split coupling is used.
13.7 AIR/OIL SEPARATOR SYSTEM
The air/oil separation function is performed in two stages:-
1st Stage: Separator Vessel 55 - 160 kW

The compression process in the airend causes oil to be mixed with the compressed air. The
mixture discharged from the airend is fed to the separator vessel where it changes direction
and velocity causing oil droplets to form and fall into the bottom of the vessel from where
they are piped into the oil cooling circuit.
1st Stage: Encapsulated Airend 2.2 - 55 kW

The encapsulated air end incorporates within the design of the casing mechanical separation
resulting in a suitable reduction in the volume of oil reaching the separator element.
2nd Stage: Separator Cartridge

The second separation stage, which recovers the finely dispersed residual oil is performed
by the separator cartridge. The air discharged from the cartridge contains 4 parts per million
(or less) of oil.
13.8 AIREND
The air-end is a positive displacement rotary screw compressor unit with oil injection.
Two helical rotors, consisting of a male rotor which drives a female rotor are contained
within a housing. Atmospheric air is drawn in through the intake regulator system and fills
the cavity between the two rotors at one end of the helice. The rotary motion closes the
intake aperture and pushes the air along the rotors into the ever diminishing space between
the rotors and the housing. At the far end of the helice the pressurised air is discharged
into the separator system.
Oil is drawn into the rotor system which acts as a lubricant, a coolant and as an air seal
between the rotors and the housing. Rotating the airend in reverse would cause rapid
airend deterioration.
13.9 OIL THERMOVALVE
The thermovalve is a 3 way valve in the oil circuit and can be within the encapsulated air
end casing (2.2 - 37 kW units) or remote to the air end (37 - 90 kW units) this ensures that
the oil temperature remains relatively stable.
The optimum temperature for the oil in the rotary screw air compressor is between 70 and
80°C; below 65°C, condensation may form and above 100°C the airend will overheat.
At start-up, the oil is cool, the thermovalve is closed and oil passes through a cooler bypass
pipe. The compression process generates heat, as the oil heats up the thermovalve begins
to open at 71°C allowing some of the warm oil to pass through the cooler system. At 83°C
the thermovalve is fully open and all oil passes through the cooler. Movement of the piston
within the thermovalve thus regulates the temperature within its optimum band provided the
ambient conditions are suitable.
On the 110 - 160 kW units the oil passes through the cooler continuously and the oil
temperature is monitored and the cooling fan air flow is varied according to oil temperature.
13.10 OIL COOLER / AIR AFTERCOOLER
The combined cooler is connected to the air/oil circuit of the compressor. It is designed to
provide operational reliability at ambient temperatures of up to 40°C subject to sufficient
cooling air being provided. The air after-cooler cools the compressed air to between 10 and
20°C above ambient temperature subject to sufficient cooling air being provided. For the
separation of the resulting condensate, it is recommended that an automatic condensate
drain is installed downstream of the cooler.
Care must be taken to avoid contact with the cooler as it becomes hot in normal use. The
compressor is labelled to indicate the hot surface.
13.11 COOLING FAN
The coolers all have forced ventilation via suitable fans forcing cooling air through the
combined cooler to reduce the oil and air temperatures. The fan/s and guard require
servicing as described in the Maintenance section. The terminal box contains connections
at 380-415 Volts when the power is switched on; the terminal box cover must only be
removed when the supply is isolated. On 110 – 160 kW units dual temperature controlled
variable speed fans are used to maintain consistent optimum oil temperature.
13.12 TEMPERATURE TRANSMITTER
The Temperature Transmitter device is fitted to the control panel and monitors the
temperature of the compressor, shutting the unit down if the maximum operating
temperature of 110°C is exceeded, thereby protecting the air-end from damage.
Restart of the compressor is not enabled until the temperature has fallen below 100°C and
the start button operated.
13.13 PRESSURE READING
The pressure monitored on the Control Panel indicates the final pressure of the compressed
air leaving the compressor. Some models are fitted with an internal pressure gauge which
measures the internal pressure sensing of the compressor, it falls to a low value when the
compressor is off load.
Some models are also fitted with an internal pressure sensor, this can also be monitored via
the controller.
13.14 HOUR COUNTER
The Hour Counter monitored on the control panel records the number of hours run by the
compressor both on and off load. It ceases counting when the compressor is switched off
and when the compressor times out.
13.15 MINIMUM PRESSURE VALVE
The minimum pressure valve is situated at the outlet of the compressor, upstream of the air
after-cooler, on units up to 55 Kw it is part of the encapsulated air end, on larger models it is
mounted remotely after the air end. The functions it performs are:
13.15.1 Pressure maintaining valve.

The MPV prevents a pressure drop below a minimum of 4.5 Bar if there is no
back pressure. This is necessary to safeguard the oil supply of the air-end. It
is also a pre-condition for good air/oil separation.
13.15.2 Check valve

The MPV prevents the back-flow of compressed air from the receiving system
into the air-end. The separator tank can therefore be fully discharged when
the unit is stopped.
13.16 PRESSURE TRANSMITTER
The Pressure Transmitter is located inside the enclosure; it is used to measure pressure the
compressor reaches including the differential pressure. The compressor with compress air
until the highest set pressure is reached whereupon the controller cuts power to the
solenoid to prevent more air being compressed. A demand for air causes the pressure to
fall until a lower pressure is reached which causes the controller to power the solenoid
allowing the unit to make air. The difference between the higher and lower pressure is the
differential pressure.
Adjustment of the pressure setting is forbidden unless prior written consent has been given
by the manufacturer.
13.17 INTAKE CONTROL
The Intake Control is located on the air intake valve. It is solenoid operated by the controller.
When the final pressure is below the lower pressure setting on the controller, the solenoid is
energised allowing air into the air-end. When the higher pressure setting on the controller is
reached, the solenoid is de-energised closing the intake and preventing further air being
compressed.
13.18 SAFETY DEVICES
The following parts have been fitted or modified to ensure safe operation of the compressor.
13.18.1 Electrical Isolation

For units not fitted with integral isolators: It is essential that an isolator is
located adjacent to the compressor at time of installation (by others). It serves
as a supply disconnection device to ensure that the electrical supply is
completely isolated from the machine whilst being worked on. The isolator
should also have the facility to be locked off to facilitate safe working practices.
This also will comply with the requirement within the Machinery Directive.
The electrical cabinet door can only be opened with the key supplied with the
machine.
For units fitted with integral isolators: It is recommended that two point isolation
is readily accessible in all installations for ‘safe working practices’. This also will
comply with the requirement within the Machinery Directive.
13.18.2 Protected Earth Terminal

Located adjacent to the incoming power connection points is a terminal marked
PE. This terminal is where the incoming earth must be connected; it is
electrically linked to the bonded earth circuit of the compressor. There is no
neutral connection to the PE terminal.
13.18.3 Emergency Stop Button

The emergency stop is easily identified by the red mushroom headed switch It
is provided as an additional stop mechanism to halt the mechanical action of the
machine. Some parts of the control circuit inside the electrical cabinet still have
the supply and control voltages present after the emergency stop has been
actuated.
This should only ever be used as a button of last resort in an emergency
situation, if used to stop the unit in normal operation the controlled stop
function is bypassed and the oil will flood the intake filter and spill out
into the compressor enclosure.
13.19 ENCLOSURE AND LATCH KEY
The enclosure forms the guarding of the machine; it is built of sufficiently substantial
material that it will not deflect and create a hazard under normal body contact. The
electrical cabinet door, rear panel and main door are all fitted with latches which cannot be
opened without the provided key. Controlled access to the key is therefore essential.
13.20 FILLER CAP
On the 2.2 - 55 kW units, the oil filler cap is located directly on the encapsulated air ends
and is red in colour. The oil filler cap has a hole and cross drilling which warn of the
presence of pressure in the system. If the cap is undone when the system is pressurised,
an audible hiss of compressed air escaping is heard before the cap becomes sufficiently
unscrewed to constitute a hazard. The oil filler cap is designed to be hand tight only so no
tools should be used. During use the oil filler cap will become hot, it is advisable to allow
the unit to cool down first prior to attempting removal.
On the larger 55 - 160 kW units, the oil filler cap is on the separator vessel. It is
ESSENTIAL that the internal pressure is at zero prior to removal of the oil filler cap,
or injury could occur. The pressure can be relieved by using the pressure relief facility on
the top of the pressure relief valve.
13.21 SAFETY VALVES
The internal safety valve is situated inside the enclosure; on 2.2 - 55 kW units where
encapsulated air ends are used, the valve is located on the top of the air end. On larger 55-
160 kW units, the safety valve is mounted on the separator vessel. It has a set pressure
slightly below the maximum working pressure of the air end. It is capable of releasing a
sufficient volume of compressed air to prevent a dangerous pressure being present in the
air end.
If the unit is supplied with an integral receiver:
The receiver safety valve is chosen to have a release value of approximately 10% above
the nominal operating pressure, or the same valve as the maximum design pressure of the
vessel, whichever is the lesser. It is capable of releasing a sufficient volume of compressed
air to prevent a dangerous pressure being present in the receiver. Under no circumstances
should the safety valve be tampered with or removed. It is the users’ responsibility to
confirm the setting of this safety valve, as it may require changing in order to comply with
national regulations such as a “Written Scheme” for the pressurised system under the
Pressure Systems Safety Regulations 2000 ISO 128.
13.22 THERMAL OVERLOAD

For On Line / Off Line units the thermal overload relay is located beneath the starter assembly
in the electrical cabinet. It protects the electrical circuit and motor against overload, phase
failure, long starting time and prolonged stalling of the motor. The value of the overload is pre-
set during manufacture and should not be adjusted without reference to the manufacturer.
For Variable Speed units the inverter is pre-set at the factory to protect the motor from being
overloaded, this value should not be adjusted without reference to the manufacturer.
14 MAINTENANCE
These are the MINIMUM safety precautions

that must be adhered to when carrying out
any maintenance operation on this unit.
Maintenance and repair work may only be carried out by an Avelair trained competent person
or person under the supervision of the same.
14.1.1 Use only tools designed for maintenance and repair work.
14.1.2 Use only original spare parts.
14.1.3 Carry out repair work only when the compressor is switched off and the mains
isolator locked in the OFF position using safe, isolation procedures and isolated
from the pressurised system. Operation of the machine with the door open must
be avoided as far as possible; no tool or part of the body is allowed to enter the
machine under this condition.
14.1.4 Shut the compressor off from all pressure sources and discharge all pressurised
air before loosening or removing any components.
14.1.5 Do not use flammable solvents, halogenated hydrocarbons or carbon tetrachloride

to clean parts. Take precautions against inhaling toxic vapours from cleaning
solvents.
14.1.6 Ensure that extreme cleanliness is observed during maintenance or repair work.
Cover parts or bare openings with a clean cloth, paper or adhesive tape.
14.1.7 Ensure that no tools, parts or cleaning materials are left in or on the unit.
14.1.8 Before releasing the unit for operation after maintenance or repair, check that the
operating pressures, temperatures and timer settings are correct and that the
control, isolator and stop devices are in working order. In addition, check that an
adequate quantity of the correct grade of oil is present in the machine and that the
sense of rotation is correct.
14.1.9 Protect the motor, air filter, electrical components, control equipment etc., against
moisture.
14.1.10 Do not use corrosive solvents which could affect the materials of the air delivery
main, such as polycarbonate bowls.
14.1.11 Ensure that any lifting gear used is adequate for its purpose and is maintained in a
safe condition.
14.1.12 Never weld or modify in any way a pressure vessel.
TRAINING
The basic service requirements of the Avelair compressor should only be carried out by an
Avelair trained authorised technician. There are maintenance procedures that require
specific training. These procedures become necessary after 200 hours operation of the
compressor. Full training for all aspects of maintenance is available from the manufacturer.
14.2 HEALTH AND SAFETY

The safety requirements outlined in the safety and prevention of accidents section of this
manual must be observed at all times.
14.2.1 It is the users’ responsibility to ensure that all operators and personnel working
on this unit are fully trained and competent to do so.
14.2.2 No work should be carried out unless the compressor is isolated electrically and
pneumatically, and locked off. A permit to work procedure should be used to
ensure safe working practices.
14.2.3 The guards must not be removed unless the compressor has been isolated
electrically and pneumatically.
14.2.4 Electrical isolation of the compressor should be via the external isolation switch
sited adjacent to the compressor or the local compressor isolator using the ‘safe
working practice’.
14.3 AIR RECEIVERS (if applicable)

For receiver mounted units, please refer to the Maintenance and Inspection Instructions,
receiver Certificate of Conformity and Written Scheme to ensure safe use.
NOTE: AFTER EACH MAINTENANCE OPERATION MAKE A NOTE IN THE SERVICE

LOG BOOK AND STICK GENUINE SERVICE STICKER WHERE REQUIRED.
Maintenance Index
14.4 Oil level
14.5 Oil recommendation
14.6 Changing the oil
14.7 Oil filter
14.8 Condensate drain
14.9 Separator cartridge
14.10 Air filter
14.11 Drive belt tension
14.12 Oil cooler/air aftercooler
14.13 Greasing of motor bearings
14.14 Maintenance intervals
Each description of the maintenance items listed above, are symbols depicting the MINIMUM
safety measures required for carrying out the operation described. Please refer to the
beginning of the manual for an explanation of each symbol if required.
14.4 OIL LEVEL Figure A
The oil level in the air end or separator vessel is an important factor Max
for the operational reliability of the system. Some units are fitted with
sight glasses for visual level checking, this should be done when the
units are cold and are not operating. All units are designed so they Min
cannot be over filled and should be filled to the level indicated.
EVO 15 – 37 units only
Please note maximum oil fill level for

these models refer fig B
Checking Intervals:
Before starting the unit Every 100
operating hours
Figure B
Checking Procedure:
14.4.1 Switch off the unit and prevent it from being switched on unintentionally
employing ‘safe working practices’.
14.4.2 Allow at least three (3) minutes after stopping the compressor, release
pressure by unscrewing knurled cap to safety valve until all pressure is released
14.4.3 Unscrew the oil filler plug.
14.4.4 Check the oil as shown in the diagram above. See Figure A or B as applicable.
14.4.5 Top up with oil of the same oil type, up to the maximum level if required.
14.4.6 Replace the oil filler plug and tighten as required, re-tighten knurled cap on the
safety valve.
14.4.7 Switch on the unit.
14.4.8 Check for leaks around the filler plug and replace the O-ring if required.
14.5 OIL RECOMMENDATION
It is essential that only AVELAIR recommended oil is used; other oils may only be used having
gained written approval from the compressor manufacturer. The use of other oils may
invalidate the warranty.
For food grade applications use only ASL FG4000 lubricant.
Under no circumstances should oil types be mixed.
Viscosity:
Viscosity at 40°C/104°F: ca. 42 - 50 mm²/s (cST).

Operating temperature: Viscosity class:
Up to 95°C/203°F ISO VG 68
Up to 100°C/212°F ISO VG 100
Caution:
It is important to observe the oil viscosity, otherwise bearing life will be reduced.
14.6 CHANGING THE OIL
The oil must only be changed when the compressor has been isolated and allowed to bleed
down to atmospheric pressure; this can be done by unscrewing the knurled cap of the
pressure relief valve and waiting until no more air is being released.
14.6.1 Slowly unscrew the oil filler cap
14.6.2 If air is released from the cap the unit has not depressurised.
14.6.3 Drain the oil from the compressor, this can be facilitated with a hose attachment
fitted to the drain connection, close the ball valve on completion of draining.
14.6.4 Refill the air end with oil up to the maximum level via the oil filler pipe. Refit the
oil filler cap.
14.6.5 Re-tighten the knurled cap on the safety valve to ensure that the valve has
returned to its’ seated position.
14.6.6 Switch on compressor and let it run for approximately three minutes. After this,
depressurise the tank and re-check the oil level topping up as necessary.
14.7 OIL FILTER REPLACEMENT
The oil filter is mounted directly on encapsulated air ends and remotely on 55 - 160 kW
units. The oil filter should be changed after 200 hours, then every 2000 operating hours
thereafter. The oil must only be changed when the compressor has been isolated and
allowed to bleed down to atmospheric pressure.
14.7.1 Drain the oil and remove the oil filter with a strap wrench.
14.7.2 Grease the gasket of the new filter.
14.7.3 The new oil filter should be fitted hand-tight.
14.7.4 Re-check the oil filter tightness after the unit has been run up.
14.7.5 Disposal of the used oil filter cartridge must be carried out in
accordance with local environmental regulations.
14.8 CONDENSATE DRAIN
The condensate content in the oil affects operating safety and life of the air-end. Operating
the compressor on a short run and consequently below the thermovalve opening
temperature may allow condensate to accumulate in the oil system.
Possible Effects:
• Insufficient lubrication of the air-end.
• Insufficient air/oil separation and high differential pressure in the separator cartridge.
• Corrosion and rust formation.
Maintenance Procedure:
Drain the condensate regularly when the screw compressor unit is cold, i.e. before start-up.
This applies to the encapsulated air ends and the separator vessel alike.
14.8.1 The condensate must only be drained when the compressor has been isolated
and allowed to bleed down to atmospheric pressure.
14.8.2 Slowly unscrew the oil filler plug.
14.8.3 Place a receptacle under the oil drain.
14.8.4 Slowly open the drain valve and drain the condensate from the air end casing or
the separator vessel as appropriate until the oil starts to come out. Shut the
valve.
14.8.5 Check the oil level in the air end and if necessary top up. Recheck the oil level
after 3 minutes of running.
14.8.6 Dispose of the condensate in accordance with local waste disposal legislation.
14.8.7 If a separate air receiver is part of the system, this should also be regularly
drained via the drain valve.
14.9 SEPARATOR CARTRIDGE
The separator elements are mounted on the encapsulated air end or after the separator
vessel. The cartridge should be replaced every two years, or 4000 hours whichever is
sooner, or as soon as the differential pressure is 1 bar. Contaminated intake air and poor
oil quality will clog the element sooner and will require changing prior to these intervals.
Replacement Procedure:
14.9.1 The separator cartridge must only be changed when the compressor has been
isolated and allowed to bleed down to atmospheric pressure.
14.9.2 Remove the cartridge with a strap wrench.
14.9.3 Grease the gasket of the new cartridge.
14.9.4 Screw the cartridge onto the fitting manually.
14.9.5 Fit a label to the new cartridge indicating the next renewal date.
14.9.6 Run the compressor and check for any oil leak between the cartridge and the
manifold.
14.9.7 Dispose of the cartridge in accordance with local waste disposal legislation.
14.10 AIR FILTER

The air filter element should be replaced every 2000 hours or once a year. If the intake air
is heavily contaminated, the element may need cleaning or replacing sooner.
Maintenance Operations:
14.10.1 The air filter must only be changed when the compressor has been isolated and
14.10.2 Remove the filter element access cover and carefully remove any dust.
14.10.3 Squeeze the dust collection valve (if fitted) to release any retained dust.
14.10.4 Remove air filter element and replace as required.
14.10.5 Refit the filter element access cover.
Care must be exercised to ensure that no dirt or dust particles reach the air-intake of the
airend.
14.11 DRIVE BELT TENSIONING
F =
A = Centre distance, TE = Deflection, F = Force.
=
Each compressor is fitted with a yellow label
denoting the force in lbs and Nm and deflection in te
mm. We have also included a frequency value in

Hz.
It is essential that the drive belts are obtained
from the manufacturer to ensure the correct A
specification is used or drive train problems
could occur if inferior belts are used. It is
essential the correct tension is used or
premature failure will occur.
The compressor is fitted with a motor slide plate the drive belt tension is achieved by
rotating the leadscrew/s on the motor base which moves the motor relative to the air-end. A
clamping screw or lock nut adjacent to the lead screw prevents unintentional movement.
Belt tension should be checked at installation, after 2 hours, 200 hours and thereafter every
1000 hours. While checking belt tension, look for signs of wear or cracking that might
indicate potential failure. If in doubt, replace the belts.
Belt Replacement/Adjustment:
14.11.1. The belts must only be changed or adjusted when the compressor has been
isolated and allowed to bleed down to atmospheric pressure.
14.11.2 Slacken the belt guard cover retaining screws and remove cover.
14.11.3. Loosen the lead-screw clamp.
14.11.4 Rotate the lead-screw enough to enable the belts to be removed, fit identical
replacement belts. Fitting inferior belts will result in premature drive belt failure and
breakdowns.
14.11.5 Rotate the lead-screw until the correct tension is achieved, tighten the clamp.
Refer to belt tensioning label for correct tension. It is important that the correct
tension is maintained or premature drive belt failure will occur. Belts should not be
under tension and “rolled” on as this can cause damage to the belt and
subsequent premature failure.
14.11.6 Refit the belt guard cover, replace door guard.
14.11.7 Note the cover fixing screws are held captive in the hole to ensure that they are
not lost please do not remove the nylock retaining nut.
14.12 OIL COOLER / AIR AFTERCOOLER
Keep the cooling fins of the cooler clean. This is a prerequisite for achieving optimum
cooling power. Adequate cooling allows the oil temperature to be maintained correctly.
We recommend that the fins are cleaned by blowing through with compressed air,
steam jet or cleansing agent.
If this cleaning process does not result in a drop of the operating temperature, clean the
cooler on the oil side with a decarboniser. The cooler will have to be removed for this
operation to be carried out.
Should the intake air (cooling air) be heavily contaminated, clean the cooler at shorter
intervals. An indication that the cooler needs cleaning can be a higher than usual
cooling air discharge temperature.
The fan blades should be brushed to remove contamination.
Maintenance Procedure:
14.12.1 The cooler must only be cleaned when the compressor has been isolated and
14.12.2 Open the main door to expose the fan fitted to the fan plenum. If required
remove the cooler plenum cover or the lid panel as appropriate to gain access
to inside the fan plenum.
14.12.3 Blow through the cooler from both directions with compressed air.
14.12.4 Vacuum out the dust and debris.
14.12.5 Refit the cooler plenum access or the lid panel as required, close and lock the
door.
14.12.6 Carry out a functional test to ensure that the compressor functions correctly.
14.13 Maintenance Periods: Greasing of Motor Bearings.
If grease nipples are fitted: Grease specification:

Different motor manufacturers recommend different Contact Avelair Ltd with
greasing intervals. The quantity and frequency of compressor serial number,
motor greasing is on the motor plate. It is the for supply.
responsibility of the client to ensure motors are
checked and greased on a regular basis as
appropriate / applicable.
15

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Avelair OM Instruction Manual 2020

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ROTARY SCREW AIR COMPRESSOR

For all Compressors from serial no. R4213E

EVO fixed speed compressors

Avelair Ltd Fred Castle Way Rougham Industrial Estate

Tel: 00 44 (0)1359 272828

2. MACHINE DESIGN PARAMETERS

3. SAFETY AND PREVENTION OF ACCIDENTS

4 EXPLANATION OF SAFETY SYMBOLS

5 GENERAL COMPRESSED AIR SAFETY

6. TRANSPORT, HANDLING AND PACKING

10. START-UP AND STOPPING

11. NORMAL OPERATION

13. TECHNICAL DESCRIPTION

15. MAINTENANCE SCHEDULE

2006/42/EC Machinery Directive 2006*

2 MACHINE DESIGN PARAMETERS

3.2 The operator is responsible for the machine to be kept in a safe

3.3 The unit must only be transported, installed, operated, serviced,

Hazard from entrapment, the equipment must be isolated prior to removal

Hazard from inhalation of untreated air from compressor.

Hazard from hot surfaces.

Risk of electric shock, isolate compressor prior to removal of any guards.

Hazard from release of pressurised air.

Risk of electric shock access to 400 volt supply.

The equipment must be isolated by safe isolation methods prior to removal

Ear defenders should be worn when appropriate during maintenance and

Safety goggles should be worn during maintenance and repair.

Suitable hand protection should be worn during maintenance and repair.

A suitably sized disconnector and breaker should be fitted adjacent to the

Waste oil, condensate and oil contaminated products must be disposed of

An Avelair trained engineer is required for this operation.

5.6 Never repair pressure lines or pressure vessel by soldering or welding.

5.9 Use eye protection when operating or servicing pneumatic equipment.

Where: Q : heat volume to be carried off (kJ s kW ), -1 -1

dt : Temperature rise (K),

WARNING: THIS UNIT IS OPERATED BY REMOTE CONTROL

As an additional protective measure, persons who start a compressor by remote

Default User Menu Item; Temperature (°C/°F menu selectable)

To view alternative User Menu Items, press Up or Down

Total Hours Run

RS485 Communication Network Address

Pressure Switch Mode

9.1.1 Status Display:

Loaded:- The compressor is running on Load.

9.1.2 Fault Codes:

Positive Displacement Air Compressor Application (E03 onwards):

9.1.4 Operational Menu:

Item Description Range Default

Operational Menu Items:

9.1.7 Blowdown Timer:

9.1.8 Stop Time:

9.1.9 Auto Restart Time:

A: Alarm (Warning) symbol illuminated on ‘Steady’; the compressor will continue

E: Shutdown (Trip) symbol will flash; the compressor will stop.

+Up Arrow:- Scroll up Stop:- Exit start condition.

- Down Arrow:- Scroll down

STATUS: Green, adjacent to Start and

FAULT: Red, adjacent to Stop and

ON: Illuminated continuously.

**SF for Alarm condition

The Display is divided into 4 areas.

Top, Left: Display Field:-

Symbolic displays used to indicate

Bottom: Item and Value Field:-