A30 A40

OPERATION AND MAINTENANCE MANUAL

A30 SERIAL No : 2221800 –>

This manual contains
important safety information A40 SERIAL No : 2241650 –>
and must be made available to
personnel who operate and
maintain this machine.

C.C.N. : 89271241 GB
DATE : MARCH 2002
 Machine models represented in this manual may be used in various locations world–wide. Machines sold and
shipped into European Union Territories require 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)

A30 A40
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 01/01/2002 BY G BAUER, GENERAL MANAGER

GEORG BAUER

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive
(97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope
of this Directive.
It may carry ”CE” marking in compliance with other applicable EC Directives.
04/02
 CONTENTS & ABBREVIATIONS 1
ABBREVIATIONS & SYMBOLS
CONTENTS
#### Contact ECOAIR for serial number
1 CONTENTS
–>#### Up to Serial No.
####–> From Serial No.
2 FOREWORD
* Not illustrated
3 GRAPHIC SYMBOLS † Option
NR Not required
8 SAFETY
AR As required
10 GENERAL INFORMATION SM Sitemaster/Sitepack
HA High ambient machine
14 INSTALLATION / HANDLING
WC Watercooled machine

16 OPERATING INSTRUCTIONS AC Aircooled machine

ERS Energy recovery system
18 MAINTENANCE T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
22 FAULT FINDING
BR Brazil
CN China
DE Germany
DK Denmark
ES Spain
FI Finland
FR France
GB Great Britain (English)
IT Italy
NL Holland
NO Norway
PT Portugal
SE Sweden
US United States

A30 A40
2 FOREWORD
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.
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.

This manual contains instructions and technical data to cover all Use of the machine fitted with non ECOAIR approved components.
routine operation and scheduled maintenance tasks by operation and
Use of the machine with safety or control components missing or
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised ECOAIR service disabled.
department.

The company accepts no responsibility for errors in translation of

The design specification of this machine has been certified as this manual from the original English version.
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.  COPYRIGHT 2002
INGERSOLL–RAND COMPANY

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 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.

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.

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.

No portable communication devices emitting more than 7,5 volts

per metre in the frequency range from 250 MHz to 280 MHz should be
operated within 5 metres of the unit.

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.

A30 A40
 ISO SYMBOLS 3
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.

A30 A40
4 ISO SYMBOLS

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

A30 A40
 ISO SYMBOLS 5

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

A30 A40
6 ISO SYMBOLS

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

A30 A40
 ISO SYMBOLS 7

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

A30 A40
8 SAFETY
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.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
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 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.
Compressed air
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 check valves and 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.
A30 A40
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.
The safety valve 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 ECOP006/95.
Should compressor lubricant come into contact with the eyes, then
irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the skin, then
wash off immediately.
Consult a physician if large amounts of compressor lubricant are
ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious or
having convulsions.
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.
 SAFETY 9
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.

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.

Coolant disposal
Steps to be taken in the case of spillage: Soak up with a suitable
absorbent material, then sweep into a plastic bag for disposal.

Method of disposal
Burn in an approved incinerator, or according to local area or
country regulations.

For further information, consult Material Data Sheets ECOP006/95.

When refitting any enclosure panels or doors, it is essential to

ensure that no persons or equipment remain inside the compressor.

The above information contains data supplied in support of United

Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)
regulations.

A30 A40
10 GENERAL INFORMATION

89211593
Revision A
12/97

KEY GENERAL OPERATION

The compressor is an electric motor driven, single stage screw
compressor, complete with accessories piped, wired and baseplate
mounted. It is a totally self contained air compressor package.
1. AIR FILTER
2. INLET VALVE The standard compressor is designed to operate in an ambient
3. SOLENOID VALVE range of 1,7_C to 46_C. The standard maximum temperature of 46_C
is applicable up to an elevation of 1000m (3280ft) above sea level.
4. COMPRESSOR Above this altitude significant reductions in ambient temperature are
required if a standard motor is to be used.
5. –
6. MOTOR Compression in the screw type air compressor is created by the
7. FAN meshing of two (male & female) helical rotors.

8. SEPARATOR TANK
9. COOLANT SEPARATOR ELEMENT
10.MINIMUM PRESSURE VALVE
11.AIR COOLER (COMBINED WITH COOLANT COOLER)
12.PRESSURE GAUGE
Air is pulled into the machine by the cooling fan and is pushed
through the combined cooler / aftercooler.
The coolant system consists of a sump, cooler, thermostatic valve
and a filter. When the unit is operating, the coolant is pressurised and
forced to the compressor bearings.

13.PRESSURE SWITCH
The compressor load control system is automatic ’On–Off line’. The
14.TEMPERATURE GAUGE compressor will operate to maintain a set discharge line pressure and
is provided with an auto restart system for use in plants where the air
15.COOLANT FILTER
demand varies widely.
16.THERMOSTATIC VALVE
17.COOLANT COOLER Panel instrumentation is provided to indicate the compressor
operating conditions and general status.
18.SAFETY VALVE
19.COOLANT DRAIN VALVE The electrical components are housed in a readily accessible sheet
metal cabinet.
20.COOLANT FILLER NECK
21.–
Safety of operation is provided for as the compressor will shut down
22.– if excessive temperatures, electrical overload conditions, or system
over pressure should occur.
23.PRESSURE GAUGE
A30 A40
 GENERAL INFORMATION 11

89209902
Revision A
12/97

KEY

CABLE
BLACK Mains 220–460Vac
RED Control 18Vac
BLUE Control 24Vdc
KM1 Main contactor
KM2 Delta contactor
KM3 Star contactor
L1 – L3 Mains terminals
F20 Motor overload
CB1–2 Control circuit breaker 400V
CB3 Control circuit breaker 230V
M Motor
S10 Emergency stop
T1 Transformer, Control 400/230Vac
T2 Transformer, Control 230/18Vac
U1 Motor lead
U2 Motor lead
V1 Motor lead
V2 Motor lead
W1 Motor lead
W2 Motor lead

A30 A40
12 GENERAL INFORMATION

89209902
Revision A
12/97

KEY

CABLE
A10 Control board PCB
S1 Off/Auto/Continuous Selector switch
S17 Discharge pressure switch
F20 Motor overload
S14 Temperature Switch
KM1 Main contactor
KM2 Delta contactor
KM3 Star contactor
Y1 Load valve solenoid
h Hours run meter
A11 Indicator board

A30 A40
 GENERAL INFORMATION 13
A30 A40
COMPRESSOR
Maximum operating 7,0 bar 8,0 bar 10,0 bar 13,0 bar 7,0 bar 8,0 bar 10,0 bar 13,0 bar
pressure
Normal operating 6,8 bar 7,8 bar 9,8 bar 12,8 bar 6,8 bar 7,8 bar 9,8 bar 12,8 bar
pressure
Maximum Pressure ratio 8:1 9:1 11:1 14:1 8:1 9:1 11:1 14:1
Maximum airend 109_C 109_C
discharge temperature
Ambient operating +2_C → +46_C +2_C → +46_C
temperature
MOTOR
Nominal power 22kW (30hp) 30kW (40hp)
Maximum power (Class 24,2kW (33hp) 33kW (44hp)
‘F’ insulation)
Speed 2920 RPM 2920 RPM
IP rating 55 55
Frame 160 160
Insulation class F F
COOLING SYSTEM
Air cooled
Cooling air flow 3,34 m3/min 3,05 m3/min 2,90 m3/min 2,24 m3/min 4,46 m3/min 4,15 m3/min 3,91 m3/min 3,18 m3/min
Compressed air outlet ∆T 8_C 8_C
GENERAL DATA
Residual coolant content 3ppm 3ppm
Separator vessel 19 l 19 l
capacity
Coolant capacity 9l 9l
Sound pressure level to 72 dB(A) 72 dB(A)
CAGI–PNEUPROP
Weight 508 kg 610 kg
Discharge connection G1 G1
Dimensions (L x W x H) 1460mm x 700mm x 1100mm 1460mm x 700mm x 1100mm
ELECTRICAL DATA
Standard voltage 3 ~ 400V 3 ~ 400V
Drive motor
Power 22kW (30kW) 30kW (40kW)
Full load current 37,32A 59,10A
(nominal)
Starting current (approx.) 95A 120A
Starting time 5S 5S
Starts per hour 10 10
Control voltage
Star/delta combination 230 VAC 230 VAC
Control 24 VDC 24 VDC
(ECOCONTROL)

A30 A40
14 INSTALLATION / HANDLING

KEY UNPACKING
The compressor will normally be delivered in a card and plastic
1 ”
container. Avoid the use of knives. The machine is suitable for handling
A /2 Coolant drain with fork lift trucks. In addition, some machines may be fitted with single
B 1”BSPP Air discharge point lifting bails.

C Power inlet
Ensure that all transport and packing materials are discarded.
D Air intake (46_C max.)
E Exhaust (80_C max.)
F Latches
G Fork lift truck channels

NOTE
All dimensions are in millimetres unless otherwise stated.

A30 A40
 INSTALLATION / HANDLING 15
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. The rear of the compressor may
be positioned against a wall although a minimum of 1,0m should be left
at the front and the sides of the unit to allow easy maintenance and
guarantee efficient cooling.

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.

NOTE
Items [2] to [5] are optional or may be existing items of plant. Refer
to your ECOAIR distributor / representative for specific
recommendations.

DISCHARGE PIPING
Discharge piping should be at least as large as the discharge
connection of the compressor. All piping and fittings should be suitably
rated for the discharge pressure.

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

total air system. This is to ensure a safe and effective total system. One
item which should be considered is liquid carryover. Installation of air
dryers [3] is always good practice since properly selected and installed
they can reduce any liquid carryover to zero.

It is good practice to locate an isolation valve close to the

compressor and to install line filters [4].

SHIPPING CLAMPS
Before operating the compressor, remove the two clamping screw
assemblies (located on the motor support) and discard. Both clamping
screws are fitted with a red identification tag.

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.

The applied voltage must be compatible with the motor and

compressor data plate ratings.

The control circuit transformer has different voltage tappings.

Ensure that these are set for the specific applied voltage prior to
starting.

CAUTION
Never test the insulation resistance of any part of the machines
electrical circuits, including the motor without completely disconnecting
the Ecocontrol controller.

A30 A40
16 OPERATING INSTRUCTIONS

OPERATING AND CONTROL INSTRUMENTS – ECOCONTROL 3 Shutdown of compressor

1 Operating lamp – Allow compressor system pressure to drop.
2 Centralized fault lamp
– Set control switch to ”0” position.
3 Discharge pressure gauge
4 Compression discharge temperature (thermometer)
– Switch off the circuit breaker, lock where applicable.
5 Total service hour meter
6 Sump pressure gauge 4 Emergency stop
7 Control switch with 3 switching positions:
– compressor OFF
– automatic operation WARNING
– continuous operation If there is a danger situation, the compressor can be stopped
from any operating condition by pressing the emergency–stop
8 EMERGENCY–STOP button
button.
9 Loaded hour meter
SUMMARY INSTRUCTIONS
EXPLANATION OF SIGNS
1 Before starting – ECOCONTROL

– Check set–up and connections.

– Close safety valve.

Compressor ON
Automatic operation
– Check coolant level

– Check direction of rotation.

Compressor ON
Continuous operation
– Close the enclosure.

2 Starting the compressor

Compressor not to be operated unless enclosure is closed. Compressor OFF

– Switch on the circuit breaker.

– Set control switch to automatic or continuous operation. Operating lamp

– Operating lamp lights up – package is ready for operation.

Centralized fault alarm lamp

A30 A40
 OPERATING INSTRUCTIONS 17

Total service hours

On–load hours

Compression discharge temperature

Process pressure

Compressor system pressure

A30 A40
18 MAINTENANCE

PERIOD MAINTENANCE ROUTINE MAINTENANCE

Daily Check the coolant level [1] This section refers to the various components which require
and replenish if necessary [2] periodic maintenance and replacement.

First 250 hours Change the coolant filter [3]

Each week Check that the safety valve easing gear
moves freely.
Each 3 months Check all hoses for signs of deterioration,
cracks, hardening etc.
Each 2000 hours Change the coolant filter [3]
Check the pressure differential [6] +[7] .
Change the separator element if the
pressure drop is zero or exceeds 1 bar (14
p.s.i.g.) [5]
Remove screened adaptor (situated at tank
lid [5]) Inspect and clear if necessary.
2000 hours / 6 Check the operation of the high temperature
months protection device(s) (109_C)
1 year Remove the safety valve from the
compressor, inspect and re–calibrate.
The SERVICE/MAINTENANCE CHART indicates the various
components’ descriptions and the intervals when maintenance has to
take place. Oil capacities, etc., can be found in the GENERAL
INFORMATION section of this manual.
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.
CAUTION: Before beginning any work on the compressor, open,
lock and tag the main electrical disconnect and close the isolation
valve on the compressor discharge. Vent pressure from the unit
by slowly unscrewing the coolant fill cap one turn. Unscrewing
the fill cap opens a vent hole, drilled in the cap, allowing pressure
to release to atmosphere. Do not remove the fill cap until all
pressure has vented from the unit. Also vent piping by slightly
opening the drain valve. When opening the drain valve or the
coolant fill cap, stand clear of the valve discharge and wear
appropriate eye protection.

Change the air filter element [4]. Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
8000 hours / 2 years Replace the ECOOL at whichever interval
system and that the machine cannot be started accidentally.
occurs first [8]
Also replace the separator element [5] and Ensure that maintenance personnel are adequately trained,
coolant filter [3]. competent and have read the Maintenance Manuals.
Change drive belt and gas spring.
Prior to attempting any maintenance work, ensure that:–
4 years Replace all hoses.
. all air pressure is fully discharged and isolated from the system. If
the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.

A30 A40
 MAINTENANCE 19
. the machine cannot be started accidently or otherwise, by posting . Remove the element from the housing.
warning signs and/or fitting appropriate anti–start devices.
. Place the old element in a sealed bag and dispose of in a safe way.
. all residual electrical power sources (mains and battery) are
isolated.
. Clean the mating face of the housing.

Prior to opening or removing panels or covers to work inside

a machine, ensure that:– . Remove the new ECOAIR replacement element from its protective
package.

. anyone entering the machine is aware of the reduced level of

protection and the additional hazards, including hot surfaces and . Apply a small amount of lubricant to the element seal.
intermittently moving parts.
. Screw the new element down until the seal makes contact with the
. the machine cannot be started accidently or otherwise, by posting housing, then hand tighten a further half turn.
warning signs and/or fitting appropriate anti–start devices.
. Start the compressor and check for leaks.
Prior to attempting any maintenance work on a running
machine, ensure that:–
ECOOL – CHANGE PROCEDURE (Capacity 11 litres)

. the work carried out is limited to only those tasks which require the It is better to drain the coolant immediately after the compressor has
machine to run. been operating as the liquid will drain more easily and any contaminant
will still be in suspension.

. the work carried out with safety protection devices disabled or

1. Attach a 1/2” tube to the barbed fitting.
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
2. Open the valve and completely drain the coolant into a suitable
. all hazards present are known (e.g. pressurised components, container.
electrically live components, removed panels, covers and guards,
extreme temperatures, inflow and outflow of air, intermittently moving 3. Replace the coolant filter.
parts, safety valve discharge etc.).

4. Replace the separator element.

. appropriate personal protective equipment is worn.

. loose clothing, jewellery, long hair etc. is made safe. CAUTION – DO NOT MIX OILS WITH ECOOL.

. warning signs indicating that Maintenance Work is in Progress are

posted in a position that can be clearly seen. 5. Close the valve and refill the compressor.

Upon completion of maintenance tasks and prior to returning 6. Start the compressor and check for leaks.
the machine into service, ensure that:–
. the machine is suitably tested. 7. Check the coolant level, refilling if necessary.

. all guards and safety protection devices are refitted.

8. Dispose of waste coolant in accordance with local and
. all panels are replaced, canopy and doors closed. governmental regulations.
. hazardous materials are effectively contained and disposed of.
NOTE
WARNING
Shorter coolant drain intervals may be necessary if the compressor
Do not under any circumstances open any drain valve or remove
is operated in adverse conditions.
components from the compressor without first ensuring that the
compressor is FULLY SHUT– DOWN, power isolated and all air
pressure relieved from the system. AIR FILTER CHANGE PROCEDURE
1. Loosen the band clamp and withdraw the old element.
COOLANT LEVEL CHECKING PROCEDURE
A coolant level tube is located on the side of the separator tank. The 2. Fit the new element ensuring that the retaining nut is secured.
coolant level should be checked daily. The level should be checked
during operation at full–load condition, showing coolant within the
green band of the sight tube level indicator decal. If there is no coolant SEPARATOR ELEMENT CHANGE PROCEDURE
visible OVERHEATING of the machine will occur.
1. Disconnect the hose at the top of the separator tank.

ADDING COOLANT
2. Loosen the discharge tube from the minimum pressure valve.
Run the compressor for a minimum of 40 seconds in the UNLOAD
condition before stopping. Fill until the coolant is level with the top of the
green area of the coolant level decal. Run the machine and refer to the 3. Disconnect the blow–down valve.
Coolant Level Checking Procedure.
4. Remove the setscrews securing the cover to the tank and remove
COOLANT FILTER CHANGE PROCEDURE the complete cover assembly.

. Loosen filter element with the correct tool.

5. Withdraw the used element, place it in a sealed bag and dispose of
it safely.

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20 MAINTENANCE
6. Clean the gasket surface on both the tank and the cover. 8. Re–assemble the components in reverse order.

7. Install the replacement element. 9. Start the compressor and check for leaks.

WARNING
CAUTION Do not remove the staple from the anti–static gasket on the
Do not use any form of sealant on either the separator tank or the separator element since it serves to ground any possible static
separator tank cover faces. build–up.

SETTING THE PRESSURE SWITCH (1PS) The lower set point is factory set 0,7 bar (10psig) below the upper
set point to suit the average application.
TO CHECK THE MAXIMUM DISCHARGE PRESSURE
(Pressure switch upper trip point)
6,3 bar (92 psig)
Slowly close the isolation valve located adjacent to the compressor. 7,3 bar (106 psig)
Observe the rise in pressure and ensure that the pressure switch 9,3 bar (135 psig)
opens (and unloads the compressor) at the correct Maximum 12,3 bar (179 psig)
discharge pressure.
TO ADJUST THE UPPER SET POINT
The maximum discharge pressure settings are as follows: Remove the transparent cover and turn the adjuster [1]. The red
pointer will move. Turn the adjuster anti–clockwise to increase the set
point or clockwise to decrease it.
7,0 bar (102 psig)
8,0 bar (116 psig)
10,0 bar (145 psig) TO ADJUST THE LOWER SET POINT
13,0 bar (189 psig)
Remove the transparent cover and turn the adjuster [2]. The green
DO NOT exceed these figures. pointer will move. Turn the adjuster anti–clockwise to increase the set
point or clockwise to decrease it.

TO CHECK THE LOWER SET POINT

NOTE
Observe the line pressure fall and note the point at which the The pressure switch scale is a guide only. Use the machine
pressure switch closes (and loads the compressor). pressure gauge to verify the upper and lower set points.

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 MAINTENANCE 21

CAUTION AIREND BEARINGS

Before working on the power band drive system, ensure that the
machine has been stopped and the electrical power supply isolated, as Airend bearings are lubricated by the compressor coolant and
rotating equipment can be dangerous. Replace all guards before require no maintenance.
restarting the compressor. (Do not allow the power band to become
contaminated with coolant or debris). MOTOR BEARINGS
Motor bearings are sealed for life and require no maintenance.
AUTOMATIC POWER BAND TENSIONING
These units are fitted with an automatic power band tensioning
device which ensures correct power band tension in all operating
conditions and compensates for any variation in power band length and
wear. It is carefully designed to avoid bounce during starting and needs
no maintenance during the life of the power band. This relieves the
operator of any concern over premature bearing failures due to over
tightening the power band.

REPLACING THE POWER BAND AND GAS SPRING

It is recommended to replace the drive belt and gas spring every
8000 to 10000 hours or two years, whichever period occurs first.

Refer to the illustration (T5375) when carrying out the following

procedures;
Remove the guard, access plate and nylon tube/elbow from the
unloader end cap. Lower the airend by inserting a 1/2” square socket
drive in pivot plate “A” and turning in direction “1” (A tube or suitable
extension may be required with the socket drive). Remove the gas
spring by taking off the locknuts and washers from the studs at each
end. Then, using a thin spanner, unscrew the studs from the tapped
holes. Using the same hole as before in link plate “A”, fit the new gas
spring Remove and replace the belt, taking care not to damage the new
belt. The airend is raised and the belt tensioned using 1/2” square
socket drive to turn link plate “A” in direction “2” until it hits stop “B”.
Replace the guard and access plate, then run for 5 minutes whilst
checking for correct operation.

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22 FAULT FINDING

FAULT CAUSE
Compressor trips INSUFFICIENT COOLANT CIRCULATION Check the coolant level.
indicating a high
compressor Check the coolant system for blockages.
temperature. Check the operation of thermostatic valve.
INSUFFICIENT COOLING TAKING PLACE Check that the cooling air flow Is not obstructed at:
. The inlet valve
. The cooler matrix
. The exhaust vents
EXCESSIVELY HIGH AMBIENT Improve the ventilation to the compressor room.
TEMPERATURE
(i.e. greater than 46oC (115oF).
Controller indicates trip CONTROL CIRCUIT INTERRUPTED BY A Check machine for indicated fault. Attempt to ’reset’ the controller. If
condition. SAFETY DEVICE the fault persists investigate further.
Compressor trips and EXCESSIVE CURRENT HAS CAUSED THE Check the actual operating pressure and lower the switch setting if it
indicates THERMAL OVERLOAD (1MO) TO TRIP is too high. Isolate the electrical supply and check that the airend
motor overload. and motor rotate freely. Check the separator element for excessive
pressure drop.
Compressor will not DEMAND TOO HIGH Check for leaks, open service valves or exceptionally high demand.
build up rated pressure.
OFFLINE PRESSURE SET TOO LOW Check the offline pressure setting.
Compressor will not INLET VALVE NOT OPENING Check that the valve is free to open.
load.
Check the operation of the load solenoid valve 1SV.
Compressor fails to – Check the operation of the inlet valve.
deliver rated
capacity. Check the operation of the load solenoid valve 1SV.
Check the offline/online pressure setting.
Check the inlet filter for contamination. The L.E.D. should indicate if
it is blocked.
Excessive coolant BLOCKED SCAVENGE LINE Clear the blockage.
consumption.
RUPTURED OR FOULED SEPARATOR Change the element.
ELEMENT
Rapid cycling or RAPID LOAD/UNLOAD CYCLING Duty cycle too rapid – Increase system capacity.
receiver will not
blow–down to unloaded MINIMUM PRESSURE VALVE (MPV) Strip the MPV, examine and repair if necessary.
running pressure. STUCK OPEN

Safety valve blows MPV STUCK CLOSED Strip MPV, examine and repair if necessary.
when compressor goes
on load. SAFETY VALVE FAULTY Check the setting of the safety valve and the rated pressure.

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Printed in the United Kingdom