P3 Electronic Air Plant RS Rennerlogic Compressors O&M Rev 3

Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
MEDICAL AIR PLANT
INSTALLATION OPERATION
&
MAINTENANCE MANUAL
HTM 02-
02-01 & HTM 2022 as Applicable
To be read in conjunction with

P3 Plant T
Test Certificate,,
est Certificate
Renner Compressor Instructions

&
Rennerlogic Compressor Instructions

Unit 9 Tel No.: +44 (0) 161 428 7200
McKenzie Industrial Park Fax No.: +44 (0) 161 428 7010
Bird Hall Lane www.p3-phoenix.com
Stockport Email: sales@p3-phoenix.com
SK3 0SB FM 669038 MD 669035
U.K. FM 669038
MD 669035
Contents
Contents Page
Section Page
SECTION 1
Safety .................................................................................................................................................. 3
SECTION 2
Installation Requirements ................................................................................................................. 4
SECTION 3
Product Description ............................................................................................................................ 5
SECTION 4
Control Panel Fascias ......................................................................................................................... 7
SECTION 5
DIP Switch Locations .......................................................................................................................... 9
SECTION 6
Configuration .................................................................................................................................... 12
SECTION 7
Initial Start Up And Commissioning ............................................................................................... 16
SECTION 8
Normal Running Configuration ...................................................................................................... 20
SECTION 9
Software Settings Including User Selectable Items ...................................................................... 21
SECTION 10
Pump Indications .............................................................................................................................. 22
SECTION 11
Fuse Ratings ...................................................................................................................................... 24
SECTION 12
Drawings ............................................................................................................................................ 25
SECTION 13
Maintenance ...................................................................................................................................... 37
SECTION 14
Spare Parts ......................................................................................................................................... 39
-2- Air Plant RS Rennerlogic O&M Manual Rev 3

1. SAFETY
Please ensure that this installation, operation and maintenance manual is read
thoroughly by all parties concerned, and that all of its contents are understood, prior to
commencement of work.
PLEASE NOTE:
This plant includes electrical circuits which operate at potentially lethal voltages.
This plant includes pneumatic circuits which operate at potentially lethal pressures.
1.1.
1.1. QUALIFIED PERSONNEL
Qualified personnel are persons who, due to their training, experience, instruction, and
their knowledge of the relevant standards, can competently undertake the work
required for the installation, operation and maintenance of this product.
1.2.
1.2. GENERAL
This equipment should be installed, operated and maintained by personnel who are
suitably trained, are fully conversant with HTM 02-01, HTM 2022 and C11, and are
familiar with this product.
1.3.
1.3. MEDICAL GASES
This equipment should be kept clean and be free from oil and grease at
all times. Oil and grease may ignite spontaneously in the presence of
medical gases. If you suspect that any equipment is contaminated, do
not use it.
No attempt should be made to use or modify this equipment for use with a gas other
than as identified.
This equipment should not be operated at pressures exceeding those stated in
HTM 02-01, HTM 2022, C11, and this manual.
1.4.
1.4. ELECTRICAL
All electrical work must be carried out by a qualified electrician.

Connection cables must be selected according to the type of use and to
the relevant voltage and current levels associated with the plant.
Connect the plant in accordance with the circuit diagrams and any local
wiring regulations. If you have any reservations about works to be
carried out contact the manufacturer.
1.5. CONFORMITY
Plants conform to HTM 02-01, HTM 2022 or C11. No attempt should be made to modify
this plant to operate under any other standard than the ones specified above.

2.0 INSTALLATION REQUIREMENTS
NOTE:
1. NO ELECTRICAL CONNECTIONS SHOULD BE MADE TO ANY TERMINAL BLOCKS

THAT HAVE RED CLIPS OR ORANGE BLOCKS INSERTED, THESE ARE INTENDED FOR
USE WITH OTHER MODELS.
2.1. SITING
Plant room ambient temperature should be between 10ºc and 35ºc.
2.2. MECHANICAL
The Plant is designed to be floor mounted. Each Compressor Unit should be mounted as
directed by the manufacturer, the receiver and the Dryer Frame should be fastened direct to
the floor using the mounting holes located at the feet of the receiver and the base of the
frame respectively, using suitable fixings.
2.3. PIPEWORK CONNECTIONS
Once sited connect the flexible pipe from the Compressors to the Vessel Pipe work and
connect this to the vessel at the lower Inlet Port.
Connect the dryer to the higher port in the receiver.
The pipeline connection to the Plant is provided by a Union Stub located downstream of
pressure reducing set.
2.4. ELECTRICAL CONNECTIONS
Electrical power supply should be provided via a fused three phase + neutral + earth supply
to each compressor pump starter panel.
Connections should be made as shown on the simplified wiring diagram located inside the
control panel, and included in the drawing section of this manual.
2.5. ALARM
ALARM CONNECTIONS
Connections should be made as shown on the simplified wiring diagram located inside the
main control panel, and included in the drawings section of this manual.

3. PRODUCT DESCRIPTION
3.1. GENERAL
The plant consists of the following major components:-
3.2. AIR RECIEVER
The plant includes one or more air receivers. Each receiver incorporates an
Automatic/Manual drain valve, to allow drainage of condensate, a pressure gauge to
indicate the operating pressure (BarG), and a pressure relief valve.
3.3 COMPRESSORS
The plant includes two or more compressors each fitted with an unloader, after cooler, and a
flexible hose.
3.4 DUPLEX OIL/WATER SEPARATION FILTERS
The filters located on the inlet side of the dryers remove moisture and oil from the air, before
it enters the dryers. Each filter is fitted with a Differential pressure gauge and an automatic
drain valve.
3.5 DUPLEX DESICCANT REGENERATING DRYERS
The Dryer assembly includes Duplex Desiccant Regenerating Dryers, to achieve the working
dewpoint. Pressure Gauges are fitted to each column to indicate the operating pressure
(BarG).
3.6 DUPLEX ACTIVATED CARBON AND DUST FILTERS
These filters are located downstream of the dryers, to remove odour and dust. Each filter is
fitted with a manual drain valve.
3.7 STERILE FILTERS
These filters are located downstream of the activated carbon filters. Each filter is fitted with
a Differential pressure gauge and a manual drain valve.
3.8 DUPLEX PRESSURE REDUCING SET
A Duplex pressure reducing set is incorporated to regulate the line pressure. One regulator
should be selected as duty while the second regulator is used as standby, allowing
maintenance to be undertaken without compromising the normal operation of the plant.
Combined air plants providing both medical and surgical air include a second duplex
pressure reducing set.

3.9 ELECTRICAL CONTROL PANELS

The plant is controlled by one plant control unit (PCU), one dryer control unit (DCU), and one
pump starter unit (PSU) for each pump.
PLANT CONTROL UNIT (PCU)
The plant control unit includes a digital pressure gauge which displays the receiver pressure.
The control unit includes three pressure transducers, one to control the primary circuit, one
to control the emergency circuit, and one to monitor the line pressure, in the event that the
primary circuit fails the emergency circuit will be activated.
The front of the panel includes two pushbutton functions, one to allow the user to select the
duty pump and thereafter auto or manual duty sequencing of the pumps as shown below.
The second pushbutton allows the user to momentarily display the line pressure.
• “Duty Auto Select” (Steady LED) This setting selects the Duty pumps automatically.
• “Duty Locked” (Flashing LED) This setting locks the Duty pumps, and prevents automatic
sequencing.
The “Plant Status” is indicated on the “Plant Control Unit”, which gives an indication of the
signals transmitted to the central alarm system. This indication also allows the user to check
that the plant is running in normal operation. If the plant is running in a fault condition,
refer to the alarm indication section which includes guidelines to return the plant to normal.
Duplicate volt free contacts are also provided to allow connection of the medical gas alarm
system and the building management system (BMS).
DRYER CONTROL PANEL (DCU)
The Plant includes a Dryer control PCB located in the lower part of the Plant Control Panel,
to control and indicate the operating conditions of both dryers which are; Power On,
Selected, Normal, Failed, Dryness Fault, Pressure Fault and running. The dryer control also
includes a duty select pushbutton, and a reset pushbutton to reset the dryer control panel
after rectification of a dryer fault.
PUMP STARTER CONTROL UNIT (PSU)
Each pump starter control unit includes an Isolator, single and three pole circuit Breakers,
Indicators for; Power On, Called For, Operating, Control Circuit Failed, Fault - Check
Compressor Status, and Failed to Load. Each Pump has a fault reset facility which can be
operated via a push button.
The pump starter unit includes a digital ammeter on the front of the panel. The hours run
counter can also be displayed by pressing the hours run push button on the front of the
pump starter control, this will briefly display the hours that particular pump has run "On
Load".
An "Auto / Manual" push button is also included on the front of each pump starter unit, so
that the pumps can be controlled automatically by the plant control unit (PCU), or selected
to run manually using the compressor manufacturers pressure controls.
The pump starter panels include a “Revert to Auto” function, is set by the manufacturer to
prevent the pumps from running continuously for a prolonged period if "Manual Control" is
inadvertently selected.
This feature should be deselected if periods of manual running exceeding 60 minutes are
required.
MOTOR PROTECTION
Each Pump Motor has a circuit breaker to protect the control panel from a short circuit, a
contactor, and an overload.
The overload protects the motor from overload or phase imbalance for example if one phase
is missing. The trip current is set on the disc on the front of the overload during manufacture
and should not need adjustment.
4.0 CONTROL PANEL FASCIAS
4.1 AIR PLANT / DRYER LAYOUT

4.2 PUMP STARTER LAYOUT

5.0 DIP SWITCH LOCATIONS

LOCATIONS
The pump starter unit below indicates the location of the plant DIP switches, and the other
major elements::-
5.1 PUMP STARTER UNIT

UNIT
Low Voltage Failed To Load Set

DC Supply Button (SW1)
DIP Switch
(SW2)
Ribbon
Cable to
Display PCB
On Control
Current Panel Door
Transformer
}
}
Green Plug In
Connector TO PCU
Local Motor
Controls and
monitoring

5.2 PLANT CONTROL UNIT
Primary Alarm / BMS

DIP Switch Connections TX ERM
(SW1)
TX Rotary Switch
(SW3) (if fitted)
TX Plant / ERM Link

(LK3) (if fitted)
Connections
To Dryer
Ribbon Cable to
AUX DIP Control Panel Door
Switch
(SW4)
Emergency
Transducer
Line
Transducer
Receiver
Transducer
Emergency
DIP Switch
Pump1 Pump 2 Pump 3 Pump 4
(SW2)
NOTE:
• Red clips or orange blocks inserted into terminals indicate that these connections are
not used on this plant model.
- 10 - Air Plant RS Rennerlogic O&M Manual Rev 3

5.3 DRYER CONTROL UNIT
Conns
To PCU
Economy/
Continuous
DIP Switch
Dewpoint
Sensor
Dryer 1 Dryer 2
NOTE:
• Red clips or orange blocks inserted into terminals indicate that these connections are
not used on this plant model.
• Economy/Continuous Switch to be set to “Economy mode” (On) once the plant is
maintaining a “Dry” signal.
• The up position as shown above is the “On” position.

6. CONFIGURATION
6.1 GENERAL
Check the test certificate to establish the type of plant, and predetermined software setup.
Prior to commencing the initial start up procedure, take time to familiarise yourself with the
general operation of the plant. It may be considered in four separate sections:-
6.2 COMPRESSORS
Check the test certificate to establish the duty and standby set pressures.
When set to "Auto Select" (Steady LED), the compressors will alternate as duty and standby,
after the requisite number of duty load cycles have been completed.
If the duty compressor(s) fails to operate or maintain pressure, the standby will run.
The control system includes the option of "2 minute minimum run timers" for use with
reciprocating compressors. (Screw compressors include this feature as part of their controls,
so this option is not selected in the PSUs).
6.3 AIR RECEIVER
Acts as an air storage vessel and condensation trap.
The autodrain will prevent excess condensation filling the receiver.
6.4 FILTER DRYER ASSEMBLY
Two filter dryer systems arranged in a parallel duty/standby configuration.
The duty filter dryer assembly is manually selected.
The duty dryer dries the compressed air, to do this the internal pressure in the dryer has to
remain high and the dryer has to maintain a dewpoint of -460C or greater.
The controls will auto select the standby dryer in the event that the internal pressure is
lower than the pressure fault setting (Check Test Certificate), or if the duty dryer fails to
maintain dewpoint.
This will be indicated by the status indicator lights indicating that the a dryer has failed, and
also the nature of the failure.
6.5 PRESSURE REGULATOR ASSEMBLY
Two pressure regulators with individual relief valves arranged is a parallel configuration.
The duty regulator is manually selected by means of isolating valves.

6.6 DUTY CYCLE (AUX Switch (Switches 4.3 & 4.4))
The plant includes a facility whereby the pump(s) selected as "Duty" run as duty for a
predetermined number of load cycles before becoming the "Standby".
The controls will then "Auto Select" the next pump(s) to run as "Duty".
This function allows the pump(s) to reach their optimum running temperature to minimise
the risk of condensate in the oil, and prolong the life of the pump(s).
Number Of Duty Cycles AUX Switch (SW4) Configuration
25
50
(Manufacturers Setting)
100
Set the DIP Switches as shown above to select the amount of load cycles, for example to run
the duty pump once set switches 3 and 4 to the 'off' position as shown above.
The manufacturers setting is 50 duty load cycles, but this can be changed easily by adjusting
DIP switches 3 and 4 as shown above.
Location of AUX
Switch (SW4)

6.7 DUTY CYCLE (AUX Switch (Switches 4.5 & 4.6))
The plant includes a facility whereby if the pump(s) selected as "Duty" runs continuously for
a set time period without stopping and restarting, the controls will then "Auto Select" the
next pump(s) to run as "Duty".
This function allows all pumps to reach their optimum running temperature to minimise the
risk of condensate in the oil, and prolong the life of the pumps.
Continuous Pump Run Time AUX Switch (SW4) Configuration

Before Changeover
N/A – Pump can run

continuously without
cycling
1.25 hours
2.5 hours
5.0 hours
Set the DIP Switches as shown above to select the maximum time that a pump will run
before cycling the duty, for example to cycle the duty pump after 5 hours of continuous
running set switches 5 and 6 to the 'on' position as shown above.
Location of AUX
Switch (SW4)

6.8 DRYER AUTO RESTART (AUX Switch (Switches 4.1 & 4.2))
This feature is used to maintain oil temperature in the compressors stop prevent oil
emulsification.
When the demand is low the dryer will start after a period of time has elapsed.
The table below shows how to configure the DIP switch to achieve the desired settings.
This switch is preset and should not need adjusting, therefore contact the manufacturer
before adjusting any settings.
Number Of Minutes AUX Switch (SW4) Configuration

Before Restart
7
(Manufacturers Setting)
11
15
19
Location of AUX
Switch (SW4)

6.9 CONNECTING RS SCREW COMPRESSORS WITH ELECTRONIC CONTROLS
Electrical connections between Screw Compressor and Pump Starter Control Panel.
The picture below shows how the compressors should be connected to the pump starter
panels:-
Green plug in
connector
Earth stud location
Compressor wiring connected to

pump starter panel
Three Phase
to screw compressor
As supplied with RS
screw compressors

7.0 INITIAL START UP AND COMMISSIONING
7.1 RS COMPRESSOR CONTROLS
IMPORTANT:-
The compressors will only run automatically when their status display LEDs show a steady
white light to indicate standby mode. If this LED is not illuminated identify and eliminate
any compressor faults, then press the ON button.
The compressors will restart automatically following a power failure, if called for by the
plant controls.
Emergency
Stop Button
ON Button
Status Display
LED
OFF Button
Emergency Stop Button
- Stops the compressor immediately.

- To unlock, turn clockwise.
- The compressor will only re-start once the ON button is pressed.
ON Button
- Starts the compressor manually.

- Press to reset after compressor faults have been cleared and place compressor into standby.
Status Display LED
- Displays the current compressor status as follows:
- Steady white light: compressor on standby.

- Extinguished (when compressor running): compressor running on load.
- Extinguished (when compressor not running): compressor manually switched off, power
failure or compressor fault.
- Flashing: compressor running off load. Compressor will stop after a short period.
OFF Button
- 'Soft stops' the compressor. Compressor will run off load for a short period, then stop.
- Stops the compressor immediately if pressed during its start-up period.
- The compressor will only re-start once the ON button is pressed.

7.2 START UP
PRE-
RE-START
Power
1. Power connected – A TPNE supply to each “Pump Starter Unit”.
Alarms
2. Alarms connected.
Valves
3. Compressor isolating valves open. Air receiver manual drains closed, auto drain
open. Dryer isolating valves open. Regulator isolating valves open, close valve
on outlet side of the duty and standby regulators.
Dryers
4. Set Dryer DIP switch to “Continuous mode” (Off) position (See page 11).
RUNNING
Correct Rotation
1. Briefly turn on each power isolator in turn and check compressor rotation is
correct. (Anti-clockwise viewed from flywheel end). If incorrect, reverse two
incoming phases on isolator.
Note:-
Note:-
Incorrect rotation may damage the compressors.
Starting Compressors
2. Turn on all isolators – all compressors will start after a short delay (Timers located
within the compressors prevent a simultaneous start). (Double check the
compressor rotation).
3. All compressors will run to cut out pressure (refer to test certificate) and then
offload. Unless there is further demand they will stop after 8 minutes.
4. Drop pressure in air receiver and check the pump selected as "Duty" runs.
5. Estimate the frequency of duty cycles and check that the plant has selected the
next compressor(s) to run as "Duty" after the requisite number of duty cycles have
been completed.
Starting Dryers
1. On first power up the dryer will not operate until the plant has achieved the
minimum operating pressure.
Once the dryers are running refer to section on ‘Drying out the dryers’ Page 16.

7.3 DRYING OUT THE DRYERS

Using the DIP switches the dryers should be set to run in continuous mode when the plant is
started for the first time. With all isolating valves open, introduce a small flow onto the
outlet side of the plant, so it runs the duty compressor(s) continuously but only on load for
30% to 40% of the time.
This action will allow air to flow through both dryers, eliminating moisture that will have
inevitably have accumulated in the filter elements and the dryers during shipping and
installation.
The Dryer control unit indicates the dewpoint temperature in degrees Celsius. The dewpoint
alarm is set to -460C. Allow the dewpoint to reach a reading of around -550C for a period of 1
hour before attempting to set the dryer circuit into economy mode.
Note:-
Note:-
-460C dewpoint represents a very low water content in the air. Reliably maintaining this
dewpoint may take some time (a period of several hours from first power up would not be
unusual).
7.4 SETTING THE DRYERS INTO ECONOMY
Once a reliable dewpoint of -550C has been achieved, open the dryer control panel. Locate
the "Economy / Continuous" DIP switch located on the dryer PCB, switch both switches to
the economy position (Identified as ‘On’).
Once both dryers are confirmed dry, it should be possible to run the dryers in economy
without generating a dewpoint fault.
Monitor the dewpoint and changeover the duty dryer every two hours, if the dewpoint
deteriorates switch both switches back into continuous mode and repeat the section above
‘Drying out the dryers’.
7.5 SELECTING THE DRYERS
Once both dryers are set to economy mode, and a dewpoint of better than -460C is displayed
and maintained, it is possible to select the duty dryer using the duty pushbutton located on
the dryer control panel.
Once the plant is in service the selected duty dryer should be changed weekly to allow the
dryers to run similar hours to equalise maintenance and maximize dryer life expectancy.
7.6 RESETTING A DRYER FAULT
On first power up the dryers will not cycle until the plant achieves the plant operating
pressure. The dryers will display “Pressure Fault” (Low internal pressure), and “Dewpoint
Fault” (High water content).
To reset a pressure fault the dryers must achieve a minimum internal pressure greater than
the pressure fault setting (Refer to test certificate). Once the dryers are up to pressure, press
and hold the dryer pushbutton for a period of 5 seconds to reset the dryer, the pressure fault
alarm should be cancelled.
The dewpoint alarm will remain in fault, and will not be possible to reset until the dryers
reliably maintain a dewpoint of -460C.
Note:-
Note:-
-460C dewpoint represents a very low water content in the air. Achieving this dewpoint may
take some time (a period of several hours from first power up would not be unusual).
Once the dewpoint has exceeded -460C, press and hold the dryer pushbutton for a period of
5 seconds to reset the dryer, the dewpoint fault alarm should cancel.

8.0 NORMAL RUNNING CONFIGURATION
Under normal running conditions the plant should be set as detailed below:-
In the event of a fault this will allow the controls to auto select duty compressor(s) or either
dryer in the event of a fault.
Valves
1. Compressor isolating valves open.
2. Air receiver manual drains closed.
3. Air receiver auto drain isolating valve open.
4. Dryer inlet isolating valves both open.
5. Dryer outlet isolating valves both open.
6. Duty pressure regulator inlet and outlet valves open.
7. Standby pressure regulator inlet and outlet valves closed.
Mode Selection
1. All compressors set to ‘Auto’ (indicated by an LED on the PSU).
2. Compressor selection set to ‘Auto’. (indicated by steady LED on PCU).
3. Dryers set to ‘Economy’ (DIP switch in “ON” position On Dryer PCB).
4. Select Dryer 1 or 2 (weekly manual changeover).
Dryers
1. Until the dryer has been in service for 8 days it is essential to frequently change
the selected duty dryer, this will complete the drying out process on both dryers.

9.0 SOFTWARE SETTINGS INCLUDING USER SELECTABLE ITEMS

All the PCB’s include DIP switches to permit selection of the correct software. As supplied
these are preset and should not require adjustment.
9.1 AIR PUMP STARTER UNITS
There is one four way DIP switch in each pump starter unit. Switch 1 and switch 2 are user
adjustable, switches 3 and 4 are set by the manufacturer and should not be adjusted. Below
is an overview of the four switches:-
Switch 1
User selection of ‘Revert to Auto’ feature, which will reset the control system if it is left in
manual for a period of 60 minutes. (As supplied “Revert to Auto” already preset).
Switch 2
User selection of minimum 2 minute run time to ensure that the compressor reaches
optimum running temperature. (This feature is already included on screw compressors,
therefore this option will not be selected.)
Switch 3 and 4
It is necessary to assign each compressor a unique identity number so that it may
communicate with the main control panel. These switches are preset and they should not be
adjusted.
Switch Number
Switch Number
ON OFF
Revert to Auto after 60
1 Stays in manual
minutes of manual running
2 2 minutes minimum run time No minimum run time
3 The combination of switches 3 and 4 establishes each
4 pump’s unique identity number, this is preset do not adjust.
9.2 AIR PLANT CONTROL UNIT
PRIMARY CIRCUIT
This controls the plant under normal conditions. The plant can be set for different
configurations, this is preset to suit the plant type and should not be adjusted. This DIP
switch (SW1) is located at the top left hand side of the plant control PCB.
Switches 1,2,3 and 4 determine the type of plant to which the P.C.B is configured.
Switches 5 and 6 identify the number of pumps that the plant is controlling.
Switches 7 and 8 determines how many pumps run as duty.
Check the plant test certificate to identify the preset DIP switch configuration.
UNDER NO CIRCUMSTANCES ADJUST THE DIP SWITCHES WITHOUT WRITTEN
INSTRUCTION FROM P3.
EMER
EMERGENCY
GENCY CIRCUIT
DIP switch (SW2) is located at the middle right hand side of the plant control PCB.
This circuit monitors the primary circuit and assumes control under certain circumstances.
Flashing “Plant Emergency” is displayed while the emergency circuit is activated. The
emergency circuit is a duplicate of the primary circuit and it will assume control in the event
of a primary circuit fault. This has been factory set and should not be adjusted.
Switches 1,2,3 and 4 determine the type of plant to which the P.C.B is configured.
Switches 5 and 6 identify the number of pumps that the plant is controlling.
Check the plant test certificate to identify the preset DIP switch configuration.
UNDER NO CIRCUMSTANCES ADJUST THE DIP SWITCHES WITHOUT WRITTEN
INSTRUCTION FROM P3.

10.0 PUMP INDICATIONS

FAULT CONDITIONS
The table below describes the following pump faults:
LOCAL FAULT INDICATION

CAUSE SOLUTIONS
SOLUTIONS
ON PUMP STARTER UNIT
• Compressor isolated. • Check that the

compressor is switched on
• Breakers Tripped. at the isolator.
• Fuse blown on pump
starter unit PCB. • Check the fuse on the
CONTROL
pump starter
starter unit PCB,
CIRCUIT FAILED • Failure of switchmode replace if necessary.
supply to produce
27VDC. • Check that the
switchmode is providing
27VDC.
• Refer to compressor
FAULT - manufacturer'
manufacturer's operating
• Overload tripped.
CHECK COMPRESSOR instructions to
to resolve
• Over Temperature.
STATUS fault.
• Emergency Stop.
Stop.
• Check that the

compressor is operating.
• Low motor amps indicate
FAILED TO LOAD compressor not • check the motor coupling
operating.
operating.
• check the setting of the
fault threshold level.

ALARM CONDITIONS
The table
table below describes the following alarm conditions:
ALARM INDICATION CAUSE SOLUTIONS
• Any pump overload

tripped. • Check that the power
supply has all three
• Any pump isolated. phases present.
• Control Circuit Failed. • Check the 27VDC supply

to the PCB.
PLANT FAULT
• Over Temp 1. • Check all circuit breakers.
• Over Temp 2. (Optional) • Check overload setting

corresponds to motor
• Other Fault. (Optional) plate. Check motor amps
using a clampmeter.
clampmeter.
• Failed To Load.
• Check the correct

• Low Receiver
Receiver pressure.
pressure. operation of pumps.
pumps.
PLANT EMERGENCY
(steady LED)
• Both dryers failed. • Check the demand on the
plant.
• Allow plant to run for 2

• Emergency Circuit has
minutes and check it
PLANT EMERGENCY overridden the primary
reverts
reverts to primary
(Flashing LED) control circuit.
operating circuit.
• Check the correct

PIPELINE • High or Low
operation of pumps, check
PRESSURE FAULT Pipeline Pressure.
Pressure.
the demand on the plant.
• Check the reserve system

• Remote Reserve below
RESERVE LOW and replenish where
where
50%.
necessary.
• Signaling from remote • Check that the wiring

reserve faulty (Wiring has linking the remote reserve
SYSTEM FAULT
an Open or Closed circuit does not show any signs
fault). of damage.

11.0 FUSE RATINGS
PUMP STARTER UNIT
DESCRIPTION
DESCRIPTION ID RATING
Pump Starter Fuse FS1 5A Slow
PLANT CONTROL / DRYER UNIT
Plant Control Fuse F1C 1A Slow
Plant Emergency Fuse F2C 1A Slow
Dryer Control Fuse F3C 5A Slow
DRYER CONTROL UNIT
Dryer 1 Fuse F1D 2A Slow
Dryer 2 Fuse F2D 2A Slow
Dewpoint Fuse F3D 1A Slow

12.0DRAWINGS
SIMPLIFIED PUMP STARTER CONNECTION DIAGRAM (Recip.

(Recip. D.O.L)

SIMPLIFIED PUMP STARTER CONNECTION DIAGRAM (Recip.

Recip. Star Delta)

SIMPLIFIED
SIMPLIFIED PUMP STARTER CONNECTION DIAGRAM
(Remote Contactor)
Contactor) RS SCREW COMPRESSORS

SIMPLIFIED PUMP STARTER CONNECTION DIAGRAM

(Remote Contactor) RS SCREW COMPRESSORS - ELECTRONIC CONTROLS

WIRING DIAGRAM PUMP STARTER UNIT (D.O.L. Contactor Fitted

Fitted In Panel)
Panel)

WIRING DIAGRAM PUMP STARTER UNIT (Star Delta Contactor Fitted In Panel)
Panel)

WIRING DIAGRAM PUMP STARTER UNIT (Remote Contactor) RS SCREW COMPRESSORS

/1.9 L01 /2.0
L 43
95 -K1
-F2 /2.1 44
Overload 96
RX1
1 3 N
2
11 15
-K2T
-S3 12 14 -OP2
- 32 -
Over 16 18
Temperature
4 /2.8
1
1 -S4 P Reset
34 54 54 13 17 2 (8.5/9.8 Bar)
-S1 Switch
-K1M -K3M -K5M -K1M -K1T
Emergency Stop 2 /2.4 33 /2.5 53 2.4 14 /2.3
/2.6 53 18 28
5
63
22 22 -K5M
-K5M -K3M /2.6 64
No Delay On Start -OP1
Timer Fitted /2.6 21 /2.5 21
No.1 Compressor
1 A1
A1 A1 X1 A1 A1 -H3 A1 A1 -MV1 A1
-K1 RX1 -H2 -K1M -K3M -K5M A2 -K2T
-K1T 2
A2 A2 X2 A2 A2 A2 A2 Funk.11 A2
/1.9 N 3Min. /2.9
/1.9 PE /2.0
Auxillary OT Lockout Unit On Y/D Relay Main Contactor Hour Meter Star Delta Solenoid Valve Run On Time
Contactor Connection Connection
Delay On Start
Timer Fitted
D.O.T 1
D.O.T 1
A1
SCREW COMPRESSOR PANEL WIRING MODIFICATIONS (RS RANGE)
-K1
N 9 A2
PE
Air Plant RS Rennerlogic O&M Manual Rev 3

SCREW COMPRESSOR PANEL WIRING MODIFICATIONS (RS RANGE - RENNERLOGIC

CONTROLS)

SIMPLIFIED CONNECTION DIAGRAM PLANT CONTROL PCB

SIMPLIFIED CONNECTION DIAGRAM DRYER CONTROL PCB

PCB

PLANT SCHEMATIC (Up to 4 Compressors)

COMBINED MEDICAL & SURGICAL PLANT SCHEMATIC (Up to 4 Compressors)

13.0 MAINTENANCE
13.
13.1 GENERAL
Pre and activated Carbon Filters should be replaced at 12-month intervals.
Sterile filters every 6 months.
Refer to the drying out section of the dryers section of this manual after filter
replacement.
13.2 ROUTINE MAINTENANCE
WEEKLY (TYPE A);
Check Drain on Receiver using Manual Valve.

Visually check duty auto cycling between both compressors.
Change Duty Dryer.
Check Oil Levels In Compressors.
Check for Oil leaks In Compressors.
Check the Oil Level is not rising indicating condensation.
MONTHLY (TYPE B);
As Type ‘A’ plus the following
Check and/or clean the intake filter on both compressors.

Check Drain on Receiver using Manual Valve.
Check each Compressor runs O.K. using Auto/Manual Selection.
Check the hours run to establish "Duty" Auto changeover is operating.
EVERY 6 MONTHS (TYPE C);
As Type ‘B’ plus the following
Check Pressure Sensor Cut In/ Cut Out point of Duty.

Change Sterile Filter Elements.
EVERY 12 MONTHS (TYPE D);
As Type ‘C’ plus the following
Tighten Electrical Connections.

Check all Switch and Sensor settings.
Change Pre and Active Carbon Filter Elements.
Recommission plant – Checking all functions (see Initial Startup and
commissioning section of this manual).
13.3 VESSEL MAINTENANCE
Manually drain condensate weekly to check function of Auto drain.

Periodic insurance inspection will be required on the Pressure Vessel. The Vessel is
provided with two inspection ports.

14. SPARE PART

PARTS
When ordering spare parts, quote the batch number of the equipment and a description of
the component required to ensure that the correct component is supplied.
Refer to the test certificate to identify the plant specific components.
Refer to the list below for a recommendation of the spare items to stock:-
Description Part Number
Oil As pump manufacturers instructions
Oil Filters As pump manufacturers instructions
Air Filters Refer to Test Certificate
Contactor Refer to Test Certificate
Overload Refer to Test Certificate
Plant Control Unit P.C.B. P3 3020
Pump Starter Unit P.C.B. P3 3010
Display P.C.B. P3 3000
Dryer P.C.B. P3 3030
Fuses Refer to Test Certificate
Pressure Gauge Refer to Test Certificate
Pressure Transducers Refer to Test Certificate
Desiccant Grade 5-8mm Bead
Pressure Switch Refer to Test Certificate
Regulator Refer to Test Certificate
Relief Valves Refer to Test Certificate
Due to our policy of continuous product improvement, Phoenix Pipeline Products Ltd. reserve the right to alter dimensions and/or
specification without notice although every effort will be made to advise of any such modifications. Certain aspects of P³ Ltd. designs are
protected.

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Phoenix Pipeline Products Limited

Installation, Operation and Maintenance Manual

MEDICAL AIR PLANT

To be read in conjunction with

Renner Compressor Instructions

Phoenix Pipeline Products Limited

-2- Air Plant RS Rennerlogic O&M Manual Rev 3

All electrical work must be carried out by a qualified electrician.

-3- Air Plant RS Rennerlogic O&M Manual Rev 3

2.0 INSTALLATION REQUIREMENTS

1. NO ELECTRICAL CONNECTIONS SHOULD BE MADE TO ANY TERMINAL BLOCKS

2.3. PIPEWORK CONNECTIONS

Connect the dryer to the higher port in the receiver.

2.4. ELECTRICAL CONNECTIONS

-4- Air Plant RS Rennerlogic O&M Manual Rev 3

The plant consists of the following major components:-

3.2. AIR RECIEVER

3.4 DUPLEX OIL/WATER SEPARATION FILTERS

3.5 DUPLEX DESICCANT REGENERATING DRYERS

3.6 DUPLEX ACTIVATED CARBON AND DUST FILTERS

3.7 STERILE FILTERS

3.8 DUPLEX PRESSURE REDUCING SET

-5- Air Plant RS Rennerlogic O&M Manual Rev 3

3.9 ELECTRICAL CONTROL PANELS

4.0 CONTROL PANEL FASCIAS

4.1 AIR PLANT / DRYER LAYOUT

-7- Air Plant RS Rennerlogic O&M Manual Rev 3

4.2 PUMP STARTER LAYOUT

-8- Air Plant RS Rennerlogic O&M Manual Rev 3

5.0 DIP SWITCH LOCATIONS

5.1 PUMP STARTER UNIT

Low Voltage Failed To Load Set

-9- Air Plant RS Rennerlogic O&M Manual Rev 3

5.2 PLANT CONTROL UNIT

Primary Alarm / BMS

TX Plant / ERM Link

- 10 - Air Plant RS Rennerlogic O&M Manual Rev 3

5.3 DRYER CONTROL UNIT

- 11 - Air Plant RS Rennerlogic O&M Manual Rev 3

6.3 AIR RECEIVER

Acts as an air storage vessel and condensation trap.

The autodrain will prevent excess condensation filling the receiver.

6.4 FILTER DRYER ASSEMBLY

Two filter dryer systems arranged in a parallel duty/standby configuration.

The duty filter dryer assembly is manually selected.

6.5 PRESSURE REGULATOR ASSEMBLY

The duty regulator is manually selected by means of isolating valves.

- 12 - Air Plant RS Rennerlogic O&M Manual Rev 3

6.6 DUTY CYCLE (AUX Switch (Switches 4.3 & 4.4))

Number Of Duty Cycles AUX Switch (SW4) Configuration

- 13 - Air Plant RS Rennerlogic O&M Manual Rev 3

6.7 DUTY CYCLE (AUX Switch (Switches 4.5 & 4.6))

Continuous Pump Run Time AUX Switch (SW4) Configuration

N/A – Pump can run

- 14 - Air Plant RS Rennerlogic O&M Manual Rev 3

Number Of Minutes AUX Switch (SW4) Configuration

- 15 - Air Plant RS Rennerlogic O&M Manual Rev 3

6.9 CONNECTING RS SCREW COMPRESSORS WITH ELECTRONIC CONTROLS

P3 Electronic Air Plant RS Rennerlogic Compressors O&M Rev 3

P3 Electronic Air Plant RS Rennerlogic Compressors O&M Rev 3

P3 Electronic Air Plant RS Rennerlogic Compressors O&M Rev 3