6000F - User Manual 1600

Oil Free Screw User Manual
C20160-1600 Issue 2, July 1997
USER MANUAL
OIL FREE ROTARY SCREW AIR COMPRESSORS
Serial Numbers from:
504 F200-0103 604 F205-0601 609 F118-1101

505 F201-0205 605 F206-0701 509 & 610 F119-1219
506 F202-0304 606 F207-0801 510 & 612 F120-1316
507 F203-0402 607 F208-0901 512 & 615 F121-1415
508 F204-0503 608 F209-1001 515 F122-1523
Note: This manual provides User information for both 6000F and Dryclon compressors. To
identify a 6000F model number add the prefix 6 to the model number, i.e. the 6504 is equivalent to
504.
CONTENTS Illustrations Page
Page Control Panel 13

Air System 14
1. Safety Procedures 5
Cooling System 15
2. General Description 11
Lubrication System 16
3. Leading Particulars 23
Regulation System 17
4. Installation 29
Regulation System (Schematic) 19
5. Commissioning 37
Starter Assembly Layout 20
6. Operation 53
Interface Assembly 21
7. Maintenance 71
Baseframe Connections 31
8. Fault Finding 87
SureScan Control Unit Menu Structure 59
Appendix 1 – Control/Remote Options 95
Servicing Points 504–508, 604–608 77
Appendix 2 – Electrical Connections 105
Servicing Points 509–515, 609–615 78
Appendix 3 – The Pressure Systems and
Transportable Gas Container Remote Input Connection 97
Regulations 1989 113
Timer Control 99
Appendix 4 – Sample Log Sheets 115
Remote Output Connection 103
Appendix 5 – Cooling Water Quality 125
Electrical Connection Diagram 106
Air Compressor Circuit Diagram 112
page 1
CompAir
OWNERSHIP DATA
TECHNICAL DATA
Model: 1st Stage

Air-end Serial
Numbers: 2nd Stage
Serial Number:
Gearbox
Year: Motor Serial Number:
Delivery Date: Intercooler Serial Number:
Maximum Pressure: Intercooler Certificate Number:
kW: Aftercooler Serial Number:
Motor rpm Aftercooler Certificate Number:
V. Ph. Hz. Compressor Lubricant:
M3/min Lubricant Capacity:
Motor Bearing Grease:

(if applicable)
LOCAL COMPAIR DISTRIBUTOR
Name:
Address:
Telephone: Fax:
Contact Names: Parts:
Service:
page 2
MODEL DESIGNATION
The Model Designation code identifies specific models as in the following example:
Designation 5 0 4 – 0 8 W
A B B – C C W
➤
A = MAINS SUPPLY FREQUENCY 5 = 50 HZ; 6 = 60 HZ
B = NOMINAL FREE AIR DELIVERY 04 = 400 CFM
C = DELIVERY PRESSURE 07 = 7.6 BAR
08 = 8 BAR
09 = 9 BAR
10 = 10.5 BAR
W = COOLING WATER
This publication relates to all standard operating pressure versions of the following models (50Hz and 60Hz):
504 505 506 507 508

604 605 606 607 608
509 510 512 515

609 610 612 615
Note: This manual provides User information for both 6000F and Dryclon compressors. To identify a 6000F
model number add the prefix 6 to the model number, i.e. the 6504 is equivalent to 504.
ASSOCIATED PUBLICATIONS
Title Part No.
Repair Manual AC20160-1556
Parts List (multi-lingual) C20160-1635 (504-508 and 604-608)
C20160-1636 (509-515 and 609-615)
page 3
CompAir
WARRANTY
! WARNING
The conditions of the CompAir Warranty are set out !
in the company’s standard Conditions of Sale
available from the Distributor supplying the ● The use of replacement parts or
machine. lubricating oils not supplied or approved
by CompAir may lead to failures in
service which would not be covered by
MAINTENANCE warranty.
To ensure the continued trouble-free operation of ● Any unauthorised modifications or

the compressor unit it is important that periodic failure to maintain this equipment in
maintenance and servicing are carried out in accordance with the maintenance
accordance with the information given in the instructions may make it unsafe. The
‘Maintenance’ section of this manual. If any use of replacement parts not supplied or
replacement or repair is needed use only CompAir approved by CompAir may create
Genuine Parts. hazardous conditions over which
CompAir has no control.
● Such hazardous conditions may lead to

accidents that can be life threatening,
cause substantial bodily injury or result
in damage to the equipment. CompAir
can bear no responsibility for equipment
in which unapproved replacement parts
are included.
USE ONLY
GENUINE PARTS
AUTHORISED SERVICE AGENTS
USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY

COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED
OUT USING NON-GENUINE PARTS.
page 4
1
SAFETY PROCEDURES
Page
General 6
Warnings, Cautions and Notes 6
General Safety Precautions 7
Installation Precautions 7
Operational Precautions 7
Maintenance and Repair Precautions 8
Precautions in the Event of Fire 9
page 5
CompAir
SAFETY PROCEDURES
1. GENERAL 2. WARNINGS, CAUTIONS AND NOTES
Most accidents which occur during the operation 2.1 Warnings

and maintenance of machinery are the result of
failure to observe basic safety rules or precautions. Warnings call attention to operations or procedures
An accident can often be avoided by recognising a involving specific hazards which could cause injury
situation that is potentially hazardous. or death and are identified by the following symbols
on the unit and in the text of the manual.
When handling, operating or carrying out
maintenance on the unit, personnel must use safe
engineering practices and observe all relevant local
health and safety requirements and regulations. WARNING: RISK OF DANGER
The attention of users in the UK is drawn to the
Health and Safety at Work Act, 1974, and to the
Regulations of the Institution of Electrical
!
Engineers.
WARNING: RISK OF ELECTRIC
CompAir cannot anticipate every possible
SHOCK
circumstance which might represent a potential
hazard. The WARNINGS in this manual are
therefore not all-inclusive. If the user employs an
operating procedure, an item of equipment or a
method of working which is not specifically WARNING: RISK OF HOT
recommended by CompAir he must ensure that the SURFACES
unit will not be damaged or made unsafe and that
there is no risk to persons or property.
Failure to observe the precautions given under

WARNING: CONSULT MANUAL
'Safety Procedures' may be considered dangerous
practice or misuse of the compressor unit.
WARNING: RISK OF HIGH

! PRESSURE
2.2 Cautions
Incorrect operational procedures causing possible

damage to the compressor unit are identified by a
‘CAUTION’ in the text of this manual.
2.3 Notes
Methods to make the job easier and points which

require particular attention are identified by a ‘Note’
in the text of the manual.
page 6
Oil Free Screw User Manual – Safety Procedures
3. GENERAL SAFETY PRECAUTIONS Ensure that the air delivery pipe from the
compressor to the user’s pipework or receiver is
If using compressed air for cleaning purposes, free to expand and that no flammable material is in
ensure safety regulations are complied with and the vicinity.
appropriate clothing and eye protection is worn.
A shut-off valve must be fitted in the delivery air line
Never direct compressed air onto your skin or at to enable the compressor unit to be isolated. This is
other people. particularly important if more than one unit is to be
coupled in parallel or connected to an existing air
Never use compressed air to clean loose dirt from supply system.
clothing.
The non-return valve is not intended as an isolating
Before releasing compressed air through a hose valve and should not be relied upon for this
make sure that the free end is held securely so that purpose. In addition, it may be necessary to install
it cannot whip and cause injury. shut-off valves elsewhere in the system to allow a
dryer or other equipment to be by-passed.
Avoid injury by using a hoist to lift heavy loads.
Check that all chains, hooks, shackles and slings A safety relief valve must be installed between any
are in good condition and are of the correct compressor unit and the shut-off valve/s.
capacity. They must be tested and approved
according to local safety regulations. A pressure-relieving device must be fitted to every
pressure vessel or equipment containing air at
Cables, chains or ropes must never be applied above atmospheric pressure, when installed
directly to lifting eyes. Always use an appropriate downstream of the unit.
shackle or hook, properly positioned. Arrange lifting
cables so that there are no sharp bends. If raised platforms are required to provide access to
the unit they must not interfere with normal
Use a spreader bar to avoid side loads on hooks, operation or obstruct access for lifting or
eyes and shackles. dismantling components. Platforms and stairs
should be of grid or plate construction with safety
When a load is on a hoist stay clear of the danger rails on all open sides.
area beneath and around it. Keep lifting
acceleration and speed within safe limits. Never In order to control the risk of Legionnaires Disease,
leave a load hanging on a hoist for longer than is CompAir strongly advise against the use of water
necessary. cooling tower systems for water cooled
compressors. A closed circuit radiator system is
preferred.
4. INSTALLATION PRECAUTIONS
Installation work must only be carried out by 5. OPERATIONAL PRECAUTIONS

competent personnel under a qualified supervisor.
The compressor unit must only be operated by
A fused isolating switch must be fitted between the competent personnel under a qualified supervisor.
main power supply and the compressor.
Do not run the compressor with doors open or
Ensure that air drawn into the air intake will not be covers removed.
contaminated with flammable fumes or vapours
since this could cause an internal fire or explosion. Never remove or tamper with the safety devices,
guards or insulation materials fitted to the unit.
Precautions must be taken to ensure that no injury
is caused to passers-by through loose clothing The compressor must only be operated at the
being sucked into the air intake. supply voltage and/or frequency for which it is
designed.
page 7
CompAir
When mains power is switched on, lethal voltages 6. MAINTENANCE AND REPAIR PRECAUTIONS
are present in the electrical circuits and extreme
caution must be exercised whenever it is necessary Maintenance, repairs or modifications must only be
to carry out any work on the electrical system. carried out by competent personnel under a
qualified supervisor.
Do not open the starter compartment or touch
electrical components while voltage is applied If replacement parts are needed use only CompAir
unless it is necessary for measurements, tests or Genuine Parts.
adjustments. Such work should be carried out only
by a qualified electrician equipped with the proper Carry out the following operations before removing
tools and wearing appropriate body protection any panels from the enclosure or dismantling any
against electrical hazards. part of the unit.
When the unit is running under automatic control, 1. Isolate the compressor unit from the main
attach a sign stating ‘THIS UNIT MAY START electrical power supply. Lock the isolator in
WITHOUT WARNING’ next to the display panel. the ‘OFF’ position and remove the fuses.
If the unit is equipped with a Remote Start device, 2. Attach a label to the isolator switch and to the
attach warning notices stating ‘THIS UNIT CAN BE display panel carrying the warning ‘WORK IN
STARTED REMOTELY’ in prominent locations, PROGRESS – DO NOT APPLY VOLTAGE’.
one on the outside of the unit, the other inside the Do not switch on electrical power or attempt
control compartment. to start the unit if such a warning label is
attached.
As a further safeguard, take adequate precautions
to make sure there is no one checking or working 3. Close the isolating valve between the
on the unit before attempting to operate remote compressor unit and the user’s pipework.
start equipment. Attach a notice stating ‘CHECK Close the isolating valves in the cooling water
THAT ALL PERSONNEL ARE CLEAR OF THE inlet and outlet pipes. Attach a label to each
UNIT BEFORE STARTING’ or similar wording to valve carrying the warning ‘WORK IN
the remote start equipment. PROGRESS – DO NOT OPEN’.
Some parts of the compressor reach extremely 4. Bleed down all air pressure in the delivery
high temperatures. If panels are removed from the pipe between the non-return valve and the
enclosure take precautions against burns. The shut-off valve by carefully slackening the
cooling water outlet pipe is likely to reach 80°C and aftercooler condensate drain connection at
must be painted or marked according to the local the strainer inlet.
safety code. The pipe must be guarded or insulated
where injury to personnel could occur. 5. First and second stage pressure will be
exhausted through the dump silencers by the
If there is any indication that the compressor is action of the unloader solenoid valve. As an
overheating it must be shut down and the cause additional precaution, slacken the drain plug
investigated. Beware of burns from hot metal parts, at the base of the regulation air line filter to
hot oil and water when working on a unit which has release any residual pressure and leave it
recently been shut down. slack while work is in progress. When work is
completed remember to re-tighten the plug
The ‘Noise at Work Regulations 1989’ suggest that before starting the compressor.
ear protectors should be worn where noise levels
are 85 dB(A) or higher. With all covers in place, the Use only lubricating oils and greases approved by
noise levels of the compressors described in the CompAir. Make sure that the selected lubricants
manual are substantially lower than this figure comply with all relevant safety regulations,
unless installed in an already noisy environment. especially with regard to the risk of explosion or fire
and the possibility of decomposition or the
Be aware that high noise levels can interfere with generation of hazardous gases.
communication.
page 8
Oil Free Screw User Manual – Safety Procedures
Always clean up oil spills from the surrounding floor Check the direction of rotation of the fan motor, oil
and outside of the compressor unit before and after pump motor and main drive motor when starting up
maintenance work. Make sure that no oil is left on the compressor initially and after any work on the
or near the air intake components, including the electrical connections or switchgear (refer to the
suction regulator, which could be drawn into the Commissioning section of this manual).
compressor and contaminate the delivered air.
Do not use any flammable liquid to clean valves,
Make sure that all instructions concerning the filter elements, air pipes or any component carrying
operation and maintenance are strictly followed and a flow of air during normal operation. If chlorinated
that the complete unit, with all accessories and hydrocarbon non-flammable fluids are used for
safety devices, is kept in good running order. cleaning, safety precautions must be taken against
any toxic vapours which may be released.
The accuracy of pressure and temperature gauges
and switching thermometers must be regularly Do not use carbon tetrachloride.
checked. They must be renewed when acceptable
tolerances are exceeded. Precautions must be taken when using acids,
alkalis and chemical detergents for cleaning
Protection devices must be tested as described in machine parts and components. These materials
the Repair manual. cause irritation and are corrosive to the skin, eyes,
nose and throat. Avoid splashes and wear suitable
Keep the compressor unit clean at all times. Protect protective clothing and goggles. Do not breathe
components and exposed openings by covering mists. Ensure that soap and water are readily
with clean cloth or tape during maintenance or available.
repair work.
When disposing of condensate, old oil, used filter
Protect the motor, air intake, electrical and elements and other parts and waste material of any
regulation components against the entry of kind make sure that there is no pollution of any
moisture, e.g., when steam cleaning. drain or natural water-course and that no burning of
waste takes place which could cause pollution of
Precautions must be taken when carrying out the air. Protect the environment by using only
welding or any repair operation which generates approved methods of disposal.
heat, flames or sparks. The adjacent components
must always be screened with non-flammable
material and if the operation is to be carried out 7. PRECAUTIONS IN THE EVENT OF FIRE
near any part of the oil system, or close to a
component which may contain oil, the system must Use extreme caution when handling components
first be thoroughly purged, preferably by steam that have been subjected to fire or very high
cleaning. temperatures. Some components may contain
fluoroelastomer materials which decompose under
Never use a light source with an open flame to these conditions to form highly corrosive residues.
inspect any part of the unit. Skin contact can cause painful and penetrating
burns resulting in permanent skin and tissue
In no circumstances must any welding work or damage.
other modification be carried out on any pressure
vessel.
Before dismantling any part of the compressor unit

ensure that all heavy movable parts are secured.
After completion of repair or maintenance work

ensure that no tools, loose items or rags are left on
or inside any part of the machine. Turn the motor
over by hand several times to ensure there is no
mechanical interference.
page 9
CompAir
page 10
2
GENERAL DESCRIPTION
Page
Introduction 12
Air-Ends 12
Electronic Controller 12
Air System 14
Cooling System 15
Lubrication System 16
Regulation System 17
Starter 20
page 11
CompAir
GENERAL DESCRIPTION
1. INTRODUCTION 2. AIR-ENDS
The unit is a fully enclosed, oil-free, two-stage, 2.1 Description

liquid-cooled, rotary screw compressor package. It
comprises a drive motor, first and second stage air- Air is compressed by two rotary screw air-ends.
ends, intercooler, aftercooler, oil cooler, first and Each comprises an intermeshing pair of helical
second stage moisture separators, air intake and screw rotors driven by a pinion fitted to the male
filter assembly, control panel and ventilation fan. rotor shaft which meshes with the main gear.
The unit is mounted on a baseframe in an acoustic
steel-panelled enclosure. Removable panels give Timing gears on each male rotor drive the female
access for routine maintenance. rotors and maintain correct clearance. Seals
between the rotors and bearings prevent air
The air-ends are driven by an electric motor via a passing into the oil system and oil passing into the
flexible coupling and a gearbox in which the single compression chambers. The rotors, shafts, seals
main gear drives both male rotors. and the internal surface of the rotor casing are
coated with an anti-corrosive/anti-wear material.
The compressor is controlled by an electronic
controller which monitors and acts on information
translated from pneumatic, electrical and 2.2 Operation
mechanical devices. Delivery pressure is monitored
by a pressure transmitter to regulate on-load and Compression takes place between the lobes on the
off-load running via a solenoid operated unloader male rotor, the flutes on the female rotor and the
valve. A visual display provides information on air-end casing. As the rotors turn, the trapped air is
compressor performance and condition. progressively compressed until the discharge port
is uncovered and is then discharged at first stage
pressure. Further compression takes place in a
similar manner in the second stage air-end and air,
at delivery pressure, passes into the user’s
pipework.
3. ELECTRONIC CONTROLLER
The electronic control system is microprocessor

based with liquid crystal display (LCD), mimic
diagram, tactile membrane switches and dedicated
(LED) pressure display, incorporating many
advanced control and monitoring features.
page 12
Oil Free Screw User Manual – General Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
bar
psi
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
PI/97/067
1. Psi Units Indicator 19. Remote Control Legend

2. Bar Units Indicator 20. Remote Control Indicator
3. Delivery Pressure Display 21. Auto Restart Indicator
4. Start Button 22. Power On Indicator
5. Status and Message Display 23. Compressor Delivery Fault Indicator
6. Plus Button 24. Oil System Fault Indicator
7. Minus Button 25. Change Oil Filter Indicator
8. Up Button 26. 2nd Stage Delivery Fault Indicator
9. Down Button 27. Low Oil Level Indicator
10. Enter Button 28. Main Motor Fault Indicator
11. Mimic Diagram 29. Oil Pump Motor Fault Indicator
12. Intake Filter Change Indicator 30. Hours Button
13. Incorrect Phase Rotation Indicator 31. Reset Button
14. 1st Stage Delivery Fault Indicator 32. Reset Indicator (LED)
15. 2nd Stage Intake Fault Indicator 33. Values Button
16. Fan Motor Fault Indicator 34. Service Button
17. Emergency Stop Button 35. Service Indicator (LED)
18. Auto Restart Legend 36. Stop Button
CONTROL PANEL
page 13
CompAir
4. AIR SYSTEM Air from the second stage air-end passes through a
silencer, non-return valve, aftercooler and moisture
4.1 Description separator to the delivery outlet. The non-return
valve prevents air re-entering the compressor
The system consists of an intake air filter, silencer, during off-load running.
suction regulator, first and second stage air-ends,
intercooler, aftercooler, associated moisture During the unloading sequence air trapped
separators and safety valves, silencers, non-return between the second stage air-end and the non-
valve, regulation air line filter, shuttle valve and return valve is discharged to atmosphere through a
solenoid valve. silencer to reduce noise levels.
The air system is protected by two safety valves.

4.2 Operation One valve is fitted to the moisture separator body
between the intercooler and the second stage air-
Air enters through the intake filter, silencer and end and the other between the second stage
suction regulator to the first stage air-end. moisture separator and the air delivery connection.
Compressed air at first-stage pressure passes into If the air pressure at either point becomes too high,
the intercooler and moisture separator. Condensate the valves will open and vent to atmosphere.
which forms in the intercooler is ejected through a
solenoid valve. The cooled air passes to the The temperature of the compressed air is
second stage air-end and is compressed to final monitored by temperature sensors at the first stage
delivery pressure. air-end discharge, second stage air-end intake,
second stage air-end discharge and the delivery
pipe.
1 2 3 4 5 6 7 8 9 10 11 12 13 7
AIR
INTAKE
19
AIR
BLOW DISCHARGE
DOWN
18
20 CONDENSATE
DRAINS
PI/97/068
20
17 16 15 14
1. Air Intake Filter 8. Interstage Pressure Transmitter 15. Unloader Solenoid Valve
2. Silencer 9. Silencer 16. Regulation Line Filter
3. Suction Regulator 10. Non-return Valve 17. Shuttle Valve
4. First Stage Air-end 11. Delivery Pressure Transmitter 18. Silencer
5. Intercooler 12. Aftercooler 19. Differential Pressure Switch
6. Moisture Separator 13. Moisture Separator 20. Condensate Drain Solenoid
7. Safety Valve 14. Second Stage Air-End Valves
AIR SYSTEM
page 14
5. COOLING SYSTEM The intercooler and aftercooler are each provided

with a moisture separator to extract condensate.
5.1 Description The condensate is ejected into the user’s drain
system by automatically controlled solenoid
The system consists of a solenoid operated water valves.
valve, air-end cooling jackets, intercooler,
aftercooler and oil cooler. Drain taps allow the The temperature of the cooling water is monitored
system to be drained for maintenance and repair. by temperature sensors in the water inlet and
outlet pipes.
The compressed air and lubricating oil are cooled
by water passing through the intercooler, The enclosure is ventilated by a fan which runs
aftercooler and oil cooler. Cooling water also when the unit is in operation. It continues running
passes through the jackets provided around both for 30 seconds after shutting down the main
air-ends. motor.
The flow of coolant is regulated by valves fitted in

the outlet pipes of each cooler and the outlet pipe
of the air-end cooling jackets.
DRAIN
9 10
8 11 VENT 2
DRAIN 12
7
4 3
PI/97/069
6 5
1. Temperature Sensor ‘Water Out’ 7. Intercooler Flow Control Valve

2. Temperature Sensor ‘Water In’ 8. Aftercooler Flow Control Valve
3. Inlet Water Strainer (Supplied as loose item) 9. Oil Cooler Flow Control Valve
4. Water Solenoid Valve 10. Oil Cooler
5. Air-End Cooling Jackets 11. Aftercooler
6. Air-End Cooling Jackets Flow Control Valve 12. Intercooler
COOLING SYSTEM
page 15
CompAir
6. LUBRICATION SYSTEM
12
7 6
13
11
10
5
8 14
14
9
4
10
2
1
15 3 PI/97/070
1. Oil Sump 9. First Stage Air-end

2. Oil Level Sensor 10. Oil Pressure Switch
3. Strainer 11. Oil Pressure Gauge
4. Oil Pump 12. Temperature Sensor
5. Oil Cooler 13. Oil Breather/Filler
6. Oil Filter 14. Gearbox
7. Pressure Relief Valve 15. Oil Level Sightglass
8. Second Stage Air-end 16. Differential Pressure Switch
LUBRICATION SYSTEM
6.1 Description The monitoring system also displays alarm and/or

trip information (as applicable) if danger levels are
The lubrication system is fully enclosed and approached in respect of oil filter blockage, low oil
pressurised. It comprises a sump, pump, cooler, level, low oil pressure, high oil temperature or oil
filter and distribution pipework through which oil pump motor overload.
circulates to the gears and bearings. Oil is
prevented from entering the compression space by A pressure relief valve on the front of the gearbox
seals fitted at the ends of each rotor shaft. controls oil pressure and releases excess oil to the
sump.
The system incorporates control and safety devices
to monitor oil level, pressure and temperature. Oil The lubricant should be a high grade turbine oil
temperature can be displayed on the display panel. containing corrosion inhibitors. A list of
recommended oils is given in ‘Leading Particulars’.
Lubrication system oil pressure is indicated on a
gauge located behind a service access panel at the
end of the compressor.
page 16
7. REGULATION SYSTEM
1 1
2 2
9 3 9 3
8 4
4
6 5 6 5
PI/97/071
UNLOADED LOADED
1. Suction Regulator 5. Non-return Valve

2. Blowdown Valve 6. Shuttle Valve
3. Unloader Solenoid Valve 7. Second Stage Air-end
4. Regulation Line Filter 8. First Stage Air-end
9. Inlet Valve
REGULATION SYSTEM
7.1 Description connected to the inlet of the first stage air end. The
higher pressure at the back of the diaphragm acts
The compressor runs continuously, loading and with the spring pressure to close the inlet valve
unloading at preset delivery pressures (P1 and P2 and open the blowdown valve, thus unloading the
set points). If air pressure remains above the P2 set compressor.
point for the run-on time the compressor will shut
down into Stand-by mode. The compressor will As the compressor unloads the interstage pressure
automatically restart as demand increases and the falls below atmospheric pressure causing the
pressure drops to the P2 set point. shuttle valve to switch. In this condition the inlet
valve is maintained closed by the vacuum at the
first stage inlet being passed via the unloader
7.2 Off Load Air Flow solenoid valve to the front of the diaphragm.
When the pressure is above the upper set point Atmospheric pressure is applied to the back of the
(P1), the controller de-energises the unloader diaphragm via the shuttle valve and unloader
solenoid valve. Interstage pressure is applied solenoid valve.
through the unloader solenoid valve to the back
(exhaust side) of the suction regulator diaphragm.
Simultaneously the front of the diaphragm is
page 17
CompAir
7.3 On Load Air Flow The compressor always starts off-load and remains
in this condition until the main motor start sequence
When the output pressure is below the lower is complete and the pre-set Load Delay time has
pressure set point (P2), the controller energises elapsed.
the unloader solenoid valve.
Suction created by the first stage air end creates a 7.4.3 Running
depression on the back (exhaust side) of the
suction regulator diaphragm chamber. The When the compressor is running a pressure
pressure differential across the diaphragm causes transmitter monitors the pressure in the user’s
the valve spindle to move and the suction regulator pipework. Pressure is maintained between the
begins to open. upper (P1) and lower (P2) pressure set points.
As the inlet valve opens, pressure in the interstage When the pressure is below the (P2) lower
increases and passes through the unloader pressure set point, the controller energises the
solenoid valve to the front (inlet side) of the unloader solenoid valve which controls the suction
diaphragm chamber. This causes the inlet valve to regulator. This causes the inlet valve to open fully
fully open and the compressor runs on load. and the compressor runs on-load.
If the compressor is started with the pressure The compressor continues to run on-load until the
above the lower pressure set point (P2), the upper (P1) pressure set point is reached. The
compressor will immediately enter Standby mode controller then de-energises the unloader solenoid
and will automatically start when the pressure falls. valve which causes the inlet valve to close, and the
compressor runs off-load. A non-return valve in the
delivery line prevents system air from exhausting
7.4 Operation through the blowdown valve.
7.4.1 Power first switched ON If the compressor is started with the pressure
above the lower (P2) pressure set point, the
When power is switched on the control system compressor will immediately enter Standby mode
checks that all pre-set conditions are correct and and will automatically start when the pressure falls.
the emergency circuits are in order. The display
shows the control program identification and part
number. When the internal checks are complete 7.4.4 Stopping
the display message changes to 'Ready to start'.
CAUTION: It is inadvisable to stop the compressor
during a motor start sequence.
7.4.2 Starting
If the EMERGENCY STOP button is pressed the
When the START button is pressed, the water stop water stop solenoid valve closes and the main
solenoid valve opens and the ventilation fan and oil motor, ventilation fan and oil pump motor will stop
pump motor starts. When the controller detects the immediately.
oil pressure is correct the main motor start
sequence begins. The display message shows CAUTION: Emergency Stop should only be used in
‘Starting’ a genuine emergency situation.
To minimise starting current the motor runs up to The compressor may be stopped manually by
speed in Star mode. After the pre-set Star/Delta pressing the stop button. When the STOP button is
time the motor drive circuit switches to Delta mode, pressed the compressor unloads and the main
drawing full load current at full motor speed. motor stops. The water stop solenoid valve,
ventilation fan and oil pump motor continue to run
for a further 30 seconds cooling down period.
page 18
12 13 14
1 2
15 16
4
5
17 6
18
3
+ -
11
19
21
M + -
20
10
7 8 9
16
15
PI/97/093
1. Intake Air Filter 12. Unloader Solenoid Valve

2. Suction Regulator 13. Regulation Air Line Filter
3. First Stage Air-end  14. Shuttle Valve

4. Intercooler  1st Stage 15. Strainer (2)
5. Pressure Relief Valve  16. Condensate Drain Valve (2)

6. Pressure Transmitter 17. Air Filter Switch
7. Second Stage Air-end
 18. Temperature Sensor

8. Non-return Valve  19. Temperature Sensor
9. Aftercooler
 20. Temperature Sensor
 2nd Stage
10. Pressure Relief Valve  21. Temperature Sensor
11. Pressure Transmitter 
REGULATION SYSTEM (SCHEMATIC)
page 19
CompAir
8. STARTER
The compressor motor has a Star/Delta starter

system to reduce starting current. The motor is
started in Star connection. As the motor
approaches its rated speed it switches to Delta
connection.
STARTER DELTA MAIN

CONTACTOR CONTACTOR CONTACTOR
THERMAL
OVERLOAD
RELAY
PI/97/155
STARTER ASSEMBLY LAYOUT
page 20
X08 X07 X06 X05
6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1
ANALOG INPUTS DIGITAL OUT
F1
F2
F3
F4
F5
X2/1
X2/1
X2/2
X2/2
X2/2
X2/4
X2/6
X3/1
X3/1
X3/1
X3/2
X4/1
X4/1
X4/2
X4/2
X5/1
X5/1
X5/2
X5/2
X6/1
X6/1
X6/2
X6/2
R301
K201
K401
K402
K403
K404
K405
K406
X04
DIGITAL IN RS-485
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2
12
F1/F2 Fused terminal, 1·6A X01 X02 X03
F3/F4 Fused terminal, 3·15A

F5 Fused terminal, 10A
F102 Fan motor thermal
overload relay
F103 Oil pump motor
thermal overload relay
Ki01 Phase rotation relay
K401 Available relay
T201 Q201 Q101 K101 KM204 KM205
K402 Group fault relay
K403 Running relay
K404 On load relay
K405 Group trip relay F102 F103
K406 Service due relay

KM204 Fan contactor
KM205 Oil pump contactor
Q101 MPCB and auxiliary
Q201 Miniature circuit
breaker
T201 Control transformer
PI/97/154
page 21
INTERFACE ASSEMBLY
CompAir
page 22
3
LEADING PARTICULARS
page 23
CompAir
LEADING PARTICULARS
MODELS 504–508 and 604–608
Air-ends: Two-stage, oil-free screw

Cooling: Liquid-cooled
Oil capacity (approx.): 35 litres
Recommended oils: Fuchs Renolin AC68; Shell Turbo T68; Mobil Rarus 426
Esso Teresso 68; Castrol Perfecto T68
Note: Compressors are factory filled with Fuchs Renolin AC68
Air delivery connection: R3
Cooling water connection: G 11/2
Condensate drain connection: 10 mm O.D. Tube
Lifting points: 4, located on baseframe
Delivery air pressure: minimum 5·0 bar
maximum Refer to Compressor data plate
Delivery air temperature (continuous operation): Typically 10°C above water inlet
Ambient temperature: minimum 0°C
maximum 40°C
Cooling water inlet temperature, maximum: 45°C
Cooling water outlet temperature: Typically 11°C above inlet temperature
Cooling water inlet pressure, maximum: 7·0 bar
Average Sound Level (±3) at 1m 504/604 75 dB(A)
(CAGI PNEUROP) 505/605 76 dB(A)
506/606 77 dB(A)
507/607 78 dB(A)
508/608 79 dB(A)
Main drive motor, nominal rating kW: 604–07W 55
504–08W/604–10W/605–07W 75
504–10W/505–08W/605–10W/606–07W 90
505–10W/506–08W/606–10W/607–07W 110
506–10W/507–08W 130
507–10W/508–08W/607–10W/608–07W 150
508–10W/606–10W 185
page 24
Oil Free Screw User Manual – Leading Particulars
Main drive motor rotation: Anti-clockwise viewed from non-drive end

Fan motor power, kW: 1·5
Fan motor rotation: Anti-clockwise viewed from non-drive end
Oil pump motor power, kW: 1·5
Oil pump motor rotation: Anti-clockwise viewed from non-drive end
Approximate Total power input, kW: 504–08/10W 82/94
505–08/10W 102/113
506–08/10W 123/139
507–08/10W 145/160
508–08/10W 160/178
604–07/10W 65/75
605–07/10W 87/101
606–07/10W 107/123
607–07/10W 129/148
608–07/10W 160/183
Approximate gross weight, kg: 604–07W 1923

(with IP22 motor) 504–08W/604–10W/605–07W 1963
504–10W/505–08W/605–10W/606–07W 2153
505–10W/506–08W/606–10W/607–07W 2233
506–10W/507–08W 2393
507–10W/508–08W/607–10W/608–07W 2393
508–10W/606–10W 2450
Approx. weight of heaviest components (compressor air-ends/gearbox, all models), kg: 400
Motor weight, (with IP22 motor) kg: 604–07W 280
504–08W/604–10W/605–07W 320
504–10W/505–08W/605–10W/606–07W 510
505–10W/506–08W/606–10W/607–07W 590
506–10W/507–08W 750
507–10W/508–08W/607–10W/608–07W 750
508–10W/606–10W 805
Dimensions (approx.), L x W x H, mm: 2300 x 1500 x 1500
Approximate Machine Full Load Current
Machine Power Pressure Motor IP 50Hz

(kW) (bar) Rating 220V 400V
504 75 8 22 255A 141A

55 260A TBD
504/505 90 10·5/8 22 TBD 176A

55 300A TBD
page 25
CompAir
Approximate Machine Full Load Current (continued)

505/506 110 10·5/8 22 365A 202A

55 361A 200A
506/507 130 10·5/8 22 435A 241A

55 421A 233A
507/508 150 10·5/8 22 N/A 266A

55 N/A 265A
508 185 10·5 22 590A 325A

55 TBD TBD
Machine Power Pressure Motor IP 60Hz (NEMA Motors)

(HP) (psi) Rating 460V 575V
604 75 110 22 TBD TBD

55 TBD TBD
604/605 100 152/110 22 TBD TBD

55 TBD TBD
605/606 125 152/110 22 TBD TBD

55 TBD TBD
606/607 150 152/110 22 TBD TBD

55 TBD TBD
607/608 200 152/110 22 236A TBD

55 226A TBD
608 250 152 22 291A TBD

55 276A TBD
page 26
Oil Free Screw User Manual – Leading Particulars
MODELS 509–515 and 609–615

Air-end: Two-stage, oil-free screw
Cooling: Liquid-cooled
Oil capacity (approx.): 70 litres
Recommended oils: Fuchs Renolin AC68; Shell Turbo T68; Mobil Rarus 426
Esso Teresso 68; Castrol Perfecto T68
Note: Compressors are factory filled with Fuchs Renolin AC68
Air delivery connection: R4
Cooling water connection: G 11/2
Condensate drain connection: 10 mm O.D. tube
Lifting points: 4, located on baseframe
Delivery air pressure: minimum 5·0 bar
maximum Refer to Compressor data plate
Delivery air temperature (continuous operation): Typically 10°C above water inlet
Ambient temperature: minimum 0°C
maximum 40°C
Cooling water inlet temperature, maximum: 45°C
Cooling water outlet temperature: Typically 11°C above inlet temperature
Cooling water inlet pressure, maximum: 4.9 bar
Average Sound Level (±3) at 1m 509/609 77 dB(A)
(CAGI PNEUROP) 510/610 78 dB(A)
512/612 79 dB(A)
515/615 80 dB(A)
Main drive motor, nominal rating kW: 509–08W/609–07W 150
509–10W/510–08W/609–10W610–10W 185
510–10W/512–08W/610–10W/612–07W 220
512–10W/515–08/612–10W 260
515–09W/615–09W 300
Main drive motor rotation: Anti-clockwise viewed from non-drive end
Fan motor power, kW: 1·5
Fan motor rotation: Anti-clockwise viewed from non-drive end
Oil pump motor power, kW: 1·5
Oil pump motor rotation: Anti-clockwise viewed from non-drive end
Approximate Total power input, kW: 509–08W/609–08W 162
509–10W/609–10W 190
510–09W/610–08W 207
510–10W/610–10W 226
512–09W/612–08W 241
512–10W/612–10W 255
515–08W/615–08W 288
515–09W/615–09W 320
page 27
CompAir
Approximate gross weight, kg: 509–08W/609–07W 3643

(with IP22 motor) 509–10W/510–08W/609–10W610–10W 3687
510–10W/512–08W/610–10W/612–07W 3799
512–10W/515–08/612–10W 3899
515–09W/615–09W 4294
Approx. weight of heaviest components (compressor air-ends/gearbox, all models), kg: 740
Motor weight, (with IP22 motor) kg: 509–08W/609–07W 750
509–10W/510–08W/609–10W610–10W 794
510–10W/512–08W/610–10W/612–07W 906
512–10W/515–08/612–10W 1005
515–09W/615–09W 1400
Dimensions (approx.), L x W x H, mm: IP22 motor 2600 x 1900 x 1840

IP55 motor 3200 x 1900 x 1840
Approximate Machine Full Load Current

509 150 8 22 TBD 266A
55 TBD 265A
509/510 185 10·5/9 22 590A 325A
55 TBD TBD
510/512 220 10·5/9 22 TBD TBD
55 TBD TBD
512/515 260 10·5/8 22 TBD TBD
55 TBD T BD
515 300 9·3 22 N/A 546A
55 N/A 504A
Machine Power Pressure Motor IP 60Hz (NEMA Motors)

(HP) (psi) Rating 460V 575V
609 200 116 ODP 236A TBD
TEFV 226A TBD
609/610 250 152/116 OPD 291A TBD
TEFV 276A TBD
610/612 300 152/116 OPD 336A TBD
TEFV 329A TBD
612/615 350 152/116 OPD TBD TBD
TEFV TBD TBD
615 400 135 OPD TBD TBD
TEFV TBD TBD
page 28
4
INSTALLATION
Page
Guidelines 30
Installation Procedure 31
Storage Procedures 32
Attention Required During Long-term Storage 32
Attention Required During Short-term Storage 33
Preparation for Storage for up to Twelve Months 33
Procedure with Power Connected to Compressor 34
Procedure with Compressor Disconnected from Power 34
page 29
CompAir
INSTALLATION
! WARNING
● Refer to the safety procedures before ● Lethal voltages are used in this equipment.
installation of the compressor unit. Use extreme caution when carrying out
electrical checks. Isolate the power supply
before starting any maintenance work.
1. GUIDELINES 4. Cooling water inlet and outlet pipes.
The compressor unit is supplied as a complete Note: Isolating valves should be installed on both
package and does not require securing to a the inlet and outlet cooling water pipes. The water
foundation. However, the supporting floor must inlet pipe should also incorporate a flow indicator. If
have a loading capacity sufficient to support the the quality of the cooling water is in doubt it should
weight of the unit (see ‘Leading Particulars’). be treated to prevent corrosion and scale
formation. Recirculating systems should be
In operation the unit will release heat into the protected against freezing, where necessary, by
surroundings. The compressor room should using a proprietary anti-freeze with inhibitors.
therefore be of adequate size and have good
ventilation. The recommended minimum size of If the compressor is to be coupled in parallel with
room is 50 m3. The inlet and outlet ventilation another compressor or connected to an existing air
openings should each have a minimum area of supply system, additional steps must be taken as
0·5 m2. set out in the ‘Safety’ section of this manual.
The ventilation inlet opening should be positioned If the compressor is coupled to a header used by
as low down as possible. The outlet opening other compressors, ensure that condensate from
should be positioned as high up as possible, the header cannot flow back into the compressor.
preferably in the roof or ceiling.
If air usage fluctuates rapidly or if the volume of the
A minimum of 1·5 m headroom is recommended user’s pipework is less than 4·25 m3 for each unit, a
above the compressor and a minimum of 1 m receiver of appropriate capacity should be installed
clearance on all sides for air circulation and to give between the compressor and the user’s pipework.
access for servicing. Do not obstruct doorways,
passages or walkways. Compressor units are inhibited against the effects
of moisture before shipment. If all blanking covers
The recommended cooling water quality is detailed and protective tapes remain secure and
in Appendix 5. undamaged the effective life of this process is 12
months from the date shown on the test card with
Service connections are required as follows: the machine. Refer to Section 3, ‘Storage
Procedures’, for details of attention required during
1. Air delivery outlet to the user’s pipework. storage and for the procedure to be followed if the
storage period is longer than 12 months.
2. Electrical power supply: 3-phase plus earth.
3. Condensate drain to the user’s disposal

system.
page 30
Oil Free Screw User Manual – Installation
1 2 3 4 5
PI/97/116
8 7 6
1. Cooling Water Inlet 5. Air Delivery Pipe

2. Cooling Water Outlet 6. Aftercooler Condensate Discharge
3. Water Drain, Intercooler 7. Intercooler Condensate Discharge
4. Oil Drain 8. Oil Cooler Water Drain
BASEFRAME CONNECTIONS
To prevent lateral movement during shipment 2. INSTALLATION PROCEDURE

transportation fixings are fitted to the flexible
mountings supporting the motor and air-end. They The following procedure is a guide for installing a
are identified by red paint and must be removed standard compressor unit. For the installation of
after the unit has been finally positioned. They non-standard units or units fitted with optional
should be retained for future use in the event of the equipment refer to the local CompAir distributor.
compressor being re-sited.
1. The compressor package may be lifted by fork
Models 504 to 508 and 604 to 608 have flexible lift or a hoist with spreader bars and hooks or
mountings designed with restricted lateral slings attached to the lifting brackets fitted to
movement, in which case transportation fixings are the baseframe. Spreader bars or frames
not fitted. should be large enough to keep slings clear of
all parts of the unit and enclosure to prevent
damage.
2. Lower the unit into position, ensuring that the

weight is evenly supported. Remove the four
lifting brackets. Check that the baseframe is
level to within 3 mm. Use packing pieces
under the baseframe if necessary.
3. Remove the transportation fixings from the

motor/air-end flexible mountings.
page 31
CompAir
4. Remove all protective blanking covers and 3. STORAGE PROCEDURES

tapes.
5. Remove the starter compartment door.

! WARNING !
6. Remove the plain gland plates from the
baseframe and the starter compartment. Drill ● Refer to the safety procedures before
the plates to take the power cable and fit carrying out any work on the compressor
suitable plates and grommets. unit.
7. Ensure the power supply to the unit is taken

from a fused isolator, the switch is locked All compressors are inhibited against corrosion
‘OFF’ and fuses removed. Connect the supply before leaving the CompAir factory to give protection
in accordance with the electrical connection during transportation and storage before installation,
diagram. Use cables complying with the for a maximum of 12 months. Proper precautions
standards of the International Electrotechnical should be taken if the storage period is longer than
Commission (IEC) or of the Institution of 12 months.
Electrical Engineers (IEE) (latest edition) for
U.K. users. The cables must be correctly sized Similarly, any compressor taken out of service or put
for the total input kW of the plant and suitably into temporary storage must be protected against
protected and clamped. corrosion. The rate at which corrosion in storage
occurs will be more rapid in a humid climate than in
CAUTION: Do not connect the intercooler and dry conditions, making it impossible to recommend a
aftercooler condensate drain pipes together; the maximum safe storage time applicable to all cases.
discharge piping must fall to atmosphere via an
open top tundish. This section details the procedures to be followed in
preparing the compressor for storage and the
8. Connect both condensate drains to the user’s periodic attention required during the storage phase.
open tundish drainage system. The drainage It will be satisfactory for most storage situations.
piping should not exceed 3 metres length, and
should slope downwards at a rate of 1 in 20.
3.1 Attention Required During Long-
9. Connect the cooling water pipes to the Term Storage (up to 12 months)
baseframe connections, fitting an isolating
valve in each pipe. This procedure makes provision for circumstances
where a compressor is delivered to site and is not
10. Refit the starter compartment door. immediately installed, but stored. It should also be
followed if a compressor is to be put into long term
CAUTION: Install a full flow isolating shut-off valve storage after a period of operation.
(NOT a non-return valve) between the delivery pipe
flange and the user’s pipework but do not connect 1. The compressor should be stored in a dry
the flange permanently at this stage. The building, preferably heated, particularly during
connection must not be secured until the corrosion the winter months. If the ambient temperature is
inhibitor has been dispersed by the initial run at the likely to fall below 0°C, it is important that the
correct stage in the commissioning procedure. electronic controller is removed and stored
separately in a temperature above 0°C.
Mechanical stress due to excessive contraction
(slackening of flange bolts, etc.) should also be
monitored.
page 32
Oil Free Screw User Manual – Installation
2. In the case of a new compressor, inspect the If power and cooling water are disconnected, rotate
crate on arrival and ensure that there is no the drive coupling by hand at weekly intervals as
water in the packing, the base of the described in para 3.1 item 4.
compressor or the protective plastic covering. If
there is evidence of moisture, dry out any damp
areas and also ensure that the packing and 3.3 Preparation for Storage for up to Twelve
plastic covering is dry before replacing. Months (full inhibition procedure)
3. The shaft of the drive motor must be turned

manually at least once a week, to prevent the WARNING
bearings developing brinelling and/or sticking,
! !
particularly if the package is subject to vibration.
● The chemical solutions used in these
4. The motor shaft can be rotated by turning the procedures are slightly toxic. Ensure that
drive coupling which can be reached through there is adequate ventilation and that all
the opening in the drive coupling housing. The personnel involved wear protective
coupling should be turned by HAND, using the gloves and breathing filter masks and do
minimum of force, in an ANTI-CLOCKWISE not smoke while working. Observe full
direction (as viewed from the motor non-drive fire and safety precautions.
end). One and a quarter turns is sufficient.
5. If resistance is experienced, the coupling may

be freed by alternating the HAND torque 3.3.1 Inhibitor solution
between CLOCKWISE and ANTI-CLOCKWISE.
Then continue turning in an ANTI-CLOCKWISE Shell VPI 280 solution is used to protect the air
direction for one and a quarter turns. pipework.
6. If this is not effective and the coupling is still not For the solution, mix 64 gm of Shell VPI 280
free, contact the local CompAir distributor. (dicychlorohexyl ammonium nitrite) with
2 litres of acetone.
7. If the compressor is stored in conditions of high
humidity, renew the desiccant packs (500 gm Quantity required: 2 litres of solution
silica gel or equivalent) in the interstage per compressor.
moisture separator after 6 months.
Note: This inhibitor solution is not oil-based.
8. In the case of a new compressor, replace
protective covering. When using Shell VPI 280 agitate the solution
by shaking the spray can during application.
9. At the end of each 12 month storage period the
full inhibition procedure must be carried out.
3.3.2 Equipment Required:
3.2 Attention Required During Short-Term One spray gun with standard nozzle and baffle
Storage (up to one month) plate nozzle.
The compressor should be started and run for 10 to One plastic storage container.
15 minutes at least once each week. This
procedure applies to (a) a compressor which is Waterproof adhesive tape, as required.
shut down for a short period but remains connected
to power and coolant, and (b) a compressor which Plastic caps.
remains on ‘Standby’ duty in a multiple unit
installation.
page 33
CompAir
3.4 Procedure with Power Connected to likely to fall below freezing point, the water
Compressor circuit should be flushed through with a good,
standard automotive grade, anti-freeze
If the compressor has already been disconnected solution at the manufacturer’s recommended
from power, see para 3.5. strength.
1. Stop compressor. 15. When the water circuit is thoroughly drained

seal the water inlet and outlet connections,
2. Disconnect delivery pipework at baseframe preferably with plastic caps such as those
connection. fitted on the connections when the
compressor is shipped.
3. Remove inlet filter element.
16. Close manual water drain valves.
4. Re-start compressor.
17. Remove the inspection flange from the
5. LOAD the compressor. This will open the interstage moisture separator and thoroughly
suction regulator inlet valve. dry the separator internally with a clean,
moisture-absorbent swab or cloth.
6. While the compressor is running, spray Shell
VPI 280 solution through inlet silencer until it 18. Place approximately 500 gm. of desiccant
appears at the delivery connection. (e.g., silica gel) in packets or cloth bags in the
moisture separator.
7. UNLOAD the compressor.
19. Leave the flange attached to the separator by
8. Spray Shell VPI 280 solution into intake means of one of the lower flange bolts and
silencer for 10 seconds (approx. 10 ml). refit the other bolts loosely for safe keeping.
9. Stop compressor. 20. Seal off the inspection opening with waterproof
tape, ensuring that the seal is air-tight.
10. Spray Shell VPI 280 solution into delivery
connection for 10 seconds (approx. 10 ml). 21. Paint all bare metal and exposed machined
surfaces with one coat of Croda CS 1033A
11. Replace inlet filter mesh and seal with preservative.
waterproof tape.
After completion of this procedure the compressor
12. Seal air delivery connection with waterproof may be left in store for up to 12 months but should
tape. be inspected regularly as detailed in para 3.2
‘Attention required during long-term storage’.
13. Place the following warning statement on
instrument panel.
3.5 Procedure with Compressor Disconnected
CAUTION: Before Starting the Compressor:- from Power
(a) Remove desiccant bags from moisture
Use the same equipment and inhibitor as described
separator and replace flange.
in para 3.4.
(b) Remove waterproof sealing tape from air
intake filter and gearbox air filter. 1. Disconnect the delivery pipework at the
baseframe connection.
14. Shut off water supply, and drain water circuit.
If possible disconnect pipework from water 2. Remove the inlet filter element and silencer.
supply. If anti-freeze has not been used in the
cooling water and if ambient temperature is
page 34
3. Remove the first stage moisture separator top
flange complete with the air pressure safety
valve.
4. Disconnect the regulation air pipe at the

unloader solenoid valve and connect a low
pressure air line (2 bar max.) to the pipe.
Apply air pressure to open the inlet valve of
the suction regulator.
5. Rotate the compressor by turning the drive

coupling which can be reached through the
opening in the drive coupling housing. The
coupling should be turned BY HAND in an
ANTI-CLOCKWISE direction (as viewed from
the motor non-drive end).
6. While the shaft is being turned inhibit the first

stage air-end by spraying Shell VPI 280
solution through the inlet valve of the suction
regulator until it appears at the first stage
moisture separator top flange.
7. Continue turning the compressor shaft and

inhibit the second stage air-end by spraying
Shell VPI 280 solution into the first stage
moisture separator through the top flange
opening until it appears at the blowdown
silencer.
8. Disconnect the slave air line from the

regulation pipe to close the suction regulator
inlet valve and bleed off pressurized air.
9. Spray Shell VPI 280 solution into the first

stage moisture separator through the top
flange opening for one minute.
10. Refit the regulation air supply pipework at the

unloader solenoid valve.
11. Refit the silencer and first stage moisture

separator top flange.
Complete the procedure by carrying out items 10 to

21 of para 3.4.
Note: Storage procedures and attention to the

compressor during storage should comply with
‘Attention required during long-term storage (up to
12 months)’ in para 3.1.
page 35
CompAir
page 36
5
COMMISSIONING
Page
Commissioning Procedure 38
Preliminary Mechanical Checks 38
Entering the Access Code 39
System Checks and Calibration 39
Checking/Altering Commissioning Parameters 43
Checking/Altering Operating Parameters 45
Re-setting Service Interval Timer 46
Final Mechanical Checks 47
Commissioning Parameters (compressor running on-load) 49
Commissioning Checklist 51
page 37
CompAir
COMMISSIONING
! WARNING
commissioning the compressor unit. Use extreme caution when carrying out
1. COMMISSIONING PROCEDURE 9. Ensure phase rotation relay voltage

adjustment is set correctly for supply voltage.
When commissioning a new compressor or re-
commissioning a compressor which has been 10. Ensure fan motor and oil pump motor thermal
overhauled or out of service, carry out the overloads are set correctly for supply voltage.
following procedures before attempting to start:
Note: We recommend that commissioning is Motor 220V/ 400V/ 220V/ 460V/ 575V/
carried out by a CompAir distributor. 50Hz 50Hz 60Hz 60Hz 60Hz
Oil 6·3A 3·5A 6·3A 3·1A 2·5A

1.1 Preliminary Mechanical Checks Pump
Canopy 5·7A 3·3A 6·1A 2·9A 2·3A
1. Remove air filter covers and silica gel bags.
Fan
2. Check that the isolator switch is locked ‘OFF’ MMS 12A 6·8A 12·4A 6·0A 4·8A
and that all pipework and electrical power (Q101)
connections are correct and secure.
3. Open the access panel to the starter 11. Remove panels as required to gain access to
compartment. Check all screws and starter motor connections.
connections for security. Check all electrical
connections are correct and secure. 12. Inspect the motor and control wiring
connections to make sure they are correct
4. Ensure the controller to Extension module unit and secure. Replace all panels.
interface cable connections are correct and
secure. 13. Check that all protection blanks, air filter
covers and tapes have been removed.
5. Ensure the main supply cables and fuse
ratings comply with regulations. 14. Remove the four air-end/motor transportation
bolts (if fitted). These are coloured red for
6. Ensure the control transformer primary identification.
tapping connections are correct for supply
voltage. 15. Open the isolating valve to the user’s
pipework.
7. Ensure main motor thermal overload is set
correctly for motor F.L.C. and supply voltage, 16. Check that the air end and motor rotate freely.
as shown on the motor data plate.
17. Check oil level and top up if required.
8. Ensure MCB Q101 (MMS) is set correctly.
page 38
Oil Free Screw User Manual – Commissioning
1.2 Entering the Access Code Note: A guide to using the menu routines and
control unit menu structure diagrams is shown in
When an attempt to alter a parameter or Section 6 – Operation
option is made for the first time after entering
the menu routines, the controller will request
an access code. When this occurs the
following procedure should be followed.
Press SPANNER, CLOCK, SPANNER,

CLOCK symbols
1.3 System Checks and Calibration
Note: The values shown throughout these procedures are examples only.
No. Action Reason Display
1. Switch power supply ‘ON’. C20619/nn/xx/nn

SF3LFnnUN ddmmmyy
Note: The POWER ON

indicator lights.
The REMOTE and AUTO

RESTART indicators will
light if these facilities
have been selected in the
installation procedure.
After several seconds the

status display changes
to:
Ready to start
Oil temperature 20°C
Note: If ‘Rotation fault’ is

displayed, isolate the
power and change over
any two of the 3 phase
incoming supply cable
connections.
2. Press ENTER. To display the main Main menu

menu. Operational settings
3. Press DOWN until To scroll through the Main menu

the message shown on the menu options. Commissioning - config.
right is displayed.
page 39
CompAir
4. Press ENTER. To choose the Commissioning - config.

Commissioning - Language English
configuration menu.
5. Press (+) or (-) and repeat To select the Commissioning - config.

until the required displayed language. Language Option
language is displayed.
(Pulsing display)
6. Press ENTER. To confirm the displayed Commissioning - config.

language. Language Option
(Steady display)
7. Press DOWN and repeat To select the Commissioning - config.

until the display required option. Return to previous menu
shown on the right is
obtained.
8. Press ENTER. To display the main menu. Main menu

Operational settings
9. Press DOWN and repeat To scroll through the Main menu

until the option menu. Service diagnostics
shown on the right
is displayed.
10. Press ENTER. To choose the Service diagnostics

Service diagnostics Reset service hours
menu.
11. Press DOWN and repeat To scroll to the Service diagnostics

until the option shown on required option. Test digital outputs
the right is displayed.
12. Press ENTER. To choose the Test digital outputs

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

fan and oil pump. Fan contactor 1
15. Check that air To check the direction

is being expelled of rotation of the fan.
from the enclosure
fan exhaust.
page 40
16. Check that oil To check the direction

pressure rises. of rotation of the oil
pump.
17. Press (-). To turn off the Test digital outputs

Fan/oil pump. Fan contactor 0
18. If the fan or oil pump rotation To reverse rotation.

is incorrect, switch power
‘OFF’ and change any two
Incoming Power Supply cables.
Switch power ‘ON’ and return
to step 8.
19. Press UP and To scroll to Test digital outputs

repeat until the option option required. Return to previous menu
shown on the right
is displayed.
20. Press ENTER. To return to the Service diagnostics

service diagnostics Reset service hours
menu.
21. Press DOWN once To choose the Set pressure at 0 bar

then ENTER. calibrate pressure Press enter when ready
menu.
22. If the zero pressure To by-pass the first

display is known to be part of the calibration
correct then press DOWN procedure.
and go to step 25.
23. Disconnect the air To ensure zero Set pressure at 0 bar

connection to the delivery pressure on the Press enter when ready
pressure transmitter. transmitter.
24. Press ENTER. To set the zero pressure Set pressure > 5.51bar
measurement in the
controller.
25. Connect a slave To establish a known Adjust +/- :- 6.9bar

air supply of more calibration pressure. Press enter when ready
than 5.51 bar to
the delivery pressure Note: If the air
transmitter. pressure is not above
5.51 bar the message
shown in step 24 is
displayed.
page 41
CompAir
26. If the slave air supply is not The alternative

constant then press UP or calibration procedure
DOWN to enter the alternative is more suitable for
calibration routine and go use with an unstable
to step 30. reference pressure.
27. Press (+) or (-) as To adjust the LCD Adjust +/- :- 7.0bar
required to adjust the display reading to Press enter when ready
value shown on the match the slave
display. air gauge. (Pulsing display)
28. When the gauge and To store the pressure Commissioning - config.
display pressures are calibration value in
equal press ENTER. the controller. (After a delay the display
reverts to:)
Service diagnostics
Reset service hours
29. Go to step 31 To by-pass the alter-

native calibration
procedure.
30. Press UP or DOWN as To adjust the control Adjust pressure up/down

required to make panel display. Press enter when ready
the LED display
follow the slave
gauge display.
31. When the gauge To calibrate the Calibration complete

and display track pressure display.
the pressure
together (After a delay the
Press ENTER. display returns to:)
Service diagnostics
Reset service hours
32. Press RESET. To exit menu Ready to start

routine. Oil temperature 20°C
33. Re-connect the air line

to the delivery pressure
transmitter.
page 42
1.4 Checking/Altering Commissioning Parameters
Refer to the Control Unit Menu Structure diagrams and check/set the commissioning parameters
1. Press ENTER. To display the Main menu.

Main menu. Operational settings.
2. Press DOWN and repeat To display the Main menu.

until the display Commissioning - config Commissioning - config.
shown on the right menu.
is obtained.
3. Press ENTER. To choose the Commissioning - config.

Commissioning - config Language English
menu.
4. Press DOWN. To display the next Commissioning - config.

option. Unit of pressure bar

option. Unit of temperature °C

option. (On multi unit Compressor number 1
installations).
7. Press ENTER. To display the Main menu. Main menu.

Operational settings.
8. Press DOWN and repeat To scroll through Main menu.

until the display the menu options. Commissioning - values.
shown on the right
is displayed.
9. Press ENTER. To select the commissioning Commissioning - values

values menu. Max. pressure 7.0bar
10. Press DOWN. To choose the Commissioning - values

next option. Max. overpress 7.5bar

next option. Star/delta time 15sec

next option. Load delay time 2sec
page 43
CompAir

next option. Max. service hours4000

next option. Auto-restart delay 10sec

next option. Interstage trip 3.5bar

next option. Interstage alarm 3.0bar

next option. Oil temp trip 70°C

next option. Oil temp alarm 65°C

next option. St1 delivery trip 210°C

next option. St1 delivery alarm 200°C

next option. St2 intake trip 55°C

next option. St2 intake alarm 50°C

next option. St2 delivery trip 220°C

next option. St2 delivery alarm 210°C

next option. Plant del trip 70°C

next option. Plant del alarm 60°C

next option. Water in trip 45°C

next option. Water in alarm 40°C

next option. Water out trip 75°C
page 44

next option. Water out alarm 70°C
31. Press RESET. To exit menu routines. Ready to start.

Oil temperature 20°C.
1.5 Checking/Altering Operating Parameters
1. Press ENTER. To display main menu. Main menu.

2. Press DOWN and repeat To scroll through the Main menu

until the display main menu. Operational settings
shown on the right
is obtained.
3. Press ENTER. To display the Operational settings

Operational settings P1 set point 7.0bar
menu.
4. Press DOWN. To choose the Operational settings

next option. P2 set point 7.3bar
5 Press DOWN. To choose the Operational settings

next option. Run on time 10min
next option. Drain open time 5sec

next option. Drain shut time 30sec
8. Press RESET. To exit the menu Ready to start

routines. Oil temperature 20°C
page 45
CompAir
1.6 Re-setting Service Interval Timer
1. Press ENTER. To display the Main menu.

Main menu. Operational settings
2. Press DOWN and repeat To scroll through the Main menu.

until the display menu. Service diagnostics
shown on the right
is obtained.
3. Press ENTER. To display the Service diagnostics

service diagnostics Reset service hours
menu.
4. Press ENTER. To reset the service Service diagnostics

hours countdown Service hours to run4000
timer to maximum
programmed hours. (After a delay, changing
to:)
Service diagnostics
Reset service hours
5. Press RESET. To exit the menu Ready to start

routines. Oil temperature 20°C
page 46
1.7 Final Mechanical Checks
Notes:
1. The values shown throughout these procedures are examples only.
2. Ensure that the air discharge pipe is disconnected from the user’s system.
3. Ensure that the discharge air is directed away from all persons in the area.
1. Open the water stop valve

in the water inlet pipe.
Turn on the water supply.
2. Switch power C20619/nn/UN/xx

supply ‘ON’. SF3LFnnUN ddmmmyy
3. After a few seconds Ready to start

the display becomes: Oil temperature 20°C
4. Press START. To start the compressor. Starting

5. If the compressor The compressor will

does NOT start not start if:
a message should be
displayed. (a) A menu routine has Menu selected
been selected. Menu option displayed
(b) Remote operation Ready to start
has been enabled. Remote start enabled
(c) A trip fault Status
condition exists. Fault message
(See fault rectification.)
6. If electrical work
has to be carried
out switch power to
the compressor ‘OFF’.
Establish the correct
starting conditions.
Go to step 2.
7. Following start-up Offload

of the motor the Oil temperature 20°C
display becomes:
8. Provided the delivery Onload

pressure is below Oil temperature 20°C
the P2 set point
the compressor loads and
the display becomes:
page 47
CompAir
9. Run the compressor To disperse corrosion

for 10 minutes. inhibitor from the
system.
10. Press STOP. To stop the compressor Ready to start

for connection to the Oil temperature 20°C
air system.
11. Check that the blowdown

valve has released
all pressure from the
compressor.
12. Connect the compressor

delivery flange to
the user’s pipework
via an isolating
shut-off valve.
Ensure that the valve
is fully open.
13. Press START. To operate the (See the displays in

compressor to check steps 4 to 10).
operating conditions
and parameters.
WARNING: RISK OF HIGH

! PRESSURE
Do not use hands to

locate leaks in the
system. Always use a
piece of paper or
card for this purpose.
14. Examine compressor

pipework for oil, water
or air leaks. If a leak is
found, stop the compressor,
rectify the fault
and go to step 4.
15. Simulate a constant To provide a normal

air demand by opening operating air demand.
a valve in the user’s
pipework.
16. Check that the compressor

loads and unloads at the
selected P1 and P2
pressure set points.
page 48
17. Run the compressor under To achieve stable

these conditions for operating conditions.
an hour.
18. Fully open water flow control To achieve full water flow.
valves.
19. Adjust intercooler flow valve. To adjust Stage 2 inlet temp

to 10°C above ambient or
between 35°C and 45°C.
Note: It may be necessary

to adjust the water flow through
the aftercooler, oil cooler and water
jackets to achieve the required
temperature.
20. Examine all pipework

again for oil, air or water
leaks.
21. Check operation of automatic

condensate drains.
22. Press STOP. Switch

power to the compressor
‘OFF’ at the isolator.
Allow several minutes for
the oil to settle.
Top up the oil level
if necessary.
23. Replace all covers and

panels.
24. Record all setpoints and

operating parameters from the
‘Operational settings’,
‘Commissioning Config’ and
‘Commissioning values’ sub-menus
for future reference.
page 49
CompAir
1.8 Commissioning Parameters (compressor running on-load)
First stage delivery 150°C to 185°C
Second stage intake 35°C to 45°C
Second stage delivery 155°C to 190°C
Lubricating oil 40°C to 50°C
Water inlet 10°C to 20°C
Water outlet 20°C to 35°C
Water differential 10°C to 15°C
Oil Pressure 2 bar approximately
Stage 1 Air Delivery 1.8–2.8 bar (Depending

on model)
Note: The temperature guidelines are for compressors working in an ambient temperature of approximately
20°C and cooling water inlet temperature of 15°C with the correct water flow.
In higher ambient temperatures, higher cooling water inlet temperatures and/or low water flow conditions the
temperatures given may be higher. In this case the temperature alarm and trip levels may need to be raised.
page 50
2. COMMISSIONING CHECK LIST 19. Drain open time set. ............
1. Pipework. ............ 20. Drain shut time set. ............
2. Cable, fuse ratings OK ............ 21. Maximum compressor pressure set. ............
3. Control transformer input voltage 22. Maximum overpressure set. ............

set correctly. ............
23. All temperature and pressure
4. Main motor, fan motor, oil pump trip limits set ............
motor overloads and
MCB Q102 set correctly. ............ 24. All temperature and pressure
alarm limits set. ............
5. Phase rotation relay voltage set. ............
25. Star/delta time set. ............
6. Starter connections OK. ............
26. Load delay time set. ............
7. Motor connections OK. ............
27. Reset service hours timer. ............
8. Protection blanks and tapes. ............
28 . Starting sequence correct. ............
9. Fill compressor with oil. ............
29. Compressor blows down OK. ............
10. Air end and motor freely rotate. ............
30. Corrosion inhibitor dispersed. ............
11. Select language. ............
31. Connected to user’s pipework. ............
12. Fan/Oil pump rotation OK. ............
32. Oil, air and water leaks check. ............
13. Main Motor rotation OK. ............
33. Compressor loads, unloads,
14. Pressure transducer calibrated. ............ stands by and stops correctly. ............
15. Display units set. ............ 34. Emergency stop correct. ............
16. Compressor number set. (if comms 35. Temperatures and pressures in limits.............
facility available/fitted) ............
36. Oil level topped up. ............
17. Pressure control set points set. ............
37. All parameters recorded from
18. Run-on time set. ............ controller menu routines. ............
page 51
CompAir
page 52
6
OPERATION
Page
Routine Operation 54
Starting 54
Pressure Control 55
Displaying the Number of Hours Run 55
Changing the Displayed Value 56
Stopping 56
Emergency Stopping 56
Condensate Drain Operation 56
Service Interval Timer 56
Warnings 57
Shutdowns 57
Fault History Recall 57
Standby Operations 58
Using the Menu Routines 58
Default Values 66
Glossary of Display Messages 66

Operator Advice Messages 66
Shutdowns 66
Warnings 69
Service Messages 70
Status Messages 70
page 53
CompAir
OPERATION
! WARNING
operating the compressor unit. Use extreme caution when carrying out
Note 1: If the compressor has been out of Note: Oil temperature is used as an example
operation for a prolonged period it is advisable to only. Actual display can be any of the
check performance and all regulation functions by displayed values in para 1.4.
carrying out the full commissioning procedure
before starting. See ‘Fault Messages’ for possible start-up
faults. If a fault exists and a repair is
necessary, power to the compressor must be
1. ROUTINE OPERATION (Refer to Control Panel isolated and the fault rectified.
diagram in Chapter 2, ‘General Description’)
If the reset indicator is lit, RESET must be
Note: The temperatures and pressures given in pressed following rectification of the fault,
the procedures are shown as examples only. before the compressor will start.
4. To start the compressor press START (4).

1.1 Starting Provided pressure at the delivery point is
below P2 set point the compressor will start. It
1. Start the cooling water flow to the compressor will otherwise enter Standby mode.
and to the energy saver pack (if fitted).
The oil pump, fan and water solenoid will
2. Switch mains power to the compressor ‘ON’ energise but the main motor will not start until
at the isolator. The front panel is now in the the oil pressure has reached its set point. The
following state. compressor will not start if:
a) The POWER ON indicator (22) is lit. a) Certain menu routines are in use.
b) The status display (5) shows: b) The remote starting facility has been
enabled. In this instance the display
C20627/nn/xx/nn panel REMOTE CONTROL indicator (20)
will be lit and the display will show:
SF3LFnnUN_ddmmmyy
Unable to start
c) Either or both the REMOTE (20) and
AUTO RESTART (21) indicators are lit if Remote start enabled
these facilities have been selected. See
also ‘Remote Control’ and ‘Automatic 5. During the initial starting period, the drive
Restart’ in Appendix 1, Remote Options. motor starts in Star connection and the status
display will show:
3. After a few seconds, provided no fault exists,
the status display will show: Starting
Ready to start
page 54
Oil Free Screw User Manual – Operation
6. Following the motor Star/Delta switch-over 2. If the compressor is off-load for longer than
and during the subsequent load delay period, the ‘Run-on Time’, the compressor will stop
the status display will show: and the status display will change to:
Offload Stopping
Oil temperature 20°C Oil temperature 40°C
7. Provided the delivery pressure is below the 3. After the stopping period the display will
lower set point (P2) the compressor runs on change to:
load.
Standby
Onload
Note: If the START button is pressed whilst the
8. Fault conditions and service requirements are compressor is stopping the display changes to
continuously monitored (from start-up) and ‘Standby’ immediately.
warning and the appropriate status messages
are displayed. 4. When air demand lowers the pressure below
the lower set point P2 the compressor will
9. To interrogate other temperature or interstage restart and run on-load. The display will show:
pressure information press VALUE (see para
2, Using The Menu Routines). Starting
10. To interrogate the hours run and service
hours information press HOURS. (see para 2, changing to:
Using The Menu Routines).
Offload
11. To show operating parameters, fault history, Oil temperature 20°C
etc. or to alter programmed settings, press
during load delay time, then:
ENTER (10) to access the menu routine (see
para 2, Using The Menu Routines). On load
1.2 Pressure Control
1.3 Displaying the Number of Hours Run.
1. The compressor will unload and load in
response to varying air demand when the
1. The HOURS button (30) is used to display the
upper and lower set points P1 and P2 are
hours run by the compressor and the hours to
reached. When the compressor goes off-load
run before a service is due.
the system blows down. The controller loads
and unloads the compressor by fully opening
2. Successive presses of the HOURS button
or fully closing the suction regulator inlet
give the following display sequence:
valve. The display alternates, as appropriate,
between:
Total hours 1000
Offload Hours on load 800
Oil temperature 45°C Service hrs to run 3000
and
3. The display will cancel itself after a short
Onload period or it can be cancelled immediately by
pressing RESET.
page 55
CompAir
1.4 Changing the Displayed Value 1.6 Emergency Stopping
1. TheVALUE button (33) is used to step through 1. When the EMERGENCY STOP (17) is
the compressor operating temperatures and pressed, the compressor will stop
interstage pressure displays. immediately and the system will blow down.
2. Successive presses of the VALUE button give 2. The RESET indicator will pulse and the
the following display sequence. display will show:
Oil temperature 45°C Fault shut down

St1 Delivery temp 160°C Emergency stop
St2 Intake temp 40°C
Note: The emergency stop button should be used
St2 Delivery temp 165°C only in a genuine emergency and must not be
used as the normal method of stopping the
Plant delivery temp 35°C
compressor.
Water in temp 20°C
Water out temp 31°C
1.7 Condensate Drain Operation
Water temp diff 11°C
When running on-load the intercooler and
Interstage press 2.0 bar
aftercooler condensate drains will operate
according to the programmed drain shut and drain
3. The selected value will remain on the display
open times. The drain will open and the timer cycle
until a new value is selected.
will begin every time the compressor loads.
When the compressor is in ‘off-load’, ‘standby’ or

1.5 Stopping
‘ready to start’, the drains will continue to operate
with a two second ‘open’ time and an extended
1. To stop the compressor press STOP (36).
‘shut’ time. This prevents any build-up of
This initiates a controlled shut down
condensate when the compressor is stopped or
sequence. The main motor will continue to
running ‘off-load’.
run for 8 seconds and the display will briefly
show:
1.8 Service Interval Timer
Offload
Oil temperature 45°C 1. The control system uses a count-down timer
which can be reset to programmed maximum
changing to:
each time a service is carried out. The
Stopping maximum service hours can be adjusted to
suit site conditions and/or service schedule
requirements.
The oil pump motor, enclosure cooling fan
When the timer reaches zero hours a service
and the water solenoid will remain energised
due advice message is displayed. When the
for 30 seconds after the main motor has
service has been completed, the reset service
stopped.
hours function should be selected from the
service diagnostics sub-menu and the service
2. After the 30 second cooling down period the
advice message reset.
display will change to:
Ready to start
page 56
2. When the compressor has reached the 4. The occurrence of another warning after any
running hours at which a service is required, previous warning has been acknowledged will
the SERVICE indicator (35) will flash. If again cause the SERVICE indicator to flash
SERVICE (34) is now pressed the SERVICE continuously and the mimic diagram indicator
indicator (35) will stop flashing and remain lit. appropriate to the second fault will also light.
The RESET indicator (32) will then flash
continuously and the status display will show 5. It may not be convenient to respond to a
the service advice message below: warning immediately. In this case press
RESET to cancel the flashing service
Onload indicator and to restore the status and
selected value displays. The mimic diagram
Service due
indicator will remain lit to indicate that
attention is required.
3. The compressor must be stopped and
isolated to carry out the required service (see
‘Safety Procedures’). On completion of the
1.10 Shutdowns
service the ‘service hrs to run’ value must be
reset to maximum by using the Service
1. If a shutdown occurs, the compressor will
Diagnostics menu routine.
stop. This can occur at any time after the
compressor has been started.
4. It may not be convenient to respond to the
service due message immediately. In this
Both RESET and the appropriate mimic
case press RESET (31) to cancel the flashing
diagram indicator will flash continuously and
RESET indicator and restore the status and
the SERVICE indicator will light. If the menu
selected value display. The service indicator
routine is in use when a shutdown occurs the
will remain lit to indicate that a service is
appropriate panel and mimic diagram
required.
indicators will light and flash as normal. The
current message will not be overwritten until
RESET is pressed or the display reverts to
1.9 Warnings
the fault message after a period of time.
1. If a service is required, the SERVICE indicator
2. The display will show:
(35) and the appropriate mimic diagram
indicator will flash continuously. If SERVICE
Fault shutdown
(34) is pressed the SERVICE indicator will
stop flashing and stay lit in acknowledgement. (Relevant shutdown message) See Display
The RESET indicator (32) will flash messages
continuously and the display will show the
required action (e.g. an air filter change) as
below: 1.11 Fault History Recall
Onload Selecting ‘Fault History Recall’ on the Main Menu

will show the compressor status at the last fault.
Change Air filter
The following parameters can be displayed
showing the conditions at the last fault.
2. Pressing SERVICE repeatedly during this
period will recall any earlier stored warnings
The fault history will retain the last 15 faults.
in chronological order (most recent first) that
have not been corrected and reset.
3. When pressing SERVICE is discontinued, the

fault/service display will be shown for several
seconds after which it reverts to the selected
value display message.
page 57
CompAir
Fault History Message Meaning
Hours run 1000 Hours run at time of fault.

Onload, Offload, Standby, Ready to start etc. State of compressor at time of fault.
Delivery Press 7.0 bar Delivery Pressure at time of fault.
Interstage press 2.0 bar Interstage pressure at time of fault.
Oil temperature 45°C Oil temperature at time of fault.
St1 delivery temp 160°C Stage 1 delivery temperature at time of fault.
St2 intake temp 40°C Stage 2 intake temperature at time of fault.
St2 delivery temp 165°C Stage 2 delivery temperature at time of fault.
Plant delivery temp 30°C Plant delivery temperature at time of fault.
Water in temp 20°C Water inlet temperature at time of fault.
Water out temp 31°C Water outlet temperature at time of fault.
1.12 Stand-by Operations With the mains power on and ENTER pressed, the
text display on the control panel will show two lines
A compressor on stand-by duty must be started of text. The top line indicates the menu in use and
and run for 10 minutes per week. the bottom line the parameters in use.
If the user’s air usage is insufficient to allow the The diagrams at the end of this section show the
compressor to run for 10 minutes the compressor sequence of messages available and the buttons
should be run Off-load as follows: to press to obtain the required message.
1. Ensure the Run On time on the controller is In the diagrams the solid line boxes represent the
set to 10 minutes. message window and the broken line boxes are
reader information or instructions.
2. At the remote inputs, ensure Remote Load
Input is open, then close the Remote Load Notes for use with SureScan menu diagrams
Enable.
1. Show program variant – Displays a reference
3. If the compressor is not already in standby, number for the controller program variant, for
start the compressor which will then go into reference only. Press Return to return to
stand by. main menu.
4. Momentarily close the Remote Load input. 2. Test digital inputs – Test routine for each
The compressor will start . individual input. Input cards test routine.
Note: Ensure that the Remote Load input is 3. Test analogue inputs – Test routine for
opened before the delta contact is closed or the pressure and temperature inputs.
compressor may load. Preconditioner card PT1000 conditioner units
and pressure transmitters test routine.
5. Open the Remote Load Enable to put control
back to the transducer. 4. Test keypad – Keypad test routine. Each key
pressed will be displayed to establish
6. The compressor will now run for the time set. operation. Press RESET to exit routine.
5. Test Display – Control panel LED, LCD and

2. USING THE MENU ROUTINES indicator test. When selected all LED’s and
indicators will light and all LCD text display
The menu routines are used to access, view and/ elements will turn on for 15 seconds. The
or alter the operating parameters and options routine will self cancel.
stored in the memory of the controller.
page 58
Status Message
Main Menu Go to 2 of 7
St1 delivery temp 160°C Total hours 1000
St1 intake temp 40°C Hours on load 800
When first attempt is made to adjust

any value, the prompt will appear:
St2 delivery temp 165°C Service hrs to run 3000
Enter code: ????

Plant del temp 35°C
Water in temp 20°C Water temp diff 20°C
To continue
Water out temp 20°C Interstage press 2.0bar

Press at any time in any
menu to return to initial display
PI/97/094
SURESCAN CONTROL UNIT MENU STRUCTURE (1 OF 7)
page 59
From 1 of 7
page 60
CompAir
Main Menu
Operational settings
Go to 3 of 7
Fault history recall

Fault history recall 1 Fault message
Fault message Status Message
Service diagnostics
Go to 3 of 7
Fault history recall 2 Total hours 1000 St2 intake temp 45°C
Fault message
Commissioning - config
Go to 6 of 7
Pressure 7.0bar St2 delivery temp 165°C
Commissioning - values
Go to 7 of 7
Interstage Press 2.0bar Plant del temp 30°C
Show program variant

Fault history recall 25
See note 1
Fault message Oil temperature 45°C Water in temp 20°C
Return to previous menu
Fault history recall 0 St1 delivery temp 160°C Water out temp 31°C
PI/97/095

Operational settings Service diagnostics
P1 setpoint 7.5bar P1 set point 8.1bar Reset service hours Service hours to run 4000 2 sec
P2 setpoint 6.9bar P2 set point 7.2bar Calibrate pressure

Go to 4 of 7
Run on time 15min Run on time 20min Test digital outputs

Go to 5 of 7
Drain open time 25sec Drain open time 15sec Test digital inputs
See Note 2
Drain shut time 125sec Drain shut time 200sec Test analogue inputs
See Note 3
Return to previous menu Test keypad

See Note 4
Test display
See Note 5
PI/97/096

page 61
page 62
CompAir
From 3 of 7 Main Program Number

Set pressure at 0bar
Name & Date
Press enter when ready
Extension Module Prog No.

Disconnect delivery pipe from
pressure transmitter Name & Date
Set pressure > 5.51bar

Connect known air pressure supply

to delivery pressure transmitter
Adjust +/-: 5.6bar Adjust until display shows

Press enter when ready correct pressure
Adjust pressure up/down Adjust until display tracks Calibration complete 2 sec
Press enter when ready pressure variations correctly
PI/97/097
SURESCAN CONTROL UNIT MENU STRUCTURE (4 of 7)

From 3 of 7 Test digital outputs
Main contactor 0 Available 0 Remote fault 3 0 Remote fault 3 1
Star contactor 0 Group fault 0 Remote fault 4 0
For each parameter
Delta contactor 0 Running 0 Remote fault 5 0
0 indicates not energised

1 indicates energised
Unloader solenoid 0 On load 0 Extension XO6/7 0
Drain solenoids 0 Group trip 0 Return to previous menu
Fan contactor 0 Service due 0
Remote control lamp 0 Remote fault 1 0
Auto restart lamp 0 Remote fault 2 0
PI/97/098

page 63
page 64
CompAir
From 1 of 7 Commissioning-Config
Language: English Language: Option
Unit of pressure bar Unit of pressure psi
Unit of temperature °C Unit of temperature °F
Compressor number 1 Compressor number 10

Trip type 3
Fault input config

Fault input config
Alarm type 1
Remote fault 1
Remote fault 1
Return to previous menu Disabled
Alarm type 2
Remote fault 2
Trip type 1
Alarm type 3
Remote fault 5
Trip type 2
Start inhibit
PI/97/099

From 1 of 7 Commissioning-Values
Max. pressure 10.5bar Oil temp trip 75°C Plant del trip 55°C Plant del trip 45°C
Max. overpress 10.6bar Oil temp alarm 70°C Plant del alarm 40°C
For each parameter
Star/delta time 25sec St1 delivery trip 200°C Water in trip 30°C
Load delay time 60sec St1 delivery alarm 180°C Water in alarm 27°C
Max. service hrs 4000 St2 intake trip 65°C Water out trip 65°C
Autorestart delay 100sec St2 intake alarm 60°C Water out alarm 55°C
Interstage trip 4.0bar St2 delivery trip 200°C Load default values Default values loaded 2 sec
Interstage alarm 3.8bar St2 delivery alarm 180°C Return to previous menu
PI/97/100

page 65
CompAir
3. DEFAULT VALUES 3. The compressor may be re-programmed with

different values at any time, and the controller
1. Default values for a number of the operational settings may be restored to the default values,
settings are stored in the controller. These are by choosing the ‘Load default values’ option in
suitable for operating the compressor in most the ‘Commissioning - values’ sub-menu.
normal situations. Alteration of the working setting values requires
the use of the access code.
2. The compressor can use these values as
operational settings. Unless the compressor is 4. The following is a list of default values together
reprogrammed during commissioning, the with the range and size of the increments/
default values will be those used by the decrements available for each setting.
compressor.
Note: The ‘Max. Pressure’ and ‘Star/Delta time’ must
be set according to compressor model.
Setting Unit Minimum Maximum Step Default

Value
P1 setpoint bar 5·1 10·5 0·1 7·0

P2 setpoint bar 5·0 10·4 0·1 6·3
Run on time minute 5 240 1 10
Drain open time second 1 20 1 5
Drain shut time second 10 120 1 30
Star delta time second 3 30 1 15
Comms baud rate baud 110 9600 options 9600
Compressor number number 1 99 1 1
Max. working pressure bar 7/8/10·5 options 7·0
Max. overpress bar 6·0 11·0 0·1 7·5
Load delay time second 2 60 1 2
Max. service hours hour 1000 4000 100 4000
Auto restart Delay second 10 240 1 10
Interstage trip bar 2·5 4·0 0·1 3·5
Interstage alarm bar 2·5 4·0 0·1 3·0
Oil temp trip °C 50 75 1 70
Oil temp alarm °C 50 75 1 65
St1 delivery trip °C 180 225 1 210
St1 delivery alarm °C 180 220 1 200
St2 intake trip °C 40 75 1 55
St2 intake alarm °C 40 75 1 50
St2 delivery trip °C 180 235 1 220
St2 delivery alarm °C 180 230 1 210
Plant del trip °C 30 90 1 70
Plant del alarm °C 30 90 1 60
Water in trip °C 10 50 1 45
Water in alarm °C 10 50 1 40
Water out trip °C 20 90 1 75
Water out alarm °C 20 90 1 70
Low oil press trip bar 1·5 1·5 – _
Oil filter blockage bar 2 2 – _
Intake filter blockage mbar 65 65 – _
page 66
4. GLOSSARY OF DISPLAY MESSAGES
4.1 Operator Advice Messages
Message displayed Meaning
Invalid Access Code The access code entered is not acceptable.
No reset indicated The ‘Reset’ button has been pressed when there is no reset required.
No service indicated The ‘Service’ button has been pressed when there is no service action
required.
Remote start enabled Starting has been attempted via the Control Panel when the remote start
facility is enabled (Panel starting is disabled).
Remote stopped Starting is inhibited by the remote stop input.
Stop compressor first The compressor is running and a menu selection has been attempted which
can only be used when the compressor is stopped.
4.2 Shutdowns
Extension Fault Extension module unit is not responding.
Emergency stop An emergency stop has been made.
Rotation fault Main supply phase rotation is detected to be incorrect or voltage is below
acceptable limits.
Main motor fault The compressor has shut down because of main motor overcurrent or high
temperature.
Fan motor fault The compressor has shut down because of fan motor overcurrent.
Oil pump fault The compressor has shut down because of oil pump motor overcurrent.
MPCB Q101 tripped The protection circuit breaker Q101 is in the tripped condition.
High air pressure The compressor has shut down because the delivery pressure has
exceeded the maximum pressure setting.
Interstage press trip The interstage pressure has exceeded the maximum set pressure limit.
Oil pressure low The compressor has shut down because the oil pressure has fallen below
the minimum pressure limit.
page 67
CompAir
Shutdowns (continued)
Oil temperature trip The compressor has shut down because the oil temperature has exceeded
the upper (trip) limit.
St1 delivery temp trip The compressor has shut down because the first stage delivery temperature
has exceeded the upper (trip) limit.
St2 intake temp trip The compressor has shut down because the second stage intake
temperature has exceeded the upper (trip) limit.
St2 delivery temp trip The compressor has shut down because the second stage delivery
temperature has exceeded the upper (trip) limit.
Plant delivery t trip The compressor has shut down because the plant air delivery temperature
has exceeded the upper (trip) limit.
Del press probe fault The compressor has shut down because the air delivery pressure transmitter
is indicating a pressure outside of normal limits.
Int.St press probe fault The compressor has shutdown because the interstage pressure transmitter
is indicating a pressure outside of normal limits.
Oil temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
St1 del temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
St2 in temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
St2 del temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
Plant del t probe fault The temperature sensor is indicating a temperature outside of normal limits.
Remote fault The compressor has shutdown because one of the remote fault inputs has
been activated.
Water in temp trip The water inlet temperature has exceeded the upper (trip) limit.
Water out temp trip The water outlet temperature has exceeded the upper (trip) limit.
Oil level low The sump oil level is detected to be low while the compressor is stopped.
(start inhibit)
page 68
4.3 Warnings
Change air filter A high differential pressure has been detected across the air filter indicating
the need for an air filter element change.
Change oil filter A high differential pressure has been detected across the oil filter indicating
the need for an oil filter change.
Interstage press alarm The interstage pressure has reached the programmed warning value.
Oil temperature alarm The oil temperature has reached the programmed warning value.
St1 delivery temp alarm The first stage delivery temperature has reached the programmed warning
value.
St2 intake temp alarm The second stage intake temperature has reached the programmed warning
value.
St2 delivery temp alarm The second stage delivery temperature has reached the programmed
warning value.
Plant delivery t alarm The plant air delivery temperature has reached the programmed warning
value.
Water in t probe fault The temperature sensor is indicating a temperature outside of normal limits.
Water out t probe fault The temperature sensor is indicating a temperature outside of normal limits.
Water in temp alarm The water inlet temperature has reached the programmed warning value.
Water out temp alarm The water outlet temperature has reached the programmed warning value.
Oil level low Indicates that oil level is low.
Remote alarm One of the remote alarm inputs has been activated.
Service due The service interval countdown timer has reached zero hours indicating a
service is now due.
Start inhibit The remote start inhibit input is open circuit.
page 69
CompAir
4.4 Service Messages
Total hours Shows the recorded total number of compressor running hours on and off
load.
Hours on load Shows the recorded total number of compressor running hours on load only.
Max. service hrs Shows the maximum programmed hours before a service is required.
Service hrs to run Indicates the number of running hours remaining before a service is
required.
Reset service hours Invitation to reset the service interval hours to the maximum programmed
service hours.
4.5 Status Messages
Auto restarting The compressor is about to automatically restart following restoration of

power.
Fault shutdown The compressor has stopped due to a fault.
Offload The compressor is running off load (the run-on time has not expired).
Onload The compressor is running on load.
Ready to start The compressor is waiting for a start signal (keypad or external) and no fault
has been detected.
Remote stopped Starting is inhibited by the remote stop input being open circuit.
Standby The compressor has been ‘started’ but is waiting for the delivery pressure to
fall below the lower setpoint, before the motor is energised.
Starting Motor starting.
Unable to start A remote shutdown fault or start inhibit is present.
Stopping The stop button has been pressed but the oil pump motor, canopy cooling fan
and the water solenoid will remain energised for 30 seconds.
page 70
7
MAINTENANCE
Page
Routine Maintenance 72
Cleanliness 72
Recording Pressures and Temperatures 72
Maintenance Record 72
Electrical Connections 72
Leaks 73
Regular Checks 73
Lubricating Oil 73
Maintenance Schedule 73
Torque Schedule 75
Recommended Maintenance Parts 79
Maintenance Procedures 81
Enclosure Filters 81
Condensate Drain 81
Regulation Air Line Filter 82
Intake Air Filter 82
Water Strainer and Condensate Strainers 83
Oil System 83
Balance Piston Diaphragms 84
Non-Return Check Valve (NRV) 84
Expansion Compensator Seal 84
Electrical System 85
Electric Motors 85
Moisture Separator 86
Flexible Drive Coupling 86
page 71
CompAir
MAINTENANCE
1. ROUTINE MAINTENANCE
! WARNING
carrying out any maintenance or servicing Use extreme caution when carrying out
work on the compressor unit. . electrical checks. Isolate the power supply
To ensure the efficient operation of the 1.2 Recording Pressures and Temperatures
compressor unit the user must check performance
regularly and carry out the necessary adjustments Keep a regular record of the compressor operating
to maintain correct settings. This section gives the pressures and temperatures by noting the value
information needed by the user for this purpose. readings, together with ambient air temperature, in
a record book. The readings should be taken when
It is a condition of the Warranty cover that the unit conditions are stable and with the compressor
is properly maintained and adjusted, that all running on full load.
checks, routine maintenance and regular servicing
listed in the Maintenance Schedule are carried out
at the specified intervals and that an accurate 1.3 Maintenance Record
record is kept of the work.
Keep a careful record of all servicing, maintenance
It is recommended that service and maintenance is and repair work carried out on the compressor.
carried out by your local CompAir Distributor. This record will form a useful reference. Any
variation from normal operation will be noticeable
All CompAir compressors are fitted with high immediately, alerting the user to a possible need
performance filtration equipment. However, if the for servicing or maintenance. The frequency of
working environment is particularly hostile the filter recurrence of a particular repair task could reveal
elements and the heat exchangers will require an unsatisfactory operating condition which should
attention at more frequent intervals than specified be corrected.
in the schedule.
1.4 Electrical Connections

1.1 Cleanliness
Regularly check the compressor unit for loose
The compressor unit must be kept in a clean connections or frayed wiring. Clean and tighten all
condition at all times. Make regular inspections for connections and repair or renew all frayed or
signs of damage, excessive wear and security of damaged wires and cables before starting up.
fittings. Ensure that any oil spillage is wiped up
immediately and any residual oil cleaned from Take care not to damage the wiring when working
external surfaces. on the unit. When refitting wires and cables make
sure they are not damaged and that they will not
CAUTION: Do not allow oil to enter the air intake, be damaged in service by chafing or contact with a
air system components or air system pipework. hot surface.
page 72
Oil Free Screw User Manual – Maintenance
1.5 Leaks 1.7 Lubricating Oil
WARNING: RISK OF HIGH It is essential to maintain the correct level of oil

! PRESSURE and to change the oil completely at the specified
intervals.
Do NOT use hands to locate leaks in the system.

Always use a piece of paper or card for this 2. MAINTENANCE SCHEDULE
purpose.
Regular maintenance should be carried out as
Inspect the unit as a matter of course when recommended in the Schedule below. The
carrying out servicing or maintenance for any sign Schedule is appropriate to most circumstances
of leaking pipe connections, a build-up of dirt or but, in some instances, changes in detail may be
debris and oil leaks. Repair or replace damaged or required. The Schedule should always be used as
leaking pipe or hose connections immediately. a guide initially, but if experience shows that an
alteration is necessary, advice should be sought
from the local CompAir distributor.
1.5.1 Prestolok Instant Pipe Connection System
Control air flexible pipes and Prestolok pipe Hours Service

connections are used throughout the compressor.
Prestolok pipe connections are a compact instant Weekly Checks –
brass fitting for flexible pipes, specially designed
Every 4000 A
for pneumatic installations.
Every 8000 or 1 year B
Assembly (whichever is sooner)
Every 16000 or 2 years C
1. Push the cover ring onto the pipe.
(whichever is sooner)
2. Insert the pipe into the fitting until the pipe
bottoms.
The above cycle from 4000 hours should then be
repeated.
3. Pull the pipe to ensure secure engagement of
the grip ring teeth.
In conditions of high ambient temperature/humidity
and/or dirty conditions all filters may need to be
4. Clip the cover ring onto the fitting.
renewed more often than the recommended
service period. Renew the filters when ‘CHANGE
Disassembly
AIR FILTERS’ is indicated on the control system.
1. To remove a pipe, disengage the cover and
In conditions of high ambient temperature/humidity
disengage the grip ring teeth by manually
and/or dirty conditions motor bearings may need to
applying pressure on the push ring sleeve
be lubricated more often than the recommended
and withdrawing the pipe and cover ring from
service period.
the fitting.
1.6 Regular Checks
The ‘Maintenance Schedule’ lists the routine

checks and services which are important to the
efficient running of the unit. The user should
ensure that the Weekly Checks become an integral
part of planned maintenance, even if the major
servicing work is contracted to a CompAir
Distributor.
page 73
CompAir
Item Action
Weekly Checks
Enclosure filter Inspect and clean if necessary.

Intercooler moisture separator Check condensate drain operation.
Aftercooler moisture separator Check condensate drain operation.
Regulation air line filter Drain condensate.
Status display Check for indicated faults/service requirements.
Every 4000 Hours (Service A)
Water strainer Clean.

All hoses and pipework Examine.
Air pipework flange bolts/screws Check torque loading.
Every 8000 Hours or 1 year, whichever is the sooner, (Service B)
Service A plus:
Oil breather filter element Replace.
Oil system Change oil.
Oil filter element Renew.
Intake air filter element Renew.
Balance piston diaphragms Renew. (Models 509–515 and 609–615 Only)
Regulation air line filter element Renew.
Intercooler tubestack Check condition.
Clean.✻
Aftercooler tubestack Check condition.
Clean.✻
Oil cooler Check condition.
Clean.
Drive motor connections Ensure secure.
Starter connections Ensure secure.
2nd stage non-return valve Inspect and renew if necessary.
Cooling Water Quality Inspect the cooling water quality against the specification
detailed in Appendix 5.
Every 16000 Hours or 2 years (Service C)
Service B plus:
Balance piston diaphragms Renew. (Models 504–508 and 604–608 Only)
★Suction regulator valve diaphragm Renew.
★Drive coupling inserts Examine and renew if necessary.
▲Starter contactors Examine and renew if necessary.
page 74
✻ Increases in temperature noted during weekly checks will indicate that the tubestacks may require
cleaning at more frequent intervals.
★ The servicing of these items should normally be carried out by a local CompAir Distributor.
▲ The servicing of these items is not covered in the Repair Manual and must only be carried out by a
qualified technician.
Note: For information on lubrication of motor bearings refer to para 4.11 ‘Electric Motors’.
2.1 Torque Schedule
Incorrect tightening of air pipework flange bolts may cause premature failure of the gaskets. All flange bolts
should be tightened in accordance with the torque schedules below and re-checked at every 4000 hour
service. The bolts should be tightened in a sequence of diametrically opposite pairs to ensure even loading.
Models 504-508 & 604-608
Location Bolt Qty Tightening

size torque, Nm
Suction regulator to 1st stage inlet M12 4 100

1st stage outlet to pipe M16 4 250
1st stage pipe to intercooler inlet bend M16 4 250
Inlet bend to intercooler flange M16 12 200
Intercooler outlet to separator M12 8 85
Separator outlet to 2nd stage inlet pipe M16 4 250
Inlet pipe to 2nd stage inlet flange M12 4 100
Separator bottom flange M16 4 250
Safety valve flange to separator M16 4 250
2nd stage delivery to silencer M12 4 100
Silencer to pipe M16 8 200
Pipe to aftercooler inlet M20 8 400
Aftercooler outlet to separator M20 8 400
page 75
CompAir
Models 509-515 & 609-615
Location Bolt Qty Tightening

size torque, Nm
Suction regulator to 1st stage inlet M12 4 100

1st stage outlet to pipe M16 4 250
1st stage pipe to intercooler inlet bend M16 8 250
Inlet bend to intercooler flange M16 16 200
Intercooler outlet to separator M16 8 200
Separator outlet to 2nd stage inlet pipe M16 8 250
Inlet pipe to 2nd stage inlet flange M16 4 250
Separator bottom flange M16 8 250
Safety valve flange to separator M16 8 250
2nd stage outlet to delivery silencer M16 4 250
Delivery silencer to aftercooler pipe M16 7 + 1 stud 250
Pipe to aftercooler inlet M20 12 400
Aftercooler outlet to separator M20 12 400
page 76
1. Motor Bearings 7. Balance Piston Diaphragms 13. Oil Reservoir

2. Intake Air Filter 8. Oil Breather Element 14. Oil Cooler
3. Aftercooler 9. Expansion Compensator Seals 15. Oil Filter
4. Check Valve 10. Condensate Drains 16. Drive Coupling
5. Suction Regulator 11. Intercooler 17. Enclosure Filters
6. Regulation Air Line Filter 12. Oil Level Sightglass
SERVICING POINTS 504–508 AND 604–608
page 77
CompAir
1. Motor Bearings 7. Balance Piston Diaphragms 13. Oil Cooler

2. Intake Air Filter 8. Oil Breather Element 14. Oil Level Sightglass
3. Aftercooler 9. Expansion Compensator Seals 15. Oil Filter
4. Check Valve 10. Condensate Drains 16. Drive Coupling
5. Suction Regulator 11. Intercooler 17. Enclosure Filters
6. Regulation Air Line Filter 12. Oil Reservoir
SERVICING POINTS 509–515 AND 609–615
page 78
3. RECOMMENDED MAINTENANCE PARTS

covering 2 years average operation or 16000 hours running
Models 504–508/604–608
Description Part No. Qty
Major kit C11158–5917 2

Element, oil filter 1
Element, intake air filter 1
Element, pre-filter 1
Element, regulation line filter 1
Diaphragm, balance piston 1
Element, oil breather 1
Suction regulator kit C11158–5830 1
Joint, suction regulator C21260–16 1
Cooler Servicing Parts
Models 504–505/604–605
Intercooler joint kit C11158–5910 2
Aftercooler joint kit C11158–5911 2
Models 506–508/606–608
page 79
CompAir
Models 509–515/609–615
Description Part No. Qty
Major kit C11158–5918 2

Element, oil filter 1
Element, intake filter 1
Element, pre-filter 1
Element, regulation line filter 1
Element, oil breather 1
Suction regulator kit C11158–5916 1
Joint, suction regulator C21260–7 2
Element, oil breather 98262–115 1
Cooler Servicing Parts
page 80
4. MAINTENANCE PROCEDURES
! WARNING
● Refer to the safety procedures before 3. Attach a label carrying the warning
carrying out any maintenance or servicing ‘WORK IN PROGRESS – DO NOT
work on the compressor unit. APPLY VOLTAGE’ to the isolator switch
and to the display panel. Do not switch on
● Lethal voltages are used in this equipment. electrical power or attempt to start the unit
Use extreme caution when carrying out if such a warning label is attached.
before starting any maintenance work. 4. Bleed down all air pressure in the delivery
pipe between the non-return valve and the
● Where a maintenance procedure below shut-off valve by carefully slackening the
includes the warning ‘The compressor aftercooler condensate drain connection at
must be stopped’ the following steps must the strainer inlet.
be taken before work is commenced:
5. First and second stage pressure will
1. Close the isolating shut-off valve to the exhaust through the dump silencers by the
user’s pipework. Close the isolating valves action of the unloader solenoid valve. As
in the cooling water inlet and outlet pipes. an additional precaution, slacken the drain
Attach a label carrying the warning ‘WORK plug at the base of the regulation air line
IN PROGRESS – DO NOT OPEN’ to each filter to release any residual pressure and
isolating valve. leave it slack while work is in progress.
When work is completed remember to re-
2. Switch the power supply ‘OFF’ at the tighten the plug before starting the
isolator. compressor.
4.1 Enclosure Filters 4.2 Condensate Drain
The compressor is provided with two coarse Moisture present in the compressed air condenses
screen filters in the panels of the enclosure. One in the interstage and second stage moisture
acts as a pre-filter for the intake air and the other separators and is drained by solenoid operated
to filter the ventilation air. valves.
Carry out a regular visual check of the condition of

the enclosure filter elements. If the elements are 4.2.1 To Check the Operation of the Condensate
seen to be heavily contaminated they should be Drain Valves:
cleaned as follows:
With the compressor running on load, disconnect
1. Remove the enclosure panel complete with the condensate drain connection at the baseframe
integral filter. and check visually that condensate is being
released automatically according to the drain open
2. Separate the filter element from the panel and shut times programmed into the controller. If
and wash it carefully in a mild detergent no condensate is being released, stop the
solution. Rinse thoroughly and allow to dry. compressor, switch power off at the isolator, clean
the strainer and check the wiring.
3. Refit the element to the panel and refit the
panel in the enclosure. If the fault persists, refer to the local CompAir
distributor.
page 81
CompAir
4.3 Regulation Air Line Filter It is always better to renew the intake air filter
element rather than to try to clean it. In any
This filter separates moisture and solid impurities cleaning operation, however carefully done, there
from the regulation air system. The moisture and is a risk of critical damage to filter efficiency and
other contaminants collect in the filter bowl and dirt particles remaining on the element or being
must be cleared regularly. carried over to the clean side.
Whenever the intake air filter element is removed,

4.3.1 To Clear the Filter: check the sealing surfaces for signs of dust
tracking and rectify if necessary.
1. With the compressor running on load, slowly
open the captive drain plug in the base of the Before carrying out any work on the intake air filter
filter bowl by screwing it upwards, into the the compressor must be stopped.
bowl. This will lift the internal valve off its seat
and air pressure will drive out the condensate
and any accumulated particles. 4.4.1 To Change the Element:
2. When the air being discharged is clean, close 1. Remove panels as required to gain access to
the drain plug. the intake air filter.
2. Remove the cover of the intake air filter, take

4.3.2 To Renew the Filter Element: out the element and discard.
The compressor must be stopped. 3. Clean the inside of the filter body.
CAUTION: Avoid excessive strain on the pipework 4. Fit the new element in the filter body and refit
when removing or refitting the filter bowl. the cover.
1. Hold the filter housing securely and unscrew Always fit a new filter element at the specified
the bowl from the housing. service intervals. However, if cleaning must be
resorted to, carry out the following procedure.
2. Unscrew the retainer assembly, remove the
collar and withdraw the element from
retainer. 4.4.2 To Clean the Element by Air Blast:
3. Clean out the bowl with a mild detergent CAUTION: Do not use high
solution. Rinse and dry it thoroughly. ! pressure air supply.
4. Clean the filter housing by blowing with low 1. Using an air line supplying dry, low-pressure
pressure (max. 0·5 bar) compressed air. air (maximum 0·5 bar) carefully blow out the
inner cavity, ensuring that the air stream
5. Fit new element over retainer, fit the collar passes through the element from the clean
and screw firmly by hand into the housing. side.
6. Hold the filter housing securely and screw the 2. When all contamination has been removed,
filter bowl firmly by hand into the housing. inspect the element for cracks, holes or other
damage by holding the element up against a
light source. If any damage is evident the
4.4 Intake Air Filter element must be discarded and a new one
fitted.
The servicing intervals required by the intake air
filter will depend on the dust conditions prevailing 3. Re-install the clean element in the filter body
on site. and refit the cover.
page 82
4.5 Water Strainer And Condensate Strainers 1. Remove enclosure panels as required.
4.5.1 To Clean the Strainer: 2. Position suitable containers under reservoir

drain connections.
1. Isolate the cooling water supply.
3. Open the reservoir drain valve and drain the
2. Isolate aftercooler condensate strainers from reservoir.
air main and clear all pressure.
4. Remove and clean the oil breather canister
3. Remove the filter gauze from the strainer. (see para 4.6.4 ‘To Clean the Oil Breather
Element’).
4. Clean the gauze and refit to the strainer.
5. Replace the oil filter element (see para 4.6.3
5. Restore the water supply. ‘To Change the Oil Filter Element’).
6. Close all drain valves and plugs.

4.6 Oil System
7. Fill reservoir with recommended oil to the ‘H’
4.6.1 To Check the Oil level: or ‘MAX’ mark.
The compressor must be stopped 8. Ensure that breather is dry and refit to filler
pipe.
Note: Allow a minimum of 30 minutes after
stopping for the oil in the system to settle. 9. Start and run unit for 60 seconds to circulate
oil, check for leaks, then press STOP button.
1. Open the enclosure to gain access to the oil
filler and sightglass. 10. Allow 30 minutes for oil to settle, check oil
level and top up as necessary.
2. Check the sightglass visually. The oil level
should be on the ‘H’ or ’MAX’ mark. 11. Refit enclosure panels.
CAUTION: Do not mix oils of different types –

always refill with the oil type in current use. 4.6.3 To Change the Oil Filter Element:
3. If the oil level is low, remove the canister Note: The oil filter element should be renewed
from the oil breather pipe and gradually top after every 8000 operating hours or every year,
up the reservoir to the correct level with whichever is sooner or when indicated by the
recommended or approved oil of the type in control system CHANGE OIL FILTER message
use. After each small quantity has been
added allow time for the change in level to be The compressor must be stopped.
indicated on the sightglass. This will prevent
overfilling. 1. Unscrew and discard the old oil filter element.
4. Refit the oil breather filter canister. 2. Carefully clean out the filter housing.
5. Close the enclosure panel. 3. Apply a thin film of clean oil to the element
seal.
4.6.2 To Change the Oil: 4. Screw in the new element by hand until seal
contact is made and then continue tightening
The compressor must be stopped for a further quarter of a turn.
Drain the oil while the compressor is hot to allow

the oil to run freely and carry out any suspended
particles.
page 83
CompAir
4.6.4 To Clean the Oil Breather Element: Note: The valve is secured between the flanges by
pressure exerted by the securing screws and nuts.
1. Remove the canister from oil filler/breather It is not positively located.
pipe.
2. Slacken the lower screws and nuts securing
2. Wash the element in warm (50°C) mild the valve between the discharge pipe
detergent solution. flanges. Remove the upper screws, washers
and nuts. Slacken the screws and nuts at the
3. Rinse thoroughly and dry. aftercooler flange if necessary.
4. Refit the canister to oil filler/breather pipe. 3. Remove the valve and renew any worn or
damaged parts. CAUTION: Do not lubricate.
4.7 Balance Piston Diaphragms 4. Fit new joints to the valve and refit between
the flanges. Ensure that the valve is correctly
4.7.1 To Renew the Diaphragms: positioned, that the lifting eye is uppermost
and that the direction of flow arrow is pointing
1. Remove the rear fill-in panel from the in the correct direction.
enclosure.
5. Refit the screws, nuts and washers and
2. Remove the regulation air pipe from the first tighten in sequence using the correct torque
stage diaphragm cover. Disconnect the loading.
regulation air pipe from the second stage
diaphragm cover. 6. Start and run the compressor until working
temperatures are reached. Stop and re-
3. Remove the screws and washers securing tighten the flange bolts.
the covers to the casing. Remove the covers.
Remove and discard the diaphragms. 7. Refit the enclosure panel.
4. Ensure that all mating faces are clean.

4.9 Expansion Compensator Seal
5. Position a new diaphragm on the first stage
casing. Locate the cover and secure with the 4.9.1 To Renew the Seal on LP delivery pipe:
screws and washers. Carry out the same
procedure on the second stage casing. 1. Remove the enclosure side panel.
6. Refit the regulation air pipe to the first stage 2. Remove the screws, nuts and washers
diaphragm cover. Re-connect the regulation securing the compensator to the intercooler.
air pipe to the second stage diaphragm
cover. 3. Remove the four bolts securing the first stage
discharge pipe flange to the compensator.
7. Refit the enclosure panel.
4. Remove the compensator from the
intercooler. Withdraw the flanged pipe from
4.8 Non-Return Check Valve (NRV) the discharge pipe. Remove and discard the
‘O’ ring.
4.8.1 To Inspect the Valve:
5. Ensure that the ‘O’ ring groove is clean and
Stop the compressor, isolate from air main without sharp edges. Ensure that all pipes
and release all pressure and component parts are free from dirt and
contaminates. Fit a new ‘O’ ring into the
1. Remove the enclosure side panel. groove. Coat the exposed part of the ‘O’ ring
with soft soap.
page 84
6. Slide the flanged pipe into the discharge pipe. 4.10.1 To Check the Electrical Connections:
Renew the joints and refit the compensator to
the intercooler. Refit the screws, washers and Carefully examine the electrical wiring and check
nuts. the security of all connections and terminals.
7. Renew the joint and fit the flanged pipe to the

compensator. Fit the screws, nuts and 4.11 Electric Motors
washers and tighten in sequence using the
correct torque loading. 4.11.1 Motor Bearings
8. Refit the enclosure panel. The main drive motor may have provision for
lubrication of the bearings at both ends of the shaft
or may be fitted with pre-packed shielded bearings
4.10 Electrical System which require attention only at major service
intervals. The cooling fan and oil pump motors are
fitted with sealed bearings and should not need
WARNING attention.
!
If a non-standard motor is fitted the user should
● Lethal voltages are used in this take advice from the local CompAir BroomWade
equipment. Use extreme caution when distributor before the compressor is put into
carrying out electrical checks. Isolate extended operation.
the power supply before starting any
maintenance work.
4.11.2 Lubricated Bearings
Lubricate the bearings in accordance with the

following schedule.
Drive Motor Greasing Schedule
Motor rating, kW Drive end greasing Non-drive end greasing
Interval, hours Quantity, grams Interval, hours Quantity, grams
Drip Proof (IP22) motors

55/75 4000 80 8000 50
90/110 4000 50 4000 50
130/150/185 2000 80 4000 80
220/260 2000 100 4000 100
300 2000 150 2000 150
TEFV (IP55) motors
55/75 4000 80 4000 80
90/110/130/150/185/220 4000 80 4000 80
260 2000 80 4000 80
300 2000 100 2000 100
Note 1: For motors above 132 kW rating it is recommended that at every second service the bearing
housings are completely cleaned of old grease before refilling
Note 2: The intervals stated may have to be reduced by up to 50% when operating in ambient temperatures
consistently above 30°C.
page 85
CompAir
4.11.3 Pre-Packed Bearings 4.13 Flexible Drive Coupling
Where no grease nipples are provided the 4.13.1 To Check the Coupling Backlash:
bearings are either single or double shielded
and pre-packed with grease. These bearings do The compressor must be stopped and isolated
not require periodic re-lubrication but should be from both the electrical supply and air pipework.
renewed after 25000 hours of operation in
normal environments. Reach through the access opening in the
bellhousing and hold the drive shaft on each side
Note: We recommend that this work is carried of the coupling. Check the coupling backlash
out by a CompAir distributor. which should not exceed 6 mm. If the backlash is
excessive it will be necessary to change the
coupling inserts.
4.11.4 To Lubricate the Motor Bearings:
The recommended grease for lubrication of the 4.13.2 To Renew the Inserts:
motor bearings is Esso (Exxon) Unirex N3 or an
equivalent lithium complex grease. It is recommended that this work is carried out by a
CompAir distributor.
Note: It is important that the motor bearings are
not over-lubricated.
The compressor must be stopped
1. Locate grease nipples and remove dust

caps.
2. Inject the recommended quantity of

grease into the nipples with a grease gun,
taking care not to over-lubricate. Remove
excess grease from around the nipples.
4.11.5 Dust Contamination
If the compressor is operating in a dusty

atmosphere it may be necessary to clean the
motors periodically to remove accumulated dust
from the windings. This applies particularly to
IP22 class motors. Service personnel should
inspect the motors visually at the regular
servicing intervals to determine the frequency
of cleaning required.
4.12 Moisture Separator
The moisture separator operates by mechanical

separation and requires no maintenance.
If a fault develops in the condensate drain

valve, refer to the local CompAir distributor.
page 86
8
FAULT FINDING
Page
Shutdown Messages 88
Warning Messages 92
page 87
CompAir
FAULT FINDING
The controller has a memory facility that retains a In operation the compressor is protected by
fault history. Details of 15 previous situations can circuits which are triggered when a fault arises and
be displayed, including the fault message together either cause the compressor to shut down or
with recorded hours, compressor state (standby, indicate that a servicing action is required.
on-load, off-load etc.), plant temperatures and
pressures.
! WARNING
● Refer to the safety procedures before ● Lethal voltages are used in this
carrying out any fault finding equipment. Use extreme caution when
investigation. carrying out electrical checks. Isolate
maintenance work.
1. SHUTDOWN MESSAGES
Message Displayed Possible Cause Action required
Emergency stop (1) Emergency Stop (1) Check cause of fault and
switch operated. rectify. Turn Emergency Stop
switch to release latch. Press
RESET.
(2) Starter circuit fuse F1 blown. (2) Check cause and rectify.
Main motor fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure
filter; ducting; motor cooling
air intake.
(3) Fan operation/rotation incorrect. (3) Check and rectify electrical
circuit.
(4) Low voltage/high current. (4) Check power supply.
(5) Thermal overload F101 (5) Check setting and reset.
incorrectly set.
page 88
Oil Free Screw User Manual – Fault Finding
Fan motor fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure
filter; ducting; motor cooling
air intake.
(4) Circuit breaker F102 (4) Check setting and reset.
incorrectly set.
Oil pump fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure filter;
ducting; motor cooling
air intake.
(4) Circuit breaker F103 (4) Check setting and reset.
incorrectly set.
MPCB Q102 tripped (1) Circuit breaker incorrectly set. (1) Check setting and reset.
(2) Oil pump/fan motor circuit fault. (2) Check cause and rectify.
Oil temperature trip (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling water (2) Check water supply. Check
flow. adjustment of water valve.
Inspect/clean water strainer.
Inspect/clean oil cooler.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) Sensor wiring fault. (4) Check wiring.
St1 delivery temp trip (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling water flow. (2) Check water supply. Check
adjustment of water valve.
(4) High interstage pressure. (4) Inspect/clean air coolers.
St2 intake temp trip (1) Insufficient cooling water flow. (1) Check water supply. Check
(2) High ambient temperature. (2) Check room ventilation.
page 89
CompAir
St2 delivery temp trip (1) Insufficient cooling water flow. (1) Check water supply. Check
(2) Air flow restriction. (2) Inspect/clean aftercooler.
Plant delivery t trip (1) Insufficient cooling water flow. (1) Check water supply. Check
Inspect/clean intercooler.
Interstage press trip (1) Air flow restriction. (1) Inspect/clean air coolers.
Oil pressure low (1) Low oil level. (1) Investigate for leaks,
top up oil level.
(2) Oil pump fault. (2) Investigate and rectify.
(3) Relief valve failure. (3) Adjust/Renew valve.
(4) Pressure switch fault. (4) Renew pressure switch.
(5) Oil cooler restriction. (5) Clean cooler.
(6) Oil filter blocked. (6) Renew oil filter element.
High air pressure (1) Compressor is failing to unload. (1) (a) Check/renew solenoid
operated unloader valve.
(b) Check suction regulator
inlet valve closing fully.
Rectify if necessary.
(2) Pressure transmitter fault. (2) Check/renew pressure
transmitter.
Del press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
(2) Transmitter wiring fault. (2) Check and rectify fault.
Int.St press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
(2) Transmitter wiring fault. (2) Check and rectify fault.
St1 del temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Sensor wiring fault. (2) Check and rectify fault.
(3) PT1000 conditioner unit fault. (3) Renew conditioner unit.
page 90
St2 in temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.
(3) Preconditioner card fault. (3) Check/renew card.
St2 del temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(3) PT1000 conditioner unit fault. (3) Renew conditioner unit.
Plant del t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.
(3) Preconditioner card fault. (3) Check/renew card.
Remote fault (1) Remote fault loop open circuit. (1) Find cause and rectify.
Extension fault (1) Fuse F2 failed. (1) Check cause and rectify.
(2) Interface cable insecure. (2) Check interface cable.
(3) Extension module failure. (3) Renew Extension module.
Rotation fault (1) Supply wiring configuration (1) Check supply wiring
incorrect, motor rotation connections U, V and W.
will be incorrect.
(2) Supply voltage low. (2) Check supply voltage.
Water in temp trip (1) User cooling water system (1) Find cause and rectify.
fault.
Water out temp trip (1) Water flow restriction. (1) Check/clean coolers.
(2) Low water flow. (2) Check cooling water flow rate.
Oil level low (1) Low oil level. (1) Check for oil leaks and
(start inhibit) rectify. Top up reclaimer to
correct level.
(2) Oil level sensor fault. (2) Find cause and rectify.
(3) Sensor wiring fault. (3) Check and rectify.
page 91
CompAir
2. WARNING MESSAGES
Service due (1) Service countdown time (1) Service compressor then
expired. reset timer.
Change air filter (1) Intake air filter blocked. (1) Check/renew element.
(2) Filter pressure switch fault. (2) Check operation. Renew if
necessary.
(3) Filter pressure switch (3) Check and rectify.
wiring fault.
Change oil filter (1) Oil filter element blocked. (1) Renew oil filter.
(2) Differential pressure (2) Check operation. Renew if
switch fault. necessary.
(3) Filter pressure switch (3) Check and rectify.
wiring fault.
Oil level low (1) Low oil level. (1) Check for oil leaks and
rectify. Top up reclaimer to
correct level.
(2) Oil level sensor fault. (2) Find cause and rectify.
(3) Sensor wiring fault. (3) Check and rectify.
(4) Input card fault. (4) Check/renew input card.
Oil temperature alarm (1) High ambient temperature. (1) Check room ventilation.
Inspect/clean oil cooler.
(4) Sensor wiring fault. (4) Check wiring.
(5) Preconditioner card fault. (5) Renew card.
St1 delivery temp alarm (1) High ambient temperature. (1) Check room ventilation.
(3) High interstage pressure. (3) Inspect/Clean air coolers.
St2 intake temp alarm (1) Insufficient cooling water flow. (1) Check water supply. Check
Inspect/clean intercooler.
(2) High ambient temperature. (2) Check room ventilation.
page 92
St2 delivery temp alarm (1) Insufficient cooling water flow. (1) Check water supply. Check
(2) Air flow restriction. (2) Inspect/Clean aftercooler.
Plant delivery t alarm (1) Insufficient cooling water flow. (1) Check water supply. Check
Inspect/clean aftercooler.
Water in temp alarm (1) Supply water temperature high. (1) Check supply
water temperature.
(2) Low water flow. (2) Check water flow.
Water out temp alarm (1) Supply water temperature high. (1) Check supply
water temperature.
(2) Low water flow. (2) Check water flow.
Inspect/clean air coolers.
Interstage press alarm (1) Air flow restriction. (1) Inspect/clean air coolers.
Water in t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(3) PT1000 conditioner fault. (3) Renew conditioner unit.
Water out t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(3) PT1000 conditioner fault. (3) Renew conditioner unit.
Remote Alarm (1) Remote alarm loop open circuit. (1) Find cause and rectify.
Start inhibit (1) Remote start inhibit loop (1) Find cause and rectify.
open circuit.
page 93
CompAir
page 94
APPENDIX 1
CONTROL/REMOTE OPTIONS
Page
Condensate Drain 96
Condensate Drain Operation 96
Inputs 96
Description 96
Input Designations 97
Input Functions 97
Outputs 102
Description 102
Output Relay 102
Output Designations 103
Output Functions 103
page 95
CompAir
APPENDIX 1
WARNING
!
● Lethal voltages are used in this ● Refer to the safety procedures before
equipment. Use extreme caution when carrying out any of the following
carrying out electrical checks. Isolate operations.
maintenance work.
Note: We recommend that the following 2. INPUTS

procedures are carried out by a CompAir
distributor. 2.1 Description
CAUTION: Do not connect any extension module

1. CONDENSATE DRAIN input terminal pin to a voltage source as this will
result in permanent damage to the module.
1.1 Condensate Drain Operation
Two sets of eight inputs are available on extension
When running on-load the condensate drain will module terminal connections X01 and X02. Each
operate according to the programmed drain shut input is designated a particular function which may
and drain open times. The drain will open and the be used as required. Each function is activated by
timer cycle will begin every time the compressor connecting the appropriate terminal pin to the input
loads. When the compressor is in ‘off-load’, terminal common connection X5/1 or X5/2. This
‘standby’ or ‘ready to start’, the drain will continue can be achieved by connecting the input pin and
to operate with a two second ‘open’ time and an the common terminal to a remote switch, relay
extended ‘shut’ time. This prevents any build-up of contact, PLC output or any switching device.
condensate when the compressor is stopped or
unloaded. Note 1: Remote input cables must be at least
1.0 mm2 in size. The maximum cable length from
If it is preferable for the drain to operate only while the compressor to a remote device must not
the compressor is running, make the following exceed 800 meters.
starter wiring changes:
Note 2: To activate an input function, only connect
1. Remove and discard the wire from controller an input terminal pin to the common terminal
terminal X08/9 to terminal block X2/1. connection X5/1 for X01 inputs or X5/2 for X02
inputs.
2. Connect a wire between terminal X08/9 and
terminal block X2/6.
page 96
Oil Free Screw User Manual – Appendix 1
X01
1 2 3 4 5 6 7 8 9
REMOTE LOAD
COMMS CONTROL ENABLE
START
STOP
500
REMOTE START ENABLE

AUTO RESTART ENABLE
REMOTE LOAD ENABLE

20V D.C. COMMON
X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1
PRESSURE SWITCH
OR CASCADE
PANEL CONNECTION
REMOTE INPUT CONNECTION
2.2 Input Designations 2.2.2 Input Terminal X02
2.2.1 Input Terminal X01

Pin No. Function
Pin No. Function X02-1 Common (20V dc) for X02 inputs
X02-5 Remote Fault Input 1
X01-1 Common (20V dc) for X01 inputs X02-6 Remote Fault Input 2
X01-2 Comms Control Enable X02-7 Remote Fault Input 3
X01-3 Auto Restart Enable X02-8 Remote Fault Input 4
X01-4 Remote Load Enable X02-9 Remote Fault Input 5
X01-5 Remote Load/Unload
X01-6 Remote Start Enable
X01-7 Remote Start 2.3 Input Functions
X01-8 Remote Stop
X01-9 No Standard Function 2.3.1 Input X01-2 RS485 Communications
Control Enable
The SureScan controller is equipped with an

RS485 communications facility on terminal X06.
The facility is activated when this input is
connected to the common terminal X5/1.
Note: The RS 485 terminal X03 on the extension

module has no standard function.
page 97
CompAir
The communications link can either be connected 3. When power is restored the following
point-to-point or networked with up to 31 message is displayed and the Auto Re-start
compressors and one master. enable indicator will flash.
The controller network communications protocol is Auto restarting

a single master system. Communication is always
—————* *
between network master and controller. Only one
communication protocol is used. Point-to-point
The time before the compressor
links are considered to be networks with only two
automatically re-starts, the auto re-start delay
nodes, master and controller. Each compressor
time, is indicated by dashes on the lower
controller on a network can be assigned a unique
display line. This time can be adjusted using
identification number from 1 to 99, the master
the auto re-start delay time setting of the
always being node 0.
‘Commissioning - values’ sub-menu of the
SureScan menu routines.
When connected, a master can read status, fault,
service, pressure and temperature data from any
4. In multiple compressor installations
controller in the network.
staggered re-starting can be achieved by
adjusting the delay time of each compressor
If the ‘Comms control enable’ input X01-1 and
‘Remote start enable’ input X01-5 are activated,
Example four compressor installation:-
the compressor Remote control indicator will light
and the compressor will respond to RS485 Start,
Stop and Reset commands.
Comp Auto re-start Delay Time
Note: The control panel Start button and the
Remote start function will be inhibited. The control 1 10 seconds
panel stop button and remote stop function remain 2 70 seconds
active. 3 150 seconds
4 210 seconds
If the ‘Comms control enable’ and the ‘Remote
pressure control enable’ input X01-3 is activated,
the compressor will respond to RS485 load and
unload comands.
2.3.3 Input X01-4 Remote Load Enable
Contact your local CompAir distributor for details.
1. Remote control of loading and unloading
allows the pressure control routines of the
SureScan controller to be overridden in
2.3.2 Input X01-3 Auto Re-start Enable
multiple compressor/cascade control
installations. The facility allows control by any
1. Automatic re-start will allow the compressor
of the I.C.C. range of multi compressor
to start automatically after a break or failure
controllers available from CompAir.
in the mains power supply. When this facility
is enabled the AUTOMATIC RE-START
2. When the remote load enable input is
indicator will be lit.
activated the compressor will load and unload
in response to the remote load/unload input
2. An automatic re-start will not be initiated if the
X01-5.
compressor was stopped when the power
failure occurred.
page 98
2.3.4 Input X01-5 Remote Load/Unload 2.3.6 Input X01-7 Remote Start
1. If input X01-5 is activated, via a remote 1. When the remote start enable and remote
pressure switch, relay, programmable logic stop inputs are activated the compressor will
controller (P.L.C.) output etc, the compressor start when the remote start input is activated.
will load. When the input is de-activated the This input reqires a sngle pulse of at least 0·5
compressor will unload. seconds to activate it. The pulse length can
be between 0·5 seconds and continuous.
2. The compressor will shutdown and the
display will show a High air pressure trip if 2. When the remote start input is continuously
the Max overpress setting of the activated the SureScan panel stop button or
Commissioning - values menu is exceeded the remote stop input will override the remote
while using this facility. The compressor ‘Max start signal and the compressor will stop.
overpress’ setting must be set above the
working pressure of the remote pressure When the compressor is stopped, the remote
control system. Where the remote pressure start signal must be de-activated before the
control system is detecting air system compressor can be re-started.
pressure downstream of dryers, filters or long
lengths of pipework, an allowance for any Note: This facility is inhibited if the RS485
pressure differential should be taken into communications control input is activated.
account.
3. Remote Timer Control
2.3.5 Input X01-6 Remote Start Enable The remote start/stop facility can also be
used to achieve automatic seven day timer
1. The compressor can be connected to accept control. Any commercially available timer with
a remote start signal. When this input is a single switching contact can be used for
activated the REMOTE CONTROL indicator this purpose. Alternatively a timer with a 24v
will be lit and the SureScan panel START ac power supply can be mounted within the
button is disabled. starter area A 24vac power supply for this
purpose is available on compressors
The SureScan panel stop button and the terminals X2/1 and X2/2. The timer unit
remote stop input are always active, should be battery backed.
regardless of remote start enable being
activated.
EXTENSION MODULE
7 DAY TIMER
X01
1 2 3 4 5 6 7 8 9
REMOTE START ENABLE
X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 CLOSED - START
OPEN - STOP
PI/97/136
TIMER CONTROL
page 99
CompAir
2.3.7 Input X01-8 Remote Stop 2.3.9 Inputs X02-5 to 9 - Remote Faults 1 to 5
1. The remote stop input is always active, There are five remote fault input functions
regardless of remote start enable being available that can be individually programmed to
activated. function as remote alarm, remote trip or start
inhibit inputs. A remote fault input can be
2. The remote stop input must be active to connected to a remote switch, relay contact,
enable the compressor to be started. The programmable logic controller (PLC) output or any
compressor will stop when the remote stop switching contact device. Each input function will
input is de-activated. operate when the connection between the
appropriate input terminal, X02-5 to X02-9, and the
3. A remote stop signal will override a remote common terminal X5/2 is broken.
start signal. When the remote stop input is
de-activated the display will show: When a remote fault input is de-activated the
appropriate remote fault number will be displayed
Remote stopped by the SureScan controller and the fault will be
stored in the fault history. The remote fault can be
reset normally using the RESET button.
4. The STOP button on the SureScan panel is
1. Remote Fault Input Configuration
not affected and will remain active at all
times.
Each remote fault input can be pre-
programmed using the SureScan controller
5. If this facility is not used the input must be
menu routines to function as a remote alarm,
continuously activated by connecting a wire
remote shutdown trip or start inhibit when the
from the input pin to terminal connection X5/
fault input is de-activated. Remote alarm and
1, to enable the compressor to be started and
shutdown trip functions can also be pre-
run.
programmed to operate only under pre-
determined conditions to suit a particular
application depending on the remote fault
2.3.8 Inputs X01-9 and X02-2 to 4
input type selected.
CAUTION: These inputs are used by the controller
Note: When a remote fault input is configured to
to monitor the operation of the compressor and
any option other than ‘Disabled’ the input must,
must not be used for any other function.
under normal circumstances, be continuously
activated to enable the compressor to operate
without indicating a remote alarm, trip or start
inhibit condition.
page 100
2. Remote Fault Input Configuration Options
Option Function Description
Disabled Input not active.
Trip type 1 Trip - active at all times.
Trip type 2 Trip - active when the main motor is running.
Trip type 3 Trip - active only when status is ‘Onload’ or ‘Offload’.
Alarm type 1 Alarm - active at all times.
Alarm type 2 Alarm - active when the main motor is running.
Alarm type 3 Alarm - active only when status is ‘Onload’ or ‘Offload’.
Start inhibit Will prevent a compressor from starting but will not stop a
compressor if already started. When activated the display will show
‘Start inhibited’. This function is not a shutdown trip or alarm and will
only function while the input is de-activated.
3. Configuring the SureScan Controller Remote Fault Inputs
All remote fault inputs will be ‘Disabled’ when the compressor is first commissioned. To enable a
remote fault input, and select a required fault input function from the Configuration Options table , use
the SureScan menu routines procedure as described below :-
1. Press ENTER. To display the main menu. Main menu

2. Press UP or DOWN To scroll through the Main menu

repeatedly until the menu options. Commissioning - config
message shown on the
right is displayed.
3. Press ENTER. To select the Commissioning - config

Commissioning - config Language English
sub menu.
4. Press UP or DOWN To scroll through the Commissioning - config

repeatedly until the sub menu options. Fault input config
message shown on the
right is displayed.
5. Press ENTER. To select the fault input Fault input config

config sub menu. Remote fault 1
page 101
CompAir
6. Press UP or DOWN To scroll through the Fault input config

repeatedly to select fault inputs available. Remote fault 2
fault input.
7. Press ENTER. To select the fault Remote fault 2

input to configure. Disabled
8. Press PLUS or MINUS. To select the required Remote fault 2

fault input function. Trip type 2
(pulsing display)
9. Press ENTER. To enter the selected fault Remote fault 2

input configuration option. Trip type 2
The display will automatically return to the fault input selection menu.
10. Repeat steps 6 to 9 for

each of the remote fault
inputs. If a remote
fault input is not required
select ‘Disabled’ from the
configuration options menu.
11. When all five remote fault Ready to start

inputs are configured press Oil temperature 20°C
RESET to exit the menu routine.
3. OUTPUTS 1. Parts required for each additional output:-
3.1 Description
Qty Description Part Number
Two sets of six outputs are available on extension
module terminal connections X05 and X06. Each 1 Relay - 24 V dc 98475-64
output is designated a particular function which 1 Relay Base 98475-65
may be used if required. Outputs which are not
used should be left unconnected.
3.2.1 Relay Specification
3.2 Output Relay Single switching contact with a common, normally

open (N/O) and normally closed (N/C) connection
Extension module outputs are 24V dc transistor rated at 250V - 5 Amps maximum.
switched with a maximum rating of 25mA. Each
output must be connected directly to a relay Note: The relay 24V dc coil is not bi-directional
module, as specified below, in order to achieve a and must be connected to an extension module
relay contact output suitable for remote output as follows :-
applications external to the compressor starter
enclosure. Six relays, K401 to K406 are supplied 1. Relay terminal ‘5’ must be connected to pin
as standard for this purpose. ‘1’ of the appropriate output terminal.
page 102
X4/1 X4/1 X4/1 X4/1 X4/1 X4/1 X4/1
COMMON 24V D.C.

K406
K405
K404
K403
K402
K401
5 3
+ 2
5 5 5 5 5 5
24V d.c.
- 4
406 1 1 1 1 1 1 1
405
404
403
402
401
400
7 6 5 4 3 2 1
X05
REMOTE OUTPUT CONNECTION
2. Relay terminal ‘1’ must be connected to the 3.3.2 Output Terminal X06
pin of the output terminal appropriate for the
required output function.
Pin No. Function
The relay base can be screw mounted or secured
to a standard type DIN rail (available from X06-1 Common (20V dc) for X06 outputs
CompAir).
X06-2 Remote Fault 1 Repeat
3.3 Output Designations
3.3.1 Output Terminal X05 X06-5 Remote Fault 4 Repeat
Pin No. Function X06-7 No Standard Function
X05-1 Common (20V dc) for X05 outputs

3.4 Output Functions
X05-2 Available
X05-3 Group Fault 3.4.1 Output X05-2 Available
X05-4 Running
The compressor available output will energise
X05-5 On Load when the compressor is ‘running’ or in the
‘standby’ state. This output indicates that the
X05-6 Group Trip
compressor has been started and is available to
X05-7 Service Due automatically respond to a fall in system pressure
without manual intervention.
The contacts of relay K401 must be used for

remote connections to this facility.
page 103
CompAir
3.4.2 Output X05-3 Group Fault 3.4.6 Output X05-7 Service Due
The group fault output will de-energise when an The service due output will energise when the
alarm, shutdown trip or power loss occurs. service hours countdown timer has reached zero
The output will be energised when power is hours and a routine service is due.
applied and no alarm or trip conditions are
detected. The contacts of relay K406 must be used for
3.4.7 Outputs X06-2 to 6
3.4.3 Output X05-4 Running Remote fault repeat outputs 1 to 5 will be normally
energised and will de-energise if a fault condition
The running output will energise when the on the appropriate remote fault input, 1 to 5, is
compressor main motor is running. detected or a power loss occurs. The output will
remain de-energised until the SureScan controller
The contacts of relay K403 must be used for is reset. See remote fault inputs.
If start inhibit is selected, the output will de-
energise when the input is de-activated and
3.4.4 Output X05-5 On Load automatically re-set when the input is re-activated.
The on load output will energise when the Note: An additional relay module, as specified in
compressor is on load. para 3.2, must be added if these outputs are used.

3.4.5 Output X05-6 Group Trip
The group trip output will de-energise when a

shutdown trip or power loss occurs.
The output will be energised when power is

applied and no trip conditions are detected.

page 104
APPENDIX 2
Electrical Connections
page 105
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CompAir
page 106
U (01) U
[BK] <2/2>
V (02)
[BK]
W (03) W
[BK] <2/2>
PE
FUSED ISOLATOR
m 3
INCOMING SUPPLY
FROM CUSTOMERS
T1 T2 T3
K101
L1
Q101
L3 U V W
L1 L2 L3
[BK]
[BK]
[BK]
[BK]
[BK]
[BK]
(101A)
(102A)
(103A)
(101C)
(102C)
(103C)
(101B)
[BK]
(102B) F101 Main Motor Thermal Overload Relay
[BK]
(103B)
[BK] F102 Fan Motor Thermal Overload Relay
F103 Oil Pump Motor Thermal Overload
KM201
KM203
KM202
KM204
KM204
Relay
K101 Phase Rotation Relay
F101
F102
F103
[BK]
M101 Main Motor
[BK]
M102 Fan Motor
[BK]
U1 V1 W1 U1 V1 W1 U1 V1 W1 M103 Oil Pump Motor
R
Q101 M.C.B. 3 Pole
(104)
M101 a M103
E [BL] <3/14> E M102 E S201/1 Emergency Stop Contact
R
3~ (105) 3~ 3~
b
R [BL] <3/14> Y201 Unloader Solenoid
[BK]
[BK]
[BK]
U2 V2 W2
E
<2/2>
E
<2/2>
[G/Y] E
<2/2>
ELECTRICAL CONNECTION DIAGRAM (1 of 6)

[G/Y] E
<2/2>
F101 F102 Q101 F103 K101

NO NC NO NC NO NC NO NC NO NC
( ) (2/12) ( ) (2/23) (5/24) (1/16) ( ) (2/25) (3/12)
(1/17) NOTES:-
(1/18) 1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106)
2. SOURCE/DESTINATION REFS. ARE SHOWN IN BRACKETS
THUS <1/09> <WHERE 1 = SHEET No. , 09 = C0LUMN No.>
< > INDICATES SPARE CONTACTS
3. WIRE COLOURS ARE SHOWN IN BRACKETS THUS [R]
WHERE [R]=RED, [BL]=BLUE, [BK]=BLACK,
[G/Y]=GREEN/YELLOW.
PI/97/148
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
280VA T201
F1 1.6A (209)
575V 24V (203)
30VA [R] [R]
F2 1.6A (224)
440/460V 0V (204)
[R] [R]
Q201 F3 3.15A 24V~
U (01) (201) 415/380V 24V (205) (210) (210)
24V~ SUPPLY TO
<1/26> [BK] 1 2 [BK] 50VA [R] [R] [R] <4/2>
F4 3.15A EXTENSION
220/230V 0V (206) (225) (225) OV (24V~)
MODULE
[R] [R] [R] <4/2>
F5 10A
W (03) 3 4 (202) 0V 24V (207)
<1/26> [BK] [BK] 200VA [R]
<4/2>
3A 0V (208)
[R]
[R]
AND
<4/2>
(211)
INTERCONNECTING
CABLE
<4/2>
[R]
[R]
(E)
[G/Y]
(224)
(209)
CABLE No.
98140/264
1 2
[R]
AC1 AC2 CONTROLLER
(208)
CONTROLLER
1 X03 X04
RELAY OUTPUT DIGITAL OUTPUTS
~
X08 X09
S201/1
2
R1 R2 R3 R4 R5 VC1 OC1 OC2 OC3
1 2 3 4 5 6 7 8 9 10 1 2 3 4
K201/1
4 3
[R]
[R]
[R]
[R]
[R]
(223C)
(223D)
(223E)
(223F)
(223B)
(223) A (223G)
[R] [R]
X2/1 X2/1 X2/1 X2/1 X2/1
[R]
[R]
(219)
(220A)
X/26
CL1/1
CL1/2
CL1/3
[R]
(218)
EARTH
X/26
X/26
BAR
[R]
[R]
[R]
(212)
(214)
(216)
[R]
[R]
[R]
(220C)
(E)
(220B)
(220D)
[R]
[R]
96
96
(219)
(219)
[G/Y]
[BL]
[BL]
(230A)
(231)
F101
(E)
95
95
[G/Y]
ML1/5
ML1/7
ML1/1
ML1/3
[R]
[R]
[R]
[R]
[R]
(213)
(215) KM203
(217) KM202
(E)
A1 (221) F102
A1 (222) F103
A2
[G/Y] <4/2>
E [G/Y]
K201
Y201
Y202
Y203
Y204
KM201
KM202
KM203
KM204
KM205
<1/26>
A1
A2
A2
E [G/Y]
<1/26>
E [G/Y]
ML1/4
ML1/6
ML1/8
ML1/2
<1/26>
E [G/Y]
<1/26>
[R]
[R]
[R]
[R]
[R]
[R]
[R]
[R]
[R]
[BL]
[BL]
(208)
(208)
(208)
(208B)
(208C)
(208D)
(208E)
(208F)
(208G)
(230)
(230B)
(208)
20V-
[R]
X2/2 X2/2 X2/2 X2/2 X2/2 X2/2 X2/2 X2/2 X2/2 X2/2 X2/4 X2/4 X2/4 X2/4
(305) [BL] d
ELECTRICAL CONNECTION DIAGRAM (2 OF 6)

[BL] <3/2>
Q201 KM201 KM202 KM203 KM204 KM205 K201

NO NC NO NC NO NC NO NC NO NC NO NC NO NC
<2/4> <1/6> <1/13> <1/9> <1/16> <1/21> <2/22>
<2/4> <1/6> <1/13> <1/10> <1/17> <1/22>
<1/7> <1/14> <2/16> <1/10> <2/14> <1/18> <1/23>
<3/14> <3/15> <3/13>
KM201 Main Contactor

Y202 Drain Solenoid KM205 Oil Pump Contactor
KM202 Star Contactor
Y203 Drain Solenoid K201 Fan Relay
KM203 Delta Contactor
Y204 Water Stop Solenoid F1 & F2 Fused Terminal 1·6A
T201 Control Transformer
KM204 Fan Contactor F3 & F4 Fused Terminal 3·15A
F5 Fused Terminal 10A PI/97/147
page 107
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CompAir
page 108
CONTROLLER CONTROLLER
DIGITAL INPUTS ANALOG INPUTS
X01 X02
VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8 VA+ ANA1 ANA2 ANA3 ANA4 VA-
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
(321)
(322)
(301)
(302)
(303)
(304)
(306)
(307)
(308)
(309)
(300A)
(320A)
R301
X3/2
CL1/4
[BL]
[BL]
[BL]
(320C)
(320B)
(304B)
R301 2K2 ohms

ML2/1
ML2/2
ML2/3
ML2/4
11
14
14
14
ML1/9
ML1/11
ML1/15
K101
KM205
KM201
KM204
12
13
13
13
1 4
2
2
3 S303
~
S301
S302
S201/2
2 2
P301
P302
(104)
1
1
1
<1/12> [BL]
R301
b
ML1/14
ML1/10
ML1/12
ML1/13
<1/12>
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
(305)
(300A)
(300B)
(300C)
(300D)
(300H)
(300E)
(300F)
(300G)
(105)
(300I)
20V-
X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 X3/1

d
<2/34>
S201/2 Emergency Stop Contact

S301 Air Filter DP Switch
S302 Oil Filter DP Switch
S303 Oil Level Sensor
R301 Resistor Terminal
P301 Delivery Pressure Transducer
P302 Interstage Pressure Transducer
PI/97/149
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
(E)
<2/7> [G/Y]
24V~ (210)
<2/25> [R]
OV (24V~) (225)
<2/25> [R]
<2/25>
<2/25>
<2/25>
CABLE No.
98140/264
1 2
AC1 AC2 EXTENSION
EXTENSION X03 X04 DIGITAL OUTPUTS
DIGITAL OUTPUTS X06
X05
VC1 OC1 OC2 OC3 OC4 OC5 OC6 VC2 OC7 OC8 OC9 OC10 OC11 OC12
1 2 3 4 5 6 7 1 2 3 4 5 6 7
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
(400)
(401)
(402)
(403)
(404)
(405)
(406)
(410)
3
3
3
3
3
3
A2
A2
A2
A2
A2
A2
K401/1 2
K402/1 2
K403/1 2
K404/1 2
K405/1 2
K406/1 2
K401
K402
K403
K404
K405
K406
A1
A1
A1
A1
A1
A1
4
4
4
4
4
4
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
(400A)
(400B)
(400C)
(400D)
(400E)
(400F)
(400G)
[BL]
(410)
20V- 20V-
X4/1 X4/1 X4/1 X4/1 X4/1 X4/1 X4/1 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2

K401 K402 K403 K404 K405 K406
NO NC NO NC NO NC NO NC NO NC NO NC
<4/21> <4/21> <4/24> <4/24> <4/27> <4/27> K401 Available Relay
<4/22> <4/22> <4/25> <4/25> <4/29> <4/29>
K402 Group Fault Relay
K403 Running Relay
K404 On Load Relay
K405 Group Trip Relay
K406 Service Due Relay
PI/97/150
page 109
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CompAir
page 110
EXTENSION EXTENSION
DIGITAL INPUTS DIGITAL INPUTS
X01 XO2
VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8 VCONT CONT9 CONT10 CONT11 CONT12 CONT13 CONT14 CONT15 CONT16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
[BL]
[BL]
[BL]
[BL]
[BL]
(500)
(511)
(512)
(513)
(LK1)
(510)A
ML1/32
ML1/30
S501
S502
13 Q101 14
ML1/31
ML1/33
[BL]
[BL]
[BL]
[BL]
[BL]
(LK1)
(500)
(510A)
(510B)
(510C)
(510D)
X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/2 X5/2 X5/2 X5/2 X5/2 X5/2 X5/2 X5/2 X5/2
ELECTRICAL CONNECTION DIAGRAM (5 of 6)

S501 St.1 Oil Pressure Switch
S502 St.2 Oil Pressure Switch
Q101 MPCB Aux. Contact
PI/97/151
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
EXTENSION EXTENSION
ANALOG INPUTS ANALOG INPUTS
X08 X07
VA18_1 ANA1 ANA2 ANA3 ANA4 GA_1 VA18_2 ANA5 ANA6 ANA7 ANA8 GA_2
1 2 3 4 5 6 1 2 3 4 5 6
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
(601)
(602)
(603)
(611)
(612)
(613)
(614)
(605A)
(615A)
ML1/24
ML1/22
ML1/26
ML1/28
ML1/16
ML1/20
ML1/18
R601 Plant Delivery Temp.
R605
R606
R607
R608
R601
R602
R603
R602 St.2 Intake Temp.
R603 Oil Temp.
R605 Water In Temp
ML1/17
ML1/19
ML1/21
ML1/25
ML1/23
ML1/27
ML1/29
R606 Water Out Temp.
R607 St.1 Out Temp.
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
[BL]
R608 St.2 Out Temp
(605B)
(605C)
(605D)
(605A)
(615B)
(615D)
(615C)
(615E)
(615A)
X6/1 X6/1 X6/1 X6/1 X6/1 X6/2 X6/2 X6/2 X6/2 X6/2

PI/97/152
page 111
CompAir
page 112
APPENDIX 3
The Pressure Systems and Transportable Gas Container Regulations 1989
page 113
CompAir
APPENDIX 3
THE PRESSURE SYSTEMS AND Note: The intervals between examination and
TRANSPORTABLE GAS CONTAINER calibration of components, e.g. pressure vessels,
REGULATIONS 1989 pressure relief valves etc., will be defined by the
‘competent person’ preparing the written scheme.
The circuit diagram shown below is provided to
assist a ‘competent person’ in preparing a written In defining these periods the ‘competent person’
scheme of examination for a system incorporating must take into account the recommendations of
the air compressor(s). the component part manufacturer, the Health and
Safety Executive (H & SE) and the British
Compressed Air Society (BCAS).
12 13 14
1 2
15 16
4
5
17 6
18
3
+ -
11
19
21
M + -
20
10
7 8 9
16
15
PI/97/093
1. Intake Air Filter
2. Suction Regulator 12. Unloader Solenoid Valve
3. First Stage Air-end  13. Regulation Air Line Filter

4. Intercooler  1st Stage 14. Shuttle Valve
5. Pressure Relief Valve  15. Strainer (2)

6. Pressure Transmitter 16. Condensate Drain Valve (2)
7. Second Stage Air-end
 17. Air Filter Switch

8. Non-return Valve  18. Temperature Sensor
9. Aftercooler
 19. Temperature Sensor
 2nd Stage
10. Pressure Relief Valve  20. Temperature Sensor
11. Pressure Transmitter  21. Temperature Sensor
AIR COMPRESSOR CIRCUIT DIAGRAM
page 114
APPENDIX 4
SAMPLE LOG SHEETS
Page
Introduction 116
Values at Commissioning 117
Commissioning Configurations 118
Operational Settings 118
Weekly Checks 119
Performance Log 120
4000 hr Service (Service A) 120
8000 hr Service (Service B) 121
16000 hr Service (Service C) 121
Compressor History Log 122
page 115
CompAir
APPENDIX 4
SAMPLE LOG SHEETS
Introduction
The following sample log sheets are issued as a

guide to the user and can be used along with the
Ownership Data sheet to form a compressor log
book.
If these sample log sheets are used, they MUST

be used in conjunction with the User Manual, not
as a replacement.
page 116
VALUES AT COMMISSIONING
Note: All readings to be taken from SureScan except oil and interstage pressures which are taken from the
gauges.
Item Value Unit Inspection Date
Max. pressure bar
Max. overpressure bar
Star/delta time sec.
Load delay time sec.
Max. service hours hrs
Auto re-start delay sec.
Interstage trip bar
Interstage alarm bar
Oil temp. trip °C
Oil temp. alarm °C
St. 1 delivery trip °C
St. 1 delivery alarm °C
St. 2 intake trip °C
St. 2 intake alarm °C
St. 2 delivery trip °C
St. 2 delivery alarm °C
Plant del trip °C
Plant del alarm °C
Water in trip °C
Water in alarm °C
Water out trip °C
Water out alarm °C
Oil pressure gauge bar
Interstage pressure gauge bar
page 117
CompAir
COMMISSIONING CONFIGURATIONS
Item Setting Inspection Date
Language
Unit of Pressure
Unit of Temperature
Compressor Number
Comms Baud Rate
Fault Input Config.
Return to Previous Menu
OPERATIONAL SETTINGS
Item Setting Inspection Date
P1 Set Point
P2 Set Point
Run On Time
Drain Open Time
Drain Shut Time
page 118
WEEKLY CHECKS
Item Week 1 Week 2 Week 3 Week 4
Date
Running Hours Total
Hours On Load
Enclosure Filters
Intercooler Condensate Drain
Aftercooler Condensate Drain
Reg. Air Line Filter
Status Display
page 119
CompAir
PERFORMANCE LOG
This log is provided to enable the user to keep a written record of compressor performance and as an aid to
fault diagnostics. It is recommended that the readings are recorded regularly, as part of the weekly service,
with the compressor in normal operating condition.
Item Value Unit Inspection Date
Delivery pressure bar
Interstage pressure bar
Total hours hrs
Hours on load hrs
Service hours to run hrs
°
Oil Temp C
°
St 1 delivery temp. C
°
St 2 intake temp. C
°
St 2 delivery temp. C
°
Plant del temp. C
°
Water in temp. C
°
Water out temp. C
Oil pressure bar
4000 hr SERVICE (Service A)
Item Value/Completed
Date
Total Hours
Hours On Load
Water Strainer
Hoses and Pipework
Flange Bolts/Screws Torque
page 120
8000 hr SERVICE (Service B)

A 4000 hr (Service A) plus the following:
Date
Total Hours
Off Load Hours
Oil Breather Filter
Oil Change
Oil Filter Element
Intake Air Filter Element
Balance Piston Diaphragms
Reg. Air Line Filter Element
Intercooler Tubestack
Aftercooler Tubestack
Oil Cooler
Drive Motor Connections
Starter Connections
2nd Stage non-return Valve
Cooling Water Quality
16000 hr SERVICE (Service C)

An 8000 hr (Service B) plus the following:
Date
Total Hours
Hours On Load
Suction Reg. Valve Diaphragm
Drive Coupling Inserts
Starter Contacts
page 121
CompAir
COMPRESSOR HISTORY LOG SHEET
Introduction
It is recommended that a written log be kept of the compressor fault history.
Model Memory Log Number
Serial 1 2 3 4 5 6 7 8 9 10 11
Date
By
Fault Message
Status Message
Total Hours
Discharge P bar
Interstage P bar
Oil Temp °C
LP Dely Temp °C
HP Inlet Temp °C
HP Dely Temp °C
Plant Dely Temp °C
Water In Temp °C
Water Out Temp °C
Oil Pressure bar
page 122
12 13 14 15 16 17 18 19 20 21 22 23 24 25
page 123
CompAir
page 124
APPENDIX 5
COOLING WATER QUALITY
page 125
CompAir
APPENDIX 5
Introduction
To ensure that the cooling water system does not foul prematurely, it is recommend that cooling water is
provided from a closed circuit radiator system and that the water quality meets the Quality (A) requirements
below. If cooling water is to be provided from another source, the cooling water should be checked
periodically to ensure that it meets the Quality (A) requirements.
ITEM QUALITY (A)* QUALITY (B)*
pH at 25°C 6.5 to 8.0 6.5 to 8.0
Conductivity at 2 Less than 800 Less than 200

(Micro-Siemens / cm)
Total hardness as CaCO3 Less than 200 Less than 50

(ppm)
M-Alkalinity as CaCO3 Less than 100 Less than 50

(ppm)
Chlorine ion; Cl- (ppm) Less than 200 Less than 50
Sulphuric acid ion; SO42- (ppm) Less than 200 Less than 50
Total iron; Fe (ppm) Less than 1.0 Less than 0.3
Silica; SiO2 (ppm) Less than 50 Less than 30
Sulphur ion; S2- (ppm) 0 0
Ammonium ion; NH4+ (ppm) 0 0
Particulates Less than 160 microns Less than 160 microns
* Where Quality (A) refers to the circulating water and Quality (B) refers to the replenishment water.
Inspect the circulating water regularly to confirm that it meets Quality (A) as the quality will gradually
deteriorate.
page 126

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6000F - User Manual 1600

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Oil Free Screw User Manual

C20160-1600 Issue 2, July 1997

OIL FREE ROTARY SCREW AIR COMPRESSORS

Serial Numbers from:

504 F200-0103 604 F205-0601 609 F118-1101

CONTENTS Illustrations Page

Page Control Panel 13

Model: 1st Stage

Year: Motor Serial Number:

Delivery Date: Intercooler Serial Number:

Maximum Pressure: Intercooler Certificate Number:

kW: Aftercooler Serial Number:

Motor rpm Aftercooler Certificate Number:

V. Ph. Hz. Compressor Lubricant:

M3/min Lubricant Capacity:

Motor Bearing Grease:

LOCAL COMPAIR DISTRIBUTOR

Contact Names: Parts:

504 505 506 507 508

509 510 512 515

Title Part No.

Repair Manual AC20160-1556

Parts List (multi-lingual) C20160-1635 (504-508 and 604-608)

C20160-1636 (509-515 and 609-615)

To ensure the continued trouble-free operation of ● Any unauthorised modifications or

● Such hazardous conditions may lead to

USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY

Warnings, Cautions and Notes 6

General Safety Precautions 7

Maintenance and Repair Precautions 8

Precautions in the Event of Fire 9

1. GENERAL 2. WARNINGS, CAUTIONS AND NOTES

Most accidents which occur during the operation 2.1 Warnings

Failure to observe the precautions given under

WARNING: RISK OF HIGH

Incorrect operational procedures causing possible

Methods to make the job easier and points which

Installation work must only be carried out by 5. OPERATIONAL PRECAUTIONS

Before dismantling any part of the compressor unit

After completion of repair or maintenance work

The unit is a fully enclosed, oil-free, two-stage, 2.1 Description

The electronic control system is microprocessor

1. Psi Units Indicator 19. Remote Control Legend

The air system is protected by two safety valves.

5. COOLING SYSTEM The intercooler and aftercooler are each provided

The flow of coolant is regulated by valves fitted in

1. Temperature Sensor ‘Water Out’ 7. Intercooler Flow Control Valve

1. Oil Sump 9. First Stage Air-end

6.1 Description The monitoring system also displays alarm and/or

1. Suction Regulator 5. Non-return Valve

1. Intake Air Filter 12. Unloader Solenoid Valve

REGULATION SYSTEM (SCHEMATIC)

The compressor motor has a Star/Delta starter

STARTER DELTA MAIN

STARTER ASSEMBLY LAYOUT

ANALOG INPUTS DIGITAL OUT

F3/F4 Fused terminal, 3·15A

K406 Service due relay

MODELS 504–508 and 604–608

Air-ends: Two-stage, oil-free screw

Main drive motor rotation: Anti-clockwise viewed from non-drive end

Approximate gross weight, kg: 604–07W 1923

Machine Power Pressure Motor IP 50Hz