CompAir

CYCLON SR, and LSR

AIR COMPRESSORS

REPAIR MANUAL
Serial Numbers from:
F180-0106 (Cyclon 345SR)
F170-0112 (Cyclon 475SR)
F180-0101 (L45SR)
F170-0112 (L75SR)
F171-0100 (L120SR)

AC20160-1822, Issue 1, November 2002

CompAir

GENERAL INFORMATION
These compressors are intended for compressing atmospheric air and are not suitable for compressing any
other gas. They are designed and manufactured to give optimum performance, with long life and reliability.
This manual gives the user all the information required to install and operate the compressors and carry out the
regular schedules for servicing and maintenance which will ensure the maximum satisfactory service life.
Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of
CompAir companies and distributors. If replacement parts are needed, the user should contact the local
CompAir company or distributor in the first instance.
The information given in this manual was correct at the time of printing but modifications to parts and
procedures may be made without notice which could affect the servicing requirements of the compressors.
Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir
company or distributor who is supplied with revised and up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL and SERIAL NUMBER.
Throughout this manual all pressures quoted are gauge pressure unless otherwise specified.

WARRANTY
The conditions of the CompAir Warranty are set out in the Company's standard Conditions of Sale available
from the CompAir company or distributor supplying the machine.

MAINTENANCE
To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenance
and servicing are carried out in accordance with the information given in the Maintenance section of this
manual. If any replacement or repair is needed use only CompAir Genuine Parts.

USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY

COULD BE AFFECTED IF A SERVICE OR REPAIR IS CARRIED
OUT USING NON-GENUINE PARTS.

AC20160-1822, Issue 1, November 2002

CompAir

CONTENTS

Chapter

Title

Safety Procedures

Product Improvements

General Description

Technical Data

Mechanical Fault Finding

Components

Maintenance

Electrical Systems and Fault Diagnosis

Disassembly and Assembly (Mechanical)

Appendix 1

Dimensions

Appendix 2

Diagrams

Associated Publications
Title

Part Number

Cyclon 345SR Parts List

C20160-1736

Cyclon 475SR Parts List

C20160-1615

L45SR Parts List

C20160-1790

L75SR Parts List

C20160-1759

L120SR Parts List

C20160-1811AX

Cyclon 345SR and 475SR User Manual

C20160-1726

L45SR, L75SR and L120SR User Manual (English)

C20160-1726

Power Converter Parts Manual

T.B.A.

AC20160-1822, Issue 1, November 2002

CompAir

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Safety Procedures

CHAPTER

1
SAFETY PROCEDURES

1.
2.
2.1
2.2
2.3
3.
4.
5.
6.
7.
8.

GENERAL
WARNINGS, CAUTIONS AND NOTES
Warnings
Cautions
Notes
GENERAL SAFETY PRECAUTIONS
INSTALLATION PRECAUTIONS
OPERATIONAL PRECAUTIONS
MAINTENANCE AND REPAIR PRECAUTIONS
PRECAUTIONS IN THE EVENT OF FIRE
DISPOSAL

AC20160-1822, Issue 1, November 2002

Chapter 1, page 1

CompAir

SAFETY PROCEDURES
1.

GENERAL

Most accidents which occur during the operation

and maintenance of machinery are the result of
failure to observe basic safety rules or precautions.
An accident can often be avoided by recognising a
situation that is potentially hazardous.
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.
The attention of users in the UK is drawn to the
Health and Safety at Work Act, 1974, the
Regulations of the Institution of Electrical Engineers
and the Pressure Systems and Transportable Gas
Container Regulations 1989.
CompAir cannot anticipate every possible
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
recommended by CompAir he must ensure that the
unit will not be damaged or made unsafe and that
there is no risk to persons or property.
The standard builds of all CompAir products are not
intended for use in either explosive or potentially
explosive atmospheres as defined in Directive 94/9/
EC. An explosive atmosphere is a mixture with air,
under atmospheric conditions, of flammable gases,
vapours, hazes or dust in which, after ignition has
occurred, combustion propagates to the entire
unburned mixture and may cause a hazard. A
potentially explosive atmosphere is an atmosphere
which could become explosive due to local
conditions.
Failure to observe the precautions given under
Safety Procedures may be considered dangerous
practice or misuse of the compressor unit.

2.

WARNINGS, CAUTIONS AND NOTES

2.1

Warnings

Warnings call attention to operations or procedures

involving specific hazards which could cause injury
or death and are identified by the following symbols
on the unit and in the text of the manual.

WARNING: RISK OF DANGER

WARNING: RISK OF ELECTRIC

SHOCK

WARNING: RISK OF HOT

SURFACES

WARNING: CONSULT MANUAL

WARNING: RISK OF HIGH

PRESSURE

WARNING: ENTRY DELAY

ENERGISED
CAPACITORS

2.2 Cautions
Incorrect operational procedures causing possible
damage to the compressor unit are identified by a
CAUTION in the text of this manual.

Chapter 1, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Safety Procedures

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.

3.

GENERAL SAFETY PRECAUTIONS

If using compressed air for cleaning purposes,

ensure safety regulations are complied with and
appropriate clothing and eye protection is worn.
Never direct compressed air onto your skin or at
other people.
Never use compressed air to clean loose dirt from
clothing.
Before releasing compressed air through a hose
make sure that the free end is held securely so that
it cannot whip and cause injury.
Avoid injury by using a hoist to lift heavy loads.
Check that all chains, hooks, shackles and slings
are in good condition and are of the correct
capacity. They must be tested and approved
according to local safety regulations.
Cables, chains or ropes must never be applied
directly to lifting eyes. Always use an appropriate
shackle or hook, properly positioned. Arrange lifting
cables so that there are no sharp bends.

Precautions must be taken to ensure that no injury

is caused to passers-by through loose clothing
being sucked into the air intake.
Ensure that the air delivery pipe from the
compressor to the users pipework or receiver is
free to expand and that no flammable material is
within the vicinity.
A shut-off valve must be fitted in the delivery air line
to enable the compressor unit to be isolated. This is
particularly important if more than one unit is to be
coupled in parallel or connected to an existing air
supply system.
The minimum pressure/non-return valve is not
intended as an isolating valve and should not be
relied upon for this purpose. In addition, it may be
necessary to install shut-off valves elsewhere in the
system to allow a dryer or other equipment to be
by-passed.
A pressure relief valve must be installed between
any compressor unit and the shut-off valve/s. A
pressure relief valve is fitted on the reclaimer
vessel as standard equipment.
A pressure relieving device must be fitted to every
pressure vessel, or equipment containing air at
above atmospheric pressure, when installed
downstream of the unit.

5.
Use a spreader bar to avoid side loads on hooks,
eyes and shackles.
When a load is on a hoist stay clear of the danger
area beneath and around it. Keep lifting
acceleration and speed within safe limits and never
leave a load hanging on a hoist for longer than is
necessary.

OPERATIONAL PRECAUTIONS

The compressor unit must only be operated by

competent personnel under a qualified supervisor.
Do not run the compressor with doors open or
covers removed except when checking reclaimer
operation.
Never remove or tamper with the safety devices,
guards or insulation materials fitted to the unit.

4.

INSTALLATION PRECAUTIONS

Installation work must only be carried out by

competent personnel under a qualified supervisor.
A fused isolating switch must be fitted between the
main power supply and the compressor.
Ensure that air drawn into the air intake will not be
contaminated with flammable fumes or vapours,
since this could cause an internal fire or explosion.

AC20160-1822, Issue 1, November 2002

The compressor must only be operated at the

supply voltage and/or frequency for which it is
designed
On a unit equipped with an Automatic Start/Stop
system, attach a sign stating THIS UNIT MAY
START WITHOUT WARNING next to the display
panel.

Chapter 1, page 3

CompAir

On a unit equipped with an Automatic Restart

device, attach a warning notice stating THIS UNIT
HAS BEEN MODIFIED AND WILL START
AUTOMATICALLY ON APPLICATION OF
POWER next to the display panel and on the inside
of the unit next to the starter contactors.

6.

WARNING

If the unit is equipped with a Remote Control device,

attach warning notices stating THIS UNIT CAN BE
STARTED REMOTELY in prominent locations, one
on the outside of the unit, the other inside the
control compartment.
As a further safeguard, take adequate precautions
to make sure there is no one checking or working
on the unit before attempting to switch on remotely
controlled equipment. Attach a CHECK THAT ALL
PERSONNEL ARE CLEAR OF THE UNIT
BEFORE STARTING or similar warning notice to
the remote start equipment.
During normal operation no internal part of the
compressor unit should reach a temperature above
120C and protection devices are fitted to prevent
excessive temperatures occurring.
If there is any indication that the compressor is
overheating it must be shut down and the cause
investigated. Beware of burns from hot metal parts
or hot oil when working on a unit which has
recently been shut down.
The compressor must not be operated at
pressures above the nominal pressure given on
the data plate.
The compressor must not be operated in ambient
temperatures outside of those given under Leading
Particulars.
The Noise at Work Regulations 1989 suggest that
ear protectors should be worn where noise levels
are 85 dB(A) or higher. With all covers in place, the
noise levels of the compressors described in the
manual are substantially lower than this figure
unless installed in an already noisy environment.
Be aware that high noise levels can interfere with
communication.

Chapter 1, page 4

MAINTENANCE AND REPAIR

PRECAUTIONS

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the
dc link capacitors have fully discharged
before starting work on the compressor.

Maintenance, repairs or modifications must only be

carried out by competent personnel under a qualified
supervisor
Lethal voltages are present in the electrical circuits
and extreme caution must be exercised whenever it
is necessary to carry out any work on the electrical
system.
If replacement parts are needed use only CompAir
Genuine Parts.
Do not open the starter compartment or touch
electrical components while voltage is applied
unless it is necessary for measurements, tests or
adjustments. Such work should be carried out only
by a qualified electrician equipped with the proper
tools and wearing appropriate body protection
against electrical hazards.
Before removing any panels from the enclosure, if
fitted, or dismantling any part of the unit, carry out
the following preparatory operations:1.

Isolate the compressor unit from the main

electrical power supply. Lock the isolator in
the OFF position and remove the fuses.

2.

Attach a label to the isolator switch and

display panel carrying the warning WORK IN
PROGRESS DO NOT APPLY VOLTAGE
Do not switch on electrical power or attempt to
start the unit if a warning label is attached.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Safety Procedures

3.

Close the isolating valve between the

compressor unit and the users pipework.
Attach a label to each valve carrying the
warning WORK IN PROGRESS DO NOT
OPEN

4.

Ensure that the blowdown system has

operated to release all pressure from the
reclaimer.

5.

Check that the pressure gauge registers zero.

Release any remaining pressure from the
delivery side of the reclaimer element by
slackening a pipe connection to the
differential pressure indicator. Release any
residual pressure from the upstream side of
the reclaimer element by slowly slackening
the oil filler plug on the reclaimer. Release
any pressure in the aftercooler by slackening
the pipe at the bottom of the moisture
separator. Tighten the plug and pipe
connections.

Use only lubricating oils and greases approved by

CompAir. Make sure that the selected lubricants
comply with all relevant safety regulations,
especially with regard to the risk of explosion or fire
and the possibility of decomposition or the
generation of hazardous gases.
Always clean up oil spills from both the inside and
outside of the compressor unit before and after
maintenance work.
Make sure that all instructions concerning operation
and maintenance are strictly followed and that the
complete unit, with all accessories and safety
devices, is kept in good running order.
The accuracy of pressure and temperature gauges
and switching thermometers must be regularly
checked. They must be renewed when acceptable
tolerances are exceeded.
Protection devices must be tested as described in
the Maintenance section of this manual.
Keep the compressor unit clean at all times. Protect
components and exposed openings by covering
with clean cloth or tape during maintenance and
repair work.
Protect the motor, air intake, electrical and
regulation components against the entry of
moisture, e.g. when steam cleaning.

AC20160-1822, Issue 1, November 2002

Precautions must be taken when carrying out

welding or any repair operation which generates
heat, flames or sparks. The adjacent components
must always be screened with non-flammable
material and if the operation is to be carried out
near any part of the oil system, or close to a
component which may contain oil, the system must
first be thoroughly purged, preferably by steam
cleaning.
Never use a light source with an open flame to
inspect any part of the unit.
In no circumstances must any welding work or
other modification be carried out on the reclaimer
or any other pressure vessel.
Before dismantling of 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.
Check the direction of rotation of the motor when
starting up the compressor initially and after any
work on the electrical connections or switchgear.
Do not use any flammable liquid to clean valves,
filter elements, cooler air passages, air pipes or any
component carrying a flow of air during normal
operation. If chlorinated hydrocarbon nonflammable fluids are used for cleaning, safety
precautions must be taken against any toxic
vapours which may be released.
Do not use carbon tetrachloride.
Precautions must be taken when using acids,
alkalis and chemical detergents for cleaning
machine parts and components. These materials
cause irritation and are corrosive to the skin, eyes,
nose and throat. Avoid splashes and wear suitable
protective clothing and goggles. Do not breathe
mists. Ensure that water and soap are readily
available.
When disposing of condensate, old oil, used filter
elements and other parts and waste material of any
kind make sure that there is no pollution of any
drain or natural water-course and that no burning of
waste takes place which could cause pollution of
the air. Protect the environment by using only
approved methods of disposal.

Chapter 1, page 5

CompAir

7.

PRECAUTIONS IN THE EVENT OF FIRE

Use extreme caution when handling components

that have been subjected to fire or very high
temperatures. Some components may contain
fluoroelastomer materials which decompose under
these conditions to form highly corrosive residues.
Skin contact can cause painful and penetrating
burns resulting in permanent skin and tissue
damage.

8.

DISPOSAL

When items of equipment are taken out of service

for disposal it is recommended that the following
instructions are adhered to:
1.

In order to prohibit the bringing back into

service of of equipment by persons unknown,
it should be rendered unusable in order to
avoid improper re-use.

2.

Alternatively all such items of equipment

should be stripped into their component form
for material composition disposal e.g. base
metals, plastics, fabrics etc and be subject to
normal industrial waste re-cycling processes.

3.

Bio-degradable items should be subject to

normal industrial waste disposal processes.
Ensure that no plastic, rubber or composite
materials are disposed of by incineration.

4.

Ensure that all fluid waste e.g. lubricating oils

and greases, anti-freeze agents, refrigerant
fluids or corrosive inhibitors should be
separated and disposed of by authorised
salvage disposal or recycling systems
ensuring that none is permitted to enter a
waste water system.

Chapter 1, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

CHAPTER

2
PRODUCT IMPROVEMENTS
1.

SUMMARY

MACHINE/S

SERIAL NUMBERS

IMPROVEMENT

475SR
475SR
345SR, 475SR
475SR
345SR
345SR
475SR
345SR
475SR
L45SR, L75SR

F170-0111 to F170-0145
all
All
All
F170 - 850 onwards
F180 - 650 onwards
All
-

Cold Start Inhibit.

Compressors Transport Packaging.
Obsolete Gate Drive Board.
Motor cable routing.
Failure of EMC filters
Phase Failure Kit (400V)
Phase Failure Kit (440/460V)
Power Converter Ventilation Kit
Power Converter Ventilation Kit
Enhancements

773
785
798
803
804
805
806
810
811
812

3
5
6
8
10
11
16
21
26
31

Single Pass Air/Oil Cooler Retrofit

Kit

822

33

475SR, L75SR

2.

BULLETIN PAGE

NEW BULLETINS

Insert when issued.

MACHINE/S

SERIAL NUMBERS

AC20160-1822, Issue 1, November 2002

IMPROVEMENT

BULLETIN PAGE

Chapter 2, page 1

CompAir

Chapter 2, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

COLD START INHIBIT

WARNING
!

1.

3.

Refer to the safety procedures in the User

Manual before carrying out any maintenance
or servicing work on the compressor unit.

CAUTION
When working wfth static sensitive components
i.e.. circuit cards and memory ICs etc., always
take aniti-static precautions.

Lethal voltages are used in this equipment.

Use extreme caution when carrying out
electrical checks. Isolate the power supply
before starting any maintenance work

INTRODUCTION

If an oil injected compressor is started when the oil

temperature is below the specified minimum of 0C,
serious damage to the air end may result. The low
oil temperature will result in high oil viscosity leading
to insufficient oil flow.
To ensure that a compressor cannot be started
during below zero conditions, a Cold Start Inhibit
feature has been added to the control program of
current production compressors, The improved
program. is also available for installation to existing
compressors.
If there is a possibility that the ambient temperature
around the compressor is likely to fall below zero, a
heater kit is available for fitting to the compressor.
Please contact Product Management at CompAir
UK for further details.

2.

1.

Always transport static sensitive components

in anti-static bags or containers.

2.

Never touch the rnetal pins of electronic IC

devices.

3.

Never place static sensifive components onto

a metal surface. Always place directly into an
anti-static bag or container.

4.

Always ensure any body static is discharged

before handling static sensitive components
by touching an earthed surface at regular
intervals.

Switch off and isolate the power supply to the

compressor.

2.

Remove the canopy panel as required and the

starter area access panel.

3.

Remove the controller from the compressor.

4.

Remove the screws located adjacent to the

electrical plug connections on the rear of the
controller.

5.

Using a spanner, remove the plug securing

nuts adjacent to the D type connector(s).

6.

Remove the rear controller enclosure securing

screws.

7.

Remove the rear controller cover.

8.

The control program IC can be removed

without dismantling the circuit cards. To
eliminate the possibility of re-connection
errors, it is recommended that the circuit
cards are not dismantled.

REPLACEMENT PROGRAM

The replacement program for the Surescan Mk.3 is

number C20620/10/**/B3

AC20160-1822, Issue 1, November 2002

REPLACEMENT PROGRAM INSTALLATION

Chapter 2, page 3

CompAir

Before removal of the control program IC,

make a note or pencil sketch of the orientation
and position of the IC in its socket. Note the
orientation marks on the 1C, socket and
circuit board.

4.

OPERATION

Note: refer to the compressor User Manual for

operating details.
When the temperature in the air end is 1C or less,

9.

Using a srnall screwdriver or similar tool,

carefully remove the control program IC from
its socket.

10.

Insert the new control prograrn 1C. Check the

orientation and ensure that each pin enters
the socket correctly. (The pins must not bend
underneath the IC during insertion.)

11.

When re-assembling the controller, replace

the rear cover securing screws first to hold the
cover in place. Then insert and tighten the
screws and nuts adjacent to the electrical
plug connections before finally tightening the
rear cover screws.

12.

a) The High Delivery Temperature indicator on the

controller will flash with a double pulse.
b) The message Start Inhibited will be shown on
the controller display (unless the compressor
is on Standby or Remote Stopped).
c) The start inhibit will not be recorded on the
Fault History Record or affect the Group Fault
Output.
The inhibit circuit will be automatically reset as the
temperature rises above 1C.

Re-connect to compressor and test.

bar
psi

HW 0274

Fig. 1 SureScan Controller

Chapter 2, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

COMPRESSORS TRANSPORT PACKAGING

1.

Locate the compressor close to the

installation position using a forklift to lift the
pallet.

2.

Remove the four nuts and washers securing

the compressor to the pallet.

3.

Raise the compressor, using the forklift, until

it is clear of the locating studs on the pallet.

This bulletin advises distributors and installers of

recommended handling procedures.

4.

Place the compressor in the designated

position.

METHOD

5.

Remove the plastic cover from the

compressor.

WARNING

6.

Remove the cardboard packing from the three

removable panels and the service door on the
compressor.

LIFTING OPERATIONS MUST BE DONE BY

QUALIFIED PERSONNEL USING APPROVED
EQUIPMENT.

7.

Install and commission the compressor as

detailed in the User Manual.

INTRODUCTION
The Cyclon 475SR compressor may be secured to
a pallet to reduce the chances of damage in transit.
Cardboard packing may also be fitted to the three
removable panels and the service door of the
compressor.

CAUTION: The preferred method of handling the

compressor is by a forklift. The compressor is not
designed for overhead lifting. If a forklift is not
available, the compressor may be lifted using jacks
and suitable spreader bars through the fork tunnels
on the compressor.

AC20160-1822, Issue 1, November 2002

Chapter 2, page 5

CompAir

OBSOLETE DRIVE BOARD

WARNING

1.

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

INTRODUCTION

The Gate Drive Board, part number C20606-83, as

fitted to some Cyclon 345SR and Cyclon 475SR
compressors is now obsolete.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

2.

METHOD

1.

Remove the old gate drive board from the

compressor and install the new one.

2.

Rewire the compressor to gate drive board

connectors as detailed in Table 1.

3.

Attach the connectors to the gate drive board.

Gate Drive Board, part number C20606-143, may be

supplied when C20606-83 is ordered.
When fitting the new Gate Drive Board, part number
C20606-143, some wiring connection changes are
required.

Chapter 2, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

Connector

Pin

C20606-83

C20606-143 C20606-183 C20606-283

A1

1
2
3
4
5
6
7

150
151
152
-

151
150
152
-

150
151
152
-

150
151
152

A2

1
2
3
4
5
6
7

156
157
158
-

157
156
158
-

156
157
158
-

156
157
158

B1

1
2
3
4
5
6
7

153
154
155
-

154
153
155
-

153
154
155
-

153
154
155

B2

1
2
3
4
5
6
7

159
160
161
-

160
159
161
-

159
160
161
-

159
160
161

Table 1 Gate Drive Board Connector Wiring

When a C20606-283 board is used four

Phoenix 7-way Combicom connectors are
required, Ref: MSTB 2,5/7 - ST5,08

AC20160-1822, Issue 1, November 2002

Chapter 2, page 7

CompAir

MOTOR CABLE ROUTING

WARNING

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

DETAIL

SOLUTION

This is to advise that on a limited number of

machines two of the four motor leads have been
routed too close to the auxiliary contactor block of
the main contactor.

Re-route the two cables that are adjacent to the

auxiliary contactor block and fit heat shield
C27399-289.

The heat from these cables has caused the

contactor block to distort and lock, thus preventing
the main contactor from operating correctly and in
some cases causing the contactor coil to fail
together with the 5 amp fuse.
Indication of this is a DC link charge fault on the
SureScan display.

METHOD
1. Stop the compressor, isolate from the main
supply and allow sufficient time for the
capacitors to discharge (refer to WARNING).
2. Open the controller enclosure door and check
that the red LEDs on gate drive board are not
illuminated.
3. Remove protective screen.
4. Slacken the two upper motor cables at the IGBT
terminal point.
5. Fit heat shield (if required) and re-route the
affected cables away from the contactor (refer to
illustrations).
6. Secure motor cables at the IGBT terminal point.
7. Re-fit protective shield, close enclosure door,
apply power to the machine and test.

Chapter 2, page 8

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

CONTACTOR HEAT SHIELD ASSEMBLY AND WIRE ROUTING

1. Heatshield C27399-289 fitted using existing fixings
2. Contactor Block
3. Motor Leads (route as shown).

AC20160-1822, Issue 1, November 2002

Chapter 2, page 9

CompAir

EMC FILTER FAILURE

WARNING

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

DETAIL

METHOD

This is to advise that a limited number of EMC filters

have failed due to the incoming power supply cables
not being properly secured at the terminal block.

1.

Remove 17mm of insulation from the end of

each of the three incoming phase cables.

2.

If finely stranded wire is used then the correct

size of ferrule must be crimped to the cable
before locating into the terminal block.

3.

Locate each cable into the terminal block and

tighten the clamp to a torque of 5Nm.

Use the following set of instructions for:

1.

All new installations.

2.

As a guide when examining existing

installations.

Note: The terminal will accept the following cables

sizes:
Rigid conductors up to 50 sq mm.
Flexible conductors up to 35 sq mm.
Conductors with ferrules up to 35 sq mm.

Chapter 2, page 10

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

PHASE FAILURE KITS 400V ( 10%)

WARNING

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

345SR MODELS
Fitting Instructions
Purpose of the kit
The kit is supplied to constantly monitor the 3
phase a.c. supply to the compressor. It monitors
both phase sequence and voltage level. If the supply
voltage on one of the phases drops, the current will
rise in the other two phases to counteract the
imbalance. This can lead to overloading of the
semiconductor fuses.
The phase failure relay will monitor the supply and
stop the compressor when one or more of the
phases drops below 70% of the set voltage. At the
same time, a Main Contactor Fault will be
displayed.
Kit

Contents

98161-32

Phase Failure Relay

98140-361

110C Black Cable

98140-362

111C Black Cable

98140-363

112C Black Cable

98140-364

137B Blue Cable

98140-365

170 Blue Cable

98150-1

Cable Ties (5 off)

98241-31

Din Rail 210mm

C20775-19

Electrical Schematic Diagram

AC20160-1822, Issue 1, November 2002

The phase failure relay is designed to be fitted on

the auxiliary control plate.
1.

Remove the finger guard.

2.

Loosen the end stops at both ends of the din

rail.

3.

Remove the third stop from the centre of the

plate and discard.

4.

Replace the existing din rail with the rail

supplied, leaving space on the left hand side
for the phase failure relay. Ensure all
connections are tight.
Drill a 6mm dia hole 15mm below the existing
earth on the auxiliary control plate.

5.

CAUTION: Make provision to ensure that no

metal particles enter the machine when
drilling.
6.

Remake the earth connection using the new

hole.

7.

Mount the phase failure relay on the din rail to

the left hand side of the manual motor starter
MCB2 (10A).

8.

Once mounted, ensure the two remaining end

stops are secured.

Chapter 2, page 11

CompAir

9.

10.

Connect wire number 110C from terminal

T1(2) on MCB2 and run to the left hand side
of the plate to terminal U of the phase failure
relay.

If the orange LED does not light:

a)

Isolate the power and allow the d.c. link to

discharge.

Repeat the instruction above for:

b)

Connect wire number 110C from terminal

T1(2) on MCB2 to terminal V of the phase
failure relay.

c)

Connect wire number 111C from terminal

T2(4) on MCB2 to terminal U of the phase
failure relay.

d)

Apply power - the orange LED should now

light.

a)

111C from MCB2 T2(4) to the phase

failure relay terminal V.

b)

112C from MCB2 T3(6) to the phase

failure relay terminal W.

11.

Connect pin of wire number 137B to terminal

14 of the phase failure relay.

12.

Connect pin of wire number 170 to terminal

11 of the phase failure relay.

13.

Run the cables 137B and 170 along the

trunking and down towards the main
contactor (RLA) located behind the auxiliary
plate.

14.

Undo the two fixing screws and remove the

auxiliary plate. Put to one side.

15.

Disconnect the blue wire number 137 from

the main contactor (RLA) auxiliary. Connect
to the new wire 137B.

16.

Connect wire number 170 to main contactor

(RLA) auxiliary.

17.

Replace the auxiliary control plate and tidy

the new wiring.

18.

Replace the finger guard.

Adjustment
The level of the monitored voltage can be adjusted
on the front of the phase failure relay using a
potentiometer. The arrow on the potentiometer
should point to the national a.c. supply voltage.
When power is applied to the machine a green LED
will indicate the power supply is ON. An orange
LED will indicate that the machine is in a
satisfactory condition.

Chapter 2, page 12

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

HW 0316

ELECTRICAL CONNECTION DIAGRAM - 1 OF 3

(SUPERSEDES DIAGRAM IN USER MANUAL)

AC20160-1822, Issue 1, November 2002

Chapter 2, page 13

CompAir

HW 0317

ELECTRICAL CONNECTION DIAGRAM - 2 OF 3

(SUPERSEDES DIAGRAM IN USER MANUAL)

Chapter 2, page 14

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

HW 0318

ELECTRICAL CONNECTION DIAGRAM - 3 OF 3

(SUPERSEDES DIAGRAM IN USER MANUAL)

AC20160-1822, Issue 1, November 2002

Chapter 2, page 15

CompAir

475SR MODELS

WARNING

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

Purpose of the kit

Fitting Instructions

The kit is supplied to constantly monitor the 3

phase a.c. supply to the compressor. It monitors
both phase sequence and voltage level. If the supply
voltage on one of the phases drops, the current will
rise in the other two phases to counteract the
imbalance. This can lead to overloading of the
semiconductor fuses.

The phase failure relay is designed to be fitted on

the din rail at the top left hand side of the enclosure.

The phase failure relay will monitor the supply and

stop the compressor when one or more of the
phases drops below 70% of the set voltage. At the
same time, a Main Contactor Fault will be
displayed.
Kit

Contents

98161-32

Phase Failure Relay

98140-356

110C Black Cable

98140-357

111C Black Cable

98140-358

112C Black Cable

98140-359

140B Red Cable

98140-360

170 Red Cable

98150-1

Cable Ties 5 off

C20775-20

Electrical Schematic Diagram

1.

Remove the finger guard.

2.

Loosen the end stops at both ends of the din

rail.

3.

Remove the third stop from the centre of the

din rail and discard.

4.

Mount the phase failure relay on the din rail

between the manual motor starter (MCB 10A)
and charging contactor (RLB).

5.

Once mounted, ensure the two remaining end

stops are secured.

6.

Connect wire number 110C from terminal

T1(2) on RLB, then run the wire to the right
hand side of the phase failure relay and
connect to terminal U.

7.

Repeat the instruction above for:

8.

Chapter 2, page 16

a)

111C from RLB T2(4) to the phase

failure relay terminal V.

b)

112C from RLB T3(6) to the phase

failure relay terminal W.

Connect pin of wire number 140B to terminal

14 of the phase failure relay.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

9.

Connect pin of wire number 170 to terminal

11 of the phase failure relay.

10.

Run the cables 140B and 170 along the

trunking and down the left hand side of of the
enclosure towards the main contactor (RLA).

11.

Disconnect the red wire number 140 from the

main contactor (RLA) coil A1. Connect the
new wire 140B to wire 140.

When power is applied to the compressor, a green

LED will indicate the power supply is ON. An
orange LED will indicate that the machine is in a
satisfactory condition.
If the orange LED does not light:

12.

Connect wire number 170 to main contactor

(RLA) coil A1.

13.

Replace the finger guard.

a)

Isolate the power and allow the d.c.

link to discharge.

b)

Connect wire number 110C from

terminal T1(2) on MCB2 to terminal V
of the phase failure relay.

c)

Connect wire number 111C from

terminal T2(4) on MCB2 to terminal U
of the phase failure relay.

d)

Apply power - the orange LED should

now light.

Adjustment
The level of the monitored voltage can be adjusted
on the front of the phase failure relay using a
potentiometer. The arrow on the potentiometer
should point to the national a.c. supply voltage.

AC20160-1822, Issue 1, November 2002

Chapter 2, page 17

CompAir

HW 0319

ELECTRICAL CONNECTION DIAGRAM - 1 OF 3

(SUPERSEDES DIAGRAM IN USER MANUAL)

Chapter 2, page 18

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

HW 0320

ELECTRICAL CONNECTION DIAGRAM - 2 OF 3

(SUPERSEDES DIAGRAM IN USER MANUAL)

AC20160-1822, Issue 1, November 2002

Chapter 2, page 19

CompAir

HW 0321

ELECTRICAL CONNECTION DIAGRAM - 3 OF 3

(SUPERSEDES DIAGRAM IN USER MANUAL)

Chapter 2, page 20

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

POWER CONVERTER VENTILATION KIT

PRODUCT IMPROVEMENT
Purpose of the Kit
This kit is supplied to combat high temperatures
within the power converter assembly. It is not
necessary to introduce this kit to all units, however
it is recommended that the modification be
performed on machines operating in a high ambient
temperature or which have experienced failure due
to high ambient temperatures within the power
converter cubicle.

The ventilation kit uses the machine cooling fan to

draw cool air through the power converter cubicle
and exhaust it via the machines cooling air
discharge, therefore allowing the components within
the cubicle to operate in free air.

WARNING

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

Kit Contents
C27349-155
C27349-136
C27349-137
C27349-157
C27349-158
C27349-159
C20089-557
A6455-64
95001-230
95179-5
95149-13
95112-4

Kit Power Converter Ventilation

Cover, Filter Retaining
1 off
Filter
1 off
Grille, Filter Retaining
1 off
Grille, Box Inlet
1 off
Grille, Box Outlet
1 off
Label, CE Electrical
1 off
Pop Rivet
8 off
Screw, Hex Head M6x25
4 off
Washer, Spring M6
4 off
Washer, Plain M6
8 off
Nut, Plain M6
4 off

Inlet Panel
Inlet Panel
Inlet Panel
Power Converter Enclosure
Power Converter Enclosure
Power Converter Enclosure
Inlet Panel
Inlet Panel
Inlet Panel
Inlet Panel
Inlet Panel

Tools Required
60mm Diameter Hole Saw
8mm Diameter Drill Bit
4mm Diameter Drill Bit
Pop Rivet Gun
Half Round File

Knife
10mm Spanner / socket
Rule
Square

AC20160-1822, Issue 1, November 2002

Chapter 2, page 21

CompAir

Fitting Instructions
1.

Remove the Inlet Panel

2.

Remove the foam from the inside of the top

section of the inlet panel and cut horizontally
across the foam approximately 420mm from
the top of the panel.

3.

Clean the remaining foam from the surface

area of the inlet panel ensuring that debris
does not enter the enclosure.

4.

Mark the centres of the four fixing and six

ventilation holes on the outside of the inlet
panel ( FIG. 1)

5.

Pilot drill both sets of holes and finish the four

fixing holes to 8mm diameter and the six
ventilation holes to 60mm diameter. De-burr
all holes and treat to prevent corrosion.

6.

Cut the filter material (C27349-137) to size

and place in filter retaining cover (C27349136).

7.

Align the assembly with the four fixing holes

on the outside of the inlet panel and using the
M6 fixings and the filter retaining grill
(C27349-157), clamp the assembly to the
inlet panel.

8.

With the inlet panel removed from the

machine, mark the centres of the fixing and
ventilation holes on the outside of the power
converter cubicle. (FIG. 2)

9.

Ensuring a safe drill length to avoid damage

to the electrical components within the power
converter pilot drill both sets of holes. Finish
the four fixing holes to 4mm diameter and the
four ventilation holes to 60mm diameter. Deburr all holes and treat to prevent corrosion.

10.

Align the grille, box inlet (C27349-158) with

the four fixing holes. Pop rivet the grille into
place and replace the inlet panel.

11.

Move the hinged auxiliary control plate to gain

access for marking out and drilling.

Chapter 2, page 22

12.

Mark the centres of the fixing and ventilation

holes on the bottom of the power converter
cubicle (FIG. 3).

13.

Ensuring a safe drill length to avoid damage

to the filter maifold assembly, pilot drill both
sets of holes.
Finish the four fixing holes to 4mm diameter
and the three ventilation holes to 60mm
diameter. De-burr all holes and treat to
prevent corrosion.

14.

Align the grille, box outlet (C27349-159) with

the four fixing holes. Pop rivet the grille into
place and replace the auxiliary control plate
and the finger guards.

15.

Apply power to the machine, enter service

diagnostics menu and through the digital
outputs run the cooling fan. Ensure a good air
flow through the power converter cubicle.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

HW 0322

FIG. 1 SIDE PANEL

AC20160-1822, Issue 1, November 2002

Chapter 2, page 23

CompAir

HW 0322

FIG. 2 INLET BOX

Chapter 2, page 24

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

HW 0323

FIG. 3 OUTLET BOX

AC20160-1822, Issue 1, November 2002

Chapter 2, page 25

CompAir

POWER CONVERTER VENTILATION KIT

PRODUCT IMPROVEMENT
Purpose of the Kit
This kit is supplied to combat high temperatures
within the power converter assembly. It is not
necessary to introduce this kit to all units, however
it is recommended that the modification be
performed on machines operating in a high ambient
temperature or which have experienced failure due
to high ambient temperatures within the power
converter cubicle.

The ventilation kit uses the machine cooling fan to

draw cool air through the power converter cubicle
and exhaust it via the machines cooling air
discharge, therefore allowing the components within
the cubicle to operate in free air.

WARNING

Refer to the safety procedures in the

User Manual before carrying out any
Maintenance work on the compressor
unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting any maintenance work.

Kit Contents
C27399-320
C27399-290
C27399-305
C27399-324
C27399-323
C27399-304
C27399-322
C20089-557
95001-230
95179-5
95149-13
95001-229
95149-13
95179-5
95001-229
A10308-10
98140-366
95001-231
95149-13
95149-18
95179-5
95112-4

Chapter 2, page 26

Kit Power Converter Ventilation

Grille, Inlet Power Converter
1 off
Filter
1 off
Grille, Filter Retaining
1 off
Guard, Bottom Finger
1 off
Outlet Cover
1 off
Outlet Grille
1 off
Label, CE Electrical
1 off
Screw, Hex Head M6x25
4 off
Washer, Spring M6
4 off
Washer, Plain M6
8 off
Screw, Hex Head M6x20
2 off
Washer, Plain M6
2 off
Washer, Spring M6
2 off
Screw, Hex Head M6x20
2 off
Washer, conical M6
2 off
Earth Cable
1 off
Screw, Hex Head M6x30
1 off
Washer, Plain M6
2 off
Washer, shakeproof M6
1 off
Washer, Spring M6
1 off
Nut, Plain M6
3 off

Door outside
Door outside
Door inside
Backplate rear
Backplate rear
Power Converter Enclosure
Door inlet filter
Door inlet filter
Door inlet filter
Outlet grille and cover
Outlet grille and cover
Outlet grille and cover
Finger Guard
Finger Guard
Finger Guard
Earth Cable to Finger Guard
Earth Cable to Finger Guard
Earth Cable to Finger Guard
Earth Cable to Finger Guard
Earth Cable to Finger Guard

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

Tools Required
7.
44mm Diameter Hole Saw
60mm Diameter Hole Saw
8mm Diameter Drill Bit
Pilot Drill Bit
Drill.

Half Round File

10mm Spanner / socket
Rule
Square

Fitting Instructions
1.

Disconnect and remove the SureScan

controller. Remove the power converter door.

2.

Mark the centres of the four fixing and nine

ventilation holes on the inside of the power
converter door (FIG. 1).

3.

Pilot drill both sets of holes and finish the four

fixing holes to 8mm diameter and the six
ventilation holes to 60mm diameter. De-burr
all holes and treat to prevent corrosion.

4.

5.

6.

Cut the filter material (C27399-305) to size

and place in the inlet grill (C27399-290) of the
power converter.

Note: Ensure no swarf or debris enters the

power converter or main drive motor when
drilling.
8.

Align the grille outlet (C27399-322) and cover

(C27399-304) with the four fixing holes to the
rear of the power converter backplate. Secure
using the M6 fixings (95001-229, 95149-13,
95179-5) from within the power converter
cubicle.

9.

Remove the perspex guard from the bottom of

the power converter cubicle and connect the
earth cable (98140-366) to the main earth bar.

10.

Fit the earth fixings to the replacement finger

guard (C27399-323).

Align the assembly with the four fixing holes

on the outside of the power converter door
and using the M6 fixings (95001-230, 9514913, 95179-5) and the filter retaining grill
(C27399-324), clamp the assembly to the
door.

Order of fitting:
95001-231
95149-18
C27399-323
95112-4
95112-4
95149-13
98140-366
95149-13
95179-5
95112-4

Mark the centres of the fixing and ventilation

holes on the back of the power converter
backplate (refer to FIG. 2 or 3 according to
serial number)
Note: To avoid damage to components within
the power converter cubicle note the following
serial numbers:Post serial number F170-0354 - refer to
FIG.2.

Ensuring a safe drill length to avoid damage

to the electrical components within the power
converter pilot drill both sets of holes. Finish
the four fixing holes to 8mm diameter and the
four ventilation holes to 44mm diameter. Deburr all holes and treat to prevent corrosion.

Screw, Hex Head M6x30

Washer, Shakeproof M6
Finger Guard
Nut, Plain M6
Nut, Plain M6
Washer, Plain M6
Terminate Earth Cable
Washer, Plain M6
Washer, Spring M6
Nut, Plain M6

Then secure the new finger guard in the

bottom of the power converter cubicle using
the M6 fixings (95001-229, A10308-10).
11.

Replace the power converter door, refit and

connect the SureScan controller.

12.

Apply power to the machine, enter service

diagnostics menu and through the digital
outputs run the cooling fan. Ensure a good air
flow through the power converter cubicle.

Pre serial number F170-0353 - refer to FIG.3.

AC20160-1822, Issue 1, November 2002

Chapter 2, page 27

CompAir

HW 0325

FIG. 1 - HOLE CENTRES - POWER CONVERTER DOOR

Chapter 2, page 28

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

HW 0326

FIG. 2 - HOLE CENTRES - POWER CONVERTER BACKPLATE

AFTER SERIAL NUMBER F170-0354

AC20160-1822, Issue 1, November 2002

Chapter 2, page 29

CompAir

HW 0327

FIG. 3 - HOLE CENTRES - POWER CONVERTER BACKPLATE

BEFORE SERIAL NUMBER F170-0353

Chapter 2, page 30

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

L45SR & L75SR SPEED REGULATED ROTARY SCREW COMPRESSOR

ENHANCEMENTS
From serial nos: F170-850 onwards, F180-650 onwards
We are pleased to announce the introduction of a
number of enhancements to the LSR-Series Speed
Regulated Rotary Screw Compressors.
Modifications have been made to the power
converter, software features and compressor
protection recommendations and are effective from
the above serial nos.
This Bulletin explains the newly developed features
and improvements, the installation requirements and
includes the technical documents considered
necessary.
This information below must be read in conjunction
with the existing User Manual.

The controller itself is designed to operate for about

0.5 secs following loss of incoming power. Thus it
has time to take action and store essential data
prior to shutdown.
The action taken following power failure detection
from either source is the same. The compressor will
be shut down and then the controller will shut down.
When power to the controller is restored it will
reboot. The recovery action when power is restored
depends on the status of the machine at time of
power faiture.
Compressor Stopped ('Ready to Start')

Phase Monitor Relay Protection with Auto

Restart

In this condition, the controller will reboot to display

'Ready to Start'. These occurrences will not be
logged as it has no consequence to the system and
would normally occur in a routine power off situation.

A phase monitor relay is fitted to all models to trip

the machine in event of a power supply fault. This
covers situations not detected by the built-in
controller power detect circuit. ln particular, this
includes loss of the single phase not supplying the
controller or low incoming voltage and protects the
power converter and motor against drawing
excessive currents that could cause subsequent
damage.

Should the controller remain powered (in the event

that the failure was on a phase not supplying
controller) then on rebooting, the display will show
'Start Inhibited - Power supply fault' and the charging
circuits wilt not be actioned. On reset of the phase
monitor relay, the controller will again reboot to
ensure correct charging sequence.
Compressor Running or in Standby

The configuration of the phase monitor relay has now

been altered such that, if the auto restart function is
enabled, the compressor wilt restart when power is
restored after phase toss or lowvoltage. This
removes the need for the user to manually reset the
fault and start the compressor.
Power Supply Failure Detection
The control system has two methods of power failure
detection. Within the controller, an internal circuit
monitors two phases of the incoming ac voltage and
will trigger the power failure routine if two successive
cycles are not detected. ]External to the controller,
a phase monitor relay, connected to a controller
input, monitors each phase and will signal to the
controller input if any phase goes below 70% of the
set voltage or the phase order is reversed. The
phase monitor relay will automatically reset within
500ms when correct supply conditions are restored.

AC20160-1822, Issue 1, November 2002

Again, should the controller remain powered, then on

rebooting the display will show 'Start Inhibited Power supply fault' and the charging circuits will not
be actioned. The fault in this case will be stored in
the history. When the phase monitor relay resets,
the controller will reboot again to ensure the correct
charging sequence.
If power to the controller is lost, then after reboot depending on which circuit triggered first - an alarm
will be displayed either with message 'Powerfail
Fault' (controller internal circuit) or message 'Power
supply fault' (phase monitor relay) and the fault
logged.
Manual reset will not be required (except to clear
display and 'service' led) and, if enabled, the
machine will auto restart to previous state.

Chapter 2, page 31

CompAir

Note: Because this feature is only operable while

the machine is 'available', any powerdip or failure
occurring after a controlled stop, but before the
motor is switched off, will result in a reboot to 'Ready
to Start' without the 'Power fail/supply fault'
indicated. This is the standard machine action.
SR Motor Overcurrent Protection
The power converter incorporates motor overcurrent
protection. To prevent repeated starts that could
damage components in the power converter, the
software has been altered to inhibit restart of the
compressor after two successive overcurrent trips
during starting. In this case the controller will display
an operator advice message, 'Reset Inhibited' and
restart of the unit will be prevented. To ensure that
the source of the fault is rectified, the controller can
only be reset by a CompAir authorised service
engineer using the special access code: view,
spanner, spanner, spanner. Entering this code will
reset the fault and return the machine to 'Ready to

Start' state. This access code should be considered

confidential and is only for the use of CompAir
company or authorised distributor service engineers.
Power Supply Fusing
In order to increase reliability, the incoming power
supply fuses have been removed from the power
converter. These fuses were previously fitted to
protect the power converter components in the event
of a current surge resulting from a short circuit or low
voltage condition. Due to improvements in the
current carrying capacity of the power converter
components these fuses are no longer required.
There is, however, still a requirement for the
customer to fit correctly rated fuses in the incoming
power supply. These fuses should comply with
BS88 Part 1, IEC269-1 and EN60269-1 and conform
to gG characteristics. The following table provides
the recommended fuse ratings to be fitted by the
customer.

Compressor
Model

Voltage

Cable Size
50/60Hz

Fuse Rating

L45SR

All voltages

3 x 35mm2

gG125A

L75SR

All voltages

3 x 70mm2

gG200A

L120SR

All voltages

3 x 120mm

gG315A

.
Note: Cable size is valid for PVC insulated, 3 core cable with a conductor operating temperature of 70C in
accordance with EN60204.
Commissioning
The commissioning engineer should check that both
the cable and fuses fitted are of the correct rating.
The compressor must not be commissioned until
this has been verified.

Chapter 2, page 32

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

475SR & L75SR COMPRESSORS - ALL SERIAL NUMBERS

FITTING INSTRUCTIONS FOR SINGLE PASS AIR/OIL COOLER
RETROFIT KIT NO. C27399-332
1.

introduction

1.1

The single pass airloil cooler retrofit kit is intended to eliminate the past issues regarding the original
cooler system.

2.

Kit Contents

ITEM No.

DRAWING No.

NAME OF PART

C11607-5

1" TO 3/4" REDUCING BUSH

ORIGINAL COOLER OIL INLET

A3764-6

3/4" PLUG

ORIGINAL COOLER OIL INLET

98418-61

ANTI VIBRATION MOUNTS

COOLER TO SUPPORTS

95148-14

WASHERS

COOLER TO SUPPORTS

95179-6

SPRING WASHER

COOLER TO SUPPORTS

95111-5

NUT M8

COOLER TO SUPPORTS

98154-337

OIL/AIR COOLER

ON SUPPORTS VIA AVMS

95635-8

COPPER WASHER

NIPPLES

C11605-25

NIPPLE 1 BSP

COOLER AND AMOT VALVE

10

95635-6

COPPER WASHER

COOLER DRAIN PORT

11

98650-109

DRAIN COCK

COOLER DRAIN PORT

12

A3764-6

PLUG

DRAIN COCK

13

95406-801

1 NIPPLE TAPER THREAD

RECLAIMER OUT

14

98650-390

AMOT VALVE

RECLAIMER OUT

15

98156-308

TEE 1" BSP

FILTER

16

98504-92

RUBBER SEALING STRIP

17

C27399-331

ASSY, FLEXIBLE HOSE

OIL COOLER TO FILTER VIA TEE

18

C27399-330

ASSY, FLEXIBLE HOSE

AMOT TO OIL COOLER INLET

19

C27399-343

ASSY, FLEXIBLE HOSE

TEE TO AMOT

20

C27399-334

BAFFLE, FOAM EXHAUST

INSIDE EXHAUST DUCT

21

C27399-335

ASSY, EXHAUST DUCT

TOP OF AIR/OIL COOLER

22

95251-276

STUD SCREWED METRIC

AIR/OIL COOLER AIR INLET

23

A3753-36

WASHERS

16

PLENUM CHAMBER TO COOLER

24

95602-85

O RING

AIR/OIL COOLER AIR INLET

AC20160-1822, Issue 1, November 2002

No. OFF

0.25M

PART LOCATION

PROTECTS HOSE C27399-331

Chapter 2, page 33

CompAir

3.

Procedure

3.1

Drain the compressor system of oil.

3.2

Remove the original cooler. Use C11607-5 (1

To 3/4 Reducing Bush) and A3764-6 (3/4
Plug) to plug the cooler oil inlet port before
removal to reduce oil spillage.

3.3

Install new Air/Oil Cooler 98154-337 using 4

off 98418-61 (Anti Vibration Mounts) secured
in place with 95148-14 (Washers), 95179-6
(Spring Washers) and 95111-5 (M8 Nuts).
See Fig 1.

3.4

Assemble 98650-390 (Amot Valve) onto the

reclaimer via 95406-801 (Nipple 1 Taper
Thread) with the Amot side port orientated
horizontally and facing towards the inside of
the machine. See fig 3.

3.5

Connect one end of hose C27399-331 (Assy,

Flexible Hose) to the outlet port of the oil
cooler section via C11605-25 (Nipple 1 BSP)
and a 95635-8 (Copper Washer). See fig 2.

3.9

Assemble 98650-109 (3/4" Drain Cock) into

the cooler drain port using 95635-6 (Copper
Washer).

Fig 1 - Securing new cooler

Note: Fig 2 also shows edges on which

C27399-331 (Assy, Flexible Hose) rests. This
will cause hose chafing so apply 98504-92
(Rubber Sealing Strip) to these edges.
3.6

Assemble 98156-308 (Tee 1 BSP) onto the

oil filter using the original production fitted
Nipple. To the horizontal port of this Tee,
connect C27399-331 (Assy, Flexible Hose).
To the downward port of the Tee, connect one
end of C27399-343 (Assy, Flexible Hose).

3.7

Connect the other end of C27399-343 (Assy,

Flexible Hose) to side port of 98650-390
(Amot Valve) via C11605-25 (Nipple 1 BSP)
and 95635-8 (Copper Washer).

Note: Hose C27399-343 now has the 90 Deg.

connector removed and replaced with a
straight connector.
3.8

Connect one end of C27399-330 (Assy,

Flexible Hose) to the inlet port of the Oil
Cooler using C11605-25 (Nipple 1 BSP) and
95635-8 (Copper Washer). Connect the other
end to the exit port of the Amot Valve using
C11605-25 (Nipple 1 BSP) and 95635-8
(Copper Washer).

Chapter 2, page 34

Fig 2 - Cooler outlet hose run

3.10

Finally, screw A3764-6 (3/4" Plug) into the

Drain Cock.

3.11

There is no change from the original

assembly procedure of the Exhaust Baffle
and Exhaust Duct Assy to the new. Among
the design changes made are:-

The thermostat clearance has been removed

Four clearance apertures have been added to
allow for the Air/Oil cooler securing bolts.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Product Improvements

17
14

16

13
15

12

6
7

HW 0109

1
2.
3.
4.
5.
6.
7.
8.
9.

95635-8
C11605-25
C27399-331
98156-308
C27399-331
C11605-25
95635-8
95406-801
98650-390

11 10

Copper Washer
Nipple 1 BSP
Hose Assy
Tee 1 BSP
Hose Assy
Nipple 1 BSP
Copper Washer
Nipple 1" B5P Taper
Amot Valve

10.
11.
12.
13.
14.
15.
16,
17.

95635-8
C11605-25
C27399-330
C11605-25
95635-8
A3764-6
95635-6
98650-109

Copper Washer
Nipple 1 BSP
Hose Assy
Nipple 1 BSP
Copper Washer
Plug 3/4
Copper Washer
Drain Cock 3/4

Fig 3 - New pipework circuit

AC20160-1822, Issue 1, November 2002

Chapter 2, page 35

CompAir

SH6(2)
WS4(2)

11

10

12

13
14

27

15

16

16

17

SP4(2)
WP2(2)
NL1(2)

16
2
1

18

2
4

23

19
20 21

22

24
25
26
HW 0297

Fig 4 - Original pipework circuit

Chapter 2, page 36

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

CHAPTER

3
GENERAL DESCRIPTION
1.
2.
2.1
2.2
3.
4.
4.1
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
6.
6.1
6.2
7.
7.1
7.2
8.
8.1
8.2
8.3

COMPRESSOR
AIR-END
Description
Operation
SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT
PROTECTION AND SAFETY EQUIPMENT
Pressure Relief Valve
Blowdown System
Minimum Pressure Non-return Valve
Emergency Stop
Overpressure Switch
Scavenge Sight Tube
AIR/OIL SYSTEM (345SR, L45SR)
Description
Operation
AIR/OIL SYSTEM (475SR, L75SR)
Description
Operation
AIR/OIL SYSTEM (L120SR)
Description
Operation
REGULATION SYSTEM
Description
Automatic Mode
Manual Mode

FIGURES
FIG. 3.1
FIG. 3.2
FIG. 3.3
FIG. 3.4
FIG. 3.5
FIG. 3.6
FIG. 3.7
FIG. 3.8
FIG. 3.9
FIG. 3.10

CYCLON 3, 4 and 5 AIR-END - GENERAL ARRANGEMENT

CONTROL PANEL
AIR/OIL SYSTEM - 345SR, L45SR
AIR/OIL SYSTEM - 475SR, L75SR old style
AIR/OIL SYSTEM - L75SR new style
AIR/OIL SYSTEM - L120SR
REGULATION SCHEMATIC - 345SR, L45SR
REGULATION SCHEMATIC - 475SR, L75SR
REGULATION SCHEMATIC - L75SR (Where Single Pass Cooler fitted)
REGULATION SCHEMATIC - (L120SR)

AC20160-1822, Issue 1, November 2002

Chapter 3, page 1

CompAir

GENERAL DESCRIPTION
1.

COMPRESSOR

The unit is an air cooled, single-stage, rotary screw

compressor. The compressor air-end is driven
through a flexible coupling by an electric Switched
Reluctance Drive (SR Drive) motor manufactured
under licence from SR Drives Ltd.
The Compressor unit consists of the drive motor,
air-end, reclaimer, oil cooler, after cooler, fan, starter
assembly and control unit. The complete
compressor unit is mounted on a baseframe and is
housed in a steel panelled acoustic enclosure.
Removable panels or hinged access doors allow
access for routine maintenance.

2.

AIR-END

2.1

Description

The air is compressed in a single-stage, positive

displacement, oil injected rotary screw air-end. The
air-end is of the Cyclon type and comprises an
intermeshing pair of helical screw rotors, male and
female, mounted horizontally within an enclosed
casing with drive being applied to the male rotor.
The male air-end rotor is larger in diameter than the
female rotor and has four lobes which mesh with
five flutes on the female rotor. The rotors are
asymmetric in profile to reduce blowback between
the lobes on the compression cycle to a minimum,
thus maximising the overall sealing and efficiency.
The rotors are fitted with bearings at each end to
provide radial and axial support, maintain adequate
shaft stiffness and to give minimum clearance and
low leakage between the rotor tip diameter and the
casing.

Heavy duty parallel roller bearings are fitted to both

rotors at the inlet end to provide radial support and
to sustain the drive load of the male rotor.

2.2

Operation

Compression takes place between the lobes on the

male rotor, the flutes on the female rotor and the airend casing. When the compressor is running the
helical engagement of the rotors provides the drive
for the female rotor.
As the rotors turn, air at atmospheric pressure
enters the inlet port and fills the space between the
lobes of the male rotor and the flutes of the female
rotor. Oil is injected into the air at this point and the
trapped air/oil mixture is progressively compressed
by the reduction in space created by continuous
rotation of the rotors within the air-end casing.
Continued rotation brings the compressed air/oil
mixture to the discharge port of the air-end, where it
passes into a reclaimer. The oil is separated from
the air/oil mixture in the reclaimer and the air passes
through a cooler into the users pipework.
Oil is continually injected into the low pressure
region of the air-end and mixes with the air during
the compression process. The oil carries out three
functions; lubrication, cooling and sealing. The oil
lubricates the rotors and bearings, acts as a coolant
by absorbing the heat of compression and seals the
fine clearances that exist between the rotors and
between the rotors and casing. The compressed air/
oil mixture is discharged from the air-end and into
the reclaimer where the oil is separated and returned
to the system.

At the delivery end the male rotor is fitted with a

single taper roller bearing and the female rotor is
provided with a matched pair of taper roller bearings.
These bearings provide axial and radial support of
both rotors and control the very fine end clearances
between the rotors and the casing.

Chapter 3, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

1.
2.
3.
4.
5.
6.
7.
8.

Parallel Roller Bearing

Male Rotor
Casing
Taper Roller Bearing
Outer Taper Roller Bearing
Inner Taper Roller Bearing
Female Rotor
Parallel Roller Bearing

FIG. 3.1 CYCLON 3, 4 AND 5 AIR-END - GENERAL ARRANGEMENT

AC20160-1822, Issue 1, November 2002

Chapter 3, page 3

CompAir

3.

SWITCHED RELUCTANCE DRIVE AND

ELECTRONIC CONTROL UNIT

The SR Drive system regulates the volume of air

delivered by the compressor by adjusting the
rotational speed of the air-end so that the output
from the compressor always matches the demand
from the users system.
This method of regulation can reduce energy
consumption as the compressor produces only the
amount of air demanded by the system and is
equally efficient at high or low output volumes. Offload idling is also eliminated and when there is no
demand for compressed air the SR motor stops
automatically with no limit to the number of times
that it can be started. Pressure in the users system
is accurately maintained to further improve the
quality of the compressed air supply.
The motor operates on the principle of magnetic
attraction. The stator has eight poles and the rotor
four poles, the stator poles being wound with coils to
form electromagnets. The electromagnets are
connected in two groups (phase A and B) of four
coils which attract the poles on the rotor causing
them to rotate into alignment with the stator poles.
The SR stator is an insulated tube formed by the
stator poles and coils vacuum impregnated in resin
to form a Sealed Insulation System which is highly
resistant to dust and corrosion. The rotor is a 4 pole
iron shaft with no current carrying coils which
ensures cool running and therefore extends bearing
life.
Continuous rotation is achieved by switching the
stator phases in the correct sequence. A position
transmitter on the rotor sends positional information
to the SR Drive controller to ensure that the
switching of the motor phases is correctly timed.
The microprocessor based compressor controller
and the SR Drive controller are housed in a single
control unit which also contains the operator keypad
and displays. The control unit is mounted on the
door of the control panel.
A gate drive board isolates the microelectronics in
the control unit from the power electronic circuits
and provides monitoring and protection for the four
insulated gate bi-polar transistor (IGBT) power
switches.

Chapter 3, page 4

The IGBTs are used to turn the motor phases on

and off and, in conjunction with the electronic
controller, to control the motor phase current and in
turn the torque and speed of the SR motor.

4.

PROTECTION AND SAFETY EQUIPMENT

In addition to the protection and warning circuits

linked to the controller the following protection
equipment is fitted:

4.1

Pressure Relief Valve

A pressure relief valve is mounted on the reclaimer.

If a fault occurs, causing pressure to build up in the
reclaimer, the relief valve will open at a pre-set
pressure and vent to atmosphere.

4.2

Blowdown System

When the compressor stops, either automatically or

by operation of the STOP switch, all pressure in
the reclaimer is automatically released by a
blowdown system which vents the pressure to
atmosphere. This ensures that the compressor is
restarted in a no-load condition.

4.3

Minimum Pressure Non-return Valve

Fitted on the reclaimer cover in the delivery air line,

the minimum pressure valve remains closed until
minimum pressure is reached. This ensures a rapid
build-up of pressure when the compressor first
starts and also prevents high velocity, low pressure
air reaching the users pipework during the start-up
period and carrying over excessive amounts of oil.
When the compressor shuts down it functions as a
non-return valve which prevents the pressure in the
users pipework feeding back into the reclaimer and
venting through the blowdown system.

4.4

Emergency Stop

An emergency stop button, complying with

international safety requirements, is fitted on the
display panel.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

4.5

Overpressure Shutdown

4.6

An overpressure shutdown is present on all

machines. This shutdown setting is below
the pressure relief valve setting and will stop
the compressor in the event of an over
pressure condition.

Scavenge Sight Tube

A transparent nylon tube is incorporated in the

scavenge oil line to allow a visual check of the flow
of scavenge oil from the reclaimer to the air-end.

10

11

12

13 14

15

18

17

Bar
PSI

31

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

30

29

28

27

26

Bar Units Indicator

Psi Units Indicator
Delivery Pressure Display
Status and Message Display
Plus
Minus
Up
Down
Enter
Mimic Diagram
Intake Filter Change Lamp
High Delivery Temperature Lamp
Reclaimer Element Check Lamp
Excess Pressure Lamp
Emergency Stop
Auto Restart Legend

25

24 23

22 21

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

20

19

16

Remote Control Legend

Remote Control Lamp
Auto Restart Lamp
Power on Lamp
Fan Motor Overload Lamp
Power Converter Fault Lamp
Main Motor Fault Lamp
Reset
Hours
Reset Lamp
Data View
Service
Service Lamp
Stop
Start

FIG. 3.2 CONTROL PANEL

AC20160-1822, Issue 1, November 2002

Chapter 3, page 5

CompAir

5.
5.1

AIR/OIL SYSTEM (345SR, L45SR)

Description

The air/oil system comprises an air intake filter, inlet

non-return valve, air-end, oil separator vessel, oil
separator filters, minimum pressure/non-return
valve, aftercooler, oil cooler with thermostatic
bypass valve and an oil filter. The flow of oil through
the circuit is achieved through the pressure
differential existing between the primary oil
separator and the oil injection point in the air-end.

5.2

Operation

Air enters the compressor unit through the intake

filter (2) and inlet non-return valve (1) to the inlet port
of the air-end (7). The air is trapped by the turning
rotors and mixes with the oil which enters the casing
through the oil injection point.
Continued rotor rotation increases the pressure and
temperature of the air/oil mixture which passes from
the air-end discharge pipe into the oil separator (4)
where primary separation takes place by centrifugal
force. Most of the oil is separated at this stage and
drops to the bottom of the vessel.

Oil from the bottom of the primary separator flows

under pressure to the oil cooler (10) and during
normal running the oil passes through the cooler to
maintain the correct temperature. A thermostatic
bypass valve (14) is installed in the inlet manifold of
the oil cooler.
When the compressor is started, the cold oil in the
system bypasses the cooler and flows through the
oil filter (8) directly to the air-end. As the oil and air
mixture is compressed by the rotors in the air-end,
the temperature of the oil increases.
When the oil has reached its normal operating
temperature the bypass valve closes and the oil is
directed through the oil cooler. The cooled oil then
flows to the oil filter where it is cleaned before
entering the air-end.
The quantity of oil injected into the air-end is
controlled by a restrictor orifice in the air-end casing.
Oil is injected under pressure through the restrictor
orifice into the rotors and a gallery supplies oil to the
air-end bearings.

The remaining air/oil mixture then passes through

oil separator elements (5) where final separation
takes place. The separated oil collects in the bottom
of the elements and is scavenged back into the
air-end through a small diameter pipe (13).
The filtered air then passes from the oil separator
elements by way of the minimum pressure/ nonreturn valve (3). Provided the air pressure at this
stage is above 3.5 to 40 bar the air passes through
the aftercooler (9) where it is cooled before passing
to the delivery outlet (12).
If the air pressure in the primary separator vessel
falls below 3.5 to 40 bar the minimum pressure
valve will close. The valve also incorporates a nonreturn valve which operates to prevent delivery air
passing back into the separator when the
compressor is running off-load.

Chapter 3, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

11
14
10
8

16

15
12

1.
2.
3.
4.
5.
6.
7.

Inlet Non-Return Valve

Intake Air Filter
Minimum Pressure Valve
Primary Oil Separator
Separator Filter Element
Discharge Pipe
Air-end

8.
9.
10.
11.
12.
13.
14.

Oil Filter
Aftercooler
Oil Cooler
Fan
Delivery Air Outlet
Scavenge Line
Thermostatic Bypass Valve

13

15. Scavenge NR Valve

16. Blow down solenoid
valve.

FIG. 3.3 AIR/OIL SYSTEM - 345SR, L45SR

AC20160-1822, Issue 1, November 2002

Chapter 3, page 7

CompAir

6.

AIR/OIL SYSTEM
(475SR, L75SR)

6.1

Description

The air/oil system comprises an air intake filter, airend, reclaimer, reclaimer filter element, minimum
pressure non-return valve, oil cooler and aftercooler,
thermostatic bypass valve and oil filter. The flow of
oil through the system is achieved by means of the
pressure differential existing between the reclaimer
and the air-end inlet.

6.2

Earlier oil circuit (Fig. 3.4). Oil from the reclaimer

flows to the oil cooler. During normal running the oil
passes through the cooler to maintain its
temperature at a correct level. A thermostatic
bypass valve (5) is installed in the oil cooler. When
the compressor is started, the cold oil in the system
bypasses the cooler and flows through the oil filters
(9) directly to the air-end. As the oil and air mixture
is compressed by the rotors in the air-end, the
temperature of the oil increases. Once the oil has
reached its normal operating temperature the 3-way
thermostatic bypass valve directs oil through
cooler. The cooled oil then flows to the oil filter
where it is cleaned before entering the air-end.

Operation

Air enters the compressor through the air intake

filter (19) to the inlet port of the air-end (18). The air
is trapped by the turning rotors and mixes with the
oil which enters the casing through a restrictor
orifice. Continued rotation increases the pressure
and temperature of the air/oil mixture which passes
through the discharge port of the air-end and, via the
non-return valve (15), into the reclaimer (12) where it
is centrifugally separated and the oil drops to the
bottom of the reclaimer vessel. The remaining air/oil
mixture then passes through the two stages of the
reclaimer element (6) where final separation takes
place.
The separated oil is collected in the bottom of the
element and is scavenged back into the air-end
through a strainer (8) and scavenge line (11). A
solenoid operated valve (10), fitted in the scavenge
line, prevents any oil loss through the air intake filter
when the compressor is stopped.

Later oil circuit (Fig. 3.5). Oil flows to the oil

cooler (4) via a 3-way thermostatic bypass valve (6)
installed in the reclaimer. During normal running the
oil passes through the cooler to maintain its
temperature at the correct level. When the
compressor is started, the cold oil in the system
bypasses the cooler and flows through the oil filters
(9) directly to the air-end. As the oil and air mixture
is compressed by the rotors in the air-end, the
temperature of the oil increases. Once the oil has
reached its normal operating temperature the 3-way
thermostatic bypass valve directs oil through the
cooler. The cooled oil then flows to the oil filter
where it is cleaned before entering the air-end.
The quantity of oil injected into the air-end rotors is
controlled by a restrictor orifice in the rotor casing.
Oil is injected under pressure through the restrictor
orifice into the rotors and a separate gallery supplies
oil to the air-end bearings.

Filtered air then passes out of the reclaimer through

the minimum pressure valve (7). Provided the air
pressure at this stage is above 4 bar the air will be
passed to the air cooler (3) where the warm air is
cooled. The cooled, filtered air then passes through
a moisture separator to the delivery air outlet (1).
The condensate in the moisture separator (2) is
automatically removed by the operation of an
electronically controlled solenoid valve (20).
If the air pressure in the reclaimer is at any time less
than 4 bar the minimum pressure valve will close.
The valve also incorporates a non-return valve which
operates to prevent delivery air passing back into the
reclaimer when the compressor is running off-load.

Chapter 3, page 8

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

7 8

21
22

10

20

14
19
11
12
13
16
18

1.
2.
3.
4.
5.
6.
7.
8.

17

Delivery Air Outlet

Moisture Separator
Air/Oil Cooler
Fan
Thermostatic Bypass Valve
Reclaimer Element
Minimum Pressure Valve
Scavenge Strainer

15

9.
10.
11.
12.
13.
14.
15.

Oil Filters
Scavenge Solenoid
Scavenge line
Reclaimer
Oil Drain
Oil Level Tube
Non-return Valve

Air flow
Air/oil mixture
Oil flow

16.
17.
18.
19.
20.
21.
22.

Oil Drain
Oil Stop Valve
Air-end
Air Intake Filter
Drain Solenoid
Strainer
Air In

FIG. 3.4 AIR/OIL SYSTEM - 475SR, L75SR (WITH EARLIER OIL CIRCUIT)

AC20160-1822, Issue 1, November 2002

Chapter 3, page 9

CompAir

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Delivery Air Outlet

Moisture Separator
Drain Cock
Air/Oil Cooler
Fan
3-way Thermostatic Bypass Valve
Reclaimer Element
Minimum Pressure Valve
Scavenge Strainer
Oil Filters
Scavenge Solenoid
Scavenge Line

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

Reclaimer
Oil Drain
Oil Level Tube
Non-return Valve
Oil Drain
Oil Stop Valve
Air-end
Air Intake Filter
Drain Solenoid
Strainer
Air In

FIG. 3.5 AIR/OIL SYSTEM - L75SR (WITH LATER OIL CIRCUIT)

Chapter 3, page 10

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

7.

AIR/OIL SYSTEM (L120SR)

7.1

Description

The air/oil system comprises an air intake filter, airend, reclaimer, reclaimer filter element, minimum
pressure non-return valve, oil cooler and aftercooler,
thermostatic mixing valve and oil filters. The flow of
oil through the system is achieved by means of the
pressure differential existing between the reclaimer
and the air-end inlet.

7.2

Operation (fig. 3.6)

Air enters the compressor through the air intake

filter (1) and intake non-return valve (2) to the inlet
port of the air-end (3). The air is trapped by the
turning rotors and mixes with the oil which enters
the casing through a restrictor orifice. Continued
rotation increases the pressure and temperature of
the air/oil mixture which passes through the
discharge port of the air-end and into the reclaimer
(5) where it is centrifugally separated and the oil
drops to the bottom of the reclaimer vessel. The
remaining air/oil mixture then passes through the
two stages of the reclaimer element where final
separation takes place.
The separated oil is collected in the bottom of the
element and is scavenged back into the air-end
through a strainer (n), non-return valve (n) and
scavenge line (n). The non-return valve prevents
any oil loss through the air intake filter when the
compressor is stopped.
Filtered air then passes out of the reclaimer through
the minimum pressure valve (8). Provided the air
pressure at this stage is above 4 bar the air will be
passed to the aftercooler (9) where the warm air is
cooled. The cooled, filtered air then passes through
a moisture separator (15) to the delivery air outlet
(10). The condensate in the moisture separator (15)
is automatically removed via the condensate drain
port (17) by the operation of electronically controlled
no loss drain (16).

AC20160-1822, Issue 1, November 2002

If the air pressure in the reclaimer is at any time

less than 4 bar the minimum pressure valve will
close. The valve also incorporates a non-return
valve which operates to prevent delivery air passing
back into the reclaimer when the compressor is
running off-load.
Oil from the reclaimer flows to the oil cooler (23).
During normal running the oil passes through the
cooler to maintain its temperature at a correct level.
A thermostatic bypass valve (21) is installed in the
outlet side of the oil cooler.
If the unit is fitted with a heat recovery option a
thermostatic mixing valve (35) diverts the flow of oil
to the cooler to first pass through the heat recovery
heat exchanger (36). This heats the water supply
passing between the water inlet and outlet
connections (37).
When the compressor is started, the cold oil in the
system bypasses the cooler via the coolewr bypass
pipe (n) and flows through the oil filters (6) directly to
the air-end. As the oil and air mixture is compressed
by the rotors in the air-end, the temperature of the
oil increases and the oil starts to flow through the
cooler. Once the oil has reached its normal
operating temperature the bypass valve (21) directs
oil through the cooler. The cooled oil then flows to
the oil filter where it is cleaned before entering the
air-end.
The quantity of oil injected into the air-end rotors is
controlled by a restrictor orifice in the rotor casing.
Oil is injected under pressure through the restrictor
orifice into the rotors and a separate gallery supplies
oil to the air-end bearings.
Cooling fan/motor (24) extracts air from the
enclosure through the air outlet grille (20), which is
replenished by cool air entering air inlet grille (13).
Cooling of the power converter heat sink is carried
out by a separate cooling fan/motor (25).

Chapter 3, page 11

CompAir

1. Switched Reluctance Drive Controller

8. Separator Filtration Element

2. Switched Reluctance Drive Motor

9. Minimum Pressure NonReturn Valve

3. Air Intake Filter

10. Oil Cooler

4. Intake Non Return Valve

11. Air Cooler

5. Temperature Sensor

12. Oil Filter

6. Compression Element

13. Pressure Transmitter

7. Separator Vessel

A Intake Air

C Air/Oil Mixture

B Compressed Air

D Oil

FIG. 3.6 AIR/OIL SYSTEM - L120SR

Chapter 3, page 12

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

8.

REGULATION SYSTEM
(See figures 3.7 to 3.9)

8.1

Description

The compressor delivery pressure can be controlled

in either Automatic (AUTO) or Manual (MAN)
modes. The normal method of operation is the
Automatic mode which varies the volume of air
delivered by the compressor by adjusting the
rotational speed of the air-end to match the demand
on the users system and maintain a target
pressure.
Manual mode controls the pressure between two
set points, the rotational speed of the air-end being
controlled by the operator.

8.2

8.3

The Manual mode should only be used if the

compressor is to be run at a fixed speed and,
therefore, fixed rate of air delivery. A pressure
transmitter measures the delivery pressure which is
compared with upper and lower set points
programmed into the control unit.
If the delivery pressure is below the upper setpoint
the air-end will run at a pre-determined speed which
can be set at any point between maximum and
minimum. If the delivery pressure exceeds the
upper setpoint the rotational speed of the air-end will
reduce to minimum and the bypass valve will open
resulting in zero delivered air volume. The bypass
condition will continue until:
a)

the delivery pressure falls below the lower

setpoint. At this point the bypass valve will
shut and the speed will be re-set to the pre-set
value, or

b)

the SR motor run-on timer expires causing the

motor to stop and the compressor to enter
Standby condition. Subsequently, if the
delivery pressure falls below the lower setpoint
the SR motor will re-start and run at the pre-set
speed.

Automatic Mode

This is the normal mode of operation. A pressure

transmitter (18),(32) or (28) measures the delivery
pressure which is compared with the target pressure
(P2) programmed into the control unit.
If the delivery pressure is lower than the target
pressure, the rotational speed of the air-end, and
therefore the delivered air volume, increases until
either the target pressure is reached or the air-end is
running at maximum speed. If the delivery pressure
is above the target pressure the rotational speed of
the air-end is reduced until either the target pressure
is reached or the air-end is running at minimum
speed.

Manual Mode

An unload pressure setpoint (P1) is also provided

and is always set above the target set point. If the
unload pressure is reached, a bypass/blowdown
valve (21), (12) or (14) opens and because the airend is running at minimum speed all of the air
produced is re-circulated in the bypass pipe
resulting in zero delivered air volume. The bypass
condition will continue until:
a)

the delivery pressure falls below the target

pressure and the bypass valve shuts, or

b)

the SR motor run-on timer expires causing the

motor to stop and the compressor to enter
Standby condition. Subsequently, if the
delivery pressure falls below the target
pressure the SR motor will re-start.

AC20160-1822, Issue 1, November 2002

Chapter 3, page 13

CompAir

32 33 34 35 36 37 38 39 40

3 PHASE POWER SUPPLY

29

1 19

30
21

17

OIL SCAVENGE LINES

16

15

18

14
8

13
2

20

9
10

22

28

23

3
4

5
27 M

11

24
12

HW 0009

25
26
31

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Intake Air Filter

Non-return Valve
Air-end
SR Drive Motor
Reclaimer
Separator Filters
Pressure Gauge
Minimum Pressure Non-return
Valve
Aftercooler
Compressor Delivery
Oil Filler
Oil Level Sight Glass
Temperature Thermistor (TE1)
Overcurrent Trip

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

Position Sensor Fault Trip

Overspeed
Stall Trip
Pressure Transducer
Differential Pressure Switch
Temperature Thermistor (TE2)
Bypass Valve
Pressure Relief Valve
Oil Cooler
Oil Filter
Thermal Overload
Temperature Thermistor (TE3)
Cooling Fan
Thermostatic Bypass Valve
Control Panel

30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.

Pressurised Oil Drain Valve

Oil Drain Valve
Emergency Stop
SR Current Sensor Trip
DC Link Overvoltage Trip
DC Link Undervoltage Trip
Capacitor Charge Volt Trip
Heatsink Sensor Fault Trip
Heatsink Temperature Alarm
Heatsink Temperature Trip
Main Contactor Fault Trip

FIG. 3.7 REGULATION SCHEMATIC - 345SR, L45SR

Chapter 3, page 14

AC20160-1822, Issue 1, November 2002

LSR Repair Manual General Description

39 40 41 42 43 44 45 46 47

400V 10%, 50 Hz, 3-Phase

400V-460V 10%, 60 Hz, 3-Phase

38

12
20

50

13

32

31

26

11
2

33
36

48

37

34 35

19

16

30

24

5 M

14
6

17

28

18

15

23

29

27

8
9

49
21

10

22

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

25

Intake Air Filter

Differential Pressure Switch
Air Inlet Connection
Air-end
SR Drive Motor
Temperature Thermistor (TE1)
Overcurrent Trip
Position Transmitter Fault Trip
Over Speed Trip
Stall Trip
Temperature Thermistor (TE2)
Bypass Valve
Scavenge Solenoid
Overpressure Switch
Pressure Gauge
Oil Filler
Reclaimer
Oil Level Tube

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Relief Valve
Diff. Pressure Indicator
Oil Filter
Oil Drain Valve
Oil Stop Valve
Non-return Valve
Oil Drain Valve
Minimum Pressure Nonreturn Valve
Thermal Overload
Temperature Thermistor
(TE3)
Cooling Fan Motor
Oil Cooler
Aftercooler
Pressure Transmitter
Moisture Separator
Strainer

HW 0010

35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.

Drain Solenoid
Compressor Delivery
Condensate Drain
Control Panel
Emergency Stop
SR Current Sensor Trip
DC Link Overvoltage Trip
DC Link Undervoltage Trip
Capacitor Charge Volt Trip
Heatsink Sensor Fault Trip
Heatsink Temperature
Alarm
Heatsink Temperature Trip
Main Contactor Fault Trip
Scavenge Strainer
Thermostatic Bypass Valve
Pressurised Oil Drain Valve

FIG. 3.8 REGULATION SCHEMATIC - 475SR, L75SR

AC20160-1822, Issue 1, November 2002

Chapter 3, page 15

CompAir

20

24
34
14
13
8
28

30

15

1
33

10

35
22

2
29

31

36

26
27

16

23
32

17

11
12
6
21

25

37

19

HW 0013

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Intake Air Filter

Air Inlet Grille
Air End
SR Drive Motor
Reclaimer
Oil Filters
Pressure Gauge
Minimum Pressure /
Non-Return Valve
Aftercooler
Compressor Delivery
Oil Filler
Oil Level Sight Glass
Air Inlet Grille
Solenoid Valve
(Blowdown)
Moisture Separator
Level Controlled
Condensate Valve

18

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Condensate Drain Point

Oil Drain (Cooler)
Oil Drain (Reclaimer)
Air Outlet Grille
Thermostatic Mixing
Valve
Pressure Relief Valve
Oil Cooler
Fan Motor
Power Converter Heat
Sink - Cooling Fan
Position Sensor
Pressure Transmitter
(Reclaimer)
Pressure Transmitter
(Air Delivery)
Inlet Non-Return Valve
Scavenge Restrictor
Scavenge NRV

32.
33.
34.
35.
36.
37.

Motor Thermistor
Temperature Transmitter
(Air End Delivery)
Differential Pressure
Indicator and Switch
Thermostatic Mixing
Valve (Heat Recovery)
Heat Recovery Heat
Exchanger
Water Inlet and
Outlet Connection
(Heat Recovery
Option Only)

FIG. 3.9 REGULATION SCHEMATIC - L120SR

Chapter 3, page 16

AC20160-1822, Issue 1, November 2002

LSR Repair Manual - Technical Data

CHAPTER

4
TECHNICAL DATA

1.
2.
3.
4.

LEADING PARTICULARS
CABLE SIZES AND FUSE RATINGS
APPROXIMATE FULL LOAD CURRENTS
FAN MOTORS THERMAL OVERLOAD SETTINGS

AC20160-1822, Issue 1, November 2002

Chapter 4, page 1

CompAir

TECHNICAL DATA
1.

LEADING PARTICULARS
MODEL

345SR
and
L45SR

475SR
and
L75SR

L120SR

Air-end:

Single Stage Oil Injected

Screw

Cooling:

Air Cooled

Oil Capacity: litres (US gal)

18.5 (4.9)

Recommended Oil:

45 (11.9)

80 (21.1)

CompAir 4000HR
CompAir FG (Food Grade)
G11/2 or
R 21/2 or
11/2in NPTM 21/2in NPTM

Air Delivery Connection:

Condensate Connection:

10mm/ 3/8 in
OD tube

flanged
BS 4504/
DIN 2633
DN80 PN16
or 3 ASA150lb RF
1

G 1/2 or
/2in NPT

Delivery Air Pressure:

Minimum bar (psig)

Maximum bar (psig)

5 (72)
13 (189)

5 (72)
13 (189)

5 (72)
11.5 (167)
or 13 (189)

Full load operation (7 bar) C (F)

10 (18)

11 (20)

10 (18)

0 (32)
45 (113)

0 (32)
43 (109)

0 (32)
45 (113)

C (F)

19 (34)

14 (25)

21 (38)

Nominal Rating kW (HP)

50 (67)

75 (100)

128 (172)

Delivery Air Temperature

above ambient:

Ambient Temperature Range: Minimum C (F)

Maximum C (F)
Typical Cooling Air Outlet
Temperature at Maximum
Operating Pressure
above ambient:
Main Drive Motor:
Motor Rotation

Clockwise viewed from drive end

Motor Speed

Maximum rpm

Fan Motor Power

kW (HP)

Fan Motor Rotation

viewed from
non-drive end

Total Power Input (Typical) kW

Approx. Nett. Weight:

kg (lbs)

Dimensions:

Length mm (ins)
Width mm (ins)
Height mm (ins)

Average Sound level at 1m

(CAGI PNEUROP)
dB(A) +/- 3dB(A)

5000

4800

3750

2.2 (3)

4 (5.45)

5.5 (7.5)

Anti-clockwise
Clockwise
56

88

144

955 (2101)

1243 (2735)

2100 (4620)

1420 (55.9) 2050 (80.7)

990 (39)
1200 (47.2)
1650 (65)
1702 (67)

2500 (98.5)
1400 (55.2)
2020 (79.6)

77

77

50Hz - 76
60Hz - 79

The air temperature is a typical figure and relates to an inlet air temperature of 20C and standard atmospheric
pressure of 1 bar a. Specific values for particular operating conditions can be supplied on request.

Chapter 4, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual - Technical Data

2.

3.

4.

Cable Sizes and Fuse Ratings

Model

Voltage
50/60Hz

Cable Size

Fuse Rating

345SR, L45SR
474SR, L75SR
L120SR

All voltages
All voltages
All voltages

3 x 35mm2
3 x 70mm2
3 x 120mm2

gG125A
gG200A
gG315A

Approximate Full Load Current, Amps

Model

380V

400V

415V

460V

345SR, L45SR
475SR, L75SR
L120SR

107
160
261

102
155
248

98
151
238

87
139
234

Fan Motors Thermal Overload Settings, Amps

Model

380V

400V

415V

460V

345SR, L45SR
475SR, L75SR
L120SR

6.0
9.5
16.0

5.5
9.0
16.0

5.4
8.9
16.0

5.0
8.5
16.0

AC20160-1822, Issue 1, November 2002

Chapter 4, page 3

CompAir

Chapter 4, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Operation

CHAPTER

5
MECHANICAL FAULT FINDING

DEFAULT SETTINGS
FAULT FINDING
1.
2.
3.

SHUTDOWN MESSAGES
WARNING MESSAGES
FAULT FINDING CHART

AC20160-1822, Issue 1, November 2002

Chapter 5, page 1

CompAir

DEFAULT SETTINGS
1.

Default settings for a number of the

operational settings are stored in the
controller. These are suitable for operating the
compressor in most normal situations.

2.

The compressor can use these settings as

operational settings. Unless the compressor is
reprogrammed during commissioning, the
default settings will be those used by the
compressor.

3.

The compressor may be re-programmed with

different settings at most times, and the
operational settings may be restored to the
default values, by choosing the Load default
values option in the Commissioning values
sub-menu.

4.

It is not possible to change any parameters

while the Emergency Stop button is pressed.
This is because when Emergency Stop is
pressed (input open circuit) the power failure
detection is inhibited. The controller therefore
assumes a power failure possibility and
suspends all data storage to prevent
corruption should the power fail during storage
operation. A message Emergency Stop is
shown if a change is attempted.

5.

The following is a list of default settings

together with the range and size of the
increments/decrements available for each
setting.

Alteration of the working setting values

requires the use of the access code.

Chapter 5, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Operation

1.

L45SR, L75SR, L120SR models.

Setting

Unit

Minimum

Maximum

Step

Default
Value

P1 for AUTO mode

bar

51

134 (11.9)*

01

74

P2 for AUTO mode

bar

50

130 (11.5)*

01

70

*P1 for AUTO mode

bar

51

134 (11.9)*

01

74

*P2 for AUTO mode

bar

50

130 (11.5)*

01

70

P1 for MAN mode

bar

51

133 (11.8)*

01

70

P2 for MAN mode

bar

50

13.0 (11.5)*

01

63

Max. overpress (L120SR)

bar

60

14.3 (128)*

01

77

60

136

01

77

Max. overpress (L45SR, L75SR)

Acceleration time

second

240

10

Cooler run-on time

minute

12

Run on time

second

20

240

20

Drain open time

second

20

Drain shut time

second

10

120

30

Oil t trip limit

85

125

110

Oil t alarm limit

85

125

105

1000

2000

100

2000

Max. service hours

hour

Machine number

number

99

Auto restart delay

second

10

240

10

Auto restart

Enabled Disabled

option

disabled

Remote start/stop (see Chapter 8, 1.2.2)

Enabled - Disabled

option

disabled

Pressure P factor

100

30

Pressure I factor

100

15

Input X01/4 (see Chapter 8, 1.2)

Disabled to Start Inhibit

option

disabled

Input X01/6 (see Chapter 8, 1.2)

Disabled to Start Inhibit

plus Pressure Range select

option

Pressure
Range sel

Input X01/7 (see Chapter 8, 1.2)

Disabled to Start Inhibit

plus Remote Start/Stop

option

Remote
start/stop

Output X08/6 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

disabled

Output X08/10 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

disabled

Output X09/2 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

Group Fault

Output X09/3 (see Chapter 8, 1.3)

Group Fault to Low Temp alarm

option

Available

Output X09/4 (see Chapter 8, 1.3)

Disabled to Start Inhibit

option

Group Trip

Disabled-SmartAir controlCommunications control

option

disabled

Communications config

* Figures in brackets are for L120SR-11 machines only.

Note: The Max. overpressure must be set above P1 settings.

AC20160-1822, Issue 1, November 2002

Chapter 5, page 3

CompAir

2.

345SR, 475SR models.

Setting

Unit

Minimum

Maximum

Step

Default
Value

*P1 for AUTO mode

bar

51

134

01

74

*P2 for AUTO mode

bar

50

130

01

70

P1 for AUTO mode

bar

51

134

01

74

P2 for AUTO mode

bar

50

130

01

70

P1 for MAN mode

bar

51

134

01

70

P2 for MAN mode

bar

50

13.2

01

63

Max. overpress

bar

60

136

01

77

Acceleration time

second

240

10

Cooler run-on time

minute

12

Run on time

second

20

240

20

Drain open time

second

20

Drain shut time

second

10

120

30

Oil t trip limit

85

125

110

Oil t alarm limit

85

125

105

1000

2000

100

2000

99

110

9600

options

9600

10

240

10

Start/Stop

Comms.
Control

option

disabled

option

disabled

Max. service hours

Machine number

hour
number

Comms baud rate

Auto restart delay
Remote control config
Auto restart

second

Enabled Disabled

Pressure P factor

100

30

Pressure I factor

100

15

Note: The Max. overpressure must be set above P1 settings.

Chapter 5, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Fault Finding

FAULT FINDING
The controller has a memory facility that retains a
fault history. Details of 15 previous situations can
be displayed, including the fault message together
with recorded hours, compressor state (standby, onload, off-load etc.), oil temperature and air pressure.

In operation the compressor is protected by circuits

which are triggered when a fault arises and either
cause the compressor to shut down or indicate that
a servicing action is required.

WARNING

1.

Refer to the safety procedures before

carrying out any fault finding
investigation on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the starter

compartment, switch the power supply OFF
at isolator and wait for 12 minutes to allow
the dc link capacitors to discharge to a safe
level. Check that the dc link capacitors
have fully discharged before starting work
on the compressor.

SHUTDOWN MESSAGES

Message Displayed

Emergency stop

Possible Cause

(1) Emergency stop switch

operated.

(2) Starter circuit fuse F2 blown.

Fan motor fault

Action required

(1) Check cause of fault and

rectify. Turn Emergency Stop
switch to release latch. Press
RESET.
(2) Check cause and rectify.

(1) Insufficient cooling air flow.

(1) Inspect/clean: enclosure

filter; ducting; air/oil cooler
matrix; motor cooling air

(2) High ambient temperature.

(3) Low voltage/high current.
(4) Circuit breaker MCB2
incorrectly set.
(5) Starter circuit breaker
MCB2 open.
(6) Fan motor thermistor fault.
(all models except L120SR).
(7) Fan motor overload (L120SR).

(2) Check room ventilation.

(3) Check power supply.
(4) Check setting and reset.

intake.

AC20160-1822, Issue 1, November 2002

(5) Check starter circuit breaker.

(6) Check thermistor.
(7) Check motor/fan. replace if
necessary.

Chapter 5, page 5

CompAir

Message Displayed

Possible Cause

Action required

Heat sink temp HI **

(1) Panel filters blocked

(2) Heat sink dirty
(3) Heat sink fan faulty (L120SR)

(1) Clean/renew filters

(2) Clean heat sink
(3) Check motor/fan. replace if
necessary.

High air pressure

(1) High pressure in user system

(4) Controller fault.

(1) Check settings of other

compressors in system.
(2) Check operation of venting
valve and solenoid operated
bypass valve. Renew if
necessary.
(3) Check/renew pressure
Transmitter.
(4) Renew controller.

(1) Fan rotation incorrect.

(1) Check/rectify wiring.

(2) Insufficient cooling air flow.

(2) Inspect/clean: enclosure

filter; ducting; air/oil cooler
matrix.
(3) Check room ventilation.
(4) Rectify/renew.

(2) Compressor fails.

(3) Pressure transmitter fault.

High oil temp fault

(3) High ambient temperature.

(4) Poor electrical connection or
Air/oil thermistor fault.
(5) Low oil level.

(6) Incorrect grade of oil.

(7) Oil stop valve not opening.

(8) Oil cooler bypass valve fault.
(9) L120SR only - Enclosure door
open.

Press probe fault *

Del pressure probe fault **
Reclaimer P probe fault **

Remote fault 1, 2 or 3 **

* 345SR and 475SR models

Chapter 5, page 6

(1) Pressure transmitter fault.

(2) Sensor wiring fault.
(3) Controller fault.

Appropriate input was open

circuit whilst conditions met.

(5) Check for leaks and rectify.

Top up reclaimer to correct
level.
(6) Drain/flush oil system. Clean
scavenge strainer. Renew
reclaimer separator and oil
filter elements. Refill the
system with the
recommended oil.
(7) Rectify or renew valve.
(8) Rectify or renew valve.
(9) Close door.

(1) Renew pressure transmitter.

(2) Check and rectify fault.
(3) Renew controller.

Check conditions (Type 1, 2

or 3) are appropriate.
Check auxiliary equipment
Check/rectify wiring.

** L120SR models

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Fault Finding

Message Displayed

SR motor high temp fault

Possible Cause

(1) Insufficient cooling air flow.

(4) Controller fault.

(1) Inspect/clean: enclosure filter;

ducting; motor cooling air
intake.
(2) Check room ventilation.
(3) Check and rectify electrical
circuit.
(4) Renew controller.

(1) Temperature sensor fault.

(2) Temperature sensor wiring fault.
(3) Controller fault.

(1) Renew temperature sensor.

(2) Check and rectify.
(3) Renew controller.

(2) High ambient temperature.

(3) Fan operation/rotation incorrect.

Temperature probe fault.

Temp probe fault.

2.

Action required

WARNING MESSAGES

Message Displayed

Change air filter

Possible Cause

(1) Intake air filter blocked.

(2) Filter pressure switch fault.
(3) Filter pressure switch wiring
fault.

Action Required

(1) Check/renew element.

(2) Check operation. Renew if
necessary.
(3) Check and rectify.

Change reclaimer
element

(1) Reclaimer filter blocked.

(2) Pressure transmitter fault

(1) Check/renew element

(2) Check and rectify.

Check reclaimer
Check reclaimer dp

(1) Service interval expired

(1) Check reclaimer differential

pressure.
(2) Renew element if required.

High oil temp alarm

See High Oil Temp Fault

Remote fault 1, 2 or 3

An input was open circuit

whilst conditions met.

Check conditions (Type 4, 5

or 6) are appropriate.
Check auxiliary equipment.
Check/rectify wiring.

Service due

Service countdown time

expired.

Service compressor then

reset timer.

Start inhibited

A start inhibit function is active.

An input configured for start

inhibit is open circuit.

AC20160-1822, Issue 1, November 2002

Chapter 5, page 7

CompAir

REM
The following chart will enable the user to identify other faults which may occur.
3.

FAULT FINDING CHART

Indication

Compressor fails to run

off-load.

Compressor fails to
run on-load.

Possible Cause

(1) Pressure transmitter faulty.

(1) Adjust to correct setting.

Renew if necessary.

(2) Solenoid bypass/blowdown valve

faulty.

(2) Find cause and rectify or

renew.

(3) Electrical wiring fault.

(3) Find cause and rectify or

renew.

(1) Solenoid bypass/blowdown valve

faulty.

(1) Rectify/renew valve.

(2) Pressure transmitter faulty.

(2) Adjust to correct setting.

Renew if necessary.
(3) Find cause and rectify.

(3) Electrical wiring fault.

Excessive oil
consumption.

Action

(1) Leaks in oil system.

(1) Examine system. Rectify if

necessary.

(2) Oil carried into users

pipework caused by:
(a) Reclaimer element
defective.
(b) Scavenge oil orifice
adaptor restricted.
(c) Incorrect grade of oil.
(d) Constant running at high
ambient temperature.
(e) Minimum pressure valve
not closing.

Chapter 5, page 8

(2) (a) Check pressure drop

across element. Renew
element if necessary.
(b) Clean scavenge strainer
and orifice adaptor.
(c) Drain the system, flush and
re-fill with an approved oil.
(d) Check/clean enclosure
filter. Improve room
ventilation.
(e) Check valve seating.
Renew spring if
necessary.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Fault Finding

Indication

Low delivery air

pressure.

Possible Cause

(1) Pressure transmitter

incorrectly set or faulty.
(2) Pressure relief valve leaking.
(3) Demand exceeds compressor
rating.
(4) Compressor speed reduced
owing to high heat sink
temperature.

Reclaimer pressure does

not fall to 4 bar when
compressor runs off-load.

(1) Minimum pressure valve not

closing.
(2) Venting valve faulty.

AC20160-1822, Issue 1, November 2002

Action

(1) Adjust to correct setting.

Renew if necessary.
(2) Check/renew seals.
Renew valve if necessary.
(3) Check for system leaks and
rectify. Review users air
requirements.
(4) Clean panel filters.
L120SR only: Check panel
fan.

(1) Check valve seating. Renew

spring if necessary.
(2) Check and renew if
necessary.

Chapter 5, page 9

CompAir

This page is intentionally left blank

Chapter 5, page 10

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

CHAPTER

6
COMPONENTS
1.
1.1
1.2
2.
2.1
2.2
2.3
3.
3.1
3.2
4.
4.1
4.2
5.
5.1
5.2
6.
7.
8.
9.
10.
10.1
10.2
11.
11.1
11.2
12.
12.1
12.2
13.
13.1
13.2
14.
14.1
14.2

PRIMARY OIL SEPARATOR AND SEPARATOR FILTER ELEMENT

(345SR, L45SR)
Description
Operation
RECLAIMER (475SR, L75SR, L120SR)
Description (475SR, L75SR
Description (L120SR)
Operation
MINIMUM PRESSURE VALVE (475SR, L75SR)
Description
Operation
MINIMUM PRESSURE VALVE (345SR, L45SR)
Description
Operation
MINIMUM PRESSURE/NON RETURN VALVE (L120SR)
Description
Operation
DIFFERENTIAL PRESSURE INDICATOR (L75SR)
EXCESS PRESSURE SWITCH (L75SR)
AIR FILTER PRESSURE SWITCH (L45SR and L75SR)
AIR FILTER PRESSURE SWITCH/INDICATOR (L120SR)
AIR AND OIL COOLERS (345SR, L45SR)
Air Cooler
Oil Cooler
AIR/OIL COOLER (475SR, L75SR)
Description
Operation
AIR COOLER (L120SR)
Description
Operation
OIL COOLER (L120SR)
Description
Operation
THERMOSTATIC BYPASS VALVE (L45SR)
Description
Operation

(continued)

AC20160-1822, Issue 1, November 2002

Chapter 6, page 1

CompAir

CONTENTS (continued)
15.
15.1
15.2
16.
16.1
16.2
17.
18.
18.1
18.2
19.
19.1
20.
20.1
20.2
21.
21.1
21.2
22.
22.1
22.2
23.
23.1
23.2
24.
24.1
24.2
25.
25.1
25.2
25.3
26.
26.1
26.2
27.
27.1
27.2
28
28.1
28.2
29.
29.1
29.2

THERMOSTATIC BYPASS VALVE (Earlier L75SR Models, L120SR)

Description
Operation
THERMOSTATIC BYPASS VALVE (Later L75SR Models)
Description
Operation
MOISTURE SEPARATOR (475SR, L75SR, L120SR)
STRAINERS
Condensate Strainer (L75SR)
Scavenge Strainer (L75SR)
FILTER MANIFOLD
Description
OIL STOP VALVE (475SR, L75SR)
Description
Operation
PRESSURE TRANSMITTER (L45SR, L75SR)
Description
Operation
SILICON TEMPERATURE SENSOR
Description
Operation
DRIVE AND FAN MOTOR THERMISTORS
Description
Operation
DELIVERY NON-RETURN VALVE (475SR, L75SR)
Description
Operation
BY-PASS VALVE
Description (L45SR, L75SR)
Description (L120SR)
Operation
INLET NON-RETURN VALVE (345SR, L45SR)
Description
Operation
INLET NON-RETURN VALVE (L120SR)
Description
Operation
BEKO DRAIN (L120SR)
Description
Operation
SCAVENGE NRV ASSEMBLY (L120SR)
Description
Operation

Chapter 6, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

FIGURES
FIG. 6.1
FIG. 6.2
FIG. 6.3
FIG. 6.5
FIG. 6.4
FIG. 6.6
FIG. 6.7
FIG. 6.8
FIG. 6.9
FIG. 6.10
FIG. 6.11
FIG. 6.12
FIG. 6.13
FIG. 6.14
FIG. 6.15
FIG. 6.16
FIG. 6.17
FIG. 6.18
FIG. 6.19
FIG. 6.20
FIG. 6.21
FIG. 6.22
FIG. 6.23
FIG. 6.24
FIG. 6.25
FIG. 6.26
FIG. 6.27
FIG. 6.28
FIG. 6.29
FIG. 6.30

SEPARATOR FILTER ELEMENT

RECLAIMER (475SR, L75SR)
RECLAIMER (L120SR)
MINIMUM PRESSURE VALVE (475SR, L75SR)
MINIMUM PRESSURE VALVE (345SR, L45SR)
MINIMUM PRESSURE/NON RETURN VALVE (L120SR)
DIFFERENTIAL PRESSURE INDICATOR (L75SR)
EXCESS PRESSURE SWITCH (L75SR)
AIR COOLER (345SR, L45SR)
OIL COOLER (345SR, L45SR)
AIR/OIL COOLER (475SR, Earlier L75SR Models)
AIR/OIL COOLER (Later L75SR Models)
AIR AND OIL COOLERS (L120SR)
THERMOSTATIC MIXING ARRANGEMENT
THERMOSTATIC BYPASS VALVE (L45SR)
THERMOSTATIC BYPASS VALVE
THERMOSTATIC BYPASS VALVE (LATER L75SR MODELS)
MOISTURE SEPARATOR (475SR, L75SR)
MOISTURE SEPARATOR (L120SR)
FILTER MANIFOLD
CONDENSATE STRAINER
OIL STOP VALVE
PRESSURE TRANSMITTER
SILICON TEMPERATURE SENSOR
NON-RETURN VALVE (475SR, L75SR)
BY-PASS VALVE
INLET NON-RETURN VALVE (345SR, L45SR)
INLET NON-RETURN VALVE (L120SR)
BEKO DRAIN (L120SR)
SCAVENGE NRV ASSEMBLY (L120SR)

AC20160-1822, Issue 1, November 2002

Chapter 6, page 3

CompAir

This page is intentionally left blank

Chapter 6, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

COMPONENTS
1.

PRIMARY OIL SEPARATOR AND

SEPARATOR FILTER ELEMENT
(345SR AND L45SR)

5
4
3

The separator vessel operates in conjunction with a

separator filter element (Fig. 5.3) where final
separation takes place. The separator element is
located on the manifold block and is fabricated from
layers of micro fine glass fibre, supported by tubes
and protected externally by a perforated steel
sheath. A scavenge pipe, located on the underside
of the manifold block, passes through the centre of
the element which screws into position against a
machined face.

2
1.2

Operation

The air/oil mixture passes from the air-end

discharge pipe into the primary oil separator vessel
where initial separation takes place by centrifugal
force. Most of the oil is separated at this stage and
drops to the bottom of the vessel.

HW 0275
1.
2.
3.
4.
5.

Filter Body
Fine Filter Layer
Supporting Tube
Second Filter Layer
Seal Ring

FIG. 6.1 SEPARATOR FILTER ELEMENT

1.1

Description

Primary separation of oil from the air/oil mixture

takes place in the separator vessel which is
positioned between the air-end and aftercooler.
The separator comprises a steel pressure vessel
with a welded cover.
The cover carries the pipe connections for the air
and oil pipework and a safety relief valve. An oil
filler pipe and oil level sightglass assembly are
fitted to the wall of the separator vessel.

AC20160-1822, Issue 1, November 2002

The remaining air/oil mixture then passes through

two separator filter elements where final separation
takes place. The separator element functions with
the principle of coalescence. The micro glass fibre
layers separate the oil droplets which collect in the
bottom of the filter and are scavenged back into the
air-end through a small diameter pipe
The filtered air then passes from the oil separation
element by way of the minimum pressure/ nonreturn valve. Provided the air pressure at this stage
is above 3.5 to 40 bar the air passes through the
aftercooler where it is cooled before passing to the
delivery outlet.
If the air pressure in the primary oil separator falls
below 3.5 to 40 bar the minimum pressure valve
will close. The valve also incorporates a non-return
valve which operates to prevent delivery air
passing back into the separator when the
compressor is running off-load.
Oil from the bottom of the primary oil separator
flows under pressure to the oil cooler and during
normal running the oil passes through the cooler to
maintain the correct temperature. A thermostatic
bypass valve is installed in the inlet manifold of the
oil cooler.

Chapter 6, page 5

CompAir

2.

RECLAIMER (475SR, L75SR, L120SR)

7
2

15
10

14

10

15

11

13

14

11
13

12
HW 0276

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Pressure Vessel
Joint
Cover
Scavenge Pipe
Minimum Pressure Valve
Air Outlet
Pressure Relief Valve
Filter Element
Oil Outlet
Air/Oil Inlet
Oil Reservoir
Drain Connection
Oil Level Sight Tube
Oil Filler
Excess Pressure Switch

FIG. 6.2 RECLAIMER (475SR, L75SR)

Chapter 6, page 6

12

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

HW 0277

Pressure Vessel
Joint
Cover
Scavenge Pipe
Minimum Pressure Valve
Air Outlet
Pressure Relief Valve
Filter Element
Oil Outlet
Air/Oil Inlet
Oil Reservoir
Drain Connection
Oil Level Sight Tube
Oil Filler
Pressure Transducer

FIG. 6.3 RECLAIMER (L120SR)

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

2.1

Description (475SR and L75SR) - fig. 6.2

Separation of oil from the oil/air mixture takes place

in the reclaimer which is positioned between the
air-end and air/oil cooler.
The reclaimer comprises a steel pressure vessel
(1) with a removable cover (3). A filter element (8)
is contained within the pressure vessel.
The filter element is fabricated from layers of micro
fine glass fibre, supported by tubes and protected
externally by a perforated steel sheath wrapped in
a pre-filter element. The element is suspended by a
flange from the top of the pressure vessel. The
assembly is sealed with a joint (2) and secured in
position by the cover.
The cover carries the minimum pressure valve (5),
scavenge oil pipe (4) and air connections for the
regulation system. A drain connection (12), oil filler
(14), pressure relief valve (7), oil level sight glass
(13) and excess pressure switch (15) are fitted to
the wall of the pressure vessel. The lower portion of
the pressure vessel forms an oil reservoir (11).
2.2

2.3

Operation

The air/oil mixture passes from the discharge port

of the air-end into the reclaimer inlet (10).
Centrifugal primary separation of the oil occurs and
most of the oil droplets fall into the oil reservoir.
The differential pressure between the inside and
the outside of the element causes the remaining oil
droplets to pass through the two stages of the
reclaimer element where final separation takes
place.
The reclaimer element functions on the principle of
coalescence. The micro glass fibre layers separate
the small oil droplets from the compressed air/oil
mixture to form larger droplets which drain down to
collect inside the bottom of the element. The
accumulation of oil in the element is returned to the
air end through the scavenge system.

Description (L120SR) - fig. 6.3

Separation of oil from the oil/air mixture takes place

in the reclaimer which is positioned between the
air-end and air/oil cooler.
The reclaimer comprises a steel pressure vessel
(1) with a removable cover (3). A filter element (8)
is contained within the pressure vessel.
The filter element is fabricated from layers of micro
fine glass fibre, supported by tubes and protected
externally by a perforated steel sheath wrapped in
a pre-filter element. The element is suspended by a
flange from the top of the pressure vessel. The
assembly is sealed with a joint (2) which is bonded
to the filter element (8) and secured in position by
the cover.
The cover carries the minimum pressure valve (5),
scavenge oil pipe (4) and air connections for the
regulation system. A drain connection (12), oil filler
(14), pressure relief valve (7), oil level sight glass
(13) and pressure transducer (5) are fitted to the
wall of the pressure vessel. The lower portion of the
pressure vessel forms an oil reservoir (11).

AC20160-1822, Issue 1, November 2002

Chapter 6, page 7

CompAir

3.

MINIMUM PRESSURE VALVE (345SR, L45SR)

1 2
3 4

11
9

12

10

HW 0278

1.
2.
3.
4.
5.
6.

Locknut
Washer
Retainer
O Ring
Valve Head
O Ring Seal

7.
8.
9.
10.
11.
12.

Guide Pin
Spring
O Ring Seal
Piston
Spring
Valve Body

FIG. 6.4 MINIMUM PRESSURE VALVE (345SR, L45SR)

3.1

Description

The minimum pressure valve fits inside the

manifold block and performs the following main
functions:
1.

It ensures a rapid pressure build-up in the

reclaimer during initial start-up. The minimum
pressure valve is held closed until the
pressure in the reclaimer reaches 3.5 to 4 bar.

2.

It prevents high velocity, low pressure air

carrying over excessive amounts of oil into
the delivery air pipe during start-up.

3.

The minimum pressure valve also

incorporates a non-return valve. This prevents
pressurised air in the users pipework passing
back into the reclaimer when the compressor
unit stops or runs off-load.

Chapter 6, page 8

The minimum pressure valve consists of a valve

body (12), valve assembly, and piston (10).
The valve assembly comprises a guide pin (7),
valve head (5), retainer (3) and two O ring seals
(4, 6) secured by a washer (2) and a locknut (1).
The guide pin houses a spring (8) and is located
inside the piston.
The valve head is seated against a face machined
in the manifold block. The piston moves inside the
bore of the valve body and two springs (11) force
the piston against the rear face of the valve
assembly. An O ring seal (9) fitted to the outside
of the piston prevents any pressure leakage past
the piston.
The piston and valve assembly move to control the
flow of air through the valve.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

3.2

Operation

4.

When the compressor starts, the minimum pressure

valve is held in the closed position by the effect of a
spring against the top of the piston and by the face
of the piston holding the valve assembly against the
seat. The valve remains closed until the pressure in
the separator vessel reaches a set minimum
pressure (3.5 to 4 bar). When the pressure in the
separator vessel overcomes the force exerted by
the two springs, the valve assembly and piston
move up allowing full air flow past the open valve,
through the outlet port and into the main delivery
pipe to the aftercooler.

MINIMUM PRESSURE VALVE

(475SR, L75SR)
1

HW 0279

15

4
14

When the compressor off-loads the flow of air

ceases between the separator vessel and the
users pipework. Pressure in the compressor
system acts to hold the minimum pressure valve
piston in the raised position against the effect of the
spring and at the same time the valve spring closes
the non-return valve onto its seat.

13
12
11

When the compressor reverts to on-load running,

the valve assembly will stay closed against the seat
until the pressure in the separator vessel exceeds
the pressure in the users pipework. The plunger
will not return to close the outlet until the pressure
in the users pipework falls below the force of the
springs.

10

1.
2.
3.
4.
5.
6.
7.
8.

7 6

Piston Housing
Outer Piston Spring
Inner Piston Spring
Piston
Valve Head
'O' Ring
Washer
Locknut

9.
10.
11.
12.
13.
14.
15.

Retainer
'O' Ring
Body
Guide Pin
'O' Ring
Spring
'O' Ring

FIG. 6.5 MINIMUM PRESSURE VALVE

(475SR, L75SR)

4.1

Description

The minimum pressure valve is mounted on the

reclaimer cover and performs the following
functions:
1.

AC20160-1822, Issue 1, November 2002

It ensures a rapid pressure build-up in the

reclaimer during initial start-up. The minimum
pressure valve is held closed until the
pressure in the reclaimer reaches
approximately 4 bar.

Chapter 6, page 9

CompAir

2.

It prevents high velocity, low pressure air

carrying over excessive amounts of oil into the
delivery air pipe during start-up.

3.

It acts as a non-return valve preventing

pressurised air in the users pipework passing
back into the reclaimer when the compressor
unit stops or runs off-load.

5. MINIMUM PRESSURE/NON RETURN VALVE

(L120SR)
5.1

The minimum pressure valve consists of a valve

body (11), a valve assembly and a piston housing
(1). The valve assembly comprises a piston (4) and
'O' ring (13), guide pin (12) and valve spring (14), a
valve head (5) with O ring seal (10) and retainer
(9) secured by a washer (7) and locknut (8). An 'O'
ring (6) provides a seal between the valve head and
guide pin. The guide pin and spring are located
inside the piston. The valve head and O ring seal
operates against a seat formed in the valve body
(11). The piston moves inside the bore of the piston
housing and two piston springs (2,3) force the
piston against the rear face of the valve assembly.
The piston and valve assembly move to control the
flow of air through the valve.
A tapped hole in the base of the valve body
provides a connection to the differential pressure
indicator.
4.2

Operation

When the compressor starts, the minimum pressure

valve is held in the closed position by the piston
springs. The valve remains closed until the pressure
in the reclaimer reaches a set minimum pressure (4
bar). When the pressure in the reclaimer overcomes
the force exerted by the two piston springs, the
valve assembly and piston move up allowing full air
flow past the open valve, through the outlet port and
into the main delivery pipe to the aftercooler.
When the compressor comes off-load the flow of air
ceases between the reclaimer and the users
pipework. Downstream pressure in the system acts
to hold the minimum pressure valve piston (4) in the
raised position against the effect of the piston
springs and at the same time the valve spring (14)
closes the non-return valve head (5) on to its seat.
The piston will not return to close the outlet until the
pressure in the users pipework falls below the set
pressure of 4 bar.
When the compressor reverts to on-load running,
the valve will stay closed against the seat until
reclaimer pressure again exceeds 4 bar.

Chapter 6, page 10

Description

The minimum pressure valve is mounted on the

reclaimer cover and performs the following
functions:
1.

It ensures a rapid pressure build-up in the

reclaimer during initial start-up. The minimum
pressure valve is held closed until the
pressure in the reclaimer reaches
approximately 4 bar.

2.

It prevents high velocity, low pressure air

carrying over excessive amounts of oil into the
delivery air pipe during start-up.

3.

It acts as a non-return valve preventing

pressurised air in the users pipework passing
back into the reclaimer when the compressor
unit stops or runs off-load.

The minimum pressure valve consists of a valve

body (8), a valve assembly and a piston housing
(1). The valve assembly comprises piston (4), 'O'
ring (6) and valve head (5). The valve head stem is
located inside the piston and has a moulded seal
which operates against a seat formed in the valve
body (8). The piston moves inside the bore of the
piston housing. The piston moves inside the bore of
the piston housing and two piston springs (2,3)
force the piston against the rear face of the valve
assembly. The piston and valve assembly move to
control the flow of air through the valve.
5.2

Operation

When the compressor starts, the minimum pressure

valve is held in the closed position by the piston
springs. The valve remains closed until the pressure
in the reclaimer reaches a set minimum pressure (4
bar). When the pressure in the reclaimer overcomes
the force exerted by the two piston springs, the
valve assembly and piston move up allowing full air
flow past the open valve, through the outlet port and
into the main delivery pipe to the aftercooler.
When the compressor comes off-load the flow of air
ceases between the reclaimer and the users
pipework. Downstream pressure in the system acts
to hold the minimum pressure valve piston (4) in the
raised position against the effect of the piston
springs and at the same time the valve head stem

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

moves out from the piston and the valve head

closes onto its seat to act as a non-return valve.
The piston will not return to close the outlet until the
pressure in the users pipework falls below the set
pressure of 4 bar.
When the compressor reverts to on-load running,
the valve will stay closed against the seat until
reclaimer pressure again exceeds 4 bar.

6.

DIFFERENTIAL PRESSURE INDICATOR

(L75SR)

1
6

5
3

2
3

4
9,10

HW 0281
8

1.
2.
3.
4.
5.
6.

9
6
4

2
Body
Adjusting screw
Dial
Low pressure inlet port
High pressure inlet port
Mounting holes

FIG. 6.7 DIFFERENTIAL PRESSURE INDICATOR

(L75SR)

HW 0280

1.
2.
3.
4.
5.
6.
7.
8.
9.
10

Piston Housing
Outer Piston Spring
Inner Piston Spring
Piston
Valve Head
'O' Ring
'O' Ring
Body
Bolt
Washer

FIG. 6.6 MINIMUM PRESSURE/NON RETURN

VALVE (L120SR)

AC20160-1822, Issue 1, November 2002

The differential pressure indicator monitors the

pressure drop across the reclaimer element. The
scale on the dial of the indicator is divided into two
sectors, green and red. As the differential pressure
across the reclaimer element rises the needle
moves across the green sector (0-1 bar range)
towards the red sector. If the needle passes into the
red sector (1-2 bar range) the differential pressure is
too high indicating that the reclaimer element should
be replaced.
The differential pressure indicator is a sealed unit
and no attempt should be made to tamper with it. If
a fault is suspected the complete indicator must be
replaced.
The low pressure inlet port is connected to the
downstream side (inside) of the reclaimer element
via a tapping in the base of the minimum pressure
valve. The high pressure inlet port is connected to
the upstream side of the element via a tapping in
the wall of the reclaimer pressure vessel.

Chapter 6, page 11

CompAir

7.

EXCESS PRESSURE SWITCH

(L75SR)

10.

AIR AND OIL COOLERS (345SR, L45SR)

10.1 Air Cooler - fig. 6.9

The excess pressure switch is a normally closed
(N.C.) switch, connected to the primary separator
side of the reclaimer.

10.1.1 Description
The air cooler cools the dicharge air before it
passes into the main distribution pipework. The
cooler is mounted vertically and comprises a bank
of finned tubes, connected to inlet and discharge
headers, attached to mounting points on the frame
adjacent to the air intake panel.
A connection (1) for the inlet air is provided in the
upper header whilst a similar discharge connection
(2) is fitted in the lower header.

IN

HW 0282

FIG. 6.8 EXCESS PRESSURE SWITCH

(L75SR)
If the pressure in the reclaimer exceeds 14 bar the
switch contacts open and a signal from the
controller stops the compressor. A shutdown
message High air pressure will be displayed on
the control panel.
The switch contacts will close again when the
pressure downstream of the switch falls below 14
bar and allows the fault to be reset.

8.

AIR FILTER PRESSURE SWITCH

(L45SR and L75SR)

A pressure switch is fitted to the air intake filter to

detect filter element blockage. The switch signals
the controller to display the warning Change air
filter when the differential pressure across the filter
exceeds a pre-set value.

9.

AIR FILTER PRESSURE SWITCH/

INDICATOR (L120SR)

A pressure switch/indicator is fitted to the air intake

filter to detect filter element blockage. The switch
signals the controller to display the warning
Change air filter when the differential pressure
across the filter exceeds a pre-set value.

Chapter 6, page 12

OUT

HW 0283

FIG. 6.9 AIR COOLER (345SR, L45SR)

10.1.2 Operation
Compressed air from the reclaimer enters the upper
header of the aftercooler, passes downwards
through the finned tubes to the lower header and
out into the user's pipework.
The cooling fan runs continuously drawing air in
through the inlet grilles and through the aftercooler
and then discharging it vertically upwards through
the oil cooler and some acoustic baffles to the
exhaust outlet.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

10.2 Oil Cooler

10.2.2 Operation

10.2.1 Description

Oil from the bottom of the separator vessel flows

under pressure to the oil cooler and during normal
running the oil passes through the cooler to
maintain the correct temperature. A thermostatic
bypass valve is installed in the inlet manifold of the
oil cooler.

Thermostat

Out
In

HW 0284

FIG. 6.10 OIL COOLER (345SR, L45SR)

The oil cooler cools the oil from the separator
vessel before it returns to the air-end via the oil
filter. The cooler comprises a two pass matrix,
connected to an inlet and outlet header, mounted
horizontally at the top of the unit. A thermoststic
bypass valve is installed in the inlet header.

AC20160-1822, Issue 1, November 2002

When the compressor is started, the cold oil in the

system bypasses the oil cooler and flows through
the oil filter directly to the air-end. As the oil and air
mixture is compressed by the rotors in the air-end,
the temperature of the oil increases.
When the oil has reached its normal operating
temperature the bypass valve closes and the oil is
directed through the oil cooler. The cooled oil then
flows to the oil filter where it is cleaned before
entering the air-end.
The cooling fan runs continuously drawing air in
through the inlet grilles and through the aftercooler
and then discharging it vertically upwards through
the oil cooler and some acoustic baffles to the
exhaust outlet.

Chapter 6, page 13

CompAir

11.

AIR/OIL COOLER (457SR, L75SR)

Cooling is provided by a cooling fan, comprising a

fan and motor assembly, attached to a cowl and
support plate and secured to the underside of the oil
cooler.

11.1 Description
The air/oil cooler cools the discharge air before it
passes into the main distribution pipework and also
cools the oil from the reclaimer before it returns to
the air-end via the oil filter. The cooler sections are
separate and comprise a matrix of cooling tubes
carried between inlet and outlet headers which are
welded together and mounted horizontally between
supports at the top of the compressor. On earlier
models the air cooler section is single pass and the
oil section double pass. On later models both the
air and oil coolers are single pass.

11.2 Operation
Compressed air from the reclaimer enters the air
section of the inlet header of the cooler, passes
through the finned tubes to the outlet header,
through the moisture separator and out into the
users pipework. Separated moisture collects in the
moisture separator, passes to the automatic
condensate drain and is expelled via the baseframe
connection and drain pipe.

On earlier models a thermostatic bypass valve is

installed in the oil inlet header. On later models a
3-way thermostatic valve is fitted to the outlet port of
the reclaimer.

On earlier models oil from the reclaimer enters the

oil section of the cooler header and makes a
double pass through the cooling matrix back into
the header before passing to the air-end via the
filter. On later models oil from the reclaimer enters
the cooler oil section via a 3-way thermostatic valve
and makes a single pass through the cooling matrix
to the air-end via the filter.

A moisture separator fitted with an automatic

condensate drain is installed between the air
section of the cooler and the discharge connection
to the users pipework.

1.
2.
3.
4.
5.
6.
7.
8.
9.

Air/Oil Cooler
Cooling Fan
Oil Inlet
Thermostatic Bypass Valve
Cooler Matrix
Oil Outlet
Air inlet
Air Outlet
Moisture Separator

5
7

6
3

HW 0285

FIG. 6.11 AIR/OIL COOLER (475SR, Earlier L75SR Models))

Chapter 6, page 14

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

On earlier models When the compressor is started

from cold, the thermostatic valve allows the cold oil
in the system to by-pass the cooler and flow
directly through the oil filter to the air-end. Once the
oil has reached its normal operating temperature
the by-pass valve directs the oil through the cooler.
On Later models, when the compressor is started
the 3-way thermostatic valve allows the cold oil in
the system to by-pass the cooler and flow directly
through the oil filters to the air-end. Once the oil
has reached its normal operating temperature the
thermostatic valve directs the oil to the oil cooler
section header.
The cooling fan runs continuously, drawing air
through the inlet grille and discharging it vertically
upwards through the air/oil cooler and an array of
acoustic baffles to the exhaust outlet.

1.
2.
3.
4.
5.
6.
7.
8.

Air/Oil Cooler
Cooling Fan
Oil Inlet
Moisture Separator
Cooler Matrix
Oil Outlet
Air inlet
Air Outlet

5
7

3
HW 0286

FIG. 6.12 AIR/OIL COOLER (Later L75SR Models)

AC20160-1822, Issue 1, November 2002

Chapter 6, page 15

CompAir

12.

AIR COOLER (L120SR)

12.1 Description
The air cooler cools the discharge air before it
passes into the main distribution pipework. The
cooler comprises a matrix of cooling tubes carried
between inlet and outlet headers which are welded
together and mounted vertically between cooler
supports at the cooling air inlet end of the
compressor. It is a single pass cooler.

A moisture separator is fitted with a pipe that takes

the condensate to the Beko no loss drain. It is
installed between the outlet of the air cooler and the
discharge connection to the User's pipework.
Cooling is provided by a cooling fan comprising a
fan and motor assembly inside a cowl, situated
centrally inside the machine.

1.
2.
3.
4.

Air In
Oil Inlet
Air Out
Oil Outlet

5.
6.
7.
8.

Air Cooler
Oil Cooler
Moisture Separator
Thermostatic Bypass Valve

FIG. 6.13 AIR AND OIL COOLERS (L120SR)

Chapter 6, page 16

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

12.2 Operation
Compressed air from the reclaimer enters the air
section of the inlet header of the cooler and passes
through finned tubes to the outlet header, through
the moisture separator and then out to the User's
pipework.
Separated moisture collects in the moisture
separator, passes to the Beko no loss drain and is
expelled via the connection in the cooler end
column.

As the temperature increases to 55C the

thermostatic valve will begin to open allowing some
oil to flow through the cooler and some through the
bypass pipe. When the oil temperature reaches
68C all of the oil will flow through the cooler

OIL OUT

OIL IN

THERMOSTATIC
VALVE

The cooling fan runs continuously, drawing air

through the inlet grilles and discharging it vertically
upwards through the exhaust duct.

13.

OIL COOLER (L120SR)

HW 0288

OIL COOLER

13.1 Description
The oil cooler cools the oil from the reclaimer
before returning it to the air end via the oil filter.

FIG. 6.14 THERMOSTATIC MIXING

ARRANGEMENT

The cooler comprises a matrix of cooling tubes

carried between inlet and outlet headers which are
welded together. These are mounted vertically
underneath the air cooler, between the cooler
supports at the cooling air inlet end of the
compressor.
It is a single pass cooler with a bypass pipe
mounted between inlet and outlet headers. A
thermostatic valve is installed in the oil outlet
header which is controlled by the temperature of
the mixed oil outlet.
Cooling is provided by a cooling fan comprising a
fan and motor assembly inside a cowl, situated
centrally inside the machine.

13.2 Operation
Oil from the reclaimer enters the oil cooler and
passes through the cooler matrix back into the
header before passing to the air end via the oil
filters.
When the compressor is started from cold all of the
oil flows through the bypass pipe and out through
the oil filters to the air end.

AC20160-1822, Issue 1, November 2002

Chapter 6, page 17

CompAir

14.

14.1

THERMOSTATIC BYPASS VALVE

(L45SR Models Not Having External
Thermostat)
Description

The oil cooler is equipped with a thermostatic

bypass valve which allows the oil in the system to
reach operating temperature rapidly. The valve is
installed in the inlet connection of the cooler header
and is held closed when the oil is cold. The cold oil
bypasses the cooler tube block until the operating
temperature (70C) is reached.

14.2

Operation

When the temperature of the oil increases to the set

point of the thermostat, the expansion of the melting
wax in the capsule forces the thrust pin out of the
capsule and moves the valve body (3) to close the
outlet to the bypass manifold (2) and open the inlet
to the cooler manifold (6). The hot oil is then
directed through the cooler tube block. A cap (9),
installed in the cooler header, holds the valve in
position and allows access for servicing purposes.

The thermostatic bypass valve consists of the

operating element (7), thrust pin (8), valve housing
(5) and spring (4). The operating element is a
sealed capsule containing wax into which is
inserted the thrust pin. The valve body (3) is
attached to the operating element. When the oil is
cold the valve is held in position by the spring (4).
Oil enters the valve through the inlet (1) and leaves
by way of the bypass manifold (2).

1.
2.
3.
4.
5.

Inlet
Bypass Manifold
Valve Body
Spring
Valve Housing

6.
7.
8.
9.

Cooler Inlet Manifold

Operating Element
Thrust Pin
Cap

FIG. 6.15 THERMOSTATIC BYPASS VALVE (L45SR)

Chapter 6, page 18

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

15.

THERMOSTATIC BY-PASS VALVE

(Earlier L75SR and all L120SR Models)

16.

THERMOSTATIC BYPASS VALVE

(Later L45SR and L75SR Models)

15.1 Description

16.1 Description

The thermostatic by-pass valve comprises the

operating element (5), thrust pin (6), valve housing
(2) and spring (3). The operating element is a
sealed capsule containing wax into which is
inserted the thrust pin. The valve body (4) is
attached to the operating element.

The thermostatic bypass valve is a fully automatic

three-way fluid temperature controller. The valve is
connected upstream of the oil cooler to allow the oil
system to reach normal operating temperature
rapidly. The valve is closed when the compressor is
started and the oil is cold. The cold oil bypasses the
cooler until the normal operating temperature (70C)
is reached.
The thermostatic bypass valve consists of the valve
body (6), cover (1), operating element (3), housing
(7), inner and outer springs (4) and 0 ring seals (8).
The operating element is a sealed capsule
containing wax which, together with the spring, is
contained within the brass housing. The upper part
of the housing is flanged and is retained in the valve
body by the cover. The lower part is free to move
inside the valve body.

;;
yy
;
;;;
;;
yy
;
;;;
;
;;
;;
yy
A cap (7) holds the valve in position in the cooler
header and allows access for servicing purposes.
8

10

HW 0291

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

11

Inlet
Valve Housing
Spring
Valve Body
Operating Element
Thrust Pin
Cap
'O' Ring
By-pass Manifold Port
Cooler Manifold Port

16.2 Operation
When the oil is cold, the valve is held in the bypass
position by the springs. Oil enters the valve through
the inlet and leaves by way of the bypass outlet.
When the temperature of the oil increases to the set
point of the thermostatic valve, the expansion of the
melting wax in the operating element causes the
lower part of the housing to move away from the
upper part, allowing the hot oil to flow through the
outlet to the coolers.

FIG. 6.16 THERMOSTATIC BY-PASS VALVE

15.2 Operation
When the oil is cold the valve is held in position by
the spring (3). Oil enters the valve through the
inlet (1) and leaves by way of the by-pass manifold
port (9).
When the temperature of the oil increases to the
set point of the thermostat, the expansion of the
melting wax in the capsule forces the thrust pin out
of the capsule and moves the valve body (4) to
close the port to the by-pass manifold (9) and open
the port to the cooler manifold (10). The hot oil is
then directed through the cooler tube block.

AC20160-1822, Issue 1, November 2002

Chapter 6, page 19

CompAir

7
4

3
8
HW 0298

1.
2.
3.
4.
5.

Cover
Bypass Outlet
Operating Element
Inner and Outer Springs
Inlet from Reclaimer

6.
7.
8.
9.

Valve Body
Housing
'O' Ring seals
Outlet to Cooler

FIG. 6.17 THERMOSTATIC BYPASS VALVE (LATER L45SR AND L75SR MODELS)

Chapter 6, page 20

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

17.

MOISTURE SEPARATOR
(475SR, L75SR, L120SR)

The moisture separator used on L120SR machines

is shown in FIG. 6.19.
The moisture separator uses the principles of
centrifugal force, impingement separation, and
laminar and turbulent flow.
The condensate collects in the bottom of the
housing and is released automatically through a
solenoid valve operated drain connected to the
bowl (L75SR) or through a Beko no-loss drain
(L120SR).

HW 0300
1.
2.
3.
4.
5.
6.

Housing
Inlet Port
Impinger Cone
Bowl
Spinner
Outlet Port

FIG. 6.19 MOISTURE SEPARATOR (L120SR)

FIG. 6.18 MOISTURE SEPARATOR

(475SR, L75SR)
L75SR and L120SR compressors are equipped
with a moisture separator to remove contamination
from the delivery air. The moisture separator is
installed in the delivery air pipe, downstream of the
aftercooler.
Moisture held in suspension in the delivery air is
removed from the compressed air passing through
the moisture separator by mechanical separation.

AC20160-1822, Issue 1, November 2002

Chapter 6, page 21

CompAir

18.

STRAINERS

18.1 Condensate Strainer (L75SR)

Condensate from the moisture separator enters the

strainer body and passes through the screen before
passing to the drain valve.

A 'Y' type strainer is fitted in the condensate drain

line between the moisture separator and the
solenoid operated condensate drain valve, to
prevent blockage of the valve.

The screen filters out any large particles which

then collect in the lower part of the body. The cap is
removable to allow the screen to be cleaned or
replaced.

The strainer consists of a body (1), screen (2) and

cap (3). The removable screen is made of a fine
wire mesh held in position by machined recesses in
the body and cap.

18.2 Scavenge Strainer (L75SR)

A simple gauze disc strainer is installed in the
scavenge line between the reclaimer and the
air-end to provide protection for the air-end
components and to prevent blockage of the
scavenge restrictor orifice. The screen removes
any solid particles from the oil being scavenged
from the bottom of the reclaimer element before it
enters the air-end.

19. FILTER MANIFOLD

2

Oil to
air end

Oil
from
cooler

3
Oil Scavenge
return to Air End
and NRV

Air to air cooler

Air/oil inlet
8
4
7

HW 0301

1.
2.
3.
4.

Control Air Isolating Valve

Unloader Solenoid Valve
Minimum Pressure Valve
Separator Filter Qty 2 on L45SR

5.
6.
7.
8.

Differential Pressure Gauge (primary position)

Differential Pressure Gauge (secondary position)
Oil Filter
Oil Drain Valve

FIG. 6.20 FILTER MANIFOLD

19.1 Description
A cast aluminium filter manifold is screwed to the
bulkhead panel to provide ease of maintenance for
the serviceable components.

Primary and secondary connections are provided

for the gauge which measures the differential
pressure across the separator filter element.

The manifold is ported and machined to provide a

housing for the separator filters, oil filter, scavenge
pipe, minimum pressure valve and differential
pressure gauge.

Pipework connections are provided for the air/oil

inlet and the air outlet from the separator element,
oil filter inlet and outlet, unloader solenoid valve and
scavenge oil return to the air-end.

Chapter 6, page 22

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

20.1 Description
The purpose of the oil stop valve is to prevent any
oil entering the air-end when the compressor is
stopped.
The oil stop valve is fitted at the oil inlet to the airend and comprises a valve body (1) and cover (2),
incorporating a diaphragm assembly (3), spindle (6)
and valve head (5). The valve head is fitted with a
return spring (4) and operates against a seat (7) in
the valve body.

20.2 Operation
1. Body 2. Screen 3. Cap
FIG. 6.21 CONDENSATE STRAINER

20.

OIL STOP VALVE (475SR, L75SR)

2

Discharge air pressure from the air-end acts on the

diaphragm to open the oil stop valve against the
spring during start up and holds it open while the
compressor is running. When the compressor stops
this pressure falls to zero allowing the return spring
to close the valve.

6
5

HW 0303

1.
2.
3.
4.
5.
6.
7.

Valve Body
Cover
Diaphragm Assembly
Spring
Valve Head
Spindle
Seat

6.22 OIL STOP VALVE (475SR, L75SR

AC20160-1822, Issue 1, November 2002

Chapter 6, page 23

CompAir

21.

PRESSURE TRANSMITTER (L45SR, L75SR)

4 to 20mA
1

X02-1

X02-2
4-20 mA PRESSURE
TRANSMITTER
HW 0304

24V D.C.

DETECTION
CIRCUITRY

0V D.C.

CONTROLLER

FIG. 6.23 PRESSURE TRANSMITTER

21.1 Description
The air pressure in the users pipework is
continuously monitored by a 4-20 mA pressure
transmitter which converts the pressure into an
electrical signal.
21.2 Operation
The transmitter converts air pressure into a linear
change of electrical current flowing in the two power
supply wires to the transmitter. Typically, the
current will change from 4 mA at zero bar to 20 mA
at 138 bar (L45SR, L75SR) or 4 mA at zero bar to
20 mA at 16 bar (L120SR).

Chapter 6, page 24

The controller detects the current flowing in the

power supply wires to the transmitter and converts
this into a pressure reading.
The controller can recognise an out of range
signal if the current is less than 4 or greater than
20mA. This will be displayed as a pressure probe
fault.
Refer to the table in chapter 8 para. 6.0

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

22.

SILICON TEMPERATURE SENSOR

HW 0305

23.

DRIVE AND FAN MOTOR THERMISTORS

From June 2002 L45SR, L75SR do not have fan

thermistors fitted. All L120SR models do not
have fan thermistors.

23.1 Description

The drive and fan motors are each equipped with

thermistors of the PTC type which are buried in the
windings to protect the compressor against motor
over-temperature.

S
23.2 Operation

3
1.
2.
3.

Probe
Body
Electrical Connectors

If the temperature of the coil windings exceeds a

set temperature, the resistance of the thermistor
will increase sharply. The sudden increase in
resistance will be detected by the controller,
causing the compressor to shut down and display a
motor fault.

FIG. 6.24 SILICON TEMPERATURE SENSOR

24.

DELIVERY NON-RETURN VALVE

(475SR, L75SR)

22.1 Description
2

A silicon temperature sensor of the spreading

resistance type is installed in the air-end adjacent
to the delivery port. The sensor protects the
compressor unit against excessive discharge
temperature by sensing the temperature of the
compressed air/oil mixture discharged from the airend. The resistance of the sensor increases with
temperature

3
1
11

10

22.2 Operation
The resistance of the temperature sensor is
processed within the controller and displayed as an
air/oil temperature reading. A high oil temperature
warning and/or compressor shut-down is activated
if the temperature of the air/oil mixture reaches the
trip setting.

1.
2.
3.
4.
5.
6.

6 5

Body
Cover
'O' Ring
Valve Head
'O' Ring
Washer

7.
8.
9.
10.
11.

HW 0306

Locknut
Retainer
'O' Ring
Guide Pin
Spring

FIG. 6.25 NON-RETURN VALVE

(475SR, L75SR)

AC20160-1822, Issue 1, November 2002

Chapter 6, page 25

CompAir

24.1 Description
The non-return valve is mounted on the discharge
outlet of the air-end. Its function is to isolate the airend from reclaimer pressure when the compressor
is stopped. This prevents oil from being blown back
through the air-end after stopping and ensures that
the air end always re-starts in the unloaded
condition.
The non-return valve consists of a valve body (1)
and cover (2) sealed by an 'O' ring (6) and a valve
assembly. The valve assembly comprises a guide
pin (10) and spring (11), a valve head (4) with 'O'
ring seal (9) and retainer (8), secured by a washer
(6) and locknut (7). An 'O' ring (5) provides a seal
between the valve head and the guide pin. Two
studs secure the flange of the discharge pipe.

24.2 Operation
When the compressor is running and the pressure
in the reclaimer is below the discharge pressure of
the air-end the non-return valve is held open. When
the discharge pressure of the air-end falls, a
condition is reached where pressure on each side
of the non-return valve is the same. The valve
spring will then lift the valve head and close it
against the seat. Reclaimer pressure will hold the
valve closed until air-end pressure rises to
overcome the effect of reclaimer pressure and the
valve spring.

25.

1.
2.
3.
4.
5.
6.

Body
Inlet Port
Valve
Spring
Solenoid Coil
'O' Ring (not illustrated)

FIG. 6.26 BY-PASS VALVE

25.2 Description (L120SR)
The by-pass valve comprises a valve body (1),
valve (3), solenoid coil (5), spring (4) and O Ring
seal (6). The function of the valve is to re-circulate
air produced by the air-end when the compressor is
running off-load at minimum speed. The by-pass
valve is a solenoid operated, normally open, valve
mounted on the reclaimer lid. The outet port is
linked to the non-return valve by a flexible hose.

BY-PASS VALVE
25.3 Operation

25.1 Description (L45SR, L75SR)

The by-pass valve comprises a valve body (1),
valve (3), solenoid coil (5), spring (4) and O Ring
seal (6). The function of the valve is to re-circulate
air produced by the air-end when the compressor is
running off-load at minimum speed. The by-pass
valve is a solenoid operated, normally open, valve
mounted on the air-end inlet connector (L75SR) or
on the intake NRV (L45SR). The inlet port (2) is
linked to the reclaimer cover by a pipe.

Chapter 6, page 26

During normal running, when the delivery pressure

is below the programmed off-load pressure, the
solenoid is energised and the by-pass valve is held
closed. If delivery pressure rises above the offload
pressure the valve solenoid is de-energised and
the by-pass valve is opened. Delivered air volume
then falls to zero.
If delivery pressure falls below the target pressure
the solenoid is energised allowing delivered air
volume to rise and reclaimer pressure to build up
again towards the target pressure.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Components

26.

INLET NON-RETURN VALVE

(345SR, L45SR)

When the compressor is stopped the valve head

returns to its seat and prevents the air/oil mixture
from blowing back through the air intake.

27.

INLET NON-RETURN VALVE (L120SR)

27.1 Description
The non-return valve is mounted on the air end inlet
and secured by 4 screws. A pipe connected to the
air intake filter is secured to the inlet of the valve
with a jubilee clip.
The inlet non-return valve consists of a body (1)
with an integral seat and a valve assembly
comprising a valve head (2), valve stem (3) and
spring (5). The valve stem is secured to the body by
an external domed nut (7).
27.2 Operation
1. Body
2. Valve Seat
3. Valve Head

4. Retaining Bar
5. Valve Stem
6. Spring

See section 26.1.

FIG. 6.27 INLET NON-RETURN VALVE

(345SR, L45SR)

1
2

26.1 Description
7

The non-return valve is mounted on the air-end

inlet and secured by four screws. A pipe connected
to the air intake filter is secured to the top of the
valve by a clip.
The inlet non-return valve consists of a valve body
(1) with an integral seat (2) and a valve assembly.
The valve assembly comprises a valve head (3),
spring (6) and a valve stem (5) with retaining bar
(4). The retaining bar secures the valve assembly
to the valve body using two screws.

26.2 Operation
When the compressor starts the depression
created by the turning rotors causes a partial
vacuum at the intake which lifts the valve head off
the seat against the light load of the spring. This
allows air to be drawn through the air-end to
pressurise the separator vessel.

AC20160-1822, Issue 1, November 2002

5
HW 0309

1.
2.
3.
4.
5.

Body
Air Inlet Valve
Stem
Bush
Spring

6.
7.
8.
9.

Washer
Nut
Washer
Plug

FIG. 6.28 INLET NON-RETURN VALVE (L120SR)

Chapter 6, page 27

CompAir

28.

BEKO DRAIN (L120SR)

29. SCAVENGE NRV ASSEMBLY (L120SR)

28.1 Description

HW 0312
FIG. 6.30 SCAVENGE NRV ASSEMBLY
(L120SR)
29.1 Description
The scavenge NRV assemble is located in the lid of
the reclaimer. It consists of a scavenge pipe braised
to a coupling with a steel ball placed within the
coupling and then a scavenge NRV swivel elbow
screwed into the top of the coupling.
HW 0311

FIG. 6.29 BEKO DRAIN (L120SR)

The Beko drain is positioned by the delivery side
cooler column. A pipe from the moisture separator
is connected to the inlet of the drain. A pipe from the
outlet of the drain is then connected to the
discharge end column via a bulkhead coupling
which is the customers condensate connection.

29.2 Operation
When the machine is running the ball inside the
scavenge moves up in the coupling and acts as a
restrictor to the scavenge line but allows the oil to
flow back down in to the air-end. Upon stopping of
the compressor the ball drops down and acts as an
NRV to the oil in the scavenge line.

28.2 Operation
The condensate accumulates in the container. A
capacitive sensor registers when the container is
totally filled. It then passes a signal to the electronic
control within the valve to activate. The pilot valve is
activated which opens the diaphragm on the outlet
line. Every time the condensate is discharged the
time the valve is opened is calculated exactly to
ensure minimum compressed air wastage.

Chapter 6, page 28

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

CHAPTER

7
MAINTENANCE

1.
1.1
1.2
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16

MAINTENANCE SCHEDULE
Service Kit Part Numbers
Oil Drain Kit (475SR, L75SR, L120SR)
MAINTENANCE PROCEDURES
Enclosure Filter
Control Panel Filter
Air Intake Filter
Oil Separator Filters (345SR, L45SR)
Reclaimer (475SR, L75SR, L120SR)
Reclaimer Element (475SR, L75SR, L120SR)
Scavenge Strainer (475SR, L75SR if fitted)
Automatic Condensate Drain (475SR, L75SR)
Oil System
Minimum Pressure Valve
Oil Cooler and Aftercooler
Flexible Hoses
Scavenge Tube
Electrical System
Electric Motors
Non-return Valve

FIGURES
FIG. 7.1
FIG. 7.2
FIG. 7.3

GENERAL ARRANGEMENT AND SERVICING POINTS (345SR, L45SR)

GENERAL ARRANGEMENT AND SERVICING POINTS (475SR, L75SR)
GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

AC20160-1822, Issue 1, November 2002

Chapter 7, page 1

CompAir

MAINTENANCE
1.

MAINTENANCE SCHEDULE

Regular maintenance should be carried out by your local CompAir distributor as detailed in the Maintenance
Schedule. The Schedule should be used as a general guide only.

Item

Action

Weekly

Oil System
Separator/Reclaimer Element(s)

Aftercooler/Oil cooler/Control Panel

Check oil level. Top up if necessary.

Check element(s). Renew if:
(345SR, L45SR) - pressure differential exceeds 1 bar.
(475SR, L75SR) - indicator in red zone.
(L120SR) - message on screen.
Check condition of pre-filters and clean as necessary.

Minor Service Every 2000 hours or 6 months (whichever is sooner)

Minor Service
Oil System
Blowdown System
Electrical Wiring
Drain Solenoid Valve
Control Panel
Aftercooler and Oil Cooler
Oil Filter
Air Filter
Electrical Cabinet Filters

Use correct Service kit for model.

Check oil level/top up.
Check operation.
Check connections and condition.
Check operation (475SR, L75SR only).
Check connections
Clean externally
Renew Oil Filter.
Renew Air Filter (345SR, L45SR, 475SR, L75SR).
Check and clean heatsink ducting if necessary.

Interim Service Every 4000 hours or 1 year (whichever is sooner)

Service
Oil system
Separator Filters
Air Filter (L120SR)

Chapter 7, page 2

Carry out Minor Service.

Change oil.
Renew Separator Filters/Reclaimer Element.
Renew Air Filter.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

Major Service Every 8000 hours or 2 years (whichever is sooner)

Major Service
Service
Minimum Pressure Valve
Non-return valve
Motor Drive
Air Pipe Couplings
Condensate Auto Drain Valve
Blowdown Valve
Scavenge Tube

1.1

1.2

Use correct Major Service Kit for model

Carry out Interim Service.
Service valve (not L120SR).
Service valve (not L120SR).
Check condition of flexible coupling inserts. Fit new inserts
if necessary.
Renew O rings.
Service valve. (L120SR only).
Renew.
Renew.

Service Kit Part Numbers

MODEL

Minor Service Kit

(2000 hrs or 6 mths)

Interim Service Kit

(4000 hrs or 1 yr)

Major Service Kit

(8000 hrs or 2 yrs)

345SR, L45SR

CK2003 - 2

98262-223 (2)

CK8003 - 4

475SR, L75SR

CK2004 - 2

CK6004 - 197

CK8004 - 5

L120SR

CK2007 - 1

CK6007-1

CK8007-1

Oil Drain Kit (457SR, L75SR)

Part number C27399-173

AC20160-1822, Issue 1, November 2002

Chapter 7, page 3

CompAir

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Oil Cooler
Cooling Fan
Intake Air Filter
Non-return Valve
Cyclon 3 Air-end
SR Drive Motor
Separator Element
Oil Filter
Air Delivery Connection
Minimum Pressure Valve

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Aftercooler
Inlet Air Flow
Inlet Air Baffle
Inlet Air Pre-filter
Primary Separator
Control Panel
Pressure Relief Valve
Oil Filler Cap
Cooling Air Exhaust Flow
Exhaust Air Baffle
Control Panel Filter

FIG. 7.1 GENERAL ARRANGEMENT AND SERVICING POINTS (345SR, L45SR)

Chapter 7, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Oil Filters
Minimum Pressure Valve
Air/Oil Separator
Pressure Relief Valve
Oil Filler Cap
Intake Air Filter
Oil Sight Tube
Air-End Intake
Oil Drain Valve
Air-End

11.
12.
13.
14.
15.
16.
17.
18.
19.

SR Drive Motor
Cooling Air Inlet
Cooling Fan
Moisture Separator
Air Delivery Connection
Air and Oil Cooler
Exhaust Air Baffles
Control Panel
Control Panel Filter

FIG. 7.2 GENERAL ARRANGEMENT AND SERVICING POINTS (475SR, L75SR)

AC20160-1822, Issue 1, November 2002

Chapter 7, page 5

CompAir

4
5
6
12
7

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Exhaust Duct
Inlet/Non-Return Valve
Aftercooler
Oil Filters
Safety Valve
Oil Cooler
Moisture Separator
Condensate Drain Valve
Air End
Drive Coupling Access
SR Drive Motor
Power Converter
Cabinet Filters

9
10
11

14

13

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

15

Minimum Pressure Valve

Blowdown Solenoid Valve
Cooling Fan
Control Panel
23
Intake Air Filter
Fork Lift Points
Oil Filler
Air/Oil Separator
Oil Level Sight Glass
22
Oil Drain
Cooling Air Inlet Grille

16

17

21

20

19

HW 0016

18

FIG. 7.3 GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

Chapter 7, page 6

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

2.

MAINTENANCE PROCEDURES

WARNING
!

Refer to the safety procedures before

carrying out any maintenance or
servicing work on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment switch the
power supply OFF at isolator and wait
for 12 minutes to allow the DC link
capacitors discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.

Where a maintenance procedure below

includes the warning The compressor
must be stopped the following steps
must be taken before work is
commenced:

2.1

Enclosure Filter

The compressor is provided with a coarse screen

filter which acts as a pre-filter for the intake air.
Carry out a regular check on the condition of the
pre-filter and if necessary remove the material from
the enclosure and wash in a mild detergent solution
before refitting.

2.2

1.

Close the shut-off valve to the users

pipework.

2.

Switch the power supply OFF at the

isolator.

3.

Ensure that the blowdown system has

operated to release all pressure from the
reclaimer.
Check that the pressure gauge registers
zero. Release any remaining pressure from
the delivery side of the reclaimer element
by slackening the pipe connection to the
differential pressure switch at the reclaimer
end. Release any residual pressure from
the upstream side of the reclaimer element
by slowly slackening the oil filler plug on
the reclaimer. Tighten the plug.

2.3

Air Intake Filter

Clean intake air is essential for satisfactory

operation of the unit. Any ingress of unfiltered air
will result in a reduction in the service life of the
separator element.
Particular care should be taken during routine
servicing to ensure that unfiltered air cannot bypass
the air intake filter element via unsound joints and
defective trunking, etc.

Control Panel Filter

L120SR only

Filters are provided to clean the cooling air for the

power electronic circuits. These should be cleaned
at specific intervals or before scheduled if Heat
sink temp high is displayed.

AC20160-1822, Issue 1, November 2002

A visual indicator is fitted which shows the condition

of the filter. In dirty conditions this may indicate a
reduction in element life.

Chapter 7, page 7

CompAir

2.3.1 To Change the Air Filter Element:

1

The compressor must be stopped.

1.

Remove the side panel or open the hinged

door (according to model) to gain access to
the intake air filter.

2.

Remove the clips from the air intake filter and

withdraw the element.

3.

Clean out the inside of the filter body

3.

Fit the new element , secure the clips and refit

the side panel or close the door.

2.4

Oil Separator Filters (345SR, L45SR)

1
2
3
4

The separator filter has a nominal service life of

4000 hours under normal operating conditions.
Adverse operating conditions or failure to carry out
regular maintenance and/or correct operating
procedures will affect the service life of the
element.

2.4.1 To Check the Differential Pressure across

the Separator Filters
1.

Ensure the compressor is running at working

pressure and temperature.

2.

Open the access door to the service area.

3.

Note the reading on the pressure gauge(s)

fitted to the manifold block.

4.

345SR models: Using the bayonet fitting,

change the pressure gauge over to the fitting
on the other side of the manifold block and
note reading.

5.

If the pressure difference exceeds 1 bar

renew the separator filters.

Chapter 7, page 8

Manifold block
Pressure gauges
Separator filters
Oil filter

HW 0046

5 Plug
6 Oil drain valve
7 Control air
isolating valve

FIG. 7.4 MANIFOLD BLOCK AND FITTINGS

(345SR, L45SR)
2.4.2 To Change the Separator Filters:

The compressor must be stopped.

1.

Open the door to the service area to gain

access to the manifold block.
Note: Models 345SR and L45SR have two
separate filters both of which must be
changed at the same time.

2.

Unscrew the old separator filters from the

manifold block and discard the filters and
sealing rings.

3.

Apply a light film of oil to the seal of the new

filters.

4.

To fit the new filters, screw into the manifold

block until the gasket contacts the sealing
surface. Then tighten a further 1/3 turn.

5.

Close the service area door.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

2.5

Reclaimer (475SR, L75SR, L120SR)

Condensate will collect in the reclaimer as the

compressor cools after shut-down and should be
drained off at the intervals specified in the
Schedule. Draining the condensate must be carried
out only when the compressor is cold.
CAUTION: Regular draining of condensate from
the reclaimer is essential in order to avoid oil
contamination and eventual problems in the users
system

2.5.1 To Drain the Condensate

2.6

Reclaimer Element (475SR, L75SR and

L120SR)

A filter element within the reclaimer recovers oil

carried in the delivery air before it is passed to the
aftercooler and the users pipework. The element
has a maximum service life of 8000 hours. This
figure is based on ideal operating conditions and if
conditions are not ideal it will be necessary to
change the element more frequently.
The service life of the element can be prolonged by
carrying out regular maintenance and correct
operational procedures, but must always be
changed after 8000 hours.

The compressor must be stopped.

2.6.1 To Check the Differential Pressure Across

the Reclaimer.

To drain the condensate from the reclaimer, slowly

crack open the reclaimer drain point (1) until
condensate starts to flow out. As soon as the flow
becomes clear oil, close off the drain.

475SR, L75SR
1.

Ensure the compressor is running at working

pressure and temperature.

2.

Open the hinged access door.

3.

The needle of the Differential Pressure

indicator should be in the green zone of the
scale.

4.

If the needle is in the red zone, renew the

reclaimer element.

NB. At service intervals the controller will display

Check Reclaimer DP warning which will be reset
when the service hours are reset.
L120SR

1
HW 0017

FIG. 7.5 RECLAIMER CONDENSATE DRAIN

A lamp lights on the panel and the message

Change separator is displayed when the reclaimer
element is blocked.
2.6.2 To Change the Reclaimer Element

The compressor must be stopped.

If the compressor is operating in conditions of high
humidity experience may show that it is necessary
to drain the condensate more frequently than
specified.

AC20160-1822, Issue 1, November 2002

1.

Open the hinged access doors and/or roof

panel to gain access to the reclaimer.

2.

Drain the oil from the reclaimer. This

procedure is described under 2.9.5 Normal
Oil Change.

3.

Disconnect all pipes from the reclaimer cover.

Disconnect and withdraw the scavenge pipe.

Chapter 7, page 9

CompAir

The element may be withdrawn through the

access panel in the roof.

3
2

L120SR: One bolt may be loosened and left

in position and used to hinge the cover.

Discard the old joint and element.

1.
2.
3.
4.
5.

6.

Inspect the underside of the reclaimer cover.

The cover has been treated and should be in
good condition. If not, remove any loose paint
or rust by shot blasting or wire brush
treatment to leave a clean, oil free surface.
Apply one coat of zinc phosphate paint,
ensuring complete coverage to a minimum
thickness of 01 mm (0.004). Allow to dry
thoroughly.

7.

Fit the new element and joint and replace the

cover (the L120SR joint is glued to the
element). Replace all the reclaimer cover
bolts and tighten by hand to position the joint
correctly.

8.

Tighten the bolts evenly, following the

tightening sequence, to an initial torque of
110 Nm / 81 ft.lbf. Check the O ring

9.

Tighten the bolts, following the tightening

sequence, to a final torque of 160 Nm / 118
ft.lbf (475SR, LS75SR) or 200Nm / 148 ft.lbf
(L120SR).

HW 0018

Scavenge pipe
Air discharge pipe
Minimum pressure valve
Cover
Jacking holes
FIG. 7.6 OIL RECLAIMER

4.

Disconnect couplings and remove the air

discharge pipe from the minimum pressure
valve.

5.

Release the reclaimer cover securing bolts

and remove the cover. If necessary, use three
of the cover bolts in the jacking holes and
tighten down to break the seal. Withdraw the
reclaimer element. Discard the old joint and
element.

HW 0313

FIG. 7.7 RECLAIMER ELEMENT

Chapter 7, page 10

FIG. 7.8 RELAIMER COVER BOLT

TIGHTENING SEQUENCE
(475SR, L75SR)

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

2.7.1 To Clean the Scavenge Strainer

7

The compressor must be stopped.

1
9

13

12
4
10

14
2

HW 0021

FIG. 7.9 RECLAIMER COVER BOLT

TIGHTENING SEQUENCE (L120SR)
Insert the scavenge pipe through the coupling
in the reclaimer cover and lower it carefully
until it contacts the base of the element.
Withdraw the pipe a distance of 3 mm (1/8)
and tighten the coupling. The couplings are
fixed length on the L120SR model.

11.

Re-connect the pipes to the reclaimer cover.

Fit new O rings to delivery pipe joints and
retighten the bolts to 100 Nm / 74 ft.lbf.

12.

Refill the compressor with new oil by following

the procedures under 2.9.5 Normal Oil
Change.
Close the access doors and refit the
enclosure panels.

CAUTION: When the compressor has reached

normal operating temperature, re-tighten the bolts
to the correct torque in the sequence shown.

2.7

2.

Remove the strainer screen and clean it

thoroughly, using a proprietary cleaning agent.

3.

Refit the clean strainer screen.

2.8

Automatic Condensate Drain (475SR,

L75SR, L120SR)

16
5

13.

Remove the scavenge strainer.

11

15

10.

1.

Moisture in the delivery air condenses in the

aftercooler or moisture separator and is drained
automatically by the action of a solenoid operated
valve (L75SR) or level control valve ((L120SR).

2.8.1 To Check the Operation of the Condensate

Drain Valve (475SR, L75SR)

The compressor must be stopped.

Disconnect the users condensate drain connection
at the baseframe and connect a length of tubing to
the base frame connection. Run the tubing to a
suitable container and visually check that
condensate is being released automatically from
the solenoid operated drain valve according to the
drain open and drain shut times set at the
controller.
If no condensate is being released check the
electrical circuit and the solenoid valve as
described in the Electrical section of the manual.
Dispose of any condensate in accordance with
local regulations. Reconnect the condensate drain
line to the compressor.
The L120SR model displays a level controlled fault
signal on the panel if the valve is not functioning
correctly. Maintenance should be carried out by a
CompAir Distributor.

Scavenge Strainer (475SR, L75SR)

If the scavenge strainer becomes restricted or

blocked it may cause oil to be carried over into the
users pipework. It is most important that the
strainer is regularly serviced to allow the scavenge
system to operate correctly.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 11

CompAir

2.9

Oil System

2.9.1 Recommended Oil

The compressor is factory filled with CompAir
4000 HR Oil or CompAir FG Lubricant.
1.

2.

CompAir 4000 HR Oil

This is a high performance oil with excellent
lubrication and cooling characteristics
formulated to maintain internal cleanliness,
reduce the build-up of deposits on filter
elements and extend component life.
CompAir FG Lubricant
A synthetic hydrocarbon based lubricant
which has been specially developed for use
where discharge air may come into contact
with foodstuffs or for reasons of health or
environment. CompAir FG Lubricant meets
the requirements of FDA regulation 21 CFR
178.3570 and is USDA H-1 approved.

The local CompAir distributor will assist in the

selection of an appropriate lubricant and in many
cases will also be able to arrange for regular
sampling of the oil to monitor the condition of the
compressor, and to determine the oil change
intervals to ensure optimum performance.

HW 0022

FIG. 7.10 CHECKING OIL LEVEL

(345SR, L45SR)
If necessary top up the separator with oil as follows:

WARNING

Risk of injury from hot oil under pressure.

The compressor must be stopped.

2.9.2 To Check the Oil Level: (345SR, L45SR)

1.

Remove the side panel.

To view the oil level sightglass (1), remove the side

panel.

2.

Unscrew the filler plug (2).

3.

Fill to the correct level with CompAir approved

lubricant.

4.

Refit the filler plug and tighten by hand.

5.

Refit side panel.

When stopped the mimimum level is indicated

when the sightglass is less than half full. The
maximum level is indicated when the sightglass is
full and the oil reaches the bottom threads in the
filler neck.
When running on-load the minimum level is
indicated when oil is no longer visible in the
sightglass.

Chapter 7, page 12

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

CAUTION: Always use the correct grade of oil and

do not mix oils of different types.

2.9.4 To Change the Oil Filter:

The compressor must be stopped.

2.9.3 To Check the Oil Level (475SR, Tornado 75,
L75SR, L120SR)
With the compressor shut down, the minimum oil
level is indicated when the level is just visible in the
oil level tube on the reclaimer. The maximum level
is indicated when the level reaches the top of the oil
level tube.

1.

Open the door to the service area or open the

enclosure according to model.

2.

Unscrew the old oil filter(s) (3) from the

manifold block or filter housing and discard.

HW 0024

The compressor must be stopped.

Note: Check the oil level with the compressor cold.
Allow a minimum of 30 minutes after stopping for
the oil in the system to settle.
1.

Open the enclosure to gain access to the

reclaimer.

2.

Check the oil level tube (1). If the oil surface

is not visible it is too low.

2
1

3
3 Oil filters
FIG. 7.12 OIL FILTERS (L75SR, L120SR)
3.

Apply a light film of oil to the seal of the new

element(s) and prime the new filter(s) with oil.

4.

To fit the new element, screw it into the

manifold block or filter housing until the gasket
contacts the sealing surface. Then tighten a
further 1/3 turn.

5.

Close the service area door.

6.

Check oil level during initial run and top up if

necessary.

HW 0023

1. Sight glass
2. Filler plug
FIG. 7.11 CHECKING OIL LEVEL
(475SR, L75SR, L120SR)
3.

4.

If topping up is required, ensure that the

reclaimer pressure is zero, remove the oil filler
plug (2) and fill the reclaimer with
recommended oil to the correct level.
Replace the oil filler plug, making sure that
the O ring is undamaged and the plug fully
tight.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 13

CompAir

2.9.5 Normal Oil Change

1

CAUTION: Always use the correct grade of oil and

do not mix oils of different types.
1.

CompAir 4000 HR Oil

Provided the air-end discharge temperature
does not normally exceed 85C CompAir
4000 HR Oil should be changed every 4000
hours service or 1 year, whichever is sooner.

Where the air-end discharge temperature

regularly exceeds 85C then a change period
of 2000 Hours or 6 months is recommended.
2.

CompAir FG Lubricant
Provided the air-end discharge temperature
does not regularly exceed 85C CompAir FG
Lubricant should be changed every 4000
hours service or 1 year, whichever is sooner.

1
2
3
4

Where the air-end discharge temperature

regularly exceeds 85C then a change period
of 2000 Hours or 6 months is recommended.

HW 0046

Manifold block
Pressure gauges
Separator filters
Oil filter

5 Plug
6 Oil drain valve
7 Control air
isolating valve

Note: Where high dust levels and/or pollution are

present the oil must be changed more frequently
and the condition of the intake filtration system
examined regularly.

4.

2.9.6 To Change the Oil and Oil Filter:

(345SR, L45SR)

Stop the compressor. Wait until the motor has

stopped rotating before proceeding.

5.

Remove the drain tap plug (5) and connect a

hose (minimum 10 mm/ 3/8 bore) to the drain
tap (6) and place the open end into a suitable
container.

FIG. 7.13 MANIFOLD BLOCK AND FITTINGS

(345SR, Tornado 45, L45SR)

To drain the oil, the system must (a) be pressurised

or (b) an alternative source of compressed air must
be available.
CAUTION: Always use the correct grade of oil and
do not mix oils of different types.
Method (a)
1.

Run the compressor on load to pressurise the

system.

2.

Open the door to the service area.

3.

Close the control air isolating valve (7), fitted

to the side of the manifold block (lever to the
vertical position) and the isolating valve in the
user's system.

Note: A minimum of 4 bar (60 psi) must be

maintained in the compressor unit prior to carrying
out the oil drain procedure.

Chapter 7, page 14

WARNING

Risk of injury from hot oil under pressure.

6.

Slowly open the drain tap and allow the oil to

drain into the container for disposal.

7.

Close the drain tap, disconnect the hose, and

remove the container. Refit the drain tap plug.

8.

Open the control air isolating valve (7) (lever

to the horizontal position) and allow any
pressure to be released through the normal
blowdown process.

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

9.

Remove and discard the old oil filter element

(4).

10.

Prime the new filter with oil.

11.

Apply a film of clean oil to the seal of a new

oil filter element. Screw the element into the
housing until it contacts the gasket and
tighten a further 1/3 turn.

8.

Close the air supply through the filler tube,

open the control air isolating valve (lever to
the horizontol position) and allow any
pressure to be released through the normal
blowdown process.

9.

Remove the air supply and fitting from the

filler tube.

10.
Fill the separator to the correct level with
CompAir approved lubricant, refit the filler cap
and tighten by hand.

Remove and discard the old oil filter element

(4).

11.

Prime the new filter with oil.

13.

Open the isolating valve to the user's system.

12.

14.

Run the compressor until it reaches working

temperature to ensure full circulation of the oil.

Apply a film of clean oil to the seal of a new

oil filter element. Screw the element into the
housing until it contacts the gasket and
tighten a further 1/3 turn.

15.

Check the oil level and top up as necessary.

13.

Fill the separator to the correct level with

CompAir approved lubricant, refit the filler cap
and tighten by hand.

12.

Method (b)
1.

Open the door to the service area.

14.

Open the isolating valve to the users system.

2.

Close the control air isolating valve, fitted to

the side of the manifold block (lever to the
vertical position) and the isolating valve in the
user's system.

15.

Run the compressor until it reaches working

temperature to ensure full circulation of the oil.

16.

Check the oil level and top up as necessary.

3.

Ensure that all pressure has been released

from the oil separator, remove the filler plug
and fit a suitable connector to the neck of the
filler pipe for the air supply.

4.

Apply pressure to the compressor unit

(minimum of 4 bar or 60 psi).

5.

Remove the plug and connect a hose

(minimum 10 mm / 3/8 bore) to the drain tap
and place the open end into a suitable
container.

WARNING

Risk of injury from hot oil under pressure.

6.

Slowly open the drain tap and allow the oil to

drain into the container for disposal.

7.

Close the drain tap, disconnect the hose and

remove the container. Refit the drain tap plug.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 15

CompAir

To Change the Oil and Oil Filter:

(475SR, L75SR)

5.

Remove the plug and connect the Oil Drain

Pipe Kit and a hose (minimum 15 mm / 5/8
bore) to the drain tap and place the open end
into a suitable container.

6.

Slowly open the drain tap and allow the oil to

drain into the container for disposal.

To drain the oil, the system must be pressurised.

CAUTION: Always use the correct grade of oil and
do not mix oils of different types.

The compressor must be stopped.

WARNING

Risk of injury from hot oil under pressure.

1.

Open the door to the service area

2.

Close the control air isolating valve (fitted to

the top of the reclaimer) (fitted on the top of
the air-end).

1
HW 0017

1
FIG. 7.15 OIL DRAIN TAP
(475SR, L75SR)

7.

Close the reclaimer drain tap, disconnect the

Oil Drain Pipe Kit and hose, remove the
container and refit the plug.

8.

Open the control air isolating valve and allow

any pressure to be released through the
normal blowdown process.

9.

Remove and discard the old oil filter

elements.

10.

Apply a film of clean oil to the seal of a new

oil filter elements. Screw the elements into the
housing until they contact the gasket and
tighten a further 1/3 turn.

11.

Fill the reclaimer to the correct level with

CompAir approved lubricant, refit the filler cap
and tighten securely.

12.

Open the isolating valve to the user's system.

13.

Run the compressor until it reaches working

temperature to ensure full circulation of the oil.

14.

Stop the compressor, check the oil level and

top up as necessary.

HW 0026

1. Control air isolating valve

2. Air end
3. Intake air filter
FIG. 7.14 CONTROL AIR ISOLATING VALVE
(475SR, L75SR)
3.

4.

Run the compressor for a short time to

pressurise the reclaimer to a minimum of 4
bar (60 psi) prior to carrying out the oil drain
procedure. Stop the compressor and close the
isolating valve between the compressor and
the user system.
Ensure that the reclaimer drain tap is closed.

Chapter 7, page 16

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

To Change the Oil and Oil Filter: L120SR

4.

Ensure that the reclaimer and oil cooler drain

taps are closed.

To drain the oil, it is recommended that the system

be pressurised. However, the L120SR may be also
drained under gravity.

5.

Put reclaimer and cooler drain hoses into a

container, open taps and allow oil to drain.

CAUTION: Always use the correct grade of oil and

do not mix oils of different types.

HW 0027

The compressor must be stopped.

2

WARNING

Risk of injury from hot oil under pressure.

1.

Open the door to the service area

2.

Close the control air isolating valve (painted

red and fitted to the top of the reclaimer).

1. Reclaimer oil drain

2. Oil cooler drain

FIG. 7.17 OIL DRAIN POINTS (L120SR)

6.

Close the reclaimer and cooler drain taps,

replace the hoses and remove the container.

7.

Open the control air isolating valve and allow

any pressure to be released through the
normal blowdown process.

8.

Remove and discard the old oil filter

elements.

9.

Apply a film of clean oil to the seal of the new

oil filter elements. Screw the elements into the
housing until they contact the gasket and
tighten a further 1/3 turn.

10.

Fill the reclaimer to the correct level with

CompAir approved lubricant, refit the filler cap
and tighten securely.

11.

Open the isolating valve to the user's system.

12.

Run the compressor until it reaches working

temperature to ensure full circulation of the oil.

13.

Stop the compressor, check the oil level and

top up as necessary.

HW 0025

FIG. 7.16 CONTROL AIR ISOLATING VALVE

(L120SR)
3.
The oil may be drained under pressure or by
gravity. To drain under pressure, run the
compressor up to 7 bar/102 lbf/in2 and stop.
Immediately open access door and close
hand valve adjacent to blowdown (see
illustration), then proceed as for gravity drain.
Beware of hot surfaces. Beware of hot
pressurised oil. On completion, open
blowdown hand valve.

AC20160-1822, Issue 1, November 2002

Chapter 7, page 17

CompAir

2.9.6 To Change the Oil Type

4.

No special precautions are required when changing

from a detergent mineral oil to CompAir 4000 HR
Oil or CompAir FG Lubricant or changing within
these grades. The system should be drained and
refilled as described under 2.9.5 Normal Oil
Change.

L120SR: Clean cooler fins using low pressure

air or water as follows.
(a) Remove cooler end panel and both side
panels.
(b) Open access doors as necessary and
clean coolers from inside the plant using
low pressure air (up to 2 bar / 29 lbf/in2) or
water. Don not use excessive pressure as
cooler tubes may be damaged.

2.10 Minimum Pressure Valve

5.

Remove any dirt or liquid from the baseframe.

The servicing of the Minimum Pressure Valve

should be carried out by a CompAir Distributor.
(See Section 9.)

6.

Replace access and enclosure panels and

close door(s).

2.11 Oil Cooler and Aftercooler

The servicing of the Oil and After Coolers should be

carried out by a CompAir Distributor.
(See section 9.)

To Clean Coolers Externally

The condition of the cooler fins must be checked
regularly. To clean the fins proceed as follows:The
compressor must be stopped
1.

Allow the compressor to cool for 30 minutes.

2.

345SR, L45SR:
Open enclosure service door and remove
access panel on cooling duct. Remove
enclosure panel in front of coolers.
Clean the cooler fins from inside the duct
using an air hose and oil-free compressed air
from inside the machine.

3.

2.12 Flexible Hoses

When fitting flexible hoses the nuts should be
tightened using the torque appropriate to the nut
sizes.
BSP Size

Torque

0.5 in
0.75 in
1.0 in
1.25 in
1.5 in
2.0 in

44 Nm/32 ft.lbf
84 Nm/62 ft.lbf
115 Nm/85 ft.lbf
189 Nm/139 ft.lbf
244 Nm/180 ft.lbf
297 Nm/219 ft.lbf

If it is required to wash the coolers, they must

first be removed from the machine.

2.13 Scavenge Tube

475SR, L75SR:

The translucent tube should be changed at the

8000 hour service interval.

Clean cooler fins with an air hose as follows:

(a) Ensure power is isolated and locked off.
(b) Remove fan guard and use low pressure
air to clean coolers from inside the
machine.
(c) Replace fan guard.
(d) Replace panels.
If it is required to wash the coolers, they must
first be removed from the machine.

Chapter 7, page 18

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Maintenance

2.14 Electrical System

2.15 Electric Motors

2.15.1 Motor Bearings

WARNING
!

Refer to the safety procedures before

operating the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

The main drive motor and cooling fan motor are

fitted with sealed bearings which are double
shielded and pre-packed with grease. These
bearings do not require periodic re-lubrication but
should be renewed after 32000 hours of operation
in normal environments.
Note: This work should be carried out by a
CompAir distributor. (See section 9.)
2.15.2 Motor Cooling

Before opening the door of the power

converter compartment, switch the
power supply OFF at isolator and wait
for 12 minutes to allow the dc link
capacitors to discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.

Ensure that the motor cooling intake grille is kept

clear of debris at all times.

2.16

Non-Return Valve

The servicing of the Non-Return Valve should be

carried out by a CompAir Distributor.
(See section 9.)

Carefully inspect all the electrical wiring and check

the security of all connections and terminals

AC20160-1822, Issue 1, November 2002

Chapter 7, page 19

CompAir

This page is intentionally left blank

Chapter 7, page 20

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Electrical Systems

CHAPTER

8
ELECTRICAL SYSTEMS AND FAULT DIAGNOSIS

CONTROL SYSTEM
1.

CONTROLLER

ELECTRICAL SYSTEM
1.
1.1
1.2
1.3
1.4
1.5
1.6

REMOTE CONTROL AND MONITORING CONNECTIONS

Inputs
Configurable Input Functions
Outputs
Configurable Output Functions
420mA Compressor Speed Output
RS485 Communications

FAULT DIAGNOSIS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2.
2.1
3.
3.1
3.2
4.
4.1
4.2
5.
5.1
6.
6.1
6.2

TEST EQUIPMENT
Test Meter
Clip-on Ammeter
Insulation Tester
DC Voltage Generator
IGBT Tester
Slave Air Supply
Inductance Tester
CAGE-CLAMP SCREWLESS TERMINALS
Cable Connection or Removal
POWER SUPPLIES
To Check the 24V ac Supply Circuits
To Check the Main Power Supply
CONTROL INPUTS
To Check the Air Filter Differential Pressure Switch
To Check the Emergency Stop Circuit
CONTROL OUTPUTS
Relay Output (connector XO8)
SENSORS
To Check the Pressure Sensor
To Check the Air/oil Temperature Sensors

Continued

AC20160-1822, Issue 1, November 2002

Chapter 8, page 1

CompAir

Contents (Continued)
7.
CONTROLLER
7.1
Application Control Program IC
7.2
Motor Drive Program IC
7.3
FPGA Data IC
8.
SR FAULT LOCATION
8.1
SR Current Sensor Fault
8.2
SR Motor High Temperature Fault
8.3
SR Motor Overcurrent
8.4
DC Link High Voltage Fault
8.5
DC Link Low Voltage Fault
8.6
SR Position Sensor Fault
8.7
SR Motor Overspeed Fault
8.8
SR Motor Stall Fault
8.9
DC Link Charge Fault
8.10 Heatsink Temperature Sensor Fault
8.11 Heatsink High Temperature Fault
8.12 Main Contactor Fault
8.13 SR Control Power Fault
8.14 Internal Comms Fault
8.15 SR PCB Internal Fault
8.16 Start Inhibit
8.17 SR Fault Location Charts
9.
SR TEST PROCEDURES
9.1
Diode Device Test Procedures
9.2
IGBT (Insulated Gate Bipolar Transistor)
9.2.1
Dual IGBT (Insulated Gate Bipolar Transistor)
9.2.2
Latest Semikron IGBTs
9.2.3
IGBT Removal and Fitting Instructions
9.3
Electrolytic Capacitor Test Procedures
9.3.1
Electrolytic Capacitor Test
9.3.2
Electrolytic Capacitor Measurement
9.3.3
Capacitor Removal and Refiiting Instructions
9.4
To Check Capacitor Bank Voltage Imbalance
9.5
To Check Capacitor Bank Balance Resistors
9.6
To Check VDR/Resistor Board (L45SR and L75SR)
9.7
To Check the SR Motor
9.7.1
Motor Insulation Test
9.7.2
Motor Inductance Test

Chapter 8, page 2

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Control System

Contents (Continued)
FIGURES
FIG. 8.1
FIG. 8.2-8.4
FIG. 8.5-8.7
FIG. 8.8-8.10
FIG. 8.11-8.13
FIG. 8.14-8.17
FIG. 8.18
FIG. 8.19
FIG. 8.20
FIG. 8.21
FIG. 8.22
FIG. 8.23
FIG. 8.24-8.25
FIG. 8.26
FIG. 8.27-28
FIG. 8.29-30
FIG. 8.31
FIG. 8.32
FIG. 8.33
FIG. 8.34
FIG. 8.35
FIG. 8.36
FIG. 8.37
FIG. 8.38
FIG. 8.39

CONTROL PANEL
ELECTRICAL CONNECTION DIAGRAM 345SR, L45SR
ELECTRICAL CONNECTION DIAGRAM 475SR, L75SR
ELECTRICAL CONNECTION DIAGRAM L45SR WITH POWER FAIL RELAY
ELECTRICAL CONNECTION DIAGRAM L75SR WITH POWER FAIL RELAY
ELECTRICAL CONNECTION DIAGRAM L120SR
CABLE CONNECTION OR REMOVAL
AIR FILTER INDICATOR SWITCH (L120SR)
MEASURING THE PRESSURE SENSOR CURRENT
PRESSURE SENSOR OUTPUT TABLE
TEMPERATURE SENSOR RESISTANCE TABLE
ARRANGEMENT OF CONTROLLER CARDS
SR CURRENT SENSOR FAULT
SR MOTOR OVERCURRENT FAULT
DC LINK HIGH VOLTAGE FAULT
DC LINK LOW VOLTAGE FAULT
SR MOTOR STALL FAULT
DC LINK CHARGE FAULT
CONNECTING TESTER TO IGBT TYPE GAL
CONNECTING TESTER TO IGBT TYPE GAR
CIRCUIT OF IGBT TYPE GAL
CIRCUIT OF IGBT TYPE GAL
L45SR POWER CONVERTER ASSEMBLY
L75SR POWER CONVERTER ASSEMBLY
L120SR POWER CONVERTER ASSEMBLY

AC20160-1822, Issue 1, November 2002

Chapter 8, page 3

CompAir

CONTROL SYSTEM
1.

CONTROLLER

A gate drive board isolates the microelectronics in

the control unit from the power electronic circuits and
provides monitoring and protection for the four
insulated gate bi-polar transistor (IGBT) power
switches. The IGBTs are used to turn the motor
phases on and off and, in conjunction with the
electronic controller, to control the motor phase
current and in turn the torque and speed of the SR
motor.

The microprocessor based compressor controller and

the SR Drive controller are housed in a single
control unit which also contains the operator keypad
and displays. The control unit is mounted on the
door of the control panel.

10

11

12

13 14

15

HW 0012

Bar
PSI

31
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

30

29

28

27

Bar Units Indicator

Psi Units Indicator
Delivery Pressure Display
Status and Message
Display
Plus
Minus
Up
Down
Enter
Mimic Diagram
Intake Filter Change Lamp

26

25

24 23

22 21

12. High Delivery

Temperature Lamp
13. Reclaimer Element
Check Lamp
14. Excess Pressure Lamp
15. Emergency Stop
16. Auto Restart Legend
17. Remote Control Legend
18. Remote Control Lamp
19. Auto Restart Lamp
20. Power on Lamp
21. Fan Motor Overload
Lamp

20

19

18

17

16

22. Power Converter Fault

Lamp
23. Main Motor Fault Lamp
24. Reset
25. Hours
26. Reset Lamp
27. Data View
28. Service
29. Service Lamp
30. Stop
31. Start

FIG. 8.1 CONTROL PANEL

Chapter 8, page 4

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Electrical System

ELECTRICAL SYSTEM
WARNING
!

Refer to the safety procedures before

operating the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate
the power supply before starting any
maintenance work.

Before opening the door of the power

converter compartment, switch the
power supply OFF at isolator and wait
for 12 minutes to allow the dc link
capacitors to discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.

Note: Any work on the electrical system should be carried out by a CompAir Distributor
1.

REMOTE CONTROL AND MONITORING

CONNECTIONS

Input X01/7

Message: Remote Fault 2 unless

Remote Start/Stop selected

Input X01/4

Message: Remote Fault 3

Three remote input options and three (five on

L120SR) remote output options are available. The
cable connections required are shown as broken
lines on the controller digital inputs and outputs on
the electrical connection diagrams on pages 40 to
66.

The functions available are defined below and may

be selected using the Remote Control Config menu
within the Commissioning Config Menu.

1.1

Default functions are assigned to each input and

some functions are only available on specified
inputs.

Inputs

CAUTION: Do not connect any input terminal pin to

a voltage source other than X3/1 as this will result in
permanent damage to the module.
Each of the three inputs is activated by connecting
the appropriate terminal pin to the input terminal X3/
1.
This can be achieved by connecting the input pin
and the common terminal to a volt free remote
switch, relay contact, PLC output or any switching
device.
Note: Remote input cables must be at least 1.0 mm2
in size. The maximum cable length from the
compressor to a remote device must not exceed 800
metres.
1.1.1

The function of some digital inputs are

configurable. These are:

Input X01/6

Message: Remote Fault 1 unless

Pressure Range Select selected

AC20160-1822, Issue 1, November 2002

1.2

Configurable Input Functions

1.2.1 Pressure Range Select

This is available on input X01/6 only and is the
default function for this input.
Connecting to the pressure range select input
enables the selection of a secondary set of Target
and Off-load pressure set points. Using a suitable
external timer this input can be used to vary the
operating pressure of the compressor at different
times. This facility enables energy savings to be
made during periods when a lower compressed air
network pressure can be used.
1.2.2 Remote Start/Stop
This is available on input X01/7 only and is the
default function for this input.

Chapter 8, page 5

CompAir

When this function is selected an open connection

on this input will cause a remote stop and a link is
necessary for keypad start. However the Remote
Start function is by default disabled and needs to be
enabled (separate menu item) for the remote start
function to operate.
With Remote Start enabled, the keypad start button
is disabled and needs to be enabled (separate menu
item) for the remote start function to operate. With
Remote Start enabled, the keypad start button is
disabled and a closing contact on this input will
cause a machine start.
Also note that selecting another function for this
input will automatically disable the Remote Start and
Remote Stop functions; an open connection will not
cause a stop.
1.2.3 Trip Type 1
An open connection will cause a trip at all times.
1.2.4 Trip Type 2
An open connection will cause a trip when the motor
is running.
1.2.5 Trip Type 3
An open connection will cause a trip when status is
Onload or Offload.

1.3

Outputs

1.3.1 Configurable Outputs

(a)
Outputs on pins X09/2, 3 & 4
These three configurable outputs are transistor
switched and only suitable for driving low current
(50mA each max) 24v DC devices. A DC interface
relay must be used (see 1.3.2)
(b)
Outputs on pins X08/5 & 6 and X08/9 & 10
(L120SR only)
These two additional outputs are relay outputs
providing a normally open contact only. Note,
therefore, that some functions (e. g. Group Trip) are
energised for healthy and the relay will present a
closed contact for OK.
As supplied, these contacts are connected to the
24v AC ancillary equipment system supply and are
suitable for driving 24v AC devices subject to the
total load on the transformer. It is, therefore,
recommended that 24v AC interface relays are used
connected between X08/6 or X08/10 and terminal
X1/1.
If VOLT FREE contacts are required for use with an
externally supplied device, then the power supply
link between X08/5 or X08/9 and terminal X2/1
MUST be removed. The external monitor should be
connected directly to the appropriate contact pair
(X08/5 & 6 or X08/9 & 10). Contacts are rated at
250V AC 8A.

1.2.6 Alarm Type 1

1.3.2 Output Relays
An open connection will cause an alarm at all times.
1.2.7 Alarm Type 2
An open connection will cause an alarm when the
motor is running.
1.2.8 Alarm Type 3
An open connection will cause an alarm when status
is Onload or Offload.
1.2.9 Start Inhibit
Will prevent a compressor from starting when a fault
is sensed 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 connection is
open. It is not recorded in the Fault History log.

Chapter 8, page 6

The outputs are 24v dc transistor switched with a

maximum rating of 25mA and an interface relay
must be used. Each output must be connected
directly to a relay module, as specified below, in
order to achieve a relay contact output suitable for
remote applications external to the compressor
starter enclosure.
Parts required for each additional output:

Qty

Description

Part Number

Relay - 24 V dc

98475-64

Relay Base

98475-65

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Electrical Systems

1.3.3 Relay Specification

1.4.4 Group Trip

Single switching contact with a common, normally

open (N/O) and normally closed (N/C) connection
rated at 250V - 5 Amps maximum.

This is the default for output X09/4

A group trip output will be energised when power is
applied and no trip conditions are detected.

Note: The relay 24V dc coil is not bi-directional and

must be connected to controller output as follows :

The output will de-energise when a shutdown trip or

power loss occurs.

1.

Relay terminal 5 must be connected to pin

X09/1.

1.4.5 Service Due

2.

Relay terminal 1 must be connected to pin

X09/2, 3 or 4 as appropriate.

The functions available are defined below and may

be selected using the Remote Control Config menu
within the Commissioning Config Menu.
Default functions are assigned to each output. An
interface relay must be used with these outputs see following diagrams for connection information.
1.4

The service due output will energise when the

service hours countdown timer has reached zero
hours and a routine service is due.
1.4.6 Group Alarm + Trip
A group trip + alarm output will be energised when
power is applied and no alarm or trip conditions are
detected.
The output will de-energise when an alarm excluding
service due, a shutdown trip or power loss occurs.

Configurable Output Functions

1.4.7 Running

1.4.1 Group Fault

This is the default for output X09/2.
A group fault output will be energised when power is
applied and no alarm or trip conditions are detected.
The output will de-energise when an alarm including
service due, a shutdown trip or power loss occurs.

A running output will energise when the compressor

main motor is running.
1.4.8 On Load
The on load output will energise when the
compressor is on load.
1.4.9 Low Temperature Alarm

1.4.2 Available
This is the default for output X09/3
A compressor available output will energise when
the compressor is running or in the standby state.
This output indicates that the compressor has been
started and is available to automatically respond to
a fall in system pressure without manual
intervention.

A Low Temperature Alarm output will energise when

the Low Temperature Alarm is active.
1.5

4 - 20mA Compressor Speed Output

An output is provided to enable remote monitoring of

compressor speed. The output range is from 4mA
(0 rev/min) to 20mA (5000 rev/min).
1.6

RS485 Communications

1.4.3 Group Alarm

A group alarm output will be energised when power
is applied and no alarm condition is detected. The
output will de-energise when an alarm or power loss
occurs.

The SureScan control unit is compatible with the

electrical RS485 communications standard. The
communication parameters are:
9600 baud, 8 data bits, no parity and 1 stop bit.
The message protocol is a proprietary multimaster
protocol compatible with the SmartAir Air Systems
Control Units and with the Active Network Interface
for connection to PCs etc.

AC20160-1822, Issue 1, November 2002

Chapter 8, page 7

CompAir

AC20160-1822, Issue 1, November 2002

T1 T2

(113)
[BK]

0V

(131) [R]

NO
NC NO
NC
< > <1/06>
< > <1/09>
<1/06>
<1/09>
<1/07>
<3/15>

(A2)
(B2)
(A1)
(B1)

(161)

(159)
(160)

LINK

22

2/03

A2 B2

A1 B1

E
4
M102

RLB

(139) [R]
(131) [R]
(124) [R]

(125) [R]
24V
200VA
(126D) [R]
0V

F2 5A

(127) [R]
24V
50VA
(128) [R]
0V
(E)

F3 3.15A

(132) [R]

(132) [R]
X1/1

(133) [R]

(126) [R]
X1/1

1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106)

2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]
WHERE [R] = RED; [BL] = BLUE; [BK] = BLACK,
[G/Y] = GREEN/YELLOW; [CR] = CLEAR;
[PK] = PINK

(133) [R]

X1/1

(128) [R]

[G/Y]
[G/Y]
[G/Y]
[G/Y]
[G/Y]

RLA
NO
NC
<1/11 > <1/24>
<1/11> < >
<1/11>
<1/26>

2/03

(E)

NOTES:MCB1

B2
CUR
SENS

(134)

(126E)
[R]

MCB2

(158)

(156)
(157)

(155)
5

(126A)
[R]

RLA
<3/15>

M101
3~
R
<3/15>

(E)

(135)

F1 2A

1 2 3 4 5

A2

HEATSINK
TEMP SENS

(112B)
[BK]

T101
280VA
(123) [R]
(114) 400V
24V
30VA
[BK]
(124) [R]
0V

1 2 3 4 5

GATE DRIVE BOARD

(139) [R]

(108) [BK]

B1

C GE

RLA (136) [BL]

(117)

(148)
(149)

1 2 3 4 5

A1

(140) [R]

(111B)
[BK]

R101

C GE

1 2 3 4 5

RLC

(110B)
[BK]

(116)

RLB (115)

[BK]

C GE

(150)
(151)

(143)
(142)
(141)

RESISTOR/VDR
P.C.B

(114) [BK]

(113) [BK]

(112A) [BK]

(111A) [BK]

MCB1 3A

MCB2 10A
(110A) [BK]

COMING SUPPLY
OM CUSTOMERS
USED ISOLATOR

(ON HEATSINK)

GE

(144) RLA (138)[R]

[R]
(137) [BL]

(109) [BK]

(126B)
[R]

F7 150A

(152)

(106) [BK]

(153)
(154)

(103) [BK]

POWER SWITCHING ASSY

(ON HEATSINK)

C4
C8

C1
C5

(108) [BK]

F6 150A

(107) [BK]

F5 150A

(105) [BK]

(109) [BK]

(104)[BK]

(107) [BK]

(101) [BK]
(102) [BK]

PE

FIG. 8.2 ELECTRICAL CONNECTION DIAGRAM - 345SR, L45SR (1 OF 3)

Chapter 8, page 8

RLB
NO
<1/14 >
<1/14>
<1/15>
< >

NC

2/02
24V
2/02
0V
2/02
24
2/02
0V
2/02
24V
2/02
0V
2/02

(E)
[R] 2/02
SAFETY GUARD
GATE DRIVE P.C.B
HEATSINK
CAPACITOR TRAY
STARTER BOX
BASE FRAME
DOOR
EARTH
BAR

HW 032

(132) [R]

S201/1

(133) [R]
(128) [R]

X20

R1

R2

R3

R4

(210E)
[R]

X2/1

X2/1

X2/1

Chapter 8, page 9

(126F)
[R]

RLC
(126C)
[R]

X1/1
RLC
NO
<1/06>

NC

X1/1
PI/98/697a

NOTES:1. WIRE NUMBERS ARE SHOWN IN BRACKETS

THUS (106)
2. WIRE COLOURS ARE SHOWN IN BRACKET
THUS [R]
WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,
[G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PIN

LSR Repair Manual Electrical Systems

39) [R]
<1/34>
0V~
26) [R] <1/34>

X09

R5

9 10

(213)
[R]

Y202

(139)
[R]

CONTROLLER
DIGITAL OUTPUT

X03

X08

X21
1

AC1 AC2

CONTROLLER
RELAY OUTPUT

(210C)
[R]

X23

(211)
[R]

34 22

SR
CONTROLLER

(210B)
[R]

X22

(210A)
[R]

24V~
34
0V~
34

(131) [R]
(124) [R]

FIG. 8.3 ELECTRICAL CONNECTION DIAGRAM - 345SR, L45SR (2 OF 3)

AC20160-1822, Issue 1, November 2002

4V~
4
0V~
34
E)
34
24V~
34

CompAir

CONTROLLER
ANALOG INPUTS

X3/1

X3/1

ANA4
5

VA6

[CR]

ANA3
4

(313)

[BK]

[CR]

(312)

[BK]

(309)

[BL]

X3/1

X3/1

X3/1

1
2

R301

P301

<1/06>

[BL]

(301E)

[BL]

(301D)

[BL]

T2

X3/1

(E)

ANA2
3

MCB2

[BL]

(301C)

[BL]

(301E)

[BL]

[BL]

S302

(303)

[BL]

(302)

(301)

S201/2
(301B)

[BL]

(301A)

T1

20VX3/1

ANA1
2
(311)

X02
VA+
1
(310)

X01
VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8
1
2
3
4
5
6
7
8
9

<1/07>

AC20160-1822, Issue 1, November 2002

FIG. 8.4 ELECTRICAL CONNECTION DIAGRAM - 345SR, L45SR (3 OF 3)

Chapter 8, page 10

CONTROLLER
DIGITAL INPUTS

X3/1

NOTES:1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106)

2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]
WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,
[G/Y]=GREEN/YELLOW, [CR]=CLEAR,
[PK]=PINK.

HW 0330

(E)

T1 T2

(125) [R]
24V
200VA
(126D) [R]
0V
24V
(113)
[BK]

0V

0V
(E)

(127) [R]
50VA
(128) [R]

(A1)
(B1)
(A2)
(B2)

2/03

22

(134)

A1 B1

A2 B2
E
4
M102

2/03

(E)

RLB

(135)

RLA (136) [BL]

(138) [R]

(139) [R]

(126B)
[R]

(139) [R]

2/02

(131) [R]

24
2/0
0V
2/0
24
2/0
0V
2/0
24
2/0
0V
2/0

(124) [R]
F2 5A

(132) [R]

(132) [R]
X1/1

F3 3.15A

(133) [R]

(126) [R]
X1/1

1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106)

2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]
WHERE [R] = RED; [BL] = BLUE; [BK] = BLACK,
[G/Y] = GREEN/YELLOW; [CR] = CLEAR;

(133) [R]

X1/1

(128) [R]

[G/Y]
[G/Y]
[G/Y]
[G/Y]
[G/Y]

NOTES:MCB1
NO
NC
< > <1/09>
<1/09>

(159)
(160)
(161)

(157)
(158)

(156)

LINK

(126E)
[R]

MCB2
NO
NC
< > <1/06>
<1/06>
<1/07>
<3/15>

B2

HEATSINK
TEMP SENS

RLA
(126A)
[R]

(131) [R]

1 2 3 4 5

A2

(144)
[R]
<3/15>

M101
3~
R

F1 2A

1 2 3 4 5

CUR
SENS

(112B)
[BK]

T101
280VA
(123) [R]
(114) 400V
24V
30VA
[BK]
(124) [R]
0V

GEC

GATE DRIVE BOARD

RLC

(E)

(154)
(155)

B1

(137) [BL]

(117)

(148)
(149)

1 2 3 4 5

A1

RLA

(111B)
[BK]

R101

1 2 3 4 5

(140) [R]

(110B)
[BK]

(152)

(150)
(151)

(143)
(142)
(141)

1 2 3

[BK]
RLB (115)

(113) [BK]

(ON HEATSINK)

(153)

(109) [BK]

POWER SWITCHING ASSY

(ON HEATSINK)
GEC
GEC
GEC

C5
C10

C1
C6

RESISTOR/VDR
P.C.B

(114) [BK]

(112A) [BK]

(108) [BK]

(106) [BK]

F7 180A

MCB1 3A

MCB2 10A
(111A) [BK]

(110A) [BK]

)[

(
F6 180A

(109) [BK]

)[

(105) [BK]

(107) [BK]

W
PE

(103) [BK]

(108) [BK]

) [

(116)

(102) [BK]

<3/15>

FROM CUSTOM
FUSED ISOLATO

RLA
NO
NC
<1/11 > <1/24>
<1/11> < >
<1/11>
<1/26>

RLB
NO
NC
<1/14 >
<1/14>
<1/15>
< >

(E)
[R] 2/02
SAFETY GUARD
GATE DRIVE P.C.B
HEATSINK
CAPACITOR TRAY
STARTER BOX
BASE FRAME
DOOR
EARTH
BAR

HW 033

LSR Repair Manual Electrical Systems

Chapter 8, page 11

FIG. 8.5 ELECTRICAL CONNECTION DIAGRAM - 475SR, L75SR (1 OF 3)

AC20160-1822, Issue 1, November 2002

CompAir

(132) [R]
(133) [R]
(128) [R]
4

R1

R2

R4

R5

9 10

X2/1

RLC
<1/06>
/

(139)

X09
3

GROUP
FAULT
RELAY
20V dc
150mA (max)

X1/1

NOTES:-

[R]

[R]

(126F)

(126E)

X1/1

Y203

Y202

(126D)
[R]

X1/1

(214)
[R]

X2/1

(213)
[R]

X2/1

(212)
[R]

X2/1

RLC
<1/34>
0V~
26) [R] <1/34>

R3

X2/1

(126C)
39) [R]

(210F)
[R]

(210E)
[R]

+
COMPRESSOR
SPEED
4 - 20 mA

CONTROLLER
DIGITAL OUTPUT

X03

X08
4

[R]

X21
2 3

AC1 AC2

CONTROLLER
RELAY OUTPUT

(210D)
[R]

X20

Y201

X23

(210C)
[R]

34 22

1
SR
CONTROLLER

(211)
[R]

X22

(210B)
[R]

34

(210A)
[R]

S201/1

24V~
34
0V~
34

(131) [R]
(124) [R]

AC20160-1822, Issue 1, November 2002

FIG. 8.6 ELECTRICAL CONNECTION DIAGRAM - 475SR, L75SR (2 OF 3)

Chapter 8, page 12

4V~
34
0V~
34
E)
34
24V~
34

X1/1

1. WIRE NUMBERS ARE SHOWN IN BRACKETS

THUS (106)
2. WIRE COLOURS ARE SHOWN IN BRACKETS
THUS [R]
WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,
[G/Y]=GREEN/YELLOW, [CR]=CLEAR, [PK]=PINK
3. TOTAL CURRENT TO X09/2, 3 & 4 MUST NOT
EXCEED 150mA

CONTROLLER
ANALOG INPUTS
VA6

[CR]

ANA4
5

(313)

[BK]

[CR]

(312)

[BK]

[BL]

(309)

ANA3
4

X3/1

X3/1

X3/1

X3/1

X3/1

(E)

R301

P301

<1/06>

<1/07>

[BL]

(301E)

[BL]

(301D)

[BL]

T2

X3/1

(E)

ANA2
3

MCB2

[BL]

(301C)

[BL]

(301E)

[BL]

[BL]

S302

(303)

[BL]

(302)

(301)

S201/2
(301B)

[BL]

(301A)

T1

20VX3/1

ANA1
2
(311)

X02
VA+
1
(310)

X01
VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8
1
2
3
4
5
6
7
8
9

X3/1

NOTES:1. WIRE NUMBERS ARE SHOWN IN BRACKETS THUS (106)

2. WIRE COLOURS ARE SHOWN IN BRACKET THUS [R]
WHERE [R]=RED, [BL]=BLUE, [BK]=BACK,
[G/Y]=GREEN/YELLOW, [CR]=CLEAR,
[PK]=PINK.

HW 0330

LSR Repair Manual Electrical Systems

Chapter 8, page 13

FIG. 8.7 ELECTRICAL CONNECTION DIAGRAM - 475SR, L75SR (3 OF 3)

AC20160-1822, Issue 1, November 2002

CONTROLLER
DIGITAL INPUTS

(108) [BK]

RLB

(107) [BK]

PCB1

RESISTOR/VDR
P.C.B

(109) [BK]

(115)
[BK]
(116)
[BK]
(117)
[BK]
(110B)
[BK]
(111B)
[BK]
(112B)
[BK]
(110C)
[BK]
(111C)
[BK]
(112C)
[BK]

R101
(149)

(148)

(141)

(142)

(143)

A1

HEATSINK
TEMP SENS

[PK]

3
4

G E

A2

5
4

PCB2

GATE DRIVE BOARD

B1

[PK]

C
C

POWER SWITCHING IGBT'S

(154)

G E

[PK]

G E

[G/Y]

[G/Y]

[G/Y]

[G/Y]

[G/Y]

[126E]
[R]

(158) [PK]

G E

(150) [VLT]
(151)
3
2
1

B2

LINK

22

L2

(A1)

(A2)

GATE DRIVE P .C.B

DOOR

BASE FRAME

STARTER BOX

CAPACITOR TRAY

HEATSINK

(B1)

24V
2/02
0V~
2/02
24V~
2/02
0V~
2/02
24V~
2/02
0V~
2/02

HW 0028

(128) [R]

(133) [R]

(126) [R]

(132) [R]

(124) [R]

2/02

2/03

(139) [R]

2/03

(131) [R]

(E)

M102

A2 B2 A1 B1

(B2)

(E)
2/02
SAFETY GUARD

(161)

EARTH

CUR
SENS

[PK]

C8

RLA

2
1

(152) [PK]
(140) [R]
(126A)
[R]

[PK]

(155)

RLB
(126B)
(144) SW1/B (138) [R]
[R]
[R]
(137) [BL]

(153) [VLT]
(139) [R]

(156) [VLT]
(157)
(136) [BL]
SW1/A

(159)[VLT]
(160)

C4

(135)

Chapter 8, page 14
(134)

C1

[PK]

C5

CompAir

FIG. 8.8 ELECTRICAL CONNECTION DIAGRAM - L45SR (1 OF 3)

WITH PHASE FAILURE RELAY

AC20160-1822, Issue 1, November 2002

(139)
[R]
(126)
[R]

<1/34>

<1/34>

0V~
<1/34>

<1/34>

22

X23

X22

SR
CONTROLLER
2

X21
4

X20

R1

X2/1

(210B)
[R]

(133)
[R]
(128)
[R]

(139)
[R]

24V~
<1/34>
0V~
<1/34>

R2

X2/1

(210C)
[R]
RLC

(132)
[R]

X1/1

[R]

24V~
<1/34>

R3

X08
6

CONTROLLER
RELAY OUTPUT

R4

X2/1

(213)
[R]

(131)
[R]
(124)
[R]

(211)
[R]
(126C)

(210E)
[R]
Y202

AC20160-1822, Issue 1, November 2002

X1/1

(126F)
[R]

24V~
<1/34>
0V~
<1/34>
(E)
<1/34>

1
2
AC1 AC2

R5
10

X03

X09
3

HW 0029

CONTROLLER
DIGITAL OUTPUT

LSR Repair Manual Electrical Systems

FIG. 8.9 ELECTRICAL CONNECTION DIAGRAM - L45SR (2 OF 3)

WITH PHASE FAILURE RELAY

Chapter 8, page 15

(210A)
[R]

S201/1

CompAir

Chapter 8, page 16
X02
3

VA6

[CR]

ANA4

[BK]

ANA3

(312)

ANA2

(311)

ANA1

[CR]

(E)

VA+

[BK]

(310)

[BL]

CONT8

E
(E)

SW2

[BL]

CONT7

(309)

CONT6

[BL]

CONT5

(301C)

[BL]

(301E)

CONT4

[BL]

CONT3

(303)

CONT2

(302)

[BL]

(301)

CONT1

(313)

X01
VCONT

R301

[BL]

(301E)

[BL]

(301D)

[BL]

(301B)

[BL]

T2

<1/07>

P301

T1

<1/06>

K101

S302

S201/2

Key to Components (diagrams 1 to 3)

(301A)

AC20160-1822, Issue 1, November 2002

FIG. 8.10 ELECTRICAL CONNECTION DIAGRAM - L45SR (3 OF 3)

WITH PHASE FAILURE RELAY

CONTROLLER
ANALOG INPUTS

CONTROLLER
DIGITAL INPUTS

Reference
EMC1
F1
F2
F3
K101
L1
L2
L208
M102
MCB1
MCB2
P301
PCB1
R101
R301
RLA
RLB
RLC
S302
SW1
T101
Y202

Name
EMC FILTER
FUSE, 2A TYPE T
FUSE, 5A ANTI-SURGE
FUSE, 3.15A SEMI-DELAY
PHASE FAILURE RELAY
LINE REACTOR
CURRENT TRANSDUCER
SPEED SENSOR - MOTOR
MOTOR - MAIN DRIVE
CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A
CIRCUIT BREAKER - FAN 10A
PRESSURE TRANSMITTER - DELIVERY PRESSURE
RESISTOR/VDR PCB
TEMPERATURE SENSOR - HEATSINK
SENSOR - OIL TEMPERATURE
CONTACTOR - MAIN
CONTACTOR DC LINK CHARGING
CONTACTOR - FAN
SWITCH - AIR FILTER DP
AUXILIARY CONTACTS
CONTROL TRANSFORMER
VALVE SOLENOID - BYPASS

Note:- Details of Control Panel components

are supplied inside the Power Converter Box

20VX3/1

X3/1

X3/1

X3/1

X3/1

X3/1

HW 0030

INCOMING SUPPLY
FROM CUSTOMERS
FUSED ISOLATOR

HW 0031

PE

(114)
[BK]

(110B)
[BK]

(E)

T2

T1

M101
3~

(113)
[BK]

(111B)
[BK]

OV
(E)

OV

24V

OV

24V

OV

T101
280VA
460V
24V

(112B)
[BK]

50VA

PCB1

RESISTOR/VDR
P.C.B

L1

L2

(128)
[R]

(127)
[R]

(126)
[R]

(125)
[R]

(124)
[R]

(123)
[R]

POWER
BRIDGE
RECTIFYER
(132)
[R]

(132)
[R]

F3 3.15A

F2 5A

F2 5A

(131)
[R]

K101

F1 2A

L3

PHASE FAILURE
RELAY

L3

m<3
L2

200VA

30VA

(106)
[BK]

(105)
[BK]

(114)
[BK]

(102)
[BK]

(110A)
[BK]

(107)
[BK]
(115)
[BK]
(110C)
[BK]

R101
(149)

(148)

(141)

(142)

(143)

C10

C6

C E

X1/1

(150)

(103)
[BK]

MCB2 10A

RLC

(108)
[BK]
(116)
[BK]
(111C)
[BK]

RLB

MCB1 3A
(113)
[BK]

(109)
[BK]
(117)
[BK]
(112C)
[BK]

A1

4
5
1

X1/1

B1

5
1

2
3

A2

X1/1

PCB2

(126E)
[R]

C G E

[G/Y]

[G/Y]

[G/Y]

[G/Y]

[G/Y]

[R]

GATE DRIVE BOARD

C G E

POWER SWITCHING IGBT'S

C G E

HEATSINK
TEMP SENS

[VLT]
(151)
3
2
1

(111A)
[BK]

<3/15>

(140)
[R]

RLA

C5

(139)
[R]

C1

RLB

(104)
[BK]

(112A)
[BK]

<3/15>

(138)
[R]
SW1
(144)
[R]
(126B)
[R]

VDR1

(137)
[BL]

(101)
[BK]

RLA

(136)
[BL]

2
1

[PK]
(152)
[PK]
(153)
[VLT]
(154)
[PK]
(126A)
[R]

(155)
[PK]
(156)
[VLT]
(157)
[PK]
SW1

2
4

B2

(E)
<2/02>

22

L2

(A1)

GATE DRIVE P.C.B

DOOR

BASE FRAME

STARTER BOX

CAPACITOR TRAY

HEATSINK

(A2)

(B2)
(B1)

(E)

M102

A1 B1 A2 B2

SAFETY GUARD

EARTH
BAR

[R]

LINK

CUR
SENS

(158)
[PK]
(159)
[VLT]
(160)
[PK]
(135)

AC20160-1822, Issue 1, November 2002

(134)

(161)
[PK]

L1

24V~
<2/02>
0V~
<2/02>

0V~
<2/02>

(128)
[R]

24V~
<2/02>
(126)
[R]
(133)
[R]

0V~
<2/02>
(132)
[R]

24V~
<2/02>

<2/02>

<2/03>

(124)
[R]

(131)
[R]

(139)
[R]

<2/03>

LSR Repair Manual Electrical Systems

FIG. 8.11 ELECTRICAL CONNECTION DIAGRAM - L75SR (1 OF 3)

WITH PHASE FAILURE RELAY

Chapter 8, page 17

<1/34>

0V~
<1/34>

(126)
[R]

22

(139)
[R]

<1/34>

<1/34>

0V~
<1/34>

(133)
[R]
(128)
[R]

X23

X22

SR
CONTROLLER
1

X21

X20

R1

X2/1

(210B)
[R]

21V~
<1/34>

(139)
[R]

(132)
[R]

R2

X2/1

(210C)
[R]
RLC

24V~
<1/34>

(211)
[R]

R3

X2/1

X08

CONTROLLER
RELAY OUTPUT

X1/1

(126C)
[R]

(210D)
[R]
Y201

(E)
<1/34>

(212)
[R]

X1/1

(126D)
[R]

R4

X2/1

(210E)
[R]
Y202

[R]

X1/1

R5

X2/1

10

2
AC2

1
X03

AC1

(210F)

(124)
[R]

(214)

(131)
[R]

(213)

(126E)
[R]

[R]
Y203

0V~
<1/34>

[R]

X1/1

[R]

Chapter 8, page 18
(126F)

24V~
<1/34>

X09
3

CONTROLLER
DIGITAL OUTPUT

HW 0032

CompAir

FIG. 8.12 ELECTRICAL CONNECTION DIAGRAM - L75SR (2 OF 3)

WITH PHASE FAILURE RELAY

AC20160-1822, Issue 1, November 2002

(210A)
[R]

S201/1

20V-

X3/1

(302)
[BL]

X3/1

(301B)
[BL]

(303)
[BL]

X3/1

(301D)
[BL]

CONT4

X3/1

CONT6

CONT5

X3/1

[BL]

S302

S201/2

X01

CONT3

(301F)

CONT2

(301C)
[BL]

CONT1

CONT7

K101

VCONT

(301A)
[BL]

(308)
[BL]

X3/1

(301H)
[BL]

(305)
[BL]

S304
(301E)
[BL]

CONT8

X3/1

T2

T1

SW2

(309)
[BL]

<1/06>
<1/07>

AC20160-1822, Issue 1, November 2002

HW 0033

(E)

VA+
1
(310)
[BK]
2

X02
ANA2
ANA3
4
3

ANA1
2
(311)
[CR]
R301

(312)
[BK]

ANA4
5

CONTROLLER
ANALOG INPUTS

VA6
(313)
[CR]

CONTROLLER
DIGITAL INPUTS

(E)

Name
EMC FILTER
FUSE, 2A TYPE T
FUSE, 5A ANTI-SURGE
FUSE, 3.15A SEMI-DELAY
PHASE FAILURE RELAY
LINE REACTOR
CURRENT TRANSDUCER
SPEED SENSOR - MOTOR
MOTOR - MAIN DRIVE
CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A
CIRCUIT BREAKER - FAN 10A
PRESSURE TRANSMITTER - DELIVERY PRESSURE
RESISTOR/VDR PCB
TEMPERATURE SENSOR - HEATSINK
SENSOR - OIL TEMPERATURE
CONTACTOR - MAIN
CONTACTOR DC LINK CHARGING
CONTACTOR - FAN
SWITCH - AIR FILTER DP
SWITCH - EXCESS PRESSURE
AUXILIARY CONTACTS
CONTROL TRANSFORMER
SOLENOID VALVE - SCAVENGE
VALVE SOLENOID - BYPASS
SOLENOID VALVE - CONDENSATE DRAIN

Note:- Details of Control Panel components

are supplied inside the Power Converter Box

Reference
EMC1
F1
F2
F3
K101
L1
L2
L208
M102
MCB1
MCB2
P301
PCB1
R101
R301
RLA
RLB
RLC
S302
S304
SW1
T101
Y201
Y202
Y203

Key to Components (diagrams 1 to 3)

LSR Repair Manual Electrical Systems

FIG. 8.13 ELECTRICAL CONNECTION DIAGRAM - L75SR (3 OF 3)

WITH PHASE FAILURE RELAY

Chapter 8, page 19

P301

HW 0034

CompAir

FIG. 8.14 ELECTRICAL CONNECTION DIAGRAM - L120SR (1 OF 4)

Chapter 8, page 20

AC20160-1822, Issue 1, November 2002

HW 0035

LSR Repair Manual Electrical Systems

FIG. 8.15 ELECTRICAL CONNECTION DIAGRAM - L120SR (2 OF 4)

AC20160-1822, Issue 1, November 2002

Chapter 8, page 21

HW 0036

CompAir

FIG. 8.16 ELECTRICAL CONNECTION DIAGRAM - L120SR (3 OF 4)

Chapter 8, page 22

AC20160-1822, Issue 1, November 2002

HW 0037

AC20160-1822, Issue 1, November 2002

Name
DIODE RECTIFIER
CAPACITOR
CAPACITOR - SNUBBER
EMC FILTER
FUSE, 2A TYPE T
FUSE, 5A ANTI-SURGE
FUSE, 3.15A SEMI-DELAY
FUSE, 2A TYPE T HEATSINK FAN
ENCLOSURE HEATER
IGBT - GAL
IGBT - GAR
CONTACTOR - MAIN
PHASE FAILURE RELAY
CONTACT DC LINK CHARGING
CONTACTOR - FAN
RELAY GROUP FAULT
LINE REACTOR
CURRENT TRANSDUCER
SPEED SENSOR - MOTOR
Reference
M101
M102
M107
MCB1
MCB2
P301
P302
R101
R105 TO R114
R2 TO R4
R301
S201
S302
SK1
T101
TS
VDR1 TO VDR4
Y202
Y215

Note:- Details of Control Panel components are supplied

inside the Power Converter Box

H101
IGBT 1 TO IGBT 4
IGBT 5 TO IGBT 8
K1
K101
K2
K3
K4
L1
L2
L208

Reference
BR1 TO BR3
C1 TO C18
C19 TO C22
EMC1
F1
F2
F3
F4

Key to Components (diagrams 1 to 4)

Name
FAN MOTOR
MOTOR - MAIN DRIVE
FAN MOTOR - HEATSINK
CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A
CIRCUIT BREAKER - FAN 16A
PRESSURE TRANSMITTER - DELIVERY PRESSURE
PRESSURE TRANSMITTER - RECLAIMER PRESSURE
TEMPERATURE SENSOR - HEATSINK
RESISTOR
RESISTOR - SOFT START
SENSOR - OIL TEMPERATURE
EMERGENCY STOP SWITCH
SWITCH - AIR FILTER DP
48 WAY UTP CONNECTOR
CONTROL TRANSFORMER
THERMOSTATIC SWITCH
VARISTOR
VALVE SOLENOID - BYPASS
VALVE - CONDENSATE DRAIN

LSR Repair Manual Electrical Systems

FIG. 8.17 ELECTRICAL CONNECTION DIAGRAM - L120SR (4 OF 4)

Chapter 8, page 23

CompAir

This page has been intentionally left blank

Chapter 8, page 24

AC20160-1822, Issue 1, November 2002

LSR Repair Manual Fault Diagnosis

FAULT DIAGNOSIS
WARNING

Refer to the safety procedures before

carrying out fault diagnosis or testing
any circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the starter

compartment, switch the power supply
OFF at isolator and wait for 12 minutes to
allow the DC link capacitors to discharge to
a safe level. Check that the DC link
capacitors have fully discharged before
starting any maintenance work.

CAUTION: Fault finding by control card substitution

without following the correct fault finding
procedures is not recommended. A fault may exist
which could cause damage to the substitute card.

1.2

Clip-on Ammeter

1.

1.3

TEST EQUIPMENT

To carry out checks on the electrical components

and the circuit cards inputs and outputs the
following test equipment will be required.

This should be suitable for measuring currents up

to 600 amps. A suitable ammeter is the Heme 6200 A model.

The tester should have a 1000V test voltage. A

suitable tester is the Megger BM222.
1.4

CAUTION: Do not use a test meter with less than a

20,000 ohm/V specification to avoid loading effects
and to prevent damage to ICs during testing.
CAUTION: The circuit boards carry CMOS
devices. When replacing circuit boards avoid
touching connector pins and devices on the boards
to prevent static damage to components. Take antistatic precautions as far as possible such as
transporting the circuit boards in anti-static bags.
1.1

Test Meter

A digital multimeter with diode and capacitor test

functions is required for the tests carried out in this
section. The meter resistance test voltage should
not exceed 15V. Always ensure that the meter and
test leads are rated for the voltage being measured:
DC - 0-1000V is normally sufficient.
AC - 0-600V rms.
A suitable test meter is the Fluke 79-III.

AC20160-1822, Issue 1, August 2002

Insulation Tester

DC Voltage Generator

The generator should provide a maximum of 30V

DC at a maximum current of up to 1 A. A suitable
generator is the Thurlby Thandar Instruments
PL310.
1.5

IGBT Tester

IGBT Tester part number 98506-24 can be ordered

from CompAir UK Ltd.
1.6

Slave Air Supply

The air supply should be capable of generating a

pressure above 5.5 bar and be fitted with an
accurately calibrated gauge.
1.7

Inductance Tester

The tester should be capable of measuring in the

uF and mH ranges.
A suitable tester is the AVO Megger B131, RS
stock number 230-6546.

Chapter 8, page 25

CompAir

2.

CAGE-CLAMP SCREWLESS TERMINALS

The connections on the controller terminal blocks

are fitted with cage-clamp screwless terminals. The
cage-clamp design ensures that the clamping force
adjusts to sizes of cable between 1 mm2 and 25
mm2. This results in a corrosion free contact area
and compensates for any deformation of the cable
end due to temperature or vibration.

2.1

Cable Connection or Removal

1.

Strip the insulation from the end of the cable

to leave approximately 8 mm of bare wire.

2.

Insert a screwdriver with a blade end width of

3 mm into the terminal slot and push to the
end stop.

3.

Insert (or remove) the cable.

4.

Withdraw the screwdriver to leave the cable

clamped.

5.

Check the connection by lightly pulling on the

cable.

2
1

HW 0333

1. Terminal Jumper Connection

2. Cable
3. Terminal Block

FIG. 8.18 CABLE CONNECTION OR REMOVAL

Chapter 8, page 26

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

3.

POWER SUPPLIES

4.

CONTROL INPUTS

CAUTION: The high voltage (primary) and low

voltage (secondary) circuits must NOT be
connected in any way (e.g. via test probes, wiring
etc.)

CAUTION: The high voltage (primary) and low

voltage (secondary) circuits must NOT be
connected in any way (e.g. via test probes, wiring
etc.)

3.1

To Check the 24V AC Supply Circuits

(Refer to Electrical Connection Diagrams)

4.1

1.

Measure the AC voltages of all the secondary

outputs of the control transformer. Always
measure across the transformer output
terminals and NOT between each terminal
and earth.

4.1.1 L45SR and L75SR models

2.

3.

4.

5.

The voltage of each output should be as

indicated 10%. If one of the voltages is
incorrect, renew the transformer. If all the
voltages are incorrect see 3.2 To Check the
Main Power Supply.
Check the fuses contained in the fused
terminal blocks F1, F2 and F3. Renew any
blown fuse. If a fuse blows repeatedly
continue to check along the circuit for any
short circuits or failed devices, as explained in
detail throughout this Chapter.
Measure the AC voltage between pins 1 and 2
of controller terminal X03. The voltage should
be the same as measured in 2 above. Check
the wiring if the voltage is incorrect.
Measure the AC voltage between pins 1 and 2
of controller terminal X20. The voltage should
be the same as measured in point 2. Check
the wiring if the voltage is incorrect.

3.2 To Check the Main Power Supply

1.

Measure and record the voltage between the

Red and Yellow, the Red and Blue, and the
Yellow and Blue incoming phases. In addition
measure the AC voltage between the primary
connections of control transformer T101. The
readings should be within 10% of the
specified working voltage on the compressor
nameplate.

2.

Measure and record any voltage drop during a

motor start sequence. Excessive voltage drop
will cause tripping problems.

AC20160-1822, Issue 1, August 2002

To Check the Air Filter Differential

Pressure Switch

The air filter differential pressure switch contacts

are normally open. This indicates that the air filter
element differential pressure is within limits. When
the filter requires changing the contacts of the
switch close.
1.

Disconnect the cables from the pressure

switch.

2.

Check that the pressure switch is open circuit

by checking continuity between the switch
terminals.

3.

Renew the pressure switch if closed circuit.

4.

Refer to the electrical connection diagrams to

verify the wiring connections from the
controller to the pressure switch.

4.1.2 L120SR model

A visual filter condition indicator is fitted adjacent to
the air intake filter. This is also a switch.
The indicator is a vacuum indicator and when the
set point of 65 mbar vacuum is reached it will send
a signal to the controller to flag up a warning. The
switch is normally open and can be checked in the
normal manner as above.
Note: The indicator has to be manually reset by
pressing the yellow button (1) on the bottom (see
figure 8.19).

Chapter 8, page 27

CompAir

3.

When checking an output ensure the AC

supply to X08/1,3,5,7 & 9 is within 10% of the
nominal voltage.

4.

Measure the voltage between the transformer

secondary 0V terminal and the output
terminal, while the output is operated using
the Test Digital Outputs function.

5.

If an output fails to function renew the

controller.

6.

Continue to check the output voltage along

the circuit being tested. Renew any
connections or wiring as necessary.

7.

If the voltage across the terminals of the

contactor or solenoid coil being tested is
correct when the controller output is switched
on, but the device fails to function, renew the
contactor coil or solenoid.

6.

SENSORS

HW 0334

FIG. 8.19 AIR FILTER INDICATOR SWITCH

(L120SR)
4.2

To Check the Emergency Stop Circuit

The Emergency Stop button has two contacts which

will open if the Emergency Stop button is pressed.
One contact is connected to the 24V AC power
supply circuit to the controller outputs. This contact
will interrupt the power supply to the motor
contactors and control solenoids in the event of an
Emergency Stop. The other contact is connected to
the DC input circuits of the controller. The two
circuits must NOT be connected in any way, e.g. via
test probes, wiring etc.
Refer to the electrical connection diagrams to
check the continuity of the emergency stop wiring.

5.

CONTROL OUTPUTS

CAUTION: The high voltage (primary) and low

voltage (secondary) circuits must NOT be
connected in any way (e.g. via test probes, wiring
etc.)
6.1

To Check the Pressure Sensors

The Pressure Sensors are 4-20 mA types,

0-13.8 Bar (L45SR and L75SR) and 0-16 Bar
(L120SR). The current in the sensor 24V DC
supply wires will change in proportion to the
pressure acting on the Pressure Sensor. The
controller monitors the current signal and
processes the information to give a pressure
display.
1.
Switch power OFF.

CAUTION: The high voltage (primary) and low

voltage (secondary) circuits must NOT be
connected in any way (e.g. via test probes, wiring
etc.)

2.

Remove the plug from the pressure sensor,

switch power ON and ignore any displayed
fault message.

5.1

Relay Output (connector X08)

3.

1.

Ensure the Emergency Stop input has not

been operated before checking the outputs,
see para. 4.2 To Check the Emergency Stop
Circuit

Measure the DC voltage between terminals 1

and 2 of the plug. The reading should be
between 20V and 28V.

4.

If the voltage is incorrect see 3.1 To Check

The 24V AC Supply Circuits.

5.

Re-connect the pressure sensor plug and

disconnect one of the plug wires.

The motor contactors and load solenoid

controller outputs are all relay contacts.

Chapter 8, page 28

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

6.

7.

8.

9.

Connect the multimeter between the

disconnected end of the wire and the plug
terminal.
Apply a calibrated known pressure to the
sensor and measure the dc current in the
sensor circuit. The reading should be as
given in the Pressure Sensor output table
below.

CONTROLLER
PRESSURE
SENSOR
PLUG
1
2

ML1/7
ML1/8

If the current is not within 5% of the figure

given check the wiring and connections of
the pressure sensor circuit.
Renew the pressure sensor if no wiring or
connection faults can be found.

X02/1
X02/2

HW 0335

FIG. 8.20 MEASURING THE PRESSURE

SENSOR CURRENT

Pressure
(bar)

Sensor
Output (mA)
L45SR, L75SR

Sensor
Output (mA)
L120SR

Pressure
(bar)

Sensor
Output (mA)
L45SR, L75SR

Sensor
Output (mA)
L120SR

0.0

4.00

4.00

85

13.86

12.50

05

4.58

4.50

90

14.44

13.00

10

5.16

5.00

95

15.02

13.50

15

5.74

5.50

100

15.60

14.00

20

6.32

6.00

105

16.18

14.50

25

6.90

6.50

110

16.75

15.00

30

7.48

7.00

115

17.33

15.50

35

8.06

7.50

120

17.91

16.00

40

8.64

8.00

125

18.49

16.50

45

9.22

8.50

130

19.07

17.00

50

980

9.00

135

19.65

17.50

55

1038

9.50

13.8

20.00

17.80

60

1096

10.00

14.0

n/a

18.00

65

1154

10.50

14.5

n/a

18.50

70

1212

11.00

15.0

n/a

19.00

75

11.50

11.50

15.5

n/a

19.50

80

12.00

12.00

16.0

n/a

20.00

FIG. 8.21 PRESSURE SENSOR OUTPUT TABLE

AC20160-1822, Issue 1, August 2002

Chapter 8, page 29

CompAir

6.2

To Check the Air/Oil Temperature

Sensors

The temperature sensors are spreading resistance

type thermistors. The resistance of the thermistors
will increase as the applied temperature increases.
The controller monitors the resistance and
processes the information to give a temperature
display.
1.

Switch power OFF. Disconnect the cables

from the temperature sensor and measure its
resistance.

Note: Drain the air-end, remove the temperature

sensor and the sensing tip and place in a calibrated
oil temperature bath if an accurate measurement is
required.

WARNING

2.

The sensor resistance depends on the

temperature, see the Temperature/Sensor
resistance table below. If the measured
resistance equates to an error of more than
2C different from the figure given below
renew the sensor.

3.

If the resistance is correct re-connect the

sensor cables.

4.

Disconnect temperature sensor cables from

controller terminal plug.

5.

Measure the resistance between the

disconnected cable ends. If the resistance is
not as given in the table renew cables as
necessary.

6.

If the resistance is correct, renew the

controller.

Risk of injury from hot oil under pressure.

Temperature
(C)

Sensor
Res. (ohms)

Temperature
(C)

Sensor
Res. (ohms)

1605

50

2448

1678

60

2638

10

1762

70

2844

15

1848

80

3058

20

1927

90

3282

25

2008

100

3520

30

2092

110

3772

40

2263

120

4043

FIG. 8.22 TEMPERATURE SENSOR RESISTANCE TABLE

Chapter 8, page 30

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

7.

CONTROLLER

CAUTION

When working with static sensitive

components, ie, circuit cards and
memory ICs etc, always take antistatic
precautions.

7.1

Application Control Program IC

Instructions for renewing the control program IC

within a SureScan controller:
1.

Remove the controller from the compressor.

2.

Remove the screws located adjacent to the

electrical plug connections on the rear of the
controller.

Always transport static sensitive

components in anti-static bags or
containers.

3.

Using a spanner, remove the (plug securing)

nuts adjacent to the sub-D connections.

2.

Never touch the metal pins of electronic

IC devices.

4.

Remove the six rear controller enclosure

securing screws (do not remove the earth tag
and stud adjacent to X03).

3.

Never place static sensitive components

onto a metal surface. Always place
directly into an anti-static bag or
container.

5.

Remove the rear controller cover.

6.

The control program IC can be removed

without dismantling the three circuit cards. To
eliminate the possibility of re-connection
errors, it is recommended that the circuit cards
are not dismantled.

1.

4.

Always ensure any body static is

discharged before handling static
sensitive components by touching an
earthed surface at regular intervals.

The controller consists of two microprocessor units,

the application subcontroller, and the motor drive
subcontroller.
The application subcontroller contains three cards
which together run the application program to
control and monitor the compressor and keypad
functions of the controller. An application program
IC is fitted to this unit.
The motor drive subcontroller contains two cards
and is mounted adjacent to the application
subcontroller and connected by a three wire internal
serial link. Motor drive program ICs, which are fitted
to this unit, control the speed of the motor drive as
required by the application program and return
condition and fault data from the drive circuits to the
application program.

Before removal of the control program IC,

make a note of the orientation and position of
the IC in its socket. Note the orientation
marks on the IC, socket and circuit board.
7.

Using a small screwdriver, or similar tool,

carefully remove the control program IC from
its socket.

8.

Insert the new control program IC. Check the

orientation and ensure that each pin enters the
socket correctly. (The pins must not bend
underneath the IC during insertion.)

9.

When re-assembling the controller, refit the six

rear cover securing screws first to hold the
cover in place but do not tighten. Then refit
the remaining screws and nuts before finally
tightening the rear cover screws.

Note: Ensure that the ribbon cable is not trapped or

displaced when replacing the cover.
10.

AC20160-1822, Issue 1, August 2002

Re-connect to compressor and test.

Chapter 8, page 31

CompAir

FIG. 8.21 ARRANGEMENT OF CONTROLLER CARDS

7.2

Motor Drive Program IC

Normally it is not necessary to change the motor

drive program IC. However some control programs
also require the drive program to be updated. If one
of these control programs is installed without the
corresponding drive IC change, the message
Wrong SR Drive program will be displayed.

7.3

FPGA Data IC

A need to change this IC is not anticipated.

However, if required, use the same procedure as
above.

To change this IC follow the basic instructions for

the control program. However to gain access it will
be necessary to fold the upper card to one side. No
connections need to be disturbed. Note also the
position of the unused sockets at the notch end.

Chapter 8, page 32

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

8.

SR FAULT LOCATION

8.1

SR Current Sensor Fault (Figs. 8.23/8.24)

8.4

The SR drive current sensor circuit has detected a

fault.
Refer to the flow chart in Figs. 8.23/8.24 for the fault
finding procedure.
HW 0337
1

Current Sensor Pin Connection (X22)

See Electrical Connection Diagrams

This fault occurs when the DC link voltage is

excessive.
Refer to the flow chart in Figs. 8.26/8.27 for the fault
finding procedure.
CAUTION: When measuring the DC link voltage
use a suitable test meter and leads (1000V test
voltage) and attach the leads to the DC link using
crocodile clips.
Route the leads to ensure that the enclosure door
can be closed and fastened before applying power.

8.5

FIG. 8.22 CURRENT SENSOR PIN

8.2

SR Motor High Temperature Fault

Under normal operating conditions the resistance of

the thermistors in the SR motor windings should be
50 to 500 ohms. Possible causes of high
temperature are:
1.

High ambient temperature.

2.

Motor cooling air intake grille blocked.

3.

Pre-filter blocked.

4.

Open circuit in thermistor cables.

5.

Recirculation of exhaust air from cooler within

the compressor.

8.3

SR Motor Overcurrent (Fig. 8.25)

DC Link High Voltage Fault

(Figs. 8.26/8.27)

DC Link Low Voltage Fault (Figs. 8.28/

8.29)

This fault occurs when the DC link voltage is below

operating level.
Refer to the flow chart in Figs. 8.28/8.29for the fault
finding procedure.

8.6

SR Position Sensor Fault

This fault occurs when the SR motor position

sensor cable is disconnected or the position sensor
is faulty.

8.7

SR Motor Overspeed Fault

This fault occurs when the SR motor measured

speed exceeds the normal operating speed.
Possible causes are:
1.

Fault in speed control harness, eg broken wire

or cable screen.

Occurs if the current sensor signal indicates

excessive SR motor phase current.

2.

Fault in controller.

Refer to the flow chart in Fig. 8.25 for the fault

finding proceedure.

8.8

SR Motor Stall Fault (Fig. 8.30)

Attempting to repeatedly start a compressor with an

SR motor overcurrent fault will produce a start
inhibit.

AC20160-1822, Issue 1, August 2002

This fault occurs when the SR motor speed remains

below 300rpm for 1 second.
Refer to the flow chart in Fig. 8.30 for the fault
finding procedure.

Chapter 8, page 33

CompAir

8.9

DC Link Charge Fault

(See Fig. 8.31)

This fault occurs during the 5 second charge period

if the voltage does not exceed expected level. At 5
seconds the voltage should exceeed the following
figure.
420V
485V
485V
485V

Serial Nos F170-0112 to F170-0353

Serial Nos F170-0354 onwards
Serial Nos F171-0100 onwards
Serial Nos F180-0106 onwards

8.12 Main Contactor Fault

This fault occurs if the main contactor auxiliary
contact is open when the contactor output is
energised.
A main contactor fault condition can also be
produced with the fitting of a phase failure retrofit
kit. This occurs when the incoming phases are
transposed.
Possible causes are:
1.

The potentiometer is set incorrectly for the

national AC supply voltage.

2.

An imbalance in the national AC supply

voltage.

3.

A faulty phase failure relay auxiliary contact.

4.

A faulty main contactor coil.

Refer to the flow chart in Fig. 8.31 for the fault

finding procedure.
8.10 Heatsink Temperature Sensor Fault
This fault occurs when the resistance of the
heatsink temperature sensor is outside of its
working range. Possible causes are:
1.

Broken wire.

2.

Faulty sensor.

8.13 SR Power Supply Fault

There has been an interruption in the power supply.
8.11 Heatsink High Temperature Fault
8.14 Internal Comms Fault
This fault occurs when the measured heatsink
temperature is above 90C (L45SR and L75SR) or
95C (L120SR). Possible causes are:

This condition exists when there is a fault on the

Surescan controller or there has been a brief
interruption in the power supply.

1.

High ambient temperature.

2.

Pre-filter blocked.

8.15 SR PCB Internal Fault

3.

Heatsink cooling duct blocked.

4.

Heatsink cooling duct missing.

This condition occurs when there is a fault on the

Surescan controller or there has been a brief
interruption in the power supply.

5.

Heatsink dirty.

8.16 Start Inhibit

6.

Power converter filters blocked.

This fault condition has two possible causes.

Note: When the heatsink temperature is above

85C (L45SR and L75SR) or 90C (L120SR) the
drive will start to limit the speed to try to limit the
heat in the heatsink.
7.

1.

Initial power up with incoming phases

transposed.

2.*

Excessive starting of machine with SR motor

overcurrent fault.

Heatsink cooling fan faulty (L120SR only)

* An access code is required to reset the fault.

Chapter 8, page 34

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

8.17 SR FAULT LOCATION CHARTS

FIG 8.23 SR CURRENT SENSOR FAULT (1 OF 2)

AC20160-1822, Issue 1, August 2002

Chapter 8, page 35

CompAir

FIG 8.24 SR CURRENT SENSOR FAULT (2 OF 2)

Chapter 8, page 36

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

FIG 8.25 SR MOTOR OVERCURRENT FAULT

AC20160-1822, Issue 1, August 2002

Chapter 8, page 37

CompAir

FIG 8.26 DC LINK HIGH VOLTAGE FAULT (1 OF 2)

Chapter 8, page 38

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

FIG 8.27 DC LINK HIGH VOLTAGE FAULT (2 OF 2)

AC20160-1822, Issue 1, August 2002

Chapter 8, page 39

CompAir

FIG 8.28 DC LINK LOW VOLTAGE FAULT ( 1 OF 2)

Chapter 8, page 40

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

FIG 8.29 DC LINK LOW VOLTAGE FAULT (2 OF 2)

AC20160-1822, Issue 1, August 2002

Chapter 8, page 41

CompAir

FIG. 8.30 SR MOTOR STALL FAULT

Chapter 8, page 42

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

FIG. 8.31 DC LINK CHARGE FAULT

AC20160-1822, Issue 1, August 2002

Chapter 8, page 43

CompAir

9.

SR TEST PROCEDURES

WARNING

9.1

Refer to the safety procedures before

carrying out fault diagnosis or testing
any circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Diode Device Test Procedures

Before opening the door of the starter

compartment, switch the power supply
OFF at isolator and wait for 12 minutes to
allow the dc link capacitors to discharge to
a safe level. Check that the dc link
capacitors have fully discharged before
starting any maintenance work.

compare with the value shown in figs. 8.33-8.35,,

the device is faulty.

Fast diodes as separate modules are only fitted to

machines with serial numbers:
F170/0112 to F170/0353 and
F180/0101 to F180/0168

Note: Each diode should also be tested for reverse

conduction. No diode should conduct in reverse.
9.1.1 Fast Diode Module (Common Cathode)

To carry out a functional test on any diode device

proceed as follows:
CAUTION: All electrical connections and
connection bars must be removed from a device
before it can be tested.

HW 0348

0.30V

0.30V

Use a digital multimeter equipped with a diode test

function (fig. 8.32). If the forward voltage does not
FIG. 8.33
Note: This diode is fitted near the top of the heat
sink, in between IGBTs A2 and B2. Check the
terminal numbers before carrying out a test.
9.1.2 Fast Diode Module (Common Anode)
mV

OFF

RED

BLACK

V
Hz

HW 0349

0.30V

0.30V

FIG. 8.34
COM

HW 0347

FIG. 8.32

Chapter 8, page 44

Note: From serial numbers F170-0354 and F1800106 onwards the fast diode is located within the
IGBT (see 9.3.1)

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

9.1.3 Rectifier Diode Module

Note: There are three rectifier diodes fitted at the
top of the heatsink (L75SR) or the bottom of the
heatsink (L45SR and L75SR). There is a diagram
on the rectifier diode module(s) to indicate the
circuit. Test accordingly.

0.45V

1.

In normal operation the lamp will light when

the test button is switched ON.

2.

If the lamp does not light when the test button

is switched ON an open circuit is indicated.

3.

If the lamp remains lit with the button ON or

OFF a short circuit is indicated.

0.45V
Use IGBT tester, CompAir part number 98506-24.
9.2.1 Dual IGBT (Insulated Gate Bipolar
Transistor)
HW 0350

FIG. 8.35
9.2

These devices contain two IGBTs and are fitted to

machines from serial numbers F170-0354 and
F180-0106 onwards.

IGBT (Insulated Gate Bipolar Transistor)

CAUTION: All electrical connections and

connection bars must be removed from a device
before it can be tested.
Using IGBT tester, CompAir part number 98506-24,
connect as shown below. In the illustrations below
the two ends of the same connecting wire are
shown by a or b.

One of the IGBTs is forced open circuit by linking its

gate connection to the emitter enabling the internal
fast diode to be tested.
On the right hand side of the IGBT there are four tab
terminals, two of which are linked together. To
locate the diode circuit it is necessary to determine
which of these terminals are linked.
If the link is made between tab terminals E1 and G1
the diode can be measured between screw
terminals C2E1 and C1.
If the link is made between tab terminals E2 and G2
the diode can be measured between screw
terminals C2E1 and E2.
Note: Refer to 9.1 Diode Test Procedures.

FIG. 8.36 CONNECTING TESTER TO IGBT

TYPE GAL

The IGBT can now be located and tested.

FIG. 8.37 CONNECTING TESTER TO IGBT

TYPE GAR

AC20160-1822, Issue 1, August 2002

Chapter 8, page 45

CompAir

If the link is made between tab terminals E1 and G1

the transistor connections are:
Gate - G2

Emitter - E2

Collector - C2E1

If the link is made between tab terminals E2 and G2

the transistor connections are:
Gate - G1

Emitter - C2E1

Collector - C1

Note: Refer to 9.3 IGBT Test Procedures.

CAUTION: Always ensure the correct tab terminals
are linked when replacing an IGBT.
9.2.2 Latest Semikron IGBTs
Test as in 9.2 and then test with diode tester
according to the diagram on the IGBT.

FIG. 8.38 CIRCUIT OF IGBT TYPE GAL

FIG. 8.39 CIRCUIT OF IGBT TYPE GAR

Chapter 8, page 46

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

C9

C10

C11

C12

HW 0357

1
2
3
4

Rectifier Diodes
IGBTs
Snubber Capacitors
Busbars

5 Gate Drive Board

6 VDR/Resistor Board
7 Capacitor Box

FIG. 8.40 L45SR POWER CONVERTER ASSEMBLY

AC20160-1822, Issue 1, August 2002

Chapter 8, page 47

CompAir

2
1

5
9

6
HW 0358
1
2
3
4
5

Rectifier Diodes
Capacitor Box
Balance Resistors
Capacitors
Gate Drive Board

6
7
8
9

Earth
Snubber Capacitors
Busbars
IGBTs

FIG. 8.41 L75SR POWER CONVERTER ASSEMBLY

Chapter 8, page 48

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

C10

159
160

R110

R105

R111

R106

R112

R107

1
519
520

161

516
517

158

R101

MOTOR CABLES A2 B2
THROUGH SENSOR

156
157

15
15 3
4

140
139
138
137
136

513
514

155

1
4
152

150
151

R113

R108

5
R114

R109

510
511

C18

HW 0359

1
2
3
4
5

Laminated Busbar
Gate Drive Board
Earth Lead
Balance Resistors
Capacitor Box

6
7
8
9

Capacitors
Lift-off Hinges
IGBTs
Snubber Capacitors

FIG. 8.42 L120SR POWER CONVERTER ASSEMBLY

AC20160-1822, Issue 1, August 2002

Chapter 8, page 49

CompAir

9.2.3 IGBT Removal and Fitting Instructions

8.

Removal (L45 and 75SR)

Removal (L120SR)

1.

Open power converter door and remove all

electrical guards.

1.

Open power converter door and remove all

electrical guards.

2.

Disconnect motor cables from IGBTs.

2.

Disconnect motor cables from IGBTs.

3.

Disconnect vertical bus bars / snubber

capacitors from IGBTs and remove.

3.

Disconnect wires and leads from gate drive

board.

4.

Carefully disconnect the pink and violet wires

from the IGBTs.

4.

Remove gate drive board

5.

Disconnect pink and violet wires from IGBTs

5.

Undo mounting screws for IGBTs and

remove. Remove IGBTs from heatsink.

6.

Remove laminated bus bars, all balance

resistors and snubber capacitors.

7.

Undo mounting screws for IGBTs and

remove.

8.

Clean residue compound from heatsink with a

mild degreaser. Ensure that there is no
spillage on to other components.

6.

Clean residue compound from heatsink with a

mild degreaser. Ensure that there is no
spillage on to other components.

Refitting (L45 and 75SR)

1.

Clean the back of the IGBTs from any

remaining thermal compound.

2.

Uniformly coat the back of the IGBT with

thermal compound (DOW CORNING DC
340). Use a rubber roller for this process to
ensure an even coating of approx
0.02-0.03mm thick.

Refit electrical guards.

Refitting (L120SR)

3.

Refit the IGBTs in the correct order as shown

hand tightening the screws in a diagonal
sequence.

4.

Tighten the screws again in a diagonal

sequence to a torque of 5Nm maximum.

5.

Refit wires from gate drive board

6.

Refit busbars and snubber capacitors to a

torque of 5Nm.

7.

Refit motor cables.

Chapter 8, page 50

1.

Clean the back of the IGBTs from any

remaining thermal compound.

2.

Uniformly coat the back of the IGBT with

thermal compound (DOW CORNING DC
340). Use a rubber roller for this process to
ensure an even coating of approx
0.02-0.03mm thick.

3.

Refit the IGBTs in the correct order as shown

hand tightening the screws in a diagonal
sequence. Tighten to a maximum of 5Nm.

4.

Refit laminated busbars, balance resistors

and snubber capacitors. Tighten IGBT
connections to 5Nm maximum and capacitor
connections to 2Nm maximum.

5.

Refit Gate Drive Board.

6.

Refit wires to Gate Drive Board and IGBTs.

7.

Refit motor cables.

8.

Refit Electrical Guard.

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

9.3

Electrolytic Capacitor Test Procedures

4.

If the capacitor is good the meter reading will

start to increase slowly from an initial low
resistance level. This is due to the small test
voltage generated by the multimeter slowly
charging the the capacitor.

5.

If the capacitor is open circuit (faulty) the

meter will immediately indicate a very high
resistance in excess of 1000k ohms or OL
(over range).

9.3.1 Electrolytic Capacitor Test

CAUTION: All electrical connections and
connection bars must be removed from a device
before it can be tested.
1.

Check that the blow-hole plug (fig. 8.43) is

intact. If the plug has blown the capacitor is
faulty. Check for distortion of the case.

2.

Measure the voltage across the terminals of

the capacitor. Although the DC link voltage
has been completely discharged to 0V before
removing the bus bars, it is possible for the
capacitors to recover a small charge voltage.
If any voltage exists, hold one of the balance
resistors across the terminals until the voltage
is dissipated to zero.

Note: The tests described above are intended as an

on site diagnostic aid only, and will enable a
technician to identify a capacitor fault in most cases.
Refer to 9.3.2 for a more thorough test.

9.3.2 Electrolytic Capacitor Measurement

1.

Use the recommended digital multimeter

switched to the resistance/capacitance
measuring range (
). Press the yellow
button (1) to select capacitance
measurements.

2.

Hold the red probe on the positive terminal of

the capacitor and the black probe on the
unmarked terminal. Note: the meter will
indicated overload if there is a residual
charge in the capacitor. The capacitor should
then be discharged using a balance resistor.

CAUTION: The resistor may become warm when

held across the terminals.
3.

Using the recommended digital multimeter

switched to the resistance/capacitance
position (
) (fig. 8.44), hold the red probe
on the positive terminal of the capacitor and
the black probe on the unmarked terminal.

Blow-Hole Plug
1

mV

~
V

OFF

RED

Hz

BLACK

Electrolytic
Capacitor

HW 0364
COM

FIG. 8.43 CAPACITOR

HW 0366

FIG. 8.44 MULTIMETER

AC20160-1822, Issue 1, August 2002

Chapter 8, page 51

CompAir

3.

Wait until a steady reading is obtained,the

meter will take a little time to switch to the
correct range.

4.

The reading for a good capacitor should be

in the range 2640 to 3960 uF.

5.

Remove screws from right hand side of

capacitor boxes.

6.

Swing capacitor boxes out on hinges and lift

off.

7.

Unscrew nylon back nuts holding capacitors

to boxes.

9.3.3 Capacitor Removal and Refitting Instructions

Removal (L45SR AND L75SR)

Refitting (L120SR)

1.

Open power converter door and remove all

electrical guards.

1.

Refitting is the reversal of removal.

2.
2.

Disconnect all the leads to the gate drive

board and remove gate drive board.

Ensure screws securing bussbars are only

tightened to 5Nm on IGBTs and 2Nrn on
capacitors.

3.

L45SR only: Disconnect and remove VDR

Resistor Board

9.4

To Check Capacitor Bank Voltage

Imbalance

4.

Remove all busbars from the IGBTs and the

rectifier diodes to the capacitors, including
balance resistors.

1.

5.

Remove earth wire from capacitor box at the

earth bar.

With the compressor stopped, isolated and the

DC link discharged, connect a 30V dc power
supply to the dc link busbars. The power
supply should have a current limit of not more
than 2A. connect the supply +ve to the +ve on
the dc link. Switch on the 30V supply.

6.

Remove capacitor housing box.

2.

Check that both the dc link LEDs on the gate

drive board are dimly lit.

7.

Remove capacitor plate from housing box.

3.

8.

Unscrew nylon back nuts holding capacitors

to plate.

Using a digital multimeter check that the dc

link is charged to the voltage of the dc power
supply.

4.

Check that the dc link is balanced to within

0.4V, ie each bank of series connected
capacitors are charged to the same voltage
within 0.4V.

5.

If this fails disconnect the capacitor sensing

connections from the gate drive board (3 pin
connector) and repeat 1, 3 and 4. If the dc link
is now balanced the gate drive board is faulty.

6.

If this test fails check the capacitor bank

balance resistors (see 9.6).

9.5

To Check Capacitor Bank Balance

Resistors

Refitting (L45SR AND L75SR)

1.

Refitting is the reversal of removal.

2.

Ensure busbars to capacitors are only

tightened to 2Nm max.

Removal (L120SR)
1.

Remove all electrical guards.

2.

Disconnect all leads to the gate drive board

and remove gate drive board.

3.

Remove both laminated bussbars from

IGBTs /capacitors including balance resistors
and snubber capacitors.

4.

Remove both earth wires at the earth bar

from capacitor boxes.

Chapter 8, page 52

Disconnect each balance resistor from the capacitor

before measuring its resistance. The resistance
should compare with the marking on the resistor.

AC20160-1822, Issue 1, August 2002

LSR Repair Manual Fault Diagnosis

9.6

To Check VDR/Resistor Board (L45SR and

(L75SR)

9.7

WARNING
!

To Check the SR Motor

WARNING
!

Before removing the safety guards or

disconnecting or connecting the motor
leads, switch the AC power supply OFF
at isolator and wait for 12 minutes to
allow the dc link capacitors to discharge
to a safe level. Check that the dc link
capacitors have fully discharged before
starting work on the compressor.

1.

Isolate AC power supply.

2.

Measure resistance across terminals A to A1,

B to B1 and C to C1 on the board. The
resistance should be 33 ohms 3 ohms in
each case.

Before removing the safety guards or

disconnecting or connecting the motor
leads, switch the AC power supply OFF
at isolator and wait for 12 minutes to
allow the dc link capacitors to discharge
to a safe level. Check that the dc link
capacitors have fully discharged before
starting work on the compressor.

9.7.1 Motor Insulation Test

(Test for end turn faults and faults to ground)
1.

Ensure that the main power supply to the

compressor is isolated.

Note: Use a calibrated 1000V insulation tester for

insulation resistance tests.
107
108
109

A
B
C

115
116
117

2.

Open starter door and remove upper and

lower safety guards.

HW 0367

3.

Disconnect all of the SR motor leads from

power converter, including the SR motor
thermistor cables.

4.

Measure the insulation resistance between

each motor winding phase, i.e. cables A1 and
B1.

A1
B1
C1

FIG. 8.45 VDR/RESISTOR BOARD

(L45SR,L75SR)
9.6.1 L120SR Resistors
Check the resistor values are within the range
shown on the side of the resistors.

Measure the insulation resistance between

each motor winding phase cable (A1 and B1)
and earth.
5.

The resistance reading in each case should

be greater than 20 megohms.

6.

If the insulation resistance is below 20

megohms renew/service the main motor.

CAUTION: DO NOT apply power to a motor which

has an insulation resistance of less than 20
megohms.

FIG. 8.46 Resistor (L120SR)

AC20160-1822, Issue 1, August 2002

Chapter 8, page 53

CompAir

9.7.2 Motor Inductance Test

(Test for turn to turn faults)

Acceptable ranges for motors

L45SR

1.

Ensure that the main power supply to the

compressor is isolated.

Lmin (mH)

Lmax (mH)

Lmax/Lmin Ratio

2.

Open the converter door and remove all

guards.

1.30 min
1.65 max

13.00 min
18.00 max

> 8.50

3.

Disconnect all SR motor leads from the power

converter .

4.

Use the meter specified in test equipment

(para. 1).

Lmin (mH)

Lmax (mH)

Lmax/Lmin Ratio

5.

Set the meter to measure 120Hz inductance

(L).

0.95 min
1.20 max

9.50 min
16.00 max

> 8.50

6.

Clip leads to phase A of the motor. Rotate the

motor very slowly and note the lowest reading
on the meter (this is Lmin). Rotate the motor
again and note the highest reading on the
meter (this is Lmax).

Lmin (uH)

Lmax (mH)

Lmax/Lmin Ratio

595 min
730 max

5.60 min
7.50 max

> 8.50

L75SR

7.

Repeat step 6. for phase B.

8.

Calculate the Lmax/Lmin ratio from the

readings taken for each phase.

9.

Compare the readings with the table below.

The motor is deemed to be faulty if the values
for Lmin and Lmax fall outside the ranges in
the table and/or if the Lmax/Lmin ratio is less
than 8.5

Chapter 8, page 54

L120SR

AC20160-1822, Issue 1, August 2002

SR Repair Manual Disassembly & Assembly

CHAPTER

9
DISASSEMBLY & ASSEMBLY

Page
A - 345SR, L45SR ...................................................................................................................................... 2
B - 475SR, L75SR ..................................................................................................................................... 19
C - L120SR ................................................................................................................................................. 35

AC20160-1822, Issue 1, November 2002

Chapter 9, page 1

CompAir

DISASSEMBLY AND ASSEMBLY

A - 345SR, L45SR
1.
1.1
1.2
1.3
1.4
1.5
2.
2.1
2.2
2.3
2.4
2.5
3.
3.1
3.2
4.
4.1
4.2
4.3
4.4
5.
5.1
5.2
5.3
5.4
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
8.
8.1
8.2
9.
9.1
9.2

INLET NON-RETURN VALVE

Remove Inlet Non-Return Valve
Install Inlet Non-Return Valve
Disassemble Inlet Non-Return Valve
Inspect/Replace Worn Parts
Assemble Inlet Non-Return Valve
MINIMUM PRESSURE VALVE
Remove Minimum Pressure Valve
Install Minimum Pressure Valve
Disassemble Minimum Pressure Valve
Inspect/Replace Worn Parts
Assemble Minimum Pressure Valve
OIL SCAVENGE PIPE
Remove Oil Scavenge Pipe
Install Oil Scavenge Pipe
DRIVE MOTOR & COUPLING
Remove Coupling Rubber Inserts
Install Coupling Rubber Inserts
Remove Drive Motor
Install Drive Motor
AIR-END
Remove Air-End
Install Air-End
Remove Air-End Oil Seal
Install Air-End Oil Seal
OIL COOLER
Remove Oil Cooler
Clean Oil Cooler
Install Oil Cooler
AFTER COOLER
Remove After Cooler
Clean After Cooler
Install After Cooler
FAN & FAN MOTOR
Remove Fan and Fan Motor
Install Fan and Fan Motor
THERMOSTATIC BYPASS VALVE
Remove Thermostatic Bypass Valve
Install Thermostatic Bypass Valve

FIGURES
FIG. 9.1 SCAVENGE COUPLING TOOL
FIG. 9.2 AIR-END OIL SEAL INSTALLATION SLEEVE

Chapter 9, page 2

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

DISASSEMBLY & ASSEMBLY (345SR, L45SR)

WARNING
!

Refer to the safety procedures before

carrying out fault diagnosis or testing any
circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

1.

INLET NON-RETURN VALVE

WARNING: RISK OF HIGH
PRESSURE

Before opening the door of the starter

compartment, switch the power supply
OFF at the isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the
dc link capacitors have fully discharged
before starting any maintenance work.

6.

Remove the non-return valve assembly from

the air-end and discard the joint.

7.

Cover the hole in the air-end to prevent

contamination.

Install Inlet Non-Return Valve

1.1

Remove Inlet Non-Return Valve (fig. 9.1)

1.

Remove right hand side panel.

1.2

2.

Disconnect the air inlet pipe from the nonreturn valve [1].

Installation is a reversal of the removal procedure.

3.

Disconnect the wiring loom from the differential

pressure switch on the side of the non-return
valve [2].

4.

Disconnect the nylon pipe from the solenoid

valve [3]. Disconnect the wiring loom plug.

5.

Remove the fourscrews securing the nonreturn valve to the air-end inlet [4].

Note: Fit a new joint between the non-return valve

and the air-end.

FIG. 9.1 INLET NON-RETURN VALVE

AC20160-1822, Issue 1, November 2002

Chapter 9, page 3

CompAir

1.3

Disassemble Inlet Non-Return Valve

1.4

Inspect/Replace Worn Parts

1.

Remove the solenoid valve.

1.

Clean and inspect all parts for wear or damage.

2.

Place the valve upside down on a flat surface.

2.

Inspect valve head for signs of wear.

3.

Remove the two cap screws securing the

valve cover (fig. 9.2).

3.

Renew spring.

4.

Change all worn or damaged components for

new items.

1.5

Assemble Inlet Non-Return Valve

Parts required:
Major Service Kit, Part No CK8003-4
Assembly is a reversal of the disassembly
procedure.

FIG. 9.2 REMOVING VALVE COVER

4.

Remove the valve assembly, comprising the

valve head, spring and valve stem with
retaining bar.

FIG. 9.4 VALVE KIT COMPONENTS

FIG. 9.3 VALVE ASSEMBLY INTERNAL

Chapter 9, page 4

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

2.

MINIMUM PRESSURE VALVE

4.

Unscrew the bolt carefully to release the

compression on the piston spring.

2.1

Remove Minimum Pressure Valve

5.

Cover the hole in the manifold block to prevent

contamination (fig. 9.7).

1.

Remove the front service panel.

2.

Screw the bolt, supplied with the repair kit,

through the valve body into the piston (fig.
9.5).

HW 0407

HW 0405

FIG. 9.7 PROTECTIVE COVER

2.2

Install Minimum Pressure Valve

1.

Push the piston towards the valve body and

screw the bolt supplied in the repair kit through
the valve body into the piston. Turn the bolt to
draw the piston into the valve body (fig. 9.8).

FIG. 9.5 SECURING PISTON SPRING

WARNING
!

3.

Do not attempt to remove the valve

assembly from the manifold block before
taking up the compression on the piston
spring. Failure to heed this warning could
result in personal injury.

Fully unscrew the valve body and remove the

minimum pressure valve assembly from the
manifold block.
HW 0406

HW 0408

FIG. 9.8 SECURING PISTON SPRING

2.

Fit the minimum pressure valve assembly into

the manifold block using a new sealing washer
supplied in the repair kit.

3.

Unscrew and remove the bolt from the valve

body (fig. 9.9).
HW 0405

FIG. 9.6 REMOVING VALVE BODY

FIG. 9.9 RELEASING PISTON SPRING

AC20160-1822, Issue 1, November 2002

Chapter 9, page 5

CompAir

2.3

Disassemble Minimum Pressure Valve

1.

Remove the minimum pressure valve. Refer to

para. 2.1 Remove Minimum Pressure Valve.

2.

Remove the valve body (fig. 9.10(1)) and

piston spring (2).

3.

Remove the valve assembly (3), small

spring (4) and piston (6). Remove and discard
the O ring seal (5) from the outer groove of
the piston.
1

4.

Disassemble the valve assembly and discard

the O ring seals (fig 9.12 (7) and (8)).

HW 0409

HW 0410

FIG. 9.11 DISMANTLING VALVE

2
7

HW 0411

6
5

FIG. 9.12 VALVE COMPONENTS

4
3

FIG. 9.10 MINIMUM PRESSURE VALVE

Chapter 9, page 6

2.4

Inspect/Replace Worn Parts

Clean and inspect all the parts for wear or damage.

Inspect the surface of the piston for scratches.
Clean and inspect the valve body for any scoring or
corrosion inside the bore. If the bore of the valve
body is corroded, remove all traces of corrosion
using a fine emery paper until the surface is smooth
and clean. Apply a light coating of a silicone based
grease to the bore of the valve body before
reassembling the valve. Change all worn or
damaged components for new items.

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

2.5

Assemble Minimum Pressure Valve

3.

Parts Required:

Fit a new O ring seal (fig. 9.14 (5)) supplied in

the repair kit to the outer groove of the piston
(6).

Major Service Kit.

1.

Fit new O ring seals (fig. 9.13 (7) and (8)),

supplied in the service kit, to the guide pin and
valve head.

HW 0409

8
7

6
5

HW 0412

FIG. 9.13 MIN PRESS VALVE 'O' RING SEALS

2.

FIG. 9.14 MINIMUM PRESSURE VALVE

Assemble the valve using a new washer and

locknut supplied in the repair kit.

AC20160-1822, Issue 1, November 2002

4.

Insert the small spring (4) into the guide pin

and insert the valve assembly (3) into the bore
of the piston.

5.

Insert piston spring (2) into the valve body (1)

followed by the piston and valve assembly.

6.

Install the valve. Refer to para. 2.2 Install

Minimum Pressure Valve in this chapter.

Chapter 9, page 7

CompAir

3.

OIL SCAVENGE PIPE

3.1

Remove Oil Scavenge Pipe

WARNING
!

Ensure all air pressure is released from

the system in accordance with
'Dismantling Precautions' in Chapter 1

Tooling Required: Scavenge Coupling Tool

3 Holes permissible
in corners of hexagon
for manufacture
17 A/F HEX

12 A/F
HEX

3 Holes permissible
in corners of hexagon
for manufacture

20.5

17 A/F HEX

9.5

13
27

17
17

17

27

14 A/F
HEX

207
Material: EN 33

1.

2.

3.

HW 0413

FIG. 9.15 SCAVENGE COUPLING TOOL

Open the service door to gain access to the
manifold block.
Close the control air isolating valve (fig. 9.16
(1)).

Unscrew and remove the oil separator filters

(2).

HW 0414

FIG. 9.16 OIL SEPARATOR FILTERS

Chapter 9, page 8

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

4.

Fit the scavenge coupling tool (fig 9.15) over

the oil scavenge pipe as shown in fig. 9.17.
Undo and remove the coupling and oil
scavenge pipe assembly from the manifold
block (fig. 9.18)).

HW 0415

FIG. 9.17 USING SCAVENGE COUPLING TOOL

HW 0416

FIG. 9.18 REMOVING OIL SCAVENGE PIPE

3.2

Install Oil Scavenge Pipe

Installation is a reversal of the removal procedure.

Fit a new scavenge pipe and coupling to the
manifold block.
Note: Fit the scavenge pipe to the coupling before
installing it into the manifold block.

AC20160-1822, Issue 1, November 2002

Chapter 9, page 9

CompAir

4.

DRIVE MOTOR & COUPLING

4.1

Remove Coupling Rubber Inserts

1.

Remove motor side panel and open service

door.

2.

Remove motor baffle (fig. 9.19 (1)).

3.

Disconnect earth strap (2) from motor. Release

and remove bolts/washers securing motor to
AVMs (3).

4.

Place suitable temporary supports under the

air-end.

5.

Remove nuts securing the motor to the air-end

(fig. 9.20)

6.

Using suitable blocks to support the motor

feet, slide the motor away from the air-end to
allow access to the flexible coupling
(fig. 9.21(4)).

FIG. 9.19 REMOVING DRIVE MOTOR

Note: Take care not to move the motor beyond the

extent of the motor cable conduit.
7.

Remove coupling rubber inserts and discard.

4.2

Install Coupling Rubber Inserts

Fit new set of rubber inserts (fig. 9.21(5)) if required.

Installation is a reversal of the removal procedure.

FIG. 9.20 REMOVING MOTOR SECURING NUTS

Note: Remove temporary supports from under the

air-end after refitting the drive motor.

FIG. 9.21 DRIVE COUPLING

Chapter 9, page 10

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

4.3

Remove Drive Motor

WARNING
!

Refer to the safety procedures before

carrying out fault diagnosis or testing any
circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

1.

Carry out procedures under 4.1 Remove

Coupling Rubber Inserts.

2.

Remove side panels on reclaimer side.

4.4

Before opening the door of the starter

compartment, switch the power supply OFF
at the isolator and wait for 12 minutes to
allow the DC link capacitors to discharge to
a safe level. Check that the dc link
capacitors have fully discharged before start
ing any maintenance work.

Install Drive Motor

Installation is a reversal of the removal procedure.

FIG. 9.22 POWER CONVERTER

3.

Open power converter door and remove left

and right safety guards.

4.

Disconnect all of the SR motor leads (fig 9.22

(1)) from the power converter, including the
thermistor cables (2). Release the motor
conduit and rpt sensor lead.

5.

Use suitable lifting equipment to slide the

motor clear of unit. The motor can be pulled
out through the service door.
Approximate weight of motor: 340kg.

AC20160-1822, Issue 1, November 2002

Chapter 9, page 11

CompAir

5.

AIR-END

WARNING
!

Ensure all air pressure is released from

the system in accordance with
'Dismantling Precautions' in Chapter 1

5.1

Remove Air-End

1.

Remove motor side and end panels.

2.

Disconnect oil injection pipe and drain oil from

the air-end.

3.

Remove inlet non-return valve. (see para.1.1)

4.

Disconnect the discharge pipe flange from the

air-end (oil may still be present in the pipe).
Discard the O ring from the pipe flange.

5.

Disconnect cables at the temperature sensor

(fig. 9.23 (1)) and disconnect the scavenge oil
pipe (2) from the air-end.

FIG. 9.24 ANTI-VIBRATION MOUNT

FIG. 9.25 REMOVING MOTOR SECURING NUTS

8.

Remove bolts securing air-end to coupling

housing and remove air-end clear of the unit.
Approximate weight: 83kg

5.2

Install Air-End

Installation is a reversal of the removal procedure.

FIG. 9.23 AIR END CONNECTIONS
6.

7.

Remove nuts/washers securing the air-end to

the anti-vibration mounting (fig. 9.24 (1)).
Using suitable lifting gear, carefully raise airend to clear anti-vibration mounting stud. Place
temporary supports under drive motor.

Chapter 9, page 12

Note 1: Replace all 'O' ring seals and self centering

bonded seals.
Note 2: Prime the air-end with 1 litre of BroomWade
4000 HR oil or an approved alternative.
Note 3: Check oil level after running machine for 5
minutes and top up if necessary.

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

5.3

Remove Air-End Oil Seal

1.

Remove the air-end.

2.

Using a suitable puller, remove the flexible

coupling.

3.

Remove the oil seal housing by removing the 8

bolts and using two jacking screws.

4.

Remove the oil seal and gasket from the oil

seal housing and discard.

5.4

Install Air-End Oil Seal

1.

Ensure that the end bearings are undamaged

and that all debris has been removed from the
Air-End and oil seal housing before installing a
new oil seal.

2.

Fit the new oil seal into the oil seal housing.
Ensure that the seal is seated firmly in the
recess.

3.

Place the oil seal installation sleeve onto the

rotor drive shaft. The installation sleeve should
fit over the end of the shaft sleeve (fig. 9.27).

Tooling Required: Air-End Oil Seal

Installation Sleeve (see fig. 9.26).

FIG. 9.27 INSTALLATION SLEEVE IN POSITION

4.

Install a new gasket to the Air-End.

5.

Carefully lower the oil seal housing onto the

Air-End, ensuring that the new oil seal fully
engages the shaft sleeve without twisting.

6.

Fit the bolts and washers, tighten them

progressively as shown using a torque of
57 Nm (42 lb.ft.) to secure the oil seal housing

7.

Remove the installation sleeve.

8.

Refit coupling.

9.

Install air-end. Refer to para. 5.2 Install AirEnd.

FIG. 9.26 AIR-END OIL SEAL INSTALLATION

SLEEVE

AC20160-1822, Issue 1, November 2002

Chapter 9, page 13

CompAir

6.

OIL COOLER

6.1

Remove Oil Cooler

WARNING
!

Ensure electrical power is isolated in

accordance with 'Dismantling
Precautions' in Chapter 1

1.

Remove the end panel, roof panel, side panels

and exhaust baffle from the compressor unit.

2.

Disconnect oil inlet and outlet pipes (fig 9.28)

from cooler and let the oil drain from the
cooler.

FIG. 9.29 FAN MOTOR CABLES

98154-300

FIG. 9.30 FAN MOTOR CONDUIT

INLET

OUTLET

4.

Remove the air inlet filter (fig. 9.31 (1)) and air
inlet pipe (2) from non-return valve (3).

98154-350

OUTLET
INLET
HW 0432

FIG. 9.28 OIL COOLER CONNECTIONS

3.

Disconnect the fan motor cables from the fan

contactor (RLC) and earth bar. Disconnect
thermistors where fitted (fig. 9.29). Disconnect
fan motor conduit from the power converter
enclosure (fig. 9.30).

Chapter 9, page 14

FIG. 9.31 AIR INLET CONNECTIONS

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

5.

Remove the six screws securing the

plenum chamber to the side frames.

6.

Remove the fan assembly through the end of

the machine.

7.

Remove the rail at the top of the end frame.

8.

Remove cross brace at rear of machine.

9.

Remove the rail at the top of the end frame.

6.3

10.

Remove cross brace at rear of machine.

Installation is a reversal of the removal procedure.

6.2

Clean Oil Cooler

The cooler should be removed and cleaned as

normal practice during Routine Maintenance.
Cleaning of the oil cooler should be carried out by
flushing through with a suitable degreaser, detergent
or vapour solvent.

Install Oil Cooler

FIG. 9.32 REMOVING FAN ASSEMBLY

11.

Remove the exhaust duct plate (if fitted).

12.

Secure the oil cooler using straps or ropes so

that it will not fall when the screws are
removed.

13.

Loosen four nuts and bolts securing the oil

cooler.

Note: Approximate weight of oil cooler: 52Kg

14.

Loosen the screws securing the side frames

to the base frame and power converter.

15.

Remove four nuts and bolts securing the oil

cooler.

16.

Use two people to lift the cooler or cooler/

support assembly out of the unit.

AC20160-1822, Issue 1, November 2002

Chapter 9, page 15

CompAir

7.

AFTER COOLER

7.2

7.1

Remove After Cooler

The cooler should be removed and cleaned as

normal practice during Routine Maintenance.

WARNING
!

Ensure all air pressure is released from

the system in accordance with
'Dismantling Precautions' in Chapter 1

Accumulated dirt in the fins of the air cooler can

normally be removed using compressed air or a
steam cleaner. Cleaning should be carried out from
the reverse side to the air flow.

7.3
1.

2.

Open the service door from the front of the

compressor unit.

Clean After Cooler

Install After Cooler

Installation is a reverse of the removal procedure.

Remove inlet baffle (fig. 9.33(1)).

FIG. 9.33 REMOVING AFTERCOOLER

3.

Loosen air delivery pipe between cooler and

filter block.

4.

Disconnect cooler from users pipework.

5.

Disconnect plastic pipe to pressure transducer.

4.

Disconnect regulation air pipe from cooler to

pressure transducer.

5.

Remove two screws securing cooler to

baseframe (2).

6.

Remove air delivery pipe between cooler and

filter block.

7.

Lift the cooler out of the unit.

Note: Approximate weight of after cooler: 23Kg

Chapter 9, page 16

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

8.

FAN & FAN MOTOR

5.

Slide the plenum chamber and fan assembly

(fig. 9.35) through the end of the machine.

WARNING
!

Ensure electrical power is isolated in

accordance with 'Dismantling
Precautions' in Chapter 1

8.1

Remove Fan and Fan Motor

1.

Remove side and end panels.

2.

Disconnect the fan motor cables from the fan

contactor (RLC) and earth bar. Disconnect
thermistors where fitted (fig. 9.29). Disconnect
fan motor conduit from the power converter
enclosure (fig. 9.30).

3.

Remove the air filter (fig. 9.34 (1)) and

disconnect air inlet pipe (2) from the non-return
valve (3).

FIG. 9.35 FAN ASSEMBLY

6.

Lay the fan/motor/cowling assembly on a flat

surface with the fan guard and motor
uppermost.

7.

Remove the fan guard.

8.

Support fan/motor assembly with suitable lifting

gear and remove four nuts/washers/bolts (fig.
9.36) securing fan arms to fan cowling. Lift fan/
motor and arms clear. Remove fan arms from
motor.

FIG. 9.36 FAN MOTOR RETAINING BOLTS

FIG. 9.34 AIR INLET CONNECTIONS

4.

Remove six screws and washers securing the

plenum chamber to the side frames.

AC20160-1822, Issue 1, November 2002

8.2

Install Fan and Motor

Installation is a reversal of the removal procedure.

Chapter 9, page 17

CompAir

9.

THERMOSTATIC BYPASS VALVE

9.1

Remove Thermostatic Bypass Valve

1.

Remove the reclaimer side panel, roof panel

and exhaust baffle assembly.

2.

Unscrew valve plug from pocket in cooler

header (fig. 9.37).

3.

Remove the valve from the cooler complete

with return spring (fig. 9.38).

FIG. 9.38 THERMOSTATIC BYPASS VALVE

Note: The thermostatic valve is supplied as a
complete unit and must be changed if defective.

FIG. 9.37 REMOVING THERMOSTATIC BYPASS

VALVE

4.

Check the thermostat element by immersing

it in a water bath at approximately 6C above
the nominal setting. Bypass port B should
close. The nominal setting of the valve will
be found stamped on the end of the element.

9.2

Install Thermostatic Bypass Valve

Installation is a reversal of the removal procedure.

Install a new sealing washer when fitting the plug.

Chapter 9, page 18

AC20160-1822, Issue 1, November 2002

SR Repair Manual Disassembly & Assembly

DISASSEMBLY AND ASSEMBLY

B - 475SR, L75SR
1.
1.1
1.2
1.3
1.4
1.5
2.
2.1
2.2
2.3
2.4
3.
3.1
3.2
3.3
3.4
3.5
4.
4.1
4.2
4.3
4.4
5.
5.1
5.2
5.3
5.4
6.
6.1
6.2
6.3
7.
7.1
7.2
8.
8.1
8.2

MINIMUM PRESSURE VALVE

Remove Minimum Pressure Valve
Install Minimum Pressure Valve
Disassemble Minimum Pressure Valve
Inspect/Replace Worn Parts
Assemble Minimum Pressure Valve
RECLAIMER
Remove Reclaimer Element
Install Reclaimer Element
Remove Reclaimer
Install Reclaimer
NON-RETURN VALVE
Remove Non-Return Valve
Install Non-Return Valve
Disassemble Non-Return Valve
Inspect/Replace Worn Parts
Assemble Non-Return Valve
DRIVE MOTOR & COUPLING
Remove Coupling Rubber Inserts
Install Coupling Rubber Inserts
Remove Drive Motor
Install Drive Motor
AIR-END
Remove Air-End
Install Air-End
Remove Air-end Oil Seal
Install Air-end Oil Seal
AIR/OIL COOLER
Remove Air/Oil Cooler Assembly
Clean Air/Oil Cooler
Install Air/Oil Cooler
FAN & FAN MOTOR
Remove Fan & Fan Motor
Install Fan & Fan Motor
THERMOSTATIC BYPASS VALVE
Remove Thermostatic Bypass Valve
Install Thermostatic Bypass Valve

FIGURES
FIG. 9.3
FIG. 9.4
FIG. 9.5
FIG. 9.6

SCAVENGE PIPE
AIR-END OIL SEAL INSTALLATION SLEEVE
THERMOSTATIC BYPASS VALVE
THERMOSTATIC BYPASS VALVE - LATER COOLER

AC20160-1822, Issue 1, October 2002

Chapter 9, page 19

CompAir

DISASSEMBLY & ASSEMBLY (475SR, L75SR)

WARNING

1.

Refer to the safety procedures before

carrying out fault diagnosis or testing
any circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate
the power supply before starting any
maintenance work.

Before opening the door of the starter

compartment, switch the power supply
OFF at isolator and wait for 12 minutes to
allow the dc link capacitors to discharge to
a safe level. Check that the dc link
capacitors have fully discharged before
starting any maintenance work.

MINIMUM PRESSURE VALVE

WARNING: RISK OF HIGH

PRESSURE

1.1

Remove Minimum Pressure Valve

1.

Open the service door of the compressor. Remove

the reclaimer side panel.

2.

Remove the two bolts/washers from the delivery

pipe coupling flange on the minimum pressure valve
Disconnect the pipe to the differential pressure
indicator and remove. If the valve is to be
disassembled, loosen the piston housing from valve
body by two threads (fig. 9.39).

3.

Release the four nuts/washers securing the minimum

pressure valve to the reclaimer cover. Remove the
valve. Remove the O ring seals from the reclaimer
cover and the delivery pipe flange and discard
(fig. 9.40).

4.

Cover the hole in the reclaimer cover to prevent

contamination.

1.2

Install Minimum Pressure Valve

FIG. 9.39 MINIMUM PRESSURE VALVE

PI/98/023

Installation is a reversal of the removal procedure.

Note: Fit new O rings between the valve and reclaimer
cover and between the valve and delivery pipe flange.
Apply Autol Top 2000 grease to the O rings before
fitting.

Chapter 9, page 20

FIG. 9.40 REMOVING MINIMUM PRESSURE

VALVE

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

1.3 Disassemble Minimum Pressure Valve

1.

Remove the minimum pressure valve. Refer to para.

1.1 Remove Minimum Pressure Valve.

2.

Take a 250mm length of M8 x 125 threaded rod

and insert through hole in top face of piston housing.
Screw the rod into the piston to the bottom of the
thread. Run a washer and nut down the exposed rod
and turn the nut 2 full turns against the piston
housing to compress the springs.

3.

Using a suitable vice unscrew the valve body from

the piston housing (fig. 9.41).

4.

Remove the valve assembly, comprising the valve

head, guide pin and spring, from the piston. Remove
and discard the O ring from the piston housing
mating face. Unscrew the 8mm nut on the threaded
rod until the springs are fully relaxed. Remove and
discard the O ring from the piston diameter (fig.
9.42). Remove the threaded rod, nut and washer and
lift the piston and springs from the housing.

5.

Hold the stem of the guide pin across the flat in soft
vice jaws. Do not overtighten the vice. Unscrew the
locknut from the guide pin and remove the washer,
valve head, O ring and retainer. Discard the O
ring. Remove and discard the O ring from the guide
pin stem (fig. 9.43).

1.4

Inspect/Replace Worn Parts

1.

Clean and inspect all parts for wear or damage.

2.

Inspect all surfaces of the piston for scratches.

3.

Clean and inspect the valve body for any scoring or

corrosion inside the piston bore.

FIG. 9.41 REMOVING VALVE BODY FROM

PISTON HOUSING

FIG. 9.42 PISTON DIAMETER WITH 'O' RING

REMOVED

Note: If the piston bore of the valve body is corroded

remove all traces of corrosion using a fine emery paper
until the surface is smooth and clean.
4.

Change all worn or damaged components for new

items.

FIG. 9.43 VALVE HEAD ASSEMBLY

AC20160-1822, Issue 1, October 2002

Chapter 9, page 21

CompAir

1.5

Assemble Minimum Pressure Valve

Parts required:
Major Service Kit, Part No CK8004-5
1.

Hold the piston housing in a suitable vice and apply

Autol Top 2000 grease to the bore of the housing.
Apply Shell Abida R2 grease to the valve springs
and locate in the bore of the housing.

2.

Screw a 250mm length of M8x125 threaded rod into

the piston and insert through the springs and
housing to enter the piston into the bore. Take care
to locate the springs correctly against the rear face
of the piston. Run a washer and nut on the exposed
threaded rod and tighten until the springs are just
compressed.

3.

Apply Autol Top 2000 grease to the new O ring

seal and fit to the groove of the piston. Tighten nut
on threaded rod to compress the springs and draw
the piston into the housing, taking care to avoid
damage to the O ring (fig. 9.44).

4.

Apply Autol Top 2000 grease to the new O ring

seals and assemble the valve head, O rings and
retainer with the guide pin using a new washer and
locknut. Tighten the locknut to a torque of 20Nm (15
lb.ft.). Do not overtighten (fig. 9.45).

5.

Apply Shell Abida R2 grease to the valve spring and

insert into the guide pin. Insert the valve assembly
into the bore of the piston. Apply Autol Top 2000
grease to the new O ring and locate in the groove in
the mating face of the piston housing. Apply light
coating of Loctite 577 to the threads of the piston
housing (fig. 9.46).

6.

Screw the valve body to the piston housing and

tighten to compress the O ring.

7.

Release the nut on the threaded rod and remove rod

from valve.

FIG. 9.44 ASSEMBLING PISTON

FIG. 9.45 ASSEMBLING VALVE HEAD

FIG. 9.46 FITTING VALVE HEAD TO PISTON

Chapter 9, page 22

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

2.

RECLAIMER

WARNING: RISK OF HIGH

PRESSURE

2.1

Remove Reclaimer Element

1.

Open the service door of the compressor. Remove

the reclaimer side panel.

2.

Remove the minimum pressure valve (see para.1.1).

3.

Disconnect and withdraw the oil scavenge pipe.

Disconnect and remove the regulation air pipe from
the reclaimer cover (fig. 9.47).

4.

Remove 10 bolts securing the reclaimer cover.

5.

Use jacking screws to break the seal between the

cover and reclaimer body (fig. 9.48).

6.

Carefully remove the cover complete with old joint.

Discard the old joint.

7.

Remove and discard the old reclaimer element (fig.

9.49).

Note: Inspect underside of reclaimer cover for any signs of

corrosion. Remove any loose paint or rust by shot blasting
or wire brush treatment to leave a clean, oil free surface.
Apply one coat of zinc phosphate paint, ensuring complete
coverage to a minimum thickness of 01 mm.

FIG. 9.47 DISCONNECTING REGULATION

AIR PIPE

FIG. 9.48 REMOVING RECLAIMER COVER

FIG. 9.49 REMOVING RECLAIMER

ELEMENT

AC20160-1822, Issue 1, October 2002

Chapter 9, page 23

CompAir

2.2

Install Reclaimer Element

Installation is a reversal of the removal procedure.

Note: Fit new joint to the reclaimer joint face and tighten
the reclaimer cover bolts in sequence to a torque setting of
410Nm (fig. 9.50). Re-tighten bolts after 8 hours running.

FIG. 9.51 SCAVENGE PIPE

FIG. 9.50 BOLT TIGHTENING SEQUENCE

CAUTION: The scavenge pipe must be fitted so that it
curves towards the centre of the reclaimer element (see
Fig. 9.51). When fitted correctly there should be no gap
between the pipe couplings. Failure to position the pipe
correctly will result in high oil carry over.

2.3

Remove Reclaimer

1.

Remove the roof panel above the reclaimer.

2.

Drain oil from the reclaimer.

3.

Disconnect electrical wiring from excess pressure

switch (fig. 9.52) and remove the plastic pipe to the
differential pressure switch.

4.

Remove minimum pressure valve (see para. 1.1).

5.

Disconnect the plastic scavenge pipe and the

regulation air pipe.

6.

Disconnect the coupling flange of the air inlet pipe at

the side of the reclaimer and secure the pipe to
provide clearance. Remove and discard the O ring
from the pipe flange (fig. 9.53).

FIG. 9.52 DISCONNECTING EXCESS

PRESSURE SWITCH

FIG. 9.53 DISCONNECTING AIR INLET PIPE

Chapter 9, page 24

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

7.

Disconnect the oil pipe between reclaimer and cooler

at the reclaimer end and secure the pipe to provide
clearance (fig. 9.54).
Note: Some oil may drain out of the cooler.

8.

Remove the screws securing the intake air filter to the

reclaimer. Move the filter aside and secure to provide
clearance.

9.

Fit eyebolts in the jacking holes on reclaimer cover

and using a suitable hoist, support the reclaimer.

10.

Release and remove three reclaimer mounting bolts

(fig. 9.55).

11.

Lift the reclaimer clear of the unit.

2.4

Install Reclaimer

FIG. 9.54 OIL PIPE - COOLER/RECLAIMER

Installation is a reversal of the removal procedure.

Note: Refill the reclaimer with oil (refer to 2.8.5 in Chapter 6
under Normal Oil Change).

3.

NON-RETURN VALVE
WARNING: RISK OF HIGH
PRESSURE
FIG. 9.55 RECLAIMER MOUNTING BOLTS

3.1

Remove Non-Return Valve

1.

Open the service door of the compressor. Remove

the reclaimer side panel.

2.

Drain oil from air-end and place suitable catch tray

under non-return valve.

3.

Remove the two nuts/washers from the discharge

pipe coupling flange on the non-return valve (fig.
9.56). Remove and discard the O ring from the pipe
flange. If the valve is to be disassembled loosen the
cover from the valve body by about two threads.

Note: Oil may still be present in the pipe.

4.

Disconnect the plastic pipe to the oil stop valve.

5.

Remove the four nuts/washers securing the non-return

valve to the air-end. Remove the valve. Remove and
discard the O ring.

AC20160-1822, Issue 1, October 2002

FIG. 9.56 DISCONNECTING DISCHARGE

PIPE

Chapter 9, page 25

CompAir

3.2

Install Non-Return Valve

Installation is a reversal of the removal procedure.

Note 1: Fit new O rings between the valve and air-end and
between the valve and discharge pipe flange. Apply Autol
Top 2000 grease to the O rings before fitting.
Note 2: After installing the non-return valve prime the airend as follows:
Remove the air intake filter and pour into the air-end 1 litre
of BroomWade 4000HR oil or an approved alternative.
Replace the intake filter.

3.3

Disassemble Non-Return Valve

1.

Remove the non-return valve. Refer to 3.1 Remove

Non-Return Valve.

2.

Using a suitable vice, unscrew the valve body from

the cover (fig. 9.57). Remove the valve assembly,
comprising the valve head, guide pin and spring, from
the cover. Remove and discard the O ring from the
cover mating face.

3.

Hold the stem of the guide pin across the flat in soft
vice jaws (fig. 9.58). Do not overtighten the vice.
Unscrew the locknut from the guide pin and remove
the washer, valve head, O ring and retainer. Discard
the O ring. Remove and discard the O ring from the
guide pin stem.

3.4

Inspect/Replace Worn Parts

1.

Clean and inspect all parts for wear or damage.

Change all worn or damaged components for new
items.

3.5

Assemble Non-Return Valve

FIG. 9.57 REMOVING VALVE COVER

FIG. 9.58 DISMANTLING VALVE HEAD

Parts required:
Major Service Kit, Part No CK8004-5
1.

Assemble the valve head, O rings and retainer with

the guide pin using a new washer and locknut.
Tighten the locknut to a torque of 20Nm (15 lb.ft.). Do
not overtighten.

2.

Hold the valve cover in the vice across the flats of

the hexagon. Apply Shell Albida R2 grease to the

Chapter 9, page 26

FIG. 9.59 FITTING VALVE ASSY TO COVER

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

new valve spring and insert the spring into the guide
pin. Insert the valve assembly into the cover (fig.
9.59).
3.

Apply Autol Top 2000 grease to the new O ring and

locate in groove in the mating face of the valve cover.

4.

Screw the valve body to the valve cover and tighten

to compress the O ring.

5.

Install the valve. Refer to 3.2, Install Non-Return

Valve.

4.

DRIVE MOTOR & COUPLING

4.1

Remove Coupling Rubber Inserts

1.

Remove two side panels at motor end.

2.

Disconnect earth strap from motor. Release and

remove bolts/washers securing motor to feet (fig.
9.60). Unclip control harness from motor foot.

3.

Disconnect motor and thermistor leads (refer to

Chapter 8 para 9.7).

4.

Unscrew gland nut from motor cable conduit in side of

starter box and ease motor power cables out of the
starter box and secure.

5.

Place suitable temporary supports under the air-end.

6.

Remove bolts securing the motor to the air-end (fig.

9.61).

7.

Using suitable blocks to support the motor pedestal,

slide the motor away from the air-end to allow access
to the flexible coupling (fig. 9.62).

8.

Remove coupling rubber inserts and discard.

4.2

Install Coupling Rubber Inserts

FIG 9.60 MOTOR MOUNTING FEET

FIG 9.61 MOTOR/AIR END SECURING BOLTS

Fit new set of rubber inserts (12) if required.

Installation is a reversal of the removal procedure.
Note: Remove temporary supports from under the air-end
after removing the drive motor.
FIG 9.62 DRIVE COUPLING

AC20160-1822, Issue 1, October 2002

Chapter 9, page 27

CompAir

4.3 Remove Drive Motor

WARNING

Refer to the safety procedures before

carrying out fault diagnosis or testing
any circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate
the power supply before starting any
maintenance work.

1.

Carry out procedures under 4.1 Remove Coupling

Rubber Inserts.

2.

Disconnect the RPT lead from the controller (fig.

9.63).

3.

Unscrew gland plate from converter.

4.

Disconnect delivery air pipe from the moisture

separator.

5.

Remove delivery panel, inlet grille and inlet panel.

6.

Remove inlet baffle complete with sound insulation

(fig 9.64).

7.

Use a suitable piece of steel plate to slide the motor

clear of unit.

Before opening the door of the starter

compartment, switch the power supply
OFF at isolator and wait for 12 minutes to
allow the dc link capacitors to discharge to
a safe level. Check that the dc link
capacitors have fully discharged before
starting any maintenance work.

Approximate weight: 340kg.

FIG. 9.63 CONTROLLER
4.4

Install Drive Motor

Installation is a reversal of the removal procedure.

FIG. 9.64 INLET BAFFLE

Chapter 9, page 28

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

5.

AIR-END

WARNING

Ensure all air pressure is released from the

system and electrical power is isolated in
accordance with Dismantling Precautions in
Chapter 1.

5.1

Remove Air-End

1.

Open compressor service door and lift from hinges.

Remove roof panel and reclaimer side panel.

2.

Drain oil from the air-end and disconnect the oil drain
pipe.

3.

Disconnect the discharge pipe flange from the nonreturn valve end (oil may still be present in the pipe)
(fig. 9.65). Discard the O ring from the pipe flange.
Disconnect the non-return valve.

4.

Disconnect cables at the inlet air filter switch.

Disconnect cables at the temperature sensor and
disconnect the scavenge oil pipe from the air-end (fig.
9.66).

5.

Disconnect the regulation air pipe from the oil stop

valve (fig. 9.67). Remove the oil stop valve and
secure to provide clearance.

FIG. 9.65 DISCONNECTING DISCHARGE

PIPE

FIG. 9.66 AIR END CONNECTIONS

FIG. 9.67 OIL STOP VALVE

AC20160-1822, Issue 1, October 2002

Chapter 9, page 29

CompAir

6.

Remove intake air filter.

7.

Remove flexible hose from the bypass valve and

remove air inlet elbow/bypass assembly. Block airend inlet to ensure no debris falls in.

8.

Remove nuts/washers securing the air-end to the

anti-vibration mounting (fig. 9.68).

9.

Using suitable lifting gear, carefully raise air-end to

clear anti-vibration mounting stud. Place temporary
supports under drive motor.

10.

Remove bolts securing air-end to coupling housing

and remove air-end clear of the unit.

FIG. 9.68 AIR END A.V.M.

Approximate weight: 160kg

5.2

Install Air-End

Installation is a reversal of the removal procedure.

Note 1: Replace all 'O' ring seals, copper and Dowty seals.
Note 2: Prime the air-end with 1 litre of BroomWade 4000
HR oil or an approved alternative.

5.3

Remove Air-End Oil Seal

1.

Remove the air-end.

2.

Using a suitable puller, remove the flexible coupling.

3.

Remove the oil seal housing by removing the 8 bolts

and using two jacking screws.

4.

Remove the oil seal and gasket from the oil seal
housing and discard.

5.4

Install Air-End Oil Seal

FIG. 9.69 INSTALLATION SLEEVE IN

POSITION

Tooling Required: Air-End Oil Seal Installation

Sleeve
1.

Ensure that the end bearings are undamaged and that

all debris has been removed from the Air-End and oil
seal housing before installing a new oil seal.

2.

Fit the new oil seal into the oil seal housing. Ensure
that the seal is seated firmly in the recess.

3.

Place the oil seal installation sleeve onto the rotor

Chapter 9, page 30

FIG. 9.70 AIR-END OIL SEAL INSTALLATION

SLEEVE

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

drive shaft. The installation sleeve should fit over the

end of the shaft sleeve.
4.

Install a new gasket to the Air-End.

5.

Carefully lower the oil seal housing onto the Air-End,

ensuring that the new oil seal fully engages the shaft
sleeve without twisting.

6.

Fit the bolts and washers, tighten them progressively

as shown using a torque of 57 Nm (42 lb.ft.) to secure
the oil seal housing

7.

Remove the installation sleeve.

8.

Refit coupling.

9.

Install air-end. Refer to para. 5.2 Install Air-End.

6.

AIR/OIL COOLER

FIG. 9.71 REMOVING FAN GUARD

WARNING
!

Ensure all air pressure is released from the

system and electrical power is isolated in
accordance with Dismantling Precautions in
Chapter 1.

6.1

Remove Air/Oil Cooler Assembly

1.

Remove two side panels at motor end.

2.

Remove fan guard from fan cowling and disconnect

fan motor cables and thermistor cables from fan
motor terminal box and remove cables (fig. 9.71).

3.

Disconnect air delivery pipe from moisture separator.

4.

Remove delivery panel, inlet grille and inlet panel.

5.

Remove exhaust panel and grille from roof and

remove acoustic baffle assembly.

6.

Position suitable funnel and container beneath oil pipe

connections at cooler. Disconnect oil inlet and outlet
pipes from cooler and drain oil from pipes and cooler
(fig. 9.72). Secure pipes to provide clearance. Fit
temporary plugs to pipe connections at cooler.

7.

Disconnect and remove reclaimer discharge pipe from

cooler and minimum pressure valve (fig. 9.73).

FIG. 9.72 OIL COOLER INLET AND OUTLET

PIPES

FIG. 9.73 RECLAIMER DISCHARGE PIPE

AC20160-1822, Issue 1, October 2002

Chapter 9, page 31

CompAir

8.

Disconnect drain pipe from moisture separator and

secure to provide clearance. Disconnect wiring plug
from drain solenoid valve. Remove solenoid valve and
strainer from moisture separator.

9.

Remove three screws securing heat sink duct to fan

support and starter box backplate and remove duct
(fig. 9.74).

FIG. 9.75 RELEASING COOLER FIXINGS

FIG. 9.74 HEAT SINK DUCT

10.

Remove 4 nuts/bolts/washers securing cooler to

cooler supports (fig. 9.75).

11.

Position rope or webbing slings under cooler sides

and hoist cooler clear complete with moisture
separator, fan support and fan motor/cowling (fig.
9.76).

12.

Transfer to flat surface to stand on fan cowling.

Position on blocks to give clearance for fan motor
(fig. 9.77).

13.

Remove moisture separator from cooler. Remove 16

bolts/washers securing cooler to fan supports and lift
cooler clear.

6.2

Clean Air/Oil Cooler

FIG. 9.76 HOISTING COOLER

The cooler should be removed and cleaned as normal

practice during Routine Maintenance.
Externally. Accumulated dirt in the fins of the air side of
the cooler can normally be removed using compressed air
or a steam cleaner. Cleaning should be carried out from the
reverse side to the air flow (top of the cooler).

FIG. 9.77 COOLER/FAN ASSY.

Internally. Cleaning of the oil side only should be carried

out by flushing through with a suitable degreaser, detergent
or vapour solvent.

Chapter 9, page 32

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

6.3

Install Air/Oil Cooler

Installation is a reversal of the removal procedure.

Note 1: Replace all O ring seals and copper washers with
new items.
Note 2: After installation replenish reclaimer with oil (refer
to Chapter 7, para 2.9.5 under Normal Oil Change).

7.

FAN & FAN MOTOR

WARNING
!

Ensure all air pressure is released from the

system and electrical power is isolated in
accordance with Dismantling Precautions in
Chapter 1.

7.1

Remove Fan & Fan Motor

1.

Remove Cooler as in para. 6.1.

2.

Remove 8 bolts/washers securing fan cowling to fan

support fig. 9.78). Lift fan support clear.

3.

Invert fan/motor/cowling assembly.

4.

Support fan/motor assembly with suitable lifting gear

and remove four nuts/washers/bolts securing fan
arms to fan cowling fig. 9.79). Lift fan/motor and arms
clear. Remove fan arms from motor.

7.2

Install Fan & Fan Motor

FIG. 9.78 FAN COWL FIXINGS

Installation is a reversal of the removal procedure.

FIG. 9.79 FAN MOTOR FIXINGS

AC20160-1822, Issue 1, October 2002

Chapter 9, page 33

CompAir

8.

THERMOSTATIC BYPASS VALVE

(Earlier model coolers)

WARNING
!

8.1

Ensure all air pressure is released from the

system and electrical power is isolated in
accordance with Dismantling Precautions
in Chapter 1.
Remove Thermostatic Bypass Valve
FIG. 9.80 REMOVING VALVE CAP

1.

Open the service door.

2.

Unscrew valve cap from pocket in cooler header (fig.

9.80). Remove and discard the 'O' ring.

3.

Remove the valve and return spring.

Note: The thermostatic valve is supplied as a complete

unit and must be changed if defective.
8.2

Install Thermostatic Bypass Valve

Installation is a reversal of the removal procedure.

Note: Fit a new O ring seal and install the valve the
correct way up in the cooler pocket as shown in Fig. 9.81,
i.e. with the spring underneath and the wax element facing
downwards.
8.3

Remove AMOT Valve (Later model coolers)

1.

Open service door.

2.

Remove Amot valve from reclaimer.

8.2

Install Amot Valve

FIG. 9.81 THERMOSTATIC BYPASS VALVE

(Earlier model coolers)

FIG. 9.82 THERMOSTATIC BYPASS VALVE

(Later model coolers)

Chapter 9, page 34

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SR Repair Manual Disassembly & Assembly

DISASSEMBLY & ASSEMBLY

C - L120SR
1.
1.1
1.2
1.3
1.4
1.5
2.
2.1
2.2
2.3
2.4
2.5
3.
3.1
3.2
3.3
3.4
4.
4.1
4.2
4.3
4.4
5.
5.1
5.2
5.3
5.4
6.
6.1
6.2
6.3
6.4
6.5
6.6
7.
7.1
7.2
8
8.1
8.2
9.
9.1
9.2

INLET NON-RETURN VALVE

Remove Inlet Non-Return Valve
Install Inlet Non-Return Valve
Disassemble Inlet Non-Return Valve
Inspect/Replace Worn Parts
Assemble Inlet Non-Return Valve
MINIMUM PRESSURE VALVE
Remove Minimum Pressure Valve
Install Minimum Pressure Valve
Disassemble Minimum Pressure Valve
Inspect/Replace Worn Parts
Assemble Minimum Pressure Valve
RECLAIMER
Remove Reclaimer Element
Install Reclaimer Element
Remove Reclaimer
Install Reclaimer
DRIVE MOTOR & COUPLING
Remove Coupling Rubber Inserts
Install Coupling Rubber Inserts
Remove Drive Motor
Install Drive Motor
AIR-END
Remove Air-End
Install Air-End
Remove Air-End Oil Seal
Install Air-End Oil Seal
COOLERS
Remove After Cooler
Install After Cooler
Clean After Cooler
Remove Oil Cooler
Install Oil Cooler
Clean Oil Cooler
FAN & FAN MOTOR
Remove Fan and Fan Motor
Install Fan and Fan Motor
THERMOSTATIC BYPASS VALVE
Remove Thermostatic Bypass Valve
Install Thermostatic Bypass Valve
BEKO DRAIN
Removal and Servicing
Installation

FIGURES
FIG. 9.7 RECLAIMER COVER BOLT TIGHTENING SEQUENCE
FIG. 9.8 AIR-END OIL SEAL INSTALLATION SLEEVE

AC20160-1822, Issue 1, October 2002

Chapter 9, page 35

CompAir

DISASSEMBLY & ASSEMBLY (L120SR)

WARNING

Refer to the safety procedures before

carrying out fault diagnosis or testing any
circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

1.

Before opening the door of the starter

compartment, switch the power supply
OFF at the isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the
dc link capacitors have fully discharged
before starting any maintenance work.

INLET NON-RETURN VALVE

WARNING: RISK OF HIGH
PRESSURE

1.1

Remove Inlet Non-Return Valve

1.

Open access doors on the motor side.

2.

Disconnect the air filter outlet hose (fig. 9.83

(5)) from the non-return valve (1) by releasing
hose clips (3).

3.

Disconnect the air filter switch pipe elbow (2)

from the non-return valve.

4.

Disconnect the blowdown flexible hose (10).

5.

Remove the four screws (6) and spring

washers (7) securing the non-return valve to
the air end assembly (9). Discard joint (8).

6.

Cover the hole in the air-end with tape to

prevent contamination.

1.2

Install Inlet Non-Return Valve

2
1
4
5
6, 7
9

FIG. 9.83 AIR INLET CONNECTIONS

Installation is a reversal of the removal procedure.

Note: Fit a new joint between the non-return valve
and the air-end.

Chapter 9, page 36

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

1.3

Disassemble Inlet Non-Return Valve

1.

Place the valve assembly (fig. 9.84 (10)) on a

flat surface.

2.

Remove the domed screw (11) and seal (12).

3.

The valve stem assembly, comprises the air

inlet valve head (13), bush (14), spring (15) and
valve stem (16). Remove the valve stem
assembly by moving the valve head to
compress the spring and pushing the stem
forward and driving the assembly out through
the bottom of the valve.
14
10
12

13

11

16

15

FIG. 9.84 INLET/NON-RETURN VALVE

1.4

Inspect/Replace Worn Parts

1.

Clean and inspect all parts for wear or damage.

2.

Inspect air inlet valve head for signs of wear.

3.

Change all worn or damaged components for

new items.

1.5

Assemble Inlet Non-Return Valve

1.

Assembly is a reversal of the disassembly

procedure.

AC20160-1822, Issue 1, October 2002

Chapter 9, page 37

CompAir

2.

MINIMUM PRESSURE VALVE

2.1

Remove Minimum Pressure Valve

1.

Remove the left front service door and

'reclaimer access' roof panel.

2.

Remove the four bolts and washers securing

the aftercooler inlet pipe (1) to the minimum
pressure valve (2). Discard Viton 'O' ring.

5.

Cover the hole in the reclaimer cover to

prevent contamination.

2.2

Install Minimum Pressure Valve

1.

Fitting the minimum pressure valve is the

reverse of the removal procedure given in 2.1.

Note: Fit a new seal on installation.

FIG. 9.85 MINIMUM PRESSURE VALVE

4.

Remove the four nuts (fig. 9.86(4)) and

washers securing the minimum pressure valve
(2) to the reclaimer cover (5) together with the
seal. Discard the seal (6).

FIG. 9.86 M. P. VALVE & RECLAIMER

Chapter 9, page 38

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

2.3

Disassemble Minimum Pressure Valve

1.

Remove the minimum pressure valve. Refer to

para. 2.1 Remove Minimum Pressure Valve.

2.

Take a 250mm length of M8 x 125 threaded

rod and insert through hole in top face of
piston housing (fig. 9.87 (1)). Screw the rod
into the piston to the bottom of the thread. Run
a washer and nut down the exposed rod and
turn the nut 2 full turns against the piston
housing to compress the springs.

FIG. 9.88 SECTIONAL ARRANGEMENT M. P. VALVE

FIG. 9.87 DISMANTLING M. P. VALVE

3.

4.

Remove the four screws (2) and washers (3)

securing the piston housing (1) to the MPV
body (4). Collect warning label (5).
Remove the piston housing and piston
assembly complete from the MPV body.
Collect 'O' ring (8).

5.

Remove valve head (11) from piston (10).

5.

Unscrew the 8mm nut on the threaded rod until

springs (6 and 7) are fully relaxed.

6.

Remove threaded rod and remove piston (10)

and springs (6 and 7) from piston housing.

7.

Remove the 'O' ring from the piston.

AC20160-1822, Issue 1, October 2002

2.4

Inspect/Replace Worn Parts

1.

Clean and inspect all the parts for wear or

damage.

2.

Inspect the surfaces of the piston and valve

head ) for scratches.

3.

Clean and inspect the valve body for any

scoring or corrosion inside the bore.

Note: If the bore of the piston housing (1) or the

valve seat (12) of the valve body are corroded,
remove all traces of corrosion using a fine emery
paper until the surface is smooth and clean.
4.

Change all worn or damaged components for

new items.

2.5

Assemble Minimum Pressure Valve

1.

Apply Shell Albida R2 grease to the springs

and insert them into place in the piston
housing.

2.

Apply Autol 'Top 2000' grease to a new 'O' ring

(9) and locate in groove in piston (10).
Assemble piston (10) and valve head (11).

3.

Apply a small amount of Autol 'Top 2000'

grease to the piston housing bore and position
the piston/valve head assembly in piston
housing.

Chapter 9, page 39

CompAir

4.

Insert threaded rod through the hole in the

piston housing (1) and screw it into piston (10).

5.

Run a washer and nut down the exposed rod

and turn the nut 2 full turns against the piston
housing to compress the springs.

6.

Position a new 'O' ring (8) on the valve body (4)

and mount the piston cover assembly on the
valve body with four screws and washers (2
and 3). Ensure that warning label (5) is
correctly in position as shown.

6.

Install the valve. Refer to para. 2.2 Install

Minimum Pressure Valve in this chapter.

HW 0019

FIG. 9.90 REMOVING RECLAIMER ELEMENT

3.
3.1

RECLAIMER
Remove Reclaimer Element

1.

Open the hinged access doors and/or roof

panel to gain access to the reclaimer.

2.

Disconnect all pipes from the reclaimer cover

(fig. 9.89 (1)). Disconnect and withdraw the
scavenge pipe(2).

3.

4.

Remove four screws and spring washers (3) at

both ends of the air discharge pipe (4) from the
minimum pressure valve (5). Remove pipe and
discard joints.

The element may be withdrawn through the

access panel in the roof.
One bolt may be loosened and left in position
and used to hinge the cover.
Discard the element.
5.

3.2

Inspect the underside of the reclaimer cover.

The cover has been treated and should be in
good condition. If not, remove any loose paint
or rust by shot blasting or wire brush treatment
to leave a clean, oil free surface. Apply one
coat of zinc phosphate paint, ensuring complete coverage to a minimum thickness of 01
mm (0.004). Allow to dry thoroughly.
Install Reclaimer Element

1.

Fit the new element and joint and replace the

cover (the joint is glued to the element). Replace all the reclaimer cover bolts and tighten
by hand to position the joint correctly.

2.

Tighten the bolts evenly, following the tightening sequence in fig. 9.91 to an initial torque of
110 Nm / 81 ft.lbf. Check the O ring.

3.

Tighten the bolts, following the tightening

sequence, to a final torque of 200 Nm/148
ft.lbf.

FIG. 9.89 RECLAIMER AND FITTINGS

Chapter 9, page 40

Release the reclaimer cover securing bolts and

remove the cover. If necessary, use three of
the cover bolts in the jacking holes and tighten
down to break the seal. Withdraw the reclaimer
element.

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

3.3

Remove Reclaimer

1.

Follow steps 1 to 4 in para 3.1 and remove the

roof.

2.

Remove the minimum pressure valve (see

para 2.1).

1
9

13

3
15

11

12

16
5

4
10

14
2

HW 0021

FIG. 9.91 RECLAIMER COVER BOLT

TIGHTENING SEQUENCE
4.

Insert the scavenge pipe assembly and tighten.

5.

Re-connect the pipes to the reclaimer cover.

Fit new O rings to delivery pipe joints and
retightened the bolts to 100 Nm/74 ft.lbf.

6.

Close the access door and roof.

CAUTION: When the compressor has reached

normal operating temperature, re-tighten the bolts to
the correct torque in the sequence shown.

AC20160-1822, Issue 1, October 2002

FIG. 9.92 RECLAIMER PIPEWORK & FITTINGS

3.

Disconnect electrical wiring from the reclaimer

pressure transducer (fig. 9.92 (1)).

4.

Disconnect the coupling flange of the air inlet

pipe (2) at the rear of the reclaimer. Discard
the 'O' ring.

5.

Disconnect the oil pipe (3) between the

reclaimer and oil cooler and secure the pipe to
provide clearance.

6.

Fit eyebolts in the jacking holes on reclaimer

cover and using a suitable hoist support the
reclaimer.

8.

Release and remove three reclaimer mounting

bolts (4).

9.

Lift the reclaimer clear of the unit.

Chapter 9, page 41

CompAir

WARNING
!

Refer to the safety procedures before

carrying out fault diagnosis or testing any
circuit on the compressor unit.

Lethal voltages are used in this

equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.

Before opening the door of the starter

compartment, switch the power supply OFF
at the isolator and wait for 12 minutes to
allow the dc link capacitors to discharge to a
safe level. Check that the dc link capacitors
have fully discharged before starting any
maintenance work.

4.

DRIVE MOTOR & COUPLING

6.

Remove coupling covers from the motor.

4.1

Remove Coupling Rubber Inserts

7.

Remove nuts (fig. 9.94 (3)) and washers (4)

securing the motor to the air-end.

1.

Remove motor end panel and open the motor

side access doors.

8.

Slide the motor (1) away from the air-end (2) to

allow access to the flexible coupling (5).

2.

Remove the fill in panel (fig. 9.93 (1)) in the

bulkhead.

Note: Take care not to move the motor beyond the

extent of the motor cable conduit.
8.

Remove coupling rubber inserts and discard.

2
1

FIG. 9.93 DRIVE MOTOR & MOUNTINGS

3.

Disconnect earth strap (2) from motor. Release

and remove bolt/washers securing AVM (3) to
the base. Use suitable blocks to support the
motor.

4.

Open the power converter door and remove

guard. Disconnect main motor and motor
thermistor leads.

5.

Place suitable temporary supports under the

air-end.

FIG. 9.94 DRIVE MOTOR & AIR END

Chapter 9, page 42

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

4.2

Install Coupling Rubber Inserts

Fit new set of rubber inserts if required (fig. 9.95).

4.3

Remove Drive Motor

1.

Carry out procedures under 4.1 Remove

Coupling Rubber Inserts, steps 1 to 7.

2.

Disconnect main motor leads (fig. 9.96 (1)),

thermistor leads (2) and RPT Sensor lead from
the back of the Surescan.

Installation is a reversal of the removal procedure.

Note: Remove temporary supports from under the
air-end and drive motor when fitting is completed.

FIG. 9.95 DRIVE COUPLING

FIG. 9.96 DRIVE MOTOR CABLES

3.

Disconnect motor conduit from power

converter and withdraw the motor leads.

4.

Remove 4 screws to disconnect the RPT

flange from the back of the converter.

5.

Use suitable lifting equipment to slide the

motor clear of unit.
Approximate weight of motor: 340kg.

4.4

Install Drive Motor

Installation is a reversal of the removal procedure.

AC20160-1822, Issue 1, October 2002

Chapter 9, page 43

CompAir

5.

AIR-END

7.

Using suitable lifting gear take the weight of

the air-end. Place temporary supports under
drive motor.

8.

Take covers off the motor and remove bolts

securing air-end to the motor.

9.

Remove air-end clear of unit.

WARNING
!

Ensure electrical power is isolated in

accordance with Dismantling
Precautions in Chapter 1.

Approximate weight: 83kg

5.1

Remove Air-End

1.

Remove motor side access doors.

5.2

2.

Disconnect oil injection pipe (fig. 9.97 (1)) to

drain oil from the air-end. Tie pipe up out of the
way to stop oil draining down from the cooler.

Installation is a reversal of the removal procedure.

3.

Remove inlet non-return valve (2). (Refer to

1.1)

4.

Disconnect the discharge pipe flange (3) from

the air-end (oil may still be present in the pipe).
Discard the O ring from the pipe flange.

5.

Disconnect the scavenge oil pipe (4) from the

air-end (5).

6.

Remove bolts/washers securing the air-end (5)

to the anti-vibration mountings (6).

Install Air-End

Note 1: Replace all 'O' ring seals and self centering

bonded seals.
Note 2: Prime the air-end with 1 litre of BroomWade
4000 HR oil or an approved alternative.

2
4

5
6
1

FIG. 9.97 AIR END AND PIPEWORK

Chapter 9, page 44

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

5.3

Remove Air-End Oil Seal

1.

Remove the air-end (refer to 5.1).

2.

Undo Taperlock bush and remove the flexible

coupling.

3.

Remove the oil seal housing by removing the 8

bolts and using two jacking screws.

4.

Remove the oil seal and gasket from the oil

seal housing and discard.

5.4

Install Air-End Oil Seal

1.

Ensure that the end bearings are undamaged

and that all debris has been removed from the
Air-End and oil seal housing before installing a
new oil seal.

2.

Fit the new oil seal into the oil seal housing.
Ensure that the seal is seated firmly in the
recess.

3.

Place the oil seal installation sleeve onto the

rotor drive shaft (fig. 9.99). The installation
sleeve should fit over the end of the shaft
sleeve.

Tooling Required: Air-End Oil Seal

Installation Sleeve

FIG. 9.99 INSTALLATION SLEEVE IN POSITION

4.

Install a new gasket to the Air-End.

5.

Carefully lower the oil seal housing onto the AirEnd, ensuring that the new oil seal fully
engages the shaft sleeve without twisting.

6.

Fit the bolts and washers, tighten them

progressively as shown using a torque of
57 Nm (42 lb.ft.) to secure the oil seal housing

7.

Remove the installation sleeve.

8.

Install air-end. Refer to 5.2, Install Air-End.

FIG. 9.98 AIR-END OIL SEAL INSTALLATION

SLEEVE

AC20160-1822, Issue 1, October 2002

Chapter 9, page 45

CompAir

6.

COOLERS

WARNING
!

Ensure electrical power is isolated in

accordance with Dismantling
Precautions in Chapter 1.

6.1

Remove After Cooler

1.

Remove cooler end panels and side panels

from the compressor unit.

2.

Disconnect and remove pipe (fig. 9.100 (1))

between MPV and after cooler by removing
flange nuts (2) and spring washers. Discard 'O'
rings.

3.

Remove after cooler discharge flexible pipe (3)

by removing flange nuts (4) and washers.
Discard 'O' rings.

4.

Disconnect plug on delivery pressure probe.

5.

Support after cooler (5) and remove fixings

from cooler columns (6).

5.

Remove aftercooler from unit.

FIG. 9.100 COOLERS & FITTINGS

3.

Remove any dirt or liquid from base and

replace panels.

Accumulated dirt in the fins of the air cooler can

normally be removed using compressed air or a
steam cleaner. Cleaning should be carried out from
the reverse side to the air flow.

Note: Approximate weight of after cooler: 25 Kg

6.2

6.4

Remove Oil Cooler

1.

Remove cooler end panel and end panel from

the compressor unit.

2.

Drain the oil from the oil cooler (11).

3.

Disconnect and remove pipe (7) between

reclaimer and oil cooler.

4.

Disconnect swivel coupling (8) on oil cooler

outlet and remove oil filter assembly (9) by
removing screws (10).

5.

Support oil cooler (12) and remove fixings from

cooler rear columns (6).

6.

Remove oil cooler (12) from unit.

Install After Cooler

Installation is a reverse of the removal procedure.

Note: Replace all 'O' rings with new items.

6.3

Clean After Cooler

The cooler should be cleaned as normal practice

during Routine Maintenance.
1.

2.

Remove cooler end panel and both side

panels.
Open access doors as necessary and clean
coolers using low pressure air (2 bar) or water.
Do not use excess pressure as this might
damage the coolers.

Note 1: Approximate weight of after cooler: 47 Kg

Note 2: Oil cooler will still contain some oil.

Chapter 9, page 46

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

6.5

Install Oil Cooler

Installation is a reversal of the removal procedure.

Note: Replace all 'O' rings and bonded seals with
new items.

6.6

Clean Oil Cooler

The cooler should be cleaned as normal practice

during Routine Maintenance.
1.

Remove cooler end panel and both side

panels.

2.

Open access doors as necessary and clean

coolers using low pressure air or water. Do not
use excess pressure as this might damage the
coolers.

3.

Remove any dirt or liquid from base and

replace panels.Accumulated dirt in the fins of
the oil cooler can normally be removed using
compressed air or a steam cleaner. Cleaning
should be carried out from the reverse side to
the air flow.

Cleaning of the oil side should be carried out by

flushing through with a suitable degreaser, detergent
or vapour solvent.

AC20160-1822, Issue 1, October 2002

Chapter 9, page 47

CompAir

7.

6.

FAN & FAN MOTOR

WARNING
!

Remove fan from motor. Lay fan assembly

down as shown in fig. 9.102 using blocks to
prevent the fan rolling around.
Remove 4 nuts/washers/bolts (11) from plate
(12) securing motor to fan assembly (13). Lift
motor from fan assembly.

Ensure electrical power is isolated in

accordance with Dismantling
Precautions in Chapter 1.
7.

7.1

Remove Fan and Fan Motor

1.

Remove side access panels.

2.

Disconnect fan motor cables in power

converter.

3.

Support Fan/Duct assembly (fig. 9.101).

4.

Release fan grille (2) by removing 12 screws

(3), washers (4) and nuts (5).

5.

Release fan assembly from fan bracket (6) and

duct (7) by removing 12 screws (8) and
washers (9).

Remove fan/motor assembly from the unit.

7
9

FIG. 9.102 FAN & FAN MOTOR ASSY.

5

7.2
3

10

Install Fan and Fan Motor

Installation is a reverse of the removal procedure.

Note: Replace fan seal if damaged.

FIG. 9.101 FAN/DUCT ASSY.

Chapter 9, page 48

AC20160-1822, Issue 1, October 2002

SR Repair Manual Disassembly & Assembly

8.

THERMOSTATIC BYPASS VALVE

8.1

Remove Thermostatic Bypass Valve

1.

Remove side panel on discharge side (filter)

panel to gain access to the cooler assemblies
(fig. 9.103 (1)).

2.

Unscrew valve cap (3) from the pocket (2) in

the oil cooler. Remove and discard 'O' ring.

3.

Remove the valve complete with return spring.

Note: The thermostatic valve is supplied as a

complete unit and must be changed if
defective.

FIG. 9.104 THERMOSTATIC BYPASS VALVE

COMPONENTS
4.

Check the thermostat element by immersing it

in a water bath at approximately 6C above the
nominal setting. Bypass port B should close.
The nominal setting of the valve will be found
stamped on the end of the element.

8.2

Install Thermostatic Bypass Valve

Installation is a reversal of the removal procedure.

Install a new 'O' ring when fitting the plug.
FIG. 9.103 THERMOSTATIC BYPASS VALVE

AC20160-1822, Issue 1, October 2002

Chapter 9, page 49

CompAir

9.

BEKOMAT DRAIN

Ensure that the device is pressureless and

de-energised

9.1

Removal and servicing

1.

Disconnect inlet and outlet pipes from the unit.

2.

Undo the screws on the top of the Bekomat

unit and disconnect the compressor wiring
loom.

9.3

Testing

1.

Briefly press the test button (fig 9.106).

2.

Valve opens for condensate discharge.

FIG. 9.106 TESTING BEKOMAT DRAIN

9.4

Checking the Alarm Signal

1.

Shut off condensate inflow.

2.

Press test button for at least 1 minute.

3.

Red LED flashes (after 1 minute).

4.

Alarm signal is being relayed.

FIG. 9.105 BEKOMAT DRAIN

3.

Replace the top on the Bekomat unit and

remove from the compressor.

4.

Unscrew the 6 pan head screws (fig. 9.105 (3))

on the bottom of the unit until the heads are
level with the outer edge and take off
diaphragm seat (4).

5.

Replace worn parts (x).

9.2

Installation

Reasemble the Bekomat unit in reverse order.

Chapter 9, page 50

AC20160-1822, Issue 1, October 2002