Preface

This service manual explains about the cautions for maintenance jobs and is to serve a
guide for the electric system, and troubleshooting for service personnel.

In this book the fundamental matters and other things already mentioned in the
“Instruction Manual” and the “Parts Catalogue” are omitted to avoid duplication.
Therefore, for the operation and handling of this unit, we request you to refer to the
instruction manual and caution plates, and further for the structure and components of
the unit, please refer to the “Parts Catalogue” separately to be supplied with the unit.
If you should find any description which does not coincide with the instruction manual
and parts catalog, we request you to make sure to start the job after clarifying it.

Service personnel is required to safely take quick and proper countermeasures as well
as to use correct technology of maintenance in case of field services and periodical
maintenance.
It is important that service personnel should have proper and sufficient knowledge
about the structure and function of the unit and should be well familiar with such
technique mentioned in them.

Also this book contains “Safety”. Make sure to observe “SAFETY principles” because if
they should be neglected and ignored, it could lead to death accidents as well as
serious injury.
When common persons are engaged in operation and servicing works, safety
instruction and maintenance services training should be given to them beforehand.
They should read “SAFETY Cautions” mentioned in this book and understand them well
so that they should work in safe environment.
 Table of Contents
1. Safety --------------------------------------------------------------------------------------------------------------------- 1-1
1.1 Caution before Operation ------------------------------------------------------------------------------------------ 1-2
1.2 Caution during Operation ------------------------------------------------------------------------------------------ 1-3
1.3 Caution during Inspection and Maintenance ------------------------------------------------------------------ 1-5
1.4 Safety Warning Labels --------------------------------------------------------------------------------------------- 1-6

2. Specifications --------------------------------------------------------------------------------------------------------- 2-1

2.1 Unit Appearance and Part Names ------------------------------------------------------------------------------ 2-1
2.2 Internal Components ----------------------------------------------------------------------------------------------- 2-2
2.3 Compressor Specifications --------------------------------------------------------------------------------------- 2-3
2.4 Motor Specifications ------------------------------------------------------------------------------------------------ 2-4
2.5 Size and Dimensions ----------------------------------------------------------------------------------------------- 2-5

3. Cautions on Maintenance Job ----------------------------------------------------------------------------------- 3-1

3.1 Cautions --------------------------------------------------------------------------------------------------------------- 3-1
3.2 Tightening ------------------------------------------------------------------------------------------------------------- 3-3

4. Periodic Inspection/Maintenance ------------------------------------------------------------------------------- 4-1

4.1 Periodic Inspection / Maintenance List ------------------------------------------------------------------------- 4-1
4.2 Inspection / Maintenance ------------------------------------------------------------------------------------------ 4-4

5. Electrical System ----------------------------------------------------------------------------------------------------- 5-1

5.1 Controller -------------------------------------------------------------------------------------------------------------- 5-1
5.2 Electrical Parts ------------------------------------------------------------------------------------------------------- 5-9
5.3 Electrical Wiring Diagram ----------------------------------------------------------------------------------------- 5-15
5.4 Adjustment ------------------------------------------------------------------------------------------------------------ 5-23

6 Troubleshooting ------------------------------------------------------------------------------------------------------- 6-1

6.1 How to Proceed Diagnosis ---------------------------------------------------------------------------------------- 6-1
6.2 Failure of Capacity Control System ----------------------------------------------------------------------------- 6-4
6.3 Function of Emergency Switch ----------------------------------------------------------------------------------- 6-6
6.4 Others ------------------------------------------------------------------------------------------------------------------ 6-12

7 Reference Data --------------------------------------------------------------------------------------------------------- 7-1

7.1 Table of Reference Data ------------------------------------------------------------------------------------------- 7-1
7.2 Piping Diagram ------------------------------------------------------------------------------------------------------- 7-2

※ For the details of operation and installation, see Instruction Manual.

 1. Safety

This manual explains and illustrates general requirements for safety and cautions for safety.

Read these safety requirements carefully and fully understand the contents before starting the
machine.

For your better recognition, according to the degree of potential danger, safety messages are classified

into three hierarchical categories, namely, , , and with a caution

symbol −attached to each message.

When one of these messages is found, please take preventive measures for safety to carry out “SAFETY
OPERATION AND PROPER MAINTENANCE OF THE UNIT.”

DANGER indicates an imminently hazardous situation which, if not avoided,

will result in death or serious injury. This signal word is to be limited to the
most extreme situations.

WARNING indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury. It may also be used to alert against
unsafe practices.

IMPORTANT indicates important caution messages for the performance or

durability of the unit.

Follow warnings mentioned in this manual. This manual does not describe all safety items. We,
therefore, advise you to pay special attention to all items (even though they may not be described in the
manual) for your safety.

1-1
 1. Safety
1.1 Caution before Operation

Air pressurized construction method prohibited

Never use the unit directly or indirectly for the following

purposes:
Never use the unit for respirator equipment by which
compressed air is supplied for human consumption. The
compressed air contains carbon monoxide and other
contaminants, and such air may cause serious injury or
even death if used by a person for respiration.
This compressor is not designed for air pressurized
construction method and underwater diving jobs. Never use
compressed air for human consumption such as PC005
pressurizing diving air tanks. Consumption of compressed
air can cause death while diving.

Follow the safety instructions

Read each instruction plate which is displayed in the manual or

on the unit carefully, understand its content and follow the
indications thereof.
Keep the Safety Warning labels clean. When they are damaged
or missing, apply new ones.
Do not modify the machine without prior approval. The safety
may be compromised, functions may be deteriorated, or
machine life may be shortened.
Never use the unit for the purpose of compression of gases TR0086
other than air, or as a vacuum pump. Otherwise, serious
accidents may occur.

Safety outfit

When handling machine, do not wear;

Loose clothes
Clothes with unbuttoned sleeves
Hanging tie scarf
Accessories such as dangling jewelry
Such outfit could be caught in the machine or dragged in
the rotating portion of the machine, and this could cause a
TR0084
serious injury.

1-2
 1. Safety

Safety equipments

Wear helmet, safety glasses, earplugs, safety shoes, safety

gloves and a mask, according to the requirements of each
operation.

TR0085

Safety fittings

Have first-aid boxes and fire-extinguishers near the unit ready

for emergency situations such as injuries and a fire.
It is advisable to have a list of phone numbers of doctors,
ambulance and the fire department available in case of
emergency.

TR0096

1.2 Caution during Operation

Never direct the compressed air to people and foods

Never blow compressed air directly at people. Scattered

impurities, dust, or foreign objects in the compressed air may
cause skin and eyes to be seriously injured.
Blowing compressed air on food is prohibited.

TR0092

Hands off from rotating parts and belts

Keep hands off from the rotating portion or belts while running. It
could cause serious injuries if hands should be caught in.

H970064

1-3
 1. Safety

Operation with compressed air supply port opened is prohibited

Do not operate the machine with service valves and relief valve
open unless air hoses and/or pipes are connected.
High-pressurized air blows out and its air pressure could cause
injury to the people nearby.
When the machine has to be unavoidably temporarily operated
with its port open, be sure to mount a silencer to reduce noise
and wear protective materials such as earplugs to prevent
D003
damage to hearing.

Do not touch hot parts

Do not touch hot portions of the machine while inspecting the

machine when running.
Such parts as pipe and discharging pipe are especially hot, so
never touch those parts, because it could cause serious burns.

W005

1-4
 1. Safety
1.3 Caution during Inspection and Maintenance

Hang a “Now Checking and under Maintenance” tag

Turn the power OFF before starting inspection, and hang a

"Now Checking and under Maintenance" tag where it can be
easily seen. The checker must keep the key during checking
and maintenance. SY001

Refilling and Draining of compressor oil

When you refill and drain the separator receiver tank with
compressor oil, stop the machine, and make sure that the
pressure gauge indicates 0MPa and there is no residual
pressure in it, and then gradually loosen the oil filler cap for
refilling oil.
In case there is residual pressure in the receiver tank, both
extremely hot compressed air and oil could jet out and you may
W011
be scalded or seriously injured.

Fear of electric shock

Be sure to keep a wet hand away from the power source or any
other electric equipment. Electric shock can cause serious
accident or even death.

W013

Cleaning by air-blow

When cleaning dust accumulated in such devices as the

air-filter, by blowing compressed air, wear safety glasses, etc. to
protect your eyes.

M003

Fear of fire

Be sure to perform the periodical check of electric equipment

such as motor, and compressor oil and oil separator.
Neglecting checks could cause overheat of the oil, resulting in a
fire.

W004

1-5
 1. Safety
1.4 Safety Warning Labels
Following labels are attached to the machine.
Keep them clean all the time. If they are damaged or peeled off, immediately place an order with
your nearest dealer for replacement, with the number indicated on the lower right corner of the
label. Adhere a new one to the original place.

1 2 3

WARNING CAUTION

BEWARE OF HIGH PREVENT

PRESSURE AIR BLOW OUT FIRE ACCIDENT
Oil supply and/or maintenance Periodicallr check compressor
jobs with residual pressure left oil and oil separator surely.
in tank are very dangeraous.
Failure of this maintenance
So release the residual
can cause fire accident.
pressure first.

39176 69800 39176 69700

4 5
6

WARNING

BEWARE OF
ENTANGLEMENT
Keep your hands AWAY from
moving parts such as
V-belts,pulleys etc..
Entanglement in them
can cause serious injury.

39176 73800

1-6
 1. Safety

Locations of warning labels attached.

2 1 4 3

6 4

A050471E
SAS22UD-58/68 (Dryer built-in Type)

1-7
 2. Specifications
2.1 Unit Appearance and Part Names

7 7

6 3 2 1

H990400

6 A050309
SAS22UD-58/68 (Dryer built-in Type)

1. Handle 5. Discharge port 25A (1B)

2. Door 6. Cooling air inlet
3. Operation panel 7. Cooling air outlet
4. Auto-drain valve

2-1
 2. Specifications
2.2 Internal Components

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17
A050466
SAS22UD-58/68 (Dryer built-in Type)

1. By-pass valve 10. After cooler

2. Air-end 11. Starter panel
3. Air filter 12. Motor
4. Solenoid valve for capacity control 13. Solenoid valve for separator recovery
5. Oil separator 14. Solenoid valve for auto-relief
6. Pressure control valve 15. Oil level gauge
7. Safety valve 16. Separator receiver tank
8. Oil cooler 17. Oil filler port
9. Oil filter

2-2
 2. Specifications
2.3 Compressor Specifications
2.3.1 Dryer built-in type
Model SAS22UD-58 SAS22UD-68 SAS37UD-58 SAS37UD-68
Type Rotary-twin screw, single stage, oil cooled
Free air delivery m3/min 3.7 2.9 3.7 2.9 6.1 5.2 6.1 5.2
Working pressure MPa 0.69 0.83 0.69 0.83 0.69 0.83 0.69 0.83
Compressor

AIRMAN Unloader (Suction port closing, Discharge chamber

Capacity control system
pressure relief, Oil volume control )
Lubrication system Forced oil injection by compressed air pressure
Driving system Belt drive
Lubrication oil All Seasons
Lubrication oil capacity L 13.5 24
Tank capacity m3 0.017 0.028
Type Three-phase squirrel cage induction/totally-enclosed fan cooled
Motor

Power output kW 22 37
Starting system Star-Delta (3-Contactors)
Air outlet port 25A(1B) 40A(1 1/2B)
Dew-point of
℃ Under the ambient pressure less than 10
discharged air
Dryer

Power consumption kW 1.15 1.43/1.43 1.5 1.9/1.9

R407C R407C
Refrigerant
（Refrigerant enclosed: 360g） （Refrigerant enclosed: 800g）
dimensions

Width mm 1,380 1,620

Approx.

Length mm 720 880

Height mm 1,350 1,460
Approx. dry weight kg 660 940
Approx. weight for
kg 670 960
maintenance
●Free air delivery is a value converted into a suction status at air temperature of 30℃.
●Dew point of discharge air is the value at the ambient temperature of 30℃.
●When the Dryer discharges sediment, the air quantity will decrease due to the deposit of sediment.

2-3
 2. Specifications
2.3.2 Without dryer type
Model SAS22U-58 SAS22U-68 SAS37U-58 SAS37U-68
Type Rotary-twin screw, single stage, oil cooled
Free air delivery m3/min 3.7 2.9 3.7 2.9 6.1 5.2 6.1 5.2
Working pressure MPa 0.69 0.83 0.69 0.83 0.69 0.83 0.69 0.83
Compressor

AIRMAN Unloader (Suction port closing, Discharge chamber

Capacity control system
pressure relief, Oil volume control )
Lubrication system Forced oil injection by compressed air pressure
Driving system Belt drive
Lubrication oil All Seasons
Lubrication oil capacity L 13.5 24
Tank capacity m3 0.017 0.028
Type Three-phase squirrel cage induction/totally-enclosed fan cooled
Motor

Power output kW 22 37
Starting system Star-Delta (3-Contactors)
Air outlet port 25A(1B) 40A(1 1/2B)
dimensions

Width mm 1,380 1,620

Approx.

Length mm 720 880

Height mm 1,350 1,460
Approx. dry weight kg 620 880
Approx. weight for
kg 630 900
maintenance
●Free air delivery is a value converted into a suction status at air temperature of 30℃.

2.4 Motor Specifications (Totally-enclosed fan cooled type)

Model SAS22U(D)-58 SAS22U(D)-68 SAS37U(D)-58 SAS37U(D)-68
Motor Type TOSHIBA TIKK-FBK21A
Power output kW 22 37
Frequency Hz 50 60 50 60
Power source V 200 200/220 200 200/220
200V Current A 93 88/83 156 147/138
Number of poles 4P
Insulation F
Frequency Hz 50 60 50 60
Power source V 400 400/440 400 400/440
400V Current A 46.5 44/41.5 78 73.5/69
Number of poles 4P
Insulation F

2-4
 2. Specifications
2.5 Size and Dimensions
2.5.1 Dryer built-in type
SAS22UD-58/68

A050392E

2-5
 2. Specifications

SAS37UD-58/68

A050457E

2-6
 2. Specifications

2.5.2 Without dryer type

SAS22U-58/68

A050472E

2-7
 2. Specifications

SAS37U-58/68

A050568E

2-8
 3. Cautions on Meintenance Job
3.1 Cautions
3.1.1 Preparations before maintenance job
(1) How to perform maintenance job
It is important to perform maintenance jobs, always considering what kinds of equipments, tools,
materials and oils should be used, what portions or parts of the machine should be inspected or
adjusted or disassembled, and also what is the important points of the maintenance jobs.
(2) Prevention of oil overflow
In order to prevent oil from overflowing in case of compressor oil change and removal or
installation of oil piping, make sure to prepare an oil reservoir. And also if an excessive oil flow is
expected beforehand, it is necessary to empty the receiver tank beforehand.
(3) On removal or installation of parts or assemblies
In case of removing complicated parts or components, mark the match mark for reinstallation.
(4) Equipments to be prepared beforehand
① Measuring instruments
Thickness gauge, Torque wrench (Preset type or spanner type)
② General tools
③ Jigs and special tools
④ Literature (Instruction manual, parts catalog and manual etc…)
⑤ Replacement parts
⑥ Auxiliary materials
Item Name Application
Cleaning agent Cosmo Flush C Compressor Air-end
Grease Epnoc AP-1 O-ring
Sealant for screwing-in Locktite No.577 Screwing-in, block plug
Inlet, power side, discharge
Liquid packing for cast iron Locktite No.515
casing
Liquid packing for aluminum
Locktite FMD-127 Unloader
(hardening time :48Hr)
Liquid packing for aluminum
acceleration hardening Locktite primer N Unloader
(hardening time :2Hr)
Compressor oil All Seasons Inside the cylinder
Diesel oil for cleaning Cleaning
Thinner Cleaning
Release agent for liquid Locktite Portion at which liquid packing
packing Gasket remover is coated
Portion at which liquid packing
Oil stone
is coated
Rag
⑦ Equipments
Hot oil bath
Chain block
Impact wrench

3-1
 3. Cautions on Meintenance Job
3.1.2 Cautions during disassembly and assembly
① Have to choose place where the machine is disassembled for maintenance job shall be clean,
good ventilation and have much space to do it.
② Hove to clean and remove dust from disassemble equipment.
③ Pay attention ventilation and disaster prevention when cleaning disassembled parts by
diesel oil.
④ Before removing nylon tubes or hoses, hove to clean dust and after removing them, make
necessary treatment to prevent dust or foreign matters from entering inside.
⑤ Make sure to check the disassembled parts for any dirt and decoration, and then wash
them by diesel oil. But, don’t soak rubber sort to diesel oil absolutely.
⑥ After washing, put it on the clean paper or cloth to arrange in disassembled order and then
do not damage them or do not make dirty.
⑦ As the parts or components are precision-made, do not damage them by falling or colliding.
⑧ Don’t use disassemble O-ring, filter, oil. (have to abrogate it). Have to use new parts for
re-assembling.
⑨ When reassembling, pace the parts according to the assembling turn and check to prepare
all parts. (without any part left unused.)
⑩ If there are any contact parts used, use parts assemblies.
⑪ Install O-ring with new lithium based grease coated on.
⑫ Make sure to check tightening torque and clearance when assembling the disassembled
parts.
⑬ When disassembling and reassembling the machine, hove to use Jigs and tools correctly. If
you use it unfit, it is cause to break machine and tools or to get injured.
⑭ When stop disassembling halfway, it is cause to occur rust or soil them by humidity or
rubbish. If it is necessary to stop disassembling job on the way, make sure to protect them
against rust and dirt.
⑮ After finishing assembling job, make sure to check following.
Oil leakage
To check tightening torque of every bolt
The direction of rotation
Part left behind to assembling
Check oil level of receiver tank
⑯ After finishing re-assembling job, make sure to carefully perform trail operation so that it
may not cause seizure or overheating to the unit.
⑰ When will perform disassembling or assembling by several person, hove to obey suggestion
of leader. And when go to next progress, to check safety to call out to each other.

3-2
 3. Cautions on Meintenance Job
3.2 Tightening
3.2.1 Tightening torque
Bolt Width of Tightening torque
Tightening place diameter across flat
(mm) (mm) N･m (kgf･cm)
Discharge casing and check valve socket
10 8(Hexagon haul) 49 (485)
bolt
Shaft seal cover socket bolt 8 6(Hexagon haul) 25 (245)
Compressor Air-end

※
8 6(Hexagon haul) 12 (124)
End cover and drain pump socket bolt
Male rotor side 6 5(Hexagon haul) 10 (100)
※
Bearing
SAS22UD 10 8(Hexagon haul) 49 (485)
pushing plate Female
socket bolt rotor side
SAS37UD 8 6(Hexagon haul) 25 (245)

Cylinder cover (oil filler plate) 8 6(Hexagon haul) 25 (245)

Unloader socket bolt 10 8(Hexagon haul) 49 (485)

Compressor Air-end fixing bolt, nut 12 19 43 (425)

SAS22UD 12 19 43 (425)
Motor fixing bolt, nut
SAS37UD 16 24 106 (1055)

Separator cover socket bolt 10 8(Hexagon haul) 49 (485)

Separator casing socket bolt 10 8(Hexagon haul) 49 (485)

V-pulley pushing socket bolt
10 8(Hexagon haul) 49 (485)
(Compressor Air-end side)
Level gauge bolt 14 22 26 (255)

Sirocco fan shaft idler bolt 8 13 25 (245)

Sirocco fan lock nut 12 19 43 (425)

※：Make sure to tighten the socket bolts fixing end-cover and bearing retainer plate, just according to
the tightening torque specified above without fail. Excessive tightening or insufficient tightening
sometimes could cause earlier damage to the bearings and it could loosen the bolts. Take special
care for tightening them.

3-3
 3. Cautions on Meintenance Job
3.2.2 General bolts and nuts tightening torque
When reassembling or rebuilding, tighten bolts and nuts, according to the following torque values in
the table.
Kind Low or Middle carbon steel bolt High tensile strength bolt
(SS400B etc…) (SCM435 etc…)
Strength 4.6∼6.8（4T∼6T） 8.8∼12.9（7T∼12T）
and sorting

Width of
across flat･
Tightening
torque Hexagon bolts Socket bolts Hexagon bolts
Hexagon bolts Tightening Socket bolts Hexagon bolts Tightening
Bolt diameter Width of across torque Width of across Width of across torque
(mm) flat (mm) N･m (kgf･cm) flat (mm) flat (mm) N･m (kgf･cm)
6 10 5 (51) 5 10 10 (100)
8 13 12 (124) 6 13 25 (245)
10 17 25 (245) 8 17 49 (485)
12 19 43 (425) 10 19 85 (845)
14 22 68 (675) 12 22 135 (1350)
16 24 106 (1055) 14 24 210 (2100)
18 27 145 (1450) 14 27 290 (2900)
20 30 205 (2050) 17 30 410 (4100)
22 32 280 (2800) 17 32 560 (5600)
24 36 345 (3450) 19 36 710 (7100)
Compressor Air-end, receiver tank and other
Using place Bonnet flame etc…
designation part

The above torque values in the table shall be applicable for the bolts and nuts used for compressor.
In general, the above torque values are applicable for the bolts and nuts used for compressor, but
such parts used for special portions need be tightened according to the specified torque values
indicated.
When tightening parts or components, make sure to remove rust and dust.

3.2.3 Terminal tightening torque

Should be tighten terminal of electric contactor, thermal relay other electric equipment etc. according
to following torque.
Tighten torque
Screw size
N･m (kgf･cm)
M3.5 1.0 (10)
M4 1.5 (15)
M5 3 (30)
M6 5 (51)
M8 10 (100)
M10 18 (175)
M12 35 (350)

3-4
 3. Cautions on Meintenance Job
3.2.4 Tightening torque for hose, joint etc…
(1) Union joint
Should be tighten union joint according to following torque.

Parallel thread for pipe

Tool Width of Tightening
Screw size torque
across flat
G (PF)
(mm) N･m (kgf･cm) R(PT) G(PF) G(PF)
1/4 19(17) 25 (250)
3/8 22(19) 50 (500)
30°
1/2 27(22) 59 (600)
3/4 36(30) 120 (1200) 30°
1 41(36) 140 (1400)
1 1/4 50 170 (1700)
1 1/2 60 210 (2100)
TXT104

How to install AQP hoses

AQP hoses are used for supplying oil to compressor air end. For the installation of AQP hoses, follow
the under-mentioned procedures to prevent hoses from twisted.

Hose Sleeve Union nut

Installation procedures
Sleeve
① Install union nut to the nipple fitted at the port of the other
hose.
Make sure to tighten the union nut with a hand till it reaches
“Stop” end of the nipple.
② Use two spanners. Hold the sleeve with the one spanner and
tighten the union nut with another spanner according to the Union nut
specified torque. Nipple
Port of the
other hose

Excessively tightening of union nut can cause excessive wedging action so that union nut can be
broken. So tighten the nut, according to the specified torques.
Damaged seating surface can cause oil leakage. So take special care when disassembling and
reassembling.

3-5
 3. Cautions on Meintenance Job
(2) Bite type union
The bite type union used for this pipe is to seal completely high pressure oil. Because the cutting
edge of sleeve bites the steel pipe firmly and it is constructed to endure shock pressure and
vibration. Therefore, this union is widely used for many hydraulic devices. But bear in mind that
oil leak will occur if you are not familiar with the structure and usage of the union. Fit it
according to the following steps.
Union (Nipple) Insert ring Sleeve Nut Pipe

1) Check and confirm the pipe

① Check whether this pipe is provided with insert
ring, sleeve and nut. (Some insert rings are not
used to be inserted, depending on the diameter.)

Sleeve Nut

② Check the direction of the sleeve and make sure

it is not caulked diagonally.

Sleeve

③ Visually make sure that there is a clearance of a

few millimeters from the end of pipe to the
sleeve (size A).
3-4 mm is recommended

When retightening the nut after loosening the tightened nut, mark “match-mark” on the location of the
nut with white chalk before loosening it and then remove it.
When tightening it again, tighten the nut a bit more tight than the position tightened before.

3-6
 3. Cautions on Meintenance Job
2) Coat pipe and nipple with lubrication oil Supply oil to
① Coat the sleeve and nut of pipe with lubricant these points
(NICHIMORI LAP spray or equivalent).

② Coat the threaded portion and seat face of Supply oil to

these points
nipple with lubricant.

When tightening it without coating lubricant, galling could take place. Therefore, the sleeve turns
together. So then it can cause oil leak.

3) Tightening steps
Tighten the nut with a hand
① Tighten the pipe to the nipple.
Make sure to tighten the pipe nut with a hand
till the nipple “Stop” position.

② Tighten the nut of pipe by one spanner with

holding the nipple by another spanner.

③ Continue to tighten the nut and when you will

find sharp torque ruse point, tighten it 1/4 more
to make the inside sleeve curves.
Spanner

3-7
 3. Cautions on Meintenance Job
(3) Pipe tapered threads
Sealing tapes are used to prevent any leakage of oil, water, fuel and air by stopping the space
between female and male threads of metal pipe and fittings (PT thread for pipe).
Be noted that how to seal varies upon the diameter of thread.

1) How to seal for tube screw less than 3/8 of screw diameter.
① Wipe out oil and fat content with wasted cloth.
② Coat sealant “Loctite 577” as shown below.

Coat the half if circumference 3

Keep space from 1 to 2 threads
threads in thread direction
at end of thread

S_M030

Sealant only can damage sealed portion after the sealant is hardened, and it can cause leakage, if the
joint connector is moved. Should the joint be moved, repeat this treatment.
In case of different metals between female thread and male thread (for example, female thread :
aluminum male thread :steel etc.) even if the thread diameter is less than 3/8, apply seal tape (Three
Bond TB4501) as well as coat sealant. (Sealant could be cut due to the different coefficient of thermal
expansion.)

2) How to seal for tube screw larger than 1/2 of thread diameter.
① Wipe out oil and fat content with wasted cloth.
② Roll seal tape (Three Bond TB4501) .
③ Coat sealant “Loctite 577” on the seal tape which is attached. According to the figure below.

Coat the half if circumference 3

Roll seal tape to right and double end of screw
threads in thread direction

Keep space of 1-2 threads on Keep space of 1-2 threads on S_M031

the extreme end of the thread the extreme end of the thread

3-8
 3. Cautions on Meintenance Job
3) How to seal for tube screw of larger than 1 1/4 (32A) of thread diameter.
① Wipe up oil and fats content from the threaded portion with rag.
② Roll seal tape (Three Bond TB4501) . [same as 2] clause]
③ C oat sealant “Loctite 577” on seal taped portion as shown below.

Keep space 2 to 3 threads at end of thread

S_M032
Keep space more than 3 threads coat
sealant fully on the circumference

(4) Standard tightening torque of piping Pt screw (Reference value)

Unit:N･m(kgf･cm)
Nominal Tightening Nominal Tightening Nominal Tightening
diameter torque diameter torque diameter torque
1/8 11(110) 3/4 65(660) 2 216(2200)
1/4 22(220) 1 108(1100) 2 1/2 270(2750)
3/8 32(330) 1 1/4 129(1320) 3 323(3300)
1/2 43(440) 1 1/2 162(1650)
Note : Over torque tightening could lead to deforming of threads and resulting in
oil leakage. (2 threads should be left as standard)

3-9
 3. Cautions on Meintenance Job
(5) Nylon tube
To size of nylon tube are used to this machine. One is Inch size and other one is meter size. Each
nylon tubes are not compatible.
Inch size …… It is use spanner when tightening sleeve nad nut to piping.
Meter size …… Install to one tach joint.
● Some inch sized nylon tubes can be inserted into one tough joint connectors…
But sometimes it is difficult to remove them. Be careful not to use inch sized nylon
tubes.
● Circumference of each nylon tube serves to prevent leaking. When any damage or
deflectionon the circumference is found, cut such damaged portions of the nylon
tube.
Each nylon tube is marked nominal size in a constant distance on it, and so it is easy to
distinguish such portions... But the circumference of nylon tube is quite same. So be careful not
to make a mistake in its installation.

Cautions on how to use one tough joint connector.

● Rubber seal isprovided inside the joint connector. As the joint is repeatedly installed and
removed many times, air leak sometimes can take place.
● Installation and/or removal must not be performed under pressurization.
● Installing any nylon tube, you find it difficult to confirm whether it is fully and correctly
installed, looking from outside. After it is installed, make sure to check that it is surely
installed and cannot be pulled out, by poulling it.
● For removal of nylon tube, press the nylon tube to the fitting side and push the release
ring of one touch joint to the fitting side, then the locked condition is released so that it can
be extracted easily.

Straight nipple Nipple elbow

Joint Release ring Release ring

Joint
Nylon tube
Nylon tube (Meter size)
(Meter size) The head from this
part can be turned
freely by 360˚

As shown in the sketch, put the nylon tube straight

against the inlet of the fitting. ○
If the tube is installed diagonally, the internal

×
diameter of lock ring gets wider and it can not hold
the tube and it drops.

3-10
 3. Cautions on Meintenance Job
(6) Tightening for joint of nylon tube & sleeve nut
Following chart is for tightening torque of each size joint and sleeve nut.

[Inch size]
1) Tightening of Joint
Screw size Tightening torque
R (PT) N･m (kgf･cm)
1/8 7.8 (80)
1/4 13 (130)
3/8 23 (230) Joint Joint
(connector) (elbow)
1/2 28 (290)
TXT106

[Meter size]

Joint Joint

Tightening torque is specified for each size thread.

In case white coated portion is peeled of, apply sealing tape to the portion, according to the next
clause.

3-11
 3. Cautions on Meintenance Job
2) Tightening sleeve nut
Installing new nylon tube, sleeve and sleeve nut, attach the nylon tube firmly to the joint
connector and tighten the sleeve nut till proper revolutions by hand, and them tighten the
sleeve nuts till proper turns, using a tightening tool such as spanner.

Sleeve nuts Joint Sleeve nut

Tube Tool width Tightening torque
proper tightening
nominal across flat
turns
diameter (mm) N･m (kgf･cm)
(turn times)
1/8 8 1/2∼1 0.8 (9)
3/16 10 1/2∼1 1.8 (18)
1/4 12 1/2∼1 4 (41)
Nylon tube
3/8 17 1/2∼1 8.3 (85) TXT107

1/2 19 1/2∼1 12 (120)

Before installing nylon tube, check the size of A. If

you do not use caulking tool, check the size of A
again after removing it once.

After having tightened it, make sure to confirm

that the tube can not be removed by pulling it off.

It cannot be
pulled off at all
Press it in completely
till it touches this face
SCTXT050

In order to tighten sleeve nut correctly, keep the correct tightening turns of sleeve nut in accordance
with the nut turning constant times.
The optimum turning times mean the revolutions times after tightening the nuts fully by hand.
The tightening torque of above chart is referent value.

3-12
 3. Cautions on Meintenance Job
(7) How to install hose
Pay attation followig part when install hose and nylon tube.

1) Nylon tube Pressure gauge

① Check 3/16 size nylon tube for any break. (Pipe
for pressure gauge) Instrument Break
panel

Break

Receiver
tank

② Connect nylon tube, preventing it from

contacting any edge of copper pipe and steel pipe
nut. Contact

Make a gap

③ Make connection of nylon tube, taking care not

to touch the edge of bracket and plate etc. Cont
act

Pipe
④ Make connection of nylon tube and flexible pipe,
taking care not to touch any copper or steel pipe.
(If it is avoidably impossible, use it, being Cont
protected by felt) act

S_M121

3-13
 3. Cautions on Meintenance Job
2) Hose and flexible pipe
① Authentic hose and flexible pipe when replacing them. If not, it will cause oil leakage,
break and disconnection, and it leads to fire.

× ○
② Never use hose and flexible pipe twisted.
Twisted hose or flexible pipe will cause oil
leakage, break and fitting disconnection when
they are loaded with high pressure, vibration
and shock. The printed mark on outside surface
of hose is a guide for prevention of twisted
connection.
× Rub ○
③ Avoid contact between hose and flexible pipe. If
the hose and flexible pipe are rubbing each
other continuously, it causes damages and also
burst on hose and flexible pipe.
× ○
Clamp Clamp
④ Take care not to make hose and flexible pipe
touch sharp edge or moving part of the unit or
component.
Rub

× ○

Rub
Clamp

3-14
 4 Periodic Inspection/Maintenance
4.1 Periodic Inspection/Maintenance List
Regarding the items or parts marked ○ in the table of periodical maintenance customers or users should
perform periodical maintenance of the items or parts marked ○ by themselves. For such items or parts
marked ●, please contact us or distributor, because they need special technical knowledge.
The following table shows the intervals of inspection and maintenance under operating conditions. Perform
the inspection and maintenance, whenever the under mentioned period or operation hours come earlier.
(A) ; In case that total operation hours per one year are less than 3,000 hours
Maintenance interval
Inspection items Inspection points Every Every Every Every Every Remarks
Daily 1 month 1 year 2 years 4 years 6 years 8 years
Indication of each gauge ○ See the item “Daily maintenance”
Insulation
Coil ● Dry or change if less than 1M Ω.
resistance
Motor

Bearing Change ●
Sirocco fan Check ○ Clean if too dirty.
Compressor

Bearing Change ※2● ※1●

air-end

Mechanical seal Check/Change ○ ● Check for oil leak

(Check) (Change)

O-ring Change ●
○ Clean the filter whenever the
Air-filter Clean/Change (Change) warning lamp for clogging goes on.
Dustproof air filter Clean/Change ○ ●
(Clean) (Change)

Oil level Check ○ In case of oil shortage, replenish it.

Separator receiver tank

Receiver tank drain Drain ○

(Every week)
○
Lubricant Change (At 4 month for ○ Change if too dirty.
the first time)

Oil level gauge Clean/Change ○ ●

(Clean) (Change)

O-ring of oil filler Check ○ Re-usable after check, if normal.

Oil separator element Change ○

Scavenging orifice Clean strainer ○ ○
First time
○
Oil filter Change (At 4 month for ○
the first time)

Nylon tube Check/Change ○ ●

Pipe system

(Check) (Change)

Rubber hose Check/Change ○ ●

(Check) (Change)

O-ring Check/Change ○ ●
(Check) (Change)

Check valve for scaveng- ●

Check/Change (Check / Re-usable after check, if normal.
ing mechanical seal drain Change)

Check valve for vacuum ●

Check/Change (Check / Re-usable after check, if normal.
relief valve Change)

Oil cooler/After cooler Clean ● Clean if too dirty.

Consumable part of ●
Capacity controller

Change
unloader
O-ring of oil quantity ●
Change
adjustment valve
Set pressure Confirm ○
Safety valve Check performance ○
Check performance ○
Safety equipment

Check/Change
Pressure control valve O-ring
●
Check/Change
piston
● Re-usable after check, if normal.
Cylinder discharge air temp.
sensor Separator discharge Check ● Re-usable after check, if normal.
air temp. sensor
Bypass valve Change Pellet ●
Solenoid valve Change ● Re-usable after check, if normal.

Adjust tension ○ If abnormal, replace it.

Belt Replace the pulley, depending on its
Change ● conditions.

4-1
 4 Periodic Inspection/Maintenance
Regarding the periodical maintenance between inspection period and operation hours, maintenance or inspection should be performed,
roughly according to 250 hours/month, 3,000 hours/year, 12,000 hours/4 years, 18,000 hours/6 years and 24,000 hours/8 years.
※1 shows the interval time of bearing replacement for the compressor of the pressure of 0.69MPa.
※2 shows the interval time of bearing replacement for the compressor of the pressure of 0.83MPa.

(B) ; In case that total operation hours per one year are less than 6,000 hours
Maintenance interval
Inspection items Inspection points Every Every Every Every Every Remarks
Daily 1 month 1 year 2 years 4 years 6 years 8 years
Indication of each gauge ○ See the item “Daily maintenance”
Insulation
Coil ● Dry or change if less than 1M Ω.
resistance
Motor

Bearing Change ●
Sirocco fan Check ○ Clean if too dirty.
Compressor

Bearing Change ※2● ※1●

air-end

Mechanical seal Check/Change ○ ● Check for oil leak

(Check) (Change)

O-ring Change ●
○ Clean the filter whenever the
Air-filter Clean/Change (Change) warning lamp for clogging goes on.
Dustproof air filter Clean/Change ○ ●
(Clean) (Change)

Oil level Check ○ In case of oil shortage, replenish it.

Separator receiver tank

Receiver tank drain Drain ○

(Every week)
○ ○
Lubricant Change (At 2 month for
(Every 6month)
Change if too dirty.
the first time)

Oil level gauge Clean/Change ○ ●

(Clean) (Change)

O-ring of oil filler Check ○ Re-usable after check, if normal.

Oil separator element Change ○

Scavenging orifice Clean strainer ○ ○
First time
○ ○
Oil filter Change (At 2 month for
(Every 6month)
the first time)

Nylon tube Check/Change ○ ●

Pipe system

(Check) (Change)

Rubber hose Check/Change ○ ●

(Check) (Change)
O-ring Check/Change ○ ●
(Check) (Change)

Check valve for scaveng- ●

Check/Change (Check / Re-usable after check, if normal.
ing mechanical seal drain Change)

Check valve for vacuum ●

Check/Change (Check / Re-usable after check, if normal.
relief valve Change)

Oil cooler/After cooler Clean ● Clean if too dirty.

Consumable part of ●
Capacity controller

Change
unloader
O-ring of oil quantity ●
Change
adjustment valve
Set pressure Confirm ○
Safety valve Check performance ○
Check performance ○
Safety equipment

Check/Change
Pressure control valve O-ring
●
Check/Change
piston
● Re-usable after check, if normal.
Cylinder discharge air temp.
sensor Separator discharge Check ● Re-usable after check, if normal.
air temp. sensor
Bypass valve Change Pellet ●
Solenoid valve Change ● Re-usable after check, if normal.

Adjust tension ○ If abnormal, replace it.

Belt Replace the pulley, depending on its
Change ● conditions.

4-2
 4 Periodic Inspection/Maintenance
Regarding the periodical maintenance between inspection period and operation hours, maintenance or inspection should be performed,
roughly according to 500 hours/month, 6,000 hours/year, 24,000 hours/4 years, 36,000 hours/6 years and 48,000 hours/8 years.
※1 shows the interval time of bearing replacement for the compressor of the pressure of 0.69MPa.
※2 shows the interval time of bearing replacement for the compressor of the pressure of 0.83MPa.

Periodic Inspection of dryer

Maintenance interval
Items Points Remark
Daily Monthly Yearly
○ ○ Make sure condensate is properly
Auto drain valve Check/Clean (Check) (Clean) drained.
Make sure motor turns smoothly and
Fan motor Check ● without unusual noise.
Make sure there is no abnormal noise
Refrigerator Check ○ and no oil leak.
Condenser Clean ● Clean dust and dirt.
Regarding the items or parts marked ○ in the table of periodical maintenance customers or users should
perform periodical maintenance of the items or parts marked ○ by themselves. For such items or parts
marked ●, please contact us or distributor, because they need special technical knowledge.
・Only main components are mentioned in the table.
・Maintenance interval means that periodical maintenance should be repeatedly carried out.
・Use AIRMAN genuine parts and recommended oil for replacement.
・The maintenance intervals mentioned above are not guaranteed periods.

4-3
 4 Periodic Inspection/Maintenance
4.2 Inspection/Maintenance
Perform this job of inspection and maintenance safely, referring to the instruction manual for routine
inspection/maintenance.
Herewith only such items which are not mentioned in the instruction manual supplied together with
each unit shall be explained.

4.2.1 Electric motor

(1) Inspection of insulation resistance of motor coil

Make sure to switch off power supply switch.

Make sure to separate cables from contactor.
Never touch any terminal of each cable because insulation resistance will be reduced if touched.

1. Insulation between phase

① Separate motor cable from contactor.
② Measure the insulation resistance between U and V, V and W, then W and U.
③ Results of measurements: In case it is more than 1Ω, normal.
In case it is less than 1Ω, abnormal.

2. Insulation between ground and motor body

① Separate motor cable from contactor.
② Measure the insulation resistance between U and motor body (motor ground), V and motor
body, then W and motor body.
③ Results of measurements: In case it is more than 1Ω, normal.
In case it is less than 1Ω, abnormal.

3. Check coiled wires for disconnection (For reference)

① Separate motor cable from contactor.
② Measure the coiled wires resistance between U and X, V and Y, then W and Z with insulation
resistance tester.
③ Results of measurements: In case it is almost 0 Ω, normal.
In case it is infinite (∞), abnormal (disconnection).

4-4
 4 Periodic Inspection/Maintenance
(2) Replacement of motor bearing
Perform the replacement of motor bearing according to the following procedures.
① Remove the fixing bolts for the brackets on both load and noload sides, and then remove the
brackets from the frame, softly patting them with plastic hammer.
② Then pull out the rotor from the stator, preventing it from touching the stator.
③ Extract the motor bearing, using such tool as gear puller shown below.

Bearing

TXT079

④ Install the bearing with the jig or pipe applied as shown below.
When no press is available, install it by patting a jig or pipe by a plastic hammer.

Bearing
Jig

Press or
Plastic Hammer

TXT080

Never hammer directly the bearing with a metal hammer for inserting the bearing.
Never press it in by hammering holding the outer-lace of the bearing with metal pad.
As the bearing is installed with non-contact rubber seal and heat resisting long-life grease filled,
contact us for the details.
It is impossible that the bearing is pushed in by heating.

4-5
 4 Periodic Inspection/Maintenance
4.2.2 Separator receiver tank
(1) Cleaning and replacing oil level gauge
① When oil level gauge is so soiled that oil level cannot be checked, remove it and spray the
brake cleaning agent (used for automobiles) (components: toluene 40 – 45% and hexane 25 –
30%) into the gauge several times.
② Periodically replace it whenever the replacement time comes.

(2) How to install oil level gauge

Install the oil level gauge in the specified direction, namely with the red line downward.
Tighten the bolts for level gauge, applied by the following torques. Other torques than those
specified below can cause damages and oil leakage trouble.

26.0N･m(255kgf･cm)

Compressor oil quantity is normal when

the oil level is indicated between red lines
of oil level gauge during operation.

4.2.3 Discharge air sensor, air temperature sensor at cylinder outlet, and air
temperature sensor at separator outlet
(1) Checking the function
Check the function according to the following procedures.
① During operation, remove the sensor cable connected to the controller.
② Make sure to confirm that the unit is stopping and the lamp indicating abnormality glows.

(2) Checking the set temperature

Checking the set temperature according to the following procedures.
① Separate the cable between controller and sensor.
② Confirm the relations between temperature and resistance according to the following table.

Be careful not to tighten it excessively.

Tightening torque 2.0N･m(20kgf･cm)
S_M002
Features of temperature and resistance
Temperature ℃ Features of criteria resistance (Ω) Range of Resistance (Ω)
10 18028.8 19905.0∼16314.7
15 14416.4 15845.7∼13104.2
20 11604.7 12700.0∼10594.3
25 9401.0 10254.1∼8618.8
80 1318.2 1256.9∼1381.2
105 640.1 619.3∼661.1
110 559.8 543.0∼576.5

4-6
 4 Periodic Inspection/Maintenance
4.2.4 By-pass valve
(1) Principle of function
The valve is provided with pellets. The pellets shrink according to the temperature of flowing oil
of the valve so that the oil flowing passage can be automatically changed. When the oil
temperature is low, the pellet is kept shrunken so that the oil flows through the by-pass passage
of oil filter. As the temperature rises, the pellet expands to close the oil passage to the by-pass
passage and to open the flow outlet to oil cooler. Therefore, the oil flows to the oil cooler, thus
preventing the oil temperature from abnormally rising.

(2) Checking function

The by-pass valve functions correctly in case any abnormal rise of temperature and any other
abnormalities are not found.

(3) Replacement of the pellets

Remove the cover and replace the pellets and O-ring. Coat the new O-ring with compressor oil
and then tighten the cover.

＊The following Fig. shows the sectional view of By-pass valve when the oil temperature is low.
To oil filter (when the oil temperature is low)
Pellets

From separator
receiver tank

O-ring
S_M003

To oil cooler (when the oil temperature is high)

4-7
 5. Electrical System
5.1 Controller
5.1.1 Specification
Item Contents
･Continuous operation (Pressure range automatic adjusting system)
･E Mode operation (Function of most suitable pressure operation)
･Auto start/stop (Stop judgment time adjusting system)
Operation mode ･Remote control
･Dryer advance operation
･Instantaneous re-start
･Multi-units control operation (Option)
･Operation time
indication
Digital

･Current
･Start
･Stop
･ECO lamp
･Air filter
Indicator lamp

Warning

Indicator lamps on
operation panel ･Dryer
･Cylinder discharge air temp. (Lamp flickers at 105℃)
･Separator discharge air temp. (Lamp flickers at 105℃)
･Cylinder discharge air temp. ( Lamp glows at 110℃)
Function of Controller

Abnormal

･Separator discharge air temp. (Lamp glows at 110℃)

･Over current
･Opposite phase
･Pressure sensor
･Operating
Remote side indicator
･Abnormal
lamp
･Remote selection signal
･Cylinder discharge air temp. sensor disconnected or discharge air
temp. rises up to 110℃
･Separator discharge air temp. sensor disconnected or discharge air
Emergency stop temp. rises up to 110℃
(Start lock) ･When thermal relay functions
･Power supply is connected in reverse phase and T phase is missing
･Pressure sensor disconnected or discharge pressure exceeds 0.98MPa
(10kgf/cm2)
･Adjusting range of full load recovery pressure : 0.50∼0.79MPa (5.1∼
Adjusting range of 8.0kgf/cm2)
discharge air pressure ･Adjusting range of unload starting pressure : differential pressure
against full load recovery pressure 0.08∼0.39MPa (0.8∼4.0kgf/cm2)
Judgment time for auto
･30∼150 seconds
start/stop mode stopping
･Y operation time 4±0.2 seconds
Y-Δtiming
･Ｙ−Δselection time 0.048±0.008 seconds

Starting unloader ･5±0.2 seconds

5-1
 5. Electrical System
＊Function of control output relay
Symbol Function Symbol Function
･It switches ON by operation ･Capacity control signal
This is used as operation indicator Switching it ON, it starts full load
RY0 RY5
lamp for remote control operation operation. Switching it OFF, it starts
unload operation
･Dryer operation signal ･Failure signal
RY1 Switching it ON, it starts dryer RY6 When it is in trouble, it switches ON. When
operation. Switching it OFF, it stops warning occurs, it will not output
RY2 ･It switches ON by operation ･Remote selection signal
RY7
RY3 ･It switches ON by Y operation It switches ON by remote selection
RY4 ･It switches ON by △ operation

5.1.2 Explanation about operation modes

Operation mode Contents
When air consumption decreases and discharge pressure rises, unloader valve
functions to close the inlet port to compressor air end and accordingly oil feed
Continuous
adjusting device functions to minimize oil feed. At the same time, it collects oil
operation
and compressed air from the discharge port of air end and sends them into the
separator receiver tank, thus reducing the power of compressor.
When selecting E mode by E mode selection switch, the set pressure is
E Mode operation automatically switched to the low pressure operation with 0.04MPa
(0.4kgf/cm³), thus enabling energy saving operation.
Conditions of Auto Stop
･When operation time passes 10 minutes or more, and unload integrating time
exceeds 60 seconds, and further longer stop time than stop judging time is
anticipated.
Auto start/stop
･After dryer built-in type unit stops, dryer continues to operate.
operation
Conditions of Re-start
In case the pressure on load drops till full load recovery pressure.
But within 30 seconds after stopping, it will not re-start because this time is
required for discharging compressed air.
Wired to the remote control terminal plate, start/stop operation can be done
remotely. Stop operation can be done at machine side also.
Remote Machine side Remote control
control
button Start Stop Start Stop
Remote control OFF ○ ○ × ×
operation ON × ○ ※1 ○ ※2 ○
※1 If stopped at machine side, remote control mode is reset. In case remote
control mode is selected again, button ON after pushing OFF first.
※2 Remote start can be done while remote start contact is OFF →
(ON continuous). Therefore, while remote start contact is ON, it will not
start even after pushing ON microprocessor remote start button.
Dryer advance
Pushing start button, dryer starts first, and then unit start 3 minutes later.
operation
Even when compressor stops by instantaneous stop of power, and if it will be
Instantaneous stop
recovered within 2 seconds, it begins to run again 30 seconds after recovery.
re-start operation
The operation mode before stopping is maintained even after restarting.
When operating some units in parallel, automatic control of the units in
Multi-units control accordance with the air consumption will serve to save much energy.
operation This is a rotary multi-unit control system. Starting the unit which is operating
(Option) for the shortest time, and stopping the unit which is operating for the longest
time. Thus it can equalize operation time for the units which are operating.
For the details, see instruction manual.

5-2
 5. Electrical System
5.1.3 Operation panel
1 6 7 8 9 10 11 12

MULTI-UNITS
CONTROL OPERATION

・
13 2 3 4 5 14 15 16
A050467E
Item Contents
･When switching power ON, this monitor digitally indicates operating hour×
10hr.
1 Digital monitor ･Pushing the selector switch, it digitally displays motor current at A.
･In order to make this monitor display the operating hour again, push the
selection switch ON.
･During auto stop (both auto start/stop indicator and start indicator lamps
light on), pushing auto start/stop button, auto start/stop mode will be released
and compressor will stop. (only stop indicator lamp lights)
Auto start/stop
2 ･During auto stop (both auto start/stop indicator and start indicator lamps
button
light on), pushing the stop button, auto start/stop mode will be maintained,
but compressor stops and it will not restart. (both auto start/stop indicator and
stop indicator lamps light on)
･While remote control indicator lamp glows, it is possible only to start remotely.
･It is possible to stop operation at machine side and remotely too. But when stopping
operation at machine side, remote control mode is reset and model become standard
mode. When selecting remote control mode again, button OFF the remote control
button and extinguish remote control indicator, then push remote control button
Remote control
3 and turn on remote control indicator again.
button
･It is possible to change standard mode to remote control mode during machine
moving under standard mode, if remote side connection is ON condition.
･In case the remote side starting contact is “ON”, it will not start even by to the
remote control mode. First, switch the remote control mode “OFF” and then
switch it “ON”. Then it can be started.
･Even when dryer is not connected or mounted, the indicator lamp of dryer
advance operation glows with this button pressed.
･When light on the dryer advance indicator lamp, push start button.
Compressor will starts after 3 minutes, even with dryer not connected.
Dryer advance ･When dryer advance indicator lamp lights, dryer will stop and compressor will
4
operation button not start if stopping dryer advance operation (namely, pushing the dryer
advance operation button again) before starting compressor, dryer stops and
compressor will not start.
･In case of auto start/stop operation, even if compressor automatically stops,
dryer still continue operating.

5-3
 5. Electrical System
Item Contents
･The number of the units to be controlled by this system: Any number of units
can be controlled with this system without limit.
･It is possible to intently decide the first starting unit by pushing the start
button of the first unit. Thus multi-unit control system can be performed.
Multi-units
･It is possible to skip such unit which is troubled or any unit which is not
5 control operation
controlled by this system, namely possible to exclude such units from the units
button (Option)
controlled by this system.
･It is possible to keep the first starting unit operated under this system and the
other units operated at full load. Thus it prevents useless start/stop operation,
and consequently it enables most efficient operation.
･ When air filter gets clogged and differential pressure reaches 6.2kPa
Air filter (635mAq), lamp glows after 10 seconds.
6
indicator lamp ･While operating compressor, lamp glows 10 seconds later after the cable to the
differential pressure switch gets short circuited.
･Lamp will glows 1 second after each sensor of dryer functions or unit stop by
Dryer indicator
7 thermal relay function.
lamp
･When it stops due to disconnection of dryer, it will not glow.
Cylinder ･When air temp. reaches 105℃, lamp flickers.
discharge air ･When air temp. reaches 110℃, it causes emergency stop.
8
temp. indicator ･Lamp glows due to disconnection or short circuit of thermo sensor and it
lamp causes emergency stop.
Separator ･When air temp. reaches 105℃, lamp flickers.
discharge air ･When air temp. reaches 110℃, it causes emergency stop.
9
temp. indicator ･Lamp glows due to disconnection or short circuit of thermo sensor and it
lamp causes emergency stop.
･When thermal relay functions, lamp glows and it causes emergency stop 0.4
Over current seconds later.
10
indicator lamp ･When thermal relay functions and it stops it is impossible to release it to push
reset button, if thermal relay is set manual operation.
･In case of reverse phase connection or T phase missing, lamp glows 1 second
after power is supplied, and it is impossible to start. When R or S phase is
missing, monitor will not indicate because power supply for controller is not
sent. And it can not start.
Opposite phase
11 ･If phase missing occurs while compressor is running, it stops. (Only in case
indicator lamp
that phase loss occurs to T phase, the indicator lights on.)
･It is possible to detect reverse phase connection of power supply, but it is
impossible to detect reverse phase connection of motor. If motor only is
connected in reverse phase, the motor starts to turn in reverse direction.
･When pressure sensor is disconnected or discharge pressure exceeds 0.98MPa
Pressure sensor
12 (10kgf/cm²), the indicator lights on and compressor stops make emergency
indicator lamp
stop.
13 ECO lamp ･This lamp lights on during unloaded operation.
･Unless contents of warning and abnormalities are revised, it is impossible to
release the mode.
14 Reset button
･ Even if they are revised, it is impossible to extinguish warning and
abnormality lamps unless they are reset.
･After power is supplied, it starts by pushing this button.
･ Lamp glows during machine moving. During automatic stop under auto
start/stop mode, and also during operation under dryer advance operation
Start button/ mode, indicator lamp glows.
15
Indicator lamp ･Indicator lamp flickers while waiting for instantaneous restart.
･Even if the start button is pushed on while compressor is kept stopping by the
auto start/stop mode, it will not start again unless the receiver tank pressure
drops.
･Pushing stop button during remote control operation, it will stop.
･When power is supplied, indicator lamp glows. During operation lamp is OFF.
･During automatic stop under auto start/stop mode, indicator is OFF.
Stop button/
16 ･During stop under auto start/stop mode, (both auto start/stop indicator and
Indicator lamp
start indicator lamps light on), pushing the stop button, auto start/stop mode
will be maintained, but compressor stops and it will not restart. (Both auto
start/stop indicator and stop indicator lamps light on)

5-4
 5. Electrical System
5.1.4 Checking indication of warning & abnormalities and also checking
emergency stop
Item How to check Normal function Time lug
Short circuit the cable connected to
Warning indicator lamp
Air filter the air filter differential pressure 10 seconds
glows.
switch.
Remove the sensor from controller
Cylinder discharge and load resistance of 619.3∼661.1 Warning indicator lamp
−
air temp. Ω to controller with variable flickers.
Warning

resistor.
Remove the sensor from controller
Separator discharge and load resistance of 619.3∼661.1 Warning indicator lamp
−
air temp. Ω to controller with variable flickers.
resistor.
During operation, trip thermal
Warning indicator lamp
Dryer relay by hand. (Be careful about 1 second
glows.
electric shock.)
･Remove sensor from controller
during operation.
Abnormality indicator
Cylinder discharge ･Remove sensor from controller
lamp glows and unit −
air temp. and load 543.0∼576.5Ω of
stops.
resistance to controller by
variable resistor.
Abnormality/Emergency Stop

･Remove sensor from controller

during operation.
Abnormality indicator
Separator discharge ･Remove sensor from controller
lamp glows and unit −
air temp. and load 543.0∼576.5Ω of
stops.
resistance to controller by
variable resistor.
Abnormality indicator
During operation thermal is 0.4
Over current lamp glows and unit
tripped by hand. seconds
stops.
When power is supplied,
After cutting power supply, charge
abnormality indicator
R phase for T phase.
Opposite phase lamp glows, and unit will 1 second
Cutting power supply, remove T
not start even by pushing
phase.
start button.
Abnormality indicator
Remove connector of pressure
Pressure sensor lamp glows and unit −
sensor during operation.
stops.

5-5
 5. Electrical System
SAS22UD-58/68

Upper side drawing Inside of starter S_M166

SAS37UD-58/68

Upper side drawing Inside of starter

S_M167

1. Dryer 5. Main motor thermal relay

2. Air filter differential pressure switch 6. Thermistor high sensitivity sensor
3. Pressure sensor 7. Thermistor high sensitivity sensor
4. Connection of power supply 8. E Mode selection switch

5-6
 5. Electrical System
5.1.5 Position of connector pins and circuit voltage

S_M105

Item Circuit voltage (V) Remark

Remote control selection single
1 AC100∼220 Supplied by customer
indicator lamp
CN1 Power supply for remote control
2 AC100∼220 Supplied by customer
indicator lamp
3 Remote operation indicator lamp AC100∼220 Supplied by customer
4 Solenoid valve for capacity control AC200/200/220
5 Electromagnet contactor for star AC200/200/220
For power supply

6 Power R2(for micon) AC200/200/220

7 Power S1(for micon) AC200/200/220
8 Electromagnet contactor of dryer AC200/200/220
9 Remote abnormality indicator lamp AC100∼220 Supplied by customer
10 Power R2 AC200/200/220
11 Electromagnet contactor for delta AC200/200/220
12 Contactor for insulation AC200/200/220
13 Power T1 AC200/200/220

5-7
 5. Electrical System

Item Circuit voltage Remark

When pressure 0MPa : 0.5V
1 Pressure sensor output DC0.5∼4.5V(between CN2-2) When pressure
CN2 0.98MPa :4.5V
2 Pressure sensor GND −
3 Current sensor − CT ratio: 1:1,000
4 Current sensor − CT ratio: 1:1,000
Normal : 0V Abnormal : OFF B
5 Failure of dryer Abnormal : DC12V(between connect
CN2-11) Time lag :1 second
Abnormal : OFF A
Air filter differential Normal : DC12V
6 connect
pressure switch Abnormal : 0V(Between CN2-11)
Time lag : 10 seconds
7 Switch GND −
During operation : 0V
8 Remote start switch During stop condition Supplied by customer
For sensor

: DC12V(Between CN2-9)
9 Remote start switch GND −
10 Pressure sensor power DC5V(Between CN2-2)
11 Switch GND −
12 Switch GND −
Normal : 0V Abnormal : OFF B
13 Thermal relay Abnormal : DC12V(between connect
CN2-11) Time lag : 0.4 seconds
14 Switch GND −
15 Blank −
16 Switch GND −
Selection of usual unit :0V
Selection switch of usual
17 Selection standby unit :DC12V Supplied by customer
unit and standby unit
(between CN2-9)
Separator discharge air Detect abnormality
1 Lass than DC5V(between TB1-2)
temp. sensor Resistance : 543.0∼576.5Ω
TB1 2 Air temp. sensor GND −
Cylinder discharge air temp. Detect abnormality
3 Lass than DC5V(between TB1-2)
sensor Resistance : 543.0∼576.5Ω

5-8
 5. Electrical System
5.2 Electrical Parts
5.2.1 Specifications
(1) Starter, Solenoid valve, Hour-meter
SAS22UD-58/68
Symbol Name Maker Model Remarks
For insulation, for delta
MITSUBISHI
42,52 Electromagnet contactor S-N65 operation (surge damping
Electric
valve built-in)
MITSUBISHI For star operation (surge
6 Electromagnet contactor S-N35
Electric damping valve built-in)
52C Electromagnet switch Fuji Electric FW-0 For dryer
MITSUBISHI
49 Thermal relay TH-N60KP For protection of motor
Electric
F Fuse holder Sakazume FHC-15 (AC250V,15A)
Fuse Not specified φ6.4×30 (AC250V,5A)
TB10 Terminal plate Izumi BN15MW(12P) For remote control
Solenoid valve(3
SV1 CKD AG4X7908 For capacity control
way)
Solenoid valve(2 For auto-relief, for
SV2,SV3 CKD FAB42-X0679
way) separator recovery

SAS37UD-58/68
Symbol Name Maker Model Remarks
For insulation, for delta
MITSUBISHI
42,52 Electromagnet contactor S-N95 operation (surge damping
Electric
valve built-in)
MITSUBISHI For star operation (surge
6 Electromagnet contactor S-N65
Electric damping valve built-in)
52C Electromagnet switch Fuji Electric FW-0 RC=9A For dryer refrigerator
52CF Electromagnet switch Fuji Electric FW-0 RC=0.64A Fan for dryer condenser
MITSUBISHI
49 Thermal relay TH-N120KP For protection of motor
Electric
F Fuse holder Sakazume FHC-15 (AC250V,15A)
Fuse Not specified φ6.4×30 (AC250V,5A)
TB10 Terminal plate Izumi BN15MW(12P) For remote control
Solenoid valve(3
SV1 CKD AG4X7908 For capacity control
way)
Solenoid valve(2 For auto-relief, for
SV2,SV3 CKD FAB42-X0679
way) separator recovery

5-9
 5. Electrical System
(2) Sensor, Switch
Name Symbol Monitor Maker Remarks
Air filter differential NIPPON 6.2kPa(635mmAg)
ACR Air filter
pressure switch DONALDSON, LTD. DC12V A contact
Cylinder discharge air
TLE1 SAGINOMIYA 543.0∼576.5Ωat 110℃
temp.
Thermo sensor
Separator discharge
TLE2 SAGINOMIYA 543.0∼576.5Ωat 110℃
air temp.
0.5∼4.5V
Pressure sensor PRS Pressure sensor Nihon DENSO
(0∼0.98MPa)
Detecting opposite
− Opposite phase − Detect it with controller
phase

5.2.2 Electromagnet contactor

Electromagnet
Electromagnet Thermal relay
Model Kinds Maker contactor Thermal relay Type
switch Type set value (A)
Type
For MITSUBISH S-N65
− − −
insulation I Electric 2a2b
MITSUBISH TH-N60KP
For motor

For
− − 54.0/51.0/48.0
protection I Electric RC=54A(43∼65A)
SAS22UD

For MITSUBISH S-N35

− − −
Star I Electric 2a2b
For MITSUBISH S-N65
− − −
Delta I Electric 2a2b
FC-0 TR-0
For dryer Fuji Electric FW-0 9.0/9.0/9.0
1a RC=9A(7∼11A)
For MITSUBISH S-N95
− − −
insulation I Electric 2a2b
TH-N120KP
MITSUBISH
For motor

For
− − RC=82A(65∼ 90.0/85.0/80.0
protection I Electric
100A)
MITSUBISH S-N65
SAS37UD

For
− − −
Star I Electric 2a2b
For MITSUBISH S-N95
− − −
Delta I Electric 2a2b
For dryer FC-0 TR-0
Fuji Electric FW-0 10.5/10.5/10.5
refrigerator 1a RC=9A(9∼13A)
Fan for TR-0
FC-0
dryer Fuji Electric FW-0 RC=0.64A 0.7/0.7/0.7
1a
condenser (0.64∼0.96A)

5-10
 5. Electrical System
(1) Electromagnet contactor
Type: S-N35

M3.5

M3.5 M5 Structure of contacts S_M160

Type: S-N65

M6

17 Structure of contacts S_M094

Type: S-N95

M6

15
Structure of contacts S_M095

Type: FC-0

Structure of contacts
M3.5 S_M093

5-11
 5. Electrical System
(2) Thermal relay
Type: TH-N60KP

M4
M6 Structure of contacts S_M161

Type: TH-N120KP

M4
Structure of contacts
M8 S_M138

Type: TR-0

Structure of contacts S_M025

5-12
 5. Electrical System
5.2.3 Solenoid valve
(1) For capacity control
NO (Rc 1/4)

COM

NC NO

･Closed while electricity is supplied (NO)

COM NC
(Rc 1/4) (Rc 1/4)
Diameter of orifice (φ2mm) S_M120

(2) For auto-relief, for separator recovery

OUT

IN IN
OUT
(Rc 1/4) (Rc 1/4) ･Closed while electricity is supplied

Diameter of orifice(φ3mm) S_M039

5.2.4 Differential pressure switch of air filter

･Operating resistance:635±58mmAq(initial feature) TXT015

･A Contact

5-13
 5. Electrical System
5.2.5 Thermo sensor

S_M008

※ For the relation between temperature and resistance, refer to 4.2.3.

5.2.6 Pressure sensor

②GND ①VOUT ③VC

SCTXT027

Cable Signal
Outlet (DC0.5∼4.5V)
2
At the pressure 0MPa(0kgf/cm ), DC0.5V
2
At the pressure 0.1MPa(1kgf/cm ), DC0.9V
①VOUT 2
At the pressure 0.6MPa(6kgf/cm ), DC2.9V
2
At the pressure 0.69MPa(7kgf/cm ), DC3.3V
2
At the pressure 0.98MPa(10kgf/cm ), DC4.5V
②GND Common
③VC 5V

5-14
 5. Electrical System
5.3 Electrical Wiring Diagram
5.3.1 Dryer built-in type
(1) SAS22UD-58/68 (200/200/220V Type)

S_M168E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-15
 5. Electrical System
(2) SAS37UD-58/68 (200/200/220V Type)

S_M169E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-16
 5. Electrical System
(3) SAS22UD-58/68 (400/400/440V Type)

S_M174E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-17
 5. Electrical System
(4) SAS37UD-58/68 (400/400/440V Type)

S_M175E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-18
 5. Electrical System
5.3.2 Without dryer type
(1) SAS22U-58/68 (200/200/220V Type)

S_M176E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-19
 5. Electrical System
(2) SAS37U-58/68 (200/200/220V Type)

S_M177E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-20
 5. Electrical System
(3) SAS22U-58/68 (400/400/440V Type)

S_M178E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-21
 5. Electrical System
(4) SAS37U-58/68 (400/400/440V Type)

S_M179E

※: Such things in the parenthesis are used for the products which were produced before September, 2007.

5-22
 5. Electrical System
5.4 Adjustment
5.4.1 Adjustment of discharge pressure

As the discharge pressure is adjusted before shipment, do not readjust it during the normal operation.
Do not set the unload start pressure higher than the specified setting value. Operation at higher
pressure than specified set value would lead to motor overloading and motor burning and parts.

The unload start pressure (PH) and full load recovery pressure (PL) can be adjusted by the following
procedures:
<Procedures>
① While watching the discharge pressure gauge
reading, turn VR3 to adjust the full load recovery
pressure. Clockwise turning increases the recovery
pressure.
During adjustment, the VR2 should be kept
minimized.
② In the same manner, turn VR2 to adjust the unload
start pressure.
Clockwise turning increases the start pressure. PK0434E

Standard setting value of pressure

Discharge pressure 0.69MPa 0.83MPa
Full load recovery 0.59 MPa 0.74 MPa
pressure (PL) (6.0 kgf/cm2) (7.5 kgf/cm2)
Unload start 0.69 MPa 0.83 MPa
pressure (PH) (7.0 kgf/cm2) (8.5 kgf/cm2)

When VR3 is turned to adjust the full load recovery pressure (PL), the unload start pressure (PH)
automatically changes by variations of PL. In such a case, readjust PH.
Even when VR2 is turned to adjust the unload start pressure (PH), the PL will remain unchanged.
Therefore, no readjustment of PL is required.

5.4.2 Adjustment of judged stop time

Compressor stop time is calculated according to
the pressure drop speed during auto start/stop Standard
Item Remarks
operation and this time is a standard one to be setting
adjusted to stop compressor. Stop criterion Turn VR1 fully
30 seconds
time (Ts) counterclockwise.
Turn VR1 to adjust the time. Adjustable ranges
are between 30 and 150 seconds.
When the compressor repeats start and stop
frequently, adjust it to prolong the time.

5-23
 6. Troubleshooting
6.1 How to Proceed Diagnosis
When performing failure diagnosis, pay special attention to the followings, observing general
cautions.

6.1.1 Safety caution

(1) Removing such cap and/or plug for receiver tank, fuel tanks and pipes where pressure is
loaded, stop the machine and relieve all the interior pressure. Install measuring instruments
connected firmly.
(2) When doing the job with co-worker(s) together, make sure to give signal to the other
person(s) and do not allow other persons to come near to the job site.
(3) Take care not to touch hot portions and not to be involved in turning portions.

6.1.2 Caution during failure diagnosis

(1) Do not make haste to disassemble the unit
If the unit is disassembled urgently.
①You may disassemble the other portions which are not related with the trouble.
②The cause of trouble may be missing.
The unnecessary reparations require more spare parts and man-hours, and reparation costs will
increase more. What is worse, you will lose reliance or trust from clients，operators and users.
Therefore, it is absolutely necessary to investigate the trouble more carefully in advance and to
follow the required procedures for failure diagnosis.

(2) Ask the clients about the trouble in details

In order to prevent misunderstanding and incorrect judgment about the trouble, it is necessary
to ask users or operators about the following questions.
①Is there any other disorder than the trouble he has informed?
②Anything abnormal occurred before this trouble?
③Did this trouble happen unexpectedly? Or the unit had been operated in bad conditions before?
④When and how did this trouble occur?
⑤Had he repaired the unit before this trouble occurred?
⑥Did he not experience similar trouble before?

(3) Inspection items before starting diagnosis

Sometimes such trouble may be caused owing to routine mishandling of the unit. Before starting
failure diagnosis, check the following items.
①Check whether compressor oil is lacking or dirty.
②Check each cable connection for any disconnection.
③Check the other portions for any damage.

6-1
 6. Troubleshooting
(4) Confirmation of trouble
Discuss with user(s) and/or operator(s) sufficiently about the trouble. As a result, judge whether
their judgment is based on the numerical comparison or sentimental basis. Make him (them)
understand well the reparation or correction you have finished.
Then check and confirm by yourself the cause of the trouble.
Note) Never proceed any investigation or measurement which may cause further greater damage.

(5) Procedures of diagnosis

When you become well experienced, you can find out the cause easily during the process of
confirmation (4). But easy understanding could cause unexpected failure. So check and judge it
according to the following procedures.
①Check the easiest thing or portion first.
②Investigate the most possible cause.
③Check the other things connected to the trouble.
④Check for the possibility of any other troubles.
⑤Start proper and careful investigation on this trouble.

(6) Prevention of repeated occurrence of similar trouble

Even if you have repaired the trouble, unless you get rid of the fundamental cause of the trouble,
it will repeatedly occur. Therefore, perform full investigation of the trouble, and it is absolutely
necessary to remove the basis of the trouble.

6-2
 6. Troubleshooting
6.1.3 How to use failure diagnosis table

Standard

Ａ Ｂ Ｃ
High

Possible

Impossible

Abnormal

Normal

① In troubleshooting column The item in the column.

This item is mentioned confirmation of abnormal phenomena.
② In troubleshooting column The item in the column.
The cause is mentioned shows the cause of the said trouble.
③ In troubleshooting column The item in the column.
The measures and/or treatment shows the measures and or treatment the said cause.
④ A
Ａ under each column shows the explanation of the column.

6-3
 6. Troubleshooting
6.2 Failure of Capacity Control System
6.2.1 Unloader will not function and safety valve blows off

Normal Repair or replace safety

Check set pressure Faulty safety valve valve

High

Check whether it is Possible Faulty pressure Re-adjust pressure

possible to adjust pressure adjustment
Ａ Ａ
Impossible

Check function of pressure Abnormal Faulty pressure sensor or Replace pressure sensor
sensor and controller controller or controller
Ｂ
Normal

Check whether solenoid Abnormal

valve SV1 functions Faulty solenoid valve Repair or replace
correctly SV1 solenoid valve SV1

Ｃ
Normal

Check for air leak in Air leaks Air leaks in unloader Repair the portion of air
unloader system line system line leak

No air leaks

Disassemble and check Abnormal

Faulty unloader valve Repair unloader valve
unloader valve
Ｄ
Normal

Abnormal Damaged mechanical seal

Check mechanical seal Replace mechanical seal

6-4
 6. Troubleshooting

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check whether it is Method of adjustment…refer to 5.4.1
possible to adjust
pressure
B Check function of Check if the pressure sensor functions properly. Check pressure sensor
controller (refer to 5.2.6) If it does not indicate proper function
signal, the pressure sensor is faulty.
If the pressure sensor is correct, check if the Replace controller
solenoid valve SV1 shows correct volume control
signal.
When it starts…no conductivity is found
About 10 seconds after it starts…conductivity is
found
After it rises to the specified pressure…no
conductivity is found
When no conductivity can be found even after the
tank pressure exceeds 0.59MPa(6kgf/cm²) at full
load or when the unloader set pressure is
lowered utmost, it means owing to the defect of
controller.
C Check whether Lower the unloader starting pressure to Repair or replace
solenoid valve minimum during full load operation. Under these solenoid valve
functions correctly
conditions, remove the pipe connected to
unloader chamber, and then make sure that
discharge air is delivered (when the solenoid
valve is switched to no conductivity) after the
pressure exceeds the pressure of about 0.59MPa
(6kgf/cm2 ).
If not, the solenoid valve is faulty.
D Disassemble and After disassemble unloader valve, check to If you find some
check unloader valve function of piston moving condition and valve abnormal function or
seal condition. scratch, scar, should
replace damage part
E Check mechanical If air is taken in through sealing portion, Replace mechanical
seal unloader valve is closed, but raise tank pressure seal
and safety valve sometimes functions.

6-5
 6. Troubleshooting
6.3 Function of Emergency Switch
6.3.1 Cylinder outlet air temperature lamp and/or separator outlet temperature
lamp glows and the machine stops

Over 40℃
Check ambient temp. Ambient temp. too high Lower ambient temp.

Ａ
Under 40℃ Unload starting pressure
is too high
Discharge pressure high Re-adjust discharge
Check discharge pressure
pressure
Unload starting Ｂ
pressure is normal
Clogged
Check oil filter clogging Oil filter clogging Replace oil filter

Not clogged

Check comp. oil level and Abnormal Shortage of comp. oil and Replenish comp. oil or
oil for dirty or dirty replace

Normal
Abnormal Dust filter clogged Clean dust filter
Check dust filter, oil cooler
Oil cooler fins clogged Clean oil cooler
and fan
Cooling fan damaged Repair cooling fan
Normal

Check disconnection of Abnormal Disconnection of thermo Repair or replace thermo

thermo sensor sensor sensor

Normal Ｃ

Check whether solenoid Abnormal

valve SV3 functions Faulty solenoid valve Repair or replace
correctly SV3 solenoid valve SV3

Ｄ
Normal

Check function of Abnormal

controller Faulty controller Replace controller

Ｅ
Normal

Check function of by-pass Abnormal Malfunction of by-pass

valve or inside of oil Replace by-pass valve or
valve and also check the
cooler clogged clean oil cooler
oil cooler for clogging
Normal

(When light on separator outlet temp. lamp only)

Check for any burned Abnormal Heated separator element Replace separator
separator element element

6-6
 6. Troubleshooting

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Lower ambient temp. It sometime happen that temperature of the Ventilate suction and
room is heated over 40℃ by compressor installed discharge air fully of
in poorly ventilated. It causes overheating the room
B Re-adjust discharge For adjustment…refer to 5.4.1
pressure
C Check disconnection It sometime happen that snapping of thermo Repair or replace
of thermo sensor sensor by vibration or faulty of fittings. So, check sensor
thermo sensor resistance by tester. (For the
relation between temp. and resistance, refer to
4.2.3)
D Check whether Make sure that the solenoid valve is switched to Repair or replace
solenoid valve SV3 supply electricity and it stops separator recovery. solenoid valve SV3 or
functions correctly
If recovery function will not stop, the solenoid electrical circuit
valve SV3 or electric circuit is faulty.
E Check function of Operate the compressor and check whether the
controller discharge air temp. exceed 110℃.
In case the unit stops even under normal temp.,
the controller is faulty. And when temp. exceeds
110℃, it is normal.
Instead of resistance value when it shows
disorder.
(For the relation between temp. and resistance,
refer to 4.2.3)

6-7
 6. Troubleshooting
6.3.2 Over current lamp glows and the unit stops
(In case it stops before full load operation starts)

Check whether
Not turn Trouble of compressor Repair compressor
compressor Air-end can be
Air-end Air-end
turned by hand

It can be turned by hand

Check if any abnormal It occurs Shortage of power or Remove the cause of

voltage drop occurs faulty connection voltage drop
No voltage Ａ
drop
Check function of Abnormal
controller Faulty controller Replace controller

(In case it stops after full load operation starts)

Unload starting pressure

is too high
Check discharge pressure Discharge pressure high Re-adjust discharge
pressure
Unload starting pressure
is normal
Check set value of thermal Too low Faulty adjustment of
Re-adjust thermal relay
relay thermal relay
Ｃ
Normal

Check current value at full Normal Repair or replace

Faulty thermal relay
load thermal relay
Abnormal
Ｄ
(Over rated
value)
Check for any unbalance Abnormal Remove the cause of
of voltage between each Abnormal voltage
phase faulty voltage

Normal

Check whether
compressor Air-end can be Not turn Trouble of compressor Repair compressor
turned with light power by Air-end Air-end
hand

6-8
 6. Troubleshooting

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check if any Check such items as shortage of power supply,
abnormal voltage length of wiring, and cable size. They cause
drop occurs
abnormal drop of voltage.
《Reference》
Allowable voltage drop rate shall be within 15％.
B Check function of Check voltage between wire No.22 and 28.
controller In case of emergency stop despite DC 0V, Replace controller
controller is faulty.
Din case of emergency stop due to occurrence of
DC12, controller is acceptable
C Check set value of For the set value, refer to 7.1
thermal relay
D Check current value For the current value, refer to 7.1
at full load

6-9
 6. Troubleshooting
6.3.3 Opposite phase lamp glows

Exchange R phase and T Light off

phase and check if the Opposite phase Exchange phases
lamp glows or not

Lamp glows

Power phase T is lost Repair power supply

6.3.4 Pressure sensor lamp glows

Disconnected
Check pressure sensor for
any disconnection Disconnection Replace

Ａ
Not disconnection found

Check function of
controller Faulty controller Replace controller

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check pressure Check whether output voltage exists properly at For the output voltage,
sensor for any the inlet of controller. And also check the coupler refer to 5.2.6
disconnection
for any defects in connection.
B Check function of If no any other causes can be guessed at all,
controller check the controller carefully. Remove the
coupler of pressure sensor, and short-circuit No.1
and 2 pin of controller CN2. Push the reset
button and if it goes of, the sensor is out of order.
If it will not go off, the controller is defective.

6-10
 6. Troubleshooting
6.3.5 Dryer lamp glows

Check for overheating of Overheated Remove cause of

Overheating
dryer overheat
Not Ａ
overheated

Check function of pressure Abnormal Faulty pressure switch Replace pressure

switch for fan control for fan control switch for fan control

Normal

Check for looseness or Fault found

disconnection of wire Faulty wire connection Check and repair
connection

Nothing wrong found

Check function of Faulty controller Replace controller

controller
Ｂ

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check for Higher ambient temperature than 40℃ and poor Suction of air and
overheating of dryer ventilation of dryer may cause overheating. Pay ventilation of the room
carefully attention to them especially in summer shall be sufficient
season. To reset, release the
reset button inside
dryer
B Check function of In case other causes can be found, check Replace controller
controller controller. Measure voltage between cable No.33
and 28.
DC0V : under normal operation
DC12V: when thermal relay functions
When dryer lamp cannot be reset under normal
operation, controller is faulty.

6-11
 6. Troubleshooting
6.4 Others
6.4.1 Oil is found mixed in discharge air (Oil consumption increases)

Too much
Check comp. oil level Too much oil Drain oil

Proper level 2
Less than 0.39MPa(4kgf/cm )
Check and adjust
Check discharge pressure Low discharge pressure
pressure control valve
2
More than 0.39MPa(4kgf/cm )

Check scavenging orifice Clogged Scavenging orifice Disassemble and clean

clogging clogging scavenging orifice

Not clogged

Check solenoid valve SV3 Clogged Solenoid valve SV3 Disassemble and clean
clogging clogging solenoid valve SV3

Not clogged

Check separator element Not good Separator element Replace separator

Not clogged
for deterioration deteriorated element

6.4.2 Abnormal noise emission from belt

Slippage found
Check belts for slipping Loose belts Adjust belt tension or
replace
Ａ

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check belts for Abnormal noise is emitted due to slippage by Adjust belt tension or
slipping primary elongation or friction replace

6-12
 6. Troubleshooting
6.4.3 Compressor start and stops too frequently while no air is consumed
(Auto-start-stop mode)

Air leaks Repair air leaking

Check air leak from piping Air leaks from piping
portion

No air leaks

Check any air leaks from Air leaks

the seat of pressure Faulty seat Repair or replace
control valve
Ａ

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check any air leaks The control valve functions as a check valve also. Replace the seat of
from the seat of If air is leaking, the air in the second side is sent pressure control valve
pressure control
out through the piping of auto relief valve, and
valve
accordingly automatically starts and stops.

6.4.4 Compressor often stops without abnormal indicator lamp glowing and
knowing no reason of the phenomena

Check function of Abnormal Repair or replace

Malfunction of controller
controller controller

Normal
Ａ
Power supply shall be
Check whether any noise Noise exists changed to the other
Noise at power side power than the power
exists at the power side
causing noise

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check function of When performing remote control operation, check
controller wiring of terminal No.34 and 36 for any looseness
or check the remote control switch for any faulty
contact.

6-13
 6. Troubleshooting
6.4.5 Even when each control switch is pushed ON, the machine will not start

Check function of Abnormal Repair or replace

Malfunction of controller
controller controller
Ａ

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check function of Check if any key is pushed due to incorrect Check installation of
controller installation of controller. If any, each operation controller
becomes impossible.
Faulty contact of each switch.
Disconnection of flat cable between monitor and Repair or replace the
controller or faulty contact. flat cable
Damage of controller. Repair or replace
controller

6.4.6 Start indicator lamp glows, but the unit will not start

Machine is mode
Check if it is in auto start operation Release or rest such
stop mode or in dryer Operation in such mode
advance operation mode mode operation

Not mode operation

Check function of Abnormal Repair or replace

Malfunction of controller
controller controller

Normal Ａ

Check function of electro Not move Malfunction of electro Repair or replace electro
magnet contactor magnet contactor magnet contactor
Ｂ

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Check function of 200V does not generate between cable No.1 ∼S1 Replace controller
controller the controller is faulty.
B Check function of If the contactor does not functions with controller Repair or replace
electromagnet working well, it is faulty or disconnection wiring.
contactor
If motor does not functions with contactor
moving, it is contactor or motor was
disconnection or burning.

6-14
 6. Troubleshooting
6.4.7 Too much current flows at unloaded condition

Adjust control valve (for

reduction of load) and It drops Faulty adjustment of
check it the voltage control valve Re-adjust control valve
decreases
It does not Ａ
drop
Check whether solenoid
Abnormal Faulty solenoid valve Repair or replace
valve SV3 functions
correctly SV3 solenoid valve SV3

Normal Ｂ

Check whether oil quantity Abnormal

control valve functions Faulty oil quantity Repair or replace oil
correctly control valve quantity control valve

Normal Ｃ

Disassemble and check Abnormal

Faulty unloader valve Repair unloader valve
unloader valve

Normal Ｄ

Check if any rise of power Abnormal Adjust the voltage to

The voltage rises
voltage exists proper level

Countermeasures
Mark Item Cause & Explanation
& Remarks
A Adjust control valve If the control valve is kept too much open, the Readjust or replace
(for reduction of load) current value will increase. So check the relation control valve
and check it the
between vacuum noise and current value. First
voltage decreases
close the valve completely and open it gradually
till the vacuum noise disappears.
B Check whether Check and confirm that at unload the oil Repair or replace
solenoid valve SV3 collection at the separator stops after the solenoid valve SV3 or
functions correctly
solenoid valve is circuited to conductivity. If the electrical circuit
oil collection sill not stop, the solenoid valve SV3
or electrical circuit is in disorder.
C Check whether oil Check and confirm that the oil volume control Disassemble it, and if
quantity control valve valve functions properly at unload. Air comes, but any disorder is found
functions correctly
it will not work. In this case, the oil volume out, it is necessary to
control valve is out of order. replace parts
D Disassemble and Disassemble unloader valve and check it for When any disorder is
check unloader valve malfunction of piston or any damage of sealing found, replace some
valve. defective part(s)

6-15
 6. Troubleshooting
6.4.8 Troubleshooting of dryer
Counter
clockwise Clockwise
1. In case the interior of heat exchanger gets frozen when the
dryer is operated with the indicator of refrigerant evaporating
pressure gauge placed lower than the range of green zone.
Adjusting screw
① Stop the compressor, and melt ice.
② Remove the rear panel, and take off the red-vinyl Vinyl cap
cap (SAS37UD:hexagon top cap) top of capacity
control valve.
③ Power source on and operate the dryer only, after
make short circuit between the coil (wire # 11) of
electric contactor (52C) for dryer and power
Capacity
source (wire # R2), what is installed in starter control valve
panel.
At the time, be care and be sure on safety, as the
dryer is start in a moment power source ON.
PK0459
④ Turn the capacity control valve clockwise by
A020250
using (−) screwdriver so that the indicator of
the refrigerant evaporating pressure gauge can SAS11∼22UD
be set higher than the lower limit. Soon the fan
motor begins to repeat 『ON』 and 『OFF』.
⑤ In case it is found impossible to adjust the
capacity control valve after above adjustments
have been done, the valve itself is defective.
Replace it with a new one.

2. In case the dew point indicator of refrigerant evaporating

pressure gauge shows unusually high temperature
while the ambient temperature is not so high.

① Stop the compressor. After power OFF remove

the panel.
② Remove the rear panel, and take off the red-vinyl
cap (SAS37UD:hexagon top cap) top of capacity
control valve.
③ Operate the dryer only, as same as above 1-③.
④ Turn the capacity control valve counterclockwise
by using (−) screwdriver so that the indicator of
the refrigerant evaporating pressure gauge can
be set higher than the lower limit. Soon the fan
motor begins to repeat 『ON』 and 『OFF』.
⑤ In case proper adjustment is impossible even A020251

after above adjustments have been done, the

SAS11∼22UD
capacity control valve itself is defective. Replace
it with a new one.

6-16
 7. Reference Data
7.1 Table of Reference Data
7.1.1 Table of set values
Item Unit SAS22UD-58/68 SAS37UD-58/68
Voltage type 200V 400V 200V 400V
・Protection Devices
Set value of main motor
A 54/51/48 27/25/24 90/85/80 45/42.5/40
thermal relay
Set value of dryer
A 9/9/9 10.5/10.5/10.5
refrigerator thermal relay
Set value of fan for dryer
A − 0.7/0.7/0.7
condenser thermal relay
Air temperature at cylinder
℃ 110
outlet
Air temperature at
℃ 110
separator outlet
・Pressure
Air filter differential kPa 6.23
pressure switch (mmAq) (635)
MPa 0.39
Pressure control valve
(kgf/cm2) (4)
MPa 0.83
Safety valve
(kgf/cm2) (8.5)
MPa 0.69MPa : 0.59 (6.0)
Full load returning pressure
(kgf/cm2) 0.83MPa : 0.74 (7.5)
MPa 0.69MPa : 0.69 (7.0)
Unload start pressure
(kgf/cm2) 0.83MPa : 0.83 (8.5)
・Timer
Auto start/stop.
sec 30∼150
Stop judgment time
Starting unloader time sec 5±0.2

7-1
 7. Reference Data
7.2 Piping Diagram
7.2.1 Compressor

A050470E-1

AC Aftercooler PC Pressure control valve

AF Air filter PRS Pressure sensor
BP By-pass valve S Silencer
C1 Oil control S0,1,2 Orifice
C2 Control valve ST Strainer
CV1,2,3,4 Check valve SV Safety valve
G1 Receiver tank pressure gauge SV1 3-way solenoid valve
OC Pressure sensor SV2,3 2-way solenoid valve
OF Oil filter

7-2
 7. Reference Data
7.2.2 Dryer
SAS22UD-58/68

Air inlet Air outlet

HEX Cooler
CM Compressor
FM Fan motor
CON Condenser
Stop valve CTR Capacity control valve
Auto drain valve Refrigerant evaporating
EPG
pressure gauge
CPT Capillary tube
ACC Accumulator
HP High pressure switch
FCP Pressure switch for fan control
CV Charge valve

A070246

SAS37UD-58/68

HX Cooler
CCV Capacity control valve
CON Condenser
CJ(L) Check joint at low pressure side
CJ(H) Check joint at high pressure side
Refrigerant evaporating
EPG pressure gauge
EXV Capillary tube
M1 compressor
M2 Fan motor
PRS1 High pressure switch
A050304 PRS2 Pressure switch for fan control
ST Strainer

7-3
This text book contains the most recent information available at the time of
printing, and the contents of the list are based on information in effect at that
time and are subject to change without notice.

2006年 2月 27日 初版

2003年 4月 20日 改訂

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