MAIN AIR COMPRESSOR Page 1 of 4

M AI N AI R COM PRESSOR

Switch on Main Circuit Breaker.

1. Three phase supply goes to the open contacts-88(1,2,3) of main contactor 88.
2. Circuit completed for primary winding of step down transformer through control circuit Fuse FC,
3. Low voltage from transformer secondary is supplied to COS ( Automatic/ manual change over switch)
through transformer fuse FT, Overload Relay N/C contact 51(1) (made), high air pressure switch PS2
( made)
4. Power available lamp circuit completed through signal lamp circuit fuse FL
5. An auxiliary relay, 51X in the alarm circuit is energized to keep the external trip alarms de-activated. It
will de-energies if either 63Y or 23X energises, or, 51(1) breaks.
6. Set the COS (The Automatic / Manual Mode Change-over Switch) to Man
7. Press the Manual Start Push (Local) 3C(1) or the Manual Start Push (Remote) 3C(2)

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8. 3T(1) Manual Stop Push (Local) and 3T(2) Manual Stop Push(Remote) are left in the made position.
9. The Contactor 4 energises through3T(2), TR4(1), 63Y(3), 23x(3)
10. As contactor 4 energies -
11. 4(1) made completes the circuit for main contactor 88
12. 88 Main Contactor of the motor energises
13. 88(1,2,3) made to start the motor
14. 88(4) made to energize 88X Auxiliary relay of 88
15. 88X(1) made to complete the circuit of GL
16. 88X(2) made to energies 88T ( time delay relay)
17. 88T Time-delay relay (10seconds) permits lubricating oil pressure to built-up after starting the
compressor. After 10 sec. 88T energises
18. 88T(1)made to prepare the energizing circuit of low Lubricating Oil Pressure Protection relay 63Y (when
oil pressure is built up PS3 breaks)
19. 4(2) made parallel to 63X2(1) it is a self-retaining contact in the automatic mode (not required in the
manual mode)
20. 4(3) made parallel to 3C (1) and 3C (2) it is a self-retaining contact in the manual mode (not required in
the automatic mode)
21. 4(4) made to energise TR1 (across 2X(2) (made) to initiate the unloading / draining process while starting
22. TRI Timer Relay (2 seconds) It energises to close its N/O contact TR1(1) so as to energise 2X in turn.
23. 2X Unloader / Drain solenoid activation relay is energized briefly for unloading while starting
24. 2X(1) made to complete the circuit of unloader / drain solenoids (MV1 and MV2)
25. 2X(2) Breaks to de-energise TR1
26. 2X(3) makes parallel to TR1(1) self-retaining contact (for 2X); is also energises TR2
27. TR2 It is a timer relay that energises but changes over its contacts after a pre-set time delay, to de-
energise the unloader solenoids MV1 and MV2; after this moment the compressor is loaded and
running.

M anual Stopping

Press the manual stop push-buttons3T (1) or 3T (2) de-energise contactor 4. This is turn de-
energises main contactor 88, finally stopping the motor.

Automatic Starting

SET COS (THE AUTOM ATI C / M ANUAL M ODE CHANGE-OVER SWI TCH) TO AUTO
1. The automatic starting and stopping process is controlled by:
2. Sequential start delay timer relay (10) directly connected across the secondary of the transformer. Its
N/O contact 10(1) makes to prepare the circuit of contractor 4 (in the auto mode)
3. PS1 Low Air-pressure switch (N/C contact made at low pressure and breaks once the pressure exceeds

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the low pressure level) used to start the compressor in the automatic mode by energizing contactor 63X2
4. PS2 High Air-pressure switch (N/C contact made as long as the pressure is below
5. the working pressure and breaks when the compressor has achieved its pre-set working pressure) used to
stop the compressor when it is in the automatic mode i.e., when it breaks it causes contactor 4 to de-
energise thereby de-energising main contactor 88 which in turn stops the motor. It permits manual
starting also as long as the air pressure has not exceeded the maximum limit.
6. 63X2 - The Auto-starting relay energises when PS1 makes under low-pressure condition (used in the auto
mode only). It breaks to de-energise 63X2 once the pressure has exceeded the low pressure level.
7. 63X2(1) -The N/O contact makes when 63X2 energises to complete the circuit for contactor 4; this
contact breaks once the pressure has exceeded the low-pressure level, but the self-retaining contact 4(2) is
made parallel to it and hence contactor 4 does not de-energise.
8. 63X2(2) - N/C contact breaks to de-energise relay 62X
9. 62X - The auto mode unloader / drain solenoid control relay is normally energized when the air pressure
is normal and the compressor is in the automatic mode. This ensures that the unloader solenoids are not
energized. When the pressure falls and 63X2 energises to re-start the compressor, it is de-energised and
its NC contact 62X(1) makes to energise the unloader / drain solenoids.
10. TR4 - This timer relay enrgises only in the automatic mode and will remain energized as long as the
working pressure is normal and relay 63X2 is de-energised. This keeps its N/C contact TR4(1) open in
the circuit of contactor 4 open in order to prevent erroneous starting while the pressure is normal.
11. When the pressure falls below normal, PS1 makes, 63X2 energises, breaks its contact 63X2(2), de-
energises 62X and TR4 to finally makes its N/C contact once again and thus complete the circuit for the
contactor 4.
12. Once contactor 4 energises the remaining circuit is the same as in steps 1 to 10 o the manual mode.

Automatic Stopping

The compressor can be automatically stopped due to the following:

Overload
1. This is a thermal over-load relay that directly breaks the 3-phase supply to the motor. In addition it has an
auxiliary contact 51(1)
2. 51(1) - Auxiliary contact of 51 (N/C contact which breaks to de-energise the whole circuit in case of any
overload condition)
Low Lubricating Oil-pressure
1. PS3 - Low Lubricating Oil-pressure switch (N/C contact makes when pressure falls below normal, to
energise contactor 63Y
2. 63Y - Low Lubricating Oil-pressure relay energises when PS3 is made and after 88T(1) makes
3. 63Y(1) - N/O contact completes supply for RL1
4. 63Y(2) - N/O contact self-retaining contact of contactor 63Y keeps it energized until 3R is pressed
5. 63Y(3) - N/C contact made under normal Lubricating Oil-Pressure conditions breaks to de-energise
contactor 4 when the pressure falls this stops the compressor
6. 63Y(4) - N/C contact made under normal Lubricating Oil-pressure conditions breaks to de-energise
contactor 51X when the pressure falls
High Cooling-water Temperature
1. TH - High Cooling-water temperature sensor (N/O contact makes to energise 23X when cooling water
temperature exceeds the nominal value

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2. 23X - High Cooling-water temperature relay

3. 23X(1) - N/O contact of 23X makes to complete the circuit of RL2
4. 23X(2) N/O contact self-retaining contact of contactor 23X keeps it energized until 3R is pressed
5. 23X(3) N/C contact made as long as cooling-water temperature is within normal limits breaks when
23X energises to de-energise contactor 4 this stops the compressor
6. 23X(4) N/C contact made under normal cooling-water temperature conditions breaks to de-energise
contactor 51X when the pressure falls.

An auxiliary relay, 51X in the alarm circuit is normally energized to keep the external trip alarms de-activated. It
will de-energise if either 63Y or 23X energises, or, 51(1) breaks. When energized, it prevents the trip alarms from
being activated under normal stopping conditions, when the compressor is either in the manual or automatic
mode.

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