Operacion y Mant. Instrument Air

Page: 1
SID-10-QFB-GMO-CMP-001
Of: 305
CLIENT: ELECTRICITY GENERATION COMPANY OF BANGLADESH LTD.
PROJECT: SIDDHIRGANJ 335 MW COMBINED CYCLE POWER PLANT
Compressed Air System
OPERATION AND MAINTENANCE MANUALS
3 23/07/2014 For Approval CA RJ JF

REV DATE DESCRIPTION AUTHOR CHECKED APPROVED
SID-10-QFB-GMO-CMP-001 OPERATION AND MAINTENANCE MANUALS

Page: 3 Of: 305
Rev.: 3
CONTENTS
COMPRESSORS D155-W - 10QFB05AN001 & 10QFB10AN001……...…… 3
COMPRESSORS D37H-W - 10QFB15AN001 &10QFB20AN001…………… 93
ADSORPTION DRYERS - 10QFB25AC001,10QFB25AC002,

10QFB30AC001 & 10QFB30AC002…………………………………………....… 154
REFRIGERATION DRYERS - 10QFB25AC003 & 10QFB25AC004............... 202
AEROS 10QFB05BB001/002, 10QFB05AP001/002, 10QFB05AC001 &

10QFB10BB001/002, 10QFB10AP001/002, 10QFB10AC001……............….. 249
CHILLERS 10QFB15AC001 & 10QFB20AC001………………………………. 256
PUMPING STATIONS 10QFB35AP001 6 10QFB35AP002 ……….....………. 299
SID-10-QFB-GMO-CMP-001 Operation and maintenance manuals

Page: 3 Of: 305
Rev.: 3

COMPRESSORS D155 W
10QFB05AN001 &10QFB10AN001

Original User Manual
D55-07W D160-08W
D75-07W/08W/10W D185-08W/09W/10W
D90-07W/08W/10W D200-08W/09W/10W
D110-07W/08W/10W D250-08W/10W
D132-08W/10W D275-09W
D150-07W/08W/10W
D155-10W
D110RS-10W D155RS-10W D275RS-10W
Oil Free Rotary Screw
Stationary Air Compressors
GB 100008776 / 06 - October 2011

DL1640FA - 07/2011
Foreword
These compressors are intended for compressing atmospheric air and are
not suitable for compressing any other gas. They are designed and
manufactured to give optimum performance, with long life and reliability.
This manual gives the user all the information required to install, commission
and operate the compressors and carry out the regular schedules for
servicing and maintenance which will ensure the maximum satisfactory
service life.
Servicing facilities and the supply of genuine replacement parts are provided
through a worldwide network of CompAir Distributors, backed up by the
Service Department. If replacement parts are needed, the user should
contact the local Distributor in the first instance.
The information given in this manual was correct at the time of printing but
modifications to parts and procedures may be made without notice which
could affect the servicing requirements of the compressors. Before any
servicing or maintenance work is undertaken the user is advised to contact
the local CompAir Distributor who is supplied with revised and up-dated
information.
In any communication concerning the compressor it is essential to quote the

MODEL and SERIAL NUMBER.
Throughout this manual all pressures quoted are gauge pressure unless
otherwise specified.
CompAir Contents
Contents
1 Ownership Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Local CompAir Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Warnings, Cautions And Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Operational Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Maintenance and Repair Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Precautions in the event of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Models D55 to D155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Models D160 To D275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Storage Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Cable Sizes And Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Cable Sizes and Fuse Rating Table (D55W-D155W, IP23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5 Cable Sizes and Fuse Rating Table (D55W-D155W, IP55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.6 Cable Sizes and Fuse Rating Table (D160W-D275W). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1 Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 System Checks and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3 Checking/Altering Commissioning Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 Checking/Altering Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Re-setting Service Interval Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.6 Final Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.7 Powered Breather - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.8 Powered Breather - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.9 Commissioning Parameters
(Compressor Running On-Load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.10 Powered Breather System - Check
Vacuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.11 Commissioning Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1 Routine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2 Using The Menu Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.4 Glossary of Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.3 Torque Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.4 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DL1640FA 3
Contents CompAir
9 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Shutdown Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10 Appendix 1 - Control Remote Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11 Appendix 2 – Sample Log Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.2 Values At Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11.3 Commissioning Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.4 Operational Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.5 Weekly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.6 Performance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.7 4000 hr Service (Service A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.8 8000 hr Service (Service B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.9 16000 hr Service (Service C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.10 Compressor History Log Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12 Appendix 3 – Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
13 Appendix 4 – The Pressure Systems And Gas Regulations 2000 No. 128. . . . . . . . . . . . . . . . . . . . . . 87
13.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 DL1640FA
CompAir Ownership Data 1
1 Ownership Data
1.1 Technical Data
1st Stage
Model:
Air-end Serial
2nd Stage
Numbers:
Serial Number:
Gearbox
Year: Motor Serial Number:
Delivery Date: Intercooler Serial Number:
Maximum Pressure: Intercooler Certificate Number:
kW: Aftercooler Serial Number:
Motor rpm Aftercooler Certificate Number:
V. Ph. Hz. Compressor Lubricant:
M3/min Lubricant Capacity:
Motor Bearing Grease:

(if applicable)
1.2 Local CompAir Distributor
Name:
Address:
Telephone: Fax:
Contact Names: Parts:
Service:
DL1640FA 5
2 Safety Procedures CompAir
2 Safety Procedures 2.2 Warnings, Cautions And Notes

2.2.1 Warnings
Warnings call attention to operations or procedures
2.1 General
involving specific hazards which could cause injury
2.1.1 Most accidents which occur during the operation and or death and are identified by the following symbols
maintenance of machinery are the result of failure to on the unit and in the text of the manual.
observe basic safety rules or precautions. An acci-
dent can often be avoided by recognising a situation WARNING:
that is potentially hazardous. Risk Of Danger
2.1.2 When handling, operating or carrying out mainte-
nance on the unit, personnel must use safe engi- WARNING:
neering practices and observe all relevant local Risk Of Electric Shock
health and safety requirements and regulations. The
attention of users in the UK is drawn to the Health
and Safety at Work Act, 1974, and to the Regula- WARNING:
tions of the Institution of Electrical Engineers. Risk Of Hot Surfaces
2.1.3 CompAir cannot anticipate every possible circum-

stance which might represent a potential hazard. WARNING:
The WARNINGS in this manual are therefore not all- Consult Manual
inclusive. If the user employs an operating proce-
dure, an item of equipment or a method of working
which is not specifically recommended by CompAir WARNING:
he must ensure that the unit will not be damaged or Risk Of High Pressure
made unsafe and that there is no risk to persons or
property. 2.2.2 Cautions
2.1.4 The standard build of all CompAir products are not Incorrect operational procedures causing possible
intended for use in either explosive or potentially ex- damage to the compressor unit are identified by a
plosive atmospheres as defined in ‘CAUTION’ in the text of this manual.
Directive 94/9/EC. 2.2.3 Notes
2.1.5 An explosive atmosphere is a mixture with air, under Methods to make the job easier and points which re-
atmospheric conditions, of flammable gases, va- quire particular attention are identified by a ‘Note’ in
pours, hazes, or dust in which, after ignition has oc- the text of the manual.
curred, combustion propagates to the entire
unburned mixture and may cause a hazard.
2.1.6 A potentially explosive atmosphere is an atmos-
phere which could become explosive due to local
conditions.
2.1.7 Failure to observe the precautions given under
'Safety Procedures' may be considered dangerous
practice or misuse of the compressor unit.
6 DL1640FA
CompAir Safety Procedures 2
2.3 General Safety Precautions 2.4.6 When connecting the compressor to the customer’s
distribution network, ensure all pipework and hoses
2.3.1 If using compressed air for cleaning purposes, are of the correct size and suitable for the working
ensure safety regulations are complied with and pressures and temperatures involved. If connection
appropriate clothing and eye protection is worn. is by means of hoses, ensure that they incorporate
2.3.2 Never direct compressed air onto your skin or at safety wires to prevent the free end from whipping in
other people. the event of failure of the hose or connection. Ensure
connecting flanges and threads are in good
2.3.3 The compressed air generated by these condition.
compressors must never be used for breathing
unless it has been conditioned for those applications 2.4.7 A shut-off valve must be fitted in the delivery air line
in line with the “Safety Requirements For to enable the compressor unit to be isolated. This is
Respiratory Air”. particularly important if more than one unit is to be
coupled in parallel or connected to an existing air
2.3.4 Never use compressed air to clean loose dirt from supply system.
clothing.
2.4.8 The non-return valve is not intended as an isolating
2.3.5 Before releasing compressed air through a hose valve and should not be relied upon for this purpose.
make sure that the free end is held securely so that In addition, it may be necessary to install shut-off
it cannot whip and cause injury. valves elsewhere in the system to allow a dryer or
2.3.6 Avoid injury by using a hoist to lift heavy loads. other equipment to be by-passed.
Check that all chains, hooks, shackles and slings are 2.4.9 A pressure relief valve must be installed between
in good condition and are of the correct capacity. any compressor unit and the shut-off valve/s. Pres-
They must be tested and approved according to sure relief valves (safety valves) are fitted to the air
local safety regulations. pipework, as standard equipment, between the in-
2.3.7 Cables, chains or ropes must never be applied tercooler and compressor delivery. The set pres-
directly to lifting eyes. Always use an appropriate sures of these relief valves (pressure at which they
shackle or hook, properly positioned. Arrange lifting will open) are indicated by the following label, at-
cables so that there are no sharp bends. tached to the exterior of the machine:-
Warning: Set pressure safety valve
2.3.8 Use a spreader bar to avoid side loads on hooks,
eyes and shackles. xx bar (value 'xx' will be shown on
the label on the compressor)
2.3.9 When a load is on a hoist stay clear of the danger
area beneath and around it. Keep lifting acceleration Note: The set pressures for these valves can be
and speed within safe limits. Never leave a load found in the ‘Technical Data’ section of this manual.
hanging on a hoist for longer than is necessary.
2.4.10 If raised platforms are required to provide access to
the unit they must not interfere with normal operation
2.4 Installation Precautions or obstruct access for lifting or dismantling compo-
2.4.1 Installation work must only be carried out by nents. Platforms and stairs should be of grid or plate
competent personnel under a qualified supervisor. construction with safety rails on all open sides.
2.4.2 A fused isolating switch must be fitted between the
main power supply and the compressor. 2.5 Operational Precautions
2.4.3 Ensure that air drawn into the air intake will not be 2.5.1 The compressor unit must only be operated by com-
contaminated with flammable fumes or vapours petent personnel under a qualified supervisor.
since this could cause an internal fire or explosion. 2.5.2 Do not run the compressor with doors open or cov-
2.4.4 Precautions must be taken to ensure that no injury is ers removed.
caused to passers-by through loose clothing being 2.5.3 Never remove or tamper with the safety devices,
sucked into the air intake. guards or insulation materials fitted to the unit.
2.4.5 Ensure that the air delivery pipe from the 2.5.4 The compressor must only be operated at the supply
compressor to the user’s pipework or receiver is free voltage and/or frequency for which it is designed.
to expand and that no flammable material is in the
vicinity. 2.5.5 When mains power is switched on, lethal voltages
are present in the electrical circuits and extreme
DL1640FA 7
caution must be exercised whenever it is necessary 1) Isolate the compressor unit from the main
to carry out any work on the electrical system. electrical power supply. Lock the isolator in the
‘OFF’ position and remove the fuses.
2.5.6 Do not open the starter compartment or touch elec-
trical components while voltage is applied unless it is
2) Attach a label to the isolator switch and to the
necessary for measurements, tests or adjustments.
display panel carrying the warning ‘WORK IN
Such work should be carried out only by a qualified
PROGRESS – DO NOT APPLY VOLTAGE’.
electrician equipped with the proper tools and wear-
Do not switch on electrical power or attempt to
ing appropriate body protection against electrical
start the unit if such a warning label is
hazards.
attached.
2.5.7 When the unit is running under automatic control, at-
tach a sign stating ‘THIS UNIT MAY START WITH- 3) Close the isolating valve between the com-
OUT WARNING’ next to the display panel. pressor unit and the user’s pipework. Attach a
label to each valve carrying the warning
2.5.8 If the unit is equipped with a Remote Start device, at-
‘WORK IN PROGRESS – DO NOT OPEN’.
tach warning notices stating ‘THIS UNIT CAN BE
STARTED REMOTELY’ in prominent locations, one
4) Bleed down all air pressure in the delivery pipe
on the outside of the unit, the other inside the control
between the non-return valve and the shut-off
compartment.
valve by carefully slackening the aftercooler
2.5.9 As a further safeguard, take adequate precautions to condensate drain connection at the strainer
make sure there is no one checking or working on inlet.
the unit before attempting to operate remote start
equipment. Attach a notice stating ‘CHECK THAT 5) First and second stage pressure will be ex-
ALL PERSONNEL ARE CLEAR OF THE UNIT BE- hausted through the dump silencers by the ac-
FORE STARTING’ or similar wording to the remote tion of the unloader solenoid valve. As an
start equipment. additional precaution, slacken the drain plug at
the base of the regulation air line filter to re-
2.5.10 Some parts of the compressor reach extremely high
lease any residual pressure.
temperatures. If panels are removed from the enclo-
sure take precautions against burns.
6) Allow compressor to cool for 30 minutes.
2.5.11 If there is any indication that the compressor is over-
heating it must be shut down and the cause investi- 2.6.4 Use only lubricating oils and greases approved by
gated. Beware of burns from hot metal parts or hot CompAir. Make sure that the selected lubricants
oil when working on a unit which has recently been comply with all relevant safety regulations, especial-
shut down. ly with regard to the risk of explosion or fire and the
possibility of decomposition or the generation of haz-
2.5.12 The ‘Noise at Work Regulations 1989’ suggest that
ardous gases.
ear protectors should be worn where noise levels
are 85 dB(A) or higher. With all covers in place, the 2.6.5 Always clean up oil spills from the surrounding floor
noise levels of the compressors described in the and outside of the compressor unit before and after
manual are substantially lower than this figure un- maintenance work. Make sure that no oil is left on or
less installed in an already noisy environment. near the air intake components, including the suction
regulator, which could be drawn into the compressor
2.5.13 Be aware that high noise levels can interfere with
and contaminate the delivered air.
communication.
2.6.6 Make sure that all instructions concerning the oper-
2.6 Maintenance and Repair Precautions ation and maintenance are strictly followed and that
the complete unit, with all accessories and safety de-
2.6.1 Maintenance, repairs or modifications must only be vices, is kept in good running order.
carried out by competent personnel under a qualified
supervisor. 2.6.7 The accuracy of pressure and temperature gauges
and switching thermometers must be regularly
2.6.2 If replacement parts are needed use only CompAir checked. They must be renewed when acceptable
Genuine Parts. tolerances are exceeded.
2.6.3 Carry out the following operations before removing 2.6.8 Protection devices must be tested as described in
any panels from the enclosure or dismantling any the Repair manual.
part of the unit.
8 DL1640FA
CompAir Safety Procedures 2
2.6.9 Keep the compressor unit clean at all times. Protect Protect the environment by using only approved
components and exposed openings by covering with methods of disposal.
clean cloth or tape during maintenance or repair
work. Warning
2.6.10 Protect the motor, air intake, electrical and regula-
tion components against the entry of moisture, e.g.,
when steam cleaning.
• The use of replacement parts or lubricating oils
2.6.11 Precautions must be taken when carrying out weld- not supplied or approved by CompAir may lead
ing or any repair operation which generates heat, to failures in service which would not be cov-
flames or sparks. The adjacent components must al- ered by warranty.
ways be screened with non-flammable material and
if the operation is to be carried out near any part of
• Any unauthorised modifications or failure to
the oil system, or close to a component which may
maintain this equipment in accordance with the
contain oil, the system must first be thoroughly
maintenance instructions may make it unsafe.
purged, preferably by steam cleaning.
The use of replacement parts not supplied or
2.6.12 Never use a light source with an open flame to in- approved by CompAir may create hazardous
spect any part of the unit. conditions over which CompAir has no control.
2.6.13 In no circumstances must any welding work or other
modification be carried out on any pressure vessel. • Such hazardous conditions may lead to acci-
dents that can be life threatening, cause sub-
2.6.14 Before dismantling any part of the compressor unit
stantial bodily injury or result in damage to the
ensure that all heavy movable parts are secured.
equipment. CompAir can bear no responsibility
2.6.15 After completion of repair or maintenance work en- for equipment in which unapproved replace-
sure that no tools, loose items or rags are left on or ment parts are included.
inside any part of the machine. Turn the motor over
by hand several times to ensure there is no mechan-
ical interference.
2.6.16 Check the direction of rotation of the fan motors, oil 2.7 Precautions in the event of fire
pump motor and main drive motor when starting up
the compressor initially and after any work on the 2.7.1 Use extreme caution when handling components
electrical connections or switchgear (refer to the In- that have been subjected to fire or very high temper-
stallation and Commissioning manual). atures. Some components may contain fluoroelas-
tomer materials which decompose under these
2.6.17 Do not use any flammable liquid to clean valves, fil- conditions to form highly corrosive residues. Skin
ter elements, air pipes or any component carrying a contact can cause painful and penetrating burns re-
flow of air during normal operation. If chlorinated hy- sulting in permanent skin and tissue damage.
drocarbon non-flammable fluids are used for clean-
ing, safety precautions must be taken against any
2.8 Disposal
toxic vapours which may be released.
2.8.1 When items of equipment are taken out of service for
2.6.18 Do not use carbon tetrachloride.
disposal it is recommended that the following in-
2.6.19 Precautions must be taken when using acids, alkalis structions are adhered to:
and chemical detergents for cleaning machine parts
and components. These materials cause irritation 1) In order to prohibit the ‘bringing back into serv-
and are corrosive to the skin, eyes, nose and throat. ice’ of equipment by persons unknown, it
Avoid splashes and wear suitable protective clothing should be rendered unusable in order to avoid
and goggles. Do not breathe mists. Ensure that soap improper re-use.
and water are readily available.
2) Alternatively all such items of equipment
2.6.20 When disposing of condensate, old oil, used filter el-
should be stripped into their component form
ements and other parts and waste material of any
for ‘material composition disposal’ e.g. base
kind make sure that there is no pollution of any drain
metals, plastics, fabrics etc. and be subject to
or natural water-course and that no burning of waste
normal industrial waste re-cycling processes.
takes place which could cause pollution of the air.
DL1640FA 9
3) Bio-degradable items should be subject to nor-

mal industrial waste disposal processes.
Ensure that no plastic, rubber or composite
materials are disposed of by incineration.
4) Ensure that all fluid waste e.g. lubricating oils

and greases, anti-freeze agents, refrigerant
fluids or corrosive inhibitors should be sepa-
rated and disposed of by authorised salvage
disposal or recycling systems ensuring that
none is permitted to enter a waste water sys-
tem.
10 DL1640FA
CompAir General Description 3
3 General Description 3.3 Electronic Controller

3.3.1 The electronic control system is microprocessor
based with liquid crystal display (LCD), mimic dia-
3.1 Introduction
gram, tactile membrane switches and dedicated
3.1.1 The unit is a fully enclosed, oil-free, two-stage, wa- (LED) pressure display, incorporating many ad-
ter-cooled, rotary screw compressor package. It vanced control and monitoring features.The control-
comprises a drive motor, first and second stage air- ler is Year 2000 compliant.
ends, intercooler, aftercooler, oil cooler, first and
second stage moisture separators, air intake and fil- 3.4 Regulation System
ter assembly, control panel and ventilation fan. The
unit is mounted on a baseframe in an acoustic steel- 3.4.1 The compressor runs continuously, loading and un-
panelled enclosure. Removable panels give access loading at preset delivery pressures (P1 and P2 set
for routine maintenance. points). If air pressure remains above the P2 set
point for the run-on time the compressor will shut
3.1.2 The air-ends are driven by an electric motor via a down into Stand-by mode. The compressor will au-
flexible coupling and a gearbox in which the single tomatically restart as demand increases and the
main gear drives the male rotor of both stages.The pressure drops to the P2 set point.
compressor is controlled by an electronic controller
which monitors and acts on information translated
from pneumatic, electrical and mechanical devices.
Delivery pressure is monitored by a pressure trans-
mitter to regulate on-load and off-load running via a
solenoid operated unloader valve. A visual display
provides information on compressor performance
and condition.
3.2 Compressor
3.2.1 Description
Air is compressed by two rotary screw air-ends.
Each comprises an intermeshing pair of helical
screw rotors driven by a pinion fitted to the male ro-
tor shaft which meshes with the main gear.
3.2.2 Timing gears on each male rotor drive the female ro-
tors and maintain correct clearance. Seals between
the rotors and bearings prevent air passing into the
oil system and oil passing into the compression
chambers. The rotors, shafts, seals and the internal
surface of the rotor casing are coated with an anti-
corrosive/anti-wear material.
3.2.3 Operation
Compression takes place between the lobes on the
male rotor, the flutes on the female rotor and the air-
end casing. As the rotors turn, the trapped air is pro-
gressively compressed until the discharge port is un-
covered and is then discharged at first stage
pressure. Further compression takes place in a sim-
ilar manner in the second stage air-end and air, at
delivery pressure, passes into the user’s pipework.
DL1640FA 11
4 Technical Data CompAir
4 Technical Data
4.1 Models D55 to D155
Airends: Two-stage, oil free screw.
Cooling: Water-cooled
Oil capacity (approx.): 35 litres
Recommended oils: Fuchs Renolin AC68; Shell Turbo T68; Mobil Rarus 426
Esso Teresso 68; Castrol Perfecto T68
Note: Compressors are factory filled with Fuchs Renolin AC68
Air delivery connection: R3
Cooling water connection: G 1½
Condensate drain connection: 10 mm O.D. Tube
Lifting points: 4, located on baseframe
Delivery air pressure: minimum 5·0 bar

maximum Refer to Compressor data plate
Delivery air temperature (continuous operation): Typically 10°C above water inlet
Ambient temperature: minimum 0°C

maximum 40°C
Cooling water inlet temperature, maximum: 45°C
Cooling water outlet temperature: Typically 11°C above inlet temperature
Cooling water inlet pressure, maximum: 7·0 bar
Main drive motor rotation: Anti-clockwise viewed from non-drive end
Fan motor power, kW: 1·5
Fan motor rotation: Anti-clockwise viewed from non-drive end
Oil pump motor power, kW: 1·5
Oil pump motor rotation: Clockwise viewed from non-drive end
Pressure relief (safety) valve set pressures Interstage 3.1 bar

Delivery 11.4 bar
Approx. weight of heaviest components (compressor air-ends / gearbox, all models), kg: 400
Dimensions (approx.), L x W x H, mm: 2300 x 1500 x 1500
F.L.C. see data plate
Compressor weight see data plate
12 DL1640FA
CompAir Technical Data 4
Oil Pump and Fan Motor Thermal Overload Settings, Amps

Model 220V, 50Hz 400V, 50Hz 220V, 60Hz 460V, 60Hz 575V, 60Hz
Oil Pump 6.3 3.5 6.3 3.1 2.5
Fan (D55-D155) 5.7 3.3 6.1 2.9 2.3
MMS (Q101) 12.0 6.8 12.4 6.0 4.8
Main Motor Thermal Overload Settings, Amps

D55-07W - 60Hz - - 110 55 45
D75-07W - 60Hz - - 140 70 60
D75-10W - 60Hz - - 140 70 60
D90-07W - 60Hz - - 175 90 70
D90-10W - 60Hz - - 175 90 70
D110-07W - 60Hz - - 215 110 85
D110-10W - 60Hz - - 215 110 85
D150-07W - 60Hz - - 285 145 115
D150-10W - 60Hz - - 285 145 115
D155-10W - 60Hz - - * * *
D75-08W - 50Hz 140 80 - - -
D90-08W - 50Hz 165 105 - - -
D90-10W - 50Hz 165 105 - - -
D110-08W - 50Hz 205 120 - - -
D110-10W - 50Hz 205 120 - - -
D132-08W - 50Hz 235 145 - - -
D132-10W - 50Hz 235 145 - - -
D150-08W - 50Hz * 160 - - -
D150-10W - 50Hz * 160 - - -
D155-10W - 50Hz 335 195
* Available on request
DL1640FA 13
4 Technical Data CompAir
4.2 Models D160 To D275

Air-end: Two-stage, oil-free screw
Cooling: Liquid-cooled
Oil capacity (approx.): 70 litres
Recommended oils: Fuchs Renolin AC68; Shell Turbo T68; Mobil Rarus 426
Esso Teresso 68; Castrol Perfecto T68
Note: Compressors are factory filled with Fuchs Renolin AC68
Air delivery connection: R4
Cooling water connection: G 1½
Condensate drain connection: 10 mm O.D. tube
Lifting points: 4, located on baseframe
Delivery air pressure: minimum 5·0 bar

maximum Refer to Compressor data plate
Delivery air temperature (continuous operation): Typically 10°C above water inlet
Ambient temperature: minimum 0°C

maximum 40°C
Cooling water inlet temperature, maximum: 45°C
Cooling water outlet temperature: Typically 11°C above inlet temperature
Cooling water inlet pressure, maximum: 4.9 bar
Main drive motor rotation: Anti-clockwise viewed from non-drive end
Fan motor power, kW: 1·5
Fan motor rotation: Anti-clockwise viewed from non-drive end
Oil pump motor power, kW: 1·5
Oil pump motor rotation: Clockwise viewed from non-drive end
Pressure relief (safety) valve set pressures Interstage 3.1 bar

Delivery 11.4 bar
Delivery 8.6 bar*
Approx. weight of heaviest components (compressor air-ends/gearbox, all models), kg: 740
Dimensions (approx.), L x W x H, mm: IP23 motor 2600 x 1900 x 1840

IP55 motor 3200 x 1900 x 1840
F.L.C. see data plate
Compressor weight see data plate
*D250-8W only
14 DL1640FA
CompAir Technical Data 4
Oil Pump and Fan Motor Thermal Overload Settings, Amps

Oil Pump 6.3 3.5 6.3 3.1 2.5
Fan(D160 -
5.7 3.3 6.1 2.9 2.3
D275)
MMS(Q101) 12.0 6.8 12.4 6.0 4.8
Main Motor Thermal Overload Settings, Amps
D160-08W 270 160 * * *
D185-08/09W 335 195 * * *
D185-10W 335 195 * * *
D200-08/09W 400 230 * * *
D200-10W 400 230 * * *
D250-08W 480 275 * * *
D250-10W 480 275 * * *
D275-09W * * * * *
* Available on request
DL1640FA 15
5 Installation CompAir
5 Installation tioned. They should be retained for future use

in the event of the compressor being re-sited.
Warning e) Models D55 - D155 have flexible mountings
designed with restricted lateral movement, in
which case transportation fixings are not fitted.
• Refer to the safety procedures before installa- 5.1.3 Compressor Building

tion of the compressor unit. a) The compressor building should be sized to
• Lethal voltages are used in this equipment. Use provide 1000mm / 39in of free space on all
extreme caution when carrying out electrical sides and 1500mm / 59in above the unit. In ad-
checks. Isolate the power supply before starting dition, consideration should be given to provid-
any maintenance work. ing adequate access for maintenance.
b) Lifting facilities should be provided over the
compressor to enable the heaviest compo-
nents to be lifted during maintenance.
5.1 Installation Procedure 5.1.4 Ventilation
a) In operation the unit will release heat into the
The following procedure is a guide for
surroundings. The compressor room should
installing a standard compressor unit. For the
therefore be of adequate size and have good
installation of nonstandard units or units fitted
ventilation. The recommended minimum size
with optional equipment refer to the local
of room is 50 m³. The inlet and outlet ventilation
CompAir distributor. openings should each have a minimum area of
0·5 m².
5.1.1 Foundations
b) The ventilation inlet opening should be posi-
The compressor is supplied as a free standing tioned as low down as possible. The outlet
package and does not require securing to a opening should be positioned as high up as
foundation. However, the supporting floor must possible, preferably in the roof or ceiling.
have a loading capacity sufficient to support c) The temperature of the air at the air intake
the weight of the unit (see ‘Technical Data’). grilles should be between 0°C / 32°F and
40°C / 104°F. If the air temperature is below
5.1.2 Unpacking, Lifting and Handling 0°C / 32°F heaters should be installed inside
a) The compressor package may be lifted by fork the compressor and precautions should be
lift under the baseframe or by spreader bars taken to prevent freezing of the condensate
and lifting frame with slings or chains attached drains. Refer to your CompAir distributor for
to lifting brackets bolted to the baseframe. To further details.
prevent damage, spreader bars or frames d) Ventilation openings should be screened to
should be wide enough to keep slings clear of prevent the ingress of debris into the compres-
the enclosure sor room.
b) Remove the polythene cover and lift the com- 5.1.5 Air and Condensate Pipework
pressor off the pallet. Lower the unit into posi-
tion, ensuring that the weight is evenly a) The air discharge flange should be connected
supported. Check that the baseframe is level to to the distribution header or air receiver using
within 3 mm / 1/8 in. Use packing pieces under piping with a minimum nominal bore of 80mm/
the baseframe if necessary. 3in. The discharge piping must connect into the
top of the distribution header to prevent con-
c) Remove all protective blanking covers and densed water from running back into the com-
tapes. pressor during periods of stand-by operation.
d) To prevent lateral movement during shipment The pipe must not be connected into either the
transportation fixings are fitted to the flexible side or bottom of the header. An isolating valve
mountings supporting the motor and air-end. should be incorporated in the discharge piping
They are identified by red paint and must be re- to enable the compressor to be isolated for
moved after the unit has been finally posi- maintenance purposes.
16 DL1640FA
CompAir Installation 5
b) A suitably sized air receiver should be installed corrosion and scale formation. Recirculating
between the compressor and distribution sys- systems should be protected against freezing,
tem. As a guide the receiver capacity should be where necessary, by using a proprietary anti-
10% of the compressor output. e.g. a 10m³/min freeze with inhibitors.
compressor will require a 1m³ / 35ft³ air receiv-
er. 5.1.7 Electrical Connections
c) The two automatic condensate drain should be a) Remove the plain gland plates from the base-
separately piped into a drain gully or open plate and bottom of the starter compartment.
tundish. The two drains must not be connected Drill the plates to take the power cable and fit
together. Piping from the drain connections suitable cable glands.
should not exceed 3 metres / 118in in length
b) It is important that the sealing and IP rating of
and must fall towards the drain gully or open
the starter compartment is maintained by the
tundish.
use of glands of the correct type and size in or-
d) In order to minimise pressure drops all valves der to seal the compartment against the in-
should be either gate or ball full flow type and gress of dust.
all bends should have a minimum radius of at
c) Ensure the power supply to the unit is taken
least 1.5 times the pipe diameter.
from a fused isolator, the switch is locked ‘OFF’
and fuses removed. Connect the supply in ac-
CAUTION: All pipework is to be adequately
cordance with the electrical connection dia-
supported outside of the compressor. The
gram. Use cables complying with the standards
compressor connections must not carry any
of the International Electrotechnical Commis-
load.
sion (IEC) or of the Institution of Electrical En-
gineers (IEE) (latest edition) for U.K. users.
CAUTION: It is important that the air supply to
The cables must be correctly sized for the total
the powered breather, which is taken from the
input kW of the plant and suitably protected
delivery pipe, is moisture free. If the
and clamped.
installation is such that condensation from the
customer's air network forms in the delivery
pipe, then the air supply must be taken from a 5.2 Storage Procedures
new location that is moisture free. 5.2.1 All compressors are inhibited against corrosion
before leaving the CompAir factory to give pro-
CAUTION: Do not install a non-return valve on tection during transportation and storage be-
the outlet side of the compressor. fore installation, for a maximum of 12 months.
Proper precautions should be taken if the stor-
e) When connecting the compressor to the cus- age period is longer than 12 months.
tomer’s distribution network, ensure all pipe-
work and hoses are of the correct size and 5.2.2 Similarly, any compressor taken out of service
suitable for the working pressures and temper- or put into temporary storage must be protect-
atures involved. If connection is by means of ed against corrosion. The rate at which corro-
hoses, ensure that they incorporate safety sion in storage occurs will be more rapid in a
wires to prevent the free end from whipping in humid climate than in dry conditions, making it
the event of failure of the hose or connection. impossible to recommend a maximum safe
Ensure connecting flanges and threads are in storage time applicable to all cases.
good condition. 5.2.3 Refer to your local distributor for advice on car-
rying out procedures for short or long term stor-
5.1.6 Cooling Water Supply age.
The recommended cooling water quality is

detailed in Appendix 4. 5.3 Cable Sizes And Fuse Ratings
5.3.1 The following assumptions have been made in
Note: Isolating valves should be installed on compiling the table of cable sizes and fuse
both the inlet and outlet cooling water pipes. ratings:
The water inlet pipe should also incorporate a
flow indicator. If the quality of the cooling water a) PVC insulated, 3-core non-armoured copper
is in doubt it should be treated to prevent cable with a rated conductor operating
temperature of 70°C (where more than
DL1640FA 17
3 conductors are specified, they are assumed

to be in separate 3-core cables)
b) Cables for any given machine are run
separately from the supply cables to other
equipment.
c) Cables are clipped directly to insulated walls
d) Cables are shaded from direct sunlight and
other sources of external heat.
Notes:
1) Where any of these assumptions is invalid, or

regulations other than BS7671 apply, cable
sizes should be calculated for the actual
conditions.
2) The voltage at the machine connections

should not be less than nominal voltage less
6%, except 400V 50Hz models which should
be no less than 360V.
3) Earth conductors should not be less than half

the cross section of the main conductors, and
may be separate or a fourth conductor in the
main cable.
4) ISO 269 fuses or equivalents (EN 60269, BS

88) must conform to gG characteristics.
18 DL1640FA
5.4 Cable Sizes and Fuse Rating Table (D55W-D155W, IP23)

Model 230V 50Hz 380V 50Hz 415V 50Hz
D75W Main Overload Setting 140 80 75

Fuse (ISO 269 gG) 315 160 160
2 2 2
Cable Size @ 30°C (BS 6231) 3x185mm 3x70mm 3x70mm
2 2 2
Fuse (UL)
Fuse (CSA)
Cable Size @ 30°C(UL/CSA)

Fuse (ISO 269 gG) 315 200 200
2 2 2
2 2 2
Fuse (UL)
Fuse (CSA)

Fuse (ISO 269 gG) 400 250 200
2 2 2
2
6x150mm or 2 2
Cable Size @ 45°C (BS 6231) 2 3x185mm 3x120mm
3x400mm
Fuse (UL)
Fuse (CSA)

Fuse (ISO 269 gG) 500 315 250
2
6x150mm or 2 2
3x400mm
2 2 2
Fuse (UL)
Fuse (CSA)
D150W Main Overload Setting 160 145

Fuse (ISO 269 gG) 315 315
2 2
Cable Size @ 30°C (BS 6231) 3x185mm 3x185mm
2 2
Cable Size @ 45°C (BS 6231) 3x240mm 3x240mm
Fuse (UL)
Fuse (CSA)

Fuse (ISO 269 gG) 630 400 315
2 2 2
2
2 6x150mm or 2
Cable Size @ 45°C (BS 6231) 6x400mm 2 3x240mm
3x400mm
Fuse (UL)
Fuse (CSA)
DL1640FA 19
5.5 Cable Sizes and Fuse Rating Table (D55W-D155W, IP55)

Model 230V 50Hz 220V 60Hz 380V 50Hz 415V 50Hz 440/460V 60Hz 575V 60Hz

Fuse (ISO 269 gG) 200 125 100
2 2 2
2 2 2
Fuse (UL)
Fuse (CSA)
D75W Main Overload Setting 145 140 85 75 70 60

Fuse (ISO 269 gG) 315 315 160 160 160 125
2 2 2 2 2 2
Cable Size @ 30°C (BS 6231) 3x185mm 3x185mm 3x70mm 3x70mm 3x70mm 3x50mm
2 2 2 2 2 2
Fuse (UL)
Fuse (CSA)

Fuse (ISO 269 gG) 315 315 200 160 160 125
2 2 2 2 2 2
2 2 2 2 2 2
Fuse (UL)
Fuse (CSA)

and Fuse (ISO 269 gG) 400 400 250 200 200 160
2 2 2 2 2 2
D110RS-W Cable Size @ 30°C (BS 6231) 3x240mm 3x240mm 3x120mm 3x95mm 3x95mm 3x70mm
2 2
6x150mm or 6x150mm or 2 2 2 2
Cable Size @ 45°C (BS 6231) 2 2 3x185mm 3x120mm 3x120mm 3x95mm
3x400mm 3x400mm
Fuse (UL)
Fuse (CSA)

Fuse (ISO 269 gG) 500 250 250
2
6x150mm or 2 2
3x400mm
2 2 2
Fuse (UL)
Fuse (CSA)
D150W Main Overload Setting 285 160 145 145 115

Fuse (ISO 269 gG) 630 315 315 315 250
2 2 2 2 2
Cable Size @ 30°C (BS 6231) 6x240mm 3x185mm 3x185mm 3x185mm 3x120mm
2 2 2 2 2
Cable Size @ 45°C (BS 6231) 6x400mm 3x240mm 3x240mm 3x240mm 3x185mm
Fuse (UL)
Fuse (CSA)
D155W Main Overload Setting 325 190 175 145 115

and Fuse (ISO 269 gG) 630 400 315 315 250
2 2 2 2 2
D155RS-W Cable Size @ 30°C (BS 6231) 6x240mm 3x240mm 3x185mm 3x185mm 3x120mm
2
2 6x150mm or 2 2 2
Cable Size @ 45°C (BS 6231) 6x400mm 2 3x240mm 3x240mm 3x185mm
3x400mm
Fuse (UL)
Fuse (CSA)
20 DL1640FA
5.6 Cable Sizes and Fuse Rating Table (D160W-D275W)

Model
Model 230V50Hz
230V 50Hz 380V50Hz
380V 50Hz 415V50Hz
415V 50Hz 230V50Hz
230V 50Hz 380V50Hz
380V 50Hz 415V50Hz
415V 50Hz
IP23
IP23 IP55
IP55
D160W
D160W MainOverload
Main OverloadSetting
Setting 270
270 160
160 145
145 270
270 160
160 145
145
Fuse(ISO
Fuse (ISO269
269gG)
gG) 500
500 315
315 315
315 500
500 315
315 315
315
2 2
6x150mm2 2 or 6x150mm2 2or
or
CableSize
Cable Size@
@30°C
30°C(BS 6231) 6x150mm or
(BS6231) 2 3x185mm2
3x185mm
22
3x185mm2
3x185mm
22 6x150mm
2 3x185mm2
3x185mm
22
3x185mm2
3x185mm
22
3x400mm2 2
3x400mm 3x400mm2 2
3x400mm
2 22 22 2 22 22
CableSize
Cable Size@
@45°C
45°C(BS
(BS6231)
6231) 6x300mm2 2
6x300mm 3x240mm2
3x240mm 3x240mm2
3x240mm 6x300mm2 2
6x300mm 3x240mm2
3x240mm 3x240mm2
3x240mm
Fuse(UL)
Fuse (UL)
Fuse(CSA)
Fuse (CSA)
CableSize
Cable Size@
@30°C(UL/CSA)
30°C(UL/CSA)
CableSize
Cable Size@
@45°C(UL/CSA)
45°C(UL/CSA)
D185W
D185W MainOverload
Setting 335
335 195
195 180
180 325
325 190
190 175
175
Fuse(ISO
Fuse (ISO269
269gG)
gG) 630
630 400
400 315
315 630
630 400
400 315
315
2 2 2 2 2 2
CableSize
Cable Size@
@30°C
30°C(BS
(BS6231)
6231) 6x240mm2 2
6x240mm 3x240mm2 2
3x240mm 3x185mm2 2
3x185mm 6x240mm2 2
6x240mm 3x240mm2 2
3x240mm 3x185mm2 2
3x185mm
6x150mm 222 or 6x150mm 222 or
CableSize
Size@
@45°C
45°C(BS
(BS6231)
6231) 6x400mm2
22 6x150mm or 3x240mm2
22
6x400mm2
22 6x150mm or 3x240mm2
22
Cable 6x400mm 2 3x240mm 6x400mm 2 3x240mm
3x400mm2 2
3x400mm 3x400mm2 2
3x400mm
Fuse(UL)
Fuse (UL)
Fuse(CSA)
Fuse (CSA)
CableSize
Cable Size@
@30°C(UL/CSA)
30°C(UL/CSA)
CableSize
Cable Size@
@45°C(UL/CSA)
45°C(UL/CSA)
D200W
D200W MainOverload
Setting 400
400 230
230 210
210 390
390 225
225 200
200
Fuse(ISO
Fuse (ISO269
269gG)
gG) 710
710 500
500 400
400 710
710 400
400 400
400
2 2 2
6x240mm2 2 or 6x150mm
6x150mm2 2or
or 6x240mm2 2or
or
CableSize
Cable Size@
@30°C
30°C(BS 6231) 6x240mm or
(BS6231) 22 2 3x240mm2
3x240mm
22 6x240mm
2 3x240mm2
3x240mm
22
3x240mm2
3x240mm
22
3x500mm
3x500mm
2 3x400mm2 2
3x400mm 3x500mm2 2
3x500mm
22 2 2
22 22 6x150mm2 or
6x150mm or 22 6x150mm2 2or
6x150mm 6x150mm2 2or
or 6x150mm or
CableSize
Cable Size@
@45°C
45°C(BS
(BS6231)
6231) 6x400mm2
6x400mm 6x300mm2
6x300mm 6x400mm2
6x400mm
3x400mm 222 3x400mm 222
3x400mm 222
3x400mm 3x400mm 3x400mm
Fuse(UL)
Fuse (UL)
Fuse(CSA)
Fuse (CSA)
CableSize
Cable Size@
@30°C(UL/CSA)
30°C(UL/CSA)
CableSize
Cable Size@
@45°C(UL/CSA)
45°C(UL/CSA)
D250W,
D250W, MainOverload
Setting 480
480 275
275 255
255 480
480 265
265 245
245
D275W
D275W Fuse(ISO
Fuse (ISO269
269gG)
gG) 1000
1000 500
500 500
500 1000
1000 500
500 500
500
2 2 2 2
and
and 22 6x150mm2 2or
or 6x150mm or 22 6x150mm2 2or
or 6x150mm or
CableSize
Cable Size@
@30°C
30°C(BS
(BS6231)
6231) 6x400mm2
6x400mm 2 6x400mm2
6x400mm
D275RS-W 3x400mm 22 3x400mm 222 3x400mm
2
22 3x400mm 222
D275RS-W 3x400mm 3x400mm 3x400mm 3x400mm
22 2 2 22 2 2
CableSize
Cable Size@
@45°C
45°C(BS
(BS6231)
6231) 9x400mm2
9x400mm 6x300mm2 2
6x300mm 6x300mm2 2
6x300mm 9x400mm2
9x400mm 6x300mm2 2
6x300mm 6x300mm2 2
6x300mm
Fuse(UL)
Fuse (UL)
Fuse(CSA)
Fuse (CSA)
CableSize
Cable Size@
@30°C(UL/CSA)
30°C(UL/CSA)
CableSize
Cable Size@
@45°C(UL/CSA)
45°C(UL/CSA)
DL1640FA 21
6 Commissioning CompAir
6 Commissioning 10) Ensure fan motor and oil pump motor thermal over-
loads are set correctly for supply voltage.
Warning Motor 220V/ 400V/ 220V/ 460V/ 575V/
50Hz 50Hz 60Hz 60Hz 60Hz
Oil
6.3A 3.5A 6.3A 3.1A 2.5A
Pump
Canopy
• Refer to the safety procedures before commis- 5.7A 3.3A 6.1A 2.9A 2.3A
Fan
sioning the compressor unit.
MMS
12A 6.8A 12.4A 6.0A 4.8A
• Lethal voltages are used in this equipment. Use (Q101)
extreme caution when carrying out electrical
checks. Isolate the power supply before starting 11) Remove panels as required to gain access to motor
any maintenance work. connections.
12) Inspect the motor and control wiring connections to
make sure they are correct and secure. Replace all
panels.
6.1 Commissioning Procedure 13) Check that all protection blanks, air filter covers and
tapes have been removed.
When commissioning a new compressor or recom-
missioning a compressor which has been over- 14) Remove the four air-end/motor transportation bolts
hauled or out of service, carry out the following (if fitted). These are coloured red for identification.
procedures before attempting to start:
15) Open the isolating valve to the user’s pipework.
Note: We recommend that commissioning is carried
16) Check that the air end and motor rotate freely.
out by a CompAir distributor.
17) Check oil level and top up if required.
6.1.1 Preliminary Mechanical Checks
1) Remove air filter cover.
2) Remove the silica gel bags from the interstage mois-
ture separator and replace the flange.
3) Check that the isolator switch is locked ‘OFF’ and
that all pipework and electrical power connections
are correct and secure.
4) Open the access panel to the starter compartment.
Check all screws and starter connections for securi-
ty. Check all electrical connections are correct and
secure.
5) Ensure the controller to Extension module unit inter-
face cable connections are correct and secure.
6) Ensure the main supply cables and fuse ratings
comply with regulations.
7) Ensure the control transformer primary tapping con-
nections are correct for supply voltage.
8) Ensure main motor thermal overload is set correctly
for motor F.L.C. and supply voltage, as shown on the
motor data plate.
9) Ensure MCB Q101 (MMS) is set correctly.
22 DL1640FA
CompAir Commissioning 6
6.2 System Checks and Calibration a) Press SERVICE, HOURS, SERVICE, HOURS sym-
bols
Note: The values shown throughout these proce-
dures are examples only. Note: A guide to using the menu routines and control
unit menu structure diagrams is shown in Section 6
6.2.1 When an attempt to alter a parameter or option is – Operation
made for the first time after entering the menu rou-
tines, the controller will request an access code. CAUTION: The fan, oil pump and main motor are
When this occurs, the following procedure should be tested for correct rotation during manufacture. Do
followed: not rewire any motor as reverse rotation may result
causing air-end seizure.
No. Action Reason Display
1. Switch power supply ‘ON’. C20619/nn/xx/nn

SF3LnnUN ddmmmyy
Note: The POWER ON indicator

lights.
The REMOTE and AUTO RESTART

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

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

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

Operational settings
3. Press DOWN until the message To scroll through the menu options. Main menu
shown on the right is displayed. Commissioning - config.
4. Press ENTER. To choose the Commissioning - Commissioning - config.

configuration menu. Language English
5. Press (+) or (-) and repeat until the To select the Commissioning - config.
required language is displayed. displayed language. Language Option
(Pulsing display)
6. Press ENTER. To confirm the displayed Commissioning - config.

language. Language Option
(Steady display)
7. Press DOWN and repeat until the To select the required option. Commissioning - config.
display shown on the right is obtained. Return to previous menu

DL1640FA 23
9. Press DOWN and repeat until the To scroll through the menu. Main menu
option shown on the right is displayed. Service diagnostics
10. Press ENTER. To choose the Service diagnostics Service diagnostics

menu. Reset service hours
11. Press DOWN and repeat until the To scroll to the required option. Service diagnostics
option shown on the right is displayed. Test digital outputs
12. Press ENTER. To choose the Test digital outputs Test digital outputs
option. Main contactor 0
13. Press DOWN and repeat until the To scroll to the required option. Test digital outputs
option shown on the right is displayed. Fan contactor 0
14. Press (+). To turn on the fan and oil pump. Test digital outputs
Fan contactor 1
15. Check that air is being expelled from To check the direction of rotation of the
the enclosure fan exhaust. fan.
16. Check that oil pressure rises. To check the direction of rotation of the
oil pump.
17. Press (-). To turn off the Fan/oil pump. Test digital outputs
Fan contactor 0
18. If the fan or oil pump rotation is To reverse rotation.

incorrect, contact your CompAir
distributor
19. Press UP and repeat until the option To scroll to option required Test digital outputs
shown on the right is displayed Return to previous menu
20. Press ENTER. To return to the service diagnostics Service diagnostics

21. Press DOWN once then ENTER. To choose the calibrate pressure Set pressure at 0 bar
menu. Press enter when ready
22. If the zero pressure display is known to To by-pass the first part of the
be correct then press DOWN and go to calibration procedure.
step 25.
23. Disconnect the air connection to the To ensure zero pressure on the Set pressure at 0 bar
delivery pressure transmitter. transmitter. Press enter when ready
24. Press ENTER. To set the zero pressure Set pressure > 5.51bar
measurement in the controller.
25. Connect a slave air supply of more To establish a known calibration Adjust +/- :- 6.9bar
than 5.51 bar to the delivery pressure pressure. Press enter when ready
transmitter.
Note: If the air pressure is not above
5.51 bar the message shown in step
24 is displayed.
24 DL1640FA
26. If the slave air supply is not constant The alternative calibration procedure
then press UP or DOWN to enter the is more suitable for use with an
alternative calibration routine and go unstable reference pressure.
to step 30.
27. Press (+) or (-) as required to adjust To adjust the LCD display reading to Adjust +/-:- 7.0bar
the value shown on the display. match the slave air gauge. Press enter when ready
(Pulsing display)
28. When the gauge and display To store the pressure calibration value Commissioning - config.
pressures are equal press ENTER. in the controller.
(After a delay the display reverts to:)
Service diagnostics
Reset service hours
29. Go to step 31 To by-pass the alternative calibration

procedure.
30. Press UP or DOWN as required to To adjust the control panel display. Adjust pressure up/down
make the LED display follow the slave Press enter when ready
gauge display.
31. When the gauge and display track the To calibrate the pressure display. Calibration complete
pressure together, press ENTER.
(After a delay the display returns to:)
Service diagnostics
Reset service hours
32. Press RESET. To exit menu routine. Ready to start

33. Re-connect the air line to the delivery

pressure transmitter.
DL1640FA 25
6.3 Checking/Altering Commissioning Parameters

Note: The values shown throughout these procedures are examples only.
Refer to the Control Unit Menu Structure diagrams and check/set the commissioning parameters
1. Press ENTER. To display the Main menu. Main menu.

Operational settings.
2. Press DOWN and repeat until the To display the Commissioning - config Main menu.
display shown on the right is obtained. menu. Commissioning - config.
3. Press ENTER. To choose the Commissioning - config Commissioning - config.

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

Unit of pressure bar
5. Press DOWN. To display the next option. Commissioning - config.

Unit of temperature °C
6. Press DOWN. To display the next option. (On multi Commissioning - config.
unit installations). Machine number 1
7. Press ENTER. To display the Main menu. Main menu.

8. Press DOWN and repeat until the To scroll through the menu options. Main menu.
display shown on the right is obtained. Commissioning - values.
9. Press ENTER. To select the commissioning values Commissioning - values

menu. Max. pressure 10.5bar
10. Press DOWN. To choose the next option. Commissioning - values

Max. overpress 10.6bar

Star/delta time 25sec

Load delay time 60sec

Max. service hours 4000

Auto-restart delay 100sec

Interstage trip 4.0bar

Interstage alarm 3.8bar

Oil press alarm 1.7bar

Oil press trip 1.5bar
26 DL1640FA

Oil temp trip 75°C

Oil temp alarm 70°C

St1 delivery trip 200°C

St1 delivery alarm 180°C

St2 intake trip 65°C

St2 intake alarm 60°C

St2 delivery trip 200°C

St2 delivery alarm 180°C

Plant del trip 55°C

Plant del alarm 40°C

Water in trip 30°C

Water in alarm 27°C

Water out trip 65°C

Water out alarm 55°C
33. Press RESET. To exit menu routines. Ready to start.

DL1640FA 27
6.4 Checking/Altering Operating Parameters

1. Press ENTER. To display main menu. Main menu

2. Press DOWN and repeat until the To scroll through the main menu. Main menu
display shown on the right is obtained. Operational settings
3. Press ENTER. To display the Operational settings Operational settings

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

P2 set point 7.3bar

Run on time 10min

Drain open time 5sec

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

6.5 Re-setting Service Interval Timer

1. Press ENTER. To display the Main menu. Main menu

2. Press DOWN and repeat until the To scroll through the menu. Main menu
display shown on the right is obtained. Service diagnostics
3. Press ENTER. To display the service diagnostics Service diagnostics

4. Press ENTER. To reset the service hours countdown Service diagnostics

timer to maximum programmed hours. Service hours to run 4000
(After a delay, changing to:)
Service diagnostics
Reset service hours
5. Press RESET. To exit the menu routines. Ready to start

28 DL1640FA
6.6 Final Mechanical Checks

Notes:
1) The values shown throughout these procedures are examples only.
2) Ensure that the air discharge pipe is disconnected from the user’s system.
3) Ensure that the discharge air is directed away from all persons in the area.
1. Open the water stop valve in the water

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

SF3LnnUN_ddmmmyy
3. After a few seconds the display Ready to start

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

5. If the compressor does NOT start a The compressor will not start if:
message should be displayed.
(a) A menu routine has been selected. Menu selected
Menu option displayed
(b) Remote operation has been Ready to start
enabled. Remote start enabled
(c) A trip fault condition exists. Status

(See fault rectification.) Fault message
6. If electrical work has to be carried out,

switch power to the compressor ‘OFF’.
Establish the correct starting
conditions. Go to step 2.
7. Following start-up of the motor the Offload

display becomes: Oil temperature 20°C
8. Provided the delivery pressure is Onload

below the P2 set point the compressor Oil temperature 20°C
loads and the display becomes:
9. Run the compressor for 10 minutes. To disperse corrosion inhibitor from

the system.
10. Press STOP. To stop the compressor for connection Ready to start
to the air system. Oil temperature 20°C
11. Check that the blowdown valve has

released all pressure from the
compressor.
12. Connect the compressor delivery

flange to the user’s pipework via an
isolating shut-off valve. Ensure that
the valve is fully open.
13. Press START. To operate the compressor to check (See the displays in steps 4 to 10).
operating conditions and parameters.
DL1640FA 29
14. Examine compressor pipework for oil,

water or air leaks.
WARNING: RISK OF HIGH

PRESSURE
Do not use hands to locate leaks in the

system. Always use a piece of paper
or card for this purpose.
If a leak is found, stop the compressor,

rectify the fault and go to step 4.
15. Simulate a constant air demand by To provide a normal operating air

opening a valve in the user’s pipework. demand.
16. Check that the compressor loads and

unloads at the selected P1 and P2
pressure set points.
17. Run the compressor under these To achieve stable operating

conditions for an hour. conditions.
18. Fully open water flow control valves. To achieve full water flow.
19. Adjust intercooler flow valve. To adjust Stage 2 inlet temp to 10°C
above ambient or between 35°C and
45°C.
Note: It may be necessary to adjust

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

or water leaks.
21. Check operation of automatic

condensate drains.
22. Press STOP. Switch power to the

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

parameters from the ‘Operational
settings’, ‘Commissioning Config’ and
‘Commissioning values’ sub-menus
for future reference.
30 DL1640FA
6.7 Powered Breather - Description 6.8.2 The vacuum generator creates a depression
which is utilised to remove any oil mist (8) from
6.7.1 The powered breather system is designed to the gearbox. The air/oil mist passed through an
prevent oil mist emission from the compressor. oil removal filter (10) after which the filtered air
exhausts to atmosphere (9). The recovered oil
6.8 Powered Breather - Operation (11) then returns to the sump tank.
See diagram below. Caution: it is important that the air supply to
the powered breather (3) is moisture free. If
6.8.1 The system works by tapping the plant dis-
the installation is such that condensation
charge for an air supply (3) which is fed through
from the customer’s air network forms in
a control filter/pressure regulator (4) to a vacu-
the delivery pipe, then the air supply must
um generator (7).
be taken from a new location that is mois-
ture free.
5 6
7
9
4 6
80
40 8
2 120
0 lbf/in2
bar
0 10
10
4
11
3
1
SM 0694
Powered Breather System
1. 2nd Stage Moisture Separator 7. Vacuum Generator

2. Tee 8. Oil Mist from Gearbox
3. Pressurised Air to Vacuum Generator 9. Vacuum Generator Exhaust Air to Atmosphere
4. Pressure Reducing Valve/Line Filter 10. Oil Removal Filter
5. Pressure Adjuster 11. Removed Oil Returned to Gearbox
6. Pressure Gauge
DL1640FA 31
6.9 Commissioning Parameters Caution: It is not possible to adjust the

(Compressor Running On-Load) vacuum in the sump accurately by setting a
specific pressure reading on the pressure
6.9.1 During the 1-hour test running period, regulator gauge (1). Inaccurate adjustment
temperatures and pressures should stabilise of the breather system will result in
between the figures given below:- pressure in the oil sump, which could
Note: The temperature guidelines are for com- create oil leakages at the air end venting
pressors working in an ambient temperature of holes and gearbox drive end seal.
approximately 20°C and cooling water inlet
temperature of 15°C with the correct water
flow. In higher ambient temperatures, higher
cooling water inlet temperatures and/or low wa-
ter flow conditions the temperatures given may
be higher. In this case the temperature alarm
and trip levels may need to be raised.)
First stage delivery 150°C to 185°C
Second stage intake 35°C to 45°C
Second stage delivery 155°C to 190°C
Lubricating oil 40°C to 50°C
Water inlet 10°C to 20°C
Water outlet 20°C to 35°C
Water differential 10°C to 15°C
Oil Pressure 2 bar approximately
Stage 1 Air Delivery 1.8–2.8 bar

(Depending on model)
6.10 Powered Breather System - Check

Vacuum.
6.10.1 With the machine stopped, connect a vacuum
gauge (5) or U-tube / manometer, capable of
reading a vacuum of 50mm (2") w.g. into the oil
mist suction line between pressure vacuum
generator and filler pipe as shown in the dia-
gram.
Vacuum Gauge Connection
6.10.2 Start the machine and check that air is being
1. Pressure Gauge
discharged from the vacuum generator/oil
removal filter vent (4). 2. Pressure Adjuster
3. Vacuum Generator
6.10.3 Check the reading on the vacuum gauge (5)
and, if necessary, adjust the pressure regulator 4. Vent
(2) to obtain a reading of approx 50mm w.g. 5. Vacuum Gauge
when the machine is on load.
32 DL1640FA
6.11 Commissioning Check List 19. Drain open time set ...................
1. Pipework ................... 20. Drain shut time set ...................
2. Cable, fuse ratings OK ................... 21. Maximum compressor pressure set ...................
3. Control transformer 22. Maximum overpressure set. ...................

input voltage set correctly ................... 23. All temperature and pressure trip
4. Main motor, fan motor, oil pump limits set ...................
motor overloads and 24. All temperature and pressure
MCB Q102 set correctly ................... alarm limits set ...................
5. Phase rotation relay voltage set ................... 25. Star/delta time set ...................
6. Starter connections OK ................... 26. Load delay time set ...................
7. Motor connections OK ................... 27. Reset service hours timer ...................
8. Protection blanks and tapes ................... 28. Starting sequence correct ...................
9. Fill compressor with oil ................... 29. Compressor blows down OK. ...................
10. Air end and motor freely rotate ................... 30. Corrosion inhibitor dispersed ...................
11. Select language ................... 31. Connected to user’s pipework ...................
12. Fan/Oil pump rotation OK ................... 32. Oil, air and water leaks check. ...................
13. Main Motor rotation OK ................... 33. Compressor loads, unloads,
14. Pressure transducer calibrated ................... stands by and stops correctly ...................
15. Display units set ................... 34. Emergency stop correct. ...................
16. Compressor number set. (if comms 35. Temperatures and pressures in limits ...................
facility available/fitted) ................... 36. Oil level topped up ...................
17. Pressure control set points set ................... 37. All parameters recorded from
18. Run-on time set ................... controller menu routines ...................
DL1640FA 33
34 DL1640FA
CompAir Operation 7
7 Operation See ‘Fault Messages’ for possible start-up faults. If a

fault exists and a repair is necessary, power to the
Warning compressor must be isolated and the fault rectified.
If the reset indicator is lit, RESET must be pressed
following rectification of the fault, before the com-
pressor will start.
• Refer to the safety procedures before operating 4) To start the compressor press START (4). Provided
the compressor unit. pressure at the delivery point is below P2 set point
• Lethal voltages are used in this equipment. Use the compressor will start. It will otherwise enter
extreme caution when carrying out electrical Stand-by mode.
checks. Isolate the power supply before starting The oil pump, fan and water solenoid will energise
any maintenance work. but the main motor will not start until the oil pressure
has reached its set point. The compressor will not
start if:
Note: If the compressor has been out of operation a) Certain menu routines are in use.
for a prolonged period it is advisable to check per- b) The remote starting facility has been enabled. In this
formance and all regulation functions by carrying out instance the display panel REMOTE CONTROL indi-
the full commissioning procedure before starting. cator (20) will be lit and the display will show:
Unable to start
7.1 Routine Operation
Remote start enabled
(Refer to Control Panel diagram in this section of the
manual) 5) During the initial starting period, the drive motor
starts in Star connection and the status display will
Note: The temperatures and pressures given in the
show:
procedures are shown as examples only.
Starting
7.1.1 Starting
1) Start the cooling water flow to the compressor and to
the energy saver pack (if fitted). 6) Following the motor Star/Delta switch-over and dur-
ing the subsequent load delay period, the status dis-
2) Switch mains power to the compressor ‘ON’ at the
play will show:
isolator. The front panel is now in the following state.
Offload
a) The POWER ON indicator (22) is lit.
b) The status display (5) shows:
7) Provided the delivery pressure is below the lower set
C20627/nn/xx/nn
point (P2) the compressor runs on load.
SF3LnnUN_ddmmmyy
Onload
c) Either or both the REMOTE (20) and AUTO RE-
START (21) indicators are lit if these facilities have
been selected. See also ‘Remote Control’ and ‘Auto- 8) Fault conditions and service requirements are con-
matic Restart’ in Appendix 1, Remote Options. tinuously monitored (from start-up) and warning and
the appropriate status messages are displayed.
3) After a few seconds, provided no fault exists, the sta-
tus display will show: 9) To interrogate other temperature or interstage pres-
sure information press VALUE (see para 2, Using
Ready to start
The Menu Routines).
10) To interrogate the hours run and service hours infor-
Note: Oil temperature is used as an example only. mation press HOURS. (see para 2, Using The Menu
Actual display can be any of the displayed values in Routines).
para 1.4.
11) To show operating parameters, fault history, etc. or
to alter programmed settings, press ENTER (10) to
DL1640FA 35
7 Operation CompAir
access the menu routine (see para 6.2, Using The 2) Successive presses of the HOURS button give the
Menu Routines). following display sequence:
7.1.2 Pressure Control Total hours 1000
1) The compressor will unload and load in response to Hours on load 800
varying air demand when the upper and lower set
Service hrs to run 3000
points P1 and P2 are reached. When the compres-
sor goes off-load the system blows down. The con- 3) The display will cancel itself after a short period or it
troller loads and unloads the compressor by fully can be cancelled immediately by pressing RESET.
opening or fully closing the suction regulator inlet
7.1.4 Changing the Displayed Value
valve. The display alternates, as appropriate, be-
tween: 1) The VALUE button (33) is used to step through the
compressor operating temperatures and interstage
Offload
pressure displays.
2) Successive presses of the VALUE button give the
and following display sequence (typical figures shown).
Onload Oil temperature 45°C
Oil temperature 45°C St1 Delivery temp 160°C
2) If the compressor is off-load for longer than the ‘Run- St2 Intake temp 40°C
on Time’, the compressor will stop and the status
St2 Delivery temp 165°C
display will change to:
Plant delivery temp 35°C
Stopping
Water in temp 20°C
Water out temp 31°C
3) After the stopping period the display will change to:
Water temp diff 11°C
Standby
Interstage press 2·0 bar
Oil pressure 2·3 bar
Note: If the START button is pressed whilst the com-
pressor is stopping the display changes to ‘Standby’ 3) The selected value will remain on the display until a
immediately. new value is selected.
4) When air demand lowers the pressure below the 7.1.5 Stopping
lower set point P2 the compressor will restart and
1) To stop the compressor press STOP (36). This initi-
run on-load. The display will show:
ates a controlled shut down sequence. The main
Starting motor will continue to run for 8 seconds and the dis-
play will briefly show:
Offload
changing to:
Offload
changing to:
Stopping
during load delay time, then:
On load
The oil pump motor, enclosure cooling fan and the
water solenoid will remain energised for 30 seconds
7.1.3 Displaying the Number of Hours Run. after the main motor has stopped.
1) The HOURS button (30) is used to display the hours 2) After the 30 second cooling down period the display
run by the compressor and the hours to run before a will change to:
service is due.
Ready to start
36 DL1640FA
CompAir Operation 7
7.1.6 Emergency Stopping service indicator will remain lit to indicate that a serv-
1) 1. When the EMERGENCY STOP (17) is pressed, ice is required.
the compressor will stop immediately and the sys- 7.1.9 Warnings
tem will blow down. 1) If a service is required, the SERVICE indicator (35)
2) 2. The RESET indicator will pulse and the display and the appropriate mimic diagram indicator will
will show: flash continuously. If SERVICE (34) is pressed the
Fault shut down SERVICE indicator will stop flashing and stay lit in
acknowledgement. The RESET indicator (32) will
Emergency stop
flash continuously and the display will show the re-
Note: The emergency stop button should be used quired action (e.g. an air filter change) as below:
only in a genuine emergency and must not be used
Onload
as the normal method of stopping the compressor.
Change Air filter
7.1.7 Condensate Drain Operation
2) Pressing SERVICE repeatedly during this period will
1) When running on-load the intercooler and aftercool-
recall any earlier stored warnings in chronological
er condensate drains will operate according to the
order (most recent first) that have not been corrected
programmed drain shut and drain open times. The
and reset.
drain will open and the timer cycle will begin every
time the compressor loads. 3) When pressing SERVICE is discontinued, the fault/
service display will be shown for several seconds af-
2) When the compressor is in ‘off-load’, ‘standby’ or
ter which it reverts to the selected value display mes-
‘ready to start’, the drains will continue to operate
sage.
with a two second ‘open’ time and an extended ‘shut’
time. This prevents any build-up of condensate 4) The occurrence of another warning after any previ-
when the compressor is stopped or running ‘off- ous warning has been acknowledged will again
load’. cause the SERVICE indicator to flash continuously
and the mimic diagram indicator appropriate to the
7.1.8 Service Interval Timer
second fault will also light.
1) The control system uses a count-down timer which
5) It may not be convenient to respond to a warning im-
can be reset to programmed maximum each time a
mediately. In this case press RESET to cancel the
service is carried out. The maximum service hours
flashing service indicator and to restore the status
can be adjusted to suit site conditions and/or service
and selected value displays. The mimic diagram in-
schedule requirements.
dicator will remain lit to indicate that attention is re-
When the timer reaches zero hours a service due quired.
advice message is displayed. When the service has
7.1.10 Shutdowns
been completed, the reset service hours function
should be selected from the service diagnostics sub- 1) If a shutdown message occurs, the compressor will
menu and the service advice message reset. stop. This event can occur at any time after the com-
pressor has been started.
2) When the compressor has reached the running
hours at which a service is required, the SERVICE in- Both RESET and the appropriate mimic diagram in-
dicator (35) will flash. If SERVICE (34) is now dicator will flash continuously and the SERVICE indi-
pressed the SERVICE indicator (35) will stop flashing cator will light. If the menu routine is in use when a
and remain lit. The RESET indicator (32) will then shutdown occurs the appropriate panel and mimic
flash continuously and the status display will show diagram indicators will light and flash as normal. The
the service advice message below: current message will not be overwritten until RESET
is pressed or the display reverts to the fault message
Onload
after a period of time.
Service due
2) The display will show:
3) The compressor must be stopped and isolated to
carry out the required service (see ‘Safety Proce- Fault shutdown
dures’). On completion of the service the ‘service hrs (Relevant shutdown message) See Display
to run’ value must be reset to maximum by using the messages
Service Diagnostics menu routine. 7.1.11 Fault History Recall
4) It may not be convenient to respond to the service Selecting ‘Fault History Recall’ on the Main Menu
due message immediately. In this case press RE- will show the compressor status at the last fault. The
SET (31) to cancel the flashing RESET indicator and following parameters can be displayed showing the
restore the status and selected value display. The conditions at the last fault. The fault history will retain
the last 15 faults.
DL1640FA 37
7 Operation CompAir
Fault History Message Meaning

Total hours 1000 Hours run at time of fault.
Onload, Offload, Standby, Ready to start etc. State of compressor at time of fault.
Pressure 7·0 bar Delivery Pressure at time of fault.
Interstage press 2·0 bar Interstage pressure at time of fault.
Oil pressure 2·3 bar Oil pressure at time of fault
Oil temperature 45°C Oil temperature at time of fault.
St1 delivery temp 160°C Stage 1 delivery temperature at time of fault.
St2 intake temp 40°C Stage 2 intake temperature at time of fault.
St2 delivery temp 165°C Stage 2 delivery temperature at time of fault.
Plant del temp 30°C Plant delivery temperature at time of fault.
Water in temp 20°C Water inlet temperature at time of fault.
Water out temp 31°C Water outlet temperature at time of fault.
7.1.12 Stand-by Operations In the diagrams the solid line boxes represent the
message window and the broken line boxes are
A compressor on stand-by duty must be started and
reader information or instructions.
run for 10 minutes per week.
Notes for use with SureScan menu diagrams
If the user’s air usage is insufficient to allow the com-
pressor to run for 10 minutes the compressor should 1. Show program variant – Displays a reference
be run Off-load as follows: number for the controller program variant, for refer-
ence only. Press Return to return to main menu.
1) Ensure the Run On time on the controller is set to 10
minutes. 2. Test digital inputs – Test routine for each individ-
ual input. Input cards test routine.
2) At the remote inputs, ensure Remote Load Input is
open, then close the Remote Load Enable. 3. Test analogue inputs – Test routine for pressure
and temperature inputs. Preconditioner card
3) If the compressor is not already in standby, start the
PT1000 conditioner units and pressure transmitters
compressor which will then go into stand by.
test routine.
4) Momentarily close the Remote Load input. The com-
4. Test keypad – Keypad test routine. Each key
pressor will start.
pressed will be displayed to establish operation.
Note: Ensure that the Remote Load input is opened Press RESET to exit routine.
before the delta contact is closed or the compressor
5. Test Display – Control panel LED, LCD and indi-
may load.
cator test. When selected all LED’s and indicators
5) Open the Remote Load Enable to put control back to will light and all LCD text display elements will turn
the transducer. on for 15 seconds. The routine will self cancel.
6) The compressor will now run for the time set.
7.2 Using The Menu Routines

The menu routines are used to access, view and/or
alter the operating parameters and options stored in
the memory of the controller.
With the mains power on and ENTER pressed, the
text display on the control panel will show two lines
of text. The top line indicates the menu in use and
the bottom line the parameters in use.
The diagrams at the end of this section show the se-
quence of messages available and the buttons to
press to obtain the required message.
38 DL1640FA
CompAir Operation 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
bar
psi
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
PI/97/067
1. Psi Units Indicator 19. Remote Control Legend

2. Bar Units Indicator 20. Remote Control Indicator
3. Delivery Pressure Display 21. Auto Restart Indicator
4. Start Button 22. Power On Indicator
5. Status and Message Display 23. Compressor Delivery Fault Indicator
6. Plus Button 24. Oil System Fault Indicator
7. Minus Button 25. Change Oil Filter Indicator
8. Up Button 26. 2nd Stage Delivery Fault Indicator
9. Down Button 27. Low Oil Level Indicator
10. Enter Button 28. Main Motor Fault Indicator
11. Mimic Diagram 29. Oil Pump Motor Fault Indicator
12. Intake Filter Change Indicator 30. Hours Button
13. Incorrect Phase Rotation Indicator 31. Reset Button
14. 1st Stage Delivery Fault Indicator 32. Reset Indicator (LED)
15. 2nd Stage Intake Fault Indicator 33. Values Button
16. Fan Motor Fault Indicator 34. Service Button
17. Emergency Stop Button 35. Service Indicator (LED)
18. Auto Restart Legend 36. Stop Button
CONTROL PANEL
Note: Please check for speed adjusted compressors

in the operating instructions "Touchpanel Pro-face".
DL1640FA 39
7 Operation CompAir
CONTROL PANEL MENUS

ENTRY MENU SUB MENUS
Main Selection Menu Operational settings Commissioning - Values
Operational settings P1 setpoint **.*bar Max. pressure **.*bar

Fault history recall P2 setpoint **.*bar Max. overpress **.*bar
Service diagnostics Run on time **min Star/delta time **sec
Commissioning - config. Drain open time **sec Load delay time ***sec
Commissioning - values Drain shut time ***sec Max service hours ****
Show program variant Return to previous menu Autorestart delay ***sec
Return to previous menu Interstage trip **.*bar
Service Diagnostics Interstage alarm **.*bar
Oil pressure alarm **.*bar
Reset service hours
Oil pressure trip **.*bar
Calibrate pressure
Oil temp trip ***˚C
Fault History Recall Test digital outputs
Oil temp alarm ***˚C
Test digital inputs
Scroll up/down last 15 St1 delivery trip ***˚C
faults in chronological Test analogue inputs
order. St1 delivery alarm ***˚C
Test keypad
St2 intake trip ***˚C
Shows status of Test display
compressor at time of St2 intake alarm ***˚C
displayed fault. Return to previous menu
St2 delivery trip ***˚C
St2 delivery alarm ***˚C
Commissioning - Config
Plant del trip ***˚C
Language: English Plant del alarm ***˚C
Unit of pressure bar Water in trip ***˚C
Unit of temperature ˚C Water in alarm ***˚C
Compressor number ** Water out trip ***˚C
Oil pressure Sensor Water out alarm ***˚C
Fault input config **** Load default values
Return to previous menu Return to previous menu
HW 0449A
CONTROL PANEL MENUS – QUICK REFERENCE GUIDE
40 DL1640FA
CompAir Operation 7
Status Message
Oil temperature 25˚C
Main Menu Go to 2 of 8
Intake temp 20˚C Total hours 1000
St1 delivery temp 160˚C Hours on load 800
When first attempt is made to adjust

any value, the prompt will appear:
St2 intake temp 40˚C Service hrs to run 3000
Enter code: ????

St2 delivery temp 165˚C
Plant del temp 35˚C
To continue
Water in temp 20˚C
Water out temp 20˚C
Water temp diff 20 C
Interstage press 2.0bar
Oil pressure 2.3bar ★
Press at any time in any

menu to return to initial display ★ Only if ‘oil pressure transmitter’ is selected
HW 0450A
SURESCAN CONTROL UNIT MENU STRUCTURE (1 OF 8)
DL1640FA 41
7 Operation CompAir
From 1 of 8
Main Menu
Go to 3 of 8
Fault history recall

Fault history recall 1 Fault message
Fault message Status Message
Service diagnostics
Go to 3 of 8
Fault history recall 2 Total hours 1000
Fault message
Commissioning - config
Go to 6 of 8
Pressure 7.0bar
Commissioning - values
Go to 8 of 8
Interstage Press 2.0bar
Show program variant See note 1 Fault history recall 25

Fault message Oil pressure 2.3bar ★
Return to previous menu To 1 of 8
Fault history recall 0 Oil temperature 45˚C

Return to previous menu
Main Program Number St1 delivery temp 160˚C

Name & Date
St2 intake temp 45˚C
Extension Module Prog No.

Name & Date
St2 delivery temp 165˚C
Plant del temp 30˚C

Water in temp 20˚C

To 2 of 8
Press at any time in any Water out temp 31˚C

menu to return to initial display
★ Shows (– – –) if ‘oil pressure transmitter’ is selected HW 0451A
42 DL1640FA
CompAir Operation 7
P1 setpoint 7.5bar P1 set point 8.1bar
P2 setpoint 6.9bar P2 set point 7.2bar
Run on time 15min Run on time 20min
Drain open time 25sec Drain open time 15sec
Drain shut time 125sec Drain shut time 200sec

Service diagnostics
Reset service hours Service hours to run 8000 2 sec
To 2 of 8
Calibrate pressure
Go to 4 of 8
Test digital outputs

Go to 5 of 8
Test digital inputs

See Note 2
Test analogue inputs

See Note 3
Test keypad
See Note 4
Test display
See Note 5

Return to previous menu Go to 2 of 8
1 of 8
HW 0452A
DL1640FA 43
7 Operation CompAir
Note: The calibration procedure corrects for zero

offset of all transducers but only corrects the range
of the delivery pressure. Therefore all pressures
(delivery, interstage and oil) must be zero for the
first stage of this routine or the routine will be
aborted with a probe error message. For
subsequent stages, only the delivery pressure
From 3 of 8 needs to be adjusted.
Set pressure at 0bar See note

Press enter when ready
Disconnect delivery pipe from

pressure transmitter
Set pressure > 5.51bar
Connect known air pressure supply

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

Press enter when ready correct pressure
Adjust pressure up/down Adjust until display tracks

Press enter when ready pressure variations correctly
Calibration complete
2 sec

To 3 of 8
HW 0453A
44 DL1640FA
CompAir Operation 7
From 3 of 8
Test digital outputs

Main contactor 0 Running 0
Star contactor 0 On load 0
Delta contactor 0 Group trip 0
Unloader solenoid 0 Service due 0
Drain solenoids 0 Remote fault 1 0
Fan contactor 0 Remote fault 2 0
Channel 7 0 Remote fault 3 0 Remote fault 3 1
Oil pump contactor 0 Remote fault 4 0
For each parameter
Available 0 Remote fault 5 0
0 indicates not energised

1 indicates energised
Group fault 0 Extension XO6/7 0
To 3 of 8

HW 0454A
DL1640FA 45
7 Operation CompAir
From 2 of 8
Commissioning-Config
Language: English Language: Option
Unit of pressure bar Unit of pressure psi
Unit of temperature ˚C Unit of temperature ˚F
Machine model Go to menu structure 7 of 8
Machine number 1 Compressor number 10
Go to menu structure 7 of 8
Communications config.
Fault input config
Remote fault 1
Remote fault 1
Disabled
Fault input config
Remote fault 2
Trip type 1, 2 or 3
Remote fault 5
Alarm type 1, 2 or 3
Start inhibit
To 6 of 8
Oil pressure sensor Oil pressure switch
To 2 of 8
HW 0455A
46 DL1640FA
CompAir Operation 7
Enter code ????
Machine model
Machine model
Model message
Machine model
see list below
To 6 of 8
Config. message
Disabled
SmartAir control
To 6 of 8
Communications control
MACHINE models
6504 / 6604 D55-W D55-08/10A
6505 / 6605 D75-W D75-08/10A
6506 / 6606 D90-W D90-08/10A
6507 / 6607 D110-W D110-08/10A
6508 / 6608 D132-W D132-08/10A
6509 / 6609 D150-W D150-08/10A
6510 / 6610 D155-W
6512 / 6612 D160-W
6515 / 6615 D185-W
D200-W
D250-W
D275-W (Default)
HW 0456A
DL1640FA 47
7 Operation CompAir
From 2 of 8
Commissioning-Values
Max. pressure 10.5bar St1 delivery alarm 180˚C
Max. overpress 10.6bar St2 intake trip 65˚C
Star/delta time 25sec St2 intake alarm 60˚C
Load delay time 60sec St2 delivery trip 200˚C
Max. service hrs 4000 St2 delivery alarm 180˚C
Autorestart delay 100sec Plant del trip 55˚C Plant del trip 45˚C
Interstage trip 4.0bar Plant del alarm 40˚C
For each parameter
Interstage alarm 3.8bar Load default values Default values loaded 2 sec
Oil pressure alarm 1.7bar Return to previous menu
Oil pressure trip 1.5bar From 2 of 8
Oil temp trip 75˚C
Oil temp alarm 70˚C
St1 delivery trip 200˚C

HW 0457A
48 DL1640FA
CompAir Operation 7
7.3 Default Values may be restored to the default values, by choosing

the ‘Load default values’ option in the ‘Commission-
7.3.1 Default values for a number of the operational set- ing - values’ sub-menu. Alteration of the working set-
tings are stored in the controller. These are suitable ting values requires the use of the access code.
for operating the compressor in most normal situa-
tions. 7.3.4 The following is a list of default values together with
the range and size of the increments/ decrements
7.3.2 The compressor can use these values as operation- available for each setting.
al settings. Unless the compressor is reprogrammed
during commissioning, the default values will be Note: The ‘Model’ and ‘Max. Pressure’ must be set
those used by the compressor. according to the compressor data plate. The default
‘Star/Delta Time’ for the model is set when the model
7.3.3 The compressor may be re-programmed with differ- is set.
ent values at any time, and the controller settings
Setting Unit Minimum Maximum Step Default Value
P1 setpoint bar 5·1 10·5 0·1 7·0
P2 setpoint bar 5·0 10·4 0·1 6·3
Run on time minute 5 240 1 10
Drain open time second 1 20 1 5
Drain shut time second 10 120 1 30
Star delta time second 3 30 1 15
Comms baud rate baud 110 9600 options 9600
Compressor number number 1 99 1 1
Max. pressure bar 7/8/10·5 options 7·0
Max. overpress bar 6·0 11·0 0·1 7·5
Load delay time second 2 60 1 2
Max. service hours hour 1000 4000 100 4000
Auto restart Delay second 10 240 1 10
Interstage pressure trip bar 2·5 4·0 0·1 3·5
Interstage pressure alarm bar 2·5 4·0 0·1 3·0
Oil temp trip °C 50 75 1 70
Oil temp alarm °C 50 75 1 65
St1 delivery trip °C 180 225 1 210
St1 delivery alarm °C 180 220 1 200
St2 intake trip °C 40 75 1 55
St2 intake alarm °C 40 75 1 50
St2 delivery trip °C 180 235 1 220
St2 delivery alarm °C 180 230 1 210
Plant del trip °C 30 90 1 70
Plant del alarm °C 30 90 1 60
Water in trip °C 10 50 1 45
Water in alarm °C 10 50 1 40
Water out trip °C 20 90 1 75
Water out alarm °C 20 90 1 70
Oil press trip bar 1·5 1·5 – 1·5
Oil press alarm bar 1·7 1·7 – 1·7
Oil filter dp switch bar – – fixed 2
Air filter dp switch mbar – – fixed 65
DL1640FA 49
7 Operation CompAir
7.4 Glossary of Display Messages
7.4.1 Operator Advice Messages
Message displayed Meaning
Invalid Access Code The access code entered is not acceptable.

No reset indicated The ‘Reset’ button has been pressed when there is no reset required.
No service indicated The ‘Service’ button has been pressed when there is no service action required.
Remote start enabled Starting has been attempted via the Control Panel when the remote start facility
is enabled (Panel starting is disabled).
Remote stopped Starting is inhibited by the remote stop input.
Stop compressor first The compressor is running and a menu selection has been attempted which can
only be used when the compressor is stopped.
7.4.2 Shutdowns
Extension module fault Extension module unit is not responding.

Emergency stop An emergency stop has been made.
Rotation fault Main supply phase rotation is detected to be incorrect or voltage is below
acceptable limits.
Main motor fault The compressor has shut down because of main motor overcurrent or high
temperature.
Fan motor fault The compressor has shut down because of fan motor overcurrent.
Oil pump fault The compressor has shut down because of oil pump motor overcurrent.
MPCB Q101 tripped The protection circuit breaker Q101 is in the tripped condition.
High air pressure The compressor has shut down because the delivery pressure has exceeded
the maximum pressure setting.
Interstage press trip The interstage pressure has exceeded the maximum set pressure limit.
Oil pressure low The compressor has shut down because the oil pressure has fallen below the
minimum pressure limit.
Oil temperature trip The compressor has shut down because the oil temperature has exceeded the
upper (trip) limit.
St1 delivery temp trip The compressor has shut down because the first stage delivery temperature
has exceeded the upper (trip) limit.
St2 intake temp trip The compressor has shut down because the second stage intake temperature
St2 delivery temp trip The compressor has shut down because the second stage delivery temperature
Plant delivery t trip The compressor has shut down because the plant air delivery temperature has
exceeded the upper (trip) limit.
50 DL1640FA
CompAir Operation 7
Del press probe fault The compressor has shut down because the air delivery pressure transmitter is
indicating a pressure outside of normal limits.
Int.St press probe fault The compressor has shutdown because the interstage pressure transmitter is
indicating a pressure outside of normal limits.
Oil press probe fault The compressor has shutdown because the oil pressure transmitter is indicating
a pressure outside of normal limits.
Oil temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
St1 del temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
St2 in temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
St2 del temp probe fault The temperature sensor is indicating a temperature outside of normal limits.
Plant del t probe fault The temperature sensor is indicating a temperature outside of normal limits.
Remote fault The compressor has shutdown because one of the remote fault inputs has been
activated.
Water in temp trip The water inlet temperature has exceeded the upper (trip) limit.
Water out temp trip The water outlet temperature has exceeded the upper (trip) limit.
Oil level low (start inhibit) The sump oil level is detected to be low while the compressor is stopped.
7.4.3 Warnings
Change air filter A high differential pressure has been detected across the air filter indicating the
need for an air filter element change.
Change oil filter A high differential pressure has been detected across the oil filter indicating the
need for an oil filter change.
Interstage press alarm The interstage pressure has reached the programmed warning value. Oil
temperature alarm The oil temperature has reached the programmed warning
value.
St1 delivery temp alarm The first stage delivery temperature has reached the programmed warning
value.
St2 intake temp alarm The second stage intake temperature has reached the programmed warning
value.
St2 delivery temp alarm The second stage delivery temperature has reached the programmed warning
value.
Plant delivery t alarm The plant air delivery temperature has reached the programmed warning value.
Water in t probe fault The temperature sensor is indicating a temperature outside of normal limits.
Water out t probe fault The temperature sensor is indicating a temperature outside of normal limits.
Water in temp alarm The water inlet temperature has reached the programmed warning value.
Water out temp alarm The water outlet temperature has reached the programmed warning value.
DL1640FA 51
7 Operation CompAir
Oil level low Indicates that oil level is low.

Remote alarm One of the remote alarm inputs has been activated.
Service due The service interval countdown timer has reached zero hours indicating a
service is now due.
Oil pressure alarm The oil pressure has dropped to the programmed warning value.
Start inhibit The remote start inhibit input is open circuit.
7.4.4 Service Messages
Total hours Shows the recorded total number of compressor running hours on and off load.
Hours on load Shows the recorded total number of compressor running hours on load only.
Max. service hrs Shows the maximum programmed hours before a service is required.
Service hrs to run Indicates the number of running hours remaining before a service is required.
Reset service hours Invitation to reset the service interval hours to the maximum programmed
service hours.
7.4.5 Status Messages
Auto restarting The compressor is about to automatically restart following restoration of power.
Fault shutdown The compressor has stopped due to a fault.
Offload The compressor is running off load (the run-on time has not expired).
Onload The compressor is running on load.
Ready to start The compressor is waiting for a start signal (keypad or external) and no fault has
been detected.
Remote stopped Starting is inhibited by the remote stop input being open circuit.
Standby The compressor has been ‘started’ but is waiting for the delivery pressure to fall
below the lower setpoint, before the motor is energised.
Starting Motor starting.
Unable to start A remote shutdown fault or start inhibit is present.
Stopping The stop button has been pressed but the oil pump motor, canopy cooling fan
and the water solenoid will remain energised for 30 seconds.
52 DL1640FA
CompAir Maintenance 8
8 Maintenance conditions are stable and with the compressor run-

ning on full load.
8.1.3 Maintenance Record
8.1 Routine Maintenance
Keep a careful record of all servicing, maintenance
and repair work carried out on the compressor. This
Warning
record will form a useful reference.
8.1.4 Electrical Connections
• Refer to the safety procedures before carrying Regularly check the compressor unit for loose con-
out any maintenance or servicing work on the nections or frayed wiring. Clean and tighten all con-
compressor unit. nections and repair or renew all frayed or damaged
wires and cables before starting up.
• Lethal voltages are used in this equipment. Use
extreme caution when carrying out electrical Take care not to damage the wiring when working on
checks. Isolate the power supply before starting the unit. When refitting wires and cables make sure
any maintenance work. they are not damaged and that they will not be dam-
aged in service by chafing or contact with a hot sur-
face.
8.1.5 Leaks
To ensure the efficient operation of the compressor
unit the user must check performance regularly and
carry out the necessary adjustments to maintain cor- Warning
rect settings. This section gives the information
needed by the user for this purpose.
It is a condition of the Warranty cover that the unit is • Risk of high pressure
properly maintained and adjusted, that all checks,
routine maintenance and regular servicing listed in
the Maintenance Schedule are carried out at the
specified intervals and that an accurate record is Do NOT use hands to locate leaks in the system. Al-
kept of the work. ways use a piece of paper or card for this purpose.
It is recommended that service and maintenance is Inspect the unit as a matter of course when carrying
carried out by your local CompAir Distributor. out servicing or maintenance for any sign of leaking
pipe connections, a build-up of dirt or debris and oil
All CompAir compressors are fitted with high per- leaks. Repair or replace damaged or leaking pipe or
formance filtration equipment. However, if the work- hose connections immediately.
ing environment is particularly hostile the filter
elements and the heat exchangers will require atten- Prestolok Instant Pipe Connection System
tion at more frequent intervals than specified in the Control air flexible pipes and Prestolok pipe connec-
schedule. tions are used throughout the compressor. Prestolok
8.1.1 Cleanliness pipe connections are a compact instant brass fitting
for flexible pipes, specially designed for pneumatic
The compressor unit must be kept in a clean condi- installations.
tion at all times. Make regular inspections for signs
of damage, excessive wear and security of fittings. Assembly
Ensure that any oil spillage is wiped up immediately 1) Push the cover ring onto the pipe.
and any residual oil cleaned from external surfaces.
2) Insert the pipe into the fitting until the pipe bottoms.
Caution: Do not allow oil to enter the air intake, air
system components or air system pipework. 3) Pull the pipe to ensure secure engagement of the
grip ring teeth.
8.1.2 Recording Pressures and Temperatures
4) Clip the cover ring onto the fitting.
Keep a regular record of the compressor operating
pressures and temperatures by noting the value Disassembly
readings, together with ambient air temperature, in a To remove a pipe, disengage the cover and disen-
record book. The readings should be taken when gage the grip ring teeth by manually applying pres-
DL1640FA 53
8 Maintenance CompAir
sure on the push ring sleeve and withdrawing the

pipe and cover ring from the fitting.
8.1.6 Regular Checks
The ‘Maintenance Schedule’ lists the routine checks
and services which are important to the efficient run-
ning of the unit. The user should ensure that the
Weekly Checks become an integral part of planned
maintenance, even if the major servicing work is
contracted to a CompAir Distributor.
8.1.7 Lubricating Oil
It is essential to maintain the correct level of oil and
to change the oil completely at the specified inter-
vals.
8.2 Maintenance Schedule

Regular maintenance should be carried out as rec-
ommended in the Schedule below. The Schedule is
appropriate to most circumstances but, in some in-
stances, changes in detail may be required. The
Schedule should always be used as a guide initially,
but if experience shows that an alteration is neces-
sary, advice should be sought from the local
CompAir distributor.
Hours Service
Weekly Checks –
Every 4000 A
Every 8000 or 1 year

B
(whichever is sooner)
Every 16000 or 2 years

C
(whichever is sooner)
The above cycle from 4000 hours should then be re-

peated.
In conditions of high ambient temperature/humidity
and/or dirty conditions all filters may need to be re-
newed more often than the recommended service
period. Renew the filters when ‘CHANGE AIR FIL-
TERS’ is indicated on the control system.
In conditions of high ambient temperature/humidity
and/or dirty conditions motor bearings may need to
be lubricated more often than the recommended
service period.
54 DL1640FA
ITEM ACTION PART DESCRIPTION PART NO

WEEKLY CHECKS
Enclosure filters Inspect and clean if necessary - -
Condensate drain solenoid valves Check condensate drain operation - -
Oil level Check oil level - -
Control system Check for indicated service requirements - -
SERVICE A - Every 4000 Hours or 6 months, weekly checks plus the following:
Customer operating log Review operating parameters - -
Control system Review fault history - -
Intake air filter Check condition, clean if necessary - -
Hoses and pipework Check for leaks - -
Electrical wiring Check connections and condition - -
Compressor internals and enclosure Clean compressor - -
Balance piston diaphragms (D160 - D275) Replace diaphragm - low pressure element Diaphragm 98210-2
Replace diaphragm - high pressure element Diaphragm 98210-4
SERVICE B - Every 8000 Hours or 12 months, weekly checks plus Service A plus the following:
Intake air filter Replace element Service kit CK3100-5
Oil filter Replace element " or
Breather filter Replace element " CK3200-2
Balance piston diaphragms (D55 - D155) Replace diaphragm - low pressure element " "
Replace diaphragm - high pressure element " "
Regulation air line filter Replace element " "
Condensate drain solenoid valves Replace complete valve - interstage drain Service kit CK4100-1
Replace complete valve - discharge drain " "
Unloader solenoid valve Overhaul valve " "
Oil Change oil - -
Oil cooler Check condition and clean if necessary Seals See parts list
Intercooler tubestack Check condition and clean if necessary Joints See parts list
Aftercooler tubestack Check condition and clean if necessary Joints See parts list
Control system Check for satisfactory operating parameters - -
Control system Test displays and operating buttons - -
Cooling water quality Check cooling water quality against specification - -
detailed in Appendix 4
Aftercooler & Intercooler Check differential pressure across each cooler.
If > 0.3 bar (4.35 psi), the cooler should be cleaned
or replaced.
SERVICE C - Every 16000 Hours or 24 months, weekly checks plus Service A and B plus the following:
Suction regulator Replace diaphragm Service kit CK7100-5
Non return check valve (D160 - D275) Replace complete valve " or
Water stop valve Overhaul valve " CK7200-2
Flexible drive coupling Check backlash and replace inserts if necessary Drive coupling inserts See parts list
DL1640FA 55
Note 1: The oil change period can be extended to 16000 hours or 24 months if oil condition monitoringindicates this to
be satisfactory.
Note 2: See the Service Kit Part Number table to identify the correct service kit part.
Note 3: For information on lubrication of motor bearings refer to para 4.11 ‘Electric Motors’.
Service Kit Part Numbers:
Model No Service A Service B Service C
D55 - D155 and No Parts required CK3100-5 and CK4100-1 CK3100-5, CK4100-1 and CK7100-5
D110RS-W,
D155RS-W
D160 - D275 and 98210-2 and 98210-4 CK3200-2 and CK4100-1 CK3200-2, CK4100-1 and CK7200-2
D275RS-W
Note: Service kit CK3200-2 includes balance piston diaphragms 98210-2 and 98210-4
56 DL1640FA
8.3 Torque Schedule

Incorrect tightening of air pipework flange bolts may
cause premature failure of the gaskets. All flange
bolts should be tightened in accordance with the
torque schedules below and re-checked at every
4000 hour service. The bolts should be tightened in
a sequence of diametrically opposite pairs to ensure
even loading.
Models D55 to D155

Tightening
Location Bolt size Qty
torque, Nm
Suction regulator to 1st stage inlet M12 4 100
1st stage outlet to pipe M16 4 250
1st stage pipe to intercooler inlet bend M16 4 250
Inlet bend to intercooler flange M16 12 250
Intercooler outlet to separator M12 8 85
Separator outlet to 2nd stage inlet pipe M16 4 250
Inlet pipe to 2nd stage inlet flange M12 4 100
Separator bottom flange M16 4 250
Safety valve flange to separator M16 4 250
2nd stage delivery to silencer M12 4 100
Silencer to pipe M16 8 200
Pipe to aftercooler inlet M20 8 400
Aftercooler outlet to separator M20 8 400
Models D160 to D275

Tightening
Location Bolt size Qty
torque, Nm
Suction regulator to 1st stage inlet M12 4 100
1st stage outlet to pipe M16 4 250
1st stage pipe to intercooler inlet bend M16 8 250
Inlet bend to intercooler flange M16 16 200
Intercooler outlet to separator M16 8 200
Separator outlet to 2nd stage inlet pipe M16 8 250
Inlet pipe to 2nd stage inlet flange M16 4 250
Separator bottom flange M16 8 250
Safety valve flange to separator M16 8 250
2nd stage outlet to delivery silencer M16 4 250
Delivery silencer to aftercooler pipe M16 7 + 1 stud 250
Pipe to aftercooler inlet M20 12 400
Aftercooler outlet to separator M20 12 400
DL1640FA 57
1. Motor Bearings 7. Balance Piston Diaphragms 13. Oil Reservoir

2. Intake Air Filter 8. Oil Breather Element 14. Oil Cooler
3. Aftercooler 9. Expansion Compensator Seals 15. Oil Filter
4. Check Valve 10. Condensate Drains 16. Drive Coupling
5. Suction Regulator 11. Intercooler 17. Enclosure Filters
6. Regulation Air Line Filter 12. Oil Level Sightglass 18. Oil Filler
Servicing Points D55 - D155
58 DL1640FA
1. Motor Bearings 7. Balance Piston Diaphragms 13. Oil Cooler

2. Intake Air Filter 8. Oil Breather Element 14. Oil Level Sightglass
3. Aftercooler 9. Expansion Compensator Seals 15. Oil Filter
4. Check Valve 10. Condensate Drains 16. Drive Coupling
5. Suction Regulator 11. Intercooler 17. Enclosure Filters
6. Regulation Air Line Filter 12. Oil Reservoir 18. Oil Filler
Servicing Points D160 - D275
DL1640FA 59
8.4 Maintenance Procedures 8.4.1 Enclosure Filters

The compressor is provided with two coarse screen
Warning filters in the panels of the enclosure. One acts as a
pre-filter for the intake air and the other to filter the
ventilation air.
• Refer to the safety procedures before carrying Carry out a regular visual check of the condition of
out any maintenance or servicing work on the the enclosure filter elements. If the elements are
compressor unit. seen to be heavily contaminated they should be
cleaned as follows:
extreme caution when carrying out electrical 1) Remove the enclosure panel complete with
checks. Isolate the power supply before starting integral filter.
any maintenance work.
• Where a maintenance procedure below includes 2) Separate the filter element from the panel and
the warning ‘The compressor must be stopped’ wash it carefully in a mild detergent solution.
the following steps must be taken before work is Rinse thoroughly and allow to dry.
commenced:
3) Refit the element to the panel and refit the
1) Close the isolating shut-off valve to the panel in the enclosure.
user’s pipework. Close the isolating valves
in the cooling water inlet and outlet pipes. 8.4.2 Condensate Drain
Attach a label carrying the warning ‘WORK Moisture present in the compressed air condenses
IN PROGRESS – DO NOT OPEN’ to each in the interstage and second stage moisture separa-
isolating valve. tors and is drained by solenoid operated valves.
2) Switch the power supply ‘OFF’ at the isola- To Check the Operation of the Condensate Drain
tor. Valves:
3) Attach a label carrying the warning ‘WORK 1) With the compressor running on load, discon-
IN PROGRESS – DO NOT APPLY VOLTAGE’ nect the condensate drain connection at the
to the isolator switch and to the display baseframe and check visually that condensate
panel. Do not switch on electrical power or is being released automatically according to
attempt to start the unit if such a warning the drain open and shut times programmed
label is attached. into the controller. If no condensate is being
released, stop the compressor, switch power
4) Bleed down all air pressure in the delivery off at the isolator, clean the strainer and check
pipe between the non-return valve and the the wiring.
shut-off valve by carefully slackening the
aftercooler condensate drain connection at 2) If the fault persists, refer to the local CompAir
the strainer inlet. distributor.
5) First and second stage pressure will 3) For variable-speed compressors, the conden-
exhaust through the dump silencers by the sate drain is controlled via Bekomat units.
action of the unloader solenoid valve. As
an additional precaution, slacken the drain 4) If no condensate is being released, stop the
plug at the base of the regulation air line fil- compressor, switch power off at the isolator,
ter to release any residual pressure and clean the strainer and check the wiring.
leave it slack while work is in progress.
When work is completed remember to re- 8.4.3 Regulation Air Line Filter
tighten the plug before starting the com- This filter separates moisture and solid
pressor. impurities from the regulation air system. The
moisture and other contaminants collect in the
filter bowl and must be cleared regularly.
60 DL1640FA
To Clear the Filter: 2) Remove the cover of the intake air filter, take
out the element and discard.
1) With the compressor running on load, slowly
open the captive drain plug in the base of the 3) Clean the inside of the filter body.
filter bowl by screwing it upwards, into the
bowl. This will lift the internal valve off its seat 4) Fit the new element in the filter body and refit
and air pressure will drive out the condensate the cover.
and any accumulated particles.
Always fit a new filter element at the specified serv-
2) When the air being discharged is clean, close ice intervals. However, if cleaning must be resorted
the drain plug. to, carry out the following procedure.
To Clean the Element by Air Blast:
To Renew the Filter Element:
Caution: Do not use high pressure air supply.
The compressor must be stopped.
Caution: Avoid excessive strain on the pipework
when removing or refitting the filter bowl.
1) Using an air line supplying dry, low-pressure
air (maximum 0·5 bar) carefully blow out the
1) Hold the filter housing securely and unscrew
inner cavity, ensuring that the air stream
the bowl from the housing.
passes through the element from the clean
side.
2) Unscrew the retainer assembly, remove the
collar and withdraw the element from retainer.
2) When all contamination has been removed,
inspect the element for cracks, holes or other
3) Clean out the bowl with a mild detergent solu-
damage by holding the element up against a
tion. Rinse and dry it thoroughly.
light source. If any damage is evident the ele-
ment must be discarded and a new one fitted.
4) Clean the filter housing by blowing with low
pressure (max. 0·5 bar) compressed air.
3) Re-install the clean element in the filter body
and refit the cover.
5) Fit new element over retainer, fit the collar and
screw firmly by hand into the housing.
8.4.5 Water Strainer and Condensate Strainers
6) Hold the filter housing securely and screw the To Clean the Strainer:
filter bowl firmly by hand into the housing.
1) Isolate the cooling water supply.
8.4.4 Intake Air Filter
2) Isolate aftercooler condensate strainers from
The servicing intervals required by the intake air filter
air main and clear all pressure.
will depend on the dust conditions prevailing on site.
It is always better to renew the intake air filter ele- 3) Remove the filter gauze from the strainer.
ment rather than to try to clean it. In any cleaning op-
eration, however carefully done, there is a risk of 4) Clean the gauze and refit to the strainer.
critical damage to filter efficiency and dirt particles
remaining on the element or being carried over to 5) Restore the water supply.
the clean side.
8.4.6 Oil System
Whenever the intake air filter element is removed,
check the sealing surfaces for signs of dust tracking To Check the Oil level:
and rectify if necessary.
The compressor must be stopped
Before carrying out any work on the intake air filter
Note: Allow a minimum of 30 minutes after stopping
the compressor must be stopped.
for the oil in the system to settle.
To Change the Element:
1) Open the enclosure to gain access to the oil
1) Remove panels as required to gain access to filler and sightglass.
the intake air filter.
DL1640FA 61
2) Check the sightglass visually. The oil level is sooner or when indicated by the control system
should be on the ‘H’ or ’MAX’ mark. CHANGE OIL FILTER message
The compressor must be stopped.
Caution: Do not mix oils of different types – always
refill with the oil type in current use.
1) Unscrew and discard the old oil filter element.
3) If the oil level is low, remove the cap from the
2) Carefully clean out the filter housing.
oil filler pipe and gradually top up the reservoir
to the correct level with recommended or
3) Apply a thin film of clean oil to the element
approved oil of the type in use. After each
seal.
small quantity has been added allow time for
the change in level to be indicated on the
4) Screw in the new element by hand until seal
sightglass. This will prevent overfilling.
contact is made and then continue tightening
for a further quarter of a turn.
4) Refit the oil filler cap.
To Replace the Oil Breather Element:
5) Close the enclosure panel.
Note: The oil breather element should be
To Change the Oil: replaced after every 8000 operating hours or
every year, whichever is sooner.
The compressor must be stopped
Drain the oil while the compressor is hot to allow the 1) Disconnect the drain line (plastic tube) from
oil to run freely and carry out any suspended parti- the bottom of the breather housing and
cles. unscrew the housing.
1) Remove enclosure panels as required. 2) Unscrew and discard the old element.
2) Position suitable containers under reservoir 3) Apply a thin film of clean oil to the new ele-
drain connections. ment seal.
3) Open the reservoir drain valve and drain the 4) Screw in the new element by hand until the
reservoir. element body is securely tightened against the
breather head.
4) Replace the oil breather element (see ‘To
Replace the Oil Breather Element’). 5) Replace the breather housing and reconnect
the drain line.
5) Replace the oil filter element (see ‘To Change
the Oil Filter Element’). 6) After changing the oil removal filter it is recom-
mended that the powered breather system is
6) Close all drain valves and plugs. checked for correct operation. Please refer to
the section “Powered Breather System” in the
7) Fill reservoir with recommended oil to the ‘H’ Commissioning section of this manual.
or ‘ MAX’ mark.
8.4.7 Balance Piston Diaphragms
8) Start and run unit for 60 seconds to circulate
To Renew the Diaphragms:
oil, check for leaks, then press STOP button.
1) Remove the rear fill-in panel from the enclo-
9) Allow 30 minutes for oil to settle, check oil
sure.
level and top up as necessary.
2) Remove the regulation air pipe from the first
10) Refit enclosure panels.
stage diaphragm cover. Disconnect the regula-
tion air pipe from the second stage diaphragm
To Change the Oil Filter Element:
cover.
Note: The oil filter element should be renewed after
every 8000 operating hours or every year, whichever
62 DL1640FA
3) Remove the screws and washers securing the 1) Remove the enclosure side panel.
covers to the casing. Remove the covers.
Remove and discard the diaphragms. 2) Remove the screws, nuts and washers secur-
ing the compensator to the intercooler.
4) Ensure that all mating faces are clean.
3) Remove the four bolts securing the first stage
5) Position a new diaphragm on the first stage discharge pipe flange to the compensator.
casing. Locate the cover and secure with the
screws and washers. Carry out the same pro- 4) Remove the compensator from the intercooler.
cedure on the second stage casing. Withdraw the flanged pipe from the discharge
pipe. Remove and discard the ‘O’ ring.
6) Refit the regulation air pipe to the first stage
diaphragm cover. Re-connect the regulation 5) Ensure that the ‘O’ ring groove is clean and
air pipe to the second stage diaphragm cover. without sharp edges. Ensure that all pipes and
component parts are free from dirt and con-
7) Refit the enclosure panel. taminates. Fit a new ‘O’ ring into the groove.
Coat the exposed part of the ‘O’ ring with soft
8.4.8 Non-Return Check Valve (NRV) soap.
To Inspect the Valve:
6) Slide the flanged pipe into the discharge pipe.
Stop the compressor, isolate from air main and re- Renew the joints and refit the compensator to
lease all pressure the intercooler. Refit the screws, washers and
nuts.
1) Remove the enclosure side panel.
7) Renew the joint and fit the flanged pipe to the
Note: The valve is secured between the flanges by compensator. Fit the screws, nuts and wash-
pressure exerted by the securing screws and nuts. It ers and tighten in sequence using the correct
is not positively located. torque loading.
2) Slacken the lower screws and nuts securing 8) Refit the enclosure panel.
the valve between the discharge pipe flanges.
Remove the upper screws, washers and nuts.
Slacken the screws and nuts at the aftercooler
flange if necessary.
3) Remove the valve and renew any worn or

damaged parts. CAUTION: Do not lubricate.
4) Fit new joints to the valve and refit between

the flanges. Ensure that the valve is correctly
positioned, that the lifting eye is uppermost
and that the direction of flow arrow is pointing
in the correct direction.
5) Refit the screws, nuts and washers and tighten

in sequence using the correct torque loading.
6) Start and run the compressor until working

temperatures are reached. Stop and re-tighten
the flange bolts.
7) Refit the enclosure panel.
8.4.9 Expansion Compensator Seal

To Renew the Seal on LP delivery pipe:
DL1640FA 63
8.4.10 Electrical System In order to check the required for lubrication,

weigh the grease gun before and after lubrica-
Warning tion of the individual electric motor bearings.
8.4.12 Moisture Separator

The moisture separator operates by mechanical
separation and requires no maintenance.
checks. Isolate the power supply before starting If a fault develops in the condensate drain valve, re-
any maintenance work. fer to the local CompAir distributor.
8.4.13 Flexible Drive Coupling
To Check the Coupling Backlash:
To Check the Electrical Connections:
The compressor must be stopped and isolated from
Carefully examine the electrical wiring and check the both the electrical supply and air pipework.
security of all connections and terminals.
Reach through the access opening in the bellhous-
8.4.11 Electric Motors ing and hold the drive shaft on each side of the cou-
pling. Check the coupling backlash which should not
1) Maintenance and lubricant recommendations exceed 6 mm. If the backlash is excessive it will be
necessary to change the coupling inserts.
Note: The compressor unit can only operate to
your complete satisfaction when maintenance To Renew the Inserts:
work is carefully carried out at the specified It is recommended that this work is carried out by a
intervals. In order to help with this task, the CompAir distributor.
scope of supply of the compressor unit
includes a "Maintenance and Inspection
Manual for CompAir Compressors”, in which
you can keep a record of what maintenance
work was carried out at which specified
intervals. The operating hours quoted in this
manual are recommended maintenance
intervals for average operating conditions.
Depending on your local intake conditions, the
operating hours may differ. You can also have
this maintenance work carried out by our
trained technicians. Please ask your technical
adviser for a maintenance contract.
2) Maintenance electric motor
The maintenance of the electric motor is to be

performed in line with the motor operating
instructions.
3) Lubrication of electric motors
The two bearings of the electric motor must be

lubricated at specified intervals, which are
determined by the type of motor. The lubricat-
ing points, intervals and quantities, specific to
each motor, can be found on the motor's
nameplate.
Note: In the case of 60 Hz drive, strictly

observe the information on the nameplate !
64 DL1640FA
CompAir Fault Finding 9
9 Fault Finding Warning

The controller has a memory facility that retains a
fault history. Details of 15 previous situations can be
displayed, including the fault message together with
recorded hours, compressor state (standby, on- • Refer to the safety procedures before carrying
load, off-load etc.), plant temperatures and pres- out any fault finding investigation.
sures. • Lethal voltages are used in this equipment. Use
In operation the compressor is protected by circuits extreme caution when carrying out electrical
which are triggered when a fault arises and either checks. Isolate the power supply before starting
cause the compressor to shut down or indicate that any maintenance work.
a servicing action is required.
Note: Please check for speed adjusted
compressors please in the operating
instructions "Touchpanel Pro-face".
9.1 Shutdown Messages

Message Displayed Possible Cause Action required
Emergency stop (1) Emergency Stop switch operated. (1) Check cause of fault and rectify. Turn
Emergency Stop switch to release latch.
Press RESET.
(2) Starter circuit fuse F1 blown. (2) Check cause and rectify.
Main motor fault (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure filter; ducting;
motor cooling air intake.
(3) Fan operation/rotation incorrect. (3) Check and rectify electrical circuit.
(4) Low voltage/high current. (4) Check power supply.
(5) Thermal overload F101 incorrectly set. (5) Check setting and reset.
Fan motor fault (1) High ambient temperature. (1) Check room ventilation.
(4) Circuit breaker F102 incorrectly set. (4) Check setting and reset.
Oil pump fault (1) High ambient temperature. (1) Check room ventilation.
(4) Circuit breaker F103 incorrectly set. (4) Check setting and reset.
MPCB Q102 tripped (1) Circuit breaker incorrectly set. (1) Check setting and reset.
(2) Oil pump/fan motor circuit fault. (2) Check cause and rectify.
Oil temperature trip (1) High ambient temperature. (1) Check room ventilation.
(2) Insufficient cooling water flow. (2) Check water supply. Check adjustment of
(3) Temperature sensor fault. water valve. Inspect/clean water strainer.
(4) Sensor wiring fault. Inspect/clean oil cooler.
(3) Rectify/renew.
(4) Check wiring.
DL1640FA 65
9 Fault Finding CompAir
St1 delivery temp trip (1) High ambient temperature. (1) Check room ventilation.
water valve. Inspect/clean water strainer.
(3) Temperature sensor fault. (3) Rectify/renew.
(4) High interstage pressure. (4) Inspect/clean air coolers.
St2 intake temp trip (1) Insufficient cooling water flow. (1) Check water supply. Check adjustment of
(2) High ambient temperature. (2) Check room ventilation.
St2 delivery temp trip (1) Insufficient cooling water flow. (1) Check water supply. Check adjustment of
(2) Air flow restriction. (2) Inspect/clean aftercooler.
Plant delivery t trip (1) Insufficient cooling water flow. (1) Check water supply. Check adjustment of
Inspect/clean intercooler.
Interstage press trip (1) Air flow restriction. (1) Inspect/clean air coolers.
Oil pressure low (1) Low oil level. (1) Investigate for leaks, top up oil level.
(2) Oil pump fault. (2) Investigate and rectify.
(3) Relief valve adjustment/failure. (3) Adjust/Renew valve.
(4) Pressure transmitter fault (4) Renew pressure transmitter
(5) Oil cooler restriction. (5) Clean cooler.
(6) Oil filter blocked. (6) Renew oil filter element.
High air pressure (1) Compressor is failing to unload. (1) (a) Check/renew solenoid operated
unloader valve.
(b) Check suction regulator inlet valve
closing fully. Rectify if necessary.
(2) Pressure transmitter fault. (2) Check/renew pressure transmitter.
Del press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
(2) Transmitter wiring fault. (2) Check and rectify fault.
Int.St press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
St1 del temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Sensor wiring fault. (2) Check and rectify fault.
St2 in temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.
St2 del temp probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
Plant del t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault. (2) Check and rectify.
Oil press probe fault (1) Pressure transmitter fault. (1) Renew pressure transmitter.
Remote fault (1) Remote fault loop open circuit. (1) Find cause and rectify.
66 DL1640FA
CompAir Fault Finding 9
Extension module fault (1) Fuse F2 failed. (1) Check cause and rectify.
(2) Interface cable insecure. (2) Check interface cable.
(3) Extension module failure. (3) Renew Extension module.
Rotation fault (1) Supply wiring configuration incorrect, (1) Check supply wiring connections U, V
motor rotation will be incorrect. and W.
(2) Supply voltage low. (2) Check supply voltage.
Water in temp trip (1) User cooling water system fault. (1) Find cause and rectify.
Water out temp trip (1) Water flow restriction. (1) Check/clean coolers.
(2) Low water flow. (2) Check cooling water flow rate.
Oil level low (1) Low oil level. (1) Check for oil leaks and rectify. Top up
(start inhibit) reclaimer to correct level.
(2) Oil level switch fault. (2) Find cause and rectify.
(3) Switch wiring fault. (3) Check and rectify.
9.2 Warning Messages

Service due (1) Service countdown time expired. (1) Service compressor then reset timer.
Change air filter (1) Intake air filter blocked. (1) Check/renew element.
(2) Filter pressure switch fault. (2) Check operation. Renew if necessary.
(3) Filter pressure switch wiring fault. (3) Check and rectify.
Change oil filter (1) Oil filter element blocked. (1) Renew oil filter.
(2) Differential pressure switch fault. (2) Check operation. Renew if necessary.
(3) Filter pressure switch wiring fault. (3) Check and rectify.
Oil level low (1) Low oil level. (1) Check for oil leaks and rectify. Top up
sump to correct level.
(2) Oil level switch fault. (2) Find cause and rectify.
(3) Switch wiring fault. (3) Check and rectify.
Oil temperature alarm (1) High ambient temperature. (1) Check room ventilation.
Inspect/clean oil cooler.
(4) Sensor wiring fault. (4) Check wiring.
St1 delivery temp alarm (1) High ambient temperature. (1) Check room ventilation.
(3) High interstage pressure. water valve. Inspect/clean water strainer.
(3) Inspect/Clean air coolers.
St2 intake temp alarm (1) Insufficient cooling water flow. (1) Check water supply. Check adjustment of
Inspect/clean intercooler.
(2) High ambient temperature. (2) Check room ventilation.
St2 delivery temp alarm (1) Insufficient cooling water flow. (1) Check water supply. Check adjustment of
(2) Air flow restriction. (2) Inspect/Clean aftercooler.
DL1640FA 67
9 Fault Finding CompAir
Plant delivery t alarm (1) Insufficient cooling water flow. (1) Check water supply. Check adjustment of
Inspect/clean aftercooler.
Water in temp alarm (1) Supply water temperature high. (1) Check supply water temperature.
(2) Low water flow. (2) Check water flow.
Water out temp alarm (1) Supply water temperature high. (1) Check supply water temperature.
(2) Low water flow. (2) Check water flow. Inspect/clean air
coolers.
Interstage press alarm (1) Air flow restriction. (1) Inspect/clean air coolers.
Water in t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
Water out t probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
Remote Alarm (1) Remote alarm loop open circuit. (1) Find cause and rectify.
Start inhibit (1) Remote start inhibit loop open circuit. (1) Find cause and rectify.
68 DL1640FA
CompAir Appendix 1 - Control Remote Options 10
10 Appendix 1 - Control 10.1.2 Input Designations

1) Input Terminal X01
Remote Options Pin No. Function
Warning X01-1 Common (20V dc) for X01 inputs
X01-2 Comms Control Enable
X01-3 Auto Restart Enable
X01-4 Remote Load Enable
• Refer to the safety procedures before carrying X01-5 Remote Load/Unload
out any of the following operations. X01-6 Remote Start Enable
X01-7 Remote Start
• Lethal voltages are used in this equipment. Use X01-8 Remote Stop
X01-9 No Standard Function
checks. Isolate the power supply before starting
any maintenance work. 2) Input Terminal X02
Pin No. Function
X02-1 Common (20V dc) for X02 inputs
Note: We recommend that the following procedures X02-5 Remote Fault Input 1
are carried out by a CompAir distributor. X02-6 Remote Fault Input 2
X02-7 Remote Fault Input 3
10.1 Inputs X02-8 Remote Fault Input 4
X02-9 Remote Fault Input 5
10.1.1 Description
Caution: Do not connect any extension module in-
put terminal pin to a voltage source as this will result
in permanent damage to the module.
Two sets of eight inputs are available on extension
module terminal connections X01 and X02. Each in-
put is designated a particular function which may be
used as required. Each function is activated by con-
necting the appropriate terminal pin to the input ter-
minal common connection X5/1 or X5/2. This can be
achieved by connecting the input pin and the com-
mon terminal to a remote switch, relay contact, PLC
output or any switching device.
Note 1: Remote input cables must be at least 1.0
mm2 in size. The maximum cable length from the
compressor to a remote device must not exceed 800
meters.
Note 2: To activate an input function, only connect
an input terminal pin to the common terminal con-
nection X5/1 for X01 inputs or X5/2 for X02 inputs.
DL1640FA 69
10 Appendix 1 - Control Remote Options CompAir
X01
1 2 3 4 5 6 7 8 9
REMOTE LOAD
COMMS CONTROL ENABLE
START
STOP
500
REMOTE START ENABLE

AUTO RESTART ENABLE
REMOTE LOAD ENABLE

20V D.C. COMMON
X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1
PRESSURE SWITCH
OR CASCADE
PANEL CONNECTION
HW 0446
REMOTE INPUT CONNECTION
10.1.3 Input Functions d) When connected, a master can read status, fault,
service, pressure and temperature data from any
1) Input X01-2
controller in the network.
RS485 Communications Control Enable
e) If the ‘Comms control enable’ input X01-1 and ‘Re-
a) The SureScan controller is equipped with an RS485
mote start enable’ input X01-5 are activated, the
communications facility on terminal X06. The facility
compressor Remote control indicator will light and
is activated when this input is connected to the com-
the compressor will respond to RS485 Start, Stop
mon terminal X5/1.
and Reset commands.
Note: The RS 485 terminal X03 on the extension
Note: The control panel Start button and the Remote
module has no standard function.
start function will be inhibited. The control panel stop
b) The communications link can either be connected button and remote stop function remain active.
point-to-point or networked with up to 31 compres-
f) If the ‘Comms control enable’ and the ‘Remote pres-
sors and one master.
sure control enable’ input X01-3 is activated, the
c) The controller network communications protocol is compressor will respond to RS485 load and unload
a single master system. Communication is always comands.
between network master and controller. Only one
g) Contact your local CompAir distributor for details.
communication protocol is used. Point-to-point links
are considered to be networks with only two nodes,
master and controller. Each compressor controller
on a network can be assigned a unique identifica-
tion number from 1 to 99, the master always being
node 0.
70 DL1640FA
2) Input X01-3 Auto Re-start Enable 3) Input X01-4 Remote Load Enable
a) Automatic re-start will allow the compressor to start a) Remote control of loading and unloading allows the
automatically after a break or failure in the mains pressure control routines of the SureScan controller
power supply. When this facility is enabled the AU- to be overridden in multiple compressor/cascade
TOMATIC RE-START indicator will be lit. control installations. The facility allows control by
any of the I.C.C. range of multi compressor control-
b) An automatic re-start will not be initiated if the com-
lers available from CompAir.
pressor was stopped when the power failure oc-
curred. b) When the remote load enable input is activated the
compressor will load and unload in response to the
c) When power is restored the following message is
remote load/unload input X01-5.
displayed and the Auto Re-start enable indicator will
flash. 4) Input X01-5 Remote Load/Unload
Auto restarting a) If input X01-5 is activated, via a remote pressure
switch, relay, programmable logic controller (P.L.C.)
—————* *
output etc, the compressor will load. When the input
The time before the compressor automatically re- is de-activated the compressor will unload.
starts, the auto re-start delay time, is indicated by
b) The compressor will shutdown and the display will
dashes on the lower display line. This time can be
show a High air pressure trip if the Max overpress
adjusted using the auto re-start delay time setting of
setting of the Commissioning -values menu is ex-
the ‘Commissioning - values’ sub-menu of the
ceeded while using this facility. The compressor
SureScan menu routines.
‘Max overpress’ setting must be set above the work-
d) In multiple compressor installations staggered re- ing pressure of the remote pressure control system.
starting can be achieved by adjusting the delay time Where the remote pressure control system is detect-
of each compressor ing air system pressure downstream of dryers, filters
or long lengths of pipework, an allowance for any
Example four compressor installation:-
pressure differential should be taken into account.
Comp Auto re-start Delay Time
5) Input X01-6 Remote Start Enable
1 10 seconds
2 70 seconds a) The compressor can be connected to accept a re-
3 150 seconds mote start signal. When this input is activated the
4 210 seconds REMOTE CONTROL indicator will be lit and the
SureScan panel START button is disabled.
b) The SureScan panel stop button and the remote
stop input are always active, regardless of remote
start enable being activated.
DL1640FA 71
6) Input X01-7 Remote Start Note: This facility is inhibited if the RS485 communi-
cations control input is activated.
a) When the remote start enable and remote stop in-
puts are activated the compressor will start when the c) Remote Timer Control
remote start input is activated. This input reqires a
The remote start/stop facility can also be used to
sngle pulse of at least 0·5 seconds to activate it. The
achieve automatic seven day timer control. Any
pulse length can be between 0·5 seconds and con-
commercially available timer with a single switching
tinuous.
contact can be used for this purpose. Alternatively a
b) When the remote start input is continuously activat- timer with a 24v ac power supply can be mounted
ed the SureScan panel stop button or the remote within the starter area A 24vac power supply for this
stop input will override the remote start signal and purpose is available on compressors terminals X2/1
the compressor will stop. When the compressor is and X2/2. The timer unit should be battery backed.
stopped, the remote start signal must be de-activat-
ed before the compressor can be re-started.
EXTENSION MODULE
7 DAY TIMER
X01
1 2 3 4 5 6 7 8 9
REMOTE START ENABLE
X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 X5/1 CLOSED - START
OPEN - STOP
PI/97/136
TIMER CONTROL
72 DL1640FA
7) Input X01-8 Remote Stop 9) Inputs X02-5 to 9 - Remote Faults 1 to 5

a) The remote stop input is always active, regardless of There are five remote fault input functions available
remote start enable being activated. that can be individually programmed to function as
remote alarm, remote trip or start inhibit inputs. A re-
b) The remote stop input must be active to enable the
mote fault input can be connected to a remote
compressor to be started. The compressor will stop
switch, relay contact, programmable logic controller
when the remote stop input is de-activated.
(PLC) output or any switching contact device. Each
c) A remote stop signal will override a remote start sig- input function will operate when the connection be-
nal. When the remote stop input is de-activated the tween the appropriate input terminal, X02-5 to X02-
display will show: 9, and the common terminal X5/2 is broken.
Remote stopped When a remote fault input is de-activated the appro-
priate remote fault number will be displayed by the
SureScan controller and the fault will be stored in the
d) The STOP button on the SureScan panel is not af- fault history. The remote fault can be reset normally
fected and will remain active at all times. using the RESET button.
e) If this facility is not used the input must be continu- a) Remote Fault Input Configuration
ously activated by connecting a wire from the input
Each remote fault input can be pre-programmed us-
pin to terminal connection X5/1, to enable the com-
ing the SureScan controller menu routines to func-
pressor to be started and run. This connection is pro-
tion as a remote alarm, remote shutdown trip or start
vided by wire LK1 in the standard wiring
inhibit when the fault input is de-activated. Remote
8) Inputs X01-9 and X02-2 to 4 alarm and shutdown trip functions can also be pre-
programmed to operate only under pre-determined
Caution: These inputs are used by the controller to
conditions to suit a particular application depending
monitor the operation of the compressor and must
on the remote fault input type selected.
not be used for any other function.
Note: When a remote fault input is configured to any
option other than ‘Disabled’ the input must, under
normal circumstances, be continuously activated to
enable the compressor to operate without indicating
a remote alarm, trip or start inhibit condition.
DL1640FA 73
b) Remote Fault Input Configuration Options
Option Function Description
Disabled Input not active.

Trip type 1 Trip - active at all times.
Trip type 2 Trip - active when the main motor is running.
Trip type 3 Trip - active only when status is ‘Onload’ or ‘Offload’.
Alarm type 1 Alarm - active at all times.
Alarm type 2 Alarm - active when the main motor is running.
Alarm type 3 Alarm - active only when status is ‘Onload’ or ‘Offload’.
Start inhibit Will prevent a compressor from starting but will not stop a compressor if already
started. When activated the display will show ‘Start inhibited’. This function is
not a shutdown trip or alarm and will only function while the input is de-activated.
c) Configuring the SureScan Controller Remote Fault Inputs

All remote fault inputs will be ‘Disabled’ when the compressor is first commissioned. To enable a remote fault input, and
select a required fault input function from the Configuration Options table , use the SureScan menu routines procedure
as described below:-

2. Press UP or DOWN repeatedly To scroll through the menu options. Main menu
until the message shown on the Commissioning - config
right is displayed.
3. Press ENTER. To select the Commissioning - Commissioning - config

config sub menu. Language English
4. Press UP or DOWN repeatedly To scroll through the sub menu Commissioning - config
until the message shown on the options. Fault input config
right is displayed.
5. Press ENTER. To select the fault input config sub Fault input config
menu. Remote fault 1
6. Press UP or DOWN repeatedly to To scroll through the fault inputs Fault input config
select fault input. available. Remote fault 2
7. Press ENTER. To select the fault input to Remote fault 2

configure. Disabled
8. Press PLUS or MINUS. To select the required fault input Remote fault 2
function. Trip type 2
(pulsing display)
9. Press ENTER. To enter the selected fault input Remote fault 2

configuration option. Trip type 2
The display will automatically return to the fault input selection menu.
74 DL1640FA
10. Repeat steps 6 to 9 for

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

are configured press RESET to exit Oil temperature 20°C
the menu routine.
DL1640FA 75
10.2 Outputs c) Relay Specification
10.2.1 Description • Single switching contact with a common, nor-

mally open (N/O) and normally closed (N/C)
a) Two sets of six outputs are available on extension connection rated at 250V - 5 Amps maxi-
module terminal connections X05 and X06. Each mum.
output is designated a particular function which may
be used if required. Outputs which are not used Note: The relay 24V dc coil is not bi-directional and
should be left unconnected. must be connected to an extension module output
as follows :-
10.2.2 Output Relay
• Relay terminal ‘5’ must be connected to pin
a) Extension module outputs are 24V dc transistor ‘1’ of the appropriate output terminal.
switched with a maximum rating of 25mA. Each out-
put must be connected directly to a relay module, as • Relay terminal ‘1’ must be connected to the
specified below, in order to achieve a relay contact pin of the output terminal appropriate for the
output suitable for remote applications external to required output function.
the compressor starter enclosure. Six relays, K401 The relay base can be screw mounted or secured to
to K406 are supplied as standard for this purpose. a standard type DIN rail (available from CompAir).
b) Parts required for each additional output:-
Qty Description Part Number
1 Relay - 24 V dc 98475-64
1 Relay Base 98475-65
X4/1 X4/1 X4/1 X4/1 X4/1 X4/1 X4/1

COMMON 24V D.C.
5
K406
K405
K404
K403
K402
K401
3
+ 2
5 5 5 5 5 5
24V d.c.
- 4
1 1 1 1 1 1 1
406
405
404
403
402
401
400
7 6 5 4 3 2 1
X05
HW 0447
REMOTE OUTPUT CONNECTION
76 DL1640FA
10.2.3 Output Designations The running output will energise when the compres-
sor main motor is running.
a) Output Terminal X05
The contacts of relay K403 must be used for remote
Pin No. Function connections to this facility.
X05-1 Common (20V dc) for X05 outputs d) Output X05-5 On Load
X05-2 Available The on load output will energise when the compres-
sor is on load.
X05-3 Group Fault
X05-4 Running connections to this facility.
e) Output X05-6 Group Trip
X05-5 On Load
The group trip output will de-energise when a shut-
X05-6 Group Trip down trip or power loss occurs.
X05-7 Service Due The output will be energised when power is applied
and no trip conditions are detected.
b) Output Terminal X06
Pin No. Function connections to this facility.
f) Output X05-7 Service Due
X06-1 Common (20V dc) for X06 outputs
The service due output will energise when the serv-
X06-2 Remote Fault 1 Repeat ice hours countdown timer has reached zero hours
and a routine service is due.
X06-3 Remote Fault 2 Repeat
X06-4 Remote Fault 3 Repeat connections to this facility.
X06-5 Remote Fault 4 Repeat g) Outputs X06-2 to 6
X06-6 Remote Fault 5 Repeat Remote fault repeat outputs 1 to 5 will be normally
energised and will de-energise if a fault condition on
X06-7 No Standard Function the appropriate remote fault input, 1 to 5, is detected
or a power loss occurs. The output will remain de-
10.2.4 Output Functions energised until the SureScan controller is reset. See
remote fault inputs.
a) Output X05-2 Available
If start inhibit is selected, the output will de-energise
The compressor available output will energise when
when the input is de-activated and automatically re-
the compressor is ‘running’ or in the ‘standby’ state.
set when the input is re-activated.
This output indicates that the compressor has been
started and is available to automatically respond to Note: An additional relay module, as specified in
a fall in system pressure without manual interven- para 2.2, must be added if these outputs are used.
tion.
connections to this facility.
b) Output X05-3 Group Fault
The group fault output will de-energise when an
alarm, shutdown trip or power loss occurs. The out-
put will be energised when power is applied and no
alarm or trip conditions are detected.
connections to this facility.
c) Output X05-4 Running
DL1640FA 77
78 DL1640FA
CompAir Appendix 2 – Sample Log Sheets 11
11 Appendix 2 – Sample Log

Sheets
11.1 Introduction
11.1.1 The following sample log sheets are issued as a
guide to the user and can be used along with the
Ownership Data sheet to form a compressor log
book.
11.1.2 If these sample log sheets are used, they MUST be
used in conjunction with the User Manual, not as a
replacement.
DL1640FA 79
11 Appendix 2 – Sample Log Sheets CompAir
11.2 Values At Commissioning

Note: All readings to be taken from SureScan.
Item Value Unit Inspection Date
Max. pressure bar
Max. overpressure bar
Star/delta time sec.
Load delay time sec.
Max. service hours hrs
Auto re-start delay sec.
Interstage trip bar
Interstage alarm bar
Oil temp. trip °C
Oil temp. alarm °C
St. 1 delivery trip °C
St. 1 delivery alarm °C
St. 2 intake trip °C
St. 2 intake alarm °C
St. 2 delivery trip °C
St. 2 delivery alarm °C
Plant del trip °C
Plant del alarm °C
Water in trip °C
Water in alarm °C
Water out trip °C
Water out alarm °C
Oil pressure bar
Interstage pressure bar
80 DL1640FA
11.3 Commissioning Configurations

Item Setting Inspection Date
Language
Unit of Pressure
Unit of Temperature
Compressor Number
Comms Baud Rate
Fault Input Config.
Return to Previous Menu
11.4 Operational Settings

Item Setting Inspection Date
P1 Set Point
P2 Set Point
Run On Time
Drain Open Time
Drain Shut Time
11.5 Weekly Checks

Item Week 1 Week 2 Week 3 Week 4
Date
Running Hours Total
Hours On Load
Enclosure Filters
Intercooler Condensate Drain
Aftercooler Condensate Drain
Reg. Air Line Filter
Status Display
DL1640FA 81
11.6 Performance Log

11.6.1 This log is provided to enable the user to keep a written record of compressor performance and as an aid to fault diag-
nostics. It is recommended that the readings are recorded regularly, as part of the weekly service, with the compressor
in normal operating condition.
Item Value Unit Inspection Date
Delivery pressure bar
Interstage pressure bar
Total hours hrs
Hours on load hrs
Service hours to run hrs
Oil temp °C
St 1 delivery temp. °C
St 2 intake temp. °C
St 2 delivery temp. °C
Plant del temp. °C
Water in temp. °C
Water out temp. °C
Oil pressure bar
11.7 4000 hr Service (Service A)

Item Value/Completed
Date
Total Hours
Hours On Load
Water Strainer
Hoses and Pipework
Flange Bolts/Screws Torque
82 DL1640FA
11.8 8000 hr Service (Service B)

A 4000 hr (Service A) plus the following:
Date
Total Hours
Off Load Hours
Oil Breather Filter
Oil Change
Oil Filter Element
Intake Air Filter Element
Balance Piston Diaphragms
Reg. Air Line Filter Element
Intercooler Tubestack
Aftercooler Tubestack
Oil Cooler
Drive Motor Connections
Starter Connections
2nd Stage non-return Valve
Cooling Water Quality
11.9 16000 hr Service (Service C)

An 8000 hr (Service B) plus the following:
Date
Total Hours
Hours On Load
Suction Reg. Valve Diaphragm
Drive Coupling Inserts
Starter Contacts
DL1640FA 83
11.10 Compressor History Log Sheet

It is recommended that a written log be kept of the compressor fault history.
Model Memory Log Number
Serial 1 2 3 4 5 6 7 8 9 10 11
Date
By
Fault Message
Status Message
Total Hours
Discharge P bar
Interstage P bar
Oil Temp °C
LP Dely Temp °C
HP Inlet Temp °C
HP Dely Temp °C
Plant Dely Temp °C
Water In Temp °C
Water Out Temp °C
Oil Pressure bar
84 DL1640FA
12 13 14 15 16 17 18 19 20 21 22 23 24 25
DL1640FA 85
12 Appendix 3 – Cooling Water Quality CompAir
12 Appendix 3 – Cooling Water Quality

12.1 Introduction
12.1.1 To ensure that the cooling water system does not foul prematurely, it is recommend that cooling water is provided from
a closed circuit radiator system and that the water quality meets the Quality (A) requirements below. If cooling water is
to be provided from another source, the cooling water should be checked periodically to ensure that it meets the Quality
(A) requirements.
Item Quality (A)* Quality (B)*
pH at 25°C 6.5 to 8.0 6.5 to 8.0
Conductivity at 2
Less than 800 Less than 200
(Micro-Siemens / cm)
Total hardness as CaCO3

(ppm)
M-Alkalinity as CaCO3
(ppm)
Chlorine ion; Cl - (ppm) Less than 200 Less than 50
Sulphuric acid ion; SO42- (ppm) Less than 200 Less than 50
Total iron; Fe (ppm) Less than 1.0 Less than 0.3
Silica; SiO2 (ppm) Less than 50 Less than 30
Sulphur ion; S2- (ppm) 0 0
Ammonium ion; NH4+ (ppm) 0 0
Particulates Less than 160 microns Less than 160 microns
* Where Quality (A) refers to the circulating water and Quality (B) refers to the replenishment water.
Inspect the circulating water regularly to confirm that it meets Quality (A) as the quality will gradually deteriorate.
86 DL1640FA
CompAir Appendix 4 – The Pressure Systems And Gas Regulations 2000 No. 128 13
13 Appendix 4 – The Pressure Systems And Gas Regulations

2000 No. 128
13.1 Introduction pressure relief valves etc., will be defined by the
‘competent person’ preparing the written scheme.
13.1.1 The circuit diagram shown below is provided to
assist a ‘competent person’ in preparing a written 13.1.2 In defining these periods the ‘competent person’
scheme of examination for a system incorporating must take into account the recommendations of the
the air compressor(s). component part manufacturer, the Health and Safe-
ty Executive (H & SE) and the British Compressed
Note: The intervals between examination and Air Society (BCAS).
calibration of components, e.g. pressure vessels,
12 13 14
1 2
15 16
4
5
17 6
18
3
+ -
11
19
21
M + -
20
10
7 8 9
16
15
HW 0478
}
1. Intake Air Filter
2. Suction Regulator 12. Unloader Solenoid Valve
3. First Stage Air-end 13. Regulation Air Line Filter
4. Intercooler 1st Stage 14. Shuttle Valve
}
5. Pressure Relief Valve 15. Strainer (2)
6. Pressure Transmitter 16. Condensate Drain Valve (2)
7. Second Stage Air-end 17. Air Filter Switch
8. Non-return Valve 2nd Stage 18. Temperature Sensor
9. Aftercooler 19. Temperature Sensor
10. Pressure Relief Valve 20. Temperature Sensor
11. Pressure Transmitter 21. Temperature Sensor
Air Compressor Circuit Diagram
DL1640FA 87
13 Appendix 4 – The Pressure Systems And Gas Regulations 2000 No. 128 CompAir
88 DL1640FA
Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland
Tel. ++49 (0)6761 832-0

Fax ++49 (0)6761 832-409
www.compair.com
e-mail: sales@compair.com
Page: 3 Of: 305
Rev.: 3

COMPRESSORS D37 H
10QFB15AN001 &10QFB20AN001

Original Operating and Service Manual
Screw Air Compressor

D37H
D37H RS
●
GB Id. no. ZS1091706 / 00 - April 2012
General Information
These compressors are for compressing atmospheric air and are not suitable for compressing any other gas. They are
designed and manufactured to give optimum performance with long life and reliability.
This manual gives the user all the information required to install and operate the compressors and carry out the regular
schedules for servicing and maintenance, which will ensure the maximum satisfactory service life.
Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of CompAir
Companies and Distributors. If replacement parts are needed, the user should, in the first instance, contact the local
CompAir Company or Distributor.
The information given in this manual was correct at the time of printing, however, as part of continuous development,
modifications to parts and procedures may be made without notice which could affect the servicing requirements of the
compressors. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir
Company or Distributor who is supplied with revised and up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL NUMBER and where
possible the YEAR of MANUFACTURE.
All pressure data given in this manual refer to overpressures (pressure gauge pressures) unless specified otherwise.
Maintenance
To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenance and
servicing is carried out in accordance with the information given in the ‘Maintenance’ section of this manual. To assist in
this matter your local CompAir Company or Distributor can provide a number of optional maintenance agreements to suit
your requirements. These agreements provide the user with the expertise of our factory trained technicians and the
guarantee that only Genuine CompAir parts will be used.
Warranty
The conditions of the CompAir Warranty are set out in the Company’s standard Conditions of Sale available from the
Gardner Denver Company or Distributor supplying the machine.
USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY

COULD BE AFFECTED IF A SERVICE OR REPAIR IS
CARRIED OUT USING NON-GENUINE PARTS.
Deutsche Basis BA - ZS1091703 / 00 1

Data sheet for users
Fig. 1
Your CompAir distributor

Name:
Address: _____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Telephone: Fax:
Contact: Spare Parts:
Service:
2
1. Foreword
1 Fore word
1.1 Notes on the compressor 1.3 Maintenance

CompAir screw compressors are the result of many Carefully performed maintenance is imperative, this
years of research and development. These ensures that your screw compressor can meet all the
prerequisites combined with high quality standards requirements placed upon it. It is therefore imperative to
guarantee the manufacture of screw compressors adhere to the specified maintenance intervals and to
providing a long service life, high reliability and cost- carry out the maintenance work with particular care,
effective operation. It stands to reason that all especially when the unit is utilized under harsh
requirements concerning environmental protection are operating conditions.
met.
Servicing
Please contact your authorized CompAir dealer in the
1.2 Intended use case of malfunctions or when spare parts are required.
The machine/unit has been constructed in accordance In the case of damage, our fully trained personnel will
with state-of-the-art technology and the recognized ensure that a quick and proper repair is carried out
safety regulations. Nevertheless, its use may constitute using genuine CompAir spare parts. Genuine CompAir
a risk to life and limb of the user or third persons or spare parts are manufactured utilizing state-of-the-art
cause damage to the machine or to other material technology, thus guaranteeing the further reliable
property, if operation of the unit.
• it is not used as intended,

• it is operated by unqualified personnel, In case of queries
• it is improperly modified or changed, Please enter the data on the nameplate of your
• the safety regulations are not observed. compressor into the nameplate shown in fig.1 on p. 2.
Therefore, any person entrusted with the operation, In the case of queries or spare parts orders, please
maintenance or repair of the machine must read and refer to the compressor type indicated on the
follow the safety regulations. If required, this has to be nameplate, the identification no. and the year of
acknowledged by signature. construction. With this information at hand it can be
guaranteed that you will receive the right information or
In addition, required spare parts.
• relevant accident prevention regulations,
• generally recognized safety regulations and
• national regulations 1.4 Notes
have to be observed. General
The machine/unit must only be used in technically These operating instructions are intended to familiarize
perfect condition and in accordance with its intended the user with the machine/unit and its intended use. The
use and the instructions set out in the operating instructions contain important notes on how to operate
manual, and only by safety-conscious persons who are the compressor safely, properly and cost-effectively.
fully aware of the risks involved in operating the Observing these instructions helps to avoid risks, to
machine/unit! Any functional defects, especially those reduce repair costs and downtimes and to increase the
affecting safety, have to be rectified immediately (or reliability and service life of the machine/unit.
rectified by others)!
The operating instructions have to be supplemented by
The machine/unit is designed exclusively for the the respective national rules and regulations regarding
generation of compressed air to power air-driven the prevention of accidents and environmental
devices. Using the machine/unit for purposes other than protection. They must always be available at the
those mentioned above is considered contrary to its location of the machine/unit. The operating instructions
intended use. The manufacturer/supplier cannot be held must be read and followed by any person carrying out
responsible for damage resulting from such use. The work in connection with the machine/unit, e.g.
risk of such misuse lies solely with the user. operation, including setting up, trouble-shooting in the
Operating the machine within the limits of its intended operation cycles, disposal of production waste, care,
use also involves observing the instructions set out in service, and disposal of waste fuels and consumables,
the operating manual and complying with the inspection upkeep (maintenance, inspection, repair), transport.
and maintenance directives.
3
1. Foreword
Besides the operating instructions and the binding

regulations for the prevention of accidents, which are
valid in the country and place of operation of the
machine/unit, the generally recognized technical
regulations for safe and proper working have also to be
observed.
Guarantee
Operate this compressor only if you have an exact

knowledge of the machine taking into respect these
instructions.
Gardner Denver cannot be held responsible for the safe

operation of the machine/unit if it is used in a manner
which does not correspond to the intended use, or for
other applications which are not mentioned in these
instructions.
Warranty claims will not be accepted in the case of
• Operating errors
• Incorrect maintenance
• Wrong auxiliary materials
• Use of spare parts other than CompAir genuine
spare parts
• Modifications and changes to the installation
The warranty and liability conditions of the general

terms and conditions of Gardner Denver will not be
extended by the notes above.
Any unauthorized change to the compressor unit/

station, or the installation of components not accepted
by the manufacturer (e.g. air filter) will result in the
withdrawal of the CE mark. As a consequence, any
liability and warranty claims will not be accepted by the
manufacturer.
Safety regulations
Danger
The safety regulations in chapter 3 of the operating

instructions have to be strictly observed.
Technical changes
In the course of technical development we reserve the
right to modify the units without further notice.
4
2. Table of contents
2 Table of conte nts
1 Foreword ...............................................................................................................................................................................3
1.1 Notes on the compressor .............................................................................................................................................3
1.2 Intended use..................................................................................................................................................................3
1.3 Maintenance..................................................................................................................................................................3
1.4 Notes .............................................................................................................................................................................3
2 Table of contents .................................................................................................................................................................5
3 Safety regulations ...............................................................................................................................................................7
3.1 Identification of safety guidelines .................................................................................................................................7
3.2 General safety regulations ...........................................................................................................................................7
3.3 Particular dangers associated with compressed air ...................................................................................................8
3.4 Particular dangers associated with machines ...........................................................................................................10
3.5 Particular dangers associated with water-cooled units.............................................................................................10
3.6 Dangers present when loading/moving machines ....................................................................................................11
3.7 General workplace dangers .......................................................................................................................................11
3.8 Dangers resulting from neglecting to perform maintenance.....................................................................................12
3.9 Dangers during maintenance and repairs .................................................................................................................12
3.10 Dangers resulting from conversion work/modifications on the machine..................................................................14
3.11 Symbols and explanations .........................................................................................................................................15
4 Design and functioning ....................................................................................................................................................17
4.1 Design of the unit ........................................................................................................................................................17
4.1.1 Design of the unit D37H RS-A........................................................................................................................17
4.1.2 Design of the unit D37H RS-W.......................................................................................................................18
4.1.3 Design of the unit D37H..................................................................................................................................19
4.2 Schematic diagram .....................................................................................................................................................20
4.2.1 Schematic diagram - air-cooled and water-cooled D37H RS .......................................................................20
4.2.2 Schematic diagram - air-cooled and water-cooled D37H .............................................................................21
4.3 Water circuit ................................................................................................................................................................22
4.4 Air circulation...............................................................................................................................................................22
4.5 Control .........................................................................................................................................................................22
4.5.1 Control D37H RS (Fig. 5)................................................................................................................................22
4.5.2 Control D37H (Fig. 6)......................................................................................................................................23
5 Transport and installation ................................................................................................................................................24
5.1 Transport .....................................................................................................................................................................24
5.2 Installation ...................................................................................................................................................................25
6 Preparations for commissioning ....................................................................................................................................26
6.1 Cooling air volume/minimum cross ............................................................................................................................26
6.2 Compressed air connection........................................................................................................................................27
6.3 Water connection for W type ......................................................................................................................................27
6.3.1 Limit values of the constituent elements in water..........................................................................................28
6.4 Electrical connection...................................................................................................................................................29
6.4.1 Electrical connection (EUROPE-Version only)..............................................................................................29
6.5 Water supply ...............................................................................................................................................................31
6.5.1 First-time water filling ......................................................................................................................................31
6.5.2 Water supply during operation .......................................................................................................................31
6.6 Demineralisation unit ..................................................................................................................................................32
6.7 Extraction of water samples .......................................................................................................................................33
6.8 Sound pressure level ..................................................................................................................................................33
7 Commissioning ..................................................................................................................................................................34
7.1 First commissioning ....................................................................................................................................................34
7.2 Putting a decommissioned compressor back into operation ....................................................................................35
7.3 Routine commissioning ..............................................................................................................................................36
7.4 Commissioning after malfunction...............................................................................................................................37
7.5 Shutoff .........................................................................................................................................................................37
7.6 Emergency stop ..........................................................................................................................................................37
5
2. Table of contents
8 Storage of compressors...................................................................................................................................................38
8.1 Shutdown.....................................................................................................................................................................38
9 Service and maintenance.................................................................................................................................................39
9.1 Maintenance recommendations.................................................................................................................................39
9.2 Maintenance electric motor ........................................................................................................................................39
9.3 Maintenance and inspection schedule ......................................................................................................................39
9.4 Change of air intake filter............................................................................................................................................42
9.5 Change water filter......................................................................................................................................................42
9.6 Replace prefilter RO unit ............................................................................................................................................43
9.7 Change the RO membrane cartridge.........................................................................................................................43
9.8 Safety valve.................................................................................................................................................................44
9.9 Connecting terminals in the switch cabinet/control transformer setting...................................................................44
9.10 Fittings .........................................................................................................................................................................44
9.11 General maintenance and cleaning ...........................................................................................................................44
9.12 Clean / change filter with cooling air inlet and control cabinet inlet..........................................................................45
9.13 Inspection of the compressor stage...........................................................................................................................46
9.14 Inspection intervals for pressure vessels and electrical installations.......................................................................46
9.15 Checking the water level sensor ................................................................................................................................47
10 Trouble-shooting ...............................................................................................................................................................48
11 Annex...................................................................................................................................................................................50
11.1 Technical data.............................................................................................................................................................50
11.1.1 Technical data EUROPE version D37H RS ..................................................................................................50
11.1.2 Technical data EUROPE version D37H ........................................................................................................51
11.2 Layout plan..................................................................................................................................................................52
11.3 Declaration of conformity............................................................................................................................................55
6
3. Safety regulations
3 Safety re gulations
3.1 Identification of safety guidelines Danger
Gardner Denver is not liable for any damage or injury Passages marked with this sign indicate a possible
resulting from the non-observance of these safety danger to persons.
instructions or negligence of the usual care and
attention required during handling, operation,
maintenance or repair, even if this is not explicitly Important
mentioned in these operating instructions. Passages marked with this sign indicate a possible
If any of the regulations contained in these instructions danger to machines or part of machines.
-especially with regard to safety - does not correspond
to the local legal provisions, the stricter of both shall Note
prevail. Passages marked with this sign provide technical
These safety regulations are general and valid for information on an optimal cost-effective use of the
various types of machines and equipment. It is machine.
therefore possible that some references do not apply to
the unit(s) described in these instructions.
3.2 General safety regulations

Danger Safety measure required
Working with compressors involves Everyone working with the machine must have first read and understood the
dangers that are not immediately operating manual. Don’t leave this until you start work – it’s too late.
apparent.
Please keep this operating manual handy at all times on the site of the
machine / installation, in the bag provided.
Pay attention to all safety and danger warnings on the machine/ installation!
Deploy trained staff only. The responsibility of the personnel for operating,
setting up and maintaining the machine / installation must be clearly defined.
Make sure that only authorized personnel use the machine.

Define who is responsible for operating the machine, and authorize him to
ignore instructions from third parties if these instructions could compromise
safety.
Symbols on the machine indicating Ensure that all safety and danger notices on the machine/system stay fully
dangers may become dirty or legible.
disappear.
Faults and modifications to the machine In the event of malfunctions, shut the machine/system down immediately and
may jeopardise safety. secure it from being switched on again! Have malfunctions corrected
immediately.
Check the machine / installation for external damage and faults at least once
per shift.
Any changes noticed (including changes in operating performance) must be
reported immediately to the authority or person in charge. If necessary, shut
down and secure it from being switched on again.
7
3.3 Particular dangers associated with compressed air
Compressed air is very powerful. It can Never play about with compressed air.
be used for example to break open
concrete but can also put lives at risk.
Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution
compressed air can penetrate the skin and always wear suitable eye protection.
or destroy an eye.
Never direct compressed air onto the skin or towards another person.
Never use compressed air for cleaning clothing.
Compressed air connections may split Only connect the compressor to the existing compressed air system when the
and put people at risk. service temperatures and service pressures are correct and the connecting
flange and connecting thread are in full working order.
All connected components must be of the correct size and be suitable for the
specified operating pressure and temperature (i.e. distributing pipes and pipe
connections).
A hose connected to an air valve must be fitted with a safety wire for
operating pressures above 7 bars; it is in fact recommended that this safety
device should be used for pressures above 4 bars. The steel wire has a
diameter of 8 mm and is firmly clamped to the hose at least every 500 mm.
Both ends are fitted with cable lugs.
Do not use chafed, damaged or poor-quality hoses.
Only use the correct type and size of hose coupling and connection.
The compressed air line connected at the air exit of the unit must not be
under strain.
No force should be applied to the outlet thread or the outlet flange by, for
example, pulling on the lines or by mounting additional equipment
(e.g. a water separator or a pneumatic oiler, etc.)
Compressed air lines may be breached Compressed-air lines have to be marked distinctly according to local
by accident. regulations.
Compressed air lines get hot and Make sure that the compressed air line from the compressor to the air
expand. network can expand as a result of heat and cannot come into contact with
inflammable materials.
Pipes and other parts with a surface temperature of more than 70 °C / 158 °F
must be suitably secured against contact and suitably marked.
Loose hose ends may flog and result in Fix the hose in such a way that it does not lash if the connection is broken.
injury.
Before blowing through a hose or air line, it is essential to hold the open end
firmly.
Before disconnecting a hose, always make sure that it is not under pressure.
8
Compression results in high The system should be set up such that hazardous mixtures (inflammable
temperatures. solvent vapours etc. but also dusts and other dangerous or toxic materials)
cannot be drawn in. The same applies to flying sparks.
Never use the machine in environments where the possibility cannot be ruled
out that inflammable or toxic vapours may be taken in.
The installation is to be set up in such a way that it is adequately accessible
and that the necessary cooling is ensured. Never block the admission of air.
Compressor units must never be operated in areas subject to explosion
hazards! (Exception: Special units with the corresponding technical
modifications)
There is strong suction at the air inlet. The air intake is to be designed in such a way that no loose clothing can be
drawn in.
There is a risk of injury, e.g. from getting The personnel must not have long, loose hair, or wear loose clothing or
stuck or being drawn in. jewellery, including rings, due to risk of injury through catching. Personal
protective equipment should be worn if necessary.
Connected compressed air tools may Before switching on the machine / installation, or starting it up, make sure that
start up unexpectedly when switching nobody can be injured by the machine / installation as it starts up.
on.
Compressed air may contain The compressed air produced by these compressors must not be used as
substances that may damage your breathable air, unless it has been processed specially for such an application
health if inhaled. in accordance with the “Safety requirements for breathable air.”
When breathing apparatus with cartridges is used, make sure that the correct
cartridge has been inserted and that its service life has not expired.
The safety valves in the system only The pressure devices/systems connected to the compressor must be secured
guarantee the pressure relief for the allowing for the weakest pressurised component (safety valve or similar).
compressor unit.
As a rule: If several compressors are arranged in a system, manually operated valves

have to be installed so that each machine may be shut off individually. For the
purpose of shutting off pressurized systems, you should never rely on the
effectiveness of return valves alone.
All pressure tanks located outside the unit with an approved operating
pressure higher than atmospheric pressure and fitted with two or more
pressure feed lines must be equipped with an additional safety device to
automatically prevent the approved operating pressure from being exceeded
by more than 10%.
Never operate the system at temperatures and/or pressures below or above
the values indicated in the technical data sheet.
9
3.4 Particular dangers associated with machines
Risk of electric shock. Electrical connections must meet the local regulations. Power units must be
connected to earth and protected from short-circuits by means of fuses.
Insufficient power quality could have Always check a correct power supply to the compressor before commissioning.
a strong effect on health & safety and The voltage supply has to fulfill the requirements of EN60204-1/IEC60204-1 for
may constitute a risk to life and limb such kind of industrial equipment.
of the user or third persons.
Remote-controlled units may start up If a remote control is used, the system must carry a clearly visible sign with the
unexpectedly. following note: Attention! This installation is operated by remote control and can
start up without prior warning!
As an additional safety measure, persons, who start remotely controlled systems,
have to take sufficient safety precautions in order to ensure that nobody is
checking the system or working on it. For this, a label with a corresponding
warning notice has to be attached to the remote control equipment.
Noise, even when it is not very loud, We recommend a separate machine room in order to keep the noise of the
can make us nervous and irritated, machine away from the workshop.
and after a longer period of time our
nervous system can suffer serious Where necessary, wear the personal hearing protection.
damage. In order to consider all noise-relevant parameters and to adequately protect the
health of the operator, the European Regulation 2003/10/EC must be satisfied
completely by the user. In states outside the European Community, the
respective noise protection directives must be taken into consideration.
Shielding and doors must be closed during operation so that the efficiency of the
sound insulating is not reduced.
3.5 Particular dangers associated with water-cooled units
If open cooling towers are used in the The growth and spread of bacteria must be prevented by corresponding service
cooling water circuit, it is possible for and water treatment methods.
legionella (Legionella pneumophila)
and other bacteria to grow and
spread.
10
3.6 Dangers present when loading/moving machines
Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can
turn like doors etc. must be secured and made immobile.
Parts to be removed for transport purposes must be carefully refitted and
fixed again before putting the machine / installation back into operation.
The compressor may fall if mistakes are Only use lifting tackle approved for the weight in question.
made when lifting.
Observe the operating manual for the lifting tackle.
When heavy loads are being conveyed by means of hoisting gear, it is

imperative to keep well clear of the load in order to avoid accidents.
The person giving the instructions must be within sight or voice contact with
the operator.
Safety components may be damaged if Machines may only be hoisted correctly using hoisting gear in accordance
lifted incorrectly. with the information in the operating manual (lifting spots for heavy-lift
facilities etc.)
To avoid damage to the system or external installations, the compressed air
connection, cooling water connection, condensate drain and electrical
connection should be isolated from external lines and hoses.
The system must be set up on a level surface with full contact between its
base frame and the supporting surface.
3.7 General workplace dangers

This manual only describes how to work Please note and pass on general statutory and other binding regulations that
safely with the compressor itself. But may supplement the operating manual for the prevention of accidents and the
other dangers will arise during work. protection of the environment. Such obligations may be for example the
handling of hazardous materials, or the provision and/or wearing of personal
protective equipment, or traffic regulations.
Instructions, including supervisory responsibility and duty of notification for
taking account of special in-plant factors, for example regarding work
organization, sequences of operations, personnel assigned to certain tasks,
are to be added to the operating manual.
Before starting work, make yourself familiar with the working environment at
the installation site.
The location and operation of fire extinguishers must be made known.
Observe the instructions concerning fire alarm and fire fighting.
Set up the machine in such a way that no inlets, outlets or gates are blocked.
When handling chemical substances, observe the safety regulations
applicable for the product.
Caution when handling process materials (risk of burning / scalding).
11
3.8 Dangers resulting from neglecting to perform maintenance
Components of importance to safety Observe the setting, maintenance, and inspection work and intervals
wear over time. stipulated in the operating manual, including information about the
replacement of parts / partial sections. This work may only be carried out by
specialists.
Observe the intervals stipulated or those given in the operating manual for
routine checks and inspections.
Verify regularly that safety valves and other pressure-relief devices are in
perfect condition and are not blocked, for example by dirt or paint
Check regularly that the safety mechanisms are fully functional. Have
malfunctions corrected immediately.
Lines perish. Check regularly that all hoses and/or pipes within the system are in good
condition, firmly fixed and do not chafe.
Spurting water can result in injuries. Check all lines, hoses, and bolted connections regularly for leaks and visible
damage. Repair damage immediately and always arrange for damaged parts
to be replaced!
Risk of electric shock. Have the electrical equipment on a machine/system checked regularly. Have
defects like loose connections or charred cables rectified immediately.
Use only original fuses with the specified current rating. In the event of faults
with the electrical power supply, switch the machine/system off immediately,
and secure it from being switched on again!
In the event of faulty sensors, the Check the accuracy of pressure and temperature indicators at regular
system can be led into a dangerous intervals. If the admissible tolerance limits have been exceeded, these
state of operation. devices have to be replaced.
3.9 Dangers during maintenance and repairs
During maintenance and repairs, parts The compressor can only be maintained by specially trained technicians.
that may be pressurised must be Contact your CompAir agent.
removed. If you maintain the
compressor and have not been trained
by CompAir, you will put yourself and
others at risk.
Incorrectly configured spare parts may Spare parts must meet the technical requirements laid down by the
jeopardise safety, e.g. tear when loaded. manufacturer. This is always guaranteed when original spare parts are used.
12
Risk of electric shock. D37HRS only: Danger of electric shock from loaded condensers! Always first
disconnect the system from the power supply and wait another 12 minutes
before touching the electrical components. The power condensers require this
time in order to discharge!
Work on the electrical systems of the machine / installation may only be
carried out by a trained electrician in accordance with electrical regulations.
The system must be secured from being switched on. Seal off the main switch
and remove the key and/or attach a warning sign to the main switch.
The machine may start up Only carry out maintenance and repair work when the system is not in
unexpectedly. operation and the power supply disconnected. Ensure that the power unit
cannot be switched on inadvertently. The system must be secured from being
switched on.
Seal off the main switch and remove the key and/or attach a warning sign to
the main switch.
Risk of injury from pressurised or Only carry out inspection, maintenance, and repair work when the screw com-
moving parts. pressor system is at a standstill and is not under pressure. The system must
be secured from being switched on.
Before removing or opening pressurized components, positively isolate any
source of pressure and depressurize the entire system.
During the course of maintenance and Never weld any pressure reservoir or change it in any way.
repairs, parts can be damaged which
are important for safety. If work which produces heat, flames or sparks has to be carried out on a
machine, the adjacent components have to be protected by means of non
inflammable material.
Motor, air filter, electrical components and regulating equipment have to
protected from the ingress of humidity, e.g. when cleaning the system by
means of a steam jet.
Under no circumstance must the sound-proofing material be removed or
modified.
Never use etching solvents which could attack the materials used.
Before cleaning the machine with water or steam jet (high pressure cleaner)
or other cleaning agents, cover/mask all openings which have to be protected
from the ingress of water, steam or detergents for safety and/or functional
reasons, in particular electric motors and switch cabinets. After cleaning,
remove the covers/masking completely.
Modifications to the machine impair After completing repair work, always check to see whether any tools, loose
safety. parts or cloths have been left in or on the machine, driving engine or driving
equipment.
After the work has been completed, replace any protective devices that have
been removed. Operation without protective devices is not permissible.
Always re-tighten screwed connections which have been loosened for
maintenance and repair work.
Machines performing a rotating movement have to be cycled several times in
order to ensure that there are no mechanical faults in the machine or the drive
member.
Before releasing the power unit for operation after maintenance or overhaul,
check that the operating pressures, temperatures and time settings are
correct and that the regulating and shut-down equipment function properly.
13
3.10 Dangers resulting from conversion work/modifications on the machine
Genuine parts are designed especially No alterations, additions, or modifications to the machine may be carried out
for the machine. Modifications may without the approval of the manufacturer. Unauthorized modifications to the
interfere with safety equipment or give machine are prohibited for reasons of safety.
rise to new dangers for which protection
is not provided. Original parts are specially designed for our machines. We must explicitly
point out that parts and special accessories not supplied by us are not
approved by us. Installing or using such products may thus adversely affect
active and/or passive safety.
The manufacturer accepts no liability whatsoever for damage resulting from

the use of non-original parts or special accessories.
This also applies to the installation and adjustment of safety devices and
valves as well as to welding on bearing and pressurized parts
If protective equipment is not Only operate the machine when all protective devices, shutdown devices,
functioning, operating the system may sound-insulating equipment and extraction equipment are in place and
put lives at risk. working.
Safety devices, protective covers, or insulations mounted on the system must
not be removed or modified in any way.
14
3.11 Symbols and explanations
Carefully read the operating manual before Never breathe in compressed air from this system.
commissioning or servicing this compressor.
Never operate the unit with open doors or loose access Warning: Hot surface
panels.
Warning: Pressurized part or system Warning: This system can start up by means of a remote
control or automatically after a power failure.
15
Warning: The system continues to run for 30 seconds Warning: Danger of electric shock
after pressing the O-key
Attention: Lifting point Attention: Check and, if required, re-tighten connection

terminals. For further details, see the operating
instructions.
Attention: Danger of electric shock from loaded

condensers! Please always first disconnect the system
from the power supply and wait another 10 minutes
before touching the electrical components. The power
condensers require this time in order to discharge!
Check the DC bus voltage at the system terminal strip
of the frequency converter by measuring this between
Attention: Opening pressure safety valve = xx bar the +DC and -DC terminals (the exact position can be
(value "xx" see sticker on compressor) found in the supplied operating manual of the frequency
converter), between the +DC terminal and the chassis
as well as between the -DC terminal and the chassis.
The voltage must read zero in the case of all three
measurements.
16
4. Design and functioning
4 Design a nd functioning
4.1 Design of the unit
4.1.1 Design of the unit D37H RS-A
Fig. 2
1 Intake filter 11 Cooling air ventilator 20 Water cooler

2 Suction inlet 12 Cooling air inlet filter mat 21 Fan protection panel
3 Electric motor 13 Compressed air outlet 22 Water level indicator
4 Screw compressor 14 Base frame 23 Water level sensor
5 Pressure reservoir 15 Control keypad 24 Network pressure sensor
6 Water filter 16 EMERGENCY OFF 25 Final compression
7 RO-Unit push-button pressure sensor
8 Safety valve 17 Control cabinet 26 Final compression temperature
9 Pressure holding valve 18 Supply cable gland sensor
10 Water connection 19 Opening for lifting gear
17
4.1.2 Design of the unit D37H RS-W
Fig. 3

2 Suction inlet 12 Cooling air inlet filter mat 22 Water level indicator
3 Electric motor 13 Compressed air outlet 23 Water level sensor
4 Screw compressor 14 Base frame 24 Network pressure sensor
5 Pressure reservoir 15 Control keypad 25 Final compression
6 Water filter 16 EMERGENCY OFF pressure sensor
7 RO-Unit push-button 26 Final compression temperature
8 Safety valve 17 Control cabinet sensor
9 Pressure holding valve 18 Supply cable gland 27 Cooling water connection
18
4.1.3 Design of the unit D37H
Fig. 4

2 Intake regulator 12 Cooling air inlet filter mat 22 Water level indicator
3 Electric motor 13 Compressed air outlet 23 Water level sensor
4 Screw compressor 14 Base frame 24 Network pressure sensor
5 Pressure reservoir 15 Control keypad 25 Final compression
6 Water filter 16 EMERGENCY OFF pressure sensor
7 RO-Unit push-button 26 Final compression temperature
8 Safety valve 17 Control cabinet sensor
9 Pressure holding valve 18 Supply cable gland
19
4.2 Schematic diagram
4.2.1 Schematic diagram - air-cooled and water-cooled D37H RS
20 21
34 31
S7 1 B1
Blende/nozzle 3mm
nozzle 3mm
17
25
Y4
7
26
Y11
28 32
Y8 18 B2
33
R1 10 9
6
3 4 11
35
B10
15
22 18 18
5
R2
30 29
Y10 Y9
19 14 18
13
12
23
24 27
Y6
Fig. 5
1. Intake filter 17. Blow-off line orifice 28. Solenoid valve (water in) (Y8)
3. Electric motor 18. Manual valve 29. Solenoid valve (water out) (Y9)
4. Compressor block 19. Mud flap 30. Solenoid valve (water stop) (Y10)
5. Final compression temperature 20. Ventilator 1 (A and W-version)
sensor (R2) 21. Ventilator 2 (only A -version) 31. Network pressure sensor (B1)
6. Pressure reservoir 22. Non-return valve 32. Final compression pressure
7. Pressure holding valve 23. Choke valve, adjustable sensor (B2)
9. Safety valve (W-version only)
10. Osmosis unit 24. Dirt trap (W-version only) 33. Motor temperature (R1)
11. Water reservoir
12. Water filter 25. Blow-off valve (Y4) 34. Differential pressure air filter (S7)
13. Water cooler 26. Bypass valve (Y11) (Option)
14. Throttle 27. Cooling-water solenoid valve 35. Water level sensor (S18/S19)
15. RS inverter (Y7) (W-version only)
20
4.2.2 Schematic diagram - air-cooled and water-cooled D37H
34 1 20 21
S7
2.2 2.1
A B 31
2
B1
2.3
7
27
Y4 25
Y1 15 16
8
32
18 B2
33 28
R1 10
Y8 9
4
3
11
35
B10
22 5 18 18
R2
30 29
Y10 Y9
19 14 18
13
12
23
24 26
Y6
Fig. 6
1 Intake filter 15 Blow-off valve 29 Solenoid valve (water out) (Y9)

2 Intake regulator 16 Minimum pressure valve 30 Solenoid valve (water stop) (Y10)
2.1 Actuator 18 Manual valve
2.2 Pressure control valve 19 Mud flap 31 Network pressure sensor (B1)
2.3 Controller block 20 Ventilator 1 (A and W-version) 32 Final compression pressure sensor
3 Electric motor 21 Ventilator 2 (only A version) (B2)
4 Compressor block 22 Non-return valve
5 Final compression temperature 23 Choke valve, adjustable 33 Motor temperature (R1)
sensor (R2) (W-version only)
6 Pressure reservoir 24 Dirt trap (W-version only) 34 Differential pressure air filter (S7)
7 Pressure holding valve (Option)
9 Safety valve 25 Solenoid valve (control valve) (Y1) 35 Water level switch (S18/S19)
10 Osmosis unit 26 Cooling-water solenoid valve (Y6) A Configuring blow-off speed
11 Water reservoir (W-version only) B minimum pressure setting
12 Water filter 27 Solenoid valve (bypass) (Y4) (min. 3,5bar)
13 Water cooler (W-version only)
14 Throttle 28 Solenoid valve (water in) (Y8)
21
4.3 Water circuit • If pressure in the load system falls below the
minimum pressure programmed on the control
The water flows from the pressure tank (- 5 - Fig. 2) system, the solenoid valve (-25-(Y4)) is energized
through the water cooler (- 20 - Fig. 2) and water filter (closed). Pressure then continues to build up in the
and is then injected into the screw compressor pressure reservoir (- 6 -).
(- 4 - Fig. 2).
• At a tank pressure of ca. 4.5bar/65 PSI, the
The entire water circulation is based on differential pressure holding non-return valve (- 7 -) opens.
pressure in the system. Thus, water is injected into the
• The compressed air transportation into the mains
screw compressor at a tank pressure of 10 bar/145 PSI
has begun.
with ca. 5.5 bar/ 80 PSI, for example.
Stopping the system:
• After pressing the OFF button on the control panel

4.4 Air circulation of the compressor control system DELCOS XL, the
magnet valve (- 25 - (Y4) is de-energized (opened)
The suctioned air makes it way into the screw compres- and the solenoid valve (-26-(Y11)) is energized
sor (- 4 - Fig. 2) via the suction filter (- 1 - Fig. 2). The (opened) when the drive motor is running.
injected water cools air during the compressing process
• The pressure reservoir (-6-) is depressurized to a
and the resulting compressed air – water mixture
constant pressure of 4 to 4.5 bar.
tangentially flows into the pressure tank (- 5 - Fig. 2).
Thereby, the water is separated extensively from the • The drive motor (-3-) reduces its number of revs to
compressed air and delivered into the mains via the the set minimum value and comes to a standstill
pressure holding and non-return valve (- 8 - Fig. 2). after 30 seconds have passed.
• Once the drive motor has stopped, solenoid valve

(-26-(Y11)) is deenergized (closed) and the
remaining pressure in the reservoir is discharged via
the orifice (-17-).
4.5 Control
4.5.1 Control D37H RS (Fig. 5)
Speed control operation
(Please also see the operating instructions for the
compressor control DELCOS XL) Speed is controlled using a software-implemented PI
regulator that adapts the RPMs according to the need
for compressed air.
System downtime
The controller attempts to maintain the mains pressure
• Solenoid valve (- 25 -(Y4)) is deenergized (open) between the values set in the control for max. and min.
when the system is shut down, solenoid valve mains pressure (target pressure).
(-26- (Y11)) is also deenergized (closed).
• The pressure vessel (- 6 -) is depressurized to Automatic operation
atmospheric pressure via the solenoid valve
(-25-(Y4)) and the orifice (-17-). • If the mains pressure achieves the preset maximum
value, then the electric motor (-3-) will have its
speed lowered in order to allow for the delivery
Starting up the system amount to adapt to the actual need for compressed
• The drive motor (- 3 -) starts up. air.
• The compressor draws air in via the air filter; a • If the motor has reached minimum speed and the
certain quantity is blown off again into the intake load-system pressure continues to rise, solenoid
zone via the solenoid valves (-25-(Y4)) and valve (-25-(Y4)) is deenergized (opened) and
solenoid valve (-26-(Y11)) continues energized
(-26-(Y11)) and via the orifice (-17-).
(open). Reservoir pressure is reduced to approx. 4 to
• This way, constant pressure of approx. 4 to 4.5 bar 4.5 bar and the pressure-maintenance valve (-7-)
is maintained in the pressure tank (- 6 -), as the closes.
pressure holding non-return valve (-7-) still remains
• This way, no more compressed air will be supplied
closed at this pressure level.
to the mains.
• The water supply of the screw compressor (- 4 -) is
provided by the drop in pressure between the • If the mains pressure does not drop to the target
pressure tank (-6-) and the injection site in the value within the programmed follow-up time, then
screw compressor. the system will shut down.
22
• If the target value is achieved before the expiration Stopping the system
of the programmed motor follow-up time, then the
magnet valve will again be energized (-25-(Y4)). • To de-energise the solenoid valve (- 25 - (Y1) and
press the OFF push-button on the keypad of the
• The system will then go into load runs. compressor control DELCOS XL.
• The pressure valve (-2.2-) in the suction controller
(-2-) closes and the tank is relieved to atmospheric
4.5.2 Control D37H (Fig. 6) pressure via the minimum pressure valve (-16-).
(Please also see the operating instructions for the • After 30 seconds, the drive motor (- 3 -) and the
compressor control DELCOS XL) cooling air ventilator motor (- 20,21 -) are shut down.
Standstill of the system Automatic operation (open-close operation)
• If the plant is shut down, the suction controller (-2-) • When the pressure reaches the upper switching
is closed by a pressure spring in the adjusting point set on the network pressure sensor (-31-(B1)),
cylinder. solenoid valve (- 25 - (Y1)) is deenergised.
• The water stop valve (-30- (Y10)) is closed. • The pressure valve (-2.2-) closes because the lower
control space of the adjusting cylinder (-2.1.-) is
• The solenoid valve (- 25 - (Y1)) is deenergised. relieved by the deenergised valve (-25-(Y1)) the
• The pressure reservoir is released via valve (-16-) to upper control space is impinged with pressure via
atmospheric pressure. the valve (-16-).
• The pressure reservoir is relieved to no-load
pressure (residual pressure) via the two valves
Starting the system
(-15- and -16-).
• The motor starts up in the Y-mode.
• The screw compressor is now running in the offload
• The intake regulator is closed. mode.
• The compressor aspires a certain amount of air • When the pressure at the network pressure sensor
through a bypass valve. Pressure builds up in the (- 31 - (B1)) does not fall to the set lower switching
reservoir. point within the set motor run-on time (e.g. 120
seconds), the drive motor (- 3 -) and the cooling air
• The water stop valve (-30- (Y10)) is open. The water ventilator motors (- 20 and 21 -) are shut down and
supply of the screw compressor (- 4 -) is provided the system is depressurised to atmospheric
by the drop in pressure between the pressure tank pressure.
(-6-) and the injection site in the screw compressor.
• The system is now in the “stand-by” mode and can
• If the drive motor is switched over to Δ operation, restart at any time when the network pressure falls
the magnetic valve switches over (-25-(Y1) since it to the lower switching point (see section “Starting of
is supplied with current. the system”).
• The air circulated in the system streams over the • When the network pressure falls to the preset lower
solenoid valve (-25- (Y1)) in the upper control area switching point before the set motor run-on time has
of the operating cylinder (-2.1-). Valves (-15-) and elapsed, solenoid valve (- 25 - (Y1)) is energised
(-16-) are closed and the lower control space of the again.
adjusting cylinder is ventilated.
• The unit now changes over to on-load operation.
• The pressure control valve (- 2.2 -) in the intake
regulator (- 2 -) opens.
• At a reservoir pressure of approx. 4.5 bar/65 PSI the
pressure holding and check valve (- 7 -) opens.
• Compressed air is now delivered into the consumer
network.
• The system is now in load running mode.
23
5. Transport and installation
5 Trans port and installation
5.1 Transport The proper lifting of the load (according to the

operating instructions of the load suspension
device) has to be ensured.
Important
Never lift or lash the compressor and its hood via

the enclosure. The screw compressor is lifted with
the help of a fork lift truck (11.2). The separation
of the forks and their length must be taken into
account for transportation.
Only use the identified lifting points. Do not slide
the unit when it is standing on the floor.
Weights
The values listed below are approximate values, they
refer to a screw compressor unit including water fill:
D37H RS-A: 1135 kg
Fig. 7
D37H RS-W: 935 kg
D37H-A: 1000 kg
D37H-W: 900 kg
Fig. 8
Note
Before transporting the unit, remove the doors. The

doors must be removed before lifting from the control
side. In addition the safety plate (-1- Fig. 8) must be
removed before lifting from the back.
Danger
The compressor must be lifted using a suitable

forklift truck which complies with the local safety
regulations.
The length of the forks must correspond at least to
the width of the unit (see Chapter 11.2).
Before lifting, all loose or slewable parts of the
machine have to be firmly secured.
It is strictly prohibited to work or stand in the
danger zone of a lifted load.
24
5. Transport and installation
5.2 Installation
Fig. 9
Danger
• The weight carrying capacity of the foundation

has to be taken into account when installing the
compressor.
• Provide for a solid and plane base.
• The system may not be operated on the transport
pallet.
• The intakes are to be located so that no
hazardous constituent (solvent vapour, etc., but
also dusts and other hazardous material) can be
sucked in. This applies also to flying sparks.
• Pipes and/or other parts with a surface
temperature higher than 70 °C/158 °F have to be
suitably identified and secured against
touching.
See also the safety regulations in chapter 3 of the
operating instructions.
Important
The operator has to provide adequate ventilation

for the compressor station.
The screw compressor unit has to be levelled.
A minimum distance from walls, other machines, etc.
should be maintained so that there is sufficient
clearance for maintenance and repair work (Fig. 9).
During operation of the screw compressor unit, heat is
generated by the electric motor and the compression
process. The screw compressor radiates a part of this
heat into the surroundings.
Proper ventilation has a considerable effect on the
service life and the performance of a compressor.
25
6. Preparations for commissioning
6 Preparations for c omm issioning
6.1 Cooling air volume/minimum cross The figures below show the recommended ventilation
sections arrangement:
AIR CHANNEL
AIR
INTAKE
Fig. 10 a VENTILATOR
1 Cooling air intake

2 Cooling air outlet
The cooling air volume required by these screw

compressors is as follows:
air-cooled unit approx. 125 m³/min

AIR
water-cooled unit approx. 25 m³/min INTAKE
Under unfavourable local conditions, we recommend

the installation of venting ducts. However, the velocity
of the cooling air should not exceed 5 m/s/17ft/sec. We
recommend a minimum duct cross-section of approx.
0,93 m2/10 ft2. Fig. 10 b
Important
The stated minimum cross-section refers to a

maximum duct length of 5 m/16.4 ft and a maximum
of one bend. In the event of differing values
(over 5 m/16.4 ft, more than one bend, filter
cartridges, screens, etc.), please contact your
technical adviser.
CompAir screw compressors are rated for ambient
temperatures and cooling temperatures of +2°C/
35.6°F to +40°C/104°F.
In the case of temperatures other than the above
limiting values, please consult your technical
adviser.
Note
In order to ensure a good heat dissipation, auxiliary

fans should be rated to process approximately 15 to
20% more air volume than the total cooling air
quantity required by the compressors installed in the
compressed air station.
26
6.2 Compressed air connection 6.3 Water connection for W type
Danger
If open cooling towers are used in the cooling

water circuit, it is possible for legionella (Legionella
pneumophila) and other bacteria to grow and
spread. The growth and spread of bacteria must be
prevented by corresponding service and water
treatment methods.
Important
The cooling water must be drained if there is a

danger of frost occurring or in case of a prolonged
shut-down of the screw compressor system.
Always perform maintenance, servicing and repair
work carefully.
Fig. 11 Note
1 Compressed air connection The following items must be noted for operation of
water-cooled screw compressor systems:
The compressed air line system is connected at the
compressed air supply of the screw compressor • Cooling water must not be discharged
(-1- Fig. 11). indiscriminately into public waste-water and
drain systems. Uncontrolled overflow of
For this you should use a flexible connection
oil-separator basins into public waste-water
(e.g. compressed air hose, compensator).
systems must be prevented.
Europe-Version: 1 1/4“
• Waste-water law provisions must be carefully
USA/CANADA-Version: 1 1/4“ NPT
adhered to.
Important The cooling-water circuit is completely installed in the
screw compressor system.
When connecting the compressor on the mains
side to the compressed air system available at the
customer‘s end, check the operating temperatures The water connections on the W type are as follows:
and operating pressures required and examine the
required connecting flange or the connection • Water inlet: G 1" (1" - NPT)
thread for proper functioning. • Water outlet: G 1" (1" - NPT)
In the case of connections by means of connecting Permissible cooling-water data:

hoses, take appropriate measures to prevent
• Cooling-water pressure: >>min./max.<<: 2/5 bar
whipping of the loose end in the event that the
• Cooling-water inlet temp.: >>min./max.<<: 5 / 35 °C
hose connection tears off. • Cooling-water outlet temp.: >>max.<<: 45 °C
Note The cooling-water requirement at maximum operating
pressure, referred to 12 to 15 °C water inlet
After-coolers, separators, collecting reservoirs and the
temperature, Δ t = 10 °C, is approx. 60 l/min
compressed air lines must be equipped with drain
facilities at their lowest points to drain collected liquids. This data is based on fresh water and the cooling-water
These facilities have to be fitted to allow the observance quality recommended by CompAir (see Chapter 6.3.1).
of the draining of such liquids. Please contact CompAir if the cooling-water data
diverges from this.
Hand-operated drain facilities have to be actuated in
accordance with the operating instructions. The flow of cooling-water for the water cooler at
commissioning can be adjusted by means of a manual
Automatic drain facilities have to be checked for proper
control valve.
function at regular intervals. When draining conden-
sates into a collecting line, which also collects the
condensate from other machines, make sure that the
collecting line is free from back pressure at all lines.
When draining condensate, observe the corresponding
regulations for waste water disposal.
27
Note 6.3.1 Limit values of the constituent

elements in water
Wherever possible, the cooling-water outlet
temperature should be below 50 °C, in order to prevent Note
excessive precipitation of limestone fur.
The information set out below is intended for guidance
and may differ under certain conditions of operation.
The total composition and the operating temperature
are always decisive. Warranty claims may not be
derived from this..
Constituent elements of Pass-

Circulating
water / characteristic through
water
values water
pH value
6–9 6–9
(at 25 °C / 77 °F)
Carbonate CaCO3 < 100 mg/l < 50 mg/l
hardness (5.6 °dH) (2.8 °dH)
Total hardness < 2 mmol/l < 0.5 mmol/l
< 200 ppm < 50 ppm
< 11.5 °dH < 2.8 °dH
< 20 °fH < 5 °fH
-
Chloride Cl < 200 mg/l < 50 mg/l
2-
Sulphate SO4 < 200 mg/l < 50 mg/l
Fig. 12
−
Nitrate NO3 < 100 mg/l < 100 mg/l
1 Water inlet
2 Water outlet Organic substances
< 25 mg/l < 10 mg/l
3 Compressed-air connection (KMnO4 absorption)
free aggressive
CO2 < 20 mg/l < 20 mg/l
carbonic acid
Silicium oxide SiO2 < 10 mg/l < 10 mg/l
free chloride Cl2 < 4 mg/l < 2 mg/l
Oxygen O2 < 2 mg/l < 2 mg/l
+
Ammonium NH4 < 1mg/l < 1mg/l
Iron Fe < 0.2 mg/l < 0.2 mg/l
Manganese Mn <0.1 mg/l <0.1 mg/l
2-
Sulphide S 0 0
Ammoniac NH3 0 0
> 50. < 800 > 50. < 200
Conductivity
µS/cm µS/cm
28
6.4 Electrical connection
6.4.1 Electrical connection (EUROPE-Version only)

Recommended supply cable cross-sections and fuses
Installed nominal Fuse protection Line cross section

Supply voltage
Compressor type motor power (slow-blow fuse) at 30 °C/86 °F
[V]
[kW] [AgL] [mm 2]
50 Hz Compressors
380V 100 3 x 35 PE 16
D37H RS 37
400V 80 4G25
3 x 35 PE 16
D37H 400V 37 100
3 x 35 PE 16
60 Hz Compressors
380V 100 3 x 35 PE 16
D37H RS 37
460V 80 4G25
Notes on the table: The main switch must meet the requirements of the
safety standard EN 60 204-1 (electrical equipment
We do not know the cable type used by you, its length of machinery) as well as of EN 60947-2 (low-
and the installation conditions (temperatures, grouping). voltage switchgear and control gear (circuit-
The table above can therefore only be regarded as a breakers)).
guideline.
The electrical connection and protective measures
The supply cable cross-sections given in the table have to be installed in accordance with VDE, BS or
comply with VDE 0298, part 4 - table 13, column 7. local regulations. As a rule, additional instructions
(Rubber hose line at 30 °C/86 °F and max. line length of of the relevant power supplier have also to be
50 m). In the case of differing conditions (line length, adhered to.
temperature and grouping), establish the cross sections
in accordance with DIN VDE 0298, part 4 or BS7671 The electrical connections must be made by an
taking into account the cable type. authorized specialist.
Important Attention: Interference voltage!
If local regulations are stricter than the values If external electric circuits, which cannot be cut out
specified above, observe the stricter regulations. via the main switch, are connected to the control,
these have to be identified according to EN60204.
Compressor units are finished in the factory according Warning signs have to be fixed near the main
to standard EN60204 (industrial machinery). Please switch and near these electric circuits. In addition,
observe the following important notes: these conductors have to be laid separately and/or
identified by colors. Work on control cabinets may
Danger only be carried out by electrotechnical specialists.
If the installation conditions of the system differ
The power supply to the compressor side has to be
from the conditions described in EN60204, please
fitted for industrial equipment and fulfilling the
contact your technical adviser.
requirements of EN60204-1/IEC60204-1. To avoid
strong damages and fire on the power electric
components, any kind of operation outside of the
stated limits of EN60204-1/IEC60204-1 is
inadmissible.
The customer has to connect a main switch in the
incoming line of the compressor unit (unless
factory-mounted as special accessories)
(DIN EN 1012 - 1).
If this switch does not provide short-circuit and
overload protection for the system, suitable
back-up fuses have to be installed according to
EN 60269-1 (low voltage directive ) (see table).
29
To establish an electrical connection, proceed as Checking the setting of the control-power

follows: transformer
Route the supply cable through the cable gland Danger

(-1 - Fig. 13) on the control cabinet and tighten screws.
When carrying out adjustment work on the control
Connect the supply line to the connecting terminals as power transformer, the unit must be electrically
shown in the circuit diagram. isolated and locked off.
Work on the control cabinet may only be carried
out by electrotechnical specialist personnel.
Danger of electric shock from loaded condensers!
Please always first disconnect the system from the
power supply and wait another 10 minutes before
touching the electrical components. The power
condensers require this time in order to discharge!
Important
A wrong setting of the control-power transformer

jeopardizes the trouble-free operation of
compressor units and can result in malfunction or
damage.
The verification of the control-power transformer
setting is a must during commissioning.
Fig. 13
The control-power transformer is factory-preset to the
rated voltage. However, practice has shown that the
Check setting of the fan protection switch actual supply voltage often differs from this value. In
order to adjust the unit to the local conditions, the
Check the setting of the motor protection switch in setting of the control-power transformer must be
accordance with the enclosed circuit diagram for the checked by measuring the control-power transformer
compressor. output voltages during under load operation and, if
Set the protection switch to the value stated in the table required, re-set. Several tapping points are provided for
corresponding to the mains voltage and frequency (see this purpose (see circuit diagram). Fig. 14 illustrates an
circuit diagram). example.
Fig. 14
30
6.5 Water supply Perform first-time water filling as follows:

• Open manual valve – water in (-1- Fig. 15).
6.5.1 First-time water filling Water flows through the inlet (-3- Fig. 15) into the
pressure tank (-7- Fig. 15).
Important
• Fill up to the fill level marking "Above" (-5- Fig. 15).
For first-time filling, only water with the following
threshold limits should be used: • Close manual valve – water in (-1- Fig. 15). Start
system and monitor the water level.
Conductivity 5 - 150 µS / cm
pH value 6-8 • Once the fill level marking "Below" (-4- Fig. 15) has
Overall hardness (CaCO3) < 3° dH been reached, turn off system via the emergency
Iron (Fe) < 0.3 mg / L off.
Chloride (Cl-) < 50 mg / L
Sulphate (SO4-2) < 50 mg / L • Open manual valve – water in (-1- Fig. 15).
Nitrate (NO3-) < 0.3 mg / L • Fill with water up to the fill level marking "Above"
Ammonium (NH4+) < 0.3 mg / L (-5- Fig. 15).
The CompAir water analysis set can be used to • Close manual valve – water in. Start system and
determine the water quality. monitor the water level.
If deviant values are present, we recommend use of the • Once the fill level marking "Below" (-4- Fig. 15) has
demineralisation unit from CompAir for first-time filling. been reached, turn off system via the emergency
For a more detailed description, see Section 6.6 off.
• Repeat this filling process until the water level has
balanced out between the fill level markings.
6.5.2 Water supply during operation

Important
The water-supply quality must not exceed the

following limits for continuous operation:
Conductivity < 2000 µS/cm
pH-Value 6,5 - 8
Overall hardness (CaCO3) < 20 °dH
Iron (Fe) < 0,3 mg / L
Fig. 15 Sulphate (SO4-2) < 240 mg / L
Nitrate (NO3-) < 50 mg / L
1 Manual valve – water in
2 Water level sensor Ammonium (NH4+) < 0,5 mg / L
3 Water supply
Important
4 Fill level marking "Below"
5 Fill level marking "Above" For long-term operation, the water quality of the
6 Water level indicator internal circulation water (water injection) must not
7 Pressure tank exceed the following limit values:
Conductivity 50 - 150 µS / cm
pH value 6-8
Overall hardness (CaCO3) < 3° dH
Iron (Fe) < 0.3 mg / L
Sulphate (SO4-2) < 50 mg / L
Nitrate (NO3-) < 0.3 mg / L
Ammonium (NH4+) < 0.3 mg / L
31
6.6 Demineralisation unit Undertake the initial filling with the

demineralisation unit as follows:
Important • Apply water connections for the inflow (-A - Fig. 16)
The following points are to be considered when and the connection between the outflow (-B- Fig. 16)
using the demineralisation unit: with the water inflow from the compressor (-C- Fig. 17)
1) To be used only for the first filling of the • Open stopcock for filling process (-2- Fig. 16).
If necessary open the vent on the filter head of the
compressor.
demineralisation unit. The water level in the filter
2) The quantity of water is reduced to approx. rises.
1 litre/minute due to the integrated flow limiter.
• Open manually operated valve – water on (-1- Fig. 15).
3) Complete filling can take up to 90 minutes. The water flows via the inflow (-C- Fig. 17) into the
pressure vessel (-7- Fig. 15).
4) The cartridge is designed for a maximum water
quantity of 45 litres. • Fill water up to the fill level marking "Above"
(-5- Fig. 15). This process may take up to
5) After initial filling the water supply to the compressor 90 minutes.
should be taken directly from the mains.
• Close manually operated valve – water on (-1- Fig. 15);
start the system and observe the water level.
• When the fill level marking "Below" (-4- Fig. 15) is

reached, switch system off via the emergency stop.
• Open manually operated valve – water on

(-1- Fig. 15).
• Fill water up to the fill level marking "Above"
(-5- Fig. 15) again.
• Close manually operated valve – water on. Start

system and observe water level.
• When the fill level marking "Below" (-4- Fig. 15) is
reached, switch system off via the emergency stop.
• Continue this filling procedure until the water level
Fig. 16 has balanced out between the fill level markings.
• After filling, remove the connection between outflow
(-B- Fig. 16) and the water inflow (-C- Fig. 17) on the
compressor.
• Connect water supply directly to the mains.
Fig. 17
32
6.7 Extraction of water samples
Danger
Water samples must only be extracted when the

rotary screw compressor unit is stationary and
depressurised.
Switch off the compressor and ensure that it is
depressurised.
• Open the ball valve at the extraction site (-2- Fig. 21)
and to flush the extraction site, allow around 0.1 l to
drain into an appropriate vessel.
• Fill the vessel provided (water analysis set) with the
sample quantity (approx. 0.3 l).
• After extracting the sample, close the ball valve.

• Check the water level on the water level indicator
(-6- Fig. 15) and add water if necessary (see
Chapter 6.5 Water supply).
6.8 Sound pressure level

Sound pressure level measured in dB(A) according to
PN8NTC 2.2 under a 70% load at a distance of 1 m
(tolerance: ± 3 dB(A)):
air-cooled unit 71 dB(A)
water-cooled unit 61 dB(A)
Subject to technical revision.
33
7. Commissioning
7 Commiss ioning
7.1 First commissioning First commissioning is carried out as follows:
• Remove transport guards, if fitted.

Danger
• Check the water level in the pressure reservoir
Make sure before commissioning that nobody is in (see also chapter 6.5) (Fig. 15)
the danger zone of the screw compressor.
• Check settings of the fan motor protection switch
Only operate the screw compressor with closed (see Chapter 6.4)
access panels.
• Check the setting of the control-power transformer
Important (see also chapter 6.4).
Although every CompAir screw compressor has • Check and re-tighten all connecting terminals of the
been subjected to a test run at the factory and has electrical control.
again been thoroughly inspected before shipment,
• Open isolator valves between the screw
damage during shipment cannot be excluded. For
compressor, reservoir and pipe.
this reason, every screw compressor should be
checked once again for damage before being • Ensure cooling water supply in accordance with
commissioned. In addition, it should be observed Chapter 6.3. (only water-cooled units).
during the first operating hours.
• Operate main power supply switch.
If the screw compressor is newly connected to a
• After the power supply was switched on, all LEDs
power supply, check the direction of rotation of the
on the compressor control DELCOS XL light up for
drive motor!
a display test. The fault shown on the display [power
The screw compressor is provided without cooling supply fault] must be acknowledged in the fault
water and may only be started after it has properly memory menu item prior to starting the unit. (The
been filled with water (also see Chapter 6.5). display language can be set in the start screen
using the "globe icon".)
When storing the screw compressor system or in
the event of a longer period of downtime, if there is • After the acknowledgement, the message [READY
the risk of frost ( t < 1°C) the cooling water should TO START] appears on the display, unless another
be completely discharged (compressor stage, fault is present.
coolers, system containers, water filters, storage • The factory setting of the setpoint value for the
containers, RO unit, lines, valves). network pressure (upper and lower switching point)
The screw compressor unit is completely factory- is saved in the compressor control DELCOS XL and
assembled. It can be directly connected to the com- depends on the relevant pressure variant of the
pressed air mains by means of a flexible connection. compressor (see nameplate fig. 1, stage pressures
= maximum operating pressure). These settings can
be checked or changed in the compressor control
DELCOS XL menu [Settings; Pressure range, p1]
(further information can be found in section 5 of the
compressor control DELCOS XL operating manual).
• Casing can be temporarily opened for rotation
direction checks. The direction of rotation of the
drive motor and the fan motor is indicated by the
arrow sticker (Fig. 18).
Important
With a wrong direction of rotation, shut down the

unit immediately by pressing the emergency STOP
button (-7- Fig. 19) (not the [O] ), otherwise the
compressor may be seriously damaged, even
during short periods of operation.
The access panels may temporarily be opened for
checking the direction of rotation (wear ear
protectors).
34
7. Commissioning
Danger 7.2 Putting a decommissioned

Beware of rotating parts! Rotating parts can lead to
compressor back into operation
injuries. Stay at a safe distance away from rotating Before commissioning the compressor all the electrical
machine parts! and electronic components and units should be
Press the START button [ I ] (-2- Fig. 19) and check the checked for the ingress of water or condensation
direction of rotation. With a wrong direction of rotation, If the electronic control system was removed during
press the emergency STOP button (-7- Fig. 19) shut down, it must be re-installed.
immediately and correct the direction of rotation.
Then proceed as described in chapter 7.1 'First
commissioning'.
Fig. 18
1 Direction of rotation of the drive motor

2 Direction of rotation of the fan motor
Note
For switching the compressor off “normally”, use only
the stop push-button (- 3 - Fig. 19), but not the
EMERGENCY STOP push-button (-7- Fig. 19). After
having been switched off, the compressor is aftercooled
for 30 seconds (soft stop).
Temperature start-up protection

The screw compressor unit will not start up if the
ambient temperature is lower than + 2 °C/35,6 °F.
35
7. Commissioning
Display of the compressor control DELCOS XL 7.3 Routine commissioning

Danger
Make sure before commissioning that nobody is in
the danger zone of the motor/screw compressor.
After completion of work: Verify that all safety
devices have been refitted and that all tools have
been removed.
Only operate the screw compressor unit with
closed access panels.
For routine commissioning, proceed as follows:

Fig. 19 • Check water level in the pressure reservoir (see
also chapter 6.5).
1. Touchscreen Display
2. Start push-button [ I ] • Open shut-off valves between the screw
3. Stop push-button [ O ] compressor, reservoir and pipe.
4. red LED Flashing slowly = Warning
Flashing rapidly = fault • Ensure cooling water supply in accordance with
5. yellow LED Flashing slowly = Maintenance required Chapter 6.3. (only water-cooled units).
6. green LED Lit up permanently = Unit in operation • Switch on the power supply master switch.
Flashing slowly = Unit in standby mode
7. Emergency stop • After the power supply was switched on, all LEDs
on the compressor control DELCOS XL light up for a
Danger display test. The fault shown on the display [power
supply fault] must be acknowledged in the fault
The compressor can be automatically started at memory menu item prior to starting the unit. (The
any time when it is in standby mode, i.e. the green display language can be set in the start screen
LED is flashing. using the "globe icon".)
• After the acknowledgement, the message [READY

TO START] appears on the display, unless another
fault is present.
• Press START button [ I ] (- 2 - Fig. 19).
• To switch off the compressor in the usual way use

the STOP button (-3- Fig. 19) and not the
emergency STOP button (-7- Fig. 19). After
shutdown the compressor has a run on time of
30 - 50 seconds (soft-stop). The time remaining is
counted down on the display.
Start-up protection of the electric motor

The screw compressor unit will not start up if the final
compression pressure is more than
0,4 bar / 5,8 PSI for the D37H and
1,0 bar / 14,5 PSI for the D37H RS.
Temperature start-up protection

The screw compressor unit will not start up if the ambi-
ent temperature is lower than + 2 °C/35,6 °F.
36
7. Commissioning
7.4 Commissioning after malfunction
Important
Do not switch the screw compressor on repeatedly

without having rectified the malfunction, since this
may cause considerable damage to the machine.
Re-start after an automatic shutdown due to a
malfunction as follows:
• Faults are shown as text in the compressor control

DELCOS XL "fault memory" display menu.
• Turn master switch off.
• Eliminate fault.
• Turn master switch on.
• Acknowledge the fault in the fault memory menu.

After the acknowledgement, the message [READY
TO START] appears on the display, unless another
fault is present.
• Press START button [ I ] (-2- Fig. 19).
7.5 Shutoff
To switch off the compressor use the O key (-3- Fig. 19)
and not the EMERGENCY STOP button. After shutdown
the compressor has a run on time of 30-50 seconds (soft-
stop).
Note
The unit may only be shut down using the emergency
off button in real emergencies. When shutting down
normally, please use the O key.
7.6 Emergency stop

The EMERGENCY STOP button is situated next to the
DELCOS XL. It is used to immediately shut down the
unit. Only use the EMERGENCY STOP button (-7- Fig.
19) to shut down the unit in emergencies. When
shutting down normally, always use the [O] key.
37
8. Storage of compressors
8 Stora ge of com press ors
8.1 Shutdown
All compressors are protected against corrosion at the
factory for transport and for brief storage before
commissioning.
If the compressors are to be stored for period
exceeding six months, additional precautions must be
taken.
Compressors which are to be shut down for a lengthy
period must also be protected from corrosion.
Since corrosion occurs more quickly in damp
atmospheres than in dry conditions, it is not possible to
specify a maximum permissible standstill time which will
apply in all cases.
Note
The following aspects must be taken into account for
storage of storing compressors.
The compressor should be stored in a dry building
which should be heated if possible. This is particularly
true during the months of winter.
The coolant is to be completely drained where there is a
risk of frost (t < 1°C) (compressor stage, coolers,
system containers, water filters, storage containers,
RO unit, lines, valves).
If there is a risk that the temperature will fall or rise
above the limits of -10 °C/14 °F to +65 °C/149 °F , the
electrical controller must be removed and stored in
ambient temperatures of +5 °C/41 °F to +30 °C/86 °F.
38
9. Service and maintenance
9 Service and ma inte nance
9.1 Maintenance recommendations 9.3 Maintenance and inspection

schedule
Note
Danger
The screw compressor unit can only operate to your
complete satisfaction when the maintenance work is When performing control, adjusting and mainte-
carefully carried out at the specified intervals. nance work, be careful with hot surfaces of
machine parts.
In order to facilitate this task, the scope of supply of the
screw compressor unit comprises the “Maintenance and Checks and maintenance work may only be carried
inspection manual for CompAir compressors”, in which out when the following points are observed:
you can list your performed maintenance work at the
specified intervals. • Press the STOP button on the control panel and
wait until the screw compressor unit has come
You can also have this maintenance work performed by to rest and the screw compressor unit is
our trained technicians. Please ask your CompAir depressurized
distributor for a maintenance contract.
• Switch the master switch to "O" (OFF) and
secure it against reactivation.
9.2 Maintenance electric motor • The pressure display does no longer indicate
pressures < 0.3 bar/4,4 PSI.
The electric motor is permanently lubricated. The
maintenance of the electric motor is to be performed in • Shortly after switching the screw compressor
line with the motor operating instructions. off, the system can contain a low residual
pressure.
• Warning:
Electrical voltage: Only work on the screw
compressor unit when it is disconnected.
• Danger of electric shock from loaded
condensers! Please always first disconnect the
system from the power supply and wait another
10 minutes before touching the electrical co
• mponents. The power condensers require this
time in order to discharge!
Intervals are valid for normal industrial environments
and operating conditions.
In the case of a very dirty atmosphere, the cleaning

intervals have to be shortened as required.
For order numbers see the spare parts list.
39
2,000 h
4,000 h
6,000 h
8,000 h
10,000 h
12,000 h
14,000 h
16,000 h
18,000 h
20,000 h
Commissioning
Due at x service hours
3m
6m
9m
12 m
15 m
18 m
21 m
24 m
27 m
30 m
At the latest after x months
Package A     
Package B  
Package C 
Maintenance every 2000 h, although at least every 3 months:
Cleaning/replacement of cooling air inlet filter          
Maintenance every 4000 h, although at least every 6 months:
Replacement of air filter cartridge     
Replacement of water filter     
Replacement of prefilter RO unit     
Inspection of the compressor stage *     
Maintenance every 8000 h, although at least each year:
Checking/tightening of connecting terminals in the switch cabinet/ and
  
checking of the “control transformer” setting
Checking/tightening screw connections   
Checking/cleaning water level sensor  
Replace pressure holding non-return valve *  
General maintenance/cleaning  
Safety valve / functional test at least once a year  
Maintenance every 16000 h, although at least every 2nd year:
Replace RO membrane 
Rework/replace water valves * 
Inspection every 4 years:
Inspection of the electrical installation by a qualified electrician
Internal inspection of the pressure vessel by a qualified person
Strength test of the pressure vessel by the appointed body
 These maintenance intervals must be observed!
x For your own benefit, put a cross on the servicing schedule against maintenance work when performed.

* We recommend that you have the work on these parts be performed by a CompAir company or by an authorised
dealer.
40
33 m 22,000 h












36 m 24,000 h
39 m 26,000 h





42 m 28,000 h
45 m 30,000 h













     



48 m 32,000 h
51 m 34,000 h





54 m 36,000 h
57 m 38,000 h













60 m 40,000 h
63 m 42,000 h





66 m 44,000 h
69 m 46,000 h















72 m 48,000 h
75 m 50,000 h





78 m 52,000 h
81 m 54,000 h












84 m 56,000 h
87 m 58,000 h





90 m 60,000 h
93 m 62,000 h
















96 m 64,000 h
99 m 66,000 h





102 m 68,000 h
105 m 70,000 h












108 m 72,000 h
111 m 74,000 h





114 m 76,000 h
117 m 78,000 h
41














                       



120 m 80,000 h
9.4 Change of air intake filter Changing intervals for air filter cartridge
The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong
influence on the service life of the filters (air filters,
water filters, fine separators).
Where such conditions exist the filter element may

require changing more frequently.
Change the air filter as follows:
• Pull snap latch outward and remove housing base.

• Detach air filter cartridge while slightly turning it.
• Carefully insert new air filter cartridge in the housing.
• Close air filter with housing base. The snap latches
must click into position.
9.5 Change water filter

Fig. 20
1 Air intake filter
Danger
Only perform checks and carry out work on the

screw compressor when the unit is out of
operation, depressurized, and secured from being
switched on again!
Important
Never operate the screw compressor unit without

the air filter (even a short operating time without
this filter can result in considerable damage to the
machine)!
As a standard, the air filter is provided with a visual in-
take filter monitor, which indicates clogging of the air
filter cartridge.
When the red service field of the intake filter monitor is
visible and remains clicked into position while the screw
compressor is out of operation, replace the air filter
Fig. 21
cartridge.
1 Water filter
However, the air filter cartridge should be replaced at
2 Extraction site for water sample
the latest as specified in chapter 9.3. Check air filter at
least once a week or, if required, daily for the accu-
Danger
mulator of dust. When carrying out maintenance work,
make sure that no dirt gets to the clean air side of the Only change water filter when the compressor
air filter. system has been shut down and depressurized!
Make sure that it is leak tight!
You will find the changing intervals listed in the
maintenance schedule.
42
Perform the water filter change as follows: Note

• Turn off compressor and make sure that it is Before the prefilter element can be installed, the
depressurized and volt-free. element should be rinsed out with clean water so that
• Let cooling water drain off via the extraction site all coaldust has been removed.
(-2- Fig. 21) and drain screw on the water filter
housing (-1- Fig. 21).
Perform the prefilter change as follows:
• Open filter housing and remove filter elements.
• Close the main water supply connection and valve
• Clean the filter head and insert a new housing seal. on the storage tank.
• Insert a new filter element and close filter housing • Screw off the filter housing (-2- Fig. 22) and remove
again. the filter element.
• Re-close drain valve and screw. • Insert a new filter element and hand tighten the filter
housing.
Changing times for the water filter • Re-open the main water supply and the storage tank
valve.
The operating conditions (e.g. cooling medium
temperatures), the operating modes and the quality of
the suctioned air (e.g. dust content, content of gaseous Changing times for prefilter RO unit
foreign matter such as SO2, solvents, etc.) has a strong
influence on the filter service life. You will find the changing intervals listed in the
In these operational cases, shorter change intervals are
possible. The quality of the main water supply has a strong
influence on the filter service life.
In the event of unfavourable conditions, shorter
9.6 Replace prefilter RO unit changing intervals are possible.
In order to determine the water quality, a water sample
can be extracted as needed (see- Fig. 21).
9.7 Change the RO membrane cartridge
Danger
Only perform all controls and works after the

compressor system has been shut down and
depressurized!
Change the RO membrane cartridge as follows:

• Close the main water supply connection and valve
on the storage tank.
• Remove the lines to the membrane (-1- Fig. 22).

Fig. 22 • Remove the old membrane cartridge and replace
with a new one.
1 RO membrane cartridge
2 Prefilter RO unit • Refit lines to the RO membrane cartridge.
3 Permeate pump
• Re-open the main water supply and the storage tank
Danger valve.
Only perform all controls and works after the

depressurized!
43
9.8 Safety valve 9.9 Connecting terminals in the switch

cabinet/control transformer setting
Danger
In the case of electric voltage:

• Actuate STOP button at the operating panel
• Set the customer-fitted main power switch to
"O" (OFF).
The connecting terminals in the switch cabinet have to
be checked and, if required, re-tightened during first
commissioning and later on in line with the maintenance
schedule.
The setting of the control transformer must be checked

according to chapter 6.4 “Electrical connection”.
Fig. 23
9.10 Fittings
1 Safety valve
2 Valve cap The fittings of the air and water circuits have to be
checked and, if required, re-tightened according to the
Testing the safety valve
Check the hose and piping for unsealed areas.
The valve should be tested on a separate compressed
air line in accordance with local legislation.
Operate the safety valve (- 1 - Fig. 23), depending on 9.11 General maintenance and cleaning
the type of valve:
Important
Slightly turn the valve cap (-2- Fig. 23) (1-2 turns), and
then re-close it. Blow off the screw compressor unit with
compressed air at the specified intervals (never
Actuation of the bleeding lever/pulling ring
direct compressed air towards persons) paying
Danger particular attention to:
Never operate a screw compressor system with a • Regulating elements

defective safety valve or without safety valve! • Fittings
• Compressor block
• Cooler
• Electric motor
• Remove and clean the dirt trap strainer
(W-version only)
44
9.12 Clean / change filter with cooling air b) Control-cabinet inlet filter (-4- Fig. 24)
(D37H RS only)
inlet and control cabinet inlet
Fig. 25
Fig. 24
1 Filter mat cooling air inlet

2 Mounting bolts
3 Sound-proofing element
4 Inlet filter (only D37H RS)
Danger
Only perform filter mat change after the

depressurized!
a) Filter mat cooling air inlet (-1- Fig. 24)

Fig. 26
Perform filter mat change as follows:
Perform filter mat change as follows:
• Remove fixing bolts (-2- Fig. 24).
• Open the louvred grilles of the inlet filter (Fig. 25).
• Take out the filter mat (-1- Fig. 24) and clean it,
replace it if damaged. • Remove the filter pad.
• Return the filter mat to the silencer chamber • Insert the new filter pad into the louvred grille.
(-3- Fig. 24). Ensure that the smooth side (-A- Fig. 26) of the filter
pad faces the air inlet side.
• Secure the filter mat using the fixing bolts.
• Place the louvred grille back onto the filter housing.
Cleaning:
Changing times for the filter mat
Clean the filter mat by brushing or washing.
The operating modes and the quality of the suctioned
Important air (e.g. dust content) has a strong influence on the filter
service life.
Never install the filter mat in a wet or moist state!
The filter should be checked on a weekly basis,
eventually daily basis, for dust build-up.
In these operational cases, shorter change intervals are
possible.
45
9.13 Inspection of the compressor stage 9.14 Inspection intervals for pressure
vessels and electrical installations
Pressure vessels
As per the requirements of the 97/23/EC Pressure
Equipment Directive, a qualified person must inspect
the pressure vessel from inside every five years.
As per the requirements of the 97/23/EC Pressure

Equipment Directive, an appointed body must perform a
strength test on the pressure vessel after ten years.
Electrical installation
The electrical installation must be inspected by a
qualified electrician after four years and also each time
work has been performed on it.
Should stricter inspection intervals apply in your

country, these must be observed.
Fig. 27
Danger

switched on again!
Caution when draining hot water: risk of scalding!
Allow the unit to cool down first.
Important
When removing the cover, water (12 litres) may

escape from the compressor. Please place an
appropriate vessel underneath it to collect the
water.
Perform an inspection as follows:
• Shut down the machine.

• Switch off the main switch or disconnect the
machine from the power supply.
• Remove the retaining bolts from the side cover of
the compressor and take off the cover (1- Fig. 27).
• Assess the condition of the compressor. The
inspection plan describes everything you need to
consider.
• Attach the side cover with a new seal. Insert the
screws to a torque of 25 Nm.
• Check the water level on the water level indicator

(-6- Fig. 15) and add water if necessary (see
Chapter 6.5 Water supply).
46
9.15 Checking the water level sensor If one of these limit values is not reached, then the
water level sensor will have to be replaced.
After the checking and possible replacement of the

water level sensor, adjust the water level in the
pressure vessel again so that it is situated between
both the fill level marks (-4- and -5- Fig. 15) once more.
Fig. 28
Fig. 29
Danger

switched on again!
Caution when draining hot water: risk of scalding!
Allow the unit to cool down first.
Check if the water level indicator on the DELCOS XL
display deviates greatly from the water level indicator
(-1- Fig. 28) on the pressure vessel.
If this is the case, or the DELCOS XL reports an error
with the water level sensor, then this should be checked
when the system is shut down as follows:
Raise the water level to approx. 50mm above the
'upper' mark of the water display indicator (-5- Fig. 15)
of the pressure vessel. The resistance value of both the
sensor connections (-1- and -2- Fig. 29) must lie
between 1376Ω and 1394Ω.
To check the lower sensor value, release the
connecting line from the lower screw connection of the
water level sensor. Drain the water level sensor into a
container provided. The drained water level sensor
must have a resistance at both the connections
(-1- and -2- Fig. 29) of between 990Ω and 1010Ω.
47
10. Trouble-shooting
10 Trouble-s hooting
In the case of faults or warnings that are detected by the compressor control DELCOS XL, please refer to the
chapter “Fault/warning table” in the operating instructions of the DELCOS XL.
Malfunction Possible cause Remedy
Unit cannot be started 1. No operating or control voltage 1. Check fuses, main switch and supply line
2. Malfunction not acknowledged 2. Acknowledge fault message
3. Pressure reservoir not depressurized 3. Wait until depressurized

Screw compressor does not start up,
when reservoir pressure is
> 1,0 bar/14,5 PSI (D37H RS) or
> 0,4 bar/5,8 PSI (D37H)
4. Electric motor defective 4. Check connections, winding, etc.
5. Compressor defective 5. Turn the compressor manually; if

required, replace
6. Ambient temperature less than 6. Make sure that the ambient temperature
+2 °C/35.6 °F is not less than +2 °C/35.6 °F; install an
auxiliary heater, if required
7. Remote control/timer has been activated 7. Deactivate remote control/timer
8. Mains pressure exceeds the lower 8. Wait until the mains pressure has fallen
switching point below the lower switching point
Unit stops during the 1. Short-circuit in the unit 1. Determine and eliminate cause; replace
start-up phase defective fuses
2. Connecting terminals in the switch 2. Check and re-tighten

cabinet are loose
3. Maximum motor switching cycles 3. Avoid frequent manual on and off-

exceeded due to too frequent manual on switching, let electric motor cool down
and off-switching
Unit does not reach 1. Mains pressure sensor set too low 1. Check, re-set
the set mains
pressure 2. Excessive air consumption 2. Reduce consumption or cut in a further
compressor
3. Air filter clogged 3. Replace air filter cartridge
4. Heavy leakage in the compressor system 4. Check unit
Unit switches off 1. Ambient temperature too high 1. Ventilate compressor room
2. Electric motor defective 2. Check electric motor and thermistor
3. Fan defective 3. Check/replace fan
4. Sensor, connections or lines defective 4. Check sensors, connections and lines
5. Cross section of the electric supply lines 5. Measure power requirement, if

too small necessary, replace lines
6. Water level too low 6. Manage the water level sensor and
water intake
7. Excessive water temperature 7. Check water cooler and fan/ Check

water thermostat
48
10. Trouble-shooting
Malfunction Possible cause Remedy
Excessive idling 1. System not unloaded 1. Check intake regulator Check solenoid
pressure valves
Water in the air filter 1. Water stop valve not closing 1. Check/ replace water stop valve
Safety valve opens 1. Safety valve defective 1. Replace
2. Pressure holding valve defective 2. Check / Replace
3. Mains pressure sensor defective 3. Replace mains pressure sensor
4. Electronics defective 4. Replace electronics
Danger
Never operate the screw compressor with defective safety valve!
49
11. Annex
11 Annex
11.1 Technical data
11.1.1 Technical data EUROPE version D37H RS

Technical data 50 Hz / 60 Hz D37H RS
Maximum operating pressure bar 10.0

Minimum operating pressure bar 5.0
Ambient temperature °C + 2 / + 40
at min. speed at max. speed

3
5 bar Flow m /min 1.25 6.87
3
8 bar Flow m /min 1.19 6.05
3
12 bar Flow m /min 1.08 5.29
Discharge temp. of air above ambient temp. °C 18 (at max. rpm)
Final air pressure temperature above water inlet temperature °C 9 (at max. rpm)
Sound pressure level (to Cagi Pneurop PN8NTC2) 400V/50Hz dB(A) 71 (at 70% load)
Sound pressure level (to Cagi Pneurop PN8NTC2) 460V/60Hz dB(A) 75 (at 70% load)
Nominal electric motor power kW 37
Voltage (frequency) V 380 - 460V (50, 60Hz)
Max. total current consumption at 380V/400V/440V/460V A 85 / 81 / 72 / 68
Motor protection type IP23 switch reluctance motor
Nominal speed min./max. 1/min 750 / 3400
Nominal fan motor power 400V/50Hz (460V/60Hz) kW 2 x 1.1 ( 2 x 1.6)
Fan motor water-cooled version KW 0.12

2
Recommended cable cross-section 380V/400V/440V/460V mm 3 x 35 PE 16
Recommended fuse size 380V / 400V / 440V / 460V A 100 AgL

3
Cooling air flow through ventilator (W-Version) m /min 125 (25)
Cooling air outlet temperature above ambient temp. °C 16
Max. allowable pressure drop in duct at ambient 20°C / 40°C Pa 70 / 0
Max. cooling water quantity l/ min 60
Cooling water inlet temperature °C + 5 / + 35
Cooling water outlet temperature (max.) °C +15 / + 45 (55)
Cooling water pressure bar 2-5
Cooling water connection (inlet/outlet) G1" / G 1"
Compressor water filling l 45
Drinking water consumption in 24h (at 3.5bar water mains pressure) l 14 (for one water change)
Drinking water mains pressure min. / max. bar 2.2 / 6.0
Compressed air connection EN 10226 R 1 1/4" (DIN 2999-R 1 1/4)
Water connection 2 x G 3/8"
RO water drain connection 1x G 1/4"
Weight [dry] air-cooled / water-cooled kg 970 / 870
Dimensions L x W x H mm 1722 x 920 x 1659
50
11. Annex
11.1.2 Technical data EUROPE version D37H

Technical data D37H D37H-W
Maximum operating pressure bar) 8 10 8 10

Minimum operating pressure bar 5.0
Ambient temperature °C + 2 / + 40
3
Flow m /min 5.86 5.04 5.86 5.04
Discharge temp. of air above ambient temp. °C 18 ---
Final air pressure temperature above water inlet temperature °C --- 9

Sound pressure level (to Cagi Pneurop PN8NTC2) dB(A) 71 61
Nominal electric motor power kW 37

Voltage (frequency) V 380 - 440V (50Hz)
Max. total current consumption at 400V A 80

Motor protection type IP55 ; EFF1
Nominal speed min./max. 1/min 3000
Nominal fan motor power 400V/50Hz kW 2 x 1.1 0.12
Recommended cable cross-section 400V mm2 3 x 35 PE 16

Recommended fuse size 400V A 100 AgL
Cooling air flow through ventilator m3/min 125 25
Cooling air outlet temperature above ambient temp. °C 16 ---

Max. allowable pressure drop in duct at ambient 20°C /40°C Pa 70 / 0 ---
Max. cooling water quantity l / min --- 60
Cooling water inlet temperature °C --- + 5 / + 35

Cooling water outlet temperature (max.) °C --- +15 / + 45
Cooling water pressure bar --- 2-5

Cooling water connection (inlet/outlet) --- G1" / G 1"
Compressor water filling l 45
Drinking water consumption in 24h (at 3.5bar water mains pressure) l 14 @ 1 water change cycle
Drinking water mains pressure min. / max. bar 2.2 / 6.0
Compressed air connection EN 10226 R 1 1/4" (DIN 2999-R 1 1/4)
Water connection 2 x G 3/8"
RO water drain connection 1x G 1/4"
Weight [dry] kg 960 860

Dimensions L x W x H mm 1722 x 920 x 1659
51
11. Annex
11.2 Layout plan

(all dimensions in mm)
1 Electrical connection
E Cooling air inlet
3 Compressed air connection

Europe version outside thread: DIN 2999 - R 1 1/2
CANADA/USA-Version: NPT 1 1/2 - 11 1/2
4 Water connection
L Cooling air outlet
Fig. 30
52
11. Annex
6 Water outlet
G 3/8“ (3/8“ NPT)
7 Water inlet
G 3/8“ (3/8“ NPT)
8 Drain RO unit
G 1/4" (1/4" NPT)
9 Drain water separator
G 1/4" (1/4" NPT)
(only D37H)
Fig. 31
53
11. Annex
W version
only water-cooled version:

9 Cooling water outlet G 1“ (G1“ NPT)
10 Cooling water inlet G 1“ (G1“ NPT)
Fig. 32
54
11. Annex
11.3 Declaration of conformity
1. EC Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A
2. We, hereby declare Gardner Denver Deutschland GmbH

Argenthaler Str.11
D-55469 Simmern
that the product: Kompressor
type: D15H; D15H RS; D22H; D22H RS; D37H; D37H RS;
D50H RS; D75H RS; D110H RS
trade mark:
manufacturer no.:
in the form as shipped by us complies with the following relevant provisions:
2009/ 105/ EG 2006/ 42/ EG 2004/ 108/ EG
This machine is exempt from the Pressure Equipment Directive. Please refer to Article 1, clauses 3.3
and 3.6 for information on this exemption.
3. If the machine is modified in a way not agreed upon with us, this statement will be void.
4. Harmonised standards applied, particularly
EN 1012-1 EN ISO 12100-1+2 EN 60034 EN 61000-6-4

EN 14121-1 EN 29001 EN 60204-1 EN 61000-6-2
5. National engineering standards and specifications applied
AD-S1/2000 BetrSichV DIN 3230 VDE 0298
6. Recording agency: CompAir Drucklufttechnik -

Zweigniederlassung der
Qualitätsmanagement: Christian Mair
Simmern,
Date Signature
55
Argenthaler Str. 11
55469 Simmern
Deutschland
Tel. ++49 (0)6761 832-0
www.compair.com
e-mail: sales@compair.com
Page: 154 Of: 305
Rev.: 3

ADSORPTION DRYERS
10QFB25AC001,10QFB25AC002,
10QFB30AC001 & 10QFB30AC002

Page 1
ADSORPTION DRYERS
HEATLESS DRYER® HD SERIES
INSTRUCTIONS MANUAL
• Important Recommendations.
• Assembly.
• Operating Principle.
• Description of Sequences.
• Start-up.
• Maintenance Care.
• Appendices:
A) Prefilter and Postfilter
B) PED-902 Programmer
C) IC912LX Thermostat
D) TPR-6741 Dewpoint Measurer
E) IC915LX Dewpoint Indicator
F) Initial Filling or Desiccant Replacement Procedure
• Warranty.
This Equipment/Machine compiles with de Directives indicated in the CONFORMITY

DECLARATION, on condition that the instructions of this MANUAL are followed. In case
of interpretation problems of manual, the Spanish version is determinative.
The following basic points should be highlighted:

1. Do not dismantle any external guard on the equipment without first having:
DISCONNECTED IT FROM THE ELECTRICITY SUPPLY
DECOMPRESSED THE PRESSURE CIRCUIT
and do not reconnect/activate those before reassembling the unit.
2. Do not manipulate the internal components without at least some knowledge of the
unit and not before reading the instructions, following the enclosed circuit and
electrical diagrams.
3. Do not forget to replace all internal guards that may be included in internal
components once they have been handled.
4. In case of doubt, do not take any action. Contact previously with the Technical
# Service of AIRSEC, S.A. to ask for clarification or ask for a site visit.
HD-08/E_EN Marzo13 jb
Page 2
5. No responsibility is accepted for additions that may have been incorporated by the
installer/user.
6. AIRSEC, S.A. is responsible for the apparatus it supplies provided it is used within
the indications of this Instruction Manual.
7. The equipment must be assembled and electrically installed in accordance with

current legislation.
8. The spare parts used for maintaining the dryer must be original ones, or, failing this,
authorised by AIRSEC, S.A.
9. Changes or modifications to the design/operation of the equipment by third parties

are not permitted and, if any are made, AIRSEC, S.A. is released from all
responsibility/warranty unless it has authorised them.
Page 3
IMPORTANT RECOMMENDATIONS
The compressed fluid drying equipment Heatless Dryer® guarantee the results for which they
were built if:
the values of flow, pressure, and temperature of the compressed

fluid at the entrance of the equipment are those which were given to
us as a basis for our draft project.
the line that supplies the compressed fluid to treat is correctly made
and particularly, that when it is a very large one or when it runs by
the outside, it has a stripper that avoids the arrival of abnormal
condensate amounts to the drying equipment.
In the case that the compressed fluid temperature at the inlet of the drying equipment surpasses
the specified value, a heat exchanger (final cooler, cooled by water, air or others refrigerant flows)
should be installed to reduce it suitably. Likewise, the condensate produced in the cooling should
be eliminated by means of a stripper.
The dew point measurements are significative only when the drying equipment is working, that is,
when two drying cycles have been completed and there has been regeneration in each one of the
drying towers. Prior to this point, the measured value could be excessively influenced by the initial
conditions of the desiccant.
Page 4
ASSEMBLY
Heatless Dryer® compressed fluid dryers constitute a compact unit mounted on a frame that is
delivered tested and adjusted in our workshops.
The unit must be sited on properly levelled flooring strong enough to support its weight. It is not
necessary to have anchorage bolts because there is no mass in movement, the equipment is
highly resistant to tipping and its own weight ensures its stability. However, if considered
necessary, the unit does have anchorage holes in the frame.
It is necessary to allow enough empty space between the equipment and the
walls of the premises or nearby elements in order so there is access to all its
components and they can be worked on in maintenance, repair or replacement
operations. With a view to this, it may be appropriate to have anchorage points
for a hoist or other lifting equipment.
Once the equipment has been sited, assembly simply consists of connecting the moist fluid inlet
and dry fluid outlet conduits to the corresponding terminals on the dryer. These terminals are
identified on the drawing of the whole unit in this instruction manual.
When the unit also includes pre- and/or post-drying treatment, the moist fluid inlet
must be connected to the pre-filter and the dry fluid outlet to the post-filter. If
nothing is said, the pre-filter is situated on the left-hand side and the post-filter on
the right-hand side of the equipment if you look at it in front of the control box;
anyway, the characteristic plates indicate the function of their corresponding
element.
Note: The respective national regulations and the general engineering rules applicable to the
installation and handling of pressurised equipment must be observed and applied if
necessary.
Power supply
The connection terminals for the power supply, to which the mains phases must be connected
respectively, can be found inside the control cabinet, properly identified.
Before connecting the power supply, check that the mains voltage corresponds
to that established for this equipment. This appears on a sign next to the
connection terminals and on the data sheet in this manual.
Connect an earth wire to the uninsulated terminal fixed to the bottom of the
internal body of the control cabinet. All electrical components outside the panel
are connected to this terminal (green/yellow wire), as well as the transformer
secondary side common manoeuvre wire (if any) to ensure protection against an
insulation failure.
a Make sure the dryer’s potential equalisation continuity for earthed exposed conductive parts
has a resistance of less than Ώ1M.
Page 5
General bypass
It is generally recommended to install sectioning and bypass valves making it possible to carry
out maintenance or repair operations without interrupting the flow. In order to prevent the dry
fluid becoming contaminated via the bypass valve in normal operation, we advise you to adopt
the following assembly system.
DRYING FLUID DRY FLUID
DRYER
In normal operation, the drain tap (5) will be open, so any leak from the valves (3) or (4) will be
detected.
When the moist fluid is circulated downwards, an accumulation of water in the section without
circulation before the valve (3) is to be expected. For this reason it is advisable to take the
precaution of partially opening this valve before closing the tap (5) when the bypass conduit has
to be used.
It will be understood that placing the tap (5) in the pipework section near the
valve (4) will make it easier to expel the water.
a If the fluid is classified under ATEX regulations, the above bypass assembly
diagram may not be the best one.
Filling with desiccant
The dryer in the Heatless Dryer® series leaves the factory with a load of desiccant contained
within the columns provided transport circumstances allow this.
Planning start-up
Once assembly is completed, the equipment is ready to be started up for the first time. This
operation does not generally require our involvement. It can be carried out by any person with
judgment based on the indications given in this Manual.
# If our presence is required, we will send a specialist technician. In this case the rates for
assembly and technical assistance services accompanying our offers will apply. For
scheduling requirements, we need to know the planned start-up date not less than 5
working days in advance.
Page 6
OPERATING PRINCIPLE
The compressed fluid to be treated is made to circulate through one of the two columns making
up the dryer, where, as it comes into contact with the desiccant, it passes almost all the water
vapour it contains to it by the physics phenomenon known as “adsorption”.
The residual vapour remaining in the compressed fluid after the drying process is evaluated
indirectly according to its dewpoint; that is, the lowest temperature the fluid (previously
depressurised to normal atmospheric pressure) can be taken to without the remaining vapour
condensing.
To determine the dewpoint, an appropriate measuring instrument is required. This does not
form part of our standard equipment, but can be incorporated (or supplied separately) on
demand. To make it easier to take samples of dry fluid, on certain models of HD type dryer
there is an angular tap with needle shut-off at the dryer outlet making it possible to adjust the
flow going to the measurer, which is connected to this tap with a copper pipe and 1/4' SAE nut.
Under normal operation, the value measured must remain below the one indicated on the data
sheet in this manual.
Each of the two columns making up the dryer has sufficient adsorption capacity to treat the
compressed fluid flow under the specified conditions for a particular period of time (semi-circle).
After this, the drying process must be interrupted to regenerate the desiccant. The time required
for this regeneration is always less than a semi-cycle so an uninterrupted drying process is
achieved with both towers, as one is always in the drying phase and the other in the
regeneration phase.
Regenerating the desiccant means re-establishing its original capacity to adsorb water vapour.
The different types of adsorption dryer included in our manufacturing programme are
characterised precisely by the procedure used in this operation. The units of the Heatless
Dryer® series belong to the group of so-called “heatless regeneration dryers” because they do
not heat the desiccant to regenerate it.
The principle of the Heatless Dryer® regeneration process consists of circulating a flow of fluid
through the inside of the column to be regenerated with an extraordinarily low vapour pressure,
which is obtained by depressurising a fraction of the flow of dry fluid present at the equipment
outlet to atmospheric pressure. Because of the low vapour pressure, the water retained by the
desiccant is vaporised at operating temperature, without the need for heating, and it passes the
vaporisation heat to the desiccant which has accumulated it during the adsorption process. This
regeneration fluid carries the water vapour outside the dryer.
The regeneration process is developed at atmospheric pressure, so it is necessary to

decompress the column to be regenerated before beginning the process and take it back to
operating pressure (pressurisation) once it is completed. The column is pressurised with a
fraction of the process fluid from the dryer outlet and this goes on until the end of the semi-cycle
(change of column). During this period, the flow of treated process fluid accumulates inside the
column, gradually raising its pressure until the operating value is reached. To reduce the time
needed to pressurise the regenerated column, a pressurisation valve is used, increasing the
section of the air passage when it is opened in the pressurisation phase.
All the manoeuvres necessary for the operation of the equipment in accordance with the
operating principle described here are carried out entirely automatically using a control system
run by a PED-902 programmer controlling the dryer valve system.
Page 7
DESCRIPTION OF SEQUENCES
The dryer operating sequence is determined by the different phases described below:
1) The initial operating sequence situation is considered to be the one where the column 1
dryer is in service, drying the process fluid, and column 2 is pressurised awaiting the
change of semi-cycle. The VE (Column 1) valve is open and the dryer’s other valves are
closed.
2) Start of the new semi-cycle, change of column in service to the one that is regenerated and
pressurised. The VE valve is set to column 2.
3) Decompression of the column to be regenerated and start of regenerating column 1. The

VSR1 valve is opened. The quantity of air required to regenerate the adsorbent bed is
passed through the AR1 gauge.
4) Once the regeneration phase is over, the regenerated column pressurisation phase begins.
The VSR1 valve is closed. The treated air to pressurise the column continues to be passed
via the AR1 gauge. The pressure in the column increases until it reaches operating
pressure.
5) The dryer operating sequence is repeated in the way described for column 2, which has
just gone into regeneration phase.
Incidents during the normal operation of the drying equipment
a) If the MSA pressure switch detects a pressure lower than that set for the air treated by the
dryer, the VSR valves will close, interrupting the adsorbent bed regeneration process. The
equipment will appear to continue operating normally, but the deficiency must be corrected
as soon as possible because there is the risk that the quality of the treated air will be poorer
(worse dewpoint) and that the necessary adsorbent material regeneration will not take
place correctly.
A lower operating pressure means an apparent increase in the flow of air to be treated and,
therefore, a larger quantity of water at the dryer inlet, which has not been designed for this.
In addition, a lower operating pressure means the air flow needed to regenerate the
columns passing through the AR orifice plates is lower. Poorer outlet air quality
subsequently affects the proper regeneration of the bed of adsorbent material, as a fraction
of the outlet air is used as regeneration air, setting off a vicious circle in successive
drying/regeneration cycles. Also bear in mind that a lower operating pressure will affect the
control air pressure reducer, which will cause a malfunction in the opening/closing of the
dryer process valves.
b) If the TEA temperature probe detects a higher temperature at the dryer inlet, the equipment
will appear to continue operating normally, but the deficiency must be corrected as soon as
possible, as there is the risk that the quality of the treated air will be poorer (worse
dewpoint).
A higher air temperature at the dryer inlet means an increase in the quantity of water, for
which it has not been designed.
Page 8
Poorer outlet air quality subsequently affects the proper regeneration of the bed of
adsorbent material, as a fraction of the outlet air is used as regeneration air, setting off a
vicious circle in successive drying/regeneration cycles.
c) If the TPR dewpoint measurer sensor detects a quality of air treated by the dryer worse
than -35ºC, with the value measured at operating pressure, it shows an alarm, so that the
possible causes of the anomaly can be analysed as soon as possible.
Incidents during the abnormal operation of the drying equipment
a) The inside of the dryer columns are full of an adsorbent material. This adsorbent material is
presented as partially spherical balls, with a grain size between certain values.
To achieve good treated air quality (dewpoint) it is necessary to keep the adsorbent
material in optimum condition at all times. It must be replaced once the end of its useful life
has been reached. In addition, to preserve all its characteristics and avoid damaging its
useful life, movements of the adsorbent bed due to air pressure surges within the columns
must be prevented. All movements of the adsorbent bed cause the phenomenon of attrition:
the balls of adsorbent material are eroded due to rubbing between them, causing a
reduction in the amount making up the bed and the appearance of dust from the adsorbent
material which will saturate the filtration elements of the post-filters.
Special care must be taken in the following cases so as not to cause the attrition
phenomenon in the adsorbent bed.
1. When the dryer is started up together with the air compressor (both begin operation)
the pressure increase must be gradual so as not to cause pressure surges in the
dryer. The pressure/time curve should not be greater than a dryer semi-cycle.
2. When the dryer is started up, as there is upstream pressure, the dryer must be
pressurised gently. It may be that the dryer is already pressurised (one of the
columns is already pressurised) when the compressor is started up. In this case,
make sure the dryer is started up at the same time as the column that needs to treat
the process air with the column already pressurised. Otherwise, the depressurised
dryer column would be pressurised suddenly, causing a pressure surge and eroding
the adsorbent bed.
Dryer unit safety equipment
The safety position consists of closing all the dryer valves. This minimises loss of process air as
far as possible. As the inlet valve is a three-way one and the outlet valves are of the non-return
flap type, air passage through the unit is guaranteed. If the safety position situation lasts more
than a semi-cycle, the dryer outlet air quality will be reduced because the bed of adsorbent
material will be over-saturated.
Page 9
STARTING UP
Once unit assembly is complete, start it up in the following order of operation.
Pressurisation
Open the unit’s compressed fluid inlet valve very slowly to make pressurisation gradual,
avoiding setting speeds that are too high and which could damage the desiccant and break the
filtration elements.
It will be observed that the pressure gauge on one of the drying columns shows the gradual
increase in pressure immediately, while the one on the other column does so slowly. When one
of them has reached operating pressure, fully open the inlet valve and leave it in this position.
Start-up
When the pressure gauges on both columns indicate the operating pressure, turn on the load
breaker switch “SG” on the side of the control cabinet.
One of the pilot lights “Drying column 1” or “Drying column 2” corresponds to the
current position of the programme.
One of the following situations will also appear, also depending on the position of programme:
1) Pressurisation: The decompression/regeneration outlet valves remain closed. The

“pressurisation” light comes on.
2) Regeneration: The decompression/regeneration outlet valve corresponding to the

column not in the drying phase opens, putting the “Regeneration” light on. The tower
is decompressed in a few seconds and the flow of the flushing fluid which is
discharged into the atmosphere through this valve is established.
Note: On its screen, the PED-902 drying unit programmer indicates the programme time, the
total operation time of the unit and its status.
Supervised operation test
It is advisable to follow the progress of the first cycle closely to make sure all the manoeuvres
are carried out correctly. To do this, use the explanation of sequences appearing in the chapters
“Operating Principle” and “Description of Sequences”, such as the information on the indicator
lights arranged on the control cabinet.
The programming diagram represented on the control circuit diagram attached to this Manual
indicates the time interval between two consecutive manoeuvres, making it possible to space
inspection visits so that each manoeuvre can be seen and the valve position, pressure gauge
and pilot light indications, etc. can be observed before and after they are carried out.
Page 10
Checking results
After ten consecutive cycles, measure the dewpoint at the dryer outlet, which must be equal to
or lower than (higher absolute value) the one specified for the unit concerned and indicated on
the Data Sheet of this Instruction Manual.
STOP
Activates the “SG” load breaker switch, taking the control and indication system out of service.
With the control system disconnected, the equipment can remain pressurised
and even have process fluid circulating. The flow going through the equipment
under these conditions will come out just as dry but, if the situation continues, the
column in the drying phase will become saturated before the order to invert the
columns can be given.
Incidents
All equipment is tested in our workshops before it is delivered, so no operating problems at all
should be expected. If, despite this, any abnormality is noticed, please notify our Technical
Service and refrain from doing anything to the control circuit or cycle programmer settings
without consulting us first.
VERY IMPORTANT
The equipment is delivered with all parameters already set during the preparation process on
the test bench in our workshops.
Because of this, it is only necessary to take action if there is any change. Instructions on how to
handle it correctly are included in the Appendices at the end of this Manual.
Page 11
MAINTENANCE CARE
- All maintenance and/or repair actions on the dryer unit must be carried out ensuring the
complete safety of the workers involved.
- Actions must be carried out by qualified personnel trained to do such jobs on the dryer.
- Before the dryer is started up again, an airtightness test must be carried out on the parts of
the unit and its accessories that have been manipulated.
Periodic checks
It is advisable to check the operation of the unit periodically to detect any anomaly that may
appear and correct it as soon as possible. For this purpose, we consider it appropriate to check
that manoeuvres are being carried out correctly.
a Check the proper condition of the dryer’s earth connections and that it is
being maintained.
You are also advised to check the proper operation of the dryer’s electronic control equipment,
located both on the control panel and on the unit.
Replacing the desiccant
The aging of the desiccant is shown in the gradual worsening of the dewpoint even though
regeneration processes are carried out correctly. This does not cause any change in the
appearance of the product, as a visual examination of it does not allow its quality as an
adsorbent to be seen.
If this situation occurs, the desiccant filling must be entirely replaced, as its degradation from
this point onwards is rapid and irreversible.
It is also advisable to replace the load of desiccant every 10,000 hours of dryer operation.
Cleaning the unit
You are recommended to clean the surface of the dryer and its accessories periodically to
prevent an accumulation of dust and dirt that could eventually affect its proper operation.
Prolonged dryer stoppages
During periods when the dryer is out of service, it must be isolated from the exterior. This
measure is necessary so that the beds of adsorbent material inside the columns are not
exposed to and contaminated with moisture from outside.
Page 12
APPENDIX A
PREFILTER AND POSTFILTER
The CSN filter is applied indiscriminately to the dry or moist compressed gas circuits as a
treatment element when the flow comes from a lubricated compressor or when, for any other
reason, it contains or may contain oil droplets or particles that need to be eliminated. By
filtration, they retain solid particles larger than 1 micron with 99.925% effectiveness.
Maintenance
The filtration elements cannot be regenerated. In operation, they are gradually filled in by
particles of dust, oil, etc. and cannot be recovered. Maintenance therefore consists of replacing
the filtration elements at the end of their useful life, which is estimated at between 6 and 12
months of operation. The filtration elements must be replaced at regular intervals. In any case, it
is recommended that they are replaced when the average load loss between the filter inlet and
outlet reaches 0.3 kg/cm2, with the nominal flow of fluid to be treated circulating. The highest
differential pressure the filtration element can stand, regardless of the absolute pressure, is 5
kg/cm2 at 20ºC. But operation under these conditions is far from being economical because of
the compression work required to overcome the resistance of the filter.
It is necessary to periodically check that the liquid (if case) is being removed by the automatic
drain, if one is included. Otherwise, periodically drain it manually. The frequency with which the
drain is discharged varies a great deal between one installation and another, as the quantity of
liquid collected depends on the route of the moist gas conduit, its temperature and the
environmental temperature, the flow of gas actually circulated, etc. and cases when there are
several discharges a day are just as common as others with just one discharge in several days.
It is important to check that the drain shut-off taps are always open, as otherwise the automatic
drain would be out of service. We also advise you to carry out manual drainage as a safety
measure and to remove any sludge that may accumulate in the bottom part of the filter case.
Important
The filters are not designed to stand up to frequently pulsing operating pressures
of more than 10% of the maximum admissible operating pressure. Nor must they
be exposed to continuous vibrations that could cause breakage.
The fluid to be treated must not contain corrosive elements that could attack and
damage the materials making up the filter (casing and element).
All maintenance jobs must be carried out by specialised, professional personnel.
Before doing any work on the filter, the fluid circuit must be decompressed and it
must not be brought into operation again during maintenance. Once the
maintenance work has been completed, the unit must be tested for airtightness.
Any modification to the filter casing and pipes or filtration elements is prohibited.
Breach of this condition is a threat both to the safety of the machine and to the
personnel around it.
Page 13
APPENDIX B
PED-902 PROGRAMMER
The PED-902 model microprocessor/programmer/time counter is based on a 16-bit

microcontroller with 32 kbytes of reprogrammable ROM and 2 kbytes of RAM, as well as an
EEPROM storing the configuration parameters and run variables.
OPERATION
Start-up:
If, when you turn the power on, the message “System Off” appears on the screen, this
indicates that the unit is receiving power, that there has been no error and that the dryer is
out of service. In this status, both the time counter and the programmer are disabled. If,
when you turn the power on, the unit’s status and cumulative time counter of the unit’s hours
of operation appear, this indicates that the unit is in service. In this status, both the time
counter and the programmer are enabled.
Equipment status
Equipment off Current time Time counter
Dryer off/on:
To move the unit from active to inactive or vice versa, press the “ON-OFF” key and
hold it down for 3 seconds. It is recommended that once the PED-902 has been
switched on for the first time you should use the “IPM” switch on the control panel for
stopping and starting the dryer unit. On heat regeneration dryers, when the heating is
activated the equipment cannot be stopped with the “ON-OFF” key. If the “ON-OFF”
key is held down continuously for 3 seconds in this situation, the programmer will
make a conditional stop and, once the unit’s heating period is complete, it will stop
automatically.
Page 14
When the conditional stop is activated, the “?” symbol will appear in the top right-
hand corner. If you want to remove the conditional stop from the unit, you need to
hold the “ON-OFF” key down for 3 seconds again, and the “?” symbol will disappear.
Fast cycle time advance:
Pressing the ‘∧’ and ‘∨’ keys increases or decreases the time of the programmed
cycle the programmer is currently in. In order to give the different mechanical
manoeuvre elements time to stabilise, a 10-second delay time has been fixed after
the change of columns for heatless regeneration units. The delay is 20 seconds for
heat regeneration units. During this time it will not be possible to access any
programmer configuration parameter with the keyboard. If the ‘∧’ or ‘∨’ key is held
down for 4 seconds, the programmed cycle time advances rapidly.
Unit status:
The PED-902 programmer has a liquid crystal alphanumeric screen showing the
status of the unit, the cycle time and the cumulative hours of operation. The
abbreviations that appear on the screen are ‘SEC’ for Drying, ‘CAL’ for Heating,
‘REG’ for Regenerating and ‘PRE’ for Pressurising, followed by the number of the
column in which the operation is being carried out (1 for the left-hand tower and 2 for
the right-hand tower). The time base will be the one corresponding to the type of unit:
minutes for heat regeneration units and seconds for heatless regeneration units.
CONFIGURATION
The PED-902 programmer can be configured with the operating parameters from the keys
on the front and remotely from a personal computer (PC) via an RS-232 communications
port and the appropriate optional software. It is also possible to interconnect and control up
to 32 drying units with PED-902 programmers using an RS-485 communication port and
configure them remotely from a personal computer using the appropriate optional software.
To go into the configuration parameters from the keys on the front of the programmer, you
need to keep the three blue keys on the right of the front pressed simultaneously. The first
configuration parameter (Time 1) is the value of the semi-cycle or change of drying column
time. The second parameter (Time 2) is the value of the heating time for heat regeneration
equipment. Finally, the third parameter (Time 3) is the value of the regeneration time. These
three parameters are common for both columns (or semi-cycles). The value of the
parameter to be configured is increased or decreased using the ‘∧’ and ‘∨’ keys. If the ‘∧’ or
‘∨’ key is held down for 2 seconds it increases or decreases rapidly. To confirm the value
introduced and move to the next parameter you need to press the ‘SET’ key for 2 seconds.
To change the terminal number and operating mode of the unit, you need to go into the
configuration parameters and then press the red and blue ‘∧’ keys simultaneously. The first
parameter that can be changed will be the terminal number (1 by default). The second
parameter will the dryer operating mode, which is changed according to the values in the
“Operating modes table”.
Page 15
- Diagram of programming parameters -
Parameter Type of equipment

01 HD with three-way valve at inlet.
02 HD with two, two-way valves at inlet.
11 ED with three-way valve at inlet.
12 ED with two, two-way valves at inlet.
13 ED with three-way valve at inlet with disturbance.
14 ED with two, two-way valves at inlet with disturbance.
15 AA with one, three-way valve at inlet.
16 AA with two, two-way valves at inlet.
- Operating mode table -
The “Operating Mode” parameter consists of two digits. The first corresponds to the time
base of the PED-902 programmer – 0 for the time base in seconds and 1 for the time base
in minutes. The second digit corresponds to the type of chart the optional software on the
personal computer must select and represent.
Once the last configuration parameter has been confirmed with the ‘SET’ key, the
programmer moves out of configuration status and restarts the cycle it was in before (the
configuration parameters in the EEPROM are updated and both the programmer and the
time counter are restarted). If no key is pressed for 15 seconds in configuration mode, the
processor moves out of configuration status, saving the last values read.
Page 16
CONNECTION TERMINALS
A1 – A2 Analogue/Digital Input 1.
B1 – B2 Analogue/Digital Input 2.
C1 – C2 Analogue/Digital Input 3.
12 – 12 12 VAC Power Supply.
PW – PW On/Off Contact.
CO Common.
T1 Column 1 Contact.
T2 Column 2 Contact.
K1 Heating Contact 1.
K2 Heating Contact 2.
R1 Regeneration Contact 1.
R2 Regeneration Contact 2.
TECHNICAL SPECIFICATIONS
Power supply voltage: 12 VAC + 20% -10% 50/60 Hz

Consumption: 200 mA max
Time base: Quartz crystal - 150 ppm
Output: Voltage-free relays
Maximum switching voltage: 250 VAC
Maximum switching current: 3A
Maximum switching power: 750 VA
Operating temperature: 0 to 50 °C
Storage temperature: -20 to 85 °C
Dimensions: 96 x 48 x 131 - DIN43700
(dimensions in millimetres)
Page 17
APPENDIX C
IC912LX THERMOSTAT
DRYER INLET TEMPERATURE INDICATOR/ALARM.
The IC912 series regulator installed in the drying equipment is a controller with a wide range of
features, of which only those concerning temperature control are used, so it acts only as a
maximum thermostat.
The configuration parameters and how to change them are indicated below. The unit, and with it
the temperature regulator, is delivered already set and checked, so only the configuration
parameters that it might be necessary to change in the field, in relation to actual working
conditions based on the established theories, are mentioned.
Changing the set point:
If you press the ‘SET’ key, the ‘SET’ folder will be displayed. To see the established set point,
press the ‘SET’ key again.
The outlet relay activation value will be the set point, adding the value of the programmed
differential. Depending on whether you want the outlet relay to act before or after the set point,
you will need to configure the HC parameter of the thermostat as appropriate (Heat or Cool
mode).
To change the value of the set point you need to press the ‘SET’ key until the set point value
appears (twice) and use the ‘Up’ and ‘Down’ keys to change the value. To confirm the new
value you need to press the ‘SET’ key.
If no key is pressed for 15 seconds or if the ‘FNC’ key is pressed, the instrument goes back to
its default status.
Changing the parameters:
If you hold down the ‘SET’ key for 5 seconds, you access the thermostat configuration
parameters. The configuration parameters are grouped in folders. To access the parameters in
each folder it will be necessary to go back and press the ‘SET’ key and use the ‘Up’ and ‘Down’
keys to move through the different parameters. To get out of a folder or a configuration
parameter you need to press the ‘FNC’ key (move up a level from where you are).
Page 18
To change the value of a parameter you need to press the ‘SET’ key and use the ‘Up’ and
‘Down’ keys to change its value. To confirm the new value, press the ‘SET’ key.
its default status.
The folders and their configuration parameters are as follows:
‘rE1’ folder: HC1, db1, dF1, HS1, LS1, dn1, dO1, di1, dE1, On1, OF1.
‘AL’ folder: PAO, SAO, tAO.
‘Add’ folder: dEA, FAA.
‘diS’ folder: LOC, PA1, ndt, CA1, dro.
‘CnF’ folder: H00, rEL, tAb.
‘FPr’ folder: Fr.
The job required of the temperature controller largely uses the configuration parameters
mentioned in the following table. Of course, all the thermostat parameters have been configured
at origin and they must not be changed under any circumstances.
Set values
Parameter Description Units
Inlet
HC1 Heat/Cold Mode - C
dF1 Differential set point °C 1
HS1 Set point upper limit °C 60
LS1 Set point lower limit °C 0
rE1
dn1 Switch-on delay min 0
dE1 Switch-off delay min 0
On1 - 1
Faulty probe → outlet relay on
Of1 - 0
ndt Decimal point display - n
DiS CA1 Calibration °C 0
dro Type of temperature degree - C
CnF H00 Probe type selection - Ptc
Inlet set point = Inlet temperature +1ºC
Page 19
APPENDIX D
TPR-6741 DEWPOINT MEASURER (+30ºC / -60ºC)
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0
HD-08/E_EN Marzo1
13 jb
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Page 43
APPENDIX E
IC915LX DEWPOINT INDICATOR
TEMPERATURE REGULATOR FOR TWO STEPPED STAGES.
The regulator installed in the equipment, from the IC915 series, is a controller with a wide range
of features, of which only those concerning temperature control are used, so it acts only as a
two-stage thermostat.
The configuration parameters and how to change them are indicated below. The unit, and with it
the temperature regulator, is delivered already set and checked, so only the configuration
parameters that it might be necessary to change in the field, in relation to actual working
conditions based on the established theories, are mentioned.
Changing the set point:
If you press the ‘SET’ key, the ‘SP1’ (set point 1) folder will be displayed and, using the ‘Up’ and
‘Down’ keys, you can display the ‘SP2’ (set point 2) folder. To see the established value for
each set point, press the ‘SET’ key again on the folder of the desired set point.
The outlet relay activation value will be the set point, adding the value of the differential
programmed for each set point. Depending on whether you want the outlet relay to act before or
after the set point, it will be necessary to configure the HC parameter of each thermostat set
point as appropriate (Heat or Cool mode).
To change the value of the set point you need to press the ‘SET’ key on the desired set point
folder and use the ‘Up’ and ‘Down’ keys to change the value. To confirm the new value you
need to press the ‘SET’ key.
its default status.
Changing the parameters:
If you hold down the ‘SET’ key for 5 seconds, you access the thermostat configuration
parameters. The configuration parameters are grouped in folders. To access the parameters in
each folder it will be necessary to go back and press the ‘SET’ key and use the ‘Up’ and ‘Down’
keys to move through the different parameters.
Page 44
To get out of a folder or a configuration parameter you need to press the ‘FNC’ key (move up a
level from where you are).
To change the value of a parameter you need to press the ‘SET’ key and use the ‘Up’ and
‘Down’ keys to change its value. To confirm the new value, press the ‘SET’ key.
its default status.
The folders and their configuration parameters are as follows:
‘rE1’ folder: HC1, db1, dF1, HS1, LS1, HA1, LA1, dn1, dO1, di1, dE1, On1, OF1.
‘rE2’ folder: HC2, db2, dF2, HS2, LS2, HA2, LA2, dn2, dO2, di2, dE2, On2, OF2.
‘AL’ folder: PAO, SAO.
‘Add’ folder: dEA, FAA.
‘diS’ folder: LOC, PA1, ndt, CA1.
‘CnF’ folder: H00, H01, H03, H04, H10, rEL, tAb, PA2.
‘FPr’ folder: UL, dL.
When you press PA2 the folders are prepared in installer mode:
Installer mode folder ‘diS*’: LdL, HdL.
The job required of the temperature controller largely uses the configuration parameters
mentioned in the following table. Of course, all the thermostat parameters have been configured
at origin and they must not be changed under any circumstances.
Parameter Description Units Configured value

HC1 Heat/Cool Mode H/C C
dF1 Differential set point - 1
HS1 Set point upper limit - 30
rE1 LS1 Set point lower limit - -60
di1 Outlet delay min 0
On1 - 1
OF1 - 0
HC2 Heat/Cold Mode H/C C
dF2 Differential set point - 1
HS2 Set point upper limit - 30
rE2 LS2 Set point lower limit - -60
di2 Outlet delay min 0
On2 - 1
OF2 - 0
CA1 Calibration °C 0
diS
ndt Decimal point display n/y n
Page 45
LdL Lower display limit - -60

diS*
HdL Upper display limit - 30
H00 Probe type selection - 420
H03 Lower current input limit - -60
CnF
H04 Upper current output limit - 30
H10 Output delay at switch-on min 0
Set point 1 = -35 / Set point 2 = -35
Page 46
APPENDIX F
INITIAL FILLING OR DESICCANT REPLACEMENT PROCEDURE
This procedure details the operations that must be carried out for replacing or initial filling with
the adsorbent material used in the columns of AIRSEC adsorption dryers.
1. Before undertaking any work on the dryer it must be switched off, without power and
depressurised.
2. If the process fluid is hazardous and/or harmful to health, the insides of the columns must
have been efficiently flushed before opening (using clean air or inert gas) leading to venting
with flame or similar.
3. Open the loading apertures at the top of the columns on the back.
4. Open the discharge apertures at the bottom of the columns at the level of the grille. To
prevent the possible sudden, uncontrolled flow of adsorbent material, it is recommended to
leave the blind flange on the discharge aperture held by a single screw at the top, sliding it
like a port to control the pouring. The containers needed to collect the load of adsorbent
material from the two columns of the drying equipment must be provided.
5. Once the adsorbent material has been discharged, blow the inside of the columns with clean
air to remove any material stuck and/or encrusted on the internal surfaces, taking care not to
damage the insides. Vacuum clean the insides of the columns as far as possible.
6. Make a visual inspection of the loading apertures to check the state of the insides. If they
are in poor condition, you must contact the AIRSEC after-sales service.
7. Close the discharge apertures and screw them up properly. Check that the joints are in good
condition and replace them if necessary.
8. Proceed to fill each column with new adsorbent material via their respective loading
apertures. It is advisable to use a wide-mouthed funnel or hopper. Loading must be carried
out by pouring in the adsorbent material slowly, avoiding possible attrition of the adsorbent
material during filling. Make sure the adsorbent material is evenly spread inside the columns
at all times. Make sure each column has been filled with the necessary load of adsorbent
material indicated on the dryer instruction manual data sheet.
9. Close the loading apertures and screw them up properly. Check that the joints are in good
condition and replace them if necessary.
10. Slowly pressurise the dryer until it reaches operating pressure. Check that the loading and
unloading apertures are properly sealed. Flush the columns with clean air by opening and
closing the drain valves quickly, removing the dust and solid remains deposited deep inside
and in their outlet pipes.
11. In time, the load of adsorbent material will settle inside the towers. It is a good idea to fill the
empty volume to the established limit to achieve optimum performance from the dryer.
Partially repeat the procedure in sections 1, 2, 3, 8, 9 and 10.
Adsorption dryers leave the factory with a load of desiccant contained within the columns,
provided transport circumstances allow this. If the columns are not loaded, apply sections 1, 2,
3, 8, 9 and 10 of this procedure to carry out the initial filling of the columns.
Page 47
WARRANTY
Equipment manufactured by AIRSEC is covered by a guarantee for 12 months from start-up or

18 months from the delivery date. Of these two periods, the first to expire will automatically
terminate the guarantee period.
Claims under guarantee must be made by the customer in writing and must be approved by
AIRSEC, if the claim is accepted as justified, also in writing.
The guarantee covers faults in materials, operation or the construction of the equipment and
AIRSEC will cover the cost of any parts replaced and the labour involved in this.
In the event that fulfilment of the guarantee only requires the replacement of defective
components, the customer must send AIRSEC the defective component as proof under the
guarantee and for assessment by AIRSEC. The customer is to collect the new component at
their own expense from AIRSEC premises. All shipping costs are to be borne by the customer.
Where it is necessary to work on a piece of equipment to repair it, the guarantee only covers
work carried out on AIRSEC premises. The customer is to bear the full cost of shipping
materials or equipment from their premises to AIRSEC and vice versa.
However, AIRSEC reserves the right, where it sees fit, to carry out work under guarantee on
the customer’s premises, in the following cases:
a) Work done by AIRSEC personnel, including the parts and labour invested in the work,
but excluding transport costs, maintenance costs, travel time and accommodation
costs for AIRSEC personnel, which are to be paid by the customer.
b) Work done by third parties authorised in writing by AIRSEC, who will be paid by AIRSEC
for the parts and labour used in the work, in accordance with a quotation previously
accepted by AIRSEC. The customer is to bear the various travel expenses incurred, such
as those listed in paragraph a) above.
Consumable components or those which require regular replacement are not covered by the
guarantee.
This guarantee will be voided by any improper handling of the equipment and/or repairs carried
out by the purchaser or a third party without written consent from AIRSEC.
AIRSEC’s maximum liability for breach of contract or for the working of the equipment will be
the purchase price of the equipment or of the component of the equipment covered by a
guarantee, regardless of the causes giving rise to such liability.
Should the purchaser suffer actual damage, direct or indirect damages or loss of earnings due
to breach of contract or defective operation of the equipment for whatever reason, AIRSEC will
bear no liability for this.
The courts and tribunals of Barcelona will be competent to settle any dispute between the
purchaser and AIRSEC, applying Spanish law. Both parties waive any other forum or right.
Page: 2029
202 of Of: 305
Rev.: 3

REFRIGERATION DRYERS
10QFB25AC003 & 10QFB25AC004

Refrigerating air dryer
RFL 500
Air cooled
EN - User’s maintenance and spare parts manual

Dear Customer,
thank you for choosing our product. In order to get the best performances out of this product, please read
this manual carefully.
To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and
strictly follow the instructions contained in this manual.
Note, these instructions are in addition to the safety rules that apply in the country where the dryer is
installed.
Before packing for shipment each RFL series refrigerated air dryer undergoes a rigorous test to ensure the
absence of any manufacturing faults and to demonstrate that the device can perform all the functions for
which it has been designed.
Once the dryer has been properly installed according to the instructions in this manual, it will be ready for
use without any further adjustment. The operation is fully automatic, and the maintenance is limited to few
controls and some cleaning operations, as detailed in the following chapters.
This manual must be maintained available in any moment for future references and it has to be
intended as inherent part of the relevant dryer.
Due to the continuous technical evolution, we reserve the right to introduce any necessary change without
giving previous notice.
Should you experience any trouble, or for further information, please do not hesitate to contact us.
2 – EN RFL 180 – 1500

Contents
1 Identification plate 6
2 Warranty conditions 6
3 Safety rules 7
3.1 Definition of the conventional signs used in this manual 7
3.2 Warnings 8
3.3 Proper use of the dryer 8
3.4 Instructions for the use of pressure equipment according to PED directive 97/23/EC 9
4 Installation 9
4.1 Transport 9
4.2 Storage 10
4.3 Installation site 11
4.4 Installation layout 12
4.5 Correction factors 13
4.6 Connection to the compressed air system 15
4.7 Electrical connections 16
4.8 Condensate drain 17
5 Start-up 17
5.1 Preliminary operation 17
5.2 First start‐up 18
5.3 Start‐up and shut down 19
6 Technical data 20

6.1 Technical data RFL 180 – 1500 3/400/50 20
7 Technical description 18

7.1 Control panel 18
7.2 Operation 18
7.3 Flow diagram (Air‐Cooled) 19
7.4 Refrigerating compressor 23
7.5 Condenser (Air‐Cooled) 23
7.6 Filter dryer 23
7.7 Capillary tube 23
7.8 Alu‐Dry module 23
7.9 Hot gas by‐pass valve 24
7.10 Refrigerant pressure switches LPS – HPS 25

RFL 180 – 1500 3 – EN

7.11 Compressor crankcase heater 25
7.12 Electronic instrument DMC24 26
7.12.1 How to switch on the dryer 27
7.12.2 How to switch off the dryer 27
7.12.3 How to display the operating parameters – INFO Menu 27
7.12.4 How a service warning is displayed 28
7.12.5 How an alarm is displayed 29
7.12.6 How to show the alarm memory – LOG Menu 30
7.12.7 How to control dryer with remote control 30
7.12.8 Operation of the failure / alarm dry contact (potential free) 30
7.12.9 Connection to serial line 30
7.12.10 How to change operating parameters – SETUP Menu 31
7.13 Electronic drainer 33
8 Maintenance, troubleshooting, spare parts and dismantling 34

8.1 Checks and maintenance 34
8.2 Troubleshooting 35
8.3 Maintenance operation on the refrigeration circuit 40
8.4 Dismantling of the dryer 40
9 Attachments 41
Exploded views – List of components 41
Electric diagrams – List of components 41
9.1 Dryers dimensions 42
9.1.1 RFL 500 42
9.2 Exploded views 43
9.2.1 RFL 500 Air Cooled 43
9.3 Electric diagrams 44
9.3.1 RFL 500 Sheet 1 of 4 44
9.3.2 RFL 500 Sheet 2 of 4 45
9.3.3 RFL 500 Sheet 3 of 4 46
9.3.4 RFL 500 Sheet 4 of 4 47

4 – EN RFL 180 – 1500

1 Identification plate
The identification plate is located on the back of the dryer and shows all the primary data of the machine. This
data should always be referred to when calling the manufacturer or distributor. The removal or alteration of
the identification plate will void the warranty rights.
2 Warranty conditions
For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty
covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and
restaurant expenses of our engineer.
The warranty doesn’t cover any responsibility for direct or indirect damages to persons, animals or equipment
caused by improper usage or maintenance, and it’s limited to manufacturing faults only.
The right to warranty repairs is subordinated to the strict compliance with the installation, use and
maintenance instructions contained in this manual.
The warranty will be immediately voided in case of even small changes or alterations to the dryer. To require
repairs during the warranty period, the data reported on the identification plate must be notified.

3 Safety rules
3.1 Definition of the conventional signs used in this manual
Carefully read instruction manual before attempting any service or maintenance procedures on the dryer.

Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not followed
properly.
Electrical hazard. Warning message indicates practices or procedures that could result in personal injury or
fatality if not followed correctly.
Danger hazard. Part or system under pressure.

Danger hazard. High temperature conditions exist during operation of system. Avoid contact until system or
component has dissipated heat.
Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may result if
precautions are not followed.

Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases
of fire.

Danger hazard. Do not operate equipment with panels removed.

Maintenance or control operation to be performed by qualified personnel only [1].

ARIA
AIR
LUFT
Compressed air inlet connection point
AIR

ARIA
AIR
LUFT
Compressed air outlet connection point
AIR

Condensate drain connection point

Cooling water inlet connection point (Water‐Cooled)

Cooling water outlet connection point (Water‐Cooled)

Operations which can be performed by the operator of the machine, if qualified.

NOTE: Text that specifies items of note to be taken into account does not involve safety precautions.
In designing this unit a lot of care has been devoted to environmental protection:
• CFC free refrigerants

• CFC free insulation parts
• Energy saving design
• Limited acoustic emission
• Dryer and relevant packaging composed of recyclable materials
This symbol requests that the user heed environmental considerations and abide with suggestions
annotated with this symbol.

3.2 Warnings
Compressed air is a highly hazardous energy source.
Never work on the dryer with pressure in the system.
Never point the compressed air or the condensate drain outlet hoses towards anybody.
The user is responsible for the proper installation of the dryer. Failure to follow instructions given in the
“Installation” chapter will void the warranty. Improper installation can create dangerous situations for
personnel and/or damages to the machine could occur.
Only qualified personnel are authorized to service electrically powered devices. Before attempting
maintenance, the following conditions must be satisfied:
• Ensure that main power is off, machine is locked out, tagged for service and power cannot be restored
during service operations.
• Ensure that valves are shut and the air circuit is at atmospheric pressure. De‐pressurize the dryer.
These refrigerating air dryers contain R407C HFC type refrigerant fluid. Refer to the specific paragraph ‐
maintenance operation on the refrigerating circuit.
Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or
misapplication. Unauthorized alterations will immediately void the warranty.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of electrical
fire.

3.3 Proper use of the dryer

This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally
contained in compressed air. Any other use has to be considered improper.
The Manufacturer will not be responsible for any problem arising from improper use; the user will bear
responsibility for any resulting damage.
Moreover, the correct use requires the adherence to the installation instructions, specifically:
• Voltage and frequency of the main power.
• Pressure, temperature and flow‐rate of the inlet air.
• Pressure, temperature and cooling water capacity (Water‐Cooled).
• Ambient temperature.
This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to the
plant in compliance with the instructions given in the following chapters.
The purpose of the machine is the separation of water and eventual oil particles present in compressed air.

The dried air cannot be used for breathing purposes or for operations leading to direct contact with
foodstuff.

This dryer is not suitable for the treatment of dirty air or of air containing solid particles.

3.4 Instructions for the use of pressure equipment according to PED directive 97/23/EC
To ensure the safe operation of pressure equipments, the user must conform strictly to the above directive and the
following:
1. The equipment must only be operated within the temperature and pressure limits stated on the manufacturer’s
data nameplate.
2. Welding on heat‐exchanger is not recommended.
3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable substances.
4. Vibration must be eliminated from the equipment to prevent fatigue failure.
5. Automatic condensate drains should be checked for operation every day to prevent a build up of condensate in the
pressure equipment.
6. The maximum working pressure stated on the manufacturer’s data nameplate must not be exceeded. Prior to use,
the user must fit safety / pressure relief devices.
7. All documentation supplied with the equipment (manual, declaration of conformity etc.) must be kept for future
reference.
8. Do not apply weights or external loads on the vessel or its connecting piping.
TAMPERING, MODIFICATION AND IMPROPER USE OF THE PRESSURE EQUIPMENT ARE

FORBIDDEN. Users of the equipment must comply with all local and national pressure
equipment legislation in the country of installation.
4 Installation
4.1 Transport
Check for visible loss or damage, if no visible damage is found place the unit near to the installation point and unpack
the contents.
• To move thepackaged unit werecommend using asuitable trolley or forklifttruck.Hand carryingis not recommended
• Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on its side or
if placed upside down.
• Handle with care. Heavy blows could cause irreparable damage.

4.2 Storage
Even when packaged, keep the machine protected
from severity of the weather.
Keep the dryer in vertical position, also when stored.
Turning it upside down some parts could be
irreparably damaged.
If not in use, the dryer can be stored in its packaging
in a dust free and protected site at a maximum
temperature of 50 °C, and a specific humidity not
exceeding 90%. Should the stocking time exceed 12
months, please contact the manufacturer.

SCC0001
The packaging materials are recyclable. Dispose of material in compliance with the rules and
regulations in force in the destination country.

4.3 Installation site

Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense
refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and performance,
overheated condenser fan motors, electrical component failure and dryer failure due to the following:
compressor loss, fan motor failure and electrical component failure. Failures of this type will affect
warranty considerations.
Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous gasses; steam
heat, areas of high ambient conditions or extreme dust and dirt.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of fire.

Minimum installation requirements:
• Select a clean dry area, free from dust, and protected from atmospheric disturbances.
• The supporting area must be smooth, horizontal and able to hold the weight of the dryer.
• Minimum ambient temperature +1°C.
• Maximum ambient temperature +50°C.
• Ensure a proper cooling air replacement.
• Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenance
operations.
The dryer does not require attachment to the floor surface.
Do not block, even partially, ventilation grid.

Avoid any possible re‐circulation of the exhaust cooling air.
Protect the dryer from air drafts or forced cooling air conditions.

4.4 Installation layout

1 Air compressor
2 Aftercooler
3 Condensate separator
4 Pre‐Filter (min. 5 micron)
5 By‐pass group
6 Dryer
7 Compressed air tank
8 Final filter
9 Condensate drain

In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend
the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the

heat exchanger.
Type A installation is suggested when the compressor operates at reduced intermittence and the total consumption
equals the compressor flow rate.
Type B installation is suggested when the air consumption can consistently change with peak values highly exceeding
the flow rate of the compressors. The capacity of the tank must be sized in order to compensate eventual
instantaneous demanding conditions (peak air consumption).

4.5 Correction factors

Correction factor for operating pressure changes:
Inlet air pressure barg 4 5 6 7 8 10 12 14
Factor (F1) 0.77 0.86 0.93 1.00 1.05 1.14 1.21 1.27
Correction factor for ambient temperature changes (Air‐Cooled):
Ambient temperature ºC 25 30 35 40 45 50
Factor (F2) 1.00 0.96 0.90 0.82 0.72 0.60
Correction factor for inlet air temperature changes:
Air temperature ºC 25 30 35 40 45 50 55 60 65 70
Factor (F3) 1.20 1.12 1.00 0.83 0.69 0.59 0.50 0.44 0.39 0.37
Correction factor for Dew Point changes:
Dew Point ºC 3 5 7 10
Factor (F4) 1.00 1.09 1.19 1.37
How to find the air flow capacity:
Air flow capacity = Nominal duty x Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)
Example:
An RFL 500 has a nominal duty of 3000 m³/h. What is the maximum allowable flow through the dryer under the
following operating conditions:
Inlet air pressure = 8 barg Factor (F1) = 1.05
Ambient temperature = 45°C Factor (F2) = 0.72
Inlet air temperature = 50°C Factor (F3) = 0.59
Pressure Dew Point = 10°C Factor (F4) = 1.37
Each item of data has a corresponding numerical factor which multiplied by the design air flow is as follows:
Air flow capacity = 3000 x 1.05 x 0.72 x 0.59 x 1.37 = 1833 m³/h
660 m³/h This is the maximum flow rate that the dryer can accept under these operating conditions.

How to select a suitable dryer for a given duty:
Design air flow
Minimum std. air flow rate =
Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)
Example:
With the following operating parameters:
Design air flow = 1000 m3/h
Factor (F1) = 1.05
Inlet air pressure = 8 barg
Factor (F2) = 0.72
Ambient temperature = 45°C
Factor (F3) = 0.59
Inlet air temperature = 50°C
Factor (F4) = 1.37
Pressure DewPoint = 10°C
In order to select the correct dryer model the required flow rate is to be divided by the correction factors relating to
above mentioned parameters:
1000
Minimum std. air flow rate = = 1636 m³/h
1.05 x 0.72 x 0.59 x 1.37
Therefore the model suitable for the conditions above is RFL 300 (1800 m³/h ‐ nominal duty).

4.6 Connection to the compressed air system

Operations to be performed by qualified personnel only.

Never work on system under pressure.
The user is responsible to ensure that the dryer will never be operated with pressure exceeding the
maximum pressure rating on the unit data tag.
Over‐pressurizing the dryer could be dangerous for both the operator and the unit.
The air temperature and the flow entering the dryer must comply within the limits stated on the data
nameplate. The system connecting piping must be kept free from dust, rust, chips and other impurities, and
must be consistent with the flow-rate of the dryer. In case of treatment of air at particularly high temperature,
the installation of a final refrigerator could result necessary. In order to perform maintenance operations, it is
recommended to install a dryer by-pass system.
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend
the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the
heat exchanger.
In realising the dryer, particular measures have been taken in order to limit the vibration which could occur
during the operation. Therefore we recommend to use connecting pipes able to insulate the dryer from
possible vibrations originating from the line (flexible hoses, vibration damping fittings, etc.).

4.7 Electricall connectio

ons
Qualifieed personneel should carrry out conneecting unit to
o the main po
ower.

Be suree to check th
he local codes in your areea.
Before connectting the un nit to the electrical

e su
upply, veriffy the dataa nameplatee for the proper
p elecctrical
inform
mation. Volltage tolerance is +/- 10%.
1 The in
nstaller is re
esponsible for supplyinng and insttalling the power
p
cablee. Be sure to provide e the prope er fuses orr breakers based on the data iinformation located on the
name eplate.
The main ns socket must be provided witth a

mains m magneto-theermal differrential bre aker
(IΔn =0.0 03A), adjussted on the e basis of the
consumpttion of the e dryer (seee the nom minal
values on n the data plate of the dryer). The
cross secction of the power supp ply cables m
must
comply w with the coonsumption of the drryer,
while kee eping into account
a als
so the amb bient
temperatu ure, the conditions
c of the mmains
installation, the leng
gth of the cables,
c and
d the
requireme ents enforcced by the e local Po ower
Provider.
CAUTION:

ATTEN
NTION SHOULD BE PAID O
ON THE ROTTATING DIREECTION OF THE COMPREESSOR!
The rotating directtion of the co
ompressor inn this machin
ne is cheched
d out by a Reeverse Phase
e Protector
(RPP).
When this protecttion trips, th

he DMC24 iss engaged (tthe alarm led flashes and the DMC24 disp
play
shows and
d ). If the
t compresssor does noot run, the rotating direection must be changed
d by
swapp
ping two phasses. These ch hanges havee to be done only by a qualified electrrician.
DO NO
OT BY PASS RPP PROTECTION: BY O
OPERATING THE MACHIINE IN WRO
ONG ROTATING DIRECTION,
THE CO
OMPRESSOR R WILL FAIL IMMEDIATELLY AND THE WARRANTY Y WILL BE VOOIDED.
Importtant: ensure that the dryeer is earthedd.
Do not t use any soc
cket adapterss at the mainns plug.
If the m
mains plug neeeds to be re
eplaced, thiss must only b
be done by a qualified eleectrician.

4.8 Condensate drain

The condensate is discharge at the system pressure.

Drain line should be secured.
Never point the condensate drain line towards anybody.
The dryer comes already fitted with an electronic condensate drainer.

Connect and properly fasten the condensate drain to a collecting plant or container.
The drain cannot be connected to pressurized systems.
Don’t dispose the condensate in the environment.
The condensate collected in the dryer contains oil particles released in the air by the compressor.
Dispose the condensate in compliance with the local rules.
We recommend to install a water‐oil separator where to convey all the condensate drain coming from
compressors, dryers, tanks, filters, etc.
5 Start-up
5.1 Preliminary operation

Verify that the operating parameters match with the nominal values stated on the data nameplate of the
dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.).
This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit could be
damaged during transportation, check the integrity of the dryer during first start‐up and monitor operation during the
first hours of operation.
Qualified personnel must perform the first start‐up.
When installing and operating this equipment, comply with all National Electrical Code and any applicable
federal, state and local codes.
Who is operating the unit is responsible for the proper and safe operation of the dryer.
Never operate equipment with panels removed.

5.2 First start-up

This procedure should be followed on first start‐up, after periods of extended shutdown or following
maintenance procedures.Qualified personnel must perform the start‐up.

Sequence of operations (refer to paragraph 7.1 Control Panel).

• Ensure that all the steps of the “Installation” chapter have been observed.
• Ensure that the connection to the compressed air system is correct and that the piping is suitably fixed and
supported.
• Ensure that the condensate drain pipe is properly fastened and connected to a collection system or container.
• Ensure that the by‐pass system (if installed) is closed and the dryer is isolated.
• Ensure that the manual valve of the condensate drain circuit is open.
• Remove any packaging and other material which could obstruct the area around the dryer.
• Activate the mains switch.
• Turn on the main switch ‐ pos. 1 on the control panel.
• The electronic instrument DMC24 shows .
• If the alarm led flashes and display DMC24 shows and the electrical power phases are not
correctly connected. Change two of the three phases on the main power supply (see paragraph 4.8)
• Wait at least two hours before starting the dryer (compressor crankcase heater must heat the oil of the
compressor).
• Ensure the cooling water flow and temperature is adequate (Water‐Cooled).
• Press key for at least 2 seconds to start the dryer: if the compressor has been shut down for enough time, it will
start up immediately; otherwise the display will show the countdown of the seconds before the compressor starts
up again, and the led flashes (max delay 5 minutes).
• Ensure the consumption matches with the values of the data plate.
• Check the rotation direction of the fan – wait for its first interventions (Air‐Cooled).
• Allow the dryer temperature to stabilise at the pre‐set value.
• Slowly open the air inlet valve.
• Slowly open the air outlet valve.
• Slowly close the central by‐pass valve of the system (if installed).
• Check the piping for air leakage.
• Ensure the drain is regularly cycling ‐ wait for its first interventions.
CAUTION:
ATTENTION SHOULD BE PAID ON THE ROTATING DIRECTION OF THE COMPRESSOR!
The rotating direction of the compressor in this machine is cheched out by a Reverse Phase Protector
(RPP).
When this protection trips, the DMC24 is engaged (the alarm led flashes and the DMC24 display
shows and ). If the compressor does not run, the rotating direction must be changed by
swapping two phases. These changes have to be done only by a qualified electrician.
DO NOT BY PASS RPP PROTECTION: BY OPERATING THE MACHINE IN WRONG ROTATING DIRECTION,
THE COMPRESSOR WILL FAIL IMMEDIATELY AND THE WARRANTY WILL BE VOIDED.

5.3 Start-up and shut down

For short periods of inactivity, (max 2‐3 days) we recommend that power is maintained to the dryer and
the control panel. Otherwise, before re‐starting the dryer, it is necessary to wait at least 2 hours for the
compressor crankcase heater to heat the oil of the compressor.
Start‐up (refer to paragraph 7.1 Control Panel)

• Check the condenser for cleanliness (Air‐Cooled).
• Ensure the cooling water flow and temperature is adequate (Water‐Cooled).
• The electronic instrument DMC24 shows .
• Press key for at least 2 seconds to start the dryer: if the compressor has been shut down for enough time, it will
start up immediately; otherwise the display will show the countdown of the seconds before the compressor starts
up again, and the led flashes (max delay 5 minutes).
• Wait few minutes; verify that the DewPoint temperature displayed on electronic instrument is correct and that the
condensate is regularly drained.
• Switch on the air compressor.
Shut down (refer to paragraph 7.1 Control Panel)

• Check that the DewPoint temperature indicated on the electronic instrument is within range.
• Shut down the air compressor.
• After few minutes, shut down the dryer keeping the button on DMC24 pressed for at least 2 seconds. The
display shows ..
Dryer remote control ON‐OFF

• See instructions on paragraph 7.15.7
Use dry contacts only (potential free) suitable for low voltage. Assure an adequate isolation of
potentially dangerous powered parts.
CAUTION :
AUTO‐RESTART / REMOTE ON‐OFF.
THE DRYER MAY POWER UP WITHOUT BEING ACTED UPON.
THE USER WILL BE RESPONSIBLE FOR THE INSTALLATION OF PROPER PROTECTIONS FOR POSSIBLE
SUDDEN POWER RESTORATION TO THE DRYER.
NOTE : A DewPoint within 0°C and +10°C displayed on electronic instrument is correct according to the
possible working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.).
During the operation, the refrigerant compressor will run continuously. The dryer must remain on during the
full usage period of the compressed air, even if the air compressor works intermittently.
The number of starts must be no more than 6 per hour.
The dryer must stop running for at least 5 minutes before being started up again.
Frequent starts may cause irreparable damage.
The user is responsible for compliance with these rules.
The DMC24 is fitted with internal protections to prevent the dryer from starting up too frequently.

6 Technical
T data
6.1 Technical data RFL500 3/400

0/50

7 Technical description
7.1 Control panel

The control panel illustrated below is the only dryer‐operator interface.
reset
log
ESC
info
set
T2
K 3
T4 T3
T1
PQS0047
1 Main switch
2 Electronic instrument DMC24
3 Air and refrigerant flow diagram
7.2 Operation
Operating principle ‐ The dryer models described in this manual operate all on the same principle. The hot moisture
laden air enters an air to air heat exchanger. The air then goes through the evaporator, also known as the air to
refrigerant heat exchanger. The temperature of the air is reduced to approximately 2°C, causing water vapor to
condense to liquid. The liquid is continuously coalesced and collected in the separator for removal by the condensate
drain. The cool moisture free air then passes back through the air to air heat exchanger to be reheated to within 8
degrees of the incoming air temperature as it exits the dryer.
Refrigerant circuit ‐ Refrigerant gas is cycled through the compressor and exits at high pressure to a condenser where
heat is removed causing the refrigerant to condense to a high‐pressure liquid state. The liquid is forced through a
capillary tube where the resulting pressure drop allows the refrigerant to boil off at a predetermined temperature.
Low‐pressure liquid refrigerant enters the heat exchanger where heat from the incoming air is transferred causing the
refrigerant to boil; the resulting phase change produces a low pressure, low temperature gas. The low‐pressure gas is
returned to the compressor, where it is re‐compressed and begins the cycle again. During those periods when the
compressed air load is reduced the excess refrigerant is by‐passed automatically back to the compressor via the hot
gas by‐pass valve circuit.

7.3 Flow diagram (Air-Cooled)

2 4 37
T2
P< 12.3 12.4 P> P
mA
12.2
T3 T4
6
36
1a
25
8
7 9 M
1
1b
12.1
T1 20
11 10
1c
DGF0105
13 21
1 Alu‐Dry module 12.1 T1 Temperature probe – DewPoint

1a Air‐to‐air heat exchanger 12.2 T2 Temperature probe – Air IN
1b Air‐to‐refrigerant heat exchanger 12.3 T3 Temperature probe – Compressor suction
1c Condensate separator 12.4 T4 Temperature probe – Compressor discharge

2 Refrigerant pressure switch LPS 13 Condensate drain service valve
4 Refrigerant pressure switch HPS 20 Refrigerant accumulator
6 Compressor 21 Electronic drainer
7 Hot gas by‐pass valve 25 Compressor crankcase heater
8 Condenser (Air‐Cooled) 36 Liquid separator
10 Filter dryer 37 Refrigerant pressure transducer BHP
11 Capillary tube Compressed air flow direction
Refrigerant gas flow direction

7.4 Refrigerating compressor

The refrigerating compressor is the pump in the system, gas coming from the evaporator (low pressure side) is
compressed up to the condensation pressure (high pressure side). The compressors utilized are manufactured by
leading manufacturers and are designed for applications where high compression ratios and wide temperature
changes are present.
The hermetically sealed construction is perfectly gas tight, ensuring high‐energy efficiency and long, useful life.
Dumping springs support the pumping unit in order to reduce the acoustic emission and the vibration diffusion. The
aspirated refrigerant gas, flowing through the coils before reaching the compression cylinders cools the electric motor.
The thermal protection protects the compressor from over heating and over currents. The protection is automatically
restored as soon as the nominal temperature conditions are reached.

7.5 Condenser (Air-Cooled)
The condenser is the component in which the gas coming from the compressor is cooled down and condensed
becoming a liquid. Mechanically, a serpentine copper tubing circuit (with the gas flowing inside) is encapsulated in an
aluminum fin package.
The cooling operation occurs via a high efficiency fan, creating airflow within the dryer, moving air through the fin
package. It’s mandatory that the ambient air temperature does not exceed the nominal values. It is also important to
keep the condenser unit free from dust and other impurities.

7.6 Filter dryer
Traces of humidity and slag can accumulate inside the refrigerant circuit. Long periods of use can also produce sludge.
This can limit the lubrication efficiency of the compressor and clog the expansion valve or capillary tube. The function
of the filter drier, located before the capillary tubing, is to eliminate any impurities from circulating through the
system.

7.7 Capillary tube
It consists of a piece of reduced cross section copper tubing located between the condenser and the evaporator, acting
as a metering device to reduce the pressure of the refrigerant. Reduction of pressure is a design function to achieve
optimum temperature reached within the evaporator: the smaller the capillary tube outlet pressure, the lower the
evaporation temperature.
The length and interior diameter of the capillary tubing is accurately sized to establish the performance of the dryer;
no maintenance or adjustment is necessary.

7.8 Alu-Dry module
The heat exchanger module houses the air‐to‐air, the air‐to‐refrigerant heat exchangers and the demister type
condensate separator. The counter flow of compressed air in the air‐to‐air heat exchanger ensures maximum heat
transfer. The generous cross section of flow channel within the heat exchanger module leads to low velocities and
reduced power requirements. The generous dimensions of the air‐to‐refrigerant heat exchanger plus the counter flow
gas flow allows full and complete evaporation of the refrigerant (preventing liquid return to the compressor). The high
efficiency condensate separator is located within the heat exchanger module. No maintenance is required and the
coalescing effect results in a high degree of moisture separation.

7.9 Hot gas by-pass valve

This valve injects part of the hot gas (taken from the discharge side of the compressor) in the pipe between the
evaporator and the suction side of the compressor, keeping the evaporation temperature/pressure constant at approx.
+2 °C. This injection prevents the formation of ice inside the dryer evaporator at every load condition.
ADJUSTMENT
The hot gas by‐pass valve is adjusted during the manufacturing testing phase. As a rule no adjustment is
required; anyway if it is necessary the operation must be carried out by an experienced refrigerating
engineer.
WARNING
the use of ¼” Schrader service valves must be justified by a real malfunction of the refrigerating system.
Each time a pressure gauge is connected, a part of refrigerant is exhausted.
Without compressed air flow through the dryer, rotate the adjusting screw (position A on the drawing)

until the following value is reached:
Hot gas setting : R407C pressure 4.5 barg (+0.1 / ‐0 bar)

RFL 180 – 360 RFL 400 – 900 RFL 1100 – 1500

8 mm
2 x A 5/16 in.
A +
4 mm
5/32 in.
-
VLY0001
+
VLY0003

7.10 Refrigerant pressure switches LPS – HPS

As operation safety and protection of the dryer a series of pressure switches are installed in the gas circuit.
LPS : Low‐pressure protection device on the suction side of the compressor, trips if the pressure drops below the
pre‐set value. The values are automatically reset when the nominal conditions are restored.
Calibrated pressure : R 407 C Stop 1.7 barg ‐ Restart 3.7 barg
HPS : This high‐pressure controller device, located on the discharge side on the compressor, is activated when the
pressure exceeds the pre‐set value. It features a manual‐resetting button mounted on the controller itself.
Calibrated pressure : R 407 C Stop 30 barg ‐ Manual reset (P<23 bar)
7.11 Compressor crankcase heater

At low temperatures oil can more easily be mixed with the refrigerant gas. So, when the compressor starts, oil can be
drawn into the refrigeration circuit and liquid hammering could occur.
To prevent this, an electrical resistance heater is installed in the suction side of the compressor. When the system is
powered and the compressor is not running, this heater keeps the oil at the correct temperature.
This heater is controlled by a thermo switch which prevents overheating the oil.
NOTE : The heater must be powered at least a couple of hours before the start up of the refrigeration compressor.

7.12 Electronic instrument DMC24
reset
log
ESC
info
PQS0046
set
DISPLAY
LED BUTTON
Compressor ON – green ON
DrainON – green OFF
Fan1 ON – green Increase

Fan 2 ON – green Decrease

Service warning – orange log Log

Alarm – red info Info menu

Remote control enabled ESC Drain test / ESC

Temperature in °C info
Setup menu on
set
reset
Temperature in °F Reset alarms and/or service
log

Pressure in barg
Pressure in psig
The DMC24 controls all the operations, alarms and dryer operation set‐up. The display and the leds show all the
operating conditions.
Led shows that the compressor is ON.
The operation of the fans is indicated by the leds and .
During normal operation the display shows the DewPoint temperature.

7.12.1 How to switch on the dryer

When the unit is powered the display shows .
The condensate drain test is always active through button ESC .
Press for at least 2 seconds to start the dryer: if the compressor has been shut down for enough time, it will start
up immediately; otherwise the display will show the countdown of the seconds before the compressor starts up again,
and the led flashes(max delay 5 minutes).
7.12.2 How to switch off the dryer

From any menu press for at least 2 seconds. The display shows .
7.12.3 How to display the operating parameters – INFO Menu

The info menu shows the dynamic operating parameters of the dryer.
With the dryer ON and not in other menus, press info
for at least 1 second to enter the info menu.
Access to the info menu is confirmed by message on the display (first parameter of the menu). Use the arrows
and to move to the following/previous. Press info
to show the value of the selected parameter. Press info

again to return to the list of displayable parameters.
Press ESC to exit info menu (if no button is pressed after 2 minutes the menu is exited automatically).
Info Description
T1 ‐ Temperature probe T1 – DewPoint
T2 – Temperature probe T2 – Air IN
T3 – Temperature probe T3 – compressor suction
T4 – Temperature probe T4 – compressor discharge
HP – condensing pressure HP
HrS – total hours of operation
SrV – hours until next service
Note : The temperatures are displayed in °C or °F (led or is lighted).
Pressure is displayed in barg or psig (led or is lighted).

The total hours of operation and the hours until the next service are shown in the field 0…999 hours and in
thousands of hours from 01.0 hours on (example : if the display shows number 35 it means 35 hours; if the
display shows number 3.5 it means 3500 hours).

7.12.4 How a service warning is displayed

A service warning is an unusual event that must recall the attention of operators/maintenance technicians. Generally it
does not stop the dryer (except for a high DewPoint parameter that can be set to stop the dryer).
When the service warning is active the led flashes. If the service warning is memorized (it tripped but then it
switched off by itself) led is lighted.
In both cases the display shows the DewPoint temperature and the service warnings that are active or not active but
that have not yet been reset.
Service warnings are not automatically reset (except for that can be set in auto‐reset).
reset
To RESET the service warning press the buttons log

simultaneously for 3 seconds. Only the memorized service
warning will be reset, whereas the service warning are still engaged will remain displayed and the led flashes.
NOTE: the operator/maintenance technician must inspect the dryer and verify/solve the problem that generated
the service warning.
Service Warning Description
PF1 ‐ Probe 1 Failure : failure temperature probe 1
HdP ‐ High DewPoint: DewPoint too high, higher than the HdA value set.
LdP ‐ Low DewPoint : DewPoint too low

Set T1<‐1°C (30°F) delay 5 minutes / Reset T1>0°C (32°F)
drn ‐ Drainer : condensate drainer failure (opening of contact DRN – if electronic level drainer
is installed – see electric diagram)
SrV ‐ Service : maintenance service time expired SrV
dt ‐ Discharge Temperature : compressor discharge temperature (probe T4) beyond normal
values, but within safety limits

Set T4>90°C (194°F) delay 3 minutes / Reset T4<85°C (185°F)
HCP ‐ High Condensing Pressure : condensing pressure (transducer BHP) beyond normal
values, but within safety limits

Set HP> 28barg (406psig) delay 3 minutes / Reset HP< 25barg (363psig)

NOTE: with dryer ON, but without compressed air pressure, the drainer failure notice may appear.

7.12.5 How an alarm is displayed

The alarm is an unusual event that always causes the dryer to switch OFF for the safety of the machine and the
operators.
When the alarm is active the led flashes. If the alarm is memorized (it tripped but then it switched off by itself) led
is lighted (dryer stay OFF in any case).
When the led flashes the message and the active alarm/s appear in sequence on the display.
When the led is lighted, the message and the alarm/s that tripped and require to be reset appear in
sequence on the display.
reset
The alarms are not automatically reset. To RESET the alarm the led must be lighted and the buttons log

must be pressed simultaneously for at least 3 seconds.
The dryer does not start up automatically after the alarms have been reset.
NOTE: the operator/maintenance technician must inspect the dryer and verify/solve the problem that generated
the service warning.
Alarm Description
HP ‐ High Pressure : the refrigerant high pressure safety pressure switch HPS tripped (note : the
pressure switch has a reset button)
LP ‐ Low Pressure : the refrigerant low pressure safety pressure switch LPS tripped
COn ‐ Compressor : the compressor’s protections and/or the reverse phase protector RPP tripped
FAn ‐ Fan : the fan protections tripped
Hdt ‐ High Discharge Temperature : compressor discharge temperature beyond the safety limit

Set T4>100°C (212°F) delay 1 minute / Reset T4<90°C (194°F)
ICE ‐ ICE / freezing : temperature inside the exchanger (probe T1) is too low and causes the
condensate to freeze.

Set T1<‐3°C (27°F) delay 1 minute / Reset T1>0°C (32°F)
LCP ‐ Low Condensing Pressure : condensing pressure too low
PF4 ‐ Probe 4 Failure : failure probe 4
PFP ‐ Probe Pressure Failure : failure condensing pressure trasducer BHP

7.12.6 How to show the alarm memory – LOG Menu

The log menu is the list of the last 10 alarms (only alarms, not service warning). They appear in chronological order
(LIFO logic).
log
With dryer ON or OFF and not in other menus, press for at least 1 second to enter the log menu.
Access to the log menu is confirmed by message (L01) on the display (first parameter of menu). Use the arrows
log
and to move to following/previous (L01 … L10). Press to show the selected log value. Alternatively the
parameter that generated the alarm and the hours of operation of the machine when the alarm tripped are shown.
log
Press again to return to the log list.
Press ESC to exit log menu (if no button is pressed after 2 minutes the menu is exited automatically).

NOTE: an empty position in the log list is displayed by the message .
7.12.7 How to control dryer with remote control

The DMC24 can be easily controlled using 2 digital inputs connected to terminals 1, 2 and 3 (see electric diagram).
Close the contact between the terminals 2 and 3 to enable the remote control, the led turns on and it is no
longer possible to switch the dryer ON or OFF from local panel (the condensate drain test is possible and access to info
and log menus).
Having contact between terminals 2 and 3 closed, close the second contact between the terminals 1 and 2 to switch
ON the dryer. Open the contact between the terminals 1 and 2 to switch OFF the dryer.
Use dry contacts only (potential free) suitable for low voltage. Assure an adequate isolation of
potentially dangerous powered parts.
CAUTION:
AUTO‐RESTART / REMOTE ON‐OFF

7.12.8 Operation of the failure / alarm dry contact (potential free)
The DMC24 is equipped with a dry contact (potential free) to display failure and/or alarm conditions.
Dryer powered and no service warning or alarm (active and not yet reset) displayed.
4 5 6
Dryer not powered or service warning or alarm (active and not yet reset) displayed.
4 5 6
7.12.9 Connection to serial line

The DMC24 can be connected to a supervision serial line, remote control or download of log file (memory) of alarms.
Contact your distributor or service centre for more information.

7.12.10 How to change operating parameters – SETUP Menu

The setup menu can be used to change the dryer’s operating parameters.
Only qualified personnel must be allowed to access to the setup menu. The manufacturer is not
responsible for malfunctioning or failure due to modification to the operating parameters.
info
With dryer ON or OFF and not in other menus, simultaneously press buttons set for at least 5 seconds to enter
the setup menu.
Access to the info menu is confirmed by message on the display (first parameter of menu). Use arrows and

to move to following/previous one.
Keep info
pressed to display the value of the selected parameter and use arrows and to change the value.
Release the button info
to confirm the value and skip to following parameter.
Press ESC to exit setup menu (if no button is pressed after 2 minutes the menu is exited automatically).
Standard
ID Description Limits Resolution
setup
Ton – drain time ON : time ON condensate drain valve
00 … 20 sec 1 sec 00
00 = Electronic drainer installed
ToF ‐ drain time OFF : pause time for condensate drain
valve 1 … 20 min 1 min 1
0.5 °C 20
HdA ‐ High DewPoint Alarm : Alarm threshold for a high 0.0…25.0 °C or
DewPoint (the alarm disappears when the temperature or or
drop 1°C / 2°F below alarm point) 32 … 77 °F
1 °F 68
Hdd ‐ High DewPoint Delay : high DewPoint alarm enable 01 … 20
delay 1 min 15
minutes
HdS ‐ High DewPoint alarm STOP : select if high DewPoint
alarm stops dryer (YES) or does not stop dryer (nO) YES … nO ‐ nO
SrV ‐ Service Setting: setting of service warning timer. 0.0 … 9.0 0.5

8.0
00 = service warning timer disabled. (x 1000) hours (x1000) hours
SCL ‐ Scale: display scale of temperatures and pressure.
(Note : setting °C = temperature in °C and pressure in bar; °C … °F ‐ °C

setting °F = temperature in °F and pressure in psi)
AS ‐ Auto Restart : automatic re‐start at power supply.
YES = at power supply dryer starts up again automatically (if
it was ON) YES … nO ‐ nO
nO = at power supply dryer is always OFF

Ard ‐ Auto Reset service drain : automatic reset of service

drain
YES = automatic reset at normal conditions YES … nO ‐ YES
nO = manual reset required
IPA ‐ IP Address : selection of IP address to use in serial
connection line 1 … 255 1 1
AS = YES ‐ CAUTION ‐


7.13 Electronic drainer

This drain consists of a condensate accumulator where a capacitive sensor continuously checking liquid level is placed:
as soon as the accumulator is filled, the sensor passes a signal to the electronic control and a diaphragm solenoid valve
will open to discharge the condensate. For a complete condensate discharge the valve opening time will be adjusted
exactly for each single drain operation. No condensate strainers are installed. No adjusting is required. A service valve
is installed before the electronic drain in order to make check and maintenance easily.At dryer start‐up verify that this
valve is open.
Control panel
Power Led On ‐ drainer ready to work / supplied
Alarm Led Blinking ‐ drainer in alarm condition
TEST Button Discharge test (keep pushed for 2 seconds)
Troubleshooting
Only qualified personnel should perform troubleshooting and ormaintenance operations.
Prior to performing any maintenance or service, be sure that :
• no part of the machine is powered and that it cannot be connected to the mains supply.
• no part of the machine is under pressure and that it cannot be connected to the
compressed air system.
• maintenance personnel have read and understand the safety and operation instructions in
this manual.
SYMPTOM POSSIBLE CAUSE ‐ SUGGESTED ACTION
No led lighting up. B Verify that the system is powered.
B Verify the electric wiring (internal and/or external).
B Check internal printed circuit board for possible damage.
Pressing of Test button, but no B The service valve located before the drain is closed - open it.
condensate discharge. B The dryer is not under pressure - restore nominal condition.
B Solenoid valve defective - replace the drain.
B The internal printed circuit board is damaged - replace the drain.
Condensate discharge only B The capacitive sensor is too dirty - open the drain and clean the sensor
when Test button is pressed. plastic tube.
Drain keeps blowing off air. B The diaphragm valve is dirty - open the drain and clean it.
B The capacitive sensor is too dirty - open the drain and clean the sensor
plastic tube.
Drain in alarm condition. B The capacitive sensor is too dirty - open the drain and clean the sensor
plastic tube.
B The service valve located before the drain is closed - open it.
B The dryer is not under pressure - restore nominal condition.
B Solenoid valve defective - replace the drain.
NOTE : When the drain is in alarm condition, the diaphragm solenoid valve will open 7.5 sec every 4 min.

8 Maintenance, troubleshooting, spare parts and dismantling
8.1 Checks and maintenance

this manual.
Before attempting any maintenance operation on the dryer, shut it down and wait at
least 30 minutes.components can reach high temperature during operation. Avoid
contact until system or component has dissipated heat.
Daily
• Verify that the DewPoint displayed on the electronic instrument is correct.
• Check the proper operation of the condensate drain systems.
• Verify the condenser for cleanliness (Air‐Cooled).
Every 200 hours or monthly

• With an air jet (max. 2 bar / 30 psig) blowing from inside towards outside clean
the condenser; repeat this operation blowing in the opposite way; be careful
not to damage the aluminum fins of the cooling package (Air‐Cooled)
• Close the manual condensate drain valve, unscrew the strainer (if installed) and clean it with
compressed air and brush. Reinstall the strainer properly tight, and then open the manual valve.
• At the end, check the operation of the machine
Every 1000 hours or yearly

• Verify for tightness all the screws of the electric system and that all the “Disconnects‐Tabs” type
connections are in their proper position inspect unit for broken, cracked or bare wires.
• Inspect refrigerating circuit for signs of oil and refrigerant leakage.
• Measure and record amperage. Verify that readings are within acceptable parameters as listed in
specification table.
• Inspect flexible hoses, and replace if necessary.
• At the end, check the operation of the machine.
Every 8000 hours

• Replace Electronic drainer service unit

8.2 Troubleshooting
this manual.
Before attempting any maintenance operation on the dryer, shut it down and wait at
least 30 minutes.Some components can reach high temperature during operation. Avoid
contact until system or component has dissipated heat.
The dryer doesn't B Verify that the system is powered.
start. B Verify the electric wiring.
B Blow of fuse (see FU1/FU2/FU4 on the electric diagram) of the auxiliary circuit -
replace it and check the proper operation of the dryer.
B DMC24 - The led is lighted - see specific point.
The compressor B Activation of the compressor internal thermal protection - wait for 30 minutes, then
doesn’t work. retry.
B Verify the electric wiring.
B DMC24 - Internal delay device – the display shows the seconds before start-up.
B DMC24 - The led is lighted - see specific point.
B If the compressor still doesn’t work, replace it.
Condenser’s fan B Verify the electric wiring.
doesn’t work B Fan power contactor (see KV1/KV2 on the electric diagram) is faulty - replace it.
(Air‐Cooled). B DMC24 - The led is lighted - see specific point.
B There is a leak in the refrigerant circuit - contact a refrigeration engineer.
B If the fan still doesn't work, replace it.
DewPoint too B The dryer doesn't start - see specific point.
high. B The DewPoint probe doesn’t correctly detect the temperature - ensure the sensor
is pushed into the bottom of probe well.
B The Compressor doesn’t work - see specific point.
B The ambient temperature is too high or the room aeration is insufficient - provide
proper ventilation (Air-Cooled).
B The inlet air is too hot - restore nominal conditions.
B The inlet air pressure is too low - restore nominal conditions.
B The inlet air flow rate is higher than the rate of the dryer - reduce the flow rate -
restore nominal conditions.
B The condenser is dirty - clean it (Air-Cooled)
B The condenser fan doesn’t work - see specific point (Air-Cooled).
B The cooling water is too hot - restore nominal conditions (Water-Cooled).
B The cooling water flow is insufficient - restore nominal conditions(Water-Cooled).
B The dryer doesn’t drain the condensate - see specific point.
B The hot gas by-pass valve is out of setting - contact a refrigeration engineer to
restore nominal setting.
B There is a leak in the refrigerant circuit - contact a refrigeration engineer.

DewPoint too B The fan is always on – verify the correct operation of the fan power contactor (see
low KV1/KV2 on the electric diagram) and/or of pressure transducer (see BHP on the
electric diagram) – (Air-Cooled).
B Ambient temperature is too low - restore nominal conditions (Air-Cooled).
B The hot gas by-pass valve is out of setting - contact a refrigeration engineer to
Excessive B The dryer doesn’t drain the condensate - see specific point.
pressure drop B The DewPoint is too low - the condensate is frost and blocks the air - see specific
point.
within the dryer.
B Check for throttling the flexible connection hoses.
The dryer doesn’t B The condensate drain service valve is closed - open it.

drain the B Verify the electric wiring.
B The DewPoint is too low - the condensate is frost and blocks the air - see specific
condensate
point.
B Inlet compressed air pressure is too low and condensate is not drained – restore
nominal conditions.
B Electronic drainer is not operating correctly (see paragraph 7.16).
The dryer B Electronic drainer is dirty (see paragraph 7.16).
continuously
drains
condensate.
Water within the B The dryer doesn't start - see specific point.

line. B If installed - Untreated air flows through the by-pass unit - close the by-pass.
B The dryer doesn’t drain the condensate - see specific point.
B DewPoint too high - see specific point.
HPS high B Check which of the following has caused the activation :
pressure switch 1. The ambient temperature is too high or the room aeration is insufficient ‐ provide proper
has been ventilation (Air‐Cooled).
activated. 2. The condenser is dirty ‐ clean it (Air‐Cooled).
3. The condenser fan doesn’t work ‐ see specific point (Air‐Cooled).
4. The cooling water is too hot ‐ restore nominal conditions (Water‐Cooled).
5. The cooling water flow is insufficient ‐ restore nominal conditions (Water‐Cooled).
B Reset the pressure switch pressing the button on the controller itself - verify the
dryer for correct operation.
B HPS pressure switch is faulty - contact a refrigeration engineer to replace it.
LPS low pressure B There is a leak in the refrigerating fluid circuit - contact a refrigeration engineer.
switch has been B The pressure switch reset automatically when normal conditions are restored -
check the proper operation of the dryer.
activated.

Compressor B Check which of the following has caused the failure :
discharge 1. Eccessive thermal load – restore nominal conditions.
temperature too 2. The inlet air is too hot ‐ restore nominal conditions.
high. 3. The ambient temperature is too high or the room aeration is insufficient ‐ provide proper
ventilation (Air‐Cooled).
4. The condenser unit is dirty ‐ clean it (Air‐Cooled).
5. The fan doesn’t work ‐ see specific point (Air‐Cooled).
6. The fan is always on – verify proper operation of fan power contactor (see KV1/KV2 on
electric diagram) and/or of pressure transducer (see BHP on electric diagram) – (Air‐
Cooled).
7. The hot gas by‐pass valve requires re‐adjusting – contact a specialized technician to
8. The temperature of the cooling water is too low – restore nominal conditions (Water‐
Cooled).
9. The cooling water flow adjusting valve requires re‐adjusting ‐ contact a specialized
technician to restore nominal setting (Water‐Cooled).
10.Refrigerant gas leak ‐ contact a refrigeration engineer.
Condensing B Check which of the following has caused the failure :

pressure too high 1. The ambient temperature is too high or the room aeration is insufficient ‐ provide proper
ventilation (Air‐Cooled).
2. The condenser unit is dirty ‐ clean it (Air‐Cooled).
3. The fan doesn’t work ‐ see specific point (Air‐Cooled).
4. The temperature of the cooling water is too hot – restore nominal conditions (Water‐
Cooled).
5. Cooling water flow is not sufficient – restore nominal conditions (Water‐Cooled).
Condensing B Check which of the following has caused the failure :

pressure too low 1. The fan is always on – verify proper operation of fan power contactor (see KV1/KV2 on
electric diagram) and/or of pressure transducer (see BHP on electric diagram) – (Air‐
Cooled).
2. Ambient temperature is too low ‐ restore nominal conditions (Air‐Cooled).
3. Air flows through the condenser even with fan off – protect dryer against wind or external
air flows (not caused by dryer’s fan) (Air‐Cooled).
4. The temperature of the cooling water is too low – restore nominal conditions (Water‐
Cooled).
5. The cooling water flow adjusting valve requires re‐adjusting ‐ contact a specialized
technician to restore nominal setting (Water‐Cooled).
6. Refrigerant gas leak ‐ contact a refrigeration engineer.
7. Compressor does not work – see specific point.

Electronic B With led flashing : one or more alarms are active and the display shows
instrument and the active alarms.
DMC24 B With led lighted : one or more alarms are waiting to be reset and the display
shows and the alarms that are no longer active but not yet reset.
The led is B The alarms are displayed with the following messages :
on or flashes. 1. : HP ‐ HPS pressure switch tripped (refrigerant high pressure) for condensing
pressure too high ‐ see specific paragraph (NOTE : when problem is solved press reset key
on HPS pressure switch).
2. : LP ‐ LPS pressure switch tripped (low pressure) due to refrigerant pressure too low
‐ see specific paragraph.
3. : Con – during first startup – power phases of compressor are not connected
properly (see RPP on the electric diagram) – Change rotating direction swapping two
phases of the power supply of dryer. These changes have to be done only by a qualified
electrician. DO NOT BY PASS RPP PROTECTION: BY OPERATING THE MACHINE IN
WRONG ROTATING DIRECTION, THE COMPRESSOR WILL FAIL IMMEDIATELY AND THE
WARRANTY WILL BE VOIDED.
4. : Con – one phase of power supply of dryer is missing (see RPP on the electric
diagram) – restore the missing phase.
5. : Con – Reverse Phase Protector (RPP) is faulty – replace it.
6. : Con – electric protection of compressor tripped (see Q1/QC1 on the electric
diagram)– reset and verify the dryer’s proper operation.
7. : Con ‐ if installed ‐ thermal protection inside the compressor tripped (see MC1 on
wiring diagram – wait 30 minutes and try again.
8. : FAn ‐ electric protection of fan tripped (see QV1 on the electric diagram) ‐ reset
and verify the dryer’s proper operation (Air‐Cooled).
9. : FAn – thermal protection inside the fan/s tripped (see MF on wiring diagram – wait
30 minutes and try again (Air‐Cooled).
10. : Hdt – compressor discharge temperature protection tripped due to very high
temperature (probe T4) – see specific paragraph.
11. : ICE – temperature inside exchanger (probe T1) too low – DewPoint is too low ‐ see
specific paragraph.
12. : LCP ‐ condensing pressure too low – see specific paragraph.
13. : PF4 – failure temperature probe T4 (compressor discharge) – verify electric wiring
and/or replace probe.
14. : PFP – failure pressure transducer BHP (condensing pressure) – verify electric
wiring and/or replace transducer.

reset
NOTE: after solving the problem, the alarms must be reset (press the keys log

simultaneously for 3 seconds).

Electronic B With led flashing: one or more service warnings are active.
instrument B With led lighted: one or more service warnings are waiting to be reset. The
DMC24 display shows the DewPoint temperature and the active or not reset service
warning.
The led is B The service warnings are displayed with the following messages :
on or flashes. 1. : PF1 – temperature probe failure T1 (DewPoint) – verify electric wiring and/or
replace probe.
2. : PF2 ‐ temperature probe failure T2 (air IN) – verify electric wiring and/or replace
probe.
3. : PF3 ‐ temperature probe failure T3 (compressor suction) – verify electric wiring
and/or replace probe.
4. : Hdp – DewPoint too high (higher than set HdA value) – see specific paragraph.
5. : Ldp ‐ DewPoint too low ‐ see specific paragraph.
6. : drn – the condensate drainer does not work properly (DRN contact open‐ if
electronic drainer is installed) ‐ see specific paragraph.
7. : SrV ‐ Service – maintenance notice time expired (parameter SrV) – carry out
planned maintenance and reset hour counter.
8. : dt – compressor supply temperature too high (probe T4) – see specific paragraph.
9. : HCP – condensing pressure too high – see specific paragraph.

reset
NOTE: after solving the problem, the services must be reset (press the keys log

simultaneously for at least 3 seconds).

8.3 Maintenance operation on the refrigeration circuit

Maintenance and service on refrigerating systems must be carried out only by certified refrigerating
engineers only, according to local rules.
All the refrigerant of the system must be recovered for its recycling, reclamation or destruction.
Do not dispose the refrigerant fluid in the environment.
This dryer comes ready to operate and filled with R407C type refrigerant fluid.
In case of refrigerant leak contact a certified refrigerating engineer. Room is to be aired before any
intervention.
If is required to re‐fill the refrigerating circuit, contact a certified refrigerating engineers.
Refer to the dryer nameplate for refrigerant type and quantity.
Characteristics of refrigerants used:
Refrigerant Chemical formula TLV GWP
R32/125/134a (23/25/52)
R407C ‐ HFC 1000 ppm 1653
CHF2CF3/CH2F2/CH2FCF3
8.4 Dismantling of the dryer

If the dryer is to be dismantled, it has to be split into homogeneous groups of materials.
Part Material
Refrigerant fluid R407C, Oil
Canopy and Supports Carbon steel, Epoxy paint
Refrigerating compressor Steel, Copper, Aluminium, Oil
Alu‐Dry Module Aluminium
Condenser Unit Aluminium, Copper, Carbon steel
Pipe Copper
Fan Aluminium, Copper, Steel
Valve Brass, Steel
Electronic Level Drain PVC, Aluminium, Steel
Insulation Material Synthetic rubber without CFC, Polystyrene, Polyurethane
Electric cable Copper, PVC
Electric Parts PVC, Copper, Brass
We recommend to comply with the safety rules in force for the disposal of each type of material.
Refrigerant contains droplets of lubrication oil released by the refrigerating compressor.
Do not dispose this fluid in the environment. Is has to be discharged from the dryer with a suitable device
and then delivered to a collection centre where it will be processed to make it reusable.

9 Attachments
Exploded views – List of components
1 Alu-Dry module 37 Refrigerant pressure transducer
1.1 Insulation material 51 Front panel
2 Refrigerant pressure switch LPS 52 Back panel
4 Refrigerant pressure switch HPS 53 Right lateral panel
6 Compressor 54 Left lateral panel
7 Hot-gas bypass valve 55 Cover
8 Condenser (Air-Cooled) 56 Base plate
9 Condenser fan (Air-Cooled) 58 Support beam
10 Filter dryer 59 Support bracket
11 Capillary tube 60 Control panel
13 Condensate drain service valve 65 Condenser filter
17 Electronic instrument 66 QE door
20 Refrigerant accumulator 81 Flow diagram sticker
21 Electronic drainer 83 Refrigerant service valve – H.P. side
22 Main switch 84 Refrigerant service valve – L.P. side
36 Liquid separator

Electric diagrams– List of components

MC1 Compressor LPS Low pressure switch
MV1 ‐ 4 Condensers fans HPS High pressure switch
DMC24 Electronic instr. DMC24 – Display module ELD Electronic drainer
DMC24MA Electronic instr. DMC24 – Main module QS Main switch with door block
BT1 ‐ 4 Temperature probes RC Compressor crankcase heater
BHP Refrigerant pressure transducer RPP Reverse phase protector

NT1 Air-Cooled only NT5 Limit of equipment
NT2 Verify transformer connection according NT6 Timed drain output
to power supply voltage
NT3 Jump if not installed
NT4 Provided and wired by customer

BN Brown OR Orange
BU Blue RD Red
BK Black WH White
YG Yellow / Green WH / BK White / Black

9.1 Dryers dimensions

9.1.1 RFL500

9.2 Exploded views

9.2.1 RFL 500 Air Cooled

9.3
9.3.1
0 1 2 3 4 5 6 7 8 9
3/400V/50Hz+PE
QS
FU1-2
Electric diagrams
QC1 QV1
3/400V/50Hz+PE (*)
RFL500 Sheet 1 of 4
OR [2-6] [2-7] 3/460V/60Hz+PE

3/460V/60Hz+PE (*)
FUSE MAX 32 A
RCD Id 0.03A suggested TF
Smin 6sqmm/10AWG
FU4
RPP
L1 L2 L3
FU3
1 3 5
KC1 KV0 KV2 KV1
[2-1] 11 12 14
[2-1] [2-3] [2-2]
2 4 6
[2-6] 11
KC1
[2-1] 12
U/T1 V/T2 W1 V2
W/T3
M MV1 V1
M U2
3 3
U1 W2
TK TK
MC1 [2-7]
W1 V2
MV2 V1
M U2
3
U1 W2 A B
TK TK RC
[2-8]
(*) See dryer nameplate
Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
FRACT5478QCD002 01
Note :
Sheet 01 of 04

9.3.2
0 1 2 3 4 5 6 7 8 9
DMC24
13
LPS QV1
[1-5]
11 13 14
HPS KHP P
QC1 [3-1]
[2-0] [1-3]
14 14
DEWPOINT TEMP.
AIR IN TEMP.
P MV2
BHP BT1 BT2 BT3 BT4
RFL 500 Sheet 2 of 4
P
mA MV1
11 [3-4]
RPP
[1-4]
14
14 29 28 27 26 25 24 23 22 21 20 19 18 17 16
J2 J1
EXP DISPLAY
DMC24MA
K J3-RS485
I II T ZL
15 13 9 12 11 10 8 7 1 2 3 4 5 6 A B
MAX 2A - 48V
4 5 6 4 5 6
A A
NO Alarm Alarm
21 and or
KHP Power ON Power OFF
[2-0]
24
A1 A1 A1 A1 A1 A1
KHP KV0 KC1 KV1 KV2 KDR
A2 A2 A2 A2 A2 00 A2
B
14 11 1 2 1 2 1 2 1 2 14 11
[2-4] [1-5] [1-3] [1-7] [1-6] [3-0]
12 3 4 3 4 3 4 3 4 12
[1-5] [1-3] [1-7] [1-6] 24 21
24 21 5 6 5 6 5 6 5 6 [3-2]
22
[2-1] [1-5] [1-3] [1-7] [1-6] 22
11 12 11 12 11 12 11 12
N.U. [1-9] N.U. N.U.
Drawing no. : Rev.
FRACT5478QCD002 01
Note :
Sheet 02 of 04

9.3.3
0 1 2 3 4 5 6 7 8 9
[2-8]
[2-8]
14 24
KDR KDR
[2-5] [2-5]
11 22
RFL 500 Sheet 3 of 4
ELD1 ELD2
3.1 L 2.3 3.1 1.1 2.3
1.3 1.3
3.2 N 2.4 3.2 1.2 2.4
Drawing no. : Rev.
FRACT5478QCD002 01
Note :
Sheet 03 of 04

TYPE
WIRE
TERMINAL
TERMINAL
0
1 024 UKK 5
HIGH PRESSURE SWITCH
2 12
HPS
3 CDI
LOW PRESSURE SWITCH
4 DI2
LPS
5 35
FAN THERMAL PROTECTION
AIR COOLED ONLY - JUMP IF NOT INSTALLED 6
MV1
1
7
FAN THERMAL PROTECTION
AIR COOLED ONLY - JUMP IF NOT INSTALLED 8 DI4
MV2
9 UDT
10 00
11 024
12 00
13 31
2
14 32
ELECTRONIC LEVEL DRAINER
15 CDI
16
ELD1
17 024
18 00
19 33
20 34
3
ELECTRONIC LEVEL DRAINER

21 DI5
22
ELD2
RC1 00 UKK 5
COMPRESSOR CRANKCASE HEATER
RC2 10
RC
4
5
6
7
Note :
Drawing no. :
L1
L2
L3
8
PE
FRACT5478QCD002
Sheet
04
9
of
04
Rev.
01
RFL500 Sheet 4 of 4 9.3.4

Page: 249 Of 305
Rev.: 3

AEROS
10QFB05BB001, 10QFB05AP001/002, 10QFB05AC001
&
10QFB10BB001, 10QFB10AP001/002, 10QFB10AC001

WATERCOOLERS by AIR
AW SERIES
INSTRUCTION MANUAL
 CHARACTERISTICS OF EQUIPMENT
 USE
 INSTALLATION
 STARTING-UP
 OPERATION
 EMERGENCY STOP
 MAINTENANCE
 ACTION ON INTERCHANGER-BATTERY
 DIGITAL THERMOSTAT
 DIAGRAMS & SPARE PARTS
This Equipment/Machine complies with the Directives indicated in the

DECLARATION OF CONFORMITY, on condition that the instructions of this MANUAL
are followed. In case of interpretation problems of the manual, the Spanish version is
determinative.
Basic points are:
1. Do not disassemble any exterior protection of the equipment before:
SWITCHING OFF THE ELECTRICAL SUPPLY.

DECOMPRESSING THE PRESSURE CIRCUIT.
and do not switch on/activate those ones before assembling the equipment
again.
2. Do not manipulate the internal components without knowledge on the matter, and
never without reading the instructions, and following the enclosed circuit and
electrical diagrams.
3. Do not let without replacing all those internal or own protections that the
components could incorporate once they have been manipulated.
4. In case of doubt do not act, contact previously with AIRSEC, S.A. Technical
Service to obtain clarifications or ask for help.
5. Exclusion of responsabilities in order to the additional elements incorporated by

the installer/user.
SHEET: 2
I. USE
These units are designed to cool a flow of water with a temperature superior to the ambient in a
closed circuit, using atmospheric air as a means of refrigeration.
The water circuit is propelled by a centrifugal -type electric pump, with a regulator tank situated at
its aspiration side.
The air circuit is driven by helicoidal -type electric fans, which take fresh air from the ambient and
eject it to the atmosphere.
The heat exchange takes place in a battery of aluminium -finned copp er tubes. The water
circulates inside them, and the atmospheric air circulates outside them.
II. INSTALLATION
Place the unit in a very well-ventilated area, on a level surface.
The equipment should not receive direct sunlight (otherwise it would lose part of its refrigerating
capacity).
Due to the large ambient air volume to be propelled through the heat exchanger, we recommend
to install the equipment at the outside protected by a roof against the weather conditions (sunstime,
snow, rain, etc.).
If it is not possible, some ideas are enclosed at the end of this Instruction Manual in order to
obtain an accurate operation of the equipment, in spite of the limitations that appear in a closed
room.
Pay attention to the heat quantity value dissipate in the ambient (indicated at the tittle -page as
"Thermic power to dissipate") which would be accumulated in the room causing anomalies if the
installation of the equipment is not correct.
III. START- UP
Before filling the circuit with water, detach the cover/flange situated at the pump intake, in order to
check that there is no foreign matter (which may have entered during assembly) that could affect the
subsequent operation of the pump or cause a breakdown if the pump were to draw it in.
Fill in the water expander tank, so that the pump circuit be also filled.
Check that the electrical characteristics are suitable before the hooking up of the electrical supply
of the control panel, and activate the internal switch of the electric panel in order to pr ovide tension to
the equipment.
ATTENTION: The pump protection is delivered disconnected so it can not operate (by mistake),
before the water circuit is full.
SHEET: 3
Give a pulsation to the front switch of the control panel in order to check the correct direction of
the turning of the pump and the fans before the definitive start-up.
Once the aforementioned procedure has been completed, start up the unit and proceed to gauge
the pump by means of the regulating valve situated at the entrance to th e tank (where the hot water
arrives), opening and closing it until the water pressure indicator situated next to the control panel
shows the pressure marked on the enclosed curve at the end.
In this way, the quantity of water to be handled in accordance with the equipment's design has
been gauged.
IV. OPERATION
The electric pump recirculating the water to be cooled is activated by a switch, which is built into,
connected to the unit itself and situated on the general control panel.
Through the therm ostatic control of the water temperature, the electric fans driving the air are
connected or disconnected in a series of steps (in the systems designed in this way).
The desired minimum cooling temperature of the water flow should be calculated beforehan d, and
set accordingly. The water temperature appears on the same regulator display.
In addition, this same display and its selector give a reading of the temperature of the inlet water,
and a reading of the atmospheric air temperature. The selector's home position controls and
indicates the cold water temperature.
An expander tank, positioned high up, compensates for the variation in volume of the water
circuit, which is caused by temperature fluctuations.
The electrical circuits are equipped with fuses to protect them against short-circuits.
Thermic safeguard motors protect the pump and fans from overload. In the event of an overload,
optical indicators will signal the anomaly.
ONLY FOR EQUIPMENT WITH A PUMP/ELECTROFAN IN RESERVE
For this manufac turing variant, there are position switches on the control panel to indicate the
pump/electrofan assigned to remain in reserve, being possible to select any pump for this function.
In case of failure of the component in operation, the magnetothermic circ uit breaker would act,
putting immediatly in operation the reserved component and giving an optical alarm signal on the
control panel and contact without tension to send the signal.
The component alternation system as well as the alarm signals are indepe ndent between pumps
and fans.
SHEET: 4
V. EMERGENCY STOP
WATER CIRCUIT
As operation is at low pressure, a failure in the circuit (pump/pipes/tank) cannot cause accidents
or failure of components.
AIR CIRCUIT
The electric fans, including protections, are provided by its manufacturer with the "EC" mark.
In case of anomaly of the fans, switch immediatly to its "OFF" position the exterior handle of the
emergency general selector, situated on the general control panel of the equipment.
If the equipment stops, the water cooling service towards the user remains without flow nor
pressure.
VI. MAINTENANCE
o Maintain the water level of the expander tank at its middle mark.
o Check the watertightness of the circuit, if there is a pronounced fall in the level.
o Periodically clean the finning of the heat exchange batteries (their outer protective grilles can
be taken off to make cleaning easier).
o Check that the temperatures are as specified by means of the display and its position
selector, which, dependin g on the position, gives a temperature reading for each of the
control points.
o Ensure that the electricity consumption of the pump and the fans is as indicated on their
plaques, and that the thermic protectors are correctly adjusted.
VERY IMPORTANT
In order to avoid the risk of the water freezing during winter, it is necessary to add glycol in the
proportions indicated for the different possible freezing conditions.
To the quantity of water indicated on the List of Specifications one should add the c apacity of the
circuit in use, in order to calculate the total quantity of monopropyleneglycol to be added.
MONOPROPYLENEGLYCOL FREEZING POINT ºC
5% - 1 °C
10% - 3 °C
15% - 5 °C
20% - 7 °C
25% -10 °C
30% -13 °C
35% -18 °C
40% -22 °C
45% -30 °C
50% -34 °C
SHEET: 5
VII. CHANGING THE BATTERY/BATTERIES
It is necessary to drain the battery, if the equipment is not used over a long period of time, or
before to be filled with the appropriate mixture of ethylene glycol and water.
In case of an eventual emergency it could also be necessary to take out or substitute the battery.
The following points cover the maximum number of steps required to be taken. Obviously, in the
st th
case of emptying or filling the circuit, only points 1 and 6 are applicable.
st
1 Empty the water by means of the cocks (GV), if necessary, using the assistance of low -
pressure compressed air to remove the remaining water (between 1 and 3 bars is sufficient),
connecting this one to a higher point (the "SA" venting, for example).
nd
2 Disassemble the front and back panels and the lateral panel and grating, so as to be able to
reach all the elements and to assure an adequate help when it will be necessary to take out
and place the battery on its guardrail.
th
3 Remove the flanges of the outlet and inlet tubes of the collectors of the battery and of the
pump connection that joint the oulet collector with the connection of the user. After these tubes
have been disassembled, the anchorage of the battery will be retired removing the bolts that fix
it to the interior frame of the structure.
th
4 Next, the battery is taken out on the pump side, pulling or pushing it carefully, so that it slides
along its roller path and can come out.
th
5 Fitting the new battery is done by following the aforementioned procedure in reverse, ensuring
that the collectors remain in their correct position (note that their connection flanges face
different ways); make sure that the battery remains lodged in its frame to avoid as far as
possible a by-pass of the cooling air (through apertures etc., which may detract from the
performance of the equipment).
th
6 Once these steps have been followed, the circuit may be filled with the appropriate proportions
of water and glycol for the desirated protect ion temperature. An attempt should be made to
remove all air from the circuit by means of the cock (GA).
To aid better understanding of this procedure, refer to the Assembly Diagram and the Assembly
Drawing.
GUARANTEE
According to our GENERAL CONDITIONS OF SALE,

number 4, the conditions of guarantee are as follows:
CONDITIONS OF GUARANTEE.
The equipment manufactured by AIRSEC shall be protected

by a guarantee of 12 months following start-up or 18 months
following the date of delivery. Of the two periods, that which
expires first shall automatically end the guarantee.
The guarantee shall only cover defects in materials or in

the functioning or construction of the equipment, while the
cost of replacement material shall be borne by AIRSEC.
However, unless other conditions are agreed, AIRSEC shall not
be liable for the costs of labour in such operations, nor for any
travelling expenses, such as travelling time, subsistence
allowances, etc.
Consumable components or those requiring periodic

replacement are not covered by the guarantee (filter elements,
dehydrating materials, purifying materials, lubricating oils,
etc.).
Page: 256 Of: 305
Rev.: 3
Operation and maintenance manuals

CHILLERS
10QFB15AC001 & 10QFB20AC001

W ATER C HILLERS
TAEevo 161
OPERATING AND MAINTENANCE MANUAL

38178800500
Original instructions
OPERATING AND MAINTENANCE MANUAL 1
- Contents
CONTENTS
CONTENTS .......................................................................................................................................................1
GENERAL INFORMATION ................................................................................................................................3
1.1 How to interpret the model...................................................................................................... 4
SAFETY.............................................................................................................................................................5
2.1 General .................................................................................................................................... 5
2.2 Liquids of the user circuit........................................................................................................ 5
2.3 Lifting and carriage precautions .............................................................................................. 5
2.4 Installation precautions............................................................................................................ 6
2.5 Precautions during operation ................................................................................................... 6
2.6 Maintenance and repair precautions ........................................................................................ 6
2.7 Refrigerant gases ..................................................................................................................... 7
2.7.1 Refrigerant safety schedule ....................................................................................................................... 7
TECHNICAL DATA............................................................................................................................................9
3.1 Other data relative to the standard machines........................................................................... 9
3.1.1 Dimensions ................................................................................................................................................ 9
3.1.2 Characteristics of pumps and of the fans ................................................................................................ 10
3.1.3 Sound Level Measurements ..................................................................................................................... 11
DESCRIPTION .................................................................................................................................................12
4.1 Components ............................................................................................................................. 12
4.2 Cooling circuit ......................................................................................................................... 12
4.3 Compressors ............................................................................................................................ 12
4.4 Condenser ................................................................................................................................ 12
4.5 Evaporator ............................................................................................................................... 12
4.6 Tank ......................................................................................................................................... 12
4.7 Pump........................................................................................................................................ 13
4.8 Fans.......................................................................................................................................... 13
4.9 Casing ...................................................................................................................................... 13
4.10 Materials in contact with the liquid to be cooled .................................................................... 14
4.11 Minimum distances from walls in the installation ambient..................................................... 14
4.12 Electrical circuit....................................................................................................................... 14
4.13 Negative ambient temperatures (not present in models for 460/3/60 power supply).............. 14
INSTALLATION ...............................................................................................................................................15
5.1 Inspection ................................................................................................................................ 15
5.2 Positioning............................................................................................................................... 15
5.3 Antifreeze protection ............................................................................................................... 15
5.3.1 Operating limits ....................................................................................................................................... 16
5.4 Hydraulic connections ............................................................................................................. 16
5.5 Expansion tank ........................................................................................................................ 17
5.6 Electrical connections.............................................................................................................. 18
START UP .......................................................................................................................................................19
ELECTRONIC BOARD ....................................................................................................................................20
7.1 Display..................................................................................................................................... 20
7.1.1 Display icons ........................................................................................................................................... 20
7.2 Function of buttons.................................................................................................................. 20
7.2.1 Function of combined buttons ................................................................................................................. 21
7.3 Symbols and leds on the display ............................................................................................. 21
7.4 Remote terminal ...................................................................................................................... 21
7.4.1 Function of buttons .................................................................................................................................. 21
TAEevo015÷351
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
2 OPERATING AND MAINTENANCE MANUAL
- Contents
7.5 Displaying during an alarm ......................................................................................................21

7.5.1 Alarm icons ..............................................................................................................................................22
7.6 How to silence the buzzer ........................................................................................................22
7.7 First start up..............................................................................................................................22
7.8 Programming by keyboard .......................................................................................................22
7.8.1 Access to “Pr1” parameters (User level) ................................................................................................22
7.8.2 How to modify a parameter’s value .........................................................................................................22
7.9 Values displayed ......................................................................................................................23
7.10 Unit switching on / off .............................................................................................................23
Function menu (* button) ......................................................................................................24

7.11 How to put the unit in stand-by................................................................................................23
7.12
7.12.1 Access to Function menu ..........................................................................................................................24
7.12.2 Exit Function menu ..................................................................................................................................24
7.12.3 How to display the alarms “ALrM” .........................................................................................................24
7.12.4 How to reset an alarm “rSt” ....................................................................................................................24
7.12.5 How to display the alarm historic “ALoG” .............................................................................................24
7.12.6 How to reset the alarm history “ArSt” ....................................................................................................24
7.12.7 Displaying the operating hours of loads “C1Hr - C2Hr - PFHr” ..........................................................25
7.13 Other functions by keyboard ....................................................................................................25
7.13.1 How to display the Set Point ....................................................................................................................25
7.13.2 How to modify the Set Point .....................................................................................................................25
7.14 Compressors unloading function..............................................................................................25
7.15 Probe key..................................................................................................................................25
OTHER COMPONENTS SETTING ....................................................................................................................26
8.1 Compressor integral protection (PI).........................................................................................26
8.2 Refrigerant high and low pressure switches.............................................................................26
8.3 Compressor operation ..............................................................................................................26
8.3.1 Compressor regulation graphic in Chiller mode .....................................................................................26
8.4 Fan speed regulation.................................................................................................................27
8.5 Level sensor..............................................................................................................................28
OPERATION AND MAINTENANCE ..................................................................................................................29
9.1 Operation..................................................................................................................................29
9.2 Maintenance .............................................................................................................................29
9.3 Unit access................................................................................................................................29
9.4 Emptying the process water circuit ..........................................................................................30
9.5 Maintenance schedule ..............................................................................................................30
TROUBLE SHOOTING .....................................................................................................................................31
SETTING TABLES ...........................................................................................................................................34
11.1 Parameter setting ......................................................................................................................34
11.1.1 Thermoregulation parameters .................................................................................................................34
11.1.2 Configuration parameters ........................................................................................................................34
11.1.3 Dymanic set point parameters (NBCP1OT ENABLED FUNCTION) .....................................................35
11.1.4 Energy Saving parameters (NOT ENABLED FUNCTION) ....................................................................35
11.1.5 Compressor parameters ...........................................................................................................................35
11.1.6 Fan parameters ........................................................................................................................................35
11.1.7 Antifreeze support resistance parameters ................................................................................................35
11.1.8 Defrost parameters (NOT ENABLED FUNCTION) ................................................................................35
11.1.9 Alarm parameters .....................................................................................................................................35
11.1.10LASER parameters (NOT ENABLED FUNCTION) ................................................................................35
ALARMS ..........................................................................................................................................................36
12.1 Alarm codes and actions ..........................................................................................................36

12.2 Outlet blocking.........................................................................................................................39
TAEevo015÷351
Chapter 1 - General Information
CHAPTER 1
GENERAL INFORMATION
The machines described in this manual are called “WATER CHILLERS”.
This manual is written for those responsible for the installation, use and maintenance of the unit.
The components used are of high quality and all the projecting process, from the production to the unit checking, has been manufactured in
conformity with ISO 9001 norms.
In most applications, the liquid of the user circuit is water and the term “WATER” will be used even if the liquid of the user circuit is different
from water (e.g. a mixture of water and glycol).
Here below the term “PRESSURE” will be used to indicate the gauge pressure.
The following symbols are shown on the stickers on the unit as well as on the overall dimension drawing and refrigeration circuits in this manual.
Their meaning is the following:
Process water inlet
Process water outlet
Indications for lifting the unit
Water drainage point from the machine
Electric shock risk
Risk of burns from contact with high-temperature surfaces
Direction of the refrigerant fluid and water circuit
Direction of pump rotation (if installed)
Water filling point
Air vent
Hole for inserting bars for lifting the machine
Table 1 SYMBOLS
TAEevo015÷351
Chapter 1 - General Information
1.1 How to interpret the model
MODEL DESCRIPTION
TAEevo XX 1
refrigerant with 1 refrigeration circuit
power indicative of the refrigeration compressor in hp
E = hermetic type compressor

A = air-cooled condenser
T = “tank”; chiller with storage tank.
ATTENTION
This manual provides the user, installer and maintenance technician with all the technical information required for installation, operation
and carrying out routine maintenance operations to ensure long life.
If spare parts are required, this must be original.
Requests for SPARE PARTS and for any INFORMATION concerning the unit must be sent to the distributor or to the nearest service centre,
providing the MODEL and MACHINE NUMBER shown on the machine data plate and on the first page of this manual.
TAEevo015÷351
Chapter 2 - Safety
CHAPTER 2
SAFETY
This machinery was designed to be safe in the use for which it was planned provided that it is installed, started up and maintained in accordance
with the instructions contained in this manual. The manual must therefore be studied by all those who want to install, use or maintain the unit.
The machine contains electrical components which operate at the line voltage, and also moving parts.
It must therefore be isolated from the electricity supply network before being opened. Maintenance operations involving work inside the machine
must be performed by skilled and adequately qualified personnel equipped with suitable protection means (active and passive, e.g. work gloves)
ton ensure work in maximum safety. Do not allow extraneous persons (such as children) where the machine is installed.
2.1 General
When handling or maintaining the unit and all auxiliary equipment, the personnel must operate with care observing all instructions concerning
health and safety at installation site.
ATTENTION
Most accidents which occur during the operation and maintenance of the machinery are a result of failure to observe basic safety rules or
precautions.
An accident can often be avoided by recognising a situation that is potentially hazardous.

The user should make sure that all personnel concerned with operation and maintenance of the unit and all auxiliary equipment have read and
understood all warnings, cautions, prohibitions and notes written in this manual as well as on the unit.
Improper operation or maintenance of the unit and auxiliary equipment could be dangerous and result in an accident causing injury or death.
We cannot anticipate every possible circumstance which might represent a potential hazard.
The warnings in this manual are therefore not all-inclusive.
If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended, he must ensure
that the unit and auxiliary equipment will not be damaged or made unsafe and that there is no risk to persons or property.
Any improper use of the machine will relieve the manufacturer from any liability for possible personal injury or property damage.
Arbitrary modifications made to the unit will automatically invalidate all forms of guarantee provided by the manufacturer.
ATTENTION
The hot / cold water produced by MTA units cannot be used directly for domestic hygiene or food applications. In the
case of such applications, the installer is responsible for fitting an intermediate exchanger.
If the intermediate exchanger is not fitted, the installer should affix a notice stating "non-drinking water".
2.2 Liquids of the user circuit

The liquids of the user circuit must be compatible with the materials used. These can be water or mixtures of water and glycol, for example.
Additives and glycol suppliers must guarantee compatibility with the materials. For further information refer to 4.10 “Materials in contact with
the liquid to be cooled” .
ATTENTION
If the liquids of the user circuit contains dangerous substances (e.g. ethylene glycol) is very important to collect any liquid which leaks
because it could cause damages to the ambient. Furthermore, when the chiller is no longer used, dangerous liquids must be disposed of by
firms specialised and authorised for treating them.
2.3 Lifting and carriage precautions

Avoid injury by using a hoist to lift heavy loads.
Check all chains, hooks, shackles and slings are in good condition and are of the correct capacity.
They must be tested and approved according to local safety regulations.
Cables, chains or ropes must never be applied directly to lifting eyes.
Always use an appropriate shackle or hook properly positioned.
Arrange lifting cables so that there are no sharp bends.
Use a spreader bar to avoid side loads on hooks, eyes and shackles.
When a load is on a hoist stay clear of the danger area beneath and around it.
Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary. The weight values
shown in the following table were obtained with the unit empty, pump P3 and axial fans.
The manufacturer does not supply bars, belts and lifting hooks with the unit.
MODEL 015 020 031 051 081 101 121 161 201 251 301 351
Weight (kg) 127 132 200 220 331 386 405 416 553 650 740 757
Weight (lb) 280 291 440 485 729 850 892 917 1219 1433 1631 1668
Table 2 WEIGHTS
TAEevo015÷351
Chapter 2 - Safety
Model 015÷161 Model 201÷351
NOTE
Weight values are guideline, with the water circuit empty. The values may vary in relation to the configuration of the unit (pump type, supply
type, and ventilation type).
2.4 Installation precautions

The connections to be made are for the process water circuit. Use the electrical diagram accompanying this manual to for the connection to the
power grid.
2.5 Precautions during operation
Operation must be carried out by competent personnel under a qualified supervisor.
All the water piping must be painted or clearly marked in accordance with local safety regulations in the place of installation.
ATTENTION
Never remove or tamper with the safety devices, guards or insulation materials fitted to the unit or auxiliary equipment.
All electrical connections must comply with local codes.

The unit and auxiliary equipment must be earthen and protected by fuses against short-circuits and overloading.
When mains power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is
necessary to carry out any work on the electrical system.
Do not open any electrical panels or cabinets or touch any electrical components or associated equipment while voltage is applied unless it is
necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the proper tools
and wearing appropriate body protection against electrical hazards.
2.6 Maintenance and repair precautions
ATTENTION
When disposing of parts and waste material of any kind make sure that there is no pollution of any drain or natural water-course and that no
burning of waste takes place which could cause pollution of the air. Protect the environment by using only approved methods of disposal.
Keep a written record of all maintenance and repair work carried out on the unit and auxiliary equipment. The frequency and the nature of the
work required over a period can reveal adverse operating conditions which should be corrected.
ATTENTION
Use only refrigerant gas specified on the specification plate of the unit.
Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and
safety devices, is kept in good working order. The accuracy of pressure and temperature gauges must be regularly checked. They must be
renewed when acceptable tolerances are exceeded.
ATTENTION
Do not weld or carry out any operation which produces heat near a system which contains oil or flammable liquids. The systems which may
contain oil or flammable liquids must be completely drained and cleaned (with steam, for example), before carrying out these operations.
TAEevo015÷351
Chapter 2 - Safety
The adjacent components must always be screened with non-flammable material and if the operation is to be carried out near any part of the
lubrication system, or close to a component which may contain oil, the system must first be thoroughly purged, preferably by steam cleaning.
Never use a light source with an open flame to inspect any part of the machine.
For every unit establish a suitable time schedule for cleaning operations.
ATTENTION
If replacement parts are needed use only original spares.
Avoid to damage the safety valves and other pressure relief devices.
All guards must be reinstated after carrying out repair or maintenance work.
ATTENTION
Check the direction of rotation of electric motors (the pump if installed) when starting up the unit initially and after any work on the
electrical connections or switch gear.
Do not use flammable liquid to clean any component during operation. If chlorinated hydrocarbon non-flammable fluids are used for cleaning,
safety precautions must be taken against any toxic vapors which may be released.
ATTENTION
Before removing any panels or dismantling any part of the unit, carry out the following operations:
- Isolate the unit from the main electrical power supply by disconnecting the cable from the electrical power source.
- Lock the isolator in the “OFF” position with a lock.
- Attach a warning label to the main isolator switch conveying: “WORK IN PROGRESS - DON NOT APPLY VOLTAGE”.
- Do not switch on electrical power or attempt to start the unit if a warning label is attached.
Coloured tracers can be used in service-maintenance operations.

Inspect all refrigerant circuit joints including connectors, flanges, and more generally all critical points (open joints) in order to prevent possible
leakage of refrigerant gas.
2.7 Refrigerant gases
R407C is used as refrigerant in these units. Never attempt to mix refrigerant gases. The manufacturer's instructions and local safety regulations
should always be observed when handling and storing high pressure gas cylinders.
2.7.1 Refrigerant safety schedule
R407C
Denomination: 23% Difluoromethane (R32);
25% Pentafluoroethane (R125);
52% R134a
INDICATION OF THE DANGERS
Major dangers: Asphyxia.
Specific dangers: Rapid evaporation can cause freezing.
FIRST AID MEASURES
General information: Do not give anything to unconscious persons.
Inhalation: Take the person outdoors. Use oxygen or artificial respiration if necessary. Do not
administer adrenaline or similar substances.
Contact with the eyes: Thoroughly wash with plenty of water for at least 15 minutes and call a doctor.
Contact with the skin: Wash immediately with plenty of water. Remove contaminated clothing immediately.
FIRE-FIGHTING MEASURES
Means of extinction: Any means.
Specific dangers: Pressure increase.
Specific methods: Cool the containers with water sprays.
MEASURES IN THE EVENT OF ACCIDENTAL LEAKAGE
Individual precautions: Evacuate personnel to safe areas. Provide adequate ventilation. Use means of personal
protection.
Environmental precautions: Evaporates.
Cleaning methods: Evaporates.
TAEevo015÷351
Chapter 2 - Safety
HANDLING AND STORAGE

Handling
technical measures/ precautions: Ensure sufficient air change and/or extraction in the work areas.
recommendations for safe use: Do not inhale vapors or aerosols.
Storage Close properly and store in a cool, dry well-ventilated place. Store in its original
containers. Incompatible products: explosives, flammable materials, organic peroxide.
CONTROL OF EXPOSURE/INDIVIDUAL PROTECTION
Control parameters: AEL (8-h e 12-h TWA) = 1000 ml/m3 for each of the three components.
Respiratory protection: For rescue and maintenance work in tanks, use autonomous breathing apparatus. The
vapors are heavier than air and can cause suffocation, reducing the oxygen available for
breathing.
Protection of the eyes: Safety goggles.
Protection of the hands: Rubber gloves.
Hygiene measures: Do not smoke.
PHYSICAL AND CHEMICAL PROPERTIES
Colour: Colourless.
Odour: Similar to ether.
Boiling point: -43.9°C at atm. press.
Flammability point: Non flammable.
Relative density: 1.138 kg/l at 25°C.
Solubility in water: Negligible.
STABILITY AND REACTIVITY
Stability: No reactivity if used with the relative instructions.
Materials to avoid: Alkaline metal, earthy alkaline metals, granulated metals salts, Al, Zn, Be, etc. in powder.
Hazardous decomposition products: Halogen acids, traces of carbonyl halides.
TOXICOLOGICAL INFORMATION
Acute toxicity: (R32) LC50/inhalation/4 hours/lab. rats >760 ml/l
(R125) LC50/inhalation/4 hours/lab. rats >3480 mg/l
(R134a) ALC/inhalation/4 hours/lab. rats = 567 ml/l.
Local effects: Concentrations substantially above the TLV can cause narcotic effects. Inhalation of
products in decomposition can lead to respiratory difficulty (pulmonary oedema).
Long-term toxicity: Has not shown any cancerogenic, teratogenic or mutagenic effects in experiments on
animals.
ECOLOGICAL INFORMATION
Global warming potential HGWP (R11=1): R125: 0.84 - R134a: 0.28
Ozone depletion potential ODP (R11=1): 0
CONSIDERATIONS ON DISPOSAL
Usable with reconditioning.
TAEevo015÷351
Chapter 3 - Technical data
CHAPTER 3
TECHNICAL DATA
The main technical data are given on the machine data plate:
MODEL and CODE They identify the size of the unit and the type of construction.
MANUAL This is the code number of the manual.
SERIAL NUMBER This is the construction number of the unit.
MANUFACTURING YEAR This is the year of the final test of the unit.
VOLTAGE/PHASE/FREQUENCY Electric alimentation characteristics.
MAX. CONSUMPTION (I max) This is electrical current consumed by the unit during the limit working conditions.
INSTALLED POWER (P max) It is the power absorbed by the unit during the limit working conditions.
PROTECTION As defined by the EN 60529 European standard .
REFRIGERANT This is the refrigerant fluid in the unit.
REFRIGERANT QUANTITY This is the quantity of refrigerant fluid contained in the unit.
For TAEevo 015÷031 models
MAX. COOLING PRESSURE This is the design pressure of the refrigeration circuit.
MAX. COOLING TEMPERATURE This is the design temperature of the refrigeration circuit.
For TAEevo 051 models and upper models
MAX. COOLING PRESSURE HP SIDE This is the design pressure of the refrigeration circuit of the high pressure side
MAX. COOLING PRESSURE LP SIDE This is the design pressure of the refrigeration circuit of the low pressure side
USER CIRCUIT FLUID Fluid used by the unit (normally water).
MAX. UTILIZATION PRESSURE Max. designed pressure of the utilization circuit.
MAX. TEMPERATURE Design temperature of the user circuit; this should not be confused with the maximum
working temperature which is established when the offer is made.
CONDENSER COOLING FLUID Fluid the machine uses to cool the condenser.
MAX. WORKING PRESSURE Maximum design pressure of the condenser cooling circuit.
MAX. TEMPERATURE Maximum designed temperature of the cooling circuit of the condenser.
SOUND PRESSURE LEVEL Sound pressure level in a free field in hemispherical irradiation conditions (open field)
at a distance of 1 m from the machine, condenser side, and at 1.6 m from the ground.
AMBIENT TEMPERATURE Min. and max. cooling air temperature value.
WEIGHT This is the approximate weight of the unit before packing.
Table 3 DATA PLATE AND MEANING OF ABBREVIATIONS
ATTENTION
The performance of the unit mainly depends on the flow and temperature of the water in the user circuit and on the temperature of the
thermal exchanger fluid of the condenser. These data are defined during the offer stage.
3.1 Other data relative to the standard machines

3.1.1 Dimensions
See enclosures.
TAEevo015÷351
3.1.2 Characteristics of pumps and of the fans
Model 015 020 031 051 081 101

(litres) 60 60 115 115 140 255
Tank capacity water volume
(galUS) 16 16 30 30 37 67
water flow rate (m 3 /h) 0.3/4.8 0.5/4.8 0.7/6 1.0/6 1.8/9.6 2.3/9.6
(gpm) 1.1/21.1 1.1/21.1 1.8/26.4 2.6/26.4 4.4/42.3 5.7/42.3
(bar) 3.2/1.4 3.2/1.4 3.1/1.5 3.0/1.4 2.9/1.3 2.9/1.5
pump head
PUMP P3 (PSI) 43.8/20.6 43.8/20.6 44.9/22.6 44.5/21.3 44.2/19.0 43.8/22.6
nominal power (kW) 0.55 0.55 0.75 0.75 0.9 0.9
nominal power
(kW) 0.75 0.75 0.75 0.75 0.9 0.9
(460/3/60 Hz)
water flow rate (m 3 /h) 0.3/4.8 0.5/4.8 0.7/4.8 1.0/4.8 1.8/13 2.3/13
(gpm) 1.1/21.1 1.1/21.1 1.8/21.1 2.6/21.1 4.4/57.2 5.7/57.2
(bar) 5.4/2.9 5.4/2.9 5.4/3.1 5.3/3.2 5.2/2.8 5.1/3.1
pump head
PUMP P5 (PSI) 79.4/42.1 79.4/42.1 78.9/45.4 78.3/46.6 75.8/40.6 75.7/45.8
nominal power (kW) 1.1 1.1 1.1 1.1 2.2 2.2
nominal power
(kW) 1.5 1.5 1.5 1.5 3 3
(460/3/60 Hz)
number of fans 1 1 1 1 1 2
AXIAL FANS total air flow (m 3 /h) 4050 3500 6900 6400 9200 16000
(50/60 Hz) (gpm) 17831 15410 30380 28178 40506 70445
number of fans -- -- 1 1 1 2
CENTRIFUGAL (Pa) 166 185 260 140
FANS available head -- --
(PSI) 0.02 0.02 0.03 0.02
(NOT present with
460/3/60 Hz supply)
total air flow (m3 /h) -- --
6900 6400 9200 13600
(gpm) 30379 28178 40506 59878
Table 4 CHARACTERISTICS OF STANDARD UNITS
Model 121 161 201 251 301 351

(litres) 255 255 350 350 350 350
Tank capacity water volume
(galUS) 67 67 92 92 92 92
water flow rate (m 3 /h) 3.0/18 3.7/18 3.9/18 4.4/18 4.9/27 5.5/27
(gpm) 7.0/79.3 8.4/79.3 8.8/79.3 8.8/79.3 11.0/118.9 11.4/118.9
(bar) 2.8/1.6 2.8/1.7 2.8/2.0 2.8/2.0 3.3/0.9 3.2/0.8
pump head
PUMP P3 (PSI) 41.5/24.2 41.4/25.1 41.4/29.8 41.4/29.8 48.8/13.3 48.7/12.3
nominal power (kW) 1.85 1.85 1.85 1.85 2.2 2.2
nominal power
(kW) 1,85 1,85 1,85 1,85 2.2 2.2
(460/3/60 Hz)
water flow rate (m3 /h) 3.0/13 3.7/13 3.9/30 4.4/30 4.9/30 5.5/30
(gpm) 7.0/57.2 8.4/57.2 8.8/132.1 8.8/132.1 11.0/132.1 11.4/132.1
(bar) 5.1/3.1 5.0/3.2 5.2/1.8 5.1/1.8 5.1/1.9 5.1/1.8
pump head
PUMP P5 (PSI) 75.6/45.8 75.4/47.1 76.5/27.1 76.5/27.1 67.2/27.3 76.1/26.1
nominal power (kW) 2.2 2.2 4 4 4 4
nominal power
(kW) 3 2.2 3 4 4 4
(460/3/60 Hz)
AXIAL FANS total air flow 3
(m /h) 15000 14200 18200 17600 23700 23700
(50/60 Hz) (gpm) 66043 62520 80132 77490 104347 104347
CENTRIFUGAL (Pa) 125 138 237 245 150 150
FANS available head
(PSI) 0.01 0.2 0.3 0.3 0.2 0.2
(NOT present with
460/3/60 Hz supply)
total air flow (m 3 /h) 13500 12780 18200 17600 20145 20145
(gpm) 59438 56268 80132 77490 88695 88695
Table 5 CHARACTERISTICS OF STANDARD UNITS
TAEevo015÷351
NOTE
The values in the table may vary in relation to the model and configuration of the unit. In this case reference should be made to the data in the
offer.
NOTE
The head is the head available to the user. It is possible for the pump installed to be different from the standard. There are two numbers for
the flow rate and pressure: the first number refers to the nominal conditions while the second to the maximum conditions.
3.1.3 Sound Level Measurements
Fan Lp dB(A) * Lw dB(A) **

TAEevo 015 axial 67,4 80,4
TAEevo 020 axial 67,4 80,4
axial 68,1 81,1
TAEevo 031
centrifugal *** 73,8 86,8
axial 68,1 81,1
TAEevo 051
axial 68,6 81,6
TAEevo 081
axial 69,1 82,1
TAEevo 101
axial 69,1 82,1
TAEevo 121
axial 70,0 83
TAEevo 161
axial 71,3 84,3
TAEevo 201
axial 71,3 84,3
TAEevo 251
axial 73,0 86
TAEevo 301
axial 73,0 86
TAEevo 351
* at distance of 1 metre (3,2 FT)

** global
*** (NOT present with 460/3/60 Hz supply)
Test conditions
Noise levels refer to operation of the unit at full load in nominal conditions.
Sound pressure level in hemispherical irradiation conditions at a distance of 1 m (3,2 FT) from the condenser side of the unit and height of 1.6 m
(5,2 FT) from the ground. Values tolerance ± 2 dB.
Sound power level: in compliance with ISO 3744.
TAEevo015÷351
Chapter 4 - Description
CHAPTER 4
DESCRIPTION
4.1 Components
The data relating to the materials refer to standard machines. In case of particular units special materials are used, so it is necessary to refer to the
data on the offer.
The machines essentially consist of the following components:
• Refrigeration compressor
• Condenser
• Evaporator
• Tank
• Pump
• Frame/outer panelling
• Electronic controller
4.2 Cooling circuit
Models TAEevo have a single refrigerant circuit with one or two compressors connected in parallel (tandem).
The circuits consist of the following components:
• refrigerant fluid used R407C;
• piston hermetic compressor or scroll compressor;
• fan pressure switch with on/off regulation;
• pressure switches for high and low refrigerant pressure;
• high pressure transducer for fan electronical regulation and for unloading (NOT present with 460/3/60 supply, centrifugal fans
and in TAEevo015÷020);
• liquid solenoid valve (with prismatic tank and plate-type evaporator);
• thermostatic throttle valve with external equalization (in models without prismatic tank present only from TAEevo031);
• dryer filter;
• liquid flow sight glass (in models without prismatic tank present only from TAEevo031);
• lamination capillary (only for TAEevo015÷020);
• refrigerant manometers (TAEevo031);
• Schrader service valves;
Consult the enclosed drawings for additional information.
4.3 Compressors
All the machines are equipped with piston or SCROLL hermetic compressors, which are distinguished for their high energy efficiency, low
vibrations and consequent silence in normal operation.
They are cooled by the aspirated gas, protected against overheating of the windings by an internal module that monitors their temperature and,
upstream, by magnetothermic circuit breakers. These components are housed in a closed, but easily accessible, compartment.
4.4 Condenser
Condensation occurs through fin-pack coils consisting of copper tubes and collectors, aluminium fins and shoulders in galvanised sheet.
4.5 Evaporator
The evaporator is a finned pack type; the water flows in contact with the finned surface and at a speed that guarantees low pressure drops, while
the refrigerant fluid flows inside the tubes.
A plate exchanger can be fitted as an alternative.
In the TAEevo models, the exchanger is protected against the formation of ice, caused by low evaporation temperatures, through an anti-freeze
function in the electronic controller. A probe monitors the temperature of the evaporator outlet water. If it is necessary to achieve a negative
ambient/water temperatures, a mixture of water and glycol must be used.
To drain the circuit, see Chapter 9.4 “Emptying the process water circuit” .
4.6 Tank
The storage tank is cylindrical.
Alternatively a prismatic atmospheric tank can be supplied.
The tank can be protected against freezing by means of an electric heater managed by the electronic controller. A level sensor in the tank serves
to signal low water level conditions. The standard supply includes anti-condensation cladding, a drain valve and an air bleed valve. An internal
bypass between the water delivery and return connections, makes it possible to read the anti-freeze probe if the unit's process water inlet and
outlet connections are inadvertently closed. In this case the unit stops due to tripping of the antifreeze alarm and the shut-off valves must be
reopened.
The bypass serves exclusively to allow an antifreeze alarm to trip (if present) and to allow the pump to run with a reduced water flow rate
without damage. It is advisable to avoid repeated antifreeze alarm trip cycles in the foregoing conditions.
TAEevo015÷351
With the prismatic atmospheric tank process water

filling is performed utilising a kit comprising a semi-
transparent plastic container secured to the rear of the
machine. In steady-state operating conditions the
liquid level must be about half way up the container.
4.7 Pump
Centrifugal pumps are installed and it is possible to choose between 2 different types, which provide two different pressures based on
requirements (a 3 or 5-barg pump). It is also possible to have units without pump.
The tandem pump can be installed in certain models.
The management procedure is manual. The selector for pumps rotation is located inside the electrical cabinet.
For more information consult the attached diagrams.
The pump seals are made of ceramics/treated carbon/EPDM.
ATTENTION
Bleed the circuit by unscrewing the bleed cap on the pump whenever the water circuit is filled .See 5.4 “Hydraulic connections” .
NOTE
The pump must never run dry.
4.8 Fans
Axial fans
The fans of axial type consist of a die-cast aluminium fan with sickle profile.
The protection rating of the fans is IP54.
The protection rating of the fans is IP44 for TAEevo015÷020.
All fans have “F” insulation class to assure the external working with all types of climates. The assembly is completed with a superior (support
to the fan) safety protection grill.
Centrifugal fans (NOT present in models with 460/3/60 supply)
Can be installed exclusively on models higher than TAEevo031.
These are double drive fans with the fanwheel coupled directly to the motor shaft and they feature ON/OFF control. The delivery port is located
on the top of the unit.
The delivery direction can be modified on models TAEevo201÷351.
4.9 Casing
The base, uprights and panels are made of galvanized carbon steel and held together by screws and/or rivets. All panels undergo a phosphor
degreasing process followed by epoxy polyester powder coating.
The frame is designed to allow easy access to all machine components.
Model width depth height
(mm) 560 1266 810

TAEevo 015÷020
(in) 22 49.8 31.9
(mm) 660 1311 1400

TAEevo 031÷051
(in) 26 51.6 55.1
(mm) 760 1858 1447

TAEevo 081÷161
(in) 29.9 73.1 57
(mm) 870 2240 2065

TAEevo 201÷351
(in) 34.3 88.2 81.3
TAEevo015÷351
4.10 Materials in contact with the liquid to be cooled

There can be two different groups.
Standard chillers: carbon steel, copper, aluminium, zinc, brass, stainless steel and plastics
in particular:
• evaporator with copper tubes, aluminium fins and shoulders in galvanised steel;
• tank in carbon steel;
Chillers with non-ferrous water circuit: stainless steel (AISI 304), copper, brass and plastics
in particular:
• evaporator with tubes and fins in copper and brass shoulders;
• tank in AISI 304 stainless steel;
alternatively
• external plate evaporator
• prismatic atmospheric tank
The pump mechanical seals are made of ceramics, graphite and/or EPDM.
4.11 Minimum distances from walls in the installation ambient
See enclosures.
4.12 Electrical circuit
For the electrical connections, see Chapter 5 “Installation“, Installation, and consult the enclosed drawings.
4.13 Negative ambient temperatures (not present in models for
460/3/60 power supply)
In the presence of sub-zero ambient temperatures (-20) the unit is equipped with a system that assures perfect operation, also in the presence of
harsh temperatures.
The additional elements fitted are:
• electronic fans speed control;
• crankcase heaters
• electrical cabinet heaters
The pump and tank can be equipped with electrical heaters to prevent icing up (instead of using glycol solutions).
TAEevo015÷351
Chapter 5 - Installation
CHAPTER 5
INSTALLATION
ATTENTION
Before carrying out the installation or operating on this machine, ensure that all the personnel has read and understood the Chapter 2
“Safety“ in this manual.
5.1 Inspection
Immediately after uncrating, inspect the unit.
5.2 Positioning
1. The unit may be installed both outdoors and indoors.
2. If installed indoors, the room must be well ventilated and with a sufficient height which allows the air to be expelled by fans. In
some cases it may be necessary to install fans or extractors to limit the temperature of the room.
3. The minimum and maximum working ambient temperature are specified on the unit data plate. In extreme temperature conditions,
the protection devices may trip.
4. The machine must be positioned on any flat surface capable of supporting its weight.
5. Leave at least one metre around the unit to permit access during service operations.
6. Do not obstruct or disturb the condenser's flow of thermal exchanging air.
5.3 Antifreeze protection

Even if the minimum working ambient temperature is above 0°C it is possible for the machine - during stoppages in the cold seasons - to find
itself in an environment with a temperature below 0°C.
In these cases, if the machine is not emptied, antifreeze (ethylene glycol) must be added in the following percentages to prevent the formation of
ice:
Ambient temperature up to Ethylene Glycol

[°C] (°F) [% in weight]
0 (32) 0
-5 (23) 15
-10 (14) 25
-15 (5) 30
-20 (-4) 40
Table 6 ADDING ETHYLENE GLYCOL BASED ON THE AMBIENT TEMPERATURE
Add the following anti-freeze (ethylene glycol) percentages in order to avoid freezing when operating at low water outlet temperature:
Water outlet temperature up to Ethylene Glycol

[°C] (°F) [% in weight]
5 (41) 0
0 (32) 19
-5 (23) 27
-10 (14) 34
-15 (5) 39
-20 (-4) 44
Table 7 ADDITION OF ETHYLENE GLYCOL ACCORDING TO THE WATER OUTLET TEMPERATURE
ATTENTION
Carry out the level sensor calibration when the unit is activated the first time. Repeat the operation each time the composition of the process
liquid changes.
TAEevo015÷351
5.3.1 Operating limits

The operating limits are decided at the time of sale. Refer to the contract data.
Minimum Maximum
ambient air temperature

°C /°F -5 /23 43 /109.4(*)
Standard version
ambient air temperature
°C /°F -20/-4(***) 43/109.4(*)
(**)
evaporator inlet water

°C /°F -5 /23(****) 35 /95
temperature
evaporator outlet water
°C /°F -10 /14(****) 30 /86
temperature
(*) With outlet water to a temperature of 15 °C

(**) Not present in models with 460/3/60 supply.
(***) With unit equipped with condensing pressure control.
(****) For temperatures below +5°C (41°F) use antifreeze solutions.
5.4 Hydraulic connections
NOTE
All hydraulic connections must be carried out by the customer.
1. Connect the unit to the water piping respecting the water flow direction as indicated in the annexed overall dimension drawings.
2. Provide two cocks (one at the inlet and one at the outlet) for excluding the unit when maintaining without emptying the user water
circuit.
3. Fill the tank with water using:
• A remote discharge system. In this case it is necessary to leak manually the air from the tank by operating on the manual valve.
• If there are frequent air infiltrations into the water circuit it is advisable to install an automatic bleed valve.
4. If the machine is supplied without a pump, make sure that the pump installed by the user has the suction directly connected to the
tank outlet.
NOTE
The pump must never run dry.
ATTENTION
If the unit is furnished without hydraulic group, it is necessary to install a pump for the evaporation water circuit.
For maintenance purposes, we recommend installing a water drainage cock in the lower part of the circuit.
Evaporator water connection size
TAEevo unit model 015÷020 031÷051 081÷161 201÷351
Evaporator water
IN/ OUT Rp 3/4” Rp 1” Rp 1” 1/2 Rp 2”
connections
ATTENTION
For correct operation, we strongly recommend the installation of a water filter to be connected to the inlet pipe to avoid the entry of solid
particles that could damage the pumps. The non-observance of this instruction can cause big damages to the evaporator.
TAEevo015÷351
Process water inlet Process water outlet
When filling the circuit with liquid check to ensure the absence of air bubbles and
PLUG contaminants. If the pump runs noisily or emits anomalous noise it may be necessary to
bleed the liquid circuit in order to prime the pump.
The procedure is as follows:
• unscrew the filler/breather plug at the top of the pump
• fill the hydraulic circuit until water starts to overflow from the filled hole
• refit the plug and tighten it
Repeat the operation if the pump continues to run noisily, in such a way as to eliminate
any air that had previously remained trapped in the impeller vanes.
In the event of double pump, keep particular attention during priming the pump. It is
necessary to verify first the pump positioned on the top.
5.5 Expansion tank

If the hydraulic circuit is of closed type, it is necessary to install an expansion tank.
The expansion tank must always be connected at pump inlet.
To calculate the minimum volume of the expansion tank required for a given installation, the formula below cab be used and is valid if the
pressure is less than or equal to 0.5 bar when the pump is stopped and the maximum working pressure of the expansion tank is greater than or
equal to 4 bar.
The volume of the expansion tank V in litres is given by the formula:
V = 2 · Vt · (Ptmin - Ptmax)
where:
Vt= total volume of the circuit in litres
Ptmin= specific weight at the minimum temperature obtainable by water
over the year in °C (even with the unit stopped)
Ptmax= specific weight at the maximum temperature obtainable by water
over the year in °C (even with the unit stopped)
Example of calculation:
Vt=200 litres
percentage of ethylene glycol in volume =30%
tmin =5°C from the table Ptmin=(1.045+1.041)/2 = 1.043
tmax =40°C from the table Ptmax=1.0282
V=2 · 200 · (1.043 - 1.0282)=5.92 litres
TAEevo015÷351
Table of specific weights P
% Glycol 0% 10% 20% 30% 40%

-20(-4) 1,0036 1,0195 1,0353 1,0511 1,0669
-10(14) 1,0024 1,0177 1,033 1,0483 1,0635
Temperature [°C]
0(32) 1,0008 1,0155 1,0303 1,045 1,0598

10(50) 0,9988 1,013 1,0272 1,0414 1,0556
20(68) 0,9964 1,0101 1,0237 1,0374 1,051
30(86) 0,9936 1,0067 1,0199 1,033 1,0461
40(104) 0,9905 1,003 1,0156 1,0282 1,0408
Table 8 SPECIFIC WEIGHTS
5.6 Electrical connections

The connection of the unit to the power supply network must be done in conformity with the laws and prescriptions in force in the installation
place.
The power supply voltage, the frequency and the phase number must be as shown on the unit data plate.
The power supply voltage must not be, also for short periods, out of the tolerances given in the wiring diagram.
Except for different indications, the frequency tolerance is +/-1% of the nominal value (+/-2% for short periods).
In the event of three-phase supply, the system must be symmetrical (equal effective voltage values and equal phase angles among consecutive
phases).
In particular, except for different indication, the max. unbalance between each phase is 2%. The unbalance is calculated as following:
Max difference of each phase from Vavg

x100
Vavg
Vavg= average of voltage phases

In the event of single-phase supply, check that there is a neutral line in the electrical installation and it is earthen in the transformer cabin (TN
system in compliance with IEC 364) or that this is done by the electricity supply company (TT system in compliance with IEC 364).
The phase conductor and the neutral wire must not be confused.
For the electrical supply:

1. connect the unit (PE terminal in the electrical panel) to the earthed system of the building
2. guarantee the automatic interruption of the power supply in the event of insulation failure (protection against indirect contacts in
compliance with IEC 364) by means of a differential device (normally with operation nominal current of 0.03 A)
3. at the beginning of the electrical supply cable must be guaranteed a protection against direct contacts with a protection degree of
IP2X or IPXXB at least
4. at the beginning of the electrical supply cable must be installed protection devices that protect against overcurrents (short circuit)
(see information in the electrical wiring)
5. use conductors which transform the max. current required to the max. operating ambient temperature, according to the selected
installation type (IEC 364-5-523) (see information in the electrical wiring)
6. protection devices must be installed to limit the short circuit current to peaks of 17 kA corresponding to the specified interruption
power if the short circuit current envisaged at the point of installation is greater than an effective value of 10 kA.
Indications of electrical wiring:

A max. size permitted for the fuse type gG.
In general, the fuses can be replaced with an automatic switch regulated by means of the unit max. absorbed current (contact the
manufacturer if necessary)
B section and type of the power supply cable (if not already supplied):
•
installation: insulated conductors, multipolar cable in duct, in air or over masonry (C type in compliance with IEC 364-5-523
1983) or without no other cable in contract
• working temperature: the max. working ambient temperature of the unit
• cable type: copper conductors, PVC insulation from 70°C (if not specified) or EPR insulation from 90°C
Consult the enclosed electrical diagram for additional information.
TAEevo015÷351
Chapter 6 - Start up
CHAPTER 6
START UP
ATTENTION
Before starting up these units be sure that all personnel have read and understood the Chapter 2 “Safety”.
1. Check that the machine's on/off valves are open.

2. Check that the tank is completely full of water and properly vented.
3. Carry out the level sensor calibration as indicated in the 8.5 “Level sensor” paragraph
4. Check that the ambient temperature is within the limits indicated in the machine data plate.
5. It is possible to check that the pressure is about 0.5 bar on the manometer located on the back of the unit (only if the water circuit is
of the closed type).
6.Check that the main switch is in the OFF position (“0”).
7.Check that the power supply voltage is correct.
8.Power the machine by means of the supply line protection device.
9.Turn the machine main switch ON (“I”).
10.Check that the water flows across the evaporator.
' button for 5 seconds if you want to start the unit.

flashes for 5 seconds and then it remains lit.
11. Press
To power-off the machine, press the ' key.

The led
12. In three-phase units, check that compressor works correctly (it must not be noisy or overheated) and check that the fans and the
pump (if installed) rotation direction is correct.
If necessary invert two phases of supply.
13. Check that the pressure difference between the value read on the manometer located on the machine control panel with the pump in
motion and the value read with the pump stopped is higher than the available pressure with the pump's maximum flow capacity. If
this difference is lower, it means that the water flow capacity is higher than the maximum value allowed. In order not to damage the
pump, it is necessary to increase the pressure drop of the hydraulic circuit by, for example, partially closing a pump discharge cock.
14. Models with centrifugal fans:
Check that the output of the centrifugal fans is correctly ducted and that the pressure drop of the ducting system is about equal to the
available head. If the pressure drops are:
- greater this means that there is a reduction in the flow of cooling air with a consequent drop in machine performance and the
possibility of protection devices tripping even at relatively low ambient temperatures;
- lower this means that the air flow may be too high for the fan and this could be dangerous for the centrifugal fan motor.
15. If with the first start-up, there is a high ambient temperature and the temperature of the water in the hydraulic circuit is much higher
than the working value (e.g. 25-30°C) this means that the chiller starts up overloaded with the consequence of possible tripping of
the protection devices. To reduce this overload, a chiller outlet valve can be gradually (but not totally!) closed to reduce the flow of
water passing through it. Open the valve as the water temperature in the hydraulic circuit reaches the working value.
16. The machine is now ready for operating.
If the thermal load is lower than that produced by the unit, the water temperature drops until it reaches the set point (ST01
parameter) set following the instruction of chapter Electronic Board.
When SET-POINT value has been reached, the electronic control controlling the water inlet temperature stops the compressor. The
water pump, on the other hand, is always in motion.
TAEevo015÷351
Chapter 7 - Electronic Board
CHAPTER 7
ELECTRONIC BOARD
7.1 Display
The display is divided in 3 zones.
It displays the temperature of temperature regulation probe.
NOTE
The displaying depends on the setting of parameter CF36 (see chapter
7.9 “ Values displayed” ).
Top-left zone
It displays the operating setpoint, OFF with stand-by unit.
NOTE
The displaying depends on the setting of parameter CF42 (see chapter
7.9 “ Values displayed” ).
Bottom-left zone
Signalling icons.
Right zone
7.1.1 Display icons

ICON MEANING ICON MEANING

Celsius degrees (If displayed) Low pressure alarm
Fahrenheit degrees (If not displayed) $ Antifreeze resistance
Bar/Psi D Pump on
Compressor 1 Flow meter alarm
Compressor 2 Time to defrost starting
P Stand-by unit B Fans on
General alarm Indication for Function Menu entering
High pressure alarm
7.2 Function of buttons
BUTTON FUNCTION
)
It selects water temperature and ambient air temperatures in the top part of the display.
During programming phase it scrolls the parameter’s codes or increases their values.
If pressed for 5 seconds, it allows to switch on or off the unit in chiller modality.
&
It selects water temperature in the top part of the display. During programming phase it
scrolls the parameter’s codes or decreases their values.
- If pressed for 5 seconds, it allows to display or modify the set point.

During programming phase it selects a parameter of confirms a value.
*
It allows to enter Function Menu.
TAEevo015÷351
7.2.1 Function of combined buttons
& +-
BUTTONS FUNCTION
To enter programming phase (pressed for 5 sec).
) +- To exit programming phase.
) +- If pressed for more than 5 seconds they allow to start a manual defrosting cycle (function not present).
7.3 Symbols and leds on the display
LED LED STATUS MEANING LED LED STATUS MEANING
4 Not enabled 5 Not enabled
Steady Unit on in chiller modality 5 Not enabled
5 led)
Programming phase (if flashes
Flashing Clock adjustment
together with
5 Not enabled
7.4 Remote terminal

7.4.1 Function of buttons
0
BUTTON FUNCTION
It allows to enter Function Menu.
2 If pressed for 5 sec., it allows to display or modify the set point.
1
During programming phase it selects a parameter or confirms a value.
It selects water temperature in the top part of the display.
During programming phase it scrolls the parameter’s codes or increases their
3
values.
It selects water temperature in the top part of the display.
During programming phase it scrolls the parameter’s codes or decreases their
/
values.
If pressed for 5 seconds it allows to switch on or off the unit.
. Not enabled
If there is no communication between the unit and the remote terminal, in the top part of the
display it appears the message “OP- ” (no link).
NOTE
The displaying depends on the setting of parameter CF43-CF44 (see chapter 7.9 “ Values displayed”).
7.5 Displaying during an alarm
During normal operation (no alarm), when an alarm occurs the alarm
code and the appropriate icon flash in the bottom part of the display,
alternated to the temperature / pressure.
TAEevo015÷351
7.5.1 Alarm icons

There are four icons for alarm signalling:
General alarm
High pressure alarm
Low pressure alarm
Flow meter alarm
7.6 How to silence the buzzer

Automatic silencing: it happens when the cause of the alarm has been eliminated.
Manual silencing: press and release one of the four buttons; the buzzer silences even if the alarm condition persists.
7.7 First start up
At the first start up of the unit in the bottom part of the display it could appear the message “ SU$ ” alternated with the temperature. It indicates
that it is necessary to regulate the clock.
If the probes used to control the unit are not connected or are damaged, the appropriate alarm will be displayed.
However, it is possible to regulate the clock or to programme the unit.
7.8 Programming by keyboard
The parameters of electronic control are divided in two groups and in two levels:
1. USER (Pr1);
2. SERVICE (Pr2).
USER level allows to access user parameters, SERVICE level allows to access the parameters of unit configuration (it is protected by a
password).
The parameter’s groups, indicated by some “Label”, are divided as follows:
LABEL ACTION
ALL It displays all parameters
ST It displays Thermoregulation parameters
CF It displays Configuration parameters
Sd It displays only the parameters of the Dynamic Setpoint (NOT ENABLED FUNCTION)
ES It displays only the parameters of the Energy Saving (NOT ENABLED FUNCTION)
CO It displays Compressor parameters
FA It displays Fan parameters
Ar It displays only the parameters of the Antifreeze Resistance
dF It displays only the parameters of the Defrosting (NOT ENABLED FUNCTION)
AL It displays only the Alarm parameters
LS It displays only the LASER parameters (NOT ENABLED FUNCTION)
7.8.1 Access to “Pr1” parameters (User level)

To enter the menu of “Pr1” parameters which can be access by the user:
1. Press for some seconds - + ' buttons (5 and start flashing), in the top of the display appears “ALL”, the first group of
parameters.
2. Select the various groups using ( and ' buttons.

3. After selecting a group, press - button: if the selected group is part of the selected menu or any parameter of this group has been
moved in this menu, in the bottom of the display it appears the “Label” and the code of the group’s first parameter present in “Pr1”,
its value appears in the top of the display.
It will not be possible to enter a parameter’s group which is not part of this menu.
4. It is possible to scroll or modify the parameters contained in the group.
7.8.2 How to modify a parameter’s value

1. Enter the programming procedure.
- button to enable the value’s adjustment.

2. Select the desired parameter.
Modify the value by means of ( and ' buttons.

3. Press
Press - to store the new value and to pass to the code of the following parameter.
4.
To exit the procedure: Press - + ( when a parameter is displayed, or wait (about 240 seconds) without pressing any button.
5.
6.
TAEevo015÷351
- button.
NOTE
The new value is stored also when the programming procedure is terminated for “time out”, without pressing
ATTENTION
You can modify the parameter of the CF (configuration parameters) family only when the unit is in stand by.
7.9 Values displayed

The values visualized on the display change according to the configuration of parameters CF36 for the top part and CF42 for the bottom part.
For remote terminal it changes according to the configuration of parameters CF43 for the top part and CF44 for the bottom part.
Parameter CF36/CF43 = 0
In the top part of the display it appears the probe BEWOT
In the top part of the display it appears the probe BTWOT
No value will appear in the top part of the display
In the top part of the display it appears the probe BAT1
In the top part of the display it appears the chiller set; off when unit in stand-by
In the top part of the display it appears “OnC” when the unit is operating; off when unit in stand-by
In the top part of the display it appears the LASER set (FUNCTION NOT ENABLED)
No value will appear in the top part of the display
In the top part of the display it appears the operating differential
In the bottom part of the display it appears the probe BEWOT
In the bottom part of the display it appears the probe BTWOT
In the bottom part of the display it appears the probe PCP1
In the bottom part of the display it appears the probe BAT1
In the bottom part of the display it appears the chiller set; off when unit in stand-by
In the bottom part of the display it appears “OnC” when the unit is operating
In the bottom part of the display it appears the LASER set (FUNCTION NOT ENABLED)
No value will appear in the bottom part of the display
( for 30 sec the top display visualizes the BEWOT probe, in the
In the bottom part of the display it appears the operating differential
If the probe BTWOT has been selected has default, every time you press
( for 30 sec the top display visualizes the BTWOT probe, in the
bottom part of the display it will appear the “Label” Pb2 than the default value will return to be displayed.
If the probe BEWOT has been selected has default, every time you press
bottom part of the display it will appear the “Label” Pb1 than the default value will return to be displayed.
' button for 5 seconds allows to switch on or off the unit.

7.10 Unit switching on / off
The pressure of
The led of icon flashes for 5 seconds then it remains lit.
7.11 How to put the unit in stand-by
P lit.
Stand-by modality is obtained every time the unit is switched off.
It is indicated by the symbol

Also in stand-by modality the controller can:
1. Display the measured values
2. Manage the alarms by displaying and signalling.
TAEevo015÷351
7.12 Function menu (* button)

The access to Function Menu allows to:
1. Display and reset the alarms (see 7.12.3 “How to display the alarms “ALrM””).
Reset the alarms (see “How to reset an alarm “rSt””).
2. Display the alarm history (see 7.12.5 “How to display the alarm historic “ALoG””).
3. Upload the parameters from the unit to the key.
4. Display the operating hours of the controlled loads.
Reset the operating hours of the controlled loads.
* button (menu).
7.12.1 Access to Function menu
Press and release
The icon “ ” will appear.
* button or wait for time out (30 seconds).

7.12.2 Exit Function menu
Press and release
The icon “ ” disappears.
* to enter Function menu.

7.12.3 How to display the alarms “ALrM”
( or ' to select “ALrM” function.

1. Press
Press and release - button.

2. Press
Press ( or ' to scroll all alarms.

3.
To exit press * or wait for time out (30 seconds).

4.
5.
* to enter Function menu.

7.12.4 How to reset an alarm “rSt”
1. Press
- , in the bottom of the display it appears the alarm code.

2. Select “ALrM” function
3. Press
( or ' button to scroll all the alarms.

4. If the alarm can be reset in the top of the display it appears the Label “rSt”, it the alarm can not be reset it appears the Label “NO”.
When the Label “rSt” is displayed, press - to reset the alarm and go to the following one.
5. Use
To exit press * button or wait for time out (30 seconds).

6.
7.
* button to enter Function menu.

7 . 1 2 . 5 H o w t o d i s p l a y t h e a l a r m h i s t o ri c “ A L o G ”
( or ' button to select the function “ALoG”.

1. Press
Press - until the Label with the alarm code will appear in the bottom of the display, and the Label “n°” with a progressive number
2. Use
3.
( or ' button scroll all the alarms.

will appear in the top of the display.

4. Using
5. To exit “ALoG” function and to return to normal displaying, press
The memory contains until 50 alarms, a further alarm will cancel from the memory the oldest one (the displaying is in increasing order, from the
oldest one to the most recent one).
7 . 1 2 . 6 H o w t o r e s e t t h e a l a r m h i s t o ry “ A r S t ”
1. Enter Function menu.
- button.
2. Select “ALoG” function in the bottom of the display.
( or ' button, select the function “ArSt” in the bottom of the display and “PAS” in the top of
3. Press
4. Inside “ALoG” function, using
- : the password is required. In the bottom of the display it appears “PAS”, “0” flashes in the top of the display.
the display.
5. Press
6. Insert the password for resetting.
7. If the password is correct the Label “ArSt” flashes for 5 seconds to confirm the resetting.
After resetting the unit returns to normal displaying.
TAEevo015÷351

7 . 1 2 . 7 D i s p l a y i n g t h e o p e r a t i n g h o u rs o f l o a d s “ C 1 H r - C 2 H r - P F H r ”
Press ( or ' button until the Label of a single load appears in the bottom of the display: C1Hr (operating hours of compressor
1. Press
2.
1), C2Hr (operating hours of compressor 2), PFHr (operating hours of water pump and of outlet fan).
will be lit.
The operating hours will appear in the top of the display.
3. The icon

7.1 2. 7. 4 Re se t o f th e lo ad op e r atin g h o ur s
Press ( or ' button until the Label of a single load appears in the bottom of the display (C1Hr, C2Hr only 201÷351 units,
1. Press
2.
- button for 3 seconds: in the top of the display it will appear “0”. It indicates that the reset has happened.
PFHr) and the operating hours appear in the top of the display.

3. Press
4. To exit Function menu, press
5. For the other loads repeat the operations from point 2. to point 4.
7.13 Other functions by keyboard
- button.
7.13.1 How to display the Set Point
Press and release
In the bottom part of the display it appears SetC (chiller set).
- button for 5 seconds at least.

7.13.2 How to modify the Set Point
1. Press
( or ' button to modify the set point value.

2. The set point will flash.
To store the new set point value press - button or wait for time out to exit programming procedure.
3. Use
4.
7.14 Compressors unloading function

This procedure is necessary when sudden peaks in cooling demand occur, for instance if the machine is restarted after a long period of inactivity.
Under these conditions the evaporator inlet water temperature might be so high as to require a cooling delivery in excess of system capacity.
The consequent system overload would require the start-up of all the compressors at once, which would be forced to operate in near-limit
conditions.
The overburdened compressors would thus be subject to dangerous overheating which would cause the activation of the thermal protections, or
the pressure of the refrigerant gas could reach alarm levels which would cause the machine to shut down.
This function enables the machine to run (through the switch-off or capacity step operation of the compressors) even when the temperature of the
water at the evaporator’s inlet is high (summer start-up with hot water accumulation), preventing the possible triggering of high pressure alarms.
It is not present in one compressor units.
The following messages will flash on the display:
AEUn= evaporator unloading function
ACUn= condensation unloading function
7.15 Probe key
In this chapter are indicated the probes BEWOT, BTWOT, BCP1 and BAT1, for their positioning consult the refrigerant drawing.
Their description is indicated in the following table:
Name in the manual Borne name Description

-BEWOT PB1 EVAPORATOR WATER OUTLET TEMPERATURE PROBE
-BTWOT PB2 TANK WATER OUTLET TEMPERATURE PROBE
-BCP1 PB3 CONDENSING PRESSURE TRANSDUCER (only with electronic regulation)
-BAT1 PB4 AMBIENT AIR TEMPERATURE PROBE (Only with antifreeze protection
function)
TAEevo015÷351
Chapter 8 - Other components setting
CHAPTER 8
OTHER COMPONENTS SETTING

8.1 Compressor integral protection (PI)
For each compressor, this protection consists of three or six thermistor probes, each inserted in the winding of a motor phase; they are connected
in series and, depending on the model, the terminals can be external. This system ensures complete protection against most of the problems
which can give rise to burning of the windings. When it trips, it is necessary to find and eliminate the cause; then you can start the machine again
by pressing ON-OFF button.
8.2 Refrigerant high and low pressure switches
The units are fitted with the following pressure switches:
1. low pressure switch (LP)
This monitors refrigerant compressor suction pressure and will trip to avoid that values dangerous for compressor normal operation
are reached. It is of an “automatic reset” type. The alarm A02 (see chapter "12.1 Alarm codes and actions"), produced by this
pressure switch tripping, can have a delay time after the compressor starting to avoid simple intake pressure fluctuations or false
alarms interfere with the unit normal operation. After the time set, the pressure switch tripping will be detected by the electronic
board which will display the alarm signal A02 (see chapter "12.1 Alarm codes and actions") band will stop the compressor/s while
the pump (if it is installed) will continue to operate. After the alarm tripping, if the compressor intake pressure increases and exceeds
the pressure switch tripping value it will restart. It will be possible to start up the unit again following the alarm reset procedure
described in Chapter 7 “ Electronic Board” . If the cause of the pressure switch tripping has not removed this cycle will repeat
continuously.
2. high pressure switch (HP)
This monitors the refrigerant compressor discharge pressure and prevents it increases to levels dangerous for compressor working
and for people safety. It is of an “automatic reset” type. Its tripping is detected by the electronic board which will open the
compressor power supply circuit and will display the alarm signal A01 (see chapter "12.1 Alarm codes and actions").
When the compressor outlet pressure drops below the reset point it is reset.
It will be possible to start up the unit again following the alarm reset procedure described in Chapter 7 “ Electronic Board” .
If the cause of the pressure switch tripping has not removed this cycle will repeat continuously.
The pressure switches LP and HP are screwed to the refrigerant circuit piping with SCHRAEDER valves (with needle) which prevent leakage
during replacement.
The TRIP and RESET values of the pressure switches depend upon the refrigerant gas used and are listed in the table below:
TRIP RESET
Pressure switch Refrigerant
bar PSI °C °F bar PSI °C °F
HP 27.2 394.5 63.4 146.1 20.5 297.3 51.5 124.7
R407C
LP 1.7 24.6 -17.3 0.9 2.7 39.1 -8.8 16.2
8.3 Compressor operation

The thermoregulation used is of proportional type. After fixing the temperature and differential values, the compressor will start when the value
measured will exceed the sum of temperature + differential. It will stop when the value will be lower than the temperature - differential. The
same logic will be applied also in two compressor units.
8.3.1 Compressor regulation graphic in Chiller mode
With 1 compressor With 2 compressors
ST09 = 2
TAEevo015÷351
8.4 Fan speed regulation

The fan speed regulation can be carried out by means of a pressure switch (FP) in ON/OFF modality or by means of a pressure transducer (speed
regulator).
1. Fan pressure switch (FP)
In these units a pressure switch detects the refrigerant compressor outlet pressure and controls the fan operation powering them on or
off.
The pressure switch FP is screwed to the refrigerant circuit piping with SCHRAEDER valves (with needle) which prevent leakage
during replacement.
The TRIP and RESET values of the pressure switch depend upon the refrigerant gas used and are listed in the table below:
Axial fans
TRIP RESET
Axial fans
R407C 18 261 46.4 115.5 14 203 37.0 98.6
FP
Centrifugal fans (NOT present in models with 460/3/60 supply)
TRIP RESET
Centrifugal fans
TAEevo 031÷051 R407C 18 261 46.4 115.5 14 203 37.0 98.6
FP
Centrifugal fans
TAEevo 081÷351 R407C 16.3 236.4 42.6 108.7 12.5 181.2 32.9 91.2
FP1
Centrifugal fans
TAEevo 081÷351 R407C 18 261 46.4 115.5 14 203.0 37.0 98.6
FP2
TAEevo 201÷351
TAEevo 051÷161 FP1
FP2 FP1 FP2
ELECTRICAL
BOARD ELECTRICAL
SIDE BOARD
SIDE
2. Speed regulator (NOT present in models with 460/3/60 Hz supply, with centrifugal fans and in TAEevo 015÷020)
The unit is furnished with a speed regulator of fan rotation, which operates to maintain the condensing pressure within a pre-fixed
value.
These units are furnished with a pressure transducer positioned on the refrigerant compressor outlet pipeline. It commutates the
measured pressure value into an electric signal, sent to the speed regulator. For example, if the temperature of the air sent to the
condenser decreases, the pressure transducer will measure a decreasing of the condensing pressure. This pressure decreasing is sent
to the speed regulator which will reduce the fan speed and consequently, the condenser air flow will be reduced. Analogously, when
the air temperature to the condenser and the condensing pressure increase, the regulator will increase continuously the fan speed to
increase the air flow through the condenser.
The following graphic shows the progress of the fan rotation speed according to the condensing pressure changings.
% of rotation speed
Vmax
Vmin
0%
P min P max
condensing
pressure [bar g]
TAEevo015÷351
8.5 Level sensor

ATTENTION
- Take all the necessary precautionary measures to avoid accidental contact with powered elements.
- The voltage values inside the electric panel can be lethal for humans.
- The manufacturer is responsible for level sensor calibration and therefore further modifications are not necessary. Key (1) is sealed to
prevent tampering by the user.
The level sensor indicates the absence of process water inside the tank. An alarm, with relative blocking of the unit, appears on the control
display.
Level sensor calibration (to be performed only on instruction by the MTA Service Centre):
1. Make sure the level probe is

immersed in the liquid (at least 1
cm).
2. Power on the system; green LED (3)
will illuminate steadily.
3. Amber LED (2) may illuminate or
remain off.
4. Press black “Teach” pushbutton (1)
and hold down for more than 2
seconds.
3 1
5. Green LED (3) will flash while
amber LED (2) can:
• illuminate, if it was previously
off
2
• remain illuminated, if it was
previously lit.
6. This sequence of steps causes the
device to self-calibrate in
accordance with the electrical
resistance of the liquid.
NOTE
If the electrical resistance of the liquid is outside the maximum range of the control device, green LED (3) will flash rapidly for 2 seconds while
amber LED (2) remains off, thus signalling a teach-in error.
ATTENTION
The level sensor has been calibrated by MTA to operate at maximum sensitivity admissible on the instrument (220kOhm).
Modifications to this setting may impair correct operation.
TAEevo015÷351
Chapter 9 - Operation and maintenance
CHAPTER 9
OPERATION AND MAINTENANCE

9.1 Operation
The machine operates in completely automatic mode.
There is not necessary to turn it off when there is no thermal load as it turns off automatically when the preset water outlet temperature has been
reached.
9.2 Maintenance
ATTENTION
Before proceeding with the installation or the maintenance of these units be sure that all personnel concerned have read and understood the
Chapter 2 “Safety“.
9.3 Unit access

ATTENTION
Everytime the panels must be removed the unit must be switched off and disconnected from power supply.
To access the components of the refrigerant circuit use an appropriate key furnished with the unit and operate on the closing bolts of the front
panel (A).
The access to the evaporator and to the components of the hydraulic circuit can be carried out by unscrewing, by a screwdriver, the screws fixing
the panel (B).
To access the components of the electrical circuit remove the front panel (C).
For models TAEevo201 and upper
To access the components of the refrigerant circuit operate on the closing bolts of the panel (A). Furthermore, it is possible to access the
components of the refrigerant circuit removing the side panels (B-D). The access to the evaporator and to the components of the hydraulic circuit
can be carried out removing the back panel (F) or the side panels (D), (E), (G) or (H).
TAEevo 015÷020
C
A
TAEevo 031÷161 TAEevo 201÷351 TAEevo 201÷351

F C
C B H
A
F
A
B E D D G
TAEevo015÷351
Chapter 9 - Operation and maintenance
9.4 Emptying the process water circuit

Use the cock installed on the unit lower side if the storage tank need to be emptied for maintenance purposes (in models fitted with a hydraulic
unit).
ATTENTION
The water circuit must be emptied when a unit that has no heating elements or anti-freeze liquid is to be left inactive for a certain period of
time in an environment where the temperature may fall low enough to freeze the water in the evaporator (with the risk of breaking the
evaporator).
9.5 Maintenance schedule
6 months
1 month
1 year
OPERATION
1 day
Check for any alarm signals. x
Check that the water outlet temperature is within the envisaged range. x
Check that the water inlet temperature is in accordance with the value used for selecting the unit. x
In units with hydraulic group, check that the pressure in the tank (with pump stopped, if present) is at least
0.5 bar with the circuit closed.
x
In units with hydraulic group, check that the difference between the discharge and the suction pressure of
the pump (measured on the manometer with the pump stopped) is within expected limits and, in particular, x
that it is not lower than the value corresponding to the maximum flow capacity.
Clean the water filter.
We recommend to clean the filter after a week from the unit starting.
x
Check that the liquid indicator (if present) is full or with a small stream of bubbles when the compressor is
running.
x
Check that the unit current absorption is within the values on the data plate. x
Carry out visual inspection of refrigerant circuit, looking out for any deterioration of the piping or any traces
of oil which might indicate a refrigerant leak.
x
Check the condition and security of piping connections. x

Check the condition and security of electrical connections. x
Using a spanner, check that the connections between the compressor inlet and outlet piping have not
slackened.
x
Check that the ambient air temperature is within the unit capacities.
Check that the environment is well ventilated.
x
Check that fan is automatically switched on .

Thoroughly clean the fins of the condenser with soft brush and/or jet of clean compressed air. x
Check that the grilles of the unit are free from dirt and any other obstructions.
Clean condenser fins with a mild detergent. x
ATTENTION
- This plan is based on an average working situation.
- In some installations it may be necessary to increase the frequency of maintenance.
TAEevo015÷351
Chapter 10 - Trouble shooting
CHAPTER 10
TROUBLE SHOOTING
PROBLEM CAUSE SYMPTOM REMEDY
A A1 A1.1 Restore the thermal load to
Tank water outlet Thermal load too high. Temperature BTWOT within the preset limits.
temperature BTWOT greater than expected
higher than the expected value.
value.
A2 A2.1 In the event of installation in a
Ambient temperature too See A1.1 closed place, if it is possible,
high. increase the change air flow
into the installation location, to
restore the ambient
temperature to within the
preset limits.
A3 A3.1 Clean the condenser fins.
Condenser fins are dirty. See A1.1
A4 A4.1 Free the front surface of the
Front surface of the See A1.1 condenser.
condenser obstructed.
A5 A5.1 Get a technician to check for
Lack of refrigerant in the leaks and eliminate them.
• See A1.1 ;
unit. Fill the unit.
• evaporating pressure too
low;
• a lot of bubbles in the liquid
indicator.
A6 A6.1 Get a technician to check for
Compressor protection • The head and the body of leaks and eliminate them.
trips. the compressor are very Fill the unit.
hot;
• the compressor stops and
try to start up again after
few seconds.
B B1 B1.1 Reduce water flow to within
Low pressure drop (water Water flow too high. • Possible increase in the the preset limits, for example
pressure) at pump outlet. Wrong working of the outlet temperature BTWOT by closing partially a pump
pump (high flow, low (see A1.1); outlet cock.
discharge head, high Reset the pump thermal
• with pump installed on the protection and check the
absorption).
machine: pressure electrical absorption.
difference, read on the
machine pressure gauge,
too low with pump stopped
and pump running;
• possible tripping of pump
thermal protection.
B2 B2.1 See point C.
See point C. See point C.
B3 B3.1 Depending on the type of dirt:
Evaporator obstructed High water temperature • clean the evaporator by
because of dirt transported difference between running a detergent
by the utilization water. input and outlet. solution which is not
aggressive for steel,
aluminium and copper;
• run a high water flow
against the stream.
Install a filter upstream from
the unit.
C C1 C1.1 Clean the upstream filter, if
Water differential pressure The filter upstream from • Water does not flow. installed.
switch FLOW alarm trips. the unit is obstructed, if Pressure difference Follow the alarm reset
installed. between inlet and outlet procedure to star up the unit
Alarm displayed: lower than 25mbar. again (chapter Electronic
A08 Board).
• Alarm displayed: A08.
• main alarm relay tripped.
C2 C2.1 Check the pump electrical
The pump is defective or supply and, if it is necessary,
• See C1.1 ;
rotate in the wrong invert the two phases.
direction. (three-phases • main alarm relay tripped. Follow the alarm reset
supply). procedure to star up the unit
again (chapter Electronic
Board).
C3 C3.1 Invert the water inlet-outlet.
Water inlet-outlet inverted Follow the alarm reset
• See C1.1 ;
(units without hydraulic procedure to star up the unit
kit). • main alarm relay tripped. again (chapter Electronic
Board).
TAEevo015÷351

D D1 D1.1 Repair or replace the fan.
High pressure switch The fan doesn’t work. • Refrigerant compressor Verify the eventual heat
tripped (HP) stops; protection of the fan/s.
Follow the alarm reset
• the indication A01 appears procedure to star up the unit
Alarm displayed:
on the display alternated to again (chapter Electronic
A01
BTWOT value; Board).

• main alarm relay tripped; Check the fan speed regulation
system.
• the led of icon lights
up.
D2 D2.1 In the event of installation in a
Ambient air temperature • Air ambient temperature closed place, reduce the
too high. higher than maximum ambient temperature to within
permitted value; design limits, for example by
increasing local ventilation.
• see D1.1 Follow the alarm reset
procedure to star up the unit
Board).
D3 D3.1 Change the position of the unit
Recirculation of warm air • Condenser thermal or the position of any adjacent
due to incorrect exchanging air temperature obstructions to avoid
installation location. higher than the permitted recirculation.
value; Follow the alarm reset
• see D1.1 again (chapter Electronic
Board).
D4 D4.1 Clean the condenser fins.
See A3 See D1.1 Follow the alarm reset
Board).
D5 D5.1 Clean the front surface of the
See A4 See D1.1 condenser.
Board).
D6 D6.1 If possible, reduce the thermal
Thermal load too high. • Water outlet temperature load to within the design
too high; limits.
• refrigerant compressor procedure to star up the unit
stops; again (chapter Electronic
• main alarm relay tripped. Board).
E E1 E1.1 Call a qualified refrigeration
Low pressure switch Lack of refrigerant (see • Refrigerant compressor engineer to check for leaks
tripped (LP) also A5 ). stops; and replenish refrigerant
charge.
• the indication A02 appears
Alarm displayed:
on the display alternated to
A02
BTWOT value;
lights
• the led of icon

up.
E2 E2.1 Clean or replace the water
The filter upstream from See E1.1 . inlet filter, if installed.
the unit is dirty, if
installed.
F F1 F1.1 Call a qualified refrigeration
Compressor protection Thermal load too high • The head and the body of engineer to check for leaks
trips combined with a shortage the compressor are very and replenish refrigerant
of refrigerant (also see hot; charge.
Alarm displayed: A5 ). • the compressor stops and
A09 or A10
tries to restart after a short
period (even a few
seconds);
• compressor thermal
protection trips;
• the indication A09 or A10
appears on the display;
lights up.
• the led of general alarm
icon
F2 F2.1 Invert two phases of the power

The rotation direction of The refrigerant fluid is supply.
scroll compressor is wrong not compressed and the
(only three-phase units). unit doesn’t cool.
TAEevo015÷351

G G1 G1.1 Check the causes of the fuse
Digital display and all LEDs Auxiliary circuit fuse Measuring with a tester tripping.
off although P1 main tripping. the voltage at the Replace the fuse.
switch On (“I”). transformer secondary
winding connector,
there will be not tension
survey.
G2 G2.1 Try to turn the unit OFF and
Abnormal power Despite presence of ON again.
consumption by one or power at the connectors If this doesn't solve the
more of the control board of the control board, the problem, contact the nearest
components. display and all LEDs service centre
remain unlit.
H H1 H1.1 Check that the temperature
Alarm displayed: Probe BEWOT, BTWOT, • See problem; probe is correctly connected to
P1, P2, P3, P4 BAT1 damaged. the control board terminals
• main alarm relay tripped. and that the cable is
undamaged. If necessary
replace the probe.
I I1 I1.1 Identify and remove the cause
Alarm displayed: Low water outlet • See problem; which provoked BTWOT
A04 temperature. temperature decreasing to a
The value fixed by the value lower than Ar03.
restarts;
parameter is lower than
the one measured by the • main alarm relay tripped.
lights up.
probe. • the led of general alarm
icon
I2 I2.1 Increase the water flow.

Too low water flow. • See problem;
restarts;
J J1 J1.1 Reset the thermal protection
Alarm displayed: The pump's thermal • See problem; device.
A08 protection device has Increase the pressure drop in
• main alarm relay tripped; the hydraulic circuit, for
pump thermal protection. tripped because the water
flow is too high. • the refrigerant compressor example by partially closing
and pump stop; the pump output valve.
• the indication A08 appears
on the display alternated to
BTWOT value;
• the pressure difference
read on the machine gauge
with the pump stopped and
pump running is lower than
the available head with
maximum pump flow.
J2 J2.1 Reset the thermal protection
The grille through which • See problem; device.
the pump cooling air Free the grille.
• main alarm relay tripped;
passes is obstructed.
• the refrigerant compressor
and pump stop.
J3 J3.1 Reset the thermal protection
The pump is defective. • See problem; device.
Replace the pump.
• main alarm relay tripped;
• the refrigerant compressor
and pump stop;
• the current absorbed by
the pump is greater than
the nominal rating;
• the pump may be noisy.
K K1 K1.1 Turn off and turn on the unit.
Alarm Configuration error. ACFx flashes on the If this does not solve the
ACF1,ACF2,ACF3, display and unit problem, contact the nearest
ACF4,ACF5 blocked. service centre.
L L1 L1.1 Turn off and turn on the unit.
Alarm The processor does not • The machine does not If this does not solve the
EE memorize the data in the work; problem, contact the nearest
right way service centre.
• EE flashes on the display;
lights up.
• the led of general alarm
icon
TAEevo015÷351
Chapter 11 - Setting tables
CHAPTER 11
SETTING TABLES
The following tables show the list of all masks which contain adjustable parameters.
On Factory setting column are indicated the setting values set during the unit testing; they are referred only to the unit which has the same serial
number you can find on the label of the first page of this manual.
DANGER
The wrong programming of the electronic control could cause big damages to the unit.
The parameters can be modified by specialized personnel only.
11.1 Parameter setting

To modify the following parameters, follow the procedure illustrated in Chapter 7 “Access to “Pr1” parameters (User level)“ and Chapter 7
“How to modify a parameter’s value“.
11.1.1 Thermoregulation parameters

Parameter Level Description Min. Max. Udm Resolution Factory setting
ST01 U Summer set point ST05 ST06 °C Dec 9°C with 1 compr.
°F Int 48°F with 1compr.
°C 8°C with 2 compr.
°F 47°F with 2compr.
ST02 U Summer differential 00.0 25.0 °C Dec 4°C with 1 compr.
00.0 45.0 °F Int 7°F with 1 compr.
°C 2°C with 2 compr.
°F 4°F with 2 compr.
ST05 U Summer min. set -40.0 ST01 °C Dec 5.0°C
-40.0 °F Int 41°F
Pr2 Password 0 999 - -
1 1 .1 . 2 C o n f i g u r a t i o n p a r a m e t e r s

CF34 U Serial address 1 247 1
CF36 U Default top displaying: 0 8 1
• 0 = BEWIT.
• 1 = BEWOT.
• 2 = none.
• 3 = BAT1.
• 4 = unit setpoint
• 5 = unit status (**)
• 6 = Laser set
• 7 = none
• 8 = operating differential
CF42 U Default bottom displaying: 0 8 4
• 0 = BEWOT.
• 1 = BTWOT.
• 2 = BCP1
• 3 = BAT1.
• 6 = Laser set
• 7 = none
CF43 U Default top displaying of remote terminal: 0 8 1
• 0 = BEWOT.
• 1 = BTWOT.
• 2 = BCP1
• 3 = BAT1.
• 6 = Laser set
• 7 = none
TAEevo015÷351
Chapter 11 - Setting tables

CF44 U Default bottom displaying of remote terminal: 0 6 4
• 0 = BEWOT.
• 1 = BTWOT.
• 2 = none.
• 3 = BAT1.
• 6 = Laser set
• 7 = none
Pr2 Password 0 999 -
1 1 . 1 . 3 D y m a n i c s e t p o i n t p a r a m e t e r s ( N B C P 1 O T E N AB L E D F U N C T I O N )
1 1 . 1 . 4 E n e r g y S a v i n g p a r a m e t e r s ( N O T EN A B L ED F U N C T I O N )
11.1.5 Compressor parameters

EVAPORATOR UNLOADING
CONDENSER UNLOADING
11.1.6 Fan parameters

HOT START
11.1.7 Antifreeze support resistance parameters

Ar03 U Antifreeze alarm set Ar01 Ar02 °C Dec 3°C
°F Int 38°F
BOILER FUNCTION (NOT ENABLED)
1 1 . 1 . 8 D e f r o s t p a r a m e t e r s ( N O T E N A B L ED F U N CT I O N )
11.1.9 Alarm parameters

1 1 . 1 . 1 0 L A SE R p a r a m e t e r s ( N O T E N A B L ED F U N CT I O N )
TAEevo015÷351
Chapter 12 - alarms
CHAPTER 12
ALARMS
12.1 Alarm codes and actions
7.12.3 “How to display the alarms “ALrM”” and 7.12.4 “How to reset an alarm “rSt”” .
See chapter
CODE MEANING CAUSE ACTION RESET

P1 Alarm of BEWOT Probe damaged or “open collector” outlet / alarm relay is Automatic
probe resistive value out of activated If the resistive value returns within the
range The buzzer is activated envisaged range.
The icon for general alarm flashes
The alarm code is displayed
P2 Alarm of BTWOT Probe damaged or “open collector” outlet / alarm relay is Automatic
P4 Alarm of BAT1 Probe damaged or “open collector” outlet / alarm relay is Automatic
A01 High pressure Digital input / high “open collector” outlet / alarm relay is Manual
switch alarm pressure switch activated The digital input is disabled and the
enabled The buzzer is activated resetting procedure is carried out
The icon for high pressure alarm flashes
Condensation fan Digital input “open collector” outlet / alarm relay is Manual
thermal protection enabled activated Digital input disabled and the resetting
The buzzer is activated procedure is carried out
A02 Low pressure Digital input / low “open collector” outlet / alarm relay is Automatic
switch alarm pressure switch activated It becomes manual after the value set of
enabled The buzzer is activated “tripping per hour”
The icon for low pressure alarm flashes Manual
The alarm code is displayed The digital input is disabled and the
resetting procedure is carried out
A03 Ambient air low Analogue input “open collector” outlet / alarm relay is Automatic
temperature alarm enabled activated
The buzzer is activated
A04 Unit outlet air low Analogue input “open collector” outlet / alarm relay is Automatic
temperature alarm enabled activated It becomes manual after nr. “tripping per
(not enabled) The buzzer is activated hour”
A05 High temperature Analogue input “open collector” outlet / alarm relay is Manual
High pressure enabled if BAT1 > activated Disabled if BAT1 < than “set value” and the
of “set value” The buzzer is activated resetting procedure is carried out
The icon for high pressure alarm flashes
A06 Low pressure / Analogue input “open collector” outlet / alarm relay is Automatic
temperature alarm enabled if BAT1 < activated It becomes manual after “tripping per hour”
“set value” The buzzer is activated Manual
The icon for low pressure alarm flashes Disabled if BAT1 > than “set value” and the
The alarm code is displayed resetting procedure is carried out
TAEevo015÷351
Chapter 12 - alarms

A07 Antifreeze alarm Digital input “open collector” outlet / alarm relay is Automatic
enabled if BTWOT activated It becomes manual after “tripping per hour”
< “set value” and The buzzer is activated Manual
actives for the “time The icon for general alarm flashes Disabling:
set” The alarm code is displayed - when the antifreeze regulation probe
BTWOT > “set value” in chiller modality;
and resetting procedure
enabled activated It becomes manual after “tripping per hour”
The buzzer is activated Manual
The icon for general alarm flashes Disabling: digital input not enabled
The alarm code is displayed resetting procedure
motocondensing enabled activated It becomes manual after “tripping per hour”
units (Not enabled) The buzzer is activated Manual
The icon for general alarm flashes Disabling: digital input not enabled
The alarm code is displayed resetting procedure
A08 Flow meter alarm Digital input “open collector” outlet / alarm relay is Automatic
and pump thermal enabled activated It becomes manual after “tripping per hour”
alarm (air/water or enabled for “time The buzzer is activated Manual
water/water units) set” The icon for flow meter alarm flashes Disabling: Digital input disabled for “time
The alarm code is displayed set” and reset procedure
A09 Compressor 1 Digital input “open collector” outlet / alarm relay is Manual
thermal alarm enabled activated Digital input disabled and the resetting
A10 Compressor 2 Digital input “open collector” outlet / alarm relay is Manual
thermal alarm enabled activated Digital input disabled and the resetting
A09- Compressor 1-2 The alarm is Relay alarm + buzzer activated If ID is not activated
A10 thermal alarm visualized but not Manual
enabled during To reset the alarm enter the programming
“compressor
thermal delay time”
after compressor
start up
A11 Condensation fan Digital input “open collector” outlet / alarm relay is Manual
(Not enabled) enabled activated Digital input disabled and the resetting
A12 Error alarm during Defrosting end Displayed code Automatic
defrosting (not (max. time) Only signalling With following correct defrosting cycle
enabled Manual
Reset procedure
A13 Compressor 1 Operating hours > “open collector” outlet / alarm relay is Manual
maintenance alarm “set threshold” activated Operating hours reset
A14 Compressor 2 Operating hours > “open collector” outlet / alarm relay is Manual
A15 Water pump Operating hours> “open collector” outlet / alarm relay is Manual
A20 Low water Only units operating “open collector” outlet / alarm relay Automatic
temperature alarm if the temperature activated
at evaporator outlet measured by PB2 is The buzzer is activated
lower than AL23 The alarm code is displayed
TAEevo015÷351
Chapter 12 - alarms

A21 High water Only units operating “open collector” outlet / alarm relay are Automatic
temperature alarm if the temperature activated
at evaporator outlet measured by PB2 is The buzzer is activated
higher than AL24 The alarm code is displayed
rtC Clock alarm Clock to be “open collector” outlet / alarm relay is Manual
regulated activated Clock regulation and resetting procedure
rtF Clock alarm Clock damaged “open collector” outlet / alarm relay is Manual
Clock malfunction activated Resetting procedure
The buzzer is activated If after resetting the alarm persists replace
The icon for general alarm flashes the clock
EE Eeprom error alarm Memory data lost “open collector” outlet / alarm relay is Manual
activated Resetting procedure
The buzzer is activated If after resetting the alarm persists the
The icon for general alarm flashes device remains blocked
ACF2 Configuration alarm Unit configured as “open collector” outlet / alarm relay is Automatic
heat pump with activated With correct re-programming
commutation valve The buzzer is activated
not configured The icon for general alarm flashes
ACF3 Configuration alarm Two digital inputs “open collector” outlet / alarm relay is Automatic
with the same activated With correct re-programming
configuration The buzzer is activated
ACF4 Configuration alarm CF28= 1 and the “open collector” outlet / alarm relay is Automatic
digital input not activated With correct re-programming
configured or The buzzer is activated
CF28= 2 probe The icon for general alarm flashes
BAT1 different from The alarm code is displayed
3
FErr Operating alarm with two digital The buzzer is activated Manual
inputs enabled at the The icon for general alarm flashes Disabling of digital inputs + reset procedure
same time
AFr Net frequency Net frequency out of “open collector” outlet / alarm relay is Automatic
alarm range activated Net frequency into operating range
ALOC General alarm ID configured as Relay alarm + buzzer activated ID configured as unit blocked generic alarm
unit blocked generic “fixed time”
alarm “time set” Automatic:
AL21 It becomes manual after “tripping per hour
set” (reset procedure in function menu). It is
memorized in the alarm historic only with
manual rearm
TAEevo015÷351
Chapter 12 - alarms
12.2 Outlet blocking
Antifreeze
Alarm code Alarm Description Comp. 1 Comp. 2 Pump
Resistances
P1 BEWOT probe Yes Yes Yes
P2 BTWOT probe Yes Yes Yes
P3 BCP1 probe Yes Yes Yes
P4 BAT1 probe Yes Yes Yes
A01 High pressure switch Yes Yes
Fan thermal protection Yes Yes
A02 Low pressure switch Yes Yes
A03 Ambient air low temperature
A04 Air low temperature at unit Yes Yes Yes
outlet
A05 High temperature High Yes Yes
pressure
A06 Low pressure Low Yes Yes
temperature
A07 Analogue input antifreeze Yes Yes
A07 Digital input antifreeze Yes Yes
A07 Motorcondensing antifreeze Yes Yes
A08 Flow meter/pump thermal Yes Yes Boiler Res. Yes
protection Yes
A09 Compressor 1 thermal Yes
protection
A10 Compressor 2 thermal Yes
protection
A09-A10 Compressor 1-2 thermal Yes Yes
protection
A13 Compressor 1 maintenance
A14 Compressor 2 maintenance
A15 Water pump maintenance
A20 Low water temperature
BTWOT
A21 High water temperature
BTWOT
rtC Clock alarm
rtF Clock alarm
EE Eeprom error Yes Yes Yes Yes
ACF2 Configuration alarm Yes Yes Yes Yes
FErr Operating error Yes Yes Yes
(motorcond.)
Afr Net frequency alarm Yes Yes Yes Yes
ALOC Generic alarm Yes Yes Yes Yes
NOTE
The electronic control board is furnished with a “history” loop, see chapter 7.12.5 “How to display the alarm historic “ALoG”” .
TAEevo015÷351
Chapter 12 - alarms
TAEevo015÷351
Page: 299 Of: 305
Rev.: 3
Operation and maintenance manuals

PUMPING STATIONS
10QFB35AP001 & 10QFB35AP002

Operacion y Mant. Instrument Air

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CLIENT: ELECTRICITY GENERATION COMPANY OF BANGLADESH LTD.

PROJECT: SIDDHIRGANJ 335 MW COMBINED CYCLE POWER PLANT

Compressed Air System

OPERATION AND MAINTENANCE MANUALS

3 23/07/2014 For Approval CA RJ JF

SID-10-QFB-GMO-CMP-001 OPERATION AND MAINTENANCE MANUALS

CLIENT: ELECTRICITY GENERATION COMPANY OF BANGLADESH LTD.

PROJECT: SIDDHIRGANJ 335 MW COMBINED CYCLE POWER PLANT

OPERATION AND MAINTENANCE MANUALS

COMPRESSORS D155-W - 10QFB05AN001 & 10QFB10AN001……...…… 3

COMPRESSORS D37H-W - 10QFB15AN001 &10QFB20AN001…………… 93

ADSORPTION DRYERS - 10QFB25AC001,10QFB25AC002,

REFRIGERATION DRYERS - 10QFB25AC003 & 10QFB25AC004............... 202

AEROS 10QFB05BB001/002, 10QFB05AP001/002, 10QFB05AC001 &

CHILLERS 10QFB15AC001 & 10QFB20AC001………………………………. 256

PUMPING STATIONS 10QFB35AP001 6 10QFB35AP002 ……….....………. 299

SID-10-QFB-GMO-CMP-001 Operation and maintenance manuals

CLIENT: ELECTRICITY GENERATION COMPANY OF BANGLADESH LTD.

PROJECT: SIDDHIRGANJ 335 MW COMBINED CYCLE POWER PLANT

OPERATION AND MAINTENANCE MANUALS

OPERATION AND MAINTENANCE MANUALS

SID-10-QFB-GMO-CMP-001 Operation and maintenance manuals

GB 100008776 / 06 - October 2011

In any communication concerning the compressor it is essential to quote the

Year: Motor Serial Number:

Delivery Date: Intercooler Serial Number:

Maximum Pressure: Intercooler Certificate Number:

kW: Aftercooler Serial Number:

Motor rpm Aftercooler Certificate Number:

V. Ph. Hz. Compressor Lubricant:

M3/min Lubricant Capacity:

Motor Bearing Grease:

1.2 Local CompAir Distributor

Contact Names: Parts:

2 Safety Procedures 2.2 Warnings, Cautions And Notes

2.1.3 CompAir cannot anticipate every possible circum-

3) Bio-degradable items should be subject to nor-

4) Ensure that all fluid waste e.g. lubricating oils

3 General Description 3.3 Electronic Controller

Oil capacity (approx.): 35 litres

Air delivery connection: R3

Cooling water connection: G 1½

Condensate drain connection: 10 mm O.D. Tube

Lifting points: 4, located on baseframe

Delivery air pressure: minimum 5·0 bar

Ambient temperature: minimum 0°C

Cooling water inlet temperature, maximum: 45°C

Cooling water outlet temperature: Typically 11°C above inlet temperature

Cooling water inlet pressure, maximum: 7·0 bar

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

Fan motor power, kW: 1·5

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

Oil pump motor power, kW: 1·5

Oil pump motor rotation: Clockwise viewed from non-drive end

Pressure relief (safety) valve set pressures Interstage 3.1 bar

Dimensions (approx.), L x W x H, mm: 2300 x 1500 x 1500

F.L.C. see data plate

Compressor weight see data plate

Oil Pump and Fan Motor Thermal Overload Settings, Amps

Main Motor Thermal Overload Settings, Amps

4.2 Models D160 To D275

Oil capacity (approx.): 70 litres

Air delivery connection: R4