CompAir 5280D.1.IAC Operator's Handbook Manual
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CompAir 5280D.1.IAC Operator's Handbook Manual

CompAir 5280D.1.IAC Operator's Handbook Manual

Water-cooled air compressor
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OPERATOR HANDBOOK
In any correspondence please quote: JOB NUMBER:
Telephone: +44 (0) 1473 242000 Fax: +44 (0) 1473 745451 Parts Fax: +44 (0) 1473 743468 Service +44 (0) 1527 838443
for a
5280D.1.IAC
Water-cooled
Air Compressor
MACHINE NUMBERS:
PUBLICATION NUMBER:
ISSUE DATE
CUSTOMER ORDER NUMBER:
CompAir UK Ltd. Reavell House
White House Road IPSWICH ENGLAND IP1 5PB
www.compair.com
(on nameplate)
98407.1440
MARCH 2006
email: Ipswich@compair.com
CompAir UK Ltd

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  • Page 1 ISSUE DATE MARCH 2006 CUSTOMER ORDER NUMBER: CompAir UK Ltd. Reavell House White House Road IPSWICH ENGLAND IP1 5PB Telephone: +44 (0) 1473 242000 Fax: +44 (0) 1473 745451 Parts Fax: +44 (0) 1473 743468 Service +44 (0) 1527 838443 www.compair.com...
  • Page 2 COMPRESSOR LOG SHEET REF. NO COMPRESSOR PRIME MOVER INSTALLED AT OIL GRADE USED: TYPE: TYPE: CHECK OIL LEVEL SPEED: B.H.P. CHECK WATER IN/OUT TEMPERATURE SERIAL NO: DRIVE: DATE INSTALLED: CHECK CONDENSATE MANUAL DRAINS 1 ST 2 ND FINAL FINAL AIR SERVICE DATE TIME...
  • Page 3 DATE REMARKS DATE REMARKS logsheet5280.d...

  • Page 4: Table Of Contents

    CompAir UK Ltd. 5280D Compressor Publication 98407.1440 Page 1 5280D.1.IAC AMENDMENT RECORD ISSUE No MOD Note No M/C SERIAL No./”M” No DATE PAGE No MAR 2006 OPERATOR MANUAL - 5000 SERIES AIR & GAS COMPRESSOR Model: 5280D.1.IAC CONTENTS Page Warnings ..................... 3 Ownership data ..................
  • Page 5 CompAir UK Ltd. 5280D Compressor Publication 98407.1440 Page 2 Appendix 3 ~ Parts Lists & Drawings ..........69 Crankcase Assembly ..................E61316 Second & Third Stage Cylinder Assembly ..........A30136 Second Stage Cooler Assembly ..............E61066 Third Stage Cooler Assembly ..............E61065 Main Air & Gas System................A30137 Control &...

  • Page 6: Warnings

    WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd, or the failure to maintain this equipment in accordance with the maintenance instructions, may invalidate the WARRANTY, cause equipment failure, create unsafe or hazardous conditions or result in damage to the equipment.

  • Page 7: Ownership Data

    Contact Names: Service: +44 (0) 1473 556027 For any comments or queries about the contents of this MANUAL please write to CompAir UK Ltd. Reavell, Ranelagh Road, Ipswich 1P2 0AQ. England marked for the attention of Mr. Dennis Beeton, Technical Publications Engineer.

  • Page 8: Foreword

    CompAir Companies and CompAir UK Ltd Distributors, backed by the Service and Parts Departments at CompAir UK Ltd, Ipswich (UK) Tel: +44 (0) 1473 602222. fax: +44 (0) 1473 601704. Customer Service +44 (0) 1473 556027 or Parts fax: +44 (0) 1473 601282.
  • Page 9 CompAir UK Ltd. 5280D Compressor Publication 98407.1440 Page 6 1440.doc...

  • Page 10: Safety Procedures

    CompAir UK Ltd. 5280D Compressor Publication 98407.1440 Page 7 SAFETY PROCEDURES Page General Warnings, Cautions and Notes General Safety Precautions Installation Precautions Operational Precautions Maintenance and Repair Precautions Precautions in the Event of Fire 1440.doc...
  • Page 11 Page 8 SAFETY • WARRANTY The Conditions of the CompAir UK Ltd Warranty are set out in the Standard Conditions of Sale. • MAINTENANCE To ensure continued trouble free operation of the compressor it is important that periodic maintenance and servicing are carried out in accordance with the information given in the "Maintenance" section of this Manual.
  • Page 12 5280D Compressor Publication 98407.1440 Page 9 SAFETY GENERAL RISK OF DANGER CompAir UK Ltd compressor safety relates to the document BS EN1012-1 Compressors and Vacuum Pumps - Safety requirements and the UK Pressure Systems and Transportable Gas Containers Regulations 1989.
  • Page 13 In order to limit the risk of • Compressed air and gas piping, together with Legionnaires Disease, CompAir UK LTD advise cooling water piping and other parts, with surface caution with the use of cooling towers for water temperature greater than 70°C and may be...
  • Page 14 • Use only lubricating oils and greases temperature of 300°C the material will approved by CompAir UK Ltd to avoid decompose. potential hazards especially the risk of explosion or fire and the possibility of •...
  • Page 15 CompAir UK Ltd. 5280D Compressor Publication 98407.1440 Page 12 • Keep the compressor clean at all times. Protect MAINTENANCE & REPAIR (Cont.) components and exposed openings by covering • Make sure all instructions concerning operation with a clean cloth or tape during repair or and maintenance are strictly followed and that the maintenance work.

  • Page 16: General Description

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 13 GENERAL DESCRIPTION INTRODUCTION The 5000 Series water-cooled compressors are heavy duty, reciprocating air and gas compressors. The 5280 D model being a three stage design with two cylinders arranged in a 90 degree Vee configuration Whilst the first stage is double acting, the second and third stages cylinders are a tandem single acting piston.
  • Page 17 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 14 SUCTION & DELIVERY VALVES First stage suction and delivery valves are of large diameter, annular multiport, low lift plate type. The valves combine a large flow area with low lift, resulting in low air speed and quiet operation. Valves fitted to second and third stages are concentric, flat plate type , low lift, and multi-port type combining suction and delivery functions.

  • Page 18: Leading Particulars

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 15 LEADING PARTICULARS GENERAL Type. 3 stage two cylinder 90 ° Vee. Direction of rotation. Clockwise viewed from driving end. Cooling. Water. Number of valves first stage. Four suction & four deliver.
  • Page 19 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 16 6.10 CONNECTIONS Final delivery RP 2" Water inlet RP 1.5" Water outlet RP 1.5" Condensate discharge RP 2" 6.11 SETTING & ADJUSTMENTS Switching Thermometer Settings SETTINGS °C Compressor Operating Pressure First stage...

  • Page 20: Installation

    5280D Compressor Publication 98407.1440 Page 17 INSTALLATION General Model 5280D.1.IAC.PED compressors are supplied with the following: Display panel carrying: See appendix 3 for details on the PET SCAN Controller. Terminals Provided for connection to a suitable Star-Delta motor starter, pressure switches and solenoid valves.
  • Page 21 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 18 Cooling Water System Install a flow indicator and an isolating valve (for maintenance purposes) in the cooling water supply line. If the quality of cooling water is poor, treat it to prevent corrosion and scale formation. Protect re- circulating cooling systems against freezing by using proprietary anti-freeze with inhibitors.
  • Page 22 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 19 Drive Belts see appendix 3 for details on alignment & tensioning. When a separate electric motor is used the compressor is driven by a matched set of vee or wedge belts. Correct compressor speed is achieved by selecting the appropriate size of motor pulley.
  • Page 23 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 20 7.10 Installation Procedure Remove the cover from the connection box on the electric motor. Open the control panel to gain access to the terminals on the control devices. Make sure the power supply to the compressor is taken from the fused isolating switch and that the switch is locked OFF and the fuses removed.

  • Page 24: Commissioning

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 21 COMMISSIONING STATIC CHECKS Check that power isolator switch is locked in the OFF position and fuses removed. Check all electrical connections are tight and that they comply with the wiring diagram supplied within the Manual.
  • Page 25 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 22 FUNCTIONAL CHECKS (cont..) 8.2.4-Start the compressor and check oil pressure. Note: the oil filter is efficient and during start up may cause a noticeable drop in indicated oil pressure. This normal and the pressure can re-established by turning the oil pump filter handle clockwise through one turn 8.2.5-Allow the compressor to run for about 30 minutes unloaded.

  • Page 26: Operation

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 23 OPERATION ROUTINE STARTING Before starting, always turn the external handle of the oil pump filter clockwise through one complete revolution. to clean the microfilter element. Repeat THIS OPERATION EVERY DAY IF THE COMPRESSOR IS IN CONTINUOUS OPERATION.
  • Page 27 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 24 Automatic Unloading and Draining 9.5.1-Continuous Running Loading / Unloading - "Topping Duty" 9.5.1.1 When the power is ON the power lamp is illuminated. A delay timer in the starter enables the compressor to be started with oil pressure switch by-passed and the pilot solenoid valves held in unload position.
  • Page 28 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 25 STOPPING & STARTING The compressor will automatically STOP if the temperature rise for any compression stage reaches a pre-set value, determined for safe, reliable operation, or should the oil pressure fall below a minimum pre-set pressure.
  • Page 29 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 26 1440.doc...

  • Page 30: Maintenance

    Personnel accustomed to mechanical equipment maintenance and servicing should have no difficulty in carrying out the following tasks. If assistance is needed refer to local CompAir company, distributor or CompAir UK Ltd. A condition of Warranty is that the user must keep the compressor and auxiliary equipment properly maintained and adjusted, and performs checks and services in the Schedule attached.
  • Page 31 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 28 10.1.9-Lubricating Oil The normal recommended service interval for an oil change is 8000 hours or 12 months, whichever is sooner. In adverse operating conditions (high temperatures, high dust levels or the presence of air pollution) this recommended period can be reduced.
  • Page 32 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 29 10.4 TORQUE WRENCH SETTINGS Description Size of Torque Setting (Nm) Fastener 2nd & 3rd Stg. Cylinder to Crosshead Guide 2nd & 3rd Stg. Cylinder to Crankcase 5/8" UNC 2nd Stg. Valve Cover to Cylinder 3rd Stg.
  • Page 33 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 30 1440.doc...

  • Page 34: Fault Finding

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 31 FAULT FINDING The following recommendations cover the more common aspects of fault location and correction. Before investigation, please ensure: Cooling water temperature rise across the machine and flow-rate are correct Direction of rotation is correct Lubricating oil is at correct level Compressor servicing is up to date.
  • Page 35 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 32 FAULT POSSIBLE CAUSE RECOMMENDATION 11.1 No electrical supply to control panel. Check that isolator is in ON Compressor will not start? position. Check for blown fuse. Faulty isolator on control panel.
  • Page 36 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 33 FAULT POSSIBLE CAUSE RECOMMENDATION 11.6 Failure of unloader valve timer Check and replace as Compressor runs but fails to necessary. build-up pressure No electrical supply to unloader Check and replace as solenoid coil.
  • Page 37 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 34 FAULT POSSIBLE CAUSE RECOMMENDATION 11.13 Low oil level Fill to maximum level Low oil pressure Loose suction pipework Check and tighten Oil filter blocked Replace as necessary Worn bearings Check and replace...

  • Page 38: General Arrangement (Typical)

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 35 Appendix 1 Drawings & Wiring Diagrams General Arrangement (Typical)..............A41043 P & I Diagram (Typical)................E46786 Electrical Wiring Diagram (Typical, compressor only).........D71419 1440.doc...
  • Page 42 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 36 1440.doc...
  • Page 43 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 37 Appendix 2 Parts Lists & Illustrations Page Crankcase – 1..................... 39 Crankcase – 2..................... 41 Crankcase – 3..................... 43 First Stage Cylinder .................... 45 First Stage Suction Valve Cover ................. 47 First Stage Delivery Valve Cover ................

  • Page 44: Crankcase - 1

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 38 CRANKCASE - 1 1440.doc...

  • Page 45: Crankcase - 1

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 39 CRANKCASE - 1 PARTS LIST REF. No PART No DESCRIPTION No OFF C20010.55 CRANKCASE C10190.85 DOOR C10190.101 JOINT A4341.100 CAPSCREW C10190.86 FILLER C10190.105 JOINT A4333.96 HEX HD SCREW C10190.115 RIGHT FOOT C10190.116 LEFT FOOT...

  • Page 46: Crankcase - 2

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 40 CRANKCASE - 2 1440.doc...

  • Page 47: Crankcase - 2

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 41 CRANKCASE - 2 PARTS LIST REF. No PART No DESCRIPTION No OFF C20010.55 CRANKCASE C10190.87 CROSSHEAD COVER C10190.102 JOINT A42341.39 CAPSCREW A3803.69 DRAIN COCK 95410.285 SOCKET 95404.800 HEX NIPPLE C10190.84 CRANKCASE DOOR C10190.101...

  • Page 48: Crankcase - 3

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 42 CRANKCASE - 3 1440.doc...

  • Page 49: Crankcase - 3

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 43 CRANKCASE - 3 PARTS LIST REF. NO PART No DESCRIPTION No OFF C20010.55 CRANKCASE C10190.63 BEARING HOUSING C20010.47 BEARING HOUSING C10190.98 JOINT C10530.315 RETAINER C10190.588 MAIN BEARING C10190.590 WASHER A6450.104 OIL SEAL C10190.745...

  • Page 50: First Stage Cylinder

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 44 CYLINDER 1st STAGE 1440.doc...
  • Page 51 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 45 CYLINDER 1st STAGE PARTS LIST REF. No PART No DESCRIPTION No OFF C20001.6 CYLINDER C20000.3 CYLINDER HEAD C20000.11 CYLINDER HEAD JOINT A3764.7 PLUG 95405.858 HEX BUSH A4341.132 CAPSCREW C11582.1 CAPSCREW C10500.191 LINER A1413.576...

  • Page 52: First Stage Suction Valve Cover

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 46 SUCTION VALVE COVER 1440.doc...
  • Page 53 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 47 SUCTION VALVE COVER PART LIST REF. No PART No DESCRIPTION No OFF C20000.32 SUCTION VALVE COVER A1475.100 LOCATING PIN C20021.35 VALVE RETAINER C20000.37 DIAPHRAGM C20021.36 DIAPHRAGM FOLLOWER A4341.13 CAPSCREW A10218.16 BEARING BUSH C20001.25...

  • Page 54: First Stage Delivery Valve Cover

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 48 DELIVERY VALVE COVER 1st STAGE 1440.doc...
  • Page 55 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 49 DELIVERY VALVE COVER 1st STAGE PARTS LIST REF. No PART No DESCRIPTION No OFF C20000.6 DELIVERY VALVE COVER A1475.100 LOCATING PIN A10347.13 "O" RING C11304.204 DELIVERY VALVE C20000.7 JOINT RING A4341.128 CAPSCREW 1440.doc...

  • Page 56: First State Suction & Delivery Valves

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 50 SUCTION VALVE DELIVERY VALVE 1st STAGE VALVES 1440.doc...
  • Page 57 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 51 1st STAGE VALVES PARTS LIST SUCTION VALVE REF. No PART No DESCRIPTION No OFF C11304.203 SUCTION VALVE C11304.237 SEAT C11304.176 VALVE PLATE C11304.168 CUSHION PLATE C11304.294 GUARD C11304.296 BOLT 95515.262 LOCATING PIN C11304.152...

  • Page 58: Crankshaft & Connecting Rods

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 52 CRANKSHAFT CONNECTING ROD 1440.doc...
  • Page 59 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 53 CRANKSHAFT CONNECTING ROD PARTS LIST REF. No PART No DESCRIPTION No OFF C10190.754 CRANKSHAFT C10500.217 BALANCE WEIGHT C10500.167 SCREW C10190.32 LOCKING PIN C10190.333 C20010.38 DRIVING PIN C10190.208 CONNECTING ROD C10190.109 BIG END BEARING - HALF C10190.637...

  • Page 60: First Stage Crosshead

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 54 CROSSHEAD 1st STAGE 1440.doc...
  • Page 61 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 55 CROSSHEAD 1st STAGE PARTS LIST REF. No PART No DESCRIPTION No OFF C10190.694 CROSSHEAD C10190.636 CROSSHEAD PIN C10190.287 END PLATE C10190.332 LOCKING PLATE A4333.91 HEX HD SCREW C20001.11 GLAND C20000.20 OIL SHIELD C20000.21...

  • Page 62: First Stage Piston

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 56 PISTON 1st STAGE 1440.doc...
  • Page 63 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 57 PISTON 1st STAGE PARTS LIST REF. No PART No DESCRIPTION No OFF C11321.8 PISTON C20040.1 RING, PRESSURE C20040.2 RING, GUIDE C10190.698 PISTON ROD C10190.700 PISTON NUT C10190.704 PISTON WASHER A10300.18 WAVED WASHER C10190.705...

  • Page 64: First Stage Air & Oil Glands

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 58 GLAND 1st STAGE 1440.doc...
  • Page 65 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 59 GLAND 1st STAGE PARTS LIST REF. No PART No DESCRIPTION No OFF C20001.11 GLAND C10190.657 CAGE, TOP A10252.236 “O” RING C20001.13 PACKING, COMPOSITE-PAIR C10190.658 CAGR, BOTTOM C20001.4 RING, SPACER C10190.659 FLANGE C20011.22...

  • Page 66: Oil Pump

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 60 OIL PUMP 1440.doc...
  • Page 67 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 61 OIL PUMP PARTS LIST REF. No PART No DESCRIPTION No OFF C20011.13 OIL PUMP C20010.29 PUMP COVER C20010.41 JOINT A4330.62 STUD A4322.6 A3764.4 PLUG, BRASS HEXAGON A1442.5 FIBRE WASHER C10589.5 PLUG A4334.53...

  • Page 68: Oil Pump Filter

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 62 OIL PUMP FILTER 1440.doc...
  • Page 69 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 63 OIL PUMP FILTER PARTS LIST REF. No PART No DESCRIPTION No OFF C20011.13 OIL PUMP 98262.199 OIL FILTER 98156.273 NIPPLE C20010.83 OIL FILTER ADAPTOR A4341.51 CAPSCREW A6454.132 PLUG 98504-65 JOINT C20010.40 FILTER DISTANCE-PIECE C20010.44...

  • Page 70: First Stage Cooler

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 64 INTERCOOLER 1440.doc...
  • Page 71 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 65 INTERCOOLER PARTS LIST REF. No PARTS No DESCRIPTION No OFF C20010.23 INTERCOOLER C11058.6 END COVER C11003.24 END COVER JOINT A4338.19 BOLT C20010.7 BODY INTERCOOLER C20010.8 BOTTOM COVER C20010.14 JOINT A4335.51 HEX HD SCREW A4335.53...

  • Page 72: First Stage Pipe Work

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 66 1st STAGE PIPE WORK 1440.doc...
  • Page 73 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 67 1st STAGE PIPE WORK PART LIST REF. No PART No DESCRIPTION No OFF C20011.6 STAGE AIR PIPE A1641-500-62 SAFETY VALVE C20010.16 JOINT C20010.15 INTERCOOLER JOINT A4335.53 HEX HD SCREW 1440.doc...
  • Page 74 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 68 1440.doc...

  • Page 75: Appendix 3 ~ Parts Lists & Drawings

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 69 Appendix 3 Parts Lists & Drawings Crankcase Assembly ..................E61316 Second & Third Stage Cylinder Assembly ..........A30136 Second Stage Cooler Assembly ..............E61066 Third Stage Cooler Assembly ..............E61065 Main Air & Gas System................A30137 Control &...
  • Page 86 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 70 1440.doc...

  • Page 87: Appendix 4 ~ Service Plan

    CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 71 Appendix 4 Service Plan 1440.doc...
  • Page 88 CompAir UK Ltd RECOMMENDED SERVICE PLAN – 5280D.1-M Page 1 5280D - MINERAL OIL IMPORTANT - DAILY & BEFORE STARTING CHECK OIL LEVEL TOP UP AS NECESSARY. FIRST RSP5280DM.1 100 HOURS Change oil & oil filter element. SERVICE Cleanse crankcase.
  • Page 89 CompAir UK Ltd RECOMMENDED SERVICE PLAN – 5280D.1-M Page 2 5280D - MINERAL OIL IMPORTANT - DAILY & BEFORE STARTING CHECK OIL LEVEL TOP UP AS NECESSARY. 8000 HOURS RSP5280DM.4 SERVICE Change oil & oil filter element. Change suction filter element.
  • Page 90 CompAir UK Ltd RECOMMENDED SERVICE PLAN – 5280D.1-M Page 3 5280D - MINERAL OIL IMPORTANT - DAILY & BEFORE STARTING CHECK OIL LEVEL TOP UP AS NECESSARY. 16000 HOURS RSP5280DM.5 SERVICE Change oil & oil filter element. Change suction filter element.
  • Page 91 CompAir UK Ltd RECOMMENDED SERVICE PLAN – 5280D.1-M Page 4 5280D - MINERAL OIL IMPORTANT - DAILY & BEFORE STARTING CHECK OIL LEVEL TOP UP AS NECESSARY. 24000 HOURS RSP5280DM.6 SERVICE Change oil & oil filter element. Change suction filter element.
  • Page 92 CompAir UK Ltd RECOMMENDED SERVICE PLAN – 5280D.1-M Page 5 5280D - MINERAL OIL IMPORTANT - DAILY & BEFORE STARTING CHECK OIL LEVEL TOP UP AS NECESSARY. 48000 HOURS RSP5280DM.7 SERVICE Change oil & oil filter element. Change suction filter element.
  • Page 93 CompAir UK Ltd RECOMMENDED SERVICE PLAN – 5280D.1-M Page 6 5280D - MINERAL OIL IMPORTANT - DAILY & BEFORE STARTING CHECK OIL LEVEL TOP UP AS NECESSARY. Check and clean separator strainers & drain lines. Check belt drive for alignment and tension. Adjust as necessary.
  • Page 94 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 72 1440.doc...
  • Page 95 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 73 Appendix 5 Ancillary Parts PET Scan Controller .................. APP408 Anti-vibration Mounts ................. APP004 Pressure Gauge..................APP070 Safety Valve....................APP167 Diaphragm Drain Valve................APP202 Solenoid Valve................... APP138 Drive Motor ....................APP034 Vee Belt Drive.................APP012 - 5280...

  • Page 96: Petscan Controller

    ISSUE DATE JANUARY 2004 CUSTOMER ORDER NUMBER: CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027 www.compair.com email: ipswich@compair.co.uk...
  • Page 97 App 408 Customer PET controller installation guide & user's manual Page 1 Table of contents GENERAL INFORMATION INTRODUCTION USER INTERFACE DISPLAYS PUSH BUTTONS LED’S BASIC SOFTWARE MENUS AND FUNCTIONS MENU CODE ENTRY / PARAMETER MODIFICATION 2.1.1 Entering Menus 2.1.2 Parameter Modification MENUS AND CHANGEABLE FEATURES 2.2.1 Status Menu...
  • Page 98 App 408 Customer PET controller installation guide & user's manual Page 2 App 408C 98155.1015...
  • Page 99 App 408 Customer PET controller installation guide & user's manual Page 3 1 General information 1.1 Introduction This controller has been developed for the control of medium to large 3 stage compressors with 3 step unloading. This model is designed to control the compressor using an analogue signal from a system pressure transducers rather than pressure switches.
  • Page 100 App 408 Customer PET controller installation guide & user's manual Page 4 1.2 Displays The controller is equipped with 3-bottom view - side lighted displays. Each display is dedicated for a specific purpose: The following messages can be displayed: Display type Message Meaning •...
  • Page 101 App 408 Customer PET controller installation guide & user's manual Page 5 2 Basic software menus and functions 2.1 Menu code entry / parameter modification This paragraph explains how to select a menu and how to scroll through the different parameters. 2.1.1 Entering menus Reset and/or returning to the basic menu...
  • Page 102 App 408 Customer PET controller installation guide & user's manual Page 6 How the different menus and sub-menus can be entered, is shown below: Software version Basic menu Error log menu Timer menu Operational settings Main sellection Sub-menus Parameters Error list Timer list Main selection Parameters...
  • Page 103 App 408 Customer PET controller installation guide & user's manual Page 7 2.1.2 Parameter modification a) Parameter modification without password protection • Within the entered menu, select the parameter to be changed by scrolling through the menu with the up and down arrow-button (step 1) •...
  • Page 104 App 408 Customer PET controller installation guide & user's manual Page 8 Entry codes • Machine configuration : 11 • Regulating settings : 11 • Service settings : 12 2.2 Menus and changeable features 2.2.1 Status menu The status menu can be considered as the default menu. It is shown at start-up of the controller and it will revert to this menu after one minute when the keyboard activity stops while displaying a different menu.
  • Page 105 App 408 Customer PET controller installation guide & user's manual Page 9 2.2.4 Operational setting menu No Code In this menu, the operator can make some modifications according to his requirements. The following parameters can be accessed and changed by the operator: Parameter Function Default...
  • Page 106 App 408 Customer PET controller installation guide & user's manual Page 10 2.2.5 Machine configuration Code 11 In the machine configuration menu, the following application specific parameters can be set: Parameter Function Default Min. Max. Control CNT - Continuous : the compressor motor runs continuously from the start command until the stop command.
  • Page 107 App 408 Customer PET controller installation guide & user's manual Page 11 2.2.7 Factory settings In the factory menu, the following fundamental parameters can be set: Parameter Function Default Min. Max. DEF fault delay The time that a fault on the digital inputs D,E or F are overridden before the compressor is shut down.
  • Page 108 App 408 Customer PET controller installation guide & user's manual Page 12 Parameter Function Default Min. Max. Starts/hour This safety feature prevents the compressor from starting too often in order to protect the motor against overheating. The controller uses an advanced start per hour handling program and when the limit of the number of starts is reached it will prevent the motor from stopping when running unloaded.
  • Page 109 App 408 Customer PET controller installation guide & user's manual Page 13 2.2.7.1 Typical Compressor Settings 5280 5281 5282 5283 PRESSURES BARS stage high stage low stage high 15.0 15.0 15.8 15.8 stage high stage low Temperatures °C Normal 25°C air 30°C water stage delivery stage delivery stage delivery...
  • Page 110 App 408 Customer PET controller installation guide & user's manual Page 14 2.2.9.1 Test digital inputs Function:- By changing the status of the input, the input can be tested. Input No. Parameter Default Emergency stop. Closed Open Closed Motor current. Closed Open Closed...
  • Page 111 App 408 Customer PET controller installation guide & user's manual Page 15 2.2.9.3 Test analogue inputs Input Parameter Function System pressure The applied voltage of the analogue input 1 is displayed. 0-5 volts Oil pressure The applied voltage of the analogue input 2 is displayed. 0-5 volts Spare The applied voltage of the analogue input 3 is displayed.
  • Page 112 App 408 Customer PET controller installation guide & user's manual Page 16 2.2.10 Input configuration 2.2.10.1Analogue calibration With offsets the display will alternate between the offset and the reading Parameter Function Default System Setting the offset of the pressure sensor. Sensor trimming - - - -100 +100...
  • Page 113 App 408 Customer PET controller installation guide & user's manual Page 17 2.2.10.2 Analogue Input configuration Function :- Selecting the input signal Selectable settings Each input can be selected for the following inputs :- 0-20mA, 0-5V, 4-20mA, 1-5V, 1-6V, 5-55V, KTY10, KTY10B, PT1000, Off Input No.
  • Page 114 App 408 Customer PET controller installation guide & user's manual Page 18 2.3 Additional software features 2.3.1 Micro interruption of the power supply Function Default setting The controller is equipped with a device that detects a micro interruption of the 40ms power supply.
  • Page 115 App 408 Customer PET controller installation guide & user's manual Page 19 Operational settings Pressure unload level Pressure load level Pressure schedule ON / OFF Pressure schedule if ON >> Current time &date set-up Pressure in BAR or PSI Pressure 1+ time & date 1 Temperature in C or F Pressure 2+time&date 2 Language...
  • Page 116 The housings on both controllers must be earthed at all times using 6mm terminals. CompAir disclaims any warranty in a case an unauthorized person has opened the module. 2.6 Power supply The power supply connector is indicated on the back cover with X03.
  • Page 117 App 408 Customer PET controller installation guide & user's manual Page 21 2.7 Fusing 2 fuses of 1.6A slow must be used for protection of the secondary winding of the transformer and they must be able to withstand 20A rms during at least 10ms. The controller is equipped with 2 fuses of 3A slow (3AT).
  • Page 118 App 408 Customer PET controller installation guide & user's manual Page 22 3 Technical specifications According to Typical Power supply 18VAC 24VAC 29VAC Internal power supply digital inputs 18VDC 20VDC 22VDC Internal power supply analogue inputs 18VDC 20VDC 22VDC Internal power supply electronic 18VDC 20VDC 22VDC...

  • Page 119: Anti-Vibration Mounts

    CompAir UK Ltd APP 004 ANTI VIBRATION MOUNTS Page 1 TRELLEBORG TYPE PART NUMBERS VARIOUS PREVENTIVE MAINTENANCE After installation and initial running in. Record height dimension (H) of each mount. After a week or 100 hours running time recheck and record dimension (H) Check this dimension every 3 to 6 months depending on usage i.e.
  • Page 120 CompAir UK Ltd APP 004 ANTI VIBRATION MOUNTS Page 2 app004.doc...

  • Page 121: Pressure Gauge

    CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL Page 1 PRESSURE GAUGES GENERAL The pressure gauge should be installed such as to avoid exposure to heat and vibration and to enable easy observation of the dial indication. IMPORTANT It is common practise to install the pressure gauge without an isolating device, so to facilitate calibration or replacement the system must be de pressurised before any work is carried out.
  • Page 122 CompAir UK Ltd PUBLICATION APP070 PRESSURE GAUGES GENERAL Page 2 app070.doc...
  • Page 123 The inlet line to the safety valve should have an effective area of flow, at least equal to that of the safety valve inlet. CompAir Limited should be consulted if the safety valve is to be mounted in any position other than vertically.
  • Page 124 CompAir UK Ltd. APP167 SAFETY VALVE I&O INSTRUCTIONS Page 2 CONFIGURATION The valves have a base number for different type valve arrangement from this information the valve set pressure can be obtained, examples:- 98650.2073 is the base unit number. 98650.2073-16.2 -16.2 being to the setting in bar g - wire locked.

  • Page 125: Safety Valve

    CompAir UK Ltd APP 202 3 U.D.S. VALVE ASSEMBLY Page 1 UNLOADER DRAIN VALVE SYSTEM D101431 Rc ¼” DRAIN FROM 3 Rc ¼” DRAIN FROM 2 Rc ¼” DRAIN FROM 1 STAGE SEPARATOR STAGE SEPARATOR STAGE SEPARATOR Rp 1/8” CONTROL AIR FROM SOLENOID VALVE ITEM NO.

  • Page 126: Solenoid Valve

    30 minutes this closes the valve for 5 to 6 seconds duration and allows the drains to blow all condensate collected. Note: In HIGH AMBIENT/HUMIDITY AREAS it is recommended that the drainage cycle time be more frequent contact CompAir UK Ltd - Customer Service Fax No. +44 (0) 1473 556027 for more details.
  • Page 127 CompAir UK Ltd PUBLICATION APP 138 - 3 WAY SOLENOID VALVES PS2197 Page 1 3 WAY SOLENOID VALVE PS2197 OPERATION 3 way normally closed energise to open, continuous duty. On starting the solenoid valve opens (energised) this operates the diaphragms which in turn closes the valves within the D.D.Vs.
  • Page 128 CompAir UK Ltd PUBLICATION APP 138 - 3 WAY SOLENOID VALVES PS2197 Page 2 app138.doc...
  • Page 129 CompAir UK Ltd PUBLICATION APP034 ELECTRIC MOTOR MAINTENANCE GENERAL Page 1 ELECTRIC MOTOR MAINTENANCE WARNING : Isolate power supply to motor before commencing any routine cleaning or maintenance work. Routine Cleaning : Remove the fan cover and ensure that all holes are completely open. Clear any dirt and fluff from behind the fan and along the ribs of the frame.
  • Page 130 CompAir UK PUBLICATION APP034 ELECTRIC MOTOR MAINTENANCE GENERAL Page 2 APP034.doc...
  • Page 131 CompAir UK Ltd PUBLICATION APP012-5280 Page 1 VEE DRIVE PARTS & BELT ADJUSTMENT BELT TENSION INDICATOR APPLIED TO MID-SPAN see Table 1 CENTRE DISTANCE mm BELT DEFLECTION STRAIGHT EDGE PULLEY PCD VEE DRIVE PARTS PART NUMBER FLYWHEEL TC39633.7 MOTOR PULLEY SPB Ø224 PCD Y193461.002...
  • Page 132 CompAir UK Ltd PUBLICATION APP012-5280 Page 2 ADJUSTMENT METHOD If the belt tension is incorrect, correct it by using the adjusting screw provided, using a suitable straight edge (long enough to span both pulleys) established the correct deflection and pulley alignment.
  • Page 133 CompAir UK Ltd 5280D Compressor Publication 98407.1440 Page 74 1440.doc...
  • Page 134 WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd. Ipswich, may lead to failure in service which would not be covered by the warranty. Any unauthorised modifications or failures to maintain this equipment is accordance with the manufacturers maintenance instructions may make it unsafe.

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