Download
Share
Print this page
  1. Manuals
  2. Brands
  3. AirMan Manuals
  4. Air Compressor
  5. AS Series
  6. Service manual

AirMan AS Series Service Manual

Motor compressor
Hide thumbs

Advertisement

Quick Links

Download this manual

Advertisement

loading
Need help?

Need help?

Do you have a question about the AS Series and is the answer not in the manual?

Questions and answers

Related Manuals for AirMan AS Series

Summary of Contents for AirMan AS Series

  • Page 2 Preface This service manual explains about the cautions for maintenance jobs and is to serve a guide for the electric system, and troubleshooting for service personnel. In the fundamental matters and other things already mentioned in the “Instruction Manual” and the “Parts Catalogue” are omitted to avoid duplication. Therefore, for the operation and handling of this unit, we request you to refer to the “Instruction Manual”...
  • Page 3 Table of Contents 1. Overview ---------------------------------------------------------------------------------------------------- 1-1 1.1 Capacity Control ------------------------------------------------------------------------------------------------------ 1-1 1.1.1 2-Point control type --------------------------------------------------------------------------------------------- 1-1 1.1.2 Regulator control type ----------------------------------------------------------------------------------------- 1-3 1.1.3 Inverter control type -------------------------------------------------------------------------------------------- 1-9 1.2 Motor Specifications ------------------------------------------------------------------------------------------------- 1-10 1.2.1 Motor for compressor ------------------------------------------------------------------------------------------ 1-10 1.2.2 Motor for cooling fan ------------------------------------------------------------------------------------------- 1-11 1.3 Warning / Abnormality Display ------------------------------------------------------------------------------------ 1-12 2.
  • Page 4 Table of Contents 3. Electrical System ----------------------------------------------------------------------------------------- 3-1 3.1 Functions --------------------------------------------------------------------------------------------------------------- 3-1 3.1.1 Specifications ---------------------------------------------------------------------------------------------------- 3-1 3.1.2 Operation modes ----------------------------------------------------------------------------------------------- 3-3 3.1.3 Controller --------------------------------------------------------------------------------------------------------- 3-5 3.1.4 Checking indication of warning, abnormalities and also checking emergency stop ------------ 3-15 3.2 Electrical Parts -------------------------------------------------------------------------------------------------------- 3-18 3.2.1 Specifications ---------------------------------------------------------------------------------------------------- 3-18 3.2.2 Inverter for main motor ---------------------------------------------------------------------------------------- 3-23 3.2.3 Inverter for cooling fan ----------------------------------------------------------------------------------------- 3-30...
  • Page 5 Table of Contents 4.4 Others ------------------------------------------------------------------------------------------------------------------- 4-33 4.4.1 Oil is found mixed in discharge air. (Oil consumption increases) ----------------------------------- 4-33 4.4.2 Abnormal noise emission from belt. ------------------------------------------------------------------------ 4-33 4.4.3 Compressor start and stops too frequently while no air is consumed. (Auto start/stop operation) ----------------------------------------------------------------------------------- 4-34 4.4.4 Compressor often stops without trouble code indicator lamp glowing and knowing no reason of the phenomena.
  • Page 6 1. Overview 1.1 Capacity Control 1.1.1 2-Point control type (15kW class) SC15080E Conditions of solenoid valve for Conditions Unloader valve capacity control (SV1) Start/Purge operation Open At a little open Full-load Close At fully open Stop Open At fully closed Conditions Function When it starts, solenoid valve for capacity control (SV1) opens and compressed...
  • Page 7 1. Overview (22･37kW class) SC17001-1E Conditions of solenoid valve for Conditions Unloader valve capacity control (SV1) Start/Purge operation Open At a little open Full-load Close At fully open Stop Open At fully closed Conditions Function When it starts, solenoid valve for capacity control (SV1) opens and compressed air flows into unloader valve.
  • Page 8 1. Overview 1.1.2 Regulator control type (15kW class) SC15082E Conditions of solenoid valve for Conditions Unloader valve purge control (SV1) Start/Purge operation Open At a little open Full-load Close At fully open Stop Open At fully closed Conditions Function When it starts, solenoid valve for purge control (SV1) opens and compressed air Start flows into unloader valve.
  • Page 9 1. Overview Conditions Function In cases when the air consumption has suddenly decreased and the service pressure (detected by the pressure sensor 1) has increased to reach the configured value (unloading operation starting pressure PH), purge operation Urgent purge will be started similar to normal purge in order to prevent the service pressure from increasing.
  • Page 10 1. Overview (18.5kW class) SC17067E Conditions of solenoid valve for Conditions Unloader valve purge control (SV1) Start/Purge operation Open At a little open Full-load Close At fully open Stop Open At fully closed Conditions Function When it starts, solenoid valve for purge control (SV1) opens and compressed air Start flows into unloader valve.
  • Page 11 1. Overview Conditions Function In cases when the air consumption has suddenly decreased and the service pressure (detected by the pressure sensor 1) has increased to reach the configured value (unloading operation starting pressure PH), purge operation Urgent purge will be started similar to normal purge in order to prevent the service pressure from increasing.
  • Page 12 1. Overview (22･37kW class) SC17002-1E Conditions of solenoid valve Solenoid valve for Conditions Unloader valve for purge control (SV1) starting unloader (SV4) Start/Purge operation Open Switching COM―NC At a little open Full-load Close Switching COM―NO At fully open Stop Open Switching COM―NO At fully closed Conditions...
  • Page 13 1. Overview Conditions Function If the air consumption decreases and the load rate, calculated from the intake negative pressure of the main compressor unit detected by the pressure sensor 1, falls below the configured value (load factor for the selection of purge operation b), the device will enter a state of standby for purge operation.
  • Page 14 1. Overview 1.1.3 Inverter control type (15kW class) SC15080E Conditions of solenoid valve for Conditions Unloader valve capacity control (SV1) Start/Purge operation Open At a little open Full-load Close At fully open Stop Open At fully closed Conditions Function When it starts, solenoid valve for capacity control (SV1) opens and compressed Start air flows into unloader valve.
  • Page 15 1. Overview 1.2 Motor Specifications 1.2.1 Motor for compressor (Totally-enclosed fan cooled type) (1) 15kW class SAS15SD,RD-5E SAS15SD,RD-6E,SAS15VD-E Model Unit SMS15ESD,ERD-5E SMS15ESD,ERD-6E,SMS15EVD-E Motor model TOSHIBA TKKH3-FBKA21E Power output 15 (Service factor 1.15) Frequency Rated voltage 200/220 400/440 Rated current 66.4 33.2 63.8/59.0 31.9/29.5...
  • Page 16 1. Overview 1.2.2 Motor for cooling fan (Totally-enclosed type) (1) 18.5kW class Model Unit SASG19RD-5E SASG19RD-6E Motor model TOSHIBA IKH3-FBKK21E Power output 0.75 (Service factor 1.0) Frequency Rated voltage 200･220 Rated current 3.4･3.4 Poles Insulation class ※ 2.89 2.89 Ω Coil resistance (20℃) (1) 22kW class SAS22SD,RD-5E...
  • Page 17 1. Overview 1.3 Warning / Abnormality Display ■Trouble code 1. “Trouble code” lamp flashes whenever it happens. 2. Next, pushing “Trouble code” switch, following signals are displayed on screen. 3. Trouble display is re-set by pressing “Trouble code” switch longer (2 seconds). Indi- Item Sensor...
  • Page 18 1. Overview ※4. The operation of the discharge air temperature detection timing are as follows: When reactivating the compressor, in cases when the temperature within the receiver tank is high, due to the time lag of the By-pass valve, the discharge air temperature overshoots and increases.
  • Page 19 1. Overview ■Display Indication Item Code Unit Air service pressure Discharge air temperature ℃ Separator discharge air ℃ temperature Intake air temperature ℃ Load factor ※6 Operation hour No mark ×10Hr Whenever “Display selector switch” switch is ON, display is switched to : 1 → 2 → 3 → 4 ･････ → 1 ･･･...
  • Page 21 2. Maintenance ⑦ Equipments Hot oil bath or bearing heater Chain block Impact wrench 2.1.2 Cautions during disassembly and assembly ① For the disassembly location, be sure to select a location that is free of dust and large enough to perform the task.
  • Page 22 2. Maintenance 2.2 Tightening 2.2.1 Tightening torque Tightening Bolt Width of torque Tightening place diameter across flat (mm) (mm) N･m (kgf･cm) ①Cylinder and discharge casing socket bolt 49.0(485) (Hexagon haul) ②Oil seal cover socket bolt 49.0(485) (Hexagon haul) Socket bolt 12.0(124) (Hexagon haul) (15kW, 22kW female,18.5kW)
  • Page 23 2. Maintenance 2.2.2 General bolts and nuts tightening torque When reassembling or rebuilding, tighten bolts and nuts, according to the following torque values in the table. Low or Middle carbon steel bolt High tensile strength bolt Kind (SS400B etc…) (SCM435 etc…) Strength 4.6―6.8（4T―6T）...
  • Page 25 2. Maintenance 2.2.4 Special tools ･18.5 kW class] Part name Part NO. Q'ty Remarks Pipe 00817 00211 Oil seal installer (Rotor shaft insert) Plate 00817 00162 Oil seal installer (Oil seal cover insert) Plate 00817 00152 Disassembly tool for rotor and discharge casing [22kW class] Part name Part NO.
  • Page 26 2. Maintenance 2.2.5 Terminal tightening torque Should be tighten terminal of electromagnet switch, thermal relay other electric equipment etc. according to following torque. Tightening torque Screw size N･m (kgf･cm) (15) (30) (50) 9.8 (100) 17.2 (175) 34.0 (350) 2.2.6 Tightening torque for hose, joint etc… (1) Union joint Should be tighten union joint according to following torque.
  • Page 27 2. Maintenance (2) Bite type union Pipe have two kind of pipe, one is copper and other one is steel. The bite type union used for this pipe is to seal completely high pressure oil. Because the cutting edge of sleeve bites the steel pipe firmly and it is constructed to endure shock pressure and vibration.
  • Page 28 2. Maintenance 2) Coat pipe and nipple with lubrication oil Supply oil to these points ① Coat the sleeve and nut of pipe with lubricant (NICHIMORI LAP spray or equivalent). ② Coat the threaded portion and seat face of nipple Supply oil to these points with lubricant.
  • Page 29 2. Maintenance 5) Tightening torque for copper pipes, brass nuts of dryer (for reference only) Unit: N･m (kgf･cm) Tightening torque Tightening torque Nominal Nominal Pressure control Pressure control diameter (φ) diameter (φ) Dryer side Dryer side valve side valve side 20 (204) 30 (306) 70 (714)
  • Page 30 2. Maintenance 3) Tightening steps ① Tighten the pipe to the nipple. Tighten the pipe nut with a hand, and further tighten it till it touches the tapered portion (finger tight position). Match mark ② Mark a match mark on nut and nipple with a chalk. ③...
  • Page 31 2. Maintenance 2) How to seal for tube screw of larger than R 1 1/4 (32A) of thread diameter ① Wipe out oil and fat content with wasted cloth. ② Roll seal tape (Gaflon threaded sealing tape). [same as previous clause] ③...
  • Page 32 2. Maintenance (5) Nylon tube Size of nylon tubes used for this machine is expressed in inch. Inch size …… It is use spanner when tightening sleeve nad nut to piping. 1) Tightening for joint of nylon tube and sleeve nut Following chart is for tightening torque of each size joint and sleeve nut.
  • Page 33 2. Maintenance 3) Tightening sleeve nut Installing new nylon tube, sleeve and sleeve nut, attach the nylon tube firmly to the joint connector and tighten the sleeve nut till proper revolutions by hand, and them tighten the sleeve nuts till proper turns, using a tightening tool such as spanner.
  • Page 34 2. Maintenance (6) How to install hose Pay attation followig part when install nylon tube and hose. 1) Nylon tube ① Check 1/8 and 3/16 size nylon tubes for any break. (Pipe for pressure gauge) ② Connect nylon tube, preventing it from contacting any edge of copper pipe and steel pipe nut.
  • Page 35 2. Maintenance 2) Hose ① Authentic hose when replacing it. If not, it will cause oil leakage, break and disconnection, and it leads to fire. × ○ ② Never use hose twisted. Twisted hose will cause oil leakage, break and fitting disconnection when they are loaded with high pressure, vibration and shock.
  • Page 36 2. Maintenance 2.3 Periodic Inspection/Maintenance List 2.3.1 15kW class (2-Point control type / Regulator control type) Periodical Inspection and maintenance (A): In case that total operation hours per one year are less than 3,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points...
  • Page 37 ※3 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 38 2. Maintenance Periodical Inspection and maintenance (B): In case that total operation hours per one year are less than 6,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points Remarks Every Every Every Every Every Daily...
  • Page 39 ※3 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 40 2. Maintenance 2.3.2 15kW class (Inverter control type) Periodical Inspection and maintenance (A): In case that total operation hours per one year are less than 3,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points Remarks Every...
  • Page 41 ※1 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 42 2. Maintenance Periodical Inspection and maintenance (B): In case that total operation hours per one year are less than 6,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points Remarks Every Every Every Every Daily month...
  • Page 43 ※1 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 44 2. Maintenance 2.3.3 18.5kW class (Regulator control type) Periodical Inspection and maintenance (A): In case that total operation hours per one year are less than 3,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Remarks Inspection items Inspection points Every Every...
  • Page 45 ※1 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE HP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4 and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 46 2. Maintenance Periodical Inspection and maintenance (B): In case that total operation hours per one year are less than 6,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points Remarks Every Every Every Every Daily month...
  • Page 47 ※1 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE HP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4. and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 48 2. Maintenance 2.3.4 22･37kW class (SAS / SMS [Excluding one-point lifting type]) Periodical Inspection and maintenance (A): In case that total operation hours per one year are less than 3,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points...
  • Page 49 ※4 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 50 2. Maintenance Periodical Inspection and maintenance (B): In case that total operation hours per one year are less than 6,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points Remarks Every Every Every Every Every Daily...
  • Page 51 ※4 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 52 2. Maintenance 2.3.5 22･37kW class (SMS one-point lifting type) Periodical Inspection and maintenance (A): In case that total operation hours per one year are less than 3,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Remarks Inspection items Inspection points Every...
  • Page 53 ※3 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 54 2. Maintenance Periodical Inspection and maintenance (B): In case that total operation hours per one year are less than 6,000 hours [A: It refers to the inspection items of dryer.] Maintenance interval Inspection items Inspection points Remarks Every Every Every Every Every Daily...
  • Page 55 ※3 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP”. However, in case AIRMAN dedicated oil is un-acquirable, using the recommendation oil of a statement in 5.4, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 56 2. Maintenance 2.4 Inspection / Maintenance Perform this job of inspection and maintenance safely, referring to the instruction manual for routine inspection/maintenance. Herewith only such items which are not mentioned in the instruction manual supplied together with each unit shall be explained. 2.4.1 Inspection of motor and bearing replacement procedure (1) Inspection of insulation resistance of motor coil ...
  • Page 57 2. Maintenance (2) Replacement of motor bearing 1. Main motor Replace the motor bearing in the manner outlined below. The following is an explanation of a method that does not involve removing the rotor (for such as on-site replacement). <Cross Section> SC12089 The above drawing illustrates a grease-sealed bearing type motor.
  • Page 58 2. Maintenance [Loaded side bearing] ① Remove the bearing bracket attachment bolt and lightly strike this with a plastic hammer to remove the bearing bracket. ② Remove the bearing from the shaft by using a gear puller, etc. as illustrated below. <Remove the bearing>...
  • Page 59 2. Maintenance [Non-loaded side bearing] ① Remove the fan cover and the fan. The fan can be pulled out by removing the C-shaped snap ring. ② Remove the bearing bracket attachment bolt and lightly strike this with a plastic hammer to remove the bearing bracket.
  • Page 60 2. Maintenance 2.4.2 Check and change cooling fan 15kW class <Inspection procedures> ● Be sure to switch the power “OFF” before performing tasks and in order to prevent the power supply from being switched back on by accident while performing the tasks, place a sign stating “Performing Maintenance –...
  • Page 61 2. Maintenance 18.5･22･37kW class SAS, SMS (Excluding one-point lifting type) <Inspection procedures> ● Be sure to switch the power “OFF” before performing tasks and in order to prevent the power supply from being switched back on by accident while performing the tasks, place a sign stating “Performing Maintenance –...
  • Page 62 2. Maintenance 2.4.3 O-ring replacement of the unloader and vacuum relief valve (1) O-ring replacement of the unloader 15･18.5kW class <Note of the O-ring replacement> Apply a thin coat of grease on the O-rings when ● replacing the O-rings “1” and “2”. O-ring “1”...
  • Page 63 2. Maintenance ③ Apply a thin coat of grease to the inner perimeter of the correctional jig and insert this into the piston “4” to correct the resin ring. IMPORTANT Gradually insert the resin ring while correcting it to prevent it from catching on the correctional jig.
  • Page 64 2. Maintenance [Insertion jig] Part number 00817 00203 Insertion jig Resin ring (Attached to the shaft end of the piston) SC13110-1 ③ Apply a thin coat of grease to the inner perimeter of the correctional jig and insert this into the piston “5”...
  • Page 65 2. Maintenance (2) O-ring replacement of the vacuum relief valve (Built in unloader) Apply a thin coat of grease on the O-rings when ● replacing the O-rings “2” and “3”. Extract piston “4” by screwing in a bolt “7” in to ※...
  • Page 66 2. Maintenance 2.4.4 Clean / change oil level gauge ① If the oil level gauge is dirty and the oil volume cannot be confirmed, remove the level gauge and spray the inside with an automotive brake cleaner (with components of 40―45% toluene and 25―30% hexane) a several times.
  • Page 67 2. Maintenance From the previous page Check the compressor oil volume by using the following method. Oil level when stopped after operation for Oil level during More than 10 minutes. loaded operation A state where the oil level can be seen towards the top of the level gauge on the top is correct.
  • Page 68 2. Maintenance 2.4.6 Clean oil cooler / aftercooler  When cleaning the cooler, be careful not to damage its fins. Blow compressed air at right angle to the cooler. Oil cooler / aftercooler <Cleaning procedure> ① Remove the cover “2” on the front side of the cooler bracket “1”.
  • Page 69 2. Maintenance 2.4.7 Maintenance adjustment of pressure control valve (1) Maintenance procedures If the discharge pressure falls below 0.34MPa during operation, perform a maintenance adjustment of the pressure control valve by following the steps outlined below. As it is possible that the O-ring has deteriorated or hardened, replace the O-ring even if the replacement cycle has not yet been reached.
  • Page 70 2. Maintenance 2.4.8 Discharge air temperature sensor and separator discharge air temperature sensor (1) Checking the function Check the function according to the following procedures. ① During operation, remove the sensor cable connected to the controller. ② Make sure to confirm that the unit is stopping and the lamp indicating abnormality glows. (2) Checking the temperature and resistance Check and confirm resistance value per each temperature, according to following.
  • Page 71 2. Maintenance 2.4.10 Inverter for cooling fan 【Excerpted from inverter manufacturer's instruction manual】 [TOSHIBA] 22･37kW class  The equipment must be inspected every day. If the equipment is not inspected and maintained, errors and malfunctions may not be discovered which could lead to accidents. ...
  • Page 72 2. Maintenance <Iinspection / cleaning> Inspection procedure Subject of Criteria for judgement Inspection inspection Inspection item Inspection method cycle 1) Dust, temperature Occasionally 1) Visual check, 1) Improve the and gas check by means of environment if it is a thermometer, found to be unfavorable.
  • Page 73 2. Maintenance 5. If no power is supplied to the inverter for a long time, the performance of its large-capacity electrolytic capacitor declines. When leaving the inverter unused for a long time, supply it with electricity once every two years, for 5 hours or more each, to recover the performance of the large-capacity electrolytic capacitor.
  • Page 74 2. Maintenance 【Excerpted from inverter manufacturer's instruction [Fuji Electric] 18.5･22･37kW class manual】  Before proceeding to the maintenance and inspection, turn OFF the power and wait at least five minutes. Make sure that the LED monitor is turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped below the safe level (+25 VDC or below).
  • Page 75 2. Maintenance Check part Check item How to inspect Evaluation criteria Ventilation Check the heat sink, intake and Visual inspection No abnormalities path exhaust ports for clogging and foreign materials. Remove dust accumulating on the inverter with a vacuum cleaner. If the inverter is stained, wipe it off with a chemically neutral cloth.
  • Page 76 2. Maintenance 2.4.11 By-pass valve 15kW class equipped only (1) Principle of function The valve is provided with pellets. The pellets shrink according to the temperature of flowing oil of the valve so that the oil flowing passage can be automatically changed. When the oil temperature is low, the pellet is kept shrunken so that the oil flows through the by-pass passage of oil filter.
  • Page 77 2. Maintenance 2.4.12 Belt replacement / alignment adjusting procedure 15kW class  Because there is an initial elongation in the belt when it is replaced with a new one, be sure to make the belt tension adjustment again after performing the loaded operation for about two hours.
  • Page 78 2. Maintenance Tension bracket Bolt Tightening torque 25N･m Forward Hexagon bolt rotation (M6) direction Bolt Tightening torque 68N･m Tension pulley Spanner (17mm) Spanner hook boss (□17) Insert the hexagon bolt, pulling the Tension arm spanner (17mm) toward you with the A100280-1 spanner hooked at the spanner hook boss.
  • Page 79 2. Maintenance <Adjustment of pulley alignment> It is necessary to adjust the pulley alignment whenever removed for change of motor or motor ● bearings and the like. Bad adjustment of alignment causes the belt not to slide on the center of pulley sliding face, so it ●...
  • Page 80 2. Maintenance 18.5･22･37kW class Inspect the rolling surface of the belt of the pulley for scratches, chips, or wear, etc. If any of these ● can be found, be sure to either repair or replace the parts. <Belt replacement procedure> ①...
  • Page 81 2. Maintenance <Adjustment of pulley alignment> 18.5･kW class It is necessary to adjust the pulley alignment whenever removed for change of motor or motor ● bearings and the like. Bad adjustment of alignment causes the belt not to slide on the center of pulley sliding face, so it ●...
  • Page 82 2. Maintenance 22･37kW class Adjustment of the alignment is performed by moving the compressor air-end. Adjustments in the lengthwise direction are made with the (M10×P1.5) bolts “2” (there are 2 on both sides of the loaded side) while adjustments of the tilt are made with the (M10×P1.5) bolts “4” (there are 2 on both sides of the loaded side).
  • Page 83 2. Maintenance 2.4.13 Inverter cooling fan replacement procedures 15kW class (200V class) Inverter model・Cooling fan part number Inverter model Cooling fan part number Q’ ty VFAS1-2185PM 38490 31400 SC15097E Replace the fan by removing the inverter unit from the actual device. Remove the screw (T20 torx) Remove the connector and remove the fan unit.
  • Page 84 2. Maintenance 2.4.14 Clean the strainer in the solenoid valve for draining condensate in dryer <Procedures> ① When cleaning the Y type strainer “1” for dryer Open Close draining condensate solenoid valve, close drain valve “2”. ② Remove nut “3” of Y type strainer, and pull out screen “4”.
  • Page 85 2. Maintenance 18.5kW class <Procedures> ① Demount regulator assembly. And loosen screw“1” (6 pieces) and disassembled it. ② Replace diaphragm“2”with new ones. ③ Retighten screw“1”(6 pieces) equally in whole circumference so that the stem“3”is straight. Tightening torque: 4N･m (40kgf･cm) ④ After replacement, refer to 3.4.3 and conduct pressure adjustment.
  • Page 86 3. Electrical System 3.1 Functions 3.1.1 Specifications (1) Function of controller Item Contents Free air delivery is automatically controlled to 0 or 100%, according to increase or decrease of air consumption. When discharge pressure exceeds 2-Point set pressure (unload starting pressure), it starts purge operation to reduce control discharge pressure but releasing pressurized air in separator receiver tank (S type)
  • Page 87 3. Electrical System Item Contents Auto-start / ･20―180 seconds stop predicted stop time Y-operating ･10 seconds (0―15 seconds) [22･37kW class] time 15kW class 18.5･22･37kW class ･Discharge air temperature Starting ･Discharge air temperature higher than 10℃ higher than 10℃for 15 seconds unload time 0℃) for 15 seconds / less than 10℃( 0℃) for...
  • Page 88 3. Electrical System 3.1.2 Operation modes Item Contents A.C.C.S. The unloaded starting pressure is automatically controlled “UP” or “DOWN”, (Automatic capacity according to air consumption. Thus power is saved. (2-Point control) control for pressure width) When the service pressure decreases, the power consumption of the compressor air-end decreases.
  • Page 89 3. Electrical System Item Contents When discharge temperature exceeds the dew point temperature according to ambient temperature or when purge operation passes longer than 2 minutes in total, it accomplishes elimination of condensate caused at start-up and it prevents emulsification of oil. Thus, it can shorten condensate elimination operation and it prevents so frequently repeated start-stop operation.
  • Page 90 3. Electrical System 3.1.3 Controller (1) Appearance Part number : 46870 66801 (15kW class, 2-Point control type) Part number : 46870 66901 (15kW class, Regulator control type) Part number : 46870 68601 (15kW class, Inverter control type) Part number : 46870 69500 (18.5kW class, Regulator control type) Part number : 46870 60302 (22･37kW class, 2-Point control type) Part number : 46870 60402 (22･37kW class, Regulator control type) ※...
  • Page 91 3. Electrical System (2) Exterior connection drawing [2-Point control type] SC15099E 15kW class (Dryer built-in type)
  • Page 92 3. Electrical System [Regulator control type] SC15100E 15kW class (Dryer built-in type)
  • Page 93 3. Electrical System [Inverter control type] SC15101E 15kW class (Dryer built-in type)
  • Page 94 3. Electrical System (3) Position of connector pins and circuit voltage [2-Point control type] SC10034 Item Circuit voltage (V) Remark AC200･200･220 S1 (Power supply for controller) 22･37kW class is AC200･200･220 R2 / R1 (Power supply for controller) connected to the R1 phase Remote abnormality indicator lamp AC100―220 Supplied by customer...
  • Page 95 3. Electrical System Item Circuit voltage Remark Connected to CN2-6 (only for 15kW class), 11, 12 inside － controller Normal : DC12V [between CN2-1, 6 (15kW class), 11 and 12] Abnormal : OFF (B connect) Dryer abnormality Abnormal : 0V [between CN2-1, 6 Time lag : 1 second (15kW class), 11 and 12] Blank...
  • Page 96 3. Electrical System Item Circuit voltage Remark Connected to CN3-2, 3 inside Sensor GND － controller Connected to CN3-1, 3 inside Sensor GND － controller Connected to CN3-1, 2 inside Sensor GND － controller Blank － － Blank － － 22･37kW class is connected Blank / Inverter for －...
  • Page 97 3. Electrical System [Regulator control type / Inverter control type] SC10034 Item Circuit voltage (V) Remark AC200･200･220 S1 (Power supply for controller) 22･37kW class is R2 / R1 (Power supply for controller) AC200･200･220 connected to the R1 phase Remote abnormality indicator lamp AC100―220 Supplied by customer Remote operation indicator lamp...
  • Page 98 3. Electrical System Item Circuit voltage (V) Remark [Regulator control type] AC200･200･220 For assisting solenoid valve for purge control [Inverter control type] For assisting solenoid valve for AC200･200･220 capacity control For assisting solenoid valve for AC200･200･220 draining condensate 15 Blank －...
  • Page 99 3. Electrical System Item Circuit voltage Remark Connected to CN3-2, 3 inside Sensor GND － controller Connected to CN3-1, 3 inside Sensor GND － controller Connected to CN3-1, 2 inside Sensor GND － controller Blank － － Blank － － 18.5･22･37kW class is Blank / Inverter for －...
  • Page 100 3. Electrical System 3.1.4 Checking indication of warning, abnormalities and also checking emergency stop Trouble Item How to check Normal function code Remove the sensor from controller and load Discharge air Trouble code lamp resistance of 640±30Ω(105℃) to controller temperature H flickers.
  • Page 101 3. Electrical System Trouble Item How to check Normal function code Remove the sensor from controller and load Trouble code lamp Separator discharge air resistance of 560±22Ω(110℃) to controller flickers and unit temperature E stops. with variable resistor. Discharge air Trouble code lamp During operation, remove the sensor from temperature sensor...
  • Page 102 3. Electrical System Sensor and switches Upper side drawing Front view Side view SC15152 SAS37SD (Dryer built-in Type) 1. Thermal protector (TP) 9. Connection of power supply 2. Capacity control valve 10. Pressure sensor 3. High pressure switch (PRS1) (Defect intake negative pressure) 4.
  • Page 103 3. Electrical System 3.2 Electrical Parts 3.2.1 Specifications (1) Starter and solenoid valve 15kW class (2-Point control type / Regulator control type) Symbol Name Maker Model Remarks MSO-N65 Electromagnet MITSUBISHI Thermal set value: 42 (49) AC200V, switch (Motor) Electric 64.0/61.0/56.5A RC=54A (43―65A) Electromagnet MITSUBISHI...
  • Page 104 3. Electrical System 18.5kW class (Regulator control type) Symbol Name Maker Model Remarks MSO-T80 Electromagnet MITSUBISHI Thermal set value: 42 (49) AC200V, switch (Motor) Electric 74.5/73.0/66.5A RC=67A (54―80A) Electromagnet MITSUBISHI S-T10 contactor (Dryer) Electric AC200V Solenoid valve VCW42-2G-02-X30 For capacity (purge) control Solenoid valve VXK2110A-02-2GR1 For draining condensate...
  • Page 105 3. Electrical System 22kW class Symbol Name Maker Model Remarks 42: For Δ operation Electromagnet MITSUBISHI S-N65 42, 52 52: For insulation contactor Electric AC200V 2a2b (Surge damping value built in) Electromagnet MITSUBISHI S-N35 For Y operation contactor Electric AC200V 2a2b (Surge damping value built in) Electromagnet FC-0...
  • Page 106 3. Electrical System Symbol Name Maker Model Remarks SMS (One-point lifting type Cooling fan Omron R87F-A6A15HP AC230V only) Cooling fan in the starter panel SMS (One-point lifting type Cooling fan Fuji Electric VAS455AN-42 only) Cooling fan Fuse holder Sakazume FHC-15 (AC250V, 15A) φ6.4×30 (AC250V, 5A) Fuse Not specified...
  • Page 107 3. Electrical System Symbol Name Maker Model Remarks Electronic thermal set value (Inverter protection) Inverter for cooling Rated current 7.5A fan (200V class) Overload current rating TOSHIBA VFNC3-2015PB SAS (SER.NO. 150% 1 minute Schneider ―102/―154) AC200V, 3φ, 1.5kW 200% 0.5 seconds Inverter SMS (SER.NO.
  • Page 108 3. Electrical System 3.2.2 Inverter for main motor 15KW class : TOSHIBA Schneider inverter corporation Inverter model Part number VFAS1-2185PM ※(200V class) 46879 66400 ※400V class has also been setting. [Outline drawing] Charge lamp Rated plate Cooling fan Main circuit Short-circuit bar terminal block Main circuit...
  • Page 109 3. Electrical System [Inverter input / output] SC15156E [Input] Pin No. Connection Function Terminal block R terminal Terminal block S terminal Inverter power supply Terminal block T terminal Standard pressure input DC voltage in accordance with the pressure Controller CN3-16 terminal configured with the operation panel (standard pressure) is input Inverter RR terminal...
  • Page 110 3. Electrical System [Output] Pin No. Connection Function In response to the consumption side air pressure Motor for compressor U1, V2 terminal detected by the pressure sensor, an optimal frequency is output Motor for compressor V1, W2 terminal Motor for compressor W1, U2 terminal When the frequency of the inverter reaches the minimum frequency (25Hz), the relay between OUT1-NO (CC) will be turned “ON”...
  • Page 111 3. Electrical System [Monitor display of inverter operation] The operating status of the unit can be confirmed with the operation panel of the inverter. The operation procedures are as listed below. ① Operate the device. The operating frequency will be displayed in the operation panel of the inverter.
  • Page 112 3. Electrical System Inverter Operation panel SC15102 A100295-2 [Trip record] Details on a past trip (of this 1 to 4) can be displayed, as shown in the table below, by pressing the ● “ ” key when the trip record is selected in the status monitor mode. LED display Status Operation...
  • Page 113 3. Electrical System Error code display ① Error code and content of trips Error code Content Overcurrent during acceleration Overcurrent during deceleration Overcurrent during fixed speed operation Overcurrent flowing in element during acceleration Overcurrent flowing in element during deceleration Overcurrent flowing in element during fixed speed operation Load short-circuit start-up (output terminal check) trip U-phase arm overcurrent V-phase arm overcurrent...
  • Page 114 3. Electrical System ② Method of resetting causes of trip Do not reset the inverter when tripped because of a failure or error before eliminating the cause. Resetting the tripped inverter before eliminating the problem causes it to trip again. For recovering inverter from trip status, 1.
  • Page 115 3. Electrical System 3.2.3 Inverter for cooling fan (22･37kW class) Model Inverter model Model Inverter model SER. NO. SER. NO. Fuji Electric TOSHIBA FRN0.75C2S-2J 051―/051― VFNC3-2015PB ―102/―154 SASG19RD-5E/6E (200V class) (200V class) SAS37SD,RD-5E/6E TOSHIBA Fuji Electric VFNC3-2007PB ―097/―142 FRN2.2C2S-2HH 103―/155― (200V class) (200V class) SAS22SD,RD-5E/6E...
  • Page 116 3. Electrical System Line Connection Function When the electrical thermal of the inverter is Controller CN2-7 terminal activated, to light up the overload lamp of the operation panel and an emergency stop. Common Grounding Output to the cooling fan for inverter from the Controller CN3-16 terminal controller of frequency setting signal.
  • Page 117 3. Electrical System 3.2.5 Electromagnet switch MSO-T10 M3.5 M3.5 SC15109E MSO-T12 M3.5 M3.5 SC15110E MSO-N65 SC10014E 3-32...
  • Page 118 3. Electrical System MSO-T80 SC17069 3-33...
  • Page 119 3. Electrical System 3.2.6 Electromagnet contactor FC-0 M3.5 SC13068E S-T10 M3.5 SC5103E S-N10 A2 A1 M3.5 SC13069E S-N35 SC13090E 3-34...
  • Page 120 3. Electrical System S-N65 SC13070E S-N95 SC13071E 3.2.7 Thermal relay TH-N60KP, N120KP TH-N60KP M6 TH-N120KP M8 SC15104E 3-35...
  • Page 121 3. Electrical System 3.2.8 Cooling fan in the starter panel 15kW class (Inverter control type) Omron Model R87F-A6A83H Frequency (Hz) Rated voltage (V) AC230V Rated input (W) SC14053E 22･37kW class (SMS one-point lifting type) Omron Model R87F-A6A15HP Frequency (Hz) Rated voltage (V) AC230V Rated input (W) SC13073E...
  • Page 122 3. Electrical System 3.2.9 Solenoid valve (1) For capacity (purge) control : (SV1) Part number : 46811 12200 (15kW class) ･Closed while electricity is supplied Diameter of orifice (φ3mm) S_M039 Part number : 46811 19100 (18.5kW class) ･Closed while electricity is supplied (Rc 1/4) (Rc 1/4) Diameter of orifice (φ2mm)
  • Page 123 3. Electrical System (2) For stating unload : (SV4) Part number : 46811 29700 (22･37kW class Regulator control type only) Full-wave rectifier 1 (N.C.) 2 (COM.) 3 (N.O.) ･Three-way solenoid valve Diameter of orifice (φ2.2mm) SC13075E (3) For draining condensate in dryer : (SV6) (Strainer built-in) Part number : 46811 30800 Mesh Strainer...
  • Page 124 3. Electrical System 3.2.11 Thermo sensor (1) Discharge air temperature sensor and separator discharge air temperature sensor Part number : 44364 08200 SC14066 ※ For the relation between temperature and resistance, refer to 2.4.8. (2) Intake air temperature sensor Part number : 44364 06800 Thermistor SC10002 ※...
  • Page 125 3. Electrical System 3.2.13 Relay (1) EMG1 Relay : OLP [Over load protector] auxiliary of the dryer (15･18.5kW class) FX / DX Relay : For assisting solenoid valve for capacity (purge) control / For assisting solenoid valve for draining condensate (15･18.5kW class) SX / LFX Relay : Start signal to the inverter / For assisting fixed rotation speed command to the inverter (15kW class Inverter control type)
  • Page 126 3. Electrical System 3.3 Electrical Wiring Diagram 3.3.1 15kW class (2-Point control type) [200/220V type] [380/400/440V type] SC15111E SC15099E 3-41...
  • Page 127 3. Electrical System 3.3.2 15kW class (Regulator control type) [200/220V type] [380/400/440V type] SC15155E SC15100E 3-42...
  • Page 128 3. Electrical System 3.3.3 15kW class (Inverter control type) [200/220V type] [380/400/440V type] SC15112E SC15101E 3-43...
  • Page 129 3. Electrical System 3.3.4 18.5kW class (Regulator control type) [200/220V type] SC17070E 3-44...
  • Page 130 3. Electrical System 3.3.5 22kW class (Excluding one-point lifting type) [200/220V type] (SER.NO. SAS : • 097/• 142, SMS : • 086/• 086) SC15113E-1 3-45...
  • Page 131 3. Electrical System (SER.NO. SAS : 098• /143• , SMS : 087• /087• ) SC16009E-1 3-46...
  • Page 132 3. Electrical System [380/400/440V type] (SER.NO. SAS : 051• /051• , SMS : 051• /051• ) SC15114 E -2 3-47...
  • Page 133 3. Electrical System 3.3.6 22kW class (One-point lifting type) [200/220V type] (SER.NO. SMS : 051• /051• ) SC15115E-2 3-48...
  • Page 134 3. Electrical System 3.3.7 37kW class (Excluding one-point lifting type) [200/220V type] (SER.NO. SAS : • 102/• 154, SMS : • 082/• 087) SC15116E-1 3-49...
  • Page 135 3. Electrical System (SER.NO. SAS : 103• /155• , SMS : 083• /088• ) SC16010E-1 3-50...
  • Page 136 3. Electrical System [380/400/440V type] (SER.NO. SAS : 051• /051• , SMS : 051• /051• ) SC15117E-2 3-51...
  • Page 137 3. Electrical System 3.3.8 37kW class (One-point lifting type) [200/220V type] (SER.NO. SMS : 051• /051• ) SC15118E-2 3-52...
  • Page 138 3. Electrical System [380/400/440V type] (SER.NO. SMS : 051• /051• ) SC16011E-1 3-53...
  • Page 139 3. Electrical System 3.4 Various Setting Methods 3.4.1 Table of various set values (1) 2-Point control type (15kW class) The following set values can be altered and adjusted. However, as far as unloading (purge) operation starting pressure is concerned, never adjust operation at higher pressure than specified initial setting value.
  • Page 140 3. Electrical System (22･37kW class) The following set values can be altered and adjusted. However, as far as unloading (purge) operation starting pressure is concerned, never adjust operation at higher pressure than specified initial setting value. ※In case of operation at higher pressure than each specified set value would lead to motor overloading and motor burning and parts.
  • Page 141 3. Electrical System (2) Regulator control type (15kW class) The following set values can be altered and adjusted. However, as far as unloading (purge) operation starting pressure is concerned, never adjust operation at higher pressure than specified initial setting value. ※In case of operation at higher pressure than each specified set value would lead to motor overloading and motor burning and parts.
  • Page 142 3. Electrical System (18.5kW class) The following set values can be altered and adjusted. However, as far as unloading (purge) operation starting pressure is concerned, never adjust operation at higher pressure than specified initial setting value. ※In case of operation at higher pressure than each specified set value would lead to motor overloading and motor burning and parts.
  • Page 143 3. Electrical System (22･37kW class) The following set values can be altered and adjusted. However, as far as unloading (purge) operation starting pressure is concerned, never adjust operation at higher pressure than specified initial setting value. ※In case of operation at higher pressure than each specified set value would lead to motor overloading and motor burning and parts.
  • Page 144 3. Electrical System (3) Inverter control type (15kW class) Range of set values Indi- Item Primary set value cation Set value Pressure (MPa) Control pressure PL 40 to 85 0.4 to 0.85 (0.60MPa) Unloading (purge) Control Control operation starting pressure +0.04 to (0.65MPa) pressure +4 to 90 pressure PH...
  • Page 145 3. Electrical System 3.4.2 Changing procedures of various setting [How to change initial setting values and switch indication] (1) 2-Point control type (15kW class) <Procedures> DOWN ① Power up the compressor. ② Hold down the Display Selector Switch (more than 2 seconds) to switch to data setting mode.
  • Page 146 3. Electrical System (2) Regulator control type (15kW class) <Procedures> ① Power up the compressor. DOWN ② Hold down the Display Selector Switch (more than 2 seconds) to switch to data setting mode. [L. ] is shown on the digital monitor. ③...
  • Page 147 3. Electrical System (3) Inverter control type (15kW class) <Procedures> DOWN ① Power up the compressor. ② Hold down the Display Selector Switch (more than 2 seconds) to switch to data setting mode. [L. ] is shown on the digital monitor. ③...
  • Page 148 3. Electrical System 3.4.3 Adjustment of service pressure (Regulator control type only)  As the service pressure is adjusted before shipment, do not readjust it during the normal operation.  Operation at higher pressure than specified set value would lead to motor overloading and motor burning and parts.
  • Page 149 4. Troubleshooting 4.1 How to Proceed Diagnosis When performing failure diagnosis, pay special attention to the followings, observing general cautions. 4.1.1 Safety caution (1) Removing such cap and/or plug for receiver tank, fuel tanks and pipes where pressure is loaded, stop the machine and relieve all the interior pressure.
  • Page 150 4. Troubleshooting (5) Procedures of diagnosis When you become well experienced, you can find out the cause easily during the process of confirmation (4). But easy understanding could cause unexpected failure. So check and judge it according to the following procedures. ①Check the easiest thing or portion first.
  • Page 151 4. Troubleshooting 4.2 Failure of Capacity Control System 4.2.1 Safety valve blows off. (1) 2-Point control type / Inverter control type High Check set up pressure Controller pressure Reset pressure (Unloading operation / setting failure purge starting pressure) Normal Abnormal Repair or replace safety Faulty safety valve Check safety valve...
  • Page 152 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Set pressure Setting methods…refer to 3.4.2 Check safety valve Check if there is an incorrect pressure setting at safety valve. Specifications of Set pressure Model service pressure (MPa) (MPa) 0.70 (2-Point control) 0.88 0.70 (Inverter control) 15kW...
  • Page 153 4. Troubleshooting (2) Regulator control type Check set up pressure High Controller pressure Reset pressure (Unloading operation / setting failure purge starting pressure) Normal Abnormal Repair or replace safety Faulty safety valve Check safety valve valve Normal Air leaks Check if air leaks from an Faulty diaphragm of Replace (refer to 2.4.15) air vent port on pressure...
  • Page 154 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Set pressure Setting methods…refer to 3.4.3 Check safety valve Check if there is no abnormality at pressure setting of safety valve. Specifications of Set pressure Model service pressure (MPa) (MPa) 0.70 0.88 15kW...
  • Page 155 4. Troubleshooting 4.3 Function of Emergency Switch 4.3.1 Stop when discharge air temperature rising trouble code [E-1] or separator discharge air temperature rising trouble code [E-5] is indicated. Over 50℃ Ambient temperature too Lower ambient Check ambient high temperature temperature Under 50℃...
  • Page 156 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Lower ambient It sometime happen that temperature of the Ventilate suction and temperature room is heated over 50℃ by compressor discharge air fully of the room. installed in poorly ventilated. It causes overheating.
  • Page 157 4. Troubleshooting 4.3.2 Stop when overload trouble code [E-4] is indicated. [In case it stops before full load operation starts] Check whether Not turn Trouble of compressor Repair compressor compressor air-end can be air-end air-end turned by hand It can be turned by hand It occurs Shortage of power or Remove the cause of...
  • Page 158 4. Troubleshooting From the previous matter Normal Faulty thermal relay Repair or replace Check current value at full Faulty inverter thermal relay load (Electronic thermal) Check or repair inverter Abnormal (15kW class only) (Over rated value) Remove the cause of Check for any unbalance Abnormal voltage Abnormal...
  • Page 159 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Check if any Check such items as shortage of power supply, abnormal voltage length of wiring, and cable size. They cause drop occurs abnormal drop of voltage. 《Reference》 Allowable voltage drop rate shall be within 15%.
  • Page 160 4. Troubleshooting 4.3.4 The motor does not run while no trip message. (Inverter control type) (15kW class) Abnormal Lighting confirmation of Is power being supplied Cause removal the LED display of the normally ? inverter operation panel Normal Not lit Repair request Inverter failure Repair request...
  • Page 161 4. Troubleshooting Indication Meaning of at operation Description Remedies indication panel (1) The insulation of the output main circuit (1) Check the cables and wires for or motor is defective. defective insulation. Loaded side (2) The motor has too small impedance. (2) If this error message appears overcurrent when a motor is not connected...
  • Page 162 4. Troubleshooting Indication Meaning of at operation Description Remedies indication panel (1) The deceleration time is too short (1) Repair request (regenerative energy is too large). (2) The dynamic braking resistor has a considerably large resistance. Dynamic braking resistor is OFF. (3) Overvoltage limit operation is OFF.
  • Page 163 4. Troubleshooting 4.3.6 Alarm at the inverter for cooling fan. (22･37kW class) 【Excerpted from inverter manufacturer's instruction manual】 [TOSHIBA] If the inverter trips, an error code is displayed to suggest the cause. In the status monitor mode, the status when the inverter trip is held. So, you can check the information at the time of trip. (Operation mode flow) The inverter can be moved through each of the modes by pressing the MODE key.
  • Page 164 4. Troubleshooting Indication Meaning of at operation Description Remedies indication panel Overcurrent (1) The insulation of the output main circuit (1) Check the secondary wiring or motor is defective. and insulation state. overcurrent (2) The motor has too small impedance. (2) Set on the load side at...
  • Page 165 4. Troubleshooting Indication Meaning of at operation Description Remedies indication panel (1) The V/F setting is improper. (1) Repair request (2) The motor is locked up. Motor (3) Low-speed operation is performed overload continuously. (4) An excessive load is applied to the motor during operation.
  • Page 166 4. Troubleshooting < Method to reset after tripping > ① Press the STOP key and make sure that displayed. ② Pressing the STOP key again will reset the inverter if the cause of the trip has already been eliminated. ・When any overload function [ : inverter overload, : motor overload] is active, the inverter cannot be reset by inputting a reset signal from an external...
  • Page 167 4. Troubleshooting [Fuji Electric] If an abnormal condition arises, the protective function is invoked and issues an alarm, then the inverter automatically enters alarm mode. At the same time, an alarm code appears on the LED monitor. ■Releasing the alarm and switching to running mode Remove the cause of the alarm and press the key to release the alarm and return to running mode.
  • Page 168 4. Troubleshooting [Possible causes / What to check and suggested measures (Provide only main items)] SC15043E 4-20...
  • Page 169 4. Troubleshooting SC15044E 4-21...
  • Page 170 4. Troubleshooting SC15045E 4-22...
  • Page 171 4. Troubleshooting SC15046E  Before proceeding to the maintenance and inspection, turn OFF the power and wait at least five minutes. Make sure that the LED monitor is turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped below the safe level (+25 VDC or below).
  • Page 172 4. Troubleshooting 4.3.7 Dryer abnormality trouble code [E-3] (Stopping if abnormality mode is set) Overheated Remove cause of Check for overheating of Overheating overheat dryer overheated Fault found Check for looseness or Faulty wire connection Check and repair disconnection of wire connection Nothing wrong found Check function of...
  • Page 173 4. Troubleshooting (1) Troubleshooting of dryer 1. Unable to run No power supplied Check power supply of Faulty wire connection Check and repair dryer Power supplied Faulty wire connection Adjust to rated voltage Check voltage Normal Malfunction of EMG1 relay．(15･18.5･22kW Check function of EMG1 Abnormal Check and repair...
  • Page 174 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Over load protector OLP/TP is equipped on the top of compressor ･OLP operating/return (OLP) operate for freezer to protect it from overload. temperature : : 15･22kW class 130℃/65℃ (4.7A/at <Cause> Thermal protector 100℃) ①...
  • Page 175 4. Troubleshooting 2. Water drained at outlet Closed Check drain valve of Open drain valve solenoid valve (SV6) for draining condensate Opened No breakage of drain pipe, Clogged Drain pipe and strainer Check and clean clogging at solenoid valve clogged (refer to 2.4.14) (SV6) for draining condensate and strainer...
  • Page 176 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Check whether 15kW class ･Check wiring solenoid valve (SV6) At a ratio of 1 second, normal solenoid valve is ･Check seizing at for draining activated when the AC200V is applied to S1 solenoid valve condensate between the line No.
  • Page 177 4. Troubleshooting 4. Air or drain blowing at drain outlet Abnormal Check function of Malfunction controller Replace controller controller Normal Malfunction solenoid Disassemble or replace Check whether solenoid Abnormal valve (SV6) for draining solenoid valve valve (SV6) for draining condensate and auxiliary Check auxiliary relay condensate functions relay (DX)
  • Page 178 4. Troubleshooting (2) Countermeasures for dryer troubles (15･22kW class) [Adjust of the hot gas by-pass valve] In case the interior of heat exchanger gets frozen when ● the dryer is operated with the indicator of refrigerant Anti- pressure gauge placed lower than the refrigerant clockwise Clockwise evaporation pressure.
  • Page 179 4. Troubleshooting (18.5･37kW class) [Adjust of the capacity control valve] In case the interior of heat exchanger gets frozen when ● “Temperature measurement position” at the dryer is operated with the indicator of refrigerant refrigerant exit pipe of heat exchanger (HX) evaporation pressure gauge placed lower than the Capacity control refrigerant evaporation pressure.
  • Page 180 4. Troubleshooting [Explanation of the fan control pressure switch (FCP) and the high pressure switch (HP)] The fan control pressure switch is a device that ● Fan control pressure switch switches the condenser fan ON/OFF to control the (FCP) condensing pressure to stay within an appropriate range.
  • Page 181 4. Troubleshooting 4.4 Others 4.4.1 Oil is found mixed in discharge air. (Oil consumption increases) Too much Too much oil Drain oil Check compressor oil level Proper level Less than 0.39MPa Check and adjust Low discharge pressure Check discharge pressure pressure control valve More than 0.39MPa Clogged...
  • Page 182 4. Troubleshooting 4.4.3 Compressor start and stops too frequently while no air is consumed. (Auto start/stop operation) Air leaks Repair air leaking Air leaks from piping Check air leak from piping portion No air leaks Air leaks Check any air leaks from Repair or replace Faulty seat the seat of pressure...
  • Page 183 4. Troubleshooting 4.4.5 Even when each control switch is pushed ON, the machine will not start. Abnormal Repair or replace Check function of Malfunction of controller controller controller Countermeasures Mark Item Cause & Explanation & Remarks Check function of Check if any key is pushed due to incorrect Check installation of controller installation of controller.
  • Page 184 5. Reference 5.1 Structure of Parts PILOT piping SC15144 Vacuum relief valve Pressure sensor (Suction negative pressure) 22･37kW class (2-Point control type) 5.1.1 Vacuum relief valve (Built in unloader) During assembling, carefully install valve so that it PILOT pressure ※ should be straight.
  • Page 185 5. Reference 5.1.2 Auto-relief circuit SC15145E 22･37kW class (2-Point control type) Function： When stopping, capacity (purge) control solenoid valve (SV1) opens thus pressurized air from separator receiver tank flows through SV1 to external piping at unloader. Pressurized air from external piping flows in the primary chamber of unloader and be released to the atmosphere through the air filter.
  • Page 186 5. Reference 5.1.3 Solenoid valve for starting unload (SV4) (Regulator control type only) NC (Unloader secondary camber) COM (Unloader spring chamber) COM (Unloader spring chamber) NO (Unloader primary camber) NC (Unloader secondary camber) Solenoid valve Gasket used on the mounting surface (Unloader primary camber) mounting surface (Solenoid valve attached)
  • Page 187 5. Reference 5.1.4 Regulator (Regulator control type only) Unloader spring Unloader activation chamber chamber Pressure adjusting screw Diaphragm Regulator secondary Valve stem pressure Primary side Secondary side (Separator (To unloader and receiver tank) vacuum relief valve) Unloader Unloader primary camber secondary camber SC13082 S_M013...
  • Page 188 5. Reference 5.2 Table of Reference Data 5.2.1 Table of set values Item Unit 15kW class 18.5kW class 22kW class 37kW class ・Protection devices Set value of main motor thermal See 3.2.1 relay Set value of dryer thermal relay See 3.2.1 －...
  • Page 189 5. Reference From the previous page Item Unit 15kW class 22kW class 37kW class ・Timer Auto start/stop predicted stop 20―180 time Discharge air Temperature higher than Discharge air temperature higher than 10℃for 10℃( 0℃) for 15 seconds 15 seconds Starting unload time ※...
  • Page 190 5. Reference 5.3 List of Belt Tension (for sonic tension meter) Start testing belt tension, using sonic tension meter, according to the following procedures. This instruction is based on GATES Sonic Tension Tester. (How to input data for sonic tension meter is referred to the manual provided together with the meter by GATES UNITTA ASIA.) (1) Inputting data Enter the following three items into the meter.
  • Page 191 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE SP” or “LONG-LIFE HP”(18.5kW class only). However, in case AIRMAN dedicated oil is un-acquirable, using of the below mentioned oil is strongly recommended, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 192 5. Reference 5.5 Wiring 5.5.1 Breaker capacity and wiring operation All the wirings in the compressor are completed; ● therefore, power supply and ground connections should be made. Fluctuation of the supply power voltage must be kept ● within rated voltage±5% and rated voltage±2% among phases.
  • Page 193 5. Reference [The connection method of a power cable] This table is indicated as a standard. ● (Keep in mind that it may change with power supply situations.) The figures of cable thickness in the above table are ● based on the straight line of 10m long for single machine connection.
  • Page 194 5. Reference 5.5.2 Desorption method for the front cover of the inverter (Inverter control type only) When removing the inverter connection cable for desorption of the inverter, and remove the cable by removing the inverter front cover with the following procedure. (15kW main motor) ①...
  • Page 195 5. Reference 5.5.3 Desorption method for cover of terminals board of inverter for cooling fan When removing the inverter connection cable for desorption of the inverter, and remove the cable by removing the inverter terminal block cover with the following procedure. (22･37kW class) [TOSHIBA] (1) Removing the lower (output and dc terminals) terminal block cover...
  • Page 196 5. Reference SC15150E  Before proceeding to the maintenance and inspection, turn OFF the power and wait at least five minutes. Make sure that the LED monitor is turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped below the safe level (+25 VDC or below).
  • Page 197 5. Reference (18.5･22･37kW class) [Fuji Electric] <Procedures> ① Loosen the screw securing the control circuit terminal block cover. ② Insert your finger in the cutout (near "PULL") in the bottom of the control circuit terminal block cover, then pull the cover towards you. ③...
  • Page 198 5. Reference 5.6 List of Consumable Parts and Electrical Appliances Item 15kW class 18.5kW class ●Element / Filter / Belt Air filter ASS’Y 32100 44800 • Air filter element 32143 16500 • Oil filter 37438 08900 37438 09200 Oil separator 34224 02801 •...
  • Page 199 5. Reference Item 15kW class 18.5kW class ●Electrical appliances Controller (2-Point control type) 46870 66801 • Controller (Regulator control type) 46870 66901 46870 69500 Controller (Inverter control type) 46870 68601 • EMG1, FX, DX relay 46177 06000×3 • SX, LFX relay (Inverter control type) 46177 06000×2 •...
  • Page 200 5. Reference Item 22kW class 37kW class ●Element / Filter / Belt Air filter ASS’Y 32100 45301 32100 45500 Air filter element 32143 17200 32143 17100 Oil filter 37438 08900 37438 09400 Oil separator 34224 03000 34224 02601 O-ring for oil separator 03402 15145 •...
  • Page 201 5. Reference Item 22kW class 37kW class ●Electrical appliances Controller (2-Point control type) 46870 60302 • Controller (Regulator control type) 46870 60402 • 46177 08000×2 FX, DX, EMG1 relay 46177 08000×3 (FX, DX relay only) Solenoid valve (SV1) 46811 29300 •...
  • Page 202 5. Reference 5.7 Dryer Structure and Functions of Component Parts 15･22kW class (Model : ACS-15J3, ACS-22J2) ACC Accumulator CCV Hot gas by-pass valve CON Condenser Compressor CPT Capillary tube Check joint Charge valve Refrigerant evaporation pressure gauge FCP Fan control switch Condenser fan motor HEX Cooler SC15024E...
  • Page 203 5. Reference [Component parts and its functions] Description Symbol Function Cooler To condense moist compressed air and separate water and air. To pressurize refrigerant from low temperature-low pressure to Compressor high pressure (high temperature) to ease the condensation. Condenser To liquidize high pressure (high temperature) from compressor. To make high pressure liquid refrigerant expanded to become low Capillary tube temperature refrigerant in order to facilitate heat absorption.
  • Page 204 5. Reference Positions of sensors When fan control switch ※6 or high pressure switch ※7 is broken, it is necessary to replace ※6 either “6” and “7” at the same time. (Replace ※7 pressure switch ass’y) ※10 SC15151 5-21...
  • Page 205 5. Reference 18.5･37kW class (Model : ACS19H,ACS37VG) Cooler Motor (refrigerating compressor) Motor (fan motor) CON Condenser Strainer EXV Capillary tube CCV Capacity control valve PRS1 High pressure switch PRS2 Fan control pressure switch EPG Evaporating pressure gauge Check joint on low-pressure CJ(L) side Check joint on high-pressure...
  • Page 206 5. Reference [Component parts and its functions] Description Symbol Function Cooler To condense moist compressed air and separate water and air. Motor (refrigerating To pressurize refrigerant from low temperature-low pressure to compressor) high pressure (high temperature) to ease the condensation. Condenser To liquidize high pressure (high temperature) from compressor.
  • Page 207 5. Reference Positions of sensors (18.5kW class) 13-1 SC15279 SC15280 (37kW class) 13-2 SC15317 SC15318 5-24...
  • Page 208 北 越 工 業 株 式 会 社 発行 本社工場 新潟県燕市下粟生津3074 TEL ０２５６－９３－５５７１ FAX ０２５６－９４－７５６７ (無断複写・転載を禁ず) ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. 8TH FLOOR SHINJUKU SAN-EI BLDG, 22-2 NISHI-SHINJUKU 1-CHOME,SHINJUKU-KU TOKYO 160-0023 JAPAN TEL:81-3-3348-7281 FAX:81-3-3348-7289 URL:http//www.airman.co.jp Copyright(C)2016 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved. NSC-0068-1 Printed FEB. 2022...

This manual is also suitable for:

Sas15sd-5eSas15sd-6eSas15vd-eSas22sd-5eSas22sd-6eSas22rd-5e ... Show all