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AirMan PROAIR AS Series Service Manual

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Summary of Contents for AirMan PROAIR 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 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 1.2 Motor Specifications ------------------------------------------------------------------------------------------------- 1-5 1.2.1 Motor for compressor ------------------------------------------------------------------------------------------ 1-5 1.2.2 Motor for cooling fan ------------------------------------------------------------------------------------------- 1-5 1.3 Warning / Abnormality Display ------------------------------------------------------------------------------------ 1-6 2.
  • Page 4 3.2.11 Pressure sensor ------------------------------------------------------------------------------------------------- 3-25 3.2.12Relay ---------------------------------------------------------------------------------------------------------------- 3-25 3.3 Electrical Wiring Diagram ------------------------------------------------------------------------------------------ 3-26 3.3.1 55,75kW class[200/220V] ----------------------------------------------------------------------------------- 3-26 3.3.2 55kW class [380/400/440V] -------------------------------------------------------------------------------- 3-27 3.3.3 75kW class [380/400/440V] -------------------------------------------------------------------------------- 3-28 3.4 Various Setting Methods ------------------------------------------------------------------------------------------- 3-29 3.4.1 Table of various set values ----------------------------------------------------------------------------------- 3-29 3.4.2 Changing procedures of various setting ----------------------------------------------------------------- 3-33 3.4.3 Adjustment of service pressure (Regulator control type only) --------------------------------------- 3-34...
  • Page 5 1. Overview Capacity Control 1.1.1 2-Point control type A150025E Unloader valve control pressure. Unloader pressure relief circuit /Auto relief air release circuit. Vacuum relief valve. Vacuum relief circuit of the compressor air-end. SC16056E Conditions of solenoid valve for Conditions Unloader valve capacity control (SV1) Start/Purge operation Open...
  • Page 6 1. Overview Conditions Function When air consumption decreases and discharge pressure exceeds set value (unloading operation starting pressure PH), solenoid valve for capacity control (SV1) opens so that compressed air in air receiver tank can be sent to unloader activation chamber. Thus, unloader valve is closed and at the same time compressed air in receiver tank is relieved to atmosphere through air filter and Purge operation the pressure is lowered.
  • Page 7 1. Overview 1.1.2 Regulator control type A1500252E Unloader valve control pressure Unloader pressure relief circuit/Auto relief air release circuit Vacuum relief valve Vacuum relief circuit of the compressor air-end Solenoid valve(SV4) connected To NC poet. Solenoid valve(SV4) connected Solenoid valve(SV4) connected To NO poet.
  • Page 8 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 9 1. Overview 1.2 Motor Specifications 1.2.1 Motor for compressor (Totally-enclosed fan cooled type) (1)55kWclass SAS55SD,RD-5E SAS55SD,RD-6E Unit SF-PRF Power nominal output Frequency Rated voltage 200/220 400/440 Rated current 214/198 107/99 Poles Insulation class Coil resistance (20 ) 0.0123 0.0490 0.0123 0.0490 Rated current includes service factor (SF: 1.1) and it is mentioned on motor serial plate.
  • Page 10 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 11 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 12 1. Overview After 3000Hr maintenance,reset to the trouble code switch and long press (longer than 2 seconds). When the maintenance time of the setting is 0Hr can not be reset. Please reset to re-input the maintenance time, refer to section 3.4. A16038E Display Indication...
  • Page 14 2. Maintenance Equipments Hot oil bath or bearing heater Chain block Impact wrench 2.1.2 Cautions during disassembly and assembly For the disassembly location, be sure to select a location that is free of dust and large enough to perform the task. Hove to clean and remove dust from disassemble equipment.
  • Page 15 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) Cylinder and discharge casing socket bolt 49.0(485) Hexagon haul Oil seal cover socket bolt 49.0(485) Hexagon haul End cover socket bolt 25.0(245) Hexagon haul...
  • Page 16 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 and sorting Torque...
  • Page 18 2. Maintenance 2.2.4 Special tools [55kW class] Part name Part NO. Q'ty Remarks Plate 00817 00200 Disassembly tool for rotor and discharge casing [75kW class] Part name Part NO. Q'ty Remarks Plate 00817 00201 Disassembly tool for rotor and discharge casing Unloader piston Teflon ring installation tool Part name Part NO.
  • Page 19 2. Maintenance 2.2.6 Tightening torque for hose, joint etc… (1) Union joint Should be tighten union joint according to following torque. Parallel thread for pipe Tool width Tightening torque Screw size across flat G (PF) N m (kgf cm) (mm) 19 (17) (250) 22 (19)
  • Page 20 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 21 2. Maintenance Supply oil to these points 2) Coat pipe and nipple with lubrication oil Coat the sleeve and nut of pipe with lubricant (NICHIMORI LAP spray or equivalent) Coat the threaded portion and seat face of nipple with Supply oil to these points lubricant When tightening it without coating lubricant, galling could take place.
  • Page 22 2. Maintenance (3) O-ring sheet type Nipple O-ring Joint Pipe SC15108-1 1) Check and confirm the pipe Supply oil to these points Check the O-ring (for end of joint) for any damage or twist. Use O-ring of specified size and material. Coat the O-ring with lubricant (NICHIMORI LAP spray or equivalent) and install it in the groove of the joint for O-ring.
  • Page 23 2. Maintenance (4) Pipe tapered threads Sealing tapes are used to prevent any leakage of oil, water, fuel and air by stopping the space between female and male threads of metal pipe and fittings (PT thread for pipe). Be noted that how to seal varies upon the diameter of thread.
  • Page 24 2. Maintenance 3) Concerning components with screw portions coated with a sealant Components with their screw portions coated with a sealant are to be screwed in upon applying a sealant (THREEBOND 1212). Apply the “THREEBOND 1212” coating portion SC14002 4) Standard tightening torque of piping PT screw (Reference value) Unit: N m (kgf cm) Nominal Tightening...
  • Page 25 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 26 2. Maintenance (6) How to install hose Pay attation followig part when install nylon tube and hose. 1) Nylon tube Check 1/8 and 3/16 size nylon tubes for any break. (Pipe for pressure gauge) Connect nylon tube, preventing it from contacting any edge of copper pipe and steel pipe nut.
  • Page 27 2. Maintenance 2) Hose Authentic hose when replacing it. If not, it will cause oil leakage, break and disconnection, and it leads to fire. 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 28 2. Maintenance 2.3 Periodic Inspection / Maintenance List 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 29 4 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 5.3, and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 30 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 31 4 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 5.3., and please reduce by half all the periods those are suggested in the table of periodic inspection/ maintenance.
  • Page 32 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 Make sure to switch off power supply switch.
  • Page 33 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> SC15061 Component Name Component Name...
  • Page 34 2. Maintenance [Loaded side bearing] Remove the bearing bracket attachment bolt and lightly strike this with a plastic hammer to remove the bearing bracket. Remove the bearing from the shaft by using a gear puller, etc. as illustrated below. <Remove the bearing> Bearing TXT079 The bearing is assembled using a bearing heater or a press fitting jig, etc.
  • Page 35 2. Maintenance [Non-loaded side bearing] Remove the fan cover and the fan. Remove the bearing bracket attachment bolt and lightly strike this with a plastic hammer to remove the bearing bracket. Remove the preload spring. Remove the motor bearing, using such tool as gear puller. The bearing is assembled using a bearing heater or a press fitting jig, etc.
  • Page 36 2. Maintenance 2.4.2 Check and change cooling fan <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 – DO NOT SWITCH ON”...
  • Page 37 2. Maintenance 2.4.3 O-ring replacement of the unloader and vacuum relief valve (1) O-ring replacement of the unloader. <Note of the O-ring replacement> Apply a thin coat of grease on the O-rings when replacing the O-rings “1” and “2”. Remove piston “5”. Otherwise it rises up by a spring tension when removing cover “6”.
  • Page 38 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 “1” and “2”. Extract piston “4” by screwing in a bolt “7” in to portion (M4×0.7 internal threads).
  • Page 39 2. Maintenance 2.4.5 Change oil separator When consumption of the oil is still unusual even after cleaning strainer in the scavenging orifice, change the oil separator with a new one. When replacing the oil separator, be sure to also replace the O-ring. <Procedures>...
  • Page 40 2. Maintenance 2.4.6 Clean oil cooler / aftercooler <Procedures> Remove the rear cover and clean the fin of the oil cooler and after cooler by blowing compressed air from the bottom to remove film or dust. Clean the remaining dirt using a brush.
  • Page 41 2. Maintenance 2.4.7 Maintenance adjustment of pressure control valve (1) Maintenance procedures If the discharge pressure falls below 0.39MPa 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 42 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. During operation, remove the sensor cable connected to the controller. 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 43 2. Maintenance 2.4.10 Inverter for cooling fan Excerpted from inverter manufacturer's instruction manual SC15025E <Iinspection / cleaning> Check part Check item How to inspect Evaluation criteria Keypad 1) Check that the display is clear. 1), 2) 1), 2) 2) Check that there is no missing Visual inspection The display can be part in the displayed...
  • Page 44 2. Maintenance Remove dust accumulating on the inverter with a vacuum cleaner. If the inverter is stained, wipe it off with a chemically neutral cloth. Inverter constituted a main circuit capacitor and electrolytic capacitor on printed board. If above mentioned parts are broken, it is necessary to return the inverter to original maker for repair or replacement.
  • Page 45 2. Maintenance 2.4.11 Clean the strainer in the solenoid valve for draining condensate in dryer <Procedures> Open Close When cleaning the Y type strainer “1” for dryer draining condensate solenoid valve, close drain valve “2”. Remove nut “3” of Y type strainer, and pull out screen “4”.
  • Page 46 2. Maintenance ＭＥＭＯ ＭＥＭＯ ＭＥＭＯ ＭＥＭＯ 2-34...
  • Page 47 3. Electrical System 3.1 Functions 3.1.1 Specifications (1) Function of controller Item Contents According to air consumption, air quantity will be regulated automatically to 0 or 100 %. When discharge air exceeds setting pressure (Unload starting 2-Point control pressure), compressed air in separator receiver tank will be purged (S type) into air and discharge pressure will be lowered to about 0.1MPa.
  • Page 48 3. Electrical System From the previous page Item Contents Auto-start / stop predicted 60 seconds (20 180 seconds) stop time Y-operating 10 seconds (0 15 seconds) time Discharge air temperature higher than 10 0 ) for 15 seconds Starting unload time / less than 10 ( 0 ) for 60 seconds Contents of...
  • Page 49 3. Electrical System (2) Function of each output relay Symbol Function Symbol Function It switches ON by operation External trouble signal (Remote) Insulation for electromagnet contactor ON at emergency For dryer operation External operation signal (Remote) Switching it ON, it starts dryer It switches ON by operation operation.
  • Page 50 3. Electrical System From the previous page 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.
  • Page 51 3. Electrical System 3.1.3 Controller (1) Appearance [2-Point control type] Part number : 46870 60302 [Regulator control type] Part number : 46870 60402 The control controllers 55kW class and 75kW class are common. Configuration of the model type is performed on the operation panel after the controller has been attached to the actual unit and the power has been turned on.
  • Page 52 3. Electrical System (2) Exterior connection drawing SC16059E...
  • Page 53 3. Electrical System (3) Position of connector pins and circuit voltage SC10034 Item Circuit voltage (V) Remark S1 (Power supply for controller)/ solenoid valve SV4 power supply for starting unloader AC200 200 220 R1 (Solenoid valve power supply for starting unloader) (Regulator control type only) AC200 200 220 R1 (Power supply for controller)
  • Page 54 3. Electrical System Item Circuit voltage Remark Connected to CN2-11, 12 inside controller Normal : DC12V [between CN2-1, 11 and 12] Abnormal : OFF (B connect) Dryer abnormality Abnormal : 0V Time lag : 1 second [between CN2-1, 11 and 12] Blank During operation (ON) : DC12V (between CN2-1)
  • Page 55 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 inverter frequency setting signal Inverter for cooling fan (GND) Blank Internal ground connection...
  • Page 56 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 30 (105 ) to controller temperature H flickers.
  • Page 57 3. Electrical System Refer to 1.3 trouble codes table for time lag and detection time. 1 Dryer warning / abnormality: Warning and abnormality can be changed by setting at the operating panel. (for details, refer to 3.4.1 & 3.4.2) (Factory default settings: “Abnormality”) 2 The discharge air temperature HH is displayed only with 2-Point control type.
  • Page 58 3. Electrical System Sensor and switches Upper side drawing Side view Front view Side view SC15027 1.Bimetal thermostat (TTH) 9.Thermal relay for dryer cooling fan (49CF) 2. Interrnal thermostat (ITH) 10.Thermal relay for main motor(49) (Built in motor winding of condenser) 11.Pressure sensor (Defect service pressure) 3.
  • Page 59 3. Electrical System 3.2 Electrical Parts 3.2.1 Specifications (1) Starter and solenoid valve [55kW class] Symbol Name Maker Model Remarks Electromagnet MITSUBISHI S-N150 42, 52 52: For insulation contactor Electric AC200V 2a2b (Surge damping value built in) Electromagnet MITSUBISHI S-N80 For Y operation contactor Electric...
  • Page 60 3. Electrical System [75kW class] Symbol Name Maker Model Remarks Electromagnet MITSUBISHI S-N180 42, 52 52: For insulation contactor Electric AC200V 2a2b (Surge damping value built in) Electromagnet MITSUBISHI S-N95 For Y operation contactor Electric AC200V 2a2b (Surge damping value built in) TH-N220HZKPSR MITSUBISHI Thermal set value :...
  • Page 61 3. Electrical System 3.2.2 Inverter for cooling fan [Outline drawing] Model Inverter model Part number 55kW class 46879 69302 FRN2.2C2S-2HH (200Vclass) 75kW class 46879 69202 400V class has also been setting. Rating plate Terminal block Cooling fan SC15028 [Inverter input / output] SC15029E-1 (1) List of functions Line...
  • Page 62 3. Electrical System From the previous page Line Pin No. Connection Function Earth It outputs frequency setting signal from controller Controller CN3-15 terminal to cooling fan inverter. Common Earth...
  • Page 63 3. Electrical System [Operation mode flow] Excerpted from inverter manufacturer's instruction manual “Programming/ LED monitor “Running”Key Volume Reset”Key “Function/Data code” “Down”Key “Up”Key “Stopping”Key SC15030 Running Key/Stopping key can not be used because it is not connected to controller. SC15031E Running mode : Run-stop command can be set at general operation.
  • Page 64 3. Electrical System [Alarm code] SC15032E For the details of alarm codes, refer inverter manual. [The oil temperature control of the cooling fan for inverter] The ambient temperature and discharge air temperature will be detected and calculated with the controller and operate the cooling fan at the optimal rotational speed. Discharge air temperature will be regulated suitably not to be under dew point according to ambient temperature.
  • Page 65 3. Electrical System 3.2.3 Sensor / switch Name Symbol Trouble code Maker Remarks Air filter Nippon 6.2kPa Air filter clogging indicator Donaldson DC12 24V A contact Discharge air Shibaura TLE1 560 22( ) at 110 temperature Electronics Separator discharge air Shibaura Thermo sensor TLE2...
  • Page 66 3. Electrical System 3.2.4 Electromagnet switch MSO-T10 SC15109E MSO-T20 SC15158E MSO-T25 SC15159E...
  • Page 67 3. Electrical System 3.2.5 Electromagnet contactor S-N80,N95 SC13071-1E S-N150 S_M134E S-N180 S_M135E 3.2.6 Thermal relay TH-N120TAHZKP SC09013E...
  • Page 68 3. Electrical System TH-N220HZKPSR SC15036E 3.2.7 Cooling fan in the starter panel SAS,SMS55 75 SANYO DENKI Model 109S025UL Frequency (Hz) Voltage (V) AC230V Input power (W) SC14060E SMS75(Single hanging type) Omron Model R87T-A6A07H Frequency(Hz) Voltage(V) AC230V Input power(W) SC14054...
  • Page 69 3. Electrical System 3.2.8 Solenoid valve (1)For capacity (purge) control(SV1) Parts number:46811 29300 Full wave rectifier (IN) (OUT) (Rc 3/8) (Rc 3/8) Normally crosed(NO) SC13074E Orifice ( 4.5mm) (2)For stating unlod (SV4)(Regurator controltype only) Parts number:46811 13300 NO (Rc 1/4) NC NO (Rc 1/4) (Rc 1/4)
  • Page 70 3. Electrical System (3) For draining condensate in dryer : (SV6) (Strainer built-in) Part number : 46811 30800 Mesh Strainer specification Material (Rc 1/4) (Rc 1/4) Nut tightening torque (N m) (Opposite side 27mm) SC15037 Opened while electricity is supplied 3.2.9 Air filter indicator Part number : 32148 03000 Operating resistance...
  • Page 71 3. Electrical System (2) Intake air temperature sensor Part number : 44364 06800 Thermistor SC10002 For the relation between temperature and resistance, refer to 2.4.9. 3.2.11 Pressure sensor Part number : 44328 20600 Trouble diagnosis of pressure sensor itself Check and confirm that output voltage between •...
  • Page 72 3. Electrical System 3.3 Electrical Wiring Diagram 3.3.1 55 75kW class[200/220V] SC16060E...
  • Page 73 3. Electrical System 3.3.2 55kW class[380/400V/440V] SC16061E...
  • Page 74 3. Electrical System 3.3.3 75kW class[380/400V/440V] SC16062E...
  • Page 75 3. Electrical System 3.4 Various Setting Methods 3.4.1 Table of various set values (1) SAS series [2-Point control type] 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 76 3. Electrical System [Regulator control type] 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 77 3. Electrical System (2) SMS series[2-Point control type] 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 78 3. Electrical System [Regulator control type] 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 79 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 <Procedures> DOWN Power up the compressor. Hold down the Display Selector Switch (more than 2 seconds) to switch to data setting mode. [L. ] is shown on the digital monitor.
  • Page 80 3. Electrical System Adjustment of service pressure(Regulator control type only) 3.4.3 Procedure of the service pressure value setting is followings. <Procedures> Pressure adjusting handle After starting operation, set to “0” the time for time Regulator required for confirmation of purge operation. In case that purge control function is released, auto start/stop mode operation will be cancelled.
  • Page 81 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 82 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. Check the easiest thing or portion first.
  • Page 83 4. Troubleshooting 4.2 Failure of Capacity Control System 4.2.1 Safety valve blows off. (1) 2-Point control type High Controller pressure Reset pressure Check set up pressure setting failure Normal Abnormal Repair or replace safety Faulty safety valve Check safety valve valve Normal Abnormal...
  • Page 84 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Set pressure Setting methods…refer to 3.4.1 3.4.2 Check if there is an incorrect pressure setting at safety valve. Check safety valve 0.93 Specifications of 0.70 0.85 service pressure (SAS series) [STD.
  • Page 85 4. Troubleshooting (2) Regulator control type High Controller pressure Reset pressure Check set up pressure setting failure Normal Abnormal Repair or replace safety Faulty safety valve Check safety valve valve Normal Check if air leaks from an Air leaks Faulty diaphragm of air vent port on pressure Replace (refer to 2.4.12) pressure regulator...
  • Page 86 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Set pressure Setting methods…refer to 3.4.1,3.4.2 and 3.4.3 Check safety valve Check if there is an incorrect pressure setting at safety valve. 0.90 Specifications of 0.70 0.85 service pressure (SAS series) [STD.
  • Page 87 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 Purge starting pressure is too high...
  • Page 88 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 89 4. Troubleshooting 4.3.2 Stop when overload trouble code [E-4] is indicated. [In case it stops before full load operation starts] It occurs Shortage of power or Remove the cause of Check if any abnormal faulty connection voltage drop voltage drop occurs No voltage drop Abnormal...
  • Page 90 4. Troubleshooting From the Previous page Normal Faulty thermal relay Repair or replace Check current value at full load thermal relay Check or repair inverter Abnormal (Over rated value) Remove the cause of Check for any unbalance Abnormal voltage Abnormal faulty voltage of voltage between each phase...
  • Page 91 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 92 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Check whether Compressor air-end is coupled with motor In case compressor compressor air-end can directly. air-end or motor shaft be turned with light Check as separating into compressor air-end rotates slowly, there power by hand.
  • Page 93 4. Troubleshooting 4.3.4 Alarm at the inverter for cooling fan. Excerpted from inverter manufacturer's instruction manual 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.
  • Page 94 4. Troubleshooting [Possible causes / What to check and suggested measures (Provide only main items)]...
  • Page 95 4. Troubleshooting SC15044...
  • Page 96 4. Troubleshooting SC15045...
  • Page 97 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 98 4. Troubleshooting 4.3.5 Dryer abnormality trouble code [E-3] (Stopping if abnormality mode is set) Overheated Remove cause of Check for overheating of Overheating overheat dryer overheated Check for looseness or Fault found Faulty wire connection disconnection of wire Check and repair connection Nothing wrong found Check function of...
  • Page 99 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 Check voltage Adjust to rated voltage Normal Abnormal Malfunction of Check function of Check and repair electromagnet switch electromagnet switch...
  • Page 100 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Check function of ITH is bimetal thermostat built in compressor ITH operating/return internal thermostat motor coil. It works as a breaker when motor temperature : (ITH) temperature rises abnormally. 135 /113 Refrigerant <Cause>...
  • Page 101 4. Troubleshooting 2. Water drained at outlet Check drain valve of Closed 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 2.4.11) (SV6) for draining condensate and strainer...
  • Page 102 4. Troubleshooting Countermeasures Mark Item Cause & Explanation & Remarks Check whether At a ratio of 5 seconds, normal solenoid valve is Check wiring solenoid valve (SV6) activated when the AC200V is applied to S1 Check seizing at for draining between the line No.
  • Page 103 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 104 4. Troubleshooting (2) Countermeasures for dryer troubles [Adjust of the capacity control valve] In case the interior of heat exchanger gets frozen when the dryer is operated with the indicator of refrigerant “Temperature measurement position” at evaporation pressure gauge placed lower than the refrigerant exit pipe of heat exchanger (HX) refrigerant evaporation pressure.
  • Page 105 4. Troubleshooting [Explanation of the fan control pressure switch (PRS2) and the high pressure switch (PRS1)] The fan control pressure switch is a device that switches the condenser fan ON/OFF to control the condensing pressure to stay within an appropriate range. The high pressure switch is arranged in a parallel manner with the fan control pressure switch and is a protective device that abnormal error or alarm of the...
  • Page 106 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 Check separator...
  • Page 107 4. Troubleshooting 4.4.3 Compressor often stops without trouble code indicator lamp glowing and knowing no reason of the phenomena. Abnormal Repair or replace Check function of Malfunction of controller controller controller Normal Power supply shall be Noise exists changed to the other Check whether any noise Noise at power side power than the power...
  • Page 108 4. Troubleshooting 4.4.5 Start indicator lamp glows, but the unit will not start. Machine is mode Check if it is in auto start operation Disengage each mode During each mode stop mode or in dryer operation operation advance operation mode No engaged in each mode operation Abnormal Repair or replace...
  • Page 109 5. Reference 5.1 Structure of Parts 5.1.1 Vacuum relief valve (Built in unloader) PILOT pressure During assembling, carefully install valve so that it should be straight. (If it is installed Relas the PILOT pressure to the vacuum relief slant, the valve top could not fit the hollowed valve from the unloader activation chamber portion of the valve.
  • Page 110 5. Reference 5.1.2 Auto-relief circuit SC16064E SC16064E-1 Function When stopping, capacity (purge) control solenoid valve (SV1) opens thus pressurized air from separator receiver tank flows through SV1 to unloader working chamber. Pressurized air from external piping flows in the primary chamber of unloader and be released to the atmosphere through the air filter.
  • Page 111 5. Reference 5.1.3 Solenoid valve for starting unload (SV4) (Regulator control type only) (starting of unloaded operation) SC16065E Function When starting, when electricity is conducted to the solenoid valve for starting unload (SV4), the unloader secondary chamber (NC) and the unloader spring chamber (COM) communicate, the spring chamber is placed under a negative pressure, and with a low pressure the unloader valve becomes completely closed and the starting of unloaded operation is performed.
  • Page 112 5. Reference 5.1.4 Regulator (Regulator control type only) Unloader Working chamber. Pressure adjusting habdle Regulator (SV1) Diaphragm Primary side Secondary side SC15106 SC15054E Function The primary side of the regulator is arranged in line with the separator receiver tank and the secondary side of the same is arranged in line with the solenoid valve for purge control (SV1) and the activation chamber of the unloader.
  • Page 113 5. Reference 5.2 Table of Reference Data 5.2.1 Table of set values Set value Item Unit Protection devices Set value of main motor thermal See 3.2.1 relay Set value of dryer thermal relay See 3.2.1 Discharge air temperature Abnormality 110 Alarm 105 Separator discharge air Abnormality 110...
  • Page 114 5. Reference 4 The temperature of the 4 mark apply from the following SER.NO.
  • Page 115 Please make sure to use the AIRMAN genuine dedicated oil “LONG-LIFE P”. 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 116 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 117 5. Reference 5.4.2 Desorption method for the front cover of the inverter 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. <Procedures> Loosen the screw securing the control circuit terminal block cover. Insert your finger in the cutout (near "PULL") in the bottom of the control circuit terminal block cover, then pull the cover towards you.
  • Page 118 5. Reference 5.5 List of Consumable Parts and Electrical Appliances Item 55kW class 75kW class Element / Filter / Belt Air filter ASS’Y 32100 43300 Air filter element 32143 15400 Oil filter 37438 09700 Oil separator 34224 03000×2 34224 02601×2 O-ring for oil separator 03402 15145×2 32163 21300×2...
  • Page 119 5. Reference Item 55kW class 75kW class Electrical appliances Controller (2-Point control type) 46870 60302 Controller (Regulator control type) 46870 60402 FX, DX relay 46177 08000×2 Solenoid valve (SV1) 46811 29300 [For capacity purge control] Solenoid valve (SV4) (For starting unload) 46811 13300 (Regulator control type only) Solenoid valve (SV6)
  • Page 120 5. Reference 5.6 Dryer Structure and Functions of Component Parts 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...
  • Page 121 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 122 5. Reference Positions of sensors SC15059 SC15060...
  • Page 123 This text book contains the most recent information available at the time of printing, and the contents of the list are based on information in effect at that time and are subject to change without notice.

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