CompAir L45SR User Manual
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CompAir L45SR User Manual

CompAir L45SR User Manual

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User Manual
L45SR, L75SR, L120SR
Stationary Air Compressors
Serial Numbers from:
L45SR - F180-0850
L75SR - F170-0650
L120SR - F171-0100
C20160-1800 (Ed 1) September 2001
GB

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  • Page 1 User Manual L45SR, L75SR, L120SR Stationary Air Compressors Serial Numbers from: L45SR - F180-0850 L75SR - F170-0650 L120SR - F171-0100 C20160-1800 (Ed 1) September 2001...

  • Page 2: Associated Publications

    LSR Series User Manual C20160-1800 (Issue 1) September 2001 USER MANUAL L45SR, L75SR AND L120SR AIR COMPRESSORS Serial Numbers from: L45SR - F180-0850 L75SR - F170-0650 L120SR - F171-0100 ASSOCIATED PUBLICATIONS Model Title Part No. L45SR Parts List C20160-1809 L75SR...

  • Page 3: Table Of Contents

    CompAir CONTENTS ASSOCIATED PUBLICATIONS OWNERSHIP DATA SAFETY PROCEDURES WARNINGS, CAUTIONS AND NOTES Warnings Cautions Notes GENERAL INSTALLATION OPERATION MAINTENANCE AND REPAIR IN THE EVENT OF FIRE GENERAL DESCRIPTION COMPRESSOR AIR-END SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT REGULATION SYSTEM Automatic Mode...
  • Page 4 Service Kit Part Numbers Oil Drain Kit (L75SR only) MAINTENANCE PROCEDURES Enclosure Filter Control Panel Filter Air Intake Filter Oil Separator Filters (L45SR) Reclaimer (L75SR) Reclaimer Element (L75SR and L120SR) Scavenge Strainer (L75SR if fitted) Automatic Condensate Drain (L75SR and L120SR) Oil System 2.10...
  • Page 5 CompAir APPENDIX 1 - THE PRESSURE SYSTEMS SAFETY REGULATIONS 2000 APPENDIX 2 - COMMISSIONING COMMISSIONING PROCEDURE Preliminary Mechanical Checks Control Panel Setting the Correct Language Pressure Calibration Checking/Altering Commissioning Values Checking/Altering Commissioning Configuration Checking/Altering Operating Parameters Setting Service Interval Timer Display Options - To View Compressor Status Information 1.10...

  • Page 6: Ownership Data

    Serial Number: Motor Serial Number: Year: Reclaimer Certificate Number: Maximum Pressure: Delivery Date: Motor rpm: Compressor Lubricant: V. Ph. Hz. Lubricant Capacity: Motor Bearing Grease: /min: (if applicable) LOCAL COMPAIR DISTRIBUTOR Name: Address: Telephone: Fax: Contact Names: Parts: Service: page 5...

  • Page 7: Safety Procedures

    O.2h The standard builds of all CompAir products are not intended for use in either explosive or potentially explosive atmospheres as defined in Directive 94/9/ EC.

  • Page 8: Installation

    LSR Series User Manual – Safety Procedures Installation, operation and maintenance of the A shut-off valve must be fitted in the delivery air line compressor unit must only be carried out by to enable the compressor unit to be isolated. This is competent personnel under a qualified supervisor.

  • Page 9: Maintenance And Repair

    CompAir When mains power is switched on, lethal voltages manual are substantially lower than this figure are present in the electrical circuits and extreme unless installed in an already noisy environment. caution must be exercised whenever it is necessary to carry out any work on the electrical system.

  • Page 10: In The Event Of Fire

    Check the direction of rotation of the motor when lubricating oils not supplied or approved starting up the compressor initially and after any by CompAir may lead to failures in work on the electrical connections or switchgear. service which would not be covered by warranty.

  • Page 11: General Description

    CompAir GENERAL DESCRIPTION COMPRESSOR SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT The unit is an air cooled, single-stage, rotary screw compressor. The compressor air-end is driven The SR Drive® system regulates the volume of air through a flexible coupling by an electric Switched delivered by the compressor by adjusting the Reluctance Drive (SR Drive®) motor manufactured...

  • Page 12: Regulation System

    LSR Series User Manual – General Description A gate drive board isolates the microelectronics in the delivery pressure falls below the target the control unit from the power electronic circuits pressure and the bypass valve shuts, or and provides monitoring and protection for the four insulated gate bi-polar transistor (IGBT) power the SR motor run-on timer expires causing the switches.
  • Page 13 11. Oil Filler 24. Oil Filter 38. Heatsink Temperature Alarm 12. Oil Level Sight Glass 25. Thermal Overload 39. Heatsink Temperature Trip 13. Temperature Thermistor 26. Temperature Thermistor 40. Main Contactor Fault Trip (TE1) (TE3) REGULATION SCHEMATIC - L45SR page 12...
  • Page 14 LSR Series User Manual – General Description 39 40 41 42 43 44 45 46 47 400V ± 10%, 50 Hz, 3-Phase 400V-460V ± 10%, 60 Hz, 3-Phase HW 0010 1. Intake Air Filter 19. Relief Valve 35. Drain Solenoid 2.
  • Page 15 CompAir HW 0013 1. Intake Air Filter 17. Condensate Drain Point 32. Motor Thermistor 2. Air Inlet Grille 18. Oil Drain (Cooler) 33. Temperature Transmitter 3. Air End 19. Oil Drain (Reclaimer) (Air End Delivery) 4. SR Drive® Motor 20. Air Outlet Grille 34.

  • Page 16: Technical Data

    Cooling: Air Cooled Oil Capacity: litres (US gal) 18.5 (4.9) 45 (11.9) 80 (21.1) Recommended Lubricants: CompAir 4000HR CompAir FG (Food Grade) Air Delivery Connection: Flanged in NPTM 2 in NPTM BS 4504/ DIN 2633 DN80 PN16 or 3” ASA -...
  • Page 17 CompAir Cable Sizes and Fuse Ratings Model Voltage Cable Size Fuse Rating 50/60Hz L45SR All voltages 3 x 35mm gG125A L75SR All voltages 3 x 70mm gG200A L120SR All voltages 3 x 120mm gG315A Approximate Full Load Current, Amps Model...

  • Page 18: Installation

    . standard compressor unit. For the installation of non-standard units or units fitted with optional Note: If L45SR or L75SR models are to be installed equipment refer to the local CompAir in a right hand corner, make all electrical representative.
  • Page 19 L45SR, L120SR - Min 0°C (32°F) max 45°C (113°F) A suitably sized air receiver should be installed L75SR - Min 0°C (32°F) max 43°C (109°F).

  • Page 20: Residual Current Devices

    Data’. at switch-on due to the inrush current of the filter capacitors. To help avoid this problem the following L45SR - A gland plate is fitted to the RH side should be considered: of the power converter compartment. Open •...
  • Page 21 CompAir page 20...

  • Page 22: Operation

    LSR Series User Manual – Operation OPERATION WARNING Refer to the safety procedures before Before opening the door of the power operating the compressor unit. converter compartment, switch the power supply OFF at isolator and wait Lethal voltages are used in this for 12 minutes to allow the dc link equipment.

  • Page 23: Routine Operation

    CompAir If the reset LED is lit, RESET (24) must be Note: If the compressor has been out of operation for a prolonged period it is advisable to carry out the full pressed following rectification of the fault, before commissioning procedure before starting.

  • Page 24: Manual Mode

    LSR Series User Manual – Operation To show operating parameters, fault history, On load etc. or to alter programmed settings, press Oil temperature 80°C ENTER (9) to access the menu routine. (See Menu Routines). during acceleration time. 1.2 Manual Mode 1.3 Automatic Mode The manual mode is to be used for This is the normal mode of operation.

  • Page 25: Changing The Pressure Control Mode

    CompAir The RESET LED (26) will pulse and the The display will cancel itself after a short period or it can be cancelled immediately by display will show: pressing RESET (24). Fault shutdown Emergency stop 1.5 Changing the Pressure Control Mode...

  • Page 26: Warnings

    LSR Series User Manual – Operation will flash continuously and the SERVICE LED It may not be convenient to respond to the service due message immediately. In this (29) will light. If the menu routine is in use case press RESET (24) to cancel the flashing when a shutdown occurs the appropriate RESET LED (26) and restore the status and panel and mimic diagram LEDs will light and...

  • Page 27: Using The Menu Routines

    CompAir Should the controller remain powered (in event that USING THE MENU ROUTINES the failure was on a phase not supplying controller) then on rebooting, the display will show ‘Start (See 4. Menu Structure on page 33.) Inhibited - Power supply fault’ and the charging circuits will not be actioned.
  • Page 28 LSR Series User Manual – Operation If the ‘Operational settings’ sub-menu is Note: Alarm and trip conditions will have been selected from the main menu using ENTER simulated during the factory test procedure. These (9). The display will change to: will have been recorded within the initial running hours under test and will remain stored in the Operational settings...

  • Page 29: Selections And Options

    CompAir SELECTIONS AND OPTIONS 3.1 Operational Settings Control mode Operating pressure control mode selected. *P1 - AUTO mode Secondary offload set point for automatic mode (only displayed if the secondary pressure range select input is enabled). *P2 - AUTO mode Secondary target pressure set point for automatic mode (only displayed if the secondary pressure range select input is enabled).

  • Page 30: Commissioning Configurations

    LSR Series User Manual – Operation 3.3 Commissioning Configurations Language Display language selection. Unit of pressure Display pressure in BAR or psi selection. Unit of temperature Display temperature in °C or °F selection. Unit of volume Display volume in m , c.f.m., litres Machine Model Press ENTER to display and change selected machine model with special...

  • Page 31: Commissioning Values

    CompAir 3.3.2 Remote Control config sub Menu Remote start/stop To enable or disable Remote start on input X01/7. Default is disabled. This input must be configured for Remote start/stop (see below). Config input X01/4 Configurable input see Page 39 for options. Default is Disabled.

  • Page 32: Default Settings

    LSR Series User Manual – Operation 3.4 Commissioning Values Continued Cooler run on time The minimum time the cooler will run after the motor has stopped in ‘standby’ condition. Max. service hours Maximum programmed hours for the service countdown timer. Set for required service interval.
  • Page 33 7·0 P2 for MAN mode 5·0 13.0 (11.5) 0·1 6·3 Max. overpress (L120SR) 6·0 14.3 (12.8) 0·1 7·7 Max. overpress (L45SR, L75SR) 6·0 13.6 0·1 7·7 Acceleration time second Cooler run on time minute Run on time second Drain open time...

  • Page 34: Menu Structure

    LSR Series User Manual – Operation MENU STRUCTURE The menus and sub-menus below are detailed on pages 34 to 40. View Button Menu Hours Button Menu Entering the Access Code Main Menu Operational Settings Menu Fault History Recall Parameters at Time of Fault Show Program Variant Menu Service Diagnostics Menu Calibrate Pressure Transmitter Routine...
  • Page 35 CompAir VIEW BUTTON MENU Comments Status Message Oil temperature 25°C View % ######### 2950rpm Percentage load and actual speed View Reclaimer dp 0.5 bar L120SR only View Drive heatsink temperature 60°C View DC link voltage 660V View Air Flow 15 m3/min...
  • Page 36 LSR Series User Manual – Operation MAIN MENU - ENTER BUTTON MENU Main Selection Menu Operational settings Enter Go to operational settings menu Up/Down Fault history recall Enter Go to Fault History recall Up/Down Service diagnostics Enter Go to Service diagnostics menu Up/Down Commissioning - config.
  • Page 37 CompAir FAULT HISTORY RECALL Fault history recall Number indicates fault log position; 1 is latest, 15 is oldest Most recent fault To view parameters at time of fault Up/Down Scroll last 15 faults Oldest fault stored To view parameters at time of fault...
  • Page 38 LSR Series User Manual – Operation SERVICE DIAGNOSTICS MENU Service diagnostics Enter To reset to predetermined value Reset service hours Up/Down Enter Go to Calibrate Pressure Transmitter Stop machine first Calibrate pressure Up/Down Enter Use Up/Down to scroll through the list of digital outputs. Use plus or Stop machine Test digital outputs minus to turn on or off.
  • Page 39 MACHINE MODEL MENU Options Default Unit Machine Model Note: ACCESS CODE: spanner,spanner,view,view L75SR L45SR, L75SR, L120SR-11, L120SR-13 L75SR options Up/Down After selecting desired value or option, press ENTER to accept and store Return to previous menu Enter Return to Commissioning config menu...

  • Page 40: Input Configuration Menu

    ’Pressure Range select’ is only available on Input X01/6 and is default for X01/6 ’Remote start/stop’ is only available on Input X01/7 and is default for X01/7 Input X01/4 is not available for configuration on model L120SR. Default is disabled for L45SR & L75SR page 39...

  • Page 41: Output Configuration Menu

    Commissioning - values Pressure P factor Up/Down Pressure I factor Up/Down 14.3 (12.8)* Max. overpressure L120SR 13.4 Max. overpressure L45SR, L75SR Up/Down Oil t trip limit Up/Down Oil t alarm limit Up/Down Acceleration time Up/Down Cooler run on time Up/Down...

  • Page 42: Glossary Of Display Messages

    Reset inhibited Repeated overcurrent trips have been detected and reset of the fault shutdown is only possible by a CompAir authorised service engineer. Stop machine first This message is displayed when the compressor is running and a menu selection is attempted which can only be used when the compressor is stopped.
  • Page 43 CompAir Message displayed Meaning High air pressure Displayed when the compressor has shut down because excess pressure has been detected in the compressor reclaimer. High oil temp fault Displayed when the compressor has shut down because the oil temperature has exceeded the upper (trip) limit.

  • Page 44: Warning Alarms

    LSR Series User Manual – Operation Message displayed Meaning Heatsink sensor fault Compressor has shut down because the SR Drive® power converter heatsink temperature sensor is faulty or disconnected. Heatsink high temp fault Compressor has shut down because the SR Drive® power converter heatsink has exceeded the maximum permissible operating temperature Main contactor fault Compressor has shut down because the SR Drive®...

  • Page 45: Start Inhibit Messages

    CompAir Message Displayed Meaning Low Temperature Alarm Temperature is below 1°C Drain Alarm The Drain Valve is reporting a fault Power fail fault A supply power failure was detected by the controller internal power circuit when the compressor was running or was in stand-by mode.

  • Page 46: Hours Button Messages

    LSR Series User Manual – Operation 5.6 Hours Button Messages Message displayed Meaning Total hours Total number of hours the compressor has run. Service hrs to run Number of hours to next service Total Air Total estimated volume of air produced to date. Number of starts Total number of starts to date.

  • Page 47: Maintenance

    CompAir MAINTENANCE MAINTENANCE SCHEDULE Regular maintenance should be carried out by your local CompAir distributor as detailed in the Maintenance Schedule. The Schedule should be used as a general guide only. Item Action Weekly Oil System Check oil level. Top up if necessary.

  • Page 48: Service Kit Part Numbers

    Major Service Use correct Major Service Kit for model Service Carry out Interim Service. Minimum Pressure Valve Service valve (L45SR and L75SR). Non-return valve Service valve (L45SR and L75SR). Motor Drive Check condition of flexible coupling inserts. Fit new inserts if necessary.
  • Page 49 7. Separator Filter 18. Oil Filler Cap 8. Oil Filter 19. Cooling Air Exhaust Flow 9. Air Delivery Connection 20. Exhaust Air Baffle 10. Minimum Pressure Valve 21. Control Panel Filter 11. Aftercooler GENERAL ARRANGEMENT AND SERVICING POINTS (L45SR) page 48...
  • Page 50 LSR Series User Manual – Maintenance 1. Oil Filters 11. SR Drive® Motor 2. Minimum Pressure Valve 12. Cooling Air Inlet 3. Air/Oil Separator 13. Cooling Fan 4. Pressure Relief Valve 14. Moisture Separator 5. Oil Filler Cap 15. Air Delivery Connection 6.
  • Page 51 CompAir 1. Exhaust Duct 2. Inlet/Non-Return Valve 3. Aftercooler 4. Oil Filters 5. Safety Valve 6. Oil Cooler 7. Moisture Separator 8. Condensate Drain Valve 9. Air End 10. Drive Coupling Access 11. SR Drive® Motor 12. Power Converter Cabinet Filters 13.

  • Page 52: Maintenance Procedures

    LSR Series User Manual – Maintenance MAINTENANCE PROCEDURES WARNING Refer to the safety procedures before Close the shut-off valve to the user’s carrying out any maintenance or pipework. servicing work on the compressor unit. Switch the power supply ‘OFF’ at the Lethal voltages are used in this isolator.

  • Page 53: Oil Separator Filters (L45Sr)

    Open the access door to the service area. access to the manifold block. Note the readings on the two pressure gauges Note: L45SR has two filters both of which fitted to the manifold block. must be changed at the same time.

  • Page 54: Reclaimer (L75Sr)

    LSR Series User Manual – Maintenance 2.5 Reclaimer (L75SR and L120SR) 2.6 Reclaimer Element (L75SR and L120SR) Condensate will collect in the reclaimer as the A filter element within the reclaimer recovers oil compressor cools after shut-down and should be carried in the delivery air before it is passed to the drained off at the intervals specified in the aftercooler and the user’s pipework.
  • Page 55 CompAir The element may be withdrawn through the access panel in the roof. L120SR: One bolt may be loosened and left in position and used to hinge the cover. Discard the old joint and element. Inspect the underside of the reclaimer cover.

  • Page 56: Scavenge Strainer (L75Sr If Fitted)

    Maintenance should be CAUTION: When the compressor has reached carried out by a CompAir Distributor. normal operating temperature, re-tighten the bolts to the correct torque in the sequence shown.

  • Page 57: Oil System

    CompAir 2.9 Oil System 2.9.2 To Check the Oil Level: (L45SR) To view the oil level sightglass (1) , remove the side 2.9.1 Recommended Oil panel. When stopped the mimimum level is indicated when the sightglass is less than half full.
  • Page 58 LSR Series User Manual – Maintenance CAUTION: Always use the correct grade of oil and 2.9.4 To Change the Oil Filter: do not mix oils of different types. The compressor must be stopped. 2.9.3 To Check the Oil Level (L75SR, L120SR) Open the door to the service area or open the With the compressor shut down, the minimum oil enclosure according to model.
  • Page 59 Remove the drain tap plug (5) and connect a To Change the Oil and Oil Filter: L45SR hose (minimum 10 mm ( ”) bore) to the drain tap (6) and place the open end into a suitable To drain the oil, the system must (a) be pressurised container.
  • Page 60 Prime the new filter with oil. Fill the separator to the correct level with CompAir approved lubricant, refit the filler cap Apply a film of clean oil to the seal of the new and tighten by hand. oil filter elements. Screw the elements into the housing until they contact the gasket and Open the isolating valve to the user's system.
  • Page 61 CONTROL AIR ISOLATING VALVE (L75SR) Fill the reclaimer to the correct level with CompAir approved lubricant, refit the filler cap Run the compressor for a short time to and tighten securely. pressurise the reclaimer to a minimum of 4 bar (60 psi) prior to carrying out the oil drain Open the isolating valve to the user's system.
  • Page 62 (see Fill the reclaimer to the correct level with illustration), then proceed as for gravity drain. CompAir approved lubricant, refit the filler cap Beware of hot surfaces. Beware of hot and tighten securely. pressurised oil. On completion, open blowdown hand valve.

  • Page 63: Minimum Pressure Valve

    L120SR: Clean cooler fins using low pressure air or water as follows No special precautions are required when changing from a detergent mineral oil to CompAir 4000 HR Remove cooler end panel and both side Oil or CompAir FG Lubricant or changing within panels.

  • Page 64: Electrical System

    2.16 Non-Return Valve The servicing of the Non-Return Valve should be Carefully inspect all the electrical wiring and check carried out by a CompAir Distributor. the security of all connections and terminals. page 63...
  • Page 65 CompAir page 64...

  • Page 66: Fault Finding

    (4) Circuit breaker MCB2 Check setting and reset. incorrectly set. (5) Starter circuit breaker Check starter circuit MCB2 open. breaker. (6) Fan motor thermistor fault. Check thermistor. (L45SR and L75SR) (7) Fan motor overload (L120SR) Check motor/fan. replace if necessary. page 65...
  • Page 67 CompAir Message Displayed Possible Cause Action Required Heat sink temp HI (1) Panel filters blocked Clean/renew filters (2) Heat sink dirty Clean heat sink (3) Heat sink fan faulty (L120SR) Check motor/fan. replace if necessary. High air pressure (1) High pressure in user system Check settings of other compressors in system.

  • Page 68: Warning Messages

    LSR Series User Manual – Fault Finding Message Displayed Possible Cause Action Required SR motor high temp fault (1) Insufficient cooling air flow. Inspect/clean: enclosure filter; ducting; motor cooling air intake. (2) High ambient temperature. Check room ventilation. (3) Fan operation/rotation incorrect. Check and rectify electrical circuit.

  • Page 69: Fault Finding Chart

    CompAir Message Displayed Possible Cause Action Required Remote fault 1, 2 or 3 An input was open circuit Check conditions (Type 4, 5 circuit whilst conditions met. or 6) are appropriate. Check auxiliary equipment. Check/rectify wiring. Service due Service countdown time Service compressor then expired.
  • Page 70 LSR Series User Manual – Fault Finding Indication Possible Cause Action Required Excessive oil (d) Constant running at high (d) Check/clean enclosure consumption. ambient temperature. filter. Improve room ventilation. (e) Minimum pressure valve (e) Check valve seating. not closing. Renew spring if necessary.

  • Page 71: Electrical System

    Note: Any work on the electrical system should be carried out by a CompAir Distributor REMOTE CONTROL AND MONITORING Input X01/7 Message: ‘Remote Fault 2’ unless...

  • Page 72: Outputs

    LSR Series User Manual – Electrical System Connecting to the remote start/stop input enables 1.3 Outputs starting and stopping of the compressor from remote equipment. 1.3.1 Configurable Outputs When this function is selected an open connection on this input will cause a remote stop and a link is Outputs on pins X09/2, 3 &...

  • Page 73: Configurable Output Functions

    CompAir 1.3.3 Relay Specification 1.4.4 Group Trip This is the default for output X09/4 Single switching contact with a common, normally A group trip output will be energised when power is open (N/O) and normally closed (N/C) connection applied and no trip conditions are detected.

  • Page 74: Electrical Diagrams

    LSR Series User Manual – Electrical System ELECTRICAL CONNECTION DIAGRAM - L45SR (1 OF 3) page 73...
  • Page 75 CompAir ELECTRICAL CONNECTION DIAGRAM - L45SR (2 OF 3) page 74...
  • Page 76 LSR Series User Manual – Electrical System ELECTRICAL CONNECTION DIAGRAM - L45SR (3 OF 3) page 75...
  • Page 77 CompAir ELECTRICAL CONNECTION DIAGRAM - L75SR (1 OF 3) page 76...
  • Page 78 LSR Series User Manual – Electrical System ELECTRICAL CONNECTION DIAGRAM - L75SR (2 OF 3) page 77...
  • Page 79 CompAir ELECTRICAL CONNECTION DIAGRAM - L75SR (3 OF 3) page 78...
  • Page 80 LSR Series User Manual – Electrical System ELECTRICAL CONNECTION DIAGRAM - L120SR (1 OF 4) page 79...
  • Page 81 CompAir ELECTRICAL CONNECTION DIAGRAM - L120SR (2 OF 4) page 80...
  • Page 82 LSR Series User Manual – Electrical System ELECTRICAL CONNECTION DIAGRAM - L120SR (3 OF 4) page 81...
  • Page 83 CompAir ELECTRICAL CONNECTION DIAGRAM - L120SR (4 OF 4) page 82...

  • Page 84: Appendix 1 - The Pressure Systems Safety Regulations 2000

    LSR Series User Manual APPENDIX 1 THE PRESSURE SYSTEMS SAFETY REGULATIONS 2000 Note: The intervals between examination and L45SR calibration of components, eg pressure vessels, pressure relief valves etc, will be defined by the The circuit diagram shown below is provided to ‘competent person’, preparing the written scheme.
  • Page 85 CompAir L75SR pressure relief valves etc, will be defined by the ‘competent person’, preparing the written scheme. The circuit diagram shown below is provided to assist a ‘competent person’ in preparing a written In defining these periods the ‘competent person’ must...
  • Page 86 LSR Series User Manual L120SR pressure relief valves etc, will be defined by the ‘competent person’, preparing the written scheme. The circuit diagram shown below is provided to assist a ‘competent person’ in preparing a written In defining these periods the ‘competent person’ must scheme of examination for a system incorporating take into account the recommendations of the the air compressor(s).
  • Page 87 CompAir page 86...

  • Page 88: Appendix 2 - Commissioning

    CompAir distributor. as follows: L45SR - Remove the air intake filter, push 1.1 Preliminary Mechanical Checks open the non-return valve and pour oil into the air-end. Remove excess oil before replacing Check that the isolator switch is locked ‘OFF’...

  • Page 89: Control Panel

    CompAir 1.2 Control Panel Entering the Access Code When an attempt to alter a parameter or option is made for the first time after entering the menu routines, the controller will request an access code. When this occurs the following procedure should be followed.

  • Page 90: Pressure Calibration

    This routine calibrates the delivery pressure transmitter for zero and range but (on L120SR only) the reclaimer pressure transmitter for zero only. Note also that the L45SR and L75SR use a 0 - 13.8 bar transmitter while the L120SR uses 0 - 16 bar transmitters and that changing the model setting will automatically set the default calibration for that model.
  • Page 91 CompAir Action Reason Display Press ENTER. To set the zero pressure Set pressure > 5.5bar See note 1.4 (a) measurement in the controller. Connect a slave air To establish a known Adjust +/– :– 7.0bar supply of more than calibration pressure.
  • Page 92 LSR Series User Manual – Commissioning Note 1.4 (a) When zero pressure is requested and delivery pressure transmitter (and/or reclaimer pressure transmitter on L120SR) are not outputting a value within allowable tolerance, the display will show: ‘Set pressure at 0 bar’ on lower line with either ‘Delivery P’ or ‘Reclaimer P’ as appropriate on the upper line on pressing ‘Enter’.

  • Page 93: Checking/Altering Commissioning Values

    CompAir 1.5 Checking/Altering Commissioning Values Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with compressor model. Action Reason Display Press ENTER. To display the main Main menu selection menu. Operational settings Press DOWN and repeat...
  • Page 94 LSR Series User Manual – Commissioning Action Reason Display Press (+) or (–) to To alter the displayed Commissioning – values change the warning value. Oil t alarm limit 110°C temperature, or press DOWN and to go (Pulsing display) step 13. When the required value To set the new value.
  • Page 95 CompAir Action Reason Display Press DOWN . To display the next option. Commissioning – values Autorestart delay 10sec (Steady display) Press (+) or (–) to To alter the displayed Commissioning – values change the delay time, value. Autorestart delay 30sec or go to step 24 .

  • Page 96: Checking/Altering Commissioning Configuration

    LSR Series User Manual – Commissioning 1.6 Checking/Altering Commissioning Configuration Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with compressor model. Action Reason Display Press ENTER. To display the main menu. Main menu. Operational settings.
  • Page 97 Machine Model L75SR (Steady display) If model is correct, go to To set Model Machine Model step 19, otherwise press L45SR (+) or (-). If access code requested, Spanner, Spanner, View, View Enter code: Press (+) or (-). To change Model...
  • Page 98 LSR Series User Manual – Commissioning Action Reason Display Press DOWN . To choose the next option. Commissioning – config. Auto restart disabled Press (+) or (–) to To alter the displayed Commissioning – config. enable the function, value. Auto restart enabled or press DOWN and go to step 27 .
  • Page 99 CompAir Action Reason Display Press ENTER To select option. Config Input X01/4 Trip Type 1 (Steady display) Press DOWN To select return to Remote Config Input X01/4 control config menu. Return to previous menu Press ENTER To select option. Remote control config.

  • Page 100: Checking/Altering Operating Parameters

    LSR Series User Manual – Commissioning 1.7 Checking/Altering Operating Parameters Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with compressor model. Note: P1 is the OFF LOAD pressure. P2 is the ON LOAD pressure in MAN mode and TARGET pressure in AUTO mode. Action Reason Display...
  • Page 101 CompAir Action Reason Display Press DOWN . To choose the next option. Operational settings P1 for man mode 7.0bar Press (+) or (–) to To alter the displayed Operational settings change the set point, value. P1 for man mode 10.0bar otherwise press DOWN and go to step 15.
  • Page 102 LSR Series User Manual – Commissioning Action Reason Display When the required To set the new value. Operational settings value is displayed, Drain open time 10sec press ENTER . (Steady display) Press DOWN . To choose the next option. Operational settings Drain shut time 30sec Press (+) or (–) to...

  • Page 103: Setting Service Interval Timer

    CompAir 1.8 Setting Service Interval Timer Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with compressor model. Action Reason Display Press ENTER. To display the main Main menu selection menu. Operational settings Press DOWN and repeat...

  • Page 104: Display Options - To View Compressor Status Information

    LSR Series User Manual – Commissioning 1.9 Display Options - To View Compressor Status Information Action Reason Display Press VIEW. To display the compressor Oil temperature 70°C oil temperature at air-end delivery. Press VIEW To indicate % of full load %nnnnn 2000rpm speed.

  • Page 105: Final Mechanical Checks

    CompAir 1.10 Final Mechanical Checks Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with compressor model. Action Reason Display Fully open the isolating valve to the users system. Switch power supply ‘ON’. C20620/nn/xx/nn...
  • Page 106 LSR Series User Manual – Commissioning Action Reason Display If the compressor does The compressor will not NOT start a message start if: should be displayed. (a) A Service diagnostics Service diagnostics menu has been selected. Menu option displayed (b) Remote operation Ready to start has been enabled.
  • Page 107 CompAir Action Reason Display CAUTION: RISK OF ELECTRIC SHOCK Switch power OFF at the isolator and wait 12 minutes to allow the dc link capacitors to discharge. If the fan motor rotation is incorrect, stop the compressor and isolate the power. Change over two incoming supply cables.
  • Page 108 LSR Series User Manual – Commissioning Action Reason Display Reduce system pressure below ‘Onload’ P2 in MAN. Check compressor speed increases to 2000 rpm. Set valve to give a constant pressure close to the P2 - AUTO setpoint. Set working mode to AUTO and check speed of compressor adjusts automatically to maintain system pressure at this setting.

  • Page 109: Commissioning Check List

    CompAir COMMISSIONING CHECK LIST 27. Reset service hours timer..... Pipework..... 28. Starting sequence correct..... Electrical connections..... 29. Fan rotation correct..... Cable, fuse ratings OK..... 30. Corrosion inhibitor dispersed..... Control transformer input voltage 31. Connected to user’s pipework.

  • Page 110: Appendix 3 - Dimensions

    LSR Series User Manual – Dimensions APPENDIX 3 DIMENSIONS page 109...
  • Page 111 U.S. AIR DELIVERY CONNECTION 1 " NPT (C27349-150) CONNECTED TO G1 " NIPPLE (98156-289) (MAY EXIT VIA FRONT OR SIDE) CABLE ENTRY ROTATING GLAND PLATE 40/50/63mm (1.575"/1.970"/2.480")GLANDS AND ONE UNDRILLED POSITION 341 [13.43"] SIDE VIEW HW 0038 DIMENSIONS - L45SR page 110...
  • Page 112 AIR INLET 309 [12.17"] 192 [7.56"] 924 [36.38"] AIR DELIVERY APERTURES BOTH SIDES FOR FLEXIBLE 192 [7.56"] OR SOLID DELIVERY PIPES 1212 [47.72"] FORK LIFT SLOTS BOTH SIDES 120 [4.72"] SIDE VIEW (AIR INLET) HW 0039 DIMENSIONS - L45SR page 111...
  • Page 113 CompAir 400 [15.75"] A - AIR END OIL DRAIN B - CONDENSATE DRAIN C - ELECTRICAL CONNECTION D - AIR DELIVERY 1200 [47.24"] 950 [37.40"] 184 [7.24"] 832 [32.74"] 155 [6.10"] 990 [38.98"] HW 0040 DIMENSIONS - L75SR page 112...
  • Page 114 LSR Series User Manual – Dimensions AIR OUTLET COOLING AIR VOLUME 289m /min (10206ft /min) INITIALS TESTED DATE England HP13 5SF STARTER BOX AIR COOLING FILTER AIR INLET 0.2h L75SR C20089-577 C20089-551 200 [7.87"] 634 [24.96"] 1366 [53.78"] 2050 [80.71"] 955 [37.60"] 650 [25.59"] 320 [12.60"]...
  • Page 115 CompAir HW 0043 DIMENSIONS - L120SR page 114...
  • Page 116 LSR Series User Manual – Dimensions HW 0044 DIMENSIONS - L120SR page 115...
  • Page 117 CompAir HW 0045 DIMENSIONS - L120SR page 116...

  • Page 118: Appendix 4 - Speed And Air Flow/Volume Calculations

    SPEED AND AIR FLOW/VOLUME CALCULATIONS Speed Calculations Air Flow Calculations The rotational speed of the compressor is L45SR EAF = 0.0015900s - 0.1716 calculated calculated using a Proportional + Integral (P+I} loop between s = 750 rpm & 5000 rpm...

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