CompAir Surescan SR Manual
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CompAir Surescan SR Manual

CompAir Surescan SR Manual

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Fault Investigation Manual
Surescan SR
Power Converter
L45SR, L75SR, L120SR
DL0062AA - Draft 3 - 06/2007
GB

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Summary of Contents for CompAir Surescan SR

  • Page 1 Fault Investigation Manual Surescan SR Power Converter L45SR, L75SR, L120SR DL0062AA - Draft 3 - 06/2007...
  • Page 3 Contents CompAir Fault Investigation Manual Surescan SR Power Converter L45SR, L75SR, L120SR DL0062AA - Draft 3 - 06/2007 DL0062AA...

  • Page 4: Table Of Contents

    Contents CompAir Contents Safety General ........... 5 Warnings, Cautions And Notes .

  • Page 5: Safety

    WARNING: CONSULT MANUAL or made unsafe and that there is no risk to persons or property. 1.1.4 The standard builds of all CompAir products are not intended for use in either explosive or WARNING: RISK OF HIGH potentially explosive atmospheres as defined PRESSURE in Directive 94/9/EC.

  • Page 6: General Safety Precautions

    1 Safety CompAir A shut-off valve must be fitted in the delivery General Safety Precautions air line to enable the compressor unit to be If using compressed air for cleaning purposes, isolated. This is particularly important if more ensure safety regulations are complied with...

  • Page 7: Maintenance And Repair Precautions

    Check that the dc link capacitors have Use only lubricating oils and greases fully discharged before starting work on approved by CompAir. Make sure that the the compressor. selected lubricants comply with all relevant safety regulations, especially with regard to...

  • Page 8: Precautions In The Event Of Fire

    1 Safety CompAir Always clean up oil spills from both the inside and Precautions must be taken when using acids, outside of the compressor unit before and after alkalis and chemical detergents for cleaning maintenance work. machine parts and components. These materials...

  • Page 9: Control System

    Control System 2 CompAir Control System Controller 2.1.2 A gate drive board isolates the microelectronics in the control unit from the 2.1.1 The microprocessor based compressor power electronic circuits and provides controller and the SR Drive® controller are monitoring and protection for the four...

  • Page 10: Earlier Models - 345Sr & 475Sr

    2 Control System CompAir Earlier Models - 345SR & 475SR CONTROL PANEL MENUS ENTRY MENU SUB MENUS Main Selection Menu Fault History Recall Operational Settings Commissioning - Config Operational settings Scroll up/down last 15 Control mode option Language English faults stored in...

  • Page 11: Later Models - L45Sr, L75Sr & L120Sr

    Control System 2 CompAir Later Models - L45SR, L75SR & L120SR CONTROL PANEL MENUS ENTRY MENU SUB MENUS Main Selection Menu Fault History Recall Operational Settings Commissioning - Config Operational settings Scroll up/down last 15 Control mode option Language English...

  • Page 12: Default Settings - General

    2 Control System CompAir 2.4.5 Access Code Details Default Settings - General • Customer Code: 2.4.1 Default settings for a number of the operational settings are stored in the SERVICE, HOURS, SERVICE, HOURS. controller. These are suitable for operating the •...

  • Page 13: Default Settings - 345Sr, 475Sr Models

    Control System 2 CompAir Default Settings - 345SR, 475SR models Setting Unit Minimum Maximum Step Default Value *P1 for AUTO mode 5·1 13·4 0·1 7·4 *P2 for AUTO mode 5·0 13·0 0·1 7·0 P1 for AUTO mode 5·1 13·4 0·1 7·4...

  • Page 14: Default Settings - L45Sr, L75Sr, L120Sr Models

    2 Control System CompAir Default Settings - L45SR, L75SR, L120SR models. Setting Unit Minimum Maximum Step Default Value P1 for AUTO mode 5·1 13·4 (11.9)* 0·1 7·4 P2 for AUTO mode 5·0 13·0 (11.5)* 0·1 7·0 *P1 for AUTO mode 5·1...

  • Page 15: Models L45Sr, L75Sr And L120Sr Fitted With Controller No. C20606-280

    Control System 2 CompAir of the set voltage or the phase order is Models L45SR, L75SR and L120SR reversed. The phase monitor will Fitted With Controller No. automatically reset within 500rns when correct C20606-280 conditions are restored. 2.7.1 This controller is fitted to LI20SR compressors 2.8.2...
  • Page 16 2 Control System CompAir the 'Power fail/supply fault' indicated. This is machine is 'Running'), Trip or Alarm Type 3 ( the standard machine action. active when the machine is Offload and Onload) and Start Inhibit. Overcurrent repeated reset lockout Output status conditions available are...
  • Page 17 Control System 2 CompAir Normal Display. This ensures that the code is cancelled. If there is no key activity for 60sec, the display returns to Normal Display. The speed display bar graph still shows load relative to normal full load speed i.e. L45SR limited to 3000rpm will show max 60%.

  • Page 18: Electrical System

    Pressure Range Select Note: Any work on the electrical system This is available on input X01/6 only and is the should be carried out by CompAir or by a default function for this input. trained and certified Distributor. Connecting to the pressure range select input...
  • Page 19 Electrical System 3 CompAir (separate menu item) for the remote start therefore, that some functions (e. g. Group function to operate. With Remote Start Trip) are energised for healthy and the relay enabled, the keypad start button is disabled will present a closed contact for OK.
  • Page 20 3 Electrical System CompAir outputs - see following diagrams for The on load output will energise when the connection information. compressor is on load. 3.1.4 Configurable Output Functions Low Temperature Alarm Group Fault A Low Temperature Alarm output will energise when the Low Temperature Alarm is active.
  • Page 21 Electrical System 3 CompAir Fig. 3.1 - Electrical Connection Diagram - 345SR, L45SR (1 of 3) DL0062AA...
  • Page 22 3 Electrical System CompAir Fig. 3.2 - Electrical Connection Diagram - 345SR, L45SR (2 of 3) DL0062AA...
  • Page 23 Electrical System 3 CompAir Fig. 3.3 - Electrical Connection Diagram - 345SR, L45SR (3 of 3) DL0062AA...
  • Page 24 3 Electrical System CompAir Fig. 3. 4 - Electrical Connection Diagram - 475SR, L75SR (1 of 3) DL0062AA...
  • Page 25 Electrical System 3 CompAir Fig. 3.5 - Electrical Connection Diagram - 475SR, L75SR (2 of 3) DL0062AA...
  • Page 26 3 Electrical System CompAir Fig. 3.6 - Electrical Connection Diagram - 475SR, L75SR (3 of 3) DL0062AA...
  • Page 27 Electrical System 3 CompAir Fig. 3.7 - Electrical Connection Diagram - L45SR (1 OF 3) With Phase Failure Relay DL0062AA...
  • Page 28 3 Electrical System CompAir Fig. 3.8 - Electrical Connection Diagram - L45SR (2 OF 3) With Phase Failure Relay DL0062AA...
  • Page 29 Electrical System 3 CompAir Fig. 3.9 - Electrical Connection Diagram - L45SR (3 OF 3) With Phase Failure Relay DL0062AA...
  • Page 30 3 Electrical System CompAir Fig. 3.10 - Electrical Connection Diagram - L75SR (1 of 3) With Phase Failure Relay DL0062AA...
  • Page 31 Electrical System 3 CompAir Fig. 3.11 - Electrical Connection Diagram - L75SR (2 of 3) With Phase Failure Relay DL0062AA...
  • Page 32 3 Electrical System CompAir Fig. 3.12 - Electrical Connection Diagram - L75SR (3 of 3) With Phase Failure Relay DL0062AA...
  • Page 33 Electrical System 3 CompAir 3.1.8 Fig. 3.13 - Electrical Connection Diagram - L120SR (1 of 4) DL0062AA...
  • Page 34 3 Electrical System CompAir Fig. 3.14 - Electrical Connection Diagram - L120SR (2 of 4) DL0062AA...
  • Page 35 Electrical System 3 CompAir Fig. 3.15 - Electrical Connection Diagram - L120SR (3 of 4) DL0062AA...
  • Page 36 3 Electrical System CompAir Fig. 3.16 - Electrical Connection Diagram - L120SR (4 of 4) DL0062AA...
  • Page 37 Electrical System 3 CompAir SM1188 Fig. 3.17 - Electrical Connection Diagram - L45SR With Phase Monitoring / Phase Failure PCB - (1 of 4) DL0062AA...
  • Page 38 3 Electrical System CompAir SM 1189 Fig. 3.18 - Electrical Connection Diagram - L45SR With Phase Monitoring / Phase Failure PCB - (2 of 4) DL0062AA...
  • Page 39 Electrical System 3 CompAir SM 1190 Fig. 3.19 - Electrical Connection Diagram - L45SR With Phase Monitoring / Phase Failure PCB - (3 of 4) DL0062AA...
  • Page 40 3 Electrical System CompAir SM 1191 Fig. 3.20 - Electrical Connection Diagram - L45SR With Phase Monitoring / Phase Failure PCB - (4 of 4) DL0062AA...
  • Page 41 Electrical System 3 CompAir SM 1192 Fig. 3.21 - Electrical Connection Diagram - L75SR With Phase Monitoring / Phase Failure PCB - (1 of 4) DL0062AA...
  • Page 42 3 Electrical System CompAir SM 1193 Fig. 3.22 - Electrical Connection Diagram - L75SR With Phase Monitoring / Phase Failure PCB - (2 of 4) DL0062AA...
  • Page 43 Electrical System 3 CompAir SM 1194 Fig. 3.23 - Electrical Connection Diagram - L75SR With Phase Monitoring / Phase Failure PCB - (3 of 4) DL0062AA...
  • Page 44 3 Electrical System CompAir SM 1195 Fig. 3.24 - Electrical Connection Diagram - L75SR With Phase Monitoring / Phase Failure PCB - (4 of 4) DL0062AA...
  • Page 45 Electrical System 3 CompAir SM 1196 Fig. 3.25 - Electrical Connection Diagram - L120SR With Phase Monitoring / Phase Failure PCB - (1 of 4) DL0062AA...
  • Page 46 3 Electrical System CompAir SM 1197 Fig. 3.26 - Electrical Connection Diagram - L120SR With Phase Monitoring / Phase Failure PCB - (2 of 4) DL0062AA...
  • Page 47 Electrical System 3 CompAir SM 1198 Fig. 3.27 - Electrical Connection Diagram - L120SR With Phase Monitoring / Phase Failure PCB - (3 of 4) DL0062AA...
  • Page 48 3 Electrical System CompAir 3.1.7 SM 1199 Fig. 3.28 - Electrical Connection Diagram - L120SR With Phase Monitoring / Phase Failure PCB - (4 of 4) DL0062AA...

  • Page 49: Fault Diagnosis

    IGBT Tester IGBT Tester part number 98506-24 can be Test Equipment ordered from CompAir UK Ltd. 4.1.1 To carry out checks on the electrical Slave air supply components and the circuit cards inputs and...

  • Page 50: Cage-Clamp Screwless Terminals

    4 Fault Diagnosis CompAir Cage-Clamp Screwless Terminals Power Supplies 4.2.1 The connections on the controller terminal Caution: The high voltage (primary) and blocks are fitted with cage-clamp screwless low voltage (secondary) circuits must NOT terminals. The cage-clamp design ensures be connected in any way (e.g. via test that the clamping force adjusts to sizes of probes, wiring etc.)

  • Page 51: Control Outputs

    Fault Diagnosis 4 CompAir 4.4.1 To check the air filter differential pressure 4.4.2 To check the emergency stop circuit switch The Emergency Stop button has two contacts L45SR and L75SR models which will open if the Emergency Stop button is pressed. One contact is connected to the...

  • Page 52: Sensors

    4 Fault Diagnosis CompAir Connect the multimeter between the Sensors disconnected end of the wire and the plug Caution: The high voltage (primary) and terminal. low voltage (secondary) circuits must NOT Apply a calibrated known pressure to the be connected in any way (e.g. via test sensor and measure the dc current in the probes, wiring etc.)
  • Page 53 Fault Diagnosis 4 CompAir 4.6.2 To check the air/oil temperature sensors Temperature (°C) Sensor Res. (ohms) The temperature sensors are spreading 1605 resistance type thermistors. The resistance of 1678 the thermistors will increase as the applied 1762 temperature increases. The controller...

  • Page 54: Controller

    4 Fault Diagnosis CompAir 4.7.2 Application Control Program IC Controller Instructions for renewing the control program Caution: When working with static IC within a SureScan controller: sensitive components, ie, circuit cards and memory IC’s etc, always take antistatic Remove the controller from the compressor.
  • Page 55 Fault Diagnosis 4 CompAir Fig. 4.6 - Arrangement of Controller Cards 4.7.3 Motor Drive Program IC 4.7.4 FPGA Data IC Normally it is not necessary to change the A need to change this IC is not anticipated. motor drive program IC. However some...

  • Page 56: Sr Fault Location

    4 Fault Diagnosis CompAir 4.8.5 DC Link Low Voltage Fault (figs. 4.12, 4.13) SR Fault Location This fault occurs when the DC link voltage is 4.8.1 SR Current Sensor Fault (figs. 4.7 and 4.8) below operating level. The SR drive current sensor circuit has Refer to the flow chart in figs.
  • Page 57 Fault Diagnosis 4 CompAir 4.8.10 Heatsink Temperature Sensor Fault 4.8.13 SR Power Supply Fault * This fault occurs when the resistance of the There has been an interruption in the power heatsink temperature sensor is outside of it’s supply. working range. Possible causes are: 4.8.14...
  • Page 58 4 Fault Diagnosis CompAir Fig 4.7 - SR Current Sensor Fault (1 of 2) DL0062AA...
  • Page 59 Fault Diagnosis 4 CompAir Fig. 4.8 - SR Current Sensor Fault (2 of 2) DL0062AA...
  • Page 60 4 Fault Diagnosis CompAir Fig. 4.9 - Motor Overcurrent Fault DL0062AA...
  • Page 61 Fault Diagnosis 4 CompAir Fig. 4.10 - Link High Voltage Fault (1 of 2) DL0062AA...
  • Page 62 4 Fault Diagnosis CompAir Fig. 4.11 - Link High Voltage Fault (2 of 2) DL0062AA...
  • Page 63 Fault Diagnosis 4 CompAir Fig. 4.12 - Link Low Voltage Fault (1 of 2) DL0062AA...
  • Page 64 4 Fault Diagnosis CompAir Fig. 4.13 - Link Low Voltage Fault (2 of 2) DL0062AA...
  • Page 65 Fault Diagnosis 4 CompAir Fig. 4.14 - Motor Stall Fault DL0062AA...
  • Page 66 4 Fault Diagnosis CompAir Fig. 4.15 - DC Link Charge Fault DL0062AA...

  • Page 67: Sr Test Procedures - Safety

    Fault Diagnosis 4 CompAir 4.8.17 LSR phase monitoring / phase failure PCB SR Test Procedures - Safety PCB part no. SR05-00060 replaces the former WARNING “Soft Start Resistor & VDR” PCB. Symptoms: Machines that feature circuit board SR05-00060 have been known to suffer spurious trip conditions, giving erroneous •...
  • Page 68 4 Fault Diagnosis CompAir Use a digital multimeter equipped with a diode 4.10.2 Fast Diode Module (Common Anode) test function (fig. 4.16). If the forward voltage does not compare with the value shown in figs. 4.17 - 4.19, the device is faulty.

  • Page 69: Igbt (Insulated Gate Bipolar Transistor) Test Procedures

    One of the IGBTs is forced open circuit by linking its gate connection to the emitter 4.11.1 Using IGBT tester, CompAir part number enabling the internal fast diode to be tested. 98506-24, connect as shown below. In the illustrations below the two ends of the same On the right hand side of the IGBT there are connecting wire are shown by ‘a’...
  • Page 70 4 Fault Diagnosis CompAir 4.11.3 Latest Semikron IGBTs Test as in 4.11 and then test with diode tester according to the diagram on the IGBT. Fig. 4.22 - Circuit of IGBT type GAL Fig. 4.23 - Circuit of IGBT type GAR...
  • Page 71 Fault Diagnosis 4 CompAir HW 0357 Fig. 4.24 - L45SR Power Converter Assembly Rectifier Diodes Gate Drive Board IGBTs VDR/Resistor Board Snubber Capacitors Capacitor Box Busbars DL0062AA...
  • Page 72 4 Fault Diagnosis CompAir HW 0358 Fig. 4.25 - L75SR Power Converter Assembly Rectifier Diodes Capacitors Snubber Capacitors Capacitor Box Gate Drive Board Busbars Balance Resistors Earth IGBTs DL0062AA...
  • Page 73 Fault Diagnosis 4 CompAir R110 R110 R105 R105 R111 R111 R106 R106 R112 R112 R107 R107 R113 R113 R108 R108 R114 R114 R109 R109 HW 0359 Fig. 4.26 - L120SR Power Converter Assembly Laminated Busbar Balance Resistors Lift-off Hinges Gate Drive Board...

  • Page 74: Igbt Removal And Fitting Instructions

    4 Fault Diagnosis CompAir Clean residue compound from heatsink with a 4.12 IGBT Removal and Fitting mild degreaser. Ensure that there is no Instructions spillage on to other components. 4.12.1 Removal (L45SR and L75SR) 4.12.4 Refitting (L120SR) Open power converter door and remove all Clean the back of the IGBT’s from any...

  • Page 75: Electrolytic Capacitor Test Procedures

    Fault Diagnosis 4 CompAir Use the recommended digital multimeter 4.14 Electrolytic Capacitor Test switched to the resistance/capacitance Procedures measuring range ( ). Press the yellow button (1) to select capacitance 4.14.1 Electrolytic Capacitor Test measurements. Caution: All electrical connections and connection bars must be removed from a device before it can be tested.

  • Page 76: To Check Capacitor Bank Balance Resistors

    4 Fault Diagnosis CompAir 4.15.2 L120SR Resistors 4.15 To Check Capacitor Bank Balance Resistors Check the resistor values are within the range shown on the side of the resistors. Disconnect each balance resistor from the capacitor before measuring its resistance. The resistance should compare with the marking on the resistor.

  • Page 77: To Check The Sr Motor

    Fault Diagnosis 4 CompAir Remove both laminated bussbars from IGBT’s Measure the insulation resistance between /capacitors including balance resistors and each motor winding phase cable (A1 and B1) snubber capacitors. and earth. Remove both earth wires at the earth bar The resistance reading in each case should from capacitor boxes.
  • Page 78 4 Fault Diagnosis CompAir 4.17.3 Acceptable ranges for motors L45SR Lmin (mH) Lmax (mH) Lmax/Lmin Ratio 1.30 min 13.00 min > 8.50 1.65 max 18.00 max L75SR Lmin (mH) Lmax (mH) Lmax/Lmin Ratio 0.95 min 9.50 min > 8.50 1.20 max 16.00 max...

  • Page 79: Parts Lists

    Parts Lists 5 CompAir Parts Lists Contents - Parts Lists Guide only. Please refer to parts list supplied with compressor to confirm actual part numbers. L45SR with Phase Protection Relay ........80 L45SR with Phase Monitoring/Phase Failure PCB.

  • Page 80: L45Sr With Phase Protection Relay

    5 Parts Lists CompAir L45SR with Phase Protection Relay Fig. 5.1 - L45SR Power Converter 98155 -14 (1of 5) DL0062AA...
  • Page 81 Parts Lists 5 CompAir Fig. 5.2 - L45SR Power Converter 98155 -14 (2 of 5) DL0062AA...
  • Page 82 5 Parts Lists CompAir Fig. 5.3 - L45SR Power Converter 98155 -14 (3 of 5) DL0062AA...
  • Page 83 Parts Lists 5 CompAir Fig. 5.4 - L45SR Power Converter 98155 -14 (4 of 5) DL0062AA...
  • Page 84 5 Parts Lists CompAir Fig. 5.5 - L45SR Power Converter 98155 -14 (5 of 5) DL0062AA...

  • Page 85: L45Sr With Phase Monitoring/Phase Failure Pcb

    Parts Lists 5 CompAir L45SR with Phase Monitoring/Phase Failure PCB Fig. 5.6 - L75SR Power Converter 98155 -13 (1 of 5) DL0062AA...
  • Page 86 5 Parts Lists CompAir Fig. 5.7 - L75SR Power Converter 98155 -13 (2 of 5) DL0062AA...
  • Page 87 Parts Lists 5 CompAir Fig. 5.8 - L75SR Power Converter 98155 -13 (3 of 5) DL0062AA...
  • Page 88 5 Parts Lists CompAir Fig. 5.9 - L75SR Power Converter 98155 -13 (4 of 5) DL0062AA...
  • Page 89 Parts Lists 5 CompAir Fig. 5.10 - L75SR Power Converter 98155 -13 (5 of 5) DL0062AA...

  • Page 90: L75Sr With Phase Protection Relay

    5 Parts Lists CompAir L75SR with Phase Protection Relay Fig. 5.11 - L75SR Power Converter 98155 -16 (1 of 4) DL0062AA...
  • Page 91 Parts Lists 5 CompAir Fig. 5.12 - L75SR Power Converter 98155 -16 (2 of 4) DL0062AA...
  • Page 92 5 Parts Lists CompAir Fig. 5.13 - L75SR Power Converter 98155 -16 (3 of 4) DL0062AA...
  • Page 93 Parts Lists 5 CompAir Fig. 5.14 - L75SR Power Converter 98155 -16 (4 of 4) DL0062AA...

  • Page 94: L75Sr With Phase Monitoring/Phase Failure Pcb

    5 Parts Lists CompAir L75SR with Phase Monitoring/Phase Failure PCB Fig. 5.15 - L75SR Power Converter 98155 -15 (1 of 4) DL0062AA...
  • Page 95 Parts Lists 5 CompAir Fig. 5.16 - L75SR Power Converter 98155 -15 (2 of 4) DL0062AA...
  • Page 96 5 Parts Lists CompAir Fig. 5.17 - L75SR Power Converter 98155 -15 (3 of 4) DL0062AA...
  • Page 97 Parts Lists 5 CompAir Fig. 5.18 - L75SR Power Converter 98155 -15 (4 of 4) DL0062AA...

  • Page 98: L120Sr With Phase Protection Relay

    5 Parts Lists CompAir L120SR with Phase Protection Relay Fig. 5.19 - L120SR Power Converter 98155 -11 iss C (1 of 5) DL0062AA...
  • Page 99 Parts Lists 5 CompAir Fig. 5.20 - L120SR Power Converter 98155 -11 iss C (2 of 5) DL0062AA...
  • Page 100 5 Parts Lists CompAir Fig. 5.21 - L120SR Power Converter 98155 -11 iss C (3 of 5) DL0062AA...
  • Page 101 Parts Lists 5 CompAir Fig. 5.22 - L120SR Power Converter 98155 -11 iss C (4 of 5) DL0062AA...
  • Page 102 5 Parts Lists CompAir Fig. 5.23 - L120SR Power Converter 98155 -11 iss C (5 of 5) DL0062AA...

  • Page 103: L120Sr With Phase Monitoring/Phase Failure Pcb

    Parts Lists 5 CompAir L120SR with Phase Monitoring/Phase Failure PCB Fig. 5.24 - L120SR Power Converter 98155 -11 iss D (1 of 5) DL0062AA...
  • Page 104 5 Parts Lists CompAir Fig. 5.25 - L120SR Power Converter 98155 -11 iss D (2 of 5) DL0062AA...
  • Page 105 Parts Lists 5 CompAir Fig. 5.26 - L120SR Power Converter 98155 -11 iss D (3 of 5) DL0062AA...
  • Page 106 5 Parts Lists CompAir Fig. 5.27 - L120SR Power Converter 98155 -11 iss D (4 of 5) DL0062AA...
  • Page 107 Parts Lists 5 CompAir Fig. 5.28 - L120SR Power Converter 98155 -11 iss D (5 of 5) DL0062AA...

This manual is also suitable for:

L45srL75srL120sr

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