User Manual

L45SR, L75SR, L120SR

Stationary Air Compressors

Serial Numbers from:

L45SR - F180-0850
L75SR - F170-0650
L120SR - F171-0100

GB C20160-1800 (Ed 1) September 2001

 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 Parts List C20160-1810

L120SR Parts List C20160-1811

All LSR models Repair Manual C20160-1822

These publications are obtainable through CompAir distributors.

page 1
CompAir

CONTENTS

ASSOCIATED PUBLICATIONS 1

OWNERSHIP DATA 5

SAFETY PROCEDURES 6
1. WARNINGS, CAUTIONS AND NOTES 6
1.1 Warnings 6
1.2 Cautions 6
1.3 Notes 6
2. GENERAL 6
3. INSTALLATION 7
4. OPERATION 7
5. MAINTENANCE AND REPAIR 8
6. IN THE EVENT OF FIRE 9

GENERAL DESCRIPTION 10
1. COMPRESSOR 10
2. AIR-END 10
3. SWITCHED RELUCTANCE DRIVE AND ELECTRONIC CONTROL UNIT 10
4. REGULATION SYSTEM 12
4.1 Automatic Mode 12
4.2 Manual Mode 12

TECHNICAL DATA 15

INSTALLATION 17
1. GUIDELINES 17
2. RESIDUAL CURRENT DEVICES 19

OPERATION 21
1. ROUTINE OPERATION 22
1.1 Starting 22
1.2 Manual Mode 23
1.3 Automatic Mode 23
1.4 Displaying the Number of Hours Run. 23
1.5 Changing the Pressure Control Mode 24
1.6 Stopping 24
1.7 Emergency Stopping 24
1.8 Service Interval Timer 24
1.9 Warnings 25
1.10 Shutdown Faults 25
1.11 Power Supply Failure Detection 25
2. USING THE MENU ROUTINES 26
3. SELECTIONS AND OPTIONS 28
3.1 Operational Settings 28
3.2 Service Diagnostics 28
3.3 Commissioning Configurations 29
3.4 Commissioning Values 30
3.5 Default Settings 31

Page 2
 LSR Series User Manual – Contents

4. MENU STRUCTURE 33

5. GLOSSARY OF DISPLAY MESSAGES 41

5.1 Operator Advice Messages 41
5.2 Shutdown Trips 41
5.3 Warning Alarms 43
5.4 Start Inhibit Messages 44
5.5 View Button Messages 44
5.6 Hours Button Messages 45
5.7 Status Messages 45

MAINTENANCE 46
1. MAINTENANCE SCHEDULE 46
1.1 Service Kit Part Numbers 47
1.2 Oil Drain Kit (L75SR only) 47
2. MAINTENANCE PROCEDURES 51
2.1 Enclosure Filter 51
2.2 Control Panel Filter 51
2.3 Air Intake Filter 51
2.4 Oil Separator Filters (L45SR) 52
2.5 Reclaimer (L75SR) 53
2.6 Reclaimer Element (L75SR and L120SR) 53
2.7 Scavenge Strainer (L75SR if fitted) 55
2.8 Automatic Condensate Drain (L75SR and L120SR) 55
2.9 Oil System 56
2.10 Minimum Pressure Valve 62
2.11 Oil Cooler and Aftercooler 62
2.12 Flexible Hoses 62
2.13 Scavenge Tube 62
2.14 Electrical System 63
2.15 Electric Motors 63
2.16 Non-Return Valve 63

FAULT FINDING 65
1. SHUTDOWN MESSAGES 65
2. WARNING MESSAGES 67
3. FAULT FINDING CHART 68

ELECTRICAL SYSTEM 70
1. REMOTE CONTROL AND MONITORING CONNECTIONS 70
1.1 Inputs 70
1.2 Configurable Input Functions 70
1.3 Outputs 71
1.4 Configurable Output Functions 72
1.5 4-20mA Compressor Speed Output 72
1.6 RS485 Communications 72
2. ELECTRICAL DIAGRAMS 73

Continued

Page 3
CompAir

APPENDIX 1 - THE PRESSURE SYSTEMS SAFETY REGULATIONS 2000 83

APPENDIX 2 - COMMISSIONING 87
1. COMMISSIONING PROCEDURE 87
1.1 Preliminary Mechanical Checks 87
1.2 Control Panel 88
1.3 Setting the Correct Language 88
1.4 Pressure Calibration 89
1.5 Checking/Altering Commissioning Values 92
1.6 Checking/Altering Commissioning Configuration 95
1.7 Checking/Altering Operating Parameters 99
1.8 Setting Service Interval Timer 102
1.9 Display Options - To View Compressor Status Information 103
1.10 Final Mechanical Checks 104
2. COMMISSIONING CHECK LIST 108

APPENDIX 3 - DIMENSIONS 109

APPENDIX 4 - SPEED AND AIR FLOW/VOLUME CALCULATIONS 117

page 4
 LSR Series User Manual

OWNERSHIP DATA

TECHNICAL DATA

MODEL: Air-end Serial Number:

Serial Number: Motor Serial Number:

Year: Reclaimer Certificate Number:

Maximum Pressure: Delivery Date:

kW:

Motor rpm: Compressor Lubricant:

V. Ph. Hz. Lubricant Capacity:

Motor Bearing Grease:

M3/min:
(if applicable)

LOCAL COMPAIR DISTRIBUTOR

Name:

Address:

Telephone: Fax:

Contact Names: Parts:

Service:

page 5
CompAir

SAFETY PROCEDURES

1. WARNINGS, CAUTIONS AND NOTES 1.3 NOTES

1.1 Warnings Methods to make the job easier and points which
require particular attention are identified by a ‘Note’
Warnings call attention to operations or procedures in the text of the manual.
involving specific hazards which could cause injury
or death and are identified by the following symbols
on the unit and in the text of the manual. 2. GENERAL

Most accidents which occur during the operation

WARNING: RISK OF DANGER and maintenance of machinery are the result of
failure to observe basic safety rules or precautions.
An accident can often be avoided by recognising a
situation that is potentially hazardous.
WARNING: RISK OF ELECTRIC
When handling, operating or carrying out
SHOCK
maintenance on the unit, personnel must use safe
engineering practices and observe all relevant local
health and safety requirements and regulations.
The attention of users in the UK is drawn to the
WARNING: RISK OF HOT
Health and Safety at Work Act, 1974, the
SURFACES
Regulations of the Institution of Electrical Engineers
and the Pressure Systems and Transportable Gas
Container Regulations 1989.

WARNING: CONSULT MANUAL CompAir cannot anticipate every possible

circumstance which might represent a potential
hazard. The WARNINGS in this manual are
therefore not all-inclusive. If the user employs an
operating procedure, an item of equipment or a
WARNING: RISK OF HIGH
method of working which is not specifically
PRESSURE
recommended by CompAir he must ensure that the
unit will not be damaged or made unsafe and that
there is no risk to persons or property.
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. An explosive atmosphere is a mixture with air,
under atmospheric conditions, of flammable gases,
WARNING: ENTRY DELAY –
vapours, hazes or dust in which, after ignition has
ENERGISED
occurred, combustion propagates to the entire
CAPACITORS
unburned mixture and may cause a hazard. A
potentially explosive atmosphere is an atmosphere
which could become explosive due to local
conditions.
1.2 CAUTIONS
Failure to observe the precautions given under
Incorrect operational procedures causing possible
‘Safety Procedures’ may be considered dangerous
damage to the compressor unit are identified by a
practice or misuse of the compressor unit.
‘CAUTION’ in the text of this manual.

page 6

Installation, operation and maintenance of the
compressor unit must only be carried out by
competent personnel under a qualified supervisor.
If using compressed air for cleaning purposes,
ensure safety regulations are complied with and
appropriate clothing and eye protection is worn.
Never direct compressed air onto your skin or at
other people.
Never use compressed air to clean loose dirt from
clothing.
Before releasing compressed air through a hose
make sure that the free end is held securely so that
it cannot whip and cause injury.
Avoid injury by using a hoist to lift heavy loads.
Check that all chains, hooks, shackles and slings
are in good condition and are of the correct
capacity. They must be tested and approved
according to local safety regulations.
Cables, chains or ropes must never be applied
directly to lifting eyes. Always use an appropriate
shackle or hook, properly positioned. Arrange lifting
cables so that there are no sharp bends.
Use a spreader bar to avoid side loads on hooks,
eyes and shackles.
When a load is on a hoist stay clear of the danger
area beneath and around it. Keep lifting
acceleration and speed within safe limits and never
leave a load hanging on a hoist for longer than is
necessary.
3. INSTALLATION
A fused isolating switch must be fitted between the
main power supply and the compressor.
Check that the prospective fault current is within
recommendations for the machine.
Precautions must be taken to ensure that no injury
is caused to passers-by through loose clothing
being sucked into the air intake.
Ensure that the air delivery pipe from the
compressor to the user’s pipework or receiver is
free to expand and that no flammable material is
within the vicinity.
LSR Series User Manual – Safety Procedures
A shut-off valve must be fitted in the delivery air line
to enable the compressor unit to be isolated. This is
particularly important if more than one unit is to be
coupled in parallel or connected to an existing air
supply system.
The minimum pressure/non-return valve is not
intended as an isolating valve and should not be
relied upon for this purpose. In addition, it may be
necessary to install shut-off valves elsewhere in the
system to allow a dryer or other equipment to be
by-passed.
A pressure relief valve must be installed between
any compressor unit and the shut-off valve/s. A
pressure relief valve is fitted on the reclaimer vessel
as standard equipment.
A pressure relieving device must be fitted to every
pressure vessel, or equipment containing air at
above atmospheric pressure, when installed
downstream of the unit.
4. OPERATION
Do not run the compressor with doors open or
covers removed except when checking reclaimer
operation. There is a risk of trapping fingers in
doors if the machine is started with the doors open.
Never run the L120SR machine with the doors
open as the cooling system will not function.
Never remove or tamper with the safety devices,
guards or insulation materials fitted to the unit.
The compressor must only be operated at the
supply voltage and/or frequency for which it is
designed.
WARNING
O.2h
● Before opening the door of the power
converter compartment, switch the
power supply OFF at isolator and wait
for 12 minutes to allow the dc link
capacitors to discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.
page 7
CompAir
When mains power is switched on, lethal voltages
are present in the electrical circuits and extreme
caution must be exercised whenever it is necessary
to carry out any work on the electrical system.
On a unit equipped with an Automatic Start/Stop
system, attach a sign stating ‘THIS UNIT MAY
START WITHOUT WARNING’ next to the display
panel.
On a unit equipped with an Automatic Restart
device, attach a warning notice stating ‘THIS UNIT
HAS BEEN MODIFIED AND WILL START
AUTOMATICALLY ON APPLICATION OF
POWER’ next to the display panel and on the inside
of the unit next to the starter contactors.
If the unit is equipped with a Remote Control
device, attach warning notices stating ‘THIS UNIT
CAN BE STARTED REMOTELY’ in prominent
locations, one on the outside of the unit, the other
inside the control compartment.
As a further safeguard, take adequate precautions
to make sure there is no one checking or working
on the unit before attempting to switch on remotely
controlled equipment. Attach a ‘CHECK THAT ALL
PERSONNEL ARE CLEAR OF THE UNIT
BEFORE STARTING’ or similar warning notice to
the remote start equipment.
During normal operation no internal part of the
compressor unit should reach a temperature above
120°C and protection devices are fitted to prevent
excessive temperatures occurring.
If there is any indication that the compressor is
overheating it must be shut down and the cause
investigated. Beware of burns from hot metal parts
or hot oil when working on a unit which has
recently been shut down.
The compressor must not be operated at pressures
above the nominal pressure given on the data
plate.
The compressor must not be operated in ambient
temperatures outside of those given under ‘Leading
Particulars’.
The ‘Noise at Work Regulations 1989’ suggest that
ear protectors should be worn where noise levels
are 85 dB(A) or higher. With all covers in place, the
noise levels of the compressors described in the
page 8
manual are substantially lower than this figure
unless installed in an already noisy environment.
Be aware that high noise levels can interfere with
communication.
5. MAINTENANCE AND REPAIR
Do not open the power converter compartment or
touch electrical components while voltage is applied
unless it is necessary for measurements, tests or
adjustments. Such work should be carried out only
by a qualified electrician equipped with the proper
tools and wearing appropriate body protection
against electrical hazards.
Before removing any panels from the enclosure, if
fitted, or dismantling any part of the unit, carry out
the following preparatory operations:-
1. Isolate the compressor unit from the main
electrical power supply. Lock the isolator in
the ‘OFF’ position and remove the fuses.
2. Attach a label to the isolator switch and
display panel carrying the warning ‘WORK IN
PROGRESS – DO NOT APPLY VOLTAGE’
Do not switch on electrical power or attempt to
start the unit if a warning label is attached.
3. Close the isolating valve between the
compressor unit and the user’s pipework.
Attach a label to each valve carrying the
warning ‘WORK IN PROGRESS – DO NOT
OPEN’
4. Ensure that the blowdown system has
operated to release all pressure from the
reclaimer.
5. Check that the display registers zero. Release
any remaining pressure from the delivery side
of the reclaimer element by slackening a pipe
connection to the differential pressure
indicator. Release any residual pressure from
the upstream side of the reclaimer element by
slowly slackening the oil filler plug on the
reclaimer. Tighten the plug.
Protection devices must be tested as described in
the ‘Maintenance’ section of this manual.

Keep the compressor unit clean at all times. Protect
components and exposed openings by covering
with clean cloth or tape during maintenance and
repair work.
Protect the motor, air intake, electrical and
regulation components against the entry of
moisture, e.g. when steam cleaning.
In no circumstances must any welding work or
other modification be carried out on the reclaimer or
any other pressure vessel.
Before dismantling of any part of the compressor
unit ensure that all heavy movable parts are
secured.
After completion of repair or maintenance work
ensure that no tools, loose items or rags are left on
or inside any part of the machine.
Check the direction of rotation of the motor when
starting up the compressor initially and after any
work on the electrical connections or switchgear.
Do not use any flammable liquid to clean valves,
filter elements, cooler air passages, air pipes or any
component carrying a flow of air during normal
operation. If chlorinated hydrocarbon non-
flammable fluids are used for cleaning, safety
precautions must be taken against any toxic
vapours which may be released.
Do not use carbon tetrachloride.
Precautions must be taken when using acids,
alkalis and chemical detergents for cleaning
machine parts and components. These materials
cause irritation and are corrosive to the skin, eyes,
nose and throat. Avoid splashes and wear suitable
protective clothing and goggles. Do not breathe
mists. Ensure that water and soap are readily
available.
When disposing of condensate, old oil, used filter
elements and other parts and waste material of any
kind make sure that there is no pollution of any
drain or natural water-course and that no burning of
waste takes place which could cause pollution of
the air. Protect the environment by using only
approved methods of disposal.
LSR Series User Manual – Safety Procedures
6. IN THE EVENT OF FIRE
Use extreme caution when handling
components that have been subjected to fire or
very high temperatures. Some components may
contain fluoroelastomer materials which decompose
under these conditions to form highly corrosive
residues. Skin contact can cause painful and
penetrating burns resulting in permanent skin and
tissue damage.
WARNING
• The use of replacement parts or
lubricating oils not supplied or approved
by CompAir may lead to failures in
service which would not be covered by
warranty.
• Any unauthorised modifications or failure
to maintain this equipment in accordance
with the maintenance instructions may
make it unsafe. The use of replacement
parts not supplied or approved by
CompAir may create hazardous
conditions over which CompAir has no
control.
• Such hazardous conditions may lead to
accidents that can be life threatening,
cause substantial bodily injury or result
in damage to the equipment. CompAir
can bear no responsibility for equipment
in which unapproved replacement parts
are included.
page 9
CompAir
GENERAL DESCRIPTION
1. COMPRESSOR
The unit is an air cooled, single-stage, rotary screw
compressor. The compressor air-end is driven
through a flexible coupling by an electric Switched
Reluctance Drive (SR Drive®) motor manufactured
under licence from SR Drives Ltd.
The Compressor unit consists of the drive motor,
air-end, reclaimer, oil cooler, after cooler, fan,
starter assembly and control unit. The complete
compressor unit is mounted on a baseframe and is
housed in a steel panelled acoustic enclosure.
Removable panels or hinged access doors allow
access for routine maintenance.
2. AIR-END
The air is compressed in a single-stage, positive
displacement, oil injected rotary screw air-end. The
air-end comprises an intermeshing pair of helical
screw rotors, male and female, mounted
horizontally within an enclosed casing with drive
being applied to the male rotor.
The male air-end rotor is larger in diameter than the
female rotor and has four lobes which mesh with
five flutes on the female rotor. The rotors are
asymmetric in profile to reduce blowback between
the lobes on the compression cycle to a minimum,
thus maximising the overall sealing and efficiency.
The rotors are fitted with bearings at each end to
provide radial and axial support, maintain adequate
shaft stiffness and to give minimum clearance and
low leakage between the rotor tip diameter and the
casing.
At the delivery end the male rotor is fitted with a
single taper roller bearing and the female rotor is
provided with a matched pair of taper roller
bearings. These bearings provide axial and radial
support of both rotors and control the very fine end
clearances between the rotors and the casing.
Heavy duty parallel roller bearings are fitted to both
rotors at the inlet end to provide radial support and
to sustain the drive load of the male rotor.
page 10
3. SWITCHED RELUCTANCE DRIVE AND
ELECTRONIC CONTROL UNIT
The SR Drive® system regulates the volume of air
delivered by the compressor by adjusting the
rotational speed of the air-end so that the output
from the compressor always matches the demand
from the user’s system.
This method of regulation can reduce energy
consumption as the compressor produces only the
amount of air demanded by the system and is
equally efficient at high or low output volumes. Off-
load idling is also eliminated and when there is no
demand for compressed air the SR motor stops
automatically with no limit to the number of times
that it can be started. Pressure in the user’s system
is accurately maintained to further improve the
quality of the compressed air supply.
The motor operates on the principle of magnetic
attraction. The stator has eight poles and the rotor
four poles, the stator poles being wound with coils to
form electromagnets. The electromagnets are
connected in two groups (phase A and B) of four
coils which attract the poles on the rotor causing
them to rotate into alignment with the stator poles.
The SR stator is an insulated tube formed by the
stator poles and coils vacuum impregnated in resin
to form a ‘Sealed Insulation System’ which is highly
resistant to dust and corrosion. The rotor is a 4 pole
iron shaft with no current carrying coils which
ensures cool running and therefore extends bearing
life.
Continuous rotation is achieved by switching the
stator phases in the correct sequence. A position
transmitter on the rotor sends positional information
to the SR Drive® controller to ensure that the
switching of the motor phases is correctly timed.
The microprocessor based compressor controller
and the SR Drive® controller are housed in a single
control unit which also contains the operator keypad
and displays. The control unit is mounted on the
door of the control panel.

A gate drive board isolates the microelectronics in
the control unit from the power electronic circuits
and provides monitoring and protection for the four
insulated gate bi-polar transistor (IGBT) power
switches. The IGBTs are used to turn the motor
phases on and off and, in conjunction with the
electronic controller, to control the motor phase
current and in turn the torque and speed of the SR
motor.
4. REGULATION SYSTEM
The compressor delivery pressure can be
controlled in either ‘Automatic’ (AUTO) or ‘Manual’
(MAN) modes. The normal method of operation is
the ‘Automatic’ mode which varies the volume of air
delivered by the compressor by adjusting the
rotational speed of the air-end to match the
demand on the user’s system and maintain a target
pressure.
‘Manual’ mode controls the pressure between two
set points, the rotational speed of the air-end being
controlled by the operator.
4.1 Automatic Mode
This is the normal mode of operation. A pressure
transmitter measures the delivery pressure which is
compared with the target pressure programmed into
the control unit.
If the delivery pressure is lower than the target
pressure, the rotational speed of the air-end, and
therefore the delivered air volume, increases until
either the target pressure is reached or the air-end
is running at maximum speed. If the delivery
pressure is above the target pressure the rotational
speed of the air-end is reduced until either the
target pressure is reached or the air-end is running
at minimum speed.
An unload pressure setpoint is also provided and is
always set above the target set point. If the unload
pressure is reached, a bypass valve opens and
because the air-end is running at minimum speed
all of the air produced is re-circulated in the bypass
pipe resulting in zero delivered air volume. The
bypass condition will continue until:
LSR Series User Manual – General Description
a) the delivery pressure falls below the target
pressure and the bypass valve shuts, or
b) the SR motor run-on timer expires causing the
motor to stop and the compressor to enter
‘Standby’ condition. Subsequently, if the
delivery pressure falls below the target
pressure the SR motor will re-start.
4.2 Manual Mode
The ‘Manual’ mode should only be used if the
compressor is to be run at a fixed speed and,
therefore, fixed rate of air delivery. A pressure
transmitter measures the delivery pressure which is
compared with upper and lower set points
programmed into the control unit.
If the delivery pressure is below the upper setpoint
the air-end will run at a pre-determined speed which
can be set at any point between maximum and
minimum. If the delivery pressure exceeds the
upper setpoint the rotational speed of the air-end
will reduce to minimum and the bypass valve will
open resulting in zero delivered air volume. The
bypass condition will continue until:
a) the delivery pressure falls below the lower
setpoint. At this point the bypass valve will
shut and the speed will be re-set to the pre-set
value, or
b) the SR motor run-on timer expires causing the
motor to stop and the compressor to enter
‘Standby’ condition. Subsequently, if the
delivery pressure falls below the lower
setpoint the SR motor will re-start and run at
the pre-set speed.
page 11
CompAir

32 33 34 35 36 37 38 39 40

3 PHASE POWER SUPPLY

29

1 19 30

17 21 OIL SCAVENGE LINES

16
7
15 A B 18
14
8 9
13
6 10
2 22
20

28
M 3 23

4
5

11 27 M
24 HW 0009
12 25
26

31

1. Intake Air Filter 14. Overcurrent Trip 27. Cooling Fan

2. Non-return Valve 15. Position Sensor Fault Trip 28. Thermostatic Bypass Valve
3. Air-end 16. Overspeed 29. Control Panel
4. SR Drive® Motor 17. Stall Trip 30. Pressurised Oil Drain Valve
5. Reclaimer 18. Pressure Transducer 31. Oil Drain Valve
6. Separator Filters 19. Differential Pressure Switch 32. Emergency Stop
7. Pressure Gauge 20. Temperature Thermistor 33. SR Current Sensor Trip
8. Minimum Pressure Non- (TE2) 34. DC Link Overvoltage Trip
return Valve 21. Bypass Valve 35. DC Link Undervoltage Trip
9. Aftercooler 22. Pressure Relief Valve 36. Capacitor Charge Volt Trip
10. Compressor Delivery 23. Oil Cooler 37. Heatsink Sensor Fault Trip
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
 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
38

12
20 32
50
13
11 26 31 33
2 48 36

37
3 4
1 19 34 35
16 30
24
5 M

14 M 29
17
6 18 28
7 23 15 27
8
9 49
10 21

22 25 HW 0010

1. Intake Air Filter 19. Relief Valve 35. Drain Solenoid

2. Differential Pressure Switch 20. Diff. Pressure Indicator 36. Compressor Delivery
3. Air Inlet Connection 21. Oil Filter 37. Condensate Drain
4. Air-end 22. Oil Drain Valve 38. Control Panel
5. SR Drive® Motor 23. Oil Stop Valve 39. Emergency Stop
6. Temperature Thermistor (TE1) 24. Non-return Valve 40. SR Current Sensor Trip
7. Overcurrent Trip 25. Oil Drain Valve 41. DC Link Overvoltage Trip
8. Position Transmitter Fault Trip 26. Minimum Pressure Non- 42. DC Link Undervoltage Trip
9. Over Speed Trip return Valve 43. Capacitor Charge Volt Trip
10. Stall Trip 27. Thermal Overload 44. Heatsink Sensor Fault Trip
11. Temperature Thermistor (TE2) 28. Temperature Thermistor 45. Heatsink Temperature
12. Bypass Valve (TE3) Alarm
13. Scavenge Solenoid 29. Cooling Fan 46. Heatsink Temperature Trip
14. Overpressure Switch 30. Oil Cooler 47. Main Contactor Fault Trip
15. Pressure Gauge 31. Aftercooler 48. Scavenge Strainer
16. Oil Filler 32. Pressure Transmitter 49. Thermostatic Bypass Valve
17. Reclaimer 33. Moisture Separator 50. Pressurised Oil Drain Valve
18. Oil Level Tube 34. Strainer

REGULATION SCHEMATIC - L75SR

page 13
CompAir

20

24
34
14
13
8
28
9
30
1 15
33 10
35
2 22
29
31 7 36

26
27 5 16
23 17

32 4 3 11
12

6
21

25
37 18

HW 0013 19

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. Differential Pressure
5. Reclaimer 21. Thermostatic Mixing Valve Indicator and Switch
6. Oil Filters 22. Pressure Relief Valve 35. Thermostatic Mixing Valve
7. Pressure Gauge 23. Oil Cooler (Heat Recovery)
8. Minimum Pressure / 24. Fan Motor 36. Heat Recovery Heat
Non-Return Valve 25. Power Converter Heat Sink Exchanger
9. Aftercooler - Cooling Fan 37. Water Inlet and
10. Compressor Delivery 26. Position Sensor Outlet Connection
11. Oil Filler 27. Pressure Transmitter (Heat Recovery
12. Oil Level Sight Glass (Reclaimer) Option Only)
13. Air Inlet Grille 28. Pressure Transmitter
14. Solenoid Valve (Blowdown) (Air Delivery)
15. Moisture Separator 29. Inlet Non-Return Valve
16. Level Controlled 30. Scavenge Restrictor
Condensate Valve 31. Scavenge NRV

REGULATION SCHEMATIC - L120SR

page 14
 LSR Series User Manual – Technical Data

TECHNICAL DATA

MODEL L45SR L75SR L120SR

Air-end: Single Stage Oil Injected
Screw
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: G11/2 or R 21/2 or Flanged
1 1
1 /2 in NPTM 2 /2 in NPTM BS 4504/
DIN 2633
DN80 PN16
or 3” ASA -
150 lb RF

Condensate Connection: - 10mm/ 3/8 in G1/2 or

1
OD tube /2 in NPT
Delivery Air Pressure: Minimum bar (psig) 5 (72) 5 (72) 5 (72)
Maximum bar (psig) 13 (189) 13 (189) 11.5 (167)
or 13 (189)
★
Delivery Air Temperature Full load operation (7 bar) °C (°F) 10 (18) 11 (20) 10 (18)
above ambient:
Ambient Temperature Range: Minimum °C (°F) 0 (32) 0 (32) 0 (32)
Maximum °C (°F) 45 (113) 43 (109) 45 (113)
Typical Cooling Air Outlet
Temperature at Maximum
Operating Pressure °C (°F) 19 (34) 14 (25) 21(38)
above ambient:
Main Drive Motor: Nominal Rating kW (HP) 50 (67) 75 (100) 128 (172)
Motor Rotation Clockwise viewed from drive end
Motor Speed Maximum rpm 5000 4800 3750
Fan Motor Power kW (HP) 2.2 (3) 4 (5.45) 5.5 (7.5)
Fan Motor Rotation viewed from Anti-clockwise Clock-
non-drive end wise
Total Power Input (Typical) kW 58 88 144
Approx. Nett. Weight: kg (lbs) 955 (2101) 1243 (2735) 2100 (4620)
Dimensions: Length mm (ins) 1420 (55.9) 2050 (80.7) 2500 (98.5)
Width mm (ins) 990 (39) 1200 (47.2) 1400 (55.2)
Height mm (ins) 1650 (65) 1702 (67) 2020 (79.6)
Average Sound level at 1m 50Hz - 76
(CAGI PNEUROP) dB(A) +/- 3 dB(A) 77 77 60Hz - 79

★
The air temperature is a typical figure and relates to an inlet air temperature of 20°C and standard
atmospheric pressure of 1 bar a. Specific values for particular operating conditions can be supplied on request.

Page 15
 CompAir

Cable Sizes and Fuse Ratings

Model Voltage Cable Size Fuse Rating

50/60Hz

L45SR All voltages 3 x 35mm2 gG125A

L75SR All voltages 3 x 70mm2 gG200A
L120SR All voltages 3 x 120mm2 gG315A

Approximate Full Load Current, Amps

Model 380V 400V 415V 460V

L45SR 107 102 98 87

L75SR 160 155 151 139
L120SR 261 248 238 234

Fan Motors Thermal Overload Settings, Amps

Model 380V 400V 415V 460V

L45SR 6.0 5.5 5.4 5.0

L75SR 9.5 9.0 8.9 8.5
L120SR 16.0 16.0 16.0 16.0

Page 16

INSTALLATION
WARNING
● Refer to the safety procedures before
installation of the compressor unit.
● Lethal voltages are used in this
equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.
1. GUIDELINES
The following procedure is a guide for installing a
standard compressor unit. For the installation of
non-standard units or units fitted with optional
equipment refer to the local CompAir
representative.
Refer to Appendix 3 for dimensional drawings.
1.1 Foundations
The compressor is supplied as a free standing
package and does not require securing to a
foundation. However, the supporting floor must
have a loading capacity sufficient to support the
weight of the unit (see ‘Technical Data’ in the User
Manual).
1.2 Unpacking, Lifting and Handling
The compressor package may be lifted by fork lift
using the slots provided in the baseframe or by
spreader bars and lifting frame with slings or chains
attached to lifting brackets bolted to the baseframe.
To prevent damage, spreader bars or frames
should be wide enough to keep slings clear of the
enclosure.
Note: the use of a pallet truck is not recommended.
Remove the polythene cover and lift the
compressor off the pallet. Lower the unit into
position, ensuring that the weight is evenly
supported. Check that the baseframe is level to
within 3 mm / 1/8in . Use packing pieces under the
baseframe if necessary.
LSR Series User Manual – Installation
● Before opening the door of the power
converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting work on the compressor.
Remove the transportation fixings (painted red)
from the drive module. L45SR, L75SR only -
remove all protective blanking covers and tapes .
Note: If L45SR or L75SR models are to be installed
in a right hand corner, make all electrical
connections before moving into position. See 1.6.
Ensure that the electrical connections are
accessible before installation in a corner.
1.3 Compressor Building
The compressor building should be sized to provide
1200mm / 47in of free space on all sides and
1500mm / 59in above the unit. In addition,
consideration should be given to providing
adequate access for maintenance.
Lifting facilities should be provided over the
compressor to enable the heaviest components to
be lifted during maintenance.
Ensure that pipe and cable runs do not obstruct
doors, create a tripping hazard or prevent access
for maintenance.
1.4 Ventilation
A ventilation inlet opening must be provided at the
cooling air inlet end of the unit to allow cool air to
enter the building. Hot air should be exhausted from
the building either by means of a duct connected to
the outlet grille of the compressor or a suitably
sized ventilation fan located in the building. The fan
should be sized to handle the total cooling air flow
of the compressor(s). The inlet opening and
ventilation fans should be sized to prevent build up
page 17
CompAir
of heat within the building, limiting the temperature
rise to an acceptable level.
The minimum duct dimensions should match the
outlet of the compressor or an equivalent cross
sectional area. The maximum duct length without
fan assistance is 3 metres / 118in of straight duct
plus one right angled bend.
If an exhaust duct is fitted a 1 metre / 39in
removable section should be provided immediately
above the compressor for maintenance
purposes.The temperature of the air at the air
intake grilles should be as follows:-
L45SR, L120SR - Min 0°C (32°F) max 45°C (113°F)
L75SR - Min 0°C (32°F) max 43°C (109°F).
If the air temperature is below 0°C / 32°F, heaters
should be installed inside the compressor and
precautions should be taken to prevent freezing of
the condensate drains. Refer to your CompAir
distributor for further details.
Ventilation openings should be screened to prevent
the ingress of debris into the compressor room.
Recommended ventilation arrangements are shown
below:
DUCT
INLET
OPENING
FAN
INLET
OPENING
HW 0011
page 18
1.5 Air and Condensate Pipework
The air discharge pipe should be connected to the
distribution header or air receiver using piping with
a minimum nominal bore of compressor outlet. The
discharge piping must connect into the top of the
distribution header to prevent condensed water from
running back into the compressor during periods of
standby operation. The pipe must not be connected
into either the side or bottom of the header.
An isolating valve should be incorporated in the
discharge piping to enable the compressor to be
isolated for maintenance purposes.
A suitably sized air receiver should be installed
between the compressor and distribution system.
As a guide the receiver capacity should be 10% of
the compressor output. eg a 10m3/min / 353cfm
compressor will require a 1m3 / 35ft3 air receiver.
The automatic condensate drain should be piped
into a drain gulley or open tundish. Piping from the
drain connections should not exceed 3 metres in
length and must fall towards the drain gulley or
open tundish.
In order to minimise pressure drops all valves
should be either gate or ball full flow type and all
bends should have a minimum radius of at least 1.5
times the pipe diameter.
CAUTION: All pipework is to be adequately
supported outside of the compressor. The
compressor connections must not carry any load.
CAUTION: Do not install a non-return valve on the
outlet side of the compressor.

1.6 Electrical Connections
1. Remove the gland plate from the electrical
cabinet. Fit suitable cable glands.
It is important that the sealing and IP rating of
the starter compartment is maintained by the
use of glands of the correct type and size in
order to seal the compartment against the
ingress of dust and moisture.
2. Ensure the power supply to the unit is taken
from a fused isolator, the switch is locked
‘OFF’ and fuses removed. Connect the supply
in accordance with the electrical connection
diagram. Use cables complying with the
standards of the International Electrotechnical
Commission (IEC) or of the Institution of
Electrical Engineers (IEE) (latest edition) for
U.K. users. The cables must be correctly
sized for the total input kW of the plant and
suitably protected and clamped. Refer to cable
sizes and fuse ratings detailed in ‘Technical
Data’.
3. L45SR - A gland plate is fitted to the RH side
of the power converter compartment. Open
the door of the compartment and rotate the
gland plate to the appropriate gland size, or
remove the plate and and drill a hole to the
required size in the spare space.
L75SR - Remove the plain gland plates from
the baseframe and the power converter
compartment. Modify the plates to take the
power cable or fit suitably pierced plates, with
grommets.
L120SR - Remove gland plate and drill for
cable glands.Note: It is important that the
cable entry is sealed, otherwise ventilation will
be compromised.
4. Ensure that the prospective fault current does
not exceed the recommended maximum
value.
5. Pass the cable through the hole in the outer
panel, then through the gland and gland plate
before connection to the starter.
6. Refit the power converter compartment top
cover and enclosure panels, or close the
door.
LSR Series User Manual – Installation
1.7 Noise Levels
The noise levels quoted in the Technical Data
section of the user manual can only be achieved in
a room where the compressor is not closely
surrounded by smooth, hard, reflective surfaces.
The noise levels quoted are for ‘free field’
conditions.
2. RESIDUAL CURRENT DEVICES
An AC input filter is fitted to LSR series
compressors.
Because filters introduce additional leakage current
to a system, they will contribute to the total residual
leakage current on the line. Excess leakage current
can be detected as a fault condition and lead to
unwanted tripping of Residual Current Devices
(RCDs).
This nuisance tripping can be especially prevalent
at switch-on due to the inrush current of the filter
capacitors. To help avoid this problem the following
should be considered:
• The RCD trip current should be chosen to be
as high as possible. Typically a leakage
current of 30mA is used but for industrial
applications higher values may be specified.
• An RCD with built in trip delay will reduce the
incidence of spurious tripping.
• Electronic RCDs are available which
discriminate between spurious signals and
fault currents. These should be used
whenever possible.
page 19
CompAir

page 20
 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. Use extreme caution when capacitors to discharge to a safe level.
carrying out electrical checks. Isolate the Check that the dc link capacitors have
power supply before starting any fully discharged before starting work on
maintenance work. the compressor.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

HW 0012

Bar
PSI

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

1. Bar Units Indicator 17. Remote Control Legend

2. Psi Units Indicator 18. Remote Control Lamp
3. Delivery Pressure Display 19. Auto Restart Lamp
4. Status and Message Display 20. Power on Lamp
5. Plus 21. Fan Motor Overload Lamp
6. Minus 22. Power Converter Fault Lamp
7. Up 23. Main Motor Fault Lamp
8. Down 24. Reset
9. Enter 25. Hours
10. Mimic Diagram 26. Reset Lamp
11. Intake Filter Change Lamp 27. Data View
12. Delivery Temperature Lamp 28. Service
13. Reclaimer Element Check Lamp 29. Service Lamp
14. Excess Pressure Lamp 30. Stop
15. Emergency Stop 31. Start
16. Auto Restart Legend

CONTROL PANEL

page 21
CompAir

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

3. To start the compressor press START (31).

1. ROUTINE OPERATION
Note: The compressor may appear to turn slowly for the
Note: The temperatures and pressures given in the first revolution before running up to speed. This is normal
procedures are shown as examples only. and should not be considered a fault condition.

Provided pressure at the delivery point is below

1.1 Starting the off-load P1 set point, the unit will run in the
chosen, programmed, start-up ‘Control Mode’. It
Note: References (1) refer to the Control Panel will enter ‘Standby’ if the pressure is above the off-
illustration in the General Description. load P1 set point. The compressor will not start if:

There are two control modes: Manual (MAN) and (a) Certain menu routines are in use.
Automatic (AUTO). The automatic mode is the control
mode used at start-up unless the compressor has been (b) The remote starting facility has been
re-programmed during commissioning or by the user. enabled. In this instance the display panel
REMOTE CONTROL LED (18) will be lit
1. Switch mains power to the compressor ‘ON’ at the and the display will momentarily show:
isolator. The front panel is now in the following
Remote start enabled
state.
4. During the initial period, the status display will
(a) The POWER ON LED (20) is lit.
show:
(b) The status display (4) shows: Onload
C20620/nn/xx/nn Oil temperature 20°C
VNVLnnxx ddmmmyy
5. Provided the delivery pressure is below the
off-load set point (P1), the compressor runs
2. After a few seconds, provided no fault exists, the
on load in the programmed start-up mode and
status display will show:
the status display will show:
DC link charging
Onload
Oil temperature 20°C
Oil temperature 75°C
Followed by:
6. The compressor now runs in the start-up
mode according to the parameters previously
Ready to start
programmed and stored in the controller.
Oil temperature 20°C Initially the oil temperature will rise rapidly to
working temperature, the thermostatic bypass
Either or both the REMOTE (18) and AUTO valve will then operate to maintain the
RESTART (19) LEDs are lit if these facilities have temperature at this level.
been selected. See also ‘Remote Control’ and
‘Automatic Restart’. 7. Fault conditions and service requirements are
continuously monitored (from start-up) and
See ‘Fault Messages’ for possible start-up faults. If warning and the appropriate status messages
a fault exists and a repair is necessary, power to are displayed.
the compressor must be isolated and the fault
rectified. 8. To interrogate the hours run and service
hours information press HOURS (25). (see
Displaying the Number of Hours Run).

page 22
 LSR Series User Manual – Operation

9. 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

1. The manual mode is to be used for
commissioning and constant speed operation
only. The compressor will unload and load in
response to varying air demand when the
upper and lower set points P1 and P2 (MAN)
are reached. When the compressor goes off-
load the reclaimer blows down. The display
alternates, as appropriate, between:
Offload
Oil temperature 60°C
and
Onload
Oil temperature 80°C
1. This is the normal mode of operation. A
pressure transmitter measures the delivery
pressure which is compared with the target
pressure set point P2 (AUTO) programmed
into the control unit. If the off-load set point P1
(AUTO) is reached the compressor runs off-
load and the status display will show:
Offload
Oil temperature 75°C
2. When air demand reduces the pressure below
the target set point P2 (AUTO), the
compressor runs on-load. The compressor is
then controlled by the speed control and the
display will change to:

2. If the compressor is off-load for longer than Onload

the ‘Run-on Time’, the compressor will stop Oil temperature 80°C
and the status display will change to:
Blowing down
1.4 Displaying the Number of Hours Run.
Oil temperature 75°C
1. The HOURS button (25) is used to display the
3. After the blowdown period the display will hours run by the compressor and the hours to
change to: run before a service is due.
Standby
2. Successive presses of the HOURS button
Oil temperature 70°C give the following display sequence.

Note: If the START button is pressed whilst the Total hours 1000hrs
compressor is blowing down the display changes to
Service hrs to run 1000
‘Standby’ immediately.
Total Air 88888 m3
4. When air demand lowers the pressure below
the lower set point P2 (MAN) the compressor Number of starts 125
will restart and run on-load. The display will Hours 0–20% 50hrs
show:
Hours 21–40% 50hrs
Starting
Hours 41–60% 150hrs
Oil temperature 70°C
Hours 61–80% 700hrs
changing to: Hours 81–100% 50hrs

page 23
CompAir

3. The display will cancel itself after a short 2. The RESET LED (26) will pulse and the
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
If the EMERGENCY STOP button (15) is reset
1. To change the control mode adopted when and RESET (24) is pressed within the
switching the power on, the Operational blowdown time, the RESET LED will
Settings menu routine must be used (See extinguish and the display will show:
Menu Routines). When re-programmed, the
Blowing down
new mode becomes effective immediately.
Oil temperature 50°C

1.6 Stopping Note: The emergency stop button should be used

only in a genuine emergency and must not be used
1. To stop the compressor press STOP (30). as the normal method of stopping the compressor.
If the compressor is stopped while on-load, or
within 8 seconds of being on-load, the main
1.8 Service Interval Timer
motor will continue to run until 8 seconds have
elapsed since the compressor was on-load.
1. The control system uses a countdown timer
The display will show:
which can be reset to programmed maximum
Stopping each time a service is carried out. The
maximum reset hours can be adjusted to suit
–––––––––––––*
site conditions and/or service schedule
requirements. When the timer reaches zero
The time until the main motor stops and the
hours a service due advice message is
compressor blows down is indicated by
displayed. When the service has been
dashes on the lower display line.
completed, the reset service hours function
should be selected from the service
The display changes to:
diagnostics sub-menu and the service advice
Blowing down message reset.
Oil temperature 50°C
2. When the compressor has reached the
running hours at which a service is required,
2. After a short time delay the display will
the SERVICE LED (29) will flash. If
change to:
SERVICE (28) is now pressed the SERVICE
Ready to start LED (29) will stop flashing and remain lit. The
RESET LED (26) will then flash continuously
Oil temperature 40°C
and the status display will show the service
advice message below:
1.7 Emergency Stopping Onload
Service due
1. When the EMERGENCY STOP (15) is
pressed, the compressor will stop immediately
3. The compressor must be stopped and
and the reclaimer will blow down.
isolated to carry out the required service (see
‘Safety’ section). On completion of the service
the ‘service hrs to run’ value must be reset to
maximum by using the Service Diagnostics
menu routine.

page 24

4. It may not be convenient to respond to the
service due message immediately. In this
case press RESET (24) to cancel the flashing
RESET LED (26) and restore the status and
oil temperature display. The service SERVICE
LED (29) will remain lit to indicate that a
service is required.
1.9 Warnings
1. If a service is required, the SERVICE LED
(29) and the appropriate mimic diagram LED
will flash continuously. If SERVICE (28) is
pressed the SERVICE LED (29) will stop
flashing and stay lit in acknowledgement. The
RESET LED (26) will flash continuously and
the display will show the required action (e.g.
an air filter change) as below:
Onload
Change Air filter
2. Pressing SERVICE (28) repeatedly during this
period will recall any earlier stored warnings in
chronological order (most recent first) that
have not been corrected and reset.
3. When pressing SERVICE (28) is
discontinued, the fault/service display will be
shown for several seconds after which it
reverts to the normal message.
4. The occurrence of another warning (e.g. High
oil temp) after any previous warning has been
acknowledged will again cause the SERVICE
LED (29) to flash continuously and the mimic
diagram LED appropriate to the second fault
will also light.
5. It may not be convenient to respond to a
warning immediately. In this case press
RESET (24) to cancel the flashing service
LED and to restore the status and oil
temperature displays. The mimic diagram LED
will remain flashing to indicate that attention is
required.
1.10 Shutdown Faults
1. If a shutdown occurs, the compressor will
stop. This can occur at any time after the
compressor has been started. Both RESET
(24) and the appropriate mimic diagram LED
LSR Series User Manual – Operation
will flash continuously and the SERVICE LED
(29) will light. If the menu routine is in use
when a shutdown occurs the appropriate
panel and mimic diagram LEDs will light and
flash as normal. The current message will not
be overwritten until RESET (24) is pressed or
the display reverts to the fault message after a
period of time.
2. The display will show:
Fault shutdown
(Relevant shutdown message)
See Display messages
1.11 Power Supply Failure Detection
The control system has two methods of power
failure detection. Within the controller, an internal
circuit monitors two phases of the incoming ac
voltage and will trigger the power failure routine if
two successive cycles are not detected. External to
the controller, a phase monitor relay, connected to
a controller input, monitors each phase and will
signal to the controller input if any phase goes
below 70% of the set voltage or the phase order is
reversed. The phase monitor will automatically
reset within 500ms when correct conditions are
restored.
The controller itself is designed to operate for about
0.5 secs following loss of incoming power. Thus it
has time to take action and store essential data
prior to shutdown. The action taken following power
failure detection from either source is the same .
The compressor will be shutdown and then the
controller will shutdown. When power to the
controller is available it will reboot. The recovery
action when power is restored depends on the
status of the machine at time of power failure.
1.11.1 Compressor stopped (‘Ready to Start’)
In this condition, the controller will reboot to display
‘Ready to Start’. These occurrences will not be
logged as it has no consequence to the system and
would normally occur in a routine power off
situation.
page 25
CompAir
Should the controller remain powered (in event that
the failure was on a phase not supplying controller)
then on rebooting, the display will show ‘Start
Inhibited - Power supply fault’ and the charging
circuits will not be actioned. On reset of the monitor,
the controller will again reboot to ensure correct
charging sequence.
1.11.2 Compressor running or in Standby
Again, should the controller remain powered then
on rebooting, the display will show ‘Start Inhibited -
Power supply fault’ and the charging circuits will not
be actioned. The fault in this case will be stored in
the history. When the monitor resets, the controller
will reboot again to ensure correct charging
sequence.
If power to the controller is lost, then after reboot,
depending on which circuit triggered first, an alarm
will be displayed with either message ‘Powerfail
Fault’ (controller internal circuit) or message ‘Power
supply fault’ (phase monitor relay) and the fault
logged.
Manual reset will not be required (except to clear
display and ‘service’ led) and, if enabled, the
machine will auto restart to previous state.
Note that because this feature is only operable
while the machine is ‘available’, any powerdip or
failure occurring after a controlled stop, but before
the motor is switched off, will result in a reboot to
‘Ready to Start’ without the ‘Power fail/supply fault’
indicated. This is the standard machine action.
1.11.3 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.
Press SERVICE, HOURS, SERVICE, HOURS .
page 26
2. USING THE MENU ROUTINES
(See 4. Menu Structure on page 33.)
1. The menu routines are used to access, view
and/or alter the operating parameters and
options stored in the memory of the controller.
The menu routines are accessed by pressing
ENTER (9).
2. The display will show:
Main menu
Operational settings
3. ‘Operational settings’ is the first of six sub-
menus.
The sub-menu headings can be stepped
through using UP (7) and DOWN (8). When
the required sub-menu is displayed, press
ENTER (9) to select and enter the sub menu.
The top line of the display will now show the
selected sub-menu and the first item of the
menu will be displayed.
All the items of the selected sub-menu can be
stepped through using UP (7) and DOWN (8).
Use PLUS (5) and MINUS (6) to change any
value or option being displayed. Pressing
ENTER (9) will then program any change into
the permanent memory. Any change that is
not entered will be ignored and the original
value maintained.
An access code may be requested when an
alteration is attempted.
Select the ‘Return to previous menu’ item to
return to the main menu from any sub-menu.
Selecting the ‘Return to previous menu’ item
of the main menu will exit the menu routine.
Press RESET (24) at any time, in any menu,
to exit the menu routines.
 LSR Series User Manual – Operation

4. If the ‘Operational settings’ sub-menu is
selected from the main menu using ENTER
(9). The display will change to:
Operational settings
Control Mode AUTO
All the displayed settings may be shown in
sequence by repeated presses of DOWN (8)
or UP (7). When the end of the list is reached
(in either direction) the display ‘wraps-round’
to the opposite end of the list. (See ‘Glossary
of Display Messages’ for further explanations
of messages).
The settings displayed are shown in para 3.1
5. A setting can be altered using the PLUS (5)
and MINUS (6) buttons. When an alteration is
made the displayed option will flash. Press
the ENTER (9) button to programme the new
option into the controller memory.
Note: Alarm and trip conditions will have been
simulated during the factory test procedure. These
will have been recorded within the initial running
hours under test and will remain stored in the
memory.
The number on the top line is the
chronological fault number, ‘1’ is the latest
fault recorded. The fault history will hold 15
faults.
9. Press UP (7) or DOWN (8) to scroll through
the faults (stored in chronological order)
10. Press PLUS (5) or MINUS (6) to give the
following sequence of information for the fault
displayed on the bottom line.
Message Meaning

The new displayed option will appear steady.

An access code may be requested when an 1000 Hrs run at time of fault.
alteration is attempted.
Onload, Offload, State of compressor
6. To return to the Main menu select ‘Return to Standby or at time of fault
previous menu’ and press ENTER (9). To Ready to start
return to the status display (at any time) press
RESET (24). 65°C or 149°F Air/oil temperature at time
of fault
7. To inspect all previous stored warnings and
faults, scroll through the main menu using UP 6.0 bar or 87 psi Delivery pressure at time
(7) or DOWN (8) until the display shows: of fault
Main menu
Fault history recall

8. Press ENTER (9). The display will change to:

Fault history recall 1
Fault message

page 27
CompAir

3. 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).

P1 - AUTO mode Offload set point for automatic mode.

P2 - AUTO mode Target pressure set point for automatic mode.

P1 - MANUAL mode Upper set point for manual mode.

P2 - MANUAL mode Lower set point for manual mode.

Run on time Time compressor will run offload before the main motor stops and the
compressor changes to Standby mode.
Drain open time Time condensate drain is switched on (not used on L120SR).

Drain shut time Time between condensate drain switching on (not used on L120SR).

Return to previous menu Returns display to main menu.

3.2 Service Diagnostics

Note: Certain menus cannot be accessed while the machine is running; a message ‘Stop machine first’ will
be momentarily displayed if access attempted when not permitted. A start is also prevented when in the
Diagnostics menu or a sub-menu.

Reset service hours Resets the service countdown timer to maximum programmed hours.
Select after a service.
Calibrate pressure Calibration routine for pressure transmitter.

Test digital outputs Test routine for each individual output.

Note: Access to ‘Test digital outputs’ is not allowed if the Emergency stop input is open; this is because the
output drivers are not powered and test not effective. A momentary message ‘Emergency Stop’ is displayed.
Test digital inputs Test routine for each individual switched input.

Test analogue inputs Test routine for pressure and temperature inputs.

Test keypad Keypad test routine. Each key pressed will be displayed to establish correct
operation, press RESET to exit routine.
Test display Displays and LED’s test routine. Will switch on all display segments and
LEDs for 15 seconds.

Return to previous menu Returns display to main menu.

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 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 m3, c.f.m., litres

Machine Model Press ENTER to display and change selected machine model with special
access code.

Machine number Network identification number.

Auto restart Power failure auto restart facility - enable or disable selection

Communications config Press ENTER to display and change current mode. See 3.3.1

Remote control config Press ENTER to select configurable inputs and outputs (including remote
start/stop) and to set the alternative pressure setpoints. See 3.3.2

Speed control disp Used to set whether the speed control display is visible when using the
VIEW button.

Return to previous menu Returns display to main selection menu.

3.3.1 Communications Config sub Menu

Disabled No control commands will be accepted by the compressor. Monitoring data

requests are accepted in this and all options.

SmartAir control The compressor will accept load & unload instructions from a SmartAir unit.
Other non RS485 pressure control sources are disabled unless RS485
instructions are not received within 22 secs.

Communications control In addition to load & unload instructions from SmartAir units, the
compressor will accept load/unload and start/stop instructions from an HMI
system connected to the net. Keypad Start is disabled. Other non RS485
pressure control sources are disabled unless RS485 instructions are not
received within 22 secs.

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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.

Config input X01/6 Configurable input see Page 39 for options. Default is Pressure Range
Select, which is only available on this input.

Config input X01/7 Configurable input see Page 39 for options. Default is Remote start/stop,
which is only available on this input. When configured for Remote start/
stop, remote stop is active and a link is required other wise display shows
‘Remote stop’.

Config output X08/6 Configurable output - see Page 40 for options. Default is Disabled. This
output is only configurable on L120SR.

Config output X08/10 Configurable output - see Page 40 for options. Default is Disabled. This
output is only configurable on L120SR.

Config output X09/2 Configurable output see Page 40 for options. Default is Group Fault.

Config output X09/3 Configurable output see Page 40 for options. Default is Available.

Config output X09/4 Configurable output see Page 40 for options. Default is Group Trip.

*P1 – AUTO mode This is the setting item for the secondary AUTO mode upper pressure
setpoint.

*P2 – AUTO mode This is the setting item for the secondary AUTO mode lower pressure
setpoint.

Return to previous menu Returns display to Commissioning - config menu.

3.4 Commissioning Values

Pressure P factor P+I control loop proportional gain for AUTO mode.

Pressure I factor P+I control loop integral gain for AUTO mode.

Max. overpress Maximum overpressure selection. Compressor will trip at this setting.

Oil t trip limit Temperature at which compressor will trip on high oil temperature fault
shutdown.

Oil t alarm limit Temperature at which a high oil temperature warning will be displayed.

Acceleration time Start up time during which the machine will run at reduced max. speed (Onload)

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 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.

Autorestart delay Time between return of power and automatic restart.

Load default values Resets all values and options to default settings. Will not affect pressure
calibration or hours run timers.

Return to previous menu Returns display to main selection menu.

3.5 Default Settings

1. Default settings for a number of the operational
settings are stored in the controller. These are
suitable for operating the compressor in most
normal situations.
2. The compressor can use these settings as
operational settings. Unless the compressor is
reprogrammed during commissioning, the default
settings will be those used by the compressor.
4. It is not possible to change any parameters while
the Emergency Stop button is pressed. This is
because when Emergency Stop is pressed (input
open circuit) the power failure detection is inhibited.
The controller therefore assumes a power failure
possibility and suspends all data storage to prevent
corruption should the power fail during storage
operation. A message ‘Emergency Stop’ is shown
if a change is attempted.

3. The compressor may be re-programmed with 5. The following is a list of default settings together
different settings at most times, and most with the range and size of the increments/
operational settings may be restored to the default decrements available for each setting.
values, by choosing the ‘Load default values’
option in the ‘Commissioning – values’ sub-menu.
Alteration of the working setting values requires the
use of the access code.

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Setting Unit Minimum Maximum Step Default

Value

P1 for AUTO mode bar 5·1 13.4 (11.9)* 0·1 7·4

P2 for AUTO mode bar 5·0 13.0 (11.5)* 0·1 7·0

*P1 for AUTO mode bar 5·1 13.4 (11.9)* 0·1 7·4

*P2 for AUTO mode bar 5·0 13.0 (11.5)* 0·1 7·0

P1 for MAN mode bar 5·1 13.3 (11.8)* 0·1 7·0

P2 for MAN mode bar 5·0 13.0 (11.5)* 0·1 6·3

Max. overpress (L120SR) bar 6·0 14.3 (12.8)* 0·1 7·7

Max. overpress (L45SR, L75SR) bar 6·0 13.6 0·1 7·7
Acceleration time second 0 240 1 10
Cooler run on time minute 2 12 1 2
Run on time second 20 240 1 20
Drain open time second 1 20 1 5
Drain shut time second 10 120 1 30
Oil t trip limit °C 85 120 1 115
Oil t alarm limit °C 85 120 1 110
Max. service hours hour 1000 2000 100 2000
Machine number number 1 99 1 1
Auto restart delay second 10 240 1 10
Auto restart Enabled - Disabled option disabled
Remote start/stop (see page 70, 1.2.2) Enabled - Disabled option disabled
Pressure P factor 1 100 1 30
Pressure I factor 1 100 1 15
Input X01/4 (see page 70, 1.2) Disabled to Start Inhibit option disabled
Input X01/6 (see page 70, 1.2) Disabled to Start Inhibit option Pressure
plus Pressure Range Select Range sel
Input X01/7 (see page 70, 1.2) Disabled to Start Inhibit option Remote
plus Remote Start/Stop start/stop
Output X08/6 (see page 72, 1.4) Group Fault to Low Temp alarm option disabled
Output X08/10 (see page 72, 1.4) Group Fault to Low Temp alarm option disabled
Output X09/2 (see page 72, 1.4) Group Fault to Low Temp alarm option Group Fault
Output X09/3 (see page 72, 1.4) Group Fault to Low Temp alarm option Available
Output X09/4 (see page 72, 1.4) Disabled to Start Inhibit option Group Trip
Communications config Disabled-SmartAir control- option disabled
Communications control

* Figures in brackets are for L120SR-11 machines only

Note: The ‘Max. overpressure’ must be set above P1 settings.

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 LSR Series User Manual – Operation

4. 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
Commissioning Configuration Menu
Machine Model Menu
Communications Configuration Menu
Remote Control Configuration Menu
Remote Start Menu
Input Configuration Menu
Output Configuration Menu
Commissioning Values Menu

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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
View
(PID settings) Only when display enabled
View
Oil temperature 25°C
The above displays will remain selected indefinitely

HOURS BUTTON MENU Comments

Status Message
Total hours 25297hrs max displayed: 99999 hrs

Hours
Service hrs to run 267
Hours
Total Air 11990778m3 max displayed: 28316846m3 (999999999 ft3)

Hours
Number of starts 453
Hours
Hours 0 - 20% 3675hrs
Hours
Hours 21 - 40% 4538hrs
Hours
Hours 41 - 60% 6432hrs
Hours
Hours 61 - 80% 4678hrs
Hours
Hours 81 - 100% 5974hrs
Hours
Total hours 25297hrs

The above displays will remain selected for 1 minute following last keypad use.

ENTERING ACCESS CODE For several menu items an Access code is required. When this
is needed the menu flow will be interrupted by this message

Menu Header Enter the sequence Spanner, Clock, Spanner, Clock

Enter Code ???? Continue

A message appears if the code is incorrect. Entry of a correct code is remembered and is not requested again unless a different
code is needed, 60 seconds has elapsed since last key press or the Reset key has been pressed.

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 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. Enter Go to Commissioning - config. menu
Up/Down
Commissioning - values Enter Go to Commissioning - values menu
Up/Down
Show program variant Enter Go to program variant display
Up/Down
Return to previous menu Enter Return to Status Display
Up/Down
Operational settings

OPERATIONAL SETTINGS MENU Min Max Default Unit

Operational settings
Control mode AUTO +/- AUTO/MAN AUTO options
Up/Down
(* PI for AUTO mode 7.4 bar) +/- upper limited by max overpress 5.1 13.4 (11.9)* 7.4 bar
Up/Down (Only dis played when s econdary pres s ure s elected)

(* P2 for AUTO mode 7.0 bar) +/- upper limited by *P1 value 5.0 13.0 (11.5)* 7.0 bar
Up/Down (Only dis played when s econdary pres s ure s elected)

P1 - AUTO mode 7.4 bar +/- upper limited by max overpress 5.1 13.4 (11.9)* 7.4 bar
Up/Down
P2 - AUTO mode 7.0 bar +/- upper limited by P1 AUTO value 5.0 13.0 (11.5)* 7.0 bar
Up/Down
P1 - MANUAL mode 7.0 bar +/- upper limited by max overpress 5.1 13.3 (11.8)* 7.0 bar
Up/Down
P2 - MANUAL mode 6.3 bar +/- upper limited by P1 MAN value 5.0 13.0 (11.5)* 6.3 bar
Up/Down
Run on time 20 sec +/- 20 120 20 second
Up/Down
Drain open time 5 sec +/- 1 20 5 second
Up/Down
Drain shut time 30 sec +/- 10 120 30 second

* Figures in brackets apply to

Up/Down L120SR-11 only
Return to previous menu Enter Return to Main Menu
Up/Down
Control mode After selecting desired value or option, press ENTER to accept and store

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CompAir

FAULT HISTORY RECALL

Fault history recall 1 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
Up/Down
Return to previous menu Enter Return to Main Menu

PARAMETERS AT TIME OF FAULT

Fault
Total hours 25297hrs Enter Return to latest fault
+/-
Delivery P 7.0 bar Enter Return to latest fault
+/-
Oil Temp 25°C Enter Return to latest fault
+/-
Status Enter Return to latest fault
+/-
Fault history recall #
Selected fault

Note: for persistent overcurrent trips on start attempt, the Status display will also show the reset attempt
number and whether reset inhibit was cleared using special access code

Starting 2C For example the message alongside shows that

this was the second unsuccessful attempt and that
the fault was cleared using the special access code

SHOW PROGRAM VARIANT MENU

C20636/100/UN/B1 Application Program Number
VW4P01UN 20Feb01 Application Program Name and Date
Up/Down
C20637/10/UN/B1 Drive Program Number
VWSR01UN 12Dec00 Drive Program Name and Date
Up/Down
Return to previous menu Enter Return to Main Menu

Note: Above numbers and names are examples and may differ from that show on the display

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 LSR Series User Manual – Operation

SERVICE DIAGNOSTICS MENU

Service diagnostics
Reset service hours Enter To reset to predetermined value
Up/Down

Calibrate pressure Enter Go to Calibrate Pressure Transmitter Stop machine first

Up/Down

Test digital outputs Enter Use Up/Down to scroll through the list of digital outputs. Use plus or Stop machine
minus to turn on or off. See wiring diagram for outputs appropriate to first
Up/Down
machine model. Configurable outputs will be listed by their connector
designation if disabled, otherwise by the function selected.

Test digital inputs Enter View state of inputs only. See wiring diagram for inputs appropriate to machine model.
Configurable inputs will be listed by their connector designation except X01/6 & 7
which will show Pressure Range Select & Remote Start/Stop respectively if these
functions are selected.

Up/Down

Test analogue inputs Enter View value of inputs only. First value shows digital conversion figure
and second the interpreted engineering unit value
Up/Down

Test keypad Test each button in turn to display button name and Stop machine first
confirm operation. Reset button will exit routine.
Up/Down

Test display Enter Will illuminate all elements and indicators for 15 Stop machine first
secs from button press or use reset to exit.
Up/Down

Return to previous menu Enter Return to Main Menu

Up/Down

Reset service hours

CALIBRATE PRESSURE TRANSMITTER

Set pressure at 0 bar This is most accurately done by disconnecting the
delivery pipe from the transmitter
Press enter when ready
Enter
Set pressure > 5.5 bar Reconnect transmitter and raise the pressure above 5.5 bar. Display will automatically
change when pressure is calculated to be above 5.5 bar using defau;t calibratiion
v l es

Adjust +/- :- 6.92 This is the preferred method where the pressure is static and a calibrated calibration
meter is available. Use plus or minus buttons to adjust displayed value to match that of
Press enter when ready meter. Press enter to set calibration and exit the routine.

Up/Down Enter
Adjust pressure up/down ALTERNATE ROUTINE
Press enter when ready Use this method where the pressure is not static or where there is a need to match
with another display. Use UP or DOWN buttons to adjust display to track the pressure
variations correctly. Press enter to set calibration and exit the routine.

Enter
Calibration complete
2 secs
Service diagnostics
Reset service hours

Calibration routine will only allow limited adjustment from nominal. If calibration limit reached, check transmitter.

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CompAir

COMMISSIONING CONFIG MENU Options Min Max Default Unit

Commissioning - config.
Language English +/- Englis h, Netherlands , German, F rench, S panis h, English options
P ortugues e, Danis h, S wedis h, Norwegian, Finnis h,
Italian, Czech, P olis h, T urkis h.
Up/Down
bar, psi bar options
Unit of pressure bar +/-
Up/Down
°C, °F °C options
Unit of temperature °C +/-
Up/Down
Unit of Volume m3 +/- m3, litre, ft3 m3 options

Up/Down
Machine Model Enter Go to Machine Model menu
Up/Down
Machine number 1 +/- 1 99 1

Up/Down
Auto restart enabled, Auto restart disabled disabled options
Auto restart disabled +/-
Up/Down
Communications config Enter Go to Communications config menu
Up/Down
Remote control config Enter Go to Remote control config menu
Up/Down
Speed control disp OFF +/- ON, OFF OFF options

Up/Down
Return to previous menu Enter Return to main menu
Up/Down
Language After selecting desired value or option, press ENTER to accept and store

MACHINE MODEL MENU Options Min Max 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

COMMUNICATIONS CONFIG MENU Options Min Max Default Unit

Communications config
Disabled, SmartAir control, disabled
L75SR +/- Communications control
Up/Down
After selecting desired value or option, press ENTER to accept and store
Return to previous menu Enter Return to Commissioning config menu

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 LSR Series User Manual – Operation

REMOTE CONTROL CONFIG MENU Min Max Default Unit

Remote control config
Remote start/stop Enter Go to Remote start menu
Up/Down
Config input X01/4 Enter Go to Input Config menu L45SR & L75SR only
Up/Down
Config input X01/6 Enter Go to Input Config menu
Up/Down
Config input X01/7 Enter Go to Input Config menu
Up/Down
Config output X08/6 Enter Go to Output Config menu L120SR only
Up/Down
Config output X08/10 Enter Go to Output Config menu L120SR only
Up/Down
Config output X09/2 Enter Go to Output Config menu
Up/Down
Config output X09/3 Enter Go to Output Config menu
Up/Down
Config output X09/4 Enter Go to Output Config menu
Up/Down
* PI for AUTO mode 7.4 bar +/- upper limited by max overpress 5.1 14.4 (12.7)* 7.4 bar
Up/Down
* P2 for AUTO mode 7.0 bar +/- upper limited by P1 value 5.1 13.0 (11.5)* 7.0 bar
Up/Down * Figs in brackets L120SR-11 only
Return to previous menu Enter Return to Commissioning config menu
Up/Down
Remote start/stop After selecting desired value or option, press ENTER to accept and store

REMOTE START MENU Options Min Max Default Unit

Remote start/stop
disabled +/- Disabled, Remote Start disabled
After selecting desired option, press ENTER to accept and store
Up/Down
Return to previous menu Enter Return to Remote Control config menu

INPUT CONFIGURATION MENU Options Min Max Default Unit

Config input X01/#
option +/- Disabled, Pressure Range select, Remote see
start/stop, Trip Type 1, Trip Type 2, Trip notes
Type 3, Alarm Type 1, Alarm Type 2, Alarm
Type 3, Start Inhibit
Up/Down
After selecting desired option, press ENTER to accept and store

Return to previous menu Enter Return to Remote Control config menu

Notes:
’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

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CompAir

OUTPUT CONFIGURATION MENU Options Min Max Default Unit

Config output X0#/#
Disabled, Available, Group Alarm, Group see
trip, Service due, Group Alarm + Trip, notes
Running, On load, Low Temperature Alarm,
option +/- Group Fault
Up/Down
After selecting desired option, press ENTER to accept and store

Return to previous menu Enter Return to Remote Control config menu

Notes:
Default for X09/2 is Group Fault
Default for X09/3 is Available
Default for X09/4 is Group Trip
L120SR only: Default for X08/6 & X08/10 is Disabled

COMMISSIONING VALUES MENU Min Max Default Unit

Commissioning - values
Pressure P factor 30 +/- 1 100 30
Up/Down
Pressure I factor 15 +/- 1 100 15
Up/Down
Max. overpressure 7.7 +/- L120SR 6.0 14.3 (12.8)* 7.7 bar
Max. overpressure 7.7
} L45SR, L75SR 6.0 13.4 7.7 bar
Up/Down
Oil t trip limit 110 +/- 85 120 115 C
Up/Down
Oil t alarm limit 105 +/- 86 120 110 C
Up/Down
Acceleration time 10 +/- 0 240 10 sec
Up/Down
Cooler run on time 2 +/- 2 12 2 min
Up/Down
Max. service hours 2000 +/- 1000 2000 2000 hrs
Up/Down
Autorestart delay 10 +/- 10 240 10 sec
Up/Down * Figs in brackets L120SR-11 only
Load default values Enter To set most values back to default.
Up/Down
Return to previous menu Enter Return to Main Menu
Up/Down
Pressure P factor After selecting desired value, press ENTER to accept and store

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 LSR Series User Manual – Operation

5. GLOSSARY OF DISPLAY MESSAGES

5.1 Operator Advice Messages

Message displayed Meaning

Emergency stop This message displayed when Digital output test attempted when
Emergency Stop is open. Test not valid as outputs are not powered.

Communications control This message is displayed if starting is attempted via the Control Panel
when the communications control is enabled (Panel starting disabled).

Invalid Access Code This message is displayed if the access code entered is not acceptable.

No fault stored This message is displayed when the fault history is accessed and no faults
are recorded.

No reset indicated This message is displayed if the ‘Reset’ button is pressed when there is no
reset required.

No service indicated This message is displayed if the ‘Service’ button is pressed when there is
no service action required.

Remote start enabled This message is displayed if starting is attempted via the Control Panel
when the remote start facility is enabled (Panel starting is disabled). It is
also displayed if access to the Service Diagnostics menu is attempted
when any remote start facility is enabled.

Remote stopped This message is displayed when starting is inhibited by the remote stop
input.

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.

5.2 Shutdown Trips

Message displayed Meaning

Emergency stop Displayed when an emergency stop has been made.

Fan motor fault Displayed when the compressor has shut down because of fan motor
overcurrent or high temperature.

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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.

Del Press probe fault Displayed when the compressor has shut down because the delivery
pressure transmitter is indicating a pressure outside of normal limits.

Reclaimer P probe fault Displayed when the compressor has shut down because the reclaimer
pressure transmitter is indicating a pressure outside of normal limits.

Temperature probe fault Displayed when the temperature sensor is indicating a temperature outside
of normal limits.

SR control power fail Compressor has shut down because the SR Drive® controller electronics
are faulty.

SR pcb internal fault Compressor has shut down because the SR Drive® controller electronics
are faulty.

SR current sensor fault The SR Drive® current sensor is disconnected or faulty.

SR motor high temp fault Compressor has shut down because of SR Drive® high motor temperature.

SR motor overcurrent Compressor has shut down because excessive SR Drive® motor current
has been detected. Reset will be inhibited following two successive
overcurrent trips immediately after a start. The controller can only be reset
by an authorised service engineer.

DC link high V fault Compressor has shut down because the DC supply to the power converter
has exceeded the normal operating maximum.

DC link low V fault Compressor has shut down because the DC supply to the power converter
is below the minimum required by the power electronics. This can be
caused by a momentary loss of power supply to the compressor.

SR position sensor fault Compressor has shut down because the SR Drive® rotor position sensor is
connected incorrectly.

SR motor overspeed fault Compressor has shut down because the SR Drive® motor has exceeded
the maximum operating speed.

SR motor stall fault Compressor has shut down because the SR Drive® motor cannot produce
enough torque to turn the compressor. The fault may be with the motor
or the air-end.

DC link charge fault Compressor is unable to start because the DC supply to the power
converter has not charged to working voltage.

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 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® main contactor is not
closed.

Remote fault 1 Input X01/6 is showing a shutdown trip condition.

Remote fault 2 Input X01/7 is showing a shutdown trip condition.

Remote fault 3 Input X01/4 is showing a shutdown trip condition.

Wrong SRD Drive program Drive card program is not compatible with the application program.

5.3 Warning Alarms

Message displayed Meaning

Change air filter A high differential pressure has been detected across the air filter indicating
the need for an air filter element change.

Change reclaimer element The controller has detected high pressure across the filter element
indicating that it should be renewed (L120SR only).

Check reclaimer dp The service interval has expired indicating the need for a reclaimer
differential pressure check. Renew the filter if necessary.

High oil temp alarm Displayed when the oil temperature has risen to the programmed warning
value.

Service due The service interval countdown timer has reached zero hours indicating a
service is now due.

Heatsink high temp alarm The SR Drive power converter heatsink has exceeded the normal
operating temperature. In this condition SR Drive® power is reduced in
an attempt to prevent further temperature rise and maximum motor
speed will be reduced.

Remote fault 1 Input X01/6 is showing an alarm warning condition.

Remote fault 2 Input X01/7 is showing an alarm warning condition.

Remote fault 3 Input X01/4 is showing an alarm warning condition.

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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.

Power supply fault A supply power failure was detected by the Phase Monitor relay when the
compressor was running or was in stand-by mode.

5.4 Start Inhibit Messages

Message Displayed Meaning

Remote Fault 1 Input X01/6 is showing an inhibit condition

Remote Fault 2 Input X01/7 is showing an inhibit condition

Remote Fault 3 Input X01/4 is showing an inhibit condition

Low Temperature Alarm Temperature is below 1°C

Power Supply Fault The Phase Monitor relay contact is open

5.5 View Button Messages

Message Displayed Meaning

Oil Temperature ??°C Instantaneous Oil/Air Temperature at airend discharge

%####### ????rpm Instantaneous Percentage of maximum load and actual speed

Reclaimer dp ??.? bar Instantaneous pressure differential across reclaimer (L120SR only)

Drive heatsink temp ??°C Instantaneous Temperature of the heatsink

DC link Voltage ???V Instantaneous Voltage of DC link

Air Flow ??m3/min Instantaneous estimated Air Flow. See appendix 4 for calculation
formulae.

e???? p???? i???? n???? Speed calculation parameters. Only displayed if ‘speed control display’ is
ON. See Appendix 4 for calculation formulae

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 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.

Hours 0 - 20% Hours run at 0 to 20% of full load.

Hours 21 - 40% Hours run at 21 to 40% of full load.

Hours 41 - 60% Hours run at 41 to 60% of full load.

Hours 61 - 80% Hours run at 61 to 80% of full load.

Hours 81 - 100% Hours run at 81 to 100% of full load.

5.7 Status Messages

Message displayed Meaning

Auto restarting The compressor is about to automatically restart following restoration of power.

Blowing down The compressor is venting pressure to atmosphere following a motor stop,
motor restart is currently prevented.

Fault shutdown Compressor has stopped due to a fault.

Offload The compressor is running off load (the run-on time has not expired).

Onload The compressor is running on load

Onload. The compressor is running on load with reduced max speed following start.

Ready to start The compressor is waiting for a start signal (from the keypad ) and no fault has
been detected.

Remote stopped This message is displayed when starting is inhibited by the remote stop input
being open circuit.

Standby The compressor has been ‘started’ but is waiting for the delivery pressure to fall
below the lower setpoint, before the motor is energised.

Start inhibited This message is displayed if a condition exists which will prevent the compressor
starting When such a condition is cleared the inhibit is removed. It is not logged in
the history. The condition has no effect while the compressor is running

Stopping The stop button has been pressed and the main motor is decelerating.

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CompAir

MAINTENANCE

1. 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.

Separator/Reclaimer Element(s) Check element(s). Renew if pressure differential exceeds
1 bar (L45SR) or indicator in red zone (L75SR) or
message on screen (L120SR).
Aftercooler/Oil cooler/Control Panel Check condition of pre-filters and clean as necessary.

Minor Service – Every 2000 hours or 6 months (whichever is sooner)

Minor Service Use correct Service kit for model.

Oil System Check oil level/top up.
Blowdown System Check operation.
Electrical Wiring Check connections and condition.
Drain Solenoid Valve Check operation (L75SR only).
Control Panel Check connections.
Aftercooler and Oil Cooler Clean externally.
Oil Filter Renew Oil Filter.
Air Filter - L45SR/L75SR Renew Air Filter.
Electrical Cabinet Filters Renew filter mats.
Check and clean heatsink ducting if necessary.

Interim Service – Every 4000 hours or 1 year (whichever is sooner)

Service Carry out Minor Service.

Oil System Change oil.
Separator Filters Renew Separator Filters/Reclaimer Element
Air Filter - L120SR Renew Air Filter

page 46
 LSR Series User Manual – Maintenance

Major Service – Every 8000 hours or 2 years (whichever is sooner)

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.
Air Pipe Couplings Renew ‘O’ rings.
Condensate Auto Drain Valve Service valve (L120SR only)
BlowDown Valve Renew
Scavenge Tube Renew

1.1 Service Kit Part Numbers

MODEL Minor Service Kit Interim Service Kit Major Service Kit
(2000 hrs or 6 mths) (4000 hrs or 1 yr) (8000 hrs or 2 yrs)

L75SR CK2004 - 2 CK6004 - 197 CK8004 - 5

L45SR CK2003 - 2 98262-223 (2) CK8003 - 4

L120SR CK2007 - 1 CK6007 - 1 CK8007 - 1

1.2 Oil Drain Kit (L75SR only)

Part Number C27399-173

page 47
CompAir

1. Oil Cooler 12. Inlet Air Flow

2. Cooling Fan 13. Inlet Air Baffle
3. Intake Air Filter 14. Inlet Air Pre-filter
4. Non-return Valve 15. Primary Separator
5. Air-end 16. Control Panel
6. SR Drive® Motor 17. Pressure Relief Valve
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
 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. Intake Air Filter 16. Air and Oil Cooler
7. Oil Sight Tube 17. Exhaust Air Baffles
8. Air-End Intake 18. Control Panel
9. Oil Drain Valve10. Air-End 19. Control Panel Filter
10. Air End

GENERAL ARRANGEMENT AND SERVICING POINTS (L75SR)

page 49
CompAir

1 2
3

1. Exhaust Duct
4 2. Inlet/Non-Return Valve
3. Aftercooler
4. Oil Filters
5 5. Safety Valve
6. Oil Cooler
6 7. Moisture Separator
12 8. Condensate Drain Valve
7 9. Air End
10. Drive Coupling Access
11. SR Drive® Motor
12. Power Converter
8 Cabinet Filters

9
10
11

13 14 15

13. Minimum Pressure Valve 16

14. Blowdown Solenoid Valve
15. Cooling Fan
23
16. Control Panel
17. Intake Air Filter
18. Fork Lift Points
19. Oil Filler 17
20. Air/Oil Separator
21. Oil Level Sight Glass 22
22. Oil Drain
23. Cooling Air Inlet Grille

HW 0016
21 20 19 18

GENERAL ARRANGEMENT AND SERVICING POINTS (L120SR)

page 50

2. MAINTENANCE PROCEDURES
WARNING
● Refer to the safety procedures before
carrying out any maintenance or
servicing work on the compressor unit.
● Lethal voltages are used in this
equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.
● Before opening the door of the power
converter compartment switch the
power supply OFF at isolator and wait
for 12 minutes to allow the dc link
capacitors discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.
● Where a maintenance procedure below
includes the warning ‘The compressor
must be stopped’ the following steps
must be taken before work is
commenced:
2.1 Enclosure Filter
The compressor is provided with coarse screen
filters which act as pre-filters for the intake air.
Carry out a regular check on the condition of the
pre-filter and if necessary remove the material from
the enclosure and wash in a mild detergent solution
before refitting.
2.2 Control Panel Filter
Filters are provided to clean the cooling air for the
power electronic circuits. These should be cleaned
as specified intervals or before scheduled if ‘Heat
sink temp high’ is displayed.
LSR Series User Manual – Maintenance
1. Close the shut-off valve to the user’s
pipework.
2. Switch the power supply ‘OFF’ at the
isolator.
3. Ensure that the blowdown system has
operated to release all pressure from the
reclaimer.
Check that the pressure gauge registers
zero. Release any remaining pressure from
the delivery side of the reclaimer element
by slackening the pipe connection to the
differential pressure switch at the reclaimer
end. Release any residual pressure from
the upstream side of the reclaimer element
by slowly slackening the oil filler plug on the
reclaimer. Tighten the plug.
2.3 Air Intake Filter
Clean intake air is essential for satisfactory
operation of the unit. Any ingress of unfiltered air
will result in a reduction in the service life of the
separator element.
Particular care should be taken during routine
servicing to ensure that unfiltered air cannot bypass
the air intake filter element via unsound joints and
defective trunking, etc.
L120SR only
A visual indicator is fitted which shows the condition
of the filter. In dirty conditions this may indicate a
reduction in element life.
page 51
CompAir

2.3.1 To Change the Air Filter Element:

1 2
The compressor must be stopped.

1. Remove the side panel or open the hinged

door (according to model) to gain access to
the intake air filter.
7
2. Remove the clips from the air intake filter and
withdraw the element.

3. Clean out the inside of the filter body

6
3. Fit the new element , secure the clips and refit
the side panel or close the door.
5 3

2.4 Oil Separator Filters (L45SR) 4 HW 0046

The separator filters have a nominal service life of 1 Manifold block 5 Plug
4000 hours under normal operating conditions. 2 Pressure gauges 6 Oil drain valve
3 Separator filters 7 Control air
Adverse operating conditions or failure to carry out 4 Oil filter isolating valve
regular maintenance and/or correct operating
procedures will affect the service life of the element.
MANIFOLD BLOCK AND FITTINGS (L45SR)

2.4.1 To Check the Differential Pressure across

the Separator Filters 2.4.2 To Change the Separator Filters:

1. Ensure the compressor is running at working The compressor must be stopped.

pressure and temperature.
1. Open the door to the service area to gain
2. Open the access door to the service area. access to the manifold block.

3. 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.

4. If the pressure difference exceeds 1 bar 2. Unscrew the old separator filters from the
renew the separator filters. manifold block and discard the filters and
sealing rings.

3. Apply a light film of oil to the seal of the new

filters.

4. To fit the new filters, screw into the manifold

block until the gasket contacts the sealing
surface. Then tighten a further 1/3 turn.

5. Close the service area door.

page 52

2.5 Reclaimer (L75SR and L120SR)
Condensate will collect in the reclaimer as the
compressor cools after shut-down and should be
drained off at the intervals specified in the
Schedule. Draining the condensate must be carried
out only when the compressor is cold.
CAUTION: Regular draining of condensate from the
reclaimer is essential in order to avoid oil
contamination and eventual problems in the user’s
system
2.5.1 To Drain the Condensate
The compressor must be stopped.
To drain the condensate from the reclaimer, slowly
crack open the reclaimer drain point (1) until
condensate starts to flow out. As soon as the flow
becomes clear oil, close off the drain.
1
HW 0017
RECLAIMER CONDENSATE DRAIN
If the compressor is operating in conditions of high
humidity experience may show that it is necessary
to drain the condensate more frequently than
specified.
LSR Series User Manual – Maintenance
2.6 Reclaimer Element (L75SR and L120SR)
A filter element within the reclaimer recovers oil
carried in the delivery air before it is passed to the
aftercooler and the user’s pipework. The element
has a maximum service life of 8000 hours. This
figure is based on ideal operating conditions and if
conditions are not ideal it will be necessary to
change the element more frequently.
The service life of the element can be prolonged by
carrying out regular maintenance and correct
operational procedures, but must always be
changed after 8000 hours.
2.6.1 To Check the Differential Pressure Across
the Reclaimer.
L75SR
1. Ensure the compressor is running at working
pressure and temperature.
2. Open the hinged access door.
3. The needle of the Differential Pressure
indicator should be in the green zone of the
scale.
4. If the needle is in the red zone, renew the
reclaimer element.
L120SR
A lamp lights on the panel and the message
‘Change reclaimer element’ is displayed when the
reclaimer element is blocked.
2.6.2 To Change the Reclaimer Element
The compressor must be stopped.
1. Open the hinged access doors and/or roof
panel to gain access to the reclaimer.
2. Drain the oil from the reclaimer. This
procedure is described under 2.9.5 ‘Normal
Oil Change’.
3. Disconnect all pipes from the reclaimer cover.
Disconnect and withdraw the scavenge pipe.
page 53
CompAir

The element may be withdrawn through the

3 access panel in the roof.
2 L120SR: One bolt may be loosened and left
1 in position and used to hinge the cover.

4 Discard the old joint and element.

6. Inspect the underside of the reclaimer cover.

The cover has been treated and should be in
good condition. If not, remove any loose paint
or rust by shot blasting or wire brush
treatment to leave a clean, oil free surface.
Apply one coat of zinc phosphate paint,
ensuring complete coverage to a minimum
thickness of 0·1 mm (0.004”). Allow to dry
5 HW 0018 thoroughly.
1. Scavenge pipe 7. Fit the new element and joint and replace the
2. Air discharge pipe cover (the L120SR joint is glued to the
3. Minimum pressure valve element). Replace all the reclaimer cover bolts
4. Cover and tighten by hand to position the joint
5. Jacking holes correctly.

OIL RECLAIMER 8. Tighten the bolts evenly, following the

tightening sequence, to an initial torque of
4. Disconnect couplings and remove the air 110 Nm / 81 ft.lbf. Check the ‘O’ ring.
discharge pipe from the minimum pressure
valve. 9. Tighten the bolts, following the tightening
sequence, to a final torque of 160 Nm/118
5. Release the reclaimer cover securing bolts ft.lbf (L75SR) or 200 Nm/148 ft.lbf (L120SR).
and remove the cover. If necessary, use three
of the cover bolts in the jacking holes and
tighten down to break the seal. Withdraw the
reclaimer element.

HW 0019

RECLAIMER ELEMENT RECLAIMER COVER BOLT TIGHTENING

SEQUENCE (L75SR)

page 54

7 1
13 9 1.
3 6
15 11
12 16
5 4
10 14
2 8
HW 0021
RECLAIMER COVER BOLT TIGHTENING
SEQUENCE (L120SR)
10. Insert the scavenge pipe through the coupling
in the reclaimer cover and lower it carefully
until it contacts the base of the element.
Withdraw the pipe a distance of 3 mm (1/8”)
and tighten the coupling. The couplings are
fixed length on the L120SR.
11. Re-connect the pipes to the reclaimer cover.
Fit new ‘O’ rings to delivery pipe joints and
retightened the bolts to 100 Nm/74 ft.lbf.
12. Refill the compressor with new oil by following
the procedures under 2.9.5 ‘Normal Oil
Change’.
13. Close the access doors and refit the
enclosure panels.
CAUTION: When the compressor has reached
normal operating temperature, re-tighten the bolts
to the correct torque in the sequence shown.
2.7 Scavenge Strainer (L75SR)
If the scavenge strainer becomes restricted or
blocked it may cause oil to be carried over into the
user’s pipework. It is most important that the
strainer is regularly serviced to allow the scavenge
system to operate correctly.
LSR Series User Manual – Maintenance
2.7.1 To Clean the Scavenge Strainer
The compressor must be stopped.
Remove the scavenge strainer.
2. Remove the strainer screen and clean it
thoroughly, using a proprietary cleaning agent.
3. Refit the clean strainer screen.
2.8 Automatic Condensate Drain (L75SR &
L120SR)
Moisture in the delivery air condenses in the
aftercooler or moisture separator and is drained
automatically by the action of a solenoid operated
valve.
2.8.1 To Check the Operation of the Condensate
Drain Valve (L75SR)
The compressor must be stopped.
Disconnect the users condensate drain connection
at the baseframe and connect a length of tubing to
the base frame connection. Run the tubing to a
suitable container and visually check that
condensate is being released automatically from
the solenoid operated drain valve according to the
‘drain open’ and ‘drain shut’ times set at the
controller. If no condensate is being released check
the electrical circuit and the solenoid valve as
described in the ‘Electrical’ section of the repair
manual. Dispose of any condensate in accordance
with local regulations. Reconnect the condensate
drain line to the compressor.
The L120SR model displays a level-controlled drain
valve fault signal on the panel if the valve is not
functioning correctly. Maintenance should be
carried out by a CompAir Distributor.
page 55
CompAir
2.9 Oil System
2.9.1 Recommended Oil
The compressor is factory filled with CompAir
4000 HR Oil or CompAir FG Lubricant.
1. CompAir 4000 HR Oil
This is a high performance oil with excellent
lubrication and cooling characteristics
formulated to maintain internal cleanliness,
reduce the build-up of deposits on filter
elements and extend component life.
2. CompAir FG Lubricant
A synthetic hydrocarbon based lubricant
which has been specially developed for use
where discharge air may come into contact
with foodstuffs or for reasons of health or
environment. CompAir FG Lubricant meets
the requirements of FDA regulation 21 CFR
178.3570 and is USDA H-1 approved.
The local CompAir distributor will assist in the
selection of an appropriate lubricant and in many
cases will also be able to arrange for regular
sampling of the oil to monitor the condition of the
compressor, and to determine the oil change
intervals to ensure optimum performance.
page 56
2.9.2 To Check the Oil Level: (L45SR)
To view the oil level sightglass (1) , remove the side
panel. When stopped the mimimum level is
indicated when the sightglass is less than half full.
The maximum level is indicated when the sightglass
is full and the oil reaches the bottom threads in the
filler neck. When running on-load the minimum level
is indicated when oil is no longer visible in the
sightglass.
2
1
HW 0022
1. Sight glass
2. Filler plug
CHECKING OIL LEVEL (L45SR)
If necessary top up the separator with oil as follows:
WARNING
● Risk of injury from hot oil under pressure.
The compressor must be stopped.
1. Remove the side panel.
2. Unscrew the filler cap (2).
3. Fill to the correct level with CompAir approved
lubricant.
4. Refit the filler cap and tighten by hand.
5. Refit side panel.
 LSR Series User Manual – Maintenance

CAUTION: Always use the correct grade of oil and
do not mix oils of different types.
2.9.3 To Check the Oil Level (L75SR, L120SR)
With the compressor shut down, the minimum oil
level is indicated when the level is just visible in the
oil level tube on the reclaimer. The maximum level
is indicated when the level reaches the top of the oil
level tube.
2.9.4 To Change the Oil Filter:
The compressor must be stopped.
1. Open the door to the service area or open the
enclosure according to model.
2. Unscrew the old oil filter(s) (3) from the
manifold block or filter housing and discard.

The compressor must be stopped. HW 0024

Note: Check the oil level with the compressor cold.

Allow a minimum of 30 minutes after stopping for
the oil in the system to settle.

1. Open the enclosure to gain access to the

reclaimer.

2. Check the oil level sight glass (1). If the oil

surface is not visible it is too low.

3 Oil filters

OIL FILTERS (L75SR, L120SR)

3. Apply a light film of oil to the seal of the new

HW 0023 element(s) and prime the new filter(s) with oil.

1. Sight glass 4. To fit the new element, screw it into the

2. Filler plug manifold block or filter housing until the gasket
contacts the sealing surface. Then tighten a
CHECKING OIL LEVEL (L75SR, L120SR) further 1/3 turn.

5. Close the service area door.

3. If topping up is required, ensure that the
reclaimer pressure is zero, remove the oil filler 6. Check oil level during initial run and top up if
cap (2) and fill the reclaimer with necessary.
recommended oil to the correct level.

4. Replace the oil filler cap, making sure that the

washer is undamaged and the cap fully tight.

page 57
CompAir

2.9.5 Normal Oil Change

1 2
CAUTION: Always use the correct grade of oil and
do not mix oils of different types.

1. CompAir 4000 HR Oil

Provided the air-end discharge temperature
does not normally exceed 85°C CompAir 4000 7
HR Oil should be changed every 4000 hours
service or 1 year, whichever is sooner.

Where the air-end discharge temperature

regularly exceeds 85°C then a change period 6
of 2000 Hours or 6 months is recommended.
5 3
2. CompAir FG Lubricant
Provided the air-end discharge temperature
does not regularly exceed 85°C CompAir FG 4 HW 0046
Lubricant should be changed every 4000
hours service or 1 year, whichever is sooner. 1 Manifold block 5 Plug
2 Pressure gauges 6 Oil drain valve
Where the air-end discharge temperature 3 Separator filters 7 Control air
regularly exceeds 85°C then a change period 4 Oil filter isolating valve
of 2000 Hours or 6 months is recommended.

Note: Where high dust levels and/or pollution are MANIFOLD BLOCK AND FITTINGS (L45SR)
present the oil must be changed more frequently
and the condition of the intake filtration system 4. Stop the compressor. Wait until the motor has
examined regularly. stopped rotating before proceeding.

5. Remove the drain tap plug (5) and connect a

To Change the Oil and Oil Filter: L45SR
To drain the oil, the system must (a) be pressurised
or (b) an alternative source of compressed air must
be available.
hose (minimum 10 mm (3/8”) bore) to the drain
tap (6) and place the open end into a suitable
container.

CAUTION: Always use the correct grade of oil and

WARNING
do not mix oils of different types.
● Risk of injury from hot oil under pressure.
Method (a)

1. Run the compressor on load to pressurise the

system.
2. Open the door to the service area.
3. Close the control air isolating valve (7),fitted to
the side of the manifold block (lever to the
vertical position) and the isolating valve in the
user's system.
Note: A minimum of 4 bar (60 psi) must be
maintained in the compressor unit prior to carrying
out the oil drain procedure.
6. Slowly open the drain tap and allow the oil to
drain into the container for disposal.
7. Close the drain tap, disconnect the hose, and
remove the container . Refit the drain tap plug.
8. Open the control air isolating valve (7) (lever
to the horizontal position) and allow any
pressure to be released through the normal
blowdown process.

page 58
 LSR Series User Manual – Maintenance

9. Remove and discard the old oil filter
element (4).
10. Prime the new filter with oil.
11. Apply a film of clean oil to the seal of the new
oil filter element. Screw the element into the
housing until it contacts the gasket and
tighten a further 1/3 turn.
12. Fill the separator to the correct level with
CompAir approved lubricant, refit the filler cap
and tighten by hand.
13. Open the isolating valve to the user's system.
8. Close the air supply through the filler tube,
open the control air isolating valve (lever to
the horizontol position) and allow any pressure
to be released through the normal blowdown
process.
9. Remove and discard the old oil filter
element (4).
10. Prime the new filter with oil.
11. Apply a film of clean oil to the seal of the new
oil filter elements. Screw the elements into the
housing until they contact the gasket and
tighten a further 1/3 turn.

14. Run the compressor until it reaches working 12. Fill the separator to the correct level with
temperature to ensure full circulation of the oil. CompAir approved lubricant, refit the filler cap
and tighten by hand.
15. Check the oil level and top up as necessary.
13. Open the isolating valve to the user's system.
Method (b)
14. Run the compressor until it reaches working
1. Open the door to the service area. temperature to ensure full circulation of the oil.

2. Close the control air isolating valve, fitted to 15. Check the oil level and top up as necessary.
the side of the manifold block (lever to the
vertical position) and the isolating valve in the
user's system.

3. Ensure that all pressure has been released

from the oil separator, remove the filler plug
and fit a suitable connector to the neck of the
filler pipe for the air supply.

4. Apply pressure to the compressor unit

(minimum of 4 bar or 60 psi).

5. Remove the plug and connect a hose

(minimum 10 mm (3/8”) bore) to the drain tap
and place the open end into a suitable
container.

WARNING

● Risk of injury from hot oil under pressure.

6. Slowly open the drain tap and allow the oil to

drain into the container for disposal.

7. Close the drain tap, disconnect the hose and

remove the container. Refit the drain tap plug.

page 59
CompAir
To Change the Oil and Oil Filter: L75SR
To drain the oil the system must be pressurised.
CAUTION: Always use the correct grade of oil and
do not mix oils of different types.
The compressor must be stopped.
WARNING
● Risk of injury from hot oil under pressure.
1. Open the door to the service area
2. Close the control air isolating valve (fitted on
top of air end).
1
2 8.
3 normal blowdown process.
HW 0026
1. Control air isolating valve
2. Air end
3. Intake air filter
CONTROL AIR ISOLATING VALVE (L75SR)
3. Run the compressor for a short time to
pressurise the reclaimer to a minimum of 4 bar
(60 psi) prior to carrying out the oil drain
procedure. Stop the compressor and close the
isolating valve between the compressor and
the user system
4. Ensure that the reclaimer drain tap is closed.
page 60
5. Remove the plug and connect the Oil Drain
Pipe Kit and a hose (minimum 15 mm (5/8”)
bore) to the drain tap and place the open end
into a suitable container.
6. Slowly open the drain tap and allow the oil to
drain into the container for disposal.
1
HW 0017
OIL DRAIN TAP (L75SR)
7. Close the reclaimer drain tap, disconnect the
Oil Drain Pipe Kit and hose and remove the
container.
Open the control air isolating valve and allow
any pressure to be released through the
9. Remove and discard the old oil filter elements.
10. Apply a film of clean oil to the seal of the new
oil filter elements. Screw the elements into the
housing until they contact the gasket and
tighten a further 1/3 turn.
11. Fill the reclaimer to the correct level with
CompAir approved lubricant, refit the filler cap
and tighten securely.
12. Open the isolating valve to the user's system.
13. Run the compressor until it reaches working
temperature to ensure full circulation of the oil.
14. Stop the compressor, check the oil level and
top up as necessary.

To Change the Oil and Oil Filter: L120SR 4.
To drain the oil, it is recommended that the system
be pressurised. However, the L120SR may be also 5.
drained under gravity.
CAUTION: Always use the correct grade of oil and
do not mix oils of different types.
The compressor must be stopped.
WARNING
● Risk of injury from hot oil under pressure.
1. Open the door to the service area
2. Close the control air isolating valve (painted
red and fitted to the top of the reclaimer).
6.
7.
HW 0025
CONTROL AIR ISOLATING VALVE (L120SR) 8.
3. The oil may be drained under pressure or by 9.
gravity. To drain under pressure, run the
compressor up to 7 bar/102 lbf/in2 and stop.
Immediately open access door and close
hand valve adjacent to blowdown (see
illustration), then proceed as for gravity drain. 10.
Beware of hot surfaces. Beware of hot
pressurised oil. On completion, open
blowdown hand valve. 11.
12.
13.
LSR Series User Manual – Maintenance
Ensure that the reclaimer and oil cooler drain
taps are closed.
Put reclaimer and cooler drain hoses into a
container, open taps and allow oil to drain.
HW 0027
1
2
1. Reclaimer oil drain
2. Oil cooler drain
OIL DRAIN POINTS (L120SR)
Close the reclaimer and cooler drain taps,
replace the hoses and remove the container.
Open the control air isolating valve and allow
any pressure to be released through the
normal blowdown process.
Remove and discard the old oil filter elements.
Apply a film of clean oil to the seal of the new
oil filter elements. Screw the elements into the
housing until they contact the gasket and
tighten a further 1/3 turn.
Fill the reclaimer to the correct level with
CompAir approved lubricant, refit the filler cap
and tighten securely.
Open the isolating valve to the user's system.
Run the compressor until it reaches working
temperature to ensure full circulation of the oil.
Stop the compressor, check the oil level and
top up as necessary.
page 61
CompAir

2.9.6 To Change the Oil Type
No special precautions are required when changing
from a detergent mineral oil to CompAir 4000 HR
Oil or CompAir FG Lubricant or changing within
these grades. The system should be drained and
refilled as described under 2.9.5 ‘Normal Oil
Change’.
2.10 Minimum Pressure Valve
The servicing of the Minimum Pressure Valve
should be carried out by a CompAir Distributor.
4. L120SR: Clean cooler fins using low pressure
air or water as follows
(a) Remove cooler end panel and both side
panels.
(b) Open access doors as necessary and
clean coolers from inside the plant using
low pressure air (up to 2 bar/29 lbf/in2) or
water. Do not use excess pressure as
cooler tubes may be damaged.
5. Remove any dirt or liquid from the baseframe.
6. Replace access and enclosure panels and
close door(s).

2.11 Oil Cooler and Aftercooler The servicing of the Oil and After Coolers should be
carried out by a CompAir Distributor.
To Clean Coolers Externally

The condition of the cooler fins must be checked
regularly. To clean the fins proceed as follows:The
compressor must be stopped
1. Allow the compressor to cool for 30 minutes.
2.12 Flexible Hoses
When fitting flexible hoses the nuts should be
tightened using the torque appropriate to the nut
sizes.

2. L45SR: Open enclosure service door and

remove access panel on cooling duct. BSP Size Torque
Remove enclosure panel in front of coolers.

Clean the cooler fins from inside the duct 0.5 in 44 Nm/32 ft.lbf
using an air hose and oil-free compressed air 0.75 in 84 Nm/62 ft.lbf
from inside the machine. 1.0 in 115 Nm/85 ft.lbf
1.25 in 189 Nm/139 ft.lbf
If it is required to wash the coolers, they must 1.5 in 244 Nm/180 ft.lbf
first be removed from the machine. 2.0 in 297 Nm/219 ft.lbf

3. L75SR: Clean cooler fins with an air hose as

follows
2.13 Scavenge Tube
(a) Ensure power is isolated and locked off.
The translucent tube should be changed at the
(b) Remove fan guard and use low pressure 8000 hour service interval.
air to clean coolers from inside the
machine.

(c) Replace fan guard.

(d) Replace panels.

If it is required to wash the coolers, they must

first be removed from the machine.

page 62

2.14 Electrical System
WARNING
● Refer to the safety procedures before
operating the compressor unit.
● Lethal voltages are used in this
equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.
● Before opening the door of the power
converter compartment, switch the
power supply OFF at isolator and wait
for 12 minutes to allow the dc link
capacitors to discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.
Carefully inspect all the electrical wiring and check
the security of all connections and terminals.
LSR Series User Manual – Maintenance
2.15 Electric Motors
2.15.1 Motor Bearings
The main drive motor and cooling fan motor are
fitted with sealed bearings which are double
shielded and pre-packed with grease. These
bearings do not require periodic re-lubrication but
should be renewed after 32000 hours of operation
in normal environments.
Note: This work should be carried out by a
CompAir distributor.
2.15.2 Motor Cooling
Ensure that the motor cooling intake grille is kept
clear of debris at all times
2.16 Non-Return Valve
The servicing of the Non-Return Valve should be
carried out by a CompAir Distributor.
page 63
CompAir

page 64
 LSR Series User Manual – Fault Finding

FAULT FINDING

The controller has a memory facility that retains a
fault history. Details of 15 previous situations can
be displayed, including the fault message together
with recorded hours, compressor state (standby,
on-load, off-load etc.), oil temperature and air
pressure.
In operation the compressor is protected by circuits
which are triggered when a fault arises and either
cause the compressor to shut down or indicate that
a servicing action is required.

WARNING

● Refer to the safety procedures before
carrying out any fault finding
investigation on the compressor unit.
● Lethal voltages are used in this
equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.
● Before opening the door of the power
converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting work on the compressor.

1. SHUTDOWN MESSAGES

Message Displayed Possible Cause Action Required

Emergency stop (1) Emergency stop switch (1) Check cause of fault and
operated. rectify. Turn Emergency Stop
switch to release latch. Press
RESET.
(2) Starter circuit fuse F2 blown. (2) Check cause and rectify.

Fan motor fault
(1) Insufficient cooling air flow. (1) Inspect/clean: enclosure
filter; ducting; air/oil cooler
matrix; motor cooling air intake.
(2) High ambient temperature. (2) Check room ventilation.
(3) Low voltage/high current. (3) Check power supply.
(4) Circuit breaker MCB2 (4) Check setting and reset.
incorrectly set.
(5) Starter circuit breaker (5) Check starter circuit
MCB2 open. breaker.
(6) Fan motor thermistor fault. (6) Check thermistor.
(L45SR and L75SR)
(7) Fan motor overload (L120SR) (7) Check motor/fan. replace if
necessary.

page 65
CompAir

Message Displayed Possible Cause Action Required

Heat sink temp HI (1) Panel filters blocked (1) Clean/renew filters
(2) Heat sink dirty (2) Clean heat sink
(3) Heat sink fan faulty (L120SR) (3) Check motor/fan. replace if
necessary.

High air pressure (1) High pressure in user system (1) Check settings of other
compressors in system.
(2) Compressor fails. (2) Check operation of venting
valve and solenoid operated
bypass valve. Renew if
necessary.
(3) Pressure transmitter fault. (3) Check/renew pressure
Transmitter.
(4) Controller fault. (4) Renew controller.

High oil temp fault (1) Fan rotation incorrect. (1) Check/rectify wiring.

(2) Insufficient cooling air flow. (2) Inspect/clean: enclosure

(3) High ambient temperature.
(4) Poor electrical connection or
Air/oil thermistor fault.
(5) Low oil level.
(6) Incorrect grade of oil.
(7) Oil stop valve not opening.
(8) Oil cooler bypass valve fault.
(9) L120SR only - Enclosure door
open.
filter; ducting; air/oil cooler
matrix.
(3) Check room ventilation.
(4) Rectify/renew.
(5) Check for leaks and rectify.
Top up reclaimer to correct level.
(6) Drain/flush oil system. Clean
scavenge strainer. Renew
reclaimer separator and oil filter
elements. Refill the system
with the recommended oil.
(7) Rectify or renew valve.
(8) Rectify or renew valve.
(9) Close door.

Del Press probe fault (1) Appropriate pressure (1) Renew appropriate pressure
transmitter fault. transmitter.
(2) Sensor wiring fault. (2) Check and rectify fault.
Reclaimer P probe fault (3) Controller fault. (3) Renew controller.

Remote fault 1, 2 or 3 Appropriate input was open Check conditions (Type 1, 2

circuit whilst conditions met. or 3) are appropriate.
Check auxiliary equipment
Check/rectify wiring.

page 66
 LSR Series User Manual – Fault Finding

Message Displayed Possible Cause Action Required

SR motor high temp fault (1) Insufficient cooling air flow. (1) Inspect/clean: enclosure filter;
ducting; motor cooling air
intake.
(2) High ambient temperature. (2) Check room ventilation.
(3) Fan operation/rotation incorrect. (3) Check and rectify electrical
circuit.
(4) Controller fault (4) Renew controller.

Temperature probe fault (1) Temperature sensor fault. (1) Renew temperature sensor.
(2) Temperature sensor wiring fault (2) Check and rectify.
(3) Controller fault. (3) Renew controller.

2. WARNING MESSAGES

Message Displayed Possible Cause Action Required

Change air filter (1) Intake air filter blocked. (1) Check/renew element.
(2) Filter pressure switch fault. (2) Check operation. Renew if
necessary.
(3) Filter pressure switch wiring (3) Check and rectify.
fault.

Change reclaimer (1) Reclaimer filter blocked. (1) Check/renew element

element (2) Pressure transmitter fault (2) Check and rectify.

Check reclaimer dp (1) Service interval expired (1) Check reclaimer differential
pressure.
(2) Renew element if required.

High oil temp alarm See High Oil Temp Fault

page 67
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. reset timer.

Start inhibited A start inhibit function is An input configured for start

active. inhibit is open circuit.

The following chart will enable the user to identify other faults which may occur.

3. FAULT FINDING CHART

Indication Possible Cause Action Required

Compressor fails to run (1) Pressure transmitter faulty. (1) Adjust to correct setting.
off-load. Renew if necessary.
(2) Solenoid bypass valve faulty. (2) Find cause and rectify or
renew.
(3) Electrical wiring fault. (3) Find cause and rectify or
renew.

Compressor fails to (1) Solenoid bypass valve (1) Rectify/renew valve.

run on-load. faulty.
(2) Pressure transmitter faulty. (2) Adjust to correct setting.
Renew if necessary.
(3) Electrical wiring fault. (3) Find cause and rectify.

Excessive oil (1) Leaks in oil system. (1) Examine system. Rectify if
consumption. necessary.
(2) Oil carried into user’s
pipework caused by:

(a) Reclaimer element (2) (a) Check pressure drop

defective. across element. Renew
element if necessary.
(b) Scavenge oil orifice (b) Clean scavenge strainer
adaptor restricted. and orifice adaptor.
(c) Incorrect grade of oil. (c) Drain the system, flush and
re-fill with an approved oil.
(continued)

page 68
 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.

Low delivery air (1) Pressure transmitter
pressure. incorrectly set or faulty.
(2) Pressure relief valve leaking.
(3) Demand exceeds compressor
rating.
(4) Compressor speed reduced
owing to high heat sink
temperature.
(1) Adjust to correct setting.
Renew if necessary.
(2) Check/renew seals.
Renew valve if necessary.
(3) Check for system leaks and
rectify. Review user’s air
requirements.
(4) Clean panel filters.
L120SR only: Check panel
fan.

page 69
CompAir
ELECTRICAL SYSTEM
WARNING
● Refer to the safety procedures before
operating the compressor unit.
● Lethal voltages are used in this
equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.
Note: Any work on the electrical system should be carried out by a CompAir Distributor
1. REMOTE CONTROL AND MONITORING
CONNECTIONS
Three remote input options and three (five on
L120SR) remote output options are available. The
cable connections required are shown as broken
lines on the controller digital inputs and outputs on
the electrical connection diagrams on pages
73 to 82.
1.1 Inputs
CAUTION: Do not connect any input terminal pin to
a voltage source other than X3/1 as this will result
in permanent damage to the module.
Each of the three inputs is activated by connecting
the appropriate terminal pin to the input terminal X3/
1.
This can be achieved by connecting the input pin
and the common terminal to a volt free remote
switch, relay contact, PLC output or any switching
device.
Note: Remote input cables must be at least 1.0
mm2 in size. The maximum cable length from the
compressor to a remote device must not exceed
800 metres.
1.1.1 The function of some digital inputs are
configurable. These are:
Input X01/6 Message: ‘Remote Fault 1’ unless
Pressure Range Select selected
page 70
● Before opening the door of the power
converter compartment, switch the
power supply OFF at isolator and wait
for 12 minutes to allow the dc link
capacitors to discharge to a safe level.
Check that the dc link capacitors have
fully discharged before starting work on
the compressor.
Input X01/7 Message: ‘Remote Fault 2’ unless
Remote Start/Stop selected
Input X01/4 Message: ‘Remote Fault 3’
The functions available are defined below and may
be selected using the Remote Control Config menu
within the Commissioning Config Menu.
Default functions are assigned to each input and
some functions are only available on specified
inputs.
1.2 Configurable Input Functions
1.2.1 Pressure Range Select
This is available on input X01/6 only and is the
default function for this input.
Connecting to the pressure range select input
enables the selection of a secondary set of Target
and Off-load pressure set points. Using a suitable
external timer this input can be used to vary the
operating pressure of the compressor at different
times. This facility enables energy savings to be
made during periods when a lower compressed air
network pressure can be used.
1.2.2 Remote Start/Stop
This is available on input X01/7 only and is the
default function for this input.

Connecting to the remote start/stop input enables
starting and stopping of the compressor from
remote equipment.
When this function is selected an open connection
on this input will cause a remote stop and a link is
necessary for keypad start.However the Remote
Start function is by default disabled and needs to be
enabled (separate menu item) for the remote start
function to operate.
With Remote Start enabled, the keypad start button
is disabled and needs to be enabled (separate
menu item) for the remote start function to operate.
With Remote Start enabled, the keypad start button
is disabled and a closing contact on this input will
cause a machine start.
Also note that selecting another function for this
input will automatically disable the Remote Start
and Remote Stop functions; an open connection will
not cause a stop.
1.2.3 Trip Type 1
An open connection will cause a trip at all times.
1.2.4 Trip Type 2
An open connection will cause a trip when the
motor is running.
1.2.5 Trip Type 3
An open connection will cause a trip when status is
‘Onload’ or ‘Offload’.
1.2.6 Alarm Type 1
An open connection will cause an alarm at all times.
1.2.7 Alarm Type 2
An open connection will cause an alarm when the
motor is running.
1.2.8 Alarm Type 3
An open connection will cause an alarm when
status is ‘Onload’ or ‘Offload’.
1.2.9 Start Inhibit
Will prevent a compressor from starting when a
fault is sensed but will not stop a compressor if
already started. When activated the display will
show ‘Start Inhibited’.This function is not a
shutdown trip or alarm and will only function while
the connection is open. It is not recorded in the
Fault History log.
LSR Series User Manual – Electrical System
1.3 Outputs
1.3.1 Configurable Outputs
(a) Outputs on pins X09/2, 3 & 4
These three configurable outputs are transistor
switched and only suitable for driving low current
(50mA each max) 24v DC devices. A DC interface
relay must be used (see 1.3.2)
(b) Outputs on pins X08/5 & 6 and X08/9 & 10
(L120SR only)
These two additional outputs are relay outputs
providing a normally open contact only. Note,
therefore, that some functions (e. g. Group Trip) are
energised for healthy and the relay will present a
closed contact for OK.
As supplied, these contacts are connected to the
24v AC ancillary equipment system supply and are
suitable for driving 24v AC devices subject to the
total load on the transformer. It is, therefore,
recommended that 24v AC interface relays are
used connected between X08/6 or X08/10 and
terminal X1/1.
If VOLTFREE contacts are required for use with an
externally supplied device, then the power supply
link between X08/5 or X08/9 and terminal X2/1
MUST be removed. The external monitor should be
connected directly to the appropriate contact pair
(X08/5 & 6 or X08/9 & 10). Contacts are rated at
250c AC 8A.
1.3.2 Output Relays
The outputs are 24v dc transistor switched with a
maximum rating of 25mA and an interface relay
must be used. Each output must be connected
directly to a relay module, as specified below, in
order to achieve a relay contact output suitable for
remote applications external to the compressor
starter enclosure.
Parts required for each additional output:
Qty Description Part Number
1 Relay - 24 V dc 98475-64
1 Relay Base 98475-65
page 71
CompAir
1.3.3 Relay Specification
Single switching contact with a common, normally
open (N/O) and normally closed (N/C) connection
rated at 250V - 5 Amps maximum.
Note: The relay 24V dc coil is not bi-directional and
must be connected to controller output as follows :
1. Relay terminal ‘5’ must be connected to pin
X09/1.
2. Relay terminal ‘1’ must be connected to pin
X09/2, 3 or 4 as appropriate.
The functions available are defined below and may
be selected using the Remote Control Config menu
within the Commissioning Config Menu.
Default functions are assigned to each output.
An interface relay must be used with these outputs -
see Electrical Section for connection information.
1.4 Configurable Output Functions
1.4.1 Group Fault
This is the default for output X09/2.
A group fault output will be energised when power
is applied and no alarm or trip conditions are
detected.
The output will de-energise when an alarm including
service due, a shutdown trip or power loss occurs.
1.4.2 Available
This is the default for output X09/3
A compressor available output will energise when
the compressor is ‘running’ or in the ‘standby’ state.
This output indicates that the compressor has been
started and is available to automatically respond to
a fall in system pressure without manual
intervention.
1.4.3 Group Alarm
A group alarm output will be energised when power
is applied and no alarm condition is detected. The
output will de-energise when an alarm or power
loss occurs.
page 72
1.4.4 Group Trip
This is the default for output X09/4
A group trip output will be energised when power is
applied and no trip conditions are detected.
The output will de-energise when a shutdown trip or
power loss occurs.
1.4.5 Service Due
The service due output will energise when the
service hours countdown timer has reached zero
hours and a routine service is due.
1.4.6 Group Alarm + Trip
A group trip + alarm output will be energised when
power is applied and no alarm or trip conditions are
detected.
The output will de-energise when an alarm
excluding service due, a shutdown trip or power
loss occurs.
1.4.7 Running
A running output will energise when the compressor
main motor is running.
1.4.8 On Load
The on load output will energise when the
compressor is on load.
1.4.9 Low Temperature Alarm
A Low Temperature Alarm output will energise
when the Low Temperature Alarm is active.
1.5 4-20mA Compressor Speed Output
An output (X21/3 & 4) is provided to enable remote
monitoring of compressor speed. The output range
is from 4mA (0 rev/min) to 20mA (5000 rev/min).
1.6 RS485 Communications
The SureScan control unit is compatible with the
electrical RS485 communications standard. The
communication parameters are:
9600 baud, 8 data bits, no parity and 1 stop bit.
The message protocol is a proprietary multimaster
protocol compatible with the SmartAir Air Systems
Control Units and with the Active Network Interface
for connection to PCs etc.
 C1 C4 POWER SWITCHING IGBT'S
L2
C5 C8
G E C G E C G E C G E C

[PK]

[PK]
[PK]

[PK]

[PK]
[PK]

(154)
(161)

(152) [PK]

(151)
(160)

(157)
(156) [VLT]
(158) [PK]

(155)

(153) [VLT]

(150) [VLT]

(107) [BK]
(159)[VLT]

(108) [BK]
(109) [BK]
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

RESISTOR/VDR A1 B1 A2 B2
(143)
(A1)

(A2)
(B2)
(B1)

3
P.C.B
(142) CUR

2
PCB1 SENS 5
(141)

1
GATE DRIVE BOARD

[BK]
[BK]
(117)
[BK]
R101 PCB2

(116)

(115)
(148)

2
HEATSINK
(149)

RLB
TEMP SENS LINK

1
22 2/03

7 6 5 4 3 2 1

[BK]

[BK]

[BK]
(112B)

(111B)

(110B)
(135) A2 B2 A1 B1
(134)

(136) [BL]

(139) [R]

(140) [R]
(137) [BL]
4
M102
2/03

[BK]

[BK]

[BK]
(110C)
(111C)
(112C)
SW1/A

[R]
(144) SW1/B (138) [R]
(E)

RLA
RLB
[R]

[R]
(126B)

(139) [R] 2/02

(126A)

(131) [R] 24V~

2/02
(124) [R] 0V~
2/02
(132) [R] 24V~
2/02
(126) [R] 0V~
2/02
(133) [R] 24V~
2/02
(128) [R] 0V~
2/02

[126E] (E)
[R] 2/02

ELECTRICAL CONNECTION DIAGRAM - L45SR (1 OF 3)

SAFETY GUARD
[G/Y]
GATE DRIVE P .C.B
[G/Y]
HEATSINK
[G/Y]
CAPACITOR TRAY
[G/Y]
STARTER BOX
[G/Y]
BASE FRAME
DOOR

EARTH
HW 0028
BAR

page 73
LSR Series User Manual – Electrical System
page 74
CompAir

24V~ (131)
<1/34> [R]
0V~ (124)
<1/34> [R]
(E)
<1/34>
24V~ (132)
<1/34> [R]

24V~ (133)
<1/34> [R]
0V~ (128)
<1/34> [R]

S201/1
<1/34> 4

1 2 1 2
X22 CONTROLLER AC1 AC2 CONTROLLER
SR X20 RELAY OUTPUT X03 DIGITAL OUTPUT
CONTROLLER
X23

[R]
<1/34> 22

(210A)
X21 X08 X09
R1 R2 R3 R4 R5
1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4

[R]
[R]
[R]

(210B)
(210E)

(210C)
X2/1 X2/1 X2/1

[R]
[R]
[R]

(139)
(211)
(213)

RLC
Y202

ELECTRICAL CONNECTION DIAGRAM - L45SR (2 OF 3)

(139)
[R]
[R]
(126F)

(126C)

[R] <1/34>
(126) 0V~
[R] <1/34>
X1/1 X1/1 HW 0029
 CONTROLLER CONTROLLER
DIGITAL INPUTS ANALOG INPUTS

X01 X02
VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8 VA+ ANA1 ANA2 ANA3 ANA4 VA-
1 2 3 4 5 6 7 8 9 E 1 2 3 4 5 6 E

(E) (E)

[BK]
(310)
(311)
[CR]
[BK]
[CR]
(313)

(312)

[BL]

[BL]
[BL]

(301)
(309)

[BL]
[BL]

(302)
[BL]

(303)
(301C)

(301E)
SW2
Key to Components (diagrams 1 to 3)
Reference Name
EMC1 EMC FILTER
F1 FUSE, 2A TYPE T
F2 FUSE, 5A ANTI-SURGE

K101
F3 FUSE, 3.15A SEMI-DELAY

S302

S201/2
K101 PHASE FAILURE RELAY
L1 LINE REACTOR
L2 CURRENT TRANSDUCER
L208 SPEED SENSOR - MOTOR
T1 M102 MOTOR - MAIN DRIVE

<1/06>
1 MCB1 CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A
MCB2 CIRCUIT BREAKER - FAN 10A
P301 PRESSURE TRANSMITTER - DELIVERY PRESSURE
R301

PCB1 RESISTOR/VDR PCB

P301
T2 R101 TEMPERATURE SENSOR - HEATSINK
2 R301 SENSOR - OIL TEMPERATURE

ELECTRICAL CONNECTION DIAGRAM - L45SR (3 OF 3)

<1/07>
RLA CONTACTOR - MAIN
RLB CONTACTOR DC LINK CHARGING
RLC CONTACTOR - FAN
S302 SWITCH - AIR FILTER DP
SW1 AUXILIARY CONTACTS
T101 CONTROL TRANSFORMER

[BL]
Y202 VALVE SOLENOID - BYPASS

[BL]
[BL]

[BL]
(301B)
(301D)
(301E)

(301A)
Note:- Details of Control Panel components
20V- are supplied inside the Power Converter Box
X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 HW 0030

page 75
LSR Series User Manual – Electrical System
page 76
VDR1
CompAir

L1 RLA
L2
U (101) (104)
[BK] [BK]
C1 C5
V (102) (105) POWER SWITCHING IGBT'S
[BK] [BK]
C6 C10
W (103) (106) C E C G E C G E C G E C

POWER
BRIDGE
RECTIFYER
[BK] [BK]
PE

[PK]

FUSED ISOLATOR

INCOMING SUPPLY
FROM CUSTOMERS
(160)

[PK]
[PK]

[PK]
[PK]
[PK]
(157)
[PK]

(154)
[VLT]

(155)
(156)

(153)
[VLT]

(152)

(151)
[VLT]
(161)

(150)
(158)
(159)
[PK]

[BK]

[BK]
[BK]
(109)

(108)

(107)
[VLT]
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
(B2)
(A2)
(B1)

A2
(A1)

A1 B1 B2
RESISTOR/VDR
(143)

3
P.C.B CUR
(142) SENS 5

MCB1 3A

MCB2 10A
PCB1
(141)

1
GATE DRIVE BOARD
R101
(148)

[BK]
[BK]
[BK]

(116)

(115)
(117)
HEATSINK PCB2
(149)

[BK]
[BK]
[BK]

[BK]
[BK]
TEMP SENS

(113)
1
LINK

(114)
<2/03>

(111A)
(112A)

(110A)
22

RLB
7 6 5 4 3 2 1
(110B)
[BK]
(111B) A1 B1 A2 B2

[R]
[BK]

[R]

[R]
[BL]
[BL]
(135)
(134)

(137)
(136)

(138)

(140)
(139)
(112B)
[BK]
4
M102
<2/03>
SW1

SW1

[BK]

[BK]
[BK]

(111C)

(110C)
(112C)
m<3 L1 L2 L3
[R]

(E)
(144)

RLC
L2 K101
RLB

L3
RLA

PHASE FAILURE (139)

T101
RELAY [R] <2/02>
[R]

280VA F1 2A
[R]

(126A)
(126B)

(114) 460V 24V (123) (131) (131) 24V~

[BK] [R] [R] [R] <2/02>
30VA
OV (124) (124) 0V~
M101 [R] [R] <2/02>
(E) 3~ F2 5A
R 24V (125) (132) (132) 24V~
[R] [R] [R] <2/02>
200VA X1/1
OV (126) F2 5A (126) 0V~
[R] [R] <2/02>
F3 3.15A X1/1 X1/1
24V (127) (132) (133) 24V~
[R] [R] [R] <2/02>
50VA

<3/15>
<3/15>
(113) OV OV (128) (128) 0V~
[BK] [R] [R] <2/02>
T1 T2 (E)

ELECTRICAL CONNECTION DIAGRAM - L75SR (1 OF 3)

(126E) (E)
[R] [R] [R] <2/02>
SAFETY GUARD
[G/Y]
GATE DRIVE P.C.B
[G/Y]
HEATSINK
[G/Y]
CAPACITOR TRAY
[G/Y]
STARTER BOX
[G/Y]
BASE FRAME
DOOR

EARTH
HW 0031 BAR
 24V~ (131)
<1/34> [R] HW 0032
0V~ (124)
<1/34> [R]
(E)
<1/34>
24V~ (132)
<1/34> [R]

21V~ (133)
<1/34> [R]
0V~ (128)
<1/34> [R]

S201/1
<1/34> 4

1 2 1 2
X22 CONTROLLER AC1 AC2
CONTROLLER
SR X20 RELAY OUTPUT X03 DIGITAL OUTPUT
X23 CONTROLLER

[R]
<1/34> 22

(210A)
X21 X08 X09
R1 R2 R3 R4 R5
1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4

[R]
[R]
[R]

[R]

[R]
(210E)

(210D)
(210F)

(210B)
(210C)
X2/1 X2/1 X2/1 X2/1 X2/1
[R]
[R]

[R]
[R]
[R]
(213)
(214)

(211)

(139)
(212)

RLC
Y201
Y203

Y202

ELECTRICAL CONNECTION DIAGRAM - L75SR (2 OF 3)

[R]

[R]
[R]
[R]
(126F)

(126C)
(126D)
(126E)

(139)
[R] <1/34>
(126) 0V~
[R] <1/34>
X1/1 X1/1 X1/1 X1/1

page 77
LSR Series User Manual – Electrical System
page 78
CompAir

CONTROLLER CONTROLLER
DIGITAL INPUTS ANALOG INPUTS

X01 X02
VCONT CONT1 CONT2 CONT3 CONT4 CONT5 CONT6 CONT7 CONT8 VA+ ANA1 ANA2 ANA3 ANA4 VA-
1 2 3 4 5 6 7 8 9 E 1 2 3 4 5 6 E

(E) (E)

[BK]

[BK]
[CR]

[BL]

[BL]
[CR]

(310)

[BL]
[BL]
(309)
(311)
(312)

[BL]
[BL]
(308)

(302)
(313)

(305)

(303)
(301C)
SW2
Key to Components (diagrams 1 to 3)
Reference Name
EMC1 EMC FILTER
F1 FUSE, 2A TYPE T
F2 FUSE, 5A ANTI-SURGE
F3 FUSE, 3.15A SEMI-DELAY
K101 PHASE FAILURE RELAY

K101

S302
S304
L1 LINE REACTOR

S201/2
L2 CURRENT TRANSDUCER
L208 SPEED SENSOR - MOTOR
M102 MOTOR - MAIN DRIVE
MCB1 CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A
T1
1 MCB2 CIRCUIT BREAKER - FAN 10A

<1/06>
P301 PRESSURE TRANSMITTER - DELIVERY PRESSURE
PCB1 RESISTOR/VDR PCB
R101 TEMPERATURE SENSOR - HEATSINK
R301

P301
R301 SENSOR - OIL TEMPERATURE
T2
2 RLA CONTACTOR - MAIN
RLB CONTACTOR DC LINK CHARGING

<1/07>
RLC CONTACTOR - FAN
S302 SWITCH - AIR FILTER DP

[BL]

[BL]
[BL]
[BL]

[BL]

ELECTRICAL CONNECTION DIAGRAM - L75SR (3 OF 3)

[BL]
S304 SWITCH - EXCESS PRESSURE

(301F)

(301B)

(301A)
(301E)

(301D)
(301H)
SW1 AUXILIARY CONTACTS
T101 CONTROL TRANSFORMER
Y201 SOLENOID VALVE - SCAVENGE
Y202 VALVE SOLENOID - BYPASS
Y203 SOLENOID VALVE - CONDENSATE DRAIN

Note:- Details of Control Panel components

20V- are supplied inside the Power Converter Box
X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 X3/1 HW 0033
 LSR Series User Manual – Electrical System

HW 0034

ELECTRICAL CONNECTION DIAGRAM - L120SR (1 OF 4)

page 79
CompAir

HW 0035

ELECTRICAL CONNECTION DIAGRAM - L120SR (2 OF 4)

page 80
 LSR Series User Manual – Electrical System

HW 0036

ELECTRICAL CONNECTION DIAGRAM - L120SR (3 OF 4)

page 81
page 82
CompAir

HW 0037 Key to Components (diagrams 1 to 4)

Reference Name Reference Name
BR1 TO BR3 DIODE RECTIFIER M101 FAN MOTOR
C1 TO C18 CAPACITOR M102 MOTOR - MAIN DRIVE
C19 TO C22 CAPACITOR - SNUBBER M107 FAN MOTOR - HEATSINK
EMC1 EMC FILTER MCB1 CIRCUIT BREAKER - TRANSFORMER PRIMARY 3A
F1 FUSE, 2A TYPE T MCB2 CIRCUIT BREAKER - FAN 16A
F2 FUSE, 5A ANTI-SURGE P301 PRESSURE TRANSMITTER - DELIVERY PRESSURE
F3 FUSE, 3.15A SEMI-DELAY P302 PRESSURE TRANSMITTER - RECLAIMER PRESSURE
F4 FUSE, 2A TYPE T HEATSINK FAN R101 TEMPERATURE SENSOR - HEATSINK
H101 ENCLOSURE HEATER R105 TO R114 RESISTOR
IGBT 1 TO IGBT 4 IGBT - GAL R2 TO R4 RESISTOR - SOFT START
IGBT 5 TO IGBT 8 IGBT - GAR R301 SENSOR - OIL TEMPERATURE
K1 CONTACTOR - MAIN S201 EMERGENCY STOP SWITCH
K101 PHASE FAILURE RELAY S302 SWITCH - AIR FILTER DP
K2 CONTACT DC LINK CHARGING SK1 48 WAY UTP CONNECTOR
K3 CONTACTOR - FAN T101 CONTROL TRANSFORMER
K4 RELAY GROUP FAULT TS THERMOSTATIC SWITCH
L1 LINE REACTOR VDR1 TO VDR4 VARISTOR
L2 CURRENT TRANSDUCER Y202 VALVE SOLENOID - BYPASS
L208 SPEED SENSOR - MOTOR Y215 VALVE - CONDENSATE DRAIN

Note:- Details of Control Panel components are supplied

inside the Power Converter Box

ELECTRICAL CONNECTION DIAGRAM - L120SR (4 OF 4)

 LSR Series User Manual

APPENDIX 1

THE PRESSURE SYSTEMS SAFETY REGULATIONS 2000

1. L45SR Note: The intervals between examination and

The circuit diagram shown below is provided to
assist a ‘competent person’ in preparing a written
scheme of examination for a system incorporating
the air compressor(s).
calibration of components, eg pressure vessels,
pressure relief valves etc, will be defined by the
‘competent person’, preparing the written scheme.
In defining these periods the ‘competent person’ must
take into account the recommendations of the
component part manufacturer, the Health and Safety
Executive (H & SE) and the British Compressed Air
Society (BCAS).

32 33 34 35 36 37 38 39 40

3 PHASE POWER SUPPLY

29

1 19 30

17 21 OIL SCAVENGE LINES

16
7
15 A B 18
14
8 9
13
6 10
2 22
20

28
M 3 23

4
5

11 27 M
24 HW 0009
12 25
26

31

1. Intake Air Filter 14. Overcurrent Trip 27. Cooling Fan

2. Non-return Valve 15. Position Sensor Fault Trip 28. Thermostatic Bypass Valve
3. Air-end 16. Overspeed 29. Control Panel
4. SR Drive® Motor 17. Stall Trip 30. Pressurised Oil Drain Valve
5. Reclaimer 18. Pressure Transducer 31. Oil Drain Valve
6. Separator Filters 19. Differential Pressure Switch 32. Emergency Stop
7. Pressure Gauge 20. Temperature Thermistor 33. SR Current Sensor Trip
8. Minimum Pressure Non-return (TE2) 34. DC Link Overvoltage Trip
Valve 21. Bypass Valve 35. DC Link Undervoltage Trip
9. Aftercooler 22. Pressure Relief Valve 36. Capacitor Charge Volt Trip
10. Compressor Delivery 23. Oil Cooler 37. Heatsink Sensor Fault Trip
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 (TE1) 26. Temperature Thermistor 40. Main Contactor Fault Trip
(TE3)

page 83
CompAir

2. L75SR pressure relief valves etc, will be defined by the

The circuit diagram shown below is provided to
assist a ‘competent person’ in preparing a written
scheme of examination for a system incorporating
the air compressor(s).
Note: The intervals between examination and
calibration of components, eg pressure vessels,
‘competent person’, preparing the written scheme.
In defining these periods the ‘competent person’ must
take into account the recommendations of the
component part manufacturer, the Health and Safety
Executive (H & SE) and the British Compressed Air
Society (BCAS).

39 40 41 42 43 44 45 46 47

400V ± 10%, 50 Hz, 3-Phase

400V-460V ± 10%, 60 Hz, 3-Phase
38

12
20 32
50
13
11 26 31 33
2 48 36

37
3 4
1 19 34 35
16 30
24
5 M

14 M 29
17
6 18 28
7 23 15 27
8
9 49
10 21

22 25 HW 0010

1. Intake Air Filter 17. Reclaimer 33. Moisture Separator

2. Differential Pressure Switch 18. Oil Level Tube 34. Strainer
3. Air Inlet Connection 19. Relief Valve 35. Drain Solenoid
4. Air-end 20. Diff. Pressure Indicator 36. Compressor Delivery
5. SR Drive® Motor 21. Oil Filter 37. Condensate Drain
6. Temperature Thermistor 22. Oil Drain Valve 38. Control Panel
(TE1) 23. Oil Stop Valve 39. Emergency Stop
7. Overcurrent Trip 24. Non-return Valve 40. SR Current Sensor Trip
8. Position Sensor Fault Trip 25. Oil Drain Valve 41. DC Link Overvoltage Trip
9. Over Speed Trip 26. Minimum Pressure Non- 42. DC Link Undervoltage Trip
10. Stall Trip return Valve 43. Capacitor Charge Volt Trip
11. Temperature Thermistor 27. Thermal Overload 44. Heatsink Sensor Fault Trip
(TE2) 28. Temperature Thermistor 45. Heatsink Temperature Alarm
12. Bypass Valve (TE3) 46. Heatsink Temperature Trip
13. Scavenge Solenoid 29. Cooling Fan 47. Main Contactor Fault Trip
14. Overpressure Switch 30. Oil Cooler 48. Scavenge Strainer
15. Pressure Gauge 31. Aftercooler 49. Thermostatic Bypass Valve
16. Oil Filler 32. Pressure Transmitter 50. Pressurised Oil Drain Valve

page 84
 LSR Series User Manual

3. L120SR pressure relief valves etc, will be defined by the

The circuit diagram shown below is provided to
assist a ‘competent person’ in preparing a written
scheme of examination for a system incorporating
the air compressor(s).
Note: The intervals between examination and
calibration of components, eg pressure vessels,
‘competent person’, preparing the written scheme.
In defining these periods the ‘competent person’ must
take into account the recommendations of the
component part manufacturer, the Health and Safety
Executive (H & SE) and the British Compressed Air
Society (BCAS).
20

24
34
14
13
8
28
9
30
1 15
33 10
35
2 22
29
31 7 36

26
27 5 16
23 17

32 4 3 11
12

6
21

25
37 18

HW 0013 19

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. Differential Pressure
5. Reclaimer 21. Thermostatic Mixing Valve Indicator and Switch
6. Oil Filters 22. Pressure Relief Valve 35. Thermostatic Mixing Valve
7. Pressure Gauge 23. Oil Cooler (Heat Recovery)
8. Minimum Pressure / 24. Fan Motor 36. Heat Recovery Heat
Non-Return Valve 25. Power Converter Heat Sink Exchanger
9. Aftercooler - Cooling Fan 37. Water Inlet and Outlet
10. Compressor Delivery 26. Position Sensor Connection (Heat Recovery
11. Oil Filler 27. Pressure Transmitter Option Only)
12. Oil Level Sight Glass (Reclaimer)
13. Air Inlet Grille 28. Pressure Transmitter
14. Solenoid Valve - Blowdown (Air Delivery)
15. Moisture Separator 29. Inlet Non-Return Valve
16. Level Controlled 30. Scavenge Restrictor
Condensate Valve 31. Scavenge NRV

page 85
CompAir

page 86

APPENDIX 2 - COMMISSIONING
WARNING
● Refer to the safety procedures before
commissioning the compressor unit.
● Lethal voltages are used in this
equipment. Use extreme caution when
carrying out electrical checks. Isolate the
power supply before starting any
maintenance work.
1. COMMISSIONING PROCEDURE
When commissioning a new compressor or re-
commissioning a compressor which has been
overhauled or out of service, carry out the following
procedures before attempting to start:
Note: We recommend that commissioning is
carried out by a CompAir distributor.
1.1 Preliminary Mechanical Checks
1. Check that the isolator switch is locked ‘OFF’
and that all pipework and electrical power
connections are correct and tight.
2. Open the access panel to the power converter
compartment. Check all screws and starter
connections for security. Check all electrical
connections are made correctly and are tight.
3. Ensure the main supply cables and fuse
ratings comply with regulations.
4. Ensure the control transformer primary
tapping connections are correct for supply
voltage.
5. Ensure fan motor M.C.B. is set correctly for
fan motor F.L.C. and supply voltage. Ensure
phase failure relay is set for the supply
voltage.
LSR Series User Manual – Commissioning
● Before opening the door of the power
converter compartment, switch the power
supply OFF at isolator and wait for 12
minutes to allow the dc link capacitors to
discharge to a safe level. Check that the dc
link capacitors have fully discharged before
starting work on the compressor.
6. Inspect the motor and control wiring
connections to make sure they are correct and
secure. Replace all panels.
7. Check that all protection blanks and tapes
have been removed.
8. Prime the air-end with 1 litre of CompAir
approved lubricant, or an approved alternative
as follows:
L45SR - Remove the air intake filter, push
open the non-return valve and pour oil into the
air-end. Remove excess oil before replacing
the filter.
L75SR - Remove the air intake filter and pour
oil into the air-end. Replace the filter.
L120SR - Remove the plug from the top of the
inlet valve and pour in oil. Replace the plug.
Note: CompAir approved lubricants are described
under 2.9 ‘Oil System’ in the maintenance section of
the manual.
9. Open the isolating valve to the user’s
pipework.
10. Check that the air end and motor rotate freely.
11. Check the oil level - the correct procedure is
described under 2.9 ‘Oil System’ in the
maintenance section of the manual.
page 87
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.

Press SERVICE, HOURS, SERVICE, HOURS .

1.3 Setting the Correct Language

Note: The values shown throughout these procedures are examples only. Ensure set values are compatible
with compressor model.

No. Action Reason Display

1. Switch power supply ‘ON’ C20620/nn/xx/nn

VNVLnnxx ddmmmyy

The POWER ON LED lights.

After several seconds the

status display changes to:

DC link charging
Oil temperature 20°C

followed by:

Ready to Start
Oil temperature 20oC

When the DC link capacitors

are charged.

The REMOTE and AUTO

RESTART LEDs will light if
these facilities have been
selected.

2. Press ENTER. To display the main menu. Main menu

Operational settings

3. Press DOWN three times. To scroll through the Main menu

menu options. Commissioning – config.

4. Press ENTER. To choose the Commissioning – config.

commissioning – Language English
configuration menu.

page 88
 LSR Series User Manual – Commissioning

No. Action Reason Display

5. Press (+) or (–) and repeat To select the displayed Commissioning – config.
until the required language. Language Option
language is displayed.
(Pulsing display)

6. Press ENTER. To confirm the displayed Commissioning – config.

language. Language Option

(Steady display)

7. Press RESET. To exit the menu routine Ready to start

Oil temperature 20oC

1.4 Pressure Calibration

This routine is only necessary where a number of machines are to be run in parallel to ensure pressure
readings are identical.

Note: The values shown throughout these procedures are examples only. Ensure set values are compatible
with compressor model.

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. Consequently, as any user calibration will be lost, the model must be set before a
pressure calibration.

No. Action Reason Display

1. Press ENTER. To display the main Main menu

selection menu. Operational settings

2. Press DOWN and repeat To display the Main menu

until the display shown required sub-menu. Service Diagnostics
on the right is obtained.

3. Press ENTER To select the required Service diagnostics

sub-menu. Reset service hours

4. Press DOWN once To choose the Calibrate Set pressure at 0 bar

then ENTER. pressure option. Press enter when ready

5. If the zero pressure To by-pass the first part

display is known to be of the calibration procedure.
correct then press DOWN
and go to step 8.

6. Disconnect the air To ensure zero pressure Set pressure at 0 bar

connection to the on the sensor(s). Press enter when ready
pressure transmitter(s).

page 89
CompAir
No. Action
7. Press ENTER.
See note 1.4 (a)
8. Connect a slave air
supply of more than
5.5 bar to the delivery
pressure transmitter.
9. If the slave air supply
is not constant then
press either UP or
DOWN to enter the
alternative calibration
routine and go to step 13.
10. Press (+) or (–) as
required to adjust the
value shown on the
display.
11. When the two
displays are equal
press ENTER.
See note 1.4. (b)
12. Press RESET.
13. Press UP or DOWN as
required to make the
LED display follow the
slave display.
14. When the two displays
track the pressure together
press ENTER.
See note 1.4. (b)
15. Press RESET.
page 90
Reason Display
To set the zero pressure Set pressure > 5.5bar
measurement in the
controller.
To establish a known Adjust +/– :– 7.0bar
calibration pressure. Press enter when ready
Note: If the air pressure
is not above 5.5 bar the
message shown in step 7
is displayed.
The alternative calibration
procedure is more
suitable for use with an
unstable reference
pressure.
To adjust the panel Adjust +/– :– 0.35bar
reading to match the Press enter when ready
slave air gauge.
(Pulsing display)
To store the pressure Calibration complete
calibration value in
the controller. After a delay the display
reverts to:
Service diagnostics
Reset service hours
To by-pass the alternative
calibration procedure.
To adjust the control panel Adjust pressure up/down
display. Press enter when ready
To calibrate the pressure Calibration complete
display.
(After a delay the
display returns to:)
Service diagnostics
Reset service hours
To exit menu routine. Ready to start
Oil temperature 20°C
 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’. After two seconds, the display returns to the normal zero pressure request display. Up to
three attempts are allowed for delivery pressure zero entry and further attempts up to a maximum of six are
allowed for reclaimer pressure zero entry. Attempts greater than these limits will result in calibration being
aborted with appropriate transmitter fault message displayed for four seconds.

Note 1.4 (b) Attempts to adjust value outside pre-defined limits will result in the message ‘Calibration limit’. If
calibration cannot be achieved, check that the machine model is correct and that the correct transmitter is
fitted, or suspect a transmitter fault.

page 91
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.

No. Action Reason Display

1. Press ENTER. To display the main Main menu

selection menu. Operational settings

2. Press DOWN and repeat To display the Main menu

until the display shown commissioning – values Commissioning – values
on the right is obtained. menu.

3. Press ENTER. To select the Commissioning Pressure P factor 20

values menu
Note: Leave the pressure
P factor and pressure I factor
values at default and adjust
later if necessary (see 1.10).

4. Press DOWN. To choose the next option. Commissioning – values

Max. overpress 7.5bar

It is essential that the Max. overpress is set below the maximum allowable pressure of the
users system.

5. Press (+) or (–) to To alter the displayed Commissioning – values

change the pressure value. Max. overpress 10.5bar
to 0.5 bar above the
maximum working (Pulsing display)
pressure, or press DOWN
and go to step 7.

6. When the required value To set the new value. Commissioning – values
is displayed press Max. overpress 10.5bar
ENTER.
(Steady display)

7. Press DOWN. To choose the next option. Commissioning – values

Oil t trip limit 110°C

8. Press (+) or (–) to To alter the displayed Commissioning – values

change the trip value. Oil t trip limit 120°C
temperature, or press
DOWN and go to (Pulsing display)
step 10.
9. When the required value To set the new value. Commissioning – values
is displayed press Oil t trip limit 120°C
ENTER.
(Steady display)

10. Press DOWN. To choose the next option. Commissioning – values

Oil t alarm limit 100°C

page 92
 LSR Series User Manual – Commissioning

No. Action Reason Display

11. 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.

12. When the required value To set the new value. Commissioning – values
is displayed press Oil t alarm limit 110°C
ENTER.
(Steady display)

13. Press DOWN. To choose the next option. Commissioning – values

Acceleration time 8sec

14. Press (+) or (–) to To alter the displayed Commissioning – values

change the acceleration value. Acceleration time 10sec
time or press
DOWN and go to
step 16. (Pulsing display)

15. When the required To set the new value. Commissioning – values
value is displayed Acceleration time 10sec
press ENTER.
(Steady display)

16. Press DOWN. To choose the next option. Commissioning – values

Cooler run on time 4min

17. Press (+) or (–) to To alter the displayed Commissioning – values

change the cooler run-on value. Cooler run on time 5min
time, or press DOWN
and go to step 19. (Pulsing display)

18. When the required To set the new value. Commissioning – values
value is displayed Cooler run on time 5min
press ENTER.
(Steady display)

19. Press DOWN. To display the next option. Commissioning – values

Max. service hours 2000
20. Press (+) or (–) to To alter the displayed Commissioning – values
change the max. reset value. Max. service hrs 1500
hours, or press
DOWN and go to (Pulsing display)
step 22.

21. When the required To set the new value. Commissioning – values
value is displayed Max. service hrs 1500
press ENTER.
(Steady display)

page 93
CompAir

No. Action Reason Display

22. Press DOWN. To display the next option. Commissioning – values

Autorestart delay 10sec

(Steady display)

23. Press (+) or (–) to To alter the displayed Commissioning – values

change the delay time, value. Autorestart delay 30sec
or go to step 24.
(Pulsing display)

24. When the required To set the new value. Commissioning – values
value is displayed Autorestart delay 30sec
press ENTER.
(Steady display)

25. Press RESET To exit the menu routine. Ready to start

Oil temperature 20°C

page 94
 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.

No. Action Reason Display

1. Press ENTER. To display the main menu. Main menu.

Operational settings.

2. Press DOWN and repeat To scroll through the menu Main menu
until the display shown options. Commissioning – config.
on the right is displayed.

3. Press ENTER. To select the commissioning Commissioning – config.

configuration menu. Language English

4. Press DOWN. To display the next option. Commissioning – config.

Unit of Pressure bar

5. If the displayed To alter the displayed Commissioning – config.

measurement unit is as measurement unit. Unit of pressure psi
required, press DOWN
and go to step 8, (Pulsing display)
or press (+).

6. Press ENTER. To set the chosen Commissioning – config.

pressure measurement Unit of pressure psi
unit.
(Steady display)

7. Press DOWN. To display the next option. Commissioning – config.

Unit of temperature °C

8. If the displayed To change the displayed Commissioning – config.

measurement unit is as measurement unit. Unit of temperature °F
required, press DOWN
and go to step 11, (Pulsing display)
or press (+).

9. Press ENTER To set the chosen Commissioning – config.

measurement unit. Unit of temperature °F

(Steady display)

10. Press DOWN. To display the next option. Commissioning – config.

Unit of volume m3

11. If the displayed measurement To change the displayed Commissioning – config.

unit is as required, press measurement unit. Unit of volume cfm
DOWN and go to step13,
or press (+). (Pulsing display)

page 95
CompAir

No. Action Reason Display

12. Press ENTER. To set the chosen Commissioning – config.

measurement unit. Unit of volume cfm

(Steady display)

13. Press DOWN. To display and set the Commissioning – config.

Machine Model Machine Model

14. Press ENTER. To display Model Machine Model

L75SR

(Steady display)

15. If model is correct, go to To set Model Machine Model

step 19, otherwise press L45SR
(+) or (-).

16. If access code requested, Spanner, Spanner, View, View

Enter code:

17. Press (+) or (-). To change Model Machine Model

L45SR

(Pulsing display)

18. Press ENTER. To select Model Machine Model

L45SR

19. Scroll UP or DOWN To display Machine Model

Return to previous menu

20. Press ENTER To return to Commissioning Commissioning – config

configuration menu. Language English

21. Press DOWN successively To display the next option. Commissioning – config.
until the following is Machine number 1
displayed.
(Pulsing display)

22. If the required number is To change the number Commissioning – config.

shown or the displayed. Machine number 3
communications facility
is not being used, press (Pulsing display)
DOWN and go to step 25
or press (+) or (-). Repeat until
the required number is
shown.

23. Press ENTER. To set the chosen Commissioning – config.

machine number. Machine number 3

(Steady display)

page 96
 LSR Series User Manual – Commissioning

No. Action Reason Display

24. Press DOWN. To choose the next option. Commissioning – config.

Auto restart disabled

25. Press (+) or (–) to To alter the displayed Commissioning – config.

enable the function, value. Auto restart enabled
or press DOWN
and go to step 27. (Pulsing display)

26. When the required To set the new value. Commissioning – config.
value is displayed Auto restart enabled
press ENTER.
(Steady display)

27. If Remote control config. is To display the next option. Commissioning – config.
required, press DOWN until Remote control config.
the following is displayed
otherwise go to step 42.

28. Press ENTER To view/select options. Remote control config.

Remote Start/Stop

29. If the remote Start/Stop To view the current status Remote Start/Stop
function is required press of the Remote Start/Stop disabled
(+) then ENTER otherwise function.
go to step 34.

30. Press + or - To change option. Remote start/stop

Remote start

(Pulsing display)

31. Press ENTER To select option. Remote start/stop

Remote start

(Steady display)

32. Press DOWN To select return to Remote Remote start/stop

control config menu. Return to previous menu

33. Press ENTER To select option. Remote control config.

Remote start/stop

34. Press DOWN To select next item Remote control config.

Config Input X01/4

35. If this remote input is to be To view current status of Config Input X01/4
configured Press ENTER Input X01/4 input config Disabled
otherwise go to Step 40. 22e

36. Press (+) or (-) To change option. Config Input X01/4

Trip Type 1

(Pulsing display)

page 97
CompAir

No. Action Reason Display

37. Press ENTER To select option. Config Input X01/4

Trip Type 1

(Steady display)

38. Press DOWN To select return to Remote Config Input X01/4

control config menu. Return to previous menu

39. Press ENTER To select option. Remote control config.

Remote start/stop

40. Repeat 35- 39 using DOWN To set remote configuration. Remote control config.
successively until all inputs Return to previous menu
and outputs and secondary
pressure setpoints are
configured as desired, until
the following is displayed.

41. Press ENTER. To return to Commissioning Commissioning – config.

cofiguration menu. Language English

42. If speed control variable display is To select the chosen option. Commissioning – config.
required, press DOWN until Speed control disp – OFF
the following is displayed,
otherwise go to Step 45.

43. Press (+) then ENTER. To change the displayed option. Commissioning – config.
Speed control disp – ON

44. Press DOWN. To choose the next option. Commissioning – config.

Return to previous menu

45. Press RESET. To exit main menu. Ready to start.

Oil temperature 20°C

page 98
 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.

No. Action Reason Display

1. Press ENTER. To display main menu. Main menu

Operational settings

2. Press ENTER. To display the operational Operational settings

settings menu. Control mode AUTO

3. Press (+) or (–) to To alter the displayed Operational settings

change the mode or option. Control mode MAN
press DOWN and go to
step 6. (Pulsing display)

4. Press ENTER. To select the chosen option. Operational settings

Control mode MAN

(Steady display)
Note: Preliminary running
should be in MAN.

5. Press DOWN. To choose the next option. Operational settings

P1 for auto mode 7.0bar

6. Press (+) or (–) to To alter the displayed Operational settings

change the set point value. P1 for auto mode 10.4bar
or press DOWN and
go to step 9. (Pulsing display)

7. When the required set To set the new value. Operational settings
point is displayed P1 for auto mode 10.4bar
press ENTER.
(Steady display)

8. Press DOWN. To choose the next option. Operational settings

P2 for auto mode 9.8bar

9. Press (+) or (–) to To alter the displayed Operational settings

change the set point value. P2 for auto mode 9.6bar
Otherwise press DOWN
and go to step 12. (Pulsing display)

10. When the required To set the chosen value. Operational settings
value is displayed P2 for auto mode 9.6bar
press ENTER.
(Steady display)

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CompAir

No Action Reason Display

11. Press DOWN. To choose the next option. Operational settings

P1 for man mode 7.0bar

12. 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. (Pulsing display)

13. When the required To set the new value. Operational settings
value is displayed P1 for man mode 10.0bar
press ENTER.
(Steady display)

14. Press DOWN. To choose the next option. Operational settings

P2 for man mode 6.3bar

15. Press (+) or (–) to To alter the displayed Operational settings

change the set point, value. P2 for man mode 9.3bar
otherwise press DOWN
and go to step 18. (Pulsing display)

16. When the required To set the new value. Operational settings
value is displayed P2 for man mode 9.3bar
press ENTER.
(Steady display)

17. Press DOWN. To choose the next option. Operational settings

Run on time 60sec

18. Press (+) or (–) to To alter the displayed Operational settings

change the run-on value. Run on time 100sec
time, or press DOWN
and go to step 20. (Pulsing display)

19. When the required To set the new value. Operational settings
value is displayed Run on time 100sec
press ENTER.
(Steady display)

20. L120 machines only

go to step 26.

21. Press DOWN To choose the next option Operational settings

Drain open time 5 sec

22. Press (+) or (–) to To alter the displayed Operational settings

change the drain open value. Drain open time 10sec
time, or press DOWN
and go to step 24. (Pulsing display)

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 LSR Series User Manual – Commissioning

No Action Reason Display

23. When the required To set the new value. Operational settings
value is displayed, Drain open time 10sec
press ENTER.
(Steady display)

24. Press DOWN. To choose the next option. Operational settings

Drain shut time 30sec

25. Press (+) or (–) to To alter the displayed Operational settings

change the drain value. Drain shut time 60sec
shut time, or go to
step 27. (Pulsing display)

26. When the required To set the new value. Operational settings
value is displayed, Drain shut time 10sec
press ENTER.
(Steady display)
27 Press RESET. To exit the menu routines. Ready to start
Oil temperature 20°C

page 101
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.

No Action Reason Display

1. Press ENTER. To display the main Main menu

selection menu. Operational settings

2. Press DOWN and repeat To scroll through the Main menu

until the display shown menu. Commissioning – values
on the right is obtained.

3. Press ENTER. To display the commissioning Commissioning – values

– values menu. Pressure P factor 20

4. Press DOWN and repeat To scroll through the options. Commissioning – values
until the display shown Max. service hrs 2000
on the right is obtained.

5. If the figure is not 2000 To alter the displayed Commissioning – values

or a different figure is value. Max. service hrs 1500
desired, then press the (+)
or (–) buttons as required. (Pulsing display)

6. Press ENTER. To set the new figure. Commissioning – values

Max. service hrs 1500

(Steady display)

7. Press DOWN and repeat To scroll through the options. Commissioning – values
until the display shown Return to previous menu
on the right is obtained.

8. Press ENTER. To display the main menu. Main menu

Operational settings

9. Press DOWN and repeat To scroll to the required Main menu

until the display shown sub-menu. Service diagnostics
on the right is obtained.

10. Press ENTER. To select the required Service diagnostics

menu. Reset service hours

11. Press ENTER. To reset the service Reset service hours

countdown timer to Service hrs to run 1500
maximum programmed
hours. (After a delay, changing to:)

Service diagnostics
Reset service hours

12. Press RESET. To exit the menu Ready to start

routines. Oil temperature 20°C

page 102
 LSR Series User Manual – Commissioning

1.9 Display Options - To View Compressor Status Information

No Action Reason Display

1. Press VIEW. To display the compressor Oil temperature 70°C

oil temperature at air-end
delivery.

2. Press VIEW To indicate % of full load %nnnnn 2000rpm

speed.

2a* Press VIEW To display reclaimer Reclaimer d.p. 0.0 bar

differential pressure

3. Press VIEW Power semiconductor Drive heatsink

heatsink temperature. temperature 68°C

4. Press VIEW Power converter DC link DC link voltage 580V

voltage.

5. Press VIEW Indicates approximate Air FLow 60m3/min

instantaneous FAD
airflow of machine.

5. Press VIEW To display speed control e0003 p0150 i3010 n3660

variable (see note).

Note: Speed control display

must be set to ON
(Commissioning – config. menu.)

* L120SR only

page 103
CompAir

1.10 Final Mechanical Checks

Note: The values shown throughout these procedures are examples only. Ensure set values are compatible
with compressor model.

No. Action Reason Display

1. Fully open the isolating valve

to the users system.

2. Switch power supply ‘ON’. C20620/nn/xx/nn

VNVLnnxx ddmmmyy

3. After a few seconds the Ready to start

display becomes: Oil temperature 20°C

4. Press VIEW To set the speed in MAN Ready to start

%- - - - - - - - - - - - -0rpm

5. Check running mode is MAN Ready to start

Press (+) to increase the MAN speed 2000rpm
MAN speed in increments
of 50 to 2000 rpm.
Press (-) to decrease
the speed.

6. Press START. To start the compressor. Starting

%- - - - - - - - - 2000rpm
Note: The compressor may
appear to turn slowly for the first
revolution before running up to
speed. This is normal and
should not be considered a fault
condition.

CAUTION: Do not repeatedly May cause motor overheating,

start and stop the compressor. contactor damage or air-end
seizure.

page 104
 LSR Series User Manual – Commissioning

No. Action Reason Display

7. 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. Remote start enabled

(c) A trip fault condition Fault shutdown

exists. (See fault Fault message
rectification.)

8. If electrical work has to be

carried out switch power to
the compressor ‘OFF’.
Establish the correct
starting conditions.
Go to step 1.

9. Provided the delivery Onload

pressure is below the %- - - - - - - - - 2000rpm
P2 set point the display
becomes:

10. The compressor now Onload

runs in the MAN mode %- - - - - - - - - 2000rpm

11. Check that air is being To establish correct fan motor

expelled from the canopy rotation
fan vent.

page 105
CompAir

No. Action Reason Display

12.

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.
Return to step 2.

CAUTION: RISK OF
HIGH PRESSURE

Do not use hands to

locate leaks in the
system. Always use a
piece of paper or
card for this purpose.

13. Examine compressor

pipework for oil
or air leaks. If a leak is
found, stop the compressor,
rectify the fault
and go to step 18.

14. Simulate an air demand To provide a normal

by opening a valve in operating air demand.
the user’s system.

15. Use the valve to adjust ‘Offload’

the system pressure.
Check that compressor
speed reduces to minimum.
when P1 set point in MAN is
reached. Check bypass open.

page 106
 LSR Series User Manual – Commissioning

No. Action Reason Display

16. Reduce system pressure below ‘Onload’

P2 in MAN. Check compressor
speed increases to 2000 rpm.

17. Set valve to give a constant

pressure close to the P2 -
AUTO setpoint.

18. Set working mode to AUTO

and check speed of compressor
adjusts automatically to maintain
system pressure at this setting.

19. Increase demand for air and check

compressor speed increases to
compensate and pressure stabilises
at P2-Auto setting.

Note: If compressor speed is not stable

adjust pressure P factor or pressure I
factor settings. (See Appendix 4)

20. Run the compressor under To achieve stable

these conditions for operating conditions.
half an hour.

21. Examine all pipework

again for oil and air leaks.

22. Check operation of automatic

condensate drain (L75SR only).

23. Press STOP. Switch power

to the compressor ‘OFF’ at
the isolator. Allow 30 minutes
for the oil to settle. Top up the
oil level if necessary.

24. Replace all covers and

panels.

25. Record all set points

and operating parameters
for future reference.

page 107
CompAir

2. COMMISSIONING CHECK LIST 27. Reset service hours timer. ............

1. Pipework. ............ 28. Starting sequence correct. ............

2. Electrical connections. ............ 29. Fan rotation correct. ............

3. Cable, fuse ratings OK. ............ 30. Corrosion inhibitor dispersed. ............

4. Control transformer input voltage 31. Connected to user’s pipework. ............

set correctly. ............
32. Oil and air leak check. ............
5. Fan motor mcb set correctly. ............
33. Compressor loads, unloads,
6. Starter connections OK. ............ stands by and stops correctly. ............

7. Motor connections OK. ............ 34. Compressor blows down correctly ............

8. Protection blanks and tapes. ............ 35. Emergency stop correct. ............

9. Prime compressor with oil. ............ 36. Oil temperature in limits. ............

10. Air-end and motor freely rotate. ............ 37. Oil level topped up. ............

11. Select language. ............ 38. All parameters and options recorded ............

12. Pressure transmitter calibrated. ............

13. Display units set. ............

14. Machine number set

(if comms facility available/fitted). ............

15. Comms configuration set. ............

16. Working mode routine checked. ............

17. Pressure control set points set. ............

18. Run-on time set. ............

19. Drain open time set. (not L120SR) ............

20. Drain shut time set. (not L120SR) ............

21. Maximum compressor pressure set. ............

22. Maximum overpressure set. ............

23. Oil temperature trip limit set. ............

24. Oil temperature alarm limit set. ............

25. Acceleration time set. ............

26. Cooler run-on time set. ............

page 108
 LSR Series User Manual – Dimensions

APPENDIX 3

DIMENSIONS

page 109
CompAir

CONTROLLER

CUSTOMER
CABLE ENTRY

AIR INLET
GRILLE

309 [12.18"]

279 [10.98"]

POWER
72 [2.84"] CONVERTER
DOOR
57 [2.25"]
215 [8.46"]

205 [8.07"]

AIR INLET
205 [8.07"]
195 [7.68"]

SERVICE DOOR

292 [11.50"]
166 [6.52"]

STANDARD AIR DELIVERY

REAR VIEW 150 [5.91"] CONNECTION G11 2 "
62 [2.44"] FRONT VIEW
100 x 100 (3.937"x 3.937")
APERTURE IN BASE
192 [7.56"] 482 [18.98"] 192 [7.56"]
U.S. AIR DELIVERY CONNECTION 11 2 " NPT (C27349-150)
CONNECTED TO G11 2 " 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
1506 [59.29"]

341 [13.43"] SIDE VIEW

HW 0038

DIMENSIONS - L45SR

page 110
 LSR Series User Manual – Dimensions

HINGED / LIFT OFF

SERVICE DOOR
AND ELECTRICAL DOOR 7

878 [34.58"]

1420 [55.91"]

142 [5.60"] 806 [31.72"]

200 [7.87"]
806 [31.72"]

990 [38.98"]
910 [35.83"]
635 [25.00"]
92 [3.63"]

355 [13.98"]
125 [4.92"]

750 [29.53"] FOR SERVICING

80 [3.15"]
300 [11.81"] FOR

AND AIR INLET

AIR INLET 405 [15.94"]

TOP VIEW
685 [26.97"]

965 [37.99"]
12 [0.47"]

AIR OUTLET STARTER BOX AIR

3 3
COOLING AIR VOLUME 150m/min (5297ft/min) COOLING FILTER

AIR INLET GRILLE

68 [2.69"]

325 [12.80"]
1650 [64.96"]
820 [32.28"]

12 [0.47"]

AIR INLET
150 [5.91"]
75 [2.95"]
25 [0.98"]

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
CompAir

112 [4.41"]
A

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"]

D
1702 [67.01"]
1343 [52.87"]
623 [24.52"]
76 [2.99"]

B
C
211 [8.32"]
152 [5.98"]
70 [2.76"]

155 [6.10"]

990 [38.98"]
HW 0040

DIMENSIONS - L75SR

page 112
 LSR Series User Manual – Dimensions

AIR OUTLET

COOLING AIR VOLUME 289m3 /min

3
(10206ft /min)

INITIALS

DATE
TESTED

England HP13 5SF

STARTER BOX AIR

COOLING FILTER
AIR INLET
76 [2.99"]
TYP

0.2h

C20089-577 L75SR
C20089-551

200 [7.87"]
634 [24.96"] TYP

1366 [53.78"]

2050 [80.71"]

955 [37.60"]
650 [25.59"]

320 [12.60"]
15 [0.59"]

SERVICE ACCESS
DOOR
910 [35.83"]
970 [38.19"]

955 [37.60"]
650 [25.59"]
30 [1.18"]

320 [12.60"]
115 [4.53"]

15 [0.59"]

30 [1.18"] 910 [35.83"]

965 [37.99"]
635 [25.00"]

995 [39.17"] 970 [38.19"]

HINGED CONTROL
PANEL DOOR HW 0041

DIMENSIONS - L75SR

page 113
CompAir

HW 0043

DIMENSIONS - L120SR

page 114
 LSR Series User Manual – Dimensions

HW 0044

DIMENSIONS - L120SR

page 115
CompAir

HW 0045

DIMENSIONS - L120SR

page 116
 LSR Series User Manual – Speed Calculations

APPENDIX 4

SPEED AND AIR FLOW/VOLUME CALCULATIONS

Speed Calculations Air Flow Calculations

The rotational speed of the compressor is
calculated using a Proportional + Integral (P+I} loop
as follows:
Speed (rpm) = (PRESSURE DEPENDENT
MINIMUM SPEED) + (PRESSURE ERROR x
(pressure P factor) + ò (PRESSURE ERROR x
Pressure I factor)
L45SR EAF = 0.0015900s - 0.1716 calculated
between s = 750 rpm & 5000 rpm
L75SR EAF = 0.0026316s - 0.1737 calculated
between s = 750 rpm & 4800 rpm
L120SR EAF = 0.0051410s - 0.0103 calculated
between s = 500 rpm & 3750 rpm

To tune the P+I control use the VIEW button to Where:

access the following display:
EAF is Estimated Air Flow in m3/min
e0003 p0150 i3010 n3660
s is the actual speed in r.p.m.
Where:
The above formulae are derived from published
e = PRESSURE ERROR (in 1/4 psi units Sales data and are the best fit straight-lines based
approx.) on 8 bar flow and speed data between minimum
and maximum speeds. The displayed values are
p = proportional term therefore approximations particularly at pressure
ie PRESSURE ERROR x pressure p factor and speed extremes and may differ from actual
measured air flow.
i = integral term
ie ò (PRESSURE ERROR x pressure I factor)
Total Air Volume Calculations
n = the calculated speed (rpm)
The air volume is updated at 10 minute intervals.
Note: Speed control display must be ON The instantaneous speed is sampled at 1 sec
(Commissioning - config. menu). intervals over each 10 minute period and the
volume estimated using the above formulae for
An increase in the pressure I factor results in an speeds within the above ranges. The display is
increase in the speed at which the integral term reset to zero when total reaches 1 x 109 ft3 (i.e. 10
changes when a PRESSURE ERROR exists. In the to the power of 9).
steady state (constant pressure), PRESSURE
ERROR should be close to zero (eOOOO), the
integral term (i ****) dominates and the pressure P
factor has no effect. Adjust the pressure I factor
until the rotational speed changes smoothly in
response to system demand.

If the air demand shows step changes, increasing

the proportional (p) term will increase the response
of the control system to step changes in demand.

page 117