2& CompAir Rotary Screw Stationary Air Compressor Models WE 200-250-300 SS SIN 4164x 4220x 4221x 4222x WM 200 - 300 SS S/N 4499x 4498x 4497x 4503x OPERATION AND MAINTENANCE MANUAL CompAir Pop $27 214 E, Russell Rl Sidney, OH 4365 Telephone: +01 {937} 498-2500, Facsimile: +01 (937) 492-2923, URL www. compairleraicom e-mait: compair@pnght net 4n Invensys companyTABLE OF CONTENTS Page SECTION 1 - GENERAL INFORMATION Air End oo. wee E EEE EEE CEEOL Oa sees wt Air and Oii"Fiow ¢ DUTIES a Control Function vecceeeyecge IEE 2 Modulating Controi (Standard) ": ree INE 3 Auto Dual. (Tinea Stop) Control (Optional) "+ 14 ECONOTROL'® ~ Electronic Sypass Control ... 28 Component Function «..cssssstererseeesererece 16 Intake Valve epeevensecesssrecerecsons 6 alr Receiver-Oil ‘Reservoir’ 2.0.00 6 Miniaum Presaure/Check Valve ws § High Air Temperature Shut Bown Switches 7 Blow Down Receiver (Dump) Valvee s...e.. 8 Return Air Bleed Line ms 8 Control Pressure Regulator Vaive (Modulating or Auto Dual COMtrOL) ..seeeseeeeeseseeee eres we 8 Pressure Switch Pg-2 (Modulating and Auto Dual Control) sesscseecsscereeceessecseerecssen ees B Pressure Switch PS-2 (Auto Dual Timed Stop controls UII 8 Pressure Switch PS-3 cossseseceresereees tte PUI Control Line Shuttle Gheck Valve 21 TI D3 Water Flow Control Valve ~ Water Cooled Unite <0. .11) : 13 Ingtrumentation seeeeeseeeceree L 3 SPower™ On Lamp s.ccccce 2210 Hourmster see ees Be ety Air Cleaner agateiction’ tndicator’ (11... 510 O41 Bressure Gages .s+ess+e+ D0 Air Pressure Gages <1.) S10 "Running" Laap : 210 stotor Ovorload* Laap 211.) 230 ‘High Temperatures Leap 2 to “High Pressure" Lamp... 210 Control Selector Switch Dio OLl Teaperature Gage (Th Dio Ap feapergture Gage, (Ihersoneter? S10 ECONOTROL'® Circuit Board Laaps «.... : aU) SECTION 11 ~ SPECIFICATIONS -. GENERAL Unit ~ General iss eee eee Eubrication ~ Compressor 1.00.0 fubrication - Electric Motor’ 1111) SECTION III ~ INSTALLATION Hounting and Space Requizecents : + 4g Hlecteleal "Supply osess-caeei;o0'coj gagteseniogs cococes ra Air Supply to Compressor (Cooling and coapresaiond ne Goong Water Supply ver-scccsecssstsssrnetersventesccccees 24 Bigchatge Plpang’e., (2220 UG! HNN n8 Checks to batade at initial Start’6p") 14a Modulating Control .-...-- Daa Auco Sual/(Simed Stop) “Gonteol 122221121 243 ECONOTROL* = Electronic Bypass Gantral 288 SEQTION JV ~ OPERATION AND PREVENTIVE MAINTENANCE S208 OS a " +5 Shut. Down n 12 Preventive Haintenance 13 Dally sasscvssececeeestece 18 Every 200°figura’ 212211 1 Every 1000 foure’<222.) 1 SECTION V - CONTROL ADJUSTHENT PROCEDURE Controls +2. Modulating Control. ~ Alto Dual contro! .. 02. Lt Ta ECONOTROL'* = Electronic Bypass ‘Control Control Pressure Regulator and Pressure Switch Rejugtaent Instructions .< bene cee Pressure Switch PSn3 Adjustment Srocedute ..00 ITILTABLE OF CONTENTS SECTION I - GENERAL INFORMATION Kir End Air and Oli ‘Flow Control Function ‘+ ereen Hodulating Contra dards i Auto Dual (Timed Stop) Control ona ECONOTROL?* "Electronic Bypass Control ....... Cogponent, Function Theake Valve vec .s.lstsliise Air Recetver-ii Raserwaiz’* Mininum Preasure/Check Valve... Separator Drain Line 2...eseeecgveyecee High Air Temperature Shit bows Switches: Blow Down Receiver (Dump) Valves +... Return Air Bleed Line wes Control Breasure Regulator Vaive tHedulating or Auto Dual Control) .... Presgure Switch PS-1 Wulating and Auto Dual Control) ra Switeh PS-2 (Auto Dual Tined Sto OODOOR @ ROIIRTREVRONEH Ingtrumentation ... "Power" On Lamp Hourmeter . Air Cleaner Restriction’ indi: Oil Breagure Gages ..--.-.e Air Preagure Cages mn Running" Laep..- PIN tHoter Overioad® Lagp 6.000 uifgh Temperature* Lamp ..sscscccccece 9} tg Pressures Camp oo .0cciec celine Control Selector ‘Switch ...... u Of] Temperature Gage (Thermometer) ..1 das fenperature Cage, (Theraoneter) : ECONOTROL?® Circuit Board Lamps ... SECTION 11 - SPECIFICATIONS - GENERAL Lubrication - Compresaor 322000000001 Lubrication - Electric Motor’: SECTION III ~ INSTALLATION Mounting and Space Requiresents Electrical "Supply. Air Supply to Compr. Cooling Water Supply . Bischatge Piping. « prs Checks fo be Made at initiai start ‘Up Modulating Control s.cccseseseesueurces Auto Qual’ (Tined Stop) ‘Control ss ECONOTROLt# ~ Electronic Bypase Conttoi’ <1. 121) SEGTION JV - OPERATION AND PREVENTIVE HAINTEKANC! tart OP veeeeeeeee ceaestsseseseenosets Shut down 01ST Preventive taintenance <.0000 011 Daily .s.ss.. Every 260"foute Bs Every 1000 Hours ..0.00000 SECTION V - CONTROL ADJUSTMENT PROCEDURE Controls eeeseerstewweseeeeee Modulating Control 1.100022 - Auto Dual Control ECONOTROL'® - Electronic Bypa Control Pressure Regulator and P: Adjustment instructions ... Pressure Switch PS-3 Adjustment Brocadi ivModutatin and Pressure Auto Dual Control ~ Pre ECOWOTROL?* Elec Temperature Actu ‘ontrol_- Control Pr TABLE OF CONTENTS (Conta) e Swit ure Switch PS-2 tronic. Bypage Control Ad; jated Water Flow Control ure Regulator (CPR) Valve PS-1 Adjustment’. 2... nen Adjustaent’ <0: justnent sec e rece jalve Adjustment 111. SECTION VI - SERVICE PROCEDURES - COMPONENTS Control Pressure Regulator Valve Service ...... Intake Valve Ser: ECONOTROL?* “Elec: Pressure Tranedu Printed Circuit Solenoid Bypass aaa bypane Valve/Piston/Cylinder Replaconc Yaninum Presaure, Blow Down (Duap) O41 Separator Se: Air End Service Air End Input Shafi oii éaai Reg ing Flexible Neaber Drive Coupling Hub Alignment. SECTION VII - SERVICE DIAGNOSIS ~ GENERAL Wodulating and Auto Dual Centro} Drive Coup, ECONOTROLT® ‘vice tronic Bypasa Control's; ser Replacement... Board Replacenent ni /Check Valve Service s Valve veevsseee vice 6. t tt iaceneni’ jenewalSAFETY NOTICE Le ROI Division, Dresser Industries, Inc., has strived through constant research and development to pro- vide this equipment with every necessary safety device. However, there is no substitute for safe operating procedures This manual contains numerous “Notes”, “Cautions” and "Warnings" intended to protest the equip- sent from damage and the operator from injury. ‘The “Notes”, “Cautions” and “Warnings” are not, however, all inclusive. Extreme care must be exercised when operating or servicing this equipment, ‘The operatoriservicemans should: 1, Learn all he can about his equipment Develop safe working habits. Never operate a unit without guards and shields in place. Never operate a unit that is not properly grounded, Never service @ unit without disconnecting and locking out the electrical power supply unless following specific operation manual instructions, 6. Never service a unit with air pressure in the air receiver-oil reservoir unless following specific operation manual instructions. 7. Take all necessary precautions, when adjusting controls, etc., to prevent electrical shock, Air delivered by these compressor must not be used for breathing air. DON'T PLAY WITH COMPRESSED AIR! DON'T POINT AIR HOSES AT ANYONE! DON'T USE COMPRESSED AIR TO BLOW DIRT FROM CLOTHING! At close range, compressed air, at the pressures these units develop, can put out eyes, burst ear drums, cause serious skin blisters and other injuries. Check Pressure Relief valves daily to make certain they are working properly. An over pressurized air receiver has the potential destructive force of a sinall bomb. A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENTSection | GENERAL INFORMATION This manual includes installation and operating instructions, and maintenance and service procedures for. the Model E2088, “WE250SS- and WEQOUSS AGT, Compressor units. 4n explanation of the eodel code follows: Example: WE3008S or WEH300SS WE Indicates the series = Maximum operating —_preasure above 125 pais 300 Approximate horaapover required toracive the air ‘end. ‘s SS Stationary Screw This series of air compressor units are electric motor driven, oil flooded, single stage, rotary screw type. These compressor units may be either air or water cooled and with or without @ housing. Aftercooling is standard for air cooled and optional for water cooled Unite. Figure I - AIR END - Typical AIR END (Figure 1) The air end is directly driven uaing a flexible coupling between the electric motor and the air end, The male rotor is driven by a gear rounted on an independent. input shart and a mating gear on the wale rotor. ‘The female rotor is driven by the sale rotor because the rotors are meshed, Figure 2 shows direction of “rotor rotation and the air/oil flow “through. the air end. Note that the air flow through the air end is between the rotors and the ineide dianeter of the cylinder. Each rotor is mounted with three angular contact ball bearings at the rear or discharge and. This provides positive rotor logation, The front oz inlet end of each rotor row roller te “supported by” aingle pPGhis allows “he "rotors. oF bearing.’ This gylinder to freely expand or contract dua to. changes in’ temperature without affecting critical running clearances. The independent input (drive? shaft is supported by a double row roller bearing at the front end and one single row roller bearing at the rear. AIR AND OIL FLOW (Figuee 2) Air circulates through the system beginning “at the air Gleaner, passes through the intake valve’ and into the air end vhere it is compressed, Froa the ed alr 18 discharged at Fated pressure into the unit air. receiver-oil reservoir. Separation of the, oil froa the air, Which “Was injected into the air end Guring compresaion, begins in. the unit gir feceiver-oi] ‘reservoir. From 90 to 95% of ‘the oi] seperation from ‘the air ia accomplishad with a decrease in air velocity, changes in. flow direction, adequate’ baffling and proper tocation of the air receiver-ol!' reservoir inlet port, Final air/oil separation is obtained aging a couposition waterial ‘cant type parator elesent to provide nearly oil free air at the separator out or service connection. Oil collected by the separator elenent is returned to the systen by a filter equipped separator drain lina. To, prevent over pressuring the air receiver-oi reservoir, an aif pressure rellef vaive is installed in” the Teceiver-reservoir. This pressure relict valve is located on the upstream or wet side of the separator elenent-Figure 2 - AIR/OIL FLOW - Typical For both air and water cooled unite, gil flows, forced by air preasure, from the air ‘receiver-oil reservoir to the thermal bypass valve. Then depending on oil temperature, oll flow bypasses the oil cooler (cold 941) or flows through the “oil cooler (hot oil). From the thermal bypass, valve, and/or the, ot cooler, oil? is forced through the filter ‘and injected into the air end to provide cooling, sealing and lubrication. The fenperature of the oil is controlled automatically by the “thermal bypass valve. Yater cooled unite abe algo equipped atic with a temperature controlled suton: water flow control valve, This allows metering water flow for water conservation. iL, injection temperatures for cooled unite should be 130° to 16 depending on ambient air temperature. Oil injection temperature for water cooled units should be 140° to 160°F depending on water temperature and flow. Figure 3 ) Watercooled O11 Cooler 9 Electrical Enclosure ) Thermal Bypass Valve ) Waterccoled aftercooler ) Air Cleaner ) Separator Drain Line D Air End ) Reservoir Drain Valve 1) Air Receiver/Oi Reservoir 10} O11 Level Sight Gages 11) 041 Filler 42) Electric Motor 13) Contro? Enclosure 13) Instrument Panel Air flow to/through the air end is controlled by “the intake valve. When there is a denand for air, up to the faked Capacity of the air’ end, the intake valve will be open (air end’ fully Toaded). When there is no demand for air, the ‘intake valve will be closed (ait end fully unloaded). When a unit is equipped with the modulating control ‘the intake valve will open’ and close (wodulata) based on air demand, CONTROL FUNCTION Three basic nodes of control are available for these units. These are: 1) Modulating ControlI) Air Cooled 011 cooler/Aftercooter 2) Electrical Enclosure 3) Instrument Paral @ off Filter &) Hheraal Brpecs, valve ‘eparator Out High Temperature Brut Down Switen PO 2) Minimum Pressure/Check Valve 2) Bigw Down (Dump) Valve 9) Mustier 410) Blow Down (Dusp) valve IL) Pressure Rolie? valve 12) air Cleaner 2 Dual Control (Modulating and 1d Stop) 3) Electronic Bypass control CECONOTROL®*) The basic modes of control are predetermined by installing the required electrical and pneumatic. ‘control components. lihen operating a unit with 2 predetermined basic © aode of “control gther, chan, modulating, the user aay select either of two types of contr available, in each basic node. As an Figure 4 13) 18, HE ovenarg ten 2 1 EE ccnrge, oh Tenpereture 16) sents bow Shean meee 417) Drain Line Filter’ ” ae a example, a unit equipped with auto dual gontrol' may be operated with modulatin {continuous run) er timed stoppe control, The ,selgction of type of control is ne: nade at the control enclosure below the instrument panel. MODULATING CONFROL (STANDARD) (Figure Te yobtain | dodulating control, a control pressure regulator is used in the control circuit.A pressure switch PS-1, in conjunction with solenoid yalve 8V-i, provides full unloading when the maximum full unload Pressure is reached. The control pressure functions to partially. of the air end by regulator valve fully unload aged on air demand. As air demand. is reduced” (unit air receiver pressure rises), the control pressure Feguiator will ’ gradually close the intake valve. When/if air demand is increased (unit air receiver pressure falls) the control Pressure regulator valve will gradually allow the intake valve to open. When the demand for, air is less than the razed capacity of the air end, the control pressure regulator. valve will hold the intake valve partially closed causing the air end to deliver air in direct proportion to demand. When/ig there ig no demand for air both the unit and storage receiver pressures will ‘rise to axi aus operating pressure. Pressure switch PS-1 will actdate. Thia will fully close the intake valve to unload the air and and gpen tha blow down valve to atmosphere lowering unit. receiver/reservoir pressure to reduce power requirements. A plant aystem or additional storage receiver may ‘not be required for modulating control provided the air demand ia very near the rated air delivery of the unit on a continuous basis. AUTO DUAL (TIMED STOP) CONTROL (OPTIONAL) (Figure 12) Auto dual control will have in addition to the control pressure regulator valve and pressure switch PS-1 a, ggcond pressure “switch PS-2 and a mar. Preseure awitch PS-1 will function to start the timed stop function aa well aa fully unloading the air end. Pregsure switch PS-2 will prevent the unit fron starting or restarting if the unit teceiver-reservoir air pressure i8 above 20 psi, approximately. The timer functions to stop the unit after it hag run unloaded fora Piadeternined ‘length’ of tine (tiaer setting). Auto dual control units require the use of a storage receiver. This receiver ig to be part of the plant. air distribution aystem. A noninal system air receiver aize 18400 gallon. OTE ACTUAL RECEIVER SIZE VARIES DEPENDING ON DISTRIBUTION PIPE SIZE, AIR USAGE, ETC, FOR FURTHER INFORMATION ON’ “SIZING A STORAGE RECEIVER, CONSULT THE CAGI HANDBOOK. (COMPRESSED AIR AND GaS INSTITUTE) Figure 5 ) Air Cleaner ) Return Air Bleed Line Check Valve D Housing Frane ) Air End ) Air End Discharge High Tenperature Shut’ Down Switch ) Control Solenoid SV1 ) Control Solenoid 5V6 (When used) ) Control Pressure Regulator Vaive Auto dual control may be used in single unit applications but is especially well suited for multiple unit installations. For single unit installations the tiner should be adjusted for longer tine delay periods (10 minutes). Ip multiple unit installations, thecontrols may be adjusted so that one (or more} unit(s) oparate(s) in the rated Pressure range with time delay "stop imes of 10 minutes. The second unit(s) (one | or more) would haye the controls set 5 psi below the first unit with a short (B°ainute) delay stop setting. When air demand is no nore than what is delivered by the first unit(s) the second unit(s) will stop. if/when there is g demand for air queater than, what the first unit(s) will feliver, the second unit(s) will restart. NOTE ADDITIONAL UNITS MAY BE ADDED FOR VERY HIGH ‘AIR DEMANDS. THE CONTROLS OF THESE ADDITIONAL UNIT(S) CAN THEN BE SET AT 5 PSi BELOW THE FIRST AND SECOND UNIT(S). "THIS ALLOWS THE CONTROLS — TO AUTORARICALLY BUT ADDITIONAL UNIT(S) "ON LINE* TO MEET AIR DEMANDS « Figure 6 2) Instrument Pane! 2) Control Enclosure (ECONOTROL'* > 5) Control Line Condensate Drain ECONOTROL** - ELECTRONIC BYPASS CONTROL The ECONOTROL'® bypass valve operating cylinder and ports are Jocated on the air end cylinder. These valves” are opened or closed by solid state control. Ac |gtart up, the electronic control initializes allowing “air pressure to extend “the “bypass “valve cylinders closing the | bypass porta for “full capacity operation. The bypass ports are opened progessively as the unit receiver air Pressure rises (air demand decreases) Teducing air delivery (oapacity) and Power consuaption. When the full unload operating pressure is reached the intake valve 13 also closed “completely by the sane control components (pressure switch PS-1 and solenoid valve SV-1) used for modulating control. The solid state control circuit board is located in the control enclosure. Signal lamps (LED or light emitting diode) on the circuit board are visible through a plexiglass window in the enclosure door. Tha green and yellow ianps indicate pressure set points. The red lamps indicate when bypass valves are open or closed. (Rod lamp 'OFF* - vaive closed? ted lap ON" = valve open) Chart I ghows the lamp indications for the normal pressure Tange of bypass control operation, ‘The ECONOTROL'# power is low voltage (2 V). This low voltage is obtained by using “a ‘transformer which naa the primiry winding connected to the unit 15-120 volt control circuit. Recaiver air eanses. Sy a pre controle tconorkot To Limit applied to the operating cylinders a pressure reductn sive, wich’aotsture separator. is°used! An electrically operated solenoid valve (one on each operating cylinder? controls air fiow into and out. of the Operating cylinders to extend the gylinder (close bypass valve) or allow gure changes are ire transducer which operation. air pressure the cylinder to’ retract (open bypass valve) User, selection of the desired operating pressure range is provided bi using a four position selector awitel which is located on the control enclosure door.CHART 1 ~ TYPICAL DISPLAY PATTERN Working vom Selector Switch Position + TOOTI07S! P.CBomd Byhos —ByPasn Pay totnte Vale mer ‘e ‘e" ‘ fecrver 1616750 ioder ides ides A Presure evn bea eva aa on OFF no 3 @ @ @ = Ine 109 g 8 g Qn, ® Witeel 108 @ @ @ LOB aaa @ Ries 107 g g a-"90 "Pam 108 & @ 08 ao g 10s @ &-"@0_O8 @ 108 B 08 gO es 8 103 Q-""20 08 Be ® 102 a0'°88 Be 8 1 comtrot_{7 S 82 Be e 100 ifferntit| OB" QQ QQ BB +— intake ® — oeas'sns| 82 OD BB BB @ wel rating arena pret ticates which Oioes re “ON Presure) 41. If the GREEN and YELLOW diodes a “ON the by-pass valve fs CLOSED, 2. If the RED diade only is "ON" the by pase valve is OPEN 3. if the YELLOW diode only is “ON” the storage reesiver presture is rising Green Yeliow R= Red 4. If the YELLOW and RED diodes are “ON” the storage racsiver pressure i falling, 2on08 Figure 7 - Chart 1 COMPONENT FUNCTION Piping and wiring dtagrana have been provided “to” aseist in locating Components on the unit and determining Somponent function. The following explanation of, gomponent function will ist in determining if the compressor is operating properly. INTAKE VALVE The intake valve is located in the upper section of the air end cylinder. The valve end, primary urpose of the intake 48 to control air flow to the air The secondary purpege of, the intake valve is to check Off possible reverse air/oil flow when the unit is shut down. AIR RECEIVER-OIL RESERVOIR The air receiver-oll reservoir provides “an ofl sump, primary, ofl Separation and a mounting location for the separator elesent. The separator element. is aounted in the receiver Teservoir by clamping the separator founting flange, “with gaskets, between the receiver-reservoir ‘cover. and top fla Other “components which are sounted on the receiver-reservoir are ‘the ‘minigun ‘pressure/check valve and Pressure relief valve, WINIMUM PRESSURE/CHECK VALVE (Figures 4 and 10) The oinisun pressure/check valve is located “on the air receiver-oil reservoir cover in the separator out port. The purpose of this valve is to maintain miniaun air preasure in the air receiver-oil reservoir. ‘The valve consists of a spring loaded piston “which opens when, ‘air pressure Teaches approximately 80 pai and Baintains a mininum prescure of 60 to 70 pale In addition, this valve checks off the return flow of sir from the systemreceiver (storage tank and/or distribution system) when the compressor is stopped or running unloaded. NOTE GOMPRESSOR SHOULD NOT BE OPERATED AT MINIM FOR | EXTENDED Peniops. EXCESSive off" Loss WEE RESULT. SEPARATOR DRAIN LINE (Figures 10 and 11) The separator drain line ia ed, "at the air receiver-oil Tver’ cover, to a tube which extenda down into and touches the bottom of the aeparator element. Fe Figure 8 1) 012 Sample Valve 3) Hininus Prosgure/Check Valve 2 rator Out High Temperature Shut Down Switch 4) Air Receiver/0il Reservoir 5) 0i2 Filter 6) 041 Filler 7) 012 Level Sight Gages 8) Air Receiver/Oil Reservoir Drain Line The other end of the drain line is connected to a low pressure port on the air end. The drain filter, a gage. The filter prevents foreign matter from entering ‘the air end, The check valve allows free flow of air/oil from the separator to the air end but prevents reverse air/oil flow at shut down: ‘The sight! gage say, be used to assist with service diagncsia. line is equipped with a Check valve and a'ftow aight Figure 9 2) tinimue _Peeaaute/ Check valve 2) Oil Fa Baie Receiver/0il Reservoir 5) HIGH | AIR TEMPERATURE SWITCHES (Figure 4) The high air temperature shut down gyitches are located in the discharge flange of the rear bearing retainer on the air end and in the minigun pressure check valve at the separator out connection. SHUT DOWN ‘These are nornally, closed temperature sensitive awitches, the purpose of thest switches is ta shut the unit down in the event the air/oil temperature at the air end @ischarge, or separator out rises above 230°F + CAUTION THE GAUSE OF GHUT, DOWN DUE, 70 HIGH AIR/OIL TEMPERA’ aus’ TURE CORRECTED BEFORE RESTARTING THE To restart a unit allow the unit to cool, and push the start button,BLOW DOWN RECEIVER (DUMP) VALVES (Figure 10) The air receiver-oil reservoir biow down or dump valves are located on the receiver-reservoir cover. The purpose of these normally closed valves "is’ to allow air to escape from the Teceiver-reservoir, to atmosphere, when the unit is runing unloaded or stopped. When the unit is running unloaded both valves are actuated. (open to by" “control system air When the unit is shut down (stopped) only one blow down valve will open, actuated by normal air presaure bui14 up below the intake valve in the air and. 1) Separator ut High Peaperet jeparator Ou renperature Shut Down Switen 2) Mintaus Pressure/Chack Valve 3) Biteaure Relie® valve 2) Muttien 5} Biby Bown (ump) Yaive Vinloaded Operation Only) 6) Separator Drain Line 5) wibeier 8) Biaia'Line Signe cage @) Drain Line check Valve 10) Drain Line Filser ID) Separator Drain Tube 12) Blow’ Bown (bump) valve (Unloaded Operation and shat Down? RETURN AIR BLEED LINE (Figure 10) The return bleed line consists of a hose, suitable fittings and a check valve. This line connects betveen the side of the intake valve housing section of the cylinder and the air cleaner. When the unit ie runaing unloaded (intake valve closed) a saali amount of air is allowed to enter the air end from ataoaphere. check vaive prevents air and oil. eacaping from the air end through the air cleaner when the unit is shat down. CONTROL | PRESSURE REGULATOR VALVE (MODULATING OR AUTO DUAL CONTROL) (Figurea 5 and 11) The control pressure regulator valve is located on tha control valve bracket. The purpose of this valve is to furnish control pressure to operate the intake valve for modulating control and begin unloading for auto’ dual (timed stop) control. This valve senses unit air receiver- oil reservoir air preseures in a 10 psi range proximately) and opens or closes the intake valve te control air delivery based on demand. The higher the unit receiver air pressure, the higher the control ressure and the sore. the intake valve jo Closed: (low demand) The lower the unit receiver air pressure, the lower the control pressure and the more the intake valve is opened. (high demand) When the unit air receiver air assure falls below the. lower limit of fhe control range, the control pressure Tegulater can no longer saintain control reaaure. hia allows the intake valve 0 fully open. (full load) NOTE THE PRESSURE SWITCH PS-1 AND CONTROL PRESSURE REGULATOR VALVE, ON SOME UNITS,” HAY" BE’ ADJUSTED’ To QBTAIN A MAXIMUM OF 125 OR 150 PSI FULL LOAD | PRESSURE. THE CONTROL OPERATION AS DESCRISED ABOVE WOULD THEN WORK BETWEEN 125-135 PSI OR 150-160 PSI. (APPROXIMATELY) | CHECK THE SPECIFICATIONS FOR EACH UNIT TO OBTAIN" THE MAXIMUM OPERATING PRESSURE BEFORE MAKING ADJUSTMENTS. PRESSURE, SWITCH PS-1 (MODULATING AND AUTO DUAL CONTROL} (Figure 11) Presaure switch PS-1 is located inthe electrical control enclosure. The fungtion, of pressure switch PS- 4g 49 conjunction vith’ solenoid valve 0-1, to fully close the intake valve, “actuate the Blow” down (dusp) valve’and start the timer for auto dual, (tined stop) mode of operation when full unioad pressure ia reached Pressure to actuate this ewitch ig gbtained from a control line connected to 4 portin the minisum preseure/check valve. The port. in the minimum pregaure/check ' is located on. the storage Teceiver (down stream) side of the valve PS-1 pressure switch must be adjusted to, actuate at 1 or 2 par balow the nodulated full ‘untoad pressure. PRESSURE SWITCH PS-2 (AUTO DUAL/TINED STOP CONTROL) (Figures 11 and 12) Pressure switch PS-2 is located in the electrical control enclosure. The function of pressure awitch PS-2 ig to prevent the unit fron atatting or Yegtarting until unit receiver pressure falls below 20 psi (approximately). This switch electrically Slosed switch, must be connected to operate as a normally Pressure to actuate this switch is obtained from the unit receiver. PRESSURE SWITCH PS-3 (Figures 11, 12 and Pressure switch PS-3 is located in the electrical control enclosure, The function of presgure, avitch PS-3 ig to stop the unit in the event the air Pressure in the storage receiver rises above the maximum desirable operating pressure, Pressure awitch PS-3 must be wired electrically as a normally open switch. CONTROL LINE SHUTTLE CHECK VALVE (Figures 11, 12 and 13) Two shuttle check valves are located in the control circuit(a), One is mounted cn (threads into) the upper or intake “valve section of the cylinder. ‘The port in the cylinder ia located below the intake valve plate. of this shuttle The purpose check valve is to: 1) Allow air from solenoid valve S¥-1 to open the blow down, (dup) valve when’ the “unit ig running unleaded, oR 2) Allow the normal build up of air pressure in the air end to low down | (dunp) unit is shut down. The second is located ‘open the valve when the in the control iping near, ang at the outlet port, of Eokenoid valve Sv-l on the conteB? vase Bracket. The purpose of thia shuttle check valve iB to: 1) Allow modulated control pressure fron'the control pressure regulator valve, to open” and close the Intake “Valve” gor” modulating control, or 2) Allow air pressure from the solenoid valve” 80-1" to ‘close the intake valve completely when the atorage receiver pressure Teaches full "unload pressure. | (PS-1. actuates, rodulating or auto dual control.) WATER FLOW CONTROL VALVE - WATER COOLED UNITS (Figure 13) The water flow control valve is located at the water inlet port of the oil cooler, or aftercooler, if used. The pPuTbese. of the | automatic adjustable water flow control valve is to’ provide sufficient cooling with mininun water usage. The 031 cooler water flow, when an aftercooler is used, is piped’ in series with “aftercooler. ‘The Affercooler is first in the serios, The | temperature — sensing _ probe (capillary) "is always located in the oil flow piping to thé air end. INSTRUMENTATION Instrusentation (gages and indicators) are provided on” these unite to “monitor function and provide agsietance with service diagnosis. The following chart lists the ingtrumentation, location of each and 3 brief description of function.ITEM “POWER® ON LAMP HOURMETER AIR CLEANER RESTRICTION INDICATOR OIL PRESSURE GAGES) AIR PRESSURE GAGE(S) “RUNNING* LAMP “MOTOR OVERLOAD* LAMP “HIGH TEMPERATURE” LAMP "HIGH PRESSURE* LAMP CONTROL SELECTOR SWITCH OIL TEMPERATURE GAGE (THERMOMETER? AIR TEMPERATURE GAGE (THERMOMETER) ECONOTROLT® CIRCUIT BOARD LAKPS LOCATION Qontrel Enclosure Door Control Enclosure Boor: Inatrument Pane Instrument Panel Instrument Panel Control Enclosure Door Control Enclosure Door Control Enclosure Boor Control Enclosure Boor Control Enclosure Boor Instrument Panel Instrument Panel Inside Control Enclosure INDICATION Shows power to unit is turned on. Ready to start. Showa unit total run tine. Shows restriction of air cleaner and need for service, (25" of water maximum) 1) Shows filter iniet oil pressure. 1) Showa filter outlet pressure. Used to check oil pressure drop across filter. 1) Shows air _ pressure upstream (wet) side of separator element. 3) Shows air pressure downatream (dry) side “of the separator element (storage and distribution syeten). Used to check air pressure drop across separator élenent, Indicates unit is running. Indicates unit shut down due to tripped,” sotor “overload “relay (switch). Indicates cause of shut down due to high air tenperature. Indicates cause of shut down due to nigh storage receiver pressure. Provides user selection of type of control in basic node of control. T.£, Dual Control - Select Modulating of Start/Stop Control. Indicates oii = injection oi. temperature. Indicates air end _ discharge temperature at inlet of air receiver- oil reservoir. Indicates pogition (open or closed) of bypass valves. 10gee Desciption 1”) fir Cooled Oi Cooler /Afmrencar sine 2 | fir End Beton Eralonre awow > 3 | Far tlotr Eloi Enclonre croab. 4 | OW'senpievaie 5 | Thevmal By ess Valve es W ceotc0 on > & | outin 2 | ntaee Vabe 12 | Ar ear Revo] 30 | Blow bom (Ou Vee 4 | Remn ticCied tuck check Vave || 19 | OW Fer {Uionied Operator On) a | Aven 20 | Senator Etament a1) Mutter fo | Shor Cree vate 21 | Gono! Line Dav Vai 32 |. Stator oat 1 | firtqa Owner SIGH Toopetce || 32 | Sracue Sich PS) 35 | Drain tine igh Gage Shot Bown Sah 25 | Paste St P53) 34 | Separator Dram abe 12 | Selmaie vane 5¥-1) 28 | Prune Switch (8.3) 35 | check Vata 13 | Convel ion Once 2 | GonrolEncowre 35 | Orantine For 14 | Shure Check Vato 26 | tnsraant Panel 37 | Blow Dawe (Oomp) Vote 15 | Goma renareRepstoor CPA) Vave || 27 | stimu PaguretCheck Vahe {Unione Operon ae Su Den) 16 | Reuvos Oran Vor 28 | Prame Ret Vale a8 | Seperator OUT High Tompertura 1 | Gitte secon 3 | Metter ShutDown Sat are Figure 11 - Piping Diagran - Air Cooled - Auto Dual Control (S/H 4164x70 & Before) ulGilt Sight as 21 | Aly Rewer Ot Reservoir 38 | Slow Down (Ouro) Vas ie 22 | OuFite [Unfoadod Operation Oxy 1 23 | Sopaetor Element 35 | Mutter 24 | Sono! Line Drain Vato 6 2 25 | Pressure Seen (PS) > 3 25 | Tronuducer Ea “ 27 | Presuee Sitch (96-2), a ® 25 | Presmre Satoh (PS 3} 40| On 6 29 | Cont! enconure 4 | low Down (Dump) vave a7 [30 Instant Pane! [Unloaded Operavien and Shut-Downh 8 131 | Minion Presure(Check Vale || 42 | Separator OUT High Temperate 18 | Reservoir Onnin Vale 232 | Pressure Rait Valo Shut Dawn Sith 308 Figure 12 - Piping Diagram ~ Air Cooled ~ ECONOTROL?* (S/N 4164270 & Before) 12ae Devription | {| Ale Cooled OW GooteriAttresaiee anem 2 | Air End Electrical Encloure anne, 3 | FanMotor Electrical Enclosure vero 4 | ot'sampte vate i) consooee 5 | Thermal By-Pass Vale om 8 | OnFiter 7 | tetake Vatve 48 | Ai Rosana i011 Resrvcie ‘32 Blow Down (Dump! Vale 8 | Retum Air Glen ack Chock Vato |! 39 | Oil Fler Wnloaded Operation Ory) 8 | Airco 20 | Soparatar Eiement an) Matter 10 | Shuttle heck Vale 21 | Gontrot Line Orsi Valve 32) Separator Oxf 11 | Air Ena Discharge HIGH Temporature || 32 | Prenure Switch 5-1) 3B | Oram uinesigne Gage Shut Down Switch 2 | reaeire Sith (P52) 34 | Separator Dean Tube 1 | Salmo Vana sv.2) 24 | rossi Site (75.33 35 | Ghede Vawo 12. | Como! Bled Orie 2s | ContolEneioure 38 | Dra Line Ftor 16 | Shute Crock Vat 26 | snsament Pel 37 | Blow Down (Dura) Valve, 15 | Contot resura Regulate (CPR) vawwe|| 27 | Mmm vate (Unloaded Operation snd Shu-Dowa} 16 | Reservoir Drain Valo 28 | Prete Relat Valve 38 | Seperstor OUT High Fempwreture 17 | Ot Laval Sight Goger 23 | Matin ‘Shr-Down Sitch Figure 11 ~ Piping Diagran aera - Air Cooled - Auto Qual Control (S/N 4164x70 & Before) iLBeerision ei Oi Conler/atereaai nd re ‘woes Blow Onwa (Duo) Vate (Unioaded Operation Oniy) Git Level Sighs Gaver Air Reeivrt0l everoie Oi Faer 11 | Air Eve Oleharge HIGH Tomspormure ‘Separator Element ‘Shut Bown Seiten = Manitou 13. | Solenoid vats (sv) 38 | Contr’ tised Grifon 35 | Shute Chore Valve £ £ seeeee eH t i i HESERVOREBNNS 7 18. | Resewot Drain Vala Presure Relat Vale Figure 12 - Piping Diagram ~ Air Cooled - ECONOTROL'* (S/N 4164x70 @ Before) 12ara our inex we. ane + | Od ample Vale anon 2 | Thermal yous Vata voron me 3 | outer COOLED On a. 4 | Sree ‘wares 5 | Water Flow Control Valve ae & | Inase vate i 1 | Berarm at Sie Quck Check Vato - 3 | artes Bi] Ai Riceeioi Reser) 3ST wate | Shun oak Va 2 | oem 38 | Blow Bowe tbu vane To | Arend Omer HtcH temperate |) 32 | Separtr Element {Unleades Operon Oy) Seat Down Swith 25} Comrot Li Drain Vaio 23 | fr 1 | Manton 26 | eure Sah) 36 | Scouser date 12 | Samoa va tsv-1) 25 | Tram 37 | Drain ine ite cape 13 | Comal Sad vice 26 | Presre Switch (0S 2) 3 | Swurtar bran Toe 14 | Strce Che Var 21 | Prema Sith (P53) | Shea vane 23 | Solano Vale (0-1 28 | Conte Enews 0 | Drab Line iter 1 | ont! Presa egultr (CPR) Yabo || 39 | foster Poe! 41 | Glow Down Dump) vate 1 | Prosure Reducing ete 30 | Citcaom {Gaoaded Operason and Shut Down 18 | Benes rain abe 31 | Minenum PressucetCheseVaie |] 42 | Senwstor Out Hn 18. | Give Sohedans 52 | Promsm Retet Varo Shutboun Sie Figure 13 > Piping Diagram ~ Water Cooled ~ ECONOTROL** RB ai (S/N 4164x70 & Before)Tae Ne. 1 | Aiccoote oi cooiarAtereoote | ra | conrolPrewsre Router Vane | 2 2 | AirEmi Eleaiea Enclonre 48 | Convo! Biwa Grit 2 3 | Fantotor etic Enciosore Reservoir Brin Vive © | Olt sample Valve IF | Oi Une Sight Gaps 2 8 By-Pass Vale 48 | Ale Recee7O4 Revowoi x 8 | aleve i Filer R 3 | tree vane ‘Seraor s 9 | Awend 21 | Cone! Live Drain Vahe 8. | Raurn Ar Bid nin chect veh | 32 | PremuneSwiuh {05 = 40 | Revurn Air Btn Sx 2 | Premuea Switch (75:2) 11 | Air Er Dinghies High Tampere | 34 | Premir Sly Promne Suits (P83) iy 25 | Cone! Eneoure 42 | Sotmoid Va (SV-1 2% | lorvumaet Pane a 13 | Shatin Chack Vatve & | Minions Prnnors Chock Vale Figure 14 - Piping Diagram ~ Air Cooled - Auto Dual Control 14 foro conten oc (S/N 4164K71 & Later)i Deseo 5 | Selmold Vat (51-5) 38 | Cantal Encore Convo! Blond Orit 3 | neurone Pat 1 | Ax Gould Oi Coniiatarcocter | 11 | ComrolProaire Rapuiatr Vow | 33 | Minimum Promur Check Vale 3 | At End iecviat Encionre 18 | SrewureMaducing Vee Gane | 38 | Pani te Valve 2 | FenMotorEkeubal Enctowe 39 | froma Redocng Veter 35 | Stow Down (oumph vabe 4 | Gisele Vere 20 | Solos Vote (SV. {Unloaded Operon Gry) & | Thwmal Par Vobe 21 | Reece Daf Valve as | Mtr 8 | oiete. 2 | Gl eet sate cone | Stoumen Gate 3 | tness ake | ReRemivr/Or Retrole 3B | Drintim Sint Gage a | seen | oir 3 | Seowstor Drain Tune 9, | Betura Air Bios Line Chace Vale | 35 | SopnatnrElrmant | check vane Sa | ftw lr Bines Shut Ort vate” | 38 | Contel ine rin Votes 48 | Bran ine Fe M1 | AWEnéDacearye High Tonperonue | 37 | Presa Sten 20) 42 | Bow Down (Our) Vas ‘hot Bown Sah 2B | Prem Sten 52) {riogid Opmetan ana 12 | Manito | Toned Seton 13) | Solmala vane is¥-4) BD | rose Sh 5.3 43 | Souter OUT High Taverne ta heck Vaio ‘Shut Boun Sn Figure 15 - Piping Diagram ~ Air Cooled - Econotrol** (S/N 4164x71 & Later) isae ‘Dacipice 34 | comraios Once 21 | oncoote is 35 | anol Prenuce Roginor Vane | 32 | Minimum Preaare Gs Vato 48 | Prom Rescing Vs 3 | Airens 3 | oi sampte vale o tee 3t | Prosure Ratt Vane 2 | Trane By Pat Vows 18 | Sete Vote (Sve) 235 | Slow Down (uel Vai. 3 | ows 5 i Orin Vale {Unlomte 0 4 | Rtarnste OirLmet Sah 3 | Matitee § | aaron controt vote Bi | Ar RecivrOH Romrvoir a ett 8 | foune Vale 2 | Ole 38 | Benin Line Sight Gage 7. | Rotor Ar Sten Line chuck Vahe | 33] Sepmatar Elomant 3 | Stoorstor eam Taso 2 | eum ansiousiconvabe | 2 | eroryrccement 40 | coma vane 3 | airénd Ducharge High Terparotae | 25 | Prenure Suan Poa 44 | Bron Line Fite Shut own Sten 25 | Promo Switch Psa | Stow Down (Dame) Vai to | santa 2 | Traaducee {Unloaded Operation an Ti | Solenoid va tsv-0) 23 | Prmure Sitch 5), rsOown) 2 | Sete chant Vave 2 | Conwaren ‘Stomator OUT High Tarps 3. | Saino vate (561 20 | tewroment ane! Shean Sata Figure 16 - Piping Diagram - Water Cooled ~ Econotrol** (S/N 4164x71 & Later) 16NOMENCLATURE + Housig Vane OL3* Fan Motor MAGNETIC SWITCH OVERLOAD HELAY Fuse PUSH BUTTON + Aie Cooled Fan Motor PILOT LAM? oa @-wire @-re0 @-sreen 6m CONTROL RELAY 13 Tewpenarune servo t hu hounMeren PS) bressune sivercn compen cor TRANSFORMER foror Sv. SoceNoID vaLve ; bis biscowwecr tran) ! ® TeRMinat soano OPTIONAL bem ot2+ — gtae BOs ae Figure 17 - Wiring Diagram - Modulating Control - Across the Line Starter a7st ou Fu at cr 1s He Ps sv cr ois. @ x Jumper ween Fan Oiconnect fanot wed NOMENCLATURE SOLID STATE STARTER MAGNETIC SHITCH OVERLOAD RELAY Fuse PUSH BUTTON swiTcH PILOT LAMP @- ware @-Reo ©-creen CONTROL RELAY TEMPERATURE SWITCH HOURMETER. PRESSURE SWITCH SOLENOID VALE VALVE ‘TRANSFORMER DISCONNECT (FANT TERMINAL BOARD ‘OPTIONAL sowing vont O19 at 0 sor i g Fan No 1 Curtomer wuoetied uh sug fauna + sic Goote : . os Piniierse 9 8 Bo pees H ar et i epee ot out 1 U3 Comme, a tower Ola aM td a u ous Otae Pad 221 Figure 18 - Wiring Diagram - Modulating Control - Part Winding Starter 18NOMENCLATURE Howting Vent OUI aM MAGNETIC SWITCH Fan Mote, OL OVERLOAD RELAY t FO Fuse PB PUSH BUTTON swiTCH *AirCooled tat PL PILOT LAMP. Fan Motor ote = WHITE AED IRS GREEN 1s eR conTnow RELAY or ‘TS TEMPERATURE SWITCH 7B Hit OURMETER compressor 4 PS PRESSURE swrrcH Mov ar SV SOLENOID VALVE 2 Pr TRANSFORMER 78, DIS DISCONNECT (FAN) aur @ TERMINAL BOARD et ‘OPTIONAL Figure 19 - Wiring Diagram - Modulating Control - Wye-Delta Starter 19o. Fu Pe au cr 13 PS sv bis umpse when Fen Disconnect ‘anot awed, owencuaTuRE MAGNETIC SwIToH SvERtonb meLay fuse ust eurron Pitor tame @ wire @-ne0 O-creew CONTROL RELAY Sempenarune sures fourmere PRESSURE SWITCH TRANSFORMER SOLENOID VALVE DISCONNECT (Fan) TERMINAL BOARD ormionat + outing Vent Ot3 Fon Motor essa OE ant ab cred, st oF & Tt 3 2 Lo High Temperature olze tae crs Figure 20 - Wiring Diagram ~ Modulating Control - Solid State Starter 20OL Fe 8 's cer sv brs, e far TR ie 10 NOMENCLATURE MAGNETIC SWITCH Castor spolied a OventonomeLay *Howimavens ols ae rose ‘Fan Motor | even Fost surrow H picor car Wi Se2Re Te @ wre ¥ + cooind one ° @® veo Frottowe no a © aneen ‘oe CONTROL RELAY i stor TenenaTune swrren Eso founweren PRESSURE SWITCH a ee Taancronen i SOLENOID VALVE red ie (2 DISCONNECT (Fan) Comores scr wl ST Stonrin conTacron Mere : tL aun! Starr conracton { ad AUN CONTACTOR vo * At. Srantina AvTOTnaNsronwen cr eT a TIME DELAY RELAY. TIME DELAY cLOSE tf Tie DELAY OPEN IncoweLere seouence Time DELAY RELAY’ STARTER CONTROL NUMBER OPTIONAL ag Jamoer whan Fan Daconnec Fenot ond” ou out nee Figure 21 - Wiring Diagram ~ Modulating Control - Autotransformer Starter aaBezeF ce 18 HM Ps bis sv 5s ™ cer S ¥ Jumper when Fan Disconnoet| Temot ver, + Hooton Vont NOMENCLATURE Fan oer MaGNeTic smnrcn OVERLOAD RELAY Fuse PUSH aUTTON swrTe Pucor Lane @-vnnre @-neo @©-sneen CONTROL RELAY ‘TEMPERATURE SWITCH HouRMETER PRESSURE SWITCH DISCONNECT (FAN) SOLENOID VALVE SELECTOR SwiTCH ‘Tien RELAY ‘TRANSFORMER TERMINAL BOAR OPTIONAL Air Cooled Fan Motor Compressor, Motor Pe2 oust oe 1 High 20 YY Temperature ' thom ' p aiks ' ' t I ' ' i b on ae 8 oe of g prion S ota fan foes? [Oe Controi my (aM 17 SPLYN High Prommre ° nt o erou e {MOTOR 0. ° tare 2 sv woputate SS! auto DUAL - ) on ath 2t_ Yay Auto RESTART Figure 22 - Wiring Diagram - Auto Dual Controd ~ Across the Line Starter 22+ Houma vent gua" NOMENCLATURE Fan Motor iwaeneriesuarcn Sventonp nea fone specgoea OS® PUSH BUTTON SWITCH Fan Motor muorawe @- write @-neo @-cnten ou cOnTHOL AELAY Tewrenarune sven fourm PRESSURE Seren Serres DISCONNECT (FAN) * aM fouenoro valve Seuscron ser iaen neva TransronMen Cs TEAMINAL HOARD OPTIONAL Pea PargranT 23222 x @Ysa2gaEdg sumer whee Fan Dionne fanotume, cas est) tra 14 9t1 OLA gts ane zd Car alba See Okan eating Fan — ets [= Goat a ot Optional ots 1, SPUN Hah Presa ous 73 az] “oe @) ous [18 Yqymoror 0.4. ker Pst avy mopucate 88" auto nuat a @ oTRy 20 6reyQ AUTO. Nt wesranr Figure 23 - Wiring Diagram - Auto Dual Control - Part Winding Starter 23ROMENCLATURE MAGNETIC SWITCH * Howirg Vent O13 Te GS ‘OL OVERLORD RELAY i are mpoties Fu FUSE ti TVR 1 Pr PB PUSH BUTTON swiTcH a nm pluor tawe @-winre @-reo © -Gneen cA CONTROL RELAY TS TEMPERATURE swiTcH HM HOURMETER Ps) PREssuRe suTcH 53 SELEcTon swe SV. SOLENOID vatve CPY TRANSFORMER DIS DISCONNECT (FAN) TR TIMER RELAY @ TERMINAL BOARD % OPTIONAL, 1 2 sumper when Fan Disconnect giz oust cas eo er Mechanical Interloce sst MODULATE ‘ auro ual, TR 28__SPLYTY AUTO . ot. aT Figure 24 - Wiring Diagram - duto Dual Control - Wye-Delta Starter 24NOMENCLATURE 8) SOLIO STATE staRTER M MaGNetic swiren OL OVERLOAD RELAY FU FUSE PB PUSH BUTTON SWITCH PL PILOT LAMP @- ware @-nreo ©~sreen CR CONTROL RELAY TS TEMPERATURE swiTCH HM HOURMETER, PS_ PRESSURE SWITCH DIS DISCONNECT (FAN? SV SOLENOID VALVE SS SELECTOR swivcH TR TIMER RELAY, CPT TRANSFORMER TERMINAL BOARD Ory € oPrtonat, urper whan Fan Disoanset] Cos lenot umd, gas h t t ' I 1 t t ' ' 1 fl zens ‘Housing Vent OL3* cone cargoes oes Fan Motor oa nf, Comore (ayo som" ne a 4 02 2 2 ea ier ese ata 1M 2 OF Te oft O02" ola cas, Ontiona etatog Fan Sonnet (3 ote 2p 8G Nah re osvona ole ee on VAY MOTOROL. aL zo vy alors @ oT 28 SHR, Figure 25 - Wiring Diagram - Auto Dual Control - Solid State Starter 2s.CONTROL RELAY hoonweren Sececron sure Sotenoio vaLve ‘Taansronmcn. Discouect tran ‘FenmnAL can mousse Figure 26 - Wiring Diagraa ~ Woduleting Control and ECONOTROL** ‘Across the Line Starter (S/N 4164x78 & Before) 26nowecuarune Mt MAGeTiC mre OL OVERLOAD RELAY PB Puan eutron smrex Feumenarue seron source Stceron enon SOUENOO vaLve ‘eansronwen DiscoAMNECT (ean 1 tenwnat onko 9 oPTIoWa, pcre Hewpaves ot9" awe , somes ogy ee ‘ta! icp ot x : : 8 =] : Co adie, maa ey : ss 5 . ( p= Fu hii. 17, PCY a ana TT ae Figure 27 ~ wirin Part Bs Diagram - Modulating Control and ECONOTROL** nding Starter (4184479 & Before) 27vane a a re . SEE & Resent meg o E TB ru quran omen Pinter wo eek sri @-neo gre, Soane Pe iets ve HOR RRETR 1 a ee acai 1 i : ext : coal I ee 7 a 2 woouate “8 | ecowornot 5 ———— Se [tt n are Joe cat, + ioe Then pene 1 Peean Ja Figure 28 - #iring Diagram - Modulating Control and ECONOTROL** Wyo-dolta Starter (3/¥ 4164470 & Before? 282aaEag. 5 @ * perrever Coun ae SOLID STATE STARTER, Fan tote sedeene ater Shenson obtaurron srr vensaast aE enn mee een uly emtmnou nesay commer “@) etrensrut ren sume wounmere reais SEueeron swine Sousnowo vate Thastronwes Disconneer ian “ermiuat soano corrioua Yaygpronon econerno. “ a, nee Figure 29 ~ Wiring Diagram - Modulating Control and ECONOTROIX® * Solid State Starter (S/N 413498 & Besora) 29be on ten es ® * IMaGNeTsc swiTcH Fuse Pug aUTrON swTCH @-oneew coNTROL RELAY ‘ouRMeTER ReSSURE SIT Seurcron sarew ‘Thansronwen TeaMWAL 99AH0 corrionat Fea Bicomaey “eager 2 + Re ceina Belo SF rst, tre gus ous eis ena n8 Figure 20 ~ Wiring Diagraa ~ Auto Qual Control and ECONOTROL** Across the Line Starter (4164x783 & Before) 30© S * aaweric smiren OventaaoneLay Pose tg eo Cees @-sreen, ‘Faéscune surest brsconnecr (Fan Sues neva ortioNa, ou Figure 31 = Wiring Diagram - Auto Dual Control and ECONOTROI*" Part Winding Starter (S/N 4164x78 & Before) 41ae act ceonorourenaato feo masse. gg eam n zA RR RPE Sf GF Qe Figure 32 - Wiring Diggran ~ auto Dual Control and ECONOTROLY* Delta Starter (S/N 4164x78 & Before) 32& a @ * NomeuceaTuRE SoLio state sranven Macnene sme ‘SUERLOAD RELAY a cournou nevay omer, Tenmcaatune swore foummecren Moor Pressune surren DISCONNECT IFan SELECTOR sartok ‘orriowat Ye jMergnon. opfcunornouauto UAL Figure 33 - Wiring Diagran - Auto Dual Control and ECONOTROL"* Solid State Starter (S/N 4164x784 & Before) 33owencs srune @- ware @-nc0 @-cnten eBxyroL RELAY ‘Tewrensrune swore Pressure santo ‘soueno1o vaive Franeronaten Biscomecr rant Foruwal soar *® cas Resenvonte ste @ Figure 34 - Wiring Diagram - Modulatin: Across the Line Starter ¢! Sint ale Control & Econotrol** 4x79 & Later} 34Se Ovencono ats FE RB orn orcs @ wermmarsonae np apulmer Reais | stun Lat aes ace Figure 95,5 Viping Diagn ee part winds Et ran - Modulatin. barter (S/N 4164x79 & Late: Gontrol & Econotrol** 35we ‘necutticsmron ‘ie Sseounccr rant 3 ‘nono SE OFTONAL BaEe Figure 36 - Wiring Diagram - Modulating Control and Econotrol** Wye-belta Starter (S/N 4164x79 & Later) 362 pu aurron sare ue, 2 Seow Seat Ea ea 2 eae 3 SEE @ renmwar soano crest sg Btosaresanre USS ene guages fe Btcame Paar Revke ie Figure 37 > Wising Diagraa - Modulating Control & Econotrolt® Solid State Starter (S/N €164x79 @ Later a7owswccatuas oe oF 2 een 2 ee 5 Rea a ygy Semen lS Bg Eye Se. sesenvornneaitn, g sien ese wean NG ram - Auto Dual Control & Econotrolt® Figure 38 ~ Wiring Dil ine Starter (4164x79 @ Later) Across the 28aan rete Lo 2, BUN wai aie mee tS é pi e I H jog Ryman Sa Figure 39 ~ Wiring Diagram ~ Auto Dual & Econotrol™* Part Winding Starter (S/N 4164x79 & Later) 39sone mato. sia 2 whey tte moet or coy! wes hae Dsagran ~ aueg Dual Control & Eeonotrol"* Figure 40 Wecbelea Starter (S/H #104x98 F Pacer 40‘& tenon sesso % serious ecenvorn neater Figure 4i > Wiring Diagram ~ Auto Dual Control & Econotrol™* ter) id State tarter (S/N 4164x72 & Late 41Section H SPECIFICATIONS — GENERAL ve ee ee ee tt frat amen sam tar aT sein sa ane zs oma cer ier is mS SWE WEST x, genean mmm mm NTE ‘ALL PRESSURES SHOWN ARE HAXINUM FULL LOAD awe a ee wg ain, Pe amma sage PR IT gain naam wlan cl caper en EAE de iggy ue uae, sn cana rr i re agra ce ms, as sss CAUTION OBSERVE THE AIR CLEANER RESTRICTION INDICATOR. CAANCE ELEMENT TREN INDICATOR ‘BROVS RED. ONDER DIRTY OPERATING CONDITioRS, THE AIG CLEANER ELEMERT VILL REQUIRE CHNGING NORE OFTEN, ‘UL FILTER CHANGE YRTREUAL, Wome 3000 1000 1100 1000 1000 1000 cootTON CONDITIONS 1 WHICH THE UNIT 16 RUWNIRG MAY EFOUIZE CHARGING THE OIL FILTER WORE ‘OFTEN. ALVATS RENEW THE OIL FILTER AT EACH OIL CHARGE. O41 pressure gages (filter in, If a difference in oil pressure filter out) “are provided so that the (rated pressure, norms] operating Pressure drop across the filter, (filter temperature) readings (filter in filter condition) may be checked. gut) i615 psi of greater, change the ter. 041 Separator Elesant Change Interval ... As Required 42CAUTION ALWAYS CHECK THE SEPARATOR DRAIN LINE AND DRAIN LINE FILTER FOR DAMAGE OR "| PLUGGING " BEFORE CONDEMNING A SEPARATOR ELEMENT. OBSERVE THE AIR PRESSURE GAGES FURNISHED TO_ CHECK THE PRESSURE DROP ACROSS THE SEPARATOR ELEMENT. (RATED PRESSURE, NORMAL OPERATING TEMPERATURE) IF THE PRESSURE DROP IS | 15 BSI OR HIGHER, RENEW THE SEPARATOR ELEMENT. LUBRICATION - COMPRESSOR cil sampling and analysie. Oi] sampling and, analysis ig recommended avery — 200" hours of, compressor operation at least until an oil/oil filter change pattern or schedule 1s established. lubricants 7, «packaged. r It is recommended that LeROI SSL-32 (petroleum) or SSL-46 (synthetic? lubricant be used. Either of these say be obtained, convenient) rom your nearest LeROi distributor. If $8L-32 or S8L-46 is not available gontact your local lubricant aupplier for a (lubricant which mate the The useful life of compressor of1 specifications given in TABLE 1. depends on the quality “of the ofl and the conditions in Shich the unit is LUBRICATION ~ ELECTRIC MOTOR operating. Refer to the motor manufacturer‘s For these reasons oil and oil filter recommendation for motor bearing change intervals are to be deterainad by lubrication. TABLE I TYPICAL LUBRICANT SPECIFICATIONS Non-Detergent Turbine or Hydraulice O11: Viscosity @ 100°F :..... Wiscooity @ 09 oi 22.: Mindaum Viecogity index’. 121111 Pour Point, Hiniaum Flash Point, °F ....seseeseeee Rust Inhibitor Oxidation Inhibitor . Anti-Foam Additive ., 160-220 ssv 1, 30 000 S80 or lese 20° lower than lowest expected 43 Starting tenperature. 400 9 ASTM, D665 (latest? No rust after 24 hours sea water. STH, D943 (latest) Neutral No. 2.0 or less after 1000 ASTH, D892 (latest) 3 cycles atability nil, hours.Section Ill INSTALLATION MOUNTING AND SPACE REQUIREMENTS A guitable smooth floor should be provided for placing the compressor. A special foundation is not required unless’ the floor or other ‘mounting surface is extremely rough or unable to support the weight of the unit, The unit should eit level, It is advisable to use shins, as requited, to make certain the Erane'is’ resting firely on the sounting surface. Xf there ig danger of the unit being moved out of position for any reason fay be bolted to the mounting surface. Adequate space must be provided to gervice the unit once it is installed. Both housed and unkouged unite suet be positioned at least 24° away from a wali breather abetruction on all sides to allow adequate. cooling. “air circulation and service accesa. NOTE IT 18 RECOMMENDED THAT THE COOLING MXR QUTLET OPENING OF THE, UNIT, BE POSITIONED. GgstRuetion to" seevenr UNcoNTROLEED RECIRCULATION OF HOT AIR, TABLE I] shows the | approxisate overall dinangions and veights which may be used “for selecting) a “suitable location for the compresser. TABLE 11 AIR COOLED - MOUNTED COOLER WITHOUT HOUSING Width. ight, WE200/¥EH20085 153.5 69.0 84.3 WE250/¥EH25085 13:5 69:0 84.3, WE200/¥EH3008S 15315 69:0 84.3, AIR COOLED - MOUNTED COOLER WITH HOUSING WE200/ ¥EH2005S 155.9 a4.3 9000 WE2S0/¥EH25038 155.0 69:0 4:3. 9150 WE300/¥EH3008S 135.0 69:0 543 9250 AIR COOLED = REMOTE COOLER WITHOUT HOUSING WE200/WEH2008S 104 58.3 78 7450 WE250/ ¥EH2505S 104 58:3 78 7600 WE300/¥EH3008S 104 58:3 78 7700 AIR COOLED - REMOTE COOLER WITH HOUSING WE200/¥EH20088 104 59. 78 8200 WE250/¥EHO508S 104 59 78 8350, WE300/WEH30085 104 59 78 8450 REMOTE COOLER - AIR COOLED WE200/¥EH2008S 44 57.2 74.3 101g WE250/WEH2S0SS 44 5922 74:3 1015 WE300/¥EHSO0SS 44 5722 74.3 1015 WATER COOLED WITHOUT HOUSING WE200/¥EH2008S 153-5 69 94.3 5950 WE2S0/WEH25085 153:5 69 84.3, 6200 WE300/¥EH3008S 183.5 63 84:3 6280 WATER COOLED WITH HOUSING WE200/¥EH2008S 155 63 84.3 6700 WE250/WEH2505S 185 69 84.3, 8950, WE300/¥EH300SS 155 69 84.3 7000 44‘Romany aeceTven OPTIONAL wate, Sie watt ourtel FAN VENTED) a SP TIOWAL WALL cengor ter Bimeer sige wate DUCTING af coaLER he i By one sears ane Tents arene ° TB Sms fe| de EO ee §e° ED) fe cote sane Feo er excrone inect noo mer at Bre NSS ts crm evens ease SLES eaten saat totes nd Ocha 31 NOT dated compose ‘ont wxhat fan arom a Ie Yvert Simportare 932° 100" ors A Inet apenion mat bat etaugh tow elt for conng tnd ndeasete ‘Miwa fase most ow 31,560 7, pais Figure Urconvatedwectsltion of eat sr mrt se prventod Far Maxinam Quiet Operation 1. venus re to orev baton. 2. Fan Dichage must ba dutnd 23 fay pen doctor it moun as Senate, ‘et wsieton tobe On. HO ra TWPIGAL OISTRIBUTION SYETERT 42 - Installation Diagram - Typical 45ELECTRICAL SUPPLY an adequate electrical ower supply of the'correct voltage must bi Bear @ provided. All control enclosure wiring has been completed at the factory. Thia includes Saghetic, “starver withng for “unste Fugnished with starter." Unite furnished without a starter require wiring the starter” on [he jop sites The electrical | su should be ogutppes™ with a cud Hoe Meets Suiteh of citeult. breaker 0. that shecerseal” power nay “be” diaconnacted watle the unit ie bethg asrviced: The fused Line disconnect should be located. “and mounted in acegrdance with aff etare, “Local” “and” maticnal Pegulation The unit must be properly grounded to provide adequate round fault PEopeepion. Aa a guide, ft 16 suggested hat the ground wire be equal in size to one of the conductors which feeds the compressor notor circuit, Make certain Ehe'ground “wire connections are clean and fight. The wire used to feed the compressor gircuit should be selected and sized based on the following conditions: 1) Motor full iad amperage plue service factor. 2) Ambient temperature in the area where the wire is located. 3) Length of wire. 4) Ineulation type. Thie information may be found in the latest ‘edition of the National Electrical Code. When installing | a unit. in a "Hazardous Location"; that is in a location where fire or explosion ie a definite hazard, refer to the appropriate, section of the National Electrical Code for further information, CAUTION IN ALL CASES LOCAL, STATE AND NATIONAL ELECTRICAL ‘GoDES HUST BE STRICTLY FOLLOWED. AIR SUPPLY TO COMPRESSOR COMPRESSION) When (COOLING AND sizing building openings and 46 inlet or exhaust fans for cooling air flow and make up air, the openings and fang must be large’ enough to flow, 31,500 cfs (cubic feet per ginute), with no’ restriction. Agr supplied to the comprossor should be free of contaminants such as paint spray Bist land vapors, and other chemical vapors as well’ as normally air borne dust and dirt particles. Inlet air to the coapressor may var} slightly in | temperature “withou adversely affecting "the perforeance of the conpressor. “owever,” ambient air temperature should be maintained between 328 and i00°F to obtain desirable performance. The air filter supplied with the compressor hag an adequate flow capacity for most applications. In particular! dirty locations clean’air may be ducta in froma clean air source or special air cleaners be installed, Generally, mast conditiong may be overcote by regular, servicing of the filter furnished with the unit. When bringing outside air into the compressor building for cooling and/or Compression the air iniet to. the Compregsor building should be located away from contaminants such as engine exhaust, gases, stean and other harmful vapors. Also, the opening to the duct/buildin aust be protected from rain, snow an: other air borne debris by hodde aa wel) as being located above the ground/roof to prevent cther foreign satter pick up. Fora typical ducting arrangenent refer to Figuré’42 Both inlet and outlet ducts aust be gized so that they are restriction free. ‘are below temperature maj ed Where ambient | temperatures 320 canter tempered by This may adjustable louvers’ oF to admit warm air from the outlet duct back into the inlet duct at a controlled rate. be recirculation, If duct filters are used, the £i1 Bae PE coweriction | thes.” Typical furnace filter material may be us COOLING WATER SUPPLY For water cooled units a sufficient supply of water must be piped to the wait. Total hardness of the water should be Lisited to 50 ppa (pazts per illion) of galcuim carbonate (CACOs) to limit scale formation in the coolerTo further reduce scale formation in the coolers, it is also desirable to limit the water outlet teaperature, from the cooler(s), to 120°F. In eome cases it may be necessary to limit ‘the corrosive materials in’ the cooling water by special treatment. ‘Closed Systema" or systens vhere life of the compressor cooler(s) in addition te preventing freezing. TABLE III, lists the approximate water ‘low in gallons per ainute (gpm) with various water temperatures required to maintain the oi] temperatures shown. This information may be used to make gertain water piping size a adequate, gooling toyers are ueed nay alee require for. the’ ‘toaparpenga’ vot thease special water treatment "eS prolong’ the achilashs, geetpereture, of 1+ TABLE IIT COOLING WATER FLOW WATER COOLED OTL COOLER ONLY wopEL ez0085 we2soss E2085 weH20088 wbizsuss wEH300SS O11 Injection Temperature, ° 140 40, 140 ater Poe 5 Ho tits es Haver Flow, pH @ 70°F 18:3 19:0 243 Water Flow, Ser 28. 20:0 35:3 Hacer Flow, GpH @ 63°F 35:3 228 a8 Water Flow, GPM @ 33°F aio 30:8 an3 COOLING WATER FLOW WATER COOLED OIL COOLER WITH APTERCOOLER MODEL vez00ss yE25055 ¥e20085 wbidooss wEzSoss whiaocss ga1_Ingect ature, °F 0 40 4 jatar btoes gee fo He Ho et Flow, GPH 8 70°F 2:0 36 25 Water Flow, SPH @ 75eF 3:9 20 23:8 Water Flow, GeH @ ascr 38:3 fae 35:0 Heter Flow, GPM @ 95°F 38 38 33:5 For temperatures of water not shown VALVE ITH THE CORRECT PRESSURE yee the next higher flowrate and water RALIEF SEtiNGTaay FORREST PRESS temperature shown in Table III. DISCHARGE PIPING Jt is recommended that all units be equipped vith a system ‘raceiver” or storage tank. “Such a tecelver ig considered to be part” of the plant equipsent (not furnished ‘with’ the compressor). The nominal size of the storage tank should be 400 gallons. The only exception to this would be where jonly one unit, with wodulating control, “is ingtalled and. matched i size to’actual air demand so. that the unit ig jrunning nearly fully loaded continously. WARNING THE SYSTEM STORAGE RECEIVER MUST BE EUIBEED "wiht AG" BRCEZVER "UBT BE 47 ‘The compressor should be located a near, fhe plant storage, “receiver a2 possible. Piping should be aa short and aa direct “as possible with eininus number of elbows and fittings. Hever reduce discharge line size, ingtall dryers or filters’ ¢ moisture “separator on af unita) in the discharge line Manual shut off yalves should also be ipciuded in the diacharge piping’ #0 that the compressor. and/or the syste Teceiver may “be isolated from the re of the systen to perait servicing the compressor. It 1g also necessary to install a drop Agog’, Have in, Ehe discharge piping: Refer to Figure 42 for « typical’ piping arrangenent: ALL piping oust be adequately supported £0" prevent excessive steak ohthe compressor or plant storage receiver CHECKS TO BE MADE AT INITIAL START UP: 1) Make certain that ail electrical, air and water (if required) Connections "have been “properly nade. 2) Check the compressor reservoir O41 level and correct gs Tequired. (Use correct type of oil) 3) Turn on cooling water, «if required. 4) Close the line disconnect, switch. The "Power" signal lamp ehould be glowing. NOTE ALSO MAKE CERTAIN THE COOLING FAN BISCONNECT “SHITCH IS CLOSED, “IF 5) Jog the compressor and fan ‘cooling and housing | vent), omotors by actuating the START ite! dumediately pushing the STOP switch. Observe the compressor and fana for correct rotaticn. NOTE ROTATION OF THE AIR END 1S CORRECT WHEN THE INPUT (DRIVE) SHAFT TURNS COUNTERCLOCKWISE WHEN VIEWING THE ALR END FHOM THE “REAR OR DISCHARGE THE COOLING FAN MOTOR ROTATION Is CORRECT WHEN THE AIR FLOW THROUGH THE COOLER 1S FROM THE MOTOR SIDE TO THE OUTSIDE. HOUSING VENTILATION FAN ROTATION 15 CORRECT WHEN AIR FLOW IS UP AND OUT THE HOUSING TOP. If rotation. is incorrect, disconnect the. line witch and compressor and/or fan motor to obtain correct direction of rotation. After rewiring return to Steps 4 and 5 to double “check rotation and “correct as required, 6) Determine the | type of control. (Modulating, | Auto Dual, oF ECONOTROL'#S Also determine full load operating pressure, (100, 125 or 150° pai) . NOTE TO, DETERMINE THE MODE (TYPE) OF CONTROL OBSERVE FOR THE FOLLOWING: a, Modulating control will have a pressure awitch PS-1" located in the control enclosure and. 2 control pressure regulator valve (CPRV) located on a frame support at the rear of the air end. Auto Dual control will have a ggntrol pressure regulator valve CCPRV) "located support, a Byitches anda the electrical control enclosure. €. BCONOTROL'® bypass control will have operating cylindera. on’ the air end and. the circuit board indicator “lamps will be visible through the control enclosure door. NOTE PRESSURE SWITCH PS-3 IS LOCATED IN THE CONTROL ENCLOSURE OF ALL UNITS. To check operation of single mode (modulating) "control proceed as follows. MODULATING CONTROL 7)a, Make certain the main electrical line | digconnect switch is closed. the '"Powar" signal lasp should glow. Make certain the fan motor © disconnect. switch is Closed, if used. NOTE IF THE UNIT 1S EQUIPPED WITH AUTO DUAL “CONTROL MAKE CERTAIN THE MODE SELECTOR SWITCH IS” POSITIONED FOR MODULATING CONTROL. b. Close the shut off valve located between the system receiver and aystem distribution piping. c. Open the system receiver vent or drop leg valve. WARNING AIR. ESCAPING TO ATMOSPHERE IS NOISY. ALWAYS WEAR EAR PROTECTION 70 PROTECT HEARING. d. Start the unit by actuating the START switch. ‘The unit should start and continue to run. @. Slowly close the drop leg or vent valve. As air pressure rises in the Unit and system receivers) the control pressure regulator (CBR) valve " should begin. to unload the unit at the pressure for-which the CPR valve is set. 200,125 or 150 psi) £, Observe that, as the systea receiver pressure approaches the full unload pressure (110, 135 or 43+ Slowly open 160 pai) the pressure ewitch PS~1 HAUL doruate, fully’ \uoloading the unit (closa intake valve) an open the blow down (dump) valve lowering unit receiver pressure. and close the drop leg valve to cycle the controls. If the controls operate as eribed, the unit is ready for use. UTO DUAL (TIMED STOP) CONTROL a b. AIR Make certain the main electrical line disconnect evitch ie closed. The ‘Power* signal lamp should low. Hake certain the fan sotor sgonnect switch is cloned, if used. Position the control mode gslector avitch in the Auto Dug) Control position. The "Auto Dual* signal lamp should glow, Close the shut off valve located betwaen the ‘syetea receiver and ayaten distribution piping. Open the system receiver atop leg valve. WARNING ESCAPING 10 vent or ATMOSPHERE 1s NOISY. ALWAYS WEAR EAR PROTECTION 10 PROTECT HEARING. e a Locate the tine delay timer (TR- 1)" in “the electri¢al control enclosure and adjust the tier to minigun tine. (30 ends, approximately) Sign the unit by actuating the START switch. ‘The unit ehould start and continue to run. Slowly close the drop leg or vent valve. Ag air’ presgure ‘rigaa in the unit and “system receivers, the control pressure regulator (CPR) valve" should begin. to unload the unit at the pressure for which the CPR valve ia set. (400, 125 or 150 pai) Observe that, aa the aysten Teceiver pressure approaches the full junloed | pressure (110, 135 @F 160 psi) the pressure ewitch Port gatild., actuate, fully unloading the unit (lose intake valve), open the blow down (di valve and turn on the tiger. The unit should continue to run unloaded, until the "set" tine of the timer ‘elapses (30 seconde approxisately),” and then stop automatically. Figure 43 Instrument Panel Control Enclosure 4) Gontrol Encloeure i Temperature Gage 4) naerument Panel 4) O11 Pressure Gages 3) AMT Pressure, Cageg 9 dir Cleaner Restriction py aytGieator a, it Tesperature Gage 8) Auto dual Timer 9) ECONOTROL** Circuit Board 10) Pressure Switch PS-1 11) Control Line Drain Valve 12) Transducer. 13) Pressure Switch PS-2 44) Pressure Switch PS-3 J. Slowly open and close the drop jeg valve to cycle the controls allowing tine for the delay tiser to stop the unit, When testi: ng is Goapleted reset the desired tine delay. (Suggest 10 sinutes) Tf the controls opera the unit is ready for use. NOTE TE THE UNIT STOPS AUTOMATICALLY, OR Is “HANUALLY SHUT DOWN FOR ‘ANY REASON, IT" WILL NOT RESTART UNTIL THE ont AIR RECEIVER/OIL RESERVOIR Alp PRESSURE IS "BELOW 20. PSI a9 as described,(APPROXIMATELY). IF THE UNIT ATTEMPTS TO START OR STARTS, SHUT DOWN AND REFER TO CONTROL ADJUSTMENT PROCEDURES . ECONOTROL'® ELECTRONIC BYPASS CONTROL aa. Make certain the natn electrical Hine disconnect switch is closed. The SPoyer’ signal, leap, should giow, ,ofiake, , ,cereain he fan jonnect switch is" closed, if Position the control apde selector | ‘switch inthe ECONOTROL** control position. The *Econctroi* signal 'iemp should glow, The EcdNotroLt#” cirouit card apps should have «Tandon display "on". Close the shut off valve located between the systea receiver and the system distribution piping. + Open the system receiver vent or drop leg valve. WARNING AIR ESCAPING TO ATMOSPHERE IS NOISY. ALWAYS WEAR) FAR PROTECTION TO PROTECT HEARING. a f. Stare the unit by actuating the "START® awitch, The unit should start and continue to run. Slowly close the drop leg or vent Valve. As the pressure rises in the unit and aystem receivera the ALERT i glectronic bypass control will initialize, “Observe that the green, LED’ (lamps) on the circuit board glow. Continue closing the receiver drop leg or vent valve. Ae ver pressure rises above the pressure of the electronic bypess control range, observe that she, fret, yellok (bypass valve *A*) “LED turns on and the green LED “turns” ‘off. As Pressure, continues to rige the Yellow, LED [wilt tury tee" and he red ZED will turn ‘on™. Aa preseure continues to this’ ‘sequence “should continu through the LED groups for B,C When the red LED for oylinder D turns on pressure awitch PS-1 should actuate cloging the intake valve (fully unloaded). Slowly: open the receiver drop leg er vent valve, As the pressure falla the LED's on the circuit board should gwitch from red "on™ to green ‘on™ in the sequence D, ¢, 8 and A until all four green Lép'* are "on™. Continue to cycle the controls by raising and lowering receiver Bfensure end, observing th Gircult board LED's. fe the sequence of events’ is aa described above the unit is ready for use. A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT! 50Section IV OPERATION AND PREVENTIVE MAINTENANCE Satisfactory performance of a stationary screw air compressor requires a good preventive maintenance program. The following information is provided as a guide for such a program. START UP Daily start up may be accomplished aa follows: 1) Drain the water from the oil ervoir. Close the drain valve securely when cil appears. 2) Check | the compressor of. reservoir oil level. NOTE SHE OU. RESERVOIR 16 FULL WHEN THE QU, LEVEL IS VISTBLE IN THE UPPER SIGHT GAGE, IF OIL IS VISIBLE IN THE LOWER SIGHT GAGE THE LEVEL 18 ADEQUATE TO OPERATE THE UNIT. 3) Operate the air receiver-oi1 reservoir pressure relief valve manually to'nake certain it will open. 4) Make certain adequate ventilation and cooling “water, if required, is supplied: 5S) Open the service valve which connects the unit. to the system recelver, | (aigeriputson piping) and actuate the START awitch to start the unit. 6) Obaerve instrument panel indicators and all” gages” for Proper readings, ‘SHUT DOWN 1) Allow the unit to fully unioad. 2) Push the STOP switch to shut the unit down. PREVENTIVE MAINTENANCE Regular, testing of oil as specified Pegite, following aaintenance guide ts intended to ‘at in establishing 01) and oil filter change intervals. It is possible, however, information about 2 iE characteristics of ‘the machine with continued of testing. | The oil teata performed should include analyzing the particulate matter in the ofl aanple, as well as testing “for oxidation to ob’ n 51 inhibitors and anti-rust additives. As an example, an increase in cast inn particles ih an oll auple say give advance warning of excessive wear. thie information could ibly prevent damaging the entire unit beyond Fepair, without periodic disassembly and visua! inspections. Normally the oi] analysis sheet will ligt the results of the oil teat, in addition to recommendations of ‘the analyzing laboratory’ showing what uaintenance is required. The oq following = information ig furnished ag a guide to the critical limits of items which are listed on an oil analysis sheet. Viscosity Increase. 1 idk over new oii Inerease (total acid) ...... 0.5% over new oii Total Solids by Weight .........., 0.20% Oxidation, by Weight, Oxidized Materia] sees 0,20 0,88 Neutral No. Sedinent, by Volume ......... Water, by Volume ....... DAILY a Check the air service as required. Di water reservoir. valve appears. cleaner and 2» fron Close securely the the when ofl drain oll NOTE ALWAYS DRAIN CONDENSATE AFTER THE UNIT HAS BEEN SHUT DOWN FOR A REASONABLE LENGTH OF TIME (USUALLY OVER NIGHT) ALLOWING THE WATER TO SETTLE. 3) Check the Faservoir oil type of of! aa over fill, NOTE 18 VISIBLE compressor oh} level. Add corract required. Do not FILL UNTIL O11, UPPER SIGHT GAGE. 4 IN THE Operate air receiver oi. reservoir pressure relief valve manually to make certain it willopen before starting the unit. 5) Visually inspect all air and oi] leaks, lines and fittings for the" ncluaes, the Siz cleane® and gry iglet “piping. gf “the air induction aya Correct leaks as required. 6) Start and run the unit at rated full load pressure long enough to feach normal operating tenperature, “(Hy 0. 7.) 7) Observe the air cleaner restriction ‘indicator. ff" the estriction indicator shows a red re Sflag*, the air cle must be cleaned or weds r element 8) With the unit running, observe the ofl pressure’ ga (inetrunent panel) the pressure readings. ineFilter Out) A pressure reading hore. indicates” filter clement aust be renewed. 9) With the the preasure Unetrunent panel) and the pressure ‘readings drop across difference in f 15 pel or of 15 pressure readin nore indicates t If the restriction is caused by dirt or other foreign matter, Tenew the separator element. NOTE QUL SATURATION CAN CAUSE EXCESSIVE RESTRICTION ACROSS "A SEPARATOR ELEMENT, ALWAYS” CHECK THE SEPARATOR DRAIN TUBE AND LINE, THE CHECK VALVE INSTALLATION AND’ CONDITION) AND CLEAN THE DRAIN LINE FILTER BEFORE CONDEMNING A SEPARATOR ELEMENT. and compare (Filter difference in pei or that the oik unit running, observe gages are (Pressure eparator element) A 98 Separator element is restricted. 10) WATER COOLED UNITS ONLY, - After "the Funning for, approximately minutes, check, the fenperature. (Tecparature gage on jastrument "panel? ‘This Egaperature, | ghoul TRF ERG LooeF thts tee, may be changed-corrected by SGjugting phe water flow contra tefer to Section (lemperature actuated Water Flok Control Valve"). Allow tine each adjustaent temperature to making further adjustments. EVERY 200 HOURS 1) Repeat daily applicable. service 2) Remove surface oil cooler and required, 3) Obtain an odd the | compressor (Air cooled units) sample and have the sample analyzed for gondition, Change oil and oii. leer, "it “required, based “on Tesulté of the oil analysis. NOTE QLL SAMPLES, HAY, BE, OBTATNED FROM THE OIL RESERVOIR (AT. FILLER, HOT DRAIN)” OR FROM THE OIL. “SAMPLING VALVE LOCATED ON THE OIL FILTER. EVERY 1000 HOURS 1) Repeat daily and 200 hours service as applicable. 2) Change compressor oil filter elenent. unit “has been 041 injection be between rature fter for the air ‘atabilize before dirt ‘and dust froa the exterior surfaces of the aftercooler, if from aten A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT 52