Rotary Screw Stationary Compressors Models 200 SS Il Installation — Operations Maintenance and Service Guide Telephone: +01 (937) 498-2500 Facsimile: ~01 (937) 492-3923 463%SAFETY NOTICE LeROl International, Ins, has stived through constant yesearc and developmeat to provide this equipitient wih every necessary salty dove, However, there is no substite bs we operating procedures. {his manual contains numeroas “Notes”, “Cautions” and “Warnings” intended to protect the equip. ‘ment from damage and the operator from injury, The "Notes", “Cautions and “Warnings” are not, however, all inclusive, Extreme care ‘must bo exorcised when operating or servicing this equipment ‘The operator/serviceman should: 1. Learn all he ean about his equipment Devolop safe working habits Never operate a unit without guards shields in place, Never operate a unit that is not properly grounded. Aater service a unit without disconnecting and lacking aut the electrical power supply unless following specific operation manual instructions, © Never service a unit with aie pressure in the air receiver reservoir unless following specific operation manua) instructions, Zeke all necessary precautions, when adjusting éotrols, ete, to revent electrical shock Alt delivered by these compressor must not be used for breathing air, DON'T PLAY WITH COMPRESSED ATR! DON'T POINT AIR HOSES AT ANYONE! DON'T USE COMPRESSED AIR TO BLOW DIRT FROM CI OTHING! 2 8 4 8, AE close rane, compressed ais, at the pressures theae units develop, can pat out eyes, Puret ear drums, eause carious ekin blisters and other injuries, Check Pressure Relief valves daily to make certain they are working properly. An over Pressurized aie receiver has the potential destructive fore of ¢ oman torte A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENTTABLE OF CONTENTS SECTION 1 = GENERAL INFORMATION Air End 20.0.0, Air and 041 Flow Control Function 111.11! Auto Dual Control. 1! 1)! Econotrol™ - Electronic & fead/tag Control aute Dual... °° bead/Lag ~ Electronic Bypass 11. Emergency Shut Down Component Function Intake Valve 22.202) )77 Air Receiver/Oil Reservoirs Minimum Pressure/Check Valve Separator Drain Line Discharge and Separator Out Blow Down (Dump) Valve ‘i Return Air Bleed Back Valves. Sontrel Pressura Regulator Valve | Pressure Switeh PS-3 Pressure Switch Pe-2 Control Line Econotror Solenoid Valve sv-3 Solenoid Valve SV-6 Ee: e2cet Fiow Control Valve Water Cooles wed Instrumentation .......0. 0" Indicators and instrumentation eVaswS SECTION 11 ~ SPECIFICATIONS - GENERAL Compressor ......,,,., iubrication - Compressor Lubrication - Electric Motor SECTION 21F ~ INSTALLATION, MouNTING aND SP; ACE REOUIRENENTS - INITIAL START UP Hownting and Space Requirement + a6 Electrical Supply .. : er dar Supply to Compressor (eae: 18 Socting Water Suppiy ...,. °° et) Discharge Piping ....1.! Checks To Be Made A Initia Auto Dual Load/Unioad (with Moduler Electronic Control (Standaca) Lead/Lag Control .- Econotrol™ Electron, Lead/Lag ConeroiTABLE OF CONTENTS (Cont*ai SECTION IV ~ OPERATING AND PREVENTIVE MAINTENANCE Page Start Up Shut Down |.) Preventive Maintenance DOLLY seveeee eel ere a, Every 200 Moura! Every 1000 Hour. ws. 32 pochotrel™ Electronic Bypaas contray Adjustment Procedure...) 3) Pressure Switeh Adjustment ., ere! Presaure Switeh PS=j Pressure Switch Ps-2 11) SECTION VI ~ SERVICE PROCEDURES — COMPONENTS Fontrol Pressure Regulator Vaive Service Intake Valve Service .. veeeteeeeen pownetrol™ Electronic Bypass Cont, Service... 02.117 3a teaser. 3B 39 40 N3nieum Pre: 40 BZow Down (Dump) Valve . az Oil Separator Service .... 42 Air Ena Service 42 Ady End Input Shaft 0: +2 42 Prive Coupling Flexible Meaben +43 Drive Coupling Hub Alignment >. ag SFCTION VIX - sERvIce pracnostg rs aa + 46 viMODEL NUMBER SERIAL NUMBER DATE INSTALLEDSECTION I GENERAL INFORMATION This manual includes inetallation end operating instruetiona, and gaintenance and service procedures for the Model WE125S511, "HEISOSSiL and WE2008S11 Air Compressor units. Ap explanation of the nodel code follow: Example: WE1SOSS1I or WEHISOSSIT WE -Indicates the series H -Maxduum operating pressure above 125 BRA NSP 150 -Approxinate horsepower re- guized to drive the air ond: S$ ~ Stationary Screw II - Vereion Two This series of air compressor units are electric motor driven, oii flooded, single staga, rotary screw type. These compressor units may be either air or water cooled and with or without 3 housing: After-coolin ic standard ‘for “2ir cooled. an optional for vater Cooled unite. AIR END (Figure 1) The air end is directly driven using “a flexible coupling petwean the @lectric notor and the ais end. FiguRE 1 ~ AIR END - TYPICAL The male rotor is driven by a gear notnted on an:independont iApue™ shaft and a mating gear on the male rotor. The female rotor iy driven by the male rotor because the rotors are neshed. Figure 2 shows direction of rotor rotation “and” the “ais/osi “Pion Ehrough tha aix ‘end. Note that the air. Mow through the air “ona "es Between the rotors and “the ‘ineids diameter ‘of the cylinder. Each voter is mounted with two angular contact bali bearings at the Fear or discharge end. This provides positive rotor location. The trong ox niet end of each rotor ig supported by single “ron Foller “bearing, This’, allows the rotors or eylinier to freely expand or “contract due ta chahgas? in temperature “without “"atPecting critical running clearances: Typaeat FIGURE 2 ~ AIR/OIL FLOW ~The independent input (drive) shage is Supported by a deep groove single row Mant bearing ‘at the front. end and tie single Fov roller bearings at tha rear ATR AND OIL FLOW Air circulates through the eystes beginning at the air cleaner, passes through the intake valve and into the air end where it is conpresaed, From the aix end compressed air is discharged at sated pressure into the unit air receiver-oil reservair. Separation of the oil from the air, which was 3njectad into the air end Suring’ coaprescion, begins “in the unit’ air receiver-oi1 reservoir Fron 90 to 95% of the oi) separation from the air is accomplished with a decrease in air velocity, changes in flow direction, adequate baffling and proper” location of the air receivar/oil reservoir inlet port. (Figure 2> Final airfoil separation as obtained “using a" composition material "can? type separator clement to provide nearly o11 free air at the separator out or service Sonnestian. 041 collected by element is returne: geet the separator to the system by equipped separator drain Yo prevent over pressuring the air receiver-oi} reservoir, an air pressure relief valve 18 installed in the receiver-reservoir. Thig Pressure relief valve ie located on the upstrean or wet side of the separator element. For both air and water cooled units, 011 flows, forced by air pressize, from the air receiver-osl, reservoir to the thermal valve. Then depending on oil temperature, os) flow bypasses the oil cooler (cold 911) or flows through the oil cooler (hot “o41)." From the thermal valve and/or the oii cooler, oi] is forced through the filter and injected into the air end to provide cooling, sealing and lubrication. The tenperature of the oil is gontrokled “automatically by the thernal bypass valve. cooled units equipped “with a temperature controlled “automatic water flow control valys, This allows metering water Elow for water gonservation: Water are also O1L injection temperatures for air cooled Units should be 1808 ty 6OSF 2 depending on ambient air tempera- ture. O11 injection temperature for water cooled units should be 140° to 160%F doponding on water tenperature and flow. Air flow to/through the air end is controlled by the intake valve. When there isa demand for air, up to the fated Capacity of the air end, the intake valve will be open (air end fully loaded), Where there aa no demand for air’ the intake valve will be closed (sir end fully unloaded). With modulating control the intake yelve will open and clase (modulate) Based on air demand: FIGURE 3 4. Oil Filter 2. O41 Sample 3. Thermal’ Bypass Valve 4. Support: CONTROL FURCTION Three basic modes of control are available for these unite. These are? 1) Auto dual Control (Modulating aud Tined Stop) 2) Eeonotrol™ Bypass Control Syetes 3) Lead/Lag Control ALL nodes of control require uging a systen storage receiver (not fare nished with unit) to obtain proper control ‘operation. AUTO DUAL CONTROL, Pressure contrel for Auto Dual mode is provided by a control pres~ pure regulator valve and a pressure transducer with solid state circuit Board. Specific wedes of control are continuous ‘run (oad/unioad with modulating control) and” automatic gtart/etop("Automatic Dual"). The “automatic Dual" ode includes atimer to provide delayed shut down (timed Stop). The user may select either contin- uous run or automatic operation with a selector switch on the instrument Panel circuit board. This is pro= vided to allow operating the unit in continuous ‘run for high air demande or start/stop for low air demands. Also located on. the control circuit hoard are components to provide a digitel read out of separator out pressure and air end diecharge tem- perature. “In addition, the control Sircuit “board provides emergency shut down due ta high air end diss charge teaperature, high separator out air temperature and over pres= FIGURE 4 4. Control Pressure Regulator Valve 2: Solenoia’ Valve tse) 3! BreSeure Reaueing Valve 2: Ais Cleaaee 5. Check bates 3: Hanuat Vent Valve 5. Return Air Bleed Valve 8: Shutele’ Gheck Pave 9: Discharge Temperature Transducer 10! air gage? "MP If: Wans2o%0 42: Sotenota Valversy-a) 43! Sotsnoid Valve (50-2) ECOROTROL™ - ELECTRONIC BYPASS ‘comTROL, The | ECONOTROL™ bypass valve operating cylinder and ports are located on/in the air snd cylinder. These valves are opaned or Glouad by the econotrol solid state control. At start up the electronic control initializes allowing air preesure to extend the bypass ‘valve cylinders closing ‘the bypass porte for full, capacity operation. The bypass pores sre opened prog- reasivelly es fhe system storage ross Giver iF pressure rises (airdeaand Gecreases) reducing air delivery (apacity) and power coneumption: When the full unload operating pressure is reached the invake valve is also closed completely by the solid state controls and’ solenoid valve 8V=1- ECONOTROL™ equipped unite may be operated (user selectable) conkin= uous run or start/stop (timed stop): ‘The ECONOTROL™ solia state contro), circuit board is located in the con~ fret enclosure: Signal lamps (LED or light enit- ting diode) on the eireuse board are visiple through a plewigiaes windos In'the anclosure oor The grean and yellow lamps sndi- gate preesure set pointe. the red lamps "indicate when bypass valves are open of closed. (Red Lamp ‘OFF =" valve ‘closed; ted lamp "ON" valve open.) The ECONOTROL™ powar is low SGustita' het dedSt Sor aPaneeBN SE oeegel Mp WhPURD SN GR Receiver air pressure changes are sensed by a (pressure, transducer which controls ECONOTROL™ operation- To limit air pressure applied to the operating cylinders a pressure Feducing valve, with moistube sepa~ rator, is useo! An electrically operated solenoid yalye Cone on each operating cylin- der} controls air flow into and out 9£ the operating cylinders to extend the cylindar (close bypass valve) oF allow the cylinder to retract (open bypass valve). User selection of the aeairedpperating pressure range is provided Sy using @ four position selector suitch “which ie "docated on Sontsol enolosure door. LEAD/LAG CONTROL (AUTO DUAL) the Lead/ tag gontrol is provided usin a“nodified control Gizcult board Which has an adjustuent to change the operating “pressure range when Using multiple unite, CFaguee 15) arjon to the circuit addition to providing adjustable pressure ranges, also inélades a ‘switch to select the @esired operating presaure range. The user ‘selector "switch may be mounted on the control cireult board, or optionally, mounted on the inatriment panel: LEAD/LAG - ELECTRONIC BYPASS Leal/leg control of ECONOTROL™ unite me} be ‘Sbtained by correctly Fangs" solestor suites. f EWERGENCY SHUT DOWN The modification board, in Emergency shut down may be caused either “by “bigh air end air/oil, discharge temperature, high sepa ator out sir teaperature, or high storage receiver preseure (over pressure). Shut down due to high air end discharge or separator put “air/otl temperature ig 238° * 2° B. Shut down due to high presaure is to be 10 psi above the rated full load aperating presaure- COMPONENT FUNCTION Piping and wiring diagrans have been provided to agaist ip Locating components on the unit and deter= wining component functions The £ollowing explanation o£ con- ponent function will asaist in de Sorpining if the compressor is ape rating. properly." This information nay then be! used to locate component naitunetiong INTAKE VALVE The dntake valve is located in the section of the air end cylin- The primary purpose of the in- fake Galyb ised domes ale Flow eo the aar end. freee The secondary function of the in- take valve isto check off possible reverse air/oil Cloy when the unalte 4 is shut down FIGURE § Separator Out Piping Attercooler Wininug Presgure/Check Valve Drain Line Filter Check Valve Sight Cage Temperature Gage (Thermometer) auttior Separator Drain Tube Blow Down (Duap) Valvo Separator Out fenperature Trans~ Pressure Relief Valve 4 Air Receiver/0il Reservoir AIR RECEIVER/OIL RESERVOIR The air receiver/oil reservoir provides an ofl sump, primary o4) Beparation and a mounting location for the separator element. The separator element is mounted in the receiver/reservoir by clam ping the separator mounting flange, With gaskets, betweon the receiver freserveir cover and top flange- Other components which are mounted on the receiver/reservoar are. the ainiaum preosure/check valve, pres- Bure relief valve and separator drain line. MINIMUM PRESSURE/CHECK VALVE The ninimua pressure/check valve is located on the air receiver/oil veserveir cover in the separator out port: The purpose of this valve as to naintain wininua aif pressure in theaix receiver/oil reservoir. The valve consists of a spring loaded piston which opens ‘when ait pressure “reaches “approximately "80 pad and maintains a minimum pressure ef 60 to 70 psi. In addition, thie valve checks off tha ‘return flow of air fron. the system receiver (storage tank and/or distribution system) when the com peegsgr is stoppad or running un- jonded - NOTE COMPRESSOR SHOULD Nor BE OPERATED AT NININUM PRESSURE FOR EXTENDED PERIODS. EXCES~ SIVE OL LOSS WILL RESULT, SEPARATOR DRAIN LINE The separator drain line is comnected, at the air receiver/oil Femervoin’ cover, to a tube which extends down into and touches the bovttom of the separator element. The other end of the drain line ts gomnected to a low pressure port on the air end. The drain line is equipped with a filter, a check valve and a flow sight gage. The filter prevents foreign matter gron entering the air end. The check valve allows {rea flow. of air/oil from the separator to the air end but prevents reverse air/oil flow at shut’ down, The sight gage may be vaed to assist with service diag- nosis. DISCHARGE AND SEPARATOR OUT AIR TEMPERATURE TRANSDUCERS . The air temperature transducers (there are two) are located in the discharge cavity of the rear bearing retainer on the air end and in the wininum pressure check valve at the separator out connection. These temperature trangducera pro- vide signals to the solid state Gon- trois, to Shut the unit down, in the eyent of high discharge temperature (2359 = 2° F) and provide a digital temperature read out on the ingtru- vent panel ‘of air end discharge Yenperature only. % CAUTION THE CAUSE OF SHUT DOWN DUE TO HIGH BIR/OIL TEMPERATURE MUST BE CORRECTED BEFORE RESTARTING Jo restart a unit allow the unit to cool, and push the start button. BLOW DOWN (DUMP) VALVE the air receiver/oii reservoir blow down or dump valve is located on the air recelver/reservoir cover- The purpose of this valve ia to allow ‘air ta escape from the air receiver/oil reservoir when the unit is stopped, FIGURE 6 (BETORN AIR BLEED BACK VALVE 2) Separator Drain Vaive 5) Return air Bleed Valve 2) Control Connection $) Air Receiver/0il Reservoir Connection This is a normally closed valve which is opened by air presoure. This valve is opened by air pres- gure build up bolow the intake Valve plate when the unit is shut down. Blow down (dump) air flows to atmosphere through a wuffier. RETURH AIR BLEED BACK VALVES One return air bleed back valve is located on “the air ‘recelyer/oil reservoir cover. A second ia located on the air end and is connected/ mounted at the separatar drain port. the bleed back valve mounted on the reservoir cover, when opened, allows air to flow from the recei ver/reservoir (separator out) to the air end where it enters below the intake valve plate. The bleed back valve mounted on the air end, when opened, allows air to flow from the receivér/reservoir on the wet (upstream) side of the Separator element to a low pressure(drain) port on the air end, Both return air bleed back valves gre opened by control pressure when the unit is running unloaded (intake valve clased). CONTROL PRESSURE REGULATOR VALVE The, geptrel preasure regulator (CPR valve is mounted on a bracket attached to the frame near the rear ef the air end. (Figure 4) The purpose of this valve is to furnish control pressure to operate the intake valve for continuous run operation (nodulating control) This valve senses unit air receiver foil reservoir air pressures between full Zoad and full unload pressure opening or closing the intake valve ontrol air delivery based on FIGURE 7 Lo Bypass Controi Circuit Board 22 Instrument Panat 2) Si Panel 2) GntrolEneiocere $) Bressure Seiten tPs-2) $3 fressure Swites ¢Pe-1) 23 Hiner Seiech’ (osnotned ‘ontrol Cireult Board 9) Pressure Transducer 102 Stap Down Trangforaer 12) BGSoure transduce® (Bypass Control) The higher the unit receiver air pressure, the higher tha control Pressure and the acre the intake vaive is 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 pressure falls to or below full load pressure, the control. pressure Feguiator can no longer paintain cohtrol pressure. This allows the intake valve to ‘sully’ open. (full On NOTE FULL LOAD AND FULL UNLOAD PRESSURE SETTINGS “VARY DE- PENDING ON UNIT. MODEL AND APPLICATION. CHECK THE SPE CLEICATIONS FoR FAcH UNIT TO OBTAIN TRE MAXIMUM OPERATING PRESSURE BEFORE MAKING AD- SUSTHENTS . PRESSURE SWITCH PS-1 Pressure avitch PS-1 is located in the electrical control enclosure. This switch is to be wired ag a nor mally open switch. The function of pressure awitch PS-1 in conjunction with solanoid valve Sv-8 je to ahut off ‘the air supply to the bypass (Econotrol) operating cylinders through a pressure range fron full Unload Presaure toe 15 psi below full unload: pressure. Pressure to actuate thie awitch ia obtained from a pressure line con~ nected to a port in the miniaum preasure/check valve. This port is located on the stor- age receiver (down stream) aide of the valve. Pressure switch PS-1 aust be ad- jugred to open at 18 pol below the full unload pressure. PRESSURE SWITCH PS-2 Pressure awitch PS-2 is located in the electrical control enclosure. The function of pressure switch PS-2 is to prevent the unit fron reatarting after shut down untit unit receiver pressure falls below 20 pai (approximately) + This switch must be connected electrically to ‘operate ag a norm= ally closed awitoh.Bressure to actuate chia switch is obtained from the unit receiver. CONTROL LINE SHUTTLE CHECK VALYE - AUTO DUAL CONTROL = ECONOTROL’ CELECTRONIG BYPASS) A shuttle check valve ia mounted at the inlet port to the intake valve operating ‘piston on the air end cylinder = This shuttle check valve: Ly Allows modulated control adr pressure to open and close the intake valve for modulating control. oR 2> Allows unmodulated —_ control pressure from solenoid valve 5V~ ito close the intake valve for Unloaded operation, SOLENOID VALVE $V~1 (Figure 4) This control aolencia located on a bracket, the frame, valve 4s attached to naar the air end. Thig is a three port valve vhich, when energized, allowa unit recaiver alr pressure to enter the control line, fully close the intake vaive (@uli unload) and” actuates the return air bleed” back valves to bleed a small amount of air from the wait receiver back into the air end. When de-energized thie solenoid valva vents the control line to atmosphere. SOLENOID VALVE SV-6 ECONOTROL™ CELECTRONIC BYPASS) Solenoid SV-6 is a two port norm- ally closed valve located on. the bracket, attached to the frame, near che control pressure ‘regulator Zhe function of this solenoid valve ig to apply ai pressure to the control pressure "regulator when operating the unit in continuous run (modulating control) aode. WATER FLOW CONTROL VALVE - WATER COOLED UNITS. The water flow control valve is located at the water inlet the oil cooler, weed, The purpose of the automatic ad- juetable water flow control vaive is to provide sufficient cooling with mininum water usage. ort of er aftercooler, if The ot] cooler water flow, when. an aftercooler ie used, ie piped in geries vith, aftercooler. The after- cooler is first in the series. The temperature senaing capillary) is always located in the oil flow piping of the air end. INSTRUMENTATION probe Instrumentation (gages and indicators) are provided on these units “to monitor function and provide assistance with service diagnosis. The following chart lista the instrunentation, Jocation of each and a brief description of function. FIGURE & J Insteument Panel 9 Air Cleaner Restriction Indicator 3) Control Englosure @) Automatic Restart Signal Lamp or bead/Lag Selector Sritch wo Econatrar gressure Range Selector Switch Eoonotre1 Node Selecter Switch Hourpecer ayesZNDICATORS AND INSTRUMENTATION ITEM "POWER" LAMP HouRMETER ALR CLEANER RESTRICTION INDIEATOR OU FILTER RESTRICTION THOLEATOR OIL SEPARATOR ELEMENT RESTRICTION INDICATOR "RUN LAMP. *CONTSnuoun* LAMP "AUTOmatio™ LAMP [RwTonatic — RESTART* (Overload) “MOTOR OL” LAMP ‘HIGH TEMPerature" LAMP “OVER PRESSure* LAMP CONTROL SELECTOR BWITCH *CONPRESSOR* WINDOW "DISCHARGE * F* LAMP LOCATION netrunent Control Boor Instrument Instrument Instrument Instrument Instrunent Instrunent Instrument Control Boor Instrument Instrument Instrument Inatrument Instrument Instrument Pane Enclosure Panel Panel Panel Panel Panel Panel Panel or Enclosure Panel Panel Panel Panel Panel Panel INDICATION Shows power to unit is turned on. Ready for manual start, Shows unit total run Shows restriction of air cleaner and need for service, (25° “of water maxiaun) Continuously —_ sonitors oil” pressure dro] (restriction) across of. filter. Continuously monitors air pressure drop (restriction) across the oil separator element. Indicates unit is runping- Indicates unit — wii operate continuous, "ran with modulating control. Indicates unit wild. gperato start/stop with timed delay shut down. Indicates unit is Btopped. “Could restart at any tine, Indicates unit shut down due “to tripped motor overload relay Cawiteh)- Indicates cause of shut down due “to high air temperature at ir end discharge or separator out (serviced connection. Indicates unit shut doyn due "to “high air pressure. Provides user selection of type of control. That £ *CONTinuoua® or "AUTOmatic" operation. Digital display | for pressure and temper= ature readings. Ipdicates digital gage shows air end discharge temperature when selec- tor switch ia actuated:TEM “LINE PSIG" LaNp Locatron Instrument Panel ECONOTROL™ UNITS ONLY CONTROL SELECTOR switcH Gentrol Enclosure or EGHSEQRS RANGE SELECTOR Control Enclosure SwiTcH Boor INDICATION Indicates digital gage shows separator out’ or service lina pressure. Provides user selection of SCONTinuous Run-oFee AUTOmatic™ on ECONOTROL equipped unite. Provides user selection of operating “pressuse range. A CAREFUL OPERATOR Is THE BEST INSURANCE AGAINST AN ACCIDENT!ge =. =a SS Hpi eect | ae Peeled a - et tat Pe ri Tp qtgel A a bearer uranaTURE ete z | Eoieoey | FIGURE 9 ~ wipING DracRAM 20oa wy ragemsone feet Bo koscot oes! 8, ste | seeetith!| Lea| Cre = wey a ceoee ote pe UR Lg [o" or tthe Ton Lie fe z= wore Lorca ve Ste ths Shon ents ERE |_| vararenttaoonee a 3 ort bo 3—QD—S ncaa P| feLetarwon| © oe nm covmoen | FF] s Mle ey rien I —— CER b> he “rieccoGm),, | a" : Bie | aber) Et oe ote ey hon hed Sar verano po ki Ceore camer EL : TED | couraesson pier Wo vac connect onroHeaT ACE NCU nt MowTUmeseranavon neaTeR ees is vacey eustonen SAR VOAR wa GIL ATOR eavonecowar not) ie Aecwaronwenten a Restmon svcercusroun oo aoe FIGURE 10 - WIRING DIaceaM ait => AON, Bab Hor OIL, ave cooLeD ONL 2 | Salanoi Vote (Sv. 2% | Soot Vato fSV-1) 28 | Pose Reducing Voeo (By Pas Coral) 27 | Selene Voie (30-6) 25 | Contot Proms Bogut Vale B | Ourine Oilsszete Vabe 31 | Rurn Ar Blond Vokes z 38 | Conte lend orcs 11] Temperature Trenstoow Server Un) | 34 = Berm Ale Vert St Ft Veh 12 | iran Pasure/ohue Ve s | one 12 | Sepwace Orla Take 36 | Aircloner Bisa Vane a Al Recehves/08 Reivcic 16 | Drain Une Few B | ikon Dit eel Bisht Coe On Ete 15 | Check Vane By Pes Govtrot Vas 18 | Sthvoage 58 | PeseSortoh 98) Premne Snitch (P51, ru Air ne Lina Fittee 38 | Airco 41 | Presiane Tesnsduce (Comat) Sees Clem 19 | Shehege Tengeratue Ttcer 42 | Procina Transducer {Oy Fup, Conuoth Pasar Ret Vai 2 20 | Reva Ais Bra Vale 43 | Stoner Elem Aeteion neter 21 | Aircooled OW GoateAteeacer 4% | Ollie Reswicinn incor 2 | Theraty Pa vai 4 | SoowolEndosre 28 | oy Passcumro!eemnawon Monit | 38 Hol Line bake Vale: ‘lew Down (Dom Vein tater ‘At Teroertsre Gage (Theatr) ease FIGURE 11 ~ PIPING DIAGRAM = AIR COOLED 12Dal ED aon mop HOT OIL np COOLED OWL ‘map WATER, ‘To Coral Endure ® BL | Thermol By Pass Vaid 2B | By Pass Cored (Pesmotral Waeoks 26 | sorenoia Valo 5-8) BD | leno Vere Ve rata Reding Vat (8 Pas Contre Soler Vole (v.83) tesa eguitor Vaio Oe ‘it amp Valeo Revore A Died Vale Somat = 4 | ToeaneTaanaraerours | 3 | en A he ve i oer | rr Sao Aes 1 [Same i) amir ine 5 | Se kteeon tee | Beahese 8 | rates Seterseete il Seay | Reset 2 | Suh | Sisco i} | fremesenc re 8 | Ream i dine ae | ape 1B | Rae aac tot $ | Eateries 1B | Skewreremermeraniee | S| Romsey Slane P| Rete 58 | Reon etcy tite 2 | See. Fae ae Bates 4S | opie amen tiie Be | Mer or vone & | Sutera Yo | Airemeeanre tas ramenmnd || 38 | Se S| comets ate sare PIGURE 12 -. PIPING DIAGRAM ~ WATER COOLED 13SECTION II Vv SPECIFICATIONS — GENERAL “ monet, Mexzsesty SLT WEISOSSIY—FERISOSSIY.—EZONSSHY——yemaonszy Tye Rotary Serer Rotery Serey Rotary Screw fatsry Screw Rotary Screw Botacy Sccer Stages one one One te oe te type of Drive - Diect w/Gears Direct wears Direct w/Geara Direct w/Geart Dieeot w/lears Direct v/Geare Hotor/tnpat Shaft Bnd, RE 1770 wi0 amo 1m 1710 wn ROTE ALL PRESSURES SHOWN ARE MAXYHUM FUIL LOAD. Rated Selivery, CA 81DQpei 625 wa mo uA 2009 wa Ratod tel-ivery, FH €125pe1 $60 wa 670 vA 900 wa Rated Delivery, EW €150pa4 N/A é0 ws 860 A 809 Mininee Yerking Pressure, pet Sage cy % % 8 9 (SAM Bar) (SAM Berd CSA Bar) (SAN Bae) 5.46 Bar) 5A Bad ‘Nininee Paeusere Yalve Set, psi Sage n » n n » 6.76 Bix) (4,76 Bar) 4.76 Har) 4.78 ae) 4.76 Bad 011 Rasew Capcity, 1.8. Gilleng ee no a 2» wD 2o 2» ‘Mix Hecelwe-011 Peservole Marin Forkitg Pressure, pa Cage ws vs vs 15 115 15 GL.9 ter) (HLS Be) Ra. (HN Bae) L.8 Bad Proapure Belief Valve Set pat 56 150 170 380 0 159 10 0. bes) WLS Ber) 9, Bar) ATS Bae) 8 Baad. Bed Air Clter type, Standard ry bry bey Dry ry Dy Mr Clune W/0, Gptionsl Ory 2 Eleeent Dry 2 flesont Ory 2 Elewent Oey 2 Flenoct Dey 2 Elonent ry 2 Elesent Air Cleaner Change Lateral, Fours te Required ba Required ba Requised As Bequired Mn Required As fagulred caurron “QUSERVE THE Al CLEANER RESTRICTION INDICATOR. CHANGE WHEN INDICATOR SHOWS RED. UNDER DIRTY OPERATING CONDITIONS, THE AIR CLEARER SILL REQUIRE CHANGING HORE O11 Filter Change Interval, Wourn 1006 1006 1000 100 3000 1000 cAUTTOR 0i1 pressure restriction (presaure drop, filter in, filter out) indic= RenmeATEORS IN, RICH IE UNIT 16 — Stobs are provided Ae chee the ee RUIMING SRY’ Beau Tie GAMING THE ker, (fitter condition) “may” be tke NORE OFTEN. AE chotked. RENEW THE OIL FILTER AT EACH OIL a If the restriction indicator shows Bote, "FERC “Fenew the filter @loment. 14Qi2 Separator — Blenent change For these raasens oil and oi} Interva, seeeel AS Required filter change intervals are to be Geternined “by oil sampling and caurion analysie. ALWAYS CHECK THE SEPARATOR DRAIN 041 sampling and analysis is reco- Eine AnD DRAIN LINE EIETER FOR anended every 205 need ak sonneeee Betclecenin cERLEIE wp BabOR® Tee" operation ae dduae uncit at 9817 Coupenuine 4 SEPawarOR EximeNT.§ 3.1 Titer changa paitenm ot ache OBSERVE THE RESTRICTION (PRE- Guile is covablisned. Ssune peop) “ryprcaroes FURR FsneD. 70. CHECK Th PRESSURE Tt de recommended that LeRor sst- BkOP ACROSS “THE SEPARATOR EL~ 22 (petroicun) on Sleds (opeeno eee) Bier. {RATED PRESSURE, NORMAL — Labsiicant be used: QRERATING TEMPERATURE) Ie THE EESUGRO" pIMDICAOR SHOE A, Either of these lubricants nay be RELAG” RENEW THE SEPARATOR obtained, ° convention ackayeds ELEWENT from your nearest LeRO! distributer, LUBRICATION - COMPRESSOR If SSL-32 of SSL-46 is not avail- able ‘contact your loca) lubricant The useful life of compressor oi) supplier for a lubricant which acces depends on the quality of the oj] the specifications given in TABLETS and the conditions in which the unis is operating. TABLE 1 ‘TYPICAL LUBRICANT SPECIFICATIONS Non-Detergent Turbine or Hydraulice 011; Viscosity @ 100°F Usscosity © OOF Ni nimum Viscosity Pour Point, °F . 260-220 $su 11,000 S80 or Less 30) 20° lower than lowest expected Starting temperature. 400 ASTM, D565 (latest) No rust afte 24 hours sea water. veteeseesecese, ASTM, Dogs Clateat) Neutral, No. 2.0 or less azter 1000 hours. seveesesees. ASTH,” D892 latest) @ cycles stability nil- Hinimun Flash Point, oF Rust Inhibitor sy... Oxidation Inhibitor .... Bn ti-Foam Additive . IABRYCATION ~ ELECTRIC HOTOR Refer to the motor manufacturer's ¥econmendation for motor bearing lubrication, BE ALERT! A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT! 1sSECTION Lit INSTALLATION, MOUNTING, SPACE REQUIREMENTS AND INITIAL START UP MOUNTING AND SPACE REQUIRENENTS Adequate space must be provided to service the unit ‘once itis instaie folded Por SROSER floor should be TSGy Bock foumty OBS unhoused units Provided for placing the compressor. inust be wos Meee, least 24" awa: equseeGaeh gFouRdation is not a1 "afabe thor, oth adequate cooling molting suttsce Sie Zie0r or other Sir oifcurecusn gua taemuaee access. mounting surface is extremely rough Shaupeble te support che wetght of NOTE Phe unit. The unit should 94% Lover? ix 28 advisable to use ghima, aa TJS RECOMMENDED THar rue Tewired, to make certain the fracc COOLING AIR OUTLET OPENING is Festing firmly on the mounting OF THE oni “BE” PosT TIONED surface: AWAY FROM ANY OBSTRUCTION TO PREVENT UNCONTROLLED RECIR® je there is danger of the unit CULATION OF HOT ATR. ROUNE Ing SurveeeP® Bolted’ to the TABLE 11 hows the approwinace nount ing surface. overall dimensions and weights anace may be used for selecting & suite ietation for the conpresacr® ‘athe 11 ALE COOLED WiTHONT HousIB Length, Ia. Width, Ia. aight, tn, Weight wesssrt 4625 semssstx 45, sxs0ist on 8 60 150 enisiss)3 tow Bite 18teu 4050 e201 . 4950 eshROISS I 4950 eI AR COOLED WITH BoUSTHG 5175 wens 5175, weIseSTT 20 co @ S200 sousesre 2Hea Yetoe Sten 5300 F200 5800 vos 50a * WE: WLEh Raine Liniting Ducts ed 20.0" width ard 9.0" hight, Wanee cooten vier nonstae vest 4195 vauzssrr 405 rencsr 2 & 6 600 weaisst Bes 10a Bia 4600 wez0esi 00 wae 000 mosey atER ceoLED wi7e HoastN 505, wont 3025 wexsosrr 2 & ao 50 Bu TT 2m 16tee Sen 5150 vost 550 went 50 16{Yas Vien snows te TyHseAL Pte LAYOUT ‘Fon CoMPReSGOR Mis AnD AN RRC eR, neste ACL B06 VALVES, WUFELERG, me ko SEU itis apes = Boece OP Ps aie oe sarin Ee ee tina nce Fs aa eters b aye, Tenis 1] | uta Poet . PREFEMRED LOCATION OF surrORTeD ae : Sra | “yes 6 Bixpuroy rossne wie ve VALVE VALVE ‘ wert Seta eesti SSomeer ANTS ree eines Seas, itn ere ms paaiw vatye [__ NENT VALVE: Real “non TET omy ee ssc FERRE ae ‘prerenstd carn or yenmurrios rate, gostiealamersetus GEteone eta San Peewesteuneryucee. Thomann ere Somat seas WatencGote>artenconee, ic seUlNEh mtn Siestoemhangenincoas ers e501, eon cM Nemes, saber ssremioaa,_— WEARS |= ‘gexsoe noon Searenarone von go.aee neeimeyation eEIa0% Roo ‘areatane yrearnen Prowetia| REIATON Soe wate maar gpewaus our er cootne awake or AHS Metin Soe ROOF LEY ROGF Oureer cooLING Brena ave sootiake Vrain FLOW ‘AIR COED = coeur eee sesgermcmer yf Rig a Seon eunssey * ourn01 soar Joronsnae Fearon SER “LA GEE «fe FIGURE 13 - INSTALLATION - TYPICALELECTEMCAL SUPPLY An adequate electrical power supply of the correct voltage must be provided. All control enclosure wiring has bean completed at the factory. This includes magnetic starter wiring for unite £urnished with starter. Units furnished without a starter require wiring the starter on the Job site. The electrical supply should be equipped with a fused line die- connec switch or circuit breaker so that electrical power may be digcon- nected while the unit is being Serviced. ‘The fused line disconnect should be located “and mounted in accordance yith ala state, local and national regulations. The unit must, be properly grounded to provide adequate ground fault protection. As a guide, it is suggested that the ground wire be equal in size to one cf the conductors which feeds the compressor motor cireuit Make certain the ground wire connections are clean and tights The wire used to feed the com~ pressor circuit should be selected and sized based on the following conditions: 1) Motor full load amperage plus service factor. 2) Aubient temperature in thé area where the wire is located. 3) Length of wire. 4) Insulation type. , This information aa: the latest edition o: Electrical Code. When installing a unit in a tHazardous Location"; that is in a location where fire ér explosion is a definite hazard, refer to. the appropriate section’ of the National Electrical Code for further infor~ be found in the National CAUTION AIR SUPPLY TO COMPRESSOR (COOLING @ND COMPRESSION) Air supplied to the compressor should be free of contaminants such as paint spray mist and vapors, and other chenical vapors aa’ weld “as normally air borne dust and dirt particles, Inlet air to the compressor may vary slightly in temperature without adversely affecting the performance Of the compressor. However, ambient, air temperature should be maintained betyeen 326 and 100°F to obtain desirable performance. ‘The air filter supplied with the compressor has’ an" adequate flow capacity for moot "applications, Tn particularly dirty Locations clean air way be ducted in from a clean air gource or special air cleaners Ray be installed. Generally, most adverse conditions may be overcome by Peguiar servicing of the filter furnished with the unit. Shen bringing outside air into the compressor building for cooling and/ or compression the air inlet to the compressor building should be loc- ated away from contaminants auch as engine exhaust, gases, steam ‘and ether harnful vapors. Also the opening to the building “muat be protected from rain, snow and other air borne debris ‘by “hoods as well aa being located above the ground/roof to prevent other foreign matter pick up. For a typical ducting arrange- ment refer to Figure 13, duct/ When mounting ducts directly on the compressor housing caution should be used to minimize the Joad and stress, due to duct weight and movement to prevent excessive strain on the housing: Both inlet and outlet ducts must be sized so that they are restric~ tion free, Where ambient tempera- tures are balow 32°F (inlet air) the temperature nay de tenpered by cont~ rolled recirculation. This may be accomplished by using adjustable louvers (or duct dampers) to adit warn air from the outlet duct back into the inlet duct at @ controlled rate. Ig duct filters are used, the filters must be rastriction ‘free. Typical furnace filter material may be used. TABLE [II shows the sir flow in cubic feat per minuta (CFA) required for, cooling: 18ble TIL TR coon pon, WELL MUNSSIwessiesiy amnesty aezeosst)——_weazonsst eglingtis Doe 18,000 wa 18,000 Bh 20,000 wa Get 0 ed {epling bir ow 18,000 wm 18,000 wm 20,008 wa Eee LS pal feghiay te How wa 18,000 uA 36,000 wh 20.000 e810 pal COOLING WATER SUPPLY For water cooled units a sufficient supply of water must ba piped to the unit. Total hardness of the water should be, limited to 50 ppm’ (parte per aillion) of caicium ‘carbonate (GACO,) to limit scala formation in the cOolers. To further reduce scale formation in the coolers, it ig also desirable to Limit ‘the ‘water outlet tempe- "Closed Systems" or systems where cooling towers are usad may “also Fequire special water treatwant to prolong the life of the compressor gooler(s) in addition to preventing freezing. TABLE IV lists water flow in gallons per minut. (gpm) with various water temps. ratures required to maintain the oi temperatures shown. the approximate This information say be used to make certain .water.piping size is rature, fron "the cooler(a). Peo adequate, for the aspen eg Stee 3S TBONES Water. avaclable, “daring iescate Tation. In sone cases it may be necessary ro 3ini® the Corrosive waterials Th Ehe’ "cooling. water by special SPeacment: ming 1 conanus ware sow vara COLE OH Gon one spe SUSU, WEISS Ses oS aos geoaeEE 1, Ings gendtes"p M0 xo ut 0 us x0 Bee for, ae OFF as as 9.0 90 we 8 ter Rr, Ba ie 110 110 H10 ne a a tater Hox, aa Ay Ls us 14 13.0 aie Gas Br MS us Mo ua 2 B pees Bon, ts BF 2 ms 16 Bo % % ‘oourg yt uu ‘aren cob OE COOLER ETF BFTRCOOER DE, USGL BEING weISeSTy eases, gmzostsgezosgmy E80 Injection, egctdeteo 1 Fr te 1a 10 m1 Hebe flee bya ee as us ne ne 2» 2 Weer Fie, Bea Se Rs ns Ma io 2 2 re Flor, bye ie a 0 8.0 19 % 2 Bees Fw. bas Ber ns 15 20 ne # = TeFor temperatures of: water not shown use the next higher flow rate and water temperature shown in Table IV, DISCWMGE PIPIKG It is recommended that ali units be equipped with a system receiver or storage tank. Such a receiver is consicered to be part of the plant equiprant (hot furnished with the compressor). Zhe may exception to this would be where only one unit, with modulating control, is installed and matched in size to actual air demand so that. the unat ae cunning nearly fully loaded continuovely. The nominal size of the storage receiver should be 400 gailone. WARING THE SYSTEM STORAGE RECEIVER nosy.” BE EOUIPPED WITH a PRESSURE RELIEF VALVE WITH THE CORRECT | PRESSURE RECTEF SETPAING AND FLOW CAPACITY. The coxipressor should be located as near the plant storage receiver as possible. Piping should be as short and as ‘direct’ as possible with minimim number of elbows and f£itt- ings. ever reduce discharge Line ysize! Never install additional check valves in this line. Never install iéryers or filters (except @ moisture «separator on aftercooled unite) in the diecharge line. Yanual shut off valves should also be included in the discharge piping so that the compressor and/or the systen receiver nay be isolated fron the reat of the syatem to permit servicing the compressor. It is also necessary to inetall a drop leg and valve in the discharge piping. Refer to Figure 15 for a typical piping arrangement. All piping must be adequately supported to prevent “excessive strain on the compressor or plant, storage receiver, CHECKS YO BE MADE AT INITIAL START 1) Make certain that all elect- ricai, air and water (if re- quired) ‘connections have been properly made, 2) Check the compressor reservoir oil level and correct as re- quired. (Use correct type of oil) 4) Turn on cooling water, if re+ quired. 4) Close the line disconnect switch. The "Power" signal lamp should ba glowing. 5) Jog the compressor motor by act~ uating the ‘START svitch inmedi- ately pushing the STOP awitch. Observe the air end for correct rotation. ROTE ROTATION OF THE AIR ESD IS CORRECT WHEN | THE merur (DRIVE) SHAFT TURNS COUNTER - CLOCKWISE WiEN VIEWING THE AIR” END £ROM TUE REAR OR DYSCHARGE END. if rotation is incorrect, open the line switch ‘and rewire ‘the com- pressor motor to obtain correct direction of rotation. After rewir~ ing return to Steps’ 4 and 5 to dotble check rotation and correct as. required. 6) Determine the type unit and type of control. a) Auto Dual tcontinuous run “aad start/atop) control with solid state cireuit board. b) EConoTROL™ Control. Electronic Bypade For Auto Dual control (electronic), proceed to Step 7. For ECONOTROL proceed to Step 9. AUTO DUAL LOAD/UNLOAD (WITH MODULATION? ~ TIMED STOP ELECTRONIC CONTROL (STANDARD) 7a)Make certain the electrical line disconneot switch ia closed, The instrument panel *PoWER™ signal amp should ‘glow. NOTE, FOR | FCONOTROL™ ELECTRONIC Bypass CONTROL | EQUIPPED UNITS, “THE ' ECONOTROL’ SELECTOR SWITCH MUST BE POSITIONED TO. *OFF*. b) Position the control node gelector switch on "the Gnstrument |“paner to the *CoNPinuous? "position. The néoNtinuous" signal Lamp should glow. ©) Close the shut off valve located between the system receiver and the. system distribution paping~ 20 id> Open the system receiver vent or drop leg valve. WARNING AIR ESCAPING TO ATMOSPHERE IS NOISY.” ALWAYS "WEAR Rap PROTECTION TO PROTECT HEARING. e? Start the unit by actuating the start switch Cinstrument patel) - £¥Slowly close the drop 1eg or vent Valve. Observe the digital pressure gage (compressor) for Fiaing pressure. Nove that when the ‘presoure réaches ‘the full Unload preseure (120, 138 or 160 psi) the unit should “fully Unload Cintake valve closed). In addition, the return air bieed back | “valves “should actuate providing return air bleed back through the air end. g? Slowly open the drop Lag or vont Valve. Observe the digital pressure gage (compressor) for felling pressure... When air pressure falls te a pressure oF 0% Cparcent) below the full load pressure, the unit' should load “(intake ' valve open). In addition,: the return air bleed valves should actuate, topping the return air bleed back. hX Slowly open and close the drop leg or vent valve to cycle the Controle, Jf the unit operates as described, proceed to Step i+ i® Allow the unit to continue to run loaded, 5% Reposition the mode selector aviteh (on the instrament, panel to FAuTOuatics.” The “contin = yous’ lamp shoula go our and the *AUTOmatic® lamp should glow. k> Locate the delay timer (SS-1) on the solid state control circuit board. (inside control enciosure Bigure 14) Set the timer to zero (observe “indicator window) by turning the knob counterclock~ sina: TT ‘ 6 [ee vy Peo] oo FIGURE 14 1)Slowly close the vent Valve pressure drop leg or Observe the digital ge a y > > leg or vent valve. As the pree ssure falls the LED’* on ‘the circuit board should ewiteh froa red “on" to green "an® in the sequence D, C, B and A until ali four green‘LED*" are “on™. Continue to cycle the controls by raising and’lowering receiver pressure and observing the cir~ cuit board LED‘*. Tr the sequance of events is as described anove the unit is ready for use in "CONTinuous" mode. 4 open the aysten receiver drop leg or vent. valve. Allow the pressure to drop until all. four green LED" are’ons (fait Toaay® ai Reposition the control mode selector avitch to the "AUTOS nati" position: Locate the sconotrol tined stop timer in the control enclosure and set the timer to minimum time. (30 seconda, approx” imately) Slowly close the system receiver drop “leq or vent valve. The ecohotrol operation ghould occur as described above, Step 9q\ the unit will be fully unloaded ‘(in take valve closed} and the delay tine will start, When the time delay elaspes (30 Seconds, approninately) the anit should ‘stop. “In addition, the blow down valve should actuate venting the unit sir recelver/ oil reservoir £9 atmosphere: Slowly gpen the, aro} valve. Obsarve the 1 pres- gure’ gage (comprassos) for fal- ling pressure. When air pressure deg gr vent falle 10 psi (approximately) the unit should seatart ”. NOTE WHEN THE UNIT STOPS AvTONAT- ICALLY OR TS "MANUALLY ‘sHUr DOWN, IT WiLL NOT” Restarr unril gue UNIT AIR RECEIVER ZOIL RESERVOIR PRESSURE 1S BELOW 20 PSI. (APPROXIMATELY) TE THE UNIT ATTEMPTS TO START WITH A UNID PECEIVER/RESER- VOIR AIR PRESSURE ABOVE 20 PSI, SHUT DOWN AND "REFER To CONTROL ~ ADJUSTMENT PROCE- DURES. If the controls operate as described the unit is ready to use. LEAD/LAG CONTROL NOTE LEAD/LAG CONTROL FOR ECONOTROL uNITS Ts OBTAINED BY POSITIONING THE ECONOTROL OPERATING " PRESSURE RANGE SELECTOR SWITCH CORRECTLY. HAKE CERTAIN’ THE “OPERATING PRESSURE RANGE FOR THE LEAD CISPECIFICATIONS", SECTION Jla)Make-certain ‘the line discon- Rect switches are closed. The "POWER" gignal lamp should glow on all unite. b) Determine which unit is to be the lead unit. Position. the econotrol *CONTinuous ~ OFF = AUTOmatic"™ switch on the toad unit to “coNTinuous*. Position the *ConTinuous ~ OFF. AUTomatic® switch on the lag unit(s) to "AUTOmatic™. NOTE IZ IS RECOMMENDED FoR NosT ABPLICATIONS THAT THE NODE SELECTOR sw SWITCH ON THE LEAD UNIT BE SET 70 THE “*CONTin~ gous" POSITION.” HERE AIR DEMAND 1S VERY "Low THE LEAD UNIT AY BE SEP “ro ‘atro- nation. €) Position the ECONCTROL™ presaure range selector switch to poai- taon 4 on the lead unit. NOTE DOQ_NOT ENCEED THE MAXIMUM OPERATING "PRESSURE RANGE. SECTION ("SPECIFICATIONS" , In} 2a