Cat Air Compressor Manual REHS9687-00

REHS9687
COMPRESSED AIR
PACKAGED SYSTEM
IAC-7.5D80ECWXH-4
OPERATOR’S MANUAL
KEEP FOR
WARRANTY NOTICE
Failure to follow the instructions and FUTURE
procedures in this manual or, misuse
of this equipment will VOID its warranty! REFERENCE

Manual Part Number 100-20140601-001 Rev 3
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TABLE OF CONTENTS
Table of Contents 2
General Information 3
Personal Protective Equipment _______3
Pressure Release _______3
Fire and Explosion _______4
Moving Parts _______5
Hot Surfaces, Sharp Edges and Sharp Corners _______5
Toxic and Irritating Substances _______6
Electrical Shock _______7
Lifting _______7
Entrapment _______8
Identifying Your Package 9
Installation—Getting Started 10
Clearance Required ______ 10
Mechanical Installation ______ 10
Electrical Installation ______ 11
First Startup Procedure ______ 13
Power Up ______ 14
Check Rotation ______ 15
System Components 16
How the System Works 17
Temperature Control 17
Touch Screen Controller 18
Compressor Unit 24
Bulk Water Separator and Coalescing Pre-Filter 39
Zero Air Loss Drain 43
Oil/Water Separator 51
Molecular Sieve Desiccant Air Dryer 58
After Filter 65
Electrical 69
Troubleshooting 72
Procedure for checking dryer operation and freeing up stuck pistons 78
1 Year Service Parts ___________________________________________________________________ 85
Available Replacement Parts_____________________________________________________________ 87
2
GENERAL
IAC Air Compression and its suppliers design and manufacture all of their products so they can be operated safely.
However, the responsibility for safe operation rests with those who use and maintain these products. The following
safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents
throughout the useful life of this equipment. The compressed air system should be operated only by those who have
been trained and delegated to do so, and who have read and understood this Operator's Manual. Failure to follow the
instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the
compressed air system unless it is safe to do so. DO NOT attempt to operate the compressed air system with a known
unsafe condition. Tag the compressed air system and render it inoperative by disconnecting and locking out all power at
source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to
operate it until the condition is corrected. Install, use and operate the compressed air system only in full compliance with
all pertinent OSHA regulations and/or any applicable Federal, State, and Local codes, standards and regulations. DO
NOT modify the system and/or controls in any way except with written factory approval. While not specifically
applicable to all types of compressed air systems with all types of prime movers, most of the precautionary statements
contained herein are applicable to most compressors and the concepts behind these statements are generally applicable
to all compressors.
PERSONAL PROTECTIVE EQUIPMENT (PPE)

Prior to installing or operating the compressor, owners, employers and users should become familiar with, and comply
with, all applicable OSHA regulations and/or any applicable Federal, State and Local codes, standards, and regulations
relative to PPE, such as eye and face protective equipment, respiratory protective equipment, equipment intended to
protect the extremities, protective clothing, protective shields and barriers and electrical protective equipment, as well as
noise exposure administrative and/or engineering controls and/or personal hearing protective equipment.
PRESSURE RELEASE
A. Install an appropriate flow-limiting valve between the service air outlet and the shut-off (throttle) valve, either at the
compressor or at any other point along the air line, when an air hose exceeding 1/2" (13mm) inside diameter is to be
connected to the shut-off (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR
1926.302(b)(7) and/or any applicable Federal, State and Local codes, standards and regulations.
B. When the hose is to be used to supply a manifold, install an additional appropriate flow -limiting valve between
the manifold and each air hose exceeding 1/2" (13mm) inside diameter that is to be connected to the manifold to reduce
pressure in case of hose failure.
C. Provide an appropriate flow-limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air
hose exceeding 1/2" (13mm) inside diameter to reduce pressure in case of hose failure.
D. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly, in accordance with
their manufacturer's recommendations.
E. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses,
pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer's rated safe operating pressures for
these items.
F. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends
from being accidentally disconnected and expelled.
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G. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor
and bleed the sump (receiver) to zero internal pressure before removing the cap.
H. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other
component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze
compound.
I. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of
compressed air discharge.
J. Use air at pressures less than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip
guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) and/or any applicable Federal,
State, and Local codes, standards and regulations.
K. DO NOT engage in horseplay with air hoses as death or serious injury may result.
FIRE AND EXPLOSION

A. Clean up spills of lubricant or other combustible substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away
and DO NOT permit smoking in the vicinity when checking or adding lubricant or when refilling air line anti-icer systems
with antifreeze compound.
C. DO NOT permit fluids, including air line anti -icer system antifreeze compound or fluid film, to accumulate on, under
or around acoustical material, or on any external surfaces of the air compressor or on internal surfaces of the enclosure.
Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical material,
clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been
torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. DO
NOT use flammable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or
of the inside of the enclosure, if any.
E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring
that has cracked, cut, abraded or otherwise degraded insulation, or terminals that are worn, discolored or corroded.
Keep all terminals and pressure connectors clean and tight.
F. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as
terminals to avoid arcing which might serve as a source of ignition.
G. Remove any acoustical material or other material that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when servicing and
operating the compressor.
I. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
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J. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of
lubricant or with degraded lubricant.
K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the
compressor has been specially designed and manufactured for that duty.
MOVING PARTS
A. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other moving
parts.
B. DO NOT attempt to operate the compressor with the fan, coupling or other guards removed.
C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to
hot or moving parts.
D. Keep access doors, if any, closed except when making repairs or adjustments.
E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it.
F. Disconnect and lock out all power at source and verify at the compressor that all circuits are de-energized
to minimize the possibility of accidental start-up, or operation, prior to attempting repairs or adjustments. This is
especially important when compressors are remotely controlled.
G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other
liquids to minimize the possibility of slips and falls.
HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.
B. Keep all parts of the body away from all points of air discharge.
C. Wear personal protective equipment including gloves and head covering when working in, on or around the
compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and
burns as they may lead to infection.
5
TOXIC AND IRRITATING SUBSTANCES
A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with OSHA
Standards 29 CFR 1910 and/or any applicable Federal, State or Local codes or regulations.
WARNING
Death or serious injury can result from inhaling compressed

air without using proper safety equipment. See OSHA stand-
ards and/or any applicable federal, state, and local codes,
standards and regulations on safety equipment.
B. DO NOT use air line anti-ice systems in air lines supplying respirators or other breathing air utilization equipment
and DO NOT discharge air from these systems into unventilated or other confined areas.
C. Operate the compressor only in open or adequately ventilated areas.
D. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic,
noxious or corrosive fumes or substances.
E. Coolants and lubricants used in this compressor are typical of the industry. Care should be taken to avoid
accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and
water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to fluid of fill.
F. Wear goggles or a full face shield when adding antifreeze compound to air line anti -ice systems.
G. If air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed
with large quantities of clean water for fifteen minutes. A physician, preferably an eye specialist, should be contacted
immediately.
H. DO NOT store air line anti-ice system antifreeze compound in confined areas.
I. The antifreeze compound used in air line antifreeze systems contains methanol and is toxic, harmful or fatal if
swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce vomiting by
administering a tablespoon of salt, in each glass of clean, warm water until vomit is clear, then administer two teaspoons
of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician
immediately.
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ELECTRICAL SHOCK
A. This compressor should be installed and maintained in full compliance with all applicable Federal, State and
Local codes, standards and regulations, including those of the National Electrical Code, and also including those relative
to equipment grounding conductors, and only by personnel that are trained, qualified and delegated to do so.
B. Keep all parts of the body and any hand -held tools or other conductive objects away from exposed live parts of
electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the
compressor when making adjustments or repairs to exposed live parts of the electrical system. Make all such
adjustments or repairs with one hand only, so as to minimize the possibility of creating a current path through the heart.
C. Attempt repairs in clean, dry and well lighted and ventilated areas only.
D. DO NOT leave the compressor unattended with open electrical enclosures. If necessary to do so, then
disconnect, lock out and tag all power at source so others will not inadvertently restore power.
E. Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to rotating
machinery and prior to handling any ungrounded conductors.
LIFTING
A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by
sling. Compressors to be airlifted by helicopter must not be supported by the lifting bail but by slings instead. In any
event, lift and/or handle only in full compliance with OSHA standards 29 CFR 1910 subpart N and/or any applicable
Federal, State, and Local codes, standards and regulations.
B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded
members and for loose bolts or nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a
rated capacity of at least the weight of the compressor. If you are unsure of the weight, then weigh compressor before
lifting.
D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail
or slings.
E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear
of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance whenever compressor is suspended.
J. Set compressor down only on a level surface capable of safely supporting at least its weight and its loading
unit.
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K. When moving the compressor by forklift truck, utilize fork pockets if provided. Otherwise, utilize pallet if
provided. If neither fork pockets or pallet are provided, then make sure compressor is secure and well balanced on forks
before attempting to raise or transport it any significant distance.
L. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the
compressor.
M. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at minimum
practical speeds.
N. Make sure pallet-mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to
forklift or transport them. NEVER attempt to forklift a compressor that is not secured to its pallet, as uneven floors or
sudden stops may cause the compressor to tumble off, possibly causing serious injury or property damage in the
process.
ENTRAPMENT
A. If the compressor enclosure, if any, is large enough to hold a man and if it is necessary to enter it to perform
service adjustments, inform other personnel before doing so, or else secure and tag the access door in the open position
to avoid the possibility of others closing and possibly latching the door with personnel inside.
B. Make sure all personnel are out of compressor before closing and latching enclosure doors.
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IDENTIFYING YOUR PACKAGE
The data plate is located in the electrical panel, mounted on or around the swing panel that also houses the HMI touch
screen interface.
This contains vital information about the package including the serial number. The serial number must be provided to
the factory in the event of requiring replacement equipment components.
IAC – AIR COMPRESSION

CATERPILLAR IDENT NO. 457-2921
MFG. MODEL NUMBER IAC-7.5D80ECWXH-4
SERIAL NUMBER 111111-1111
AIR QUALITY ISO 8573.1 2.2.1
HORSEPOWER / kW 7.5 / 5.5
POWER REQUIREMENT 460V / 3 PH / 60 HZ
MIN/MAX CIRCUIT FUSE 20 / 30 AMP
COMPRESSOR CAPACITY 20 ACFM @ 175 PSIG MAX
OP. TANK PRESSURE 125 – 160 PSIG
MIN/MAX AMBIENT TEMP 0°F / 104°F
Proudly Manufactured in Indiana, USA
9
GETTING STARTED—INSTALLATION
There are two different methods of shipping the compressed air packaged system. The basic packaging consists of a
heavy duty skid with a light wood frame with heavy duty plastic and plastic wrap. Depending on shipping location, the
system could come fully crated as well.
To remove from basic packaging, carefully cut the plastic away making sure not to cut through the paint of the package.
Any penetrations of the paint may cause corrosion in that area in the future. Remove all of the plastic. The frame is
nailed and sometimes screwed together. Remove the wood that surrounds the package, leaving the heavy skid intact
which supports the unit. Once the full wood frame and plastic are removed, remove the lag bolts which secure the
package feet to the heavy skid.
If your unit was shipped fully wood crated, carefully disassemble the crate by removing the screws with a power drill,
ensuring you use safety precautions when lifting panels off, they can be heavy. Once the wood crating is removed,
carefully cut the plastic away making sure not to cut through the paint of the package. Any penetrations of the paint may
cause corrosion in that area in the future. Remove all of the plastic. Once the plastic is removed, remove the lag bolts
which secure the package feet to the heavy skid.
The package will require a forklift to remove the package from the heavy duty skid. CAREFULLY maneuver the forks
from the forklift either into the end forklift slots or the side forklift slots. MAKE SURE FORKS ENTER LEVEL AND NOT
AT AN ANGLE OR YOU MAY RISK DAMAGE TO THE PACKAGE. Forks should be as far in as possible, ensuring the
mast or vertical portion of the forks do not damage the exterior of the enclosure or tank. Gently lift the system off of the
shipping skid. The unit can now be maneuvered into place.
GETTING STARTED—CLEARANCE REQUIRED
Select a location to ensure that there is at least three (3) feet around the entire package for easy service access. The
control panel side should have the easiest access and should be visible when walking past the unit.
GETTING STARTED—MECHANICAL INSTALLATION
The support feet come with slotted holes which can be used to secure the entire package to the floor. Although this unit
is not subject to “walking” from vibration, it is recommended that the unit be secured to the floor for safety reasons.
There are two options for connection to the 80 gallon tank. Each side of the tank is equipped with a 1/2 inch NPT female
connection. Each is open for use, but if only one is used, the other should be fitted with an iron plug.
There is a plugged 1 inch NPT female opening in the bottom of the tank which can be used to install a customer supplied
drain if desired, however there should not ever be any moisture in the tank because the compressed air is stored at a –
40°F (-40°C) pressure dew point, meaning liquid water will not be present unless the tank is in an environment that is –
40°F or below. A 1 inch ball valve can be inserted if customer desires for manual purge of tank.
Always install a short piece of flexible line from the tank to the pipe leading to the end use. This eliminates the possibility
of vibration in the piping, or vibration from the system from transferring to the other. Continued stress on piping can lead
to eventual failure.
On the bottom of the enclosure base, at the back right hand corner, you will find a bulkhead fitting. This is where water
will drain out of the package. Refer to section on Oil/Water separator for further information on what to do with this
condensate discharge.
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GETTING STARTED—ELECTRICAL INSTALLATION
Interior electrical wiring is performed at the factory. Required customer wiring is minimal, but should be done by a
qualified electrician in compliance with OSHA, National Electrical Code, and any other applicable State, Federal and
local electrical codes concerning isolation switches, fused disconnects, etc. The factory can provide a wiring diagram for
use by the installer. A few electrical checks should be made to help assure that the first start-up will be trouble-free.
1. Check incoming voltage. Be sure that compressor is wired for the correct incoming voltage.
2. Ensure that overload setting are in the ‘D’ position.
3. Check all electrical connections for tightness.
Prior to doing any electrical work, ensure the power is off and you have followed your facilities proper lockout-tag out
procedures.
If you are looking at the control panel side of the compressed air packaged system, that is the front. To the right, will be
the right side, to the left, the left side and on the opposite side, the back. There is a plugged hole on the right side of the
enclosure, in the corner near the front. The purpose of this hole is for incoming power. The 460V / 3 Phase / 60 Hz
incoming power supply cord should enter the package here.
Remove the enclosure panel door on the back left hand side (if you are facing the back) of
the enclosure by lifting up on the handles and pulling the bottom out. There is a black
connector on the power supply cord for the inlet damper on the back side of the enclosure
door for the left side of the system (standing facing the front). Unplug the connector by
pulling it apart, shown in the picture to the right.
Then move to the right side of the enclosure, and remove the enclosure door by lifting up
on the handles and pulling the door out. This door will be slightly heavier with the additional
weight of the damper and the bird screen.
The opening from the right side of the enclosure give you access to pull the incoming power
cord through the enclosure and into the opening in the electrical enclosure which is just
slightly above the height level of the opening in the enclosure. This is so that any moisture
that may end up on the power cord will migrate away from the electrical enclosure. Feed the electrical cord into the
electrical enclosure.
In order to open the electrical enclosure door, take a flathead screwdriver and turn the slot until the exterior door with the
window will open.
CHECK NOW TO ENSURE THAT THE SWITCH DIRECTLY BELOW THE TOUCHSCREEN IS IN THE OFF
POSITION AND REMOVE THE KEY (IF INSERTED). If the key is not in the switch, they will be located inside the
electrical cabinet. From factory the key is mounted to the back of the HMI touch screen panel.
Use the screwdriver again to turn the cam-locks at the top right and bottom right of the swing panel. Use the handle at
the top right to open the enclosure swing plate revealing the electrical components.
The incoming electrical power cord should be directed towards the inside top of the panel to the opposite side of the
electrical enclosure from which it entered (left side). The three phase wires should be secured to the top of the circuit
breaker marked INCOMING POWER CONNECTION on the following page diagram. Ensure that you do not remove the
existing power cables which lead to the transformer for 110 V single phase power supply.
11
Secure the three phases of the incoming tightly.
Secure the ground wire to the GROUNDING LUG at the top left hand corner of the inside of the electrical panel marked
on the following page diagram.
Ensure that the circuit breaker indicators display a ‘red’ flag. (this indicates that they are open)
ENSURE THAT YOU KEEP THE KEY SWITCH IN THE “OFF” POSITION. IF THE KEY SWITCH IS IN THE “ON”
POSITION, THE COMPRESSOR WILL START AUTOMATICALLY AFTER A SHORT DELAY WHEN POWER IS
APPLIED.
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GETTING STARTED—FIRST STARTUP PROCEDURE
There are a few checklist items that need to be covered prior to applying power to the system:
ENSURE KEY IS IN THE OFF POSITION
1. Remove both back enclosure doors and the front enclosure door.
2. From the back side of the unit, ensure that all of the piping is secure and that it did not come loose during shipment.
3. Try to turn the bulk water separator housing bowl clockwise to ensure it is fully secure.
4. Try to turn the pre-filter housing bowl clockwise to ensure it is fully secure.
5. Check the clear tubing connecting the bulk-water separator to the oil/water separator. (tug gently).
6. Check clear tubing from the discharge of the dryer pre-filter to the oil-water separator connection (tug gently).
7. Check clear tubing from the discharge of the oil water separator to the bulkhead fitting (tug gently).
8. Ensure the mufflers on the bottom of the dryer cannot be tightened by hand.
9. Try to turn the after filter bowl clockwise to ensure it is fully secure. There is no drain on this filter to check as it is a
dust filter only.
10. Ensure that the isolation valve in the pipe between the after filter and the tank is fully open (handle is in-line with
pipe).
11. Check all control line tubing (1/4 inch tubing) to ensure it is all secure in the fittings.
Turn power on to the system. ( Make sure key is in the off position)
1. Make sure that the menu screen comes up on the touch screen.
2. Ensure that the electronic drain on the bulk water separator filter has a solid green light next to “power”.
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GETTING STARTED—POWER UP
With the key still in the “OFF” position, turn on power to the system. The touchscreen will light up and give you five (5)
different options.
Control Screen
Monitor Screen
Alarm Screen
Factory Setup
View Setup
Main Menu F1
Control Factory
Screen Setup F2
F keys are for
programming
Monitor View F3 only and are
Screen Setup
not used.
Alarm F4
Screen
F5
Push firmly on “View Setup”. Turn to Page 22 and confirm all of the settings in the program are correct. Pressing “Next”
will scroll you through the screens. Once verified, continue.
Back at the main menu, push firmly on “Control Screen” and the screen will change to the below image. The program
version will appear in the upper right hand corner of the system control menu.
Back System Control
Start Stop
Run Status
10
Stopped
Unload Timer (min) 0

Run Hours 2
System OK
Turn the key to ‘on’. Press the Stop button and ensure the Run Status says Stopped. This will disable the auto start
feature.
14
Prior to starting the compressor, it is necessary to check the fluid level in the sump. Should the level be low, simply add
the necessary amount. If the addition of fluid becomes too frequent, a minor problem has developed which is causing
this excessive loss. See the Troubleshooting Section under Excessive Fluid Consumption for a probable cause and
remedy.
GETTING STARTED—CHECK ROTATION

Due to the fact that this is a three phase power main motor on the
compressor, rotation must be checked. The only way to check rotation is to
jog the compressor on and off. This will require two people. Running the
compressor backwards for longer than two seconds can permanently
damage the compressor and will not be covered under warranty.
Remove the enclosure door on the left side of the machine by lifting up on the
handles and pulling out. There is a damper power cord that is attached to the
door, but there is a long enough lead that it should not need to be
disconnected. Set the door on the ground, leaning against the package
directly below the opening to expose the compressor’s cooing fan and the
recirculating damper. DO NOT lay the panel flat on the floor. Ensure there is
enough room for the dampers to open. Proper rotation is clockwise when
looking at the fan and can be confirmed by the sticker on the compressor
itself if you remove the enclosure door to the left of the control panel and look
inside the panel. (see image below)
REMEMBER When the key is turned into the on position, the compressor will
automatically start in 10 seconds. Unless the stop button is pushed.
With one person watching the fan, have another turn the key to the on
position and then quickly press the start button on the control screen and
then the stop button within 1-2 seconds. The compressor will jog and allow
the person watching the fan to determine proper rotation.
Note: When the compressor stops, the pressure in the compressor

could cause the unit to rotate backwards slightly, do not mistake that
for direction of rotation.
If rotation is correct, turn key back to off and

prepare to perform first startup procedure.
If rotation is incorrect, turn key back to off and

shut off the power to the unit, follow proper
lockout-tag out procedures and switch two of
the leads on the incoming power connections,
either at the disconnect or the compressor
starter where the incoming power was secured.
15
SYSTEM COMPONENTS
INTRODUCTION
Your new compressed air system will provide you with improved reliability and greatly reduced maintenance. Compared
to other types of compressors, the rotary screw is unique in mechanical reliability, with "no wear" and "no inspection"
required of the working parts within the compressor unit.
Read Maintenance Section to keep your compressor in top operating condition. Should any questions arise which cannot
be answered in the following text, call your nearest factory authorized Service Department.
DESCRIPTION OF PACKAGE COMPONENTS

Refer to Figure below. The major components and assemblies of the air compressor system are clearly shown. The
complete system consists of an encapsulated compressor, filtration, dryer, heater, electrical panel, oil / water separator,
dampers for cooling and temperature control, and an 80 gallon tank (not shown). The design of the entire system allows
for easy access to all serviceable components.
4
2 3
5
15
1
6
12
13
11
7
14
8 9
10
1. Compressor 9. Heater
2. Bulk Water Separator 10. Electrical Enclosure / Controls
3. Pre-Filter (oil removal) 11. Inlet Damper
4. Zero-Air-Loss Condensate Drain 12. Exhaust Damper
5. Oil-Water Separator 13. Recirculation Damper
6. Twin Tower Molecular Desiccant Air Dryer 14. Baseplate / Tank
7. After Filter (Dust Removal) 15. Hot Air Distribution Chamber
8. Transformer
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HOW THE SYSTEM WORKS
The compressor (1) is designed to bring in filtered ambient air and through a set of twin screws, compressed the air to
between 125 and 160 PSIG tank pressure. When the compressed air leaves the compressor, it will be cooled to
approximately 15°F above ambient temperature and be 100% saturated with moisture. The cool compressed air is
delivered through piping to a bulk water separator (2) where the liquid water is removed, about 70% of the overall
moisture in the air. The zero-air-loss drain (4) takes the bulk liquid and potentially some oil carry over and when full, will
open a valve and discharge the oil/water mixture to the oil-water separator (5). The dryer pre-filter (3) is designed for oil
removal down to 0.01 ppm. This protects the dryer from contamination from oil. It has a float drain in order to drain oil
and moisture that may be missed by the bulk water separator, it is discharged to the oil/water separator as well. The oil-
water separator (5) separates the small amounts of oil from the water and stores it within the replaceable cartridge. The
clean water is discharged through the bulkhead fitting on the bottom of the baseplate on the back right side. The liquid
free wet air is then put through the desiccant dryer (6). This is a twin tower dryer which passes the wet air across
molecular sieve desiccant, which has a very low relative humidity, attracting the water molecules out of the air and
allowing very dry air to pass out of the discharge port of the dryer. When leaving the dryer, the air has a dew point below
minus 40°F which means there will be no liquid moisture in the air until the air’s temperature reaches below (-40°F).
One tower is always drying, and one regenerating. The dryer consumes approximately 2 SCFM of the dry air to
regenerate the offline tower and vents the stored water molecules to atmosphere as a vapor. When the dry air leaves
the dryer, it is sent through an after filter (7) which removes any possible desiccant dust from the air. Air is then sent
through the baseplate (14) to be stored in the tank for use. The system will continue to run as long as air is demanded.
Once the system has set idle for a period of 10 minutes it will begin a shut down sequence by building pressure back up
to 160 PSIG for a final time then shut down until pressure drops below 125 PSIG.
TEMPERATURE CONTROL
The complete package is insulated with 1.5 inch foam with the exception of the baseplate. Temperature in the cabinet is
controlled by a heater (9) as well as dampers (11),(12) & (13). When the system is off, all of the dampers are closed and
the heater is used to maintain an internal temperature between 40°F and 50°F to prevent freezing. The heater is
controlled by the PLC using a temperature probe installed in the mounting bracket for the dryer.
When the system is running, if the ambient temperature is above 70°F, the inlet damper (11) and the exhaust damper
(12) are open, and the recirculating damper (13) is closed. As the temperature inside the package drops to 65°F, the
recirculation damper opens allowing some of the hot discharge air from the hot air distribution chamber (15) to
recirculate back into the package. If the temperature inside the package continues to drop to 60°F, the inlet and the
exhaust dampers shut. This forces all of the hot air to recirculate into the package. As the ambient temperature
increases, the package temperature will increase. When the temperature inside the package reaches 70°F, the inlet and
exhaust dampers open, allowing fresh air to be brought in, and hot air to be discharged. The recirculation damper will
shut when the package temperature
reaches 75°F.
15
The offset temperatures between the inlet
and outlet dampers as well as the
Hot air
recirculating damper will prevent all out
12
13
11
Hot air Cool

dampers from being shut a the same time, recirculating air in
which would prevent proper cooling of the

compressor. DO NOT adjust these
temperatures or overheating of the 9
compressor may occur and shut down the
system.
17
TOUCH SCREEN CONTROLLER
Main Menu F1
Control Factory
Screen Setup F2
Monitor View F3
Screen Setup
Alarm F4
Screen
F5
18
SYSTEM PLC CONTROL
The PLC Controls are used to control the entire compressed air system package. Users have the ability to go to the “Control
Screen” which is used to start and stop the system, and view run status and system status. Monitor Screen is used to view all of
the parameters of the system operation such as pressure, temperatures, damper positions, heater and exerciser. The Alarm
screen is used to view and clear alarms. Factory set up is for authorized dealers only and is password protected. Parameters
should not be changed to ensure proper operation of the package.
Menu Tree
Main Menu
Control Factory
Screen Setup
Monitor View
Screen Setup
Alarm
Screen
Back System Control Back System Alarms
Start Stop Drain Fault
Run Status
Standby

Run Hours 2
System OK Reset
Factory Setup Climate

Intake Damper Setup
Factory Exerciser70
Open/Close 60 Deg F
Exhaust Damper Open/Close 70 16860 Deg F

Factory
Max Setup
off timer Control
for Exerciser (Hours)
Recirc Damper Open / Close 70 75 Deg F
Exerciser
Compressor Timer
Load (Minutes) 125
Pressure Psig 30
Heater On Temperature 40 Deg F
Min Pressure
Compressor 160 Psig 120
(Turns off Exerciser)
Unload Pressure
Heater Off Temperature 50 Deg F
Compressor Safety Pressure
120 Psig Next
Back
Unload 70
Unload
Back Timer (Min) 10 Next
Back Next
19
SYSTEM CONTROL SCREEN
WARNING
On first start of the system you must verify rotation of the compressor. See Page 15.
WARNING
When the key is turned on, the system will start automatically after 10 seconds unless the stop
button is pushed.
In order for the compressed air system to be started, the key must be turned to Back System Control
the ON position. This unit is equipped with an “auto power failure restart”
option. This means that when power is first put to the PLC, it will attempt to Start Stop
turn on the compressor after 10 seconds. To stop this from happening, press
the stop button so that the run status says Stopped. Run Status
Standby
The System Control screen allows you to start and stop the compressed air
package system by utilizing the START button and the STOP button. Unload Timer (min) 10
Run Hours 2
When the start button is pressed the “Run Status” will show Running Loaded or
Standby System OK
If the pressure in the receiver tank is above 125 psig, the compressor will Back System Control
automatically go into standby mode and will wait for the tank pressure to drop
to 125 psig before starting, unless the compressor was running loaded. Start Stop
Run Status
If the pressure in the receiver tank is below 125 psig, the compressor will start
immediately and go into Running Loaded mode. Pressure will begin to Running Loaded
increase.
Once the tank pressure reaches 160 psig, the compressor will unload but Run Hours 2
continue to run for the duration of the unload timer. Factory setting is 10
System OK
minutes.
NOTE: The compressor is controlled by the pressure in the tank, not the Back System Control
“compressor pressure” shown on the monitoring screen. The compressor is
Start Stop
designed for up to 175 PSIG full operating pressure at its discharge, therefore
pressure is monitored at the compressor’s discharge as well. Should the Run Status
differential across the filters and the dryer go beyond 15 psid, the compressor
may unload prior to the tank reaching 160 psig. Running10
Unloaded
When the tank pressure reaches 160 psig, the compressor unloads, run status Unload Timer (min) 7
will change to Running Unloaded and the Unload Timer will begin to count Run Hours 2
down in minutes from 10 to zero. Once it reaches zero, the compressor will System OK
stop and enter Standby mode. If the pressure falls below 125 psig before the
timer reaches zero, the compressor will go into Running Loaded mode again
Back System Control
and the Unload Timer will reset.
Start Stop
Run hours tracks how many hours the compressor has run (both loaded and
unloaded combined) for its life. Maintenance intervals can be tracked using Run Status
the hours shown here. 10
Stopped
The bottom status message shows if the system is OK or if there is a problem.

If it shows a system problem—see alarm screen, go back to the main menu
and push the alarm screen button. Run Hours 2
System Problem See Alarm
20
SYSTEM MONITORING SCREEN
WARNING
On first start of the system you must verify rotation of the compressor. See Page 15.
WARNING
When the key is turned on, the system will start automatically after 10 seconds unless the stop button is pushed.
This screen allows you to monitor the pressures, temperatures, damper

operation, heater operation, and exerciser operation of the system. No
functionality or buttons are on this screen.
Tank Pressure (psig): This is the air pressure in the tank

This value is normally between 125 and 160
psig.
Compressor Pressure (psig): This is the pressure at the discharge of the

compressor, before the pre filter.
When in Running Loaded mode, this value is
normally 5-10 psig higher than the tank
Back System Monitoring
pressure. When in Running Unloaded mode,
Standby or Stopped, this value will Tank Pressure Enclosure
stabilize to be the same as the tank pressure. (psig)
150 Temp (Deg F) 50
Compressor Oil Temp
155 170
Enclosure Temp (°F): Displays the temperature inside the enclosure Pressure (psig) (Deg F)
Damper Operation Heater

Oil Temp (°F): Displays the temperature of the compressor oil
Intake Closed Standby
Recir Open Exerciser
Damper Operation:
Exhaust Closed Active
Intake: Intake damper position, open or closed
Recir: Recirculating damper position, open or closed
Exhaust: Exhaust damper position, open or closed Back System Monitoring
Heater: Heater status, Standby or Heating Tank Pressure
135
Enclosure
50
On temperature 40°F (psig) Temp (Deg F)
Off temperature 50°F Compressor

0
Oil Temp
50
Pressure (psig) (Deg F)
Only operates if compressor is in Standby or
OFF Damper Operation Heater
Intake Closed Heating
Exerciser: Exerciser status, Standby or Active. Recir Closed Exerciser
The Exerciser activates a 1/16 inch orifice to Exhaust Closed Standby
vent tank pressure for 30 minutes if the
package has not run in a continuous 168
hours. This will cause the pressure in the tank to slowly drop to 125 psig. The orifice is
sized so that the compressor can overcome the amount of air venting to atmosphere
and will increase the pressure in the tank. Once the system starts to build pressure, the
exerciser will remain on for the 30 minutes unless the tank pressure drops to 120 psig.
If the tank drops to 120, the compressor is producing less capacity than the demand,
which means there is an end use need, and will shut off the exerciser to allow full
capacity to supply the demand.
21
VIEW SETUP
View setup allows you to view the factory settings. This is a view only set of screens, it does not allow you to make any
changes to the values. This is primarily to confirm that the proper settings are in place at the time of startup, or
reference in the future.
FACTORY SETUP CONTROL

Compressor Load Pressure:
Factory Setup Control
Default: 125 psig
For description, see following page Compressor Load Pressure 125 Psig
Compressor Unload Pressure:
Default: 160 psig Compressor Unload Pressure 160 Psig
For description, see following page
Compressor Safety Pressure Unload: Compressor Safety Pressure
175 Psig
Unload
Default: 175 psig
For description, see following page Unload Timer (Min) 10
Unload Timer:
Default: 10 minutes Back Next
FACTORY SETUP EXERCISER

Factory Setup Exerciser
Max off timer for Exerciser:
Default: 168 hours Max off timer for Exerciser (Hours) 168
Exerciser Timer: Exerciser Timer (Minutes) 30
Default: 30 minutes
For description, see following page Min Pressure (Turns off Exerciser) 120
Min Pressure (Turns off Exerciser):
Default: 120 psig
Back Next
FACTORY SETUP CLIMATE

Intake Damper Open/Close
Default: open 70°F, close 60°F
For description, see following page Factory Setup Climate
Exhaust Damper Open/Close
Intake Damper Open/Close 70 60 Deg F
Default: open 70°F, close 60°F
For description, see following page Exhaust Damper Open/Close 70 60 Deg F
Recirc Damper Open/Close
Default: open 65°F, close 75°F Recirc Damper Open / Close 65 75 Deg F

Heater On Temperature 40 Deg F
Heater On Temperature
Default: 40°F Heater Off Temperature 50 Deg F
Back 70 Next
Heater Off Temperature
Default: 50°F
22
FACTORY SETUP (PASSWORD PROTECTED)
Factory Setup is only to be used by your Authorized Factory Dealer only. For this generator application, settings are
preset to values that have been tested for the purposes of your generator needs and is also suitable to any environment
within the limits of the package as shown in the specifications.
FACTORY SETUP CONTROL

Compressor Load Pressure:
Factory Setup Control
This is the tank pressure setting where the compressor will start and
enter the Running Loaded mode. If the compressor is already running
Compressor Load Pressure 125 Psig
unloaded, it will change status from Running Unloaded to Running
Loaded when the pressure drops tot his value (default 125 psig).
Compressor Unload Pressure 160 Psig
Compressor Unload Pressure:
This is the tank pressure setting where the compressor will unload and Compressor Safety Pressure
175 Psig
enter the Running Unloaded mode (default 160 psig). Unload
Compressor Safety Pressure Unload: Unload Timer (Min) 10
This is the maximum discharge pressure at the compressor (before the
pre filter) which will force the compressor into the Running Next
Back
Unloaded mode. This is to protect the compressor from running
above it’s maximum full load design pressure in the event that the differential pressure of the filters and dryer
cause the discharge pressure to go too high (default 175 psig).
Unload Timer:
The amount of time the compressor will run in the Running Unloaded mode before shutting down and entering
the Standby mode (default 10 min).
FACTORY SETUP EXERCISER

Max off timer for Exerciser:
This is the number of hours the system has to remain off for Factory Setup Exerciser
consecutively before the exerciser will start its operation. This ensures
the system will run and reach operating temperatures once per week Max off timer for Exerciser (Hours) 168
(default 168 hours).
Exerciser Timer (Minutes) 30
Exerciser Timer:
This is how long the Exerciser allows air to bleed from the tank (default Min Pressure (Turns off Exerciser) 120
30 minutes)
Min Pressure (Turns off Exerciser):
This is the minimum tank pressure we want to allow when the
Exerciser is running. Dropping below this pressure means there is a
demand from the system and the system needs to divert all the air to Back Next
the generator.
FACTORY SETUP CLIMATE

Intake Damper Open/Close
Enclosure temperature set points at which the damper opens and
closes automatically default open 70°F, close 60°F) Factory Setup Climate
Exhaust Damper Open/Close Intake Damper Open/Close 70 60 Deg F
closes automatically (default open 70°F, close 60°F) Exhaust Damper Open/Close 70 60 Deg F
Recirc Damper Open/Close
Recirc Damper Open / Close 65 75 Deg F
closes automatically (default open 65°F, close 75°F) Heater On Temperature 40 Deg F
Heater On Temperature
Enclosure temperature set point at which heater turns on (default 40°F) Heater Off Temperature 50 Deg F
Heater Off Temperature Back Next
70
Enclosure temperature set point at which heater turns off (default 50°F)
NOTE: Factory password is only available to Authorized Dealers. Changing factory set points without authorization in
writing from the manufacturer will void warranty.
23
COMPRESSOR UNIT
24
ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION
WARNING
DO NOT remove caps, plugs and/or other components when compressor is running
or pressurized. Stop compressor and relieve all internal pressure before doing so.
While the Factory has built into this compressor a comprehensive array of controls and indicators to assure you that it is
operating properly, you will want to recognize and interpret the reading which will call for service or indicate the
beginning of a malfunction. Before starting your system, read this section thoroughly and familiarize yourself with the
controls and indicators, their purpose, location and use.
The encapsulated compressor includes compressor unit, oil management system, cooling system and motor section.
The compressor unit is a single-stage positive displacement lubricated type compressor. This unit is equipped with
tapered roller bearings on the discharge, and cylindrical roller bearings on the inlet end for high load carrying capacity.
This unit provides continuous pulse-free air compression to meet your needs.
Oil is injected into the compressor unit in large quantities and mixes directly with the air as the rotors turn, compressing
the air. The oil flow has three main functions:
1. As coolant, it controls the rise of air temperature normally associated with the heat of compression.
2. It seals the leakage paths between the rotors and the stator and also between the rotors themselves.
3. It acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler.
The air/oil mixture discharges directly into the oil management system.
The oil cooler bypass valve helps assure proper cooling by directing the oil to the oil cooler when discharge temperature
reaches the thermostat temperature setting.
During start-up in cool ambient conditions, the cooler pressure drop will cause the oil filter bypass valve to open up,
assuring adequate oil supply to the compressor.
All oil entering the compressor unit passes through the replaceable oil filter element. This replaceable filter element
contains a built-in bypass valve. Under conditions of restricted flow through the element, the bypass valve helps ensure
adequate compressor oil flow, as well as helps prevent element failure.
FUNCTIONAL DESCRIPTION OF OIL MANAGEMENT SYSTEM

The oil management system consists of a multi-chambered primary/secondary separator, the final air/oil separator
element, cooler bypass group and oil filter. As compressed air/oil enters the sump, the first oil separation takes place
due to a reduction of flow speed coupled with a change of direction of the flow within the sump housing. Then the
compressed air reaches the separator, where the finest oil drops and mist are separated.
FUNCTIONAL DESCRIPTION OF MOTOR / DRIVE SECTION

The motor / drive section consists of a 460 volt, 3 phase, 60 Hz, 1800 rpm squirrel cage induction motor and integrated
drive gearing which is separated from the motor by a replaceable shaft seal. It is a dual shaft motor which drives the
compressor air end unit on one end, and the cooling fan on the other.
25
FUNCTIONAL DESCRIPTION OF MINIMUM PRESSURE CHECK VALVE
The minimum pressure/discharge check valve is mounted on the compressor drive housing. Its functions are as follows:
1. Maintain a minimum sump pressure of 60 psig (4.1 bar) under full load operation to help assure adequate fluid
pressure.
2. Act as a check valve to isolate the compressor from the system at shutdown or unload.
FUNCTIONAL DESCRIPTION OF COMPRESSOR COOLING SYSTEM

The compressor cooling system consists of a oil cooler, fan and cooler shroud.
The fan is mounted on the motor's shaft end opposite the compressor. Air is drawn over the motor as well as through the
cooler. The air provides motor cooling and removes compression heat from the oil.
FUNCTIONAL DESCRIPTION OF AIR INLET SYSTEM

The compressor inlet system consists of a dry-type air filter and an air control valve. Reacting on a pressure signal, the
valve closes the intake for unloaded operation. The valve also acts as a check valve upon shutdown.
FUNCTIONAL DESCRIPTION OF CONTROL SYSTEM

The purpose of the compressor control system is to operate the compressor to meet the system demand. The control
scheme is load / unload. During the load mode, compressed air is produced and is fed into the system. During the
unload mode, the compressor does not compress air and a minimal pressure is kept within the unit to ensure proper fluid
lubrication to components. The control system consists of an inlet valve and a load / unload solenoid valve which is
controlled by the PLC.
FUNCTIONAL DESCRIPTION OF AUTOMATIC CONTROL

When the compressor motor starts, load / unload control solenoid will be energized (closed.) During this time the inlet
valve is fully open due to inlet air flow, and the compressor will start to deliver compressed air. When the air demand is
less than the rated flow for the compressor, the tank pressure will rise to the unload setting on the PLC control. The PLC
interrupts the electrical power to the solenoid valve. The solenoid valve opens allowing pressure to be applied to the inlet
valve causing the inlet valve to fully close. The purge will also be stopped on the dryer through the purge shut off
solenoid valve. The compressor will continue to run unloaded until the tank pressure drops to the load setting in the
PLC, reenergizing the normally open solenoid valve and allows the compressor to load again.
If there is little to no demand on the compressor, when the compressor unloads, the unit will run unloaded by the
duration set in the unload timer. If the pressure does not fall to the load pressure within the 10 minute unload timer
setting, the compressor motor will stop and the purge on the dryer will remain off. The compressor will automatically
restart when the storage pressure drops to below the set-point of the PLC load pressure (125 psig).
NOTE
At compressor unload or shutdown, the sump pressure
within the compressor (shown on the gauge mounted
on the compressor) is released to atmosphere through
the solenoid valve and intake valve. The tank pressure
on the monitoring screen will continue to read the
control pressure.
26
FUNCTIONAL DESCRIPTION OF OIL LEVEL SIGHT GLASS
Indicates oil level. The level is checked by looking at the oil level
sight glass on the end bell. The fluid level should cover 1/2 to1/4
of the sight glass during operation. With the compressor shut
down, the level should be 3/4 of the sight glass. DO NOT
OVERFILL.
FUNCTIONAL DESCRIPTION OF COOLER BYPASS VALVE

Regulates oil flow to and around the cooler. Designed to maintain
a minimum operating temperature of 170°F (77°C). Used for fast
warm-up and start-up.
FUNCTIONAL DESCRIPTION OF COMPRESSOR OIL TEMP

SENSOR
Monitors the temperature of the compressor oil. Shuts the
compressor down when the compressor discharge temperature
exceeds 235°F (113°C).
FUNCTIONAL DESCRIPTION OF PRESSURE RELIEF VALVE

Opens sump pressure to the atmosphere should pressure inside
the sump be come too high. Operation of this valve indicates that
the load / unload solenoid is stuck in the closed position and is
faulty.
FUNCTIONAL DESCRIPTION OF AIR PRESSURE TRANSDUCERS

Senses discharge pressure and tank pressure and displays on touch screen. When tank pressure reaches maximum
setting, the PLC opens a solenoid valve circuit to unload the compressor.
FUNCTIONAL DESCRIPTION OF LOAD / UNLOAD SOLENOID VALVE

Controls the action of loading or unloading the compressor based on pressure. It also vents sump pressure through inlet
control valve to the atmosphere during unload conditions and shutdown.
FUNCTIONAL DESCRIPTION OF SUMP PRESSURE GAUGE

Displays the pressure within the compressor sump tank. Under full load conditions, it should be 2-7 psig higher than the
discharge pressure shown on the touch screen. This is present for troubleshooting only.
27
COMPONENTS OF THE COMPRESSOR
1. After Cooler and Oil Cooler

2. Compressor Unit
3. Oil Fill Plug
4. Oil Filter
5. Oil Level Sight Glass
6. Air/Oil Separator
7. Pressure Relief Valve
8. Discharge Air
9. Air path
10. Air/Oil path
11. Oil path
12. Sump Pressure gauge (not shown)
13. Oil Drain Valve
28
COMPRESSOR LUBRICATION GUIDE
View page 28 for oil fill plug location. For best value and longest uninterrupted WARNING
service, the compressor is factory filled with Sullair’s Sullube brand oil.
“The Plastic Pipe Institute
Always keep spare lubrication on hand for top off due to oil carry over or leak.
recommends against the use of
thermoplastic pipe to transport
Maintenance of all other components is still recommended as indicated in the compressed air or other compressed
recommended maintenance section. gases in exposed above ground
locations, e.g. in exposed plant
In the event that the oil becomes milky looking, an oil flush and replacement is piping." (I) Sullube should not be
required. Ensure the unit’s exerciser is operational and set for a minimum of used with PVC piping systems. It
30 minutes every 168 hours of run time. Another cause is very high humidity. may affect the bond at cemented
The compressor oil normal operating temperature should be 170°F minimum joints. Certain other plastic materials
to ensure liquid is flashed off. Only use OEM Sullube oil in this compressor. may also be affected.
Contamination of non-detergent mineral fluids with traces of automatic (I) Plastic Pipe Institute,
transmission fluid (ATF) or detergent motor fluids may lead to operational Recommendation B, Adopted
problems such as foaming, filter plugging, orifice or line plugging. Flushing is January 19, 1972.
required if the unit is contaminated with another oil.
CAUTION
Mixing of other oils within the compressor will
void all warranties.
LOCATION OF COMPRESSOR
The compressor unit must be in the specified location within the enclosure on a level surface which is able to support its
weight. The unit is bolted to a fixed mounting surface with vibration isolators to avoid the possibility of externally applied
forces or vibration which would disturb the piping or wiring.
VENTILATION AND COOLING

Select a location to permit sufficient unobstructed air flow in and out of the system through the dampers to keep the
operating temperature stable. The minimum distance that the machine should be from surrounding walls is three (3) feet
(0.91m) or more.
OIL LEVEL CHECK AND CHANGE PROCEDURE

The air compressor is equipped with the proper amount of oil. However, it is necessary to check the oil level at
installation. The level is checked by looking at the fluid level sight glass located on the end bell. See page 27. If the sump
is properly filled, the oil level should cover 1/4 to 1/2 of the sight glass during operation. DO NOT OVERFILL.
29
MAINTAINING YOUR COMPRESSOR
WARNING
Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate
compressor from line pressure by closing recommended discharge shut-off valve and releasing all internal pressure
from compressor.
As you proceed in reading this section, it will be easy to see that the Maintenance Program for the air compressor is
quite minimal yet important.
MOTOR BEARING LUBRICATION

See Motor Bearing Lubrication Schedule table below. If lubrication instructions are shown on the motor or in a separately
provided manual, they will supersede this general instruction.
1. Remove the fan guard by removing the four (4) self-tapping screws holding the guard and fan ring to the cooler.
2. Remove the 1/8" NPT plugs in the filler and drain connection for both bearings.
3. Free drain hole of any hard grease (use piece of wire if necessary).
4. Add grease to grease zerk fitting (see note at bottom of page) using a low pressure grease gun.
5. Wipe off any drained grease, and replace filler and drain plugs.
6. Replace fan guard.
7. Motor is now ready for operation.
Motor Bearing Lubrication Schedule
Model Standard Conditions (I) Severe Conditions (II) Extreme Conditions (III)
IAC-7.5D80ECWXH-4 2.5 Years 10 1/2 Months 5 1/2 months
(I) Eight hours per day, normal or light loading, clean 100°F (38°C) maximum ambient.
(II) Twenty Four hours per day, normal or shock loadings, vibration, or in dirt or dust at 100°F to 104°F
(38°C to 40°C) ambient.
(III) Twenty Four hours per day, heavy shock or vibration, or in dirt or dust at 100°F to 104°F (38°C to
40°C) ambient.
NOTE: Use Chevron SRI-2 grease when lubricating motor bearings. Fill the cavity 1/3 to 1/2 full by repacking or
use a low pressure grease gun and fill through the lubricating provisions on the motor end bell housing.
30
AIR FILTER MAINTENANCE
Refer to figure below. Maintenance on the air filter should be performed every six (6) months or more frequent
if conditions so require. Perform inspection only if the unit is in standby the majority of the time.
WARNING
Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate
compressor from line pressure by closing recommended discharge shut-off valve and releasing all internal pressure
from compressor. Confirm zero pressure on sump pressure gauge mounted on compressor.
AIR FILTER ELEMENT MAINTENANCE

1. When performing maintenance, care must be taken that no dirt or
foreign matter enters intake housing.
2. Clean exterior of air filter cover.
3. Remove the air filter cover by loosening the winged securing the
cover.
4. Remove element and base. Clean base and interior of cover using a
damp cloth. DO NOT use compressed air to clean cover and base.
5. At this time replace element.
6. Replace cover.
ELEMENT INSPECTION
1. Place a bright light inside the element to inspect for damage or leak
holes. Concentrated light will shine through the element and locate
any holes.
2. Inspect all gaskets and gasket contact surfaces of the housing.
Should faulty gaskets be evident, correct the condition immediately.
3. If the clean element is to be stored for later use, it must be stored in
a clean container.
4. After the element has been installed, inspect and tighten (if
necessary) all air inlet connections prior to resuming operation.
1. Cover 3. Air Filter Element (I)
2. Pre-Filter 4. Base
(I) Replacement Element Kit P/N 457-2941
31
WARNING
Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor
from line pressure by closing the self-vending isolation valve between the after filter and the tank and releasing all internal
pressure from compressor. Ensure Discharge pressure and Sump pressure gauge (located on compressor) read zero psig.
COOLER MAINTENANCE
If cooler becomes restricted, use standard spray degreaser/cleaner and brush to clean cooler. Use air pressure to blow
cooler clean. Care must be taken as not to damage cooler fins. Wipe up any material and liquid from the enclosure floor.
DRAINING THE COMPRESSOR OIL

When the compressor oil is ready to be changed, the compressor needs to be shutdown with the power to the
compressor shut off, and locked out.
1. To prevent spillage, place a contaminate-free fluid receptacle beneath oil drain valve and oil filter.
2. Drain the oil from the compressor using the oil drain valve (See figure below).
3. Remove the plug and open the drain valve and allow the oil to flow out.
4. Remove the oil fill plug to allow air to enter the sump.
WARNING
Fluid filter has internal bypass. DO NOT SUBSTITUTE
FLUID FILTER MAINTENANCE

FLUID FILTER REPLACEMENT
1. Refer to image to the right. Oil filter should be changed every 8000 hours.
2. Drain oil by removing oil drain valve cap at tee located beneath compressor (for complete oil change, drain oil from
cooler by disconnecting stainless steel oil lines at cooler).
3. Using a strap wrench, remove the old oil filter and gasket.
4. Clean gasket seating surface.
5. Apply a light film of oil to the new gasket.
6. Hand tighten new oil filter until gasket is seated.
7. Continue tightening oil filter an additional 1/2 to 3/4 turn.
8. Replace oil with new. DO NOT OVERFILL.
9. Restart compressor and check for leaks.
1. Oil Fill Plug 3. Oil Sight Glass
2. Oil Drain Ball Valve 4. OIl Filter (I)
(I) Replacement Element Kit P/N 457-2947
32
SEPARATOR ELEMENT REPLACEMENT
Refer to figure below. Separator element should be changed every 8000 hours or 1 year, whichever occurs first. The
separator element should also be changed if the oil is changed prematurely. Follow the procedure explained below for
element replacement.
WARNING
1. Insert a 4" maximum length, 1/4" diameter pin into the

radially drilled hole in the separator cap. Loosen,
unscrew counterclockwise and remove the cap.
2. Pull out the old element by gripping the end of the
element with channel lock pliers or a similar tool
3. Install new O-rings on separator cap and separator
element filter and oil lightly to make installation easier.
4. Insert and push the new element in place.
5. Reinstall the cap. Hand-tighten using a 4" maximum
length, 1/4" diameter pin in the radially drilled hole.
1. Oil Fill Plug 4. Separator Element (I)

2. O-Ring (I) 5. Sight Glass
3. Cap (I) Replacement Element Kit P/N 457-2948
FILLING THE COMPRESSOR LUBRICANT
1. Ensure that the oil drain ball valve is closed.

2. Ensure the oil filter is installed properly
3. Ensure the separator element is installed and the separator cap is in place.
4. Open Oil Fill Plug.
5. Use a funnel and slowly pour in the compressor oil, closely monitoring the level on the sight glass.
6. When oil is 3/4 from the top of the sight glass, stop filling and replace the oil fill plug.
7. Use proper starting procedures and allow the compressor to run for 30 seconds.
8. Shut off compressor, allow oil to stabilize and look at level. Should be 1/2 to 3/4 high on the sight glass.
9. If lower, perform lock out tag out procedure, depressurize the line by closing the self venting valve to the tank, and
repeat from step 4.
33
MINIMUM PRESSURE/CHECK VALVE MAINTENANCE
Refer to top Figure below. Minimum pressure/check valve maintenance is minimal. The only parts which normally require
replacement are the O-ring seal around the piston and the valve seat on the check valve. To replace any of the two
parts, follow the procedure explained below.
WARNING
1. Unscrew the minimum pressure valve from the drive

housing.
2. Remove all parts.
3. Clean and inspect all parts.
4. Remove the screw holding the check valve seat.
Replace valve seat. Reinstall securing with Loctite®
#222.
5. Install new O-ring. Before reinstallation, lubricate with
Parker Super "O" ring seal or an equivalent grease.
6. Reinstall the whole valve assembly. Tighten and
secure.
1. Valve Spring 3. Valve Stem 5. Screw 7. Check Spring
2. O-ring 4. Washer 6. Valve Seat 8. Cap
(I) Replacement Kit P/N 457-2936
THERMOSTAT ACTUATOR MAINTENANCE

Refer to bottom right figure. The only part which would ever need
replacement is the thermostat valve actuator. For replacement,
follow the procedure explained below.
1. To prevent spillage and loss of re-usable oil, place a
contaminate-free fluid receptacle beneath fluid drain valve and
fluid filter.
2. Drain fluid by opening the oil drain ball valve located beneath
compressor.
3. Unscrew and remove hollow hex plug.
4. Remove spring and piston.
5. By using long nosed pliers, pull the actuator out.
6. Install new actuator.
7. Install piston and spring with centering guide. 1. Thermostat Actuator (I) 3. Pin 5. Plug 7. Spring
8. Re-install plug.
2. Piston 4 O-ring 6. Guide
9. Refill compressor with oil before operating (page 33)
(I) Repair Kit P/N 457-2937
34
LOAD / UNLOAD SOLENOID VALVE MAINTENANCE
Unloader valve maintenance is minimal, but a periodic cleaning is desirable. The time between cleanings will vary de-
pending on operating conditions. In general, if the voltage to the coils is correct, sluggish valve operation or excessive
leakage will indicate that cleaning is required. It is not necessary to remove the valve from the pipe line for repairs.
DANGER
DO NOT touch the electrical contacts, terminal or leads with any part of the body or any uninsulated metallic
object. Severe electrical shock may occur.
WARNING
Turn off all power, relieve sump pressure, and disconnect coil lead wires to the solenoid valve before making repairs.
DISASSEMBLY AND REASSEMBLY

1. Unscrew the solenoid base assembly. Remove the core assembly, core spring and body gasket.
3. All parts are now accessible for cleaning or replacement.
4. Reassemble in reverse order of disassembly.
35
INLET CONTROL VALVE MAINTENANCE
Refer to figure below. The only parts which normally require replacement are the piston seal on the intake valve piston
and gasket. Follow this procedure for inlet control maintenance.
WARNING
from line pressure by closing the self-vending isolation valve between the after filter and the tank and releasing all internal pressure
from compressor. Ensure Discharge pressure and Sump pressure gauge (located on compressor) read zero psig.
1. Remove the inlet filter assembly.

2. Disconnect tubing from intake control
housing at 90° elbow.
3. Remove the two (2) 3/8" ferry head cap
screws securing the intake control
housing to the inlet plate.
4. Remove intake control housing
assembly and gasket.
5. Remove retaining ring, cap and intake
check spring from intake housing bore.
6. Remove socket head cap screw,
washers, and check spring from intake
valve rod.
7. Remove intake valve from valve
housing. Remove intake valve rod,
check spring, spring retainer and intake
valve head. 1. Nylok Screw 4. Intake 7. Intake 10. Spring 13. Retaining
8. Remove intake piston from intake/inlet Valve Head Valve Rod Washers Ring
control housing. Remove and discard old
2. Piston Seal 5. Spring 8. Gasket (I) 11. Intake
piston seal from intake piston.
(I) Retainer Check Spring
9. Clean intake housing gasket surface and
internal piston bore. 3. Intake 6. Check 9. Inlet Valve 12. Cap
10. Lubricate internal piston bore using Piston Spring Housing
lubricant supplied with kit. (I) Repair Kit P/N 457-2938
11. Install new piston seal onto piston
12. Reinstall intake valve rod, check spring, spring retainer and intake valve head into intake control housing. Install
assembled intake piston into intake control bore and onto intake valve rod.
13. Install washers. Apply screw lock adhesive provided in kit to socket head cap screw. Replace socket head cap screw
into the valve rod and torque socket head cap screw to 18 to 24 in.-lbs. (2.0 to 2.7Nm).
14. Install intake check spring, cap and retaining ring.
15. Replace gasket and reinstall the whole inlet control valve assembly.
16. Apply screw lock adhesive to inlet control housing assembly ferry head cap screws and install. Torque to 30 ft.-lbs.
(40.7Nm).
17. Reconnect tubing to inlet control valve housing at 90° elbow.
18. Reinstall air inlet filter assembly.
36
MOTOR SHAFT SEAL REPLACEMENT
There is a clear tube coming from the bottom of the compressor directly behind the heater. The tube is secured to the
support bracket of the transformer. If you have a leak in the shaft seal, you will see lubricant build up in the tube, it is
from a chamber at atmospheric conditions, so there is no chance that lubricant will come out of the tube.
If you notice lubricant in the tube, there could be a shaft seal leak. If only minimal amounts, it could be due to normal
operation of the seal.
Replacement of motor shaft seal requires that the compressor be separated from the drive housing. This operation
requires qualified personnel. Detailed instructions and a list of needed tooling are included in each motor shaft seal
replacement kit no. 250028-035.
Please contact your Authorized Dealer if you suspect or find a shaft seal leak.
Shaft Seal weep hose
37
COMPRESSOR SPECIFICATIONS
COMPRESSOR
Compressor Type Single Stage Fluid Injected Screw Compressor
Compressor Horsepower / kW 7.5 / 5.5
Compressor Capacity (ACFM / m3/min) 20 / 57
Minimum Full Load Operating Pressure (psig / bar) 60 / 4.1
Maximum Full Load Operating Pressure (psig / bar) 175 / 12
Bearing Type Anti-friction
Cooling Pressurized Fluid
Lubricant Sullube Polyglycol
Sump Capacity 4.6 Quarts
Sound Level (dBA) 70
MOTOR
Motor Type 7.5 HP (5.5kW) 1.15 S.F.
Motor Enclosure Total Enclosed Air Over
Synchronous Speed 1800 RPM
Voltage 460V 3 Phase 60 Hz
Insulation Class “F”
Maximum Ambient Temperature 104°F (40°C)
Shaft Diameter Fan Nominal 5/8 Inch
Key Size Fan Nominal 3/16 x 3/16 x 1 1/4 inch
FLUID FILTER (Internal Bypass Valve Set at 25 PSIG)

Type Spin on, Proprietary
Micron 23 Microns Abs
FLUID SEPARATOR ELEMENT

Type Push in Cartridge, Proprietary
Efficiency at Maximum Capacity 3 PPM Maximum
MAINTENANCE INTERVALS / LUBRICATION GUIDE

LUBRICANT FLUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGE
Sullube 8000 hours or once per year Every 8000 Hours 8000 hours or once per year
38
BULK WATER SEPARATOR
AND
COALESCING PRE-FILTER
39
WARNING
Disconnect or depressurize compressed air line prior to any installation or maintenance activity. Eye protection goggles
or safety glasses are always recommended during installation and maintenance.
DANGER
Compressed air from this package is not for breathing purposes.
Compressed air filters have been designed to remove airborne contamination in a compressed air
stream, delivering energy efficient operation and reliable performance. There are three filters in this
package, the first to remove bulk liquid moisture, the second to coalesce any oil carry over prior to
the dryer down to 0.01 ppm. The third filter is used as a dust filter and is located after the dryer. It
can remove particulate down to 1 micron. Filters comply with Pressure Equipment Directive (PED)
and perform as per related ISA 8573.1 Standards.
Zero-porosity aluminum and durable epoxy powder coat finish, along with a corrosion-resistant
internal coating gives long service life. These filters are equipped with a visual differential pressure
gauge for easy maintenance and energy efficiency.
Filter Element Specifications
Efficiency and Media Flow Max Max Minimum Dry Wet

Element
Coalescer Type / Operating Operating Operating Pressure Pressure
Type Direction
Performance Pattern Pressure Temperature Temperature Drop (psig) Drop (psig)
SF
3 Micron Bulk
(Orange Wrapped In to Out 250 psig 150°F 35°F 0.8 1.0
Water Removal
Top)
UF
0.01 Micron & 0.01
(Yellow Wrapped In to Out 232 psig 150°F 35°F 0.8 2.0
mg/m3 carryover
Top)
NOTE: Collected liquids must be removed to ensure proper operation

Model Max Flow Connection ‘A’ Width ‘B’ Height ‘C’ Height ‘D’ Bowl Weight
Clearance
F04 50 SCFM 1/2 inch 4.5 inches 9.9 inches 8.5 inches 4.0 inches 1.9 lbs
Depressurize system slowly to avoid element

If slide indicator is in the red zone,
damage by slowing closing the valve between the
change element regardless of hours
after filter and the tank. This valve is self venting
and will exhaust the compressed air upstream of
the valve. As another precaution, push the test
button on the drain below the bulk water separator
to exhaust any potentially trapped air.
40
FILTERS—MAINTENANCE AND OPERATION
The Bulk water separator is fitted with an external zero air loss drain. Check function of the installed drain to ensure it is
operating properly by pressing the test button. Water or air should discharge through the clear tube to the oil/water
separator. For service on the drain, see ZERO AIR LOSS DRAIN SECTION. Pre-filter / Coalescing filter is fitted with a
float drain. You will see very little volume coming from this drain, eventually the discharge tube will be filled with a milky,
oily liquid which goes to the oil-water separator for processing.
WARNING
Filter performance will decrease dramatically after approximately 1 year due to deterioration of the fragile fibers of the
filtration media caused by the acidity of the condensate and bombardment by fast moving particles. This most often
occurs with little or no increase in differential pressure. Filter elements MUST be changed annually regardless of
differential pressure. For maximum filtration efficiency, replace element when pressure drop reached 4.3 PSI (indicator
in red area), or annually, whichever comes first.
NOTE: Pressure drop may temporarily increase when flow is resumed after flow stoppage. Pressure drop should return
to normal within 1 hour.
WATER SEPARATOR AND PRE-FILTER—REPLACING THE ELEMENT

1. Filter elements must be replaced once per year or when the differential pressure indicator turns from green to red.
Performance should be monitored.
2. While there is still pressure in the system, press the test button on the top of the drain directly below the water
separator 2 times to ensure that all liquid has been evacuated.
3. IMPORTANT: Make sure the compressor is off, key is in “OFF” position. Shut self vending ball valve slowly
between the after filter and the tank (inside the enclosure). This will release all of the pressure in the lines and the
compressor. Do not stand in front of or place your hand in front of the vent opening of the valve. Push drain test
button once more to release any trapped pressure.
4. Remove the zero air loss drain by taking apart the brass union directly
above the drain. If the filter has not been fully depressurized before
disassembly, pressure will begin to release when you loosen the union.
If this occurs, stop disassembly and see step 3.
5. If the filter bowl is removed before depressurized, it will emit a sound.
If this happens, go to step 3.
6. Remove the air filter bowl from the housing by turning it counter
clockwise. If difficult to turn, use strap wrench or C spanner to free the
connection. Pull the bowl straight down.
7. Clean the inside of the bowl.
8. Gently pull the filter element straight down, gently wiggle to break seal
connection. Discard the dirty element.
9. Wipe the wall inside of the filter head to remove air dirt.
10. Orange element is for water separator, yellow is for the second filter.
11. Check the O-ring on the new element to ensure it is not damaged,
lubricate the O-ring (with non-petroleum based lubricant provided) ,
and install the element into the housing.
12. Align the slot in the element top cap with the projection inside the filter head (see image to the right)
13. NOTE: Handle all elements by the bottom end cap only. Insert the element into the head making sure the element
slot and the projection inside the filter remain aligned.
41
13. Replace housing O-ring (located at the top of the filter bowl) if needed. Make certain the O-ring is generously lubri-
cated.
14. Reassemble bowl to head. Generously lubricate threads with a high grade/temperature resistant lubricant (150°F /
66°C) or use lubricant provided.
15. Perform drain maintenance if needed (see zero air loss drain section), or reattach drain to the bottom of the filter with
the union.
In the event that the entire housing needs to be replaced, follow these steps:
Installation of a new filter housing

1. Turn off the air supply and discharge of air.
2. Before installing, ensure the pipe line is free of scale and other foreign matter.
3. The filter has DRYSEAL pipe threads; use pipe compound or Teflon™ tape sparingly to male threads only.
4. Mount so that the inlet and outlet connections are horizontal (filter bowl vertical) to ensure proper liquid drainage.
5. Flow direction—Install so that the air flow is in the direction of the arrows on the filter head. Air flow is from the com-
pressor discharge to the inlet of the dryer.
6. Connect the system to the air supply and then check the connections under pressure for any air leaks.
Service Air Piping

Direction of airflow is critical to filter performance. Please follow air flow directional arrows and/or inlet and outlet decals.
Filters will not operate correctly if installed backwards. Do not reduce the size of the compressed air piping if it needs to
be replaced for any reason.
42
ZERO AIR LOSS DRAIN
43
ZERO AIR LOSS DRAIN
Drain Min / Max operating temperature: 34°F / 140°F
Condensate feed: 1/2in. NPT
Condensate Discharge: 1/4in. NPT
Peak Filter Performance: 2250 SCFM Max
Min / Max Operating Pressure: 12 / 230 psig
Weight (lbs / kg) 2.2 / 1.0
Condensate Oil Contaminated or Oil Free
Housing Material Aluminum, Plastic, Fiberglass
Supply Voltage 115 VAC +/- 10%
Max Power Input 2.0 VA
DANGER
Compressed air! In the case of contact with quickly or suddenly released compressed air or in the case of bursting plant
components there is a risk of serious injury or death. Maintenance work is only allowed when the device is in a de-
energized condition! All types of electrical works must be carried out by authorized and qualified personnel only.
Safety rules
1. Installation and operation must also be in compliance with the valid national regulations and safety rules.
2. Do not use the drain in hazardous areas (with potentially explosive atmospheres).
3. If conical connectors are used on the inlet side, avoid excessive tightening of the connectors.
4. For locking or holding in position during installation, use spanner area at inflow point (spanner size 27) !
5. Although when powered up, the enclosure climate control will keep the inside of the enclosure from freezing, do not
operate the drain when in a freezing climate until the enclosure temperature has been above 32°F for longer than 30
minutes, as potential damage may occur.
6. The condensate drain will only function when power is turned on to the package and voltage is being applied to the
drain.
7. Do not use the test button for continuous draining.
8. Only employ original spare parts, This is imperative to ensure perfect functioning and the guarantee will no longer be
valid.
9. The service unit must not be taken apart!
10. The feed pipe must be tubed firmly. Discharge pipe: short, fixed pressure hose onto pressure-resistant pipe.
11. Make sure that persons or objects cannot be hit by condensate or
escaping compressed air.
44
FUNCTION OF THE DRAIN
The condensate flows through the feed line (1) into the zero air loss drain and
accumulates in the container (2). A capacitive sensor (3) continuously registers the
liquid level and passes a signal to the electronic control as soon as the container is
filled.
The pilot valve (4) is then activated and the diaphragm (5) opens the outlet line (6) for
discharging the condensate. When the container unit has been emptied, the outlet line
is closed again quickly and tightly without wasting compressed air.
Two LEDs show the individual operating states of the zero air loss drain
Ready to operate, Voltage is applied
In the event that the condensate discharge is disturbed, an alarm mode starts which is
indicated by flashing of the red alarm LED. Alarm will be shown on Package Control
Screen.
Malfunction / alarm
Test of the valve function (manual drainage): Press the button for approximately two
seconds.
Test of the alarm function: Press the button for at least one minute.
DO NOT use for permanent drainage
Alarm Mode
In the event that the BEKOMAT is not empty after one minute, a trouble
indication is released:
• The alarm LED flashes.
• The alarm relay switches over (the signal can be picked off potential-
freely).
• The valve opens every four minutes for 7.5 seconds.
• When the malfunction has been eliminated, the drain will switch back
automatically into the normal mode.
45
Only the displayed installation position of the Drain (3) is permissible. Never
install in a horizontal or any other tilted position.
Bulk Water Separator housing (1)
Union separating drain from filter (2)
Do not install a filter or screen in the inlet line (2)
Operating pressure: min. 12 psi, max. 230 psi.
Clear hose leading to inlet of Oil/Water separator (4) fixed.
Prior to the start-up, always carry out a leak test and verify the correct
engagement of the control unit.
46
DRAIN POWER SUPPLY:
1. Read the permissible mains voltage on the type plate and
make sure this voltage is observed.
2. At an AC supply, a reliably accessible separator must be
provided close-by (e.g. power plug or switch), which separates
all current-carrying conductors.
3. At a DC supply, only use a protective extra-low voltage (PELV)
in accordance with IEC 60364-4-41.
4. Carry out installation in accordance with VDE 0100 / IEC
60364.
5. Observe the terminal assignment.
6. Do not install when the device is energized.
7. Unscrew the screw (1) and remove the upper part of the cover
(2).
8. Unscrew the threaded cable connection (3) (if there is one),
remove the plug and lead the cable (4) for the supply voltage
through.
9. Connect the cable (4) with terminals KL1 (1.1 … 1.3) (5).
10. Install the cables as shown (see also terminal assignment in
the following text).
11. Tighten the threaded cable connection (3) with a slightly
sealing effect.
12. Put on the upper part of the cover (2) and tighten the screw (1)
finger tight.
13. Between the earth conductor/PE connection and the piping, a
potential difference is not admissible. If required, potential
equalization in accordance with IEC 60364 / VDE 0100 must
be provided for.
Connection of the potential-free contact and of the external test:

Selection of the suitable cable.
Connection to KL2 and KL3, as is shown.
The installation steps are the same as for the power supply connection
• KL 1.1 L or N mains connection

• KL 1.2 N or L mains connection
• KL 1.3 PE mains connection
L = Outer conductor
N = Neutral conductor
PE = Protective earth conductor
Normally Closed
Normally Open
Neutral/Phase
Phase/Neutral
Common
47
Drain Maintenance
It is imperative to observe all hazard statements and warnings listed here.
Please also observe all regulations and notes regarding industrial safety and fire prevention at the place of installation.
As a matter of principle, only use suitable and appropriate tools and materials in a proper condition.
Do not use aggressive cleaners and improper devices such as high-pressure cleaners.
Please note that condensates may contain aggressive or harmful components. Therefore, skin contact should be
avoided.
Condensate is subject to mandatory waste disposal. As such, it must be collected in suitable containers, and disposed of
or processed properly.
1. Replace the service unit (5) after 8,000 operating hours or one
year, whichever occurs first (If in an operating site):
2. Standby site, replace every 3 years.
3. Remove the control unit (1) by pressing the arresting hook (2)
4. Unfasten drain assembly from the outlet (3)
5. Detach the service unit (5) from the tubing at the inlet by
removing the union nut
6. or remove screws (6) from the elbow hose connector (7)
7. or unscrew screws (8) at the intermediate adapter (9) and
remove the latter from the service unit by pulling it in a
downward direction
8. Check whether or not the new service unit (5) goes with the
control unit (1) (model designation and color of the arresting
hook (2))
9. Installation of the new service unit (5) in reverse order. Please
consider the starting torque for the screws (8) with 35 to 45 lb-
in.
48
Installation of the control unit on the service unit:
1. Check whether or not the service unit (5) goes with the
control unit (1) (model designation and color of the
arresting hook)
2. Check whether or not the sensor tube plate (14) with
contact springs (13) is clean, dry and free from impurities
3. Introduce the sensor (12) into the sensor tube plate (14)
4. Hang the hook (15) of the control unit (1) in the sensor
tube plate (14)
5. Press the control unit (1) against the service unit (5) and
snap into place
Start-up subsequent to maintenance:

Always carry out prior to the start-up:
• Leak test of the screwed connector
• Control of the electrical connections
• Check of the correct engagement of the control unit
49
50
OIL-WATER SEPARATOR
51
QWIK-PURE 25 OIL-WATER SEPARATOR
The QWIK-PURE oil-water separator unit is designed for the treatment of demulsifiable
compressor condensates in compliance with legal requirements such as the oil provided
within this air system, Sullube.
WARNING
Oil-contaminated condensate contains substances that are hazardous both to health
and environment. These substances may cause irritation or damage to the skin, eyes
and mucous linings. Oil-contaminated condensate must not be allowed to get into
water bodies or the soil. Contaminated objects have to be cleaned or disposed of
according to the legal regulations.
This unit is not under pressure, however, when the zero loss drain or float drain discharges,
condensate will be introduced to this unit under pressure. Do not install this unit outside of
the climate controlled environment. Ensure that if there is liquid inside the oil/water
separator, and if the climate reaches below freezing temperatures, that the compressed air
system has power to it at all times and the doors remain on the enclosure.
This system is designed to limit oil carry over to 20 ppm or under in the water discharge if
properly maintained. It is the owners responsibility to determine where the water needs to
be discharged from the compressed air system.
Record of maintenance and proper upkeep has to be documented and reports must be filed and presented to the responsible local
authority if requested.
The operator must ensure through constant monitoring that the QWIK-PURE oil-water separator is in a leak tight condition and
functioning properly.
 Check the oil-water separator for leaks regularly

 Check the outflowing clean water every 500 hours using the reference test kit
 Always keep a spare filter set
52
Technical Data for the Oil/Water Separator
Maximum Compressor Capacity 55 scfm

with Polyglycol based oil (Sullube)
Container Capacity 2.64 gal
Filling volume with pre-separation 1.14 gal
Condensate Feed (hose) 2 x 1/2 in
Water outlet 1/2 in
Weight empty 7.7 lbs
Min/max temperature (in enclosure) 41 to 140°F
Max operating pressure at inlet 232 psig
Prefilter 0.66 gal
Main filter 0.68 gal
K = Condensate Feed
W = Water outlet
P = Sampling valve
53
OIL-WATER SEPARATOR FUNCTION
The oil-contaminated condensate can be fed under pressure to
the oil/water separator unit (1).
The pressure is reduced in the pressure relief chamber (2).
The condensate flows steadily into the subjacent filter stage
without turbulence and runs through the two-stage
OEKOSORB filter.
The OEKOSORB filter unit (3) comprises a pre-filter and a main
filter for binding any residual oil constituents. The water flows
out of the oil-water separator through the water outlet (6) and is
directed to a 1/4 inch NPT bulkhead fitting on the bottom of the
enclosure base (rear right side).
A sampling valve (5) is provided so that the waste water quality
can be checked at any time as long as the unit has fluid to the
level of the water outlet.
Putting the oil-water separator into operation

1. Remove the black vented cap and the filter mat from inside
the pressure relief chamber.
2. Pour clean water into the oil/water separator opening until
water starts coming out of the water outlet. Pour slowly to
allow filters to absorb the water.
3. Replace the filter mat and vented cap.
4. The unit is ready for operation.
5. Check all connections for leaks.
54
WATER TEST
500 hour water test.
1. Fill test tube at the sampling cock

2. Compare the cloudiness with the reference jar.
3. If the sample is clearer than the reference
cloudiness the filter is OK. (Fig. 1)
4. If the sample is cloudier than the reference
cloudiness, the filter needs to be changed. (Fig.
2)
MAINTENANCE
Changing the filters
Be prepared with new filters prior to beginning

maintenance. It is important that condensate gets
removed prior to the dryer or liquid water will begin
to come out of the purge mufflers. Before
maintenance, shut condensate inlet by pinching
the inlet hose with a clamp. Remove the hose
clamp and the hose from the inlet if you wish.
1. Place new OEKOSORB filter set near the unit.

Keep the PE packaging of the new set for
putting in the old filters.
2. Open the quick pure cover (vented cap) and
remove the filter mat. Remove the inlet
3. Slowly remove the used pre-filter and the main
filter from the container and let them drain
4. Put the drained filter set into the PE packaging
and ensure correct disposal. (EWC 150202 =
European waste disposal key)
5. Insert a new filter set into the filter receptacle
of the container.
6. Insert the inlet, filter mat and replace the cover.
7. Re-attached / re-open the condensate inlet
hose.
GENERAL CLEANING (every 8,000 hours). DO NOT USE ANY CLEANING AGENTS
1. Remove the cap and filter mat

2. Remove the OEKOSORB filter
3. Pump out the container
4. Ensure correct disposal of the liquid (EWC 13 08 02 = European waste disposal key)
5. Clean the container
6. Replace the OEKOSORB filter, inlet, filter mat, and cover. Fill with fresh water.
55
OIL-WATER SEPARATOR COMPONENTS
1 Cap
2 Filter mat
3 Inlet pipe
4 OEKOSORB filter
5 Hose Connector G 1/2, dia = 10 mm
6 Screw plug G1/2 in
7 Sampling valve
8 Test tube
56
Clear tube from Oil/
Water Separator to
Clear tube from Bulkhead fitting
Drain to Oil/
CLEAR TUBE FROM DRAIN TO OIL/WATER SEPARATOR
CLEAR TUBE FROM OIL/WATER SEPARATOR TO BULKHEAD FITTING
Sampling Valve
and Test Tube
57
TWIN TOWER MOLECULAR SIEVE DESICCANT DRYER
58
DRYER OPERATION
Dryer removes water and contaminants protecting the downstream components from moisture, oil and dirt that can
damage delicate pneumatic controls reducing machine life and productivity. Moisture alone is the main cause of most
pneumatic equipment failures. Water and related contaminants affect pneumatic systems commonly found within
concrete plants, food processing, mining operations and countless other applications relying on compressed air systems.
Oil, water, or particulates in compressed air contribute to increased maintenance, higher operating costs, and lower
productivity. Many plants have installed some type of water removal devices to control compressed air contamination are
often unreliable, cost-prohibitive, maintenance-intense or simply do not work.
Patented designs surround accessible valves, spin-on desiccant cartridges, a patented filtration system and manifold
mounting systems facilitate effective preventive maintenance acknowledged in saving you money. This reliable dryer
technology is proven in harsh applications.
59
DRYER SPECIFICATIONS
Dryer Control Micro Logic Timer with Purge cut off solenoid
Electrical Requirement 110 Volt 0.072 ampere NEMA 4
Desiccant Cartridges 4 pounds molecular sieve per cartridge
Inlet / Outlet Ports 1 1/2 inch NPT
Operating Pressures 90 to 190 PSIG Inlet Pressure
Weight including desiccant 50 pounds
Dimensions L x W x H 13.62 x 10.75 x 21.00 inches
WARNING
BEFORE PROCEEDING WITH INSTALLATION, MAINTENANCE OR SERVICE PROCEDURES
READ AND OBSERVE FOLLOWING SAFETY PRECAUTIONS:
Always wear proper eye protection when installing or servicing dryer. Never look directly into ports of the dryer.
Never exceed recommended working air pressure of 190 psi/13.1 bar
Never attempt to service the dryer until you read and understand all recommended procedures
Use only proper tools and observe all precautions pertaining to the use of those tools.
60
Basic Operation and Installations Mounting Guidelines
This dryer uses a Micro Logic Timer (MLT) to control the cycling. The MLT manages regeneration cycles by energizing
and de-energizing operating air control valve at two (2) minute intervals. An indicator light on MLT will be "on" during
energized cycle and "off" during de-energized cycle.
During operation (single unit with two cartridges), a light flow of air from ONE exhaust port (muffler) is normal as this
represents regeneration cycle of desiccant. Air flow will alternate (every 2-minutes) from one exhaust port to other
exhaust port.
When the dryer cycles, there will be a momentary burst of air from the purge muffler. This is normal and will occur each
time dryer cycles.
The dryer must be mounted with the exhaust ports positioned downward and desiccant cartridges in upright position as
they are from the factory. Do not change configuration.
Power source: 110-120 Volt AC (grounded) is provided by the compressed air package transformer, and is pre-wired.
No external power source is required other than the main incoming power to the package.
Air Compresser Maintenance Cycle/ Air Dryer Inspection
Operational Check:
1. Check electrical power to Micro Logic Timer
2. Check all air connections for leaks or damages signal lines
3. Listen for unit to exhaust (discharge) every two minutes
4. During operation, a light flow approximately 1.6 cfm (45.30 lpm) of air from exhaust port is normal representing
regeneration cycle of desiccant
5. When cartridge 1 regenerates, cartridge 2 dries and vice versa.
6. If dryer fails to cycle, remove timer solenoid, and manually cycle dryer several times turning small brass screw from
12 o’clock position to 2 o’clock position (approximately ¼ turn) located on spool valve. If dryer cycles manually,
return brass screw back to original vertical position.
7. If it does not cycle, the switching pistons may have stuck. Reference “Procedure for Freeing Stuck Dryer Pistons”.
Timer Solenoid
Brass Screw
61
Service Procedures Air Dryer
WARNING
BEFORE SERVICING DRYER, READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 8 REVIEW DE-
SCRIPTION OF AIR DRYER OPERATION/CYCLE
Annual Maintenance on Dryer
1. IMPORTANT: Make sure the compressor is off, key is in “OFF” position. Shut self vending ball valve slowly
between the after filter and the tank (inside the enclosure). This will release all of the pressure in the lines and the
compressor. Do not stand in front of or place your hand in front of the vent opening of the valve. Push drain test
button once more to release any trapped pressure.
2. Relieve all system air pressure.
3. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove it. Discard.
4. Remove and discard O-ring from adapter plate stud.
5. Clean top surface of adapter plate and threaded stud.
6. Using grease supplied, apply a light coating on O-ring. Install O-ring on stud.
7. Apply a generous coat of grease on the new desiccant cartridge gasket surface
8. Thread new cartridge onto stud turning clockwise. When gasket contacts adapter plate, tighten cartridge 1/2 to 3/4
turn DO NOT OVER-TIGHTEN!
Replacing Air Control Valve (Switching Valve)
1. Relieve all system air pressure

2. Disconnect power from system.
3. Remove two (2) air lines connected to fittings in air valve
4. Remove plastic retaining nut and MLT from valve stem and set aside both for re-assembly later
5. Remove three (3) screws holding valve to manifold remove valve and discard
6. Install new push connect air line fittings to open ports of new valve
7. Install new small O-ring on top of valve (use small amount of grease to hold in place)
8. Attach valve to manifold with three (3) screws included within kit
9. Tighten screws to 15-20 in lb
10. Re-connect two (2) air lines to push connect fittings in back ports of valve
11. Re-assemble MLT assembly onto valve stem and secure with retaining nut (finger tight)
62
Replacing Purge (Exhaust) Valves
2. Remove two bolts that attach the purge valve retainer and remove from housing
3. Remove the purge valve assembly and O-ring from the purge cavity, trash screen and discard
4. Clean the cavity thoroughly
5. Remove the three (3) O-rings from retainer and discard
6. Using lubricant supplied, lightly grease all three new O-rings
7. Install on the retainer the two (2) larger O-rings then install the third (smaller) O-ring
8. Apply a light coating of grease around the O-ring seat on valve assembly and install the thin O-ring on the purge
valve seat
9. Insert valve assembly into cavity and insure that hole in valve sleeve aligns over housing exhaust port (muffler) Use
care not to dislodge the thin O-ring from its seat
WARNING: If the purge valve port does not align with housing exhaust port, dryer will not exhaust!
10. Install retainer to housing
11. Apply a light coating of grease on the threads of the two retainer bolts
12. Install two retainer bolts and tighten to 10-15 ft. lb
Replacing Inlet Check Valves

2. Remove two bolts from inlet check valve retainer and remove seal retainer
3. Remove inlet check valve spindle from cavity and discard
4. Clean cavity thoroughly
5. Remove all O-rings from retainer and discard
6. Install two (2) large O-rings and (1) smaller O-ring into grooves of seal retainer
7. Lubricate O-rings on check valve sleeve and install valve assemble (small end first) into the inlet cavity Make sure
spindle is completely seated
8. Lubricate O-rings on seal retainer and reinstall retainer AVOID TWISTING SEAL RETAINER
9. Apply a light coating of grease on the threads of the two retainer bolts
10. Reinstall the retainer bolts torque to 10-15 ft. lb.
Replacing Outlet Check Valve

2. Disconnect air line from dryer outlet port
3. Remove check valve nut
4. Remove and discard O-ring, spring, spindle, and ball
5. Clean nut and check valve cavity thoroughly
NOTE: If excessive oil is evident in check valve cavity, oil separator and desiccant cartridges require servicing
6. Install new ball into cavity
7. Install spindle with spring pocket facing up into cavity
8. Place spring into spring pocket of spindle
9. Apply a light coating of grease onto O-ring and place onto check valve nut
10. Apply light coating of grease to nut threads Install nut and tighten to 60 ft Ibs
11. Re-connect air line to outlet port
63
Replacing Regeneration valve

2. Disconnect air line from dryer outlet port
3. Remove the eight (8) socket head bolts fasting manifold to dryer
4. Remove manifold
5. Discard O-rings, springs and regeneration valves
6. Clean valve cavities in housing
7. Position new valve spindles into cavities with spring pockets out
8. Position springs into valves
9. Lubricate new O-rings and install onto manifold bosses
10. Position manifold onto adaptor castings ensuring O-rings are properly positioned in bores.
11. Install eight (8) socket head bolts and tighten to 50-60 in. lbs. Torque.
12. Reconnect air line to outlet port.
64
AFTER FILTER
(Dust Removal)
65
WARNING
DANGER
Compressed air from this package is not for breathing purposes.
Compressed air filters have been designed to remove airborne contamination in a compressed air
stream, delivering energy efficient operation and reliable performance. There are two filters in this
package, the first to remove liquid moisture and coalesce any lubricant carry over prior to the dryer down
to 0.01 ppm. The second filter is used as a dust filter and is located after the dryer. It can remove
particulate down to 1 micron. Filters comply with Pressure Equipment Directive (PED) and perform as
per related ISA 8573.1 Standards
Zero-porosity aluminum and durable epoxy powder coat finish, along with a corrosion-resistant internal
coating gives long service life. These filters are equipped with a visual differential pressure gauge for
easy maintenance and energy efficiency.
After Filter Element Specifications
Flow Max Minimum

Element Particulate Removal Media Type / Max Operating Dry Pressure
Operating Operating
Type Performance Pattern Direction Temperature Drop (psig)
Pressure Temperature
HF6 1 micron particulate Wrapped Out to In 300 psig 150°F 0°F 1.0
NOTE: There should be no liquid present at this filter

Depressurize system slowly to avoid element damage by slowing closing the valve between the after filter and the tank. This valve
is self venting and will exhaust the compressed air upstream of the valve.
Model Max Flow Connection ‘A’ Width ‘B’ Height ‘C’ Height ‘D’ Bowl Weight
Clearance
16 35 SCFM 1/2 inch 4.03 inches 10.05 inches 8.59 inches 3.00 inches 4.5 lbs
If slide indicator is in the red zone,

change element regardless of hours
66
MAINTENANCE AND OPERATION
The after filter is equipped with an external manual drain. There should be no water present in this filter so a routine
check for moisture in this filter would be recommended. Turn the manual drain screw to the right to open, left to close. If
any moisture is present, the system has been contaminated with water.
WARNING
Filter performance is expected to last one year due to dust carry over from
the dryer. Filter elements MUST be changed annually regardless of
differential pressure. For maximum filtration efficiency, replace element
when pressure drop reached 6 PSI (indicator in yellow area), or annually,
whichever comes first.
FILTER REPLACEMENT
1. Filter elements must be replaced once per year or when the differential
pressure indicator turns from green to yellow. Performance should be
monitored.
2. IMPORTANT: Ensure the compressor is off, key is in “OFF” position
and the isolation valve is closed between the after filter and the tank.
Shut self vending ball valve between the after filter and the tank (inside
the enclosure). This will release all of the pressure in the lines and the
compressor. Do not stand in front of or place your hand in front of the
vent opening of the valve.
3. Open the manual drain by turning the valve to the right to ensure there
is no pressure.
4. These filters have a bayonet mount—push bowl up, turn bowl 1/8 turn
to your left, and pull bowl straight down.
5. Clean the inside of the bowl.
6. Gently pull the filter element straight down, gently wiggle to break seal
connection. Discard the dirty element.
7. Wipe the wall inside of the filter head to remove all dirt.
8. Make certain O-ring inside top of replacement element is in place and
push element onto filter head. Make certain O-rings are generously
lubricated.
9. After making certain that O-ring inside of top bowl and wave spring are in place, reassemble bowl to head by
pushing up and turning 1/8 turn to your right until it stops. It should lock into place. Attempt to turn to the left without
pushing up and it should not turn.
NOTE:
Direction of airflow is critical to filter performance. Please follow air flow directional arrows and/or inlet and outlet decals.
Filters will not operate correctly if installed backwards. Do not reduce the size of the compressed air piping if it needs to
be replaced for any reason.
67
FILTER ELEMENT PUSH UP AND TURN 1/8 IN LEFT
PULL BOWL STRAIGHT DOWN REMOVE FILTER ELEMENT

(KEEP BASE FOR NEW FILTER)
68
ELECTRICAL
69
1. Three phase circuit breaker for motor 10. Recirculating Damper Relay
2. Circuit Breaker for Transformer Primary Side 11. Exhaust Damper Relay
3. Circuit Breaker for Transformer Secondary Side 12. PLC
4. Compressor / Dryer Start Relay 13. Main Motor Starter
5. Load Relay 14. Main Motor Overloads
6. Exerciser Relay 15. Fuse Block
7. Stop Purge Relay 16. Terminal Strip
8. Heater Relay 17. Power Supply for Instrumentation
9. Intake Damper Relay 18. Ground lug
70
71
TROUBLESHOOTING
The information contained in the Troubleshooting chart is based upon both the actual applied situations and extensive
testing at the factory. It contains symptoms and usual causes for the described problems. However DO NOT assume
that these are the only problems that may occur. All available data concerning the trouble should be systematically
analyzed before undertaking any repair or component replacement procedures. A detailed visual inspection is worth
performing for almost any problems which may prevent unnecessary damage to the compressor. Always remember to:
• Check for loose wiring.
• Check for damaged piping.
• Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor.
Should your problem persist after making the recommended check, consult your nearest Authorized Distributor.
SYMPTOM PROBABLE CAUSE REMEDY
E-Stop Tripped Release E-Stop
Main Disconnect Switch Open Close switch.
Line Fuse Blown Replace fuse.
Main Power circuit breaker

COMPRESSOR WILL Reset breaker- determine cause of trip
tripped.
NOT START
Control Power circuit breaker
Reset breaker-determine cause of trip
tripped
Reset. Should trouble persist, check whether motor starter

Motor Starter Overloads Tripped
contacts are functioning properly.
Check voltage. Should voltage check low, consult power

Low incoming Line Voltage
company.
Low Incoming Voltage Consult power company.
Check compressor pressure, if above 165 check operation of

Excessive Operating Pressure
unload solenoid valve or compressor intake valve.
Cooling air flow restricted; clean cooler and check for proper
ventilation.
COMPRESSOR
SHUTS DOWN WITH Ambient temperature too high; provide sufficient ventilation.
AIR DEMAND PRE-
SENT
Low oil level; add oil.
Discharge Temperature RTD
Open
Clogged filter; change the oil filter element.
Thermal valve not functioning; replace element.
Defective discharge temperature RTD; check for a short or

open circuit to probe and correct wiring or replace switch.
72
COMPRESSOR
SHUTS DOWN WITH Motor Overload Tripped Reset overload—determine cause of trip
AIR DEMAND PRE-
SENT
Continued... Check compressor rotation- sump pressure gauge on unit
Compressor rotation incorrect
should build pressure immediately at start up.
Air Demand Is Too Great Check service lines for leaks or open valves.
Dirty Air Filter Check filter and change element if required.
COMPRESSOR WILL
NOT BUILD UP FULL Condensate drain stuck open Check drain, clean, and test
DISCHARGE PRES-
SURE Air dryer switching valve not
See dryer trouble shooting bulletin
shifting, venting to atmosphere
A normally open solenoid must energize to load compressor;

Defective Solenoid Valve
check for proper operation.
Clogged Return Line Remove element cover and clean orifice.
Separator Element Damaged Or

Change separator element.
Not Functioning Properly
LOSS OF OIL IN
SUMP, or EXCES- Leak In The Lubrication System Check all pipes, connections and components.
SIVE FLUID CON-
SUMPTION Excess Fluid Foaming Drain and change.
Fluid Level Too High Drain excess.
Replace shaft seal.- Oil will appear in the tube running from
Shaft Seal Failure
the shaft seal weep hole
Compressor Operating Pressure See Symptom “Line Pressure Rises Above Cutout Pressure
PRESSURE RELIEF
Too High Setting on Pressure Switch” above.
VALVE OPENS RE-
PEATEDLY Defective Pressure Relief Valve Replace pressure relief valve
73
BULK WATER SEPARATOR AND PRE-FILTER
Check voltage on the type plate.

Drain LED does not Supply voltage incorrect
light up Check the connections and the supply voltage.
(Zero-Loss Air Drain)

Circuit board defective Check the circuit boards for possible damage
Feed pipe and/or discharge pipe Check feed and discharge pipe to ensure it is not obstructed,
blocked or obstructed click test with hose off—stand clear of discharge
Wear and tear Replace service unit, if problem continues replace drain
Test button pressed

Circuit board defective Check the circuit boards for possible damage
but no condensate
discharge
Check whether or not the valve opens audibly (press the test
(Zero-Loss Air Drain) Service unit defective
button several times for more than 2 seconds)
Minimum Pressure not reached Check Compressor Pressure
Maximum Pressure exceeded Check Compressor Pressure
No Condensate
Coming out of drain Service Unit Extremely dirty Replace the service unit
unless test button is
pressed
(Zero-Loss Air Drain) Inlet is blocked or vapor locked Install feed pipe with a slope or check for blockage
Dropping below the minimum

Check compressor pressure
pressure
Drain in Alarm
Take outlet hose off and press test button to ensure drain is
Blocked / obstructed outlet line
working properly. If so, clear outlet line
Extreme amount of dirt particles Replace service unit
Frozen pipe work Make sure heater or cabinet dampers are working correctly
Drain blows off
continuously Service unit defective or dirty Replace the service unit
Pre-Filter drain does
Float not working Remove housing, clean or replace float
not drain
Pre-Filter
Float stuck open Remove housing, clean or replace float
drains continuously
74
Troubleshooting Air Dryer
MLT Controlled Operation/Cycle & Problem Scenarios
Micro Logic Timer (MLT) controls regeneration cycles by energizing and de-energizing the air control valve at two (2)
minute intervals. An indicator light on MLT will be "on" for two minutes and "off" for two minutes.
Air control valve directs air flows through the dryer. During a cycle, one cartridge regenerates while the other cartridge
receives wet contaminated air.
A continuous flow rate of approximately 1.6 cfm (45.30 lpm) air from ONE exhaust port (muffler) per dryer occurs as nor-
mal regeneration air flow for desiccant bed drying. This air flow will switch in two (2) minute intervals from one exhaust
port to other in conjunction with MLT cycles. When dryer cycles (switching from one cartridge to other) a momentary
burst of air expels from one exhaust port. This short burst of air occurs each time dryer cycles.

Worn Inlet Check Valves (O- Clean cavities and replace valve assemblies included in ser-
rings) vice kit “B”
Worn Purge Valves or Dirt / For-
HEAVY FLOW FROM Clean cavities and replace regeneration valve assemblies
eign Material Stuck in Purge
EXHAUST PORTS within service kit “C”
Valve
Clean cavities and replace regeneration valve assemblies
Regeneration Valve Not Closing
within service kit “C”
Test: Unplug timer, manually cycle dryer by turning brass
screw in valve assembly to 2 o’clock (1/4 turn right) and back
Micro logic timer malfunctioning to 12 o’clock position.
Ensure MLT is connected to power source
DRYER WILL NOT Replace MLT timer part service kit “F”
CYCLE EVERY TWO Air Control Valve Malfunction,
MINUTES Replace air control valve “E”
I.E., Leaking
(should hear an audi- Air Tubing Connecting Air Con-
ble sound when cy- trol valve And Valve Housing
cles) Replace 1/4 inch air line tubing
And/Or Manifold Damaged Or
Missing
Air Control Air Vents Clogged
Clean air control vents
(Plugged)
Control solenoid not working Check operation of solenoid- replace if not shifting
75
Desiccant Cartridges Require
Service w 0.1 Micron Internal Replace desiccant cartridges—Service Kit “A”
INADEQUATE AIR
Filter
FLOW (VOLUME) AF-
TER DRYER Air Flow Restriction Contact your authorized service center
Service valve not open Open service valve to tank
Compressor condensate drain
See drain troubleshooting
not working
Desiccant Cartridge Contami-
Replace desiccant cartridges—Service Kit “A”
nated
Micro Logic Timer Malfunction-
Replace MLT “F”
ing
Air control Valve malfunctioning Replace air control valve assembly “E”
Regeneration Valve malfunc-
Replace regeneration valve “C”
tioning
WATER IN SYSTEM 1/4 Inch Tubing Connecting Air

Control Valve And Valve hous-
Repair or replace 1/4 inch air line tubing
ing And / Or Manifold Damaged
Or Missing
Worn, Stuck Or Clogged Purge
Replace purge valve assemblies “D”
Valve
Purge Valves Incorrectly Ser- Align exhaust ports in purge valve as detailed within service
viced kit instructions
Compressed Air Usage Ex-
ceeds Drying Capacity of Dryer Contact your authorized service center
System
System Pressure Exceeds 200
psi (13.7 bar) Relief Valve Set- Reduce system pressure
PRESSURE RELIEF VALVE
ting
OPENS
Pressure Relief Valve Malfunc-
Replace pressure relief valve service kit “G”
tion
76
ENCLOSURE FREEZING
CHECK FUSE
TEMPERATURE INSIDE POWER IS OFF TO UNIT
TURN POWER ON
ENCLOSURE IS BELOW
FREEZING WHEN OFF. CHECK BREAKER FOR 110V POWER, IF POWER, REPLACE HEATER
HEATER IS NOT WORKING
THERMODISC OPEN. REPLACE HEATER
CHECK FUSE
PLUG IS APART, CHECK PLUGS IN POWER LINES NEAR ACTUATORS
TEMPERATURE INSIDE DAMPERS NOT WORKING

ENCLOSURE IS BELOW NO POWER TO DAMPERS, CHECK 110V BREAKER
FREEZING WHEN ON. CHECK RELAY TO DAMPER
ACTUATOR FAILED—REPLACE ACTUATOR
DISCHARGE OR INLET DAMPERS
FREE BLOCKAGE
BLOCKED
77
Service Parts
1 Year Maintenance Kit
ITEM NO. PART NO. DESCRIPTION. SHIPPING WEIGHT.
A 457-2945 Oil (5 Liter Sullube) 11

B 457-2941 Air Filter (with Prefilter) 1
C 457-2947 Oil Filter Kit 1
D 457-2948 Separator Kit (Air/Fluid) 1
E 457-2931 Bulk Liquid Separator/Filter 1
F 457-2949 Air Dryer Kit (Oil removal) 1
G 457-2950 Air Dryer Kit ( Dry Particulate) 1
H 457-2951 Cartridge Kit (Dessicant) 26
I 457-2952 Silencer Kit 1
J 457-2953 Separator Kit (Oil/Water) 5
See Diagram on Page 86
78
Service Parts
1 Year Maintenance Kit
79
Service Parts
Available Replacement Parts
ITEM NO. PART NO. DESCRIPTION. SHIPPING WEIGHT.

A 457-2922 Electric Motor (Compressor) 400
B 457-2923 Air Dryer (Dessicant) 47
C 457-2924 Solenoid (Dryer) 1
D 457-2925 Solenoid Valve(Exerciser) 1
E 457-2926 Solenoid (Unload) 1

F 457-2927 Heater (600W) 5
G 457-2928 Panel (Touch) 1

H 457-2929 Transducer (Air Pressure) 1
I 457-2930 Transducer (Enclosure Temp) 1

J 457-2930 Transducer (Oil Temp) 1
K 457-2932 Software 2
L 457-2933 Actuator (Louver) 1
M 457-2935 Transformer 41
N 457-2936 Check Valve Kit (Min Pressure) 1
O 457-2937 Actuator Kit (Thermostat) 1
P 457-2938 Valve Kit (Inlet) 1
Q 457-2939 Valve Kit (Dryer) 1
R 457-2940 Valve Kit (Zero Air Less Drain) 2

S 457-2942 Separator (Oil/Water) 9
See Diagram on Page 88
80
Service Parts
Available Replacement Parts
81

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REHS9687

of this equipment will VOID its warranty! REFERENCE

PERSONAL PROTECTIVE EQUIPMENT (PPE)

FIRE AND EXPLOSION

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

Death or serious injury can result from inhaling compressed

C. Operate the compressor only in open or adequately ventilated areas.

F. DO NOT attempt to lift in high winds.

I. Keep lift operator in constant attendance whenever compressor is suspended.

IAC – AIR COMPRESSION

GETTING STARTED—CLEARANCE REQUIRED

GETTING STARTED—MECHANICAL INSTALLATION

ENSURE KEY IS IN THE OFF POSITION

Back System Control

Unload Timer (min) 0

GETTING STARTED—CHECK ROTATION

Note: When the compressor stops, the pressure in the compressor

If rotation is correct, turn key back to off and

If rotation is incorrect, turn key back to off and

DESCRIPTION OF PACKAGE COMPONENTS

2. Bulk Water Separator 10. Electrical Enclosure / Controls

3. Pre-Filter (oil removal) 11. Inlet Damper

4. Zero-Air-Loss Condensate Drain 12. Exhaust Damper

5. Oil-Water Separator 13. Recirculation Damper

6. Twin Tower Molecular Desiccant Air Dryer 14. Baseplate / Tank

7. After Filter (Dust Removal) 15. Hot Air Distribution Chamber

Hot air Cool

which would prevent proper cooling of the

Back System Control Back System Alarms

Start Stop Drain Fault

Unload Timer (min) 10

Factory Setup Climate

Exhaust Damper Open/Close 70 16860 Deg F

The bottom status message shows if the system is OK or if there is a problem.

This screen allows you to monitor the pressures, temperatures, damper

Tank Pressure (psig): This is the air pressure in the tank

Compressor Pressure (psig): This is the pressure at the discharge of the

Damper Operation Heater

Off temperature 50°F Compressor

FACTORY SETUP CONTROL

FACTORY SETUP EXERCISER

FACTORY SETUP CLIMATE

For description, see following page

FACTORY SETUP CONTROL

FACTORY SETUP EXERCISER

FACTORY SETUP CLIMATE

FUNCTIONAL DESCRIPTION OF OIL MANAGEMENT SYSTEM

FUNCTIONAL DESCRIPTION OF MOTOR / DRIVE SECTION

FUNCTIONAL DESCRIPTION OF COMPRESSOR COOLING SYSTEM

FUNCTIONAL DESCRIPTION OF AIR INLET SYSTEM

FUNCTIONAL DESCRIPTION OF CONTROL SYSTEM

FUNCTIONAL DESCRIPTION OF AUTOMATIC CONTROL

FUNCTIONAL DESCRIPTION OF COOLER BYPASS VALVE

FUNCTIONAL DESCRIPTION OF COMPRESSOR OIL TEMP

FUNCTIONAL DESCRIPTION OF PRESSURE RELIEF VALVE

FUNCTIONAL DESCRIPTION OF AIR PRESSURE TRANSDUCERS

FUNCTIONAL DESCRIPTION OF LOAD / UNLOAD SOLENOID VALVE

FUNCTIONAL DESCRIPTION OF SUMP PRESSURE GAUGE

1. After Cooler and Oil Cooler

VENTILATION AND COOLING

OIL LEVEL CHECK AND CHANGE PROCEDURE

MOTOR BEARING LUBRICATION

Motor Bearing Lubrication Schedule

AIR FILTER ELEMENT MAINTENANCE