L-SERIES

FRAME 3-4
SERVICE TRAINING
Frame 3 L22S-37 (30-50 Hp)
Frame 4 L37S-75 (50-100 Hp)
 Model Designations
• L37S
• L = CompAir Global Industrial Screw Series
• 37 = 37 kilowatt
• S = Increased Frame Size

Note: Kilowatts X 1.341 = Horsepower

Compressor Identification
Baldor Motor = Sidney Built
(4570X212)
Brook Compton = Simmern Built
(349015/0050)
 Frame 3 Specifications
• 110 mm Air End
• 30 - 50 Horsepower Range
• Available Pressures
• 99-109
• 122-132
• 150-160
• 180-190
 Frame 3 Specifications
• Star-Delta Starter Only
• UL Approved
• Air Cooled Only
 Frame 4 Specifications
• 145 mm Air End
• 50 - 100 Horsepower Range
• Available Pressures
• 99-109
• 122-132
• 150-160
• 180-190
 Frame 4 Specifications
• Star-Delta Starter Only
• Air or Water Cooled
Frame 3&4 Installation

A = 35 1/2”
B = 35 1/2”
 Frame 3&4 Installation
Cooling air
outlet

Cooling
air inlet
Frame 3&4 Installation

Control Transformer Tap

Adjust for Correct Line Voltage
 Frame 3&4 Installation

Discharge Connection
Frame 3 = 1-1/2” NPT
Frame 4 = 2” NPT
Direction of Rotation

Counterclockwise
Looking At Compressor
Input Shaft End
 Preventative Maintenance
• Kit C
• Minor Kit (2000 Hrs)
• Kit D
• Separator Kit (4000 Hrs)
• Kit E
• Major Kit (8000 Hrs)
• Kit V
• V-Belts (12000 Hrs)
• PWP Kit
• (3) Minor Kits + (1) Separator Kit
Preventative Maintenance
 Preventative Maintenance
• W1 = Oil Change
• W2 = Oil Filter
• W3 = Separator Element
• W4 = Air Filter Element
• W5 = Safety Valve Test
• W6 = V-Belt Inspection
 Preventative Maintenance
• W7 = Electrical Connections
• W8 = General Fasteners
• W9 = Cleaning
• W10 = Replace V-Belts
• W11 = Change Cooling Air Inlet Filter
 Preventative Maintenance
MODEL Minor Kit "C" Major Kit "E" Separator Kit "D" PWP Kit

L22S SG CK 2110-1P SG CK8110-1 SG CK 4110-252 A204-2137

L30 SG CK 2110-1P SG CK8110-1 SG CK 4110-252 A204-2137

L37 SG CK 2110-1P SG CK8110-1 SG CK 4110-252 A204-2137

SG CK 8145-1 (AIR)
L37S SG CK 2145-1 SG CK 8145-2 (WATER) SG CK 4145-252 A204-2138
SG CK 8145-1 (AIR)
L45 SG CK 2145-1 SG CK 8145-2 (WATER) SG CK 4145-252 A204-2138
SG CK 8145-1 (AIR)
L55 SG CK 2145-1 SG CK 8145-2 (WATER) SG CK 4145-252 A204-2138
SG CK 8145-1 (AIR)
L75 SG CK 2145-1 SG CK 8145-2 (WATER) SG CK 4145-252 A204-2138
 Oil Level

Frame 3
Frame 4
 Oil Change

Oil Drain Valve

Oil Filter Removal

CompAir Lubricants
Frame 3 & 4 P&I Diagram

Pneumatic & Instrumentation

Diagram
L22S-75 Normally Closed Inlet
 Frame 3 & 4 Control
1. Air Filter
2. Inlet Valve
19. Load/Unload Solenoid Valve
(3 way)
20. Blowdown Solenoid Valve
(NO 2 way)

Receiver
Pressure

Air End
Inlet
LOAD / UNLOAD CONTROL
Frame 3 & 4 Control Unloaded

Receiver
Pressure
Frame 3 & 4 Controls Loaded

Energize
to Load

Receiver
Pressure
Upper Range Modulation
109 --

105 --
Receiver
Pressure

100 --
 Modulation Valve
• Normally Closed Intakes Only
• Negative Pilot
Delcos 3000/3100 Control
4-20 ma

24VDC
 Compressor Check Load/Unload
Will Not Load Values in Delcos

No No
Is the Delcos Display Does the 4-20ma
Replace Transducer
Reading Correct psi? Signal Match Chart?

Yes
Yes
Is the Solenoid No
Replace Delcos
Being Energized?

Yes
Is Solenoid Supplying No
Replace Solenoid
Air Signal to Inlet?
Yes
Rebuild Inlet
End Test
 FRAME 3 & 4 L-SERIES AIR/OIL FLOW

TEMPERATURE
SENSOR
AIR FILTER
PRESSURE
INLET VALVE
SENSOR
TEMPERATURE PRESSURE
SENSOR SENSOR
DISCHARGE AIR
AIR COOLER
COOLIING

OIL COOLER
DRIVE
AIR

MOTOR
OIL FILTER

DISCHARGE AIR COMPRESSED AIR AIR

COOLING AIR COMPRESSED AIR/OIL OIL

 Inlet Air Filter

Frame 4

Frame 3
Use Minor Kit CK2110-1 PWP A204-2173
Frame 3 & 4 Inlet
Frame 3 & 4 Inlet
A11387574 Valve
(Optional Frame 3)
Serviced in
Components Only
 Frame 3 Inlet

A11383574 Valve
2 Position Valve (No Modulation)
A11388474 Kit
EK 110 Air End
 Compression Element
• Air Ends
• EK-110 Frame 3
• EK-145 Frame 4
 Compression Element
• Simple Design
• 6 Bearings
• Shaft Seal
• Lip Seal
• Replaceable Seal Surface
• No Gears
• 5 Lobes Male
• 6 Grooves Female
Compression Element
Continuous Monitoring
 Compression Element
• Repair to Air End
• Limited to Shaft Seal Replacement
• Exchange Program
 Components
O-ring
• Shaft Seal Leakage seal Main

• Replaceable Seal Surface Dust seal

seal

• Breather
• Drain Line
• 3 Lip Seal
Pulling off device
Assembly bevel

recirculation
 Reclaimer Vessel
• ASME Certified
• Tangential Inlet
• Cyclone Effect
• 95% Separation
• Oil Volume
• Frame 3 (6.6 US Gal)
• Frame 4 (10.6 US Gal)
Separator Service
• Frame 3
• One Separator
• Frame 4
• Two Separators

3 Micron Spin On
Element
Separator Housing
 Components
• Separator Scavenge System
• Orificed Line
• Check Valve
 Minimum Pressure Valve
• “Low Pressure Valve”
• Adjustable Pressure
• 70 psi
 Thermal Valve

• Mixing Valve
• Standard 158°F
• Optional 131°F
 Oil Cooler
• Low Oil Temperature
• Large Face Area
• Easy Cleaning
 Aftercooler
• Approach Temp 9-18°F
• Large Face Area
• Easy Cleaning

FRAME 4
SHOWN
Cooling Air Flow

Cooling
air inlet
 Cooling Air Flow
• Pressurized Cabinet
• Compressor Intake Pressurized
• Doors Must Remain Shut & Latched
• Independent Cooling Fan Motor
• Thermostatically Controlled (176ºF)
Drive Unit
Power Transmission by High Capacity
V-BELTS

Fully Maintenance Free

High Operational Reliability
Efficiency Over 98%

V-BELT
12,000
Operational Hours
Fully Automatic Dynamic Belt
Tensioning

Tension
spring

V-belt

Machine frame Bearing Motor plate

Machine frame
Fully Automatic Dynamic Tensioning System

Correct Tension During All Phases of Operation:

Maximum Tension During Load Run
Release During Idle Run and Standby
Advantage: Higher Service Life for V-belts and
Bearings
Self-Adjusting
Minimized Slippage
Constant Efficiency Throughout Service Life
Advantage: - Fully Maintainance Free, High Reliability,
Security of Operation
 Frame 3 Belt Tensioning
Frame 3 Belt Tensioning
Model/PSI Baldor ODP Baldor TEFC Brook IP55
L22S/109 1-7/8" 1" 2-3/8"
L22S/132 2" 1-1/4" 3-15/16"
L22S/160 1-1/8" 1-5/8" 3-1/8"
L22S/190 1-15/16" 1-1/8" 3-9/16"
L30/109 2-1/16" 7/16" 1-9/16"
L30/132 2-3/16" 11/16" 1-3/4"
L30/160 2-3/8" 1-5/16" 1-9/16"
L30/190 2-15/16" 1-15/16" 1-15/16"
L37/109 3-1/16" 2-7/16" 2-3/16"
L37/132 3-1/4" 1-13/16" 1-15/16"
L37/160 3-9/16" 2-1/4" 3-3/8"
L37/190 2-13/16" 1-1/4" 2-3/16"
 Frame 4 Belt Tensioning
Frame 4 Belt Tensioning
Model/PSI Baldor ODP Baldor TEFC Brook IP55
L37S/109 2-13/16" 2-7/16" 3-1/8"
L37S/132 3" 2-5/8" 3-3/8"
L37S/160 3-1/8" 2-7/8" 3-3/4"
L37S/190 3-1/8" 2-3/4" 3-9/16"
L45/109 3-5/16" 2-13/16" 3-1/8"
L45/132 3-7/16" 3-15/16" 2-3/4"
L45/160 3-3/16" 2-1/2" 2-15/16"
L45/190 3-5/16" 2-3/4" 3-9/16"
L55/109 3-1/2" 2-13/16" 2-3/4"
L55/132 3-5/8" 3" 2-15/16"
L55/160 3-3/4" 3-1/4" 2-15/16"
L55/190 3-5/8" 3" 2-15/16"
L75/109 3-15/16" 2-13/16" 2-3/4"
L75/132 4-1/16" 3-1/16" 2-9/16"
L75/160 4-3/16" 3-5/16" 2-3/4"
L75/190 4-3/16" 3-3/8" 2-9/16"
 Sound Control
• Silenced Housing
• Sound Level DIN 45635
• 67-74 dB(A)
• Washable Foam Face
• Removable
 Vibration Isolation
• Air End to Machine Frame
• Machine Frame to Base
• Base to Ground
 Filter Specifications
• Oil Filter - 10 Micron
• Air Filter - 15-20 Micron
• Separator Element - 3 Micron
 Standard Warranty Policy
• Package
• 1 Year From Start-Up or 18 Months From
Date of Shipment
 Performance Warranty Plan
• 5 Year PWP
• SSL-46+
• 10 Year PWP
• CompLube 10 PWP Kit To Include (3) Minor
Kits & (1) Separator Kit

Oil Sampling & Purchase of Yearly

Maintenance Kit Required
 Electronic Controllers
• Frame 3 - 6
• DELCOS 3000
• DELCOS 3100

DELCOS 3100
DELCOS 3000
 Language Selection
• Menu Routine Not Activated

Push Enter and Reset at the Same Time

 Language Choices
• German
• French
• Italian
• Spanish
• English UK (°C / bar)
• English USA (°F / psi)
DELCOS 3000 / 3100 Features
• Thermostatically Controlled Fan
• <176
F Fan Cycles
• Onload Fan On
• Offload Fan Off
• >176°F Fan Runs Continuously
• Control of Accessories
• 3 Relay Outputs
• Dyers, Filters, Etc.
DELCOS 3000 / 3100 Features
• Low Temperature Start Protection
• Selectable Service Timer Shutdown
• Optional On-Board Sequencing with
Base Load Selector
 Sensor Based Control
• Capable of 3 psi Pressure Band
• Precise Regulation

Dropping Operating Pressure 2psi

Saves 1% Total Energy Cost
DELCOS 3000 / 3100

START, Push to Start

 DELCOS 3000 / 3100

EMERGENCY
STOP

STOP, Push to “Soft Stop”

DELCOS 3000 / 3100

RESET, Push to Reset a Fault

DELCOS 3000 / 3100
a. Motor Running
(Flashing = Standby)
b. Menu Activated
c. Auto Restart Enabled
d. Remote Operation
e. Timer Control
f. Service Due
g. Warning
h. Collective Fault
DELCOS 3000 / 3100

1= Final Temperature
2= Compressor Pressure (Sump)
3= Line Pressure
 DELCOS 3000 / 3100

Status Display (e.g.) READY TO START

ONLOAD
SOFT STOP TIME XX
RUN ON TIME XXX
 DELCOS 3000 / 3100

Menu
Access Key

Code Enter
 DELCOS 3000 / 3100

Menu
Navigation
Keys
 DELCOS 3000 / 3100
• Menu Routines
• 5 Main Menus
• 2 Optional Menus
 DELCOS 3000 /3100
• Main Menus
• Maintenance Schedule Menu
• Control Menu
• Fault Memory Menu
• Limit Values Menu
• Optional Inputs Menu
 DELCOS 3000 / 3100
• Optional Menus
• Timer Control Menu
• Base Load Selector Menu
Maintenance Schedule Menu
• Total Running (Hours)
• Loaded Hours (Hours)
• Air Filter In (Hours)
• Oil Filter In (Hours)
• Separator In (Hours)
• Oil Change In (Hours)
• Drive Belts / Motor Greasing In (Hours)
• Shutdown (Deactivated / Activated)
(----) Blocks Timer
 Control Menu
• Cut-Out Point (psi)
• Cut-In Point (psi)
• Automatic Operation
• Remote Control
• Timer Control (Optional)
• Auto Restart
 Control Menu (cont’d)
• Power Loss Time
• Start-Up Delay
• Protocol (3100)
• Baud Rate (3100)
• Number of Slave

Use Code “8888” for Unlimited Power Fail

Time (3100 Only)
 Fault Memory Menu
• Stores Last Eight (8) Faults
• Number of Occurrences
• Shutdown or Warning
• Fault Message
• Hours @ Fault

12! COMP TEMP 9877 h

 Limit Values Menu
• Design Pressure
• Start Protect
• Final Temp Warning
• Final Temp Max
• Min Start Temp
 Limit Values Menu (cont’d)
• Run On Time (360 Seconds)
• Soft Stop (30 Seconds)
• Star/Delta Time (8 Seconds)
• Software (S1D3V1.00)
 Optional Inputs Menu (3)
• Oil Pressure
• Oil Level
• Ext. Fault
• Oil Temp
• Discharge Temp
• Rot / Belts
Select “FREE” if Options are
• Operate B1 Not Installed
• Free
 Timer Control Menu
• 7 Blocks Available
• Block Number
• Day of Week
• Time Off
• Time On

1 SMTWTFS 07:30 18:00

 Timer Control Menu
• Off-Peak Pressure Reduction
• REDUCE
• REDUCE BY
REDUCE 22:00 06:00
REDUCE BY 20PSI
(e.g.) The System Pressure
will Drop 20psi @ 10:00 pm
Normal System Pressure
will Resume @ 6:00 am
 Base Load Selector (Option)
= electrical cables
= compressed air lines

Receiver

Pressure Sensor
 Base Load Selector (Option)
• Sequences Up to 4 Compressors
• No External Device
• Includes Real Time Clock
• Simple Pressure Cascade
 Base Load Selector
• Auto Change Over
• Timer Control
• Base Load Comp
• Status 123h K2 K3 k4 k5 k1
• Changeover Time
• Start Delay
• Number of Slaves
Base Load Selector
 Base Load Selector
• Line 1 Max 110
• Line 1 Min 100
• Line 2 Max 105
• Line 2 Min 95
• Line 3 Max 100
• Line 3 Min 90
• Line 4 Max 95
• Line 4 Min 85
 Access Codes
• Maintenance 3031
• Factory Code 0111 (Limits Values)
• Setup Code 2222 (DELCOS Replacement)
• Rotation Off 9998
• Rotation On 9997
• Power Fail Time 8888 (3100 Only)
 Delcos 3000 / 3100
Replacement
• Enter Code “2222”
• Prompt Code 1 “XXXX”
• Prompt Code 2 “XXXX”
• Prompt Code 3 “XXXX”

Inside Starter Cabinet

 Analog Input Configuration
• Pressure Transducer (2)
• 4-20 ma Signal
• Temperature Probe (1)
• KTY 10 Signal
 Analog Inputs
• Fault Terminology
• R2 Fault = Discharge Temperature
• B1 Fault = Network Pressure
• B2 Fault = Discharge Pressure

TERMINOLOGY ALSO USED IN OPTIONAL

RELAY OUTPUT MENU
Testing Pressure Transducers
Controller
X2/7,9 +20VDC
X2/6 Sump (4-20ma)
X2/8 Line (4-20ma)

Test Supply Voltage First

 4-20ma 16bar Pressure Transducer Output Table
Pressure (bar) Pressure (psi) Output (ma) Pressure (bar) Pressure (psi) Output (ma)
0 0 4 8.5 123.25 12.5
0.5 7.25 4.5 9 130.5 13
1 14.5 5 9.5 137.75 13.5
1.5 21.75 5.5 10 145 14
2 29 6 10.5 152.25 14.5
2.5 36.25 6.5 11 159.5 15
3 43.5 7 11.5 166.75 15.5
3.5 50.75 7.5 12 174 16
4 58 8 12.5 181.25 16.5
4.5 65.25 8.5 13 188.5 17
5 72.5 9 13.5 195.75 17.5
5.5 79.75 9.5 13.8 200.1 17.8
6 87 10 14 203 18
6.5 94.25 10.5 14.5 210.25 18.5
7 101.5 11 15 217.5 19
7.5 108.75 11.5 15.5 224.75 19.5
8 116 12 16 232 20
 Testing Temperature Probes
Remove Connector, Check Resistance Between
Sensor Terminals
KTY-10 Temperature Sensor Resistance Table
Temp (C) Temp (F) Resistance Temp (C) Temp (F) Resistance
0 32 1605 50 122 2448
5 41 1678 60 140 2638
10 50 1762 70 158 2844
15 59 1848 80 176 3058
20 68 1927 90 194 3282
25 77 2008 100 212 3520
30 86 2092 110 230 3772
40 104 2263 120 248 4043
 Fault Shutdowns
• Discharge Temperature
• Discharge Pressure
• Network Pressure
• Motor Rotation
• Motor Overload
• Service Timer (Selectable)
 OPTIONAL Warnings
• Separator Differential
• Oil Filter Differential
• Air Filter Differential
 TROUBLESHOOTING
• “FAULT POWER LOSS”
• “FAULT EM-STOP”
• “FAULT MOTOR TEMP” Motor
Overload
• “FAULT COMP TEMP”
• “WARNING HIGH TEMP”
• “FAULT START TEMP”
 TROUBLESHOOTING
• “WARNING HIGH PRESS”
• “FAULT OVER PRESS”
• “FAULT SENSOR B1”
• “FAULT SENSOR B2”
• “FAULT SENSOR R2”
• “FAULT DIRECT ROT”
• “FAULT MAINT PER”
• “FAULT SOLENOID”
 TROUBLESHOOTING
• “FAULT COOLING”
• “FAULT DRIVE BELT” Optional
• “FAULT OIL PRESS” Optional
• “FAULT EXT FAULT” Optional
• “FAULT ELECTRONIC”
 TROUBLESHOOTING
• “WARNING SEPARATOR” Optional
• “WARNING AIR FILTER” Optional
• “WARNING OIL FILTER” Optional
• “WARNING OIL TEMP” Optional
• “WARNING DISH TEMP” Optional
• “WARNING OIL LEVEL” Optional
• “WARNING LINE PRESSURE”
• “WARNING BATTERY”
 Delcos 3000 / 3100 Electrics
3100 Main Motor is Thermister Protected Star-Delta Contactors

Fan Motor Thermal Overload Control Transformer

Terminal Blocks
Delcos 3000 / 3100 Electrics
 Star Delta Starting
3K3 3K1 3K2

X10 2 X10 3

3K1

120 VAC Signal

 Star Delta Running
3K3 3K1 3K2

X10 1 X10 3

3K2

120 VAC Signal

Delcos 3000 / 3100 Electrics

TAP CONTROL TRANSFORMER

FOR CORRECT VOLTAGE
Delcos 3000 / 3100 Electrics
 Delcos 3000 / 3100 Remote
• Remote ON / OFF
• Select Remote Control “ON” in Control Menu
• Terminal Strip Connection, Close X3 25/26
38 39 40 41 42 43 44 45 46

X3 26 Closed = Run
X3 25
Open = Off
Delcos 3000 / 3100 Remote
Remote Load/Unload

Adjust Cut In & Cut Out in

Control Menu
 Delcos 3000 / 3100 Remote
• Collective Fault Output
• X3 35-36
• 250V 1A Max
46 47 48 49 50 51 52 53 54

X3/36
To Ext Relay

Closes on Fault
X3/35
To Ext Relay
 RS485 Communication
• Delcos 3100
• Modbus
• Profibus with Profibus Master (Optional)
• Delcos 3000
• CompAir Specific
Sequencing 3000 / 3100