Compressor Model 1030 / 1031 - Maintenance Manual
Contents
1. MoT BLACK WHITE SOLENOID VALVE Green ZEN Mac nun ag WHITE CIRCUIT BOARD ate fi 1 NO 1 3LACK DR SLACK SEE SOLENOID WI MD VALVE SH Allen Air JUMPER WIRE ge HIT Me gt V2 HE We SOLENOID LAC Ceo LE VALVE ae Mac EDU CIRCUIT BOARD 1 ND SOLENOID LACK a VALVE ae LAC Allen Air LACK J 7 ae f Communications Cable Note On Rev J boards and earlier Allen Air solenoid connects across V1 amp L1 Terminal doubler 105473 is needed on one of the two boards Electrical Diagram New style COMPUTER CONTROL SYSTEM TANK TERLENA AS A TEFLON TUBING AN TUBING er u MOTOR MOTOR y 2 ORIFICE N DRYER PURGE A IS PURGE DRYER C COOLING ANK TANK N TANK ANK COOLING COLL R S f COLL pe SOLE SOLENDID VALVE EMERGENCY EMERGENCY VALVE SHUT OFF VALVE SHUT OFF VALVE _ DRAIN SPONGE DRAIN SPONGE DISSIPATION 10 5501 Rev F W CHECK VALVES 15 DISSIPATION PARTS LIST 2 _11 5000 60 TANK BEN a ee2. po 12 CD eSsd re 7 M2 vg 8 CO DO Part 105800 80 Button Switches Figure 3 Typical In Lt e Servicing of the CCS circuit board will become necessary in the unlikely event the board fails to operate within the specifications set by Keiser Corporation The CCS circuit board 10 5501 Rev F 5 is located within the box between the two compressor motors Replacing the CCS circuit board is the only servicing that can be done in the field All terminal connections are clearly marked on the circuit board We recommend that you label each wire using a pen and masking tape as you remove them This will help you when the time comes to reinstall all wiring In the event that the labeling comes off or is not available follow the circuit board diagram Table 1 Once all wire connections have been removed remove the air hoses by using long nose pliers and gently pry the hose off the barb Care must be taken as the barb can be damaged easily We recommend you label the air hoses Remove the three screws and one nut that mount the circuit board to the box Replace with new circuit board Reinstall all fasteners Prior to reinstalling the air lines trim inch off the hose to remove any over stretch of the
3. gt 10581500 Daan cock sau ONA VS 55 5 95310200 TEFLONCLEAR TUBING 57 2 11 5366 00 BARB 1 8 X 1 8 X 90 ELBOW 10 8076 00 MALE CONNECTOR 1 4 X 1 1 a III 2 10000 CNC N fT 9285 00 PASTS PHIL 10 24 UNC X 3 4 ZP a e oop 9255 00 PHILLIPS HMS 6 32 X 174 qe BEE BOARD ASSY uI GROMMET 1 2 X 3 8 0 8009 00 FEW RESTOR O Oooo SS 76 1 _10 5501 00 SERVICEMANUAL ee 10 0807 00 DRAIN TUBE ASSY 78 9050 00 SCREW F H 6 32 x 5 8 8 _9366 00 6 INTERNAL TOOTHLOCK WASHER it _ _ Nile ali ALNININ i 2 10 5501 Rev F 16 KEISER SERVICE DEPARTMENT 1 800 888 7009 Keiser Corporation Telephone 559 256 8000 FAX 559 256 8100 Internet www keiser com 10 5501 Rev F 17
4. 2 _ __25 5318 33 PURGE TANK I4SCUBICINCHES BIK 2 _10 0925 33 DRYERSUPPORT BLK 5 2 6 i 1809 53 BRACKET PRBCOOLER 8 D BER 9176 00 HEX HEAD CAP SCREW 5 16 18 UNC X I ZP aa PHSTS TF PHLPS 6 X 3 4 BLK gt 4 __9231 00 HEX JAMNUT 2 10 0863 00 ELBOW O O O O O OCOS ia f 2 1051600 15 4 __9260 00 PANHEADMACHINESCREW PHILLIPS AADUNCKI 4 9364 00 INTTTHLOCK WASHER 3A Ze O OOO ORN 9226 00 HEX ELASTIC LOCK NUT 5 16 18 UNC ZP 22 eo END VALE ASSY EIS MAG AMAR A mmeone e ooo Bere ELBOW 1 4 NPT X 10 32 0 5373 20 CAP 1 4 10 32 BARBS 27 2 _10 5312 00 CHECK VALVE 227WIVITON 7 31 gt sn ee ALA PN 2 N N N N N i i N 33 0 5423 00 GLIDE 34 4 9279 00 HEX WASHER HEAD TFTDC 5 16 18 UNC X 3 4 ZP 1 STREET E MALE CONNECTOR 1 2 X 1 4 0 5467 00 BALL VALVE 200 PSI 1 4 2 10 5387 N ae _1_ __10 5007 00 BOX CIRCUITBOARD _11 537200 LARGEKEISERDECAL ee on ison weation orator 9225 00 NUT HEX JAM 1 4 20 UNC 2 _8157 00 ADJUSTABLEELBOW 032 7 52 1 10 541021 POWERCORDASsY 0
5. figure 4 a rar N End Check Valve SEN Hex nipple Male Portion Barb with Orifice X Female Portion SS ge Air Hose a Figure 4 Caution Follow all safety procedures prescribed earlier e When the compressor shuts off the solenoid valve bleeds off the pressure in the drier module This should take less than 1 minute If air continues to bleed from the drier sponge for more than 1 minute the most likely problem is the check valve This may be confirmed by an error code E r 1 on the Computer control system CCS circuit board Refer to the CCS section on page 7 8 If the check valve is leaking it will allow air from the main storage tank to leak into the air drier module and out to the atmosphere The computer will shut this side of the compressor down but the leak will continue The other side of the compressor will continue to run trying to replenish the air that is leaking If this occurs the manual valve on the solenoid which is located on the side of the compressor that is leaking can be closed to enable the compressor to build pressure The leaking check valve should then be replaced Once the check valve is replaced the manual valve must be reopened e The check valve is mounted on the main tank under the drier assemblies on the backside near the center figure 4 10 5501 Rev F 9 e To remove the check valve label the hose and Bottom Hose and
6. hose Reinstall all wire connections using either Table 1 or the labels that were placed on each wire connection Circuit Board Terminals Wire Source Wire Color M1 Motor Black V1 Solenoid Valve Black L1 Power Black L2 Power White V2 Solenoid Valve Black M2 Motor White Solenoid Valve Black Table 1 Note Solenoid valves manufactured by MAC connect across V1 amp V2 Solenoid valves manufactured by Allen Air connect across V1 amp V3 on Rev K boards or later across V1 amp L1 on Rev J boards or earlier PUSH BUTTON SWITCHES The functions of the Push Button Switches are Time If this switch is pressed and held the number of hours that this controller has applied power to the motor is displayed There is no way to reset this number in the field Starts If this switch is pressed and held the number of times this controller has applied power to the motor is displayed There is no way to reset this number in the field Both If both switches are pressed and held the pressure in the purge tank is displayed When the switches are released the display reverts to displaying system pressure 10 5501 Rev F 6 LEDS The compressor has an LED that displays the pressure and also any errors it might encounter while it is running If you suspect a problem look at the display to see if an error code is displayed Normally the display will be reading pressure by sequentially displ
7. compressors start again This is the bleed down time It should be about 45 seconds If this time is much longer than it should be suspect a plugged solenoid valve or hoses running to and from it Make a note to observe that the difference in time from the first compressor stopping until the second compressor stops is about the same as the time from the first compressor to start until the final compressor starts If the run time is too long try running the test with the intake mufflers removed If the time is still too long run the test on each compressor separately to determine which compressor is the cause of the problem To run the same test on one compressor at a time lower the pressure slowly then when the motor starts stop the leak Repeat for the other motor If the same motor starts each time you can disconnect the wires to the motor on the side you do not want to test 10 5501 Rev F 13 11 Approximate times at various altitudes Sea Level 4000 Feet 7000 Feet Fill Time 4 minutes 4 MN 45 SEC 5 MN 20 SEC Bleed Time 45 seconds 50 seconds 47 seconds Run Time BOTH 1 MN 20 SEC 1 MN 30 SEC Run Time ONE 1 MN 55 SEC 2 MN 10 SEC Table 2 The effects of some common failures are as follows Check Valve Leaking On the air compressor when a check valve leaks on one side the system will build to full pressure from a cold start unit plugged in with no pressure in the tank When the compressor motors st
8. remove the air hoses that are connected to the end cap Be careful not to damage the barbs when removing hoses When unscrewing the end cap a wrench must be placed on the male portion of the check valve to keep it from rotating figure 4 e To unscrew the check valve place a wrench on the female portion of the valve and rotate it figure 4 You may need to hold the hex nipple on one side to prevent it from loosening e To install the new check valve clean threads on the male part of the tee Apply a small amount of Locktite 242 on the threads Install the check valve place the wrench on the female portion of the valve and rotate figure 4 e Apply a small amount of Locktite 342 to the threads on the check valve Place a wrench on the male portion of the valve hold the valve and screw on the end cap Note The end cap has two barbs that are attached to it One of the barbs contains a small plastic orifice Make sure the barb with the small orifice ends up on top while the other barb is directly underneath it e Trim 4 inch off the air hoses to eliminate the over stretch and reinstall the air hoses to the end cap being careful to attach them to the correct barb 10 5501 Rev F 10 Solenoid Valve The solenoid valves allow purge air to pass through the air drier canisters These valves are mounted on the bracket that holds the drier assembly The solenoid valves are also equipped with a shut off valve installed on the solenoid
9. Compressor Model 1030 1031 Maintenance Manual Rev F Taking Performance to a Higher Level Table of Contents Ke luresssu 2 SEL VICING 3 The Air Dryer System sun ae 4 Intake Filter va na a a ee 5 Troubleshooting esossesssecesosscsosesossessooseesossesosessesooseeoo 5 Computer Control System CCS ssesssssosssscccoossssecseeseoocose 5 6 Push Button Switch een 6 7 8 Check Valve ui 9 10 Solenoid Valve 11 Compressor Motor a ea 12 Extended Troubleshooting cccscccccscccccccccsccccccccscesscecs 13 14 Plumbing and Electrical Diagram cccccccccccsscccccsceeeees 15 Exploded Assembly View 15 Parts List aa seen 16 10 5501 Rev F 1 COMPRESSOR MODEL 1030 1031 Features Model 1030 115 VAC at 60 Hz 1 hp 1200 watts 12 amps Rated flow is 3 0 CFM at 100 psig Model 1031 230 VAC at 50 Hz 2 3 hp 1000 watts 6 amps Rated flow of 2 4 CFM at 100 psig The following features are included with both models Quiet operation noise level of approximately 53 dB at 3 feet Delivery of clean dry and oil free air at room temperature Unit dimensions of 20 wide x 48 long x 25 high 10 ga
10. aying the pressure as one number after another If there is an error the display will read and then a number It will continue to repeat this error code until the error corrects itself or the unit is unplugged and plugged back in to attempt to fix the error Any time an error occurs a small alarm will sound to alert someone of the condition The alarm does not sound on errors that can retry and recover The following is a list of error codes and their meaning E r 1 The computer thinks that the check valve is leaking The computer detects this condition by watching the pressure drop in the purge tank Once the purge tank pressure has fallen to about 5 psig the computer tests the pressure in the main tank If it has also fallen to a low value this error condition is set A very likely cause of this condition is a leaking check valve Er 2 Er 8 The unit is running for an extended period of time without reaching the shut off pressure These errors are given when the unit runs for over an hour and pressure is not reaching the shut off setting approximately 120 psi The unit will still shut off every 5 minutes to allow itself to purge the dryer assembly even if it does not reach the shut off pressure and it will display Er 8 If after 20 cycles the unit fails to reach the shut off pressure the compressor will shut down and not restart displaying Er 2 This condition means there must be a leak within the system or the compressor is
11. for a short time while the compressor is building up pressure This problem can easily be confused with the error messages that occur when the solenoid valve leaks In the case of the plugged muffler there will not be any air leaking from the sponge chamber Solenoid Valve Plugged If the solenoid valve becomes blocked so as to reduce the air flow through it the display will show Er3 or Er4 or Er5 with 5 the most likely If the blockage is not too serious this problem will reset itself however does warrant attention The emergency shutoff petcock valve on the solenoid valve being closed could also cause this problem Communications Jumper Unplugged If the jumper cable that connects the two boards black cable with small white plugs on both ends is damaged or unplugged the unit will not operate correctly The most obvious symptom of this will be that the numbers on the display will read upside down If the cable is plugged in properly and the unit is displaying E r A either the cable is bad or the computer has a defect This cable tells the CCS what model of machine this is and it will not operate correctly without it For any service problems or questions call 1 800 888 7009 Service 10 5501 Rev F 14 Plumbing Diagram
12. g the unit in and listen for the compressor to attempt to start and see if the motor tries to start or the solenoid valve closes If the motor does not start and the solenoid valve clicks then the motor is faulty and must be replaced If the solenoid valve does not click and the motor does not start then the computer board must be replaced It is best to use a voltmeter to insure that the computer is sending voltage to the motor Contact Keiser Service for assistance If the motor runs then check plumbing to insure that all hoses are connected 10 5501 Rev F 7 E r 7 Compressor stopped because pressure did not rise quickly enough in storage tanks A large leak probably exists in one of the exercise machines or in the compressor plumbing or the air distribution system E r 9 The computer thinks that the intake muffler is plugged It detects this condition by testing the rate of pressure increase in the drier when the compressor first starts The computer is not able to communicate with the other computer The communications cable is damaged or the computer itself has a defect Check the condition of the cable Either computer could cause itself or the other to display this error 10 5501 Rev F 8 Check Valve e Acheck valve is installed between the purge tank and the main air pressure in the storage tank This check valve allows the purging of the drying module and the purge tank while maintaining system pressure in the main tank
13. g to disassemble any of the major components Using a standard screwdriver unscrew the small screw that attaches the hose on to the top of the canister Figure 2 Twist the air dryer canister counter clockwise until it is completely loose Pull the canister straight up Be careful not to damage the copper tube that travels up inside the canister Replace with a new canister carefully sliding the copper tube up inside the bottom opening of the canister Twist the canister clockwise hand tight and attach screw with hose to the top of the new canister 10 5501 Rev F 4 e Air Intake Filter e The air intake filter is located on the compressor motor and filters all air entering the system The Keiser compressor unit was designed to operate in an environmentally controlled room The servicing of this filter is dependent upon the location of the compressor If the compressor is located in a dirty or harsh environment the filter must be checked or serviced every 6 months We recommend replacing the filter once per year e To remove the inlet filter twist the entire filter housing off and remove it from the unit e Replace the filter housing with a new one Screw it into the compressor motor hand tight Troubleshooting Keiser Corporation has always taken pride in designing and engineering the highest quality equipment on the market Only the highest quality products have the Keiser name displayed and this compressor is no exception In t
14. he unlikely event that any malfunctions may occur the following section will facilitate troubleshooting and replacing any part s that may fail Remember that this compressor has two computers two air drier systems and two motors If the right computer system indicates an error then that error will be associated with the components on the right side likewise a left error would indicate a problem with the components on the left side Computer Control System CCS Circuit Board e computer controls system CCS controls and regulates the compressor s motor It monitors the pressure system and aids in troubleshooting when it senses a problem If the CCS senses an irregular condition it will display a system error code on the LED located on the circuit board If the CCS senses a serious condition the CCS will shut that section of the system down and flash an error code on the LED figure 3 All codes are explained in the troubleshooting section of this manual e The CCS keeps track of how long each motor has run since the last time the unit was plugged in This information is used to help insure that each motor gets equal usage under light load conditions Terminal Connections kea i SILK SCREEN Compressor A Sa gt U4 RI C5 C6 U5 a 9969 69 68 L 0 Rev WY je co
15. ith the electronic controller and it must be replaced Record the time it takes for the motors to stop The total time should be about 4 minutes at sea level This is the empty pump up time See table 2 for times at other elevations The pressure should display 117 124 PSIG at this time The pressure readings should be within 4 PSI from one side to the other Verify that the unit is holding steady pressure not leaking Pressure could drop 1 to 2 PSI in the first minute due to thermal effects but should not drop after that Leave it sit for at least 2 minutes After setting for over a minute the air bleeding from the drain sponge should stop If there is still air coming out of either sponge chamber after 2 minutes A check valve is leaking or a solenoid valve is partially plugged Unplug the unit for a few seconds then plug it back in Next lower the pressure at a rate of approximately 1 PSI per cycle of the display until the compressors both start Start timing when the compressors start Let the compressors run until they just stop Record the time to the stop and start timing again The time you just recorded is the run time and the time you are just starting is the bleed time If you do not have a split time or dual stop watch you may have to repeat the procedure and time run time and bleed time separately on two passes Very quickly drop the pressure in the system to about 90 PSIG by using the tank drain valve Stop timing when the
16. itself In the event one of the check valves fail the manual shut off valve can be used to stop the leak created by the leaking check valve The other half of the compressor will continue working until the bad check valve can be replaced To remove the solenoid valve remove the wires going from the valve to the computer Review and make note which terminals the wires go to Remove the wires from the circuit board by holding the electrical terminals and pulling straight up Shut Allen Air valve shown N es Figure 5 Using a pair of needle nose pliers place the jaws on either side of the air hose and gently pry the hose off the barb that is mounted to the valve Take care not to damage the barbs figure 5 Install the new valve and tighten the mounting screws Check the ends of the air hoses for any cracks or over stretching Always trim inch off the ends of the air hoses where they have stretched When reinstalling the air hoses push the edge of the hose onto the last ridge of each barb Reconnect the wire terminals to their corresponding locations on the circuit board 10 5501 Rev F 11 Compressor Motor e The Keiser compressor motor is a highly durable motor that should last years without experiencing malfunctions If the motor fails to perform contact our service department to determine if a new motor is needed e If you need to replace the moto
17. llons of air storage tank Delivery of pressurized air between 100 psig and 125 psig Computer controlled for alternating motors and demand A redundant system consisting of two complete systems for reliability Description of Compressor The compressor is divided into four major components The compressor motor the air drying system the storage tanks and the computer control system e The air drying system The system consists of a dryer module and purge tank e The storage tank The tank holds the pressurized air produced by the compressor e The computer control system The computer control system controls and regulates the pressure that is delivered by the compressor This system determines when and which motor will start and stop e The compressor motor This is where the air is compressed and where most of the noise is generated Warning Keiser Corporation requires that the compressor be plugged directly into the wall outlet with the proper voltage and at 15 amps or greater for the 110 volt model and 10 amps for the 220 volt unit The use of an extension cord can cause the unit to run irregular or damage the compressor or possibly do physical harm to you 10 5501 Rev F 2 Servicing Caution Prior to performing any type of service to this unit perform the following steps Failure to follow these procedures may result in serious physical harm to you and or damage to the unit Safety procedures 1 Prior to
18. not pumping properly Shut off the valve supplying air to the main airline and reset the compressor by unplugging it for a few seconds Run the compressor and note if the compressor builds up pressure and shuts off A view hole on top of the circuit box housing assembly will allow you to see at what pressure the compressor shuts off If the compressor builds up pressure and shuts off the leak is in one of the exercise machines or an air supply line leading to them If the compressor does not build pressure then the problem is in the compressor In this case inspect the compressor for any leaks If the compressor is not the problem then the machines should be unplugged and the valve opened to fill the air line The machines should be plugged in one at a time to see which one has the leak E r 3 E r 4 Er 5 Purge tank pressure did not drop as quickly as it should The purge tank must bleed air through the dryer to regenerate it This must happen before the compressor can restart If this takes too long then this error will be displayed Probable cause is the solenoid valve or dryer module is plugged Anything that restricts the air from exiting the purge tank through the drier and then to the solenoid valve can cause this error E r 6 Computer thinks the motor did not start The motor was given a signal to start but pressure in the purge tank did not build up as fast as it should have The motor or start circuit could be faulty Drain the air plu
19. op the solenoid valves will open allowing air to drain from the drier through the sponge Since a check valve is bad there will be constant air coming from the sponge on the bad side The compressor on the other side will start when the system pressure drops back to the start pressure and air will continue leaking from the sponge on the bad side Eventually the good side will time out after several cycles through Er8 and stop at Er2 The bad side will have stopped at Er5 or Er3 while this is happening Once the good side times out and stops completely the pressure will drop almost all the way to 0 and the bad compressor will start up again The clue that will help find the cause of this problem is to feel for air leaking from the sponge continuously after the compressor stops If you do not have another check valve it is possible to keep the system in service on one compressor by closing the petcock valve located on the solenoid valve on the side with the leaky check valve Solenoid Valve Leaking If the solenoid valve develops a leak several different error messages are possible from the display Air will be escaping from the sponge chamber while the compressor is running If air is coming from the sponge chamber while the compressor motor is running the solenoid valve is leaking and must be changed Intake Muffler Plugged When the air flow through the intake muffler is reduced the display may display Er9 Usually this error message will last only
20. r yourself the following procedures will assist you 1 Disconnect the electrical wires from the motor that leads to the computer control circuit board Disconnect the ground wire green wire from the grounding screw at this time also 2 Remove the nut that holds the Teflon hose to the motor figure 6 3 Remove the four nuts that mount the motor to the frame Be careful when unscrewing the nuts to hold the rubber mounts to keep them from twisting 4 Replacement of the new motor is done in reverse order of disassembly Muffler SS Teflon Hose Nut Motor Figure 6 10 5501 Rev F 12 Extended Troubleshooting Use this procedure to determine if your Keiser air compressor is performing correctly 1 10 Unplug the compressor Next drain the tank by opening the drain petcock at the bottom of the tank Close the petcock when the tank is completely drained The output valve valve that allows air to the exercise machines should be closed for the duration of this entire test Close the drain valve and plug the compressor in Start timing with a stopwatch when the motors start Both motors should start at about the same time several seconds after plugging the unit in If they do not locate and repair the cause of this problem before proceeding If a solenoid valve clicks several seconds after plugging the unit in and its motor does not start the motor is defective If a motor starts immediately there is a problem w
21. servicing the compressor unplug the unit from the electrical supply 2 Slowly bleed all pressure stored in the compressor using the drain valve located on the bottom of the tank figure 1 3 After bleeding all of the pressure out of the compressor close the drain valve Compressor Handle Inspection Port Drain valve Figure 1 10 5501 Rev F 3 The Air Drying System The air drying system consists of a dryer module and a purge tank The dryer module is the smaller tank that has a black air line attached to the top The drying module s main purpose is to extract any moisture that may exist within the system and deliver dry pressurized air to the main air line The purge tank is the larger tank located next to the dryer module The purge tank s purpose is to dry the crystals in the dryer module canister figure 2 Screw ee Air Line Hose N Dryer Tank Purge Tank Copper Tube The Air Drying System Figure 2 Servicing of the dryer module is recommend when the drying module becomes so saturated with moisture that it allows moisture to pass through it and into the main air pressure line If this occurs moisture will be visible in the exercise machine s filter element refer to Keiser exercise machine maintenance manual and at the tank drain when it is opened The air dryer module is designed to be replaced without havin
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