SERVICE MANUAL - Soilmoisture Equipment Corp
Contents
1. position AUTO gt Switch on the compressor unit at the pressure switch turn switch to position I Shutting down the compressor unit Switch off the compressor unit at the pressure switch turn switch to position O Operate and lock out the main disconnect device pull out the mains plug to isolate the compressor from the mains power supply 8 2 Trouble Shooting Possible cause Remedy Always comply with all general and local safety regulations when MN carrying out faultfinding and repair Restarting after a fault see chapter 7 Initial Start up Explanation of symbols in the following faultfinding help A 1 have checked by a specialist A 2 contact you authorized Soilmoisture distributor 8 2 1 Compressor does not start Possible cause Remedy No motor power supply fuses blown Replace the fuses A 1 Contact in pressure switch defective Replace the pressure switch A 1 Motor overload protection switch released Check function of the overload protection switch see chapter 7 2 A 1 18 8 2 2 8 2 3 8 2 4 8 2 5 Compressor starts with difficulty Possible cause Unloading valve at the pressure switch not opening Damaged bearings Pistons siezed no oil or wrong oil Power supply fault Voltage too high or too low Oil level too high Compressor overheating Possible cause Ambient temperature too high over 105 F The fan cannot draw in air freely2. To ensure sufficient ventilation the compressor unit must be installed with a minimum dis tance of 19 7 inches to the wall Safe operation of the compressor unit is only ensured if the ambient temperature remains within the limits stated in chapter 1 8 If the compressor is used in the open take care that it is protected against the direct rays of the sun and against the ingress of dust and rain Connection of the Compressed Air Supply The compressor unit is piped ready for use 1 Compressed air discharge connection on the pressure reduction valve 2 Compressed air discharge connection on the air receiver Two compressed air connections are provided for the consumers The consumers are con nected via a flexible hose and a coupling Electrical Connection The main power supply and overcurrent protection must be installed by AN a gualified electrician in accordance with NEC OSHA and any appli cable local codes For fuse and cable recommendations see chapter 1 4 The compressor is wired ready for connection to the power supply with a mains plug Maximum dual element time delay fuses are selected according to ARO 2002 N E C Article 240 6 430 52 and Tables 430 52 430 148 amp 150 Select multi strand copper core wire at 40 C ambient temperature according to 2002 N E C 110 14 c 220 3 310 15 Table 310 16 430 6 430 22 430 24 and Tables 430 148 amp 150 1 25x LA wire temperature correction factor see chapt
3. Valve plate leaking corroded or the valve reeds are broken Operation Remedy Clean or renew the unloading valve see chapter 9 10 A 1 Renew the bearings or fit an exchange compressor A2 A2 Check the power supply fuses A 1 Reduce the oil level to the maximum mark on the oil level sight glass see chapter 9 3 Remedy Lower the ambient temperature see chap ter 1 8 Ensure that inlet air is available for the fan Replace valve plate A 1and 42 Motor overload protection switch releases after a short period Possible cause Defect in the mains power supply voltage too high or too low Defect on the motor Remedy Check the mains fuses A 1 Change the motor A1 and A2 Motor overload protection switch releases after a long period Possible cause Defect in the mains power supply voltage too high or too low 19 Remedy Check the cable cross section see chap ter 6 3 At Check the terminal connections tighten screws if necessary 8 2 6 8 2 7 8 2 8 8 2 9 8 2 10 8 2 11 Operation Compressor runs continuously discharge pressure not reached Possible cause Air filter blocked Valve plate leaking coked or valve reeds broken Pressure losses within the unit Air demand higher than the capacity of the compressor Losses at the consumer in the air main Compressor cutting in too often Possible cause Air receiver filled with condensate u
4. 000 operating hours In addition inspect the valve plates for coking and clean if necessary If the cylinder head or valves show sign of malfunction they should be repaired or renewed by an authorized Soilmoisture facility We recommend a general overhaul of the machine should be carried out at a Soilmoisture facility after 10 000 operating hours Checking Compressor Unit Performance c The effective compressor unit performance can be determined by measuring the charging time of the air receiver Shut down the compressor unit see chapter 8 1 Lock the main disconnect in the off position in accordance with applicable lock out tag out procedures example OSHA CFR 29 c Isolate the compressor from the air main close the user s shut off valve C Vent the air receiver with the condensate drain cock and then close the cock again see chapter 9 4 cs Close the shut off valve on the air receiver gt Start the compressor unit see chapter 8 1 and simultaneously measure and compare the charging time taken to achieve the gauge pressure stated in the technical specifi cation see chapter 1 10 29 Maintenance 9 13 Maintenance Schedule Model No cias Serial NO cccccececeececenceceeeueaes Description of work Operating hours 30 Spare Parts and After Sales Service 10 Spare Parts and After Sales Service 10 1 Service Parts and Maintenance Parts AAA AA Air filter insert 0505V 0000 01 Check valve 0505V 00
5. OPIN correct function of the cylinder head and valves Every 10 000 h Change the motor bearings a Carry out a general compressor overhaul Maintenance interval may change depending on model installation motor starting freguency and ambient conditions It is recommended that a log is kept of maintenance work done See chapter 9 13 for a sample list of maintenance tasks If daily maintenance is impractical because the machine is used so little it should be carried out every 24 operating hours 23 Maintenance 9 3 Oil Level Check and Top Off Compressor Block Check the oil level daily through the oil sight glass when the compressor unit is shut down If the oil level has sunk to the lower mark top off the oil immediately according to the oil recommendations see chapter 1 9 Never top off to a level exceeding the maximum oil mark on the oil level sight glass When topping off the oil always use a strainer or pour the oil directly from the new oil can max min 1 Oil filler with crankcase venting plug 2 Oil level sight glass c Shut down the compressor see chapter 8 1 Lock the main disconnect in the off position in accordance with AN applicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch c Remove the crankcase venting plug 1 from the oil filler Let oil settle a few minutes before filling to
6. are indeed de pressurized Any alterations or reconstruction carried out without the prior written authorization of Soilmoisture Eguipment Corp will invalidate the war ranty No welding heat treatment or mechanical work may be carried out on pressure retaining components e g pipes air mains receivers etc Safety devices may not be modified or deactivated Signs and labels of reference may not be removed or rendered unre adable 2 3 2 4 2 5 Safety Additional Safety Precautions Comply with the following Do not allow open flame and flying sparks at the installation site Take necessary precaution when welding on or near the compressor unit to ensure that sparks or high temperatures cannot cause fire or explosion Ensure that the compressor unit is supplied only with clean uncontaminated air Do not allow the maximum ambient temperature to be exceeded see chapter 1 8 unless special measures have been agreed upon between the manufacturer and the customer This machine is not explosion proof It may not be operated in areas in which specific requirements with regard to explosion protection are applied Electrical Power Supply The main power supply and over current protection must be installed by a qualified electrician in accordance with NEC OSHA and any appli cable local codes Compressor units must be installed with a lockable main disconnect and fuses or other short circuit and ground fault protec
7. mode the compressor must be allowed to shut off every 30 minutes for at least 5 minutes 11 9 4 3 6 8 15 12 16 14 Construction and Operation Components of the Compressor Unit 1 Air filter cleans the inlet air Compressor block draws in the air and compresses it to the discharge pressure Check valve prevents the compressed air from flowing back into the block Air receiver compressed air tank and accumulation of condensate Safety valve on the air receiver protects the air receiver blows off if the max pressure is exceeded Pressure switch controls compressor stop and start Eectric motor drives the compressor block Fan on OD shaft end provides the necessary cooling air 10 11 12 13 14 15 16 12 si d E k MTU Is j Apo Cites 7 il E a J SEN n Fel k i A it pe L I h i mi a il Hit m i oS S na Y gt T a Pressure gauge indicates the current pressure in the air receiver Oil level sight glass Oil filler Oil drain plug Compressed air discharge connection on the air receiver Condensate drain cock Pressure reduction valve reduces the pressure to the required working pressure Pressure gauge on reduction valve indicates the working pressure Compressed air discharge connection on the reduction valve 6 6 1 6 2 6 3 Installation Installation Installation Instructions
8. than the maximum gauge working pressure see chapter 1 1 15 Initial Start 5 3 4 1 Y 2 E NSA Y q KFB002521 Cover Screw Upper switching point Cut out pressure adjusting screw Pressure difference adjusting screw ON OFF Switch OAK ON gt Shut down the compressor unit see chapter 8 1 Lock the main disconnect in the off position in accordance with applicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch C Unscrew the screws 2 to the right and left of the cover 1 gt Remove the cover 1 of the pressure switch cs Carry out the adjustment of the pressure switch Replace the cover 1 after every adjustment of the pressure shitch and before A starting the compressor unit CS Replace the cover 1 To increase the cut out pressure gt Turn the screw 3 clockwise in the direction To decrease the cut out pressure c Turn the screw 3 counterclockwise in the direction To increase the pressure difference between the cut in and cut out pressures CS Turn the screw 4 clockwise in the direction To decrease the pressure difference between the cut in and cut out pressures c Turn the screw 4 counterclockwise direction 7 3 1 Cut in frequency of the compressor unit from standstill to load The cut in frequency of the compressor unit from standst
9. the maximum oil level mark The oil must flow through the crankcase first cs Top off the oil to the maximum mark See chapter 1 3 for the quantity of oil required for topping off from the minimum mark to the maximum mark Replace the crankcase venting plug in the oil filler 24 Maintenance 9 4 Air Receiver The provisions of the Pressure Vessels Act must be conformed with The relevant regulations of the country concerned must also be ob served Drain the condensate collecting in the air receiver daily with the condensate drain valve 1 ES Drain the condensate into a suitable container and dispose of according to environmental care regulations 1 Condensate drain 9 5 Oil Change Compressor Block Change the oil with the compressor unit at normal operating temperature A Danger of scalding by hot oil Danger of burns from hot components Change the oil after approximately the first 50 service hours Change the oil futher see chapter 1 9 If under unsuitable operational conditions condensed water is observed in the oil recognizable by the milky color in the oil level sight gauge 2 carry out an oil change immediately Lock the main disconnect in the off position in accordance with ap AN plicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch 1 Oil Filler 2 Oil level sight glass 3 Ol drain
10. 00 02 Model 505 20 Bar Compressor Series Part No 0505V2206 Test Press 35 Bars 441 psi Serial No 505 1001 R Yr of Mfg 200_ Receiver Vol 4 Liters 61 cu in Press Relief Set 21 37 Bars 310 psi Va 7 97 23eG Shell Thk 34 04 mm 134 in Avg Delv at 6 Bars 80L min 2 83 cfm EN 286 11 End Cap Thk 30 23 mm 119 in Country of Mfg Germany Thy 1271 11 Max Pressure 20 Bar 294 psi SOILMOISTURE EQUIPMENT CORP 801 5 Kellogg Ave Goleta CA USA Ph 805 964 3525 Fax 805 683 2189 h pin soilmoistuna com SOILMOISTURE 10 2 Ordering Spare Parts When ordering spare parts always state see nameplate Compressor model Serial Number Year of manufacture Important for all orders and inquiries Enter the data from the nameplate of the compressor unit in the nameplate shown above Caution Always order original spare parts from the compressor manufacturer to avoid lower quality spare parts in your compressor unit We want to point out that maintenance parts spare parts and accessories not supplied by us are also not tested and authorized by us The use of such products could change design characteristics of the compressor unit negatively and might therefore affect the safety of the unit It should be noted that substitution of original parts or assemblies will void the warranty coverage in most circumstances and in worst case expose the user to hazards and liabilities not cov
11. 22 430 24 and Tables 430 148 150 1 5 1 6 1 7 1 8 Technical Specification Under unsuitable mains conditions operation of the compressor can have an adverse effect on other equipment No interference should be expected if the mains network impedance is less than 0 30 ohms Generally the maximum permissible impedance will not be exceeded if the compressor is supplied from a domestic power outlet or a sub distribution cabinet with a rated current of 25 A Drive Motor A A 1 0 TAP FRANCO Decio s tt tse 19002 TDM Enclosure TAI tn ER PHASES seua SINGIE pllase Max starts per hour s s net ss lset steln s je N seim srei alsm ieemmastttsisss 90 Mes Air Pressure Switch Setting Possible adjustment range of the air mains pressure switch Cut in pressure psig 60 90 120 150 180 210 240 270 300 330 360 380 Cut out pressure psig Factory settings CLIN Pressure Drin Susie air site 9 PSIO Cut out PIC SSUFSPnakamuommsadoa aaseista ESIM es tn m 290 psig Settings specific to a customer may differ Safety Relief Valve Setting SET PIM nd a e ia lod 290 psig Installation Requirements Max height above sea level at place of installation oooococccncccccnoo 3000 ft for all heights above please contact authorized Soilmoisture Equip Corp distributor Min ambient temperature cccoocccccccccccccnnccncnnccnnncnonononnnnnnono seseeesseeesssteesseeeees AD OF Max ambie
12. VSUS Y 20 BAR COMPRESSOR 12 2006 SERVICE MANUAL SOILMOISTURE EOUIPMENT CORP 801 S Kellogg Ave Goleta CA 93117 soilmoisture com PH 1 805 964 3535 FAX 1 805 683 2189 SOILMOISTURE sales soilmoisture com Table of Contents Chapter Page 1 Technical Specification oocooccoccconconiccnconionnconcononcnnoncnnonononoos 1 1 1 1 Compressor UM o sedes ld e 1 1 1 2 SOUNG EMS NN did eee 1 1 1 3 Compressor Block it la konna sisaan 1 1 14 EICCA PE ONIINES LON mernes aims do es 1 1 1 5 DVE MOTO ss colada 1 2 1 6 Air Pressure Switch Setting cccococcoccocononccconnnnoconcnnonanonnonannnnnnnnnnnnnnannnnnnnns 1 2 1 7 Safety Relief Vale Seting simm inen A A AAA 1 2 1 8 Installation Requirements ooccooocccocncoccncconccnnnoconnncannonanonnnncnnnnonancnnnnnnannonaninnans 1 2 1 9 Recommended Olleros its casas lalola 1 3 1 10 Air Receiver Charging TiM ccccoooncccoccnnonccconncononnncnonononononnnnnononnnnnnnnnnnnnannnnnnnns 1 3 tit Dimensional Drawing a o as 1 4 2 Satety Regulations ieii panal eat deceo des o dec ad 2 5 2 1 Explanation of Symbols and References ooccccccoccccconoccncononcnnconacononnanoncnnoncnnnnnnos 2 5 2 2 General Safety PrecautioNS coooccococonnncccoonnconononcnnannnnncnnnnnonnnnnnnnnnnnnonannnnnnnns 2 6 2 3 Additional Safety PreCcautiOns scort di ide 2 7 2 4 El cifical Power SUDD casita ie 2 7 2 5 Spare Pals na i 2 7 2 6 Environmental Protect
13. at is preset to a fixed value Voltage fluctuations can release the overload protection switch because of increasing motor current shutting down the compressor unit If the overload protection switch has released and shut down the compressor unit start the compressor again as follows Before pressing the release button turn the ON OFF switch of the pressure switch to the 0 position first Turn the ON OFF switch to the 0 position Press the release button Turn the ON OFF switch to the I position If the release button does not latch in straightaway wait until the motor has cooled down If the overload protection switch repeatedly shuts down the com pressor over a succession of short periods other defects e g insula tion fault on the motor or in the cables seized compressor could cause the overload protection switch to release Have the motor checked by a gualified electrician 1 Overload protection switch release button 7 3 Setting the Air Pressure Switch Lock the main disconnect in the off position in accordance with ap MN plicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch See chapter 1 6 for the factory setting of the air pressure switch and the possible setting range Caution Do not adjust pressure switch unless it is mounted and pressurized Do not set the maximum cut out pressure higher
14. carefully If the inserts are heavily contaminated or have been cleaned several times they should be changed c Alter drying the filter inserts take them again CT Fit the rubber cap of the air filter 1 again 26 Maintenance 9 7 Cleaning or Replacing the Check Valve The check valve is located at the inlet port of the built in air receiver It prevents the com pressed air flowing back from the air receiver into the compressor block Check and if necessary clean the check valve every 500 service hours or at least once annually KFB001021 VL Or o OT K 1 4 3 5 6 2 1 Check valve 4 Valve seat 2 End plug 5 Spring 3 Valve piston 6 Sealing ring lt Shut down the compressor see chapter 8 1 Lock the main disconnect in the off position in accordance with A applicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch c Remove the crankcase venting plug 1 from the oil filler Prepare a container to catch the oil Collect the used oil and dispose of according to environmental care regulations CS Unscrew the oil drain plug 3 and drain the oil into the container When topping off the oil always use a strainer or pour the oil directly from the new oil can Flush out the crankcase with a small quantity of new oil Screw the oil drain plug back into the crankcase Fill up with new oil see chap
15. e available at the compressor unit s place of use Proper Use of the Compressor The compressor unit is intended solely for the purpose of generating compressed air Any other use is considered improper The manufacturer cannot accept liability for any damage caused by such improper use the user alone is liable for any risks incurred Proper use of the compressor also includes compliance with the installation removal ap plication operational and maintenance instructions laid down by the manufacturer The equipment may only be used or serviced by authorized and trained personnel Improper Use Never direct compressed air toward persons Compressed air is a con O centrated form of energy and as such dangerous to life Never use compressed air for breathing purposes and production O methods where the air has direct contact with food without subjecting the compressed air to additional treatment O Inlet air may not contain any explosive or chemically unstable gas or vapor O Danger of injury and or damage Under no circumstances are persons allowed to climb on this compressor O Do not place any objects on the compressor or use it as a working sur face Copyright This Manual produced by Soilmoisture Eguipment Corp USA in cooperation with Keaser Compressors Inc of Germany All rights reserved No part of this manual may be reproduced in any form without permission of these parties Handling the Document The service ma
16. eeeeeeeeeeeeeseeeeeeaeeeess 8 20 8 2 11 Air escapes from the pressure switch ooccccoccccccccncccncncconnnononnnonannnnoncnononenononos 8 20 8 2 12 Whistling noises at the cylinder head ccoooccconccccoccncccccnconocnconcnnnnncnonnncnonnncnonnnos 8 21 8 2 13 Safety valve blowing off prematurely cccooonccnccconcncccccnnconoconnononennnnnnnononnncnnononons 8 21 8 2 14 Oil consumption of compressor too high oocccccccncccccncccccnocccnnonncnnnnncnononenononos 8 21 2 MAINTENANCE rota sa ar enano 9 22 9 1 Observe the following rules during all maintenance and servicing work 9 22 9 2 Regular Maintenance Work ooooossoooss ona ana aan aan aan ana a aan a aa aan a aan ana aa aaaaaen 9 23 9 3 Oil Level Check and Top Off Compressor Block ooooccccccocconcccccnnconanonnss 9 24 9 4 AIRES CSIVOT aan Osso base ela a e Shan TKO ETM AKE ees deta annas EE 9 25 9 5 Oil Change Compressor BloCk ooocccccooccocococcnncconcnnconononnononcnnconanonnonanens 9 25 9 6 Cleaning or Changing the Air Filter oooccccccoccnncccccnnconanonnnnoncnnononcnncnnanonoos 9 26 9 7 Cleaning or Replacing the Check Valve oooccccoocccccoccocccooconconanoncononononnanononnns 9 27 9 8 Testing the Safety Relief Valve oocccoooococcccononccconnncccnnconnonanonconannnnnnonnnnnos 9 27 9 9 Maintenance of the Motor BearingS cccccooccoccconccnconononcononcn
17. er 1 4 rating for 40 C 13 7 1 Initial Start Putting into Operation Points to be Observed before Putting into Operation Every compressor unit is given a test run at the factory and carefully checked before ship ment The test run confirms that the compressor unit conforms to the specification data and runs perfectly However independent of the checks made at the factory the compressor unit could be damaged during transport For this reason we recommend that the compressor unit is examined for such possible damage Observe the compressor unit carefully during the first hours of operation for any possible malfunction Important functional components in the compressor unit Such as check valve safety relief valve and solenoid valve are adjusted and fitted to factory standards and specifications Alterations to these components are not allowed without prior written authorization from the manufacturer Do not disassemble the check valve and safety relief valve They are heavily spring loaded Points to be observed before starting the compressor unit A A ANY NON OBSERVANCE OF THIS OR OTHER REFERENCES WARN ING ATTENTION DANGER CAN LEAD TO ACCIDENTS CAUSING IN JURY TO PERSONS OR DAMAGE TO EQUIPMENT The compressor unit starts automatically after a power failure providing the line pressure is lower than the setting on the air pressure switch Do not operate the compressor without belt guards or open doors as inj
18. ered by the manufacturer or supplier of this compressor 31 APPENDIX 11 0 Appendix Electrical Diagram Compressor Wiring PLUG Fuse s b c with Connector cable and Plug PRESSURE SWITCH PE a LT K K AAA AAA AAA AA ada aaa aaa dl M Compressor Motor A C incl overload protection switch 2 1 See service manual Technical Specs Electrical Connection 2 See service manual Technical Specs Drive Motor LINP 1 Connector cable Only PRESSURE SWITCH PE A Compressor Motor A C incl overload protection switch 2 Soilmoisture Equipment Corp Model 0505V 20 Bar Compressor ELECTRICAL DESIGN SPECS 32
19. ill to load can be changed within a limited range by changing the switching difference To change the cut in fre quency the pressure switch must be adjusted see chapter 7 3 See chapter 1 5 for the maximum cut in frequency from standstill to load per hour e Increasing the switching difference causes a decrease in the cut in frequency e Decreasing the switching difference causes an increase in the cut in frequency 16 7 4 Initial Start Setting up the Pressure Reducer The working pressure of a compressor unit fluctuates according to the pressure limits set on the pressure switch see chapter 1 6 The pressure reducer reduces this fluctuating working pressure to the working pressure required and holds it constant 1 Regulating screw 2 Locking nut gt Switch on the compressor unit and allow it to run without any consumers until the cut out pressure is reached gt Turn the regulating screw 1 anticlockwise until no more resistance is felt This measure unloads the pressure reducer c Turn the regulating screw 1 clockwise until the required pressure is indicated on the pressure gauge 3 c Lock the regulating screw 1 to this position with the locking nut 2 17 Operation 8 Operation 8 1 Starting and Stopping the Compressor Unit Starting the compressor unit Operate the main disconnect device main switch or plug see chapter 2 4 KER A 7 1 ON OFF switch 0 position OFF
20. in serious injury Read this service manual carefully and observe cautionary references before putting the compressor unit into operation and before carrying out any maintenance on the unit The machine is constructed to the latest technological standards and to accepted safety regulations Despite this fact physical danger to the user or third parties or damage to the machine and other property exists Use the machine as specified according to the service manual and only if it is in perfect technical order Repair defects that could degrade safety or have them repaired immediately Explanation of Symbols and References A This symbol is placed before all regulations concerning safety where dangerous life and limb can occur during work It is especially important that these regulations are observed and that extreme care is taken For their own protection inform all other users of these safety regulations Observe all general safety and accident prevention regulations as well as the those laid down in this service menu This symbol is placed by text where considerable attention must be SON paid to recommendations regulations references and the correct se guence of work so that damage and or destruction of the compressor unit and or other eguipment is prevented This symbol identifies environmental care measures gt This symbol indicates operations and actions to be carried out by the operator or service technician Thi
21. ion ooocccocnccccncconnoconnononccnnncnnnnonononnannonanconnnonannnnaninnans 2 8 A A K mme taas sena 3 9 3 1 Proper Use of the Compressor ooccccocccccocncoccconcocnnnconnnononononannnonnnnnnonnnonannnenanonenas 3 9 3 2 MProper Us uan dd ic 3 9 3 3 5 a gatan da Ment adueul a a 3 9 3 4 Handling the Document sssini a a a 3 9 4 Transport soooooooemeememmemnennsansau ana aa aa a naan a aokk a kaan aak aak a ana anaaaaaa 4 10 4 1 Transport INStTrUCHONS serien sis ees ried eet eee ets 4 10 4 2 SAD O nro Meme eri epee ae K T hytin Kte TSS an en a ee en ee ee ee eee 4 10 5 Construction and Operati0N cooccocccoccocccoccoccconcoconcnonncononcnnannns 5 11 5 1 PrRCIple OFC OMPISSSION iii 5 11 5 2 Bier DOSSCKIDIOM 22000 ino 5 11 5 3 Compressor Control Stop Start Control ooocccconccnccconcnnononconcnnanonconanoncononons 5 11 5 4 Components of the Compressor Unit oocccccccccccccnccccnncncncnnconnnnonnnnononononononos 5 12 6 IRStall tt m siii it 6 13 6 1 mstalatioiNSTUCIONS a eii 6 13 6 2 Connection of the Compressed Air Supply occcocccccoccncccccnnccccnconcncnononononononononos 6 13 6 3 Electrical Connection a 6 13 Table of Contents Chapter Page 7 Putting into ODEN all ON decai 7 14 7 1 Points to be Observed before Putting into Operation ccccoccccccnoccnnononcnncnnanonos 1 14 1 2 Function of the Overload Protection Switch oooccccccocccnccnoccncononcnnnno
22. ion The compressor block is driven by an electric motor The compressor block is directly coupled to the motor via the motor shaft A fan supplying the cooling air necessary for the motor and compressor block is fitted to the other end of the shaft The heat generated is dissipated via the cooling fins on the cylinder and the cylinder head The crankshaft is supported by anti friction bearings the connecting rod is supported by shell bearings The cylinder liner piston crankshaft and connecting rod are splash lubricated To enable an unloaded start the pressure switch is fitted with an unloading valve A check valve is fitted upstream of the air receiver to prevent compressed air flowing back into the block The air receiver is constructed to the regulations of the pressure vessels act and fitted with all necessary fittings such as safety valve pressure gauge pressure switch and check valve Compressor Control Stop Start Control The compressor is controlled by the pressure switch After the compressor is first switched on the pressure switch switches the compressor de pending on the air demand between the two operating states load and standstill within the limits Pmin Pmax See chapter 1 6 for the works setting of the pressure switch The compressed air pipe from the compressor block up to the check valve is vented when the cut out gauge pressure is reached to ensure an unloaded compressor start When operating in this
23. ncnnconanonoos 7 15 7 3 Setting the Air Pressure Switch ccooooccccccccnococonconoconcnnnonononoconnnnnnnanonnnnannnnnnnns 7 15 7131 Cut in frequency of the compressor unit from standstill to load 1 16 7 4 Setting up the Pressure Reducer occccccoccococcoconccoocnncononnocononnnnnnnnnnnnonannnconannnnnnnns 7 17 SB Operation i 8 18 8 1 Starting and Stopping the Compressor Unit ccooocccccccncccccnccconnnccncnononononononos 8 18 8 1 Trouble Shooting Possible cause Remedy cccceecceesseeeeeeeeeeeeeeeeeeeesaeeeeens 8 18 8 21 Compressordoes not sta s sumsussissettki mimma si aiak est amen ivaa 8 18 8 2 2 Compressor starts with difficulty ooooonccccooonnnncocononconononnononcnnononronconanenoos 8 19 8 29 COMPpressor Overheatihd seco A AA 8 19 8 2 4 Motor overload protection switch releases after a short period oo 8 19 8 2 5 Motor overload protection switch releases after a long period o oo cccco 8 19 8 2 6 Compressor runs continuously discharge pressure not reached 8 20 9 2 7 Compressor cutting IN too OMEN iii ape dasaa ae 8 20 8 2 8 Compressor shuts down air escapes constantly at the unloading valve 8 20 8 2 9 Air escapes from the unloading valve when the compressor is running 8 20 8 2 10 Unloading valve not unloading after shut down ccccccse
24. nononconcnnancnnononons 9 28 9 10 Clean the unloading valve on the pressure SWitCh occccoccccccccncccononoconononos 9 28 9 11 Inspect the cylinder head and valves and renew if required ooccccocccccoccncoo 9 29 9 12 Checking Compressor Unit Performance ooccccccccnncccncnnconoconcnnoncnononnononnanennnnonons 9 29 9 19 i Maintenance Schedule ocios a a 9 30 10 Spare Parts and After Sales Service oocooccoonionionionionionionooccorinnonnon 10 31 10 1 Service Parts and Maintenance PartS cccccconnnccccoccncononcnnononcnnnnnanononnncnnononcnnnnnos 10 31 10 2 Ord rno Spare asa taa ida 10 31 T ADDENADK maamassa maa amen o O 11 32 E ELRADII a ao j k rtt k Kaivua k k t a at Nmt a na s meviathamaaae 11 32 1 1 1 2 1 3 1 4 Technical Specification Compressor Unit Model escri catala ibas Maximum gauge Working pressure scccccseeeeceeeeeeeeeeeae caaeeeeeaeeeusaeeeaaes PIN ATM A TN MTT TO 71 lbs Air receiver GAD ACh sieustsat ieee NE Drawings Dimensional CraWwing ccceeeeeeeeeeeeeeeaes Elecmcal diagr arn anios Sound emission Guaranteed sound power level ccoooccccccccccccnnccononocanon kanaa to 2000 14 EG Directive Emission sound pressure level c oocccconncccccccccccconccannno kannan nananana Technical Specification niiina Premium compact 130 4 W einen 290 PSIG ia 1 gal Max
25. nt temperature oocccccocccocccnnococococonnconanncnannnnnno caseeeeeesssseessseeessees OD OF 1 9 1 10 1 11 Technical Specification Recommended Oil THIS COMPRESSOR COMES UNFILLED WITH OIL IT MUST BE FILLED PRIOR TO USE Oil type SAE 5 W30 Description High performance oil Synthetic oil for workshop com pressors Application Suitable for all applica Specially for use in compressors tions except in con where the air comes in direct nection with foodstuff contact with foodstuff processing Maximal permissible fluid 1000 2 1000 2 change interval in operating hours years Material part 9 4943 00010 9 0874 0 number quantity 0 5 1 0 Type of oil flled N S Cool to moderate ambient temperatures low humidity high duty cycle Mark the type of oil in your machine in the table Air Receiver Charging Time Air receiver charging time to 145 290 psig O min 46 s Mechanical Drawing with Some Dimensions see following page Pressure Switch Off On Quick Connect Regulated air STD BSPT 3 8 Connect R Quick Connect Unregulated air STD BSPT 3 8 Connect U OIL FILLING PORT pull out and fill Oil Sight Port do not overfill Air Reciever Drain Valve 14 1 2 20 20 1 2 Soilmoisture Eguipment Corp Model 0505V 20 Bar Compressor SOILMOISTURE Ko MECHANICAL DESIGN SPECS 2 1 Safety Safety Regulations Disregarding this notice can result
26. nual is part of the machine gt Keep the service manual safe throughout the life of the machine cs Pass the manual on to the next owner user of the machine gt Ensure that all amendments are entered in the manual 4 4 1 4 2 Transport Transport Transport Instructions Always use a fork lift truck a lift truck or lifting equipment when transporting the compressor unit to avoid damage to cabinet and framework See chapter 1 1 for details of the weight Storage Always store the compressor whether packaged or not in an enclosed dry location The ambient temperature may not exceed the limits of 13 F and 140 F 10 9 1 9 2 9 3 Construction and Operation Construction and Operation Principle of Compression The compressor is an air cooled oil lubricated reciprocating compressor working on the single stage principle of compression Atmospheric air is drawn in through the air filter into the compression chamber of the com pressor block The downward movement of the piston creates a vacuum When the piston has passed the bottom dead center the air drawn into the cylinder is compressed by the upward movement of the piston At the same time the inlet valves close and the outlet valves open The compressed air is forced through a check valve into the air receiver The check valve prevents the compressed air flowing back from the air receiver to the compressor block after shutdown Brief Descript
27. p to the discharge valve Remedy Clean or replace the air filter see chapter 9 6 A 1 Check decoke or replace valve plate gt fc and A2 Brush soapy water on piping and fittings seal leaks replace leaking parts A1 Extend the compressed air supply Check for possible leakage points Remedy Drain the condensate observe environmen tal care regulations carry out routine main tenance regularly see chapter 9 4 A 1 Compressor shuts down air escapes constantly at the unloading valve Possible cause Defective unloading valve Possible cause Unloading valve not closing dirty or defec tive Remedy Replace the seal or replace the valve cone see chapter 9 7 A1 Air escapes from the unloading valve when the compressor is running Remedy Clean or replace the unloading valve see chapter 9 10 A 1 Unloading valve not unloading after shut down Possible cause Dirty unloading valve Air escapes from the pressure switch Possible cause Defective diaphragm Unloading valve does not close 20 Remedy Clean the unloading valve see chapter 9 10 A 1 Remedy Replace the pressure switch A 1 Replace the unloading valve A 1 8 2 12 Whistling noises at the cylinder head Possible cause Loose cylinder head bolts or defective gas kets 8 2 13 Safety valve blowing off prematurely 8 2 14 Possible cause Safety valve blows even though the cut out
28. permissible gauge working pressure occcoccccccnccncnccno hikan eunnnnn n 290 psig EAE PEP ETETEA ES 0505 VHHH Mech a DDOOV HF HHH Elec coc 99 dB A uneen 77 5 dB A calculated from the measured mean sound power level Directive 2000 14 EG basic standard for noise measurement ISO 3744 to EN ISO 11203 1995 para 6 2 3 d at distance d 1m Q 2 12 9 dB A Compressor Block Model rutosta vaania nio Theoretical inlet capacity iii A E EAT Oy E O505ViHHHI 3000 coman 4 6 cfm Free air delivered at 87 psi gauge working pressure n s cece cence eee ee ee eeeee kannan 2 8 cfm Maximum gauge Working pressure cccccseeeeceeeeeseeeeeee anna anna aan ana aaaan Number otoyInders atan Ea Oil capacity Oil TOP CIP QUAMTILY sa a ARE al Electrical Connection Mal Volta rica Ul TOG curent FLA a do Frequency Mae dica Recommended main disconnect fuses Dual element or time delay c ooooncncccoccnnccnccncononcnnnnonennnono cease ease eeeeeeaeeeeaeeenees Recommended power supply cable Cu multi stranded CAUTION uunin 290 psi O 230V 1PH ri OA a OZ CTOSSSOCHON oooccccccccnccccccn nos 14 AWG Maximum dual element time delay fuses are selected according to 2002 N E C Article 240 6 430 52 and Tables 430 52 430 148 150 Select multi strand copper core wire at 40 C ambient temperature according to 2002 N E C 110 14 c 220 3 310 15 Table 310 16 430 6 430
29. plug gt Shut down the compressor see chapter 8 1 25 Maintenance Remove the crankcase venting plug 1 from the oil filler gt Prepare a container to catch the oil Collect the used oil and dispose in an acceptable environmental manner cs Unscrew the oil drain plug 3 and drain the oil into the container When topping off the oil always use a strainer or pour the oil directly from the new oil can Flush out the crankcase with a small quantity of new oil Gs Screw the oil drain plug back into the crankcase gt Fill up with new oil see chapter 9 3 9 6 Cleaning or Changing the Air Filter c The replaceable cartridge 2 is made of foam cs Ifan obvious layer of dust is found on the filter cartridges they must be cleaned The filter inserts should be cleaned at the latest after 500 service hours Cs Shut down the compressor see chapter 8 1 su 2 Filter insert P p NOT A RES i J 1 Air filter cap a An E MO Lock the main disconnect in the off position in accordance with applicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch gt Remove the rubber cap of the air filter 1 cs Take out the filter inserts wash them in hot water with a grease solvent additive and then carefully rinse CS Clean out the filter housing Clean the sealing surfaces very
30. pressure is not yet reached Defective valve spring Wrong set point Safety valve was opened dirt particles stuck in valve seat Oil consumption of compressor too high Possible cause Viscosity of oil too low Defective crankcase venting system Piston rings worn or damaged Piston rings worn or damaged after only a short period 21 Operation Remedy Tighten the bolts or replace the gaskets A land A 2 Remedy Check that the pressure gauge functions correctly replace if necessary Check the pressure setting Replace the safety valve A 1 Set 10 15 psig above max working pres sure see chapter 1 1 of the compressor unit A 1 Open the safety valve completely for a short period to allow it to blow itself clean Remedy Fill with correct oil see chapter 1 9 A 1 Clean the crankcase venting system or re place the filter A 1 Replace piston rings and cylinder A2 Replace piston rings and cylinder A2 ensure that the inlet air is clean e g by using an air filter with a higher grade of fil tration Maintenance Maintenance 9 1 Observe the following rules during all maintenance and servicing work Work on power driven equipment may only be carried out N by trained or specialized personnel Follow all applicable OSHA and local safety regulations The compressor unit restarts automatically after a power failure if the line pressure is lower than the pressure setting on the air pre
31. s bullet identifies listings This warning label identifies hot surfaces DO NOT TOUCH O DO NOT DO THIS Safety 2 2 General Safety Precautions A A Work on power driven equipment may only be carried out or super vised by persons trained in that particular equipment or by a special Ist Work on the electrical eguipment of the compressor unit may only be carried out by a gualified electrician or trained personnel under the supervision of a qualified electrician according to the NEC and any ap plicable local codes Prior to working on electrical systems of the compressor always per form the following steps in the seguence shown 1 Lock the main disconnect in the off position in accordance with applicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart 2 Ensure the package cannot be switched on again 3 Check that no voltage is present 4 Lock the isolation shut off valve in the closed position and vent all compressed air trapped between the compressor and the isolation shut off valve in accordance with applicable lock out tag out pro cedures example OSHA CFR 29 8 1910 147 The following actions must be carried out in the order given before working on any pressurized parts or enclosures e g pipes vessels valves 1 Shut off and depressurize all pressurized components and enclosures 2 Secure them in the depressurized state 3 Check that they
32. ssure switch Lock the main disconnect switch in the off position in accordance with applicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart see chapter LEERER MERKER for main disconnect switch Ensure that no maintenance personnel is working on the compressor unit that all panels are latched back on again and all maintenance doors are closed before restarting the compressor unit To start the compressor unit see chapter 8 1 Always tighten down any screw connection that has been loosened during maintenance work The following points must be observed when handling MN lubricating and cooling materials e Avoid contact with skin and eyes e Donot inhale vapors and oil mist e Donot eat or drink when handling such materials e Fire open flame and smoking are strictly forbidden Ensure that all lubricants consumable materials and replacement parts accumulating during operation and servicing of the compressor package are disposed of according to environmental regulations 22 9 2 Maintenance Regular Maintenance Work Daily Check the crankcase oil level Drain condensate from the air receiver 50 h after initial Start up Change the compressor oil rra Jas Every 500 h At least Check and clean the air filter eS once a year Check the safety relief valve Check and clean the check valve a Variable ees the compressor oil Every 3 000 h viaksi
33. ter 9 3 9 8 Testing the Safety Relief Valve If the maximum permissible gauge working pressure in the air receiver is exceeded the safety valve 2 opens and blows off the excess air to protect the compressor unit and the users connected to the air system To prevent the valve seat from sticking activate the safety valve every 900 service hours or at least annually Safety valve Knurled ring 27 Maintenance It is essential to wear ear protection when testing the pressure relief valve because of the loud noise produced by escaping air c Switch the compressor off see chapter 8 1 applicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart See chapter 2 4 for the main disconnect switch Lock the main disconnect in the off position in accordance with c Turn the knurled screw on the pressure relief valve anticlockwise until air escapes and then turn back again Caution A defective pressure relief valve must be renewed completely Tampering with the pressure relief valve and damaging the lead seal is forbidden and will invalidate all liability 9 9 Maintenance of the Motor Bearings O The motor bearings are sealed and lubricated for the lifetime of the bearing e Under normal operating conditions with ambient temperatures around 77 F the motor bearings should be replaced approximately every 10 000 service hours The wear on the bearings increases
34. tion device For fuse and wire recommendations see chapter 1 4 Please note that the conductors fuses and procedure are Soilmoisture s recommendations These recommendations do not supersede other applicable codes Spare Parts Safe and reliable operation of the compressor unit is guaranteed only with original spare parts Safety 2 6 Environmental Protection Condensate drainage Condensate accumulating during compression must be drained via a suitable draining system and collected in disposal canisters The con densate must be disposed of according to environmental care regula tions Maintenance materials wear items replacement parts Dispose of all used materials and parts accumulating during operation maintenance and repair of the compressor unit according to envi ronmental care regulations Disposing of the Machine Dispose of all used materials and parts accumulating during operation maintenance and repair of the compressor unit according to envi ronmental care regulations When disposing of a machine drain out all liquids and remove dirty filters CS Take the machine out of service see chapter 8 1 CS Drain all oil completely from the machine see chapter 9 5 css Remove dirty filters Use the services of an approved local disposal specialist to ensure environmentally correct disposal of the empty machine 3 1 3 2 3 3 3 4 General GENERAL The service manual must always b
35. ury to persons could occur from the drive belts and electrical equip ment gt Remove all packaging materials tools and transport securing devices on and in the compressor unit It is expected that the user employs safe working techniques and that all lawful operating and safety regulations are followed when operating this compressor unit The operator of this compressor unit is responsible for its safe operating condition Do not operate this compressor unit in locations where heavy dust conditions poison ous or inflammable gases could exist Do not connect the compressor unit to a supply voltage other than that stated on the nameplate Install the compressor unit in a location not subject to freezing temperatures The air temperature reguirements at the air intake must be complied with see chapter 1 8 During installation of the compressor unit ensure that a distance of at least 19 7 is kept between the air intake of the unit and any wall A Lock the main disconnect in the off position in accordance with ap plicable lock out tag out procedures example OSHA CFR 29 8 1910 147 to ensure the compressor does not restart Check all screws on the electrical connections for tightness and tighten if necessary carry out this check again after 50 hours of operation 14 Initial Start 7 2 Function of the Overload Protection Switch The alternating current motor is provided with a thermal overload protection switch th
36. with higher ambient temperatures With very high ambient temperatures of around 95 F replace the bearings approximately every 6000 hours e Change the motor bearings every 3 years independent of service hours The bearings must be changed by your authorized Soilmoisture distributor when the above maintenance Is due 9 10 Clean the unloading valve on the pressure switch If the machine starts with difficulty because of contamination in the unloading valve or does not vent from the pressure switch when shut down the unloading valve must be cleaned Unloading Valve Screw Screw Plug Ball Spring Gasket Valve pin Fitting 0 N O 0 BEN waa A 0 28 9 11 9 12 Maintenance c Close the user s shut off valve between the machine and the air main Clean the unloading valve c Remove the fitting 8 from the unloading valve 1 c Remove the securing screw 2 and lift off the unloading valve 1 Open the valve carefully c Remove the plug 3 and take out the individual parts cs Extract the valve pin 7 and clean it and the other parts c Reassemble and replace the valve and tighten the securing screw 2 Start the machine and carry out a test run c Open the user s shut off valve between the machine and the air main c Switch the machine on c Carry outa visual check for leaks Inspect the cylinder head and valves and renew if required Check the function of the cylinder head and valves after 3
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