Ecoair D100 Operation And Maintenance Manual Download

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C.P.N. : 89290720 GB
DATE : AUGUST 2000

D60 D75

D100 D102

OPERATION AND MAINTENANCE MANUAL

1090200

D102

SERIAL No:

–>>

1085120

D100

SERIAL No:

–>>

1080110

D75

SERIAL No:

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1075080

D60

SERIAL No:

–>>

This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.

Manual Closed Out

Machine no longer in production

Summary of Contents for D100

Page 1: ...CE MANUAL 1090200 D102 SERIAL No 1085120 D100 SERIAL No 1080110 D75 SERIAL No 1075080 D60 SERIAL No This manual contains important safety information and must be made available to personnel who operate and maintain this machine Manual Closed Out Machine no longer in production ...

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Page 3: ...d result in the CE certification and marking being rendered invalid A declaration of that conformity follows EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES 98 37 EC 93 68 EEC 89 336 EEC WE ECOAIR GEWERBEALLE 17 D 45478 MÜLHEIM DEUTSCHLAND DECLARE THAT UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY THE PRODUCT S D60 D75 D100 D102 TO WHICH THIS DECLARATION RELATES IS ARE IN CONFORMITY WIT...

Page 4: ...BOLS Contact ECOAIR for serial number Up to Serial No From Serial No Not illustrated Option NR Not required AR As required SM Sitemaster Sitepack HA High ambient machine WC Watercooled machine AC Aircooled machine ERS Energy recovery system T E F C Totally enclosed fan cooled motor IP54 O D P Open drip proof motor D Germany DK Denmark E Spain F France GB Great Britain I Italy N Norway NL Netherlan...

Page 5: ...approved parts list may create hazardous conditions over which ECOAIR has no control Therefore ECOAIR cannot be held responsible for equipment in which non approved repair parts are installed ECOAIR reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously The intende...

Page 6: ...on risk WARNING Air gas flow or Air discharge X XBAR WARNING Pressurised component or system WARNING Hot and harmful exhaust gas WARNING Maintain correct tyre pressure Refer to the GENERAL INFORMATION section of this manual 0 C WARNING Flammable liquid WARNING Before connecting the tow bar or commencing to tow consult the operation and maintenance manual WARNING For operating temperature below 0 C...

Page 7: ... Do not remove the Operating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guard being fitted Do not stand on any service valve or other parts of the pressure system Do not operate with the doors or enclosure open Do not use fork lift truck from this side XX km h Do not exceed the trailer speed limit No naked lights Do not open the s...

Page 8: ...fore operation or maintenance of this machine is undertaken When parking use prop stand handrake and wheel chocks Contains asbestos SET SEQUENCER STATUS LOAD SEQUENCER AUTOMATIC CONTROL COMPRESSOR OFF LOAD UNLOADED RESET COMPRESSOR STATUS MODULATE MALFUNCTION POWER SOILED FILTER POWER INLET ELECTRIC MOTOR HOURS ...

Page 9: ...URISED TANK ON OFF CYCLE COOLANT FILTER AIR FILTER ON OFF PUSH BUTTON COOLANT PRESSURE AIR PRESSURE STAR DELTA IEC 617 7 AUTOMATIC RESTART HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL MANUAL SELECT TEMPERATURE HIGH TEMPERATURE ...

Page 10: ...ISO SYMBOLS 7 D60 D75 D100 D102 BELT TENSION FILTER MOTOR LUBRICATION FRAGILE KEEP DRY THIS WAY UP USE NO HOOKS NO SIDE CLAMPS ROTATION POWER INLET AC WATER IN WATER OUT ...

Page 11: ...ompressor lubricating oil and care should be taken to ensure that downstream equipmentis compatible If the discharged air is to be ultimately released into a confined space adequate ventilation must be provided When using compressed air always use appropriate personal protective equipment All pressure containing parts especially flexible hoses and their couplings must be regularly inspected be fre...

Page 12: ...ations and regulations in their particular area ECOAIR and its associated distributors are happy to advise and assist in these matters Coolant disposal Steps to be taken in the case of spillage Soak up with a suitable absorbent material then sweep into a plastic bag for disposal Burn in an approved incinerator or according to local area or country regulations For further information consult Materi...

Page 13: ... 23 55 23 55 23 55 23 55 Frame B3 B5 B3 B5 B3 B5 B3 B5 Insulation class F F F F D60 D75 D100 102 COOLING SYSTEM Air cooled Cooling air flow 8100 m3 min 9700 m3 min 13400 m3 min 13400 m3 min Maximum P in air ducts 59 6 Pa mm WG 59 6 Pa mm WG 59 6 Pa mm WG 59 6 Pa mm WG Heat to be dissipated 45kW 55kW 75kW 8 bar 75kW 10 bar 90kW Compressed air outlet T 8 C 12 C 8 C 12 C 8 C 12 C 8 C 12 C D60 D75 D10...

Page 14: ...54 Fan motor Power 1 5kW 1 5kW 1 5kW 1 5kW Full load current 3 8A 3 8A 3 8A 3 8A Control voltage Star delta combination 230 VAC 230 VAC 230 VAC 230 VAC Control ECOMATIC 24 VDC 24 VDC 24 VDC 24 VDC Control ECOCONTROL 12 24 VDC 12 24 VDC 12 24 VDC 12 24 VDC Mains supply cable cross section 1 50 PVC PVC 70 PVC PVC 95 PVC PVC 8 bar 95 PVC PVC 10 bar 120 PVC PVC Fuse rating 2 125A 160A 200A 8 bar 200A ...

Page 15: ...GENERAL INFORMATION 12 D60 D75 D100 D102 ECOCONTROL ECOCONTROL ...

Page 16: ...GENERAL INFORMATION 13 D60 D75 D100 D102 ECOCONTROL ECOCONTROL ...

Page 17: ...GENERAL INFORMATION 14 D60 D75 D100 D102 ECOCONTROL U MAX 220V I MAX 8A P MAX 24V 150 WATTS ECOCONTROL ...

Page 18: ...ansformer 230V PTC Thermistor protection X1 Socket 24 way KEY INSTRUMENTS T2 Transformer 18V ECOCONTROL T2 Transformer 18V 10V ECOMATIC X1 Plug 24 way S10 Emergency stop P24 Hourmeter Total P25 Hourmeter Load V1 Solenoid valve Load Y5 Valve coolant stop X73 Block terminal S33 Air filter vacuum switch S34 Coolant filter vacuum switch S17 Switch maximum pressure S1 Switch auto continuous S14 1 Gauge...

Page 19: ... board ECOMATIC A12 Circuit board option A13 Circuit board option A10 Circuit board ECOCONTROL X71 Socket cable loom machine NLZ Off load timer S H Starts per hour GLW Sequencer connection SO1 Button stop SO2 Button start SO3 Switch Auto Continuous ECOMATIC ...

Page 20: ...GENERAL INFORMATION 17 D60 D75 D100 D102 ECOMATIC ECOMATIC ...

Page 21: ...GENERAL INFORMATION 18 D60 D75 D100 D102 ECOMATIC ECOMATIC ...

Page 22: ...1 Plug 24 way S10 Emergency stop P24 Hourmeter Total P25 Hourmeter Load V1 Solenoid valve Load Y5 Valve coolant stop X73 Block terminal S33 Air filter vacuum switch S34 Coolant filter vacuum switch S17 Switch maximum pressure S1 Switch auto continuous S14 1 Gauge temperature A11 Indicator board ECOCONTROL S35 Separator vacuum switch S40 Rotation vacuum switch KEY A20 Circuit board ECOMATIC A12 Cir...

Page 23: ...Safety valve 11 Non return valve 12 Dirt trap 13 Scavenge check with orifice 14 Minimum pressure valve 15 Compressed air cooler 16 Pressure switch 17 Coolant filler neck 18 Coolant level guage 19 Pressure hold valve 20 Coolant drain valve 21 Coolant filter 22 Thermostatic valve 23 Coolant cooler 24 Airend discharge temperature thermometer 25 Sump pressure pressure gauge 26 Discharge pressure press...

Page 24: ...he compressed air is completely discharged through the discharge nozzle Figs 3 4 and 5 1 into the separator Fig 5 2 The rotors have a field proven and energy saving asymmetrical profile Whilst compression is in progress coolant is injected into the compression chamber This coolant is designed to absorb the compression heat to lubricate the rotors bearings and gear unit and to seal off the gap betw...

Page 25: ...sed air cooler 8 Pressure gauge Indicates the process system pressure 9 Pressure switch Controls the control valve 3 10 Temperature guage Indicates the compression discharge temperature display 11 Thermostatic switch Trips the compressor when the discharge temperature becomes too high 12 Coolant control block coolant filter Used for thermostatic control of temperature in the coolant circuit and to...

Page 26: ...ilter 6 Stop valve opened in operation for coolant drain 7 Minimum pressure valve 8 Coolant separator cartridge 9 Safety valve 10 Oil drain nozzle 11 Stop valve coolant drain 12 Coolant filler neck 13 Separator 14 Coolant flow viewing window 15 Coolant filter cartridge 16 Coolant control block 17 Coolant filter condition indicator 18 Driving motor 19 Starter cabinet ...

Page 27: ...max system pressure with connection for base load alternating operation Fault signalling input connections for four transmitters in series arrangement on the circuit board for fault display centralized fault indication Fig 9 2 and compressor shutdown Back signal that delta contactor has picked up for resetting the control upon control voltage failure wire fracture in the star delta combination Out...

Page 28: ...ntilation of the mounting location must be ensured so as to dissipate the compression heat Cooling air flow see table Fig 11 The compressor is to be positioned at a minimum distance from walls and other machinery Fig 11 If there is no natural ventilation of the compressor mounting location i e windows wall breakthroughs etc or if the openings for supply air F and exhaust air G are of an insufficie...

Page 29: ...atures around 0 C E Exhaust air for heating Waste heat recovery MODEL D60 D75 D100 D102 Supply air opening H m2 0 9 1 1 1 5 Exhaust air opening G m2 Exhaust air fan B m3 h 12600 15400 21000 Warm air flow m3 h 8100 9700 13400 Recommended duct cross section for heating K m2 0 75 0 9 1 2 Fig 13 AMBIENT TEMPERATURE CAUTION The compressor must be set up protected from frost The temperature of the intak...

Page 30: ...sed air always use suitable personal protective equipment Avoid all bodily contact with compressed air Fig 16 ELECTRICAL CONNECTION WARNING Connection to the electrical mains and the necessary protective measures shall be provided and supervised by an Authorized Specialist according to EN regulations and the rules of the respective public utility company A circuit breaker is to be fitted before th...

Page 31: ...vice hour meter 6 Sump pressure gauge 7 Control switch with 3 switching positions compressor OFF automatic operation continuous operation 8 EMERGENCY STOP button SUMMARY INSTRUCTIONS 1 Before starting Check set up and connections Close safety valve Check coolant level Check direction of rotation Close the enclosure 2 Starting the compressor Compressor not to be operated unless enclosure is closed ...

Page 32: ...Process pressure Compressor system pressure Compression discharge temperature Total service hours On load hours Fig 20 OPERATING AND CONTROL INSTRUMENTS ECOMATIC 1 ON button for compressor start 2 Operating lamp 3 LED display for automatic compressor starting 4 LED display for selected continuous operating mode 5 LED display for selected automatic operating mode 6 Operating mode selector button 7 ...

Page 33: ... condition by pressing the emergency off button Fig 20 18 Fig 22 COMMISSIONING WARNING Do not operate compressor beyond admissible operating pressure or admissible discharge temperature 1 Check for correct set up and connections 2 Close safety valve Close the safety valve by clockwise turning of knurled screw 3 Check coolant level 4 Check the direction of rotation WARNING Incorrect direction of ro...

Page 34: ...ory Operating gauge pressure bar Lower switch point bar Upper switch point bar 8 7 8 10 9 10 13 12 13 Fig 25 WARNING Observe admissible operating pressure of compressed air process system when adjusting the upper switch point and do not set unless compressor is in on load operation Screw off the screw Fig 25 1 Remove cap Fig 25 2 from discharge pressure switch Fig 26 Adjusting the switch off press...

Page 35: ...off load time and star delta transfer time Fig 27 ECOCONTROL Fig 27 Potentiometer 1 min off load time Potentiometer 2 star delta transfer time Fig 28 ECOMATIC Fig 28 Potentiometer 1 min off load time Potentiometer 2 star delta transfer time 7 Commissioning after transport of compressor WARNING Coolant may have entered the coolant separator cartridge in transit Operate the compressor for approx 10 ...

Page 36: ...rmittent operation In this control mode the compressor delivery flowrate is so adjusted to the air requirements that according to the demand of the consumer the compressor runs either under full load idling control or is shut down The compressor is automatically stopped in case that the upper switch point is reached and the motor min running time and off load time have expired It will restart auto...

Page 37: ... The compressor unit is fitted with an automatic operation monitor to trip the unit if there is any malfunction Fig 34 ECOCONTROL Fig 34 Three locations are monitored as a standard feature Detection of a malfunction by the operation monitor causes the centralized fault alarm lamp 2 to light up Starting of the compressor after correction of the malfunction or recurrence of mains voltage after a pow...

Page 38: ...window Fig 36 1 with shutdown compressor 2 Maintenance indicator for coolant filter cartridge Fig 37 Exchange of the coolant filter cartridge becomes necessary if the red service field is fully visible in the transparent window Fig 37 1 with shutdown compressor 3 Monitoring of coolant separator cartridge Fig 38 The coolant separator cartridge must be exchanged if the pressure differential between ...

Page 39: ...e compressor unit take care that air or an air coolant mixture passes by the flow gauge 1 of the coolant flow check fitting If coolant only is visible on the flow gauge without any noticeable flow movement the dirt trap 2 and restrictor bore in the coolant fitting must be checked for soiling and cleaned ...

Page 40: ...blockage clean if required 1 year Remove the safety valve from the compressor inspect and re calibrate 1 year Check the calibration of the pressure guage 2000 hours Lubricate the main motor drive end bearing Quantity of grease ESSO UNIREX N3 cpn 93685832 required B 12g L 20g Lubricate the main motor non drive end bearing Quantity of grease ESSO UNIREX N3 cpn 93685832 required B 6g L 20g To determi...

Page 41: ...the work carried out is limited to only those tasks which require the machine to run the work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed all hazards present are known e g pressurised components electrically live components removed panels covers and guards ex...

Page 42: ...ized compressor system pressure gauge 2 must show 0 bar Before performing any work on the compressor lift the safety valve for security to confirm the air receiver tank has been depressurized Fig 43 Open the safety valve by anticlockwise turning of knurled screw Fig 43 1 The compressed air escapes through the safety valve Close safety valve again by turning the knurled screw clockwise Fig 44 CHECK...

Page 43: ...oolant do not permit coolant to seep into ground and ensure ecological disposal 1 Coolant to be changed in service temperature conditions Have the compressor operate for approx 5 minutes 2 Stop the compressor 3 Observe pressure drop on compressor system pressure gauge Fig 46 1 System pressure gauge ECOCONTROL Fig 47 1 System pressure gauge ECOMATIC 4 When system pressure has dropped to 2 bar throw...

Page 44: ...e absorbed by piping and cooling system Fig 49 Fig 50 Fig 51 EXCHANGE OF COOLANT FILTER CARTRIDGE WARNING Coolant filter cartridge to be exchanged with motor at rest and compressor depressurized Risk of scalding Hot coolant Do not spill any coolant 1 Depressurize the compressor 2 Loosen coolant filter cartridge Fig 50 1 by strap wrench and screw off WARNING Collect the escaping used coolant do not...

Page 45: ...olts Fig 52 3 4 Take off cover Fig 52 2 and take out coolant separator cartridge with old gaskets WARNING Collect the escaping used coolant do not permit coolant to seep into ground and ensure ecological disposal together with old coolant separator cartridge Fig 53 5 Clean sealing face and place new gasket Fig 53 3 6 Put new coolant separator cartridge Fig 53 2 into separator vessel Fig 53 1 7 Pla...

Page 46: ...cartridge with combustibleliquids solvents or hot liquids Check intake filter cartridge for damage to filter paper examine against light or gaskets exchange if necessary 5 Replace cleaned or new intake filter cartridge fit filter cover and screw on the wing nut finger tight Fig 55 6 If the intake filter is monitored by a maintenance indicator Fig 55 1 reset the indicator by pressing the resetting ...

Page 47: ...completed on the compressor and motor 1 Start the compressor 2 Operate the compressor in the AUTOMATIC mode and check for proper functions 3 Check compressor for tightness during the test run 4 Check the safety valve NOTE The safety valve blow off pressure was set to 1 5 bar above compressor discharge pressure at the factory The safety valve has been lead sealed and may not be readjusted Fig 57 Op...

Page 48: ...ING Check that the valve is free to open load Check the operation of the load solenoid valve Y1 Compressor fails to deliver rated INLET VALVE NOT OPENING Check the operation of the inlet valve deliver rated capacity Check the operation of the load solenoid valve Y1 capacity Check the offline online pressure setting Check the inlet filter for contamination AIR FILTER BLOCKED Check visual service in...

Page 49: ...OOLANT LEVEL IN SEPARATOR TANK TOO HIGH Bring to normal level MIN PRESSURE TOO LOW Check min pressure Coolant escaping through intake nozzle after sh tdown of INTAKE CONTROLLER FAILS TO CLOSE Check exchange if necessary after shutdown of compressor DRAINAGE LINE FROM COOLANT SEPARATOR CARTRIDGE CLOGGED Clean and or connect See also malfunction Coolant in air piping Compressor unit fails to start N...

Page 50: ...nd operation display zero potential Automatic starting after power failure Motor thermistor protection With ECOCONTROL only Direction of rotation control On load hour meter External ON OFF control With ECOMATIC only Unassigned fault input with display Unassigned maintenance input with display Local remote transfer Any questions concerning the optional outfit should be addressed to our aftersales s...

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Page 53: ...Printed in the United Kingdom ...

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