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  4. D100
  5. Operation And Maintenance Manual

Ecoair D100 Operation And Maintenance Manual - Contents & Abbreviations

Summary of D100

  • Page 1

    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: –>> 1075080 d60 serial no: –>> this manual contains important safety information and must be made available to personnel who opera...

  • Page 3: D60 D75 D100 D102

    Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into european common market countries requires that the machine display the ec mark and conform to various directives. In such cases, the design specification of this machine has been cert...

  • Page 4: Contents & Abbreviations

    Contents & abbreviations 1 d60 d75 d100 d102 contents 1 contents 2 foreword 3 iso symbols 8 safety 10 general information 25 installation / handling 28 operating instructions 37 maintenance 45 fault finding 47 options abbreviations & symbols #### contact ecoair for serial number –>#### up to serial ...

  • Page 5: Foreword

    Foreword 2 d60 d75 d100 d102 the contents of this manual are considered to be proprietary and confidential to ecoair and should not be reproduced without the prior written permission of ecoair. Nothing contained in this document is intended to extend any promise, warranty or representation, expresse...

  • Page 6: Iso Symbols

    Iso symbols 3 d60 d75 d100 d102 graphic form and meaning of iso symbols prohibition / mandatory information / instructions warning warning: electrical shock risk. Warning – pressurised vessel. Warning – hot surface. Warning – pressure control. Warning – corrosion risk. Warning – air/gas flow or air ...

  • Page 7: Iso Symbols

    Iso symbols 4 d60 d75 d100 d102 warning – do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. Warning – consult the operation and maintenance manual before commencing any maintenance. Do not breathe the compressed air...

  • Page 8: Iso Symbols

    Iso symbols 5 d60 d75 d100 d102 lifting point. On (power). Off (power). A read the operation and maintenance manual before 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...

  • Page 9: Iso Symbols

    Iso symbols 6 d60 d75 d100 d102 coolant separator pressure air discharge pressurised 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 drai...

  • Page 10: Iso Symbols

    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: Safety

    Safety 8 d60 d75 d100 d102 warnings warnings call attention to instructions which must be followed precisely to avoid injury or death. Cautions cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings. Notes notes are used fo...

  • Page 12: Safety

    Safety 9 d60 d75 d100 d102 condensate disposal condensate cannot be discharged into fresh/surface water drains. In some regions compressor condensate containing ecool can be fed directly into a drainage system that has downstream sewerage treatment. As waste water regulations vary by country and reg...

  • Page 13: General Information

    General information 10 d60 d75 d100 d102 d60 d75 d100 102 compressor maximum operating pressure 8,0 bar 10,0 bar 13,0 bar 8,0 bar 10,0 bar 13,0 bar 8,0 bar 10,0 bar 13,0 bar 8,0 bar 10,0 bar 13,0 bar normal operating pressure 7,8 bar 9,8 bar 12,8 bar 7,8 bar 9,8 bar 12,8 bar 7,8 bar 9,8 bar 12,8 bar...

  • Page 14: General Information

    General information 11 d60 d75 d100 d102 weight (ip23/55) 990kg/1015kg 1025kg/1070kg 1160kg/1310kg 8bar = 1325kg/1475kg 10bar = 1460kg/1640kg discharge connection g2 g2 g2 g2 dimensions (l x w x h) 1950mm x 1150mm x 1700mm 1950mm x 1150mm x 1700mm 1950mm x 1150mm x 1700mm 1950mm x 1150mm x 1700mm d6...

  • Page 15: General Information

    General information 12 d60 d75 d100 d102 ecocontrol ecocontrol.

  • Page 16: General Information

    General information 13 d60 d75 d100 d102 ecocontrol ecocontrol.

  • Page 17: General Information

    General information 14 d60 d75 d100 d102 ecocontrol u max = 220v i max = 8a p max 24v=150 watts ecocontrol.

  • Page 18: General Information

    General information 15 d60 d75 d100 d102 ecocontrol key starter pe terminal, earth l1–l3 mains terminals cb1/2 circuit breaker cb3 circuit breaker k1m main contactor k2m delta contactor k3m star contactor m1 main drive motor m31 fan motor f20 relay, thermal overload f30 relay, thermal overload t1 tr...

  • Page 19: General Information

    General information 16 d60 d75 d100 d102 key a20 circuit 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/...

  • Page 20: General Information

    General information 17 d60 d75 d100 d102 ecomatic ecomatic.

  • Page 21: General Information

    General information 18 d60 d75 d100 d102 ecomatic ecomatic.

  • Page 22: General Information

    General information 19 d60 d75 d100 d102 key starter pe terminal, earth l1–l3 mains terminals cb1/2 circuit breaker cb3 circuit breaker k1m main contactor k2m delta contactor k3m star contactor m1 main drive motor m31 fan motor f20 relay, thermal overload f30 relay, thermal overload t1 transformer 2...

  • Page 23: General Information

    General information 20 d60 d75 d100 d102 key 1 intake filter 2 intake valve 3 pressure balancing valve 4 vent valve 5 control valve (3/2way) 6 airend 7 drive motor 8 separator 9 coolant separator cartridge 10 safety valve 11 non return valve 12 dirt trap 13 scavenge check with orifice 14 minimum pre...

  • Page 24: General Information

    General information 21 d60 d75 d100 d102 fig. 4 fig. 3 fig. 5 screw airend 1 the airend is a single–stage screw–type compressor cooled by coolant injection. Running in its casing (fig. 4) are two helical rotors, viz. The male rotor (fig. 3/1) and the female rotor (fig. 3/2) with meshing teeth. Whils...

  • Page 25: General Information

    General information 22 d60 d75 d100 d102 the ecoset system 1 intake filter used for cleaning the intake air. 2 intake valve opens when air is delivered, closes during idling and standstill conditions. Vents the separator during idling and standstill conditions, being controlled by the discharge pres...

  • Page 26: General Information

    General information 23 d60 d75 d100 d102 fig. 7 overview 1 operator panel 2 pressure switch 3 coolant/compressed air cooler 4 air filter condition indicator 5 intake filter 6 stop valve (opened in operation) for coolant drain 7 minimum pressure valve 8 coolant separator cartridge 9 safety valve 10 o...

  • Page 27: General Information

    General information 24 d60 d75 d100 d102 fig. 8 fig. 9 control system general configuration the circuitry is designed in cmos technique, open–loop type, for industrial use. The circuit board (fig. 8/1) is rated for top–hat rail attachment (ts35). The electric terminations for the inputs and outputs ...

  • Page 28: Installation / Handling

    Installation / handling 25 d60 d75 d100 d102 fig. 10 transport and mounting caution screw compressors must be transported and mounted with due regard to the applicable regulations for the prevention of accidents. Transport transport the compressor unit by fork–lift. Weights see table. Travel under t...

  • Page 29: Installation / Handling

    Installation / handling 26 d60 d75 d100 d102 fig. 12 ventilation, and recovery of exhaust–air heat caution if the discharged air is released into a confined space, adequate ventilation must be provided. The air intake is to be so arranged that any loose personal clothing cannot be sucked in. A natur...

  • Page 30: Installation / Handling

    Installation / handling 27 d60 d75 d100 d102 compressed–air connection caution connecting pipes shall have the correct size, and must be suitable for the respective operating pressure. The compressor has been fully assembled at the manufacturer’s works and fitted with a nonreturn valve. Connection t...

  • Page 31: Operating Instructions

    Operating instructions 28 d60 d75 d100 d102 explanation of signs – ecocontrol compressor on automatic operation compressor on continuous operation compressor off operating lamp centralized fault alarm lamp total service hours on–load hours compression discharge temperature process pressure compresso...

  • Page 32: Operating Instructions

    Operating instructions 29 d60 d75 d100 d102 – switch off the circuit breaker, lock where applicable. 4. Emergency stop warning if there is a danger situation, the compressor can be stopped from any operating condition by pressing the emergency–off button (fig.20/18). Explanation of signs – ecomatic ...

  • Page 33: Operating Instructions

    Operating instructions 30 d60 d75 d100 d102 – check direction of rotation. – close the enclosure. 2. Starting the compressor compressor not to be operated unless enclosure is closed. – switch on the circuit breaker. – switch on compressor with the on button. – operating lamp lights up. – choose mode...

  • Page 34: Operating Instructions

    Operating instructions 31 d60 d75 d100 d102 – should the direction of rotation be wrong, incoming wires l1 and l2 (fig. 24/1) require reconnection in the switch cabinet. Ecomatic – switch on the circuit breaker. – press the on button, and instantly press the off button. – should the motor fail to st...

  • Page 35: Operating Instructions

    Operating instructions 32 d60 d75 d100 d102 – fit the cap (fig. 25/2), and fix by screw (fig. 25/1). 6. Adjusting the motor running time. Warning the motor running time must be adjusted by an authorized specialist. The motor running time shall be checked and, where applicable, corrected on initial c...

  • Page 36: Operating Instructions

    Operating instructions 33 d60 d75 d100 d102 ecocontrol (fig. 29) 1. Switch on the circuit breaker. 2. Set the control switch [2] to automatic operation [4] or continuous operation [1]. Compressor will start up in automatic or continuous operation. Operating lamp will light up [5]. 3. Switch–off of c...

  • Page 37: Operating Instructions

    Operating instructions 34 d60 d75 d100 d102 2. Compressor system pressure gauge [2]. 3. Thermometer (compression discharge temperature) [3]. Fig. 33 thermometer warning do not operate the compressor beyond the admissible compression discharge temperature. The compression discharge temperature is mea...

  • Page 38: Operating Instructions

    Operating instructions 35 d60 d75 d100 d102 flashing of any display indicates the faulted location that has caused automatic tripping. By actuation of the off button [5], the flashing display is switched to steady light. The faulted display is not extinguished until actuation of the off button has b...

  • Page 39: Operating Instructions

    Operating instructions 36 d60 d75 d100 d102 fig. 40 coolant flow check fitting (fig. 40) when monitoring the 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 noticeab...

  • Page 40: Maintenance

    Maintenance 37 d60 d75 d100 d102 period maintenance daily check the coolant level and replenish if necessary. When the separator element indicator light flashes check the pressure differential when the unit is operating on full load at rated pressure. Light flashes change the separator element if th...

  • Page 41: Maintenance

    Maintenance 38 d60 d75 d100 d102 routine maintenance this section refers to the various components which require periodic maintenance and replacement. The service/maintenance chart indicates the various components’ descriptions and the intervals when maintenance has to take place. Coolant capacities...

  • Page 42: Maintenance

    Maintenance 39 d60 d75 d100 d102 fig. 41 ecocontrol (fig. 41): 1 switch compressor to continuous operation. Close stop valve to compressed–air process system, and idle for approx. 2 min. Then stop the compressor, and set control switch [1] to ”0” position. 2 separator must have been depressurized; c...

  • Page 43: Maintenance

    Maintenance 40 d60 d75 d100 d102 2 screw out plug (fig. 44/2) from coolant filler neck (fig. 44/3). 3 fill up the coolant to top edge of level gauge in separator (max.). Fig. 45 4 check seal (fig. 45/1) on plug; exchange plug if seal is damaged. 5 screw in and tighten the plug. Warning plug is press...

  • Page 44: Maintenance

    Maintenance 41 d60 d75 d100 d102 8 remove coolant drain hose, and screw on plug again (fig. 49/1). 9 depressurize the compressor. 10 drain coolant from coolant cooler. 11 fill with fresh coolant. Coolant fill: 45 litres always re–fill the unit with ecool. This coolant has been developed to optimise ...

  • Page 45: Maintenance

    Maintenance 42 d60 d75 d100 d102 fig. 52 exchange of coolant separator cartridge warning coolant separator 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. Secure to prevent restarting! ...

  • Page 46: Maintenance

    Maintenance 43 d60 d75 d100 d102 fig. 54 intake filter maintenance warning perform all inspections and all work with motor at rest and compressor depressurized! 1 screw off the wing nut (fig. 54/1). 2 remove filter cover (fig. 54/2) and take out the intake filter cartridge (fig. 54/3). 3 either exch...

  • Page 47: Maintenance

    Maintenance 44 d60 d75 d100 d102 motor cleaning warning do not hose down motors with water or other liquids. Depending on soiling, motors are to be regularly cleaned along the entire cooling–air path. Rolling–contact bearings with relubrication facility warning the operational safety of the motors d...

  • Page 48: Fault Finding

    Fault finding 45 d60 d75 d100 d102 fault cause remedy ’power on’. L.E.D. Does not ill minate control voltage not available check the control circuit breaker cb3. Not illuminate. Available check the transformer secondary windings for the control voltage. Compressor will not b ild p rated press re dem...

  • Page 49: Fault Finding

    Fault finding 46 d60 d75 d100 d102 fault cause remedy compression discharge temperature too high. Ambient temperature too high contact the aftersales service. Cooling system fouled clean cooling system, remove any coolant residues internally. Insufficient coolant flow in coolant circuit renew coolan...

  • Page 50: Options

    Options 47 d60 d75 d100 d102 optional outfit optional mechanical outfit – water cooling – heat recovery optional electrical outfit – compressor anti–condensation heater – starter cabinet heater – centralized–fault and operation display (zero–potential) – automatic starting after power failure – moto...

  • Page 53

    Printed in the united kingdom.