Part IV: Troubleshooting Excessive Oil Carryover Pump-Up Time Test Excessive oil carryover can have adverse effects on the performance of pneumatic climate control systems. Although some oil entrainment is inherent to all lubricated air compressors, an oil carryover level from the air compressor receiver tank exceeding 4 parts per million (ppm) is cause for concern. Addition of a submicron coalescing oil removal filter and an activated carbon oil vapor removal filter (as outlined in the Properly Configured Air Supply System section of Part I) will reduce the oil carryover into the system to near zero. If it is suspected that the level of oil carryover from the receiver tank may be excessive, it is recommended that an oil carryover test be performed, in order to determine the actual parts per million value of oil entrained in the air. To perform this test, refer to the procedures outlined in the Oil Carryover Test section of Part III. If, after performing the oil carryover test, the level of oil entrainment is above 4 ppm (indicating an excessive oil carryover condition), refer to Table 4.3 for a comprehensive list of probable causes and suggested remedies. If the PureFlow air compressor appears to be running excessively, or if the unit is unable to maintain the desired system pressure at a specified flow rate without running continuously, the air compressor may not be delivering its rated volume of air, or the system demand may be too high (indicating the air compressor may be undersized). To verify air compressor delivery, perform a pump-up time test. On PureFlow AD Series Duplex Air Compressors, the pump-up time test will need to be performed twice; once on each compressor pump. Do not run both compressor pumps simultaneously while performing the pump-up time test. To perform a pump-up time test, proceed as follows: 1. Disconnect the electrical power to the air compressor following Occupational Safety and Health Administration (OSHA) standard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. 2. Isolate the receiver tank from the rest of the pneumatic climate control system by closing off the hand valve on the discharge line at the air compressor receiver tank outlet. Doing so will ensure that only the receiver tank will be timed during the pump-up time test. Installation and Service Manual for PureFlow Air Compressors 63
3. While wearing proper eye protection, relieve the pressure at the tank drain (either manual or automatic tank drain depending on the aircompressor model). At the same time, pull on the ring of the safety relief valve. Check that the reading on the tank pressure gage is 0 PSIG (0 kpa) before proceeding further. 4. Close the tank drain (on air compressors equipped with a manual tank drain) or discontinue depressing the manual pushbutton (on air compressors equipped with an automatic tank drain). 5. Replace the intake filter element(s) according to the procedures outlined in the Intake Filter Element Replacement section of Part VI. Refer to Table 5.1 for a complete list of replacement intake filter elements available. 6. Restore the electrical power to the air compressor and record the time that the air compressor was restarted. 7. When the tank pressure gage reaches 90 PSIG (630 kpa), record the time again. Calculate the exact time that has elapsed (in whole minutes and seconds) to determine the actual pump-up time. Table 4.1: PureFlow AS Series Simplex and AD Series Duplex Air Compressors Nominal Pump-up Times* (One Pump Running) Base Air Receiver Tank Size (Gallons) Model Compressor Series Horsepower 30 60 80 120 200 AS/AD-005, AS/AD-105 1/2 AS/AD-007, AS/AD-107 3/4 AS/AD-010, AS/AD-110 1 AS/AD-015 1-1/2 12 Minutes and 23 Seconds 9 Minutes and 10 Seconds 6 Minutes and 2 Seconds 4 Minutes and 21 Seconds AS/AD-020 2 -- 24 Minutes and 45 Seconds 18 Minutes and 20 Seconds 12 Minutes and 5 Seconds 8 Minutes and 41 Seconds 5 Minutes and 30 Seconds AS/AD-030 3 -- -- AS/AD-050 5 -- -- AS/AD-075 7-1/2 -- -- 33 Minutes and 0 Seconds -- -- 24 Minutes and 27 Seconds -- -- 16 Minutes and 6 Seconds -- -- 11 Minutes and 35 Seconds -- -- 7 Minutes and 20 Seconds -- -- 5 Minutes and 0 Seconds 2 Minutes and 44 Seconds 1 Minute and 55 Seconds 7 Minutes and 30 Seconds -- 4 Minutes and 6 Seconds 2 Minutes and 52 Seconds 6 Minutes and 49 Seconds 4 Minutes and 46 Seconds AS/AD-100 10 -- -- -- 2 Minutes and 20 Seconds 3 Minutes and 53 Seconds * Pump-up time is the time required (±10%) to pressurize the receiver tank from 0 to 90 PSIG (0 to 630 kpa). 64 Installation and Service Manual for PureFlow Air Compressors
8. Compare the actual pump-up time determined in Step 7 to the nominal pump-up time listed in Table 4.1. If the actual pump-up time from Step 7 is less than or equal to the time listed in Table 4.1 (within plus or minus 10%), the compressor pump is delivering its rated volume of air. The excessive runtime is caused by either a high system demand or an undersized aircompressor. Refer to the System Consumption Test section below for more details. If the actual pump-up time from Step 7 exceeds the time listed in Table 4.1 by more than 10%, the air compressor is not delivering its rated volume of air. Refer to Table 4.3 for a comprehensive list of probable causes of excessive pump-up time, as well as suggested remedies. 9. Reopen the hand valve on the discharge line at the air compressor receiver tank outlet to reconnect the receiver tank to the rest of the pneumatic climate control system. 10. Observe the air compressor through two complete cycles to ensure proper operation. System Consumption Test If the PureFlow air compressor is delivering its rated volume of air (actual pump-up time is less than or within plus or minus 10% of the nominal pump-up time; refer to the Pump-Up Time Test section for more details) and the unit is running excessively, the system demand may be too high. To check the system consumption, proceed as follows: 1. Wait for the air compressor to automatically cycle off and record the time. 2. When the pressure in the receiver tank drops 20 PSI (as read on the tank pressure gage), record the time again. Calculate the exact time that has elapsed (in seconds) to determine the air compressor off-time. 3. Depending on the air compressor receiver tank size, refer to either the graph illustrated in Figure 4.1 (for PureFlow air compressors with 30, 60, or 80 gallon receiver tanks) or the graph illustrated in Figure 4.2 (for PureFlow air compressors with a 120, 200, or 240 gallon receiver tanks). Using the off-time determined in Step 2, locate the appropriate point on the SECONDS REQUIRED scale on the bottom of the graph. Installation and Service Manual for PureFlow Air Compressors 65
10 9 8 SYSTEM CONSUMPTION (SCFM) 7 6 5 4 3 30 GALLON RECEIVER TANK 60 GALLON RECEIVER TANK 80 GALLON RECEIVER TANK 2 1 0 0 50 100 150 200 250 300 350 400 SECONDS REQUIRED FOR TANK PRESSURE TO DECREASE 20 PSI (140 kpa) Figure 4.1: Actual System Consumption for PureFlow Air Compressors with 30, 60, or 80 Gallon Receiver Tanks 50 40 SYSTEM CONSUMPTION (SCFM) 30 20 120 GALLON RECEIVER TANK 200 GALLON RECEIVER TANK 240 GALLON RECEIVER TANK 10 0 0 50 100 150 200 250 300 350 400 450 500 SECONDS REQUIRED FOR TANK PRESSURE TO DECREASE 20 PSI (140 kpa) Figure 4.2: Actual System Consumption for PureFlow Air Compressors with a 120, 200, or 240 Gallon Receiver Tanks 66 Installation and Service Manual for PureFlow Air Compressors
4. Project a vertical line from the point on the SECONDS REQUIRED scale up to the bold line for the appropriate receiver tank size. 5. At the point where the two lines intersect, project a horizontal line to the SYSTEM CONSUMPTION scale on the left side of the graph. The point where this projected line intersects the scale is the actual system consumption. 6. Compare the actual system consumption determined in Step 5 to the available air compressor output listed in Table 4.2 for the appropriate horsepower size. If the actual system consumption is equal to or less than the value listed in Table 4.2, the PureFlow air compressor is properly sized for the present application. If the actual system consumption is greater than the value listed in Table 4.2, the demand on the PureFlow air compressor is too high. First check the entire pneumatic climate control system for air leaks. If no leaks are found, the air compressor is improperly sized for the present application. Table 4.2: Available Output (SCFM* at 80 PSIG Flow) From PureFlow Air Compressors at Typical On-Times Air Compressor Size (Horsepower) Available Output (scfm*) AS Series Simplex Air Compressors (@ Typical 33% On-Time) Available Output (scfm*) AD Series Duplex Air Compressors (@ Typical 50% On-Time: 25% per Compressor Pump) 1/2 0.6 0.9 3/4 0.8 1.3 1 1.2 1.9 1-1/2 1.7 2.6 2 2.7 4.1 3 4.0 6.0 5 7.3 11.0 7-1/2 10.5 15.8 10 13.0 19.5 * SCFM x 0.472 = L/s Installation and Service Manual for PureFlow Air Compressors 67
Air Compressor Troubleshooting Checklist Table 4.3: Air Compressor Troubleshooting Checklist Trouble Probable Cause Suggested Remedy Low Discharge Pressure or Excessive Pump-Up Time or Excessive On-Time or Compressor Pump(s) Will Not Shut Off Vibration/Noise 1. Air Leaks and/or Open Air Lines 1. Listen for escaping air around the air compressor and throughout the system. If necessary, apply leak detector solution to all fittings, connections, and tank mounted components. Bubbles will appear at points of leakage. Apply thread sealant and tighten or replace leaking fittings or connections. 2. Leaking Valve Plates 2. Remove valve plate from head and inspect component parts for valve breakage, scored valve seats, carbon buildup, etc. Replace entire valve plate assembly. Note: Be sure that the old valve plate gaskets and spacers are removed from the assembly and are replaced with new ones each time the valve plate is removed from the head. 3. Dirty Air Compressor Intake Filter Element, or System is Restricted 3. Replace the intake filter and check for other restrictions in the intake system. 4. Slipping Belts 4. Inspect the belts for looseness and wear (cracks or nicks, fraying, glazing, or separation), and adjust the belt tension or replace entirely. 5. Blown Gaskets or Spacers 5. Replace gaskets or spacers proven faulty on inspection. 6. Worn Cylinder and/or Rings 6. Inspect the rings and cylinder walls for wear and replace if necessary. 7. Excessive System Demand 7. Check the system demand versus air compressor sizing, and size up the air compressor or reduce the demand. 8. Defective PE Switch(es) 8. Replace all defective components. and/or Motor Starter(s) 1. Loose Motor Pulley or Pump Flywheel 2. Bent or Damaged Pump Flywheel 3. No Isolation Between Receiver Tank and Mounting Surface 1. Tighten all bolts and/or set screws. 2. Inspect the flywheel and replace it if necessary. 3. Install vibration/isolation pads under each air compressor leg. 4. Air Compressor Not Level 4. Level the legs of the air compressor to within 1/16 in. of each other. Continued on next page... 68 Installation and Service Manual for PureFlow Air Compressors
Trouble (Cont.) Probable Cause Suggested Remedy Knocking/Noise Compressor Pump Over Heating 1. Lack of Oil in the Crankcase 1. Check for proper oil level and replenish if necessary. Also, check for possible damage to the compressor pump and replace any worn components. 2. Worn Piston Pin Bushing 2. Replace the compressor pump. 3. Worn or Burned Out 3. Replace the compressor pump. Bearings 4. Loose Valve Assemblies on Valve Plate 5. Piston Hitting the Valve Plate 1. Poor Ventilation, Excessive Ambient Conditions, and/or Air Compressor Located in a Tightly Enclosed Area 4. Remove the valve plate and gaskets from the head and inspect. If defective, replace the entire valve plate assembly. 5. Remove the head and inspect for carbon deposits or other foreign material on top of the piston. Remove all foreign material and replace any damaged components. 1. Relocate the air compressor to an area where an ample supply of cool, clean, dry, and well-circulated air is available. 2. Dirty Cooling Surfaces 2. Clean the cooling surfaces of the cylinder. 3. Obstructed Cooling Fan 3. Clean the cooling fan intake and fan under the shroud. 4. Incorrect Pump Rotation 4. Check the arrow on the cooling fan shroud for correct rotation. If incorrect, reverse the motor rotation. 5. Low Oil Level 5. Check for proper oil level and replenish if necessary. Also, check for possible damage to the compressor pump and replace any worn or scored components. 6. Valve Leaking 6. Inspect the valves for carbon buildup, obstruction, or breakage. Replace entire valve assembly if necessary. Continued on next page... Installation and Service Manual for PureFlow Air Compressors 69
Trouble (Cont.) Probable Cause Suggested Remedy Compressor Pump(s) Not Operating 1. Starter Overload(s) Tripped 1. Press the RESET button/bar and determine the cause of the overload. An input voltage less than the motor nameplate may increase the amp draw. Have a qualified electrician check the input voltage during startup, then proceed with the electrician's recommendations. Note: The PE switch setting(s) can be temporarily lowered by 10 to 20 PSI (70 to 140 kpa) to keep the air compressor running until the low input voltage can be corrected. Stalling 1. Overloaded Motor 1. Have a qualified electrician examine the motor and wiring, then proceed with the electrician's recommendations. 2. Low Voltage 2. Have a qualified electrician check the input voltage during startup, then proceed with the electrician's recommendations. Excessive Belt Wear 3. Compressor Pump Starting Under Load 3. Inspect the check valve, shuttle valve, and unloader mechanism and replace if necessary. 4. Low Oil Level 4. Check for proper oil level and replenish if necessary. Also, check for possible damage to the compressor pump and replace any worn or scored components. 1. Motor Pulley and Pump Flywheel Out of Alignment 2. Belt Too Loose or Too Tight 1. Realign the motor pulley with the pump flywheel. 2. Adjust the tension on the belt. 3. Mismatched Belts 3. On dual belted air compressors, check that the tension of both belts is equal, and replace with a properly matched set if necessary. 4. Motor Pulley and/or Pump Flywheel Wobble 4. Inspect the air compressor for a bent motor pulley, bent pump flywheel, bent shafts, loose bolts, and/or loose set screws and replace any damaged components. 5. Defective Belt 5. Replace the belt(s). Continued on next page... 70 Installation and Service Manual for PureFlow Air Compressors
Trouble (Cont.) Probable Cause Suggested Remedy Excessive Oil Carryover from the Receiver Tank Oil Escaping from the Crankcase Breather Opening 1. Worn Cylinder and/or Rings 1. Replace cylinder and rings. 2. Air Compressor Intake System Restricted 3. Restricted Oil Fill Breather Cap 4. Poor Ventilation and/or Excessive Ambient Conditions 5. Excessive Oil in the Crankcase 6. Improper Oil Viscosity for the Ambient Temperature 7. Air Compressor is Running Excessively 1. Excessive Oil in the Crankcase. 2. Improper Oil Viscosity for the Ambient Temperature 2. Replace the intake filter and check for other restrictions in the intake system. 3. Inspect the breather cap for obstructions and clean if necessary. 4. Relocate the air compressor to an area where an ample supply of cool, clean, dry, and well-circulated air is available. 5. Drain down the compressor pump to the full mark on the oil level sight glass. 6. Refer to the Oil Lubrication section of Part II for the correct viscosity. 7. Perform a pump-up time test and a system consumption test. 1. Drain down the compressor pump to the full mark on the oil level sight glass. 2. Refer to the Oil Lubrication section of Part II for the correct viscosity. 3. Incorrect Pump Rotation 3. Check the arrow on the cooling fan shroud for correct rotation. If incorrect, reverse the motor rotation. 4. Crankcase Over 4. Replace cylinder and rings. Pressurized by Cylinder Ring Air Blow-By Installation and Service Manual for PureFlow Air Compressors 71
Alternator Troubleshooting Checklist Table 4.4: Alternator Troubleshooting Checklist (PureFlow AD Series Duplex Alternated Air Compressors Only) Trouble Probable Cause Suggested Remedy Neither Compressor Pump is Operating Both Compressor Pumps Running on Consecutive Starts Continued on next page... 1. Both Starter Overloads Tripped 2. Faulty Control Transformer 1. Press the RESET button/bar, and determine the cause of the overload. An input voltage less than the motor nameplate may increase the amp draw. Have a qualified electrician check the input voltage during startup, then proceed with the electrician's recommendations. Note: Both PE switch settings can be temporarily lowered equally by 10 to 20 PSI (70 to 140 kpa) to keep the air compressor running until the low input voltage can be corrected. 2. Check the control transformer for proper operation and replace if if necessary. 3. Blown Transformer Fuse 3. Inspect the fuse(s) and replace if necessary. 4. Blown Line Power Fuse 4. Inspect the fuse(s) and replace if necessary. 1. Pressure Setting of Lead Pressure Electric (PE) Switch is Below Setting of Lag PE Switch 1. Check the lead and lag PE switch settings and adjust to the correct settings if necessary. The lead PE switch should be set to cut-in at 70 PSIG (490 kpa) and cut-out at 90 PSIG (630 kpa). The lag PE switch should be set to cut-in at 60 PSIG (420 kpa) and cut-out at 80 PSIG (560 kpa). Note: The above cut-in and cutout settings are for normal operating conditions; adjusting the settings to a higher value may result in air compressor pump and/or motor damage, and may void the warranty. 72 Installation and Service Manual for PureFlow Air Compressors
Trouble (Cont.) Probable Cause Suggested Remedy Failure to Alternate 1. Alternator Selector Switch Set in Wrong Position 1. Move the selector switch to the AUTO/ALTERNATE position for normal alternated air compressor operation. 2. One Starter Overload Out 2. Press the RESET button/bar, determine the cause of the overload, and correct the problem. 3. Faulty Starter Assembly 3. Check the starter assembly for proper operation and repair or replace it if necessary. 4. Faulty Alternator Relay 4. Check the alternator relay for proper operation and replace it if necessary. Installation and Service Manual for PureFlow Air Compressors 73
74 Installation and Service Manual for PureFlow Air Compressors