Solaris Air Compressor - Service Manual
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Updated date
07 November 19
Title
Solaris Air Compressor - Service Manual
Keywords
Solaris, Air, Compressor, Service, Manual
Product Range
Other
Language
UK English
Company Brand
Peak Scientific
Extracted text
Corona
Compressed Air
Service Manual
2019 © Peak Scientific – Rev 6 – 07/11/2019
Corona CA Service Manual
Contents
Change History
3
How to use this Manual
3
Related Documents
3
Safety Notices
4
Symbols
4
Safety Notice to Users
4
Safely Isolated Condition
5
Technical Specifications
6
Environment
6
Generator Outlets
6
Electrical Requirements
6
General
6
Principle of Operation
7
System Description
7
Normal Operation
7
Service Requirements
8
Service Schedule
8
Product Overview
9
Electrical Panel Layout
10
Pressure switch overview
11
Air pressure switch settings
11
Compressor Contactor
12
Valve Relay
12
Compressor Inlet Filter Replacement
13
Duplex Filter Element Replacement
14
Compressor Replacement
15
Corona Compressed Air Pneumatic
Schematic
16
Corona Compressed Air Electrical Schematic
110V
17
Corona Compressed Air Electrical Schematic
230V
20
Trouble Shooting
Page 2
23
Corona CA Service Manual
Change History
Rev.
Comment
Name
Date
1
Update Pressure Switch Settings
Liam Couttie
25/04/2014
2
Content Update
Liam Couttie
27/01/2015
3
Electrical Panel Upgrade
Liam Couttie
12/02/2015
4
Component Upgrade
Liam Couttie
20/03/2018
5
Electrical Diagram Update
Liam Couttie
18/06/2019
6
Updates to Incorporate CSA Feedback
Liam Couttie
07/11/2019
How to use this Manual
This manual is intended for Field Service Engineers and technically competent
end users. It has been written as a reference document where you can skip to
the relevant information.
This manual does not cover all information that is included in other manuals.
Please see the Related Manuals section if you require further information.
Users of a hard copy version can refer to the contents page to find the relevant
information. Users of the soft copy version can you the hyperlinks from the
contents page as well as the hyperlinks between sections.
Related Documents
Document number
Manual name
Description
Describes:
UM-CoronaCompressedAir
Page 3
Corona Compressed Air
User Manual
•
Installation
•
User menu structure
•
Service requirements
Corona CA Service Manual
Safety Notices
Symbols
This manual uses the following symbols to highlight specific areas important to
the safe and proper use of the Generator
A WARNING notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause
personal injury or in the worst case death. Do not proceed beyond a WARNING notice
until the indicated conditions are fully understood or met.
A CAUTION notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause damage
to the Generator or the Application. Do not proceed beyond a CAUTION notice until
the indicated conditions are fully understood or met.
Caution, risk of electric shock. Ensure power to the Generator has been removed
before proceeding.
Safety Notice to Users
These instructions must be read thoroughly and understood
before installation and operation of your Peak Corona
Compressed Air Generator. Use of the Generator in a manner
not specified by Peak Scientific MAY impair the SAFETY
provided by the equipment.
When handling, operating or carrying out any maintenance,
personnel must employ safe engineering practices and observe
all relevant local health and safety requirements and
regulations. The attention of UK users is drawn to the Health
and Safety at Work Act 1974, and the Institute of Electrical
Engineers regulations.
Page 4
Corona CA Service Manual
Safely Isolated Condition
Definition: The unit is in a Safely Isolated Condition when it is disconnected
from its application, fully de-pressurised and isolated from the Electrical Supply.
Directions for isolating the Generator are shown below.
Failure to place the Generator in a safely isolated condition
when instructed to do so may lead to personal injury or injury
to others and even death.
Isolating the Generator:
a) Switch off the unit.
b) Unplug the unit from the mains supply and remove the power cord from
the rear of the unit.
c) Ensure the output pressure gauge read zero. (If gauge does not fall to
zero, loosen the outlet fitting slightly to allow trapped gas to escape.)
d) Ensure that tank pressure gauge located on electrical panel reads zero.
(If gauge does not fall to zero, close pressure regulator and loosen the
outlet fitting to allow trapped air to escape.)
e) Disconnect from the application.
Page 5
Corona CA Service Manual
Technical Specifications
Environment
Min/Max Operating Ambient Temperature
5°C - 35°C / 41°F - 95°F
Maximum Altitude
Maximum Relative Humidity
Min/Max Storage Temperature
2000 metres
70% Non-condensing
-20°C - 60°C / -4°F - 140°F
Generator Outlets
Max Flow Rate
Max Pressure
30 l/min
110 psi / 7.58 bar
Particles
<0.01µm
Phthalates
None
Suspended Liquids
None
Gas Outlets
1
Drain Outlets
1
Pressure Gauges
1
Electrical Requirements
Voltage
Frequency
Current
Input Connection Type
~220-240 / 208230VAC
23050/60
VAC ±10%
Hz
~100 / 100-115VAC
50/60 Hz
12x10x29
5.0
/ 5.2A
12x10x29
TBC
2.3-2.7 / 3.2A
0.17A
C14 Plug
Power Cord Type
TBCSocket to Local Connection
C13
Pollution Degree
2
Insulation Category
II
General
Generator Dimensions HxWxD
Generator Weight Kg (lbs)
Shipping crate dimensions HxWxD WxDxH
Shipping Weight Kg (lbs)
406 x 417 x 540 mm / 16 x 16.4 x 21.3”
41.5 (91.5)
21 (46.2)
60.5 x 79.0 x 58.2
/ 17.1 x 31.1 x 22.9”
26(57.3)
64 (141)
24 (53)
29(64)
Page 6
Corona CA Service Manual
Principle of Operation
System Description
Normal Operation
The Corona Compressed Air Generator is designed specifically to minimize
operator involvement. Given that the system is installed correctly and is
serviced in accordance with the specified maintenance recommendations (see
Service Requirements), it should simply be a matter of turning the generator on
when required.
The generator has been factory set to produce the required outlet pressure.
Flow from the generator is unrestricted internally but is instead controlled by
the consuming nitrogen generator. This ensures minimal pressure drops
between generators. It is therefore important to note that normal operation of
the air compressor system can only be achieved when it is connected to the
nitrogen generator. Unconnected it will not reach pressure.
Connected as required, the compressor will periodically stop to eject moisture
from its drain bowls. Other than during this time, the compressor will run
continuously when powered on.
Figure 1: System Outline
Page 7
Corona CA Service Manual
Service Requirements
Service Schedule
Service Interval
12 months
Component
Corona Compressed Air Generator
Annual Service Kit
Visit
Qty.
www.peakscientific.com/ordering
1
Table 1: Service schedule
** Compressors can be re-fitted as an alternative to replacement up to a
maximum of 3 times, this is a more cost effective solution, however a degree of
technical expertise is required and this can be time consuming. Please contact
your service provider for more information.
Page 8
Corona CA Service Manual
Product Overview
Cooling Fan
Re-Heat Coil
Compressor NRV
BPRV
Tank
Compressor
Fin Tube Cooler
Electrical Panel
Power Switch
Duplex Filter
Assembly
Dryer Membrane
IEC Power Inlet
Inlet Filter
Drain Valves
Silencer
Pressure Regulator
Page 9
Air Output and Drain
Corona CA Service Manual
Electrical Panel Layout
Page 10
Corona CA Service Manual
Pressure switch overview
Output B indicator
Output A indicator
Pressure display
Bar graph display
Edit button
Button “B”
Button “A”
NOTE: The pressure switch is for indication only. Calibration is not required.
Air pressure switch settings
Output
A
B
Mode
(default)
Set point (SP)
8.3
Hysteresis (HY)
1.6
Switching
NO (default)
(default)
9.5
0.7
NO (default)
Table 2: Air pressure switch settings
Page 11
Corona CA Service Manual
Compressor Contactor
Accessing the electrical panel without safely isolating the
Generator should only be carried out by trained service
personnel
The compressor contactors can be manually
activated by sliding the switch on the front of the
contactor to the left.
Valve Relay
Accessing the electrical panel without safely isolating the
Generator should only be carried out by trained service
personnel
Manual Activation of Relays
As a means of checking the valve operation, the relays can be manually
activated in the following manor:
Page 12
Corona CA Service Manual
Compressor Inlet Filter Replacement
Ensure that Generator is in Safely Isolated Condition
1.
Remove the filter lid by turning it clockwise
and pulling upwards
2. The filter element is fitted into the filter
lid. Pull it out and clean the inside of the
lid before fitting a replacement filter
element into the lid.
3. Clean the filter bowl (situated inside of
the unit) and then re-fit the lid (including
attached filter element) to the filter
housing, turning it anti-clockwise to lock
it in position.
Page 13
Corona CA Service Manual
Duplex Filter Element Replacement
Ensure that Generator is in Safely Isolated Condition
1.
Remove 6mm drain tubing
from push-fit stud situated
on under-side of both of the
bowls.
2. Remove the filter bowls by
turning the bowl anticlockwise
3. Remove the filter elements
by pulling downwards.
4. Fit replacement elements.
5. Re-fit the filter bowls.
Page 14
Corona CA Service Manual
Compressor Replacement
Ensure that Generator is in Safely Isolated Condition
Removing the Compressor
1.
Disconnect the quick release coupling on the compressor hose, located
behind the compressor. Un-clip safety latch on electrical plug and
disconnect electrical power supply plug.
2. Disconnect 10mm tubing from compressor intake 10mm push-fit fitting.
3. Remove 10mm compressor mount nut from all four corners of the
compressor footplate.
4. The compressor can now be lifted out.
Re-fitting the Compressor
1.
Lift the compressor into position and locate the compressor mounts
through their corresponding holes in the footplate.
2. Replace the 10mm compressor mount nuts, and tighten, ensuring
mounts are not twisted.
3. Reconnect the 10mm tubing from compressor intake to the push-fit
fitting.
4. Reconnect the compressor hose quick release coupling
5. Reconnect the electrical plug ensuring that the safety latch is clipped
securely back into position.
Page 15
Corona CA Service Manual
Corona Compressed Air Pneumatic Schematic
Page 16
Corona CA Service Manual
Corona Compressed Air Electrical Schematic 110V
Page 17
Corona CA Service Manual
Page 18
Corona CA Service Manual
Page 19
Corona CA Service Manual
Corona Compressed Air Electrical Schematic 230V
Page 20
Corona CA Service Manual
Page 21
Corona CA Service Manual
Page 22
Corona CA Service Manual
Trouble Shooting
Problem
The Generator will not switch on
and the power switch does not
illuminate.
The Generator will not switch on
but the power switch is
illuminated.
Compressor is running but
pressure is not building in system.
The mass spec is reporting low
pressure.
Yellow Service LED on front panel
is on constantly.
Page 23
Possible solution
•
Ensure power cord is plugged into the Generator
and that the power socket is turned on.
•
Check the fuse in the power cord plug.
•
Check for any disconnected terminals at
power socket connected at inside rear of unit.
•
Check for loose connections at inside of power switch
located on front of Generator.
•
Check for 230VAC going into DC power supply
•
Check for 24VDC coming from power supply
•
Check circuit breakers are ON – switched up
•
Contact Peak Scientific Technical Help.
•
Disconnect power cord from the rear of the
Generator and open LH panel:
•
Check that both circuit breakers are turned on
(switch in the up position). Reconnect power cord.
•
Check that both compressor electrical plugs are connected.
•
Check compressor contactors for loose wires.
•
Check PLC for loose wires.
•
Check pressure switch for loose wires.
•
Connect power cord and power up Generator and open LH
panel:
•
Check for 24V coming out of power supply.
•
Check pressure switch LED is lit.
•
Check PLC to ensure RUN light is illuminated.
•
Check continuity across compressor contactors
•
Contact Peak Scientific Technical Help.
•
Check drain outlet at rear of Generator is not
passing air.
•
Open the right hand panel and check if tank
pressure gauge is rising thus pressure being built in receiver
tanks.
•
Open right hand panel and check pressure regulator.
•
Check for leaks in system.
•
Contact Peak Scientific Technical Help.
•
Check pressure gauge is set to factory settings.
•
Check output flow from the Generator is set to factory
settings.
•
Check for leaks between receiver tanks and Generator
output.
•
Check for leaks between Generator output and Mass
Spectrometer.
•
Contact Peak Scientific Technical Help.
•
Compressor due for service.
•
Replace compressor – refer to Compressor Replacement OR
•
Refit compressor
Corona CA Service Manual
Yellow Service LED on front panel
is flashing.
Yellow Pressure LED in front panel
is flashing.
Page 24
•
Contact Peak Scientific Technical Help.
•
Compressor is overdue for service.
•
Replace compressor – refer to Compressor Replacement OR
•
•
Refit compressor
•
LOW pressure has been detected for a minimum of 30mins
•
The compressor has not cycled.
•
Ensure ambient temperatures are within specification.
•
Check for leaks between the Generator and application.
•
Contact Peak Scientific Technical Help.
Contact Peak Scientific Technical Help.
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