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AIRWELL PUMPS PTY LTD
DESIGNED AND MANUFACTURED IN AUSTRALIA
A.B.N. 46 009 323 871
The contents and specifications herein
are subject to change without notice.
All rights reserved.
November 2004
Airwell Pumps Pty Ltd
30 Harris Road
Malaga 6090
Western Australia.
Telephone: (61) 08 9209 3355
Facsimile: (61) 08 9209 2666
Email: [email protected]
http://www.airwellpumps.com
Air Compressor Manual (Version 3)
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3
Index
Index ................................................................................................................................................3
Introduction to Air Compressors for use with Airwell systems ...............................................5
Air Compressor Drawing – ACAW3(K8) ....................................................................................8
Spare Parts List – ACAW3(K8) ...................................................................................................9
Air Compressor Drawing – ACAW5(K17) ...............................................................................10
Spare Parts List – ACAW5(K17) ...............................................................................................11
Air Compressor Drawing – ACAW10(K25) .............................................................................12
Spare Parts List – ACAW10(K25) ............................................................................................13
Connection Drawing – 240VAC Unloader Valve ....................................................................14
Installation instructions for 240VAC Unloader Valves ...........................................................15
Connection Drawing – Unloader Valve for 140VSD Only .....................................................16
Installation instructions for Controller Driven Unloader Valve ..............................................17
Variable Speed Drive Settings ..................................................................................................18
Variable Speed Drive - Wiring Diagram .................................................................................. 22
Counterweight/Pulley Assembly – ACAW3(K8) & ACAW5(K17) ....................................... 23
Counterweight/Pulley Assembly - ACAW10(K25)..........................................................24 Performance Figures – ACAW10(K25) Air Compressor ...................................................... 25
Performance Details – Air Compressors ACAW3(K8) & ACAW5(K17) ............................ 26
Compressor Power Usage Graph ........................................................................................... 27
Air Production Chart................................................................................................................... 28
Air Production per KWh Chart .................................................................................................. 29
Maintenance Details .................................................................................................................. 31
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5
Introduction to Air Compressors for use with Airwell systems In today’s world air compressors are probable one of the most common and diverse items of equipment, used by a very wide variety of domestic, commercial and industrial utilities. As with all things mechanical the quality and resulting performance and reliability is also very diverse.
The air compressor that is chosen to supply an Airwell Pumping system is very literally the heart of the system. Great care is taken to make the Airwell pump as reliable as possible; many units continue to operate for years longer than many thought possible in especially harsh conditions. This reputation for high reliability can very quickly and easily be lost through the selection of a poor quality or badly matched air compressor. The Airwell system is demanding of compressors however, by following a few simple rules, relatively inexpensive compressors can be made to achieve considerable service life.
The factors that influence the long life and efficiency are as follows:-
The Brand
The brand of an air compressor is important because of differences in manufacturing quality and support offered through manufacturers and dealer networks.
In the experience of Airwell pumps Pty Ltd, some of the worst service and very unreasonable repair costs have come from some of the biggest brand names. It also follows that the plethora of cheap imported units manufactured in developing countries are better suited to the DIY and light industry market rather than running constantly on an Airwell pump at high pressure.
The brand that we have come to recommend for a wide variety of reasons is the “Pilot” compressor. This Sydney (Australia) based company predominately uses the Italian “Chinook” compressor pump. It is easy for the uninformed to not make a distinction between this Italian equipment and similar looking pumps that currently come from much cheaper countries of manufacture. This would be a big mistake.
The level of communication and cooperation between “Pilot” and “Airwell pumps” over many years has resulted in this company manufacturing three units that are specifically modified to the particular needs of Airwell pumps.
The Style
The size range in air delivery that we require does not give much scope in regard to the style or methodology of compressing air. It is too little air for screw type options etc. to be viable and too harsh for most small close coupled types. Belt driven reciprocating piston compressors are the simplest and most cost effective at this time for single Airwell pump operation.
Where there are many Airwell pumps to be operated from one compressor, the use of screw type compressors comes into play.
Operating speed (RPM) and duty cycle
This is an area were we find that Airwell rubs up against conventional wisdom in the air compressor field. The standard line coming from most suppliers of reciprocating compressors is that they are not supposed to run full time, (not 100% duty cycle rated). They would suggest that a much larger compressor be selected. This is designed to cause the unit to cycle ON and OFF. This is said to give the compressor pump time to cool off. We reject this approach completely and would offer another solution.
If a compressor pump is de-rated sufficiently in RPM, the heat generated is reduced proportionally. Further to this the air compressor will only be producing the air volume and pressure that is required to operate an Airwell pump at that particular water pumping head and flow.
It is often the case that when a compressor is slowed down and is not over producing air, it may well be continuously running at say 500KPa rather than turning off at 1000KPa and back on again at 800KPa. We can assure you that running a piston compressor continuously at lower pressure will result in far less wear and consume less energy than the same unit, producing the same amount of air while cycling between 800 and 1000KPa.
6
If you are in any doubt about this try an experiment. Take your car and travel on a 500 kilometre journey, maintaining a constant speed of 100 kilometres an hour. It will take you about 5 hours. Now on the way home try this instead. Drive your car at 200kilometres an hour for 10 minutes and spend the next 10 minutes parked under a shady tree. Repeat this driving style all the way home. This journey will also take about 5 hours, (baring delays with traffic police). Your fuel consumption and vehicle wear and tear will be dramatically worse with this stop, start method.
By reducing the RPM of good quality reciprocating compressor pumps and changing the oil regularly with the correct grade of oil, we have come to expect excellent performance.
Some examples have achieved 7 years plus of 24 hour, 365 day running, at 800KPa before requiring a $300 rebuild ACAW10(K25).
Variable speed drives (VSD)
There are a number of reasons why we have come to use VSD’s on the majority of our air compressor units, with the first of these being the regrettable lack of three phase power in most rural areas. A three phase motor is a far more reliable and cheaper motor inherently than a single phase motor.
A VSD of the style that we use, can be plugged into a 15 amp single phase outlet and can produce three phase at any Hz to drive a compressor motor at variable speed.
The variable speed and therefore variable compressed air output is very useful in matching the air compressor to the Airwell job.
Side benefits of VSD’s are that you can achieve full ramp up starting, which completely eliminates the start up spike in the motor power consumption normally associated with motor starting. The unit also provides excellent motor protection from over current and under voltage.
Finally, the VSD only requires a start signal from the compressor pressure switch to start and stop the motor. This means that a very simple inexpensive pressure switch is required.
Single and two stage compressors
As you will see from the attached graphs and tables there are marked advantages in using two stage compressors ACAW10(K25) over single stage units ACAW3(K8) & ACAW5(K17). The term two stage refers to the number of times the same air is compressed to achieve the desired pressure. A single stage compressor, regardless of how many cylinders it may have, draws the air in and achieves the desired pressure in one push. A two stage compressor on the other hand must have at least two cylinders and typically one of these cylinders is of bigger diameter than the other. The air is drawn into the larger diameter cylinder and pushed across to the other smaller cylinder. Here it is compressed again to a higher pressure and delivered to the air receiver.
So why would you go to so much more trouble to compress it twice. To understand this you need to remember a bit of high school physics. Notably Boyle’s Law, Charles law and Ideal Gas Law, the relationship between Pressure, Volume, and Temperature.
P1 x V1 = P2 x V2
T1 T2
This law states a number of things. Firstly it simply says that if you start of with a body of gas at a starting pressure which for our purposes will be atmospheric pressure (101.2 KPa or 14.69 psi), if you halve the volume you will double the pressure that you started with, 2 to 1 ratio. If you have an 8 to 1 compression ratio you will simply achieve an 8 fold increase in pressure etc.
As a consequence of this compression, all the heat energy that was contained in the larger mass of gas is now contained or concentrated within a smaller space.
At a compression ratio of 8 to 1 the compressed gas temperature will be 8 times hotter than the starting temperature.
An 8 to 1 compression ratio would take atmospheric pressure from 14.69 psi or 101.2 KPa to 117.52 psi or 809.6 KPa actual pressure. When read on a standard pressure gauge (that starts at 1 atmosphere), this pressure would read 102.83 psig or 708.4 KPag.
7
You can see that even at 102.83 psig the air will get very hot when compressed at 8 to 1 ratio.
A two stage compressor has the advantage that it need only operate at a much lower compression ratio to achieve the same end pressure, and therefore will run much cooler, more efficiently and with less maintenance.
As you will be able to see from the attached tables and graphs, two stage compressors will always be more efficient than single stage under all test conditions. However the greatest benefits of efficiency and reliability are gained when the operating pressure is higher. There are exceptions, however we (Airwell pumps) tend to specify only two stage units were the operating pressure exceeds 500 KPa continuous.
Oil type and oil change intervals
A side benefit of de-rating or reducing the working RPM of a reciprocating compressor is the much reduced oil carry over, resulting in reduced oil level in the compressor pump. If an air compressor pump runs out or runs low in oil, it will quickly degrade. As the RPM is reduced we recommend that the compressor be slightly over filled but not to more than to the top of the sight glass. The RPM of any compressor pump should never be run below 500 RPM as it will suffer from reduced splash lubrication. Pilot Compressors and Airwell pumps have developed a simple and very useful Auto top up device that when fitted to a compressor will virtually eliminate the possibility of dry running.
When deciding how frequently the oil should be changed there are a number of things to consider, however one thing will always remain true, more often is better than less. In extreme cases where the compressor runs non stop, 24hours seven days, the oil should be changed each month. If it were to operate for 12 hours in a day this can be extended to two months. For best life even at low duty cycle the change period should not exceed 4 months as the oil will become degraded by moisture in any event. Oil changing is made a lot easier with the additional purchase of the oil drain extension kit.
The type of oil used is important. Standard motor oils should not be used mainly because they tend to carbon up the valves in the head and contaminate the tank check valve. Castrol Aircol PD68 or an equivalent is preferred. This is a mineral oil.
Synthetic oils provide very great advantages in reciprocating air compressors over mineral oils and are preferred and recommended by some compressor manufacturers. Some will even extend the standard warranty from 1 to 2 years if used. It is also suggested that by using synthetic oils, the oil change interval can be extended to 12 months. Though Airwell pumps acknowledge that the oil change interval could be lengthened with synthetic oil use, we feel that though the oil may not break down it never the less will become contaminated and require changing anyway.
Synthetic oils are very good and further reduce the possibility of carbon build-up in the cylinder head, however they are very expensive and this price difference does create buyer resistance to synthetic oils.
Drive pulley weights and cast iron fly wheels
An unfortunate consequence of reducing the RPM of an air compressor is that as the RPM is reduced, the load on the motor and drive belt becomes more lumpy. To rectify this problem we add more weight to the drive pulley and replace the alloy compressor fly wheel with a heavier cast iron one. The result is to reduce the kWh power draw considerably and improve the operating smoothness, especially at low RPM. Drive belt life is also improved.
Both these measures are standard equipment on compressors ordered from “Pilot compressors” as “Airwell specials”.
It is true that by adding this weight, the motor starting load is increased, however we generally set up an air compressor on an Airwell system so that it does not cycle on and off much anyway. The increased starting load is of no consequence to the Pilot ACAW10(K25) model fitted with a VSD as the VSD achieves full ramp up to speed as a feature.
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ACAW3(K8) Air Compressor Drawing
9
Spare Parts List – ACAW3(K8)
Item Part Nos Description Qty 1 ACAW3(K8)B Pilot Bare Pump – K8 (n.b. standard aluminium flywheel) 1 2 ACAW3(K8)M Electric Motor – 1.65kw, 240v 1 3 E202 Pressure Switch – 240v 1 4 AC160 Air Filter 1 5 AC331 Counterweight/Pulley 1 7 AC333 Bush Asy – 19mm 1 9 AC321 V-Belt – A46 1
10 AC330 Cast Iron Pulley – 310PD 1 11 AC155 Drain Kit – Oil 1 12 AC150 Drain Kit – Water 1
Performance Details – ACAW3(K8)
Motor Revs - 2820 RPM Drive Pulley - 71A PD Pump Pulley - 310 PD Pump Revs - 678 RPM Compressor Output - 1.11 L/Sec/FAD ( @ 6Bar ) 2.35 CFM/FAD
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ACAW5(K17) Air Compressor Drawing
11
Spare Parts List – ACAW5(K17)
Item Part Nos Description Qty 1 ACAW5(K17)B Pilot Bare Pump – K17 (n.b. standard aluminium flywheel) 1 2 ACAW5(K17)M Electric Motor – 1.65kw, 240v 1 3 E202 Pressure Switch – 240v 1 4 AC160 Air Filter 1 5 AC331 Counterweight/Pulley 1 7 AC333 Bush Asy – 19mm 1 9 AC323 V-Belt – A52 1 10 AC330 Cast Iron Pulley – 310PD 1 11 AC155 Drain Kit – Oil 1 12 AC150 Drain Kit – Water 1
Performance Details – ACAW5(K17)
Motor Revs - 2820 RPM Drive Pulley - 71A PD Pump Pulley - 310 PD Pump Revs - 678 RPM Compressor Output - 2.48 L/Sec/FAD ( @ 6 Bar ) 5.23 CFM/FAD
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ACAW10(K25)VVVF Air Compressor Drawing
13
Spare Parts List – ACAW10(K25)VVVF
Item Part Nos Description Qty 1 ACAW10(K25)B Pilot Bare Pump – K25 (n.b. standard aluminium flywheel) 1 2 ACAW10(K25)M Electric Motor – 2.2kw, 415v 1 3 E202 Pressure Switch – 240v 1 E200 Pressure Switch – Low Hysteresis 1 E203 Pressure Switch – 415v 1
4 AC170 Air Filter 1 5 AC331 Counterweight/Pulley 1 7 AC334 Bush – 24mm 1 9 AC332 V-Belt – A51 1 10 AC330 Cast Iron Pulley – 310PD 1 11 AC155 Drain Kit – Oil 1 12 AC150 Drain Kit – Water 1 13 AC265 Solenoid Unloader Valve Kit 1 14 AC307 Variable Speed Drive – Lenze SMVector 1
Performance Details – ACAW10(K25)VVVF
Motor Revs - 2840 RPM Drive Pulley - 80A PD Pump Pulley - 310 PD Pump Revs - 517 to 885 RPM Compressor Output - 2.97 to 4.94 L/Sec/FAD ( @ 6 Bar ) 6.27 to 10.42 CFM/FAD
14
Connection Drawing – 240VAC Unloader Valve
15
Installation instructions for 240VAC Unloader Valves
Suits any air compressor Application
The purpose of this valve is to prevent the compressor from trying to start while still under load (under pressure).
Most compressors are fitted with an unloading system that is operated by the electric pressure switch. In the event of a power failure the pressure switch will not have toggled over and therefore will not have operated the standard unloading valve.
If the power is out for an extended period of time the compressor system pressure will probably have fallen away anyway.
The addition of this extra valve may therefore be required in areas were power failures are common.
Installation
The valve is installed by cutting into the nylon unloader tube that connects the electric pressure switch to the compressor tank check valve and then plumbing this valve in line.
It is best to cut this nylon tube closer to the pressure switch end to avoid excess heat. You will notice that there are TWO ports of the valve that have fittings screwed into them. One of these is marked P and the other is marked A. The fitting marked A should be connected to the tube running to the compressor tank check valve and the fitting marked P should be connected to the tube running to the existing unloader valve under the pressure switch. It should be noted that the fittings supplied with the new valve are PUSH FIT style. Simply pushing the cut end of the nylon tube into the fitting makes connection. If it is require that you remove this tube you must push the plastic ring around the fitting IN as you pull the tube OUT. Plug the lead provided into a convenient GPO. The valve will remain energised while power is available. If power fails for any reason the valve will vent system pressure to the atmosphere and unload the compressor for easy starting when power resumes.
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Connection Drawing – Unloader Valve for 140VSD Only
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17
Installation instructions for Controller Driven Unloader Valve
ONLY FOR COMPRESSOR UNITS POWERED BY TYPE 140 VARIABLE SPEED DRIVES
Application
The purpose of this valve is to prevent the compressor from trying to start while still under load (under pressure).
Most compressors are fitted with an unloading system that is operated by the electric pressure switch. In the event of a power failure the pressure switch will not have toggled over and therefore will not have operated the standard unloading valve.
If the power is out for an extended period of time the compressor system pressure will probably have fallen away anyway.
The addition of this extra valve may therefore be required in areas were power failures are common.
Installation
The valve is installed by cutting into the nylon unloader tube that connects the electric pressure switch to the compressor tank check valve and then plumbing this valve in line.
It is best to cut this nylon tube closer to the pressure switch end to avoid excess heat. You will notice that there are TWO ports of the valve that have fittings screwed into them. One of these is marked P and the other is marked A. The fitting marked A should be connected to the tube running to the compressor tank check valve and the fitting marked P should be connected to the tube running to the existing unloader valve under the pressure switch. It should be noted that the fittings supplied with the new valve are PUSH FIT style. Simply pushing the cut end of the nylon tube into the fitting makes connection. (Cut with sharp blade). If it is require that you remove this tube you must push the plastic ring around the fitting IN as you pull the tube OUT. Plug the lead provided into the matching power socket under the Variable Speed Drive. The valve will open and release pressure until the compressor has reached the speed selected on the VSD. If power fails for any reason the valve will vent system pressure to the atmosphere and unload the compressor for easy starting when power resumes. Low Differential Pressure Switch In situations were the air compressor is to be operated at very high pressure it may be necessary to fit a low differential pressure switch. This will allow the switch on pressure to be increased without raising the switch off pressure any more than necessary. These low differential switches generally have a poor reliability unloader valve if they have one fitted at all. Therefore this is an ideal use for a solenoid valve unloader. As there would be no pressure switch unloader to connect to, it is necessary to plug the valve port marked P with a 1/8” BSP threaded plug.
18
Variable Speed Drive Settings
To set or change the parameters you must first be in Local (LOC) mode.
Press and hold down the MENU and ENTER buttons simultaneously to change from Remote to Local (and back). The REM or LOC status will be displayed on the left side of the screen.
Press the MENU button to display the first of the parameter groups. This may be -99- etc. Press ENTER once to go to specific parameters, 9902 etc. By using the UP and DOWN buttons you can go to any specific parameter address. Once at an address (like 9902) you can momentarily view the setting in this address by pressing the ENTER. If this setting is to be changed it is necessary to hold down the ENTER button for three seconds. The status of this parameter will now be permanently displayed and can be changed by using the UP and DOWN buttons. After you are happy with a setting, you can save the setting by pressing ENTER again. The UP and DOWN buttons can now take you to other parameters. After all parameters are set and saved, press the MENU button twice until 0.0Hz is displayed.
To complete the process, hold down the MENU and ENTER buttons for three seconds to return to the REMOTE (REM).
Settings for ABB type 100 VSD’s Parameter Value Description
0201 240V Nominal Operating Voltage 0204 2840 RPM Nominal Motor Speed 0206 60Hz Max Frequency 0208 2 Direction Lock 0303 0.5 Acceleration Time 0403 35 Minimum Run Hertz 0404 60 Maximum Run Hertz 0504 0 Start Inhibit 0505 3 Auto Reset
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Settings for ABB type 140 VSD’s
Parameter Value Description
9902 1 ABB Standard Configuration 9908 2840 Motor Speed - Optional 1001 1 Specify Input 1 as Start/Stop 1003 1 Operates in Forward direction only 1103 0* Speed reference* 0=Panel, 1=Potentiometer 1104 35 Minimum Operating Speed - Hertz 1105 60 Maximum Operating Speed - Hertz 1201 0 Disable Constant Speed group 1401 11 Unload Heads when not up to speed 1601 1 Run Enable = Input 1 1608 1 Display ALL alarms 2007 35 Minimum Operating Speed - Hertz 2008 60 Maximum Operating Speed - Hertz 2101 3 Start drive with Torque Boost 2107 0 Allow auto restart after fault 2201 0 Set Acc Time 1 as default 2202 0.5 Ramp Up Time in Seconds 3001 0 Disable AI<Min function 3101 5 Number of Auto Resets after Fault 3102 300 Time to complete Auto Reset sequence 3103 60 Interval between Auto Reset attempts 3104 1 Enable auto reset Over current 3105 1 Enable auto reset Over voltage 3106 1 Enable auto reset Under voltage
Notes: Entering the motor speed is not a specific requirement
The ABB141 drive allows a few more operating parameters to be viewed. To access these, press the MENU button, and then use the arrows to select LG. The LG should look like this: = LG =. If it looks like this - LG -, hold the ENTER key for a few seconds, and it will change.
The following useful parameters can then be viewed Parameter Value Description
0102 0-
9999rpm Motor Speed in rpm 0103 0-300Hz Drive output frequency in Hertz 0104 A Drive current in Amps 0106 KW Power in KW 0107 0-679V DC bus Voltage 0109 0-480V Drive output voltage in V 0110 0-150°C Drive temperature
0115 0-
9999KWh KWh counter 0117 Status of digital input from the pressure switch Should equal 0001
when below cut-off pressure, and 0000 when up to pressure 0128 0-22 Last fault 0129 0-22 Previous fault 0130 0-22 Oldest fault
20
Settings for Delta type VFD-B
Parameter Value Description 00-00 6 Identity code 00-01 7.0 Rated current 00-07 ??? Password decode (Contact Airwell Pumps) 00-08 ??? Password code input (Contact Airwell Pumps) 00-10 1 Reserved 01-03 35.00 Mid-point freq Hz 01-04 160.0 Mid-point volt V 01-05 1.00 Min output freq Hz 01-08 58 Lower bound freq % 01-09 0.5 Acceleration time 1 sec 01-10 3.0 Deceleration time 1 sec 02-01 2 1st CMD source 02-02 1 Stop method 02-03 09 PWM Carrier frequency 02-04 1 Motor DIR ctrl 02-05 1 2/3 wire control 02-08 1 UP/DOWN freq mod 02-09 0.10 UP/DOWN rate 02-15 38.34 Keypad freq CMD 03-00 2 MF output relay 03-12 3 Fan control 06-03 2 Over-torque mode 06-04 140 Over-torque level % 06-05 15.0 Over-torque time sec 06-08 6 Present fault 07-02 10.0 Torque comp 07-04 2 Poles of motor 08-04 1 Power loss mode 08-05 5.0 Power loss time sec 08-06 5.0 B.B. time sec 08-14 10 Auto restart
The above parameters are factory set and password protected. They should not require adjustment, however if found to be corrupted please contact Airwell Pumps head office.
21
Settings for Lenze 2.2kW type SMVector VSD’s
Parameter Value Description P199 4 Programme selection – Reset to 50 Hz default settings P100 01 Start control source – Terminal strip P102 35 Minimum frequency - Hz P103 60 Maximum frequency - Hz P104 1.0 Acceleration time 1 - Sec P105 2.0 Deceleration time 1 - Sec P110 03 Start method – Auto restart P136 34 Preset speed # 6 - Hz P140 07 Relay output – Above preset speed # 6 P168 1.5 Fixed boost - %
Settings for Lenze 7.5kW type SMVector VSD’s
Parameter Value Description P199 4 Programme selection – Reset to 50 Hz default settings P100 01 Start control source – Terminal strip P102 35 Minimum frequency - Hz P103 60 Maximum frequency - Hz P104 2.0 Acceleration time 1 - Sec P105 3.0 Deceleration time 1 - Sec P110 03 Start method – Auto restart P136 34 Preset speed # 6 - Hz P140 07 Relay output – Above preset speed # 6 P168 1.5 Fixed boost - %
The above parameters are factory set and password protected. They should not require adjustment, however if found to be corrupted please contact Airwell Pumps head office.
22
Variable Speed Drive - Wiring Diagram
TO
PO
WE
R S
UP
PLY
TO
SO
LE
NO
IDU
NLO
AD
ER
VA
LV
E
KIT
IF
SU
PP
LIE
D
VA
RIA
BLE
SP
EE
DD
RIV
E
RE
PO
SIT
ION
LIN
KS
IN V
ER
TIC
AL D
ELT
AP
OS
ITIO
N
4
DE
TA
IL ’B
’
DE
TA
IL ’A
’
FO
R W
IRIN
GR
EF
ER
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IL ’B
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OR
WIR
ING
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FE
R T
O D
ET
AIL
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2
3
14
YE
LL
OW
/GR
EE
N
BLU
EB
RO
WN
BLA
CK
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CO
MP
RE
SS
OR
TO
TA
L W
EIG
HT
75K
g
23
Counterweight/Pulley Assembly ACAW3 (K8) & ACAW5 (K17)
24
Counterweight/Pulley Assembly ACAW10 (K25)
Receiver tank capacity = 55.51L
Power Cost - Cents per kW/H $0.15
HZ KPA kW/hours Revs L/Sec/FAD CFM/FAD L/Sec per kW/h
CFM per kW/h
Cost per hour
60 100 1.469 885 5.69 12.00 3.869 8.164 $0.22
200 1.727 885 5.38 11.35 3.113 6.568 $0.26
300 1.967 885 5.13 10.83 2.609 5.504 $0.30
400 2.169 885 5.06 10.67 2.331 4.919 $0.33
500 2.353 885 5.00 10.54 2.124 4.482 $0.35
600 2.535 885 4.94 10.42 1.949 4.112 $0.38
700 2.667 885 4.88 10.30 1.830 3.861 $0.40
800 2.802 885 4.85 10.23 1.730 3.651 $0.42
900 2.927 885 4.82 10.16 1.645 3.472 $0.44
1000 3.033 885 4.79 10.10 1.579 3.332 $0.45
50 100 1.125 742 4.87 10.28 4.329 9.134 $0.17
200 1.309 742 4.55 9.60 3.474 7.331 $0.20
300 1.471 742 4.31 9.10 2.932 6.185 $0.22
400 1.618 742 4.24 8.94 2.620 5.527 $0.24
500 1.764 742 4.18 8.82 2.370 5.000 $0.26
600 1.910 742 4.17 8.81 2.185 4.611 $0.29
700 2.019 742 4.16 8.78 2.062 4.351 $0.30
800 2.153 742 4.14 8.73 1.921 4.054 $0.32
900 2.264 742 4.11 8.68 1.817 3.833 $0.34
1000 2.353 742 4.09 8.63 1.739 3.668 $0.35
40 100 0.935 594 4.08 8.61 4.364 9.209 $0.14
200 1.036 594 3.62 7.64 3.497 7.379 $0.16
300 1.143 594 3.46 7.31 3.032 6.397 $0.17
400 1.252 594 3.44 7.26 2.749 5.799 $0.19
500 1.349 594 3.42 7.21 2.535 5.348 $0.20
600 1.446 594 3.37 7.12 2.334 4.924 $0.22
700 1.542 594 3.34 7.05 2.166 4.571 $0.23
800 1.614 594 3.26 6.88 2.019 4.260 $0.24
900 1.686 594 3.23 6.83 1.918 4.048 $0.25
1000 1.760 594 3.22 6.80 1.833 3.867 $0.26
35 100 0.803 517 3.57 7.53 4.447 9.383 $0.12
200 0.925 517 3.25 6.86 3.511 7.407 $0.14
300 1.016 517 3.12 6.59 3.073 6.485 $0.15
400 1.108 517 3.08 6.50 2.781 5.867 $0.17
500 1.200 517 3.02 6.37 2.517 5.311 $0.18
600 1.286 517 2.97 6.27 2.313 4.880 $0.19
700 1.352 517 2.93 6.19 2.170 4.578 $0.20
800 1.400 517 2.89 6.09 2.063 4.352 $0.21
900 1.455 517 2.84 6.00 1.954 4.124 $0.22
1000 1.490 517 2.78 5.87 1.867 3.939 $0.22
25
Performance Details – ACAW(K25)VVVF
ACAW10(K25) Compressor-VVVF Drive
Cast Iron Fly Wheel
Receiver tank capacity = 55.51L
Power Cost - Cents per kW/H $0.15
HZ KPA kW/hours Revs L/Sec/FAD CFM/FAD L/Sec per kW/h CFM per kW/h
Cost per hour
60 100 1.469 885 5.69 12.00 3.869 8.164 $0.22
200 1.727 885 5.38 11.35 3.113 6.568 $0.26
300 1.967 885 5.13 10.83 2.609 5.504 $0.30
400 2.169 885 5.06 10.67 2.331 4.919 $0.33
500 2.353 885 5.00 10.54 2.124 4.482 $0.35
600 2.535 885 4.94 10.42 1.949 4.112 $0.38
700 2.667 885 4.88 10.30 1.830 3.861 $0.40
800 2.802 885 4.85 10.23 1.730 3.651 $0.42
900 2.927 885 4.82 10.16 1.645 3.472 $0.44
1000 3.033 885 4.79 10.10 1.579 3.332 $0.45
50 100 1.125 742 4.87 10.28 4.329 9.134 $0.17
200 1.309 742 4.55 9.60 3.474 7.331 $0.20
300 1.471 742 4.31 9.10 2.932 6.185 $0.22
400 1.618 742 4.24 8.94 2.620 5.527 $0.24
500 1.764 742 4.18 8.82 2.370 5.000 $0.26
600 1.910 742 4.17 8.81 2.185 4.611 $0.29
700 2.019 742 4.16 8.78 2.062 4.351 $0.30
800 2.153 742 4.14 8.73 1.921 4.054 $0.32
900 2.264 742 4.11 8.68 1.817 3.833 $0.34
1000 2.353 742 4.09 8.63 1.739 3.668 $0.35
40 100 0.935 594 4.08 8.61 4.364 9.209 $0.14
200 1.036 594 3.62 7.64 3.497 7.379 $0.16
300 1.143 594 3.46 7.31 3.032 6.397 $0.17
400 1.252 594 3.44 7.26 2.749 5.799 $0.19
500 1.349 594 3.42 7.21 2.535 5.348 $0.20
600 1.446 594 3.37 7.12 2.334 4.924 $0.22
700 1.542 594 3.34 7.05 2.166 4.571 $0.23
800 1.614 594 3.26 6.88 2.019 4.260 $0.24
900 1.686 594 3.23 6.83 1.918 4.048 $0.25
1000 1.760 594 3.22 6.80 1.833 3.867 $0.26
35 100 0.803 517 3.57 7.53 4.447 9.383 $0.12
200 0.925 517 3.25 6.86 3.511 7.407 $0.14
300 1.016 517 3.12 6.59 3.073 6.485 $0.15
400 1.108 517 3.08 6.50 2.781 5.867 $0.17
500 1.200 517 3.02 6.37 2.517 5.311 $0.18
600 1.286 517 2.97 6.27 2.313 4.880 $0.19
700 1.352 517 2.93 6.19 2.170 4.578 $0.20
800 1.400 517 2.89 6.09 2.063 4.352 $0.21
900 1.455 517 2.84 6.00 1.954 4.124 $0.22
1000 1.490 517 2.78 5.87 1.867 3.939 $0.22
26
Performance Details – ACAW3(K8) & ACW5(K17) Compressors
ACAWA(K17) Compressor
Cast Iron Fly Wheel
Receiver tank capacity = 55.51L
Power Cost - Cents per kW/H $0.15
50HZ KPA kW/hours Revs L/Sec/FAD CFM/FAD L/Sec per kW/h CFM per kW/h
Cost per hour
100 1.183 678 3.44 7.26 2.909 6.138 $0.18
200 1.226 678 3.08 6.51 2.516 5.309 $0.18
300 1.303 678 2.86 6.03 2.193 4.627 $0.20
400 1.381 678 2.75 5.81 1.994 4.207 $0.21
500 1.431 678 2.64 5.57 1.846 3.894 $0.21
600 1.479 678 2.48 5.23 1.676 3.537 $0.22
700 1.522 678 2.37 5.00 1.557 3.286 $0.23
800 1.563 678 2.27 4.79 1.452 3.063 $0.23
900 1.593 678 2.16 4.55 1.354 2.856 $0.24
1000 1.630 678 2.07 4.37 1.272 2.683 $0.24
ACAW3(K8) Compressor
Cast Iron Fly Wheel
Receiver tank capacity = 46.06L
Power Cost - Cents per kW/H $0.15
50HZ KPA kW/hours Revs L/Sec/FAD CFM/FAD L/Sec per kW/h CFM per kW/h
Cost per hour
100 0.701 678 1.55 3.27 2.211 4.664 $0.11
200 0.750 678 1.32 2.79 1.766 3.725 $0.11
300 0.799 678 1.21 2.55 1.509 3.185 $0.12
400 0.842 678 1.14 2.41 1.357 2.864 $0.13
500 0.872 678 1.15 2.42 1.314 2.772 $0.13
600 0.896 678 1.11 2.35 1.242 2.622 $0.13
700 0.914 678 1.07 2.25 1.169 2.467 $0.14
800 0.927 678 1.01 2.13 1.090 2.300 $0.14
900 0.936 678 0.95 2.00 1.013 2.138 $0.14
1000 0.942 678 0.87 1.83 0.922 1.945 $0.14
27
Compressor Power Usage Graph
28
Air Production Chart
29
Air Production per KWh Chart
30
31
Maintenance Details
Warning
Important Notice
Your Air Compressor has been de-rated (slowed down) to enable it to be run for extended periods of time. However, there are a few important things to remember over and above the Pilot documentation
supplied with your compressor to give your air compressor longevity.
You must keep the oil level in the sight glass to ¾ full.
We recommend that the oil should be changed every month unless the compressor only gets intermittent use. Remember that it is working much harder than a
normal workshop compressor
The air filter should be checked every two months and replaced when dirty.
Water should be drained from the air receiver at least
weekly, more regularly during humid conditions.
