Compressor Troubleshooting

This article will go over the safety precautions that you need to consider when using the Compressor 50L.

Due to the nature of the compressor, there are a number of risks that need to be assessed before and during usage. These are listed in more detail inside your manual. Here is a summation:

TABLE OF CONTENTS

• Proper Usage
• Risk of explosion
• Wearing correct safety gear
• Risk of injury

Proper Usage

• There is only one purpose for this machine - to produce compressed air for pneumatic tools.

Risk of explosion

• Never use the machine in a poorly ventilated area, and never in conjunction with dusts, acids, vapours or flammable gases.
• Only operate the compressor at an ambient temperature of at least +5 °C and no more than +40 °C. Starting the motor at temperatures below +5 °C poses a risk due to stiffness. In an enclosed working environment, ambient temperature should be no more than +25 °C.
• Keep flammable substances away from the machine.
• Do not spray water on the machine.
• Do not smoke near the machine.
• Do not light a naked flame near the machine.

Wearing correct safety gear

• Please wear goggles, good gloves and sturdy, tight-fitting clothing.
• Ear noise protection (eg. muffs).
• A mask is crucial if you are using the compressor for spray-painting.

Risk of injury

• Do not separate connections when the machine is in a pressurised state.
• Do not use the machine if there are signs of damage, rust, deformations (including welds, holes and modifications).
• Always de-pressurise the tank when transporting it.
• Switch the On/Off switch (pressure monitor) to the “OFF 0” position once the compressor has been switched off.
• Do not repair lines which have worn or are damaged - replace them, instead.
• Make sure that you only use pneumatic lines for compressed air that are suitable for the maximum pressure corresponding to the compressor.
• Use a compressed air hose with a hose safety catch if you are working with pressures of 7 bar or more.
• Danger of burns: some parts of the compressor may get hot, please avoid touching them.

This article will cover the process of preparing and setting up the compressor.

TABLE OF CONTENTS

• Oil Check
• Physical Check & Correct Placement
• Electrical Checks

Checks

There are a few things you must check first before starting up the compressor:

Oil Check:

• Always keep the compressor in an upright position to prevent oil from leaking.
• Before each use, make sure that there is enough oil in the compressor (it is supplied with oil when you receive the machine).
• Insert the oil plug - remove the transport cap from oil fill opening, and screw the plug into this.

Physical Check & Correct Placement:

• The wheels & supporting feet must be securely fitted.
• Mount the two air filters. Make sure they are securely threaded.
• Make sure that all the individual parts are present and fitted on to the compressor. Check manual for full list of parts.
• Place the compressor on a level, stable surface. Ensure that it cannot move.
• Do not place it on any edges.
• Make sure that it is not leaning against any walls. (Keep 1m distance)
• Make sure vents & valves are not blocked.
• Make sure the surrounding environment is dry and has clean air - not wet.

Electrical Checks:

• Do not use long feed lines or cable drums.
• Operate the compressor with a residual current device (RCD) with a maximum release current of no more than 30 mA. Use of a residual current device (RCD) reduces the risk of electric shock.
• When the compressor is starting, a brief voltage drop may occur, particularly if the mains quality is poor. These drops can affect other devices (e.g. lights may flicker). For grid impedance Z max < 0.322 Ω, such disruptions cannot be expected. Please contact your local energy utility for more information.

You are now ready to start the machine. Please go to the next step, 'starting the machine'

This article will go through the process in which you start up the compressor.

Starting the Compressor

Please do the following:

1. Make sure that the mains voltage corresponds to the electrical data on the rating plate. The permissible variance amounts to no more than 5 %.
2. Make sure that the On/Off switch (3) is set to the “OFF 0” position (see Fig. G). 
3. Make sure that the drain cock (10) for condensed water is closed (see Fig. A above). 
4. Check the oil level at the viewing window of the oil drain plug (13) and, if necessary, add oil. 
5. Connect the mains plug to a properly installed socket with earthing contact. 
6. Connect a pneumatic tool to one of the two quick couplings (14 / 16) so that it audibly locks into place (see Fig. A above). The adjustable control pressure can be determined on the left quick coupling and the uncontrolled tank pressure can be determined on the right quick coupling. 
7. Set the On/Off switch to the “ON 1” position by pulling it out slightly (see Fig. G). The compressor has now been switched on and is starting up.
8. Turn the pressure regulator (15) (see Fig. A): • clockwise to increase the control pressure, • anticlockwise to decrease the control pressure. You can read the set control pressure on the control pressure gauge (17).
9. You can read the pressure of the air contained in the compressed air tank (8) on the tank pressure gauge (18).
10. The tank pressure is not controlled, that is, it cannot be adjusted. 
11. Push the On/Off switch down so that it is set to the “OFF 0” position to switch the compressor off. 
12. If you no longer wish to use the compressor, pull the mains plug out of the socket. 
13. Vent the compressor via the connected pneumatic tool. 
14. Take the pneumatic tool off of the compressor by slightly pushing the quick coupling back and pulling the pneumatic tool off (see Fig. A). 
15. Let the compressor cool off completely. 
16. Clean the compressor.

This article covers the checks you can take if you aren't having power and if it isn't set up correctly,

1. Please check that the power cable is correctly plugged into the socket.
2. Please check the the mains cable is not damaged.
3. If the cable is damaged it will need to be replaced by a specialist workshop or by a qualified specialist staff.
4. The cable for this machine is not available for purchase, as it is not supplied by the manufacturer.
5. Cutting through the power cable is not covered under the warranty as it is classed as user error.

This article will cover the soft fixes for pressure issues you may face with your compressor.

TABLE OF CONTENTS

• 1. Lack of pressure
• 2. Pressure builds up, but no pneumatic output to the tools
• 3. Compressor does not stop running

1. Lack of pressure:

If the pressure does not build up correctly, this could be a sign that there is a leak somewhere in the system. 

• Check all the gaskets to see if they are in the right condition. If there is a broken gasket, it will need replacing.
• Check the drain cock to see if it is secure.

2. Pressure builds up, but no pneumatic output to the tools:

• Check the hose connections to see if there's a leak. Run soapy water through the hoses to see where the leaks are. Replace if necessary.
• OR Quick coupling may be leaking - this needs to be replaced, if so.
• OR Pressure regulator may be too low, so it may need to be opened up more.

3. Compressor does not stop running:

If the maximum pressure has been reached, and the safety valve automatically activates, it could be that the compressor is defective. There is nothing you can do to repair this.

This article will cover the procedure of adding/changing the oil of your compressor.

TABLE OF CONTENTS

• Checking the Oil Level
• Draining the Oil
• Adding Oil

Unsuitable oil or an insufficient or excessive amount of oil in the compressor could damage it.

• Before each use, check the oil level and, if applicable, add oil or drain off excess oil.
• Use multi-grade oils SAE 10W40/15W40.
• Perform a complete oil change no later than after 100 operating hours or 6 months.

Note: Used oil that ends up in the environment or the sewer system will pollute the environment.

• Only dispose of used oil as hazardous waste in accordance with valid local guidelines.

Use synthetic SAE 10W40 oil for operation at an ambient temperature of +5 °C to +40 °C. Synthetic oil has the advantage that its characteristics remain unchanged at different temperatures, e.g. in the summer or winter.

Checking the Oil Level

•  Always check the oil level before you use the compressor.
• Check the oil level at the viewing window of the oil drain plug: The optimal oil level is between the “max.” mark and the “min.” mark (see figure below)

Draining the Oil

• This compressor is shipped with the synthetic oil SAE 10W40. Completely replace the oil after the first 100 hours of operation.
• To open the oil drain plug, you will need an AF 24 open-ended spanner (not included in the package contents).

1. Make sure that the On/Off switch is set to the “OFF 0” position 
2. Before draining the oil, pull the mains plug out of the socket to disconnect the compressor from the power supply.
3. Let the compressor cool off completely.
4. Vent the compressor using the connected pneumatic tool.
5. Have a collecting container ready to collect the old oil.
6. Use the open-ended spanner to loosen the oil drain plug (see figure above, in the centre of the motor)
7. If necessary, tip the compressor slightly and let the oil drain completely into the collecting container.
8. Screw the oil drain plug back onto the compressor and use the open-ended spanner to tighten it again.
9. Add new oil as described below.

Adding Oil

1. Make sure that the On/Off switch is set to the “OFF 0”position 
2. Before adding oil, pull the mains plug out of the socket to disconnect the compressor from the power supply.
3. Let the compressor cool off completely.
4. Vent the compressor via the connected pneumatic tool.
5. Screw the oil plug anticlockwise out of the threading of the oil fill opening. (See figure below)
6. Add enough oil so that the oil level is between the “max.” and “min.” mark. (See figure above)
7. Then screw the oil plug clockwise into the threading of the oil fill opening. (See figure below)