Air Techniques AERO100 User manual

AERO100 •AERO100M •AERO200 •AERO200M
OPERATING
INSTRUCTIONS
AERO200M

Air Techniques, Inc. Page 2
The present operating instructions give you all the necessary advice for the proper and safe handling of the oil-free
compressor stations.
Please read and carefully observe the operating instructions to avoid mistakes and dangerous situations.
The operating instructions are arranged as follows:
Chapter Planned purpose Target group
Chapter 1 Gives you safety advice and important
general information for the products.
Installer, operator, qualied per-
sonnel, user
Chapter 2
Contains detailed instructions and advice
for the transport, storage, installation and
the initial operation of the product.
Operator, installer and qualied
personnel
Chapter 3 Contains instruction and advice for safe
technical handling of the product. User
Chapter 4-6 Gives detailed instruction for cleaning,
maintenance and servicing the product. Operator, qualied personnel
Appendix In the appendix you will nd important
technical information. Qualied personnel
This operating manual is valid for oil-free compressor stations, hereinafter called product.
The operating manual is only valid so long as your product complies with the information described within.
These instructions contain all details required for the transport, installation, operation, shut-down and maintenance of
these products.
Therefore please read the operating instructions carefully prior to the rst operation, thus ensuring the safe and eco-
nomic application of the products.
When a fault occurs or maintenance is required, which is not covered by the operating manual, you should contact your
authorized distributor.
Therefore it is essential to hold the exact product description in readiness.
(see type plate at REF)
All service and maintenance work must be carried out by qualied personnel.
If service and maintenance work is neglected or carried out improperly, our warranty will be invalidated.
Should you have any problems understanding the operating instructions please contact your local Air Techniques rep-
resentative or distributor from which the unit was purchased.
Preface

Page 3Air Techniques, Inc.
CONTENT
1. Introduction and General Advice....................................................................................... 4
1.1 Symbol explanation and denition ........................................................................................ 4
1.1.1 Symbol explanation............................................................................................................... 4
1.1.2 Denitions ............................................................................................................................. 4
1.2 General safety advice ........................................................................................................... 4
1.3 Product description ............................................................................................................... 5
1.3.1 Agreed application ................................................................................................................ 5
1.3.2 Function description without drying installation.................................................................... 6
1.3.3 Function description with drying installation.......................................................................... 7
2. Transport, Storage, Initial Operation................................................................................. 8
2.1 Transport and Storage .......................................................................................................... 8
2.2 Transport and storage requirements..................................................................................... 8
2.3 Assembly advice and initial operation................................................................................... 8
2.3.1 Environmental conditions...................................................................................................... 8
2.3.2 Compressed air connection .................................................................................................. 9
2.3.3 Electrical installation.............................................................................................................. 9
2.3.4 Motor protection .................................................................................................................... 9
2.3.5 Circuit diagram..................................................................................................................... 10
2.4 Initial operation..................................................................................................................... 10
3. Operation ............................................................................................................................ 11
3.1 Switching on the product...................................................................................................... 11
3.2 Switching off the product...................................................................................................... 11
3.3 Switching on the product after a power supply interruption ................................................. 11
3.4 Pressure tank check............................................................................................................. 11
3.5 Pressure reducer.................................................................................................................. 12
3.5.1 Setting of the pressure reducer............................................................................................ 12
4. Maintenance ....................................................................................................................... 13
4.1 Maintenance, Cleaning ........................................................................................................ 13
4.2 Maintenance......................................................................................................................... 13
4.2.1 Drain condensate water from pressure tank ........................................................................ 13
4.2.2 Changing suction lters........................................................................................................ 14
4.2.3 Check safety valve function ................................................................................................. 14
4.2.4 Change of lter for membrane dryer .................................................................................... 15
4.3 Repairs................................................................................................................................. 15
5. Shutdown and disposal..................................................................................................... 15
6. Operating Instructions Vessel .......................................................................................... 16
Appendix
Appendix 1: Technical data...................................................................................................................... 17
Appendix 2: Trouble shooting .................................................................................................................. 18
Appendix 3: Spare Parts ......................................................................................................................... 19
Appendix 4: Contacts .............................................................................................................................. 22
Table of Contents

Air Techniques, Inc. Page 4
1. INTRODUCTION AND GENERAL ADVICE
1.1 Symbol explanation and denition
1.1.1 Symbol explanation
In the manual and on the product hand symbols and pictograms are used whose meaning you should memorize.
These symbols help you to understand the information in this manual quicker and make you aware of potential
danger or important advice.
Attention! Danger sign. It points out danger as well as
rules and bans to prevent personal and /or danger to
property.
Advice! Attention is brought to advise on the handling
and economic use of product.
Warning against electric energy! Your life could be in
danger. Make sure that all electrical work is carried out
by a qualied electrician.
Warning advice. The product can start without
warning!
On the product and in the operating instruction special information
signs and warning Symbols with following meaning are used:
Warning of hot surfaces! There is a danger of burns!
Observe especially that these surfaces may still be
hot after the product has been switched off. Work near
these surfaces only after they have cooled off.
1.1.2 Denitions
User, Operator: The responsible person who has the authorization to use the product. The user must have been
given instructions on the safe handling of the unit from the appropriate authority.
Operator Authority: Responsible for the safe installation, regular servicing and cleaning of the product.
Qualied personnel: Trained by the operating authority or by authorised Air Techniques personnel who are aware
of the dangers of the product and familiar with the technical aspects of the product. Qualied personnel are trained
to carry out service and repair on the product.
Product: General term used for oil-free compressor stations.
1.2 General safety advice
During use, care and maintenance of the product, the following fundamental safety measures must be observed for
the protection of the operator, maintenance and service engineers as well as the product:
During the development and manufacture of the product, the recognized regulations of the technical
aspects, as well as the recognized valid standards and guide-lines were taken into account and used.
In addition the product has been designed and constructed in such a way that endangerment through
the agreed use are minimized. Nonetheless we feel obliged to describe the following safety measures
so the remaining dangers can also be minimized.
Warning! When electrical equipment is being used, the basic safety precautions must be followed, to
prevent risk of re, electric shock and personal injury.
Therefore please read the manual prior to starting work. Keep this manual within reach for the engineer
and the operator. The information should be passed on to any successor.
Introduction and General Advice

Page 5Air Techniques, Inc.
During operation of the product the relevant laws and regulations for the place of deployment must be observed.
In the interest of safe operation the authorized operator and the supervisory personnel are responsible for
keeping within the regulations.
Check during all work on the product for possible dangers. All parts must be correctly tted and all requirements
fullled to ensure safe operation. Should the product be damaged in any way, the product should no longer be
used. The product should only be repaired by experts. Mark the defect clearly and pull out the mains plug, so that
until the repair is effected, no accidents or damage can occur through the defective product.
Take account of environmental inuences!
Do not operate the product in a wet or damp environment.
Do not use the power connection line for purposes it was not meant for. Do not pull the plug out of the socket by
the cable. Only pull the plug from the socket by pulling the plug casing. Protect the cable against heat, oil and
sharp edges.
In dangerous situations or during technical problems, separate the product at once from the
power supply (pull the plug).
Check regularly the power supply line and the casings of electrical components and if they are damaged, have
them repaired by a qualied electrician.
Check the electrical equipment for external damage before work starts. Check thoroughly whether lines or cables
are damaged. If there is damage, do not operate the product.
If there is damage, do not operate the product. Pull out mains plug!
For all maintenance and repair work the mains plug must be pulled out of the socket.
Attention! Work on electrical equipment must only be carried out by a qualied electrician.
Only original spare parts must be used. Otherwise there may be injury to the user.
Warning! The use of other spare parts and other accessories, as stated in this manual, can cause
personal injury. Only use spare parts permitted by the manufacture
Warning of hot surfaces! Do not touch hot surfaces. The surfaces of the machine can still be hot
after shutdown. Mind this especially at mobile compressor stations.
1.3 Product description
1.3.1 Agreed application
The product is intended for the compression of air.
The aspiration of uids, aggressive or explosive gases is forbidden! It will cause danger to
health and the possible danger of explosion or re!
The product is designed for operation in a dry, well ventilated room. Never expose the compressor station to rain.
The product should not operate in a damp or wet environment. In addition, operating near gases or ammable uids
is forbidden.
Introduction and General Advice

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1.3.2 Function description without drying installation
The product consists of a piston compressor, a pressure tank and control gear with operating and safety elements.
Via the suction lter (8) Figure 1a atmospheric air is aspirated. This air is compressed by the piston in the cylinder.
The inlet or outlet valve shuts off ow in one direction, so the compressed air is made to lead via the pressure hose
(7) through the check valve integrated in the manifold into the pressure tank (2).
The compressor aggregate (1) supplies compressed air until the set shut-off pressure of 7 bar is indicated in the
pressure switch (3) before switching off. The tank pressure is indicated by the pressure gauge (9). Pressure is re-
leased in the pressure hose by the integrated relief valve.
If compressed air is taken out by user, the tank pressure reduces. On reaching the switch-on pressure, the product
is automatically switched on again via the pressure switch. A safety valve (10) prevents the maximum permitted
tank pressure being exceeded
1 Compressor 5 Condensate solenoid 10 Safety valve
2 Pressure tank 7 Pressure hose 11 Vibration damper
3 Pressure switch 8 Suction lter 12 Capacitor
4 Starter solenoid 9 Pressure gauge
Figure 1a. AERO100 Key Components
Introduction and General Advice

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1 Compressor
2 Pressure tank
3 Pressure switch
4 Cooler
5 Membrane dryer
7 Pressure hose
8 Suction lter
9 Pressure gauge
10 Safety valve
11 Vibration damper
12 Capacitor
Figure 1b. AERO200M Key Components
1.3.3 Function description with drying installation
The product consists of a piston compressor aggregate, a pressure receiver, a control unit with control and safety
elements, a cooler and a membrane dryer.
Atmospheric air will be sucked in by the suction lter Figure 1b. This air will be compressed by the piston in the
cylinder. The inlet and outlet respectively close a ow direction, which leads the compressed air to the cooler (4)
and then the membrane dryer (5).
The hot and humidity saturated compressed air coming from the compressor aggregate ows into the cooler (4).
In the cooler the compressed air will be cooled down to only a few degrees C above the room temperature, hereby
condensing out water. 100 % saturated compressed air and condensate are separated from the cooler and ow
into the drain-valve. The condensate which is in the air will be separated by the sinter lter and accumulated in the
water collecting receiver. The automatic condensate drain valve blows off the water, level-controlled, periodically.
Thereafter the air will be directed to the membrane element. The air ows through the membrane bres thereby the
water molecules contained in the air diffuse through the membrane wall and accumulate outside of the bre. The
dried air ows now via the ne lter, the relief valve and the check valve to the receiver (2).
For regeneration a small portion of dried air will be directed via the purge air nozzle to the outside of the membrane
bre, absorbs the accumulated humidity and will be discharged to the ambient. This
regeneration is made continuously during operation. No standstill periods are necessary. The relief valve which
is built in in the upper part of the membrane makes sure that the membrane dryer reaches its nominal operation
value within the shortest possible time. The moisture indicator which is installed in the upper part of the membrane
is visible through the transparent upper part. In case of a failure of the dryer which causes an insufcient air drying,
there will be a color change from blue into pink.
The compressor aggregate (1) generates compressed air as long as the pressure switch (3) signalizes that the
adjusted shut-off pressure is reached. Now the machine shuts down. The pressure is indicated by the pressure
gauge. (9) The pressure hose will be depressurized by the integrated relief valve.
The tank pressure declines when taking out pressure for a consumer. On reaching the start-up-pressure the
compressor aggregate will be automatically restarted by the pressure switch. A safety valve (10) prevents that the
maximum permitted tank pressure is exceeded.
Introduction and General Advice

Air Techniques, Inc. Page 8
2. TRANSPORT, STORAGE, INITIAL OPERATION
2.1 Transport and Storage
The products are sent from the factory packaged in a transport carton. With this the equipment is safe against
transit damage. Always use the original packaging of the product as necessary. Transport the product in an upright
position. Do not pick up the unit by the membrane dryer or cooler assembly.
Protect the equipment during transport and storage against damp and extreme temperatures. Take
special care that the electrical equipment does not get damp or wet.
Only transport products depressurized! Remove air pressure from any tted pressure containers
and hoses prior to shipment.
Before transporting or storage, the condensate water in the tank must be drained completely (see chapter 4: main-
tenance and service). The products are delivered for immediate assembly. Products still in the original packing
can be stored in warm, dry and dust free rooms. If the products should be stored long term, e.g. as a replacement
product, it must be protected against dust and damp.
Keep packaging if at all possible.
Environmental rules regarding the disposal of the packaging must be observed and to assist this please note the
labels on the packaging.
2.2 Transport and storage requirements
Temperature: -25 °C to + 55 °C
Relative humidity: 10% to 90%
(without condensation).
2.3 Assembly advice and initial operation
The installation and initial operation must only be carried out by a specialist familiar with the handling of the product.
2.3.1 Environmental conditions
The product must only be installed and operated in dry, well ventilated and dust free rooms.
Take care when choosing the site for installation that the product is easily accessible for operating, cleaning and
maintenance. Especially the connection piece and the operational parts must be easily accessible.
The product should be installed on a level and solid surface. To reduce vibration the supplied vibration dampers
should be mounted. If the product is built into a machine or housing, it must be noted that the identication plate
is visible and readable, without having to dismantle the product. Also ensure that the connection clamps are easily
accessible when taking off or opening the housing.
Make sure that the suction sides of the air lter and the cooler are free of any obstructions. Verify
that the ventilation ribs of the product are not blocked and there is sufcient space from the side wall
distance (approximately 4 cm).
Make sure that the power line connection and the air lines are not kinked.
Room temperature must not fall below 5°C, otherwise problems with the operation of the product may occur.
The room temperature must not exceed 40°C. Room temperatures above 40°C will require additional ventilation.
Most suitable ambient temperatures are between 10 °C to 15 °C.
Approximately 70% of the products induced electrical energy is converted into heat and is given off
to the surrounding area.
The motor ventilator normally ensures an effective pressurized cooling of the product. To do this the air must be able
to ow unhindered. Ventilation openings must be large enough to allow this to happen. In unsuitable cases, e.g.
when the product is built-in an independent air cooling system might be required.
Transport, Storage, Initial Operation

Page 9Air Techniques, Inc.
2.3.2 Compressed air connection
The compressor stations are tted as standard with control gear, consisting of a pressure switch, pressure gauge,
safety valve, check valve and condensate drain.
The compressed air connection takes place at the pressure switch via a 0.635 cm ID thread. A quick coupling with
hose nozzle if not included in the scope of delivery, is available as an accessory. Fasten the pressure hose at the
hose nozzle with the help of a hose clamp.
Approximately 70% of the products induced electrical energy is converted into heat and is given off
to the surrounding area.
To prevent vibration transference it is advisable to install a exible pressure hose between the pressure switch and
user’s line. As a further accessory, a pressure reducer unit (see gure 4) can be connected.
2.3.3 Electrical installation
The connection to the mains voltage supply must only be carried out by a qualied electrician! (with
the exception of the ready to plug-in supplied stations for connection to the safety plug socket).
Observe closely the local regulations for power undertakings. The connection must only be carried out on a power
supply with correctly installed protective conductor. Equipment with safety contact plug must be connected to a
safety contact socket.
The product should only be connected to a safety plug socket, DE1 with correctly installed
protective conductor. If this is not tted the plug has to be exchanged by a qualied electri-
cian according to the customary loading system.
If the equipment is hard wired to the power supply a switch arrangement must be arranged with at least a 3 mm wide
contact opening (e.g. heavy duty switch).
If the product is connected to the power supply with the aid of a plug, the socket must be easily accessible for safety
reasons, so that in the event of danger the equipment can be isolated from the power supply. Please make sure
that the connection cable does not run across the machine. The hot surface of the compressor station could dam-
age the insulation of the cable.
Prior to making the electrical connection, check the mains voltage and frequency. They should correspond with the
specications on the model label.
Please observe that the relevant circuit is protected by the correct fuse.
2.3.4 Motor protection
Attention! After cooling off, products with temperature switch start again automatically!
If the motor locks for example on starting against pressure or a short circuit in the motor windings,
the current consumption can become so high that a tted temperature switch might get damaged.
This can only be controlled in a safe way by the installation of an external overload protector.
When using outside of normal operating conditions the installation of an overcurrent switch is absolutely
essential!
Should the installation procedures be disregarded or carried out incorrectly the warrantee will be
invalidated.
Motor protection for 1-stage AC-current motors (230 V AC):
The motors are equipped with a thermal protection switch to prevent overheating of the motor windings. In the case
of too high an ambient temperature, the thermal protection switch shuts down the unit by cutting off the operating
current.
Transport, Storage, Initial Operation

Air Techniques, Inc. Page 10
2.3.5 Circuit diagram
The connection to the mains voltage supply must only be carried out by a qualied electrician! (with
the exception of the ready to plug-in supplied stations for connection to the safety plug socket).
Figure 2. Circuit diagram for one-phase alternating current
2.4 Initial operation
• Make sure the product pressure switch is off.
• Check the connections are correct to the compressed air components.
• Make sure the machine is correctly connected to the power supply.
• Check that the air lter is correctly tted.
• Switch the compressor station on at the pressure switch.
• Listen during operation for unusual noises.
• Check the switch-off pressure of the product.
• Check the switch-on pressure of the station by releasing the pressure.
• Check the safety valve for correct function.
Advice! Write down the correct operation in the equipment log book.
Transport, Storage, Initial Operation

Page 11Air Techniques, Inc.
3. OPERATION
The operation of the product is quite simple and is mostly automatic.
Please always remember that the product has hot surfaces. There is a danger of burns if
the surface is touched.
In the case of danger, separate the machine from the mains (pull the mains plug).
3.1 Switching on the product
The product is switched on at the pressure switch to setting “I” - “ON”. The product starts and the pressure tank
lls up. When reaching the switch-off pressure, the product turns off automatically.
Please watch closely that the maximum permitted operating pressure is not exceeded. The permitted operating
pressure is marked on the tted pressure gauge with a red line.
If the permitted operating pressure is exceeded, you must switch the product off and separate it from the mains
supply (pull out mains plug). Inform the responsible qualied staff.
3.2 Switching off the product
Switch off the product to setting “0” - “OFF”.
3.3 Switching on the product after a power supply interruption
Advice: The product will not start against pressure. Therefore the products are tted either with
an expansion tank (1) and a mechanical vent valve (2) Figure 3 or with an automatic starter
valve.
Switching on machines with expansion tank and mechanical vent valve and machines with drying installation:
1. Switch off product at pressure switch.
2. Restart the machine at the pressure switch, after the air has been blown-off of the starting volume (this will take
approximately 5 seconds).
Machines with automatic starter valve:
If the product is tted with an electric starter relief valve, the normally closed valve provides for the pressure free
starting of the product.
3.4 Pressure tank check
According to the regulations pressure receivers up to 25 l, corresponding to the pressure tank contents p x l < 200,
are allocated to group 1 of paragraph 8 classication and not subject to recurrent tests pursuant to paragraph 10.
The pressure tank conforms to the EU guidelines 87/404 EEC.
Operation

Air Techniques, Inc. Page 12
3.5 Pressure reducer
The pressure reducer regulates the tank pressure (primary pressure) to the required working pressure (secondary
pressure). With the additional secondary valve the increase of pressure in the user line when not in use is pre-
vented. The pressure reducer is mounted at the pressure switch (0.635 cm thread).
3.5.1 Setting of the pressure reducer
By slightly lifting the regulator knob (1) the constant pressure can be altered. Increase (+) pressure by rotating the
regulator knob clockwise or decrease (-) pressure by turning the regulator knob counterclockwise.
When the pressure is set, push the regulator knob downwards and let it engage. The set pressure is now xed. It
can be read on the pressure gauge (2).
Operation
Figure 3. Start Against Pressure
1 Starting Sphere
2 Mech. Ventilation Valve
3 Safety Valve
4 Mech. Condensate Screw
Figure 4. Pressure Reducer
1 Regulator Knob
2 Pressure Gauge
1
2
1
2
3
4

Page 13Air Techniques, Inc.
4. MAINTENANCE
Chapter 4 contains all the details which are needed for carrying out the necessary maintenance procedures. If faults
occur or a repair is needed which is not dealt with in this chapter, contact our engineer immediately.
4.1 Maintenance, Cleaning
For the proper and safe function of the product, regular cleaning and rotational maintenance is required.
When faults appear or a repair is needed, inform an authorised engineer. Before any cleaning work is carried out
the product must be switched off and separated from the mains power supply (pull out mains plug).
The product has hot surfaces. Please let the product cool down before starting any cleaning work.
Clean the surfaces of the product with a dust free cloth. Take special care to keep the ventilation openings of the
crankcase chamber and the cylinder head free from dust and dirt.
4.2 Maintenance
The stated maintenance intervals are guidelines for normal working conditions. If there are extreme working conditions
(e.g. long work times under full load, high ambient temperature, very dusty atmosphere, high humidity) the maintenance
intervals will need to be shorter. When carrying out maintenance work, the product must be disconnected from the
power supply.
The product has hot surfaces. Please let the product cool down before starting any cleaning work.
4.2.1 Drain condensate water from pressure tank
Mechanical condensate drainage:
Drain the condensate from the compressed air tank once a week.
Automatic condensate drainage:
Should the product be tted with an automatic condensate drain valve, it will empty the compressed air tank on its
own at regular intervals.
For compressor types with drying installation the condensate will be separated automatically by the drying
installation.
Table 4-1. Maintenance Intervals
Required Maintenance Chapter Time interval
Drain water condensate 4.2.1 Weekly (only with mechanical condensate drain),
for machines with drying installation check 2 x
yearly, drain when necessary
Change suction lter 4.2.2 Yearly
Check safety valve 4.2.3 Half yearly
Inspect carbon brushes 4.2.4 Half yearly
Change lter of membrane dryer 4.2.5 Yearly
Maintenance

Air Techniques, Inc. Page 14
4.2.2 Changing suction lters
The suction lter (example Figure 5) needs to be changed
only once a year, if the surrounding conditions are clean.
If the atmosphere is excessively dusty the suction lter
must be changed more often.
Dirty lters decrease the delivery output
and the lifespan of your product!
Prior to changing lters, switch product
off and pull out the mains plug!
To change the air lter, proceed as follows:
1. Turn the lter housing (1) clockwise. The bayonet lock
opens and the lter can be pulled off.
2. Exchange the air lter insert.
3. Turn the lter housing counterclockwise until the bayonet
lock is closed again.
Attention! Never clean lter inserts with
petrol or oil!
4.2.3 Check safety valve function
The safety valve (see Figure 7) is set in the factory at the
tank pressure, tested and lead sealed according to the
current regulations. Under no circumstance should
the seal be removed or the safety valve be reset. Any
tampering of the seal will invalidate all liability.
The safety valve is to be function tested semi annually.
With working pressure in the tank, turn the valve lifter (1)
counterclockwise until blown off compressed air is heard.
Turn the valve lter again in a clockwise direction until it
is closed.
Figure 6. Filter
Figure 7. Safety Valve 1 Knob
Figure 8. Replace Sintered Filter
Maintenance
Figure 5. Suction lter, Example Bayonet Lock
Suction Filter

Page 15Air Techniques, Inc.
4.2.4 Change of lter for membrane dryer
Change the Sintered and ne lter in a clean ambient environment according to Figures 8 and 9 once a year.
4.3 Repairs
Attention! Repair work can only be carried out by qualied and authorized specialists.
Attention! Only use the spare parts and accessories permitted by the manufacturer. The
use of spare parts and accessories other than the ones stated in the manual could cause
injury to you.
Attention! Before starting repair work, the compressor station must be separated from the
power supply (pull out the plug) and all lines must be depressurized.
If the necessary spare parts are not available the compressor station must be sent to the manufacturer for repair.
Figure 9. Change of Fine or Sterile Filter
Note: Membrane Dryer is shipped with a ne lter.
A sterile lter is an option.
5 Shutdown and Disposal
If the product is not in operation over a longer period, it is recommended to drain off the condensation from the
pressure receiver until the switch-off pressure is achieved. Thereafter open the drain plug until the condensation
stops leaking. Afterwards cut-off the machine from the pressure switch, close the condensation drainage and pull
out mains plug, depressurize the machine and pressure hoses.
The disposal has to be carried out in an appropriate way. The national laws and stipulations have to be followed.
For further questions please contact Air Techniques.
Shutdown and Disposal
Maintenance

Air Techniques, Inc. Page 16
6 Vessel Operations Instructions
Pressure receivers from company Behälter-Werk Burgau GmbH are used in these products.
Type 316034 / 5430-200-51
PS 8 bar V 25l CE 0036
Tmax 100°C Tmin -10°C Ph 12 bar
EN 286-1:19 F
Serial number and year of fabrication (look at the nameplate)
Application: Pressure vessel for stationary installations
Medium: Air / Nitrogen
Corrosion allowance: c=0 mm
The pressure vessel is only to be used for the application specied above in accordance with the
technical specications. Safety reasons prohibit any other applications.
The pressure vessel has been manufactured according to the EEC regulation 87/404 as a single
component without safety equipment for the above mentioned application. The layout was mainly
effected for a permanent load by internal pressure.
Before commissioning, the vessel is to be provided with the required safety equipment such as
manometer, overpressure control devices, and safety valve, etc. These components are not part
of our supply. No welding or heat treatment of any kind is permitted to those vessel walls which are
exposed to pressure.
It must be ensured that the internal pressure will not permanently exceed the maxi-mum working
pressure PS stipulated on the vessel nameplate; however, it may momentarily do so by up to 10%.
Suitable measures are to be taken to prevent both vibrating stress and corrosion.
The pressure vessel is to be installed in a way that guarantees its safety in use (e.g. no rigid connection
with the oor, the machine frame or oscillation damper).
Taking into consideration all components of the equipment , the instructions, issued by the supplier of
the pressure vessel, must include:
a) instructions for discharging the condensate
b) information referring to the maintenance of the pressure vessel in order to guarantee is safety in use.
The supplier must also decide whether the pressure vessel, once equipped and ready for operation,
is to be subjected to an acceptance test before operation. The supplier/operator is obliged to observe
the laws and decrees regarding the operation of the pressure vessel valid in the respective country.
The vessel is resistant to fatigue strength at a pressure variation range of 2 bar
(10% PS)
Remarks: The condensation drain must be performed under interior pressure according to the
operating instruction of Air Techniques.
Vessel Operating Instructions

Page 17Air Techniques, Inc.
Appendix 1: Technical Data
See type plate of the compressors or stations. Details as per documentation attached to the shipment.
Advice: The product will not start against pressure. Therefore the products are tted either with
an expansion tank (1) and a mechanical vent valve (2) Figure 3 or with an automatic starter
valve.
Since our products are subject to a process of continuous improvement, the technical specication may have
changed. If you propose to base your planning on these Directions for Use, please contact us beforehand for
details of current data and dimensions.
Specications AirStar AERO100/100M* AirStar AERO200/200M*
Dimensions
(H x W x D) (cm) 68 x 64 x 49 68 x 64 x 49
Weight (kgs) 43 54
Delivery rate at Pe 0 bar (110 l/min) 0 bar (195 l/min)
Delivery rate at Pe 5 bar (60 l/min) 5 bar (120 l/min)
Nominal Pressure PN 8 bar (max. operating pressure) 8 bar (max. operating pressure)
Safety pressure PS 10 bar (max. pressure permitted) 10 bar (max. pressure permitted)
Noise level at nominal
pressure PN 66 dB (A) 69 dB (A)
Motor voltage 230 V, 50/60 Hz 230 V, 50 Hz
Motor power 920/970 W 1370 W
Current consumption 4.3 / 4.9 (A) 6.3 (A)
Motor protection temperature switch temperature switch
Duration of operation 100% continuous running at an
ambient temperature up to 40°C
100% continuous running at an
ambient temperature up to 40°C
Receiver Capacity 25 L 25 L

Air Techniques, Inc. Page 18
Appendix 2: Troubleshooting
The following description for fault nding is only meant for authorized personnel. Repairs must only
be carried out by authorized personnel.
Fault Possible Cause Remedy
Compressor does
not start
• no mains voltage • check mains voltage
• low voltage • check mains voltage
• capacitor defective • check capacitor, if necessary change it
• pressure switch in (0) position • set to the ON (I) position
• Motor defective • Change product
• Protector in motor has switched off • Allow compressor to cool
Attention, compressor will switch on
again automatically!
1. High ambient temp. 1. make better cooling arrangement
2. Mechanically sluggish 2. factory repair
3. Pressure in the line 3. Ventilate air intake
• Over current switch has switched off • State cause
• Suction lter dirty • Replace lter
Decrease in delivery
performance
• Lines, hoses or connections leaking • Check lines, hoses and connections (if
possible, seal, otherwise replace
• Suction lter very dirty • Change lter, if necessary t lter with
greater surface area
• Gasket defective • Replace
• Cup seal leaking • Remedy
1. Worn or pitted 1. Exchange cup seal, cylinder and
washers (spare part kit)
2. Very dirty 2. Change lter
3. Too high ambient temperature 3. Arrange for better ventilation
4. Unsuitable substances aspirated 4. Only handle suitable medium
• Lamellar valve defective • Change lamellar and if necessary
valve plate and seals
Compressor station
too noisy
• Bearing damaged • Factory repair
• Vibrations transferred to the housing • Fit suitable vibration damper (see
parts list)
• Vibration damper defective • Fit new vibration dampers
Water drops out of the
air consumer
• Condensate in the pressure receiver.
Drying installation defective
• Exchange of drying installation
• Station without drying installation • Drain the condensate regularly (see
par. 4.2.1)
Pressure dew point is
not suitable
• Purge air nozzle too small or too big • Change the purge air nozzle
Moisture indicator at
the membrane dryer
is pink.
• The product had not been used over a
longer period.
• On operation of the product the mois-
ture indicator will regenerate itself and
change the colour back into blue.
• During operation there is a malfunction
of the dryer, insufcient air drying.
• Exchange of drying installation.

Page 19Air Techniques, Inc.
Appendix 3: Spare Parts
Item No. Description AERO100/100M AERO200/200M
1 Compressor 87611 87612
2 Pressure Switch 87613 87614
3 Pressure Switch Cover 87615
4 Pressure Gauge 0-16 Bar 87616
5 Air Filter Complete C1154
6 Air Filter Element C1154-1
7 Vibration Dampner Set 87617 87618
8 Capacitor 87619 87620
9 Safety Relief Valve 87621
10 Tank Drain Valve 87622
11 Starting Sphere C1188 AERO100 and AERO200 ONLY
12 Non return valve (receiver) 87623 AERO100M and AERO200M ONLY
12 Non return valve (receiver) 87624 AERO100 and AERO200 ONLY
13 Tank Rubber Mount 87625
14 Unloader valve 87626
AERO100M and AERO200M ONLY
15 Membrane Dryer 86760
16 Cooler Assembly 230V 87160
17 Fine Filter
(shipped with Membrane Dryer) 87366
18 Sterile Filter
(optional ne lter replacement) 87627
19 Sintered Filter 87367
20 Nozzle Kit 87628

Air Techniques, Inc. Page 20
Figure 10. AERO100 and AERO200 Parts Location (AERO100 shown)
1
3
4
2
5
13
7
12 11
14
9
8
8
10
6
4
Appendix 3: Spare Parts