THORLABS PTA011 User manual

AIR COMPRESSOR
Model Number PTA011 and PTA511

THORLABS
About the Company
Thorlabs has been an active member of the Photonics community for over 15 years.
We strive to be the ultimate resource for the photonics community-a place to find the
products you need to enable your experiments, as well as the information you need to get
your application working.
Thorlabs designs, develops, and manufactures building blocks for the photonics industry
including equipment for opto-mechanics, motion control, nano-positioning, alignment,
optical components, laser diodes, tunable lasers and vibration isolation systems. In
addition to core photonics building blocks, we now provide system level solutions
including complete OCT and imaging systems.
Trademarks
The Thorlabs device is a registered
trademark of Thorlabs Inc.
Revision History
Issue No. Date Summary
1 150401 Initial Issue
2 170801 New format
3 031202 CN 3102
4 231109 Reformat

1
Contents
INTRODUCTION ........................................................................................... 2
Safety Precautions ................................................................................ 2
INSTALLATION ............................................................................................ 3
Siting ...................................................................................................... 3
Electrical Connections ........................................................................... 3
Preparation ............................................................................................4
Operation ...............................................................................................5
Maintenance .......................................................................................... 7
TROUBLESHOOTING .................................................................................. 9
PUMP WIRING DETAILS ........................................................................... 11

2
Chapter 1
Introduction
This handbook contains all the information necessary to install and operate the
compressor. Read the safety information below before using the equipment, and
carefully heed all cautionary notes. If you have any questions or comments about this
manual please call your local sales or service office or contact the factory at
[phone] and ask for Customer Service.
Safety Precautions
Warning. An instruction which draws attention to the risk of injury or death.
Caution. An instruction which draws attention to the risks of damage to the product,
process or surroundings.
Note. Clarification of an instruction or additional information.
What you must do:
• Read this manual before using your compressor.
• Ensure the compressor has been correctly installed, electrically connected and piped in
by a suitably qualified person.
• Ensure the compressor is kept upright at all times.
What you must not do:
• Do not attempt any maintenance on the compressor until it has been isolated from the
power supply.
• Do not attempt any work on the compressor until the air receiver and pipe work systems
are depressurized.
• Compressed air is dangerous and can prove fatal. Avoid any bodily contact with
compressed air.
• During operation the motor will become hot to the touch. Avoid contact to prevent burns.
At no time must the oil temperature be allowed to exceed 100°C.
• Never tamper with the pressure relief valve.
• Never change the oil when the compressor is still warm. Take necessary precautions to
avoid oil contact with skin and eys.

3
Chapter 2
Installation
2.1 Siting
Caution. When choosing the site, observe the following precautions:
• Site the compressor on a level surface of sufficient load bearing capacity.
• Choose a dry, well ventilated, dust free area, with a cool ambient temperature (35°C
Maximum).
• Avoid damp or humid conditions.
• Ensure sufficient free space to allow access for maintenance.
• To avoid overheating problems, do not box-in the compressor.
• If sited in a closed room, ensure adequate ventilation. Do not allow hot air to re circulate.
• If sited outdoors, ensure provision of adequate protection from the weather.
• Intake air must be free from dirt, coarse solids, abrasive particles and gaseous impurities.
2.2 Electrical Connections
The compressor operates from a normal domestic power supply and is supplied with
cable which conforms to IEC227 and IEC245.
Caution. If a Residual Circuit Breaker (RCB) is used, it must have a minimum rating of
30mA.

4
Installation
2.3 Preparation
The compressor is shipped without oil. Before use you must fill the motor to the
correct level as follows.
1) Remove the oil filler plug from the motor housing (see Fig. 2.1).
Warning. Although the oil used in the compressor does not contain any hazardous
substances, care should be taken to avoid contact with the skin.
Cautions.
• During item (2), use only ISO 32 Fully Synthetic Compressor Oil.
• Do not overfill the reservoir. Damage to the oil seals could occur if the level indicated on
the sight glass is exceeded.
2) Fill the housing with oil until the level is aligned with the mark on the sight glass
(approx 500cc).
3) Refit the oil filler plug, taking care not to overtighten.
Fig. 2.1 Rear view
Oil Filler Plug
Oil Level Sight Glass Control Box
Capacitor
Pressure Relief Valve
Air Filter Housing

5
2.4 Operation
Warning.
• After prolonged use, the outer casing of the compressor becomes very hot. Do not touch
the compressor casing.
• Compressed air is dangerous if misused and can prove fatal. Avoid all bodily contact with
compressed air.
2.4.1 Starting/Stopping
Plug the compressor into a mains power outlet socket of the correct voltage and fitted
with a 13 A fuse.
The compressor ON/OFF button is located on top of the pressure switch housing –
see Fig. 2.2. Pull the switch up to turn on the compressor. When switched on, the
compressor runs until the maximum working pressure is reached and than
automatically switches off. As air is used, the pressure drops until the minimum
operating pressure is reached, at which point the compressor automatically switches
on.
Caution. The pressure switch is set at the factory and should not be adjusted.
2.4.2 Component Identification
Fig. 2.2 Front View
Key
1 Pressure switch
2 On/off valve
3 Outlet pressure adjuster
4 Filter/regulator unit
5 outlet pressure gauge
6 Delivery pipe
7 Tank pressure gauge
8 Air Tank
9 Non-return valve
10 Drain valve and tube
11 ON/OFF Switch
12 Pressure relief valve
13 Control Box
14 Capacitor
1
23
10
12
9
11
8
7
6
5
4
14
13

6
Installation
2.4.3 Setting the Outlet Pressure
Outlet pressure is adjusted by rotating the knob on the Filter/Regulator unit – see
Fig. 2.2 item 3, clockwise adjustment increases the pressure. The setting can be
locked by depressing the knob.
2.4.4 Using The Compressor
The compressor has a maximum 50% duty cycle, which means that the motor must
not be allowed to run for more than 50% of the time the compressor is in use. The
motor must never be allowed to run continuously otherwise it will overheat and may
become damaged.
Do not ignore air leaks. All air connections must be leak free to prevent the
compressor from overheating.
The motor control box incorporates a thermal overload protector which cuts the power
if the oil temperature is too high – see Fig. 2.1. If the cutout operates, allow the
compressor to cool down (approx 50 mins) before restarting and ensure adequate
airflow around the unit (see Section 2.1 – Siting).
Cautions.
The thermal overload protector is set at the factory and should not be adjusted.
You must rectify the cause of the overload before continuing to use the compressor.
Check for:
Drain tap not closed properly
Air leaks on the pneumatic fittings
Excessive workload on compressor, e.g. running too many systems from one
compressor.

7
Air Compressor
2.5 Maintenance
Warning. Do not attempt any maintenance on the compressor until the mains supply has
been isolated and system pressure has been vented. To vent system pressure, operate the
pressure relief valve.
2.5.1 Scheduled Maintenance Frequencies
Caution. The maintenance tasks detailed in Table 2.1 must be performed within the
periods stated.
Note. Procedures for performing these tasks are detailed below.
Draining the Air Receiver Unit
During the following procedure, refer to Fig. 2.2 for identification of components.
1) Position the drain tube in a suitable container.
2) Open the drain valve.
3) Close the drain valve when all the water is drained.
Draining the Filter/Regulator Unit
During the following procedure, refer to Fig. 2.2 for identification of components.
1) Position a suitable container below the filter/regulator unit.
2) Locate the drain valve at the bottom of the filter/regulator unit and turn to open the
valve.
3) Close the drain valve when all the water is drained.
Table 2.1 Maintenance Periodicity
Operation Maintenance period
Drain the Air Receiver Daily
Check the oil level Daily
Replenish the oil level Weekly
Drain the Filter/Regulator Monthly
Replace oil Annually
Replace Air Intake filter Annually
Check pipe fittings and electrical connections Annually
Check pressure relief activation Annually

8
Installation
Replacing the Oil
During the following procedure, refer to Fig. 2.1 for identification of components.
1) Tilt the compressor forwards until no oil is visible in the sight glass, then remove
the sight glass housing.
2) Tilt the compressor backwards and drain the oil through the sight glass hole into
a suitable container.
3) Refit the oil level sight glass, taking care not to overtighten the nut.
4) Remove the oil filler plug from the top of the motor housing.
Cautions.
• During item (7), use only ISO 32 Fully Synthetic Compressor Oil.
• Do not overfill the reservoir. Damage to the oil seals could occur if the level indicated on
the sight glass is exceeded.
5) Refill with oil reservoir until the level is aligned with the mark on the sight glass.
6) Refit the oil filler plug.
Replacing the Air Intake Filter
During the following procedure, refer to Fig. 2.2 for identification of components.
1) Remove the cap from the air filter housing.
2) Remove the air filter and discard.
3) Fit a new air filter.
Refit the air filter housing cap.
Checking the Pressure Relief Valve Activation
During the following procedure, refer to Fig. 2.2 for identification of components.
1) Ensure that the air receiver is not pressurized.
2) Unscrew the knurled end of the pressure relief valve until an audible ‘click’ is
heard.
3) Retighten the valve, without using excessive force.

9
Chapter 3
Troubleshooting
Warning. Before attempting any maintenance on the compressor;
• disconnect the mains electrical supply
• release the pressure in the air tank
• maintenance should be performed only by personnel suitably trained in the operation of
the compressor
Compressor does not start
1) No power from mains. Check fuses and socket.
2) Faulty electrical connections. Check continuity.
3) Oil level too high. Drain oil and replenish to correct level.
4) Excessive pressure in air tank. Operate the pressure relief valve to exhaust the
tank pressure.
5) Leaking non-return valve. Check for air leaking from the valve. Unscrew the valve
cap and remove the rubber seal. Clean the rubber seal and its seat with a dry
cloth. Refit the seal and the valve cap. If leakage persists replace the valve.
6) Faulty starter relay. Contact the service agency.
7) Faulty condenser. Replace the condenser or contact the service agency.
8) Thermal overload switch active. Wait for compressor to cool and ensure adequate
ventilation.
Compressor runs but pressure increases too slowly
1) The transportation cap has not been removed from the air intake pipe.
2) Air filter clogged. Clean or replace the filter.
3) Air leaks. Can be due to a bad seal/connection of any pipe. Check all pipe
connections.
Compressor does not reach maximum pressure
1) Air leaks. Can be due to a bad seal/connection of any pipe. Check all pipe
connections.
2) A failure in the non-return valve is creating a flow restriction. Replace the valve.
Compressor stops after working normally
1) The motor incorporates automatic thermal protection which stops the compressor
when the oil temperature is too high. The compressor can be restarted after
approx 50 minutes.

10
Troubleshooting
Compressor starts when no air Is tapped
1) Air leaks. Can be due to a bad seal/connection of any pipe. Check all pipe
connections.
Compressor starts and stops more frequently than usual
1) Large amount of condensate in air tank. Drain air tank.
2) Air leaks. Can be due to a bad seal/connection of any pipe. Check all pipe
connections.
Compressor does not switch on when pressure is under the minimum level
and/or does not switch off at maximum pressure
1) Replace pressure switch.
Compressor gets very hot and/or uses a lot of oil
1) Oil level incorrect. Replenish oil to correct level.
2) Wrong oil used in compressor. Drain and refill with correct oil.
3) Air Leak. Can be due to a bad seal/connection of any pipe. Check all pipe
connections.
4) Air filter clogged. Clean or replace the filter.
5) Outside air temperature too high. Ensure adequate ventilation.

11
Chapter 4
Pump Wiring Details
Wiring details for the pump unit are shown below.
Fig. 4.1 Pump unit wiring details
starter relay
overload
protector
capacitor
to pressure
switch
black
black
black
brown
blue
yellow/green

12
Intentionally Blank

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Tel: [phone]
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Product Warranty
All Thorlab products are covered by a
manufacturers warranty against faulty
workmanship and materials, valid for 12
months from the date of original purchase.
All products returned under warranty must
be returned in their original packaging.
Prior to installation, the equipment
referred to in this handbook must be
stored in a clean, dry environment, in
accordance with any instructions given.
Periodic checks must be made on the
equipment’s condition.
Customer Feedback
It is always helpful to have detailed and
accurate information about any problems
encountered by customers
We welcome comments or suggestions
about any aspect of the equipment and
instruction handbooks.

THORLABS © Thorlabs 2009 Printed in UK (1109)
HA 0103T Issue 4
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