THORLABS PTA522 User manual

PTA522, PTA523 and
PTA524
Automatic Silent
Compressors
Operating Manual
Original Instructions

Table of Contents
Chapter 1 Safety............................................................................................................................. 1
1.1. General Warnings and Cautions.............................................................................1
Chapter 2 Installation.................................................................................................................... 2
2.1. Environmental Conditions ......................................................................................2
2.2. Parts List..................................................................................................................2
2.3. Main Compressor Components..............................................................................3
2.4. Air Intake/Pressure Diagram...................................................................................4
2.5. Wiring Diagram........................................................................................................4
Chapter 3 Operation...................................................................................................................... 5
3.1. Machine Set Up – Oil Fill .........................................................................................5
3.2. Electrical Connection..............................................................................................6
3.3. Pneumatic Connection............................................................................................6
3.4. Operation .................................................................................................................7
3.4.1. Locating the Compressor................................................................................................7
3.4.2. Starting............................................................................................................................7
3.4.3. Adjusting the Outlet Pressure .........................................................................................7
3.4.4. Draining the Condensate ................................................................................................8
3.4.5. Venting the Compressor Air Tank...................................................................................8
3.4.6. Checking the Pressure Filling Time ................................................................................8
3.4.7. Maintenance....................................................................................................................9
3.4.8. Draining and Replacing the Oil .....................................................................................10
Chapter 4 Troubleshooting......................................................................................................... 12
4.1. Typical Faults.........................................................................................................12
4.1.1. The compressor does not start .....................................................................................12
4.1.2. The compressor does not reach the maximum pressure .............................................12
4.1.3. The compressor works, but pressure does not increase in tank (or increases too
slowly) ...........................................................................................................................13
4.1.4. The compressor stops while working............................................................................13
4.1.5. Air leaks.........................................................................................................................13
4.1.6. Leak from the condensate valve located under the on/off switch.................................13
4.1.7. The compressor starts when no air is being tapped.....................................................13
4.1.8. The compressor starts and stops more frequently than usual......................................13
4.1.9. The compressor does not switch on when pressure is under the minimum level and/or
does not switch off at max. pressure ............................................................................13
4.1.10.The compressor gets very hot and/or uses a lot of oil..................................................13
4.2. Spare Parts.............................................................................................................14
Chapter 5 Specifications............................................................................................................. 16
Chapter 6Regulatory .................................................................................................................. 16
6.1. Declarations of Compliance..................................................................................16
6.1.1. For Customers in Europe..............................................................................................16
6.1.2. For Customers In The USA...........................................................................................16
Chapter 7Thorlabs Worldwide Contacts.................................................................................. 17

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 1: Safety
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Chapter 1 Safety
For the continuing safety of the operators of this equipment, and the protection of the equipment itself, the operator should
take note of the Warnings, Cautions and Notes throughout this handbook and, where visible, on the product itself.
Warning: Risk of Electrical Shock
Given when there is a risk of electrical shock.
Warning
Given when there is a risk of injury to the user.
Warning: Risk of Finger Trap
Given when there is a risk of trapping fingers between parts.
Caution
Given when there is a possibility of damage to the product.
Note
Clarification of an instruction or additional information.
1.1. General Warnings and Cautions
Warning:
If this equipment is used ina mannernot specified by themanufacturer, the protection provided by the equipment
may be impaired. In particular, excessive moisture may impair operation.
The equipment is for indoor use only. The equipment is not designed for use in an explosive atmosphere.
Where a Warning symbol appears on the product (e.g. finger trap warning), users must consult this manual to
ascertain the nature of the potential hazard and the means of avoiding them.
When using the compressor, keep it out of reach of children, never leave it unattended and not direct air stream
towards persons.
When a flammable liquid is sprayed, there may be danger of fire or explosion, especially in closed rooms: Ensure
the area is ventilated adequately.
Do not repair the compressor while it is connected to the electric circuit or when the tank is under pressure.
The safety valve is calibrated and sealed by the manufacturer. DO NOT ATTEMPT TO TAMPER WITH IT OR
CHANGE THE SETTING.
While running, the motor / air hose unit reaches a high temperature. If working near this unit do not touch.
Warning
Do not dispose of collected condensate down drain as it contains some oil. Refer to local regulations.
Warning
When properly installed, the compressor should work with a duty cycle of less than 50%. If there are air leaks
in the system, the compressor may work more than this, causing excess heating and auto-shutdown via the
thermal cut-out protection circuit. If this happens, the system should be checked and air leaks fixed, before
continuing.

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Chapter 2 Installation
2.1. Environmental Conditions
Warning
Operation outside the following environmental limits may adversely affect operator safety.
Location: Indoor use only
Maximum altitude: 2000 m
Temperature range: 15°C to 40°C
Maximum Humidity: Less than 80% RH (non-condensing) at 31°C
Line Voltage Fluctuations: Less than ±10% of the line voltage
To ensure reliable operation the unit should not be exposed to corrosive agents or excessive moisture, heat or dust.
If the unit has been stored at a low temperature or in an environment of high humidity, it must be allowed to reach ambient
conditions before being powered up.
The unit is not designed to be used in explosive environments.
2.2. Parts List
On unpacking, the kit should include the following items, as shown in Figure 1:
•The compressor
•one oil bottle, type ROLOIL - SINCOM/32E; one bottle nozzle; 20 cm length of clear plastic tube
•Instruction manual
To avoid damage during transport, the outlet regulation valve (a) has been removed from the main compressor unit, and
should be re-attached to connection port (c) using a 19 mm (or adjustable) spanner, as detailed in Figure 1.
Figure 1 (Left) Compressor Parts and Accessories. (Right) Re-attaching the Outlet Regulator

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2.3. Main Compressor components
Figure 2Component Identification
1 Motor 5 Outlet pressure regulator 9 Non return valve
2 Air tank 6 Outlet pressure gauge 10 Drainage bottle
3 On/Off switch 7 Pressure relief valve 11 Manual isolation valve
4 Tank pressure gauge 8 Automatic draining system

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2.4. Air Intake/Pressure Diagram
Figure 3 Air Intake Rate / Outlet Pressure Diagram
2.5. Wiring Diagram
Figure 4Wiring Schematic

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 3: Operation
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Chapter 3 Operation
3.1. Machine Set Up – Oil Fill
Install the compressor on a flat surface, in a dry, well ventilated room, where the temperature is not likely to rise above
35°C. If there is not enough air ventilation, install a suitably sized exhauster or fan.
Warning
The compressor is normally shipped empty of oil. Check the oil level through the oil sight glass. If oil is missing,
follow the oil-fill instructions given below.
1. Identify the Air Intake and Oil Fill ports on the motor – see Figure 5a.
2. Remove the rubber transportation plug from the oil intake pipe (Figure 5b).
3. Remove the air intake filter (Figure 5c).
Figure 5 Identifying the Motor Ports and Removing the Fittings
4. Fit the spout supplied to the oil bottle, after snipping the end open at an angle (~45°). To avoid oil spillage when
filling, firmly fix the plastic tube supplied to the spout (Figure 6a).
5. Add the oil through the side pipe (Figure 6b) until reaching optimum level, as indicated on the oil level label and
visible through the oil level viewing glass (Figure 6c). From empty, a fill should normally require 400 mL of oil.
DO NOT overfill.
DO NOT pour oil down the air intake pipe.
DO NOT use oil other than that supplied or specified.
DO NOT overturn or excessively tilt the the compressor as this could cause oil to damage the compressor unit.
Oil can be obtained from www.thorlabs.com, part number PTA1006.
6. Once filled, replace the Air Intake filter and rubber cap for the Oil Fill port.
7. Keep any remaining oil left in the bottle for future topping up.

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Figure 6 Filling the Oil
3.2. Electrical Connection
Warning
The compressor must be connected to an outlet protected by a suitable circuit breaker.
The cable powering the compressor or any extensions must have a wire cross section proportional to the length,
i.e. 1 mm2for lengths up to 3 m, and 1.5 mm2for lengths from 3 m to 20 m.
Install the compressor on a flat surface, in a dry, well ventilated room, where the temperature is not likely to rise above 35°C.
3.3. Pneumatic Connection
The pressurized outlet of the compressor unit is supplied with a push-fit connector suitable for ∅6 mm outside diameter
pressure hose. To fit the hose – simply push in. To release the hose, push the blue collar towards the fitting, and pull the
hose in the opposite direction. See Figure 7.
Figure 7 (a,b) Fitting the Pneumatic Hose and (c) Removal of the Hose

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3.4. Operation
3.4.1. Locating the Compressor
The compressor has an extremely low noise emittance at 50 dB(a), but is not entirely vibration-free. Consequently it is
recommended to locate the unit as far as possible away from the Optical Table (or other vibration-sensitive hardware it is
connected to) and not on any structure (shelving etc.) attached to the Table.
Warning
Only use the compressor on a flat surface
3.4.2. Starting
1. Ensure the module is in the Off state (see Figure 8).
2. Insert the power plug into the mains outlet.
3. Start the compressor by turning the switch to “Auto”.
4. The compressor’s working process is automatic and it switches on and off as necessary to maintain the tank
pressure.
Figure 8Start Switch
3.4.3. Adjusting the Outlet Pressure
Pressure within the compressor air tank is controlled automatically and cannot be adjusted: it varies from between the
maximum value allowed (8 bar/120 psi standard) and starts refilling again when the pressure drops to the minimum value
(6 bar/90 psi standard).
The outlet air pressure is fully adjustable between zero and the tank pressure by turning the knob on the regulator valve
(see Figure 9): Fully anticlockwise = regulator valve closed (no output from the compressor unit). Fully clockwise = regulator
valve fully open, max. output pressure available from the compressor unit.
Figure 9Adjusting the Outlet Pressure

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3.4.4. Draining the Condensate
Compressing air with non-zero humidity causes condensation in the system, which needs to be drained to avoid damage.
The Thorlabs PTA52x compressors are fitted with a timer controlled system that automatically drains condensate
accumulated inside the air tank, collecting the discharge in the drainage bottle provided (item 10, Figure 2). A draining cycle
is performed every time the compressor is started, and periodically while the compressor motor is running, with the
period settable on the timer unit (Figure 10). Note: the auto drain does not operate when the motor is idle.
Note
Note: Because there is some oil mixed with the water in the drained condensate, this appears as a brown colour
in the bottle, and is completely normal.
Figure 10 Condensate Drain Timer
To perform a manual drain, push the TEST button. Note: The tank must be under pressure, and the motor running.
3.4.5. Venting the Compressor Air Tank
The compressor air tank may need to be vented for several reasons, including during maintenance. There are two ways to
achieve this: by venting through the pressure relief valve, or through the outlet pressure valve. The latter is the most
controlled method, and the preferred route where possible.
1. Venting via the outlet pressure regulator. Close the valve on the outlet pressure regulator by turning the knob fully
anticlockwise, and disconnect any tubing from the outlet that might be connected. Ensure the manual isolation valve
(Figure 2, Item 11) is open. The pressure in the air tank can now be vented in a fully controlled way, by slowly
opening the outlet pressure regulator valve.
2. Venting via the pressure relief valve. The pressure relief valve on the air tank (Figure 2 Item 7) has a loose end
normally used for connecting to hosing; pulling on this will vent pressure in the air tank directly. The more pressure
there is in the tank, the easier this is to achieve.
Caution
If venting via the pressure relief valve, there is asudden release of air which is very noisy and could cause alarm
to other people in the vicinity. A
verbal warning should be given that a vent is about to happen, before
commencing the vent.
3.4.6. Checking the Pressure Filling Time
Check the compressor as follows:
1. Empty the compressor air tank using either method given in section 3.4.5.
2. Close the manual isolation valve at the outlet (Figure 2 Item 11).
3. Start the compressor and check the time elapsed between starting and automatic switch off; this should be around
90 seconds for 115 V models and 110 seconds for 230 V models.
4. Check that there are no leaks on connections.
5. Check that the max. pressure (8 bar/120 Psi) is achievable.

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3.4.7. Maintenance
It is essential that the following maintenance schedule is adhered to, in order to ensure the effective long-term functioning
of the compressor.
Once a Day
Drain the water collected in the air outlet pressure regulator by pushing the needle valve button at the base of the filter
bowl as shown in as Figure 11: the operation should be done with the tank under pressure.
Figure 11 Filter Housing Water Drain
Once a Week
Check the oil level via the view glass. When the motor is off, the oil level must correspond to the one shown by the label.
Perform a manual draining cycle by pressing "TEST" button on the timer (see section section 3.4.4: Draining the
Condensate). Empty the drainage bottle.
Note.
The condensate will include a small amount of oil mixed with the water, and should not be poured down the
sink. Dispose of responsibly according to local regulations.
The mixture of oil and water in the drained condensate appears as a brown colour in the bottle, and is
completely normal.
Once a Month
Check the integrity of the compressor, including: possible connectors slackening, pressure hose wear, screws tightening,
electric circuit integrity, etc.
Clean the compressor with a soft cloth; excessive dust and dirt can prevent the compressor from cooling efficiently.
Every 3 Months
Check and clean the air intake filter with compressed air. Replace as necessary.
The lower portion of the outlet pressure regulator (Figure 12) contains a coalescing cartridge to collect condensate in this
part of the unit. Unscrew, disassemble and clean both the filter bowl and plastic valve placed inside. This operation must be
done with the tank’s air pressure vented.
Figure 12Accessing the coalescing cartridge on the pressure regulator

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Once a Year
Check for any air leaks on the outlet pressure regulator (Figure 2, Item 5).
Check the safety valve (Figure 2, Item 7) by pulling the hose-connector end gently when there is pressure in the tank, and
ensuring that air escapes. Note: this test is easier to perform, the higher the pressure is within the tank (easiest at 8 bar).
Caution
If venting via the pressure relief valve, there is a sudden release of air when the vent is pulled. This is very noisy
and could cause alarm to other people in the vicinity. A verbal warning should be given that a vent is about to
happen, before commencing the vent.
Drain and replace the oil – see section 3.4.8.
3.4.8. Draining and Replacing the Oil
Note: motor oil is drained through the oil sight glass port, but refill is via the dedicated oil refill tube on the side of the housing
(see section 3.1). Do not refill oil through the sight glass port. Do not drain oil via the refill tube.
1. Using a 13 mm spanner, remove all four bolts that attach the motor unit to its base via the rubber vibration dampers
- Figure 13a.
2. Disconnect the flexible hose at the outlet of the motor using a 13 mm spanner – Figure 13b.
3. Arrange the compressor on a block, elevated from the intended drained oil tray and tilt the motor back as shown in
Figure 13c. Do not turn it upside down.
4. Using a 27 mm tube spanner, remove the oil sight glass (Figure 13d) and empty all the oil through the open port.
Figure 13 Draining the Oil

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5. Check the integrity of the O-ring of the oil level glass and replace if damaged.
6. Tighten the oil level glass in its seat again and check that during the operations the O-ring is sealing properly; if
needed, put some sealing liquid on the oil level glass thread before re-inserting it in its seat.
7. Refit the flexible hose and the four base locating bolts
8. Refill with oil – see section 3.1

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 4: Troubleshooting
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Chapter 4 Troubleshooting
Warning
Before any operation on the compressor, disconnect the unit from the power socket.
Vent the air tank before dismantling any part of compressor unit’s pressure system.
The following operations must only be performed by someone trained and familiar with the maintenance of
compressors.
4.1. Typical Faults
4.1.1. The compressor does not start
a. No power from mains.Check fuses, circuit breaker and socket.
b. Breakage or loose joints in electrical connections.Check for continuity as per wiring diagram (See Figure 4Wiring
Schematic).
c. Pressure in the air tank is above the cut-in threshold.The compressor will only start if the tank pressure is below
the minimum set level (6 bar/90 psi); if needed, vent to below this pressure to allow the motor to cut in again.
d. Leaky non-return valve (Figure 14, item 1). Remove the flexible pressure pipe (item 2) to check if air leaks out from
the valve. If so, unscrew the valve cap (item 3), clean the rubber disk (item 4) and its seat with a dry cloth and re-
assemble the unit with care. If leakage persists, the whole valve must be replaced.
Figure 14Non-return Valve Location (Left) and Dismantled (Right)
e. The starting relay is defective. Contact Thorlabs Tech Support..
f. The protective thermal relay has switched off the compressor due to overheating. When cooled, the compressor
will automatically turn on again.
4.1.2. The compressor does not reach the maximum pressure
a. Check for air leaks (See section 4.1.5).
b. The air intake filter is clogged. Clean with compressed air, or replace it.

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 4: Troubleshooting
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4.1.3. The compressor works, but pressure does not increase in tank (orincreases too slowly)
a. Check for air leaks (See section 4.1.5).
b. Air intake filter clogged. Clean with compressed air, or replace it.
c. Failure of a motor valve or gasket. Refer to your local TechSupport team for replacing the damaged component(s).
4.1.4. The compressor stops while working
The motor has an automatic resetting thermal protection that stops the compressor when the temperature is too high. The
compressor will start again automatically after 15 to 20 minutes. Check the room temperature is <40°C and the compressor
ventilation is adequate. In addition, the compressor should work with a duty cycle of less than 50%, but if there are air leaks
in the system, this may cause the cycle to be higher, resulting in excessive heating. In this case, check for air leaks and fix
before continuing.
4.1.5. Air leaks
Can be due to a bad seal of any connection.Check all connections by wetting with soapy water or suds as appropriate.
4.1.6. Leak from the condensate vent valve located under the on/off switch unit
Figure 15Condensate Vent Valve
a. If the leak happens while the compressor runs: Damaged valve, replace it.
b. If the leak happens when the compressor is switched off: The problem can be due to a defective seal on the non-
return valve (See 4.1.1 d).
4.1.7. The compressor starts when no air is being tapped
a. Check for air leaks (See 4.1.5).
b. Leaky non-return valve: See section 4.1.1 d.
4.1.8. The compressor starts and stops more frequently than usual
a. Large amount of condensate in air tank. Remove condensate by shortening the period between drains (Figure 10).
b. Air leak (See 4.1.5).
4.1.9. The compressor does not switch on when pressure is under the minimum level and/or
does not switch off at max. pressure
Defective pressure switch. Replace.
4.1.10. The compressor gets very hot and/or uses a lot of oil
a. Check oil level.
b. Wrong oil has been filled in the compressor. Only use oil recommended by Thorlabs, part PTA1006.

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 4: Troubleshooting
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c. Air leak (See 4.1.5).
d. Clogged air intake filter. Clean with compressed air, or replace.
e. The ambient temperature is too high. Do not enclose the unit in a cupboard unless adequately ventilated.
f. Over-running. Ensure the compressor is the correct model for your work load.
4.2. Spare Parts
Defectiveparts mustbe replaced only by trained and authorized personnel;all possible safety regulations mustbe observed
in order to avoid personal injury or any damage to the equipment.
Spare parts are available on request from your local Thorlabs Tech Support contact.

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 5: Specifications
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Chapter 5 Specifications
Parameter
Value
PTA522
PTA523
PTA524
Connector Style
US
UK
EU
Input Voltage (Frequency)
115 V (60 Hz)
230 V (50 Hz)
Rated Input Current
1.9 A
1.0 A
Rated Power
140 W
130 W
Free Air Delivery
20 L/min (0.71 cfm)
17 L/min (0.53 cfm)
Air Tank Pressure (min/max)
6 bar (90 psi) / 8 bar (120 psi)
Air Tank Capacity
3.5 L (0.92 US gal.)
Air Tank Fill Time from empty
110 seconds (@ 50 Hz)
Sound Pressure Level
50 dB(A) at 1 m
Gross Weight
17 kg (37 lbs)
Unit Dimensions
(410 x 360 x 360) mm; (16 x 14 x 14) inches
Oil Type
ROLOIL – SINCOM/32E

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Chapter 6 Regulatory
6.1. Declarations of Compliance
6.1.1. For Customers in Europe
6.1.2. For Customers In The USA
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the
FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Operation ofthis equipment ina residential area is likely tocause harmful interference in which case the user will be required
to correct the interference at his own expense.
Changes or modifications not expressly approved by the company could void the user’s authority to operate the equipment.

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 7: Thorlabs Worldwide Contacts
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Chapter 7 Thorlabs Worldwide Contacts
For technical support or sales inquiries, please visit us at www.thorlabs.com/contact for our most up-to-date contact
information.
Thorlabs verifies our compliance with the WEEE (Waste Electrical and Electronic Equipment) directive of
the European Community and the corresponding national laws. Accordingly, all end users in the EC may
return “end of life” Annex I category electrical and electronic equipment sold after August 13, 2005 to
Thorlabs, without incurring disposal charges. Eligible units are marked with the crossed out “wheelie bin”
logo (see right), were sold to and are currently owned by a company or institute within the EC, and are
not dissembled or contaminated. Contact Thorlabs for more information. Waste treatment is your own
responsibility. “End of life” units must be returned to Thorlabs or handed to a company specializing in
waste recovery. Do not dispose of the unit in a litter bin or at a public waste disposal site.
Annex I
USA, Canada, and South America
Thorlabs, Inc.
[e-mail]
[e-mail]
UK and Ireland
Thorlabs Ltd.
[e-mail]
[e-mail]
Europe
Thorlabs GmbH
[e-mail]
Scandinavia
Thorlabs Sweden AB
[e-mail]
France
Thorlabs SAS
[e-mail]
Brazil
Thorlabs Vendas de Fotônicos Ltda.
[e-mail]
Japan
Thorlabs Japan, Inc.
[e-mail]
China
Thorlabs China
[e-mail]

www.thorlabs.com