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

PTA522, PTA523 and PTA524 Automatic Silent Compressors Chapter 2: Installation
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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.