Chicago Pneumatic CPC 40 G Instruction Book
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Chicago Pneumatic CPC 40 G Instruction Book

Oil-injected rotary screw compressors
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Oil-injected rotary screw compressors
People. Passion. Performance.
CPC 40 G, CPC 50 G, CPC 60 G, CPD 75 G, CPD 100 G, CPE 100,
CPE 120, CPE 150
Instruction book

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Summary of Contents for Chicago Pneumatic CPC 40 G

  • Page 1 Oil-injected rotary screw compressors People. Passion. Performance. CPC 40 G, CPC 50 G, CPC 60 G, CPD 75 G, CPD 100 G, CPE 100, CPE 120, CPE 150 Instruction book...
  • Page 3 Oil-injected rotary screw compressors CPC 40 G, CPC 50 G, CPC 60 G, CPD 75 G, CPD 100 G, CPE 100, CPE 120, CPE 150 From following serial No. onwards: API172431 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................6 ........................... 6 AFETY ICONS ......................6 ENERAL SAFETY PRECAUTIONS ................... 7 AFETY PRECAUTIONS DURING INSTALLATION ....................8 AFETY PRECAUTIONS DURING OPERATION ................9 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description...................... 11 ..........................11 NTRODUCTION .........................
  • Page 5 Instruction book 3.15 ..................33 ALLING UP RESETTING THE SERVICE TIMER 3.16 ................ 34 ELECTION BETWEEN LOCAL REMOTE OR CONTROL 3.17 .................. 35 ALLING UP MODIFYING ADDRESS CONTROL 3.18 IP, G ................ 36 ALLING UP MODIFYING ATEWAY AND UBNETMASK 3.19 .................38 ALLING UP MODIFYING PRESSURE BAND SETTINGS...
  • Page 6 Instruction book ............................60 TOPPING ........................61 AKING OUT OF OPERATION Maintenance........................62 ....................62 REVENTIVE MAINTENANCE SCHEDULE ......................64 TORAGE AFTER INSTALLATION ..........................64 ERVICE KITS ......................65 ISPOSAL OF USED MATERIAL Adjustments and servicing procedures..............66 ............................66 IR FILTER .......................67 IL AND OIL FILTER CHANGE ........................
  • Page 7 Instruction book 10.6 ................ 118 OTATION DIRECTION INDICATOR HASE CONTROLLER 10.7 ..........................118 PECIAL OILS 10.8 .....................118 ENTRIFUGAL WATER SEPARATION 10.9 ........................119 RAPHIC ONTROLLER 10.10 ....................... 120 ROPICAL THERMOSTATIC VALVE Guidelines for inspection...................121 Pressure equipment directives................. 122 Declaration of conformity..................124 2920 7101 41...

  • Page 8: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note General safety precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.

  • Page 9: Safety Precautions During Installation

    Instruction book Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.

  • Page 10: Safety Precautions During Operation

    Instruction book 16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high temperature piping must be clearly marked. 17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure.

  • Page 11: Safety Precautions During Maintenance Or Repair

    Instruction book • Air cooling filters of the electrical cabinet are not clogged 9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air. 10.
  • Page 12 Instruction book 12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted. 13.

  • Page 13: General Description

    Introduction General CPC 40 G up to CPC 60 G, CPD 75 G, CPD 100 G, CPE 100, CPE 120 and CPE150 are single-stage, oil- injected screw compressors, gearbox driven by an electric motor. The compressors are available in air- cooled and water-cooled version.
  • Page 14 Instruction book Main components Ref. Name Air filter Air receiver Location of air outlet valve Air cooler Oil cooler Controller Drive motor Oil filter Emergency stop button 2920 7101 41...

  • Page 15: Air And Oil Circuit

    Instruction book Air and oil circuit Air circuit Flow diagram, air circuit Reference Description Intake air Air/oil mixture Wet compressed air Description Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. A mix of compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV).
  • Page 16 Instruction book Oil circuit Flow diagram, oil circuit Description In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture by centrifugal action. The remaining oil is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil separator (AR), which serves as an oil tank.

  • Page 17: Cooling System

    Instruction book Cooling system Cooling system air-cooled compressors The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling air flow is generated by a fan (FN). Cooling system water-cooled compressors Water-cooled compressors are connected to a cooling water circuit. The water flows through the inlet pipe to the air cooler (Cwa), further through the oil cooler (Cwo) to the outlet pipe.

  • Page 18: Regulating System

    Instruction book Regulating system Load/unload regulating system Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure (1) via the solenoid valve.

  • Page 19: Electrical System

    Instruction book Electrical system General Electrical components The electrical system comprises following components: Electric cubicle, typical example Reference Designation F1/2/3 Fuses (F3 is only provided in case a phase sequence relay is provided) Overload relay, compressor motor Circuit breaker, fan motor (on air-cooled compressors) Line contactor Star contactor Delta contactor...
  • Page 20 Instruction book Electrical diagram There is a copy of the electrical diagram inside the electrical cubicle. 2920 7101 41...

  • Page 21: Controller

    Instruction book Controller Controller View of the ES 4000 Standard controller Introduction The electronic controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure Automatic control of the compressor The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor.

  • Page 22: Control Panel

    Instruction book Air-cooled compressors will also be stopped in the event of overload of the fan motor. Before remedying, consult the Safety precautions. Shut-down warning A shut-down warning level is a programmable level below the shut-down level. If one of the measurements exceeds the programmed shut-down warning level, this will also be indicated to warn the operator before the shut-down level is reached.

  • Page 23: Icons Used On The Display

    Instruction book Reference Designation Function Automatic operation symbol LED, Automatic operation Indicates that the regulator is automatically controlling the compressor: the compressor is loaded, unloaded, stopped and restarted depending on the air consumption and the limitations programmed in the regulator. Warning symbol LED, Warning Flashes in case of a shut-down, is lit in case of a...
  • Page 24 Instruction book Function Icon Description Machine control mode Remote start / stop LAN control Automatic restart after Automatic restart after voltage failure is active voltage failure Timer Active protection functions Emergency stop Service Service required Units Pressure unit (Mega Pascal) Pressure unit (pounds per square inch) Pressure unit (bar) Temperature unit...

  • Page 25: Main Screen

    Instruction book Function Icon Description Motor (overload) Element outlet temperature. Filter Drain Energy saving (dryer) Ambient temperature Dewpoint temperature Main screen When the voltage is switched on, the first screen is a test screen. The next screen is the Main screen, shown automatically.

  • Page 26: Shut-Down Warning

    Instruction book Shut-down warning Description A shut-down warning will appear in the event of: • Too high a temperature at the outlet of the compressor element • Too high a dewpoint temperature (Full-Feature compressors) Compressor element outlet temperature • If the outlet temperature of the compressor element exceeds the shut-down warning level (see section Programmable settings), warning LED (5) starts blinking.

  • Page 27: Shut-Down

    Instruction book Warning screen, dewpoint temperature The screen shows that the dewpoint temperature is 9˚C. • It remains possible to scroll through other screens (using Scroll buttons 12) to check the actual status of other parameters. • Press button (11) to stop the compressor and wait until the compressor has stopped. •...

  • Page 28: Service Warning

    Instruction book Shut-down screen, element outlet temperature The screen shows that the temperature at the outlet of the compressor element is 120 ˚C. • Switch off the voltage and remedy the trouble. • After remedying and when the shut-down condition has disappeared, switch on the voltage and restart the compressor.

  • Page 29: Scrolling Through All Screens

    Instruction book Example of service timer screen The screen shows that the reading of the service timer is 4002. • Press Scroll button (12) to scroll to <d.1> and the running hours symbol is shown. Press button (13): the actual reading of the service timer appears and is shown in <hrs> or <x1000 hrs> (if the service timer value is higher than 9999).
  • Page 30 Instruction book Example The screen shows the screen number <d.1>, the unit used <hrs> and the related symbol for running hours. Press Enter key (13) to call up the actual running hours. Overview of the screens Digital input Designation Related topic screens <d.in>...
  • Page 31 Instruction book Parameter Designation Related topic screens <P.10> Selection between Y-D or DOL starting See section Selection bewteen YD or DOL staring This parameter is not supported for all units. <P.11> Setting of load delay time See section Calling up modifying load delay time <P.12>...
  • Page 32 Instruction book Menu flow Simplified menu flow Ref. Description Ref. Description Compressor outlet pressure (16) Pressure band setting Compressor outlet temperature (17) Service timer settings Dewpoint temperature (18) Temperature unit Digital input status (19) Unit pressure 2920 7101 41...

  • Page 33: Calling Up Outlet And Dewpoint Temperatures

    Instruction book Ref. Description Ref. Description Running hours (20) Auto restart Motor starts (21) Selection Y-D/DOL Module hours (22) Load delay time Loading hours (23) Minimum stop time Load relay (24) Password settings (10) Service timer reading (25) Remote pressure sensing (11) Actual program version (26)

  • Page 34: Calling Up Running Hours

    Instruction book • Press Scroll button (12) to scroll downwards or upwards through the screens. 3.10 Calling up running hours Starting from the Main screen: • Press Scroll button (12) until <d.1> is shown and then press Enter button (13): The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the compressor are 11250 hours.

  • Page 35: Calling Up Loading Hours

    Instruction book 3.13 Calling up loading hours Starting from the Main screen: • Press Scroll button (12) until <d.4> is shown and then press Enter button (13): The screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1755>: the compressor has been running loaded during 1755 hours.

  • Page 36: Selection Between Local, Remote Or Lan Control

    Instruction book • Press Scroll button (12) until <d.6> is shown and then press Enter button (13): This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example shown, the compressor has run 1191 hours since the previous service. Resetting the service timer After servicing, see section Service...

  • Page 37: Calling Up/Modifying Can Address Control

    Instruction book To change: press Enter button (13) and - if necessary - enter the password (see section Activating password protection). The actually selected control mode is blinking. Use Scroll button (12) to change the control mode. Press Enter button (13) to program the new control mode or press Escape button (14) to cancel. 3.17 Calling up/modifying CAN address control Calling up Starting from the main screen, press the Scroll button (12) until <P.

  • Page 38: Calling Up/Modifying Ip, Gateway And Subnetmask

    Instruction book It is also possible to change the channels. The controller has 4 channels. When changing the channels, the controller can act as a Mk IV controller (a previous version of the controller). To set the channels, go to the screen where the node ID is visible.
  • Page 39 Instruction book The next screen shows either <OFF> or <On>. If <On>, press the Enter button (13) to modify it to <OFF>. Use the Scroll buttons Up or Down (12) to scroll between the items in this list (<IP> for IP address, <Sub> for Subnetmask or <GAtE>...

  • Page 40: Calling Up/Modifying Pressure Band Settings

    Instruction book 3.19 Calling up/modifying pressure band settings Calling up the settings Starting from the Main screen: • Press Scroll button (12) until <P.04> is shown and then press Enter button (13). Pressure band 1 (<Pb. 1>) is shown on the display. Button (12) can be used to scroll to pressure band 2 (<Pb.2>). •...

  • Page 41: Modifying The Pressure Band Selection

    Instruction book Loading pressure Unloading pressure Modification • Press Enter button (13) to modify the load level (value starts blinking). A password may be required. Use Scroll buttons (12) to change the loading pressure. • Press Enter button (13) to program the new values or press the Escape button (14) to cancel. 3.20 Modifying the pressure band selection Starting from the Main screen: •...

  • Page 42: Calling Up/Modifying The Unit Of Temperature

    Instruction book • Press Enter button (13) to program the new value. 3.22 Calling up/modifying the unit of temperature Control panel Starting from the Main screen: • Press Scroll button (12) until <P.07> is shown and then press Enter button (13). The actually used unit is shown.

  • Page 43: Selection Between Y-Dor Dol Starting

    Instruction book 3.25 Selection between Y-D or DOL starting Control panel Starting from the Main screen: • Press Scroll button (12) until <P.10> and the motor pictograph is shown and then press Enter button (13). The actually used starting mode is shown: <Y-D> (star-delta) or <doL> (Direct-On Line). •...

  • Page 44: Activating Password Protection

    Instruction book • This screen shows the minimum stop time (20) and the unit <s> (seconds). • To modify this value press the Enter button (13). The value starts blinking and Scroll buttons (12) can be used to modify this value. •...

  • Page 45: Calling Up/Modifying Protection Settings

    Instruction book • The function of this screen is to activate the remote load/unload relay. To be able to activate this remote Load/Unload functionality, a physical digital input with function Load/Unload is required. Once this parameter is activated, the physical digital input can be used to switch the compressor between Load and Unload.

  • Page 46: Test Screens

    Instruction book Example of protection screens Protection setting element outlet temperature Warning alarm high element outlet temperature Changing the settings Starting from the Main screen (the example given describes the protection of the element outlet temperatures): Press Scroll buttons (12) until <Pr.> followed by a number and the element outlet temperature pictograph is shown and press Enter button (13): •...

  • Page 47: Programmable Settings

    Instruction book Safety valve test In the test screen <t. 2>, a safety valve test is provided. The safety valves can only be tested after entering a code. Consult your supplier if the safety valves are to be tested. Production test Test screen <t.
  • Page 48 Instruction book Minimum Factory Maximum setting setting setting Number of motor starts starts/day Minimum stop time Programmed stop time Power recovery time (ARAVF) 3600 Restart delay 1200 Communication time-out Protections Minimum Factory Maximum setting setting setting Compressor element outlet temperature ˚C (shut-down warning level) ˚F...
  • Page 49 Instruction book Term Explanation Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is Loading pressure programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the loading pressure changes to 6.9 bar(e) (100 psi(g)). The recommended minimum pressure difference between loading and unloading is 0.6 bar (9 psi(g)).

  • Page 50: Installation

    CPC 40 G up to CPC 60 G water-cooled compressors See document 9820 6706 11 on the CD supplied with your machine CPC 40 G up to CPC 60 G air-cooled compressors with dryer See document 9820 6706 17on the CD supplied with your machine...

  • Page 51: Installation Proposal

    Instruction book Text on drawings Translation or Explanation Prepared for manual drain Prepared for manual drain Dryer cooling air inlet Dryer cooling air inlet Dryer cooling air outlet Dryer cooling air outlet Centre of gravity Centre of gravity Mass Mass of the machine Type Machine type Installation proposal...

  • Page 52: Installation Guidelines

    Instruction book Text on drawing Reference Designation Ventilation proposals Minimum free area to be reserved for the compressor installation All piping to be connected stress free to the compressor. Installation guidelines 1. Install the compressor unit on a solid, level floor suitable for taking its weight. 2.
  • Page 53 Instruction book • Δp = Pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi)) • L = Length of the pipe in m • Q = Free air delivery of the compressor in l/s • d = Inner diameter of the pipe in mm •...

  • Page 54: Pictographs

    Instruction book Pictographs Description Pictographs Reference Designation Read manual for oil specification Rotation arrow Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn) 2920 7101 41...
  • Page 55 Instruction book Reference Designation Warning: Voltage Warning: Hot surface Earth connection Cooling water outlet Cooling water inlet Automatic condensate drain Manual condensate drain Switch of the voltage and at least wait 6 min. before removing the screen Disconnect the electric supply before opening Lock out/ tag out Before connecting compressor electrically, consult instruction book for motor rotation direction...

  • Page 56: Operating Instructions

    Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. Procedure For the position of the air outlet valve and the drain connections, see sections Introduction. 1. Consult the sections Electric cable size, Installation proposal Dimension drawings 2.
  • Page 57 Instruction book Transport fixtures 3. Check that the electrical connections correspond to the local codes and that all wires are clamped tight to their terminals. The installation must be earthed and protected against short circuits by fuses of the inert type in all phases.
  • Page 58 Instruction book The drain pipes to the drain collector must not dip into the water. If the pipes have been fitted outside the room where freezing is possible, they must be insulated. 7. On water-cooled compressors, drain valves, shut-off valves and a regulating valve should be fitted by the customer in the cooling water piping.

  • Page 59: Before Starting

    Instruction book If it does not spin in the right direction reverse two mains cables. When it rotates in the correct direction, the oil level should drop after 4 or 5 seconds of operation Incorrect rotation of the drive motor can cause damage to the compressor. Fan direction arrow It is very important to remember to check the direction of rotation of the fan (shown by an arrow on the fan (1)).

  • Page 60: Starting

    Instruction book Starting Procedure For the position of the air outlet valve and the drain connections, see sections Introduction. Control panel ES 4000 Std Step Action Switch on the voltage. Check that voltage on LED (7) lights up. Open the air outlet valve. Press start button (10) on the control panel.

  • Page 61: During Operation

    Instruction book During operation Warnings The operator must apply all relevant Safety precautions. Also consult section Problem solving. Removing the front panel (service panel) during operation will lead to an automatic shutdown of the unit after a certain time depending of the compressor version. Keep the doors closed during operation;...

  • Page 62: Automatic Restarting

    Instruction book 6. Remove the plug and add oil until the level reaches the filler opening. 7. Fit and tighten the plug (FC). 8. Unlock the emergency stop button and press the "Reset key" on the controller before restarting Automatic restarting Description The electronic controller has a built-in function to automatically restart the compressor when the voltage is restored after voltage failure.

  • Page 63: Taking Out Of Operation

    Instruction book Step Action Press the test button on the top of the electronic water drain(s) until the air system between the air system receiver and the outlet valve is fully depressurised. See section Automatic drain Switch off the voltage. If available, open the condensate drain valve of the compressor (Dm) to drain the water trap completely.

  • Page 64: Maintenance

    For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits). Service contracts CHICAGO PNEUMATIC offers several types of service contracts, relieving you of all preventive maintenance work. Consult your Customer Center. General When servicing, replace all removed gaskets, O-rings and washers.
  • Page 65 Instruction book Preventive maintenance schedule Period Operation Daily Check oil level. Check readings on display. Check that condensate is discharged during loaded operation of the compressor. On water-cooled units: check for cooling water flow. Check the pressure dew-point temperature (compressors with integrated dryer). 3-monthly (1) Check coolers, clean if necessary.

  • Page 66: Storage After Installation

    Instruction book Interval (hours) 2000 6000 12000 24000 4000 18000 8000 10000 14000 18000 16000 20000 22000 Overhaul the main drive motor (*) If available When compressor oil Rotair Xtra is used, the standard oil change interval can be extended to 8000 h The indicated oil exchange intervals are valid for standard operating conditions (see section Reference...

  • Page 67: Disposal Of Used Material

    Instruction book Disposal of used material Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation. Electronic components are subject to the EU Directive 2002/96/EC for Waste Electrical and Electronic Equipment (WEEE).

  • Page 68: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filter IMPORTANT If you do not replace the filtering element when needed, permanent dirt build-up will result. This reduces the air inflow to the compressor and could damage the oil separator and the compressor. 1.

  • Page 69: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Warning The operator must apply all relevant Safety precautions. Always drain the compressor oil at all drain points. Used oil left in the compressor can contaminate the oil system and can shorten the lifetime of the new oil. Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties.

  • Page 70: Oil Separator Change

    Instruction book Oil drain plugs 4. Collect the oil and deliver it to the local collection service. Refit and tighten the drain and vent plugs after draining. Re-tighten the top connection of the oil cooler. 5. Remove the oil filter (OF). Clean the seat on the manifold. Oil the gasket of the new filter and screw it into place.

  • Page 71: Coolers

    Instruction book Oil separator components 3. Remove the oil separator (OS). 4. Clean the seat on air receiver/oil tank (AR). Place the new separator into the air receiver/oil tank and replace the vessel cover (Ac) with the bolts. Take care that no dirt drops into the system. Refit and tighten filler plug (FC). 5.

  • Page 72: Filtering Panel

    Instruction book Never use a high pressure water jet to clean the compressor. Instructions for air-cooled compressors 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove any dirt from the coolers with a fibre brush. Never use a wire brush or metal objects. 3.

  • Page 73: Safety Valves

    Instruction book Safety valves Location of safety valve Operating Operate the safety valve by unscrewing the cap one or two turns and retighten it. Testing Before removing the valve, depressurise the compressor. See section Problem solving. Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure stamped on the valve, it needs to be replaced.
  • Page 74 Instruction book Local legislation Local legislation may stipulate that: • Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function must be undertaken by an authorised control body. • The installation should be checked once a year by an authorised control body. General For all references see section Introduction.

  • Page 75: Problem Solving

    Instruction book Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped, press the emergency stop button and switch off the voltage. Close the air outlet valve and lock it if necessary. Depressurize the air connection between the minimum pressure valve and the compressor outlet ball valve.
  • Page 76 Instruction book Condition Fault Remedy Choked air filter element Replace filter element Solenoid valve malfunctioning Replace valve Leak in control air flexibles Replace leaking flexibles Inlet valve does not fully open Have valve checked Oil separator clogged Have element replaced Air leakage Have leaks repaired Safety valve leaking...
  • Page 77 Instruction book Condition Fault Remedy On water-cooled compressors, Consult your supplier restriction in cooling water system Oil cooler clogged Clean cooler Thermostatic bypass valve Have valve tested malfunctioning Air cooler clogged Clean cooler Compressor element out of order Consult your supplier Oil filter clogged Replace Dryer...
  • Page 78 Instruction book Condition Fault Remedy Condensate trap continuously Automatic drain out of order Have system checked. If necessary, discharges air and water replace the automatic drain. Evaporator pressure is too Hot gas bypass valve Have hot gas bypass valve adjusted high or too low at unload incorrectly set or out of order Condenser pressure too high...

  • Page 79: Technical Data

    Instruction book Technical data Electric cable size and fuses Important • The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1).
  • Page 80 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 30kW 30kW 30kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW...
  • Page 81 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 45kW 45kW 45kW 45kW 45kW 45kW 45kW 45kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 55kW 55kW 55kW 55kW 55kW 55kW 55kW 55kW 55kW...
  • Page 82 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 90kW 90kW...
  • Page 83 Instruction book IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 110kW 110kW 110kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 30kW 30kW 30kW 30kW 30kW 30kW 30kW 30kW IEC approval Max Fuse Max Fuse Compressor specification...
  • Page 84 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 45kW 45kW 45kW 45kW 45kW 45kW 45kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 55kW 55kW 55kW 55kW 55kW 55kW 55kW 55kW IEC approval Max Fuse...
  • Page 85 Instruction book IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 90kW 90kW 90kW 90kW 90kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 30kW 30kW 30kW 30kW 30kW 30kW 30kW 30kW UL/cUL approval Max Fuse...
  • Page 86 Instruction book UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 45kW 45kW 45kW 45kW 45kW 45kW 45kW 45kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 55kW 55kW 55kW 55kW 55kW 55kW 55kW...
  • Page 87 Instruction book UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 90kW 90kW 90kW 90kW 90kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 110kW 110kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2)
  • Page 88 Instruction book UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) UL class UL class RK5 CSA Type RK5 CSA HRC form HRC form II 45kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) UL class UL class RK5 CSA Type RK5 CSA...
  • Page 89 Instruction book UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) UL class UL class RK5 CSA Type RK5 CSA HRC form HRC form II 110kW I: current in the supply lines at maximum load and nominal voltage (1): compressor without integrated dryer (2): compressor with integrated dryer Fuse calculations for IEC are done according to 60364-4-43 electrical installations of buildings, part 4: protection for safety- section 43: protection against overcurrent.
  • Page 90 Instruction book Installation method B2 according table B.52.1. Multi-core cable in conduit on a wooden wall Maximum allowed current in function of the ambient temperature for installation method B2 Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...
  • Page 91 Instruction book Installation method F according table B.52.1. Single-core cables, touching in free air Clearance to wall not less than one cable diameter Maximum allowed current in function of the ambient temperature for installation method F Ambient temperature Cable section 30 °C 40 °C 45 °C...
  • Page 92 Instruction book Cable sizing according CSA Calculation method according CEC part 1, table 2: allowable ampacities for not more than 3 copper conductors in raceway or cable (based on an ambient temperature of 30 °C (86 °F). Correction factors for other temperatures table 5A.
  • Page 93 Instruction book • Single supply cables (3 phases + PE - configuration (1)): • I = 128 A + 10 % = 128 x 1.1 = 140.8 A • AWG3/0 (000), allows a maximum current of 200 A at 30 °C (86 °F).When the conductor has a maximum temperature of 75 °C at 45 °C, the maximum current is 164 A ( 200 A * 0.82 = 164 A, see table 5A col.

  • Page 94: Reference Conditions And Limitations

    Instruction book < 100 A: use AWG8 < 200 A: use AWG6 < 300 A: use AWG4 Always check the voltage drop over the cable (less than 5 % of the nominal voltage is recommended). Example of supply cable calculation: I = 128 A, maximum ambient temperature is 45 °C, recommended fuse = 150 A •...

  • Page 95: Compressor Data

    Instruction book Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F On water-cooled units also: Maximum cooling water outlet temperature ˚C Maximum cooling water outlet temperature ˚F Maximum cooling water inlet temperature ˚C Maximum cooling water inlet temperature ˚F Maximum cooling water inlet pressure bar(e)
  • Page 96 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Set point, ˚C thermostatic valve ˚F Units 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Set point, ˚C thermostatic valve...

  • Page 97: Options

    Instruction book Options 10.1 Energy recovery 10.1.1 Energy recovery unit Description A large part of the energy required for any compression process is transformed into heat. For oil-injected screw compressors, the major part of the compression heat is dissipated through the oil system. The energy recovery (ER) systems are designed to recover most of the above-mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance.
  • Page 98 Instruction book Energy recovery unit (ER-unit) Main components of the ER unit (typical installation) Reference Designation Water inlet pipe Water outlet pipe Temperature sensor, water inlet pipe Temperature sensor, water outlet pipe Oil line to HE Oil line from compressor oil separator vessel to ER unit Oil line from ER unit to oil filter housing Location of heat exchanger by-pass valve (BV2) Heat exchanger...
  • Page 99 Instruction book Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult your customer centre for installing and connecting the energy recovery unit. 10.1.2 Energy recovery systems General The energy recovery systems can be applied as low temperature rise/high water flow systems or as high temperature rise/low water flow systems.
  • Page 100 Instruction book 10.1.3 Operation Description The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimum energy recovery. Bypass valve (BV1) is integrated in the oil filter housing of the compressor and controls the oil flow through the main oil cooler (Co) of the compressor.
  • Page 101 Instruction book On compressors versions with a maximum pressure lower than 13 bar (175 psi), BV2 starts opening at 40 ˚C (104 ˚F) and is completely open at 55 ˚C (131 ˚F). On compressors with a maximal pressure of 13 bar (175 psi), BV2 starts opening at 60 ˚C (140 ˚F) and is completely open at 75 ˚C (167 ˚F).
  • Page 102 Instruction book BV1 must have a higher opening temperature (set point) than BV2 in order to prevent the heat from being dissipated in the compressor oil cooler (Co) rather than in the oil/water heat exchanger (HE) when using the compression heat as source for energy recovery. Thermostat BV1 starts to open at 75 ˚C (167 ˚F) and is completely open at 90 ˚C (194 ˚F).
  • Page 103 Instruction book 10.1.4 Maintenance Compressor oil For references used consult section Energy recovery Oil change: 1. Check if the wheel (V1) is totally turned in clockwise (energy recovery in use). 2. Run the unit until warm. Stop the unit, switch off the isolating switch and close the air outlet valve of the compressor.
  • Page 104 Instruction book • The cooling water outlet temperature of the compressor Modifying settings If the programmed warning settings for the water temperatures are exceeded, a warning indication is shown on the Elektronikon: Temperature input Minimum Nominal Maximum setting setting setting Water inlet temperature of energy recovery ˚C Water inlet temperature of energy recovery...

  • Page 105: Eco6I

    Instruction book Parameters Units 55kW 75kW 90kW 110kW Recoverable 48,4 79,2 80,4 energy Water flow l/Min 69,3 113,4 Temperature at °C inlet Temperature at °C outlet Pressure drop 0,21 0,46 0,53 0,55 Data for high temperature rise/low water flow systems Typical values parameters units...
  • Page 106 Instruction book Local Area Network (LAN) The compressors to be controlled must be connected with each other in a Local Area Network (LAN) using CAN (Controller Area Network) technology. The controller with the integrated ECOi function serves as master regulator for the compressors. The regulators of the other compressors act as slave regulators.
  • Page 107 Instruction book Connecting electro-pneumatically controlled machines and machines of other brands The only way to connect this type of machines to the regulator with the activated ECOi function is to use a CANBox interface (part number 1900 0712 61) , which in turn is connected to the LAN network via hardwiring.
  • Page 108 Instruction book Commissioning via the display Programming the ECOi in the master regulator How to activate the ECOi in the master regulator ? 1. Starting from the main screen 2. Press the enter button 3. Use the scroll buttons ▲▼►◄ to select the ECO icon 4.
  • Page 109 Instruction book 5. A list of items is shown, the button modify is selected, press enter and use the scroll buttons ▲▼►◄ to select the menu item “Number of Compressors”. Press enter. 6. A dialogue screen opens (choose between 1 to 6 by using the scroll buttons ▲▼►◄). 7.
  • Page 110 Instruction book Flowchart how to integrate the compressors into the LAN Programming the node ID number For the master regulator: 1. Starting from the main screen, press the enter button. 2. Use the scroll buttons ▲▼►◄ to select the settings icon. 3.
  • Page 111 Instruction book Flowchart how to program the node ID number Parameters that can be modified via the display Parameters master module Number of Compressors Pressure Band 1 High Pressure Band 2 High Pressure Band 1 Low Pressure Band 2 Low Pressure Band in Use Digital Pressure Band Selection Scheme in Use...
  • Page 112 Instruction book Forced time Remote To Local Time Start/Load Time Unload Time Delta Time Remote Start/Stop System Stop Function System Forced Function Automatic restart Maximum Power Down Time Parameters slave module(s) Scheme 1 Priority Start/Load Reaction time Scheme 2 Priority Load Reaction Time Unload Reaction Time Stop Reaction Time...
  • Page 113 Instruction book 10.2.4.2 Before starting Status icons for each compressor on the main screen of the master regulator. Icon Status Description No valid compressor type An unknown compressor type is detected No communication Fixed Speed or VSD: No reply from the connected compressor within a time out.
  • Page 114 Instruction book 10.2.4.4 During operation The ECOi main screen will be similar to the one below. ECO main screen Reference Description Compressor 1 is stopped Compressor 2 is running local Compressor 3 : No communication between regulator and related slave Compressor 4 is starting up Compressor 5 : Master VSD is loaded Compressor 6 : No valid compressor type...
  • Page 115 Instruction book 10.2.4.7 Stopping To stop all compressors: • Use the scroll buttons ▲▼►◄ to select the ECO icon • Press the enter button • In the next screen, select the ECO Stop by using the scroll buttons ▲▼ • Press the enter button to confirm •...

  • Page 116: Automatic Drain

    Instruction book • 0-5 V pressure transducer: • If a Pressure input is free on the Master controller, this input can be used to connect the pressure transducer. If no input is free an additional I/O2 module (expansion module) is required. •...

  • Page 117: Heavy Duty Filter

    Instruction book Technical features Maximum capacity of the compressor : /min Working pressure : 0.8 / 16 bar Operating + 1 / + 60°C temperature : Electric power supply : 230 / 110 / 24/ … AC socket in the compressor electric cabinet. 10.4 Heavy duty filter Description This system is equipped for "high efficiency"...
  • Page 118 Instruction book This option is recommended if the heavy duty filtration option is installed Overview The pre-filtration panels eliminate 90% of the particles normally admitted inside the compressor and considerably decrease internal contamination of the machine. The high quality of the ventilation air is also essential for protecting internal components of the compressor and, more specifically, the motor and the air / air and air / oil exchangers.
  • Page 119 Instruction book Pleated medium on support grid placed downstream the direction of the airflow Assembly Technical features Filter medium: Degree of filtration : 90% of the dust emitted is filtered. Total nominal flow : 6 000 m3/h Filter panel number : Initial charge loss : 75 Pa Dimensions...

  • Page 120: Rotation Direction Indicator - Phase Controller

    Instruction book 10.6 Rotation direction indicator - Phase controller Description The phase controller enables permanent and easier verification of the rotation direction of the machine by means of a diode. This prevents any risk of physical damage by disabling the compressor start up in case of phase reversal or if a phase is disconnected and indicates a machine fault.

  • Page 121: Graphic Controller

    Instruction book Note: This option is always included with the dryer option. Overview The cooling of the compressed air allows the suction air to be dried, thus removing the humidity that collects in the bottom of the separator after being condensed in the aftercooler. The condensates are evacuated from the separator through a trap with a solenoid drip valve or a trap with level detector if this option is installed.

  • Page 122: Tropical Thermostatic Valve

    Instruction book Description The graphic controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure Overview graphic menu • All the controller functions are shown as graphic icons in the Menu screen. •...

  • Page 123: Guidelines For Inspection

    Instruction book Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.

  • Page 124: Pressure Equipment Directives

    Instruction book Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive The following table contains the necessary information for the inspection of all pressure equipment of category II and higher according to the Pressure Equipment Directive 97/23/EC and all pressure equipment according to the Simple Pressure Vessel Directive 209/105/EC.
  • Page 125 Instruction book Compressor type Component Description Minimum Visual wall inspection thickness frequency 55-90 kW (≥10bar) 1202 5401 00 Safety valve 110 kW 6211 1116 69 Safety valve Overall rating The compressors conform to PED smaller than category I. 2920 7101 41...

  • Page 126: Declaration Of Conformity

    Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: International Compressor Distribution NV Boomsesteenweg 957 B-2610 Wilrijk (Antwerp) Belgium 2920 7101 41...
  • Page 127 Instruction book On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this device.
  • Page 130 People. Passion. Performance. www.cp.com...

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