Chicago Pneumatic CPVS 95 Instruction Book
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Chicago Pneumatic CPVS 95 Instruction Book

Oil-injected rotary screw compressors
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Oil-injected rotary screw compressors
People. Passion. Performance.
CPVS 40, CPVS 50, CPVS 60, CPVS 75, CPVS 95, CPVS 100,
CPVS 120, CPVS 150
Instruction book

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  • Page 1 Oil-injected rotary screw compressors People. Passion. Performance. CPVS 40, CPVS 50, CPVS 60, CPVS 75, CPVS 95, CPVS 100, CPVS 120, CPVS 150 Instruction book...
  • Page 3 Oil-injected rotary screw compressors CPVS 40, CPVS 50, CPVS 60, CPVS 75, CPVS 95, CPVS 100, CPVS 120, CPVS 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......................5 ........................... 5 AFETY ICONS ......................5 ENERAL SAFETY PRECAUTIONS ................... 6 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description...................... 10 ..........................10 NTRODUCTION .........................
  • Page 5 Instruction book 3.15 ............................. 49 EST MENU 3.16 ......................50 ODIFYING GENERAL SETTINGS 3.17 ..........................51 ENERAL MENU 3.18 ........................52 SER PASSWORD MENU 3.19 ........................... 54 CCESS KEY MENU 3.20 .........................54 ROGRAMMABLE SETTINGS Installation........................57 ........................57 IMENSION DRAWINGS ........................57 NSTALLATION PROPOSAL ..........................
  • Page 6 Instruction book ........................77 IL SEPARATOR CHANGE ............................78 OOLERS ..........................79 ILTERING PANEL ..........................80 AFETY VALVES ....................80 RYER MAINTENANCE INSTRUCTIONS Problem solving......................82 Technical data.......................86 ......................86 LECTRIC CABLE SIZE AND FUSES .................... 96 EFERENCE CONDITIONS AND LIMITATIONS ..........................96 OMPRESSOR DATA Options..........................

  • Page 7: 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 8: 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 9: 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 10: 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 11 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 12: General Description

    Instruction book General description Introduction General CPVS 40 up to CPVS 150 are single-stage, oil-injected screw compressors, gearbox driven by an electric motor. The compressors are available in air-cooled and water-cooled version. The compressors are enclosed in sound-insulated bodywork. The compressors are controlled by the ES 4000 Advanced controller. The ES 4000 controller and the emergency stop button are integrated in the door panel of the electric cubicle.
  • Page 13 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 Inverter 2920 7101 51...

  • Page 14: 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 15 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 16 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 17: 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 18: 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 19 Instruction book Electrical diagram There is a copy of the electrical diagram inside the electrical cubicle. 2920 7101 51...

  • Page 20: Graphic Controller

    Instruction book Graphic controller Controller View of the ES 4000 Advanced 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 (fixed speed compressors) or by adapting the motor speed (compressors with frequency converter).

  • Page 21: Control Panel

    Instruction book Example: If the compressor element outlet temperature exceeds the programmed shut-down level, the compressor will be stopped. This will be indicated on the display of the controller. The compressor will also be stopped in case of overload of the drive motor. Air-cooled compressors will also be stopped in the event of overload of the fan motor.

  • Page 22: Icons Used

    Instruction book Reference Designation Function Display Shows icons and operating conditions. 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.
  • Page 23 Instruction book Name Icon Description Machine control mode Local start / stop Remote start / stop Network control Automatic restart after voltage Automatic restart after voltage failure is active failure Week timer Week timer is active Active protection functions Emergency stop Shutdown Warning Service...
  • Page 24 Instruction book Name Icon Description Not valid Input icons Icon Description Pressure Temperature Digital input Special protection System icons Icon Description Compressor element (LP, HP, ...) Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem 2920 7101 51...
  • Page 25 Instruction book Icon Description General alarm Menu icons Icon Description Inputs Outputs Protections (Warnings, shutdowns) Counters Test Regulation (Settings) Service Event history (saved data) Access key / User password Network Setpoint Information Week Timer General 2920 7101 51...

  • Page 26: Main Screen

    Instruction book Navigation arrows Icon Description Down Main screen Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 5 different main screen views can be chosen: 1.
  • Page 27 Instruction book Element outlet Load, ... (text varies upon the compressors actual condition) Menu Running hours Load relay (one of the input signals of fixed speed compressors) Flow (compressors with frequency converter) • Section A shows information regarding the compressor operation (e.g. the outlet pressure or the temperature at the compressor outlet).

  • Page 28: Calling Up Menus

    Instruction book When Chart (High Resolution) is selected, the chart shows the variation of the selected input (in this case the pressure) per minute. Also the instantaneous value is displayed. The screen shows the last 4 minutes. The switch button (icon) for selecting other screens is changed into a small Chart and is highlighted (active).

  • Page 29: Inputs Menu

    Instruction book • To go to the Menu screen, highlight the Menu button (4), using the Scroll keys. • Press the Enter key to select the menu. Following screen appears: • The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected.
  • Page 30 Instruction book • Press the Enter key. A screen similar to the one below appears: Text on image Inputs Compressor outlet Element outlet Ambient air Emergency stop • The screen shows a list of all inputs with their corresponding icons and readings. •...

  • Page 31: Outputs Menu

    Instruction book Select Yes to remove or No to quit the current action. In a similar way, another input signal can be highlighted and selected as Main Chart signal: (1): Set as main chart signal Outputs menu Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact (on air cooled compressors), the Emergency stop contact, etc.

  • Page 32: Counters

    Instruction book • Press the Enter key. A screen similar to the one below appears: Outputs screen (typical) Text on image Outputs Fan motor contact Blow-off contact General shutdown Automatic operation • The screen shows a list of all outputs with their corresponding icons and readings. If an output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively.

  • Page 33: Control Mode Selection

    Instruction book Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. • Using the Scroll keys, move the cursor to the Counters icon (see below) • Press the Enter key. A screen similar to the one below appears: Text on image Counters Running hours...

  • Page 34: Service Menu

    Instruction book Next, use the scroll buttons to go to the Status icons (see section Main screen) and select the Regulation icon (2). When the icon is active, this icon is highlighted with a grey background colour. Press the enter button: There are 3 possibilities: •...
  • Page 35 Instruction book Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. • Using the Scroll keys, move the cursor to the Service icon (see below). • Press the Enter key. Following screen appears: Text on image Service Overview...
  • Page 36 Instruction book Text on image Overview Running Hours Real Time hours Reset Example for service level (A): The figures at the left are the programmed service intervals. For Service interval A, the programmed number of running hours is 4000 hours (upper row) and the programmed number of real time hours is 8760 hours, which corresponds to one year (second row).
  • Page 37 Instruction book Press the Enter key. Following screen appears: Modify the value as required using the ↑ or ↓ scroll key and press the Enter key to confirm. Note: Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1 hour.

  • Page 38: Regulation Menu

    Instruction book History The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is the most recent service action. To see the details of a completed service action (e.g. Service level, Running hours or Real time hours), use the Scroll keys to select the desired action and press the Enter key.

  • Page 39: Modifying The Setpoint

    Instruction book Modify • The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify the settings, move the cursor to the action button Modify and press the Enter key. Following screen appears: • The first line of the screen is highlighted. Use the Scroll keys to highlight the setting to be modified and press the Enter key.
  • Page 40 Instruction book • Activate the menu by pressing the enter key. A screen similar to the one below appears: Text on image Regulation Setpoint 1 Indirect stop level 1 Direct stop level 1 Setpoint 2 Modify • The screen shows the actual settings. To modify the settings, move the cursor to the action button Modify and press the Enter key.

  • Page 41: Event History Menu

    Instruction book The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑ or ↓ key of the Scroll keys to modify the settings as required and press the Enter key to accept. If necessary, change the other settings as required in the same way as described above.

  • Page 42: Week Timer Menu

    Instruction book Example of Event History screen • Scroll through the items to select the desired shut-down or emergency stop event. • Press the Enter key to find the date, time and other data reflecting the status of the compressor when that shut-down or emergency stop occurred.
  • Page 43 Instruction book Text on image Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time The first item in this list is highlighted. Select the item requested and press the Enter key on the controller to modify. Programming week schemes •...
  • Page 44 Instruction book Week Action Scheme 1 Monday Tuesday Wednesday Thursday Friday Saturday Sunday • A new window opens. The Modify action button is selected. Press the enter button on the controller to create an action. Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller.
  • Page 45 Instruction book Remove Start Stop Pressure Setpoint 1 Modify • A new window opens. The action is now visible in the first day of the week. Monday Start Save Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. Monday Start Save...
  • Page 46 Instruction book Monday Time Save Modify • Press the Escape key on the controller. The action button Modify is selected. Use the Scroll keys to select the action Save. Monday Start Save Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions. Press the Enter key to confirm.
  • Page 47 Instruction book Save Modify Press the Escape key to leave this window. • The action is shown below the day the action is planned. Week Action Scheme 1 Monday - Start Tuesday Wednesday Thursday Friday Saturday Sunday Press the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks.
  • Page 48 Instruction book Week Timer Inactive Remaining Running Time • A list of 10 weeks is shown. Week Cycle Week 1 Week 2 Week 3 Week 4 Modify Press twice the Enter key on the controller to modify the first week. •...
  • Page 49 Instruction book Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time • A new window opens. Select Week 1 to set the Week Timer active. Week Timer Week Week Timer Inactive Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active. 2920 7101 51...
  • Page 50 Instruction book Week Timer Week Action Schemes Week Cycle Status Remaining Running Time • Press the Escape key on the controller to go to the main Week Timer menu. Select Remaining Running Time from the list and press the Enter key on the controller to Modify. Week Timer Week Action Schemes Week Cycle...

  • Page 51: Test Menu

    Instruction book 3.15 Test menu Menu icon, Test Function • To carry out a display test, i.e. to check whether the display and LEDs are still intact. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. •...

  • Page 52: Modifying General Settings

    Instruction book 3.16 Modifying general settings Menu icon, Settings Function To display and modify a number of settings. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. • Using the Scroll keys, move the cursor to the Settings icon (see below). •...

  • Page 53: General Menu

    Instruction book Example: Selecting the General Settings icon gives the possibility to change e.g. the language, the date, the date format, etc.: Text on image General Language used Time Date Date format Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. •...

  • Page 54: User Password Menu

    Instruction book • Press the Enter key. A screen similar to the one below appears: Text on figure General Language in use Time Date Date format Modify • A screen similar to the one above is shown, a selection bar is covering the first item (Language). Use the ↓...
  • Page 55 Instruction book Function The end customer can activate and choose a personal password. Once the password option activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the submenu screen (see Modifying general settings), • Using the Scroll keys, move the cursor to the User Password icon (see below) •...

  • Page 56: Access Key Menu

    Instruction book 3.19 Access key menu Menu icon, Access Key Function Only a number of basic Icons will be displayed in the Menu screen. Using the Access Key with the proper access code allows the user to see more Icons, or have access to more parameters. Procedure Starting from the submenu screen (see Modifying general...
  • Page 57 Instruction book Parameters variable speed drive Minimum Factory Maximum setting setting setting Motor running time in star Load delay time (star-delta) 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...
  • Page 58 Instruction book Term Explanation Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum time stop time, whatever happens with the net air pressure. Consult your supplier if a setting lower than 20 seconds is required. Unloading/ The regulator does not accept illogical settings, e.g.

  • Page 59: Installation

    Instruction book Installation Dimension drawings CPVS 100 and CPVS 120 air-cooled compressors See document 9820 6706 09 on the CD supplied with your machine CPVS 100 and CPVS 120 water-cooled compressors See document 9820 6706 15 on the CD supplied with your machine CPE 150 and CPVS 150 air-cooled compressors See document 9820 7100 60 on the CD supplied with your machine CPE 150 and CPVS 150 water-cooled compressors...
  • Page 60 Instruction book Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage the bodywork during lifting or transport. Make sure that the forks protrude from the other side of the frame. The compressor can also be lifted after inserting beams in the slots.
  • Page 61 Instruction book 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. Position of the compressed air outlet valve. 3. The pressure drop over the air delivery pipe can be calculated from: 1.85 Δp = (L x 450 x Q ) / (d...

  • Page 62: Pictographs

    Instruction book • Qc= Free air delivery of the compressor in l/s • P1= Compressor air inlet pressure in bar absolute • fmax= Cycle frequency =1 cycle/30s • ΔP= P unload - P load in bar • T1= Compressor air inlet temperature in K •...
  • Page 63 Instruction book 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) Warning: Voltage Warning: Hot surface Earth connection Cooling water outlet Cooling water inlet Automatic condensate drain Manual condensate drain...

  • Page 64: 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 65 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 66 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 67: 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 68: Starting

    Instruction book Starting Procedure For the position of the air outlet valve and the drain connections, see sections Introduction. Control panel ES 4000 Advanced 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 69: 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 70: Automatic Restarting

    Instruction book Checking the oil level Position of oil level sight-glass Regularly check the oil level. To do so: 1. Press stop button (11). 2. A few minutes after stopping, the oil level should be between the oil filler neck (FC) and the top of the sight glass (Gl).

  • Page 71: Stopping

    Instruction book Stopping Regulator Control panel ES 4000 Advanced Procedure Step Action Press stop button (11). Automatic operation LED (3) goes out and the compressor stops after 30 seconds of unloaded operation. To stop the compressor in the event of an emergency, press emergency stop button. Alarm LED flashes (5).

  • Page 72: Taking Out Of Operation

    Instruction book Taking out of operation Procedure Step Action Stop the compressor and close the air outlet valve. Switch off the voltage and disconnect the compressor from the mains. If available, open the condensate drain valve(s) (Dm). Shut off and depressurise the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net.

  • Page 73: 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 74 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 75: 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 76: 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 77: 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 78: 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 79: 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 80: 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 81: 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 82: 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 83 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 84: 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 85 Instruction book Condition Fault Remedy Compressor air output or Air consumption exceeds air Check equipment connected pressure below normal delivery of compressor 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...
  • Page 86 Instruction book Condition Fault Remedy On water-cooled compressors, Increase flow cooling water flow too low 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...
  • Page 87 Instruction book Condition Fault Remedy Electronic condensate drain Electronic drain system Have system inspected remains inoperative clogged Clean the filter of the automatic drain by opening the manual drain valve. Check functioning of the drain by pushing the test button. Condensate trap continuously Automatic drain out of order Have system checked.

  • Page 88: 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 89 Instruction book 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 IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 45kW 45kW 45kW 45kW 45kW 45kW 45kW...
  • Page 90 Instruction book IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 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 90kW 90kW 90kW IEC approval Max Fuse...
  • Page 91 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 30kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) UL class UL class RK5 CSA Type RK5 CSA...
  • Page 92 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 75kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) UL class UL class RK5 CSA Type RK5 CSA...
  • Page 93 Instruction book • (1): Single supply cables. • (2): Parallel supply cables • (3) is only valid for Y-D versions Cable sizing according IEC The tables below indicate the current carrying capacities of cables for 3 commonly used installation methods, calculated according to standard 60364-5-52 - electrical installations of buildings part 5 - selection and erection equipment and section 52 - current carrying capacities in wiring systems.
  • Page 94 Instruction book Installation method C according table B.52.1. Single-core or multi-core cable on a wooden wall Maximum allowed current in function of the ambient temperature for installation method C Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...
  • Page 95 Instruction book • When using 2 x 3 phases + PE as in (3): • Add 10 % to the total compressor current (I Pack or I FF from the tables) and divide by √3 • Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1)) •...
  • Page 96 Instruction book • Add 10 % to the total compressor current (I Pack or I FF from the tables) • Install the prescribed fuse on each cable • Parallel supply cable (2 x 3 phases + 2 PE - configuration (2)): •...
  • Page 97 Instruction book AWG or kcmil Maximum current < 115 A < 130 A < 150 A < 175 A < 200 A Calculation method for UL: • Single supply cables (3 phases + 1 PE - configuration (1)): • Add 25 % to the total current from the tables (see UL 508A 28.3.2: "Ampacity shall have 125 % of the full load current") •...

  • Page 98: Reference Conditions And Limitations

    Instruction book Reference conditions and limitations Reference conditions Air inlet pressure (absolute) Air inlet pressure (absolute) 14.5 Air inlet temperature ˚C Air inlet temperature ˚F Relative humidity On water-cooled units also: Cooling water inlet temperature ˚C Cooling water inlet temperature ˚F Limits Maximum working pressure...
  • Page 99 Instruction book Gearbox driven units Units 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Frequency Nominal working bar(e) 7 12.5 10.3 pressure psig Maximum working bar(e) 7.5 10.8 12.5 pressure psig Unloading pressure bar(e) 7.2 12.7 10.5...

  • Page 100: 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 101 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 102 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 103 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 104 Instruction book Variable speed driven (VSD) air-cooled compressors are equipped with a bypass valve BV2 that starts opening at 40 ˚C (104 ˚F) and which is completely open at 55 ˚C (131 ˚F). Variable speed driven (VSD) water-cooled compressors are equipped with a bypass valve BV2 that starts opening at 60 ˚C (140 ˚F) and which is completely open at 75 ˚C (167 ˚F).
  • Page 105 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 60 ˚C (140 ˚F) and is completely open at 75 ˚C (167 ˚F).
  • Page 106 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 107 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 108: 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 109 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 110 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 111 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 112 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 113 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 114 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 115 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 116 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 117 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 118 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 119: 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 120: 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 121 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 122 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 123: 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 124: Tropical Thermostatic Valve

    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 125: Specific Information Frequency Converter

    Instruction book Specific information frequency converter 11.1 Description CPVS machines are compliant with the Electromagnetic compatibility in industrial environments Standards 50081-2 and 50082-2 Standard equipment A electronic frequency adjusting device replaces the star-delta starter. A fuse holder section switch completes the compressor standard's safety devices. A protection foam to protect the frequency converter against dust contamination.
  • Page 126 Instruction book The internal components and the plates (except the electrically insulated I/O terminals) are at the mains voltage when the inverter is connected to the mains. This voltage is extremely dangerous and can cause severe injuries or even death in case of involuntary contact. When the inverter is connected to the mains, the connection terminals U, V, W of the motor as well as +/- connectors of the braking resistors are under power even if the motor is not running.
  • Page 127 Instruction book The fuses for the section switch are defined as follows Motor power (kW) Mains voltage 380/400/415 Volt / 3 / 50/60 Hz Nominal current (400 V) Power supply cable H 07 Section mm² L= 10 m maxi Upstream fuses (type gG) Attention Motors and drives can only be guaranteed where the supply voltage does not exceed the rated voltage by more than 10%.
  • Page 128 Instruction book 2 - Control of rotation direction on start up This control must be implemented when the machine is put into operation for the first time, after any work has been carried out on the motor and after any changes to the mains supply. Important •...
  • Page 129 Instruction book • If the mains pressure is stronger than the pressure set point, the motor will slow down causing the pressure to drop. The controller provides the compressor control functions and also controls the whole pressure feedback loop. It therefore includes a device to compare the indicated pressure with that from the pressure sensor, associated with a compensating device, Proportional integral control PI.
  • Page 130 Instruction book towards the indicated pressure and, at the end of the minimum time delay (since reaching the no-load pressure), the drive allows the motor to restart. The pressure then rises again and the cycle starts over. To avoid pumping the system - frequent stop / start - drainage time may be increased. Energy saving For demand of compressed air within the machine's flow range - minimum flow to maximum flow, the frequency converter or the variable speed drive feed the motor in order to ensure that it turns at the speed...
  • Page 131 Instruction book The most likely incidents, along with the procedures to be applied, are listed in the controller manual. 2920 7101 51...

  • Page 132: 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 133: 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 134 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 51...

  • Page 135: 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 51...
  • Page 136 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 138 People. Passion. Performance.

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