Related Manuals for Chicago Pneumatic CPI 75
Summary of Contents for Chicago Pneumatic CPI 75
- Page 1 Oil-injected screw compressors CPI 75, CPI 100, CPI 101, CPI 120, CPV 60VS PM, CPV 75VS PM, CPV 100VS PM, CPV 101VS PM, CPV 120VS PM, CPM 75, CPM 100, CPM 120 Instruction book...
- Page 3 CP Chicago Pneumatic Oil-injected screw compressors CPI 75, CPI 100, CPI 101, CPI 120, CPV 60VS PM, CPV 75VS PM, CPV 100VS PM, CPV 101VS PM, CPV 120VS PM, CPM 75, CPM 100, CPM 120 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.
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Page 4: Table Of Contents
Instruction book Table of contents Safety precautions......................6 Safety icons..........................6 General safety precautions....................6 Safety precautions during installation................7 Safety precautions during operation..................8 Safety precautions during maintenance or repair.............. 9 Dismantling and disposal......................11 General description...................... 12 Introduction..........................12 Air and oil circuit........................18 Cooling system.........................21 Condensate system........................22... - Page 5 Instruction book Auxiliary equipment parameters menu..................40 Data menu..........................41 Service menu..........................42 3.10 Controller settings menu..................... 44 3.11 Information menu........................46 Touch controller......................48 Controller functions......................48 Control panel.......................... 50 Icons used..........................51 Main screen..........................55 Quick access screen........................56 Menu screen..........................57 Data menu..........................58 Service menu..........................
- Page 6 Instruction book Electrical connections......................80 Pictographs..........................83 Energy recovery......................86 Energy recovery (ER) unit..................... 86 Energy recovery (ER) systems....................87 Energy recovery (ER) operation..................88 Energy recovery (ER) maintenance..................90 Energy recovery (ER) data....................91 Energy recovery (ER) cooling water requirements............92 Operating instructions....................
- Page 7 Instruction book Coolers............................117 Filtering panel........................117 Safety valves.......................... 118 Dryer maintenance instructions..................119 8.10 Service kits..........................120 8.11 Storage after installation....................120 Problem solving......................121 Technical data......................125 10.1 Readings on display....................... 125 10.2 Electric cable size and fuses....................126 10.3 Dryer switches........................139 10.4 Reference conditions and limitations................
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Page 8: Safety Precautions
Instruction book Safety precautions Safety icons Danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Notice: Indicates a potential situation which, if not avoided, might result in property damage or in an undesirable result or state. -
Page 9: Safety Precautions During Installation
Instruction book • If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration. -
Page 10: Safety Precautions During Operation
Instruction book • On machines with automatic start/stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning" must be affixed near the instrument panel. • In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return valves (check valves) must not be relied upon for isolating pressure systems. -
Page 11: Safety Precautions During Maintenance Or Repair
Instruction book • All guards are in place and securely fastened • All hoses and/or pipes inside the machine are in good condition, secure and not rubbing • No leaks occur • All fasteners are tight • All electrical leads are secure and in good order •... - Page 12 Instruction book • Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. See section Maintenance. • Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapors of cleaning liquids.
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Page 13: Dismantling And Disposal
Instruction book These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. -
Page 14: General Description
Instruction book General description Introduction CPI 75-120, CPM 75-120 and CPV 60VS-120VS PM are single-stage, oil-injected screw compressors, driven by an electric motor. The units are air-cooled or water-cooled. The units are controlled by a controller. The controller and the emergency stop button are integrated in the door panel of the electric cubicle. - Page 15 Instruction book Figure 1: Front view 2920 7217 01...
- Page 16 Instruction book Figure 2: Motor side view, Pack 2920 7217 01...
- Page 17 Instruction book Figure 3: Service side view, Pack 2920 7217 01...
- Page 18 Instruction book Figure 4: Motor side view, Full-Feature 2920 7217 01...
- Page 19 Instruction book Figure 5: Service side view, Full-Feature Reference Description Electric cabinet Outlet valve Air cooler Oil cooler Compressor element Controller Cooling fan Motor of the compressor Emergency stop button 2920 7217 01...
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Page 20: Air And Oil Circuit
Instruction book Reference Description Condensate outlets Unloader Air filter Air receiver (oil separator tank) Oil filter Dryer (only on units with integrated dryer) Air and oil circuit Air circuit Figure 6: Flow diagram, air circuit (units without integrated dryer) 2920 7217 01... - Page 21 Instruction book Figure 7: Flow diagram, air circuit (units with integrated dryer) Reference Description Intake air Air/oil mixture Wet compressed air Condensate Dried compressed air Description Air drawn through the inlet filter (AF) and the open inlet valve (IV) of the unloader is compressed in the compressor element (E).
- Page 22 Instruction book Under all circumstances, the minimum pressure valve (Vp) keeps the pressure in the separator tank (AR) above the minimum value that is required for lubrication of the compressor element. An integrated check valve prevents the compressed air downstream the minimum pressure valve from being vented to the atmosphere during unloaded operation.
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Page 23: Cooling System
Instruction book Cooling system Air-cooled Figure 9: Cooling system, air-cooled units Reference Description Intake air Air/oil mixture Wet compressed air Condensate Description The cooling system on air-cooled units comprises an air cooler (Ca) and oil cooler (Co). The cooling air flow is generated by the fan (FN). 2920 7217 01... -
Page 24: Condensate System
Instruction book Water-cooled Figure 10: Cooling system, water-cooled units Reference Description Intake air Air/oil mixture Wet compressed air Cooling water flow Description The cooling system on water-cooled units comprises an air cooler (Cwa) and oil cooler (Cwo). They are connected to a cooling water circuit. The water flows through the inlet pipe, the coolers and the outlet pipe. -
Page 25: Regulating System
Instruction book Figure 11: Condensate drain Drain connections Figure 12: Condensate drain connections Reference Description Automatic drain connection Manual drain valve Regulating system 2.5.1 Unloader Applicable to units with an unloader. 2920 7217 01... - Page 26 Instruction book Load/unload regulating system Figure 13: Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, the solenoid valve (Y1) is energized. Results: • The space above the unloading valve/blow-off valve (UV) is connected to the oil separator tank pressure (1) via the solenoid valve.
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Page 27: Electrical System
Instruction book 2.5.2 Check valve Applicable to units with a check valve. When the unit is started and the net pressure is below the setpoint, the motor speed increases until the net pressure reaches the setpoint or until the maximum motor speed is reached. If the air consumption is less than the air delivery of the unit, the net pressure increases further. - Page 28 Instruction book Reference Designation Transformer Customer supply connection 1X3-PE Earth terminal Fan contactor Line contactor Star contactor Delta contactor Electrical components, variable speed units Figure 15: Electrical cabinet, variable speed units Reference Designation Transformer Customer supply connection 1X3-PE Earth terminal Fan contactor Frequency converter Electrical diagram...
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Page 29: Air Dryer
Instruction book 9820 7264 56 Fixed speed, analog control module, Swipe controller 9820 7264 69 Fixed speed, analog control module, Touch controller Table 1: Fixed speed units 9820 7264 81 Variable speed, power module 9820 7264 83 Analog control module, variable speed motor 9820 7264 99 Analog control module, permanent magnet variable speed motor Table 2: Variable speed units... - Page 30 Instruction book Reference Description Liquid refrigerant dryer / filter Capillary Bypass valve Condenser cooling fan Pressure switch, fan control Liquid separator Compressed air circuit Compressed air enters the heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the incoming air starts to condense.
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Page 31: Swipe Controller
Instruction book Swipe controller Controller Figure 17: The ES4000 Swipe controller Introduction The controller has following functions: • Controlling the unit • Protecting the unit • Monitoring components subject to service • Automatic restart after voltage failure (ARAVF) Automatic control of the unit The controller maintains the net pressure between programmable limits by automatically loading and unloading the unit. - Page 32 Instruction book If the element outlet temperature exceeds the programmed shutdown level, the unit will be stopped. The unit will also be stopped in case of overload of the drive motor or fan motor. Warning: Before remedying, consult the Safety precautions. Before resetting a warning or shutdown message, always solve the problem.
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Page 33: Control Panel
Instruction book Control panel Figure 18: Control panel Parts and functions Reference Designation Function Flashes in case of a shut-down, is lit in case of Warning sign a warning condition. Service sign Is lit when service is needed. Operation sign Is lit when the unit is running. -
Page 34: Icons Used
Instruction book Icons used Menu icons Menu Icon Main screen Machine Settings Aux. Equipment Parameters Data Service Controller Settings Information Status icons Icon Description Motor Stopped Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded Running Loaded Wait Machine Control Mode, Local Machine Control Mode, Remote 2920 7217 01... -
Page 35: Menu
Instruction book Machine Control Mode, LAN Auto Restart After Voltage Failure (ARAVF) System icons Icon Description Basic User Advanced User Service User Change between screens (indication) Reset Note: This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine. - Page 36 Instruction book Menu structure Reference Designation Function Next to the main screen, a maximum of 3 extra values can be Main screen shown. Setpoints, Regulation settings and Control parameters can be Machine settings viewed and modified through this menu. Settings for auxiliary equipment can be viewed and modified Aux.
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Page 37: Main Screen
Instruction book This is the main menu structure. The structure can be different depending on the configuration of the unit. Select or modify a setting Several settings can be modified. The process of selecting or modifying a setting anywhere in the menu is basically the same. - Page 38 Instruction book Description Reference Designation Function On the main screen, the screen information bar shows the current status Screen information of the machine. When scrolling through menus, the name of the current menu item is shown. The access level icon shows the current access level setting.
- Page 39 Instruction book Parameters Starting from the main screen, swipe left to scroll through predefined IO or counter data. (optional) Figure 20: Example Setpoint used Starting from the main screen, swipe left until the Setpoint used screen is shown. To switch to a different setpoint, swipe up or down on the left vertical swipebar or tap next to the corresponding square.
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Page 40: Machine Settings Menu
Instruction book To reset the alarm, press the confirm button under the reset icon. To cancel without resetting, press the cancel button under the red ‘X’ icon. Warning: Before remedying, consult the Safety precautions. Before resetting a warning or shutdown message, always solve the problem. Frequently resetting these messages without remedying may damage the unit. - Page 41 Instruction book To select a load and unload setpoint, or to modify the values, see section Select or modify a setting. Setpoint 2 Starting from the Machine Settings menu, swipe left until the Setpoint 2 screen is shown. To select a load and unload setpoint, or to modify the values, see section Select or modify a setting.
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Page 42: Auxiliary Equipment Parameters Menu
Instruction book The controller has a built-in function to automatically restart the compressor when voltage is restored after voltage failure. This function is deactivated in compressors leaving the factory and can only be modified after entering a password, please consult your supplier to activate this function. -
Page 43: Data Menu
Instruction book SmartBox Starting from the Aux. Equipment parameters menu, swipe left until the Internal SmartBox screen is shown. The reception quality of the internal antenna can be monitored. To select a menu item, or to change the setting, see section Select or modify a setting. Data menu Function The Data menu provides the ability to view several important values. -
Page 44: Service Menu
Instruction book Counters Starting from the Data menu, swipe left until the Counters screen is shown. Select To select a different item, swipe up or down on the left vertical swipebar. Inputs Starting from the Data menu, swipe left until the Inputs screen is shown. Select To select a different item, swipe up or down on the left vertical swipebar. - Page 45 Instruction book • Next service • Safety valve test Procedure To view the Service menu: 1. Use the controller as a Service user See Controller settings menu to change the user profile. 2. Tap the Home button on top of the screen to go to the main screen. 3.
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Page 46: Controller Settings Menu
Instruction book On the horizontal swipebar, tap ‘V’ to confirm or ‘X’ to decline. 3.10 Controller settings menu Function The Controller Settings menu provides the ability to view and modify several settings of the controller. Swipe left to navigate to the following screens: •... - Page 47 Instruction book Enter a password The Service user profile is protected by a password. After selecting the Service user profile, the following screen pops up: The user can enter the password by swiping up or down on the right vertical swipebar to select the first digit.
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Page 48: Information Menu
Instruction book Display timeout is used to save energy and save the lifetime of the display. Timer starts after last operator actions on the push buttons or swipe bars. To modify the setting, see section Select or modify a setting. 3.11 Information menu Function... - Page 49 Instruction book 2920 7217 01...
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Page 50: Touch Controller
Instruction book Touch controller Controller functions Figure 21: The ES4000 Touch controller Introduction The controller has the following functions: • Controlling the unit. • Protecting the unit. • Monitoring components subject to service. • Automatic restart after voltage failure (ARAVF). This function can only be activated by a service technician. - Page 51 Instruction book Shutdown Several sensors are provided on the unit. If one of the measured signals exceeds the programmed shutdown level, the unit will be stopped. Example: If the outlet pressure exceeds the programmed shutdown level, the unit will be stopped. This will be indicated on the display of the controller.
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Page 52: Control Panel
Instruction book Control panel Figure 22: Control panel Reference Designation Function Shows the unit operating condition and several icons to Touch screen navigate through the menu. The screen can be operated by touch. Flashes in case of a shut-down, Warning sign is lit in case of a warning condition. -
Page 53: Icons Used
Instruction book Icons used Menu icons Menu Icon Menu Icon Menu Icon Data Status Inputs Outputs Counters Auxiliary Equipment Converters Parameters Service Service Overview Service Plan Service History Service Functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data Machine Alarms... - Page 54 Instruction book Menu Icon Menu Icon Menu Icon Internal SmartBox Auto Restart Controller Network Ethernet Settings Settings Settings CAN Settings Localisation Language Date/Time Units User Password Help Information Status icons Icon Description Motor Stopped Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded 2920 7217 01...
- Page 55 Instruction book Icon Description Failed to Load Running Loaded Wait Manual Stop Machine Control Mode, Local Machine Control Mode, Remote Machine Control Mode, LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description Basic User Advanced User Service User Antenna 25% Antenna 50%...
- Page 56 Instruction book Icon Description Dryer Element Drain(s) Analogue Output Menu Reset Auto Restart Filter(s) Cooler Valve(s) Power Meter Input icons Icon Description Pressure Temperature Special Protection Open Closed Note: This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine.
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Page 57: Main Screen
Instruction book Main screen Function The main screen is the screen that is shown automatically when the voltage is switched on. It is switched off automatically after a few minutes when there is no touch input. Description Reference Designation Function The home button is always shown and can be Home button tapped to return to the main screen. -
Page 58: Quick Access Screen
Instruction book Quick access screen Function The screen is used to directly access some frequently used functions. Procedure The quick access screen can be viewed by swiping left, starting from the main screen. Description Through this screen, several important settings can be viewed and modified. Reference Function Description... -
Page 59: Menu Screen
Instruction book Reference Function Description Auto restart can be activated by tapping this Auto Restart icon. Menu screen Function This screen is used to display the different menus where settings can be viewed or changed. Procedure The menu screen can be viewed by tapping the menu button or by swiping right, starting from the main screen. -
Page 60: Data Menu
Instruction book Menu structure Operating the controller can be done by swiping through screens and tapping icons or menu items. This is the main structure. It can differ depending on the configuration of the unit. Data menu Function This screen is used to display the following submenus: •... - Page 61 Instruction book Description Reference Description Status menu Inputs menu Outputs menu Counters Auxiliary equipment menu Status menu Tap the Status icon to enter the Status menu. This menu shows the current status of the unit. If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the reset button.
- Page 62 Instruction book Outputs menu Tap the Outputs icon to enter the Outputs menu. This menu shows information about all the outputs. Danger: Voltage-free outputs may only be used to control or monitor functional systems. They should NOT be used to control, switch or interrupt safety related circuits. Check the maximum allowed load on the label.
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Page 63: Service Menu
Instruction book Service menu Function This screen is used to display the following submenus: • Service • Service Functions (visible as advanced user) • Clean Screen These submenus can be entered by tapping the icons. Procedure To enter the Service menu screen: 1. -
Page 64: Week Timer Menu
Instruction book 1. Tap the desired service plan. A selection screen will pop up. 2. Change the Running Hours by tapping ‘–’ or ‘+’. 3. Confirm by tapping ‘V’ or decline by tapping ‘X’. The service history can be viewed by tapping icon (3). When a service plan interval is reached, a message will appear on the screen. -
Page 65: Event History Menu
Instruction book Description Reference Designation Function If less than 4 weeks are programmed, tap the ‘+’ Add or select week button to add a week. Remove week Tap to remove a programmed week timer. A selection screen pops up. The user can choose the correct week by tapping ‘–’... -
Page 66: Machine Settings Menu
Instruction book Reference Description Saved Data Saved data Tap the Saved Data icon to enter the Saved Data menu. Scroll through the items swiping up and down in this list. The event date and time is shown at the right side of the screen. Press on one of the items in the list for more information reflecting the status of the unit when the shutdown occurred. - Page 67 Instruction book Alarms menu Tap the Alarms icon to enter the Alarms menu. A list of all alarms is shown. When pressing on one of the items in the underlying list, the warning and/or shutdown levels are shown for this alarm. Regulation menu Tap the Regulation icon to enter the Regulation menu.
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Page 68: Controller Settings Menu
Instruction book Auxiliary equipment parameters menu Tap the Aux. Equipment Parameters icon to enter the Aux. Equipment Parameters menu. This menu shows an overview of all the auxiliary equipment fitted. Through this menu, the parameters of the auxiliary equipment can be changed. Modify a setting When tapping a list item, a selection screen pops up. - Page 69 Instruction book • Information These submenus can be entered by tapping the icons. Procedure To enter the Controller Settings menu screen: 1. Tap the Menu button. 2. Tap the Controller Settings icon. Description Reference Description Network Settings menu Localisation menu User Password menu Help menu Information menu...
- Page 70 Instruction book Localisation menu Tap the Localisation icon to enter the Localisation menu. Language The language setting of the controller can be modified through this menu. Date/Time The date and time settings of the controller can be modified through this menu. Units The units displayed can be modified through this menu.
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Page 71: Access Level
Instruction book This menu can show a link to the web page of your supplier, a helpdesk phone number or other helpful information. Information menu Tap the Information icon to enter the Information menu. This menu shows information about the controller. 4.13 Access level Function... -
Page 72: Technical Data Controller
Instruction book Reference Designation Function Confirm Tap to confirm the selected user level. Service access level Tap the Service access level icon (1) and confirm (2). The screen information bar (1) now shows the current status of the unit instead of the machine serial number. -
Page 73: Web Server
Instruction book Digital outputs Number of outputs Type Relay (voltage free contacts) Rated voltage AC 250 V AC / 10 A max. Rated voltage DC 30 V DC / 10 A max. Minimum amperage 10 mA on potential free contact Digital inputs Number of inputs Supply by controller... - Page 74 Instruction book • Click on Change adapter settings (1). • Select the Local Area Connection, which is connected to the controller. • Click with the right button and select Properties (1). • Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked.
- Page 75 Instruction book • Subnetmask 255.255.255.0(2) Click OK (3) and close network connections. Configure a company network (LAN) connection • Ask your IT department to generate a fixed IP address in your company’s network. That IP address will be excluded from the DNS server, so it will be reserved for the controller. Also get the correct Gateway and Subnet mask settings.
- Page 76 Instruction book • Adapt IP adress • Adapt Gateway IP • Adapt Subnetmask • Switch on the Ethernet communication • Wait a few minutes so the controller can be connected to the LAN network. Configuration of the web server ® The internal web server is designed and tested for Microsoft Internet Explorer.
- Page 77 Instruction book • Machine: shows all generator settings. • ES: shows the ESi status (if a license is provided). • Preferences: allows to change temperature and pressure unit. 2920 7217 01...
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Page 78: Installation
Instruction book Installation Dimension drawings The dimension drawing can be found in the technical documentation, supplied with the unit. Dimension drawing Model 9828 5225 40 Pack, PM units 9828 5225 41 Full-Feature, PM units 9828 5225 42 Pack, fixed speed units with inlet basket 9828 5225 43 Full-Feature, fixed speed units with inlet basket 9828 5225 44... - Page 79 Instruction book Compressor room example Reference Description Ventilation proposals Minimum free area to be reserved for the compressor installation Note: 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 80 Instruction book 1.85 Δp = (L x 450 x Q ) / (d x P), with • Δp = pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi)) • L = length of the pipe in m • = Free air delivery of the compressor in l/s •...
- Page 81 Instruction book • fmax= Cycle frequency =1 cycle/30s • ΔP= P unload - P load in bar • T1= Compressor air inlet temperature in K • To= Air receiver temperature K 10. To prevent feedback of exhaust air to the cooling inlet, sufficient space should be foreseen above the unit to evacuate the exhaust air.
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Page 82: Electrical Connections
Instruction book • Main Motor: Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of the drive motor while the motor is coasting to a stop. The correct rotation direction of the drive is indicated by an arrow shown on the motor fan cowl. If the rotation direction of the drive motor is incorrect, open the isolating switch and reverse two incoming main power lines. - Page 83 Instruction book The complete electrical diagram can be found in the technical documentation supplied with the unit. Figure 23: Electrical connections, fixed speed units 2920 7217 01...
- Page 84 Instruction book Figure 24: Electrical connections, variable speed units Reference Description Customer’s installation Power circuit Motor Description Note: You can find the correct position for the electrical connections in the section Dimension drawings. 1. Provide an isolating switch. 2. Check that the motor cables and wires inside the electrical cabinet are clamped tight to their terminals.
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Page 85: Pictographs
Instruction book Compressor control mode The following control modes can be selected: • Local control: The compressor will react to commands entered by means of the buttons on the control panel. Compressor start/stop commands via Clock function are active, if programmed. •... - Page 86 Instruction book Table 3: Pictographs Reference Description Warning: Always read the manual, switch off the voltage, depressurize compressor and lock out/ tag out before repairing. Keep the doors closed during operation. Switch off the voltage before removing protecting cover inside electrical cubicle. Warning, voltage.
- Page 87 Instruction book Reference Description Compressor remains pressurized for 180 seconds after switching off the voltage. Torques for steel (Fe) or brass (CuZn) bolts. Switch off the voltage and wait at least 6 minutes before removing the screen. Oil outlet. Cooling water inlet. Cooling water outlet.
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Page 88: Energy Recovery
Instruction book Energy recovery Energy recovery (ER) unit Description A large part of the energy required for any compression process is transformed into heat. The major part of the compression heat is dissipated through the oil system. Energy recovery (ER) systems are designed to recover most of this heat by transforming it into warm or hot water without any adverse effects on compressor performance. -
Page 89: Energy Recovery (Er) Systems
Instruction book Reference Description Oil drain plug Oil flexible from compressor oil separator vessel to ER unit Oil flexible from ER unit to oil filter housing Pressure relief valve Location of heat exchanger by-pass valve (BV2) Heat exchanger Selector valve Oil separator tank Oil filter housing Location of oil cooler bypass valve (BV1) -
Page 90: Energy Recovery (Er) Operation
Instruction book deposits. Although the heat exchanger is made of stainless steel, the water circuit connected to the compressor may require corrosion inhibitors. Add an anti-freeze product such as ethylene-glycol to the water in proportion to the expected temperature to avoid freezing. Water requirements for open water circuits In open, non-recirculating water circuits, major problems that are usually encountered are related to deposit control, corrosion control, and microbiological growth control. - Page 91 Instruction book Reference Description Oil cooler of the compressor Water inlet Oil filter Oil separator vessel Thermostatic bypass valve in the oil filter housing Aftercooler of the compressor Water outlet The thermostatic bypass valve of the energy recovery unit (BV2) starts closing the bypass line over the heat exchanger (HE) at the lower limit of its temperature range.
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Page 92: Energy Recovery (Er) Maintenance
Instruction book Operation principle at different loads: • Low consumption of recovered energy: The temperature of the oil leaving the heat exchanger (HE) rises. When the temperature rises above its set point, the oil cooler bypass valve (BV1) will gradually allow the oil to be cooled in the oil cooler (Co). -
Page 93: Energy Recovery (Er) Data
Instruction book the heat exchanger in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult your supplier. Energy recovery (ER) data Reference conditions See section Reference conditions and limitations. Effective working pressure See section Compressor data for the normal working pressure. -
Page 94: Energy Recovery (Er) Cooling Water Requirements
Instruction book Parameter Unit 45kW 55kW 75kW 76kW 90kW Recoverable energy 39.4 48.1 65.6 66.5 78.8 Recoverable energy 52.8 64.5 88.0 89.2 105.6 Water flow l/min 28.1 34.4 46.9 47.5 56.3 Water flow 59.6 72.8 99.3 100.6 119.1 Temperature at inlet ˚C Temperature at inlet ˚F... - Page 95 Instruction book application (Standard – max 65 °C cooling water temperature at the outlet) or energy recovery (water temperature up to 95 °C). In case water is not in line with recommended values or if any doubt, consult the manufacturer. Cooling water parameters 1.
- Page 96 Instruction book Ca (ppm Ca CO Type of cooling system Standard Energy recovery (ER) Single pass < 500 < 2 Recirculating (with tower) < 500 not applicable Closed loop < 1000 < 50 4. The Ryznar Stability Index (RSI) The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate.
- Page 97 Instruction book Total Temperature Ca hardness dissolved (°C) (ppm CaCO Alkalinity solids (ppm (mg/l) CaCO 62 - 67 142 - 177 142 - 177 68 - 73 178 - 223 178 - 223 74 - 79 224 - 281 224 - 281 80 - 85 282 - 355 282 - 355...
- Page 98 Instruction book Dissolved iron (ppm) Dissolved manganese (ppm) Type of cooling Standard Energy Standard Energy system recovery (ER) recovery (ER) Single pass < 1 < 0.2 < 0.2 < 0.05 Recirculating < 1 not applicable < 0.2 not applicable (with tower) Closed loop <...
- Page 99 Instruction book Note: If additives are used in the cooling water, take into account that the cooling capacity will change. Δm = ((C ) * X) / (C *(1-X) + X*C ) * 100 % with Δm: change of mass flow of the coolant : specific heat capacity of water : specific heat capacity of the additives X: the percentage of additives...
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Page 100: Operating Instructions
Instruction book Operating instructions Initial start-up Warning: The operator must apply all relevant safety precautions. Note: For the location of the air outlet valve and the drain connections, see sections Introduction and Condensate system. Preparations 1. Consult the sections Electrical cable size, Installation proposal and Dimension drawings. 2. - Page 101 Instruction book Figure 27: Electrical cubicle, fixed speed 2920 7217 01...
- Page 102 Instruction book Figure 28: Electrical cubicle, variable speed 5. Fit air outlet valve (AV). See section Introduction for the location of the valve. 6. Close the valve. 7. Connect the air net to the valve. 8. Connect the condensate drain outlet(s) to a drain collector. See section Condensate system. The drain pipes to the drain collector must not dip into the water.
- Page 103 Instruction book 3. Pour approximately 0.75 l (0.20 US gal, 0.17 Imp gal) of compressor oil into the compressor element inlet. For oil specifications, see section Oil specifications. 4. Reinstall the unloader (UA) or inlet valve and reconnect the inlet hose. 5.
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Page 104: Before Starting
Instruction book correct rotation direction on the fan motor. If the rotation direction of the fan motor is incorrect, open the isolating switch and reverse two incoming main power lines. 4. Start and run the compressor for a few minutes. Check that the compressor operates normally. 5. - Page 105 Instruction book Figure 31: Swipe controller Figure 32: Touch controller 1. Open the air outlet valve. 2. Switch on the voltage. Check that voltage on LED lights up. 3. Press start button on the control panel. The compressor starts running and the automatic operation LED lights up.
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Page 106: During Operation
Instruction book than 100 °C, this will lead to more rapid oil deterioration, which will have an impact on oil service intervals. Consult your supplier for best practices in this case. Also consult your supplier in case condensate should form in the oil. For optimal operation, the cooling water outlet temperature must never exceed the value specified in section Reference conditions and limitations. - Page 107 Instruction book Note: Removing the service panel during operation will lead to an automatic shutdown of the unit after a certain time, depending on the version of the unit. Note: Keep the doors closed during operation. Figure 34: Swipe controller Figure 35: Touch controller 2920 7217 01...
- Page 108 Instruction book Checking the oil level Figure 36: Position of the oil level sight-glass Regularly check the oil level. To do so: 1. Press the stop button. 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).
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Page 109: Checking The Display
Instruction book Checking the display Figure 37: Swipe controller Figure 38: Touch controller Check the main screen regularly for readings and messages. The display normally shows the compressor outlet pressure, while the status of the compressor is indicated by pictographs. Remedy the trouble if the alarm LED is lit or flashes, see section Shutdown warning, Shutdown and Problem solving. -
Page 110: Stopping
Instruction book Carry out the service actions of the indicated plans or replace the component and reset the relevant timer, see section Service warning. Stopping Figure 39: Swipe controller Figure 40: Touch controller Procedure 1. Press the stop button. The automatic operation LED goes out and the compressor stops after 30 seconds of unloaded operation. -
Page 111: Taking Out Of Operation
Instruction book 2. To stop the compressor in the event of an emergency, press the emergency stop button. The alarm LED flashes. a. Remedy the problem cause and unlock the button by pulling it out. b. Press the alarm icon. c. -
Page 112: Maintenance
Instruction book Maintenance Preventive maintenance schedule Warning: Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Close the air outlet valve. • Wait 10 minutes for the vessel to depressurize. • Press the emergency stop button. •... - Page 113 When reaching the interval, a message will appear on the screen indicating which service plans are to be carried out. See section Service menu. After servicing, the intervals must be reset. The following table is valid for CPI 75-120 and CPV 60VS-120VS PM. Interval A-service B-service...
- Page 114 Instruction book Interval A-service B-service C-Service D-Service Operations to be carried out Every 4000 Every 8000 Every 16000 Every 24000 running running running running hours hours hours hours Clean the filter mats Change the oil filter Change the lubricant Change the air filter Change the inverter filter and the cubicle filter...
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Page 115: Oil Specifications
Instruction book Interval A-service B-service C-Service D-Service Operations to be carried out Every 2000 Every 4000 Every 8000 Every 24000 running running running running hours hours hours hours Change the inverter filter and the cubicle filter Change the oil separator element Overhaul the drain valve Overhaul the unloader valve Oil stop valve (check valve) kit... -
Page 116: Drive Motor
Instruction book Rotair Plus Rotair Plus is a high-quality lubricant for oil-injected screw compressors which keeps the compressor in excellent condition. See the table below for oil exchange intervals: Ambient temperature Element outlet Exchange interval Maximum time temperature interval up to 30°C (95°F) up to 95°C (203°F) 4000 1 year... -
Page 117: Air Filter
Instruction book Air filter Location of air filter Recommendations 1. Never remove the element while the compressor is running. 2. For minimum downtime, replace the dirty element by a new one. 3. Discard the element when damaged. Procedure 1. Stop the compressor. Switch off the voltage. Lock Out and Tag Out. 2. - Page 118 Instruction book Procedure Figure 41: Oil drain and filler plug on the oil separator vessel Figure 42: Vent plug, oil cooler 1. Run the compressor until warm. 2. Stop the compressor after 3 minutes of unloaded operation. 3. Close the air outlet valve and switch off the voltage. 4.
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Page 119: Coolers
Instruction book 18. Fill the air receiver with oil until the level reaches the filler neck. 19. Tighten the filler plug. 20. Reset the service warning after carrying out all service actions in the relevant Service Plan. See section Service menu. Coolers General Keep the coolers clean to maintain their efficiency. -
Page 120: Safety Valves
Instruction book 4. Clean the inlet filtering panel with a jet of air or wash it with water, but do not use solvents. 5. Replace the cubicle filter. 6. Once the operation has been completed, reassemble the filter panel. Safety valves Figure 43: Position of safety valve 2920 7217 01... -
Page 121: Dryer Maintenance Instructions
Instruction book Operating Operate the safety valve from time to time by unscrewing the cap one or two turns. Retighten it afterwards. Testing Before removing the valve, depressurize the compressor. See also section Problem solving. The safety 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 122: Service Kits
Instruction book • Next, clean with an air jet in the reverse direction to normal flow. Use low pressure air. If necessary, the pressure may be increased up to 6 bar(e) (87 psig). • Clean the condenser area with a vacuum cleaner. •... -
Page 123: Problem Solving
Instruction book Problem solving Danger: Before starting any maintenance or repair work, switch off the voltage and close the air outlet valve. Danger: Only pressing the emergency stop button is not sufficient to make the compressor voltage free. Danger: If the machine is equipped with an automatic restart after voltage failure function and if this function is active, be aware that the machine will restart automatically when the power is restored if it was running when the power was interrupted! Warning: The operator must apply all relevant safety precautions. - Page 124 Instruction book Condition Fault Remedy Find cause and remedy. Wiring interrupted. Replace if necessary. Compressor starts running, but does not load after a delay Solenoid valve out of order. Replace valve. time. Inlet valve stuck in closed Have valve checked. position.
- Page 125 Instruction book Condition Fault Remedy Check for cooling air restriction or improve ventilation of the compressor Insufficient cooling air or cooling room. Avoid recirculation of air temperature too high. cooling air. If installed, check capacity of compressor room fan. Oil cooler clogged. Clean cooler.
- Page 126 Instruction book Condition Fault Remedy Thermal protection of Motor will restart when motor windings refrigerant compressor have cooled down. motor has tripped. Have system inspected. Clean the filter of the drain by opening Condensate drain remains the manual drain valve. Drain system clogged.
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Page 127: Technical Data
Instruction book Technical data 10.1 Readings on display Figure 44: Swipe controller Figure 45: Touch controller Important Note: The data is valid under the reference conditions. See section Reference conditions and limitations. 2920 7217 01... -
Page 128: Electric Cable Size And Fuses
Instruction book Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures. Compressor element Approx. 60 ˚C (108 ˚F) above cooling air inlet temperature. outlet temperature 10.2 Electric cable size and fuses Important Warning: The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. - Page 129 Instruction book Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) gL/gG gL/gG Table 7: Fixed speed units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) Table 8: Variable speed units Currents and fuses, water-cooled, IEC approved units Max. Max.
- Page 130 Instruction book Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) gL/gG gL/gG Table 9: Fixed speed units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) Table 10: Variable speed units 2920 7217 01...
- Page 131 Instruction book Currents and fuses, air-cooled, UL approved units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) Class J Class J Table 11: Fixed speed units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) Class T Class T Table 12: Variable speed units Currents and fuses, water-cooled, UL approved units Max.
- Page 132 Instruction book Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) Class T Class T Table 14: Variable speed units Currents and fuses, air-cooled, CSA approved units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) HRC form II HRC form II Table 15: Fixed speed units Max.
- Page 133 Instruction book Currents and fuses, water-cooled, CSA approved units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) HRC form II HRC form II Table 17: Fixed speed units Max. Max. Imax(1) Imax(2) fuse(1) fuse(2) Compresso r (kW) Class T Class T Table 18: Variable speed units I: current in the supply lines at maximum load and 10% under voltage.
- Page 134 Instruction book • (1): Single supply cables. • (2): Parallel supply cables Supply cable Minimum and maximum connection possibilities. 1X0 L1, L2, L3 Finely Stranded 1 Finely Stranded 2 cable/phase equal cables/phase Compres sor (kW) Voltage Frequenc Approval Min. Max. Min.
- Page 135 Instruction book 1X0 L1, L2, L3 Finely Stranded 1 Finely Stranded 2 Compres cable/phase equal cables/phase sor (kW) Voltage Frequenc Approval Min. Max. Min. Max. y (Hz) 25 mm² 300 mm² 50 mm² 150 mm² 25 mm² 50 mm² 50 mm² 150 mm²...
- Page 136 Instruction book 1X3-PE Finely Stranded 1 cable/ Compressor phase (kW) Frequency Voltage (V) Approval Min. Max. (Hz) 35 mm² 95 mm² 35 mm² 95 mm² 25 mm² 50 mm² 4 mm² 35 mm² 4 mm² 35 mm² 4 mm² 35 mm² UL/cUL 2 AWG 3/0 AWG...
- Page 137 Instruction book 1X3-PE Finely Stranded 1 cable/ Compressor phase (kW) Frequency Voltage (V) Approval Min. Max. (Hz) 2.5 mm2 35 mm2 2.5 mm2 35 mm2 2.5 mm2 35 mm2 UL/cUL 12 AWG 2 AWG 10 mm2 50 mm2 10 mm2 50 mm2 10 mm2 50 mm2...
- Page 138 Instruction book Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 70 mm² < 216 A < 188 A < 171 A < 153 A < 132 A 95 mm² < 264 A < 230 A <...
- Page 139 Instruction book • Fuse size: the recommended maximum fuse size divided by √3 on each cable. • Size of the PE cable: • For supply cables up to 35 mm²: same size as supply cables • For supply cables larger than 35 mm²: half the size of the supply wires Always check the voltage drop over the cable (less than 5 % of the nominal voltage is recommended).
- Page 140 Instruction book Size AWG or kcmil Maximum current (For 75°C, copper wire) < 335 A < 380 A < 420 A < 460 A The selection of the cable should be such that its current carrying capacity shall always be higher than the maximum fuse value.
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Page 141: Dryer Switches
Instruction book • For a AWG4, the maximum current is 85 A x 0.8 = 68 A, which is insufficient. For an AWG3, the maximum current is 100 x 0.8 = 80 A. So, 2 parallel cables of 3 x AWG3 + 2 x AWG8 are sufficient. -
Page 142: Compressor Data
Compressor data Reference conditions Note: The data is valid under the reference conditions. See section Reference conditions and limitations. Fixed speed The following table is valid for CPI 75-120 and CPV 60VS-120VS PM. Units 7 Bar 8 Bar 10 Bar... - Page 143 Instruction book Units 100 psi 125 psi 150 psi 175 psi Nominal \Reference bar(e) 10.3 working pressure Nominal \Reference psig working pressure Maximum working bar(e) 10.8 12.5 pressure Maximum working psig 107.3 131.95 156.6 pressure Set point of thermostatic ˚C valve Set point of thermostatic...
- Page 144 Instruction book Units 7 Bar 8 Bar 10 Bar 13 Bar Maximum working bar(e) pressure Maximum working psig 108.75 123.25 pressure Set point of thermostatic ˚C valve Set point of thermostatic ˚F 100.4 100.4 100.4 valve Motor Shaft r/min 2980 2980 2980 2980...
- Page 145 Instruction book Units 100 psi 125 psi 150 psi 175 psi Motor Shaft r/min 3575 3575 3575 3575 Speed Nominal motor power Nominal motor 100.5 100.5 100.5 100.5 power Oil Capacity Oil Capacity US gal Sound pressure level (according to db(A) 2151:2004) Table 26: 75kW...
- Page 146 Instruction book Units 7 Bar 8 Bar 10 Bar 13 Bar Sound pressure level (according to db(A) 2151:2004) Units 100 psi 125 psi 150 psi 175 psi Frequency Nominal \Reference bar(e) 10.3 working pressure Nominal \Reference psig working pressure Maximum working bar(e) 10.8...
- Page 147 Instruction book Units 7 Bar 8 Bar 10 Bar 13 Bar Nominal \Reference bar(e) 12.5 working pressure Nominal \Reference psig 101.5 137.75 181.25 working pressure Maximum working bar(e) pressure Maximum working psig 108.75 123.25 pressure Set point of thermostatic ˚C valve Set point of thermostatic...
- Page 148 Instruction book Units 100 psi 125 psi 150 psi 175 psi Maximum working psig 107.3 131.95 156.6 pressure Set point of thermostatic ˚C valve Set point of thermostatic ˚F 100.4 100.4 100.4 valve Motor Shaft r/min 3575 3575 3575 3575 Speed Nominal motor power...
- Page 149 Instruction book Units 7 Bar 8 Bar 10 Bar Nominal motor 73.7 73.7 73.7 power Oil Capacity Oil Capacity US gal Sound pressure level (according to db(A) ISO 2151:2004) Units 100 psi 125 psi 150 psi Frequency Nominal \Reference bar(e) 10.3 working pressure Nominal...
- Page 150 Instruction book Units 7 Bar 8 Bar 10 Bar Maximum working psig 108.75 123.25 pressure Set point of ˚C thermostatic valve Set point of ˚F 100.4 100.4 100.4 thermostatic valve Motor Shaft r/min 2980 2980 2980 Speed Nominal motor power Nominal motor 100.5 100.5...
- Page 151 Instruction book Units 7 Bar 8 Bar 10 Bar Frequency Nominal \Reference bar(e) working pressure Nominal \Reference psig 101.5 137.75 working pressure Maximum working bar(e) pressure Maximum working psig 108.75 123.25 pressure Set point of ˚C thermostatic valve Set point of ˚F 100.4 100.4...
- Page 152 Instruction book Units 100 psi 125 psi 150 psi Nominal motor 120.6 120.6 120.6 power Oil Capacity Oil Capacity US gal Sound pressure level (according to db(A) ISO 2151:2004) Table 31: 90kW Variable speed Units 13 Bar 175 psi Frequency Nominal\Reference bar(e) 12.5...
- Page 153 Instruction book Units 13 Bar 175 psi Set point of ˚C thermostatic valve Set point of ˚F 100.4 100.4 thermostatic valve Motor Shaft Speed r/min 5100 5100 Nominal motor power Nominal motor power 73.7 73.7 Oil Capacity Oil Capacity US gal Sound pressure level (according to ISO db(A)
- Page 154 Instruction book Units 13 Bar 175 psi Maximum working bar(e) 12.5 pressure Maximum working psig pressure Set point of ˚C thermostatic valve Set point of ˚F 100.4 100.4 thermostatic valve Motor Shaft Speed r/min 6154 6154 Nominal motor power Nominal motor power 101.84 101.84 Oil Capacity...
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Page 155: Technical Data Controller
Instruction book 10.6 Technical data controller General 24 V AC /16 VA 50/60Hz (+40%/-30%) Supply voltage 24 V DC/0.7 A IP54 (front) Type of protection IP21 (back) Ambient and temperature IEC60068-2 conditions • Operating temperature range • -10°C…..+60°C (14 °F ..140 °F) •... -
Page 156: Instructions For Use
Instruction book Instructions for use Oil separator vessel This vessel can contain pressurized air. This can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator tank and must be operated within the limits specified on the data plate. -
Page 157: 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 158: Pressure Equipment Directives
Instruction book Pressure equipment directives Components subject to 2014/68/EU 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 2014/68/EU and all pressure equipment according to the Simple Pressure Vessel Directive 2014/29/EU. - Page 159 Instruction book Minimum and Design maximum Component Description Volume PED Class pressure design temperature Vessel CCW 1629034341 CE/ASME BP 62 L 15(bar) -10 ˚C/ 120 ˚C II 8000 Vessel CCW 1629034347 ASME/CRN 62 L 15(bar) -10 ˚C/ 120 ˚C II BP 8000 Safety valve 1649 8120 01...
- Page 160 Instruction book Visual Hydrostatic Number of Minimum wall Component Description inspection inspection cycles thickness frequency frequency Vessel CCW 1629034331 CE/ASME BP 2 x 10 8 mm 1 year 10 years 4000 Vessel CCW 1629034334 AS1210 BP 2 x 10 8 mm 1 year 10 years 4000...
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Page 161: Declaration Of Conformity
Instruction book Declaration of conformity Figure 46: Typical example of a Declaration of Conformity document Contact address: C. Aria C. S.R.L. Via Selva Maiolo, 5/7 Montecchio, Maggiore, Vicenza Italy Applicable directives Standards used 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. - Page 164 People. Passion. Performance. www.cp.com...