Chicago Pneumatic CPC 40 G Instruction Book Download Page 97 | Manualshive

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10

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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. The water can be used
for diverse applications.

Components

The energy recovery system is completely integrated and mainly comprises:

• Stainless steel oil/water heat exchanger
• Selector handle (V1) to enable/disable Energy Recovery
• Thermostatic by-pass valve for energy recovery heat exchanger(s) (BV)
• Two temperature sensors for water inlet and outlet control (3 and 4)
• The necessary bolts, flexibles, etc.

Instruction book

2920 7101 41

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Summary of Contents for CPC 40 G

Page 1: ...Oil injected rotary screw compressors People Passion Performance CPC 40 G CPC 50 G CPC 60 G CPD 75 G CPD 100 G CPE 100 CPE 120 CPE 150 Instruction book ...

Page 2: ......

Page 3: ... unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2014 12 No 2920 7101 4...

Page 4: ...13 2 3 REGULATING SYSTEM 16 2 4 ELECTRICAL SYSTEM 17 3 Controller 19 3 1 CONTROLLER 19 3 2 CONTROL PANEL 20 3 3 ICONS USED ON THE DISPLAY 21 3 4 MAIN SCREEN 23 3 5 SHUT DOWN WARNING 24 3 6 SHUT DOWN 25 3 7 SERVICE WARNING 26 3 8 SCROLLING THROUGH ALL SCREENS 27 3 9 CALLING UP OUTLET AND DEWPOINT TEMPERATURES 31 3 10 CALLING UP RUNNING HOURS 32 3 11 CALLING UP MOTOR STARTS 32 3 12 CALLING UP MODULE...

Page 5: ...3 24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE 40 3 25 SELECTION BETWEEN Y D OR DOL STARTING 41 3 26 CALLING UP MODIFYING LOAD DELAY TIME 41 3 27 CALLING UP MODIFYING MINIMUM STOP TIME 41 3 28 ACTIVATING PASSWORD PROTECTION 42 3 29 ACTIVATE LOAD UNLOAD REMOTE PRESSURE SENSING 42 3 30 CALLING UP MODIFYING PROTECTION SETTINGS 43 3 31 TEST SCREENS 44 3 32 PROGRAMMABLE SETTINGS 45 4 Installat...

Page 6: ...ND OIL FILTER CHANGE 67 7 3 OIL SEPARATOR CHANGE 68 7 4 COOLERS 69 7 5 FILTERING PANEL 70 7 6 SAFETY VALVES 71 7 7 DRYER MAINTENANCE INSTRUCTIONS 71 8 Problem solving 73 9 Technical data 77 9 1 ELECTRIC CABLE SIZE AND FUSES 77 9 2 REFERENCE CONDITIONS AND LIMITATIONS 92 9 3 COMPRESSOR DATA 93 10 Options 95 10 1 ENERGY RECOVERY 95 10 2 ECO6I 103 10 3 AUTOMATIC DRAIN 114 10 4 HEAVY DUTY FILTER 115 1...

Page 7: ... 7 SPECIAL OILS 118 10 8 CENTRIFUGAL WATER SEPARATION 118 10 9 GRAPHIC CONTROLLER 119 10 10 TROPICAL THERMOSTATIC VALVE 120 11 Guidelines for inspection 121 12 Pressure equipment directives 122 13 Declaration of conformity 124 Instruction book 2920 7101 41 5 ...

Page 8: ... the voltage Depressurize the compressor Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and chec...

Page 9: ...essor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials 9 No external force may be exerted on the air outlet valve the connected pipe must be free of strain 10 If remote control is installed the machine must bear a clear sign stating DANGER This machine is remotely controlled and may start without warning The operator has ...

Page 10: ...r Precautions during operation 1 Never touch any piping or components of the machine during operation 2 Use only the correct type and size of hose end fittings and connections When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury Make sure that a hose is fully depressurized before disconnecting it 3 Persons switching on remotely...

Page 11: ...vance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be disclaimed by the manufacturer Precautions during maintenance or repair 1 Always use the correct safety equipment such as safety glasses gloves safety shoes etc 2 Use only the correct tools for maintenance and repair work 3 Use only genuine spare parts for maintenanc...

Page 12: ...ng them e g when steam cleaning 19 Make sure that all sound damping material and vibration dampers e g damping material on the bodywork and in the air inlet and outlet systems of the compressor is in good condition If damaged replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing 20 Never use caustic solvents which can damage materials of the air n...

Page 13: ...ooled and water cooled version The compressors are enclosed in sound insulated bodywork The compressors are controlled by the ES 4000 Standard controller The ES 4000 Advanced controller is available as option The ES 4000 controller and the emergency stop button are integrated in the door panel of the electric cubicle An electric cabinet comprising the motor starter is located behind this panel Fro...

Page 14: ...mponents Ref Name AF Air filter AR Air receiver AV Location of air outlet valve Ca Air cooler Co Oil cooler ER Controller M1 Drive motor OF Oil filter S3 Emergency stop button Instruction book 12 2920 7101 41 ...

Page 15: ...V The air is discharged through outlet valve AV via minimum pressure valve Vp and air cooler Ca During loaded operation minimum pressure valve Vp keeps the pressure in the separator tank AR above a minimum value required for lubrication An integrated check valve prevents the compressed air downstream the valve from being vented to atmosphere during unloaded operation When the compressor is stopped...

Page 16: ...s valve BV shuts off the supply to oil cooler Co and the oil cooler is bypassed Air pressure forces the oil from air receiver oil separator AR through oil filter OF and oil stop valve Vs to compressor element E Bypass valve BV starts opening the supply from cooler Co when the oil temperature has increased to the set point At approx 15 C 27 F above the set point all the oil flows through the oil co...

Page 17: ...r 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 Instruction book 2920 7101 41 15 ...

Page 18: ...ompressor the net pressure increases When the net pressure reaches the unloading pressure solenoid valve Y1 is de energised Results The pressure above unloading valve blow off valve UV is released to atmosphere and the space above valve UV is no longer in connection with the oil separator tank pressure 1 Unloading valve blow off valve UV moves upwards connecting the oil separator tank pressure 1 w...

Page 19: ...le Reference Designation F1 2 3 Fuses F3 is only provided in case a phase sequence relay is provided F21 Overload relay compressor motor Q15 Circuit breaker fan motor on air cooled compressors K21 Line contactor K22 Star contactor K23 Delta contactor T1 Transformer X103 X108 Connectors PE Earth terminal Instruction book 2920 7101 41 17 ...

Page 20: ...Electrical diagram There is a copy of the electrical diagram inside the electrical cubicle Instruction book 18 2920 7101 41 ...

Page 21: ...consumption and restarts it automatically when the net pressure decreases If the expected unloading period is to short the compressor is kept running to prevent too short stand still periods A number of time based automatic start stop commands may be programmed Take into account that a start command will be executed if programmed and activated even after manually stopping the compressor Protecting...

Page 22: ... warn the operator to carry out some service actions Automatic restart after voltage failure The controller has a built in function to automatically restart the compressor when the voltage is restored after voltage failure For compressors leaving the factory this function is made inactive If desired the function can be activated If the function is activated and provided the regulator was in the au...

Page 23: ... Is lit when service is needed 10 Start button This button starts the compressor Automatic operation LED 3 lights up The controller is operative 11 Stop button This button is used to stop the compressor Automatic operation LED 3 goes out 12 Scroll buttons Use these buttons to scroll through the menu 13 Enter button Use this button to confirm the last action 14 Escape button Use this button to go t...

Page 24: ...ice Service required Units Pressure unit Mega Pascal Pressure unit pounds per square inch Pressure unit bar Temperature unit Temperature unit Hours always shown together with seconds Percent The value shown must be multiplied by 10 to get the actual value The value shown must be multiplied by 100 to get the actual value The value shown must be multiplied by 1000 to get the actual value Instruction...

Page 25: ...e 3 4 Main screen When the voltage is switched on the first screen is a test screen The next screen is the Main screen shown automatically The Main screen shows The compressor status by means of pictographs The air outlet pressure Always consult your supplier if the pressure on the display is preceded by a t Instruction book 2920 7101 41 23 ...

Page 26: ...C It remains possible to scroll through other screens using the Scroll buttons up and down 12 to check the actual status of other parameters Press button 11 to stop the compressor and wait until the compressor has stopped Switch off the voltage inspect the compressor and remedy The warning message will disappear as soon if the warning condition disappears Dewpoint temperature On compressors with i...

Page 27: ...outlet of the compressor element exceeds the shut down level In case of error of the outlet pressure sensor In case of overload of the drive motor In case of overload of the fan motor on air cooled compressors Compressor element outlet temperature If the outlet temperature of the compressor element exceeds the shut down level factory setting 120 C 248 F programmable the compressor will be shut dow...

Page 28: ...ain screen with shut down indication motor overload Switch off the voltage and remedy the trouble After remedying and when the shut down condition has disappeared switch on the voltage and restart the compressor 3 7 Service warning Description A service warning will appear when the service timer has reached the programmed time interval If the service timer exceeds the programmed time interval alar...

Page 29: ...unning hours interval as well as those belonging to the 4000 running hours interval The setting of the service timer can be changed in function of the operating conditions See section Preventive maintenance schedule After servicing reset the service timer See section Calling up resetting the service timer 3 8 Scrolling through all screens Scroll buttons 12 can be used to scroll through all screens...

Page 30: ...ter screens Designation Related topic P 01 Selection between local remote or LAN control See section Selection between local remote or LAN P 02 Setting a node ID for LAN control and the channels for Mk 4 and Mk 5 See section Calling up modifying CAN address control P 03 Settings for IP gateway and Subnet mask See section Calling up modifying IP Gateway and Subnetmask P 04 Pressure band settings Se...

Page 31: ...Modifying minimum stop time P 13 Setting a password See section Activating password protection P 14 Remote pressure sensing See section Activate Load Unload remote sensing Protections screens Designation Related topic Pr 01 Pr 02 Pr 03 Protections screens See section Calling up modifying protection settings Test screens Designation Related topic t 01 Display test See sections Test screens t 02 Saf...

Page 32: ...on Ref Description 1 Compressor outlet pressure 16 Pressure band setting 2 Compressor outlet temperature 17 Service timer settings 3 Dewpoint temperature 18 Temperature unit 4 Digital input status 19 Unit pressure Instruction book 30 2920 7101 41 ...

Page 33: ... LAN selection 27 Display test 13 Settings node ID 28 Safety valve test 14 IP settings 29 Production test 15 Pressure band selection 3 9 Calling up outlet and dewpoint temperatures Starting from the Main screen Press Scroll button 12 The outlet temperature will be shown The screen shows that the outlet temperature is 82 C For Full Feature compressors Press Scroll button 12 The dewpoint temperature...

Page 34: ...s Scroll button 12 until d 2 is shown and then press Enter button 13 A screen similar to the following appears This screen shows the number of motor starts x 1 or if x1000 lights up x 1000 In the above example the number of motor starts is 10100 3 12 Calling up module hours Starting from the Main screen press Scroll button 12 until d 3 is shown and then press Enter button 13 A screen similar to th...

Page 35: ... during 1755 hours 3 14 Calling up load relay Starting from the Main screen Press Scroll button 12 until d 5 is shown and then press Enter button 13 This screen shows the number of unload to load actions x 1 or if x1000 lights up x 1000 In the above example the number of unload to load actions is 10100 3 15 Calling up resetting the service timer Calling up the service timer Starting from the Main ...

Page 36: ... button 13 The reading e g 4000 will appear Press Enter button 13 and if a password is set enter the password The icon will flash indicating that resetting is possible Press Enter button 13 to reset the timer to 0 000 or press the Escape button 14 to cancel the operation 3 16 Selection between local remote or LAN control Starting from the Main screen press Scroll button 12 until P 1 is shown and t...

Page 37: ...he function is ON or OFF Press the Enter button 13 to change this mode Use the Scroll buttons 12 to select On or OFF and press Enter to program When this function is ON use the Scroll buttons up or down 12 to see the node ID If desired the user can change this ID Press the Enter button 13 the node ID value starts blinking Use the Scroll buttons 12 to change the node ID Press the Enter button 13 to...

Page 38: ...screen appears Press the Enter button 13 to modify the setting The utmost left value will blink Change this value by using the Scroll buttons 12 Press the Enter button 13 to confirm Change the other values in the same way as required After modifying the settings the screen may look as follows 3 18 Calling up modifying IP Gateway and Subnetmask Calling up Starting from the Main screen press the Scr...

Page 39: ...IP for IP address Sub for Subnetmask or GAtE for Gateway Modification Press the Enter button 13 and if necessary enter the password The first digits are blinking Use the Scroll buttons Up or Down 12 to modify the settings and press Enter 13 to confirm Modify the next digits the same way The standard IP address is set as 192 168 100 100 Instruction book 2920 7101 41 37 ...

Page 40: ...P 04 is shown and then press Enter button 13 Pressure band 1 Pb 1 is shown on the display Button 12 can be used to scroll to pressure band 2 Pb 2 Press Enter button 13 on the desired pressure band The load level of the selected pressure band appears Button 12 can be used to scroll to the unload level Instruction book 38 2920 7101 41 ...

Page 41: ... button 13 to modify the pressure band selection a password may be required The active pressure band Pb 1 starts blinking Press button 12 to modify the active pressure band Press Enter button 13 to confirm or the Escape button 14 to cancel 3 21 Calling up modifying service timer settings Starting from the Main screen Press Scroll button 12 until P 6 is shown and then press Enter button 13 the sett...

Page 42: ... pressure Starting from the Main screen Press Scroll button 12 until P 08 and the possible settings are shown Mpa psi and bar Press Enter button 13 and the actually used unit is shown Press Enter button 13 unit starts blinking and use the Scroll buttons 12 to select another unit of pressure Press Enter button 13 to program the new unit of pressure Press the escape button 14 to return to the parame...

Page 43: ...reen Press Scroll button 12 until P 11 and the compressor load pictograph is shown and press the Enter button 13 This screen shows the load delay time 10 and the unit s seconds To modify this value press the Enter button 13 a password may be required The value starts blinking and Scroll buttons 12 can be used to modify the value Press the Enter button 13 to program the new value The minimum and ma...

Page 44: ... 12 until P 13 is shown and press Enter button 13 Password PASS appears on the screen Press the Enter button 13 The screen shows the password status ON On or OFF OFF Press Enter button 13 to modify Change the value with Scroll buttons 12 Select On and press Enter button 13 Enter the new password and press Enter button 13 to confirm Enter the password again and press Enter button 13 to confirm On a...

Page 45: ...wed by a number and one of the next pictographs Pictograph Designation Pr shown with the pressure pictograph shows the pressure protections Pr shown with the element outlet temperature pictograph shows the element outlet temperature protections Pr shown with the dewpoint temperature pictograph shows the dewpoint temperature protections Pr shown with the ambient temperature pictograph shows the amb...

Page 46: ... H and the high temperature shut down level Sd H become visible Use Scroll keys 12 to move between the warning level AL and the shut down level Sd press the Enter button 13 to modify the value An optional password may be required the value starts blinking and Scroll buttons 12 can be used to modify the value Press the Enter button 13 to program the new value Programmable settings can only be modif...

Page 47: ... solve Use the Scroll buttons 12 and scroll to menu t 3 The screen shows Press the Enter button 13 the text starts blinking Press enter again and the menu disappears 3 32 Programmable settings Parameters unloading loading pressures Minimum setting Factory setting Maximum setting Unloading loading pressures see Compressor data see Compressor data see Compressor data Parameters fix speed drive Minim...

Page 48: ...c restart Power recovery time Is the period within which the voltage must be restored to have an automatic restart Is accessible if the automatic restart is activated To activate the automatic restart function consult your supplier Restart delay This parameter allows to programme that not all compressors are restarted at the same time after a power failure ARAVF active Compressor element outlet Th...

Page 49: ...ical settings e g if the unloading pressure is programmed at 7 0 bar e 101 psi g the maximum limit for the loading pressure changes to 6 9 bar e 100 psi g The recommended minimum pressure difference between loading and unloading is 0 6 bar 9 psi g Instruction book 2920 7101 41 47 ...

Page 50: ...G water cooled compressors with dryer See document 9820 6706 23 on the CD supplied with your machine CPE 100 and CPE 120 air cooled compressors See document 9820 6706 09 on the CD supplied with your machine CPE 100 and CPE 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 suppl...

Page 51: ...ons must be taken In this case consult your supplier 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 Make sure that the beams cannot slide and that they protru...

Page 52: ...ng 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 Δp L x 450 x Qc 1 85 d5 x P with Instruction book 50 2920 7101 41 ...

Page 53: ... the water of the drain collector Any flow back must be avoided Oil water separators to separate the major part of the oil from the condensate to ensure that the condensate meets the requirements of the environmental codes are available 6 Control module with monitoring panel 7 Position of the main cable entry Power supply cable to be sized and installed by a qualified electrician To preserve the p...

Page 54: ...iption Pictographs 15 Reference Designation 1 Read manual for oil specification 2 Rotation arrow 3 Lightly oil the gasket of the oil filter screw it on and tighten by hand approx half a turn Instruction book 52 2920 7101 41 ...

Page 55: ...rain 10 Manual condensate drain 11 Switch of the voltage and at least wait 6 min before removing the screen 12 Disconnect the electric supply before opening 13 Lock out tag out 14 Before connecting compressor electrically consult instruction book for motor rotation direction 15 Auto Restart After Voltage Failure ARAVF Instruction book 2920 7101 41 53 ...

Page 56: ...dure For the position of the air outlet valve and the drain connections see sections Introduction 1 Consult the sections Electric cable size Installation proposal and Dimension drawings 2 The following transport fixtures painted red must be removed Bolts on service door B Supports 1 Instruction book 54 2920 7101 41 ...

Page 57: ... switch must be installed near the compressor 4 Check transformer T1 for correct connection Check the settings of drive motor overload relay F21 Check that the motor overload relay is set for manual resetting Electric cubicle typical example 5 Fit the air outlet valve AV see section Introduction for the position of the valve Close the valve Connect the air net to the valve 6 Connect the automatic ...

Page 58: ...be between the top of the sight glass GI and the filling point FC Position of oil level sight glass 9 Provide labels warning the operator that The compressor may automatically restart after voltage failure The compressor is automatically controlled and may be restarted automatically 10 Check the voltage between the three phases before using the unit for the first time Motor direction arrow Check t...

Page 59: ...ct the inlet hose remove the unloader UA and pour 0 75 l 0 20 US gal 0 17 Imp gal of oil into the compressor element Reinstall the unloader and reconnect the inlet hose Make sure that all connections are tight On compressors with dryer switch on the voltage 4 hours before starting to energise the crankcase heater of the refrigerant compressor of the dryer Procedure Check the oil level top up if ne...

Page 60: ...ts up After the start up cycle the compressor starts running loaded On water cooled compressors regulate the cooling water flow during loaded running to obtain the most suitable temperature at the outlet of the compressor element i e between 2 and 7 C 4 and 13 F above the relevant temperature in the figure below For optimum operation the cooling water outlet temperature must never exceed the value...

Page 61: ...matically Regulator 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 3 If the oil level is too low push the emergency stop button to avoid the compressor to start unexpectedly 4 Next close the air outlet valve ...

Page 62: ...ncy push button must be pressed or the electricity isolating switch opened 5 6 Stopping Regulator Control panel ES 4000 Std 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 On compressors with an Standard co...

Page 63: ...ling system completely 5 7 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 On water c...

Page 64: ...amage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability Service kits 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 se...

Page 65: ...drain valve s Dm Dm1 to clean the filter inside the EWD 1 More frequently when operating in a dusty atmosphere Interval operations Interval hours 500 2000 4000 8000 10000 14000 18000 16000 20000 22000 6000 18000 12000 24000 Operations to be carried out Visit A Visit B Visit C Visit D 1 Control measured parameters x x x x x 2 Clean the filtermats x x x x x 3 Change the oil filter x x x x 4 Change t...

Page 66: ...lt your supplier if a service timer setting has to be changed For the change interval of oil and oil filter in extreme conditions consult your Customer Centre Any leakage should be attended to immediately Damaged hoses or flexible joints must be replaced 6 2 Storage after installation Procedure Run the compressor regularly e g twice a week until warm Load and unload the compressor a few times If t...

Page 67: ...e 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 As such these parts must not be disposed of at a municipal waste collection point Refer to local regulations for directions on how to dispose of this product in an environmental friendly manner Instruction book 2920 7101 ...

Page 68: ...move 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 2 Release the snap clips of air filter AF and remove the dust trap and the air filter element Clean the trap Discard the filter element Position of air filter 3 Fit the new element and the cover 4 Re...

Page 69: ... tank Procedure Oil system components 1 Run the compressor until warm Stop the compressor Close the air outlet valve and switch off the voltage Depressurise the compressor by opening manual drain valve s if available Wait a few minutes and depressurise the air receiver oil tank AR by unscrewing oil filler plug FC just one turn to permit any pressure in the system to escape Also depressurize the ai...

Page 70: ... settle 8 Depressurise the system by unscrewing filler plug FC just one turn to permit any pressure in the system to escape Remove the plug Add oil the oil level should be between the top of the sight glass Gl and the filling point FC Tighten the filler plug 9 Reset the service warning after carrying out all service actions in the relevant Service Plan see Service menu 7 3 Oil separator change War...

Page 71: ...he middle of sight glass Gl 6 Run the compressor loaded for a few minutes Stop the compressor and wait a few minutes to allow the oil to settle 7 Depressurise the system by unscrewing filler plug FC just one turn to permit any pressure in the system to escape Remove the plug Fill the oil tank with oil The oil level should be between the top of the sight glass Gl and the filling point FC Tighten th...

Page 72: ...ure may be increased up to 6 bar e 87 psig Instructions for water cooled compressors Consult your supplier 7 5 Filtering panel Cleaning the filtering panel Before carrying out any operation on the machine ensure that the electric power supply has been disconnected Stop the compressor Close the air outlet valve and switch off the voltage Remove the air inlet filter panel s FP1 and the cubicle filte...

Page 73: ...cautions must be observed Please be specifically aware of the following points Contact of refrigerant with the skin will cause freezing Special gloves must be worn If contacted with the skin the skin should be rinsed with water On no account may clothing be removed Fluid refrigerant will also cause freezing of the eyes always wear safety glasses Refrigerant is harmful Do not inhale refrigerant vap...

Page 74: ...pt in mind Keep the dryer clean Brush or blow off the finned surface of condenser monthly Switch off the voltage and close the air outlet valve Remove the panel where the condenser is situated see the picture below Clean the condenser fins with compressed air Do not use water or solvents Close the panel Inspect and clean the electronic condensate drain monthly Functioning of the drains can be chec...

Page 75: ...ns Introduction and Initial start up Open and lock the isolating switch The operator must apply all relevant Safety precautions Position of air vent plug Compressor Condition Fault Remedy Compressor starts running but does not load after a delay time Solenoid valve out of order Replace valve Inlet valve stuck in closed position Have valve checked Leak in control air flexibles Replace leaking flexi...

Page 76: ... oil flow through air inlet filter after stopping compressor Check valve leaking or oil stop valve jammed Replace defective parts Replace air filter element Condition Fault Remedy Safety valve blows after loading Inlet valve malfunctioning Have valve checked Minimum pressure valve malfunctioning Have valve checked Safety valve out of order Have valve replaced Compressor element out of order Consul...

Page 77: ...ks and recharged Refrigerant compressor M1 does not run See 3 Evaporator pressure too high See 5 Condenser pressure too high See 2 2 Condenser pressure too high or too low Fan control switch out of order Replace Fan blades or fan motor out of order Check fan fan motor Ambient temperature too high Check and correct if necessary draw cooling air via a duct from a cooler place or relocate the compres...

Page 78: ...f necessary replace the automatic drain 5 Evaporator pressure is too high or too low at unload Hot gas bypass valve incorrectly set or out of order Have hot gas bypass valve adjusted Condenser pressure too high or too low See 2 Shortage of refrigerant Have circuit checked for leaks and recharged Instruction book 76 2920 7101 41 ...

Page 79: ...n applicable if they are stricter than the values proposed below Currents are calculated with the full service factor but we suggest to add 10 due to over and under voltage Fuses are maximum allowed values for full service factor and 10 over and under voltage Causion Always double check the fuse size versus the calculated cable size If required reduce the fuse size or enlarge the cable size Cable ...

Page 80: ...00 X 37kW 230 60 149 160 A1 37kW 400 50 85 100 91 100 A2 37kW 400 50 85 100 91 100 X 37kW 400 50 85 100 A1 37kW 440 60 75 100 82 100 A2 37kW 440 60 75 100 82 100 X 37kW 440 60 75 100 A1 37kW 380 60 89 100 96 125 A2 37kW 380 60 89 100 96 125 X 37kW 380 60 89 100 IEC approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 45kW 230 50 179 200 188 200 A2 45kW 2...

Page 81: ...230 50 204 224 217 250 X 55kW 230 50 204 224 A1 55kW 220 60 217 250 234 250 A2 55kW 220 60 213 250 230 250 X 55kW 220 60 213 250 A1 55kW 230 60 213 250 229 250 X 55kW 230 60 209 224 A1 55kW 400 50 119 160 126 160 A2 55kW 400 50 117 125 124 160 X 55kW 400 50 117 125 A1 55kW 440 60 107 125 116 125 A2 55kW 440 60 106 125 115 125 X 55kW 440 60 106 125 A1 55kW 380 60 125 160 136 160 A2 55kW 380 60 123 ...

Page 82: ...0 A2 75kW 440 60 149 160 157 200 X 75kW 440 60 149 160 A1 75kW 380 60 168 200 179 200 A2 75kW 380 60 166 200 176 200 X 75kW 380 60 166 200 IEC approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 90kW 230 50 349 400 A2 90kW 230 50 343 400 A1 90kW 220 60 346 400 A2 90kW 220 60 339 400 A1 90kW 230 60 339 400 A2 90kW 230 60 332 355 A1 90kW 400 50 200 224 A2...

Page 83: ...0kW 440 60 59 63 A1 30kW 380 60 69 80 76 100 A2 30kW 380 60 69 80 76 100 X 30kW 380 60 69 80 IEC approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 37kW 400 50 85 100 91 100 A2 37kW 400 50 85 100 91 100 X 37kW 400 50 85 100 A2 37kW 440 60 76 100 82 100 X 37kW 440 60 76 100 A1 37kW 380 60 89 100 96 125 A2 37kW 380 60 89 100 96 125 X 37kW 380 60 89 100 I...

Page 84: ... 400 50 119 160 126 160 A2 55kW 400 50 117 125 124 160 X 55kW 400 50 117 125 A2 55kW 440 60 106 125 115 125 X 55kW 440 60 106 125 A1 55kW 380 60 125 160 136 160 A2 55kW 380 60 123 160 133 160 X 55kW 380 60 123 160 IEC approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 75kW 400 50 164 200 171 200 A2 75kW 400 50 163 200 170 200 X 75kW 400 50 163 200 A2 7...

Page 85: ... gL gG V Hz A A A A A1 30kW 230 60 112 125 A2 30kW 230 60 112 125 X 30kW 230 60 112 125 A1 30kW 460 60 56 60 A2 30kW 460 60 56 60 X 30kW 460 60 56 60 A2 30kW 575 60 45 50 X 30kW 575 60 45 50 UL cUL approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 37kW 230 60 147 175 A2 37kW 230 60 147 175 X 37kW 230 60 147 175 A1 37kW 460 60 73 80 A2 37kW 460 60 73 8...

Page 86: ...2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 55kW 230 60 207 225 A2 55kW 230 60 204 225 X 55kW 230 60 204 225 A1 55kW 460 60 103 125 A2 55kW 460 60 102 125 X 55kW 460 60 102 125 A2 55kW 575 60 81 90 X 55kW 575 60 81 90 UL cUL approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 75kW 230 60 276 300 A2 75kW 230 60 273 300 X 75kW 230 60 273 300 A1 75kW 460...

Page 87: ...use 1 I 2 Max Fuse 2 Type gL gG gL gG V Hz A A A A A1 110kW 460 60 205 225 A1 110kW 575 60 162 175 UL cUL approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type UL class RK5 CSA HRC form II UL class RK5 CSA HRC form II V Hz A A A A A2 30kW 460 60 56 70 UL cUL approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type UL class RK5 CSA HRC form II UL class RK5 CSA HRC form II...

Page 88: ...class RK5 CSA HRC form II UL class RK5 CSA HRC form II V Hz A A A A A2 55kW 460 60 102 125 UL cUL approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type UL class RK5 CSA HRC form II UL class RK5 CSA HRC form II V Hz A A A A A2 75kW 460 60 136 150 UL cUL approval Compressor specification I 1 Max Fuse 1 I 2 Max Fuse 2 Type UL class RK5 CSA HRC form II UL class RK5 CSA HRC form II A2 90...

Page 89: ...d UL The indicated fuse size is the maximum fuse size in order to protect the motor against short circuit For cUL fuse HRC form II for UL fuse class RK5 Possible configurations There are 3 possible cabling layouts 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 comm...

Page 90: ... A 91 A 95 mm 179 A 156 A 141 A 127 A 109 A 120 mm 206 A 179 A 163 A 146 A 126 A 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 mm 32 A 28 A 25 A 23 A 20 A 6 mm 41 A 36 A 32 A 29 A 25 A 10 mm 57 A 50 A 4...

Page 91: ... 3 Add 10 to the total compressor current ItotPack or ItotFF from the tables and divide by 3 Multiply the ampacity of the cables with 0 8 see table A 52 17 52 E1 Fuse size the recommended maximum fuse size divided by 3 on each cable Size of the PE cable For supply cables up to 35 mm same size as supply cables For supply cables larger than 35 mm half the size of the supply wires Always check the vo...

Page 92: ...om the tables Install the prescribed fuse on each cable Parallel supply cable 2 x 3 phases 2 PE configuration 2 Add 10 to the total compressor current ItotPack or ItotFF from the tables and divide by 2 Multiply the ampacity of the cables with 0 8 see CEC Part 1 table 5C Install fuses of half the size of the recommended maximum fuse size on each cable When using 2 x 3 phase 2 PE as in 3 Add 10 to t...

Page 93: ...ent 10 30 A 8 50 A 6 65 A 4 85 A 3 100 A 2 115 A 1 130 A 1 0 150 A 2 0 175 A 3 0 200 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 Install the prescribed maximum fuse on each cable Parallel supply cable 2 x 3 phases 2 PE configuration 2 Add 25 to the tota...

Page 94: ...he maximum current is 100 x 0 8 80 A So 2 parallel cables of 3 x AWG3 2 x AWG8 are sufficient Install 80 A fuses on each cable Recommended fuse values are based on full service factor and 10 under and over voltage Causion Always double check the fuse size against the calculated cable size If required increase the cable size 9 2 Reference conditions and limitations Reference conditions Air inlet pr...

Page 95: ...60 Nominal working pressure bar e 7 8 9 5 12 5 6 9 8 6 10 3 12 psig 102 116 138 181 100 125 150 175 Maximum working pressure bar e 7 5 8 10 13 7 4 9 1 10 8 12 5 psig 109 116 145 189 107 132 157 181 Unloading pressure Maximum setting bar e 7 2 8 2 9 7 12 7 7 1 8 8 10 5 12 2 psig 104 119 141 184 103 128 152 177 Unloading pressure Factory setting bar e 7 8 9 5 12 5 6 9 8 6 10 3 12 psig 102 116 138 18...

Page 96: ... psi 150 psi 175 psi Set point thermostatic valve converter C 65 65 65 65 65 65 65 65 F 149 149 149 149 149 149 149 149 Power hp 40 50 60 75 100 100 125 150 Refrigerant type units with Dryer R404a R404a R404a R404a R404a Total amount refrigerant units with Dryer kg 1 2 1 2 1 2 1 2 1 2 Oil capacity air cooled units l 20 20 20 25 25 30 33 42 A weighted sound level dB A Instruction book 94 2920 7101 ...

Page 97: ...e mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance The water can be used for diverse applications Components The energy recovery system is completely integrated and mainly comprises Stainless steel oil water heat exchanger Selector handle V1 to enable disable Energy Recovery Thermostatic by pass valve for energy recovery heat exch...

Page 98: ...t pipe 4 Temperature sensor water outlet pipe 5 Oil line to HE 6 Oil line from compressor oil separator vessel to ER unit 7 Oil line from ER unit to oil filter housing BV2 Location of heat exchanger by pass valve BV2 HE Heat exchanger V1 Selector valve AR Oil separator vessel OF Oil filter housing BV1 Location of oil cooler bypass valve BV1 Instruction book 96 2920 7101 41 ...

Page 99: ...is heated by the energy recovery system for use in a factory e g pre heating of boiler feed water Recovery water flow The recovery water enters the unit at inlet connection 1 In heat exchanger HE the compression heat is transferred from the compressor oil to the water The water leaves heat exchanger HE via outlet connection 2 Water requirements for closed water circuits The use of a closed water c...

Page 100: ...t mounted in a housing Flow diagram of compressor with energy recovery system Reference Designation Reference Designation BV2 Thermostatic bypass valve of ER unit OF Oil filter HE Oil water heat exchanger ER unit AR Oil separator vessel E Compressor element BV1 Thermostatic bypass valve in oil filter housing Co Oil cooler compressor Ca Aftercooler compressor 1 Water inlet 2 Water outlet BV2 starts...

Page 101: ...d in the oil circuit and will recover energy when the wheel is completely turned in clockwise When the wheel is turned out anticlockwise the heat exchanger HE is bypassed and no energy will be recovered valve housing of BV2 with wheel V1 ER label Attention It is only allowed to turn the wheel completely in or out No in between position is allowed The oil cooler bypass valve BV1 starts closing the ...

Page 102: ...at recovery water is maximum The oil from the heat exchanger outlet flows via oil filter OF oil stop valve Vs if present compressor element E and separator AR back to the inlet of heat exchanger HE Bypass valve BV1 bypasses the oil cooler Co as long as the oil temperature remains below its set point Operation principle at different loads Low consumption of recovered energy The temperature of the o...

Page 103: ...a period of time with the same basic working conditions the heat exchanger should be inspected To clean the oil side soak the heat exchanger in a degreasing solution To remove scale formation in the water compartment a proper descaling process should be applied Consult your customer centre 10 1 5 Energy recovery data Reference conditions See section Reference conditions and limitations Effective w...

Page 104: ...water outlet temperature C 0 Depends on application 99 Energy recovery water outlet temperature F 32 Depends on application 210 Delay at signal sec 0 Consult your customer centre 255 Delay at start should be less than delay at signal sec 0 Consult your customer centre 255 Recoverable energy The recoverable energy can be calculated from RECOVERED ENERGY kW 4 2 x water flow l s x water temperature r...

Page 105: ...parameters units 55kW 75kW 90kW 110kW Recoverable energy kW 48 4 50 2 79 2 79 7 Water flow l Min 9 8 10 3 16 0 16 5 Temperature at inlet C 20 20 20 20 Temperature at outlet C 91 91 91 91 Pressure drop bar 0 005 0 009 0 013 0 014 10 2 ECO6i 10 2 1 General description Introduction ECO6i All graphic controllers can be used to control a number of other compressors They can automatically start load unl...

Page 106: ... regulator for all compressors in the LAN and label this compressor as Master Compressor 1 Select the compressor regulators which will serve as slave regulators Label the compressors Compressor 2 3 and 4 5 6 respectively 10 2 2 Installation instructions Important remark Always stop each compressor and switch off the voltage before making any connection Connecting compressors equipped with 4th gene...

Page 107: ...cription 1 LAN network 3 hardwired connection 2 CANBox interface 4 Electro pneumatically controlled machine 10 2 3 Set up of parameters Remarks There are 2 ways to modify the ECOi parameters in the regulators 1 Via the display 2 Via Modi5 the previous version of this program called FSP Field Service Program However some modifications are only possible via the display while some other modifications...

Page 108: ...ears press enter ECO is highlighted press enter again 5 A dialogue screen opens choose ON to activate or OFF to deactivate Flowchart how to activate the ECOi in the master regulator Select the number of compressors that will be used in the LAN 1 Starting from the main screen 2 Press the enter button 3 Use the scroll buttons to select the ECO icon 4 Press the enter button the master is highlighted ...

Page 109: ...Flowchart how to select the number of compressors in the LAN Activating into LAN for master and slave regulators For the master regulator 1 Switch on the voltage 2 Starting from the main screen 3 Use the scroll buttons to select the Local control icon in the main screen 4 Press the enter button 5 A dialogue screen appears choose LAN Control from the list 6 Press the enter button Each slave needs t...

Page 110: ... buttons to select CAN from the list and press the enter button 6 Use the scroll buttons to select CAN Address from the list 7 Use the and scroll buttons to modify the node ID number and press the enter button ID should be set to 30 for the master regulator 8 Select CAN item from the list and press the enter button 9 Select in the next dialogue ON and press the enter button 10 Press the escape but...

Page 111: ...d via the display Parameters master module ECO 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 Digital Scheme Selection Instruction book 2920 7101 41 109 ...

Page 112: ...s of the participating compressors via menu Clock function these commands will not be taken into account Variable speed compressors In case one or more IVR compressors are participating one IVR will act as control IVR 1 The set point of the control IVR will be in the middle of the net pressure band 1 The Indirect stop level will equal the maximum level of the net pressure band 1 The Direct stop le...

Page 113: ...s stopped and is counting out the Minimum Stop Time During this time the compressor is Not Available to the ECOntrol6 algorithm Shutdown Compressor is in Shutdown condition Stopped Running The compressor is running local Input icons for each compressor on the main screen of the master regulator Icon Description Frequency converter driven compressor Unload compressor Load compressor When the ECO6 i...

Page 114: ...le to isolate a compressor from regulation by the master regulator 1 On the regulator of the compressor to be isolated use the scroll buttons to select the icon LAN Control on the main screen 2 Press the enter button 3 Scroll to Local control in this list 4 Press the enter button 5 The icon Local Control appears on the main screen 10 2 4 6 Integrating a compressor To integrate an isolated compress...

Page 115: ... sensor 10 2 5 1 Adding an external net pressure sensor The net pressure also called System Pressure is provided by the Master controller and is identical to the Compressor Output pressure of this controller If required the net pressure can be measured locally on the net itself net vessel or piping To do so two type of sensors can be used 0 5 V pressure transducer similar to the sensor used on the...

Page 116: ...e to the level detection system an inductive sensor detects the level of water and thus controls the opening of the electric bleed valve A low level of condensation is also detected in order to close the electric drain valve and to prevent compressed air from being wasted This type of purge valve does not require any maintenance The purge valve does not require the use of the metallic intake filte...

Page 117: ...ential Low quality air creates the following Quick pollution of the oil thus an increase in draining cycles Binding of the air oil separator before 4000 hours thus an increase in maintenance cycles and operation costs Pollution increases the elements that filter into the air and oil speeding up the damage to the mechanical components of the compressor screw element Installation of the filter s dep...

Page 118: ...s in the following Fast pollution of the oil thus an increase in oil change cycles Increased pollution of the air and oil filtering components that increases the deterioration of the mechanical components in the compressor screw block Binding of the air oil separator before 4000 Hours thus an increase in maintenance cycles and maintenance costs Access to the filtering media is allowed by removal t...

Page 119: ...tures Filter medium Degree of filtration 90 of the dust emitted is filtered Total nominal flow 6 000 m3 h Filter panel number 2 Initial charge loss 75 Pa Dimensions Width 500 mm Height 500 mm Thickness 200 mm This option may be fitted to a compressor already installed Instruction book 2920 7101 41 117 ...

Page 120: ...of use 8000 hours oil longer interval between 2 drainage operations 8000 hours under standard conditions of use Food Grade Oil use of the compressor in the agricultural food beverage industry Note If this option is chosen on a machine that has previously run on standard oil the flushing procedure must first be strictly complied with Overview 4000 and 8000 hours oil The qualities of these oils enab...

Page 121: ...g 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 Drains Regularly check that condensate is discharged during operation The amount of condensate depends on environmental and working conditions 10 9 Graphic Controller View of the ES 4000 Advanced controller Instruction b...

Page 122: ... Menu screen Each icon indicates a menu item The status bar shows the name of the menu that corresponds with the selected icon Typical example of a graphic Menu Use the scroll keys to select an icon Press the Escape key to return to the main screen 10 10 Tropical thermostatic valve Description Installing a tropical thermostat allows the compressor running at higher environment temperature This opt...

Page 123: ...r 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 Local legal requirements and or use outside the limits and or conditions as specified by the manufacturer may require other inspection periods as mentioned below Instruction book 2920 7101 41 121 ...

Page 124: ...1 0138 80 51 l SPV 75 90 kW 1631 0164 80 70 l SPV 110 kW 1631 0831 80 84l SPV 75 90 kW 1631 0164 80 70 l SPV 30 45 kW 10bar 0830 1000 78 Safety valve IV 30 45 kW 10bar 0830 1000 79 Safety valve IV 55 90 kW 10bar 1202 5749 00 Safety valve IV 55 90 kW 10bar 1202 5401 00 Safety valve IV 110 kW 6211 1116 69 Safety valve IV Compressor type Component Description Minimum wall thickness Visual inspection ...

Page 125: ...ption Minimum wall thickness Visual inspection 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 Instruction book 2920 7101 41 123 ...

Page 126: ...n of conformity Typical example of a Declaration of Conformity document 1 Contact address International Compressor Distribution NV Boomsesteenweg 957 B 2610 Wilrijk Antwerp Belgium Instruction book 124 2920 7101 41 ...

Page 127: ...er 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 Instruction book 2920 7101 41 125 ...

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Page 130: ...No 2920 7101 41 2014 12 Printed in Belgium People Passion Performance www cp com ...

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