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Chicago Pneumatic CPF 175, Instruction Book

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Chicago Pneumatic CPF 175 Instruction Book Download Page 132

8

Problem solving

8.1

Problem solving

Warning

Before carrying out any maintenance, repair work or adjustment, stop the compressor,
press the emergency stop button and switch off the voltage. Close the air outlet valve and
open the manual condensate drain valves.

 

Open and lock the isolating switch.

 

The operator must apply all relevant 

Safety precautions

.

Faults and remedies

A service message appears on the display

Stop the compressor and carry out the indicated service actions.
Reset the message.

A shut-down warning message appears on the display

The alarm LED will light up indicating that the temperature at the outlet of the compressor elements is too
high. The message disappears as soon as the cause of the problem is remedied.

Unit is shut down

The alarm LED will flash indicating either that the outlet temperature of the compressor element is too high
or that the motor overload relay has tripped. Remedy the problem. It may be necessary to reset the display
after remedying the fault.

Excessive oil consumption

Have the compressor inspected by the Customer Centre.

Condition

Fault

Remedy

Condensate is not discharged from
condensate traps during loading.

Discharge pipe of condensate trap
clogged.

Check and correct as necessary.

Float valve of condensate traps
malfunctioning.

Remove float valve assembly,
clean and check.

Electronic water drain
malfunctioning.

Consult your Customer Centre.

Instruction book

130

2920 1804 00

Summary of Contents for CPF 175

Page 1: ...CPF 175 CPVS 175 Instruction book ...

Page 2: ......

Page 3: ...hereof 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 2012 08 No 2920 1804 00 www cp com ...

Page 4: ...L SYSTEM 13 2 3 COOLING AND CONDENSATE SYSTEM 18 2 4 REGULATING SYSTEM 19 2 5 ENERGY RECOVERY SYSTEM 20 3 Electronic regulator 23 3 1 ELECTRONIC CONTROLLER 23 3 2 CONTROL PANEL 25 3 3 CHANGING THE DISPLAY LANGUAGE 27 3 4 REGULATION 28 3 5 STRUCTURE OF MENUS 29 3 6 MODIFYING A PARAMETER 33 3 7 STATUS MENUS 34 3 8 INPUTS IN THE MAIN MENUS 40 3 9 ERROR MENU 42 3 10 SETTINGS MENU 44 3 11 COUNTERS MENU...

Page 5: ...EXTERNAL COMMUNICATION OPTIONAL 74 3 26 COMMON OPERATIONS 75 3 27 REINITIALISATION OF MAINTENANCE COUNTERS 75 3 28 OPERATIONAL INCIDENTS 76 3 29 LIST OF MESSAGES 76 4 Installation 83 4 1 DIMENSION DRAWING 83 4 2 INSTALLATION REMARKS 95 4 3 INSTALLATION PROPOSAL 97 4 4 ELECTRIC CABLE SIZE 101 4 5 PICTOGRAPHS 107 5 Operating instructions 109 5 1 INITIAL START UP 109 5 2 BEFORE STARTING 111 5 3 START...

Page 6: ... 6 6 SERVICE KITS 126 6 7 DISPOSAL OF USED MATERIAL 127 7 Adjustments and servicing procedures 128 7 1 AIR FILTERS 128 7 2 COOLERS 129 7 3 SAFETY VALVE 129 8 Problem solving 130 8 1 PROBLEM SOLVING 130 9 Technical data 132 9 1 READINGS ON DISPLAY 132 9 2 REFERENCE CONDITIONS 132 9 3 LIMITS 133 9 4 SETTINGS OF SAFETY VALVE 133 9 5 SETTINGS FOR OVERLOAD RELAY AND FUSES 133 9 6 COMPRESSOR DATA 135 10...

Page 7: ...11 Declaration of conformity 148 Instruction book 2920 1804 00 5 ...

Page 8: ...compressor press the emergency stop button switch off the voltage and depressurize the compressor In addition the power isolating switch must be opened and locked On units powered by a frequency converter wait six minutes before starting any electrical repair If the machine is equipped with an automatic restart after voltage failure function and if this function is active be aware that the machine...

Page 9: ...ted 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 to make sure that the machine is stopped and depressurized and that the electrical isolating switch is open locked and labelled with a temporary warning before any...

Page 10: ...rolled machines shall take adequate precautions to ensure that there is no one checking or working on the machine To this end a suitable notice shall be affixed to the remote start equipment 4 Never operate the machine when there is a possibility of taking in flammable or toxic fumes vapors or particles 5 Never operate the machine below or in excess of its limit ratings 6 Keep all bodywork doors s...

Page 11: ...ttached to the starting equipment 6 Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine To this end a suitable notice shall be affixed to the remote start equipment 7 Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting a pipe 8 Before removing any pre...

Page 12: ...ssure level from increasing 20 Never use caustic solvents which can damage materials of the air net e g polycarbonate bowls 21 The following safety precautions are stressed when handling refrigerant Never inhale refrigerant vapours Check that the working area is adequately ventilated if required use breathing protection Always wear special gloves In case of refrigerant contact with the skin rinse ...

Page 13: ...e drive motor to the air net pressure The following features are available as an option Foodgrade Foodgrade oil is a unique high quality synthetic lubricant specially created for oil injected screw compressors that provide air for the food industry Rotair Xtra oil RXD oil is a special long life lubricant for oil injected screw compressors It provides better cooling and extends the oil change inter...

Page 14: ...ny malfunction of the draining process the electronic water drain generates a warning message on the display of the electronic regulator Energy recovery The compressor is provided with an energy recovery system to recover the major part of the compression heat in the form of hot water without any influence on the compressor performance Phase Sequence Relay The phase sequence relay prevents the dri...

Page 15: ...2 2 Air and oil system Flow diagrams Flow diagram air cooled compressor Instruction book 2920 1804 00 13 ...

Page 16: ...Flow diagram air cooled compressor with energy recovery Flow diagram air cooled compressor with modulating control Instruction book 14 2920 1804 00 ...

Page 17: ...Flow diagram air cooled compressor with energy recovery and with modulating control Flow diagram water cooled compressor Instruction book 2920 1804 00 15 ...

Page 18: ...Flow diagram water cooled compressor with modulating control Instruction book 16 2920 1804 00 ...

Page 19: ...es the oil from receiver AR through oil cooler Co filters OF oil stop valve Vs and an oil injection valve to the compressor element E and the lubrication points On air cooled compressors an oil injection valve will open at higher ambient temperatures to keep the element outlet temperature low For air cooled units the oil temperature is controlled by regulating the speed of the fans FN to avoid ove...

Page 20: ...oler to prevent condensate from entering the air outlet pipe The trap is provided with a float valve for automatically draining condensate and with a manual drain valve Cooling system On air cooled compressors the air and oil coolers are cooled by fans Water cooled compressors are provided with a cooling water system including combined oil and air coolers Instruction book 18 2920 1804 00 ...

Page 21: ...2 4 Regulating system Flow diagrams Flow diagram Reference Designation A To air cooler B To from oil cooler Instruction book 2920 1804 00 19 ...

Page 22: ...delivery is stopped 0 the compressor runs unloaded while chamber 6 contains a steady overpressure receiver unload pressure minus Blow Off valve 4 pressure drop Loading When the net pressure decreases to the lower limit of the working pressure loading pressure solenoid valve 5 is energized The plunger of solenoid valve 5 moves upwards against spring force Phase 1 The plunger of solenoid valve 5 ope...

Page 23: ... A manual valve for isolation and water flow control will be installed on the water outlet in order to optimize the flow The required qualities are given as a general rule in order to avoid problems caused by the cooling water If in any doubt contact your service representative For the following specifications dependent on the compressor type contact your service representative Minimum water inlet...

Page 24: ...the pipes Water hoses must be of correct size and suitable for the working pressure The water connections must be free of strain Pipe work or other parts with a temperature in excess of 80 C 176 F must be guarded or insulated Other high temperature pipe work must be clearly marked The water system installed outside the machine has to be protected by a safety device with set pressure according to t...

Page 25: ...ns including the management of control management of alarms and faults information on the operational status of the unit the configuration of remote control and the multi controller management optional The AIRLOGIC allows in particular The management of multiple analog inputs An oil temperature sensor An internal pressure sensor A unit output pressure sensor The control and the management of fixed...

Page 26: ... warning limit before reaching the limit of the fault which when reached would stop the machine This allows anticipating a malfunctioning and dealing with it without compromising your production of compressed air The indication of the nature of warning is transmitted to the AIRLOGIC Management of functional faults On the appearance of a functional fault the AIRLOGIC stops the compressor indicates ...

Page 27: ...e information necessary for the navigation the control of functional parameters and the error messages The choice of 3 languages among 25 configurable by the software simplifies the understanding of the messages and the parameters Instruction book 2920 1804 00 25 ...

Page 28: ...if necessary Error red flashing light Warning fixed red light Keys Start button to start the compressor in automatic mode the compressor will stop and restart automatically depending on the pressure variations in the network Stop button to stop the compressor when it is in automatic operation mode The complete shutdown takes place only after a depressurization cycle of a modifiable period of 30 se...

Page 29: ...ue of a parameter during its modification 3 3 Changing the display language Procedure The display language can be configured according to the following operating procedure described starting from one of the status screens Press the Validate key for accessing the list of menus Using the vertical navigation buttons select Conf User from the menu Press the Validate key for accessing the list of menu ...

Page 30: ...ufficiently the controller considers that the motor is running in the wrong direction the air is not compressed therefore the air is not heated and stops the compressor It is then necessary to cut off the power supply to the compressor interchange the two phases of the supply to the main motor then restart the power This error cannot be cancelled by manipulations of the controller Analog input dry...

Page 31: ...ped by the local controller maintenance The control mode must be first changed and returned to local mode A shortcut using the Cancel key is provided for this 3 5 Structure of menus Description The screens displayed on the controller are organized into menus submenus display screens and or modification of parameter screens The following section describes the general structure of the menus However ...

Page 32: ...s relating to the functional status of the machine these are usable as check lists The rest of the structure offers the parameters for configuring the compressor Some of these parameters are read only while others can be modified with restriction of access through password depending on the qualification of the operator Instruction book 30 2920 1804 00 ...

Page 33: ...Menu structure for fixed speed compressors Instruction book 2920 1804 00 31 ...

Page 34: ...Menu structure for variable speed compressors Instruction book 32 2920 1804 00 ...

Page 35: ... a screen indicates that the screen can be reached from the one located below at the tip of the arrow by pressing on the navigation down key 3 6 Modifying a parameter Description Use the vertical navigation buttons to select a menu item Use the horizontal navigation keys to enter or leave a submenu The cancel key allows to reach the parameter to be modified Screen for fixed speed compressors Scree...

Page 36: ...nus Description These status menus only display the different parameters values relating to the functional state or settings of the compressor Fixed speed compressors Screen Description Compressor outlet pressure Indication of the pressure read by the sensor in the machine outlet Element outlet temperature Indication of the temperature read by the sensor in the outlet of the compressor element Man...

Page 37: ...art up Module hours Number of hours during which the AIRLOGIC remains powered on Load relay Number of passages of the compressor in load from its start up Compressor outlet pressure Reuse of the first parameter From this parameter the menu displays the status of all the analog and logical inputs that are activated Receiver press Pressure as read by the sensor placed on the deoiling tank of the com...

Page 38: ...ed Remote pressure Input determining whether the control is local open or remote closed Overload motor Overload of main motor input activated by the thermal protection relay of the main motor Overload fan motor Overload of turbine motor input activated by the thermal protection relay of the turbine motor Phase sequence Input triggering an error if the phase controller in option detects a wrong dir...

Page 39: ...or read by the compressor is the integrated sensor and not an external sensor Indicates that the weekly programming function is not activated Max pressure Maximum limit of unloading pressure setting Setpoint 1 Setpoint pressure Two programmable setpoint pressures can be chosen Compress Speed Indicates the motor rotation speed Running hours Number of running hours of the compressor motor operation ...

Page 40: ...Percentage of operating time during which the compressor has operated between 20 and 40 of its maximum speed VSD 40 60 RPM Percentage of operating time during which the compressor has operated between 40 and 60 of its maximum speed VSD 60 80 RPM Percentage of operating time during which the compressor has operated between 60 and 80 of its maximum speed VSD100 80 RPM Percentage of operating time du...

Page 41: ...emote Status of the logical inputs indicating to the AIRLOGIC that it is remotely started input closed in the Remote control operating mode Overload fan motor Overload of turbine motor input activated by the thermal protection relay of the turbine motor Phase sequence Input triggering an error if the phase controller in option detects a wrong direction of the phases and therefore the motor or else...

Page 42: ...counters for reading can be accessed running hours loaded hours number of motor starts number of passages into load Service Access menu for data relating to compressor maintenance delay from last intervention before next intervention type of maintenance performed to the menus for parameterizing types of maintenance periods and also to menu Stop Under Pres Timer function Menu of weekly programming ...

Page 43: ...ng a protection Test outputs Menus allowing to test the display the LED s as well as each of the logical outputs Caution coils may be powered Version Indicates the version number of the application uploaded into the controller Info Distrib Menu for displaying information can be customized by the distributor using the FSP software Password In this menu the password coded on 4 digits is entered See ...

Page 44: ... Pressing the enter key allows deactivating the display of error if of course the cause of this error has been resolved If no error or warning is active the message All conditions are OK is displayed Definition of different types of error Fixed speed compressors Instruction book 42 2920 1804 00 ...

Page 45: ...nding to the type of warning flashes This indicates the menu that has to be entered in order to identify the input port of the warning and the protection that is activated When the cause of the warning has been removed the flashing message of the menu Status 0 1 disappears and the message All conditions are OK is displayed on the Error menu When an error occurs the compressor stops and the screen ...

Page 46: ...d The AIRLOGIC allows configuring two bands of operating pressures and selecting one of them depending on your needs at a given time Fixed speed compressors Structure Definition Minimum Maximum Pressure at machine outlet below which the compressor passes into load the suction box is open 4 bar 58 psi value of next parameter Pressure above which the compressor passes to unloading the suction box is...

Page 47: ...default No error is generated Value of previous parameter 1 5 bar 21 7 psi Minimum rotation speed of the main compressor motor This new setpoint is only taken into account when it is greater than the standard minimum speed 460RPM depends on the compressor 900RPM depends on the compressor Percentage maximum speed reduction Allows the user to limit this maximum speed for certain applications 75 100 ...

Page 48: ...ering on of the controller Loaded hours Number of hours during which the compressor has operated in load from the first powering on of the controller Number of motor starts From the first powering on of the controller Number of module hours Period during which the AIRLOGIC remained powered on Number of load relays Number of times the output Run in load is passed from deactivated to activated from ...

Page 49: ...ansitions from no load operation to on load operation starting from the point at which the controller is first switched on Percentage of operating time during which the compressor has operated between 1 and 20 of its maximum speed Percentage of operating time during which the compressor has operated between 20 et 40 of its maximum speed Percentage of operating time during which the compressor has ...

Page 50: ... to compressor maintenance delay from last intervention before next intervention type of maintenance performed to the menus for parameterizing types of maintenance periods and also to menu Stop Under Pres Fixed speed compressors Instruction book 48 2920 1804 00 ...

Page 51: ...eed compressors Service counter This menu allows the operator to find out when the last maintenance operation took place and when the next should take place Fixed speed compressors Instruction book 2920 1804 00 49 ...

Page 52: ...ing hours displayed are incremented with the functioning of the compressor Number of running hours at which the last service was carried out and the corresponding service type from A to J Number of hours of the machine calculated from its date of commissioning machine powered on or not at which the next service has to take place and the corresponding service type from A to J The life period displa...

Page 53: ...vice has to be performed And so on up to the type J service level Interval of number of running hours at which the service type J has to be performed This service at 500h takes place only once It is necessary to deactivate this timer after it has completed by replacing the period 500h by Interval of number of hours of service life with or without functioning at which type A service has to be perfo...

Page 54: ...f number of hours of service life with or without functioning at which type B service has to be performed And so on up to the type J service level Interval of number of hours of service life with or without functioning at which type J service has to be performed Interval of volume of compressed air produced by the machine at which service type A should be carried out And so on up to the type J ser...

Page 55: ...pressure Structure Definition If the machine is running in load the validation of this menu allows to program a stop under pressure The compressor passes to unload then a few seconds later the motor stops When the pressure has dropped below a given limit the unloading solenoid is again supplied with power for stopping the depressurization of the internal tank When the unloading is completed press ...

Page 56: ...The parameter is saved in memory 2 Selection of the day of the week giving access to the 6 steps of timer programming 3 Selection of timer programming steps 6 max The command will be made in the order of display 4 Configuring the hour 5 Configuring the minutes Instruction book 54 2920 1804 00 ...

Page 57: ...when the controller is the master of a network of several compressors in MULTILOGIC mode It indicates that the entire network will be ready to start at the indicated time The pressure band used is the one defined in the menu Settings of the master compressor Stop sys is used when the controller is the master of a network of several compressors in MULTILOGIC mode and indicates that the entire netwo...

Page 58: ...e time when error number 1 occurred Starting point of indications recorded for error number 2 Starting point of indications recorded for error number 3 Starting point of indications recorded for error number 4 Starting point of indications recorded for error number 5 3 15 Safety Menu Description The access to this menu for modification is restricted to advanced users It allows modifying the safety...

Page 59: ...s On variable speed compressors the tree structure is large and is divided into 2 main sections Variable speed compressors Safety of Inputs Summary of the structure of the menu Safety inputs Instruction book 2920 1804 00 57 ...

Page 60: ...Fixed speed compressors Instruction book 58 2920 1804 00 ...

Page 61: ...on element has a first protection for stopping the compressor if this temperature exceeds a certain value and a second protection preventing the compressor from starting if this temperature is too low A detailed description of the protections of each of these inputs is provided on the following pages Receiver pressure Protections of the input internal pressure receiver The pressure sensor is insta...

Page 62: ...n an error will be generated 0 s 10 s This parameter defines the maxi value that can be set for the parameter shd Maxi 0 bar 0 psi 17 bar 246 5 psi Signifies that the compressor cannot start as long as the tank pressure is higher than this value 1 5 bar 21 7 psi 0 bar 0 psi 2 5 bar 36 psi This parameter defines the maximum value that can be set for the parameter P start Maxi 0 bar 0 psi 17 bar 246...

Page 63: ...er the starting of the compressor when this protection becomes active 0 s 120 s An error shall be generated if the temperature crosses the maximum threshold 110 C 230 F plus 3 seconds value of this parameter 0 s 10 s Protection against the wrong direction of rotation no parameter is modifiable but the protection is active Delta P Protections on the calculated analog input Delta P This dummy analog...

Page 64: ...exceed the maximum thresholds during more than 5 minutes for an error to be generated 0 min 15 min The presence of two similar protections on this input can be explained as follows The first protection at 1 8 bar 26 psi is the safety limit beyond which the oil separator faces the risk of implosion An error shall therefore be generated if this value is crossed for more than 3 s The second protectio...

Page 65: ...etected during one second so that the absence of the signal can be considered an error 0 s 10 s Phase sequence option Protections on the input of the option phase control Logical input in option corresponding to the phase controller of the electrical cabinet Structure Definition Minimum Maximum An error is generated if the input phase sequence activated only if the option phase controller is avail...

Page 66: ...a certain time If during this time interval Temp Duration the temperature has not increased more than the value of the parameter Diffr Temp it is considered that the compressor is running in the wrong direction For deactivating this error message it is necessary to switch off the power to the compressor interchange two of the three power supply phases to the motor and switch on the power again Set...

Page 67: ...possible by reloading the application Choice of the unit for displaying the pressure bar kg cm MPa or psi Choice of the unit for displaying the temperatures C F or K Choice of the unit for displaying the vibrations microns or mils Choice of the unit for displaying the levels not used in our application mm or inches In the factory 3 languages are configured out of a choice of 25 available If the co...

Page 68: ...ork 1 31 The Multilogic MCC It is used when several up to 4 compressors are connected in a network and are controlled by a master Activated Not activated The pressure band selection menu allows activating or deactivating the possibility of using input 10 for selecting the pressure band to use Activated Not activated Load delay delay between the passage in triangle in the case of a star triangle st...

Page 69: ...00 s Permissive start time time during which the compressor starter protections type permissive START are tested 0 s 15 min Communication time out time beyond which a communication fault with other elements of a LAN network is displayed as a fault 10 s 60 s Dryer status allows activating deactivating the integrated dryer management parameters Activated Not activated Drain time opening period of th...

Page 70: ... are connected in a network and are controlled by a master Activated Not activated Allows activating or deactivating the possibility of using input 10 for selecting the pressure band to use Activated Not activated Maximum number of turbine starts per day Facilitates limitation of the frequency of turbine starts by increasing the operating time where necessary The value 240 is equal to 10 starts ho...

Page 71: ...unication fault with other elements of a LAN network is displayed as a fault 10 s 60 s Dryer status allows activating deactivating the integrated dryer management parameters Activated Not activated Drain time opening period of the condensates purge solenoid valve 1 s 25 s Drain interval interval between two condensate purges 1 min 60 min 3 18 Input State Menu Description This menu displays the val...

Page 72: ...Fixed speed compressors Instruction book 70 2920 1804 00 ...

Page 73: ...Variable speed compressors 3 19 Output test menu Description Menu used for testing the display the LEDs and each of the logical outputs Instruction book 2920 1804 00 71 ...

Page 74: ...lay as well as the LEDs of the controller they are all lit as long as the key C is not pressed The second submenu Outputs allows testing the correct activation of the outputs of the controller one by one The compressor has to be stopped before these tests can be performed Instruction book 72 2920 1804 00 ...

Page 75: ...modify the parameters in the Conf distr menu In case no key is activated during a period of 2 minutes the password is no longer valid 3 23 MCC menu Description The Multilogic noted M C C is a function that can be activated in the presence of an electronic key allowing the connection of four compressors equipped with an AIRLOGIC The operating principle is based on a control managed by a master comp...

Page 76: ...or this input to be operational the parameter Control Mode of the menu Conf Distr must have the value Remote control Connection to a Leadair The compatibility of a network of several compressors with control by a Leadair is provided through a Com Box module for CAN Serial protocol conversion 3 25 External communication optional Box electronic modules Electronic modules are boxes connected to the A...

Page 77: ...ings required for starting the compressor are listed below LANGUAGE access by the menu Conf user see section Changing the display language DATE access by the menu Conf user see section Configuration user Menu TIME access by the menu Conf user see section Configuration user Menu PRESSURE UNIT access by the menu Conf user see section Configuration user Menu TEMPERATURE UNIT access by the menu Conf u...

Page 78: ... The oil temperature has exceeded the high alarm threshold 105 C 221 F but is less than the maximum temperature which then generates an error 110 C 230 F Tank high pressure pre alarm Shutd Warn The tank pressure has exceeded the high alarm threshold but is less than the maximum pressure which then generates an error De oiler clogging pre alarm Shutd Warn Verify the loss of de oiler load verify de ...

Page 79: ...ror messages Description Main screen message Error menu message Solution High temperature error Elem outlet 113 C 235 F Shd Max 110 C 230 F The oil temperature has exceeded the high error threshold 110 C 230 F Rotation direction The Airlogic has calculated that the oil temperature has not increased sufficiently during starting and therefore the compressor turns in the wrong direction Elem outlet 8...

Page 80: ...and or valve suction box remains open VPM blocked closed The approximate loss of load has exceeded the maximum threshold P tank P output AC Approach 3 0 bar 43 5 psi Shd Max 1 8 bar 26 psi Verify de oiler loss of load verify de oiling and replace de oiler if necessary Verify the VPM The approximate loss of load has exceeded the maximum threshold P tank P output Delta P 2 1 bar 30 5 psi Shd Max 1 8...

Page 81: ...ctions condition of cables Disconnect the sensor It should then indicate the ambient temperature It is also possible to measure the resistance indicated by the sensor and to verify whether or not it has drifted using the tables The tank pressure sensor measures a pressure outside the normal range 0 17 bar 0 246 5 psi Sensor Error Verify connections condition of cables Disconnect the sensor It must...

Page 82: ... of motor phase current is not zero insulation failure in cables or motor Check motor cables and motor 5 Charging switch The charging switch is open when the START command has been given faulty operation component failure Reset the fault and restart Should the fault re occur contact the distributor near to you 6 Emergency stop Stop signal has been given from the option board 7 Saturation trip Very...

Page 83: ...ase the motor load If no motor overload exists check the temperature model parameters 17 Motor underload Motor underload protection has tripped Decrease the motor load If no motor overload exists check the temperature model parameters 22 23 EEPROM checksum fault Parameter save fault faulty operation component failure 24 Changed data warning Changes may have occurred in the different counter data d...

Page 84: ...lected signal range 4 to 20 mA Current at the analogue input is 4mA control cable is broken or loose signal source has failed Set the deceleration time longer Use external brake resistor Check the current loop circuitry 51 External fault Digital input fault 52 Keypad communication fault The connection between the control keypad and the frequency converter is broken Check keypad connection and poss...

Page 85: ...4 Installation 4 1 Dimension drawing Compressor dimensions Dimension drawing in mm of air cooled compressor 110 kW with prefiltration panel Instruction book 2920 1804 00 83 ...

Page 86: ...Dimension drawing in mm of air cooled compressor 110 kW with high efficiency prefiltration panel Instruction book 84 2920 1804 00 ...

Page 87: ...Dimension drawing in mm of air cooled compressor 110 kW with prefiltration panel and heavy duty air inlet filter Instruction book 2920 1804 00 85 ...

Page 88: ...Dimension drawing in mm of air cooled compressor 110 kW with high efficiency prefiltration panel and heavy duty air inlet filter Instruction book 86 2920 1804 00 ...

Page 89: ...Dimension drawing in mm of air cooled compressor 132 kW with prefiltration panel Instruction book 2920 1804 00 87 ...

Page 90: ...Dimension drawing in inch of air cooled compressor 132 kW with prefiltration panel Instruction book 88 2920 1804 00 ...

Page 91: ...Dimension drawing in mm of air cooled compressor 132 kW with prefiltration panel and heavy duty filter Instruction book 2920 1804 00 89 ...

Page 92: ...Dimension drawing in inch of air cooled compressor 132 kW with prefiltration panel and heavy duty filter Instruction book 90 2920 1804 00 ...

Page 93: ...Dimension drawing in mm of air cooled compressor 132 kW with high efficiency prefiltration panel Instruction book 2920 1804 00 91 ...

Page 94: ...Dimension drawing in inch of air cooled compressor 132 kW with high efficiency prefiltration panel Instruction book 92 2920 1804 00 ...

Page 95: ...Dimension drawing in mm of air cooled compressor 132 kW with high efficiency prefiltration panel and heavy duty air inlet filter Instruction book 2920 1804 00 93 ...

Page 96: ...oled compressor 132 kW with high efficiency prefiltration panel and heavy duty air inlet filter Text on drawing Reference Explanation 1 Compressed air outlet 2 Cooling air outlet 3 Outlet energy recovery Instruction book 94 2920 1804 00 ...

Page 97: ...ended for indoor use only Working with machinery controlled by a frequency converter requires special safety precautions which depend on the type of network TN TT or IT Consult Atlas Copco The compressors comply with class A limits for radiated emissions according to EN 55011 A 2007 Beware of possible electromagnetic interference if stricter limits are valid The compressors comply with limits in a...

Page 98: ...present in the cabinet up to five minutes after it has been disconnected due to the DC link capacitors For this reason the cabinet should not be opened until after a reasonable period of time has elapsed The operator is responsible for ensuring that the Power Module and other components are installed and connected in accordance with the recognized technical rules in the country of installation and...

Page 99: ...4 3 Installation proposal Compressor room lay out Compressor room lay out in mm Instruction book 2920 1804 00 97 ...

Page 100: ... lay out in inch Text on drawing Drawing reference Designation 1 Minimum free area to be reserved for compressor installation 2 Ventilation proposals 3 Alt 1 Alternative 1 4 Notations Instruction book 98 2920 1804 00 ...

Page 101: ...r unit roof and the compressor room ceiling is 1200 mm 47 2 in 2 Compressed air outlet valve not in scope of supply 3 Air delivery pipe The pressure drop over the air outlet pipe can be calculated as follows For SI Units dp L x 450 x Qc1 85 d5 x p dp Pressure drop recommended maximum 0 1 bar L Length of outlet pipe in m Qc Free air delivery of the compressor in l s d Inner diameter of the outlet p...

Page 102: ...Units On air cooled compressors Qv 2618 5 N dT Qv Required ventilation capacity in cfm N Shaft input of compressor in hp for Pack compressors N Shaft input of compressor in hp heat dissipated by dryer in hp for Full Feature compressors dT Temperature increase in compressor room 5 Drain pipes to condensate collector The drain pipes should be connected to an open circuit 6 Control cubicle with monit...

Page 103: ...4 4 Electric cable size Electrical connections Electrical connections for IEC fixed speed compressors Instruction book 2920 1804 00 101 ...

Page 104: ...Electrical connections for IEC variable speed compressors Instruction book 102 2920 1804 00 ...

Page 105: ...Electrical connections for CSA UL fixed speed compressors Instruction book 2920 1804 00 103 ...

Page 106: ...ing number 25 mm2 7 6 mm 16 0698 5140 71 35 mm2 9 2 mm 20 0698 5140 72 50 mm2 11 mm 25 0698 5140 73 70 mm2 13 mm 25 0698 5140 73 95 mm2 15 mm 25 0698 5140 73 120 mm2 17 mm 32 0698 5140 74 150 mm2 19 mm 40 0698 5140 75 185 mm2 21 mm 40 0698 5140 75 AWM 3 10 2 mm 20 0698 5140 72 AWM 2 10 8 mm 20 0698 5140 72 AWM 2 0 15 2 mm 25 0698 5140 73 AWM 4 0 19 5 mm 32 0698 5140 74 Instruction book 104 2920 18...

Page 107: ... grouping 2 cables bunched 132 kW with 4 pole motor 400V 2X 3X 70 mm2 35 mm2 grouping 2 cables bunched Fixed speed compressors IEC 50 Hz air cooled Compressor type Voltage Cable size air cooled compressors Remark 110 kW 400V 2X 3X 70 mm2 35 mm2 grouping 2 cables bunched 132 kW with 4 pole motor 400V 2X 3X 70 mm2 35 mm2 grouping 2 cables bunched Fixed speed compressors IEC 60 Hz water cooled Compre...

Page 108: ...g 2 cables bunched Fixed speed compressors CSA UL air cooled Compressor type Voltage Cable size air cooled compressors Remark 132 kW 460V 2X 3X AWG4 0 AWG4 Grouping 2 cables bunched Variable speed compressors IEC Compressor type Voltage Cable size air cooled compressors Remark 132 kW 400V 2X 3X 95 mm2 50 mm2 Grouping 2 cables bunched Variable speed compressors CSA UL Compressor type Voltage Cable ...

Page 109: ...4 5 Pictographs Control panel Ref Designation 1 Start 2 Stop 3 Cancel key 4 Enter key 5 Scroll keys 6 Alarm 7 Automatic operation 8 Voltage on 9 Emergency stop Instruction book 2920 1804 00 107 ...

Page 110: ...or before maintenance or repair 20 Before connecting the compressor electrically consult the Instruction book for the motor rotation direction 21 Torques for steel Fe or brass CuZn bolts 22 Consult the Instruction book before greasing 23 Switch off the voltage before removing the protecting cover inside the electric cabinet 24 Oil the gaskets screw on the filters and tighten by hand approx one hal...

Page 111: ...st be placed in such a way that the compressor is lifted perpendicularly Lift gently and avoid twisting General preparations Step Action 1 Install the compressor see the sections Dimension drawing Installation proposal and Electric cable size 2 Stick labels near the control panel to warn the operator that the compressor may start automatically after a voltage failure the compressor is automaticall...

Page 112: ...according to IEC 60721 3 3 Step Action 1 Check that the electrical connections correspond to the local codes The installation must be earthed and protected by fuses in all phases An isolating switch must be fitted 2 Check the wires on transformers for correct connection 3 Check the setting of the circuit breakers see the section Settings of circuit breakers 4 Check that overload relay F21 is set f...

Page 113: ...cooled compressors check the rotation direction of the fan motor the fan is visible through the grating in the air inlet panel see section Dimension drawing The correct rotation direction is indicated by arrows on the fan inlet plate 4 If the rotation direction is wrong press the emergency stop button switch off the voltage and reverse two incoming electric lines If the rotation direction of the f...

Page 114: ...n the green range or orange range 5 3 Starting Warning The operator must apply all relevant Safety precautions Control panel Control panel Step Action 1 Press start button 1 The compressor starts running in unloaded condition Automatic operation LED 8 lights up 2 Approx 10 seconds later programmable the compressor starts running loaded The message on display 2 changes from Automatically unloaded t...

Page 115: ...all relevant Safety precautions The operator should immediately stop the machine in case of oil leaks internally in the machine as well as externally and consult a competent technician to resolve the cause The machine should not be restarted before the problem has been remedied The load cycle of the compressor must be limited to maximum two cycles per minute Instruction book 2920 1804 00 113 ...

Page 116: ...er readings on display 2 If the compressor is stopped it may start automatically 5 5 Checking the display Warning Before carrying out any maintenance repair work or adjustment stop the compressor press the emergency stop button and switch off the voltage Close the air outlet valve If an optional water separator drain is installed open the manual condensate drain valve Instruction book 114 2920 180...

Page 117: ...ut the service actions of the indicated service plans or replace the component and reset the relevant timer 4 Regularly check the actual compressor status by pressing the arrow down key from the main screen 5 6 Stopping Important After pressing stop button 9 the compressor will run unloaded for 30 seconds The compressor stops after this period A start command during this period is ignored After st...

Page 118: ...led open the condensate drain valve For compressors equipped with electronic water drains press the test buttons on top of the electronic drains until the air system between the air receiver and the outlet valve is fully depressurized 5 Switch off the voltage 5 7 Storage after installation Procedure Run the compressor e g twice a week until warm Load and unload the compressor a few times to operat...

Page 119: ...used material 5 9 Use of air receiver Instructions Step Action 1 This equipment can contain pressurized air and oil be aware of its potential danger if used improperly 2 This equipment must only be used as compressed air oil separator and must be operated within the specified limits 3 No alterations must be made to this equipment by welding drilling grinding or other methods of mechanical working ...

Page 120: ...essure load cycles A visual inspection for damage non authorized alterations of the vessel at the outside and inside is recommended every 5 years Make sure the vessel is fully depressurized and isolated before carrying out an internal inspection 9 At every inspection also check the oil drain flexible Replace if there is any wear or damage Instruction book 118 2920 1804 00 ...

Page 121: ...ll removed gaskets O rings and washers Preventive maintenance schedule Period Running hours Operation Daily 8 Check readings on display Daily 8 Check oil level Before starting the level should be in the middle of the sight glass Daily 8 If an optional water sepatator drain is installed chek that condensate is discharged during loading Weekly Check the cleanliness of the cubicle filters Replace or ...

Page 122: ...p when the compressor is running loaded and preferably with a stable working pressure Damaged flexibles must be replaced immediately Service plan A number of service operations are grouped called Level A Level B Level C Each level stands for a number of service actions to be carried out at the time intervals programmed in the electronic regulator When a level is reached a message will appear on th...

Page 123: ...es between 1 C 34 F and 40 C 104 F If the compressor is regularly operating in ambient temperatures close to 40 C 104 F the oil lifetime is reduced In such case it is recommended to use RXD oil Rotair Plus Rotair Plus oil is a specially developed lubricant for use in single stage oil injected screw compressors Its specific composition keeps the compressor in excellent condition Rotair Plus oil can...

Page 124: ... lubricant keeps the compressor in excellent condition Foodgrade oil can be used for compressors operating at ambient temperatures between 0 C 32 F and 40 C 104 F Important Never mix oils of different brands or types 6 4 Oil change Warning The operator must apply all relevant Safety precautions Control panel Control panel Instruction book 122 2920 1804 00 ...

Page 125: ... minutes and depressurize by unscrewing the vent plug on top of the air receiver to permit any pressure in the system to escape Wait until all the pressure in the system is released 2 To drain the oil remove the drain plug Dp and open the valve Draining the oil cooler on air cooled compressors Instruction book 2920 1804 00 123 ...

Page 126: ...stall the side panel of the compressor Draining the compressor element oil filter housing and oil stop valve 1 Remove the drain plug 1 to drain the oil stop valve 2 Remove the drain plug of the flexible 2 to drain the oil from the gearbox 3 Reinstall the drain plugs after draining Oil filter change Instruction book 124 2920 1804 00 ...

Page 127: ...nlet hose pour 3 l 0 79 US gal 0 66 Imp gal 0 11 cu ft of oil into the compressor element Reinstall the air inlet hose after filling the element Filling the air receiver with oil 1 Reinstall and tighten the oil drain plug of the air receiver 2 Remove filler plug FC 3 Fill the air receiver with oil until the maximum level of oil is located at from the bottom of the indicator 4 Refit and tighten fil...

Page 128: ...right and activate by pressing key 2 4 Press the Reset key 3 the timer is reset to 0 6 5 Storage after installation Procedure Run the compressor e g twice a week until warm Load and unload the compressor a few times to operate the components of the unloading loading system If the compressor is going to be stored without running from time to time protective measures must be taken Consult your Custo...

Page 129: ...tre can 6215 7150 00 See Oil specifications Foodgrade Foodgrade oil can be ordered in the following quantities 20 litre can 1630 0605 00 See Oil specifications 6 7 Disposal of used material Used filters or any other used material e g desiccant lubricants cleaning rags machine parts etc must be disposed of in an environmentally friendly and safe manner and in line with the local recommendations and...

Page 130: ...e voltage The operator must apply all relevant Safety precautions Position of air filter Procedure Step Action 1 Remove the panel in front of the air filter from the compressor 2 Remove the filter element 3 Fit the new filter element 4 Reinstall the panel 5 Reset the message and service timer see section Electronic regulator Instruction book 128 2920 1804 00 ...

Page 131: ...lers at the cooling air side clean them at regular intervals see also section Maintenance 7 3 Safety valve Warning Stop the compressor and switch off the voltage The operator must apply all relevant Safety precautions Never run the compressor without safety valves No adjustments are allowed Testing The valve can be tested on a separate compressed air line Consult the Customer Centre if the valve d...

Page 132: ...e outlet of the compressor elements is too high The message disappears as soon as the cause of the problem is remedied Unit is shut down The alarm LED will flash indicating either that the outlet temperature of the compressor element is too high or that the motor overload relay has tripped Remedy the problem It may be necessary to reset the display after remedying the fault Excessive oil consumpti...

Page 133: ...eck and correct Condition Fault Remedy Compressor element outlet temperature or delivery air temperature above normal Oil level too low Check and correct Oil coolers clogged Consult the section Coolers Air cooler clogged Consult the section Coolers On air cooled compressors insufficient cooling air or cooling air temperature too high Check and correct as necessary Instruction book 2920 1804 00 131...

Page 134: ...ading and loading pressures Pressure drop over air filters bar Below 0 05 Pressure drop over air filters psi Below 0 73 Pressure difference over oil separator bar Below 0 8 Pressure difference over oil separator psi Below 12 Compressor element outlet temperature C Below 120 Compressor element outlet temperature F Below 248 9 2 Reference conditions Reference conditions Absolute inlet pressure bar a...

Page 135: ... maximum working pressure of 7 5 8 0 9 5 or 10 bar 12 bar e For compressors with a maximum working pressure of 12 0 12 5 or 13 bar 15 bar e For compressors with a maximum working pressure of 100 125 140 or 150 psi 174 psig For compressors with a maximum working pressure of 180 psi 218 psig 9 5 Settings for overload relay and fuses Overload relay 50 Hz IEC compressors Compressor type Voltage F21 F2...

Page 136: ... II UL Class K5 according UL248 9 IEC 50 Hz air cooled compressors Compressor type Voltage Temp reduction not needed CSA HRC form II UL Class K5 Temp reduction not needed Type2 gL gG 110 kW 400 V 3X315 2X 3X160 132 kW 400 V NA 2X 3X200 IEC 60 Hz air cooled compressors Compressor type Voltage Temp reduction not needed CSA HRC form II UL Class K5 Temp reduction needed Type2 gL gG Temp reduction not ...

Page 137: ...on not needed Type2 gL gG 132 kW 460 V 2X 3X200 9 6 Compressor data Data for 6 9 bar 100 psi CSA UL compressors 132 kW 60 Hz fixed speed compressor Nominal working pressure bar 6 9 Nominal working pressure psi 100 Power input kW 141 85 Power input hp 190 22 Motor shaft speed rpm 1785 Frequency Hz 60 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Soun...

Page 138: ...2 Minimum cooling water flow cfm 2 54 132 kW 50 Hz fixed speed compressor Nominal working pressure bar 7 Nominal working pressure psi 101 5 Power input air cooled kW 144 33 Power input air cooled hp 193 55 Power input water cooled kW 137 93 Power input water cooled hp 184 97 Motor shaft speed rpm 2986 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 So...

Page 139: ...33 Power input air cooled hp 193 55 Power input water cooled kW 137 93 Power input water cooled hp 184 97 Motor shaft speed rpm 1785 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Sound pressure level dB A 77 Maximum cooling water flow l s 3 2 Maximum cooling water flow cfm 6 8 Minimum cooling water flow l s 1 4 Minimum cooling water flow cfm 3 Data ...

Page 140: ...m 2986 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Sound pressure level dB A 77 Maximum cooling water flow l s 3 2 Maximum cooling water flow cfm 6 8 Minimum cooling water flow l s 1 4 Minimum cooling water flow cfm 3 110 kW 60 Hz fixed speed compressor Nominal working pressure bar 8 Nominal working pressure psi 116 Power input air cooled kW 118 2...

Page 141: ...el dB A 77 Maximum cooling water flow l s 3 2 Maximum cooling water flow cfm 6 8 Minimum cooling water flow l s 1 4 Minimum cooling water flow cfm 3 Data for 8 6 bar 125 psi CSA UL compressors 132 kW 60 Hz fixed speed compressor Nominal working pressure bar 8 6 Nominal working pressure psi 125 Power input air cooled kW 141 85 Power input air cooled hp 190 22 Motor shaft speed rpm 1785 Oil capacity...

Page 142: ...flow l s 1 4 Minimum cooling water flow cfm 3 Data for 12 bar 174 psi compressors 132 kW 50 60 Hz CE CSA UL variable speed compressor Nominal working pressure bar 12 Nominal working pressure psi 175 Power input air cooled kW 145 88 Power input air cooled hp 195 63 Power input water cooled kW 139 68 Power input water cooled hp 187 31 Motor shaft speed rpm 805 3042 Oil capacity l 86 Oil capacity US ...

Page 143: ... 75 Power input air cooled kW 118 2 Power input air cooled hp 158 51 Power input water cooled kW 115 3 Power input water cooled hp 154 62 Motor shaft speed rpm 1487 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Sound pressure level dB A 77 Maximum cooling water flow l s 2 8 Maximum cooling water flow cfm 5 9 Minimum cooling water flow l s 1 2 Minimu...

Page 144: ...7 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Sound pressure level dB A 77 Maximum cooling water flow l s 2 8 Maximum cooling water flow cfm 5 9 Minimum cooling water flow l s 1 2 Minimum cooling water flow cfm 2 54 132 kW 60 Hz fixed speed compressor Nominal working pressure bar 9 5 Nominal working pressure psi 137 75 Power input air cooled kW 14...

Page 145: ...ng water flow cfm 6 8 Minimum cooling water flow l s 1 4 Minimum cooling water flow cfm 3 Data for 12 5 bar 181 psi CE compressors 110 kW 50 Hz fixed speed compressor Nominal working pressure bar 12 5 Nominal working pressure psi 181 25 Power input air cooled kW 118 2 Power input air cooled hp 158 51 Power input water cooled kW 115 3 Power input water cooled hp 154 62 Motor shaft speed rpm 1487 Oi...

Page 146: ... kW 60 Hz fixed speed compressor Nominal working pressure bar 12 5 Nominal working pressure psi 181 25 Power input air cooled kW 118 2 Power input air cooled hp 158 51 Power input water cooled kW 115 3 Power input water cooled hp 154 62 Motor shaft speed rpm 1787 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Sound pressure level dB A 77 Maximum cool...

Page 147: ...5 Oil capacity l 86 Oil capacity US gal 22 72 Oil capacity Imp gal 18 92 Oil capacity cu ft 3 04 Sound pressure level dB A 77 Maximum cooling water flow l s 3 2 Maximum cooling water flow cfm 6 8 Minimum cooling water flow l s 1 4 Minimum cooling water flow cfm 3 Instruction book 2920 1804 00 145 ...

Page 148: ... the machine and fall under the exclusion of article I section 3 6 Air receiver is subject to article 1 3 3 SPVD 2009 105 EC Design pressure 12 5 bar e 15 bar e Volume 160 l Design standard ASME section VIII div 1 The following pressure bearing parts are of category higher than I Safety valve Cat IV Design code AD Merkblätter A2 Re inspection data Text on figure Reference Description 1 Cover seria...

Page 149: ...12 5 bar 181 3 psi Casting factor cover 0 8 Welding factor vessel 0 85 15 bar 217 6 psi compressors Minimum wall thickness after corrosion vessel 4 606 mm 0 181 in Minimum wall thickness after corrosion cover 36 85 mm 1 451 in Lifetime infinite according to AD2000 S1 4 2 2 Delta p 15 bar 217 6 psi Casting factor cover 0 8 Welding factor vessel 0 85 Instruction book 2920 1804 00 147 ...

Page 150: ...n of conformity Typical example of a Declaration of Conformity document 1 Contact address International Compressor Distribution n v Boomsesteenweg 957 B 2610 Wilrijk Antwerp Belgium Instruction book 148 2920 1804 00 ...

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