Chicago Pneumatic CPF 270 Instruction Book Download Page 103 | Manualshive

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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

.

Control panel

Faults and remedies

If the alarm LED is lit or flashes, consult sections Event history menu or Service menu.

Unit is shut down

The alarm LED will flash indicating either that the outlet temperature 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:
press the “Reset” key (2); the message “All protection functions are OK” will appear, after which the
compressor can be restarted.

Excessive oil consumption

Have the compressor inspected by a service representative.

Instruction book

2920 1796 01

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Summary of Contents for CPF 270

Page 1: ...CPF 270 CPF 340 Instruction book ...

Page 2: ......

Page 3: ...ereof 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 2013 02 No 2920 1796 01 www cp com ...

Page 4: ...ION 10 2 2 COOLING AND CONDENSATE SYSTEM 11 2 3 REGULATING SYSTEM 12 3 Electronic regulator 14 3 1 ELECTRONIC CONTROL SYSTEM 14 3 2 CONTROL PANEL 16 3 3 ICONS USED 17 3 4 MAIN SCREEN 20 3 5 CALLING UP MENUS 23 3 6 INPUTS MENU 24 3 7 OUTPUTS MENU 26 3 8 COUNTERS 28 3 9 CONTROL MODE SELECTION 30 3 10 SERVICE MENU 31 3 11 SETPOINT MENU 35 3 12 EVENT HISTORY MENU 37 3 13 MODIFYING GENERAL SETTINGS 38 ...

Page 5: ...EFORE STARTING 79 5 3 STARTING 80 5 4 DURING OPERATION 81 5 5 CHECKING THE DISPLAY 82 5 6 STOPPING 83 5 7 TAKING OUT OF OPERATION 84 5 8 USE OF AIR RECEIVER 85 6 Maintenance 86 6 1 PREVENTIVE MAINTENANCE SCHEDULE 86 6 2 MOTORS 87 6 3 OIL SPECIFICATIONS 89 6 4 OIL CHANGE 89 6 5 OIL FILTER CHANGE 93 6 6 STORAGE AFTER INSTALLATION 95 6 7 SERVICE KITS 95 6 8 DISPOSAL OF USED MATERIAL 96 7 Adjustments ...

Page 6: ... 103 9 1 READINGS ON DISPLAY 103 9 2 REFERENCE CONDITIONS 103 9 3 LIMITS 104 9 4 SETTINGS OF SAFETY VALVE 104 9 5 SETTINGS FOR OVERLOAD RELAY AND FUSES 105 9 6 SETTINGS OF CIRCUIT BREAKERS 107 9 7 COMPRESSOR DATA 109 10 Pressure equipment directives 115 11 Declaration of conformity 117 Instruction book 4 2920 1796 01 ...

Page 7: ...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 10 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 8: ...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 9: ...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 10: ... maintenance work shall only be undertaken when the machine has cooled down 5 A warning sign bearing a legend such as Work in progress do not start shall be attached 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 remo...

Page 11: ...ce 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 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...

Page 12: ...nd prevents water from entering the compressed air net For any malfunction of the draining process the electronic water drain generates a warning message on the display of the 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 Modulating co...

Page 13: ...ll appear on the display and the general alarm LED will light up if one of the temperatures exceeds the shut down warning setting RXD oil RXD oil is a special long life lubricant for oil injected screw compressors It provides better cooling and extends the oil change interval Foodgrade Foodgrade oil is a unique high quality synthetic lubricant specially created for oil injected screw compressors t...

Page 14: ...sors are provided with a cooling water system including combined oil and air coolers 2 3 Regulating system Flow diagrams Flow diagram Reference Designation A To air cooler B To from oil cooler Regulating system The compressor is controlled by electronic regulator 1 The regulator keeps the net pressure within programmable pressure limits by automatically loading and unloading the compressor dependi...

Page 15: ...ards releasing receiver pressure through flexible 6 and channels 3 and 4 towards the air inlet 4 A small flow of air remains drawn in through hole 8 and channel 3 and is blown from receiver 10 via flexible 6 to the air inlet 5 Air delivery is stopped 0 the compressor runs unloaded Loading When the net pressure decreases to the lower limit of the working pressure loading pressure solenoid valve 5 i...

Page 16: ...e settings e g the unloading and loading pressures the minimum stop time and the maximum number of motor starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case the expected unloading period is too short the compressor is kept running to prevent too short standstill peri...

Page 17: ...eded The message disappears as soon as the warning condition disappears Service warning A number of service operations are grouped called Service Plans Each Service Plan has a programmed time interval If a time interval is exceeded a message will appear on display 1 to warn the operator to carry out the service actions belonging to that Service Plan Automatic restart after voltage failure The regu...

Page 18: ...icates that the regulator is automatically controlling the compressor 8 Voltage on LED Indicates that the voltage is switched on 9 Pictograph Voltage on 10 Escape key To go to previous screen or to end the current action 11 Enter key Key to select the parameter indicated by the horizontal arrow Only the parameters followed by an arrow pointing to the right can be modified 12 Scroll keys Keys to sc...

Page 19: ...pressor is running the icon is rotating Compressor status Motor stopped Running unloaded Running loaded Machine control mode or Local start stop Remote start stop Network control Automatic restart after voltage failure Automatic restart after voltage failure is active Week timer Week timer is active Instruction book 2920 1796 01 17 ...

Page 20: ...red Main screen display Value lines display icon General icons No communication network problem Not valid Input icons Icon Description Pressure Temperature Digital input Special protection System icons Icon Description Compressor element LP HP Dryer Instruction book 18 2920 1796 01 ...

Page 21: ...tor Failure expansion module Network problem General alarm Menu icons Icon Description Inputs Outputs Alarms Warnings shutdowns Counters Test Settings Service Event history saved data Access key User password Instruction book 2920 1796 01 19 ...

Page 22: ...nter key 3 Escape key Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed It is switched off automatically after a few minutes when no keys are pushed Typically 2 different main screen views can be chosen Instruction book 20 2920 1796 01 ...

Page 23: ... 4 parameters see section Inputs menu Typical Main screen 2 value lines Text on figures 1 Compressor Outlet 2 Compressor Outlet 3 Menu Typical Main screen 4 value lines Text on figures 1 Compressor Outlet 2 Loaded Hours 3 Standby text varies upon the compressor s actual condition 4 Menu Instruction book 2920 1796 01 21 ...

Page 24: ...keys and press the enter key Section C is called the Status bar This bar shows the text that corresponds to the selected icon Section D shows the Action buttons These buttons are used To call up or program settings To reset a motor overload service message or emergency stop To have access to all data collected by the regulator The function of the buttons depends on the displayed menu The most comm...

Page 25: ...he voltage is switched on the main screen is shown automatically see section Main screen Typical Main screen 2 value lines To go to the Menu screen highlight the Menu button 3 using the Scroll keys Press the Enter key to select the menu Following screen appears Instruction book 2920 1796 01 23 ...

Page 26: ...ion icon is selected The status bar shows the name of the menu that corresponds with the selected icon Use the Scroll keys to select an icon Press the Escape key to return to the Main screen 3 6 Inputs menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Inputs Instruction book 24 2920 1796 01 ...

Page 27: ... from the main screen see section Main screen Move the cursor to the Menu action button and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Inputs icon see above section Menu icon Press the Enter key A screen similar to the one below appears Text on image 1 Inputs 2 Compressor outlet 3 Dp air filter 4 Oil injection element...

Page 28: ...e 3 7 Outputs menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact on air cooled compressors the Emergency stop contact etc Procedure Starting from the Main screen see section Main screen Move the cursor to the Menu action button and press the Enter k...

Page 29: ...he one below appears Outputs screen typical Text on figure 1 Outputs 2 Line contactor 3 Star contactor 4 Delta contactor 5 Load Unload The screen shows a list of all outputs with their corresponding icons and readings If an output is in warning or shutdown the original icon is replaced by the warning or shutdown icon respectively Instruction book 2920 1796 01 27 ...

Page 30: ...hours The loaded hours The number of motor starts The number of hours that the regulator has been powered The number of load cycles Procedure Starting from the Main screen see section Main screen Move the cursor to the Menu action button and press the Enter key Following screen appears Instruction book 28 2920 1796 01 ...

Page 31: ...wing screen appears Text on figure 1 Counters 2 Running hours 3 Motor starts 4 Load relay 5 Module hours The screen shows a list of all counters with their actual readings Note the example above is for a frequency converter driven compressor For a fixed speed compressor the actual screen will be somewhat different Instruction book 2920 1796 01 29 ...

Page 32: ...l mode i e whether the compressor is in local control or remote control Procedure Starting from the main screen use the scroll buttons to go to the machine control mode icon see section Icons used and press the enter button There are 2 possibilities Local control Remote control Instruction book 30 2920 1796 01 ...

Page 33: ...creen See section Icons used for the meaning of the icons 3 10 Service menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Service Function To reset the service plans which are carried out To check when the next service plans are to be carried out To find out which service plans were carried out in the past Instruction book 2920 1796 01 31 ...

Page 34: ...ollowing screen appears Using the Scroll keys move the cursor to the Service icon see above section Menu icon Press the Enter key Following screen appears Text on figure 1 Service 2 Overview 3 Service plan 4 Next service 5 History Scroll through the items to select the desired item and press the Enter key to see the details as explained below Instruction book 32 2920 1796 01 ...

Page 35: ...ller is not powered The figures within the bars are the number of hours to go till the next service intervention In the example above the compressor was just started up which means it still has 4000 running hours or 8280 hours to go before the next Service intervention Service plans A number of service operations are grouped called Level A Level B etc Each level stands for a number of service acti...

Page 36: ... the Scroll keys to select the value to be modified A screen similar to the one below appears Press the Enter key Following screen appears Modify the value as required using the or scroll key and press the Enter key to confirm Note Running hours can be modified in steps of 100 hours real time hours can be modified in steps of 1 hour Next Service Text on figure Instruction book 34 2920 1796 01 ...

Page 37: ...o see the details of a completed service action e g Service level Running hours or Real time hours use the Scroll keys to select the desired action and press the Enter key 3 11 Setpoint menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Setpoint Function On fixed speed compressors the operator can program two different pressure bands This menu is also used to select the active pre...

Page 38: ...ys Press the Enter key Following screen appears Text on figure 1 Regulation 2 Unloading pressure 1 3 Loading pressure 1 4 Unloading pressure 2 5 Loading pressure 2 6 Modify The screen shows the actual unloading and loading pressure settings for both pressure bands To modify the settings move the cursor to the action button Modify and press the Enter key Following screen appears Instruction book 36...

Page 39: ... limit of the setting is shown in grey the actual setting is shown in black Use the or key of the Scroll keys to modify the settings as required and press the Enter key to accept If necessary change the other settings as required in the same way as described above 3 12 Event history menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Instruction book 2920 1796 01 37 ...

Page 40: ...g the Scroll keys move the cursor to the Event History icon see above section Menu icon The list of last shut down and emergency stop cases is shown Scroll through the items to select the desired shut down or emergency stop event Press the Enter key to find the date time and other data reflecting the status of the compressor when that shut down or emergency stop occurred 3 13 Modifying general set...

Page 41: ...its Procedure Starting from the Main screen see section Main screen Move the cursor to the Menu action button and press the Enter key Following screen appears Using the Scroll keys move the cursor to the Settings icon see above section menu icon Press the Enter key Following screen appears The screen shows a number of icons Instruction book 2920 1796 01 39 ...

Page 42: ...ified and press the Enter key Modifying network settings Select the network settings icon as described above and press the Enter button 1 Following screen appears Text on figure 1 Network 2 Ethernet 3 CAN A red selection bar is covering the first item Ethernet Use the key of the Scroll keys to select the setting to be modified and press the Enter key Following screen appears Instruction book 40 29...

Page 43: ...net and press the Enter button 1 A pop up screen appears Use the or key to select the required parameter and press the Enter key to confirm Regulation settings This menu allows to view and modify the regulation settings see section Modifying the setpoint General settings Select the General settings icon as described above and press the Enter button 1 Following screen appears Instruction book 2920 ...

Page 44: ... bar is covering the first item Language in use Use the key of the Scroll keys to select the setting to be modified and press the Enter key A pop up screen appears Use the or key to select the required parameter and press the Enter key to confirm Automatic restart Select the Automatic restart settings icon as described above and press the Enter button 2 Following screen appears Text on figure Inst...

Page 45: ...ed to change the security level Scroll to the correct icon using the scroll key Press the enter button Press the enter button again to modify the security level Press the enter button again a pop up menu appears Use the scroll keys to enter the password of the new security level Press the enter key to confirm the change User password If the password option is activated it is impossible for not aut...

Page 46: ...on Main screen Move the cursor to the Menu action button and press the Enter key Following screen appears Using the Scroll keys move the cursor to the Info icon see above section Menu icon Press the Enter key The internet address appears on the screen 3 15 Week timer menu Control panel Instruction book 44 2920 1796 01 ...

Page 47: ... cycle can be programmed a week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen Procedure Starting from the Main screen see section Main screen Move the cursor to the Menu action button and press the Enter key Use the Scroll buttons to select the Timer icon Text on figure 1 Menu 2 Week Timer Press the Enter key on the controller Foll...

Page 48: ...ect Week action schemes and press Enter A new window opens The first item in the list is highlighted Press the Enter key on the controller to modify Week Action Scheme 1 1 Week Action Schemes 2 Week Action Scheme 1 3 Week Action Scheme 2 4 Week Action Scheme 3 5 Week Action Scheme 4 A weekly list is shown Monday is automatically selected and highlighted Press the Enter key on the controller to set...

Page 49: ...ns The Modify action button is selected Press the enter button on the controller to create an action 1 Monday 2 Modify A new pop up window opens Select an action from this list by using the Scroll keys on the controller When ready press the Enter key to confirm 1 Monday 2 Actions Instruction book 2920 1796 01 47 ...

Page 50: ... week 1 Monday 2 Start 3 Save 4 Modify To adjust the time use the Scroll keys on the controller and press the Enter key to confirm 1 Monday 2 Start 3 Save 4 Modify A pop up window opens Use the or key of Scroll keys to modify the values of the hours Use the or Scroll keys to go to the minutes Instruction book 48 2920 1796 01 ...

Page 51: ...ton Modify is selected Use the Scroll keys to select the action Save 1 Monday 2 Start 3 Save 4 Modify A new pop up window opens Use the Scroll keys on the controller to select the correct actions Press the Enter key to confirm 1 Monday 3 Are you sure 4 No Instruction book 2920 1796 01 49 ...

Page 52: ...hursday 6 Friday 7 Saturday 8 Sunday Press the Escape key on the controller to leave this screen Programming the week cycle A week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen Select Week Cycle from the main Week Timer menu list 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status Instruction book 50 2920 1796 01 ...

Page 53: ...ller to modify the first week A new window opens Select the action example Week Action Scheme 1 1 Week Cycle 2 Week 1 3 Week Action Scheme 1 4 Week Action Scheme 2 5 Week Action Scheme 3 6 Modify Check the status of the Week Timer Use the Escape key on the controller to go back to the main Week Timer menu Select the status of the Week Timer Instruction book 2920 1796 01 51 ...

Page 54: ...ctive 6 Remaining Running Time A new window opens Select Week 1 to set the Week Timer active 1 Week Timer 2 Week 3 Week Timer Inactive 4 Week 1 Press the Escape key on the controller to leave this window The status shows that week 1 is active Instruction book 52 2920 1796 01 ...

Page 55: ...mer is used when the week timer is set and for certain reasons the compressor must continue working for example 1 hour it can be set in this screen This timer is prior to the Week Timer action 1 Week Timer 2 Week action schemes 3 Remaining Running Time In the regulator different timers can be selected on one day up to 8 actions It is however not possible to programme 2 actions at the same time The...

Page 56: ... Main screen see Main screen Move the cursor to the Menu action button and press the enter key 2 following screen appears Using the scroll keys 1 move the cursor to the test icon see above section Menu icon and press the enter key 2 The safety valve test can only be performed by authorized personnel and is protected by a security code Instruction book 54 2920 1796 01 ...

Page 57: ...sig 65 3 116 0 123 3 Unloading pressure 10 bar compressor bar e 4 5 9 5 10 005 Unloading pressure 145 psi compressor psig 65 3 137 8 145 Unloading pressure 13 bar compressor bar e 4 5 12 5 13 005 Unloading pressure 190 psi compressor psig 65 3 181 3 188 5 Unloading pressure 6 9 bar compressor bar e 4 5 6 9 7 405 Unloading pressure 100 psi compressor psig 65 3 100 1 107 3 Unloading pressure 8 6 bar...

Page 58: ...r outlet pressure shut down warning level psi 0 239 3 246 5 Compressor outlet pressure shut down level bar 0 17 0 17 0 Compressor outlet pressure shut down level psi 0 246 5 246 5 Oil injection pressure element start protection bar 2 0 2 5 13 2 Oil injection pressure element start protection psi 29 36 2 191 4 Compressor outlet temperature delay at signal sec 5 5 5 Compressor element outlet tempera...

Page 59: ...ce warning level for air filters psi 1 45 0 7 0 7 Delay at signal air filter sec 0 60 255 Terminology Term Explanation ARAVF Automatic restart after voltage failure See section Electronic control system Required stop period Minimum stop time Once the compressor has automatically stopped it will remain stopped for the minimum stop time approx 20 seconds whatever the net air pressure In automatic op...

Page 60: ... between loading and unloading is 0 6 bar 9 psig Delay at shut down signal Is the time for which the signal must exist before the compressor is shut down If it is required to program this setting to another value consult your Customer Centre Permissive start level The compressor will not start if this level is exceeded at the moment of starting If the level remains too high for 30 seconds the mess...

Page 61: ...Instruction book 2920 1796 01 59 ...

Page 62: ...4 Installation 4 1 Dimension drawing Compressor dimensions Dimension drawing of air cooled compressor Instruction book 60 2920 1796 01 ...

Page 63: ...Dimension drawing water cooled compressor Text on drawing Reference Designation 1 Compressed air outlet 2 Cooling air outlet 3 Air inlet 4 Cooling air inlet Instruction book 2920 1796 01 61 ...

Page 64: ... of gravity 9 With door fully open 10 Manual drain 11 Automatic drain 23 Opening for transportation 24 Slotted holes for horizontally pulling unit out of container 25 Net mass approximately 27 Outlet motor cables medium voltage motor 28 Low voltage Instruction book 62 2920 1796 01 ...

Page 65: ...4 2 Installation proposal Compressor room example Compressor room example air cooled compressor Instruction book 2920 1796 01 63 ...

Page 66: ...Compressor room example water cooled compressor Text on drawing Reference Designation 1 Minimum free area 2 Ventilation proposals 3 Cooling systems Instruction book 64 2920 1796 01 ...

Page 67: ... pipe in m p Absolute pressure at the compressor outlet in bar a Qc Free air delivery of the compressor in l s It is recommended that the connection of the compressor air outlet pipe is made on top of the main air net pipe in order to minimize carry over of possible condensate residue As a rule of thumb the following formula can be used to calculate the recommended volume of the air net V 30 x C x...

Page 68: ...f water shut off valves are installed a safety device with set pressure according to the maximum cooling water inlet pressure has to be installed between the compressor water outlet pipe and the shut off valve When operating the unit the operator must ensure that the cooling water system cannot be blocked The above mentioned also applies for the energy recovery cooling system Remove the plastic pl...

Page 69: ...4 3 Electric cable size Electrical connections Electrical connections Cable size 50 Hz compressors Instruction book 2920 1796 01 67 ...

Page 70: ...ors Compressor variant Supply voltage Cable size 200 kW 270 hp 380 V 2x 3x185 mm2 95 mm2 200 kW 270 hp 440 460 V 2x 3x150 mm2 70 mm2 250 kW 340 hp 380 V 2x 3x240 mm2 120 mm2 250 kW 340 hp 440 460 V 2x 3x185 mm2 95 mm2 60 Hz CSA UL compressors Compressor variant Supply voltage Cable size 200 kW 270 hp 440 460 V 2x 3xMCM500 AWG0 200 kW 270 hp 575 V 2x 3xMCM300 AWG2 250 kW 340 hp 440 460 V 4x 3xAWG3 ...

Page 71: ...graphs Control panel Pictographs of control panel Reference Description 1 Alarm 2 Service 3 Automatic operation 4 Voltage on 5 Cancel 6 Enter 7 Up down left right 8 Start 9 Stop Instruction book 2920 1796 01 69 ...

Page 72: ...er inside the electric cabinet 24 Oil the gaskets screw on the filters and tighten by hand approx one half turn 25 Consult the Instruction book before maintenance or repair 28 Oil outlet 4 5 Cooling water requirements General Cooling water needs to fulfill certain requirements in order to avoid problems of scaling fouling corrosion or bacterial growth In open circuit cooling towers protective meas...

Page 73: ...eady included in the Ryznar Stability Index RSI see item 4 below but also the pH itself is subject to limitations pH Type of cooling system Materials Standard Energy recovery Single pass Containing copper 6 8 9 3 6 8 9 3 Stainless steel with carbon steel and or cast iron 6 8 9 3 6 8 9 3 Stainless steel only 6 9 3 6 9 3 Recirculating with tower Containing copper 6 8 9 3 not applicable Stainless ste...

Page 74: ... water sample pHs pH at saturation pHs is calculated from pHs 9 3 A B C D in which A depends on the total solids concentration B depends on the water temperature at the outlet of the heat exchanger C depends on the calcium hardness CaCO3 D depends on the HCO3 concentration or M alkalinity The values of A B C and D can be found in below table Total dissolved solids mg l A Temperature C B Ca hardnes...

Page 75: ...exceeded For shock treatments a maximum limit of 2 ppm for maximum 30 minutes day applies 6 Chlorides Cl Chloride ions will create pitting corrosion on stainless steel Their concentration should be limited depending from the RSI value RSI 5 5 5 6 RSI 6 2 6 3 RSI 6 8 6 9 RSI 7 5 7 6 RSI Cl ppm 200 350 500 350 200 For energy recovery systems the limit is 100 ppm 7 Sulphates SO4 2 Sulphate ppm Type o...

Page 76: ...Single pass 10 1 Recirculating with tower 10 not applicable Closed loop 10 1 12 Oil or grease 1 ppm rejection value 13 Biology If biology is present it must be aerobic Anaerobic biology in closed systems must be avoided Biology CFU ml Type of cooling system Standard Energy recovery Single pass 105 107 103 105 Recirculating with tower 105 107 not applicable Closed loop 103 105 103 105 The table sho...

Page 77: ...sor is designed for indoor use Moving lifting The compressor can be moved by a lift truck using the slots in the frame 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 protrude from the frame equally The chains must be held parallel to the bodywork by chain spr...

Page 78: ...ompressor is automatically started and stopped the compressor may be remotely controlled 3 A number of VCI Volatile Corrosion Inhibitor plates are provided inside the bodywork to protect the compressor against corrosion Remove the plates 4 Remove filler plugs 1 Pour approx 1 l 0 26 US gal 0 22 Imp gal of oil into the compressor elements Refit the plugs 5 Check that the compressor is filled with oi...

Page 79: ...ports are secured to the frame immobilising the vibration dampers during transport 2 Remove the bushes 1 from the gear casing supports and the motor support 3 Remove the brackets fitted next to the air receiver supports Electric cabinet Example of a cubicle with starter Instruction book 2920 1796 01 77 ...

Page 80: ...wires on transformers T1 T2 for correct connection 3 Check the setting of the circuit breakers see the section Settings of circuit breakers Water circuit Step Action 1 Check that the cooling water drain valves customer s installation in the inlet and outlet lines are closed 2 Check that the water shut off valves customer s installation are open 3 Open the water regulating valve and check for water...

Page 81: ...stop button switch off the voltage and reverse two incoming electric lines The correct direction of rotation is indicated for the drive motor by an arrow on the gear casing and for the fan motors by arrows on the motor housings 5 Run the compressor for a few minutes and check that it is operating normally 5 2 Before starting Warning The operator must apply all relevant Safety precautions If the wa...

Page 82: ...y all relevant Safety precautions Control panel Step Action 1 Press start button 14 The compressor starts running in unloaded condition Automatic operation LED 2 lights up 2 Approx 10 seconds later programmable the compressor starts running loaded 3 On water cooled compressors regulate the cooling water flow with the compressor running loaded Adjust the water flow to obtain the most suitable air t...

Page 83: ...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 1796 01 81 ...

Page 84: ... on display 1 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 and open the manual condensate drain valve Instruction book 82 2920 1796 01 ...

Page 85: ...ace the component and reset the relevant timer 4 Regularly check the Inputs and Outputs menus for a quick look at the compressor status 5 6 Stopping Important After pressing stop button 13 the compressor will run unloaded for 30 seconds The compressor stops after this period A start command during this period is ignored After stopping the compressor is prevented from restarting within a programmab...

Page 86: ...ut off valves 7 On water cooled compressors if the compressor is installed in a room where freezing temperatures are expected drain the cooling system by opening the drain valves in the water inlet and outlet pipes customer s installation 5 7 Taking out of operation Disconnecting the compressor At the end of the service life of the compressor proceed as follows Step Action 1 Stop the compressor an...

Page 87: ...ressed air oil separator and must be operated within the specified limits as mentioned on the dataplate 3 No alterations shall be made to this vessel by welding drilling or other methods of mechanical working without written permission of the manufacturer 4 Original bolts have to be used after opening for inside inspection Maximum torque has to be taken into consideration 5 Devices for pressure an...

Page 88: ...s is not covered by Warranty or Product Liability General When servicing replace all removed gaskets O rings and washers Preventive maintenance schedule Period Running hours Operation Daily 8 Check readings on display Daily 8 Check that condensate is discharged during loading Daily 8 Check oil level Before starting the level should be in the middle of the sight glass Weekly Drain condensate from t...

Page 89: ...agreement It will ensure optimum operational efficiency minimize downtime and reduce the total life cycle costs 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 the screen After carryi...

Page 90: ... 4000 h 90 gr 3 15 oz 60 Hz IEC Compressor type Interval Amount 200 kW 270 hp 4000 h 90 gr 3 15 oz 250 kW 340 hp 4000 h 90 gr 3 15 oz WEG drive motor WEG motors must be greased with Screwguard Slide Blue 50 Hz Compressor type Interval D end Amount D end Interval N end Amount N end 200 kW 270 hp 7 5 bar 109 psi 4000 h 27 gr 0 95 oz 4000 h 27 gr 0 95 oz 200 kW 270 hp 8 5 bar 123 psi 4000 h 27 gr 0 9...

Page 91: ...n such case it is recommended to use RXD oil Rotair Xtra RXD oil is a high quality synthetic lubricant for oil injected screw compressors which keeps the compressor in excellent condition RXD oil can be used for compressors operating at ambient temperatures between 0 C 32 F and 46 C 115 F see section Service kits Rotair FoodGrade Special oil delivered as an option Foodgrade oil is a unique high qu...

Page 92: ...Control panel Vent filler and drain plugs Oil drain plugs compressor elements Instruction book 90 2920 1796 01 ...

Page 93: ...Vent filler and drain plugs on air cooled compressors Instruction book 2920 1796 01 91 ...

Page 94: ...m Stop the compressor close the air outlet valve and switch off the voltage Wait a few minutes and depressurize by unscrewing plug 8 only one turn to permit any pressure in the system to escape 2 Loosen the vent plugs on top of the oil coolers Instruction book 92 2920 1796 01 ...

Page 95: ...oler 5 Run the compressor loaded for a few minutes to allow the oil cooler by pass valve to open Stop the compressor and wait a few minutes 6 Depressurize the system by unscrewing plug 8 only one turn to permit any pressure in the system to escape Remove the plug Fill the air receiver with oil until the level reaches the filler opening Tighten filler plug 8 7 After carrying out all service actions...

Page 96: ...e oil spillage Unscrew oil filters 3 only one turn and wait a few minutes to let the oil of the filter flow back into the oil separator Remove the oil filters 3 Clean the filter seats on the manifold Oil the gaskets of the new filters and screw the filters into place until the gaskets contact their seats Then tighten by hand 4 Tighten plug 4 5 Reset the service warning after carrying out all servi...

Page 97: ...indicated in the relevant Parts Lists Rotair Rotair oil can be ordered in the following quantities 5 litre can 6215 7140 00 20 litre can 6215 7141 00 209 litre can 6215 7142 00 1000 litre can 6215 7143 00 See the section Oil specifications Rotair Plus Rotair Plus oil can be ordered in the following quantities 5 litre can 6215 7144 00 20 litre can 6215 7145 00 209 litre can 6215 7146 00 1000 litre ...

Page 98: ...01 0338 13 Screwguard Slide Green 2908 8514 10 Screwguard Slide Blue 2908 8521 10 Screwguard Slide Beige 2908 8523 10 6 8 Disposal of used material Used filters or any other used material e g desiccant lubricants cleaning rags machine parts etc must be disposed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation Instruction boo...

Page 99: ...age The operator must apply all relevant Safety precautions Position of air filters Position of air filters Procedure Step Action 1 Remove the covers of the air filters 2 Remove the filter elements 3 Fit the new filter elements 4 Reinstall the covers of the air filters 5 Reset the air filter service warning see section Service menu Instruction book 2920 1796 01 97 ...

Page 100: ...ng Stop the compressor press the emergency stop button and switch off the voltage The operator must apply all relevant Safety precautions Procedure Cooler block of air cooled compressors Instruction book 98 2920 1796 01 ...

Page 101: ...direction to normal flow Use low pressure air if necessary the pressure may be increased up to 6 bar e 87 psig 4 If it is necessary to clean the coolers with a cleaning agent consult your Customer Centre 5 Reposition and fix the fan Make sure that the fan rotates freely On water cooled compressors consult your Customer Centre if it is necessary to clean the coolers 7 3 Safety valve Warning Stop th...

Page 102: ...cation of safety valve on water cooled compressors The valve can be tested on a separate compressed air line Consult your Customer Centre if the valve does not open at the correct pressure see the section Settings of safety valve Instruction book 100 2920 1796 01 ...

Page 103: ...and remedies If the alarm LED is lit or flashes consult sections Event history menu or Service menu Unit is shut down The alarm LED will flash indicating either that the outlet temperature 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 press the Reset key 2 the message All protection functions are OK wi...

Page 104: ...sor Check equipment connected Choked air filters Replace filters Air leakage Check 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 temper...

Page 105: ...ssures Compressor outlet temperature air cooled compressors C Approx 29 Compressor outlet temperature air cooled compressors F Approx 84 Compressor outlet temperature water cooled compressors C Approx 25 Compressor outlet temperature water cooled compressors F Approx 77 Compressor element outlet temperature C Between 55 and 100 Compressor element outlet temperature F Between 131 and 212 Cooling ai...

Page 106: ...let temperature F 104 Maximum cooling water outlet temperature open systems C 50 Maximum cooling water outlet temperature open systems F 122 Maximum cooling water outlet temperature recirculating systems C 60 Maximum cooling water outlet temperature recirculating systems F 140 Maximum cooling water inlet pressure bar e 10 Maximum cooling water inlet pressure psig 145 9 4 Settings of safety valve C...

Page 107: ...ridges to be installed by customer 200 kW 270 hp 400 233 2x 3x315 200 kW 270 hp 500 186 2x 3x250 3x400 50 Hz IEC compressors with Siemens motors Compressor type Supply voltage V Overload relay A Fuses Class gL gG Type 2 A 2X3 fuses 2X3 cables to contactor Fuses Class gL gG Type 2 A 3 fuses 2X3 cables to contactor Fuses Class gL gG Type 2 A 3 fuses 3 cables to contactor bridges to be installed by c...

Page 108: ...kW 340 hp 400 284 2x 3x355 L 300 m L 985 ft 3x630 L 160 m L 525 ft 250 kW 340 hp 500 227 2x 3x315 L 200 m L 656 ft 3x500 L 160 m L 525 ft 60Hz IEC compressors with ABB motors Compressor type Supply voltage V Overload relay A Fuses Class gL gG Type 2 A 2X3 fuses 2X3 cables to contactor Fuses Class gL gG Type 1 A 3 fuses 2X3 cables to contactor Fuses Class gL gG Type 1 A 3 fuses 3 cables to contacto...

Page 109: ...voltage V Overload relay A Fuses CSA HRC UL Class 5 A 2x3 fuses 2x3 cables to contactor Fuses UL Class K5 A 3 fuses 2x3 cables to contactor Fuses UL Class K5 A 3 fuses 3 cables to contactor bridges to be installed by customer 200 kW 270 hp 440 460 215 2x 3x300 3x450 200 kW 270 hp 575 165 2x 3x250 3x350 250 kW 340 hp 440 460 245 2x 3x300 3x500 250 kW 340 hp 575 187 2x 3x250 3x400 9 6 Settings of ci...

Page 110: ...25 Q26 7 7 For bodywork ventilation fan water cooled 50 Hz Compressor type Supply voltage V Circuit breakers Setting A 200 kW 270 hp 230 Q25 2 5 200 kW 270 hp 400 Q25 1 4 200 kW 270 hp 500 Q25 1 1 250 kW 340 hp 230 Q25 2 5 250 kW 340 hp 400 Q25 1 4 250 kW 340 hp 500 Q25 1 1 For bodywork ventilation fan water cooled 60 Hz Compressor type Supply voltage V Circuit breakers Setting A 200 kW 270 hp 220...

Page 111: ...0 hp 575 Q1 0 6 0 9 1 4 1 8 9 7 Compressor data Data for 7 5 bar 109 psi 50 Hz compressors Units 200 kW 270 hp 250 kW 340 hp Maximum working pressure bar e 7 5 7 5 Maximum working pressure psig 109 109 Nominal working pressure bar e 7 0 7 0 Nominal working pressure psig 102 102 Motor shaft speed r min 1490 1490 Power input air cooled compressor kW 224 272 Power input air cooled compressor hp 300 3...

Page 112: ... 262 Power input water cooled compressor hp 278 351 Oil capacity air cooled compressor l 130 130 Oil capacity air cooled compressor US gal 34 3 34 3 Oil capacity air cooled compressor Imp gal 28 6 28 6 Oil capacity air cooled compressor cu ft 4 55 4 55 Oil capacity water cooled compressor l 113 113 Oil capacity water cooled compressor US gal 29 8 29 8 Oil capacity water cooled compressor Imp gal 2...

Page 113: ...led compressor dB A 72 72 Maximum cooling water flow l s 5 5 6 9 Maximum cooling water flow cfm 11 7 14 6 Minimum cooling water flow l s 1 3 1 6 Minimum cooling water flow cfm 2 8 3 4 Data for 13 bar 189 psi 50 Hz compressors Units 200 kW 270 hp Maximum working pressure bar e 13 Maximum working pressure psig 189 Nominal working pressure bar e 12 5 Nominal working pressure psig 181 Motor shaft spee...

Page 114: ...air cooled compressor l 130 130 Oil capacity air cooled compressor US gal 34 3 34 3 Oil capacity air cooled compressor Imp gal 28 6 28 6 Oil capacity air cooled compressor cu ft 4 55 4 55 Oil capacity water cooled compressor l 113 113 Oil capacity water cooled compressor US gal 29 8 29 8 Oil capacity water cooled compressor Imp gal 24 9 24 9 Oil capacity water cooled compressor cu ft 3 96 3 96 Sou...

Page 115: ...m 11 2 13 6 Minimum cooling water flow l s 1 3 1 6 Minimum cooling water flow cfm 2 8 3 4 Data for 10 4 bar 150 psi 60 Hz compressors Units 200 kW 270 hp 250 kW 340 hp Maximum working pressure bar e 10 8 10 8 Maximum working pressure psig 157 157 Nominal working pressure bar e 10 3 10 3 Nominal working pressure psig 149 149 Motor shaft speed r min 1790 1790 Power input air cooled compressor kW 222...

Page 116: ...1 Power input water cooled compressor kW 217 260 Power input water cooled compressor hp 291 349 Oil capacity air cooled compressor l 130 130 Oil capacity air cooled compressor US gal 34 3 34 3 Oil capacity air cooled compressor Imp gal 28 6 28 6 Oil capacity air cooled compressor cu ft 4 55 4 55 Oil capacity water cooled compressor l 113 113 Oil capacity water cooled compressor US gal 29 8 29 8 Oi...

Page 117: ...into the machine and fall under the exclusion of article I section 3 6 Parts subject to the Simple Pressure Vessel Directive 87 404 EEC are excluded from 97 23 EC according to article I section 3 3 The following pressure bearing parts are of category higher than I Oil separator vessel Cat IV 1 vessel design pressure 15 bar e content 305 l Design standard ASME section VIII div 1 Safety valve Cat IV...

Page 118: ...ate here Corrosion allowance 1 mm 0 039 in Minimum wall thickness vessel 8 mm 0 315 in Minimum wall thickness cover 12 mm 0 472 in Lifetime infinite according to EN13445 3 6 Delta p 13 3 bar 192 9 psi Casting factor cover 0 8 Instruction book 116 2920 1796 01 ...

Page 119: ...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 2920 1796 01 117 ...

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