CPF 175, CPVS 175

CPF 175, CPVS 175

Instruction book

Chicago Pneumatic

CPF 175, CPVS 175

Instruction bookOriginal instructions

Copyright NoticeAny unauthorized use or copying of the contents or any part thereof is prohibited.

This applies in particular to trademarks, model denominations, part numbers and drawings.

This instruction book is valid for CE as well as non-CE labelled machines. It meets therequirements for instructions specified by the applicable European directives as identifiedin the Declaration of Conformity.

2013 - 02

No. 2920 1804 02

www.cp.com

Table of contents

1 Safety precautions..........................................................................................................6

1.1 SAFETY ICONS...................................................................................................................................6

1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6

1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7

1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................8

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................9

2 General description......................................................................................................11

2.1 INTRODUCTION.................................................................................................................................11

2.2 AIR AND OIL 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............................................................................................................................46

3.12 SERVICE MENU...............................................................................................................................48

3.13 WEEKLY PROGRAM - TIMER FUNCTION.................................................................................................53

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3.14 HISTORY MENU................................................................................................................................55

3.15 SAFETY MENU.................................................................................................................................56

3.16 CONFIGURATION USER MENU..............................................................................................................64

3.17 CONFIGURATION DISTRIBUTOR MENU....................................................................................................66

3.18 INPUT STATE MENU..........................................................................................................................69

3.19 OUTPUT TEST MENU.........................................................................................................................71

3.20 VERSION MENU................................................................................................................................73

3.21 INFORMATION DISTRIBUTOR MENU........................................................................................................73

3.22 PASSWORD MENU.............................................................................................................................73

3.23 MCC MENU....................................................................................................................................73

3.24 EXTERNAL CONNECTION.....................................................................................................................74

3.25 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 STARTING.....................................................................................................................................112

5.4 DURING OPERATION........................................................................................................................113

5.5 CHECKING THE DISPLAY...................................................................................................................114

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5.6 STOPPING.....................................................................................................................................115

5.7 STORAGE AFTER INSTALLATION.........................................................................................................116

5.8 TAKING OUT OF OPERATION..............................................................................................................117

5.9 USE OF AIR RECEIVER.....................................................................................................................117

6 Maintenance................................................................................................................119

6.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................119

6.2 MOTORS.......................................................................................................................................120

6.3 OIL SPECIFICATIONS........................................................................................................................121

6.4 OIL CHANGE..................................................................................................................................122

6.5 STORAGE AFTER INSTALLATION.........................................................................................................126

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 Pressure equipment directives.................................................................................146

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11 Declaration of conformity..........................................................................................148

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 Safety precautions, general

General precautions

1. The operator must employ safe working practices and observe all related work safety requirements andregulations.

2. If any of the following statements does not comply with the applicable legislation, the stricter of the twoshall apply.

3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,specialized personnel.

4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,the compressed air must be adequately purified according to the applicable legislation and standards.

5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, thepower 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 thisfunction is active, be aware that the machine will restart automatically when the power isrestored if it was running when the power was interrupted!

6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Neveruse the air to clean dirt from your clothes. When using the air to clean equipment, do so with extremecaution and wear eye protection.

7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shallbe replaced if unsuitable for safe operation.

8. It is not allowed to walk or stand on the unit or on its components.

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1.3 Safety precautions during installationAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable safetyregulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden todwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept withinsafe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.

2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;consult your supplier.

3. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suctionduct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.

4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or

worn hoses. Distribution pipes and connections must be of the correct size and suitable for the workingpressure.

6. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can leadto internal fire or explosion.

7. Arrange the air intake so that loose clothing worn by people cannot be sucked in.8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under

heat and that it is not in contact with or close to flammable materials.9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is

remotely controlled and may start without warning.The operator has to make sure that the machine is stopped and depressurized and that the electrical isolatingswitch is open, locked and labelled with a temporary warning before any maintenance or repair. As afurther safeguard, persons switching on or off remotely controlled machines shall take adequateprecautions to ensure that there is no one checking or working on the machine. To this end, a suitablenotice shall be affixed to the start equipment.

11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available andthat the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.

12. The electrical connections must correspond to the applicable codes. The machines must be earthed andprotected against short circuits by fuses in all phases. A lockable power isolating switch must be installednear the compressor.

13. On machines with automatic start/stop system or if the automatic restart function after voltage failure isactivated, a sign stating "This machine may start without warning" must be affixed near the instrumentpanel.

14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-returnvalves (check valves) must not be relied upon for isolating pressure systems.

15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressurevessel or auxiliary installed outside the machine to contain air above atmospheric pressure must beprotected by a pressure relieving device or devices as required.

16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touchedby personnel in normal operation must be guarded or insulated. Other high temperature piping must beclearly marked.

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17. For water-cooled machines, the cooling water system installed outside the machine has to be protected bya safety device with set pressure according to the maximum cooling water inlet pressure.

18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.

Also consult following safety precautions: Safety precautions during operation and Safetyprecautions during maintenance.These precautions apply to machinery processing or consuming air or inert gas.Processing of any other gas requires additional safety precautions typical to the applicationwhich are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

1.4 Safety precautions during operationAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during operation

1. Never touch any piping or components of the compressor during operation.2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or

air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make surethat a hose is fully depressurized before disconnecting it.

3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that thereis no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remotestart equipment.

4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors orparticles.

5. Never operate the machine below or in excess of its limit ratings.6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to

carry out routine checks. Wear ear protectors when opening a door.On compressors without bodywork, wear ear protection in the vicinity of the machine.

7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)shall wear ear protectors.

8. Periodically check that:• All guards are in place and securely fastened• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing• No leaks occur• All fasteners are tight• All electrical leads are secure and in good order• Safety valves and other pressure relief devices are not obstructed by dirt or paint• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free

of wear or abuse• Air cooling filters of the electrical cabinet are not clogged

9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, takeprecautions against air pollution and possible contamination of the breathing air.

10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken toavoid the growth of harmful bacteria such as Legionella pneumophila bacteria.

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11. Do not remove any of, or tamper with, the sound-damping material.12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure

vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall beprotected by a pressure relieving device or devices as required.

13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must berespected. Local regulations remain applicable if they are more strict.

Also consult following safety precautions: Safety precautions during installation and Safetyprecautions during maintenance.These precautions apply to machinery processing or consuming air or inert gas.Processing of any other gas requires additional safety precautions typical to the applicationwhich are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

1.5 Safety precautions during maintenance or repairAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).2. Use only the correct tools for maintenance and repair work.3. Use only genuine spare parts.4. All 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 remotestart equipment.

7. Close the compressor air outlet valve and depressurize the compressor before connecting or disconnectinga pipe.

8. Before removing any pressurized component, effectively isolate the machine from all sources of pressureand relieve the entire system of pressure.

9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions againsttoxic vapours of cleaning liquids.

10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the partsand exposed openings with a clean cloth, paper or tape.

11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completelypurged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify,pressure vessels.

12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, themachine shall be stopped but no inspection covers shall be opened before sufficient cooling time haselapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.

13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.14. Make sure that no tools, loose parts or rags are left in or on the machine.

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15. All regulating and safety devices shall be maintained with due care to ensure that they function properly.They may not be put out of action.

16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,temperatures and time settings are correct. Check that all control and shut-down devices are fitted and thatthey function correctly. If removed, check that the coupling guard of the compressor drive shaft has beenreinstalled.

17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separatorvessel for carbon deposits; if excessive, the deposits should be removed.

18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from enteringthem, e.g. when steam cleaning.

19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodyworkand in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it bygenuine 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, usebreathing protection.

• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. Ifliquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flushabundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medicalfirst aid.

Also consult following safety precautions: Safety precautions during installation and Safetyprecautions during operation.These precautions apply to machinery processing or consuming air or inert gas.Processing of any other gas requires additional safety precautions typical to the applicationwhich are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

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2 General description

2.1 Introduction

General view

Description

These units are single-stage, oil-injected screw compressors, driven by an electric motor and enclosed insound-insulated bodywork.

Compressors with variable speed drive optimize energy consumption and reduce the operating pressure bandby continuously matching the speed of the 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 compressorsthat 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 andextends the oil change interval.

Water separator drain

The water separator drain prevents water from entering in the compressed air net.

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Oil preheater (only for 400 V-50 Hz)

This oil preheating system is installed in the oil tank in order to preheat the lubricant at low temperatures.

High efficiency air filtration

The high efficiency air filtration improves the quality of the air at the intake. This option is particularly usefulin very dusty surroundings.

Pre-filtration panel

The pre-filtration panel protects the compressor's internal from dust and helps to avoid clogging of the aircoolers (cooling air side).

High pre-filtration panel

The pre-filtration panel protects the compressor's internal from dust and helps to avoid clogging of the aircoolers (cooling air side). This option is particularly useful in very dusty surroundings.

Modulating control

The modulating control system is designed to maintain a narrow net pressure band by throttling the air inlet,thus reducing the air flow (50% - 100%).

Electronic drain (only for 400 V-50 Hz)

The electronic water drain assures proper draining of condensate and prevents water from entering thecompressed air net. For any malfunction of the draining process, the electronic water drain generates a warningmessage 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 heatin the form of hot water without any influence on the compressor performance.

Phase Sequence Relay

The phase sequence relay prevents the drive motor from rotating in the wrong direction.

Automatic restart after voltage failure

For compressors leaving the factory, this function is made inactive. If desired, the function can be activated.Consult your Customer Centre.

If activated and provided the regulator was in the automatic operation mode and thecompressor control mode (local, remote 1 or remote 2) was not changed during the voltagefailure, the compressor will automatically restart if the supply voltage to the module isrestored within a programmed time period (this time period is called the power recoverytime).The power recovery time can be set between 1 and 254 seconds or to 0. If the powerrecovery time is set to 0, the compressor will always restart after a voltage failure, no matterhow long it takes to restore the voltage.

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2.2 Air and oil system

Flow diagrams

Flow diagram, air-cooled compressor

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Flow diagram, air-cooled compressor with energy recovery

Flow diagram, air-cooled compressor with modulating control

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Flow diagram, air-cooled compressor with energy recovery and with modulating control

Flow diagram, water-cooled compressor

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Flow diagram, water-cooled compressor with modulating control

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Air flow

Air-cooled compressor

Air drawn through filter and unloader (UA) is compressed in compressor element (E). Compressed air andoil are discharged through check valve (CV) to air receiver/oil separator (AR) where oil is separated from thecompressed air. The air is blown through minimum pressure valve (Vp) to air cooler (Ca).

The cooled air is discharged through the outlet towards the air net. An optional condensate trap may beprovided between the air cooler and outlet valve.

Check valve (CV) prevents blow-back of compressed air.

Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure.

Oil system

Air pressure forces the oil from receiver (AR) through oil cooler (Co), filters (OF), oil stop valve (Vs) and anoil injection valve to the compressor element (E) and the lubrication points. On air-cooled compressors, anoil 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 avoidovercooling and consequently condensation in the air receiver (AR).

On air-cooled compressors with energy recovery or on water-cooled compressors, the oil temperature iscontrolled by a thermostatic valve to avoid overcooling and consequently condensation in the air receiver(AR).

In the air receiver (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oilis removed by the separator element.

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2.3 Cooling and condensate system

Condensate drain system

Position of condensate drain

(1) Automatic condensate drain

As an option, a condensate trap can be installed downstream of the air cooler to prevent condensate fromentering the air outlet pipe. The trap is provided with a float valve for automatically draining condensate andwith 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.

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2.4 Regulating system

Flow diagrams

Flow diagram

Reference DesignationA To air coolerB To/from oil cooler

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Regulating system

The compressor is controlled by electronic regulator (1).

The regulator keeps the net pressure within programmable pressure limits by automatically loading andunloading the compressor depending on the air consumption. It also protects the compressor and monitorscomponents subject to service.

Unloading

If the air consumption is less than the air delivery of the compressor, the net pressure increases. When the netpressure reaches the upper limit of the working pressure (unloading pressure), solenoid valve (5) is de-energized by the electronic regulator (1). The plunger of solenoid valve (5) moves downwards by spring force:

Phase Description1 The plunger of solenoid valve (5) shuts off the supply of receiver pressure towards

chamber (2).2 Control pressure present in chamber (2) is vented to atmosphere. Plunger (3) of blow-off

valve (4) is moved by air receiver pressure allowing air receiver pressure to chamber (6).3 Valve (7) is pushed upwards closing off the air inlet.4 A small flow of air remains drawn in via channel (8), and is finally blown from receiver via

channel (10) to the air inlet.5 Air 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:

Phase1 The plunger of solenoid valve (5) opens the supply of receiver pressure towards chamber

(2). Plunger (3) of blow-off valve (4) moves, closing off the air pressure supply towardschamber (6).

2 Valve (7) moves downwards since the pressure in chamber (6) drops below atmosphericpressure, opening the air inlet to the compressor element.

3 Air delivery is resumed (100%), the compressor runs loaded while the piston-rod-valveassembly is only surrounded by atmospheric pressure.

2.5 Energy recovery system

General description

The maximum allowed pressure at the water side of the heat exchanger is 10 bar (145 psi).When the energy recovery system is not used, make sure that all water is out of the energyrecovery system.

The energy required in any compression process is mainly transformed into heat. The major part of thecompression heat is dissipated through the oil system. The energy recovery systems are designed to recover

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most of the above-mentioned heat as warm or hot water without any adverse influence on the compressorperformance.

After the compression stage, the oil is separated from the compressed air. The compressed air flows to theaftercooler and the oil flows to the oil cooler. The energy in the oil can be recovered by installing a heatexchanger in front of the oil cooler.

The energy recovery systems can be applied as low temperature rise / high water flow systems (e.g. centralheating in closed water circuits) or as high temperature rise / low water flow systems (e.g. pre-heating ofboiler feed water in open water circuits).

Main components

The system mainly comprises:

• Oil/water heat exchanger• Energy recovery valve• Oil by-pass valve• The necessary pipes, brackets, bolts, etc.

Installation

The compressor frame is prepared for the Energy recovery system. The connections must be 1".

The use of a filter on the water intake is recommended to protect the cooling agents and the valves. A manualvalve 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. Ifin any doubt, contact your service representative.

For the following specifications, dependent on the compressor type, contact your service representative:• Minimum water inlet temperature• Maximum water inlet temperature• Required cooling water flow• Maximum water pressure• Recoverable energy

Energy recovery system

The recovery water enters the unit at the heat exchanger inlet connection. In the heat exchanger thecompression heat is transferred from the compressor to the water. The water leaves the heat exchanger viathe outlet connection. The oil flow of the compressor is controlled by a by-pass valve to ensure a reliablecompressor operation and an optimum recovery of energy.

Formula for recovered energy is : ==> Q = m x c x dT

==> m = Q / (c x dT)

Q = the recovered energy in w

m = the mass flow in kg/s

c = the specific heat capacity in J/kgK (4.2 J/kgK for water)

dT = the specific temperature change (inlet versus outlet) in K

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Additional safety precautions

• The parts must only be lifted using suitable equipment in accordance with the applicable safety regulations.Loose or pivoting parts must be securely fastened before lifting.

• Wear a safety helmet when working in the area of overhead or lifting equipment.• Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.• Protection caps, bags, etc. must be removed before connecting 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 the maximum cooling water inlet pressure.• All maintenance work shall only be undertaken when the machine has cooled down.• Never weld or perform any operation involving heat near the oil system.

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3 Electronic regulator

3.1 Electronic controller

Control panel

The display and the luminous indicator of AIRLOGIC® allows:

• Viewing the operational status of the compressor at a given instant• Viewing the maintenance messages (alarms, faults)• Viewing the setting parameters of the compressor

Description

The AIRLOGIC® is an electronic control plate equipped with a microprocessor used for the surveillance,management and monitoring of the compressor range of compressors at fixed speed and compressors withvariable speed, as well as the compressors with integrated dryer.

The AIRLOGIC® offers several functions including the management of control, management of alarms andfaults, 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 speed or variable speed compressor.• The programming of operating time of loading and shutdown with possible selection of two control bands.• The control, the fault reporting and the display of the operational status of the compressor by remote

control.• The automatic restarting in cascade after a mini-outage in power supply.• The management of the integrated dryer module.

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• In option, the centralized management of up to 4 compressors equipped with an AIRLOGIC®.

The exceptional modularity of the AIRLOGIC® allows connecting additional electronic modules to addlogical and/or analog inputs/outputs necessary for certain special applications (the modules available aredescribed in section External communication). For example, the pressure loss of the air treatment chain canbe managed from the AIRLOGIC®.

Indication of maintenance operations

When a maintenance operation becomes necessary, either because the machine has reached the number ofhours necessary before an intervention or because a sensor has detected a limit, a red indicator flashes and amessage is displayed indicating the nature of the operation. The machine does not stop.

Management of warnings

The warning characterizes either a maintenance operation or a warning limit before reaching the limit of thefault, which when reached, would stop the machine. This allows anticipating a malfunctioning and dealingwith it without compromising your production of compressed air. The indication of the nature of warning istransmitted to the AIRLOGIC®.

Management of functional faults

On the appearance of a functional fault, the AIRLOGIC® stops the compressor, indicates the fault by a redfault indicator and displays the message allowing rapid identification of the cause of the incident.

An entry is added to the menu Historyof faults, displaying the nature of the fault, the date and the time aswell as the value of certain parameters recorded when the fault appeared.

Programming of pressure timers

The real time clock of the AIRLOGIC® allows, after programming the pressure timers, automatic startingand stopping of the compressor. While programming the loaded running, two pressure limits are availableallowing to vary the control pressure over a time, depending on the applications.

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3.2 Control panel

Regulator

Display

The screen displays all the information necessary for the navigation, the control of functional parameters andthe error messages.

The choice of 3 languages among 25 (configurable by the software) simplifies the understanding of themessages and the parameters.

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Luminous indicators

Power supply indicator (green lamp lit): controller powered on.

Automatic operation mode: green lamp on (the compressor was not stoppedmanually, it was either loaded or unloaded or stopped but ready to startautomatically, if necessary).

Error: red flashing lightWarning: fixed red light

Keys

Start button, to start the compressor in automatic mode (the compressor will stopand restart automatically depending on the pressure variations in the network).

Stop button, to stop the compressor when it is in automatic operation mode. Thecomplete shutdown takes place only after a depressurization cycle of a modifiableperiod of 30 seconds.

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Cancel button:• to cancel a modification of the value of a parameter.• to return to a previous level in the menus.• Shortcut to the menu Control Mode.

Validate button:• to enter the menu currently displayed while navigating the menu (the screen

then displays the list of parameters of this menu)• to validate the modification of the value of a parameter• to enter the mode of modification of the value of a parameter. The value starts

flashing.• to rearm after a fault or a warning when the cause has been eliminated.

Navigation Up• to display the previous menu or parameter• to increment the value of a parameter during its modification.

Navigation Down• to display the next menu or parameter• to decrement the value 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 startingfrom 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 parameters.• Using the vertical navigation buttons, select Language in use from the parameters menu.• Activate the language parameter by pressing the Validate key. The language currently used is displayed.• Press the Validate key again for activating the modification mode. The parameter flashes.• A list with three languages is shown. Scroll to the desired language using the Navigation buttons.• Validate your choice by pressing the Validate key. The parameter stops flashing.

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• Use the Cancel button to return to the operational screen.

3.4 Regulation

Command of the regulation

In the case of ON/OFF regulation, the AIRLOGIC® manages:

• The command of unloading when the pressure measured by the analog sensor reaches the idling pressure.• The command of loading when the pressure measured by the analog sensor reaches the minimum

regulation pressure (loading pressure).• The command of motor shutdown after a period of idling.• The restriction on restarting the motor if the pressure in the oil tank is higher than 1.5 bar (21.7 psi) or if

the oil temperature at the outlet of the compression block is less than 2 °C (35.6 °F).• If it is necessary to intervene on the machine when it is stopped, it should be placed in total safety by

cutting off the electrical power supply.

Stop on fault

The following inputs and parameters will stop the compressor on fault when their status switches (for inputs)or when their value crosses the predefined values (top or bottom limits for the analog parameters or inputs):

• Input : Emergency stop• Input : Motor overload• Input : Turbine motor overload• Input : Phase controller (option)• Input : External fault (dryer, filter, other equipment …)• Analog Input: temperature in outlet of compression block. In addition to the value of this temperature, its

increase is also monitored during about 15 seconds after the starting of the compressor. If the temperaturedoes not increase sufficiently, 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 tocut 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: dryer temperature (estimate of the dew point set as a dryer "LAT parameter") too high ortoo low. There will be a warning if the temperature moves out of these high and low limits.

• Analog input internal pressure: this input replaces the high and low pressure switches of older regulationsystems. If the internal pressure of the tank is too high, the controller displays a first warning notifyingthe user that the pressure is approaching dangerously close to the maximum limit. Then an error will betriggered (and shutdown the compressor) if the pressure continues increasing.

• Parameter differential pressure: a calculation of the difference of pressure between the machine outlet andthe internal tank also replaces the differential pressure switches.

• Analog Input : motor temperature (sensors in option on certain machines)

Warning before stop on fault

Most of the values measured or calculated have before fault warning thresholds whose values are slightlybelow (or above) the maximum (or minimum) fault thresholds. The operator is warned that the operation ofthe compressor is approaching an error threshold.

Control mode

The AIRLOGIC® has three control modes, Local/Remote/LAN.

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• In Local mode, it is possible to start or stop the compressor directly from the controller.• In Remote mode, the stop and start control is via a dry external contact (adjustment may still be internal

(via the machine's sensor) or external (pressure switch….))• In LAN mode, start and stop control is by using the CANBUS compressor network through a master

supervisor.

For the latter two cases, the compressor is stopped 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/ormodification of parameter screens.

The following section describes the general structure of the menus. However, depending on the options ofthe compressor, additional screens and/or parameters may be displayed. The logic of navigation andmodification of parameters remains identical.

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General structure

The structure of the AIRLOGIC® is composed of two sections. The left hand column represents the statusmenus transmitting the parameters relating to the functional status of the machine; these are usable as checklists.

The rest of the structure offers the parameters for configuring the compressor. Some of these parameters areread only while others can be modified, with restriction of access through password, depending on thequalification of the operator.

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Menu structure for fixed speed compressors

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Menu structure for variable speed compressors

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Reading the structure

A vertical arrow pointing to a screen indicates that this screen is reached from the screen located above (theorigin of the arrow) by pressing the navigation down key.

A horizontal arrow indicates that it is possible to:

• go to the menu located at the top of the arrow by pressing the validate key.• go to the screen for modifying the parameter displayed by pressing the validate key.• return to the screen located at the end of the arrow pointing to the screen by pressing the cancel key.

A vertical arrow leaving from 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 leavea submenu. The cancel key allows to reach the parameter to be modified.

Screen for fixed speed compressors

Screen for variable speed compressors

Displaying the parameter value

When the cursor is positioned against the parameter (loading press/setpoint 1), press the validate key to displaythe value of the parameter. This value is displayed along with its minimum and maximum limits.

Activating the modification mode

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Press the validate key; the flashing of the value indicates that the parameter can be modified withinprogramming limits.

Modifying the value

Using the navigation up key to increase or the navigation down key to decrease the value within the definedlimits.

Validating a parameter

By pressing the validate key, the modification of the parameter is validated. The value stops flashing.

Canceling a modification

By pressing the cancel key, the modification is cancelled and the parameter returns to its initial value.

Exiting the menu

Press the cancel key to return to the parameter selection list of the menu.

3.7 Status menus

Description

These status menus only display the different parameters/values relating to the functional state or settings ofthe compressor.

Fixed speed compressors

Screen DescriptionCompressor outlet pressure: Indication of the pressure read by the sensor in themachine outlet

Element outlet temperature: Indication of the temperature read by the sensor in theoutlet of the compressor element

Manual operation/Local control/Timer inactive: Indicates that the compressor is inautonomous operating mode (it is not controlled by an external controller) / indicatesthat the pressure sensor read by the compressor is the integrated sensor (and notan external sensor) / Indicates that the weekly programming function is notactivated.

Max. pressure : Maximum limit of unloading pressure setting.

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Screen DescriptionPres. Band used : Range of pressure used. Two different pressure bands can bechosen.

Running hours : Number of running hours of the compressor motor operation(unloaded or loaded) from its start-up.

Loaded hours : Number of hours of loaded operation of the compressor from itsstart-up.

Number of motor starts : Number of motor starts from its start-up.

Module hours : Number of hours during which the AIRLOGIC® remains poweredon.

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, themenu 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 thecompressor

Element outlet temperature: Indicates the temperature read by the sensor in theoutlet of the compression element

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Screen DescriptionPressure difference: Indicates the difference between the internal tank pressureand the pressure in the compressor outlet.

Emergency stop : Status of the logical input emergency stop (closed = no error)

Start/stop remote : Status of the logical inputs indicating to the AIRLOGIC® that itis remotely started (input closed) in the Remote control operating mode

Load/unload remote : Status of the logical input of regulation control. Used whenthe compressor is remotely controlled (Input "Remote pressure" closed).

Remote pressure : Input determining whether the control is local (open) or remote(closed).

Overload motor : Overload of main motor -- input activated by the thermal protectionrelay of the main motor.

Overload fan motor : Overload of turbine motor - input activated by the thermalprotection relay of the turbine motor.

Phase sequence : Input triggering an error if the phase controller (in option) detectsa wrong direction of the phases (and therefore the motor) or else, an absence ofphase.

Status of the input for selection of the pressure band. Pressure band 1 if open,pressure band 2 if closed (active if the parameter Digital PB set of the menuConf.distr is activated)

Variable speed compressors

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Screen DescriptionCompressor outlet pressure: Indication of the pressure read by the sensor in themachine outlet

Element outlet temperature: Indication of the temperature read by the sensor in theoutlet of the compressor element

Manual operation/Local control/Timer inactive: Indicates that the compressor is inautonomous operating mode (it is not controlled by an external controller) / indicatesthat the pressure sensor read by the compressor is the integrated sensor (and notan external sensor) / Indicates that the weekly programming function is notactivated.

Max. pressure : Maximum limit of unloading pressure setting.

Setpoint 1 : Setpoint pressure. Two programmable setpoint pressures can bechosen.

Compress. Speed : Indicates the motor rotation speed.

Running hours : Number of running hours of the compressor motor operation(unloaded or loaded) from its start-up.

Loaded hours : Number of hours of loaded operation of the compressor from itsstart-up.

Number of motor starts : Number of motor starts from its start-up.

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Screen DescriptionModule hours : Number of hours during which the AIRLOGIC® remains poweredon.

Accumulated vol : for compressors at variable speed, an internal calculation in theAIRLOGIC® enables the display of an estimated volume of air produced sincecommissioning.

Load relay : Number of passages of the compressor in load from its start-up.

VSD 1-20% RPM : Percentage of operating time during which the compressor hasoperated between 1 and 20% of its maximum speed.

VSD 20-40% RPM: Percentage of operating time during which the compressor hasoperated between 20 and 40% of its maximum speed.



VSD100-80% RPM : Percentage of operating time during which the compressorhas operated between 80 and 100% of its maximum speed.

Compressor outlet pressure: Reuse of the first parameter. From this parameter, themenu displays the status of all the analog and logical inputs that are activated.

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Screen DescriptionReceiver press. : Pressure as read by the sensor placed on the deoiling tank of thecompressor

Element outlet temperature: Indicates the temperature read by the sensor in theoutlet of the compression element

Pressure difference: Indicates the difference between the internal tank pressureand the pressure in the compressor outlet.

Emergency stop : Status of the logical input emergency stop (closed = no error)

Start/stop remote : Status of the logical inputs indicating to the AIRLOGIC® that itis remotely started (input closed) in the Remote control operating mode

Overload fan motor : Overload of turbine motor - input activated by the thermalprotection relay of the turbine motor.

Phase sequence : Input triggering an error if the phase controller (in option) detectsa wrong direction of the phases (and therefore the motor) or else, an absence ofphase.

Status of the input for selection of the pressure band. Pressure band 1 if open,pressure band 2 if closed (active if the parameter Digital PB set of the menuConf.distr is activated)

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3.8 Inputs in the main menus

Description

From each of the inputs in the status menu, pressing the enter key will show the first menu of the followinglist:

Screen DescriptionError: this menu will show when an error or a warning is activated/active. Pressingthe enter key allows deactivating the display of error, if, of course, the cause of thiserror has been resolved. If no error/warning is active, then the message Allconditions are OK is displayed.

Settings: In this menu appear all the basic settings used for controlling thecompressor (unloading pressures and loaded running for each of the two usablepressure bands, pressure band used)

Counters: In this menu, the different counters for reading can be accessed: runninghours, loaded hours, number of motor starts, number of passages into load.

Service: Access menu for data relating to compressor maintenance (delay from lastintervention, before next intervention, type of maintenance performed), to themenus for parameterizing types of maintenance periods and also to menu StopUnder Pres.

Timer function: Menu of weekly programming of pressures

History: This menu and its submenus allow displaying the latest errors occurred aswell as a list of values of certain parameters and inputs recorded at the time of thiserror.

Safety: Access to menus reserved for advanced users having to deal with thecompressor safety parameters (warning and error thresholds, delays) on the analoginputs and certain logical inputs

Conf. User: Menu for configuring the date, time, units, language, etc.

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Screen DescriptionConf. Distrib: Menu reserved for the distributor (password protected) in which theparameters of compressor control and operation can be modified.

Status of inputs: Displays the protection elements configured on certain logical andanalog inputs (those having a protection).

Test outputs: Menus allowing to test the display, the LED's as well as each of thelogical outputs. (Caution, coils may be powered).

Version: Indicates the version number of the application uploaded into thecontroller.

Info Distrib: Menu for displaying information, can be customized by the distributorusing the FSP software.

Password: In this menu, the password coded on 4 digits is entered.

See section MCC Menu.

See section MCC Menu.

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3.9 Error Menu

Description

This menu will show when an error or a warning is activated/active. Pressing the enter key allows deactivatingthe 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


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When there is a warning, the error LED is lit fixed. A message flashes on the last line of the screen STATUS0.1 stipulating the type of warning:

• Alarm• Sensor error• Pre-alarm• Fault• Key absent• Internal fault• Starting fault

Pressing the enter key shows the Error menu and the parameter corresponding 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 theprotection that is activated.

When the cause of the warning has been removed, the flashing message of the menu Status 0.1 disappearsand the message All conditions are OK is displayed on the Error menu.

When an error occurs, the compressor stops and the screen displays the name of the input in fault as well asthe cause of the error. For example:

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Pressing the cancel key then displays the menu Error with the type fault flashing. Pressing on the enter keythen displays again the same error message.

When the cause of the error has been removed (rearming the thermal protection relays, for example), pressingthe enter key displays the message All conditions are OK. The error indicator is turned off and the compressorcan be restarted.

When an error occurs, a new entry is added in the menu History with the corresponding saved data.

3.10 Settings Menu

Description

In this menu all the basic settings appear that are used to control the compressor (unloading pressures andloaded running for each of the two usable pressure bands, pressure band used)

The AIRLOGIC® allows configuring two bands of operating pressures and selecting one of them dependingon your needs at a given time.


Structure Definition Minimum MaximumPressure (at machineoutlet) below which thecompressor passes intoload (the suction box isopen).

4 bar (58 psi) < value of nextparameter

Pressure above whichthe compressor passesto unloading (the suctionbox is closed).

> value of previousparameter

Value ofparameterSetpoint Limit ofSafety menu

The same applies toLoading Pres. 1 but forthe second pressureband.

4 bar (58 psi) < value of nextparameter

The same applies toUnloading Pres. 1 but forthe second pressureband.

> value of previousparameter

Value ofparameterSetpoint Limit ofSafety menu

Selection of pressureband to use : 1 or 2depending on thesettings above.

Pres. Band 1 Pres. band 2


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Structure Definition Minimum MaximumSetpoint 1: thecompressor will try tomaintain this pressure inthe network if this settingis selected.

4 bar (58 psi) Value ofparameterSetpoint LimitSafety menu

Setpoint pressure 2: thecompressor will try tomaintain this pressure inthe network if this settingis selected.

4 bar (58 psi) Value ofparameterSetpoint LimitSafety menu

Selection of the setpointpressure to be appliedfor operation of thecompressor.

Setpoint 1 Setpoint 2

Value added to thecurrent setpointpressure above whichthe compressor willswitch to no-loadoperation.

0.1 bar (1.4 psi) 10.0 bar (145 psi)

Value added to theactual setpoint pressureabove which thecompressor will stop andswitch to default. Noerror is generated.

Value of previousparameter

1.5 bar (21.7 psi)

Minimum rotation speedof the main compressormotor. This new setpointis only taken intoaccount when it isgreater than thestandard minimumspeed.

460RPM dependson the compressor

900RPM dependson thecompressor

Percentage maximumspeed reduction. Allowsthe user to limit thismaximum speed forcertain applications.

75 % 100 %

If the unloaded running period is too long (if the pressure remains high in the customer network -- due todecreased demand for air, for example), the compressor will stop automatically (the period depends on theparameter Progr. Stop Time in the menu Conf. Distri). The compressor will be ready to restart if the pressuredrops again below the setting of Loading Pres. 1.

The pressure bands used can also be configured in the menu clock for using the weekly programming of start-stop cycles.

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3.11 Counters Menu

Description

In this menu, the different counters for reading can be accessed : running hours, loaded hours, number ofmotor starts, number of passages into load.


Structure DefinitionRunning hours : Number of hours during which the motor has runfrom the first powering on of the controller.Loaded hours : Number of hours during which the compressor hasoperated "in load" from the first powering on of the controller.Number of motor starts: From the first powering on of thecontroller.

Number of module hours: Period during which the AIRLOGIC®

remained powered onNumber of load relays: Number of times the output Run in load ispassed from deactivated to activated from the first powering on ofthe controller.


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Structure DefinitionRunning hours : Number of hours during which the motor has runfrom the first powering on of the controller.Loaded hours : Number of hours during which the compressor hasoperated "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.Accumulated volume: volume of compressed air produced when thecontroller is first switched on.Number of transitions from no-load operation to on-load operationstarting from the point at which the controller is first switched on.Percentage of operating time during which the compressor hasoperated between 1 and 20% of its maximum speed.Percentage of operating time during which the compressor hasoperated between 20 et 40% of its maximum speed.Percentage of operating time during which the compressor hasoperated between 40 and 60% of its maximum speed.Percentage of operating time during which the compressor hasoperated between 60 and 80% of its maximum speed.Percentage of operating time during which the compressor hasoperated between 80 and 100% of its maximum speed.

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3.12 Service Menu

Description

Access menu for data relating to compressor maintenance (delay from last intervention, before nextintervention, type of maintenance performed), to the menus for parameterizing types of maintenance periodsand also to menu Stop Under Pres.


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Service counter

This menu allows the operator to find out when the last maintenance operation took place and when the nextshould take place.


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Structure DefinitionNumber of hours at which the next service should be conductedand the corresponding service type (from A to J). The runninghours displayed are incremented with the functioning of thecompressor.Number of running hours at which the last service was carriedout and the corresponding service type (from A to J).Number of hours of the machine (calculated from its date ofcommissioning -- machine powered on or not) at which the nextservice has to take place and the corresponding service type(from A to J). The life period displayed increments with thefunctioning of the compressor.Number of hours of the machine (calculated from its date ofcommissioning - machine powered on or not) at which the lastservice was conducted and the corresponding type (from A toJ)


Structure DefinitionNumber of hours at which the next service should be conductedand the corresponding service type (from A to J). The runninghours displayed are incremented with the functioning of thecompressor.Number of running hours at which the last service was carriedout and the corresponding service type (from A to J).Number of hours of the machine (calculated from its date ofcommissioning -- machine powered on or not) at which the nextservice has to take place and the corresponding service type(from A to J). The life period displayed increments with thefunctioning of the compressor.Number of hours of the machine (calculated from its date ofcommissioning - machine powered on or not) at which the lastservice was conducted and the corresponding service type(from A to J)Volume of air produced (calculated since start commissioning)at which the next service should be carried out and thecorresponding service type (from A to J).Volume of air produced (calculated since commissioning) atwhich the last service was carried out and the correspondingservice type (from A to J).

Service Plan

This menu allows viewing and modifying (not recommended) the maintenance intervals according to theirlevel as defined in the compressor instruction manual.

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Please refer to the compressor instruction manual for finding the correspondence between the service leveldisplayed and the maintenance operations to be performed.

The first maintenance at 500 hours does not take place at regular intervals. It is necessary to deactivate it afterit is completed. For this, the value of the parameter Level J has to be changed from 500 Hours to ----- bydecrementing the value displayed.


Structure DefinitionInterval of number of running hours at which the type A servicehas to be performed.Interval of number of running hours at which the type B servicehas to be performed.And so on up to the type J service level…Interval of number of running hours at which the service type Jhas to be performed. This service at 500h takes place only once.It is necessary to deactivate this timer after it has completed byreplacing the period 500h by ------.Interval of number of hours of service life (with or withoutfunctioning) at which type A service has to be performed. If thecompressor remains without functioning during one year, an oilchange has to be made nevertheless.Interval of number of hours of service life (with or withoutfunctioning) at which type B service has to be performed.Interval of number of hours of service life (with or withoutfunctioning) at which type J service has to be performed.


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Structure DefinitionInterval of number of running hours at which the type A servicehas to be performed.Interval of number of running hours at which the type B servicehas to be performed.And so on up to the type J service level…Interval of number of hours of service life (with or withoutfunctioning) at which type A service has to be performed. If thecompressor remains without functioning during one year, an oilchange has to be made nevertheless.Interval of number of hours of service life (with or withoutfunctioning) 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 withoutfunctioning) at which type J service has to be performed.Interval of volume of compressed air produced by the machineat which service type A should be carried out.And so on up to the type J service level…

When a maintenance becomes due, the menu Status 0.1 displays on its last line the flashing message *ServiceRequired*.

Pressing the enter will call up the Error menu, pressing the enter key again displays the following menu:

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The service level required is displayed. The message Reset flashes at the bottom of the screen. Press the enterkey again and confirm that the maintenance operation has been completed correctly. The message Allconditions are OK confirms the validation of the service performed.

Stop Under Pressure

Please refer to the compressor instruction manual for a detailed description of unloading under pressure.

Structure DefinitionIf the machine is running in load, the validation of this menuallows to program a stop under pressure. The compressorpasses to unload, then a few seconds later, the motorstops. When the pressure has dropped below a given limit,the unloading solenoid is again supplied with power forstopping the depressurization of the internal tank. When theunloading is completed, press the cancel key several timesto return to the screen Status 0.1

3.13 Weekly program - Timer Function

Description

This menu allows weekly programming of pressures.

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Text on figure:

Reference Description(1) Activation or deactivation of the programming timer. 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.

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Reference Description(6) Configuration of the action to be performed on the programmed date.(7) Refer to the definition of actions given below.(8) Scroll(9) Validation(10) Modification(11) Setting(12) Selection

The menu Weekly Program allows programming over a week, the starts and stops of the compressor as wellas the pressure regulation bands. For each day of the week, up to 6 programme steps can be defined. For eachof these steps, the time and type of the action to be performed can be defined from the following list:

• ---------: cancellation of the programme step. No action shall be taken into account.• Start: the compressor is started at the indicated time, the pressure band is used as defined in the menu

Settings.• Stop: the compressor is stopped at the time indicated.• Settings 1: the use of the control parameters as defined in the menu Settings for the pressure band 1 starting

from the time indicated.• Settings 2: same as Settings 1 but with pressure band 2

If the compressor is part of the multi-compressor MULTILOGIC network (in option) and when it is the mastercompressor, the following choices are also possible:

• Start.sys: is used when the controller is the master of a network of several compressors in MULTILOGICmode. It indicates that the entire network will be ready to start at the indicated time. The pressure bandused 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 MULTILOGICmode and indicates that the entire network will be stopped at the indicated time.

• MCC P1: is used when the controller is the master of a network of several compressors in MULTILOGICmode. It indicates that the entire network will be ready to start at the indicated time. The pressure bandused is the one defined in the menu MCC Settings for the band 1 of the MULTILOGIC mode.

• MCC P 2: is used when the controller is the master of a network of several compressors in MULTILOGICmode. It indicates that the entire network will be ready to start at the indicated time. The pressure bandused is the one defined in the menu MCC Settings for the band 2 of the MULTILOGIC mode

3.14 History menu

Description

This menu and its submenus allow displaying the latest errors occurred as well as a list of values of certainparameters and inputs recorded at the time of this error.

This menu displays the data recorded during the last 5 errors.

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Structure DefinitionThe first screen indicates which input has triggered error number1.Indicates the time at which error number 1 occurred.Indicates the date on which error number 1 occurred.Indicates the number of running hours of the compressor whenerror number 1 occurred.Indicates the number of loaded running hours of the compressorat which error number 1 occurred.Indicates the status of different logical and analog inputs at thetime 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 safetyparameters of the compressor (warning thresholds of errors, delays) on the analog inputs and on certain logicalinputs.

On fixed speed compressors, the tree structure is large and is divided into 3 main sections:

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On variable speed compressors, the tree structure is large and is divided into 2 main sections:


Safety of Inputs

Summary of the structure of the menu Safety/inputs

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This menu displays logical and analog inputs for which one or more protections can be defined.

Some inputs may appear several times if they have several protections. For example, the input T elementoutlet corresponding to the temperature sensor at the outlet of the compression element has a first protectionfor stopping the compressor if this temperature exceeds a certain value and a second protection preventingthe 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 installed with a pressure tap in theoil tank, before the Air-oil separator.

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Structure Definition Minimum MaximumSignifies that an error will begenerated if the pressurecrosses 9.0 bar (130.5 psi).

> value ofnextparameter

Limit P maxi ofthis parameter

Corresponding to the pressure(7.5 bar (108 psi)) at which apre-alarm will be displayed forinforming the user that aprotection limit is beingapproached.

0 bar (0 psi) < value of theaboveparameter

The pressure must cross themaxi threshold plus 5 seconds(value of this parameter) whenan error will be generated.

0 s 10 s

This parameter defines themaxi value that can be set forthe parameter shd.Maxi.

0 bar (0 psi) 17 bar (246.5psi)

Signifies that the compressorcannot start as long as the tankpressure is higher than thisvalue (1.5 bar (21.7 psi))

0 bar (0 psi) 2.5 bar (36 psi)

This parameter defines themaximum value that can be setfor the parameter P start.Maxi.

0 bar (0 psi) 17 bar (246.5psi)

Element outlet

Protects the input Temperature at element outlet. Analog input corresponding to the temperature sensorinstalled at the outlet of the compression element, taking AIR-OIL temperature at the highest point.

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Structure Definition Minimum MaximumSignifies that an error will begenerated if the temperaturecrosses 110°C (230 °F).

> value offixedparameter

120 °C (248 °F)

Corresponding to thetemperature (105 °C (221 °F))at which a pre-alarm will bedisplayed to inform the operatorthat a protection limit is beingapproached.

0°C (32 °F) < value of theaboveparameter

Time after the starting of thecompressor when thisprotection becomes active.

0 s 120 s

An error shall be generated ifthe temperature crosses themaximum threshold (110 °C(230 °F)) plus 3 seconds (valueof this parameter).

0 s 10 s

Protection against the wrongdirection of rotation, noparameter is modifiable but theprotection is active.

Delta P

Protections on the calculated analog input Delta P. This dummy analog input corresponds to the differencebetween the pressure in the internal tank and the pressure at the compressor outlet.

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Structure Definition Minimum MaximumMaximum value of the differentialpressure beyond which an erroris triggered.

0 bar (0 psi) (3 bar (43.5psi)

Maximum value of the differentialpressure beyond which awarning appears in the menuStatus 0.1

0 bar (0 psi) < value of thepreviousparameter

Delay after starting during whichthis protection is inactive.

0 s 120 s

The differential pressure mustexceed the maximum thresholdsduring more than 3 s for an errorto be generated.

0 s 10 s

Maximum value of the differentialpressure beyond which awarning is displayed.

0 bar (0 psi) 1.8 bar (26psi)

Delay after starting during whichthis protection is inactive.

0 s 120 s

The differential pressure mustexceed the maximum thresholdsduring more than 5 minutes for anerror 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 ofimplosion. An error shall therefore be generated if this value is crossed for more than 3 s.

• The second protection at 1.3 bar (19 psi) allows warning the operator that the de-oiler filter is saturatedand has to be replaced. Only a warning shall be displayed if the value of the differential pressure crossesthis threshold for more than 5 minutes.

Emergency Stop

The protections on the input Emergency Stop. Information about the status of the analog input.

Structure Definition Minimum MaximumAn error shall begenerated if the inputEmergency Stop is open.

Open Closed

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Overload motor (only for fixed speed compressors)

Protections on the input overload main motor. Logical input corresponding to the magnetothermic switch ofthe main motor.

Structure Definition Minimum MaximumAn error is generated if theinput Overload motor isopen.

Open Closed

The opening of the inputmust be detected duringone second so that theabsence of the signal canbe considered an error.

0 s 10 s

Overload fan motor

Structure Definition Minimum MaximumAn error is generated ifthe input Overload fanmotor is open.

Open Closed


0 s 10 s

Phase sequence (option)

Protections on the input of the option "phase control ". Logical input in option corresponding to the phasecontroller of the electrical cabinet.

Structure Definition Minimum MaximumAn error is generated ifthe input phase sequence(activated only if theoption phase controller isavailable) is open.

Open Closed


0 s 10 s

Setting Limit P

Settings of safety limits that cannot be crossed on the input pressure at compressor outlet. Analog inputcorresponding to the pressure sensor at the compressor outlet.

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The modification of this parameter is justified only if a change is made in the transmission ratio. No otherreason can justify increasing the value of this parameter.

Structure Definition Minimum MaximumThis menu has only oneparameter that allowslimiting the maxi pressureserving as the limit of allthe user pressure settings(loading, unloadingpressure).

7.5 bar (108 psi) 17 bar (246.5 psi)

Motor Rotations (only for fixed speed compressors)

The parameters of this menu allow defining the protection against the wrong direction of motor rotation. Thisprotection intervenes only after turning on the power to the AIRLOGIC® controller.

At the time of first loading of the compressor, after turning on the power, the controller measures thetemperature increase at the outlet of the compression block during a certain time. If during this time intervalTemp Duration, the temperature has not increased more than the value of the parameter Diffr.Temp., it isconsidered 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 twoof the three power supply phases to the motor and switch on the power again.

Setting these two parameters to zero deactivates this protection.

Structure Definition Minimum MaximumPeriod, after the firstpassage in load (afterrestarting the power),during which thetemperature is scanned.

0 s 255 s

Minimum temperaturevariation that should beexceeded during Temp.Duration for consideringthat the motor is rotatingin the wrong direction.

-3277 °C (-590.6°F)

3277 °C (5930.6°F)

3.16 Configuration user menu

Description

Configuration menu for numerous parameters, making it possible to adapt signals to the standards of thecustomer: date, time, unit, language, etc …

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Structure DefinitionMode of control of compressor:• Local (by the keyboard)• Remote (by the inputs/outputs)• LAN (through the network).

Current local timeCurrent date in the format indicated below.Date display format:• DD/MM/YY• MM/DD/YY• YY/MM/DD

Language used:One language from among the 3 that were loaded in thecontroller. A choice of 3 languages out of 25 is possibleby reloading the application.Choice of the unit for displaying the pressure : bar, kg/cm², MPa or psiChoice of the unit for displaying the temperatures : °C,°F or KChoice of the unit for displaying the vibrations : micronsor milsChoice of the unit for displaying the levels (not used inour application) : mm or inches

In the factory, 3 languages are configured out of a choice of 25 available. If the compressor is shipped to aparticular location, contact your local after-sale service to update the language configuration.

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3.17 Configuration distributor menu

Description

Menu reserved for the distributor (password), in which he can modify the control and operating parametersof the compressor.


Structure Definition Minimum MaximumType of starter : Choice betweenY/D (star/triangle) and Direct(direct starting - no managementof passage from star to triangle)

Y/D Direct

Automatic restart after break inpower supply. Activated allowsthe restarting if the outage doesnot exceed a certain timeT.energy saving. Infinite allowsrestarting without any time limit.

Not activatedActivatedInfinite

Compressor number in the LANnetwork

1 31

The Multilogic (MCC). It is usedwhen several (up to 4)compressors are connected in anetwork and are controlled by amaster.

Activated Not activated

The pressure band selectionmenu allows activating ordeactivating the possibility ofusing input 10 for selecting thepressure band to use.


Load delay: delay between thepassage in triangle (in the case ofa star-triangle starting) andopening of the suction valve.

0 s 10 s

Number of starts per day. Allowslimiting the frequency of motorstarts by increasing if necessarythe unloaded running period. Thevalue 360 corresponds to 15restarts/hour.

0 360

This minimum stop time allowsdepressurization of the tank toprevent a restart under pressureand to limit the forces on the motorduring this restart.

0 s 30 s

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Structure Definition Minimum MaximumProgrammed stop time : Period ofunloaded running beforestopping.

0 s 60 s

Power recovery time: timebeyond which the automaticrestarting shall not take place if itis parameterized as Active.

10 s 3600 s

Automatic restart delay. Allowsrestarts in cascade when severalcompressors are workingtogether.

0 s 1200 s

Permissive start time: time duringwhich the compressor starterprotections (type permissiveSTART) are tested.

0 s 15 min

Communication time out: timebeyond which a communicationfault with other elements of a LANnetwork is displayed as a fault.

10 s 60 s

Dryer status: allows activating/deactivating the integrated dryermanagement parameters.


Drain time: opening period of thecondensates purge solenoidvalve.

1 s 25 s

Drain interval: interval betweentwo condensate purges.

1 min 60 min

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Structure Definition Minimum MaximumID number of the compressor inthe LAN network.

1 31

Automatic restart after break inpower supply. Activated allowsthe restarting if the outage doesnot exceed a certain timeT.energy saving. Infinite allowsrestarting without any time limit.

Not activatedActivatedInfinite

The Multilogic (MCC). It is usedwhen several (up to 4)compressors are connected in anetwork and are controlled by amaster.


Allows activating or deactivatingthe possibility of using input 10 forselecting the pressure band touse.


Maximum number of turbinestarts per day. Facilitateslimitation of the frequency ofturbine starts by increasing theoperating time where necessary.The value 240 is equal to 10starts/hour.

0 720

This minimum stop time allowsdepressurization of the tank toprevent a restart under pressureand to limit the forces on the motorduring this restart.

0 s 30 s

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Structure Definition Minimum MaximumPower recovery time: timebeyond which the automaticrestarting shall not take place if itis parameterized as Active.

10 s 3600 s

Automatic restart delay. Allowsrestarts in cascade when severalcompressors are workingtogether.

0 s 1200 s

Permissive start time: time duringwhich the compressor starterprotections (type permissiveSTART) are tested.

0 s 15 min

Communication time out: timebeyond which a communicationfault with other elements of a LANnetwork is displayed as a fault.

10 s 60 s

Dryer status: allows activating/deactivating the integrated dryermanagement parameters.


Drain time: opening period of thecondensates purge solenoidvalve.

1 s 25 s

Drain interval: interval betweentwo condensate purges.

1 min 60 min

3.18 Input State Menu

Description

This menu displays the values and the different protections of all the active logical and analog inputs. It doesnot allow modifying the values of the protections. It reproduces a part of the Status menu and the Safety menuin read only.

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3.19 Output test menu

Description

Menu used for testing the display, the LEDs and each of the logical outputs.

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The first submenu Test screen allows testing the display as well as the LEDs of the controller (they are all litas 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.

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3.20 Version menu

Description

Displays the version number of the application uploaded in the controller.

3.21 Information distributor menu

Description

Displays information that can be customized using the FSP software.

3.22 Password menu

Description

This menu is used to enter a password, needed to modify the parameters (only used by the distributor).

This password is used to 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 allowingthe connection of four compressors equipped with an AIRLOGIC®. The operating principle is based on acontrol managed by a master compressor commanding the regulation of other machines of the network.

The Multilogic allows maximum one variable speed compressor in the network.

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The Multilogic is a simple device for optimizing the operation of a multiple compressor installation.

• Control within one same pressure band eliminating the mode of control by pressure cascade. The energyconsumptions are reduced and the pressure delivered is more stable.

• Balances the operating hours in order to facilitate the after-sales management of the production of air.• Programs the timings of pressures for defining two pressure bands depending on the applications during

the week.• Simultaneous starting of compressors, programmable, for an immediate output of air, in order to rapidly

inflate an unloaded network during an extended shutdown period.• Instant programmable shutdown of all the compressors in the network to stop the production of air instantly

at the end of the day.• Starting in cascade to eliminate the intensity peak.

This menu is described in a separate document delivered with the option.

3.24 External connection

Fault report

The output K09 is an inverter contact free of potential that allows to make a general fault report. The outputis activated when an error occurs.

Remote start-stop

The input DI02 allows remote controlling, the start and stop of the compressor through an external contact.For this input to be operational, the parameter Control Mode of the menu Conf Distr must have the valueRemote 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 AIRLOGIC® that can manage signals from supplementaryoptional sensors installed either in the compressor fairing or close-by. From the AIRLOGIC®, only thethresholds of faults parametered using the software (only for use by factory technicians) will be visible andwill make it possible to centralize management of compressed air production.

A few examples of applications:

• Controlling the pressure loss on the air treatment network indicating the acceptable limits of pressure loss.• Measurement of ventilation air temperature Delta for indicating a radiator clogging.• Measurement of the humidity of the compressed air for controlling the quality of air produced.• All other applications that can use measurements from a sensor 4-20 mA….

Sensors must be controlled separately from the electronic module Box. A parameter modification software(only to be used by qualified personnel) is necessary to configure warning thresholds and sensor errors orlogic inputs connected to the electronic module.

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Al-BOX3 5 temperature inputs PT 100Al-BOX4 5 temperature inputs PT 10000AIO-BOX 4 analog inputs 16 bits + 2 analog outputs 4-20 mASPM-BOX Shock Pulse Meter, device used for vibration measurements of bearing (or bush)

wear, for example, on the main motor or a compression element.DIO-BOX 4 logical inputs + 4 logical outputsMIX-BOX 2 pressure inputs

1 Temperature input PT 10003 logical inputs2 logical outputs

Communication modules

MOD-BOX Modbus communicationPROFI-BOX Profibus communicationCOM-BOX Conversion of protocols. Contact our local after-sale service for more details.

All the parameters of the status menu can be displayed in order to obtain an instant diagnosis of the operationof the compressor. The alarms or error messages can be displayed and managed by remote control fortriggering an intervention at the site.

3.26 Common operations

Quick start

The minimum settings 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.user, see section Configuration user Menu.• LOADING PRESSURE: access by the menu Settings, parameter Loading pressure, see section Settings

Menu.• UNLOADING PRESSURE: access by the menu Settings, parameter Loading pressure, see section

Settings Menu.• SELECTION OF THE CONTROL BAND: access by the menu Settings, parameter Pressure band used,

see section Settings Menu.

The mode of accessing and modifying the above parameters is described in section Modifying a parameter.

This procedure enables starting a compressor and producing air according to the pressure needs of the air net.

3.27 Reinitialisation of maintenance counters

Description

See section Service Menu.

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3.28 Operational incidents

Description

The operational incidents are indicated both by the faults/warning LEDs as well as by displaying the natureof faults on the AIRLOGIC®.

An error is indicated by a flashing red light, a warning is indicated by a fixed red light.

3.29 List of messages

Warning messages

Description Main screen message Solution(Definition of the type of alarm in theError\Protection\Alarms menu) Highoil temperature pre-alarm **Shutd.Warn.**

The oil temperature has exceeded the highalarm threshold (105 °C/221 °F) but is lessthan the maximum temperature, which thengenerates an error (110 °C/230 °F ).

Tank high pressure pre-alarm **Shutd.Warn.** The tank pressure has exceeded the highalarm threshold but is less than themaximum pressure, which then generatesan error

De-oiler clogging pre-alarm **Shutd.Warn.** Verify the loss of de-oiler load, verify de-oiling, and replace the de-oiler if necessary.Verify the VPM.

Maintenance cycle J lasting 500 h hasbeen reached

* Serv.Requir.* Carry out J type maintenance as describedin the instructions.Once maintenance iscompleted, Reset

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Alarm messages

Description Main screenmessage

Error menumessage

Solution

The approximate loss of loadhas exceeded the alarmthreshold but remains less thanthe maximum threshold. (Ptank - P output)

AC Approach 1.5bar/22 psi ShdMax. 1.3 bar/19psi

Verify de-oiler loss of load, verify de-oiling, and replace de-oiler ifnecessary. Verify the VPM.2

The approximate loss of loadhas exceeded the alarmthreshold but remains less thanthe maximum threshold. (Ptank - P output)

Delta P 1.6 bar/23psi Shdw Max 1.3bar/19 psi

Verify de-oiler loss of load, verify de-oiling, and replace de-oiler ifnecessary. Verify the VPM.

Dryer frozen. Dryertemperature less than - 1°C/-33.8 °F. The dryer isstopped and restarts at LAT =7 °C/44.6 °F

** Warning **

Dryer LAT -5 °C/41 °F Min. frze -1°C/33.8 °F

Verify ambient temperature.Verifycorrect operation of the drier. (HGBV+ PS)

Dryer temperature too high.The alarm will disappear whenthe temperature drops

** Warning ** Dryer LAT DewpNot normal

Dryer temperature too high.The alarm will disappear whenthe temperature drops

** Warning ** Dryer LAT 232 °C/449.6 °F Max.alarm 25 °C/77 °F

Error messages


Error menumessage

Solution

High temperature error Elem. outlet 113°C/235 °F ShdMax. 110 °C/230°F

The oil temperature has exceeded thehigh error threshold (110 °C/230 °F )

Rotation direction. The Airlogichas calculated that the oiltemperature has not increasedsufficiently during starting andtherefore the compressor turnsin the wrong direction.

Elem. outlet 88°C/190.4 °F Rota

Verify the direction of rotation of thecompressor and the power supplycable. Down-powering required forreset + phase changes. Do not carryout too many tests.

The temperature sensormeasures a temperature out ofthe normal range (-40 °C/340°C) (-104 °F/644 °F)

Elem. outlet ******°C/°F Shd Max.110°C/230°F

Verify connections, condition ofcables. Disconnect the sensor. Itshould then indicate the ambienttemperature. It is also possible tomeasure the resistance indicated bythe sensor and to verify whether or notit has drifted, using the tables.

The tank pressure sensormeasures a pressure outsidethe normal range (0/17 bars)(0/246.5 PSI) during operationunder load

Receiver Press.****** bar/psi ShdMax. 9.0 bar/130.5 psi

Verify connections, condition ofcables. Disconnect the sensor. Itmust then indicate 0 bar/0 psi. Verifythe sensor for correct operation.

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Error menumessage

Solution

The tank pressure is greaterthan the maximum startingpressure (1.5 bar/21.7 psi)

Receiver Press.1.7 bar/24.7 psiMax.PeSt 1.5 bar/21.7 psi

Verify the emptying circuit (solenoidvalve and/or valve) . VPM blockedopen, network pressure returned tothe tank.

The pressure regulationsensor (machine output),measures a pressure outsidethe normal range (0/17 bars)( 0/246.5 psi) during operationunder load.

****** (flashing)Compressor Off/*Sensor Error*


The tank pressure sensormeasures a pressure outsidethe normal range (0/17 bars)(0/246.5 psi) during operationunder load

Receiver Press.****** bar/psi ShdMax. 9.0/130.5psi


The tank pressure is greaterthan the maximum servicepressure (here, 9.0 bar/130.5psi)

Receiver Press.9,3 bar/135 psiShd Max. 9.0 bar/130 psi

Verify the regulation sensor (machineoutput), verify the emptying circuit(solenoid valve and/or valve), suctionbox remains open. VPM blockedclosed.

The approximate loss of loadhas exceeded the maximumthreshold. (P tank - P output)

AC Approach 3.0bar/43.5 psi ShdMax. 1.8 bar/26psi


The approximate loss of loadhas exceeded the maximumthreshold (P tank - P output)

Delta P 2.1 bar/30.5 psi Shd Max.1.8 bar/26 psi


Emergency stopping triggered Emergency stopShd Open

Release the emergency stop device.Verify connection and operation of theemergency stop push-button.

The phase controller indicatesthat the connection of phasesis reversed.

Phase SequenceFail. Open

Verify the value and its use, andsupply of each phase. Verifyoperation of the controller. Changethe phase connection order.

The main motor is overloaded. Overload MotorFail. Open

The fan motor is overloaded Overl. FanmotorFail. Open

An error has been generated **Shutdown** Go to the error menu to identify thefault

Communication problemAirlogic/regulator

Compr. MotorConvert.Timeout

Verify:• the regulator is in good condition• the communication cables• continuity of shielding earths of

regulator/regulator controlmodule link cables

• regulator communicationparameters

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Information messages


Error menumessage

Solution

Permissible starting conditionsnot reached

Process Starts The machine is verifying the followingparameters (time is adjustabledepending on whether the dryer isenabled or disabled) : -ambienttemperature measured by Elementoutlet temperature (>2 °C/35.6 °F)-tank pressure (<1.5 bar/21.7 psi)-Dryer LAT (correct) , dryertemperature>-1 °C/-33.8 °F

The machine is under load. It isautomatically regulated by itsinternal sensor.

Auto Loaded

The compressor is stopped, aswell as the motor.

Compressor Off

The compressor as well as themotor are stopped, but couldre-start at any time.

Motor Stopped

The machine is operatingunder no load. It isautomatically regulated by itsinternal sensor.

Auto Unloaded

Stopping is requested. Themachine switches to no load.

Progr. stop

The temperature sensormeasures a temperature out ofthe normal range (-40 °C/340°C) (-104 °F/644 °F)

****** * SensorError*

Verify connections, condition ofcables. Disconnect the sensor. Itshould then indicate the ambienttemperature. It is also possible tomeasure the resistance indicated bythe sensor and to verify whether or notit has drifted, using the tables.

The tank pressure sensormeasures a pressure outsidethe normal range (0/17 bar)(0/246.5 psi)

* Sensor Error*


The pressure regulationsensor (machine output),measures a pressure outsidethe normal range (0/17 bar)(0/246.5 psi)

* Sensor Error* Verify connections, condition ofcables. Disconnect the sensor. Itmust then indicate 0 bar/0 psi. Verifythe sensor for correct operation.

No load switch-over commandgiven by the Airlogic (max.internal pressure of themachine reached) , whereasthe machine is controlled by anexternal regulation device(Digital, LAN…), giving it theunder load operatingcommand.

Unload: Overpr. Adjustment of the external operatingorder to a lower threshold than themaximum permissible pressure of themachine.

Remote stopping/starting Remote control

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Error menumessage

Solution

Control carried out via a LANtype network

LAN control

The Airlogic is in remotecontrol mode, internalregulation and receives aremote emptying command.

Manual Unload

The regulator is starting themotor but cannot yet give thesignal to the Airlogicconcerning motor speed.

Motor starting

Inverter messages (variable speed compressors)

Fault code Fault Possible cause Correcting measures1 Overcurrent Frequency converter has detected

too high a current (>4*In) in the motorcable:• sudden heavy load increase• short circuit in motor cables• unsuitable motor

Check loading. Check motor size.Check cables.

2 Overvoltage The DC-link voltage has exceededthe limits defined in table 4.2 (NXmanual)• too short a deceleration time• high over voltage spikes in supply

Make the deceleration time longer.

3 Earth fault Current measurement has detectedthat the sum of motor phase currentis not zero.• insulation failure in cables or

motor

Check motor cables and motor.

5 Charging switch The charging switch is open, whenthe START command has beengiven.• faulty operation• component failure

Reset the fault and restart. Should thefault re-occur, contact the distributornear to you.

6 Emergency stop Stop signal has been given from theoption board.

7 Saturation trip Very high overload. Defectivecomponent

Cannot be reset from the keypad.Switch off power. If this does not help,contact the distributor near to you.

8 Unknown fault The frequency convertertroubleshooting system is unable tolocate the fault.


9 Undervoltage DC-link voltage is under the voltagelimits.• most probable cause: too low a

supply voltage• frequency converter internal fault

In case of temporary supply voltagebreak, reset the fault and restart thefrequency converter. Check thesupply voltage. If it is adequate, aninternal failure has occurred. Contactthe distributor near to you.

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Fault code Fault Possible cause Correcting measures10 Input line

supervisionInput line phase is missing. Check supply voltage and cable.

11 Output phasesupervision

Current measurement has detectedthat there is no current in one motorphase.

Check motor cable and motor.

12 Brake choppersupervision

• no brake resistor installed• brake resistor is broken• brake chopper failure

Check brake resistor. If the resistor isok, the chopper is faulty. Contact thedistributor near to you.

13 Frequencyconverter undertemperature

Heatsink temperature is under -10°C/-50 °F

14 Frequencyconverter overtemperature

Heatsink temperature is over 90 °C/194 °F. Over temperature warning isissued when the heatsinktemperature exceeds 85 °C/185 °F.

Check the correct amount and flow ofcooling air. Check the heatsink fordust. Check the ambient temperature.Make sure that the switchingfrequency is not too high in relation toambient temperature and motor load.

15 Motor stalled Motor stall protection has tripped. Check motor.16 Motor

overtemperatureMotor overheating has been detectedby frequency converter motortemperature model. Motor isoverloaded.

Decrease the motor load. If no motoroverload exists, check thetemperature model parameters.

17 Motor underload Motor underload protection hastripped.

Decrease the motor load. If no motoroverload exists, check thetemperature model parameters.

2223

EEPROMchecksum fault

Parameter save fault• faulty operation• component failure

24 Changed datawarning

Changes may have occurred in thedifferent counter data due to mainsinterruption

No special actions required. Take acritical attitude to the counter data.

25 Microprocessorwatchdog fault

• faulty operation• component failure


32 Fan cooling Cooling fan of the frequencyconverter does not start, when ONcommand is given

Contact the distributor near to you.

36 Control unit NXS Control Unit can not control NXPPower Unit and vice versa

Change control unit

37 Device change Option board changed. Differentpower rating of drive.

Reset

38 Device added Option board added. Drive of differentpower rating added.

Reset

39 Device removed Option board removed. Driveremoved.

Reset

40 Device unknown Unknown option board or drive.41 IGBT temperature IGBT Inverter Bridge over

temperature protection has detectedtoo high a short term overload current

Check loading. Check motor size.

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Fault code Fault Possible cause Correcting measures42 Brake resistor

overtemperatureBrake resistor over temperatureprotection has detected too heavybraking

Set the deceleration time longer. Useexternal brake resistor.

50 Analogue input Iin< 4mA (selectedsignal range 4 to20 mA)

Current at the analogue input is <4mA.• control cable is broken or loose• signal source has failed

Set the deceleration time longer. Useexternal brake resistor.Check the current loop circuitry.

51 External fault Digital input fault.52 Keypad

communicationfault

The connection between the controlkeypad and the frequency converteris broken.

Check keypad connection andpossible keypad cable.

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4 Installation

4.1 Dimension drawing

Compressor dimensions

Dimension drawing (in mm) of air-cooled compressor 110 kW with prefiltration panel

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Dimension drawing (in mm) of air-cooled compressor 110 kW with high efficiency prefiltration panel

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Dimension drawing (in mm) of air-cooled compressor 110 kW with prefiltration panel and heavy duty air inlet filter

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Dimension drawing (in mm) of air-cooled compressor 110 kW with high efficiency prefiltration panel and heavy duty air inletfilter

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Dimension drawing (in mm) of air-cooled compressor 132 kW with prefiltration panel

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Dimension drawing (in inch) of air-cooled compressor 132 kW with prefiltration panel

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Dimension drawing (in mm) of air-cooled compressor 132 kW with prefiltration panel and heavy duty filter

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Dimension drawing (in inch) of air-cooled compressor 132 kW with prefiltration panel and heavy duty filter

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Dimension drawing (in mm) of air-cooled compressor 132 kW with high efficiency prefiltration panel

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Dimension drawing (in inch) of air-cooled compressor 132 kW with high efficiency prefiltration panel

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Dimension drawing (in mm) of air-cooled compressor 132 kW with high efficiency prefiltration panel and heavy duty air inletfilter

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Dimension drawing (in inch) of air-cooled compressor 132 kW with high efficiency prefiltration panel and heavy duty air inletfilter

Text on drawing

Reference Explanation(1) Compressed air outlet(2) Cooling air outlet(3) Outlet energy recovery

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Reference Explanation(4) Automatic drain outlet(5) Opening for transportation(6) 4 slotted holes to pull unit horizontally out of container(7) Cooling air inlet(8) COG (Center Of Gravity)(9) Compressed air outlet According to DIN 2566 DN80 PN16(1:5)

(10) Cooling water Outlet G 1 3/4"(11) Cooling water Inlet G 1 3/4"(12) Outlet WSD diameter 20 mm

4.2 Installation remarks

General

• The compressor is intended 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 themanufacturer.

• The compressors comply with class A limits for radiated emissions according to EN55011-A (2007). Beware of possible electromagnetic interference if stricter limits arevalid.

• The compressors comply with limits in accordance with the EN61800-3:2004,EN61000-4-2:2009, EN61000-4-3:2006, EN61000-4-4:2004 and EN61000-4-6:2009standards regarding the immunity of the equipment.

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Safety precautions for the frequency converter

• This equipment is used in high-voltage installations. During operation, this equipmentcontains rotating and live, bare parts. For this reason, it could cause severe injury orsignificant material damage if the required covers are removed or have not been properlymaintained.

• When the machines are used in non-industrial areas, the installation location must beprotected against unauthorized access (protective fencing, appropriate signs).

• All connection procedures must be carried out with the cabinet de-energized. All the workon the units must be carried out by trained personnel only. Death, serious injury, orsubstantial material damage can result if these warnings are not taken into account.

• Work on an open device must be carried out with extreme caution because externalsupply voltages may be present. The power and control terminals may be live even whenthe motor is not running.Dangerously high voltage levels are still present in the cabinet up to five minutes after ithas been disconnected due to the DC link capacitors. For this reason, the cabinet shouldnot be opened until after a reasonable period of time has elapsed.

• The operator is responsible for ensuring that the Power Module and other componentsare installed and connected in accordance with the recognized technical rules in thecountry of installation and applicable regional guidelines. Special attention should be paidto cable dimensioning, fuses, grounding, shutdown, disconnection, and overcurrentprotection.

• If an item of protecting gear trips in a branch circuit, a leakage current may have beendisconnected. To reduce the risk of fire or an electric shock, the current-carrying partsand other components in the cabinet unit should be inspected and damaged partsreplaced. When an item of protective gear trips, the cause of tripping must be identifiedand rectified.

• The storage period should not exceed two years. If the device is stored for more than twoyears, the DC link capacitors of the devices must be reformed during commissioning.Consult your Service Centre for the reforming procedure.

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4.3 Installation proposal

Compressor room lay-out

Compressor room lay-out (in mm)

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Compressor room lay-out (in inch)

Text on drawing

Drawingreference

Designation

(1) Minimum free area to be reserved for compressor installation(2) Ventilation proposals(3) Alt.1 (= Alternative 1)(4) Notations

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Drawingreference

Designation

(5) Motor ventilation air outlet(6) Motor ventilation air inlet(7) Compressor air inlet(8) Cooling air outlet(9) Cooling air inlet

Description

Unused holes in the cubicle should be plugged.All electrical screens in the control cubicle and drive cubicle should be installed beforestart-up and shouldn't be removed during operation.

Drawingreference

Description

1 Install the compressor on a level floor suitable for taking its weight. For ventilationalternatives 1 and 2 (indicated as Alt. 1 and Alt. 2), the minimum distance between thecompressor 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 mQc = Free air delivery of the compressor in l/sd = Inner diameter of the outlet pipe in mmp = Absolute pressure at the compressor outlet in bar(a)For British/American Units:dp = (L x Qc1.85) / (1470 x d5 x p)dp = Pressure drop (recommended maximum = 1.45 psi)L = Length of outlet pipe in ftQc = Free air delivery of the compressor in cfmd = Inner diameter of the outlet pipe in inp = Absolute pressure at the compressor outlet in psig

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Drawingreference

Description

4 The inlet grids and ventilation fan should be installed in such a way that any recirculationof cooling air to the compressor inlet grid is avoided. The maximum air velocity throughthe grids is 5 m/s (16.5 ft/s).If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is30 Pa (0.12 in wc).The air temperature at the compressor inlet grid should be between 0 °C and 46 °C (32°F and 114.8 °F).The required ventilation to limit the compressor room temperature can be calculated asfollows:For SI Units:On air-cooled compressors: Qv = 0.92 N/dTQv = Required ventilation capacity in m3/sN = Shaft input of compressor in kW (for Pack compressors)N = Shaft input of compressor in kW + heat dissipated by dryer in kW (for Full-Featurecompressors)dT = Temperature increase in compressor roomFor British/American Units:On air-cooled compressors: Qv = 2618.5 N/dTQv = Required ventilation capacity in cfmN = Shaft input of compressor in hp (for Pack compressors)N = Shaft input of compressor in hp + heat dissipated by dryer in hp (for Full-Featurecompressors)dT = Temperature increase in compressor room

5 Drain pipes to condensate collector. The drain pipes should be connected to an opencircuit.

6 Control cubicle with monitoring panel7 Main cable entry- A water shut-off valve and water drain valve in the energy recovery water inlet pipe and

outlet pipe can be installed by the customer. If water shut-off valves are installed, a safetydevice with set pressure according to the maximum water inlet pressure has to be installedbetween the energy recovery water outlet pipe and the shut-off valve.

Notes• For more information concerning air nets, cooling systems, etc. check the compressor installation manual.• All pipes should be connected stress free to the compressor unit.• For dimensions and air flow directions check the dimension drawings.

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4.4 Electric cable size

Electrical connections

Electrical connections for IEC fixed speed compressors

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Electrical connections for IEC variable speed compressors

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Electrical connections for CSA/UL fixed speed compressors

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Electrical connections for CSA/UL variable speed compressors

Cable connection

Cable glands

Always use the correct cable glands:

Cable section Cable diameter70 °C

Cable diameter90 °C

Cable gland size Ordering 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 72AWM 2 10.8 mm 20 0698 5140 72AWM 2/0 15.2 mm 25 0698 5140 73AWM 4/0 19.5 mm 32 0698 5140 74

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Cable section Cable diameter70 °C

Cable diameter90 °C

Cable gland size Ordering number

MCM 300 22.2 mm 40 0698 5140 75MCM 400 - 40 0698 5140 75

Cable size

See table if cables need to be spaced!Connect cables in the cubicle with the correct cable lugs. Spacing of 10 mm between nakedcable parts should be obtained.Supply Cables :• IEC type: XLPE 90 ˚C• CSA/UL type: 110 ˚C insulation cable

Fixed speed compressors, IEC 50 Hz water-cooled

Compressor type Voltage Cable size, water-cooledcompressors

Remark

110 kW 400V 2X (3X 70 mm2 + 35 mm2) grouping 2 cables bunched

132 kW with 4-polemotor

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-cooledcompressors

Remark


132 kW with 4-polemotor

400V 2X (3X 70 mm2 + 35 mm2) grouping 2 cables bunched

Fixed speed compressors, IEC 60 Hz water-cooled

Compressor type Voltage Cable size, water-cooledcompressors

Remark





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Fixed speed compressors, IEC 60 Hz air-cooled


Remark





Fixed speed compressors, CSA/UL air-cooled


Remark

132 kW 460V 2X (3X AWG4/0 + AWG4) Grouping 2 cables bunched

Variable speed compressors, IEC


Remark

132 kW 400V 2X (3X 95 mm2 + 50 mm2) Grouping 2 cables bunched

Variable speed compressors, CSA/UL


Remark

132 kW 460V 2X (3X AWG4/0 + AWG3) Grouping 2 cables bunched

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4.5 Pictographs

Control panel

Ref. Designation1 Start2 Stop3 Cancel key4 Enter key5 Scroll keys6 Alarm7 Automatic operation8 Voltage on9 Emergency stop

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Other locations

Reference Description13 Automatic condensate drain14 Automatic condensate drain15 Manual condensate drain16 Stop the compressor before maintenance or repair17 Warning: under tension18 Read Instruction book before starting the compressor19 Switch off the voltage and depressurize the compressor before maintenance or repair20 Before connecting the compressor electrically, consult the Instruction book for the motor

rotation direction21 Torques for steel (Fe) or brass (CuZn) bolts22 Consult the Instruction book before greasing23 Switch off the voltage before removing the protecting cover inside the electric cabinet24 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)25 Consult the Instruction book before maintenance or repair28 Oil outlet

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5 Operating instructions

5.1 Initial start-up

Warning

The operator must apply all relevant Safety precautions.

Switch off the voltage before making any adjustment.

Outdoor/altitude operation

If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautionsmust be taken. In this case, and also if operating at high altitude, consult your service representative.

Moving/lifting

The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrudefrom the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Makesure that the beams cannot slide and that they protrude from the frame equally. The chains must be held parallelto the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment must beplaced in such a way that the compressor is lifted perpendicularly. Lift gently and avoid twisting.

General preparations

Step Action1 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 automatically started and stopped• the compressor may be remotely controlled

3 A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork toprotect the compressor against corrosion. Remove the plates.

4 If the compressor has not run for the past 6 months, it is required to improve the lubricationof the compressor element before starting. Fill up the compressor element as describedin section Oil change (paragraph: Filling the compressor element with oil).

5 Check that the compressor is filled with oil; the pointer of the oil level indicator should bein the green range (see the section Oil change).

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Protection during transport

Transport fixtures

Step Action1 The gear casing supports and motor support are secured to the frame, immobilizing the

vibration dampers during transport.2 Remove the bushes (1) from the gear casing supports and the motor support.

Electric cabinet

Environmental condition for the electrical equipment: 3K3 according to IEC 60721-3-3

Step Action1 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 for automatic resetting and check its setting (see

the section Setting of overload relay and fuses).

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Start up

Step Action1 Close the drain valves (see the section Cooling and condensate system).2 Switch on the voltage.3 Start the compressor and stop it immediately. Check the rotation direction of the drive

motor while the motor is coasting to a stop. To determine the rotation direction of the motor,look at the fan through the grating at the non-drive end of the motor. The correct rotationdirection is indicated by an arrow on the gear casing and on the fan cowl.On air-cooled compressors, check the rotation direction of the fan motor, the fan is visiblethrough the grating in the air inlet panel (see section Dimension drawing). The correctrotation 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 voltageand reverse two incoming electric lines.If the rotation direction of the fan motor is wrong, consult your customer centre.

5 Run the compressor for a few minutes and check that it is operating normally.

5.2 Before starting

Warning


Control panel

Control panel

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Step Action1 Switch on the voltage. Voltage on LED (6) lights up.2 Close the condensate drain valves (see the section Cooling and condensate system).3 Open the air outlet valve.4 Check the oil level indicator (see the section Oil change). The pointer should be in the

green range or orange range.

5.3 Starting

Warning


Control panel

Control panel

Step Action1 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” to “Automatically loaded”.

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Reference NameA Air inlet temperature in ˚CB Condensation temperature in ˚CC Effective working pressure in barD Relative air humidity in %

5.4 During operation

Warning


The operator should immediately stop the machine in case of oil leaks internally in themachine 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.

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Control panel

Control panel

1. When the automatic operation LED (8) is lit, the starting and stopping of the motor is controlledautomatically.

2. Check the outlet temperature of the compressor element and other 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. Ifan optional water separator drain is installed, open the manual condensate drain valve.

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Control panel

Control panel

Step Action1 Regularly check the display for readings and messages. Normally, the main display is

shown, indicating the compressor outlet pressure, the status of the compressor and thefunctions of the keys below the display.

2 Always check the display and remedy the problem if alarm LED (7) is lit or flashing.3 The display will show a service message if a service plan interval has been exceeded or

if a service level for a monitored component has been exceeded. Carry out the serviceactions of the indicated service plans or replace the component and reset the relevanttimer.

4 Regularly check the actual compressor status by pressing the arrow down key from themain screen.

5.6 Stopping

Important

After pressing stop button (9), the compressor will run unloaded for 30 seconds. Thecompressor stops after this period. A start command during this period is ignored.After stopping, the compressor is prevented from restarting within a programmable time(20 seconds). A start command given during this minimum stop time will be memorised;the automatic operation LED lights up. The compressor will start when the minimum stoptime has elapsed.

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Control panel

Control panel

Reference Name1 Press stop button (9). LED (8) goes out. The message “Programmed stop” appears. The

compressor runs unloaded for 30 seconds and then stops.2 To stop the compressor in the event of an emergency, press emergency stop button (S2).

Alarm LED (7) blinks. After remedying the fault, unlock the button by pulling it out3 Close the air outlet valve.4 If an optional water separator drain is installed, open the condensate drain valve.

For compressors equipped with electronic water drains, press the test buttons on top ofthe electronic drains until the air system between the air receiver and the outlet valve isfully 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 operatethe components of the unloading/loading system.

If the compressor is going to be stored without running from time to time, protectivemeasures must be taken. Consult your Customer Centre.

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5.8 Taking out of operation

Disconnecting the compressor

At the end of the service life of the compressor, proceed as follows:

Step Action1 Stop the compressor and close the air outlet valve.2 Switch off the voltage and disconnect the compressor from the mains.3 Depressurize the compressor by opening the drain valve and loosening the oil filler plug

one turn.For compressors equipped with electronic water drains, press the test buttons on top ofthe electronic drains until the air system between the air receiver and the outlet valve isfully depressurized.

4 Shut off and depressurize the part of the air net which is connected to the outlet valve.Disconnect the compressor air outlet pipe from the air net.

5 Drain the oil and condensate circuits.On water-cooled compressors, drain the water circuits.

6 Disconnect the compressor condensate piping from the condensate drain net.7 On water-cooled compressors, disconnect the cooling water pipes from the compressor.8 Also read section Disposal of used material.

5.9 Use of air receiver

Instructions

Step Action1 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 without written permission of the manufacturer. If there isdamage to a part under pressure from any cause, the complete part must be replaced.

4 For the oil separator vessel: original bolts have to be used after opening for insideinspection. The bolts must be removed and fitted with the correct tool. The bolts must betightened with a torque of 185 Nm (+/- 45 Nm). Damaged bolts must not be re-used. O-rings must be replaced.

5 The safety valve is designed in such a way that the pressure will not permanently exceedthe maximum allowable operating pressure of the vessel, except for short pressure surgesup to 1.1 times the design pressure.

6 Only use oil specified by the manufacturer.7 Make sure the vessel is fully depressurized before opening the drain plug or fill plug.

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Step Action8 This vessel and other parts under pressure have been designed and built to guarantee an

operational lifetime in excess of 20 years and an infinite number of pressure load cycles.A visual inspection (for damage, non-authorized alterations,...) of the vessel (at the outsideand inside) is recommended every 5 years. Make sure the vessel is fully depressurizedand isolated before carrying out an internal inspection.

9 At every inspection, also check the oil drain flexible. Replace if there is any wear ordamage.

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6 Maintenance

6.1 Preventive maintenance schedule

Warning

Before carrying out any maintenance, repair work or adjustment, proceed as follows:• Stop the compressor.• Press emergency stop button (S2).• Close the air outlet valve and open the manual condensate drain valves.• 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 valveis fully depressurized.

• Switch off the voltage.• Open and lock the isolating switch.


Warranty - Product Liability

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not coveredby Warranty or Product Liability.

General

When servicing, replace all removed gaskets, O-rings and washers.

Preventive maintenance schedule

Period Running hours OperationDaily 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 clean if dusty.Weekly -- Drain condensate from air receiver, if installedMonthly 150 Clean air cooler by air jet, cooling air side3-Monthly -- Clean compressor.-- 500 After first start, retighten power cable connections.3-Monthly -- Check for possible leaks.3-Monthly -- Remove air filter elements and inspect.3-Monthly 500 Check the coolers; clean them if necessary. See the section Coolers.3-Monthly 500 Check measured parametersYearly -- Have safety valve tested. The valves can be tested on a separate

compressed air line.Yearly -- Have all flexibles inspected.

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Period Running hours OperationYearly 2000 Test safety temperature.Yearly 2000 Retighten the power connections.Yearly 2000 Check coupling.Yearly 2000 Replace air filter element.Yearly 2000 If Rotair oil is used, change oil.Yearly 4000 If Rotair Plus oil is used, change oil.Yearly 4000 If Foodgrade oil is used, change oil.Yearly 6000 Replace oil filters.Yearly 8000 If RXD oil is used, change oil.Yearly -- Regrease motor. For the interval and quantity, see section Motors.2-Yearly 6000 Have oil separator element replaced.

When operating in a dusty atmosphere, inspect the air filters more frequently.Use always genuine filters.The separator element must also be replaced when the pressure difference over the elementexceeds 0.8 bar (12 psi). Check the pressure drop when the compressor is running loadedand 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 anumber 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 carrying out all service actions, the intervaltimers must be reset using the “Reset” key in the “Service” menu. Consult your Service Centre.

6.2 Motors

Warning

Stop the compressor and switch off the voltage. The operator must apply all relevant Safetyprecautions.

Never mix greases of different brands or types.

Fan motors

The bearings of the fan motors are greased for life. The bearings of the fan motor must be replaced after 24000operating hours.

ABB drive motor

ABB motors must be greased with Screwguard Slide Amber

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IntervalD end

AmountD end

IntervalND end

AmountND end

110 kW (150 hp) 4 pole 6000 h 70 gr (2.47oz)

6000 h 70 gr (2.47oz)

132 kW (175 hp) 2 pole 4000 h 20 gr (0.71oz)

2000 h 20 gr (0.71oz)

132 kW (175 hp) 4 pole 4000 h 90 gr (3.17oz)

4000 h 70 gr (2.47oz)

WEG drive motor

WEG motors must be greased with Screwguard Slide Blue

Compressor type IntervalD end

AmountD end

IntervalND end

AmountND end

132 kW (175 hp) 460 V 4 pole 6000 h 45 gr (1.59oz)

6000 h 35 gr (1.23oz)

132 kW (175 hp) variablespeed

2x2 pole 4000 h 27 gr (0.95oz)

4000 h 27 gr (0.95oz)

6.3 Oil specifications

Rotair

Rotair oil is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specificcomposition keeps the compressor in excellent condition. Rotair oil can be used for compressors operatingat ambient temperatures between 1 ˚C (34 ˚F) and 40 ˚C (104 ˚F). If the compressor is regularly operating inambient temperatures close to 40 °C (104 °F), the oil lifetime is reduced. In such case it is recommended touse RXD oil.

Rotair Plus

Rotair Plus oil is a specially developed lubricant for use in single stage oil-injected screw compressors. Itsspecific composition keeps the compressor in excellent condition. Rotair Plus oil can be used for compressorsoperating at ambient temperatures between 1 ˚C (34 ˚F) and 40 ˚C (104 ˚F). If the compressor is regularlyoperating in ambient temperatures close to 40 °C (104 °F), the oil lifetime is reduced. In such case it isrecommended to use RXD oil.

Rotair Xtra

Rotair Xtra oil is a high-quality synthetic lubricant for oil-injected screw compressors which keeps thecompressor in excellent condition. RXD oil can be used for compressors operating at ambient temperaturesbetween 1 ˚C (34 ˚F) and 40 ˚C (104 ˚F) (see section Service kits).

Foodgrade

Special oil, delivered as an option.

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Foodgrade oil is a unique high quality synthetic lubricant, specially created for oil-injected screw compressorsthat provide air for the food industry. This lubricant keeps the compressor in excellent condition. Foodgradeoil 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


Control panel

Control panel

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Procedure

1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage.Wait a few minutes and depressurize by unscrewing the vent plug on top of the air receiver to permit anypressure 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:

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1. Take off the side panel of the compressor.2. Remove the drain plug (1) of the oil coolers.3. Reinstall the plugs after draining.4. Reinstall 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

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1. Use an oil pan to avoid oil spillage. Unscrew the oil filters (OF).2. Clean the filter seats on the manifold.3. Oil the gaskets of the new filters and screw the filters into place until the gaskets contact their seats. Then

tighten by hand.

Filling the compressor element with oil

Disconnect the air inlet 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 ¾ from the bottom of the indicator.4. Refit and tighten filler plug (FC) and tighten the vent plug on top of the air receiver.

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5. Run the compressor loaded for a few minutes.6. Stop the compressor and wait a few minutes.7. Depressurize the system by unscrewing the vent plug on top of the air receiver.8. Remove the filler plug and fill the air receiver with oil until the maximum level of oil is located at ¾ from

the bottom of the indicator.9. Tighten filler plug (FC).10. Tighten the vent plug on top of the air receiver.

Resetting the electronic regulator

After carrying out all service actions in the relevant “Service Plan”, reset the service warning as follows:

1. Press the “Menu” key (3).2. Press key (1) until “Service” is followed by an arrow pointing to the right. Activate the menu by pressing

key (2).3. Press key (1) until the related “Service Plan” is followed by an arrow pointing to the 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 operatethe components of the unloading/loading system.

If the compressor is going to be stored without running from time to time, protectivemeasures must be taken. Consult your Customer Centre.

6.6 Service kits

General

Service kits comprise all parts needed for servicing components and offer the benefits of genuine parts whilekeeping the maintenance budget low. All service kits are 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:

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• 5-litre can: 6215 7144 00• 20-litre can: 6215 7145 00• 209-litre can: 6215 7146 00• 1000-litre can: 6215 7147 00

See Oil specifications.

Rotair Xtra

Rotair Xtra oil can be ordered in the following quantities:

• 5-litre can: 6215 7148 00• 20-litre can: 6215 7149 00• 209-litre can: 6215 7150 00


Foodgrade

Foodgrade oil can be ordered in the following quantities:

• 5-litre can: 1630 0821 00• 20-litre can: 1630 0605 00• 209-litre can: 1630 0821 01


Grease

Grease can be ordered with following ordering numbers:

Grease type Ordering numberScrewguard Slide Amber 2901 0338 13Screwguard Slide Green 2908 8514 10Screwguard Slide Blue 2908 8521 10Screwguard Slide Beige 2908 8523 10

6.7 Disposal of used material

Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must bedisposed of in an environmentally friendly and safe manner, and in line with the local recommendations andenvironmental legislation.

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7 Adjustments and servicing procedures

7.1 Air filters

Warning

Stop the compressor, close the air outlet valve, press the emergency stop button andswitch off the voltage. The operator must apply all relevant Safety precautions.

Position of air filter

Procedure

Step Action1 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).

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7.2 Coolers

Checking the coolers for cleanliness on air-cooled compressors

A clogged cooler at the air side will increase the power consumption. Heavy clogging will increase thetemperature of the compressed air and can cause operational issues due to a higher oil temperature.

To prevent clogging of the air coolers at the cooling air side, clean them at regular intervals; see also sectionMaintenance.

7.3 Safety valve

Warning

Stop the compressor and switch off the voltage. The operator must apply all relevant Safetyprecautions.

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 does not open at the correct pressure (see the section Settings ofsafety valve).

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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 andopen 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 displayStop the compressor and carry out the indicated service actions.Reset the message.

A shut-down warning message appears on the displayThe alarm LED will light up indicating that the temperature at the outlet of the compressor elements is toohigh. The message disappears as soon as the cause of the problem is remedied.

Unit is shut downThe alarm LED will flash indicating either that the outlet temperature of the compressor element is too highor that the motor overload relay has tripped. Remedy the problem. It may be necessary to reset the displayafter remedying the fault.

Excessive oil consumptionHave the compressor inspected by the Customer Centre.

Condition Fault RemedyCondensate is not discharged fromcondensate traps during loading.

Discharge pipe of condensate trapclogged.

Check and correct as necessary.

Float valve of condensate trapsmalfunctioning.

Remove float valve assembly,clean and check.

Electronic water drainmalfunctioning.

Consult your Customer Centre.

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Condition Fault RemedyCompressor air delivery or pressurebelow normal.

Air consumption exceeds airdelivery of compressor.

Check equipment connected.

Choked air filters. Replace filters.Air leakage. Check and correct.

Condition Fault RemedyCompressor element outlettemperature or delivery airtemperature 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 coolingair temperature too high.

Check and correct as necessary.

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9 Technical data

9.1 Readings on display

Important

The readings are valid when operating under reference conditions. See the sectionReference conditions.

Normally the main display is shown, indicating the actual air outlet pressure andthe actual compressor status. The arrow down key allows the operator to call upother information such as actually measured pressures and temperatures.

Important readings

Compressor outlet pressure bar(e) (psig) Depends on programmedunloading and loadingpressures

Pressure drop over air filters bar Below 0.05Pressure drop over air filters psi Below 0.73Pressure difference over oil separator bar Below 0.8Pressure difference over oil separator psi Below 12Compressor element outlet temperature ˚C Below 120Compressor element outlet temperature ˚F Below 248

9.2 Reference conditions

Reference conditions

Absolute inlet pressure bar(a) 1Absolute inlet pressure psi 14.5Relative air humidity % 0Air inlet temperature ˚C 20Air inlet temperature ˚F 68Nominal working pressure See Compressor dataCooling medium inlet temperature ˚C 20Cooling medium inlet temperature ˚F 68

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9.3 Limits

Limits

Maximum air inlet/ambient temperature ˚C 40Maximum air inlet/ambient temperature ˚F 104Minimum air inlet/ambient temperature ˚C 1Minimum air inlet/ambient temperature ˚F 34Maximum cooling air temperature ˚C 40Maximum cooling air temperature ˚F 104Minimum cooling air temperature ˚C 1Minimum cooling air temperature ˚F 34Maximum working pressure See section Compressor

data

9.4 Settings of safety valve

Compressor type SettingFor compressors with a 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 psigFor 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 F25 F26110 kW 400 V 137.2 A 16 A --132 kW 400 V 159.4 A 16 A 16 A

60 Hz IEC compressors

Compressor type Voltage F21 F25 F26110 kW 380 V 146.9 A 16 A --110 kW 440 V 126.8 A 16 A --132 kW 380 V 169.1 A 16 A 16 A132 kW 440 V 147.6 A 16 A 16 A

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IEC compressors with variable speed drive

Compressor type Voltage F21 F25 F26132 kW 400 V -- 16 A 16 A

60 Hz CSA/UL compressors

Compressor type Voltage F21 F25 F26132 kW 460 V 143.4 A 16 A 16 A

CSA/UL compressors with variable speed drive

Compressor type Voltage F21 F25 F26132 kW 460 V -- 16 A 16 A

Maximum fuses

Explanation fuse types:

• Type2: gL/gG: IEC: 60947-4-1 according:• IEC60269• DIN43620• VDE0636

• CSA: HRC form II/UL: Class K5 according:• UL248-9

IEC 50 Hz air-cooled compressors

Compressor type Voltage Temp reductionnot neededCSA: HRC formII/ UL: Class K5

Temp reductionnot neededType2: 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 Tempreduction notneededCSA: HRCform II/ UL:Class K5

TempreductionneededType2: gL/gG

Tempreduction notneededType2: gL/gG

110 kW 380 V 3X315 NA 2X (3X160)110 kW 440 V 3X315 NA 2X (3X160)132 kW 380 V NA NA 2X (3X200)132 kW 440 V 3X315 2X (3X160) 2X (3X160)

CSA/UL air-cooled compressors

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Compressor type Voltage Tempreduction notneededCSA: HRCform II/ UL:Class K5

TempreductionneededType2: gL/gG

Tempreduction notneededType2: gL/gG

132 kW 460 V 3x315 2X (3X160) 2X (3X160)

IEC compressors with variable speed drive

Compressor type Voltage Temp reduction notneededType2: gL/gG

132 kW 400 V 2X (3X200)

CSA /UL compressors with variable speed drive

Compressor type Voltage Temp reduction notneededType2: 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 6.9Nominal working pressure psi 100Power input kW 141.85Power input hp 190.22Motor shaft speed rpm 1785Frequency Hz 60Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

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Data for 7 bar (101.5 psi) CE compressors


Nominal working pressure bar 7Nominal working pressure psi 101.5Power input, air-cooled kW 118.2Power input, air-cooled hp 158.51Power input, water-cooled kW 115.3Power input, water-cooled hp 154.62Motor shaft speed rpm 1487Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 2.8Maximum cooling water flow cfm 5.9Minimum cooling water flow l/s 1.2Minimum cooling water flow cfm 2.54


Nominal working pressure bar 7Nominal working pressure psi 101.5Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 2986Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3


Nominal working pressure bar 7Nominal working pressure psi 101.5Power input, air-cooled kW 118.2

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Power input, air-cooled hp 158.51Power input, water-cooled kW 115.3Power input, water-cooled hp 154.62Motor shaft speed rpm 1787Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 2.8Maximum cooling water flow cfm 5.9Minimum cooling water flow l/s 1.2Minimum cooling water flow cfm 2.54


Nominal working pressure bar 7Nominal working pressure psi 101.5Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

Data for 8 bar (116 psi) CE compressors


Nominal working pressure bar 8Nominal working pressure psi 116Power input, air-cooled kW 118.2Power input, air-cooled hp 158.51Power input, water-cooled kW 115.3Power input, water-cooled hp 154.62Motor shaft speed rpm 1487

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Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 2.8Maximum cooling water flow cfm 5.9Minimum cooling water flow l/s 1.2Minimum cooling water flow cfm 2.54


Nominal working pressure bar 8Nominal working pressure psi 116Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 2986Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3


Nominal working pressure bar 8Nominal working pressure psi 116Power input, air-cooled kW 118.2Power input, air-cooled hp 158.51Power input, water-cooled kW 115.3Power input, water-cooled hp 154.62Motor shaft speed rpm 1787Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 2.8

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Maximum cooling water flow cfm 5.9Minimum cooling water flow l/s 1.2Minimum cooling water flow cfm 2.54


Nominal working pressure bar 8Nominal working pressure psi 116Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3



Nominal working pressure bar 8.6Nominal working pressure psi 125Power input, air-cooled kW 141.85Power input, air-cooled hp 190.22Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

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Data for 9 bar (130 psi) CE/CSA/UL compressors

132 kW 50/60 Hz variable speed compressor

Nominal working pressure bar 9Nominal working pressure psi 130Power input, air-cooled kW 145.88Power input, air-cooled hp 195.63Power Input, water-cooled kW 139.68Power Input, water-cooled hp 187.31Motor shaft speed rpm 805-3042Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 78.1Maximum cooling water flow l/s 3.3Maximum cooling water flow cfm 7Minimum cooling water flow l/s 1.4Minimum 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 12Nominal working pressure psi 175Power input, air-cooled kW 145.88Power input, air-cooled hp 195.63Power input, water-cooled kW 139.68Power input, water-cooled hp 187.31Motor shaft speed rpm 805-3042Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 78.1Maximum cooling water flow l/s 3.3Maximum cooling water flow cfm 7Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

132 kW 60 Hz CSA/UL fixed speed compressor

Nominal working pressure bar 12

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Nominal working pressure psi 175Power input, air-cooled kW 141.85Power input, air-cooled hp 190.22Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

Data for 9.5 bar (138 psi) CE compressors


Nominal working pressure bar 9.5Nominal working pressure psi 137.75Power input, air-cooled kW 118.2Power input, air-cooled hp 158.51Power input, water-cooled kW 115.3Power input, water-cooled hp 154.62Motor shaft speed rpm 1487Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 2.8Maximum cooling water flow cfm 5.9Minimum cooling water flow l/s 1.2Minimum cooling water flow cfm 2.54


Nominal working pressure bar 9.5Nominal working pressure psi 137.75Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 2986

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Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3




Nominal working pressure bar 9.5Nominal working pressure psi 137.75Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2

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Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3



Nominal working pressure bar 10.4Nominal working pressure psi 150Power input kW 141.85Power input hp 190.22Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

Data for 12.5 bar (181 psi) CE compressors



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Nominal working pressure bar 12.5Nominal working pressure psi 181.25Power input, air-cooled kW 144.33Power input, air-cooled hp 193.6Power input, water-cooled kW 137.93Power input, water-cooled hp 185.0Motor shaft speed rpm 2986Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3




Nominal working pressure bar 12.5Nominal working pressure psi 181.25Power input, air-cooled kW 144.33Power input, air-cooled hp 193.55

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Power input, water-cooled kW 137.93Power input, water-cooled hp 184.97Motor shaft speed rpm 1785Oil capacity l 86Oil capacity US gal 22.72Oil capacity Imp gal 18.92Oil capacity cu.ft 3.04Sound pressure level dB(A) 77Maximum cooling water flow l/s 3.2Maximum cooling water flow cfm 6.8Minimum cooling water flow l/s 1.4Minimum cooling water flow cfm 3

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10 Pressure equipment directives

Category I

Product: see cover page of this instruction book

This machine is a pressure assembly of cat. I according to 97/23/EC.

Parts of article 3.3 of 97/23/EC are subject to good engineering practice.

Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of articleI, 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 serial number here(2) Data plate here

12.5 bar (181.3 psi) compressors

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Minimum wall thickness after corrosion vessel 4.306 mm (0.170 in)Minimum wall thickness after corrosion cover 28.55 mm (1.124 in)Lifetime infinite according to AD2000-S1 § 4.2.2.Delta p 12.5 bar (181.3 psi)Casting factor cover 0.8Welding 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 0.8Welding factor vessel 0.85

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11 Declaration 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

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Documents

CPF 175, CPVS 175