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Installation Operation

&
Instructions Manual
For PET Compressors

1903019295

REV:00

This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorization.

Section 1 :

General

Section 2 :

Transportation, Storage &
Installation

Section 3 :

Pre Start up Checks &
Trouble Shooting

Section 4 :

Maintenance

Section 5 :

Mark IV CP Tronic And VSD
Instructions

This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorization.

Section :1 General

This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorisation.

1

- Contents Section :1 General____________________________________________________________________ 1
1-

Foreword ___________________________________________________________________________1-1
1:
2:
3:

2-

Foreword ________________________________________________________________________________ 1-2
To obtain the Best Results ___________________________________________________________________ 1-2
Important ________________________________________________________________________________ 1-2

Legislation and Operating Precautions __________________________________________________2-3
1:
2:

3-

Operating and safety measures applicable to compressors __________________________________________ 2-4
Area subject to storms (lightning) _____________________________________________________________ 2-6

General features _____________________________________________________________________3-1
1:

4-

Compressor Package _______________________________________________________________________ 3-1

Operating principle __________________________________________________________________4-2
1:
2:
3:
4:
5:

5-

Functional description ______________________________________________________________________
Compression cycle_________________________________________________________________________
Staging__________________________________________________________________________________
Intercooling ______________________________________________________________________________
Aftercooling______________________________________________________________________________

4-1
4-1
4-1
4-2
4-2

Construction ________________________________________________________________________5-1

Compressor Proper _______________________________________________________________________5-1
1:
2:
3:
4:
5:
6:
7:
8:

6-

Consruction of the compressor _______________________________________________________________
Cylinders ________________________________________________________________________________
Piston rod________________________________________________________________________________
Pistons __________________________________________________________________________________
Oil scraper rings ___________________________________________________________________________
Packing _________________________________________________________________________________
Compressor valves ________________________________________________________________________
Drive units _______________________________________________________________________________

5-2
5-4
5-4
5-4
5-5
5-5
5-5
5-5

Construction ________________________________________________________________________6-1

Peripheral equipments ____________________________________________________________________6-1
1:
2:
3:
4:
5:
6:
7:
8:
9:
10 :

Intake filter ______________________________________________________________________________ 6-2
Coolers__________________________________________________________________________________ 6-2
High pressure Air Receiver _________________________________________________________________ 6-2
Air dryer ________________________________________________________________________________ 6-3
Dust and Micro filters(optional) ______________________________________________________________ 6-3
Electrical motors __________________________________________________________________________ 6-3
The electrical cabinet_______________________________________________________________________ 6-3
Safety Devices ____________________________________________________________________________ 6-4
Indicating Instruments _______________________________________________ Error! Bookmark not defined.
Auto Drain Traps __________________________________________________________________________ 6-4

Note :The Illustration shown in these chapters are indicative, actual item may vary
depending up on the Model of the Compressor

This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorisation.

2

Chapter:
1 - Foreword

This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorisation.

1-1

1 : Foreword
Congratulations on your purchase of the ‘Chicago Pneumatic’ High Pressure Compressor Package ! You
are now a part of ever growing family of ‘Satisfied CP Customers’.
This Manual containing ‘Operating and Servicing Instructions’ is an integral part of your HP Compressor
Package and should be kept with it at all times so as to be available to the operator or service engineer.
Before starting the H.P. Compressor Package read this manual carefully so as to understand the contents
clearly. For additional information, please contact the nearest Chicago Pneumatic office or the dealer
from whom the machine was purchased.

2 : To obtain the Best Results
1. Read this Instruction manual carefully.
2. Install the Package as Instructed. Good installation pays you in terms of performance and
reliability.
3. Use only recommended brands of lubricating oil.
4. Never run the compressor without suction silencer.
5. Ensure that compressor runs on full load most of the time. Running it in unloaded condition for
a long time reduces the life of piston and rider rings.
6. Drain moisture separators regularly. Avoid moisture getting accumulated in the suction vessels.
7. Ensure stabilised control voltage to the instruments. Use voltage stabilisers if voltage
fluctuations are very high in your area.
8. Record compressor parameters in the log book. This will help diagnose the cause in the event of
troubles.
9. Always follow the preventive maintenance schedules rather than fire fighting.
10. Always use Genuine Spare Parts available from Chicago Pneumatic to get better and consistent
results.

3 : Important
The company reserves the right to alter the design or construction of the machine and to supply the
same when so altered without reference to the illustrations or description given in this manual.
Since Chicago Pneumatic is dedicated to a process of ongoing improvements in its products, the
illustrations and specifications are subject to change without notice.
This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorisation.

1-2

published or communicated without the Company’s explicit authorisation.Legislation and Operating Precautions This document is the property of Chicago Pneumatic Sales and may neither be used.Chapter : 2 . 2-3 .

Therefore.cabinet. Do not run the compressor at pressures greater than the nominal pressure indicated on the motor data plate. one must apply the strictest of both. Close inspection openings. control. the user must apply sure working methods and observe all local security instructions and regulations in force. the compressor heats gas by compressing it. the cabinet supply terminals remain live. The compressor is equipped with indicators. Do not attempt to work on any part when the machine is running. 2-4 . 1 : Operating and safety measures applicable to compressors Chicago Pneumatic compressors apply relatively high operating loads. the wearing of a soundproofing helmet is recommended in the vicinity of the compressor. explosive or flammable. Follow supplier recommendations. even when it is disconnected. Check the temperature of any component before touching it. Check the output pressure daily to ensure that the automatic adjustment system maintains the compressor’s operation within acceptable limits. Regularly check the satisfactory operation of safety units (oil. The same applies to a lack of observation or the basic lack of good monitoring in handling. Compressors are noisy units even when noise reduction provisions have been implemented. Take great care when handling lubricants and anti-freeze fluids. When an unspecified statement of this handbook is not in conformity with the local legislation. Recover any fluids which have leaked or been spilled to avoid any form of pollution. In addition to a number of obvious safety rules. Do not attempt any dismantling whatsoever before By using this compressor package. The compressor’s electricity supply having been disconnected. Chicago Pneumatic will not be held liable in the event of material damage or defect to the body as a result of negligence in the application of these precautions. we would submit the following safety hints : Disconnect the electrical supply before commencing any maintenance on the compressor. maintenance or repair. In such cases. Supply pipes and cylinders can reach dangerous temperature levels. published or communicated without the Company’s explicit authorisation. hand openings or manholes when the machine is running. follow the special safety instructions applicable to hazardous products and areas. compressed gases may be dangerous. always ensure that the guard has been properly re-fitted. air and water). Never play around with This document is the property of Chicago Pneumatic Sales and may neither be used. The compressor’s rotating components are protected by a removable guards. Special care must be taken when working inside the electricity having released pressure within the system. In particular. Do not operate the compressor at speeds greater than the nominal speed indicated on the motor’s data plate. do not open inspection openings. even if not explicitly specified in this handbook. By its very design. Warning: the compressor is geared to automatic start-up. All common sense safety precautions must be observed when using the machine since any negligence concerning its operation or maintenance could have disastrous consequences for personnel. manholes or hand openings before starting the machine up again. Avoid all contact with this type of fluid. In some cases. in particular concerning security. Use a pressure gauge to ensure that there is no pressure. The Chicago Pneumatic compressor is equipped with a disconnect device. Before starting the machine up.

safety equipment must be sealed by a Chicago Pneumatic agent. The removal of seals from the valve and alteration of setting values is formally prohibited. Only use manual operation during the equipment testing phase. Do not fit a stop cock onto the supply pipe without inserting a safety valve between the stop cock and the compressor output. even when these precautions are not explicitly specified. hot components). take the opportunity of checking the tightening of the wheel onto the crankshaft. All inspections must be carried out when the installation is not operating and power disconnected. In such cases. in freezing conditions. (tools. even when they are protected by housings or cylinders. Ensure that spurious items are not left on the equipment is removed. Never use the compressor in areas where toxic or flammable fumes might be drawn in. In winter. ‘Do not start up’ may be placed on the compressor or its control panel. mechanical components). Similarly. Call in the Chicago Pneumatic Product Support Division if the valve sparks. attach a panel stating ‘WARNING. Chicago Pneumatic declines any responsibility for any damage or injury consequential on the failure to respect the above precautions or in the absence of fundamental precautions and suitable care appropriate to the operation of compressors. The compressor comprises heavy moving parts such as wheels and pistons. air under pressure is capable of inflicting serious injury.compressed air. Do not operate the compressor without ensuring that housings and protective screens are properly installed (moving parts. Never use a naked flame to inspect the inside of a compressor or pressure vessel. published or communicated without the Company’s explicit authorisation. WORK IN PROGRESS on any machine which is down or being overhauled. It is therefore recommended to keep away from these units. an additional precaution consists in removing control circuit or motor protection fuses. drain all water systems when they are not filled with a glycol solution. Whenever the housing This document is the property of Chicago Pneumatic Sales and may neither be used. rags. Once inspections have been completed. Do not use flammable solvents to clean components. 2-5 .

especially when it is located in an area subject to storms. This document is the property of Chicago Pneumatic Sales and may neither be used. Under no circumstances will Chicago Pneumatic be held responsible for damage caused by lightning to its electrical installations.2 : Area subject to storms (lightning) The user must take all necessary precautions to protect against the harmful effects of lightning strikes on electrical equipment. published or communicated without the Company’s explicit authorisation. Under no circumstances may a claim under warranty be submitted in the case of equipment damaged by lightning or by its secondary effects. 2-6 .

General features This document is the property of Chicago Pneumatic Sales and may neither be used. 3-1 .Chapter : 3 . published or communicated without the Company’s explicit authorisation.

e. This reduces the installation commissioning time considerably. Customer has to provide air discharge connection. 3-1 .1 : Compressor Package The messaging system also provides the information regarding servicing of components which helps to carryout preventive maintenance thus increasing the availability and reliability of the machine. This document is the property of Chicago Pneumatic Sales and may neither be used. water cooled heat exchangers. interconnecting air and water piping. drive motor. easy to commission. All parameters are set and very little adjustments are required at site. Customer can put the compressor directly into the use. cabling etc. Cp Tronic PLC with easy to understand messaging system (MMI) makes the Package user friendly to operate and diagnose the fault very quickly. and ordered optional accessories duly mounted on a rigid deck. Compressor control is through a Programmable Logic Controller i. user friendly to operate. starters. one on single deck two on elastic mountings (AVMs) which reduce the vibrations from being transmitted to the floor. These packages are available in two different configurations. PLC based control panel. The compressor is safeguarded against abnormal conditions and the control system is so designed that it trips the compressor in the event of any abnormality. safety devices. published or communicated without the Company’s explicit authorisation. The entire package is assembled and fully tested before it leaves the factory. hence eliminating elaborate civil foundation. power connection. v-belt drive system. easy to maintain and extremely reliable package specifically designed for PET blowing application. High Pressure Compressor Package is a complete unit ready to install. Since the package is tested at factory no load trials are necessary. The package comprises of state-of-art horizontal balanced opposed reciprocating water cooled air compressor. cooling water in and out connections and drain connections to make the unit ready for commissioning.

Operating principle This document is the property of Chicago Pneumatic Sales and may neither be used. 4-2 . published or communicated without the Company’s explicit authorisation.Chapter : 4 .

while intake valves A and D remain closed. this is a two-stroke operation as described below. The discharge valves A1 and D1 remain closed during suction stroke. between the inner face of the piston and the inner head gets reduced the air in this chamber gets compressed. Number of stages shall depend on This document is the property of Chicago Pneumatic Sales and may neither be used. During this action. as the volume of the inner chamber i. 4-1 . The metallurgy provided will not withstand such high temperature.2: 1 : Functional description This is a reciprocating horizontal type compressor with single or double acting cylinders. The crankshaft comprises of 2 crankpins which are offset at 180 Deg. During this action. as the piston moves from outer dead centre to the inner dead centre compressor takes air in through the suction valves A and D. This layout significantly enhances compressor equilibrium and avoids the need for enhanced [pile] foundations. However. It leaves the cylinder through discharge valves B1 and C1 while intake valves B and C remain closed. between the outer face of the piston and the outer head gets reduced the air in this chamber gets compressed. Hence it is necessary to achieve final pressure step by step and by removing the heat of compresson between the stages to restrict the final discharge temperatuer.e.e. 1: First stroke 1 Head end C1 Discharge 2 B Crank end Suction A1 Discharge C Suction Figure : 'Compression cycle first stroke' In the forward stroke as the piston moves from inner dead centre to the outer dead centre compressor takes air in through the suction valves B and C. 3 : Staging As per thermodynamic laws when the gas is compressed suddenly its temperature increases. 2 A Crank end Suction B1 Discharge D Suction Figure : 'Second compression cycle stroke' In the reverse stroke. It leaves the cylinder through discharge valves A1 and D1. 2 : Compression cycle In effect. 3: 1 Head end D1 Discharge Second stroke Cylinders running in tandem Tandem cylinders operate in the same way as normal cylinders. as the volume of the outer chamber i. published or communicated without the Company’s explicit authorisation. the two compression strokes take place at different stages and pressures. which is 40 bar in our case. Hence if the air is compressed to the discharge pressure. in one stroke its temperature will shoot up tremendously high. The discharge valves B1 and C1 remain closed during suction stroke.

This helps in restricting the discharge air temperature and also in saving the power required to compress the air in the subsequent stage. 5 : Aftercooling Air leaving the final stage of compressor is also very hot and is normally not desirable. This document is the property of Chicago Pneumatic Sales and may neither be used. The first stage cylinder is on one crankpin and the second and third stage cylinders are on the second crankpin in tandem arrangement. An air cooler called aftercooler is provided to bring down the air temperature to near about ambient temperature. 4-2 .the overall pressure ratio of the compressor. The present machine is provided with 3 stages. published or communicated without the Company’s explicit authorisation. 4 : Intercooling Between the stages air passes through the air coolers called intercoolers in which the heat of compression is removed and the air temperature is brought to near about atmospheric temperature.

Construction Compressor Proper This document is the property of Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. 5-1 .Chapter : 5 .

5-2 . published or communicated without the Company’s explicit authorisation. . 1: Flywheel The object of the flywheel is to optimise the compressor's cycle regularity factor. Ancillary equipment (dryers. made of high grade cast iron.Oil tank constituted by the shape of the casing .2: 1 : Consruction of the compressor This description solely refers to components directly associated with air compression. The shaft is provided with oil seal on the wheel side. It is generally mounted on the crankshaft through a taper key. It transmits mechanical power to the pistons. . precision machined and stress relieved for permanent alignment.Large size inspection openings to facilitate maintenance .) are covered in a separate chapters (see Contents). 1: Crankcase Totally enclosed. This document is the property of Chicago Pneumatic Sales and may neither be used. etc. Running Gear 'Running Gear' refers to all items associated with the transmission of reciprocating motion to the pistons. rigid.Major rib structure . electrical equipments. It has following additional features : .Bearings of which 2 on the wheel side. . 1 3 Drive pulley Flywheel 2 4 Compressor Motor Figure : ‘Flywheel’ 3: Crankshaft Constructed of SG iron or forged steel with counterweights incorporated into the body of the crankshaft.

pressure-lubricated bearing. Large size inspection openings facilitate access to this component. It is made of surface hardened steel.It is fitted with oil scraper rings to prevent oil travelling from the running gear towards the cylinders. The big end bearings are of the thin walled. The crankshaft rests on two bearings located on the wheel side.4: 6: Main Bearings This is a thin walled. anti-friction metal whereas the small end bearings are of bronze materials. made of steel and an anti-friction material. 8: Crosshead Pin The crosshead pin connects the crosshead to the connecting rod. It is held in position by two circlips. 5-3 . They convert the rotating crankshaft action into the reciprocating action required by the pistons. in one or two parts. 10 : Oil pump Attached to the end of the crankshaft. published or communicated without the Company’s explicit authorisation. Crosshead These are monobloc type SG iron crossheads. the oil pump circulates oil under pressure throughout the lubrication system. This document is the property of Chicago Pneumatic Sales and may neither be used. It is bolted to the crankcase. 1 Cylinder 2 Distance piece 3 Crankcase Figure : ‘Distance piece location’ 7: 1 Crankshaft bearing Figure : 'Location of crankshaft bearings' 5: Connecting rod These are made of forged steel and equipped with a detachable cap bolted onto the body. 9: Crosshead guide This device centres the crosshead. Distance piece The distance piece connects the crankcase to the cylinder.

Cylinders provide the compression chambers in which the piston moves forward and backward. On water passages large doors are provided to facilitate inspection and cleaning of water chambers. They are made up of graded cast iron and have large openings for air and water passages. Figure : 'Lubrication system' This document is the property of Chicago Pneumatic Sales and may neither be used. oil filter. a disposable 10 micron filter is provided to filter out the oil before it goes to the bearings. it connects the crosshead to the piston. 4 : Pistons 1 3 5 7 9 Oil pressure switch Pump Pressure adjustment valve Oil filter Bearings 2 4 6 8 Oil tank breather Strainer Drain CrossSlide Made of aluminium alloy casting or of stainless steel as required. At the end of the oil distribution piping an oil pressure gage and a oil switch is provided. Any drop in the oil pressure is detected by the oil pressure switch and immediately stops the compressor.. The cylinder bore is honed to the required finish to provide smooth surface. It is fitted with a deflector which stops any lubricant penetrating into the cylinder.Downstream of the pump. They are fitted with rider and piston rings. The oil pump provides the system with pressurised lubricant. 5-4 . Air chamber houses suction and discharge valves. oil cooler (in case of HP-80 and HP-100 compressors only) a pressure gauge and a low pressure safety switch. The piston is fixed to the rod by means of a piston nut with adequate torque. published or communicated without the Company’s explicit authorisation. 3 : Piston rod Made of a special treated steel. 2 : Cylinders 1 Oil pump Figure : 'Oil pump location' 11 : Lubrication system It consists of oil pump.

1: V-belt drives The electric motor drives the compressor wheel via a set of belts. They are of the self-lubricating type made of filled teflon material. These parts hare held together by means of valve seat.. Figure : ‘Oil scraper rings’ 6 : Packing These provide the best possible seal between the compression chamber and the outside at the point where the piston rod emerges from the cylinder. The valves operate automatically based on differential pressure across them.7 : Compressor valves Photo : ‘Piston’ 5 : Oil scraper rings The compressor valve consists of a valve plate. These are used to prevent oil going to the distance piece and to the cylinders.B. Motor movement tensions the belts. 1 Compressor 2 Flywheel Guard 3 Motor fig : ‘Garter spring assembly' This document is the property of Chicago Pneumatic Sales and may neither be used. 8 : Drive units N. The oil scraped by the scraper rings goes back to the crankcase. the damper plates and the lift washers. Compressor's direction of rotation is usually clockwise when seen by an observer standing in front of the wheel. spring plates or helical springs. 5-5 . of suction and discharge valves depends upon the volume to be handled and the pressure. valve keeper and the valve stud. published or communicated without the Company’s explicit authorisation. No.

6-1 .Construction Peripheral equipments This document is the property of Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation.Chapter : 6 .

1 At the floating end of the cooler two ‘O’ rings are provided with an intermediate flange sandwiched in between for sealing water side and air side. The flange has two radial holes called ‘Tell Tale” holes. If water side ‘O’ ring fails. In case one of the ‘O’ ring fails water and air streams do not get mixed up immediately. This type of cooler may include a pulsation damper at its inlet and a moisture separator on the outlet. 1 4 7 Intake chamber Shell Outlet chamber 2 5 Seal Water inlet 3 6 Tube Bundle Water outlet Figure : 'Schematic cross-section of a cooler' The 1 4 Cylinder Filter 2 Filtered air outlet 3 Air intake Figure : 'Example of an intake filter' 2 : Coolers These are of shell and tube removable tube bundle type design. fitted with a auto drain system. The ‘Tell Tale’ holes gives the information as to which ‘O’ ring is failed If air side ‘O’ ring fails. water will start coming out from the holes. published or communicated without the Company’s explicit authorisation. 6-2 . The air receiver is provided with safety valve .Figure : 'Cooler' 1 : Intake filter When the compressor intake uses normal ambient air. air will start coming out of the holes. Thus there is always a warning of potential danger ahead. the intake is protected from dust by a filter fitted direct onto the cylinder. Coolant This document is the property of Chicago Pneumatic Sales and may neither be used. Large inspection openings are also provided for inspection purpose. Acoustic pulsations are attenuated by a soundproof-tube silencer. 3 : : High pressure Air Receiver This is used to damp out pulsations in the delivery side as well as to store the compressed air. Air is usually through tubes and water through shell in counterflow direction. a pressure gauge and auto drain valve as a standard.

Electrical motors are Sq. The construction is totally enclosed fan cooled (TEFC) and suitable upto 45 degC ambients as a standard.starters for motor(s) . Both these filter are provided with drain valves to enable remove condensate if gets collected in the filters. Cage Induction motors. 6 : Electrical motors Figure : ‘High pressure Air Receiver' 4 : Air dryer Refrigerated air dryer (optional) is provided after the air receiver in order to bring down dew point to the desired level. suitable for 415 /380 VAC. published or communicated without the Company’s explicit authorisation. such as : . Its power is supplied via a star / delta starter unit equipped with the appropriate protection.5: Dust and Micro filters(optional) Down stream the air receiver and before the refrigerated dryer a dust filter is provided to remove particles upto 5 microns.controls (PLC based) . . For further information. . 3ph.Compressor motor : This motor drives the compressor crankshaft.man /machine interface . Class of insulation is ‘F’. . 50 /60 Hz Supply.1 microns. Differential pressure gauge provided on the filter shows the condition of the filter.protection devices . Motors started via the electrical cabinet (the relevant wiring diagram can be found inside the cabinet). Figure : 'Air dryer' The photo graph is for illustration only actual actual dryer may vary depending up on the model offered This document is the property of Chicago Pneumatic Sales and may neither be used. 7 : The electrical cabinet It contains all the systems needed for the satisfactory operation of the compressor. At the down stream of air dryer a micro filter is provided to remove particle down to 0.indicating instruments . 6-3 . please refer a separate section on the Air Dryer.

Pressure Transducers for Oil pressure . Condensate is collected in moisture separators and in the Air Receivers.As the Instumantation may vay depending up on the Model of the Compressor.8 : Safety Devices Following safety devices are provided with each compressor.electrically operated vent valve . moisture contained in the air condenses. / flow switch . Arrangement may vary depending up on Model This document is the property of Chicago Pneumatic Sales and may neither be used.Low cooling water pr. Automatic timer operated drain traps / solenoid valves are provided to remove the condensate collected at these points.Temp Transducers . . An isolation and a bypass valve is provided to facilitate maintenance without shutting down the compressor. Auto Drain with By pass .Capacity control thro PLC . 6-4 .l 9 : Auto Drain Traps When air is cooled after compression. published or communicated without the Company’s explicit authorisation.Motor overload protection Refer the P &ID Diagram for details of Instrumantation used.Solenoid Valves .Safety relief valves .

Storage and Installation This document is the property of Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. 2-1 .Section 2 : Transportation.

. actual item may vary depending up on the Model of the Compressor This document is the property Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. 2 : 1-1 .Contents Section 2 : Transportation. handling and storage________________________________________________________1-1 1: 2: 3: 2- Transport ________________________________________________________________________________ 1-2 Unloading at site __________________________________________________________________________ 1-2 Storage__________________________________________________________________________________ 1-3 Installation__________________________________________________________________________2-1 1: 2: 3: 4: 5: 6: General _________________________________________________________________________________ Ventilation and heat removal_________________________________________________________________ Adjustment and bolting down ________________________________________________________________ Connections ______________________________________________________________________________ Several compressors installed in parallel________________________________________________________ Drain Connections _________________________________________________________________________ 2-2 2-2 2-3 2-4 2-6 2-6 Note :The Illustration shown in these chapters are indicative. Storage and Installation______________________________________ 2-1 1- Transport.

2 : 1-1 . published or communicated without the Company’s explicit authorisation. handling and storage This document is the property Chicago Pneumatic Sales and may neither be used.Transport.Chapter : 1 .

Each box is marked with customer’s name address. etc. position of slings. Following operations are carried out as a routine : - - - Cooling water is drained off . The base frame of the package unit is firmly bolted to the base of the box. Metallic hoses are removed if under stress. Also inform local office of Chicago Pneumatic for inspection of damages. Depending upon the size of the package a closed or open truck is chosen. Net weight. AVM mounted packages are provided with AVM locking devices to avoid transit movements. Gross weight.The total equipment weight has been specified in the ‘General Arrangement’ drawing. After having cleared in performance test the package is taken up for despatch preparations. The number of boxes depend upon the size of the package and the loose items which do not constitute the part of main skid. list with boxwise contents is fixed on the individual box. After having done above preparation the package unit is packed in a wooded box or crate. Internal parts of the fame are provided with preservative spray. Valve packets are provided with silica gel bags to absorb moisture. UP arrow. 1: Slings The following recommendations must be followed : . Etc.1 : Transport 1: Preparation for transportation Each package is thoroughly tested on load before despatch. Most of the operating parameters and timers are set and hardly required to be changed during operation. Various instruction stickers are put. Transportation is done through company approved transportation agency or customer appointed agency. Any unsupported pipe / equipment which may get damaged during transit are removed and sent loose. it is the responsibility of the customer to provide necessary tools and tackles and arrange for unloading the package. supplier’s name. 2 : 1-2 . ‘Store Under Roof’ symbol etc. Entire equipment is pained either in enamel or epoxy paint as the case may be. The packing 1 Slinging point For lifting purpose always use the lifting This document is the property Chicago Pneumatic Sales and may neither be used. All the machined surfaces are protected with anti-rust oils. 2 : Unloading at site Once the consignment is reached the site. published or communicated without the Company’s explicit authorisation. Lub oil in the sump is drained off and the frame is wiped off. 2: Transport vehicle The inland transportation is mostly effected in trucks. immediately inform to the insurance agency and make a report. All openings are plugs or blanking plates / tapes. After opening the box if damages are observed.

steel sling diameter for a compressor must be a minimum of 16 mm). Plug and seal all opening thoroughly so the moist air and dirt do nor enter. Do not spray RUSTOP-286 in the cylinders of non-lube compressor. and especially not on compressor components which are not sufficiently resistant to take the load (coolers.P. If the storage period is going to be extended further then follow the procedure given below : Procedure - - - The compressor must be stored in a clean. Avoid using steel slings with bare cables. The sling diameter must be appropriate to the load to be lifted (For guidance. Water cooling system for cylinder jackets and coolers: Drain water from cooling system and thoroughly flush with clean water and HP Radiator cleaner. vibration and freezing conditions . slacken the belts completely. electrical cabinet). dry location. The Package is normally protected for 3 months storage when it leaves the factory. water pipes. Clean the crankcase and fill it with H. impact. - ambient is likely to be very low where water freezing occur. or. It This document is the property Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. away from direct sun. drain it immediately. Put silica gel bags in the distance piece chamber.hooks provided to the main skid. System then to be filled with 10:1 mixture of water and SHELL DONAX C / SHELL DORMUS oil or HP RADIATOR PROTECTOR. Drain all the protector after 4/5 days. dust. use the spreader bars (stiffened spreader). Do not allow the slings to come into contact with and damage paintwork. Do not let slings bear on the equipment. 2 : 1-3 . In case of V-belt drive. 3 : Storage Storage precautions required will depend on the length of storage time. Comply with safety instructions applicable to handling and lifting. allow for local protection over contact points. Place silica gel bags in the valve pockets and re-fit the valve covers. RUSTOP-286 oil and rotate the crankshaft several times to circulate the oil to all moving parts. in such cases. even better.

Chapter : 2 .Installation This document is the property Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. 2 : 2-1 .

1 : General Following instructions are provided to aid in the proper installation of the machine. Packages with single skid and Packages with Anti Vibration Mountings (AVMs). inspection and maintenance of the unit. The following recommendations are compulsory : . The unbalanced forces and couples generated by the action of the compressor are to be absorbed by the foundation. heat exchanger tube bundles etc.Under no circumstance may the load loss exceed 5 mm WC . Packages with single skid are required to be mounted on BLOCKTYPE foundation. The premises should include an adequate air This document is the property Chicago Pneumatic Sales and may neither be used. . An overhead crane of sufficient capacity may be installed for handling the package components. well-lit and ventilated place (preferably having cross ventilation provision) with sufficient space reserved for the cleaning. 2: foundation for reciprocating machinery. 90 to 95% of calories will be evacuated through the water system. the remainder through ambient air. 2 : 2-2 . Location Install the compressor in clean. Chicago Pneumatic service engineers are available to guide you from selection of site to successful commissioning of the machine. BLOCK-TYPE foundation need to be designed by the expert civil engineers who have experience in designing 2 : Ventilation and heat removal 1: General rules When the dimensions of the room or its natural ventilation do not suffice for maintaining the requisite ambient temperature conditions. Space required for removal of pistons. Generally. . If there are gaps between the floor and deck then same are to be filled with mortar. The unbalanced forces and couples transmitted to the floor in this type of machine are very negligible. The access doors of the compressor room should be large enough to enable take the Package inside the room in assembled condition only. is shown in the General Arrangement drawings. It is necessary that 80~90 % of the bottom surface of the main deck rests on the floor.Flow speeds shall not exceed 5 m/sec.When installing the compressor. avoid recycling the hot air discharge towards the air intake . The capacity of the crane is to be decided accordingly. If the gaps are left without fillings there is a possibility of excessive vibrations in the machine. provisions must be made for ventilation and a suction duct to remove air around the compressor. The instructions given hereunder are intended for use with the General Arrangement and Foundation drawings provided for particular compressor installation. dry. We recommend to use their services to avoid costly installation errors. published or communicated without the Company’s explicit authorisation. 1: AVM mounted compressors do not require an elaborate foundation but a levelled industrial floor of adequate bearing capacity. Normally electric motor is the maximum weight to be handled. Chicago Pneumatic is able to analyse your installation for the purpose of heat recycling. Foundation There are two types of packages available from Chicago Pneumatic. A badly designed foundation will affect the performance of the machine and reduces its reliability.

Tolerance is 0. .convection heat (frame. check anchoring point conformity and depth of holes provided. - 1: Compressor positioning and adjustment 1 2 3 4 A B Base plate Anchor bolt 20 millimetre shim Levelling screw Approximately 30 millimetres Approximately 20 millimetres Figure : ‘Laying the chassis over the shims’ Use the levelling screws (Item 4) to level the compressor. Allow the compressor frame to rest on the shims by releasing the levelling screws (item 4). insert the shims of varying thickness provided over the 20 millimetre shims (Item 3) previously inserted. .) . starter equipment. allowing a length of approximately 30 millimetres to protrude. . . .After curing.Clean and/or level the areas destined to take the levelling shims delivered with the machine.intake for the following : .An air intake required for cooling the electric motor.Fresh air renewal by providing an adequate hot air outlet in the upper part of the room. and for dissipating . with unobstructed bolt holes. . cylinder. Once the compressor is levelled.5 millimetres/metre. This document is the property Chicago Pneumatic Sales and may neither be used.If applicable. Insert the anchor bolts into the chassis and fix them in position using the first nut. 1 4 Hot air outlet Fresh air intake 2 A Paddles : 1 to 2 meters 3 Extractor Figure : ‘Position of air intakes and outlets in the premises’ Insert the fixing bolts into the holes left for this purpose. etc. pipes. 3 : Adjustment and bolting down 1: Foundation Block construction Construct the Foundation Block according to instructions contained in the Foundation Drawing providing anchoring points. 2 : 2-3 . the air needed for cooling radiator cooling (closed circuit water system ) when it is located within the compressor room .The slab must be clean and dry. 2 3 Anchor bolt 20 millimetre shim Figure : ‘Anchor bolt and shim positions prior to installing the chassis’ Bring to compressor chassis (item 1) over its position on the slab see Foundation Drawing .Fresh air supply to the compressor when the filter is fitted direct onto the compressor . Lay the compressor chassis on the 20 millimetre shims inserted on either side of the anchor bolts. published or communicated without the Company’s explicit authorisation. Insert a 20 millimetre shim on either side of the anchor bolt.

However a flexible hose / pipe is to be installed between the compressor suction flange and air intake pipe. Compression glands must be provided for the removable plate in the electrical cabinet. in force. Provide adequate supports to avoid stresses coming on compressor suction flange. It is advisable to have independent air intake piping for each compressor if number of compressors are to be operated in parallel. shrink-proof concrete must be used. published or communicated without the Company’s explicit authorisation. It is recommended that a circuit breaker or a switch fuse unit to be installed before the electrical cabinet in order to isolate the electrical supply. 2: Air Suction Piping Chicago Pneumatic HP compressor package is supplied with a suction filter cum silencer mounted on the LP cylinder inlet flange or on the package itself. In case the compressor location is such that it is not possible to provide such atmosphere in the compressor house then it is advisable to take an air intake from clean and cool atmosphere.A high fluidity. type of cable. Pour finishing concrete between the slab (item 5) and the chassis (item 1) (see figure below). Cable section depends on the current intensity. Fit and tighten lock-nuts (item 2). Guide lines for Air Intake piping : - 1 2 3 4 5 Base plate Lock-nuts 20 millimetre shims Finishing concrete Slab Figure : ‘Finalising compressor installation’ - - 4 : Connections - 1: Electrical The three phase electricity supply line with neutral and earth conductors must be correctly dimensioned to standards and to user client specifications. Avoid critical lengths as it may create resonance with pulsating flow causing heavy vibrations in the piping system. This will give a reduction in capacity by 1% The velocity of air through pipe should not exceed 400m/min Pipe should be either galvanised or coated with rust preventive material from inside.We recommend Shrinkomp Grout of ACC Allow it to cure (Refer to product sheet for time required). 2 : 2-4 . cable length. It is imperative that the air sucked in by the compressor should be clean. . 3: Finalising compressor installation Clamp the compressor to the foundation slab. installation of cable and ambient temperature. The installation must provide means to cut and protect the power supply line upstream the compressor cabinet according to the rules - - Pipe should be at least one size larger than the compressor intake nozzle Do not run the pipe along with hot pipes The pressure drop in the pipe should not exceed 100mm WC. This document is the property Chicago Pneumatic Sales and may neither be used. dry and cool. .2: Bolting down Pour concrete into the holes left in the concrete slab and ensure that there is no shrinkage.

The inlet water pressure is recommended between 1. in particular. The scale deposits unless removed. the safety valve is set for a pressure which is 10% above operating pressure. 1 hour circulating capacity. When the systems pipe work is very long and. A safety valve must be fitted upstream of each valve. 4: Cooling Water Rigid or flexible connections may be fitted as shown in the two following figures. there must be no bends in discharge piping.3: Air Discharge Piping The locations and dimensions of connections are shown on the General Arrangement drawing. . Please refer General Arrangement or the Compressor Specifications for cooling water quality and quantity to be provided.5 kg/cm2g. fit scrubbers. Generally. cooling or adsorption type air dryers according to the characteristics required of the purified air.A 1% gradient. sections installed outside). 1 Water outlet 2 Water inlet 3 Supports Figure : ‘Flexible coupling’ The position and size of inlet and outlet connections are shown on the General Arrangement drawings. 2 : 2-5 . coolers etc. OPEN TANK Where the cooling tower is not available and location requires open tank system. If possible. 1 Water outlet 2 Water inlet 3 Supports Figure : ‘Rigid coupling’ This document is the property Chicago Pneumatic Sales and may neither be used. mud or other impurities. The water temperature differential should not exceed 8 to 10 degC and preferably lower. An isolating valve must be fitted to compressor discharges. A good clean cooling tower water must be provided for cooling. sulphur. If cooling water has high percentage of lime. Further. These pipes must slope down to the reservoir and. The inlet water temperature must not exceed 32 degC and this should be very strictly taken care off. It is preferred to have a low depth tank so that large surface area is available to cool the water by natural evaporation in addition to water sprinklers. if operation requires a fully purified and dehydrated air supply. they must be fitted with drains.5 to 3. published or communicated without the Company’s explicit authorisation. Rigid pipes or reinforced hoses may be used for making connections. particularly when several compressors are discharging into the same space. head. these will be get deposited in the cylinder jackets.g. silt. lower the rate of heat transfer and may result in damage to the equipment. then the tank should have min. when it is wholly or partly installed in cooler areas (e. will obstruct the flow of water.Low points with drains for removing condensates which are formed when the system’s temperature falls . if low points cannot be avoided. the following are essential : .

Connection between each compressor and the trap is shown below. 2 : 2-6 . adequate ventilation is essential. A compressor’s purge circuits must be set out in such a way that the pressure from another compressor cannot ‘return’ into its circuits. actual item may vary depending up on the Model of the Compressor This document is the property Chicago Pneumatic Sales and may neither be used. Pressure pulses arising from the presence of other compressors or return waves from the system must be eliminated by installing a reservoir which has an adequate capacity. It is recommended that the drain pipe is taken away from the compressor house at suitable location as when drain valves operate lot of noise and splashing of water takes place due to high pressure.5 : Several compressors installed in parallel 1: Compressors on the same system When several compressors discharge into the same system. 2: Compressors in the same room When several compressors are installed in the same room. 1 2 From compressor no. 6 : Drain Connections Various drain points in the package are connected to a common manifold which are located at the edge of the package. in order to facilitate maintenance whilst the other machines continue running. 2 3 General manifold outlet Figure : ‘Parallel connected compressors discharging into the same system’ The manifold shall have a gradient of approximately 1% to allow condensates to flow away and a low point for purging. Connect a suitable drain pipe. it locks the compressor’s operation. Note :The Illustration shown in these chapters are indicative. Compressors must discharge into a system where pressure is relatively stable. and a non-return valve (provided in Chicago Pneumatic packages if ordered). at the outlet of each compressor. When a stop valve closes. Purge circuits may be connected into the same system subject to standard precautions applicable in the potential presence of different pressures. to the drain disposal system of the user. it is recommended that a stop cock be fitted on the discharge pipe. published or communicated without the Company’s explicit authorisation. preferably 15NB. 1 From compressor no.

Section 3 : Operation Pre start check & Trouble Shooting. 2 .

................................................................................................................................................12 1: 2: 3: 4: 5: 6: 7: 8: 9: 10 : 11 : The compressor does not start ............................................................................................................................................. 14 Discharge pressure not achieved .............................................................................. 11 Troubleshooting........ 5 Checks and operations to be carried out after prolonged storage ............................................................. 7 Inspections to be carried out on commissioning or after major works .............................................................................................................................................................................................................................. when operating under load................. 19 Inter-stage pressure...................................................................... 8 Stopping or disconnecting the compressor .................................................................................................. 16 Nominal discharge pressure greater than anticipated ..24 1: 2: 3: 4: 3- 4- Checks to be carried out before commissioning for the first time........... no-load operation......................................................................................................................................................................................................................................................... higher than anticipated ................................................................................................................................ 21 Noisy operation ....................................................... 18 Inter-stage pressure....................................................................................... 13 The compressor stops .......................................................................................................................................................... 18 Inter-stage pressure................................................ .......................... lower than anticipated .......... 1 1- Pre-Startup Checks and Adjustments ............................................................................. lower than anticipated.................................................................... 17 Inter-stage pressure when operating under loads higher than anticipated................................... no-load operation................... 22 3 ........ 20 Oil problems ............................. 19 Discharge temperature too high (intermediate or final)..........................CONTENTSSection 3 : Operation .............................

Chapter : 1 .Pre-Start up Checks and Adjustments 4 .

Fill the crankcase with correct grade of lubricating oil upto the centre mark of oil level gauge. cables etc. instruments.). Manually check electric motor rotation. piping.. and then wiped dry with lint free rags).1 : Checks to be carried out before commissioning for the first time CHECKS TO BE CARRIED OUT DONE (*) COMMENTS COMPRESSOR Check the general condition of the equipment Remove protection and silica gel bags Remove preservation oils and greases Remove AVM protection spacers painted in RED and jacking bolts. Rotate the beltwheel manually in the direction of rotation for about 20-30 revolutions to ensure bearing lubrication and free rotation. Drain condensed water from moisture separators and 5 . Turn on the cooling water and remove air lock from the water system.( Applicable for Packages with AVMs ) Refit parts which have been sent loose for transportation purpose (metallic hoses. valves. Check electric motor insulation and lubrication (refer procedure outlined below) Remove motor shaft lock screw (if fitted) Check and clean the crankcase thoroughly ( The entire interior should be washed with “VARSOL” or any other equivalent cleaning agent.

Alternatively. when cold. Once this value is stabilised stop the heating process and allow the motor to cool down to ambient temperature. hot air blast can be blown on the motor but the air temperature should nor be higher than 85 degC and the air should be moisture free.filters. 6 . 3) By applying DC current not exceeding 80% of the rated current. The temperature should not exceed 85 degC. subject to a minimum of 2 mega ohm. Check whether unloading line from the Air Receiver or discharge piping connected. Method of “Drying Out” motor : 1) A convenient method of doing this is to lock the motor shaft so that it cannot rotate and apply a very low voltage about 10% of the rated voltage to the starter terminals. 2) The motor can be placed in the oven if available. Measure the isulation value in the cold condition. Check all electrical connections for tightness. and the motor needs to be dried out. Give tension of ‘V’ belts and tightness them if necessary. The insulation resistance to be checked every hour during drying process till the isulation value stabilises at certain point. If this is not the case. presence of moisture or dust in the windings is indicated. Table : ‘Checks and inspections to be carried out before commissioning the compressor for first time‘ (*) tick Checking of Insulation resistance of electric motor : Check insulation resistance of electric motor with a megger. Its value should not be less than 1 mega ohm per rated kilovolt of the machine plus 1 mega ohm. It should be within the allowable limits.

Check electric motor insulation and lubrication Remove motor shaft lock screw (if fitted) Manually check compressor rotation. motor. CHECKS TO BE CARRIED OUT DONE (*) COMMENTS COMPRESSOR Check the general condition of the equipment Remove protection and silica gel bags Remove preservation oils and greases Refit parts which have been removed (coupling.2 : Checks and operations to be carried out after prolonged storage These inspection operations must be carried out with the equipment stopped and power disconnected. pressure gauge. belts. safety valves. thermometers.). etc. Manually check electric motor rotation Table : ‘Checks and inspections to be carried out after prolonged storage‘ (*) tick 7 ..

8 . water solenoid valve if fitted. air temperature controllers. Fill the water circuit. / flow switch. cooling water pr / flow ) Check belt tension or coupling alignment Check connections (air system. load / unload pressure. drain system) Drain the various separators and condensation points.3 : Inspections to be carried out on commissioning or after major works 1: Inspections and adjustments carried out when the system has been shut down INSPECTIONS TO BE CARRIED OUT DONE (*) COMMENTS Check preservation condition Check electrical connections of safety devices (oil pressure switch. Auto drain Traps. air temperature sensor Check trip settings (oil pressure . Voltage and frequency must be identical to those indicated on the motor data plate. drain it and ensure that there are no leaks from any circuit Table : ‘Inspections and checks carried out when the system is not running’ 2: Inspection the direction of rotation This inspection must be carried out after each major electrical intervention. Check that the compressor discharge isolation valve is open Check that water inlet and outlet valves are open Check that vent valves are closed Check oil levels Check electrical connections. water pr. air pressure switch. water system.

on starter equipment .). Check that the frame oil pressure is correct : . If the compressor stops after a few seconds operation check that oil pressure sensor stabilises after a few seconds. After checks and adjustments have been completed again.on the electrical system (mains) INSPECTIONS TO BE CARRIED OUT DONE (*) COMMENTS Close the circuit-breaker Start the compressor in ‘Base Duty’ mode by pressing start push button. In the event of the direction of rotation being wrong. Check that transition from Star to Delta takes place correctly.on the electric motor .5 à 2 bar 9 .1. press the ‘Reset’ button.. reverse wiring at motor. Check that the beltwheel direction of rotation matches that shown by the arrow on the frame (clockwise for the observer located on the beltwheel side. Table : ‘Checks carried out on the direction of rotation’ 3: Starting up CHECKS TO BE CARRIED OUT DONE (*) COMMENTS Close the circuit breaker Select “base Duty’ mode and press ‘Start’ push button Star-Delta starter phase: 10 to 12 second delay to go from first to second. If the compressor does not start. ensure that all checks and adjustments have been correctly carried out. Immediately press the stop push button.

1st stage . Use ammeter to check current input Use thermometers to check water temperature Ensure that there are no leaks on any circuit Table : ‘Start-up’ 4 : Stopping or disconnecting the compressor CHECKS TO BE CARRIED OUT DONE (*) COMMENTS Press the ‘Emergency Stop’ push button.3rd stage Use the temperature controller to establish air temperature sensor settings Check their operation by reducing the pre-set levels until they are actuated After checking. reset to initial levels Check the operation of the load /unload pressure switch on actuation and de-activation Check cooling water pressure / flow switch actuation. 10 .Check discharge pressure at following stages.2nd stage . Switch off the incoming Isolator if provided. .

if freezing is anticipated. drain all cooling circuits when glycol-free water is used. 11 . Table : ‘Shutting down or isolating the compressor’ In winter.Close air valve at compressor delivery. Close water inlet valve and the discharge valve Drain the separators and tanks (drain off condensate).

Chapter :2 Troubleshooting 12 .

Damaged power and Replace faulty fuses. L2. switch. Check wiring and fuses Fault not cleared. NO POWER TO CONTROL Circuit-breaker Actuate Isolation switch PANEL triggered. high’ Insufficient water flow/ pr Check supply water pressure and to actuate flow / pr.1 : The compressor does not start SYMPTOMS CAUSES REMEDY MOTOR OVERLOAD Power and control fuses Identify reason for actuation TRIGGERED damaged Replace faulty fuses Insufficient electrical Check voltage between phases power WILL NOT START IN BASE/ Missing phase (cut-out). L3 and Neutral COMPRESSOR Motor thermal relay Check settings and reset thermal TRIPPED actuated relay. Check no fault present and clear STANDBY DUTY Emergency stop triggered Trigger emergency stop One or more faulty Identify and repair faulty component components. control fuses Check motor insulation and phases . 13 . that the isolating valve has opened. Connect electricity cables L1. Ensure water system free of trapped air. Faulty air temperature See chapter ‘Output temperature too sensor (cylinder outputs). switch Check the water flow / pr. NO TORQUE Normal shut-down in Wait until pressure in the system ‘Standby’ mode after 10 drops before resuming automatic min no-load operation operation. Clear fault.

check the pressure sensor. its setting and the lubrication system. Switch switch COMPRESSOR STOPPED Water pump faulty Check electrical supply to the pump operation and strainer. Resume operation JUST AFTER STARTING If the fault persists. switch Check the water flow / pr. If the fault persists.NO ROTATION Faulty electrical motor Check motor insulation and phases. INSUFFICIENT WATER Water cock not Check the water system and its FLOW completely open supply. that the isolating valve has opened. after start-up delay Reset and clear fault. Ensure water system free of trapped air. SPEED TOO LOW Faulty electrical motor Check motor insulation and phases AIR TEMPERATURE TOO Faulty air temperature See chapter ‘ Output temperature HIGH sensor (cylinder output) too high’ Insufficient water flow/ pr Check supply water pressure and to actuate flow / pr. check pressure 14 . switch. Table : ‘Compressor does not work not work’ 2 : The compressor stops SYMPTOMS CAUSES REMEDY COMPRESSOR TRIPPED Insufficient oil pressure Reset and clear fault. Line Contactor tripped Check oil timer setting (20 seconds). Check the water flow / pr. Faulty water flow / pr. Normal stopping in Wait for air pressure to drop in the ‘Standby’ mode after 10 system before re-starting operation min no-load operation in auto mode.

Not enough mains power Incorrect supply cable section. clear fault and restart. clear fault and restart. check voltage and compressor output air pressure. Reset. check voltage and connections. Electric motor jammed Identify cause. Too many re-starts Restrict number of re-starts or output Thermal relay wiring Check contacts and wiring. If fault persists. its setting and the lubrication system. Faulty motor Check motor. MOTOR: ROTATING AT 3/4 Star-Delta transition Check and adjust delay (10 to 12 NOMINAL SPEED period too short NO ROTATION Overload relay triggered Check contact condition MOTOR OVERLOAD seconds). wiring. Over current Identify cause. disconnected Incorrect mains Consult electrical department frequency Table : ‘Compressor stops operating‘ 15 . Reset. RELAY TRIGGERED If the fault persists.sensor.

Check that Dust / Microfilters are clean. triggered for a pressure which is either too high or too low. Check to see if system air consumption has not been accidentally increased. Look for air leaks. Valve stuck. Blocked air intake filter Replace filter element. Control pressure switch Check pressure switch and setting. PRESSURE NOT ACHIEVED Air demand too high Isolate compressor from mains. replace pressure gauge. Faulty electrical Identify and repair faulty equipment component. Drain system open. Second stage vent sol Check winding electrical connections valve remains open.3 : Discharge pressure not achieved SYMPTOMS CAUSES REMEDY COMPRESSOR IN Air demand too high Isolate compressor from mains. gland Check condition of components. Look for air leaks CONTINUOUS OPERATION Check to see if system air consumption has not been accidentally increased. Leaking valves. Check drain bypass valve. If necessary. packings Replace if required. 16 . NO PRESSURE READOUT Faulty air pressure gauge Check stop cock open. and operation. WRONG SETTINGS Safety valve leaking Check valve. drain sol.

Compressor not Faulty electrical connections. setting. Replace if necessary. SYMPTOMS CAUSES REMEDY 17 . Table : ‘Nominal discharge pressure greater than anticipated’ 5 : Inter-stage pressure when operating under loads higher than anticipated. Check electrical connections. Check air line. Check beltwheel / motor pulley running loose. operating at its normal Re-tension belts speed. Load / unload sol. Faulty pressure switch or Check pressure switch and its settings got disturbed. operation. Check pulley groove wear.Suction valves remain Check unloading systems operation locked open and adjust if required. control air supply pipes. Replace sol. relays and wiring. valve if necessary. Valve Check that there are no leaks in the is not operating. Table : ‘Discharge pressure not achieved’ 4 : Nominal discharge pressure greater than anticipated SYMPTOM CAUSES REMEDY AIR RECEIVER SAFETY Suction valves remain Check condition of unloading VALVE BLOWING closed during unload system.

or discharge suction valves Leaking lower stage Check valve condition and verify safety valve.INTER – STAGE PRESSURE One or more upper stage Check suction valve air tightness. Stage cooler Auto drain Check condition of Auto Drain valve remains open or has Valves. Replace filter element. lower than anticipated’ 18 . Table : ‘ Inter-stage pressure. Faulty first stage intake Replace faulty valves. Table : ‘Inter-stage pressure when operating under loads higher than anticipated‘ 6 : Inter-stage pressure. when operating under load. setting. WHEN OPERATING UNDER in the unloading position. Upper stage piston rings Check upper stage piston rings. TOO HIGH suction valves locked in Check valve gaskets. a major leak. open position or valve Check valve seating for any internals damaged distortion. SYMPTOMS CAUSES REMEDY INTERMEDIATE PRESSURE One or more lower stage Check condition of unloading GAUGE READING LOW suction valves are locked pistons. Replace as required. when operating under load. LOAD Blocked air intake filter. lower than anticipated. Leaking piston rings Check condition of components. leaking.

higher than anticipated SYMPTOMS CAUSES REMEDY INTERMEDIATE PRESSURE Worn upper stage Check and replace as necessary. lower than anticipated SYMPTOMS CAUSES REMEDY INTERMEDIATE PRESSURE Worn lower stage Check and replace as necessary. suction valves locked in operating under load 19 .7 : Inter-stage pressure. Table : ‘ Inter-stage pressure. upper stage discharge valves. IN NO-LOAD OPERATING CONDITIONS. GAUGE READING TOO HIGH discharge valves IN NO-LOAD OPERATING CONDITIONS. higher than anticipated’ 8 : Inter-stage pressure. Unloading system leak Check upper stage unloading system. One or more upper stage Check upper unloading system. no-load operation. no-load operation. GAUGE READING TOO LOW discharge valves. One or more stage suction Check stage unloading system valves remains in operation under load position. towards the upper stage piston Faulty gaskets beneath Replace gasket. no-load operation.

Cooler output Check water circuit and any fouling temperature too high. Lower stage air intake Broken lower stage discharge valve.position. Check water system and fouling. Check and replace as necessary. NO WATER CIRCULATION Faulty gauge. pressure too high. Table : ‘Discharge temperature too high’ 20 . Leaking inter-stage safety Check valve condition and setting. valve. Water circuit valve not Check water system and cooler open. no-load operation. discharge valves TEMPERATURE TOO HIGH Worn piston rings Replace piston rings. Worn piston rings Check piston rings. chambers for fouling. lower than anticipated’ 9 : Discharge temperature too high (intermediate or final) SYMPTOMS CAUSES REMEDY PRESSURE TOO HIGH Faulty stage suction and Check and replace as necessary. of the cooler. Table : ‘ Inter-stage pressure. Water system blocked.

Faulty pressure gauge or Open root valve. Replace cartridge. Top up oil Intake filter or strainer Clean screen. ABNORMAL PRESSURE Not enough oil in VARIATIONS crankcase. closed root valve. Faulty pump. Replace cartridge if clogged. Loosened oil pump. Clogged filter. Carry out an analysis and take appropriate action. Air entrained in pump Check seal and connection sealing. Bypass valve not working Check cleanliness and mechanical 21 . Replace pressure gauge.10 : Oil problems SYMPTOMS CAUSES REMEDY LACK OF PRESSURE Recommended Lubricant Carry out an analysis and act Not used accordingly. ABNORMALLY LOW Oil circuit blocked or Check oil pipe and bearing rotated bearing. Clean strainer. necessary. intake pipe Oil foaming. Clogged strainer. Check bypass valve spring Low grade oil. priming. Carry out an analysis and take PRESSURE appropriate action. Check and replace interconnecting pipe. Top up. No oil. Pump faulty or requires Replace or reprime oil pump. Replace pin. condition.

DEFAULT) Table : ‘Oil problems’ 11 : Noisy operation SYMPTOMS CAUSES REMEDY KNOCKING Too much play in Check and replace as necessary. Connecting rod small end Check connecting rod crosshead pins created play in crosshead. Replace oil pump. Replace pressure gauge. Low grade oil Carry out an analysis and take appropriate action. FOAMING IN CRANKCASE Faulty pressure gauge. Oil pressure too high Re-establish normal pressure. (possible presence of foreign bodies). and small end bushing.. See oil level. Check spring. connecting rod small end and big end. Analyse oil and take appropriate action. Faulty pressure gauge.properly. ABNORMALLY HIGH Bypass valve not working Check condition and cleanliness PRESSURE properly. condition. Replace faulty crosshead pin and bushing. Check spring. Water in crankcase Check oil cooler sealing. Check for possible foreign bodies. Replace pressure gauge. Faulty oil pump. Replace if 22 . Piston loosened from rod Remove unit and check nut and bearing surface. COMPRESSOR STOPS Process switch has Identify and correct symptom. BECAUSE OF ALARM (BY triggered control circuits. Low grade oil.

Tighten the nut and check piston clearances. necessary and tighten up bolts. Tighten valve covers. the piston and the Remove foreign bodies and identify cylinder head (welding source. deposits. Table : ‘Noisy operation’ 23 .necessary. NOISY VALVES Loose valves flapping Check valve condition. Ensure that they are not distorted. splashes. given in Clearance chart at ambient temperature. Cross Head nut loose. Loose connecting rod big Check and replace bearing if end bolts. against seat. Foreign bodies between Replace valves. Piston clearance Adjust the clearances as per values incorrectly adjusted. valve disk Take all necessary steps to avoid fragment) or even water repetition.

4-2 . published or communicated without the Company’s explicit authorisation.Section 4 : Maintenance This document is the property of Chicago Pneumatic Sales and may neither be used.

actual item may vary depending up on the Model of the Compressor This document is the property of Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. 4-3 .piston rotation for monobloc PTFE piston ring _____________________________________________ 1-14 Piston Nut ______________________________________________________________________________ 1-15 Fitting the PTFE monobloc Rider rings________________________________________________________ 1-16 Replacing piston rings _____________________________________________________________________ 1-16 Replacing piston rod packing _______________________________________________________________ 1-17 Crankcase oil ____________________________________________________________________________ 1-19 Cylinder and Head Water jackets ____________________________________________________________ 1-20 Heat Exchangers _________________________________________________________________________ 1-20 Main Bearings ___________________________________________________________________________ 1-20 Lubrication _________________________________________________________________________1-1 1: 3- Oil _____________________________________________________________________________________ 1-2 Maintenance schedule ________________________________________________________________2-1 1: 2: 3: Precautions ______________________________________________________________________________ 2-1 General _________________________________________________________________________________ 2-1 Record Logbook __________________________________________________________________________ 2-2 Note :The Illustration shown in these chapters are indicative..CONTENTS – Section 4 : Maintenance ____________________________________________________________ 4-2 1- Maintenance ________________________________________________________________________1-1 1: 2: 3: 4: 5: 6: 7: 8: 9: 10 : 11 : 12 : 13 : 14 : 15 : 16 : 17 : 18 : 2- Automatic Condensate drain _________________________________________________________________ 1-2 Oil Drain from distance piece chamber _________________________________________________________ 1-2 Belt tension ______________________________________________________________________________ 1-2 Suction filters_____________________________________________________________________________ 1-4 Dust and Micro filters ______________________________________________________________________ 1-5 Miscellaneous control units __________________________________________________________________ 1-5 Torques and clearances _____________________________________________________________________ 1-8 Maintenance of valves ____________________________________________________________________ 1-12 Inspecting rider rings and piston rings and clearance _____________________________________________ 1-13 Rod .

3 : 1-1 .Chapter : 1 . published or communicated without the Company’s explicit authorisation.Maintenance This document is the property of Chicago Pneumatic Sales and may neither be used.

1 : Automatic Condensate drain 1: Functional inspection Functioning of Automatic drain valve (ADT)is one of the important operation since if it not functioning properly the condensate collected in the moisture separators gets carried into the next stages of the compressor cylinders. Hence it is extremely important to inspect the functioning of Automatic Drain Valve periodically. Open the valve.parallel shaft layout . about ½ a litre of oil every day. Since the system is under pressure care must be taken while carrying out manual drainage operation. 3 : Belt tension Satisfactory performance of a V-belt drive relies on: . / motor pulley 3 : 1-2 .belt quality . In order to check whether Automatic Drain Valves are functioning properly - - - - - Manually crack open the bypass valve. Re-fit the valve after assembly. depressurise the pipe line leading to ADT and remove the ADT for maintenance. This document is the property of Chicago Pneumatic Sales and may neither be used. the frequency of automatic draining can be increased or decreased by setting the knob at proper timing marked on the dial. If even after cleaning the chamber. If there is a profused leakage. minor leakage of oil wiper rings is expected. If the oil goes into the cylinder heavy wear of piston and rider rings are expected. For ADTs operated through PLC set the timers in the PLC. As the moisture going in the liquid form washes away the PTFE layer on the cylinder walls. There is also a possibility of dirt or carbon deposits in the oil wiper chamber which is to be cleaned. 2: Adjusting the frequency of automatic draining For ADTs provided with local timer. If lot of water comes out for a longer period then the ADT is not functioning properly. published or communicated without the Company’s explicit authorisation. the piston ring and rider ring wear increases abnormally high. Hence it is essential that the inspection of distance piece is done periodically for oil accumulation. the oil wiper rings need to be attended immediately. 2 : Oil Drain from distance piece chamber The function of oil wiper rings is to ensure that oil from the running gear does not pass into the distance piece chamber along the piston rod and subsequently to the non-lubricated chamber. . Check the coil. In normal operation. Close the ADT isolation valve.correct beltwheel alignment . If the valve is still not functioning properly you may have to replace it. Same can be done by opening the plug or valve provided at the bottom of the distance piece. Clean the orifices and the strainer fitted in it. The oil collected from the distance piece is to be disposed off and not to be reused. the oil leakage persists then oil wiper rings need to be replaced. Follow the procedure for setting the timers outlined in the ‘Starter cum Control Panel’ section. . .clean pulley grooves.

Comments : 1 3 5 Motor Drive pulley Belts 2 4 6 Compressor Ruler Wheel Figure : ‘Belt alignment’ 2: Fitting a new set of belts Belts must be replaced as sets and not individually. 1 2 3 4 5 Tension screw Motor Tension screw Drive pulley Belts Figure : ‘Setting and locking motor position’ 1 3 Drive pulley Wheel 2 4 Compressor Motor Figure : ‘Belt drive’ Proceed as follows : . Compressor and motor shafts must be parallel. 1 to adjust motor in order to ensure that motor and compressor shafts are parallel . 1 and 3 .Therefore. . With the machine stopped. it is recommended that they be checked at frequent intervals and retensioned if necessary. proceed as follows .Use tension screw Ref. Move the deflection cursor to the figure calculated previously. . . .check that motor and compressor shafts are parallel. The complete set will comprise belts of the same quality and length. . published or communicated without the Company’s explicit authorisation.Push the motor towards wheel. . Move the force cursor to the zero position. . 3 : 1-3 . remove old belts .Loosen the tension screws on the slide rails Ref.0156 E).Fit new set of belts .Push motor using tension screws 3 to tension belts . .1: Alignment and parallelism Compressor beltwheel grooves must be properly aligned to those of drive pulley. .use a rule to check wheel/pulley alignment . 3: 1: Checking belt tension Using a tension meter (not in scope of supply) Measure distance between centres and calculate deflection (f = 0.Loosen motor mounting bolts on slide .Tighten motor mounting bolts. Apply the tension meter to the centre This document is the property of Chicago Pneumatic Sales and may neither be used.Belt tension will reduce during initial running hours .

from inside out. Clean the cartridge as follows : - - Remove filter element .point of the belt to obtain the deflection required. 4 : Suction filters 1: Standard filter It is located on the compressor intake. 3 : 1-4 .5. Read the force required indicated by the force cursor. 1 3 Flexion force Belt 2 Deflection Figure : ‘Using a test stylus to measure tension’ 1 Intake filter Figure : ‘Position of intake filter’ Refer to inspection tables for inspection and cleaning frequencies.5 and 5. The force required must be between 4. published or communicated without the Company’s explicit authorisation. compressed air at pressure not exceeding 2-3kg/cm2g. Refit the filter element. then release. This document is the property of Chicago Pneumatic Sales and may neither be used. Vigorously blow.

Figure : ‘Water flow switch’ 2: Low Oil pressure Sensor With the Cp tronic PLC . This document is the property of Chicago Pneumatic Sales and may neither be used. with the manual drain valve open. The filter elements are to be replaced if the above conditions exist.Clean the head. It is recommended to replace the filter elements at least once in a year for better performance. 3 : 1-5 .Bleed off the filter by opening its manual drain valve.Fit the new filter element and refit the head.. close the manual drain valve.To check the operation.Open the filter and remove the filter element. Pressure sensor is provided to measure the Oil pressure. or disconnect an electrical wire from the switch (in case of older models where Pressure SW were provided). . Re-open the valve . .Temporarily close the water inlet valve and check that the PLC sets off the ‘Cooling water flow low fault’..Open the downstream valve. moisture is present in the discharge air). . 6 : Miscellaneous control units 1: Water flow switch Inspect as follows : 1 Filter cartridge Figure : ‘Filter cartridge’ . After draining off for a few seconds. To change the filter element.Progressively increase the setting above the pressure currently shown by the pressure gauge for testing purpose.Close the valves upstream and downstream of the filter. proceed as follows: .. proceed as follows with the compressor running : . published or communicated without the Company’s explicit authorisation.Check the Low oil pressure setting in the Cp tronic. 5 : Dust and Micro filters 1: Maintenance Dust and micro filters are due for maintenance when the pressure drop across the filter exceeds the maximum recommended or when their performance do not match to the requirements (e.Slowly open the valve upstream of the filter. .g. . Ensure the Low oil pressure setting done in Cp tronic.

With CP tronic PLC loading Unloading of the Compressor is achieved by the Pressure Sensor. . published or communicated without the Company’s explicit authorisation. The following actions are required when maintaining or adjusting safety valves : 1: Maintenance Inspection of exhaust orifices to ensure that they are not blocked by impurities and that they are free of any leaks. 3 : 1-6 . DAMAGED BY THE PENETRATION OF HARD If the fault persists. 3: Load / Unload switch In case of the older modes for Loading & Unload of Compressor is achieved by the Pressure Switch.& follow the recommended procedre Electric motor Proceed as follows : 5: Electrical connections Open the main circuit breaker in order to disconnect the system from the mains electricity supply and check condition of wiring and insulation (no hot points. Reconnect compressor to electricity supply.Too check the operation of this component. However sometimes if the valve starts leaking after blowing off it may be necessary to open it for maintenance. WORKING PRESSURE TOO CLOSE TO Set a set pressure which is at least 10% SETTING PRESSURE. SYMPTOMS OPERATIONS TO BE CARRIED OUT VALVE AND SEATING SEALING SURFACES Clean and sand valve seating and disks. Refer to the manual from motor manufacturer for the details.Lubricate bearings at least once a year. FLASHING CORRODED OR WORN SPRINGS Replace springs. This document is the property of Chicago Pneumatic Sales and may neither be used.Reset the setting to original value or reconnect the wire. proceed as follows with the compressor running : ..Check that the PLC trips the compressor on a ‘Low oil pressure fault’ condition . .Progressively decrease the pressure switch setting for testing purposes or disconnect one electrical wire from the switch . Check that the valve cuts in correctly when calibration pressure is reached. machine or lap FOREIGN BODIES surfaces. . blackening. Ensure the Proper setting of loading Unloading Of compressor in the CpTronic PLC 4: . In the case of very significant corrosion..Check that motor cooling fan is running smoothly. Also check terminal blocks. 6: Safety valves Tampering of safety valve settings is prohibited.Check that PLC switches the compressor to unloaded running. Clear any build-up of dust . RESULTING IN higher than the stage discharge pressure. odours). use stainless steel springs. and then reset the setting to its original value or reconnect the electrical wire. Check that all electrical connections are properly tightened in order to reduce any overheating.

Slacken off lock nut and tighten adjustment screw by quarter turns . if the opening pressure is increased. After each test.Tighten the lock nut and re-test opening . . . published or communicated without the Company’s explicit authorisation. the gap diminishes.Blowdown too low Close up valve ring by turning one notch per test.Blowdown too high Move the valve ring away by turning one notch per test. It is adjusted as follows : .Tighten lock nut and re-test opening .Repeat if necessary. . similarly. To increase the set pressure : . . To decrease the set pressure : . For the same ring position. This document is the property of Chicago Pneumatic Sales and may neither be used. the ring remaining free within the space of one notch.Repeat as necessary. inserted between two notches. the ring locator screw must be refitted. 3: Adjusting Blowdown Blowdown is the difference between opening pressure and closing pressure.2: Adjusting the valve Check opening and closing using a calibrated pressure gauge. the gap increases. This gap MUST be adjusted after the opening has been altered. if the opening pressure is reduced. 3 : 1-7 .Slacken off the lock nut and unscrew the setting screw by 1/4 turn at a time . The sole function of the adjustment screw is to prevent the ring from rotating. .

5 49.3 13 18 22 33 45 11 19.2 62 110 67.8 68 95.8 9.8 161 241.3 6.5 2. 3 : 1-8 .7 4. GENERAL TORQUES BOLT DIA mm 10 12 14 16 18 20 22 24 27 30 TORQUE kg-m ft-lbs 1.5 This document is the property of Chicago Pneumatic Sales and may neither be used.7 : Torques and clearances 1: Recommended torque table 1.77 31. COMPONENT 1 2 3 4 Connecting rod bolt Valve lock nut (This nut can be used 3 to 4 times and there after must be replaced) Piston rod nut Crosshead nut TORQUE kg-m HX frames HN frames 9 2/2.5 2. published or communicated without the Company’s explicit authorisation.2 131. SPECIFIC TORQUES FOR COMPRESSOR COMPONENTS.45 22 - 67.5 329.

60 4.75 155.62 27 33.00 325.00 2.04 108. published or communicated without the Company’s explicit authorisation.00 65.21 231.25 50.45 14.2 7.32 30 45.00 54.50 128.72 12 3.50 29.03 31.00 220.40 26.10 79.00 40.56 18 12.82 14 5. 3 : 1-9 .50 37.80 29.51 22 24.50 177.00 238. SPECIFIC TORQUES FOR VALVE HOLDER NUTS THREAD SIZE TORQUE kg-m TORQUE ft-lbs mm MIN MAX MIN MAX 8 1.3.70 6.58 This document is the property of Chicago Pneumatic Sales and may neither be used.5 17.68 10 2.25 8.69 289.37 24 30.00 11.0 1.00 90.50 20 17.48 390.90 41.50 15.00 16 9.60 266.

50 2:1 Ratio - 4 5 6 7 Bumping clearance shall be 2:1 ratio i.11 0.05/0. WEAR LIMITS FOR HX FRAMES SR.25 0.80 0.36 0.15/0.5 mm(Max.e outer end 2 and frame end 1 8 Teflon piston ring end gap 9 Diametrical clearance between piston and cylinder Aluminium piston Teflon rider ring will protrude out from rider ring Groove Min 0.22/0.2: Operating Clearances RUNNING CLEARANCES.09 0.4/100 mm of cyl dia Mix: 8/100 mm of cyl dia 3 to 4 69. COMPONENT RUNNING CLEARENCE mm WEAR LIMITS mm 1 2 3 Diametrical clearance main bearings Diametrical clearance con.20 0.993 x 46 This document is the property of Chicago Pneumatic Sales and may neither be used.951 x 153 69.25 0. Rod big end bearing Diametrical clearance small end bush and Crosshead pin Diametrical clearance crosshead and guide Crankshaft end float/axial clearance Connecting rod big end side clearance Piston bumping clearance 0. published or communicated without the Company’s explicit authorisation.994 / 69.50 0.10 0.50 0.06/0. 3 : 1-10 .970 / 69.25 0.04/0. wear limit) Main journal dia x length Crankpin dia x length 10 11 Min:2.25/0.

06/0.12 WEAR LIMITS Mm 0.08/0.RUNNING CLEARENCES.26 0.5 110.3 0.14/0.00/109.0 This document is the property of Chicago Pneumatic Sales and may neither be used.978X55. WEAR LIMITS FOR HN FRAMES MODELS SR COMPONENT 1 2 3 Diametrical clearance main bearings Diametrical clearance con.222 0.00/109.978X191.70 0.3 0.9 0.e outer end 2 and frame end 1 8 Teflon piston ring end gap 9 Diametrical clearance between piston and cylinder Aluminium piston Teflon rider ring will protrude out from rider ring Groove 10 11 Main journal dia x length Crankpin dia x length Min:2.4/100 mm of cyl dia Mix: 8/100 mm of cyl dia 3 to 4 110. published or communicated without the Company’s explicit authorisation.6 0.3 0.15 0.42 0. 3 : 1-11 .6 2:1 ratio Bumping clearance shall be 2:1 ratio i.4/0. Rod big end bearing Diametrical clearance small end bush and Crosshead pin Diametrical clearance crosshead and guide Crankshaft end float/axial clearance Connecting rod big end side clearance Piston bumping clearance 4 5 6 7 RUNNING CLEARENCE mm 0.33/0.18/0.

Generally remachining is done by concentric grinding and lapping. Do not machine valve seats excessively otherwise there is a danger of breakage. Re-machining has to be extended over entire seat. thus preventing valve leakage. burrs are best removed with fine emery paper. The height of the locating pins/dowel pins will alter after the valve seat has been machined / ground. It is therefore essential that the height of This document is the property of Chicago Pneumatic Sales and may neither be used. The holding pins on the fixture do not permit the valve to rotate when the self locking nut is unscrewed. Be careful not to scratch the valve plate or sears and before installing a valve on the compressor. published or communicated without the Company’s explicit authorisation. Never should a valve be directly tightened in a vice on the shoulder. We allow a maximum wear about 10% of total thickness of valve plate. Locating pins. Please contact the respective Sales office for the Compressor Valves Reconditioning offer. in order to avoid any change of valve lift. 3: Seats For highest efficiency of the valve it is important that seat face is flat and free from any traces of wear. Photo : ‘Discharge flap valve’ Note: It is recommended that valve maintenance is done with the help of trained technician only. Also remachining on centre lathe with very low feed rate may be considered. even if no breakage has occurred. If any damage to the seat face appears. 3 : 1-12 . When cleaning the valve. if fitted. it is imperative to replace these parts. a thorough soaking in trichloroethelene followed by brushing with a soft brush will remove any carbon formation. 1: Valve Dismantling It is advisable to use a simple fixture to facilitate dismantling assembling valves and also to avoid damage to the valve and inside locking pins.3: 8 : Maintenance of valves 1: Inspection and Reconditioning Valve plate When a valve plate or damper plate shoes a sign of wear. Valve plates when worn out more than 10% are to be replaced. Do not hammer on the wrench when loosening or tightening the nut. it is necessary to re-machine and lap the seating areas. particular attention being paid to the seat face being machined plane. If the seat faces show any slight defects. not ground or inverted. 2: Valve Cleaning Examine all parts thoroughly when the valve is dismantled. else the presence of trichloroethelene may cause an explosion. lapping alone may prove satisfactory. have to be removed first before carrying out any operations. including the centre part where lift washers or guide pins are located. these must be replaced immediately. face. 2: Springs and spring plates If springs or spring plates show any type of wear. be absolutely sure that it is completely dry.

. do not install discharge valves upside down failing which a danger of damage may occur. or else there is a danger of either valve or valve seat falling into the cylinder causing sever damage. do not interchange suction and discharge valves.Remove one outer and one inner valve . published or communicated without the Company’s explicit authorisation. by turning the wheel . check the appropriate chapter concerning piston rotation or ring replacement .Use a set of shims/ filler gauge to check that the clearance between the lower part of the piston and the cylinder is at least equal to 0. 1 3 Piston 2 Access through outer head Cylinder/piston clearance Figure : ‘Measuring the cylinder/piston clearance’ Checking piston bumping clearance .the locating pins/ dowel pins is maintained either by grinding these or deepening the holes. measure the clearance between the piston and outer head by inserting filler gauge This document is the property of Chicago Pneumatic Sales and may neither be used. 3 : 1-13 .Bring piston to outer dead centre. 5 mm (1. tighten valve nut to proper torque. Check valve plate for free movement. .Rotate the crankshaft to bring the piston towards outer head. Checking clearance beneath the piston .Refer to the ‘checking and adjustment of cylinder clearance’ chapter : . anew valve plate must be used to ensure proper seating.Bring the piston to top dead centre. .Remove the outer head and one access opening to the crosshead . holding the valve and valve cover in place have to be tightened to specific torques. When the valve seat is re-machined. 4: Re-assembly and Installation 9 : Inspecting rider rings and piston rings and clearance Proceed as follows : . d) When re-installing valves. Should this not be the case. a) after valve has been re-assembled.5 mm in the case of a new piston ring). the clearance between valve plate and lifter as well as the clearance between unloading piston and lifter is to be checked. using the fixture. . e) Valve cover nuts. Also. rotate the compressor manually at least a complete revolution to be certain that there is no interference with moving parts. as far out as possible. f) After all the valves are installed. b) Test valve for leakage and ensure that after testing it is made dry before installing on the compressor. c) For suction valves equipped with unloaders.The compressor has been stopped and all safety instructions carried out .

When the clearance below piston of a piston fitted with monobloc PTFE rings falls to a minimum of 0. If it is damaged. . . 1: 1 4 Rider ring 2 Access to crosshead 5 Piston ring 3 Cross head nut Connecting rod Figure : ‘Piston dismantling line’ Rod .Check these figures before locking off. 3 : 1-14 . 10 : Check condition of rings. refit the components. . ensure that all precautions have been taken. Remove cylinder outer head. . Check for the presence of any additional clearance plate between the cylinder and the outer head : 1 2 Additional clearance plate Head end cylinder head Figure : ‘Additional clearance plate’ This document is the property of Chicago Pneumatic Sales and may neither be used. refer to the appropriate chapter on piston ring replacement .5 mm. loosen the cross head nut (item 3) and separate the rod from the crosshead .piston rotation for monobloc PTFE piston ring Access to the piston Having stopped the compressor and complied with all safety instructions..If there is no damage.from the outer valve pocket.Visually check the condition of the piston rings (items 1 and 2). . Similarly bring the piston to the inner dead centre and measure the clearance between inner head and the piston face.Or replace monobloc PTFE rings as specified in the chapter on ‘Replacement of monobloc PTFE rider rings’ when two rotations have already been carried out.rod assembly provided it has undergone not more than one rotation previously .Rotate the piston . The maximum permissible number of rotations is two.Through the crosshead door. published or communicated without the Company’s explicit authorisation.Withdraw the piston . the user shall either : .

Clearances indicated above are given for an initial clearance of 1 mm inner and 2 mm outer bumping clearance. The adopter is provided with every machine and it is highly recommended that it should be used while loosening or tightening the piston nut. please refer the procedure for the opening of the Piston assembly. This document is the property of Chicago Pneumatic Sales and may neither be used. taking the same precautions as for loosening it. The piston nut should be adequately torqued to the value specified elsewhere failing which there is a danger of loosening the piston assembly during operation. 3: Piston Nut Second rotation This procedure is identical to the initial rotation.2: Initial rotation Remove the suction and discharge valve. Apart from torquing the piston nut it should be locked in position in the notch provided on the rod. Refit the outer head and the additional clearance plate and its gasket if applicable. Rotate the rod piston assembly anti clockwise through 120° as seen by an observer standing in on the outer head side.rod assembly’ Tighten the crosshead nut. 11 : 1 Initial position 2 Final position at 180 degrees Figure : ‘Initial and final positions when rotating a piston . published or communicated without the Company’s explicit authorisation. Through the suction and discharge valve openings measure the bumping clearances. Fit 2 (including 1 additional) new cylinder gaskets side by side (2 x 2 mm). 3 : 1-15 . taking care to immobilise the crosshead with a rod through the crosshead pin in order to prevent the connecting rod from twisting. 1: Description Piston nut (tension nut )provided are of special type . except there are no additional gaskets to be put. Put a mark on the topside of the piston rod. 4: Bumping Clearance (measured cold) CLEARANCE INNER OUTER (FRAME SIDE) (EXTERNAL SIDE) MIN CLEARANCE 1 mm 2 mm AFTER 1ST 2 mm 3 mm 3 mm 2 mm BETWEEN THE PISTON AND THE HEAD ROTATION AFTER 2ND ROTATION Table : ‘Clearance between piston and head’ . from position 1 to position 2. The following table specifies clearances to be kept in cold condition. Rotation is to be effected by rotating the rod from cross head. In case of older Models Piston nut is of a special design and requires a special adopter for fixing it. The rod is provided a square section for putting the spanner for this purpose. Release the crosshead nut.

force the monobloc rider ring down until it is in line with its groove. This document is the property of Chicago Pneumatic Sales and may neither be used.Position piston rings by staggering the gaps. Ensure that it goes down smoothly so that the rider ring remains well within the piston’s axis: .The PTFE grade used . published or communicated without the Company’s explicit authorisation. will partially shrink in contact with the cold piston but will not be fully shrunk. This phenomenon is called ‘plastic memory’. Figure : ‘Complete piston crosshead connecting rod assembly‘ . .Ensure that piston ring moves freely in the groove. distorted under heat at a temperature of X° C. . . 1: Tools required A tapered bush and a thrust collar suitable for the rider diameter (equipment available from Chicago Pneumatic) 2: Fitting Using a bearing collar.Or by evenly striking the upper side of the collar in opposite directions. The monobloc rider ring. 1 Piston nut 2 Piston 3 Piston rod Figure : ‘Piston nut mounting’ 12 : Fitting the PTFE monobloc Rider rings The monobloc rider ring is fitted tight into the groove and has been designed according to the following criteria: .: A PTFE component.The dimensions of the piston and its type . The bearing ring is usually bigger than the piston ring.Either by manually applying pressure to the bearing collar . 1 Rider or piston ring * 2 Piston or bearing ring * 3 Oil slinger 4 Cross Head Nut 5 Crosshead pin 6 Connecting rod * According to the type of cylinder. . once correctly located.Compressor operating conditions. taking care to place the piston ring end gap against the upper section .Position each ring in its groove. 3 : 1-16 . 1 4 Bearing collar Piston 3 Taper bush 2 Rider ring Figure : ‘Stacking components in order to position the monobloc rider ring’ 13 : 1: Replacing piston rings Piston removal Remove the piston and rod assembly as explained in the previous procedures. tends to resume its original shape and dimensions when it is again subjected to a temperature in excess of X° C..

. Proceed as follows while following safety instructions : .Fully withdraw the piston .Continue with the ‘Checking and adjustment of clearances’. .Drain the compressor water system as soon as the cover has cooled .3 min to 8 mm max.3 mm (original) and 8 mm (maximum) (item B) .Remove cross head nut . (item A2) . .Remove oil slinger . check the following clearances : . .Record front and rear clearance figures . Figure : ‘Piston operating clearances’ . . check for noise and air leaks .Release the oil scraper ring flange to avoid damage to oil scraper rings . .Press down on the lower packing ring to remove it from its housing .2: Piston operating clearance 14 : Having replaced the piston in the cylinder. refit the door. . . . .Stop the compressor and comply with safety instructions . . .Mark the piston angular position . recording the part sequence.Rotate the compressor crankshaft to bring the crosshead nut is accessible position.Check that there is approximately 2 mm diametric clearance between the cylinder and the upper part of the piston (item A1) .Carefully withdraw the assembly. This document is the property of Chicago Pneumatic Sales and may neither be used.If there is no noise or air leak. 2: Packing Removal Proceed as follows : A1 : 2 mm approximately (new) A2 : 1. .Check that there is approximately 1. .Remove the packing gland .Unscrew the piston rod .Open the distance piece and cross head doors . . . the clearance at the piston ring gap is between 2. published or communicated without the Company’s explicit authorisation. 1: Replacing piston rod packing Checking packing condition This check is carried out with the machine running.Remove outer cylinder head .Release the crosshead nut. . .With the compressor running.Check that for each 100 mm of diameter and for each 100 °C.5 mm approximately (new) B : 2. .Unscrew the oil slinger screw on the rod.rod assembly having first fitted the protection cap to the threaded end of the rod . 3 : 1-17 . . .5 mm clearance at the bottom of the piston provided rider ring is new.Remove inspection door .

Rotate the wheel so as to bring the piston towards inner dead centre.Remove the packing flange . 4: Assembly This must be done carefully. This document is the property of Chicago Pneumatic Sales and may neither be used.Packing rings must be inserted individually onto the rod.Allow the compressor to run unloaded for 4 to 5 hours.1 1 4 7 Crosshead Oil scraper ring Oil slinger 2 5 8 2 3 Cross head nut Piston rod Packing 4 5 3 6 6 7 8 Inspection door (access to oil scraper rings and crossheads) Inspection door (access to packing) Figure : ‘Removing the packing’ 3: Packing Inspection If the condition of packing is to be observed without removing them then proceed as follows : . making sure it is tightened evenly . In short.Tighten locknut on crosshead while firmly holding the crosshead. on a thoroughly clean rod. . the effectiveness of cylinder sealing at piston rod depends upon the condition of packing rings. . .Set clearances between the piston and the cylinder cover (according to marks made prior to removal) .Open the inspection door on distance piece . . .Fit the oil slinger.Fit the gland packing flange.Set oil slinger position and immobilise it by allowing maximum clearance on the oil scraper ring side to avoid suction .Refit the locknut on the crosshead side . .Inspect the condition of packings . .Lock oil retainer rings and the packing .rod assembly with the protective cap on the threaded end into the cylinder .After having passed through inner head. . . 3 : 1-18 . Ensure that they are laid flat on each of the intermediate plates which precede them . .If the condition is ok put back the packings alongwith their cases in the housing and tighten the gland plate. the oil scraper rings in sequence . stack all the parts comprising the packing onto the rod . published or communicated without the Company’s explicit authorisation. . run at normal pressure in the case of low pressure compressors (8 bar max.Remove the protective cap . 5: Running in and commissioning Proceed as follows : .) and at a pressure reduced by the same amount for high pressure compressors before gradually coming up to pressure .Packing with their cases will come out from the housing.Retighten the rod into the crosshead . . .Put the piston . . If this is not possible.If packing are found to be worn out excessively the they are to be removed as explained above and to be replaced. .

While the machine is running. Add oil. Examine the oil drained off.During this running-in period. above figure ). rust. If the temperature tends to rise. 3 : 1-19 . the oil level should come up to the middle of the oil level indicator (item 2). Clean if necessary. Oil level must not come above the middle of the oil level indicator. stop the machine and remove the packing in order to check whether a packing ring has become jammed in its housing. 1 Filter cartridge Figure : ‘Oil filter' Place a container having a capacity of approximately 0. published or communicated without the Company’s explicit authorisation. above figure). Check that topping up oil is the same as that used in the crankcase. Start the compressor. With the machine running. metal. Clean the oil level indicator. (item 4. Do not use inflammable product. Clean the base of the casing using a lint-free cloth. Moisten the seal using clean oil This document is the property of Chicago Pneumatic Sales and may neither be used. Replace filter cartridge. Check the cleanliness of the oil strainer and filter. 1 Oil strainer Figure : ‘Oil strainer’ 1 4 Oil drain valve Breather 2 Oil level indicator Figure : ‘Oil Level Indicator’ 2: Topping up oil Only recommended oil should be used. Lightly spray the rod with liquid PTFE in aerosol form.. Check that all oil and any condensates have been drained off. Oils from different sources must not be mixed. the oil level should not come higher than the middle of the oil level indicator (item 2. 1: Checking the oil level Place a container under the drain plug (item 1. the oil level must not rise above the middle of the indicator. When it is running. 3: 1: Draining and replacing the oil By gravity 4: Replacing the oil filter 1: Position The filter is located outside the crankcase. Open drain plug and drain oil. Check its colour. the rod temperature can rise to 90 °C. 15 : Crankcase oil Refer to the ‘Lubrication’ chapter for data on lubrication. Top up. and whether it contains any varnish.5 litres beneath the filter to collect the oil. Use a filter spanner to undo the filter cartridge. Remove crankcase breather. above figure).

. Large doors are provided for the inspection of the water jackets. Check for corrosion. scales etc.The inside if the tubes may be cleaned by conventional type of tube cleaning brushes.Remove inspection door . In case they are required to be changed please call Chicago Pneumatic service engineer for doing the job as it is a precision assembly and requires knowledge and experience. scale etc. Only use original Chicago Pneumatic as these cartridges have been specifically designed for this application. mud etc. In order to inspect the water jackets proceed as follows: - - Stop the compressor Close water inlet and outlet valves and drain the cooling water from the compressor Open the metallic doors on the cylinders and outer air heads. Necessary fixtures are available for bearing removal and fitment which may be procured and kept in your maintenance kit for emergency.Adjust pressure by means of calibration screw . . erosion. Hand tighten the cartridge to bring the seal into contact with the filter head Tighten the filter another 1/4 turn using the filter spanner. To clean the coolers follow the procedure given below : - 16 : Cylinder and Head Water jackets Cylinder and Head water jackets are required to be cleaned periodically depending upon the condition of water to improve thermal efficiency. 3 : 1-20 . 17 : LOCTITE : 542 or Heat Exchangers After the unit has worked for three months the water side of the coolers should be checked for erosion. is very little the cylinders and heads can be cleaned in position. refitment should be done using thread This document is the property of Chicago Pneumatic Sales and may neither be used.Release calibration set screw . Remove the fixed head and floating head of the cooler . The outside of the tube bundle can normally be cleaned by using steam. corrosion. 5: Oil pump The oil pump is located inside the crankcase. Otherwise the cylinders and heads are required to be removed and cleaned separately. Proceed as follows : . yearly inspection of the water side of the cooler should be sufficient. a competent water treatment engineer to be consulted for recommendations. published or communicated without the Company’s explicit authorisation. If the cylinder studs are removed for any reason.Pull the tube bundle out . If any of these are noticed. 18 : Main Bearings These bearings are full precision bearings and should not require attention for many months. dirt. If the amount of scales. Top up crankcase oil if necessary. .Retighten set screw and refit inspection door. After the water has been treated properly.and refit the new cartridge. high pressure air. dirt. mud. sealant compound equivalent.

Chapter :2 Lubrication This document is the property of Chicago Pneumatic Sales and may neither be used. published or communicated without the Company’s explicit authorisation. 3 : 1-1 .

reduced performances or increased oil changes. in case of dusty environments . Fill up with oil after replacing the oil cartridge. Kg/cm2g 1. Frequencies specified constitute an average figure and may alter according to the use made of the compressor such as temperature. published or communicated without the Company’s explicit authorisation. As explained in earlier chapters. or if the compressor is placed . This monitoring procedure becomes compulsory. we would remind the reader that different grades of oil must never be mixed. where it does not have clean suction air. 2. Only recommended oil should be used Note: Please contact respective Customer Centre for the details of the Recommended Oil The use of a non-recommended oil without our approval may cause us to withdraw our guarantee. dust levels. Any deviation may result in unsatisfactory compressor operation.19 : Oil:Selecting the oil The compressor running gear requires adequate lubrication for smooth and efficient operation. 3 : 1-2 .5 in steady condition Oil Sump Capacity 15 Litres 35 Litres 70 Litres NOTE: FOR PROPER DISPOSAL OF USED OIL PLEASE ADHERE TO LOCAL ENVIRONMENTAL REGULATIONS 1: Oil replacement The crankcase oil must be replaced after commissioning or no later than after one week’s operation (50 to 100 hours). etc. The crankcase must be cleaned. This document is the property of Chicago Pneumatic Sales and may neither be used. Thereafter replace oil as frequently as specified by the periodic maintenance table. proper grade of oil to be used failing which there is danger of seizure of moving parts leading to major break down. Oil change frequency may be optimised by analysing oil after 500 hours operation. usage rate. Again. OIL SUMP CAPACITY Model HX frame Models HN frame models HN4 frames Oil pr.

Chapter :
2 - Maintenance
schedule

This document is the property of Chicago Pneumatic Sales and may neither be used,
published or communicated without the Company’s explicit authorisation.

3 : 2-1

1 : Precautions
In all cases, refer to general and to company’s inhouse safety procedures. A fault logging
procedure has been established for Chicago
Pneumatic operatives.

1:

Notify personnel

Any personnel who might need to be made
aware, must be informed of possible compressor
shut-down in order to prevent them from
attempting a re-start.

2:

Indication

A ‘WARNING. WORK IN PROGRESS. DO NOT
START UP’ panel must be attached to the

compressor and its control panel for any machine
which is down or being overhauled.

3:

Disconnect electrical power

Disconnect electrical power prior to undertaking
any maintenance work on the compressor. If
possible, padlock the reset device. For further
protection, remove the fuses from the motor
protection or control circuits. Even when the
compressor is disconnected, the supply terminals
in the cabinet remain live. Take special care
when working inside the electrical cabinet, even
when it is disconnected.

4:

Disconnect and allow
pressure to drop

Never dismantle a pressurised component. Never
try to dismantle anything before having
depressurised the system. Use a pressure gauge
to ensure the system is depressurised. Close air
shut-off valve at compressor discharge and open
drain cocks. Close compressor water intake and
discharge valves and drain if necessary.

5:

Equipment integrity

Do not weld. In no way modify pressure vessel
equipment covered by regulation requirements.
Do not undertake any work involving the use of
heat in the vicinity of electrical or hydraulic

circuits.
Only
use
Chicago Pneumatic approved original spare
parts.
Never use a naked flame to inspect the inside of
a compressor or pressure vessel.

6:

Handle products with care

Lubricants and anti-freeze fluids must be
handled with care. Avoid any contact with these
fluids. Follow manufacturer instructions. Any
fluids spilled or any leakages must be recovered
to avoid pollution. Do not use flammable
solvents to clean components. Only use safe
solvents. Petrol and petroleum must be banned.
In some cases, compressed gases may be
dangerous, explosive or flammable. In such
cases, follow special safety instructions
applicable to hazardous products and areas.

7:

Before starting up

Ensure that the installation is free of all
extraneous items (tools, rags, mechanical
components). Close inspection doors, manholes
or hand openings. Do not operate the compressor
when safety are not properly installed. Whenever
the housing is removed, check that the wheel is
properly tightened onto the crankshaft.

2 : General
Our compressors can operate for lengthy periods
without the need for special precautions.
However, we recommend that all units be
inspected at regular intervals. When air is
properly filtered, no significant deposits will be
found in the cylinders. Air pipes and coolers
must also be inspected and cleaned of any dust.
In the case of water systems, remove sludge
deposits and, if necessary, use a non-corrosive
descaler. Intake filters must be cleaned as
frequently as possible to ensure satisfactory
compressor performance. Pressure equipment is
covered by regulations and requires regular
inspection and maintenance. All inspection
results must be made available to Chicago
Pneumatic. Should these inspection procedures

This document is the property of Chicago Pneumatic Sales and may neither be used,
1
published or communicated without the Company’s explicit authorisation.

2-

not be applied, Chicago Pneumatic may
withdraw its guarantee.

3 : Record Logbook
A record logbook should be completed and kept
up to date. The maintenance record log must be
filled in each time an inspection / work is carried
out, giving details of the operation concerned, its
date, and machine running hours.
Keeping a record log is compulsory throughout
the guarantee period.
This log must be submitted to Chicago
Pneumatic personnel each time work is carried
out otherwise , Chicago Pneumatic may
withdraw its guarantee.
The following information constitutes minimum
requirements :
- Date, total, partial, no-load running times
- Pressures and temperatures ;
Operations carried out as recommended in the
manual :
- Check drains, filters, levels, oil change, etc.
Any malfunctions reported and action taken.
Safety checks.

Records should be maintained :
-

Every two hours(for manual drains
only) ;
- Daily operations ;
- Every 500 hours ;
- Every 2000 hours.

Note: Please check with the Local Sales &
Service
office for the periodic check &
maintenance plan offer for the Compressor .
This document is the property of Chicago Pneumatic Sales and may neither be used,
2
published or communicated without the Company’s explicit authorisation.

2-

Section :5 Mark IV CPTronic AND VSD Instructions .

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The BOP features a five-digit. seven-segment display.2). CHK NM-5500 APPD SH 1/6 REV. set points and actual values.1 & 1. alarms. One can change the factory settings to match the application using BOP. values. fault messages. 0 . Figure 1. 1. MICROMASTER 440 is fitted with Basic Operator Panel (BOP) with which it is possible to use the inverter with pre-assigned factory settings (see Fig 1.MARK IV VSD INSTRUCTIONS MARK IV-VSD PANEL VSD used is MICROMASTER 440. NO.1 Basic Operator Panel (BOP) DRN SSG 17/11/06 REV IND ALTERATION BY DATE DCN DRG. It shows parameter numbers. Commissioning with Basic Operator Panel (BOP) One can alter parameter values via the BOP available on drive.

CHK NM-5500 APPD SH 2/6 REV.MARK IV VSD INSTRUCTIONS 1. 0 .2 Buttons on BOP DRN SSG 17/11/06 REV IND ALTERATION BY DATE DCN DRG. NO.1 Buttons on the BOP Fig 1.

NO. Changing parameters with the BOP The procedure for changing the value of parameter P0004 is described below. CHK APPD 0 .MARK IV VSD INSTRUCTIONS 2. SH 3/6 NM-5500 REV. Modifying the value of an indexed parameter is illustrated using the example of P0719. Follow exactly the same procedure to alter other parameters that you wish to set via the BOP.1 Changing parameter via BOP DRN SSG 17/11/06 REV IND ALTERATION BY DATE DCN DRG. 2. Changing P0004 Changing P0719 an indexed parameter Fig.

Press (function button). Note The function button may also be used to acknowledge a fault condition. Changing single digits in parameter values For changing the parameter value rapidly. when set to 1. Press the to leave the parameter value changing level. P0003 (user access level) can be used to select the parameters to be accessed. When P0010=1 is chosen. Change the value of this digit by pressing / . It is important that parameter P0010 is used for commissioning and P0003 is used to select the access level. Press 4. Quick commissioning includes motor and ramp setting parameters. the inverter is then ready to run.MARK IV VSD INSTRUCTIONS Note In some cases . 5. which. NO. This means the 3. Quick Commissioning concludes with P3900. 1.1 Quick commissioning (P0010=1) Mechanical and electrical installation of the inverter must be completed before running Quick Commissioning. CHK NM-5500 APPD SH 4/6 REV. After completing Quick Commissioning with P3900 = 1. will perform the necessary motor calculations and clear all other parameters (not included in P0010 = 1) to the default settings. 3. Perform steps 2 to 4 until the required value is displayed. which causes the right hand digit to blink.the display on the BOP shows inverter is busy with tasks of higher priority. the single digits of the display can be changed by performing the following actions: Ensure you are in the parameter value changing level (see "Changing parameters with BOP"). Commissioning functions with BOP 4. extended and expert. DRN SSG 17/11/06 REV IND ALTERATION BY DATE DCN DRG. set P3900 = 1 to carry out the necessary motor calculations and clear all other parameters (not included in P0010=1) to their default settings. standard. The values for these parameters are either the default settings or are calculated during quick commissioning. Note This applies only in Quick Commissioning mode. 0 . (function button) again causes the next digit to blink. 2. 4. There are three user levels. this will only happen in the Quick Commissioning mode. The lower the access level fewer parameters can be seen while performing Quick commissioning. At the end of the quick commissioning sequence.when changing parameter values .

0 . For motor data identification set P1910=[1] . SSG 17/11/06 REV IND ALTERATION BY DATE DCN DRG. Speed)] Changing the parameter is only possible with P0010=1 Before selecting motor data identification “quick commissioning “has to be performed in advance. Min. Max. CHK NM-5500 APPD SH 5/6 REV.MARK IV VSD INSTRUCTIONS 4. If the motor identification is not within the range of 20(+5˚C) then the correct functioning of V/F control can not be guaranteed. NO. Press start button on drive so data identification starts and VSD display shows “Busy” .A0541 generates warning that motor data identification is active.2 Quick commissioning parameters and value (P0010=1) Parameter Parameter Text Index Index Text Parameter Value P0010 P0003 Commissioning parameter User access level ------- ------- [1] Quick Commissioning [3] Expert use only P0100 Europe/North America ---- ---- P0205 Inverter application ---- ---- [0] Frequency default 50 hz [0] Constant Torque P0300 Select motor type 0 ---- [1] Asynchronous motor P0304 Rated motor voltage 0 1st drive data Motor name plate voltage st P0305 P0307 P0310 Rated motor current Rated motor power Rated motor frequency 0 0 0 1 drive data 1st drive data 1st drive data Motor name plate current Motor name plate power [50]Hz P0311 P0700 P0700 P1000 Rated motor speed Selection of command Selection of command Selection of frequency 0 0 1 0 1st drive data 1st command data 2nd command data 1st command data Motor name plate RPM [1]BOP Set point [1] BOP Set point [1] BOP Set point P1000 P1080 P1082 P1120 Selection of frequency Min. Note • DRN Motor identification must be performed with a cold motor (20˚C). frequency Max. Speed*50Hz)/ (Comp. frequency Ramp-up time 1 0 0 0 2nd command data 1st drive data 1st drive data 1st drive data [1] BOP Set point [*]HZ [50]Hz Varies from 25to 60S P1121 P3900 Ramp down time End of quick commissioning 0 ---- 1st drive data ---- Varies from 35to 80S [1] Note • • *: Minimum Frequency=[(Comp.

SSG 17/11/06 REV IND ALTERATION BY DATE DCN DRG. OFF2 BI:1. NO. OFF3 0 1 0 1 1st command data 2nd command data 1st command data 2nd command data [722:01:00] [722:01:00] [2036:02:00] [2036:02:00] P0852 P0852 P1000 P1000 BI: Pulse enable BI: Pulse enable Selection of frequency Selection of frequency 0 1 0 1 1st command data 2nd command data 1st command data 2nd command data [2036:03:00] [2036:03:00] [2] [5] P2010 P2010 P2011 P2013 USS baud rate USS baud rate USS address USS PKW length 0 1 0 0 Serial Interface Serial Interface Serial Interface 1st command data [7] [7] [1] [3] P2013 P2103 P2104 P2106 USS PKW length BI:1 faults acknowledgement BI:2 faults acknowledgement BI: External fault 1 0 0 0 2nd command data 1st command data 1st command data 1st command data [3] [0] [2036:07:00] [1] Note • DRN For detailed information refer SIEMENS MICROMASTER 440 DRIVE USER DOCUMENTATION (CD) . Parameter P0700 P0700 P0701 P0701 Parameter Text Selection of command Selection of command Function of digital input1 Function of digital input1 Index 0 1 0 1 Index Text 1st command data 2nd command data 1st command data 2nd command data Parameter Value [5] [5] [99] [99] P0702 P0702 P0703 P0703 Function of digital input2 Function of digital input2 Function of digital input3 Function of digital input3 0 1 0 1 1st command data 2nd command data 1st command data 2nd command data [3] [3] [0] [0] P0810 0 Digital input 1 [722:00] P0840 P0840 BI:CDS bit 0 (Local/Remote) BI:ON/OFF1 BI:ON/OFF1 0 1 1st command data 2nd command data [2036:00:00] [2036:00:00] P0844 P0844 P0848 P0848 BI:1. CHK NM-5500 APPD SH 6/6 REV. 0 . Final parameter installation After motor data identification get over it is must to enter following parameters. OFF2 BI:1. OFF3 BI:1.MARK IV VSD INSTRUCTIONS 5.