Comp Manual REV 00 PET

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 Companys 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
published or communicated without the Companys explicit authorization.
Section :1 General
published or communicated without the Companys explicit authorisation.
- 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
Chapter:
1 - Foreword
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.
1-2
Chapter :
2 - Legislation and
Operating
Precautions
2-3
cabinet, even when it is disconnected. Do not

attempt any dismantling whatsoever before
By using this compressor package, the user
must apply sure working methods and
observe all local security instructions and
regulations in force.
When an unspecified statement of this
handbook is not in conformity with the
local legislation, in particular concerning
security, one must apply the strictest of
both.
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. The
same applies to a lack of observation or the
basic lack of good monitoring in handling,
control, maintenance or repair, even if not
explicitly specified in this handbook.
1 : Operating and safety

measures applicable
to compressors
Chicago Pneumatic compressors apply
relatively high operating loads. 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.
In addition to a number of obvious safety
rules, we would submit the following safety
hints :
Disconnect the electrical supply before
commencing any maintenance on the
compressor. The Chicago Pneumatic
compressor is equipped with a disconnect
device. The compressors electricity supply
having been disconnected, the cabinet supply
terminals remain live. Special care must be
taken when working inside the electricity
having released pressure within the system.

Use a pressure gauge to ensure that there is no
pressure. In particular, do not open inspection
openings, hand openings or manholes when
the machine is running. Close inspection
openings, manholes or hand openings before
starting the machine up again. The
compressors rotating components are
protected by a removable guards. Before
starting the machine up, always ensure that
the guard has been properly re-fitted. By its
very design, the compressor heats gas by
compressing it. Supply pipes and cylinders
can reach dangerous temperature levels.
Check the temperature of any component
before touching it. The compressor is
equipped with indicators. Compressors are
noisy units even when noise reduction
provisions
have
been
implemented.
Therefore, the wearing of a soundproofing
helmet is recommended in the vicinity of the
compressor. Take great care when handling
lubricants and anti-freeze fluids. Avoid all
contact with this type of fluid. Follow
supplier recommendations. Recover any
fluids which have leaked or been spilled to
avoid any form of pollution. In some cases,
compressed gases may be dangerous,
explosive or flammable. In such cases, follow
the special safety instructions applicable to
hazardous products and areas. Do not attempt
to work on any part when the machine is
running. Warning: the compressor is geared to
automatic start-up. Do not run the compressor
at pressures greater than the nominal pressure
indicated on the motor data plate. Do not
operate the compressor at speeds greater than
the nominal speed indicated on the motors
data plate. Check the output pressure daily to
ensure that the automatic adjustment system
maintains the compressors operation within
acceptable limits. Regularly check the
satisfactory operation of safety units (oil, air
and water). Never play around with
2-4
compressed air; air under pressure is capable

of inflicting serious injury. Ensure that
spurious items are not left on the equipment
is removed, take the opportunity of checking

the tightening of the wheel onto the
crankshaft.
(tools, rags, mechanical components). Do not

use flammable solvents to clean components.
Do not operate the compressor without
ensuring that housings and protective screens
are properly installed (moving parts, hot
components). Do not fit a stop cock onto the
supply pipe without inserting a safety valve
between the stop cock and the compressor
output. All inspections must be carried out
when the installation is not operating and
power disconnected. Once inspections have
been completed, safety equipment must be
sealed by a Chicago Pneumatic agent. In
winter, in freezing conditions, drain all water
systems when they are not filled with a glycol
solution. Only use manual operation during
the equipment testing phase. The removal of
seals from the valve and alteration of setting
values is formally prohibited. Call in the
Chicago Pneumatic Product Support
Division if the valve sparks. Never use the
compressor in areas where toxic or flammable
fumes might be drawn in. Never use a naked
flame to inspect the inside of a compressor or
pressure vessel. Similarly, attach
a panel stating WARNING. WORK IN
PROGRESS on any machine which is down
or being overhauled. Do not start up may be
placed on the compressor or its control panel.
In such cases, an additional precaution
consists in removing control circuit or motor
protection fuses. 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,
even when these precautions are not explicitly
specified. The compressor comprises heavy
moving parts such as wheels and pistons. It is
therefore recommended to keep away from
these units, even when they are protected by
housings or cylinders. Whenever the housing
2-5
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,
especially when it is located in an area subject

to storms. Under no circumstances may a
claim under warranty be submitted in the case
of equipment damaged by lightning or by its
secondary effects. Under no circumstances
will Chicago Pneumatic be held
responsible for damage caused by lightning to
its electrical installations.
2-6
Chapter :
3 - General features
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.
High Pressure Compressor Package is a

complete unit ready to install, easy to
commission, user friendly to operate, easy to
maintain and extremely reliable package
specifically designed for PET blowing
application.
The package comprises of state-of-art
horizontal balanced opposed reciprocating
water cooled air compressor, water cooled
heat exchangers, drive motor, v-belt drive
system, starters, PLC based control panel,
safety devices, interconnecting air and water
piping, cabling etc. and ordered optional
accessories duly mounted on a rigid deck.
These packages are available in two different
configurations, one on single deck two on
elastic mountings (AVMs) which reduce the
vibrations from being transmitted to the floor,
hence eliminating elaborate civil foundation.
The entire package is assembled and fully
tested before it leaves the factory. All
parameters are set and very little adjustments
are required at site. This reduces the
installation commissioning time considerably.
Customer has to provide air discharge
connection, power connection, cooling water
in and out connections and drain connections
to make the unit ready for commissioning.
Since the package is tested at factory no load
trials are necessary. Customer can put the
compressor directly into the use.
Compressor
control
is
through
a
Programmable Logic Controller i.e. Cp
Tronic PLC with easy to understand
messaging system (MMI) makes the Package
user friendly to operate and diagnose the fault
very quickly. 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.
3-1
Chapter :
4 - Operating principle
4-2
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.
This layout significantly enhances compressor
equilibrium and avoids the need for enhanced
[pile] foundations.
2 : Compression cycle
In effect, this is a two-stroke operation as
described below.
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. The discharge valves
B1 and C1 remain closed during suction
stroke.
During this action, as the volume of the outer
chamber i.e. between the outer face of the
piston and the outer head gets reduced the air
in this chamber gets compressed. It leaves the
cylinder through discharge valves A1 and D1.
while intake valves A and D remain closed.
2
A
Crank end
Suction
B1 Discharge
D Suction
Figure : 'Second compression cycle stroke'
In the reverse stroke, as the piston moves

from outer dead centre to the inner dead
centre compressor takes air in through the
suction valves A and D. The discharge valves
A1 and D1 remain closed during suction
stroke.
During this action, as the volume of the inner
chamber i.e. between the inner face of the
piston and the inner head gets reduced the air
in this chamber gets compressed. It leaves the
cylinder through discharge valves B1 and C1
while intake valves B and C remain closed.
3:
1 Head end
D1 Discharge
Second stroke
Cylinders running in
tandem
Tandem cylinders operate in the same way as

normal cylinders. However, the two
compression strokes take place at different
stages and pressures.
3 : Staging
As per thermodynamic laws when the gas is
compressed suddenly its temperature increases.
Hence if the air is compressed to the discharge
pressure, which is 40 bar in our case, in one
stroke its temperature will shoot up
tremendously high. The metallurgy provided will
not withstand such high temperature. 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. Number of stages shall depend on
4-1
the overall pressure ratio of the compressor. The

present machine is provided with 3 stages. The
first stage cylinder is on one crankpin and the
second and third stage cylinders are on the
second crankpin in tandem arrangement.
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. 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. An air
cooler called aftercooler is provided to bring
down the air temperature to near about ambient
temperature.
4-2
Chapter :
5 - Construction
Compressor Proper
5-1
2:
1 : Consruction of the
compressor
This description solely refers to components
directly associated with air compression.
Ancillary equipment (dryers, electrical
equipments, etc.) are covered in a separate
chapters (see Contents).
1:
Flywheel
The object of the flywheel is to optimise the

compressor's cycle regularity factor.
It is generally mounted on the crankshaft
through a taper key.
Running Gear
'Running Gear' refers to all items associated

with the transmission of reciprocating motion
to the pistons.
1:
Crankcase
Totally enclosed, rigid, made of high grade

cast iron, precision machined and stress
relieved for permanent alignment. It has
following additional features :
- Major rib structure ;
- Large size inspection openings to
facilitate maintenance ;
- Oil tank constituted by the shape of the
casing ;
- 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. It transmits mechanical power
to the pistons. The shaft is provided with oil
seal on the wheel side.
5-2
4:
6:
Main Bearings
This is a thin walled, pressure-lubricated

bearing, in one or two parts, made of steel and
an anti-friction material. The crankshaft rests
on two bearings located on the wheel side.
Distance piece
The distance piece connects the crankcase to

the cylinder.It is fitted with oil scraper rings
to prevent oil travelling from the running gear
towards the cylinders. Large size inspection
openings facilitate access to this component.
Cylinder
Distance piece
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.
The big end bearings are of the thin walled,
anti-friction metal whereas the small end
bearings are of bronze materials.
Crosshead
These are monobloc type SG iron crossheads.

They convert the rotating crankshaft action
into the reciprocating action required by the
pistons.
8:
Crosshead Pin
The crosshead pin connects the crosshead to

the connecting rod. It is made of surface
hardened steel. It is held in position by two
circlips.
9:
Crosshead guide
This device centres the crosshead. It is bolted

to the crankcase.
10 : Oil pump
Attached to the end of the crankshaft, the oil

pump circulates oil under pressure throughout
the lubrication system.
5-3
Downstream of the pump, a disposable 10

micron filter is provided to filter out the oil
before it goes to the bearings. 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.
2 : Cylinders
1
Oil pump
Figure : 'Oil pump location'
11 : Lubrication system
It consists of oil pump, oil filter, oil cooler (in

case of HP-80 and HP-100 compressors only)
a pressure gauge and a low pressure safety
switch. The oil pump provides the system
with pressurised lubricant.
Cylinders provide the compression chambers

in which the piston moves forward and
backward. They are made up of graded cast
iron and have large openings for air and water
passages. On water passages large doors are
provided to facilitate inspection and cleaning
of water chambers. Air chamber houses
suction and discharge valves. The cylinder
bore is honed to the required finish to provide
smooth surface.
3 : Piston rod
Made of a special treated steel, it connects the
crosshead to the piston. It is fitted with a
deflector which stops any lubricant
penetrating into the cylinder.
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.. They are fitted
with rider and piston rings. The piston is fixed
to the rod by means of a piston nut with
adequate torque.
Figure : 'Lubrication system'
5-4
7 : Compressor valves
Photo : Piston
5 : Oil scraper rings
The compressor valve consists of a valve

plate, spring plates or helical springs, the
damper plates and the lift washers. These
parts hare held together by means of valve
seat, valve keeper and the valve stud. The
valves operate automatically based on
differential pressure across them. No. of
suction and discharge valves depends upon
the volume to be handled and the pressure.
These are used to prevent oil going to the

distance piece and to the cylinders. The oil
scraped by the scraper rings goes back to the
crankcase.
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. They are of the self-lubricating
type made of filled teflon material..
8 : Drive units
N.B. Compressor's direction of rotation is
usually clockwise when seen by an observer
standing in front of the wheel.
1:
V-belt drives
The electric motor drives the compressor

wheel via a set of belts. Motor movement
tensions the belts.
Compressor
Flywheel Guard
Motor
fig : Garter spring assembly'
5-5
Chapter :
6 - Construction
Peripheral equipments
6-1
Figure : 'Cooler'
1 : Intake filter
When the compressor intake uses normal
ambient air, the intake is protected from dust
by a filter fitted direct onto the cylinder.
Acoustic pulsations are attenuated by a
soundproof-tube silencer.
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
Filtered air outlet
Air intake
Figure : 'Example of an intake filter'
2 : Coolers
These are of shell and tube removable tube
bundle type design. Air is usually through
tubes and water through shell in counterflow
direction.
This type of cooler may include a pulsation
damper at its inlet and a moisture separator on
the outlet, fitted with a auto drain system.
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. In case one of the O
ring fails water and air streams do not get mixed
up immediately. The Tell Tale holes gives the
information as to which O ring is failed If air
side O ring fails, air will start coming out of the
holes. If water side O ring fails, water will start
coming out from the holes. Thus there is always
a warning of potential danger ahead.
3 : : High pressure Air

Receiver
This is used to damp out pulsations in the
delivery side as well as to store the
compressed air. The air receiver is provided
with safety valve , a pressure gauge and auto
drain valve as a standard. Large inspection
openings are also provided for inspection
purpose.
Coolant
6-2
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. At the down
stream of air dryer a micro filter is provided
to remove particle down to 0.1 microns. Both
these filter are provided with drain valves to
enable remove condensate if gets collected in
the filters. Differential pressure gauge
provided on the filter shows the condition of
the filter.
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.
For further information, please refer a
separate section on the Air Dryer.
Electrical motors are Sq. Cage Induction

motors, suitable for 415 /380 VAC, 3ph, 50
/60 Hz Supply. The construction is totally
enclosed fan cooled (TEFC) and suitable upto
45 degC ambients as a standard. Class of
insulation is F. Motors started via the
electrical cabinet (the relevant wiring diagram
can be found inside the cabinet).
- Compressor motor :
This motor drives the compressor crankshaft.

Its power is supplied via a star / delta starter
unit equipped with the appropriate protection.
7 : The electrical cabinet

It contains all the systems needed for the
satisfactory operation of the compressor, such
as :
- indicating instruments
- starters for motor(s)
- protection devices ;
- controls (PLC based) ;
- man /machine interface ;
Figure : 'Air dryer' The photo graph
is for illustration only actual actual
dryer may vary depending up on the
model offered
6-3
8 : Safety Devices
Following safety devices are provided with
each compressor.
- Pressure Transducers for Oil pressure
- Low cooling water pr. / flow switch
- Temp Transducers
- Capacity control thro PLC
- Solenoid Valves
- electrically operated vent valve
- Safety relief valves
- Motor overload protection
Refer the P &ID Diagram for details of
Instrumantation used.As the Instumantation may
vay depending up on the Model of the
Compressor.l
9 : Auto Drain Traps

When air is cooled after compression,
moisture contained in the air condenses.
Condensate is collected in moisture separators
and in the Air Receivers. Automatic timer
operated drain traps / solenoid valves are
provided to remove the condensate collected
at these points. An isolation and a bypass
valve is provided to facilitate maintenance
without shutting down the compressor.
Auto Drain with By pass ,

Arrangement may vary depending
up on Model
6-4
Section 2 :
Transportation, Storage
and Installation
2-1
- Contents Section 2 : Transportation, Storage and Installation______________________________________ 2-1

1-
Transport, 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, 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,
2 : 1-1
Chapter :
1 - Transport, handling
and storage
2 : 1-1
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.
After having cleared in performance test the
package is taken up for despatch preparations.
Following operations are carried out as a
routine :
-
Cooling water is drained off .

Lub oil in the sump is drained off and the
frame is wiped off.
Internal parts of the fame are provided
with preservative spray.
Valve packets are provided with silica gel
bags to absorb moisture.
AVM mounted packages are provided
with AVM locking devices to avoid
transit movements.
Metallic hoses are removed if under
stress.
Any unsupported pipe / equipment which
may get damaged during transit are
removed and sent loose.
All openings are plugs or blanking plates /
tapes.
Various instruction stickers are put.
All the machined surfaces are protected
with anti-rust oils.
Entire equipment is pained either in
enamel or epoxy paint as the case may be.
Etc. etc.
list with boxwise contents is fixed on the

individual box.
Each box is marked with customers name
address, suppliers name, Gross weight, Net
weight, position of slings, UP arrow, Store
Under Roof symbol etc.
2:
Transport vehicle
The inland transportation is mostly effected in

trucks. Depending upon the size of the package a
closed or open truck is chosen. Transportation is
done through company approved transportation
agency or customer appointed agency.
2 : Unloading at site
Once the consignment is reached the site, it is
the responsibility of the customer to provide
necessary tools and tackles and arrange for
unloading the package. After opening the box
if damages are observed, immediately inform
to the insurance agency and make a report.
Also inform local office of Chicago
Pneumatic for inspection of damages.
1:
Slings
The following recommendations must be

followed :
- The total equipment weight has been
specified in the General Arrangement
drawing.
After having done above preparation the

package unit is packed in a wooded box or
crate. The base frame of the package unit is
firmly bolted to the base of the box.
The number of boxes depend upon the size of
the package and the loose items which do not
constitute the part of main skid. The packing
Slinging point
For lifting purpose always use the lifting
2 : 1-2
hooks provided to the main skid. Do not let

slings bear on the equipment, and especially
not on compressor components which are not
sufficiently resistant to take the load (coolers,
water pipes, electrical cabinet). Do not allow
the slings to come into contact with and
damage paintwork. Avoid using steel slings
with bare cables. in such cases, allow for local
protection over contact points, or, even better,
use the spreader bars (stiffened spreader).
The sling diameter must be appropriate to the
load to be lifted (For guidance, steel sling
diameter for a compressor must be a
minimum of 16 mm). Comply with safety
instructions applicable to handling and lifting.
ambient is likely to be very low where

water freezing occur, drain it
immediately.
In case of V-belt drive, slacken the
belts completely.
Put silica gel bags in the distance piece
chamber.
Plug and seal all opening thoroughly so
the moist air and dirt do nor enter.
3 : Storage
Storage precautions required will depend on
the length of storage time. The Package is
normally protected for 3 months storage when
it leaves the factory. 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, dry location, away from direct
sun, dust, impact, vibration and
freezing conditions ;
Clean the crankcase and fill it with
H.P. RUSTOP-286 oil and rotate the
crankshaft several times to circulate the
oil to all moving parts.
Do not spray RUSTOP-286 in the
cylinders of non-lube compressor.
Place silica gel bags in the valve
pockets and re-fit the valve covers.
Water cooling system for cylinder
jackets and coolers: Drain water from
cooling system and thoroughly flush
with clean water and HP Radiator
cleaner. 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. It
2 : 1-3
Chapter :
2 - Installation
2 : 2-1
1 : General
Following instructions are provided to aid in
the proper installation of the machine. The
instructions given hereunder are intended for
use with the General Arrangement and
Foundation drawings provided for particular
compressor installation. Chicago Pneumatic
service engineers are available to guide you
from selection of site to successful
commissioning of the machine. We
recommend to use their services to avoid
costly installation errors.
1:
AVM mounted compressors do not require

an elaborate foundation but a levelled
industrial floor of adequate bearing capacity.
The unbalanced forces and couples
transmitted to the floor in this type of
machine are very negligible. It is necessary
that 80~90 % of the bottom surface of the
main deck rests on the floor. If there are gaps
between the floor and deck then same are to
be filled with mortar. If the gaps are left
without fillings there is a possibility of
excessive vibrations in the machine.
Location
Install the compressor in clean, dry, well-lit

and ventilated place (preferably having cross
ventilation provision) with sufficient space
reserved for the cleaning, inspection and
maintenance of the unit. Space required for
removal of pistons, heat exchanger tube
bundles etc. is shown in the General
Arrangement drawings. The access doors of
the compressor room should be large enough
to enable take the Package inside the room in
assembled condition only.
An overhead crane of sufficient capacity may
be installed for handling the package
components. Normally electric motor is the
maximum weight to be handled. The capacity
of the crane is to be decided accordingly.
2:
foundation for reciprocating machinery. The

unbalanced forces and couples generated by
the action of the compressor are to be
absorbed by the foundation. A badly designed
foundation will affect the performance of the
machine and reduces its reliability.
Foundation
There are two types of packages available

from Chicago Pneumatic. Packages with
single skid and Packages with Anti Vibration
Mountings (AVMs). Packages with single
skid are required to be mounted on BLOCKTYPE foundation. 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, provisions must be made for
ventilation and a suction duct to remove air
around the compressor. The following
recommendations are compulsory :
- When installing the compressor, avoid
recycling the hot air discharge towards the
air intake ;
- Under no circumstance may the load loss
exceed 5 mm WC ;
- Flow speeds shall not exceed 5 m/sec.
Generally, 90 to 95% of calories will be

evacuated through the water system, the
remainder through ambient air. Chicago
Pneumatic is able to analyse your installation
for the purpose of heat recycling. The
premises should include an adequate air
2 : 2-2
intake for the following :

- Fresh air supply to the compressor when
the filter is fitted direct onto the
compressor ;
- An air intake required for cooling the
electric motor, starter equipment, and
for dissipating
- convection heat (frame, cylinder, pipes,
etc.) ;
- If applicable, the air needed for cooling
radiator cooling (closed circuit water
system ) when it is located within the
compressor room ;
- Fresh air renewal by providing an
adequate hot air outlet in the upper part of
the room.
1
4
Hot air outlet

Fresh air intake
2
A
Paddles
: 1 to 2 meters
Extractor
Figure : Position of air intakes and outlets in the premises
Insert the fixing bolts into the holes left for

this purpose. Insert a 20 millimetre shim on
either side of the anchor bolt.
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
. Lay the compressor chassis on the 20
millimetre shims inserted on either side of the
anchor bolts. Insert the anchor bolts into the
chassis and fix them in position using the first
nut, allowing a length of approximately 30
millimetres to protrude.
3 : Adjustment and
bolting down
1:
Foundation Block
construction
Construct the Foundation Block

according to instructions contained in the
Foundation
Drawing
providing
anchoring points.
- After curing, check anchoring point
conformity and depth of holes provided.
- The slab must be clean and dry, with
unobstructed bolt holes.
- Clean and/or level the areas destined to
take the levelling shims delivered with the
machine.
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.
Tolerance
is
0.5
millimetres/metre. Once the compressor is
levelled, insert the shims of varying thickness
provided over the 20 millimetre shims (Item
3) previously inserted. Allow the compressor
frame to rest on the shims by releasing the
levelling screws (item 4).
2 : 2-3
2:
Bolting down
Pour concrete into the holes left in the

concrete slab and ensure that there is no
shrinkage. Pour finishing concrete between
the slab (item 5) and the chassis (item 1) (see
figure below).
- A high fluidity, shrink-proof concrete
must be used.
- We recommend Shrinkomp Grout of
ACC
Allow it to cure (Refer to product sheet for
time required).
3:
Finalising compressor
installation
Clamp the compressor to the foundation slab.

Fit and tighten lock-nuts (item 2).
in force. 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. Compression glands
must be provided for the removable plate in
the electrical cabinet.
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.
It is imperative that the air sucked in by the
compressor should be clean, dry and cool. 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.
However a flexible hose / pipe is to be installed
between the compressor suction flange and air
intake pipe.
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. Cable section depends on the
current intensity, type of cable, cable length,
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 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.
Avoid critical lengths as it may create
resonance with pulsating flow causing
heavy vibrations in the piping system.
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.
2 : 2-4
3:
Air Discharge Piping
The locations and dimensions of connections

are shown on the General Arrangement
drawing. If possible, there must be no bends
in discharge piping. These pipes must slope
down to the reservoir and, if low points
cannot be avoided, they must be fitted with
drains. Rigid pipes or reinforced hoses may
be used for making connections. Generally,
the safety valve is set for a pressure which is
10% above operating pressure. An isolating
valve must be fitted to compressor discharges,
particularly when several compressors are
discharging into the same space. A safety
valve must be fitted upstream of each valve.
When the systems pipe work is very long and,
in particular, when it is wholly or partly
installed in cooler areas (e.g. sections
installed outside), the following are essential :
- Low points with drains for removing
condensates which are formed when the
systems temperature falls ;
- A 1% gradient.
Further, if operation requires a fully purified
and dehydrated air supply, fit scrubbers,
cooling or adsorption type air dryers
according to the characteristics required of the
purified air.
4:
Cooling Water
Rigid or flexible connections may be fitted as

shown in the two following figures.
Water outlet
Water inlet
Supports
Figure : Flexible coupling
The position and size of inlet and outlet

connections are shown on the General
Arrangement drawings. The inlet water
pressure is recommended between 1.5 to 3.5
kg/cm2g. The inlet water temperature must
not exceed 32 degC and this should be very
strictly taken care off. The water temperature
differential should not exceed 8 to 10 degC
and preferably lower.
A good clean cooling tower water must be
provided for cooling. If cooling water has
high percentage of lime, sulphur, silt, mud or
other impurities, these will be get deposited in
the cylinder jackets, head, coolers etc. The
scale deposits unless removed, will obstruct
the flow of water, lower the rate of heat
transfer and may result in damage to the
equipment.
Please refer General Arrangement or the
Compressor Specifications for cooling water
quality and quantity to be provided.
OPEN TANK
Where the cooling tower is not available and
location requires open tank system, then the
tank should have min. 1 hour circulating
capacity.
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.
Water outlet
Water inlet
Supports
Figure : Rigid coupling

2 : 2-5
5 : Several compressors
installed in parallel
1:
Compressors on the same

system
When several compressors discharge into the

same system, it is recommended that a stop
cock be fitted on the discharge pipe, at the
outlet of each compressor, in order to
facilitate maintenance whilst the other
machines continue running, and a non-return
valve (provided in Chicago Pneumatic
packages if ordered). When a stop valve
closes, it locks the compressors operation.
Compressors must discharge into a system
where pressure is relatively stable. 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. A
compressors purge circuits must be set out in
such a way that the pressure from another
compressor cannot return into its circuits.
Purge circuits may be connected into the same
system subject to standard precautions
applicable in the potential presence of
different pressures. Connection between each
compressor and the trap is shown below.
1 From compressor no. 1

2 From compressor no. 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.
2:
Compressors in the same room
When several compressors are installed in the

same room, adequate ventilation is essential.
6 : Drain Connections
Various drain points in the package are
connected to a common manifold which are
located at the edge of the package. Connect a
suitable drain pipe, preferably 15NB, to the drain
disposal system of the user. 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.
Note :The Illustration shown

in these
chapters are indicative, actual item may vary
depending up on the Model of the
Compressor
2 : 2-6
Section 3 : Operation
Pre start check &
Trouble Shooting.
- CONTENTSSection 3 : Operation .................................................................................................................................. 1

1-
Pre-Startup Checks and Adjustments .......................................................................................................24

1:
2:
3:
4:
3-
4-
Checks to be carried out before commissioning for the first time.............................................................................. 5

Checks and operations to be carried out after prolonged storage ............................................................................... 7
Inspections to be carried out on commissioning or after major works ....................................................................... 8
Stopping or disconnecting the compressor ............................................................................................................... 11
Troubleshooting...........................................................................................................................................12
1:
2:
3:
4:
5:
6:
7:
8:
9:
10 :
11 :
The compressor does not start .................................................................................................................................. 13

The compressor stops ............................................................................................................................................... 14
Discharge pressure not achieved .............................................................................................................................. 16
Nominal discharge pressure greater than anticipated ............................................................................................... 17
Inter-stage pressure when operating under loads higher than anticipated. ............................................................... 18
Inter-stage pressure, when operating under load, lower than anticipated................................................................. 18
Inter-stage pressure, no-load operation, higher than anticipated .............................................................................. 19
Inter-stage pressure, no-load operation, lower than anticipated ............................................................................... 19
Discharge temperature too high (intermediate or final)............................................................................................ 20
Oil problems ............................................................................................................................................................. 21
Noisy operation ........................................................................................................................................................ 22
Chapter :
1 - Pre-Start up Checks
and Adjustments
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.( Applicable for Packages with AVMs )
Refit parts which have been sent loose for transportation
purpose (metallic hoses, piping, valves, instruments, cables
etc..).
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, and then wiped dry with lint
free rags). Fill the crankcase with correct grade of
lubricating oil upto the centre mark of oil level gauge.
Rotate the beltwheel manually in the direction of rotation
for about 20-30 revolutions to ensure bearing lubrication
and free rotation.
Manually check electric motor rotation.
Turn on the cooling water and remove air lock from the
water system.
Drain condensed water from moisture separators and
filters.
Give tension of V belts and tightness them if necessary.
Check all electrical connections for tightness.
Check whether unloading line from the Air Receiver or
discharge piping connected.
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, subject to a minimum of 2 mega ohm, when cold. If
this is not the case, presence of moisture or dust in the windings is indicated, and the motor needs to be
dried out.
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. The temperature should not exceed 85 degC.
Alternatively, 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.
3) By applying DC current not exceeding 80% of the rated current.
The insulation resistance to be checked every hour during drying process till the isulation value stabilises
at certain point. Once this value is stabilised stop the heating process and allow the motor to cool down to
ambient temperature. Measure the isulation value in the cold condition. It should be within the allowable
limits.
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.
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, motor,
belts, safety valves, pressure gauge, thermometers, etc..).
Check electric motor insulation and lubrication
Remove motor shaft lock screw (if fitted)
Manually check compressor rotation.
Manually check electric motor rotation
Table : Checks and inspections to be carried out after prolonged storage
(*) tick
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, air pressure switch, Auto drain Traps, water pr. /
flow switch, water solenoid valve if fitted, air temperature
sensor
Check trip settings (oil pressure , air temperature
controllers, load / unload pressure, cooling water pr / flow )
Check belt tension or coupling alignment
Check connections (air system, water system, drain system)
Drain the various separators and condensation points.
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. Voltage and frequency must
be identical to those indicated on the motor data plate.
Fill the water circuit, 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.
8
- on the electric motor

- on starter equipment
- 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. Immediately press the stop push button.
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.).
In the event of the direction of rotation being wrong,
reverse wiring at motor.
Table : Checks carried out on the direction of rotation
3:
Starting up
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. After checks
and adjustments have been completed again, press the
Reset button.
If the compressor stops after a few seconds operation
check that oil pressure sensor stabilises after a few seconds.
Check that transition from Star to Delta takes place
correctly.
Check that the frame oil pressure is correct :
- 1,5 2 bar
Check discharge pressure at following stages.

- 1st stage
- 2nd stage
- 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.
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

DONE (*)
COMMENTS
Press the Emergency Stop push button.

Switch off the incoming Isolator if provided.
10
Close air valve at compressor delivery.

Close water inlet valve and the discharge valve
Drain the separators and tanks (drain off condensate).
Table : Shutting down or isolating the compressor
In winter, if freezing is anticipated. drain all cooling circuits when glycol-free water is used.
11
Chapter :2
Troubleshooting
12
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).
Check wiring and fuses
Fault not cleared.
Check no fault present and clear
STANDBY DUTY
Emergency stop triggered Trigger emergency stop
One or more faulty
Identify and repair faulty component
components.
NO POWER TO CONTROL
Circuit-breaker
Actuate Isolation switch
PANEL
triggered.
Connect electricity cables

L1, L2, L3 and Neutral
COMPRESSOR
Motor thermal relay
Check settings and reset thermal
TRIPPED
actuated
relay. Clear fault.
Faulty air temperature
See chapter Output temperature too
sensor (cylinder outputs). high

Insufficient water flow/ pr Check supply water pressure and
to actuate flow / pr.
that the isolating valve has opened.
switch
Check the water flow / pr. switch.

Ensure water system free of trapped
air.
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.
Damaged power and
Replace faulty fuses.
control fuses
Check motor insulation and phases .

13
NO ROTATION
Faulty electrical motor
Check motor insulation and phases.
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.
that the isolating valve has opened.
switch
Check the water flow / pr. switch.

Ensure water system free of trapped
air.
Table : Compressor does not work not work
2 : The compressor stops

SYMPTOMS
CAUSES
REMEDY
COMPRESSOR TRIPPED
Insufficient oil pressure
Reset and clear fault. Resume

operation
JUST AFTER STARTING
If the fault persists, check the

pressure sensor, its setting and the
lubrication system.
INSUFFICIENT WATER
Water cock not
Check the water system and its
FLOW
completely open
supply.
Faulty water flow / pr.
Check the water flow / pr. Switch
switch
COMPRESSOR STOPPED
Water pump faulty
Check electrical supply to the pump
operation
and strainer.
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.
Line Contactor tripped
Check oil timer setting (20 seconds).
after start-up delay
Reset and clear fault.

If the fault persists, check pressure
14
sensor, its setting and the lubrication

system.
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).
Faulty motor
Check motor, wiring.
Electric motor jammed
Identify cause.
Reset, clear fault and restart.
RELAY TRIGGERED
If the fault persists, check voltage

and connections.
Over current
Identify cause.
Reset, clear fault and restart.
If fault persists, check voltage and
compressor output air pressure.
Not enough mains power
Incorrect supply cable section.
Too many re-starts
Restrict number of re-starts or

output
Thermal relay wiring
Check contacts and wiring.
disconnected
Incorrect mains
Consult electrical department
frequency
Table : Compressor stops operating
15
3 : Discharge pressure not achieved

SYMPTOMS
CAUSES
REMEDY
COMPRESSOR IN
Air demand too high
Isolate compressor from mains.

Look for air leaks
CONTINUOUS OPERATION
Check to see if system air

consumption has not been
accidentally increased.
Check that Dust / Microfilters are
clean.
NO PRESSURE READOUT
Faulty air pressure gauge Check stop cock open.

If necessary, replace pressure gauge.
PRESSURE NOT ACHIEVED
Air demand too high
Isolate compressor from mains.

Look for air leaks.
Check to see if system air
consumption has not been
accidentally increased.
Blocked air intake filter
Replace filter element.
Leaking valves, gland
Check condition of components.
packings
Replace if required.
Faulty electrical
Identify and repair faulty
equipment
component.
Drain system open.
Check drain bypass valve, drain sol.

Valve stuck.
WRONG SETTINGS
Safety valve leaking
Check valve.
Control pressure switch
Check pressure switch and setting.
triggered for a pressure

which is either too high or
too low.
Second stage vent sol
Check winding electrical connections
valve remains open.
and operation.
16
Suction valves remain
Check unloading systems operation
locked open
and adjust if required.
Compressor not
Faulty electrical connections.
operating at its normal
Re-tension belts
speed.
Check pulley groove wear.

Check beltwheel / motor pulley
running loose.
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.
operation.
Load / unload sol. Valve
Check that there are no leaks in the
is not operating.
control air supply pipes.

Check electrical connections.
Replace sol. valve if necessary.
Faulty pressure switch or Check pressure switch and its

settings got disturbed.
setting. Replace if necessary.

Check air line, relays and wiring.
Table : Nominal discharge pressure greater than anticipated
5 : Inter-stage pressure when operating under loads higher

than anticipated.
SYMPTOMS
CAUSES
REMEDY
17
INTER STAGE PRESSURE
One or more upper stage
Check suction valve air tightness.
TOO HIGH
suction valves locked in
Check valve gaskets.
open position or valve
Check valve seating for any
internals damaged
distortion.
Upper stage piston rings
Check upper stage piston rings.
leaking.
Table : Inter-stage pressure when operating under loads higher than anticipated
6 : Inter-stage pressure, when operating under load, lower

than anticipated.
SYMPTOMS
CAUSES
REMEDY
INTERMEDIATE PRESSURE
One or more lower stage
Check condition of unloading
GAUGE READING LOW
suction valves are locked
pistons.
WHEN OPERATING UNDER
in the unloading position.
LOAD
Blocked air intake filter.
Replace filter element.
Faulty first stage intake
Replace faulty valves.
or discharge suction
valves
Leaking lower stage
Check valve condition and verify
safety valve.
setting.
Leaking piston rings
Check condition of components.

Replace as required.
Stage cooler Auto drain
Check condition of Auto Drain
valve remains open or has Valves.

a major leak.
Table : Inter-stage pressure, when operating under load, lower than anticipated
18
7 : Inter-stage pressure, no-load operation, higher than

anticipated
SYMPTOMS
CAUSES
REMEDY
Worn upper stage
Check and replace as necessary.
GAUGE READING TOO HIGH
discharge valves
IN NO-LOAD OPERATING
CONDITIONS.
One or more stage suction Check stage unloading system

valves remains in
operation under load
position.
Unloading system leak
Check upper stage unloading system.
towards the upper stage

piston
Faulty gaskets beneath
Replace gasket.
upper stage discharge

valves.
Table : Inter-stage pressure, no-load operation, higher than anticipated
8 : Inter-stage pressure, no-load operation, lower than

anticipated
SYMPTOMS
CAUSES
REMEDY
Worn lower stage
GAUGE READING TOO LOW
discharge valves.
IN NO-LOAD OPERATING
CONDITIONS.
One or more upper stage
Check upper unloading system.
suction valves locked in

operating under load
19
position.
Leaking inter-stage safety Check valve condition and setting.
valve.
Table : Inter-stage pressure, no-load operation, lower than anticipated
9 : Discharge temperature too high (intermediate or final)

SYMPTOMS
CAUSES
REMEDY
PRESSURE TOO HIGH
Faulty stage suction and
discharge valves
TEMPERATURE TOO HIGH
Worn piston rings
Replace piston rings.
Lower stage air intake
Broken lower stage discharge valve.
pressure too high.
NO WATER CIRCULATION
Faulty gauge.
Worn piston rings
Check piston rings.
Cooler output
Check water circuit and any fouling
temperature too high.
of the cooler.
Water circuit valve not
Check water system and cooler
open.
chambers for fouling.
Water system blocked.
Check water system and fouling.
Table : Discharge temperature too high
20
10 :
Oil problems
SYMPTOMS
CAUSES
REMEDY
LACK OF PRESSURE
Recommended Lubricant
Carry out an analysis and act
Not used
accordingly.
Pump faulty or requires
Replace or reprime oil pump.
priming.
Loosened oil pump.
Replace pin.
Faulty pressure gauge or
Open root valve.
closed root valve.
Replace pressure gauge.

Check and replace interconnecting
pipe.
ABNORMALLY LOW
Oil circuit blocked or
Check oil pipe and bearing
rotated bearing.
condition.
Clogged filter.
Replace cartridge.
Clogged strainer.
Clean strainer.
No oil.
Top up.
Faulty pump.
Check bypass valve spring
Low grade oil.
Carry out an analysis and take
PRESSURE
appropriate action.
ABNORMAL PRESSURE
Not enough oil in
VARIATIONS
crankcase.
Top up oil
Intake filter or strainer
Clean screen. Replace cartridge if
clogged.
necessary.
Air entrained in pump
Check seal and connection sealing.
intake pipe
Oil foaming.

appropriate action.
Bypass valve not working Check cleanliness and mechanical

21
properly.
condition. Check for possible foreign

bodies. Check spring.
Faulty pressure gauge..
Low grade oil.
Analyse oil and take appropriate

action.
Faulty oil pump.
Replace oil pump.
ABNORMALLY HIGH
Bypass valve not working Check condition and cleanliness
PRESSURE
properly.
(possible presence of foreign bodies).

Check spring.
FOAMING IN CRANKCASE
Faulty pressure gauge.
Low grade oil

appropriate action.
Oil pressure too high
Re-establish normal pressure.
Water in crankcase
Check oil cooler sealing.
COMPRESSOR STOPS
Process switch has
Identify and correct symptom.
BECAUSE OF ALARM (BY
triggered control circuits. See oil level.
DEFAULT)
Table : Oil problems
11 :
Noisy operation
SYMPTOMS
CAUSES
REMEDY
KNOCKING
Too much play in
connecting rod small end

and big end.
Connecting rod small end Check connecting rod crosshead pins
created play in crosshead. and small end bushing.
Replace faulty crosshead pin and
bushing.
Piston loosened from rod
Remove unit and check nut and

bearing surface. Replace if
22
necessary.
Piston clearance
Adjust the clearances as per values
incorrectly adjusted.
given in Clearance chart at ambient

temperature.
Foreign bodies between
Replace valves.
the piston and the
Remove foreign bodies and identify
cylinder head (welding
source.
deposits, valve disk
Take all necessary steps to avoid
fragment) or even water
repetition.
splashes.
Loose connecting rod big
Check and replace bearing if
end bolts.
necessary and tighten up bolts.
Cross Head nut loose.
Tighten the nut and check piston

clearances.
NOISY VALVES
Loose valves flapping
Check valve condition.
against seat.
Ensure that they are not distorted.

Tighten valve covers.
Table : Noisy operation
23
Section 4 : Maintenance
4-2
- 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 - 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, actual item may vary
depending up on the Model of the Compressor
4-3
Chapter :
1 - Maintenance
3 : 1-1
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. As the moisture going in the liquid
form washes away the PTFE layer on the
cylinder walls, the piston ring and rider ring
wear increases abnormally high. Hence it is
extremely important to inspect the functioning
of Automatic Drain Valve periodically.
In order to check whether Automatic Drain
Valves are functioning properly
-
Manually crack open the bypass valve.

Since the system is under pressure care
must be taken while carrying out
manual drainage operation.
If lot of water comes out for a longer
period then the ADT is not functioning
properly.
Close the ADT isolation valve,
depressurise the pipe line leading to
ADT and remove the ADT for
maintenance.
Open the valve. Clean the orifices and
the strainer fitted in it. Check the coil.
Re-fit the valve after assembly.
If the valve is still not functioning
properly you may have to replace it.
2:
Adjusting the frequency

of automatic draining
For ADTs provided with local timer, the

frequency of automatic draining can be
increased or decreased by setting the knob at
proper timing marked on the dial. For ADTs
operated through PLC set the timers in the
PLC. Follow the procedure for setting the

timers outlined in the Starter cum Control
Panel section.
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. If
the oil goes into the cylinder heavy wear of
piston and rider rings are expected.
In normal operation, minor leakage of oil wiper
rings is expected. Hence it is essential that the
inspection of distance piece is done periodically
for oil accumulation. Same can be done by
opening the plug or valve provided at the bottom
of the distance piece. The oil collected from the
distance piece is to be disposed off and not to be
reused.
If there is a profused leakage, about a litre of
oil every day, the oil wiper rings need to be
attended immediately. There is also a possibility
of dirt or carbon deposits in the oil wiper
chamber which is to be cleaned. If even after
cleaning the chamber, the oil leakage persists
then oil wiper rings need to be replaced.
3 : Belt tension
Satisfactory performance of a V-belt drive
relies on:
- belt quality ;
- correct beltwheel
alignment ;
- parallel shaft layout ;
- clean pulley grooves.
motor
pulley
3 : 1-2
1:
Alignment and
parallelism
Compressor beltwheel grooves must be

properly aligned to those of drive pulley.
Compressor and motor shafts must be
parallel.
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 :
- use a rule to check wheel/pulley
alignment ;
- check that motor and compressor shafts
are parallel.
With the machine stopped, proceed as follows

- Loosen the tension screws on the slide
rails Ref. 1 and 3 ;
- Loosen motor mounting bolts on slide ;
- Push the motor towards wheel, remove
old belts ;
- Fit new set of belts ;
- Push motor using tension screws 3 to
tension belts ;
- Use tension screw Ref. 1 to adjust motor
in order to ensure that motor and
compressor shafts are parallel ;
- Tighten motor mounting bolts.
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.
The complete set will comprise belts of the
same quality and length.
- Belt tension will reduce during initial

running hours ;
- Therefore, it is recommended that they be
checked at frequent intervals and retensioned if necessary.
3:
1:
Checking belt tension

Using a tension meter (not in
scope of supply)
Measure distance between centres and

calculate deflection (f = 0,0156 E). Move the
deflection cursor to the figure calculated
previously. Move the force cursor to the zero
position. Apply the tension meter to the centre
3 : 1-3
point of the belt to obtain the deflection

required, then release. Read the force required
indicated by the force cursor. The force
required must be between 4.5 and 5.5.
4 : Suction filters
1:
Standard filter
It is located on the compressor intake.
1
3
Flexion force
Belt
Deflection
Figure : Using a test stylus to measure tension
Intake filter
Figure : Position of intake filter
Refer to inspection tables for inspection and

cleaning frequencies.
Clean the cartridge as follows :
-
Remove filter element ;

Vigorously blow, from inside out,
compressed air at pressure not
exceeding 2-3kg/cm2g;
Refit the filter element.
3 : 1-4
- Slowly open the valve upstream of the

filter, with the manual drain valve open.
After draining off for a few seconds, close
the manual drain valve.
- Open the downstream valve.
6 : Miscellaneous control
units
1:
Water flow switch
Inspect as follows :
1
Filter cartridge
Figure : Filter cartridge
- Temporarily close the water inlet valve

and check that the PLC sets off the
Cooling water flow low fault. Re-open
the valve ;
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.g.
moisture is present in the discharge air).
The filter elements are to be replaced if
the above conditions exist. It is
recommended to replace the filter elements
at least once in a year for better
performance..
To change the filter element, proceed as
follows:
- Close the valves upstream and
downstream of the filter.
- Bleed off the filter by opening its manual
drain valve.
- Open the filter and remove the filter
element.
- Clean the head.
- Fit the new filter element and refit the
head.
Figure : Water flow switch
2:
Low Oil pressure Sensor
With the Cp tronic PLC , Pressure sensor is

provided to measure the Oil pressure. Ensure
the Low oil pressure setting done in Cp
tronic.Check the Low oil pressure setting in
the Cp tronic.To check the operation, proceed
as follows with the compressor running :
- Progressively increase the setting above
the pressure currently shown by the
pressure gauge for testing purpose,, or
disconnect an electrical wire from the
switch (in case of older models where
Pressure SW were provided);
3 : 1-5
- Check that the PLC trips the compressor

on a Low oil pressure fault condition ;
- Reset the setting to original value or
reconnect the wire.
3:
Load / Unload switch
In case of the older modes for Loading &

Unload of Compressor is achieved by the
Pressure Switch..Too check the operation of
this component, proceed as follows with the
compressor running :
- Progressively decrease the pressure
switch setting for testing purposes or
disconnect one electrical wire from the
switch ;
- Check that PLC switches the compressor
to unloaded running, and then reset the
setting to its original value or reconnect the
electrical wire.
With CP tronic PLC loading Unloading of
the Compressor is achieved by the Pressure
Sensor. Ensure the Proper setting of loading
Unloading Of compressor in the CpTronic
PLC
4:
- Check that motor cooling fan is running

smoothly. Clear any build-up of dust ;
- Lubricate bearings at least once a year.
Refer to the manual from motor
manufacturer for the details.& follow the
recommended procedre
Electric motor
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,
blackening, odours). Check that all electrical
connections are properly tightened in order to
reduce any overheating. Also check terminal
blocks. Reconnect compressor to electricity
supply.
6:
Safety valves
Tampering of safety valve settings is

prohibited. However sometimes if the valve
starts leaking after blowing off it may be
necessary to open it for maintenance. 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. Check that the
valve cuts in correctly when calibration
pressure is reached.
SYMPTOMS
OPERATIONS TO BE CARRIED OUT
VALVE AND SEATING SEALING SURFACES
Clean and sand valve seating and disks.
DAMAGED BY THE PENETRATION OF HARD
If the fault persists, machine or lap
FOREIGN BODIES
surfaces.
WORKING PRESSURE TOO CLOSE TO
Set a set pressure which is at least 10%
SETTING PRESSURE, RESULTING IN
higher than the stage discharge pressure.
FLASHING
CORRODED OR WORN SPRINGS
Replace springs. In the case of very

significant corrosion, use stainless steel
springs.
3 : 1-6
2:
Adjusting the valve
Check opening and closing using a calibrated

pressure gauge.
To decrease the set pressure :
- Slacken off the lock nut and unscrew the
setting screw by 1/4 turn at a time ;
- Tighten the lock nut and re-test opening ;
- Repeat if necessary.
To increase the set pressure :
- Slacken off lock nut and tighten
adjustment screw by quarter turns ;
- Tighten lock nut and re-test opening ;
- Repeat as necessary.
3:
Adjusting Blowdown
Blowdown is the difference between opening

pressure and closing pressure.
It is adjusted as follows :
- 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.
For the same ring position, if the opening
pressure is increased, the gap increases;
similarly, if the opening pressure is reduced,
the gap diminishes. This gap MUST be
adjusted after the opening has been altered.
After each test, the ring locator screw must be
refitted, inserted between two notches, the
ring remaining free within the space of one
notch. The sole function of the adjustment
screw is to prevent the ring from rotating.
3 : 1-7
7 : Torques and clearances

1:
Recommended torque table
1. GENERAL TORQUES
BOLT DIA
mm
10
12
14
16
18
20
22
24
27
30
TORQUE
kg-m
ft-lbs
1.5
2.7
4.3
6.8
9.3
13
18
22
33
45
11
19.77
31.5
49.8
68
95.2
131.8
161
241.5
329.5
2. SPECIFIC TORQUES FOR COMPRESSOR COMPONENTS.

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
2/2.45
22
-
67.2
62
110
67.5
3 : 1-8
3. SPECIFIC TORQUES FOR VALVE HOLDER NUTS

THREAD SIZE
TORQUE kg-m
TORQUE ft-lbs
mm
MIN
MAX
MIN
MAX
1.0
1.2
7.25
8.68
10
2.00
2.45
14.5
17.72
12
3.60
4.40
26.03
31.82
14
5.70
6.90
41.25
50.00
16
9.00
11.00
65.10
79.56
18
12.50
15.00
90.04
108.50
20
17.80
29.50
128.75
155.51
22
24.50
29.50
177.21
231.37
24
30.50
37.00
220.60
266.62
27
33.00
40.00
238.69
289.32
30
45.00
54.00
325.48
390.58
3 : 1-9
2:
Operating Clearances
RUNNING CLEARANCES, WEAR LIMITS FOR HX FRAMES
SR.
COMPONENT
RUNNING
CLEARENCE
mm
WEAR
LIMITS mm
1
2
3
Diametrical clearance main bearings

Diametrical clearance con. 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
0.05/0.10
0.06/0.11
0.04/0.09
0.25
0.25
0.20
0.15/0.25
0.25/0.50
0.22/0.36
0.50
0.80
0.50
2:1 Ratio
4
5
6
7
Bumping clearance shall be 2:1 ratio

i.e outer end 2 and frame end 1
Teflon piston ring end gap
Diametrical clearance between piston and

cylinder
Aluminium piston
Teflon rider ring will protrude out from rider
ring Groove
Min 0.5 mm(Max. wear limit)
Main journal dia x length
Crankpin dia x length
10
11
Min:2.4/100 mm of cyl dia

Mix: 8/100 mm of cyl dia
3 to 4
69.970 / 69.951 x 153

69.994 / 69.993 x 46
3 : 1-10
RUNNING CLEARENCES, WEAR LIMITS FOR HN FRAMES MODELS
SR
COMPONENT
1
2
3
Diametrical clearance main bearings

Diametrical clearance con. 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
0.14/0.222
0.08/0.15
0.06/0.12
WEAR
LIMITS
Mm
0.3
0.3
0.3
0.18/0.26
0.4/0.70
0.33/0.42
0.6
0.9
0.6
2:1 ratio
Bumping clearance shall be 2:1 ratio
i.e outer end 2 and frame end 1
8
Teflon piston ring end gap
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
110.00/109.978X191.5
110.00/109.978X55.0
3 : 1-11
3:
8 : Maintenance of
valves
1:
Inspection and
Reconditioning
Valve plate
When a valve plate or damper plate shoes a

sign of wear, it is imperative to replace
these parts, even if no breakage has
occurred. We allow a maximum wear
about 10% of total thickness of valve plate.
Valve plates when worn out more than
10% are to be replaced, not ground or
inverted.
Photo : Discharge flap valve
Note:
It is recommended that valve maintenance is
done with the help of trained technician only.
Please contact the respective Sales office for the
Compressor Valves Reconditioning offer.
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. The holding pins on the fixture
do not permit the valve to rotate when the self
locking nut is unscrewed.
Never should a valve be directly tightened in
a vice on the shoulder. Do not hammer on the
wrench when loosening or tightening the nut.
2:
Valve Cleaning
Examine all parts thoroughly when the valve

is dismantled. When cleaning the valve, a
thorough soaking in trichloroethelene
followed by brushing with a soft brush will
remove any carbon formation. Be careful not
to scratch the valve plate or sears and before
installing a valve on the compressor, be
absolutely sure that it is completely dry, else
the presence of trichloroethelene may cause
an explosion.
2:
Springs and spring plates
If springs or spring plates show any type of

wear, these must be replaced immediately.
3:
Seats
For highest efficiency of the valve it is important

that seat face is flat and free from any traces of
wear, thus preventing valve leakage. If any
damage to the seat face appears, it is necessary
to re-machine and lap the seating areas. Locating
pins, if fitted, have to be removed first before
carrying out any operations. Generally remachining is done by concentric grinding and
lapping. If the seat faces show any slight defects,
lapping alone may prove satisfactory. Also remachining on centre lathe with very low feed
rate may be considered, particular attention
being paid to the seat face being machined plane,
burrs are best removed with fine emery paper.
Do not machine valve seats excessively
otherwise there is a danger of breakage.
Re-machining has to be extended over entire
seat, face, including the centre part where lift
washers or guide pins are located, in order to
avoid any change of valve lift.
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
3 : 1-12
the locating pins/ dowel pins is maintained either

by grinding these or deepening the holes.
When the valve seat is re-machined, anew valve
plate must be used to ensure proper seating.
4:
Re-assembly and Installation
9 : Inspecting rider rings

and piston rings and
clearance
- The compressor has been stopped and all
safety instructions carried out ;
- Remove the outer head and one access
opening to the crosshead ;
- Rotate the crankshaft to bring the piston
towards outer head.
a) after valve has been re-assembled, tighten

valve nut to proper torque, using the
fixture. Check valve plate for free
movement.
b) Test valve for leakage and ensure that
after testing it is made dry before
installing on the compressor.
Checking clearance beneath the piston

- Bring the piston to top dead centre, as far
out as possible, by turning the wheel ;
- 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. 5 mm (1.5 mm in the case of a
new piston ring). Should this not be the
case, check the appropriate chapter
concerning piston rotation or ring
replacement
;
c) For suction valves equipped with

unloaders, the clearance between valve
plate and lifter as well as the clearance
between unloading piston and lifter is to
be checked.
d) When re-installing valves, do not
interchange suction and discharge valves.
Also, do not install discharge valves
upside down failing which a danger of
damage may occur.
e) Valve cover nuts, holding the valve and
valve cover in place have to be tightened
to specific torques, or else there is a
danger of either valve or valve seat falling
into the cylinder causing sever damage.
f) After all the valves are installed, rotate
the compressor manually at least a
complete revolution to be certain that
there is no interference with moving
parts.
1
3
Piston
2
Access through outer head
Cylinder/piston clearance
Figure : Measuring the cylinder/piston clearance
Checking piston bumping clearance

- Refer to the checking and adjustment of
cylinder clearance chapter :
- Remove one outer and one inner valve ;
- Bring piston to outer dead centre,
measure the clearance between the piston
and outer head by inserting filler gauge
3 : 1-13
from the outer valve pocket. Similarly

bring the piston to the inner dead centre
and measure the clearance between inner
head and the piston face.;
- Check these figures before locking off.
10 :
Check condition of rings.

- Through the crosshead door, loosen the
cross head nut (item 3) and separate the

rod from the crosshead
- Withdraw the piston ;
- Visually check the condition of the piston
rings (items 1 and 2). If it is damaged,
refer to the appropriate chapter on piston
ring replacement ;
- If there is no damage, refit the
components.
The maximum permissible number of

rotations is two.
When the clearance below piston of a piston
fitted with monobloc PTFE rings falls to a
minimum of 0,5 mm, the user shall either :
- Rotate the piston - rod assembly provided
it has undergone not more than one
rotation previously ;
- 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.
1:
1
4
Rider ring
2
Access to crosshead 5
Piston ring 3 Cross head nut

Connecting rod
Figure : Piston dismantling line
Rod - piston
rotation for monobloc
PTFE piston ring
Access to the piston
Having stopped the compressor and complied

with all safety instructions, 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
3 : 1-14
2:
Initial rotation
Remove the suction and discharge valve.

Release the crosshead nut, taking care to
immobilise the crosshead with a rod through
the crosshead pin in order to prevent the
connecting rod from twisting. Put a mark on
the topside of the piston rod. Rotate the rod piston assembly anti clockwise through 120
as seen by an observer standing in on the
outer head side, from position 1 to position 2.
Rotation is to be effected by rotating the rod
from cross head. The rod is provided a
square section for putting the spanner for this
purpose.
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

- Clearances indicated above are given for an
initial clearance of 1 mm inner and 2 mm

outer bumping clearance;
11 :
1
Initial position
Final position at 180 degrees
Figure : Initial and final positions when rotating a piston - rod

assembly
Tighten the crosshead nut, taking the same

precautions as for loosening it. Fit 2
(including 1 additional) new cylinder gaskets
side by side (2 x 2 mm). Refit the outer head
and the additional clearance plate and its
gasket if applicable. Through the suction and
discharge valve openings measure the
bumping clearances. The following table
specifies clearances to be kept in cold
condition.
3:
Piston Nut
Second rotation
This procedure is identical to the initial

rotation, except there are no additional
gaskets to be put.
1:
Description
Piston nut (tension nut )provided are of special

type , please refer the procedure for the opening
of the Piston assembly.
In case of older Models Piston nut is of a special
design and requires a special adopter for fixing
it. The adopter is provided with every machine
and it is highly recommended that it should be
used while loosening or tightening the piston
nut.
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.
Apart from torquing the piston nut it should be
locked in position in the notch provided on the
rod.
3 : 1-15
- Or by evenly striking the upper side of

the collar in opposite directions.
The monobloc rider ring, once correctly
located, will partially shrink in contact with
the cold piston but will not be fully shrunk.
Piston nut
Piston
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:
- The dimensions of the piston and its type
;
- The PTFE grade used ;
- Compressor operating conditions.
1
4
Bearing collar
Piston
Taper bush
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.:
A PTFE component, distorted under heat at a

temperature of X C, tends to resume its
original shape and dimensions when it is
again subjected to a temperature in excess of
X C. This phenomenon is called plastic
memory.
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, force the monobloc

rider ring down until it is in line with its
groove. Ensure that it goes down smoothly so
that the rider ring remains well within the
pistons axis:
- 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. The bearing ring is
usually bigger than the piston ring.
Figure : Complete piston crosshead connecting rod assembly
- Position each ring in its groove, taking
care to place the piston ring end gap

against the upper section ;
- Position piston rings by staggering the
gaps.
- Ensure that piston ring moves freely in
the groove.
3 : 1-16
2:
Piston operating
clearance
14 :
Having replaced the piston in the cylinder,

check the following clearances :
- Check that there is approximately 2 mm
diametric clearance between the cylinder
and the upper part of the piston (item A1) ;
- Check that there is approximately 1.5 mm
clearance at the bottom of the piston
provided rider ring is new. (item A2) ;
- Check that for each 100 mm of diameter
and for each 100 C, the clearance at the
piston ring gap is between 2.3 mm
(original) and 8 mm (maximum) (item B) ;
- Continue with the Checking and
adjustment of clearances.
1:
Replacing piston
rod packing
Checking packing
condition
This check is carried out with the machine

running. Proceed as follows while following
safety instructions :
- Remove inspection door ;
- With the compressor running, check for
noise and air leaks ;
- If there is no noise or air leak, refit the
door.
2:
Packing Removal
A1 : 2 mm approximately (new)
A2 : 1.5 mm approximately (new)
B : 2.3 min to 8 mm max.
Figure : Piston operating clearances
- Stop the compressor and comply with

safety instructions ;
- Drain the compressor water system as
soon as the cover has cooled ;
- Record front and rear clearance figures ;
- Remove outer cylinder head ;
- Mark the piston angular position ;
- Open the distance piece and cross head
doors ;
- Rotate the compressor crankshaft to bring
the crosshead nut is accessible position;
- Unscrew the oil slinger screw on the rod;
- Release the crosshead nut,
- Release the oil scraper ring flange to
avoid damage to oil scraper rings ;
- Unscrew the piston rod ;
- Remove cross head nut ;
- Remove oil slinger ;
- Fully withdraw the piston - rod assembly
having first fitted the protection cap to the
threaded end of the rod ;
- Remove the packing gland ;
- Press down on the lower packing ring to
remove it from its housing ;
- Carefully withdraw the assembly,
recording the part sequence.
3 : 1-17
1
1
4
7
Crosshead
Oil scraper ring
Oil slinger
2
5
8
Cross head nut

Piston rod
Packing
5
3
6
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
:
- Open the inspection door on distance
piece
- Remove the packing flange
- Rotate the wheel so as to bring the piston
towards inner dead centre.
- Packing with their cases will come out
from the housing.
- Inspect the condition of packings
- If the condition is ok put back the
packings alongwith their cases in the
housing and tighten the gland plate.
- If packing are found to be worn out
excessively the they are to be removed as
explained above and to be replaced.
4:
Assembly
This must be done carefully. In short, the

effectiveness of cylinder sealing at piston rod
depends upon the condition of packing rings.
- Put the piston - rod assembly with the
protective cap on the threaded end into the
cylinder ;
- After having passed through inner head,
stack all the parts comprising the packing
onto the rod ;
- Packing rings must be inserted individually

onto the rod. Ensure that they are laid flat on
each of the intermediate plates which
precede them ;
- Fit the gland packing flange, making sure
it is tightened evenly ;
- Fit the oil slinger, the oil scraper rings in
sequence ;
- Remove the protective cap ;
- Refit the locknut on the crosshead side ;
- Retighten the rod into the crosshead ;
- Set clearances between the piston and the
cylinder cover (according to marks made
prior to removal) ;
- Lock oil retainer rings and the packing ;
- Set oil slinger position and immobilise it
by allowing maximum clearance on the oil
scraper ring side to avoid suction ;
- Tighten locknut on crosshead while firmly
holding the crosshead.
5:
Running in and
commissioning
- Allow the compressor to run unloaded for
4 to 5 hours, on a thoroughly clean rod. If
this is not possible, run at normal pressure in
the case of low pressure compressors (8 bar
max.) and at a pressure reduced by the same
amount for high pressure compressors
before gradually coming up to pressure ;
3 : 1-18
- During this running-in period, the rod

temperature can rise to 90 C. Lightly spray
the rod with liquid PTFE in aerosol form. If
the temperature tends to rise, stop the
machine and remove the packing in order to
check whether a packing ring has become
jammed in its housing.
15 :
Crankcase oil
Refer to the Lubrication chapter for data on

lubrication.
1:
Checking the oil level
Place a container under the drain plug (item 1,

above figure). Open drain plug and drain oil.
Clean the base of the casing using a lint-free
cloth. Clean the oil level indicator. Do not use
inflammable product. Check that all oil and any
condensates have been drained off. Examine
the oil drained off. Check its colour, and
whether it contains any varnish, rust, metal.
Check the cleanliness of the oil strainer and
filter. Clean if necessary. Replace filter
cartridge. Add oil. Oil level must not come
above the middle of the oil level indicator. Start
the compressor. When it is running, the oil
level must not rise above the middle of the
indicator.
While the machine is running, the oil level

should come up to the middle of the oil level
indicator (item 2).
Oil strainer
Figure : Oil strainer
1
4
Oil drain valve

Breather
Oil level indicator
Figure : Oil Level Indicator
2:
Topping up oil
Only recommended oil should be used.

Remove crankcase breather. (item 4, above
figure). Check that topping up oil is the same as
that used in the crankcase. Oils from different
sources must not be mixed. Top up. With the
machine running, the oil level should not come
higher than the middle of the oil level indicator
(item 2, above figure ).
3:
1:
Draining and replacing

the oil
By gravity
4:
Replacing the oil filter
1:
Position
The filter is located outside the crankcase.
Filter cartridge
Figure : Oil filter'
Place a container having a capacity of

approximately 0.5 litres beneath the filter to
collect the oil. Use a filter spanner to undo the
filter cartridge. Moisten the seal using clean oil
3 : 1-19
and refit the new cartridge. 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. Top up crankcase oil if
necessary. Only use original Chicago
Pneumatic as these cartridges have been
specifically designed for this application.
5:
Oil pump
The oil pump is located inside the crankcase.

- Remove inspection door ;
- Release calibration set screw ;
- Adjust pressure by means of calibration
screw ;
- Retighten set screw and refit inspection
door.
sealant compound
equivalent.
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, corrosion, dirt, scales etc. If any of these
are noticed, a competent water treatment engineer
to be consulted for recommendations. After the
water has been treated properly, yearly inspection
of the water side of the cooler should be sufficient.
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. Large doors are provided for the
inspection of the water jackets. 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.
Check for corrosion, erosion, mud, dirt,
scale etc.
If the amount of scales, mud etc. is very
little the cylinders and heads can be
cleaned in position. Otherwise the
cylinders and heads are required to be
removed and cleaned separately.
Remove the fixed head and floating head

of the cooler
- Pull the tube bundle out
- The inside if the tubes may be cleaned by
conventional type of tube cleaning
brushes.
The outside of the tube bundle can normally be
cleaned by using steam, high pressure air.
18 :
Main Bearings
These bearings are full precision bearings and

should not require attention for many months.
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.
Necessary fixtures are available for bearing
removal and fitment which may be procured
and kept in your maintenance kit for
emergency.
If the cylinder studs are removed for any

reason, refitment should be done using thread
3 : 1-20
Chapter :2
Lubrication
3 : 1-1
19 :
Oil:Selecting the oil
The compressor running gear requires

adequate lubrication for smooth and efficient
operation. As explained in earlier chapters,
proper grade of oil to be used failing which
there is danger of seizure of moving parts
leading
to
major
break
down.
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.
2. OIL SUMP CAPACITY

Model
HX frame Models
HN frame models
HN4 frames
Oil pr. Kg/cm2g

1.5 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
weeks operation (50 to 100 hours). The
crankcase must be cleaned. Fill up with oil
after replacing the oil cartridge. Thereafter
replace oil as frequently as specified by the
periodic maintenance table. Any deviation
may result in unsatisfactory compressor
operation, reduced performances or increased
oil changes. Again, we would remind the
reader that different grades of oil must
never be mixed.
Frequencies specified constitute an average
figure and may alter according to the use
made of the compressor such as temperature,
dust levels, usage rate, etc. Oil change
frequency may be optimised by analysing oil
after 500 hours operation. This monitoring
procedure becomes compulsory, in case of

dusty environments , or if the compressor is
placed , where it does not have clean suction
air.
3 : 1-2
Chapter :
2 - Maintenance
schedule
3 : 2-1
1 : Precautions
In all cases, refer to general and to companys 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
1
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 .
2
2-
Section :5
Mark IV CPTronic
AND VSD
Instructions
MARK IV VSD INSTRUCTIONS

MARK IV-VSD PANEL
VSD used is MICROMASTER 440. 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 1.1 & 1.2).
One can change the factory settings to match the application using BOP.
1. Commissioning with Basic Operator Panel (BOP)
One can alter parameter values via the BOP available on drive. The BOP features a five-digit,
seven-segment display. It shows parameter numbers, values, alarms, fault messages, set points and actual
values.
Figure 1.1 Basic Operator Panel (BOP)
DRN
SSG
17/11/06
REV
IND
ALTERATION
BY
DATE
DCN
DRG. NO.
CHK
NM-5500
APPD
SH
1/6
REV.
0

1.1 Buttons on the BOP
Fig 1.2 Buttons on BOP
DRN
SSG
17/11/06
REV
IND
ALTERATION
BY
DATE
DCN
DRG. NO.
CHK
NM-5500
APPD
SH
2/6
REV.
0

2. Changing parameters with the BOP
The procedure for changing the value of parameter P0004 is described below. 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.
Changing P0004
Changing P0719 an indexed parameter
Fig. 2.1 Changing parameter via BOP

DRN
SSG
17/11/06
REV
IND
ALTERATION
BY
DATE
DCN
DRG. NO.
SH
3/6
NM-5500
REV.
CHK
APPD

Note
In some cases - when changing parameter values - the display on the BOP shows
inverter is busy with tasks of higher priority.
This means the
3. Changing single digits in parameter values

For changing the parameter value rapidly, 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").
1. Press
(function button), which causes the right hand digit to blink.
2. Change the value of this digit by pressing
(function button) again causes the next digit to blink.

3. Press
4. Perform steps 2 to 4 until the required value is displayed.
5. Press the
to leave the parameter value changing level.
Note
The function button may also be used to acknowledge a fault condition.
4. Commissioning functions with BOP
4.1 Quick commissioning (P0010=1)
Mechanical and electrical installation of the inverter must be completed before running Quick
Commissioning.
It is important that parameter P0010 is used for commissioning and P0003 is used to select the
access level.
There are three user levels, standard, extended and expert. The lower the access level fewer
parameters can be seen while performing Quick commissioning. The values for these parameters are either
the default settings or are calculated during quick commissioning.
Quick commissioning includes motor and ramp setting parameters.
Quick Commissioning concludes with P3900, which, when set to 1, will perform the necessary
motor calculations and clear all other parameters (not included in P0010 = 1) to the default settings. After
completing Quick Commissioning with P3900 = 1, the inverter is then ready to run; this will only happen in
the Quick Commissioning mode.
When P0010=1 is chosen, P0003 (user access level) can be used to select the parameters to be
accessed. At the end of the quick commissioning sequence, set P3900 = 1 to carry out the necessary motor
calculations and clear all other parameters (not included in P0010=1) to their default settings.
Note
This applies only in Quick Commissioning mode.
DRN
SSG
17/11/06
REV
IND
ALTERATION
BY
DATE
DCN
DRG. NO.
CHK
NM-5500
APPD
SH
4/6
REV.
0

4.2 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
----
[1] Asynchronous motor
P0304
Rated motor voltage
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 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
Min. frequency
Max. 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. Min. Speed*50Hz)/ (Comp. Max. Speed)]

Changing the parameter is only possible with P0010=1
Before selecting motor data identification quick commissioning has to be performed in
advance.
For motor data identification set P1910=[1] ,A0541 generates warning that motor data
identification is active.
Press start button on drive so data identification starts and VSD display shows Busy .
Note
DRN
Motor identification must be performed with a cold motor (20C). If the motor identification is not
within the range of 20(+5C) then the correct functioning of V/F control can not be guaranteed.
SSG
17/11/06
REV
IND
ALTERATION
BY
DATE
DCN
DRG. NO.
CHK
NM-5500
APPD
SH
5/6
REV.
0

5. Final parameter installation
After motor data identification get over it is must to enter following parameters.
Parameter
P0700
P0700
P0701
P0701
Parameter Text
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

0
1
0
1
1st command data

2nd command data
1st command data
2nd command data
[3]
[3]
[0]
[0]
P0810
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. OFF2
BI:1. OFF2
BI:1. OFF3
BI:1. 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
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) .
SSG
17/11/06
REV
IND
ALTERATION
BY
DATE
DCN
DRG. NO.
CHK
NM-5500
APPD
SH
6/6
REV.
0

Comp Manual REV 00 PET

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Comp Manual REV 00 PET

Uploaded by

Copyright:

Available Formats

Installation Operation

Transportation, Storage &

Pre Start up Checks &

Mark IV CP Tronic And VSD

- Contents Section :1 General____________________________________________________________________ 1

Foreword ________________________________________________________________________________ 1-2

Legislation and Operating Precautions __________________________________________________2-3

Operating and safety measures applicable to compressors __________________________________________ 2-4

General features _____________________________________________________________________3-1

Compressor Package _______________________________________________________________________ 3-1

Operating principle __________________________________________________________________4-2

Functional description ______________________________________________________________________

Compressor Proper _______________________________________________________________________5-1

Consruction of the compressor _______________________________________________________________

Peripheral equipments ____________________________________________________________________6-1

Intake filter ______________________________________________________________________________ 6-2

2 : To obtain the Best Results

cabinet, even when it is disconnected. Do not

1 : Operating and safety

having released pressure within the system.

compressed air; air under pressure is capable

is removed, take the opportunity of checking

(tools, rags, mechanical components). Do not

2 : Area subject to storms

especially when it is located in an area subject

The messaging system also provides the

High Pressure Compressor Package is a

Figure : 'Compression cycle first stroke'

In the forward stroke as the piston moves

Figure : 'Second compression cycle stroke'

In the reverse stroke, as the piston moves

Tandem cylinders operate in the same way as

the overall pressure ratio of the compressor. The

The object of the flywheel is to optimise the

'Running Gear' refers to all items associated

Totally enclosed, rigid, made of high grade

Constructed of SG iron or forged steel with

This is a thin walled, pressure-lubricated

The distance piece connects the crankcase to

Figure : Distance piece location

Figure : 'Location of crankshaft bearings'

These are made of forged steel and equipped

These are monobloc type SG iron crossheads.

The crosshead pin connects the crosshead to

This device centres the crosshead. It is bolted

Attached to the end of the crankshaft, the oil

Downstream of the pump, a disposable 10

Figure : 'Oil pump location'

It consists of oil pump, oil filter, oil cooler (in

Cylinders provide the compression chambers

Oil pressure switch

Oil tank breather

Made of aluminium alloy casting or of

Figure : 'Lubrication system'

5 : Oil scraper rings

The compressor valve consists of a valve

These are used to prevent oil going to the

Figure : Oil scraper rings

The electric motor drives the compressor

fig : Garter spring assembly'

Figure : 'Schematic cross-section of a cooler'

Filtered air outlet

Figure : 'Example of an intake filter'