Chicago Pneumatic CPE 100-150 CPE 125-250 Instruction Book en 2205601002

Code
2205 6010 02
Edition 07/2013
CPE125-180
CPVS125-180
I
Instruction Book
Instruction Book
Table of Content
1 Safety Precautions ................................................... 1
1.1 Safety Icons ............................................................................................................................................ 1

1.2 Safety precautions during installation .................................................................................................... 1
1.3 Safety precautions during operation ....................................................................................................... 3
1.4 Safety precautions during maintenance or repair ................................................................................... 4
2 Introduction .......................................................... 7
2.1 Brief Introduction ................................................................................................................................... 7

2.2 Hazardous Areas ..................................................................................................................................... 7
2.3 Safety Devices ........................................................................................................................................ 8
2.4 Air flow ................................................................................................................................................ 10
2.5 Lubricating Oil System ........................................................................................................................ 10
2.6 Flow Chart .............................................................................................................................................11
2.7 Main parts............................................................................................................................................. 13
2.8 Control Panel and electrical Diagram................................................................................................... 17
2.9 Capacity Controlling ............................................................................................................................ 17
3．Installation ........................................................ 18
3.1 Compressor Room ................................................................................................................................ 18

3.2 Lifting and OOBA ................................................................................................................................ 19
3.3 Dimension Drawing and Technical specification ................................................................................. 20
3.4 Installtion Propose ................................................................................................................................ 22
3.5 Cooling Water Requirements................................................................................................................ 24
3.6 Identify ................................................................................................................................................. 28
4 Operation ........................................................... 30
4.1 Brief Introduction to Operation ............................................................................................................ 30

4.2 Preparation Work for the First Boot ..................................................................................................... 30
4.3 Stop and Emergency Stop..................................................................................................................... 32
4.4 Motor Startup Frequency...................................................................................................................... 32
4.5 Considerations of Compressor in Operation ........................................................................................ 32
4.6 Going Out of Service............................................................................................................................ 33
5 Maintenance ........................................................ 33
5.1 General ................................................................................................................................................. 33

5.2 Preventive Maintenance Program ........................................................................................................ 34
5.3 Clear and change air filter .................................................................................................................... 35
5.4 Fill Oil .................................................................................................................................................. 36
5.5 Replace Oil ........................................................................................................................................... 37
5.6 Replacing Oil Filter .............................................................................................................................. 38
5.7 Replacing oil separator ......................................................................................................................... 38
Instruction Book
5.8 Cooler Maintenance ............................................................................................................................. 39

5.9 The motor bearing greasing .................................................................................................................. 41
5.10 Discharging Condensed Water ........................................................................................................... 41
5.11 Clean the scavenge line ...................................................................................................................... 41
5.12 Safety valve maintenance ................................................................................................................... 42
5.13 Handle the old parts............................................................................................................................ 42
5.14 Service Agreement ............................................................................................................................. 43
5.15 Service Kit .......................................................................................................................................... 43
6 Problem solving ..................................................... 43
7 Principal Data ....................................................... 44
7.1 Overload Relay ..................................................................................................................................... 44

7.2 Fuse and Cable Size ............................................................................................................................. 44
7.3 Reference Condition ............................................................................................................................. 45
7.4 Limit ..................................................................................................................................................... 45
8 Registration Form for Compressor Maintenance ....................... 46
9 Compressor Breakdown Maintenance Records ........................ 47

Instruction Book
1 Safety Precautions
1.1 Safety Icons
Interpretation
Caution
Warning
Important note
1.2 Safety precautions during installation

Warranty shall be provided under the precondition that the machine is commissioned by our expert
engineer or service staff of formally authorized agent only.
All responsibility for any damage or injury resulting from neglecting these precautions, or non observance
of the normal caution and care required for installation, operation, maintenance and repair, even if not
expressly stated, will be disclaimed by the manufacturer.
General Preventive Measures

1． The operator must employ safe working practices and observe all related work safety requirements and
regulations.
2． If any of the following statements does not comply with the applicable legislation, the stricter of the two shall
apply.
3． Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised
personnel.
4． The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the
compressed air must be adequately purified according to the applicable legislation and standards.
5． Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press
the emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power
isolating switch must be opened and locked.
6． Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use
the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and
wear eye protection.
7． The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall be
replaced if unsuitable for safe operation.
8． Standing or walking on the unit roofing is forbidden.
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Precautions during installation

The manufacturer will assume no liability for any damage or injury resulted from negligence of these
preventive measures or failure in abiding by the normal warning and notices (even though not specified) on
installation, operation, maintenance and repairing.
1． The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations.
Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk
zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety
helmet when working in the area of overhead or lifting equipment.
2． This equipment is typically designed for indoor operation.
3． Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct.
Never obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air.
4． Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5． Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn
hoses. Distribution pipes and connections must be of the correct size and suitable for the working pressure.
6． The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, which can lead to
internal fire or explosion.
7． Arrange the air intake so that loose clothing worn by people cannot be sucked in.
8． Ensure that the discharge pipe from the compressor to the after cooler or air net is free to expand under heat
and that it is not in contact with or close to flammable materials.
9． No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10． If remote control is installed, clear warning sign indicating:" dangerous! This machine is subject to remote
control and may start up without warning" must be marked with on the machine.
Prior to maintenance or repairing, the operator must make sure that the machine has been stopped and the
isolating switch has been opened and locked.
For further safety guarantee, staff switching on the power source of the remote control machine should take
sufficient preventive measures to make sure that no one is checking or operating the machine. Thus,
corresponding notice should be stuck to the starting equipment.
11． Air-cooled machine must be installed to meet the following requirements: enough cooling air can be available;
waste air will not recirculated into the air inlet of compressor or cooling air inlet.
12． Electrical connection must be in keeping with the local regulations. The machine must be connected to the
earth and fuse must be installed in each phase to prevent short circuit.
Lockable isolating switch of power source must be mounted near the compressor.
13． Warning sign indicating "this machine may be started up without warning" must be stuck near the instrument
panel of machine on which automatic starting- shutdown system is mounted or function of automatic restarting
after power failure is activated.
14． Manual valve must be mounted to isolate each compressor in a system with multiple compressors. Pressure
system shall not be isolated with check valve (non-return valve).
15． Please don't remove or tamper with the safety device, protective device or insulator configured on the machine.
One or more pressure relief devices must be mounted as required to protect each pressure vessel or auxiliary
equipment installed outside of the machine, in which the air pressure is greater than atmospheric pressure.
16． Pipework or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally touched
by personnel in normal operation must be guarded or insulated. Other high-temperate pipework must be clearly
marked.
17． The cooling water system installed outside the machine has to be protected by a safety device with set
pressure according to the maximum cooling water inlet pressure.
18． If the ground is not level or can be subject to variable inclination, consult the manufacturer.
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The following safety measures, i.e. safety measures during operation process and safety measures
during maintenance process may also be referred to.
These preventive measures apply to machining, air consumed or inert gases.
The treatment of any other gases shall follow the additional safety measures generally applied to other
products uncovered here.
Some preventive measures are universal to a certain degree and cover a number of machine types and
equipment; thus, some instructions may not apply to your machine.
1.3 Safety precautions during operation

All responsibility for any damage or injury resulting from neglecting these precautions, or non
observance of the normal caution and care required for installation, operation, maintenance and repair,
even if not expressly stated, will be disclaimed by the manufacturer.
General precautions
1． The operator must employ safe working practices and observe all related work safety requirements and
regulations.
apply.
personnel.
compressed air must be adequately purified according to the applicable legislation and standards.
6． Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use
the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and
wear eye protection.
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Precautions during operation

1． Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line,
ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is
fully depressurized before disconnecting it.
2． Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no
one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start
equipment.
3． Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or particles.
4． Never operate the machine below or in excess of its limit ratings.
5． Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry
out routine checks. Wear ear protectors when opening a door.
6． People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall
wear ear protectors.
7． Periodically check that:
z All guards are in place and securely fastened
z All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
z There are no leaks
z All fasteners are tight
z All electrical leads are secure and in good order
z Safety valves and other pressure-relief devices are not obstructed by dirt or paint
z Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear
or abuse
8． If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workshop take
precautions against air pollution and possible contamination of the breathing air.
9． Do not remove or tamper with any sound insulation material.
10． Do not remove or tamper with safety device, protective device or insulator mounted on the machine.
One or more pressure relief devices must be mounted as required to protect each pressure vessel or auxiliary
equipment installed outside of the machine, in which the air pressure is greater than atmospheric pressure.
The following safety measures, i.e. safety measures in operation process and safety measures in
maintenance process may also be referred to.
Some preventive measures are universal to a certain degree and cover a number of machine types
and equipment; thus, some instructions may not apply to your machine.
1.4 Safety precautions during maintenance or repair

All responsibility for any damage or injury resulting from neglecting these precautions, or non
observance of the normal caution and care required for installation, operation, maintenance and repair,
even if not expressly stated, will be disclaimed by the manufacturer.
General precautions
1． The operator must employ safe working practices and observe all related local work safety requirements and
regulations.
apply.
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Instruction Book
personnel.
compressed air must be adequately purified according to local legislation and standards.
6． Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the
air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear
eye protection.
Precautions during maintenance or repair
1． Please always use appropriate protective articles (e.g. safety glasses, gloves and safety shoes, etc.).
2． Use only the correct tools for maintenance and repair work.
3． Use only genuine spare parts.
4． All maintenance work shall only be undertaken when the machine has cooled down.
5． A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting
equipment.
6． Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no
one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start
equipment.
7． Close the compressor air outlet valve before connecting or disconnecting a pipe.
8． Before removing any pressurized component, effectively isolate the machine from all sources of pressure and
relieve the entire system of pressure.
9． Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic
vapours of cleaning liquids.
10． Observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed
openings with a clean cloth, paper or tape.
11． Never weld or perform any operation involving heat near the oil system. Vessels must be completely purged,
e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure
vessels.
12． Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine
shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to
avoid the risk of spontaneous ignition of the oil vapour when air is entering.
13． Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14． Make sure that no tools, loose parts or rags are left in or on the machine.
15． All regulating and safety devices shall be maintained with due care to ensure that they function properly. They
may not be put out of action.
16． Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that they
function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled.
17． Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator
vessel for carbon deposits; if excessive, the deposits should be removed.
18． Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them,
e.g. when steam-cleaning.
19． Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork and
in the air inlet and outlet systems of the compressor, are in good condition. If damaged, replace it by genuine
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material from the manufacturer to prevent the sound pressure level from increasing.
20． Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate base.
21． The following safety precautions are stressed when handling refrigerant:
z Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.
z Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid
refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with
fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.
22． Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
The following safety measures, i.e. safety measures in operation process and safety measures in
maintenance process may also be referred to.
Some preventive measures are universal to a certain degree and cover a number of machine types and
equipment; thus, some instructions may not apply to your machine.
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2 Introduction
2.1 Brief Introduction

Description
CP Series Screw Compressors are single stage, oil-injected screw compressors, driven by an electric motor
and enclosed in sound-insulated bodywork.
2.2 Hazardous Areas
1 2 3 4 5 6 7
Safety Valve Danger! Irrespirable High-tempera Noise With Internal The Fan May
Electric High ture Parts Pressure Injure Your
Voltage! Hands
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2.3 Safety Devices

1) Safety bolt 6) Differential pressure warning of air
intake filter
2) Electrical cabinet doors and doors can be opened 7) Differential pressure warning of oil filter
only with special keys
3) Fan protection 8) Differential pressure warning of oil
separator
4) Emergency stop button 9) Safety valve
5) Motor phase sequence protection 10) Electrical cabinet, vessel earthing
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safety valve The safety valve installed on the vessel, in case the capacity controlling is failure or the separator
clogged, the pressure in the vessel will rise continuously, when reaches to the safety valve set point, the valve will
open and releases the vessel pressure to the safe pressure. The safety valve will be closed automatically when the
pressure drops to the closing pressure of safety valve.
High pressure protection When working pressure goes beyond the setting value (rated working
pressure+0.12MPa), the controller will cut off the power source automatically to enable the compressor will
emergency stop. A message will be displayed on the display.
High temperature protection when Element discharge temperature reaches to the set point (115℃), the
compressor will be stopped automatically.
Low cooling water flow protection When there is a shortfall of water cooling or water flow, the water flow
switch will act. If the water flow fails to come back to normal in 20 seconds and the exhuast temperature has risen to
110℃, then the power source of motor will be cut off automatically and the compressor will stop.
Oil filter, oil separator and air filter blocked warning When the oil filter, oil separator or air filter is blocked
and the differential pressure goes beyond the setting value, the differential pressure indicator will act and there will be
a prompt of "replacing new parts" on the display screen of the control panel.
Electric protection functions: Phase sequence protection (preventing the inversion of compressor) and open
phase function as well as motor's thermal overload protection function.
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2.4 Air flow

Description
Air →Air filter 1→Unloader 4→Element 13→Oil stop Valve 12→Oil Separator 8、9→Min pressure valve 54→Air
cooler 20→water separator 22→Air outlet (Air supply) .
The condensate separate is drained by solenoid valve 23.
14
6
7
12 10
13 8
20
Cooling water 11
Inlet
21
Cooling water
Outlet 9
18 17 15
16
22
23
19
2.5 Lubricating Oil System

Description
Lubricating oil→Oil separator 9→Thermostatic valve 17→Cooler 19 OR Bypass →Oil filter 15→Oil stop valve
12→Element 13
The Mix of air and oil goes into the vessel and oil will be pre-separator, most of the oil is separated out and the
rest small portion of oil is then separated out by the oil separator 9. The oil then pumped out by the pipe inserted in
the bottom of the oil separator and flows to the element low pressure section Via non stop valve 10，which function to
pump out the oil out completely, while not letting too much compressed air out. If the non stop valve is blocked, the oil
separator will be filled with oil, seriously affecting the separation effect.
The hot oil in vessel flows to the thermostat valve, which controls over the proportions of oil flowing to the cooler
and bypass according to the temperature of oil inflow so that the element outlet temperature will not be too low
(ambient temperature+50℃). Extremely low element outlet temperature will cause condensation and make the
oil be emulsified and useless. At last, the oil is injected into the element via oil filter.
Lubicating oil circulation is maintained by the differential pressure between the vessel and the low-pressure
chamber of element . To keep the oil circulating in the running process of the machine, there must be a pressure of
0.07-0.09MPa in the vessel all the time, and the minimum pressure valve 5 is exactly designed for this purpose.
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2.6 Flow Chart

Flow chart of air cooled system
6
7
22 20
10
8
18 14 13 12
11
9
17 15
21 16
19
Flow chart of air cooled system
No. Name No. Name

1 Air filter 12 Oil stop valve
2 Pressure different sensor 13 Element
3 Solenoid 14 Motor
4 Unloader Check valve 15 Oil filter
5 Minimum pressure valve 16 Pressure different sensor
6 Pressure different sensor 17 Thermostat valve
7 Safety valve 18 Air cooler
8 Oil separator 19 Oil cooled
9 Vessel 20 Water separator
10 Non stop valve 21 Drain solenoid valve
11 Temperature sensor 22 Pressure sensor
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Flow chart of water cooled system
14
6
7
12 10
13 8
20
Cooling water 11
Inlet
21
Cooling water
Outlet 9
18 17 15
16
22
23
19
Flow chart of water cooled system
No. Name No. Name

1 Air filter 13 Element
2 Pressure different sensor 14 Motor
3 Solenoid 15 Oil filter
4 Unloader Check valve 16 Pressure different sensor
5 Minimum pressure valve 17 Thermostat valve
6 Pressure different sensor 18 Water flow swith
7 Safety valve 19 Oil cooled
8 Oil separator 20 Air cooler
9 Vessel 21 Pressure sensor
10 Non stop valve 22 Water separator
11 Temperature sensor 23 Drain solenoid valve
12 Oil stop valve
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2.7 Main parts

Main parts include：
z Air filter
z Unloader
z Air and Oil separator
z Minimum pressure valve
z Cooler
z Water separator
z Thermostat valve End cover
z Oil filter
z Oil stop valve Dust remover
z Air filter
Air filter is the first device preventing dirts and particles entering into the compressor. Thus, it can prevent the
screw and bearing cause unnecessary wearing, effectively reduce the load of oil separator and oil filter and prolong
their life time. Machine adopts the original imported filter with reliable sealing technology and pre-separation effect,
which guarantee to prevention dirts entering into the system. The filter medium is featured with the highest filtration
precision, dirt-holding capacity and very low pressure drop, which make the compressor running more cost-effective
and energy-conservative. Hence, air filter element should be cleaned or replaced timely according to the service
environment and time. The cleaning method is as follows: take the air filter element out, slap at the upper and lower
end faces gently and blow the air filter element from the inside to the outside with a compressed air less than 0.3MPa.
Then, dust and dirts on the filter element will be removed. Scrubbing with oil or water is unacceptable. In case of filter
paper damage or lots of dirts, serious blocking and difficulties in cleaning up, a new one must be used to replace it.
To achieve superior pre-separation effect, detaching of the end cover of filter and dust remover
during the running of machine is forbidden.
z Unloader
Unloader is composed of valve housing, piston, piston rod, upper cover, valve, solenoid valve and sealing ring,
etc. The functions of unloader are: load and unload compressor. During compressor starting, the unloader closed to
reduce starting load of compressor, after starting, unloader opening completely, compressor is fully loading, if the air
consumption is less than the capacity of the compressor, the pressure of the net will go up, when it reaches the upper
limit pressure, the solenoid valve on the unloader is de-energized by the PLC, the unloader closed and the
compressor is unloading, the pressure in the vessel is blown down to 0.07-0.09Mpa, if air consumption continue, the
pressure of the net will go down, when it reaches the lower limit pressure, the solenoid valve on the unloader is
energized by the PLC, the unloader open and the compressor is loading again. When the compressor stop, the
unloader will vent the compressed air in the vessel.
The flexibility of the starting/closing action of unloader valve is vital to the reliability of compressor. Therefore,
unloader should subject to scheduled maintenance (once per 8000 hours, at least once per year) to keep it in good
working condition.
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z Vessel and Oil separator

Oil is separated by vessel (5) and separator (6), the mixture of air and oil go in to the vessel. Most of the oil is
collected on the wall of the vessel by flowing centrifugally, the rest oil is
separated by separator in the vessel, the scavenge oil that separated by the
Oil Fill
separator go through the scavenge line and the Non stop valve (14) to the
low pressure point of the Element. For safety there is a safety valve installed
on the vessel, when the pressure rise to the set point, it release the pressure,
there are a filler plug and a oil level indicator on the vessel, the oil level
should be kept between within the green area. position when the
compressor running. The pressure different sensor(16) will give a message
on the display when the separator is too dirty. The drainer on the bottom of
Green Area
the vessel is used drain oil and condensate water, it is necessary to drain
condensate in the vessel water termly. If the oil content in the outlet air,
please check the scavenge line if it is block. As the compressor stops after
running for a period of time, moisture in the air will condensate and deposit at
the bottom of vessel. So, condensate should often be discharged by the oil
drain valve mounted at the bottom of vessel to prolong the service life of
lubricating oil. If a great quantity of oil is contained in the air exhaust, then the
scavenge line and the Non stop valve (14) shall be checked. If it is confirmed
no problem, then the oil separator should be dismantled for a check. In case
of short circuit in filtering process or serious blocking due to damage, the oil
separator must be replaced with a new one.
z Minimun pressure valve

Min pressure valve is composed of body, plunger, springs, seal rings
and adjust screw. It is installed after the separator to keep the vessel
pressure not lower than 0.25Mpa for good separating and lubricant cycle,
min pressure valve is also a check valve for protecting the air back to the
vessel. The sealing of minimum pressure valve should be checked on a
regular basis (once per 8000 hours, at least once per year).
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z Cooler
Cooler is designed to cool down the compressed air exhausted from compressor and the lubricating oil.
plate-fin cooler, completely made up of aluminium alloy materials by welding, is used in air-cooled unit; oil cooler and
after-cooler used in water-cooled unit are both shell and tube high-efficiency coolers, the helical structure inside of
which improves the heat exchange effect of cooler.
A large quantity of heat produced by the compressor is taken away by lubricating oil and then by the cooling air
through forced convection in oil cooler (cooling water for water-cooled machine type). Thermal resistance in the air is
dominant in the heat exchange process of air-cooled machine type, thus the cooling fin and tube sheet surface shall
always be kept clean. Large quantity of oil stain and dirt (scale for water-cooled unit) shall be cleared up on a regular
basis, if any.
z Water separator
The condensate water is separated in the water separator and then is drained out by the solenoid valve.
Y-type strainer at the front end of blowoff valve needs regular maintenance. The first running-in
of a new machine lasts for 300 hours and regular cleaning is required at an interval of 2000
hours afterwards.
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z Thermostatic valve
The thermostatic valve controls the Element outlet
temperature not lower than the dew point to protect the
condensate forming in vessel. The condensate water will
short lifetime of the oil. The thermostatic valve keeps the
Element outlet temperature always higher than dew point.
The operating principle is as follows:oil from the
separation vessel enters into t thermostatic valve. All
bypass orifices of thermostatic valve will open when the
temperature is below 70℃ and part of the hot oil directly
enters into the elememt; when the temperature is above
70℃, the thermostatic valve element will stretch out to push the piston forward and begin to close bypass oil
gradually. The amount being closed depends on the oil inlet temperature. When the oil inlet temperature is higher, all
bypass oil will be closed and all the oil will enter into the cooler and be cooled down. Temperature control valve
should subject to scheduled maintenance (once per 8000 hours, at least once per year) to keep it in good working
condition.
z Oil filter
Oil filter functions to filter the particles, dust and other foreign matters in
lubricating oil during its circulation to guarantee the operation of compressor. It
should be replaced after 300 hours' running of new machine and be replaced
regularly at an interval of 2000 hours afterwards. Or, it should be replaced when the
pressure drop between the pressure before filtering and the oil injection pressure is
above 0.13Mpa (warning will be displayed on PLC) to guarantee the oil supply and
cooling effect of the machine.
z Oil stop valve

When the machine is going to stop, the oil cut off valve functions to disconnect the oil line of host machine to
avoid spill of lubricating oil from the air inlet. After the machine being started up, it will automatically open. A check
and cleaning per 8000 hours or per year is required.
This valve is mounted at the bottom of element.
Oil stop valve
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2.8 Control Panel and electrical Diagram

Control panel
Code Name Where Use Code Name Where Use

1 Controller ES4000 Display the work station 2 Button Emergency stop
Electrical diagram Please reference to the “PLC Instruction and Operation Manual”
2.9 Capacity Controlling

Operating principle of control system
The system adjusts the capacity of the compressor according to the consumption of the compressed air
automatically to guarantee the compressor works within the scope of preset maximum and minimum working
pressure. Automatic control by the control system is achieved through the pressure of compressed air. This system is
mainly composed of pressure sensor, solenoid valve and unloader, etc.
When the compressor starts, it running on unloading status, the unloader is closed, the pressure in the vessel is
0.08-0.11 Mpa, after 1-3 minutes from the starting and the element outlet temperature up to 50℃, press the
“load/unload” button, the unloader will open completely, compressor is fully loading, the pressure will rise gradually.
If the air consumption is less than the capacity of compressor, the pressure will go up and reaches the upper
limit point, PLC de-energize the solenoid valve on the unloader, the unloader closed, the compressor is unloading, if
the net pressure go down to the lower limit, the solenoid will be energized, the unloader opens and the compressor
will full loading again. The pressure upper limit and the lower limit can be set between 0.05Mpa.
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3．Installation
3.1 Compressor Room
150mm
Concrete plane
100mm
100mm
Foundation
1. Standard, flat and industrial floor able to afford the weight of machine must be used (referring to the Ground Plot
for the details).
2. Compressor must be mounted at the 150mm high cement platform (see the drawing below) so as to connect
inlet and outlet piping system.
Ventilation
1. When the machine is working, the temperature at machine room should be kept within 1~46℃.
2. Machine room space: refer to (3.4 Installtion Propose)
3. Two air vents must be provided for air-cooled machine room, the minimum area of air vents shall be no less
than 1.5 ㎡.
The first air vent is overhead for exhausting hot air; the second air vent is in the lower for intaking cold air from
the outside. If there is too much dust in the environment, the mounting of filter plate shall be recommended;
4. Hot air exhausted by air-cooled machine type should be exhausted with pipe;
The minimum area of pipe shall be no less than 1.5 ㎡, and the pressure drop at outlet airduct shall be no more
than 3mm water column, or the cooling effect of the cooler will be affected. Pressure drop at outlet airduct may
be reduced by the installation of exhaust fan. The exhaust fan capacity shall not be lower than that specified
below.
Compressor Cooling fan
power (kw) capacity (m³/h)
90-132 20000
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Instruction Book
3.2 Lifting and OOBA

Lifting
Lifting the machine with iron wire is forbidden
Do not passby under lifting objects
Check the packing container for intactness and check the unit for damage before lifting. After opening the
container, the handling and installation of unit shall be conformed in strict accordance with the relevant handling
considerations. There are two forklift holes beneath the base of unit. While conveying with forklift, square timber
should be placed lest the forklift should crush the door panel of unit (see the drawing). If sling is used, then cross bar
must be adopted for it may offset the side pressure produced by the sling against the container. Caution: the practice
of padding some protective materials between sling and the acoustic hood of unit is unacceptable for it will crush the
door panels at both sides on the unit.
Compressor shall be swang by hoisting equipment whose bearing capacity is greater than the weight of unit.
Both the swing speed and acceleration should be within the permitted limits.
OOBA
Check carefully for damage after unpacking the machine. If there is any doubt, please do not use the machine
and please contact with the Service Department of manufacturer or the supplier. Packing materials (plastic bag,
cystosepiment, iron nail and woods, etc.) shall be properly disposed so as to avoid environmental pollution or
personal injury.
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Instruction Book
3.3 Dimension Drawing and Technical specification

Air cooled FS unit dimension drawing
（Variable Speed）
Hot air out
1300
Cooling air in
925
2120
Outlet DN65 PN1.6
1025
645
Drain pipe G1/2
310 180 180

80
80
80
80
40
510
1600 58
620 980
30
2400
330
φ1
00
4-φ
20 1930
Cable inlet
1390
1550
00
φ1
310
Spare Cable inlet

205
739 310
Technical specification
TYPE CPE125（CPVS125） CPE150（CPVS150） CPE180（CPVS180）
Pressure (Mpa) 0.5 0.7 0.8 1.0 1.3 0.5 0.7 0.8 1.0 1.3 0.7 0.8 1.0 1.3
3
FAD (m /min) 21.1 17.2 17.0 14.2 12.5 24.4 21.0 20.6 17.0 14.0 24.2 24.0 20.5 17.0
Noise dB(A) 76 76 76
Weight (kG) 2210（2340） 2300（2430） 2650（2780）
Power(kW) 90 110 132
Oil load (L) ~57 ~57 ~60
Note: Voltage Supply 380V/50Hz

Important interpretation
The measurement of sound pressure level shall be conducted according to
PNEUROP PN8NTC2.2 and in free field 1m away (3.281 ft). Tolerance of 3dB is
acceptable.
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Instruction Book
Water cooled FS unit dimension drawing
（Variable Speed）
Hot air out
330 646
Cooling air in
367
2120
1280
Outlet DN65 PN1.6

645
Drain pipe G1/2
310 180 180

80
80
80
80
40
510
1600 58
620 980
2400
φ100
330
1930
4-φ
20 750 435
Cable inlet
Water outlet G1 1/4 Water inlet G1 1/4
570
460 470
1550
460
0
φ 10
310
Spare cable inlet

205
Technical specificationN
TYPE CPE125W（CPVS125W） CPE150W（CPVS150W） CPE180W（CPVS180W）
Pressure (Mpa) 0.7 0.8 1.0 1.3 0.7 0.8 1.0 1.3 0.7 0.8 1.0 1.3
FAD (m3/min) 17.2 17.0 14.2 12.5 21.0 20.6 17.0 14.0 24.2 24.0 20.5 17.0
Noise . dB(A) 76 76 76
weight (kg) 2180（2310） 2270（2400） 2600（2730）
Power (kW) 90 110 132
Oil load (L) ~46 ~46 ~63
Cooling water (m3/h) 3.5~10.5 3.5~10.5 5.2~15.6
Note1: Cooling water temp. <=35℃, pressure 0.2Mpa-0.6Mpa, with min flow, temp. diff 24℃; with max flow,
temp. diff 8℃. Water flow shall be determined according to the water quality.
Note2: Voltage Supply 380V/50Hz
Important interpretation
The measurement of sound pressure level shall be conducted according to PNEUROP
PN8NTC2.2 and in free field 1m away (3.281 ft). Tolerance of 3dB is acceptable.
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Instruction Book
3.4 Installtion Propose

Indoor installation propose of Air-cooled unit
Air outlet Hot air
R1
45
R7
0
00
1450
〉2500
200
250 Canvas
750
804
Air intake
150
Concrete plane
Cable inlet（φ100）
00
15
150
0
150
0
00
15
Spare cable inlet（φ100）
Indoor installation propose of water-cooled unit
Air outlet Hot air

〉1500
Air intake
Concrete plane
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Instruction Book
Description
1. Install the compressor on level floor suit for bearing its weight.
2. The recommended minimum distance between the top of compressor and the ceiling is 1.5m (58.5 inch) for the
convenience of ventilation and lifting.
3. While piping, all pipes and pipe joints should fit to the rated pressure, use of elbows and various valve banks
should be reduced as far as possible to reduce the pressure loss.
The pressure drop of delivery pipe can be calculated by the following formula:
dp = (L×450×Qc1.85)/(d5×P)
z dp = pressure drop (recommended maximum value= 0.1 bar)
z L = length of delivery pipe in the unit of m
z d = internal diameter of delivery pipe in the unit of mm
z P = absolute pressure at the outlet of compressor in the unit of bar (a)
z Qc = air displacement of compressor in the unit of 1/s
4. Air outlet grid and ventilation fan mounting should always avoid hot air goes into the compressor.
Ventilation air speed should be lower 5 m/s (16.5 inch/s).
Ventilation air flow can calculation by :
For water cooled unit: Qv = 0.1N/dT
For air cooled unit: Qv = 0.9N/dT
z Qv = ventilation air flow m3/s
z N = shaft power kW
z dT = compressor room temperature rise ℃
5. The blow-off pipe can not be soaked in the water of collector so as to observe the flow of condensed water.
6. Check the electrical connection for the compliance with local regulations. The installation must be connected to
the earth and fuse must be mounted in each phase to prevent short circuit. Isolating switch must be installed
around the compressor.
7. For water-cooled unit, the water supply pressure of cooling water should be 0.2-0.6MPa. Valves should be
mounted at both the inlet and outlet (see the drawing). It is recommended that a strainer should be provided at
the water inlet to filter particles greater than 0.1mm. The water supply shall not be lower than:
z For once-through water supply whose quality is in keeping with the regulation, the water supply= the quantity
specified in the Technical specification Table.
z For circulating water, the water supply= the quantity specified in 24x Technical specification/temperature
difference of cooling tower.
z If the quality of cooling water can not meet the specified requirements, water supply shall be increased to keep
the discharge temperature within 50℃.
Water inlet Manometer
z Water supply= quantity specified in 24x
Technical specification /temperature Water outlet Thermometer
Ball valve G1/2
difference between water inlet and
Ball valve G1/2
outlet Ball valve G1/2
Water outlet G1 1/4 Water inlet G1 1/4 Air outlet
Drain
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Instruction Book
3.5 Cooling Water Requirements

Recommendations
The quality of cooling water must comply with the given minimum requirements.
Any general recommendation can not cover the effect produced by the arbitary combination of various mixtures, solid
and gas, which usually exist in the cooling water interacting with different materials.
This recommendation is the general guideline of the acceptable coolant quality.
System type
First, you must consider the system you treat. Is it closed or open? This is very important.
In closed system, the same cooling water circulates in the system without contacting the air.
Open system is a through system or a circulating system with cooling tower.

In case of the latter, the composition of water entering into the cooler instead of that of make-up water must be taken
into consideration.
Thanks to the evaporation effect in cooling tower, higher ion concentration can be acquried in circulating water than
in make-up water.
Ryznar Stability Index (RSI)

Ryznar stability index (RSI) is a parameter designed to predict whether the water will dissolve or precipitate calcium
carbonate.
The adherency and its effect of scale on different matters differ, but the water balance (scaling or corrosion) only
depends on the actual pH value and saturated pH value (pHs), which in turn depends on the relationship among
calcium hardness, total alkalinity, total solid concentration and temperature.
Ryznar index can be calculated by the following formula:
RSI=2*pHs-pH
Symbol Interpretation
pHs Actual pH value of water sample (at room temperature)
pHs Saturated pH value
pHs can be calculated by the following formula:

pHs=（9.3+A+B）-（C+D）
Symbol Interpretation
A Depend on the total solid concentration (mg/l)
B Depend on the max. temperature (°C/°F), (T=65°C/149°F) of cooling water
C Depend on the calcium hardness (ppmCaCO3)
D Depends on the concentration of HCO3 or the alkalinity of M (mva1/1)
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Instruction Book
The values of A, B, C and D can be found in the table below.

TDS A Temperature B Calcium hardness C M alkalinity D
（mg/l）（℃）（ppmCaCO3）（mval/l）
50-300 0.1 0-1 2.6 10-11 0.6 0.20-0.22 1.0
400-1000 0.2 2-6 2.5 12-13 0.7 0.24-0.26 1.1
7-9 2.4 14-17 0.8 0.28-0.34 1.2
10-13 2.3 18-22 0.9 0.36-0.44 1.3
14-17 2.2 23-27 1.0 0.46-0.54 1.4
18-21 2.1 28-34 1.1 0.56-0.70 1.5
22-27 2.0 35-43 1.2 0.72-0.88 1.6
28-31 1.9 44-45 1.3 0.90-1.10 1.7
32-37 1.8 56-69 1.4 1.12-1.38 1.8
38-44 1.7 70-87 1.5 1.40-1.76 1.9
45-50 1.6 88-110 1.6 1.78-2.20 2.0
51-56 1.5 111-138 1.7 2.22-2.78 2.1
57-63 1.4 138-174 1.8 2.80-3.54 2.2
64-71 1.3 175-220 1.9 3.54-4.40 2.3
72-80 1.2 230-270 2.0 4.6-5.4 2.4
280-340 2.1 5.6-7.0 2.5
350-430 2.2 7.2-8.8 2.6
440-550 2.3 9.0-11.0 2.7
560-690 2.4 11.2-13.8 2.8
700-870 2.5 14.0-17.6 2.9
880-1000 2.6 17.8-20.0 3.0
Explain the values acquried
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Instruction Book
RSI Water quality Operation

RSI<3.9 Very serious scaling Such water can not be used
4.0<RSI<5.5 Serious scaling on boiler Check and necessary scale removal operation shall be
conducted on a regular basis.
5.6<RSI<6.2 Slight scaling on boiler Water treatment is necessary.
6.3<RSI<6.8 Neutral water Aperiodical check is recommended.
6.9<RSI<7.5 Slight corrosion at high Water treatment is necessary.
temperature
7.6<RSI<9.0 Serious corrosion Aperiodical check is recommended.
9.1<RSI<11 Very serious corrosion Water treatment is necessary.
RSI<11 Very serious corrosion in Aperiodical check is recommended.
the whole set of water
system
This table suggests that distilled water and softened water can never be used, for their RSI is above 11.
RSI only indicates the balance between scaling and descaling. RSI conditions indicate that good cooling water may
still be unacceptable due to other factors.
According to the table above, the RSI index should be in between 5.6 and 7.5. Otherwise, please contact with the
relevant expert.
pH
pH results have been counted in Ryznar indices. Moreover, pH itself has some additional restrictions: 6.8<pH<8.5
Total dissolved solids（TDS）

This value is equivalent to the sum of all icons in water.
It can be derived from the remanent dry residues after evaporation (but excluding suspended particles) and
estimated according to conductivity.
For closed system, the following restriction will apply: TDS<3000mg/l(<3800 microS/cm)
For open system, the following restriction will apply: TDS<750mg/l(<960 microS/cm)
Chloride (CL-)
Chloride ion will lead to pitting corrosion on stainless steel. Its concentration should be defined as:
Closed cooling system: chloride <500ppm
Open cooling system: chloride <150ppm
However, if the water is scaling, then lower restriction should be adopted. (Please refer to "Ryznar stability index
(RSI)").
Free chlorine(Cl2)
The content shall not exceed 0.5ppm for a long time.
In case of short-time treatment, the time shall be limited at 30 minutes each day and the maximum content of free
chlorine shall be 2ppm.
Sulphate（SO4-）
Closed cooling system: sulphate <400ppm
Open cooling system: sulphate <150ppm
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Instruction Book
Hardness of carbonate
losed cooling system: 50-1000ppm CaCO3
Open cooling system: 50-500ppm CaCO3
HCO3-/SO42- should be >1
Ammonia
<0.5ppm
Copper
<1ppm
Iron and manganese

<1ppm
Organic matter
Algae-free category
Oil-free category
Suspended particles
The size of insoluble particles <1mm
<10ppm
Remarks
Chemical reaction may occur between chlorides and sulphate.
In open system, the quadratic sum of the value of chlorides and sulphate shall not exceed
85,000.
The quadratic sum of recirculation system with proper control and treatment measures may be
as high as 520,000.
Please note that the value of sulphate must include any sulfite contained in water.
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Instruction Book
3.6 Identify
Water system
1 2 3
Water inlet Water outlet Drain
Electrial system
1 2 3 4
Connection mode of leader Warning! Note the turning direction of Earthing

cable and tightening torque Electric High motor!
Voltage!
Other location
1 2 3 4 5 6 7
Warning! Fluid jet Irrespirable Internal The fan Warning! Automatical

High high may injure Noise! start
Temperature! pressure your hands
8 9 11
Please cut off
the power and
depressurize the
compressor
Please read the Instruction before Special lubricating oil for compressor
Manual before starting the maintenance
compressor
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P a g e | 29
C146 series service tag and service kit
12
Instruction Book
Instruction Book
4 Operation
4.1 Brief Introduction to Operation

Safety
Operators must implement all the relevant safety measures, including those covered in this
Manual.
Electrical safety
To keep the protection level of electric room and prevent the components from being affected by
dust in the environment, please make sure that correct cable coupling sleeve will be used when
connecting the cable to compressor.
Protection level of frequency converter
Compressor under the control of frequency converter (VSD) can be mounted indoor only, and
must be equipped with sufficient ventilation and filtration conditions to prevent dust from being
deposit in the environment. If such compressor is going to be mounted at places with
conductive dust, then corresponding measures should be taken in the mounting or
commissioning process. Please contact with the manufacturer. Optional parts for rain
protection are not provided for frequency converter-driven compressor.
Environmental condition
Action must be taken if the ambient or air inlet temperature is below 1℃ or above 46℃.
Please contact with the manufacturer. if the machine is operated altitude above 1000m (3300 feet).
4.2 Preparation Work for the First Boot

Description-check list before startup
Step Operation
1 Check the connections of all parts for loosening, tighten the loosening (if any) lest there should be oil leakage,
gas leakage or other accidents during operation.
2 Please check the electric connection for the compliance with local regulation and check all electric wires for
the securing at their own terminal blocks.
3 The machine must be connected to the earth and plug-in fuse must be mounted in each phase to prevent
short circuit. Isolating switch must be mounted near the compressor.
4 Please check the voltage selection and connection of primary transformer for the correctness.
5 Please check the set value of breaker. In addition, please check if the switch on the breaker is in OFF state.
6 Properly connect the electric component and earthing cableaccording to the Electrical diagram . Check the
wiring in electrical cabinet and avoid faults resulted from loose wiring as a result of transportation.
7 Check measuring apparatus for loosening or damage.
8 Check if the lubricating oil for the compressor is sufficient. Top up if not and drain if it is surplus. About 3L
lubricating oil should be filled in the air inlets of element for unit stopped (or ex-factory time) or unused (or
ex-factory time) for more than 4 months lest there is no oil in the element while starting up. Oil filled in the
element must be absolutely clean and foreign matter-free.
9 Please open the ball valve at manual drain and close the ball valve at automatic drain when starting up for the
first time. Please connect the condensing blow-off outlet to blow-off collector. If the blow-off pipe is mounted
outdoors (may be frozen), then heat insulation treatment must be provided for the blow-off pipe.
10 Clear all irrelevant articles near and on the unit away.
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Instruction Book
11 Before start up,make sure that transport red pads have been effectively removed.
Description-starting up check list

Step Operation
1 Switch on the breaker and power ON, the indicator light of power source will light up.
2 Open the water inlet valve and outlet valve (mounted by the customer) and the flow control valve to check
the water flow.
3 Check PLC controller for the correctness of set parameter values and warning. The next operation can be
conducted only when the warning (if any) is released.
4 Check if the switching on/off of high voltage cabinet is normal and if the feedback of emergency stop signal
is normal through simulated start-up. Then, the high voltage power supply can be switched on. (Apply for
high voltage)
5 Drive the motor by inching (the time is as short as possible) and then stop the machine immediately. Check
the rotation direction of the motor driven when the compressor is going to stop: the arrow on gear box
indicates the correct direction. If it is incorrect, please cut off the power supply, exchange the two input
cables and reconnect.
Compressor inching method is as follows: press down the start button and then stop the machine by
pressing down emergency stop button while the compressor beginning to rotate. Meanwhile, observe if the
rotation direction of compressor is correct.
6 Check if the rotation direction of fan motor is wrong. If it is incorrect, please stop the machine immediately,
exchange the two input cables and reconnect.
7 For inverter motor, check if the rotation direction of the independent cooling fan of the main motor is correct.
If it is incorrect, please stop the machine immediately, exchange the two input cables and reconnect.
8 Restart the compressor to enable motor to live up to the rated speed after the rotation direction being
corrected. In case of unusual sound, stop the machine immediately and solve the problem.
9 After the compressor starting normal operation, the oil pressure will rise to 0.07~0.09MPa. After operating
under such working condition for 3-5 minutes, press down the loading button on instrument panel and the
compressor will work normally.
10 Check if the oil of the vessel is placed at safety zone. Please refer to the specification of lubricating oil. If the
oil is deficient, lubricating oil of the same brand should be filled.
11 After 3-5 minutes of load operation, close the manual blow-off valve and open the automatic blow-off valve.
The machine will enter the automatic blow-off state.
12 After 1-2 hours of running, check the machine for leakage as well as the compliance with requirements for
temperature and pressure.
Under unloader condition, the oil pressure must be kept within 0.07~0.09MPa, or system
lubrication will be affected. In case of defficient oil pressure, the machine should be stopped
immediately to check the leakage of the system.
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Instruction Book
4.3 Stop and Emergency Stop

Description
Press down the stop button while a stop is required, then the stop procedure will be completed automatically; or
manual shutdown can be implemented by pressing down "unloading" button, then the compressor will unload. Wait
until oil pressure drops to below 0.1MPa, press down the stop button. Upon shutdown, the vessel shall blow off
immediately via the vent hole in unloader. Pull down the power switch upon the completion of blow-off. Close the
cooling water valve (water-cooled unit).
Emergency stop button is only used in case of an emergency.
Generally speaking, power switched shall not be pulled down until 2~5 minutes after the
shutdown in a bid to guarantee that the compressed air in the vessel is emptied through
blow-off solenoid valve, so that there will be no load during the next start-up.
In winter, cooling water valve (water-cooled unit) shall be closed and cooling water in oil
cooler (see the drawing below) shall be drained off, lest freezing should damage the cooler
due to swelling.
4.4 Motor Startup Frequency

Decription
Computer controller will restrict the motor startup frequency. Please refer to Regulation Setting part.
4.5 Considerations of Compressor in Operation

Decription
1. Attention shall always be paid to oil level upon the operation of compressor. Check and treatment shall be
performed pursuant to Troubleshooting Reference Table in case of quick drop of oil level and great oil content in
the exhausted compressed air.。
2. Observe if the indicator readings of instruments are in the normal scope. The air pressure should be within the
rated pressure scope. When the air intake temperature of compressor is lower than 46℃, the exhaust
temperature should be lower than 105℃.
3. In case of great differential pressure between the inlet and outlet of oil separator and oil filter, and warning
displayed on the controller screen, the compressor can still work. But, the machine should be stopped timely to
replace with new parts lest oil shortage in the machine should lead to serious accident such as machine
burning.
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Instruction Book
4. In case of excessively high exhaust temperature (or pressure) and warning displayed on the controller screen,
the compressor will stop automatically and the display screen will display over-temperature (over-pressure)
prompt, please restart after finding out the reason and troubleshooting.
4.6 Going Out of Service

Please perform the following operations when the compressor is out of service for a long time:
1. If you need to put the compressor aside for a long time, you should drain off the lubricating oil, seal it with new
oil of the same brand, operate it for 3-5 minutes and drain off the water in water-air separator and cooler.
2. The compressor should be kept at dry and sheltered place during transportation or storage since its delivery.
Regular check and maintenance should be particularly reinforced when storing at scorching or humid zones.
3. The retention period of the oil seal of this unit is six months (from the ex-factory date), beyond which, the oil seal
must be redone.
Please perform the following operations when the service life of compressor expires:
Step Operation
1 Close the air outlet valve and stop the compressor.
2 Cut off the power supply and disconnect the main power.
3 Close the air oulet valve and depressurize the parts of air pipe network.
Disconnect the air outlet pipe of the compressor.
4 Discharge water, oil and condensed water circuit.
5 Disconnect the condensed water pipe of compressor and condensed water blow-off pipe network.
6 Disconnect cooling water inlet and outlet piping.
Warning
Operators must implement all relevant safety measures.
5 Maintenance
Guarantee that the operate can see the whole machine at the operation panel and that no irrelevant
staff stays beside the machine.
5.1 General
Daily maintenance must be performed pursuant to the specified maintenance forms.
Prior to any maintenance or repairing, please press down the stop button. After the compressor being
stopped, press down the emergency stop button, cut off power supply and depressurize the compressor.
Prevent accidental power-on.
Please comply with all the relevant descriptions in the "safety measures" part.
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Instruction Book
5.2 Preventive Maintenance Program

Considerations
Safe working and increase of service life must be ensured. Please perform the following operations at
the shortest time interval (cycle or running time).
"Longer time interval" check must also include "shorter time interval" check.
Please read the relevant part prior to taking any maintenance measures.
Customer center is entitled to formulate maintenance plan according to the environment and working
condition of compressor.
Please replace all knocked-down gaskets, O-rings and washers during maintenance.
Check or replacement cycle (h)

Item Service Content
8 300 2000 4000 8000 12000 24000 Remarks
Air filter element Clean the dust on the ★ According to the ambient
condition to long or short the
surface period.
Change a new one ★
Oil Enough? ★ Rotair replace at an interval of

2000 hour. Rotair Xtra replace
Change new oil at an interval of 8000 hours.
Rotair Xtra
Rotair
Replacement must be
performed at least once per
year.
Oil filter Change a new one ★ Oil filter Change a new one after
300 hours for the first time and
replace at an interval of 2000
hours afterwards.
Oil separator Change a new one ★ The max. service time is 4000
hours.
Oil stop valve Check and Maintain ★ At least once per year
Cooler Clean dust (Water side) ★ Extend or shorten the cleaning
period according to the water
quality
Clean dust (Oil side) ★ Cleaning must be conducted
when replacing lubricating oil
Clean dust (Air cooler) ★ Operate as required with air
tools
Coarse strainer Change a new one ★ Cleaning every 300 hours
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Instruction Book
Electrical Check and tighten ★ Rescrew after 50 hours
connection
Safety Valve Check ★ Checked by the local
Administration of Quality
Supervision each year
Unloader Change the maintenance kit ★ At least once per year
Thermostat Valve Change the maintenance kit ★ At least once per year
Min. pressure valve Change the maintenance kit ★ At least once per year
Piping Check/Change ★
Solenoid valve Check ★
Blow-off valve Check ★
Pressure sensor Check ★
Pressure gauge Check ★
Drain water Drain ★ Drain condensed water in vessel
Coupling Check ★ Check the elastic parts
Change ★
Bearing Check ★ Every year
Shaft seals Check ★ Every year
Motor Re-grease bearing According to the Motor
regreasing dateplate
5.3 Clear and change air filter

Description
Generally, air filter is replace every 2000 hours or replace timely as long as the differential pressure being above
0.005MPa. During the replacement, the surface of filter element could use compressor air to clean. Poor air quality
may increase the frequency of filter blocking, so replacement period should be shortened, as the case may be.
Please perform the following operations when cleaning or replacing air intake filter:
Step Operation
1 Stop the compressor.
2 Cut off the power supply and disconnect the compressor main power.
3 Turn off air outlet valve and depressurize.
Disconnect the air outlet pipe of compressor. Ensure that there is no pressure in the machine.
4 Open the end cover of air filter and take the filter element out.
5 Remove dirts with hammering method: hammer the upper and lower end faces of the filter
element gently, the dust and dirts on it will be cleaned. Pay attention to the hammering effort to
P a g e | 35
Instruction Book
avoid damage of filter element.

6 Dirts on the surface of filter element can be removed by blowing the filter element from the
inside to the outside with dry compressed air, but the pressure of compressed air shall be kept
within 0.3MPa.
7 Clean the dirts in housing.
8 Assemble in reverse order.
9 Fill in the replacement records.
Check the seal ring of filter element for the intactness before assembly to guarantee the sealing
performance.
5.4 Fill Oil

Description
In the running state, the oil level of compressor shall be kept within the green area. Excessive oil may affect the
separation effect and deficient oil may affect the lubrication and cooling performance of the machine. If the oil level is
below the minimum oil level during the oil replacement period, lubricating oil should be refill timely with the following
method:
Step Operation
4 Screw out the vessel filler plug, fill the rest oil into the vessel.
5 Fill in the oil refill records.
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Instruction Book
5.5 Replace Oil

Description
This machine adopts special lubricating oil produced, which is the special purpose lubricating oil of compressor
and is able to ensure the best lubricity of rotor and bearing of compressor and the best cooling performance of the
machine. Thus, correct lubricating oil for compressor must be used and oil must be replaced in strict accordance with
the requirements. Inferior lubricating oil for compressor may lead to:
z Carbon deposition or oil emulsification, oil system blocking, valve malfunction, failure of the entire system in
serious case, burning down of the element.
z Poor oil separation effect and reduction of the service life of oil separator and oil filter.。
z Reduction of service life of the moving parts of element.
Thus, dedicate lubricating oil for screw compressor should be adopted and lubricating oil of the same
manufacturer and brand should be applied or replaced. Lubricating oil of different manufacturers and
brands can not be mixed in use.
As an option, CP also provide the superior Rotair Xtra lubricating oil. The replacement of lubricating oil of
different type for CP compressor should be operated by professional service staff authorized by manufacturer.
The screw compressor oil must satisfy the following requirements:
z High antioxidant stability
z High stability of high temperature
z Reduce the formation of deposit oil sludge
z Reduce foaming tendency , which is conducive to separation
z High spontaneous combustion point and flash point, not inflammable. The flash point should be above 200℃
z Pour point must be 5℃ below the minimum ambient temperature
z Better air separation performance, which is conducive to separation and reducing the oil content in the air
z Very good anti-corrosion performance
z Long service life
z Must be dedicate lubricating oil for screw compressor

Some lawless manufacturers in the market pass ordinary lubricating oil off as screw compressor
oil and result in major failure of the machine. Hence, purchasing must be careful.。
The trade mark of oil applied when the machine leaving factory is described in the label on the
vessel and the ISO viscosity grade of the oil is 46.。
Oil drain shall be performed as follows:：
Step Operation
1 Start the compressor to make the element outlet temperature up to 60-80℃ and the lubricating oil be fully
preheated.
3 Cut off the power supply and disconnect the main power.
5 Get the oil container ready and screw out the screw plugs in the front of ball valves at the bottom of vessel,
gear box and oil cooler.
6 Open the ball valve slowly and drain the oil.
7 Close the ball valve and screw in the screw plugs.
8 The waste oil drained should be disposed properly.
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Instruction Book
New oil shall be fill in as follows:

Step Operation
1 Screw out the vessel filler plug and fill specified quantity oil into the vessel.
2 Load after startup for 3-5 minutes and observe the oil level indicator. Oil level must be kept within the green
area. Drain the surplus oil and refill in case of oil shortage.
Oil volume for water-cooled unit Oil volume for air-cooled unit
90/110kW 46 57
132kW 63 60
5.6 Replacing Oil Filter

Description
It shall be replaced after 300h running-in of new machine and replaced regularly at an interval of 2000 hours
afterwards. Or, it will be replaced when the difference between the pressure ahead of oil filtration and the oil injection
pressure is greater than 0.13Mpa (warning will be displayed on PLC) to guarantee the oil supply and cooling effect of
the machine.
The replacement of oil filter shall be performed as follows:：
Step Operation
4 Screw out the filter counterclockwise with dismantling tool and prevent residual oil from being spilt out.
5 Check the new filter and seal ring for the intactness.
6 Screw in the new filter clockwise.
7 Check for the normal operation after startup.
5.7 Replacing oil separator

Description
The performance of oil separator has a direct impact on the oil content in compressor air.
Oil separator is located in the vessel. It shall be replaced in time if only the differential pressure is above 0.1MPa.
Otherwise, the service time can be appropriately extended, but it shall be kept within 4000 hours. Oil separator shall
be replaced at least once a year, as poor quality of air or lubricating oil will deteriorate the blocking of oil separator.
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Instruction Book
The replacement of oil separator shall be performed as follows:：

Step Operation
4 Disconnect the piping and take out the oil pumping pipe.
5 Screw out the trip bolt of the cover.
6 Screw out the liftout bolt clockwise to enable the cover to be lifted out for 2-5mm.
7 Screw out the cover so that the oil separator can be taken out.
8 Take out the oil separator.
9 Replace with a new oil separator and properly mount in reverse order.
10 Check for the normal operation after startup.
While mounting the oil pumping pipe, ensure that the pipe is about 3mm away from the bottom of
olein separator.
5.8 Cooler Maintenance

Description
Cooler should be cleaned on a regular basis according to the environment to guarantee that the compressor
works at normal temperature and has longer service life. When the compressor is dirty or blocked, the exhaust
temperature of compressor will rise. Generally speaking, the water side of cooler should be cleaned at an interval of
4000h and oil side at an interval of 8000h (being synchronous with oil replacement). Regularly cleaning the cooler
will:
1. Enable the unit to work at ideal working temperature (below 95℃) all the time, which is good for the
performance and service life of the machine.
2. Be able to remove dirts with cleaning solution. Or else, when the dirt becomes thick, the cleaning will be quite
troublesome and the cooler must be dismantled to conduct the cleaning with mechanical method.
Appropriately extend or shorten the cleaning time according to the water quality.
Cleaning procedures for the cooling medium of water cooler:

Step Operation
4 Take the cooling water inlet and outlet pipes apart.
5 Soak with cleaning solution or wash out through pump circulation (the effect of backflushing will be better).
6 Flush with clear water.
7 Mount the cooling water inlet and outlet pipes properly.
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Instruction Book
In case of serious scaling on oil cooler which can not be satisfactorily cleaned with the said
method, you may dismount the oil cooler separately, open the end covers at both ends and remove
scales with dedicate wire brush or other tools.
If the cleaning of medium side of cooler can not lower the temperature effectively, then the oil side should be cleaned.
Cleaning procedures of oil side of water cooler：
Step Operation
4 Take the inlet and outlet oil pipes apart.
5 Soak with cleaning solution or wash out through pump circulation (the effect of backflushing will be better).
6 Flush with clear water.
7 Dry it with dry gas or remove the water with dehydrated oil.
8 Mount the inlet and outlet oil pipes properly.
Solvent tank
Pump ＞50 liters
Water outlet Water inlet
Water outlet G1 1/4 Water inlet G1 1/4
Cleaning procedures for the exterior of air cooler:

Step Operation
4 Open the air director cover plate or dismount the cooling fan.
5 Blowback the dirts down with compressed air and then take the dirts out of air director; if it is quite dirty,
blowing should be conducted after spraying some oil removal agent. In case of failure of the said methods,
the cooler should be dismounted and the cleaning must be conducted by soaking, spraying or flushing with
cleaning solution and by cleaning with brush (the use of wire brush is strictly forbidden).
6 Mount the cover plate or cooling fan properly.
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Instruction Book
5.9 The motor bearing greasing

Description
Effective lubrication of motor bearings shall be guaranteed in the running process. Lubricating grease shall be
regressed or replaced pursuant to Motor Operation Instruction. In case of overheat of bearings or deterioration of
lubricating grease, it must be replaced and the lubricating grease filled in shall account for 2/3 of the bearing housing.
The oil inlets of motor are respectively located on the Drive side and No driver side. Lubricating grease can be
regressed with oil gun.
5.10 Discharging Condensed Water

Description
Gaseous moisture may be separated out from oil tank when the element outlet temperature is lower than the
pressure and dew point temperature of the gas or when the machine is stopped for cooling. Thus, the condensed
water in vessel should be discharged per 300 hours. Especially in humid weather, more condensed water will be
separated out. Too much moisture in oil will emulsify the lubricating oil and affect the safe operation of machine, such
as:
z Resulting in poor lubrication of the element of compressor;
z Worsening oil separation effect and intensifying the differential pressure of oil separator;
z Leading to corrosion of parts.
Discharge method for condensed water:
Step Operation
4 Screw out the screw plug in the front of the blow-off pipe of vessel.
5 Open the ball valve slowly to discharge the water until oil flows out. Then, close the ball valve.
6 Screw in the screw plug in the front of ball valve.
Condensed Water Discharge Schedule should be formulated according to the humidity. The time
interval for the discharge of condensed water shall not exceed 300 hours.
Condensed water should be discharged upon stoppage or sufficient cooling of the machine and after
complete deposit of condensed water, such as before startup on morning.
5.11 Clean the scavenge line

Description
The scavenge line is used to draw out the oil in the separator, if it is clogged, more and more oil will be collected
in the bot-tom of the separator, that will cause high oil content in the compressed air, check the line by hand, feeling
the temperature of the tube, if it is not so hot, that means there is no oil pass and the line clogged, disassembly the
tube, throttle, filter for cleaning.
Clean procedure:
Step Operation
P a g e | 41
Instruction Book

4 Disassembly the tube and the throttle assembly.
5 Take out the throttle and the filter.
6 Clean the parts using solvent, then dry them by dry compressed air.
7 Check the seal ring for intactness and assembly in reverse order.
5.12 Safety valve maintenance

Description
The safety valve must be checked by authorized department every year.。
Maintenance procedures of safety valve:
Step Operation
4 Screw out the safety valve.
5 Check the opening pressure and the closing pressure, if necessary adjust the pressure: re-move the lead
seal and turn the adjust nut.
6 Assembly the valve back.
The opening pressure of safety valve is shown in the table below:

Working pressure MPa 0.75/0.85 1.0 1.3
Opening pressure P(MPa) 1.0 1.2 1.5
The opening pressure of the safety valve must lower than the vessel design pressure
5.13 Handle the old parts

Description
The replaced lubricating oil, oil filter, air filter element and oil separator element shall be properly disposed according
to the local laws and regulations.
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Instruction Book
5.14 Service Agreement

Description
The Customer Service Center could provides a string of service agreements to satisfy your needs:：
z Check plan
z Preventive maintenance plan
z Full responsibility plan
Please contact with your Customer Service Center to customize service agreements.。
It will guarantee the optimal operating efficiency, minimum stop time and reduce the total cost for life cycle.
5.15 Service Kit

Description
The Customer Service Center will be very glad to provide you with a string of service kits.
The service kit covers all parts required for maintenance and enables you to enjoy the benefits of the original parts
manufactured by Customer Service Center while keeping a lower maintenance budget.
6 Problem solving
Warning
Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the
emergency stop button and switch off the voltage. Close the air outlet valve and open the manual
condensate drain valves. Open and lock the isolating switch.
Prevent accidental power-on.
The operator must apply all relevant Safety precautions.
A service message appears on the display

z Stop the compressor and carry out the indicated service actions.
z Reset the message
Compressor element outlet or air delivery temperature about normal

z Oil level too low.
z Oil coolers clogged
z Air coolers clogged
z Cooling water flow too low or a restriction in the flow
A shut-down warning message appears on the display
z The alarm LED will light up indicating that the temperature at the outlet of the compressor element is too high.
z The message disappears as soon as the cause of the problem is remedied.
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Instruction Book
UNIT IS SHUT DOWN

z The alarm LED will flash indicating either that the outlet temperature is too high or that the motor overload relay
has tripped. Remedy the problem. It may be necessary to reset the display after remedying the fault: press the
“Reset” key , and no alarm appear, after which the compressor can be restarted.
Excessive oil consumption
z Have the compressor inspected by the Customer Centre.
Condesate is not discharge from condensate traps during loading
z Discharge pipe of condensate trap is clogged.
Compressor air delivery or pressure below normal

z Air consumption exceeds capacity of the compressor. Check for leaks or the capacity of the equipment that is
connected.
z Choked airfilter lead to a reduced airflow. Check the cleanliness of the filter and the pressure drop over the
filters. Change if necessary.
7 Principal Data
7.1 Overload Relay

Compressor setting
Supply Voltage Frequency Approval Fan Motor Power Fan Motor Remark
V Hz - kW A
380 50 IEC 0.37 0.9 Water cooled
380 50 IEC 3 7 Air cooled 90-110kW
380 50 IEC 4 9 Air cooled 132kW
7.2 Fuse and Cable Size

Considerations
If the local rules are stricter than the following recommended values, then these rules will still
apply.
Voltage drop shall not exceed 5% of the rated voltage.
Cable with dimensions larger than those specified may be used to satisfy this requirement.
Low-voltage Frequency Main Motor power Approval Cable size Fuse

power supply gL/gG
V Hz kW - - A
380 50 90 IEC 3×120mm2+50mm2 193
380 50 110 IEC 3×120mm2+50mm2 234
380 50 132 IEC 3×120mm2+50mm2 283
Note
This dimension is valid for PVC cable at 70℃ (158℉) when the embient temperature is 40℃ (104
℉), according to IEC60364-5-523.
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Instruction Book
7.3 Reference Condition

Reference condition
Absolute inlet pressure bar(a) 1
RH (relative air humidity) % 0
Air inlet temperature ℃ 20
Working pressure bar(e) Refer to the performance parameters of compressor
Cooling water inlet temperature (water-cooled) ℃ 20
Cooling air inlet temperature (air-cooled) ℃ 20
Motor rotate speed-50Hz machine type r/min 1492
7.4 Limit
Pressure limit
Max. setting pressure bar(e) Refer to the performance parameters of compressor
Max. cooling water pressure bar(e) 6
Min. cooling water pressure bar(e) 2
Temperature limit
Max. air inlet temperature ℃ 46
Min. air inlet temperature ℃ 0
Max. ambient temperature ℃ 40
Min. ambient temperature ℃ 0
Max. cooling water inlet temperature (open cooling system) ℃ 35
Min. water inlet temperature ℃ 1
Temperature difference between inlet and outlet with min. water flow ℃ 24
Temperature difference between inlet and outlet with max. water flow ℃ 8
Max. outlet temperature of element ℃ 115
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Instruction Book
8 Registration Form for Compressor Maintenance

Running
Air Filter Oil Filter Oil Separator Replace Oil Date Signature
Hours （h）
Details for maintenance: the item of air filter: cleaning, replacement; the item of lubricating oil: filling xx
liters, replace xx brand; other items: replacement.
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Instruction Book
9 Compressor Breakdown Maintenance Records

Running
Fault description Solution Date Signature
Hours （h）
P a g e | 47

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Code

1 Safety Precautions ................................................... 1

1.1 Safety Icons ............................................................................................................................................ 1

2.1 Brief Introduction ................................................................................................................................... 7

3．Installation ........................................................ 18

3.1 Compressor Room ................................................................................................................................ 18

4 Operation ........................................................... 30

4.1 Brief Introduction to Operation ............................................................................................................ 30

5 Maintenance ........................................................ 33

5.1 General ................................................................................................................................................. 33

5.8 Cooler Maintenance ............................................................................................................................. 39

6 Problem solving ..................................................... 43

7 Principal Data ....................................................... 44

7.1 Overload Relay ..................................................................................................................................... 44

8 Registration Form for Compressor Maintenance ....................... 46

9 Compressor Breakdown Maintenance Records ........................ 47

1.2 Safety precautions during installation

General Preventive Measures

Precautions during installation

1.3 Safety precautions during operation

Precautions during operation

1.4 Safety precautions during maintenance or repair

2.1 Brief Introduction

2.2 Hazardous Areas

2.3 Safety Devices

2.4 Air flow

2.5 Lubricating Oil System

2.6 Flow Chart

Flow chart of air cooled system

No. Name No. Name

Flow chart of water cooled system

Flow chart of water cooled system

No. Name No. Name

2.7 Main parts

z Vessel and Oil separator

z Minimun pressure valve

z Oil stop valve

Oil stop valve

2.8 Control Panel and electrical Diagram

Code Name Where Use Code Name Where Use

2.9 Capacity Controlling

3.1 Compressor Room

3.2 Lifting and OOBA

3.3 Dimension Drawing and Technical specification

Drain pipe G1/2

310 180 180

Spare Cable inlet

Weight (kG) 2210（2340） 2300（2430） 2650（2780）

Power(kW) 90 110 132

Oil load (L) ~57 ~57 ~60

Note: Voltage Supply 380V/50Hz

Water cooled FS unit dimension drawing

Hot air out

Outlet DN65 PN1.6

Drain pipe G1/2

310 180 180

Water outlet G1 1/4 Water inlet G1 1/4

Spare cable inlet

weight (kg) 2180（2310） 2270（2400） 2600（2730）

Power (kW) 90 110 132

Oil load (L) ~46 ~46 ~63

Cooling water (m3/h) 3.5~10.5 3.5~10.5 5.2~15.6

3.4 Installtion Propose