CPD7948/075 Specification Oil-Free, Air Cooled, Rotary Screw Compressors - Dryclon Range Models D75, D90, D110, D132, D150 (50Hz) D55, D75, D90, D110, D150 (60Hz) COMPRESSOR PACKAGE An enclosed two stage air cooled oil-free rotary screw compressor consisting of first and second stage compression elements driven via a gearbox and 2 pole IP55 motor, intercooler, aftercooler, lubrication system and SureScan microprocessor control system. COMPRESSION ELEMENT ASSEMBLY Drive is transmitted from main motor via a flexible coupling and helical main gear onto the pinion gear on the male rotors of the first and second stage compression elements. Helical timing gears synchronise the male and female rotors to maintain the correct clearances. Rotors, rotor shafts and rotor casings are coated with an anti-corrosive and anti wear coating to prolong element life and efficiency. Each rotor is carried on a duplex ball bearing for axial loads and a roller bearing for radial loads at each end. A single piece windback labyrinth oil seal guarantees 100% oil-free compression. Stainless steel sealing rings prevent air leakage from the compression element. The space between the oil and air seals is vented to atmosphere. The helical main gear is supported on two ball bearings and one roller bearing and the input shaft is sealed by a windback labyrinth seal. The flange coupled compressor motor assembly is supported on three vibration absorbing mounts. AIR CIRCUIT When onload atmospheric air enters the acoustic enclosure via a dedicated intake grille before being drawn into the first stage compression element via an intake filter and suction regulator. The air is compressed to 2.0-2.6 bar.g in the first stage element and then passes via a pulsation dampener to the air cooled intercooler and interstage moisture separator. The air then passes into the second stage compression element and is compressed to the final discharge pressure and passes through a pulsation dampener, non return valve, air cooled aftercooler and discharge moisture separator. Solenoid valves timed via the control system drain condensate separated by the interstage and discharge moisture separators. Strainers protect the solenoid valves. COOLING SYSTEM The air cooled oil cooler, intercooler and aftercooler are mounted vertically at one end of the package and comprise single pass aluminium finned air blast coolers. Ambient temperature cooling air is drawn across the coolers by two motor driven cooling fans. A duct directs the air from the coolers across the fans to the outlet grille in the enclosure roof. The duct is secured by ¼ turn fasteners and can easily be removed for maintenance purposes. Motor cooling air enters the enclosure via a separate grille and passes across the motor and compression elements before entering the cooling duct via two outlet vents. LUBRICATION SYSTEM Oil is used to lubricate the bearings and gears within the compression elements and gearbox and to cool the compression elements. A motor driven oil pump pumps oil from the integral sump via the air cooled oil cooler into the cooling jackets of low pressure and high pressure compression elements before passing through a full flow 10 micron oil filter, and pressure relief valve to the gears and bearings. The oil pump and cooling fans are initiated prior to the compressor start up and after the compressor stops ensuring full lubricant pressure and cooling prior to rotation of the compression element and during stopping. REGULATION SYSTEM A pressure transmitter connected to the control system monitors the compressor discharge pressure and the pressure is continuously displayed on an LED display. The control system unloads the compressor by closing the suction regulator when the programmed P1 pressure set point is achieved and loads the compressor by opening the suction regulator when the pressure falls to the P2 set point. When the compressor unloads the blowdown valve exhausts all pressure within the compressor ensuring low unloaded power. If the pressure remains above the P2 set point for the programmed run on time the main motor will stop and the compressor will revert to standby mode. When in standby mode the compressor will restart automatically if the pressure falls to the P2 set point and go onto load. Internal use only Marketing May 1999
MAINTENANCE Two hinged and removable doors provide access to a grouped service component area. The air intake filter, oil filter, breather filter, oil level indicator, oil fill point and pumped quick oil drain hoses are all serviceable via these two doors. The pumped quick oil drain facility enables oil changes to be undertaken quickly and cleanly. SILENCING ENCLOSURE The compressor is housed in an acoustically lined epoxy coated steel enclosure with complete access for maintenance purposes via hinged lift-off doors. A cabinet filter is fitted in the ventilation air intake to provide particle filtration. The cooling air outlet is located in the enclosure roof. CONTROL AND ELECTRICAL SYSTEM The compressor is fitted with a SureScan microprocessor based electronic control system incorporating a liquid crystal message display, mimic diagram with LED fault indicators, dedicated LED pressure display, membrane switches and providing advanced compressor monitoring and operating possibilities. Features: Mains power on LED Auto restart enabled LED Remote control enabled LED Start button Stop button Emergency stop button Service required button Values button Hours button Reset button Menu operating buttons Mimic diagram with LED fault indicators Pressure display bar/psi selectable Temperature display 0 C/ 0 F selectable Status message display Fault history store (last 15 faults) Standard control facilities: - Remote stop and start - Remote start enable - Remote load enable - Remote load/unload - Auto restart - Auto restart enable - 5 remote fault inputs - 5 remote fault repeat outputs - Available output - Group alarm output - Running output - On load output - Group trip output - Service due output - Timer control (timer not supplied) - RS485 communications port Note: All outputs are via volt free contacts. Values displayed: - Plant discharge pressure - Total hours run - Hours run onload - Service hours to run - Oil pressure and temperature - 1st stage delivery air temperature - 2nd stage intake air temperature - 2nd stage outlet air temperature - Plant delivery temperature - Cooling air inlet temperature - Interstage pressure Fault protection facilities: Extension module fault shutdown Emergency stop Rotation fault shutdown (reverse rotation, phase loss or imbalance) Main motor fault shutdown (overcurrent or high winding temperature) Fan or oil pump motor fault shutdown (overcurrent) Circuit breaker tripped High air pressure shutdown Interstage pressure alarm and shutdown Oil pressure low alarm and shutdown Oil temperature high alarm and shutdown 1st stage delivery air temp high alarm and shutdown 2nd stage intake air temp high alarm and shutdown 2nd stage outlet air temp high alarm and shutdown Plant delivery temperature high alarm and shutdown Air and oil temperature probe fault shutdown Service monitoring messages: Change intake filter Change oil filter Oil level low (when stopped) Service due (programmed interval exceeded) STANDARD PACKAGE Comprises: Two stage oil-free compression element assembly IP55 totally enclosed fan cooled main motor IP55 motor driven cooling fans Air intake filter and automatic regulation system Air cooled intercooler, aftercooler and oil cooler First and second stage moisture separators with solenoid operated condensate drain valves First and second stage pulsation dampeners / silencers Interstage and discharge pressure relief valves Discharge check valve Blowdown valve and silencer IP55 Motor driven oil pump Full flow oil filter Internal air and oil piping SureScan control system and instrumentation Emergency stop button IP54 Electrical enclosure housing the control system, star delta main motor starter and direct on line fan and oil pump motor starters Free standing steel baseframe with forklift slots Epoxy coated steel silencing enclosure with hinged removable doors for maintenance access with key lockable catches OPTIONS Level controlled condensate drains Door interlocked mains switch Low ambient heaters Soft (ramped) main motor starting Weatherproof and rental versions
CPD7941/055NA Compressor Performance Data Oil-Free, Air Cooled, Rotary Screw Compressors - Dryclon Range Models D55, D90, D110, D150 (60Hz) Performance Data Minimum working pressure psi.g D55 D75 Maximum working pressure psi.g 125 125 145 125 145 125 145 125 145 Minimum ambient temperature Maximum ambient temperature D75 D90 D90 D110 D110 D150 D150 104 0 F/40 0 C 104 0 F/40 0 C 104 0 F/40 0 C 113 0 F/45 0 C 104 0 F/40 0 C 113 0 F/45 0 C 104 0 F/40 0 C 113 0 F/45 0 C 104 0 F/40 0 C 60 psi.g cfm* 277 413 364 531 477 644 594 815 786 40.76 54.86 54.86 77.70 65.90 92.55 91.51 125.18 123.44 51.53 66.31 66.32 89.93 77.43 107.44 106.34 141.27 139.44 85 psi.g cfm* 273 408 360 527 473 639 589 808 781 47.62 64.28 61.72 86.12 75.32 103.79 99.93 137.37 134.68 58.91 77.38 73.64 98.83 87.41 119.33 115.24 154.10 151.27 100 psi.g cfm* 270 405 357 524 470 636 587 803 777 51.74 69.94 65.84 91.17 80.98 110.53 104.98 144.68 141.42 63.34 82.42 78.04 104.18 93.39 126.46 120.59 161.80 158.36 110 psi.g cfm* 269 403 355 522 468 633 585 800 775 54.49 73.71 68.59 94.54 84.75 115.02 108.34 149.56 145.91 66.29 86.45 80.98 107.74 97.38 131.22 124.15 166.93 163.09 125 psi.g cfm* 266 401 353 520 465 630 582 796 772 58.53 79.27 72.71 99.50 90.40 121.64 113.40 156.74 152.65 70.64 92.38 85.38 112.99 103.37 138.22 129.49 174.49 170.19 145 psi.g cfm* - - 349-462 - 579-768 152 psi.g cfm* - - 78.21-97.96-120.14-161.66 - - 91.26-111.36-136.63-179.67 Total Package Input kw at no load 16.6 21.8 20.1 26.6 24.4 32.6 30.5 41.1 40.1 1st/2nd stage male rotor speeds Discharge temperature of compressed air* rpm 5894 / 8970 79 0 F/26 0 C 8059 / 11985 Free field noise level @ 1 metre** db(a) 73 74 75 76 77 Electrical Data Nominal Motor Rating HP 75 100 125 150 200 Standard drive motor detail Oil pump motor detail Cooling Fan motor detail 7253 / 10289 10441 / 14605 9161 / 12777 12079 / 17910 11234 / 15447 15044 / 21940 14627 / 20252 2 x 4HP, NEMA13(IP55), totally enclosed 2 x 7.5HP, NEMA13(IP55), totally enclosed Full load current - 460volts amps 109 137 164 210 270 Starting current - 460volts amps 250 280 365 509 679 Full load current - 575volts amps 86 109 130 167 215 Starting current - 575volts amps 200 224 292 407 543 Cooling Data Cooling fan capacity cfm 13278 19211 Heat rejected by cooling fans Btu/min 4020 5257 5194 6430 6337 7866 7776 9930 10225 Max. pressure drop in cooling air outlet ducting Maximum length of cooling air outlet ducting Recommended cooling air outlet duct dimensions Weight, Dimensions and Capacities Compressor oil capacity US galls Compressed air delivery connection Condensate drain connections Weight-package lbs 5038 5478 5632 6138 6486 Weight-compression element lbs 1098 Weight-IP55, TEFC motor lbs 506 Package dimensions - LxWxH Miscellaneous Proposal drawing Specification inches CPD CPD *Measured and stated in accordance with ISO1217 Annex C and Pneurop/Cagi PN2CPTC2 and at the following reference conditions : Air Intake Pressure - 14.5 psi.a(1 bar a), Air Intake Temperature - 68 0 F(20 0 C), Humidity - 0%(dry) **+/- 3dB(A) according to Pneurop/Cagi Conversion factors: m 3 /min = cfm / 35.3147, HP = kw / 0.746 58 32 0 F/0 0 C (Refer to Product Management for higher or lower ambients) Refer to Product Management 81 0 F/27 0 C 82 0 F/28 0 C 79 0 F/26 0 C 82 0 F/28 0 C NEMA13(IP55), totally enclosed fan cooled, service factor 1.15, motor speed 3585 rpm 2.0HP, NEMA13(IP55), totally enclosed fan cooled 0.59 inches H 2 O 118" of straight duct plus 1 right angle bend 57.87" x 23.23" or equivalent cross section area 10.57 Flanged 3" ASA 150lb Raised Face Automatic:2 x 3/8" NPT Female / Manual: 2 x 1/2" NPT Female 946 1100 1430 1826 114 x 63 x 80.7 CPD7946/075 CPD7948/075 Internal use only Marketing September 1999
CPD7946/075 Proposal Dimensions Oil-Free, Air Cooled Rotary Screw Compressor - Dryclon Range Models D55, D75, D90, D110, D132, D150 Cooling Air Outlet END VIEW F A 1012/39.84" 2050/80.7" FRONT VIEW 2895/114" 45/1.77" E D C B 189/7.44 " Motor Cooling& Suction Air Inlet Cooling Air Inlet 143/5.63" 101/ 3.98" 34/1.3" CTRS Cooling Air Outlet PLAN VIEW 925/36.42" 1600/63" A AIR DISCHARGE FLANGE DN80 BS4504 (DIN2633) PN16 3 ASA 150lb RF B C D E F MANUAL CONDENSATE DRAIN - INTERSTAGE AUTOMATIC CONDENSATE DRAIN - INTERSTAGE MANUAL CONDENSATE DRAIN - DISCHARGE AUTOMATIC CONDENSATE DRAIN - DISCHARGE ELECTRICAL CABLE ENTRY GLAND PLATE G1/2 1/2 NPT.F G3/8 3/8 NPT.F G1/2 1/2 NPT.F G3/8 3/8 NPT.F 298 x 198 11.73 x 7.8 Cooling Air Inlet All dimensions in millimetres and inches DO NOT COPY Internal use only Marketing August 1999
Abc P&I Diagram Dryclon Air Cooled Models D55 to D150 Uncontrolled Document