CCi CC40 User manual

Operation and Maintenance
Manual
Natural Gas Booster
40 HP @ 2200 RPM

2
Table of Contents
INTRODUCTION………………….………………………………………….…………4
Contact Information………………………………………………….………….4
How to Use This Manual....................……………………………….…………..4
Compressor Identification ………………………………………….…………...5
Parts and Service …………………………………………………….…………..5
SAFETY PROCEDURES…..…..………….……………………………………………6
STARTUP AND SHUTDOWN INSTRUCTIONS……………………….……………7
Installation Instructions…………………………………………….…………...7
Purge and Leak Test Instructions………………………………….…………...7
Starting The Compressor…………………………………………….………….8
Power Test …………………………………………………………….………….9
Setup Instructions …………………………………………………….………..10
ENGINE…………………………………………………………………………………10
Safety Gauges………………………………………………………….………..10
Fuel System …………………………………………………………….……….10
Adjustment………………………………………………………………….…10
Stopping ……………………………………………………………….………..11
Timing…………………………………………………………………………...11
Valve adjustment ……………………………………………………………….11
Oil ………………………………………………………………………………11
Oil Change Interval…..…………………………………………….…………11
Spark Plugs……………………………………………………………………...12
Oil Filter…………………………………………………………………………12
Air Flow and Fan……………………………………………………………….13
COMPRESSOR ………………………………………………………………………...13
Starting After Extended Storage (1 Month or More) ………………………..13
Oil and Filter……………………………………………………………………14
Coalescing Filter………………………………………………………………...15
High Recycle Regulator………………………………………………………...16
Low Recycle Regulator…………………………………………………………17
Inlet Regulator ………………………………………………………………….18
Utility Regulator……………………………………………………………….. 19
Fuel Gas Regulator……………………………………………………………..20
Belts and Sheaves……………………………………………………………….20
Replacement......................................................................................................20
Ratio Change…………………………………………………………………..20
Ratio Table ……………………………………………………………………...21
ENGINE CONTROL PANEL………………………………………………………....22
COMPRESSOR CONTROL PANEL ……………………………………………...…23
ANNUNCIATOR……………………………………………………………………….24

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APPENDIX ………………………………….………………………………………….26
Bolt Torques …………………………………………….……………………26
Recommended Spare Parts ……………………………………………………26
Shutdown and Alarm Setpoints………………………………………………..27
Compressor Compartment Panel Side …………………………………….…28
Compressor Compartment Compressor Side …………………………….…29
Engine Compartment Panel Side …………………….…………………….…30
Engine Compartment Compressor Side …………….……………………..…31
Warranty Information ……....…………………………………………………32
Inspection, Maintenance and Service Log……………………...……………..34
VI Planning Sheet……………………………………………………………….38
P&ID……………………………………………………………………………. 39
Electrical Wiring Diagrams…………………………………………………….40

4
Introduction
Compact Compression Inc. is pleased that you have selected our equipment for your
requirements. CCI boosters are inspected and tested before leaving the shop. However,
certain checks should be made before placing the booster into regular service. Please
read the Initial Installation and Start-Up section in this manual.
Contact Information
General
Compact Compression Inc.
#8, 1820 – 30th Ave NE
Calgary AB, T2E 7M5
Ph: 1-403-219-3026
Fax: [phone]
How to Use this Manual
This manual contains instructions on the safe operation and preventative maintenance of
your CCI natural gas booster. We urge you to read this manual prior to start-up or
operation of the package.
The Table of Contents permits you to quickly open the manual to any section.
Compact Compression Inc., boosters are built with a variety of standard and/or optional
components to suit a broad range of customer requirements. This manual does not
identify equipment as standard or optional. All the equipment described in this manual
may not be found on your package.
Please pay special attention to the NOTES, CAUTIONS, and WARNINGS.
WARNINGS remind you to be careful in areas where carelessness can cause personal
injury. CAUTIONS are given to prevent you from error that could cause damage to the
equipment. NOTES give you added information designed to help you.
The descriptions and specifications contained in this manual were in effect at the time of
publication. Compact Compression Inc. reserves the right to discontinue models at any
time, or to change specifications or design without notice and without incurring
obligation.

5
Compressor Identification
An identification label is affixed to the left side of the trailer below the control panels.
The label contains the date of manufacture, serial number, model, horsepower, and area
classification. The model and serial number are required when seeking information
concerning the operation and/or ordering replacement parts.
Parts and Service
Replacement parts and service can be obtained from Compact Compression Inc. by
calling 1-403-219-3022. The compressor model and serial number will be required when
seeking information and/or ordering parts.
Service and technical support supplied by Compact Compression Inc. can be obtained by
contacting 1-403-219-3022.

6
Safety Procedures
CAUTION: Read all instructions before operation
A natural gas compressor has complex controls and operating procedures which are
detailed in this manual and must be understood and followed for safe and effective
operation.
1. Do not alter the plumbing or wiring in any way without authorization in writing
by the manufacturer. Injury, death or damage to equipment can result.
2. Always Purge and Leak Test the system after installing on site or when any of the
process piping has been opened. See Purge and Leak Test system. WARNING
Failure to purge completely can introduce oxygen into the system. When
combined with natural gas as a fuel and a source of ignition (high temperature)
this may produce an explosion which can injure or kill people and destroy
equipment.
3. Do not have an open flame or spark near a Natural Gas Compressor. Natural Gas
compressors process natural gas which can form a flammable or explosive
mixture with air, an open flame or spark will ignite this mixture.
4. Always carry a functional Hydrogen Sulfide monitor while working in the
vicinity of a natural gas compressor. Natural gas can contain Hydrogen sulfide
which is fatal if inhaled, even in low concentrations.
5. Do not set discharge pressure higher than 250 psi. Injury, death, or damage to
equipment can occur if specified pressure is exceeded.
6. Do not set inlet pressures above 70 psi. Injury, death, or damage to equipment can
occur if specified pressure is exceeded.
7. Keep enclosure doors closed while running. The compressor has moving fans,
shafts, belts, gears, and couplings, which are dangerous and can kill or maim. All
Compact Compression machines are designed with sufficient cooling capacity to
be run with the doors closed.
8. Do not place any part of your body near moving machinery in the event that the
doors must be kept open while running the machine to adjust settings or
troubleshoot.

7
Startup and Shutdown Instructions
Installation Instructions
1. Jack and level compressor
2. Open front and rear louvers
3. Inlet ball valve closed
4. Inlet pressure reducing regulator to 0: All the way out
5. Attach Process Vent Pipe. Yellow pipe (loose in enclosure) screws into elbow at
right rear and u-clamped to bracket on roof)
6. Connect suction and discharge lines
7. Connect condensate line as required
8. Open engine oil maintainer block valve
9. Open glycol tank block valves
Purge and Leak Test Instructions
1. Set Inlet Regulator to a pressure of 0
2. Close the manual recycle valves along with the high and low pressure recycle
valves
3. Open the Purge Valve(blowdown valve). Allows purge gas to flow to process vent
4. Open Inlet Ball Valve
5. Increase inlet pressure by screwing inlet valve in 1/ 2 turn
6. Turn on main power and ignition. Press “Test” button on Annunciator. This will
give 5 Minutes to purge and leak test the unit. If you run out of time, press
“Reset” and “Test” again for another 5 Minutes.
7. Purging will start as inlet pressure increases.
There will be an audible indication of gas passing through the piping and out the
vent stack
8. After venting for a couple of minutes all air will have been vented from the
system
9. Close Purge Valve (Blowdown Valve).
10. Increase inlet pressure as much as possible to a maximum of 65 psi. Well pressure
may limit maximum
11. Listen for leaks, depressurize and repair if necessary.
12. Decrease inlet pressure to 0. Screw Inlet Regulator all the way out
13. Open Purge Valve to relieve pressure in system
14. Close Purge Valve (blowdown valve).

8
START UP (NOTE: *Only required on initial startup on a location)
1. *When starting for the first time read all instructions for starting and adjusting
unit.
2. *Set high suction pressure shutdown at 65 psi
3. *Set low suction pressure shutdown at 0 psi
4. *Set high discharge pressure shutdown at 250 psi
5. *Set low discharge pressure shutdown at 0 psi
6. *Low pressure recycle block valve closed
7. *High pressure recycle block valve closed
8. Check fluid levels
a. Engine oil level
b. Engine oil day tank level.
Does not have to be full but should be topped up to prevent shutdown on
low oil level
c. Glycol day tank level
d. Compressor oil level
e. Scrubber level
9. Blow down unit.
This relieves backpressure on the screw allowing a minimum power start
which aids in cooling and extending belt life.
10. Open inlet ball valve.
11. Open manual recycle valve
12. Back inlet regulator adjusting screw all the way OUT and then IN until it meets
resistance
13. Open compressor oil bypass valve (oil temp < 20C)
14. Engine speed control to idle (ccw)
15. Disengage belts (start position)
16. Power ON
17. If outside temperature below -10C Depress start button with ignition off until
engine oil pressure gauge reaches 20 psi.
18. Ignition ON
19. Depress Starter Switch to turn engine
20. The annunciator has a 2 min timer for oil pressure and low discharge pressure. If
engine doesn’t start, turn Power Switch OFF and ON and try again
21. Check oil press
22. Set inlet regulator @ 3-5 psi.
23. Check to ensure compressor fan is turning
24. In winter time ensure dampers are closed ( open in summer)
25. At idle engage belts (clutch switch in ENGAGED position then pull up on handle
to push the drive sheave down)
Discharge pressure above 50 psi within 1 minute
26. *Ensure Fuel Gas Regulator @ 50 psi.
27. Set engine speed @1200rpm. And wait for compressor oil to reach >20C then
slowly close the bypass valve
28. Wait for discharge temp to reach 130C
29. Turn speed to desired setting
30. Slowly close Manual Recycle valve
31. Set inlet regulator to desired pressure

9
POWER TEST
1. Start with package running normal.
2. Raise suction pressure as high as possible,DO NOT EXCEED 70 psi.
3. Choke discharge to increase backpressure as high as possible,DO NOT EXCEED
250 psi.
4. When the engine RPM starts to drop, max HP has been reached.
5. On compressors equipped with a low vi. the pressure ratio should not exceed
five.For example: suction press.=10(+14) x 5 = 120. With 10 pounds of pressure
on the suction gauge the discharge should not exceed 120 lbs.
6. Now reduce the discharge pressure until the engine vacuum gauge reads -2”.This
will be the pressure setting for the HP recycle regulator.
SETUP INSTRUCTIONS
1. Determine LP recycle setting. Determined by well conditions. Must be min. 5
psig or above.
2. Determine low suction pressure shutdown , 5psi. below LP recycle or 0 min.
3. Determine high suction pressure shutdown , 5 psi. above power test. DO NOT
EXCEED 70 psi.
4 Determine HP recycle setting.Typically 20-25 psig above normal operating
pressure. Can be set higher (determined by power test) but DO NOT EXCEED
250 psi.
5. Determine high discharge pressure shutdown. Set 10psi. higher than HP recycle
setting but DO NOT EXCEED 250 psi.
6. Determine low discharge pressure shutdown. Has to be at least 50 psi above
minimum suction pressure.
7. Set Hp recycle.
a. Start with manual bypass valve open.
b. Close HP recycle block valve.
c. Close LP recycle block valve.
d. Screw out HP recycle valve adjusting screw all the way.
e. Slowly open HP recycle block valve.
f. Slowly close manual recycle valve.
g. Isolate compressor from pipeline by shutting valve between compressor
discharge and pipeline
h. Screw in high pressure recycle valve to maximum expected line pressure
or engine vacuum reaches -2” on the gauge
i. Lock HP recycle valve adjusting screw
j. Slowly open valve between compressor and pipeline
8. Set LP recycle
a. Set LP recycle only after setting HP recycle.
b. Close LP recycle block valve.
c. Choke well pressure using inlet ball valve to reduce inlet pressure to
1-2psi
d. Screw out low pressure recycle valve all the way
e. Open block valve
f. Screw in LP recycle valve until suction pressure rises to the min desired
suction pressure
g. Lock LP recycle valve adjusting screw
h. Slowly open Inlet ball valve.

10
Engine
Safety Gauges
The engine is equipped with instrument panels which contain shutdown gauges for High
Engine Coolant Temperature and Low Engine Oil Pressure. The fault light for the Air
Fuel Ratio controller indicates malfunction of the controller. Causes could be the O2
sensor needs replacement but commonly the unit just needs the power to be cycled. This
is easily accomplished by tripping and resetting the breakers in the back of the panel.
Fuel System
The engine fuel system is simple to adjust using the supplied gauges and LCD readout.
The Fisher S402 regulator is used to regulate the fuel pressure. Set at 17” H2O as
indicated by the Fuel Press gauge on the instrument panel.
Powervalve limits the maximum horsepower output of the engine by restricting the gas
flow. The initial setting is 7 mm (9/32 in), measured from the top of the adjusting screw
to the top of the nut.
Fuel ratio is adjusted by removing the top cap of the Maxitrol and turning the adjuster.
An initial setpoint is 10 mm (3/8 in) measured from the top of the Maxitrol to the top of
the adjuster. Turning the adjuster downwards richens and upwards leans the mixture.
Adjustment
If the mixture is badly out of adjustment set the power valve and mixture to the stock
settings above. Otherwise begin at the next step.
1. Remove one of the wires to the solenoid so there is no adjustment by the air/fuel
ratio controller. Ensure it does not touch any metallic parts or it may blow a fuse.
2. Bring the engine to idle.
3. Adjust the mixture until the light on the AFR Controller blinks from red to green.
If it is solid red then lean it, and if solid green richen it. Move in small
adjustments, 1/8 turn, and after each adjustment seal the top of the Maxitrol to get
an accurate reading. Repeat until the color of the LCD has just changed. Replace
the Maxitrol top cap.
4. Plug in the wire previously removed.
5. The duty cycle LCDs should indicate a duty cycle and the single LCD should be
blinking from green to red.
6. Bring the compressor up to power.
7. The duty cycle should be around 50% and the green-red LCD blinking back and
forth.
8. If the engine leans out (goes solid green) or the duty cycle goes to 0% the power
valve is set too far in. To allow more gas turn out the power valve in small
increments until the duty cycle rises and the blinking returns. Lock it in place.
9. A few iterations may be required to get it right. On the second try start back at the
idle setting with the solenoid wires both connected.
10. You now have the mixture set to stoichiometric across the rpm/power band. The
goal of this procedure is to have a green-red blinking LCD with about a 50% duty
cycle when the compressor is at operating conditions.

11
Stopping
Reduce the power requirements of the compressor compartment by reducing the suction
pressure to 2-3 psi. Bring the engine to idle. Run the engine for a few minutes at idle to
allow the coolant system to cool down before turning the Ignition switch to the OFF
position. Turn the panel power switch OFF.
Timing
Rotate the distributor counter clockwise to advance and clockwise to retard timing.
Remember to tighten the body clamp.
Factory setting is 28˚BTDC.
Valve Adjustment
Warm engine to operating temperature
Shut off and remove valve cover
Turn clockwise (looking at front) to TDC of #1 on compression stroke
At this position you can adjust:
#1 Intake & Exhaust
#3 Exhaust
#4 Intake
Turn engine clockwise one full turn and adjust
#2 Intake & Exhaust
#3 Intake
#4 Exhaust
Replace the Valve cover
Valve Adjustment
Back off the adjusting nut until the rocker has play
Rotate the pushrod with your fingers while slowly tightening the adjusting nut
When the lash is removed (pushrod stops spinning freely) STOP.
Tighten the adjusting nut ¼ turn further.
The valve is now done.
Oil
Compact Compression Inc. 5W30 Engine Oil.
Oil Change Interval
It is recommended to change the engine oil monthly, or every 700 hrs. Both the oil in the
engine sump and the bypass filter housing should be changed.

12
Spark Plugs
Spark Plugs should always be replaced with the proper type and heat range. Stock plugs
are AC DELCO R46 TS and the gap is 0.045 inches. Firing order is 1-3-4-2
The correct plug wiring is included for reference.
Oil Filters
The engine oil filter used is a PH11 or equivalent. The engine oil filter should be changed
every service.
The bypass filter element is a Harvard H-O778. It is recommended to change this element
annually, or if the oil has become contaminated with any foreign substance like glycol.

13
Air Flow and Fan
The engine compartment air flow is in through the front louver and out through the sides
of the top front duct. The fan has a manually adjustable pitch. If the engine coolant runs
too hot pitch can be added in 5 degree increments. In the winter one can either partially
close the inlet louvers or reduce the fan pitch. When required; clean off the bug screen or
washout the radiator in the reverse direction of flow. Excess bugs and debris in the
radiator core will cause the unit to run hot.
The stock fan pitch is 35 degrees. When adjusting the fan be sure to mark all pieces,
including any balancing washers so they go back together the same way and maintain
balance. When you disassemble the fan hub 5 small white cylinders will fall out. These
are used to set the pitch of the fan.
Compressor
Starting after Extended Storage (1 month or more)
If the screw has been sitting without
operation for more than one month it
will require priming with oil before
starting.
Relieve all pressure from the compressor
compartment
Remove the 1” plug above the screw
inlet
Pour about 1 liter of suitable CCI screw
compressor oil into the elbow and
replace the plug.
Follow the standard startup instructions
when this is done.

14
Oil and Filter
Replace the oil at the recommended intervals with Compact Compression Inc.
recommended Screw Oil. Fill it to the level shown below. When replacing the oil filter
ALWAYS use an anti-seize product on the threads to prevent galling of the aluminum.
Oil Fill Level Oil Filter

15
Coalescing Filter
The coalescing filter periodically needs to be replaced. It is housed in the upright vessel
shown below. Replace it if the differential pressure reaches 8 psid.

16
High Recycle Regulator
Kimray 130 SGT-BP-D
Pictured below is the 1” back pressure regulator. It controls the high recycle
pressure. Turn the top adjuster inwards to increase the set pressure and outwards to
decrease. If the pipeline gets backed up the discharge pressure will rise. To avoid having
the compressor shut-down the high recycle allows gas back to the suction side and limits
the screw discharge pressure to acceptable limits. A starting value would be 20 psig
above the pipeline pressure. If the pipe pressure continues to rise, the discharge check
will close and the unit should continue to run in full recycle. The high recycle should be
set below the high discharge pressure shutdown.

17
Low Pressure Recycle
Fisher 627
The low pressure recycle is a pressure reducing regulator used to prevent the well
pressure from becoming too low. To adjust, remove the top cap and turn the adjusting
screw. In for increased setting and out to decrease. This regulator should be set above the
low pressure shutdown switch and below the inlet regulator setting. Capable settings are
in the 5-20 psig range.

18
Inlet Regulator
Kimray 230-SGT-PRB-D
The inlet regulator pictured below is a balanced pressure reducing regulator. Its purpose
is to limit the suction pressure to the screw when wellhead pressures are high. Turning
the top adjuster inwards increases the set pressure and turning it outwards decreases the
set pressure. Anything over 70 psig is not allowed by limits of the screw. If the well
pressure is higher than the setpoint then the regulator will maintain the set pressure to the
screw. If the well pressure falls below set pressure the regulator will open fully and allow
gas to flow at that pressure. For example at 20 psig setpoint, 10 psig well, the regulator
will be fully open and the screw suction pressure will be 10 psig. The inlet regulator
should be set at a pressure above the low recycle regulator setpoint.
Adjustment
In →Increase
Out →Decrease
Setpoint: Preferred inlet pressure. 70 psig max

19
Utility Gas Regulator
Control Air 700-DF
The regulator sets the pressure for the scrubber pneumatic dump and inlet pressure to the
fuel gas regulator and clutch cylinder. Turn clockwise to increase and counter clockwise
to decrease the setpoint. Recommended setting is 50 psig. If the pressure is set below 50
psi. there is a danger of belt slippage.
Fuel Gas Regulator
Fisher HSR
Used to set pressure for the engine fuel system and gas fired heaters. Recommended
setpoint is 17” H2O. To adjust remove the top cap and turn inwards to increase and
outwards to decrease. Use the fuel pressure gauge to set the pressure and always have a
small amount of flow and the top cap installed to make accurate settings.

20
Belts and Sheaves
The belts will need replacing due to normal wear or the drive ratio will need changing if
conditions change dramatically. The two procedures are outlined below.
Replacement
WARNING: Suitably prepare the compressor unit for maintenance and use safe work
practices. Unhooking the battery cables and relieving all pressures is a minimum.
Remove the belt guard.
Remove Allen head bolts from the driveshaft yolk and slide it out of the way.
Slip the belts off the sheaves.
One at a time, remove the belts. They should just slip through between the shaft and the
drive sheave.
Replacement is the reversal of removal.
Ratio Change
When a ratio change is necessary the belts and driven sheave must be replaced. Due to
the nature of the belt tensioner and belt alignment, only CCI sheave ratios are
recommended. A table of available ratios can be found on the next page.
Remove the belt guard.
Remove the old belts as above.
Remove the driven sheave and bushing and replace with the new sheave and bushing.
Install the new belts.
Replace the belt guard.