Powerex WhisperAir PCC Series Manual

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 1 of 32
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect
yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property
damage! Retain instructions for future reference.
Installation, Operation and Basic Maintenance Instructions
Description
The Powerex WhisperAir™ Rotary Tooth Compressor
System is an enclosed two-stage air-cooled oil-free
rotary tooth air compressor. A touch panel control is
installed on the compressor enclosure.
Air Flow
Air drawn in through intake filter (IF) and intake
throttle valve (IV) is compressed in the low-pressure air
end and is discharged to the intercooler (CI). Air,
cooled in the intercooler (CI), is discharged to the drain
separator for intercooler (DS1), removing the
condensate water, and is compressed in the high-
pressure air end (Eh). Then, the compressed air passes
through the pulsation damper (PD) and flows into
aftercooler (Ca). Air, cooled in the aftercooler (Ca), is
then discharged to the drain separator for aftercooler
(DS2), removing the water and is delivered to the air
outlet.
The water, separated by the drain separators
(DS1/DS2), will be discharged through electronic drain
valves (EV1/EV2). When the compressor switches to
unload operation, the air trapped in the pulsation
damper (PD) and the high-pressure air end (Eh) is
blown off through unload silencer (US). The check
valve (CV) is installed downstream of pulsation damper
(PD) to prevent compressed air blows back into the
compressor during unloaded operation.
For PCCMD models, the intake air is configured for
connection to the facility remote intake piping.
Oil Flow
Oil is circulated by oil pump (OP). Oil flows from oil
tank (GC), through oil cooler (Co) and oil filter (OF), to
bearings and the gears. When the oil pressure reaches
a given value, by-pass valve is opened to decrease the
pressure.
Symbol
Name
Symbol
Name
IF
Intake filter
Co
Oil cooler
US
Unload silencer
OF
Oil filter
IV
Intake valve
FN
Cooling fan
EI
Air end (low pressure)
PS
Pulsation damper
Ci
Intercooler
CV
Check valve
EV1
Electronic drain valve
Ca
Aftercooler
Eh Air end (high pressure) EV2
Electronic drain valve
(for aftercooler)
OP Oil pump DS1
Drain separator
(combined with EV1)
GC Oil tank (gear case) DS2
Drain separator
(combined with EV2)
Diagram 1: Air Flow and Oil Flow

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 2 of 32
Cooling System
The compressor is equipped with an intercooler (Ci),
aftercooler (Ca), and oil cooler (Co) to cool down the
compressed air and oil. Cooling fan (FN) generates the
cooling air.
Load Operation
When the pressure drops down to the load setting
pressure, the solenoid valve is opened, and air is
supplied to intake valve (IV) through pulsation damper
(PD). When the air reaches intake valve (IV), the valve
is opened and the compressor starts load operation.
Unload Operation
When the demand for compressed air is satisfied and
reaches the unload setting pressure, the solenoid valve
is closed, and air is released to atmosphere through
unload silencer (US). When intake valve (IV) is closed,
the compressor switches to unload operation.
VFD Model operation:
At low system pressures the VFD control increases
the main motor speed to 106% of nominal in order to
increase air output. Because of the lower pressure,
motor load is acceptable at this speed.
When the demand for compressed air is low and
system pressure rises near to the final pressure, the
VFD control slows down the motor to reduce air
output. If the air output can match the system demand
the control will seek to maintain pressure at a balance
point between supply and demand. Speed can be
reduced to 40% of nominal. If demand is lower than
this, the system pressure will continue to rise and the
unload control will take over. Speed is maintained at
40% while unloaded. When demand returns, the
control will increase speed and reload the compressor.
If the unit remains unloaded, an automatic shutdown
will occur after 7 minutes of total run time. The system
will automatically restart when pressure drops. The
VFD reduces wear on the intake valve parts, reduces
power consumption when demand is less than 100%
and reduces the undesirable electrical supply system
effects of starting and stopping the main motor.
Safety Guidelines
A SEPARATE SAFETY BOOKLET IS PROVIDED ALONG
WITH THIS MANUAL. READ AND UNDERSTAND THE
SAFETY BOOKLET. This manual contains information
that is very important to know and understand. This
information is provided for SAFETY and to PREVENT
EQUIPMENT PROBLEMS. To help recognize this
information, observe the following symbols. MAKE
SURE EVERYONE OPERATING OR SERVICING THE
COMPRESSOR READS AND UNDERSTANDS ALL THE
INFORMATION PROVIDED. The operator must install
equipment in a safe location and is responsible for
following all related local work safety requirements
and regulations.
Danger indicates an
imminently hazardous
situation which, if not avoided, WILL result in death or
injury.
Warning indicates a
potentially hazardous
situation which, if not avoided, COULD result in death
or serious injury.
Caution indicates a
potentially hazardous
situation which, if not avoided, MAY result in minor or
moderate injury.
Notice indicates important
information which, if not
followed, may cause damage to equipment.
Powerex shall not be responsible for any damage or
injury caused by inappropriate operation, or from not
following the instruction manual.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 3 of 32
Model Description

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 4 of 32
Specifications for Standard System
Type
Unit
Model PCC500
Main Body
No. of Compression Stages
–
2
Rotating Speed Fixed speed version
RPM
6950
Speed adjusting range VFD mode –
105% at pressures below 100 psig, 100% to target setting, psig,
decreasing to 40% at max pressure
Unit
Suction gases, pressure, temperature
–
Air/Atmospheric Pressure 35-104°F
Discharge pressure
PSIG
109
F.A.D. (Free Air Delivery)
SCFM @ 100 PSIG
204, 209 (VFD)
Driving method
–
Direct driven with coupling, step-up gears
Control mode –
Load/Unload with automatic start/stop
(Models with R control use VFD operation of Main Drive Motor Only)
Working pressure PSIG
102-109 default setting for Load/Unload
105 default target pressure for VFD
Cooling method
–
Radiator + cooling fan air-cooled
Discharge air temperature
°F
Inlet temperature +22°F
Air outlet connection
NPT
1-1/2°F
Oil volume
Quarts
27
Oil Type
–
ISO32 PAO Synthetic gear oil ISEL2015-32
Noise level
dB(A)
68
The level of ground vibration
dB
Below 45 (the front side of the air compressor, above concrete)
Electrical Equipment
Power supply
–
Three-phase AC rated voltage ±10% 60 Hz
Starting method
–
Electromagnetic Star Delta starter or VFD
Compressor motor
Specification –
Horizontal shaft, D-flange, 3 phase, totally enclosed fan cooled, 2-
pole, type F insulation, IP55
Power
HP
50 (Service Factor S.F. 1.25)
Cooling fan motor
Specification
–
Three-phase, totally enclosed fan cooled, 6-pole, F insulation, IP54
Power
kW
0.75
Oil pump motor
Specification
–
Three-phase, totally enclosed fan, 4-pole, B insulation, IP44
Output
kW
0.4
Protection
Temperature
–
Detected by temperature sensors
Overload current, open phase
protection
– Detected thermal overload
Low oil pressure
–
Detected by oil pressure sensor
Suction filter clogging
–
Detected by negative pressure sensor
Over pressurization
–
Safety valve
Other
Dimensions (compressor only)
in
77”W x 40”D x 65”H
Weight (including oil)
lb
2940
NOTE: 1. F.A.D (Free Air Delivery) means the volume of atmospheric air that can be taken in by the compressor at inlet
conditions of atmospheric pressure. Equal to SCFM if inlet condition is standard.
2. Noise level is measured at the distance of 1.5m from the front of a compressor and at the height of 1m from ground.
3. Service factor means the allowable limit of the air compressor motor.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 5 of 32
Specifications for High Pressure System
Type
Unit
Model PCC500HP
Main Body
No. of Compression Stages
–
2
Rotating Speed Fixed speed version
RPM
6320
Speed adjusting range VFD mode –
105% at pressures below 116 psig, 100% to target setting, psig,
decreasing to 40% at max pressure
Unit
Suction gases, pressure, temperature
–
Air/Atmospheric Pressure 36 F to 104°F
Discharge pressure
PSIG
125
F.A.D. (Free Air Delivery)
SCFM @ 100 PSIG
179, 183 (VFD)
Driving method
–
Direct driven with coupling, step-up gears
Control mode –
Load/Unload with automatic start/stop
(Models with R control use VFD operation of Main Drive Motor Only)
Working pressure PSIG
118-125 default setting for Load – unload
121 default target pressure for VFD
Cooling method
–
Radiator + cooling fan air-cooled
Discharge air temperature
°F
Inlet temperature +22°F
Air outlet connection
NPT
1-1/2°F
Oil volume
Quarts
27
Oil Type
–
ISO32 PAO Synthetic gear oil ISEL2015-32
Noise level
dB(A)
68
The level of ground vibration
dB
Below 45 (the front side of the air compressor, above concrete)
Electrical Equipment
Power supply
–
Three-phase AC rated voltage ±10% 60 Hz
Starting method
–
Electromagnetic Star Delta starter or VFD
Compressor motor
Specification –
Horizontal shaft, D-flange, 3 phase, totally enclosed fan cooled, 2-
pole, type F insulation, IP55
Power
HP
50 (Service Factor S.F. 1.25)
Cooling fan motor
Specification
–
Three-phase, totally enclosed fan cooled, 6-pole, F insulation, IP54
Power
kW
0.75
Oil pump motor
Specification
–
Three-phase, totally enclosed fan, 4-pole, B insulation, IP44
Output
kW
0.4
Protection
Temperature
–
Detected by temperature sensors
Overload current, open phase
protection
– Detected by thermal overload
Low oil pressure
–
Detected by oil pressure sensor
Suction filter clogging
–
Detected by negative pressure sensor
Over pressurization
–
Safety valve
Other
Dimensions (compressor only)
in
77”W x 40”D x 65”H
Weight (including oil)
lb
2940
NOTE: 1. F.A.D (Free Air Delivery) means the volume of atmospheric air that can be taken in by the compressor at inlet
conditions of atmospheric pressure. Equal to SCFM if inlet condition is standard.
2. Noise level is measured at the distance of 1.5m from the front of a compressor and at the height of 1m from ground.
3. Service factor means the allowable limit of the air compressor motor.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 6 of 32
For maximum reliability
and life follow the
recommendations below:
1. Do not install this unit outside. It is intended for
indoor installation and operation protected from
the effects of weather, Moisture may damage the
equipment and may create hazards.
2. Install the unit where it safe from mechanical
damage. Install it on a solid, level floor. (Isolation
pads may be used, but may not be needed as the
unit has all internal moving parts isolated already)
3. Install the unit on an electrical supply system that
has the correct voltage and sufficient capacity to
operate the motor loads. Make sure the supply is
protected from power surges or spikes and that
the voltage does not drop more than 10% below
the nominal value.
4. Make sure the unit is grounded. Improper
grounding can create a risk of electrical shock and
may cause erratic operation of the unit controls.
5. Install the compressor unit where it can intake
cool, clean air. Do not use this machine for
compressing any gas other than air, or in an
environment where there are corrosive gasses or
liquid mists of any kind. Compressing flammable
gasses may result in explosion and death or injury
and damage the unit. Avoid dusty areas. The
system intake filter will become loaded quickly in
dusty conditions and will need to be changed
frequently, and the dust will reduce the ability of
the internal heat exchangers to function as
desired.
6. Make sure the electrical supply is configured and
installed according to national and local codes and
has local service disconnect that can be easily
accessed and operated when maintenance must
be performed. The Powerex unit does not include
a built in power disconnect.
7. Do not use this compressor as-is to provide
breathing air (get the rest of this warning from
other manuals).
8. Make sure the environment around this
compressor is controlled to prevent operating in
temperatures below 35°F (freezing will damage
the unit). Also make sure that the environment has
sufficient cooling to keep the temperature below
104°F under worst case conditions. Ambient
temperatures higher than 90°F will reduce service
life and may require more frequent than normal
maintenance.
9. Avoid operating the unit for extended time with
the panels off or access doors open.
10. Do not modify or alter the structure or electrical
circuit. Do not install any components that are not
approved by Powerex.
11. Make sure the condensate output ports are
connected to suitable collection and disposal
source. The unit has an oil lubricated gearbox that
will generate a small amount of oil vapor under
normal conditions and the condensate water may
need to be treated before it is disposed of. Follow
all national and local regulations for managing the
condensate. Do not restrict the condensate output
lines. Having condensate lines discharge into
storage containers with the outlet of the line
submerged will restrict the flow and may interfere
in their proper operation.
12. Make sure there is adequate space and
accessibility to perform required maintenance.
13. The compressor will shut down if there is a Power
failure unless the Automatic Restart is engaged
using the control panel. If a shutdown does occur
follow the restart procedure.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 7 of 32
Unpacking
Immediately upon receipt of the air system, inspect
for any damage which may have occurred during
shipment. Repair or replace damaged items before
use. The name-plate should be checked to verify the
correct model and voltage.
Do not operate unit if
damaged during shipping,
handling or use. Damage may result in bursting and
cause injury or property damage.
Product Check List
1. Check the model name, serial number, and
frequency of the compressor. Verify the
information matches the order and the Powerex
supply list.
2. Check the equipment for deformity or damage that
may have happened during transportation.
3. Check that all the following items have been
included with the compressor:
a. Instruction Manual – 1
b. Air outlet valve – 1
c. Panel key – 2
Moving and Lifting
Do not lift or move unit
without appropriately
rated equipment. Be sure the unit is securely attached
to lifting device used.
Moving with a forklift:
•Before moving the compressor, remove the front
and the back panels and insert forks in the slots.
•Make sure that the forks protrude from the other
side of the frame.
Lifting with a lifting device:
•As shown below, lift the compressor using forklift
slots and sling belt.
When lifting the
compressor, use protection
in order to avoid any damage on the compressor.
Make sure the sling belt is
strong enough to handle
the weight of the compressor. When lifting, the lifting
device must hold the compressor perpendicularly.
Make sure to keep the balance at all times.
Refer to the dimension drawing on the next page for
the center of gravity of the compressor.
If the sling belt is not strong enough to handle the
weight of the compressor when moving or lifting, the
compressor may fall onto the ground, causing serious
injuries or serious damages to the compressor.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 8 of 32
Dimension Drawing

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 9 of 32
Identification of Major Components:
Internal components front view

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 10 of 32
Internal components rear view:

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 11 of 32
Details of Outlet Ports:

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 12 of 32
Installation
1. Do not install outside.
2. The compressor system must be located in a clean,
well lit and well-ventilated area.
3. The area should be free of excessive dust, toxic or
flammable gases and moisture.
4. Never install the system where the surrounding
temperature is higher than 104°F or where
humidity is high.
5. Clearance must allow for safe, effective inspection
and maintenance.
6. Install the compressor on a level floor. If necessary,
use metal shims or leveling pads to level the
system. Never use wood to shim the unit. Unlevel
floor may cause vibration, noise, or failure of the
compressor.
7. Do not block the air compressor intake or exhaust
grating.
NOTE: Minimum of 36 in. of clearance is recommended
on all sides. Minimum recommended distance
between the top of the compressor and the ceiling is
48 in.
Piping
1. The drain pipes, from five drain outlets on the right
side of the compressor, to the drain collector, must
not be restricted. Do not allow the pipe outlet to
extend into the accumulated water in whatever
container is used.
Discharged drain may
contain oil. Condensate
disposal methods must account for conditions where
some oil mist from the gearbox ventilation system is
contained in the condensate.
2. When determining the diameter and the length of
compressed air outlet pipes, consider the pressure
drop and allow for the possible expansion of piping
network in the future. Avoid sharp bends. Keep
pressure drop to less than 1.5 psi. Refer to pipe
sizing charts as needed.
3. When installing branch pipes, make sure the pipes
are connected to the top side of the main pipes in
order not to let condensation water in the branch
pipes.
4. The main pipe shall have about 1/100 downward
slope away from the compressor to the end. When
encountering a U-shaped bend in piping and rising
piping, be sure to install a drip leg and drain valve
at the bottom.
5. Install the air receiver after setting up the
compressor. Do not place check valves or filters,
other than water separators, between the
compressor and the air receiver.
6. If you install an air dryer, install it after the air
receiver.
As the compressor is
regulated by load/unload
system, always install an air receiver.
Using an undersized air receiver will increase the use of
electricity and will decrease the product life. The
minimum size requirement of air receiver is 240 gal for
model PCC500.
For the pipe connection of the compressor, the flange
or union connection is recommended for easier
maintenance. When connecting outlet pipes to the
compressor use a union to facilitate maintenance in the
future. An isolation valve may be installed, make sure
it is open when the compressor is in use. Do not install
a check valve between the compressor unit and the air
receiver/tank.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 13 of 32
Ventilation
1. Installation area of the compressor must be
ventilated at all time for efficient operation.
While operating the
compressor, ventilate the
workplace to maintain the temperature in the range of
35-104°F. Operating the compressor with ambient
temperature above 104°F will damage the compressor
and will cause shut down of the equipment.
Temperatures above 90°F decrease the product. Cooler
temperatures increase operating efficiency, decrease
the product reliability, and requires reduced
maintenance intervals.
2. For general ventilation, as in the figure below, the
minimum amount of ventilation required to
prevent temperature rise is 16,500cfm for model
PCC500.
3. When installing ventilation fans, consider the
positions of cooling air inlet and cooling air outlet.
Inappropriate installation of fans will disturb the
air circulation in the workplace and may affect
performance of the compressor.
4. The ventilation air speed at cooling air inlet must
be slower than 980 ft/min.
Local ventilation A (auxiliary duct with no fan)
A duct only, without a fan may be utilized to
channel warmed cooling airflow out of the
compressor room if the duct backpressure is below
0.11 inches WC. At a flow of 4240 scfm.
In order to facilitate
maintenance and repair, a
flexible connection must be installed that is removable
at your convenience, as shown above. Make sure that
duct weight is completely supported by the wall or
ceiling, not by the compressor enclosure.
5. For local ventilation B (duct installed with a
ventilation fan), refer to the figure below for the
details.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 14 of 32
6. The ventilation air speed at cooling air inlet must
be slower than 980 ft/min.
7. Minimum volume of ventilation for local
ventilation B is 4,240cfm for model PCC500.
As shown in Figures
above, when the exhaust
fan is installed, make sure to leave 12-20 in. space
between the compressor and duct to facilitate
maintenance.
A flexible connector may be installed if desired. Make
sure the duct is supported by the ceiling or wall and not
by the compressor enclosure.
Wiring
Internal electrical wiring of the compressor has been
completed. Refer to the internal wiring, circuit diagram
that is packed into the control panel in the document
pocket.
A service disconnect must be installed ahead of the
compressor. The service disconnect may be a circuit
breaker.
RISK OF ELECTRICAL
SHOCK. Lock out and tag
out all sources of energy before servicing.
Wiring must be performed by a specialist in accordance
with national and local electric regulations.
Inappropriate wiring may cause electric shock or fire,
and may decrease the product life or cause failure of
the compressor.
1. Open each panel as shown in the figure below.
2. Connect the power cable (L1, L2, L3) to the
terminal block.
Use screwdriver
here after center
panel is removed,
right side panel will
swing out on hinges.
Use Panel Key here

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 15 of 32
3. Connect the ground wire to the ground terminal as
shown in the figure below – 1 X 3.
Input power and ground
connection for VFD models
are similar, panel layout will vary.
Grounding resistance must
be no more than 100Ω.
Inadequate grounding may cause malfunction of the
compressor and decrease the product life.
Remote Signals and Remote Monitoring
The Remote Control feature is enabled from the touch
screen. Activating this feature allows an external
contact closure to turn the unit on, open contacts turn
the unit off.
For remote control signals and remote monitoring,
connect appropriate wiring to the designated
terminals in the control box.
Refer to the circuit diagram for detailed information
and terminal numbers.
Alarm Signals: Terminals on the terminal strip provide
external alarm connection points as indicated on the
wiring diagram.
Commissioning
Preparation
1. Open the center front panel and the back panels.
2. Unscrew the yellow bolts on the gear case and the
motor and remove the shipping supports (yellow)
– (4)
3. Check the oil level on the sight glass.
a. Appropriate oil level is above the center of oil
gauge.
b. If the oil level is below the venter of the oil
gauge, add oil before performing test
operation (Use only Powerex Rotary Tooth
compressor gear oil or approved equivalent).
4. Open the control box and make sure all the wires,
including the power cable, are connected.
5. Confirm the power supply and voltage of the
compressor match and turn on the circuit breaker
or service disconnect.
Close the front panels.
6. Make sure the touch panel display is illuminated.
Check the Direction of Rotation
1. Touch “ON” on the switch to start the compressor
and touch “OFF” immediately. While the
compressor is being stopped, check the direction
of rotation to see if it is the same as the direction
Power conductors here

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 16 of 32
marked on the gear box. There is a small window
in the casting of the coupling housing between the
motor and gearbox to allow viewing of the rotating
parts.
2. If the compressor operates in the opposite
direction, the air compressor will stop due to the
low oil pressure. At this time, alarm message will
appear.
3. The oil pump motor and cooling fan motor are
wired at the factory to have the correct rotation
when the main motor is correct. You can check the
fan motor rotation by confirming that airflow is
upward from the top of the unit. If the oil pump
rotation is incorrect the pump will not generate
any oil pressure.
4. After correct rotation is confirmed, close the back
panels.
Starting
1. Open the compressed air outlet valve at the outlet
fitting. If possible open the outlet valves from the
receiver tank as well so the unit can start without
any compression load.
2. Close the manual drain valves (manual drain
outlet).
3. Push “ON” on the switch. On the touch panel, push
the “STATUS” button. As the compressor starts
running, the operation indicator on the lower right
will illuminate.
During Operation
1. Close the air outlet valves at the exit of the receiver
tank slowly. Check the display of touch panel to see
if the outlet pressure rises.
2. When outlet pressure reaches unloading pressure,
the compressor will be automatically switched to
unloaded operation. After the compressor runs in
unloaded operation for a total run time of 7
minutes the compressor will automatically stop.
Check the status of the compressor by touching
“STATUS” on the touch panel.
3. Open the air outlet valve slowly. Check the display
of the touch panel to confirm the outlet pressure
decreases.
4. When outlet pressure drops to the loading
pressure, the compressor will be automatically
switched to loaded operation. If the compressor
stopped automatically, it will automatically restart.
5. For VFD modes the operating sequence is similar,
except that as the pressure increase to be near to
the unload pressure, the main motor is slowed
down. When pressure decreases the main motor
speed is increased. The minimum motor speed is
40% of nominal and if the pressure continues to
rise under this condition, the unload operation will
take over. If the machine remains unloaded an
automatic shutdown will occur.
6. Operate the compressor in loaded operation for an
hour and check if there is any unusual noise,
vibration, or oil leakage.
7. If problems are detected, shut down the unit and
make corrections.
Stopping
1. Push “OFF” on the control panel switch. As the
compressor is being stopped, a message will be
displayed on the touch panel. If the compressor
was in loaded mode when the OFF button was
pushed, the control will force an unload condition.
The unit will run 30 seconds unloaded before
stopping.
2. After the compressor is completely stopped,
disconnect the circuit breaker.
3. Open the manual drain valve, and empty
condensate remaining in the separator.
Operation
Before Operation
1. Open the front panel and check the oil level.
Appropriate oil level is above the center of the oil
gauge. If the oil level is below the center of oil
gauge, add oil before operation.
2. Open the air outlet valves.
3. Close the manual drain valves (manual drain port).
4. Close the front panel.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 17 of 32
Starting
1. Switch the power supply on. Check that the touch
panel is illuminated.
2. Push “ON” on the switch and select “STATUS” on
the touch panel. As the compressor starts running,
the operation indicator lights up. The compressor
switches from Star operation to Delta operation 10
seconds after the start-up. Two seconds after Delta
operation, the compressor switches to loaded
operation.
During Operation
1. Regularly check the status of the compressor by
touching “STATUS” on the touch panel. Refer to
the controls section for more information.
2. The touch panel will provide warnings or shut
down the unit if necessary. The display will indicate
the reason if a shutdown occurs.
Minimum Stop Time
Frequent starting and stopping can damage the main
motor. The control is programmed to prevent stopping
at short intervals. If necessary, using the Emergency
Stop will override the program settings. DO NOT USE
EMERGENCY STOP UNLESS NEEDED.
Stopping
1. Push “OFF” on the control panel switch. As the
compressor is being stopped, a message will be
displayed on the touch panel. If the compressor
was in loaded mode when the OFF button was
pushed, the control will force an unload condition.
The unit will run 30 seconds unloaded before
stopping.
2. Open the manual drain valve, empty the drain
remained in the separator.
3. Close the air outlet valves and disconnect the
circuit breaker.
Removal
At the end of service life of the compressor, perform
the following procedures:
1. Stop the compressor and close the air outlet
valves.
2. Disconnect the circuit breaker and then remove
the wires.
3. Discharge the pressure in pipes connected to air
outlet valves.
4. Remove the pipes.
5. Drain the oil.
6. Remove the compressor.
Control Panel
Components
Automatic Control
Depending on air consumption, the control panel
automatically switches load / unload operation within
the range of pressure setting. In order to reduce the
power consumption, the control panel stops the
compressor whenever possible to reduce the power
consumption and restarts it automatically when the
pressure drops to setting pressure. If the time of
unload operation is too short, the compressor will
continue to run unload operation without stopping.
On VFD models, the control will automatically slow
down the main motor to reduce compressed air
delivery as pressure rises near the unloading set point.
If pressure drops the control will speed up the motor
again. This operating mode minimizes the power use
associated with operating at higher line pressure than
needed and reduces the unloaded run time (which is
consuming power but making compressed air) and
reduces the total number of starts and stops.
Compressor Protection
The control panel will stop the compressor if
necessary. Refer to the table on the next page for the
list of conditions that may affect the compressor. In
case of “Caution”, messages will be displayed on the
Components
Function
Emergency Stop button
Press the button to stop the
compressor immediately
Power lamp (combined
with the ON-OFF switch)
The lamp lights up when the
compressor has been turned ON
Touch panel
Touch the screen to operate or to
manage the compressor

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 18 of 32
touch panel. In case of “Emergency stop”, alarm
conditions will be displayed on the touch panel.
Pressure Bands
The control panel provides the function that can
change the pressure band of the compressor.
Remote Control
Remote control is the function that you can
start/stop the compressor remotely. The setting of the
compressor needs to be changed in order to activate
the function. Use the SET UP menu.
Automatic Restart after Voltage Failure
Automatic restart is the function that automatically
restarts the compressor after the voltage is restored.
This function is disabled at the initial set-up. If you wish
to enable this function, contact a local Powerex
distributor.

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 19 of 32
Compressor Protection
For PCCMD models, the
fault alarms output
contacts are field wired to the system control panel for
connection to the facility master alarm system.
Signs
Conditions
Status
Touch Panel
Emergency Stop
conditions
Outlet temperature of low pressure/high pressure air end or
inlet temperature of high pressure air end rises above the
emergency value set-up
Stop Sign displayed
Oil pressure decreases below the set-up value
Motor is overloaded with the emergency value set-up
Outlet temperature sensor of low pressure/high pressure air
end or inlet temperature sensor of high pressure air end
malfunctions
Inlet pressure of high pressure air end malfunctions
Outlet pressure sensor of the compressor malfunctions
Oil pressure sensor malfunctions
Protection device is activated by overload of cooling fan motor
or oil pump motor
Emergency stop button is pressed
Caution
Conditions
Outlet temperature of low pressure/high pressure air end or
inlet temperature of high pressure air end rises above the
caution value set-up
Continue to
operate Sign displayed
Pressure differential of an air filter is above the caution value
set-up
Pressure differential sensor of an air filter malfunctions
The total operating hours exceed the scheduled maintenance
time

WhisperAir™ Oil-free Rotary Tooth Compressor
Model Series PCC & PCCMD – 50 HP
Powerex •150 Production Drive •Harrison, OH 45030 •USA
(T) 1.888.769.7979 •(F) 513.367.3125 •www.powerexinc.com
IN594501AV • 02/2016
Page 20 of 32
Control Panel
General Description
•Everything in blue is a button and can be pushed to
execute a function.
•Things in green are indicators and will light up and
display messages to signal something has
happened.
•Things in white are gauges. The gauges can display
historical data graphs.
•The touch panel will open to the HOME screen
below.
•The three blue rectangles at the bottom are
selection buttons.
•STATUS will lead a display of the operating
conditions.
•ALARMS will display a history of Alarms and
warnings.
•SETUP will allow changing the operating pressures
and enabling REMOTE CONTROL and AUTOMATIC
RESTART.
•The SYSTEM STATUS screen shows the condition of
pressure and temperature and other operating
parameters. At the lower right is the operating
indicator that shows whether the unit is loaded,
unloaded or off (waiting for an automatic restart)
•The blue rectangles are buttons and can be
pressed to access graphs of the various displays
and to go to other screens. The I/O DIAGNOSTICS
button is useful if troubleshooting an operating
control problem.
•The Alarms button takes you to the SYSTEM
ALARMS screen.
•The green indicators show what each alarm pane
is. The green background color indicates the
condition is good. The color will change to red if
the alarm is tripped. If an alarm has a yellow
background, it indicates the level is near a trip
condition.