Oil-injected rotary screw compressors
People. Passion. Performance.
CPF 200-125 460/220V-60Hz - YD
BRY190070/UTO-1 BRY190156/ACA-1 CP
Instruction manual Compressor Instruction Manual
CPF-150, CPF-175, CPF-200
Copyright Statement
Any non-authorized use or copy of its contents or any part thereof is prohibited.
This refers especially to trademarks, model names, part numbers and data.
This manual is valid for compressors with serial number greater than BQD108496. 1 01/2020
No. 1093 1387 37 - Ed. 0 Visit us on: www.chicagopneumatic.com STORAGE, CONSERVATION AND TRANSPORT CONDITIONS
1. Introduction 3. Conservation after installation
The non-painted surface of all out-of-service compressors, 1. Run the unit at least twice a week, for a minimum of 30 whether installed or waiting installation, is subject to oxidation minutes and operate the load/relief system a few times. and corrosion. 2. Stop the unit, close the outlet valve and open the The corrosion level ranges according to the environment condensate drains (after the air cooler and condensate conditions (temperature, humidity etc.) and the care taken for separator manual). Ensure none of the drains is clogged. storing and conserving the unit. 3. Close the drains after 02 minutes. Therefore, it is impossible to establish the period in which the unit can be stored without rust damage. NOTES:
The higher the humidity and the longer the stopping and/ 1. This oil should be removed prior to the technical start- or storage period, the more care must be taken. For CPF up of the equipment, otherwise, a “hydrolock” could compressors, in addition to the precautions for the compressor, form, causing irreparable damage to the compressor specific preventive measures should be taken for the electric unit. motor, according to the manufacturer’s instructions. 2. This instruction does not provide for cases of aggressive Compressors are not normally expected to be out of service or environment, which should be analyzed individually. stored for long periods, so they are shipped ready for storage for a maximum of 75 days from the date of manufacture. After 4. Movement and transport that, the procedure described in 2 should be followed. If the unit is to be moved or transported, the original fittings Should the compressor be out of service for more than one and guards must be reinstalled to immobilize the vibration week, follow the instructions in item 3. dampers and the engine and compressor assembly.
2. Storage and conservation prior to The compressor can be handled with a forklift using the installation openings in the frame. The forklift must have capacity suitable for the sizes and weight of the compressor. The 1. Store the compressor in a clean, dry, well-ventilated compressor may also be lifted by inserting beams into the environment, free of dust and humidity. openings. Make sure that the beams are properly fixed and equally spaced on both sides of the frame. Ropes/chains must 2. The entire lower section of the compressor should stand be kept parallel to the bodywork by means of an expander, on a flat, vibration-free floor. not touching it in order not to damage the compressor. Lifting equipment should be placed so that the compressor is raised 3. Ensure that there is no water in the grate, plastic cover perpendicular, slightly and without twisting. or any part of the bodywork or base of the unit.
4. Remove the intake valve and fill the compressor unit with the lubricating oils recommended by Chicago Pneumatic (see note 1).
5. Reinsert the intake valve.
6. Rotate the coupling 10 turns once a month, to change the position of the compressor element bearings balls and rollers. In case there is no access to the motor shaft, remove the rear motor cover for access through the motor fan.
7. Should the compressor be stored for more than 6 months, the oil, oil filter and separator element should be replaced. For engine, check engine manufacturer’s instructions on material delivered (on CD) with compressor. Pay attention to the engine resistance connection, if any, to avoid inside the engine.
2 WARRANTIES
Chicago Pneumatic ensures to the Buyer free repair for products, its components or accessories, sold and manufactured by our company that eventually present proven manufacturing defects, for the period and pursuant to the conditions indicated below, provided that such defects do not result from improper use or by fault of the Buyer.
Warranty periods are counted from the date the invoice(s) are issued, considering: a. for stationary or portable compressors: for eighteen (18) months after invoice issue or twelve (12) months after technical delivery, whichever occurs first, and twenty-four (24) months for the compressor. b. for other equipment: for eighteen (18) months after invoice issue or twelve (12) months after technical delivery, whichever occurs first.
No repair, modification or replacement under the warranty will extend the terms indicated above, whether for the equipment or for its replaced accessories or components.
Warranties provided for this instrument refer only to components manufactured at our facilities. Each manufacturer is solely responsible for the warranties for parts, engines and accessories manufactured them.
Effectiveness of these warranties is conditioned to immediate written communication of the defect verified by the Buyer to Chicago Pneumatic, and any intervention on the product or equipment by the Buyer or third parties must not be done, under penalty of voiding the warranty.
Our products are coated according to ISO 12944 standard; our corrosion class is “C3 medium”.
Warranty will become void in case of: a. stationary compressors installed or assembled by the Buyer without inspection and approval by Chicago Pneumatic; except for CPM models. b. lack of Technical Delivery by Chicago Pneumatic; c. inappropriate or incorrect maintenance of equipment or products, including: (i) non-authorized modifications; and (ii) non-compliance with maintenance instructions provided by Chicago Pneumatic, poor or irregular lubrication; d. use of non-original parts or accessories, or not approved by Chicago Pneumatic; e. inappropriate or incorrect use of equipment or products; f. work overload not been previously authorized in written by Chicago Pneumatic; g. normal wear and tear of equipment or products; h. damage arising from Act of God or force majeure, such those resulting from fires, floods, depredation, strikes, rampage or similar harmful actions, among others; i. inappropriate transport, irregular or extended storage periods by the Buyer; and j. the Buyer is in arrears or default of payments set in the Purchase and Sale Agreement.
No manufacturing defect shall be considered a fair reason for Buyer non-compliance with the obligations under this instrument and included proposal.
Services related to these warranties will be performed in workshops previously authorized by Chicago Pneumatic; and the Buyer is responsible for delivering and retrieving products at/from these locations, and for the respective transport and insurance expenses. At Chicago Pneumatic’s sole discretion, the warranted services may be provided at the Buyer’s facilities. In such case, all expenses related to mileage and air tickets, travel time, food and accommodation of technicians and/or mechanics shall be borne by the Buyer.
3 CONTENTS
1 Safety precautions ����������������������������������������������������������5 5 Operating instructions ������������������������������������������������43 1.1 Safety icons ������������������������������������������������������������5 5.1 Initial start ������������������������������������������������������������43 1.2 Safety precautions during installation ��������������������5 5.2 Before starting ������������������������������������������������������44 1.3 Safety precautions during operation ����������������������6 5.3 Start-up ����������������������������������������������������������������44 1.4 Safety precautions during maintenance or repair ��7 5.4 During operation ��������������������������������������������������45 5.5 Display check ������������������������������������������������������45 2 General description ��������������������������������������������������������9 5.6 Manual load/relief ������������������������������������������������46 2.1 Introduction ������������������������������������������������������������9 5.7 Stop ����������������������������������������������������������������������46 2.2 Regulating system ������������������������������������������������10 5.8 Removal from service ������������������������������������������47 2.3 Special Features ��������������������������������������������������11 5.9 Use of air tank ������������������������������������������������������47 3 Graphic controller ��������������������������������������������������������12 5.10 Storage conditions ������������������������������������������������47 3.1 Controller ������������������������������������������������������������12 5.10.1 Introduction ����������������������������������������������47 3.2 Control panel ��������������������������������������������������������13 5.10.2 Storage and conservation prior to 3.3 Icons used ������������������������������������������������������������14 installation ������������������������������������������������47 3.4 Main screen ����������������������������������������������������������17 5.10.3 Conservation after installation ����������������48 3.5 Accessing menus ��������������������������������������������������19 5.10.4 Movement and transport ��������������������������48 3.6 Input menu ����������������������������������������������������������19 6 Maintenance ������������������������������������������������������������������48 3.7 Outputs menu ������������������������������������������������������20 6.1 Preventive maintenance program ������������������������48 3.8 Counters ��������������������������������������������������������������21 6.2 Motors ������������������������������������������������������������������50 3.9 Selecting the control mode ����������������������������������21 6.3 Oil specifications ��������������������������������������������������51 3.10 Service menu ��������������������������������������������������������22 6.3.1 Chicago Pneumatic ROTAIR Plus ����������51 3.11 Regulation menu ��������������������������������������������������24 6.3.2 Chicago Pneumatic CP-46 ����������������������51 3.12 Event history menu ����������������������������������������������24 6.3.3 CP-46 F ����������������������������������������������������51 3.13 Week timer menu ������������������������������������������������25 6.3.4 Oil filter change ����������������������������������������51 3.14 Test Menu ������������������������������������������������������������29 6.4 Oil change ������������������������������������������������������������51 3.15 Modification of general parameters ��������������������30 6.5 Storage after installation ��������������������������������������52 3.16 General Menu ������������������������������������������������������30 6.6 Service kits ����������������������������������������������������������52 3.17 User Password Menu ������������������������������������������31 6.7 Filter disposal ������������������������������������������������������52 3.18 Access key Menu ������������������������������������������������31 6.8 Safety valve ����������������������������������������������������������52 3.19 Programmable Parameters ����������������������������������32 3.20 Start-up ����������������������������������������������������������������34 7 Troubleshooting ������������������������������������������������������������53 3.21 During operation ��������������������������������������������������34 7.1 Troubleshooting ��������������������������������������������������53 3.22 Automatic restart ��������������������������������������������������35 8 Technical data ��������������������������������������������������������������55 3.23 Stop ����������������������������������������������������������������������35 3.24 Removal from service ������������������������������������������36 9 Instructions for using the air-oil separator vessel ����56 4 Installation ��������������������������������������������������������������������37 10 Environmental information ����������������������������������������57 4.1 Dimensional drawing ������������������������������������������37 4.2 Installation suggestions ��������������������������������������39 4.3 Electric Diagrams ������������������������������������������������41 4.4 Cable size, fuses and circuit breaker settings ������41 4.5 Pictographs ����������������������������������������������������������42
4 1 Safety precautions Precautions during installation 1. The machine must only be lifted using suitable 1.1 Safety icons equipment and in accordance with applicable safety Explanation regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell Life-threatening or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe Warning limits. Wear a safety helmet when working in the area of overhead or lifting equipment. Important note 2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. 1.2 Safety precautions during installation Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air. All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance 3. Any blanking flanges, plugs, caps and desiccant bags of the normal caution and care required for must be removed before connecting the pipes. installation, operation, maintenance and repair, even 4. Air hoses must be of correct size and suitable for the if not expressly stated, will be disclaimed by Chicago working pressure. Never use frayed, damaged or worn Pneumatic. hoses. The distribution pipes and connections must have proper size and be suitable for the working pressure. General precautions 5. The aspirated air must be free of flammable fumes, 1. The operator must employ safe working practices vapors or particles, such as solvents, that can lead to and observe all related work safety requirements and internal fire or explosion. regulations. 6. Arrange the air intake so that loose clothing worn cannot 2. If any of the following statements does not comply with be sucked in. the applicable legislation, the stricter of the two shall apply. 7. Ensure that the discharge pipe from the compressor to the aftercooler or the air net is free to expand under heat 3. Installation, operation, maintenance and repair work and that it is not in contact with or close to flammable must only be performed by authorized, trained and materials. specialized technicians. 8. No external force can be exerted on the air outlet valve; 4. The compressor is not considered capable of producing the connected pipe must be free of strain. breathable air. To obtain breathable air, the compressed air must be adequately purified according to the 9. If remote control is installed, the machine must bear a applicable legislation and standards. clear sign stating: DANGER: This machine is remotely controlled and may start without warning. The operator 5. Before any maintenance, repair, adjustment or any has to make sure that the machine is stopped and that other non-routine checks, stop the compressor, press the isolating switch is open and locked before any the emergency stop button, switch off the power and maintenance or repair. As a further safeguard, persons depressurize the compressor. In addition, the isolating switching on remotely controlled machines shall take switch must be opened and locked. adequate precautions to ensure that there is no one 6. Never play with compressed air. Do not apply air to checking or working on the machine. To this end, a your skin or direct an air stream at people. Never use suitable notice shall be affixed to the start equipment. air to clean dirt from your clothes. When using the air to 10. Air-cooled machines must be installed in such a way clean equipment, do so with extreme caution and wear that an adequate flow of cooling air is available and that eye protection. the exhausted air does not recirculate to the compressor 7. The owner is responsible for maintaining the unit in or cooling air inlet. safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.
5 11. The electrical connections must correspond to the must only be performed by authorized, trained and applicable codes. The machines must be earthed and specialized technicians. protected against short circuits by fuses in all phases. A 4. The compressor is not considered capable of producing lockable power isolating switch must be installed near breathable air. To obtain breathable air, the compressed the compressor. air must be adequately purified according to the 12. On machines with automatic start/stop system or if applicable legislation and standards. the automatic restart function after power failure is 5. Before any maintenance, repair, adjustment or any activated, a sign stating “This machine may start without other non-routine checks, stop the compressor, press warning” must be affixed near the instrument panel. the emergency stop button, switch off the power and 13. In multiple compressor systems, manual valves must be depressurize the compressor. In addition, the isolating installed to isolate each compressor. Non-return valves switch must be opened and locked. (check valves) must not be relied upon for isolating 6. Never play with compressed air. Do not apply pressure systems. air to your skin or direct an air stream at people. 14. Never remove or tamper with the safety devices, guards Never use air to clean dirt from your clothes. When or insulation fitted on the machine. Every vessel or using the air to clean equipment, do so with extreme auxiliary installed outside the machine to contain air caution and wear eye protection. above atmospheric pressure must be protected by a pressure relieving device or devices as required. Precautions during operation 15. Piping and other parts with a temperature above 80 °C 1. Use only the correct type and size of hose end fittings (176 °F) that may be accidentally touched in normal and connections. When blowing through a hose or air operation must be guarded or insulated. Other high line, ensure that the open end is held securely. A free end temperature piping must be clearly marked. will whip and may cause injury. Make sure that a hose is fully depressurized before disconnecting it. 16. For water-cooled machines, the cooling water system installed outside the machine has to be protected by 2. Persons switching on remotely controlled machines a safety device with set pressure according to the shall take adequate precautions to ensure that there is maximum cooling water inlet pressure. no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start 17. If the ground is not level or can be subject to variable equipment. inclination, consult the manufacturer. 3. Never operate the machine when there is a possibility of Also consult following safety precautions: Safety taking in flammable or toxic fumes, vapors or particles. precautions during operation and Safety precautions during maintenance. 4. Never operate the machine below or in excess of its These precautions apply to machines processing or limit ratings. consuming air or inert gas. Processing of any other 5. Keep all bodywork doors shut during operation. The gas requires additional safety precautions typical to doors may be opened for short periods only, e.g., to the application not included herein. carry out routine checks. Wear ear protectors when Some precautions are general and cover several opening a door. machine types and equipment; hence, some statements may not apply to your machine. 6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall 1.3 Safety precautions during operation wear ear protectors. 7. Periodically check that: All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance •• All guards are in place and securely fastened of the normal caution and care required for installation, •• All hoses and/or pipes inside the machine are in good operation, maintenance and repair, even if not expressly condition, secure and not rubbing stated, will be disclaimed by the manufacturer. •• There are no leaks General precautions •• All fasteners are tight •• All electrical leads are secure and in good order 1. The operator must employ safe working practices and observe all related work safety requirements and •• Safety valves and other pressure relief devices are regulations. not obstructed by dirt or paint •• Air outlet valve and air net, i.e., pipes, couplings, 2. If any of the following statements does not comply with manifolds, valves, hoses, etc. are in good condition, the applicable legislation, the stricter of the two shall not worn or damaged apply. 8. If warm cooling air from compressors is used in heating 3. Installation, operation, maintenance and repair work systems, e.g., to warm up a workroom, take precautions
6 against air pollution and possible contamination of Precautions during maintenance or repair breathing air. 1. Always wear safety glasses. 9. Do not remove any of or tamper with the sound-damping 2. Use only the correct tools for maintenance and repair material. work. 10. Never remove or tamper with the safety devices, guards 3. Use only genuine spare parts. or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain 4. All maintenance work shall only be undertaken when air above atmospheric pressure must be protected by a the machine has cooled down. pressure relieving device or devices as required. 5. A warning sign stating “Work in progress; do not start” Also consult following safety precautions: Safety shall be attached to the starting equipment. precautions during operation and Safety precautions 6. Persons switching on remotely controlled machines during maintenance. shall take adequate precautions to ensure that there is These precautions apply to machines processing or no one checking or working on the machine. To this consuming air or inert gas. Processing of any other end, a suitable notice shall be affixed to the remote start gas requires additional safety precautions typical to equipment. the application not included herein. Some precautions are general and cover several 7. Close the compressor air outlet valve before connecting machine types and equipment; hence, some statements or disconnecting a pipe. may not apply to your machine. 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and 1.4 Safety precautions during maintenance or depressurize the entire system. repair 9. Never use flammable solvents or carbon tetrachloride All responsibility for any damage or injury resulting for cleaning parts. Take safety precautions against toxic from neglecting these precautions, or non-observance vapors of cleaning liquids. of the normal caution and care required for installation, 10. Scrupulously observe cleanliness during maintenance operation, maintenance and repair, even if not expressly and repair. Keep dirt away by covering the parts and stated, will be disclaimed by the manufacturer. exposed openings with a clean cloth, paper or tape. General precautions 11. Never weld or perform any operation involving heat 1. The operator must employ safe working practices and near the oil system. Oil tanks must be completely observe all related local work safety requirements and purged, e.g., by steam cleaning, before carrying out regulations. such operations. Never weld on, or in any way modify, pressure vessels. 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 authorized, trained and specialized technicians. 4. The compressor is not considered capable of producing breathable air. To obtain breathable air, the compressed air must be adequately purified according to the local legislation and standards. 5. Before any maintenance, repair, adjustment or any other non-routine checks, stop the compressor, press the emergency stop button, switch off the power and depressurize the compressor. In addition, the isolating switch must be opened and locked. 6. Never play with compressed air. Do not apply air to your skin or direct an air stream at people. Never use air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection.
7 12. Whenever there is an indication or any suspicion that Also consult following safety precautions: Safety an internal part of a machine is overheated, the machine precautions during operation and Safety precautions shall be stopped but no inspection covers shall be during maintenance. opened before sufficient cooling time has elapsed; this These precautions apply to machines processing or is to avoid the risk of spontaneous ignition of the oil consuming air or inert gas. Processing of any other vapor when air is admitted. gas requires additional safety precautions typical to 13. Never use a light source with open flame for inspecting the application not included herein. the interior of a machine, pressure vessel etc. Some precautions are general and cover several machine types and equipment; hence, some statements 14. Make sure that no tools, loose parts or rags are left in or may not apply to your machine. on the machine. 15. All regulating and safety devices shall be maintained with due care to ensure that they function properly They WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov. should not be disabled. 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 replaced, 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., on the bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing. 20. Never use caustic solvents that can damage materials of the air net, e.g., polycarbonate bowls. 21. The following safety precautions are stressed when handling lubricant: •• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if required, use breathing protection. •• 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 prevent injury from hot machine parts, e.g., during oil drainage.
8 2 General description
2.1 Introduction CPF-150, CPF-175 and CPF-200 models are single-stage, oil-injected screw, gearbox driven by an electric motor with sound- insulated bodywork. The models with “S” abbreviations are air-cooled, and those with “SW”, water-cooled. The compressors are available for a maximum working pressure of: 7, 8, 10 or 13 bar (e) They essentially feature:
•• Air filter •• Compressor element •• Air vessel / Oil separator •• Air cooler •• Oil cooler •• Drive motor •• Gear box •• Inlet / regulation assembly •• ES4000 control system •• Safety devices
9 2.2 Regulating system Flow diagram
Flow diagram
Reference Designation A To air cooler B To/from oil cooler
10 Regulating system The compressor is controlled by ES4000 controller (1). The controller maintains the net pressure within programmable limits by automatically loading and unloading the compressor, according to the air consumption. It also protects the compressor and monitors components subject to service.
Unloading If the air consumption is less than the air output of the compressor, the net pressure increases. When the net pressure reaches the work pressure upper limit (unloading pressure), solenoid valve (5) is de-energized by ES4000 controller (1). The plunger of the valve (5) returns by spring force:
Stage Description 1 The valve (5) plunger cuts the supply of vessel pressure toward the chamber (2). 2 The control pressure present in the chamber (2) is vented to atmosphere. The unloading valve (4) plunger (3) is moved by the pressure in the air vessel, allowing pressure to pass from the air vessel to the chamber (6). 3 The valve (7) is pushed up, the closing air inlet. 4 A small air flow continues to be drawn through the channel (8) and is expelled from the vessel through the channel (10) to the air inlet. 5 Air flow is stopped (0%) and the compressor runs unloaded, while the chamber (6) maintains a constant overpressure (vessel unload pressure minus Unloading Valve (4) pressure drop).
Loading When the net pressure decreases to the work pressure lower limit (loading pressure), solenoid valve (5) is energized. The plunger of the valve (5) advances by spring force:
Stage Description 1 The valve (5) plunger opens the supply of vessel pressure toward the chamber (2). The plunger (3) of the unloading valve (4) moves, closing the air pressure passage to the chamber (6). 2 The valve (7) moves downwards, as the pressure in the chamber (6) drops below atmospheric pressure, opening the air inlet to the compressor element. 3 Air flow is resumed (100%) and the compressor runs loaded, while the piston-bar-valve assembly is only surrounded by atmospheric pressure.
2.3 Special Features The compressor supplied herein has the following special features: -- Special certifications: ASME/CRN and CSA/UL -- Air/oil separator must be ASME/CRN-certified. -- Special electric motor: WEG W22 – IE3 Premium efficiency. 460V voltage -- UL-certified electrical system components -- Export packaging.
11 3 Graphic controller Air-cooled compressors will also be stopped in the event of overload of the fan motor. 3.1 Controller Before remedying, consult the Safety precautions.
Shutdown warning A shutdown warning level is a programmable level below the shutdown level. If one of the measurements exceeds the programmed shutdown warning level, this will also be indicated to warn the operator before the shutdown level is reached.
Service warning If the service timer exceeds a programmed value, this will be indicated on the display to warn the operator to carry out some service actions. View of the ES 4000 Advanced controller Automatic restart after voltage failure Introduction The controller has a built-in function to automatically restart The electronic controller has the following functions: the compressor when the voltage is restored after voltage failure. •• Controlling the compressor •• Protecting the compressor Provided the controller is in the automatic operation •• Monitoring components subject to service mode, the compressor will automatically restart when the supply voltage to the module is restored. •• Automatic restart after voltage failure Automatic control of the compressor The controller maintains the net pressure within programmable limits by adjusting the motor speed. A number of programmable settings, e.g., the unloading and loading pressures, the minimum stop time and the maximum number of motor starts are taken into account. The controller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases. If the expected unloading period is too short, the compressor is kept running to prevent too short standstill periods.
Protecting the compressor Shutdown If the compressor element outlet temperature exceeds the programmed shutdown level, the compressor will be stopped. This will be indicated on the display of the controller. The compressor will also be stopped in case of overload of the drive motor.
12 3.2 Control panel Detailed description
Function keys of the controller
Reference Designation Function 1 Function Shows icons and operating conditions. 2 Automatic operation symbol Indicates that the controller is automatically controlling the compressor: the compressor is loaded, unloaded, stopped 3 LED, automatic operation and restarted depending on the air consumption and the limitations programmed in the controller. 4 Warning symbol 5 LED, warning Is lit if a warning condition exists. 6 Voltage symbol 7 LED, voltage on Indicates that the voltage is switched on. 8 Service symbol 9 LED, service Is lit when service is needed. This button starts the compressor. Automatic operation LED 10 Start button (3) lights up. The Controller is operative. This button is used to stop the compressor. Automatic 11 Stop button operation LED (3) goes out. 12 Scroll buttons Use these buttons to scroll through the menu. 13 Enter button Use this button to confirm the last action. Use this button to go to previous screen or to end the current 14 Escape button action.
13 3.3 Icons used Status icons
Function Icon Function Compressor status When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating.
Motor stopped
Running unloaded
Running loaded
Machine control mode Local start/stop
Remote start/stop
LAN control
Automatic restart after Automatic restart after voltage failure is active voltage failure
Week timer Week timer is active
Active protection Emergency stop functions
Shutdown
Warning
Service Service required
14 Main screen view Value lines preview icon
Graphic preview icon
General icons No communication/network problem
Invalid
Input icons
Icon Description Pressure
Temperature
Digital input
Special protection
Input icons
Icon Drain Filter
Engine
Description
Compressor element (LP, HP etc.)
Dryer
Cooler
Frequency converter
15 Expansion module failed
Network problem
General alarm
Menu icons
Icon Description Inputs
Outputs
Guards (Shutdown warnings)
Counters
Test
Regulation (Settings)
Service
Event history (saved data)
Access key / User password
Network
Setpoint
Information
Week timer
General
16 Scroll arrows
Icon Description Up
Down
3.4 Main screen Function The main screen is the screen automatically displayed when the voltage is switched on and one of the buttons is pressed. It is automatically turned off after a few minutes if no button is pressed. Generally, 5 different main screen views can be chosen: 1. Two value lines 2. Four value lines 3. Graphic (High resolution) 4. Graphic (Medium resolution) 5. Graphic (Low resolution) Screens with two or four value lines This type of Main screen has the value of 2 or 4 settings (see Input menu section).
Typical main display (2-value lines), fixed speed Typical main display (4-value lines), fixed speed compressors compressors
(1) Compressor outlet (2) Element outlet (3) Load, ... (text varies with actual compressor status) (4) Menu (5) Running Hours (6) Load relay (one of the input signals of fixed speed compressors) Flow (compressors with frequency converter)
•• Section A shows information about compressor operation (for example, outlet pressure or compressor outlet temperature). In compressors with a frequency converter, the degree of load (flow) is displayed as a percentage of the maximum flow.
17 • Section B shows status icons. The following types of icons When Chart (High resolution) is selected, the chart displays are displayed in this field: the variation of the selected input (in this case, the pressure) • Fixed icons per minute. The actual value is also displayed. The screen These icons are always displayed on the main screen shows the last 4 minutes. and cannot be selected with the cursor (for example, The selector button (icon) to select other screens is changed to Stopped or running compressor, Compressor Status a small Chart and highlighted (active). (running, unloading or stopped motor)). • Option icons These icons are only displayed if the respective function is activated (for example, week timer, automatic restart after voltage failure etc.). • Warning icons These icons are displayed if an abnormal condition occurs (warnings, shutdowns, service etc.). To access more information about the displayed icons, When Chart (Medium resolution) is selected, the chart select the icon in question using the scroll buttons and displays the variation of the selected input per hour. The press Enter. screen displays the last 4 hours. • Section C is designated as the status bar This bar displays the text corresponding to the selected icon. • Section D displays the action buttons. These buttons are used to: • Access and define settings • Reset a motor overload, service message or emergency stop When Chart (Low resolution) is selected, the chart displays • Access all data collected by the controller the variation of the selected input per day. The screen displays The function of the buttons depends on the menu displayed. the progress in the last 10 days. The most common functions are: Selecting a main screen view Designation Function To switch between different screen layouts, select the Menu To go to the menu rightmost icon in the control icon row (see the value line Modify To modify programmable parameters display icon or chart display icon in the Icons used section) Reset To reset a timer or message and press Enter. A screen similar to the following will appear: To activate an action button, highlight the button using the scroll buttons and press Enter. To return to the previous menu, press Escape. Chart views Instead of displaying values, you can also display a chart of one of the input signals (see Input menu section) as a function of time.
Select the desired layout and press Enter. See also the Input menu section.
18 3.5 Accessing menus Procedure Description On the main screen (see Main Screen): When the voltage is switched on, the main screen automatically • Move the cursor to the Menu button and press the Enter displays (see Main screen section): button. • Using the scroll buttons, move the cursor to the Inputs icon, as shown in the following screen:
• To access the menu screen, select the Menu (4) button using the scroll buttons. • Press Enter to select the menu. The following screen is • Press the Enter button. A screen similar to the following displayed: will appear:
• The screen displays several icons. Each icon indicates a menu item. By default, the pressure parameter icon (Regulation) is selected. The status bar displays the menu Figure text name corresponding to the selected icon. (1) Inputs • Use the scroll buttons to select an icon. (2) Compressor outlet • Press Escape to return to the main screen. (3) Element outlet (4) Ambient Air 3.6 Input menu (5) Emergency stop Menu icon, Inputs • The screen displays a list of all inputs, with their respective icons and readings. • If an input is in warning or shutdown, the original icon is replaced, respectively, by the warning or shutdown icon (in this case, the shutdown icon and the warning icon shown Function above). • To display the actual value of the measured data (analog A small chart icon, displayed below an item in the list, means inputs) and digital input status (for example, emergency that this input signal is displayed in the chart on the main stop contact, motor overload relay etc.). screen. Any analog input can be selected. • To select the digital input to be displayed in the main screen chart.
19 Selecting another input signal as the main chart signal With the Modify button active (light gray background on the screen above), press Enter on the controller. A screen similar to the following will appear:
(1): Set as main chart signal
3.7 Outputs menu Menu icon, Outputs The first item in the list is highlighted. In this example, Net pressure is selected (chart icon). To change it, press Enter again, and a warning window will appear:
Function To access the information about the actual status of some outputs, such as the status of the fan overload contact (for air- cooled compressors), emergency stop contact etc. Procedure On the main screen (see Main Screen): • Move the cursor to the Menu button and press the Enter Press Enter again to remove this input from the chart. A button. confirmation window will appear: • Move the cursor to the Outputs icon (see section below).
Select Yes to remove or No to exit the current action. • Press the Enter button. A screen similar to the following Similarly, another input signal can be highlighted and selected will appear: as the main signal of the chart:
Outputs screen (typical)
20 Figure text
(1) Outputs (2) Fan Motor (3) Blow-off (4) General Shutdown (5) Automatic Operation
• The screen displays a list of all outputs, with their respective icons and readings. If an output is in warning or shutdown, the original icon is Figure text replaced, respectively, by the warning or shutdown icon. (1) Counters 3.8 Counters (2) Running Hours (3) No. of Motor Starts Menu icon, Counters (4) Load Relay (5) VSD 1-20% RPM in % (percentage of time the motor speed was between 1 and 20%) (compressors with frequency converter) The screen displays a list of all counters, with their respective Function actual readings. To access: Note: the example above refers to a compressor driven by frequency converter. For fixed speed compressor, the • Running hours displayed screen will be slightly different. • Loading hours • Number of motor starts 3.9 Selecting the control mode • Number of hours the controller was on • Number of load cycles Function Procedure To select the control mode: for example, if the compressor is in local control, remote control or controlled via a Local Area On the main screen (see Main Screen): Network (LAN). • Move the cursor to the Menu button and press the Enter button. Procedure • Using the scroll buttons, move the cursor to the Counters On the main screen, ensure the Menu button (1) is selected: icon (see section below).
Then use the scroll buttons to access the Status icons (see • Press the Enter button. A screen similar to the following Main screen) and select the Regulation icon (2). When the will appear: icon is active, it is highlighted with a gray background.
21 Press Enter: • Using the scroll buttons, move the cursor to the Service icon (see section below).
Three options are available: • Local control • Press the Enter button. The following screen is displayed: • Remote control • LAN control
Figure text
After selecting the intended control mode, press Enter on the (1) Service controller to confirm the selection. The new setting is now (2) Overview displayed on the main screen. See the Icons used section for the meaning of the icons. (3) Service Plan (4) Next Service 3.10 Service menu (5) History
Menu icon, Service • Scroll down to select the desired item and press Enter to see the details, as explained below.
Overview
Function • To reset the service plans that are performed. • To check when the next service plans should be performed. • To know what service plans were performed before. • To modify the scheduled service intervals. Figure text Procedure On the main screen (see Main Screen): (1) Overview • Move the cursor to the Menu button and press the Enter (2) Running Hours button. (3) Real Time Hours (4) Reset
22 Example of service level (A): Modifying a service plan The numbers shown on the left are the scheduled service Depending on operation conditions, service intervals may intervals. For service interval A, the scheduled number of need to be modified. To do so, use the scroll buttons to select running hours is 4000 hours (top row, green) and the scheduled the value to modify. A screen similar to the following will number of real time hours is 8760 hours, which corresponds appear: to a year (second row, blue). This means the controller will issue a service warning when it reaches 4000 running hours or 8760 real time hours, whichever occurs first. Consider that the real-time hour counter is not interrupted when the controller is off. The numbers next to the bars are the number of hours left for the next service intervention. In the example above, the compressor has just started, which means that there are still 4000 running hours or 8299 hours left for the next service intervention.
Service plans Press the Enter button. The following screen is displayed: Several service operations are grouped (called Level A, Level B etc.). Each level represents a number of service actions to be performed at the intervals defined in the controller. When a service plan interval is reached, a message appears on the screen. After performing the service actions at the corresponding levels indicated, the timers must be reset. On the Service menu above, select Service Plan (3) and press Enter. The following screen is displayed:
Modify the value as needed using the scroll buttons or and press Enter to confirm. Note: The running hours can be modified in 100-hour steps, real time hours can be modified in 1-hour steps.
Figure text
(1) Service Plan (2) Level (3) Running Hours (4) Real Time Figure text (5) Modify (1) Next Service (2) Level (3) Running Hours (4) Actual In the example above, service level A is set to 4000 running hours, of which 0 hour has elapsed.
23 History Figure text
The History screen lists all past service actions, sorted by (1) Regulation date. The date at the top is the date of the most recent service (2) Unloading pressure 1 action. To see the details of a completed service action (for example, service level, running hours or real time hours), use (3) Loading pressure 1 the scroll buttons to select the desired action and press Enter. (4) Unloading pressure 2 (5) Loading pressure 2 3.11 Regulation menu (6) Modify Menu icon, Setpoint • The screen displays the actual unloading and loading pressure parameters for both pressure ranges. To change parameters, move the cursor to the Modify button and press Enter. The following screen is displayed:
Function On fixed speed compressors, the operator can set two different pressure ranges. This menu is also used to select the active pressure range.
Procedure On the main screen (see Main Screen): • Move the cursor to the Menu button and press the Enter button. • The first row of the screen is highlighted. Use the scroll buttons to select the parameter to be changed and press • Using the scroll buttons, move the cursor to the Setpoint Enter. The following screen is displayed: icon (see section below).
• Press the Enter button. The following screen is displayed: • The upper and lower limits of the parameter are displayed in gray; the actual value is displayed in black. Use the scroll buttons or to change the parameters as needed and press Enter to accept. Change the other parameters if required, as described above.
3.12 Event history menu
Menu icon, Event History
24 Function • To set timed switching commands for the net pressure range. To access data from last shutdown and last emergency stop. • Four different week schemes can be set. Procedure • A cycle of weeks can be set; one week cycle is a 10-week On the main screen (see Main Screen): sequence. For each week of the cycle, one of the four set • Move the cursor to the Menu button and press the Enter week schemes can be selected. button. Procedure • Using the scroll buttons, move the cursor to the Event On the main screen (see Main Screen): History icon (see section below). • Move the cursor to the Menu button and press the Enter button. • Use the scroll buttons to select the timer icon (see section below).
• Press the Enter button. The last shutdown and emergency stop cases are listed.
• Press Enter. The following screen is displayed:
Example of Event History screen • Scroll down the items to select the desired shutdown or emergency stop event. • Press Enter to access the date, time and other information that reflected the status of the compressor when this Figure text shutdown or emergency stop occurred. (1) Week Timer 3.13 Week timer menu (2) Week Action Schemes Menu icon, Week Timer (3) Week Cycle (4) Status (5) Week Timer Inactive (6) Remaining Running Time The first item in this list is highlighted. Select the desired item and press Enter on the controller to modify. Function • To set timed start/stop commands for the compressor. Setting week schemes • Select Week Action Schemes and press Enter. A new window will appear. The first item in the list is highlighted in red. Press Enter on the controller to modify Week Action Scheme 1
25 • A new warning window will appear. Select an action from this list with the scroll buttons on the controller. Then press Enter to confirm.
(1) Week Action Schemes (2) Week Action Scheme 1 (3) Week Action Scheme 2 (1) Monday (4) Week Action Scheme 3 (2) Actions (5) Week Action Scheme 4 (3) Remove (4) Start-up (5) Stop (6) Pressure Setpoint 1 (7) Modify
• A new window will appear. The action is now displayed in the first day of the week.
(1) Week Action Scheme 1 (2) Monday (3) Tuesday (4) Wednesday (5) Thursday (6) Friday (7) Saturday (8) Sunday (1) Monday (2) Start-up • A new window will appear. The Modify button is selected. Press Enter on the controller to create an action. (3) Save (4) Modify
• To set the time, use the scroll buttons on the controller and press Enter to confirm.
(1) Monday (2) Modify
26 (1) Monday (2) Start-up (3) Save (4) Modify
• A warning window will appear. Use the scroll button or to change the hour value. Use the scroll button or to change the minutes.
(1) Monday (3) Are you sure? (4) No (5) Yes (6) Save (7) Modify
• Press Escape to exit this window. The action is displayed (1) Monday under the day for which it is planned. (2) Start-up (3) Save (4) Modify
• Press Escape on the controller. The Modify button is selected. Use the scroll buttons to select Save.
(1) Week Action Scheme 1 (2) Monday - Start (3) Tuesday (4) Wednesday (5) Thursday
(1) Monday (6) Friday (2) Start-up (7) Saturday (3) Save (8) Sunday (4) Modify • Press Escape on the controller to exit this screen. • A new warning window will appear. Use the scroll buttons Setting the week cycle on the controller to select the right actions. Press Enter to confirm. One week cycle is a 10-week sequence. For each week of the cycle, one of the four set week schemes can be selected. • Select Week Cycle from the list in the Week Timer main menu.
27 (1) Week Cycle (2) Week 1 (3) Week Action Scheme 1 (4) Week Action Scheme 2 (5) Week Action Scheme 3 (6) Modify
• Checking the Week Timer status. Use the Escape button on the controller to return to the Week Timer main menu. Select Week Timer status. (1) Week Timer (2) Week Action Schemes (3) Week Cycle (4) Status (5) Week Timer Inactive (6) Remaining Running Time
• A list of 10 weeks is displayed.
(1) Week Timer (2) Week Action Schemes (3) Week Cycle (4) Status (5) Week Timer Inactive (6) Remaining Running Time
• A new window will appear. Select Week 1 to define the (1) Week Cycle Week Timer as active. (2) Week 1 (3) Week 2 (4) Week 3 (5) Week 4 (6) Modify
• Double press Enter on the controller to modify the first week. • A new window will appear. Select the action, for example: Week Action Scheme 1 (1) Week Timer (2) Week (3) Week Timer Inactive (4) Week 1
• Press Escape on the controller to exit this window. The status indicates that Week 1 is active.
28 (1) Week Timer (2) Week Action Schemes (3) Remaining Running Time
3.14 Test Menu
Test Menu
(1) Week Timer (2) Week Action Schemes (3) Week Cycle Function (4) Status • To perform a display test, i.e. to check that display and (5) Remaining Running Time LEDs are still intact.
Procedure • Press Escape on the controller to return to the Week Timer main menu. Select Remaining Running Time from the list On the main screen (see Main Screen): and press Enter on the controller to modify. • Move the cursor to the Menu button and press the Enter button. • Using the navigation buttons, move the cursor to the Test icon (see section below).
(1) Week Timer (2) Week Action Schemes • Press the Enter button; The following screen appears: (3) Week Cycle (4) Status (5) Remaining Running Time
• This timer is used when the week timer is set and, for certain reasons, the compressor must continue to operate for 1 hour, for example. This option can be set in this screen. This timer is prior to the action of the Week Timer.
Figure text
(1) Test (2) Safety Valve Test . (3) Not allowed (4) Audit Date
29 • The safety valve may only be tested by authorized 3.16 General Menu personnel and must be protected by a safety code. Menu icon, General • Select the display test item and press the Enter button. A screen appears to inspect the display; At the same time, all LEDs are lit.
3.15 Modification of general parameters
Menu Icon, Parameters Function This menu covers a list of general parameters: • Language • Time • Date Function • Date Format • Units Present and change many general parameters. Procedure Procedure On the sub-menu screen (see Modification of general On the main screen (see Main Screen): parameters), • Move the cursor to the Menu button and press the Enter • Using the navigation buttons, move the cursor to the button. General icon (see section below). • Using the navigation buttons, move the cursor to the Parameter icon (see section below).
• Press the Enter button. A screen similar to the following will appear: • Press the Enter button. A second menu screen will appear:
Figure text • This sub-menu screen shows many icons again. The User Password icon is selected by default. In addition, the (1) General status bar displays the menu name that corresponds to the (2) Language in Use selected icon. (3) Time (4) Date (5) Date Format (6) Modify
30 • A screen similar to the one above appears with a selection • Select the Activate button and press the Enter button. bar over the first item (Language). Use the navigation • Then complete the User Password and press the Enter button to select the parameter to be changed and press button; A confirmation window will appear. the Enter button. • Type the password again and press the Enter button to • To change, select Modify by using the navigation buttons confirm. and press the Enter button. • A warning appears on the screen. Use the or button to select the desired parameter and press the Enter button to confirm.
Figure text
(1) User Password (2) Inactive 3.17 User Password Menu (3) Activate
Manu icon, Password 3.18 Access key Menu
Menu icon, Access Key
Function The end customer may activate and select a personal password Once the password option is enabled, it is impossible for Function unauthorized persons to change parameters. The Menu screen only presents some basic icons. Access Key Procedure with the proper access code allows the user to view more icons or access more parameters. On the sub-menu screen (see Modification of general parameters), Procedure • Using the navigation buttons, move the cursor to the User On the sub-menu screen (see Modification of general Password icon (see section above). parameters), • Using the navigation buttons, move the cursor to the Access Key icon (see section above).
• Press the Enter button. The following screen is displayed.
• There are three access levels. • 0: You can view a basic set of parameters without requiring a password.
31 • 1: You can change a basic set of parameters. • 2: You can view and modify additional parameters. • The Access Level can be changed through the Modify button. A warning window will be prompted to enter an Access Key.
3.19 Programmable Parameters
Parameters: relief / load pressures
Minimum Factory default Maximum parameter setting parameter see Compressor see Compressor see Compressor Discharge / load pressures data data data
Parameters: Variable Speed Activation
Minimum Factory default Maximum parameter setting parameter Radial engine running time sec ND ND ND Load Delay Time (Star/Delta) sec ND ND ND Number of motor starts starts/day ND ND ND Minimum shutdown time sec 10 10 30 Scheduled Shutdown Time sec 0 3 20 Power Recovery Time (ARAVF) sec 30 30 3600 Restart Delay sec 0 0 1200 Communication Timeout sec 10 30 60
Protections
Minimum Factory default Maximum parameter setting parameter Compressor output temperature (operating ˚C 50 113 119 cutoff warning level) ˚F 122 235 246 Compressor output temperature (operating ˚C 111 120 120 cutoff level) ˚F 232 248 248
32 Assistance Plan The built-in service timer gives a service warning message after a prescheduled time period has elapsed. See also the Maintenance program section. Contact your supplier if a timer parameter needs to be modified. See Access/Modification section of the service timer parameters. Ranges cannot exceed nominal ranges and must logically match.
Terminology
Term Explanation ARAVF Auto Restart After Voltage Failure. Refer to Controller section. Power recovery This is the period within which the current has to be restored for automatic restart. It is accessible if time automatic restart is enabled. To activate the automatic restart function, contact your supplier. Restart Delay This parameter allows programming so that compressors are not all restarted at the same time after a power failure (active ARAVF). Compressor output The regulator does not accept inconsistent parameters, e.g. If the warning level is set to 95 ˚C temperature (203 ˚F), the lower limit for the operating cutoff level changes to 96 ˚C (204 ˚F).The recommended difference between the warning level and the operating cutoff level is 10 ˚C (18 ˚F). Delay in operating This is the period during which the signal must exist before the compressor is turned off. If you need cutoff signal to set this parameter to another value, contact your supplier. Minimum shutdown After automatically stopping, the compressor remains idle for the minimum downtime, regardless of time the air line pressure. Contact your supplier if a parameter shorter than 20 seconds is required. Relief / load The regulator does not accept illogical parameters; e.g. if discharge pressure is set to 7.0 bar(e) (101 pressure psi (g)), the upper limit for the load pressure changes to 6.9 bar(e) (100 psi (g)). The recommended minimum pressure difference between load and discharge is 0.6 bar (9 psi (g)).
33 3.20 Start-up 3.21 During operation
Procedure Notes
For the position of the air outlet valve and drain The operator should employ all relevant safety connections, see the Introduction section. precautions. See also the Troubleshooting section.
Removing the front panel (service panel) during operation will automatically shut down the unit after a certain period of time, depending on the compressor version. Keep doors closed during operation; they can be opened for short periods of time to perform checks.
When the engines are stopped and the LED (3) (automatic operation) is lit, the engines can be started automatically.
Regulator
ES 4000 Advanced Control Panel
Step Action - Turn on the power. Check if the voltage LED (7) lights up. - Open the air outlet valve. - Press the starter button (10) on the control panel. The compressor starts and the automatic operation LED (3) lights up. After the radial engine operation time end (Y-time, see Parameters in the Modifiable Parameters section), the drive motor ES 4000 Advanced Control Panel will change from star to delta and the compressor will start running under load.
34 Checking the oil level 3.23 Stop
Regulator
Oil level sight glass position ES 4000 Advanced Control Panel Check the oil level regularly. During operation, the oil level must be between the lower section and center of the sight glass Step Action (Gl). If the level is too low, stop the compressor, wait until it has stopped, depressurize the oil system by unscrewing the oil - Press the stop button (11). The automatic operation LED (3) turns off and the filler plug (FC) one turn and wait a few minutes. Remove the compressor stops after 30 seconds of relief plug and fill in with oil until the sight glass is full. Install and operation. tighten the plug (FC). - To stop the compressor in an emergency, 3.22 Automatic restart press the emergency stop button. The alarm LED (5) flashes. Description • Solve the cause of the problem and unlock The electronic controller has a built-in function to the button by pulling it out. automatically restart the compressor when power is restored • Go to the Stop icon on the display using after a voltage drop. the navigation buttons (12) and press the Select button. Press the reset button. Do Each time the compressor is turned off, the emergency not use the emergency stop button for stop button must be pressed or the power disconnect normal stop! switch opened. - Close the air outlet valve (AV). - Press the test button on the top of the electronic water drain(s) until the air system between the air system tank and the outlet valve is completely depressurized. See Automatic drain section. Turn off the power. - If available, open the compressor condensate drain valve (Dm) to completely drain the watertrap.
35 3.24 Removal from service
Procedure
Step Action - Stop the compressor and close the air outlet valve. - Turn off the power and disconnect the compressor from the power supply. - If available, open the condensate drain valve(s) (Dm). - Close and depressurize the air network section connected to the outlet valve. Disconnect the air outlet pipe of the compressor from the air network. - Drain the oil. - Drain the condensate circuit and disconnect the condensate piping from the condensate network.
36 4 Installation
4.1 Dimensional drawing
Compressor dimensions 15 0 VS15 0 P CP F C
Dimensional CPF-150
37 F20 0 P C
Dimensional CPF-175 and CPF-200
38 4.2 Installation suggestions
Example of compressor room
Example of a compressor room for air refrigerated CPF compressors
39 Stage Description For British/American units: 1 Install the compressor on a horizontal position that In air-cooled compressors: Qv = 2618.5 N/dT properly supports the weight of the compressor. In water cooled compressors: Qv = 284.5 N/ For ventilation alternative 1 (indicated as Alt. 1), dT Qv = Required ventilation capacity, in cfm the minimum distance between the top part of the N = Compressor input power, in hp (for Pack frame and the ceiling is 1200 mm (47.2 in.). compressors) N = Compressor input power, in 2 Remove the plastic plug (if supplied) from the hp + heat dissipated by the dryer, in hp (for Full- compressor air outlet pipe and place the air outlet Feature compressors) valve (to be supplied by the customer) on the pipe. dT = Compressor room temperature rise If the Close the valve and connect it to the network. cooling air ducts are installed, the maximum 3 The pressure drop over the air outlet pipe can be allowable pressure drop over the ducts is 30 calculated as follows: Pa (0.12 in. of water column). The maximum For SI units: pressure drop depends on the room temperature. dp = (Lx450xQc1.85)/(d5 xp) dp = Pressure drop The fan capacity must correspond to the (maximum recommended = 0.1 bar) p = Absolute compressor fan capacity at a load height equal to pressure at compressor outlet, in bar(a) Qc = the pressure drop caused by the cooling air outlet Compressor free air throughput, in l/s ducts. Consult Chicago Pneumatic. For British/American units: 5 Remove the plastic plugs (if supplied) from dp = (L x Qc1 85)/(1470 x d5 x p) dp = Pressure the condensate outlets and install the manual drop (maximum recommended = 1.45 psi) condensate drain valve. Place the drain piping p = Absolute pressure at compressor outlet, in psig towards the condensate collector. Drain pipes Qc = Compressor free air throughput, in cfm It is should not immerse in the water from the drain recommended that the compressor air outlet pipe be connected to the top part of the main air network colector. It is recommended to provide a hopper pipe to minimize transfer of possible condensate to allow visual inspection of the condensate flow. waste. As a basic method, the following formula 6 Location of the ES4000 regulator. can be used to calculate the recommended air 7 See Dimension of electric cables for the network volume: recommended size of power cables. Check if V = (30 x C xpx Q) / Dp C = Correction factor the electrical connections comply with local Dp = Pressure difference between discharge and legislation. The installation must be earthed and load pressures, in bar (minimum recommended = protected against short circuits by fuses in all 0.6) p = Absolute pressure at compressor inlet, in bar Q = Compressor free air throughput in l/s V = phases. A disconnect switch must be installed Recommended air network volume in l near the compressor. Correction Factors Customer may install a water shutoff valve and Air consumption divided by Correction a water drain valve on the compressor water compressed air production factor C inlet and outlet pipe. If water shutoff valves are 0.9 0.10 installed, a safety device shall be installed at the 0.8 0.15 0.7 0.20 pressure set according to the maximum cooling 0.5 0.25 water inlet pressure between the compressor 0.3 0.20 water outlet pipe and the shutoff valve. When 0.2 0.15 0.1 0.10 operating the unit, the operator must make sure that the cooling water system cannot be blocked. 4 The inlet grates and the fan must be installed to The above also applies to the energy recovery prevent any recirculation of the cooling air to the cooling system. Remove the plastic plugs (if compressor. The maximum air speed through the grates is 5 m/s (16.5 ft/s). The ventilation required supplied) from the compressor water pipes and to limit the compressor room temperature can be connect the pipes to the cooling water circuit. calculated as follows: For water-cooled compressors, the cooling water system For SI units: In air-cooled compressors: Qv = 0.92 installed outside the compressor has to be protected by a N/dT In water cooled compressors: Qv = 0.1 N/ safety device with set pressure according to the maximum dT Qv = Required ventilation capacity, in m3/s cooling water inlet pressure. N = Compressor input power, in kW (for Pack compressors) N = Compressor input power, in kW + heat dissipated by the dryer, in kW (for Full- Feature compressors) dT = Compressor room temperature rise
40 4.3 Electric Diagrams See electrical diagram 1093 1387 35 that is included in the machine CD.
4.4 Cable size, fuses and circuit breaker settings
Attention Sizing performed in accordance with NBR 5410 for the following conditions: Local regulations will apply if more stringent than the values proposed below; Insulated conduits or unipolar cables in conduit over the wall; The voltage drop may not exceed 4% of the rated voltage. It may be necessary to use cables longer than those indicated to meet this requirement; Maximum cable length = 30 m; Maximum ambient temperature = 40°C; For other conditions, sections should be resized
Recommended cables, fuses and adjustments for CPF (YD) compressors
Length Power Adjustment Adjustment Adjustment Rec. fuse Rec. Cables F21 Q15 Q16 . . CPF-150 380V-60Hz 139A 9A Not applicable 3x (2x250A) 2x (3x95 + 50mm2) CPF-150 440V-60Hz 120A 7.8A Not applicable 3x (2x250A) 2x (3x70 + 35mm2) CPF-175 380V-60Hz 162A 9A 9A 3x (2x315A) 2x (3x120 + 70mm2) CPF-175 440V-60Hz 140A 7.8A 7.8A 3x(2x250A) 2x (3x95 + 50mm2) CPF-200 380V-60Hz 188A 9A 9A 3x (2x315A) 2x (3x150 + 95mm2) CPF-200 440V-60Hz 163A 7.8A 7.8A 3x(2x315A) 2x (3x120 + 70mm2) CPF-200 460V-60Hz 163A 7.8A 7.8A 3x(2x315A) 2x (3x120 + 70mm2)
41 4.5 Pictographs
Ref. Designation 13 Automatic condensate drain 21 Tightening torques for steel (Fe) or brass (CuZn) screws 14 Automatic condensate drain for oil/water separator 22 See Instruction Manual before performing lubrication. (OSD type) 15 Manual condensate drain 23 Turn off the power before removing the protective cover inside the electrical compartment 16 Stop the compressor prior to perform any maintenance 24 Lubricate joints, screw the filters and tighten by hand or repair operations. (approx. half turn) 17 Warning: energized 25 See Instruction Manual prior to perform any maintenance or repair 18 Read the Instruction Manual before starting the 26 Cooling water inlet compressor 19 Turn off power and depressurize the compressor prior 27 Cooling water outlet to perform any maintenance or repair 20 Before wiring the compressor, refer to the Instruction 28 Oil outlet Manual to check the direction of engine rotation.
42 5 Operating instructions 3 If the compressor has not been used in the last 6 months, it is recommended to increase the 5.1 Initial start lubrication of the compressor element before starting. Fill the compressor element as described The operator should employ all relevant safety in the Oil Change section (paragraph Filling the precautions. compressor element with oil). Turn off the power before performing any repairs. 4 Check if the compressor is filled with oil: the oil level gauge pointer should be in the green section (see Oil Change section). Transport/lifting The compressor can be moved with a forklift using the grooves Protection during transport in the frame. Make sure the forks appear on the other side of the frame. The compressor can also be lifted by inserting beams into the grooves. Make sure the beams do not slide and are at equal distance from the frame. Chains must be kept parallel to the frame by means of chain expanders, in order not to damage the compressor. The lifting equipment must be positioned so the compressor is lifted in perpendicular position. Lift slowly and avoid twisting.
General preparations for CPF compressors
Transport fittings for CPF compressors
Step Action 1 Gear compartment brackets, engine support and air tank brackets are fixed to the frame, immobilizing the vibration dampers during transport. 2 Remove bolts (1) from gear compartment brackets and engine support. 3 Remove the brackets installed near the air tank brackets. Plug to fill the compressor element at initial start Electrical compartment Step Action 1 Install the compressor; see sections Dimensional Step Action drawing, Installation suggestion and Size of 1 Check if the electrical connections comply with electrical cables. local legislation. The installation must be earthed 2 Attach labels near the control panel to warn the and protected by fuses in all phases. A disconnect operator that: switch must be installed. • the compressor may start automatically after a 2 Check proper connection of transformers. power failure • the compressor starts and stops automatically • the compressor can be remotely controlled
43 Start-up 5.3 Start-up
Step Action Warning
1 Close the drain valves (see section Cooling and The operator should employ all relevant safety condensate system). precautions. 2 Turn on the power. 3 Start the compressor and stop it immediately. Step Action Check the direction of rotation of the drive motor 1 Press the start button (10). The compressor runs in when the engine is almost stopped. To determine the relief condition. the direction of engine rotation, see the fan through the grating at the opposite end of the The automatic operation LED (3) lights up. motor drive. The correct direction of rotation is 2 Approx. after 10 seconds (programmable), the indicated by an arrow on the gear compartment compressor starts running under load. The display and fan cover. On air-cooled compressors, check message (1) changes from “Automatic Unloading” the direction of rotation of the fan motor - the to “Automatic Loading”. fan is visible through the grating on the air intake panel (see section Dimensional drawing). The correct direction of rotation is indicated by arrows on the inside plate of the fan. 4 If the direction of rotation is incorrect, push the emergency stop button, turn off the power and reverse two of the input power lines. If the direction of rotation of the fan motor is wrong, consult your Chicago Pneumatic Customer Center. 5 Run the compressor for a few minutes and check if it operates normally.
5.2 Before starting
Control panel
Ref. Name A Air inlet temperature, in °C B Condensation temperature in °C C Effective working pressure in bar D Relative air humidity, in %
Step Action 1 Turn on the power. The voltage LED (7) lights up. 2 Close the condensate drain valves (see section Cooling and condensate system). 3 Open the air outlet valve. 4 Check the oil level gauge (see section Oil Change). The pointer must be in the green section, or in the orange section.
44 5.4 During operation 5.5 Display check
Warning Warning
The operator should employ all relevant safety Before carrying out any maintenance, repair or precautions. adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air In case of oil leaks inside or outside the machine, outlet valve and open manual condensate drain valve. the operator must stop the machine immediately and consult a qualified technician to solve the problem. The machine should not be reused until the problem Step Action is solved. 1 Check display readings and messages regularly. Normally, the main display is shown, indicating Control panel the compressor outlet pressure, compressor status, and functions of keys below the display. 2 Always check the display and solve the problem if the alarm LED (5) is lit or flashing. 3 The display shows a service message if the range of a service plan has been exceeded, or if a service level of a monitored component has been exceeded. Carry out the service actions of the indicated service plans, or replace the component and reset the corresponding timer. 4 Regularly check the current status of the compressor by pressing the down arrow key on the main screen.
Main menu example “Status Data” → Step Action “Measured Data” ↓ 1. When the automatic operation LED (3) is lit, the “Counters” engine start and stop are controlled automatically. “Prin Screen” 2. Check readings on display (1). F1 F2 F3 3. To relieve the compressor manually, press the Main display example “Empty” key. To put the compressor back into automatic operation, press the “Load” key. Main display of CPF compressors “Compressor Outlet” 7.5 bar If the compressor is stopped, it can start “Automatic Load” ↓ automatically. “Menu” “Empty” F1 F2 F3
45 5.6 Manual load/relief 5.7 Stop
Control panel Notice
After pressing the stop button (11), the compressor operates in relief for 30 seconds. The compressor stops after this time. During this time, a start command is ignored. After stopping, the compressor is prevented from starting within a programmable time (20 seconds). A start command executed during this minimum stop time will be memorized; the automatic operation LED lights up. The compressor starts once the minimum stop time has elapsed.
Step Action 1 Press the scheduled stop button (11). The LED (3) goes out. The message “Scheduled Stop” is Main display example displayed. The compressor runs in relief for 30 seconds and then stops. Main display of CPF compressors 2 To stop the compressor in an emergency, press “Compressor Outlet” 7.5bar(109psi) the button (S2). The alarm LED (5) flashes. After . troubleshooting, unlock the button by pulling it “Automatic Load” ↓ out. “Menu” “Empty” 3 Close the air outlet valve. F1 F2 F3 4 Open the condensate drain valves. For Automatic operation compressors equipped with electronic water drains, press the test buttons on the top section of Normally the compressor runs automatically, i.e., the the electronic drains until the air system between electronic regulator controls the automatic loading, relief, the air tank and the air outlet valve is fully stop and restart of the compressor. Then, the LED (3) lights depressurized. up. 5 Turn off the power. Manual relief 6 In water cooled compressors, close the water Press the “Empty” key (F3); LED (3) goes out. The message shutoff valves. “Manual Empty” appears on the display. The compressor continues to operate in relief unless manually reloaded.
Manual load Press the “Load” key (F3); LED (3) lights up. The “Load” command does not force the compressor to load, but returns the compressor to automatic operation; The compressor will execute loading if the air network pressure drops below the set level.
46 5.8 Removal from service 6 Use only the oil specified by the manufacturer. Turning off the compressor 7 Make sure to completely depressurize the tank before opening the drain plug or filler plug. At the end of the compressor operation cycle, proceed as 8 This tank and other pressurized parts are designed follows: and built to ensure an operational life cycle of over 20 years and an infinite number of pressure Step Action loading cycles. A visual inspection (for damage, 1 Stop the compressor and close the air outlet valve. unauthorized changes etc.) of the tank (outside and inside) is recommended every 5 years. 2 Turn off the power and disconnect the compressor Make sure the tank is completely depressurized from the power supply. and insulated before performing an internal 3 Depressurize the compressor by opening the drain inspection. valve and unscrewing the oil filler plug one turn. 9 At each inspection also check the oil drain hose. For compressors equipped with electronic water Replace it if there are signs of wear or damage. drains, press the test buttons on the top section of the electronic drains until the air system between 5.10 Storage conditions the air tank and the air outlet valve is fully depressurized. 5.10.1 Introduction 4 Close and depressurize the air network section The non-painted surface of all out-of-service compressors, connected to the outlet valve. Disconnect the whether installed or waiting installation, is subject to oxidation air outlet pipe of the compressor from the air and corrosion. network. The corrosion level ranges according to the environment 5 Drain the oil and condensate circuits. In water conditions (temperature, humidity etc.) and the care taken for cooled compressors, drain the water circuits. storing and conserving the unit. 6 Disconnect the compressor condensate piping Therefore, it is impossible to establish the period in which the from the condensate drain network. unit can be stored without rust damage. 7 In water cooled compressors, disconnect the The higher the humidity and the longer the stopping and/ compressor cooling water pipes. or storage period, the more care must be taken. For CPF compressors, in addition to the precautions for the compressor, 5.9 Use of air tank specific preventive measures should be taken for the electric motor, according to the manufacturer’s instructions. Instructions Compressors are usually not expected to remain out of service Step Action or stored for long periods, which is why they leave the factory 1 This equipment may contain pressurized air and ready to be stored for a maximum period of 75 days from the oil; be aware of this potential hazard in case of date of manufacture; after this period the procedure in item misuse. 5.10.2 should be followed. 2 It must only be used as a compressed air/oil Should the compressor be out of service for more than one separator and should be operated within specified week, proceed as described in item 5.10.3. limits. 5.10.2 Storage and conservation prior to 3 Changes to this equipment must not be made by installation means of hard welding, drilling, grinding or other mechanical working methods without written 1. Store the compressor in a clean, dry, well-ventilated permission of the manufacturer. If a pressurized environment, free of dust and humidity. part is damaged, regardless of the cause, the 2. The entire lower section of the compressor should stand whole part must be replaced. on a flat, vibration-free floor. 4 For the oil separator tank: the original screws 3. Make sure there is no water in the crate, plastic cover or must be used after opening it for inspection. The any part of the unit’s bodywork or base. screws must be removed and replaced with the correct tool. The screws must be tightened using a torque of 355 Nm (+/- 85 Nm). Damaged screws should not be reused. O-rings must be replaced. 5 The safety valve is designed so that the pressure does not permanently exceed the maximum allowable operating pressure of the tank except for short pressure fluctuations up to 1.1 times the design pressure.
47 5.10.3 Conservation after installation 6 Maintenance 1. Run the unit at least twice a week, for a minimum of 30 minutes and operate the load/relief system a few times. 6.1 Preventive maintenance program 2. Stop the unit, close the outlet valve and open the Warning condensate drains (after the air cooler and condensate separator manual). Ensure none of the drains is clogged. Before any maintenance, repair or adjustment operation, follow the procedure below: 3. Close the drains after 02 minutes. • Stop the compressor. 4. Rotate the coupling 10 turns once a month, to change • Press the emergency stop button (S2). the position of the compressor element bearings balls • Close the air outlet valve and open manual and rollers. In case there is no access to the motor shaft, condensate drain valves. remove the rear motor cover for access through the • For compressors equipped with electronic water motor fan. drains, press the test buttons on the top section of the electronic drains until the air system between 5. Should the compressor be stored for more than 6 the air tank and the air outlet valve is fully months, the oil, oil filter and separator element should depressurized. be replaced. For the motor, check engine manufacturer’s • Turn off the power. instructions on material delivered (on CD) with • Open and block the disconnecting switch. the compressor. Pay attention to the engine resistor The operator should employ all relevant safety connection, if any, to avoid humidity inside the engine. precautions. NOTE: This instruction does not provide for cases of aggressive Warranty – Product Liability environment, which should be analyzed individually. Use only authorized parts. No damages or defects caused by 5.10.4 Movement and transport the use of non-authorized parts are covered by the Product Liability Warranty. If the unit is to be moved or transported, the original fittings and guards must be reinstalled to immobilize the vibration General dampers and the motor and compressor assembly. During assistance operations, replace all joints, O-rings and The compressor can be handled with a forklift using the washers. openings in the frame. The forklift must have capacity suitable for the sizes and weight of the compressor. The compressor may also be lifted by inserting beams into the openings. Make sure that the beams are properly fixed and equally spaced on both sides of the frame. Ropes/chains must be kept parallel to the bodywork by means of an expander, not touching it in order not to damage the compressor. Lifting equipment should be placed so that the compressor is raised perpendicular, slightly and without twisting.
48 List of Tasks for CPF150-200 (CPVS) compressors
10 3 4
13 11 9
17 2 15 14 8 10 1 7 6 16
12
MAINTENANCE TASKS POINTS PERIOD ACTIVITIES I A B C D 1 Check work pressure setting X X X X X 8 Check the oil level and top it up, if needed. X X X X X Daily 16 Check operation of condensate drains X X X X X 1 Check temperatures and pressures X X X X X 2,11 Check operation of the admission valve X X X X Internally and externally clean the unit X X X X 2000 hours or Externally clean oil and air coolers X X X X 6 months Check all adjustments set in the CP-Tronic module X X X X Replace air and oil filter X X X X 8 Replace the lubricating oil (1) X X X X 9 Replace the lubricating oil (2) X X X Motors Lubricate bearings of electric motor(s) (3) X X X Replace the air/oil separator filter X X 10 Review minimum pressure valve X X 3 Review intake valve X X 7 6000 hours or Review oil check valve X X 6 2 years Review air check valve X X 10 Review transition valve X X 15 Review condensate separator X X 10 Replace thermostatic valve X X Gearbox Replace rubber coupling X Motors 24000 hours Replace bearings of electric motors (4) X 17 Review the e compressor element and gearbox X
Notes: (1) – Every 2000 hours for Rotair (2) – Every 4000 hours for Rotair Plus (factory default). Electric motor lubrication should be performed with up to 3000 hours. (3) – Lubricate bearings of motor(s) according to the data on the plate. (4) – Based on predictive analysis. Types of maintenance may vary according to the use of compressors and conditions in the workplace.
49 When operating in a dusty environment, inspect air filters at shorter intervals. Always use Chicago Pneumatic filters. The separator element must also be replaced when the pressure difference on the element exceeds 0.8 bar (12 psi). Check the pressure drop when the compressor is running under load and preferably with a stable working pressure. Damaged hoses must be replaced immediately. Service contracts Chicago Pneumatic Customer Centers have a wide range of service contracts tailored to your needs: • An Inspection Plan • A Preventive Maintenance Plan • A Total Responsibility Plan Contact your Customer Center to agree a service contract tailored to your needs. It ensures operating efficiency, minimizes downtime and reduces operating costs.
Assistance Plan Several service operations are grouped (called Level A, Level B, Level C...). Each level represents a number of service actions to be performed at intervals defined in the ES4000 regulator. When a level is reached, a message appears on the display. After performing all service actions, reset the interval timers using the “Reset” key in the “Service” menu. Contact Chicaco Pneumatic’s Authorized Technical Service.
6.2 Motors
Warning Stop the compressor and switch off the power. The operator should employ all relevant safety precautions. Never mix lubricants of different brands or types. Fan motors The fan motor bearings are lubricated to ensure a long service life. Fan motor bearings must be replaced after 20000 hours of operation.
Interval Compressor Interval End Brand Grease Amount Opposite end Amount type of motor drive of motor drive
CPF WEG - 3000 h 34 g 3000 h 34 g
50 6.3 Oil specifications 6.4 Oil change
6.3.1 Chicago Pneumatic ROTAIR Plus Warning “Chicago Pneumatic ROTAIR Plus” - mineral with The operator should employ all relevant safety antioxidant, anti-corrosive, defoaming additives etc. precautions. For Chicago Pneumatic standard use in rotary compressors with oil injection under moderate operating conditions. For a life cycle of 3000 hs. This oil lasts long and provides excellent lubrication as long as the values in the table below are complied with. 6.3.2 Chicago Pneumatic CP-46 Chicago Pneumatic CP-46 - synthetic with antioxidant, anti- corrosive, defoaming additives etc. It can be used in compressors where there are more extreme operating and environmental conditions, where the CP-46 does not meet oil life requirements. For a life cycle of 6000 hs. 6.3.3 CP-46 F Procedure Chicago Pneumatic CP-46 F - commonly used in compressors 1. Run the compressor until warm. Stop the compressor, applied to food, pharmaceutical and other sector companies. close the air outlet valve and switch off the voltage. Wait a few minutes and depressurize the system by Notice loosening the vent plug on top of the air tank to allow pressure to be relieved. Wait until all the pressure in the Never mix oils of different brands or types. system has been relieved.
6.3.4 Oil filter change 2. Drain the oil by removing the drain plug from the hose attached to the bottom of the air tank. 1. Stop the compressor, turn off the voltage and unscrew the plug (5-Fig.3.5) one turn to allow any pressure in the Oil filter change system to be relieved. 1. Use an oil collector to prevent spillage. Unscrew the oil 2. Insert a container to collect the oil and prevent it from filters (6). dirtying the equipment. Remove the oil filters (1- 2. Clean the filter seats on the collector. Fig.3.5). 3. Lubricate new filter joints and screw the filters in place 3. Clean the mounting site of the filters in the housing. until the joints contact the seats. Then tighten manually. Lubricate joints on new filters and manually screw them back until joints fit into housings. 4. Loosen the air inlet hose (8) and pour 3 liters of oil into the compressor element. After filling the element, refit 4. Tighten the filler plug (5-Fig.3.5). the air inlet hose (8) and pour 3 liters of oil into the 5. Reschedule the oil filter service warning using the compressor element. After filling the element, refit the “Reset” key in the “Service” submenu. air inlet hose (8). 6. Refer to “ES400 Controller User Manual”, “SERVICE Filling the air tank with oil Submenu” section. 1. Refit and tighten the air tank oil drain plug. 2. Remove the filler plug (FC). 3. Fill the air tank with oil until the level reaches the filler neck. 4. Refit and tighten the filler plug (FC) and the vent plug on top of the air tank. 5. Run the compressor loaded for a few minutes.
51 6. Stop the compressor and wait a few minutes. 6.6 Service kits 7. Depressurize the system by loosening the vent plug on top of the air tank to allow pressure to be relieved. General 8. Remove the filler plug and fill the air tank with oil until Service kits contain all parts required to service the equipment the level reaches the filler neck. and offer the benefit of genuine Chicago Pneumatic parts, 9. Tighten the filler plug (FC). maintaining lower maintenance costs. All service kits are listed in the corresponding List of Spare Parts. Reseting ES4000 controller Chicago Pneumatic Rotair Plus Control panel Rotair Plus can be ordered in the following amounts: • 5 liter gallon: 6215 7144 00 • 20 liter gallon: 6215 7145 00 • 209 liter barrel: 6215 7146 00 See Oil specifications section.
Chicago Pneumatic CP-46 CP-46 can be ordered in the following amounts: • 5 liter gallon: 1031 4012 78 • 18.9 liter gallon: 1031 4012 61 • 209 liter barrel: 1031 4013 97 See Oil specifications.
After performing all service actions of the “Scheduled Service 6.7 Filter disposal Plan”, reset the service warning as follows: The filters used must be disposed of in a safe and 1. Press the “Menu” key in the display (1). environmentally friendly manner, always in accordance with 2. Press key (12) until “Service” is followed by an arrow the applicable local environmental standards and legislation. pointing to the right. Activate the menu by pressing the Warranty and Product Liability key (13). 3. Press the key (12) until “Scheduled Service Plan” is Use only genuine parts authorized by Chicago Pneumatic. No followed by an arrow pointing to the right, then activate damages or defects caused by the use of non-authorized parts by pressing the key (13). are covered by the Product Liability Warranty. 4. Press the “Reset” (14) key; the timer will be set to 0. 6.8 Safety valve 6.5 Storage after installation Warning Procedure Stop the compressor and switch off the voltage. Run the compressor twice a week, for example, until warm. The operator should employ all relevant safety Load and unload the compressor sometimes to operate the precautions. Never run the compressor without safety unloading/loading system components. valves. If the compressor is stored and not run periodically, Testing protective measures must be taken. Contact Chicaco Pneumatic’s Authorized Technical Service. The valve can be tested on a separate compressed air line. If the valve does not open at the set pressure (see section Safety valve parameters), contact the Authorized Chicago Pneumatic Technical Assistance.
52 7 Troubleshooting
7.1 Troubleshooting
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 manual condensate drain valves. Open and block the disconnecting switch. The operator should employ all relevant safety precautions.
Control panel
Problems and solutions
A service message is shown in the display Stop the compressor and carry out the service actions displayed. Reset the message: • Press the “Menu” key in the display (1). • Press key (12) until the message “Assistência” is followed by an arrow pointing to the right. Activate the menu by pressing the key (13). • Press the “Reset” (14) key; the timer will be set to 0.
A shutdown warning message is shown in the display The alarm LED lights up to indicate that the outlet temperature of compressor elements is too high. The message disappears immediately after the cause of the problem is eliminated.
The unit switches off The alarm LED flashes to indicate that the outlet temperature is too high or that the motor overload relay has tripped. Solve the problem. It may be necessary to reset the display after troubleshooting: press the "Reset" (2) key; the message "Todas as Funções de Proteção OK" (All Protection Features OK) will be displayed, and then the compressor can be restarted.
Excessive oil consumption Request compressor inspection to the Authorized Chicago Pneumatic Technical Assistance
53 Condition Problem Solution Request compressor inspection to the Discharge pipe of condensate trap Check and correct, if necessary. Authorized Chicago Pneumatic Technical clogged. Assistance Malfunction of the condensate trip Remove the float assembly, clean and float valves. check.
Condition Problem Solution Compressor air flow or pressure below Air consumption exceeding Check the equipment connected. normal. compressor air flow. Clogged air filters. Replace filters. Air leak. Check and correct.
Condition Problem Solution Compressor element outlet temperature or Low level oil. Check and correct. outlet air temperature above normal. Oil coolers clogged. Perform external cleaning. Air coolers clogged. Perform external cleaning. In air-cooled compressors, Check and correct, if necessary. insufficient cooling air or cooling air temperature too high.
54 8 Technical data Data for 7 bar (100 psi) CPF compressors of 60 Hz
Units CPF-150 CPF-175 CPF-200 Maximum working pressure, CPF Pack bar(e) 7.4 7.4 7.4 Maximum working pressure, CPF Pack psig 107.3 107.3 107.3 Nominal working pressure bar(e) 6.9 6.9 6.9 Nominal working pressure psig 100 100 100 Motor shaft speed r/min 1780 1780 1780 Input power, CPF Pack kW 131 148 176 Oil capacity, CPF l 66 80 90 Acoustic pressure level, CPF dB(A) 81 75 84
Data for 8 bar (125 psi) CPF compressors of 60 Hz
Units CPF-150 CPF-175 CPF-200 Maximum working pressure, CPF Pack bar(e) 9.1 9.1 9.1 Maximum working pressure, CPF Pack psig 132 132 132 Nominal working pressure bar(e) 8.6 8.6 8.6 Nominal working pressure psig 125 125 125 Motor shaft speed r/min 1780 1780 1780 Input power, CPF Pack kW 132 148 177 Oil capacity, CPF l 66 80 90 Acoustic pressure level, CPF dB(A) 81 75 84
Data for 10 bar (150 psi) CPF compressors of 60 Hz
Units CPF-150 CPF-175 CPF-200 Maximum working pressure, CPF Pack bar(e) 10.9 10.9 10.9 Maximum working pressure, CPF Pack psig 132 132 132 Nominal working pressure bar(e) 10.4 10.4 10.4 Nominal working pressure psig 125 125 125 Motor shaft speed r/min 1780 1780 1780 Input power, CPF Pack kW 131 150 176 Oil capacity, CPF l 66 80 90 Acoustic pressure level, CPF dB(A) 81 75 84
Data for 13 bar (200 psi) CPF compressors of 60 Hz
Units CPF-150 CPF-175 CPF-200 Maximum working pressure, CPF Pack bar(e) 14 14 14 Maximum working pressure, CPF Pack psig 202 202 202 Nominal working pressure bar(e) 13.5 13.5 13.5 Nominal working pressure psig 195 195 195 Motor shaft speed r/min 1780 1780 1780 Input power, CPF Pack kW 131 195 178 Oil capacity, CPF l 66 80 90 Acoustic pressure level, CPF dB(A) 81 75 84
55 9 Instructions for using the air-oil separator vessel 1. This vessel may contain pressurized air and may be potentially dangerous if the equipment is misused. 2. It should only be used as an air-oil separator and must be operated within the limits specified on the data plate. 3. No change must be made to the vessel by welding, drilling or other mechanical methods without the written consent of the manufacturer. 4. If the safety valve needs to be replaced, it must follow the manufacturer’s specification in full. 5. Use only the oil specified by the manufacturer. 6. In case of equipment misuse (too low oil temperature or long shut-off interval), certain amount of condensate may build up in the oil separator vessel, which must be properly drained. To do this, disconnect the equipment from the mains, wait until it cools and depressurize. Drain the condensate through the oil drain valve, located at the bottom of the air-oil separator vessel. The local legislation may require periodic inspection of the air-oil separator vessel.
56 10 Environmental information Check the Environmental Information file recorded on the manual CD provided with the Chicago Pneumatic equipment. This file has guidance on environmental aspects involved in use of Chicago Pneumatic equipment.
57 NOTES NOTES NOTES NOTES NOTES Chicago Pneumatic Brasil LTDA. Rua São Paulo, 147 - Alphaville Empresarial - Barueri - São Paulo - Brazil Phone: (011) 2189-3900 CNPJ: 51.609.568/0001-45 Visit us on: www.chicagopneumatic.com