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Instruction Manual EN CP COMPRESSOR Model CPE 75 - 100 - 125 - 150 CPVS 100 - 125 - 150 CPE 150 62 305 793 65 CPVS 125

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Page 1: Model CPE 75 - 100 - 125 - 150 CPVS 100 - Rev Up CPrevupcp.com/wp-content/uploads/2015/05/CPE-75-150-CPVS-100-150... · Instruction Manual EN CP COMPRESSOR Model CPE 75 - 100 - 125

Instruction Manual EN

CP COMPRESSOR

Model CPE 75 - 100 - 125 - 150CPVS 100 - 125 - 150

CPE 150

62 305 793 65

CPVS 125

Page 2: Model CPE 75 - 100 - 125 - 150 CPVS 100 - Rev Up CPrevupcp.com/wp-content/uploads/2015/05/CPE-75-150-CPVS-100-150... · Instruction Manual EN CP COMPRESSOR Model CPE 75 - 100 - 125

11/2008Page 2

Chicago Pneumatic Compressors62 305 793 65

The CP Compressors should never be operated beyond its capabilitiesor in any way which does not comply with the instructions contained

in this operating and maintenance guide.

Chicago Pneumatic Compressors will decline any responsibilityif these instructions are not respected.

This equipment has been factory tested and satisfies normaloperating conditions: they must not be exceeded

as this would place the compressor under abnormal stress and effort.

INSTALLATION INSTRUCTIONSFor the guarantee to be valid, the unit must be assembled in covered

premises with temperatures not exceeding :

Mini: + 36 °F (frost free)

Maxi: + 104 °FYou must also have:

3,33 ft space around the compressor-

low ventilation (fresh air) proportionate to the ventilation flow necessary for the compressor and protectedfrom any infiltration of humidity (splashes of water during bad weather) and all pollution

-top insulation or extraction to ensure reversal of the flow of warm air and evacuation of the heat to

outside the equipment room-

a link from the condensation water evacuation pipe to the drain discharger.-

In case of dusty ambient environment, a pre-filtration is made by micro-filter on the air inlet of the room used for cooling andperhaps a special filter on the compressor air inlet.

TECHNICAL DATASTANDARD MACHINES

CPE 75 100 125 150

Nominal pressure at full flow PSI 100 125 150 175 100 125 150 175 100 125 150 175 100 125 150 175Actual flow* cfm 374 334 - - 517 455 410 379 566 528 504 450 687 615 561 526(as per ISO 1217 ed 1996)

Motor power hp 75 100 125 150Ø Pressure outlet (M) NPT 2" 2" 2" 2"Capacity gal 6.6 6.6 9.25 9.25Carryover ppm 2 2 2 3Noise level at 3,3 ft dB(A) 65 66 71 75(according to ISO 2157 + 3db(A))

**Suction pressure : 14.5 PSI absolute - Relative humidity : 0 % - Ambient temperature : 68 °F

- Effective delivery pressure : 102 PSI, 109 PSI, 138 PSI or 181 PSI (effective)

Dimensions (in) L x W x H 87.86 x 41.76 x 63.04 87.86 x 41.76 x 63.04 87.86 x 41.76 x 63.04 87.86 x 41.76 x 63.04

Approximate weight lbs 3153 3307 3583 3990

Page 3: Model CPE 75 - 100 - 125 - 150 CPVS 100 - Rev Up CPrevupcp.com/wp-content/uploads/2015/05/CPE-75-150-CPVS-100-150... · Instruction Manual EN CP COMPRESSOR Model CPE 75 - 100 - 125

Chicago Pneumatic Compressors62 305 793 65

11/2008Page 3

CPE 75 100 125 150

Motor power hp 80 100 125 150

Main Voltage 230 Volt / 3 / 60 Hz

Nominal current (A) 231 321 - -Power supply cable AWG 300 AWG 500 - -Fuse protection (RK5) 250 350 - -

Main Voltage 460 Volt / 3 / 60 Hz

Nominal current (A) 114 163 184 217Power supply cable AWG 1 AWG 000 AWG 0000 AWG 250Fuse protection (RK5) 125 175 200 250

Main Voltage 575 Volt / 3 / 60 Hz

Nominal current (A) 82 119 133 158Power supply cable AWG 2 AWG 0 AWG 00 AWG 000Fuse protection (RK5) 90 125 150 175

Connection of the electric plate to an external control box

• Install an RC filter on the KM1 coil.• Install an RC filter on the KM2 coil.• All connections between external parts and the compressor must be carried out using a shielded cable, which must be grounded at one of its

ends.

WARNING: the operation connection cables between the different elements must never follow the same path as the existing powercords. A separate installation from the power cords must be carried out.

• Install an RC filter on all the relay coils of the external operation units.

TECHNICAL DATAVARIABLE SPEED MACHINES

Note : For specific information on variable speed machines see Chapter 6.

CPVS 100 125 150

CPVS VERSION (as per ISO 1217 ed 1996)

Nominal pressure at full flow PSI 58 102 138 58 102 138 58 102 138Actual flow* cfm 524 518 451 644 576 508 688 673 600(as per ISO 1217 ed 1996)

Motor power hp 100 125 150Ø Pressure outlet (M) NPT 2" 2" 2"Capacity gal 6.6 7.66 9.25Carryover ppm 2 2 3Noise level at 3,3 ft dB(A) 66 71 75(according to ISO 2157 + 3db(A))

* *Suction pressure : 14.5 PSI absolute - Relative humidity : 0 % - Ambient temperature : 68 °F

- Effective delivery pressure : 102 PSI, 138 PSI or 181 PSI (effective)

Dimensions (in) L x W x H 87.86 x 41.76 x 63.04 87.86 x 41.76 x 63.04 87.86 x 41.76 x 63.04

Approximate weight lbs 3307 3583 3990

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11/2008Page 4

Chicago Pneumatic Compressors62 305 793 65

CONTENTSSpace requirement and installation diagram CPE 75, CPE 100, CPE 125, CPE 150,CPVS 100, CPVS 125, CPVS 150 ...................................................................................................................................................... 5

Section 1 - Description ................................................................................................................................................................................. 6

A - General Information ...................................................................................................................................................................... 6B - Respect of the environment and prevention of pollution ............................................................................................................. 6C - Standard equipment ...................................................................................................................................................................... 6D - Definition of the pictograms ........................................................................................................................................................ 7E - Electronic board ............................................................................................................................................................................ 7

Section 2 - Installation ................................................................................................................................................................................. 8

A - Handling ........................................................................................................................................................................................ 8B - Room ............................................................................................................................................................................................ 8C - Assembly ...................................................................................................................................................................................... 8D - Air discharge pipes ....................................................................................................................................................................... 8E - Condensate drain pipes ................................................................................................................................................................. 9F - Electric cabling .............................................................................................................................................................................. 9

Section 3 - Commissioning ....................................................................................................................................................................... 10

A - Preparation for start-up .............................................................................................................................................................. 10B - First start-up .............................................................................................................................................................................. 10C - Discharge pressure adjustment ................................................................................................................................................... 10D - Parallel compressor assembly .................................................................................................................................................... 10E - Safety .......................................................................................................................................................................................... 10

Section 4 - Operation ................................................................................................................................................................................. 11

A - Air and oil circuits ....................................................................................................................................................................... 11B - Regulation principles .................................................................................................................................................................. 12

Section 5 - Options ..................................................................................................................................................................................... 13

A - Level detection bleed valve (Fig. 9) ............................................................................................................................................ 13B - Advanced filtration to the compression air inlet (Fig. 10a and 10b) ........................................................................................... 13C - Pre-filtration panels .................................................................................................................................................................... 14D - Automatic restarting ................................................................................................................................................................... 15E - Remote starting and stopping ..................................................................................................................................................... 15F - Rotation direction indicator - Phase controller ........................................................................................................................... 15G - Centrifugal separator .................................................................................................................................................................. 15

Section 6 - Specific information for CPVS 100 - 125 - 150 ................................................................................................................... 16

A - Description (cf Section 1) ........................................................................................................................................................... 16B - Safety .......................................................................................................................................................................................... 16C - Installation .................................................................................................................................................................................. 16D - Commissioning ........................................................................................................................................................................... 17E - Operating incidents ..................................................................................................................................................................... 19

Section 7 - Maintenance ............................................................................................................................................................................ 20

A - Oil level and change .................................................................................................................................................................... 20B - Air filter ...................................................................................................................................................................................... 21C - Turbine ....................................................................................................................................................................................... 21D - Oil and air cooler ........................................................................................................................................................................ 21E - Oil separator ............................................................................................................................................................................... 22F - Draining condensation water ...................................................................................................................................................... 22G - Temperature safety tests ............................................................................................................................................................ 22H - Refastening electric connections ................................................................................................................................................. 22I -Decommissioning the compressor at the end of its useful life ...................................................................................................... 22

Section 8 - Trouble shooting ..................................................................................................................................................................... 23

A - Main incidents ............................................................................................................................................................................ 23

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Chicago Pneumatic Compressors62 305 793 65

11/2008Page 5

31.5

87.86

63.0

4

49.4

5.9

39.4

31.418.3 7.3 28.7 7.3

78.7

31.331.3

Ø5.5

25.6

32.7

9

16.4

90.

821.

02

A

B C1.1

6xØ0.3

1

32

41.7

612

0.28

0.28

3.9

12

19.9

Ø21.3

14.2 14.2

20.9

4.3 4.3

Space requirement and installation diagram CPE 75, CPE 100, CPE 125, CPE 150,CPVS 100, CPVS 125, CPVS 150

(see page 2 - installation instructions)Fig. 1

Model A B C

CPE 75 23 12.6 5.3CPE/CPVS 100 33 17.4 7.6CPE/CPVS 125 35.4 18.8 8.3CPE/CPVS 150 41.5 21.9 9.8

Air outlet female NPT 2"Air inlet

Air inlet

Air inlet without deflector

Dimensions (in)

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Chicago Pneumatic Compressors62 305 793 65

11/2008Page 6

Section 1 - DescriptionA - General InformationThe Chicago Pneumatic Compressors air compressor CP Model,constitute a central compressed air which is fully equipped andtested, driven by an electric motor and enclosed by a sound-proofcover, necessary to keep the entire apparatus cool.

The compression element is a single-stage, oil-refrigerated, ro-tary screw compressor. The oil is stored in a vertical tank, whichis fitted with an oil separator.

The compression element and the motor are fixed to the frameusing silent blocks.

B - Respect of the environment andprevention of pollution

1 - Maintenance of the compressorMake sure that the used components of the compressor (wasteoil, oil and air filters, oil separators, etc.) are disposed of accordingto national and local regulations.

2 - Condensate bleed pipeMake sure that the condensates (water, oil) are drained and treatedaccording to national and local regulations.

3 - End of life of the compressorMake sure that the compressor as a whole is disposed of accordingto national and local regulations. ( Refer Chapter 7-I )

C - Standard equipmentIn its standard version, the covered unit includes:

- Operating components:

1. A twinned screw-type compressor.2. An electric motor: 3600 rpm, short-circuit rotor, 230/460

V or 575 V voltage according to the type.3. Star delta starting.4. A direct drive or gearbox drive .5. Air and oil tank in compliance with applicable legislation

ASME (USA) or CRN (Canada).6. "All or nothing" flow regulation for the aspiration vent.7. A greasing system using the circuit's differential pressure,

thus avoiding the need for an oil pump.8. An oil separator based oil separation system.9. A heat discharge system : oil and compressed air cooler

with forced ventilation.10. A dry air filter.11. An oil filter.12. A command and control electronic board.

- Safety devices:

1. A safety valve mounted on the oil reservoir.2. An thermal protection device for the motor, situated in the

starting box, to protect the motor from excessive overload.3. An air temperature sensor that stops the compressor when

the temperature rises abnormally or during an oil coolingdefect.

- Control devices:

1. A minimum pressure valve located at the oil tank outlet,just beyond the oil separator, which guarantees minimumpressure in the lubrication circuit.

2. An automatic vacuum that allows the use of air to stop,thus ensuring a vaccum start relieving the engine.

3. An oil level gauge on the front panel ( see fig. 19).4. An electronic controller including:– a control keyboard,– the main safety and control indications.5. The pressure sensor ensures control over the compressed

air flow.

The CP compressed air unit has been designed, produced andtested in accordance with the following recommendations, codesand standards :- machine safety: European Directive 98/37/CE, 91/368/CEE and

93/68/CEE.- pressure vessels: European Directive for simple pressure vessels

n° 87/404/CEE.- electrical equipment:

• electrical equipment: European Directive Low tension 73/23/CEE.

• electromagnetic compatibility European Directive: 89/336/CEE,92/31/CEE.

- performance levels: ISO 1217 : 1996.- noise level : ISO 2157 + 3db(A).- European Directive 97/23/EC

" Pressure Equipment Directive ".

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D - Definition of the pictogramsTypical examples of pictograms valid for CP Compressors:

1. Water outlet2. Manual condensation water draining3. Water inlet4. Automatic condensation water draining5. Unplug and decompress the compressor

before maintenance6. Hot parts

E - Electronic boardSee the specific instructions for a description of the electronic plate,together with operating instructions:Notice N° 62 305 516 99 for version StandardNotice N° 62 305 517 99 for version CPVS

DANGERThis symbol identifies immediate hazards which willresult in severe personal injury, death or substantialproperty damage.

CAUTIONIdentifies hazards or unsafe practies which couldresult in minor personal injury or property damage.

DANGERThis symbol identifies life threatening electricalvoltage levels which will result in severe personalinjury or death. All electrical work must beperformed by a qualified electrician.

CAUTIONThis symbol identifies hot surfaces which cooldresult in personal injury or property damage.

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Section 2 - InstallationA - Handling

The CP Compressors must always be handled with care. It maybe lifted either with a forklift truck or by means of a travellingcrane. In the latter case, precautions must be taken in order not todamage the unit's canopy.

B - Room

The CP Compressors is designed to operate in a frost-freeenvironment, supplied with air at a temperature of no more than104 °F. The premises must be well-aired and as close as possibleto the place where the compressed air is used. A space must beleft around the unit, for cleaning and maintenance purposes. It isvery important for the compressor to have an abundant supply offresh air. (see page 2).

COMMENTWhen the atmosphere is contaminated by organic or mineral dust orby corrosive chemical emanations the following precautions must betaken:

1. Provide another air inlet as close as possible to thecompressor suction.(recommendation which is valid if theonly room available is excessively damp).

2 - Use an additional air supply filter. Consult us.

Installation with heat dispersion sleeve

If the operation of the compressor increases the ambienttemperature above 104 °F, it is necessary to discharge the hot airleaving the cooler to the exterior by means of a sleeve.

LV

Fig. 2a - Sleeve with roof outlet

L

V

Fig. 2b - Sleeve with an elbow

V maxi = 18,04 ft/s(Ratio of volume flow rate of the ventilation to the sleeve

cross section)L maxi = 32,8 ft (without mechanical extractor)

Cross section of room air inlet > 2 x Duct outlet cross section2 elbows accepted with large radius of curve and fluid gui-

dance vanesRatio (Length/Width of sleeve) maxi = 1.6

Make sure that no outside air, especially if humid, can be fedback into the compressor and damage electric and electroniccomponents or rust metal parts.

The maximum admissible pressure loss of the sleeve should notexceed 30 Pa (3 mmCE). In case of higher value, provide anadditional ventilation (mechanical extractor) with a flow equivalentto that of the compressor.

C - AssemblyPut the unit on a stable surface. The CP compressor does notneed foundations. Any flat surface that can support their weightwill be sufficient (industrial floor).

D - Air discharge pipesThe diameter of the air discharge pipe must be at least2"NPT.Current legislation requires that a valve which is lockablein the closed position be installed at the air box outlet, connectedto the compressor by a union and flexible line to allow it to becut off during repair work.

If CPVS has to operate in parallel with other CPE, or the analog-model compressors, the discharge pipes can be connectedtogether.

If CPVS has to operate in parallel with one or several alterna-tive compressors, an air tank which is common to the alterna-tive compressors is essential. The pulses emitted by the alterna-tive compressors would seriously damage the non-return valve,the CPVS oil separator component and disturb the controlsystem. When the rotary compressor operates in parallel withan alternative compressor, the latter have to be adjusted so thatthe rotary compressor carries the base load. The result of this ismore economic operation.

Flexible fitting

Compressor

Prevailing wind

Flexible fitting

Compressor

Prevailing wind

Ventilation Duct minimum cross sectionflow rate ( d ≤ L ≤ 1,6d )

cfm sqmCPE 75 7650 7.07CPE/CPVS 100 7650 7.07CPE/CPVS 125 8836 8.16CPE/CPVS 150 8836 8.16

d

L

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Chicago Pneumatic Compressors62 305 793 65

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E - Condensate drain pipes

A separator with automatic solenoid valve drain is providedinside the set ( see Section 5-K) to remove the condensate atthe final cooler outlet and stop the compressor pipe condensatereturn lines. Connect the discharge pipe to a condensatemanifold.(see B Section 1)

F - Electric cabling

Each CP compressor is wired for a pre-determined voltage,i.e. 230 V, 460 V or 575 V.

NEVER OPERATE THE CP COMPRESSOR AT A VOL-TAGE OTHER THAN THE ONE SHOWN ON THEELECTRICAL CABINET.

The electric current supply to the CP Compressor must complywith the following table :

Type of cable to be used : 167 °FPower cable size

(for a maximum 32.8 ft length)

VOLTAGE CPE

230 V 460 V 575 V75 AWG300 AWG1 AWG2

100 AWG500 AWG000 AWG0125 - AWG0000 AWG00150 - AWG250 AWG000

SAFETY REGULATIONS

It should be remembered that safety regulations require :• An earth socket to be used.• A manual isolating switch, cutting all three phases ; this switch

must be clearly visible near the CP Compressor unit.• The electric current must be cut whenever maintenance work is

carried out on the compressor (except for pressurized oil change)

Fuses to be used forthe isolating switch (RK5)CPE

230 V 460 V 575 V75 250 125 90

100 350 175 125125 - 200 150150 - 250 175

Note : For specific information on variable speed machines seeChapter 6.

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Section 3 - CommissioningA - Preparation for start-upBefore starting the set for the first time, the operator must get toknow the different systems. The main locations which have to beexamined are shown on the figures.

IMPORTANTBefore start up, make sure that transport red wedges have beeneffectively removed.

ATTENTIONThe power circuit must be turned off whenever adjusting electricalequipment or to prevent accidental starting.

Loosening of electrical power cables that may be due to vibra-tions caused by transport or initial heating entails abnormal heatingof contactors, which may even destroy them. Therefore, thesecables must be re-tightened at line contactor incoming andoutgoing, star and triangle before use.

Before start-up, check the following points :

1 - Make sure that the unit is properly grounded.2 - Check the oil level in the tank.

NOTE : the tank has been filled with suitable oil in thefactory. See Section 7 - A for the quality of oil to be usedor for oil renewal conditions.

3 - Make sure the oil change valve is properly closed.

ATTENTIONThe oil filler cap, the oil change valve and plugs must alwaysremain closed during operation and never be opened before thesystem has been completely vented to atmospheric pressure seeSection 7 - A.

B - First start-upCheck the voltage between the three phases before using the unitfor the first time.

Fig. 7

Check the direction of rotation (following the arrow on the couplinghousing rep. 1-fig. 7) by pressing the "Start" button, followedimmediately by the emergency stop. If it does not spin in the rightdirection reverse two stages of the power cord. When it rotates inthe correct direction, the oil level (fig. 19) should drop after 4 or5 seconds of operation.It is also very important to verify the direction of rotation of thefan (indicated on it by an arrow) anti-clockwise seen from insidethe compressor or clockwise seen from outside the compressor.

1 - Press the ON button, the motor starts up.

2 - Keep it running for a few minutes with the discharge valveslightly open to observe the compressor under load. Ensurethat there are no leaks. Reblock the connectors if necessary.

3 - Press the OFF button. The motor will stop and the unit willautomatically vent to atmospheric pressure.

C -Discharge pressure adjustment

The unit is adjusted in the factory for a MAXIMUM pressure (forthe maximum output from the outlet of the central unit) of 100,125, 150 or 175 PSI depending on the model. To adjust thebackflow pressure setting to a lower value, refer to the manual ofthe electronic controller.

D - Parallel compressor assemblyIf the CP compressor is intended to operate in parallel with otherCP or similar compressors, the discharge piping can be linkedtogether.

If the CP compressor is intended to operate in parallel with otherCP or similar compressors, there must be an air tank common to allthe alternative compressors. The pulses emitted by alternativecompressors may cause serious damage to the minimum pressurevalve and the CP oil separator, and disrupt the regulation system.When the rotary compressor is operating in parallel with an alter-native compressor, the latter should be adjusted so that the rotarycompressor takes the main load. It is cheaper to run this way.

E - SafetyThe oil used for cooling the compressor is a liquid combustibleunder the effect of strong heat. In case of fire in the compressor, itis essential to respect the regulatory measures on the compressor.The type of fire in a compressor is defined as "class B" and inpresence of a live electrical conductor, it is recommended to use aCO2 extinguisher functioning by "smothering" (starvation ofoxygen) while observing the user instructions applicable to the type.

1

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Section 4 - OperationA - Air and oil circuits

1 - Air circuits (see Fig. 8)

The air is sucked into the compressor through a filter (rep. 23).This air passes through the compression element where it is mixedwith oil injected during compression. Inside the oil tank, thecompressed air is pre-de-oiled by shocks, then flows through theoil separator (rep 49). It then passes through the mini pressurevalve (rep 34) forming a check valve, the aftercooler (rep 51A),the condensate separator (in option), and then the outlet valve(not supplied) to which the distribution pipe is connected.

2 - Oil circuit (see Fig. 8)

The oil, under discharge pressure, flows from the bottom of the tankthrough the cooler (rep. 51H), the oil filter (rep. 26) which retainssolid impurities, and then into the compressor (rep. 20). At each coldstart, the thermostat valve (rep. 47) short circuits the oil cooler, thusenabling the optimum operating temperature to be reached quickly.When it leaves the compressor, the oil returns to the tank. Part of theoil remains suspended in the air as mist. This mist passes through theoil separator. (rep. 49). The remaining oil, which is separated by thelast stage of the oil separator, is drawn up by a dip tube and dispatchedto the compressor.

Key fig. 820 Compressor

21 Suction element

23 Air filter

26 Oil filter

34 Minimum pressure valve

41 Ventilator

47 Thermostat valve

49 Oil separator

51 A Air cooler

51 H Oil cooler

56 Motor

57 Tank

Fig. 8 - Air / oil circuit

20

56

41

34

23

57

51A51H

49

26

47

21

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B - Regulation principles

1 - "On off Load" regulation (see Fig. 8bis)standard version

The CPE 75-100-125-150 units are fitted with an automaticregulation system, enabling the compressor to be stopped afterit has run unloaded for a given (adjustable) period of time. Thisperiod of unloaded running is necessary to avoid excessivelyclose start-ups in highly varied periods of compressed airconsumption.

When the compressor reaches its maximum pressure, the pres-sure switch (rep. 45) closes the electrovalve (rep. 22). Thecompressed air on the suction housing piston and the vacuumpiston are depressurised; the housing is closed and complete drai-nage of the tank is carried out.

The compressor draws in air via a by-pass valve (rep. 25).

The low pressure obtained in the oil tank enables the compressorto be lubricated and cooled during the whole unloaded runningperiod.

If the user network's compressed air pressure reaches the mini-mum pressure switch trip value before the end of the unladenrunning time, the pressure switch (rep. 45) opens the electrovalve(rep. 22), causing the suction valve to open and the vacuumsystem to close. The compressor compresses at full rate again.

When the compressor stops, the solenoïd valve (rep. 22) is nolonger powered and closes; the suction housing closes and theoil tank is evacuated. The tank is thus vented to atmosphericpressure, for the next time the unit is started up.

Key fig. 8bis20 Compressor

21 Suction housing

22 Solenoïd valve

23 Air filter

25 By-pass valve

26 Oil filter

34 Minimum pressure valve

36 Pneumatic pump out

37 Safety valve

41 Ventilation

45 Regulation pressure switch

46 Safety temperature sensor

47 Thermostat valve

49 Oil separator

51 A Air cooler

51 H Oil cooler

57 Oil tank

2 - Speed regulator( see Section 6)

Fig. 8bis - "On off Load" regulation

23

20

25

26

57

21

36

22

3435

46

51A

51H

45

49

37

47

41

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2 - Option overview- This option is used as a replacement for the standard filter- Certain atmospheric particles are smaller than 7810-6 in, a limitingthreshold for traditional paper cartridge filters. The filter increasesfiltration effectiveness by eliminating 99.97% of particles thatare larger than or equal to 11810-6 in.- The quality of the air intake by a compressor is essential. Lowquality air creates the following :• Quick pollution of the oil thus an increase in draining cycles.• Binding of the air / oil separator before 4000 hours thus anincrease in maintenance cycles and operation costs.• Pollution increases the elements that filter into the air and oil,speeding up the damage to the mechanical components of thecompressor, screw element,...

Filters in compliance with standard ISO 5011/2000.- Exceptional filter longevity, from 18 months to 3 years ofcontinuous service (24 hours a day, 7 days a week), which is alittle more than 10,000 hours of operation of the compressor undernormal conditions.- Installation of the filter(s), depending on the model, outside thecompressor, for intake of fresh air, hence resulting in a lower oiltemperature and more efficient compression (Fig. 10a and 10b).

x y

Fig. 10a

Fig. 10b

Section 5 - OptionsA - Level detection bleed valve (Fig. 9)

1 - DescriptionThe BEKOMAT type level detection bleed valve allows all airconsumption to be avoided while the compressor is not running.

2 - Option overview- There is no air consumption due to the level detection system : aninductive sensor detects the level of condensation and thus controlsthe opening of the electric bleed valve. A low level of condensationis also detected in order to close the electric bleed valve and to preventcompressed air from being wasted.

- This type of purge valve does not require any maintenance. Thepurge valve does not require the use of the metallic intake filter thatis usually installed on electronic purge valves to protect the solenoidvalve. The solenoid valve will not be damaged.

- Condensate treatment is made easier because it is not evacuated bypressure, which enables easy separation of the water and oil stages.

1 - Condensation intake 4 - Main duct2 - Capacitive sensor 5 - Electric valve3 - Receiver 6 - Membrane

3 - Technical featuresMaximum capacity of the compressor : 706 cfmWorking pressure : 11,6 / 232 PSIOperating pressure : 33,8 / 140 °FElectric power supply : 115 V / 24 VAC socket in the compressor electric cabinet.

B -Advanced filtration to the compressionair inlet (Fig. 10a and 10b)

1 - Description

This system is equipped for "high efficiency" air filtration in orderto improve the quality of the air intake and to preserve thecompressor's oil and internal filter components.

This option is particularly useful in very dusty surroundings.

Fig. 9

1

2

3

4

5

6

Cartridge

Air filter

Extraction duct

VORTEX pre-filter

x y

CPE/CPVS 75-100 87,86 in 13,58 inCPE/CPVS 125-150 87,86 in 16,93 in

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3 - Technical features

Operating temperature :-104 °F to 194 °F

C - Pre-filtration panels

1 - Description

Installing air filtration panels on the ventilation intakes(compressor and built-in dryer) guarantees protection of thecompressor's internal components and an increase in air suckedinto the compression assembly. This option is recommended ifthe forced filtration option is installed (see § B).

2 - Option overview

The pre-filtration panels eliminate 90% of the particles normallyadmitted inside the compressor and considerably decrease internalcontamination of the compressor.

The high quality of the ventilation air is also essential for protectinginternal components of the compressor and, more specifically, themotor and the air / air and air / oil exchangers. Clogging in theexchangers creates an increase in temperature, deterioration ofthe lubricant and the motor becomes overloaded thus increasingthe energy consumed.

The quality of the air drawn in by a compressor is essential. Lowquality air results in the following :

• Fast pollution of the oil thus an increase in oil change cycles.

• Increased pollution of the air and oil filtering components thatincreases the deterioration of the mechanical components in thecompressor, screw block, ...

• Binding of the air / oil separator before 6000 Hours thus anincrease in maintenance cycles and maintenance costs.

Access to the filtering medium is allowed by removal that doesnot require any particular tool. The panel frame can be unlockedmanually in order to clean the medium.

Exceptional longevity of the medium that is quick to take apart.The medium can be scoured by blowing compressed air in thusincreasing the usage term for the filtering medium.

Fig. 11

Easy to disassemble for rapid cleaning

Galvanised steel covered frame.

Flammable medium (belonging to fire protection class M1) madeof polyester fibres.Pleated medium on support grid placed downwards in the direc-tion of the airflow.

Support grid

Fig. 12

3 - Technical featuresFILTER MEDIUM :

Degree of filtration : 90% of the dust emitted is filtered.Total nominal flow : 8946 cfmFilter panel number : 4Initial charge loss : 75 PaDimensions : Width : 19.68 in

Length : 24.6 inThickness : 7.87 in

This option may be installed on a compressor already in place.

4 pannels pre-filtration

Pre-ventilationlock

Disassemblyhinges

dimensions (in)

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D -Automatic restarting

1 - DescriptionThis management system enables the compressor to be restartedautomatically after a power cut.

2 - Option overviewNot available in standard version in order to prevent any incident duringmaintenance operations carried out by a non-trained person. This op-tion is proposed in cases where the production of compressed air shouldsuffer only the minimum periods of shutdowns.The standard microcut time accepted by AIRLOGIC isapproximately : 40 ms.However, certain electrical fittings create longer micro cut-offsthat will cause a compressor shut down, then a manual restart.Automatic compressor restarting enables immediate air produc-tion after a power cut and thus avoids the time lapse required formanual compressor restarting that would mean a fall in pressurein the air circuit.Particularly used for industries where air production should notbe subject to shut downs that waste the products manufactured ordamage the production equipment.

THIS OPERATION REQUIRES THE CONFIGURA-TION OF MENUS IN THE CONTROLLER, ACCESSRESTRICTED TO TECHNICIANS CERTIFIED BY

CHICAGO PNEUMATIC COMPRESSORS.

AN INFORMATIVE INSERT MUST BE PLACEDON THE ELECTRIC CABINET TO WARN THEUSER OF THE RISK THAT THE COMPRESSOR

MAY AUTOMATICALLY RESTART AT ANY TIME.

3 - Technical featuresThis option requires configuration of the electronic plate and ins-tallation of an informative insert on the door of the compressorelectric cabinet.

Every time the compressor stops, it must be secured byopening and locking the electric section switch.

E - Remote starting and stoppingThis option allows the compressor to be remotely started andstopped. However, in all cases, stopping the compressor at themachine itself is essential. If the compressor is shut down from adistance, it may be restarted from a distance as well. For any inter-vention to be conducted on the compressor, it is essential to activatethe emergency stop of the compressor in order to ensure safe con-ditions (Refer to AIRLOGIC Manual)

F -Rotation direction indicator - Phase controller

1 - DescriptionThe phase controller option is designed to:- control the rotation direction of the machine's electric powersupply phases.- check that electric power is supplied to each phase.These two functions are permanently guaranteed.

2 - Option overview

The advantages of this option are:- starting the compressor with the warranty that it will work (ifthis option was factory-installed), the configuration of the rota-tion direction having been configured during the production tests.- protecting the motor and the electrical fittings from any loss ofpower supply (phase cuts, blown fuses, voltage threshold lowerthan 130 volts).- protecting the compressor (motor and especially the compres-sion assembly) when restarting it following electrical work onthe power supply line or when switching from the mains supplyto a backup power supply, such as a power generator.

3 - Operation

In the event of a phase failure (detectable by this option) or anincorrect rotation direction, the trip switch sets off the machine'ssafety system (preventing immediate stopping and starting of thecompressor) and shows the following message on the display ofthe electronic plate: "ventilation flaw".

4 - Features

scanning time / measurement cycle < 80 msminimum operating voltage 200 voltsmaximum acceptable voltage between phases 500 voltspower consumption 15 VA

G - Centrifugal separatorFig. 16

1 - Description

This device allows bleeding of the condensates formed in the aircooler.

2 - Description of the option

The cooling of the compressed air allows the suction air to bedried, thus removing the humidity that collects in the bottom ofthe separator after being condensed in the aftercooler. Thecondensates are evacuated from the separator through a trap witha solenoid drip valve or a trap with level detector if this option isinstalled.

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2 - Safety instructions

No connection work is allowed when the inverter isunder power.

No measurement work is allowed on the inverter whenit is under power.

To undertake any work on the inverter, it is necessaryto disconnect the equipment from the mains. Wait forthe internal ventilation to stop and the indicators to beturned off. Then, wait 5 minutes before opening thecover.

No voltage or insulation verification test is allowed onthe inverter components.

Disconnect the cables from the motor and the inverterbefore taking measurements on them.

Do not touch the integrated circuits, the electrostaticdischarges may damage them.

Before connecting the inverter, make sure that its coveris properly closed.

Make sure that no compensation capacitor of cosinephi is connected to the motor cable.

C - Installation

The "CPVS" must be installed away from a transformeror autotransformer.(see Section 2 and 3).

The fuses for the section switch are defined as follows

Main Voltage 460 Volts / 3 / 60Hz

CPVS 100 125 150

Nominal current (A) 155 186 210

Power supply cable AWG 00 AWG 000 AWG 250

Fuse protection 175 200 250( Type J )

ATTENTION

Motors and drives can only be guaranteed where the supply voltage"460 V" does not exceed the rated voltage by more than 10%.The connection of the power supply to the section switch (ifpresent) requires the use of properly insulated terminals.

Refer also to the chapters concerning the standard compressor.

"CPVS" compressors are compliant with the Electromagneticcompatibility in industrial environments Standards 50081-2 and50082-2

A - Description (cf Section 1)

Standard equipementA electronic frequency adjusting device replaces the star-deltastarter.

B - Safety

For your safety, please respect the instructions carrying the warningsymbols as given below:

SAFETY RULES

The safety rules require:• The presence of an earth socket• The existence of a manual switch cutting-off the three pha-

ses that should be placed visibly near the CPVS• It is necessary to cut out the electric current before any

intervention on the compressor (except drainage under pres-sure).

= Dangerous voltage

= Attention

ELECTRICAL INSTALLATIONS MUST ONLY BECARRIED OUT BY A SPECIALISED AND COMPETENT

TECHNICIANS

1 - Warning

The internal components and the plates (except theelectrically insulated I/O terminals) are at the mainsvoltage when the inverter is connected to the mains.This voltage is extremely dangerous and can causesevere injuries or even death in case of involuntarycontact.

When the inverter is connected to the mains, theconnection terminals U, V, W of the motor as well as+/- connectors of the braking resistors are under powereven if the motor is not running.

The I/O control terminals are insulated from the mains,the relay outputs can nevertheless be under power evenif the inverter is disconnected. This also applies to otherI/O control terminals even if the X4 switch is in OFFposition (Stop).

The inverter has a load circuit of thermally limitedcapacitors. Therefore, it is important to allowminimum 5 minutes between two successive power-ons. If this instruction is not respected, the switch andthe resistor of the load circuit may be damaged.

1

2

3

4

1

2

3

4

5

6

7

8

Section 6 - Specific information for CPVS 100 - 125 - 150

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D - Commissioning1 - Preparation for start-up

(See Section 3).

ATTENTION

The power circuit will have to be cut off when adjusting theelectrical equipment or if inadvertent start-up is to be avoided.Before start-up, check the following points:

1 - Ensure that the unit has a suitable earth,2 - Check the oil level in the compressor,

NOTE: the tank was filled in the factory with a suitable oil. SeeChapter 7 - A for the quality of oil to be used and for the oilrenewal conditions.

3 - Check that the drainage valve is properly closed.4 - Make sure that the conveyor assembly's blocking lugs(compressor) have been removed from the compressorsilentblocks.

ATTENTIONThe oil filler plug, the valve and the drainage plugs have always tobe closed during operation and must never be opened before thesystem has reached atmospheric pressure.

2 - Control of rotation direction on start upThis control must be implemented when the compressor is putinto operation for the first time, after any work has been carriedout on the motor and after any changes to the mains supply.

IMPORTANT :• Check the direction of rotation (as per the arrow shown on thesump) by jogging over with the START button.If it is incorrect, swap over two of the motor's phase cables underthe drive.When rotating in the right direction, the oil level (fig. 18) mustdrop after 4 to 5 seconds of operation.• Also check the direction of rotation of the fan for air-cooledplants (counter-clockwise, as seen from inside the casing).

1 - Press the START button so that the motor starts.2 - Allow to rotate for several seconds with the discharge valveslightly open to observe the compressor at load.3 - Press the STOP button. The motor stops and the plantautomatically returns to atmospheric pressure.

3 - Setting of pressure - compressor(Refer E Section 1 refer also to the AIRLOGIC controller manual)

The unit is factory pre-set for a given delivery pressure. As anenergy saving measure, it is strongly advised to reduce the pres-sure to the exact requirement by adjusting the "Set point 1"setting.The stop pressure"Indirect shutdown"used when running at lessthan the minimum flow-rate - must be set to 7.25 PSI above thatof the "Set point 1". In this way, the current used by the compressoris minimised (see notice AIRLOGIC).Do not set the stop pressure at a level beyond the machine's max P.

4 - Assembly and settings for parallel operationwith other compressors

Pressure for the CPVS compressor must be adjusted at a valuewithin the range of adjustment values for the rest of thecompressors..

CPVS C1 C2 C3

Variouscompressors

Adjustments pressure

Stop P

Setpoint 1

5 - Regulating the pressure by changing the speedThis method of regulating the pressure allows precise adjustmentof the compressor's flow-rate at the compressed air demand valve:

The accuracy is of the order of 1.425 PSI when pressure regulationis achieved by changing the speed, provided that the flow-ratelies between the maximum and minimum rates for the compressor.

• The principle of the pressure regulation by changing the speed

The AIRLOGIC controller controls the motor and the compressoras a function of the system pressure as measured by an internalpressure sensor (fig. 18a).

- If the mains pressure is weaker than the pressure set point

(user-defined parameter in the AIRLOGIC) the motor willaccelerate and the pressure will increase (fig. 18b)

- If the mains pressure is stronger than the pressure set point, themotor will slow down causing the pressure to drop.

The AIRLOGIC provides the compressor control functions andalso controls the whole pressure feedback loop. It thereforeincludes a device to compare the indicated pressure with that fromthe pressure sensor, associated with a compensating device,Proportional integral control PI (fig. 18c).

The drive, a result of the latest developments in power electronics,is one of the smallest in size on the market, thanks to its use ofhigh cut-out frequencies with IGBT transistors.

At the same time, the motor control method known as "open loopvector flux control " provides good stability for the system againstdisruption.

In this way, the pressure feedback loop is more stable to suddenchanges in consumption (changes in the flow-rate).

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• Pressure regulation for low rates of flow

For an air consumption rate lower than the minimum rate of flowfor the compressor, the pressure is adjusted by the machine's time-delayed START/STOP controls.

Since the operation element cannot function below a certain speed(corresponding to the minimum output), the compressor continuesto run and compress at the minimum speed until the pressure reachesthe limit called "Indirect shutdown ".Once this threshold has been reached, the motor will stop, thecompressor will go into stand-by mode after a certain period ofinactivity and the full drainage process will be carried out.The pres-sure then drops towards the indicated pressure and, at the end ofthe minimum time delay (since reaching the no-load pressure), thedrive allows the motor to restart. The pressure then rises again andthe cycle starts over (fig. 18 d).To avoid pumping the system - frequent stop / start - drainagetime may be increased(cf. notice AIRLOGIC).

• Energy saving

For demand of compressed air within the machine's flow range -min flow to max flow, the frequency converter or the variablespeed drive feed the motor in order to ensure that it turns at thespeed required to supply air demand both for pressure and flow.

It is used to adjust the power supply to the motor (and thus thecompressor) to the exact power requirement for the compressionof the air, without a drainage stage being necessary.

COMMENT :Energy savings are increased if compressor maintenance is carriedout in accordance with the maintenance instructions and frequency.

Fig. 18aThe principle of the pressure regulation by variable speed

ControllerPressurerequired

Drive Motor Compressorunit

Tank

System

Pressure sensor

Frequency speed

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Fig. 5 b Fig. 5 c Fig. 5 d

Pressure

Speed

Flow Q

Time

Time

Time

Stopthreshold

Instructions

Min speed

Min Q

Requiredpressure

stop timing

minimun time

Fig. 18b Fig. 18c Fig. 18d

E - Operating incidents

The staff in charge of maintenance of the CP compressor must become fully acquainted with this compressor, in order to be able to easilydiagnose any anomaly. Under normal operating conditions, the CP compressor must provide full satisfaction.

1 - Main incidents

The main incidents likely to occur are listed below, along with the remedies to be applied. The keys to the control lamps relate to theinstrument panel (refer to the AIRLOGIC Manual ).

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Section 7 - MaintenanceThe maintenance period is limited to several essential operations.It is strongly recommended that the power supply be cut off duringany adjustment or repair.

The summary on the CP Compressor instrument panel shows at aglance the type and periodicity of operations to be carried out for thecompressor to function correctly.

Operations to be carried out

Daily Every Every Every Every Every Every Every500 hr 150 hr 2 000 hr (*) 4 000 hr 6 000 hr 8 000 hr 12 000 hr

Service A Service B Service CDrain the condensates

Draining cock X from the cold oil circuit(Section 7 - G)Check and top up if

Oil level X necessary(Section 7 - A)

Air filter X Replace the filter

Oil tank, Oil change, oil refillOil change X X with recommended oil

(Section 7 - A)Control Renovation of the

Suction housing cleaning Overhaul kit housing. Use thelubrication suction housing kit

Check the cleanliness ofOil return pipe Overhaul the oil return pipe and

Kits the state of the seal(Section 7 - F)Change the part

Oil separator X according to theinstrument panel indication(Section 7 - E)

Oil filter X X Filter changeOil cooler Blowing of cooling

Final coolant X elementsCleaning (Section 7 - D)

Control Exchange the accessoriesValve at minimum cleaning Overhaul kits supplied with the

pressure lubrication maintenance kitFor motors fitted with

Motor for grease fitting, useCPE X KLUBERQUIET

75-100-125-150 BQH72-102 (0.56 ocsper grease fitting)For motors fitted with

Motor for grease, useCPVS X KLUBERQUIET

100-125-150 BQH72-102 (0.56 ocsper grease fitting)

Electric cabinet X X Retighten power cableconnections.

Safety temperature Check operationtest X (Section 7 - H)

NOTE : maintenance kits are available (see spare parts list). (*) or at least every year

Parts Observations

A - Oil level and change(see fig. 19 and B Section 1)

The recommended oil used for the first compressor fill up is asynthetic oil with the following properties :

- viscosity : 40 cSt at 104 °F- viscosity index : 130 minimum- antioxidant additives- anti-rust additives- anti-foam additives

This oil was specially designed for Chicago PneumaticCompressors and guarantees to the operator an oil change periodof 8000 hours, with the replacement of the oil separator filterafter 4000 hours.

THE FIRST OIL CHANGE MUST BE CARRIED OUTAFTER THE FIRST 500 HOURS OPERATION.

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Using a synthetic oil for compressors is also acceptable and meansless frequent oil changes : please speak to us about the compatibilityand oil change methods.

The oil change and the replacement of oil filter must be carriedout when the indication is seen on the electronic controller andwhen the corresponding time counter reaches "0" (refer toelectronic controller manual).

Drain the compressor when warm. For this, shut it down takingcare to disconnect the power cable. Release pressure in the tankby unscrewing the filler plug by a single turn. Open the purge valveand drain the oil. Do not forget to close the valve after drainingthe oil.

After maintenance, reset the time counter which tells you howlong you have before the next oil change is due, refer to electroniccontroller manual.

OIL LEVEL

When shut down, the MAXI level of oil is located at ¾ from thebottom of the indicator, the MINI level corresponds to the lowestvisible parts of the indicator (rep. 1 Fig. 19).

Fig. 19

CHECKING THE OIL LEVEL MUST BE CARRIED OUTJUST AFTER STOPPING THE COMPRESSOR

(THERMOSTAT VALVE OPEN).

DRAINAGE UNDER PRESSURESo as to carry out a quick and full oil change, your CP Compressorsis equipped with a system that allows low level pressure to bemaintained in the oil circuit. This pressure is shown by the pres-sure gauge situated in the tank. (see Notice AIRLOGIC ).

Proceed as follows :• When hot, compressor in load for programming a shutdown under

pressure (refer notice AIRLOGIC § 4.9.3). The compressor isemptied and stops automatically.

• Change the oil by opening the oil change valve very slowly.• When there is no pressure left in the oil tank, change the oil filter

cartridge.• As soon as the oil is no longer flowing, close the valve and refill

with new oil.

• Reinitialise the timers that will warn you when to carry out thenext oil change and the next oil filter change(see the AIRLOGIC Manual),

• Reseal the filler cap when replacing it and check that all openingsare properly closed.

• The compressor can be restarted only after pressing the buttonC several times to return to STATE 0.1. Check the clamping ofconnections.

• After restarting, check that there are no oil leaks.

NOTEIf the oil is in a bad state ; that is a pungent smell or containsparticles or varnish or other solid matter, the system will have tobe rinsed : pour about 50% or the normal contents of clean oil andoperate the unit for 3 hours and carefully change the oil. Duringrinsing, leave the old oil filter cartridge in the compressor.

B - Air filter(see B Section 1)

The air filter is of the dry, encapsulated type. Change thecartridge every 2,000 hours. Check the cleanliness of the filterevery week and change it if necessary. (see notice on theelectronic plate for resetting the time).

ATTENTION :If you do not replace the filtering element when needed, per-manentdirt build-up will result. This reduces the air inflow to thecompressor and could damage the oil separator and the compressor.

C - Turbine

Replacement of the complete fan is recommended if one or moreblades are deformed or broken If replaced, check the fan rotationdirection reversal of the rotation direction will reduce compressorcooling and damage the motor in time.

D - Oil and air coolerThe aluminium air and oil cooler is a vital system in the CPCompressors. It needs special care. In order to avoid deformingor destroying the tube bundles, cooler connectors and lines mustbe dismantled or assembled while maintaining in rotation thecooler sleeves using a wrench. The outer surface of the tube bundlemust always be clean to insure the best heat exchange. If leaksoccur, seek their source by:

- Stopping CP Compressors,- Cleaning any greasy locations,- Seeking leaks using conventional methods (e.g.: soap solution,

etc.).

Pressurized shutdown retains the pressure in the compressor cir-cuit for a few moments so that any leak can be more easily located.

1

usyjs3
Text Box
If unit runs continuously for about a day, it will shut down on high temp if fan rotation is wrong.
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E - Oil separator(see B Section 1)

The oil separator's lifespan depends on the cleanliness of the aircoming into the compressor, on regular oil filter changes, on thequality of the oil used, on the attention with which the oil tankcondensate drains are carried out and on the ambient temperatureof the room. (see notice on the electronic plate for resetting thetime).

Check the cleanliness of the pipe that returns the oil to be aspired(transparent) to prevent the injector from becoming blocked and toensure that the oil recovered can pass through easily.

Excessive oil consumptionThe presence of excess oil in the discharge air, a rapid drop inlevel show a probable deterioration in the oil separator that mustbe changed.

The unit must first be checked to make sure that there is no oilloss and that the oil return is working properly.

Changing the oil separatorDismantle all the piping connected to the tank's upper flange (airdischarge, regulation system supply, and oil return). Undo thescrews that hold the tank cover and remove it.

- If the old oil separator must be remounted, use new seals.

- Be very careful during installation of the oil separator so as toavoid possible damage.

- The new oil separator is delivered with its two seals on eitherside of the flange.

- Slight undulations in the flange will flatten out when the screwsare tightened.

- Apply a 6 mkg torque.

F - Draining condensation water(see B Section 1)

Condensation water prevents proper lubrication. The resultingsubstantial wear leads to a reduction in the lifespan of the CPCompressors. It is therefore essential to drain condensation water.

Draining of condensates in the oil circuit :Draining will only take place at least 12 hours after the CPCompressors has been shut down. It can be carried out for exampleon the morning of the start-up.To do this :- Slowly open the oil change tap and let the water escape.- When the oil appears, close the valve immediately to avoid any

loss.- Refill with oil if necessary.

G - Temperature safety tests(see Notice AIRLOGIC).

IF THE SENSOR IS NOT WORKING, IT MUST BECHANGED.

H - Refastening electric connections

A loosening of the electric power cables leads to the contactorsove-rheating which can lead to their destruction.

Periodic refastening is therefore necessary at the star and triangleline contactor arrivals and departures. (see Maintenance Table).

All electric power supply to the compressor must be cut off beforeopening the electric cabinet.

I - Decommissioning the compressor at theend of its useful life

1. Stop the compressor and close the air outlet valve.2. Unplug the compressor from the electric supply.3. Decompress the compressor : unplug the 4/6 piping on the

oil separator cover.4. Close and decompress the section of the air network which

is linked to the exit valve. Disconnect from the compressedair exit pipe from the air network.

5. Empty the circuits of oil and condensates.6. Disconnect the compressor condensate piping from the

condensate draining system.

CAUTIONWhen the compressed air cools, part of the moisture sucked in by the compressor condenses. In order to protect the dryer againstthe risk of an ice plug forming, it is essential to check regularly that the condensate drains are operating properly :

On the compressed air storage reservoir and on the filters :• With a manual drain, drain regularly according to the moisture content of the ambient air.• With an automatic drain, set the draining cycle accordingly and check that the drain is in good working condition.

This recommendation is also fundamental in a circuit comprising an absorption dryer (risk of saturation of the alumina).

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Section 8 - Trouble shootingThe staff in charge of maintenance of the CP Compressor must become fully acquainted with this compressor, in order to be able to easilydiagnose any anomaly. Under normal operating conditions, the CP Compressor must provide full satisfaction.

A - Main incidentsThe main incidents likely to occur are listed below, along with the remedies to be applied. The markers of the indicator lights relate to thecontrol panel.

Observed defects Possible causes Solutions

1. THE COMPRESSOR DOES NOT a) Main switch open. a) Close the switch.START b) Phase missing. b) Check the circuits.

c) Fuse. c) Replace.d) Insufficient voltage at motor terminals. d) Check the voltage and the connections.e) Compressor under pressure. e) Check the vacuum device and change if

necessary. Check the water-tightnessof the minimum pressure valve.

2. THE COMPRESSOR a) Ambient temperature too high. a) Make openings or install ducts toOVERHEATS evacuate the hot air (see Section 2).

b) Obstruction of the passage of cooling b) Clean the cooler (see Section 7).through the oil cooler. c) Check and top-up oil level.

c) Oil level too low. d) Check that the oil filter is clean. Drain.d) Oil circuit blocked. Replace the cartridge. Check the tightness

of connections.

3. THE COMPRESSOR STOPS WHEN a) Compressor motor overload. a) Check it is connected and the electricTHE MOTOR PROTECTION connections are tight. Check the pressureUNIT TRIPS of the compressed air and the pressure

switch settings.b) Phase unbalance b) Check the phase intensities

4. OPENING OF SAFETY VALVE a) To clean de-oiling cartridge. a) Change the de-oiling cartridge.b) Valve of suction box out of use or b) Check valve, piston and joints of suction

not closed. box.c) Faulty pressure switch, sensor c) Check that the pressure switch and

or solenoid valve. electrovalve and sensor pressure are ind) Working pressure too high good working order.

5. EXCESSIVE OIL CONSUMPTION a) Blocked oil retainer. a) Check the oil return pipes.b) Oil leaks in the CP compressor. b) Look for oil leaks and rectify.c) Faulty oil separator element c) Replace the de-oiling cartridge.

(see Section 7-E)

6. DELIVERY PRESSURE TOO LOW a) Incorrect pressure settings. a) Adjust the pressure.b) The desired output is higher than that b) Check consumption and possible leaks.

of the compressor.c) Closed suction valve. c) Check electrovalve, pressure switch,d) Release nozzle incorrectly adjusted valve.

(modulating adjustment option). d) Check setting.

7. COMPRESSED AIR OUTPUT a) Blocked air filter. a) Clean filter.TOO LOW b) Adjusting electrovalve not working. b) Check setting.

8. EXCESSIVE NOISE OF UNIT a) Fixing bolts of compressor or motor a) Tighten.have come loose.

b) Soundproof panels incorrectly closed. b) Check that they are closed.c) Transport retainer blocks (red parts) c) Remove retainer blocks.

not removed.

9. THE COMPRESSOR STOPS a) Electromagnetic disturbance a) Add an interference suppression kitRANDOMELY OR CREATES on the Airlogic controller. (contact the after sales department)NON-EXISTING FAULTS

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CP Compressors1800 Overview Dr

Rock Hill, SC 29730

support

[email protected]

1 - 877 - 861 - CPAC