Instruction Manual EN

CP COMPRESSOR
Model CPF 200 and CPVS 250

62 305 799 65

CPVS 250
 The CP COMPRESSOR should never be operated beyond its capabilities
or in any way which does not comply with the instructions contained
in this operating and maintenance guide.

Chicago Pneumatic Compressors will decline any responsibility

if these instructions are not respected.

This equipment has been factory tested and satisfies normal

operating conditions: they must not be exceeded
as this would place the machine under abnormal stress and effort.

INSTALLATION INSTRUCTIONS
For the guarantee to be valid, the unit must be assembled in covered
premises with temperatures not exceeding :

Mini: + 4 °C / + 36 °F (frost free)

Maxi: + 40 °C / + 104 °F
You must also have:
1 m / 3,33 ft space around the compressor
-
low ventilation (fresh air) proportionate to the ventilation flow necessary for the machine and protected
from 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 and
perhaps a special filter on the compressor air inlet.

TECHNICAL CHARACTERISTICS
STANDARD MACHINES

CPF 200 (in imperial units) 200 (in metric units)

Nominal pressure at full capacity PSI 100 125 150 175 bar 7,5 8 10 13
Real flow* air cfm 999.4 911.1 821.7 701 air m3/h 1717 1641 1490 1240
(as per ISO 1217 ed 1996) water cfm 1001 957 869 725 water m3/h 1700 1625 1476 1231
Motor power kW/hp 160-220 kW/hp 160-220
Ø Pressure outlet (F) inch 3" PN16 DN80 inch 3" PN16 DN80
Oil receiver capacity gal 23,7 liter 90
Residual quantity of oil ppm 3 ppm 3
Noise level at 3,3 ft (air) dB(A) 74 dB(A) 74
(according to PNEUROP PN 8 NT C2)
* Suction pressure : 14.5 PSI / 1 bar absolute - Relative humidity : 0 % - Ambient temperature : 68 °F / 20 °C
- Effective delivery pressure : 102 PSI / 7bar, 109 PSI / 7,5 bar, 138 PSI / 9,5 bar or 181 PSI / 12,5 bar (effective)
Dimensions L x w x h inch 111,8x63,3x78,4 mm 2842x1610x1992
Approximate weight (Air/Water) lbs 6239/6076 kg 2830/2756

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 CPF 200

Motor power (hp) / (kW) 200 / 160

Main Voltage 460 Volt / 3 / 60 Hz

Nominal current (460V) (A) 282

Power supply cable H 07 350 Kcmil
Fuse protection (RK5) 300 A

Main voltages 380/400/415 Volt / 3 / 50 Hz

Nominal intensity (400V) (A) 324
Power supply cable H 07 3x185+1x95 (earth)
Section mm2 (L=10m maximum)
Upstream fuses (Type aM) 400

TECHNICAL CHARACTERISTICS
VARIABLE SPEED MACHINES
CPVS 250 (in imperial units) 250 (in metric units)

Nominal pressure at full capacity PSI 87 101 138 bar 6 7 9.5

Real flow* cfm 1076 1071 950 m /h
3
1828 1820 1615
(as per ISO 1217 ed 1996)
Motor power hp 250 kW-ch 160-240
Ø Pressure outlet (F) inch 3" PN16 DN80 inch 3" PN16 DN80
Oil receiver capacity gal 23,7 liter 90
Residual quantity of oil ppm 3 ppm 3
Noise level at 3,3 ft (air) dB(A) 76 dB(A) 76
(according to PNEUROP PN 8 NT C2)

* Suction pressure : 14.5 PSI / 1 bar absolute - Relative humidity : 0 % - Ambient temperature : 68 °F / 20 °C
- Effective delivery pressure : 102 PSI / 7bar, 109 PSI / 9,5 bar or 181 PSI / 12,5 bar (effective)
Dimensions L x w x h inch 115,8x63,3x78,4 mm 2492x1610x1992
Approximate weight (Air) lbs 8113 kg 3680

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

Connection of the electric controler 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 earthed at one of its ends.

WARNING: the operation connection cables between the different elements must never follow the same path as the existing power
cords. 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.

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 CONTENTS
Space requirement and installation diagram CPF 200 - CPVS 250 (Air cooled) .............................................................................. 6
Space requirement and installation diagram CPF 200 - CPVS 250 (Water cooled) .......................................................................... 7

Chapter 1 - Description ................................................................................................................................................................................. 8

A - General Information ...................................................................................................................................................................... 8
B - Respect of the environment and prevention of pollution ............................................................................................................. 8
C - Standard equipment ...................................................................................................................................................................... 8
D - Definition of the pictograms ......................................................................................................................................................... 8
E - Electronic board ............................................................................................................................................................................ 8

Chapter 2 - Installation ................................................................................................................................................................................. 9

A - Handling ....................................................................................................................................................................................... 9
B - Room ............................................................................................................................................................................................ 9
C - Assembly ....................................................................................................................................................................................... 9
D - Air discharge pipes ....................................................................................................................................................................... 9
E - Water pipe ................................................................................................................................................................................... 10
F - Electric cabling .......................................................................................................................................................................... 10

Chapter 3 - Commissioning ........................................................................................................................................................................ 11

A - Preparation for start-up ............................................................................................................................................................... 11
B - First start-up ................................................................................................................................................................................ 11
C - Discharge pressure adjustment ................................................................................................................................................... 11
D - Parallel compressor assembly ..................................................................................................................................................... 11
E - Cooling water regulation for water cooled variants .................................................................................................................... 11
F - Safety ........................................................................................................................................................................................... 11

Chapter 4 - Operation ................................................................................................................................................................................. 12

A - Air and oil circuits ...................................................................................................................................................................... 12
B - Regulation principles .................................................................................................................................................................. 13

Chapter 5 - Options ..................................................................................................................................................................................... 14

A - Level detection bleed valve (Fig. 12) ......................................................................................................................................... 14
B - Advanced filtration to the compression air inlet (Fig. 13a and 13b) .......................................................................................... 14
C - Pre-filtration panels (Fig. 14 and 15) ......................................................................................................................................... 15
D - Automatic restarting ................................................................................................................................................................... 16
E - Remote starting and stopping ..................................................................................................................................................... 16
F - Special oils .................................................................................................................................................................................. 16
G - Centrifugal separator (see B chapter 1) ...................................................................................................................................... 16
H - Condensate drain pipes ............................................................................................................................................................... 16
I - Modulating control (Fig. 18) ...................................................................................................................................................... 17
J - Energy recovery ........................................................................................................................................................................... 18

Chapter 6 - Specific information for CPVS 250 ....................................................................................................................................... 19

A - Description (cf Chap. 1) ............................................................................................................................................................. 19
B - Safety .......................................................................................................................................................................................... 19
C - Installation .................................................................................................................................................................................. 19
D - Commissioning ........................................................................................................................................................................... 20
E - Operating incidents ..................................................................................................................................................................... 22

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 CONTENTS

Chapter 7 - Maintenance ............................................................................................................................................................................ 23

A - Oil level and change ................................................................................................................................................................... 23
B - Oil return (Fig. 22) ..................................................................................................................................................................... 24
C -Air filter (see B chapter 1) ........................................................................................................................................................... 24
D - Fan .............................................................................................................................................................................................. 25
E -Oil and air cooler ......................................................................................................................................................................... 25
F - Oil separator (see B chapter 1) .................................................................................................................................................... 25
G - Draining condensation water (see B chapter 1) .......................................................................................................................... 26
H - Motors ........................................................................................................................................................................................ 26
I - Coupling ....................................................................................................................................................................................... 26
J - Suction control system (see Fig. 25) ........................................................................................................................................... 26
K - Temperature safety tests .............................................................................................................................................................. 26
L - Refastening electric connections ................................................................................................................................................. 27
M - Decommissioning the compressor at the end of its useful life ................................................................................................... 27

Chapter 8 - Trouble shooting ...................................................................................................................................................................... 28

A - Main incidents ............................................................................................................................................................................ 28

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 Space requirement and installation diagram CPF 200 - CPVS 250 (Air cooled)
(see page 2 - installation instructions)
Fig. 2

4.76 30.31

Air inlet

36.41
23.62
43.30 7.40 24.56 7.40
94 62.38
4.72 111.89
Air inlet side

Air delivery

Pre-filtering
option standard
on the CPVS 250
Cooling air outlet
1.14
0.33
0.33
11.71
10.05

29.33 24.64 24.64

Dimensions for outlet duct
Electric power
diam. 1.88x3 + 2.83
diam. 1.45

4.33
22.83
51.08
78.42

64.96

23.62
7.08

Ø0.78
0.39 *
2.75
0.39

1.96
3.54

3.54 25.98
33.07

* Hole 0.32x0.32

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 Space requirement and installation diagram CPF 200 - CPVS 250 (Water cooled)
(see page 2 - installation instructions)
Fig. 3

2505 121

2 : water outlet1"1/4 G female

1 : water inlet 1"1/4 G femelle

240 150
160
762 188 624 188

94
2504

Air delivery

Cooling air outlet

400,5
85
85
297,5
255,5

694 620 620

Electric power diam.
48x3 + diam.37

123

Air inlet
1938
1659

Air inlet side

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Chapter 1 - Description
A - General Information
The Chicago Pneumatic Compressors air compressor CPF, CPVS
model, constitute a central compressed air which is fully equipped
and tested, driven by an electric motor and enclosed by a sound-
proof cover, necessary to keep the entire apparatus cool.
The compression element is a single-stage, oil-refrigerated, rotary
screw compressor. The oil is stored in a vertical tank, which is
fitted with an oil separator.
The compression element and the motor are fixed to the frame
using silent blocks.
B - Respect of the environment and
prevention of pollution
1 - Maintenance of the machine
Make sure that the used components of the machine (waste oil,
oil and air filters, oil separators, etc.) are disposed of according to
national and local regulations.
2 - Condensate bleed pipe (optional)
Make sure that the condensates (water, oil) are drained and treated
according to national and local regulations.
3 - Water cooled machines
For this type of machine, when the cooling circuit is made of an
open circuit, a hydrocarbons filter is recommended after passing
through the cooler, particularly for installations located in
ecologically sensitive areas.
4 - End of life of the machine
Make sure that the machine as a whole is disposed of according
to national and local regulations. ( Refer Chapter 7 - M )
- Safety devices:
1. A safety valve mounted on the oil receiver.
2. An thermal protection device for the motor, situated in the
starting box, to protect the motor from excessive over-load.
3. An air temperature sensor that stops the compressor when
the temperature rises abnormally or during an oil cooling
defect.
- Control devices:
1. A minimum pressure valve located at the oil tank outlet,
just beyond the oil separator, which guarantees minimum
pressure in the lubrication circuit.
2. Automatic draining allowing the unit to be exposed to the
atmosphere when stopping to thus ensure empty start up
which relieves the motor,
3. An oil level indicator situated on the front side of the tank
( see fig. 21).
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 and
tested in accordance with the following recommendations, codes
and 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 : PNEUROP PN 8 NT C2.
- European Directive 97/23/EC
" Pressure Equipment Directive ".

C - Standard equipment D - Definition of the pictograms

In its standard version, the covered unit includes: Typical examples of pictograms valid for CP compressors:
1. Water outlet
- Operating components:
2. Manual condensation water draining
1. A twinned screw-type compressor. 3. Water inlet
2. An electric motor: 1500 rpm, short-circuit rotor, voltage 4. Automatic condensation water draining
according to the model. 5. Unplug and decompress the compressor
3. Star-Delta starting (or inverter). before maintenance
4. Gear drive with elastic coupling linking the motor to the
compressor.
5. Air and oil tank in compliance with applicable legislation
ASME.
6. Flow rate control by cut-off of suction.
7. A greasing system using the circuit's differential pressure,
thus avoiding the need for an oil pump.
8. An oil separation system by oil separator filter.
9. A heat evacuation system : 1 2
- forced-air ventilation for air-cooled units,
- heat exchanger for water-cooled units.
10. A dry air filter.
11. Oil filters.
12. A command and control electronic board. 3 4 5
E - Electronic board
See the specific instructions for a description of the electronic
controler, together with operating instructions:
Notice N° 62 305 516 99 for version Standard
Notice N° 62 305 517 99 for version CPVS

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Chapter 2 - Installation
A - Handling
The CP Compressors must always be handled with care. It may Prevailing wind
be lifted either with a forklift truck or by means of a travelling
crane. In the latter case, precautions must be taken in order not to
damage the unit's canopy.
L
B - Room Flexible fitting
V
The CP Compressors is designed to operate in a frost-free
environment, supplied with air at a temperature of no more than
40 °C / 104 °F. The premises must be well-aired and as close as
possible to the place where the compressed air is used. A space
must be left around the unit, for cleaning and maintenance Compressor
purposes. It is very important for the compressor to have an
abundant supply of fresh air. (see page 2).

COMMENT
When the atmosphere is contaminated by organic or mineral dust or Fig. 5b - Sleeve with an elbow
by corrosive chemical emanations the following precautions must be
taken: V maxi = 18,04 ft/s / 5,5 m/s
1. Provide another air inlet as close as possible to the (Ratio of volume flow rate of the ventilation to the sleeve
compressor suction.(recommendation which is valid if the cross section)
only room available is excessively damp). L maxi = 32.8 ft / 10 m (without mechanical extractor)
2 - Use an additional air supply filter. Consult us.
Cross section of room air inlet > 2 x Duct outlet cross section
2 elbows accepted with large radius of curve and fluid gui-
dance vanes
Installation with heat dispersion sleeve
Ratio (Length/Width of sleeve) maxi = 1.6
If the operation of the compressor increases the ambient
Make sure that no outside air, especially if humid, can be fed
temperature above 40 °C / 104°F, it is necessary to discharge the
back into the machine and damage electric and electronic
hot air leaving the cooler to the exterior by means of a sleeve.
components or rust metal parts.

Prevailing wind The maximum admissible pressure loss of the sleeve should not
exceed 30 Pa (3 mmCE). In case of higher value, provide an
additional ventilation (mechanical extractor) with a flow
equivalent to that of the machine, C1 converter controlled (see
V electrical diagram).
L Regulation type 0-10V
Flexible fitting
0V extractor shutdown
10V full rate operation

C - Assembly
Compressor Put the unit on a stable surface. The CP does not need foundations.
Any flat surface that can support their weight will be sufficient
(industrial floor).
Fig. 5a - Sleeve with roof outlet
D - Air discharge pipes
d
The diameter of the air discharge pipe must be at least 3" gas for
the CPF 200 and CPVS 250.Current legislation requires that a
Ventilation Duct minimum cross section valve which is lockable in the closed position be installed at the
L

flow rate ( d ≤ L ≤ 1,6d ) air box outlet, connected to the compressor by a union and flexi-
cfm sqm ble line to allow it to be cut off during repair work.
CPF 200 16485 15.22
CPVS 250 16485 15.22
m3/s m2
CPF 2000 7,78 1,414
CPVS 250 7,78 1,414

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E - Water pipe
For water-cooled units. Reference conditions:
The diameters of the pipes to be provided are as follows: • 460V tri, 60 Hz
- refrigerant input/output: 1" 1/4 gas thread. • TNC setting
• Ambient temperature: 106°F / 40°C
The input filter is recommended for protection of refrigerants
and valves. The set is equipped with an automatic solenoid • Installation in cable troughs in the open air
valve for closing off the water. This is situated on the water • Maximum length: 32.8 ft / 10 m
inlet pipe. A manual control and check valve will be installed • Type of cables to be used: Cu-PVC
on the water discharge to optimize flow.
VOLTAGE
If the inlet water temperature is lower than 25°C / 77 °F, the CPF
minimum recommended flow rate is 7.5 m3/h / 4,4 cfm for the 380/400/415 V
CPF 200. 200 3 x 185 mm2
Figure 8 show the water rates necessary to obtain the proper + 1 x 95mm2 (earth)
compressed air temperature in accordance with requirements.
SAFETY REGULATIONS
F - Electric cabling
It should be remembered that safety regulations require :
Each CP is wired for a pre-determined voltage, i.e. • An earth socket to be used.
• A manual isolating switch, cutting all three phases ; this switch
NEVER OPERATE THE CP COMPRESSORS AT A VOL-
must be clearly visible near the CP unit.
TAGE OTHER THAN THE ONE SHOWN ON THE
ELECTRICAL CABINET. • The electric current must be cut whenever maintenance work is
carried out on the machine (except for pressurized oil change)
NOTE
Equipment with 230 V star-delta starting: in accordance with decree Fuses to be used for
CPF the isolating switch (Type AM)
69164 in application of act 601375, this setup can only be supplied
if expressly requested by the customer.
380/400/415 V
Consequently, in the event of a change in voltage by the electricity 200 400
supplyer, we will under no circumstance be liable for the cost of
the modification. NOTE
For variable speed machines see Chapter 6.
WARNING
The electric motors are only guaranteed if the voltage at the motor
terminals doesn't exceed 10% of nominal voltage. The CP input
wiring must correspond to the following table:

Fig. 8 - Water flow diagram CPF 200 - CPVS 250

100.0

Te = 30°C
Oil temperature (°C) in 20°C ambient condition

95.0
Te = 25°C

90.0 Te = 20°C

Te = 15°C

85.0
Te = 10°C

80.0

Correction due to ambience (4°C - 40°C)

75.0 T oil=T oil 20°C + 0.25 x (T ambiance -20)

70.0
4.00 4.50 5.00 5.50 6.00 6.50 7.00 8.00 8.50
Flow rate of water (m3/h)

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Chapter 3 - Commissioning
A - Preparation for start-up
Before starting the set for the first time, the operator must get to
know the different systems. The main locations which have to be
examined are shown on the figures.
IMPORTANT
Before start up, make sure that transport red wedges have been
effectively removed.
ATTENTION
The power circuit must be turned off whenever adjusting electrical
equipment 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 heating
of contactors, which may even destroy them. Therefore, these
cables must be re-tightened at line contactor incoming and
outgoing, star delta before use.
Before start-up, check the following points :
1 - Make sure that the unit is properly earthed.
2 - Check the oil level in the tank.
NOTE : the tank has been filled with suitable oil in the
factory. See Chapter 7 - A for the quality of oil to be used
or for oil renewal conditions.
3 - Make sure the oil change valve is properly closed.
ATTENTION
The oil filler cap, the oil change valve and plugs must always
remain closed during operation and never be opened before the
system has been completely vented to atmospheric pressure ( see
Chapter 7 - A).
B - First start-up
Check the voltage between the three phases before using the unit
for the first time.
1
Fig. 9
Chicago Pneumatic Compressors
62 305 799 65
Check the direction of rotation (following the arrow on the
coupling housing rep. 1-Fig. 9) by pressing the "Start" button,
followed immediately by the emergency stop. If it does not spin
in the right direction reverse two stages of the power cord. When
it rotates in the correct direction, the oil level (Fig.21) should
drop after 4 or 5 seconds of operation.
It is also very important to verify the direction of rotation of the
fan (indicated on it by an arrow) anti-clockwise seen from inside
the machine or clockwise seen from outside the machine.
1 - Press the ON button, the motor starts up.
2 - Keep it running for a few minutes with the discharge valve
slightly open to observe the compressor under load. Ensure
that there are no leaks. Reblock the connectors if necessary.
3 - Press the OFF button. The motor will stop and the unit will
automatically vent to atmospheric pressure.
C -Discharge pressure adjustment
The unit is adjusted in the factory for a MAXIMUM pressure (for
the maximum output from the outlet of the central unit) of 100,
125, 150 or 175 PSI (or 7.5, 8, 10, or 13 bar) depending on the
model. To adjust the backflow pressure setting to a lower value,
refer to the manual of the electronic controler.
D - Parallel compressor assembly
If the CP Compressors is intended to operate in parallel with other
CP or similar compressors, the discharge piping can be linked
together.
If the CP Compressors is intended to operate in parallel with other
CP or similar compressors, there must be an air tank common to all
the alternative compressors. The pulses emitted by alternative
compressors may cause serious damage to the minimum pressure
valve and the CP Compressors oil separator, and disrupt the
regulation system. When the rotary compressor is operating in
parallel with an alternative compressor, the latter should be adjusted
so that the rotary compressor takes the main load. It is cheaper to
run this way.
E - Cooling water regulation for water
cooled variants
The rate will be adjusted so that the oil temperature (at the outlet of
the compression element) displayed on the control panel is between
70 / 238 and 90°C / 306 °F.
F - Safety
The oil used for cooling the machine is a liquid combustible under
the effect of strong heat. In case of fire in the machine, it is essential
to respect the regulatory measures on the compressor. The type of
fire in a compressor is defined as "class B" and in presence of a live
electrical conductor, it is recommended to use a CO2 extinguisher
functioning by "smothering" (starvation of oxygen) while observing
the user instructions applicable to the model.
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Chapter 4 - Operation
A - Air and oil circuits
1 - Air circuits (see Fig. 10) Key fig. 10
The air is sucked into the compressor through a filter (Item. 23). 20 Compressor
This air passes through the compression element where it is mixed 21 Suction element
with oil injected during compression. Inside the oil tank, the
compressed air is pre-deoiled by shocks, then flows through the 23 Air filter
oil separator (Item. 49). It then passes through the mini pressure 26 Oil filter
valve (Item. 34) forming a check valve, the aftercooler (Mark
51A), the condensate separator (in option), and then the outlet 34 Minimum pressure valve
valve (not supplied) to which the distribution pipe is connected. 41 Turbine

2 - Oil circuit (see Fig. 10) 44 Drain solenoid valve (optional )

49 Oil separator
The oil, under discharge pressure, flows from the bottom of the tank
through the cooler (Item. 51H), the oil filter (Item. 26) which retains 51 A Air cooler
solid impurities, and then into the compressor (Item. 20). The oil 51 H Oil cooler
temperature is monitored by an electronic box varying the air ventila-
tion to ensure that the temperature of the oil remains constantly at the 55 Condensation water separator (optional )
optimum. When it leaves the compressor, the oil returns to the tank. 56 Motor
Part of the oil remains suspended in the air as mist. This mist passes
through the oil separator. (Item. 49). The remaining oil, which is 57 Tank
separated by the last stage of the oil separator, is drawn up by a dip
tube and dispatched to the compressor.

Fig. 10 - Air / oil circuit

34

49

57

26
21
23

56 51A
51H
20 55

44

41

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B - Regulation principles
1 - "On/off Load" regulation (see Fig. 11) Key fig. 11
standard version
20 Compressor
The CPF 200 units are fitted with an automatic regulation system, 21 Suction housing
enabling the machine to be stopped after it has run unloaded for 22 Solenoid-valve
a given (adjustable) period of time. This period of unloaded 23 Air filter
running is necessary to avoid excessively close start-ups in highly 25 By-pass valve
varied periods of compressed air consumption. 26 Oil filter
34 Minimum pressure valve
When the compressor reaches maximum pressure, the pressure
sensor (Item. 45) closes the solenoid valve (Item. 22). The 36 Pneumatic pump out
compressed air on the suction housing piston and the vacuum 37 Safety valve
piston are depressurised; the housing is closed and complete 38 Oil return solenoid valve
drainage of the tank is carried out. 41 Ventilation
45 Regulation pressure switch
The compressor draws in air via a by-pass valve (Item. 25).
46 Safety temperature sensor
The low pressure obtained in the oil tank enables the compressor 47 Ventilation regulation temperature sensor
to be lubricated and cooled during the whole unloaded running 49 Oil separator
period. 51 A Air cooler
51 H Oil cooler
If the compressed air pressure of the user network drops to the 57 Oil tank
minimum value at which the pressure sensor trips back in before
64 Oil return filter
the end of the "no-load running" time-out, the pressure sensor
(Item. 45) controls closure of the solenoid valve (Item. 22),
opening the intake check valve and closing the opening to
atmosphere. The compressor again runs on full throughput. 2 - Speed regulator
( see chapter 6)
When the compressor stops, the solenoid valve (Item. 22) is no
longer powered and closes; the suction housing closes and the
oil tank is evacuated. The tank is thus vented to atmospheric
pressure, for the next time the unit is started up.

Fig. 11 - "On/off Load" regulation

36

22

41 45
38 34
64
51A
35
21 37
51H
23 49

25
57
46 47
20

26

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Chapter 5 - Options
A - Level detection bleed valve (Fig. 12)
1 - Description
The BEKOMAT type level detection bleed valve allows all air
consumption to be avoided while the compressor is not running.
2 - Option overview
- There is no air consumption due to the level detection system : an
inductive sensor detects the level of condensation and thus controls
the opening of the electric bleed valve. A low level of condensation
is also detected in order to close the electric bleed valve and to prevent
compressed air from being wasted.
- This type of purge valve does not require any maintenance. The
purge valve does not require the use of the metallic intake filter that
is usually installed on electronic purge valves to protect the solenoid
valve. The solenoid valve will not be damaged.
- Condensate treatment is made easier because it is not evacuated by
pressure, which enables easy separation of the water and oil stages.
Fig. 12
2 - Option overview
- This option is used as a replacement for the standard filter
- Certain atmospheric particles are smaller than 7810-6 in, a limiting
threshold for traditional paper cartridge filters. The filter increases
filtration effectiveness by eliminating 99.97% of particles that are
larger than or equal to 11810-6 in.
- The quality of the air intake by a compressor is essential. Low
quality 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 an
increase 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 the
compressor, screw element,...
Filters in compliance with standard ISO 5011/2000.
- Exceptional filter longevity, from 18 months to 3 years of
continuous service (24 hours a day, 7 days a week), which is a
little more than 10,000 hours of operation of the compressor under
normal conditions.
- Installation of the filter(s), depending on the model, outside the
compressor, for intake of fresh air, hence resulting in a lower oil
temperature and more efficient compression (Fig. 13a and 13b).
Extraction duct

VORTEX pre-filter
1 4
Air filter

2 5

6
3

x y

1 - Condensation intake 4 - Main duct x y

2 - Capacitive sensor 5 - Electric valve
inch 111,8 16,9
3 - Receiver 6 - Membrane CPF 200
mm 2842 430
3 - Technical features
CPF 200 Fig. 13a
Maximum capacity of the compressor :3178 cfm 90 m3/min
Working pressure :11.6/232 PSI 0,8/16 bar
Operating pressure :+ 33.8/ + 140°F + 1/+ 60°C
Electric power supply :115V/24V 230/110/24
AC socket in the compressor electric cabinet. Cartridge

B -Advanced filtration to the compression

air inlet (Fig. 13a and 13b)
1 - Description

This system is equipped for "high efficiency" air filtration in order

to improve the quality of the air intake and to preserve the
compressor's oil and internal filter components.
Fig. 13b
This option is particularly useful in very dusty surroundings.

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3 - Technical features Fig. 14
Operating temperature :
-104 °F to +194 °F / -40 °C to +90 °C

C - Pre-filtration panels (Fig. 14 and 15)

1 - Description

Installing air filtration panels on the ventilation intakes (machine

and built-in dryer) guarantees protection of the compressor's
internal components and an increase in air sucked into the com-
pression assembly. This option is recommended if the forced fil-
tration option is installed (see § B).

2 - Option overview Easy to disassemble for rapid cleaning

The pre-filtration panels eliminate 90% of the particles normally

admitted inside the compressor and considerably decrease internal
contamination of the machine.

The high quality of the ventilation air is also essential for protecting
internal components of the compressor and, more specifically, the
motor and the air / air and air / oil exchangers. Clogging in the
exchangers creates an increase in temperature, deterioration of
the lubricant and the motor becomes overloaded thus increasing
the energy consumed. Galvanised steel covered frame.
Flammable medium (belonging to fire protection class M1) made
The quality of the air drawn in by a compressor is essential. Low of polyester fibres.
quality air results in the following :
Pleated medium on support grid placed downwards in the direc-
tion of the airflow.
• Fast pollution of the oil thus an increase in oil change cycles.
Support grid
• Increased pollution of the air and oil filtering components that
increases the deterioration of the mechanical components in the Fig. 15
compressor, screw block, ...
Pre-filtration pannels

• Binding of the air / oil separator before 6000 Hours thus an Pre-ventilation
increase in maintenance cycles and maintenance costs. lock

Access to the filtering medium is allowed by removal that does

not require any particular tool. The panel frame can be unlocked
manually in order to clean the medium. Disassembly
hinges
Exceptional longevity of the medium that is quick to take apart.
The medium can be scoured by blowing compressed air in thus
increasing the usage term for the filtering medium.
3 - Technical features
FILTER MEDIUM :
Degree of filtration : 90% of the dust emitted is filtered.
CPF model 200
Total nominal flow :
Filter panel number : 8
Initial charge loss :
Dimensions : Width : 56,7 in / 1 440 mm
Length : 72,8 in / 1850 mm
Thickness : 9,5 in / 240 mm

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

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D -Automatic restarting Note: if this option is chosen on a machine that has previously
run on standard oil, the flushing procedure must first be strictly
1 - Description complied with.

This management system enables the compressor to be restarted
automatically after a power cut.
2 - Option overview
Not available in standard version in order to prevent any incident during
maintenance operations carried out by a non-trained person. This op-
tion is proposed in cases where the production of compressed air should
suffer only the minimum periods of shutdowns.
The standard microcut time accepted by AIRLOGIC is
approximately : 40 ms.
However, certain electrical fittings create longer micro cut-offs
that 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 for
manual compressor restarting that would mean a fall in pressure
in the air circuit.
Particularly used for industries where air production should not
be subject to shut downs that waste the products manufactured or
damage the production equipment.
2 - Description of the option
Rotair Xtra
The properties of these oils enable the maintenance planning
schedule to be based on main drainage operations of 4000 or
8000 hours (under standard conditions of use).
The maintenance tasks are consequently less frequent, thus making
for certain savings, such as the availability of the equipment and
lower operating cost of the compressor.
Food Grade Oil
This oil has been specially developed for use as a lubricant that
may come into contact with foodstuffs.
G - Centrifugal separator
(see B chapter 1)
Fig. 17

THIS OPERATION REQUIRES THE CONFIGURA-

TION OF MENUS IN THE CONTROLLER, ACCESS
RESTRICTED TO TECHNICIANS CERTIFIED BY
CHICAGO PNEUMATIC COMPRESSORS

AN INFORMATIVE INSERT MUST BE PLACED

ON THE ELECTRIC CABINET TO WARN THE
USER OF THE RISK THAT THE COMPRESSOR
MAY AUTOMATICALLY RESTART AT ANY
TIME.

3 - Technical features
This option requires configuration of the electronic controler and
installation of an informative insert on the door of the compressor
electric cabinet.
1 - Description
Every time the compressor stops, it must be secured by
opening and locking the electric section switch. This device allows bleeding of the condensates formed in the air
cooler.
E - Remote starting and stopping
2 - Description of the option
This option allows the compressor to be remotely started and
stopped. However, in all cases, stopping the compressor at the The cooling of the compressed air allows the suction air to be
machine itself is essential. If the compressor is shut down from a dried, thus removing the humidity that collects in the bottom of
distance, it may be restarted from a distance as well. For any inter- the separator after being condensed in the aftercooler. The
vention to be conducted on the machine, it is essential to activate condensates are evacuated from the separator through a trap with
the emergency stop of the machine in order to ensure safe condi- a solenoid drip valve or a trap with level detector if this option is
tions (Refer to AIRLOGIC Manual) installed.

F - Special oils H - Condensate drain pipes

1 - Description
Different oils meet different needs:
Rotair Xtra: longer time interval between 2 drainage operations -
8000 hours (use of special oil filters).
Food Grade Oil: use of the compressor in the agricultural foodstuffs
industry.
A separator with automatic solenoid valve drain is provided
inside the set ( see Chapter 5-K) to remove the condensate at
the final cooler outlet and stop the compressor pipe condensate
return lines. Connect the discharge pipe to a condensate
manifold.(see B chapter 1)

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I - Modulating control (Fig. 18) Key fig. 18
This type of regulation means that the compressor's flow-rate can 20 Compressor
be adjusted to the required level of compressed air using very 21 Suction housing
slight pressure variation in the operating network. 22 Solenoid-valve
The compressor operates at full flow-rate (suction housing valve 23 Air filter
(Item. 21) fully open) as long as the pressure is lower than the 25 By-pass valve
discharger pressure (Item. 38). If compressed air consumption is 26 Oil filter
lower than the compressor flow, the pressure will rise, the 34 Minimum pressure valve
discharger starts to close and orders the partial closure of the 35 Pressure gauge
suction housing valve (Item. 21) so that the compressor air flow 36 Pneumatic vacuum system
is equal to the air flow consumed and the pressure remains cons- 37 Safety valve
tant as long as air pressure does not vary. 38 Oil return solenoid valve
When consumption varies, the discharger progressively controls 39 Discharger
the movement of the suction housing valve to maintain constant 41 Ventilation
air flow equal to consumption. 44 Draining solenoid valve
In order to restrict energy consumption for low compressed air 47 Ventilation temperature regulation sensor
requirements, the pressure set point (Item. 62) is adjusted in such 48 Calibrated orifice
a way that it works with no oil (zero flow and weak pressure in 49 Oil separator
the oil tank) when the compressed air consumption is about 30 % 51 A Air cooler
lower than the maximum flow of the compressor. 51 H Oil cooler
Therefore, when the pressure set point is reached (Item. 62), the 55 Condensate separator
solenoid valves are closed (Item. 22 and Item. 58) which, in turn, 57 Oil tank
triggers, on one hand the total close of the suction valve and, on 58 Solenoid valve
the other, the full drainage (Item. 36) of the oil tank, as in the 62 Pressure sensor
"All or Nothing" principle. 63 Temperature sensor
64 Oil return filter

Fig. 18 - Modulating control

36
22

41 45
38 39 34
48 64
51A
21 35
37
51H
23 49

25
57
46 47
20

26

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J - Energy recovery Fig. 19
1 - Description
The energy recovery option consists of including a cooling circuit
that bypasses the machine's air-cooled oil circuit in order to heat a
water flow according to the "temperature" parameters, which are
controlled automatically by the thermostatic valve.

2 - Option overview
Optimisation of the compressor's heat capacity:
A certain amount of energy is dispersed by the compressor as heat.
In air-cooled compressors, this dispersion is carried out with the
help of the airflow that passes through the machine. This energy
can be recovered, either as a ventilation air insulation system for
heating purposes, or as a cooling system using water adjacent to
the oil circuit for re-heating the water used in industrial applica- 2 5
tions.
Automatic management of the choice of cooling circuit:
The energy recovery system is built-in to the standard air-cooled
compressor. It consists of installing an oil/air heat exchanger in 3
front of the standard oil/air cooler to reheat the water. This
exchanger is sized according to the features of the flow, pressure,
intake temperature and desired water temperature.
4

Key fig. 19
1. Water intake 1
2. Water outlet
3. Water-oil plate heat exchanger
Sized according to the temperature, pressure and flow
of the coolant water features.
Circulation is carried out against the flow within th 3 - Technical features
heat exchanger. The diameters of the tubes to be used are as follows: water inlet/
4. Thermostatic valve outlet: 1'' gas (socket).
Graded at 131 - 140 °F / 55 - 60 °C, it authorises or bypasses
the the water-oil heat exchanger, thus producing a recovery We recommend using a filter on the water intake to protect the
of energy. cooling agents and the valves. The central unit is equipped with
5. Injection of cooled oil into the compression element. an automatic water shutoff solenoid valve, located on the water
intake pipes. A manual valve for insulation and water-flow control
will be installed on the water outlet in order to optimise the flow.
The water must be relatively fresh in order to prevent dangerous
deposits and scaling of the pipes.
The required qualities are given as a general rule in order to avoid
problems caused by the cooling water ( see E-2 chapter 7). If
you have any doubts, please contact CP Compressors.

Please contact CP compressors for the following specifications

depending on the power of the machine:
- Minimum water intake temperature
- Maximum water intake temperature
- Cooling water flow required
- Water circulation pressure
- Recoverable energy

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Chapter 6 - Specific information
for CPVS 250 The inverters feature a capacitor charging circuit with
a thermal cut-off. It is thus essential to wait for at least
4 5 minutes between two connecting operations. Failure
Refer also to the chapters concerning the standard machine.
to comply with this instruction can result in damage
"CPVS" machines are compliant with the Electromagnetic to the contactor and the heat resistor on the charging
compatibility in industrial environments Standards 50081-2 and circuit.
50082-2
2 - Safety instructions
A - Description (cf Chap. 1)
No connection work is allowed when the inverters is
Standard equipement 1 under power.
A electronic frequency adjusting device replaces the star-delta No measurement work is allowed on the inverters when
starter.
2 it is under power.
B - Safety To undertake any work on the inverters, it is necessary
to disconnect the equipment from the mains. Wait for
For your safety, please respect the instructions carrying the the internal ventilation to stop and the indicators to be
warning symbols as given below: 3 turned off. Then, wait 5 minutes before opening the
cover.
SAFETY RULES
No voltage or insulation verification test is allowed
The safety rules require: 4 on the inverters components.
• The presence of an earth socket
Disconnect the cables from the motor and the inverters
• The existence of a manual switch cutting-off the three phases
5 before taking measurements on them.
that should be placed visibly near the CPVS
• It is necessary to cut out the electric current before any
Do not touch the integrated circuits, the electrostatic
intervention on the machine (except drainage under pres-
6 discharges may damage them.
sure).
Before connecting the inverters, make sure that its
= Dangerous voltage
7 covers is correctly closed.
Make sure that no compensation capacitor of cosine
= Attention 8 phi is connected to the motor cable.
ELECTRICAL INSTALLATIONS MUST ONLY BE
CARRIED OUT BY A SPECIALISED AND COMPETENT C - Installation
TECHNICIANS
The "CPVS" must be installed away from a transformer
1 - Warning or autotransformer.
(see Chapter 2 and 3).
The internal components and the plates (except for
The fuses for the built-in section switch are defined as follows
the electrically insulated I/O terminals) are at the
voltage of the mains power supply when the inverters Main voltage 460 V / 3 / 60Hz 400 V / 3 / 50Hz
1 are connected to the mains power supply. This voltage
250
is extremely dangerous and it can cause serious injury
or even death in the event of involuntary contact. Nominal current 300A 340A
Power supply cable H 07 600Kcmil 3x185+1x95(earth)
When the inverters are connected to the mains power
Fuse protection 350A 400
supply, connection terminals U, V, and W on the motor,
( Type J )
2 together with the +/- terminals on the braking resistor,
are live even if the motor is not running.
ATTENTION
The I/O control terminals are insulated from the mains • Motors and drives can only be guaranteed where the supply
power supply, but the relay outputs may nonetheless voltage "460 V" does not exceed the rated voltage by more
be live even if the inverters are not connected. This is than 10%.
3 also the case for the other I/O control terminals, even • The connection of the power supply to the section switch
if switch X4 is in the OFF position (Stop). (if present) requires the use of properly insulated terminals.

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62 305 799 65 Page 19
D - Commissioning
1 - Preparation for start-up
(See Chapter 3).
ATTENTION
The power circuit will have to be cut off when adjusting the
electrical 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. See
Chapter 7 - A for the quality of oil to be used and for the oil
renewal 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 compressor
silentblocks.
ATTENTION
The oil filler plug, the valve and the drainage plugs have always
to be closed during operation and must never be opened before
the system has reached atmospheric pressure.
2 - Control of rotation direction on start up
This control must be implemented when the machine is put into
operation for the first time, after any work has been carried out on
the motor and after any changes to the mains supply.
IMPORTANT :
• Check the direction of rotation (as per the arrow shown on the
sump) by jogging over with the START button.
If it is incorrect, swap over two of the motor's phase cables under
the drive.
When rotating in the right direction, the oil level (fig. 21) must
drop after 4 to 5 seconds of operation.
• Also check the direction of rotation of the fan for air-cooled
plants (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 valve
slightly open to observe the compressor at load.
3 - Press the STOP button. The motor stops and the plant
automatically returns to atmospheric pressure.
3 - Setting of pressure - machine
(Refer E Chapter 1 refer also to the AIRLOGIC controller manual)
The unit is factory pre-set for a given delivery pressure. As an
energy 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 less
than the minimum flow-rate - must be set to 7.26 PSI above that
of the "Set point 1". In this way, the current used by the compressor
is minimised (see notice AIRLOGIC).
Do not set the stop pressure at a level beyond the machine's max P.
09/2014
Page 20
4 - Assembly and settings for parallel operation
with other compressors
Pressure for the CPVS compressor must be adjusted at a value
within the range of adjustment values for the rest of the
compressors..
Adjustments pressure
Stop P
Set
point 1
Various
compressors
CPVS C1 C2 C3
5 - Regulating the pressure by changing the speed
This method of regulating the pressure allows precise adjustment
of the compressor's flow-rate at the compressed air demand valve:
The accuracy is of the order of 1.45 PSI when pressure regulation
is achieved by changing the speed, provided that the flow-rate
lies between the maximum and minimum rates for the machine.
• The principle of the pressure regulation by changing the speed
The AIRLOGIC controller controls the motor and the compressor
as a function of the system pressure as measured by an internal
pressure sensor (fig. 20a).
- If the mains pressure is weaker than the pressure set point
(user-defined parameter in the AIRLOGIC) the motor will
accelerate and the pressure will increase (fig. 20b)
- If the mains pressure is stronger than the pressure set point, the
motor will slow down causing the pressure to drop.
The AIRLOGIC provides the compressor control functions and
also controls the whole pressure feedback loop. It therefore
includes a device to compare the indicated pressure with that from
the pressure sensor, associated with a compensating device,
Proportional integral control PI (fig. 20c).
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 of
high cut-out frequencies with IGBT transistors.
At the same time, the motor control method known as "open loop
vector flux control " provides good stability for the system against
disruption.
In this way, the pressure feedback loop is more stable to sudden
changes in consumption (changes in the flow-rate).
Chicago Pneumatic Compressors
62 305 799 65
 Fig. 20a
The principle of the pressure regulation by variable speed

Pressure Controller Drive Motor Compressor Tank

required unit

Frequency speed

Pressure sensor

System

• Pressure regulation for low rates of flow • Energy saving

For an air consumption rate lower than the minimum rate of flow For demand of compressed air within the machine's flow range -
for the machine, the pressure is adjusted by the machine's time- min flow to max flow, the frequency converter or the variable
delayed START/STOP controls. speed drive feed the motor in order to ensure that it turns at the
speed required to supply air demand both for pressure and flow.
Since the operation element cannot function below a certain speed
(corresponding to the minimum output), the compressor continues It is used to adjust the power supply to the motor (and thus the
to run and compress at the minimum speed until the pressure machine) to the exact power requirement for the compression of
reaches the limit called "Indirect shutdown ". the air, without a drainage stage being necessary.
Once this threshold has been reached, the motor will stop, the COMMENT :
machine will go into stand-by mode after a certain period of
Energy savings are increased if machine maintenance is carried
inactivity and the full drainage process will be carried out.The
out in accordance with the maintenance instructions and
pressure then drops towards the indicated pressure and, at the end
frequency.
of the minimum time delay (since reaching the no-load pressure),
the drive allows the motor to restart. The pressure then rises again
and the cycle starts over (fig. 20d).
To avoid pumping the system - frequent stop / start - drainage
time may be increased
(cf. notice AIRLOGIC).

Chicago Pneumatic Compressors 09/2014

62 305 799 65 Page 21
 Fig.
Fig. 520b
b Fig.5 20c
Fig. c Fig.
Fig. 520d
d
Pressure
Stop
threshold

Instructions
Required
pressure

Time
Speed

stop timing

minimun time
Min speed

Time
Flow Q

Min Q

Time

E - Operating incidents
The staff in charge of maintenance of the CPVS compressor must become fully acquainted with this machine, in order to be able to easily
diagnose any anomaly. Under normal operating conditions, the CPVS 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 the
instrument panel (refer to the AIRLOGIC Manual).

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Chapter 7 - Maintenance
The maintenance period is limited to several essential operations. The summary on the CP Compressor instrument panel shows at a
It is strongly recommended that the power supply be cut off during glance the type and periodicity of operations to be carried out for the
any adjustment or repair. compressor to function correctly.

Operations to be carried out

Parts Daily Every Every Every Every Every Every Observations
500 h 150 h 2 000 h (*) 4 000 h 6 000 h 12 000 h
Service A Service B Service C
Drain the condensates
Draining cock X from the cold oil circuit
(Chapter 7 - G)
Check and top up if
Oil level X necessary
(Chapter 7 - A)
Air filter X Replace the filter
Oil tank, Oil change, oil refill
Oil change X X with recommended oil
(Chapter 7 - A)
Control Renovation of the
Suction housing cleaning Overhaul kit housing. Use the
lubrication suction housing kit
Check the cleanliness of
Oil return pipe Overhaul the oil return pipe and
Kits the state of the seal
(Chapter 7 - F)
Change the part
Oil separator X according to the
instrument panel indication
(Chapter 7 - E)
Oil filter X X Filter change
Oil cooler Blowing of cooling
Final coolant X elements
Cleaning (Chap. 7 - D)
Control Exchange the accessories
Valve at minimum cleaning Overhaul supplied with the
pressure lubrication kits maintenance kit
For motors fitted with
Motor for grease fitting, use
CPF 200 X KLUBERQUIET
BQH72-102
(16 g per grease fitting)
For motors fitted with
Motor for grease, use Polyrex
CPVS 250 X EM-ESSO (16 g per
ase fitting)
(16 g per grease fitting)
Electric cabinet X X Retighten power cable
connections.
Safety temperature Check operation
test X (Chapter 7 - H)
Coupling X Check coupling condition

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

A - Oil level and change

(see fig. 21 and B chapter 1)
The recommended oil used for the first compressor fill up is a mineral
Caution : oil with the following properties :
Never mix oils of different makes and types. To maintain opti- - viscosity: 40 cSt at 104°F / 40 °C
mum oil quality, drain all the drainage points of the compressor. - viscosity index: 90 minimum
The spent oil that remains in the compressor may contaminate the - antioxidant additives
oil system. - anti-rust additives
It is strongly recommended to use Chicago Pneumatic - anti-foam additives
Compressors oil.

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62 305 799 65 Page 23
This Rotair Xtra oil was specially designed for Chicago Pneumatic
Compressors and guarantees to the operator an oil change period
of 2000 hours, with the replacement of the oil separator filter after
6000 hours.
THE FIRST OIL CHANGE MUST BE CARRIED OUT
AFTER THE FIRST 500 HOURS OPERATION.
Using a synthetic oil for compressors is also acceptable and means
less frequent oil changes : please speak to us about the
compatibility and oil change methods.
The oil change and the replacement of oil filter must be carried
out when the indication is seen on the electronic controller and
when the corresponding time counter reaches "0" (refer to
electronic controller manual Chap 1 E ).
Drain the compressor when warm. For this, shut it down taking
care to disconnect the power cable. Release pressure in the tank
by unscrewing the filler plug by a single turn. Open the purge
valve and drain the oil. Do not forget to close the valve after
draining the oil.
After maintenance, reset the time counter which tells you how
long you have before the next oil change is due, refer to electronic
controler manual Chap 1 E.
OIL LEVEL
When shut down, the MAXI level of oil is located at ¾ from the
bottom of the indicator, the MINI level corresponds to the lowest
visible parts of the indicator (rep. 1 Fig. 21).
Fig. 21
1
CHECKING THE OIL LEVEL MUST BE CARRIED OUT
JUST AFTER STOPPING THE MACHINE.
DRAINAGE UNDER PRESSURE
So as to carry out a quick and full oil change, your CP Compressor
is equipped with a system that allows low level pressure to be
maintained in the oil circuit. This pressure is shown by the pressure
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 machine is
emptied and stops automatically.
• Change the oil by opening the oil change valve very slowly.
• As soon as the oil ceases to flow through the drainage orifice,
close the valve and top up with new oil,
• When there is no longer any residual pressure in the oil tank,
reset pressure drainage and then check the pressure drop at 0 PSI
and change the oil filter cartridges,
• Reinitialise the timers that will warn you when to carry out the
next oil change and the next oil filter change
(see the AIRLOGIC Manual - E chapter 1),
09/2014
Page 24
• Reseal the filler cap when replacing it and check that all openings
are properly closed.
• The machine can be restarted only after pressing the button C
several times to return to STATE 0.1. Check the clamping of
connections.
• After restarting, check that there are no oil leaks.
NOTE
If the oil is in a bad state ; that is a pungent smell or contains
particles or varnish or other solid matter, the system will have to
be rinsed : pour about 50% or the normal contents of clean oil
and operate the unit for 3 hours and carefully change the oil. When
rinsing, leave the former oil filtering cartridges in place.
If you need to dismount the float-actuated oil level assembly, when
re-assembling make sure that the angle of the hex-head located in
the middle of the green area is directed upwards, in line with the
receiver.
B - Oil return (Fig. 22)
If the oil return pipe between the oil separator and the com-
pressor is blocked, the oil will accumulate at the bottom of the
oil separator and there is a risk of it being expelled from the
unit with the compressed air.
Under normal conditions, you should see the oil flowing though
the transparent tube when the compressor is operating under load.
If the oil doesn't move, stop the machine and check that the cir-
cuit is clean.
Fig. 22
Scavenge
tube
Transparent
tube
C - Air filter
(see B chapter 1)
The air filter is of the dry, encapsulated type. Change the
cartridge every 2 000 hours. Check the cleanliness of the filter
every week and change it if necessary. (see notice on the
electronic controler for resetting the time).
ATTENTION :
If you do not replace the filtering element when needed, perma-
nent dirt build-up will result. This reduces the air inflow to the
compressor and could damage the oil separator and the compressor.
Chicago Pneumatic Compressors
62 305 799 65
D - Fan
Replacement of the complete fan is recommended if one or more Manganese less than 0,1 less than 0,1
blades are deformed or broken If replaced, check the fan rotation Oxygen less than 3 less than 3
direction reversal of the rotation direction will reduce machine Hardness of carbonates
cooling and damage the motor in time. (like CaCO3) 50-1000 50-500
Organic compounds
(KMnO4 less than 25 less than 10
E - Oil and air cooler Consumption)

1 -Air-cooled
The aluminium air and oil cooler is a vital system in the CP
Compressor. It needs special care. In order to avoid deforming or
destroying the tube bundles, cooler connectors and lines must be
dismantled or assembled while maintaining in rotation the cooler
sleeves using a wrench. The outer surface of the tube bundle must
always be clean to insure the best heat exchange. If leaks occur,
seek their source by:
- Stopping CP Compressor,
- Cleaning any greasy locations,
- Seeking leaks using conventional methods (e.g.: soap solution,
etc.).
If you need to dismount the coolers, remove the front or rear post
(fig.23, item. 1) and pull them out of the compressor like drawers.
Pressurized shutdown retains the pressure in the machine circuit
for a few moments so that any leak can be more easily located.
Fig. 23
The cooling water tends to be acid and often needs special
treatment. The pH level can vary between 7 and 9. For optimum
results, the water used must be analysed and treated in order to
meet the above specifications.
Remarques
- No algae nor oil..
- Chlorides and sulphates are interactive. In open systems, the
sum of the square of these values must not exceed 85 000. In
closed systems which are carefully controlled and treated, the sum
of the squares can go up to 520 000. Note that the value of the
sulphates must include any presence of sulphites.
F - Oil separator
(see B chapter 1)
The oil separator's lifespan depends on the cleanliness of the air
coming into the compressor, on regular oil filter changes, on the
quality of the oil used, on the attention with which the oil tank
condensate drains are carried out and on the ambient temperature
of the room. (see notice on the electronic controler for resetting the
time).

Fig. 24

1
1

Off-centre
Item. 1 : removable post (front or rear) for replacement of coolers, hole to
if needed swivel the
cover
2 - Water cooled
2
The required water quality is given as a general rule to avoid
problems caused by the cooling water.
If in doubt, consult CP Compressors.
Maximum content
recommended - mg/l Closed system Open system
Chloride (Cl-) less than 100 less than 100
Sulphate (SO 4--) less than 400 less than 250
Total solids less than 3000 less than 750
(like SiO2) less than 10 less than 10
Free chlorine (Cl2) less than 4 less than 2 Check that the suction oil return tube is clean (transparent) to avoid
Ammonia (NH4+) less than 0,5 less than 0,5 clogging of the nozzle (see fig. 22).
Copper less than 0,5 less than 0,5
Iron less than 0,2 less than 0,2

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Excessive oil consumption
The presence of excess oil in the discharge air, a rapid drop in
level show a probable deterioration in the oil separator that must
be changed.
The unit must first be checked to make sure that there is no oil
loss and that the oil return is working properly.
I - Coupling
Non-lubricated flexible coupling doesn't require any particular
maintenance. It is made up of two half-flanges and one or more
intermediary rubber elements. The rubber elements must be
checked periodically for any cracks, tears, loss of elasticity or
signs of excessive wear.

Changing the oil separator

Testing the wear tell-tale
Disassemble the "VICTAULIC" union up-line from the minimum
pressure valve (See Fig. 24, Item 1). Disassemble the regulating
and oil return connections situated on the top flange of the tank.
Unscrew the screws holding the tank cover and remove the cover
(See Fig. 24, Item 2).
- if the former oil separator has to be reinstalled, use two new
gaskets,
- take the outmost care and attention when installing the oil
separator to avoid possible damage, Machine running at fixed speed

- the replacement oil separator is delivered complete with its two Alignment
gaskets for the two sides of the flange,
Perfect alignment is obtained automatically thanks to the cen-tring
- slight undulations in the flange will flatten out when the screws bell between the compressor and the motor.
are tightened hard,
- apply a tightening torque of 15 m-kg to tighten the cover screws, WARNING
- re-screw the flange onto the cooler, The retainer locks of the two shafts must be positioned at 180°
- connect the regulation system and oil return, from each other for proper balance.
- refit the "VICTAULIC" union.
J - Suction control system (see Fig. 25)
G - Draining condensation water If the compressor's suction control system is showing signs of
(see B chapter 1) malfunction (vibrations, noise, leaks, does not open or close), the
suction valve must be removed for inspection.
Condensation water prevents proper lubrication. The resulting
substantial wear leads to a reduction in the lifespan of the CP
Compressor. It is therefore essential to drain condensation water. Fig. 25
Draining of condensates in the oil circuit :
Draining will only take place at least 12 hours after the CP
Compressor has been shut down. It can be carried out for example
on 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.

H - Motors
The motors must be lubricated in accordance with manufacturer K - Temperature safety tests
instructions printed on the motor plate. (see Notice AIRLOGIC - E chapter 1).
Type of lubricant for motor IP55: ASONIC HQ 72-102
IF THE SENSOR IS NOT WORKING, IT MUST BE
(Kluber Lubrication)
CHANGED.
In the event of a motor replacement, check for the correct direc-
tion of rotation by starting then IMMEDIATELY stopping the
motor. If the direction of rotation is incorrect, change two phases
on the motor power cable in the electrical cabinet.

If you have chosen the phase control option check that the
controller indicator is on (sequence correct).

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L - Refastening electric connections
A loosening of the electric power cables leads to the contactors
ove-rheating which can lead to their destruction.

Periodic refastening is therefore necessary at the star and triangle

line contactor arrivals and departures.

All electric power supply to the machine must be cut off before
opening the electric cabinet.

M - Decommissioning the compressor at

the end 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 compressed
air 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.

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Chapter 8 - Trouble shooting
The staff in charge of maintenance of the CP Compressor must become fully acquainted with this machine, in order to be able to easily
diagnose any anomaly. Under normal operating conditions, the CP Compressor must provide full satisfaction.

A - Main incidents
The main incidents likely to occur are listed below, along with the remedies to be applied. The markers of the indicator lights relate to the
control 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-tightness
of the minimum pressure valve.

2. THE COMPRESSOR a) Ambient temperature too high. a) Make openings or install ducts to
OVERHEATS evacuate the hot air (see Chapter 2).
b) Obstruction of the passage of cooling b) Clean the coolers (see Chapter 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 electric
THE MOTOR PROTECTION connections are tight. Check the pressure
UNIT 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 oil separator cartridge.
b) Valve of suction box out of use or
not closed.
c) Faulty pressure switch, sensor
or solenoid valve.
d) Working pressure too high
a) Change the oil separator cartridge.
b) Check valve, piston and joints of suction
box.
c) Check that the pressure switch and
solenoid valve and sensor pressure are in
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 oil separator cartridge.
(see Chapter 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 solenoid valve, 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 solenoid valve 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 kit

RANDOMELY OR CREATES on the electronic controler. (contact the after sales department)
NON-EXISTING FAULTS

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NOTE

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 support
http://www.cp.com/en/contactus/compressors/

CP Compressors
1800 Overview Dr
Rock Hill, SC 29730