Chicago Pneumatic CPVS 50 User's Manual
Contents
1. viscosity 40 cSt at 104 F viscosity index 90 minimum antioxidant additives anti rust additives anti foam additives 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 methodes 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 plate manual Section 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 plate manual Section 1 E OILLEVEL When the machine is not running the MAXIMUM oil level cor responds to the top part of the green area and the MINIMUM level is represented by the low part of this green area CHECKING THE OIL LEVEL MUST BE CARRIED OUT JUST AFTER STOPPING THE MACHINE THERMOSTAT VALVE OPEN DRAINAGE UNDER PRESSURE So as to carry out a quick and full oil change your CPVS is equip ped with a system that allows low level pre2. 3db A European Directive 97 23 EC Pressure Equipment Directive Chicago Pneumatic Compressors 62 305 258 65 D Definition of the pictograms Typical examples of pictograms valid for CP Compressors 1 Water outlet 2 Manual condensation water draining 3 Water inlet 4 Automatic condensation water draining 5 Unplug and decompress the compressor before maintenance 6 Hot parts DIE A DE em as E 5 DANGER This symbol identifies immediate hazards which will result in severe personal injury death or substantial property damage CAUTION Es Identifies hazards or unsafe practies which could result in minor personal injury or property damage De DANGER This symbol identifies life threatening electrical voltage levels which will result in severe personal injury or death All electrical work must be performed by a qualified electrician CAUTION AN This symbol identifies hot surfaces which coold result in personal injury or property damage N E Electronic board See the specific instructions for a description of the electronic plate together with operating instructions Notice N 62 305 169 xx for version CPVS Chicago Pneumatic Compressors 62 305 258 65 01 2008 Page 7 Section 2 Installation A Handling The CPVS Compressor must always be handled with care It may be lifted either with a forklift truck or by means of a travelling crane In the latter case precautions mu
3. Blowing of cooling elements Cleaning Section 8 D Valve at minimum pressure Control cleaning lubrication Overhaul kits Exchange the accessories supplied with the maintenance kit Motor for CPVS 40 50 60 75 For motors fitted with grease use Type ESSO UNIREX N3 0 53 ocs per grease fitting Electric cabinet Retighten power cable connections Safety temperature test X X X X X X NOTE maintenance kits are available see spare parts list or at least every year Check operation Section 8 H CAUTION When the compressed air cools part of the moisture sucked in by the compressor condenses In order to protect the dryer against the 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 e With a manual drain drain regularly according to the moisture content of the ambient air e 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 01 2008 Page 20 Chicago Pneumatic Compressors 62 305 258 65 A Oil level and change see fig 19 see B Section 1 The recommended oil used for the first compressor fill up is a mineral oil with the following properties
4. A Level detection bleed Valeri naaa bid la Didi lele 12 B Advanced filtration to the compression air inlet non conc non conca ocn cn non ann on cnn aan once on conoce ano nn arc an anni ncinnns 12 C Presfillration pal ii A i AAA AA 13 D Automatierestarimo io ES e a 14 E R mote statting and ST PDIOS sunrise talia VIa rai aaa aa lei 14 F Rotation direction indicator Phase controller i 14 G Centrifugal separatori ille id cale 15 Section 6 Specific information for CPVS 40 50 60 75 eeerrrrrrrrerererreerice cene rere sane rene eenerenee rio neoneseneeenesenene rea noc arene nin coco roce sese nese necenenne 16 AC Descripuoticira MOLA ROLO ra 16 BeSafe enan na iaia ibas 16 COM ii EE E E T E E E TE 16 D Commissioning piana laica A E ARI ai ii Ala 17 Ep Operating incidents ti LOT IA IRA E I IRA 19 Section 7 PEA NN 20 As Oil level andchanges visi O A AA DIL Lada 21 BS Att filter lira a E T FAR A a E 21 C Turbine ara a II NOOO E 21 D Oil and air cooler RNA 22 E Oil separatofi purple andina A aa alal 22 Es Onl TA UI piperita RAIN A A rta 22 G Draining Condensation Waters oseon UAN ao na aio OE aio 22 H Temperature safety tests mad rr E TRIO E a dnd RATA 22 T Refasteninig electric connections ina idas 22 J Decommissioning the compressor at the end of its useful life i 22 Section 8 Operating incidents
5. A command and control electronic board 01 2008 Page 6 Safety devices 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 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 gauge on the front panel see fig 19 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 ISO 2157
6. d Check that the oil filter is clean Drain Replace the cartridge Check the tightness of connections a Check it is connected and the electric connections are tight Check the pressure of the compressed air and the pressure switch settings a Change the de oiling cartridge b Check valve piston and joints of suction box c Check that the pressure switch and electrovalve and sensor pressure are in good working order a Check the oil return pipes b Look for oil leaks and rectify c Replace the de oiling cartridge see Section 8 E a Adjust the pressure see Section 3 b Check consumption and possible leaks c Check electrovalve pressure switch valve d Check setting a Clean filter b Check setting a Tighten b Check that they are closed c Remove retainer blocks a Add an interference suppression kit contact the after sales department 01 2008 Page 23 support support CPcompressor com 1 877 861 CPAC CP Compressors Ch i ca g O 1800 Overview Dr gt Rock Hill SC 29730 Pn eum at IC
7. rrrrrrrrrrrerreereeeeisee nine ee nin ere nie erioeen zio nio zio nese ein eie nio nio nio nio nio nio ninni ninni ezine conio nio nin ezio nio nio nio nie nio nio nioninnenne 23 Ar MAI Ineidetits ciccia AA AAA baila eli alii Alle alano 23 01 2008 Page 4 Chicago Pneumatic Compressors 62 305 258 65 Space requirement and installation diagram CPVS Model 40 50 60 75 see page 2 installation instructions Fig 1 Air outlet Air outlet e St niet ee de e A 1 1 2 NPT AIR DELIVERY 1 4 NPT Drain D To POWER SUPPLY CPVS 40 CPVS 50 CPVS 60 75 Dimensions in Air inlet without deflector Chicago Pneumatic Compressors 01 2008 62 305 258 65 Page 5 Section 1 Description A General Information The Chicago Pneumatic Compressors CP model air compressor is a compressed air unit and is presented as an entire unit completely assembled and tested It is driven by an electric motor and enclosed in a sound proof cowling which is necessary for proper cooling The compression element is a single stage oil refrigerated ro t
8. CPVS Model 40 50 60 75 cnn nn cnnnnnnnnn canon nro non ren ncnos 5 Section 1 Descriptioi A ON NON 6 A General Informiatoni irradia 6 B Respect of the environment and prevention of pollution i 6 E O io Re RL ER O IA A TR 6 D Definition ofthe pietopramis 3 ose biro co ul i i ie iii i ai ui ila i 7 ES Electronic board ss trivago en alal BO a ala o ona 7 Section 2 AAA NAO 8 A Handling B Room C Assembly Dy Att discharge Pipetas 8 E Condensate drain pipes sic s s cs cenccscereavesseat and a ELLA ana iaia 8 F Electrics Cabling ii A A A Ra 9 Section 3 Implementation oocnonconoonoononnnonnonnoanonaoancnncnncnnoonconoonconocn nio nio nese orazio nio nio nio nio nioninnen neo nen ein zie ezio nio nio nio nin azionio zio nio nio nio nio nio nio neo neonionenn 10 A Preparation for start up B First start up C Discharge pressure adjustment rie A eens a MINIM ea hak aoeueats Memes tte a ess 10 D Parallel compressor assembly ciccscceccscccssescsseecoeccbecvesvecsvsteasses dada diiniita dan secdecuacutcabeatcatccncsdcondendendescesde incendiada sais 10 ESSA AOSTA IA ORE A A 10 Section ASS OR 11 ASA TANA CUCA i iaia ala lieti a el 11 Section 5 OptionS rsrrrrrrrreereeren ren zio zin ze see eee cene eie eis nic eis nise ennio zi oS osese nio nin ee Conon nio nio nio nono ninni Se non non ezio nio eee nio nin ezio zio nio nio nio nio nionionennenne 12
9. Compressors 62 305 258 65 F Electric cabling Each CPVS is wired for a pre determined voltage i e 460 V NEVER OPERATE THE CPVS ON A VOLTAGE OTHER THAN THAT SHOWN ON THE ELECTRIC CABINET The electric current supply to the CPVS must comply with the following table Type of cable to be used Power cable size for a maximum 32 8 ft length VOLTAGE CPVS Model 460 V SAFETY REGULATIONS It should be remembered that safety regulations require e An earth socket to be used A manual isolating switch cutting all three phases this switch must be clearly visible near the CPVS unit The electric current must be cut whenever maintenance work is carried out on the machine except for pressurized oil change Fuses to be used for CPVS Model the isolating switch RKS type 460 V 40 80 50 100 60 125 75 150 Chicago Pneumatic Compressors 62 305 258 65 01 2008 Page 9 Section 3 Implementation 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 whenever adjusting electrical equipment or to prevent accidental starting Loosening of electrical power cables that may be due to vibrations caused by transport or initial
10. 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 e 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 19 must drop after 4 to 5 seconds of operation e 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 Section 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 25 PSI above that of the Set point 1 In this way the current used by the compressor is minimised seenotice AIRLOGIC Do not set the stop pressure at a level beyond the mach
11. full flow PSI 58 Actual flow cfm 195 1 194 5 166 4 239 1 234 1 204 4 291 2 280 2 244 7 374 3 342 3 304 8 Motor power hp Pressure outlet F NPT Capacity gal Carryover ppm Noise level at 3 3ft dB A 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 75x37 4x69 3 75x37 4x69 3 75x37 4x69 3 75x37 4x69 3 Approximate weight Ibs 1874 1995 2226 2679 01 2008 Chicago Pneumatic Compressors Page 2 62 305 258 65 CPVS Model Motor power hp Main Voltage 460 Volt 3 60 Hz Nominal current A Power supply cable Fuse protection Type RK5 Connection of the electric plate to an external control box Install an RC filter on the KM1 coil e Install an RC filter on the KM2 coil e 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 power cords A separate installation from the power cords must be carried out e Install an RC filter on all the relay coils of the external operation units Chicago Pneumatic Compressors 01 2008 62 305 258 65 Page 3 CONTENTS Space requirement and installation diagram
12. machine 1 Press the ON button the motor starts up 2 Leave 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 To adjust the backflow pressure setting to a lower value refer to the manual of the electronic plate refer E Section 1 D Parallel compressor assembly If the CPVS is intended to operate in parallel with other CP or similar compressors the discharge piping can be linked together If the CPVS 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 CPVS 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 rotary compressor takes the main load It is cheaper to run this way E Safety The oil used for cooling the machine is a liquid combustible under the effect of strong heat In case of fire
13. 5 Possible causes a Main switch open b Phase missing c Fuse d Insufficient voltage at motor terminals e Compressor under pressure a Ambient temperature too high b Obstruction of the passage of cooling through the oil radiator c Oil level too low d Oil circuit blocked a Compressor motor overload a To clean de oiling 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 Blocked oil retainer b Oil leaks in the CPVS compressor c Faulty oil separator element a Incorrect pressure settings b The desired output is higher than that of the compressor c Closed suction valve d Release nozzle incorrectly adjusted progressive adjustment option a Blocked air filter b Adjusting electrovalve not working a Fixing bolts of compressor or motor have come loose b Soundproof panels incorrectly closed c Transport retainer blocks red parts not removed a Electromagnetic disturbance on the Airlogic controller Solutions a Close the switch b Check the circuits c Replace d Check the voltage and the connections e Check the vacuum device and change if necessary Check the water tightness of the minimum pressure valve a Make openings or install ducts to evacuate the hot air see Section 2 b Clean the radiator see Section 8 c Check and top up oil level
14. 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 plate for resetting the time ATTENTION If you do not replace the filtering element when needed per manent dirt build up will result This reduces the air inflow to the compressor and could damage the oil separator and the compressor Fig 19 Oil level Filler plug MM Oil level Drainage C Turbine Replacement of the complete fan is recommended if one or more blades are deformed or broken If replaced check the fan rotation direction reversal of the rotation direction will reduce machine cooling and damage the motor in time 01 2008 Page 21 D Oil and air cooler The aluminium oil and air cooler is a vital part in the CPVS system Please take care of this element To prevent the nest of tubes from being deformed or damaged when assembling or disassembling the radiator unions and hoses the radiator sleeves must be kept rotating by means of a wrench The outer surface of the nest of tubes must always be kept clean in order to enable proper heat transfer In the event of a leak the source of the leak must be detected In order to do this Stop the CPVS Clean the greasy areas Look for leaks using conventional means soap solution Pressurized shutdown retains the pressure in the machine circuit for a few moments so that any leak can be more easily locat
15. Chicago Pneumatic Instruction Manual EN CP COMPRESSOR Model CPVS 40 50 60 75 62 305 258 65 ed00 CPVS 50 The CP Compressors 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 36 F frost free Maxi 104 F You must also have 1 meter 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 dusty environment pre filtering the room s air intake and a special filter on the machine s ventilation inlets TECHNICAL DATA VARIABLE SPEED MACHINES VERSION CPVS as per ISO 1217 ed 1996 Nominal pressure at
16. F THE RISK THAT THE COMPRESSOR MAY AUTOMATICALLY RESTART AT ANY TIME 3 Technical features This option requires configuration of the electronic plate and installation of an informative insert on the door of the compressor electric cabinet Every time the compressor stops it must be secured by opening and locking the electric section switch E Remote starting and stopping This option allows the compressor to be remotely started and stopped However in all cases stopping the compressor at the machine itself is essential If the compressor is shut down from a distance it may be restarted from a distance as well For any intervention to be conducted on the machine it is essential to activate the emergency stop of the machine in order to ensure safe conditions Refer to AIRLOGIC Manual E Section 1 01 2008 Page 14 F Rotation direction indicator Phase controller 1 Description The phase controller option is designed to control the rotation direction of the machine s electric power supply 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 machine with the guarantee that it will work if this option was factory installed the configuration of the rotation direction having been configured during the production tests protecting the motor and the electrical fittings from any l
17. and oil stages Fig 6 1 Condensation intake 4 Main duct 2 Capacitive sensor 5 Electric valve 3 Receiver 6 Membrane 3 Technical features Maximum capacity of the compressor 706 cfm min Working pressure 11 6 232 PSI Operating pressure 33 8 140 F Electric power supply 115V 24V AC socket in the compressor electric cabinet B Advanced filtration to the compression air inlet Fig 7a and 7b 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 This option is particularly useful in very dusty surroundings 01 2008 Page 12 2 Option overview This option is used as a replacement for the standard filter Certain atmospheric particles are smaller than 78 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 118 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 e 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 co
18. ary 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 Make sure that the condensates water oil are drained and treated according to national and local regulations 3 End of life of the machine Make sure that the machine as a whole is disposed of according to national and local regulations See F Section 7 and J Section 8 C Standard equipment In its standard version the covered unit includes Operating components A twinned screw type compressor 2 Anelectric motor 3600 rpm short circuit rotor 230 460V or 575V voltage according to the model 3 Star delta starting A direct drive or gearbox drive Air and oil tank in compliance with applicable legislation ASME All or nothing regulation for the aspiration vent A greasing system using the circuit s differential pressure thus avoiding the need for an oil pump An oil separator based oil separation system A heat discharge system oil and compressed air radiator with forced ventilation 10 A dry air filter 11 An oil filter 12
19. e allows the motor to restart The pressure then rises again and the cycle starts over fig 14 d To avoid pumping the system frequent stop start drainage time may be increased cf notice AIRLOGIC 01 2008 Page 18 Motor Compressor Tank unit Frequency speed gt Pressure sensor System Energy saving For demand of compressed air within the machine s flow range min flow to max flow the frequency converter or the variable 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 It is used to adjust the power supply to the motor and thus the machine to the exact power requirement for the compression of the air without a drainage stage being necessary COMMENT Energy savings are increased if machine maintenance is carried out in accordance with the maintenance instructions and frequency Chicago Pneumatic Compressors 62 305 258 65 Fig 14b Pressure Stop threshold Instructions Required pressure stop timing lt _ _ _ minimun time Min speed 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 list
20. ed E Oil separator see B Section 1 The oil separator s lifespan depends on the cleanliness of the air coming into the compressor on regular oil filter changes on the qua lity 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 plate for resetting the time Check the cleanliness of the pipe that returns the oil to be aspired transparent to prevent the injector from becoming blocked and to ensure that the oil recovered can pass through easily 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 Changing the oil separator Dismantle all the piping connected to the tank s upper flange air discharge regulation system supply and oil return Undo the screws that hold the tank cover and remove it If the old oil separator musty be remounted use new seals Be very careful during installation of the oil separator so as to avoid possible damage The new oil separator is delivered with its two seals on either side of the flange Slight undulations in the flange will flatten out when the screws are tightened Apply a 6 mkg torque Replace the oil return tube correctly so
21. ed below along with the remedies to be applied The keys to the control lamps relate to the instrument panel refer to the AIRLOGIC Manual E Section 1 Chicago Pneumatic Compressors 01 2008 62 305 258 65 Page 19 Section 7 Maintenance The summary on the CP instrument panel shows at a glance the type and periodicity of operations to be carried out for the compressor to function correctly The maintenance period is limited to several essential operations It is strongly recommended that the power supply be cut off during any adjustment or repair Operations to be carried out Every Every Observations 6 000 hr Every 12 000 hr Every 8 000 hr Draining cock Daily Every Every 500 hr 150 hr 2 000 hr Service A Service B Service C Drain the condensates from the cold oil circuit Section 8 G Oil level Check and top up if necessary Section 8 A Air filter Replace the filter Oil tank Oil change Oil change oil refill with recommended oil Section 8 A Suction housing Control cleaning lubrication Overhaul kit Renovation of the housing Use the suction housing kit Oil return pipe Overhaul Kits Check the cleanliness of the oil return pipe and the state of the seal Section 8 F Oil separator Change the part according to the instrament panel indication Section 8 E Oil filter Filter change Oil radiator Final coolant
22. ernal 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 The quality of the air drawn in by a compressor is essential Low quality air results in the following Fast pollution of the oil thus an increase in oil change cycles e Increased pollution of the air and oil filtering components that increases the deterioration of the mechanical components in the compressor screw block Chicago Pneumatic Compressors 62 305 258 65 e Binding of the air oil separator before 6000 Hours thus an increase in maintenance cycles and maintenance costs 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 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 Galvanised steel covered frame Flammable medium belonging to fire protection class M1 made of polyester fibres Pleated medium on support grid placed downwards in the direction of the airflow Support grid Fig 9 Pre ventilation lock 2 pannels Disassembly hinges 3 Technical features FILTER MEDIUM Degree of fil
23. fic information for CPVS 40 50 60 75 Refer also to the chapters concerning the standard machine CPVS compressors are compliant with the Electromagnetic compatibility in industrial environments Standards 50081 2 and 50082 2 A Description cf Section 1 Standard equipment A electronic frequency adjusting device replaces the star delta starter A fuse holder section switch completes CP standard s safety devices B Safety For your safety please respect the instructions carrying the warning symbols as given below SAFETY RULES The safety rules require e The presence of an earth socket e The existence of a manual switch cutting off the three pha ses that should be placed visibly near the CP e It is necessary to cut out the electric current before any intervention on the machine except drainage under pres sure Dangerous voltage A Attention ELECTRICAL INSTALLATIONS MUST ONLY BE CARRIED OUT BY A SPECIALISED AND COMPETENT A TECHNICIANS A 1 Warning The internal components and the plates except the electrically insulated I O terminals are at the mains A 1 voltage when the inverter is connected to the mains This voltage is extremely dangerous and can cause severe injuries or even death in case of involuntary contact connection terminals U V W of the motor as well as connectors of the braking resistors are under power even if the motor is not running When the inverter is connected to
24. flow rate of the ventilation to the sleeve cross section L maxi 32 8 ft without mechanical extractor Cross section of room air inlet gt 2 x Duct outlet cross section 2 elbows accepted with large radius of curve and fluid guidance vanes Ratio Length Width of sleeve maxi 1 6 Make sure that no outside air especially if humid can be fed back into the machine and damage electric and electronic components or rust metal parts The maximum admissible pressure loss of the sleeve should not exceed 30 Pa 0 12 in CE In case of higher value provide an additional ventilation mechanical extractor with a flow equivalent to that of the machine C Assembly Put the unit on a stable surface The CPVS does not need foundations Any flat surface that can support its weight will be sufficient industrial floor D Air discharge piping The diameter of the air discharge pipe must be at least 2 NPT Current legislation requires that a valve which is lockable in the closed position be installed at the air box outlet connected to the compressor by a union and flexible line to allow it to be cut off during maintenance E Condensate drain pipes A separator with automatic solenoid valve drain is provided inside the set see Section 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 Section 1 Chicago Pneumatic
25. from a transformer or autotransformer see Section 2 and 3 The fuses for the section switch are defined as follows Main Voltage 460 Volt 3 60 Hz Nominal current A Power supply cable Fuse protection Type RK5 ATTENTION Motors and drives can only be guaranteed where the supply vol tage does not exceed the rated voltage by more than 10 The connection of the power supply to the section switch so present requires the use of properly insulated terminals Chicago Pneumatic Compressors 62 305 258 65 D Commissioning 1 Preparation for start up See Section 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 Section 8 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
26. g the compressor at the end of its useful life see B Section 1 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 ofthe 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 Chicago Pneumatic Compressors 62 305 258 65 Section 8 Operating incidents 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 1 THE COMPRESSOR DOES NOT START 2 THE COMPRESSOR OVERHEATS 3 THE COMPRESSOR STOPS WHEN THE MOTOR PROTECTION UNIT TRIPS 4 OPENING OF SAFETY VALVE 5 EXCESSIVE OIL CONSUMPTION 6 DELIVERY PRESSURE TOO LOW 7 COMPRESSED AIR OUTPUT TOO LOW 8 EXCESSIVE NOISE OF UNIT 9 THE COMPRESSOR STOPS UNTIMELY OR CREATES NON EXISTING FAULTS Chicago Pneumatic Compressors 62 305 258 6
27. 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 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 the factory See Section 8 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 except pressurized oil change See Chapitre 8 A Fig 3 01 2008 Page 10 B First start up Check the voltage between the three phases before using the unit for the first time Check the direction of rotation following the arrow on the coupling housing rep 1 Fig 3 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 19 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
28. 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 Chicago Pneumatic Compressors 62 305 258 65 Section 4 Operation A Air and oil circuits 1 Air circuits see Fig 4 The air is sucked into the compressor through a filter rep 23 This air passes through the compression element where it is mixed with oil injected during compression Inside the oil tank the compressed air is pre deoiled by shocks then flows through the oil separator rep 49 It then passes through the mini pressure valve rep 34 forming a check valve the aftercooler rep 51A the condensate separator in option and lastly the outlet valve not supplied to which the distribution pipe is connected 2 Oil circuit see Fig 4 The oil under discharge pressure flows from the bottom of the tank through the cooler rep 51H the oil filter rep 26 which retains solid impurities and then into the compressor rep 20 At each cold start the thermostat valve rep 47 short circuits the oil radiator thus enabling the optimum operating temperature to be attained quickly When it leaves the compressor the oil returns to the tank Part of the oil remains suspended i
29. ine s max P Chicago Pneumatic Compressors 62 305 258 65 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 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 e 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 14a 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 14b 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 associa
30. it touches the bottom of the oil separator F Oil return pipe see fig 20 Placed under the compressor Dismantle the body of the anti oil return pipe Lift the anti oil return pipe e Check the state of the o ring rep 64 e Reassemble 01 2008 Page 22 Fig 20 Oil return pipe G Draining condensation water see B Section 1 Condensation water prevents proper lubrication The resulting substantial wear leads to a reduction in the lifespan of the CPVS It is therefore essential to drain condensation water Draining of condensates in the oil circuit see fig 19 Draining will only take place at least 12 hours after the CPVS 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 Temperature safety tests See instructions electronic board IF THE SENSOR IS NOT WORKING IT MUST BE CHANGED I 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 see Maintenance Table All electric power supply to the machine must be cut off before opening the electric cabinet J Decommissionin
31. mpressor 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 7a and 7b Extraction duct VORTEX pre filter Air filter L Fig 7a Fig 7b Chicago Pneumatic Compressors 62 305 258 65 3 Technical features Operating temperature 104 F to 194 F C Pre filtration panels Fig 8 Easy to disassemble for rapid cleaning 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 compression assembly This option is recommended if the forced filtration option is installed see B 2 Option overview 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 int
32. n the air as mist This mist passes through the oil separator rep 49 The remaining oil which is separated by the last stage ofthe oil separator is drawn up by a dip tube and dispatched to the compressor Fig 4 Air oil circuit Chicago Pneumatic Compressors 62 305 258 65 20 21 23 26 34 41 47 49 SIA 51H 56 57 Key fig 4 Compressor Suction element Air filter Oil filter Minimum pressure valve Ventilator Thermostat valve Oil separator Air cooler Oil cooler Main motor Tank 01 2008 Page 11 Section 5 Options A Level detection bleed valve Fig 6 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
33. oss of power supply phase cuts blown fuses voltage threshold lower than 130 volts protecting the machine motor and especially the compression assembly when restarting it following electrical work on the power supply line or when switching from the mains supply to a backup power supply such as a power generator 3 Operation In the event of a phase failure detectable by this option or an incorrect rotation direction the trip switch sets off the machine s safety system preventing immediate stopping and starting of the machine and shows the following message on the display of the electronic plate ventilation flaw 4 Features scanning time measurement cycle lt 80 ms minimum operating voltage 200 volts maximum acceptable voltage between phases 600 volts power consumption 15 VA Chicago Pneumatic Compressors 62 305 258 65 G Centrifugal separator See B Section 3 Fig 13 1 Description This device allows bleeding of the condensates formed in the air cooler 2 Description of the option The cooling of the compressed air allows the suction air to be dried thus removing the humidity that collects in the bottom of the separator after being condensed in the aftercooler The condensates are evacuated from the separator through a trap with a solenoid drip valve or a trap with level detector if this option is installed Chicago Pneumatic Compressors 62 305 258 65 01 2008 Page 15 Section 6 Speci
34. ssure to be maintained in the oil circuit This pressure is shown by the pressure gauge situated in the tank see Notice AIRLOGIC E Section 1 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 e 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 e 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 the next oil change and the next oil filter change see the AIRLOGIC Manual E Section 1 e Reseal the filler cap when replacing it and check that all openings are properly closed e 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 Chicago Pneumatic Compressors 62 305 258 65 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 During rinsing leave the old oil filter cartridge in the machine B Air filter see B Section 1 The air filter is of the dry encapsulated type
35. st be taken so as not to damage the unit s cowling B Room The CPVS is designed to operate in a frost free environment supplied with air at a temperature of no more than 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 purposes It is very important for the compressor to have an abundant supply of fresh air see page 2 If operating the compressor causes the ambient temperature to rise above 104 F the warm air leaving the radiator must be discharge outside COMMENT When the atmosphere is contaminated by organic or mineral dust or by corrosive chemical emanations the following precautions must be taken 1 Provide another air inlet as close as possible to the compressor suction 2 Use an additional filter see options Section 5 on the machine s ventilation intakes Installation with heat dispersion sleeve If the operation of the compressor increases the ambient temperature above 104 F it is necessary to discharge the hot air leaving the radiator to the exterior by means of the sleeve Prevailing wind d SI Ventilation Duct minimum cross section flow rate d lt L lt 1 6d cfm sqf CVS 50 CPVS 00 CPVS 75 01 2008 Page 8 lt Prevailing wind gt Flexible fitting Fig 2b Sleeve with an elbow V maxi 18 04 ft s Ratio of volume
36. ted with a compensating device Proportional integral control PI fig 14c 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 01 2008 Page 17 Fig 14a The principle of the pressure regulation by variable speed Pressure Controller Drive required E ainvomie 1 Pressure regulation for low rates of flow For an air consumption rate lower than the minimum rate of flow for the machine 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 conti nues to run and compress at the minimum speed until the pres sure reaches the limit called Indirect shutdown Once this threshold has been reached the motor will stop the machine will go into stand by mode after a certain period of inactivity and the full drainage process will be carried out The pressure then drops towards the indicated pressure and at the end of the minimum time delay since reaching the no load pres sure the driv
37. the mains the A 2 The I O control terminals are insulated from the mains the relay outputs can nevertheless be under power A 3 even if the inverter is disconnected This also applies to other I O control terminals even if the X4 switch is in OFF position Stop 01 2008 Page 16 The inverter has a load circuit of thermally limited capacitors Therefore it is important to allow minimum A 4 5 minutes between two successive power ons If this instruction is not respected the switch and the resistor of the load circuit may be damaged 2 Safety instructions A No connection work is allowed when the inverter is 1 under power AN No measurement work is allowed on the inverter when 2 it is under power To undertake any work on the inverter it is necessary to disconnect the equipment from the mains Wait for AN the internal ventilation to stop and the indicators to be 3 turned off Then wait 5 minutes before opening the cover A No voltage or insulation verification test is allowed on 4 the inverter components A Disconnect the cables from the motor and the inverter S before taking measurements on them A Do not touch the integrated circuits the electrostatic 6 discharges may damage them AN Before connecting the inverter make sure that its cover 7 is properly closed Make sure that no compensation capacitor of cosine 8 phiis connected to the motor cable C Installation The CPVS must be installed away
38. tration 90 of the dust emitted is filtered Total nominal flow 324893 cfin h Filter panel number 2 Initial charge loss 75 Pa Dimensions Width 24 in Length 24 in Thickness 7 9 in 01 2008 Page 13 D Automatic restarting 1 Description This management system enables the compressor to be restarted automatically after a power outage 2 Option overview Not available in standard version in order to prevent any incident during maintenance operations carried out by an untrained person This option 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 250 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 outage and thus avoids the time lapse required for manual compressor restarting that would mean a fall in pres sure 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 THIS OPERATION REQUIRES THE CONFIGURATION OFMENUS 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 O
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