Chicago Pneumatic Air Compressor CPVS 40 User Manual

Instruction Manual  
EN  
CP COMPRESSOR  
Model CPVS 40 - 50 - 60 - 75  
62 305 258 65 ed00  
CPVS 50  
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CPVS Model  
(hp)  
40  
50  
60  
75  
Motor power  
40  
50  
60  
75  
Main Voltage 460 Volt / 3 / 60 Hz  
Nominal current  
Power supply cable  
Fuse protection  
(A)  
69  
AWG 4  
80  
81  
AWG 3  
100  
89  
AWG 1  
125  
125  
AWG 0  
150  
(Type RK5)  
Connection of the electric plate to an external control box  
• Install an RC filter on the KM1 coil.  
• Install an RC filter on the KM2 coil.  
• All connections between external parts and the compressor must be carried out using a shielded cable, which must be grounded at one of its  
ends.  
WARNING: the operation connection cables between the different elements must never follow the same path as the existing 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 : CPVS Model 40-50-60-75 ......................................................................................... 5  
Section 1 - Description .................................................................................................................................................................................. 6  
A - General Information...................................................................................................................................................................... 6  
B - Respect of the environment and prevention of pollution ............................................................................................................. 6  
C - Standard equipment ...................................................................................................................................................................... 6  
D - Definition of the pictograms ........................................................................................................................................................ 7  
E - Electronic board ............................................................................................................................................................................ 7  
Section 2 - Installation................................................................................................................................................................................... 8  
A - Handling ....................................................................................................................................................................................... 8  
B - Room ............................................................................................................................................................................................ 8  
C - Assembly....................................................................................................................................................................................... 8  
D - Air discharge piping ..................................................................................................................................................................... 8  
E - Condensate drain pipes ................................................................................................................................................................. 8  
F - Electric cabling ............................................................................................................................................................................. 9  
Section 3 - Implementation ......................................................................................................................................................................... 10  
A - Preparation for start-up ............................................................................................................................................................... 10  
B - First start-up ............................................................................................................................................................................... 10  
C -Discharge pressure adjustment .................................................................................................................................................... 10  
D - Parallel compressor assembly..................................................................................................................................................... 10  
E - Safety .......................................................................................................................................................................................... 10  
Section 4 - Operation................................................................................................................................................................................... 11  
A - Air and oil circuits ...................................................................................................................................................................... 11  
Section 5 - Options....................................................................................................................................................................................... 12  
A - Level detection bleed valve ........................................................................................................................................................ 12  
B - Advanced filtration to the compression air inlet......................................................................................................................... 12  
C - Pre-filtration panels .................................................................................................................................................................... 13  
D - Automatic restarting ................................................................................................................................................................... 14  
E - Remote starting and stopping ..................................................................................................................................................... 14  
F - Rotation direction indicator - Phase controller ........................................................................................................................... 14  
G - Centrifugal separator .................................................................................................................................................................. 15  
Section 6 - Specific information for CPVS 40-50-60-75 ........................................................................................................................... 16  
A - Description ................................................................................................................................................................................. 16  
B - Safety .......................................................................................................................................................................................... 16  
C - Installation .................................................................................................................................................................................. 16  
D - Commissioning........................................................................................................................................................................... 17  
E - Operating incidents ..................................................................................................................................................................... 19  
Section 7 - Maintenance .............................................................................................................................................................................. 20  
A - Oil level and change ................................................................................................................................................................... 21  
B - Air filter ...................................................................................................................................................................................... 21  
C - Turbine........................................................................................................................................................................................ 21  
D - Oil and air cooler ........................................................................................................................................................................ 22  
E - Oil separator................................................................................................................................................................................ 22  
F - Oil return pipe ............................................................................................................................................................................. 22  
G - Draining condensation water ...................................................................................................................................................... 22  
H - Temperature safety tests ............................................................................................................................................................. 22  
I - Refastening electric connections.................................................................................................................................................. 22  
J - Decommissioning the compressor at the end of its useful life .................................................................................................... 22  
Section 8 - Operating incidents .................................................................................................................................................................. 23  
A - Main incidents ............................................................................................................................................................................ 23  
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Space requirement and installation diagram : CPVS Model 40-50-60-75  
(see page 2 - installation instructions)  
Fig. 1  
75  
Air outlet  
Air outlet  
Air inlet  
3.9  
1"1/2 NPT  
AIR DELIVERY  
2
Air inlet  
1/4" NPT  
Drain  
16  
7.6  
25.8  
7.6  
37.4  
66.5  
66.5  
A
* : POWER SUPPLY  
*
dia. 2.2  
24.9  
Air outlet  
23  
29.3  
16  
16  
Type  
A
CPVS 40  
14.7  
19.6  
27  
CPVS 50  
CPVS 60-75  
Dimensions (in)  
R10.6  
18.7  
Air inlet without deflector  
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Section 1 - Description  
- Safety devices:  
A - General Information  
1. A safety valve mounted on the oil reservoir.  
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.  
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.  
The compression element is a single-stage, oil-refrigerated, ro-  
tary screw compressor. The oil is stored in a vertical tank, which  
is fitted with an oil separator.  
- 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.  
The compression element and the motor are fixed to the frame  
using silent blocks.  
2. Automatic draining allowing the unit to be exposed to the  
atmosphere when stopping to thus ensure empty start up  
which relieves the motor,  
B - Respect of the environment and  
prevention of pollution  
3. An oil level gauge on the front panel ( see fig. 19).  
4. An electronic controller including:  
1 - Maintenance of the machine  
a control keyboard,  
the main safety and control indications.  
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.  
5. The pressure sensor ensures control over the compressed  
air flow.  
2 - Condensate bleed pipe  
The CP compressed air unit has been designed, produced and  
tested in accordance with the following recommendations, codes  
and standards :  
Make sure that the condensates (water, oil) are drained and treated  
according to national and local regulations.  
- machine safety : European Directive 98/37/CE, 91/368/CEE and  
93/68/CEE.  
3 - End of life of the machine  
- pressure vessels: European Directive for simple pressure vessels  
n° 87/404/CEE.  
- electrical equipment :  
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 ).  
electrical equipment : European Directive Low tension  
73/23/CEE.  
electromagnetic compatibility European Directive: 89/336/CEE,  
92/31/CEE.  
C - Standard equipment  
In its standard version, the covered unit includes:  
- performance levels: ISO 1217 : 1996.  
- noise level : ISO 2157 + 3db(A)  
- European Directive 97/23/EC  
- Operating components:  
1. A twinned screw-type compressor.  
" Pressure Equipment Directive ".  
2. An electric motor: 3600 rpm, short-circuit rotor, 230/460V  
or 575V voltage according to the model.  
3. Star delta starting.  
4. A direct drive or gearbox drive .  
5. Air and oil tank in compliance with applicable legislation  
ASME  
6. "All or nothing" regulation for the aspiration vent.  
7. A greasing system using the circuit's differential pressure,  
thus avoiding the need for an oil pump.  
8. An oil separator based oil separation system.  
9. A heat discharge system : oil and compressed air radiator  
with forced ventilation.  
10. A dry air filter.  
11. An oil filter.  
12. A command and control electronic board.  
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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  
DANGER  
This symbol identifies immediate hazards which will  
result in severe personal injury, death or substantial  
property damage.  
CAUTION  
Identifies hazards or unsafe practies which could  
result in minor personal injury or property damage.  
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  
This symbol identifies hot surfaces which coold  
result in personal injury or property damage.  
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  
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Section 2 - Installation  
Prevailing wind  
Flexible fitting  
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 must be taken so as not to  
damage the unit's cowling.  
L
V
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).  
Compressor  
Fig. 2b - Sleeve with an elbow  
V maxi = 18.04 ft/s  
If operating the compressor causes the ambient temperature to  
rise above 104 °F, the warm air leaving the radiator must be  
discharge outside.  
(Ratio of volume flow rate of the ventilation to the sleeve  
cross section)  
L maxi = 32.8 ft (without mechanical extractor)  
COMMENT  
Cross section of room air inlet > 2 x Duct outlet cross section  
When the atmosphere is contaminated by organic or mineral dust or  
by corrosive chemical emanations the following precautions must be  
taken:  
2 elbows accepted with large radius of curve and fluid  
guidance vanes  
Ratio (Length/Width of sleeve) maxi = 1.6  
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.  
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.  
Installation with heat dispersion sleeve  
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.  
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.  
C - Assembly  
Prevailing wind  
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).  
V
L
Flexible fitting  
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.  
Compressor  
Fig. 2a - Sleeve with roof outlet  
E - Condensate drain pipes  
d
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)  
Ventilation Duct minimum cross section  
flow rate  
cfm  
( d L 1,6d )  
sqf  
CPVS 40  
CPVS 50  
CPVS 60  
CPVS 75  
2860  
2860  
3920  
5300  
2.6  
2.6  
3.6  
4.9  
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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  
40  
50  
60  
75  
AWG4  
AWG3  
AGW1  
AWG0  
SAFETY REGULATIONS  
It should be remembered that safety regulations require :  
• An earth socket to be used.  
• A manual isolating switch, cutting all three phases ; this switch  
must be clearly visible near the 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  
the isolating switch (RK5 type)  
CPVS Model  
460 V  
40  
50  
60  
75  
80  
100  
125  
150  
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Section 3 - Implementation  
A - Preparation for start-up  
B - First start-up  
Check the voltage between the three phases before using the unit  
for the first time.  
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.  
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.  
IMPORTANT  
Before start up, make sure that transport red wedges have been  
effectively removed.  
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).  
ATTENTION  
The power circuit must be turned whenever adjusting electrical  
equipment or to prevent accidental starting.  
1 - Press the ON button, the motor starts up.  
Loosening of electrical power cables that may be due to vibrations  
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  
and triangle before use.  
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.  
Before start-up, check the following points :  
C -Discharge pressure adjustment  
1 - Make sure that the unit is properly grounded.  
2 - Check the oil level in the tank.  
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).  
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.  
D - Parallel compressor assembly  
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).  
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 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.  
1
Fig. 3  
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Section 4 - Operation  
A - Air and oil circuits  
Key fig. 4  
20  
Compressor  
1 - Air circuits (see Fig. 4)  
21  
Suction element  
Air filter  
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.  
23  
26  
Oil filter  
34  
Minimum pressure valve  
Ventilator  
41  
47  
Thermostat valve  
Oil separator  
Air cooler  
49  
2 - Oil circuit (see Fig. 4)  
51 A  
51 H  
56  
Oil cooler  
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 in the air as mist. This mist passes through the oil separator.  
(rep. 49). The remaining oil, which is separated by the last stage of the  
oil separator, is drawn up by a dip tube and dispatched to the  
compressor.  
Main motor  
Tank  
57  
Fig. 4 - Air / oil circuit  
34  
26  
47  
49  
57  
21  
23  
56  
51A  
51H  
20  
41  
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Section 5 - Options  
2 - Option overview  
A - Level detection bleed valve (Fig. 6)  
- This option is used as a replacement for the standard filter  
1 - Description  
- 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 BEKOMAT type level detection bleed valve allows all air  
consumption to be avoided while the compressor is not running.  
- The quality of the air intake by a compressor is essential. Low  
quality air creates the following :  
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.Alow level of condensation is  
also detected in order to close the electric bleed valve and to prevent  
compressed air from being wasted.  
• 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,...  
- 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.  
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.  
- Condensate treatment is made easier because it is not evacuated by  
pressure, which enables easy separation of the water and oil stages.  
- 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).  
Fig. 6  
Extraction duct  
1
2
3
4
VORTEX pre-filter  
5
6
Air filter  
1 - Condensation intake  
2 - Capacitive sensor  
3 - Receiver  
4 - Main duct  
5 - Electric valve  
6 - Membrane  
x
y
x
y
3 - Technical features  
CPVS 40-50-60  
CPVS 75  
71 in  
71 in  
11.2 in  
13.6 in  
Maximum capacity of the compressor : 706 cfm/min  
Working pressure  
Operating pressure  
Electric power supply  
: 11.6 / 232 PSI  
: 33.8 / + 140°F  
: 115V / 24V  
Fig. 7a  
AC socket in the compressor electric cabinet.  
Cartridge  
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.  
Fig. 7b  
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3 - Technical features  
Operating temperature :  
-104 °F to + 194 °F  
• 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.  
C - Pre-filtration panels  
Fig. 8  
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  
Easy to disassemble for rapid cleaning  
Fig. 9  
Pre-ventilation lock  
2 pannels  
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).  
15.75 in  
2 - Option overview  
Disassembly hinges  
The pre-filtration panels eliminate 90% of the particles normally  
admitted inside the compressor and considerably decrease internal  
contamination of the machine.  
3 - Technical features  
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.  
FILTER MEDIUM :  
Degree of filtration : 90% of the dust emitted is filtered.  
Total nominal flow :  
Filter panel number :  
Initial charge loss :  
324893 cfm/h  
2
75 Pa  
24 in  
24 in  
Dimensions :  
Width :  
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.  
• Increased pollution of the air and oil filtering components that  
increases the deterioration of the mechanical components in the  
compressor, screw block, ...  
Length :  
Thickness :  
7.9 in  
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D -Automatic restarting  
F - Rotation direction indicator -  
Phase controller  
1 - Description  
1 - Description  
This management system enables the compressor to be restarted  
automatically after a power outage.  
The phase controller option is designed to:  
2 - Option overview  
- control the rotation direction of the machine's electric power  
supply phases.  
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.  
- check that electric power is supplied to each phase.  
These two functions are permanently guaranteed.  
2 - Option overview  
The standard microcut time accepted by AIRLOGIC is  
approximately : 250 ms.  
The advantages of this option are:  
However, certain electrical fittings create longer micro cut-offs  
that will cause a compressor shut down, then a manual restart.  
- 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.  
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.  
- protecting the motor and the electrical fittings from any loss of  
power supply (phase cuts, blown fuses, voltage threshold lower  
than 130 volts).  
Particularly used for industries where air production should not  
be subject to shut downs that waste the products manufactured  
or damage the production equipment.  
- 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.  
THISOPERATIONREQUIRESTHECONFIGURATION  
OFMENUSINTHECONTROLLER,ACCESS  
RESTRICTED TO TECHNICIANS CERTIFIED BY  
CHICAGO PNEUMATIC COMPRESSORS.  
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".  
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.  
4 - Features  
scanning time / measurement cycle  
minimum operating voltage  
< 80 ms  
200 volts  
3 - Technical features  
maximum acceptable voltage between phases 600 volts  
power consumption  
15 VA  
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)  
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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.  
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Section 6 - Specific information for CPVS 40-50-60-75  
Refer also to the chapters concerning the standard machine.  
The inverter has a load circuit of thermally limited  
capacitors. Therefore, it is important to allow minimum  
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.  
"CPVS" compressors are compliant with the Electromagnetic  
compatibility in industrial environments Standards 50081-2 and  
50082-2  
4
2 - Safety instructions  
A - Description (cf Section 1)  
No connection work is allowed when the inverter is  
under power.  
Standard equipment  
1
2
A electronic frequency adjusting device replaces the star-delta  
starter.  
A fuse holder section switch completes CP standard's safety  
devices.  
No measurement work is allowed on the inverter when  
it is under power.  
To undertake any work on the inverter, it is necessary  
to disconnect the equipment from the mains. Wait for  
the internal ventilation to stop and the indicators to be  
turned off. Then, wait 5 minutes before opening the  
cover.  
B - Safety  
3
For your safety, please respect the instructions carrying the warning  
symbols as given below:  
No voltage or insulation verification test is allowed on  
the inverter components.  
SAFETY RULES  
4
5
The safety rules require:  
Disconnect the cables from the motor and the inverter  
before taking measurements on them.  
The presence of an earth socket  
The existence of a manual switch cutting-off the three pha-  
ses that should be placed visibly near the CP  
It is necessary to cut out the electric current before any  
intervention on the machine (except drainage under pres-  
sure).  
Do not touch the integrated circuits, the electrostatic  
discharges may damage them.  
6
7
8
Before connecting the inverter, make sure that its cover  
is properly closed.  
= Dangerous voltage  
= Attention  
Make sure that no compensation capacitor of cosine  
phi is connected to the motor cable.  
C - Installation  
ELECTRICALINSTALLATIONS MUST ONLYBE  
CARRIED OUT BY A SPECIALISED AND COMPETENT  
TECHNICIANS  
The "CPVS" must be installed away from a transformer or  
autotransformer.  
(see Section 2 and 3).  
1 - Warning  
The fuses for the section switch are defined as follows  
Main Voltage 460 Volt / 3 / 60 Hz  
The internal components and the plates (except the  
electrically insulated I/O terminals) are at the mains  
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.  
1
40  
69  
50  
81  
60  
100  
75  
126  
Nominal current (A)  
Power supply cable  
AWG4 AWG3 AWG1 AWG0  
Fuse protection (Type RK5) 80  
100  
125  
150  
When the inverter is connected to the mains, the  
connection terminals U, V, W of the motor as well as  
2
ATTENTION  
+/- connectors of the braking resistors are under power  
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.  
even if the motor is not running.  
The I/O control terminals are insulated from the mains,  
the relay outputs can nevertheless be under power  
even if the inverter is disconnected. This also applies  
to other I/O control terminals even if the X4 switch is  
3
in OFF position (Stop).  
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D - Commissioning  
1 - Preparation for start-up  
4 - Assembly and settings for parallel operation  
with other compressors  
(See Section 3).  
Pressure for the CPVS compressor must be adjusted at a value  
within the range of adjustment values for the rest of the  
compressors..  
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,  
Adjustments pressure  
Stop P  
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.  
Set  
point 1  
Various  
compressors  
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.  
CPVS  
C1  
C2  
C3  
5 - Regulating the pressure by changing the speed  
2 - Control of rotation direction on start up  
This method of regulating the pressure allows precise adjustment  
of the compressor's flow-rate at the compressed air demand valve:  
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.  
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.  
IMPORTANT :  
• The principle of the pressure regulation by changing the  
speed  
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.  
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).  
When rotating in the right direction, the oil level (fig. 19) must  
drop after 4 to 5 seconds of operation.  
- If the mains pressure is weaker than the pressure set point  
Also check the direction of rotation of the fan for air-cooled  
plants (counter-clockwise, as seen from inside the casing).  
(user-defined parameter in the AIRLOGIC) the motor will  
accelerate and the pressure will increase (fig. 14b)  
1 - Press the START button so that the motor starts.  
- If the mains pressure is stronger than the pressure set point, the  
motor will slow down causing the pressure to drop.  
2 - Allow to rotate for several seconds with the discharge valve  
slightly open to observe the compressor at load.  
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. 14c).  
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 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.  
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.  
At the same time, the motor control method known as "open loop  
vector flux control " provides good stability for the system against  
disruption.  
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).  
In this way, the pressure feedback loop is more stable to sudden  
changes in consumption (changes in the flow-rate).  
Do not set the stop pressure at a level beyond the machine's max P.  
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Fig. 14a  
The principle of the pressure regulation by variable speed  
Motor  
Compressor  
unit  
Tank  
Drive  
Pressure  
required  
Controller  
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 the machine, the pressure is adjusted by the machine's time-  
delayed START/STOP controls.  
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.  
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 ".  
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.  
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 drive allows the motor to restart. The pressure then  
rises again and the cycle starts over (fig. 14 d).  
COMMENT :  
Energy savings are increased if machine maintenance is carried out  
in accordance with the maintenance instructions and frequency.  
To avoid pumping the system - frequent stop / start - drainage  
time may be increased  
(cf. notice AIRLOGIC).  
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Fig. 14b  
Fig. 14c  
Fig. 14d  
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 - E Section 1).  
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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 Every  
Daily Every Every  
500 hr 150 hr 2 000 hr (*) 4 000 hr 6 000 hr  
Every  
8 000 hr  
Every  
12 000 hr  
Service C  
Parts  
Observations  
Service A  
Service B  
Drain the condensates  
from the cold oil circuit  
(Section 8 - G)  
Draining cock  
X
X
Check and top up if  
necessary  
(Section 8 - A)  
Oil level  
Air filter  
X
Replace the filter  
Oil tank,  
Oil change  
Oil change, oil refill  
with recommended oil  
(Section 8 - A)  
X
X
Control  
cleaning  
lubrication  
Renovation of the  
Overhaul kit housing. Use the  
suction housing kit  
Suction housing  
Oil return pipe  
Check the cleanliness of  
Overhaul the oil return pipe and  
Kits  
the state of the seal  
(Section 8 - F)  
Change the part  
Oil separator  
Oil filter  
X
according to the  
instrument panel indication  
(Section 8 - E)  
X
X
Filter change  
Oil radiator  
Final coolant  
Blowing of cooling  
elements  
X
Cleaning (Section 8 - D)  
Control  
cleaning  
lubrication  
Exchange the accessories  
supplied with the  
maintenance kit  
Valve at minimum  
pressure  
Overhaul  
kits  
For motors fitted with  
grease, use  
Type ESSO  
UNIREX N3 (0.53 ocs  
per grease fitting)  
Motor for  
CPVS  
40-50-60-75  
X
X
X
Electric cabinet  
X
Retighten power cable  
connections.  
Safety temperature  
test  
Check operation  
(Section 8 - H)  
NOTE : maintenance kits are available (see spare parts list).  
(*) or at least every year  
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 :  
• With a manual drain, drain regularly according to the moisture content of the ambient air.  
• With an automatic drain, set the draining cycle accordingly and check that the drain is in good working condition.  
This recommendation is also fundamental in a circuit comprising an absorption dryer (risk of saturation of the alumina).  
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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 :  
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.  
- viscosity: 40 cSt at 104 °F  
- viscosity index: 90 minimum  
- antioxidant additives  
- anti-rust additives  
- anti-foam additives  
B - Air filter  
THE FIRST OIL CHANGE MUST BE CARRIED OUT  
AFTER THE FIRST 500 HOURS OPERATION.  
(see B Section 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 plate for resetting the time).  
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 ).  
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.  
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.  
Fig. 19 - Oil level  
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.  
Filler plug  
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.  
Oil level  
CHECKING THE OIL LEVEL MUST BE CARRIED OUT  
JUSTAFTER STOPPINGTHE 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 pressure 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).  
Drainage  
C - Turbine  
Proceed as follows :  
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.  
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.  
When there is no pressure left in the oil tank, change the oil filter  
cartridge.  
As soon as the oil is no longer flowing, close the valve and refill  
with new oil.  
Reinitialise the timers that will warn you when to carry out the  
next oil change and the next oil filter change  
(see the AIRLOGIC Manual - E Section 1),  
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.  
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D - Oil and air cooler  
Fig. 20 - Oil return pipe  
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.  
64  
- 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 located.  
G - Draining condensation water  
(see B Section 1)  
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).  
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.  
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.  
To do this :  
Excessive oil consumption  
- Slowly open the oil change tap and let the water escape.  
- When the oil appears, close the valve immediately to avoid any  
loss.  
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.  
- Refill with oil if necessary.  
The unit must first be checked to make sure that there is no oil  
loss and that the oil return is working properly.  
H - Temperature safety tests  
(See instructions electronic board).  
Changing the oil separator  
IF THE SENSOR IS NOT WORKING, IT MUST BE  
CHANGED.  
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.  
I - Refastening electric connections  
- 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.  
A loosening of the electric power cables leads to the contactors  
ove-rheating which can lead to their destruction.  
- The new oil separator is delivered with its two seals on either  
side of the flange.  
Periodic refastening is therefore necessary at the star and triangle  
line contactor arrivals and departures. (see Maintenance Table).  
- Slight undulations in the flange will flatten out when the screws  
are tightened.  
- Apply a 6 mkg torque.  
All electric power supply to the machine must be cut off before  
opening the electric cabinet.  
- Replace the oil return tube correctly so it touches the bottom of  
the oil separator.  
J - Decommissioning the compressor at  
the end of its useful life (see B Section 1)  
F - Oil return pipe (see fig. 20)  
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.  
Placed under the compressor  
• Dismantle the body of the anti-oil return pipe.  
• Lift the anti-oil return pipe.  
• Check the state of the o-ring (rep. 64).  
• Reassemble.  
5. Empty the circuits of oil and condensates.  
6. Disconnect the compressor condensate piping from the  
condensate draining system.  
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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  
Possible causes  
Solutions  
1. THE COMPRESSOR DOES NOT  
START  
a) Main switch open.  
b) Phase missing.  
a) Close the switch.  
b) Check the circuits.  
c) Fuse.  
c) Replace.  
d) Insufficient voltage at motor terminals.  
e) Compressor under pressure.  
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.  
2. THE COMPRESSOR  
OVERHEATS  
a) Ambient temperature too high.  
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.  
b) Obstruction of the passage of cooling  
through the oil radiator.  
c) Oil level too low.  
d) Oil circuit blocked.  
d) Check that the oil filter is clean. Drain.  
Replace the cartridge. Check the tightness  
of connections.  
3. THE COMPRESSOR STOPS WHEN  
THE MOTOR PROTECTION  
UNIT TRIPS  
a) Compressor motor overload.  
a) Check it is connected and the electric  
connections are tight. Check the pressure  
of the compressed air and the pressure  
switch settings.  
4. OPENING OF SAFETY VALVE  
a) To clean de-oiling cartridge.  
b) Valve of suction box out of use or  
not closed.  
a) Change the de-oiling cartridge.  
b) Check valve, piston and joints of suction  
box.  
c) Faulty pressure switch, sensor  
or solenoid valve.  
d) Working pressure too high  
c) Check that the pressure switch and  
electrovalve and sensor pressure are in  
good working order.  
5. EXCESSIVE OIL CONSUMPTION  
6. DELIVERY PRESSURE TOO LOW  
a) Blocked oil retainer.  
b) Oil leaks in the CPVS compressor.  
c) Faulty oil separator element  
a) Check the oil return pipes.  
b) Look for oil leaks and rectify.  
c) Replace the de-oiling cartridge.  
(see Section 8-E)  
a) Incorrect pressure settings.  
b) The desired output is higher than that  
of the compressor.  
a) Adjust the pressure (see Section 3).  
b) Check consumption and possible leaks.  
c) Closed suction valve.  
c) Check electrovalve, pressure switch,  
d) Release nozzle incorrectly adjusted  
(progressive adjustment option).  
valve.  
d) Check setting.  
7. COMPRESSED AIR OUTPUT  
TOO LOW  
a) Blocked air filter.  
b) Adjusting electrovalve not working.  
a) Clean filter.  
b) Check setting.  
8. EXCESSIVE NOISE OF UNIT  
a) Fixing bolts of compressor or motor  
have come loose.  
a) Tighten.  
b) Soundproof panels incorrectly closed.  
c) Transport retainer blocks (red parts)  
not removed.  
b) Check that they are closed.  
c) Remove retainer blocks.  
9. THE COMPRESSOR STOPS  
UNTIMELY OR CREATES  
NON-EXISTING FAULTS  
a) Electromagnetic disturbance  
on the Airlogic controller.  
a) Add an interference suppression kit  
(contact the after sales department)  
01/2008  
Page 23  
Chicago Pneumatic Compressors  
62 305 258 65  
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support  
support@CPcompressor.com  
1 - 877 - 861 - CPAC  
CP Compressors  
1800 Overview Dr  
Rock Hill, SC 29730  
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