Chicago Pneumatic CPF Series User manual

Oil-injected rotary screw compressors
CPF 200-125 460/220V-60Hz - YD
People. Passion. Performance.
Instruction manual
BRY190070/UTO-1
BRY190156/ACA-1
CP

Compressor Instruction Manual
CPF-150, CPF-175, CPF-200
Visit us on: www.chicagopneumatic.com
No. 1093 1387 37 - Ed. 0101/2020
Copyright Statement
Any non-authorized use or copy of its contents or any part thereof is prohibited.
This refers especially to trademarks, model names, part numbers and data.
This manual is valid for compressors with serial number greater than BQD108496.

2
STORAGE, CONSERVATION AND TRANSPORT CONDITIONS
1. Introduction
The non-painted surface of all out-of-service compressors,
whether installed or waiting installation, is subject to oxidation
and corrosion.
The corrosion level ranges according to the environment
conditions (temperature, humidity etc.) and the care taken for
storing and conserving the unit.
Therefore, it is impossible to establish the period in which the
unit can be stored without rust damage.
The higher the humidity and the longer the stopping and/
or storage period, the more care must be taken. For CPF
compressors, in addition to the precautions for the compressor,
specic preventive measures should be taken for the electric
motor, according to the manufacturer’s instructions.
Compressors are not normally expected to be out of service or
stored for long periods, so they are shipped ready for storage
for a maximum of 75 days from the date of manufacture. After
that, the procedure described in 2 should be followed.
Should the compressor be out of service for more than one
week, follow the instructions in item 3.
2. Storage and conservation prior to
installation
1. Store the compressor in a clean, dry, well-ventilated
environment, free of dust and humidity.
2. The entire lower section of the compressor should stand
on a at, vibration-free oor.
3. Ensure that there is no water in the grate, plastic cover
or any part of the bodywork or base of the unit.
4. Remove the intake valve and ll the compressor unit
with the lubricating oils recommended by Chicago
Pneumatic (see note 1).
5. Reinsert the intake valve.
6. Rotate the coupling 10 turns once a month, to change
the position of the compressor element bearings balls
and rollers. In case there is no access to the motor shaft,
remove the rear motor cover for access through the
motor fan.
7. Should the compressor be stored for more than 6
months, the oil, oil lter and separator element should
be replaced. For engine, check engine manufacturer’s
instructions on material delivered (on CD) with
compressor. Pay attention to the engine resistance
connection, if any, to avoid inside the engine.
3. Conservation after installation
1. Run the unit at least twice a week, for a minimum of 30
minutes and operate the load/relief system a few times.
2. Stop the unit, close the outlet valve and open the
condensate drains (after the air cooler and condensate
separator manual). Ensure none of the drains is clogged.
3. Close the drains after 02 minutes.
NOTES:
1. This oil should be removed prior to the technical start-
up of the equipment, otherwise, a “hydrolock” could
form, causing irreparable damage to the compressor
unit.
2. This instruction does not provide for cases of aggressive
environment, which should be analyzed individually.
4. Movement and transport
If the unit is to be moved or transported, the original ttings
and guards must be reinstalled to immobilize the vibration
dampers and the engine and compressor assembly.
The compressor can be handled with a forklift using the
openings in the frame. The forklift must have capacity
suitable for the sizes and weight of the compressor. The
compressor may also be lifted by inserting beams into the
openings. Make sure that the beams are properly xed and
equally spaced on both sides of the frame. Ropes/chains must
be kept parallel to the bodywork by means of an expander,
not touching it in order not to damage the compressor. Lifting
equipment should be placed so that the compressor is raised
perpendicular, slightly and without twisting.

3
WARRANTIES
Chicago Pneumatic ensures to the Buyer free repair for products, its components or accessories, sold and manufactured by our
company that eventually present proven manufacturing defects, for the period and pursuant to the conditions indicated below,
provided that such defects do not result from improper use or by fault of the Buyer.
Warranty periods are counted from the date the invoice(s) are issued, considering:
a. for stationary or portable compressors: for eighteen (18) months after invoice issue or twelve (12) months after technical
delivery, whichever occurs rst, and twenty-four (24) months for the compressor.
b. for other equipment: for eighteen (18) months after invoice issue or twelve (12) months after technical delivery, whichever
occurs rst.
No repair, modication or replacement under the warranty will extend the terms indicated above, whether for the equipment or
for its replaced accessories or components.
Warranties provided for this instrument refer only to components manufactured at our facilities. Each manufacturer is solely
responsible for the warranties for parts, engines and accessories manufactured them.
Eectiveness of these warranties is conditioned to immediate written communication of the defect veried by the Buyer to
Chicago Pneumatic, and any intervention on the product or equipment by the Buyer or third parties must not be done, under
penalty of voiding the warranty.
Our products are coated according to ISO 12944 standard; our corrosion class is “C3 medium”.
Warranty will become void in case of:
a. stationary compressors installed or assembled by the Buyer without inspection and approval by Chicago Pneumatic;
except for CPM models.
b. lack of Technical Delivery by Chicago Pneumatic;
c. inappropriate or incorrect maintenance of equipment or products, including: (i) non-authorized modications; and (ii)
non-compliance with maintenance instructions provided by Chicago Pneumatic, poor or irregular lubrication;
d. use of non-original parts or accessories, or not approved by Chicago Pneumatic;
e. inappropriate or incorrect use of equipment or products;
f. work overload not been previously authorized in written by Chicago Pneumatic;
g. normal wear and tear of equipment or products;
h. damage arising from Act of God or force majeure, such those resulting from res, oods, depredation, strikes, rampage
or similar harmful actions, among others;
i. inappropriate transport, irregular or extended storage periods by the Buyer; and
j. the Buyer is in arrears or default of payments set in the Purchase and Sale Agreement.
No manufacturing defect shall be considered a fair reason for Buyer non-compliance with the obligations under this instrument
and included proposal.
Services related to these warranties will be performed in workshops previously authorized by Chicago Pneumatic; and the
Buyer is responsible for delivering and retrieving products at/from these locations, and for the respective transport and insurance
expenses. At Chicago Pneumatic’s sole discretion, the warranted services may be provided at the Buyer’s facilities. In such
case, all expenses related to mileage and air tickets, travel time, food and accommodation of technicians and/or mechanics shall
be borne by the Buyer.

4
CONTENTS
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety precautions during installation. . . . . . . . . . 5
1.3 Safety precautions during operation . . . . . . . . . . . 6
1.4 Safety precautions during maintenance or repair . 7
2 General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Regulating system. . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Special Features . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Graphic controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Icons used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Main screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Accessing menus. . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Input menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.7 Outputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8 Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.9 Selecting the control mode . . . . . . . . . . . . . . . . . 21
3.10 Service menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.11 Regulation menu . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.12 Event history menu . . . . . . . . . . . . . . . . . . . . . . . 24
3.13 Week timer menu . . . . . . . . . . . . . . . . . . . . . . . . 25
3.14 Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.15 Modication of general parameters . . . . . . . . . . 30
3.16 General Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.17 User Password Menu . . . . . . . . . . . . . . . . . . . . . 31
3.18 Access key Menu . . . . . . . . . . . . . . . . . . . . . . . . 31
3.19 Programmable Parameters . . . . . . . . . . . . . . . . . 32
3.20 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.21 During operation . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.22 Automatic restart. . . . . . . . . . . . . . . . . . . . . . . . . 35
3.23 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.24 Removal from service . . . . . . . . . . . . . . . . . . . . . 36
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Dimensional drawing . . . . . . . . . . . . . . . . . . . . . 37
4.2 Installation suggestions . . . . . . . . . . . . . . . . . . . 39
4.3 Electric Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Cable size, fuses and circuit breaker settings . . . 41
4.5 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Initial start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Display check . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.6 Manual load/relief. . . . . . . . . . . . . . . . . . . . . . . . 46
5.7 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.8 Removal from service . . . . . . . . . . . . . . . . . . . . . 47
5.9 Use of air tank. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.10 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . 47
5.10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . 47
5.10.2 Storage and conservation prior to
installation. . . . . . . . . . . . . . . . . . . . . . . . 47
5.10.3 Conservation after installation . . . . . . . . 48
5.10.4 Movement and transport . . . . . . . . . . . . . 48
6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1 Preventive maintenance program . . . . . . . . . . . . 48
6.2 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 Oil specications. . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3.1 Chicago Pneumatic ROTAIR Plus . . . . . 51
6.3.2 Chicago Pneumatic CP-46 . . . . . . . . . . . 51
6.3.3 CP-46 F. . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3.4 Oil lter change. . . . . . . . . . . . . . . . . . . . 51
6.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.5 Storage after installation . . . . . . . . . . . . . . . . . . . 52
6.6 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7 Filter disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.8 Safety valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 53
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9 Instructions for using the air-oil separator vessel . . 56
10 Environmental information . . . . . . . . . . . . . . . . . . . . 57

5
1 Safety precautions
1.1 Safety icons
Explanation
Life-threatening
Warning
Important note
1.2 Safety precautions during installation
All responsibility for any damage or injury resulting
from neglecting these precautions, or non-observance
of the normal caution and care required for
installation, operation, maintenance and repair, even
if not expressly stated, will be disclaimed by Chicago
Pneumatic.
General precautions
1. The operator must employ safe working practices
and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with
the applicable legislation, the stricter of the two shall
apply.
3. Installation, operation, maintenance and repair work
must only be performed by authorized, trained and
specialized technicians.
4. The compressor is not considered capable of producing
breathable air. To obtain breathable air, the compressed
air must be adequately puried according to the
applicable legislation and standards.
5. Before any maintenance, repair, adjustment or any
other non-routine checks, stop the compressor, press
the emergency stop button, switch o the power and
depressurize the compressor. In addition, the isolating
switch must be opened and locked.
6. Never play with compressed air. Do not apply air to
your skin or direct an air stream at people. Never use
air to clean dirt from your clothes. When using the air to
clean equipment, do so with extreme caution and wear
eye protection.
7. The owner is responsible for maintaining the unit in
safe operating condition. Parts and accessories shall be
replaced if unsuitable for safe operation.
Precautions during installation
1. The machine must only be lifted using suitable
equipment and in accordance with applicable safety
regulations. Loose or pivoting parts must be securely
fastened before lifting. It is strictly forbidden to dwell
or stay in the risk zone under a lifted load. Lifting
acceleration and deceleration must be kept within safe
limits. Wear a safety helmet when working in the area of
overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and
clean as possible. If necessary, install a suction duct.
Never obstruct the air inlet. Care must be taken to
minimize the entry of moisture at the inlet air.
3. Any blanking anges, plugs, caps and desiccant bags
must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the
working pressure. Never use frayed, damaged or worn
hoses. The distribution pipes and connections must have
proper size and be suitable for the working pressure.
5. The aspirated air must be free of ammable fumes,
vapors or particles, such as solvents, that can lead to
internal re or explosion.
6. Arrange the air intake so that loose clothing worn cannot
be sucked in.
7. Ensure that the discharge pipe from the compressor to
the aftercooler or the air net is free to expand under heat
and that it is not in contact with or close to ammable
materials.
8. No external force can be exerted on the air outlet valve;
the connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a
clear sign stating: DANGER: This machine is remotely
controlled and may start without warning. The operator
has to make sure that the machine is stopped and that
the isolating switch is open and locked before any
maintenance or repair. As a further safeguard, persons
switching on remotely controlled machines shall take
adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a
suitable notice shall be axed to the start equipment.
10. Air-cooled machines must be installed in such a way
that an adequate ow of cooling air is available and that
the exhausted air does not recirculate to the compressor
or cooling air inlet.

6
11. The electrical connections must correspond to the
applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A
lockable power isolating switch must be installed near
the compressor.
12. On machines with automatic start/stop system or if
the automatic restart function after power failure is
activated, a sign stating “This machine may start without
warning” must be axed near the instrument panel.
13. In multiple compressor systems, manual valves must be
installed to isolate each compressor. Non-return valves
(check valves) must not be relied upon for isolating
pressure systems.
14. Never remove or tamper with the safety devices, guards
or insulation tted on the machine. Every vessel or
auxiliary installed outside the machine to contain air
above atmospheric pressure must be protected by a
pressure relieving device or devices as required.
15. Piping and other parts with a temperature above 80 °C
(176 °F) that may be accidentally touched in normal
operation must be guarded or insulated. Other high
temperature piping must be clearly marked.
16. For water-cooled machines, the cooling water system
installed outside the machine has to be protected by
a safety device with set pressure according to the
maximum cooling water inlet pressure.
17. If the ground is not level or can be subject to variable
inclination, consult the manufacturer.
Also consult following safety precautions: Safety
precautions during operation and Safety precautions
during maintenance.
These precautions apply to machines processing or
consuming air or inert gas. Processing of any other
gas requires additional safety precautions typical to
the application not included herein.
Some precautions are general and cover several
machine types and equipment; hence, some statements
may not apply to your machine.
1.3 Safety precautions during operation
All responsibility for any damage or injury resulting
from neglecting these precautions, or non-observance
of the normal caution and care required for installation,
operation, maintenance and repair, even if not expressly
stated, will be disclaimed by the manufacturer.
General precautions
1. The operator must employ safe working practices
and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with
the applicable legislation, the stricter of the two shall
apply.
3. Installation, operation, maintenance and repair work
must only be performed by authorized, trained and
specialized technicians.
4. The compressor is not considered capable of producing
breathable air. To obtain breathable air, the compressed
air must be adequately puried according to the
applicable legislation and standards.
5. Before any maintenance, repair, adjustment or any
other non-routine checks, stop the compressor, press
the emergency stop button, switch o the power and
depressurize the compressor. In addition, the isolating
switch must be opened and locked.
6. Never play with compressed air. Do not apply
air to your skin or direct an air stream at people.
Never use air to clean dirt from your clothes. When
using the air to clean equipment, do so with extreme
caution and wear eye protection.
Precautions during operation
1. Use only the correct type and size of hose end ttings
and connections. When blowing through a hose or air
line, ensure that the open end is held securely. A free end
will whip and may cause injury. Make sure that a hose is
fully depressurized before disconnecting it.
2. Persons switching on remotely controlled machines
shall take adequate precautions to ensure that there is
no one checking or working on the machine. To this
end, a suitable notice shall be axed to the remote start
equipment.
3. Never operate the machine when there is a possibility of
taking in ammable or toxic fumes, vapors or particles.
4. Never operate the machine below or in excess of its
limit ratings.
5. Keep all bodywork doors shut during operation. The
doors may be opened for short periods only, e.g., to
carry out routine checks. Wear ear protectors when
opening a door.
6. People staying in environments or rooms where the
sound pressure level reaches or exceeds 90 dB(A) shall
wear ear protectors.
7. Periodically check that:
•All guards are in place and securely fastened
•All hoses and/or pipes inside the machine are in good
condition, secure and not rubbing
•There are no leaks
•All fasteners are tight
•All electrical leads are secure and in good order
•Safety valves and other pressure relief devices are
not obstructed by dirt or paint
•Air outlet valve and air net, i.e., pipes, couplings,
manifolds, valves, hoses, etc. are in good condition,
not worn or damaged
8. If warm cooling air from compressors is used in heating
systems, e.g., to warm up a workroom, take precautions

7
against air pollution and possible contamination of
breathing air.
9. Do not remove any of or tamper with the sound-damping
material.
10. Never remove or tamper with the safety devices, guards
or insulation tted on the machine. Every pressure vessel
or auxiliary installed outside the machine to contain
air above atmospheric pressure must be protected by a
pressure relieving device or devices as required.
Also consult following safety precautions: Safety
precautions during operation and Safety precautions
during maintenance.
These precautions apply to machines processing or
consuming air or inert gas. Processing of any other
gas requires additional safety precautions typical to
the application not included herein.
Some precautions are general and cover several
machine types and equipment; hence, some statements
may not apply to your machine.
1.4 Safety precautions during maintenance or
repair
All responsibility for any damage or injury resulting
from neglecting these precautions, or non-observance
of the normal caution and care required for installation,
operation, maintenance and repair, even if not expressly
stated, will be disclaimed by the manufacturer.
General precautions
1. The operator must employ safe working practices and
observe all related local work safety requirements and
regulations.
2. If any of the following statements does not comply with
the applicable legislation, the stricter of the two shall
apply.
3. Installation, operation, maintenance and repair work
must only be performed by authorized, trained and
specialized technicians.
4. The compressor is not considered capable of producing
breathable air. To obtain breathable air, the compressed
air must be adequately puried according to the local
legislation and standards.
5. Before any maintenance, repair, adjustment or any
other non-routine checks, stop the compressor, press
the emergency stop button, switch o the power and
depressurize the compressor. In addition, the isolating
switch must be opened and locked.
6. Never play with compressed air. Do not apply air to
your skin or direct an air stream at people.
Never use air to clean dirt from your clothes. When
using the air to clean equipment, do so with extreme
caution and wear eye protection.
Precautions during maintenance or repair
1. Always wear safety glasses.
2. Use only the correct tools for maintenance and repair
work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when
the machine has cooled down.
5. A warning sign stating “Work in progress; do not start”
shall be attached to the starting equipment.
6. Persons switching on remotely controlled machines
shall take adequate precautions to ensure that there is
no one checking or working on the machine. To this
end, a suitable notice shall be axed to the remote start
equipment.
7. Close the compressor air outlet valve before connecting
or disconnecting a pipe.
8. Before removing any pressurized component, eectively
isolate the machine from all sources of pressure and
depressurize the entire system.
9. Never use ammable solvents or carbon tetrachloride
for cleaning parts. Take safety precautions against toxic
vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance
and repair. Keep dirt away by covering the parts and
exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat
near the oil system. Oil tanks must be completely
purged, e.g., by steam cleaning, before carrying out
such operations. Never weld on, or in any way modify,
pressure vessels.

8
12. Whenever there is an indication or any suspicion that
an internal part of a machine is overheated, the machine
shall be stopped but no inspection covers shall be
opened before sucient cooling time has elapsed; this
is to avoid the risk of spontaneous ignition of the oil
vapor when air is admitted.
13. Never use a light source with open ame for inspecting
the interior of a machine, pressure vessel etc.
14. Make sure that no tools, loose parts or rags are left in or
on the machine.
15. All regulating and safety devices shall be maintained
with due care to ensure that they function properly They
should not be disabled.
16. Before clearing the machine for use after maintenance or
overhaul, check that operating pressures, temperatures
and time settings are correct. Check that all control
and shut-down devices are tted and that they function
correctly. If removed, check that the coupling guard of
the compressor drive shaft has been reinstalled.
17. Every time the separator element is replaced, examine
the discharge pipe and the inside of the oil separator
vessel for carbon deposits; if excessive, the deposits
should be removed.
18. Protect the motor, air lter, electrical and regulating
components etc. to prevent moisture from entering
them, e.g., when steam cleaning.
19. Make sure that all sound-damping material and vibration
dampers, e.g., on the bodywork and in the air inlet and
outlet systems of the compressor, is in good condition.
If damaged, replace it by genuine material from the
manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents that can damage materials of
the air net, e.g., polycarbonate bowls.
21. The following safety precautions are stressed when
handling lubricant:
•Never inhale refrigerant vapors. Check that the
working area is adequately ventilated; if required,
use breathing protection.
•Always wear special gloves. In case of refrigerant
contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing,
never tear o or remove the latter; ush abundantly
with fresh water over the clothing until all refrigerant
is ushed away; then seek medical rst aid.
22. Protect hands to prevent injury from hot machine parts,
e.g., during oil drainage.
Also consult following safety precautions: Safety
precautions during operation and Safety precautions
during maintenance.
These precautions apply to machines processing or
consuming air or inert gas. Processing of any other
gas requires additional safety precautions typical to
the application not included herein.
Some precautions are general and cover several
machine types and equipment; hence, some statements
may not apply to your machine.
WARNING :CancerandReproductiveHarm– www.P65Warnings.ca.gov.

9
2 General description
2.1 Introduction
CPF-150, CPF-175 and CPF-200 models are single-stage, oil-injected screw, gearbox driven by an electric motor with sound-
insulated bodywork.
The models with “S” abbreviations are air-cooled, and those with “SW”, water-cooled.
The compressors are available for a maximum working pressure of: 7, 8, 10 or 13 bar (e)
They essentially feature:
•Air lter
•Compressor element
•Air vessel / Oil separator
•Air cooler
•Oil cooler
•Drive motor
•Gear box
•Inlet / regulation assembly
•ES4000 control system
•Safety devices

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2.2 Regulating system
Flow diagram
Flow diagram
Reference Designation
ATo air cooler
BTo/from oil cooler

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Regulating system
The compressor is controlled by ES4000 controller (1).
The controller maintains the net pressure within programmable limits by automatically loading and unloading the compressor,
according to the air consumption. It also protects the compressor and monitors components subject to service.
Unloading
If the air consumption is less than the air output of the compressor, the net pressure increases. When the net pressure reaches
the work pressure upper limit (unloading pressure), solenoid valve (5) is de-energized by ES4000 controller (1). The plunger of
the valve (5) returns by spring force:
Stage Description
1The valve (5) plunger cuts the supply of vessel pressure toward the chamber (2).
2The control pressure present in the chamber (2) is vented to atmosphere. The unloading valve (4) plunger (3) is moved
by the pressure in the air vessel, allowing pressure to pass from the air vessel to the chamber (6).
3The valve (7) is pushed up, the closing air inlet.
4A small air ow continues to be drawn through the channel (8) and is expelled from the vessel through the channel
(10) to the air inlet.
5Air ow is stopped (0%) and the compressor runs unloaded, while the chamber (6) maintains a constant overpressure
(vessel unload pressure minus Unloading Valve (4) pressure drop).
Loading
When the net pressure decreases to the work pressure lower limit (loading pressure), solenoid valve (5) is energized. The
plunger of the valve (5) advances by spring force:
Stage Description
1The valve (5) plunger opens the supply of vessel pressure toward the chamber (2). The plunger (3) of the unloading
valve (4) moves, closing the air pressure passage to the chamber (6).
2The valve (7) moves downwards, as the pressure in the chamber (6) drops below atmospheric pressure, opening the
air inlet to the compressor element.
3Air ow is resumed (100%) and the compressor runs loaded, while the piston-bar-valve assembly is only surrounded
by atmospheric pressure.
2.3 Special Features
The compressor supplied herein has the following special features:
- Special certications: ASME/CRN and CSA/UL
- Air/oil separator must be ASME/CRN-certied.
- Special electric motor:
WEG W22 – IE3 Premium eciency.
460V voltage
- UL-certied electrical system components
- Export packaging.

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3 Graphic controller
3.1 Controller
View of the ES 4000 Advanced controller
Introduction
The electronic controller has the following functions:
•Controlling the compressor
•Protecting the compressor
•Monitoring components subject to service
•Automatic restart after voltage failure
Automatic control of the compressor
The controller maintains the net pressure within
programmable limits by adjusting the motor speed. A number
of programmable settings, e.g., the unloading and loading
pressures, the minimum stop time and the maximum number
of motor starts are taken into account.
The controller stops the compressor whenever possible to
reduce the power consumption and restarts it automatically
when the net pressure decreases. If the expected unloading
period is too short, the compressor is kept running to prevent
too short standstill periods.
Protecting the compressor
Shutdown
If the compressor element outlet temperature exceeds the
programmed shutdown level, the compressor will be stopped.
This will be indicated on the display of the controller. The
compressor will also be stopped in case of overload of the
drive motor.
Air-cooled compressors will also be stopped in the event of
overload of the fan motor.
Before remedying, consult the Safety precautions.
Shutdown warning
A shutdown warning level is a programmable level below the
shutdown level.
If one of the measurements exceeds the programmed shutdown
warning level, this will also be indicated to warn the operator
before the shutdown level is reached.
Service warning
If the service timer exceeds a programmed value, this will
be indicated on the display to warn the operator to carry out
some service actions.
Automatic restart after voltage failure
The controller has a built-in function to automatically restart
the compressor when the voltage is restored after voltage
failure.
Provided the controller is in the automatic operation
mode, the compressor will automatically restart when
the supply voltage to the module is restored.

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3.2 Control panel
Detailed description
Function keys of the controller
Reference Designation Function
1 Function Shows icons and operating conditions.
2 Automatic operation symbol
3 LED, automatic operation
Indicates that the controller is automatically controlling the
compressor: the compressor is loaded, unloaded, stopped
and restarted depending on the air consumption and the
limitations programmed in the controller.
4 Warning symbol
5 LED, warning Is lit if a warning condition exists.
6 Voltage symbol
7 LED, voltage on Indicates that the voltage is switched on.
8 Service symbol
9 LED, service Is lit when service is needed.
10 Start button This button starts the compressor. Automatic operation LED
(3) lights up. The Controller is operative.
11 Stop button This button is used to stop the compressor. Automatic
operation LED (3) goes out.
12 Scroll buttons Use these buttons to scroll through the menu.
13 Enter button Use this button to conrm the last action.
14 Escape button Use this button to go to previous screen or to end the current
action.

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3.3 Icons used
Status icons
Function Icon Function
Compressor status When the compressor is stopped, the icon stands still.
When the compressor is running, the icon is rotating.
Motor stopped
Running unloaded
Running loaded
Machine control mode Local start/stop
Remote start/stop
LAN control
Automatic restart after
voltage failure
Automatic restart after voltage failure is active
Week timer Week timer is active
Active protection
functions
Emergency stop
Shutdown
Warning
Service Service required

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Main screen view Value lines preview icon
Graphic preview icon
General icons No communication/network problem
Invalid
Input icons
Icon Description
Pressure
Temperature
Digital input
Special protection
Input icons
Icon Drain
Filter
Engine
Description
Compressor element (LP, HP etc.)
Dryer
Cooler
Frequency converter

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Expansion module failed
Network problem
General alarm
Menu icons
Icon Description
Inputs
Outputs
Guards (Shutdown warnings)
Counters
Test
Regulation (Settings)
Service
Event history (saved data)
Access key / User password
Network
Setpoint
Information
Week timer
General

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Scroll arrows
Icon Description
Up
Down
3.4 Main screen
Function
The main screen is the screen automatically displayed when the voltage is switched on and one of the buttons is pressed. It is
automatically turned o after a few minutes if no button is pressed.
Generally, 5 dierent main screen views can be chosen:
1. Two value lines
2. Four value lines
3. Graphic (High resolution)
4. Graphic (Medium resolution)
5. Graphic (Low resolution)
Screens with two or four value lines
This type of Main screen has the value of 2 or 4 settings (see Input menu section).
Typical main display (2-value lines), xed speed
compressors
Typical main display (4-value lines), xed speed
compressors
(1) Compressor outlet
(2) Element outlet
(3) Load, ... (text varies with actual compressor status)
(4) Menu
(5) Running Hours
(6) Load relay (one of the input signals of xed speed compressors)
Flow (compressors with frequency converter)
•Section A shows information about compressor operation (for example, outlet pressure or compressor outlet temperature).
In compressors with a frequency converter, the degree of load (ow) is displayed as a percentage of the maximum ow.

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• Section B shows status icons. The following types of icons
are displayed in this eld:
• Fixed icons
These icons are always displayed on the main screen
and cannot be selected with the cursor (for example,
Stopped or running compressor, Compressor Status
(running, unloading or stopped motor)).
• Option icons
These icons are only displayed if the respective function
is activated (for example, week timer, automatic restart
after voltage failure etc.).
• Warning icons
These icons are displayed if an abnormal condition
occurs (warnings, shutdowns, service etc.).
To access more information about the displayed icons,
select the icon in question using the scroll buttons and
press Enter.
• Section C is designated as the status bar
This bar displays the text corresponding to the selected
icon.
• Section D displays the action buttons. These buttons are
used to:
• Access and dene settings
• Reset a motor overload, service message or emergency
stop
• Access all data collected by the controller
The function of the buttons depends on the menu displayed.
The most common functions are:
Designation Function
Menu To go to the menu
Modify To modify programmable parameters
Reset To reset a timer or message
To activate an action button, highlight the button using the
scroll buttons and press Enter. To return to the previous menu,
press Escape.
Chart views
Instead of displaying values, you can also display a chart of
one of the input signals (see Input menu section) as a function
of time.
When Chart (High resolution) is selected, the chart displays
the variation of the selected input (in this case, the pressure)
per minute. The actual value is also displayed. The screen
shows the last 4 minutes.
The selector button (icon) to select other screens is changed to
a small Chart and highlighted (active).
When Chart (Medium resolution) is selected, the chart
displays the variation of the selected input per hour. The
screen displays the last 4 hours.
When Chart (Low resolution) is selected, the chart displays
the variation of the selected input per day. The screen displays
the progress in the last 10 days.
Selecting a main screen view
To switch between dierent screen layouts, select the
rightmost icon in the control icon row (see the value line
display icon or chart display icon in the Icons used section)
and press Enter. A screen similar to the following will appear:
Select the desired layout and press Enter. See also the Input
menu section.

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3.5 Accessing menus
Description
When the voltage is switched on, the main screen automatically
displays (see Main screen section):
• To access the menu screen, select the Menu (4) button
using the scroll buttons.
• Press Enter to select the menu. The following screen is
displayed:
• The screen displays several icons. Each icon indicates
a menu item. By default, the pressure parameter icon
(Regulation) is selected. The status bar displays the menu
name corresponding to the selected icon.
• Use the scroll buttons to select an icon.
• Press Escape to return to the main screen.
3.6 Input menu
Menu icon, Inputs
Function
• To display the actual value of the measured data (analog
inputs) and digital input status (for example, emergency
stop contact, motor overload relay etc.).
• To select the digital input to be displayed in the main
screen chart.
Procedure
On the main screen (see Main Screen):
• Move the cursor to the Menu button and press the Enter
button.
• Using the scroll buttons, move the cursor to the Inputs
icon, as shown in the following screen:
• Press the Enter button. A screen similar to the following
will appear:
Figure text
(1) Inputs
(2) Compressor outlet
(3) Element outlet
(4) Ambient Air
(5) Emergency stop
• The screen displays a list of all inputs, with their respective
icons and readings.
• If an input is in warning or shutdown, the original icon is
replaced, respectively, by the warning or shutdown icon (in
this case, the shutdown icon and the warning icon shown
above).
A small chart icon, displayed below an item in the list, means
that this input signal is displayed in the chart on the main
screen. Any analog input can be selected.