Chicago Pneumatic CPF 175 User manual

CPF 175, CPVS 175
Instruction book

Chicago Pneumatic
CPF 175, CPVS 175
Instruction book
Original instructions
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified
in the Declaration of Conformity.
2012 - 08
No. 2920 1804 00
www.cp.com

Table of contents
1 Safety precautions..........................................................................................................6
1.1 SAFETY ICONS...................................................................................................................................6
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7
1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................8
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................9
2General description......................................................................................................11
2.1 INTRODUCTION.................................................................................................................................11
2.2 AIR AND OIL SYSTEM.........................................................................................................................13
2.3 COOLING AND CONDENSATE SYSTEM....................................................................................................18
2.4 REGULATING SYSTEM........................................................................................................................19
2.5 ENERGY RECOVERY SYSTEM...............................................................................................................20
3 Electronic regulator......................................................................................................23
3.1 ELECTRONIC CONTROLLER.................................................................................................................23
3.2 CONTROL PANEL..............................................................................................................................25
3.3 CHANGING THE DISPLAY LANGUAGE.....................................................................................................27
3.4 REGULATION...................................................................................................................................28
3.5 STRUCTURE OF MENUS......................................................................................................................29
3.6 MODIFYING A PARAMETER..................................................................................................................33
3.7 STATUS MENUS................................................................................................................................34
3.8 INPUTS IN THE MAIN MENUS................................................................................................................40
3.9 ERROR MENU.................................................................................................................................42
3.10 SETTINGS MENU..............................................................................................................................44
3.11 COUNTERS MENU............................................................................................................................46
3.12 SERVICE MENU...............................................................................................................................48
3.13 WEEKLY PROGRAM - TIMER FUNCTION.................................................................................................53
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3.14 HISTORY MENU................................................................................................................................55
3.15 SAFETY MENU.................................................................................................................................56
3.16 CONFIGURATION USER MENU..............................................................................................................64
3.17 CONFIGURATION DISTRIBUTOR MENU....................................................................................................66
3.18 INPUT STATE MENU..........................................................................................................................69
3.19 OUTPUT TEST MENU.........................................................................................................................71
3.20 VERSION MENU................................................................................................................................73
3.21 INFORMATION DISTRIBUTOR MENU........................................................................................................73
3.22 PASSWORD MENU.............................................................................................................................73
3.23 MCC MENU....................................................................................................................................73
3.24 EXTERNAL CONNECTION.....................................................................................................................74
3.25 EXTERNAL COMMUNICATION (OPTIONAL)................................................................................................74
3.26 COMMON OPERATIONS......................................................................................................................75
3.27 REINITIALISATION OF MAINTENANCE COUNTERS.......................................................................................75
3.28 OPERATIONAL INCIDENTS...................................................................................................................76
3.29 LIST OF MESSAGES...........................................................................................................................76
4 Installation.....................................................................................................................83
4.1 DIMENSION DRAWING........................................................................................................................83
4.2 INSTALLATION REMARKS.....................................................................................................................95
4.3 INSTALLATION PROPOSAL...................................................................................................................97
4.4 ELECTRIC CABLE SIZE.....................................................................................................................101
4.5 PICTOGRAPHS...............................................................................................................................107
5 Operating instructions...............................................................................................109
5.1 INITIAL START-UP............................................................................................................................109
5.2 BEFORE STARTING..........................................................................................................................111
5.3 STARTING.....................................................................................................................................112
5.4 DURING OPERATION........................................................................................................................113
5.5 CHECKING THE DISPLAY...................................................................................................................114
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5.6 STOPPING.....................................................................................................................................115
5.7 STORAGE AFTER INSTALLATION.........................................................................................................116
5.8 TAKING OUT OF OPERATION..............................................................................................................117
5.9 USE OF AIR RECEIVER.....................................................................................................................117
6 Maintenance................................................................................................................119
6.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................119
6.2 MOTORS.......................................................................................................................................120
6.3 OIL SPECIFICATIONS........................................................................................................................121
6.4 OIL CHANGE..................................................................................................................................122
6.5 STORAGE AFTER INSTALLATION.........................................................................................................126
6.6 SERVICE KITS................................................................................................................................126
6.7 DISPOSAL OF USED MATERIAL...........................................................................................................127
7 Adjustments and servicing procedures...................................................................128
7.1 AIR FILTERS..................................................................................................................................128
7.2 COOLERS.....................................................................................................................................129
7.3 SAFETY VALVE...............................................................................................................................129
8 Problem solving..........................................................................................................130
8.1 PROBLEM SOLVING.........................................................................................................................130
9 Technical data.............................................................................................................132
9.1 READINGS ON DISPLAY....................................................................................................................132
9.2 REFERENCE CONDITIONS.................................................................................................................132
9.3 LIMITS..........................................................................................................................................133
9.4 SETTINGS OF SAFETY VALVE.............................................................................................................133
9.5 SETTINGS FOR OVERLOAD RELAY AND FUSES.......................................................................................133
9.6 COMPRESSOR DATA........................................................................................................................135
10 Pressure equipment directives.................................................................................146
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11 Declaration of conformity..........................................................................................148
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1 Safety precautions
1.1 Safety icons
Explanation
Danger for life
Warning
Important note
1.2 Safety precautions, general
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,
specialized personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,
the compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the
power isolating switch must be opened and locked.
On units powered by a frequency converter, wait six minutes before starting any electrical repair.
If the machine is equipped with an automatic restart after voltage failure function and if this
function is active, be aware that the machine will restart automatically when the power is
restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the 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.
8. It is not allowed to walk or stand on the unit or on its components.
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1.3 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 the
manufacturer.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the 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. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. 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.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
6. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
7. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. 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 depressurized and that the electrical isolating
switch is open, locked and labelled with a temporary warning before any maintenance or repair. As a
further safeguard, persons switching on or off 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 affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and
that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
12. 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.
13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
14. 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.
15. Never remove or tamper with the safety devices, guards or insulation fitted 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.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched
by personnel in normal operation must be guarded or insulated. Other high temperature piping must be
clearly marked.
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17. 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.
18. 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 machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are 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 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.
Precautions during operation
1. Never touch any piping or components of the compressor during operation.
2. Use only the correct type and size of hose end fittings 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.
3. 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 affixed to the remote
start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
5. Never operate the machine below or in excess of its limit ratings.
6. 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.
On compressors without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. 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
• No leaks occur
• 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 repair, free
of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
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11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be
protected by a pressure relieving device or devices as required.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.5 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.
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
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 bearing a legend such as "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 affixed to the remote
start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting
a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours 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.
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 sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
13. Never use a light source with open flame 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 may not be put out of action.
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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 fitted 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 renewed, 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 filter, 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. damping material 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 which can damage materials of the air net, e.g. polycarbonate bowls.
21. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. 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 off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical
first aid.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
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2 General description
2.1 Introduction
General view
Description
These units are single-stage, oil-injected screw compressors, driven by an electric motor and enclosed in
sound-insulated bodywork.
Compressors with variable speed drive optimize energy consumption and reduce the operating pressure band
by continuously matching the speed of the drive motor to the air net pressure.
The following features are available as an option:
Foodgrade
Foodgrade oil is a unique high quality synthetic lubricant, specially created for oil-injected screw compressors
that provide air for the food industry.
Rotair Xtra oil
RXD oil is a special, long-life lubricant for oil-injected screw compressors. It provides better cooling and
extends the oil change interval.
Water separator drain
The water separator drain prevents water from entering in the compressed air net.
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Oil preheater (only for 400 V-50 Hz)
This oil preheating system is installed in the oil tank in order to preheat the lubricant at low temperatures.
High efficiency air filtration
The high efficiency air filtration improves the quality of the air at the intake. This option is particularly useful
in very dusty surroundings.
Pre-filtration panel
The pre-filtration panel protects the compressor's internal from dust and helps to avoid clogging of the air
coolers (cooling air side).
High pre-filtration panel
The pre-filtration panel protects the compressor's internal from dust and helps to avoid clogging of the air
coolers (cooling air side). This option is particularly useful in very dusty surroundings.
Modulating control
The modulating control system is designed to maintain a narrow net pressure band by throttling the air inlet,
thus reducing the air flow (50% - 100%).
Electronic drain (only for 400 V-50 Hz)
The electronic water drain assures proper draining of condensate and prevents water from entering the
compressed air net. For any malfunction of the draining process, the electronic water drain generates a warning
message on the display of the electronic regulator.
Energy recovery
The compressor is provided with an energy recovery system to recover the major part of the compression heat
in the form of hot water without any influence on the compressor performance.
Phase Sequence Relay
The phase sequence relay prevents the drive motor from rotating in the wrong direction.
Automatic restart after voltage failure
For compressors leaving the factory, this function is made inactive. If desired, the function can be activated.
Consult your Customer Centre.
If activated and provided the regulator was in the automatic operation mode and the
compressor control mode (local, remote 1 or remote 2) was not changed during the voltage
failure, the compressor will automatically restart if the supply voltage to the module is
restored within a programmed time period (this time period is called the power recovery
time).
The power recovery time can be set between 1 and 254 seconds or to 0. If the power
recovery time is set to 0, the compressor will always restart after a voltage failure, no matter
how long it takes to restore the voltage.
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2.2 Air and oil system
Flow diagrams
Flow diagram, air-cooled compressor
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Flow diagram, air-cooled compressor with energy recovery
Flow diagram, air-cooled compressor with modulating control
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Flow diagram, air-cooled compressor with energy recovery and with modulating control
Flow diagram, water-cooled compressor
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Flow diagram, water-cooled compressor with modulating control
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Air flow
Air-cooled compressor
Air drawn through filter and unloader (UA) is compressed in compressor element (E). Compressed air and
oil are discharged through check valve (CV) to air receiver/oil separator (AR) where oil is separated from the
compressed air. The air is blown through minimum pressure valve (Vp) to air cooler (Ca).
The cooled air is discharged through the outlet towards the air net. An optional condensate trap may be
provided between the air cooler and outlet valve.
Check valve (CV) prevents blow-back of compressed air.
Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure.
Oil system
Air pressure forces the oil from receiver (AR) through oil cooler (Co), filters (OF), oil stop valve (Vs) and an
oil injection valve to the compressor element (E) and the lubrication points. On air-cooled compressors, an
oil injection valve will open at higher ambient temperatures to keep the element outlet temperature low.
For air-cooled units, the oil temperature is controlled by regulating the speed of the fans (FN), to avoid
overcooling and consequently condensation in the air receiver (AR).
On air-cooled compressors with energy recovery or on water-cooled compressors, the oil temperature is
controlled by a thermostatic valve to avoid overcooling and consequently condensation in the air receiver
(AR).
In the air receiver (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oil
is removed by the separator element.
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2.3 Cooling and condensate system
Condensate drain system
Position of condensate drain
(1) Automatic condensate drain
As an option, a condensate trap can be installed downstream of the air cooler to prevent condensate from
entering the air outlet pipe. The trap is provided with a float valve for automatically draining condensate and
with a manual drain valve.
Cooling system
On air-cooled compressors, the air and oil coolers are cooled by fans.
Water-cooled compressors are provided with a cooling water system, including combined oil and air coolers.
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