Instruction Book

Instruction BookCPC 40 - 50 - 60 - 75

Instruction BookOWNERSHIP DATAUnit type: ........................................................................... Owner’s machine No.: ...............................................................Motor type: ......................................................................... Unit Serial No.: ........................................................................Delivery date: ..................................................................... Motor serial No.: .......................................................................Service Plan: ...................................................................... First start-up date:

Capacity: ................................................................................

Local CP RepresentativesName: ..........................................................................................................................................................................................................Address: ........................................................................................................................................................................................................Telephone: ..............................................................................Contact persons: Service: ..............................................................Telex: ..................................................................................... Parts ..................................................................

SAFETY PRECAUTIONSTo be read attentively and acted accordingly before installing, operating or repairing the unit.

These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requiresadditional safety precautions typical to the application which are not included herein.

In addition to normal safety rules which should be observed with stationery air compressors and equipment, the following safety directions and precautions are ofspecial importance.

When operating this unit, the operator must employ safe working practices andobserve all related local work safety requirements and ordinances.

The owner is responsible for maintaining the unit in a safe operating condition.Parts and accessories shall be replaced if unsuitable for safe operation.

Installation, operation, maintenance and repair shall only be performed byauthorized, trained, competent personnel.

Normal ratings (pressures, temperatures, time settings etc.) shall be durablymarked.

Any modifications on the compressor shall only be performed in agreement withCP and under supervision of authorized, competent personnel.

If any statement in this book, especially with regard to safety, does not complywith local legislation, the stricter of the two shall apply.

These precautions are general and cover several machine types and equipment;hence some statements may not apply to the unit(s) described in this book.

Installation

Apart from general engineering practice in conformity with the local safetyregulations, the following directives are specially stressed:

1. A compressor shall be lifted only with adequate equipment in conformitywith local safety rules.

Loose or pivoting parts shall be securely fastened before lifting. It isstrictly forbidden do dwell or stay in the risk zone under a lifted load.Lifting acceleration and retardation shall be kept within safe limits.

Wear a safety helmet when working in the area of overhead or liftingequipment.

2. Any blanking flanges, plugs, caps and desiccant bags shall be removedbefore connecting up the pipes. Distribution pipes and connections shallbe of correct size and suitable for the working pressure.

3. Place the unit where the ambient air is as cool and clean as possible. Ifnecessary, install a suction duct. Never obstruct the air inlet. Care shallbe taken to minimize the entry of moisture with the inlet air.

4. The aspirated air shall be free from flammable fumes or vapours, e.g.paint solvents, that can lead to internal fire or explosion.

5. Air-cooled units shall be installed in such a way that an adequate flow ofcooling air is available and that the exhausted air does not recirculate tothe inlet.

6. Arrange the air intake so that loose clothing of people cannot be suckedin.

7. Ensure that the discharge pipe from the compressor to the after cooler orair net is free to expand under heat and that it is not in contact with orclose to flammable material.

8. No external force may be exerted on the air outlet valve; the connectedpipe must be free of strain.

9. If remote control is installed, the unit shall bear an obvious sign reading:

DANGER: This machine is remotely controlled and may start withoutwarning.

As a further safeguard, persons switching or remotely controlled unitsshall take adequate precautions to ensure that there is no one checking orworking on the machine. To this end, a suitable notice shall be affixed tothe start equipment.

10. On units with automatic start-stop system, a sign stating “This machinemay start without warning” shall be attached near the instrument panel.

11. In multiple compressor systems manual valves shall be installed toisolate each compressor. Non-return valves (check valves) shall not berelied upon for isolating pressure systems.

12. Never remove or tamper with the safety devices, guards or insulationsfitted on the unit. Every pressure vessel or auxiliary installed outside theunit to contain air above atmospheric.

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Instruction BookCPC 40 - 50 - 60 - 75

March 2005

Chicago Pneumatic Sales,Chemtex House,Main Street, 1st FloorHiranandani Gardens,Powai, Mumbai 400 076

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ContentsPart A: Information fof the user1.0 General characteristics2.0 Intended use3.0 Operation4.0 General safety standards5.0 Description of dander signals6.0 Danger zones7.0 Safety devices9.0 Compressor room10.0 Transport and handling11.0 Unpacking12.0 Installation13.0 Dimensions and technical data14.0 Machine illustration15.0 Ordinary maintenance to be done by the user16.0 Periods of inactivity17.0 Scrapping the unit18.0 List of spare parts for routine maintenance19.0 Trouble-shooting and emergency remedies20.0 Starting up21.0 General ordinary maintenance requires trained personnel22.0 Changing the oil23.0 Replace the separator filter and the oil filter24.0 Belt tension25.0 Flow diagram

Important: There is a copy of the wiring diagram inside the electric panel

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Addresses of assistance centers

In the event of breakdown or malfunction of the machine, switch it off and do not tamper with it.If repairs are needed, apply only to a technical assistance centre approved by the manufacturer and insist on the use oforiginal spare parts.Failure to comply with the above may endanger the safety of the machine. Please contact Chicago Pneumatic

IntroductionKeep this manual with care for future consultation; the use and maintenance manual is an integral part of the machine.

Read this manual carefully before carrying out any operations on the compressor unit.The installation of the compressor unit and all operations involving it must be performed in conformity with the regulationsin force concerning electric plants and personal safety.

Characteristics and safety precautions

Machine with automatic start

Before removing the protection devices for any maintenance work on the machine, disconnect theelectrical power supply and make sure that there is no internal residual pressure

The failed compliance with the instructions contained in this handbook determines the expiration ofthe warranty terms

All work on the electric plant, however slight, must be carried out by professionally skilled personnel

The manufacturer does not accept responsibility for damage caused as a result of negligence of failure to abide by theinstructions given above.

This machine in not suitable for external installation

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1.0 General characteristicsThe compressor units use single-stage screw rotary air compressors with oil injection.The central unit comprises:compressor; oil separator; oil cooler and output air cooler; fan; electric start; safety and regulation devices; instrumentpanel.The system is self-bearing and does not require bolts or other devices to anchor it to the floor.The unit is completely assembled in the factory; the necessary connections for setting it up are:· connection to the power mains (see installation chapter)· connection to the compressed air network (see installation chapter)The compressor-motor unit is fitted on the machine chassis by means of flexible supports: this allows the compressor unitto be laid directly on the floor without any need of further vibration-damping systems

2.0 Intended useThe compressor has been built to supply compressed air for industrial use.The machine cannot be used in premises where there is a risk of fire or explosion or where work is carried outwhich releases substances into the environment which are dangerous with regard to safety (for example: sol-vents, inflammable vapours, alcohol, etc.).In particular the appliance cannot be used to produce air to be breathed by humans or used on direct contact withfoodstuffs. These uses are allowed if the compressed air produced is filtered by means of a suitable filtering system(Consult the manufacturer for these special uses.)This appliance must be used only for the purpose for which it was specifically designed.All other uses are to be considered incorrect and therefore unreasonable.The Manufacturer cannot be held responsible for any damage resulting from improper, incorrect or unreasonable use

3.0 OperationThe electric motor and the compressor unit are coupled by means of a belt transmission.The compressor unit takes in the outside air through the suction valve. The air taken in is filtered by panel pre-filter fitted one thepanel of the external covering and by the filter cartridge fitted upstream from the suction valve. Inside the compressor unit, the airand the lubricating oil are compressed and sent to the oil separating filter where the oil is separated from the compressed air; the airis then filtered again by the oil separating cartridge to reduce the amount of suspended oil particles to a minimum. At this point thetwo flows (of oil and air) are sent to two separate coolers where they are cooled, using a flow of air taken from the environment by aspecial fan inside the machine.The cooled oil returns to the circuit while the compressed air is sent to the using network.

4.0 General safety standardsThe appliance may be used only by specially trained and authorized personnel.Any tampering with the machine or alterations not approved beforehand by the Manufacturer relieve the latter of respon-sibility for any damage resulting from the above actions.

All work on the electric plant, however slight, must be carried out by profrssionally skilled personel

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5.0 Description of danger signals

6.0 Dangers zones

FIG. 2

1) Dangerous electric voltage

2) Air not fit for breathing

3) Noise

4) Fan rotating

5) High pressure

6) Hot parts

7) Moving parts

8) Fluid ejection

9) Machine with automaticstart

Risk present on the whole machine

FIG. 3

7

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7.0 Safety devices

1) Safety screws 4 Emergency stop

2) Side guard and electric board door can be opened 5) Oil filling cap (with safety breather)using a special key

3) Fixed protection device - pulleys 6) Safety valve

FIG. 4

6

5

3

124

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8 Position of the data plates

1) Identification plate 5) Oil plate

2) Maintenance program (see chapter 15.2) 6) Draining condensate

3) Plate direction of rotation 7) Electric lead fixing plate

4) Air not filt for breathing

FIG. 6

Oil plate

4

6

2

1

7

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9.0 Compressor room

9.1 FloorThe floor must be even and of industrial type; the total weight of the machine is about Kg. (See Ch. 13.0).Remember the total weight of the machine when positioning it.9.2 VentilationWhen the machine is operating, the room temperature must not be higher than 40 °C or lower than 1 °C.The volume of the room must be about 100 m3

The room must be provided with 2 openings for ventilation with a surface area of about 2 m2 each.The first opening must be in a high position to evacuate the hot air, the second opening must be low to allow the intake ofexternal air for ventilation.If the environment is dusty it is advisable to fit a filtering panel on this opening.The hot air ejected by the compressor may be led outside with a pipe.This pipe must have a minimum section as the size of the Compressor vent and it must not be longer than 3 m.For longer pipes an extra fan must be fitted

9.3 Examples of ventication of the compressor room

FIG. 7

Hot air ejection Fan air output

Attention: Removable pipe toallow cleaning of the Cooler

Hot air pipe

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10.0 Transport and handling

Attention : the machine must only be moved with the panels fitted (fig. 8)The machine must be transported as shown in the following figures

During the procedures there must not be any person, animal and/thing within the operation area whose safety may beendangered

40 – 50 HP

Cardboard protectionavoid damaging thebodywork

60 - 75 HP

Fig. 8

Cardboard protectionavoid damaging thebodywork

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11.0 Unpacking

After removing the packing, ensure that the machine is unbroken and that there are no visibly damaged parts. If you arein doubt, do not use the machine but apply to the manufacturer technical assistance service or to your dealer. Thepacking material (plastic bags, polystyrene foam, nails, screws, wood, metal strapping, etc.) must not be left within thereach of children or abandoned in the environment, as they are a potential source of danger and pollution. Dispose ofthese materials in the approved collection centres.

Fig. 9

12.0 Installation

All damage due to failure to observe the indications given below cannot be attributed to the manufacturer andmay cause the guarantee terms to become invalid

12.1 PositioningAfter unpacking the equipment and preparing the compressor room, put the machine into position, checking the followingitems:

••••• Ensure that there is sufficient space around the machine to allow maintenance (see fig. 10)••••• Check the compressor is standing on a perfectily flat floor

Fig. 10

1

2

3

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12.2 Electrical connection

Machine with automatic start• Check that the supply voltage is the same as the value indicated on the machine data plate.

• Check the condition of the line leads and ensure that there is an efficient earth lead.

• Connect the machine power cables with the greatest care, according to the standards in force. These cablesmust be as indicated on the machine wiring diagram.

• After the first 50 working hours, check that the screws on the electric terminals are tight.

Only professionally skilled personnel may have access to the electric to the electric panel, switch off the powerbefore opening the door of the electric panel

Compliance with the regulations in force concerning electric plants is fundamental for operator safety and for theprotection of the machine

Cables, plugs and all other type of electric material used for the connection must be suitable for the use andcomplying with the requirements stated by the regulations in force

12.3 Connection to the compressed air networkFit a manual interception valve Ref. 1 Fig. 10 between the machine and the compressed air network so that the com-pressor may be isolated during maintenance operations.Condensate must be drained from the oil receiver (manually) Ref. 2 Fig. 10, in conformity with the local regulations inforce.

Pipes, fittings and connections used for the connection of the electrocompressor to the compressed air networkmust be suitable to the use according to the prescriptions of the regulations in force in the sountry of use

All damage due to the failure to comply with these indications cannot be attributed to the manufacturer and maycause invalidity of the guarantee conditions

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13.0 Diensions and techical data

LU55-7

Air OutletG1 1/2

Electrical Entry

Cooling Air

ELECTRONIC

Cooling Air

Hot Air

Air OutletG1 1/4

Motor Power HP 40 50 60 75

Pressure bar 8 10 13 8 10 13 8 10 13 8 10 13

Noise Level dB(A) 69 69 69 70 70 70 71 71 71 71 71 71

Weight kg 695 695 695 715 715 715 790 790 790 810 810 810

Motor Power kW 30 30 30 37 37 37 45 45 45 55 55 55

Oil Capacity (L) 28 28 28 28 28 28 32 32 32 32 32 32

CPC 40

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14.0 Machine illustration14.1 General lay-out

1 Air suction filter 12 Oil discharge

2 Thermostatic valve 13 Oil collector

3 Oil filter 14 Pressure gauge tank

4 Air-oil cooler 15 Control card

5 Filter panel 16 Safety valve

6 Belt tightening system 17 Isolating switch

7 Minimum pressure valve 18 Electric motor

8 Air-oil separator ( inside the oil collector) 19 Screw compressor

9 Top-up or oil filling cap 20 Suction unit

10 Control panel

11 Oil gauge

It is forbidden to tamper with the setting values of the safety valve

Fig. 11

11

12

219

9

5

8

16

14

6

78

20

17

15

10

1

37

13

19

4

22

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14.2 Command and control panel

Before carrying out the operation test, read carefully and acquire a good knowledge of thecommand functions

1) Control card2) Emergency stop

1

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14.3 Electronic card models “ES 3000”

Fig. 13

There is an electronic control and diagnostics card on the electric panel ; this card includes the display of the functions asshown in figure 13.

1) Superior display: indicates the compressor pressure.2) Inferior display: indicate the temperature, total hours, loaded hours.3) Button to create a vacuum in the compressor.4) Tabulation key to move to the next field of the screen on the display Ref. 25) Buttons to programme the board.

Symbol Description

Pressing the pushbutton cancels the stored alarm indication. Pressing the pushbutton for more than 3seconds, the central control units tested: all the LEDs must be on

Pressing the pushbutton switches onthe compressor is switched on. N.B. there is a delay of about 15seconds before start up

Pressing the pushbuitton starts the compressor switch-off phase: the compressor runs idle for 30 sec-onds before stopping

(7)

(6)

(5)

5

4

2

31

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Symbol Led flshing Led on

Overpressure alarm in progress Machine stopped for overpressure

- -

Oil overtemperature alarm in progress (>950 C) Machine stopped for oil overtemperature(> 1000 C)

Fan magnetothermal alarm Machine lock out due to fan motorthermal trigger

Motor thermal relay alarm in progress Machine stopped for motor thermal relaycut-in

General alarm in progress for fault in pressure andtemperature probes -

Led – indicates compressor operating status “Red” pilot lamps (cause machine stoppage)

N.B. To switch off the red LEDs press “reset”Led – indicates compressor operating status “Yellow” pilot lamps (do not cause machine stoppage)

Symbol Led flshing Led on

Not enabled Not enabled

- Compressor running under load

Manual loadless operation of compressor Loadless operation of compressor

Compressor in stand-by for start-up(15 seconds) or in shut-down phase Compressor on(30 seconds)

N.B. To switch off the red LEDs see chapter 14.6Led – indicates compressor operating status “green” pilot lamps

Symbol Led flshing Led on

Not enabled Not enabled

Forewarning to replace oil filter Replace oil filter

Forewarning to replace separator filter Replace separator filter

Forewarning to replace suction filter Replace suction filter

Forewarning to change oil Change oil

Forewarning for general check Perform general check

(R)

(Q)

(P)

(O)

(N)

(M)

(L)

(I)

(H)

(A)

(G)

(F)

(E)

(D)

(C)

(B)

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Attention : To start up again after a protection has been triggered (alarm) press “RESET” followed bythe start button “I”

Attention : Start-up takes place about 15 seconds after the board is supplied with power or from themoment it is switched off with the button (5)

Operation of the central control unitThe central control unit operation is programmed for Energy Saving; it switches off the compressor, thus reducing idlerunning to a minimum.The card is preset to run idle before switching off for a period that is shorter the lower the consumption of air.The control unit also indicates when filters require maintenance etc.. (Yellow LEDs).14.4 Viewing the hours of operationTo view the total hours of operation press Ref. 3, Fig. 13a, the hours of operation appear in the bottom display and a dotlights up in the top display (confirm LED).To view the LOADED hours of operation press Ref. 3 Fig. 13a again and a dot lights up on the right side of the topdisplay (confirm LED).

14.5 Viewing the hours of operation of components subject to maintenanceTo view the hours of operation of individual components subject to maintenance, proceed according to Chapter 14.6, topoint 4); the operating hours will be viewed on the bottom display.- Press the button Ref. 3 Fig 13a to exit.14.6 Resetting the maintenance interval counters (Yellow LEDs excluding LED “A”)To reset a counter (i.e. Ref. L air filter) after having performed the relevant maintenance, proceed as follows: (see Fig.13a)1) Press buttons Ref. 7 and Ref. 4 simultaneously until the LED ref. H lights up.2) Release the buttons Ref. 7 and Ref. 43) Use the buttons Ref. 1 and Ref. 2 to select the LED Ref. L (air filter) relevant to the component in question.4) The operating hours of the component Ref. L (air filter) are viewed on the 5-digit bottom display.5) Press the button Ref. 4 once and the value viewed flashes, press the button Ref. 4 again; the display is now resetand the LED Ref. L is lit.6) Press the button Ref. 3 to exit from RESET7) To reset another component, move to the relevant LED using the buttons Ref. 1 and Ref. 2.N.B. the board exits automatically from programming after 30 seconds of inactivity

H

7

L

Q

1

2

3

4

14.7 Activating / deactivating the loadless-loaded operation mode

1) Press the button Ref. 1 Fig. 13a and the LED Ref. Q flashes, the machine operates in MANUAL UNLOAD mode.2) Press the button Ref. 1 Fig. 13a again and the machine returns to the automatic cycle.

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14.8 Operating parameters of the board

The board is programmed in the factory with a preset value of the following parameters:P0 = cut-off pressure (8 -10 - 13 bar)P1 = cut-in pressure (6.5 - 8.5 - 11.5 bar)r 2 = maximum operating temperature (100 °C)t 3 = not activet 4 = not activeC5 = maximum number of start-ups per hour (10)

The board is also programmed to measure the pressure in “bar” (parameter C7) and the temperature in °C (parameter C6).The pressure and temperature units of measurement correspond to the table below

Name of the parameter Value of the parameter

C6 0 = 0 C 1 = 0 F

C7 0 = bar 1 = FSI

All parameters described above can be viewed and modified with the procedure indicated in paragraph 14.9.The parameter number appears in the top display and the value of the parameter appears in the bottom display.

14.9 VIEWING AND MODIFYING THE VALUE OF BOARD PARAMETERS.

To view the board parameters proceed as follows:- Press and hold the button 4 Fig. 13a for a few seconds, until “P0” (cut-off pressure) appears on the top display: the

value of the cut-off pressure in bar (8, 10 or 13 bar) appears simultaneously on the bottom display.

- By pressing the button Ref. 1 Fig. 13a all the board parameters (P0, P1, r2, t3, t4, C5, C6, C7) will appear in sequenceon the top display while the values set for each parameter will appear on the bottom display. To exit press the buttonRef. 3 until the luminous dot on the display is positioned on the symbol.

To change the value of parameters follow the example indicated below:Example: the maximum temperature value is to be modified to 95°C.

- Press and hold the button Ref. 4 fig. 13a for a few seconds, until the parameter “P0” appears on the top display.- Press the button Ref. 1 Fig. 13a until reaching the parameter “r2” (maximum temperature).- Press the button Ref. 4 Fig. 13a: the value of the temperature indicated on the bottom display flashes.- Press the button Ref. 2 Fig. 13a until reaching the value 95.- Press the button Ref. 4 Fig. 13a to confirm the modification; the value 95 stops flashing.- Exit from programming by pressing the button Ref. 3 Fig. 13a.The new maximum temperature value is now 95.

14.10 Displaying a temperature level that is too lowThe card is programmed in the factory with a minimum temperature level set at (+ 4 °C), if the read level is lower, it isshown by the bottom display flashing. This fault signal does not mean the compressor cannot be started, but warns theoperator that the room temperature is too low.

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15.0 Ordinary maintenance to be done by the user

Befor carrying out any maintenance jobs it is obligatory to stop the machine anddisconnect it from the power mains

The maintenance jobs described in this chapter may be carried out by the user.The more complex maintenance jobs which require professionally skilled personnel are listed in the chaper on Generalroutine maintenance (See Chap. 21.0)

15.1 General InformationRoutine maintenance must be carried out according to the maintenance schedule affixed to the machine.15.2 Maintenace schedule

* Operations that may be carried out by the user

These maintenance intervals are recommended for work environments that are not dusty and are will ventilated.For particularly dusty environments, double the frequency of controls

Befor carrying out amy maintenance jobs it is obligatory to stop the machine and disconnect it from the power mains

The maintenance interventions on the electrocompressor can be performed exclusiverly by qualified mechanicalmaintenance technical engineers and/or by specialised technical personeel authorised by the manufacturer

Every 50 working hours !!!!! Drain condensate from oil collector!!!!! check the oil level!!!!! Clean thefiltering panel

Every 500 hours !!!!! Clean the air suction filter (see control board LED)!!!!! !!!!! Check belt tension

Every 2000 hours !!!!! !!!!! Change the oil filter (see control board LED)!!!!! Change the suction filter (see control board LED)

Every 4000 hours !!!!! !!!!! Clean the finned surface of the air-oil cooler!!!!! !!!!! Change the oil separating filter (see control board LED)!!!!! !!!!! Change the oil (see control board LED)

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15.3 Draining condensate from the oil collectorIf the compressor work cycle contemplates long pauses during which the machine cools down, a certain amount ofcondensate will gather in the oil collector. This happens, for example, when stopping overnight or at weekends.The condensate must be drained off every 50 hours or every week. This operation may be performed only when themachine is cold, that is when it has been switched off for at least 8 hours

Before draining the condensate it si obligatory to stop the machine and disconnect from the power mains

Proceed as follows:- Press the “STOP” button Ref. 1 Fig. 14- Press the “EMERGENCY STOP” button Ref. 2 Fig. 14

3

4

5

6

2

5

Fig. 14

- Wait for the machine to cool down.- Remove the side maintenance guard using the supplied key.- SLOWLY turn on the tap Ref. 3 Fig. 14 and let the condensate flow out.- When the first traces of oil appear, turn off the tap

Condensate must be disposed of in conformity with the local regulations in force

- Check the oil level on the indicator Ref. 4 Fig. 14- If the oil level is under the minimum, top up as described at point 15.4

1

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15.4 Check oil level and top up- Switch off the machine using the button Ref. 1 Fig. 14: the machine will stop after running loadless for a few seconds.- Press the “EMERGENCY STOP” button Ref. 2 Fig. 14.- Turn on the supply automatic differential switch Ref. 3 Fig. 14- Remove the side maintenance guard using the supplied key.- Wait a few minutes for the foam in the oil collector to abate.- Check the oil level on the indicator Ref. 4 Fig. 14- If the oil level is under the minimum, top up.

Use oil of the same type as that already in the machine, do not mix different types of oil

Before carrying out any operation on the machine, ensure that the electric power supply has beendisconnected- Slowly open the oil plug Ref. 5 Fig. 14

- Top up to maximum level Ref. 4 Fig. 14, with oil of the same type in the compressor.- Turn off the cap of the oil tank Ref. 8 Fig. 14.- Close the side maintenance guard using the supplied key

15.5 Cleaning the filtering panel- Press the “STOP” button Ref. 1 Fig. 15- Press the “EMERGENCY STOP” button Ref. 2 Fig. 15.- Turn on the supply automatic differential switch Ref. 3 Fig. 15.- Remove the filter panel Ref. 4 Fig. 15.- Clean the filtering panel with a jet of air wash it with water, do not use solvents.- Once the operation has been completed, reassemble the filter panel

Fig. 15

60 - 75 HP 40 - 50 HP

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15.6 Cleaning the suction filter or changing the filter- Press the “STOP” button Ref. 1 Fig. 15a.- Press the “Emergency stop” button Ref. 2 Fig. 15a.

Hot parts inside

- Remove the side maintenance guard using the supplied key.- Remove the cover Ref. 4 Fig. 15a.- Remove the filter Ref. 5 Fig. 15a.

fig. 15a

Avoid dropping foreign bodies into the suction manifold

- Clean the filter with a jet of air, working from inside to outside.Do not use water for solvents. Alternatively, fit a new filter.- Clean the disk on which the filter rests with a clean cloth.- Fit the filter and the cover.- If necessary, dispose of the old filter in conformity with the local regulations in force.- Reclose the side maintenance guard using the supplied key.

1

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16.0 Periods of inactivityIf the machine has to remain inactive for a long period:- Press the “STOP” button Ref. 1 Fig. 15a- Turn the isolating switch Ref. 2 Fig. 15a to position “0” and block it with the padlock.- Turn on the supply automatic differential switch Ref. 3 Fig. 15a.- Turn off the tap Ref. 6 Fig. 15a.During periods of inactivity the weather must be protected against atmospheric agents, dust and humidity which coulddamage the motor and the electrical system.To restart the machine after periods of inactivity, consult the manufacturer

17.0 Scrapping the unitIf the machine is to be scrapped, it must be dismantled into parts of the same material, to be disposed of according to thelocal regulations in force

The lubricating loquids and other eventul fluids must not be discharged in the environment. These polluting andhazardous products must compulsory be disposed by charging authorised and specialised firms according tothe different typology of product

Always respect the regulations in force for disposing of lod oil and other polluting materials such as sounddeadening, foam, etc.

18.0 List of spare parts for routine maintenance

Description 40 HP 50HP 60 HP 75 HP

Filtering panel ! ! ! !

Suction filter ! ! ! !

Oil filter ! ! ! !

Separator cartridge ! ! ! !

1

4

2

3

1

1

Fig. 16

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19.0 Trouble-shooting and emergency redmedies

All work must be carried out by professionally skilled personnel, before carrying out any maintenance jobs it isobligatory to stop the machine and disconnect it from the power mains

N.B. Operations marked ** must be carried out by professionally skilled personnel approved the manufacturer

Fault found Possible causes Observations

1) The machine does not start 1A - Not powert - Check the power supply line.

1B - The transformer protection Chapter 12.2 device has tripped - Replace fuses

2) The machine does not start 2A - The transformer protection - Reset the automatic switch thatthe pilot lamp Ref. 1 (F) device has tripped protects the fanis flashes (see Fig. A)

3) Themachine does not start 3A - The oil high temperature - Environment temperature too highthe pilot lamp Ref. 2 (D) thermostat has tripped improve ventilation in theis flashes (see Fig. A) - compressor room, Chapter 9.2

!!!!!!!!!! - Cooler is dirty, clean the Cooler

- Oil level too low, top up the oil tank

4) The machine does not start 4A - The fan motor thermal protection - Ream the fan motor thermalthe pilot lamp Ref. 3 (E) had triggered protectionis flashes (see Fig. A)

5) The compressor does not 5A - The compressor air consumptionreach working pressure is too high

5B - The discharge electrovalve !!!!!!!!!! - Check the electric system remains open, Ref. EV/SC wiring diagram

6) Excess oil consumption 6A - Deteriorated oil separating filter !!!!!!!!!! - Change the oil separating filter oil level is too high - chapter 23

Fig. A

2

3

1

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20.0 Starting up

Machine with automatic start

Before carrying out any operation on the machine, ensure that the electric power supply has been disconnected

20.1 Preparing for setting upAfter checking everything as indicated in Chap. 12, folow the instructions in Fig. 17.- Fit the sound-deadening panels Ref. 1 Fig 17.These parts are packed inside the bodywork.

20.2 Preliminary checks- Check the oil level Ref. 1 Fig. 17 when supplied the machine is filled with oil;if the oil is not at the correct level, top upwith the same oil as the original type.If more than 3 months have passed between the inspection in the factory and the date of installation, lubricate the screwgroup before starting up, following the procedure described below:- Remove the side maintenance guard.- Remove the cover Ref. 3 Fig. 17- Remove the air filter Ref. 4 Fig. 17- Pour a little oil into the suction unit.- Reassemble the air filter Ref. 4 Fig. 17- Reassemble the cover Ref. 3 Fig. 17

If more than 6 months have passed between the inspection in the factory and the date of installation, consultthe manufacturer.

Fig. 17

1

2

11

3

4

Oil

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20.3 Check the direction of rotation

- Check that all fixed guards are in their correct position.- Remove the side maintenance guard using the supplied key (Ref. 1 Fig. 17a).- Connect the control board to the power supply with the automatic circuit-breaker switch of the line Ref. 7 Fig. A and themaster switch of the machine Ref. 5 Fig. A.

- Start up the compressor pushing in sequence I button Fig. 17A and immediately after about 1 second the 0 button Fig.17A to stop if.

- Check the motor rotation direction is the same as the arrow marked on the compressor.

All work on the electric Panel, must be carried out by professionally skilled personnel

- If the rotation direction is not correct, turn off the power and invert the two connections at point Ref. 2 Fig. 17a

It is advisable not to do anything on the machine panel

If all the instructions found in this manual have been observed the machine can be started

Attention: Machine start-up is delayed for a few seconds from the moment the card is powered or of the scheduledstop

Rotation direction

1

2

Fig. 17a

3

Instruction Book

29

21.0 General ordinary maintenance requires trained personnel

Before carrying out any maintenance jobs it is obligatory to stop the machineand disconnect it from the powermains

Maintenance scheduleThese maintenance intervals are recommended for work environments that are not dusty and are will ventilated. Forparticularly dusty environments, double the frequency of controls

Every 50 working hours !!!!! Drain condensate from oil collector!!!!! check the oil level!!!!! Clean thefiltering panel

Every 500 hours !!!!! Clean the air suction filter (see control board LED)!!!!! !!!!! Check belt tension

Every 2000 hours !!!!! !!!!! Change the oil filter (see control board LED)!!!!! Change the suction filter (see control board LED)

Every 4000 hours !!!!! !!!!! Clean the finned surface of the air-oil cooler!!!!! !!!!! Change the oil separating filter (see control board LED)!!!!! !!!!! Change the oil (see control board LED)

N.B.: The operations marked ! ! ! ! ! are described in part “A” of this manual on chapter 15.3

Instruction Book

30

22.0 Changing the oil

Before carrying out any maintenance jobs it is obligatory to stop the machine and disconnect it from the powermains and from the compressed air distribution network Oil changing is an important operation for the compressor:

if the lubrication of the bearings is not efficient, the compressor life will be short.The oil must be changed when the machine is still warm, that is immediately after stopping it.The suggestions listed below should be scrupulously followed.After draining the old oil out of the machine Ref. 1 Fig. 18.- Fill the oil tank to the MAX level, Ref. 2 Fig. 18.- Pour a little oil into the suction unit.- Start the compressor.- After about 1 minute switch off the machine by pressing “STOP” (Ref. 3 Fig. 18) after a few seconds of idle running the

machine will switch off.Proceed as described at point chapter 14.5

Fig. 18

3

1

2

OIL

The old oil must be disposed of in compliance with the regulations in force. Do not top up with different oils

Note on lubricantsWhen delivered the machine is filled with oil;In normal conditions of use, these lubricants have proved to be able to withstand use for as many as 4.000 hours. However,due to the external polluting agents that get into the compressor with the air that it takes in, it is advisable to change the oilat more frequent intervals, as indicated on the routine maintenance chart.If the compressor is being used at high temperatures (continuous operation above 90 °C) or in particularly severe conditions,we advise changing the oil at shorter intervals than those recommended in the maintenance chart

Instruction Book

31

23.0 Changing the oil separator filter

Before carrying out any maintenance the machine must be stopped, cut off the machine from the electricalmains and from the compressed air distribution circuit, check that the machine is not under pressure

Proceed as follows:- Press the “STOP” button Ref. 1 Fig. 19- Press the “EMERGENCY STOP” button Ref. 2 Fig. 19.- Check there is no pressure inside the machine: check the pressure gauge Ref. 4 Fig. 19.- Let off the internal pressure through the minimum valve Ref. 5 Fig. 19 and the manual valve Ref. 6 Fig.19.- Take off the cover Ref. 7 fig. 19- Change the oil-separator filter.

Fig. 19

1

6

5

2

3

4

7

Instruction Book

32

24.0 Belt tention

Before carrying out any maintenance the machine must be stopped, cut off the machine from the electricalmains and from the compressed air distribution circuit, check that the machine is not under pressure

Tightening or retightening new beltsProceed as follows:- Press the “STOP” button Ref. 1 Fig. 20.- Press the “EMERGENCY STOP” button Ref. 2 Fig. 20.- Remove the fixed protection device Ref. 4 Fig. 20.- Slacken the screws by half a turn Ref. 5 Fig. 20- Loosen the locknut Ref. 6 Fig. 20- Adjust the belt tension by turning the nut Ref. 7 Fig. 20.- Lock the locknut again Ref. 6 Fig. 20- Close the screws again Ref. 5 Fig. 20- Refit the fixed protection device with its safety screws Ref. 4 Fig. 20

FIG. 20

5

7

fF

5

1

2

3

4

6

HP 40 - 50 - 75F = 3,5 Kg. Force to be applied at the centre line, at right angles to the new belt.

f = 6 mm Clearance after the application of F. (after 100 h operation F = 2,5 kg.)

HP 75F = 4,5 Kg. Force to be applied at the centre line, at right angles to the new belt.

f = 7,5 mm Clearance after the application of F. (after 100 h operation F 3,5 ÷ 4 Kg.)

24.1 Tightening torque (Fig. 21]

Type bush Tightening torqueN.m Key

2012 31 52517 48 63020 90 83535 112 10

TYPE

FIG. 21

Instruction Book

33

25.0 System diagram

○ ○ ○ ○ ○ ○ ○ ○ ○

Air circuitOil circuitControl circuit

1 Suction filter 10 Minimum pressure valve 2 Suction regulator 11 Air-oil separator 3 Screw compressor 12 Pressure gauge 4 Oil discharge valve 13 Safety valve 5 Air-oil presepator 14 Temperature sensor 6 Oil filter 15 Electric motor 7 Thermostatic valve 16 No-load running solenoid valve 8 Air-oil cooloer 17 Oil level 9 Presssure transducer 18 Bleed valve

Instruction Bookpressure shall be protected by a pressure-relieving device or devices asrequired.

13. Pipework or other parts with a temperature in excess of 80 degresscelsius and which may be accidentally touched by personnel in normaloperation shall be guarded or insulated. Other high-temperature pipeworkshall be clearly marked.

14. If the ground is not level or can be subject to variable inclination, consultChicago Pneumatic.

15. The electrical connections shall correspond to the local codes. The unitsshall be grounded and protected against short circuits by fuses.

Operation

1. Air hoses shall be of correct size and suitable for the working pressure.Never use frayed, damaged or deteriorated hoses. Use only the correcttype and size of hose and fittings and connections. When blowing througha hose or air line, ensure that the open end is held securely. A free end willwhip and may cause injury. Make sure that a hose is fully depressurizedbefore disconnecting it.Never play with compressed air. Do not apply it to your skin or direct anair stream at people. Never use it to clean dirt from your clothes. Whenusing it to clean equipment, do so with extreme caution and use eyeprotection.

2. The compressor is not considered as capable of producing air of breathingquality. For breathing air quality, the compressed air must be adequatelypurified according to local legislation and standards.

3. Never operate the unit when there is a possibility of taking in flammableor toxic fumes.

4. Never operate the unit at pressures below or in excess of its limit ratingsas indicated on the Principal Data sheet.

5. Keep all bodywork doors shut during operation. The doors may be openedfor short period ony e.g. to carry out checks. Wear ear protectors whenopening a door.

6. People staying in environments or rooms where the sound pressure levelreaches or exceeds 90 dB (A) shall wear ear protectors.

7. Periodically check that:a. All guards are in place and securely fastenedb. All hoses and / or pipes inside the unit are in good condition, secure

and not rubbing.c. There are no leaksd. All fasteners are tighte. All electrical leads are secure and in good order.f . Safety valves and other pressure - relief devices are not obstructed

by dirt or paint.g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves,

hoses, etc. are in good repair, free of water or abuse.8. 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 possiblecontamination of the breating air.

9. Do not remove any of, or tamper with, the sound - damping material.MaintenanceMaintenance and repair work shall only be carried out under supervisior of

someone qualified for the job.1. Use only the correct tools for maintenance and repair work.2. Use only genuine spare parts.3. All maintenance work, other than routine attention, shall only be undertaken

when the unit is stopped, the main power supply is switched off and themachine has cooled down. Take positive precaution to ensure that the unitcannot be started inadvertently. In addition, a warning sign bearing a

legend such as “work in progress; do not start” shall be attached to thesrarting equipment.

4. Before removing any pressurized component, effectively isolate the unitfrom all sources of pressure and relieve the entire system of pressure.

5. Never use flammable solvents or carbon tetrachloride for cleaning parts.Take safety precautions against toxic vapours of cleaning liquids.

6. Scrupulously observe cleanlines during maintenance and repair. Keep dirtaway by covering the parts and exposed openings with a clean cloth,paper or tape.

7. Never weld or perform any operation involving heat near the oil system.Oil tanks must be completely purged. e.g. by steam-cleaning, beforecarrying out such operations.Never weld on, or in any way modify, pressure vessels.Whenever there is an indication or any suspicion that an internal part ofa machine is overheated, the machine shall be stopped but no inspectioncovers shall be opened before sufficient cooling time has elapsed; this toavoid the risk of spontaneous ignition of the oil vapour when air isadmitted.Never use a light source with open flame for inspecting the interior ofmachine, pressure vessel, etc.

8. Make sure that no tools, loose parts or rags ae left in or on the unit.9. Before cleaning the unit for use after maintenance or overhaul, check

that operating pressures, temperaturea and time settings are correct andtha the control and shut-down devices function correctly. If removed,check that the coupling guard of the compressor drive shaft has beenreinstalled.

10. Every time the separator element is renewed, examine the discharge pipeand the inside of the oil separator vessel for carbon deposits; if excessive,the deposits should be removed.

11. Protect the motor, air filter, electrical and regulating components, etc. toprevent moisture from entering them e.g. when steam-cleaning.

12. Make sure that all sound-damping material, e.g. on the bodywork and inthe air inlet and outlet systems of the compressor, is in good condtions.If damaged, repalce it by genuine CP material to prevent the soundpressure level from increasing.

13. Never use caustic solvents which can damage materials of the air net,e.g. polycarbonate bowls.

14. The following safety precautions are stressed when handling refregerant:a Never inhale refrigerant vapours. Check that the working area is

adequately ventilated; if rquired, use breathing protection.b Always wear special gloves. In case of regrigerant contact with

the skin, rinse the shin with water. If liquid refrigerant contacts theskin through clothing, never tear off or remove the latter; flushabundantlty with fresh water over seek medical until all regrigerantis flushed away; then seek medical first aid.

c Always wear safety glasses.

15. protect hands to avoid injury from hot machine parts, e.g. during drainingof oil.

Note : With stationery machine units driven by an internalcombustion engine, allowance has to be made for extrasafety precautions, e.g. spark arrestors, fuelling care, etc.

Consult Chicago Pneumatic.All responsibility for any damage or injury resulting from neglectingthese precautions, or by non-obsrvance of ordinary caution and due carerequired in handling, operating, maintenance or repair, even if notexpressly mentioned in this book, will be discalimed byChicago Pneumatic.

SAFETY PRECAUTIONS (CONTINUED)

Instruction Book

Sveanagar, Dapodi, Mumbai -Pune Road, Pune 411 012 Fax: 39852093[A Division of Atlas Copco (India) Ltd.]

Office Address Phone Fax

Bangalore : System Compund, 1A Peenya Industrial Area, Phase II, Bangalore- 560 058. 080-39280177 080-2663366Baroda : M-2,Mezzanine Floor,Prestige Complex,Race Course, Baroda 390 00 0265- 3096994

Kolkata : Trinity Plaza, 2nd Floor, East Wing, 84/1A, Topasia Road(South), Kolkata 700 046. 9830033581

Secunderabad : Brij Tarang, 6-3-1191 to1196 , Green Lands, Begumpet, Hyderabad 500 001 040-27801635 040-27801637Chennai : 10/1, Dr. Ambedkar Road, 4th Avenue, Ashok Nagar, Chennai 600 083 044-24835503/09 044-24835417 Gurgaon : Unitech Cyber park, Tower -C, Ground Floor,Sector 39, NS Marg, Gurgon. 9312406866Pune : J209/1A/1B, 2nd Floor, Tellus Technologies, Range Hills Road, Pune 411 020 020-30257102 020-30257107

Resident Offices : Coimbature 0422-2340828, Indore 0731-2562865, Jaipur 0141-2352206, Madurai 0452-2383916, Nellore 0861-2320254,Udaipur 0294- 2452048, Vijayawada 0866-2481549