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Chicago Pneumatic CPC 4, Instruction Manual, Page: 4 / 36

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Chicago Pneumatic CPC 4 Instruction Manual Download Page 4

11/2008 

Chicago Pneumatic Compressors 

Page 4 

62 305 549 65

 

 

INTRODUCTION

 

 

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

 

 
Keep this manual for future consultation; the use and maintenance manual is an integral part of the compressor. 
 
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 accordance 
applicable with electrical and safety regulations at the installation site.

 

 
 

CHARACTERISTICS AND SAFETY PRECAUTIONS 

 
 
 

COMPRESSOR WITH AUTOMATIC START 

 
 
 

BEFORE REMOVING THE PROTECTION DEVICES FOR ANY MAINTENANCE WORK ON THE COMPRESSOR, 
DISCONNECT THE ELECTRICAL 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 OF THE WARRANTY TERMS.

 

 
ALL WORK ON THE ELECTRICALS, 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 the 
instructions given above. 

 

THIS COMPRESSOR IS NOT DESIGNED FOR OUTDOOR INSTALLATION 
 
THIS COMPRESSOR CORRESPONDS TO THE SAFETY REQUIREMENTS FORESEEN BY OSHA 
 
 

THE LUBRICATING LIQUIDS MUST NOT BE DISCHARGED INTO THE ENVIRONMENT. THESE PRODUCTS MUST 
BE DISPOSED OF IN ACCORDANCE WITH GOVERNMENT REGULATIONS. 

 
 
 
 
 
 
 
 
 
 

 

Summary of Contents for CPC 4

Page 1: ...Instruction Manual EN CP COMPRESSOR Model CPC 40 50 60 62 305 549 65 CPC 50 ...

Page 2: ... hp 40 50 60 Main Voltage 230 Volt 3 60Hz Nominal current A 123 152 190 Power supply cable AWG 0 AWG 00 AWG 0000 Fuse protection RK5 150 175 200 Main Voltage 460 Volt 3 60Hz Nominal current A 66 79 100 Power supply cable AWG 0 AWG 00 AWG 0000 Fuse protection RK5 80 100 125 Main Voltage 575 Volt 3 60Hz Nominal current A 46 57 71 Power supply cable AWG 6 AWG 4 AWG 3 Fuse protection RK5 50 70 80 Conn...

Page 3: ...USTRATION 15 0 ROUTINE MAINTENANCE 16 0 PERIODS OF INACTIVITY 17 0 SCRAPPING THE UNIT 18 0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE 19 0 TROUBLE SHOOTING AND EMERGENCY REMEDIES PART B INFORMATION RESERVED FOR TECHNICALLY SKILLED PERSONNEL 20 0 STARTING UP 21 0 ROUTINE MAINTENANCE FOR TRAINED PERSONNEL 22 0 CHANGING THE OIL 23 0 CHANGING THE OIL SEPARATION FILTER 24 0 BELT TENSION 25 0 FLOW DIAG...

Page 4: ...y regulations at the installation site CHARACTERISTICS AND SAFETY PRECAUTIONS COMPRESSOR WITH AUTOMATIC START BEFORE REMOVING THE PROTECTION DEVICES FOR ANY MAINTENANCE WORK ON THE COMPRESSOR DISCONNECT THE ELECTRICAL 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 OF THE WARRANT...

Page 5: ...any damage resulting from improper incorrect or unreasonable use 3 0 OPERATION Reference flow diagram in section 25 0 The 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 a panel pre filter fitted on the panel of the cabinet and by the filter cartridge fitted ups...

Page 6: ...ian 6 CAUTION This symbol identifies hot surfaces which could result in personal injury or property damage 2 DANGER Air from this compressor will cause severe injury or death if used for breathing or food processing Air used for these process must meet OSHA29CFR1910 OR FDA21XDE178 3570 regulations 7 DANGER This symbol identifies immediate hazards which will result in severe personal injury death o...

Page 7: ...essure relief valve 8 0 POSITION OF LABELS 8 1 POSITION OF THE DANGER LABELS The labels fitted on the compressor unit are part of the compressor they have been applied for safety purposes and must not be removed or spoiled for any reason 1 Dangers label Code D09688 6 Moving parts 2 Label Compressor with automatic start 7 Dangerous electric voltage 3 Air not fit for breathing 8 Hazard Label atmosph...

Page 8: ...05 549 65 8 2 POSITION OF THE DATA LABELS 1 Identification label 5 Oil label 2 Maintenance schedule 6 Draining condensate 3 Direction of rotation label 7 Electric cable label 4 Air not fit for breathing FIG 6 7 D51258 4 Oil Label 5 2 6 D04289 3 610109 ...

Page 9: ...igher than 104 F or lower than 36 F 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 of 35 3 sqft and it must not be longer than 9 8 ft For longer pipes an extra fan must be fitted 9 3 EXAMPLES OF VENTILATION OF THE COMPRESSOR ROOM FIG 7 FAN AIR OUTPUT HOT ...

Page 10: ...62 305 549 65 10 0 TRANSPORT AND HANDLING ATTENTION the compressor must only be moved with the panels fitted fig 8 The compressor must be transported as shown in the following figures FIG 8 CPC 40 50 60 WOODEN PROTECTION AVOID DAMAGING THE CABINET ...

Page 11: ...screws wood metal strapping etc must be disposed of appropriately 12 0 INSTALLATION ANY DAMAGE DUE TO FAILURE TO OBSERVE THE PRECAUTIONS GIVEN BELOW CANNOT BE ATTRIBUTED TO THE MANUFACTURER AND MAY RESULT IN WARRANTY DENIAL 12 1 POSITIONING After unpacking the equipment and preparing the compressor room put the compressor into position checking the following items ensure that there is sufficient s...

Page 12: ...LLED PERSONNEL SHOULD HAVE ACCESS TO THE ELECTRIC PANEL SWITCH OFF THE POWER BEFORE OPENING THE DOOR OF THE ELECTRIC PANEL COMPLIANCE WITH THE APPLICABLE REGULATIONS CONCERNING THE ELECTRICALS IS FUNDAMENTAL FOR OPERATOR SAFETY AND FOR THE PROTECTION OF THE COMPRESSOR CABLES PLUGS AND ALL OTHER TYPE OF ELECTRIC MATERIAL USED FOR THE CONNECTIONS MUST BE SUITABLE FOR THE USE AND COMPLY WITH THE REQU...

Page 13: ...Chicago Pnematic Compressors 11 2008 62 305 549 65 Page 13 13 0 DIMENSIONSAL DRAWING ELECTRICAL ENTRY A Air delivery A HP 40 50 HP 60 1 NPT 1 NPT ...

Page 14: ...inimum pressure valve 8 Air oil separator inside the SUMP TANK 9 Top up or oil filling cap 10 Control panel 11 Oil gauge 12 Oil discharge 13 SUMP TANK 14 Pressure gauge tank 15 Control card 16 Safety valve 17 Emergency stop button 18 Electric motor 19 Screw compressor 20 Suction unit 22 Electrical fan IT IS FORBIDDEN TO TAMPER WITH THE SETTINGS OF THE SAFETY VALVE FIG 11 7 13 4 22 18 6 20 17 15 10...

Page 15: ...Chicago Pnematic Compressors 11 2008 62 305 549 65 Page 15 14 2 CONTROL PANEL BEFORE OPERATING CAREFULLY READ AND UNDERSTAND THE COMMAND FUNCTIONS 1 Control panel 2 Emergency stop button FIG 12 1 ...

Page 16: ...te a vacuum in the compressor 4 Navigate to the next field of the screen on the display Ref 2 5 Buttons to program the controller Symbol Description Pressing the button cancels the stored alarm indication Pressing the button for more than 3 seconds the central control unit is tested all the LEDs must be on By pressing this button the compressor is switched on There is a delay of about 15 seconds b...

Page 17: ...ch off the red LEDs press reset LED indicates compressor operating status YELLOW pilot lamps do not cause compressor stoppage Symbol LED flashing LED on Not enabled Not enabled Warning to replace oil filter Replace oil filter Warning to replace separator filter Replace separator filter Warning to replace air filter Replace air filter Warning to change oil Change oil Warning for general check Perfo...

Page 18: ...nt 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 ...

Page 19: ...he 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 sequence on the top display while the values set for each parameter will appear on the bottom display To exit press the button Ref 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 m...

Page 20: ...l 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 Every 8000 hours Change the oil see control board LED BEFORE CARRYING OUT ANY MAINTE...

Page 21: ... IS MANDATORY TO STOP THE COMPRESSOR AND DISCONNECT IT FROM THE MAIN POWER Proceed as follows Press the STOP button Ref 1 Fig 14 Switch off the compressor Turn off main power and lockout disconnect Ref 3 Fig 14 Wait for the compressor to cool down Remove the side maintenance panel using the supplied key SLOWLY turn on the tap Ref 3 Fig 14 and let the condensate flow out When the first traces of oi...

Page 22: ...THE COMPRESSOR DO NOT MIX DIFFERENT TYPES OF OIL BEFORE CARRYING OUT ANY OPERATION ON THE COMPRESSOR ENSURE THAT THE ELECTRIC POWER SUPPLY HAS BEEN DISCONNECTED Slowly open the fill port Ref 6 Fig 14 Top off to maximum level Ref 4 Fig 14 with oil of the same type in the compressor Replace the cap on the fill ports Ref 6 Fig 14 Close the side maintenance panel using the supplied key 15 5 CLEANING T...

Page 23: ...plied key Remove the cover Ref 4 Fig 15a Remove the filter Ref 5 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 OR SOLVENTS Alternatively add a new filter Clean the disk on which the filter rests with a clean cloth Replace the filter and the cover If necessary dispose of the old filter in accordance...

Page 24: ...e manufacturer 17 0 SCRAPPING THE UNIT If the compressor is to be scrapped it must be dismantled into parts of the same material to be disposed of in accordance with local regulations THE LUBRICATING LIQUIDS MUST NOT BE DISCHARGED INTO THE ENVIRONMENT THESE PRODUCTS MUST BE DISPOSED OF IN ACCORDANCE WITH GOVERNMENT REGULATIONS 18 0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE HP40 HP50 HP60 Ref DES...

Page 25: ...set the automatic switch that protects the fan 3 The compressor does not start the pilot lamp Ref 2 D flashes see Fig A 3A the oil high temperature thermostat has tripped ambient temperature too high improve ventilation in the compressor room Section 9 2 cooler is dirty clean the cooler oil level too low top off the oil tank 4 The compressor does not start the pilot lamp Ref 3 E flashes see Fig A ...

Page 26: ...5 549 65 PART B ALWAYS WAIT FOR FIVE MINUTES BEFORE REMOVING THE FRONT COVER ALWAYS CHECK THAT THERE ARE NO DANGEROUS VOLTAGES BEFORE PERFORMING MAINTENANCE ON THE MOTOR THIS PART B OF THE INSTRUCTIONS MANUAL IS RESERVED FOR FACTORY AUTHORIZED PERSONNEL ...

Page 27: ...pplied the compressor is filled with oil if the oil is not at the correct level top off with 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 screw before starting up following the procedure described below Remove the side maintenance panel using the supplied key Remove the cover Ref 3 Fig 17 Remove...

Page 28: ...button Fig 17A to stop Check the motor rotation direction is the same as the arrow marked on the compressor ALL WORK ON THE ELECTRICALS HOWEVER SLIGHT 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 CONTROLLER IF ALL THE INSTRUCTIONS FO...

Page 29: ...he frequency of maintenance Every 50 working hours Drain condensate from the sump tank Check the oil level Clean the filter panel Every 500 hours Clean the air suction filter see controller LED Check belt tension Every 2000 hours Change the oil filter see controller LED Change the suction filter see controller LED Every 4000 hours Clean the finned surface of the air oil cooler Change the oil separ...

Page 30: ...he 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 compressor by pressing STOP Ref 3 Fig 18 after a few seconds of idle running the compressor will switch off PROCEED AS DESCRIBED AT POINT SECTION 15 4 THE OLD OIL MUST BE DISPOSED OF IN COMPLIANCE WITH LOCAL REGULATIONS DO NOT TOP OFF WITH DIFFERENT OILS NOTE O...

Page 31: ...K CHECK THAT THE COMPRESSOR IS NOT UNDER PRESSURE Proceed as follows Press the STOP button Ref 1 Fig 19 Switch off the compressor Turn off main power and lockout disconnect Ref 3 Fig 19 Check there is no pressure inside the compressor 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...

Page 32: ...nect Ref 3 Fig 20 Remove the panel Ref 4 Fig 20 Loosen 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 Fasten the panel with its safety screws Ref 4 Fig 20 HP 40 50 60 F 7 7 lbs Force to be applied at the center line at right angles to the new belt ...

Page 33: ...TOR 11 AIR OIL SEPARATOR 3 SCREW COMPRESSOR 12 PRESSURE GAUGE 4 OIL DISCHARGE VALVE 13 SAFETY VALVE 5 AIR OIL PRE SEPARATION 14 TEMPERATURE SENSOR 6 OIL FILTER 15 ELECTRIC MOTOR 7 THERMOSTATIC VALVE 16 NO LOAD RUNNING SOLENOID VALVE 8 AIR OIL COOLER 17 OIL LEVEL 9 PRESSURE TRANSDUCER 18 BLED VALVE AIR CIRCUIT OIL CIRCUIT CONTROL CIRCUIT ...

Page 34: ...11 2008 Chicago Pneumatic Compressors Page 34 62 305 549 65 NOTE ...

Page 35: ...Chicago Pnematic Compressors 11 2008 62 305 549 65 Page 35 NOTE ...

Page 36: ...support support CPcompressor com 1 877 861 CPAC CP Compressors 1800 Overview Dr Rock Hill SC 29730 ...

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